Motion control

The MotiFlex e180 is designed to control a wide range of applications from simple point-to-point to advanced motion. Motion features include homing,

indexing, change of target “on the fly”,electronic gearing, CAM profiler, flying shear and high speed position latch features for registration.

Embedded Ethernet

Ethernet support includes EtherCAT® or PowerLink for real-time control of multiaxis systems. In addition EtherNet/IPTM,

Modbus TCP and RAW Ethernet are supported with other controllers such as PLCs and Industrial PCs.

The MotiFlex e180 servo drive delivers capability and performance you can depend on.

It combines Ethernet technology, advanced multitasking programming and safety as standard.

The MotiFlex e180 can operate from 200 to 480 V AC three-phase with motor rms current range from 3 to 50 A servo duty.

Ethernet and motor feedback interfaces are fully integrated and optimized for demanding motion applications.

Dynamic control of rotary and linear motors

Overload modes up to 300 percent provide dynamic control of servo motors, both rotary and linear.

Universal encoder interface can be simply configured by software to support a wide range of feedback types.

The MotiFlex e180 servo drive delivers capability and performance you can depend on.

It combines Ethernet technology, advanced multitasking programming and safety as standard.

The MotiFlex e180 can operate from 200 to 480 V AC three-phase with motor rms current range from 3 to 50 A servo duty.

Ethernet and motor feedback interfaces are fully integrated and optimized for demanding motion applications.

Highlights

− Wide range of motion functions

− EtherCAT®, Modbus TCP,

EtherNet/IPTM, and PowerLink

− Dynamic control of rotary and linear servo motors

− Safety as standard with integrated safe torque off in accordance to IEC 61800-5-2, SIL3, PL e

Applications

− Metal cutting and forming

− Printing and converting

− Laser/water-jet/textile cutting

− Rubber and plastics

− Wood working

− Textiles

− Packaging

Motor thermal switch:

The motor may be supplied with a sensor/switch that either opens completely or provides a high impedance when the motor

temperature limit is reached. This should be wired directly to the dedicated motor temperature switch input (X10) on a MotiFlex

e180 drive. If using a MicroFlex e190 drive use of this temperature sensor is optional, but if it is used it should be wired using an

isolated 24Vdc supply (this can be the same supply used for a motor brake) and then included into the control scheme via an

intermediate relay, contacts of which can either be used to disable the drive in some way or fed into the MicroFlex e190 as an

input assigned to be the MOTORTEMPERATUREINPUT.

For a drive controlled via a Real-time Ethernet network it is

typical to connect this signal to the motion controller instead. Removal of the STO inputs would be delayed to allow the drive (or

motion controller) time to profile the axis to a controlled stop before finally disabling the motor output via the STO function.

Actual implementation must be determined by the user according to the result of a risk assessment performed on the system –

please refer to application note AN00206, available on the ABB motion support website, for further details

Emergency stop input:

When either or both of the SIL3/PLe STO inputs are activated the drive will turn off the power to the motor immediately. If the

load has any kind of momentum and/or high inertia it may continue to ‘free wheel’ which may not be desirable. For this reason

sometimes it is required for the drive to quickly decelerate the motor, in a controlled manner, before activating the STO function.

If you have a programmable drive (with the Mint memory module option +N8020) it is possible to configure a STOPINPUT on

the drive which can provide a means of quickly decelerating the drive. A contact from the system’s safety circuit that opens

instantly would be wired to the drive’s configured STOPINPUT. For a drive controlled via a Real-time Ethernet network it is

typical to connect this signal to the motion controller instead. Removal of the STO inputs would be delayed to allow the drive (or

motion controller) time to profile the axis to a controlled stop before finally disabling the motor output via the STO function.

Actual implementation must be determined by the user according to the result of a risk assessment performed on the system –

please refer to application note AN00206, available on the ABB motion support website, for further details

Motor brake control output:

If the motor you are using has a brake then the drive has the ability to control a motor brake via any of the available digital

outputs (Note that by default output 0 is pre-configured as a GLOBALERROROUTPUT – i.e. a drive status output – so it is

common to use an alternative output for brake control). The OUTPUTACTIVELEVEL keyword should be used to ensure the

specific output channel selected to control the motor brake is configured to be active low. Motor brake control is configured via

drive parameters dedicated to this function (these keywords all start with the text MOTORBRAKE). It’s important to consider

where the 24Vdc supply for the brake will come from. This should be from a separate isolated power supply from that which is

used to supply logical devices such as the drive control card, and other control equipment.

Drive enable signal:

The drive will need to be enabled to allow it to control the motor. The source of this enable signal can be defined during the

commissioning wizard and can also be set using the Mint keyword ‘DRIVEENABLEMODE’ which defines if the drive is enabled

via a hardware input only or whether some form of software interlock (e.g. a Mint program or a communications control word) is

also included. If DRIVEENABLEMODE will be set to include a hardware input (other than the STO inputs) then the

DRIVEENABLEINPUT keyword should be used to specify which input channel is used for this function during the

commissioning process (described later). Drives running as intelligent single axis systems (i.e. running a Mint program) and

Real-time Ethernet controlled drives (i.e. EtherCAT or Ethernet Powerlink) do not typically use a dedicated drive enable input

and tend to rely only on the STO inputs for the hardware control of the drive’s power stage.

The OUTPUTACTIVELEVEL keyword should be used to ensure the

specific output channel selected to control the motor brake is configured to be active low. Motor brake control is configured via

drive parameters dedicated to this function (these keywords all start with the text MOTORBRAKE). It’s important to consider

where the 24Vdc supply for the brake will come from. This should be from a separate isolated power supply from that which is

used to supply logical devices such as the drive control card, and other control equipment.

Overview

1.1 Recommended I/O connections

If there is any kind of safety requirement in the process then use of the two Safe Torque Off (STO) inputs on the drive which

provide a TUV certified SIL 3 STO functionality should be made. Apart from these STO connections it is not essential to add any

additional control connections although it is common to include a drive enable input when using the drive in combination with a

motion controller providing hardwired analog and/or digital control connections (e.g. NextMove ESB-2).

The digital inputs on the drive allow connection of devices such as a home sensor or limit switches. Two of these inputs (1 and

2) can be used for high speed registration, capturing position in the order of nS to μS (depending on feedback type). Digital

outputs can be configured for functions such as ‘drive ready’ and the relay output (DO4) can be used for functions such as

motor brake control (remembering to follow the instructions in the installation manual to use an isolated 24Vdc supply for the

motor brake circuit via this relay).

Equipment required:

– MotiFlex e180 servo drive running the latest firmware, with the correct feedback option module fitted

– BSM motor with either Incremental encoder, SSi, EnDat, SinCos, Hiperface, SmartAbs, Resolver1

 or BiSS feedback

– PC running Windows 7 or later

– Motor feedback cable terminated with suitable connectors at both ends

– Motor power cable with a suitable connector at the motor end

– Mains supply to the MotiFlex e180 (3 phase 200-480VAC or 1 phase 230VAC is also possible with frame sizes A and B

providing the PHASELOSSMODE parameter is set to 0)2

– Ethernet Cable

The MicroFlex e190 and MotiFlex e180 are sophisticated servo drives which have been designed to meet the requirements of

both de-centralised single axis intelligent solutions and centralised multi-axis systems, providing high performance in an

economically priced device.

They provide an ideal solution to many machine applications and are ideal components for machine builders and system

integrators.

In this application note we will describe the commissioning process for a MotiFlex e180. The process is almost identical for a

MicroFlex e190 drive so references in this document to MotiFlex e180 are generally interchangeable with MicroFlex e190 unless

stated otherwise.

Introduction

The purpose of this application note is to explain the steps required to get an ABB motion drive operating in conjunction with an

AC servo motor and ‘tuned’ to achieve the best possible performance. Although some references are made to induction motor

parameters, setup and tuning of induction motors is covered by a separate application note.

MicroFlex e190 and MotiFlex e180 motion drives

The MicroFlex e190 and MotiFlex e180 are sophisticated servo drives which have been designed to meet

the requirements ofboth de-centralised single axis intelligent solutions and centralised multi-axis systems,

providing high performance in an economically priced device.

They provide an ideal solution to many machine applications and are ideal components for machine

builders and system integrators.

In this application note we will describe the commissioning process for a MotiFlex e180. The process is

almost identical for a MicroFlex e190 drive so references in this document to MotiFlex e180 are generally

interchangeable with MicroFlex e190 unless stated otherwise.

The ACQ580 is available in both normal and heavy-duty

ratings. Normal duty ratings provide a 110% short term

overload rating for one minute every ten minutes. Heavy

duty ratings provide a 150% short term overload rating for

one minute every ten minutes. All ACQ580 drives and their

protective functions are thoroughly tested for optimal performance.

Typical applications

• Pumps

• Blowers

• Mixers

Installation type

• Wall-mounted

High enclosure class

• UL (NEMA) Type 1 / IP21

• UL (NEMA) Type 12 / IP55

Built-in pump functionality

• Intelligent multi-pump control

• Pump cleaning

• Level control

• Sensorless flow calculations

• Min/max flow and pressure protection

• Dry pump protection

• Quick ramps

• Cavitation Detection and Control

• Soft pipe filling

• Motor disconnect detection

• Communication fail functionality

• Adaptive programming

• Start-up assistants

• Diagnostic assistant

• Sleep boost

• Auto change

• Two independent adjustable accel/decel ramp

• Motor preheating

• PID control with PID sleep / wake-up

• Dry run protection

• Pressure protection

• Inlet pressure protection

• Maximum pressure protection

• Minimum pressure protection

• Energy optimizer and calculator

• Load profile

Standard Hand/Off/Auto Control Panel:

• Primary Settings menu to ease drive startup

• Real Time Clock

• Diagnostic and Maintenance functions

• Full Graphic Display, including Chart, Graph,

Meter options

• 21 editable home views

• USB interface for PC and tool connection

• Parameters are Alpha-numeric

• Back-up and Restore function built into panel

• Automatic back-up after parameter change