ABB / Servo drives and motors

The memory unit on a MotiFlex e180 carries the tuning parameters into a replacement drive, but only if the replacement is an identical specification. If it is not, the machine must be retuned before it runs.

ABB servo covers MicroFlex and MotiFlex drives with eSM, HDS, DSM, HY and BSM motors. Common on packaging, labelling, cut-to-length and flying shear applications.

The memory unit, and its one condition

The most useful thing to know about replacing a MotiFlex e180.

The drive carries a memory unit attached to the control unit, holding the tuning parameters. ABB states it can be inserted into an identical replacement drive.

But if the replacement drive does not have an identical specification, it must be retuned before being used to drive machinery. Retuning through Mint WorkBench then saves the correct parameters back into the memory unit.

So the memory unit is not a universal transfer. Identical spec means the config moves. Different spec means a commissioning job.

That is the same principle as the Pilz IDFIX on our Jokab page, with a condition attached.

And it will not fit anything else

ABB is explicit: the memory unit can be used only with MotiFlex e180 drives, and is not compatible with any other product that uses a similar unit, such as the ZMU-02.

Similar looking, not interchangeable. Worth knowing if you have several ABB motion products on a site.

All e180 frame sizes share the control unit

Genuinely useful for spares holding.

The MotiFlex e180 comes in frame sizes A, B, C and D depending on output power. ABB states that all frame sizes use the same control unit.

So a control unit fault on a large drive can be fixed with a control unit from a small one. One spare control unit covers every e180 on a site regardless of rating.

To determine a drive's frame size, ABB directs you to the rating tables rather than the model name. Send us the full designation and we will identify it.

The protocol is set by switches, not by part number

A useful piece of flexibility on the MotiFlex e180.

One drive covers three real-time protocols. You do not need a different part number for EtherCAT than for PROFINET, which is unusual and simplifies stocking considerably.

It also means a replacement drive arrives with the switches at default. Check the setting on the old one before it goes in the bin.

The encoder interface is also software configurable

ABB describes a universal encoder interface, configurable by software to support a wide range of feedback types.

So the feedback type is not fixed by the hardware either. Another reason a replacement needs its configuration, and another reason one part number covers many applications.

The e180 drives both rotary and linear servo motors.

The drive families

e150 and e190 are different generations of the same idea. If you have an e150 and it is failing, an e190 is the current equivalent but it is not a drop-in.

The motor families

Drive and motor are matched. Tell us both, and the feedback type, when quoting a replacement for either.

Safe Torque Off is standard

Worth knowing because it removes hardware from a design.

ABB specifies Safe Torque Off as a standard feature on the MicroFlex e150, with built-in machine safety to SIL 3 and PL e, able to integrate into safety systems without extra equipment.

So the drive can be part of the safety function directly, rather than needing a contactor in the motor circuit dropped by a safety relay.

The usual caution applies: if the existing installation relies on the drive's STO, a replacement must have it, and whether a substitution is valid belongs with whoever holds the machine's safety assessment.

The earthing requirement is specific

From the ABB MicroFlex e150 manual, and it is more demanding than a general earth.

The protective earth, the threaded hole on the top of the MicroFlex e150, must be connected to safety earth using either a 25 A conductor, or a conductor sized on the peak current rating, whichever is the greater.

That is a minimum 25 A earth conductor regardless of drive size. On a small drive that is much heavier than the supply cable, and it is a common install shortcut.

ABB also specifies the drive must be secured by the slots in the flange, and warns against locating it immediately above or beside heat generating equipment.

Two things ordered separately

The regen resistor is the one that gets forgotten. A servo axis that decelerates a real load needs somewhere to put the energy. Without the resistor the drive trips on DC bus overvoltage, and the symptom looks like a drive fault rather than a missing part.

If you are replacing a drive, check whether a regen resistor is fitted and whether it is staying.

Absolute feedback keeps position through a power cut

ABB describes the capability as maintaining present positional information in a power outage, allowing immediate restart without the need to datum.

That is worth real production time on a machine with a long homing sequence. If your existing installation has it, a replacement without it means the machine homes on every restart.

Check the feedback type before substituting.

Software

MINT means the drive may hold a program

Important for replacement. ABB describes MicroFlex e150 as an intelligent drive with embedded programming capability compatible with MINT, a multi-tasking motion language providing control of communications, logic, motion and HMI interaction.

ABB names cut to length systems, labellers and flying shears as typical applications.

So on some installations the machine logic lives in the drive, not in a PLC. A replacement drive arrives without it, and the memory unit only helps if the specification is identical.

If your servo drives run MINT programs, confirm the program files are backed up. That is the same warning as every programmable device on this site, and it applies more often on servo than people expect.

The EtherCAT ESI file

A practical detail: the ESI file can be downloaded from the drive itself using a web browser, from the fieldbus description files area.

ABB notes that if a browser cannot find the drive, it may be because the network uses a proxy that forwards all requests. Worth knowing before assuming the drive is faulty.

Other useful details

Dual encoder input on the MicroFlex e150, for line shaft encoder following or dual loop control to eliminate mechanical errors.

Drives manufactured from week 19 of 2014 carry serial numbers beginning U1419 and later. If a manual references a change from that date, the serial number tells you which side of it your drive falls.

The MotiFlex e180 complies with Ecodesign Regulation (EU) 2019/1781.

What to send us

The drive type and full designation. MicroFlex e150, e190, MotiFlex e180 with frame size.

The motor type, since the pair is matched.

The feedback type, and whether it is absolute.

The protocol in use, since it is switch-selected rather than in the part number.

Whether the drive runs a MINT program.

Whether a regen resistor, choke or filter is fitted.

Whether you need the drive, the control unit, or just the memory unit.

What we can supply

Current production. MotiFlex e180, MicroFlex e190, E530 and NextMove, plus eSM, HDS, DSM and HY motors, chokes, filters and regen resistors. Quoted with a delivered lead time.

Superseded. MicroFlex e150, earlier MicroFlex and BSM R series motors. Surplus and tested used, which is usually the fastest way to keep an existing machine on its original tuning.

Control units and memory units separately. On the e180 the control unit is common across frames, so that is often the cheaper fix.

We buy ABB servo

MicroFlex and MotiFlex drives and their motors hold value, and the matched pairs are worth more together. If you are decommissioning, keep the memory unit with the drive. See Sell To Us.

Related

ABB overview. Robotics and IRC5.

For servo systems from other brands see Allen-Bradley Kinetix, Omron G5 and 1S and Siemens SINAMICS.

Send us your part numbers

Tell us whether you need the whole drive or just the control unit, and whether the replacement has to match the existing specification exactly so the memory unit transfers. Quotes in NZD including GST.

Request a quote

Industech is an independent supplier of new, surplus and used industrial automation equipment. We are not an authorised distributor of, approved by, sanctioned by, or affiliated with ABB Ltd. ABB, MicroFlex, MotiFlex, NextMove, MINT and Mint WorkBench are trademarks of ABB Ltd. EtherCAT is a trademark of Beckhoff Automation. EtherNet/IP is managed by ODVA. All trademarks, brand names and part numbers are the property of their respective owners and are used here for identification purposes only.