ABB motion control
User’s manual
MicroFlex e150 servo drive
MN1961WEN
List of related manuals
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.
Drive hardware manuals and guides Code (English)
MicroFlex e150 Quick Installation Guide LT0307
Safety Manual: Safe Torque Off (STO) function for
MicroFlex e150 drives
LT0313
MicroFlex e150 wall chart LT0296
MicroFlex e150 flyer 3AUA0000097609
MicroFlex e150 CE certificate 3AXD10000409551
MicroFlex e150 TÜV certificate DE00043-100
Table of contents 5
Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Safety
Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2. Introduction to the manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Quick installation and start-up flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3. Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connections - front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connections - top panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4. Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Mounting and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Effects of mounting surface and proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5. Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Safety
6 Table of contents
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Implementing the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6. Electrical installation: AC input, motor and brake
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Earthing / grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Input power conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Supplying input power from a variac (variable transformer) . . . . . . . . . . . . . . . . . . . . . . . 47
Power supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Harmonic suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Reversing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power disconnect and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Drive overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
24 V control circuit supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Motor power cable shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Motor circuit contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Sinusoidal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Motor brake connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Thermal switch connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Brake resistor (regeneration resistor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7. Electrical installation: input / output
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog inputs AIN0, AIN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog output AOUT0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Using a digital input as a drive enable input (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Using a digital input as a home switch input (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Digital inputs - Safe Torque Off (STO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Digital inputs - general purpose DIN0, DIN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Digital inputs - general purpose DIN1, DIN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Special functions on inputs DIN1, DIN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Digital inputs - general purpose DIN4 - DIN9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Status output (DOUT0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Table of contents 7
Digital outputs DOUT1, DOUT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Digital outputs DOUT3 - DOUT6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
USB interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
RS485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Standard Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
EtherCAT® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
EtherCAT configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Ethernet connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
DIP switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Motor feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Incremental encoder interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
BiSS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SSI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
EnDat interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Smart Abs interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SinCos interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Extra incremental encoder interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPT-MF-201 Resolver adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8. Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Safe Torque Off (STO) connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9. Start-up
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Install Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connect the MicroFlex e150 to the PC using USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connect the MicroFlex e150 to the PC using Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Firmware versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Configure the PC Ethernet adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Enable the Ethernet adapter for Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Start the MicroFlex e150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Power on checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Mint Machine Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Starting MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Help file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Starting Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Further tuning - no load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Further tuning - with load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Optimizing the velocity response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Performing test moves - continuous jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Performing test moves - relative positional move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8 Table of contents
Configuration tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Parameters tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Spy window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Other tools and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Modbus configuration (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Safe Torque Off (STO) acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Ethernet LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Drive status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11. Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Dimension drawing (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Effect of AC power supply voltage on DC-bus voltage . . . . . . . . . . . . . . . . . . . . . . . . . 130
Effect of AC power supply voltage on DC-bus ripple voltage . . . . . . . . . . . . . . . . . . . . . 130
Effect of output current on DC-bus ripple voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Derating characteristic for 3 A models (E152A03...): . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Derating characteristic for 6 A models (E152A06...): . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Derating characteristic for 9 A models (E152A09...): . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Overtemperature trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Heat dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Recommended fuses, circuit breakers and wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Input power-cycling and inrush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Discharge period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Power supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
24 V control circuit supply (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Motor output power (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Motor output rating adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Brake (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Braking capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Brake resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Braking energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Braking power and average power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Resistor choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Resistor derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Table of contents 9
Input / output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Analog inputs AIN0, AIN1 (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Analog output AOUT0 (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Digital inputs STO1, STO2 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Digital inputs DIN0, DIN3 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Digital inputs DIN1, DIN2 - high speed (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Digital inputs DIN4 - DIN9 (OPT1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Digital outputs DOUT0 (Status), DOUT1, DOUT2 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . 147
Digital outputs DOUT3 - DOUT6 (OPT1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Incremental encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
BiSS encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
SSI encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
SinCos / EnDat encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Smart Abs encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Ethernet interface (E1, E2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Design and test standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Environmental test standards: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Functional safety standards: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
C-tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
WEEE notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
RoHS compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Compliance with the EN 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Validating the operation of the Safe Torque Off function . . . . . . . . . . . . . . . . . . . . . . . . 155
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
EtherCAT Conformance Test Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Torque servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
12. Accessories
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Fan tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Foot-mount filter (single phase only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
24 V power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Encoder breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
10 Table of contents
Resolver adapter OPT-MF-201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Motor power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Ethernet cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
13. Appendix: Safe Torque Off (STO)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Operation of the STO function and diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Validating the operation of the Safe Torque Off function . . . . . . . . . . . . . . . . . . . . . . . . 178
Technical data: Digital inputs STO1, STO2 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
STO function: data related to safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Safety 11
1
Safety
Safety in installation and maintenance
These warnings are intended for all who work on the drive, motor cable or motor.
Electrical safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
Only qualified electricians are allowed to install and maintain the drive!
• Be sure the system is properly earthed/grounded before applying power. Do not
apply AC power before earths/grounds are connected.
• Never work on the drive, motor cable or motor when input power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, motor or motor
cable. Always ensure by measuring with a multimeter (impedance at least
1 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 the 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 equipment damage, be certain that input and output signals are
powered and referenced correctly.
• To ensure reliable performance of this equipment be certain that all signals
to/from the drive are shielded correctly.
• Do not tin (solder) exposed wires. Solder contracts over time and can cause loose
connections. Use crimp connections where possible.
• 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.
• Motor overtemperature sensing is required to satisfy UL 508C. The drive has no
provisions for motor overtemperature protection, so external provisions are
required.
• 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 concerning 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:
Safety 13
• 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:
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.
General safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
• The drive is not field repairable. Never attempt to repair a malfunctioning drive;
contact your local ABB representative or Authorized Service Center for
replacement.
• When operating a rotary motor with no load coupled to its shaft, remove the shaft
key to prevent it flying out when the shaft rotates.
• Operating the MicroFlex 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 start-up and operation
These warnings are intended for all who plan to start-up or operate the drive.
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.
• Do not control the motor with an AC contactor or disconnecting device
(disconnecting means); use instead external commands (I/O or fieldbus).
• If a 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 industrial motors can result
in a serious health hazard to persons with cardiac pacemakers, internal cardiac
defibrillators, neurostimulators, metal implants, cochlear implants, hearing aids,
and other medical devices. To avoid risk, stay away from the area surrounding a
motor and its current carrying conductors.
• 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.
• A brake resistor can generate enough heat to ignite combustible materials. To
avoid fire hazard, keep all combustible materials and flammable vapors away
from brake resistors.
Introduction to the manual 15
2
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 installation, 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 15) 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 applying 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 127) 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 175) describes STO features, installation,
and technical data.
• Accessories (page 163) 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 See
Plan the electrical installation and acquire
the accessories needed (cables, fuses,
etc.).
Check the ratings, required cooling air
flow, input power connection,
compatibility of the motor, motor
connection, and other technical data.
Planning the electrical installation
(page 43)
Technical data (page 119)
Check the installation site. Requirements for the installation site
(page 27)
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.
Checking the delivery (page 28).
Mounting and cooling (page 29).
Route the cables. Routing the cables (page 39)
Check the insulation of the supply cable,
the motor and the motor cable.
Checking the insulation of the assembly
(page 44)
Connect the power cable.
Connect the motor cable.
Connect the control cables.
Connecting the power cables (page 45).
Motor connections (page 52).
Electrical installation: input / output
(page 59).
Check the installation. Installation checklist (page 87).
Start the drive. Start-up (page 89)
18 Introduction to the manual
Terms and abbreviations
The following units and abbreviations might appear in this manual.
General terms
Unit / term /
abbreviation
Description
WWatt
A Ampere
Ω Ohm
μF microfarad
pF picofarad
mH millihenry
Φ phase
ms millisecond
μs microsecond
ns nanosecond
mm millimeter
m meter
in inch
ft feet
cu.ft cubic feet
lbf-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
CiA CAN in Automation International Users and Manufacturers Group e.V.
CTRL+E on the PC keyboard, press Ctrl and E at the same time.
DAC Digital to Analog Converter
DS402 CiA Device Profile for Drives and Motion Control
EDS Electronic Data Sheet
EMC Electromagnetic Compatibility
HMI 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
See also page 179 for safety related abbreviations.
Trademarks
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.
(NC) Not Connected
RF Radio Frequency
SSI Synchronous Serial Interface
TCP/IP Transmission Control Protocol / Internet Protocol
UDP User Datagram Protocol
Unit / term /
abbreviation
Description
20 Introduction to the manual
Hardware description 21
3
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.
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 control 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,
SinCos or Smart Abs feedback.
• Position, velocity and current control.
• 10 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.
• 7 optically isolated general purpose digital outputs.
• 2 analog inputs (±10 V) and 1 analog output (±10 V).
• USB serial port (compatible with USB 2.0 and USB 3.0).
• EtherCAT support.
• Programmable in Mint (except models E152AxxEINA).
22 Hardware description
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.
R1 R2
U
V
W
L1
L2
L3
Rectifier Capacitor
bank
Inverter
Brake chopper
AC supply
AC motor
Hardware description 23
Product overview
Connections - front panel
Earth/Ground
Earth/Ground
(NC)
L1 AC Phase 1/L
L2 AC Phase 2 / N
L3 AC Phase 3
UMotor U
VMotor V
WMotor W
R1 Brake
R2 Brake
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
RS485 settings. See DIP switches on page 79.
1+5V
2Data-
3Data+
4GND
2-wire 4-wire
1 TXA(+)/RXA(+) TXA(+)
2 TXB(-)/RXB(-) TXB(-)
3GND GND
47 V out 7 V out
5 (NC) RXA(+)
6 (NC) RXB(-)
1 Status- 11 Status+
2 DOUT2- 12 DOUT2+
3 DOUT1- 13 DOUT1+
4 DIN2- 14 DIN2+
5 DIN3- 15 DIN3+
6 DIN1- 16 DIN1+
7 DIN0- 17 DIN0+
8SREF 18STO1
9SREF 19STO2
10 Shield 20 Shield
1AOUT0 5AGND
2AIN1+ 6AIN1-
3AIN0+ 7AIN0-
4 Shield 8 Shield
Pin
Incremental BiSS/SSI/ Smart Abs EnDat 2.1 SinCos
EnDat 2.2
1 CHA+ Data+ Data+ Data+ (NC)
2 CHB+ Clock+ (NC) Clock+ (NC)
3 CHZ+ (NC) (NC) (NC) (NC)
4 (NC) (NC) (NC) (NC) (NC)
5 Hall U- (NC) (NC) Sin-* Sin-
6 Hall U+ (NC) (NC) Sin+* Sin+
7 Hall V- (NC) (NC) Cos-* Cos-
8 Hall V+ (NC) (NC) Cos+* Cos+
9 CHA- Data- Data- Data- (NC)
10 CHB- Clock- (NC) Clock- (NC)
11 CHZ- (NC) (NC) (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) (NC) (NC) (NC)
15 Hall W+ (NC) (NC) (NC) (NC)
Shell Shield Shield Shield Shield Shield
0 V
+24V
(NC) = Not Connected. Do not
make a connection to this pin.
* EnDat v2.1 only. EnDat v2.2 does not use the Sin and Cos signals.
Tightening torque for terminal block connections X1 & X2 is 0.5-0.6 N·m (4.4-5.3 lb-in).
Maximum wire sizes: X1: 2.5 mm
2
; X3: 0.5 mm
2
.
Connector X3 is designed to accept bare wires only; do not use ferrules.
X1 Power LEDs
DIP switches
U1 USB
X6 RS485 serial port
X3 Input / Output
X4 Input / Output
X8 Feedback in
X2 Control circuit power
24 Hardware description
Connections - top panel
See chapter Electrical installation: AC input, motor and brake on page 43 for
installation in general.
14 Shield 7 DIN4
13 CREF1 6 DIN5
12 DIN8 5 DIN6
11 DIN9 4 DIN7
10 USRV+ 3 CREF0
9 DOUT5 2 DOUT3
8 DOUT6 1 DOUT4
OPT1: Input / Output
E1 / E2 EtherCAT®
1TX+
2TX-
3RX+
4 (NC)
5 (NC)
6RX-
7 (NC)
8 (NC)
Both connectors have
identical pinouts.
EtherCAT
IN
E2
E1
EtherCAT
OUT
E1 is also used for standard
Ethernet if DIP switch 4 is in the
ON position (see page 79).
Hardware description 25
Type designation label
A description of the product’s catalog numbering system is shown below:
* Note: Model ..EINA.. cannot store or run a Mint program, but it does support
individual Mint commands entered in the Mint WorkBench Command window.
Commands received from a host application using the Mint ActiveX control are also
supported, although the application cannot be used to download a program file to the
drive.
Serial number
The first digit of the serial number refers to the manufacturing plant. The next four
digits refer to the unit’s manufacturing year and week, respectively. The remaining
digits complete the serial number so that there are no two units with the same
number. Drives manufactured from week 19, 2014 (serial number U1419... or
greater) support the resolver adapter (page 171).
CAT.
S/No.
OUTPUT
Desc.
INPUT
U0316010002
9A Cont/18A Pk 0-250V 3Ø, 3kW
MicroFlex e150 Drive 9A
105-250 AC 50/60 Hz 1 3Ø/ Ø
Made in the UK
FMH2A03TR-EN23
E152A09ENOA
U0316010002
MicroFlex e150 Drive 9A
E152A09EIOA
E152A09ENOA
E 1 5 2 A 0 9 E I O A x x x
E15
2A
09
E
A
O
I
xxx
MicroFlex e150.
115 - 230 V AC supply input.
Rated amps: 03 = 3 A, 06 = 6 A, 09 = 9 A.
Feedback: E = Universal Encoder (connector X8, see page 23).
Extra digital inputs / outputs present (connector OPT1).
Build option: O = Programmable, N = Not programmable.*
Hardware revision.
(Optional) Custom variant.
Typical label shown.
Actual appearance may differ.
26 Hardware description
Mechanical installation 27
4
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
3
(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 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 are 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 #4-40 UNC jack screw with
an external male threaded section no longer than 10 mm (0.4 in).
Required tools
• A small 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.
• For UL installations, use UL listed closed loop connectors that are of appropriate
size for the wire gauge being used.
• Connectors are to be installed using only the crimp tool specified by the
manufacturer of the connector.
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 150.
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 the MicroFlex e150. Detailed
dimensions are shown in Dimension drawing (all models) on page 128.
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 without 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
132.
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 FAN001-024, mounted exactly
as shown in Fan tray on page 164, ensures that correct cooling is provided and
allows the MicroFlex e150 to be UL listed.
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 it is 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.
It is recommended to allow approximately 60 mm
(2.4 in) at the front to accommodate wiring and
connectors.
15 mm
15 mm
90 mm
1
1
Metal backplane
Forced air flow
Cool Warm Hot
Fan Fan
Mechanical installation 31
Installing
1. Mark the hole locations. See
Dimension drawing (all models) on
page 128 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.
167.7 mm (6.6 in)
63.5 mm (2.5 in)
32 Mechanical installation
Planning the electrical installation 33
5
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 motor and drive
Check that the 3-phase AC motor and the drive are compatible according to the
Motor output power (X1) on page 139.
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
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:
• a switch-disconnector of utilization category AC-23B (EN 60947-3)
• a disconnector 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)
• a circuit breaker suitable for isolation in accordance with EN 60947-2.
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 175.
Planning the electrical installation 35
Thermal overload and short circuit protection
Thermal overload protection
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal
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 drive trips on a motor phase short
circuit and will not restart unless AC power is removed. Remove all power from the
drive, correct the short circuit and restart the drive. The motor outputs are fully short
circuit proof according to EN 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 136. 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 136. 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 necessary. UL compliance can only be
achieved when using the recommended fuses.The use of circuit breakers does not
guarantee UL compliance and provides protection for the wiring only, not the
MicroFlex e150. 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
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 129 and Motor
output power (X1) on page 139 for the rated currents.
• The cable must be rated for at least 70 °C (US: 75 °C / 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 V AC cable is accepted for up to 500 V AC.
•Refer to Technical data on page 154 for the 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):
Allowed for AC power cabling
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
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.
Symmetrical shielded cable: three phase
conductors and a concentric or otherwise
constructed PE conductor, and a shield.
Check with local / state / country electrical
codes for allowance.
Note: A separate PE conductor is required
if the conductivity of the cable shield is not
sufficient for the purpose.
A four-conductor system: three phase
conductors and a protective conductor.
1 Insulation jacket
2 Copper wire screen
3 Helix of copper tape or copper wire
4 Inner insulation
5 Cable core
PE
conductor
PE
Shield
PE
Shield
PE
Shield
PE
1 23
4
5
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 the I/O terminal block.
1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode
24 V DC
0 V DC
230 V AC
230 V AC
1
2
3
4
0 V DC
24 V DC
4
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, ÖLFLEX 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 separate 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.
a b
40 Planning the electrical installation
A diagram of the cable routing is shown below:
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.
Control cables
min. 300 mm
Motor cable
Power cable
Drive
(12 in)
min. 500 mm
(20 in)
24 V 24 V 230 V230 V
Planning the electrical installation 41
Typical installation example
Mount AC filter and
MicroFlex e150 on the
same metal panel.
AC power
from fuses
or reactor
AC power wires should be as short as
possible, typically less than 0.3 m (1 ft).
Longer wires must be shielded as shown.
Wire colors can vary according to region.
Connect AC power
cable shield to metal
panel, using
conductive shield
earth/ground clamps.
On painted panels,
remove paint to
expose bare metal.
Drive earth wire
must be at least
10 mm
2
(7 AWG)
Protective Earth
(PE)
DO NOT TOUCH!
Brake resistors can
become extremely hot!
Locate away from
vulnerable components
and wiring.
CAUTION
Installation cabinet ‘star point’
42 Planning the electrical installation
Electrical installation: AC input, motor and brake 43
6
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 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.
See the requirements in Electrical power network specification on page 129. 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 before 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
MicroFlex e150 is designed to be powered from standard single or three-phase lines
that 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 lb-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).
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 connection first, disconnection
last. Earthing methods are shown in Typical installation example on page 41.
Route L1, L2, L3 and
earth/ground together
in conduit or cable
Circuit breaker
or fuses
AC filter
Connect
earth/ground
to protective
earth on top
of drive
To earth/ground outer shield,
use 360° clamps connected
to enclosure backplane.
STAR POINT
Isolating switch
Incoming safety
earth/ground (PE)
Line (L1)
Line (L2)
Line (L3)
AC
Supply
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 I (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 166). If the MicroFlex e150 and filter
are mounted in an enclosure, it is recommended the enclosure is earthed using a
10 mm
2
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
permanently 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.
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 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.
Harmonic suppression
When operating the 3 A MicroFlex e150 (part E152A03...) on a single-phase AC
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
1kW.
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
FI0015A02. Alternative filters or protection devices must be connected as
specified by the manufacturer.
See Power supply filters on page 138.
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 installed,
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 136. For CE compliance, see Technical
data on page 154.
NOTE: Metal conduit or shielded cable should be used. Connect conduits so the use
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.
L
N
L
N
L
N
L
N
From
supply
Circuit breaker
From
supply
Fuse
Circuit breaker and fuse, single-phase
L1 L1
L2 L2
L3 L3
L1 L1
L2 L2
L3 L3
From
supply
Circuit breaker From
supply
Fuse
Circuit breaker and fuse, three-phase
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 are configured automatically by the
Commissioning Wizard (page 100). If they need to be changed, use the Parameters
tool in Mint WorkBench (page 112).
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.
24 V filter
(optional)
Use a twisted pair cable.
STAR
POINT
Incoming safety
earth/ground (PE)
Customer supplied
24 V DC
Fuse *
* Recommended fuse: Bussman S504 20 x 5 mm anti-surge 2 A.
** Recommended ferrite sleeve: Fair-Rite part 0431164281 or similar.
X2
+24 V
GND
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.
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). 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.
The motor outputs are fully short circuit proof according to EN 61800-5-1. The drive
trips on a motor phase short circuit and will not restart unless AC power is removed.
See page 35.
When using a motor in the Mint WorkBench catalog, the parameters for managing
motor overloads are configured automatically by the Commissioning Wizard (page
100). If they need to be changed, or you are using an alternative motor, use the
Parameters tool (page 112).
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
corresponding U, 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, circuit breakers and wire sizes on page 136 for recommended
wire sizes.
Electrical installation: AC input, motor and brake 53
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 damaged.
2. Slide the section of outer sheath towards the end 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.
V
W
U
Motor
Earth
Connect motor
earth/ground
to protective
earth on top of
drive.
Unshielded
lengths should
be as short as
possible.
To earth/ground outer
shield, use 360° clamp
connected to backplane.
Optional motor
circuit contactors.
54 Electrical installation: AC input, motor and brake
Continuation of motor power cable shielding
When using a motor contactor, or extending the motor cable through a terminal box,
ensure that the motor cable shielding is continued all the way to the motor.
1. Make a single circular cut
in the cable’s outer
sheath, ensuring that the
cable’s braided shield is
not damaged.
2. Slide the section of outer
sheath towards the end of
the cable to expose an
area of braided shield.
Carefully remove the
excess sheath at the end
of the cable.
from
MicroFlex e150
On painted
panels, remove
paint to expose
bare metal.
Optional Motor Cable Management Bracket
OPT-CM-001 (recommended)
from
MicroFlex e150
Metal P-clip
M-Contactor Terminal box
Motor
from
MicroFlex e150
Electrical installation: AC input, motor and brake 55
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 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.
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.
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:
56 Electrical installation: AC input, motor and brake
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
separate supply as shown in the diagram. Do not use the supply that is
powering the MicroFlex e150 digital outputs. The brake wires often carry noise that
could cause erratic drive operation or damage. The brake contacts must never be
wired directly to the digital outputs. The relay should be fitted with a protective flyback
diode, as shown. The separate 24 V DC supply used for the motor brake can also be
used to power the relay in the thermal switch circuit.
3
+24 V 0 V
13
X3
DOUT1+
DOUT1-
User
supply
GND
User
supply
V+
Relay
Separate
customer
supplied
24 V DC supply
The relay has normally open
contacts and is shown deactivated
(contacts open, brake engaged).
The inner shield
surrounding the
brake wires should
be earthed/grounded
at one point only.
from motor brake
connections
Electrical installation: AC input, motor and brake 57
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 DIN0 as the input, is shown in the
following diagram.
WARNING! The 24 V DC power supply connected to the thermal switch must
be a separate supply as shown in the diagram. The thermal switch wires often
carry noise that could cause erratic drive operation or damage. The thermal switch
contacts must never be wired directly to a digital input. The separate 24 V DC supply
used for the thermal switch can also be used for the motor brake circuit.
+24 V 0 V+24 V 0 V
17
7
X1
DIN0+
DIN0-
The relay has normally open
contacts and is shown deactivated
(contacts open, motor overheated).
motor
thermal
switch
Separate
customer
supplied
24 V DC supply
Customer
supplied
24 V DC
supply
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 Ω, an inductance of less than 100 μH, 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 140. Suitable brake resistors are listed in
Resistor choice on page 143. 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).
Earth/ground outer shield,
using 360° conductive
clamp connected to
enclosure backplane
Brake resistor
STAR
POINT
Electrical installation: input / output 59
7
Electrical installation:
input / output
What this chapter contains
The chapter describes how to connect low voltage control signals.
The following conventions will be used to refer to the inputs and outputs:
I/O . . . . . . . . . . . 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 page 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.
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.
Analog inputs AIN0, AIN1
Location: X4, pins 3 & 7 (AIN0), 2 & 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 ADC keyword. See the Mint help file for
full details of ADC, ADCMODE and other related ADC... keywords.
Input circuit:
For differential inputs connect input lines to AIN+ and AIN-. Leave AGND
unconnected:
Mint
ADC.0
+15V
MicroFlex e150
AIN0-
7
X4
3
5
AIN0+
AGND
-15V
-
+
-
+
AIN0+ AIN0+
33
X4 X4
77
AIN0 AIN0
()ADC.0 ()ADC.0
55
AIN0-
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
Analog output AOUT0
Location: X4, pin 1 (AOUT0), 5 (AGND)
The analog output can be used to drive loads of 4 kΩ 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:
+24VDC
3
X4
7
AIN0
()ADC.0
5
0V
Nȍ:
Nȍ:
potentiometer
MicroFlex e150
AD5530BRUZ
X4
1
5
AOUT0
AGND
-15V
+15V
Demand
±100%
62 Electrical installation: input / output
Digital I/O
The MicroFlex e150 provides:
• 10 general purpose digital inputs.
• 2 dedicated Safe Torque Off (STO) inputs.
• 7 general purpose digital outputs.
Connector Digital input /
output
Common
connection
Purpose
X3 STO1
SREF
To enable the drive and provide the Safe
Torque Off (STO) function (page 64).
STO2
X3 DIN0 (Separate) General purpose input (page 65).
DIN1 (Separate)
General purpose 'fast' inputs (page 66).
DIN2 (Separate)
DIN3 (Separate) General purpose input (page 65).
OPT 1
(top panel)
DIN4
CREF1 General purpose inputs (page 68).
DIN5
DIN6
CREF0 General purpose inputs (page 68).
DIN7
DIN8
DIN9
X3 Status out
(DOUT0)
(Separate)
Status output (page 69).
Can also be used as a general purpose output
X3 DOUT1 (Separate)
General purpose outputs (page 70).
DOUT2 (Separate)
OPT 1
(top panel)
DOUT3
USRV+ General purpose outputs (page 71).
DOUT4
DOUT5
DOUT6
Electrical installation: input / output 63
Using a 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 I/O tool in Mint WorkBench.
Using a digital input as a home switch input (optional)
If homing is being handled locally by the 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. 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 175.
Safe Torque Off digital input - STO1:
Safe Torque Off digital input - STO2:
33R 6k8
33R
Vcc
DGND
TLP281
18
8SREF
20
STO1
MicroFlex e150
X3
STO
circuit
Shield
33R 6k8
33R
Vcc
DGND
TLP281
19
9SREF
20
STO2
MicroFlex e150
X3
STO
circuit
Shield
Electrical installation: input / output 65
Digital inputs - general purpose DIN0, DIN3
Location: X3, pins 17 & 7 (DIN0), 15 & 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 - DIN0 shown:
Digital input - typical connections from an ABB NextMove e100:
33R
33R
3k3
Vcc
DGND
17
7DIN0-
DIN0+
MicroFlex e150
X3
TLP280
Mint
UDN2982
Mint
DRIVEENABLEOUTPUT
MicroFlex e150
USR GND
DOUT0
DIN0-
17
10k
TLP280
7
10
1
9
DIN0+
USR V+
X11
X3
NextMove e100 / controller
User
supply
24 V
User
supply
GND
66 Electrical installation: input / output
Digital inputs - general purpose DIN1, DIN2
Location: X3, pins 16 & 6 (DIN1), 14 & 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 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 fast digital input - DIN1 shown:
Digital input - typical connections from an ABB NextMove e100:
TLP115
33R
33R
3k3
Vcc
DGND
16
6
DIN1-
DIN1+
MicroFlex e150
Mint
X3
UDN2982
Mint
OUTX(0)
MicroFlex e150
USR
GND
DOUT0
DIN1-
16
10k
TLP115
6
20
10
1
9
DIN1+
USR V+
X11
X3
NextMove e100 / controller
User
supply
24 V
User
supply
GND
Shield
Electrical installation: input / output 67
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 speed 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 80 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 on the feedback device. For
an incremental encoder, the latency is approximately 150 - 300 ns. For other
feedback devices latency can be up to 62.5 μs, resulting from the 16 kHz sampling
frequency used for these types of feedback device. The fast interrupt will be latched
on a pulse width of about 30 μs, although a width of 100 μs is recommended to
ensure capture. The captured value is latched in software to prevent subsequent
inputs causing the captured value to be overwritten.
NOTE: The fast inputs are particularly sensitive to noise, so inputs must use shielded
twisted pair cable. Do not connect mechanical switches, relay contacts or other
sources liable to signal ‘bounce’ directly to the fast inputs. This could cause unwanted
multiple triggering.
68 Electrical installation: input / output
Digital inputs - general purpose DIN4 - DIN9
Location: OPT1, pin 3 (CREF0), pin 4 (DIN7), 5 (DIN6), 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 DIN4 and DIN5 share a
common reference, CREF1. Inputs DIN6 - DIN9 share a common reference, CREF0.
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 - DIN4 shown:
Digital input - typical connections from an ABB NextMove e100:
33R
33R
3k3
Vcc
DGND
7
13CREF1
DIN4
MicroFlex e150
OPT1
TLP280
UDN2982
Mint
OUTX(0)
MicroFlex e150
USR GND
DOUT0
CREF1
7
10k
TLP280
13
10
1
9
DIN4
USR V+
X11
OPT1
NextMove e100 / controller
User
supply
24 V
User
supply
GND
Electrical installation: input / output 69
Status output (DOUT0)
Location: X3, 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:
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 OUTPUTACTIVELEVEL can be used. The output’s state is displayed in the
Spy window. See the Mint help file for details.
General purpose output DOUT0
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.
TLP127
200 mA
MicroFlex e150
X3
11
1
Status+
Status-
User supply
V+
User supply
GND
Load
(relay with
diode shown)
Fuse
[Error]
70 Electrical installation: input / output
Status output - typical connections to an ABB NextMove e100:
Digital outputs DOUT1, DOUT2
Location: X3, pins 13 & 3 (DOUT1), 12 & 2 (DOUT2)
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 °C. 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-energized.
Digital output circuit - DOUT1 shown:
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.
MicroFlex e150
Status-
CREF1
8
TLP280
9
1
11
DIN4
Status+
X3 X9
TLP127
User
supply
24 V
User
supply
GND
NextMove e100 / controller
Mint
OUTX(1)
TLP127
200 mA
MicroFlex e150
X3
13
3
DOUT1+
DOUT1-
User supply
V+
User supply
GND
Load
(relay with
diode shown)
Fuse
Electrical installation: input / output 71
DOUT1 - typical connections to an ABB NextMove e100:
Digital outputs DOUT3 - DOUT6
Location: OPT1, pin 2 (DOUT3), 1 (DOUT4), 9 (DOUT5), 8 (DOUT6), 10 (USRV+)
The optically isolated general purpose outputs are designed to source current from a
common user supply (USRV+). The TLP127 has a maximum power dissipation of
200 mW at 25 °C. 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-energized.
Digital output circuit - DOUT3 shown:
MicroFlex e150
DOUT1-
CREF1
8
TLP280
9
3
13
DIN4
DOUT1+
X3 X9
TLP127
User
supply
24 V
User
supply
GND
NextMove e100 / controller
Mint
OUTX(3)
TLP127
200 mA
MicroFlex e150
OPT1
10
2
USRV+
DOUT3
User supply
V+
User supply
GND
Load
(relay with
diode shown)
Fuse
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.
DOUT3 - typical connections to an ABB NextMove e100:
MicroFlex e150
DOUT3
CREF1
8
TLP280
9
2
10
DIN4
USRV+
OPT1 X9
TLP127
User
supply
24 V
User
supply
GND
NextMove e100 / controller
Electrical installation: input / output 73
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 should 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.
DIP switches 1 and 2 are used to introduce termination resistors; see page 79.
Connections to a 2-wire RS485 device - ABB AC500-eCo PLC shown:
MicroFlex e150ABB AC500-eCo PLC
RxD/TxD-P
3
5
8
1
3
2
TXA(+)/RXA(+)
SGND GND
RxD/TxD-N TXB(-)/RXB(-)
COM1 X6
74 Electrical installation: input / output
Connections to a 4-wire RS485 device - ABB Keypad KPD202-501 shown:
Note: The MicroFlex e150 and other ABB equipment use ‘big endian’ word order and
byte order for Modbus protocols. If this is incompatible with other Modbus equipment,
the word and byte order for the MicroFlex e150 can be changed in Mint WorkBench.
See the Mint WorkBench help file for details.
MicroFlex e150ABB Keypad KPD202-501
RXA
8
5
3
2
7
1
3
6
2
5
TXA(+)
GND GND
TXB RXB(-)
RXB TXB(-)
RXA(+)TXA
Serial X6
Electrical installation: input / output 75
Ethernet interface
The Ethernet interface supports EtherCAT® (CoE and EoE) and standard Ethernet.
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 79) 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:
Note: The MicroFlex e150 and other ABB equipment use ‘big endian’ word order and
byte order for Modbus protocols. If this is incompatible with other Modbus equipment,
the word and byte order for the MicroFlex e150 can be changed in Mint WorkBench.
See the Mint WorkBench help file for details.
E1 E1 E1 E1
Host PC
External switch
MicroFlex e150 drives
76 Electrical installation: input / output
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 and other EtherCAT enabled
controllers. EtherCAT's ‘CAN application layer over EtherCAT’ (CoE) capability allows
the drive to implement a device protocol based on IEC61800-7 ‘Generic interface and
use of profiles for power drive systems’ (previously CiA 402).
MicroFlex e150 incorporates a 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:
Ring topology EtherCAT network:
12 3456789
OUT OUT OUT OUT OUT OUT OUT OUT OUT
IN IN IN IN IN IN IN IN IN
EtherCAT master
Machine 1:
MicroFlex e150 drives 1-9
12 3456789
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
EtherCAT master
Machine 1:
MicroFlex e150 drives 1-9
Electrical installation: input / output 77
Multi-branch EtherCAT network:
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.
12 3456789
10 11 12 13 14 15 16 17 18 19 20
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
EtherCAT master
Machine 1:
MicroFlex e150 drives 1-9
Machine 2:
MicroFlex e150 drives 10-20
External
switch
78 Electrical installation: input / output
Ethernet connectors
Location: E1 & E2
Ethernet port E2 (IN) is fixed in EtherCAT mode. To set port E1 (OUT) to EtherCAT
mode, front panel DIP switch 4 (page 79) 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 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 173. 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.
The EtherCAT interface supports the 100Base-TX (100 Mbit/s) speed.
Electrical installation: input / output 79
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
< OFF ON >
4 E1 (OUT) port: EtherCAT mode E1 (OUT) port: Standard Ethernet mode
3 Normal operation Firmware recovery mode
2 X6 port: 2-wire TX/RX (or 4-wire TX):
disconnect 120 Ω termination resistor
X6 port: 2-wire TX/RX (or 4-wire TX):
connect 120 Ω termination resistor
1 X6 port: 4-wire RX:
disconnect 120 Ω termination resistor
X6 port: 4-wire RX:
connect 120 Ω termination resistor
80 Electrical installation: input / output
Motor feedback
Location: X8
MicroFlex e150 supports incremental encoder, encoder with BiSS (Bi-directional
Synchronous Serial Interface) or SSI (Synchronous Serial Interface), EnDat or
Smart Abs absolute encoder, or SinCos encoder feedback, for use with linear and
rotary motors. Resolvers are supported by using the optional Resolver adaptor (see
page 171). 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 Increment.
encoder
BiSS, SSI
or
EnDat 2.2
Smart Abs Extra
incremental
encoder
EnDat
2.1
SinCos
1 CHA+ Data+ Data+ (NC) Data+ (NC)
2 CHB+ Clock+ (NC) (NC) Clock+ (NC)
3 CHZ+ (NC) (NC) (NC) (NC) (NC)
4 (NC) (NC) (NC) (NC) (NC) (NC)
5 Hall U- (NC) (NC) CHA- Sin- Sin-
6 Hall U+ (NC) (NC) CHA+ Sin+ Sin+
7 Hall V- (NC) (NC) CHB- Cos- Cos-
8 Hall V+ (NC) (NC) CHB+ Cos+ Cos+
9 CHA- Data- Data- (NC) Data- (NC)
10 CHB- Clock- (NC) (NC) Clock- (NC)
11 CHZ- (NC) (NC) (NC) (NC) (NC)
12 +5 V out +5 V out +5 V out +5 V out +5 V out +5 V out
13 DGND DGND DGND DGND DGND DGND
14 Hall W- (NC) (NC) CHZ- (NC) (NC)
15 Hall W+ (NC) (NC) CHZ+ (NC) (NC)
1
9
8
15
Electrical installation: input / output 81
When using BiSS, SSI, EnDat 2.2, Smart Abs or resolver adapter, an extra
incremental encoder can be simultaneously connected.
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.
Incremental encoder interface
See Connection summary on page 80 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
CHA+
CHA-
1
9
13
DGND
120R
to CPU
X8
to encoder signal loss detection
MAX3096
Differential
line receiver
82 Electrical installation: input / output
Hall input circuit - U phase shown:
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:
+5V
MicroFlex e150
Hall U+
Hall U-
6
5
13
DGND
to CPU
X8
MAX3096
Differential
line receiver
CHA+
CHA-
CHB+
CHB-
CHZ+ (INDEX)
CHZ- (INDEX)
+5 V out
DGND
1
9
2
10
3
11
12
13
X8
Encoder
Feedback
Motor
Twisted pairs
Connect overall shield to
connector backshells
Electrical installation: input / output 83
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 speed control or positioning control.
Halls-only feedback cable connections - rotary motors:
BiSS interface
The BiSS (Bi-directional Serial Synchronous 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:
+5 V out
DGND
Hall U+
Hall U-
Hall W+
Hall W-
Hall V+
Hall V-
12
13
6
5
15
14
8
7
X8
Hall
Feedback
Motor
Twisted pairs
Connect overall shield to
connector backshells
X8
1
9
2
10
12
13
Data+
Data-
Clock+
Clock-
+5V out
DGND
Chassis
Absolute
Encoder
Motor
Twisted pairs
Connect overall shield to
connector backshells
BiSS
Interface
Connect
internal
shields to
pin 13.
84 Electrical installation: input / output
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.
Contact ABB technical support to confirm compatibility of other SSI devices. The SSI
encoder connections are made using the 15-pin D-type female connector X8.
SSI interface cable connections:
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:
X8
1
9
2
10
12
13
Data+
Data-
Clock+
Clock-
+5V out
DGND
Chassis
Absolute
Encoder
Motor
Twisted pairs
Connect overall shield to
connector backshells
SSI
Interface
Connect
internal
shields to
pin 13.
X8
1
9
5
6
7
8
2
10
12
13
Data+
Data-
Sin-
Sin+
Cos-
Cos+
Clock+
Clock-
+5V out
DGND
Absolute
Encoder
Motor
Twisted pairs
Connect overall shield to
connector backshells
EnDat
Interface
Connect
internal
shields to
pin 13.
Electrical installation: input / output 85
Smart Abs interface
The Smart Abs encoder connections are made using the 15-pin D-type female
connector X8.
Smart Abs interface cable connections:
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:
X8
1
9
12
13
Data+
Data-
+5V out
DGND
Chassis
Absolute
Encoder
Motor
Twisted pairs
Connect overall shield to
connector backshells
Smart Abs
Interface
Connect
internal
shields to
pin 13.
X8
5
6
7
8
12
13
Sin-
Sin+
Cos-
Cos+
+5V out
DGND
Chassis
SinCos
Feedback
Motor
Twisted pairs
Connect overall shield to
connector backshells
Connect
internal
shields to
pin 13.
86 Electrical installation: input / output
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, Smart Abs). In Mint,
the main digital encoder source remains as encoder 0, and the extra incremental
encoder is 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:
OPT-MF-201 Resolver adapter
The optional resolver adapter OPT-MF-201 allows a motor with resolver feedback to
be connected to the MicroFlex e150. See page 171 for details.
+5V
MicroFlex e150
CHA+
CHA-
6
5
13
DGND
to CPU
MAX3096
Differential
line receiver
Installation checklist 87
8
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.
All 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 conductors to check).
88 Installation checklist
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 175.
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 instruments have been properly calibrated.
Check that …
Start-up 89
9
Start-up
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.
Install Mint WorkBench
The Windows user account requires administrative user rights to install Mint
WorkBench. To install Mint WorkBench from www.abbmotion.com, download the
application and run it.
90 Start-up
Connect the MicroFlex e150 to the PC using USB
The MicroFlex e150 can be connected to the PC using either USB or Ethernet.
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.
USB driver
The USB driver for the MicroFlex e150 is installed with Mint WorkBench.
• If you are using Windows 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 >, 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.
To confirm that the USB driver is installed, check that a Motion Control category is
listed in Windows Device Manager:
Start-up 91
Connect the MicroFlex e150 to the PC using Ethernet
The MicroFlex e150 can be connected to the PC using either USB or Ethernet.
Connect a CAT5e Ethernet cable between the PC and the E1 / OUT Ethernet port on
the top of the MicroFlex e150.
Firmware versions
The IP addresses used in the following section apply to a MicroFlex e150 product
with firmware version 5715 or greater, which sets a default IP address of 192.168.0.1.
If your MicroFlex e150 uses firmware version 5714 or lower its default IP address is
192.168.100.110, and you should use 192.168.100.241 for the Ethernet adapter.
Alternatively, use Mint WorkBench to upgrade your MicroFlex e150 firmware to the
latest version.
Configure the PC Ethernet adapter
It is necessary to alter the PC's Ethernet adapter configuration to operate correctly
with the MicroFlex e150. By default, the MicroFlex e150 has a static IP address of
192.168.0.1. This can be changed using the Configuration tool in Mint WorkBench.
NOTE! You cannot connect an ordinary office PC to the MicroFlex 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. A USB to Ethernet adapter is a convenient way to add a second
Ethernet adapter to a PC. If you are unsure about making changes to your PC's
Ethernet adapter configuration, or are prevented by user permission levels, ask your
I.T. administrator to assist you.
The following explanation assumes the PC is connected directly to the
MicroFlex 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 is allowed
and is not already allocated on the network.
1. On the Windows 7 Start menu, choose Control Panel, then Network and Sharing
Center. (Windows 8.1: From the Start screen, click the down arrow or swipe up to
go to the Apps screen. Choose Control Panel, Network and Internet, Network and
Sharing Center).
2. On the left of the window, click Change Adapter Settings. Double click the icon for
the required Ethernet adapter, then click Properties.
3. Select the ‘Internet Protocol Version 4 (TCP/IPv4)' entry and click Properties.
4. On the General tab, make a note of the existing settings. Click Advanced... and
make a note of any existing settings. Click Cancel and then click the Alternate
Configuration tab and make a note of any existing settings.
92 Start-up
5. On the General tab, choose the ‘Use the following IP address' option.
6. In the IP address box, enter an IP address, e.g. 192.168.0.241. This is the IP
address that will be assigned to the Ethernet adapter.
7. In the Subnet mask box, enter 255.255.255.0 and click OK.
8. Click Close to close the Local Area Connection Properties dialogue.
9. Click Close to close the Local Area Connection Status dialogue.
Enable the Ethernet adapter for Mint WorkBench
Before Mint WorkBench can use the Ethernet adapter to discover the
MicroFlex e150, the adapter must be enabled in the Mint HTTP server.
1. On the Windows 7 task bar in the notification area, right-click the Mint HTTP
server icon and choose Properties. (Windows 8.1: On the Start screen, click the
Desktop icon to access the desktop first.)
2. In the Discovery area, check the required local area connection, then click OK.
For the latest information about Mint WorkBench and the Mint HTTP server, see the
Mint WorkBench help file.
Start-up 93
Start 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 Installation checklist,
starting on page 87.
Power on checks
See section MicroFlex e150 indicators on page 119 for symbols that show if the drive
has detected a fault.
1. Turn on the 24 V DC supply.
2. Turn on the AC supply.
3. The drive status display shows the following test sequence, which normally takes
approximately 15-20 seconds: ,
(in sequence), (in sequence). The
sequence ends with the symbol, or if an STO input is not powered. Startup
can take more than 1 minute after downloading new firmware.
4. If the motor wires were disconnected in Preliminary checks on page 93, turn off
the AC supply and reconnect the motor wires. Turn on the AC supply.
5. To allow the Commissioning Wizard to function, the Safe Torque Off inputs (page
175) need to be powered to allow the MicroFlex e150 to be enabled.
6. If you do not wish to enable the MicroFlex e150 yet, the Commissioning Wizard
will inform you when this step is necessary.
94 Start-up
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 98 to configure the
MicroFlex e150.
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 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.
Toolbars
Information pane
Menu system
Controller pane
Start-up 95
Starting MMC
1. On the Windows Start menu, select Programs, Mint WorkBench, Mint Machine
Center.
2. In the 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 100 to continue the configuration
in Mint WorkBench.
96 Start-up
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.
Toolbars
Control and
Menu system
Toolbox
test area
Start-up 97
Help file
Mint WorkBench includes a comprehensive help file that contains information about
every Mint keyword, how to use Mint WorkBench and background information on
motion control topics. 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 . 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.
For help on using Mint WorkBench, click the Contents tab, then click the small sign
beside the Mint WorkBench & Mint Machine Center book icon. Double click a topic
name to display it.
98 Start-up
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 the Windows Start menu, select Programs, Mint WorkBench, Mint
WorkBench.
2. In the opening dialog box, click Start New Project...
Start-up 99
3. Click Scan to search for the MicroFlex e150.
When the search is complete, click MicroFlex e150 in the list, then click Select.
Note: If the MicroFlex e150 is not listed, check the USB or Ethernet 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 & Debug mode is displayed.
100 Start-up
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 configuration information for your drive/motor combination, so
this is the first tool that should be used. If necessary, any of the parameters set by the
Commissioning Wizard can be adjusted manually after commissioning is complete.
Using the Commissioning Wizard
Each screen of the Commissioning Wizard requires you to enter information about
the motor, drive or application. Read each screen carefully and enter the required
information. When you have completed a screen, click Next > to display the next
screen. If you need to change something on a previous screen, click the < Back
button. The Commissioning Wizard remembers information that you have entered so
you will not need to re-enter everything if you go back to previous screens. If you
need extra help, click Help or press F1.
Start-up 101
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 can be found stamped on the motor's nameplate. If you are
using a motor with EnDat feedback, are using a different manufacturer’s motor, or
need to enter the specification manually, select the ‘I 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 ‘I 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 previous page, it is not necessary
to change anything on this screen; the feedback resolution will be entered already.
However, if you selected the ‘I 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 acceleration 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
102 Start-up
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.
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.
Autotune:
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 105.
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 175.
Start-up 103
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.
The main area of the Mint WorkBench window displays the capture window.
When further tuning tests are performed, this will display a graph representing the
response.
2. The Fine-tuning window has a
number of tabs the bottom.
Click on the Velocity tab.
Some tabs might not be available depending on the configuration mode you
selected in the Commissioning Wizard.
3. In the Test Parameters area at the
bottom of the tab, click in the Move
Type drop down box and select
Forward.
Enter values in the Velocity and
Distance boxes to create a short
move. The values you enter depend on the velocity scaling factor that was
selected in the Commissioning Wizard. This example assumes the velocity
scaling factor was selected as Revs Per Minute (rpm), so entering a value of 1000
here will create a move with a velocity of 1000 rpm. Similarly, assuming the
104 Start-up
position scaling factor had been set to 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
WorkBench will perform the test
move and display a graph of the
result.
5. Click on the graph labels to turn off
unwanted traces. Leave just Demand
Velocity and Measured Velocity
turned on.
Typical autotuned response (no load):
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 105.
Measured
velocity
Demand
velocity
Start-up 105
Further tuning - with load attached
To allow Mint WorkBench to adjust the basic tuning to compensate for the intended
load, it is necessary to attach the load to the motor and then perform the autotune
procedure again.
1. Attach the load to the motor.
2. Click the Autotune icon in the Toolbox
on the left of the screen.
3. Click the Autotune on load check box.
4. Click START to begin the auto-tuning
process. Mint WorkBench will take
measurements from the motor and
then perform small test moves.
5. Click the Fine-tuning icon in the
Toolbox on the left of the screen.
6. In the Velocity tab's Test Parameters
area, ensure the same move
parameters are entered and then
click Go to start the test move.
Mint WorkBench will perform the test
move and display a graph of the
result.
106 Start-up
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.
To reduce the amount of overshoot,
click Calculate... and increase the
bandwidth using the slider control.
Alternatively, type a larger value in
the Bandwidth box.
Click OK to close the Bandwidth
dialog.
2. Click Go to start the test move. Mint
WorkBench will perform the test
move and display a graph of the
result.
Velocity overshoots demand:
Measured
velocity
Demand
velocity
Start-up 107
Correcting zero-speed noise in the velocity response
The following graph shows a response where there is very little overshoot but a
significant amount of zero-speed noise. This can cause undesirable humming or
ringing in the motor.
1. Go to the Fine-tuning window's
Velocity tab.
To reduce the amount of noise, click
Calculate... and decrease the
bandwidth using the slider control.
Alternatively, type a smaller value in
the Bandwidth box.
Click OK to close the Bandwidth
dialog.
2. Click Go to start the test move. Mint
WorkBench will perform the test
move and display a graph of the
result.
Zero-speed noise:
Noise in
measured
velocity at
zero speed
Demand
velocity
108 Start-up
Ideal velocity response
Repeat the tests described in Correcting overshoot and Correcting zero-speed noise
in the velocity response until the optimal response is achieved. The following graph
shows an ideal velocity response. There is only a small amount of overshoot and very
little zero-speed noise.
Ideal velocity response:
Measured
velocity
Demand
velocity
Start-up 109
Performing test moves - continuous jog
This section tests the basic operation of the drive and motor by performing a
continuous jog. To stop a move in progress, click the red stop button or the drive
enable button on the toolbar. Alternatively, use the Mint WorkBench ‘Red Stop Button’
feature.
1. Check that the Drive enable button is
pressed (down).
2. In the Toolbox, click the Edit & Debug
icon.
3. Click in the Command window.
Type:
JOG(0)=10
This 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).
4. To stop the test, type:
STOP(0)
5. If you have finished testing click the
Drive Enable button to disable the
drive.
110 Start-up
Performing test moves - relative positional move
This section tests the basic operation of the drive and motor by performing a
positional move. To stop a move in progress, click the red stop button or the drive
enable button on the toolbar. Alternatively, use the Mint WorkBench ‘Red Stop Button’
feature.
1. Check that the Drive enable button is
pressed (down).
2. In the Toolbox, click the Edit & Debug
icon.
3. Click in the Command window.
Type:
MOVER(0)=10
GO(0)=10
This will cause the motor to move to a
position 10 units from its current position.
The move will stop when completed.
4. If you have finished testing click the
Drive Enable button to disable the
drive.
Start-up 111
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.
2. Select Upload configuration
from controller or Start new
configuration.
3. Enter a descriptive name for
the controller and click the
green arrow.
4. Continue through the screens
making the required changes.
Click Apply at any time to
save the changes.
5. When you have finished, click
Apply to complete the
configuration.
112 Start-up
Parameters tool
The Parameters tool can be used to view or change most of the drive's parameters.
1. Click the Parameters icon in the
Toolbox on the left of the screen.
The main area of the Mint
WorkBench window displays the
Parameters editor screen.
Items listed with a grey icon are read only so cannot be changed.
Items listed with a green icon are currently set to their factory default value.
Items listed with a yellow icon have been changed from their factory default
value, either during the commissioning process or by the user.
2. In the parameters tree, scroll to the
required item. Click on the small +
sign beside the item's name. The list
will expand to show all items in the
category. Click on the item you wish
to edit.
3. The adjacent table will list the chosen
item. 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.
Many of the MicroFlex e150's parameters are set automatically by the
Commissioning Wizard, or when tests are performed in the fine-tuning window.
Start-up 113
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 109 or
Performing test moves - relative positional move on page 110 then you have already
seen the Spy window, as it is displayed in conjunction with Edit & Debug mode. See
the Mint help file for full details of each tab.
1. Click the Edit & Debug icon in the
Toolbox on the left of the screen.
The Spy Window is displayed on the
right of the screen. Click on the tabs
at the bottom of the window to select
the required function.
2. The Axis tab displays the five most
commonly monitored parameters,
together with the state of special
purpose inputs and outputs.
3. The I/O tab displays the state of all
the digital inputs and outputs.
Clicking on an output LED will toggle
the output on/off.
4. The Monitor tab allows up to six
parameters to be selected for
monitoring.
Click in a drop down box to select a
parameter.
At the bottom of the Monitor tab, real-
time data capture can be configured.
114 Start-up
Other tools and windows
Remember, for help on each tool press F1 to display the help file, then navigate to the
Mint WorkBench book. Inside this is the Toolbox book.
• Edit & Debug Tool
This tool provides a work area including
the Command window and Output
window. The Command window can be
used to send immediate Mint commands
to the MicroFlex e150. If you tried the
test moves in Performing test moves -
continuous jog on page 109 or Performing test moves - relative positional move
on page 110, then you have already used Edit & Debug mode.
Press Ctrl+N to open a Mint programming window (except models ..EINA..).
• Scope Tool
Displays the capture screen. This screen is also shown when the Fine-tuning tool
is selected.
• Digital I/O Allows you to configure the
active states and special assignments
for the digital inputs and outputs.
For example, a general purpose
digital input can be configured as an
optional ‘drive enable input’, which
must be active to enable the drive;
see pages 63 and 65 - 68.
If a digital input is to be used as a
home switch input, see Using a digital
input as a home switch input
(optional) on page 63 for important
details.
Start-up 115
Modbus configuration (optional)
Modbus communication is set up using the Configuration tool in Mint WorkBench.
1. Click the Configuration tool icon in the Toolbox on the left of
the screen.
2. Select Upload configuration
from controller or Start new
configuration.
3. (Modbus RTU only)
Choose the Serial tab, and
then select Modbus RTU as
the Protocol.
4. Choose the Modbus Server
tab and Modbus TCP Client
tabs to make other changes
to the configuration.
Click Apply at the bottom of
the screen to save the
changes.
Press F1 to view help file
topics that explain each
setting.
116 Start-up
Safe Torque Off (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 175.
Fault tracing 117
10
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 119.
Problem diagnosis
If you have followed all 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.
• In Mint WorkBench, use the Error Log tool to view recent errors and then check
the help file.
• If you cannot solve the problem or the problem persists, the SupportMe feature
can be used.
118 Fault tracing
SupportMe feature
The SupportMe feature is available from the Help menu, or by clicking the button
on the motion toolbar. SupportMe can be used to gather information which can then
be e-mailed, saved as a text file, or copied to another application. The PC must have
e-mail facilities to use the e-mail feature. If you prefer to contact ABB technical
support by telephone or fax, contact details are provided on the back cover of this
manual.
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.
• A clear description of what you are trying to do, for example trying to establish
communications with Mint WorkBench or trying to perform fine-tuning.
• A clear description of the symptoms that you can observe, for example the Status
LED, error messages displayed in Mint WorkBench, or errors reported by the Mint
error keywords ERRORREADCODE or ERRORREADNEXT.
• The type of motion generated in the motor shaft.
• A list of any parameters that you have setup, for example the motor data you
entered/selected in the Commissioning Wizard, the gain settings generated
during the tuning process and any gain settings you have entered yourself.
Power-cycling the MicroFlex 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
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)
standard at the time of production.
NET ERR (Red)
Off: No errors or not powered.
Blinking:
Invalid mailbox configuration in BOOT.
Invalid mailbox configuration in
PREOP.
Invalid Sync manager configuration.
Invalid output configuration.
Invalid input configuration.
Invalid watchdog configuration.
Invalid DC Sync configuration.
Invalid DC latch configuration.
1 flash:
Unspecific error.
No memory.
Invalid request state change.
Unknown requested state.
Bootstrap not supported.
No valid firmware.
No valid inputs available.
No valid output.
Synchronisation error.
Invalid Sync manager types.
Slave needs cold start.
Slave needs INIT.
Slave needs PREOP.
Slave needs SAFEOP.
Invalid input mapping.
Invalid output mapping.
Inconsistent settings.
FreeRun not supported.
SyncMode not supported.
2 flashes: Sync manager watchdog.
FreeRun needs 3 buffer mode.
Background watchdog occurred.
No valid inputs and outputs.
Fatal sync error.
No sync error.
PLL error.
DC sync IO error.
DC sync time-out error.
Invalid DC Sync cycle time.
DC Sync0 cycle time.
DC Sync1 cycle time.
Message box EoE error.
Message box CoE error.
Message box FoE error.
Message box SoE error.
Message box VoE error.
EEPROM no access.
EEPROM error.
Slave restarted locally.
120 Fault tracing
LED flash periods
The following diagram shows the definitions of the terms ‘blinking’, ‘flashing’ and
‘flickering’ used in the previous sections, as defined by the EtherCAT Technology
Group.
LED flash timing definitions:
NET RUN (Green)
Off: INITIALISATION state (or not powered).
Blinking: PRE-OPERATIONAL state.
1 flash: SAFE-OPERATIONAL state.
3 flashes: Device identification. This state can be set from the master to locate the
device.
Continuously illuminated, not flashing: Node in OPERATIONAL state. EtherCAT is
operating normally.
200 ms
1 s
1 s
1 s
1 s
1 s
Off
1 flash
2 flashes
Inverted 2 flashes
3 flashes, etc.
Blinking
Flickering
On
(Not illuminated)
(Continuously illuminated)
Fault tracing 121
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:
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 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 and is active.
Motion will be ramped to zero demand whilst active.
Firmware loading (segments are illuminated sequentially). This sequence is
followed by a numerical sequence representing firmware initialization stages.
Hold to Analog (HTA) mode. The axis is in Hold To Analog mode. See the Mint
keyword
HTA.
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.
STO error
1 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
122 Fault tracing
User defined symbols can be displayed using Mint keywords LED and LEDDISPLAY.
Homing. The drive is currently homing. See the Mint keyword HOME.
Incremental move. An incremental linear move is in progress. See the Mint
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.
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.
Symbol Description
Fault tracing 123
Power
Drive does not start when applying AC power:
• Check that the motor output phases are not short circuited. The drive trips on a
motor phase short circuit and will not restart unless AC power is removed.
Remove all power from the drive, correct the short circuit and restart the drive.
Communication
Drive status display is off:
• Check that the 24 V DC control circuit supply is correctly connected at X2, and is
switched on.
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 that the MicroFlex e150 is powered and the drive status display is
illuminated (page 121).
• 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 Configure the PC Ethernet adapter on page 91).
• 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).
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).
124 Fault tracing
Cannot communicate with the controller after downloading firmware:
• After firmware download, always power cycle the MicroFlex e150.
Mint WorkBench loses contact with MicroFlex e150 while connected using
USB:
• Check that the MicroFlex e150 is powered.
• 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.
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 X3 pins 18 & 8 and 19 & 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.
• Use the Mint WorkBench Autotune Wizard to retune the motor.
• If the motor is still unstable, select the Mint WorkBench Autotune Wizard once
more. Click Options.... On the Bandwidth tab, move the Current and/or Position
and Speed Control sliders to a slower position to select a lower bandwidth. Click
OK to exit and then start the Autotune Wizard again.
Ethernet
Cannot connect to the drive over TCP/IP:
• Check that the PC's Ethernet adapter has been correctly configured, as described
in Configure the PC Ethernet adapter on page 91.
How do I configure my EtherCAT manager to operate with the MicroFlex e150?
• An EtherCAT ESI file (.xml) that describes the drive to the EtherCAT manager can
be uploaded from the controller using the Mint WorkBench Configuration tool.
Fault tracing 125
I 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 (DS402)’ 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.
126 Fault tracing
Technical data 127
11
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.
128 Technical data
Dimension drawing (all models)
6
63.4
(2.5)
79.5
(3.13)
82
(3.23)
11
(0.4)
5
(0.2)
6
(0.24)
167.3
(6.59)
6
(0.24)
180
(7.1)
Dimensions shown as: mm (inches)
Depth: 157 mm (6.2 in)
Weight: 3 A: 1.45 (3.2 lb)
6 A: 1.50 kg (3.3 lb)
9 A: 1.55 kg (3.4 lb)
Technical data 129
Electrical power network specification
A 115 - 230 V AC 3-phase power source (EN 61010 over-voltage category III 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 154).
* The MicroFlex e150 will operate at lower input voltages, although the drive will trip if
the DC-bus voltage falls below 50 V or 60% of the no-load voltage, whichever occurs
first.
Description Unit AC input
1Φ 3Φ
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
@ maximum rated output current
A 7.515224 812
Nominal DC-bus voltage
@ 230 V AC input
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 TN (grounded) systems.
Corner grounded TN, and IT (ungrounded)
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 136.
130 Technical data
Effect of AC power supply voltage on DC-bus voltage
Effect of AC power supply voltage on DC-bus ripple voltage
100
100
150
200
250
300
350
125 150 175 200 225 250
AC supply voltage (rms)
DC-bus voltage (V DC)
Three-phase AC supply
Single-phase AC supply
100
0
10
20
30
40
50
125 150 175 200 225 250
AC supply voltage (rms)
DC-bus ripple (% of DC-bus voltage)
Three-phase AC supply
Single-phase AC supply
Technical data 131
Effect of output current on DC-bus ripple voltage
20
0
10
20
30
40
50
60
30 40 50 60 70 80 90 100 110 120 130 140 150
Single-phase AC supply
Three-phase AC supply
% of drive rated current
DC-bus ripple voltage (V
pk-pk
)
132 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 7% if there
is no forced air cooling, or 15% if forced air cooling is present. See also Mounting and
cooling on page 29.
Derating characteristic for 3 A models (E152A03...):
30
0
1
2
3
35 40 45 50 55
30
0
1
2
3
35 40 45 50 55
Ambient temperature (°C)
Three-phase AC supply
Single-phase AC supply
Natural cooling
1 m/s forced air
1 m/s forced air
Natural cooling
Rated output current (A
rms
)Rated output current (A
rms
)
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for models E152A03... is 6 A.
Technical data 133
Derating characteristic for 6 A models (E152A06...):
30
0
2
4
6
1
3
5
2
4
6
1
3
5
35 40 45 50 55
30
0
35 40 45 50 55
Ambient temperature (°C)
Three-phase AC supply
Single-phase AC supply
Natural cooling
1 m/s forced air
1 m/s forced air
Natural cooling
Rated output current (A
rms
)Rated output current (A
rms
)
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for models E152A06... is 12 A.
1.5 m/s forced air
1.5 m/s forced air
134 Technical data
Derating characteristic for 9 A models (E152A09...):
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
models). This limit can be read using the TEMPERATURELIMITFATAL keyword - see
the Mint help file for details.
30
0
2
4
6
7
8
9
1
3
5
35 40 45 50 55
30
0
2
4
6
7
8
9
1
3
5
35 40 45 50 55
Ambient temperature (°C)
Three-phase AC supply
Single-phase AC supply
Natural cooling
1 m/s forced air
1 m/s forced air
Natural cooling
Rated output current (A
rms
)Rated output current (A
rms
)
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for models E152A09... is 18 A.
1.5 m/s forced air
1.5 m/s forced air
2.5 m/s forced air
2.5 m/s forced air
3.5 m/s forced air
3.5 m/s forced air
Technical data 135
Heat dissipation
These figures assume drive efficiency = 95%, power factor = 0.8:
MicroFlex e150
model
Heat dissipation
(W)
3A 50
6A 101
9A 151
136 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.
Note: All wire sizes are 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
control output current and no harmonic current. Earth/ground wires must be the same
gauge, or larger, than the L1, L2 and L3 wires.
Drive
catalog
number
Cont.
output
amps
(RMS)
AC
supply
type
Input fuse Circuit
breaker
(C-type)
Minimum
wire gauge
AWG
mm
2
E152A03.. 3 A 1Ø Ferraz Shawmut:
6x32 FA series, 10 A
(W084314P)
or
BS88 2.5 URGS 10 A
(N076648J)
10 A 14 2.0
3Ø Ferraz Shawmut:
6x32 FA series, 8 A
(V084313P)
or
BS88 2.5 URGS, 7 A
(M076647J)
8 A 14 2.0
E152A06.. 6 A 1Ø Ferraz Shawmut:
6x32 FA series, 20 A
(A084318P)
or
BS88 2.5 URGS, 20 A
(L097507J)
20 A 14 2.0
3Ø Ferraz Shawmut:
6x32 FA series, 12.5 A
(X084315P)
or
BS88 2.5 URGS, 12 A
(P076649J)
12.5 A 14 2.0
E152A09.. 9 A 1Ø Ferraz Shawmut:
BS88 2.5 URGS, 25 A
(R076651J)
25 A 14 2.5
3Ø Ferraz Shawmut:
6x32 FA series, 20 A
(A084318P)
or
BS88 2.5 URGS, 20 A
(L097507J)
20 A 14 2.0
Technical data 137
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:
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 the
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
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
current rating
Minimum power cycle delay period
(seconds)
3A 25
6A 45
9A 65
MicroFlex e150
current rating
Time for DC-bus to discharge to 50 V or less
(maximum, seconds)
3A 83
6 A 166
9 A 248
138 Technical data
Power supply filters
* See EMC filters starting on page 166 for further details.
** See Foot-mount filter (single phase only) on page 165 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 166).
24 V control circuit supply (X2)
MicroFlex e150
current rating
230 V AC, 1Ø 230 V AC, 3Ø
3 A FI0015A00 + line reactor *
or
FI0029A00 **
FI0018A00 *
6 A FI0015A02 *
or
FI0029A00 **
FI0018A00 *
9 A FI0029A00 ** FI0018A03 *
Description Unit 3 A 6 A 9 A
Nominal input voltage V DC 24
Minimum input voltage V DC 20
Maximum input voltage V DC 30
Maximum ripple % ±10
Typical input current
(not powering feedback device)
A 0.5 - 0.6
Typical input current
(powering feedback device)
A 0.6 - 0.8
Maximum continuous current
@ 24 V DC
A1
Power on surge current (typical)
@ 24 V DC, 100 ms
A4
Technical data 139
Motor output power (X1)
Motor output rating adjustment
Description Unit 3 A 6 A 9 A
Nominal phase current A
rms
369
Peak phase current
for 3 s
A
rms
61218
Nominal output
@ 230 V, 3Φ
VA 1195 2390 3585
Output voltage (line-line)
@ V DC-bus = 320 V
V
rms
0 - 230
Output frequency Hz 0 - 550
Output dV/dt
at drive, phase-phase
at drive, phase-ground
at motor (using 20 m cable), phase-phase
at motor (using 20 m cable), phase-ground
kV/µs
2
1.1
1.9
1.8
Nominal switching frequency kHz 8.0
Minimum motor inductance mH 1
Efficiency % >95
3A 6A 9A
200%, 3 s
overload
300%, 3 s
overload
200%, 3 s
overload
300%, 3 s
overload
200%, 3 s
overload
300%, 3 s
overload
3A 2.5A 6A 5.25A 9A 7.5A
140 Technical data
Brake (X1)
Braking capacity
The braking capacity of the MicroFlex e150 can be calculated from the following
formula:
where the Brake switching threshold is 388 V. This gives the following typical values:
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.
Description Unit All models
Nominal switching threshold V DC on: 388, off: 376
Nominal power
(10% peak power, r = 57 Ω
kW 0.25
Peak power
(10% peak power, r = 57 Ω
kW 2.7
Maximum brake switching current A
pk
10
Minimum load resistance Ω 39
Minimum load inductance µH 100
MicroFlex e150
catalog number
DC-bus
capacitance (μF)
Braking capacity (J)
115 V AC supply 230 V AC supply
E152A03... 560 34.7 12.5
E152A06... 1120 69.4 25
E152A09... 1680 104.2 37.6
E
= — × DC bus capacitance × (Brake switching threshold)
2
–
2
2 × Supply voltage
(
()
)
¥
1
2
Technical data 141
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,
in radians per second.
Multiply RPM by 0.1047 to get radians per
second. This value will be zero if the load is
going to be stopped.
Final motor speed:
V = _____________ rad/s
c) The deceleration time from initial speed to final
speed, in seconds.
Decel time:
D = _____________ s
d) The total cycle time (i.e. how frequently the
process is repeated), in seconds.
See Duty cycle on page 144.
Cycle time:
C = _____________ s
e) Total inertia.
This is the total inertia seen by the drive,
accounting for motor inertia, load inertia and
gearing. Use the Mint WorkBench Autotune tool
to tune the motor, with the load attached, to
determine the value. This will be displayed in
kg·m
2
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 kg·cm
2
by 0.0001 to give kg·m
2
.
Multiply lb-ft
2
by 0.04214 to give kg·m
2
.
Multiply lb-in-s
2
by 0.113 to give kg·m
2
.
Total inertia:
J = _____________ kg·m
2
142 Technical data
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:
where E is energy, J is the moment of inertia, and ω is the angular velocity.
The braking energy, which is the difference between the initial energy and the final
energy, is therefore:
= ________________ J (joules)
Calculate E using the values for J, U and V entered in the table on page 141. If E is
less than the drive's braking capacity (see Braking capacity on page 140), a brake
resistor is not required.
If E is greater than the drive's braking capacity, then continue to the next section to
calculate the braking and average power dissipation.
Braking power and average power
The braking power P
r
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.
= ________________ W (watts)
The resistors shown in the following table can withstand brief overloads, but the
average power dissipation, P
av
, 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)
E
= — × JîȦ
2
1
2
— ×
J × U
2
E
=–
1
2
— × J × V
2
1
2
()()
— × J × (U
2
– V
2
)=
1
2
P
r
= —
E
D
P
av
= P
r
× —
D
C
Technical data 143
Resistor choice
P
av
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 × P
av
________________ W (watts)
The range of suitable brake resistors is shown in the following table. Choose the
resistor that has a power rating equal to or greater than the value calculated above.
WARNING! The brake resistance must be 39 Ω or greater to ensure the
drive’s maximum regeneration switching current (10 A) is not exceeded.
Failure to observe the minimum resistance could result in damage to the drive. See
Brake (X1) on page 140.
Dimensions of brake resistors are shown in Brake resistors on page 169.
* The brake resistors listed in the table above can withstand a brief overload of 10
times the rated power for 5 seconds. Please contact ABB if larger power ratings are
required.
Part Resistance Power rating
RGJ139 39 Ω 100 W
RGJ160 60 Ω 100 W
RGJ260 60 Ω 200 W
RGJ360 60 Ω 300 W
144 Technical data
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.
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):
Resistor part
number
Nominal
power rating
(W)
In free air On heat sink
RGJ139
RGJ160
100 Derate power linearly from:
80% @ 25 °C (77 °F)
to
70% @ 55 °C (113 °F)
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
RGJ260
RGJ360
200
300
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
0.5 s 0.5 s 0.5 s
t
v
Deceleration time
Braking active
2.5 s
(Cycle time)
2.5 s
(Cycle time)
2.5 s
(Cycle time)
Technical data 145
Input / output
Analog inputs AIN0, AIN1 (X4)
Analog output AOUT0 (X4)
Digital inputs STO1, STO2 (X3)
See Technical data: Digital inputs STO1, STO2 (X3) on page 179.
Description Unit All models
Type Differential
Common mode voltage range V DC ±10
Common mode rejection dB 40
Input impedance kΩ 60
Input ADC resolution bits 12
(includes sign bit)
Equivalent resolution mV ±4.9
Sampling interval µs 1000 (Mint)
250 (Control loop)
Description Unit All models
Type Bipolar
Output voltage range V DC ±10
Output current (max) mA 1
Output DAC resolution bits 12
(includes sign bit)
Equivalent resolution mV ±4.9
Update interval ms 1
146 Technical data
Digital inputs DIN0, DIN3 (X3)
Digital inputs DIN1, DIN2 - high speed (X3)
Description Unit All models
Type Opto-isolated inputs
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
VDC
24
12
30
> 12
< 2
Input current (maximum, per input) mA 50
Sampling interval ms 1
Minimum pulse width µs 5
Description Unit All models
Type Opto-isolated inputs
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
VDC
24
12
30
> 12
< 2
Input current (maximum, per input) mA 20
Sampling interval ms 1
Minimum pulse width ns 250
Minimum step time ns 250
Minimum space time ns 250
Direction input setup time ns 100
Direction input hold time ns 100
Technical data 147
Digital inputs DIN4 - DIN9 (OPT1)
Digital outputs DOUT0 (Status), DOUT1, DOUT2 (X3)
Digital outputs DOUT3 - DOUT6 (OPT1)
Description Unit All models
Type Opto-isolated inputs
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
VDC
24
12
30
> 12
< 2
Input current (maximum, per input) mA 50
Sampling interval ms 1
Minimum pulse width µs 5
Description Unit All models
User supply (maximum) V DC 28
Output current (maximum) mA 100
Fuse:
Approximate trip current
Reset time
mA
s
200
< 20
Update interval ms 1
Description Unit All models
User supply (maximum) V DC 28
Output current (maximum) mA 100
Fuse:
Approximate trip current
Reset time
mA
s
200
< 20
Update interval ms 1
148 Technical data
Incremental encoder interface (X8)
BiSS encoder interface (X8)
SSI encoder interface (X8)
* Total current for this encoder and extra incremental encoder, which may be
connected simultaneously (see page 86).
Description Unit All models
Encoder interface RS422 A/B Differential, Z index
Maximum input frequency
(quadrature)
MHz 8
Hall inputs RS422 A/B Differential
Output power supply to encoder 5 V DC (±7%), 400 mA max.*
Maximum recommended cable length 30.5 (100 ft)
Description Unit All models
BiSS encoder interface Differential Data and Clock
Operating mode
(Baldor motors)
Single or multi-turn.
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%), 400 mA max.*
Maximum recommended cable length 30.5 (100 ft)
Description Unit All models
SSI encoder interface Differential Data and Clock
Operating mode
(Baldor motors)
Single turn.
Positioning resolution up to 262144
counts/rev (18-bit).
Contact ABB technical support
before selecting a device.
Output power supply to encoder 5 V DC (±7%), 400 mA max.*
Maximum recommended cable length 30.5 (100 ft)
Technical data 149
SinCos / EnDat encoder interface (X8)
Smart Abs encoder interface (X8)
* Total current for this encoder and extra incremental encoder, which may be
connected simultaneously (see page 86).
Ethernet interface (E1, E2)
Description Unit All 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 (±7%), 400 mA max.*
Maximum recommended cable length 30.5 (100 ft)
Description Unit All models
Smart Abs encoder interface Differential Data
Operating mode Single or multi-turn.
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%), 400 mA max.*
Maximum recommended cable length 30.5 (100 ft)
Description Unit All models
Signal 2 twisted pairs,
magnetically isolated
Protocols EtherCAT®
& TCP/IP
Bit rates Mbit/s 100
150 Technical data
Ambient conditions
Applicable standards
MicroFlex e150 complies with the following standards.
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.
Description Unit All models
Operating temperature range °C °F
Minimum
Maximum
Derate
VDC +0
+45
See Temperature
derating on page
132.
+32
+113
See Temperature
derating on page
132.
Storage temperature range -40 to +85 -40 to +185
Humidity (maximum) % 93
3A 6A 9A
Forced air cooling flow
(vertical, from bottom to top)
m/s None
required
12.5
Maximum installation altitude
(above m.s.l.)
m
ft
1000
Derate 1.1% / 100 m over 1000 m
3300
Derate 1.1% / 330 ft over 3300 ft
Shock 10 G
Vibration 1 G, 10-150 Hz
Technical data 151
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 Environmental testing, Test Ea. Shock.
EN 60068-2-30:2005 Environmental testing, Test Db. Damp heat, cyclic.
EN 60068-2-31:2008 Environmental testing, Test Ec. Rough handling shocks
EN 60068-2-78:2001 Environmental testing, Test Cab. Damp heat, steady state.
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.
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.
152 Technical data
Marks
See also CE marking on page 154 for general recommendations for CE compliance.
C-tick marking
"C-tick" marking is required in Australia and New Zealand. A "C-tick" mark is
attached to each drive in order to verify compliance with the relevant
standard (IEC 61800-3, Adjustable speed electrical power drive systems -
Part 3: EMC product standard including specific test methods), mandated by
the Trans-Tasman Mutual Recognition Arrangement (TTMRA).
RCM marking
RCM marking is pending for the drive.
WEEE notice
According to the requirements of the Waste Electrical and Electronic
Equipment Directive (WEEE) the following information is provided.
This symbol indicates that the product must not be disposed of with other
general waste. It is your responsibility to dispose of your waste electrical
equipment by handing it over to a designated collection point for the
recycling of waste electrical and electronic equipment. The separate collection and
recycling of your waste equipment at the time of disposal will help conserve natural
resources and ensure that it is recycled in a manner that protects human health and
the environment. For more information about where you can recycle your waste,
please contact your local authority.
RoHS compliance
MicroFlex e150 is in conformity with Directive 2011/65/EU of the European
parliament and of the council of 8th June 2011 on the restriction of the use of certain
hazardous substances in electrical and electronic equipment. The RoHS declaration
3AXD10000377752 is available on www.abb.com/drives
.
Technical data 153
China RoHS marking
The People's Republic of China Electronic Industry Standard SJ/T 11364-
2014 specifies the marking requirements for hazardous substances in
electronic and electrical products. The '20' logo indicates the period, in
years, during which the hazardous substances contained in the product
will not leak or cause environmental pollution, bodily injury, or damage to
other assets during normal use of the product.
Part Hazardous substances
Lead
(Pb)
Mercury
(Hg)
Cadmium
(Cd)
Hexavalent
chromium
(Cr(VI))
Polybrominated
biphenyls (PBB)
Polybrominated
diphenyl ethers
(PBDE)
PCB O O O O O O
Heat sink X O O O O O
Metal parts O O O O O O
Plastic parts O O O O O O
Other non-metal
parts
OO O O O O
Fans O O O O O O
Cables/wires O O O O O O
The table is prepared in accordance with the provision of SJ/T 11364.
O: Indicates that said hazardous substance contained in all of the homogeneous materials for this part is
below the limit requirement of GB/T 26572.
X: Indicates that said hazardous substance contained in at least one of the homogeneous materials used for
this part is above the limit requirement of GB/T 26572. The limits are:
Pb: 1000 ppm (0.1%)
Cr6+: 1000 ppm (0.1%)
Hg: 1000 ppm (0.1%)
PBB: 1000 ppm (0.1%)
Cd: 100 ppm (0.01%)
PBDE: 1000 ppm (0.1%)
PCBA: Includes Printed Circuit Board and the components.
Depending on the model/type of the product, it may not contain all of the above parts. It is subject to the
actual model/type purchased.
The environmental protection period applies only when the product is used according to the conditions
required by the user manual. To protect the environment and human health:
1.The scrapped product should be separated from domestic waste and sent to a qualified place of disposal.
2.Recycling center should use appropriate methods to recycle/deal with the materials.
For more information about recycling this product, please contact local government, recycling center or your
local dealer.
154 Technical data
Materials
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.
Compliance with the EN 61800-3
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 installing
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.
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 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 removed and
handled according to local regulations.
Technical data 155
Category C2
The drive complies with the standard with the following provisions:
1. The drive is equipped with a suitable EMC filter; see Power supply filters on page
138.
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.
Category C3
The drive complies with the standard with the following provisions:
1. The drive is equipped with a suitable EMC filter; see Power supply filters on page
138.
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.
Compliance with the European Machinery Directive
This safety related drive complies with the European Union Machinery Directive
requirements for a safety component intended to be integrated into machinery.
Compliance with the machinery directive has been verified according to standards
IEC 61800-5-2:2007, EN ISO 13849-1:2008, IEC 62061:2005, and IEC 61508:2010
parts 1 & 2. The drive has been designed, constructed and equipped in such a way
that when installed as instructed in this manual, all hazards of an electrical nature are,
or can be, prevented. The drive complies with EN 61800-5-1 which specifies safety
requirements in terms of electrical, thermal and energy.
Note: The final assembler of the machinery must take the necessary precautions to
prevent all hazards of an electrical nature when integrating this equipment. General
specifications for design of electrical equipment of machinery is given in EN 60204-1
and EN 60204-11. Specifications for electrical equipment are also given in many
standards for specific categories of machinery.
Validating the operation of the Safe Torque Off function
See Appendix: Safe Torque Off (STO) on page 175.
156 Technical data
UL marking
The MicroFlex e150 is C-UL US Listed (file NMMS.E470302) only when used in
conjunction with optional Fan Tray (part FAN001-024, see page 164). The approval is
valid with rated voltages. When used without optional fan tray FAN001-024, the
MicroFlex e150 is UL Recognized.
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
150.
• 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 °C
(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 136 lists IEC fuses that are suitable for UL
applications. For suitable circuit breakers, contact your local ABB representative.
• 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 157
EtherCAT Conformance Test Certificate
158 Technical data
Control system
The MicroFlex e150 can use two main control configurations:
• Servo (Position).
• Torque Servo (Current).
The configuration is selected using the Mint CONFIG 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).
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 159.
The universal encoder interface reads 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 drive 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.
Technical data 159
PID
PI + TF
PI + TF PWM
KVTIME
CURRENTMEAS
+
+
+
+
++
+
-
-
--
CURRENTLIMIT
VELERROR
KVELFF
FOLERROR
POSDEMAND
U
V
T
P, V
P
V
KVEL
KACCEL
6062h
60F4h
60FBh
si5
si1
si1
si2
si2
si3
si3
si4
si1
si2
si8
KDERIV
si7
si3
60FB
KINTLIMIT
KINTMODE
KINT
KPROP
6060h
5007h
5023h
EFFORT
5033h
5022h
6073h
60FBh
si4
si1
si2
si4KVTRACK
KVINT
KVPROP
60F9h
VEL 606Ch
POS 6064h
60F9h si3
6060h
500Ah & 500Bh
60FBh
si6
6078h
TORQUEFILTERDEPTH
TORQUEFILTERBAND
TORQUEFILTERFREQ
TORQUEFILTERTYPE
TORQUELIMITNEG
TORQUELIMITPOS
60F6h
KITRACK
KIINT
KIPROP
VELDEMAND
606Bh
TORQUEDEMAND
6074h
ACCELDEMAND
5025h
Servo configuration control structure, showing DS402 objects
Current
Sensors
Encoder
Motor
Offset
Comp.
Current
Conv.
Position
Feedback
Interface
Temperature drift
compensation
Raw encoder signals
Current
controllers
LimitingTorque
filters
Control mode
switch
Velocity controller
Velocity filter
Commutation
Electrical angle
Measured torque and
magnetizing currents
Speed
Estimator
Control mode
switch
Position controller
Four-digit numbers indicate DS402 objects.
si indicates the object’s sub index.
160 Technical data
Torque servo configuration
The diagram on page 161 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.
Technical data 161
+
+
+
-
PID
PI + TF PWM
KVTIME
CURRENTMEAS
+
+
+
+
-
-
CURRENTLIMIT
KVELFF
FOLERROR
POSDEMAND
VELDEMAND
606Bh
TORQUEDEMAND
6074h
ACCELDEMAND
5025h
U
V
T
P
KVEL
KACCEL
6062h
60F4h
60FBh
si5
si1
si1
si2
si2
si3
si3
si4
si1
si2
si8
KDERIV
si7
si3
60FB
KINTLIMIT
KINTMODE
KINT
KPROP
5023h
EFFORT
5033h
5022h
6073h
60FBh
si4
VEL
606Ch
POS 6064h
60F9h si3
6060h
500Ah & 500Bh
60FBh
si6
6078h
TORQUEFILTERDEPTH
TORQUEFILTERBAND
TORQUEFILTERFREQ
TORQUEFILTERTYPE
TORQUELIMITNEG
TORQUELIMITPOS
60F6h
KITRACK
KIINT
KIPROP
Torque servo configuration control structure, showing DS402 objects
Four-digit numbers indicate DS402 objects.
si indicates the object’s sub index.
Motor
Current
controllers
LimitingTorque
filters
Control mode
switch
Position controller
Current
Sensors
Encoder
Offset
Comp.
Current
Conv.
Position
Feedback
Interface
Temperature drift
compensation
Raw encoder signals
Velocity filter
Commutation
Electrical angle
Measured torque and
magnetizing currents
Speed
Estimator
162 Technical data
Accessories 163
12
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 are
required for compliance with CE regulations. All connectors and other components
must be compatible with the shielded cable.
164 Accessories
Fan tray
The fan tray (part FAN001-024) provides sufficient cooling for the 6 A and 9 A
MicroFlex e150. The fan tray might be required for the 3 A model when operating in
high ambient temperatures (see Temperature derating on page 132). The fan 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
(file NMMS.E470302) when used in conjunction with the fan tray, mounted exactly as
shown in the following diagram.
94 (3.7)
21.5
(0.85)
142.5 (5.6)
17.3
(0.68)
16
(0.63)
4.5
(0.18)
84 (3.3)
66 (2.6)
Fan tray
dimensions
Fan tray
FAN001-024
Assembled MicroFlex e150 and fan tray
Position of fan tray mounting holes relative to
MicroFlex e150
Bottom of
MicroFlex e150
Fan tray
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.
All dimensions shown as mm (inches)
Accessories 165
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 166 and 168 for
details of filter FI0029A00.
24 V power supplies
A range of compact 24 V DIN rail mounting power supplies are available. The
supplies include short circuit, overload, over-voltage and thermal protection.
Part Input voltage 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)
MicroFlex e150 E152A0...
Foot-mount filter FI0029A00
Fan tray FAN001-024
166 Accessories
EMC 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 Power supply filters on page 138
.
Filter dimensions, types FI0018A00 and FI0018A03:
Part Manufacturer Rated
volts
Rated
amps
@ 40°C
Leakage
current
(mA)
Weight
kg (lbs)
FI0014A00 Schaffner FN9675-3/06 250 3 0.4 0.27 (0.6)
FI0015A00 Schaffner FN2070-6/06 250 6 0.4 0.45 (0.99)
FI0015A02 Schaffner FN2070-12/06 250 12 0.4 0.73 (1.61)
FI0018A00 Schaffner FN3258-7/45 480 7 33 0.5 (1.1)
FI0018A03 Schaffner FN3258-16-44 480 16 33 0.8 (1.76)
FI0029A00 Epcos B84142A22R215 250 22 33 3.0 (6.6)
Dimensions: mm (inches)
Dimension FI0018A00 FI0018A03
A 190 (7.48) 250 (9.84)
B 160 (6.30) 220 (8.66)
C 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)
F
B
A
C
G
ED
M5
Accessories 167
Filter dimensions, types FI0014A00, FI0015A00, FI0015A02:
Dimensions: mm (inches)
Dimension FI0014A00 FI0015A00 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)
F
G
H
C
L
AED
B
JK
168 Accessories
Filter dimensions, type FI0029A00:
Dimensions mm (inches)
Dimension FI0029A00
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)
B
AC
D
G
G
K
J
H
G 5.5 mm
H 11 mm
K 5 mm
J 10 mm
F
E
Mounting keyhole
and slot detail
Accessories 169
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. See
section Brake (X1) on page 140 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:
Part Power
W
Res.
Ω
Dimensions mm (inches)
ABCDEFG
RGJ139 100 39 165
(6.49)
41
(1.61)
22
(0.87)
152
(5.98)
12
(0.47)
10
(0.39)
4.3
(0.17)
RGJ160 100 60 165
(6.49)
41
(1.61)
22
(0.87)
152
(5.98)
12
(0.47)
10
(0.39)
4.3
(0.17)
RGJ260 200 60 165
(6.49)
60
(2.36)
30
(1.18)
146
(5.75)
17
(0.67)
13
(0.51)
5.3
(0.21)
RGJ360 300 60 215
(8.46)
60
(2.36)
30
(1.18)
196
(7.72)
17
(0.67)
13
(0.51)
5.3
(0.21)
B
A C
G
D
E
F
170 Accessories
Encoder breakout
The encoder breakout (part OPT-MF-200) can be used to connect motor feedback
and an extra incremental encoder (see page 80). Alternatively, the connectors can be
used together to connect a single motor that has separate cables for encoder and
Halls (e.g. a linear motor).
Motor feedback Incremental encoder
MicroFlex e150
OPT-MF-200
OPT-MF-200
Accessories 171
Resolver adapter OPT-MF-201
The resolver adapter (OPT-MF-201) allows a motor with resolver feedback to be
connected to the MicroFlex e150.* The MicroFlex e150 must be power-cycled after
connecting the resolver adapter. The resolver adapter sends an absolute position to
the MicroFlex e150 at startup, so a phase search is not required. In Mint WorkBench,
select a resolver motor in the Drive Setup Wizard. The wizard’s Feedback page will
show the feedback type as Resolver Adapter. The resolver adapter can be used in
conjunction with the encoder breakout (OPT-MF-200).
Resolver adaptor specifications
• Excitation frequency: 10 kHz
• Maximum input speed: 60000 rpm (2 pole resolver)
• Output resolution: 12-bit
• Accuracy: +/-11 arc minutes
Resolver requirements
• Transformation ratio: 0.5
• Excitation supply load: 100 mA maximum.
* This feature is not supported on older MicroFlex e150 models. In Mint WorkBench, click the
SupportMe icon and find the Controller Hardware information. The Functional Revision entry
must be 8 or greater to support the resolver adapter. Drives manufactured from week 19, 2014
(serial number U1419... or greater) support the resolver adapter.
172 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
1.5 5*
2.5 8.2
3.0 10*
5.0 16.4
6.1 20*
7.5 24.6
9.1 30*
10 32.8
15 49.2
15.2 50*
20 65.6
22.9 75*
30.5 100*
RP
SP
WP
S
-
6
12
20
35
50
90
BSM style threaded motor
connector (motor end only)
Raw cable
(no connector)
Current
(Amps)
Standard
connector
Stainless
connector
* North America only
Larger motors requiring 35 A cable or greater normally use terminal box connections, so a motor power connector is
not required. For this reason connectors are not available on 35 A - 90 A cable.
Examples:
A 6.1 m cable, with a CE threaded standard connector, rated for 12 A has part number 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.
SDM style threaded motor
connector (motor end only)
Accessories 173
Feedback cables
The part number for a feedback cable is derived as follows:
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
2
(22 AWG) wire minimum, with an
overall shield. Ideally, the cable should not exceed 30.5 m (100 ft). Maximum wire-to-
wire or wire-to-shield capacitance is 50 pF per 300 mm (1 ft) length, to a maximum of
5000 pF for 30.5 m (100 ft).
Ethernet cables
The cables listed in this table connect MicroFlex 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
mft
CAT5e Ethernet cable CBL002CM-EXS
CBL005CM-EXS
CBL010CM-EXS
CBL020CM-EXS
CBL050CM-EXS
CBL100CM-EXS
CBL200CM-EXS
0.2
0.5
1.0
2.0
5.0
10.0
20.0
0.65
1.6
3.3
6.6
16.4
32.8
65.6
CBL 020 SF -E 1 S
RF
DF
WF
SF
D
B
E
S
A
1
-
2
S
-
m
ft
0.5
1.6
1.0
3.3
2.0
6.6
2.5
8.2
5.0
16.4
7.5
24.6
10
32.8
15
49.2
20
65.6
Raw cable Standard
connector
Stainless steel
connector
Incremental
encoder
EnDat
SinCos
BiSSBSM servo motor
feedback cable with at
least 1 connector
Raw cable
(no connector)
Other lengths available on request
Example:
A 2 m encoder feedback cable for a MicroFlex e150 drive, with required connectors at both ends, has part number
CBL020SF-E2.
Legacy
controllers
e100 / e150
SSI
Smart Abs
Servo motor feedback
cable with drive
connector only
SDM servo motor
feedback cable with at
least 1 connector
174 Accessories
Appendix: Safe Torque Off (STO) 175
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 supports 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.
176 Appendix: Safe Torque Off (STO)
WARNING! The STO function does not disconnect the voltage of the main and
auxiliary circuits from the drive. Therefore maintenance work on electrical parts
of the drive or the motor can only be carried out after isolating the drive system from
the main supply. If the drive was connected to the input power, wait for 5 minutes after
disconnecting the input power.
X3:18
X3:19
X3:9
X3:8
X1:U
DC+
DC-
MicroFlex e150
U+
V+
W+
U-
V-
W-
+24 V
+24 V
+0 V
Safety circuit
(emergency stop
switch, relay etc.
Motor output (U phase shown)
Integrated
Power
Module
PWM control
circuit
Safe Torque Off
connections
Drivers
High
Low
PWM power
circuit
Common
Appendix: Safe Torque Off (STO) 177
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 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:
See Safety Manual: Safe Torque Off (STO) function for MicroFlex e150 drives
(LT0313...) 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.
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 STO2 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
STO error
178 Appendix: Safe Torque Off (STO)
Installation
Typical input connections:
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:
• at initial start-up of the safety function
• after any changes related to the safety function (wiring, components, settings,
etc.)
• after any maintenance work related to the safety function.
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...).
X3:18
X3:19
X3:9
X3:8
MicroFlex e150
+24 V
+0 V
Safety circuit
(emergency stop
switch, relay etc.)
Safe
Torque Off
connections
24 V
External Supply
Common
Appendix: Safe Torque Off (STO) 179
Technical data: Digital inputs STO1, STO2 (X3)
STO function: data related to safety standards
* According to the categorization defined in EN ISO 13849-1:2008.
Description Unit All models
Type Opto-isolated inputs
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
VDC
24
12
30
> 12
< 2
Input current (maximum, per input) mA 50
Sampling interval ms 1
Minimum pulse width µs 5
IEC 61508 EN ISO 13849-1
SIL PFH HFT SFF PTI PFD PL CCF MTTF
D
DC* Category
3
1.12 x 10
-10
/h
(0.112 FIT)
196.48%10
years
1.12 x 10
-5
e75
points
20420.9
years
90% 3
Abbreviation Reference Description
CCF EN ISO 13849-1 Common Cause Failure (%)
DC EN ISO 13849-1 Diagnostic Coverage
FIT IEC 61508 Failure In Time: 1E-9 hours
HFT IEC 61508 Hardware Fault Tolerance
MTTF
D
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 (%)
SIL IEC 61508 Safety Integrity Level
STO IEC 61800-5-2 Safe Torque Off
180 Appendix: Safe Torque Off (STO)
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.abb.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.
LT0291A08EN
LT0291A08 (EN) EFFECTIVE: 2017-01-01
Contact us
ABB Oy
Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone +358 10 22 11
Fax +358 10 22 22681
www.abb.com/drives
ABB Inc.
Automation Technologies
Drives & 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 Beijing Drive Systems Co. Ltd.
No. 1, Block D, A-10 Jiuxianqiao Beilu
Chaoyang District
Beijing, P.R. China, 100015
Telephone +86 10 5821 7788
Fax +86 10 5821 7618
www.abb.com/drives
ABB Motion Ltd
6 Hawkley Drive
Bristol, BS32 0BF
United Kingdom
Telephone +44 (0) 1454 850000
Fax +44 (0) 1454 859001
www.abb.com/drives
