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MicroFlex e190
ABB MicroFlex e190 User Manual
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Electrical installation: AC input / DC input, motor and brake 53
AC power cable connection
Supply cable
Cover bare shield with
insulating tape
Cable cla
mp on bare shie
ld
Cable cla
mp on bare shie
ld
0.5...0.6
N·m (4.4..
.5.3 lbf·i
n)
Motor cable
0.5...0.6
N·m (4.4..
.5.3 lb
f·in)
M4, 10 mm max.
1.0...1.3
N·m (8.9...1
1.5 lbf·in
)
M4, 10 mm max.
1.0...1.3
N·m (8.9...1
1.5 lbf·in
)
Motor earth wire
52
54
Table of Contents
Default Chapter
5
Table of Contents
5
1 Safety
13
What this Chapter Contains
13
Use of Warnings
13
Safety in Installation and Maintenance
14
Electrical Safety
14
Grounding
16
Permanent Magnet Motor Drives
17
General Safety
18
Printed Circuit Boards
18
Safe Start-Up and Operation
19
General Safety
19
Network Security
20
2 Introduction to the Manual
21
What this Chapter Contains
21
Target Audience
21
Contents of this Manual
22
Related Documents
23
Quick Installation and Start-Up Flowchart
24
Terms and Abbreviations
25
General Terms
25
Trademarks
25
3 Operation Principle and Hardware Description
27
What this Chapter Contains
27
Product Overview
27
Layout - Front
28
Layout - Top
29
Layout - Bottom
29
Main Circuit
30
Type Designation Label
31
Type Designation Key
31
Memory Unit - MU
32
4 Mechanical Installation
33
What this Chapter Contains
33
Contents of the Package
34
Main Dimensions
35
Cabinet Construction
36
Cooling and Degrees of Protection
36
Disposition of the Devices
38
Preventing the Recirculation of Hot Air
38
Grounding of Mounting Structures
39
Cabinet Heaters
39
Installation Procedure
39
Requirements for the Installation Site
39
Required Tools
39
Direct Wall Mounting
40
Mains Filter Installation
40
Braking Resistor Installation
40
5 Planning the Electrical Installation
41
What this Chapter Contains
41
Motor Selection
41
Supply Connection
41
Supply Disconnecting Device
42
Thermal Overload and Short Circuit Protection
42
Thermal Overload Protection
42
Protection against Short-Circuit in Motor Cable
42
Protection against Short-Circuit in the Supply Cable or the Drive
42
Motor Thermal Protection
43
Ground Fault Protection
43
Emergency Stop Devices
43
Residual Current Device (RCD) Compatibility
43
Safe Torque off
44
Selecting the Power Cables
45
General Rules
45
Alternative Power Cable Types
45
Motor Cable Shield
46
Selecting the Control Cables
46
Connection of a Motor Temperature Sensor to the Drive
46
Routing the Cables
47
Control Cable Ducts
47
Typical Installation Example
48
6 Electrical Installation: AC Input / DC Input, Motor and Brake
49
What this Chapter Contains
49
Checking the Insulation of the Assembly
50
Drive
50
Supply Cable
50
Motor and Motor Cable
50
Braking Resistor Assembly
50
Power Cable Connection
51
AC Power Cable Connection Diagram
51
Procedure
52
DC Power Cable Connection Diagram (Optional)
54
Control Circuit Supply (Optional)
56
Motor Brake Connection
57
Thermal Switch Connection
58
7 Electrical Installation: Input / Output
59
What this Chapter Contains
59
Connecting the Control Cables
60
Analog I/O
61
X3: Analog Input AI0
61
X3: Analog Output AO0
63
Digital I/O
64
Using a Digital Input as a Drive Enable Input (Optional)
64
Using a Digital Input as a Home Switch Input (Optional)
64
X4: Digital Inputs - Safe Torque off (STO) Inputs
64
X3: Digital Inputs - General Purpose DI1 & DI2
65
Special Functions on Inputs DI1 & DI2
66
X3: Digital Inputs - General Purpose DI0 & DI3
69
X3: Digital Outputs - General Purpose DO0 - DO3
71
Other I/O
72
X2: External Power Supply for the Control Unit (Optional)
72
SW1 Linear Switches - Startup Functions
72
Control Cable Grounding
73
Ethernet Ports
74
E1 / E2: Real-Time Ethernet Port
74
E1 / E2: Ethernet Port Configuration
75
E3: Ethernet Host
75
Motor Feedback (X8)
76
Incremental Encoder with Halls
77
Serial Interfaces & Sincos
78
Extra Incremental Encoder
81
Incremental Encoder Input/Output (X7)
83
OPT-MF-201 Resolver Adapter
85
Supported Feedback Type
86
Encoder 0 Input
88
Encoder 1 Input
89
Encoder 2 Input
89
8 Installation Checklist
91
Checklist
91
9 Start-Up
93
What this Chapter Contains
93
Safety
93
Introduction
93
Connect the Microflex E190 to the PC
93
Install Mint Workbench
94
Configure the PC Ethernet Adapter
94
Enable the Ethernet Adapter for Mint Workbench
95
Start the Microflex E190
95
Preliminary Checks
95
Power on Checks
95
Start Mint Workbench
96
Commissioning Wizard
97
Using the Commissioning Wizard
97
Further Tuning - no Load Attached
99
Further Tuning - with Load Attached
101
Optimizing the Velocity Response
102
Correcting Overshoot
102
Correcting Zero-Speed Noise in the Velocity Response
103
Ideal Velocity Response
104
Performing Test Moves - Continuous Jog
104
Performing Test Moves - Relative Positional Move
105
Further Configuration
106
Configuration Tool
106
Ethercat Tool
106
Ethernet POWERLINK
106
Parameters Tool
107
Spy Window
107
Other Tools and Windows
108
Safe Torque off (STO) Acceptance Test
108
10 Fault Tracing
109
What this Chapter Contains
109
Problem Diagnosis
109
Supportme Feature
109
Power-Cycling the Microflex E190
110
Microflex E190 Indicators
111
Ethercat® Mode
111
Ethernet POWERLINK Mode
112
Drive Status Display
114
Power
116
Communication
116
Mint Workbench
116
Tuning
117
Ethernet
117
Warning Messages Generated by the Drive
119
Axis Warnings
119
Controller Warnings
120
Error Messages Generated by the Drive
122
Autotuning Errors
122
Parameter Errors
131
Communication Errors
132
Axis Errors
133
Controller Errors
139
11 Maintenance
141
What this Chapter Contains
141
Safety
141
Maintenance Intervals
141
Heat Sink
142
Cooling Fan
143
Removing the Fan
143
Replacing the Fan
144
Reforming the Capacitors
145
Other Maintenance Actions
145
Transferring the Memory Unit to a New Drive
145
12 Technical Data
147
What this Chapter Contains
147
Ratings
148
Derating
149
Cooling
150
Cooling Characteristics, Noise Levels
150
Efficiency
150
Supply Cable Fuses
151
AC Input (Supply) Connection
152
Effect of AC Power Supply Voltage on DC-Bus Voltage
152
DC Input (Supply) Connection
154
Motor Connection
154
Brake Resistor Connection
154
Control Unit
155
Feedback
156
X7 Incremental Encoder Without Halls
156
X8 Incremental Encoder with Halls
156
X8 Serial Interfaces + Sincos
156
Dimensions and Weights
157
Ambient Conditions
157
Degrees of Protection
158
Materials
158
WEEE Notice
158
Rohs Compliance
159
China Rohs Marking
159
Applicable Standards
160
Design and Test Standards
160
Environmental Test Standards
160
Functional Safety Standards
161
RCM Marking
161
CE Marking
161
Compliance with the European EMC Directive
161
Compliance with the European Machinery Directive
163
UL Marking
164
UL Checklist
164
13 Mains Filters
165
What this Chapter Contains
165
When Is a Mains Filter Required
165
Footprint Filter (Single Phase Only)
166
Installation Guidelines
167
Connection Diagram
167
Selection Table
167
Specifications and Dimensions
168
14 Resistor Braking
171
What this Chapter Contains
171
Introduction
172
System Braking Capacity
172
Braking Energy Calculation
173
Braking Energy
174
Braking Power and Average Power
174
Resistor Choice
175
Resistor Derating
176
Duty Cycle
176
Dimensions
177
15 Accessories
179
What this Chapter Contains
179
Power Supplies
179
Encoder Breakout OPT-MF-200
180
Resolver Adapter OPT-MF-201
181
Option Card OPT-SIO-1
182
Cables
183
Motor Power Cables
183
Feedback Cables
184
Ethernet Cables
184
Connectors
185
16 Appendix: Safe Torque off (STO)
187
What this Chapter Contains
187
Basics
187
Special Considerations for Using the STO Function
190
Drive Location
190
Hazard Analysis
190
Additional Stopping Methods
190
IGBT Failure
190
Terminology
190
Wiring Principles
191
Connected Components
191
Short Circuit Testing
191
Power Supply
191
Drive Enable Input
191
Single Drive Module: Internal Power Supply
192
Single Drive Module: External Power Supply
192
Multiple Drive Modules: Internal Power Supply
193
Multiple Drive Modules: External Power Supply
194
Operation of the STO Function and Diagnostics
195
Hardware Activation of the STO Function
195
Firmware Monitoring of the STO Function
195
Software Monitoring of the STO Function
196
STO Status Indications
197
STO Software Functional Diagram
198
Monitoring the Delay between the STO Inputs
198
STO Function Activation and Indication Delays
198
Validating the Operation of a Safety Function
199
Authorized Person
199
Acceptance Test Reports
199
Preliminary Checks
199
Start-Up, Acceptance, and Proof Test Interval Checklist
200
Restarting the Drive
201
Maintenance / Servicing
201
Error Messages Generated by the Drive
202
Decommissioning
203
Technical Data
204
STO Safety Relay Type
204
STO Cable
205
Ambient Conditions
205
Data Related to Safety Standards
206
Safety Data
206
Failure Rates
206
Abbreviations
207
Product and Service Inquiries
209
Product Training
209
Providing Feedback on ABB Drives Manuals
209
Document Library on the Internet
209
Other manuals for ABB MicroFlex e190
Quick Installation Guide
20 pages
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ABB MicroFlex e190 Specifications
General
Brand
ABB
Model
MicroFlex e190
Category
Servo Drives
Language
English
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