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ABB MicroFlex e190 User Manual

ABB MicroFlex e190
210 pages
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Table of Contents

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ABB MicroFlex e190 Specifications

General IconGeneral
CommunicationEtherCAT, CANopen
SafetySTO (Safe Torque Off)
Output Power0.4 kW
Communication InterfaceEtherCAT, CANopen
Protection ClassIP20
Storage Temperature-25 to +70 °C
Operating Temperature0 to +40 °C
Relative Humidity5 to 85 %, non-condensing

Summary

Safety

Use of Warnings

Explains warning symbols and their meaning for hazard identification.

Electrical Safety

Covers safe practices for electrical installation and maintenance of the drive.

Grounding

Details proper grounding procedures for personnel safety and interference reduction.

General Safety

General handling, installation environment, and operational precautions.

Safe Start-up and Operation

Guidelines for safe initial power-up and operation of the drive.

Network Security

Responsibilities for securing network connections and data for the drive.

Introduction to the Manual

Target Audience

Defines the intended readers and their expected knowledge.

Contents of this Manual

Lists the chapters and their respective page numbers for easy navigation.

Quick Installation and Start-up Flowchart

Provides a visual guide for installation and initial setup steps.

Terms and Abbreviations

Defines common technical terms and abbreviations used in the manual.

Operation Principle and Hardware Description

Product Overview

Introduces the MicroFlex e190 drive and its general capabilities.

Front Layout

Identifies and describes the components on the front panel of the drive.

Top and Bottom Layouts

Identifies and describes components on the top and bottom panels of the drive.

Main Circuit Diagram

Illustrates the internal main electrical circuit of the drive.

Type Designation Label and Key

Explains how to interpret the drive's type designation label.

Memory Unit (MU)

Describes the function and importance of the memory unit.

Mechanical Installation

Contents of the Package

Lists the items included in the drive's packaging.

Main Dimensions and Weights

Provides physical dimensions and weight specifications for the drive.

Cabinet Construction and Cooling

Details requirements for cabinet installation and cooling air flow.

Device Disposition and Airflow Management

Guides on arranging devices and preventing hot air recirculation.

Installation Procedure and Requirements

Outlines the steps for drive installation and site requirements.

Mounting, Filters, and Resistors

Covers direct wall mounting, mains filter, and braking resistor installation.

Planning the Electrical Installation

Motor Selection and Supply Connection

Guidance on choosing the motor and establishing the power supply connection.

Disconnecting Devices and Protection

Requirements for supply disconnecting devices and thermal/short-circuit protection.

Motor Protection and Safety Features

Covers motor thermal protection, ground fault protection, and emergency stops.

Safe Torque Off (STO) Function

Details the Safe Torque Off function for safety-critical applications.

Selecting Power Cables

Guidelines for selecting appropriate power cables, including shielding.

Control Cables and Motor Temperature Sensor

Recommendations for control cables and connecting motor temperature sensors.

Cable Routing and Control Cable Ducts

Best practices for routing cables and using control cable ducts.

Typical Installation Example

Illustrates a standard electrical installation setup for the drive.

Electrical Installation: AC Input / DC Input, Motor and Brake

Insulation Checks

Procedures for checking insulation of drive, supply, and motor cables.

AC Power Cable Connection

Detailed diagram and notes for connecting AC power cables.

Cabling Procedure and Grounding

Steps for connecting cables and grounding motor cable shields.

DC Power Connection Options

Explains DC sharing and direct DC supply configurations.

24 V Control Circuit Supply

Information on using an optional external 24 V DC supply for the control unit.

Motor Brake and Thermal Switch Connections

Wiring instructions for motor brake control and thermal switch input.

Electrical Installation: Input / Output

Analog I/O

Details analog input (AI0) and output (AO0) specifications and connections.

Digital I/O and STO Inputs

Covers general purpose digital inputs/outputs and dedicated Safe Torque Off inputs.

Special Input Functions

Explains special configurations for DI1/DI2 like encoder or step/direction inputs.

Control Cable Grounding and Ethernet Ports

Proper grounding of control cables and configuration of Ethernet ports.

Motor Feedback Interfaces

Overview of supported motor feedback types and connection summaries.

Supported Encoder Types and Inputs

Lists supported feedback types and their configuration parameters.

Installation Checklist

Mechanical Installation Checklist

Verifies proper mechanical mounting and environmental conditions.

Electrical Installation Checklist

Confirms correct electrical connections, fusing, and grounding.

Start-up

Connecting to PC and Software Installation

Steps to connect the drive to a PC and install Mint WorkBench software.

PC Ethernet Adapter Configuration

How to configure the PC's Ethernet adapter for drive communication.

Initial Power-On and Preliminary Checks

Essential checks before applying power and during the initial start-up sequence.

Commissioning Wizard and Autotuning

Guided process for motor setup, tuning, and configuration.

Fine-Tuning and Response Optimization

Methods for adjusting drive parameters for optimal motor performance.

Mint WorkBench Tools

Overview of tools like Configuration, EtherCAT, Parameters, and Spy windows.

STO Acceptance Test

Procedure for validating the Safe Torque Off function as part of commissioning.

Fault Tracing

Problem Diagnosis and SupportMe

Initial steps for identifying and reporting drive problems using diagnostic tools.

Drive Status Display and Indicators

Explains the meaning of LED indicators and drive status display codes.

Power and Communication Faults

Troubleshooting common issues related to power supply and communication failures.

Tuning and Ethernet Faults

Addresses problems encountered during tuning and Ethernet connectivity.

Warning and Error Messages

Lists and explains various warning and error codes generated by the drive.

Maintenance

Maintenance Intervals and Safety

Recommends routine maintenance intervals and emphasizes safety precautions.

Heat Sink Cleaning

Instructions for cleaning the drive's heat sink to ensure proper cooling.

Cooling Fan Replacement

Procedures for removing and replacing the drive's cooling fan.

Capacitor Reforming and Memory Unit Transfer

Maintenance actions for capacitors and transferring drive parameters via memory unit.

Technical Data

Drive Ratings and Derating Factors

Specifies drive current ratings and conditions requiring derating.

Cooling Characteristics and Efficiency

Details cooling methods, air flow, noise levels, and drive efficiency.

Supply Cable Fuses and AC Input

Lists fuse recommendations and specifications for AC supply connections.

DC Input, Motor, and Brake Resistor Connections

Technical data for DC supply, motor, and brake resistor connections.

Control Unit and Feedback Interfaces

Specifications for control unit I/O and various motor feedback interfaces.

Dimensions, Weights, and Ambient Conditions

Physical specifications and environmental operating limits for the drive.

Standards Compliance (RoHS, CE, EMC, UL)

Information on compliance with various safety, environmental, and regulatory standards.

Mains Filters

When a Mains Filter is Required

Criteria for determining if a mains filter is necessary for EMC compliance.

Footprint Filter and Installation

Describes the single-phase footprint filter and its installation guidelines.

Filter Selection and Connection

Provides a table and diagram for selecting and connecting the appropriate mains filter.

Filter Specifications and Dimensions

Technical data, including electrical specifications and physical dimensions of filters.

Resistor Braking

System Braking Capacity Calculation

Formula and values for calculating the drive's system braking capacity.

Braking Energy and Power Calculation

Steps to calculate braking energy and power required for resistor selection.

Resistor Selection and Derating

Guidance on choosing suitable brake resistors and applying derating factors.

Duty Cycle and Resistor Dimensions

Explains duty cycle calculation and provides resistor dimensions.

Accessories

24 V Power Supplies

Lists available 24 V DC power supplies with their specifications.

Encoder Breakout and Resolver Adapter

Describes accessories for connecting encoders and resolvers to the drive.

Option Card and Cables

Details the OPT-SIO-1 option card and various cable types.

Connectors

Information on the drive connector pack and its contents.

Appendix: Safe Torque Off (STO)

STO Basics and Standards

Explains the fundamental principles and standards behind the Safe Torque Off function.

STO Wiring Principles and Connections

Details wiring guidelines, component connections, and power supply for STO inputs.

STO Operation, Diagnostics, and Status

Describes how the STO function operates, its diagnostics, and status indications.

Validating Safety Functions and Acceptance Tests

Outlines procedures for validating safety functions and requirements for acceptance test reports.

STO Safety Relay and Cable Data

Provides technical data on STO safety relays and the required STO cable specifications.

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