Control Techniques Epsilon EP Drive Installation Guide

Epsilon EP Drive

Installation Manual

Information furnished by Control Techniques Americas LLC (Control Techniques) is believed to be accurate and reliable. However, no responsibility is assumed by Control Techniques for its use. Control Techniques reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. Control Techniques also assumes no responsibility for any errors that may appear in this document. Information in this document is subject to change without notice.

P/N 400518-01

Revision: A6

Date: September 30, 2008

© Control Techniques Americas LLC, 2006-2008 Part Number: 400518-01 Revision: A6 Date: September 2008 Printed in United States of America Information in this document is subject to change without notice. No part of this document may be

reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Control Techniques Americas LLC.

Control Techniques Americas LLC a division of EMERSON Co. Control Techniques Americas LLC is not affiliated with Microsoft Corporatio n, owner of the

Microsoft, Windows, and Windows NT trademarks. Modbus is a trademark of Gould, Inc.

Schaffner is a trademark of Schaffner Mate-N-Lok is a trademark of Amp Incorporated Corp.

DeviceNet is a trademark of Open DeviceNet Vendor Association.

This document has been prepared to conform to the current released version of the product. Because of our extensive development efforts and our desire to further improve and enhance the product, inconsistencies may exist between the product and documentation in some instances. Call your customer support representative if you encounter an inconsistency.

Customer Support

Control Techniques Americas LLC 12005 Technology Drive Eden Prairie, Minnesota 55344-3620 U.S.A.

Telephone: (952) 995-8000 or (800) 893-2321 It is Control Techniques’ goal to ensure your greatest possible satisfaction with the

operation of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you need. Whether it’s by phone, fax or modem, you can access Con trol Techniques support information 24 hours a day, seven days a week. Our wide range of services include:

FAX (952) 995-8099

You can FAX questions and comments to Control Techniques. Just send a FAX to the number listed above.

Website and Email www.emersonct.com

Website: www.emersonct.com Email: info@emersonct.com If you have Internet capabilities, you also have access to technical support using our

website. The website includes technical notes, frequently asked questions, release notes and other technical documentation. This direct technical support connection lets you request assistance and exchange software files electronically.

Technical Support (952) 995-8033 or (800) 893-2321

Email: service@emersonct.com Control Techniques’ “Motion Made Easy” products are backed by a team of professionals

who will service your installation. Our technical support center in Eden Prairie, Minnesota is ready to help you solve those occasional problems over the telephone. Our technical support center is available 24 hours a day for emergency service to help speed any problem solving. Also, all hardware replacement parts, if needed, are available through our customer service organization.

When you call, please be at your computer, with your docum entation easily availab le, and be prepared to provide the following information:

• Product version number, found by choosing About from the Help menu

• The type of controller or product you are using

• Exact wording of any messages that appear on your screen

• What you were doing when the problem occurred

• How you tried to solve the problem

iii

Need on-site help? Control Techniques provides service, in most cases, the next day. Just call Control Techniques’ technical support center when on-site service or maintenance is required.

Training Services (952) 995-8000 or (800) 893-2321

Email: training@emersonct.com Control Techniques maintains a highly trained staff of instructors to familiarize customers

with Control Techniques’ “Motion Made Easy” products and their applications. A number of courses are offered, many of which can be taught in your plant upon request.

Application Engineering (952) 995-8000 or (800) 893-2321

Email: service@emersonct.com An experienced staff of factory application engineers provides complete customer support

for tough or complex applications. Our engineers offer you a broad base of experience and knowledge of electronic motion control applications.

Customer Service (Sales) (952) 995-8000 or (800) 893-2321

Email: customer.service@emersonct.com Authorized Control Techniques distributors may place orders directly with our Customer

Service department. Contact the Customer Service department at this number for the distributor nearest you.

Reference Materials

The following related reference manuals may be useful with your particular system.

Epsilon EP-I Indexing Drive and FM-2 Indexing Module Reference Manual (400518-02) Epsilon EP-B Drive Reference Manual (400518-03) Epsilon EP-P Drive and FM-3/4 Modules Reference Manual (400518-04) Epsilon EP-P Drive Connectivity Reference Manual (400518-05) Epsilon EP-IDN DeviceNet Reference Manual (400518-08)

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Safety Information

Safety Precautions

This product is intended for professional incorporation into a complete system by qualified persons. If you install the product incorrectly, it may present a safety hazard. The product and system may use high voltages and currents, carry a high level of stored electrical energy, or are used to control mechanical equipment that can cause injury.

You must give close attention to the electrical installation and system design to avoid hazards either in normal operation or in the event of equipment malfunction. System design, installation, commissioning and maintenance must be carried out by personnel who have the necessary training and experience. Read and follow this safety information and this instruction manual carefully.

Qualified Person

For the purpose of this manual and product, a “qualified person” is one who is familiar with the installation, construction and operation of the equipment and the hazards involved. In addition, this individual has the following qualifications:

Is trained and authorized to energize, de-energize, clear and ground and tag circuits and equipment in accordance with established safety practices.

Is trained in the proper care and use of protective equipment in accordance with established safety practices. Is trained in rendering first aid.

Enclosure

This product is intended to be mounted in an enclosure that prevents access except by qualified persons and that prevents the ingress of contamination. This product is designed for use in an environment classified as pollution degree 2 in accordance with IEC664-1. This means that only dry, non-conducting contamination is acceptable.

Setup, Commissioning and Maintenance

It is essential that you give careful consideration to changes to drive settings. Depending on the application, a change could have an impact on safety. You must take appropriate precautions against inadvertent changes or tampering. Restoring default parameters in certain applications may cause unpredictable or hazardous operation.

Safety of Machinery

Within the European Union all machinery in which this product is used must comply with Directive 89/392/EEC, Safety of Machinery.

The product has been designed and tested to a high standard, and failures are very unlikely. However the level of integrity offered by the product’s control function – for example stop/start, forward/reverse and maximum speed – is not sufficient for use in safety-critical applications without additional independent channels of protection. All applications where malfunction could cause injury or loss of life must be subject to a risk assessment, and further protection provided where needed.

Identification of Safety Information

Safety related information through out this manual is identified with the following markings.

“Warning” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

“Caution” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

Safety Information v

Safety Information Product Overview Installation Diagnostics

“Caution” used without the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result in property damage.

For the purpose of this manual and product, “Note” indicates essential information about the product or the respective part of the manual.

Throughout this manual, the word “drive” refers to an Epsilon EP drive.

Options and Accessories

Specification

General warning

Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in this unit can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to this equipment. The installation must comply with all relevant safety legislation in the country of use.

Supply isolation device

The AC supply or high voltage DC supply must be removed from the drive using an approved isolation device or disconnect before any servicing work is performed, other than adjustments to the settings or parameters specified in the manual. The drive contains capacitors which remain charged to a potentially lethal voltage after the supply has been removed. Allow at least 6 minutes for Epsilon EP206/209/216 and 3 minutes for Epsilon EP202/204 after removing the supply before carrying out any work which may involve contact with electrical connections to the drive.

Products connected by plug and socket

A special hazard may exist where the drive is incorporated into a product which is connected to the AC supply by a plug and socket. When unplugged, the pins of the plug may be connected to the drive input, which is only separated from the charge stored in the bus capacitor by semiconductor devices. To avoid any possibility of electric shock from the pins, if they are accessible, a means must be provided for automatically disconnecting the plug from the drive (e.g., a latching contactor).

Grounding (Earthing, equipotential bo nding) - High Leakage Current

The drive must be grounded by a conductor sufficient to carry all possible fault current in the event of a fault. This equipment has high earth leakage current. You must comply with local safety regulations with respect to minimum size and special installation requirements on the protective earth conductor for high leakage current equipment. The ground connections shown in the manual must be followed.

Fuses

Fuses or over-current protection must be provided at the input in accordance with the instructions in the manual. The drive alone does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local codes.

Isolation of control circuits

The installer must ensure that the external control circuits are isolated from human contact by at least one layer of insulation rated for use at the applied AC supply voltage. External control circuits identified as PELV circuits do not need this isolation when they are completely within a zone of equipotential bonding, generally within a single enclosure or group of enclosures bonded together.

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Underwriters Laboratories Listed

LISTED 768R IND. CONT. EQ. File E 58592 Sec.5

The Epsilon Digital Servo Drives are marked with the “UL Listed” label after passing a rigorous set of design and testing criteria developed by UL (UL508C). This label indicates that UL certifies this product to be safe when installed according to the installation guidelines and used within the product specifications.

The “conditions of acceptability” required by UL are:

• Operating within ratings for Input Voltage, Input Current, and Output Current

Rated Output Current (Amps RMS)

Drive Model

EP202 2.2 4.4 EP204 4.0 8.0 EP206 6.5 13.0 EP209 9.0 18.0 EP216 16.0 32.0

• Epsilon drive maximum surrounding air temperature 40°C (104°F) at rated Full Load Amperes (FLA)

• Epsilon drive maximum surrounding air temperature 50°C (122°F) with output current derated 15% for EP209, 20% for EP206, 10% for EP204, and no derating required for EP202 or EP216

• Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local codes

• Copper only conductors with 75°C minimum insulation rating at all power and motor terminals

• This product is suitable for use on a circuit capable of delivering not more than 10,000 RMS symmetrical amperes, 240 volts maximum, when protected by a Class RK1 or Class CC fuse, rated not more than 20 A

• Logic power and I/O power are to be supplied with a UL listed or "recognized component" power supply rated as limited voltage/limited current or limited voltage/limited power

• The following warning is presented here and furnished on a label to be placed on the enclosure door

Continuous

(Full Load Amperes)

Peak

Drive has high fault current rating. The opening of the branch circuit protective device may be an indication that a fault current has been interrupted. All current carrying parts and other components protected by this device should be examined and replaced if damaged. If burn-out of the current element of an overload relay occurs, the complete overload relay must be replaced.

Safety Information vii

Safety Information Product Overview Installation Diagnostics

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Specification

Drive Overload Protection

Solid state motor overload protection is provided in each model at no more than 115% of rated FLA. This overload protection is based on maximum continuous output current capacity. It will allow up to 200 percent of drive FLA to be delivered for the amount of time determined by the following chart.

Drive Output Current vs. Time graph

Time (seconds)

100 125 150 175 200

% Driv e Rated Current

When motor rated FLA is less than drive FLA, the motor FLA parameter is to be entered into drive configuration. Drive will then provide motor overload protection at correct value.

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CE Declaration of Conformity

The Epsilon Digital Servo Drives are marked with the “Conformite Europeenne Mark” (CE mark) after passing a rigorous set of design and testing criteria. This label indicates that this product meets safety and noise immunity and emissions (EMC) standards when installed according to the installation guidelines and used within the product specifications.

Declaration of Conformity

Manufacturer’s Name:

Manufacturer’s Address:

Declares that the following products:

Product Name:

EP202-B00, EP202-I00, EP202-IDN, EP202-P00, EP202-PDN, EP202-PPB, EP204-B00, EP204-I00, EP204-IDN, EP204-P00, EP204-PDN, EP204-PPB,

Model Number:

System Options:

Electomagnetic Compatibility (EMC):

EN 61800-3; 1997, For second environment restricted distribution

Electrical Thermal and Energy Safety Requirements:

EN 61800-5-1:2003

The products herewith comply with the requirements of the Low Voltage Directive (LVD) 73/23/EEC and amended by 93/

This servo drive is intended to be used with an appropriat e mo tor, electrical protection compon ent s a nd oth er equip ment

to form a complete end product or system. It must be installed by a professional assembler who is familiar with safety

and electromagnetic compatibility (“EMC”) requirements. The assembler is responsib le for ensuring that the end prod uct

or system complies with all the relevant laws in the country where it is to be used. Refer to the product manual for

EP206-B00, EP206-I00, EP206-IDN, EP206-P00, EP206-PDN, EP206-PPB, EP209-B00, EP209-I00, EP209-IDN, EP209-P00, EP209-PDN, EP209-PPB, EP216-B00, EP216-I00, EP216-IDN, EP216-P00, EP216-PDN, EP216-PPB

STI-24IO Interface Board, STI-SNCOA Analog/Sync Output Interface Board,

STI-SNCI Sync Input Interface Board, BRM-1 Motor Brake Relay, and SM-

Conforms to the following product specification:

Supplementary information:

68/EEC and the EMC Directive 89/336/EEC

installation guidelines.

Control Techniques Americas LLC

12005 Technology Drive

Eden Prairie, MN 55344

Epsilon EP Digital Servo Drive

Heatsink DBR-1 Brake Resistor

USA

December 12, 2006

Steve Bartz, Director, Motion Control Product Line Date

Sobetra Automation

European Contact:

Langeveldpark Lot 10

P. Dasterleusstraat 2

1600 St. Pieters Leeuw, Belgium

Safety Information ix

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Table of Contents

Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Reference Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Safety Information v

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Qualified Person. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Setup, Commissioning and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Safety of Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Identification of Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Underwriters Laboratories Listed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

Drive Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

CE Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Product Overview 1

Epsilon EP Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation 3

Step 1: Basic Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Achieving Low Impedance Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Electrostatic Discharge (ESD) Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Panel Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cable to Enclosure Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

AC Line Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 2: Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 3: High Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Transformer Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Line Fusing and Wire Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

AC Input Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operation on DC Input Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

External Shunt Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Motor Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Step 4: Low Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DC Logic Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Motor Feedback Wiring (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Motor Brake Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Input/Output and Drive Enable Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Analog Command Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Encoder Output Signal Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Diagnostics and Troubleshooting 51

Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Status Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Drive Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Options and Accessories 59

Epsilon EP Drive Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

STI-24IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

STI-SNCOA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

STI-SNCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

STI-ENC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Specifications 65

Epsilon EP Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Epsilon EP Drive Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Cable Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

XV Motor Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

NT and MG Motor Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Sync Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Communications Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Index 87

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Product Overview

Epsilon EP Drive

The Epsilon EP drive is a stand-alone, fully digital brushless servo drive designed and built to reliably provide high performance and flexibility without sacrificing ease of use.

The use of State-Space algorithms make tuning very simple and forgiving. The drives are designed to operate with up to a 10:1 inertia mismatch right out of the box. Higher (50:1 and more) inertia mismatches are possible with two simple parameter settings.

The Epsilon EP drive can be quickly configured to many applications in less than 5 minutes with PowerTools Pro software on a PC running Windows® 98, NT 4.0, 2000, ME and XP.

Complete diagnostics are provided for quick troubleshooting. A status/diagnostic display on the front of the drive informs the user of the operational or fault status. The last 10 faults are stored in non-volatile memory along with a time stamp for easy recall.

Shunt Connector (J8)

Status/Diagnostic Display

Reset Button

AC Power Connections Motor Connections 24 Vdc Logic Power Supply Connections

Serial Connectors (J2)

Ethernet Connector (J4) (EP-Pxx only)

DeviceNet Connector (J9) (EP-IDN or EP-PDN only)

Digital I/O Connector (J3)

Model Number, Part Number, Revision and Serial Number Label

Sync Input Connector (J10)

Analog/Sync Output Connector (J5)

Encoder Feedback Connector (J6)

Figure 1: Epsilon EP-PDN Drive Feature Location

Product Overview 1

Safety Information Product Overview Installation Diagnostics

Shunt Connector (J8)

Status/Diagnostic Display

Options and Accessories

Specification

Reset Button

24 Vdc Logic Power Supply Connector

AC Power Connections

Serial Connectors (J2)

Ethernet Connector (J4) (EP-Pxx only)

Motor Power Connections

Model Number, Part Number, Revision and Serial Number Label

Sync Input Connector (J10)

Digital I/O Connector (J3)

Profibus Connector (J13) (EP-PPB only)

Analog/Sync Output Connector (J5)

Encoder Feedback Connector (J6)

Figure 2: Epsilon EP216 Drive Feature Location

Epsilon EP drives are rated at 240 Vac input voltage and can operate with an input voltage from 20 Vac to 264 Vac. The EP drives are available in five current ratings.

Drive Model Continuous Power Rating Continuous Current Peak Current

Epsilon EP202 775 W 2.2 A RMS 4.4 A RMS Epsilon EP204 1275 W 4.0 A RMS 8.0 A RMS Epsilon EP206 1775 W 6.5 A RMS 13.0 A RMS Epsilon EP209 2325 W 9.0 A RMS 18.0 A RMS Epsilon EP216 4800 W 16.0 A RMS 32.0 A RMS

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Installation

Installation of the Epsilon EP drive is completed by following a simple step-by-step process. The Epsilon EP installation begins by mounting the drive to a metal mounting panel. Next, the high power connections are made to the drive, then the low power connections are made.

Step 1: Basic Installation and Panel Layout, page 3 Step 2: Mechanical Installation, page 8 Step 3: High Power Connections, page 13 Step 4: Low Power Connections, page 31

Step 1: Basic Installation Guidelines

You are required to follow all safety precautions during start-up such as providing proper equipment grounding, correctly fused power and an effective Emergency Stop circuit which can immediately remove power in the case of a malfunction. See the "Safety Considerations" section for more information.

Electromagnetic Compatibility (EMC)

Drives are designed to meet the requirements of EMC. Under extreme conditions a drive might cause or suffer from disturbances due to electromagnetic interaction with other equipment. It is the responsibility of the installer to ensure that the equipment or system into which the drive is incorporated complies with the relevant EMC legislation in the country of use.

The following instructions provide you with installation guidance designed to help you meet the requirements of the EMC Directive 89/336/EEC.

Adhering to the following guidelines will greatly improve the electromagnetic compatibility of your system, however, final responsibility for EMC compliance rests with the machine builder, and Control Techniques Americas LLC cannot guarantee your system will meet tested emission or immunity requirements.

If you need to meet EMC compliance requirements, EMI/RFI line filters must be used to control conducted and radiated emissions as well as improve conducted immunity.

Physical location of these filters is very important in achieving these benefits. The filter output wires should be kept as short as practical and routed away from the filter input wires. In addition:

• Choose an enclosure made of a conductive material such as steel, aluminum or stainless steel.

• Devices mounted to the enclosure mounting plate, which depend on their mounting surfaces for grounding, must have the paint removed from their mounting surfaces and the mating area on the mounting plate to ensure a good ground. See “Achieving Low Impedance Connections” on page 3 for more information.

• If grounding is required for cable grommets, connectors and/or conduit fittings at locations where cables are mounted through the enclosure wall, paint must be removed from the enclosure surface at the contact points.

• Cables should be shielded, and all shields must be grounded to the enclosure.

To meet radiated emissions requirements, the enclosure door must be closed and have electrical conduction at hinges and closure hardware or be fitted with a conductive gasket. Route cables away from the door where possible to minimize coupling emissions to door where they can re-radiate. The door generally must be bonded to the enclosure for electrical safety, but this is not sufficient to meet EMC.

Achieving Low Impedance Connections

Noise immunity can be improved and emissions reduced by making sure that all the components have a low impedance connection to the same ground point. A low impedance connection is one that conducts high frequency current with very little resistance. Impedance cannot be accurately measured with a standard ohmmeter, because an ohmmeter measures DC resistance. For example, a 12 inch long 8 gauge round wire has a significantly higher impedance than a 12 inch long 12 gauge flat braided conductor. A short wire has less impedance than a long one.

Multiple connections such as at the four corners of a plate provide much lower impedance than a single connection. Straight line connections provide much lower impedance than ones with bends or corners.

Low impedance connections can be achieved by bringing large areas of conductive surfaces into direct contact with each other. In most cases this requires paint removal because a ground connection through bolt threads is not sufficient. However, component materials should be conductive, compatible and exhibit good atmospheric corrosion

Installation 3

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resistance to prevent loss through corrosion that will hinder the low impedance connection. Enclosure manufacturers offer corrosion resistant, unpainted mounting plates to help.

Bringing components into direct contact cannot always be achieved. In these situations a conductor must be relied upon to provide a low impedance path between components. Remember a flat braided wire has lower impedance than a round wire of a large gauge rating.

A low impedance connection should exist between the following components, but not limited to:

• Enclosure and mounting plate

• Enclosure and door, if door does not have RF gaskets

• Servo drive chassis and mounting plate

• EMI/RFI AC line filter chassis and mounting plate

• Other interface equipment chassis and mounting plate

• Cable shields and enclosure, or terminal block, or connector

• Enclosure and conduit fittings or electrical connectors

• Enclosure mounting plate and earth ground

• Motor frame and conduit fittings or electrical connectors

• Encoder chassis and electrical connector

Options and Accessories

Specification

Electrostatic Discharge (ESD) Protection

Do not allow ESD to the drive while operating.

Though no damage occurs with electrostatic discharge at levels tested for EMC compliance, ESD directly to the drive cover can interrupt proper drive operation. ESD to terminals on the breakout boards has not been evaluated because wiring to these terminals is a maintenance activity. When doing any maintenance activity, make sure static electric charge is drained off by touching the enclosure away from the drive before contacting the drive or its wiring terminals. Use of ground straps or other techniques to prevent static buildup is a necessary part of any maintenance activity.

Environmental Considerations

The drive is rated to operate only in a pollution degree 2 environment, meaning that normally only non-conductive pollution occurs and there is no condensation, but occasional condensation may occur when not operating.

If the installation environment contains atmospheric contaminants such as moisture, oils, conductive dust, chemical contaminants and metallic particles, you must mount it vertically in a metal NEMA type 12 enclosure.

To prevent operation with condensation present, it is best to energize the logic power several minutes before applying main power or keep logic power applied continuously.

If the ambient temperature inside the enclosure will exceed 40°C (104°F), you must consider forced air cooling.

It is necessary to maintain the drive surrounding air temperature at 40°C (104°F) or 50°C (122ºF) with appropriate derating or below to maintain the drive UL ratings. See “Specifications” on page 65.for derating by model.

The amount of cooling depends on the size of the enclosure, the thermal transfer of the enclosure to the ambient air and the amount of power being dissipated inside the enclosure. Consult your enclosure manufacturer for assistance with determining cooling requirements.

The power dissipated by a EP202-P is 35 W, a EP204-P is 55 W, a EP-206-P is 85 W, a EP209-P is 115 W and a EP216 is 200 W. The power dissipation values includes up to 12 W of power from the logic power supply.

Wiring Notes

• To avoid problems associated with EMI (electromagnetic interference), you should route high power lines (AC input power and motor power) away from low power lines (encoder feedback, serial communications, etc.).

Safety Information Product Overview Installation Diagnostics

• If a neutral wire (not the same as Earth Ground) is supplied from the building distribution panel, it should never be bonded with PE wire in the enclosure.

• You should consider future troubleshooting and repair when installing all wiring. All wiring should be either color coded and/or tagged with industrial wire tabs.

Options and Accessories

Specification

• As a general rule, the minimum cable bend radius is ten times the cable outer diameter.

• All wiring and cables, stationary and moving, must be protected from abrasion.

• Ground wires should not be shared or "daisy-chained" with other equipment.

• Ensure that full metal to metal surface contact is made between the enclosure ground lug and the metal enclosure, not simply through the mounting bolt and threads.

• All inductive coils must be suppressed with appropriate devices, such as diodes or resistor/capacitor (RC) networks, except as described in this manual.

• If using a non-shielded Ethernet cable, install a clamp on ferrite, Control Techniques part number 157016-07, Steward 28A0593-0A2 or equivalent.

Installation 5

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Panel Layout

Options and Accessories

Specification

Metallic Raceway

C In

External Encoder

Fuses

NEMA Enclosure

Filter

Through wall shield grommets

Customer supplied terminal strip (optional) Connect shield through and to mounting plate

Motor

Motor Feedback Cable

Motor Power Cable

Bonded to mounting plate and enclosure wall

Drive

Figure 3: AC Filter and Cable Connections

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Options and Accessories

Specification

Cable to Enclosure Shielding

Shielded motor, feedback, serial communications and external encoder cables were used for compliance testing and are necessary to meet the EMC requirements. Each cable shield was grounded at the enclosure wall by the type of grommet described earlier and shown in the following figure.

Outside Enclosure

O-Ring seals against outside of enclosure

to meet IP68 (comparable to NEMA 6)

Spring Contacts

Cable Shielding

Cable Jacket

Figure 4: Through Wall Shield Grommet

Inside Enclosure

When Lock Nut is tightened to inside of enclosure, lock nut will cut through varnished, anodized, and powder coated finishes. Tighten lock nut so it cuts through the finish and into housing.

Remove 1/2 to 1 inch of cable jacket. The Spring Contacts will make a continuous electrical path from the shield of the cable to equipment ground.

After tightening lock nut and positioning cable so that Spring Contacts are contacting the cable shield, tighten Cable Seal Housing.

Cable Type Cable Model

Shielded Cable Grommet

Kit Model

Actual Hole Size

Motor Cable, 18 Ga XTMDS CGS-047 0.8125 or 13/16"

Motor Cable, 16 Ga

CMDS CGS-047 0.8125 or 13/16"

4X16SS CGS-047 0.8125 or 13/16"

Motor Cable, 18 Ga XCMDS CGS-047 0.8125 or 13/16"

Motor Cable, 12 Ga

Feedback Cable

Flex Motor Cable, 16 Ga

Flex Motor Cable, 12 Ga

CMMS CGS-069 1.125 or 1 1/8"

4X12SS CGS-069 1.125 or 1 1/8"

CFOS CGS-047 0.8125 or 13/16" MGFS CGS-047 0.8125 or 13/16" CMDF CGS-047 0.8125 or 13/16"

4X16SF CGS-047 0.8125 or 13/16"

CMMF CGS-069 1.125 or 1 1/8"

4X12SF CGS-069 1.125 or 1 1/8"

CFCF CGS-069 1.125 or 1 1/8"

Flex Feedback Cable

CFOF CGS-069 1.125 or 1 1/8"

MGFF CGS-069 1.125 or 1 1/8"

External Encoder ENCO CGS-047 0.8125 or 13/16"

AC Power user supplied user supplied user supplied

Installation 7

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Options and Accessories

Specification

AC Line Filters

The AC line filters are necessary to comply with EMC emission and immunity standards. The drive was tested with the filters presented in the table below and recommended by Control Techniques.

Epsilon EP Part # Control Techniques Part # Rating

EP202, EP204

EP206 Sch affner FS5278-16/08 960305-01 EP209 Corcom 20EQ1 960308-01 20 A, 240 V, 1 Ø EP216 Schaffner FN3258-16-44 960310-01 16 A, 480 V, 3 Ø

The following filters are a suitable alternative:

Epsilon EP Part # Control Techniques Part # Rating

EP202 Schaffner FN2070-6/06 6 A, 240 V, 1 Ø

EP202, EP204, EP206 Corcom 20EQ1 20 A, 240 V, 1 Ø

EP206 Schaffner FN2070M-16/08 16 A, 240 V, 1 Ø EP209 Schaffner FN2070-25/08 25 A, 240 V, 1 Ø

EP216

AC Line Filter Installation Notes

• It is important to keep the filter inputs routed away from any electrical noise sources.

• EMC criteria can be met in installations where multiple drives are supplied through a single filter, however, it is the installers responsibility to verify EMC compliance.

Schaffner FN2070-10/06 960307-01 10 A, 240 V, 1 Ø Schaffner FS5278-16/08 960305-01

Schaffner FN3270H-20-29 20 A, 480 V, 3 Ø

Schaffner FN258/16 960304-01 16 A, 480 V, 3 Ø

16 A, 240 V, 1 Ø

Step 2: Mechanical Installation

The drive must be back mounted vertically on a metal mounting panel such as a NEMA enclosure, Additional space is necessary above and below the drive for wiring and cable connections.

To allow sufficient air flow for cooling, leave at least 0.25" [6.3 mm] clear space on vented cover (left) side plus 0.50" [12.7 mm] on heatsink (right) side. Leave additional space if cables are routed through this space.

When drilling holes in mounting plate or trimming wires during installation of this or other equipment, do not allow drill shavings or wire trimmings to enter the EP drive. Such foreign objects can compromise electrical isolation creating a hazard or result in equipment failure.

Safety Information Product Overview Installation Diagnostics

The following table applies to the "A" dimension as shown in figure 5 below for the EP202 - EP206 base and indexing drives.

Options and Accessories

Specification

Drive Model

Dimension "A"

inches [mm]

Minimum Panel Width

EP202-B, -I, -IDN 2.11 [53. 59] 2.90 [74] EP204-B, -I, -IDN 2.11 [53. 59] 2.90 [74] EP206-B, -I, -IDN 2.82 [71.63] 3.60 [91]

5.94

[150.88]

5.22

[132.59]

.200

[5.08]

8.099

[205.72]

7.70

[195.58]

inches [mm]

2.11

[53.59]

1.20

[30.48]

0.45

[23.4]

“A”

(4X)Ø.219

[5.56]

Figure 5: Mechanical Drawing for Epsilon EP202-206 Base and Indexing Drives

Installation 9

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Options and Accessories

Specification

The following table applies to the "A" dimension as shown in figure 6 for the EP202 - EP206 programming drives.

Drive Model

Dimension "A"

inches [mm]

Minimum Panel Width

EP202-P, -PDN, -PPB 2.69 [68.3] 3.45 [88] EP204-P, -PDN, -PPB 2.69 [68.3] 3.45 [88] EP206-P, -PDN, -PPB 3.40 [86.4] 4.15 [105]

5.94

[150.88]

5.22

[132.59]

.200

[5.08]

8.099

[205.72]

7.70

[195.58]

inches [mm]

2.69

[68.3]

1.20

1.03 [30.48]

[26.16]

“A”

(4X)Ø.219

[5.56]

Figure 6: Mechanical Drawing for Epsilon EP202-206 Programming Drive

To prevent drive from dropping out of position during installation, partially pre-install lower mounting screws, then set drive in place with lower mounting screws in slots and then install at least one upper mounting screw. For removal, loosen lower screws, remove upper screws and lift drive out.

Safety Information Product Overview Installation Diagnostics

The following table applies to the minimum panel width for the EP209 drive.

Options and Accessories

Specification

5.86

[148.85]

Drive Model

Minimum Panel Width

inches [mm]

EP209-B, -I, -IDN, -P, -PDN, -PPB 4.15 (105)

5.94

[150.88]

5.23

[132.84]

9.60

[243.84]

0.20 [5.08]

9.20

[233.68]

1.03

[26.16]

2.69

[68.33]

3.40

[86.36]

1.20

[30.48]

4X Ø.219

EP209-XXX-XX00 9606XX-XX A1 SN 0610E014

Figure 7: Mechanical Drawing for All Epsilon EP209 Models (EP209-PDN shown)

Installation 11

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The following table applies to the minimum panel width for the EP216 drive.

Options and Accessories

Specification

Drive Model

Minimum Panel Width

inches [mm]

EP216-B, -I, -IDN, -P, -PDN, -PPB 4.15 (105)

5.96

[151.38]

5.23

[132.84]

9.60

9.20

[243.84]

[233.68]

1.03

[26.16]

3.40

[86.36]

1.20

[30.48]

Figure 8: Mechanical Drawing for All Epsilon EP216 Models (EP216-PDN shown)

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Step 3: High Power Connections

System Grounding

To insure a safe and quiet electrical installation, good system grounding is imperative. The figure below is an overview of the recommended system grounding. For more information on achieving an electrically quiet installation refer to “Step 1: Basic Installation Guidelines” on page 3.

Conduit or

Metal

Raceway

AC Power Supply

Enclosure

To Enclosure Door

Door Bond Wire

Redundant PE Connection

Conduit Raceway Bond

Single Point Ground

(Bonded to Enclosure)

Fuses

3 Phase

Line Power

Connection

Epsilon EP

reset

serial (J2)

+ _

logic motor

3 MIN

digital i/o (J3)

EP204-I00-0000 9606XX-XX A1 SN 0610E014

J6J5J10

Epsilon

EP202-206

Drive

Control

Transformer

Output

Neutral Hot

Convenience

Outlet

Logic Power Supply

24 Vdc

+ -

Epsilon

EP209

Drive

EMERSON

Industrial Automation

Epsilon

Drive

Connection

EP209-I00-0000 9606XX-XX A1 SN 0610E014

Motor Motor

NOTE: The aluminum heatsink is electrically connected to the PE terminal.

Figure 9: Typical System Grounding Diagram

Installation 13

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Options and Accessories

Specification

Fixed Protective Earth (PE) connections are mandatory for human safety and proper operation. These connections must not be fused or interrupted by any means. Failure to follow proper PE wiring can cause death or serious injury. This equipment has high earth leakage current and requires a redundant PE connection from either terminal marked PE at J8 to PE connection point.

AC Power Requirements

The Epsilon EP drives require 20 Vac to 264 Vac single phase power but, may operate on DC supplies, (See Operation on DC Supply). An Epsilon EP drive can be connected to any pair of power phases on a 1 Ø or 3 Ø power source that is grounded as shown in the following diagrams. Local electrical codes should be consulted before installation.

When operating the drive at 90 V or less disable the Low DC Bus fault so the drive does not fault.

Where regeneration occurs, bus voltage will rise to 400 Vdc before shunt operation or a High DC Bus fault limit voltage, whether shunt resistor is installed or not. Motors must have insulation rated for inverter duty at 240 Vac no matter what the operating voltage is, or bus voltage must be limited by other means.

The maximum voltage applied to the drive terminals must not exceed 264 Vac phase to phase and phase to PE ground. The AC supply must be earthed (type TN) with PE connected to the earthed point at the source, which is usually a distribution transformer but could be a service entrance.

AC Supplies NOT Requiring Transformers

If the distribution transformer is configured as shown in the figures below, the AC power supply can be connected directly to the drive terminals.

DISTRIBUTION PANEL

SECONDARY

EARTH GROUND

Typ. 208 Vac

120 Vac

(Protective Earth)

Neutral is used only when 120 Vac operation is desired. It is never fused.

L1 PE

To Fusing and Drive Terminals

Figure 10: Earth Grounded WYE Distribution Transformer, 120/208Y 3Ø

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DISTRIBUTION PANEL

Options and Accessories

Specification

SECONDARY

230 Vac

No Fuse

EARTH GROUND

NOTE: For single phase drives using lines L1 & L2 or L1 & L3, only one fuse is required on the high leg (L2 or L3). Lines L2 & L3 may be used to balance the load, requiring two fuses.

(Protective Earth)

(N)

To Fusing and Drive Terminals

Figure 11: Earth Grounded Delta Distribution Transformer, 240 Vac 3Ø

DISTRIBUTION PANEL

SECONDARY

Typ. 240 Vac

EARTH GROUND

Used only for 120 Vac operation

NOTE: L3 is a high leg, 208 Vac from Neutral/PE. For single phase drives it is best to use lines L1 and L2. L1 & L3 or L2 & L3 maybe used to balance loads.

(Protective Earth)

with L1 or L2.

Figure 12: Three Phase Delta (with mid-phase GND) Distribution,

120 Vac split/240 Vac 3Ø supply

AC Supplies Requiring Transformers

If the distribution transformer is configured as shown in the figures below, an isolation transformer is required. If an isolation transformer is used between the power distribution point and the drives, the transformer secondary

must be grounded for safety reasons as shown in the figures below.

Installation 15

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DISTRIBUTION PANEL 3 Ø Isolation Transformer

Options and Accessories

To Fusing and Drive Terminals

L1 N

EARTH GROUND

(Protective Earth)

Figure 13: Three-Phase WYE (ungrounded) Distribution to a Three-Phase Delta/WYE

Isolation Transformer

Specification

DISTRIBUTION PANEL

EARTH GROUND

3 Ø Isolation Transformer

(Protective Earth)

No Fuse

To Fusing and Drive Terminals

Figure 14: Three-Phase Delta (ungrounded) Distribution to a Three-Phase Delta

Isolation Transformer

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DISTRIBUTION PANEL 3 Ø Isolation Step Down Transformer

Options and Accessories

Specification

> 140 Vac

EARTH GROUND

(Protective Earth)

To Fusing and Drive Terminals

L1 N

Figure 15: Grounded WYE Distribution >140 Vac Phase to Neutral. Recommend Using

Step Down Transformer so Line to Line is 240 Vac or less.

Fuse

To Drive Terminal

Figure 16: Single Phase Power Supply Connections

Transformer Sizing

If your application requires a transformer, choose a transformer with a continuous power rating greater then the maximum power usage of the drive/motor combination. Other factors that may influence the required KVA rating are high transformer ambient temperatures (>40° C or >104° F) and drive operation near the maximum speeds.

Transformer output voltage drop may become a limiting factor at motor speeds and loads near maximum ratings. Typically, higher KVA transformers have lower voltage drop due to lower impedance.

When multiple drives are connected to a single isolation transformer, add the suggested KVA ratings of the drives that would be operating simultaneously together for transformer sizing.

Installation 17

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Options and Accessories

Specification

Line Fusing and Wire Size

You must incorporate over current protection for the incoming AC power with the rating shown here. The drive alone does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local codes.

Fuse Miniature Circuit Breaker

Ferraz-

Shawmut

Allen Bradley Square D

1489-A1D060

6 A, 1 pole

1489-A2 D060

6 A, 2 pole

1489-A1D100

10 A, 1 pole

1489-A2D100

10 A, 2 pole

1489-A1D150

15 A, 1 pole

1489-A2D150

15 A, 2 pole

1489-A1D200

20 A, 1 pole

1489-A2D200

20 A, 2 pole

1489-A1D200

20 A, 1 pole

1489-A2D200

20 A, 2 pole

1489-A3D200

20 A, 3 pole

60124

6 A. 1 pole

60158

6 A, 2 pole

60127

10 A, 1 pole

60161

10 A, 2 pole

60129

15 A, 1 pole

60163

15 A, 2 pole

60130

20 A, 1 pole

60164

20 A, 2 pole

60130

20 A, 1 pole

60164

20 A, 2 pole

60196

20 A, 3 pole

Drive Model

EP202

EP204

EP206

EP209

EP216

Recommended Minimum AC/PE Line Wire Gauge

16 AWG

ISO 1,5

16 AWG

ISO 1,5

14 AWG

ISO 2,5

12 AWG

ISO 4

12 AWG

ISO 4

Fuse Class & Action Bussman

RK1 Time-Delay LPN-RK-6SP A2D6R

RK1 Quick-Acting KTN-R-6 A2K6R

CC Time-Delay LP-CC-6 ATDR6

CC Quick-Acting KTK-R-6 ATMR6

RK1 Time-Delay LPN-RK-10SP A2D10R

RK1 Quick-Acting KTN-R-10 A2K10R

CC Time-Delay LP-CC-10 ATDR10

CC Quick-Acting KTK-R-10 ATMR10

RK1 Time-Delay LPN-RK-15SP A2D15R

RK1 Quick-Acting KTN-R-15 A2K15R

CC Time-Delay LP-CC-15 ATDR15

CC Quick-Acting KTK-R-15 ATMR15

RK1 Time-Delay LPN-RK-20SP A2D20R

RK1 Quick-Acting KTN-R-20 A2K20R

CC Time-Delay LP-CC-20 ATDR20

CC Quick-Acting KTK-R-20 ATMR20

RK1 Time-Delay LPN-RK-20SP A2D20R

RK1 Quick-Acting KTN-R-20 A2K20R

CC Time-Delay LP-CC-20 ATDR20

CC Quick-Acting KTK-R-20 ATMR20

Use copper conductors only. Conductors must be rated 75°C or higher, preferably 90°C. Suitable for use on a circuit capable of delivering not more than 10,000 rms symmetrical Amperes. When one of the

above current protection devices are used.

The Protective Earth (PE) wire connection is mandatory for human safety and proper operation. This connection must not be fused or interrupted by any means. Failure to follow proper PE wiring can cause death or serious injury.

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Options and Accessories

Specification

Drive Model Input Voltage (Vac)

EP202

EP204 8.5 65 (5 ms)

EP206 12.0 100 (5 ms)

EP209 16.0 34 (5 ms)

EP216

This inrush current specification assumes the drive has been powered off for at least 8 minutes at 40ºC (104ºF) ambient or 5 minutes at 25ºC (77ºF) ambient. If this amount of time has not elapsed since power off, the inrush current will be higher. Exception is the EP209 and EP216, they use active inrush limiting. Listed inrush current is

240 / 1 Ø

240 / 3 Ø or

240 / 1 Ø

Frequency

(Hz)

47 - 63

Input Current (Amps RMS) at

Full Drive Output Current

5.0 40 (5 ms)

16.0 34 (5 ms)

Inrush Current

(Amps)

maximum.

AC Input Power Connections

Power must be "Off" for a minimum of 6 minutes for the Epsilon EP206, EP209 and EP216 drives and 3 minutes for the Epsilon EP202 and EP204 drives before unplugging the power connection. This will ensure the bus voltage has bled down to a safe level (below 50 Vdc).

Do not connect or disconnect AC power by inserting or removing the AC power connector. Using the connector in this manner, even once, will damage the connector making it unusable.

Installation 19

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B-

Front View

PE SH PE

B+

Options and Accessories

Redundant PE connection

Specification

EP204-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

24 Vdc

Terminals are suitable for one 16 AWG to 12 AWG

Tighten screws

to 5 in-lb.

or ISO 1,5 or ISO 2,5 stranded conductors.

* Note: If L2 is 120 Vac neutral it should not be fused.

Figure 17: Epsilon EP202-206 AC Power Wiring Diagram

B-

PE SH PE

B+

Redundant PE connection

50/60 Hz

90-264 Vac

L1 L2

50/60 Hz

90-264 Vac

Tighten screws

to 5 in-lb.

EP209-I00-0000 9606XX-XX A1 SN 0610E014

Terminals are suitable for one 16 AWG to 12 AWG

or ISO 1,5 or ISO 4 stranded conductors.

* Note: If L2 is 120 Vac neutral it should not be fused.

Figure 18: Epsilon EP209 AC Power Wiring Diagram

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Options and Accessories

Specification

B-

PE SH PE

B+

Redundant PE connection

MOTOR

Terminals are suitable for one 16 AWG to 10 AWG

or ISO 1,5 to ISO 6 stranded conductors.

* Note: If L2 or L3 is 120Vac Neutral it should not be fused.

Tighten screws

to 5 in-lb.

Figure 19: Epsilon EP216 AC Power Wiring Diagram

L2*

50/60 Hz

90-264 Vac

L3*

Operation on DC Input Supply

At this time, the EP drive is NOT UL listed for operation on a DC input supply,

The Epsilon EP202, EP204 and EP206 drive can operate on DC input as low as 20 Vdc, recommended minimum is 24 Vdc. The Epsilon EP209 and EP216 drive’s minimum is 140 Vdc. It can also operate from a common DC link with voltage to 373 Vdc, the voltage resulting from 264 Vac applied to a rectifier, with regen to 400 Vdc intermittently.

For DC input supply less than 24 Vdc, the DC input should be connected to the B+ and B- terminals at J8 to avoid losses in the rectifier and inrush limiter. At such low voltages the bus caps do not need inrush protection. For DC supply greater than 24 Vdc, the supply should be connected to L1 and L2 terminals on J1. Polarity does not matter. The rectifier blocks reverse current so regen energy will not come back to the supply. DC supply greater than 24 Vdc may be applied to the B+ and B- terminals of J8, but the supply must provide soft-start or inrush current limiting and must be able to handle any anticipated regen energy.

Both supply conductors must be fused except one that is grounded. The fuse must be rated for at least the voltage applied. The current rating of the fuse should match the rated output current of the drive. A slow-blow fuse should be used if high peak loads are expected.

Please contact Technical Support at Control Techniques Americas before connecting any EP drives with a common DC link.

Installation 21

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Options and Accessories

Specification

External Shunt Electrical Installation

Shunt connections at J8 remain at dangerous Voltages after disconnecting AC Power. Power must be "Off" for a minimum of 6 minutes for an EP206/209/216 and 3 minutes for an EP202/204 before touching these terminals.

The EP204, EP206, EP209, and EP216 drives provide an internal shunt transistor to direct regen energy to an external shunt or braking resistor. The resistor is connected to the B+ and SH terminals at J8 on the top of the drive.

Shunt Control

The shunt transistor turns on when the bus voltage reaches 405 Vdc and shuts off when the bus voltage falls below 390 Vdc. An internal shunt control algorithm is used to prevent the external shunt resistor from overloading. It is necessary to enter shunt energy rating, power rating and resistance for the attached shunt resistor in PowerTools Pro software. Energy rating is the amount of energy that the resistor can absorb in a single shunt event assumed to be so short that power dissipation is negligible. Power rating is the long term average power that can be dissipated. PowerTools Pro default values are for the Control Techniques "SM-Heatsink DBR-1" resistor kit, marked P/N 12202756-01 on the resistor.

External Shunt Resistor

Control Techniques offers an external shunt resistor kit, SM-Heatsink DBR-1, that attaches directly to the EP drive heatsink. The resistance is 75 Ohms and has 1500 Joule energy rating and 50 W continuous power rating. It is adequate for most infrequent machine stop sequences due to relatively high energy rating for its power rating. It should be suitable for any EP204 application unless average power exceeds 50 W for repetitive cycles. For EP206, EP209 and EP216, some applications may require lower resistance to prevent a high bus fault or higher energy rating for a single event, as well as higher average power rating. The resistor in the kit is designed to eventually open in the event of a shorted control transistor when operating with an AC input greater than 200 Vac. At this time the kit should be used only when the drive is operating at 200 Vac to 240 Vac.

A different external shunt resistor should be used if average power is above 50 W, or other limits are exceeded as described above. Higher power resistors should be mounted away from the drive to prevent overheating. If thermal loading inside a cabinet is an issue, a resistor with suitable enclosure may be installed external to the drive enclosure. The minimum resistance for an external shunt resistor is 33 Ohms. The resistor must have thermal overload protection to remove power in the event of a shorted control transistor. The protection can simply open the circuit, in which case a high bus fault will occur, or be wired to a contactor that isolates input power from the drive on overtemp.

Shunt Resistor Kit Installation

The SM-Heatsink DBR-1 attaches to the side of the EP204, EP206, EP209, or EP216 drive by lining up the two captive screws to the special width slots in the heat sink. The exact position along the slot does not matter as long as the body of the resistor does not extend beyond the top or bottom of the drive. Use a T-20 Torx driver to thread the screws into position. After both are well started but not tight, carefully turn each screw until it is seated against the resistor and the resistor back is seated against the heat sink. Then turn the screw 1/8 turn more. Do not overtighten.

Strip 0.12 inch [3.0 mm] insulation from the ends of the resistor wires. Install the wires in the SH and B+ terminals of J8 and tighten to 5 in-lb. Make sure the locking screws are installed on J8 to prevent the connector from pulling out.

Safety Information Product Overview Installation Diagnostics

Options and Accessories

SELF TAPPING SCREW (2)

Specification

B-

B+

Figure 20:Shunt Resistor Installation for the Epsilon EP and SM-Heatsink DBR-1 Kit

Do Not make any shunt resistor connections to B-.

Shunt connections are at main voltage potential. Components connected must be rated for the voltage and selected for safety. The external shunt resistor must have protection for a failed ON state of the shunt control.

Installation 23

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Motor Power Wiring

The following paragraphs provide details of motor connections. When motor power cables are long, 100ft. [30 m], a ferrite (Control Techniques p/n 157016-13, Steward p/n 28A3851-0A2 or equivalent) installed on the three phase conductors but not the shield, near J1 can significantly reduce high frequency switching harmonics that in some cases can cause communications and encoder errors, see figures below. Maximum cable length is 200 ft [60 m]. With the Epsilon EP202/204/206/209 drive the J1 terminals are suitable for one 18 AWG to 14 AWG or ISO 0,75 to ISO 2,5 stranded conductors. The Epsilon EP216 drive J1 terminals are suitable for one 16 AWG to 10 AWG or ISO 1,5 to ISO 6 stranded conductors. The ground/shield terminal may contain the shield and ground conductors together if each is 16 AWG or ISO 0,75 or ISO 1,5. Otherwise a ferrule must be used to crimp both connectors together.

Front View

EP204-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

24 Vdc

Ferrite

Motor

Power Connections

Ground

Connector Shell

Figure 21: EP202-206 Ferrite Placement with Cable Lengths Longer Than 100 FT.

Front View

EP209-I00-0000 9606XX-XX A1 SN 0610E014

Ferrite

MOTOR

logic

Motor

Power Connections

Ground

Connector Shell

Figure 22: EP209 Ferrite Placement with Cable Lengths Longer Than 100 FT.

Safety Information Product Overview Installation Diagnostics

Front View

Options and Accessories

Specification

MOTOR

Ferrite

Motor

Power Connections

Ground

Connector Shell

Figure 23: EP216 Ferrite Placement with Cable Lengths Longer Than 100 FT.

Installation 25

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

NT and MG Motors

NT and MG motors are equipped with up to three male MS (Military Standard) connectors, one for stator connections, one for encoder connections and one for the brake (if so equipped).

Stator connections from the drive to the motor are made with the CMDS or CMMS cable have a female MS style connector on the motor end and four individual wires and shield that connect to the motor power connector on the front of the drive.

The motor ground wire and shields must be run all the way back to the drive terminal and must not be connected to any other conductor, shield or ground except the enclosure wall for EMC.

Wire crimp ferrules are recommanded: For ground lead use Pheonix Contact p/n AI-TWIN 2X1, 5-8Bk/32 00 82 3 American Electrical/DigiKey 1381015/288-1130-ND For motor leads use Pheonix Contact p/n AI 1,5-8 RD/32 01 13 6 or

Front View

EP204-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

24 Vdc

ALTEC p/n H1.5/14 2204.0 Pk/100

Brown Black Blue Green/Yellow

Shield

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

Tighten screws to 5 in-lb.

NT or MG Motor

Power Connection

Ground

Connector Shell

2" and 3" motor cable connector (CMDS-xxx cable)

Figure 24: Epsilon EP202-EP206 Drive - NT/MG Motor Power Wiring Diagram

Safety Information Product Overview Installation Diagnostics

Front View

Options and Accessories

NT or MG Motor

Power Connection

Specification

Brown Black Blue Green/Yellow

Shield

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

Ground

Connector Shell

2" and 3" motor cable connector (CMDS-xxx cable)

EP209-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

logic

Tighten screws to 5 in-lb.

Figure 25: Epsilon EP209 - NT/MG Motor Power Wiring Diagram

Front View

MOTOR

ALTEC p/n H1.5/14 2204.0 Pk/100

Brown

Black

Blue

Green/Yellow

Shield

NT or MG Motor

Power Connections

Ground

Connector Shell

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

3" motor cable connector (CMDS-xxx cable)

Figure 26: Epsilon EP216 - NT/MG Motor Power Wiring Diagram

Installation 27

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

XV Motor Power Wiring

The XV 40 mm to 80 mm motors are equipped with up to three connectors, one for stator connections, one for encoder connections and one for the brake (if so equipped).

Stator connections from the drive to the motor are made using the XTMDS cable, the motor end of the cable has an Amp "Mate-N-Lok"® connector and the drive end has four individual wires and shield that connect to the motor power connector on the front of the drive.

Front View

EP204-I00-0000 9606XX-XX A1 SN 0610E014

Figure 27: Epsilon EP202-EP206 - XV 40 mm - 80 mm Motor Power Wiring Diagram

MOTOR

24 Vdc

Wire crimp ferrules are recommanded: For ground lead use Pheonix Contact p/n AI-TWIN 2X1-8RD/32 00 81 0 or American Electrical/DigiKey 1381010/288-1127-ND For motor leads use Pheonix Contact p/n AI 1-RD/32 00 03 0 or American Electrical/DigiKey 1181010/288-1015-ND

XVM 40M, 60M, 80M Motor

Power Connection

Brown Black Blue Green/Yellow

Shield

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

Tighten screws to 5 in-lb.

Ground

Connector Shell

motor cable connector (XTMDS-xxx)

Front View

EP209-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

logic

XVM 40M, 60M, 80M Motor

Power Connection

Brown Black Blue Green/Yellow

Shield

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

Ground

Connector Shell

motor cable connector (XTMDS-xxx)

Tighten screws to 5 in-lb.

Figure 28: Epsilon EP209 - XV 40 mm - 80 mm Motor Power Wiring Diagram

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Front View

MOTOR

American Electrical/DigiKey 1181010/288-1015-ND

Brown

Black

Blue

Green/Yellow

Shield

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

XVM 40M, 60M, 80M Motor

Power Connections

Ground

Connector Shell

motor cable connector (XTMDS-xxx cable)

Figure 29: Epsilon EP216 - XV 40 mm - 80 mm Motor Power Wiring Diagram

The XV 130 mm motors have two MS (Military Standard) connectors, one for the stator connections and one for the encoder connections. Stator connections from the drive to the motor are made with the XCMDS (motor without brake) or the XCMDBS (motor with brake) cable.

Wire crimp ferrules are recommanded: For ground lead use Panduit p/n PV10-P55-L For motor leads use Pheonix Contact p/n AI 1,5-8 BU/32 00 52 2

Front View

XVM 130M Motor

Power Connection

motor cable connector (XCMDS-xxx)

Ground

Connector Shell

EP204-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

24 Vdc

Brown Black Blue Green/Yellow

Shield

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

Tighten screws to 5 in-lb.

Figure 30: Epsilon EP202-EP206 - XV 130 mm Motor Power Wiring Diagram

Installation 29

Safety Information Product Overview Installation Diagnostics

Front View

Wire crimp ferrules are recommanded: For ground lead use Panduit p/n PV10-P55-L For motor leads use Pheonix Contact p/n AI 1,5-8 BU/32 00 52 2

Options and Accessories

XVM 130M Motor

Power Connection

Specification

Brown Black Blue

Green/Yellow

Shield

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

Tighten screws to 5 in-lb.

Ground

Connector Shell

motor cable connector (XCMDS-xxx)

EP209-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

logic

Figure 31: Epsilon EP209 - XV 130 mm Motor Power Wiring Diagram

Front View

Wire crimp ferrules are recommanded: For ground lead use Panduit p/n PV10-P55-L For motor leads use Pheonix Contact p/n AI 1,5-8 BU/32 00 52 2

MOTOR

Brown

Black

Blue

Green/Yellow

Shield

XVM 1300M Motor

Power Connections

Ground

Connector Shell

Important: PE ground should connect to drive and motor only. Nothing should be connected between these devices.

motor cable connector (XCMDS-xxx cable)

Figure 32: Epsilon EP216 - XV 130 mm Motor Power Wiring Diagram

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Step 4: Low Power Connections

DC Logic Power Supply Wiring

The Epsilon drive requires a user supplied logic power supply, 24 Vdc ±10%, to power the internal logic of the drive. Use the table below to determine the current requirements of the application. Users should consider keeping logic power energized at all times because it helps prevent condensation and maintains position information in the drive.

Logic Power Supply Specification

Voltage Range Model Current

24 Vdc ±10%

(21.6 Vdc to 26.4 Vdc)

All EP Models except EP-Pxx

EP-Pxx

* All Epsilon EP216 models will draw an additional 100 mA.

Do not wire AC line into the logic power supply input. Doing so will damage the drive.

Front View

motor

+ _

logic

motor

+ _

logic

Fuse, if required

to protect wiring

0.50 A* without sync encoder

0.57 A* with 250 mA sync encoder

0.31 A* without sync encoder

0.38 A* with 250 mA sync encoder

24 Vdc

Logic Power Supply

(User Supplied)

24 Vdc 24 V RTN

Single point PE ground

EP204-I00-0000 9606XX-XX A1 SN 0610E014

Tighten screws

to 5 in-lb.

To other drives or equipment , I/O supplies, etc..

Figure 33: Logic Power Supply Wiring Diagram for EP202-EP206 Drives

Installation 31

Safety Information Product Overview Installation Diagnostics

Front View

Options and Accessories

Specification

EP209-I00-0000 9606XX-XX A1 SN 0610E014

MOTOR

logic

Tighten screws

to 5 in-lb.

Fuse, if required

to protect wiring

24 Vdc

Logic Power Supply

(User Supplied)

24 Vdc 24 V RTN

Single point PE ground

To other drives or equipment , I/O supplies, etc.

Figure 34: Logic Power Supply Wiring Diagram for EP209 Drive

Front View

Fuse, if required to protect wiring

logic

To other drives or equipment , I/O supplies, etc.

24 Vdc

Logic Power Supply

(User Supplied)

24 Vdc 24 V RTN

Single point PE ground

Figure 35: Logic Power Supply Wiring Diagram for EP216 Drive

Safety Information Product Overview Installation Diagnostics

For UL applications, the logic power supply must be a UL recognized or UL listed limited voltage/limited energy or limited voltage/limited current supply, or a limited voltage supply with overcurrent protection appropriate for the wiring and not to exceed 12 A. Isolate line connected circuits from low voltage circuits.

For applications to meet the EU Low Voltage Directive, an approved 24V supply must be used and the negative side must be grounded to PE. PELV circuits must have protective separation for 300 V system voltage from mains connected circuits, including separation between encoder circuits and motor power wiring. If all circuits connected to the logic supply are PELV, the wiring need not be isolated from direct contact within a zone of equipotential bonding, normally an enclosure or set of enclosures bonded together. Otherwise, logic wiring and circuits must be isolated from direct contact by basic insulation for 300 V system voltage.

In all applications, do not interconnect extra low voltage power supplies so that voltages add.

Options and Accessories

Specification

Motor Feedback Wiring (J6)

Encoder feedback connections are made with the 15-pin high density “D” connector (J6) on the drive. Maximum feedback cable length is 200 ft [60 m]. Voltage drop in encoder power connections is usually the limiting factor on encoder cable lengths.

Connection of Encoder Quadrature and Marker Signals

For A, A/, B, B/ and Z, Z/ pairs, Control Techniques cables use low capacitance (~10 pf/ft) wire to get a high characteristic impedance and low loss. The differential input circuit accepts RS-485 level signals, but if the differential voltage is less than ±400 mV, an encoder fault is generated.

Connection of Encoder Commutation Signals to the Drive

The drive is capable of receiving U, V, and W commutation signals from either a differential or single ended source. Figures 36 through 38 show a simplified circuit for the U, U/, V, V/, W, and W/ inputs on the drive. For single-ended encoder outputs, leave U/, V/, and W/ unconnected at the drive. No PowerTools configuration is required. U, V, and W have a 1K pull-up to 5V. Logic threshold is about 2.5 V with 0.1 V hysteresis.

Motor Overtemp Wiring

The motor overtemp circuit is compatible with PTC thermistor sensor with 2 k ohm resistance at the over temperature trip point. The circuit provides 5V open circuit and 0.5 mA closed contacts to an overload switch. For motors without over temperature protection sensors, pins 14 and 15 of J6 must be shorted together to prevent an overtemp fault in the drive. Fault turn-on threshold is 0.83V and fault turn-off (reset) threshold is approximately 0.41 V

Installation 33

Safety Information Product Overview Installation Diagnostics

NT/MG Motor

Options and Accessories

Specification

Internal

Motor

Thermal

Switch

NT or MG Motor

GND Motor

Overtemp

Overtemp GND

Connector Shell

+ 5 Vdc

Shield

K T A J L

X Y Z

Motor Feedback Cable

Model # UFCS-XXX

Green Brown

Blue

Orange

Black

Yellow White/Gray Gray/White

White/Brown Brown/White

Red/Orange Orange/Red

*Red/Blue

*Blue/Red Red/Green Green/Red

* = Note:18 ga Wire

= Twisted Pair

Epsilon EP

Drive

+5 Vdc

GND

Motor Overtemp

Single Point

Figure 36: Motor Encoder Feedback Connector Pinout

XV 40-80 mm Motor

3 4 1 2 5 6 9

8 11 12 13 14 15

Motor Feedback Cable

Model # XUFTS-XXX

Green Brown

Blue

Orange

Black

Yellow White/Gray Gray/White

White/Brown Brown/White

Red/Orange Orange/Red

*Red/Blue

*Blue/Red Red/Green Green/Red

Overall Shield Drain Wire

* = 18 ga Wire

= Twisted Pair

10 11 12 13 14 15

XVM 40mm, 60mm, and 80mm Motor

A A/ B

Z Z/ U U/ V

+ 5 Vdc

GND

Shield

Connector Shell

10 Ohm

Ground

Epsilon

Drive

V/ W

+5 Vdc

GND

Motor Overtemp

+5 V

10K

10 Ohm

Single Point

Ground

+5 V

220 Ohm

+5 V

10K

+5 V

Turn OFF: 0.41 V

+5 V

Differential

Receiver

Differential

Receiver

Fault Thersholds

Turn ON: 0.83 V

220 Ohm

Fault Thersholds Turn ON: 0.83 V

Turn OFF: 0.41 V

Figure 37: Motor Encoder Feedback Connection For XV 40-80 mm Motors

Safety Information Product Overview Installation Diagnostics

XV 130 mm Motor

Options and Accessories

Specification

C D A B E F M N K L P R H G J

Motor Feedback Cable

Model # XUFCS-XXX

Green

Brown

Blue

Orange

Black

Yellow White/Gray Gray/White

White/Brown Brown/White

Red/Orange Orange/Red

*Red/Blue

*Blue/Red Red/Green Green/Red

Overall Shield Drain Wire

* = 18 ga Wire

= Twisted Pair

Epsilon

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

Drive

A A/ B B/ Z Z/ U U/

V/ W

+5 Vdc

GND

Motor Overtemp

10 Ohm

+5 V

220 Ohm

+5 V

Fault Thersholds Turn ON: 0.83 V

+5 V

Turn OFF: 0.41 V

10K

XVM 130mm Motor

A A/ B

Z Z/ U U/ V

+ 5 Vdc

GND

Shield

Connector Shell

Single Point

Ground

Figure 38: Motor Encoder Feedback Connection For XV 130 mm Motors

Motor Brake Wiring

The NT and MG motors equipped with brakes have a three-pin MS style connector. The brake power cable (model CBMS-XXX) has an MS style connector on the motor end and three wire leads on the drive end (see the following wiring diagrams). The XV 40-80 mm motors with brakes have a two-position connector. The brake power cable (model XTBMS-XXX) has a two position connector on the motor end and three wire leads on the drive end. The XV 130 mm motors equipped with brakes have two MS style connectors; one is the encoder feedback and the other has the motor power and brake connections. The motor power/brake cable (model XCMDBS-XXX) has an MS style connector on the motor end and six wire leads on the drive end.

You must provide a DC power supply rated at +24 Vdc with a 2 A minimum current capacity for the brake. If you use this voltage source to power other accessories such as I/O or more than one brake, size the power supply for total load.

Installation 35

Safety Information Product Overview Installation Diagnostics

motor

logic

digital i/o (J3)

EP204-I00-0000 9606XX-XX A1 SN 0610E014

+ _

Output #3

Drive Enable

I/O Common

I/O Supply

Customer

supplied drive

enable contact

1 Amp

Fuse

2 Amp

Fuse

Relay:

Model# BRM-1

Options and Accessories

CBMS-xxx Cable

Black -

Red +

NT or MG

Motor

Specification

Internal

to Motor

Single point

PE ground

24 VDC

Figure 39: Epsilon EP to NT or MG Motor Brake Wiring Diagram

motor

+ _

logic

digital i/o (J3)

EP204-I00-0000 9606XX-XX A1 SN 0610E014

Output #3

Drive Enable

I/O Supply

I/O Common

Single point PE ground

Customer supplied drive enable contact

1 Amp

Fuse

2 Amp

24 VDC

Fuse

Relay:

Model# BRM-1

Black -

Red +

Figure 40: Epsilon EP/XV 40-80 mm Motor Brake Wiring Diagram

Connected to grounded mounting panel.

XV 40mm-80mm

Motor

XTBMS-xxx Cable

Connected to grounded mounting panel.

Internal

to Motor

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

motor

+ _

logic

digital i/o (J3)

EP204-I00-0000 9606XX-XX A1 SN 0610E014

Output #3

Drive Enable

I/O Supply

I/O Common

Single point PE ground

Customer supplied drive enable contact

1 Amp

Fuse

2 Amp

24 VDC

Fuse

Relay:

Model# BRM-1

Blue/Wht - -

Blu +

XV 130mm

Motor

Internal to Moto

XCMDBS-xxx Cable

Figure 41: Epsilon EP/XV 130 mm Motor Brake Wiring Diagram

Input/Output and Drive Enable Wiring

The Epsilon EP-B drive is equipped with 5 optically isolated input lines (one is dedicated to a drive enable function) and 3 optically isolated output lines. The Epsilon EP-I, EP-IDN and EP-P drives are equipped with 16 optically isolated input lines (one is dedicated to a drive enable function) and 8 optically isolated output lines. All inputs and outputs are configured as sourcing; that is, the outputs "source" current from the positive side of the I/O supply when ON and the inputs are compatible with a sourcing output returning current to the grounded negative side of the I/O supply.

Inputs are ON with +10 Vdc to +30 Vdc applied and OFF when less than +1.5 Vdc or 0.2 mA is applied. Input current at 24 Vdc is 4.8 mA and input resistance is about 4.8k ohms.

Maximum load on each output channel is 150 mA with 3.5 Vdc max voltage drop from I/O supply + to output. Outputs are rugged and require no freewheeling diode on inductive loads. Outputs are short-circuit proof to ground (0 V) or any voltage from 0V to the I/O power supply voltage.

Optical isolation for I/O is functional only and does not provide safety rated isolation. I/O circuits must be PELV for any extra low voltage circuits to be PELV. For UL installations, I/O wiring must be from a limited voltage/limited energy or limited voltage.limited current supply.

Installation 37

Safety Information Product Overview Installation Diagnostics

Front View

I/O supply

4.8 K

+10 to +30 Vdc

Drive Enable Input

I/O Supply +

I/O Conmmon -

Output #3

Output #2

Output #1

Input #4

Input #3

Input #2

Input #1

motor

+ _

logic

devicenet (J9)

digital i/o (J3)

EP204-I00-0000 9606XX-XX A1 SN 0610E014

Options and Accessories

Fuse if required to protect wiring

Specification

Figure 42: Epsilon EP-B Input/Output Wiring Diagram

As part of PELV wiring, I/O circuits are intended to be used within a zone of equipotential bonding where cables or wiring would typically be no more than 10 ft [3 m] long. These circuits have not been evaluated for EMC immunity which would be required for longer cables.

I/O Connector (J3) Functions

The I/O connector is a 26-pin male high-density dsub connector on the front of the drive. A low profile standard terminal interface board (STI-24IO) and cable assembly (EIO26-xxx) are available for making connections convenient. Figure 42 shows pin-outs for I/O channels supported in the EP-B drive and for external wiring typical of all I/O channels. Figure 43 shows pin-outs for EP-I and EP-P models. Input channels 1-8 have high speed capture capability in the EP-P models. Figure 44 shows the STI-24IO interface board for discrete wiring to I/O.

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

J3 Connector

Pin#

Function

Input Line 1

Input Line 3

Input Line 5

Input Line 7

Input Line 9

Input Line 11

Output Line 1

Output Line 3

Output Line 5

Enable

Input Line 2

Input Line 4

Input Line 6

Input Line 8

Input Line 10

Input Line 12

Output Line 2

Output Line 4

I/O +V

I/O Common

Output Line 8

Input Line 13

Input Line 14

Input Line 15

Output Line 6

Output Line 7

Figure 43: I/O Connector (J3) Functions

INPUTS

3.2

+24V

OUTPUTS

TB1

TB2

TB3

TB4

2.1

Figure 44: STI-24IO Interface Board

Installation 39

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Analog/Sync Output Connector (J5)

All command, diagnostic, and sync signals are available using the 15-pin Analog/Sync Output connector. If interfacing the drive using field wiring, the optional standard terminal interface board (STI-SNCOA) may be used.

It provides convenient connections using screw terminal strips.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

Figure 45: STI-SNCOA

J5 Connector

Pin#

Motor Encoder A

Motor Encoder B

Motor Encoder Z

Pulse

Analog Input +

Analog Ground

Analog Output 1

Logic Common

Motor Encoder A/

Motor Encoder B/

Motor Encoder Z/

Direction

Analog Input -

Analog Ground

Analog Output 2

Figure 46:Analog/Sync Output Connector (J5) Functions

Function

Safety Information Product Overview Installation Diagnostics

Function Pin Numbers Electrical Characteristics

Encoder Out 1, 2, 3, 9, 10, 11 Differential line driver output (RS 422) Diagnostic Output 7, 15 ± 10 Vdc 10 mA maximum analog diagnostic, ref. to pins 6 and 14 Diagnostic Output Common 6, 14 0.0 V, 10 ohms away from PE. 0 ohms away Logic Common (pin 8) Pulse In 4 Single ended pulse input Direction 12 Single ended direction input Analog Command 5, 13 Differential; Analog Command Input

As part of PELV wiring, circuits at J5 are intended to be used within a zone of equipotential bonding where cables or wiring would typically be no more than 10 ft [3 m] long. These circuits have not been evaluated fro EMC immunity

Options and Accessories

Specification

which would be required for longer cables.

Installation 41

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Sync Input Connector (J10)

Sync Input signals are connected to the drive using the 9-pin Sync Input connector. If interfacing the drive using field wiring, the optional standard terminal interface board (STI-SNCI) may be used.

1 2 3 4 5 6 7 8

Figure 47: STI-SNCI Interface Board

J10 Connector

Pin#

Function

Encoder A

Encoder A/

Encoder B

+ 5 Vdc

Encoder B/

Encoder Z

Encoder Z/

Logic Common

Figure 48:Sync Input Connector (J10) Functions

Function Pin Number Electrical Characteristics

Encoder In 1, 2, 3, 5, 6, 7 Differential line driver input (RS 422) 5 Vdc 4 +5 Vdc supply voltage Ground 8 Logic Common

The Sync Input power meets EMC emissions and immunity for cables longer than 3 meters [10 ft], when using a shielded cable. When a remote encoder is used, cable length may be limited by encoder supply voltage drop, and should not exceed 200 ft [60 m].

Safety Information Product Overview Installation Diagnostics

Analog Command Wiring

(Internal) 10 Ohm

Logic

- Analog In Common

Analog/Sync Output

Connector (J5)

Vdc

+ Analog In

External Controller

Single Point Panel Ground

Options and Accessories

CW Rotation + Command = CW With positive direction = CW

Specification

Single Point Panel Ground

Controller Logic Common

Figure 49: Analog Command, Differential Wiring Diagram

(Internal) 10 Ohm

Logic

- Analog In Common

Analog/Sync Output

Single Point Panel Ground

Connector (J5)

Vdc

Controller Logic Common

+ Analog In

Single Point Panel Ground

External Controller

CW Rotation + Command = CW With positive direction = CW

Figure 50: Analog Command, Single Ended Wiring Diagram

Encoder Output Signal Wiring

The encoder outputs meet RS-422 line driver specifications and can drive up to ten RS-422 signal receivers. The default encoder output scaling is set to output the actual motor encoder resolutions. The standard MG and NT

motors have 2048 lines per revolution. With PowerTools Pro software this resolution is adjustable in one line per revolution increments up to the density of the encoder in the motor.

Installation 43

Safety Information Product Overview Installation Diagnostics

If the external controller does not have an internal terminating resistor

Note:

R1, R2 and R3 must be mounted within 3 ft [1 m] of the external controller. A 120 ohm resistor is recommended for high frequency encoders (over 250 kHz) or cables longer than 25 feet. If encoder signals are multi-dropped, termination resistors are required only at the last drop point. Do not terminate at more than

Drive (J5)

one point.

External Controller

Encoder Input

Connector Shell

Internal

10 Ohm

Single Point PE Ground

= Twisted Pair

Figure 51: Analog/Sync Output Connector (J5) Encoder Output Wiring

Options and Accessories

Specification

Figure 52: Direction Convention Diagram

Safety Information Product Overview Installation Diagnostics

Pulse Mode Wiring, Differential Inputs

Options and Accessories

Specification

500 ns Minimum

Motion occurs

500 ns Minimum

250 ns Minimum

Drive

Sync Input Connector (J10)

on rising edge

(A) Pulse

RS-422 Type Differential Drives

CCW

(B) Direction

Single Point PE Ground

If the external controller does not have an internal terminating

Note:

resistor R1, and R2 must be mounted within 3 ft [1 m] of the drive. A 120 ohm resistor is recommended for high frequency (over 250 kHz) feedback signals or cable lengths longer than 25 feet.

A A/ B B/

1 2 3 5

Figure 53: Pulse Mode, Differential Output to Differential Input

500 ns Minimum

Motion occurs on falling edge

500 ns Minimum

250 ns Minimum

(A/) Pulse

Drive

Sync Input Connector (J10)

Shield connected to connector shell

10 Ohm

Single Point

Panel Ground

Shield connected to connector shell

10 Ohm

= Twisted Pair

A A/ B B/

1 2 3 5

R1, R2

Single Point Panel Ground

Resistor Values

1K Ohm Maximum 240 Ohm Minimum

1/2 R3 120 Ohm Minimum

Pulse

+5 Out

Direction

CCW

Single Point PE Ground

(B) Direction

= Twisted Pair

Figure 54: Pulse Mode, Single Ended Output to Differential Input

Installation 45

Safety Information Product Overview Installation Diagnostics

Pulse Mode Wiring, Single Ended Inputs

Options and Accessories

Specification

1 µs Minimum

Motion occurs on falling edge

Sinking

Outputs (typ)

1 µs Minimum

500 ns Minimum

CCW

Pulse

Direction

Drive

Analog/Sync Output

(J5)

Pulse

Common isolated from other sources

Pulse

Direction

Shield connected to connector shell

Ohm

Single Point Panel Ground

= Twisted Pair

Figure 55: Pulse Mode, Single Ended Output to Single Ended Input (twisted pair cable)

1 µs Minimum

Motion occurs on falling edge

Sinking

Outputs (typ)

CCW

1 µs Minimum

500 ns Minimum

Pulse

Direction

Pulse

Drive

Analog/Sync Output Connector

(J5)

Pulse

Direction

Shield connected to connector shell

10 Ohm

Single Point Panel Ground

logic common

Direction

Common isolated from other sources

Figure 56: Pulse Mode, Single Ended Output to Single Ended Input (non-twisted pair

cable)

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

1 µs Minimum

Motion occurs on falling edge

Sinking

Outputs (typ)

1 µs Minimum 500 ns Minimum

CCW

CW Pulse

CCW Pulse

Drive

Analog/Sync Output Connector

(J5)

CW Pulse

CCW Pulse

Common isolated from other sources

Shield connected to connector shell

logic common

Pulse

Direction

Ohm

Single Point Panel Ground

Figure 57: Pulse/Pulse Mode, Single Ended Output to Single Ended Input (non-twisted

pair cable)

Slave Drive

Sync Input Connector (J10)

A A/ B B/ Z Z/

1 2 3 5 6 7

R1 R2 R3

Master Encoder or Drive Output

RS-422 Drivers

Slave Drive

Sync Input Connector (J10)

A A/ B B/ Z Z/

1 2 3 5 6 7

Slave Drive

Sync Input Connector (J10)

A A/ B B/ Z Z/

1 2 3 5 6 7

R1, R2, and R3 must be mounted within 3 ft [1m] of the end drive.

Note:

= Twisted Pair

A 120 ohm resistor is recommended for high frequency (over 250 kHz) stepping or cable lengths longer than 25 feet.

Figure 58: Master/Slave Encoder Connections

Encoder outputs meet RS-422 driver specifications and can drive up to 10 RS-422 signal receivers. Each differential pulse input is an RS-422 line receivers. The default encoder output resolution is 2048 lines per motor revolution. This resolution is adjustable in one line per revolution increments with PowerTools Pro software. The range is between 1 and the actual motor encoder density.

Installation 47

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Communications

Communications with the drive is provided through the RJ45 connectors located on the front of the drive. The two RJ45 connectors are identical and are used to provide a way to daisy chain two or more drives together using the DDC-RJ45 cable, see Figure 60. The Epsilon EP serial communication connector (serial port) as standard, supports 2 wire EIA485 communications. The RS-485 communications port is not isolated from drive electronics and the "0V" pins are internally connected through a 10 Ohm resistor to PE. Interconnected drives should be within a zone of equipotential bonding. Connection to a master device on the network, such as a MMI, SCADA, PLC, or PR can be remote, but care should be taken to make sure the entire network operates within the +/-7 V common mode voltage range of RS-485. Though the comm port is part of PELV circuits when properly installed, if the master device is outside the zone of equipotential bonding the circuit needs to be isolated against direct contact. The minimal RS-485 network cable contains a shielded twisted pair for RX TX (pin 2) and RX/ TX/ (pin 7) with shield to the shell, though a 0 V reference signal (pin 3) can improve immunity to ground differentials. See the following table for the connection details for the RJ45 serial communication connector.

Pin Function

1 220 ohm T ermination resistor to RX TX 2RX TX 3Isolated 0V 4 +15V (100 mA max) 5NC 6 TX Enable 7RX/ TX/ 8 RX/ TX/ (If termination resistors are required, link to pin 1)

SHELL PE

The provision for connection of the internal 220 ohm terminating resistor at pin 1 and pin 8 would rarely, if ever, be needed unless data rates much higher than 19.2K are supported. Since a terminator connection is only made at the end of a trunk, it is most conveniently accomplished by crimping a short link from pin 1 to pin 8 in a new RJ45 connector and plugging it into the second RJ45 port on the "last" drive. Cable conductors should not be connected to these pins.

The modbus protocol is sensitive to transitions on an idle line. In some cases it may be necessary to apply bias to the trunk consisting of a pull-up resistor to RX TX and a pull-down resistor to RX/ TX/. Biasing is most important when termination resistors are used. As an example, if the internal 220 ohm termination is connected at the last node on the trunk, a 10K resistor from RX TX (pin 2) to +15 V (pin 4) and a 1 K resistor from RX/ TX/ (pin 7) to Isolated 0V (pin 3) would provide good idle line bias. Only one node needs to provide bias, even with terminators at each end. It is usually most convenient to provide bias at the connection to the Modbus master node.

Communication Converter Cables

The CT-Comms cable is an isolated RS-232 to RS-485 converter cable that may be used to connect one or more EP drives to a master device using a standard 9 pin D-sub RS-232 serial comms port. The CT-USB-Cable is an isolated USB to RS-485 converter cable that may be used to connect one or more drives to a master device using a USB port.

The +15 V supply (pin 4) and the 0 V connection (pin 3) are intended only to provide power to the isolators in the CT converter cables and are not to be used for any other purpose.

The TX Enable signal (pin 6) and 0 V (pin 3) provide a transmit enable signal from each interconnected drive to the CT converter cable and are not to be used for any other purpose. They may be wired from drive to drive in a zone of equipotential bonding to allow the CT converter cable to communicate with all drives in the group.

The DDC-RJ45 cable provides drive to drive (daisy chain) connections between EP drives, including support for the CT converter cable in a group of drives.

Safety Information Product Overview Installation Diagnostics

Figure 59: Epsilon EP Serial Communicat ion Connector

Options and Accessories

Specification

DDC-RJ45 cable

Figure 60: 2 Epsilon Drives Daisy Chained Together

When connecting the serial port of your PC to the serial port of the drive, verify that your PC’s ground is the same as the drive PE ground. Failure to do so can result in damage to your PC and/or your drive. It is best to use an isolating cable such as the CT-Comms cable.

Installation 49

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Modbus Communications

The drive’s serial communication protocol is Modbus RTU slave with a 32 bit data extension. The Modbus protocol is available on most operator interface panels and PLC’s.

Serial Communications Specifications

Max baud rate 19.2k

Start bit 1 Stop bit 2

Parity none

Data 8

Ethernet Port

The Ethernet port at J11 has only functional isolation from other low voltage circuits and PE at the drive. In order to classify any low voltage circuits in the drive as PELV, the ethernet circuit must be installed as a PELV circuit. Refer to installation instructions with the hub, switch or other devices connected for details.

The system meets EMC emissions and immunity requirements using unshielded ethernet cables when a clamp on ferrite is attached to the ethernet cable as it leaves the enclosure or when using shielded ethernet cables.

DeviceNet Port

The DeviceNet port at J9 has only functional isolation from other low voltage circuits and PE at the drive. In order to classify any low voltage circuits in the drive as PELV, the DeviceNet circuit must also be installed as a

PELV circuit.

Profibus Port

The Profibus port at J13 conforms to standard Profibus implementation, and may be used with a variety of trunk to node connectors for Profibus. The signal wires are isolated to SELV requirements but the shell (shield connection) is directly connected to PE. Classification of the Profibus circuit as PELV is independent of other circuits in the drive.

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Diagnostics and Troubleshooting

Diagnostic Display

Status Codes

The diagnostic display on the front of the drive shows drive status and fault codes. When a fault condition occurs, the drive will display the fault code, overriding the status code. The decimal point is “On” when the drive is enabled and the Stop input is not active. This indicates that the drive is ready to run and will respond to motion commands. Commands will not cause motion unless the decimal point is “On”.

Display Indication Status Description

Motor brake is mechanically engaged. This

Brake Engaged (Output "Off")

Disabled Power Stage is disabled.

character will only appear if the Brake output

function is assigned to an output line.

See Brake Operation section for detailed

description of Brake Output function.

Ready

Program

Position or Pulse Pulse mode operation.

Velocity Velocity mode operation.

Decelerating from Stop or Travel

Limit Decel

Torque Analog Torque mode operation.

The system is functioning normally and is ready

to execute a motion command

Program is executing. Other motion commands

Deceleration ramp after the Stop or Travel Limit

function is activated. The ramp is displayed while

decelerating, and the display will go back to

normal after completing the decel ramp.

do not function.

Diagnostics and Troubleshooting 51

Safety Information Product Overview Installation Diagnostics

Display Indication Status Description

Summation Summation mode operation.

RMS Foldback Motor torque is limited to 80 percent.

Options and Accessories

Specification

Stall Foldback

Ready to Run Drive enabled, no Stop input.

Homing

Indexing

Jogging

AutoTune AutoTune function is executing.

Gearing Gear function is executing.

Drive output current is limited to 80 percent o f th e

A Index is executing. Other motion commands do

Jog function is executing. Other motion

drive’s stall current.

Home cycle is executing. Other motion

commands do not function.

not function.

commands do not function.

Fault Codes

A number of diagnostic and fault detection circuits are incorporated to protect the drive. Some faults, like high DC bus and drive or motor over temperature, can be reset with the Reset button on the front of the drive or the Reset input function. Other faults, such as encoder faults, can only be reset by cycling power “Off” (wait until the diagnostics display turns “Off”), then power “On”.

The drive accurately tracks motor position during fault conditions. For example, if there is a "Low DC Bus" fault where the power stage is disabled, the drive will continue to track the motor’s position provided the logic power is not interrupted.

Safety Information Product Overview Installation Diagnostics

The +/- Travel Limit faults are automatically cleared when the fault condition is removed. The table below lists all the fault codes in priority order from highest to lowest. This means that if two faults are active, only the higher priority fault will be displayed.

Display Fault Action to Reset Bridge Disabled

Flash Invalid Reprogram the Flash Yes

Drive Power Up Test Cycle Logic Power Yes

NVM Invalid Reset Button or Input Line Yes

Invalid Configuration Reset Button or Input Line Yes

Drive Overtemp Allow Drive to cool down Yes

Options and Accessories

Specification

Power Module Reset Button or Input Line Yes

High DC Bus Reset Button or Input Line Yes

Low DC Bus Reset Button or Input Line Yes

Encoder State

Encoder Hardware

Reset Button or Input Line on EP-P drive

Cycle Logic Power on the other models

Reset Button or Input Line on EP-P drive

Cycle Logic Power on the other models

and

Yes

Diagnostics and Troubleshooting 53

Safety Information Product Overview Installation Diagnostics

Display Fault Action to Reset Bridge Disabled

Options and Accessories

Specification

Motor Overtemp

RMS Shunt Power

Shunt Short Circuit

Overspeed Reset Button or Input Line Yes

Following Error

(Pulse mode only)

Travel Limit +/- Auto No

Sync Fault Cycle Logic Power Y es

Run Time

(EP-P Only)

Allow Motor to cool down, Reset Button or Input Line

Reset Button or Input Line Yes

Yes

All "On"

Normally "On" for one second during power-

Yes

Fault Descriptions

Flash Invalid

This fault indicates that the firmware checksum has failed. From the Tools>Program Flash menu in PowerTools Pro the firmware stored in flash memory can be reprogram or upgrade. If this problem persists, call Control Techniques. A common cause would be an interrupted F/W Flash upgrade (cable disconnected during an upgrade process).

Power Up Test

This fault indicates that the power-up self-test has failed. This fault cannot be reset with the reset command or reset button.

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

NVM Invalid

At power-up the drive tests the integrity of the non-volatile memory. This fault is generated if the contents of the nonvolatile memory are invalid.

Invalid Configuration

This fault will occur if the digital board in the drive does not match the power board settings. It is only useful during manufacturing. A drive with this fault should be returned for service.

Drive Overtemp

Indicates the drive internal temperature has reached an over temperature condition - not currently implemented in the EP202, EP204 or EP206 models. For Epsilon EP209 and EP216 drive models, this fault will occur if the soft-start circuit has failed or mis-wiring of the bus or shunt prevents proper start-up, resulting in overheating the soft-start resistor internal to the drive. With the EP216 model this over temperature condition could be the result of fan failure.

Power Module

This fault is generated when a power stage over-temperature, over-current or loss of power stage logic supply occurs. This can be the result of a motor short to ground, a short in the motor windings, a motor cable short or the failure of a switching transistor.

High DC Bus

This fault will occur whenever the voltage on the DC bus exceeds the High DC Bus threshold. The most likely cause of this fault would be an open external shunt, a high AC line condition, or an application that requires an external shunt (e.g., a large load with rapid deceleration) but none is installed.

High DC Bus Threshold

Epsilon EP 415 Vdc

Low DC Bus

This fault will occur whenever the voltage on the DC bus drops below the Low DC Bus threshold. The most likely cause of this fault is a reduction (or loss) of AC power. A 50 ms debounce time is used with this fault to avoid faults caused by intermittent power disruption. With an Epsilon EP drive, the low DC bus monitoring can be disabled. In an EP-B and EP-I this fault is disabled by clearing the check box on the Faults view, and for an EP-P the check box is located on the Advanced view

Low DC Bus Threshold

Epsilon EP 60 Vdc

Special note for EP209 and EP216 drives, the Low DC Bus fault may not be disabled. The bus voltage must reach 140 Vdc (100 Vac input) before this fault will reset and it will reset automatically. It will occur again when the bus voltage drops by 50 V from the voltage on the bus when soft-start mode ends and the drive is ready to run.

Encoder State

Certain encoder state transitions are invalid and will cause the drive to report an encoder state fault. This is usually the result of noisy encoder feedback caused by poor shielding. For some types of custom motors it may be necessary to disable this fault. With an Epsilon EP drive, the Encoder State monitoring can be disabled. In an EP-B and EP-I this fault is disabled by clearing the check box on the Faults view, and for an EP-P the check box is located on the Advanced view.

Diagnostics and Troubleshooting 55

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Encoder Hardware

If any pair of complementary encoder lines (A, B, Z) are in the same state, an encoder line fault is generated. Also, can be generated if all three commutation channels (U, V, W) are 0 or 1, an illegal state. The most likely cause is a missing or bad encoder connection.

Motor Overtemp

This fault is generated when the motor thermal switch is open due to motor over-temperature or incorrect wiring.

Overspeed

This fault occurs in one of two circumstances:

1. When the actual motor speed exceeds the Overspeed Velocity Limit parameter or 150% of motor maximum operating speed. This parameter can be accessed with PowerTools Pro software.

2. If the combination of command pulse frequency and Pulse Ratio can generate a motor command speed in excess of the fixed limit of 13000 RPM, an Overspeed Fault will be activated. In Pulse mode operation and any Summation mode which uses Pulse mode, the input pulse command frequency is monitored and this calculation is made. For example, with a Pulse Ratio of 10 pulses per motor revolution, the first pulse received will cause an Overspeed fault even before there is any motor motion.

RMS Shunt

This fault is generated when filtered average shunt power dissipation is greater than the design rating of the shunt resistor.

Following Error

This fault is generated when the following error exceeds the following error limit (default following error limit for an EP-I and EP-B is 0.2 revs). With PowerTools Pro you can change the Following Error Limit value or disable it in the Position view. In an EP-B and EP-I the Following Error Limit is functional in Pulse mode only.

Travel Limit +/-

This fault is caused when either the + or - Travel Limit input function is active.

Sync Fault

This fault occurs when the user selected trajectory update rate is set too short based on the processor requirements. The three possible trajectory update rates are 800µs, 1200 µs, or 1600 µs. Try changing the trajectory update rate to the largest value (1600 µs) and run the application again. If the problem persists after setting to 1600 µs, contact

Control Techniques technical support. For more information on the trajectory update rate see the

Drive and FM-3/4 Modules Reference Manual

(P/N 400518-04).

Epsilon EP-P

Run Time Faults (EP-P only)

The "4" fault is caused by any of the following internal routine faults:

Trajectory Fault #1

This fault occurs when the drive commands motion that cannot be achieved due to excessive following error, accel, decel, velocity settings, or unusable user units. Check the user units, velocities, accels and decels for correct values.

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Trajectory Fault #2

This fault occurs when using the "Using Capture.#" option in a user program. If the capture has never been triggered, or the capture data has gone "stale", the drive will not be able to process motion properly.

Program Fault

This fault indicates a problem was encountered in a user program. For example: an illegal math operation resulting in a divide by zero or overflow of 32-bit data. This error can also occur if trying to access a drive parameter that is non-existent or not available to the user.

Invalid Configuration Fault #2

The user program in flash memory will not run. Download the user program again using PowerTools Pro. A common cause of this fault could be an interrupted configuration download, such as a cable being disconnected during the download.

No Program

This fault will be displayed on initial power-up indicating that no configuration has been downloaded to the drive. To clear the fault, download a valid configuration to the drive.

All "On"

This is a normal condition during power up of the drive. It will last for less than 1 second. If this display persists, call Control Techniques Americas LLC for service advice.

Normally, "All On" for less than one second during power-up. All segments dimly lit when power is "Off" may occur when an external signal is applied to the encoder inputs (motor or master) or serial port from an externally powered device.

Diagnostic Analog Output Test Points

The drive has two 10-bit real-time Analog Outputs which may be used for diagnostics, monitoring or control purposes. These outputs are referred to as Channel 1 and Channel 2. They can be accessed from the Analog/Sync Output Connector (J5) on the drive.

Each Channel provides a programmable Analog Output Source.

Analog Output Source options are:

• Velocity Command

• Velocity Feedback

• Torque Command (equates to Torque Command Actual parameter)

• Torque Feedback

• Following Error

• Position Feedback (EP-B, EP-I, and EP-IDN)

• Custom Variable (EP-P only)

• Analog In (EP-P only)

Channel

Analog/Sync Output Connector (J5)

17 215

Pin#

Drive Faults

The Active Drive Faults dialog box is automatically displayed whenever a fault occurs. There are two options in this dialog box: Reset Faults and Ignore Faults.

Diagnostics and Troubleshooting 57

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Figure 61: Active Drive Faults Detected Dialog Box

Resetting Faults

Some drive faults are automatically reset when the fault condition is cleared. Other faults require drive logic power to be cycled or the drive to be “rebooted”. If you wish to continue working in the PowerTools Pro software without resetting the fault, click the Ignore Fault button.

To reset faults that can be reset with the Reset Faults button, simply click the Reset Faults button in the Drive Faults Detected dialog box or push the Reset button on the front of the drive where the fault occurred.

Viewing Active Drive Faults

To view all active drive faults, select the View Faults command from the Device menu or by clicking on the View Faults button on the toolbar. The dialog box displayed is the same as Active Drive Faults Detected dialog box described above.

Rebooting the Drive

To reboot the drive, cycle power or select the Reboot Drive command from the Device menu. This command reboots the drive attached to the active Configuration Window.

Safety Information Product Overview Installation Diagnostics

Epsilon EP Drive Options

External Shunt Resistor, SM-Heatsink DBR1

Options and Accessories

Specification

Options and Accessories

Drive Brake Relay, BRM-1

Motor Power Cable, XTMDS-xxx

40, 60, 80 mm XV Motors

Windows 98, NT 4.0, 2000 or XP

Compatible Computer

(Customer Supplied)

CT-MME-POWER-CD

Contains PowerTools Pro

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

Drive Sync Out Breakout Board,

STI-SNCOA

CTVue HMI to Drive,

CTVUE-EP-485-xxx

Drive to Drive,

Drive RS-485 to Drive RS-485,

DDC-RJ45-xxx

PC to Drive, PC RS232 to Drive RS485

Serial Interface Cable,

CT-COMMS

Ethernet to Drive,

ETH-PATCH--xxx

Ethernet 4-port Switch,

Epsilon EP I/O Cable,

EIO26-xxx

OUTPUTS

ETH-S4

INPUTS

+24V

STI-24IO

Drive Sync Out to

Drive Sync In Cable,

SNCDD-915-xxx

Drive Sync Out Cable,

SNCFLOA-xxx

Drive Sync Out to

FM-3/4 Module In Cable,

SNCMD-815-xxx

Drive Command to

MC Controller Cable,

MC-CEP-xxx

Epsilon EP

reset

motor

serial (J2)

+ _

act

logic

link

ethernet ( J4)

digital i/o (J3)

EP204-IDN-EN00

EP204-P00-0000

9606XX-XX A1

SN 0610E014

J10

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

Motor Feedback Breakout Board,

STI-ENC

Motor Brake Cable, XTBMS-xxx

Motor Power or Motor Power/Brake Cable, XCMDS-xxx or XCMDBS-XXX

Motor Power Cable, CMDS-xxx or CMMS-xxx*

Motor Brake Cable, CBMS-xxx*

Motor Power Cable, PSBAA-xxx, PBBAA-xxx

130 mm XV Motors

NT or MG Motors

FM Motors

Drive Sync In to Drive Sync Out Cable, SNCDD-915-xxx

3 MIN

Drive Sync In Cable, SNCFLI-xxx

Drive Sync In from FM-3/4 Module Out Cable, SNCMD-89-xxx

Drive Sync In from SCSLD Encoder Cable, SNCE-xxx

1 2 3 4 5 6 7 8

Drive Sync In Breakout Board, STI-SNCI

40, 60, 80 mm XV Motors

Motor Feedback Cable, XUFTS-XXX

130 mm XV Motors

Motor Feedback Cable, XUFCS-XXX

NT or MG Motors

Motor Feedback Cable, UFCS-XXX

FM Motors

Motor Feedback Cable, SIBAA-xxx

* Flex duty versions of these cables are also available.

Figure 62: Epsilon EP-P Drive shown with Options

Options and Accessories 59

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

STI-24IO

The STI-24IO interface board allows access to all digital input and output signals. The STI-24IO mounts directly to the digital I/O connector (J3) on the front of the EP drive. See figure 63 below.

Do not allow ESD directly to terminals. Always discharge static electricity to enclosure, not the drive when performing maintenance.

Shield connection points are connected to the shell of the 26 pin “D” connector on the STI-24IO.

The STI-24IO wire range is #18 to 24 AWG stranded insulated wire.

Wiring should be done with consideration for future troubleshooting and repair. All wiring should be either color coded and/or tagged with industrial wire tabs. Low voltage wiring should be routed away from high voltage wiring.

INPUTS

+24V

3.2

OUTPUTS

TB1

TB2

TB3

TB4

2.1

Figure 63: Dimensions of the STI-24IO Board

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

STI-SNCOA

The STI-SNCOA interface board allows access to the analog/sync signals. The STI-SNCOA plugs directly into the J5 connector on the bottom of the drive. The numbers printed on the connector label correlate to the screw terminal numbers.

Do not allow ESD directly to terminals. Always discharge static electricity to enclosure, not the drive when performing maintenance.

Shield connection points are connected from the shell of the "D" connector to the faston lug connector.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

Figure 64: STI-SNCOA Drive Analog/Sync Output Breakout Board

Options and Accessories 61

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

STI-SNCI

The STI-SNCI interface board allows access to the sync input connections on the EP drive. The STI-SNCI plugs directly into the J10 connector on the bottom of the drive. The numbers printed on the connector label correlate to the screw terminal numbers.

Do not allow ESD directly to terminals. Always discharge static electricity to enclosure, not the drive when performing maintenance.

Shield connection points are connected from the shell of the "D" connector to the faston lug connector.

1 2 3 4 5 6 7 8

Figure 65: STI-SNCI Drive Sync In Breakout Board

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

STI-ENC

The STI-ENC interface board allows the user access to the encoder feedback connector (J6) on the EP drive. The STI-ENC plugs directly in J6 on the bottom of the drive. The numbers printed on the connector label correlate to the screw terminal numbers.

Do not allow ESD directly to terminals. Always discharge static electricity to enclosure, not the drive when performing maintenance.

Shield connection points are connected from the shell of the "D" connector to the faston lug connector.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

Figure 66: STI-ENC Drive Encoder Feedback Board

Options and Accessories 63

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Safety Information Product Overview Installation Diagnostics

Epsilon EP Specifications

Epsilon EP Series

Model AC Power

Power Requirements

(240 Vac for rated performance)

SCCR (Short Circuit Current Rating)

Solid State Motor Overload Protection

Rated Output Current and Power

Continuous Input Current (AC Input)

EP202 EP204 EP206

EP209

EP216

10,000 Symmetrical RMS Amps

115% of rated FLA

Model Continuous Power Continuous Current Peak Current

EP202 775 W 2.2 A RMS at 40°C or 50°C 4.4 A RMS EP204 1275 W

EP206 1775 W

EP209 2325 W EP216

3 Ø Input

EP216

1 Ø Input

20 Vac-264 Vac,

1 Ø, 47-63 Hz

90 Vac - 264 Vac

1 Ø, 47-63 Hz

90 Vac - 264 Vac

3 Ø, 47-63 Hz

90 Vac - 264 Vac

1 Ø, 47-63 Hz

4800 W

2325 W

Model Continuous Current Inrush Current

EP202 5.0 A RMS at 40° C or 50° C 40 A RMS for 5 ms EP204

EP206

EP209

EP216, 3 Ø Input EP216, 1 Ø Input

Options and Accessories

Specifications

DC Power

(UL Pending)

10 Vdc - 340 Vdc

140 Vdc - 340 Vdc

4.0 A RMS at 40° C

3.6 A RMS at 50° C

6.5 A RMS at 40° C

5.2 A RMS at 50° C

9.0 A RMS at 40° C

7.7 A RMS at 50° C

16.0 A RMS at 40° C

16.0 A RMS at 50° C

16.0 A RMS at 40° C

16.0 A RMS at 50° C

8.5 A RMS at 40° C

7.6 A RMS at 50° C

12.0 A RMS at 40° C

9.6 A RMS at 50° C

16.0 A RMS at 40° C

13.6 A RMS at 50° C

16.0 A RMS at 40° C

16.0 A RMS at 50° C

Specification

Type TN (Grounded) Installation Category III

8 A RMS

13 A RMS

18 A RMS

32 A RMS

65 A RMS for 5 ms

100 A RMS for 5 ms

34 A RMS for 5 ms

Specifications 65

Safety Information Product Overview Installation Diagnostics

Epsilon EP Series

Logic Power Supply Input

Switching Frequency Power Supply Output Efficiency - Drive AC Power

Ingress Protection (IP) Rating

Serial Interface

EtherNet Interface EP-P Only

DeviceNet Interface EP-xDN Only

Control Inputs

Control Outputs

Encoder Input

* = All EP216 drive models will draw an additional 100 mA 10 kHz

5 Vdc, 250 mA maximum (for master encoder) 95% at full rated output power for each model

Drive: IP20 NT motors: IP65/IP54 Molded motor and feedback cables: IP65

RS-485 IModbus protocol with 32 bit data extension

19.2 k baud (default) or 9600 baud 10/100 M baud, auto negotiated

Auto crossover Full/Half Duplex, auto negotiated EtherNet I/P, Modbus TCP/IP, HTTP, and SMSC

Baud Rates: 125K, 250K, 500K Power from Network: 25 mA max.

Analog Command: Absolute Maximum Input Voltage Input: +/- 14 Vdc to ground or differential, including

drive enable Digital Inputs: 5 on the EP-B and 16 on the EP-I and EP-P including the drive enable

input, 10 Vdc - 30 Vdc, 4.8 kohm impedance; current sourcing signal compatible (active high); max input response time is 500 µs; optically isolated. EP-P only; High speed capture inputs: 1 - 2µs

Input Debounce: 0-2000 ms configured in PowerTools Pro Diagnostic Analog Outputs: (2) ±10 Vdc into 10 kohm (single ended), short circuit proof

to ground, short circuit proof to ground, 10 bit, software selectable output signals Digital Outputs: 3 on EP-B, 8 on the EP-I and EP-P, 150 mA max each, short circuit

proof, current source from 10 Vdc - 30 Vdc I/O power supply , 3.5 Vdc max supply to output voltage drop @ 150 mA, opto-isolated

Motor Temp Sensor: Contact: 5 Vdc O.C. (tripped), 0.5 mA S.C. (normal) Compatible with PTC thermistor with 2 kohm resistance at trip point. Fault Turn-on Threshold = 0.83V and Fault Turn-off (Reset) Threshold = 0.41 V

Interface: Software selectable differential (RS422) or single ended (TTL Schmitt Trigger) Maximum Input Frequency:

Differential - 1 MHz per channel; (4 million counts/second in quadrature),

0.5 µs minimum pulse width Single ended - 500 kHz per channel; (2 million counts/second in quadrature), 1 µs minimum pulse width

Ratio Capabilities: 20 to 163,840,000 PPR Single ended inputs have 1 kohm pull-up to 5 V

24 Vdc ±10%

±10 Vdc 14 bit, 100 kohm impedance, differential

Options and Accessories

EP-Pxx: 0.50 A* without master encoder,

0.57 A* with master encoder Other models: 0.31 A* without motor encoder,

0.38 A* with master motor encoder

Specification

Safety Information Product Overview Installation Diagnostics

Epsilon EP Series

Encoder Output Signal

Differential line driver, RS-422 and TTL compatible Scalable in one line increment resolution up to 2048 lines/rev of the motor (NT)

Energy storage available in bus caps:

EP202: 8 J @ 240 Vac, 18 J @ 208 Vac, 39 J @ 120 Vac EP204: 12 J @ 240 Vac, 28 J @ 208 Vac, 58 J @ 120 Vac EP206: 20 J @ 240 Vac, 46 J @ 208 Vac, 97 J @ 120 Vac EP209: 24 J @ 240 Vac, 55 J @ 208 Vac, 117 J @ 120 Vac EP216: 28 J @ 240 Vac, 62 J @ 208 Vac, 132 J @ 120 Vac

Options and Accessories

Specification

Shunt Resistor Capacity/ Regeneration Capacity

Earth Leakage Current and RCD Compatibility

Fault Detection Capability

Cooling Method

Power Dissipation

Environmental

Standards and Agency Approvals

Values are calculated based on maximum allowable input voltage above nominal which is +10%. Operating at input voltages below this may increase the energy storage available.

EP204/EP206/EP209 External Shunt Control: 12 A peak, 2 kW max average power, 30 ohm minimum external resistor EP216 External Shunt Control: 20 A peak, 5 kW max average power, 20 ohm minimum external resistor

25 mA AC and < 0.1 mA DC with 15 ft (4.6 m) CMDS motor power cable and NT-330 motor at 240 Vac. Lea kage is higher with longer cables. The EP drive is compatible with a Type A Residual current Detector (RCD) that allows expected leakage currents.

Low DC bus (can be disabled) High DC bus Power Stage fault Logic power Encoder state Encoder line break Drive overtemperature Motor overtemperature Overspeed Travel limit (+) Travel limit (-) Following error Power-up self test failure Non-volatile memory invalid

EP202, EP204, EP206, EP209: Natural Convection EP202-P - 35 W* at Continuous Full Load

EP204-P - 55 W* at Continuous Full Load EP206-P - 85 W* at Continuous Full Load EP209-P - 115 W* at Continuous Full Load EP216-P - 200 W* at Continuous Full Load * Includes up to 12 W of power from Logic Power Supply

Pollution degree 2 environment, Maximum surrounding air temperature: 40°C full ratin g, 50°C with derating Minimum operating temperature: 0°C Storage Temperature: -25°C to 75°C Rated Altitude: 3250 ft [1000 m] Higher Altitude: Derate output current; 1% / 100m above 1000m Humidity: 10% to 95% - non-condensing Vibration: 2g, 10 Hz to 2000 Hz

UL listed Canadian UL listed CE Mark: Low voltage directive; EMC directive

Specifications 67

Safety Information Product Overview Installation Diagnostics

Epsilon EP Series

EP202-B, -I, -IDN 3.6 lb (1.63 kg) EP204-B, -I, -IDN 3.6 lb (1.63 kg) EP206-B, -I, -IDN 4.2 lb (1.91 kg) EP209-B, -I, -IDN 5.2 lb (2.35 kg)

Drive Weights

EP202-P, PDN, PPB 3.9 lb (1.77 kg) EP204-P, PDN, PPB 3.9 lb (1.77 kg) EP206-P, PDN, PPB 4.5 lb (2.04 kg) EP209-P, PDN, PPB 5.5 lb (2.50 kg) EP216-P, PDN, PPB 5.6 lb (2.54 kg)

Options and Accessories

Specification

Safety Information Product Overview Installation Diagnostics

Epsilon EP Drive Dimensions

The following table applies to A* and B* as shown in Figure 67 below.

Options and Accessories

Specification

Drive Model

Dimension A*

(shown in inches/mm)

Dimension B*

(shown in inches/mm)

EP202-B,-I,-IDN 2.11 [53.59] 0.45 [11.4] EP204-B,-I,-IDN 2.11 [53.59] 0.45 [11.4] EP206-B,-I,-IDN 2.82 [71.63] 0.45 [11.4]

EP202-P 2.69 [68.3] 1.03 [26.16] EP204-P 2.69 [68.3] 1.03 [26.16] EP206-P 3.40 [86.9] 1.03 [26.16]

[150.88]

5.22

[132.59]

5.94

2.5

[63.50]

DDC-RJ45

8.099

[205.72]

“B”

7.70

[195.58]

.200

[5.08]

1.20

[30.48]

“A”

(4X)Ø.219

[5.56]

3.50

[88.0]

Cable

Clearence

0.75

[19.05]

EIO26 Cable

Figure 67: Dimensional Drawing for the Epsilon EP202 through EP206 Drives

Specifications 69

Safety Information Product Overview Installation Diagnostics

5.94

[150.88]

5.86

[148.85]

5.23

[132.84]

2.5

[63.50]

DDC-RJ45

9.60

[243.84]

0.20 [5.08]

[233.68]

Options and Accessories

3.40

[86.36]

2.69

[68.33]

1.03

1.20

[26.16]

[30.48]

9.20

EP209-XXX-XX00 9606XX-XX A1 SN 0610E014

Specification

4X Ø.219

3.50

[88.0]

Cable

Clearence

0.75

[19.05]

EIO26 Cable

Figure 68: Dimensional Drawing for all Epsilon EP209 Drives

Safety Information Product Overview Installation Diagnostics

5.96

[151.38]

5.23

[132.84]

2.5

[63.50]

1.03

[26.16]

Options and Accessories

3.40

[876.9]

1.20

[30.48]

Specification

3.50

[88.0]

Cable

Clearence

DDC-RJ45

0.75

[19.05]

EIO26 Cable

9.60

[243.84]

9.20

[233.68]

Figure 69: Dimensional Drawing for all Epsilon EP216 Drives

Specifications 71

Safety Information Product Overview Installation Diagnostics

Cable Diagrams

EIO26-XXX

1.530

PIN 1

Options and Accessories

Specification

0.770

OUTPUT LINE 1

OUTPUT LINE 2

OUTPUT LINE 3

OUTPUT LINE 4

OUTPUT LINE 8

OUTPUT LINE 5

OUTPUT LINE 6

OUTPUT LINE 7

EIO

ENABLE

INPUT LINE 1

INPUT LINE 2

INPUT LINE 3

INPUT LINE 4

INPUT LINE 5

INPUT LINE 6

INPUT LINE 7

I/O +V

I/O COM

INPUT LINE 8

INPUT LINE 9

INPUT LINE 10

INPUT LINE 11

INPUT LINE12

INPUT LINE 13

INPUT LINE 14

INPUT LINE15

LT. BLU

RED/WHT

LT. BLU/WHT

ORG/WHT

LT. GRN/WHT

GRN/WHT

YEL/GRY

PNK/WHT

ORG

YEL

PNK

BLU

RED

BLK

BLU/WHT

GRY/WHT

PUR/WHT

BRN/WHT

BRN

BLK/WHT

WHT/BLK

GRN

LIGHT GRN

GRY

PUR

WHT

DRAIN WIRE

12 3 4 65879

1110 151312 14 1716 18

2019 242221 23 2625

SOLDER SIDE

Socket

Safety Information Product Overview Installation Diagnostics

XV Motor Cables

XTMDS-XXX

PIN 1

BRAID SHIELD FORM WIRE

PE/GND

GRN/YEL

BRN

BLK

BLU

Options and Accessories

Specification

REAR VIEW OF CONNECTOR

Specifications 73

Safety Information Product Overview Installation Diagnostics

XCMDS-XXX

BRAID SHIELD FORM WIRE

PE/GND

GRN/YEL

BRN

BLK

BLU

BLU (20 AWG)

BLU/WHT (20 AWG)

Drain Wire

Options and Accessories

Specification

Socket

SOLDER SIDE

Safety Information Product Overview Installation Diagnostics

XCMDBS-XXX

Options and Accessories

Specification

PE/GND

BRK+

BRK -

SOLDER SIDE

Socket

BRAID SHIELD

FORM WIRE

GRN/YEL

BRN

BLK

BLU

BLU (20 AWG)

BLU/WHT (20 AWG)

Drain Wire

Specifications 75

Safety Information Product Overview Installation Diagnostics

XTBMS-XXX

PIN 1

Options and Accessories

Specification

+24V

REAR VIEW OF CONNECTOR

RED

BLK

DRAIN WIRE

Safety Information Product Overview Installation Diagnostics

XEFTS-XXX / XUFTS-XXX

Options and Accessories

Specification

+5 VDC

SHIELD

PIN 1

12345

11 12 13 14 15

REAR VIEW OF CONNECTOR

GRN

BRN

Inner Drain Wire

BLU

ORN

Inner Drain Wire

BLK

YEL

WHT/GRY

Inner Drain Wire

GRY/WHT

WHT/BRN

BRN/WHT

RED/ORG

ORG/RED

RED/BLU (18 ga.)

BLU/RED (18 ga.)

RED/GRN

Inner Drain Wire

GRN/RED

Overall Shield Drain Wire

Pin 1

+5 VDC

COMMON

MOTOR TEMP

543 12

910 786

1213 11

SOLDER SIDE

Specifications 77

Safety Information Product Overview Installation Diagnostics

XEFCS-XXX / XUFCS-XXX

Pin 1

Options and Accessories

Specification

+5 VDC

SHIELD

SOLDER SIDE

Socket

GRN

BRN

Inner Drain Wire

BLU

ORN

Inner Drain Wire

BLK

YEL

WHT/GRY

Inner Drain Wire

GRY/WHT

WHT/BRN

BRN/WHT

RED/ORG

ORG/RED

RED/BLU (18 ga.)

BLU/RED (18 ga.)

RED/GRN

Inner Drain Wire

GRN/RED

+5 VDC

COMMON

MOTOR TEMP

Overall Shield Drain Wire

8 13

SOLDER SIDE

7 12

Safety Information Product Overview Installation Diagnostics

NT and MG Motor Cables

CMDS-XXX

Options and Accessories

Specification

1 1/2" MAX.

CMMS-XXX

1 1/2" MAX.

3 3/4" MAX.

GRN/YEL BRN BLK BLU

LDER SIDE

GRN/YEL BRN BLK BLU

SHELL

D A B C

LDER SIDE

Specifications 79

Safety Information Product Overview Installation Diagnostics

CBMS-XXX

Options and Accessories

Specification

GND

SOLDER SIDE

Socket

RED

BLK

DRAIN WIRE

Safety Information Product Overview Installation Diagnostics

EFCS-XXX / UFCS-XXX

Pin 1

Options and Accessories

Specification

+5 VDC

GND

MOTOR OVERTEMP

NOT USED

SOLDER SIDE

To Motor MG/NT/MH

Socket

GRN

BRN

BLU

Inner Drain Wire

ORN

Inner Drain Wire

BLK

YEL

WHT/GRY

Inner Drain Wire

GRY/WHT

WHT/BRN

BRN/WHT

RED/ORG

ORG/RED

RED/BLU

BLU/RED

RED/GRN

Inner Drain Wire

GRN/RED

Outer Drain Wire

+5 VDC

COMMON

MOTOR TEMP

8 13

SOLDER SIDE

To Epsilon EP

Specifications 81

Safety Information Product Overview Installation Diagnostics

Sync Cables

SNCDD-915-XXX

Options and Accessories

Specification

SNCFLOA-XXX

Pin 1

GND

SOLDER SIDE

Pin 1

ENCODER OUT A

ENCODER OUT B

ENCODER OUT Z

PULSE IN A (SINGLE ENDED)

PULSE IN B (SINGLE ENDED)

ANALOG OUT CHANNEL 1 +

ANALOG OUT CHANNEL 2 +

ANALOG OUT 0V

ANALOG COMMAND IN +

ANALOG COMMAND IN -

Pin 1

BLK

BRN

RED

ORG

YEL

GRN

BLU

PUR

Drain Wire

GND

13614715

SOLDER SIDE

BLU

ORN

GRN

BRN

BLK

YEL

WHT/BRN

BRN/WHT

WHT/GRY

GRY/WHT

RED/ORG

ORG/RED

RED/BLU

BLU/RED

GRN/RED

RED/GRN

12 11

GND

Blunt end

13614715

SOLDER SIDE

1012 11

Safety Information Product Overview Installation Diagnostics

SNCMD-815-XXX

Pin 1

Options and Accessories

Specification

SNCFLI-XXX

Pin 1

-A

-B

-Z

GND

+5 VDC

CONNECTOR END VIEW

GND

N/C

RED

ORG

GRN

YEL

BLK

BRN

PUR

BLU

DRAIN WIRE

BLK

BRN

RED

ORG

YEL

GRN

BLU

PUR

Drain Wire

9 2

13614715

SOLDER SIDE

1012 11

Blunt end

SOLDER SIDE

Specifications 83

Safety Information Product Overview Installation Diagnostics

SNCMD-89-XXX

Pin 1

Options and Accessories

Specification

SNCE-XXX

Pin 1

+5 Vdc

GND

N/C

798

SOLDER SIDE

A+

A-

B+

B-

Z+

Z-

RED

ORG

GRN

YEL

BLK

BRN

PUR

BLU

Drain Wire

CONNECTOR END VIEW

RED/WHT

YEL/WHT

BLU/WHT

BLK/WHT

YEL

BLU

RED

BLK

DRAIN WIRE

Pin removed

Completely remove pin 4

A+

A-

B+

B-

Z+

Z-

+5 Vdc

GNDGND

Safety Information Product Overview Installation Diagnostics

8 7

Communications Cables

ESA-SP-485-XXX

Options and Accessories

Specification

SIGNAL GND

ETH-PATCH-XXX

TXRX+

TXRX-

PIN 1

Drain Wire

WHT/GRN

GRN

WHT/BLU

BLU

WHT/ORG

ORG

WHT/BRN

BRN

470 Ω

1111131312

252524

220 Ω

SOLDER SIDE

Pin 1

SIGNAL GND

TXRX+

TXRX-

220 Ω

181816

212123

470 Ω

WHITE

ORANGE

LIGHT GREEN

GREEN

BLUE

LIGHT BLUE

LIGHT BROWN

BROWN

Specifications 85

Safety Information Product Overview Installation Diagnostics

Options and Accessories

Specification

Index

AC Line Filter Installation Notes, 8 AC Line Filters, 7 AC Supplies NOT Requiring Transformers,

14 AC Supplies Requiring Transformers, 15 Achieving Low Impedance Connections, 3 Analog Command Wiring, 43

Basic Installation Guidelines, 3

Cable Diagrams, 72 Cable to Enclosure Shielding, 7 CMDS-XXX Cable, 79 CMMS-XXX Cable, 79

EIO26-XXX Cable, 72 Electromagnetic Compatibility, 3 Encoder Output Signal Wiring, 43 Environmental Considerations, 4 Epsilon EP Drive Options, 59 Epsilon EP Specifications, 65

Fault Codes, 52 Fault Descriptions, 54 Feature Location, 1

High Power Connections, 13

DC Logic Power Supply Wiring, 31 Declaration of Conformity, ix Diagnostic Analog Output Test Points, 57 Diagnostic Display, 51 Diagnostics and Troubleshooting, 51 Drive Enable Wiring, 37 Drive Faults, 57 Drive overload protection, viii

Input Power Connections, 19 Input/Output, 37 Installation, 3

Line Fusing, 18 Logic Power Supply Specification, 31

Motor Brake Wiring, 35 Motor Feedback Wiring, 33 Motor Power Wiring, 24

Options and Accessories, 59

Product Overview, 1 Pulse Mode Wiring, 45

Rebooting the Drive, 58 Resetting Faults, 58

Underwriters Laboratories Recognition, vii

Viewing Active Drive Faults, 58

Wire Size, 18 Wiring Notes, 4

Safety Information, v Safety of Machinery, v Safety Precautions, v Setup, Commissioning and Maintenance, v Shunt Control, 22 Shunt Resistor Kit Installation, 22 Specifications, 65

Transformer Sizing, 17

Control Techniques Epsilon EP Drive Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual