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User`s manual MicroFlex e150 servo drive

1. EtherCAT configuration EtherCAT configuration is usually performed from the EtherCAT manager To assist with configuration the MicroFlex e150 provides an EtherCAT Slave Information ESI file This xml file describes the drive s capabilities to the EtherCAT manager The ESI file can be uploaded from the MicroFlex e150 using the Configuration tool in Mint WorkBench Electrical installation input output 79 B Ethernet connectors Location E1 amp E2 Ethernet port E2 IN is fixed in EtherCAT mode To set port E1 OUT to EtherCAT mode front panel DIP switch 4 page 80 must be in the off position If only one port is used for EtherCAT operation it must be the E2 IN port To connect the MicroFlex e150 to other EtherCAT devices use CAT5e Ethernet cables either S UTP unshielded screened foiled twisted pairs or preferably S FTP fully shielded screened foiled twisted pairs To ensure CE compliance Ethernet cables longer than 3 m should be S FTP cables bonded to the metal backplane at both ends using conductive clamps Cables can be up to 100 m 328 ft long Two varieties of CAT5e cable are available straight or crossed Straight cables have the TX pins of the connector at one end of the cable wired to the TX pins of the RJ45 connector at the other end of the cable Crossover cables have the TX pins of the connector at
2. Accessories 163 Filter dimensions types FI0014A00 FI0015A00 FI0015A01 FI0015A02 a oaf i E el H D ie G F 07 1 m K J A Hne B Dimensions mm inches Dimension FI0014A00 FI0015A00 FI0015A01 FI0015A02 A 85 3 35 113 5 4 47 156 6 14 B 54 2 13 57 5 2 26 C 40 1 57 46 6 1 83 D 65 2 56 94 3 70 130 5 5 14 E 75 2 95 103 4 06 143 5 63 F 27 1 06 25 0 98 G 12 0 47 12 4 0 49 H 29 5 1 16 32 4 1 28 J 5 3 0 21 4 4 0 17 5 3 0 21 K 6 3 0 25 6 0 24 L 13 5 0 53 15 5 0 61 164 Accessories Filter dimensions type FI0029A00 B E m o F tr Ti 0 D i G gt lt Pee Ld CB T NEN E p C a Um G gt K G 5 5mm H 11mm K 5mm J 10 lo D o o E EN Tov Dimensions mm inches A 255 10 04 B 100 3 94 C 244 5 9 63 D 70 2 76 E 40 1 57 F 20 0 79 Accessories 165 B Brake resistors Depending on the application MicroFlex e150 might require an external brake resistor to be connected to pins R1 and R2 of connector X1 The brake resistor dissipates energy during braking to prevent an over voltage error occurring Se
3. 169 BASICS fees stes qa ahi e ated eg cee datas d ct 169 Operation of the STO function and diagnostics 171 Installation 2 unde Dem bet oodd e C hoe dee do deas 172 10 Table of contents Validating the operation of the Safe Torque Off function 172 Technical data Digital inputs STO1 STO2 173 STO function data related to safety standards 173 STO function certificate leslie 174 Further information Product and service inquiries 175 Prod ct x23 eee trn eret Rc 175 Providing feedback on ABB Drives manuals 175 Document library on the Internet 175 Safety 11 Safety Safety in installation and maintenance These warnings are intended for all who work on the drive motor cable or motor Electrical safety A 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 sure the system is properly earthed grounded before applying power Do not apply AC power before earths grounds are connected Never work on the drive motor c
4. Electrical installation input output 83 Hall input circuit U phase shown MicroFlex e150 MAX3096 Differential line receiver Encoders without Halls Incremental encoders without Hall feedback connections can be connected to the MicroFlex e150 However if Hall connections are not present it will be necessary for the MicroFlex e150 to perform an automatic phase search sequence each time it is powered This will cause motor movement of up to 1 turn on rotary motors or one pole pitch on linear motors Encoder cable connections without Halls rotary motors Motor Twisted pairs CHA CHA CHB Encoder CHB Feedback CHZ INDEX CHZ INDEX 5 V out DGND Sense NS Connect overall shield to A connector backshells 84 Electrical installation input output Halls only feedback devices Feedback devices using only Hall sensors can be connected to the MicroFlex e150 However since there are no encoder connections the MicroFlex e150 will not be able to perform smooth speed control or accurate positioning control Halls only feedback cable connections rotary motors Motor Twisted pairs Sense 5 V out DGND Hall U Hall U Hall W Hall W Hall V Hall V Hall Feedback NS Connect overall shield to 7 connector backshells B BiSS interface The BiSS Bi directional Serial Syn
5. 116 10 Fault tracing What this chapter contains 117 Problem diagnosis 117 SupportMe feature 118 Power cycling the MicroFlex e150 118 MicroFlex e150 indicators 119 Etherneb LEDS m retra ea e ente a dae du eS a gre dede 119 Drive status display deise dr er e deeds eraot d nee ddr 120 COMMUNICALION woe 122 Mint WorkBench 122 TUBING 903i sie tee Die Or RE E er web eiie eed eben 123 Ethernet nae e oerte Pob RR dut 123 11 Technical data What this chapter contains 125 Dimension drawing all models 126 Electrical power network specification 127 Effect of AC power supply voltage on DC bus voltage 128 Effect of AC power supply voltage on DC bus ripple voltage 128 Effect of output current on DC bus ripple voltage 129 Temperature derating 130 Derating characteristic for A models 152 03 130 Derat
6. 30 oclo cM 31 5 Planning the electrical installation What this chapter contains 33 Checking the compatibility of the motor and drive 33 Selecting the supply disconnecting device 33 6 Table of contents European hea eddie de MAE ong a ird 34 COMETS GIONS s etos netaan dead E b amie tps RAE ARIS 34 Emergency stop devices 34 Implementing the STO function 34 Thermal overload and short circuit protection 35 Selecting the power cables 36 General ueneno npe m a kac argue alee coed 36 Protecting the contacts of relay outputs and attenuating inductive loads 38 Selecting the control cables 39 Connection of a motor temperature sensor to the drive I O 39 Routing the cables beading IND peso Lua eerie ea ERR 39 Separate control cable ducts 2 2 lees 40 6 Electrical installation AC input motor and brake What this chapter contains eR rn 43 Checking the insulation of t
7. User User supply supply x3 V GND a C t from motor brake DOUT1 13 A 1 connections Z Relay 1 DOUTi 3 lt The inner shield surrounding the ET brake wires should be earthed grounded MEAM ov at one point only Separate customer supplied 24 V DC supply The relay has normally open contacts and is shown deactivated contacts open brake engaged This circuit uses DOUT1 as a motor brake output The output is configured using Mint keyword MOTORBRAKEOUTPUT see the Mint help file for details With this configuration the following sequences can be used to control the brake To engage the brake The motor is brought to rest under normal control The relay is deactivated causing the brake to engage The drive is disabled removing power from the motor To disengage the brake The drive is enabled The drive applies power to the motor to hold position under normal control The relay is activated causing the brake to be disengaged It is sometimes necessary to include a small delay after the relay has been activated before starting motion This delay allows time for the relay contacts to engage and the brake to release See the MOTORBRAKEDELAY keyword WARNING The 24 V DC power supply used to power the brake must be a A separate supply as shown in the diagram Do not use the supply that is powering the MicroFlex e150 digital outputs The brake w
8. 4 R 5585 e i Dimensions shown as mm inches Depth Weight 157 mm 6 2 in 1 45 3 2 Ib 6 A 1 50 kg 3 3 Ib 9 A 1 55 kg 3 4 Ib Electrical power network specification Technical data 127 A 115 230 3 phase power source EN 61010 over voltage category or less is required An AC power filter is required to comply with the CE directive for which the MicroFlex e150 was tested see CE marking on page 150 230 VAC input Description Unit AC input 19 30 Nominal input voltage VAC 115 or 230 115 or 230 Minimum input voltage 105 105 Maximum input voltage 250 250 3A 6A 9A 3A 6A 9A Nominal input current 7 5 15 22 4 8 12 maximum rated output current Nominal DC bus voltage 305 321 Frequency 48 to 63 Hz maximum rate of change 17 s Imbalance Max 3 of nominal phase to phase input voltage Fundamental power factor 0 98 at nominal load Network type Corner grounded TN and IT ungrounded TN grounded systems systems not allowed Short circuit current protection UL 508C The drive is suitable for use on a circuit capable of delivering not more than 5000 A symmetrical amperes rms at 230 V maximum when protected by fuses given in the fuse table on page 734 The MicroFlex e150 will operate at lower input voltages although the drive w
9. Date 20 February 2012 Bob Combes R amp D Manager ABB Ltd Bristol U K The technical documentation for the product is available from ABB Ltd Bristol BS32 OBF U K Ref DE00037 100 154 Technical data UL marking The MicroFlex e150 is C UL US Listed only when used in conjunction with optional Fan Tray part FANO01 024 see page 760 The approval is valid with rated voltages When used without optional fan tray FAN001 024 the MicroFlex e150 is UL Recognized B UL checklist The drive is to be used in a heated indoor controlled environment The drive must be installed in clean air according to enclosure classification Cooling air must be clean free from corrosive materials and electrically conductive dust See page 147 The maximum ambient air temperature is 45 C 113 F at rated current The current is derated for 45 to 55 C 113 to 131 F The drive is suitable for use in a circuit capable of delivering not more than 5 000 rms symmetrical amperes 230 V maximum The ampere rating is based on tests done according to UL 508C The cables located within the motor circuit must be rated for at least 75 167 F in UL compliant installations Use copper conductors only The input cable must be protected with fuses Circuit breakers must not be used without fuses in the USA Page 134 lists IEC fuses that are suitable for UL applications For suitable circuit breakers contact your local ABB re
10. The type of motion generated in the motor shaft Alistof 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 B Power cycling the MicroFlex e150 The term power cycle the MicroFlex e150 is used in the Troubleshooting sections Remove the 24 V supply wait for the MicroFlex e150 to power down completely the Status LED will turn off then re apply the 24 V supply Fault tracing 119 MicroFlex e150 indicators B Ethernet LEDs The Ethernet LEDs display the overall condition of the Ethernet interface once the startup sequence has completed The LED codes conform to the EtherCAT Technology Group ETG m lt 270 gt 40 standard at time of production NET RUN Green Off INITIALISATION state or not powered X Blinking PRE OPERATIONAL state 1 flash SAFE OPERATIONAL state 3 flashes Device identification This state can be set from the master to locate the device Continuously illuminated not flashing Node in OPERATIONAL state EtherCAT is operating normally NET ERR Red Off No errors or not powered Blinking Invalid configuration The state change requested by the master cannot be accomplished due to register or object settings or invalid hardware configuration 1 flash Local e
11. 66 Electrical installation input output B Digital inputs general purpose DIN1 DIN2 Location X3 pins 16 amp 6 DIN1 14 amp 4 DIN2 These general purpose fast digital inputs are buffered by a TLP115 opto isolator allowing the input signals to be connected with either polarity The inputs do not share a common reference When the MicroFlex e150 is connected to Mint WorkBench the digital inputs can be configured using the Digital tool Alternatively Mint keywords including DRIVEENABLEINPUT RESETINPUT ERRORINPUT and STOPINPUT can be used The state of the digital inputs can be viewed using the Mint WorkBench Spy window s Axis tab See the Mint help file for details General purpose fast digital input DIN1 shown MicroFlex e150 Xr TLP115 NextMove e100 controller MicroFlex e150 UDN2982 Mint OUTX 0 vx TLP115 Electrical installation input output 67 W Special functions on inputs DIN1 DIN2 DIN1 and DIN2 can be configured to perform special functions Step pulse and direction inputs DIN1 and DIN2 can be configured using the statement ENCODERMODE 1 4 to become step and direction inputs DIN1 is used as the step input The step frequency controls the sp
12. 150443 49409 4eZ09 42205 DANLINITANOYOL SOdLINITANDYOL siosuag A dwog AUOD queuing SHO queuing i n suana pue anbio peinseey jeoujoe 3 40909 sio yous vis 138 0801 IS QNVEYALTINASNOYOL 215 03X443 1 143 0401 LIS 3dA L3 ETd300HOL 48009 8 uvoos 49909 qns s32 fqo ay sejeoipur is sioe qo suequinu jip ino 909 SOd TAA IS AINA 215 LIINFLLNDI 815 3GOIALLNIM 215 1 dOHdM 8309 Je jonuoo gt ONVIA3QSOd X 42909 HOHH3104 Ur309 ONVIA3Q TJA 4yag09 GONVIA3Q T39OV 49209 09 Accessories 159 Accessories What this chapter contains This section describes accessories and options that you might need to use with your MicroFlex e150 Shielded screened cables provide EMI RFI shielding and required for compliance with CE regulations All connectors and other components must be compatible with the shielded cable 160 Accessories B Fan tray The fan tray part FANOO1 024 provides sufficient cooling for the 6 A and MicroFlex e150 The fan tray might be required for the 3 A model when operating in high ambient temperatures see Temperature derating on page 130 The fa
13. MicroFlex e150 Safe Torque Off connections Safety circuit emergency stop switch relay etc te X3 18 24V X3 9 External Supply E 5 24 V Se Note If the contacts of the safety circuit do not open close within 1 ms of each other then a fault in the STO circuit or wiring is assumed and the drive will become disabled The maximum allowed cable length between the drive and the activation switch is 30 m 98 ft Validating the operation of the Safe Torque Off function IEC 61508 and EN 62061 require that the final assembler of the machinery validates the operation of the safety function with an acceptance test The acceptance test must be performed atinitial start up of the safety function after any changes related to the safety function wiring components settings etc after any maintenance work related to the safety function If you connect an external Safe Torque Off circuit to the drive perform the acceptance test for the Safe Torque Off function as described in Safety Manual Safe Torque Off STO function for MicroFlex e150 drives LT0313 Appendix Safe Torque Off STO 173 Technical data Digital inputs STO1 STO2 X3 Description Unit All models Type Opto isolated inputs Input voltage VDC Nominal 24 Minimum 12 Maximum 30 Active gt 12 Inactive lt 2 Input current maximum per input mA 50 Sa
14. 6 1 20 20 7 5 24 6 35 9 1 30 50 10 32 8 90 15 49 2 15 2 50 20 65 6 22 9 75 30 5 100 76 250 1525 500 Larger motors requiring 35 A cable or greater normally use terminal box connections so a motor power connector is not required For this reason connectors are not available on 35 A 90 A cable Examples A 6 1 m cable with a CE threaded standard connector rated for 12 A has part number CBL061SP 12 A 30 5 m cable with a CE threaded stainless steel connector rated for 20 A has part number CBL305SP 20S A 50 ft cable with no connector rated for 50 A has part number CBL152RP 50 Accessories 167 B Feedback cables The part number for a feedback cable is derived as follows r2 SF Servo motorfeedback E Incremental Raw cable Standard 5 6 cable with at least 1 encoder connector connector 1 Legacy 1 0 3 3 controllers 15 49 D EnDat S Stainless steel 20 66 SinCos connector 50 16 RF Raw cable 2 e100 e150 5 no connector BiSS Other lengths 5 SSI available on request Example A 2 m encoder feedback cable for a MicroFlex e150 drive with required connectors at both ends has part number CBLO2OSF E2 These feedback cables have the outer shield tied to the connector housing s If you are using an alternative cable with your chosen feedback device be sure to obtain a cable that is a shielded twisted pair 0 34 mm 22 AWG wire minimum w
15. Check that a ABB USB Motion Product device is listed in Windows Device Manager and MicroFlex e150 is listed in Windows Devices and Printers Windows 7 If not there could be a problem with the PC s USB interface B Tuning Cannot enable the MicroFlex e150 because there is an error 10010 Check the drive enable input if assigned is connected and powered correctly Cannot enable the MicroFlex e150 because there is an error 10033 10034 and or 10035 Check the Safe Torque Off inputs on connector pins 18 amp 8 and 19 amp 9 are both connected and powered correctly When the MicroFlex e150 is enabled the motor is unstable Check that the load is firmly coupled to the motor Use the Mint WorkBench Drive Setup Wizard to confirm that the correct motor data has been entered Usethe Mint WorkBench Autotune Wizard to retune the motor Ifthe 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 E Ethernet Cannot connect to the drive over TCP IP Checkthat the PC s Ethernet adapter has been correctly configured as described in Configuring the TCP IP connection optional on page 93 How configure my EtherCAT manager to operate with the MicroFlex e150 AnEtherCAT
16. DIM Typical abe shown Made in the Uk Actual appearance E152A09ENOA E152A09EIOAxxx 15 2A 09 XXX MicroFlex e150 with Mint Lite programming 115 230 V AC supply input Rated amps 03 06 6 09 Feedback E Universal Encoder connector X8 see page 23 y differ Build option NO No Option EO Encoder Out option 10 Input Output option Hardware revision Optional Custom variant 26 Hardware description Mechanical installation 27 Mechanical installation What this chapter contains The chapter describes the mechanical installation procedure of the drive Requirements for the installation site The safe operation of this equipment depends upon its use in the appropriate environment The following points must be considered The MicroFlex e150 must be installed indoors permanently fixed and located so that it can only be accessed by service personnel using tools When installed in a cabinet the cabinet must have a volume of at least 0 19 m 6 84 cu ft If not installed in a cabinet barriers around the equipment are required The MicroFlex e150 must be secured by the slots in the flange The protective earth ground the threaded hole on the top of the MicroFlex e150 must be bonded to a safety earth ground using either a 25 A conductor or a conductor of three times the peak current rating whichever is the greater Avoid locating the
17. output connection X3 STO1 SREE To enable the drive and provide the Safe STO2 Torque Off STO function page 64 X3 DINO Separate General purpose input page 65 DIN1 Separate General purpose fast inputs page 66 DIN2 Separate DIN3 Separate General purpose input page 65 oe CREF1 G inputs 68 eneral purpose inputs page 68 top panel DINS purp puts pag models EIOA DING only DIN7 CREFO General purpose inputs page 68 DIN8 DIN9 X3 Status out Status output page 69 DOUTO Separate Can also be used as a general purpose output X3 DOUT1 Separate General purpose outputs page 70 DOUT2 Separate OPT 1 DOUT3 top panel models USRV 0 General purpose outputs page 77 EIOA DOUT5 only DOUT6 Electrical installation input output 63 E Using digital input as a drive enable input optional A general purpose digital input can be configured as a drive enable input This input must be activated to allow the drive to operate This provides an additional method for stopping the drive using a hardware switch or external PLC controller e g NextMove e100 although it does not provide any of the formal safety features of the Safe Torque Off inputs page 64 The optional drive enable input is configured using the Digital tool in Mint WorkBench E Using a digital input as a home switch input optional If homing is being handled locally by th
18. Input circuit MicroFlex e150 15V X4 AINO AINO AGND For differential inputs connect input lines to AIN and AIN Leave AGND unconnected AINO 5 AINO AINO 7 AINO 5 GND Differential connection Single ended connection Electrical installation input output 61 Typical input circuit to provide 0 10 V approx input from a 24 V source 24VDC 1 5 0 25 W 1 0 25 W potentiometer ov E Analog output AOUTO Location X4 pin 1 AOUTO 5 AGND The analog output can be used to drive loads of 4 or greater Shielded twisted pair cable should be used The shield connection should be made at one end only In Mint the analog output can be controlled using the DAC keyword See the Mint help file for full details of DAC and other related DAC keywords Output circuit MicroFlex e150 Demand 100 AD5530BRUZ 62 Electrical installation input output Digital I O The MicroFlex e150 provides 10 general purpose digital inputs 2 dedicated Safe Torque Off STO inputs 6 general purpose digital outputs 1 dedicated status output Connector Digital input Common
19. This safety related drive complies with the European Union Machinery Directive requirements for a safety component intended to be integrated into machinery Compliance with the machinery directive has been verified according to standards IEC 61800 5 2 2007 EN ISO 13849 1 2008 IEC 62061 2005 and IEC 61508 2010 parts 1 amp 2 The drive has been designed constructed and equipped in such a way that when installed as instructed in this manual all hazards of an electrical nature are or can be prevented The drive complies with EN 61800 5 1 which specifies safety requirements in terms of electrical thermal and energy Note The final assembler of the machinery must take the necessary precautions to prevent all hazards of an electrical nature when integrating this equipment General specifications for design of electrical equipment of machinery is given in EN 60204 1 and EN 60204 11 Specifications for electrical equipment are also given in many standards for specific categories of machinery Validating the operation of the Safe Torque Off function See Appendix Safe Torque Off STO on page 169 Technical data 153 W CE Declaration of Conformity EC Declaration of Conformity In accordance with EN ISO IEC 17050 1 2010 and EC Directives 2004 108 EC amp 2006 42 EC Manufacturer Ltd Address 6 Bristol Distribution Park Hawkley Drive Bristol BS32 OBF U K In accordance with the following Directive s 2004 108 EC
20. 3 5 m s forced air 2 5 m s forced air 1 5 m s forced air 1 m s forced air Natural cooling 55 30 35 40 45 50 55 Ambient temperature C Three phase AC supply 9 _ 8 6 g 55 54 8 3 5 2 14 1 0 30 35 40 45 50 Ambient temperature C Notes Load power factor 0 75 Overload limit for models E152A09 is 18 A Overtemperature trips The MicroFlex e150 contains internal temperature sensors that will cause it to trip and disable if the temperature exceeds 80 C 3 A model or 75 C 6 A and 9 A EMP ERATUR ELIMITFATAL keyword see models This limit can be read using the T the Mint help file for details B Heat dissipation Technical data These figures assume drive efficiency 95 power factor 0 8 133 MicroFlex e150 Heat dissipation model W 3A 50 6A 101 9A 151 134 Technical data Recommended fuses circuit breakers and wire sizes The following table describes the recommended fuses and circuit breakers for AC power connections and suitable wires sizes for AC and motor power connections Cont output amps RMS Drive catalog number AC supply type Input fuse Circuit breaker C type Minimum wire gauge AWG mm E152A03 3A 16 38 Ferraz Shawmut 6x32 FA series 10 W084314P or BS88 2 5 URGS 10A N076648J Ferraz S
21. Click Options to configure optional autotuning parameters These include Triggered Autotune which allows the autotuning process to be delayed until the drive is enabled WARNING The motor will move during autotuning For safety it is advisable to disconnect any load from the motor during initial autotuning The motor can be tuned with the load connected after the Commissioning Wizard has finished Click START to begin the auto tuning process Mint WorkBench will take measurements from the motor and then perform small test moves For further information about tuning with the load attached see Further tuning with load attached on page 106 NOTE Even if you do not perform any further tuning or configuration the STO function must be tested see Appendix Safe Torque Off STO on page 169 D 104 Start up E Further tuning no load attached The Autotune Wizard calculates many parameters that allow the MicroFlex e150 to provide good control of the motor In some applications these parameters might need to be fine tuned to provide the exact response that you require 1 Click the Fine tuning icon in the Toolbox on the left of the screen The Fine tuning window is displayed at the right of the screen This already shows some of the parameters that have been calculated by the Commissioning Wizard Fine tuning The main area of the Mint WorkBench window displays the capture window When
22. Maximum ripple 96 10 Typical input current A 0 5 0 6 not powering feedback device Typical input current A 0 6 0 8 powering feedback device Maximum continuous current A 1 24 V DC Power on surge current typical A 4 Technical data 137 Motor output power X1 Description Unit 3A 6A 9A Nominal phase current Arms 3 6 9 Peak phase current Arms 6 12 18 for3s Nominal output VA 1195 2390 3585 230 V Output voltage line line Vims 0 230 V DC bus 320 V Output frequency Hz 0 2000 Output dV dt kV us at drive phase phase 2 at drive phase ground 1 1 at motor using 20 m cable phase phase 1 9 at motor using 20 m cable phase ground 1 8 Nominal switching frequency kHz 8 0 Minimum motor inductance mH 1 Efficiency 96 295 138 Technical data Brake X1 Description Unit All models Nominal switching threshold V DC on 388 off 376 Nominal power kW 0 25 10 peak power r 57 O Peak power kW 2 7 10 peak power r 57 O Maximum brake switching current 10 Minimum load resistance Q 39 Minimum load inductance uH 100 E Braking capacity The braking capacity of the MicroFlex e150 can be calculated from the following formula 2 DC bus capacitance Brake switching threshold v2 x Supply voltage where the Brake switching threshold is 388 V This gives
23. On painted panels Wire colors can vary according to region remove paint to CAUTION expose bare metal DO NOT TOUCH Brake resistors can become extremely hot Locate away from vulnerable components and wiring Protective Earth PE 42 Planning the electrical installation Electrical installation AC input motor and brake 43 Electrical installation AC input motor and brake What this chapter contains The chapter describes how to connect input power cables motor and brake resistor WARNING The work described in this chapter may only be carried out by a qualified electrician Follow the instructions in chapter Safety on page 17 Ignoring the safety instructions can cause injury or death Make sure that the drive is disconnected from the input power during installation If the drive is already connected to the input power wait for 5 minutes after disconnecting the input power ae See the requirements in Electrical power network specification on page 127 Use a fixed connection to the AC power line 44 Electrical installation AC input motor and brake Checking the insulation of the assembly Drive Every drive has been tested for insulation between the main circuit and the chassis at the factory If further high potential hipot testing is performed use only DC voltages as AC voltage hipot tests could damage the drive It is recommended to seek advice from your ABB sales representative be
24. Red Stop Button feature 1 Check that the Drive enable button is pressed down m Direct In the Toolbox click the Edit amp Debug icon ns Tk Edit amp Debug Click in the Command window Type JOG 0 10 This will cause the motor to move continuously at 10 units per second In Mint WorkBench look at the Spy window located on the right of the screen Check that the axis tab is selected The Spy window s Velocity display should show 10 approximately If there seems to be very little motor movement it is probably due to the scale factor In the Commissioning Wizard on the Select Scale Factor page if you did not adjust the scale factor then the current unit of movement is feedback counts per second Depending on the motor s feedback device 10 feedback counts per second could equate to a very small velocity Issue another JOG command using a larger value or use the Operating Mode Wizard to select a suitable scale factor e g 4000 if the motor has a 1000 line encoder or 10 000 for a 2500 line encoder To stop the test type x STOP 0 If you have finished testing click the Drive Enable button to disable the m Direct drive Start up 111 E 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
25. 24 V DIN rail mounting power supplies are available The supplies include short circuit overload over voltage and thermal protection Part Input voltage Output voltage Output rating DR 75 24 110 230 V AC 24 V DC 75 W 3 2 A DR 120 24 120 W 5 A DR 240 24 240 W 10 A 162 Accessories B filters AC filters remove high frequency noise from the AC power supply protecting the MicroFlex e150 These filters also prevent high frequency signals from being transmitted back onto the power lines and help meet EMC requirements To select the correct filter see Filters on page 136 Part Rated volts Rated amps Leakage Weight kg Ibs 40 C current mA FI0014A00 250 3 0 4 0 27 0 6 FI0015A00 250 6 0 4 0 45 0 99 FI0015A01 250 10 0 4 0 73 1 61 FI0015A02 250 12 0 4 0 73 1 61 FI0018A00 480 7 33 0 5 1 1 FI0018A03 480 16 33 0 8 1 76 F10029A00 250 22 33 3 0 6 6 Filter dimensions types FI0018A00 and 0018 03 1 B a n A al gn D G o o Dimensions mm inches Dimension FI0018A00 FI0018A03 A 190 7 48 250 9 84 B 160 6 30 220 8 66 Cc 180 7 09 235 9 25 D 20 0 79 25 0 98 E 4 5 0 18 5 4 0 21 F 71 2 80 70 2 76 G 40 1 57 45 1 77
26. Click in the Active Table cell and enter a value This immediately sets the parameter which will remain in the MicroFlex e150 until another value is defined The icon to the left of the item will become yellow to indicate that the value has been changed 2 Encoder v 5 ScaleFacto VelScaleFa VelScaleUr Active Table 10000 00 Counts Parameter osScaleF actor Many of the MicroFlex e150 s parameters are set automatically by the Commissioning Wizard or when tests are performed in the fine tuning window 114 Start up E Spy window The Spy window can be used to monitor and capture parameters in real time If you tried the test moves in Performing test moves continuous jog on page 110 or Performing test moves relative positional move on page 111 then you have already seen the Spy window as it is displayed in conjunction with Edit amp Debug mode See the Mint help file for full details of each tab 1 Click the Edit amp Debug icon in the Toolbox on the left of the screen D The Spy Window is displayed on the Edit amp Debug 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 Ax purpose inputs and outputs Velocity Velocity Error Position ETE 3 The I O tab displays the state of all the digit
27. Contro N EDS ElectronicDataSheet EMC Electromagnetic Compatibility Human Machine Interface ISO International Standards Organization Kbit s kilobits per second LCD Liquid Crystal Display Mbit s megabits per second MB megabytes MMC Mint Machine Center Introduction to the manual 19 Unit term Description abbreviation NC Not Connected RF Radio Frequency SSI Synchronous Serial Interface TCP IP Transmission Control Protocol Internet Protocol UDP User Datagram Protocol See also page 773 for safety related abbreviations B Trademarks EtherCAT EtherCAT is a registered trademark and patented technology licensed by Beckhoff Automation GmbH Germany Windows XP Windows Vista and Windows 7 are registered trademarks of the Microsoft Corporation 20 Introduction to the manual Hardware description 21 Hardware description What this chapter contains The chapter briefly describes the operation principle layout type designation label and type designation information It also shows a general diagram of power connections and control interfaces 22 Hardware description Features The MicroFlex e150 is a versatile servo drive providing a flexible and powerful motion control solution for rotary and linear motors Standard features include Single axis drive for AC brushless servo motors Can also contr
28. Electromagnetic Compatibility Directive 2006 42 EC Machinery Directive Hereby declare that the following safety component MicroFlex e150 Integrated safe torque off drive with type markings E152A followed by additional alpha numeric digits to signify product variant Is in conformity with the applicable requirements of the following documents Standard Title Edition date EN 61800 3 Adjustable Speed Electrical Power Drive Systems Part 3 2004 EMC Requirements and Specific Test Methods 61800 5 1 Adjustable Speed Electrical Power Drive Systems Part 5 1 2007 Safety requirements Electrical thermal and energy 61800 5 2 A Adjustable Speed Electrical Power Drive Systems Part 5 2 2007 Safety requirements Functional EN ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 2008 General principles for design EN 62061 Safety of machinery Functional safety of safety related electrical electronic 2005 and programmable electronic control systems In addition the safety function is certified by EC type examination T V NORD Systems GmbH amp Co KG Branch South Halderstr 27 86150 Augsburg Germany Notified Body No 0044 Certification No SLA 0041 2010 I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications and is in accordance with the requirements of the Directive s Signed
29. H 41 ld C uz909 45104 18 MOVED HLdaCYSLU4aNOYOL 42005 ZIS 1 gis GNVEYALNASNOYOL 915 dOHdPl 215 03949 11438 0 01 yg409 uge0s 140443 49309 AdALMALTSSNOYOL 399v ugoos uvoos 409 LINMLNSYYND GNVIN3G TJA 42205 OANLINITSNOYOL 48909 SOdLINITANDYOL 1 2 45205 CGNVWSGSN0YOL 209 Technical data 157 B Torque servo configuration The diagram on page 758 shows the torque servo control configuration Here the velocity loop has been removed and the output of the position controller is fed into the current loop via the torque filters The torque servo configuration is useful when the drive is operating as a closed loop position controller and settling time must be minimized Although the servo configuration tends to give better velocity tracking when operating in position mode settling times can be longer The control mode switch allows the drive to operate in either torque or position modes but not velocity mode 158 Technical data s 2 fqo zopsq eunjonujs omas Jepoou3 xoeqpaa SsjeuDis uonisogd uonesueduioo 48209 Joyeums3 peeds 5 46409 AWILAM Jay yupamessduay SV3IALNSMHHOO quauing Jojo 215 MOVULIM 215 1
30. It is recommended to allow approximately 60 mm 2 4 in at the front to accommodate wiring and connectors Metal backplane Forced air flow Hot Warm Cool Mechanical installation 31 Installing 1 Mark the hole locations See Dimension drawing all models on page 126 for complete dimensions 2 Position the drive and check the hole positions are correct 3 Drill the holes mount the drive and tighten all four screws until the drive is secure 32 Mechanical installation Planning the electrical installation 33 Planning the electrical installation What this chapter contains The chapter contains the instructions that you must follow when checking the compatibility of the motor and drive selecting cables protective devices and cable routing Note The installation must always be completed according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive might experience problems that are not covered by the warranty The installation methods described in this chapter will improve the reliability of the system reduce troubleshooting time and optimize the EMC electromagnetic compatibility behavior of the control system Checking the compatibility of the
31. MicroFlex e150 can be connected to PC using either USB or TCP IP To use USB connect a USB cable between a PC USB port and the MicroFlex e150 USB port Your PC must be using Windows XP Windows Vista or Windows 7 To use TCP IP connect a CAT5e Ethernet cable between the PC and the MicroFlex e150 E1 Ethernet port and set DIP switch 4 to the ON position WARNING You cannot connect an ordinary office PC to the MicroFlex e150 without first altering the PC s Ethernet adapter configuration However if you have installed a second Ethernet adapter dedicated for use with the MicroFlex e150 then this adapter s configuration can be altered without affecting the PC s office Ethernet connection If you are unsure about making changes to your PC s Ethernet adapter configuration or are prevented by user permission levels ask your I T administrator to assist you B Installing Mint WorkBench The Windows user account requires administrative user rights to install Mint WorkBench To install Mint WorkBench from the CD OPT SW 001 1 Insert the CD into the drive 2 After a few seconds the setup wizard should start automatically If the setup wizard does not appear select Run from the Windows Start menu and type d start where d represents the drive letter of the CD device 3 Follow the on screen instructions to install Mint WorkBench To install Mint WorkBench from the website To install Mint WorkBench from www abbmotion com
32. OR RR ao RUE oder eps 15 Contents ofthis manual bea hex ase E ur PX UAR eR ELE ds 16 Related documents 16 Quick installation and start up flowchart 17 Terms and abbreviations 0 0 0 00 ccc 18 General terms 1 pedea bep es rt eco pf e nad 18 Trademarks tanaka cia ho Lebe PS dad e br bae x EE Rei 19 3 Hardware description What this chapter contains 21 FOatures Lue ze cone ei nte neq md oed d mata Roe d eR E ta 22 Operating principle wie eae eee ated PA Sg UR APAURU RC 22 Prod ct oVerVIeW ar ERR dem etae n ERU RU dd Ji 23 Connections front panel 23 Connections top panel 24 Type designation label esii esaia La sev beets me 25 4 Mechanical installation What this chapter contains 2 27 Requirements for the installation site 27 Required tools x dre er be tbe dts pee CEU Hp y ee a in 28 Checkirigithe delivery spese m deb om steht ere does 28 Mounting and cooling 29 Effects of mounting surface and proximity
33. address box enter an IP address e g 192 168 100 241 This is the IP address that will be assigned to the Ethernet adapter 7 In the Subnet mask box enter 255 255 255 0 and click OK 8 Click Close to close the Local Area Connection Properties dialog Configuring the MicroFlex e150 The MicroFlex e150 is supplied as a DHCP Dynamic Host Configuration Protocol client This means that when the MicroFlex e150 is connected to an Ethernet 94 Start up network it broadcasts a request to be assigned IP address A DHCP server in this case a software service installed with Mint WorkBench assigns an IP address and other IP parameters to the MicroFlex e150 When Mint WorkBench is started it should be able to automatically find the MicroFlex e150 using the Ethernet TCP IP connection Static configuration In unusual cases it might be necessary to manually assign a specific IP address to the MicroFlex e150 This can be performed using the Mint WorkBench Configuration Wizard Start up 95 Mint Machine Center The Mint Machine Center MMC is installed as part of the Mint WorkBench software It is used to view the network of connected controllers in a system Individual controllers and drives are configured using Mint WorkBench If you have only a single MicroFlex e150 connected to your PC then MMC is probably not required See Starting Mint WorkBench on page 99 to configure the MicroFlex e150 21 untitled M
34. are configured automatically by the Commissioning Wizard page 101 If they need to be changed use the Parameters tool in Mint WorkBench page 113 Electrical installation AC input motor and brake 51 24 V control circuit supply A 24 V DC supply must be provided to power the controlling electronics This is useful for safety reasons where AC power is removed from the power stage but the controlling electronics must remain powered to retain position and I O information A separate fused 24 V supply should be provided for the MicroFlex e150 If other devices are powered from the same 24 V supply a filter part FI0014A00 should be installed to isolate the MicroFlex e150 from the rest of the system Alternatively a ferrite sleeve can be attached to the supply cable near connector X2 Customer supplied 24 V filter Ferrite 24V DC Fuse optional sleeve x2 24 V GND XO E Use a twisted pair cable iem with ferrite sleeve attached close to connector X2 Incoming safety T earth ground PE STAR POINT Recommended fuse Bussman 5504 20 x 5 mm anti surge 2 Recommended ferrite sleeve Fair Rite part 0431164281 or similar 52 Electrical installation AC input motor and brake Motor connections MicroFlex e150 will operate with a large number of brushless servo motors For information on selecting servo motors please contact your local ABB representative
35. be dragged onto the MicroFlex e150 icon itself creating a visible representation of the machine A text description for the system and associated files can be added and the resulting layout saved as an MMC Workspace When you next need to administer the system simply loading the workspace automatically connects to all the required controllers See the Mint help file for full details of MMC 96 Start up B Starting MMC 1 On the Windows Start menu select Programs Mint WorkBench Mint Machine Center 21 Untitled Mint Machine Center File Edit View Help OLX 105815 20 2112012 3b Host Scan Node Address wh TCP IP Scan range from E 5 x Scan single node ee COM Scan all nodes COMB Serial Baud Rates t3 Application View U Controller View 38400 Baud 19200 Baud 9600 Baud 115200 Baud Change baud rate __ _____ _____ 2 Inthe controller pane ensure that Host is selected In the information pane click Scan 3 When the search is complete click once on MicroFlex e150 in the controller pane to select it then double click to open an instance of Mint WorkBench The MicroFlex e150 will be already connected to the instance of Mint WorkBench ready to configure Go straight to Commissioning Wizard on page 101 to continue the configuration in Mint WorkBench 2 Untitled Mi
36. been powered and the fault has been cleared The SAFETORQUEOFF Mint keyword reports the status of the STO hardware registers SAFETORQUEOFF contains an array of values indicating the states of the STO1 and STO2 inputs two internal hardware fault circuits and one internal STO status output This array is described in the following table Parameter Meaning SAFETORQUEOFF 0 The combined state of the two STO inputs STO1 bit 0 STO2 bit 1 SAFETORQUEOFF 1 The state of STO1 input 0 not powered 1 powered SAFETORQUEOFF 2 The state of 5702 input 0 not powered 1 powered SAFETORQUEOFF 3 The combined state of the two hardware fault circuits STO1 bit 0 STO2 bit 1 SAFETORQUEOFF 4 The state of the STO1 internal hardware fault circuit 0 no fault 1 fault SAFETORQUEOFF 5 The state of the STO2 internal hardware fault circuit 0 no fault 1 fault SAFETORQUEOFF 6 The state of the internal STO status output 0 fault 1 no fault See Safety Manual Safe Torque Off STO function for MicroFlex e150 drives 70313 for full details Status display When an STO error occurs the drive displays error code 10033 10034 or 10035 on its front panel Drive Status display The right decimal point is always and only illuminated for STO errors STO error 172 Appendix Safe Torque Off STO B Installation Typical input connections
37. damaged 2 Slide the section of outer sheath towards the of the cable to expose an area of braided shield Carefully remove the excess sheath at the end of the cable 3 Attach the metal P clip or clamp to the exposed area of braided shield 4 Ensure that the P clip or Motor Cable Management Bracket OPT CM 001 is securely attached to an unpainted area of the metal backplane 54 Electrical installation AC input motor and brake not damaged Slide the sectio sheath toward the cable to e area of braid Carefully excess sheath of the cable Continuation of motor power cable shielding MicroFlex e150 Electrical installation AC input motor and brake 55 B Motor circuit contactors If required by local codes or for safety reasons an M Contactor motor circuit contactor can be installed to provide a physical disconnection of the motor windings from the MicroFlex e150 see Motor connections on page 52 Opening the M Contactor ensures that the MicroFlex e150 cannot drive the motor which might be necessary during equipment maintenance or similar operations If an M Contactor is installed the MicroFlex e150 must be disabled at least 20 ms before the M Contactor is opened If the M Contactor is opened while the MicroFlex e150 is supplying voltage and current to the motor the MicroFlex e150 can be damaged Incorrect installation or failure of the M Contactor or its wiring can result in damage
38. download the application and run it Start up 91 Starting the MicroFlex e150 If you have followed the instructions in the previous sections you should have now connected the power sources your choice of inputs and outputs and the USB cable or Ethernet cable linking the PC to the MicroFlex e150 Preliminary checks Before you apply power for the first time check all items in nstallation checklist starting on page 87 E Power on checks See section MicroFlex e150 indicators on page 119 for symbols that show if the drive has detected a fault 1 2 3 Turn on the 24 V DC supply Turn on the AC supply The drive status display shows the following test sequence which normally takes approximately 15 20 seconds 8 in sequence J in sequence The sequence ends with the symbol or 7 if an STO input is not powered Startup can take more than 1 minute after downloading new firmware If the motor wires were disconnected in Preliminary checks on page 97 turn off the AC supply and reconnect the motor wires Turn on the AC supply To allow the Commissioning Wizard to function the Safe Torque Off inputs page 169 need to be powered to allow the MicroFlex e150 to be enabled If you do not wish to enable the MicroFlex e150 yet the Commissioning Wizard will inform you when this step is necessary USB driver The USB driver for the MicroFlex e150 is installed with Mint WorkBench If you are using Window
39. following tests were performed EtherCAT Protocol Test CTT Ver 1 20 52 0 Indicator Test Labeling Test Interoperability Test n Nuremberg March 14 2012 150 Technical data Degree of protection MicroFlex e150 complies with EN 60529 IP20 provided connector X1 is shrouded For UL purposes the MicroFlex e150 is defined as an open type single or three phase single axis servo amplifier The drive must be installed in a cabinet to fulfil the requirements for shielding from contact Access to the cabinet should be restricted to trained maintenance staff NOTE The top surface of cabinets enclosures which are accessible when the equipment is energized shall meet at least the requirement of protective type IP3x with regard to vertical access only Materials Drive enclosure Side cover PC ABS FR Bayblend FR3010 Black Front Cover PC ABS GN 5001RFH Lupoy Light grey RAL9002 Heat sink Die cast Aluminium LM6 Package Cardboard Disposal The drive contains raw materials that should be recycled to preserve energy and natural resources The package materials are environmentally compatible and recyclable All metal parts can be recycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations Most recyclable parts are marked with recycling marks The electrolytic DC capacitors and Integrated Power Module are classified as hazardous waste within the EU and must be
40. motor and drive Check that the 3 phase AC motor and the drive are compatible according to the Motor output power X1 on page 137 Selecting the supply disconnecting device Install a hand operated supply disconnecting device disconnecting means between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work 34 Planning the electrical installation E European Union To meet the European Union Machinery Directive according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types aswitch disconnector of utilization category AC 23B EN 60947 3 adisconnector having an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector EN 60947 3 acircuit breaker suitable for isolation in accordance with EN 60947 2 B Other regions The disconnecting device must conform to the applicable safety regulations Emergency stop devices For safety reasons install emergency stop devices at each operator control station and at other operating stations where emergency stop might be needed Implementing the STO function See Appendix Safe Torque Off STO on page 169 Planning the electrical installation 35 Thermal overload and short circuit protection Thermal overload protection The drive p
41. 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 N Operating the MicroFlex e150 in torque mode with no load attached to the motor can cause the motor to accelerate rapidly to excessive speed Make sure that dust from drilling does not enter the drive during the installation Electrically conductive dust inside the drive can cause damage or lead to malfunction Drives must be installed inside an electrical cabinet that provides environmental control and protection Installation information for the drive is provided in this manual Motors and controlling devices that connect to the drive should have specifications compatible with the drive If not installed in an electrical cabinet barriers around the equipment are required Avoid locating the drive immediately above or beside heat generating equipment directly below water or steam pipes or in the vicinity of corrosive substances or vapors metal particles and dust Ensure sufficient cooling Failure to meet cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips The metal heat sink on the left side of the MicroFlex e150 can become very hot during normal operation 14 Safety Safe star
42. one end of the cable wired to the RX pins of the RJ45 connector at the other end of the cable Recommended cables are listed in Ethernet cables on page 167 Crossover or straight cables can be used Many Ethernet devices including hubs and ABB e100 e150 products incorporate Auto MDIX switching technology which automatically compensates for the wiring of straight cables The MicroFlex e150 Ethernet interface is galvanically isolated from the rest of the MicroFlex e150 circuitry by magnetic isolation modules incorporated in each of the Ethernet connectors This provides protection up to 1 5 kV The connector cable Screen is connected directly to the chassis earth of the MicroFlex e150 Termination components are incorporated in each of the Ethernet connectors so no further termination is required The EtherCAT interface supports the 100Base TX 100 Mbit s speed F 80 Electrical installation input output DIP switches Location SW1 The MicroFlex e150 has four DIP switches which allow special settings to be selected on power up Changing the switch positions after power up has no effect DIP switch settings Switch Description lt OFF ON gt E1 OUT port EtherCAT mode E1 OUT port Standard Ethernet mode Normal operation Firmware recovery mode X6 port 2 wire TX RX or 4 wire TX X6 port 2 wire TX RX or 4 wire TX disconnect 120 Q termination resistor connect 120 termination resistor 1 X6 port 4 w
43. previous page it is not necessary to change anything on this screen the feedback resolution will be entered already However if you selected the 1 would like to define a custom motor option it will be necessary to enter the feedback resolution before continuing Drive Setup complete This screen confirms that drive setup is complete Select Operating Mode and Source In the Operating Mode section choose the required operating mode In the Reference Source section it is important to select Direct Host Mint as the Reference Source This will allow the Autotune Wizard to operate correctly and allow further initial testing to be performed using Mint WorkBench Although the MicroFlex e150 might eventually be controlled over EtherCAT the RT Ethernet reference source should only be selected after the MicroFlex e150 has been commissioned and is ready to add to the EtherCAT network This can be selected by choosing the Operating Mode tool in the Toolbox Application Limits It is not necessary to change anything on this screen However if you wish to adjust the application peak current App Peak Current and or application maximum speed App Max Speed then click in the appropriate box and enter a value Select Scale Factor It is not necessary to change anything on this screen However it is recommended to select a user unit for position velocity and acceleration This allows Mint WorkBench to display distance speed and a
44. the instructions in this manual in sequence you should have few problems installing the MicroFlex e150 If you do have a problem read this section first n Mint WorkBench use the Error Log tool to view recent errors and then check the help file f you cannot solve the problem or the problem persists the SupportMe feature can be used 118 Fault tracing SupportMe feature The SupportMe feature is available from the Help menu or by clicking the 8 button on the motion toolbar SupportMe can be used to gather information which can then be e mailed saved as a text file or copied to another application The PC must have e mail facilities to use the e mail feature If you prefer to contact ABB technical support by telephone or fax contact details are provided on the back cover of this manual Please have the following information ready The serial number of your MicroFlex e150 if known Open the Help SupportMe menu item in Mint WorkBench to view details about your system The catalog and specification numbers of the motor that you are using Aclear description of what you are trying to do for example trying to establish communications with Mint WorkBench or trying to perform fine tuning Aclear description of the symptoms that you can observe for example the Status LED error messages displayed in Mint WorkBench or errors reported by the Mint error keywords ERRORREADCODE Or ERRORREADNEXT
45. 150 Compliance with the EN 61800 3 151 elm ecto de eden ml E 151 07 151 Category ETT 151 Compliance with the European Machinery Directive 152 Validating the operation of the Safe Torque Off function 152 CE Declaration of Conformity 153 UL ride ERICH ee ee deta ae eee do ene eee eee 154 8 redo 154 Control waa beheaded ace tle ob 155 Servo configurallon ede eee edad 155 Torque servo configuration 157 12 Accessories What this chapter contains trases ccc tet ee 159 Ran RC 160 Foot mount filter single phase 161 24 V power supplies cc ete e 161 eal sme cpm 162 Brake seio Rec ere eee i eode HR e TOR HO Ra e eae eS 165 Cables sistere uer m pact hcec do ed ARR end do Ao d BG Ra e RC doen 166 Motor power cables rid eem koennen en er RUE Rr on ders 166 Feedback cables 4 ester rong een gn le nce 167 Ethemetcables c i obe Oe EROR Ep Yea tut ed esa bids 167 13 Appendix Safe Torque Off STO What this chapter contains
46. 19 Decet 3008 uas 13 m 7 Store Parameters on Controter brdeectional move Move Type Trapezoid Distance 5 w Durston 139 1 ON Q Analog input X Graph 1 Gah 2 Grach 3 Graph 4 Graph S 7 gt X Position Current Digital Allows you to configure the fou active states and special assignments Bank Dg Configuration for the digital inputs and outputs For example a general purpose digital input can be configured as an High optional drive enable input which must be active to enable the drive see pages 63 and 65 68 Low IN1 If a digital input is to be used as a mi home switch input see Using a digital Rising IN2 input as a home switch input optional on page 63 for important details 116 Start up Safe Torque STO acceptance test Drive commissioning is not complete until the STO function has been tested The acceptance test of the safety function must be carried out by an authorized person with expertise and knowledge of the safety function The test must be documented and signed by the authorized person See Appendix Safe Torque Off STO on page 169 Fault tracing 117 Fault tracing What this chapter contains This section explains common problems and their solutions The LED indicators are described in MicroFlex e150 indicators on page 179 E Problem diagnosis If you have followed all
47. ABB motion control Power and productivity ab EP MN1961WEN for a better world PA Hp List of related manuals Drive hardware manuals and guides Code English MicroFlex e150 Quick Installation Guide LT0307 Safety Manual Safe Torque Off STO function for LT0313 MicroFlex e150 drives MicroFlex e150 wall chart LT0296 MicroFlex e150 flyer 3AUA0000097609 You can find manuals and other product documents in PDF format on the Internet See section Document library on the Internet on the inside of the back cover For manuals not available in the Document library contact your local ABB representative User s manual MicroFlex e150 2012 ABB Oy All Rights Reserved LT0291A01 EN EFFECTIVE 2012 06 28 Table of contents 5 Table of contents List of related mar als ssc emm tem AG me deme ect eara de ae 2 1 Safety Safety in installation and maintenance 11 Electrical safely Leere e Oe 8 bile ae e A Re 11 General safety MERC 13 Safe start up and operation 14 General Safety Lee artes tal ade V a E 14 2 Introduction to the manual What this chapter contains 2 15 elena Ba RA aaa 15 Targeta dience u54 c nme Exe ae eedem eee gba a Palo aie 15 Purpose of the manual 5 nere ese decade mate
48. DC a ix era emer 1 Relay outputs 2 Varistor 3 RC filter 4 diode Planning the electrical installation 39 Selecting the control cables It is recommended that all control cables are shielded Double shielded twisted pair cable is recommended for analog signals For pulse encoder cabling follow the instructions given by the encoder manufacturer Use one individually shielded pair for each signal Do not use a common return for different analog signals Double shielded cable is best for low voltage digital signals but single shielded twisted multi pair cable Figure b may also be used Run the analog signal and digital signals in separate cables Relay controlled signals providing their voltage does not exceed 48 V may be run in the same cables as digital input signals It is recommended that the relay controlled signals are run as twisted pairs Never mix 24 V DC and 115 230 V AC signals in the same cable Relay cable The cable type with braided metallic screen for example OLFLEX by LAPPKABEL has been tested and approved by ABB Connection of a motor temperature sensor to the drive I O See Thermal switch connection on page 57 Routing the cables Route the motor cable away from other cable routes Motor cables of several drives may be run in parallel installed next to each other It is recommended that the motor cable input power cable and control cables are installed on separa
49. EL can be used The output s state is displayed in the Spy window See the Mint help file for details General purpose output DOUTO The status function must be disabled before the output can be used for other purposes To disable the status function the command GLOBALERROROUTPUT 1 must be issued from a Mint WorkBench command window or included in a Mint program The command GLOBALERROROUTPUT 0 enables the status function See the Mint help file for details 70 Electrical installation input output Status output typical connections to an ABB NextMove e100 MicroFlex e150 T User NextMove e100 controller Status Status TLP127 VA ah User supply GND B Digital outputs DOUT1 DOUT2 Location X3 pins 13 amp 3 DOUT1 12 amp 2 DOUT2 TLP280 The optically isolated general purpose outputs are designed to source current from an individual user supply connection The TLP127 has a maximum power dissipation of 200 mW at 25 Each output includes a self resetting fuse that operates at approximately 200 mA The fuse can take up to 20 seconds to reset after the load has been removed If the output is used to directly drive a relay a suitably rated diode must be fitted across the relay coil observing the correct polarity This is to protect the output from the back EMF generated by the relay coil when it is de
50. ESI file xml that describes the drive to the EtherCAT manager can be uploaded from the controller using the Mint WorkBench Configuration tool 124 Fault tracing can t control the MicroFlex e150 from my EtherCAT manager The drive s reference source must be set to allow the EtherCAT manager to take control of the MicroFlex e150 There are several ways to do this Set the CONTROLREFSOURCESTARTUP parameter to 1 using the Mint WorkBench Parameter viewer or Command window and restart the drive This will give control to the manager each time the MicroFlex e150 starts Set the Control Ref Source to RT Ethernet CiA402 in the Mint WorkBench Operating Mode Wizard or Commissioning Wizard Click the Direct button on the Mint WorkBench Motion tool bar and select RT Ethernet 05402 in the Axis 0 drop down Confirm that the reference source on all controlled nodes has been set to EtherCAT in the Mint WorkBench Operating Mode Wizard and that the master has been configured correctly Technical data 125 Technical data What this chapter contains The chapter contains the technical specifications of the drive for example the ratings sizes and technical requirements as well as provisions for fulfilling the requirements for CE and other marks 126 Technical data Dimension drawing all models 82 3 23 gt 79 5 3 13 11 63 5 i15 Q 4 25 0 2 Oe gt lt
51. MicroFlex e150 immediately above or beside heat generating equipment or directly below water steam pipes Avoid locating the MicroFlex e150 in the vicinity of corrosive substances or vapors metal particles and dust Failure to meet cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips The maximum suggested operating altitude is 1000 m 3300 ft The MicroFlex e150 must be installed where the pollution degree according to EN 60664 shall not exceed 2 The atmosphere must not contain flammable gases or vapors There must not be abnormal levels of nuclear radiation or X rays 28 Mechanical installation The threaded holes in the top and bottom of the case for cable clamps The holes are threaded for M4 bolts no longer than 11 mm 0 43 in The D type connectors on the front panel of the MicroFlex e150 are secured using two hexagonal jack screws sometimes known as screwlocks If a jack screw is removed accidentally or lost it must be replaced with a 44 40 UNC jack screw with an external male threaded section no longer than 10 mm 0 4 in Required tools Asmall slot screwdriver s with a blade width of 3 mm or less for connector X1 and 2 mm 1 10 in or less for connectors X3 and X4 A drill and M5 screws or bolts for mounting the MicroFlex e150 Wire stripper ForUL installations use UL listed closed loop connectors that are of appropriate size for the wi
52. N2 high speed 144 Table of contents 9 Digital inputs DIN9 OPT1 models EIOA only 144 Digital outputs DOUTO Status DOUT1 DOUT2 145 Digital outputs DOUT3 DOUT6 OPT1 models EIOA only 145 Encoder output OPT1 models EEOA only 145 Incremental encoder interface X8 145 SSI encoder interface X8 146 BiSS encoder interface X8 146 SinCos EnDat encoder interface X8 146 Ethernet interface E1 E2 147 Ambienticonditions ete ed NO eaaet oy ake 147 Applicable standards 2 2 rn acre acque cesa ER chida 148 Design and test standards 148 Environmental test lt 148 Functional safety standards 148 LE 148 Degree Gf protection osp qat secte teh e eerte adu te Bre e 150 VECCHIO 150 CE marking ruht ann Pa eee ene pacer es Oe dee b tes 150 Compliance with the European EMC Directive
53. Product overview E Connections front panel X1 Power X2 Control circuit power NC Not Connected Do not make a connection to this pin L1 L2 L3 Earth Ground Earth Ground NC AC Phase 1 L AC Phase 2 AC Phase 3 Motor U Motor V Motor W Brake 0v 24V LEDs DIP switches Hardware description 23 The seven segment display and the two EtherCAT LEDs are described in MicroFlex e150 indicators on page 119 These switches select the Ethernet mode and U1 USB M 1 5 2 Data 01 3 Data 4 GND X3 Input Output H RS485 settings See D P switches on page 80 swi 1 X6 RS485 serial port 2 wire 4 wire TXA TXB RXB TXB GND GND 7Vout 7Vout NC RXA NC RXB 1 11 1 Status 11 Status 2 2 DOUT2 12 DOUT2 3 3 DOUT1 13 DOUT1 4 4 DIN2 14 DIN2 5 5 DIN3 15 DIN3 6 X3 6 DIN1 16 DIN1 7 7 DINO 17 DINO 8 8 SREF 18 STO1 9 9 SREF 19 STO2 10 20 10 Shield 20 Shield Input Output 1 5 1 AOUTO 5 AGND 2 2 AIN1 6 AIN1 3 3 7 AINO 4 8 4 Shield 8 Shield X8 Feedback in Pin Incremental SinCos BiSS SSI EnDat 2 1 EnDat 2 2 1 CHA NC Data Data 2 CHB NC Clock Clock 3 CHZ NC NC NC 4 Sense Sense Sense Sense 5 Hall U Sin NC Sin 6 Hall U Sin NC Sin T Hall V Cos NC Cos 8 Hall V Cos NC Cos 9 CHA NC Data D
54. The motor must be capable of being powered by an inverter PWM output The motor can be connected directly to the MicroFlex e150 or through a motor contactor M Contactor The motor outputs are conditionally short circuit proof Motors should ideally have a minimum inductance of 1 mH per winding for motors with lower inductance an output reactor can be fitted in series with the motor When using a motor in the Mint WorkBench catalog the parameters for managing motor overloads are configured automatically by the Commissioning Wizard page 101 If they need to be changed or you are using an alternative motor use the Parameters tool page 113 in WARNING Hazardous voltages can exist on the motor output connections Do not touch the motor output connections before you first ensure there is no high voltage present WARNING The motor cables U V and W must be connected to their L corresponding V or W terminal on the motor Misconnection will result in uncontrolled motor movement WARNING Do not connect supply power to the MicroFlex e150 UVW outputs The MicroFlex e150 might be damaged For CE compliance the motor earth ground should be connected to the drive earth ground and the motor power cable must be shielded see Motor power cable shielding on page 53 The connector or gland used at the motor must provide 360 degree shielding The maximum recommended cable length is 30 5 m 100 ft See Recommended fuses circui
55. able or motor when input power is applied After disconnecting the input power always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive motor or motor cable Always ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage between the drive input phases L1 L2 and L3 and the ground Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits can carry dangerous voltage even when the input power of the drive is switched off Do not make any insulation or voltage withstand tests on the drive All ELV extra low voltage circuits connected to the drive must be used within a zone of equipotential bonding i e within a zone where all simultaneously accessible conductive parts are electrically connected to prevent hazardous voltages appearing between them This is accomplished by proper factory grounding 12 Safety Even when the motor is stopped dangerous voltage is present at power circuit terminals L1 L2 L3 U V W R1 R2 connector X1 If a motor is driven mechanically it can generate hazardous voltages that are conducted to its power terminals The enclosure must be earthed grounded to prevent possible shock hazard To prevent equipment damage be certain that the input power has correctly sized protective devices installed To prevent equipme
56. ace Differential Data and Clock Operating mode Single turn Baldor motors Positioning resolution up to 262144 counts rev 18 bit Output power supply to encoder 5 V DC 7 250 mA max Maximum recommended cable length 30 5 100 ft BiSS encoder interface X8 Description Unit All models Operating mode Single or multi turn Baldor motors A wide range of devices can be supported Contact ABB technical support before selecting a device Output power supply to encoder 5 V DC 7 250 mA max Maximum recommended cable length 30 5 100 ft SinCos EnDat encoder interface X8 Description Unit models Absolute encoder interface EnDat SinCos differential inputs and data input Operating mode Baldor motors Single or multi turn 512 or 2048 Sin Cos cycles per turn with absolute positioning resolution of up to 65536 steps Many other encoder specifications are supported contact ABB Output power supply to encoder 5 V DC 47 250 mA max Maximum recommended cable length 30 5 100 ft B Ethernet interface E1 22 Technical data 147 Description Unit All models Signal 2 twisted pairs magnetically isolated Protocols EtherCAT amp TCP IP Bit rates Mbit s 100 Ambient conditions Description Unit All models Operating temperature range c F Minimum VDC 0 32 Maximum 45 113 Derate See Temperatu
57. ads rotor position from the encoder and estimates velocity The commutation block uses the position to calculate the electrical angle of the rotor The current sensor system measures U and V phase currents These are fed into a current conversion block that converts them into quantities representing torque producing and magnetizing currents the vector currents which are locked to the rotor In the current control loop a current demand and the final measured current values form the inputs to a PI Proportional Integral control system This control system generates a set of voltage demands that are fed into a PWM pulse width modulation block The PWM block uses the space vector modulation method to convert these voltage demands into a sequence of U V and W phase switching signals which are applied to the output bridge of the drive The PWM block uses the measured DC bus voltage to compensate for variations in supply voltage The torque controller converts a torque demand into a current demand and compensates for various load non linearities A 2 stage notch or low pass filter allows the effects of load compliance to be reduced To avoid motor damage a user defined application current limit is also applied as well as individual positive and negative torque limits In the velocity control loop a velocity demand and measured velocity form the inputs to a PI control system The output of the control system is a torque demand which when the d
58. al inputs and outputs Input Qutput Clicking on an output LED will toggle EE E the output on off 0400000000 10500000001 50 1 1 32 4 The Monitor tab allows up to six oy parameters to be selected for monitoring Velocity demand AxisO Click in a drop down box to select a parameter Position AxisO At the bottom of the Monitor tab real time data capture can be configured OFF M Y Start up 115 B 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 amp Debug Tool This tool provides a work area including 10 REF 0 50 the Command window and Output window The Command window can be used to send immediate Mint commands to the MicroFlex e150 If you tried the test moves in Performing test moves continuous jog on page 110 or Performing test moves relative positional move on page 777 then you have already used Edit amp Debug mode Press Ctrl N to open new Mint programming window Scope Tool Displays the capture screen This screen is also shown when the Fine tuning tool is selected Axis 0 m Position Control Terms 000 KINTMODE Never hd KNT 000 KINTUMIT 10000 0 00 000 Feedtorward Torms KVELFF 000 KACCEL 000 Calculate Profile Parameters Speed 400 3008 Accelime
59. allation input output B EnDat interface The absolute encoder interface supports both incremental and absolute multi and single turn feedback using EnDat technology It is possible to read and write information to the encoder The absolute encoder connections are made using the 15 pin D type female connector X8 Version 2 2 EnDat encoders do not use the Sin and Cos channels EnDat 2 1 interface cable connections Motor Twisted pairs 1 Data 9 Data Absolute 5 Sin Encoder 6 Sin 7 Cos 8 2 Clock 10 Clock 12 5V Connect 13 DGND internal 4 Sense shields to pin 13 o Connect overall shield to 7 connector backshells E Extra incremental encoder interface The extra incremental encoder becomes available when using a digital encoder type that does not require the Sin Cos inputs BISS SSI EnDat 2 2 In Mint the main digital encoder source remains as encoder 0 and the extra incremental encoder 15 encoder 2 Note that encoder 1 is the input formed by digital inputs DIN1 and DIN2 see Special functions on inputs DIN1 DIN2 on page 67 The 5 V encoder inputs CHA CHB and CHZ can be used as differential inputs recommended for improved noise immunity or single ended inputs When used as single ended inputs leave the CHA CHB and CHZ pins unconnected Extra encoder input circuit channel A shown MicroFlex e150 MAX3096 Differential li
60. also Mounting and cooling on page 29 B Derating characteristic for 3 A models E152A03 Single phase AC supply 3 _ 1 m s forced air 2 g 5 o 8 Natural cooling 1 o w 14 0 30 35 40 45 50 55 Ambient temperature C Three phase AC supply 3 1 m s forced air L N Natural cooling Rated output current Arms 0 30 35 40 45 50 55 Ambient temperature C Notes Load power factor 0 75 Overload limit for models E152A03 is 6 A Technical data 131 Derating characteristic for 6 A models E152A06 Single phase AC supply 6 5 1 5 m s forced air x 4 g 5 1 m s forced air o3 5 8 2 E a4 Natural cooling 0 30 35 40 45 50 55 Ambient temperature C Three phase AC supply 6 35 1 5 m s forced air lt 4 g 5 1 m s forced air o3 amp 5 2 8 1 Natural cooling 0 30 35 40 45 50 55 Ambient temperature C Notes Load power factor 0 75 Overload limit for models E152A06 is 12 A 132 Technical data Derating characteristic for 9 A models E152A09 Single phase AC supply 3 5 m s forced air 2 5 m s forced air 1 5 m s forced air 1 m s forced air N wo A A DN Rated output current Arms Natural cooling
61. aphs 7 Typical autotuned response no load 1000 4 i Measured velocity 800 4 500 Demand velocity Data 1 400 4 200 4 p r T TT 0T 7 Ton T 0 100 200 300 400 500 600 700 800 300 1000 Time ms D Note The graph that you see will not look exactly the same as this one Each motor has a different response The graph shows that the response reaches the demand quickly and only overshoots the demand by a small amount This can be considered an ideal response for most systems For further information about tuning with the load attached see Further tuning with load attached on page 106 106 Start up E 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 2 Attach the load to the motor Click the Autotune icon in the Toolbox on the left of the screen Click the Autotune on load check box Click START to begin the auto tuning process Mint WorkBench will take measurements from the motor and then perform small test moves Click the Fine tuning icon in the Toolbox on the left of the screen In the Velocity tab s Test Parameters area ensure the same move parameters are entered and then click Go to start the test move Mint WorkBench will perform the test move and displ
62. ard 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 gt to display the next screen If you need to change something on a previous screen click the lt Back button The Commissioning Wizard remembers information that you have entered so you will not need to re enter everything if you go back to previous screens If you need extra help click Help or press F1 102 Start up Select your Motor Type Select the type of motor that you are using rotary or linear brushless or induction Select your Motor Carefully enter the details of your motor If you are using a Baldor motor the catalog number or spec number 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 1 would like to define a custom motor option Confirm Motor and Drive information If you entered the catalog or spec number on the previous page it is not necessary to change anything on this screen all the required data will be entered already However if you selected the 1 would like to define a custom motor option it will be necessary to enter the required information before continuing Motor Feedback If you entered the catalog or spec number on the
63. at are electrically symmetrical with respect to earth ground The power supply module within the MicroFlex e150 provides rectification smoothing and current surge protection Fuses or circuit breakers are required in the input lines for cable protection For three phase supplies connect the supply to L1 L2 and L3 as shown above For single phase supplies connect the supply and neutral to any two line inputs for example L1 and L2 For CE compliance an AC filter must be connected between the AC power supply and the MicroFlex e150 If local codes do not specify different regulations use at least the same gauge wire for earth ground as used for L1 L2 and L3 The X1 mating connector is a Phoenix COMBICON MSTB 2 5HC 11 ST 5 08 Tightening torque is 0 5 0 6 N m 4 4 5 3 Ib in The threaded hole in the top or bottom of the case may be used as an additional functional earth ground connection for signals on connector X3 The threaded holes may also be used to attach shield or strain relief clamps The holes are threaded for M4 bolts no longer than 11 mm 0 43 in B Earthing grounding A permanent earth ground bonding point is provided on the heat sink which must be used as the protective earth It is labeled with the protective earth symbol in the casting and does not form any other mechanical function Connector X1 contains earth terminals but these must not be used as protective earth since the connector does not guarantee earth connecti
64. ata 10 CHB NC Clock Clock 11 CHZ NC NC NC 12 5 V out 5 Vout 5Vout 5 Vout 13 DGND DGND DGND DGND 14 Hall W NC NC NC 15 Hall W NC NC NC Shell Shield Shield Shield Shield EnDat v2 1 only EnDat v2 2 does not use the Sin and Cos signals Tightening torque for terminal block connections X1 amp X2 is 0 5 0 6 N m 4 4 5 3 Ib in Maximum wire sizes X1 2 5 mm 0 5 mm Connector X3 is designed to accept bare wires only do not use ferrules 24 Hardware description Connections top panel OPT1 Input Output option 14 Shield 7 DIN4 13 CREF1 6 DINS 12 DIN8 5 DING 11 DIN9 4 DIN7 10 USRV 0 3 CREFO 9 DOUTS 2 DOUT3 8 DOUT6 1 DOUT4 OPT1 Encoder Output option 9 NO 5 DGND 4 NC 8 CHZ CHZ 7 CHB 6 2 1 dh E1 E2 EtherCAT pm EtherCAT 1 TX 2 TX 3 RX 4 NC EtherCAT 5 NC OUT 6 RX 7 8 NC Both connectors have E1 is also used for standard 5 identical pinouts Ethernet if DIP switch 4 is in the ON position see page 80 See chapter Electrical installation AC input motor and brake on page 43 for installation in general Hardware description 25 Type designation label A description of the product s catalog numbering system is shown below ABB CEIS2A09EOAD S No _ 00316810002 A C Desc MicroFl x e150 Drive ot US INPUT 105 250 AC 50 60 Hz 12 32 ourrur scomndpoosorso
65. ay a graph of the result Autotune Autotune on load R START Aer Fine tuning Test Parameters Move Type Forward Velocity 1000 uu utu Distance 10 uu Start up 107 E Optimizing the velocity response It might be desirable to optimize the default autotuned response to better suit your application The following sections describe the two main tuning factors and how to correct them Correcting overshoot The following graph shows a response where the measured velocity overshoots the demand by a significant amount 1 Go to the Fine tuning window s Velocity tab Calculate To reduce the amount of overshoot click Calculate and increase the Autotune Bandidih Reset bandwidth using the slider control M 2000 E Alternatively type a larger value in the Bandwidth box i Slowest S Fastest coe Click OK to close the Bandwidth dialog 2 Click Go to start the test move Mint G WorkBench will perform the test move display graph of the result Velocity overshoots demand 1000 4 r Measured velocity 800 4 500 Demand velocity Data 1 4004 200 4 0 100 200 300 400 500 600 700 800 900 1000 Time ms 108 Start up Correcting zero speed noise in the velocity response The following graph shows a response where there is very little overshoot but a significant amount of zero speed noise This can cause undesirable humming or ringi
66. bb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to www abb com drives and select Document Library You can browse the library or enter selection criteria for example a document code in the search field Contact us ABB Oy Drives P O Box 184 Fl 00381 HELSINKI FINLAND Telephone 358 10 22 11 Fax 358 10 22 22681 www abb com drives Baldor Electric Company A member of the ABB group 5711 R S Boreham Jr St P O Box 2400 Fort Smith AR 72901 USA Telephone 1 479 646 4711 Fax 1 479 648 5792 www baldor com ABB Inc Automation Technologies Drives amp Motors 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 1 800 HELP 365 Fax 262 780 5135 www abb com drives ABB Ltd Motion Control 6 Bristol Distribution Park Hawkley Drive Bristol 532 United Kingdom Telephone www abb com drives 44 0 1454 850000 Fax 44 0 1454 859001 ABB Beijing Drive Systems Co Ltd No 1 Block D A 10 Jiuxiangiao Chaoyang District Beijing P R China 100015 Telephone 86 10 5821 7788 Fax 86 10 5821 7618 www abb com drives LT0291A01 EN EFFECTIVE 2012 06 28 y Power and productivity for a better world PA aD ID
67. cceleration using meaningful units instead of encoder counts For example selecting a Position User Unit of Revs r will mean that all position values entered or displayed in Mint WorkBench will represent revolutions The Position Scale Factor value will change automatically to represent the required scale factor the number of quadrature counts per revolution If you need to use an alternative unit for example degrees type Degrees in the Position User Unit box Start up 103 and enter a suitable value in the Position Scale Factor box Separate velocity and acceleration units can also be defined See the Mint help file for more information about scale factors Profile Parameters It is not necessary to change anything on this screen However if you wish to adjust the parameters for any control method click in the appropriate box and enter a value Analog input parameters It is not necessary to change anything on this screen However if you wish to adjust the analog inputs click Common Settings to select the input range The Tune Offset button automatically adjusts the input to compensate for any DC offset Operation setup complete This screen confirms that operation setup is complete Autotune Wizard The Autotune Wizard tunes the MicroFlex e150 for optimal performance with the attached motor This removes the need for manual fine tuning of the system although in some critical applications this still might be required
68. chronous interface is an open source interface that can be used with many types of absolute encoder The BiSS interface connections are made using the 15 pin D type female connector X8 BiSS interface cable connections Motor X8 Twisted pairs Data Data Clock Clock 5V out DGND Sense Absolute Encoder Interface Chassis NI Connect overall shield to 7 connector backshells Electrical installation input output 85 B SSI interface The SSI Synchronous Serial Interface encoder interface is specifically designed for use with Baldor SSI motors which incorporate a custom Baumer SSI encoder Correct operation with other SSI interfaces cannot be guaranteed The SSI encoder connections are made using the 15 pin D type female connector X8 SSI interface cable connections Motor X8 Twisted pairs Data 5V out DGND Sense Absolute Connect Data Encoder pn internal 5 shields to o 2 5 Clock 13 E Chassis WI Connect overall shield to connector backshells B SinCos interface The SinCos connections Sin and Cos incremental channels only are made using the 15 pin D type female connector X8 SSI cable connections Motor X8 Twisted pairs Sin Sin Connect Cos internal Cun shields to eedbacl 5V out PI 13 DGND Sense tees Chassis S Connect overall shield to connector backshells 86 Electrical inst
69. complies with the CE specifications for which it has been tested Ideally one filter should be provided for each MicroFlex e150 filters should not be shared between drives or other equipment B Harmonic suppression When operating the 3 A MicroFlex e150 part E152A03 on a single phase supply a 13 mH 4 A rms 10 A peak line reactor is required to ensure compliance with EN 61000 3 2 class A limits when the total equipment supply load is less than 1 kW B Reversing the filter When using filters FI0015A00 or FI0015A02 they must be reversed to ensure that the MicroFlex e150 complies with the CE specifications for which it has been tested The AC power supply should be connected to the filter terminals marked as the outputs with the MicroFlex e150 connected to the filter terminals marked as the inputs WARNING This recommendation applies only to filters FI0015A00 and F10015A02 Alternative filters or protection devices must be connected as specified by the manufacturer Electrical installation AC input motor and brake 49 Power disconnect and protection devices A power disconnect should be installed between the input power supply and the MicroFlex e150 for a fail safe method to disconnect power The MicroFlex e150 will remain in a powered condition until all input power is removed from the drive and the internal bus voltage has depleted The MicroFlex e150 must have a suitable input power protection device instal
70. ctors to check 88 Installation checklist Check that Appropriate supply fuses and disconnector have been installed The motor cable has been connected to appropriate terminals the phase order is correct and the terminals have been tightened pull conductors to check The brake resistor cable if present has been connected to appropriate terminals and the terminals have been tightened pull conductors to check The motor cable and brake resistor cable if present has been routed away from other cables No power factor compensation capacitors have been connected to the motor cable All low voltage control cables have been correctly connected If a drive bypass connection will be used for induction motors The direct on line contactor of the motor and the drive output contactor are either mechanically or electrically interlocked cannot be closed simultaneously There are no foreign objects or dust inside the drive Drive and motor connection box covers are in place Verify that all wiring conforms to applicable codes The motor and the driven equipment are ready for start up Disconnect the load from the motor until instructed to apply a load If this is not possible disconnect the motor wires at connector X1 Check no physical damage is present Check all
71. e wo eee 60 Analog inputs AINT 2 60 Analog output AOUTO teens 61 Digital E 62 Using a digital input as a drive enable input 63 Using a digital input as a home switch input optional 63 Digital inputs Safe Torque Off 5 64 Digital inputs general purpose DINO 65 Digital inputs general purpose DIN1 DIN2 66 Special functions on inputs 1 2 67 Digital inputs general purpose DIN9 models EIOA only 68 Status Output DOUTO suede e e cen a E a eos ud an as e RE Rp ten 69 Digital outputs 0 1 00072 RII e 70 Table of contents 7 Digital outputs DOUT3 DOUT6 models EIOA only 71 Encoder output models EEOA only 73 USBinterface 2 wal ek ae ar ees dcs 74 RS485 Interface oen olan coc e o f inre WR edd 74 Ethernetinterface er md et ee tee eae d erg es eate tnde Dos 76 Standard Etherriet enne bares E Ra ade A dear es 76 EtherCA T i1 ou edt m ated s aate e duae a ceti as te 7T Et
72. e drive more frequently could cause high inrush current and corresponding nuisance operation of circuit breakers or fuses Repeated failure to observe the delay period could reduce the lifetime of the MicroFlex e150 Discharge period WARNING After AC power has been removed from the MicroFlex e150 high AN voltages greater than 50 V DC can remain on the brake resistor connections until the DC bus circuitry has discharged The high voltage can remain for the period specified in the table below MicroFlex e150 Time for DC bus to discharge to 50 V or less current rating maximum seconds 3A 83 6A 166 9A 248 136 Technical data Filters MicroFlex e150 230 VAC 18 230 VAC 30 current rating 3A FI0015A00 line reactor FI0018A00 FI0029A00 6A FI0015A02 FI0018A00 FI0029A00 9A FI0029A00 FI0018A03 See EMC filters starting on page 162 for further details See Foot mount filter single phase only on page 161 for further details Maximum earth leakage from the MicroFlex e150 is 3 4 mA per phase 230 V 50 Hz supply This value does not include the earth leakage from the AC power filter which could be much larger see EMC filters on page 162 24 V control circuit supply X2 24 V DC 100 ms Description Unit 3A 6A 9A Nominal input voltage V DC 24 Minimum input voltage V DC 20 Maximum input voltage V DC 30
73. e section Brake X1 on page 138 for details about choosing the correct resistor WARNING Electrical shock hazard DC bus voltages can be present at these terminals Use a suitable heat sink with fan if necessary to cool the brake resistor The brake resistor and heat sink if present can reach temperatures in excess of 80 C 176 F Brake resistor dimensions 0 4 i D Part Power Res Dimensions mm inches NW B F G RGJ139 100 39 165 41 22 152 12 10 4 3 6 49 1 61 0 87 5 98 0 47 0 39 0 17 RGJ160 100 60 165 41 22 152 12 10 4 3 6 49 1 61 0 87 5 98 0 47 0 39 0 17 RGJ260 200 60 165 60 30 146 17 13 5 3 6 49 2 36 1 18 5 75 0 67 0 51 0 21 RGJ360 300 60 215 60 30 196 17 13 5 3 8 46 2 36 1 18 7 72 0 67 0 51 0 21 166 Accessories Cables A wide range of motor and feedback cables are available Motor power cables For easier installation it is recommended that a color coded motor power cable is used The part number for a BSM rotary motor power cable is derived as follows CBL 025 SP 12 S m ft SP style threaded motor Current Standard 1 5 5 connector motor end only Amps connector 2 5 8 2 3 0 10 6 S Stainless 50 164 12
74. e EMC requirements A symmetrical shielded motor cable must be used to meet the EMC requirements of the CE and C Tick marks see the following diagrams A four conductor system is allowed for input cabling but a shielded symmetrical cable is recommended Compared to a four conductor system the use of a symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear The motor cable and its PE pigtail twisted shield should be kept as short as possible in order to reduce electromagnetic emission Planning the electrical installation 37 Alternative power cable types Motor cables also recommended for supply cabling Symmetrical shielded cable three phase Note A separate PE conductor is required conductors and a concentric or otherwise if the conductivity of the cable shield is not constructed PE conductor and a shield sufficient for the purpose Check with local state country electrical codes for allowance PE Shield Shield conductor PE PE Allowed for AC power cabling A four conductor system three phase Shield 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 the phase conductors when they are made of the same metal To effectively suppress radiated and conducted radio frequency emissions the shield conductivity
75. e MicroFlex e150 the axis home switch if present must be wired directly to the home input on the MicroFlex e150 otherwise it will not be able to complete its internal homing routines The home switch input is configured using the Digital I O tool in Mint WorkBench or by using the Mint HOMEINPUT keyword within a program Other HOME keywords define the homing sequence If homing is being handled by an EtherCAT master over Ethernet and the master is profiling the motion there are two options The choice depends on the accuracy required for the homing and the EtherCAT cycle time The axis home switch can be wired to an input on the MicroFlex e150 and then mapped back to the master over EtherCAT The home switch can be wired directly to the EtherCAT master 64 Electrical installation input output Digital inputs Safe Torque Off STO Location X3 pin 18 STO1 8 SREF 19 STO2 9 SREF The two safe torque off STO inputs are identical Each input directly enables part of the motor output control circuit Both inputs must be powered to allow the MicroFlex e150 to supply power to the motor If an additional hardware drive enable input is used to control the MicroFlex e150 it must not be wired with the STO input circuit The state of the STO inputs can be viewed using the Mint WorkBench Spy window s Axis tab See the Mint help file for details See Appendix Safe Torque Off STO on page 169 Safe Torque O
76. eed of the motor DIN2 is used as the direction input The state of the direction input controls the direction of motion An active input will result in forward motion An inactive input will result in motion in the opposite direction Encoder input DIN1 and DIN2 can be configured using the statement ENCODERMODE 1 0 to form an additional encoder input The two channels are read as a quadrature CHA CHB encoder input In Mint the encoder input formed by digital inputs DIN1 and DIN2 is encoder 1 The primary motor feedback encoder source on connector X8 is encoder 0 and the extra incremental encoder on connector X8 is encoder 2 see pages 81 and 86 Fast latch input DIN1 or DIN2 can be configured using the LATCHTRIGGERCHANNEL keyword to become a fast latch input This allows the position of the axis to be captured in real time and read using the Mint keyword LATCHVALUE The input can be configured using the LATCHTRIGGEREDGE keyword to be triggered either on a rising or falling edge Further control of position capture is provided by various other keywords beginning with LATCH See the Mint help file for details The maximum latency to read the fast position depends 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 us resulting from the 16 kHz sampling frequency used for these ty
77. energized Digital output circuit DOUT1 shown MicroFlex e150 Mint OUTX 1 TLP127 o User supply V Load relay with diode shown User supply o GND When the MicroFlex e150 is connected to Mint WorkBench the active level of the outputs can be configured using the Digital I O tool Alternatively the Mint keyword OUTPUTACTIVELEVEL can be used The state of the outputs is displayed in the Spy window See the Mint help file for details Electrical installation input output 71 DOUT1 typical connections to an ABB NextMove e100 MicroFlex e150 User NextMove e100 controller supply x3 24V m DOUT1 V 4 u DOUT1 TLP127 TLP280 User supply GND Digital outputs DOUT3 DOUT6 models EIOA only Location OPT1 pin 2 DOUT3 1 DOUTA 9 DOUT5 8 DOUT6 10 USRV 0 The optically isolated general purpose outputs are designed to source current from a common user supply USRV 0 The TLP127 has a maximum power dissipation of 200 mW at 25 Each output includes a self resetting fuse that operates at approximately 200 mA The fuse can take up to 20 seconds to reset after the load has been removed If the output is used to directly drive a relay a suitably rated diode must be fitted across the relay coil observing the correct polari
78. ff digital input STO1 MicroFlex e150 STO STO1 circuit Y lt TLP281 SREF Shield Safe Torque Off digital input STO2 MicroFlex e150 x3 STO STO2 circuit TLP281 SREF Shield Electrical installation input output 65 B Digital inputs general purpose DINO DIN3 Location X3 pins 17 amp 7 DINO 15 amp 5 DIN3 These general purpose digital inputs are buffered by a TLP280 opto isolator allowing the input signals to be connected with either polarity The inputs do not share a common reference When the MicroFlex e150 is connected to Mint WorkBench the digital inputs can be configured using the Digital I O tool Alternatively Mint keywords including DRIVEENABLEINPUT RESETINPUT ERRORINPUT and STOPINPUT can be used The state of the digital inputs can be viewed using the Mint WorkBench Spy window s Axis tab See the Mint help file for details General purpose digital input DINO shown MicroFlex e150 VA TLP280 Digital input typical connections from an ABB NextMove e100 NextMove e100 controller MicroFlex e150 UDN2982 Mint DRIVEENABLEOUTPUT TLP280
79. firmware the Select button is replaced with Update firmware Scan all serial ports Scan Add Specific Controller Search up to serial node ID s Hex 08 7 Scanning PCI bus done Scanning USB done Controllers found i MicroFlex e150 on USB node 2 W Virtual Controller Launch Commissioning Wizard 9 Note If the MicroFlex e150 is not listed check the USB or serial cable between the MicroFlex e150 and the PC Check that the MicroFlex e150 is powered correctly Click Scan to re scan the ports It can take up to 5 seconds for Mint WorkBench to detect the MicroFlex e150 When detection is complete the Commissioning Wizard is displayed If Launch Commissioning Wizard was not checked Edit amp Debug mode is displayed Start up 101 Commissioning Wizard Each type of motor and drive combination has different performance characteristics Before the MicroFlex e150 can be used to control the motor accurately the MicroFlex e150 must be tuned Tuning is the process where the MicroFlex e150 powers the motor in a series of tests By monitoring the drive s output and the feedback from the motor s encoder the MicroFlex e150 can make small adjustments to the way it controls the motor This information is stored in the MicroFlex e150 and can be uploaded to a file if necessary The Commissioning Wizard provides a simple way to tune the MicroFlex e150 and create the necessary configura
80. fore performing hipot tests Input power cable Check the insulation of the input power cable according to local regulations before connecting to the drive Motor and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the motor cable is connected to the motor and disconnected from the drive output terminals U V and W 2 Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 500 V DC The insulation resistance of the motor must exceed 100 Mohm reference value at 25 C or 77 F Please consult the manufacturer s instructions Moisture inside the motor casing reduces the insulation resistance If moisture is suspected dry the motor and repeat the measurement Electrical installation AC input motor and brake 45 Connecting the power cables Connection diagram AC input Connect earth ground to protective earth on top AC Route L1 L2 L3 and Circuit breaker AC filter of drive Supply earth ground together or fuses incondutorcable T s 4 Line L1 Ti jy Line L2 La La Line L3 a Isolating switch uu uu Incoming safety earth ground PE To earth ground outer shield use 360 clamps connected to enclosure backplane STAR POINT MicroFlex e150 is designed to be powered from standard single or three phase lines th
81. further tuning tests are performed this will display a graph representing the response The Fine tuning window has a gt number of tabs the bottom 4 gt V Position ed 5 Click on the Velocity tab Some tabs might not be available depending on the configuration mode you selected in the Commissioning Wizard In the Test Parameters area at the bottom of the tab click in the Move Test Parameters Type drop down box and select Move Type Forward Forward Velocity 1000 uu utu Distance 10 uu Enter values in the Velocity and Distance boxes to create a short move The values you enter depend on the velocity scaling factor that was selected in the Commissioning Wizard This example assumes the velocity scaling factor was selected as Revs Per Minute rpm so entering a value of 1000 here will create a move with a velocity of 1000 rpm Similarly assuming the Start up 105 position scaling factor had been Revolutions r the value 10 will create a move lasting for 10 revolutions of the motor 4 Click Go to start the test move Mint Go WorkBench will perform the test move and display a graph of the result 5 Click on the graph labels to turn off ON Axis 0 Demand velocity vel units unwanted traces Leave just Demand ON Axis 0 Measured velocity vel units Velocity and Measured Velocity OFF Axis 0 Measured torque producing current Amps turned on Graph 2 taph 3y Graph 4 Gr
82. hat the MicroFlex e150 is powered and the drive status display is illuminated page 120 Check that the Ethernet or USB cable is connected between the PC and MicroFlex e150 For Ethernet connections check that DIP switch 4 is in the ON position to set standard Ethernet mode Power cycle the MicroFlex e150 after changing DIP Switch 4 Check that the cable is connected to port E1 the port nearest the front panel Check that the PC s Ethernet port has been correctly configured for TCP IP operation see Configuring the TCP IP connection optional on page 93 Try an alternative cable or different port on the PC For USB connections check that the cable is properly connected Check the USB connector socket pins for damage or sticking Check that the USB device driver has been installed a ABB USB Motion Product device should be listed in Windows Device Manager and MicroFlex e150 should be listed in Windows Devices and Printers Windows 7 B Mint WorkBench The Spy window does not update The system refresh has been disabled Go to the Tools Options menu item select the System tab and then choose a System Refresh Rate 500 ms is recommended Cannot communicate with the controller after downloading firmware After firmware download always power cycle the MicroFlex e150 Fault tracing 123 Mint WorkBench loses contact with MicroFlex e150 while connected using USB Check that the MicroFlex e150 is powered
83. hawmut 6x32 FA series 8 A V084313P or BS88 2 5 URGS 7 A 076647 10A 8A 14 14 2 0 2 0 E152A06 6A 16 Ferraz Shawmut 6x32 FA series 20 A A084318P or BS88 2 5 URGS 20A L097507J 20A 14 2 0 30 Ferraz Shawmut 6x32 FA series 12 5 A X084315P or BS88 2 5 URGS 12A P076649J 12 5A 14 2 0 E152A09 9A 16 Ferraz Shawmut BS88 2 5 URGS 25A 076651 25A 14 2 5 30 Ferraz Shawmut 6x32 FA series 20A A084318P or BS88 2 5 URGS 20A L097507J 20A 14 2 0 Note All wire sizes based on 75 C 167 F copper wire Higher temperature smaller gauge wire can be used per National Electric Code NEC and local codes Recommended fuses are based on 25 C 77 F ambient maximum continuous Technical data 135 control output current and no harmonic current Earth ground wires must be the same gauge or larger than the L1 L2 and L3 wires Input power cycling and inrush If AC power has been removed from the MicroFlex e150 it should remain disconnected for the specified period before it is reapplied MicroFlex e150 Minimum power cycle delay period current rating seconds 3A 25 6A 45 9A 65 This delay allows the input surge protection circuit to perform correctly ensuring that the inrush current typically 1 7 A is below the drive rated current Power cycling th
84. he assembly 44 Connecting the power cables 45 Earthing grouriding sce trente o tds e eR OR n RC eR RE on de 45 Input power conditioning 47 Supplying input power from a variac variable 47 Power supply fillers 2 cime e tob Ead baute Ros Dodd ant b ee edd 48 es rem er grt Garnet ea rr eee ds 48 Reversing the filter i ule dl bueno du d d sende Edda 48 Power disconnect and protection devices 49 Drive overload protection 50 24 V control circuit supply RR hn 51 Motor Connections sga erasia ce 52 Motor power cable shielding 53 Motor circuit contactOrS rrr erre hh yh re ee eR E en Re dae ete 55 Sin soidal filter rat hr deg Rege sete tart ul ce 55 Motor brake connection erre 55 Thermal switch connection 2 57 Brake resistor regeneration lt 5 58 7 Electrical installation input output What this chapter contains 59 Analogi O bowen pitta we ed
85. herCAT configuration 78 Ethernet connectors eee eee eee eens 79 DIP Switches BY ne PP bp eld uid 80 Motor feedback dst rare bens E e RAPI Ts eran eee ee ate eee 81 Incremental encoder interface 82 BISS interface s ads Rosia roce ote Re ea mines ea aE d RUE erre Wo ee 84 SSI uro ae synodo tondere eoa ORE ta aera thos tet sree 85 SinCos interfaGe br ROME ee be ee a a xe ee dd 85 usum Race ce at aca deter eere ale een De dy eto dite 86 Extra incremental encoder interface 86 8 Installation checklist GE dr a tures bebe te 87 Safe Torque Off STO connections 88 9 Start up What this chapter contains 89 Introduction esent ce iden 89 Connecting the MicroFlex e150 tothe 90 Installing Mint WorkBench 90 Starting the MicroFlex 150 91 Preliminary CHECKS ussi optet Ec RR de Rn c e a LR RR RR eine 91 Power orn CHECKS n Deor DR da UG GRR cie p
86. i MER so ie 91 USB driver ns nee d qe Roa c Roe 91 Configuring the TCP IP connection optional 93 Configuring the network adapter 93 Configuring the MicroFlex e150 93 Mint Machine Center teer Eee ede oaths e dee dede ae ene s Leeds 95 StatrtingMMG a ma se erbe sod laser EAE 96 Mint WorkBerich sisses cesa eR re et He 97 lale qe LP 98 Starting Mint WorkBench 99 Commissioning Wizard 101 Further tuning no load attached 104 Further tuning with load attached 106 Optimizing the velocity response 107 Performing test moves continuous jog 110 Performing test moves relative positional move 111 Further configuration 112 Configuration tool 2 ee RR oe eee RERO eR ERR ek ee 112 Parameters tool enere Riana ele oe RE eo 113 SPY WINKOW Sg 114 8 Table of contents Other tools and windows 115 Safe Torque Off STO acceptance test
87. ill trip if the DC bus voltage falls below 50 V or 60 of the no load voltage whichever occurs first 128 Technical data W Effect of AC power supply voltage on DC bus voltage DC bus voltage V DC 350 300 250 Three phase AC suppl lt 200 Si gle phase AC suppl 150 100 100 125 150 175 200 AC supply voltage rms 225 250 E Effect of AC power supply voltage on DC bus ripple voltage DC bus ripple of DC bus voltage 50 40 30 20 Single phase AC 10 0 T Three phase AC supply 100 125 150 175 200 AC supply voltage rms 225 250 Technical data 129 Effect of output current on DC bus ripple voltage 605 gt J gt 50 gt IS 40 gt J Singl phase AC supply 9 304 4 Q J 204 4 3 J Q 10 AC supply J Q J 91 20 30 40 50 60 70 80 90 100 110 120 130 140 150 of drive rated current 130 Technical data Temperature derating The derating characteristics assume the MicroFlex e150 is mounted vertically on 3 mm thick or less metal plate If the MicroFlex e150 is mounted on 10 mm metal plate the current characteristics shown below can be increased by up to 796 if there is no forced air cooling or 15 if forced air cooling is present See
88. ing characteristic for 6 A models 152 06 131 Derating characteristic for 9 A models 152409 132 trips rn 132 Heat dissipation Res ones ui Sib esa 133 Recommended fuses circuit breakers and wire sizes 134 Input power cycling and 5 135 Discharge period Rep RAM e Edu RR 135 dic teeta ek eee ee ae eee 136 24 V control circuit supply X2 2 tenes 136 Motor output power X1 137 Brake NY pc un 138 Braking Capacity ee ex ee 138 Brake resistor selection err ree Oe Mae hm n ance are 138 Braking energy cde sce m bed oto ede xt OR uod tl deed 140 Braking power and average power 140 Resistor choii uo oo gt eia 141 Resistor derating 0 142 c 142 Output esse paa bin wt Sad oe ded dibs 143 Analog inputs AINO AIN1 X4 RI 143 Analog output AOUTO X4 2 1 2 cette eee 143 Digital inputs STO1 5702 3 ete 143 Digital inputs DINO 144 Digital inputs DIN1 DI
89. instruments have been properly calibrated E Safe Torque Off STO connections The STO inputs are an intrinsic part of a safe drive installation The acceptance test of the safety function must be carried out by an authorized person with expertise and knowledge of the safety function The test must be documented and signed by the authorized person The MicroFlex e150 will operate only when the STO inputs are powered See Appendix Safe Torque Off STO on page 169 Start up Start up 89 What this chapter contains This chapter describes software installation and the start up procedure of the drive Introduction Before powering the MicroFlex e150 you will need to connect it to the PC using a USB or Ethernet cable and install the Mint WorkBench software This includes a number of applications and utilities to allow you to configure tune and program the MicroFlex e150 Mint WorkBench and other utilities can be found on the Mint Motion Toolkit CD OPT SW 001 or downloaded from www abbmotion com The PC must have the following minimum specification Minimum specification Processor 1GHz RAM 512 MB Hard disk space 2GB CD ROM A CD ROM drive Serial port USB port or Ethernet port Screen 1024 x 768 16 bit color Mouse A mouse or similar pointing device Operating system Windows XP or newer 32 bit or 64 bit 90 Start up Connecting the MicroFlex e150 to the PC The
90. int Machine Center GI x p Toolbars 8 90 19 Yv Virtual Controller PCI Node Address Q EF NextMove PCI Cai Scan range from 3 to pa USB Scan single node Pa 2 MicroFlex e150 soan at nodes 4 TCP IP EE Serial Serial Baud Rates 57600 Baud B 38400 Baud 19200 Baud Controller pane 9600 Baud Controller wit 115200 Baud C Application View U Controller View Information pane gt Add Controller MMC provides an overview of the controller network currently accessible by the PC MMC contains a controller pane on the left and an information pane on the right In the controller pane select the Host item then in the information pane click Scan This causes MMC to scan for all connected controllers Clicking once on a controller s name causes various options to be displayed in the information pane Double clicking on a controller s name launches an instance of Mint WorkBench that is automatically connected to the controller Application View allows the layout and organization of controllers in your machine to be modelled and described on screen Controllers can be dragged onto the Application View icon and renamed to give a more meaningful description for example Conveyor 1 Packaging Controller Drives that are controlled by another product such as MicroFlex e150 can
91. ire RX X6 port 4 wire RX disconnect 120 Q termination resistor connect 120 termination resistor Electrical installation input output 81 Motor feedback Location X8 MicroFlex e150 supports incremental encoder encoder with BiSS Bi directional Synchronous Serial Interface encoder with SSI Synchronous Serial Interface EnDat absolute encoder or SinCos encoder feedback for use with linear and rotary motors When using BiSS SSI or EnDat 2 2 an extra incremental encoder is also available There are some important considerations when wiring the feedback device The inputs are not isolated The feedback device wiring must be separated from power wiring Where feedback device wiring runs parallel to power cables they must be separated by at least 76 mm 3 in Feedback device wiring must cross power wires at right angles only To prevent contact with other conductors or earths grounds unearthed ungrounded ends of shields must often be insulated Linear motors use two separate cables encoder and Hall The cores of these two cables will need to be wired to the appropriate pins of the 15 pin D type mating connector Connection summary Pin Incremental BiSS SSI or Extra EnDat 2 1 SinCos encoder EnDat 2 2 incremental encoder 1 CHA Data Data NC 2 CHB Clock Clock NC 3 CHZ NC NC NC 4 Sense Sense Sense Sen
92. ires often carry noise that could cause erratic drive operation or damage The brake contacts must never be wired directly to the digital outputs The relay should be fitted with a protective flyback diode as shown The separate 24 V DC supply used for the motor brake can also be used to power the relay in the thermal switch circuit Electrical installation AC input motor and brake 57 B Thermal switch connection You can use the motor s thermal switch contacts normally closed to control a relay connected to a digital input on connector X3 or OPT1 see Connections front panel on page 23 and Connections top panel on page 24 This allows the MicroFlex e150 to respond to motor over temperature conditions Using the Mint WorkBench Digital I O tool the input can be configured to be the motor temperature input The Mint keyword MOTORTEMPERATUREINPUT can also be used to configure a digital input for this purpose A typical circuit using DINO as the input is shown in the following diagram The relay has normally open contacts and is shown deactivated contacts open motor overheated x1 DINO 17 motor 5 thermal 9 bs switch vi A B u alt T DINO 24 V 0v 24 V 0v Separate Customer customer supplied supplied 24 V DC 24 V DC supply supply WARNING The 24 V DC power supply connected to the thermal switch must be a separate supply a
93. ith 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 B Ethernet cables The cables listed in this table connect MicroFlex e150 to other Ethernet nodes such as NextMove e100 additional MicroFlex e150s or other Ethernet compatible hardware The cables are standard CAT5e shielded twisted pair S UTP crossover Ethernet cables Cable description Part Length m ft CAT5e Ethernet cable CBLO02CM EXS 0 2 0 65 CBLOO5CM EXS 0 5 1 6 CBLO10CM EXS 1 0 3 3 CBL020CM EXS 2 0 6 6 CBL050CM EXS 5 0 16 4 CBL100CM EXS 10 0 32 8 168 Accessories Appendix Safe Torque Off STO 169 13 Appendix Safe Torque Off STO What this chapter contains The appendix describes the basics of the Safe torque off function STO for the MicroFlex e150 In addition application features and technical data for the safety system calculation are presented Basics The STO function disables the control voltage of the power semiconductors of the drive output stage which prevents the inverter generating the voltage required to rotate the motor see diagram below By using this function short time operations like cleaning and or maintenance work on non electrical parts of the machinery can be performed without switching off the power supply to the drive The drive suppo
94. l models Type Opto isolated inputs Input voltage V DC Nominal 24 Minimum 12 Maximum 30 Active gt 12 Inactive lt 2 Input current maximum per input mA 50 Sampling interval ms 1 Minimum pulse width us 5 Technical data 145 B Digital outputs DOUTO Status DOUT1 DOUT2 X3 Description Unit All models User supply maximum V DC 28 Output current maximum mA 100 Fuse Approximate trip current mA 200 Reset time S 20 Update interval ms 1 Digital outputs DOUT3 DOUT6 OPT1 models only Description Unit models User supply maximum V DC 28 Output current maximum mA 100 Fuse Approximate trip current mA 200 Reset time 5 lt 20 Update interval ms 1 B Encoder output OPT1 models EEOA only Description Unit All models Encoder interface RS422 A B Differential Z index Output frequency Matches encoder input X8 E Incremental encoder interface X8 Description Unit All models Encoder interface RS422 A B Differential Z index Maximum input frequency MHz 8 quadrature Hall inputs RS422 A B Differential Output power supply to encoder 5 V DC 47 250 mA max Maximum recommended cable length 30 5 100 ft 146 Technical data E SSI encoder interface X8 Description Unit All models SSI encoder interf
95. ld be connected directly to a USB port on the host PC If it is connected to a hub shared by other USB devices communication could be affected by the activity of the other devices The maximum recommended cable length is 5 m 16 4 ft RS485 interface Location X6 The RS485 interface is used to connect third party serial devices such as operator panels and PLCs The interface can operate in 2 wire or 4 wire RS485 mode which is selected using the Configuration tool in Mint WorkBench The default mode is 2 wire RS485 57600 Baud 8 data bits 1 stop bit with no parity MicroFlex e150 supports various protocols over the RS485 interface such as Modbus RTU and HCP Host Comms Protocol as well as simple ASCII character handling The 7 V supply on pin 4 is provided for future accessories so care should be taken to ensure this supply will not damage connected devices The RS485 port could be damaged if a USB plug is accidentally inserted while the drive is powered Connections to a 2 wire RS485 device ABB AC500 eCo PLC shown ABB AC500 eCo PLC MicroFlex e150 Electrical installation input output 75 Connections to a 4 wire RS485 device ABB Keypad KPD202 501 shown MicroFlex e150 ABB Keypad KPD202 501 Serial GND TXB RXB 76 Electrical installation output Ethernet interface The Ethernet interface supports EtherCAT CoE and E
96. led preferably a fuse Recommended circuit breakers are thermal magnetic devices 1 or 3 phase as required with characteristics suitable for heavy inductive loads C type trip characteristic Circuit breaker or fuses are not supplied see Recommended fuses circuit breakers and wire sizes on page 134 For CE compliance see Technical data on page 150 From Circuit breaker supply N From supply Fuse Circuit breaker and fuse single phase From Circuit breaker supply L1 2208 L2 13 MNV L1 L2 L3 From supply Fuse L1 2 41 I 12 L3 Circuit breaker and fuse three phase NOTE Metal conduit or shielded cable should be used Connect conduits so the use L3 of a line reactor or RC device does not interrupt EMI RFI shielding Using 2 phases of a 3 phase supply Power can be derived by connecting two phases of an appropriate three phase supply L1 and L2 for example When supplying AC power in this way the voltage between the two phases must not exceed the rated input voltage of the MicroFlex e150 A two pole breaker must be used to isolate both lines Fuses must be fitted in both lines P d 50 Electrical installation AC input motor and brake Drive overload protection The MicroFlex e150 will immediately trip and disable if there is an overload condition The parameters for managing drive overloads
97. ling and or starting up power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment Category C2 The drive complies with the standard with the following provisions 1 The drive is equipped with a suitable EMC filter see Filters on page 136 2 The motor and control cables are selected as specified in this manual 3 The drive is installed according to the instructions given in this manual 4 Maximum cable length is 30 meters WARNING The drive can cause radio interference if used in residential or domestic environment The user is required to take measures to prevent interference in association to the requirements for the CE compliance listed above if necessary B Category The drive complies with the standard with the following provisions 1 The drive is equipped with a suitable EMC filter see Filters on page 136 2 The motor and control cables are selected as specified in this manual 3 The drive is installed according to the instructions given in this manual 4 Maximum cable length is 30 meters WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network 152 Technical data Compliance with the European Machinery Directive
98. mmended The encoder output consists of an A and B quadrature pulse train A and B are square waves with a duty cycle of 5096 out of phase by 907 with a Z pulse if required The frequency of the pulse train is updated at 62 5 us intervals and varied to match the source encoder Due to this update interval the position of the encoder output lags the source encoder by 125 us See the keyword ENCODEROUTRESOLUTION in the Mint help file Encoder output typical connections to an ABB NextMove e100 MicroFlex e150 NextMove e100 encoder output Twisted encoder input pairs CHB CHB CHZ CHZ CHZ CHZ DGND DGND Connect internal Connect overall shield shields to AGND to connector backshells Baldor cable parts CBLOxxMF E3B are recommended where xx represents a choice of available lengths 74 Electrical installation output USB interface Location U1 The USB connector is used to connect the MicroFlex e150 to a PC running Mint WorkBench The MicroFlex e150 is a self powered USB 2 0 12 Mbps compatible device If it is connected to a slower USB 1 0 host PC or hub communication speed will be limited to the USB 1 0 specification 1 5 Mbps If it is connected to a faster USB 2 0 high speed 480 Mbps or USB 3 0 5 Gbps host PC or hub communication speed will remain at the USB 2 0 specification of the MicroFlex e150 Ideally the MicroFlex e150 shou
99. mpling interval ms 1 Minimum pulse width us 5 E STO function data related to safety standards IEC 61508 EN ISO 13849 1 SIL PFH HFT SFF PTI PFD PL CCF MTTFp DC Category 3 442x410 jh 1 96 48 10 142x105 e 75 20420 9 9096 3 0 112 FIT years points years According to the categorization defined in EN ISO 13849 1 2008 Abbreviation Reference Description EN ISO 13849 1 Common Cause Failure 96 DC EN ISO 13849 1 Diagnostic Coverage FIT IEC 61508 Failure In Time 1E 9 hours HFT IEC 61508 Hardware Fault Tolerance MTTFp EN ISO 13849 1 Mean Time To dangerous Failure The total number of life units the number of dangerous undetected failures during a particular measurement interval under stated conditions PFD IEC 61508 Probability of Failure on Demand PFH IEC 61508 Probability of Dangerous Failures per Hour PL EN ISO 13849 1 Performance Level Corresponds SIL Levels a e PTI Proof Test Interval SFF IEC 61508 Safe Failure Fraction 96 SIL IEC 61508 Safety Integrity Level STO IEC 61800 5 2 Safe Torque Off 174 Appendix Safe Torque Off STO B STO function certificate TUV NORD Certificate TUV NORD Systems GmbH amp Co KG hereby certifies Baldor UK Ltd Mint Motion Centre 6 Bristol Distribution Park Hawkley Drive Bristol BS32 United Kingdom that the
100. must be at least 1 10 of the phase conductor conductivity The requirements are easily met with a copper or aluminium shield The minimum requirement of the motor cable shield of the drive is shown below It consists of a concentric layer of copper wires The better and tighter the shield the lower the emission level and bearing currents Insulation jacket Copper wire screen Helix of copper tape or copper wire Inner insulation aj A N gt Cable core 38 Planning the electrical installation Protecting the contacts of relay outputs and attenuating inductive loads Inductive loads relays contactors motors cause voltage transients when switched off Equip inductive loads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances might connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install protective components at I O terminal block D 2 wa 230 o MENT 3 230V AC o s 4 eX 29 24V
101. n file as a starting point Start new configuration Select this option to create a new configuration file j 3 Entera descriptive name for onveyor the controller and click the green arrow gt 4 Continue through the screens king the required changes ma 9 q ges DHCP Enabled iv Click Finish at any time to go Address 192369 IUIS to the last screen and save Mask 255 255 255 0 the changes Gateway 192 168 100 241 Modbus TCP gt Modbus RTU gt Serial gt HCP gt USB 5 On the final screen click UEM Finish to complete the configuration B Parameters tool Start up 113 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 4 Parameters Items listed with a grey RO icon are read only so cannot be changed Items listed with a green Ell icon are currently set to their factory default value Items listed with a yellow E icon have been changed from their factory default value either during the commissioning process or by the user In the parameters tree scroll to the required item Click on the small sign beside the item s name The list will expand to show all items in the category Click on the item you wish to edit The adjacent table will list the chosen item
102. n tray requires 23 27 5 V DC at 325 mA which can be sourced from the same filtered control circuit supply used for the MicroFlex e150 The MicroFlex e150 is UL Listed NMMS E128059 when used in conjunction with the fan tray mounted exactly as shown in the following diagram Fan tray Fan tray FANO001 024 dimensions Assembled MicroFlex e150 and fan tray 94 3 7 84 3 3 99 oo00000 Daogogaagad 0000 66 2 6 gt All dimensions shown as mm inches Position of fan tray mounting holes relative to MicroFlex e150 Bottom of MicroFlex e150 lt gt 8970 Fan tray JE 0 63 0 18 It is important that the fan tray is mounted in close proximity to the MicroFlex e150 as shown above Failure to do so will result in decreased cooling efficiency Accessories 161 B Foot mount filter single phase only The single phase foot mount AC power filter part FI0029A00 provides mounting holes for the MicroFlex e150 and fan tray This allows the filter fan tray and MicroFlex e150 to use minimal panel mounting space See pages 162 and 164 for details of filter FI0029A00 Foot mount filter FI0029A00 MicroFlex e150 E152A0 Fan tray 1 024 E 24V power supplies A range of compact
103. nd background information on motion control topics The help file can be displayed at any time by pressing F1 On the left of the help window the Contents tab shows the tree structure of the help file each book contains a number of topics 2 The Index tab provides an alphabetic list of all topics in the file and allows you to search for them by name The Search tab allows you to search for words or phrases appearing anywhere in the help file Many words and phrases are underlined and highlighted with a color normally blue to show that they are links Click on the link to go to an associated keyword Most keyword topics begin with a list of relevant See Also links BP Mint The Real Time Automation Language iG x Eg e u D Hide Locate Back Fond Print Options _ SuppotMe Update Help Contents Index Search Favores 7 Btwise OR 2 Btwise NOT i2 Logical NOT 12 ABORT AB 7 ABORTMOOE ABM 7 Abs ACCELTIME ACT ActiveX Purpose To define the acceleration rate of an axis Format ACCELTIME axis expression v ACCELTIME axis 2 ABSENCODERMODE 2 ABSENCODEROFFSE 2 ABSENCODERTURN 12 2 ACCELDEMANDIACE 3 ACCELIERK ACJ aot 12 ACCELJERKTIME AC 2 AcCELSCALEFACTC Select controller 2 ACCELSCALEUNTS C NextMove C NextMove e100 Flex MintDiive Parameters IB 2 ACCEL TIMEMAX AT gt 2 Acos 2 ACTIVERS485NOOE Eu
104. nd other EtherCAT enabled controllers EtherCAT s CAN application layer over EtherCAT CoE capability allows Mint to implement a drive protocol based on the CANopen DS402 Device Profile for Drives and Motion Control MicroFlex e150 incorporates built in multi port EtherCAT slave controller providing two ports for connection to other equipment This allows nodes to be connected in many configurations such as a ring star or tree with EtherCAT s self terminating technology automatically detecting breaks or an intended end of line If only one port is used for EtherCAT operation it must be the E2 IN port Straight line topology EtherCAT network Machine 1 EtherCAT master MicroFlex e150 drives 1 9 Ring topology EtherCAT network Machine 1 EtherCAT master MicroFlex e150 drives 1 9 78 Electrical installation output Multi branch EtherCAT network Machine 1 MicroFlex e150 drives 1 9 EtherCAT master OG External switch Machine 2 MicroFlex e150 drives 10 20
105. ne receiver Installation checklist 87 Installation checklist This chapter contains a list for checking the mechanical and electrical installation of the drive Checklist Check the mechanical and electrical installation of the drive before start up Go through the checklist together with another person WARNING Only qualified electricians are allowed to carry out the work described below Follow the complete safety instructions of the drive Ignoring the safety instructions can cause injury or death Open the main disconnector of the drive and lock it to open position Measure to ensure that the drive is not powered Check that The ambient operating conditions meet the specification in chapter Technical data There is an adequately sized protective earth ground conductor between the drive and the metal mounting surface There is an adequately sized protective earth ground conductor between the motor and the drive protective earth ground conductors have been connected to the appropriate terminals and the terminals have been tightened pull conductors to check The supply voltage matches the nominal input voltage of the drive Check the type designation label The input power cable has been connected to appropriate terminals the phase order is correct and the terminals have been tightened pull condu
106. ng in the motor 1 Go to the Fine tuning window s EVE Velocity tab reduce the amount of noise click FORES Calculate and decrease the bandwidth using the slider control Alternatively type a smaller value in Slowest Fastest the Bandwidth box Click OK to close the Bandwidth dialog Click Go to start the test move Mint _______ WorkBench will perform the test 0 move and display a graph of the result Zero speed noise Data1 1000 4 8004 600 4 400 3 Noise in measured velocity at zero speed 200 4 1 Time ms Start up 109 Ideal velocity response Repeat the tests described in Correcting overshoot and Correcting zero speed noise in the velocity response until the optimal response is achieved The following graph shows an ideal velocity response There is only a small amount of overshoot and very little zero speed noise Ideal velocity response 1000 4 Measured velocity 800 600 Demand velocity Data 1 400 200 r T T T T T T T T T T T T T T T T T T 0 100 200 300 400 500 600 700 800 900 1000 Time ms 110 Start up Performing test moves continuous jog This section tests the basic operation of the drive and motor by performing a continuous jog To stop a move in progress click the red stop button or the drive enable button on the toolbar Alternatively use the Mint WorkBench
107. nmental testing Test Ea Shock EN 60068 2 30 2005 Environmental testing Test Db Damp heat cyclic EN 60068 2 31 2008 Environmental testing Test Ec Rough handling shocks EN 60068 2 78 2001 Environmental testing Test Cab Damp heat steady state B Functional safety standards IEC 61508 2010 Functional safety of electrical electronic programmable electronic safety related systems IEC 61800 5 2 2007 Adjustable speed electrical power drive systems Safety requirements Functional EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Basic principles IEC 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems E Marks See also CE marking on page 150 for general recommendations for CE compliance C EtherCAT Technical data 149 EtherCAT Conformance Test Certificate Certificate EtherCAT Conformance Test 8 5 Hiomotie 13 P O Box 184 Fl 00381 Helsinki Finland EF q EtherCAT Technology Group hereby confirms the above named company that the following device is successfully EtherCAT Conformance Tested Device under Test MicroFlex 150 Product Code Ox2BC Revision Number 0x164A Assigned Vendor ID 7 Test Report Number 0xB7_001 EtherCAT Test Center Beckhoff Automation GmbH Nuremberg Germany The
108. nt Machine Center File Edit Yiew Help 1058500 206 E Y Virtual Y Virtual Controll Q MF NextMove PCI E USB MicroFlex e150 on U Start up 97 Mint WorkBench Mint WorkBench is a fully featured application for programming and controlling the MicroFlex e150 The main Mint WorkBench window contains a menu system the Toolbox and other toolbars Many functions can be accessed from the menu or by clicking a button use whichever you prefer Most buttons include a tool tip hold the mouse pointer over the button don t click and its description will appear Mint WorkBench New Project Fine tuning x Ele Edi Tools Production Program Scope 1 Ed Uy Toolbars 5 gt i 000 Ohms ne i 00 E Configuration Measure 1 000 Drive Setup 3 i Feedback Alignment Operating Mode Test 5 Autotune A i 1 Finetuning Test Parameters Control ee 100 200 300 test area Duration 50 00 Edit amp Debug Timeims Speed Limit 25 00 ON Channel 0 ADC percentage BI ai oon iy corren MicroFlex e150 Build 5705 1 3 BetaXWIP b 61 59628 f Z 98 Start up Help file Mint WorkBench includes a comprehensive help file that contains information about every Mint keyword how to use Mint WorkBench a
109. nt damage be certain that input and output signals are powered and referenced correctly To ensure reliable performance of this equipment be certain that all signals to from the drive are shielded correctly Do not tin solder exposed wires Solder contracts over time and can cause loose connections Use crimp connections where possible If the drive is subjected to high potential hipot testing only DC voltages may be applied AC voltage hipot tests could damage the drive For further information please contact your local ABB representative The safe integration of the drive into a machine system is the responsibility of the machine designer Be sure to comply with the local safety requirements at the place where the machine is to be used In Europe these are the Machinery Directive the ElectroMagnetic Compatibility Directive and the Low Voltage Directive In the United States this is the National Electrical code and local codes To comply with CE directive 2004 108 EC an appropriate AC filter must be installed Both the AC supply and the 24 V DC supply must be fused The 24 V DC control circuit supply must be installed so that the 24 V DC supplied to the unit is isolated from the AC supply using double or reinforced insulation or by using basic insulation with a protective earth The input of the control circuit must be limited to Safety Extra Low Voltage circuits Permanent magnet motor drives These are additional warnings c
110. oE and standard Ethernet E Standard Ethernet The standard Ethernet connection supports several protocols including EtherNet IP Modbus TCP HTTP and ICMP See the application notes at www abbmotion com for details Ethernet port E2 is fixed in EtherCAT mode so port E1 must be used for other Ethernet connections To set port E1 OUT to standard Ethernet mode front panel DIP switch 4 page 80 must be in the ON position Connecting Mint WorkBench using standard Ethernet TCP IP allows the MicroFlex e150 to support standard Ethernet communication with a host PC running Mint WorkBench The connection uses a high level Immediate Command Mode ICM protocol to allow Mint commands Mint programs and even firmware to be sent to the controller over the Ethernet network The host PC must be connected to the controller either directly or via a switch as shown in the following diagram Connecting to drives using TCP IP in standard Ethernet mode Host PC MicroFlex e150 drives External switch Electrical installation input output 77 EtherCAT MicroFlex e150 supports the EtherCAT protocol This protocol provides deterministic communication over a standard 100 Mbit s 100Base TX Fast Ethernet IEEE 802 3u connection This makes it suitable for the transmission of control and feedback signals between the MicroFlex e150 a
111. oFlex e150 VA TLP280 MicroFlex e150 NextMove e100 controller UDN2982 Mint OUTX 0 TLP280 10 USR GND User supply GND Electrical installation input output 69 Status output DOUTO Location pins 1 Status 11 Status The optically isolated status output is designed to source current from the user supply The TLP127 has a maximum power dissipation of 200 mW at 25 C The output includes a self resetting fuse that operates at approximately 200 mA The fuse can take up to 20 seconds to reset after the load has been removed If the output is used to directly drive a relay a suitably rated diode must be fitted across the relay coil observing the correct polarity This is to protect the output from the back EMF generated by the relay coil when it is de energized Status output circuit o User supply MicroFlex e150 V Fuse cig CO vit 200 Error p Load TLP127 relay with diode shown User supply GND The status output becomes active in the event of an error or when the STO function is activated When the MicroFlex e150 is connected to Mint WorkBench the active level of the output can be configured using the Digital I O tool Alternatively the Mint keyword OUTPUTACTIVELEV
112. ol induction motors Range of models with continuous current ratings of 3 A 6 A or 9 A Direct connection to 115 V AC or 230 V AC single phase or 230 V AC three phase supplies Universal feedback interface supporting incremental encoder BiSS SSI EnDat or SinCos feedback Position velocity and current control 3 optically isolated general purpose digital inputs Two inputs have fast input capability providing real time position capture 2 dedicated Safe Torque Off STO digital inputs 3 optically isolated general purpose digital outputs 2 analog inputs 10 V and 1 analog output 10 V option provides an additional 6 digital inputs and 4 digital outputs Encoder Out option provides an encoder output USB serial port compatible with USB 2 0 and USB 3 0 EtherCAT support Programmable in Mint B Operating principle The figure below shows the simplified main circuit diagram of the drive The rectifier converts three phase AC voltage to DC voltage The capacitor bank of the intermediate circuit stabilizes the DC voltage The inverter converts the DC voltage back to AC voltage for the AC motor The brake chopper connects the external brake resistor to the intermediate DC circuit when the voltage in the circuit exceeds its maximum limit Rectifier Capacitor Inverter L1 bank p U ACsupply L2 oe V L3 W AC motor Brake chopper
113. on first disconnection last Earthing methods are shown in Typical installation example on page 41 46 Electrical installation AC input motor and brake When using unearthed ungrounded distribution systems an isolation transformer with an earthed grounded secondary is recommended This provides three phase AC power that is symmetrical with respect to earth ground and can prevent equipment damage Protection class User protection has been achieved using Protective Class EN 61800 5 1 which requires an earth connection to the unit whenever hazardous voltages are applied The equipment provides protection against electric shock by Means of connection of protective earth to accessible live conductive parts Basic insulation Earth leakage Maximum earth leakage from the MicroFlex e150 is 3 4 mA per phase 230 V 50 Hz supply This value does not include the earth leakage from the AC power filter which could be much larger see EMC filters on page 162 If the MicroFlex e150 and filter are mounted in an enclosure it is recommended the enclosure is earthed using a 10 mm conductor Electrical installation AC input motor and brake 47 Input power conditioning Certain power line conditions must be avoided an AC line reactor an isolation transformer or a step up step down transformer might be required for some power conditions If the feeder or branch circuit that provides power to the MicroFlex e150 has permanentl
114. oncerning permanent magnet motor drives Ignoring the instructions can cause physical injury or death or damage to the equipment WARNING Do not work on the drive when the permanent magnet motor is rotating Also when the supply power is switched off and the inverter is stopped a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live Before installation and maintenance work on the drive Stop the motor Ensure that there is no voltage on the drive power terminals according to step 1 or 2 or if possible according to the both of the following steps Safety 13 1 Disconnect the motor from the drive with a safety switch or by other means Measure that there is no voltage present on the drive input L1 L2 L3 motor output U V W or brake terminals R1 R2 2 Ensure that the motor cannot rotate during work Make sure that no other system like a hydraulic crawling drive is able to rotate the motor directly or through any mechanical connection like felt nip rope etc Measure that there is no voltage present on the drive input L1 L2 L3 output U V W or brake regeneration terminals R1 R2 Ground the drive output terminals temporarily by connecting them together as well as to the PE E General safety WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment The drive is
115. out any additional cooling methods The 6 A and 9 A models require a forced air flow passing vertically from the bottom to the top of the MicroFlex e150 case to allow full rated current at 45 C 113 F Temperature derating characteristics are shown in Temperature derating on page 130 Failure to meet cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips It is recommended to check periodically the operation of the cooling equipment Optional fan tray 1 024 mounted exactly as shown in Fan tray on page 160 ensures that correct cooling is provided and allows the MicroFlex e150 to be UL listed 7 30 Mechanical installation Effects of mounting surface and proximity The proximity of the MicroFlex e150 to other components could affect cooling efficiency If the MicroFlex e150 is mounted beside another MicroFlex e150 or other obstruction there should be a minimum space of 15 mm 0 6 in to maintain effective cooling If the MicroFlex e150 is mounted above or below another MicroFlex e150 or other obstruction there should be a minimum space of 90 mm 3 5 in to maintain effective cooling Remember that a MicroFlex e150 will be receiving air that has been already heated if itis mounted above another MicroFlex e150 or heat source Multiple MicroFlex e150 units mounted above each other should be aligned not offset to promote air flow across the heat sinks
116. pes of feedback device The fast interrupt will be latched on a pulse width of about 30 us although a width of 100 us 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 P 68 Electrical installation input output B Digital inputs general purpose DIN9 models EIOA only Location OPT1 pin 3 CREFO pin 4 DIN7 5 DING 6 DIN5 7 DIN4 11 DIN9 12 DIN8 13 CREF1 These general purpose digital inputs are buffered by a TLP280 opto isolator allowing the input signals to be connected with either polarity Inputs and DIN5 share a common reference CREF1 Inputs DIN6 DIN9 share a common reference CREFO When the MicroFlex e150 is connected to Mint WorkBench the digital inputs can be configured using the Digital I O tool Alternatively Mint keywords including DRIVEENABLEINPUT RESETINPUT ERRORINPUT and STOPINPUT can be used The state of the digital inputs can be viewed using the Mint WorkBench Spy window s Axis tab See the Mint help file for details General purpose digital input shown Micr
117. presentative For installation in the United States branch circuit protection must be provided in accordance with the National Electrical Code NEC and any applicable local codes To fulfill this requirement use the UL classified fuses For installation in Canada branch circuit protection must be provided in accordance with the Canadian Electrical Code and any applicable provincial codes To fulfill this requirement use the UL classified fuses The drive provides overload protection in accordance with the National Electrical Code NEC Technical data 155 Control system The MicroFlex e150 can use two main control configurations Servo Position Torque Servo Current The configuration is selected using the Mint CONF IG keyword object 5000h or by using the Mint WorkBench System Configuration Wizard Each configuration supports different control modes selected using the Tools Control Mode menu item or by using the CONTROLMODE keyword in the Command window see the Mint help file This sets the control mode switch object 6060h B Servo configuration The servo configuration is the default configuration for the drive allowing the motor control system to operate as a torque controller a velocity controller or a position controller This configuration comprises 3 nested control loops a current control loop a velocity control loop and a position control loop as shown on page 156 The universal encoder interface re
118. r use with the MicroFlex e150 then this adapter s configuration can be altered without affecting the PC s office Ethernet connection If you are unsure about making changes to your PC s Ethernet adapter configuration or are prevented by user permission levels ask your 1 administrator to assist you The following explanation assumes the PC is connected directly to the MicroFlex e150 and not across an intermediate Ethernet network If you wish to attempt the connection through an intermediate Ethernet network then the network administrator must be consulted to ensure that the necessary IP address will be allowed and is not already allocated on the network 1 On the Windows 7 Start menu choose Control Panel then Network and Sharing Center Windows XP Choose Start Settings Control Panel then Network Connections 2 Click Local Area Connection then click Properties Windows XP Right click the Local Area Connection entry for the required Ethernet adapter and choose Properties 3 Select the Internet Protocol Version 4 TCP IPv4 entry Windows XP Internet Protocol Version TCP IP and click Properties 4 On the General tab make a note of the existing settings Click Advanced and make a note of any existing settings Click Cancel and then click the Alternate Configuration tab and make a note of any existing settings 4 5 On the General tab choose the Use the following IP address option 6 In the IP
119. re See Temperature derating on page derating on page 130 130 Storage temperature range 40 to 85 40 to 185 Humidity maximum 93 3A 6A 9A Forced air cooling flow m s None 1 2 5 vertical from bottom to top required Maximum installation altitude m 1000 above m s l Derate 1 196 100 m over 1000 m ft 3300 Derate 1 1 330 ft over 3300 ft Shock 10G Vibration 1 G 10 150 Hz 148 Technical data Applicable standards MicroFlex e150 complies with the following standards B Design and test standards UL508C Power Conversion Equipment UL840 Insulation coordination including clearance and creepage distances for electrical equipment EN 61800 5 1 2007 Adjustable speed electrical power drive systems Safety requirements Electrical thermal and energy EN 60529 1991 A1 2000 Degrees of protection provided by enclosures EN 61800 3 2004 Electromagnetic compatibility When installed as directed in this manual MicroFlex e150 conforms to the category C2 emission limits and the second environment immunity requirements defined by this standard See also the CE Declaration of Conformity on page 153 E Environmental test standards EN 60068 1 1994 Environmental testing general and guidance EN 60068 2 1 2007 Environmental testing Test A Cold EN 60068 2 2 2007 Environmental testing Test B Dry heat EN 60068 2 6 2008 Environmental testing Test Fc Vibration sinusoidal EN 60068 2 27 2009 Enviro
120. re gauge being used Connectors are to be installed using only the crimp tool specified by the manufacturer of the connector Checking the delivery Check that there are no signs of damage Notify the shipper immediately if damaged components are found If MicroFlex e150 is to be stored for several weeks before use be sure that it is stored in a location that conforms to the storage humidity and temperature specifications shown in Ambient conditions on page 147 Before attempting installation and operation check the information on the type designation label of the drive to verify that the drive is of the correct type See section Type designation label on page 25 Mechanical installation 29 Mounting and cooling Ensure you have read and understood Requirements for the installation site on page 27 Mount the MicroFlex e150 vertically on its rear side the side opposite the front panel M5 bolts or screws should be used to mount MicroFlex e150 Detailed dimensions are shown in Dimension drawing all models on page 126 For effective cooling the MicroFlex e150 must be mounted upright on a smooth vertical metal surface The MicroFlex e150 is designed to operate in an ambient temperature of 0 C to 45 C 32 F to 113 F Output current must be derated between 45 C 113 F and the absolute maximum ambient temperature of 55 C 131 F Within the ambient temperature range The 3 A model is designed to operate with
121. removed and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB distributor CE marking A CE mark is attached to the drive to verify that the unit follows the provisions of the European EMC and machinery directives Compliance with the European EMC Directive The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 covers requirements stated for drives See section Compliance with the EN 61800 3 below Technical data 151 Compliance with the EN 61800 3 B Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment Note A professional is a person or organization having necessary skills in instal
122. rive is operating as a velocity controller forms the input to the current control loop Finally in the position control loop a position demand and measured position form the inputs to a PID Proportional Integral Differential control system incorporating velocity feedback velocity feed forward and acceleration feed forward The output of the position control system is a velocity demand which when the drive is operating as a position controller forms the input to the velocity control loop 156 Technical data syoalqo Bulmous eunonujs onas Jopoou3 yoeqp 4 sjeuBbls uonisod peeds Jojeumns3 uonesueduioo 48109 yupanjyesodwey SVAWLNAYYND qns sjoe qo ay is eipe qo eieorpur sequinu 4 els ug4gg 909 SOd 3IALLAM Ug09 49909 THAM Je suosuag A dwog 215 uang 1950 0 8 n sjuauno BurzneuBeui 81S 3GOILLNDI pue anbio painseayy 715 MOVS LAM IS LNIM 215 LNIAM dOHdM jeouj 9 3 LIS 8409 46409 40909 40909 U91IMS uonisog SJe josuoo yms JO OW Buw C C gt dL 14
123. ro MicroFlex 2 Apc MicroFlex 100 MicroFlex 150 MotiFlex e100 C H2VS1 Inverter H2 VS1 Servo HYVS1 Vector Attributes Read Write Scaled Default Range 133 0 lt lt 8388607 Desctiption ACCELTIME is used as an alternative method of setting the acceleration rate of the velocity profile is the period expressed in milliseconds to accelerate from zero to the existing profiler SPEED 0 For help on using Mint WorkBench click the Contents tab then click the small sign beside the Mint WorkBench amp Mint Machine Center book icon Double click a 2 topic name to display it Start up 99 E Starting Mint WorkBench Note If you have already used MMC to install firmware and start an instance of Mint WorkBench go straight to section 6 4 3 to continue configuration 1 On Windows Start menu select Programs Mint WorkBench Mint WorkBench tdt Mew Took Production moyan Window Heb Z O0 2 In the opening dialog box click Start New Project Mint WorkBench xi Mint WorkBench r Recent Ero Start New Project Starr efie Project Open Recent Project 100 Start up 3 Click Scan to search for the MicroFlex e150 When the search is complete click MicroFlex e150 in the list then click Select Select Controller L2 1x To find serial controllers click Scan For a controller with no
124. rol cables Check the installation Start the drive See Planning the electrical installation page 43 Technical data page 119 Requirements for the installation site page 27 Checking the delivery page 28 Mounting and cooling page 29 Routing the cables page 39 Checking the insulation of the assembly page 44 Connecting the power cables page 45 Motor connections page 52 Electrical installation input output page 59 Installation checklist page 87 Start up page 89 18 Introduction to the manual Terms and abbreviations The following units and abbreviations might appear in this manual B General terms Unit term Description abbreviation Watt A Ampere Q Ohm uF microfarad pF picofarad mH millihenry phase ms millisecond us microsecond ns nanosecond mm millimeter m meter in inch ft feet cu ft cubic feet Ibf in pound force inch torque N m Newton meter torque ADC Analog to Digital Converter ASCII American Standard Code for Information Interchange AWG American Wire Gauge CDROM Compact Disc Read Only Memory ___ Automation International Users and Manufacturers Group e V CTRL E onthe PC keyboard press Ctrl and E atthe same time DAC Digital to Analog Converter 08402 CiA Device Profile for Drives and Motion
125. rotects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive No additional thermal protection devices are needed WARNING If the drive is connected to multiple motors a separate thermal L overload switch or a circuit breaker must be used for protecting each cable and motor These devices might require a separate fuse to cut off the short circuit current Protection against short circuit in motor cable The drive protects the motor and motor cable in a short circuit situation when the motor cable is dimensioned according to the nominal current of the drive No additional protection devices are needed The motor outputs are fully short circuit proof according to 61800 5 1 Protecting against short circuit in the supply cable or drive Protect the supply cable with fuses or circuit breakers Size the fuses according to instructions given in Technical data on page 134 The fuses protect the input cable in short circuit situations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Fuses Recommended fuses are listed in Recommended fuses circuit breakers and wire sizes on page 134 Alternative fuses must be compatible fast acting types Circuit breakers It is highly recommended that fuses are used instead of circuit breakers Circuit breakers should only be used when absolutely necessa
126. rror The local node has changed its EtherCAT state 2 flashes Process data watchdog time out or EtherCAT watchdog time out Flickering Booting error Continuously illuminated Application controller failure A critical communication or application error has occurred LED flash periods The following diagram shows the definitions of the terms blinking flashing and flickering used in the previous sections as defined by the EtherCAT Technology Group 120 Fault tracing LED flash timing definitions Off Not illuminated 1 flash 15 a 15 gt 2 flashes 4 15 gt Inverted 2 flashes I 15 3 flashes etc 15 gt Blinking PELL ey Continuously illuminated 14 200 ms Drive status display The drive status display indicates errors and general MicroFlex e150 status information When an error occurs the drive displays a sequence starting with the symbol E followed by the five digit error code For example error code 10015 is displayed STO error 2 00 IS L UU L o 0 25s 0 25 s 0 25s 0 25s 0 25s 0 25s 0 25s 0 25 5 0 25s 0 25s The decimal point to the right of the number also illuminates to indicate STO errors For a complete list of error codes open Mint WorkBench press F1 and locate the Error Handling book This contains topics listing the drive
127. rts the Safe Torque Off STO function according to standards IEC 61800 5 2 EN 61508 2010 EN ISO 13849 1 and IEC 62061 2005 See Safety Manual Safe Torque Off STO function for MicroFlex e150 drives LT0313 before using the STO function 170 Appendix Safe Torque Off STO Safety circuit emergency stop switch relay etc MicroFlex e150 PWM control circuit Safe Torque Off connections X3 18 ALI Pe aav 1 Common 0 PWM power circuit Integrated DC Drivers Power High Module Motor output U phase shown WARNING The STO function does not disconnect the voltage of the main and A auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply If the drive was connected to the input power wait for 5 minutes after disconnecting the input power Appendix Safe Torque Off STO 171 Operation of the STO function and diagnostics If both STO inputs are powered the STO function is in the standby state and the drive operates normally If power is removed from one or both of the STO inputs the STO function is activated the drive s motor output power stage is disabled and the status output page 69 becomes inactive Starting is possible only after both STO inputs have
128. ry Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known Motor thermal protection According to regulations the motor must be protected against thermal overload and the current must be switched off when overload is detected The drive can be configured to include a motor temperature input that protects the motor and switches off the current when necessary For more information about motor thermal protection see Thermal switch connection on page 57 and the Mint keyword MOTORTEMPERATUREINPUT in the Mint WorkBench help file Brake output short circuit protection The brake resistor output is fully short circuit proof according to EN 61800 5 1 36 Planning the electrical installation Selecting the power cables B General rules Dimension the input power and motor cables according to local regulations The input power and the motor cables must be able to carry the corresponding load currents See Electrical power network specification on page 127 and Motor output power X1 on page 137 for the rated currents The cable must be rated for at least 70 C US 75 167 F maximum permissible temperature of the conductor in continuous use The conductivity of the PE conductor must be equal to that of the phase conductor same cross sectional area 600 VAC cable is accepted for up to 500 V AC Referto Technical data on page 151 for th
129. s Vista or a newer operating system no USB driver configuration should be necessary If you are using Windows XP it will prompt for the driver Click Next gt choose Install the software automatically and click Next again Windows will locate and install the driver The MicroFlex e150 is now ready to be configured using Mint WorkBench If the MicroFlex e150 is later connected to a different USB port on the host computer Windows might report that it has found new hardware Either install the driver files again for the new USB port or connect the MicroFlex e150 to the original USB port D 92 Start up To confirm that the USB driver is installed check that Motion Control category is listed in Windows Device Manager Mice and other pointing devices Monitors iB Motion Control ES ABB USB Motion Product 88 Network adapters 2 Ports COM amp LPT SB Processors Start up 93 Configuring the TCP IP connection optional If you have connected the MicroFlex e150 to the PC using the Ethernet connection it will be necessary to alter the PC s Ethernet adapter configuration to operate correctly with the MicroFlex e150 Configuring the network adapter WARNING You cannot connect an ordinary office PC to the MicroFlex e150 without first altering the PC s Ethernet adapter configuration However if you have installed a second Ethernet adapter dedicated fo
130. s is the total inertia seen by the drive kg m 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 m in the Autotune tool If you already know the motor inertia from the motor spec and the load inertia by calculation insert the total here Multiply by 0 0001 to give kg m Multiply 16 2 by 0 04214 to give kg m Multiply Ib in s by 0 113 to give 140 Technical data B 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 zi 2 2 wW where E is energy J is the moment of inertia and w is the angular velocity The braking energy which is the difference between the initial energy and the final energy is therefore Es 1520 xsx v d 2 2 Jx U V 2 J joules Calculate E using the values for J U and V entered in the table on page 139 If E is less than the drive s braking capacity see Braking capacity on page 138 a brake resistor is not required If E is greater than the drive s braking capacity then continue to the next section to calcula
131. s shown in the diagram The thermal switch wires often carry noise that could cause erratic drive operation or damage The thermal switch contacts must never be wired directly to a digital input The separate 24 V DC supply used for the thermal switch can also be used for the motor brake circuit 58 Electrical installation AC input motor and brake Brake resistor regeneration resistor An optional external brake resistor might be required to dissipate excess power from the internal DC bus during motor deceleration The brake resistor must have a resistance of at least 39 an inductance of less than 100 uH and a minimum power rating of 44 W Care should be taken to select the correct resistor for the application see the Brake X1 section starting on page 138 Suitable brake resistors are listed in Resistor choice on page 141 The brake resistor output is conditionally short circuit proof WARNING Electrical shock hazard DC bus voltages can be present at these terminals Use a suitable heat sink with fan if necessary to cool the brake resistor The brake resistor and heat sink if present can reach temperatures in excess of 80 C 176 F STAR Earth ground outer shield POINT using 360 conductive clamp connected to enclosure backplane Electrical installation input output 59 Electrical installation input output What this chapter contains The chapter describes how to connect low voltage con
132. safety function Safe Torque STO in the drive system MicroFlex e150 is capable for safety related applications up to SIL 3 PL e respectively The requirements listed in the following standards are fulfilled 61508 part 1 2010 part 2 2010 capable up to SIL 3 ISO 13849 1 2008 capable up to PL e 62061 2005 capable up to 5 3 IEC 61800 5 2 2007 capable up to SIL 3 The certification is based on the report No SLA 0041 2010TB 2 in the valid version This certificate entitles the holder to use the pictured Safety Approved mark Expiry date 2017 01 31 Reference No _ G SEB BS 02 027 01 031 Hi i X A t aS ES f MicroFlex e150 gt IEC 61508 SIL3 Gerhard zs Augsburg 2012 1 61800 5 25 3 SLA 0041 2010 lt TOV NORD Systems GmbH amp Co KG Branch South Halderstr 27 86150 Augsburg Germany Further information Product and service inquiries Address any inquiries about the product to your local ABB representative quoting the type designation and serial number of the unit in question A listing of ABB sales support and service contacts can be found by navigating to www abb com drives and selecting Sales Support and Service network Product training For information on ABB product training navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www a
133. se contact ABB if larger power ratings are required 142 Technical data E 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 In free air On heat sink Derate power linearly from 80 25 C 77 F to 70 55 C 113 F Derate power linearly from 100 25 C 77 F to 88 55 C 113 F Typical heat sink 200 mm x 200 mm x 3 mm Derate power linearly from 70 25 C 77 F to 62 55 C 113 F Derate power linearly from 100 25 C 77 F to 88 55 C 113 F Typical heat sink 400 mm x 400 mm x 3 mm Resistor part Nominal number power rating W RGJ139 100 RGJ160 RGJ260 200 RGJ360 300 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 EN A NN 3 lt lt Deceleration time Braking active 25s Cycle time gt x 25s Cycle time 25s Cycle time Input o
134. se u 5 Hall U NC Sin Sin 10 6 Hall U Sin Sin 7 Hall V Cos Cos 9 15 8 Hall V Cos Cos 9 CHA Data NC 10 CHB Clock NC 11 CHZ NC NC 12 5 V out 5 V out 5 V out 5 V out 5 V out 13 DGND DGND DGND DGND DGND 14 Hall W NC CHZ NC NC 15 Hall W NC CHZ NC NC Simultaneous inputs 82 Electrical installation input output Twisted pairs must be used for each complementary signal pair e g CHA and CHA or Data and Data The overall cable shield screen must be connected to the metallic shell of the D type connector Connector X8 includes a Sense pin which is used to detect the voltage drop on long cable runs This allows the MicroFlex e150 to increase the encoder supply voltage on pin 12 to maintain a 5 V supply at the encoder 250 mA max B Incremental encoder interface See Connection summary on page 81 for pin configuration The incremental encoder connections ABZ channels and Hall signals are made using the 15 pin D type female connector X8 The encoder inputs CHA CHB and CHZ accept differential signals only The Hall inputs can be used as differential inputs recommended for improved noise immunity or single ended inputs When used as single ended inputs leave the Hall U Hall V and Hall W pins unconnected Encoder channel input circuit channel A shown MicroFlex e150 to encoder signal loss detection MAX3096 Differential line receiver
135. stallation installing commissioning using and servicing the drive 16 Introduction to the manual Contents of this manual The manual consists of the following chapters Safety page 11 gives safety instructions you must follow when installing commissioning operating and servicing the drive Introduction to the manual this chapter page 75 describes applicability target audience purpose and contents of this manual It also contains a quick installation and commissioning flowchart Hardware description page 21 describes the operation principle connector layout type designation label and type designation information in short Mechanical installation page 27 describes how to check the installation site unpack check the delivery and install the drive mechanically Planning the electrical installation page 33 describes the requirements for the AC supply cabling and RCDs Electrical installation AC input motor and brake page 43 describes the installation of high power connections including the AC supply motor output and brake resistor Electrical installation input output page 59 describes the installation of low power connections including analog and digital input outputs including Safe Torque Off motor feedback and Ethernet Installation checklist page 87 provides a list of checks to confirm that the physical installation has been completed correctly Start up page 89 describes the steps for appl
136. status display indicators and basic error codes The following information symbols can be displayed Symbol Description Drive disabled and one or both STO inputs are not powered The drive must be enabled before operation can continue Both STO inputs must be powered If an optional drive enable input has been configured it must also be powered Drive disabled The drive must be enabled before operation can continue If an optional drive enable input has been configured it must also be powered Suspend active The Mint SUSPEND command has been issued is active Motion will be ramped to zero demand whilst active Fault tracing 121 Symbol Description Firmware loading segments are illuminated sequentially This sequence is followed by a numerical sequence representing firmware initialization stages Hold to Analog HTA mode The axis is in Hold To Analog mode See the Mint keyword HTA Drive enabled but idle Cam move A cam profile is in progress See the Mint keyword CAM Dwell A dwell wait move is in progress See the Mint keyword MOVEDWELL Flying shear A flying shear is in progress See the Mint keyword FLY Follow move The drive is in follow mode See the Mint keyword FOLLOW Homing The drive is currently homing See the Mint keyword HOME Incremental move An incremental linear move is in progress See the Min
137. t keywords INCA and INCR Jog The drive is jogging See the Mint keywords JOG JOGCOMMAND and related topics Offset move An offset move is in progress See the Mint keyword OFFSET Position move A linear move is in progress See the Mint keywords MOVEA and MOVER Torque move The drive is in torque mode See the Mint keywords TORQUEREF TORQUEREFSOURCE and related commands Stop input active A Mint STOP command has been issued or an optional stop input is active MILAN DO CLl 57 20111 Velocity reference move The drive is under velocity control See the Mint keywords VELREF and related keywords Spline A spline move is in progress See the Mint keyword SPLINE and related keyword In DS402 mode under the control of an EtherCAT master the outer segments will rotate clockwise or counter clockwise User defined symbols can be displayed using Mint keywords LED and LEDDISPLAY 122 Fault tracing B Communication Drive status display is off Check that the 24 V DC control circuit supply is correctly connected at X2 and is Switched on Drive status display shows r The MicroFlex e150 is in firmware recovery mode This means that it cannot boot fully so will allow Mint WorkBench to download firmware from the scan controller dialog Mint WorkBench fails to detect the MicroFlex e150 Ensure t
138. t breakers and wire sizes on page 134 for recommended wire sizes Electrical installation AC input motor and brake 53 Motor Connect motor earth ground to protective earth on top of drive Earth Lat Py Fa fy 1 1 boa u H T 1 1 1 1 1 1 1 rT 1 1 V 1 ub v Unshielded W 734 i V ri lengths should _ be as short as Optional motor To earth ground outer possible circuit contactors shield use 360 clamp connected to backplane B Motor power cable shielding It is essential that the motor cable shield is correctly bonded to a functional earth typically the same earthed metal backplane on which the MicroFlex e150 is mounted The motor power output cable carries a high frequency high current waveform to the motor so the cable s shielding must be earthed to prevent the cable radiating electromagnetic contamination into the surrounding area Such contamination can cause spurious errors in unrelated parts of the installation such as low voltage communication cables To provide a low impedance path to earth and effective shielding the conductor must provide contact with a large proportion of the cable s circumference The following diagram shows two possible methods Exposing the cable shield 1 Make a single circular cut in the cable s outer sheath ensuring that the cable s braided shield is not
139. t up and operation These warnings are intended for all who plan to start up or operate the drive E General safety WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Before adjusting the drive and putting it into service make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line Improper operation or programming of the drive can cause violent motion of the motor and driven equipment Be certain that unexpected motor movement will not cause injury to personnel or damage to equipment Do not activate automatic fault reset functions if dangerous situations can occur When activated these functions will reset the drive and resume operation after a fault not control the motor with an AC contactor or disconnecting device disconnecting means use instead external commands I O or fieldbus e Ifa drive enable signal is already present when power is applied to the MicroFlex e150 the motor could begin to move immediately The metal heat sink on the left side of the MicroFlex e150 can become very hot during normal operation MEDICAL DEVICE PACEMAKER DANGER Magnetic and electromagnetic fields in the vicinity of current carrying conductors and ind
140. te the braking and average power dissipation E Braking power and average power The braking power P is the rate at which the braking energy is dissipated This rate is defined by the deceleration period D The shorter the deceleration period the greater the braking power r olm W watts The resistors shown in the following table can withstand brief overloads but the average power dissipation Pay must not exceed the stated power rating The average power dissipation is determined by the proportion of the application cycle time C spent braking The greater the proportion of time spent braking the greater the average power dissipation W watts B Resistor choice Technical data 141 Pav is the value to use when assessing which brake resistor to use However a safety margin of 1 25 times is recommended to ensure the resistor operates well within its limits so Required resistor power rating 1 25 x Pay W watts The range of suitable brake resistors is shown in the following table Choose the resistor that has a power rating equal to or greater than the value calculated above Part Resistance Power rating RGJ139 390 100 W RGJ160 600 100 W RGJ260 600 200 W RGJ360 600 300 W Dimensions of brake resistors are shown in Brake resistors on page 165 The brake resistors listed in the table above can withstand a brief overload of 10 times the rated power for 5 seconds Plea
141. te trays Avoid long parallel runs of motor cables with other cables to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure that they are arranged at an angle as near to 90 degrees as possible The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential 40 Planning the electrical installation A diagram of the cable routing is shown below Power cable min 300 mm 12 in Motor cable Drive min 500 mm 20 in Control cables E Separate control cable ducts Route 24 V and 230 V cables in separate ducts unless the 24 V cable is insulated for 230 V or insulated with an insulation sleeving for 230 V 24V 230V 24V 230V Planning the electrical installation 41 Typical installation example Installation cabinet star point Drive earth wire 5 moz must be at least AC power 2 Q 10 mm 7 AWG from fuses en lt or reactor E 9 Mount AC filter and MicroFlex e150 on the i Connect power cable shield to metal panel using AC power wires should be as short as conductive shield possible typically less than 0 3 m 1 ft earth ground clamps A Longer wires must be shielded as shown
142. the following typical values MicroFlex e150 catalog number DC bus Braking capacity J capacitance uF 115 VAC supply 230 supply E152A03 560 34 7 12 5 E152A06 1120 69 4 25 E152A09 1680 104 2 37 6 B Brake resistor selection The following calculations can be used to estimate the type of brake resistor that will be required for the application Some basic information is required to complete the calculation Remember to use the worst case scenario for the application to ensure that the braking power is not underestimated For example use The maximum possible motor speed The maximum inertia The minimum deceleration time The minimum cycle time Technical data 139 Requirement Enter value here a Initial motor speed before deceleration begins in radians per second Multiply RPM by 0 1047 to give radians per second Initial motor speed U rad s b Final motor speed after deceleration is complete Final motor speed in radians per second V rad s Multiply RPM by 0 1047 to get radians per second This value will be zero if the load is going to be stopped c The deceleration time from initial speed to final Decel time speed in seconds D s d The total cycle time i e how frequently the Cycle time process is repeated in seconds See Duty cycle on page 142 C 5 e Total inertia Total inertia Thi
143. the toolbar Alternatively use the Mint WorkBench Red Stop Button feature 1 2 Check that the Drive enable button is pressed down dd Direct In the Toolbox click the Edit amp Debug icon p Edit amp Debug Click in the Command window OVER 0 10 Type MOVER 0 210 GO 0 10 This will cause the motor to move to a position 10 units from its current position The move will stop when completed If you have finished testing click the Drive Enable button to disable the m Direct drive 112 Start up Further configuration Mint WorkBench provides a number of other tools for testing and configuring the MicroFlex e150 Every tool is explained fully in the help file Press F1 to display the help file then navigate to the Mint WorkBench book Inside this is the Toolbox book Configuration tool The Configuration tool shows the MicroFlex e150 s integrated configuration interface 1 Click the Configuration tool icon in the Toolbox on the left of the screen The main area of the Mint WorkBench window displays the Configuration MicroFlex e150 web interface 2 Select Load configuration from the controller or Start 2 Load configuration from controller M Select this option to modify the controller s configuration data new configuration and click the green arrow Open existing configuration file Select this option to use a previously saved configuratio
144. tion 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 Welcome to the Commissioning Wizard This simple step by step guide will assist you in configuring your drive and motor for your application If starting new application it is recommended you perform factory defaults If you are returning to modify previous configuration then do not perform the factory default option by clearing the check box below Before continuing you should have completed the following Read carefully the Installation manual provided with the control in ts entirely Ensuted that the control is wired correctly according to those instructions and any local wiring regulations Tested and proven that the Enable your machine Emergency Stop and any other safety controls work correctly Disconnected the motors from any mechanics removing belts couplings etc Choose your preferred measurement a Iv starting new application Reset memory to factory defaults Metric C Engish Imperial Warming this software is intended as an aid to a suitably qualified engineer The manufacturer accepts no liability for damage caused to machinery any injury caused as a result of Rs use or mis use peck Nen Doe Using Commissioning Wiz
145. to the MicroFlex e150 Ensure that shielding of the motor cable is continued on both sides of the M Contactor as shown in the previous diagram B Sinusoidal filter A sinusoidal filter is used to provide a better quality waveform to the motor reducing motor noise temperature and mechanical stress It will reduce or eliminate harmful dV dt values voltage rise over time and voltage doubling effects which can damage motor insulation This effect occurs most noticeably when using very long motor cables for example 30 5 m 100 ft or more ABB servo motors intended to be used with drives are designed to withstand the effects of large dV dt and overvoltage effects However if very long motor cables are unavoidable and are causing problems then a sinusoidal filter can be beneficial B Motor brake connection A rotary motor might require a brake The brake prevents the uncontrolled release of suspended or tensioned loads when power to the motor is removed or disconnected e g by a motor circuit contactor Contact your local supplier for details of appropriate brakes You can wire a motor s brake via relays to digital outputs on connector X3 or OPT1 see Connections front panel on page 23 and Connections top panel on page 24 This provides a way for the MicroFlex e150 to control the motor s brake A typical circuit is shown in the following diagram T d Vd 56 Electrical installation AC input motor and brake
146. trol signals The following conventions will be used to refer to the inputs and outputs LO sel Input Output AIN Analog Input AOUT Analog Output DIN Digital Input DOUT 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 11 Ignoring the safety instructions can cause injury or death Make sure that the drive is disconnected from the input power during installation If the drive is already connected to the input power wait for 5 minutes after disconnecting the input power P d 60 Electrical installation input output Analog I O The MicroFlex e150 provides Two 12 bit resolution 10 V analog inputs One 12 bit resolution 10 V analog output An analog input receives the torque velocity reference signal when operating as an analog drive See CONTROLREFSOURCE in the Mint help file or it can be used as a general purpose ADC input E Analog inputs AINO AIN1 Location X4 pins 3 amp 7 AINO 2 amp 6 AIN1 5 AGND The analog inputs pass through a differential buffer and second order low pass filter with a cut off frequency of approximately 1 2 kHz In Mint analog inputs can be read using the keyword See the Mint help file for full details of ADC ADCMODE and other related ADC keywords
147. ty This is to protect the output from the back EMF generated by the relay coil when it is de energized Digital output circuit DOUT3 shown o User supply MicroFlex e150 V P d L oO 4 200mA Mint OUTX 3 TLP127 K Load relay with diode shown User supply o GND 72 Electrical installation input output When the MicroFlex e150 is connected to Mint WorkBench the active level of the outputs can be configured using the Digital I O tool Alternatively the Mint keyword OUTPUTACTIVELEVEL can be used The state of the outputs is displayed in the Spy window See the Mint help file for details DOUTS typical connections to an ABB NextMove e100 MicroFlex e150 NextMove e100 controller eC TLP127 24V X9 DIN4 vast CREF1 TLP280 Electrical installation input output 73 Encoder output models EEOA only Location OPT1 The encoder output can be used for position feedback to a host controller or in master slave situations where the axis movement can be transmitted to another controller or drive It is recommended that this output drives only one output circuit load The encoder output signals are driven by 05261531 differential line driver and conform to the RS422 electrical specification Shielded twisted pair cable is reco
148. ustrial motors can result in a serious health hazard to persons with cardiac pacemakers internal cardiac defibrillators neurostimulators metal implants cochlear implants hearing aids and other medical devices To avoid risk stay away from the area surrounding a motor and its current carrying conductors When operating a rotary motor with no load coupled to its shaft remove the shaft key to prevent it flying out when the shaft rotates Abrake resistor can generate enough heat to ignite combustible materials To avoid fire hazard keep all combustible materials and flammable vapors away from brake resistors Introduction to the manual 15 Introduction to the manual What this chapter contains The chapter describes applicability target audience and purpose of this manual It describes the contents of this manual and refers to a list of related manuals for more information The chapter also contains a flowchart of steps for checking the delivery and installing and commissioning the drive The flowchart refers to chapters sections in this manual Applicability The manual is applicable to the MicroFlex e150 drive Target audience The reader is expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Purpose of the manual This manual provides information needed for planning the in
149. utput B Analog inputs AINO AIN1 X4 Technical data 143 Description Unit All models Type Differential Common mode voltage range V DC 10 Common mode rejection dB 40 Input impedance kQ 60 Input ADC resolution bits 12 includes sign bit Equivalent resolution mV 4 9 Sampling interval us 1000 Mint 250 Control loop B Analog output AOUTO X4 Description U X Allmodels Type Bipolar Ouputvollagerange VDC s00 Output current max mA 1 Output DAC resolution bits 12 includes sign bit Equivalent resolution mV 4 9 ms 1 Digital inputs STO1 5702 X3 Update interval See Technical data Digital inputs STO1 5702 X3 on page 173 144 Technical data Digital inputs DINO DIN3 X3 Description Unit All models Type Opto isolated inputs Input voltage V DC Nominal 24 Minimum 12 Maximum 30 Active gt 12 Inactive lt 2 Input current maximum per input mA 50 Sampling interval ms 1 Minimum pulse width us 5 B Digital inputs DIN1 DIN2 high speed X3 Description Unit All models Type Opto isolated inputs Input voltage V DC Nominal 24 Minimum 12 Maximum 30 Active 212 Inactive 2 Input current maximum per input mA 20 Sampling interval ms 1 Minimum pulse width ns 250 BW Digital inputs DIN4 DIN9 OPT1 models EIOA only Description Unit Al
150. y connected power factor correction capacitors an input AC line reactor or an isolation transformer must be connected between the power factor correction capacitors and the MicroFlex e150 to limit the maximum symmetrical short circuit current to 5000 A If the feeder or branch circuit that provides power to the MicroFlex e150 has power factor correction capacitors that are switched on line and off line the capacitors must not be switched while the drive is connected to the AC power line If the capacitors are switched on line while the drive is still connected to the AC power line additional protection is required A Transient Voltage Surge Suppressor TVSS of the proper rating must be installed between the AC line reactor or isolation transformer and the AC input to the MicroFlex e150 E Supplying input power from a variac variable transformer When AC power is supplied from a variac the MicroFlex e150 s pre charge circuit might not operate correctly To ensure that the pre charge circuitry operates correctly increase the variac voltage to the desired level and then power cycle the 24 V DC control circuit supply This will restart the pre charge circuit and allow it to operate correctly 48 Electrical installation AC input motor and brake Power supply filters To comply with EC directive 2004 108 EC an AC power filter of the appropriate type must be connected This can be supplied by ABB and will ensure that the MicroFlex e150
151. ying power to the drive installing the Mint Machine Center software and tuning and optimizing the motor drive combination Fault tracing page 117 describes the drive s LED indicators and provides solution to common problems encountered during installation Technical data page 125 contains the technical specifications of the drive e g the dimensions ratings technical specifications and provisions for fulfilling the requirements for CE and other markings Appendix Safe Torque Off STO page 169 describes STO features installation and technical data Accessories page 159 describes optional accessories Related documents See List of related manuals on page 2 inside the front cover Introduction to the manual 17 Quick installation and start up flowchart Task 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 cont

User`s manual MicroFlex e150 servo drive

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