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ABB MicroFlex e190 User Manual Download Page 187

Appendix: Safe Torque Off (STO) 187

16

Appendix: Safe Torque Off

(STO)

What this chapter contains

The appendix describes the basics of the Safe torque off function (STO) for the
MicroFlex e190. In addition, application features and technical data for the safety
system calculation are presented.

Basics

The drive supports the Safe Torque Off (STO) function according to standards:

EN ISO 13849-1: 2015



EN ISO 13849-2: 2012



EN 61508-1/-2/-4/-6/-7: 2010



EN 61800-5-2: 2007, IEC 61800-5-2: 2016



EN 62061: 2005 + A1: 2013 + A2: 2015.

The STO function disables the control voltage of the power semiconductors of the
drive output stage, which prevents the inverter generating the voltage required to
rotate the motor (see diagram below). By using this function, short-time operations
(like cleaning) and/or maintenance work on non-electrical parts of the machinery can
be performed without switching off the power supply to the drive.

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Summary of Contents for MicroFlex e190

Page 1: ...ABB motion control User s manual MicroFlex e190 servo drive ...

Page 2: ...nd guides Code English MicroFlex e190 Quick Installation Guide 3AXD50000037325 MicroFlex e190 Wall chart 3AXD50000037323 Certificates MicroFlex e190 OPT SIO 1 EU Single Declaration of Conformity 3AXD10000540159 MicroFlex e190 STO TÜV Certificate 3AXD10000540318 MicroFlex e190 UL Certificate 3AXD10000540319 Option manuals and guides OPT MF 200 Encoder Breakout Quick Installation Guide 3AXD100006922...

Page 3: ...ex e190 3AXD50000037326 REV C EN EFFECTIVE 2020 6 9 2020 ABB Beijing Drive Systems Co Ltd All Rights Reserved 1 Safety Table of contents 4 Mechanical installation 6 Electrical installation AC input DC input motor 9 Start up ...

Page 4: ......

Page 5: ...his manual 22 Related documents 23 Quick installation and start up flowchart 24 Terms and abbreviations 25 General terms 25 Trademarks 25 3 Operation principle and hardware description What this chapter contains 27 Product overview 27 Layout front 28 Layout top 29 Layout bottom 29 Main circuit 30 Type designation label 31 Type designation key 31 Memory unit MU 32 4 Mechanical installation What thi...

Page 6: ...3 Residual current device RCD compatibility 43 Safe Torque Off 44 Selecting the power cables 45 General rules 45 Alternative power cable types 45 Motor cable shield 46 Selecting the control cables 46 Connection of a motor temperature sensor to the drive 46 Routing the cables 47 Control cable ducts 47 Typical installation example 48 6 Electrical installation AC input DC input motor and brake What t...

Page 7: ...Real time Ethernet port 74 E1 E2 Ethernet port configuration 75 E3 Ethernet host 75 Motor feedback X8 76 Incremental encoder with Halls 77 Serial interfaces SinCos 78 Extra incremental encoder 81 Incremental encoder input output X7 83 OPT MF 201 Resolver adapter 85 Supported feedback type 86 Encoder 0 input 88 Encoder 1 input 89 Encoder 2 input 89 8 Installation checklist Checklist 91 9 Start up W...

Page 8: ...pportMe feature 109 Power cycling the MicroFlex e190 110 MicroFlex e190 indicators 111 EtherCAT mode 111 Ethernet POWERLINK mode 112 Drive status display 114 Power 116 Communication 116 Mint WorkBench 116 Tuning 117 Ethernet 117 Warning messages generated by the drive 119 Axis warnings 119 Controller warnings 120 Error messages generated by the drive 122 Autotuning errors 122 Parameter errors 131 ...

Page 9: ...bient conditions 157 Degrees of protection 158 Materials 158 WEEE notice 158 RoHS compliance 159 China RoHS marking 159 Applicable standards 160 Design and test standards 160 Environmental test standards 160 Functional safety standards 161 RCM marking 161 CE marking 161 Compliance with the European EMC Directive 161 Compliance with the European Machinery Directive 163 UL marking 164 UL checklist 1...

Page 10: ...g methods 190 IGBT failure 190 Terminology 190 Wiring principles 191 Connected components 191 Short circuit testing 191 Power supply 191 Drive enable input 191 Single drive module internal power supply 192 Single drive module external power supply 192 Multiple drive modules internal power supply 193 Multiple drive modules external power supply 194 Operation of the STO function and diagnostics 195 ...

Page 11: ...rated by the drive 202 Decommissioning 203 Technical data 204 STO safety relay type 204 STO cable 205 Ambient conditions 205 Data related to safety standards 206 Safety data 206 Failure rates 206 Abbreviations 207 Product and service inquiries 209 Product training 209 Providing feedback on ABB Drives manuals 209 Document library on the Internet 209 ...

Page 12: ...12 Table of contents ...

Page 13: ...s 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 General warning warns about conditions other than those caused by electricity which can result in physical injury and or damage to the equipme...

Page 14: ... 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 res...

Page 15: ...C 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 cir...

Page 16: ... 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 Note 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 touc...

Page 17: ...als 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 mot...

Page 18: ... 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 instal...

Page 19: ...us 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 torque off are validated in start up See chapter Start up for reference of the validation instructions The drive is not field repairable Never attempt to repair a malfunctioning dr...

Page 20: ...mmunicate 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 e...

Page 21: ...rt refers to chapters sections in this manual and to other manuals 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 S...

Page 22: ...stallation input output page 59 describes the installation of low power connections including analog and digital input outputs including Safe Torque Off motor feedback and Ethernet Installation checklist page 91 provides a list of checks to confirm that the physical installation has been completed correctly Start up page 93 describes the steps for applying power to the drive installing the Mint Ma...

Page 23: ...Introduction to the manual 23 Related documents See List of related manuals on page 2 inside the front cover ...

Page 24: ...net construction page 36 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 Contents of the package page 34 Installation procedure page 39 Route the cables Routing the cables page 47 Check the insulation of the supply cable the motor and the motor cable Checking the insulation of the assembl...

Page 25: ...rive RFI Radio frequency interference RGJxxx Series of optional braking resistors for the MicroFlex e190 See also page 207 for safety related abbreviations 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 m...

Page 26: ...26 Introduction to the manual ...

Page 27: ... 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 ...

Page 28: ...ldbus status LEDs page 111 7 segment display page 114 Fieldbus mode selectors page 75 Start up function selectors page 72 Safe Torque Off inputs page 187 Digital inputs outputs pages 64 71 Analog inputs output page 61 63 PC host Ethernet connection page 75 Earth bar Brake resistor connection page 171 Option card page 182 Encoder breakout page 180 Resolver adapter page 181 ...

Page 29: ...ription 29 Layout top Ethernet fieldbus ports page 74 PE connection page 53 Memory unit page 32 Layout bottom X8 voltage output selector page 78 Optional 24 V control circuit supply input page 56 Incremental encoder feedback input page 83 ...

Page 30: ... 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 necessar...

Page 31: ...it 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 Digits 6 to 10 are a running integer starting every week at 00001 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 select...

Page 32: ...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 sim...

Page 33: ...Mechanical installation 33 4 Mechanical installation What this chapter contains The chapter describes the mechanical installation of the drive ...

Page 34: ...tallation Contents of the package The box contains MicroFlex e190 drive Connector pack containing terminal blocks for the drive Memory unit Quick Installation Guide MicroFlex e190 Quick Installation Guide Connector pack ...

Page 35: ... space requirements are shown below 72 2 83 155 6 10 200 7 87 7 0 28 5 0 2 6 0 24 188 4 7 42 200 7 87 223 8 78 Ø 5 0 20 5 0 20 5 0 20 Ø 12 0 47 73 45 2 89 Unit mm inches Approximate dimensions Allow extra space for feedback and other control cables Weights 1 6 A 1 65 kg 3 64 lb 3 A 1 70 kg 3 75 lb 6 A 1 75 kg 3 86 lb 9 A 1 75 kg 3 86 lb ...

Page 36: ...ling 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 0 mm 0 90 mm 3 54 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 enteri...

Page 37: ...inuous 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 tempera...

Page 38: ...tes 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 fa...

Page 39: ...e 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 Ambient conditions page 157 The wall is vertical not flammable and strong enough to hold the weig...

Page 40: ... dimensions on page 35 2 Fix the screws or bolts to the marked locations 3 Position the drive onto the screws on the wall Note Only lift the drive by its chassis 4 Tighten the screws Mains filter installation See the chapter Mains filters on page 165 Braking resistor installation See the chapter Resistor braking on page 171 ...

Page 41: ...aches the local laws and or other regulations Motor selection Select the 3 phase AC induction motor according to the rating table in the chapter Technical data The table lists the typical motor power for each drive 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 ou...

Page 42: ...inst 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 nee...

Page 43: ...onal 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...

Page 44: ...rcuit 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 See Appendix Safe Torque Off STO on page 187 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...

Page 45: ...ur 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 A...

Page 46: ...ield the lower the emission level and the bearing currents Insulation jacket Copper wire screen Helix of copper tape Cable core Inner insulation 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 manufacturer Use one individuall...

Page 47: ...es 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 A diagram of the cable routing is below min 500 mm 20 Control cables min 200 mm 8 min 300 mm 12 Supply cable M...

Page 48: ...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 Longer wires must be shielded as shown Wire colors may vary according to region Protective Earth PE DO NOT TOUCH Brake resistors can become extremely hot Locate away from vulnerable components and wiring CAUTION Drive earth wire must...

Page 49: ...nd brake resistor WARNING The work described in this chapter may only be carried out by a qualified electrician Follow the instructions in chapter Safety on page 13 Ignoring the safety instructions can cause injury or death Make sure that the drive is disconnected from the input power during installation If the drive is already connected to the input power wait for 5 minutes after disconnecting th...

Page 50: ...e 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 Mohm ohm M 3 U V W PE Braking resistor assembly Check the insulation of the braking r...

Page 51: ... 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 ground conductors See also section Selecting the power cables on page 45 AC supply 3 1 phase 200 240 V 10 or 3 phase 200 2...

Page 52: ...ield 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 dist...

Page 53: ...nnection Supply cable Cover bare shield with insulating tape Cable clamp on bare shield Cable clamp on bare shield 0 5 0 6 N m 4 4 5 3 lbf in Motor cable 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 M4 10 mm max 1 0 1 3 N m 8 9 11 5 lbf in Motor earth wire ...

Page 54: ...e 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 M 3 M 3 UDC UDC UDC UDC M 3 UDC UDC AC supply Fuses The MicroFlex e190 DC connection is not designed to provide the primary power source to other drives DC supply MicroFlex e190 can use a DC supply as the primary power source see page 154 Each ...

Page 55: ...ation AC input DC input motor and brake 55 Each drive has an independent DC capacitor pre charging circuit UDC UDC L2 L3 L1 V W U MicroFlex e190 Pre charging circuit The ratings of the DC connection are given on page 154 ...

Page 56: ...or 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 Use a twisted pair cable Customer supplied 24 V DC Fuse Recommended fuse Bussman S504 20 x 5 mm anti surge 2 A X2 24 V GND ...

Page 57: ...nt 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 ...

Page 58: ... purpose A typical circuit using DI2 as the input is shown in the following diagram 24 V 0 V 24 V 0 V 14 4 X3 DI2 DI2 The relay has normally open contacts and is shown deactivated contacts open motor overheated motor thermal switch Separate customer supplied 24 V DC supply Customer supplied 24 V DC supply WARNING The 24 V DC power supply connected to the thermal switch must be a separate supply as...

Page 59: ...Input AO Analog Output DI Digital Input DO Digital Output STO Safe Torque Off WARNING The work described in this chapter may only be carried out by a qualified electrician Follow the instructions in chapter Safety on page 13 Ignoring the safety instructions can cause injury or death Make sure that the drive is disconnected from the input power during installation If the drive is already connected ...

Page 60: ...ided in this chapter and the chapter Technical data E1 E2 Ethernet fieldbus IN E2 OUT E1 X1A AC input 200 240 V AC 10 L1 1 L2 2 L3 3 DC bus UDC 4 Brake R 5 DC bus Brake R UDC 6 X1B Motor output U 1 V 2 W 3 E3 Ethernet host PC 1 X3 X3 1 Status DO0 Status DO0 11 2 DO2 DO2 12 3 DO1 DO1 13 4 DI2 DI2 14 5 DI3 DI3 15 6 DI1 DI1 16 7 DI0 DI0 17 8 AGND AO0 18 9 AI0 AI0 19 10 Shield Shield 20 E2 E1 X1A X1B ...

Page 61: ...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 ...

Page 62: ...rom a 24 V source Analog input typical connections from a PLC controller Mint ADC 0 15V MicroFlex e190 AI0 19 X3 9 AI0 15V Shield PLC controller Connect overall shield at one end only Analog input typical connections from an ABB AO561 Mint ADC 0 15V MicroFlex e190 AI0 19 X3 9 AI0 15V 18 13 O0U 17 O01 SG AO561 Connect overall shield at one end only ...

Page 63: ...nalog output can be controlled using the DAC keyword See the Mint help file for full details of DAC and other related DAC keywords Analog output typical connections to a PLC controller 18 X3 PLC controller MicroFlex e190 8 10 GND AO0 AI AI Shield Connect overall shield at one end only Analog output typical connections to an ABB AI523 2 0 1 0 18 X3 AI523 MicroFlex e190 8 10 GND AO0 I0 I0 Shield Con...

Page 64: ... home switch input is configured using the Digital I O tool in Mint WorkBench or by using the Mint HOMEINPUT keyword 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...

Page 65: ...RORINPUT STOPINPUT FORWARDLIMITINPUT REVERSELIMITINPUT DRIVEENABLEINPUT MOTORTEMPERATUREINPUT PHASESEARCHINPUT and HOMEINPUT can be used The state of the digital inputs can be viewed using the Mint WorkBench Spy window s Axis tab See the Mint help file for details Digital input typical connections from a PLC controller PLC controller X3 16 6 TLP118 10 MicroFlex e190 DI1 DI1 Shield User supply 24 V...

Page 66: ...ese types of feedback device The fast interrupt is latched on a pulse width of about 30 μs although a width of 100 μs is recommended to ensure capture The captured value is latched in software to prevent subsequent inputs causing the captured value to be overwritten Note The fast inputs are particularly sensitive to noise so inputs must use shielded twisted pair cable Do not connect mechanical swi...

Page 67: ...d for these signals twist the signal for DIN1 with the signal for DIN1 and twist the signal for DIN2 with the signal for DIN2 Step and direction inputs typical connections from a PLC controller using open emitter outputs PLC Controller X3 16 6 MicroFlex e190 DI1 DI1 Shield TLP118 10 14 4 DI2 DI2 TLP118 Shield User supply 24 V User supply GND Direction Output Dir Step Output Step Step Direction 10 ...

Page 68: ...rom a PLC controller using open collector outputs PLC Controller 11 X3 16 6 MicroFlex e190 DI1 DI1 Shield TLP118 10 14 4 DI2 DI2 TLP118 Shield User supply 24 V User supply 24 V User supply GND GND GND Step Output Direction Output GND Dir Step Step Direction 10 Twisted pairs Twisted pairs ...

Page 69: ...g RESETINPUT ERRORINPUT STOPINPUT FORWARDLIMITINPUT REVERSELIMITINPUT DRIVEENABLEINPUT MOTORTEMPERATUREINPUT PHASESEARCHINPUT and HOMEINPUT can be used The state of the digital inputs can be viewed using the Mint WorkBench Spy window s Axis tab See the Mint help file for details Digital input typical connections from a PLC controller X3 17 7 MicroFlex e190 PLC controller DI0 DI0 User supply 24 V U...

Page 70: ...70 Electrical installation input output Digital input typical current sourcing connections to a digital input X3 17 7 MicroFlex e190 DI0 DI0 User supply 24 V User supply GND ...

Page 71: ...t 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 OUTPUTACTIVELEVEL can be used in the command window Other Mint keywords such as COMPAREOUTPUT GLOBALERROROUTPUT DRIVEENABLEOUTPUT and MOTORBRAKEOUTPUT can be use...

Page 72: ...ion 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 norm...

Page 73: ...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 a...

Page 74: ... 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 network the connectors are identical See MicroFlex e190 indicators on page 111 for a description of the ...

Page 75: ...See page 74 Value Mode 00 EtherCAT slave mode 01 EF Ethernet POWERLINK CN mode selected value is node ID F0 FF Reserved E3 Ethernet host The Ethernet host port is used to connect a PC for configuring the MicroFlex e190 See section Start up on page 93 for details about configuring the PC s Ethernet adapter for communication with the MicroFlex e190 The host port also can be used for Modbus TCP Ether...

Page 76: ...ncoder and Hall The cores of these two cables will need to be wired to the appropriate pins of the 15 pin D type mating connector or the encoder breakout option see page 180 can 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...

Page 77: ...re 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...

Page 78: ...tary 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 less if other encoder outputs are in use see page 76 WARNING Check the feedback device s...

Page 79: ...ls EnDat Interface Connect internal shields to pin 13 SinCos interface SinCos interface cable connections X8 5 6 7 8 12 13 Sin Sin Cos Cos 5 5 V out DGND Chassis SinCos Feedback Motor Twisted pairs Connect overall shield to connector backshells Connect internal shields to pin 13 BiSS B interface The BiSS B Bi directional Serial Synchronous interface is an open source interface that can be used wit...

Page 80: ... 9 12 13 Data Data 5 5 V out DGND Chassis ER6V Absolute Encoder Motor Twisted pairs Connect overall shield to connector backshells Smart Abs Interface 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 X8 1 9 5 6 7 8 12 13 Data Data Sin Sin Cos Cos 8 V out DGND Cha...

Page 81: ...ver 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 connector X7 has been configured as an encoder output see page 84 When connector X8 is specified as encode 2 a 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 m...

Page 82: ... less if other encoder inputs are in use see page 76 Maximum cable length is 30 m Extra incremental encoder cable connections 1 9 2 10 3 11 12 X8 6 5 8 7 15 14 13 1 9 2 10 3 11 12 13 7 Connect overall shield to connector backshells Twisted pairs 5 5 V out DGND Encoder Feedback CHA CHA CHB CHB CHZ INDEX CHZ INDEX Extra incremental encoder Used by incremental encoder without Halls BiSS B SSI EnDat 2...

Page 83: ...Incremental encoder cable connections 1 6 2 7 3 8 9 X7 5 Connect overall shield to connector backshells Twisted pairs CHA CHA CHB CHB CHZ INDEX CHZ INDEX 5 5 V out DGND Encoder Feedback 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...

Page 84: ... as an encoder output encoder output 0 This automatically enables the extra incremental encoder input on connector X8 which then becomes encoder input 2 see page 81 When 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 EN...

Page 85: ...he 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 ent...

Page 86: ...n 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 motor is selected in Mint WorkBench The Mint keyword ...

Page 87: ...s Encoder 0 Primary encoder input on connector X8 see page 76 Encoder 1 Extra optional incremental encoder input on connector X3 see page 66 Encoder 2 Extra optional incremental encoder input on connector X7 see page 83 or to X8 by using the OPT MF 200 encoder breakout option see page 81 ...

Page 88: ... Linear incremental encoder with Halls ENCODERTYPE 0 3 5 Hall sensor Rotary Hall sensors only without encoder ENCODERTYPE 0 4 6 Linear Hall sensors only without encoder ENCODERTYPE 0 5 7 SSI Baumer SSI encoder of ABB motor ENCODERTYPE 0 6 8 Linear SSI encoder ENCODERTYPE 0 19 9 Generic SSI encoder ENCODERTYPE 0 24 10 Rotary EnDat v2 1 ENCODERTYPE 0 7 11 EnDat v2 2 Rotary EnDat v2 2 ENCODERTYPE 0 9...

Page 89: ... 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 See application note AN00262 for more information about dual encoder control No Feedback type Parameter 1 Rotary incremental encoder without Halls ENCODERTYPE 1...

Page 90: ...90 Electrical installation input output ...

Page 91: ...re to ensure that the drive is not powered Check MECHANICAL INSTALLATION The ambient operating conditions are allowable See Mechanical installation Technical data Ratings Ambient conditions The unit is fastened properly to the cabinet See Cabinet construction and Mechanical installation The cooling air will flow freely The motor and the driven equipment are ready for start See Planning the electri...

Page 92: ... 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...

Page 93: ...nd 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 Mint WorkBench and other utilities can be downloaded from the pages of 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 cabl...

Page 94: ...Flex 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 Pane...

Page 95: ... 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 Before you apply power for the first time check all items in Installation checklist starting on page 91 Power on checks See section Drive status display on page 114 for symbols that show if the drive has detected a fault 1 Turn o...

Page 96: ...ject 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 ...

Page 97: ...u 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 ent...

Page 98: ... 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 wil...

Page 99: ...e Further tuning with load attached on page 101 Note Even if you do not perform any further tuning or configuration the STO function must be tested see Appendix Safe Torque Off STO on page 187 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 t...

Page 100: ...ve 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 Ty...

Page 101: ...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...

Page 102: ... 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 display...

Page 103: ... 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 Measured vel...

Page 104: ...forming 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 Comman...

Page 105: ... 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 toolba...

Page 106: ...g 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 ab...

Page 107: ...oose 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 you tried the test moves in Performing test moves continuous jog on page 104 or Perfor...

Page 108: ...lays 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 the drive see pages 64 to 69 If a digital input is to be ...

Page 109: ...rtMe 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...

Page 110: ...d 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 remo...

Page 111: ...mory Invalid request state change Unknown requested state Bootstrap not supported No valid firmware No valid inputs available No valid output 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 FreeRun needs 3 buff...

Page 112: ...CAT is operating normally 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 ...

Page 113: ... previous sections as defined by the EtherCAT Technology Group LED flash timing definitions 200 ms 1 s 1 s 1 s 1 s 1 s Off 1 flash 2 flashes Inverted 2 flashes 3 flashes etc Blinking Flickering On Not illuminated Continuously illuminated Red error Off Ethernet POWERLINK is working correctly Continuously illuminated An error has occurred ...

Page 114: ...bols 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 ...

Page 115: ...d INCR Jog The drive is jogging See the Mint keywords JOG JOGCOMMAND and related topics Offset move An offset move is in progress See the Mint keyword OFFSET Position move A linear move is in progress See the Mint keywords MOVEA and MOVER Torque move The drive is in torque mode See the Mint keywords TORQUEREF TORQUEREFSOURCE and related commands Firmware recovery mode in operation see SW1 linear s...

Page 116: ...etect the MicroFlex e190 Ensure that the MicroFlex e190 is powered and the drive status display is illuminated page 114 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 Wo...

Page 117: ...ered 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 Ethernet Cannot connect to the drive Check that the...

Page 118: ...er 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 ...

Page 119: ...S_WARNINGS_CLEA RED This information message can appear in the error log to indicate that all axis warnings have been cleared No Action required 20004 Encoder battery low _ecENCODER_BATTERY_L OW When using an encoder with battery backup e g Smart Abs multi turn a battery low condition has been reported Consider changing the Encoder battery ...

Page 120: ...ervo axes were configured To fix this issue use the System Config Wizard to reduce the number of configured servo axes 40014 Attempted to assign too many stepper axes _ecTOO_MANY_STEPPER _AXES During the processing of the CMCF DCF device configuration file too many stepper axes were configured To fix this issue use the System Config Wizard to reduce the number of configured stepper axes 40015 Atte...

Page 121: ... If this error is received please contact ABB technical support 40026 Invalid Licence file _ecINVALID_LICENCE_FIL E_PRESENT Licence data hash does not match the one in the Licence File If this error is received please contact ABB technical support 40027 Warning applying parameter value _ecPARAM_WARNING This warning will be generated if an attempt is made to write to a parameter that is no longer s...

Page 122: ... 4006 Inductance value is zero E For the selected motor the winding inductance is zero To avoid this error 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 4007 Resistance...

Page 123: ...age constant and Measure the motor inertia tests a torque is applied to the motor This error will occur if the resulting motion is in the opposite direction to the torque a positive torque should cause positive velocity The most common cause of this error is an incorrectly wired or set up feedback device encoder or resolver or an incorrectly wired motor Select the Test the feedback option This wil...

Page 124: ...un 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 dir...

Page 125: ... motor resistance and inductance test a gradually increasing voltage is 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...

Page 126: ... not reach a sufficient speed or travel a sufficient distance within the duration of the test Error 4021 can occur if the torque or force generated by the motor is insufficient to overcome friction in the load 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 If the Measur...

Page 127: ...of the Drive Setup Wizard see manufacturer s motor data or run the Measure the voltage constant test 4025 Load model is invalid _ecINVALID_LOAD_MODEL If this error occurs during the Measure the motor inertia test it suggests that the characteristics of the load are such that inertia cannot be accurately calculated See error 4020 for more information Error 4025 can also occur during the Calculate t...

Page 128: ...time constant 4035 Can t set load inertia _ecCANNOT_SET_LOAD_INERTI A Can t set load inertia 4036 Can t set load damping _ecCANNOT_SET_LOAD_DAMPI NG Can t set load damping 4037 Can t set controller proportional gain _ecCANNOT_SET_GAIN_KIPRO P Can t set controller proportional gain 4038 Can t set current controller integral gain _ecCANNOT_SET_GAIN_KIINT Can t set current controller integral gain 40...

Page 129: ...K2 _ecCANNOT_SET_OBSERVER_ GAIN_K2 Can t set observer gain K2 4052 Can t set observer gain KJ _ecCANNOT_SET_OBSERVER_ GAIN_KJ Can t set observer gain KJ 4053 Can t enable integral position control _ecCANNOT_SET_KINT_MODE Can t enable integral position control 4054 Can t set integral term limit _ecCANNOT_SET_KINT_LIMIT Can t set integral term limit 4055 Invalid autotuning operation number _ecINVALI...

Page 130: ...d 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 not tuned Current loop has not been tuned before performing the Rotor parameters autotuning applicable to asynchronous motors only Re run Autotuning 4069 Autotuning doesn t support motor type Cannot do the wanted A...

Page 131: ...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 6004 Parameter definition has changed _ecPARAM_DEFINITION_ERRO R The specified parameter exists but its definition has chang...

Page 132: ...erted to hexadecimal to give the specific CIP general status code This error status indicates that the EtherCAT master has been sent a CIP error code by the drive Check the error log to determine what the real drive error code is 8002 POWERLINK error code _ecPOWERLINK_ERROR This error is listed together with a Profile Code in the Mint WorkBench Error Log The displayed profile code must be converte...

Page 133: ...int Program and or Parameter file See SOFTLIMITREVERSE and SOFTLIMITMODE 10005 Fatal following error exceeded _ecFOLLOWING_ERRO R FOLERRORFATAL sets the maximum permissible following error before an error is generated The following error is defined as the demand position minus the actual motor position If the following error exceeds the value set by FOLERRORFATAL maximum following error an error m...

Page 134: ...he DRIVERATEDCURRENT value Check tuning check motion profile especially acceleration and deceleration If necessary select a larger drive which may also require an alternative motor 10012 Power base is not ready to enable _ecPOWER_BASE_NOT _READY The Power base has been asked to enable but is not ready For it to be so it must have the correct voltage and supply and not be overheated Check of power ...

Page 135: ...uired if the needed acceleration cannot be achieved 10018 Motor I 2 T exceeded limit _ecMOTOR_OVERLOAD The motor overload algorithm has integrated up to 100 and has tripped the drive to protect the motor This will happen if the RMS current for the application exceeds the MOTORRATEDCURRENT value Check tuning check motion profile If necessary select a larger motor which may also require an alternati...

Page 136: ...hannel 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 _ecENCODER_SUPPLY_ LOSS Power supply to encoder has been lost or has dropped below the minimum level f...

Page 137: ... and decel cycles then you can disable phase loss detection using PHASELOSSMODE 0 0 10030 PDO data is not present Cn to Mn _ecPDO_DATA_MISSIN G_CN_TO_MN PDO data from the remote axis CN to the manager MN has been lost This error occurs if the manager detects that at least two consecutive PDO packets have not been received correctly This error will occur on the NextMove e100 if it detects a drive d...

Page 138: ...ll axis errors have been cleared No action required 10038 Encoder battery dead _ecENCODER_BATTER Y_DEAD This information message can appear at startup or when the drive is enabled if the battery backup supply for a Smart Abs encoder has failed Change the Encoder battery 10039 Resolver signals lost or incorrect _ecRESOLVER_SIGNAL _LOSS An error has occurred when using the Resolver Adapter OPT MF 20...

Page 139: ...oad or during startup Some of the parameters could not be applied correctly See the Error Log for details of the failures The controller s status display will flash only E and will not be followed with the usual error code digits This Error is most commonly ascociated with either a parameter file ptx issue It is a common problem if the parameter file is generated from an older firmware version wit...

Page 140: ...ler errors have been cleared No Action 30032 Hardware revision does not support EPL _ecHARDWARE_DOES _NOT_SUPPORT_EPL The controller does not support Ethernet POWERLINK Earlier Hardware revisions of e180 with 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 st...

Page 141: ...d in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Maintenance Interval Instruction Capacitor reforming Every year of storage See Reforming the capacitors Heat sink temperature check and cleaning Depends on the dustiness of the environment every 6 to 12 months See Heat sink Cooling fan change Every 6 year...

Page 142: ... 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 to Electrical safety on page 14 3 Remove the cooling fan see section Cooling fan on page 143 4 Blow clean dr...

Page 143: ...ve 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 Careful...

Page 144: ...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 see page 78 to check the correct position Check that the retaining clips are fitted into the mounting plate 7 Airflow directi...

Page 145: ...entative Other maintenance actions Transferring the memory unit to a new drive When a drive is replaced the parameter settings can be retained by transferring the memory unit from the defective drive to the new However non volatile data stored using the NVRAM keywords is not stored on the memory unit by default Before removal use the NVRAMSAVE keyword to store the data on the memory unit WARNING D...

Page 146: ...146 Maintenance ...

Page 147: ...al data What this chapter contains The chapter contains the technical specifications of the drive for example the ratings sizes and technical requirements as well as provisions for fulfilling the requirements for CE and other marks ...

Page 148: ...frequency Hz 300 3 s overload Arms 200 3 s overload Arms Low speed output 2 Hz Arms Stationary DC output any phase A 01A6 2 8000 1 6 1 6 1 6 2 3 Drive type MFE190 04xx PWM switching frequency Hz 300 3 s overload Arms 200 3 s overload Arms Low speed output 2 Hz Arms Stationary DC output any phase A 03A0 2 8000 2 5 3 0 3 0 4 2 Drive type MFE190 04xx PWM switching frequency Hz 300 3 s overload Arms 2...

Page 149: ...ting the 1 6 A models in ambient temperatures between 45 C 113 F and the maximum of 50 C 122 F Ambient temperature 1 00 0 80 45 C 50 C 113 F 122 F Derating factor for 1 6 A models Ambient temperature derating 3 A 6 A 9 A models No temperature derating is required in ambient temperatures up to the maximum of 55 C 131 F Altitude derating At altitudes from 1000 to 2000 m 3280 to 6560 ft above sea lev...

Page 150: ...nal power level Method Internal fan flow from bottom to top air cooled heat sink Free space around the unit See Cooling and degrees of protection on page 36 Drive type MFE190 04xx Power loss W Air flow m3 h Noise level dBA 01A6 2 20 No fan No fan 03A0 2 40 56 4 45 06A0 2 80 56 4 45 09A0 2 120 56 4 45 ...

Page 151: ...r current rating must not be used 1Φ AC supply 3Φ AC supply Drive type MFE190 04xx Input current A IEC fuse UL fuse Cross sectional area of cable Rated current A Voltage V Class Rated current A Voltage V UL Class mm2 AWG 01A6 2 3 20 500 gG 20 600 CC 1 5 4 16 12 03A0 2 7 500 gG 600 1 5 4 16 12 06A0 2 14 500 gG 600 1 5 4 16 12 09A0 2 20 500 gG 600 1 5 6 16 10 Drive type MFE190 04xx Input current A I...

Page 152: ...50 60 Hz 5 Network type Grounded TN TT 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 Short circuit current protection UL 61800 5 1 The drive is suitable for use on a circuit capable of delivering not more than 5000 A...

Page 153: ...els three phase AC supply 9 A model single phase AC supply 1 6 A 3 A 6 A models single phase AC supply Effect of output current on DC bus ripple voltage 20 0 10 20 30 40 50 60 70 30 40 50 60 70 80 90 100 110 120 130 140 150 of drive rated current DC bus ripple voltage V pk pk All models three phase AC supply 9 A model single phase AC supply 1 6 A 3 A 6 A models single phase AC supply ...

Page 154: ...es Asynchronous induction motors asynchronous servo motors synchronous permanent magnet motors Frequency 0 550 Hz Current See section Ratings Switching frequency 8 kHz Maximum motor cable length 50 m 164 ft with screened cable Terminals Detachable screw terminal block for 0 20 6 mm2 wire Description Unit All models Nominal switching threshold V DC on 388 off 376 Nominal power 10 peak power r 57 Ω ...

Page 155: ...hing 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 Sampling interval 1 kHz Filtering Adjustable using INPUTDEBOUNCE keyword see Mint WorkBench help file X3 Digital inputs DI0 DI3 Connector pitch 3 5 mm wire size 1 0 mm2 Logic levels 0 2 V 1 12 V Rin 3 3 kohm Minimum puls...

Page 156: ...erential Z index Max input frequency A B 2 MHz 8 MHz quadrature counts Output power supply to encoder 5 5 V DC 7 500 mA max Maximum recommended cable length 30 m Encoder interface RS422 A B differential Z index Max input frequency A B 2 MHz 8 MHz quadrature counts Hall inputs RS422 A B differential Output power supply to encoder 5 5 V DC 7 500 mA max or 8 V DC set by switch Maximum recommended cab...

Page 157: ... 3 A 6 A 9 A models 0 to 55 C 32 to 131 F No frost allowed See section Derating on page 149 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158 F Relative humidity 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 classificat...

Page 158: ...ycling of your waste equipment at the time of disposal will help conserve natural resources and ensure that it is recycled in a manner that protects human health and the environment For more information about where you can recycle your waste please contact your local authority Drive enclosure PC ABS color NCS 1502 Y RAL 9002 PMS 1C Cool Grey and RAL 9017 Traffic black Hot dip zinc coated steel she...

Page 159: ...oxic and hazardous substances or elements above the maximum concentration values and that it is an environmentally friendly product which can be recycled and reused Hazardous substances Lead Pb Mercury Hg Cadmium Cd Hexavalent chromium Cr VI Polybrominated biphenyls PBB Polybrominated diphenyl ethers PBDE O O O O O O O O O O O O O O O O O O Hg 1000 ppm 0 1 PBB 1000 ppm 0 1 Cd 100 ppm 0 01 PBDE 100...

Page 160: ...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 60068 1 2014 Environmental testing general and guidance EN 60068 2 1 2007 Environmenta...

Page 161: ...00 3 category C4 below The chapter Planning the electrical installation in this manual 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 mu...

Page 162: ... 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 preve...

Page 163: ...to the instructions given in this manual 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...

Page 164: ...cordance with the Canadian Electrical Code and any applicable provincial codes To fulfill this requirement use the UL classified fuses given in section Supply cable fuses on page 151 Power cable selection See section Selecting the power cables on page 45 Power cable connections For the connection diagram and tightening torques see section Power cable connection on page 51 Control connections For t...

Page 165: ...ements 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 EN 61800 3 product standard EN 61800 3 product standard EN 55011 product family standard for in...

Page 166: ...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 ohm 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 spa...

Page 167: ...s not block the airflow through the drive Keep the cable between the drive and the filter as short as possible Connection diagram AC supply MicroFlex e190 Mains choke if present Mains filter L1 L2 L3 L1 L2 L1 L2 L3 PE PE L3 L1 L2 L3 Selection table 230VAC 1Ø Meets EN 61800 3 category C2 with motor cable 50m 230VAC 3Ø Meets EN 61800 3 category C2 with motor cable 50m The mains filters are protected...

Page 168: ...ensions type OFI 01 Part Rated volts Rated amps 40 C Leakage current mA Weight kg lbs OFI 02 250 8 0 7 0 33 0 73 OFI 03 480 7 33 0 5 1 1 JFI 02 480 16 33 0 8 1 76 OFI 01 250 20 12 0 72 1 59 Dimension OFI 01 Dimensions mm inches A 260 10 23 B 73 2 87 C 239 5 9 43 D 50 1 97 E 40 1 57 F 21 5 0 87 I M5 10 0 39 max depth ...

Page 169: ... E D B J K Mains filters 169 Dimensions type OFI 02 Dimension OFI 02 Dimensions mm inches A 113 5 4 47 B 57 5 2 26 C 45 4 1 79 D 94 3 7 E 103 4 06 F 25 0 98 G 12 4 0 49 H 32 4 1 28 J 4 4 0 17 K 6 0 24 L 15 5 0 61 ...

Page 170: ...Mains filters Dimensions types OFI 03 JFI 02 Dimensions mm inches Dimension OFI 03 JFI 02 A 190 7 48 250 9 84 B 40 1 57 45 1 77 C 70 2 76 70 2 76 D 160 6 30 220 8 66 E 180 7 09 235 9 25 F 20 0 79 25 0 98 G 4 5 0 18 5 4 0 21 ...

Page 171: ...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 ...

Page 172: ...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 formul...

Page 173: ...complete in radians per second Multiply RPM by 0 1047 to get radians per second This value will be zero if the load is going to be stopped Final motor speed V _________ rad s c The deceleration time from initial speed to final speed in seconds Decel time D _________ s d The total cycle time i e how frequently the process is repeated in seconds Cycle time C _________ s e Total inertia This is the t...

Page 174: ... joules Calculate the braking energy for the motor If the value is less than the system braking capacity Bdc calculated on page 172 a brake resistor will not be required Braking power and average power The braking power Pgen max is the rate at which the braking energy is dissipated This rate is defined by the deceleration period D see page 172 The shorter the deceleration period the greater the br...

Page 175: ...ower rating 1 25 Pgen 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 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 ...

Page 176: ...h 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 t v Decel time Braking active 2 5 s Cycle time 2 5 s Cycle time 2 5 s Cycle time 0 5 s 0 5 s 0 5 s Resistor part number Nominal power rating W In free air On heat sink RGJ139 RGJ160 100 Derate power linearly from 80 25 C 77 F to 70 55 C 113 F Der...

Page 177: ... F G RGJ139 100 39 165 6 49 41 1 61 22 0 87 152 5 98 12 0 47 10 0 39 4 3 0 17 RGJ160 100 60 165 6 49 41 1 61 22 0 87 152 5 98 12 0 47 10 0 39 4 3 0 17 RGJ260 200 60 165 6 49 60 2 36 30 1 18 146 5 75 17 0 67 13 0 51 5 3 0 21 RGJ360 300 60 215 8 46 60 2 36 30 1 18 196 7 72 17 0 67 13 0 51 5 3 0 21 ...

Page 178: ...178 Resistor braking ...

Page 179: ...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 CP E 24 0 75 100 240 V AC 24 V DC 0 75 A CP E 24 1 25 100 240 V AC 24 V DC 1 25 A CP E 24 2 5 100 240 V AC 24 V DC 2 5 A CP E 24 5 0 115 230 V AC 24 V DC 5 A CP E 24 10 0 115 230 V AC 24...

Page 180: ...used to connect motor feedback and an extra incremental encoder see page 76 Alternatively the connectors can be used together to connect a single motor that has separate cables for encoder and Halls e g a linear motor Motor feedback MicroFlex e190 OPT MF 200 OPT MF 200 Incremental encoder ...

Page 181: ...artup 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 A...

Page 182: ...pply 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 X9 X10 Pin 1 Pin 8 Pin 14 Pin 7 Switch Purpose ...

Page 183: ...nector motor end only Raw cable no connector Current Amps Standard connector Stainless connector North America only Larger motors requiring 35 A cable or greater normally use terminal box connections so a motor power connector is not required For this reason connectors are not available on 35 A 90 A cable Examples A 6 1 m cable with a CE threaded standard connector rated for 12 A has part number C...

Page 184: ...lver These feedback cables have the outer shield tied to the connector housing s If you are using an alternative cable with your chosen feedback device be sure to obtain a cable that is a shielded twisted pair 0 34 mm2 22 AWG wire minimum with an overall shield Ideally the cable should not exceed 30 5 m 100 ft Maximum wire to wire or wire to shield capacitance is 50 pF per 300 mm 1 ft length to a ...

Page 185: ...190 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 X1B 1 3 X2 1 4 X3 1 5 X4 1 ...

Page 186: ...186 Accessories ...

Page 187: ... according to standards EN ISO 13849 1 2015 EN ISO 13849 2 2012 EN 61508 1 2 4 6 7 2010 EN 61800 5 2 2007 IEC 61800 5 2 2016 EN 62061 2005 A1 2013 A2 2015 The STO function disables the control voltage of the power semiconductors of the drive output stage which prevents the inverter generating the voltage required to rotate the motor see diagram below By using this function short time operations li...

Page 188: ...icroFlex e190 U V W U V W Safety circuit emergency stop switch relay etc Motor output U phase shown Integrated Power Module PWM control circuit Safe Torque Off connections Drivers High Low PWM power circuit Internal 24V source Using internal 24 V drive source ...

Page 189: ...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 Appendix Safe Torque Off STO 189 Using external 24 V sources WARNING The STO function does not disconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical pa...

Page 190: ...ed 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 numbe...

Page 191: ...ure 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 provi...

Page 192: ... 4 X4 2 MicroFlex e190 X4 1 Safety circuit emergency stop switch relay etc Safe Torque Off connections Single drive module external power supply X4 1 X4 2 X4 3 MicroFlex e190 24 V 0 V Safety circuit emergency stop switch relay etc Safe Torque Off connections External 24 V source ...

Page 193: ...supply X4 4 X4 2 MicroFlex e190 MicroFlex e190 X4 3 MicroFlex e190 X4 1 X4 1 X4 2 X4 3 X4 1 X4 2 X4 3 Safety circuit emergency stop switch relay etc Safe Torque Off connections Note The maximum number of drives is 16 Safe Torque Off connections Safe Torque Off connections ...

Page 194: ...0 V X4 1 X4 2 MicroFlex e190 MicroFlex e190 X4 3 MicroFlex e190 X4 1 X4 2 X4 3 X4 1 X4 2 X4 3 24 V External Supply Safety circuit emergency stop switch relay etc Safe Torque Off connections Note The maximum number of drives is 16 Safe Torque Off connections Safe Torque Off connections ...

Page 195: ...n 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 hardwa...

Page 196: ... in the following table See the table in STO status indications on page 197 for a complete listing of SAFETORQUEOFF values See Error messages generated by the drive on page 202 which describes the error codes displayed by the drive Parameter Meaning SAFETORQUEOFF 0 The combined state of the two STO inputs STO1 bit 0 STO2 bit 1 0 not powered 1 powered SAFETORQUEOFF 1 The state of STO1 input 0 not p...

Page 197: ...RQUEOFF 6 0 STO activated Motor output disabled SAFETORQUEOFF 0 2 SAFETORQUEOFF 1 0 SAFETORQUEOFF 2 1 SAFETORQUEOFF 6 0 STO activated Motor output disabled SAFETORQUEOFF 0 2 SAFETORQUEOFF 1 0 SAFETORQUEOFF 2 1 SAFETORQUEOFF 6 0 STO activated Motor output disabled SAFETORQUEOFF 0 2 SAFETORQUEOFF 1 0 SAFETORQUEOFF 2 1 SAFETORQUEOFF 6 0 STO2 not powered STO activated Motor output disabled SAFETORQUEO...

Page 198: ...unction and diagnostics on page 195 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 mi...

Page 199: ...ty 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 Acceptance test reports Signed acceptance 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 f...

Page 200: ... STO function remove power from the STO inputs and attempt to enable the drive Ensure that the drive can not be enabled see section Operation of the STO function and diagnostics on page 195 Deactivate the STO function apply power to the STO inputs Test the operation of the STO function when the motor is running Deactivate the STO circuit apply power to the STO inputs Document and sign the acceptan...

Page 201: ...System toolbar followed by the Drive Enable button on the Motion toolbar Enable the drive from the Ethernet master device if connected Maintenance servicing Include the STO operation tests described in Start up acceptance and proof test interval checklist on page 200 in the routine maintenance program of the machinery to which the drive is connected The STO function must be tested by authorized se...

Page 202: ... 3 Additionally the right decimal point is illuminated for any 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 STOINPUTMISMATCHTIME Mint keyword a fault in the safety circuit or wiring is assumed and an e...

Page 203: ...while the drive is enabled or disabled Check the operation of the emergency stop switch Check that the contacts close correctly when the switch is reset Check that the period defined 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 w...

Page 204: ...ms Internal supply multiple units Maximum length of safety circuit from operating contact to most distant drive 30 m 98 4 ft Maximum number of drives in circuit 16 External supply multiple units External power supply 24 V DC 10 SELV Current requirement 20 mA per connected drive Example 1 Simple SIL3 approved safety relay Type and manufacturer PSR SCP 24UC ESP4 2X1 1X2 by Phoenix Contacts Approvals...

Page 205: ...ient conditions Description Unit 1 6 A model Operating temperature range C F C F Minimum Maximum 0 55 32 122 0 55 32 131 Storage temperature range C F 40 to 85 40 to 185 All models Humidity maximum non condensing 95 Maximum installation altitude above m s l non STO parts STO function m ft m ft 1000 Above 1000 m derate 1 1 100 m 3280 Above 3280 ft derate 1 1 330 ft 2000 6560 Shock 10 G Vibration 1 ...

Page 206: ...ates Tested with Control board build version 3AXD100000451859 Rev 03 Power unit build version 3AXD100000446920 Rev 03 Firmware build version MicroFlex e190 Build 5850 1 34 and later Frame SIL SILCL PL SFF PFHD 1 h PFDG 1 h MTTFd a DC SC Cat HFT CCF Lifetime a UEI 3 e 98 32 3 04E 09 2 33E 05 13943 90 3 3 1 80 20 Channel λsd FIT λsu FIT λdd FIT λdu FIT SFF Total 209 2 225 0 0 7 7 4 98 3 CHX 15 2 6 8...

Page 207: ... failures during a particular measurement interval under stated conditions PFD EN 61508 Probability of Failure on Demand PFH EN 61508 Probability of Dangerous Failures per Hour PL EN ISO 13849 1 Performance Level Corresponds SIL Levels a e PTI EN 61508 Proof Test Interval SFF EN 61508 Safe Failure Fraction SIL EN 61508 Safety Integrity Level STO EN 61800 5 2 IEC 61800 5 2 Safe Torque Off CE Declar...

Page 208: ...208 Appendix Safe Torque Off STO ...

Page 209: ...and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to new abb com drives manuals feedback form and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to new abb com drives and select Drives Document Library You can ...

Page 210: ...Contact us new abb com motion new abb com drives new abb com drives drivespartners new abb com PLC 3AXD50000037326 REV C EN EFFECTIVE 2020 6 9 ...

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