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ABB SERVO PRODUCTS
MicroFlex e190 servo drive
User’s manual
User’s manual
MicroFlex e190
©2021 ABB Beijing Drive Systems Co., Ltd.
All Rights Reserved.
3AXD50000037326 REV D
EN
EFFECTIVE: 2021-04-30
Table of contents 5
Table of contents
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Network security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Quick installation and start-up flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Layout - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Layout - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Layout - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Memory unit - MU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Table of contents
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Direct wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Mains filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Braking resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Protection against short-circuit in motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Protection against short-circuit in the supply cable or the drive . . . . . . . . . . . . . . . . . . . . 44
Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Residual current device (RCD) compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connection of a motor temperature sensor to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Typical installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Braking resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Power cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
AC power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DC power cable connection diagram (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
24 V control circuit supply (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table of contents 7
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X3: Analog input AI0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X3: Analog output AO0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X4: Digital inputs - Safe Torque Off (STO) inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X3: Digital inputs - general purpose DI1 & DI2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X3: Digital inputs - Special function DI1 & DI2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X3: Digital inputs - general purpose DI0 & DI3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X3: Digital inputs - special function DI0 & DI3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
X3: Digital outputs - general purpose DO0 - DO3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
X3: Digital outputs - special function DO0 - DO3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Other I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X2: External power supply for the control unit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SW1 linear switches - startup functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Control cable grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Ethernet ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
E1 / E2: Real-time Ethernet port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
E1 / E2: Ethernet port configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
E3: Ethernet host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Motor feedback (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Incremental encoder with Halls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Serial interfaces & SinCos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Extra incremental encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Incremental encoder input/output (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPT-MF-201 Resolver adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Supported feedback type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Encoder 0 input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Encoder 1 input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Encoder 2 input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Connect the MicroFlex e190 to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Install Mint Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Configure the PC Ethernet adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Enable the Ethernet adapter for Mint Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Start the MicroFlex e190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Power on checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8 Table of contents
Using the Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Further tuning - no load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Further tuning - with load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Optimizing the velocity response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Correcting overshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Correcting zero-speed noise in the velocity response . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Ideal velocity response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Performing test moves - continuous jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Performing test moves - relative positional move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Configuration tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
EtherCAT tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Ethernet POWERLINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Parameters tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Spy window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Other tools and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Safe Torque Off (STO) validation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Problem diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
SupportMe feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Power-cycling the MicroFlex e190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
MicroFlex e190 indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
EtherCAT® mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Ethernet POWERLINK mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Drive status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Mint Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Dual encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Warning messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Axis warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Controller warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Error messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Autotuning errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Parameter errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Communication errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Axis errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Controller errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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Replacing the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Overview of the reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Reforming time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Checking the drive age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Reforming with power on for 30 minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Reforming with external DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Reforming with another e190 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Transferring the memory unit to a new drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Cooling characteristics, noise levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Supply cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
AC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Effect of AC power supply voltage on DC-bus voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Effect of AC power supply voltage on DC-bus ripple voltage . . . . . . . . . . . . . . . . . . . . . 164
Effect of output current on DC-bus ripple voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
DC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Brake resistor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Circuit breaker connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
X7 Incremental encoder without Halls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
X8 Incremental encoder with Halls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
X8 Serial interfaces + SinCos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
WEEE notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
RoHS compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Design and test standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Environmental test standards: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Functional safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Compliance with the European WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
When is a mains filter required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Footprint filter (single phase only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Specifications and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
EMC screw disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
System braking capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Braking energy calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Braking energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Braking power and average power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Resistor choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Resistor derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
24 V power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Encoder breakout OPT-MF-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Resolver adapter OPT-MF-201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Option card OPT-SIO-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Motor power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Ethernet cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Screws and clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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Connected components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Short circuit testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Drive enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Start-up including validation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Validation test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Validation test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Restarting the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Hardware activation of the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Firmware monitoring of the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Software monitoring of the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
STO status indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Monitoring the delay between the STO inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
STO function activation and indication delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Special considerations for using the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Error messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
TüV Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
STO technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
STO safety relay type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
STO cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
12 Table of contents
Safety 13
1
Safety
What this chapter contains
This chapter contains the safety instructions which you must obey when
installing, operating and servicing the drive. If ignored, physical injury or death
may follow, or damage may occur to the drive, motor or driven equipment. Read
the safety instructions before you work on the unit.
Use of warnings
Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment and advise on how to avoid the danger.
The following warning symbols are used in this manual:
Electricity warning warns of hazards from electricity which can
cause physical injury and/or damage to the equipment.
Avertissement électrique met en garde contre les dangers
d‘électricité qui peuvent causer des blessures corporelles et / ou
des dommages à l'équipement.
General warning warns about conditions, other than those caused
by electricity, which can result in physical injury and/or damage to
the equipment.
Avertissement général met en garde contre des conditions autres
que celles causées par l'électricité qui peuvent entraîner des
blessures physiques et / ou des dommages à l'équipement.
14 Safety
Electrostatic sensitive devices warning warns of electrostatic
discharge which can damage the equipment.
Avertissement des appareils sensibles électrostatiques met en
garde contre les décharges électrostatiques qui peuvent
endommager l'équipement.
Hot surface warning warns of component surfaces that may
become hot enough to cause burns if touched.
Avertissement de surface chaude avertit des surfaces des
composants qui peuvent devenir suffisamment chaudes pour
provoquer des brûlures si elles sont touchées.
Safety 15
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 or DC 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 MΩ) that:
1. Voltage between drive input phases L1, L2 and L3 is close to 0 V.
2. Voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
3. There is no voltage between terminals R+ and R- 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 may cause
dangerous voltages inside the drive even when the main power on the drive
is switched off.
•
•
Do not make any insulation or voltage withstand tests on the drive.
Do not connect the drive to a voltage higher than that marked on the type
designation label. Higher voltage can activate the brake chopper and lead to
brake resistor overload, or activate the over-voltage controller which can
lead to the motor rushing to maximum speed.
•
•
If a drive is installed on a corner-grounded TN system, the drive could be
damaged.
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.
•
•
•
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.
16 Safety
•
•
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 2014/13/EU an appropriate AC filter must be
installed.
Motor overtemperature sensing is required to satisfy UL 61800-5-1. The
drive has no provisions for motor overtemperature protection, so external
provisions are required. The motor thermistor connection must be isolated
•
•
The AC supply, DC supply (if used) and the 24 V DC control circuit 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.
•
•
For UL installations use 75 °C copper wiring only.
For UL installations: Integral solid state short circuit protection does not
provide branch circuit protection. Branch circuit protection must be
provided in accordance with the National Electrical Code and any additional
local codes.
•
For use in Canada: Transient surge suppression shall be installed on the line
side of this equipment and shall be rated 240V (phase to ground), 240V
(phase to phase), suitable for overvoltage category III, and shall provide
protection for a rated impulse withstand voltage peak of 2.5kV.
Note:
•
•
•
The motor cable terminals on the drive are at a dangerously high voltage
when the input power is on, regardless of whether the motor is running or
not.
The DC terminals (UDC+, UDC-) carry a dangerous DC voltage that is
approximately 1.4 times the AC supply voltage, e.g. 336 V DC when operating
on a 240 V AC supply.
The Safe Torque Off function does not remove the voltage from the main
and auxiliary circuits. The function is ineffective against deliberate sabotage
Safety 17
Grounding
These instructions are intended for all who are responsible for the grounding of
the drive.
WARNING! Ignoring the following instructions can cause physical injury or
death, increased electromagnetic interference and equipment
malfunction:
•
Ground the drive, motor and adjoining equipment to ensure personnel
safety in all circumstances, and to reduce electromagnetic emission and
interference.
•
•
•
Make sure that grounding conductors are adequately sized as required by
safety regulations.
In a multiple-drive installation, connect each drive separately to protective
earth (PE).
Where EMC emissions must be minimized, make a 360° high frequency
grounding of cable entries in order to suppress electromagnetic
disturbances. In addition, connect the cable shields to protective earth (PE)
in order to meet safety regulations.
Notes:
•
Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
•
Standard EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch
current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a
fixed protective earth connection and:
2
- cross-section of the protective earthing conductor of at least 10 mm Cu
2
or 16 mm Al, or
- automatic disconnection of the supply in case of discontinuity of the
protective earthing conductor, or
- a second protective earthing conductor of the same cross-sectional area
as the original protective earthing conductor.
18 Safety
Permanent magnet motor drives
These are additional warnings concerning permanent magnet motor drives.
WARNING! Ignoring the following instructions can cause physical injury or
death, increased electromagnetic interference and equipment
malfunction.
•
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 both steps:
1. Disconnect the motor from the drive with a safety switch or by other
means. Check by measuring that there is no voltage present on the drive
input or output terminals (L1, L2, L3, U, V, W, R+/UDC+, UDC-, R-).
2. Ensure that the motor cannot rotate during work. Make sure that no other
system, like hydraulic crawling drives, is able to rotate the motor directly or
through any mechanical connection like felt, nip, rope, etc. Check by
measuring that there is no voltage present on the drive input or output
terminals (L1, L2, L3, U, V, W, R+/UDC+, UDC-, R-). Ground the drive output
terminals temporarily by connecting them together as well as to the PE.
•
Do not run the motor over the rated speed. Motor over-speed leads to over-
voltage which may damage or explode the capacitors in the intermediate
circuit of the drive.
Safety 19
General safety
These instructions are intended for all who install and service the drive.
WARNING! Ignoring the following instructions can cause physical injury or
death, increased electromagnetic interference and equipment
malfunction:
•
•
Handle the unit carefully.
Take care when lifting. When carrying, do not suspend the unit from the
front panel as it could detach and cause the unit to be dropped.
•
Beware of hot surfaces. The metal heat sink on the left side of the
MicroFlex e190 can become very hot during normal operation. The surfaces
of drive system components (such as a mains choke or braking resistor, if
present) become hot when the system is in use, and remain hot for a while
after disconnection of the electrical supply. 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.
•
•
Ensure that debris from drilling and grinding does not enter the drive when
installing. Electrically conductive debris inside the unit may cause damage or
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.
Do not attach the drive by riveting or welding.
The MicroFlex e190 must be installed where the pollution degree according
to UL and EN 61800-5-1 shall not exceed 2.
Printed circuit boards
WARNING! Ignoring the following instructions can cause damage to the
printed circuit boards and/or void the warranty:
•
Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily. The printed circuit boards contain components
sensitive to electrostatic discharge.
20 Safety
Safe start-up and operation
General safety
These warnings are intended for all who plan the operation of the drive or
operate the drive.
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
•
•
After changing or maintaining the fan, make sure that the bottom cover is
correctly attached before connecting voltage to the drive. Keep the bottom
cover attached during operation.
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.
•
•
Do not activate any automatic fault reset functions of the drive control
program 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); instead, use external commands via fieldbus or the
I/O of the drive. The maximum allowed number of charging cycles of the DC
capacitors (i.e. power-ups by applying power) is one per two minutes.
•
•
Make sure that any safety circuits (for example, emergency stop and Safe
validation instructions.
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 e190 in torque mode with no load attached to the
motor can cause the motor to accelerate rapidly to excessive speed.
Improper operation or programming of the drive may cause violent motion
of the motor and driven equipment. Be certain that unexpected motor
movement will not cause injury to personnel or damage to equipment. Peak
torque of several times the rated motor torque can occur during control
failure.
•
Violent jamming (stopping) of the motor during operation may damage the
motor and drive.
Safety 21
•
•
The drive can be programmed to start up and begin to turn the motor (auto-
enable) immediately after an input voltage break or a fault reset. If an
external source for start command is selected and it is ON, the drive could
start immediately after an input voltage break or fault reset.
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.
Network security
This product is designed to be connected to and to communicate information
and data via a network interface. It is the customer’s sole responsibility to
provide and continuously ensure a secure connection between the product and
the customer network or any other network (as the case may be). The customer
shall establish and maintain any appropriate measures (such as but not limited
to the installation of firewalls, application of authentication measures,
encryption of data, installation of anti-virus programs, etc) to protect the
product, the network, its system and the interface against any kind of security
breaches, unauthorized access, interference, intrusion, leakage and/or theft of
data or information. ABB and its affiliates are not liable for damages and/or
losses related to such security breaches, any unauthorized access, interference,
intrusion, leakage and/or theft of data or information.
22 Safety
Introduction to the manual 23
2
Introduction to the manual
What this chapter contains
This chapter describes the manual. It contains a flowchart of steps for checking
the delivery, installation and start-up of the drive. The flowchart refers to
chapters/sections in this manual and to other manuals.
Applicability
This manual is applicable to MicroFlex e190 drives with the type code MFE190-
1
Target audience
This manual is intended for people who plan the installation, install, start-up,
use and service the drive. Read the manual before working on the drive. You are
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.
1. Supported firmware build version: Build 5903.4 onwards.
24 Introduction to the manual
Contents of this manual
The manual consists of the following chapters:
•
•
commissioning, operating and servicing the drive.
target audience, purpose and contents of this manual. It also contains a
quick installation and commissioning flowchart.
•
•
principle, connector layout, type designation label and type designation
information in short.
unpack, check the delivery and install the drive mechanically. It also provides
the dimensions of the drive.
•
•
AC supply, cabling and RCDs.
the installation of high power connections including the AC supply, motor
output, brake resistor, and optional DC supply / sharing.
•
power connections, including analog and digital input/outputs (including
Safe Torque Off), motor feedback and Ethernet.
•
•
physical installation has been completed correctly.
installing the Mint Workbench software, and tuning and optimizing the
motor/drive combination.
•
•
•
solution to common problems encountered during installation.
optimum performance from the drive.
e.g. ratings, technical specifications, and provisions for fulfilling the
requirements for CE and other markings.
•
•
•
•
the drive.
braking choppers and resistors.
the drive installation.
features, installation, and technical data.
26 Introduction to the manual
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.
Check the installation site.
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.
Route the cables.
Check the insulation of the supply cable,
the motor and the motor cable.
Connect the power cable.
Connect the motor cable.
Connect the control cables.
Check the installation.
Start the drive.
Introduction to the manual 27
Terms and abbreviations
The following units and abbreviations might appear in this manual.
General terms
Term
Explanation
/Abbreviation
EMC
IGBT
Electromagnetic Compatibility.
Insulated Gate Bipolar Transistor; a voltage-controlled
semiconductor type widely used in inverters due to their
easy controllability and high switching frequency.
I/O
Input/Output.
MU-xx
RFI
The memory unit attached to the control unit of the drive.
Radio-frequency interference.
RGJxxx
Series of optional braking resistors for the
MicroFlex e190.
Trademarks
®
EtherCAT is registered trademark and patented technology,
licensed by Beckhoff Automation GmbH, Germany.
®
PROFINET is defined by Profibus & Profinet International, an
umbrella organization headquartered in Karlsruhe, Germany.
Ethernet/IP™ is managed by ODVA, Inc., a global trade and
standards development organization.
Windows 7, Windows 8 and Windows 10 are registered trademarks of the
Microsoft Corporation.
®
Mint™ and MicroFlex are registered trademarks of Baldor, a member of the
ABB group.
28 Introduction to the manual
Operation principle and hardware description 29
3
Operation principle and
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.
Product overview
The MicroFlex e190 is an IP20 drive for controlling AC motors. It is to be installed
into a cabinet by the customer. The MicroFlex e190 is available with several
output power ratings.
32 Operation principle and hardware description
Main circuit
The diagram below shows the main circuit of the drive. For further information
on the power unit, see the chapter Electrical installation: AC input / DC input, motor
AC supply
1
1-phase or 3-phase supply
Mains choke (optional)
R+/UDC+ UDC-
L1 L2 L3
Mains filter
MicroFlex e190
~
2
=
+
–
3
5
=
4
Inverter
~
U
V
W
R-
R+/UDC+
Motor output
RGJxxx braking resistor
(optional)
1. AC supply. 1-phase 200...240 V or 3-phase 200...240 V phase-to-phase
(±10%).
2. Rectifier. Converts alternating current and voltage to direct current and
voltage.
3. DC link. DC circuit between rectifier and inverter.
4. Inverter. Converts direct current and voltage to alternating current and
voltage.
5. Brake chopper. Conducts the surplus energy from the intermediate DC
circuit of the drive to the brake resistor when necessary. The chopper
operates when the DC link voltage exceeds a certain maximum limit. The
voltage rise is typically caused by deceleration (braking) of a high inertia
motor. The user must obtain and install a brake resistor when needed.
Operation principle and hardware description 33
Type designation label
Before attempting installation and operation, check the information on the type
designation label to verify that the unit is of the correct type. The label is
located on the right-hand side of the drive.
Type code (see description below)
Materialcode
MFE190-04UD-03A0-2
*3AXD50000637096*
Input
U1 1 / 3 ~ 200. ..240 V AC
ABB Beijing Drive
Sy st em s Co., Lt d.
I1 7A
f1 50/60 Hz
No.1, Block D, A-10
Jiuxianqiao Beilu,
Chaoyang District,
Beij ing, P.R . Chi na
Compliance markings
Output U2 3 ~
U1
I2 3A
3A
Normal
200% 3s O verlo ad
2.5A 300% 3s O verl oad
f2 0...500Hz
Air cooling
IP2 0
Op en t ype
IE2 (90;100) 3.1%
Ic c 5 kA
S/N W203030001
I1 = Input current
I2 = Output current
Serial number
The first digit of the serial number refers to the manufacturing plant. The 2nd
and 3rd digits indicate the year of manufacture, while the 4th and 5th digits
indicate the week. The 6th digit indicates the rating. Digits 7 to 10 are a running
integer starting every week at 0001.
Type designation key
The type code contains information on the specifications and configuration of
the drive. The type code is explained in the following table. Not all selections are
necessarily available for all types; refer to MicroFlex e190 Ordering Information,
available on request.
MFE190-04UD-03A0-2
MicroFlex e190
MFE190
-04
Drive module
U
Universal encoder
Dual port PROFINET
D
Input voltage: 2 = 200...240 V AC ±10%
-03A0
-2
34 Operation principle and hardware description
Part number
Type code
Part number (order code)
3AXD50000637096
3AXD50000637102
3AXD50000637416
MFE190-04UD-03A0-2
MFE190-04UD-06A0-2
MFE190-04UD-09A0-2
Memory unit - MU
The memory unit defines the identity and features of the drive,
and holds the drive’s firmware and saved parameters. The
memory unit holds the Mint program on models with
programming capability. The memory unit is an essential part
of the drive and must always be fitted. It is not designed for
frequent removal and insertion.
All power to the drive must be turned off before removing or
inserting the memory unit.
The memory unit can be inserted into an identical replacement
drive. If the replacement drive does not have an identical
specification, it must be re-tuned before using the memory unit to the drive.
Retuning the drive using Mint Workbench allows the correct tuning parameters
to be saved in the memory unit.
The memory unit can be used only with MicroFlex e190 drives. It is not
compatible with any other product that uses a similar unit, e.g. ZMU-02. The
MicroFlex e190 memory unit can be identified by the part MFE190-MU-
OCU+N8020 on the label and provide motion programming capability.
The older drive is not provided with the MFE190-MU-OCU+N8020 (order code:
3AXD50000048603) memory unit. Contact your local supplier for details.
Mechanical installation 37
Main dimensions
MicroFlex e190 drives can be installed side by side. The main dimensions of the
drive and free space requirements are shown below.
*
Approximate dimensions. Allow extra
space for feedback and other control
cables.
Weights:
3 A:
6 A:
9 A:
1.70 kg (3.75 lb)
1.75 kg (3.86 lb)
1.75 kg (3.86 lb)
38 Mechanical installation
Cabinet construction
The cabinet frame must be sturdy enough to carry the weight of the drive
components, control circuitry and other equipment installed in it.
The cabinet must protect the drive against contact and meet the requirements
Cooling and degrees of protection
The cabinet must have enough free space for the components to ensure
sufficient cooling. Observe the minimum clearances given for each component.
90 mm [3.54”]
90 mm [3.54”]
0 mm [0”]
The air inlets and outlets must be equipped with gratings that
•
•
•
guide the air flow
protect against contact
prevent water splashes from entering the cabinet.
The temperature of the cooling air entering the unit must not exceed the
Mechanical installation 39
Technical data). Consider this when installing heat-generating components
(such as other drives and braking resistors) nearby.
The drawing below shows two typical cabinet cooling solutions. The air inlet is
at the bottom of the cabinet, while the outlet is at the top.
Air outlet
Air outlet
Air inlet
Arrange the cooling of the drives so that the requirements given in chapter
Technical data are met:
•
nominal load. If the load is less than nominal, less cooling air is required.
•
Allowed ambient temperature.
Make sure the air inlets and outlets are sufficient in size. Note that in addition to
the power loss of the drive, the heat dissipated by cables and other additional
equipment must also be ventilated.
The internal cooling fans of the drives are usually sufficient to keep the
component temperatures low enough in IP22 cabinets.
In IP54 cabinets, thick filter mats are used to prevent water splashes from
entering the cabinet. This entails the installation of additional cooling
equipment, such as a hot air exhaust fan.
The installation site must be sufficiently ventilated.
40 Mechanical installation
Disposition of the devices
For easy installation and maintenance, a spacious layout is recommended.
Sufficient cooling air flow, obligatory clearances, cables and cable support
structures all require space.
Preventing the recirculation of hot air
Air baffle plates
COOL AREA
Airflow in
Outside the cabinet
Prevent hot air circulation outside the cabinet by leading the outgoing hot air
away from the area where the inlet air to the cabinet is taken. Possible solutions
are listed below:
•
•
•
gratings that guide air flow at the air inlet and outlet
air inlet and outlet at different sides of the cabinet
cool air inlet in the lower part of the front door and an extra exhaust fan on
the roof of the cabinet.
Inside the cabinet
Prevent hot air circulation inside the cabinet with leak-proof air baffle plates. No
gaskets are usually required.
Mechanical installation 41
Grounding of mounting structures
Make sure all cross-members or shelves on which drive system components are
mounted are properly grounded and the connecting surfaces left unpainted.
Notes:
Ensure that the components are properly grounded through their fastening
points to the installation base. It is recommended that the mains filter (if
present) and the drive be mounted on the same mounting plate.
Cabinet heaters
Use a cabinet heater if there is a risk of condensation in the cabinet. Although
the primary function of the heater is to keep the air dry, it may also be required
for heating at low temperatures. When placing the heater, follow the
instructions provided by its manufacturer.
Installation procedure
Requirements for the installation site
The drive must be installed in an upright position with the mounting plate
against a wall. MicroFlex e190 drives can be installed tightly side by side. Make
sure that the installation site complies with these requirements:
•
•
•
The installation site has sufficient ventilation to prevent overheating of the
drive.
The operation conditions of the drive agree with the specifications in
The wall is vertical, not flammable and strong enough to hold the weight of
•
•
The material below the installation is not flammable.
There is enough free space above and below the drive for cooling air flow,
service and maintenance. There is enough free space in front of the drive for
operation, service and maintenance.
Required tools
•
•
•
•
Slot screwdrivers for the screw type connectors.
A drill and screws or bolts for mounting the MicroFlex e190.
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.
Planning the electrical installation 43
5
Planning the electrical
installation
What this chapter contains
This chapter contains the instructions that you must follow when selecting the
motor, cables, protections, cable routing and way of operation for the drive. If
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
Note: The installation must always be designed and made 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.
Motor selection
Select the (3-phase AC induction) motor according to the rating table in the
type.
Only one permanent magnet synchronous motor can be connected to the
inverter output. It is recommended to install a safety switch between the
permanent magnet motor and the drive output in order to isolate the motor
from the drive during maintenance work on the drive.
Supply connection
Use a fixed connection to the AC power line or DC supply. Alternatively, the drive
can be powered from a suitable fixed DC supply.
44 Planning the electrical installation
WARNING! As the leakage current of the device typically exceeds 3.5 mA, a
fixed installation is required according to EN 61800-5-1.
Supply disconnecting device
Install a hand-operated input 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.
Europe:
If the drive is used in an application which must 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 that has 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).
Other regions:
The disconnecting means must conform to the applicable safety regulations.
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.
Protection against short-circuit in motor cable
The drive protects the motor cable and the motor 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.
Protection against short-circuit in the supply cable or the drive
Protect the supply cable with fuses. Fuse recommendations are given in the
fuses or UL type CC fuses will 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.
Planning the electrical installation 45
Operating time of the fuses
Check that the operating time of the fuse is below 0.5 seconds. The operating
time depends on the type, the supply network impedance, and the cross-
sectional area, material and length of the supply cable. US fuses must be of the
CC “fast acting” type. Circuit breakers cannot be used with the MicroFlex e190
for UL compliant applications. Fuses must be used.
Motor thermal protection
According to regulations, the motor must be protected against thermal
overload and the current must be switched off when overloading 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
the Mint keyword MOTORTEMPERATUREINPUTin the Mint Workbench help file.
Ground fault protection
The drive is equipped with an internal ground fault protective function to
protect the unit against ground faults in the motor and the motor cable. This is
not a personal safety or a fire protection feature.
The optional mains filter includes capacitors connected between the main
circuit and the frame. These capacitors and long motor cables increase the
ground leakage current and may cause fault current circuit breakers to function.
Emergency stop devices
For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Note: Stopping motion and/or disabling the drive in software does not
separate the drive from dangerous potential.
Residual current device (RCD) compatibility
MicroFlex e190 drives are suitable to be used with residual current devices of
Type B. Other measures for protection in case of direct or indirect contact, such
as separation from the environment by double or reinforced insulation or
isolation from the supply system by a transformer, can also be applied.
46 Planning the electrical installation
Safe Torque Off
The drive supports the Safe Torque Off function according to standards
EN 61800-5-2; IEC 61800-5-2; EN 60204-1; EN 61508.
The Safe Torque Off function disables the control voltage of the power
semiconductors of the drive output stage, thus preventing the inverter from
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.
MicroFlex e190
X4:4
+24 V
Activation
switch
Safe Torque Off
connection
X4:1
X4:2
UDC+
Control
circuit
Output stage
(1 phase shown)
U/V/W
UDC-
Notes:
•
The STO function is activated when one or both of the safety circuit contacts open. If the period
between both contacts opening or closing exceeds a predefined value, a fault in the safety circuit
•
The maximum cable length between the drive and the activation switch is 30 m (98 ft).
WARNING! The Safe Torque Off 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.
Note: It is not recommended to stop the drive by using the Safe Torque Off
function. If a running drive is stopped by using the Safe Torque Off function, the
drive will stop by coasting. If this is not acceptable (e.g. causes danger), the
drive and machinery must be stopped using the appropriate stopping mode
before using this function.
Planning the electrical installation 47
For further information on the function, see Appendix: The Safe Torque Off (STO)
Selecting the power cables
General rules
Dimension the supply (input power) and motor cables according to local
regulations.
•
•
The cable must be able to carry the drive load current. See the chapter
Technical data for the rated currents.
The cable must be rated for at least 70 °C maximum permissible
temperature of conductor in continuous use. For UL installations use 75 °C
copper wiring only.
•
The conductivity of the PE conductor must be equal to that of a phase
conductor (i.e. same cross-sectional area).
•
•
600 VAC cable is accepted for up to 500 VAC.
Symmetrical shielded motor cable must be used (see the figure below) to meet
the EMC requirements of the CE mark.
A four-conductor system is allowed for input cabling, but shielded symmetrical
cable is recommended. Compared to a four-conductor system, the use of
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) must be kept as short as
possible in order to reduce electromagnetic emission.
48 Planning the electrical installation
Alternative power cable types
Power cable types that can be used with the drive are represented below.
Motor cable
(also recommended for supply cabling)
Symmetrical shielded cable: three phase conductors Note: A separate PE conductor is
and a concentric or otherwise symmetrically
constructed PE conductor, and a shield.
required if the conductivity of the
cable shield is not sufficient for the
purpose.
PE conductor
and shield
Shield
Shield
PE
PE
Shield
Allowed for supply cabling
A four-conductor system: three phase
conductors and a protective conductor.
PE
PE
Motor cable shield
To function as a protective conductor, the shield must have the same cross-
sectional area as a phase conductor 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 aluminum shield. The
minimum requirement of the motor cable shield of the drive is shown below. It
consists of a concentric layer of copper wires with an open helix of copper tape.
The better and tighter the shield, the lower the emission level and the bearing
currents.
Insulation jacket
Copper wire screen Helix of copper tape
Inner insulation
Cable core
Selecting the control cables
It is recommended that all control cables be shielded.
Double-shielded twisted pair cable is recommended for analog signals. For
pulse encoder cabling, follow the instructions given by the encoder
Planning the electrical installation 49
manufacturer. Use one individually-shielded pair for each signal. Do not use a
common return for different analog signals.
Double-shielded cable (Figure a) is the best alternative for low-voltage digital
signals but single-shielded twisted multi-pair cable (Figure b) is also usable.
a
b
Run analog and digital signals in separate cables.
Never mix 24 VDC and 240 VAC signals in the same cable.
Connection of a motor temperature sensor to the drive
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several
drives can be run in parallel installed next to each other. It is recommended that
the motor cable, input power cable and control cables be installed on separate
trays. Avoid long parallel runs of motor cables with other cables in order to
decrease electromagnetic interference caused by the rapid changes in the drive
output voltage.
Where control cables must cross power cables make sure they are arranged at
an angle as near to 90 degrees as possible. Do not run extra cables through the
drive.
The cable trays must have good electrical bonding to each other and to the
grounding electrodes. Aluminum tray systems can be used to improve local
equalizing of potential.
50 Planning the electrical installation
A diagram of the cable routing:
Supply cable
Supply cable
Motor cable
min 200 mm (8”)
90°
min 300 mm (12”)
Control cables
Drive
min 500 mm (20”)
min 500 mm (20”)
Braking resistor cable
Motor cable
90°
90°
Control cable ducts
24 V 240 V
24 V 240 V
Lead 24 V and 240 V control cables
in separate ducts inside the cabinet.
Not allowed unless the 24 V cable is
insulated for 240 V or insulated with
an insulation sleeving for 240 V.
Planning the electrical installation 51
Typical installation example
Footprint filter OFI-01 saves
panel space.
The filter can be inverted if
the AC input is above the
drive.
DO NOT TOUCH!
Brake resistors can become
CAUTION
extremely hot! Locate away from
vulnerable components and wiring.
Protective
Earth
(PE)
Drive earth wire
must be at least
2
10 mm (7 AWG)
Connect AC power cable shield to metal panel, using
conductive shield earth/ground clamps.
On painted panels, remove paint to expose bare metal.
AC power wires should be as short as possible, typically
less than 0.3 m (1 ft).
Installation
cabinet
‘star point’
Longer wires must be shielded as shown.
Wire colors may vary according to region.
AC power
from fuses
or reactor
52 Planning the electrical installation
Electrical installation: AC input / DC input, motor and brake 53
6
Electrical installation:
AC input / DC 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
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.
54 Electrical installation: AC input / DC input, motor and brake
Checking the insulation of the assembly
Drive
Do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or
megger) on any part of the drive as testing can damage the drive. Every drive
has been tested for insulation between the main circuit and the chassis at the
factory. Also, there are voltage-limiting circuits inside the drive which cut down
the testing voltage automatically.
Supply cable
Check the insulation of the supply (input) 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:
•
Check that the motor cable is connected to the motor, and disconnected
from the drive output terminals U, V and W.
•
Measure the insulation resistance between each phase and the motor PE
conductor by using a measuring voltage of 1 kV DC. The insulation resistance
must be higher than 1 MΩ.
U
M
V
3~
Ω
W
PE
Braking resistor assembly
Check the insulation of the braking resistor assembly (if present) as follows:
1. Check that the resistor cable is connected to the resistor, and disconnected
from the drive output terminals R- and R+.
2. At the drive end, connect the R- and R+ conductors of the resistor cable
together. Measure the insulation resistance between the combined
conductors and the PE conductor by using a measuring voltage of 1 kV DC.
The insulation resistance must be higher than 1 MΩ.
R-
R+
Ω
PE
Electrical installation: AC input / DC input, motor and brake 55
Power cable connection
AC power cable connection diagram
L1/L L2/N L3
PE
For alternatives, see Planning the
Mains filter (optional). See the
(1)
The UDC+/UDC- connectors can be
used for common DC
MicroFlex e190
L1/L L2/N L3
(3)
PE
W
UDC- UDC+
R-
R+ PE
PE
(2)
U
V
V
U
PE
W
Optional braking
resistor (see the
chapter Resistor
Notes:
•
•
•
If shielded supply (input) cable is used, and the conductivity of the shield is less than 50% of
the conductivity of a phase conductor, use a cable with a ground conductor or a separate PE
cable (1).
For motor cabling, use a separate ground cable (2) if the conductivity of the cable shield is
less than 50% of the conductivity of a phase conductor and the cable has no symmetrical
AC supply (3), 1-phase 200...240 V (±10%) or 3-phase 200...240 V phase-to-phase (±10%). L1
and L2 are used for single phase supply.
56 Electrical installation: AC input / DC input, motor and brake
Procedure
1. Strip the power cables so that the shields are bare at the cable clamps.
2. Twist the ends of the cable shield wires into pigtails.
3. Strip the ends of the phase conductors.
4. Connect the phase conductors of the supply cable to the L1 and L2 terminals
of the drive (or L1, L2 and L3 for three phase supply).
Connect the phase conductors of the motor cable to the U, V and W
terminals.
Connect the conductors of the resistor cable (if present) to the R- and R+
terminals.
5. Tighten the cable clamps onto the bare cable shields.
6. Crimp a cable lug onto each shield pigtail. Fasten the lugs to ground
terminals.
Note: Try to work out a compromise between the length of the pigtail and
the length of unshielded phase conductors as both should ideally be as short
as possible.
7. Cover visible bare shield and pigtail with insulating tape.
8. Secure the cables outside the unit mechanically.
9. Ground the other end of the supply cable shield or PE conductor(s) at the
distribution board. In case a mains choke and/or a mains filter is installed,
make sure the PE conductor is continuous from the distribution board to the
drive.
Grounding the motor cable shield at the motor end
For minimum radio frequency interference, ground the cable shield 360 degrees
at the lead-through of the motor terminal box or ground the cable by twisting
the shield so that the flattened shield is wider than 1/5 of its length.
360 degrees grounding
Conductive gaskets
b
a
b > 1/5 · a
Electrical installation: AC input / DC input, motor and brake 57
AC power cable connection
Supply cable
Cable clamp on bare shield
Cover bare shield with
insulating tape
0.5...0.6 N·m (4.4...5.3 lbf·in)
M4, 10 mm max.
1.0...1.3 N·m (8.9...11.5 lbf·in)
0.5...0.6 N·m (4.4...5.3 lbf·in)
Motor earth wire
M4, 10 mm max.
1.0...1.3 N·m (8.9...11.5 lbf·in)
Cable clamp on bare shield
Motor cable
58 Electrical installation: AC input / DC input, motor and brake
DC power cable connection diagram (optional)
The UDC+ and UDC- terminals are intended for common DC configurations of a
number of MicroFlex e190 drives.
AC supply (DC sharing)
DC sharing allows regenerative energy from one drive to be utilized by other
drives that are in motoring mode. Each drive is connected to the AC supply* and
has its own brake resistor. The MicroFlex e190 drives’ DC connections are linked
as shown in the diagram below.
AC supply
UDC+
UDC-
UDC+
UDC-
UDC+
UDC-
~
~
~
~
~
~
Fuses
M
3~
M
3~
M
3~
* The MicroFlex e190 DC connection is not designed to provide the primary
power source to other drives.
DC supply
Each drive is powered from the DC supply and has its own brake resistor. There
is no AC supply.
DC supply
Fuses
UDC+
UDC-
UDC+
UDC-
UDC+
UDC-
~
~
~
~
~
~
M
3~
M
3~
M
3~
Electrical installation: AC input / DC input, motor and brake 59
Each drive has an independent DC capacitor pre-charging circuit.
UDC+ UDC-
L1 L2 L3
~
=
+
–
Pre-charging circuit
=
~
U
V
W
60 Electrical installation: AC input / DC input, motor and brake
24 V control circuit supply (optional)
A 24 V DC supply can be provided to power the controlling electronics. This is
useful for safety reasons where the main AC (or DC) power supply is removed
from the power stage, but the controlling electronics must remain powered to
retain position, I/O information and communications.
A separate fused 24 V supply should be provided for the MicroFlex e190.
Customer supplied
24 V DC
Fuse *
+24 V
GND
Use a twisted pair cable.
X2
* Recommended fuse: Bussman S504 20 x 5 mm anti-surge 2 A.
Electrical installation: AC input / DC input, motor and brake 61
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 a digital output on connector X3; see
MicroFlex e190 to control the motor's brake. A typical circuit is shown in the
following diagram:
User
supply
V+
User
supply
GND
X3
from motor brake
connections
Relay
DO2+ 12
The inner shield
surrounding the
DO2-
2
brake wires should be
earthed/grounded at
one point only.
+24 V
0 V
The relay has normally open
contacts and is shown
deactivated (contacts open,
brake engaged).
Separate
customer
supplied
24 V DC supply
This circuit uses DO2 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 Mint keyword MOTORBRAKEDELAY.
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 e190 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
62 Electrical installation: AC input / DC input, motor and brake
motor brake can also be used to power the relay in the thermal switch circuit
(see below).
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. This allows the MicroFlex
e190 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 MOTORTEMPERATUREINPUTcan also be
used to configure a digital input for this purpose. A typical circuit, using DI2 as
the input, is shown in the following diagram:
The relay has normally open contacts
X3
and is shown deactivated (contacts
open, motor overheated).
DI2+
14
motor
thermal
switch
DI2-
4
+24 V
0 V
+24 V
0 V
Separate
customer
supplied
Customer
supplied
24 V DC
supply
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.
Electrical installation: input / output 63
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
AI
AO
DI
Input / Output
Analog Input
Analog Output
Digital Input
DO
STO
Digital Output
Safe Torque Off
WARNING! The work described in this chapter may only be carried out by
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.
64 Electrical installation: input / output
Connecting the control cables
E1/E2
Ethernet fieldbus
IN
OUT
E2
E1
X1A
1
2
3
E2
E1
L1
L2
L3
AC input
200...240 V AC ±10%
DC bus-
Brake-
UDC-
R-
4
5
DC bus+ / Brake+
R+/UDC+
6
X1B
1
2
U
V
M
Motor output
W
3
E3
1
Ethernet host (PC)
X1A
X1B
X3
X3
11
E3
Status-/DO0-
DO2-
DO1-
Status-/DO0+
DO2+
DO1+
DI2+
1
2
X3
X4
12
13
14
15
16
17
3
4
5
DI2-
X8
DI3-
DI3+
6
7
DI1-
DI1+
DI0-
DI0+
X2
8
9
10
AGND
AI0-
AO0
18
19
20
AI0+
X7
Shield
Shield
Feedback voltage
selector
DO0-DO2: Maximum 100 mA per output, R
> 250 Ω.
load
AI0: Differential and single-ended connections are possible.
Wire sizes and tightening torques:
X4
1
X4
5
X1A: Dinkle EC762V-B3253206P-BK
STO1
STO2
STO1
STO2
X1B: Dinkle EC762V-B3253203P-BK
2
0.2...6.0 mm (30*...10 AWG)
2
3
4
6
7
* Minimum size for UL installations is 14 AWG.
Torque: 0.7 N·m (6.2 lbf·in)
X2: Phoenix Contact MVSTBR 2,5HC/ 2-ST-5,08
SGND
SGND
2
0.2...2.5 mm (24...12 AWG)
Torque: 0.6 N·m (5.3 lbf·in)
24 V out
24 V out
8
X3, X4: Weidmüller B2L 3.50/20/180,
Weidmüller B2L 3.50/8/180
2
0.2...1.0 mm (28...16 AWG)
Safe Torque Off: Both circuits must be closed for the drive to start.
Notes:
The wiring shown is for demonstrative
purposes only. Complete information for all
connectors, including X7 and X8, is provided in
X2
1
2
0 V
+24 V IN
(Optional) Control circuit
supply input: 24 V, 1 A
Electrical installation: input / output 65
Analog I/O
The MicroFlex e190 provides:
•
•
One 12-bit resolution ±10 V analog input.
One 12-bit resolution ±10 V analog output.
An analog input receives the torque / velocity reference signal when operating
as an analog drive (see CONTROLREFSOURCEin the Mint help file) or it can be
used as a general purpose ADC input.
X3: Analog input AI0
The analog input passes through a differential buffer and second order low-
pass filter with a cut-off frequency of approximately 1.2 kHz.
The analog input can be connected as either a differential or a single ended
input as shown below. The analog input is not optically isolated from internal
power rails, so care must be taken to avoid earth/ground loops and similar
associated problems. To minimize the effects of noise, the analog input signal
should be connected to the system using an individually shielded twisted pair
cable with an overall shield. The overall shield should be connected to the
chassis at one end only. No other connection should be made to the shield.
When the MicroFlex e190 is connected to Mint Workbench, the analog input
value (expressed as a percentage) can be viewed using the Spy window’s
Monitor tab. Alternatively, the command Print ADC(0)can be used in the
command window to return the value of the analog input. See the Mint help file
for full details of ADC, ADCMODEand other related ADC... keywords.
Differential inputs: connect input to AIN+ and AIN-. Leave AGND unconnected:
X3
X3
AIN0+
AIN0-
AIN0+
GND
19
19
AI0
(ADC.0)
AI0
(ADC.0)
9
8
9
8
Differential connection
Single ended connection
66 Electrical installation: input / output
Typical input circuit to provide 0-10 V (approx.) input from a 24 V source:
+24 V DC
ꢀꢁꢂꢃNȍꢄꢃꢅꢁꢆꢂꢃ:
X3
ꢀꢃNȍꢄꢃꢅꢁꢆꢂꢃ:
potentiometer
19
AI0
(ADC.0)
0 V
9
8
Analog input - typical connections from a PLC/controller:
PLC/controller
MicroFlex e190
+15V
X3
AI0+
AI0-
19
9
Mint
ADC.0
-15V
Shield
Connect overall shield at
one end only
Analog input - typical connections from an ABB AO561:
AO561
MicroFlex e190
+15V
X3
O0U+
O01-
AI0+
AI0-
13
17
19
9
Mint
ADC.0
-15V
SG
18
Connect overall shield at
one end only
Electrical installation: input / output 67
X3: Analog output AO0
The analog output can be used to drive loads of 1 k? 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 DACkeyword.
See the Mint help file for full details of DACand other related DAC... keywords.
Analog output - typical connections to a PLC/controller:
PLC/controller
MicroFlex e190
X3
AO0
AI+
AI-
18
8
GND
Shield
10
Connect overall shield at
one end only
Analog output - typical connections to an ABB AI523:
AI523
MicroFlex e190
X3
AO0
I0+
I0-
18
8
2.0
1.0
GND
Shield
10
Connect overall shield at
one end only
68 Electrical installation: input / output
Digital I/O
The MicroFlex e190 provides:
•
•
•
4 general purpose digital inputs.
2 dedicated Safe Torque Off (STO) inputs.
3 general purpose digital outputs.
6 additional general purpose digital inputs and 4 additional general purpose
X4: Digital inputs - Safe Torque Off (STO) inputs
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 e190 to supply power to the motor. If an additional hardware
drive enable input is used to control the MicroFlex e190, 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 or via the Mint SAFETORQUEOFF keyword. See the
X3: Digital inputs - general purpose DI1 & DI2
These general purpose fast digital inputs are buffered by an opto-isolator,
allowing the input signal to be connected with either polarity. When the
MicroFlex e190 is connected to Mint Workbench, the digital inputs can be
configured using the Digital I/O tool. Alternatively, Mint keywords including
RESETINPUT, ERRORINPUT, STOPINPUT, FORWARDLIMITINPUT,
REVERSELIMITINPUT, DRIVEENABLEINPUT, MOTORTEMPERATUREINPUT,
PHASESEARCHINPUTand HOMEINPUTcan 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.
Electrical installation: input / output 69
Digital input - typical connections from a PLC/controller:
User
supply
24 V
PLC/controller
MicroFlex e190
X3
DI1+
16
TLP118
DI1-
6
Shield
10
User
supply GND
Digital input - typical connections from an ABB DO561 PLC output module:
User
supply
24 V
DO561
MicroFlex e190
X3
UP
O0
19
11
DI1+
16
TLP118
ZP
DI1-
6
20
Shield
10
User
supply GND
X3: Digital inputs - Special function DI1 & DI2
DI1 and DI2 can be configured to perform special functions. The ENCODERMODE
keyword controls the configuration. When operating as an encoder input or
step and direction inputs, DI1 and DI2 can be used for a dual-loop feedback
system or connected to a master encoder for position following applications
(see the FOLLOW, FLYand CAMkeywords in the Mint help file).
Fast latch input
(ENCODERMODEbit 2 = 0)
DI1 or DI2 can be configured using the LATCHTRIGGERCHANNELkeyword to
become a fast latch input. This allows the position of the axis to be captured in
real-time and read using the Mint keyword LATCHVALUE. The input can be
configured using the LATCHTRIGGEREDGEkeyword to be triggered either on a
70 Electrical installation: input / output
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 ?s, resulting from the 16 kHz
sampling frequency used for these types of feedback device. The fast interrupt
is latched on a pulse width of about 30 ?s, although a width of 100 ?s 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.
Encoder input
(ENCODERMODEbit 2 = 0)
Whilst operating as general purpose digital inputs, DI1 and DI2 are
simultaneously interpreted by the drive as an additional quadrature (CHA, CHB)
incremental encoder input. DI1 is CHA and DI2 is CHB. In Mint, the input formed
by digital inputs DI1 and DI2 is encoder 1. The encoder value can be read using
the ENCODERkeyword.
Step (pulse) and Direction inputs
(ENCODERMODEbit 2 = 1)
If ENCODERMODEbit 2 is set, DI1 and DI2 are interpreted as step and direction
inputs. In Mint, the input formed by digital inputs DI1 and DI2 is channel
(encoder) 1.
•
DI1 is used as the step input. The step frequency controls the speed of the
motor.
•
DI2 is used as the direction input. The state of the direction input controls
the direction of motion. The motor direction itself can be reversed if
necessary via the MOTORDIRECTIONMint keyword.
The controller providing the step and direction signals may use current sourcing
/ open emitter outputs or it may use current sinking / open collector outputs.
In both cases it is still vital to ensure twisted pairs are used for these signals
(twist the signal for DIN1+ with the signal for DIN1- and twist the signal for
DIN2+ with the signal for DIN2-).
Electrical installation: input / output 71
Step and direction inputs - typical connections from a PLC/controller using
open emitter outputs:
PLC/Controller
MicroFlex e190
User
supply
24 V
Step
Output
X3
Step
Twisted pairs
Step
DI1+
16
User
supply
24 V
TLP118
DI1-
6
Shield
10
Direction
Output
User
supply
GND
Direction
TLP118
Dir
Twisted pairs
DI2+
14
DI2-
4
Shield
10
User
supply
GND
72 Electrical installation: input / output
Step and direction inputs - typical connections from a PLC/controller using
open collector outputs:
PLC/Controller
MicroFlex e190
User
supply
24 V
X3
Step
Twisted pairs
DI1+
16
TLP118
DI1-
Step
Step
Output
6
Shield
10
User
supply
24 V
GND
Direction
TLP118
Twisted pairs
DI2+
14
Dir
DI2-
Direction
Output
4
Shield
10
GND
GND
User
supply
GND
Electrical installation: input / output 73
X3: Digital inputs - general purpose DI0 & DI3
These general purpose digital inputs are buffered by an opto-isolator, allowing
the input signals to be connected with either polarity. When the MicroFlex e190
is connected to Mint Workbench, the digital inputs can be configured using the
Digital I/O tool. Alternatively, Mint keywords including RESETINPUT,
ERRORINPUT, STOPINPUT, FORWARDLIMITINPUT, REVERSELIMITINPUT,
DRIVEENABLEINPUT, MOTORTEMPERATUREINPUT, PHASESEARCHINPUTand
HOMEINPUTcan 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.
Digital input - typical connections from a PLC/controller:
User
supply
24 V
PLC/controller
MicroFlex e190
X3
DI0+
DI0-
17
7
User
supply
GND
Digital input - typical connections from an ABB DO561 PLC output module:
User
supply
24 V
DO561
MicroFlex e190
X3
UP
O0
19
11
DI0+
DI0-
17
7
ZP
20
User
supply
GND
74 Electrical installation: input / output
Digital input - typical current sourcing connections to a digital input:
User
supply
24 V
MicroFlex e190
X3
DI0+
DI0-
17
7
User
supply
GND
X3: Digital inputs - special function DI0 & DI3
Drive enable input
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. AC500) although it does not provide any of the formal
enable input is configured using the Digital I/O tool in Mint Workbench.
Home switch input
If homing is being handled locally by the MicroFlex e190, the axis home switch
(if present) must be wired directly to the home input on the MicroFlex e190,
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 HOMEINPUTkeyword. 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 three options. The choice depends on
the accuracy required for the homing and the EtherCAT cycle-time:
•
The axis home switch is wired to an input on the MicroFlex e190, and then
mapped back to the master over EtherCAT;
•
•
The home switch is wired directly to the EtherCAT master;
The home switch is wired to one of the fast inputs (DI1 / DI2), and the master
(or the manager node) enables the drive’s touch probe function. See the
Mint Workbench help file for details.
Electrical installation: input / output 75
X3: Digital outputs - general purpose DO0 - DO3
The general purpose digital outputs are optically isolated. They source current
from the user supply as shown below. The maximum saturated voltage across
the outputs when active is 1.0 V DC, so it can be used as a TTL compatible
output.
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 or any other inductive
load, a suitably rated diode must be fitted across the load, observing the
correct polarity. This is to protect the output from the back-EMF generated by
the load when it is de-energized.
When the MicroFlex e190 is connected to Mint Workbench, the active level of the
output can be configured using the Digital I/O tool. Alternatively, the Mint
keyword OUTPUTACTIVELEVELcan be used in the command window. Other
Mint keywords such as COMPAREOUTPUT, GLOBALERROROUTPUT,
DRIVEENABLEOUTPUTand MOTORBRAKEOUTPUTcan be used to configure the
output. The state of the digital outputs can be viewed using the Mint
Workbench Spy window Axis tab.
Digital output - typical connections to a PLC/controller:
User
supply
24 V
PLC/controller:
MicroFlex e190
X3
DO1+
DO1-
13
3
User
supply
GND
76 Electrical installation: input / output
Digital output - typical connections to an ABB DI561 PLC input module:
User
supply
24 V
DI561
MicroFlex e190
X3
DO1+
DO1-
13
3
I0
2
1
C0..7
User
supply
GND
X3: Digital outputs - special function DO0 - DO3
The general-purpose digital outputs can be assigned to special purpose
functions. If an output has been assigned to one special purpose function, it
cannot be assigned to other sepcial purpose function at the same time.
Global error output
By default DO0 is configured as a global error output. Use the Digital I/O tool or
the Mint command GLOBALERROROUTPUT = -1to release the output for other
purposes.
When an asynchronous error occurs, Mint can deactivate a digital output (or
relay) known as the global error output. The output is assigned with the
GLOBALERROROUTPUTkeyword. The output is deactivated as soon as the error
occurs on any axis - it does not wait for any assigned default action to be
completed.
Drive enable ready output
A general-purpose digital output can be configured as a ‘drive enable ready
indication output’ by using the parameter DriveEnableReadyOutput(P12.4),
or by using the Mint DRIVEENABLEREADYOUTPUTkeyword in Mint Workbench.
The Mint DRIVEENABLEREADYkeyword returns true(1) or false(0) to indicate if
the drive axis is ready to be enabled. When the DRIVEENABLEREADY is true, the
assigned digital output will be high level, otherwise the digital output will be
low level.
Target position reached output
A general-purpose digital output can be configured as a ‘target position
reached indication output’ by using the parameter TargetPosReachedOutput
(P12.5), or by using the Mint TARGETPOSREACHEDOUTPUTkeyword in Mint
Workbench.
Electrical installation: input / output 77
How to determine when the drive has reached the target position value:
•
Remote control: DS 402 mode of operation is profile position mode,status
word (object 6041h) Bit10 is true and control word (object 6040h) Bit8 is
false.
•
Direct control: Control mode is position control (CONTROLMODE=3) and the
Keyword IDLEis true.
After the above conditions are met, the assigned digital output is high level,
otherwise the digital outputs low level.
Target velocity reached output
A general purpose digital output can be configured as a ‘target velocity reached
indication output’ by using the parameter TargetVelReachedOutput(P12.7),
or by using the Mint TARGETVELREACHEDOUTPUTkeyword in Mint Workbench.
How to determine when the drive has reached the target velocity value and keep
constant speed:
•
Remote control: DS 402 mode of operation is profile velocity mode,status
word (object 6041h) Bit10 is true and contrl word (object 6040h)Bit8 is false.
•
Direct control: Control mode is velocity control (CONTROLMODE=2) and the
keyword MOVESTATUSbit3 is true.
After the above conditions are met, the assigned digital output is high level,
otherwise the digital outputs low level.
Home completed output
A general-purpose digital output can be configured as a ‘home completed
indication output’ by using the parameter HomeCompleteOutput(P12.6), or by
using the Mint HOMECOMPLETEOUTPUTkeyword in Mint Workbench.
How to determine when the drive has completed the homing process:
•
Remote control: DS 402 mode of operation is homing mode and the status
word (object 6041h) Bit10 is true.
•
Direct control: The keyword HOMESTATUSis true.
After the above conditions are met,the assigned digital output is high level,
otherwise the digital outputs low level.
78 Electrical installation: input / output
Other I/O
X2: External power supply for the control unit (optional)
An external +24 V, 1 A power supply for the control board can be connected to
terminal block X2. Using an external supply is recommended if:
•
the application requires fast start after connecting the drive to the main
input supply.
•
fieldbus communication is required when the main input supply is
disconnected.
SW1 linear switches - startup functions
The linear switches are read once at startup.
1: Selects normal IP address configuration, or a fixed IP address. The fixed IP
address (192.168.0.1) allows the drive to be accessed if the software assigned IP
address is not known.
Software assigned IP address
Fixed IP address 192.168.0.1
2
1
2
1
2: Selects normal operation or firmware recovery mode. Recovery mode allows
new firmware and other configuration files to be downloaded. The fixed IP
address 192.168.0.1 is enabled and the symbol is displayed. Mint Workbench
allows you to update firmware and view the file system.
Normal operation
Recovery mode
2
1
2
1
Electrical installation: input / output 79
Control cable grounding
The shields of all control cables must be grounded at the earth bar. Use M4
screws to fasten cable clamps.
The shields should be continuous as close to the terminals as possible. Only
remove the outer jacket of the cable at the cable clamp so that the clamp
presses on the bare shield. At the terminal block, use shrink tubing or insulating
tape to contain any stray strands. The shield (especially in case of multiple
shields) can also be terminated with a lug and fastened with a screw at the
earth bar. Leave the other end of the shield unconnected or ground it indirectly
via a few nanofarads high-frequency capacitor (e.g. 3.3 nF / 630 V). The shield
can also be grounded directly at both ends if they are in the same ground line
with no significant voltage drop between the end points.
Keep any signal wire pairs twisted as close to the terminals as possible.
Twisting the wire with its return wire reduces disturbances caused by inductive
coupling.
Use shrink tubing or tape to contain
strands
Remove outer jacket of cable at clamp to
expose cable shield
Earth bar
M4, 10 mm, 1.0...1.3 N·m (8.9...11.5 lbf·in)
80 Electrical installation: input / output
Ethernet ports
E1 / E2: Real-time Ethernet port
Pin 1
1
2
3
4
5
6
7
8
TX+
TX-
RX+
(NC)
(NC)
RX-
Link
Activity
(NC)
(NC)
The E1 and E2 Ethernet ports on the top panel of the MicroFlex e190 are used for
real-time Ethernet fieldbus connections such as EtherCAT®, Ethernet
POWERLINK® and PROFINET®. For full details about the fieldbus connections,
see the Mint Workbench help file.
In an EtherCAT network the E2 (IN) port must be connected to the master side
of the network. The E1 (OUT) port, if used, must be connected to the IN port of
the next slave device in the network. Set both front panel rotary HI / LO
switches to 0 to select EtherCAT slave mode.
In an Ethernet POWERLINK and PROFINET network the connectors are identical.
indicators.
EtherCAT connections:
EtherCAT master
Electrical installation: input / output 81
E1 / E2: Ethernet port configuration
The rotary switches are read once at startup. The switches select the mode of
operation for the E1 and E2 Ethernet fieldbus connectors on the top panel of the
Value
Mode
00
EtherCAT slave mode
Ethernet POWERLINK CN mode: selected value is node ID
Reserved
PROFINET slave mode
Reserved
01-EF
F0-F1
F2
F3-FF
E3: Ethernet host
The Ethernet host port is used to connect a PC for configuring the
PC’s Ethernet adapter for communication with the MicroFlex e190.
The host port also can be used for Modbus TCP, Ethernet/IP and PROFINET
fieldbus connections.
Note: E3 port supports PROFINET when rotary switches are set to 00-EF. E1 and
E2 ports support PROFINET when rotary switches are set to F2.
82 Electrical installation: input / output
Motor feedback (X8)
MicroFlex e190 supports incremental encoder, EnDat 2.1, SinCos, BiSS-B (Bi-
directional Synchronous Serial Interface), SSI (Synchronous Serial Interface),
EnDat 2.2, Smart Abs absolute encoder or Hiperface feedback, for use with
linear and rotary motors. Resolvers are supported by using the optional resolver
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
be used to simplify linear feedback connections.
•
A maximum combined total of 500 mA can be supplied by X8 pin 12 and X7
pin 9 to feedback devices. Self-resetting fuses protect the 5.5 / 8-12 V supply
on X8 and the 5.5 V supply on X7.
Connection summary
Inc.encoder
Pin
EnDat
2.1
SinCos
BiSS-B,
SSI
EnDat 2.2
Smart
Abs
Hiperface
with Halls
CHA+
CHB+
CHZ+
(NC)
1
2
Data+
Clock+
(NC)
(NC)
(NC)
(NC)
(NC)
Sin-
Data+
Clock+
(NC)
Data+
Clock+
(NC)
Data+
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
Data-
(NC)
(NC)
Data+
(NC)
(NC)
(NC)
Sin-
3
4
(NC)
(NC)
(NC)
5
Hall U-
Hall U+
Hall V-
Hall V+
CHA-
Sin-
(NC)
(NC)
6
Sin+
Sin+
Cos-
Cos+
(NC)
(NC)
(NC)
(NC)
(NC)
Sin+
Cos-
Cos+
Data-
(NC)
(NC)
7
Cos-
(NC)
(NC)
8
Cos+
Data-
Clock-
(NC)
(NC)
(NC)
1
8
9
9
Data-
Clock-
(NC)
Data-
Clock-
(NC)
10
11
12
13
14
15
CHB-
CHZ-
15
+5.5 V out +5.5 V out +5.5 V out +5.5 V out +5.5 V out +5.5 V out +8 V out*
DGND
Hall W-
Hall W+
DGND
(NC)
DGND
(NC)
DGND
(NC)
DGND
(NC)
DGND
(NC)
DGND
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
Electrical installation: input / output 83
Twisted pairs must be used for each complementary signal pair e.g. CHA+ and
CHA-or Data+ and Data-.
The overall cable shield (screen) must be connected to the metallic shell of the
D-type connector.
In Mint Workbench, the primary motor feedback encoder on connector X8 is
encoder 0. The extra incremental encoder input formed by digital inputs DI1 and
Incremental encoder with Halls
The incremental encoder connections (ABZ channels and Hall signals) are made
using the 15-pin D-type female connector X8. The encoder inputs (CHA, CHB and
CHZ) accept differential signals only. Twisted pairs must be used for each
complementary signal pair e.g. CHA+ and CHA-. The Hall inputs may be used as
differential inputs (recommended for improved noise immunity) or single
ended inputs. When used as single ended inputs, leave the Hall U-, Hall V- and
Hall W- pins unconnected. The overall cable shield (screen) must be connected
to the metallic shell of the D-type connector. The encoder supply on pin 12
typically provides 5.5 V to the encoder (500 mA maximum, less if other encoder
Motor
Twisted pairs
X8
1
CHA+
CHA-
9
CHB+
CHB-
CHZ+ (INDEX)
CHZ- (INDEX)
Encoder
Feedback
2
10
3
11
+5.5 V out
DGND
12
13
6
Hall U+
Hall U-
Hall V+
Hall V-
Hall W+
Hall W-
5
Hall
Feedback
8
7
15
14
Connect overall
shield to connector
backshells
84 Electrical installation: input / output
Serial interfaces & SinCos
The MicroFlex e190 supports the following feedback types, for use with linear
and rotary motors:
•
•
•
EnDat 2.1
SinCos encoders (1 V pk-pk, 2.5 V reference)
BiSS-B (Bi-directional Synchronous Serial Interface), SSI (Synchronous Serial
Interface) or EnDat 2.2
•
•
Smart Abs absolute encoders
Hiperface
Twisted pairs must be used for each complementary signal pair e.g. CHA+ and
CHA-or Data+ and Data-. Maximum cable length is 30 m.
The overall cable shield (screen) must be connected to the metallic shell of the
D-type connector. The encoder supply on pin 12 provides either 5.5 V or 8-12 V to
the encoder, selected using the switch behind connector X7 (500 mA maximum,
WARNING! Check the feedback device’s power input specifications before
using the 8 V position. Selecting the wrong voltage could damage your
feedback device. Typically 8 V is only used when using a Hiperface
encoder.
5 V
8 V
(Default)
Electrical installation: input / output 85
EnDat interface
Incremental and absolute (multi and single turn) devices are supported. It is
possible to read and write information to the encoder. The Sin and Cos channels
are not required when using a version 2.2 EnDat encoder.
EnDat 2.1 interface cable connections:
Motor
X8
Twisted pairs
1
9
5
6
7
8
2
Data+
Data-
Sin-
Absolute
Encoder
Sin+
Cos-
Cos+
Clock+
10 Clock-
12 +5.5 V out
13 DGND
Connect
internal
shields to
pin 13.
Connect overall shield to
connector backshells
SinCos interface
SinCos interface cable connections:
Motor
X8
Twisted pairs
5
6
7
8
Sin-
Sin+
Cos-
SinCos
Feedback
Cos+
12 +5.5 V out
13 DGND
Connect
internal
shields to
pin 13.
Chassis
Connect overall shield to
connector backshells
BiSS-B interface
The BiSS-B (Bi-directional Serial Synchronous interface) is an open-source
interface that can be used with many types of absolute encoder.
BiSS-B interface cable connections:
Motor
Absolute
Encoder
X8
Twisted pairs
1
9
2
Data+
Data-
Clock+
10 Clock-
12 +5.5 V out
13 DGND
Connect
internal
shields to
pin 13.
Chassis
Connect overall shield to
connector backshells
86 Electrical installation: input / output
SSI encoders
SSI interface cable connections:
Motor
X8
Twisted pairs
Absolute
Encoder
1
9
2
Data+
Data-
Clock+
10 Clock-
12 +5.5 V out
13 DGND
Connect
internal
shields to
pin 13.
Chassis
Connect overall shield to
connector backshells
Smart Abs encoders
Smart Abs interface cable connections:
Motor
X8
Twisted pairs
Absolute
Encoder
1
9
Data+
Data-
12 +5.5 V out
13 DGND
Chassis
Connect overall shield to
connector backshells
ER6V
Multi-turn Smart Abs encoders require an additional battery supply
to retain position information when the drive is not powered.
Hiperface interface
Hiperface interface cable connections:
Motor
X8
Twisted pairs
1
9
5
6
7
8
Data+
Data-
Sin-
Sin+
Cos-
Cos+
Absolute
Encoder
12 +8 V out
13 DGND
Connect
internal
shields to
pin 13.
Chassis
Connect overall shield to
connector backshells
Electrical installation: input / output 87
Extra incremental encoder
Some applications require the connection of multiple encoders typically when:
•
A single axis has multiple encoders on the same motion system to eliminate
mechanical errors (a dual encoder application).
•
The drive is required to follow encoder signals given to it from a master
encoder input.
In both cases the drive can support a connection to an extra incremental
(encoder 2) is X7.If X7 is occupied as an encoder output and the primary
feedback type is one that does not use the Hall/sin/cos inputs (Incremental
encoder without Halls, BiSS-B, SSI, EnDat 2.2, Smart Abs or resolver), the extra
incremental encoder also can be connected to X8.
Note: In Mint, this extra encoder input (encoder 2 on X8) is available only when
Input mode: ABZ incremental encoder (default)
By default, connector X8 is configured as an ABZ incremental encoder input
when operating as encoder 2.
Input mode: Step (Pulse) and Direction
Optionally, connector X8 can be configured as a step and direction input when
operating as encoder 2. Use one of the following methods to select step and
direction mode.
•
In Mint Workbench, choose the Parameters tool and expand the Encoder
family. Click the EncoderMode entry, then click the value next to
EncoderMode (Encoder Channel 2). Check Bit 2: Step/Direction, then click
OK. On the menu, choose Tools, Store Drive Parameters.
•
In Mint Workbench, choose the Edit & Debug tool. In the Command window
enter the command: ENCODERMODE(2)=4(or other value where bit 2 is set).
On the menu, choose Tools, Store Drive Parameters.
The step and direction inputs are both differential and must be controlled from
a RS422 differential source. Single-ended connections cannot be used.
•
•
•
The A channel pins (1 & 6) are used as the step input. The step frequency
controls the speed of the motor.
The B channel pins (2 & 7) are used as the direction input. The state of the
direction input controls the direction of motion.
The Z channel input is not used.
88 Electrical installation: input / output
When connector X8 is specified as encode 2, an encoder breakout OPT-MF-200
need to be mounted to split one 15-pin connector X8 into one 15-pin connectors
X8A and one 9-pin X8B. X8A is connected to motor feedback, while X8B is
Pin
X8A (Primary encoder)
Inc. encoder
BiSS-B
SSI
EnDat 2.2
Smart Abs
without Halls
1
2
CHA+
CHB+
CHZ+
(NC)
Data+
Clock+
(NC)
Data+
Clock+
(NC)
Data+
Clock+
(NC)
Data+
(NC)
3
(NC)
4
(NC)
(NC)
(NC)
(NC)
5
(NC)
(NC)
(NC)
(NC)
(NC)
6
(NC)
(NC)
(NC)
(NC)
(NC)
7
(NC)
(NC)
(NC)
(NC)
(NC)
8
(NC)
(NC)
(NC)
(NC)
(NC)
9
CHA-
CHB-
CHZ-
+5.5 V out
DGND
(NC)
Data-
Clock-
(NC)
Data-
Clock-
(NC)
Data-
Clock-
(NC)
Data-
(NC)
10
11
12
13
14
15
(NC)
+5.5 V out
DGND
(NC)
+5.5 V out
DGND
(NC)
+5.5 V out
DGND
(NC)
+5.5 V out
DGND
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
Pin
X8B (extra Inc. encoder without
Halls/PTO)
Corresponding pin on X8
1
2
3
4
5
6
7
8
9
CHA+/Step+
CHB+/Dir+
CHZ+
6
8
15
(NC)
13
5
(NC)
DGND
CHA-/Step-
CHB-/Dir-
CHZ-
7
14
12
+5.5 V out
Electrical installation: input / output 89
The inputs may 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. The overall cable shield (screen)
must be connected to the metallic shell of the D-type connector. The encoder
supply on pin 12 provides 5.5 V to the encoder (500 mA maximum, less if other
Extra incremental encoder cable connections:
Twisted pairs
;ꢀ$
X8
1
1
9
9
2
2
Encoder
Feedback
Used by incremental encoder
without Halls, BiSS-B, SSI,
EnDat 2.2, or Smart Abs
primary encoder
10
3
10
3
11
11
12
13
12
13
+5.5 V out
DGND
;ꢀ%
Extra incremental encoder:
ꢀ
6
CHA+
CHA-
CHB+
CHB-
CHZ+
CHZ-
ꢁ
ꢂ
7
ꢄ
ꢃ
5
Encoder
Feedback
8
7
15
14
Connect overall
shield to connector
backshells
Extra Step and Direction inputs cable connections:
Twisted pairs
;ꢀ$
X8
1
1
9
9
Encoder
Feedback
2
2
Used by incremental encoder
without Halls, BiSS-B, SSI,
EnDat 2.2, or Smart Abs
primary encoder
10
3
10
3
11
11
+5.5 V out
DGND
12
13
12
13
Extra Step/Direction inputs:
;ꢀ%
ꢀ
Step+
Step-
Dir+
6
Pulse train
output
ꢁ
ꢂ
7
5
8
7
Dir-
Connect overall
shield to connector
backshells
90 Electrical installation: input / output
Incremental encoder input/output (X7)
The incremental encoder input/output connection provides A/B channels and a
Z index channel. Twisted pairs must be used for each complementary signal pair
e.g. CHA+ and CHA-. The Mint keyword ENCODEROUTCHANNELis used to set the
mode of operation for X7. When set to the default value of -1, X7 operates as an
input.
Pin 1
1
2
3
4
5
CHA+
CHB+
CHZ+
(NC)
6
7
8
9
CHA-
CHB-
CHZ-
+5.5 V out
GND
Input mode: ABZ incremental encoder (default)
By default, X7 is configured as an extra ABZ incremental encoder input (encoder
2). When operating as an encoder input, X7 can be used for a dual-loop feedback
system or connected to a master encoder for position following applications.
Incremental encoder cable connections:
Twisted pairs
X7
CHA+
1
6
2
7
3
8
CHA-
CHB+
CHB-
CHZ+ (INDEX)
CHZ- (INDEX)
Encoder
Feedback
9
5
+5.5 V out
DGND
Connect overall
shield to connector
backshells
Input mode: Step (Pulse) and Direction
Optionally, connector X7 can be configured as a step and direction input. Use
one of the following methods to select step and direction mode.
•
In Mint Workbench, choose the Parameters tool and expand the Encoder
family. Click the EncoderMode entry, then click the value next to
Electrical installation: input / output 91
EncoderMode (Encoder Channel 2). Check Bit 2: Step/Direction, then click
OK. On the menu, choose Tools, Store Drive Parameters.
•
In Mint Workbench, choose the Edit & Debug tool. In the Command window
enter the command: ENCODERMODE(2)=4(or other value where bit 2 is set).
On the menu, choose Tools, Store Drive Parameters.
The step and direction inputs are both differential and must be controlled from
a RS422 differential source. Single-ended connections cannot be used.
•
•
•
The A channel pins (1 & 6) are used as the step input. The step frequency
controls the speed of the motor.
The B channel pins (2 & 7) are used as the direction input. The state of the
direction input controls the direction of motion.
The Z channel input is not used.
Step / Direction inputs - typical connections from a PLC/controller:
X7
PLC/controller
MicroFlex e190
Step+
1
6
Step
output
Step-
Twisted pairs
Dir+
Dir-
2
7
Dir
output
Shield
Connect shields at
one end only.
Note: The inputs should be use shielded twisted pair cable with an overall
shield. Connect the input signals correctly according to the pin assignment for
connector X7.
Encoder output mode
Optionally, connector X7 can be configured as an encoder output (encoder
output 0). This automatically enables the extra incremental encoder input on
operating as an encoder output, X7 can be connected to the encoder input of a
motion controller to provide position feedback. The A/B outputs are a pair of
synthesized pulse trains with a 50% duty cycle, 90 degrees out of phase. The
92 Electrical installation: input / output
ENCODEROUTCHANNELMint keyword is used to define the source signal that will
be output at X7:
•
•
•
-1 = (Default) No encoder source assigned, X7 operates as an encoder input.
0 = Encoder 0, the primary encoder input on X8.
1 = Encoder 1, the encoder input formed by digital inputs DI1 and DI2 when
they are set to behave as an encoder input (see X3: Digital inputs - Special
•
2 = Encoder 2, the extra incremental encoder interface on X8.
The frequency of the A/B outputs is varied according to the source signal, and
can be scaled using the ENCODEROUTRESOLUTIONMint keyword. The output at
X7 is identical to the input at X8, with no propagation delay, provided the
output resolution is set to match the input resolution. In all other cases there is
a propagation delay of up to 125 ?s.
Use one of the following methods to configure X7 as an encoder output:
•
•
•
In Mint Workbench, choose the Drive Setup tool and proceed to the Motor
Feedback page. In the Simulated Encoder Output 0 area, click in the Encoder
source channel drop down and choose one of the encoder sources 0, 1, or 2
as described above. Proceed to the end of the wizard and follow the
instructions to save the changed parameter.
In Mint Workbench, choose the Parameters tool and expand the Encoder
family. Click the EncoderOutChannel entry, then click the value next to
EncoderOutChannel (Encoder Channel 0). Choose one of the encoder
sources 0, 1, or 2 as described above. On the menu, choose Tools, Store Drive
Parameters.
In Mint Workbench, choose the Edit & Debug tool. In the Command window
enter the command: ENCODEROUTCHANNEL(0)=n, where n is 0, 1, or 2, as
described above. On the menu, choose Tools, Store Drive Parameters.
Electrical installation: input / output 93
OPT-MF-201 Resolver adapter
The optional resolver adapter OPT-MF-201 allows a motor with resolver
Supported feedback type
Various feedback types are offered as options on linear and rotary servo
motors, the feedback types supported by MicroFlex e190 include the
incremental encoder, EnDat 2.1, SinCos, BiSS-B, SSI, EnDat 2.2, Smart Abs
absolute encoder, Hiperface encoder and resolvers (supported by using the
When selecting an encoder, you need to determine which type of encoder
feedback is required in order to be compatible with the drive that will be
receiving the encoder signals. Choosing the wrong encoder type will result in a
non-functional system and possibly hardware damage.
The right feedback type for your application is automatically set when the
94 Electrical installation: input / output
motor is selected in Mint Workbench. The Mint keyword ENCODERTYPEcan also
be used to define the feedback type of encoder input. Moreover, MicroFlex e190
supports two different types of incremental encoder signal inputs (primary
encoder and optional inc. encoder), see more details below.
The MicroFlex e190 has 3 encoder input channels:
•
•
Encoder 1: Extra optional incremental encoder input on connector X3 (see
•
Encoder 2: Extra optional incremental encoder input/PTO on connector X7
Electrical installation: input / output 95
Encoder 0 input
Encoder 0 on connector X8 is the e190 drive's universal encoder input channel,
supports a wide range of feedback types as follows.
No.
1
Feedback type
Parameter
Rotary incremental encoder without Halls ENCODERTYPE(0)=0
2
Linear incremental encoder without Halls ENCODERTYPE(0)=1
Incremental
encoder
3
Rotary incremental encoder with Halls
Linear incremental encoder with Halls
ENCODERTYPE(0)=2
ENCODERTYPE(0)=3
4
5
Rotary Hall sensors only without encoder ENCODERTYPE(0)=4
Hall sensor
SSI
6
Linear Hall sensors only without encoder ENCODERTYPE(0)=5
7
Baumer SSI encoder of ABB motor
Linear SSI encoder
ENCODERTYPE(0)=6
ENCODERTYPE(0)=19
ENCODERTYPE(0)=24
ENCODERTYPE(0)=7
ENCODERTYPE(0)=9
ENCODERTYPE(0)=10
ENCODERTYPE(0)=11
ENCODERTYPE(0)=12
ENCODERTYPE(0)=21
ENCODERTYPE(0)=13
ENCODERTYPE(0)=16
ENCODERTYPE(0)=17
ENCODERTYPE(0)=18
ENCODERTYPE(0)=25
8
9
Generic SSI encoder
10 Rotary EnDat v2.1
11
11
13
Rotary EnDat v2.2
EnDat v2.2
Linear EnDat v2.2
Rotary SinCos encoder
Linear SinCos encoder
Linear SinCos encoder with Halls
14 SinCos
15
16 Rotary Hiperface encoder
17 Smart Abs absolute encoder
18
19
Rotary BiSS encoder
Linear BiSS encoder
BiSS-B
20 Resolver (fitted with OPT-MF-201 resolver adapter)
Note: When using the incremental without Halls, BiSS-B, SSI, EnDat 2.2, Smart
Abs or resolver (via OPT-MF-201), an extra incremental encoder can be
simultaneously connected to X8 (configured as encoder 2, via OPT-MF-200, see
96 Electrical installation: input / output
Encoder 1 input
Encoder 1 is an extra incremental encoder input channel and can be used to set
up dual-encoder control system or be connected to a master encoder. It comes
from fast digital inputs 1 and 2 on connector X3.
The incremental encoder signal type:
•
•
•
•
24 V DC signal levels
Logic levels: “0” < 2 V, “1” > 12 V
A/B single ended, no Z index
User power supply: 24 V DC
No.
Feedback type
Parameter
ENCODERTYPE(1)=0
ENCODERTYPE(1)=1
ENCODERMODE(1)=4
1
2
3
Rotary incremental encoder without Halls
Linear incremental encoder without Halls
Step & Direction inputs
Encoder 2 input
Encoder 2 is extra incremental encoder input channel and can be used to set up
dual-encoder control system or be connected to a master encoder. The encoder
input is 5V differential line driver (RS422).
The incremental encoder signal type:
•
•
•
RS422 A/B/Z differential
Max. input frequency A / B: 2 MHz
Power supply: 5.5 V DC
No.
Feedback type
Rotary incremental encoder without Halls
Linear incremental encoder without Halls
Step & Direction inputs
Parameter
ENCODERTYPE(2)=0
ENCODERTYPE(2)=1
ENCODERMODE(2)=4
1
2
3
Installation checklist 97
8
Installation checklist
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. Read the safety instructions on the first pages of this
manual before you work on the unit. 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
MECHANICAL INSTALLATION
The cooling air will flow freely.
The motor and the driven equipment are ready for start. (See Planning the
The capacitors are reformed if stored over one year (ask local ABB
representative for more information).
The drive is grounded properly.
98 Installation checklist
Check
The supply (input power) voltage matches the drive nominal input voltage.
The supply (input power) is connected to L1/L2/L3 (UDC+/UDC- in case of a DC
supply) and the terminals are tightened to specified torque.
Appropriate supply (input power) fuses and disconnector are installed.
The motor is connected to U/V/W, and the terminals are tightened to specified
torque.
The braking resistor (if present) is connected to R- and R+/UDC+, and the
terminals are tightened to specified torque.
The motor cable (and braking resistor cable, if present) is routed away from
other cables.
There are no power factor compensation capacitors in the motor cable.
The external control connections to the control unit are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
The supply (input power) voltage cannot be applied to the output of the drive
through a bypass connection.
Start-up 99
9
Start-up
What this chapter contains
This chapter describes software installation and the start-up procedure of the
drive.
Safety
before performing any maintenance on the equipment. Ignoring the
safety instructions can cause injury or death.
Introduction
Before powering the MicroFlex e190 you must connect it to the PC using an
Ethernet cable and install the Mint Workbench software on the PC. This includes
a number of applications and utilities to allow you to configure, tune and
program the MicroFlex e190.
Connect the MicroFlex e190 to the PC
Connect a CAT5e Ethernet cable between the PC and the MicroFlex e190 E3
Ethernet port on the front panel. Do not connect the cable to the E1 or E2 ports
on the top of the drive.
NOTE! You cannot connect an ordinary office PC to the MicroFlex e190
without first altering the PC's Ethernet adapter configuration. See
100 Start-up
Install Mint Workbench
The Windows user account requires administrative user rights to install Mint
Workbench. To install the software, download the application from
new.abb.com/motion and run it.
Configure the PC Ethernet adapter
It is necessary to alter the PC's Ethernet adapter configuration to operate
correctly with the MicroFlex e190. By default, the MicroFlex e190 has a static IP
address of 192.168.0.1. This can be changed using the Configuration tool in Mint
Workbench.
NOTE! You cannot connect an ordinary office PC to the MicroFlex e190
without first altering the PC's Ethernet adapter configuration. However, if
you have installed a second Ethernet adapter dedicated for use with the
MicroFlex e190, then this adapter's configuration can be altered without
affecting the PC's office Ethernet connection. A USB to Ethernet adapter is a
convenient way to add a second Ethernet adapter to a PC. 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 e190, 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 is 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 8.1: Apps screen, Control Panel, Network and
Internet, Network and Sharing Center. Windows 10: Start, Settings, Network
& Internet, Ethernet).
2. On the left of the window, click Change Adapter Settings (Windows 10:
Change adapter options). Double click the icon for the required Ethernet
adapter, then click Properties.
3. Select the ‘Internet Protocol Version 4 (TCP/IPv4)' entry 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. 192.168.0.241. 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.
Start-up 101
9. Click Close to close the Local Area Connection Status dialog.
Enable the Ethernet adapter for Mint Workbench
Before Mint Workbench can use the Ethernet adapter to discover the
MicroFlex e190, the adapter must be enabled in the Mint Sidebar.
1. On the Windows 7/10 task bar in the notification area, right-click the Mint
HTTP Server icon and choose Properties. (Windows 8.1: On the Start screen,
click the Desktop icon to access the desktop first.)
2. In the Discovery area, check the required local area connection, then click OK.
Note: If the Mint Sidebar cannot discover the drive then you may need to disable
or modify your Firewall and/or Anti-virus settings.
Start the MicroFlex e190
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
Ethernet cable linking the PC to the MicroFlex e190.
Preliminary checks
Power on checks
has detected a fault.
1. Turn on the 24 V DC control circuit supply (if present).
3. The drive status display shows a test sequence which normally takes
approximately 15-20 seconds. The sequence ends with the
symbol, or
minute after downloading new firmware.
4. To allow the Commissioning Wizard to function, the Safe Torque Off inputs
102 Start-up
Start Mint Workbench
Mint Workbench is a fully featured application for programming and controlling
the MicroFlex e190. 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. Press F1 to display the
help file. For help on using Mint Workbench, click the red Mint Workbench icon
on the opening page.
1. On the Windows Start menu, select All Programs, ABB, Mint Workbench, Mint
Workbench. (Windows 8.1: On the Apps screen, click the Mint Workbench
icon.)
2. In the opening dialog box, click Start Online Project...
3. Wait until the MicroFlex e190 is listed in the Controllers found box, e.g.
“MicroFlex e190 on 192.168.0.1”.
4. Select the MicroFlex e190 in the list, and check Launch Commissioning
Wizard.
5. Click Select.
Note: If the MicroFlex e190 is not listed, check the Ethernet cable is connected
to the E3 port on the front panel of the drive, not E1 or E2 on the top panel.
Check that the MicroFlex e190 is powered correctly and the start-up sequence
ports. It can take up to 5 seconds for Mint Workbench to detect the
MicroFlex e190.
6. Mint Workbench connects to the MicroFlex e190 and displays the
Commissioning Wizard.
Note: If Launch Commissioning Wizard was not checked, Edit & Debug mode is
displayed.
Start-up 103
Commissioning Wizard
Each type of motor and drive combination has different performance
characteristics. Before the MicroFlex e190 can be used to control the motor
accurately, the MicroFlex e190 must be ‘tuned'. Tuning is the process where the
MicroFlex e190 powers the motor in a series of tests. By monitoring the drive's
output and the feedback from the motor's encoder, the MicroFlex e190 can
make small adjustments to the way it controls the motor. This information is
stored in the MicroFlex e190 and can be uploaded to a file if necessary.
The Commissioning Wizard provides a simple way to tune the MicroFlex e190
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 do not need to re-enter everything if you go back to
previous screens. If you need extra help, click Help or press F1.
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 an ABB 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
‘Enter motor parameters manually’ 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 is entered
already. However, if you selected the ‘Enter motor parameters manually’ option,
it is 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 is entered
104 Start-up
already. However, if you selected the ‘Enter motor parameters manually’ option,
it is 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 the correct operating source
(‘Direct’ or ‘RT Ethernet’) as the Reference Source. This allows the Autotune
Wizard to operate correctly, and allows further initial testing to be performed
using Mint Workbench. Although the MicroFlex e190 might eventually be
controlled over EtherCAT (or Ethernet POWERLINK), the ‘RT Ethernet' reference
source should be selected only after the MicroFlex e190 has been commissioned
and is ready to add to the EtherCAT (or Ethernet POWERLINK) network. This is
selected by choosing the Operating Mode tool in the Toolbox.
Application Limits:
Application maximum speed (App. Max. Speed) defaults to zero and need to be
entered the correct speed value. It is often not necessary to change other
parameters on this screen. However, if you wish to adjust the application peak
current (App. Peak Current) , then click in the appropriate box and enter a value.
Select Scale Factor:
It is often 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) means that all position values entered or displayed in Mint
Workbench will represent revolutions. The Position Scale Factor value changes
automatically to represent the required scale factor (the number of quadrature
counts per revolution). If you need to use an alternative unit, for example
degrees, type “Degrees” in the Position User Unit box and enter a suitable value
in the Position Scale Factor box. Separate velocity and acceleration units can
also be defined. See the Mint help file for more information about scale factors.
Profile Parameters:
It is often 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
Start-up 105
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 e190 for optimal performance with
the attached motor. This removes the need for manual fine-tuning of the
system, although in some critical applications this might be required.
Click Options... to configure optional autotuning parameters. Each Option
shows settings relevant to the adjacent test.
WARNING! The motor moves 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 takes
measurements from the motor and then performs small test moves.
For further information about tuning with the load attached, see Further tuning -
Note: Even if you do not perform any further tuning or configuration, the STO
Further tuning - no load attached
The Autotune Wizard calculates many parameters that allow the MicroFlex e190
to provide good control of the motor. In some applications, these parameters
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, it displays a graph representing
the response.
106 Start-up
2. The Fine-tuning window has a number of tabs the bottom.
Click on the Current tab to fine tuning the current loop.
Click on the Velocity/ Position tab to fine tuning the velocity/position loop
in velocity / torque servo configuration.
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 creates a move with a velocity of 1000 rpm. Similarly, assuming the
position scaling factor had been set to Revolutions (r), the value 10 creates a
move lasting for 10 revolutions of the motor.
4. Click Go to start the test move. Mint Workbench performs the test move and
displays 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
Start-up 107
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 -
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. Clear all of the check boxes. Only “Measure the inertia” and “Calculate speed
and position loop gains” must be selected.
4. Click START to begin the auto-tuning process. Mint Workbench takes
measurements from the motor and then performs 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 performs the test move and displays a graph of the result.
108 Start-up
Optimizing the velocity response
It can 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 performs the test move and
displays a graph of the result.
Velocity overshoots demand:
Measured
velocity
Demand
velocity
Start-up 109
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 performs the test move and
displays a graph of the result.
Zero-speed noise:
Demand
velocity
Measured
velocity
110 Start-up
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
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 causes 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
Start-up 111
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.
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 causes the motor to move to a position 10 units from its current
position.
The move stops 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 e190. 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 e190 integrated configuration
interface.
1. Click the Configuration tool icon in the Toolbox on the left of the screen.
2. Select Upload configuration from controller or Start new configuration.
3. Enter a descriptive name for the controller and click NEXT at the bottom of
the screen.
4. Continue through the screens making the required changes. Press F1 to
display help.
5. Click APPLY to save the changed settings, then CLOSE to complete the
configuration.
EtherCAT tool
The EtherCAT tool shows all information relating to the EtherCAT connection.
1. Click the EtherCAT tool icon in the Toolbox on the left of the screen.
2. Wait until data is uploaded from the MicroFlex e190.
3. The Summary tab shows basic information about the EtherCAT connection.
4. Click the Object Dictionary tab (above the table) to view the current state of
the drive’s object dictionary. Press F1 to see the Mint Workbench help file for
instructions about the screen’s tool bar.
5. Click the “Save as...” button to export the ESI file.
Ethernet POWERLINK
The Ethernet POWERLINK tool shows all information relating to the Ethernet
POWERLINK connection.
1. Click the Ethernet POWERLINK tool icon in the Toolbox on the left of the
screen.
2. Wait until data is uploaded from the MicroFlex e190.
3. The Summary tab shows basic information about the Ethernet POWERLINK
connection.
Start-up 113
4. Click the Object Dictionary tab (above the table) to view the current state of
the drive’s object dictionary. Press F1 to see the Mint Workbench help file for
instructions about the screen’s tool bar.
Click the “Save as...” button to export the XDD file.
Parameters tool
The Parameters tool can be used to view or change most of the drive's
parameters.
1. Click the Parameters icon in the Toolbox on the left of the screen. The main
area of the Mint Workbench window displays the Parameters editor screen.
Items listed with a grey
Items listed with a green
value.
icon are read only so cannot be changed.
icon are currently set to their factory default
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 expands to show all items in the category.
Click on the item you wish to edit.
3. The adjacent table lists the chosen item. Click in the Active Table cell and
enter a value. This immediately sets the parameter, which remains in the
MicroFlex e190 until another value is defined or power is removed. The icon
to the left of the item becomes yellow to indicate that the value has been
changed. On the menu, choose Tools, Store Drive Parameters to ensure the
value remains after a power cycle.
Many of the MicroFlex e190's parameters are set automatically by the
Commissioning Wizard, or when tests are performed in the Fine-tuning
window.
Spy window
The Spy window can be used to monitor and capture parameters in real-time. If
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.
114 Start-up
3. The I/O tab displays the state of all the digital inputs and outputs.
Click on an output LED to toggle the output on/off.
4. The Monitor tab allows up to six parameters to be selected for monitoring.
Click in a drop down box to select a parameter.
At the bottom of the Monitor tab, real-time data capture can be configured.
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 e190. If you tried the test moves in Performing test
to open a Mint programming window.
Note: Mint programming only supported if a Mint memory unit is installed.
Scope Tool
Displays the capture screen. This screen is also shown when the Fine-tuning
tool is selected.
Digital I/O Tool
This tool 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
Safe Torque Off (STO) validation test
Drive commissioning is not complete until the STO function has been tested.
The validation 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.
Fault tracing 115
10
Fault tracing
What this chapter contains
This section explains common problems and their solutions. The LED indicators
Problem diagnosis
If you have followed all the instructions in this manual in sequence, you should
have few problems installing the MicroFlex e190. 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.
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. Have the following information
ready:
•
•
The serial number of your MicroFlex e190 (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.
116 Fault tracing
•
•
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 ERRORREADCODEor 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 e190
The term ‘power-cycle the MicroFlex e190’ is used in the Troubleshooting
sections. If the mains AC supply (or DC supply) is removed, wait for 2 minutes
before reapplying the supply.
Fault tracing 117
MicroFlex e190 indicators
EtherCAT® mode
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 ERR (Red)
Off: No errors or not powered.
Blinking:
Invalid mailbox configuration in BOOT.
Invalid mailbox configuration in PREOP.
Invalid Sync manager configuration.
Invalid output configuration.
Invalid input configuration.
Invalid watchdog configuration.
Invalid DC Sync configuration.
Invalid DC latch configuration.
1 flash:
Unspecific error.
FreeRun needs 3 buffer mode.
No memory.
Background watchdog occurred.
No valid inputs and outputs.
Fatal sync error.
Invalid request state change.
Unknown requested state.
Bootstrap not supported.
No valid firmware.
No sync error.
PLL error.
No valid inputs available.
No valid output.
DC sync IO error.
DC sync time-out error.
Invalid DC Sync cycle time.
DC Sync0 cycle time.
DC Sync1 cycle time.
Message box EoE error.
Message box CoE error.
Message box FoE error.
Message box SoE error.
Message box VoE error.
EEPROM no access.
EEPROM error.
Synchronization error.
Invalid Sync manager types.
Slave needs cold start.
Slave needs INIT.
Slave needs PREOP.
Slave needs SAFEOP.
Invalid input mapping.
Invalid output mapping.
Inconsistent settings.
FreeRun not supported.
SyncMode not supported.
Slave restarted locally.
2 flashes: Sync manager watchdog.
118 Fault tracing
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.
Ethernet POWERLINK mode
The Ethernet LEDs display the overall condition of the
Ethernet interface once the startup sequence has
completed. The LED codes conform to the Ethernet
POWERLINK Standardization Group (EPSG) standard at the
time of production.
Green (status)
Off: Node in NOT ACTIVE state or a previous initialization state. The
controlled node is waiting to be triggered by the manager node.
1 flash: Node in PRE-OPERATIONAL1 state. Ethernet POWERLINK mode
is starting.
2 flashes: Node in PRE-OPERATIONAL2 state. Ethernet POWERLINK
mode is starting.
3 flashes: Node in READY TO OPERATE state. The node is signalling its
readiness to operate.
Blinking (continuous flashing): Node in STOPPED state. The controlled
node has been deactivated.
Flickering (very fast flashing): Node in BASIC ETHERNET state
(Ethernet POWERLINK is not operating, but other Ethernet protocols
may be used).
Continuously illuminated, not flashing: Node in OPERATIONAL state.
Ethernet POWERLINK is operating normally.
Fault tracing 119
Red (error)
Off: Ethernet POWERLINK is working correctly.
Continuously illuminated: An 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.
LED flash timing definitions:
(Not illuminated)
Off
1 flash
1 s
1 s
2 flashes
Inverted 2 flashes
3 flashes, etc.
Blinking
Flickering
On
1 s
1 s
1 s
(Continuously illuminated)
200 ms
120 Fault tracing
Drive status display
The drive status display indicates errors and general
MicroFlex e190 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:
STO error
The decimal point to the right of the number also illuminates to indicate STO
errors. If a symbol appears followed by an error code, please contact ABB
technical support. 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. See also Start the
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.
Initialization error / recovery mode. If this is the only symbol shown
after powering the drive, remove all power, check the memory unit is
inserted correctly, then reapply power. This symbol is also displayed
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 SUSPENDcommand has been issued and is
active. Motion ramps down to zero demand whilst active.
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.
Fault tracing 121
Symbol Description
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 INCAand INCR.
Jog. The drive is jogging. See the Mint keywords JOG, JOGCOMMANDand
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
MOVEAand MOVER.
Torque move. The drive is in torque mode. See the Mint keywords
TORQUEREF, TORQUEREFSOURCEand related commands.
Firmware recovery mode in operation; see SW1 linear switches - startup
Stop input active. A Mint STOPcommand has been issued or an
optional stop input is active.
Velocity reference move. The drive is under velocity control. See the
Mint keywords VELREFand related keywords.
Spline. A spline move is in progress. See the Mint keyword SPLINEand
related keyword.
User defined symbols can be displayed using Mint keywords LEDand
LEDDISPLAY.
122 Fault tracing
Power
Drive does not start when applying AC power:
•
Check that the motor output phases are not short circuited. The drive trips
on a motor phase short circuit and will not restart unless AC power is
removed. Remove all power from the drive, correct the short circuit and
restart the drive.
Communication
Drive status display is off:
•
Check that the 24 V DC control circuit supply is correctly connected at X2,
and is switched on. If a 24 V DC supply is not provided, an AC supply (or DC
Drive status display shows ‘I’:
•
The MicroFlex e190 is in firmware recovery mode. This means that it does
not boot fully, and allows Mint Workbench to download firmware from the
78.
Mint Workbench fails to detect the MicroFlex e190:
•
Ensure that the MicroFlex e190 is powered and the drive status display is
•
Check that the Ethernet cable is connected between the PC and
MicroFlex e190. Check that the cable is connected to port E3 (on the front
panel) and not port E1 or E2.
•
•
•
Check that the PC's Ethernet port has been correctly configured for TCP/IP
operation, and enabled for use with Mint Workbench (see Configure the PC
Check that any PC firewall or security software does not prevent
communication on TCP ports 5000 and 5001, and UDP port 5050. These
ports are essential for communication with the MicroFlex e190.
Try an alternative cable or different port on the PC.
Fault tracing 123
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 e190.
•
Tuning
Cannot enable the MicroFlex e190 because there is an error 10010:
•
Check the drive enable input, if assigned, is connected and powered
correctly.
Cannot enable the MicroFlex e190 because there is an error 10033 and/or
10035:
•
Check the Safe Torque Off inputs on connector X2 are both connected and
powered correctly.
When the MicroFlex e190 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 re-tune 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.
124 Fault tracing
Ethernet
Cannot connect to the drive:
•
Check that the PC's Ethernet adapter has been correctly configured, as
How do I configure my EtherCAT manager to operate with the MicroFlex e190?
•
An EtherCAT ESI file (.xml) that describes the drive to the EtherCAT manager
can be uploaded from the controller using the Mint Workbench EtherCAT
tool.
I cannot control the MicroFlex e190 from my EtherCAT or Ethernet
POWERLINK manager
The drive reference source must be set to allow the EtherCAT or Ethernet
POWERLINK manager to take control of the MicroFlex e190. There are several
ways to do this:
•
Set the CONTROLREFSOURCESTARTUPparameter to '1' using the Mint
Workbench Parameter viewer or Command window, save the parameters
and restart the drive. This gives control to the manager each time the
MicroFlex e190 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 (CiA402)’ in the Axis 0 drop down.
Confirm that the reference source on all controlled nodes has been set to
real time Ethernet in the Mint Workbench Operating Mode Wizard, and that
the master has been configured correctly.
Fault tracing 125
Dual encoder
axis exceeds its maximum deviation error limit. For ensure accuracy, an
incremental calculation period is defined by using the keyword
POSVELENCODERDEVIATIONCLEARPERIOD. At the beginning of each calculation
period, the deviation value is initialized to 0 and recalculated.
If POSVELENCODERDEVIATIONCLEARPERIOD is set to 0, the deviation tracing
function will be closed, and error 10045 will not be reported.
The maximum deviation error limit is set with the keyword
POSVELENCODERDEVIATIONFATAL. The keyword POSVELENCODERDEVIATION
returns the instantaneous deviation value. So the deviation error occurs when
the value of POSVELENCODERDEVIATION is greater than the value of
POSVELENCODERDEVIATIONFATAL.
The keyword POSVELENCODERDEVIATIONERRORMODEis used to specify the
default action to be taken in the event of a deviation error. The available modes
are ‘crash stop and disable’ and ‘error decel as velocity mode’.
Set POSVELENCODERDEVIATIONERRORMODE(0)=1 to select crash stop and
disable mode, when a deviation error occurs, the drive will:
·
·
·
Perform crash stop.
Call the error event and the error 10045 is generated.
Be disabled.
Set POSVELENCODERDEVIATIONERRORMODE(0)=10to select error decel as
velocity mode, when a deviation error occurs, the drive will:
·
·
·
·
Switch to velocity mode automatically.
Call the error event and the error 10045 is generated.
Stop the motor to zero at the ERRORDECELrate.
Keep enabled (if no other error occurs) and velocity mode until next
command.
126 Fault tracing
Warning messages generated by the drive
Axis warnings
Code Warning
Cause
What to do
20003 All axis warnings cleared
This information message can
No Action required.
(_ecAXIS_WARNINGS_CLEAR appear in the error log to
ED)
indicate that all axis warnings
have been cleared.
20004 Encoder battery low
When using an encoder with
Consider changing the Encoder
battery.
(_ecENCODER_BATTERY_LO battery backup (e.g. Smart Abs
W)
multi-turn) a battery low
condition has been reported.
Fault tracing 127
Controller warnings
Code
Warning
Cause
What to do
Re-run the System Configuration Wizard.
40006 Attempt to configure too
many axes
The device configuration
file has attempted to
(_ecTOO_MANY_AXES)
assign more axes than are
available on the controller.
40007
40012
CamBox segments have
been skipped
(_ecCAM_BOX_OVERRUN)
The cam box has skipped See CAMBOX in Mint Workbench Help,
a segment. This can
happen if the source is
moving fast enough to
cause a segment to be
skipped.
look at “position array”. Either slow down
the source or increase the size of the
segments.
A host event has failed
with retries
(_ecEVENT_RETRY_WARNI acknowledge an event
A host (i.e. ActiveX) event If the host does not acknowledge the
handler has failed to
event after 3 time-out periods, the
controller generates warning 40012. See
ERRDATA for details of the error.
NG)
that has been raised by
the controller. There is a
'time-out' period of 1
second in which the host
must acknowledge an
event.
40013
40014
40015
40016
40021
40022
Attempted to assign too
many servo axes
(_ecTOO_MANY_SERVO_A configuration file), too
During the processing of
the ..CMCF / .DCF (device Wizard to reduce the number of
To fix this issue, use the System Config
configured servo axes.
XES)
many servo axes were
configured.
Attempted to assign too
many stepper axes
(_ecTOO_MANY_STEPPER_ configuration file), too
During the processing of
the ..CMCF / .DCF (device Wizard to reduce the number of
To fix this issue, use the System Config
configured stepper axes.
AXES)
many stepper axes were
configured.
Attempted to assign too
many virtual axes
(_ecTOO_MANY_VIRTUAL_ configuration file), too
During the processing of
the ..CMCF / .DCF (device Wizard to reduce the number of
To fix this issue, use the System Config
configured virtual axes.
AXES)
many virtual axes were
configured.
Attempted to assign too
many remote axes
(_ecTOO_MANY_REMOTE_ configuration file), too
During the processing of
the ..CMCF / .DCF (device Wizard to reduce the number of
configured remote axes.
many remote axes were
configured.
To fix this issue, use the System Config
AXES)
All controller warnings
cleared
(_ecCONTROLLER_WARNI
NGS_CLEARED)
This information message No Action Required.
can appear in the error log
to indicate that all
controller warnings have
been cleared.
Last reset was not
controlled
(_ecRESET_NOT_CONTRO
LLED)
Last reset was not
controlled.
To fix this issue, use the System Config
Wizard to reduce the number of
configured servo axes.
128 Fault tracing
Code
Warning
Cause
What to do
40023
Default MAC detected
Default MAC has been
Set valid MAC address.
(_ecDEFAULT_MAC_DETEC detected, valid MAC
TED)
address is not set.
40024
40025
Could not open license file
or Error reading license file file or Error reading
(_ecMISSING_LICENCE_FIL license file.
E)
Could not open license
If this error is received, please contact
ABB technical support.
Licence file doesn't match Wrong licencing version or If this error is received, please contact
hardware platform, or Flash unique ABB technical support.
ID(_ecFOREIGN_LICENCE_ ID does not match the one
FILE_PRESENT)
in the license file.
40026
40027
Invalid Licence file
(_ecINVALID_LICENCE_FIL not match the one in the
E_PRESENT)
Licence data hash does
If this error is received, please contact
ABB technical support.
Licence File.
Warning applying
parameter value
(_ecPARAM_WARNING)
This warning will be
generated if an attempt is create a new parameter table.
made to write to a
If necessary recommission the drive to
parameter that is no
longer supported.
40028
Warning fan fault
The fan is possibly faulty, Firstly ensure the latest firmware is in
(_ecFAN_FAULT_WARNING unplugged or jammed.
)
use (as the fan is controlled by firmware).
Check the bottom of the drive to
determine that the fan inlets are not
blocked and the fan is rotating. If the
drive fan does not turn see the drive
installation manual for instructions on
how to replace the fan.
error handing.
Fault tracing 129
Error messages generated by the drive
Autotuning errors
Code Error
Cause
What to do
4000 No autotuning error
(_ecAUTOTUNE_SUCCE
SS)
There is no autotuning error.
No Action.
4001 Drive rating data invalid One of the following conditions has Check memory module is connected
not been met
1. Drive bus nominal voltage < 1
2. Drive rated current <= 0
correctly, check power supply level is
correct.
4002 Drive speed max invalid DriveSpeedMax <= 0
Re-run commissioning and check that
DriveSpeedMax is set correctly.
Only check AutoTune test ID
auoDESIGN_MOTION_CONTROL.
4003 Config doesn't support The autotuning operation does not This error will not occur unless the
that test
support this controller
configuration has been manually
(_ecCONFIG_NOT_RIGH configuration.
T_TYPE)
changed using the CONFIG keyword.
4004 Axis error has occurred An asynchronous axis error or drive See the Mint Workbench Motion
(_ecAXIS_ERROR)
error has occurred during the
autotuning operation.
toolbar for more information on the
error.
4005 Calculated torque
constant invalid
Drive had calculated a Torque
Constant which is too small.
Check motor data is correct.
4006 Inductance value is zero For the selected motor the winding To avoid this error, make sure that a
inductance is zero.
motor has been selected from the
database in the Drive Setup Wizard.
Alternatively, if a custom motor has
been selected and you are unsure of
motor data, check that the “Measure
motor resistance and inductance”
test has been selected and run using
the Autotune tool.
4007 Resistance value is zero For the selected motor the winding To avoid this error, make sure that a
(_ecZERO_RESISTANCE resistance is zero.
_VALUE)
motor has been selected from the
database in the Drive Setup Wizard.
Alternatively, if a custom motor has
been selected and you are unsure of
motor data, check that the “Measure
motor resistance and inductance”
test has been selected and run using
the Autotune tool.
4008 User has aborted test
)
The autotuning operation has been This will occur if the Autotune tool's
(_ecUSER_TEST_ABORT manually aborted.
STOP button is clicked while tests are
being performed.
4009 Cannot capture data
during test
Many of the autotuning operations Not normally a problem, but to
use the data capture facility. This
prevent this before autotuning, type
CP=0 in the Command window to halt
any capture operations.
(_ecCAPTURE_FAILED) error message can occur if the
capture facility is in use prior to
performing the autotuning
operation.
130 Fault tracing
Code Error
Cause
What to do
4010 Resistance too low,
possible short circuit
This error can occur during the
Measure motor resistance and
Check that there are no short circuits
between the U, V and W terminals of
the motor and that the motor power
cable is wired correctly.
(_ecPOSSIBLE_SHORT_ inductance test and indicates that
CIRCUIT)
the effective motor winding
resistance is very low.
4011
Autotuning doesn't
support feedback
device
The Test the feedback or Feedback This error will not normally occur
calibration test (EnDat absolute because Mint Workbench will not
encoders only) does not operate on allow autotuning on unsupported
(_ecUNSUPPORTED_FE this feedback type.
EDBACK_TYPE)
feedback types. Ie the combination of
Motor and Feedback device is not
supported by Mint Workbench.
4012 Encoder resolver
During the Measure the voltage
The most common cause of this error
is an incorrectly wired or set up
feedback device (encoder or resolver),
rotation sense is wrong constant and Measure the motor
(_ecFEEDBACK_SENSE_ inertia tests, a torque is applied to
WRONG)
the motor. This error will occur if the or an incorrectly wired motor. Select
resulting motion is in the opposite the Test the feedback option. This will
direction to the torque (a positive
torque should cause positive
velocity).
indicate if there is a problem with the
wiring or setup of the drive and will
automatically compensate for certain
wiring errors. Note that the Test the
feedback test should ideally be run
with the motor disconnected from
the load.
This error can also occur when
autotuning a motor connected to
some types of load. In particular,
loads with a lot of compliance (e.g.
belt drives) or torque offsets (e.g.
gravitational loading) can cause
problems for autotuning.
Another cause of the error may be
because the position feedback is
noisy, perhaps due to long cables on
resolver feedback systems, for
example. In either of these cases, it
may be necessary to manually tune
the system using the Fine-tuning tool.
Fault tracing 131
Code Error
Cause
What to do
4013 Hall sequence doesn't
behave as expected
The Hall sequence doesn't behave as
expected. This error can occur
The error can occur for a number of
reasons, so try the following tests:
• Return to the Confirm Motor
Information page of the Drive Setup
Wizard to check these values. If the
resolver is not a standard ABB
product, check that the specification
is compatible in the drives hardware
manual
(_ecHALL_FAULT_OR_N during the Test the feedback test
O_ROTATION)
when using an incremental encoder
+ Halls feedback system.
• A common cause of this error is an
incorrectly wired or set up
encoder/resolver. Try manually
moving the rotor and watching the
position field in the Axis tab. If the
position does not change, or it
changes erratically, this indicates a
problem with the encoder wiring.
• Run the Test the feedback test
again. Ideally, the Test the feedback
test should be run with the motor
disconnected from the load, although
it will operate successfully where the
load is purely inertial or load friction
is small.
Note: watch the movement of the
rotor. For rotary motors, the shaft
should rotate through just over one
revolution in one direction followed
by one revolution in the opposite
direction. For linear motors, the rotor
should move through just over one
pole pitch in one direction followed by
one pole pitch in the opposite
direction. If the rotor moves
significantly more or less than these
distances, this indicates that the
number of motor poles is not set
correctly (rotary motors), or the pole
pitch is not set correctly (linear
motors). If the motion during the test
is not smooth, this indicates that
friction is high and the test will not be
able to obtain conclusive results.
4015 Position control update Position loop control rate
rate invalid (ControlRate(0, 1)) < 1.
Change control rate to expected value
(normally 4000).
132 Fault tracing
Code Error
Cause
What to do
4016 Mathematic error in
gain calculations
This error can occasionally occur
during the Calculate current loop
The error can usually be cleared by
changing the design bandwidth for
the appropriate operation (click
Options... in the Autotune tool). If that
fails, try running the entire
(_ecGAIN_CALCS_FAILE gains or Calculate the speed and
D)
position gains tests, indicating a
numerical problem in the gain
equations. It can also indicate a
problem with the values of motor
resistance and inductance
autotuning sequence again.
(MOTORRS and MOTORLS) when it
occurs during current loop gain
calculations, or with the values of
inertia and damping (LOADINERTIA
and LOADDAMPING) when it occurs
during speed/position loop gain
calculations.
4017 Drive setup is invalid
This error can potentially occur in
any of the autotuning operations,
although it is rare. It indicates a
problem with the fundamental
setup of the drive such as the
settings for motor rated current or
peak current.
Try running the Commissioning
Wizard again, making sure that the I
am starting a new application. Reset
memory to factory defaults option on
the Welcome page is selected.
4018 Can't fit model to
voltage/current data
During the Measure motor
resistance and inductance test, a
Check the wiring between the drive
and motor and the motor windings
for open circuits.
(_ecCANNOT_FIT_RESIS gradually increasing voltage is
TANCE_MODEL)
applied to the motor and the
generated current is logged. The
process is stopped when the drive
current reaches 80% of the
specified motor rated current value.
The resulting voltage/current
characteristic is used to calculate
the resistance of the windings and
certain parameters of the drive's
power stage. Error 4018 will occur if
there is not enough data in the
voltage/current characteristic to
perform the calculation.
4019 Can't fit model to
voltage/current
transient
During the Measure motor
resistance and inductance test,
stator inductance is measured by
Try skipping the Measure motor
resistance and inductance test. To do
this, manually enter the motor
(_ecCANNOT_FIT_INDU applying a voltage step to the motor resistance and inductance in the
CTANCE_MODEL)
and logging the generated current
waveform. Inductance is then
calculated from the resulting
Confirm Motor Information page of
the Drive Setup Wizard (most motor
manufacturers will supply this
voltage/current characteristic. Error information) and confirm that the
4019 indicates that this calculation test is not selected in the Autotune
cannot be performed because of
insufficient data or an unusual
characteristic.
tool. Once autotuning is complete,
check that the response of the
current controllers is satisfactory
using the Fine-tuning tool's Current
tab.
Fault tracing 133
Code Error
Cause
What to do
4020 Can't fit load model
speed data
During the Measure the motor
inertia test, a torque waveform is
Click Options... in the Autotune tool
and then select the Limits tab.
(_ecCANNOT_FIT_LOAD applied by the motor and the motor Increase the value in the Max Travel
_MODEL)
speed logged. A simple
box to allow the motor to rotate
further during the test and
consequently log more data. The
model fitting process can also fail for
certain types of load. For example,
inertia/damping model is then
fitted numerically to the resulting
torque/speed characteristic. Error
4020 indicates that the fitting
process failed. A common cause for loads with high coulomb or static
this is lack of sufficient information friction will not conform well to an
to fit the load model.
inertial load model. Likewise
gravitational loading (i.e. vertical
axes) will cause problems for
autotuning. If the Measure the motor
inertia test continues to fail then the
subsequent Calculate the speed and
position gains test will also fail, as it
require values for load inertia and
damping. It may be necessary to
manually tune the system using the
Fine-tuning tool's Speed and Position
tabs.
4021 Motor test timed out
During the Measure the voltage
Click Options... in the Autotune tool
and then select the Limits tab.
Increase the value in the Max Torque
box to allow the motor to generate
sufficient torque to overcome
friction.
(_ecAUTOTUNE_TEST_T constant and Measure the motor
IMEOUT)
inertia tests, current is applied to
the motor to accelerate the motor
and load. Error 4021 indicates that
the rotor did not reach a sufficient
speed, or travel a sufficient
If the Measure the motor inertia test
distance, within the duration of the continues to fail then the subsequent
test. Error 4021 can occur if the
torque (or force) generated by the
motor is insufficient to overcome
friction in the load.
Calculate the speed and position
gains test will also fail, as it requires
values for load inertia and damping. It
may be necessary to manually tune
the system using the Fine-tuning
tool's Speed / Velocity and Position
tabs.
4022 Motor travelled too far During the Measure the voltage
during test constant and Measure the motor
(_ecAUTOTUNE_TEST_ inertia tests, current is applied to
Click Options... in the Autotune tool
and then select the Limits tab.
Increase the value in the Max Travel
box to allow the motor to rotate
further during the test. Also, try
reducing the value in the Max Speed
box. If the Measure the motor inertia
OVERTRAVEL)
the motor to accelerate the motor
and load. Once the motor has
reached a sufficient speed, the
direction of applied current is
reversed to bring the rotor to a halt test continues to fail then the
within specified travel limits. Error
4022 indicates that the test was
unable to impose these limits.
subsequent Calculate the speed and
position gains test will also fail, as it
requires values for load inertia and
damping. It may be necessary to
manually tune the system using the
Fine-tuning tool's Speed / Velocity
and Position tabs.
134 Fault tracing
Code Error
Cause
What to do
4023 Not enough test data to This error can occur during any of
analyse the autotuning tests, namely the
(_ecINSUFFICIENT_TES Measure motor resistance and
See errors 4018, 4019 and 4020 for
the reasons why these tests fail.
T_DATA)
inductance test, the Measure the
voltage constant and Measure the
motor inertia tests, and the
Feedback calibration test (for
absolute encoders only). Generally,
error 4023 means that insufficient
data was logged during the test to
obtain accurate parameter
measurement.
4024 Flux model parameters The Measure the motor inertia test To determine the voltage constant,
are invalid will fail with this error if the voltage either select a standard motor from
(_ecINVALID_FLUX_MO constant has not been defined.
DEL)
the database in the Drive Setup
Wizard, enter a voltage constant value
in the Confirm Motor Information
page of the Drive Setup Wizard (see
manufacturer's motor data), or run
the Measure the voltage constant
test.
4025 Load model is invalid
If this error occurs during the
See error 4020 for more information.
(_ecINVALID_LOAD_MO Measure the motor inertia test, it
DEL)
suggests that the characteristics of
the load are such that inertia cannot
be accurately calculated.
Error 4025 can also occur during the In this case, run the Measure the
Calculate the speed and position
gains test if the values of load
inertia and damping have not been
defined.
motor inertia test to measure load
inertia and damping.
4026 Encoder parameter
invalid
Either; EncoderResolution < 1 or
EncoderCycleSize = 0.
Correct Encoder parameters and re
run autotune tests
4027 Motor inductance is not When motor type is AM, Lm or Llr <= To avoid this error, make sure that a
set
0.
motor has been selected from the
database in the Drive Setup Wizard.
Alternatively, if a custom motor has
been selected and you are unsure of
motor data, check that the “Measure
motor resistance and inductance”
test has been selected and run using
the Autotune tool.
Fault tracing 135
Code Error
Cause
What to do
4028
Can't set stator
resistance
(_ecCANNOT_SET_STATO
R_RESISTANCE)
Can't set stator resistance.
Error codes 4028 to 4054 will occur if the
associated drive parameter, calculated
by one of the autotuning tests, or set by
the user is outside the allowable range of
values. These errors should not normally
occur.
4029
Can't set stator leakage
inductance
Can't set stator leakage inductance.
If the problems persist, make sure that a
motor has been selected from the
database in the Drive Setup Wizard.
Alternatively, if a custom motor has been
selected and you are unsure of motor
data, check that the “Measure motor
resistance and inductance” test has been
selected and run using the Autotune tool.
If the problem persists you will need to
manually tune the control loops in the
drive.
(_ecCANNOT_SET_STATO
R_INDUCTANCE)
4030
4031
4032
4033
Motor pole pitch invalid
Calculated motor pole pitch <= 0.
Motor pole number invalid Calcualted motor poles < 2.
Load inertia is not set Calcaulted load inertia <= 0.
Can't set maximum motor Can't set motor flux model time
flux
constant.
(_ecCANNOT_SET_MOTO
R_MAX_FLUX)
4035
4036
4037
Can't set load inertia
(_ecCANNOT_SET_LOAD_I
NERTIA)
Can't set load inertia.
Can't set load damping.
Can't set controller proportional gain.
Can't set load damping
(_ecCANNOT_SET_LOAD_
DAMPING)
Can't set controller
proportional gain
(_ecCANNOT_SET_GAIN_
KIPROP)
4038
4039
4040
4041
4042
4043
Can't set current
controller integral gain
(_ecCANNOT_SET_GAIN_
KIINT)
Can't set current controller integral
gain.
Can't set speed controller Can't set speed controller integral gain.
proportional gain
(_ecCANNOT_SET_GAIN_
KVPRO
Can't set speed controller Can't set speed controller integral gain.
integral gain
(_ecCANNOT_SET_GAIN_
KVINT)
Can't set position
proportional gain
(_ecCANNOT_SET_GAIN_
KPROP)
Can't set position proportional gain.
Can't set position derivative gain.
Can't set position
derivative gain
(_ecCANNOT_SET_GAIN_
KDERIV)
Can't set position integral Can't set position integral gain.
gain
(_ecCANNOT_SET_GAIN_
KINT)
136 Fault tracing
4044
4045
4046
4047
Can't set velocity
feedforward gain
(_ecCANNOT_SET_GAIN_
KVELFF)
Can't set velocity feedforward gain.
Can't set velocity feedback gain.
Can't set velocity
feedback gain
(_ecCANNOT_SET_GAIN_
KVEL)
Can't set acceleration
feedforward gain
(_ecCANNOT_SET_GAIN_
KACCEL)
Can't set acceleration feedforward
gain.
Inertia test failed
(_ecINERTIA_TEST_FAILE
D)
Inertia measurement failed
Fault tracing 137
Code Error
Cause
What to do
4048 Voltage constant test
failed
Voltage constant measurement
failed
Error codes 4028 to 4054 will occur if
the associated drive parameter,
calculated by one of the autotuning
tests, or set by the user is outside the
allowable range of values. These
errors should not normally occur.
If the problems persist, make sure
that a motor has been selected from
the database in the Drive Setup
Wizard. Alternatively, if a custom
motor has been selected and you are
unsure of motor data, check that the
“Measure motor resistance and
inductance” test has been selected
and run using the Autotune tool. If the
problem persists you will need to
manually tune the control loops in the
drive.
(_ecVOLTAGE_CONSTA
NT_TEST_FAILED)
4049 Can't set offset angle
Can't set motor feedback offset
(_ecCANNOT_SET_ANG angle (Possible encoder fault or
LE_OFFSET) wrong config)
4050 Can't set observer gain Can't set observer gain K1.
K1
(_ecCANNOT_SET_OBS
ERVER_GAIN_K1
4051 Can't set observer gain Can't set observer gain K2.
K2
(_ecCANNOT_SET_OBS
ERVER_GAIN_K2)
4052 Can't set observer gain Can't set observer gain KJ.
KJ
(_ecCANNOT_SET_OBS
ERVER_GAIN_KJ)
4053 Can't enable integral
position control
Can't enable integral position
control.
(_ecCANNOT_SET_KINT
_MODE)
4054 Can't set integral term Can't set integral term limit.
limit
(_ecCANNOT_SET_KINT
_LIMIT)
4055 Invalid autotuning
operation number
This will only occur if Mint
Workbench attempts to run an
Check Drive parameters and Re run
Autotuning tests
(_ecINVALID_OPERATIO autotuning operation not supported
N)
by the firmware.
4060 Cannot enable drive
A drive cannot be enabled unless;
Go to Mint Workbench Parameter
view and Check; Enabling >
(_ecCANNOT_ENABLE_ the hardware enable is configured
DRIVE)
but not active or the AC supply (or
shared DC bus supply) is present.
DriveEnableInput setting is correct - if
so ensure that the input is active
before running autotune.
To check drives connected voltage Go
to Mint Workbench Parameter view
and Check;
Drive > DriveBusVolts is at the correct
level (325VDC for 230VAC supply)
4061 Drive communications Communication between the host
Check the serial or USB cable.
error
PC and the controller has failed.
(_ecDRIVE_COMMS_ERR
OR)
138 Fault tracing
Code Error
4062
Cause
What to do
4063 Encoder fault
General Encoder fault
Check encoder configuration, wiring
and encoder operation when rotating
by hand.
(_ecPOSSIBLE_ENCODE
R_FAULT)
4065 Test move will take too Test move takes too long time in.
long
Check that test moves are set so that
they will not take an excessive
amount of time, Also check scaling is
set correctly by checking
SCALEFACTOR
4066 Test move velocity is
too high
Calculated velocity >
DriveSpeedMax in velocity autotune. DriveSpeedMax is set correctly
Re-run commissioning and check that
4067 Motor rated current
undefined
Motor rated current < 0.2A
Check Motor data is correct, if the
motor current is below 0.2A then its
too small to be controlled by the drive
4068 Current control loop is Current loop has not been tuned
Re-run Autotuning
not tuned
before performing the Rotor
parameters autotuning (applicable
to asynchronous motors only)
4069 Autotuning doesn't
support motor type
Cannot do the wanted Autotune for Check Motor data is correct
this motor type.
4070 Can't set flex control
proportional gain
Can't set flux control loop
proportional gain.
Check Motor data is correct
Check Motor data is correct
Check Motor data is correct
4071 Can't set flex control
integral gain
Cannot be shown because there is
no error in API.
4074 Can't set magnetizing
inductance
Cannot set motor Lm.
Parameter errors
Code Error
Cause
What to do
6001 Parameter value out of range
The value supplied for
The value you have entered or that is
stored in the parameter file (.ptx) you
have loaded does not fit within the limits
specified by the drive firmware version
loaded. If needed update the firmware
first then load the parameter file. To do
this in Mint Workbench go to Tools >
Download Firmware > Select and
download firmware file. Once complete
try again
(_ecPARAM_VALUE_OUT_OF_RA the parameter is out of
NGE)
range.
6004 Parameter definition has
changed
The specified parameter Check the latest documentation for the
exists, but its definition parameter.
(_ecPARAM_DEFINITION_ERROR) has changed.
Fault tracing 139
Communication errors
Code Error
Cause
What to do
8000 EtherCAT AL status code
This error is listed together with a This error status indicates that the
(_ecETHERCAT_AL_STATUS Profile Code in the Mint
EtherCAT master has been sent an
error code by the drive. Check the
error log to determine what the “real”
CODE)
Workbench Error Log. Note: The
displayed profile code must be
converted to hexadecimal to give drive error code is.
the specific EtherCAT error code.
8001 CIP configuration error
(_ecCIP_CFG_ERROR)
This error is listed together with a This error status indicates that the
Profile Code in the Mint
EtherCAT master has been sent a CIP
error code by the drive. Check the
error log to determine what the “real”
Workbench Error Log. The
displayed profile code must be
converted to hexadecimal to give drive error code is.
the specific CIP general status
code.
8002 POWERLINK error code
(_ecPOWERLINK_ERROR)
This error is listed together with a This error status indicates that the
Profile Code in the Mint
POWERLINK master has been sent an
error code by the drive. Check the
error log to determine what the “real”
Workbench Error Log. The
displayed profile code must be
converted to hexadecimal to give drive error code is.
the specific POWERLINK error
code.
8003 PROFInet error code
This error is reported when
This error status indicates that the
(ecPROFINET_CFG_ERROR) multicast MAC filter configuration PROFInet master has tried to
fails. configure the device ID but has failed.
140 Fault tracing
Axis errors
Code Error
Cause
What to do
10000 Motion aborted
(_ecABORT)
This error is caused by using the
ABORT keyword or breaking a Mint the mint program. This may be normal in
The ABORT keyword has been issued by
program. See ABORT and
ABORTMODE.
the operation. If its not find the issue
with the Mint program.
10001 Forward hard limit hit Drive has been configured to have a Check Drive configuration, Mint Program
(_ecFWD_HARD_LIMI Forward Limit input and its
T) currently active.
and/or Parameter file. See
LIMITFORWARD and LIMITMODE.
10002 Reverse hard limit hit See LIMITREVERSE and LIMITMODE. Check Drive configuration, Mint Program
(_ecREV_HARD_LIMIT
)
and/or Parameter file. See
LIMITREVERSE and LIMITMODE.
10003 Forward soft limit hit The axis may be configured to have Check Drive configuration, Mint Program
(_ecFWD_SOFT_LIMIT a maximum and minimum limit of
travel in software. If the axis
and/or Parameter file. See
SOFTLIMITFORWARD and
)
position exceeds one of these limit SOFTLIMITMODE.
values, a motion error will be
generated.
10004 Reverse soft limit hit The axis may be configured to have Check Drive configuration, Mint Program
(_ecREV_SOFT_LIMIT) a maximum and minimum limit of
travel in software. If the axis
and/or Parameter file. See
SOFTLIMITREVERSE and
position exceeds one of these limit SOFTLIMITMODE.
values, a motion error will be
generated.
10005 Fatal following error FOLERRORFATAL sets the
If this error occurs the axis may not be
free to move, is moving when it should
exceeded
maximum permissible following
(_ecFOLLOWING_ERR error before an error is generated. not (e.g. a suspended load with a bad
OR)
The following error is defined as
the demand position minus the
actual motor position. If the
motor brake) or there could be a
limitation within the drive (e.g. current or
speed limit) or motor size (e.g. Inertia)
that stops it moving to the target
following error exceeds the value
set by FOLERRORFATAL (maximum position with the given ACCEL/DECEL
following error) an error may be
generated.
rates before the following error is
beyond the value set by the user. See
FOLERRORFATAL and FOLERRORMODE.
Note: If this error occurs when using a
Smart Inc encoder, see Smart Inc
encoders in Mint Help.
10006 Fatal velocity error
exceeded
VELFATAL, velocity error checking
allows the measured velocity (VEL) of velocity demand is not attempting to
Check the Mint program or other source
(_ecVEL_FATAL)
of an axis to be compared to its
demand velocity (VELDEMAND). If
the difference between the two
values exceeds the limit set with
VELFATAL, then an error will be
created.
run the axis faster than the programmed
DRIVESPEEDMAX
10007 Error input active
(_ecERROR_INPUT)
An input is defined as an
ERRORINPUT and it is activated by ERRORINPUTMODE.
an error condition.
See ERRORINPUT and
Fault tracing 141
Code Error
Cause
What to do
10009 Invalid trajectory
Trajectory generation error. The
Check Mint CAM parameter file for
anamolus Data points. Excel is a helpful
tool to help with this.
(_ecPROFILE_ERROR) controller was unable to perform
the requested profile. This can
occur during CAM moves if an
invalid element is detected (e.g. a
negative master distance). An axis
performing a cam profile can skip
over very short slave segments if
the master velocity is such that the
slave segment is less than one
profiler tick in length. If more than 5
slave segments are skipped in one
profiler tick, this error will be
generated. The axis will be crash
stopped and disabled.
10010 Drive enable input is DRIVEENABLEINPUTMODE is
Check Digital Input status and correct.
inactive
configured to
(_ecDRIVE_ENABLE_I _emCRASH_STOP_DISABLE and the
NACTIVE)
input defined by
DRIVEENABLEINPUT has become
inactive whilst the drive was
enabled.
10011 Drive I.T exceeded
limit
The drive overload algorithm has
integrated up to 100% and has
Check tuning, check motion profile
(especially acceleration and
(_ecDRIVE_OVERLOA tripped the drive to protect it. This deceleration). If necessary select a larger
D)
will happen if the RMS current for
the application exceeds the
DRIVERATEDCURRENT value.
drive (which may also require an
alternative motor).
10012 Power base is not
ready to enable
The Power base has been asked to Check of power base ambient conditions
enable but is not ready. For it to be and supply voltage. Include interlocks in
(_ecPOWER_BASE_N so it must have the correct voltage any program being used that check
OT_READY) and supply and not be overheated. DRIVEENABLEREADY.
10013 Power module has an There’s circuit detection in power Possible causes of this are Over
error unit and the signal is connected to temperature, Over Current, Brake
(_ecPOWER_MODULE the DSP. The power unit generated chopper Short circuit or poor earthing or
_FAULT)
an error while in operation. over
current, earth fault, over
shielding (particularly of motor power
cables). Power cycle to clear the error.
temperature on power board
10014 Over current trip
Based on the drives currently
Check the motor is free to rotate, has
(_ecOVER_CURRENT) configured DRIVERATINGZONE the been sized correctly and there are no
drive has detected a motor
short circuits on the drive output wiring.
overcurrent state. Measured
current should not exceed the
maximum current. The maximum
current is related with the over
current and the rated current.
142 Fault tracing
Code Error
Cause
What to do
10015 Over speed trip
(_ecOVER_SPEED)
The drive has detected the
apparent motor velocity has
Note: If this error occurs when using a
Smart Inc encoder, see Smart Inc
exceeded the trip threshold set by encoders (setting a high application max
DRIVESPEEDMAX and the
VELFATAL parameters
speed and 200% velocity threshold may
be necessary when using Smartabs). For
other feedback types check the integrity
of the feedback wiring and the
earthing/shielding of all cables to/from
the drive.
10016 Over voltage trip
AGE)
The drive has shut down to protect Decrease deceleration rate, add a regen
(_ecBUS_OVER_VOLT itself after the measured dc bus
resistor if one is not fitted. Consider use
voltage exceeded the preset limit. of common dc bus if there are multiple
This can often occur during
drives where some regenerate and some
deceleration, particularly with large motor.
inertial loads
10017 Under voltage trip
TAGE)
The drive has shut down to protect Decrease the acceleration rate. If the
(_ecBUS_UNDER_VOL itself after the measured dc bus
fault occurs when the axis is not
accelerating check the supply
connections to the drive. A larger
voltage fell below a preset limit.
This can often occur during
acceleration, particularly with large motor/drive combination may be
inertial loads
Note: if
required if the needed acceleration
cannot be achieved.
DRIVEBUSUNDERVOLTSOVERRIDE
is 0, low limit will use power data,
otherwise will use
DRIVEBUSUNDERVOLTSOVERRIDE.
10018 Motor I^2.T exceeded The motor overload algorithm has Check tuning, check motion profile. If
limit
integrated up to 100% and has
necessary select a larger motor (which
may also require an alternative drive).
(_ecMOTOR_OVERLO tripped the drive to protect the
AD)
motor. This will happen if the RMS
current for the application exceeds
the MOTORRATEDCURRENT value.
Fault tracing 143
Code Error
Cause
What to do
When using feedback temperature
10019 Motor temperature
trip
#1. Motor Over Temperature has
been detected on the drive and the monitoring, X10 connections TH1 and
(_ecMOTOR_TEMP_IN drives hardwired Thermistor X10
TH2 should be connected with a wire link
(short-circuited) to suppress the normal
temperature trip function.
Note: MOTORTEMPERATURETRIP does
not monitor the drive's X10 motor
thermistor input. Also look for a fault
with feedback cable or wiring.
PUT)
input has detected Motor
overheating from the connected
motor PTC sensor
#2. Motor Over Temperature has
Set MOTORTEMPERATURETRIP to a
been detected on the drive and the resistance that is suitable for the
Motor Encoder is of a serial variety motor's thermistor device. e.g.
(such as Hiperface DSP which
provides motor thermistor
MOTORTEMPERATURETRIP(0) = 1200.
Also look for a fault with feedback cable
resistance as part of the feedback or wiring.
data). If this value exceeds
MOTORTEMPERATURETRIP the
drive trips with a motor
overtemperature error
Note: MOTORTEMPERATURETRIP
operates only with motors that have a
positive temperature coefficient (PTC)
thermistor, where resistance increases
with temperature, or with motors that
have a switch that goes open-circuit at
high temperatures.
10020 Phase search failure
Phase search must be completed to Phase search must be completed to
(_ecPHASE_SEARCH_ control a motor with type “encoder control a motor with type “encoder
FAILED)
only”
only”- if it does not finish successfully
check encoder settings in drive and
check the correct number of motor poles
has been configured.
10021 Hall signals lost or
incorrect
This error indicates that a feedback This error would normally indicate a
type of halls only or Encoder + Halls faulty encoder in the motor (the
(_ecHALL_SIGNAL_LO is used and has detected an error. If encoders include simulated hall signals)
SS)
this is so the halls sensor state is
checked by the drive and that the
Hall state detected is illegal (0 or
7).
or bad wiring to the motor encoder.
Check the quality of installation, wiring
and encoder type selection.
Note: You can use Mint Workbench to
scope Encoder Hall State to look for
problems.
144 Fault tracing
Code Error
Cause
What to do
10022 Encoder signals lost
or incorrect
This indicates that either there has Check the quality of installation, wiring
been a total break or total
and encoder type selection.
(_ecENCODER_SIGNA disruption with the encoder
Note: You can use Mint Workbench to
scope Encoder Hall State and Encoder to
look for problems.
L_LOSS)
signals.
Note: To get more information on this
error connect to the Drive with Mint
Workbench go to “Parameters > Encoder
> Channel 0 > Encoder
Parameter(Encoder0, Fault Register)” If
this contains a value other than 0 you can
use this value to give you more help on
the error. See help file subject:
ENCODERPARAMETER. Check all
earthing and shielding arrangements are
as per the instruction manual.
10023 Encoder power
supply loss
Power supply to encoder has been Check that there are no shorts in the
lost or has dropped below the
encoder wiring to the encoder supply
(e.g. ensure the shields are not shorting
to the supply or other signal pins). If the
wiring is OK and the problem persists
(_ecENCODER_SUPPL minimum level for the selected
Y_LOSS)
encoder type.
Note: encoder voltage is supplied
by the drive.encoder power is given then it is likely one of the internal power
from power board, then transferred supplies is failing.
from 8v to 5v by control board.
10026 PDO data is not
present (Mn to Cn)
EtherCAT or EPL PDO data from the This error will occur on the drive if it has
manager (MN) to the remote axis
lost its connection to the Manager.
Check that the Manager is running,
configured correctly and the network is
(_ecPDO_DATA_MISSI (CN) has been lost. This error
NG_MN_TO_CN)
occurs if the remote axis detects
that at least two consecutive PDO operating correctly.
packets have not been received
correctly.
10027 Remote motion
command failed
Unable to load motion on the
remote axis. Generally speaking,
This can be caused by a number of
reasons, such as incorrect operating
(_ecREMOTE_MOTIO this error indicates MML in drive is mode, the motor brake being enabled or
N_FAILED)
10028 Encoder not ready to The drive is configured to use a
operate
not ready for operation.
the move buffer being full.
The encoder may take several seconds to
Serial Encoder and it is not able to become ready and this error will be
(_ecENCODER_NOT_ provide position information.
READY)
generated if an attempt is made to
enable the axis before the encoder is
ready. This error can also occur if the
resolution configured on the drive is not
compatible with the encoder. The axis
will be crash stopped and disabled.
Note: To get more information on this
error connect to the Drive with Mint
Workbench go to “Parameters > Encoder
> Channel 0 > Encoder
Parameter(Encoder0, Fault Register)” If
this contains a value other than 0 you can
use this value to give you more help on
the error. See help file subject:
ENCODERPARAMETER
Fault tracing 145
Code Error
Cause
What to do
10029 Supply phase loss
detected
The three phase drive has detected Check the connection of the input
that one of the AC supply phases
phases. If the connections are OK and a
MotiFlex e180 is tripping spuriously (e.g.
(_ecSUPPLY_PHASE_L may been lost. The drive can
OSS)
normally only operate using a three because the application requires harsh
phase supply. MotiFlex e100 drives repeated accel and decel cycles) then you
have dedicated phase monitoring
hardware, MotiFlex e180 drives
monitor the ripple on the dc bus
and if this becomes excessive then
they assume an input phase has
been lost
can disable phase loss detection using
PHASELOSSMODE(0) = 0
10030 PDO data is not
present (Cn to Mn)
PDO data from the remote axis
(CN) to the manager (MN) has been e100 if it detects a drive disappears from
This error will occur on the NextMove
(_ecPDO_DATA_MISSI lost. This error occurs if the
the network. This may be “normal” for an
manager detects that at least two optional node (and the error must be
consecutive PDO packets have not handled via the ONERROR event). If this
NG_CN_TO_MN)
been received correctly.
error is unexpected check the drive is not
resetting and check the integrity of the
Ethernet (EPL) cabling.
10032 PDO value out of
range
When controlling an axis using Real Connect to the drive whilst the error is
time Ethernet one of the PDOs sent active and use the Error Log to
(_ecPDO_VALUE_OUT to the drive were out of range. This determine which PDO is out of range. If
_OF_RANGE)
is often the velocity reference PDO it's velocity then check the Mint program
and can be caused when an axis is to ensure axes that are geared to master
geared to a master axis/encoder
and the master position/encoder
references are not geared when those
master references position/encoder
value is changed via the program to values are written to.
a new value causing an infinite
velocity demand.
10033 STO active
Either one or both of the Safe
Check drive STO inputs, if used check the
(_ecSTO_ACTIVE)
Torque Off inputs is not powered. wiring of the safety circuit or for open
This error can occur only when the guards or Emergency stops etc.
drive is enabled.
10034 STO hardware fault
Either one or both of the internal
Check drive STO inputs, if used check the
wiring of the safety circuit or for open
guards or Emergency stops etc.
(_ecSTO_HARDWARE_ fault circuit outputs has been
FAULT)
asserted, indicating an internal
hardware fault in the STO circuits.
This error can occur when the drive
is enabled or disabled.
10035 STO input mismatch The drive has detected a mismatch Check the two drive STO inputs are in the
(_ecSTO_INPUT_MIS in its internal STO registers. This
same state with a multimeter. It may be
necessary to adjust STOMISMATCHTIME
to account for any timing discrepancies
in the connected safety circuit.
MATCH)
error can occur when the drive is
enabled or disabled.
10036 Encoder reading
wrong or Hall fault
The drive has detected that the
measured Hall transition angle
Check the quality of installation, wiring
and encoder type selection.
(_ecENCODER_READI differs from the electrical angle
Note: You can use Mint Workbench to
scope Encoder Hall State and Encoder to
look for problems. Check that all
earthing / shielding is as per the drive
installation manual.
NG_WRONG)
used in the control by at least 70
degrees.
146 Fault tracing
Code Error
Cause
What to do
10037 All axis errors cleared This information message can
(_ecAXIS_ERRORS_CL appear in the error log to indicate
No action required.
EARED)
that all axis errors have been
cleared.
10038 Encoder battery dead This information message can
(_ecENCODER_BATTE appear at startup, or when the drive
Change the Encoder battery.
RY_DEAD)
is enabled, if the battery backup
supply for a Smart Abs encoder has
failed.
10039 Resolver signals lost An error has occurred when using
or incorrect
(_ecRESOLVER_SIGNA or FB-03). The error is caused by the motor connector, and the connections
Check the wiring to the motor’s
the Resolver Adapter (OPT-MF-201 feedback device, the integrity of the
L_LOSS)
loss of resolver signals.
inside to the adapter.
Note: To get more information on this
error connect to the Drive with Mint
Workbench go to “Parameters > Encoder
> Channel 0 > Encoder
10040 Hiperface DSL
encoder error
An error has occurred when reading
the position over Hiperface DSL.
(_ecHIPERFACE_DSL_
ENCODER_ERROR
Parameter(Encoder0, Fault Register)” If
this contains a value other than 0 you can
use this value to give you more help on
the error. See help file subject:
ENCODERPARAMETER. Check all
earthing / shielding is as per the drive
installation manual.
10041 Output frequency
over limit
The drive has detected that the
output frequency exceeded 550 Hz.
Reduce your application's speed.
(_ecOUTPUT_FREQ_O This restriction is required to meet
VER_LIMIT)
relevant European Export Control
Regulation.
10042 Drive speed
Motor velocity is above parameter Go to parameters > Drive >
DriveSPeedMax(0) DriveSpeedMax and check value is set
Maximum is out of
range
(ecDRIVESPEEDMAX_
OUT_OF_RANGE)
correctly. Check Commanded Drive
Speed is not too high.
10045 Position and velocity The drive has detected that the axis 1 Check the motor, the encoders, other
encoder deviation
exceeded
exceeds its deviation error limit
during the dual encoder operation. 2 Check the value of the keyword
equipments and connections.
The drive acts according to the
FOLERRORFATALis not too low.
stop mode configured by
POSVELENCODERDEVIATIONERROR
MODE.
10046 Brake chopper short An error has occurred when the
Check the wiring to the brake chopper.
The error could not be reset until the
system is restart.
circuit
drive detected that the brake
chopper is short-connected at
power-on.
Fault tracing 147
Controller errors
Code
Error
Cause
What to do
30001
Controller
The drive has detected it is
dangerously hot.
Check the drive ambient conditions
allow for sufficient cooling.
Note: TEMPERATURE will return the
current temperature, in degrees
Celsius, from the drive's internal
temperature sensor. If the temperature
exceeds the predefined
over-temperature
(_ecOVER_TEMPERATUR
E)
TEMPERATURELIMITFATAL value
(model dependent), then an
overtemperature trip will be caused.
TEMPERATURELIMITFATAL for each
drive is;
e190 3A is 80°C,
e190 6A and 9A is 75°C
30005
30007
FPGA failed to initialise The controller FPGA has failed Power cycle. If Error Persists Replace
(_ecFPGA_INITIALISATIO to initialize.
N_ERROR)
the Drive.
Error accessing non-
volatile memory
Unable to access non-volatile Power cycle. If Error Persists Replace
memory. the Drive.
(_ecNON_VOL_MEMORY
_FAILURE)
30008
Error applying
parameter value
(_ecPARAM_ERROR)
Errors have occurred during a This Error is most commonly associated
parameter table download or with either a parameter file (.ptx) issue.
during startup. Some of the
parameters could not be
It is a common problem if the
parameter file is generated from an
applied correctly. See the Error older firmware version with either
Log for details of the failures. different parameters or different
The controller's status display parameter limits. Read the Error log for
will flash only 'E', and will not be specific guidance on the effected
followed with the usual error
code digits.
parameters.
30009
30010
General internal
controller error
(_ecINTERNAL_ERROR)
An internal error has occurred. Power cycle. If Error Persists Replace
Read parameter failed. the Drive.
Fan is not operating
correctly
(_ecFAN_LOSS)
The drive has detected that an Check the bottom of the drive to
internal cooling fan has failed. determine that the fan inlets are not
blocked and the fan is rotating. If the
drive fan does not turn, the general is
the fan hardware failure, need to
replace the fan.
30029
Controller under-
temperature
(_ecUNDER_TEMPERAT than -5 °C.
URE)
The controller has detected an The ambient temperature must be
ambient temperature lower
increased before the drive can be
enabled.
148 Fault tracing
Code
Error
Cause
What to do
30030
All controller errors
cleared
This information message can No Action.
appear in the error log to
(_ecCONTROLLER_ERRO indicate that all controller
RS_CLEARED) errors have been cleared.
Hardware revision does The controller does not
30032
Earlier Hardware revisions of e180 (with
not support EPL
(_ecHARDWARE_DOES_
NOT_SUPPORT_EPL)
support Ethernet POWERLINK. GCU-01 control cards before Rev A) do
not support EPL and on these old
hardware revisions if the EPL address
switches are not both set at '0' then this
error will be generated. Old drives will
still work in every other mode but if EPL
is needed the Hardware will need to be
exchanged.
error handing.
Maintenance 149
11
Maintenance
What this chapter contains
This chapter contains preventive maintenance instructions.
Safety
before performing any maintenance on the equipment. Ignoring the
safety instructions can cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little
maintenance. This table lists the routine maintenance intervals recommended
by ABB.
Maintenance
Capacitor
Interval
Instruction
Every year of storage
See Reforming
reforming
Heat sink
temperature
check and
cleaning
Depends on the dustiness of the
environment (every 6 to 12 months)
150 Maintenance
Cooling fan
change
Every 6 years if the ambient
temperature does not exceed 45 °C
(113 °F).
Every 3 years if the ambient
temperature is higher than 45 °C
(113 °F).
Heat sink
The heat sink fins pick up dust from the cooling air. The drive might report
overtemperature warnings and faults if the heat sink is not clean. In a normal
environment, the heat sink should be checked annually, in a dusty environment
more often.
instructions can cause physical injury or death, or damage to the
equipment.
WARNING! Use a vacuum cleaner with an anti-static hose and nozzle. A
normal vacuum cleaner can cause static discharges which can cause
damage to circuit boards:
Clean the heat sink as follows (when necessary):
1. Stop the drive and disconnect it from input power.
2. Wait for 5 minutes and measure to make sure that there is no voltage. Refer
4. Blow clean, dry, and oil free compressed air from the bottom of the heat sink
to the top. Use a vacuum cleaner at the air outlet to trap the dust. If there is
a risk that dust can go into other equipment, clean the heat sink in another
room.
5. Install the cooling fan.
Maintenance 151
Cooling fan
The actual lifespan of the cooling fan depends on the drive usage and ambient
temperature. Fan failure can be predicted by the increasing noise from fan
bearings and the gradual rise in the heat sink temperature in spite of heat sink
cleaning. If the drive is operated in a critical part of a process, fan replacement
is recommended once these symptoms start appearing. Replacement fans are
available from ABB. Do not use other than ABB-specified spare parts.
Removing the fan
Place the drive on its side as shown. Push in the two retaining clips (1) at the
back of the drive. Remove the base (2) by pulling on the top edge first.
Disconnect the fan cable (3). Carefully bend the clips on the fan holder (4) to
release the fan.
1
2
3
Airflow direction
4
152 Maintenance
Replacing the fan
Insert the new fan (1) ensuring the airflow direction is bottom-to-top. Route the
wire through the retaining clip and connect the cable to the circuit board (2).
Insert the front edge of the base into the front panel (3). Apply outward
pressure at the centre of the base and simultaneously push the fan into the
drive (4). Check that the plastic lug fits into the recess in the heat sink (5). Check
that the fan cable has not moved or obstructed the encoder voltage switch (6,
fitted into the mounting plate (7).
2
1
Airflow direction
5
6
4
3
4
4
7
Maintenance 153
Reforming the capacitors
Overview of the reforming
ElectrolyticDC capacitorsin theservodriveDClinkneedtobe reformed (re-aged)if
the drive has been non-operational for a year or more. The reforming time
depends on how long the drive has been non-operational.
Without reforming, the capacitors can get damaged when the drive starts to
operate.
Besides the reforming methods presented in this manual, ABB can supply you
with ready-made reforming devices. For more information, contact your local
ABB representative.
Reforming time
The intermediate circuit (DC link) of the drive is connected to its nominal
voltage for the reforming time to “wake up” the capacitors. The diagram below
shows the required reforming time.
•
If the drive has been non-operational for less than one year, the capacitors
do not need reforming.
•
If the drive has been stocked (non-operational) for one to two years, it can
be reformed with power on for 30 minutes method. See section Reforming
•
If the drivehas been stocked (non-operational) for moretwo years, it can be
reformed using the method in section Reforming with external DC power
154 Maintenance
Checking the drive age
The serial number (S/N) defines the year and the week when the drive was
manufactured:
•
•
The 2nd and 3rd digits indicate the year of manufacture.
The 4th and 5th digits indicate the week.
For example, in S/N W195260084, 19 denotes manufacturing year (2019), 52
denotes manufacturing week.
Reforming with power on for 30 minutes
This method can be used for capacitor reforming if the drive has been stocked
(non-operational) for one to two years.
1. Switch the power on to the drive for 30 minutes.
2. Do not load the drive while the reforming is ongoing.
The drive “wakes up” its capacitors on its own, after which it is ready for use.
Reforming with external DC power supply
This method can be used for capacitor reforming if the drive has been stocked
(non-operational) for two years or longer.
ignore them, injury or death, or damage to the equipment can occur.
Never switch on the drive power supply while the reforming circuit is connected.
Lock the disconnector (if any) to an open position.
1. Make sure that the drive is disconnected from all possible power sources (all
AC and DC inputs/outputs are disconnected).
2. Measure that the installation is de-energized:
•
•
Use a multimeter with an impedance of at least 1 MΩ.
Make sure that the voltage between the drive input power terminals (L1,
L2 and L3) and the grounding terminal (PE) is close to 0 V.
•
Make sure that the voltage between the drive DC terminals (UDC+ and
UDC-) and the grounding terminal (PE) is close to 0 V.
3. Make this reforming circuit and connect it to the DC terminals of the drive.
Maintenance 155
Note: Limit the reforming current to max. 200 mA. If the DC power supply does
not have an adjustable current limiter, increase the voltage gradually from 0 V
to 400 V.
WARNING! The capacitors can get damaged if you use excessive DC
voltage during the reforming.
5. Switch off the reforming circuit.
6. Wait for 5 minutes to let the DC capacitors discharge.
7. Measure that the voltage of the DC terminals of the drive is close to 0 V.
8. Disconnect the reforming circuit from the drive.
156 Maintenance
Reforming with another e190 drive
This method can be used for capacitor reforming if the drive has been stocked
(non-operational) for two years or longer and only external AC power supply can
be provided.
ignore them, injury or death, or damage to the equipment can occur.
Never switch on the drive power supply while the reforming circuit is connected.
Lock the disconnector (if any) to an open position.
1. Make sure that the drive is disconnected from all possible power sources (all
AC and DC inputs/outputs are disconnected).
2. Measure that the installation is de-energized:
•
•
Use a multimeter with an impedance of at least 1 MΩ.
Make sure that the voltage between the drive input power terminals (L1,
L2 and L3) and the grounding terminal (PE) is close to 0 V.
•
Make sure that the voltage between the drive DC terminals (UDC+ and
UDC-) and the grounding terminal (PE) is close to 0 V.
3. Make this reforming circuit and connect it to the DC terminals of the drive.
As shown below, the another normal operational e190 needs to be connected to
AC power supply (1-phase or 3-phase) to provide DC power supply to the drive
which need to be reformed.
Maintenance 157
4. Switch on the AC power supply of the reforming circuit for the time defined
5. Switch off and disconnect the AC power supply of the reforming circuit.
6. Wait for 5 minutes to let the DC capacitors discharge.
7. Measure that the voltage of the DC terminals of the drive is close to 0 V.
8. Disconnect the reforming circuit from the drive.
160 Technical data
Ratings
The nominal current ratings for the MicroFlex e190 with 200...240 V AC supply
are given below. For example, if a 3 A model is required to provide brief 300%
overloads, assume its rated current is only 2.5 A.
Drive type
MFE190-04UD... switching
PWM
300%
3 s
overload
200%
3 s
overload
Low speed
output*
(< 2 Hz)
Stationary:
DC output,
any phase
(A)
frequency
(Hz)
(Arms
)
(Arms
)
(Arms)
-03A0-2
8000
2.5
3.0
3.0
4.2
Drive type
MFE190-04UD... switching
PWM
300%
3 s
overload
200%
3 s
overload
Low speed
output*
(< 2 Hz)
Stationary:
DC output,
any phase
(A)
frequency
(Hz)
(Arms
)
(Arms
)
(Arms)
-06A0-2
8000
5.25
6.0
6.0
8.5
Drive type
MFE190-04UD... switching
PWM
300%
3 s
overload
200%
3 s
overload
Low speed
output*
(< 2 Hz)
Stationary:
DC output,
any phase
(A)
frequency
(Hz)
(Arms
)
(Arms
)
(Arms)
-09A0-2
8000
7.5
9.0
9.0
12.7
The DriveSize dimensioning tool available from ABB is recommended for
selecting the drive, motor and gear combination for the required motion profile.
* The maximum overload current between 0 Hz and 2 Hz is 150% of rated
current.
Derating
At altitudes from 1000 to 2000 m (3280 to 6560 ft) above sea level, the derating
is 1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize
PC tool.
Technical data 161
Cooling
Method
Internal fan, flow from bottom to top, air-cooled heat sink.
Free space around the
unit
Cooling characteristics, noise levels
Drive type
MFE190-04UD...
Max. power loss
W
Air flow
m3/h
56.4
56.4
56.4
Noise level
dBA
-03A0-2
-06A0-2
-09A0-2
60
130
135
45
45
45
Efficiency
Approximately 98% at nominal power level.
The efficiency has not been defined according to IEC 61800-9-2.
162 Technical data
Supply cable fuses
Fuses for short circuit protection of the supply cable are listed below. The fuses
also protect the adjoining equipment of the drive in case of a short circuit.
Check that the operating time of the fuse is below 0.5 seconds. The operating
time depends on the supply network impedance and the cross-sectional area
Note: Fuses with a higher current rating must not be used.
1Φ AC supply
Drive type
MFE190-04UD... current
(A)
Input
IEC fuse
UL fuse
Cross-sectional
area of cable
Bussmann
series:C10G20
Bussmann Class
CC KTK-R-20
2
Rated Voltage Class Rated Voltage UL
AWG
mm
current
(V)
current
(V)
Class
(A)
(A)
-03A0-2
-06A0-2
-09A0-2
7
14
20
500
500
500
gG
gG
gG
600
600
600
1.5...4 16…12
1.5...4 16…12
1.5...6 16…10
20
20
CC
3Φ AC supply
Drive type
MFE190-04UD... current
(A)
Input
IEC fuse
UL fuse
Cross-sectional
area of cable
Bussmann
series:C10G20
Bussmann Class
CC KTK-R-20
2
Rated Voltage Class Rated Voltage UL
AWG
mm
current
(V)
current
(V)
Class
(A)
(A)
-03A0-2
-06A0-2
-09A0-2
4
8
12
500
500
500
gG
gG
gG
600
600
600
1.5...4 16…12
1.5...4 16…12
1.5...6 16…10
20
20
CC
Technical data 163
AC input (supply) connection
1Φ
3Φ
Voltage (U1)
200...240 V AC ±10%
50...60 Hz 5%
Grounded (TN, TT).
200...240 V AC ±10%
±
Frequency
Network type
Corner grounded TN, and IT (ungrounded) systems not allowed.
Imbalance
±
Max. 3% of nominal phase to
phase input voltage
Fundamental power
factor (cos phi1)
0.98 (at nominal load)
Terminals
Detachable screw terminal block for 0.20..6 mm2 wire.
The drive is suitable for use on a circuit capable of delivering not
more than 5000 A rms symmetrical amperes, 264 V maximum, when
Short circuit current
protection
(UL 61800-5-1)
Effect of AC power supply voltage on DC-bus voltage
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)
164 Technical data
Effect of AC power supply voltage on DC-bus ripple voltage
50
40
30
9 A model, single-phase AC supply
20
3 A, 6 A models, single-phase AC supply
10
All models, three-phase AC supply
0
100
125
150
175
200
225
250
AC supply voltage (RMS)
Effect of output current on DC-bus ripple voltage
70
60
50
9 A model, single-phase AC supply
40
30
3 A, 6 A models, single-phase AC supply
All models, three-phase AC supply
20
10
0
20
30
40
50
60
70
80
90
100
110
120
130
140
150
% of drive rated current
Technical data 165
DC input (supply) connection
Voltage
Ratings
270...340 V DC ±10%
Drive type
MFE190-04UD...
IdcN
(A)
C
(µF)
-03A0-2
-06A0-2
-09A0-2
3.67
7.35
11.02
560
1120
1120
IdcN is the average DC input current requirement.
Detachable screw terminal block for 0.20...6 mm2 wire.
Terminals
Motor connection
Motor types
Asynchronous induction motors, asynchronous servo motors,
synchronous permanent magnet motors
Frequency
0...550 Hz
Current
8 kHz
Switching frequency
Maximum motor cable
length
30 m (98 ft) with screened cable
Detachable screw terminal block for 0.20...6 mm2 wire.
Terminals
Brake resistor connection
Description
Unit
V DC
kW
All models
on: 388, off: 376
0.25
Nominal switching threshold
Nominal power
(10% peak power, r = 57 Ω
Peak power
kW
2.7
(10% peak power, r = 57 Ω
Maximum brake switching current
Apk
10
Minimum load resistance
Maximum load inductance
Ω
39
µH
100
166 Technical data
Circuit breaker connection
Recommended circuit breaker selection table for the AC supply cable protection
with the drive.
Note: supply cable and network variables (cable size, short circuit current, etc.)
must always be evaluated before commissioning any circuit breaker.
1-phase 220Vac power supply
DRIVE
MFE190-
MCB (S 200 series)
S 202 Dxx*
MCB (S 200 series)
S 202 M- Dxx*
TYPE
04UD-xxxx-2
I2n [A]
In [A]
Ue [VAC
]
Icu [kA]
In [A]
Ue [VAC
]
Icu [kA]
03A0
06A0
09A0
10
20
25
400
400
400
6
6
6
10
20
25
400
400
400
10
10
10
3-phase 220Vac power supply
DRIVE
MFE190-
MCB (S 200 series)
S 203 Dxx*
MCB (S 200 series)
S 203 M- Dxx*
TYPE
04UD-xxxx-2
I2n [A]
In [A]
Ue [VAC
]
Icu [kA]
In [A]
Ue [VAC
]
Icu [kA]
03A0
06A0
09A0
10
20
25
400
400
400
6
6
6
10
20
25
400
400
400
10
10
10
Nomenclature:
= nominal output current of the drive
I
2n
I = nominal current of the circuit breaker (or limiter)
n
U = rate supply voltage
e
I
= breaking capacity of the circuit breaker
cu
xx* = I
n
Technical data 167
Control unit
X2: Control circuit supply
input
24 V (±10%) DC, 1 A
Optional external power supply through connector X2
(pitch 5.08 mm, wire size 2.5 mm2).
Connector pitch 3.5 mm, wire size 1.0 mm2
X3: Analog input AI0
Voltage input: –10…10 V, Rin: 120 kΩ
Differential inputs, common mode ±10 V
Sampling interval per channel: 0.25 ms
Filtering: Adjustable using ADCTIMECONSTANTkeyword
(see Mint Workbench help file)
Resolution: 11 bit + sign bit (±4.9 mV)
Connector pitch 3.5 mm, wire size 1.0 mm2
X3: Analog output AO0
AO0 (voltage): –10…10 V, Rload > 1 kΩ
Update interval: 1 kHz
Resolution: 11 bit + sign bit (±4.9 mV)
Connector pitch 3.5 mm, wire size 1.0 mm2
Logic levels: “0” < 5 V, “1” > 15 V
Rin: 2 kΩ
X3: Digital inputs DI1…DI2
Hardware latching:
Minimum pulse width: 250 ns
Minimum step time: 250 ns
Minimum space time: 250 ns
Direction input setup time: 250 ns
Direction input hold time: 100 ns
Maximum input frequency: 2 MHz, PTO maximum 500 kHz
Sampling interval: 1 kHz
Filtering: Adjustable using INPUTDEBOUNCEkeyword (see
Mint Workbench help file)
Connector pitch 3.5 mm, wire size 1.0 mm2
Logic levels: “0” < 5 V, “1” > 15 V
Rin: 2 kΩ
X3: Digital inputs DI0, DI3
Minimum pulse width: 5 µs
Filtering: Adjustable using INPUTDEBOUNCEkeyword (see
Mint Workbench help file)
X3: Digital outputs
DO0...DO2
User supply: 24 V DC
Output current: 100 mA max. per output, Rload > 250 Ω
Connector pitch 3.5 mm, wire size 1.0 mm2
Output supply: STO power, 30 mA per input
Pulse tolerance: < 1 ms
X4: Safe Torque Off (STO)
For the drive to start, both connections STO1 and STO2
must be powered.
E1: Ethernet host PC
connection
Connector: RJ-45
Cable length < 3 m
Memory capacity
256 KB program / variables; 1 KB non-volatile data
168 Technical data
Feedback
X7 Incremental encoder without Halls
Encoder interface
RS422 A/B differential, Z index,
RS422 Pulse+Direction differential
Max. input frequency A / B
2 MHz (8 MHz quadrature counts)
Output power supply to encoder 5.5 V DC (±7%) 350 mA max.*
Maximum recommended cable
length
30 m
* Total combined current for this encoder and X8 primary encoder, which may
X8 Incremental encoder with Halls
Encoder interface
Max. input frequency A / B
Hall inputs
RS422 A/B differential, Z index
2 MHz (8 MHz quadrature counts)
RS422 A/B differential
Output power supply to encoder 5.5 V DC (±7%) 350 mA max.* or 8 V DC set by switch
Maximum recommended cable
length
30 m
* Total combined current for this encoder and the X7 encoder input, which may
X8 Serial interfaces + SinCos
Supports BiSS-B, SSI, EnDat 2.1, EnDat 2.2, Smart Abs, SinCos and Hiperface
using required combinations of the following inputs:
Signals
Differential input pairs for Data, Clock, Sin, Cos.
Device types:
BiSS-B, Smart Abs
SSI
EnDat, SinCos
Hiperface
Single or multi-turn devices.
Single turn devices up to 18-bit.
Single or multi-turn devices, 512 or 2048 cycles per
turn, absolute positioning up to 65536 steps.
SinCos signal: 1 V pk-pk sine wave centered on a 2.5 V
reference.
Output power supply to encoder 5.5 V or 8-12 V set by switch, 350 mA max.*
Maximum recommended cable
length
30 m
* Total combined current for this encoder and either the X8 extra incremental
Technical data 169
Dimensions and weights
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a
heated, indoor, controlled environment.
Operation
Storage
Transportation
installed for stationary in the protective in the protective
use
package
package
Installation site
altitude
0 to 2000 m (6560 ft)
above sea level. [See also
160.]
-
-
Air temperature
Relative humidity
-40 to +70 °C
(-40 to +158 °F)
-40 to +70 °C
(-40 to +158 °F)
0 to +55 °C (32 to 131 °F).
No frost allowed.
0 to 95%
Max. 95%
Max. 95%
No condensation allowed. Maximum allowed relative humidity is
60% in the presence of corrosive gases.
Contamination levels No conductive dust allowed.
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.
Sinusoidal vibration: Tested according to,
–
–
EN 60068-2-6: 2008
mechanical conditions:
2…9 Hz: 3.0 mm (0.12”)
9…200 Hz: 1g
Shock:
EN 60068-2-27: 2009
IEC 60068-2-27:2008
–
Max. 10g, 11 ms
76 cm (30”)
Max. 10g, 11 ms
76 cm (30”)
Free fall
Not allowed
170 Technical data
Degrees of protection
MicroFlex e190 complies with EN 60529, IP20.
For UL purposes the MicroFlex e190 is defined as an open-type, three phase
single axis servo amplifier.
The drive must be installed in a cabinet to fulfill the requirements for shielding
from contact. Access to the cabinet should be restricted to trained
maintenance staff.
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
PC/ABS, color NCS 1502-Y (RAL 9002 / PMS 1C Cool Grey) and RAL
9017 (Traffic black).
Hot-dip zinc coated steel sheet extruded aluminum AlSi.
Packaging
Disposal
Corrugated cardboard, PP bands.
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.
If recycling is not feasible, all parts excluding electrolytic
capacitors and printed circuit boards can be landfilled. The DC
capacitors contain electrolyte, which is classified as hazardous
waste within the EU. They must be removed and handled
according to local regulations.
For further information on environmental aspects and more
detailed recycling instructions, contact your local ABB distributor.
WEEE notice
According to the requirements of the Waste Electrical and Electronic
Equipment Directive (WEEE) the following information is provided.
This symbol indicates that the product must not be disposed of with
other general waste. It is your responsibility to dispose of your waste
electrical equipment by handing it over to a designated collection
point for the recycling of waste electrical and electronic equipment. The
separate collection and recycling of your waste equipment at the time of
disposal will help conserve natural resources and ensure that it is recycled in a
Technical data 171
manner that protects human health and the environment. For more information
about where you can recycle your waste, please contact your local authority.
RoHS compliance
MicroFlex e190 is in conformity with Directive 2011/65/EU of the European
parliament and of the council of 8th June 2011 on the restriction of the use of
certain hazardous substances in electrical and electronic equipment. The RoHS
declaration 3AXD10000540158 is available on new.abb.com/motion.
China RoHS marking
The People's Republic of China Electronic Industry Standard (SJ/T
11364-2014) specifies the marking requirements for hazardous
substances in electronic and electrical products. The green mark is
attached to the drive to verify that it does not contain toxic and
hazardous substances or elements above the maximum
concentration values, and that it is an environmentally-friendly
product which can be recycled and reused.
Part
Hazardous substances
Lead Mercury Cadmium
Hexavalent
chromium
(Cr(VI))
Polybrominated Polybrominated
biphenyls (PBB) diphenyl ethers
(PBDE)
(Pb)
(Hg)
(Cd)
PCB
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
Metal parts
Plastic parts
O: Indicates that said hazardous substance contained in all of the homogeneous materials for this
part is below the limit requirement of GB/T 26572.
X: Indicates that said hazardous substance contained in at least one of the homogeneous materials
used for this part is above the limit requirement of GB/T 26572. The limits are:
Pb: 1000 ppm (0.1%)
Cr6+: 1000 ppm (0.1%)
Hg: 1000 ppm (0.1%)
PBB: 1000 ppm (0.1%)
Cd: 100 ppm (0.01%)
PBDE: 1000 ppm (0.1%)
172 Technical data
Applicable standards
MicroFlex e190 complies with the following standards.
Design and test standards
UL 61800-5-1:2018
EN 61800-5-1:2007
Power Conversion Equipment.
Adjustable speed electrical power drive systems. Safety
requirements. Electrical, thermal and energy.
EN 60529:1991 +
A2:2013
Degrees of protection provided by enclosures.
EN 61800-3:2004 +
A1:2012
Adjustable speed electrical power drive systems. Electromagnetic
compatibility.
Conducted emissions:
When installed as directed in this manual, MicroFlex e190
conforms to Category C2 conducted limits.
Radiated emissions:
When installed as directed in this manual, MicroFlex e190
conforms to Category C2 radiated limits.
All frame sizes conform to the ‘second environment’ immunity
requirements defined by this standard.
EN 61800-9-2:2017
Adjustable speed electrical power drive systems. Ecodesign for
power drive systems, motor starters, power electronics and their
driven applications.
See also the CE Declaration of Conformity available on the Internet, see
Environmental test standards:
EN 60068-1:2014
EN 60068-2-1:2007
EN 60068-2-2:2007
EN 60068-2-6:2008
Environmental testing, general and guidance.
Environmental testing, Test A. Cold.
Environmental testing, Test B. Dry heat.
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 60068-2-78:2013 Environmental testing, Test Cab. Damp heat, steady state.
Technical data 173
Functional safety standards
EN 61508:2010,
Parts 1, 2
Functional safety of electrical/electronic/programmable
electronic safety-related systems
EN 61800-5-2:2007
IEC 61800-5-2:2016
Adjustable speed electrical power drive systems: Safety
requirements, Functional
EN ISO 13849-1:2015 Safety of machinery: Safety-related parts of control systems. Part
1: General Principles for Design
EN ISO 13849-2:2012 Safety of Machinery: Safety-related parts of control systems. Part
2: Validation
EN 62061:2005 +
A1: 2013 + A2: 2015
Safety of machinery: Functional safety of safety-related electrical,
electronic and programmable electronic control systems
RCM marking
RCM marking is required in Australia and New Zealand. A RCM mark is
attached to each drive in order to verify compliance with the relevant
standard (IEC 61800-3, Adjustable speed electrical power drive systems -
Part 3: EMC product standard including specific test methods).
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.
CE Declaration of Conformity
The declaration (3AXD10001229164) is available on the Internet. See Document
Compliance with the European Low Voltage Directive
The compliance with the European Low Voltage Directive has been verified
according to standard EN 61800-5-1:2007. Declaration is available on the
Internet.
Compliance with the European RoHS Directive
The RoHS Directive defines the restriction of the use of certain hazardous
substances in electrical and electronic equipment. The declaration is available
on the Internet.
174 Technical data
Compliance with the European WEEE Directive
The WEEE Directive defines the regulated disposal and recycling of electric and
electronic equipment.
Compliance with the European EMC Directive
The cabinet builder is in responsible for the compliance of the drive system with
the European EMC Directive. For information on items to consider, see:
•
with EN 61800-3, category C4, below.
•
•
Technical Guide No. 3 – EMC Compliant Installation and Configuration for a
Power Drive System (3AFE61348280 [English]).
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 domestic premises. It also includes establishments
directly connected without intermediate transformers to a low-voltage network
which supplies buildings used for domestic purposes.
Second environment includes all establishments other than those directly
connected to a low-voltage network which supplies buildings used for domestic
purposes.
Drive of category C2. Power drive system with rated voltage less than 1000 V
which is neither a plug-in device nor a movable device and, when used in the
first environment, is intended to be installed and commissioned only by a
professional.
Drive of category C3. Power drive system with rated voltage less than 1000 V,
intended for use in the second environment and not intended for use in the first
environment.
Drive of category C4. Power drive system with rated voltage equal to or above
1000 V, or rated current equal to or above 400 A, or intended for use in complex
systems in the second environment.
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.
Technical data 175
Compliance with EN 61800-3, category C2 & C3
The drive meets the requirements of the EMC Directive with the following
provisions:
2. The motor and control cables are selected as specified in the chapter
3. The drive is installed according to the instructions given in this manual.
Motor cable length does not exceed 30 metres (98.4 ft)
Compliance with EN 61800-3, category C4
The drive meets the requirements of the EMC Directive with the following
provisions:
1. It is ensured that no excessive emission is propagated to neighbouring low-
voltage networks. In some cases, the natural suppression in transformers
and cables is sufficient. If in doubt, a supply transformer with static
screening between the primary and secondary windings can be used.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage
Low voltage
Equipment
(victim)
Drive
Equipment
Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A
template is available from the local ABB representative.
3. The motor and control cables are selected as specified in the chapter
4. The drive is installed according to the instructions given in this manual.
176 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 EN 61800-5-2, IEC 61800-5-2, EN ISO 13849-1, EN 62061, and
EN 61508 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.
UL marking
See the type designation label for the valid markings of your drive.
UL checklist
Disconnecting device (Disconnecting means) – See section Supply disconnecting
Ambient conditions – The drive is to be used in a heated indoor controlled
Input cable fuses – 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
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 given in section
Power cable connections – For the connection diagram and tightening torques,
Control connections – For the connection diagram and tightening torques, see
Overload protection – The drive provides overload protection in accordance
with the National Electrical Code (US).
Technical data 177
Braking – The MicroFlex e190 has an internal braking chopper. When applied
with appropriately sized braking resistors, the braking chopper allows the drive
to dissipate regenerative energy (normally associated with quickly decelerating
a motor). Braking resistor selection is discussed in the chapter Resistor braking
178 Technical data
Mains filters 179
13
Mains filters
What this chapter contains
This chapter describes how to select and install mains filters for the
MicroFlex e190. The chapter also contains the relevant technical data.
When is a mains filter required?
The EMC product standard (EN 61800-3) covers the specific EMC requirements
stated for drives (tested with motor and cable) within the EU. EMC standards
such as EN 55011 or EN 61000-6-3/4 apply to industrial and household
equipment and systems including drive components inside. Drive units
complying with the requirements of EN 61800-3 are always compliant with
comparable categories in EN 55011 and EN 61000-6-3/4, but not necessarily
vice versa. EN 55011 and EN 61000-6-3/4 do neither specify cable length nor
require a motor to be connected as a load. The emission limits are comparable
according to the following table.
EMC standards in general
EN 61800-3, product
standard
EN 61800-3,
product standard
EN 55011, product family
standard for industrial,
scientific and medical (ISM)
equipment
1st environment,
unrestricted distribution
1st environment,
restricted distribution
2nd environment,
unrestricted distribution
Category C1
Category C2
Category C3
Category C4
Group 1 Class B
Group 1 Class A
Group 2 Class A
Not applicable
2nd environment,
restricted distribution
180 Mains filters
A mains filter is required in order for MicroFlex e190 to meet the category C2
level, using a motor with a max. 30 m cable. This level corresponds to the A
limits for Group 1 equipment according to EN 55011.
WARNING! A mains filter must not be installed if the drive is connected to
an IT power system (i.e. an ungrounded, or a high resistance grounded
[over 30 Ω] power system).
Footprint filter (single phase only)
The single-phase footprint AC power filter, part OFI-01, provides mounting
holes for the MicroFlex e190. This allows the filter and MicroFlex e190 to use
minimal panel mounting space.
P r o t e c t i v e
Earth (PE)
Mains filters 181
Installation guidelines
•
If a mains choke is also installed, the mains filter is connected between the
mains choke and the drive. See the diagram below.
•
For optimal operation of the filter, the drive and the filter must be mounted
on the same conductive surface.
•
•
•
Ensure the filter does not block the airflow through the drive.
Keep the cable between the drive and the filter as short as possible.
Connect the filter grounding cable to the protective earth (PE) point of the
drive. The PE point is located on the top panel of the drive.
Connection diagram
AC supply
L1
L2
L3
PE
Mains choke (if present)
Mains filter
L1
L2
L3
L1’
L1
L2’
L2
L3’
L3
PE
MicroFlex e190
~
~
Selection table
Drive type
230VAC 1Ø
230VAC 3Ø
MFE190-04UD...
Meets EN 61800-3, category C2 Meets EN 61800-3, category C2
with motor cable <30 m
with motor cable <30 m
-03A0-2
-06A0-2
-09A0-2
OFI-02 or OFI-01
OFI-03
OFI-01
JFI-02
The mains filters are protected to IP20.
182 Mains filters
Specifications and dimensions
Part
Rated
volts
Rated
amps
@ 40°C
Leakage
current
(mA)
Weight
kg (lbs)
OFI-02
OFI-03
JFI-02
OFI-01
250
480
480
250
8
7
0.7
33
33
12
0.33 (0.73)
0.5 (1.1)
16
20
0.8 (1.76)
0.72 (1.59)
Dimensions, type OFI-01:
Mounting slot detail
Dimension
OFI-01
Dimensions: mm (inches)
A
B
C
D
E
F
I
260 (10.23)
73 (2.87)
239.5 (9.43)
50 (1.97)
40 (1.57)
21.5 (0.87)
M5×10 (0.39) max. depth
Mains filters 183
Dimensions, type OFI-02:
L
C
H
D
E
A
G
F
K
J
B
Dimension
OFI-02
Dimensions: mm (inches)
113.5 (4.47)
57.5 (2.26)
45.4 (1.79)
94 (3.7)
A
B
C
D
E
F
G
H
J
103 (4.06)
25(0.98)
12.4 (0.49)
32.4 (1.28)
4.4 (0.17)
K
L
6 (0.24)
15.5 (0.61)
184 Mains filters
Dimensions, types OFI-03 / JFI-02:
D
C
M5
A
F
B
G
E
Dimension
Dimensions: mm (inches)
OFI-03
JFI-02
A
B
C
D
E
190 (7.48)
40 (1.57)
70 (2.76)
160 (6.30)
180 (7.09)
20 (0.79)
4.5 (0.18)
250 (9.84)
45 (1.77)
70 (2.76)
220 (8.66)
235 (9.25)
25 (0.98)
5.4 (0.21)
F
G
EMC screw disconnection
This operation is applicable only to special application that the filter is not
suitable for, such as the leakage current sensitive environment.
Please contact ABB technical support for more information.
Resistor braking 185
14
Resistor braking
What this chapter contains
This chapter contains information about calculating the regenerative power
created by the motor when it decelerates or is driven by the load. The chapter
then describes the process for selecting an appropriate resistor to dissipate
the regenerative power.
WARNING! Electrical shock hazard. DC-bus voltages can be present at the
brake resistor 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).
186 Resistor braking
Introduction
Each drive has a braking capacity that defines the amount of regenerative
energy its DC bus capacitors can store before the voltage on the capacitors
exceeds the drive’s over-voltage level. In a common DC system, all of the drive’s
DC bus capacitors are connected, so the system braking capacity becomes the
sum of all the drives’ braking capacities. If the total regenerative energy in the
system exceeds the system braking capacity, the excess energy must be
diverted into a brake resistor (also known as a regeneration or ‘regen’ resistor)
to be dissipated as heat. The brake resistor can be connected to one drive in the
system, but if that drive’s braking chopper cannot withstand the total
regenerative power in the system, more than one drive must be fitted with a
brake resistor.
System braking capacity
The braking capacity of the drive is calculated from the following formula:
B
= 0.5 x DC bus capacitance x ((Brake switching threshold)2 – ( 2 x Supply voltage)2
)
dc
where the Brake switching threshold is 388 V. This gives the following typical
values:
Braking capacity, Bdc (J)
MicroFlex e190
Model Frame
DC bus
capacitance (μF)
240 V AC supply
03A0-2
06A0-2
09A0-2
A
A
A
560
12.5
1120
25
Resistor braking 187
Braking energy calculation
The following calculations can be used to estimate the type of brake resistor
that will be required for the application. To complete the calculation, some
basic information is required. Remember to use the worst-case values to ensure
that the braking power is not underestimated. For example, use the maximum
possible motor speed, maximum inertia, minimum deceleration time and
minimum cycle time that the application might encounter.
Requirement
Enter value here
a) Initial motor speed, before decelera-
tion begins, in radians per second.
Initial motor speed, U = _________ rad/s
Multiply RPM by 0.1047 to give radians
per second.
b) Final motor speed after deceleration
is complete, in radians per second.
Final motor speed, 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
Cycle time, C
= _________ s
= _________ s
d) The total cycle time (i.e. how fre-
quently the process is repeated), in
seconds.
e) Total inertia.
This is the total inertia seen by the drive,
accounting for motor inertia, load inertia
and gearing. Use the Mint Workbench
Autotune tool to tune the motor, with the
load attached, to determine the value.
This will be displayed in kg·m2 in the
Autotune tool. If you already know the
motor inertia (from the motor spec.) and
the load inertia (by calculation) insert the
total here.
Total inertia, J
= ________ kg·m2
2
2
Multiply kg·cm by 0.0001 to give kg·m .
2
2
Multiply lb-ft by 0.04214 to give kg·m .
2
2
Multiply lb-in-s by 0.113 to give kg·m .
188 Resistor braking
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
2
2
--
E = J
where E is energy, J is the moment of inertia, and ω is the angular velocity.
The braking energy, which is the difference between the initial energy and the
final energy, is therefore:
1
--
1
--
2
2
E =
J U
–
J V
2
2
J U – V2
1
--
2
=
2
= ________________ J (joules)
Calculate the braking energy for the motor. If the value is less than the system
dc
required.
Braking power and average power
The braking power, P
, is the rate at which the braking energy is
gen,max
shorter the deceleration period, the greater the braking power.
E
Pgen,max
=
D
P
= ________________ W (watts)
gen,max
overloads, but the average power dissipation must not exceed the stated
continuous power rating. The average power dissipation is determined by the
proportion of the application cycle time spent braking. The greater the
Resistor braking 189
proportion of time spent braking, the greater the average power dissipation.
This average value can be used to represent an equivalent continuous braking
D
Pgen,ave = Pgen,max
×
C
= ________________ W (watts)
Calculate the maximum braking power P
and the equivalent continuous
gen,max
braking power P
for the motor.
gen,ave
Resistor choice
P
is the value to use when assessing which brake resistor to use.
gen,ave
However, a safety margin of 1.25 times is recommended to ensure the resistor
1
operates well within its limits , so:
Required resistor power rating = 1.25 × P
gen,ave
________________ 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
39 Ω
Power rating
100 W
RGJ139
RGJ160
RGJ260
RGJ360
60 Ω
100 W
60 Ω
200 W
60 Ω
300 W
WARNING! The brake resistance must be 39 Ω or greater to ensure the
drive’s maximum regeneration switching current (10 A) is not exceeded.
Failure to observe the minimum resistance could result in damage to the drive.
1. The brake resistors listed in the following table can withstand a brief overload of 10 times
the rated power for 5 seconds. Please contact ABB if larger power ratings are required.
190 Resistor braking
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.
Resistorpart
number
Nominal
power rating
(W)
In free air
On heat sink
RGJ139
RGJ160
100
Derate power linearly from: Derate power linearly from:
80% @ 25 °C (77 °F)
to
100% @ 25 °C (77 °F)
to
70% @ 55 °C (113 °F)
88% @ 55 °C (113 °F)
Typical heat sink:
200 mm x 200 mm x 3 mm
RGJ260
RGJ360
200
300
Derate power linearly from: Derate power linearly from:
70% @ 25 °C (77 °F)
to
100% @ 25 °C (77 °F)
to
62% @ 55 °C (113 °F)
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
Decel time
v
0.5 s
0.5 s
0.5 s
t
2.5 s
(Cycle time)
2.5 s
(Cycle time)
2.5 s
(Cycle time)
Resistor braking 191
Dimensions
B
A
D
C
E
F
G
Part
Power
W
Res.
Ω
Dimensions mm (inches)
A
B
C
D
E
F
G
RGJ139
RGJ160
RGJ260
RGJ360
100
100
200
300
39
60
60
60
165
(6.49)
41
(1.61)
22
152
12
10
4.3
(0.17)
(0.87) (5.98) (0.47) (0.39)
22 152 12 10
(0.87) (5.98) (0.47) (0.39)
165
(6.49)
41
(1.61)
4.3
(0.17)
165
60
30
(1.18)
146
(5.75)
17
(0.67)
13
(0.51)
5.3
(0.21)
(6.49) (2.36)
215 60
(8.46) (2.36)
30
(1.18)
196
(7.72)
17
(0.67)
13
(0.51)
5.3
(0.21)
192 Resistor braking
Accessories 193
15
Accessories
What this chapter contains
This section describes accessories and options that you might need to use with
your MicroFlex e190. 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.
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
100-240 V AC
100-240 V AC
100-240 V AC
115/230 V AC
115/230 V AC
115/230 V AC
Output voltage
24 V DC
Output rating
0.75 A
1.25 A
2.5 A
CP-E 24/0.75
CP-E 24/1.25
CP-E 24/2.5
CP-E 24/5.0
CP-E 24/10.0
CP-E 24/20.0
24 V DC
24 V DC
24 V DC
5 A
24 V DC
10 A
24 V DC
20 A
194 Accessories
Encoder breakout OPT-MF-200
The encoder breakout (part OPT-MF-200) can be used to connect motor
connectors can be used together to connect a single motor that has separate
cables for encoder and Halls (e.g. a linear motor).
OPT-MF-200
MicroFlex e190
OPT-MF-200
Motor feedback
Incremental encoder
Accessories 195
Resolver adapter OPT-MF-201
The resolver adapter (OPT-MF-201) allows a motor with resolver feedback to be
connected to the MicroFlex e190. The MicroFlex e190 must be power-cycled
after connecting the resolver adapter. The resolver adapter sends an absolute
position to the MicroFlex e190 at startup, so a phase search is not required. In
Mint Workbench, select a resolver motor in the Drive Setup Wizard. The wizard’s
Feedback page will show the feedback type as Resolver Adapter. The resolver
adapter can be used in conjunction with the encoder breakout (OPT-MF-200).
Resolver adapter specifications
•
•
•
•
Excitation frequency: 10 kHz
Maximum input speed: 60000 rpm (2 pole resolver)
Output resolution: 12-bit
Accuracy: +/-11 arc minutes
Resolver requirements
When selecting the resolver, you must connect it to the OPT-MF-201 adapter
a resolver which satisfies the following criteria:
•
2 x Sin / Cos pairs (2 pole resolver)
Winding ratio 0.5
•
196 Accessories
Note: These are the key characteristics to be used when deciding if the resolver
is compatible or not.
Further information on the resolver adapter can be found below:
•
•
•
•
•
Excitation supply load (REF output) 100 mA max.
Excitation frequency 10 kHz
Typical accuracy ± 5 arc minutes
Maximum recommended cable length 30 m
Maximum input speed 60000 rpm
Accessories 197
Option card OPT-SIO-1
The option card can provides:
1 general purpose analog input
6 general purpose digital inputs
4 general purpose digital outputs
1 RS485/ RS422 serial port
One analog input with a 12-bit resolution receives a wide range from -10V to
+10V.
Six digital input channels are divided into 2 groups. Each group is powered by
separate external power supply and allows the input signal to be connected
with either polarity. All digital outputs share one common external power
supply and the maximum voltage across the outputs when active is 30VDC.
Serial port supports 4-wire or 2-wire connections. DIP switch SW2 is used for
connecting terminal resistor.
See OPT-SIO-1 option card user’s manual (code:3AXD50000351336) for details.
Note: The firmware build version that supports the option card is MicroFlex
e190 Build 5900.4.0 and later.
Switch
Purpose
RS422 RX terminator
OFF
NO
NO
ON
120Ω
120Ω
2
1
RS422 TX terminator
or RS485 terminator
X9
X10
Pin 1 Pin 8
Pin 14 Pin 7
1
2
3
TX+/ A
TX-/ B
Shield
8
9
TX+/ A
TX-/ B
14 Shield
7
6
5
DIN4
DIN5
DIN6
13 CREF1
10 Shield
12
DIN8
4
5
6
7
RX+
11 RX+
11 DIN9
4
3
2
1
DIN7
RX-
12 RX-
10 USRV+
CREF0
DOUT3
DOUT4
Shield
AIN1-
13 Shield
14 AIN1+
9
8
DOUT5
DOUT6
198 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 -12
S
BSM style threaded motor
connector (motor end only)
Current
(Amps)
Standard
m
ft
SP
WP
RP
-
connector
1.5
2.5
3.0
5.0
6.1
7.5
9.1
10
5*
8.2
Stainless
connector
6
S
10*
16.4
20*
24.6
30*
32.8
49.2
50*
65.6
75*
100*
SDM style threaded motor
connector (motor end only)
12
20
35
50
90
Raw cable
(no connector)
15
15.2
20
22.9
30.5
* 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 199
Feedback cables
The part number for a feedback cable is derived as follows:
CBL 020 SF -E
1
S
BSM servo motor
feedback cable with
at least 1 connector
BiSS
Raw cable
Standard
m
ft
SF
WF
DF
B
D
-
-
connector
Legacy
controllers
EnDat
SinCos
1
2.5
5.0
7.5
10
8.2
Stainless steel
connector
SDM servo motor
feedback cable with
at least 1 connector
S
16.4
24.6
32.8
49.2
65.6
98.4
Incremental
encoder
e100 / e150
e180 / e190
E
2
Servo motor
feedback cable with
drive connector only
15
SSI
S
A
R
20
30
Smart Abs
RF Raw cable
(no connector)
Resolver
Other lengths available on request
Example:
A 2 m encoder feedback cable for a MicroFlex e190 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
2
obtain a cable that is a shielded twisted pair 0.34 mm (22 AWG) wire minimum,
with an overall shield. Ideally, the cable should not exceed 30.5 m (100 ft).
Maximum wire-to-wire or wire-to-shield capacitance is 50 pF per 300 mm (1 ft)
length, to a maximum of 5000 pF for 30.5 m (100 ft).
Ethernet cables
The cables listed in this table connect MicroFlex e190 to other Ethernet nodes
such as the controller, additional MicroFlex e190s, or other Ethernet compatible
hardware. The cables are standard CAT5e shielded twisted pair ‘crossover’
Ethernet cables:
Cable description
Part
Length
m
ft
CAT5e Ethernet cable
CBL002CM-EXS
CBL005CM-EXS
CBL010CM-EXS
CBL020CM-EXS
CBL050CM-EXS
CBL100CM-EXS
CBL200CM-EXS
0.2
0.5
1.0
2.0
5.0
10.0
20.0
0.65
1.6
3.3
6.6
16.4
32.8
65.6
200 Accessories
Connectors
The MFE190 DRIVE CONNECTOR KIT (order code: 3AXD50000038521)
containing terminal blocks for the e190 drive can be provided separately if
necessary.
The connector pack contains:
No.
Connector
Description
Quantity
1
X1A
1
2
3
X1B
X2
1
1
4
5
X3
X4
1
1
Note: The pictures are for reference only. Actual connectors are subject to
change without notice.
Accessories 201
Screws and clamps
The MFE190 DRIVE INSTALLATION KIT (order code: 3AXD50000447121)
containing memory unit (MU) fixing screw, grounding screws and cable shield
clamps for the e190 drive can be provided separately if necessary.
The installation pack contains:
No.
Name
Description
Quantity
P-CLIP, AL5
1
Cable shield clamp
3
M4x8
M3x8
2
3
5
1
Grounding screw
MU fixing screw
202 Accessories
Appendix: The Safe Torque Off (STO) function 203
16
Appendix: The Safe Torque
Off (STO) function
Contents of this chapter
The appendix describes the Safe torque off (STO) function for the servo drive
and gives instructions for its use. In addition, application features and technical
data for the safety system calculation are presented.
Description
The STO function disables the control voltage of the power semiconductors of
the drive output stage, which prevents the drive generating the voltage
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 STO function has a redundant architecture, that is, both channels must be
used in the safety function implementation. The safety data given in this
manual is calculated for redundant use, and does not apply if both channels are
not used.
The STO function complies with these standards:
Standard
Name
IEC 60204-1:2016
EN 60204-1:2018
EN 61000-6-7:2015
Safety of machinery – Electrical equipment of machines – Part 1:
General requirements
Electromagnetic compatibility (EMC) – Part 6-7: Generic
standards – Immunity requirements for equipment intended to
perform functions in a safety-related system (functional safety)
in industrial locations
204 Appendix: The Safe Torque Off (STO) function
Standard
Name
EN 61326-3-1:2017
Electrical equipment for measurement, control and laboratory
use – EMC requirements – Part 3-1: Immunity requirements for
safety-related systems and for equipment intended to perform
safety-related functions (functional safety) – General industrial
applications
EN 61508-1:2010
EN 61508-2:2010
Functional safety of electrical/electronic/programmable
electronic safety-related systems – Part 1: General requirements
Functional safety of electrical/electronic/programmable
electronic safety-related systems – Part 2: Requirements for
electrical/electronic/programmable electronic safety-related
systems
EN 61511-1:2016
Functional safety – Safety instrumented systems for the process
industry sector
EN 61800-5-2:2007
IEC 61800-5-2:2016
Adjustable speed electrical power drive systems – Part 5-2: Safety
requirements – Functional
Safety of machinery – Functional safety of safety-related
electrical, electronic and programmable electronic control
systems
EN 62061:2005 +
AC:2010 + A1:2013 +
A2:2015
EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems –
Part 1: General principles for design
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems –
Part 2: Validation
The function also corresponds to Prevention of unexpected start-up as
specified by EN ISO 14118:2018 (ISO 14118:2017), and Uncontrolled stop (stop
category 0) as specified in EN/IEC 60204-1.
Compliance with the European Machinery Directive
The Declaration of Conformity is shown at the end of this chapter.
Appendix: The Safe Torque Off (STO) function 205
Wiring
For information on the specifications of the STO input, see section Safety data
Activation switch
In the wiring diagrams below, the activation switch represents a component
such as a manually operated switch, an emergency stop push button switch, or
the contacts of a safety relay or safety PLC.
•
If a manually operated activation switch is used, the switch must be of a
type that can be locked out to the open position.
•
The STO inputs must be switched on/off within 200 ms of each other.
Cable types and lengths
•
•
Double-shielded twisted-pair cable is recommended.
Maximum cable length 30 m (98 ft) between activation switch and the drive.
Note: A short-circuit in the wiring between the switch and an STO terminal
causes a dangerous fault. Therefore, it is recommended to use a safety relay
(including wiring diagnostics), or a wiring method (shield grounding, channel
separation) which reduces or eliminates the risk caused by the short-circuit.
Note: The voltage at each channel of STO input terminal X4 must be at least 13 V
DC to be interpreted as “1”. The pulse tolerance of the input channels is 1 ms.
Grounding of protective shields
•
Ground the shield in the cabling between the activation switch and the
control unit at the control unit only.
•
Ground the shield in the cabling between two control units at one control
unit only.
206 Appendix: The Safe Torque Off (STO) function
Connection principle
Single MicroFlex e190 drive, internal power supply
MicroFlex e190
Safe Torque Off
connections
Internal
24V
source
Activation switch
(emergency stop
switch, relay etc.)
PWM control circuit
X4:4
X4:1
X4:2
PWM power
circuit
Integrated
Power
Module
DC+
Drivers
High
U+
V+
U
W+
Motor output (U phase shown)
Low
U-
V-
W-
DC-
Appendix: The Safe Torque Off (STO) function 207
Single MicroFlex e190 drive, external power supply
Activation switch
(emergency stop
switch, relay etc.)
External
24 V
source
MicroFlex e190
PWM control
circuit
Safe Torque Off
connections
X4:1
+24 V
X4:2
X4:3
+24 V
+0 V
Common
PWM power
circuit
Integrated
DC+
Power
Drivers
High
Module
U+
V+
U
W+
Motor output (U phase shown)
Low
U-
V-
W-
DC-
Notes:
* The STO function is activated when one or both of the safety circuit contacts open. If the period
between both contacts opening or closing exceeds a predefined value, a fault in the safety circuit or
wiring is assumed and an error is reported.
* The maximum cable length between drive and the safety switch is 30 m (98 ft).
208 Appendix: The Safe Torque Off (STO) function
Wiring examples
Single drive module: internal power supply
MicroFlex e190
Safe
Torque Off
connections
Activation switch
(emergency stop
switch, relay, etc.)
X4:4
X4:1
X4:2
Single drive module: external power supply
MicroFlex e190
Safe
Torque Off
connections
Activation switch
(emergency stop
switch, relay, etc.)
External
24 V
source
X4:1
+24 V
X4:2
X4:3
+0 V
Appendix: The Safe Torque Off (STO) function 209
Multiple drive modules: internal power supply
MicroFlex e190
Activation switch
(emergency stop
switch, relay, etc.)
Safe
Torque Off
connections
X4:4
X4:1
X4:2
X4:3
MicroFlex e190
Safe
Torque Off
connections
X4:1
X4:2
X4:3
MicroFlex e190
Safe
Torque Off
connections
X4:1
Note: The maximum number of drives is 16.
X4:2
X4:3
210 Appendix: The Safe Torque Off (STO) function
Multiple drive modules: external power supply
MicroFlex e190
Activation switch
(emergency stop
switch, relay, etc.)
Safe
Torque Off
connections
24 V External
Supply
X4:1
+24 V
X4:2
X4:3
+0 V
MicroFlex e190
Safe
Torque Off
connections
X4:1
X4:2
X4:3
MicroFlex e190
Safe
Torque Off
connections
X4:1
Note: The maximum number of drives is 16.
X4:2
X4:3
Appendix: The Safe Torque Off (STO) function 211
Operation principle
The Safe Torque Off connector is X4 on MicroFlex e190 drives.
possible safety relay types.
1. The wiring to each STO input must be routed separately.
2. Wiring the STO inputs in accordance with the diagrams provides Safety
Integrity Level 3 (SIL3). It is not permissible to control both STO inputs from
one safety circuit, as this does not provide SIL3 protection.
3. The Safe Torque Off (STO) function provides a stop function equivalent to
‘stop category 0’ according to EN 60204-1.
4. The STO element is classified as type A, according to EN 61508-2.
Connected components
Ensure that all components controlling the STO inputs, including cabling, do not
cause the STO inputs to become constantly powered (a ‘dangerous failure’) or
constantly unpowered (a ‘safe failure’).
Diagnostic pulses produced by Safe Digital Output devices are not recognized
by the MicroFlex e190, and will not activate the STO function provided they have
a period of less than 1 ms.
Short circuit testing
Short circuit conditions on the STO inputs must be tested within the proof test
interval.
Power supply
It is recommended to use the 24 V DC supply provided on pin 4 of connector X4.
This supply is derived from the bus voltage (if present) or from the optional 24 V
logic supply on connector X2 (if present).
If an external 24 V DC power supply is connected to X4 it must fulfill the
following criteria:
•
•
•
•
•
It must be a Safety Extra Low Voltage (SELV) supply.
It must be suitable for the desired safe application and safety integrity level.
It must be protected against over voltages.
It must limit the output voltage under all fault conditions <60V.
It must be TüV certified to EN 60950.
Appendix: The Safe Torque Off (STO) function 213
Start-up including validation test
To ensure the safe operation of a safety function, validation is required. The
final assembler of the machine must validate the function by performing a
validation test. The validation test must be performed:
•
•
•
by an authorized person
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
after a drive firmware update
at the proof test interval, T
1
Competence
The validation test of the safety function must be carried out by a competent
person with adequate expertise and knowledge of the safety function as well as
functional safety, as required by IEC 61508-1 clause 6. The test procedures and
report must be documented and signed by this person.
Validation test reports
Signed validation test reports must be stored in the logbook of the machine.
The report shall include documentation of start-up activities and test results,
references to failure reports and resolution of failures. Any new validation tests
performed due to changes or maintenance shall be recorded in the logbook.
Preliminary checks
Before powering the drive, check:
•
•
•
•
•
•
•
•
Grounding has been properly connected.
Energy sources have been properly connected and are operational.
Transportation stops and packing materials have been removed.
No physical damage is present.
All instruments have been properly calibrated.
All field devices are operational.
Interfaces are operational.
Interfaces to other systems and peripherals are operational.
214 Appendix: The Safe Torque Off (STO) function
Validation test procedure
After wiring the Safe torque off function, validate its operation as follows.
Action
WARNING! Obey the safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.
Ensure that the drive can be run and stopped freely during the commissioning.
Stop the drive (if running), switch off the input power and isolate the drive from
the power line by a disconnector.
Check the STO circuit connections against the circuit diagram.
Check that the shield of the STO input cable is grounded to the drive frame.
Close the disconnector and switch on the power.
Test the operation of the STO function when the motor is stopped:
•
•
Disable the drive and ensure the motor shaft is not rotating.
Activate the STO function (remove power from the STO inputs) and attempt
to enable the drive.
•
•
Deactivate the STO function (apply power to the STO inputs).
Test the operation of the STO function when the motor is running:
•
•
•
•
•
•
Enable the drive and start motion. Ensure the motor is rotating.
Activate the STO function (remove power from the STO inputs).
Ensure that the drive disables and the motor stops rotating.
Attempt to enable the drive.
Deactivate the STO circuit (apply power to the STO inputs).
Document and sign the validation test report which verifies that the safety
function is safe and accepted to operation.
Appendix: The Safe Torque Off (STO) function 215
Restarting the drive
Restarting the drive is not part of the STO test or certification processes, but is
included here for convenience.
Action
Deactivate the STO circuit (apply power to the STO inputs).
If the drive holds a Mint program, or is connected to an Ethernet master device that
can enable the drive, it is possible for the drive to restart and begin to control the
motor without further intervention. If the drive does not hold a Mint program, some of
the following actions are necessary, depending on the installation:
•
•
Activate the additional drive enable input (if present).
In Mint Workbench (if connected), click the Clear errors button on the System
toolbar, followed by the Drive Enable button on the Motion toolbar.
•
Enable the drive from the Ethernet master device (if connected).
216 Appendix: The Safe Torque Off (STO) function
Use
1. Open the activation switch, or activate the safety functionality that is wired to
the STO connection.
2. The STO inputs on the drive control unit de-energize, and the control unit cuts
off the control voltage from the output IGBTs.
3.The control program generates an indication, see section STO status
4. The motor coasts to a stop (if running). The drive will not restart while the
activation switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or resetting the safety
functionality that is wired to the STO connection.
6. Reset any faults before restarting.
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 from the supply and all other voltage sources. If the drive was
connected to the input power, wait for 5 minutes after disconnecting the input
power.
Hardware activation of the STO function
The drive contains two STO inputs. 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 motor output power stage is disabled. Enabling is possible
only after both STO inputs have been powered, and all the faults have been
cleared.
Firmware monitoring of the STO function
STO function activation
The firmware detects when the STO function is activated and will generates the
‘STO active’ error (10033) if the drive is enabled. The drive can be enabled again
only after all the faults have been cleared.
STO input states
The state of the STO inputs are monitored by the firmware. The state of the
STO inputs are stored in a hardware register within the drive. The register is
monitored by the drive over a period specified by the STOINPUTMISMATCHTIME
Mint keyword (the default value is 100ms). If the inputs are in different states
Appendix: The Safe Torque Off (STO) function 217
after the specified period has elapsed, the ‘STO input mismatch’ error (10035) is
generated.
WARNING! The drive cannot detect or memorize any changes in the STO
circuitry when the drive control unit is not powered. If both STO circuits
are closed and a level-type start signal is active when the power is restored, it is
possible that the drive starts without a fresh start command. Take this into
account in the risk assessment of the system.
Software monitoring of the STO function
The drive can be programmed using the Mint language. The software
application Mint Workbench is available for configuring, programming and
monitoring the status of the drive. The SAFETORQUEOFFMint keyword can be
used to report the status of the STO hardware registers. SAFETORQUEOFF
contains an array of values indicating the states of the STO channel 1 and STO
channel 2, the internal STO status output and the internal STO fault latch. This
array is described in the following table:
Parameter
Meaning
The combined state of the two STO inputs:
STO1 = bit 0, STO2 = bit 1
SAFETORQUEOFF(0)
0 = not powered, 1 = powered
The state of STO1 input:
0 = not powered, 1 = powered
The state of STO2 input:
0 = not powered, 1 = powered
The state of the internal STO status output:
0 = fault, 1 = no fault
The latch state of the internal STO status output:
0 = fault, latched, 1 = no fault, not latched
The latched value (0) can not be cleared until the drive is
enabled.
SAFETORQUEOFF(1)
SAFETORQUEOFF(2)
SAFETORQUEOFF(6)
SAFETORQUEOFF(7)
SAFETORQUEOFFvalues.
codes displayed by the drive.
218 Appendix: The Safe Torque Off (STO) function
STO status indications
The following table lists the state of the STO function with reference to:
•
•
status of the STO inputs STO1 and STO2.
SAFETORQUEOFF(1)and SAFETORQUEOFF(2)return 1 when the respective STO
input is powered (STO in standby, motor output enabled).
SAFETORQUEOFF(6)returns 1 when both inputs are powered.
No FAULTs
FAULT
FAULT
FAULT
FAULT
STO1 STO2
STO1
STO2
present
present
both present
STO in standby.
STO activated.
STO activated.
STO activated.
STO1
&
STO2
powered
Motor output enabled.
Motor output disabled. Motor output disabled. Motor output disabled.
SAFETORQUEOFF(0)=3 SAFETORQUEOFF(0)=3 SAFETORQUEOFF(0)=3 SAFETORQUEOFF(0)=3
SAFETORQUEOFF(1)=1 SAFETORQUEOFF(1)=1 SAFETORQUEOFF(1)=1 SAFETORQUEOFF(1)=1
SAFETORQUEOFF(2)=1 SAFETORQUEOFF(2)=1 SAFETORQUEOFF(2)=1 SAFETORQUEOFF(2)=1
SAFETORQUEOFF(6)=1
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
STO activated.
STO activated.
STO activated.
STO activated.
Motor output disabled. Motor output disabled. Motor output disabled. Motor output disabled.
STO1
not
powered
SAFETORQUEOFF(0)=2 SAFETORQUEOFF(0)=2 SAFETORQUEOFF(0)=2 SAFETORQUEOFF(0)=2
SAFETORQUEOFF(1)=0 SAFETORQUEOFF(1)=0 SAFETORQUEOFF(1)=0 SAFETORQUEOFF(1)=0
SAFETORQUEOFF(2)=1 SAFETORQUEOFF(2)=1 SAFETORQUEOFF(2)=1 SAFETORQUEOFF(2)=1
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
STO activated.
STO activated.
STO activated.
STO activated.
Motor output disabled. Motor output disabled. Motor output disabled. Motor output disabled.
STO2
not
powered
SAFETORQUEOFF(0)=1 SAFETORQUEOFF(0)=1 SAFETORQUEOFF(0)=1 SAFETORQUEOFF(0)=1
SAFETORQUEOFF(1)=1 SAFETORQUEOFF(1)=1 SAFETORQUEOFF(1)=1 SAFETORQUEOFF(1)=1
SAFETORQUEOFF(2)=0 SAFETORQUEOFF(2)=0 SAFETORQUEOFF(2)=0 SAFETORQUEOFF(2)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
STO activated.
STO activated.
STO activated.
STO activated.
STO1
STO2
both not
powered
Motor output disabled. Motor output disabled. Motor output disabled. Motor output disabled.
SAFETORQUEOFF(0)=0 SAFETORQUEOFF(0)=0 SAFETORQUEOFF(0)=0 SAFETORQUEOFF(0)=0
SAFETORQUEOFF(1)=0 SAFETORQUEOFF(1)=0 SAFETORQUEOFF(1)=0 SAFETORQUEOFF(1)=0
SAFETORQUEOFF(2)=0 SAFETORQUEOFF(2)=0 SAFETORQUEOFF(2)=0 SAFETORQUEOFF(2)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
SAFETORQUEOFF(6)=0
Appendix: The Safe Torque Off (STO) function 219
STO software functional diagram
MicroFlex e190
STO
X4:1
X4:2
STO1
STO1
STO2
SAFETORQUEOFF(6)
SAFETORQUEOFF(0)
STO2
SAFETORQUEOFF(1)
SAFETORQUEOFF(2)
Monitoring the delay between the STO inputs
The STO function monitors the switching time difference between the STO
STO function activation and indication delays
Hardware activation delay (the delay between removing power from an STO
input and switching off the drive output bridge): <50 ms.
Hardware indication delay (the delay between switching off the drive output
bridge and being indicated to the Mint program): <50 ms.
Software STO indication delay, Mint program (the delay between a mismatch
occurring on the STO inputs and being indicated to the Mint program): <200 ms
user defined period, set by STOINPUTMISMATCHTIME.
Special considerations for using the STO function
Drive location
The MicroFlex e190 and all associated STO wiring must be installed in an indoor
location. The MicroFlex e190 must be installed in a cabinet. The suitability of the
cabinet for the intended environment must be determined by the installer. See
Hazard analysis
A hazard analysis of the application should be performed before using the STO
function in the application.
220 Appendix: The Safe Torque Off (STO) function
Additional stopping methods
It is not recommended to stop the drive by using the STO function. If a running
drive is stopped by using the function, the drive trips and stops by coasting. If
this is not acceptable e.g. causes danger, the drive and machinery must be
stopped using the appropriate stopping mode before using this function. For
example, suspended or tensioned loads (e.g. cranes, hoists) will require
additional brakes or mechanical interlocks.
IGBT failure
If a permanent magnet motor drive experiences multiple power semiconductor
failure, the drive system can produce an alignment torque which maximally
rotates the motor shaft by 180/p degrees (p = pole pair number), even if the
STO function has been correctly activated.
Failure of one or more IGBTs can cause the drive output to fail due to:
•
•
IGBT desaturation protection causing all IGBTs to be stopped.
Rupture of the AC input fuse.
Terminology
‘Active’ or ‘activated’ means that the STO function has been triggered. This
removes power from the motor and disables the drive. The drive cannot be
restarted without further operator intervention.
‘Standby’ means that the STO function has not been triggered. The drive can
power the motor, provided all other criteria are satisfied to allow motor
operation.
Appendix: The Safe Torque Off (STO) function 221
Maintenance
After the operation of the circuit is validated at start-up, the STO function shall
be maintained by periodic proof testing. In high demand mode of operation, the
maximum proof test interval is 20 years. In low demand mode of operation, the
is assumed that all dangerous failures of the STO circuit are detected by the
Note: See also the Recommendation of Use CNB/M/11.050 (published by the
European co-ordination of Notified Bodies) concerning dual-channel safety-
related systems with electromechanical outputs:
•
When the safety integrity requirement for the safety function is SIL 3 or PL e
(cat. 3 or 4), the proof test for the function must be performed at least every
month.
The STO input terminals do not need any maintenance. Maintain the drive
according to the instructions given in this manual.
The exchange of safety related systems or subsystems must be performed only
in a powerless condition.
The STO function does not contain any electromechanical components.
In addition to proof testing, it is a good practice to check the operation of the
function when other maintenance procedures are carried out on the machinery.
Include the STO operation tests described in Special considerations for using the
to which the drive is connected.
If any wiring or component change is needed after start up, or the parameters
Use only spare parts approved by ABB.
Record all maintenance and proof test activities in the machine logbook.
Competence
The maintenance and proof test activities of the safety function must be carried
out by a competent person with adequate expertise and knowledge of the
safety function as well as functional safety, as required by IEC 61508-1 clause 6.
222 Appendix: The Safe Torque Off (STO) function
Fault tracing
The diagnostics of the STO function cross-compare the status of the two STO
channels. In case the channels are not in the same state, a fault reaction
function is performed and the drive trips on an “STO hardware failure” fault. An
attempt to use the STO in a non-redundant manner, for example activating only
one channel, will trigger the same reaction.
Any failure of the STO function must be reported to ABB.
Error messages generated by the drive
When an error occurs, the drive displays the error
code on its front panel 7 segment display. The
symbol E is displayed, followed by the digits of the
error code in sequence.
For example, error code 10033 is displayed as
E....1..0..0..3..3.
Additionally, the right decimal point is illuminated
for any STO error.
STO error
The STO errors are listed in the following table.
Note: The STO function is activated when one or both of the safety circuit
contacts open. If the period between both contacts opening or closing exceeds
a predefined value (defined by the STOINPUTMISMATCHTIMEMint keyword) a
fault in the safety circuit or wiring is assumed and an error is reported. The
maximum allowed cable length between the drive and the activation switch is
30 m (98 ft).
Appendix: The Safe Torque Off (STO) function 223
Error
Cause
What to do
10033
STO active
ecSTO_ACTIVE
Either one or both of the
STO inputs is not
powered.
This error is detected
when the drive is enabled,
or when attempting to
enable the drive in
software.
- safe switch or relay has
dropped an output that
controls the STO input.
Use a test meter to check that
the device controlling the STO
input is providing the
required output.
- emergency stop switch
has been operated.
Check the operation of the
emergency stop switch.
Check that the contacts close
correctly when the switch is
reset.
- faulty safety relay
Check the operation of the
safety relay.
10034
Either one or both of the
internal fault circuit
outputs has been
Check drive STO inputs, if
used check the wiring of the
safety circuit or for open
guards or Emergency stops
STO hardware fault
(_ecSTO_HARDWARE_
FAULT)
asserted, indicating an
internal hardware fault in etc.
the STO circuits. This
error can occur when the
drive is enabled or
disabled.
10035
The drive has detected a
mismatch in its internal
STO registers.
Check the operation of the
emergency stop switch.
Check that the contacts close
correctly when the switch is
reset.
STO input mismatch
ecSTO_INPUT_MISMATCH
This error can occur while Check that the period defined
the drive is enabled or
disabled.
by STOINPUTMISMATCHTIME
is long enough to allow both
STO inputs to settle.
- emergency stop switch
fault
Check the operation of the
emergency stop switch.
Check that the contacts close
correctly when the switch is
reset.
- wiring fault
Check all wiring for the STO
inputs.
224 Appendix: The Safe Torque Off (STO) function
Decommissioning
Before decommissioning any safety system from active service:
•
Evaluate the impact of decommissioning on adjacent operating units and
facilities or other field services.
•
•
Conduct a proper review and obtain required authorization.
Ensure that the safety functions remain appropriate during
decommissioning activities.
Implement appropriate change management procedures for all
decommissioning activities.
Appendix: The Safe Torque Off (STO) function 225
Safety data
The safety data for the STO function and failure rates are given below.
Note: The safety data is calculated for redundant use, and does not apply if
both STO channels are not used.
Drive SIL / PL SFF
PFH
1
(1/h)
PFD
PFD
MTTF
(a)
DC SC Cat. HFT CCF
(%)
T
M
(a)
avg
avg
D
SILCL
(%) (T =20a)
(T =2a) (T =5a)
1
1
3
e
>99 1.84E-09 1.61E-05 4.03E-05 41836 ≥90
3
3
1
80
20
e190
3AXD10000462009 B
•
The following temperature profile is used in safety value calculations:
•
•
•
•
•
•
670 on/off cycles per year with ΔT = 71.66 °C
1340 on/off cycles per year with ΔT = 61.66 °C
30 on/off cycles per year with ΔT = 10.0 °C
32 °C board temperature at 2.0% of time
60 °C board temperature at 1.5% of time
85 °C board temperature at 2.3% of time.
•
•
The STO is a type A safety component as defined in IEC 61508-2.
Relevant failure modes:
•
•
The STO trips spuriously (safe failure)
The STO does not activate when requested
A fault exclusion on the failure mode “short circuit on printed circuit board”
has been made (EN 13849-2, table D.5). The analysis is based on an
assumption that one failure occurs at one time. No accumulated failures
have been analyzed.
•
•
•
•
•
•
STO reaction time (shortest detectable break): 1 ms
STO response time: 5 ms (typical), 10 ms (maximum)
Fault detection time: Channels in different states for longer than 200 ms
Fault reaction time: Fault detection time + 10 ms
STO fault indication delay: < 500 ms
STO warning indication delay: < 1000 ms
226 Appendix: The Safe Torque Off (STO) function
Abbreviations
Abbreviation Reference
Description
Classification of the safety-related parts of a
control system in respect of their resistance to
faults and their subsequent behavior in the fault
condition, and which is achieved by the structural
arrangement of the parts, fault detection and/or by
their reliability. The categories are: B, 1, 2, 3 and 4.
Cat.
EN ISO 13849-1
CCF
DC
EN ISO 13849-1
EN ISO 13849-1
EN 61508
Common Cause Failure (%)
Diagnostic Coverage
HFT
IGBT
Hardware Fault Tolerance
Insulated-gate bipolar transistor: The electrical
components that drive the motor power outputs
MTTFD
PFDavg
PFH
EN ISO 13849-1
EN 61508
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.
Average probability of dangerous failure on
demand, that is, mean unavailability of a safety-
related system to perform the specified safety
function when a demand occurs.
IEC 61508
Average frequency of dangerous failures per hour,
that is, average frequency of a dangerous failure of
a safety related system to perform the specified
safety function over a given period of time.
PL
EN ISO 13849-1
EN 61508
Performance level. Levels a…e correspond to SIL.
Systematic capability
SC
SFF
SIL
EN 61508
Safe failure fraction (%)
EN 61508
Safety integrity level (1…3)
SILCL
IEC/EN 62061
Maximum SIL (level 1…3) that can be claimed for a
safety function or subsystem.
STO
T1
IEC/EN 61800-5-2 Safe Torque Off
IEC 61508-6 Proof test interval. T1 is a parameter used to define
the probabilistic failure rate (PFH or PFD) for the
safety function or subsystem. Performing a proof
test at a maximum interval of T1 is required to keep
the SIL capability valid. The same interval must be
followed to keep the PL capability (EN ISO 13849)
valid.
Appendix: The Safe Torque Off (STO) function 227
TM
EN ISO 13849-1
Mission time: the period of time covering the
intended use of the safety function/device. After
the mission time elapses, the safety device must be
replaced. Note that any TM values given cannot be
regarded as a guarantee or warranty.
CE Declaration of Conformity
The declaration (3AXD10001229164) is available on the Internet. See Document
TüV Certificate
The TüV Certificate (3AXD10001229165) is available on the Internet. See
228 Appendix: The Safe Torque Off (STO) function
STO technical data
STO safety relay type
General requirements
Output requirements
EN 61508 and/or EN 61511 and/or EN ISO 13849-1
No. of current paths
2 independent paths (one for each STO path)
30 V DC per contact
Switching voltage capability
Switching current capability
10 mA per contact per drive
<200 ms
Maximum switching delay
between contacts
Internal supply/multiple units
Maximum length of safety
circuit from operating contact
to most distant drive
30 m (98.4 ft)
16
Maximum number of drives in
circuit
External supply/multiple units
External power supply
Current requirement
Example 1
24 V DC ±10% SELV
20 mA per connected drive
Simple SIL3 approved safety relay
PSR-SCP- 24UC/ESP4/2X1/1X2 by Phoenix Contacts
EN 954-1, cat 4; EN 61508, SIL3
Programmable safety logic
Type and manufacturer
Approvals
Example 2
Type and manufacturer
Approvals
PNOZ Multi M1p by Pilz
EN 954-1, cat 4; EN 61508, SIL3; and EN ISO 13849-1, PL e
Appendix: The Safe Torque Off (STO) function 229
STO cable
2
Type
2×2×0.75 mm low voltage, single shielded,
twisted pair cable
Maximum length
Example cable
30 m between STO inputs and the operating
contact
2
Li YCY TP 2×2×0.75 mm shielded twisted pair
cable by HELUKABEL or CEAM
Ambient conditions
Description
Unit
All models
Operating temperature range
Minimum °C
°F
0
+32
Maximum °C
°F
+55
+131
Storage temperature range
°C
°F
-40 to +85
-40 to +185
95
Humidity
%
(maximum, non-condensing)
Maximum installation
altitude (above m.s.l.)
non-STO parts
m
ft
m
ft
1000. Above 1000 m derate 1.1%/100 m
3280. Above 3280 ft derate 1.1%/330 ft
STO function
2000
6560
Shock
10 G
Vibration
1 G, 2-200 Hz
230 Appendix: The Safe Torque Off (STO) function
—
Further information
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quoting the type designation and serial number of the unit in question.
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Specifications subject to change without notice.
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