Emerson 400518-01 User Manual
Epsilon EP Drive
Installation Manual
Date: December 15, 2006
© Control Techniques Americas LLC, 2006
P/N 400518-01
Revision: A1
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: A1
Date: December 15, 2006
© Control Techniques Americas LLC, 2006
© Control Techniques Americas LLC, 2006
Part Number: 400518-01
Revision: A1
Date: December 2006
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 Corporation, 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.
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)
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.
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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 iii
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 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 bonding) - 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.
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.
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Underwriters Laboratories Listed
LISTED 51Y8
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
• 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 20% for EP206,
10% for EP204, and no derating required for EP202
• 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 15 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 ports 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.
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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
60
50
40
30
20
Time (seconds)
10
0
100 125 150 175 200
% Drive 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,
Model Number:
System Options:
Conforms to the following product specification:
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
This servo drive is intended to be used with an appropriate motor, electrical protection components and other
equipment 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 responsible for ensuring that
the end product or system complies with all the relevant laws in the country where it is to be used. Refer to the
by 93/68/EEC and the EMC Directive 89/336/EEC
product manual for installation guidelines.
EP204-B00, EP204-I00, EP204-IDN, EP204-P00, EP204-PDN,
EP206-B00, EP206-I00, EP206-IDN, EP206-P00, EP206-PDN
STI-24IO Interface Board, STI-SNCOA Analog/Sync Output Interface
Board, STI-SNCI Sync Input Interface Board, BRM-1 Motor Brake
Supplementary information:
Control Techniques Americas LLC
12005 Technology Drive
Eden Prairie, MN 55344
Epsilon EP Digital Servo Drive
Relay, and SM-Heatsink DBR-1 Brake Resistor
USA
Director, Motion Control Product Line
Steve Bartz
European Contact:
December 12, 2006
Date
Sobetra Automation
Langeveldpark Lot 10
P. Dasterleusstraat 2
1600 St. Pieters Leeuw, Belgium
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viii
Table of Contents
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Safety Information iii
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Qualified Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Setup, Commissioning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Safety of Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Identification of Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Underwriters Laboratories Listed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Drive Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
CE Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cable to Enclosure Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 2: Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 3: High Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transformer Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Line Fusing and Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AC Input Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operation on DC Input Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
External Shunt Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Motor Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Step 4: Low Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DC Logic Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ix
Motor Feedback Wiring (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Motor Brake Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Input/Output and Drive Enable Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Analog Command Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Encoder Output Signal Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Diagnostics and Troubleshooting 41
Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Status Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Options and Accessories 49
Epsilon EP Drive Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
STI-24IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
STI-SNCOA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
STI-SNCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
STI-ENC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Specifications 55
Epsilon EP Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Epsilon EP Drive Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
XV Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
NT and MG Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Sync Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Communications Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Index 73
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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 (J11)
(EP-Pxx only)
DeviceNet Connector (J9)
(EP-IDN or EP-PDN only)
Digital I/O Connctor (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
Epsilon EP drives are rated at 240 Vac input voltage and can operate with an input voltage from 20 to 264 Vac. The
EP drives are available in three current ratings.
Drive Model Continuous Power Rating Continuous Current Peak Current
Epsilon EP202 670 W 2.2 A RMS 4.4 A RMS
Epsilon EP204 1140 W 4.0 A RMS 8.0 A RMS
Epsilon EP206 1610 W 6.5 A RMS 13.0 A RMS
Options and
Accessories
Specification
2
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 7
Step 3: High Power Connections, page 10
Step 4: Low Power Connections, page 22
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.
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
resistance to prevent loss through corrosion that will hinder the low impedance connection. Enclosure manufacturers
offer corrosion resistant, unpainted mounting plates to help.
Installation 3
Safety Information Product Overview Installation Diagnostics
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
• Other interface equipment chassis and electrical connectors
• 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
A good rule to follow when specifying conductors for high frequency applications is to use a metal strap with a length
to width ratio that is less than 3:1.
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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 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.
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.).
• 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.
4
Safety Information Product Overview Installation Diagnostics
A
• 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.
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• 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.
Panel Layout
Metallic
Raceway
PE
C In
L2
L1
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 2: AC Filter and Cable Connections
Installation 5
Safety Information Product Overview Installation Diagnostics
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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 3: 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
6
Safety Information Product Overview Installation Diagnostics
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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 Schaffner Part # Control Techniques Part # Rating
EP202, EP204
EP206 FS5278-16/08 960305-01
The following filters are a suitable alternative:
Epsilon EP Part # Rating
EP206 Schaffner FN 2070M-16/8
EP202, EP204, EP206 Corcom 20EQ1
EP202 Schaffner FN 2070-6-06 6 A, 240 V, 1 Ø
FN2070-10/06 960307-01 10 A, 240 V, 1 Ø
FS5278-16/08 960305-01
16 A, 240 V, 1 Ø
20 A, 240 V, 1 Ø
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.
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.
Installation 7
Safety Information Product Overview Installation Diagnostics
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Specification
The following table applies to the "A" dimension as shown in figure 4 below for the base and indexing drives.
[150.88]
5.22
[132.59]
Drive Model
-B or -I only
Dimension "A"
inches [mm]
Minimum Panel Width
EP202 2.11 [53.59] 2.90 [74]
EP204 2.11 [53.59] 2.90 [74]
EP206 2.82 [71.63] 3.60 [91]
5.94
.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 4: Mechanical Drawing for Epsilon Base and Indexing Drives
8
Safety Information Product Overview Installation Diagnostics
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The following table applies to the "A" dimension as shown in figure 5 for the programming drives.
Specification
Drive Model
Dimension "A"
inches [mm]
EP202-Pxx-xxxx 2.69 [68.3] 3.45 [88]
EP204-Pxx-xxxx 2.69 [68.3] 3.45 [88]
EP206-Pxx-xxxx 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]
Minimum Panel Width
inches [mm]
“A”
2.69
[68.3]
1.20
1.03
[30.48]
[26.16]
(4X)Ø.219
[5.56]
Figure 5: Mechanical Drawing for Epsilon 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.
Installation 9
Safety Information Product Overview Installation Diagnostics
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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
L1
L2
PE
R
S
T
serial (J2)
+
_
logic motor
digital i/o (J3)
EP204-I00-0000
9606XX-XX A1
SN 0610E014
Epsilon
Drive
PE
J8
3 MIN
J6J5J10
Logic
Power
Supply
24 Vdc
+ -
Epsilon EP
reset
L1
L2
PE
R
S
T
serial (J2)
+
_
logic motor
digital i/o (J3)
EP204-I00-0000
9606XX-XX A1
SN 0610E014
Epsilon
Drive
PE
Connection
J8
3 MIN
J6J5J10
Motor Motor
Figure 6: Typical System Grounding Diagram
Control
Transformer
Output
Neutral Hot
Convenience
Outlet
10
Safety Information Product Overview Installation Diagnostics
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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
L3
SECONDARY
EARTH
GROUND
Typ. 208 Vac
120 Vac
(Protective Earth)
Neutral is used only when 120 Vac operation
is desired. It is never fused.
L2
L1
PE
N
To Fusing and
Drive Terminals
Figure 7: Earth Grounded WYE Distribution Transformer, 120/208Y 3Ø
Installation 11
Safety Information Product Overview Installation Diagnostics
DISTRIBUTION PANEL
L3
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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)
L2
L1
PE
To Fusing and
Drive Terminals
Figure 8: Earth Grounded Delta Distribution Transformer, 240 Vac 3Ø
DISTRIBUTION PANEL
L3
SECONDARY
Typ. 240 Vac
L2
L1
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)
PE
N
with L1 or L2.
Figure 9: 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.
12
Safety Information Product Overview Installation Diagnostics
DISTRIBUTION PANEL 3 Ø Isolation Transformer
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L3
L2
To Fusing and
Drive Terminals
L1
N
EARTH
GROUND
(Protective Earth)
PE
Figure 10: 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
L3
L2
L1
PE
To Fusing and
Drive Terminals
Figure 11: Three-Phase Delta (ungrounded) Distribution to a Three-Phase Delta
Isolation Transformer
Installation 13
Safety Information Product Overview Installation Diagnostics
s
s
DISTRIBUTION PANEL 3 Ø Isolation Step Down Transformer
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L3
L2
Specification
> 140 Vac
EARTH
GROUND
(Protective Earth)
To Fusing and
Drive Terminals
L1
N
PE
Figure 12: Grounded WYE Distribution >140 Vac Phase to Neutral. Recommend Using
Step Down Transformer so Line to Line is 240 Vac or less.
Fuse
Fuse
Fuse
L1
To Drive
Terminal
L2
L1
To Drive
Terminal
L2
Figure 13: Single Phase Power Supply Connections
Transformer Sizing
If your application requires a transformer, use the following table for sizing the KVA rating. The values in the table
are based on “worst case” power usage and can be considered a conservative recommendation. You can down-size
the values only if the maximum power usage is less than the transformer continuous power rating. 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.
14
Safety Information Product Overview Installation Diagnostics
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.
Drive/Motor Combination Suggested KVA Rating
EP202/NT-207 1.2
EP202/NT-212 1.2
EP204/NT-207 1.2
EP204/NT-212 1.7
EP206/NT-212 1.7
EP206/NT-320 3.0
EP206/NT-330 3.0
EP206/NT-345 3.0
EP202/XV-402 0.2
EP202/XV-403 0.3
EP202/XV-604 0.8
EP202/XV-606 0.8
EP204/XV-6011 1.3
EP204/XV-8017 2.0
EP204/XV-8022 2.2
EP204/XV-8023 2.1
EP206/XV-8014 2.0
EP206/XV-8022 2.2
EP206/XV-8023 2.1
EP206/XV-8028 2.6
EP206/XV-13046 3.3
EP206/XV-13051 2.1
EP206/XV-13089 3.6
Options and
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Specification
Installation 15
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