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Error categories

Controllers use an error handling system that allocates a unique number for each error. This means that

an error code does not need to be deciphered to determine exactly which individual error has occurred.

Errors are recorded in two ways:

• Error List: This is designed to be manipulated by the Mint program. The controller’s error list can store

up to 256 entries on MicroFlex e190 and MotiFlex e180.

• Error Log: This is a historical record of errors and is displayed in Mint WorkBench using the Error Log

tool.

On MicroFlex e190 and MotiFlex e180. 5 KB of memory is reserved for the error log, where each error is

dynamically sized. This allows approximately 100 or more errors to be stored.

Entries in the error list can be viewed by type or sequentially, for which there are additional keywords

(shown in brackets in the following lists). Errors are arranged in several categories, with each error having

a unique code.

Problem diagnosis

There are 3 ways to get information on the faults that have occurred;

• In Mint WorkBench, connect to the drive and use the Error Log tool to view recent errors, get the

descriptions and then check the help files for more information.

• The drive status display indicates errors and general status information. When an error occurs, the drive

displays a sequence starting with the symbol “E” or “b”, followed by the five-digit error code.

• The drive also has two Network status LEDs that indicate the status of a used RTE master. You can check

the drives hardware manual for more information on how to diagnose the LED status.

What this Document contains

If you have followed all the instructions in this manual in sequence, you should have few problems installing the

ABB Servo Drives. If you do have a problem, this document will help you to navigate then diagnose and resolve

the problem. The following pages contain information on how to understand and resolve issues that can occur.

Before we get to this it’s important to first discuss the fault diagnosis system used in ABB Motion products.

Problem diagnosis

There are 3 ways to get information on the faults that have occurred;

• In Mint WorkBench, connect to the drive and use the Error Log tool to view recent errors, get the descriptions

and then check the help files for more information.

• The drive status display indicates errors and general status information. When an error occurs, the drive

displays a sequence starting with the symbol “E” or “b”, followed by the five-digit error code.

• The drive also has two Network status LEDs that indicate the status of a used RTE master. You can check

the drives hardware manual for more information on how to diagnose the LED status.

In scalar control, some standard features are not available.

IR compensation for a scalar controlled drive IR stands for voltage.

I (current) × R (resistance) = U (voltage).

IR compensation is active only when the motor control mode is scalar.

When IR compensation is activated, the drive gives an extra voltage

boost to the motor at low speeds. IR compensation is useful in applications that

require a high break-away torque. In direct torque control (DTC) mode, IR

compensation is automatic and manual adjustment is not needed.

Sensors like absolute encoders and resolvers indicate the rotor position at all times

after the offset between the zero angle of rotor and that of the sensor has been

established. On the other hand, a standard pulse encoder determines the rotor

position when it rotates but the initial position is not known. However, a pulse

encoder can be used as an absolute encoder if it is equipped with Hall sensors,

albeit with coarse initial position accuracy. The Hall sensors generate so-called

commutation pulses that change their state six times during one revolution, so it is

only known within which 60° sector of a complete revolution the initial position is.

The drive monitors the motor status continuously, also during flux braking.

The other benefits of flux braking are:

• The braking starts immediately after a stop command is given. The function does

not need to wait for the flux reduction before it can start the braking.

• The cooling of the induction motor is efficient. The stator current of the motor

increases during flux braking, not the rotor current. The stator cools much more

efficiently than the rotor.

• Flux braking can be used with induction motors and permanent magnet

synchronous motors.

Two braking power levels are available:

• Moderate braking provides faster deceleration compared to a situation where flux

braking is disabled. The flux level of the motor is limited to prevent excessive

heating of the motor.

• Full braking exploits almost all available current to convert the mechanical braking

energy to motor thermal energy. Braking time is shorter compared to moderate

braking. In cyclic use, motor heating may be significant.

Autophasing

Autophasing is an automatic measurement routine to determine the angular position

of the magnetic flux of a permanent magnet synchronous motor or the magnetic axis

of a synchronous reluctance motor. The motor control requires the absolute position

of the rotor flux to control the motor torque accurately.

Sensors like absolute encoders and resolvers indicate the rotor position at all times

after the offset between the zero angle of rotor and that of the sensor has been

established. On the other hand, a standard pulse encoder determines the rotor

position when it rotates but the initial position is not known. However, a pulse

encoder can be used as an absolute encoder if it is equipped with Hall sensors,

albeit with coarse initial position accuracy. The Hall sensors generate so-called

commutation pulses that change their state six times during one revolution, so it is

only known within which 60° sector of a complete revolution the initial position is.

The drive monitors the motor status continuously, also during flux braking.

Therefore, flux braking can be used both for stopping the motor and for changing the

speed. 

Motor control features

Scalar motor control

It is possible to select scalar control as the motor control method instead of Direct

Torque Control (DTC). In scalar control mode, the drive is controlled with a frequency

reference. However, the performance of DTC is not achieved in scalar control.

It is recommended to activate the scalar motor control mode in the following situations:

• In multimotor drives: 1) if the load is not equally shared between the motors, 2) if

the motors are of different sizes, or 3) if the motors are going to be changed after

motor identification (motor ID run)

• If the nominal current of the motor is less than 1/6 of the nominal output current of the drive

• If the drive is used without a motor connected (for example, for test purposes)

• If the drive runs a medium-voltage motor through a step-up transformer.

Operation modes

The DriveSPC tool offers the following operation modes:

Off-line

When the off-line mode is used without a drive connection, the user can

• open a application program file (if exists).

• modify and save the application program.

• print the program pages.

When the off-line mode is used with a drive(s) connection, the user can

• connect the selected drive to DriveSPC.

• upload an application program from the connected drive (an empty template

which includes only the firmware blocks is available by default.)

• download the configured application program to the drive and start the program

execution. The downloaded program contains the function block program and the

parameter values set in DriveSPC.

• remove the program from the connected drive.

On-line

In the on-line mode, the user can

• modify firmware parameters (changes are stored directly to the drive memory)

• modify application program parameters (ie, parameters created in DriveSPC)

• monitor the actual values of all function blocks in real time.

How to start up the drive

The drive can be operated:

• locally from PC tool or control panel

• externally via I/O connections or fieldbus interface.

The start-up procedure presented uses the DriveStudio PC tool program. Drive

references and signals can be monitored with DriveStudio (Data Logger or Monitor Window).

The start-up procedure includes actions which need to be performed only when the

drive is powered up for the first time (eg, entering the motor data). After the first start

up, the drive can be powered up without using these start-up functions. The start-up

procedure can be repeated later if start-up data needs to be changed.

In addition to the PC tool commissioning and drive power-up, the start-up procedure

includes the following steps:

• entering the motor data and performing the motor identification run

• setting up the encoder/resolver communication

• checking the emergency stop and Safe Torque Off circuits

• setting up the voltage control

• setting the drive limits

• setting up the motor overtemperature protection

• tuning the speed controller

• setting up the fieldbus control.

Cybersecurity disclaimer

This product is designed to be connected to and to communicate information and

data via a network interface. It is Customer’s sole responsibility to provide and

continuously ensure a secure connection between the product and Customer

network or any other network (as the case may be). Customer shall establish and

maintain any appropriate measures (such as but not limited to the installation of

firewalls, application of authentication measures, encryption of data, installation of

anti-virus programs, etc) to protect the product, the network, its system and the

interface against any kind of security breaches, unauthorized access, interference,

intrusion, leakage and/or theft of data or information. ABB and its affiliates are not

liable for damages and/or losses related to such security breaches, any

unauthorized access, interference, intrusion, leakage and/or theft of data or information.

Drive tools

The control panel offers quick access to simple settings and changes.

DriveStudio is an advanced PC tool for more complicated applications.

DriveSPC tool further extends the functionality having a function block

interface with drive firmware functions. The extensive standard function block

library covers most needs for custom modifications. The application control

programs have dedicated function block libraries, such as those for the

CAM profiler. The desired CAM profile is programmed with the DriveCAM tool.

The DriveSize selection tool helps to choose the optimum motor and drive

combination. The ready-made sizing examples, within the tool, cover the most

typical linear and rotary movements. 

Modular and compact design

− Seven compact frame sizes with several with several mounting and cooling options

− Function block programming capability according to IEC61131

− Scalability with internal and external options

− Global compatibility with machinery environment and standards