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MicroFlex e150
ABB MicroFlex e150 User Manual
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40 Planning the
electrical installation
A diagram of the
cable routing i
s shown below:
Sep
arate control cable duct
s
Route 24
V and
230
V cabl
es in separate du
cts unless the 24
V cabl
e is insulated for
230
V or insulated with an insulation slee
ving 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 V
230 V
39
41
Table of Contents
Default Chapter
2
List of Related Manuals
2
Table of Contents
5
Table of Contents
7
Table of Contents
9
1 Safety
11
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
15
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
21
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
4 Mechanical Installation
27
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
33
What this Chapter Contains
33
Checking the Compatibility of the Motor and Drive
33
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
43
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
59
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
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
8 Installation Checklist
87
Checklist
87
Safe Torque off (STO) Connections
88
9 Start-Up
89
What this Chapter Contains
89
Introduction
89
Connecting the Microflex E150 to the PC
90
Installing Mint Workbench
90
Starting the Microflex E150
91
Preliminary Checks
91
Power on Checks
91
USB Driver
91
Configuring the TCP/IP Connection (Optional)
93
Configuring the PC Network Adapter
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
Configuration Tool
111
Parameters Tool
112
Spy Window
113
Other Tools and Windows
114
Safe Torque off (STO) Acceptance Test
115
10 Fault Tracing
117
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
127
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
Control Circuit Supply (X2)
138
Motor Output Power (X1)
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
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)
146
Digital Outputs DOUT0 (Status), DOUT1, DOUT2 (X3)
147
Digital Outputs DOUT3 - DOUT6 (OPT1)
147
Incremental Encoder Interface (X8)
147
Biss Encoder Interface (X8)
148
SSI Encoder Interface (X8)
148
Sincos / Endat Encoder Interface (X8)
148
Smart Abs Encoder Interface (X8)
149
Ethernet Interface (E1, E2)
149
Ambient Conditions
150
Applicable Standards
151
Design and Test Standards
151
Environmental Test Standards
151
Functional Safety Standards
151
Marks
151
Degree of Protection
153
Materials
153
CE Marking
153
Compliance with the European EMC Directive
153
Compliance with the en 61800-3
154
Definitions
154
Category C2
154
Category C3
154
Compliance with the European Machinery Directive
155
Validating the Operation of the Safe Torque off Function
155
CE Declaration of Conformity
156
UL Marking
157
UL Checklist
157
Control System
158
Servo Configuration
158
Torque Servo Configuration
160
12 Accessories
163
What this Chapter Contains
163
Fan Tray
164
Foot-Mount Filter (Single Phase Only)
165
Power Supplies
165
EMC Filters
166
Brake Resistors
169
Encoder Breakout
170
Cables
171
Motor Power Cables
171
Feedback Cables
172
Ethernet Cables
172
13 Appendix: Safe Torque off (STO)
173
What this Chapter Contains
173
Basics
173
Operation of the STO Function and Diagnostics
175
Installation
176
Validating the Operation of the Safe Torque off Function
176
Technical Data: Digital Inputs STO1, STO2 (X3)
177
STO Function: Data Related to Safety Standards
177
STO Function: TüV Certificate
178
Further Information
179
Product and Service Inquiries
179
Product Training
179
Providing Feedback on ABB Drives Manuals
179
Document Library on the Internet
179
Other manuals for ABB MicroFlex e150
Quick Installation Guide
74 pages
4
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ABB MicroFlex e150 Specifications
General
Brand
ABB
Model
MicroFlex e150
Category
Control Unit
Language
English
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