Baldor MicroFlex e100 MFE230A003, MFE230A006, MFE230A009 Servo Drive Installation Manual

Contents
1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1
MicroFlex e100 features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.2
Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2.2.1
2.3
3
Identifying the catalog number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2-3
Basic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1
3.1.2
3.1.3
3.1.4
3.2
Mechanical installation and cooling requirements . . . . . . . . . . . .
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.3
3.4
MN1942
3-1
3-1
3-2
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-8
3-9
3.3.1
3.3.2
3-9
3-10
Front panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Earthing / grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single-phase or three-phase power connections . . . . . . . . . . . . . . . . . . . . .
Input power conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power disconnect and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended fuses, circuit breakers and wire sizes . . . . . . . . . . . . . . . .
Drive overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24V control circuit supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11
3-12
3-13
3-14
3-15
3-15
3-16
3-17
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting and cooling the MicroFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating characteristic - 3A model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating characteristic - 6A model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating characteristic - 9A model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overtemperature trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.5
Power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and miscellaneous hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other information needed for installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor circuit contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor power cable pin configuration - Baldor BSM rotary motors . . . . . . .
Motor cable pin configuration - Baldor linear motors . . . . . . . . . . . . . . . . . .
Sinusoidal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal switch connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor brake connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19
3-19
3-20
3-20
3-21
3-22
Regeneration resistor (Dynamic Brake resistor) . . . . . . . . . . . . . 3-23
Contents i
4
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1
5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4.1.1
4.1.2
4.1.3
4.1.4
4-2
4-6
4-8
4-10
Input / Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5.2
Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5-3
5-5
5-7
5-8
5-9
5-11
5.3
5.4
TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ETHERNET Powerlink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14
5-15
5-16
CAN connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17
5-17
5-18
Other I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.6.1
5.7
5-13
CAN interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.1
5.5.2
5.5.3
5.6
USB port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.4.1
5.4.2
5.4.3
5.5
Drive enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General purpose digital input DIN0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General purpose digital inputs DIN1 & DIN2 . . . . . . . . . . . . . . . . . . . . . . . .
Special functions on inputs DIN1 and DIN2 . . . . . . . . . . . . . . . . . . . . . . . . .
General purpose / status output DOUT0 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General purpose output DOUT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USB communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3.1
6
Incremental encoder feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SSI feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SinCos feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EnDat (absolute encoder) feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Node ID selector switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-20
Connection summary - recommended system wiring . . . . . . . . . 5-23
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1
6.1.2
6.2
Starting the MicroFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1
6.2.2
6.2.3
6.2.4
6.3
Connecting the MicroFlex e100 to the PC . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Mint Machine Center and Mint WorkBench . . . . . . . . . . . . . . . . .
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power on checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring the TCP/IP connection (optional) . . . . . . . . . . . . . . . . . . . . . . .
Mint Machine Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1
ii Contents
Starting MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-1
6-2
6-2
6-2
6-2
6-3
6-5
6-7
MN1942
6.4
6.5
Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8
6.4.1
6.4.2
6.4.3
6.4.4
6-9
6-10
6-11
6-13
Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5.1
6.5.2
6.5.3
7
Fine-tuning tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameters tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other tools and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14
6-16
6-17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
7.1.2
7.1.3
7.2
Problem diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SupportMe feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-cycling the MicroFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MicroFlex e100 indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
8
Help file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing a test move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATUS LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ETHERNET LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-1
7-1
7-1
7-2
7-2
7-3
7-4
7-5
7-5
7-5
7-6
7-6
7-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.1.12
8.1.13
8.1.14
MN1942
AC input power and DC bus voltage (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . .
24VDC control circuit supply input (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor output power (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regeneration (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs - drive enable and DIN0 general purpose (X3) . . . . . . . . . . .
Digital inputs DIN1, DIN2 - high speed general purpose (X3) . . . . . . . . . .
Digital outputs DOUT0, DOUT1 - status and general purpose (X3) . . . . .
Incremental encoder feedback option (X8) . . . . . . . . . . . . . . . . . . . . . . . . . .
SSI encoder feedback option (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SinCos / EnDat encoder feedback option (X8) . . . . . . . . . . . . . . . . . . . . . .
Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-3
8-3
8-3
8-4
8-4
8-4
8-5
8-5
8-5
8-5
8-6
8-6
8-7
Contents iii
Appendices
A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A.1.1
A.1.2
A.1.3
A.1.4
A.1.5
A.1.6
A.1.7
A.1.8
A.1.9
A.1.10
A.1.11
A-2
A-3
A-4
A-7
A-8
A-8
A-9
A-9
A-10
A-10
A-11
Fan tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Footprint filter (single-phase only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regeneration resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor power cable part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SSI feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder / Hall feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EnDat (absolute encoder) and SinCos feedback cables . . . . . . . . . . . . . .
Feedback cable part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.1.1
B.1.2
Servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
B-2
B-4
C CE Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.1.1
C.1.2
C.1.3
C.1.4
C.1.5
C.1.6
iv Contents
EMC Conformity and CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MicroFlex e100 compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of CE compliant components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC wiring technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC installation suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring of shielded (screened) cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-1
C-1
C-1
C-2
C-2
C-3
C-4
MN1942
1
1
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General Information
Copyright Baldor (c) 2006. All rights reserved.
This manual is copyrighted and all rights are reserved. This document or attached software may not, in
whole or in part, be copied or reproduced in any form without the prior written consent of Baldor.
Baldor makes no representations or warranties with respect to the contents hereof and specifically
disclaims any implied warranties of fitness for any particular purpose. The information in this document
is subject to change without notice. Baldor assumes no responsibility for any errors that may appear in
this document.
Mintt is a registered trademark of Baldor.
Windows 95, Windows 98, Windows ME, Windows NT, Windows XP and Windows 2000 are registered
trademarks of the Microsoft Corporation. UL and cUL are registered trademarks of Underwriters
Laboratories.
MicroFlex e100 is UL listed; file NMMS.E128059.
Limited Warranty
For a period of two (2) years from the date of original purchase, Baldor will repair or replace without
charge controls and accessories that our examination proves to be defective in material or workmanship.
This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused,
or improperly installed and has been used in accordance with the instructions and/or ratings supplied.
This warranty is in lieu of any other warranty or guarantee expressed or implied. Baldor shall not be held
responsible for any expense (including installation and removal), inconvenience, or consequential
damage, including injury to any person or property caused by items of our manufacture or sale. (Some
countries and U.S. states do not allow exclusion or limitation of incidental or consequential damages, so
the above exclusion may not apply.) In any event, Baldor’s total liability, under all circumstances, shall not
exceed the full purchase price of the control. Claims for purchase price refunds, repairs, or replacements
must be referred to Baldor with all pertinent data as to the defect, the date purchased, the task performed
by the control, and the problem encountered. No liability is assumed for expendable items such as fuses.
Goods may be returned only with written notification including a Baldor Return Authorization Number and
any return shipments must be prepaid.
Baldor UK Ltd
Mint Motion Centre
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
Telephone:
+44 (0) 1454 850000
Fax:
+44 (0) 1454 850001
E-mail:
[email protected]
Web site:
www.baldor.co.uk
See rear cover for other international offices.
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Product notice
Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are controlled
by this equipment. Improper use can cause serious or fatal injury.
Safety Notice
Intended use: These drives are intended for use in stationary ground based applications in industrial
power installations according to the standards EN60204 and VDE0160. They are designed for machine
applications that require variable speed controlled three-phase brushless AC motors. These drives are
not intended for use in applications such as:
H
Home appliances
H
Medical instrumentation
H
Mobile vehicles
H
Ships
H
Airplanes.
Unless otherwise specified, this drive is intended for installation in a suitable enclosure. The enclosure
must protect the drive from exposure to excessive or corrosive moisture, dust and dirt or abnormal
ambient temperatures. The exact operating specifications are found in section 8 of this manual. The
installation, connection and control of drives is a skilled operation, disassembly or repair must not be
attempted. In the event that a drive fails to operate correctly, contact the place of purchase for return
instructions.
Precautions
DANGER:
Do not touch any circuit board, power device or electrical connection before you first
ensure that no high voltage is present at this equipment or other equipment to which
it is connected. Electrical shock can cause serious or fatal injury. Only qualified
personnel should attempt to start-up, program or troubleshoot this equipment.
DANGER:
The motor circuit might have high voltages present whenever AC power is applied,
even when the motor is not moving. Electrical shock can cause serious or fatal
injury.
DANGER:
If a motor is driven mechanically, it might generate hazardous voltages that are
conducted to its power terminals. The enclosure must be earthed/grounded to
prevent possible shock hazard.
DANGER:
Be sure the system is properly earthed/grounded before applying power. Do not
apply AC power before you ensure that earths/grounds are connected. Electrical
shock can cause serious or fatal injury.
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WARNING: Be sure all wiring complies with the National Electrical Code and all regional and
local codes. Improper wiring may result in unsafe conditions.
WARNING: Be sure that you are completely familiar with the safe operation and programming of
this equipment. This equipment may be connected to other machines that have
rotating parts or parts that are controlled by this equipment. Improper use can cause
serious or fatal injury.
WARNING: The stop input to this equipment should not be used as the single means of
achieving a safety critical stop. Drive disable, motor disconnect, motor brake and
other means should be used as appropriate.
WARNING: Improper operation or programming of the drive may cause violent motion of the
motor and driven equipment. Be certain that unexpected motor movement will not
cause injury to personnel or damage to equipment. Peak torque of several times the
rated motor torque can occur during control failure.
WARNING: When operating a rotary motor with no load coupled to its shaft, remove the shaft key
to prevent it flying out when the shaft rotates.
WARNING: A regeneration resistor may generate enough heat to ignite combustible materials.
To avoid fire hazard, keep all combustible materials and flammable vapors away
from the brake resistors.
CAUTION:
To prevent equipment damage, be certain that the input power has correctly sized
protective devices installed.
CAUTION:
To prevent equipment damage, be certain that input and output signals are powered
and referenced correctly.
CAUTION:
To ensure reliable performance of this equipment be certain that all signals to/from
the drive are shielded correctly.
CAUTION:
Suitable for use on a circuit capable of delivering not more than the RMS
symmetrical short circuit amperes listed here at rated voltage.
Horsepower
RMS Symmetrical Amperes
1-50
5,000
CAUTION:
Avoid locating the drive immediately above or beside heat generating equipment, or
directly below water or steam pipes.
CAUTION:
Avoid locating the drive in the vicinity of corrosive substances or vapors, metal
particles and dust.
CAUTION:
Do not connect AC power to the drive terminals U, V and W. Connecting AC power
to these terminals may result in damage to the drive.
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CAUTION:
Baldor does not recommend using “Grounded Leg Delta” transformer power leads
that may create earth/ground loops and degrade system performance. Instead, we
recommend using a four wire Wye.
CAUTION:
Drives are intended to be connected to a permanent main power source, not a
portable power source. Suitable fusing and circuit protection devices are required.
CAUTION:
The safe integration of the drive into a machine system is the responsibility of the
machine designer. Be sure to comply with the local safety requirements at the place
where the machine is to be used. In Europe these are the Machinery Directive, the
ElectroMagnetic Compatibility Directive and the Low Voltage Directive. In the United
States this is the National Electrical code and local codes.
CAUTION:
Drives must be installed inside an electrical cabinet that provides environmental
control and protection. Installation information for the drive is provided in this
manual. Motors and controlling devices that connect to the drive should have
specifications compatible to the drive.
CAUTION:
Failure to meet cooling air flow requirements will result in reduced product lifetime
and/or drive overtemperature trips.
CAUTION:
Violent jamming (stopping) of the motor during operation may damage the motor and
drive.
CAUTION:
Operating the MicroFlex e100 in Torque mode with no load attached to the motor can
cause the motor to accelerate rapidly to excessive speed.
CAUTION:
If the drive enable signal is already present when power is applied to the
MicroFlex e100, the motor could begin to move immediately.
CAUTION:
Do not tin (solder) exposed wires. Solder contracts over time and may cause loose
connections. Use crimp connections where possible.
CAUTION:
Electrical components can be damaged by static electricity. Use ESD (electrostatic
discharge) procedures when handling this drive.
CAUTION:
Ensure that encoder wires are properly connected. Incorrect installation may result
in improper movement.
CAUTION:
The threaded holes in the top and bottom of the case are for cable clamps. The holes
are 11.5 mm deep and accept M4 screws, which must be screwed in to a depth of
at least 8mm.
CAUTION:
Removing the cover will invalidate UL certification.
CAUTION:
The metal heatsink on the left side of the MicroFlex e100 can become very hot
during normal operation.
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Introduction
2.1 MicroFlex e100 features
The MicroFlex e100 is a versatile brushless servo drive, providing a flexible and powerful motion
control solution for rotary and linear motors. Standard features include:
H
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Single axis AC brushless drive.
Range of models with continuous current ratings of 3A, 6A
or 9A.
Direct connection to 115VAC or 230VAC single-phase or
230VAC three-phase supplies.
Universal feedback interface supporting incremental
encoder, SSI, EnDat or SinCos feedback.
Position, velocity and current control.
Auto-tuning wizard (including position loop) and software
oscilloscope facilities provided by Mint WorkBench v5.5
configuration software (supplied).
3 optically isolated general purpose digital inputs. Two
inputs have ‘fast input’ capability, providing real-time
position capture.
1 optically isolated drive enable input.
1 optically isolated general purpose digital output.
1 optically isolated digital output to indicate error
conditions.
USB 1.1 serial port (compatible with USB2.0).
CANopen protocol for communication with Mint controllers
and other third party CANopen devices.
ETHERNET Powerlink & TCP/IP support: Twin Ethernet
ports with integrated hub for communication with host PC
or other ETHERNET Powerlink devices.
MicroFlex e100 will operate with a large range of brushless rotary and linear servo motors - for
information on selecting Baldor servo motors, please see the sales brochure BR1202 available
from your local Baldor representative.
This manual is intended to guide you through the installation of MicroFlex e100. The sections
should be read in sequence.
The Basic Installation section describes the mechanical installation of the MicroFlex e100, the
power supply connections and motor connections. The other sections require knowledge of the
low level input/output requirements of the installation and an understanding of computer software
installation. If you are not qualified in these areas you should seek assistance before proceeding.
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2.2 Receiving and inspection
When you receive your MicroFlex e100, there are several things you should do immediately:
1. Check the condition of the shipping container and report any damage immediately to the
carrier that delivered your MicroFlex e100.
2. Remove the MicroFlex e100 from the shipping container and remove all packing material.
The container and packing materials may be retained for future shipment.
3. Verify that the catalog number of the MicroFlex e100 you received is the same as the catalog
number listed on your purchase order. The catalog number is described in the next section.
4. Inspect the MicroFlex e100 for external damage during shipment and report any damage to
the carrier that delivered your MicroFlex e100.
5. If MicroFlex e100 is to be stored for several weeks before use, be sure that it is stored in a
location that conforms to the storage humidity and temperature specifications shown in
section 8.1.13.
2.2.1 Identifying the catalog number
The MicroFlex e100 is available with different current ratings. The catalog number is marked on
the side of the unit. It is a good idea to look for the catalog number (sometimes shown as ID/No:)
and write it in the space provided here:
Catalog number:
Installed at:
MFE_____________________
________________________
Date:
______
A description of a catalog number is shown here, using the example MFE230A003:
Meaning
Alternatives
MFE
MicroFlex e100 family
-
230
Requires an AC supply voltage of 115-230 Volts, 1Φ or 3Φ
A003 Continuous current rating of 3A
2-2 Introduction
A006=6A; A009=9A
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2.3 Units and abbreviations
The following units and abbreviations are used in this manual:
V ...............
W ..............
A ...............
Ω ...............
µF . . . . . . . . . . . . . .
pF . . . . . . . . . . . . . .
mH . . . . . . . . . . . . .
Volt (also VAC and VDC)
Watt
Ampere
Ohm
microfarad
picofarad
millihenry
Φ...............
ms . . . . . . . . . . . . . .
µs . . . . . . . . . . . . . .
ns . . . . . . . . . . . . . .
phase
millisecond
microsecond
nanosecond
mm . . . . . . . . . . . . .
m...............
in . . . . . . . . . . . . . . .
ft . . . . . . . . . . . . . . .
lbf-in . . . . . . . . . . . .
N·m . . . . . . . . . . . . .
millimeter
meter
inch
feet
pound force inch (torque)
Newton meter (torque)
ADC . . . . . . . . . . . .
ASCII . . . . . . . . . . .
AWG . . . . . . . . . . . .
CAL . . . . . . . . . . . .
CAN . . . . . . . . . . . .
CDROM . . . . . . . . .
CiA . . . . . . . . . . . . .
CTRL+E . . . . . . . . .
DAC . . . . . . . . . . . .
DS301 . . . . . . . . . .
DS401 . . . . . . . . . .
DS402 . . . . . . . . . .
DS403 . . . . . . . . . .
EDS . . . . . . . . . . . .
EMC . . . . . . . . . . . .
EPL . . . . . . . . . . . .
HMI . . . . . . . . . . . . .
ISO . . . . . . . . . . . . .
Kbaud . . . . . . . . . . .
LCD . . . . . . . . . . . .
Mbps . . . . . . . . . . .
MB . . . . . . . . . . . . .
MMC . . . . . . . . . . . .
(NC) . . . . . . . . . . . .
RF . . . . . . . . . . . . . .
SSI . . . . . . . . . . . . .
TCP/IP . . . . . . . . . .
UDP . . . . . . . . . . . .
Analog to Digital Converter
American Standard Code for Information Interchange
American Wire Gauge
CAN Application Layer
Controller Area Network
Compact Disc Read Only Memory
CAN in Automation International Users and Manufacturers Group e.V.
on the PC keyboard, press Ctrl then E at the same time.
Digital to Analog Converter
CiA CANopen Application Layer and Communication Profile
CiA Device Profile for Generic I/O Devices
CiA Device Profile for Drives and Motion Control
CiA Device Profile for HMIs
Electronic Data Sheet
Electromagnetic Compatibility
ETHERNET Powerlink
Human Machine Interface
International Standards Organization
kilobaud (the same as Kbit/s in most applications)
Liquid Crystal Display
megabits/s
megabytes
Mint Machine Center
Not Connected
Radio Frequency
Synchronous Serial Interface
Transmission Control Protocol / Internet Protocol
User Datagram Protocol
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2-4 Introduction
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Basic Installation
3.1 Introduction
You should read all the sections in Basic Installation to ensure safe installation.
This section describes the mechanical and electrical installation of the MicroFlex e100 in the
following stages:
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Location considerations
Mounting the MicroFlex e100
Connecting the AC power supply
Connecting the 24VDC control circuit supply
Connecting the motor
Installing a regeneration resistor (Dynamic Brake)
Connecting the feedback device
These stages should be read and followed in sequence.
3.1.1 Power sources
A 115 - 230VAC power source (IEC1010 over-voltage category III or less) in the installation area
is required. This may be single-phase or three-phase. An AC power filter is required to comply
with the CE directive for which the MicroFlex e100 was tested (see section 3.4.7).
The 24VDC control circuit supply must be a regulated power supply with a continuous current
supply capability of 1A (4A power on surge).
3.1.2 Hardware requirements
The components you will need to complete the basic installation are:
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H
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MN1942
24VDC power supply.
AC power supply filter (for CE compliance).
The motor that will be connected to the MicroFlex e100.
A motor power cable.
An encoder feedback cable, SSI cable, or EnDat / SinCos cable. A separate Hall cable might
also be required for linear motors.
A USB cable.
(Optional) A regeneration resistor (Dynamic Brake) might be required, depending on the
application. Without the regeneration resistor, the drive may produce an overvoltage fault. All
MicroFlex e100 models have overvoltage sensing circuitry. Regeneration resistors may be
purchased separately - see Appendix A.
A cooling fan may be required to allow operation of the MicroFlex e100 at full rated current
(see section 3.2.2).
Basic Installation 3-1
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H
A PC with the following specification:
Minimum specification
Recommended specification
Intel Pentium 500MHz
Intel PentiumIII 1GHz or faster
RAM
64MB
128MB
Hard disk space
40MB
40MB
Processor
CD-ROM
Communication
Screen
Mouse
Operating
system
A CD-ROM drive
USB port or Ethernet* port
1024 x 768, 16-bit color
1152 x 864, 16-bit color
A mouse or similar pointing device
Windows 2000 or Windows XP
* The Ethernet configuration used by a normal office PC is not suitable for direct
communication with the MicroFlex e100. It is recommended to install a separate dedicated
Ethernet adapter in the PC, which can be configured for use with the MicroFlex e100. See
section 6.2.4.
3.1.3 Tools and miscellaneous hardware
H
Your PC operating system user manual might be useful if you are not familiar with Windows.
H
Small screwdriver(s) with a blade width of 3mm or less for connector X1, and 2.5mm (1/10
in) or less for connector X3.
H
M5 screws or bolts for mounting the MicroFlex e100.
3.1.4 Other information needed for installation
This information is useful (but not essential) to complete the installation:
H
The data sheet or manual provided with your motor, describing the wiring information of the
motor cables/connectors.
H
Knowledge of whether the digital input signals will be ‘Active Low’ or ‘Active High’.
3-2 Basic Installation
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3.2 Mechanical installation and cooling requirements
It is essential that you read and understand this section before beginning the
installation.
CAUTION:
To prevent equipment damage, be certain that the input power has correctly
rated protective devices installed.
CAUTION:
To prevent equipment damage, be certain that input and output signals are
powered and referenced correctly.
CAUTION:
To ensure reliable performance of this equipment be certain that all signals
to/from the MicroFlex e100 are shielded correctly.
CAUTION:
Avoid locating the MicroFlex e100 immediately above or beside heat
generating equipment, or directly below water steam pipes.
CAUTION:
Avoid locating the MicroFlex e100 in the vicinity of corrosive substances or
vapors, metal particles and dust.
CAUTION:
Failure to meet cooling air flow requirements will result in reduced product
lifetime and/or drive overtemperature trips.
The safe operation of this equipment depends upon its use in the appropriate environment.
The following points must be considered:
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The MicroFlex e100 must be installed indoors, permanently fixed and located so that it can
only be accessed by service personnel using tools.
The maximum suggested operating altitude is 1000m (3300ft).
The MicroFlex e100 must be installed where the pollution degree according to IEC664 shall
not exceed 2.
The 24VDC control circuit supply must be installed so that the 24VDC supplied to the unit is
isolated from the AC supply using double or reinforced insulation.
The input of the control circuit must be limited to Safety Extra Low Voltage circuits.
Both the AC supply and the 24VDC supply must be fused.
The atmosphere must not contain flammable gases or vapors.
There must not be abnormal levels of nuclear radiation or X-rays.
To comply with CE directive 89/336/EEC an appropriate AC filter must be installed.
The MicroFlex e100 must be secured by the slots in the flange. The protective earth/ground
(the threaded hole on the top of the MicroFlex e100) must be bonded to a safety earth/ground
using either a 25A conductor or a conductor of three times the peak current rating whichever is the greater.
The threaded holes in the top and bottom of the case are for cable clamps. The holes are
threaded for M4 bolts no longer than 11mm (0.43 in) in length.
The D-type connectors on the front panel of the MicroFlex e100 are secured using two
hexagonal jack screws (sometimes known as “screwlocks”). If a jack screw is removed
accidentally or lost it must be replaced with a #4-40 UNC jack screw with an external male
threaded section no longer than 10mm (0.4 in).
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3.2.1 Dimensions
80
(3.2)
5
(2.5)
(0.2)
6
63.5
Mounting hole and slot detail
(0.24)
11
(0.4)
180
(7.1)
(6.6)
167.7
5.5 mm
Dimensions shown as: mm (inches).
6
(0.24)
Depth: 157 mm (6.2 in)
Weight: 3A: 1.45kg (3.2lb)
6A: 1.50kg (3.3lb)
9A: 1.55kg (3.4lb)
Figure 1 - Mounting and overall dimensions
3-4 Basic Installation
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3.2.2 Mounting and cooling the MicroFlex e100
Ensure you have read and understood the Mechanical installation and location requirements in
section 3.2. Mount the MicroFlex e100 vertically on its rear side, the side opposite the front panel.
M5 bolts or screws should be used to mount the MicroFlex e100. Detailed dimensions are shown
in section 3.2.1.
For effective cooling, the MicroFlex e100 must be mounted upright on a smooth vertical metal
surface. The MicroFlex e100 is designed to operate in an ambient temperature of 0°C to 45°C
(32°F to 113°F). Output current must be derated between 45°C (113°F) and the absolute
maximum ambient temperature of 55°C (131°F). Within the ambient temperature range:
The 3A model is designed to operate without any additional cooling methods.
The 6A and 9A models require a forced air flow, passing vertically from the bottom to the top of
the MicroFlex e100 case, to allow full rated current at 45°C (113°F).
Temperature derating characteristics are shown in sections 3.2.3 to 3.2.5.
Note:
Failure to meet cooling air flow requirements will result in reduced product lifetime
and/or drive overtemperature trips. It is recommended to check periodically the
operation of the cooling equipment. Optional fan tray FAN001-024, mounted exactly
as shown in section A.1.1., ensures that correct cooling is provided and allows the
MicroFlex e100 to be UL listed.
3.2.2.1 Effects of mounting surface and proximity
Hot
Metal backplane
15mm
If the MicroFlex e100 is mounted above or
below another MicroFlex e100 (or other
obstruction), there should be a minimum space
of 90mm to maintain effective cooling.
Remember that when a MicroFlex e100 is
mounted above another MicroFlex e100 or
heat source, it will be receiving air that has
been already heated by the device(s) below it.
Multiple MicroFlex e100 units mounted above
each other should be aligned, not offset, to
promote air flow across the heatsinks.
Warm
The proximity of the MicroFlex e100 to other
components could affect cooling efficiency. If
the MicroFlex e100 is mounted beside another
MicroFlex e100 (or other obstruction), there
should be a minimum space of 15mm to
maintain effective cooling.
90mm
It is recommended to allow approximately
60mm at the front to accommodate wiring and
connectors.
MN1942
Cool
Forced air flow
15mm
The derating characteristics assume the
MicroFlex e100 is mounted on 3mm thick (or
less) metal plate. If the MicroFlex e100 is
mounted on 10mm plate then the current
characteristics shown in sections 3.2.3 to 3.2.5
may be increased by up to 7% if there is no
forced air cooling, or 15% if forced air cooling
is present.
Fan
Fan
Figure 2 - Cooling and proximity
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3.2.3 Derating characteristic - 3A model
The following derating characteristics are for model MFE230A003.
Single-phase AC supply
Rated output current (Arms)
3
1m/s forced air
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Three-phase AC supply
3
Rated output current (Arms)
1m/s forced air
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for model MFE230A003 is 6A.
3-6 Basic Installation
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3.2.4 Derating characteristic - 6A model
The following derating characteristics are for model MFE230A006.
Single-phase AC supply
Rated output current (Arms)
6
1.5m/s forced air
5
4
1m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Three-phase AC supply
Rated output current (Arms)
6
1.5m/s forced air
5
4
1m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for model MFE230A006 is 12A.
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3.2.5 Derating characteristic - 9A model
The following derating characteristics are for model MFE230A009.
Single-phase AC supply
9
Rated output current (Arms)
8
7
3.5m/s forced air
6
2.5m/s forced air
5
1.5m/s forced air
4
1m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Three-phase AC supply
9
Rated output current (Arms)
8
3.5m/s forced air
7
2.5m/s forced air
6
1.5m/s forced air
5
4
1m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Notes:
Load power factor = 0.78.
Overload limit for model MFE230A009 is 18A.
3.2.6 Overtemperature trips
The MicroFlex e100 contains internal temperature sensors that will cause it to trip and disable if
the temperature exceeds 80°C on the 3A model, or 75°C on the 6A and 9A models. This limit can
be read using the TEMPERATURELIMITFATAL keyword - see the Mint help file for details.
3-8 Basic Installation
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3.3 Connector locations
3.3.1 Front panel connectors
X1 Power
LEDs
Earth/Ground
The STATUS, CAN and ETHERNET
LEDs are described in section 7.2.1.
Earth/Ground
(NC)
L1
AC Phase 1 / L
L2
AC Phase 2 / N
L3
AC Phase 3
U
Motor U
V
Motor V
W
Motor W
R1
Regen
R2
Regen
Node ID
These switches set the MicroFlex e100’s
node ID for ETHERNET Powerlink, and the
final value of the IP address when using
TCP/IP. See sections 5.6.1 and 6.2.4.
USB
1
2
3
4
(NC)
DataData+
GND
X6 Auxiliary port
(Currently unused)
X3 Input / Output
1 Status2 DGND
3 DOUT14 DIN25 DGND
6 DIN17 DIN08 DGND
9 Drive enable10 Shield
11
12
13
14
15
16
17
18
19
20
Status+
DGND
DOUT1+
DIN2+
DGND
DIN1+
DIN0+
DGND
Drive enable+
Shield
X8 Feedback In
X2 Control circuit power
0V
+24V
(NC) = Not Connected. Do not
make a connection to this pin.
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Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Shell
Incremental
CHA+
CHB+
CHZ+
Sense
Hall UHall U+
Hall VHall V+
CHACHBCHZ+5V out
DGND
Hall WHall W+
Shield
SinCos
(NC)
(NC)
(NC)
Sense
SinSin+
CosCos+
(NC)
(NC)
(NC)
+5V out
DGND
(NC)
(NC)
Shield
SSI
Data+
Clock+
(NC)
Sense
(NC)
(NC)
(NC)
(NC)
DataClock(NC)
+5V out
DGND
(NC)
(NC)
Shield
EnDat
Data+
Clock+
(NC)
Sense
Sin-*
Sin+*
Cos-*
Cos+*
DataClock(NC)
+5V out
DGND
(NC)
(NC)
Shield
* EnDat v2.1 only. EnDat v2.2 does not use the Sin and
Cos signals.
Tightening torque for terminal block connections (X1 & X3) is 0.5-0.6Nm
(4.4-5.3 lb-in). Maximum wire sizes: X1: 2.5mm2; X3: 0.5mm2.
Basic Installation 3-9
www.supportme.net
3.3.2 Top panel connectors
CAN
1
2
3
4
5
6
7
8
9
(NC)
CANCAN GND
(NC)
Shield
CAN GND
CAN+
(NC)
CAN V+
Ethernet
1
2
3
4
5
6
7
8
3-10 Basic Installation
TX+
TXRX+
(NC)
(NC)
RX(NC)
(NC)
Both connectors
have identical
pinouts.
MN1942
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3.4 Power connections
This section provides instructions for connecting the AC power supply.
The installer of this equipment is responsible for complying with NEC (National Electric Code)
guidelines or CE (Conformite Europeene) directives and application codes that govern wiring
protection, earthing/grounding, disconnects and other current protection.
DANGER:
Electrical shock can cause serious or fatal injury. Do not touch any
power device or electrical connection before you first ensure that
power has been disconnected and there is no high voltage present
from this equipment or other equipment to which it is connected.
MicroFlex e100 drives are designed to be powered from standard single and three-phase lines
that are electrically symmetrical with respect to earth/ground. The power supply module within
all MicroFlex e100 models provides rectification, smoothing and current surge protection. Fuses
or circuit breakers are required in the input lines for cable protection.
Note:
A Residual Current Device (RCD) must not be used for fusing the drive.
An appropriate type of circuit breaker or fuse must be used.
All interconnection wires should be in metal conduits between the MicroFlex e100, AC power
source, motor, host controller and any operator interface stations. Use UL listed closed loop
connectors that are of appropriate size for the wire gauge being used. Connectors are to be
installed using only the crimp tool specified by the manufacturer of the connector. Only class 1
wiring should be used.
3.4.1 Earthing / grounding
A permanent earth/ground bonding point is provided on the heatsink, which must be used as the
protective earth. It is labeled with the protective earth symbol in the casting and does not form any
other mechanical function.
Connector X1 contains earth terminals, but these must not be used as protective earth since the
connector does not guarantee earth connection first, disconnection last. Earthing methods are
shown in section 3.4.2.
Note:
When using unearthed/ungrounded distribution systems, an isolation transformer
with an earthed/grounded secondary is recommended. This provides three-phase
AC power that is symmetrical with respect to earth/ground and can prevent
equipment damage.
3.4.1.1 Protection class
User protection has been achieved using Protective Class I (EN61800-5-1, 3.2.20), which
requires an earth connection to the unit whenever hazardous voltages are applied. The
equipment provides protection against electric shock by:
H
Means of connection of protective earth to accessible live conductive parts.
H
Basic insulation.
3.4.1.2 Earth leakage
Maximum earth leakage from the MicroFlex e100 is 3.4mA per phase (230V 50Hz supply). This
value does not include the earth leakage from the AC power filter, which could be much larger
(see section A.1.3). If the MicroFlex e100 and filter are mounted in an enclosure, it is
recommended the enclosure is earthed using a 10mm2 conductor.
MN1942
Basic Installation 3-11
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3.4.2 Single-phase or three-phase power connections
Location Connector X1
(Mating connector: Phoenix COMBICON
MSTB 2,5HC/11-ST-5,08)
Nominal input voltage 115VAC or 230VAC, 1Φ or 3Φ line to line
Minimum input voltage 105VAC, 1Φ or 3Φ line to line (see Note*)
Maximum input voltage 250VAC, 1Φ or 3Φ line to line
Note:
* The MicroFlex e100 will operate at lower input voltages, although performance
could be impaired. The drive will trip if the DC-bus voltage falls below 50V or 60% of
the no-load voltage, whichever occurs first.
For three phase supplies, connect supply to L1, L2 and L3 as shown in Figure 3. For single phase
supplies, connect the supply and neutral to any two line inputs, for example L1 and L2.
For CE compliance, an AC filter must be connected between the AC power supply and the
MicroFlex e100. If local codes do not specify different regulations, use at least the same gauge
wire for earth/ground as is used for L1, L2 and L3.
Tightening torque for terminal block connections is 0.5-0.6Nm (4.4-5.3 lb-in). The threaded hole
in the top and bottom of the case may be used as an additional functional earth/ground
connection for signals on connector X3. They may also be used to attach shield or strain relief
clamps. The holes are threaded for M4 bolts no longer than 11mm (0.43 in) in length.
AC
Supply
Route L1, L2, L3 and Circuit breaker or fuses.
earth/ground together
See section 3.4.4
in conduit or cable
AC filter.
See section
3.4.7
Connect
earth/ground
to protective
earth on top of
drive
Line (L1)
Line (L2)
Line (L3)
Isolating switch
Incoming safety
earth/ground (PE)
To earth/ground outer shield,
use 360° clamps connected
to enclosure backplane
STAR POINT
Figure 3 - Single or three-phase power connections
3-12 Basic Installation
MN1942
www.supportme.net
3.4.3 Input power conditioning
Certain power line conditions must be avoided; an AC line reactor, an isolation transformer or a
step up/step down transformer may be required for some power conditions:
H
If the feeder or branch circuit that provides power to the MicroFlex e100 has permanently
connected power factor correction capacitors, an input AC line reactor or an isolation
transformer must be connected between the power factor correction capacitors and the
MicroFlex e100 to limit the maximum symmetrical short circuit current to 5000A.
H
If the feeder or branch circuit that provides power to the MicroFlex e100 has power factor
correction capacitors that are switched on line and off line, the capacitors must not be
switched while the drive is connected to the AC power line. If the capacitors are switched on
line while the drive is still connected to the AC power line, additional protection is required.
A Transient Voltage Surge Suppressor (TVSS) of the proper rating must be installed
between the AC line reactor (or isolation transformer) and the AC input to the
MicroFlex e100.
3.4.3.1 Input power-cycling and inrush
If AC power has been removed from the MicroFlex e100, it should remain disconnected for the
period specified in Table 1, before it is reapplied.
MicroFlex e100
current rating
Minimum power cycle delay period
(seconds)
3A
25
6A
45
9A
65
Table 1 - Power cycle intervals
This delay allows the input surge protection circuit to perform correctly, ensuring that the inrush
current (typically 1.7A) is below the drive rated current. Power-cycling the drive more frequently
could cause high inrush current and corresponding nuisance operation of circuit breakers or
fuses. Repeated failure to observe the delay period could reduce the lifetime of the
MicroFlex e100.
3.4.3.2 Discharge period
DANGER:
After AC power has been removed from the MicroFlex e100, high voltages
(greater than 50VDC) can remain on the regeneration resistor connections
until the DC-bus circuitry has discharged. The high voltage can remain for
the period specified in Table 2.
MicroFlex e100
current rating
Time for DC-bus to discharge to 50V or less
(maximum, seconds)
3A
83
6A
166
9A
248
Table 2 - DC-bus discharge periods
MN1942
Basic Installation 3-13
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3.4.3.3 Supplying input power from a variac (variable transformer)
When AC power is supplied from a variac, the MicroFlex e100’s pre-charge circuit may not
operate correctly. To ensure that the pre-charge circuitry operates correctly, increase the variac
voltage to the desired level and then power cycle the 24VDC control circuit supply. This will restart
the pre-charge circuit and allow it to operate correctly.
3.4.4 Power disconnect and protection devices
A power disconnect should be installed between the input power supply and the MicroFlex e100
for a fail-safe method to disconnect power. The MicroFlex e100 will remain in a powered
condition until all input power is removed from the drive and the internal bus voltage has depleted.
The MicroFlex e100 must have a suitable input power protection device installed, preferably a
fuse. Recommended circuit breakers are thermal magnetic devices (1 or 3 phase as required)
with characteristics suitable for heavy inductive loads (C-type trip characteristic). Circuit breaker
or fuses are not supplied - see section 3.4.5. For CE compliance, see Appendix C.
From
supply
Circuit Breaker
From
supply
Fuse
L
L
L
L
N
N
N
N
Figure 4 - Circuit breaker and fuse, single-phase
From
supply
Circuit Breaker
From
supply
L1
L1
L1
L2
L2
L2
L3
L3
L3
Fuses
Circuit breaker or fuse are not supplied.
For CE Compliance, see Appendix C.
Figure 5 - Circuit breaker and fuse, three-phase
Note:
Metal conduit or shielded cable should be used. Connect conduits so the use of a
line reactor or RC device does not interrupt EMI/RFI shielding.
3.4.4.1 Using 2 phases of a 3-phase supply
Power may be derived by connecting two phases of an appropriate three-phase supply (L1 and
L2 for example). When supplying AC power in this way, the voltage between the two phases must
not exceed the rated input voltage of the MicroFlex e100. A two pole breaker must be used to
isolate both lines. Fuses must be fitted in both lines.
3-14 Basic Installation
MN1942
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3.4.5 Recommended fuses, circuit breakers and wire sizes
Table 3 describes the recommended fuses, circuit breakers and suitable wires sizes to be used
for power connections.
Catalog
Number
MFE A003
MFE..A003
MFE..A006
MFE..A009
Cont.
Output
p
A
Amps
(RMS)
AC
Supply
pp y
T
Type
Input Fuse
Circuit
breaker
(C t
(C-type)
)
Minimum
Wire Gauge
AWG
mm2
1Φ
Ferraz Shawmut:
6x32 FA series, 10A (W084314P)
or
BS88 2.5 URGS 10A (N076648)
10A
14
20
2.0
3Φ
Ferraz Shawmut:
6x32 FA series, 8A (V084313P)
or
BS88 2.5 URGS, 7A (M076647)
8A
14
20
2.0
1Φ
Ferraz Shawmut:
6x32 FA series, 20A (A084318P)
or
BS88 2.5 URGS, 20A (L097507)
20A
14
20
2.0
3Φ
Ferraz Shawmut:
6x32 FA series, 12.5A
(X084315P)
or
BS88 2.5 URGS, 12A (P076649)
12 5A
12.5A
14
20
2.0
1Φ
Ferraz Shawmut:
BS88 2.5 URGS, 25A (R076651)
25A
14
25
2.5
3Φ
Ferraz Shawmut:
6x32 FA series, 20A (A084318P)
or
BS88 2.5 URGS, 20A (L097507)
20A
14
20
2.0
3A
6A
9A
Table 3 - Protection device and wire ratings
Note:
All wire sizes are based on 75°C (167°F) copper wire. Higher temperature smaller
gauge wire may be used per National Electric Code (NEC) and local codes.
Recommended fuses are based on 25°C (77°F) ambient, maximum continuous
control output current and no harmonic current. Earth/ground wires must be the
same gauge, or larger, than the Line wires.
3.4.6 Drive overload protection
The MicroFlex e100 will immediately trip and disable if there is an overload condition. The
parameters for managing drive overloads are configured automatically by the Commissioning
Wizard (see section 6.4.3). If they need to be changed, use the Parameters tool in Mint
WorkBench (see section 6.5.2).
MN1942
Basic Installation 3-15
www.supportme.net
3.4.7 Power supply filters
To comply with EEC directive 89/336/EEC, an AC power filter of the appropriate type must be
connected. This can be supplied by Baldor and will ensure that the MicroFlex e100 complies with
the CE specifications for which it has been tested. Ideally, one filter should be provided for each
MicroFlex e100; filters should not be shared between drives or other equipment. Table 4 lists the
appropriate filters:
MicroFlex e100
current
rating
Input voltages
230VAC, 1Φ
230VAC, 3Φ
3A
FI0015A00 + line reactor
(see sections 3.4.7.1 and 3.4.7.2)
or
FI0029A00 (see section A.1.2)
FI0018A00
6A
FI0015A02 (see section 3.4.7.2)
or
FI0029A00 (see section A.1.2)
FI0018A00
FI0029A00 (see section A.1.2)
FI0018A03
9A
Table 4 - Baldor filter part numbers
Maximum earth leakage from the MicroFlex e100 is 3.4mA per phase (230V 50Hz supply). This
value does not include the earth leakage from the AC power filter, which could be much larger
(see section A.1.3).
3.4.7.1 Harmonic suppression
When operating the 3A MicroFlex e100 (part MFE230A003) on a single-phase AC supply, a
13mH 4Arms (10A peak) line reactor is required to ensure compliance with EN61000-3-2:2000
class A limits, when the total equipment supply load is less than 1kW.
3.4.7.2 Reversing the filter
When using filters FI0015A00 or FI0015A02 as specified in Table 4, they must be reversed to
ensure that the MicroFlex e100 complies with the CE specifications for which it has been tested.
The AC power supply should be connected to the filter terminals marked as the outputs, with the
MicroFlex e100 connected to the filter terminals marked as the inputs.
WARNING: This recommendation applies only to filters FI0015A00 and FI0015A02.
Alternative filters or protection devices must be connected as specified by
the manufacturer.
3-16 Basic Installation
MN1942
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3.4.8 24V control circuit supply
A 24VDC supply must be provided to power the controlling electronics. This is useful for safety
reasons where AC power needs to be removed from the power stage but the controlling
electronics must remain powered to retain position and I/O information.
A separate fused 24V supply should be provided for the MicroFlex e100. If other devices are
likely to be powered from the same 24V supply, a filter (Baldor catalog number FI0014A00)
should be installed to isolate the MicroFlex e100 from the rest of the system. Alternatively, a
ferrite sleeve may be attached to the supply cable near connector X2.
Location
Nominal input
voltage
Range
Input current
Maximum
Typical
Connector X2
24V
20-30VDC
1A continuous (4A typical power on surge, limited by NTC)
0.5A - 0.6A (not powering feedback device)
0.6A - 0.8A (powering feedback device)
Tightening torque for terminal block connections is 0.5-0.6Nm (4.4-5.3 lb-in).
Customer supplied
24VDC
24V filter
(optional)
Fuse *
Ferrite
sleeve**
+24V
GND
Use a twisted pair cable, with
ferrite sleeve attached close
to connector X2.
Incoming safety
earth/ground (PE)
STAR
POINT
* Recommended fuse: Bussman S504 20x5mm anti-surge 2A.
** Recommended ferrite sleeve: Fair-Rite part 0431164281 or similar.
Figure 6 - 24V control circuit supply connections
MN1942
Basic Installation 3-17
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3.5 Motor connections
MicroFlex e100 will operate with a large number of brushless servo motors. For information on
selecting Baldor servo motors please see the sales brochure BR1202, available from your local
Baldor representative. The motor must be capable of being powered by an inverter PWM output
- see section 8.1.3 for details. The motor can be connected directly to the MicroFlex e100 or
through a motor contactor (M-Contactor). The motor outputs are conditionally short-circuit proof.
Motors should ideally have a minimum inductance of 1mH per winding; for motors with lower
inductance an output reactor may be fitted in series with the motor.
When using a Baldor motor, the parameters for managing motor overloads are configured
automatically by the Commissioning Wizard (see section 6.4.3). If they need to be changed, or
you are using an alternative motor, use the Parameters tool in Mint WorkBench (see section
6.5.2).
Location
AC supply voltage
Output voltage range
Connector X1
115VAC, 1Φ
230VAC, 1Φ
230VAC, 3Φ
0-115VAC, 3Φ
0-230VAC, 3Φ
0-230VAC, 3Φ
Motor
To earth/ground outer
shield, use 360°
clamp connected to
backplane.
Connect motor
earth/ground
to protective
earth on top of
drive.
Earth
U
V
W
To earth/ground
outer shield,
use 360° clamp
connected to
backplane.
Optional motor
circuit contactors.
Unshielded
lengths should
be as short as
possible.
Figure 7 - Motor connections
CAUTION:
Do not connect supply power to the MicroFlex e100 UVW outputs. The
MicroFlex e100 might be damaged.
CAUTION:
The motor leads U, V and W must be connected to their corresponding U,
V or W terminal on the motor. Misconnection will result in uncontrolled motor
movement.
The motor power cable must be shielded for CE compliance. The connector or gland used at the
motor must provide 360 degree shielding. The maximum recommended cable length is 30.5m
(100ft).
Note:
For CE compliance the motor earth/ground should be connected to the drive
earth/ground.
3-18 Basic Installation
MN1942
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3.5.1 Motor circuit contactors
If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor) may be
installed to provide a physical disconnection of the motor windings from the MicroFlex e100 (see
section 3.5). Opening the M-Contactor ensures that the MicroFlex e100 cannot drive the motor,
which may be necessary during equipment maintenance or similar operations. Under certain
circumstances, it may also be necessary to fit a brake to a rotary motor. This is important with
hanging loads where disconnecting the motor windings could result in the load falling. Contact
your local supplier for details of appropriate brakes.
CAUTION:
If an M-Contactor is installed, the MicroFlex e100 must be disabled at least
20ms before the M-Contactor is opened. If the M-Contactor is opened while
the MicroFlex e100 is supplying voltage and current to the motor, the
MicroFlex e100 may be damaged. Incorrect installation or failure of the
M-Contactor or its wiring may result in damage to the MicroFlex e100.
Ensure that shielding of the motor cable is continued on both sides of the contactor.
3.5.2 Motor power cable pin configuration - Baldor BSM rotary motors
Figure 8 shows the pin configuration for a typical Baldor motor cable, part number CBL025SP-12:
Motor / cable pin
Motor cable wire color
Motor U
1
Black, labeled ‘1’
Motor V
4
Black, labeled ‘2’
Motor W
3
Black, labeled ‘3’
Signal name
Earth/ground
2
Green/Yellow
Thermal switch
A
Green
Thermal switch
B
White
Brake
C
Blue
Brake
D
Red
Note:
Not all motors
are fitted with
a brake so
pins C and D
might not be
connected.
B
C
A
D
C
4
1
B
A
D
4
3
2
Motor power connector
(male)
3
1
2
Cable connector end view
(female)
Figure 8 - Baldor motor power cable pin configuration
MN1942
Basic Installation 3-19
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3.5.3 Motor cable pin configuration - Baldor linear motors
The following table shows the pin colors used in a typical Baldor linear motor cable set, part
number AY1763A00:
Signal name
Motor cable wire color
Motor U
Black
Motor V
Red
Motor W
White
Motor ground
Green
Thermal switch
Blue
Thermal switch
Orange
Signal name
Hall 1 (U)
Hall cable wire color
White
Hall 2 (V)
Red
Hall 3 (W)
Black
Hall ground
Green
Hall +5VDC
Brown
3.5.4 Sinusoidal filter
A sinusoidal filter is used to provide a better quality waveform to the motor, reducing motor noise,
temperature and mechanical stress. It will reduce or eliminate harmful dV/dt values (voltage rise
over time) and voltage doubling effects which can damage motor insulation. This effect occurs
most noticeably when using very long motor cables, for example 30m (100 ft) or more. Baldor
motors intended to be used with drives are designed to withstand the effects of large dV/dt and
overvoltage effects. However, if very long motor cables are unavoidable and are causing
problems, then a sinusoidal filter may be beneficial.
3-20 Basic Installation
MN1942
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3.5.5 Thermal switch connection
You might wish to wire the motor’s thermal switch contacts (normally closed), using a relay, to a
digital input on connector X3 (see section 3.3.1). Using the Mint WorkBench Digital I/O tool, the
input can be configured to be the motor trip input. This allows the MicroFlex e100 to respond to
motor over-temperature conditions. The Mint keyword MOTORTEMPERATUREINPUT can also be
used to configure a digital input for this purpose. A typical circuit, using DIN1 as the input, is shown
in Figure 9.
‘X3’
DIN1+
16
A
motor
thermal
switch
Relay
B
DIN1+24VDC
0V
Separate
customer
supplied
24VDC supply
+24VDC
6
0V
Customer
supplied
24VDC
supply
Figure 9 - Motor thermal switch circuit
CAUTION:
The 24VDC power supply connected to the thermal switch must be a
separate supply as shown in Figure 9. Do not use the 24V supply used for
the drive enable signal, or the internally generated supply (if present). The
thermal switch wires often carry noise that could cause erratic drive
operation or damage. The thermal switch contacts must never be wired
directly to a digital input.
The separate 24VDC supply used for the thermal switch may also be used
for the motor brake circuit (section 3.5.6).
MN1942
Basic Installation 3-21
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3.5.6 Motor brake connection
You might wish to wire a motor’s brake, via relays, to digital outputs on connector X3 (see section
3.3.1). This provides a way for the MicroFlex e100 to control the motor’s brake. A typical circuit
is shown in Figure 10.
‘X3’
User supply V+
11
13
1
3
DOUT0+
The relays have normally open
contacts and are shown deactivated
(contacts open, brake engaged).
DOUT1+
C
DOUT0-
D
DOUT1-
from motor brake
connections
Relay 1
The inner shield
surrounding the
brake wires should
be earthed/grounded
at one point only.
Relay 2
User supply GND
+24VDC
0V
Separate
customer
supplied
24VDC supply
Figure 10 - Motor brake control circuit
This circuit uses the drive enable signal (configured using DRIVEENABLEOUTPUT to appear on
DOUT0) in conjunction with DOUT1 (configured as the MOTORBRAKEOUTPUT). See the Mint help
file for details. With this configuration, the following sequences can be used to control the brake.
To engage the brake:
H The motor is brought to rest under normal control;
H Relay 2 is deactivated, causing the brake to engage;
H The drive is disabled. This removes power from the motor and causes Relay 1 to be
deactivated.
To disengage the brake:
H The drive is enabled, activating Relay 1;
H Power is applied to the motor to hold position under normal control;
H Relay 2 is activated, causing the brake to be disengaged.
It may be necessary to include a small delay, after Relay 2 has been activated, before starting
motion. This delay will allow time for the relay contacts to engage and the brake to release.
CAUTION:
The 24VDC power supply used to power the brake must be a separate
supply as shown in Figure 10. Do not use the supply that is powering the
MicroFlex e100 digital outputs. The brake wires often carry noise that could
cause erratic drive operation or damage. The brake contacts must never be
wired directly to the digital outputs. The relay(s) should be fitted with a
protective flyback diode, as shown. The separate 24VDC supply used for the
motor brake may also be used to power the relay in the thermal switch circuit
(section 3.5.5).
3-22 Basic Installation
MN1942
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3.6 Regeneration resistor (Dynamic Brake resistor)
An optional external regeneration resistor may be required to dissipate excess power from the
internal DC bus during motor deceleration. The regeneration resistor must have a resistance of
at least 39Ω, an inductance of less than 100µH, and a minimum power rating of 44W. Suitable
regeneration resistors are listed in section A.1.4. The regeneration resistor output is conditionally
short-circuit proof.
Regeneration
resistor
STAR
POINT
Connect outer shield
to resistor body
Earth/ground outer
shield, using 360°
conductive clamp
connected to
enclosure backplane
Figure 11 - Regeneration resistor connections
DANGER:
MN1942
Electrical shock hazard. DC bus voltages may be present at these
terminals. A regeneration resistor may generate enough heat to ignite
combustible materials. To avoid fire hazard, keep all combustible materials
and flammable vapors away from the resistor.
Basic Installation 3-23
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3-24 Basic Installation
MN1942
4
4
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Feedback
4.1 Introduction
MicroFlex e100 supports many feedback options for use with linear and rotary motors, including
incremental encoder, encoder with SSI (Synchronous Serial Interface), SinCos encoder, or
EnDat absolute encoder. All suitable types of feedback device can be connected to the universal
feedback interface available on connector X8.
There are some important considerations when wiring the feedback device:
H
The feedback device wiring must be separated from power wiring.
H
Where feedback device wiring runs parallel to power cables, they must be separated by at
least 76mm (3 in)
H
Feedback device wiring must cross power wires at right angles only.
H
To prevent contact with other conductors or earths/grounds, unearthed/ungrounded ends of
shields must often be insulated.
H
Linear motors use two separate cables (encoder and Hall). The cores of these two cables will
need to be wired to the appropriate pins of the 15-pin D-type mating connector.
H
The inputs are not isolated.
MN1942
Feedback 4-1
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4.1.1 Incremental encoder feedback
The incremental encoder connections (ABZ channels and Hall signals) are made using the
15-pin D-type female connector X8. The encoder inputs (CHA, CHB and CHZ) accept differential
signals only. Twisted pairs must be used for each complementary signal pair e.g. CHA+ and
CHA-. The Hall inputs may be used as differential inputs (recommended for improved noise
immunity) or single ended inputs. When used as single ended inputs, leave the Hall U-, Hall Vand Hall W- pins unconnected. The overall cable shield (screen) must be connected to the
metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to
detect the voltage drop on long cable runs. This allows the MicroFlex e100 to increase the
encoder supply voltage on pin 12 to maintain a 5V supply at the encoder (200mA max).
Pin
1
9
15
8
Incremental encoder function
1
CHA+
2
CHB+
3
CHZ+
4
Sense
5
Hall U-
6
Hall U+
7
Hall V-
8
Hall V+
9
CHA-
10
CHB-
11
CHZ-
12
+5V out
13
DGND
14
Hall W-
15
Hall W+
MicroFlex e100
to encoder signal loss detection
CHA+
1
1nF
CHA-
120R
MAX3096
Differential
line receiver
to CPU
9
1nF
DGND
Figure 12 - Encoder channel input circuit - Channel A shown
4-2 Feedback
MN1942
www.supportme.net
MicroFlex e100
+5V
2k2
Hall U+
10k
6
MAX3096
Differential
line receiver
1nF
Hall U-
to CPU
5
1nF
4k7
DGND
Figure 13 - Hall channel input circuit - U phase shown
4.1.1.1 Encoder cable configuration - Baldor rotary motors
Motor
Twisted pairs
Encoder
Feedback
Hall
Feedback
X8
1
9
2
10
3
11
CHA+
CHACHB+
CHBCHZ+ (INDEX)
CHZ- (INDEX)
12
13
4
+5V out
DGND
Sense
6
5
15
14
8
7
Hall U+
Hall UHall W+
Hall WHall V+
Hall V-
Connect overall shield
to connector backshells.
Figure 14 - Encoder cable connections - rotary motors
Note:
MN1942
If the Hall inputs are used as single ended inputs, leave the Hall U-, Hall V- and
Hall W- pins unconnected; do not connect them to ground.
Feedback 4-3
www.supportme.net
4.1.1.2 Encoders without Halls
Incremental encoders without Hall feedback connections may be connected to the
MicroFlex e100. However, if Hall connections are not present, it will be necessary for the
MicroFlex e100 to perform an automatic phase search sequence each time it is powered. This
will cause motor movement of up to 1 turn on rotary motors, or one pole-pitch on linear motors.
Motor
Twisted pairs
X8
1
9
2
10
3
11
12
13
4
Encoder
Feedback
CHA+
CHACHB+
CHBCHZ+ (INDEX)
CHZ- (INDEX)
+5V out
DGND
Sense
Connect overall shield
to connector backshells.
Figure 15 - Encoder cable connections without halls - rotary motors
4.1.1.3 Halls-only feedback devices
Feedback devices using only Hall sensors may be connected to the MicroFlex e100. However,
since there are no encoder connections, the MicroFlex e100 will not be able to perform smooth
speed control or accurate positioning control.
Motor
X8
4
12
13
6
5
15
14
8
7
Hall
Feedback
Sense
+5V out
DGND
Hall U+
Hall UHall W+
Hall WHall V+
Hall V-
Connect overall shield
to connector backshells.
Figure 16 - Halls-only feedback cable connections - rotary motors
Note:
4-4 Feedback
If the Hall inputs are used as single ended inputs, leave the Hall U-, Hall V- and
Hall W- pins unconnected; do not connect them to ground.
MN1942
www.supportme.net
4.1.1.4 Encoder cable pin configuration - Baldor linear motors
Baldor linear motors use two separate cables (encoder and Hall). The cores of these two cables
must be wired to the appropriate pins of the 15-pin D-type mating connector (supplied):
Signal name
MicroFlex e100
X8 pin
CHA+
1
CHA-
9
CHB+
2
CHB-
10
CHZ+
3
CHZ-
11
Hall U+
6
Encoder cable internal wire colors
Please refer to MN1800 Linear Motors
Installation & Operating Manual for details.
Baldor Hall cable internal wire colors
White
Hall V+
8
Red
Hall W+
15
Black
+5V out
12
Brown
Hall GND
13
Green
Motor
Twisted pairs
Encoder
Feedback
Hall
Feedback
X8
1
9
2
10
3
11
12
13
4
CHA+
CHACHB+
CHBCHZ+ (INDEX)
CHZ- (INDEX)
+5V
DGND
Sense
6
5
15
14
8
7
Hall U+
Hall UHall W+
Hall WHall V+
Hall V-
Leave pins 5, 7 & 14
unconnected
Connect overall shield to
connector backshells.
Figure 17 - Encoder cable connections - linear motors
MN1942
Feedback 4-5
www.supportme.net
4.1.2 SSI feedback
The SSI (Synchronous Serial Interface) encoder interface is specifically designed for use with
Baldor SSI motors, which incorporate a custom Baumer SSI encoder. Correct operation with
other SSI interfaces cannot be guaranteed. The SSI encoder connections are made using the
15-pin D-type female connector X8. Twisted pair cables must be used for the complementary
signal pairs e.g. Data+ and Data-. The overall cable shield (screen) must be connected to the
metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to
detect the voltage drop on long cable runs. This allows the MicroFlex e100 to increase the
encoder supply voltage on pin 12 to maintain a 5V supply at the encoder (200mA max).
Pin
1
8
Data+
2
Clock+
3
(NC)
4
Sense
5
(NC)
6
(NC)
7
(NC)
8
(NC)
9
Data-
10
Clock-
11
(NC)
12
+5V out
13
DGND
14
(NC)
15
(NC)
9
15
Motor
Twisted pairs
X8
1
9
2
10
12
13
4
SSI
Interface
Absolute
Encoder
SSI function
1
Data+
DataClock+
Clock+5V out
DGND
Sense
Connect internal
shields to pin 13.
Chassis
Connect overall shield
to connector backshells.
Figure 18 - SSI encoder cable connections
4-6 Feedback
MN1942
www.supportme.net
4.1.2.1 SSI cable pin configuration
Figure 19 shows the pin configuration for a typical Baldor SSI feedback cable, part number
CBL025SF-S2
Signal name
MicroFlex e100
X8 pin
Motor / cable
pin
Baldor SSI cable
internal wire colors
+5V out
12
1
Red
Sense
4
9
Orange
DGND
13
2
Blue
Clock+
2
3
Green
Clock-
10
4
Yellow
Data+
1
5
Pink
Data-
9
6
Grey
1
2
Pins 7-12
are not used
and may not
be present
9
10
11
3
4
8
8
12
7
6
5
Motor SSI connector
(male)
7
9
12
1
10
11
6
5
2
3
4
Cable connector end view
(female)
Figure 19 - Baldor motor SSI feedback cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
MN1942
Feedback 4-7
www.supportme.net
4.1.3 SinCos feedback
The SinCos connections (Sin and Cos incremental channels only) are made using the 15-pin
D-type female connector X8. Twisted pair cables must be used for the complementary signal
pairs e.g. Sin+ and Sin-. The overall cable shield (screen) must be connected to the metallic shell
of the D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage
drop on long cable runs. This allows the MicroFlex e100 to increase the encoder supply voltage
on pin 12 to maintain a 5V supply at the encoder (200mA max).
Pin
1
9
15
8
Motor
SinCos function
1
(NC)
2
(NC)
3
(NC)
4
Sense
5
Sin-
6
Sin+
7
Cos-
8
Cos+
9
(NC)
10
(NC)
11
(NC)
12
+5V out
13
DGND
14
(NC)
15
(NC)
Twisted pairs
X8
5
6
7
8
12
13
4
SinCos
Feedback
SinSin+
CosCos+
+5V out
DGND
Sense
Connect internal
shields to DGND.
Connect overall shield to
connector backshells.
Figure 20 - SinCos cable connections
4-8 Feedback
MN1942
www.supportme.net
4.1.3.1 SinCos cable pin configuration
Figure 21 shows the pin configuration for a typical Baldor SinCos feedback cable, part number
CBL025SF-D2.
Signal name
MicroFlex e100
X8 pin
Motor / cable
pin
Baldor EnDat / SinCos
cable internal wire
colors
(Not used)
9
1
Brown / White
Sin+
6
2
Green
Cos+
8
4
Purple
(Not used)
10
5
Pink / Black
(Not used)
2
7
Pink
Cos-
7
8
Purple / White
Sense
4
9
Orange
+5V out
12
9
Red
DGND
13
10
Blue
Sin-
5
11
Green / White
(Not used)
1
12
Brown
1
2
9
10
12
11
3
4
8
8
7
6
5
Motor SinCos connector
(male)
7
9
12
1
10
11
6
5
2
3
4
Cable connector end view
(female)
Figure 21 - Baldor motor SinCos feedback cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
MN1942
Feedback 4-9
www.supportme.net
4.1.4 EnDat (absolute encoder) feedback
The absolute encoder interface supports both incremental and absolute (multi and single turn)
feedback using EnDat technology. It is possible to read and write information to the encoder.
The absolute encoder connections are made using the 15-pin D-type female connector X8.
Twisted pair cables must be used for the complementary signal pairs e.g. Sin+ and Sin-. The
overall cable shield (screen) must be connected to the metallic shell of the D-type connector.
Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs.
This allows the MicroFlex e100 to increase the encoder supply voltage on pin 12 to maintain a 5V
supply at the encoder (200mA max). Version 2.2 EnDat encoders do not use the Sin and Cos
channels.
Pin
1
8
9
15
Motor
Absolute encoder function
1
Data+
2
Clock+
3
(NC)
4
Sense
5
Sin-
6
Sin+
7
Cos-
8
Cos+
9
Data-
10
Clock-
11
(NC)
12
+5V out
13
DGND
14
(NC)
15
(NC)
Twisted pairs
X8
1
9
5
6
7
8
2
10
12
13
4
Absolute
Encoder
Data+
DataSinSin+
CosCos+
Clock+
Clock+5V out
DGND
Sense
Connect internal
shields to DGND.
Connect overall shield
to connector backshells.
Figure 22 - Absolute encoder cable connections
4-10 Feedback
MN1942
www.supportme.net
4.1.4.1 Absolute encoder cable pin configuration
Figure 23 shows the pin configuration for a typical Baldor absolute encoder feedback cable, part
number CBL025SF-D2.
Signal name
MicroFlex e100
X8 pin
Motor / cable
pin
Baldor EnDat / SinCos
cable internal wire
colors
Data -
9
1
Brown / White
Sin+
6
2
Green
Cos+
8
4
Purple
Clock-
10
5
Pink / Black
Clock+
2
7
Pink
Cos-
7
8
Purple / White
Sense
4
9
Orange
+5V out
12
9
Red
DGND
13
10
Blue
Sin-
5
11
Green / White
Data +
1
12
Brown
7
7
1
2
9
10
12
11
3
4
8
8
6
1
10
11
6
5
5
Motor absolute encoder connector
(male)
9
12
2
3
4
Cable connector end view
(female)
Figure 23 - Baldor rotary motor absolute encoder cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
MN1942
Feedback 4-11
www.supportme.net
4-12 Feedback
MN1942
5
5
www.supportme.net
Input / Output
5.1 Introduction
This section describes the various digital input and output capabilities of the MicroFlex e100, with
descriptions of each of the connectors on the front panel.
The following conventions are used to refer to the inputs and outputs:
I/O . . . . . . . . . . . . . . Input / Output
DIN . . . . . . . . . . . . . Digital Input
DOUT . . . . . . . . . . . Digital Output
MN1942
Input / Output 5-1
www.supportme.net
5.2 Digital I/O
The MicroFlex e100 provides as standard:
H
3 general purpose digital inputs.
H
1 dedicated drive enable input.
H
1 general purpose digital output.
H
1 general purpose / drive status output.
The general purpose digital inputs can be configured for typical input functions:
H
Error input
H
Reset input
H
Stop input
H
Forward / reverse limit input
H
Home input.
5-2 Input / Output
MN1942
www.supportme.net
5.2.1 Drive enable input
Location
Name
Description
9
19
Connector X3, pins 9 & 19
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Drive enable
Dedicated drive enable input.
Nominal input voltage: +24VDC
(input current not to exceed 50mA)
Sampling interval:
1ms
The drive enable input is buffered by a TLP280 opto-isolator, allowing the input signal to be
connected with either polarity.
MicroFlex e100
Vcc
10k
3k3
Drive
Enable+
19
Drive
Enable-
9
Mint
DRIVEENABLESWITCH
74LVC14
100R
TLP280
4n7
4n7
DGND
Figure 24 - Drive enable input circuit
In normal use, the drive enable input controls the enabled status of the drive. However, when the
MicroFlex e100 is connected to Mint WorkBench, additional methods are available for controlling
the drive enable status. In all cases, the drive enable input must be active and there must be no
errors present before the MicroFlex e100 can be enabled.
H
The drive enable button
on the motion toolbar toggles the enable/disable status.
Alternatively, the Mint command DRIVEENABLE.0=1 can be used in the command window
to enable the MicroFlex e100; DRIVEENABLE.0=0 will disable the MicroFlex e100.
H
The Tools, Reset Controller menu item will clear errors and enable the MicroFlex e100.
Alternatively, the Mint command RESET.0 can be used in the command window to perform
the same action.
The state of the drive enable input is displayed in the Mint WorkBench Spy window.
Alternatively, the state of the drive enable input can be read (but not set) using the Mint command
Print DRIVEENABLESWITCH in the command window. See the Mint help file for details.
MN1942
Input / Output 5-3
www.supportme.net
NextMove e100 / controller
‘X11’
User
supply
24V
UDN2982
Mint
DRIVEENABLEOUTPUT
9
1
‘X3’
USR V+
DOUT0
MicroFlex e100
Drive
Enable+
Drive
Enable-
10k
10
3k3
19
9
100R
TLP280
USR GND
User
supply
GND
Figure 25 - Drive enable input - typical connection from a Baldor NextMove e100
5-4 Input / Output
MN1942
www.supportme.net
5.2.2 General purpose digital input DIN0
Location Connector X3, pins 7 & 17
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name DIN0
7
17
Description General purpose opto-isolated digital input.
Nominal input voltage: +24VDC
(input current not to exceed 50mA)
Sampling interval:
1ms
This general purpose digital input is buffered by a TLP280 opto-isolator, allowing the input signal
to be connected with either polarity. The state of the digital input is displayed in the Mint
WorkBench Spy window. The input can be can be configured for different user definable
functions.
MicroFlex e100
Vcc
10k
DIN0+
17
DIN0-
7
3k3
Mint
74LVC14
100R
TLP280
4n7
4n7
DGND
Figure 26 - General purpose digital input circuit
When the MicroFlex e100 is connected to Mint WorkBench, the digital input can be configured
using the Digital I/O tool. Alternatively, Mint keywords including RESETINPUT, ERRORINPUT
and STOPINPUT can be used in the command window. The state of the digital input can be
viewed using the Mint WorkBench Spy window’s Axis tab. See the Mint help file for details.
MN1942
Input / Output 5-5
www.supportme.net
NextMove e100 / controller
‘X11’
User
supply
24V
UDN2982
9
Mint
OUTX.0
1
MicroFlex e100
‘X3’
USR V+
DOUT0
DIN0+
DIN0-
10k
10
3k3
17
7
100R
TLP280
USR GND
User
supply
GND
Figure 27 - Digital input - typical connection from a Baldor NextMove e100
5-6 Input / Output
MN1942
www.supportme.net
5.2.3 General purpose digital inputs DIN1 & DIN2
Location Connector X3, pins 6 & 16 (DIN1), 4 & 14 (DIN2)
(Mating connector: Weidmüller Minimate B2L 3.5/20)
4
14
6
16
Name DIN1, DIN2
Description General purpose fast opto-isolated digital inputs.
Nominal input voltage: +24VDC
(input current not to exceed 20mA)
Maximum input frequency: 1 MHz maximum
These general purpose fast digital inputs are buffered by a TLP115 opto-isolator, allowing the
input signal to be connected with either polarity. The state of the digital input is displayed in the
Mint WorkBench Spy window. The inputs can be can be configured for different user definable
functions.
MicroFlex e100
Vcc
‘X3’
DIN1+
10k
3k3
16
Mint
TLP115A
DIN1-
100R
6
DGND
4n7
4n7
Figure 28 - General purpose fast digital input circuit
When the MicroFlex e100 is connected to Mint WorkBench, the digital input can be configured
using the Digital I/O tool. Alternatively, the Mint keywords RESETINPUT, ERRORINPUT and
STOPINPUT can be used in the command window. The state of the digital input can be viewed
using the Spy window’s Axis tab. See the Mint help file for details.
MN1942
Input / Output 5-7
www.supportme.net
NextMove e100 / controller
‘X11’
User
supply
24V
MicroFlex e100
UDN2982
9
Mint
OUTX.0
1
‘X3’
USR V+
DOUT0
DIN1+
DIN1-
10k
10
USR
GND
16
6
TLP115A
Shield
User
supply
GND
10
Connect overall
shield at one end only
Figure 29 - Digital input - typical connection from a Baldor NextMove e100
5.2.4 Special functions on inputs DIN1 and DIN2
DIN1 and DIN2 can be configured to perform special functions.
5.2.4.1 Fast position capture
DIN1 or DIN2 can be configured using the FASTSELECT keyword to become a fast latch input.
This allows the position of the axis to be captured in real-time and read using the Mint keyword
FASTPOS. or FASTENCODER. The input can configured using the FASTLATCHEDGE keyword to
be triggered either on a rising or falling edge. Further control of position capture is provided by the
FASTLATCH and FASTLATCHMODE keywords.
The maximum latency to read the fast position depends on the feedback device. For an
incremental encoder, the latency is approximately 150 - 300ns. For other feedback devices
latency may be up to 62.5µs, resulting from the 16kHz sampling frequency used for these types
of feedback device. The fast interrupt will be latched on a pulse width of about 30µs, although a
width of 100µs is recommended to ensure capture. To prevent subsequent inputs causing the
captured value to be overwritten, the interrupt is latched in software.
Note:
The fast inputs are particularly sensitive to noise, so inputs must use shielded
twisted pair cable. Do not connect mechanical switches, relay contacts or other
sources liable to signal ‘bounce’ directly to the fast inputs. This could cause
unwanted multiple triggering.
5-8 Input / Output
MN1942
www.supportme.net
5.2.5 General purpose / status output DOUT0
1
11
Location Connector X3, pins 1 & 11
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name Status / DOUT0
Description General purpose opto-isolated digital output
Output current:
100mA maximum
User supply
+28VDC maximum
Update interval:
1ms
The optically isolated general purpose / status output is designed to source current from the user
supply as shown in Figure 30. The PS2562L has a maximum power dissipation of 200mW at
25°C. The maximum saturated voltage across the outputs when active is 1.0VDC, so it can be
used as a TTL compatible output.
The output includes a self-resetting fuse that operates at approximately 200mA. The fuse may
take up to 20 seconds to reset after the load has been removed. If the output is used to directly
drive a relay, a suitably rated diode must be fitted across the relay coil, observing the correct
polarity. This is to protect the output from the back-EMF generated by the relay coil when it is
de-energized. The sense of the output can be configured in Mint WorkBench, and its state is
displayed in the Spy window.
User supply
V+
MicroFlex e100
+3.3V
‘X3’
220R
Fuse
11
DOUT0+
200mA
[Error]
4n7
TLP 127
4n7
1
DOUT0-
Load
(Relay with
diode shown)
User supply
GND
Figure 30 - DOUT0 output circuit
By default, DOUT0 is configured as an error status output, which becomes inactive in the event
of an error. When the MicroFlex e100 is connected to Mint WorkBench, the active level of the
output can be configured using the Digital I/O tool. Alternatively, the Mint keyword
OUTPUTACTIVELEVEL can be used in the command window. See the Mint help file for details.
MN1942
Input / Output 5-9
www.supportme.net
MicroFlex e100
‘X3’
11
1
User
supply
24V
NextMove e100 / controller
‘X9’
DOUT0+
DOUT0-
DIN4
100R
TLP127
CREF1
User
supply
GND
6k2
8
9
4n7
TLP280
Figure 31 - DOUT0 - typical connections to a Baldor NextMove e100
5-10 Input / Output
MN1942
www.supportme.net
5.2.6 General purpose output DOUT1
3
13
Location Connector X3, pins 3 & 13
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name DOUT1
Description General purpose opto-isolated digital output
Output current:
100mA maximum
User supply:
+28VDC maximum
Update interval:
1ms
The optically isolated general purpose output is designed to source current from the user supply
as shown in Figure 30. The PS2562L has a maximum power dissipation of 200mW at 25°C. The
maximum saturated voltage across the outputs when active is 1.0VDC, so it can be used as a
TTL compatible output.
The output includes a self-resetting fuse that operates at approximately 200mA. The fuse may
take up to 20 seconds to reset after the load has been removed. If the output is used to directly
drive a relay, a suitably rated diode must be fitted across the relay coil, observing the correct
polarity. This is to protect the output from the back-EMF generated by the relay coil when it is
de-energized. The sense of the output can be configured in Mint WorkBench, and its state is
displayed in the Spy window.
User supply
V+
MicroFlex e100
+3.3V
‘X3’
220R
Fuse
13
DOUT1+
200mA
[Error]
4n7
TLP 127
4n7
3
DOUT1-
Load
(Relay with
diode shown)
User supply
GND
Figure 32 - DOUT1 output circuit
When the MicroFlex e100 is connected to Mint WorkBench, the active level of the output can be
configured using the Digital I/O tool. Alternatively, the Mint keyword OUTPUTACTIVELEVEL can
be used in the command window. See the Mint help file for details.
MN1942
Input / Output 5-11
www.supportme.net
MicroFlex e100
‘X3’
13
3
User
supply
24V
NextMove e100 / controller
‘X9’
DOUT1+
DOUT1-
DIN4
100R
TLP127
CREF1
User
supply
GND
6k2
8
9
4n7
TLP280
Figure 33 - DOUT1 - typical connections to a Baldor NextMove e100
5-12 Input / Output
MN1942
www.supportme.net
5.3 USB communication
5.3.1 USB port
Location
1
2
4
3
USB
Mating connector: USB Type B (downstream) plug
Pin
Name
Description
1
VBUS
USB +5V
2
D-
Data-
3
D+
Data+
4
GND
Ground
The USB connector is used to connect the MicroFlex e100 to a PC running Mint WorkBench. The
MicroFlex e100 is a self-powered, USB 1.1 (12Mbps) compatible device. If it is connected to a
slower USB1.0 host PC or hub, communication speed will be limited to the USB1.0 specification
(1.5Mbps). If it is connected to a faster USB2.0 (480Mbps) host PC or hub, communication
speed will remain at the USB1.1 specification of the MicroFlex e100.
Ideally, the MicroFlex e100 should be connected directly to a USB port on the host PC. If it is
connected to a hub shared by other USB devices, communication could be affected by the
activity of the other devices. A 2m (6.5 ft) standard USB cable is supplied. The maximum
recommended cable length is 5m (16.4 ft).
MN1942
Input / Output 5-13
www.supportme.net
5.4 Ethernet interface
The Ethernet interface provides TCP/IP and ETHERNET Powerlink (EPL) networking capabilities.
5.4.1 TCP/IP
Transmission Control Protocol / Internet Protocol (TCP/IP) is a common set of protocols used to
transfer information between devices over a network, including the internet. TCP enables two
devices to establish a connection, and guarantees the delivery of packets (datagrams) of
information in the correct order. IP specifies the format of the individual packets (which includes
the destination address of the receiving device) but has no influence on whether the packet is
delivered correctly.
TCP/IP allows the MicroFlex e100 to support standard Ethernet communication with a host PC
running Mint WorkBench. The connection uses Baldor’s high level ICM (Immediate Command
Mode) protocol to allow Mint commands, Mint programs and even firmware to be sent to the
controller over the Ethernet network.
When operating in standard Ethernet mode, TCP/IP cannot be used to communicate with a
controller on a daisy-chained network. This is due to cumulative timing errors caused by each
controller’s internal hub. It is necessary to connect the host PC to the controller either directly or
via a single hub, as shown in Figure 34:
Host PC
MicroFlex e100 drives
External hub
Figure 34 - Connecting to drives using TCP/IP in standard Ethernet mode
When operating in EPL mode, in conjunction with an EPL compatible router, the host PC can use
TCP/IP to communicate with controllers on a daisy-chained network. In this situation, the router
will use TCP/IP only within EPL’s asynchronous time slots. See the Mint help file for further
details.
Host PC
ETHERNET Powerlink
compatible router
NextMove e100
Master Node
MicroFlex e100 drives
Figure 35 - Connecting to daisy-chained drives using TCP/IP and EPL mode
5-14 Input / Output
MN1942
www.supportme.net
5.4.2 ETHERNET Powerlink
MicroFlex e100 supports the deterministic ETHERNET Powerlink (EPL) protocol. This protocol
provides very precise and predictable ‘real-time’ communication over a 100Mbit/s (100Base-T)
Fast Ethernet (IEEE 802.3u) connection. This makes it suitable for the transmission of control
and feedback signals between the MicroFlex e100 and other EPL enabled controllers such as
NextMove e100. The EPL protocol implemented in Mint is based on the CANopen DS402 Device
Profile for Drives and Motion Control.
MicroFlex e100 incorporates a built-in repeating hub, providing two ports for connection to other
equipment. This allows nodes to be connected as a ‘daisy-chain’ network of up to 10 nodes,
avoiding the need for additional hubs. If the network comprises more than 10 nodes, an external
hub must be used. The structure of the physical network is informal so does not need to reflect
the logical relationship between nodes. Ethernet switches must not be used in EPL networks as
their timing cannot be guaranteed.
NextMove e100
Manager Node
MicroFlex e100
Drive
MicroFlex e100 MicroFlex e100
Drive
Drive
MicroFlex e100
Drive
‘Daisy chained’ network
Figure 36 - Simple daisy-chained EPL network
NextMove e100
Manager Node
Machine 1
MicroFlex e100 Drives 1-9
1
2
3
4
5
6
7
8
9
Machine 1
MicroFlex e100 Drives 10-16
External hub
10
11
12
NextMove e100
Controlled Node
13
14
15
16
Machine 2
MicroFlex e100 Drives 17-20
17
18
19
20
Figure 37 - Example multi-branch EPL network
MN1942
Input / Output 5-15
www.supportme.net
5.4.3 Ethernet connectors
Ethernet connections are made using the identical RJ45 Ethernet receptacles.
Location E1 & E2
Pin Name
1
8
Description
1 TX+
Transmit+
2 TX-
Transmit-
3 RX+
Receive+
4
-
(NC)
5
-
(NC)
6 RX-
Receive-
7
(NC)
-
8 Shield
Shield connection
To connect the MicroFlex e100 to other EPL devices, ordinary shielded CAT5 Ethernet cables
are used. Cables may be up to 100m (328 ft) long. Two varieties of CAT5 cable are available;
‘straight’ or ‘crossed’. Straight cables have the TX pins of the connector at one end of the cable
wired to the TX pins of the RJ45 connector at the other end of the cable. Crossover cables have
the TX pins of the connector at one end of the cable wired to the RX pins of the RJ45 connector
at the other end of the cable.
Provided the network consists of only Baldor EPL controllers and drives (and any hub), straight
or crossed cables may be used. This is because many Ethernet devices, including hubs and all
Baldor EPL products, incorporate Auto-MDIX switching technology which automatically
compensates for the wiring of the straight cable. However, if other manufacturer’s EPL nodes are
included in the network, crossover cables should be used as recommended by the ETHERNET
Powerlink Standardization Group (EPSG).
The MicroFlex e100 Ethernet interface is galvanically isolated from the rest of the MicroFlex e100
circuitry by magnetic isolation modules incorporated in each of the Ethernet connectors. This
provides protection up to 1.5kV. The connector/cable screen is connected directly to the chassis
earth of the MicroFlex e100. Termination components are incorporated in each of the Ethernet
connectors, so no further termination is required.
The EPL network supports the 100Base-TX (100Mbit/s) system only, so attempting to connect
slower 10Base-T (10Mbit/s) nodes will cause a network error.
5-16 Input / Output
MN1942
www.supportme.net
5.5 CAN interface
The CAN bus is a serial based network originally developed for automotive applications, but now
used for a wide range of industrial applications. It offers low-cost serial communications with
very high reliability in an industrial environment; the probability of an undetected error is
4.7x10-11. It is optimized for the transmission of small data packets and therefore offers fast
update of I/O devices (peripheral devices) connected to the bus.
The CAN protocol only defines the physical attributes of the network, i.e. the electrical,
mechanical, functional and procedural parameters of the physical connection between devices.
The higher level network functionality on MicroFlex e100 is defined by the CANopen protocol,
one of the most used standards for machine control.
5.5.1 CAN connector
Location CAN
Mating connector: 9-pin female D-type
Pin Name
1
6
9
1
5
-
Description
(NC)
2 CAN-
CAN channel negative
3 CAN GND
Ground/earth reference for CAN signals
4
(NC)
-
5 Shield
Shield connection
6 CAN GND
Ground/earth reference for CAN signals
7 CAN+
CAN channel positive
8
(NC)
-
9 CAN V+
CAN power V+ (12-24V)
5.5.2 CAN wiring
A very low error bit rate over CAN can only be achieved with a suitable wiring scheme, so the
following points should be observed:
H
The two-wire data bus line may be routed parallel, twisted and/or shielded, depending on
EMC requirements. Baldor recommend a twisted pair cable with the shield/screen
connected to the connector backshell, in order to reduce RF emissions and provide immunity
to conducted interference.
H
The bus must be terminated at both ends only (not at intermediate points) with resistors of a
nominal value of 120Ω. This is to reduce reflections of the electrical signals on the bus, which
helps a node to interpret the bus voltage levels correctly. If the MicroFlex e100 is at the end
of the network then ensure that a 120Ω resistor is fitted (normally inside the D-type
connector).
H
All cables and connectors should have a nominal impedance of 120Ω. Cables should have
a length related resistance of 70mΩ/m and a nominal line delay of 5ns/m.
MN1942
Input / Output 5-17
www.supportme.net
H
The maximum bus length depends on the bit-timing
configuration (baud rate). The table opposite shows
the approximate maximum bus length (worst-case),
assuming 5ns/m propagation delay and a total
effective device internal in-out delay of 210ns at
1Mbit/s, 300ns at 500 - 250Kbit/s, 450ns at 125Kbit/s
and 1.5ms at 50 - 10Kbit/s.
(1)
For bus lengths greater than about 1000m,
bridge or repeater devices may be needed.
CAN
Baud Rate
Maximum
Bus Length
1Mbit/s
500Kbit/s
250Kbit/s
125Kbit/s
100Kbit/s
50Kbit/s
20Kbit/s
10Kbit/s
25m
100m
250m
500m
600m
1000m
2500m(1)
5000m(1)
H
The compromise between bus length and CAN baud
rate must be determined for each application. The
CAN baud rate can be set using the BUSBAUD keyword. It is essential that all nodes on the
network are configured to run at the same baud rate.
H
The wiring topology of a CAN network should be as close as possible to a single line/bus
structure. However, stub lines are allowed provided they are kept to a minimum (<0.3m at
1Mbit/s).
H
The 0V connection of all of the nodes on the network must be tied together through the CAN
cabling. This ensures that the CAN signal levels transmitted by MicroFlex e100 or CAN
peripheral devices are within the common mode range of the receiver circuitry of other nodes
on the network.
5.5.2.1 Opto-isolation
On the MicroFlex e100, the CAN channel is opto-isolated. A voltage in the range 12-24V must
be applied between pin 9 (+24V) and pin 3 or 6 (0V) of the CAN connector. From this supply, an
internal voltage regulator provides the 5V at 100mA required for the isolated CAN circuit. CAN
cables supplied by Baldor are ‘category 5’ and have a maximum current rating of 1A, so the
maximum number of MicroFlex e100 units that may be used on one network is limited to ten.
5.5.3 CANopen
Baldor have implemented a CANopen protocol in Mint (based on the ‘Communication Profile’ CiA
DS-301) which supports both direct access to device parameters and time-critical process data
communication. The MicroFlex e100 complies with CANopen slave device profile DS402, and
can be a DS401 or DS403 master device (with limited functionality). It is able to support and
communicate with a variety of devices including:
H
Any third party digital and analog I/O device that is compliant with the ‘Device Profile for
Generic I/O Modules’ (CiA DS-401).
H
Baldor HMI (Human Machine Interface) operator panels, which are based on the ‘Device
Profile for Human Machine Interfaces’ (DS403).
H
Other Baldor controllers with CANopen support for peer-to-peer access using extensions to
the CiA specifications (DS301 and DS302).
The functionality and characteristics of all Baldor CANopen devices are defined in individual
standardized (ASCII format) Electronic Data Sheets (EDS) which can be found on the Baldor
Motion Toolkit CD supplied with your product, or downloaded from www.supportme.net.
Figure 38 shows a typical CANopen network with a NextMove e100 manager node, one
MicroFlex e100 slave node and a Baldor HMI operator panel:
5-18 Input / Output
MN1942
www.supportme.net
Baldor HMI
Operator Panel
CANopen
D-type
7
Power
supply
terminal
block
24V
0V
2
6
Twisted pairs
CAN+
CAN-
TR
0V
24V
1
2
NextMove e100
D-type
5
7
End
node
MicroFlex e100
D-type
Twisted pairs
7
7
2
2
6
6
6
9
9
9
5
5
TR
2
Figure 38 - Typical CANopen network connections
Note:
The MicroFlex e100 CAN channel is opto-isolated, so a voltage in the range 12-24V
must be applied between pin 9 and pin 6 of the CAN connector.
The configuration and management of a CANopen network must be carried out by a single node
acting as the network manager (for example NextMove e100), or by a third party CANopen
manager device.
Up to 126 CANopen nodes (node IDs 2 to 127) can be added to the network by the manager node
using the Mint NODESCAN keyword. If successful, the nodes can then be connected to using the
Mint CONNECT keyword. Any network and node related events can then be monitored using the
Mint BUS1 event.
Note:
All CAN related Mint keywords are referenced to CANopen using the ‘bus’ dot
parameter. For CANopen the ‘bus’ dot parameter must be set to 1.
Please refer to the Mint help file for further details on CANopen, Mint keywords and dot
parameters.
MN1942
Input / Output 5-19
www.supportme.net
5.6 Other I/O
5.6.1 Node ID selector switches
The MicroFlex e100 has two selector switches which determine the unit’s
node ID on EPL networks. Each switch has 16 positions, allowing selection
of the hexadecimal values 0 - F. In combination, the two switches allow
node IDs of 0 - 255 (hexadecimal FF) to be selected. The switch labelled ‘HI’
sets the high nibble (half byte), and the switch labelled ‘LO’ sets the low
nibble. The following table lists all node IDs from 0 to 255 with the equivalent
HI and LO switch settings:
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
0
0
0
64
4
0
128
8
0
192
C
0
1
0
1
65
4
1
129
8
1
193
C
1
2
0
2
66
4
2
130
8
2
194
C
2
3
0
3
67
4
3
131
8
3
195
C
3
4
0
4
68
4
4
132
8
4
196
C
4
5
0
5
69
4
5
133
8
5
197
C
5
6
0
6
70
4
6
134
8
6
198
C
6
7
0
7
71
4
7
135
8
7
199
C
7
8
0
8
72
4
8
136
8
8
200
C
8
9
0
9
73
4
9
137
8
9
201
C
9
10
0
A
74
4
A
138
8
A
202
C
A
11
0
B
75
4
B
139
8
B
203
C
B
12
0
C
76
4
C
140
8
C
204
C
C
13
0
D
77
4
D
141
8
D
205
C
D
14
0
E
78
4
E
142
8
E
206
C
E
15
0
F
79
4
F
143
8
F
207
C
F
16
1
0
80
5
0
144
9
0
208
D
0
17
1
1
81
5
1
145
9
1
209
D
1
18
1
2
82
5
2
146
9
2
210
D
2
19
1
3
83
5
3
147
9
3
211
D
3
20
1
4
84
5
4
148
9
4
212
D
4
21
1
5
85
5
5
149
9
5
213
D
5
22
1
6
86
5
6
150
9
6
214
D
6
23
1
7
87
5
7
151
9
7
215
D
7
24
1
8
88
5
8
152
9
8
216
D
8
25
1
9
89
5
9
153
9
9
217
D
9
26
1
A
90
5
A
154
9
A
218
D
A
27
1
B
91
5
B
155
9
B
219
D
B
28
1
C
92
5
C
156
9
C
220
D
C
29
1
D
93
5
D
157
9
D
221
D
D
30
1
E
94
5
E
158
9
E
222
D
E
5-20 Input / Output
MN1942
www.supportme.net
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
31
1
F
95
5
F
159
9
F
223
D
F
32
2
0
96
6
0
160
A
0
224
E
0
33
2
1
97
6
1
161
A
1
225
E
1
34
2
2
98
6
2
162
A
2
226
E
2
35
2
3
99
6
3
163
A
3
227
E
3
36
2
4
100
6
4
164
A
4
228
E
4
37
2
5
101
6
5
165
A
5
229
E
5
38
2
6
102
6
6
166
A
6
230
E
6
39
2
7
103
6
7
167
A
7
231
E
7
40
2
8
104
6
8
168
A
8
232
E
8
41
2
9
105
6
9
169
A
9
233
E
9
42
2
A
106
6
A
170
A
A
234
E
A
43
2
B
107
6
B
171
A
B
235
E
B
44
2
C
108
6
C
172
A
C
236
E
C
45
2
D
109
6
D
173
A
D
237
E
D
46
2
E
110
6
E
174
A
E
238
E
E
47
2
F
111
6
F
175
A
F
239
E
F
48
3
0
112
7
0
176
B
0
240
F
0
49
3
1
113
7
1
177
B
1
241
F
1
50
3
2
114
7
2
178
B
2
242
F
2
51
3
3
115
7
3
179
B
3
243
F
3
52
3
4
116
7
4
180
B
4
244
F
4
53
3
5
117
7
5
181
B
5
245
F
5
54
3
6
118
7
6
182
B
6
246
F
6
55
3
7
119
7
7
183
B
7
247
F
7
56
3
8
120
7
8
184
B
8
248
F
8
57
3
9
121
7
9
185
B
9
249
F
9
58
3
A
122
7
A
186
B
A
250
F
A
59
3
B
123
7
B
187
B
B
251
F
B
60
3
C
124
7
C
188
B
C
252
F
C
61
3
D
125
7
D
189
B
D
253
F
D
62
3
E
126
7
E
190
B
E
254
F
E
63
3
F
127
7
F
191
B
F
255
F
F
Figure 39 - Decimal node IDs and equivalent HI / LO hexadecimal switch settings
Note:
MN1942
If the node ID selector switches are set to FF, the node’s firmware will not run on
power up. However, Mint WorkBench will still be able to detect the MicroFlex e100
and download new firmware.
Input / Output 5-21
www.supportme.net
In many networking environments, the node ID may also be referred to as the address. On EPL
networks, limitations apply to the node IDs that may be selected:
H
Node ID 0 is reserved for special purposes and cannot be used.
H
Setting the switches to select a node ID between 1 and 239 causes the node to become a
‘controlled node’, a node that will accept commands from the manager node.
H
Node ID 240 is reserved for the EPL manager node (for example NextMove e100) so cannot
be used by MicroFlex e100.
H
Node IDs between 241 and 255 are reserved for special purposes and cannot be used.
For all other communication channels such as CANopen and USB, the node ID is set in software.
Each channel can have a different node ID, selected using the Mint WorkBench Connectivity
Wizard or the Mint BUSNODE keyword. See the Mint help file for details.
5-22 Input / Output
MN1942
www.supportme.net
5.7 Connection summary - recommended system wiring
As an example, Figure 40 shows the recommended wiring necessary for the MicroFlex e100 to
control a motor, while conforming to the EMC requirements for ‘industrial’ environments.
From L1
fuses
L2
L3
L1
L2
L3
Filter
AC power
L1
AC power in
Connect motor power cable
shield to metal backplane using
conductive shield clamp
Motion controller
L2
L3
Ethernet
PE
Star
point
Optional
regen
resistor
(Dynamic
brake)
Connect AC power cable shield to
metal backplane using conductive
shield clamp (see section C.1.6).
PC
Shielded twisted pair, clamped to
metal backplane near drive using
conductive shield earth/ground
clamp (see sections 3.6 and C.1.6).
USB
Regen
Motor power U V W
Ferrite
Motor feedback
+24VDC 0V
Drive enable
input
2A
Motor
+24VDC 0V
Control circuit supply (fused).
Use twisted pair cable with a
ferrite sleeve (see section 3.4.8).
H
H
H
H
H
The MicroFlex e100 should be mounted on an earthed metal backplane.
Ensure cables do not obstruct airflow to the heatsink.
Motor represents a typical Baldor BSM motor. Linear motors may also be controlled by MicroFlex e100.
Conductive shield earth/ground clamps are not supplied.
When using single phase supplies it may be necessary to reverse the AC power filter - see section 3.4.7.2.
Figure 40 - Recommended system wiring
MN1942
Input / Output 5-23
www.supportme.net
5-24 Input / Output
MN1942
6
6
www.supportme.net
Configuration
6.1 Introduction
Before powering the MicroFlex e100 you will need to connect it to the PC using a USB or Ethernet
cable and install the supplied Mint Machine Center software. This software includes a number of
tools to allow you to configure and tune the MicroFlex e100. If you do not have experience of
software installation or Windows applications you may need further assistance for this stage of
the installation.
6.1.1 Connecting the MicroFlex e100 to the PC
The MicroFlex e100 can be connected to the PC using either USB or TCP/IP.
To use USB, connect a USB cable between a PC USB port and the MicroFlex e100 USB port.
Your PC must be using Windows 2000 or Windows XP.
To use TCP/IP, connect a CAT5 Ethernet cable between the PC and one of the MicroFlex e100
Ethernet ports.
CAUTION:
You cannot connect an ordinary office PC to the MicroFlex e100 without first
altering the PC’s Ethernet adapter configuration. However, if you have
installed a second Ethernet adapter dedicated for use with the
MicroFlex e100, then this adapter’s configuration can be altered without
affecting the PC’s office Ethernet connection. If you are unsure about
making changes to your PC’s Ethernet adapter configuration, or are
prevented by user permission levels, ask your I.T. administrator to assist
you.
CAUTION:
If there is a EPL manager node (node ID 240) on the Ethernet network, then
the network will be operating in EPL mode. This means any TCP/IP
connection from the PC must pass through an EPL compatible router.
6.1.2 Installing Mint Machine Center and Mint WorkBench
You will need to install Mint Machine Center (MMC) and Mint WorkBench to configure and tune
the MicroFlex e100. Any previous version of Mint WorkBench must be uninstalled before
proceeding with this installation:
1. Insert the CD into the drive.
2. After a few seconds the setup wizard should start automatically. If the setup wizard does not
appear, select Run... from the Windows Start menu and type
d:\start
where d represents the drive letter of the CD device.
Follow the on-screen instructions to install MMC (including Mint WorkBench). The setup
wizard will copy the files to appropriate folders within the C:\Program Files folder, and place
shortcuts on the Windows Start menu.
MN1942
Configuration 6-1
www.supportme.net
6.2 Starting the MicroFlex e100
If you have followed the instructions in the previous sections, you should now have connected all
the power sources, inputs and outputs, and the Ethernet cable or USB cable linking the PC to the
MicroFlex e100.
6.2.1 Preliminary checks
Before you apply power for the first time, it is very important to verify the following:
H
Disconnect the load from the motor until instructed to apply a load. If this cannot be done,
disconnect the motor wires at connector X1.
H
Verify that the AC line voltage matches the specification of the MicroFlex e100.
H
Inspect all power connections for accuracy, workmanship and tightness.
H
Verify that all wiring conforms to applicable codes.
H
Verify that the MicroFlex e100 and motor are properly earthed/grounded.
H
Check all signal wiring for accuracy.
6.2.2 Power on checks
If at any time the Status LED flashes red, the drive has detected a fault - see section 7.
1. Turn on the 24VDC supply.
2. Turn on the AC supply.
3. Within approximately 20-30 seconds, the test sequence should complete and the Status
LED should illuminate red. If the Status LED is not lit then re-check the power supply
connections. If the Status LED flashes red, this indicates that the MicroFlex e100 has
detected a fault - see section 7. Note that after downloading firmware, startup may take more
than 1 minute.
4. If the motor wires were disconnected in section 6.2.1, turn off the AC supply and reconnect
the motor wires. Turn on the AC supply.
5. To allow the Commissioning Wizard to function, the drive enable signal will need to be
present on connector X3 to allow the MicroFlex e100 to be enabled (see section 5.2.1.). If
you do not wish to enable the MicroFlex e100 yet, the Commissioning Wizard will inform you
when this step is necessary.
6.2.3 Installing the USB driver
It is now necessary to install the USB driver. When the MicroFlex e100 is powered, Windows
(2000 or XP only) will automatically detect the controller and request the driver. The driver
consists of two files, USBmotion.inf and USBmotion.sys. Both files must be present for
installation.
1. Follow the on-screen instructions to select and install the driver. The driver files are available
on the supplied Baldor Motion Toolkit CD. If you are using a copy of the driver located on the
hard disk, a floppy disk or another CD, the two driver files must be in the same folder.
2. During installation, Windows XP may report that the driver is ‘unsigned’. This is normal for the
MicroFlex e100 driver, so click the Continue Anyway button to continue with the installation.
When installation is complete, a new USB Motion Controller device will be listed in the
Universal Serial Bus controllers section of Windows Device Manager.
6-2 Configuration
MN1942
www.supportme.net
The MicroFlex e100 is now ready to be configured using Mint WorkBench.
Note:
If the MicroFlex e100 is later connected to a different USB port on the host computer,
Windows may report that it has found new hardware. Either install the driver files
again for the new USB port, or connect the MicroFlex e100 to the original USB port
where it will be recognized in the usual way.
6.2.4 Configuring the TCP/IP connection (optional)
If you have connected the MicroFlex e100 to the PC using the Ethernet connection, it will be
necessary to alter the PC’s Ethernet adapter configuration to operate correctly with the
MicroFlex e100.
CAUTION:
You cannot connect an ordinary office PC to the MicroFlex e100 without first
altering the PC’s Ethernet adapter configuration. However, if you have
installed a second Ethernet adapter dedicated for use with the
MicroFlex e100, then this adapter’s configuration can be altered without
affecting the PC’s office Ethernet connection. If you are unsure about
making changes to your PC’s Ethernet adapter configuration, or are
prevented by user permission levels, ask your I.T. administrator to assist
you.
The following explanation assumes the PC is connected directly to the MicroFlex e100, and not
across an intermediate Ethernet network. If you wish to attempt the connection through an
intermediate Ethernet network, then the network administrator must be consulted to ensure that
the necessary IP addresses will be allowed and are not already allocated on the network. The
MicroFlex e100 has a fixed IP address of the format 192.168.100.xxx. The last number, xxx, is
the decimal value defined by the MicroFlex e100’s node ID selector switches (see section 5.6.1).
1. On the Windows Start menu, select Settings, Network Connections.
2. In the Network Connections Window, right-click the ’Local Area Connection’ entry for the
required Ethernet adapter and choose Properties.
3. In the Local Area Connection Properties dialog, in the ’This connection uses the following
items’ list, select the ‘Internet Protocol (TCP/IP)‘ entry and click Properties.
4. In the Internet Protocol (TCP/IP) Properties dialog, on the General tab, make a note of the
existing settings. Click Advanced... and make a note of any existing settings. Click the
Alternate Configuration tab and make a note of any existing settings.
5. On the General tab, choose the ’Use the following IP address’ option.
6. In the IP address box, enter the IP address 192.168.100.241. This is the IP address that will
be assigned to the Ethernet adapter. The value 241 is deliberately chosen as it is outside the
range that can be used by MicroFlex e100, so avoiding possible conflicts.
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7. In the Subnet mask box, enter 255.255.255.0 and click OK.
Click OK to close the Local Area Connection Properties dialog.
8. On the Windows Start menu, select Command Prompt (often found under Accessories).
9. In the Command Prompt window, type PING 192.168.100.16, where the final value (16 in this
example) is the value selected by the MicroFlex e100’s node ID selector switches. In this
example, the MicroFlex e100’s switches would be set to HI=1 LO=0, which represents
hexadecimal 10, equivalent to decimal 16 (see section 5.6.1 for a list of hexadecimal /
decimal equivalents). A reply message should be returned.
10. It should now be possible to run Mint WorkBench and connect to the MicroFlex e100 using
the Ethernet / TCP/IP connection.
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6.3 Mint Machine Center
The Mint Machine Center (MMC) is used to view the network of connected controllers in a
system. Individual controllers and drives are configured using Mint WorkBench.
Note:
If you have only a single MicroFlex e100 connected to your PC, then MMC is
probably not required. Use Mint WorkBench (see section 6.4) to configure the
MicroFlex e100.
Toolbars
Menu system
Controller pane
Information pane
Figure 41 - The Mint Machine Center software
The Mint Machine Center (MMC) provides an overview of the controller network currently
accessible by the PC. The MMC contains a controller pane on the left, and an information pane
on the right. In the controller pane select the Host item, then in the information pane click Scan.
This causes MMC to scan for all connected controllers. Clicking once on a controller’s name
causes various options to be displayed in the information pane. Double-clicking on a controller’s
name launches an instance of Mint WorkBench that is automatically connected to the controller.
Application View allows the layout and organization of controllers in your machine to be modelled
and described on screen. Controllers can be dragged onto the Application View icon, and
renamed to give a more meaningful description, for example “Conveyor 1, Packaging Controller”.
Drives that are controlled by another product, such as a NextMove e100, can be dragged onto
the NextMove e100 icon itself, creating a visible representation of the machine. A text description
for the system and associated files can be added, and the resulting layout saved as an “MMC
Workspace”. When you next need to administer the system, simply loading the workspace
automatically connects to all the required controllers. See the Mint help file for full details of
MMC.
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MintDrive II
Mint WorkBench
MintDrive II
Mint WorkBench
NextMove e100
Mint WorkBench
MicroFlex e100
Mint WorkBench
RS232
RS485/422
Host PC
Mint Machine Center
USB
Ethernet
MicroFlex e100
Mint WorkBench
USB
Figure 42 - Typical network visibility provided by Mint Machine Center
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6.3.1 Starting MMC
1. On the Windows Start menu, select Programs, Mint Machine Center, Mint Machine Center.
2. In the controller pane, ensure that Host is
selected. In the information pane, click
Scan.
3. When the search is complete, click once
on ‘MicroFlex e100’ in the controller pane
to select it, then double click to open an
instance of Mint WorkBench. The
MicroFlex e100 will be already connected
to the instance of Mint WorkBench, ready
to configure.
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6.4 Mint WorkBench
Mint WorkBench is a fully featured application for commissioning the MicroFlex e100. The main
Mint WorkBench window contains a menu system, the Toolbox and other toolbars. Many
functions can be accessed from the menu or by clicking a button - use whichever you prefer.
Most buttons include a ‘tool-tip’; hold the mouse pointer over the button (don’t click) and its
description will appear.
Menu system
Toolbox
Toolbars
Control and
test area
Figure 43 - The Mint WorkBench software
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6.4.1 Help file
Mint WorkBench includes a comprehensive help file that contains information about every Mint
keyword, how to use Mint WorkBench and background information on motion control topics. The
help file can be displayed at any time by pressing F1. On the left of the help window, the Contents
tab shows the tree structure of the help file. Each book
contains a number of topics . The
Index tab provides an alphabetic list of all topics in the file, and allows you to search for them by
name. The Search tab allows you to search for words or phrases appearing anywhere in the help
file. Many words and phrases are underlined and highlighted with a color (normally blue) to show
that they are links. Just click on the link to go to an associated keyword. Most keyword topics
begin with a list of relevant See Also links.
Figure 44 - The Mint WorkBench help file
For help on using Mint WorkBench, click the Contents tab, then click the small plus sign
beside the Mint WorkBench book icon. Double click a
topic name to display it.
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6.4.2 Starting Mint WorkBench
Note:
If you have already used MMC to start an instance of Mint WorkBench then the
following steps are unnecessary. Go to section 6.4.3 to continue configuration.
1. On the Windows Start menu, select Programs, Mint Machine Center, WorkBench v5.5.
2. In the opening dialog box, click Start New Project... .
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3. In the Select Controller dialog, click Scan to search for the MicroFlex e100. Mint WorkBench
will scan the PC’s ports for the MicroFlex e100.
When the search is complete, click ‘MicroFlex e100’ in the list to select it, then click Select.
This check box is already selected for you. When you
click Select, it means that the Commissioning Wizard
will start automatically.
Note:
If the MicroFlex e100 is not listed, check the USB or Ethernet cable between the
MicroFlex e100 and the PC. Check that the MicroFlex e100 is powered correctly.
Click Scan to re-scan the ports.
6.4.3 Commissioning Wizard
Each type of motor and drive combination has different performance characteristics. Before the
MicroFlex e100 can be used to control the motor accurately, the MicroFlex e100 must be ‘tuned’.
This is the process where the MicroFlex e100 powers the motor in a series of tests. By monitoring
the feedback from the motor’s encoder and performing a number of calculations, the
MicroFlex e100 can make small adjustments to the way it controls the motor. This information is
stored in the MicroFlex e100 and can be uploaded to a file if necessary.
The Commissioning Wizard provides a simple way to tune the MicroFlex e100 and create the
necessary configuration information for your drive/motor combination, so this is the first tool that
should be used. If necessary, any of the parameters set by the Commissioning Wizard can be
adjusted manually after commissioning is complete.
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6.4.3.1 Using the Commissioning Wizard
CAUTION:
The motor will move during commissioning. For safety it is advisable to
disconnect any load from the motor during initial commissioning. The motor
can be tuned with the load connected after the Commissioning Wizard has
finished.
Each screen of the Commissioning Wizard requires you to enter information about the motor or
drive. Read each screen carefully and enter the required information.
On the Operating Mode screen, it is important to select ‘Host/Mint’ as the Reference Source.
This will allow the Autotune Wizard to operate correctly, and allow further initial testing to be
performed using Mint WorkBench. Although the MicroFlex e100 may eventually be controlled
over ETHERNET Powerlink (EPL), this reference source should only be selected after the
MicroFlex e100 has been commissioned and is ready to add to the EPL network. This can be
selected by choosing the Operating Mode tool in the Toolbox.
If you need extra help, click Help or press F1 to display the help file.
When you have completed a screen, click Next > to display the next screen. If you need to
change something on a previous screen, click the < Back button. The Commissioning Wizard
remembers information that you have entered so you will not need to re-enter everything if you
go back to previous screens.
During commissioning, changed parameters are stored in the MicroFlex e100’s temporary
(volatile) memory. For this reason, the Commissioning Wizard will occasionally prompt you to
save the parameters. Selecting Yes will cause the parameters to be saved in the
MicroFlex e100’s non-volatile flash memory, to be retained when power is removed. If you select
No, you must remember to use the Save Drive Parameters function before removing power from
the MicroFlex e100; this function is available on the Tools menu, or by clicking the
button on
the Mode toolbar. Saving parameters into flash memory will cause the MicroFlex e100 to be
reset.
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6.4.4 Performing a test move
This section tests the basic operation of the drive and motor.
1. Check that the Drive enable button is
pressed (down).
2. In the Toolbox, click the Edit & Debug icon.
3. Click in the Command window.
4. Type:
JOG.0 = 10
This will cause the motor to move
continuously at 10 units per second. In Mint
WorkBench, look at the Spy window located
on the right of the screen. The Spy window’s
Velocity
display
should
show
10
(approximately). If there seems to be very little motor movement, it is probably due to the scale
factor. In the Commissioning Wizard, on the Select Scale Factor page, if you did not adjust
the scale factor then the current unit of movement is feedback counts per second. Depending
on the motor’s feedback device, 10 feedback counts per second could equate to a very small
velocity. Issue another JOG command using a larger value, or use the Operating Mode Wizard
to select a suitable scale factor (e.g. 4000 if the motor has a 1000 line encoder, or 10,000 for
a 2500 line encoder).
5. To stop the test, type:
STOP.0
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6.5 Further configuration
Mint WorkBench provides a number of tools, each of which has an icon on the left of the screen.
Click once on an icon to select the tool. Two of the main tools used for tuning and configuring the
MicroFlex e100 are described in the following sections. Every tool is explained fully in the help
file. Press F1 to display the help file, then navigate to the Mint WorkBench book. Inside this is the
Toolbox book.
6.5.1 Fine-tuning tool
The Commissioning Wizard calculates many parameters that allow the MicroFlex e100 to
provide basic control of the motor. These parameters may need to be fine-tuned to provide the
exact response that you require. The Fine-tuning screen allows you to do this.
1. Click the Fine-tuning icon in the Toolbox on the left of the screen.
The Fine-tuning window is displayed at the right of the screen.
This already shows some of the parameters that have been
calculated by the Commissioning Wizard.
The main area of the Mint WorkBench window displays the
capture window. When further tuning tests are performed, this will
display a graph representing the response.
2. The Fine-tuning window has four tabs
at the bottom - Position, Velocity,
Current and Filter. Click on a tab to
select it.
Click the tab for the type of tests you wish to perform.
Note:
Some tabs may not be available depending on the configuration mode you selected
in the Commissioning Wizard.
6.5.1.1 Fine-tuning - Position tab
The Position tab allows you to adjust position loop settings and perform test moves. The
Commissioning Wizard may have already set some of these values, depending on the type of
system selected on the mode screen.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Test Parameters area at the bottom of the tab. Enter
test values and then click Go to perform the test move. If you need help, just press F1 to display
the help file.
6.5.1.2 Fine-tuning - Velocity tab
The Velocity tab allows you to set velocity loop gains and perform test moves. The
Commissioning Wizard may have already set some of these values, depending on the type of
system selected on the mode screen.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Test Parameters area at the bottom of the tab. Enter
test values and then click Go to perform the test move. If you need help, just press F1 to display
the help file.
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6.5.1.3 Fine-tuning - Current tab
The Current tab allows you to set current loop gains and perform test moves. The
Commissioning Wizard may have already set some of these values, depending on the type of
system selected on the mode screen. Normally, it should not be necessary to alter these values.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Test Parameters area at the bottom of the tab. Enter
test values and then click Go to perform the test move. If you need help, just press F1 to display
the help file.
The additional Measure and Feedback alignment buttons can be used to repeat the same
measurement and alignment tests that are used by the Commissioning Wizard.
6.5.1.4 Fine-tuning - Filter tab
The Filter tab allows you to set the properties of the MicroFlex e100’s two torque filters. It should
only be necessary to use the torque filters if there is a particular problem with resonant
frequencies in the load.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Frequency Response Params area at the bottom of
the tab. Enter test values and then click Go to perform the test move. If you need help, just press
F1 to display the help file.
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6.5.2 Parameters tool
The Parameters tool can be used to view or change most of the drive’s parameters.
1. Click the Parameters icon in the Toolbox
on the left of the screen.
The main area of the Mint WorkBench
window displays the Parameters editor
screen.
2. In the parameters tree, scroll to the
required item. Click on the small + sign
beside the item’s name.
3. The adjacent table will list the parameters
for the chosen item.
Scroll to the required entry.
Click in the Active Table cell and enter a
value. This immediately sets the
parameter, which will remain in the
MicroFlex e100 until another value is defined. The icon to the left of the item will change from
green to yellow to indicate that the value has been changed.
Many of the MicroFlex e100’s parameters are set automatically by the Commissioning
Wizard, or when tests are performed in the fine-tuning window.
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6.5.3 Other tools and windows
Each tool and window is explained fully in the help file, so is not described here in detail.
H
Edit & Debug Tool
This tool provides a work area including
the Command window and Output
window. The Command window can be
used to send immediate Mint
commands to the MicroFlex e100. If
you tried the test move in section 6.4.4,
then you have already used Edit &
Debug mode.
H
Scope Tool
Displays the capture screen. This screen is also shown when the Fine-tuning tool is
selected.
H
Spy window
Allows you to monitor all the important
parameters for the axis.
Remember, for help on each tool just
press F1 to display the help file, then
navigate to the Mint WorkBench book.
Inside this is the Toolbox book.
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6-18 Configuration
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Troubleshooting
7.1 Introduction
This section explains common problems that may be encountered, together with possible
solutions. If you want to know the meaning of the LED indicators, see section 7.2.
7.1.1 Problem diagnosis
If you have followed all the instructions in this manual in sequence, you should have few
problems installing the MicroFlex e100. If you do have a problem, read this section first.
In Mint WorkBench, use the Error Log tool to view recent errors and then check the help file.
If you cannot solve the problem or the problem persists, the SupportMe feature can be used.
7.1.2 SupportMe feature
The SupportMe feature is available from the Help menu or by clicking the
button on the motion
toolbar. SupportMe can be used to gather information which can then be e-mailed, saved as a
text file, or copied to another application. The PC must have e-mail facilities to use the e-mail
feature. If you prefer to contact Baldor technical support by telephone or fax, contact details are
provided at the front of this manual. Please have the following information ready:
H
The serial number of your MicroFlex e100 (if known).
H
Use the Help, SupportMe menu item in Mint WorkBench to view details about your system.
H
The catalog and specification numbers of the motor that you are using.
H
A clear description of what you are trying to do, for example trying to establish
communications with Mint WorkBench or trying to perform fine-tuning.
H
A clear description of the symptoms that you can observe, for example the Status LED, error
messages displayed in Mint WorkBench, or errors reported by the Mint error keywords
ERRORREADCODE or ERRORREADNEXT.
H
The type of motion generated in the motor shaft.
H
Give a list of any parameters that you have setup, for example the motor data you
entered/selected in the Commissioning Wizard, the gain settings generated during the tuning
process and any gain settings you have entered yourself.
7.1.3 Power-cycling the MicroFlex e100
The term “Power-cycle the MicroFlex e100” is used in the Troubleshooting sections. Remove the
24V supply, wait for the MicroFlex e100 to power down completely (the Status LED will turn off),
then re-apply the 24V supply.
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7.2 MicroFlex e100 indicators
7.2.1 STATUS LED
The Status LED indicates general MicroFlex e100 status information.
Solid green:
Drive enabled (normal operation).
Flickering / blinking green:
Firmware download / update in progress.
Solid red:
Drive disabled, but no errors are latched.
Flashing red:
Powerbase fault or error(s) present. The number of flashes indicates which
error has occurred. For example, to display error 3 (overcurrent trip), the LED
flashes 3 times at 0.1 second intervals, followed by a 0.5 second pause. The
sequence is repeated continuously.
Error code
(no. of flashes)
Meaning
1 ...............
2 ...............
3 ...............
4 ...............
5 ...............
6 ...............
7 ...............
8 ...............
9 ...............
10 . . . . . . . . . . . . . .
11 . . . . . . . . . . . . . .
12 . . . . . . . . . . . . . .
DC bus overvoltage trip.
IPM (integrated power module) trip.
Overcurrent trip.
Overspeed trip.
Feedback trip.
Motor overload (I2t) trip.
Overtemperature trip.
Drive overload (It) trip.
Following error trip.
Error input triggered.
Phase search error.
All other errors, including: Internal supply error, encoder
supply error, parameter restore failure, power base not
recognized.
If multiple errors occur at the same time, the lowest numbered error code will be
flashed. For example, a MicroFlex e100 which has tripped on both feedback
error (code 5) and over-current error (code 3) will flash error code 3. If the drive
is already displaying an error code when a new error with a lower code occurs,
the drive will start flashing the new code. Note that undervoltage trip does not
appear in the table because it is already indicated by the green/red flashing
state. If an undervoltage trip occurs in conjunction with another error, the drive
will flash the code of the additional error.
Further details about error codes can be found in the Mint WorkBench help file.
Press F1 and locate the Error Handling book.
Alternate red/green flashing:
Undervoltage warning (no AC power), but no errors are latched.
The DC-bus voltage has dropped below the powerbase undervoltage level (see
DRIVEBUSUNDERVOLTS). This error will only be generated if the drive is in the
enabled state. Check the AC power is connected.
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7.2.2 CAN LEDs
The CAN LEDs display the overall condition of the CANopen interface,
once the startup sequence has completed. The LED codes conform to
the CAN in Automation (CiA) DR303_3 indicator standard. The green
LED indicates the state of the node’s internal CANopen ‘state machine’.
The red LED indicates the state of the physical CANopen bus.
Green (run)
X
Off: Node initializing or not powered.
1 flash: Node in STOPPED state.
3 flashes: Software is being downloaded to the node.
Continuous flashing: Node in PRE-OPERATIONAL state.
Flickering (very fast flashing): Auto-baudrate detection or LSS services in
progress; flickers alternately with red LED.
Continuously illuminated, not flashing: Node in OPERATIONAL state.
Red (error)
X
Off: No errors or not powered.
1 flash: Warning - too many error frames.
2 flashes: Guard event or heartbeat event has occurred.
3 flashes: The SYNC message has not been received within the timeout period.
Flickering (very fast flashing): Auto-baudrate detection or LSS services in
progress; flickers alternately with green LED.
Continuously illuminated, not flashing: The node’s CAN controller is in the BUS
OFF state, preventing it from taking part in any CANopen communication.
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7.2.3 ETHERNET LEDs
The ETHERNET LEDs display the overall condition of the Ethernet
interface once the startup sequence has completed. The LED codes
conform to the ETHERNET Powerlink Standardization Group (EPSG)
standard at the time of production.
Green (status)
X
Off: Node in NOT ACTIVE state. The controlled node is waiting to be triggered by
the manager node.
1 flash: Node in PRE-OPERATIONAL1 state. EPL mode is starting.
2 flashes: Node in PRE-OPERATIONAL2 state. EPL mode is starting.
3 flashes: Node in READY TO OPERATE state. The node is signalling its
readiness to operate.
Blinking (continuous flashing): Node in STOPPED state. The controlled node has
been deactivated.
Flickering (very fast flashing): Node in BASIC ETHERNET state (EPL is not
operating, but other Ethernet protocols may be used).
Continuously illuminated, not flashing: Node in OPERATIONAL state. EPL is
operating normally.
Red (error)
X
Off: EPL is working correctly.
Continuously illuminated: An error has occurred.
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7.2.4 Communication
Status LED is off:
H
Check that the 24VDC control circuit supply is connected correctly to connector X2 and is
switched on.
ETHERNET LEDs blinking green and red simultaneously:
H
Does the MicroFlex e100 have firmware in it? If you tried to download new firmware and the
download failed, the controller may not have firmware. Download new firmware.
Mint WorkBench fails to detect the MicroFlex e100:
H
Ensure that the MicroFlex e100 is powered and the Status LED is illuminated (see section
7.2.1).
H
Check that the Ethernet or USB cable is connected between the PC and MicroFlex e100.
H
Try an alternative cable or different port on the PC.
H
In the “Search up to Nodexx“ option in Mint WorkBench’s Select Controller dialog, check that
the MicroFlex e100’s node ID is not higher than the selected value, or search up to a greater
node ID.
H
For USB connections, check that the cable is properly connected. Check the USB connector
socket pins for damage or sticking. Check that the USB device driver has been installed; a
‘USB Motion Controller’ device should be listed in Windows Device Manager.
H
Check that the PC’s Ethernet port has been correctly configured for TCP/IP operation (see
section 6.2.4).
7.2.5 Power on
The Status LED is flashing red:
H
The MicroFlex e100 has detected a motion error. Click the Error button on the motion toolbar
to view a description of the error. Alternatively, select the Error Log tool to view a list of errors.
Click the Clear Errors button on the motion toolbar.
7.2.6 Mint WorkBench
The Spy window does not update:
H
The system refresh has been disabled. Go to the Tools, Options menu item, select the
System tab and then choose a System Refresh Rate (500ms is recommended).
Cannot communicate with the controller after downloading firmware:
H
After firmware download, always power cycle the MicroFlex e100 (remove 24V power and
then reconnect).
Mint WorkBench loses contact with MicroFlex e100 while connected using USB:
H
Check that the MicroFlex e100 is powered.
H
Check that a ‘USB Motion Controller’ device is listed in Windows Device Manager. If not,
there could be a problem with the PC’s USB interface.
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7.2.7 Tuning
Cannot enable the MicroFlex e100 because there is an error 10010:
H
Check the drive enable input on connector X3 pins 9 and 19 is connected and powered
correctly.
When the MicroFlex is enabled the motor is unstable:
H
Check that the load is firmly coupled to the motor.
H
Use the Mint WorkBench Drive Setup Wizard to confirm that the correct motor data has been
entered.
H
Use the Mint WorkBench Autotune Wizard to retune the motor.
H
If the motor is still unstable, select the Mint WorkBench Autotune Wizard once more. Click
Options.... On the Bandwidth tab, move the Current and/or Position and Speed Control
sliders to a slower position to select to a lower bandwidth. Click OK to exit and then start the
Autotune Wizard again.
7.2.8 Ethernet
Cannot connect to the drive over TCP/IP:
H
H
Check that there is not an EPL manager node (for example NextMove e100 with node ID
240) on the network. If there is a manager node on the network, then an EPL compatible
router must be used to allow TCP/IP communication on the EPL network.
Check that the PC’s Ethernet adapter has been correctly configured, as described in section
6.2.4.
The ETHERNET Powerlink network does not seem to be operating correctly:
H
Confirm that only one device on the newtork is set to be the ETHERNET Powerlink manager
node (node ID 240, selector switches LO = F, HI = 0).
H
Confirm that the reference source on all controlled nodes has been set to EPL in the Mint
WorkBench Operating Mode Wizard, and that the manager node has been configured
correctly. For a NextMove e100 manager node, this requires the System Config Wizard to be
used in Mint WorkBench.
Confirm that each device on the network has a different node ID.
H
H
Confirm that there are no more than 10 ‘daisy-chained’ devices on each branch of the
network.
7.2.9 CANopen
The CANopen bus is ‘passive’:
This means that the internal CAN controller in the MicroFlex e100 is experiencing a number of Tx
and/or Rx errors, greater than the passive threshold of 127. Check:
H
12-24V is being applied between pin 9 (+24V) and pin 6 or 3 (0V) of the CAN connector, to
power the opto-isolators.
H
There is at least one other CANopen node in the network.
H
The network is terminated only at the ends, not at intermediate nodes.
H
All nodes on the network are running at the same baud rate.
H
All nodes have been assigned a unique node ID.
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H
The integrity of the CAN cables.
The MicroFlex e100 should recover from the ‘passive’ state once the problem has been rectified
(this may take several seconds).
The CANopen bus is ‘off’:
This means that the internal CAN controller in the MicroFlex e100 has experienced a fatal
number of Tx and/or Rx errors, greater than the off threshold of 255. At this point the node will
have switched itself to a state whereby it cannot influence the bus. Check:
H
12-24V is being applied between pin 9 (+24V) and pin 6 or 3 (0V) of the CAN connector, to
power the opto-isolators.
H
There is at least one other CANopen node in the network.
H
The network is terminated only at the ends, not at intermediate nodes.
H
All nodes on the network are running at the same baud rate.
H
All nodes have been assigned a unique node ID.
H
The integrity of the CAN cables.
To recover from the ‘off’ state, the source of the errors must be removed and bus then reset. This
can be done using the Mint BUSRESET keyword, or by resetting the MicroFlex e100.
The Manager node cannot scan/recognize a node on the network using the Mint
NODESCAN keyword:
Assuming that the network is working correctly (see previous symptoms) and the bus is in an
‘Operational’ state, check:
H
Only nodes that conform to DS401, DS403 and other Baldor CANopen nodes are
recognized by the Mint NODESCAN keyword. Other types of node will be identified with a type
“unknown” (255) when using the Mint NODETYPE keyword.
H
Check that the node in question has been assigned a unique node ID.
H
The node must support the node guarding process. MicroFlex e100 does not support the
Heartbeat process.
H
Try power-cycling the node in question.
If the node in question does not conform to DS401 or DS403 and is not a Baldor CANopen node,
communication is still possible using a set of general purpose Mint keywords. See the Mint help
file for further details.
The node has been successfully scanned / recognized by the Manager node, but
communication is still not possible:
For communication to be allowed, a connection must be made to a node after it has been
scanned:
H
Baldor controller nodes are automatically connected to after being scanned.
H
Nodes that conform to DS401, DS403 must have the connections made manually using the
Mint CONNECT keyword.
If a connection attempt using CONNECT fails then it may be because the node being connected
to does not support an object which needs to be accessed in order to setup the connection.
MN1942
Troubleshooting 7-7
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7-8 Troubleshooting
MN1942
8
8
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Specifications
8.1 Introduction
This section provides technical specifications for the MicroFlex e100.
8.1.1 AC input power and DC bus voltage (X1)
All models
AC input
Unit
1Φ
Nominal input voltage
3Φ
115 or 230
VAC
Minimum input voltage
105*
Maximum input voltage
250
Nominal DC-bus voltage
@230VAC input
VDC
Nominal input current
@ maximum rated output current
A
305
321
3A
6A
9A
3A
6A
9A
7.5
15
22
4
8
12
* The MicroFlex e100 will operate at lower input voltages, although the drive will trip if the DC-bus
voltage falls below 50V or 60% of the no-load voltage, whichever occurs first.
8.1.1.1 Effect of AC power supply voltage on DC-bus voltage
DC-bus voltage (VDC)
350
300
250
Three-phase AC supply
Single-phase AC supply
200
150
100
100
125
150
175
200
225
250
AC supply voltage (rms)
MN1942
Specifications 8-1
www.supportme.net
8.1.1.2 Effect of AC power supply voltage on DC-bus ripple
DC-bus ripple (% of DC-bus voltage)
50
40
30
Single-phase AC supply
20
10
Three-phase AC supply
0
100
125
150
175
200
225
250
AC supply voltage (rms)
8.1.1.3 Effect of output current on DC-bus ripple voltage
60
DC-bus ripple voltage (Vpk-pk)
55
50
45
40
Single-phase AC supply
35
30
25
20
15
Three-phase AC supply
10
5
0
20
30
40
50
60
70
80
90 100 110 120 130 140 150
% of Drive Rated Current
8-2 Specifications
MN1942
www.supportme.net
8.1.2 24VDC control circuit supply input (X2)
Unit
Nominal input voltage
3A
6A
VDC
9A
24
Minimum input voltage
20
Maximum input voltage
30
Maximum ripple
%
±10
Maximum continuous current @24VDC
A
0.6
Power on surge current (typical)
@24VDC, 100ms
A
4
8.1.3 Motor output power (X1)
Unit
3A
Nominal phase current
ARMS
3
6
9
Peak phase current
for 3s
ARMS
6
12
18
1195
2390
3585
Nominal output
@ 230V, 3Φ
Output voltage range (line-line)
@VDC-bus=320V
Output frequency
Output dV/dt
VA
6A
VRMS
0 - 230
Hz
0 - 2000
kV/µs
at drive, phase-phase
at drive, phase-ground
at motor (using 20m cable), phase-phase
at motor (using 20m cable), phase-ground
2
1.1
1.9
1.8
Nominal switching frequency
kHz
8.0
Minimum motor inductance (per winding)
mH
1
Efficiency
9A
%
>95
8.1.4 Regeneration (X1)
Unit
Nominal switching threshold (typical)
VDC
3A
6A
Nominal power
(10% power cycle, R=57Ω)
kW
0.25
Peak power
(10% power cycle, R=57Ω)
kW
2.7
APK
10
Maximum regeneration switching current
Minimum load resistance
Ω
39
Maximum load inductance
µH
100
MN1942
9A
on: 388, off: 376
Specifications 8-3
www.supportme.net
8.1.5 Digital inputs - drive enable and DIN0 general purpose (X3)
Unit
Type
All models
Opto-isolated inputs
Input voltage
VDC
Nominal
Minimum
Maximum
24
12
30
Input current (maximum, per input)
mA
50
Sampling interval
ms
1
Minimum pulse width
µs
5
8.1.6 Digital inputs DIN1, DIN2 - high speed general purpose (X3)
Unit
Type
All models
Opto-isolated inputs
Input voltage
VDC
Nominal
Minimum
Maximum
Input current (maximum, per input)
Maximum input frequency
Minimum pulse width
24
12
30
mA
MHz
ns
20
1
250
8.1.7 Digital outputs DOUT0, DOUT1 - status and general purpose (X3)
Unit
User supply (maximum)
Output current (max. continuous)
All models
V
28
mA
100
mA
s
200
<20
ms
1
Fuse
Approximate trip current
Reset time
Update interval
8-4 Specifications
MN1942
www.supportme.net
8.1.8 Incremental encoder feedback option (X8)
Unit
Encoder input
Maximum input frequency
(quadrature)
All models
RS422 A/B Differential, Z index
MHz
8
Hall inputs
RS422 A/B Differential
Output power supply to encoder
5V, 200mA max.
Maximum recommended cable length
30.5m (100ft)
8.1.9 SSI encoder feedback option (X8)
Unit
All models
SSI encoder inputs
Differential Data and Clock
Operating mode
(Baldor motors)
Single turn.
Positioning resolution up to
262144 counts/rev (18-bit)
Output power supply to encoder
5V, 200mA max.
Maximum recommended cable length
30.5m (100ft)
8.1.10 SinCos / EnDat encoder feedback option (X8)
Unit
Absolute encoder input
All models
EnDat / SinCos differential
inputs and data input
Operating modes
(Baldor motors)
Single or multi-turn.
512 or 2048 Sin/Cos cycles per
turn, with absolute positioning
resolution of
2048 or 8192 steps.
(Many other encoder
specifications are supported contact Baldor.)
Output power supply to encoder
5V, 200mA max.
Maximum recommended cable length
30.5m (100ft)
8.1.11 Ethernet interface
Description
Unit
Signal
2 twisted pairs,
magnetically isolated
Protocols
Bit rates
MN1942
Value
ETHERNET Powerlink
& TCP/IP
Mbit/s
100
Specifications 8-5
www.supportme.net
8.1.12 CAN interface
Description
Unit
Value
Signal
2-wire, isolated
Channels
1
Protocol
CANopen
Bit rates
Kbit/s
10, 20, 50, 100, 125, 250, 500, 1000
8.1.13 Environmental
All models
Unit
All models
Operating temperature range*
Minimum
Maximum
Derate
Storage temperature range*
Humidity (maximum)*
Forced air cooling flow
(vertical, from bottom to top)
Maximum installation altitude
(above m.s.l.)
Shock*
Vibration*
IP rating
°C
°F
+0
+45
See sections
3.2.2 to 3.2.5
+32
+113
See sections
3.2.2 to 3.2.5
-40 to +85
-40 to +185
%
m/s
93
3A
6A
9A
None required
1
2.5
m
1000
Derate 1.1% / 100m over 1000m
ft
3300
Derate 1.1% / 330ft over 3300ft
10G
1G, 10-150Hz
IP20**
* MicroFlex e100 complies with the following environmental test standards:
BS EN60068-2-1:1993 low temperature operational 0°C.
BS EN60068-2-2:1993 high temperature operational 45°C.
BS EN60068-2-1:1993 low temperature storage/transportation -40°C.
BS EN60068-2-2:1993 high temperature storage/transportation +85°C.
BS 2011:part2.1 Cb: 1990: 45°C 93%RH humidity/high temperature operational.
DIN IEC 68-2-6/29
** MicroFlex e100 complies with EN61800-5-1:2003 part 5.2.2.5.3 (Impact test), provided all front
panel connectors are inserted.
8-6 Specifications
MN1942
www.supportme.net
8.1.14 Weights and dimensions
Description
Weight
Nominal overall dimensions
MN1942
3A
6A
9A
1.45kg (3.2 lb)
1.5kg (3.3 lb)
1.55kg (3.4 lb)
180mm x 80mm x 157mm
(7.1in x 3.2in x 6.2in)
Specifications 8-7
www.supportme.net
8-8 Specifications
MN1942
A
A
www.supportme.net
Accessories
A.1 Introduction
This section describes accessories and options that you may need to use with your
MicroFlex e100. Shielded (screened) cables provide EMI / RFI shielding and are required for
compliance with CE regulations. All connectors and other components must be compatible with
the shielded cable.
MN1942
Accessories A-1
www.supportme.net
A.1.1 Fan tray
The fan tray (Baldor part FAN001-024) provides sufficient cooling for the 3A, 6A or 9A
MicroFlex e100. It requires 23 - 27.5VDC at 325mA, which may be sourced from the same
filtered control circuit supply used for the MicroFlex e100. The MicroFlex e100 is UL listed (file
NMMS.E128059) when used in conjunction with the fan tray, mounted exactly as shown in
Figure 45.
Fan tray
FAN001-024
94 (3.7)
Fan tray
dimensions
84 (3.3)
21.5
(0.85)
142.5 (5.6)
66 (2.6)
Assembled MicroFlex e100
and fan tray
Position of fan tray mounting
holes relative to MicroFlex e100
17.3
(0.68)
Bottom of
MicroFlex e100
Fan tray
16
4.5
(0.63)
(0.18)
It is important that the fan tray is mounted in
close proximity to the MicroFlex e100 as shown
above. Failure to do so will result in decreased
cooling efficiency.
Figure 45 - Fan tray
A-2 Accessories
MN1942
www.supportme.net
A.1.2 Footprint filter (single-phase only)
The single-phase footprint AC power filter (Baldor part FI0029A00) provides mounting holes for
the MicroFlex e100 and fan tray. This allows the filter, fan tray and MicroFlex e100 to use minimal
panel mounting space. See section A.1.3 for details of filter FI0029A00.
Footprint filter
FI0029A00
MicroFlex e100
MFE230A00x
Fan tray
FAN001-024
Figure 46 - Assembled footprint filter, fan tray and MicroFlex e100
MN1942
Accessories A-3
www.supportme.net
A.1.3 EMC filters
AC filters remove high frequency noise from the AC power supply, protecting the MicroFlex e100.
These filters also prevent high frequency signals from being transmitted back onto the power
lines and help meet EMC requirements. To select the correct filter, see sections 3.4.7 and 3.4.8.
A.1.3.1 Catalog numbers
Baldor
catalog number
Rated volts
Rated amps
@ 40°C
Leakage current
(mA)
Weight
kg (lbs)
FI0014A00
FI0015A00
FI0015A01
FI0015A02
FI0018A00
FI0018A03
FI0029A00
250
250
250
250
480
480
250
3
6
10
12
7
16
22
0.4
0.4
0.4
0.4
33
33
33
0.27 (0.6)
0.45 (0.99)
0.73 (1.61)
0.73 (1.61)
0.5 (1.1)
0.8 (1.76)
3.0 (6.6)
B
F
M5
A
D
E
G
C
Dimension
A
B
C
D
E
F
G
Dimensions mm (inches)
FI0018A00
FI0018A03
190 (7.48)
250 (9.84)
160 (6.30)
220 (8.66)
180 (7.09)
235 (9.25)
20 (0.79)
25 (0.98)
4.5 (0.18)
5.4 (0.21)
71 (2.80)
70 (2.76)
40 (1.57)
45 (1.77)
Figure 47 - Filter dimensions, types FI0018A00 and FI0018A03
A-4 Accessories
MN1942
www.supportme.net
L
H
D
E
C
A
G
F
K
J
B
Dimension
FI0014A00
A
B
C
D
E
F
G
H
J
K
L
85 (3.35)
54 (2.13)
40 (1.57)
65 (2.56)
75 (2.95)
27 (1.06)
12 (0.47)
29.5 (1.16)
5.3 (0.21)
6.3 (0.25)
13.5 (0.53)
Dimensions mm (inches)
FI0015A00
FI0015A01
FI0015A02
113.5 (4.47)
156 (6.14)
57.5 (2.26)
46.6 (1.83)
94 (3.70)
103 (4.06)
130.5 (5.14)
143 (5.63)
25 (0.98)
12.4 (0.49)
32.4 (1.28)
4.4 (0.17)
5.3 (0.21)
6 (0.24)
15.5 (0.61)
Figure 48 - Filter dimensions, types FI0014A00, FI0015A00, FI0015A01, FI0015A02
MN1942
Accessories A-5
www.supportme.net
B
E
D
F
Mounting keyhole and slot detail
G
H
C
A
C
A
J
G
G
H
J
K
K
5.5mm
11mm
10mm
5mm
Dimensions shown as: mm (inches).
Dimension
A
B
C
D
E
F
Dimensions mm (inches)
FI0029A00
255 (10.04)
100 (3.94)
244.5 (9.63)
70 (2.76)
40 (1.57)
20 (0.79)
Figure 49 - Filter dimensions, type FI0029A00
A-6 Accessories
MN1942
www.supportme.net
A.1.4 Regeneration resistors
Depending on the application, MicroFlex e100 might require an external regeneration resistor to
be connected to pins R1 and R2 of connector X1. The regeneration resistor dissipates energy
during braking to prevent an over-voltage error occurring.
Baldor part number RG56 is recommended (56Ω, 44W). However, if the required dissipation is
greater than this, Baldor part number RG39 may be used, rated at 100W.
45 (1.7)
100
(3.9)
90
(3.54)
RG56: 140 (5.5)
RG39: 226 (8.9)
M4
65 (2.6)
Dimensions: mm (inches)
Figure 50 - Regeneration resistor dimensions
WARNING: A regeneration resistor may generate enough heat to ignite combustible
materials. To avoid fire hazard, keep all combustible materials and
flammable vapors away from the brake resistors. Ensure that the resistor
has clearance of at least 50mm (2 in) above and below and 26mm (1 in) left
and right.
MN1942
Accessories A-7
www.supportme.net
A.1.5 Motor power cables
Cable
rated current
Cable assembly
description
Power Cable:
no connectors
12 Amps
Power Cable
Assembly:
CE style threaded
motor connector
(motor end only)
Power Cable:
no connector
20 Amps
35 Amps
Length
Catalog number
Power Cable
Assembly:
CE style threaded
motor connector
(motor end only)
Power Cable:
no connector
CBL050-501
m
ft
Available by the meter or on
100m drum.
CBL015SP-12*
CBL025SP-12
CBL030SP-12*
CBL050SP-12
CBL061SP-12*
CBL075SP-12
CBL091SP-12*
CBL100SP-12
CBL150SP-12
CBL152SP-12*
CBL200SP-12
CBL229SP-12*
CBL051-501
1.5
2.5
3.0
5.0
6.1
7.5
9.1
10
15
15.2
20
22.9
5
8.2
10
16.4
20
24.6
30
32.8
49.2
50
65.6
75
Available by the meter or on
100m drum.
CBL015SP-20*
CBL025SP-20
CBL030SP-20*
CBL050SP-20
CBL061SP-20*
CBL075SP-20
CBL091SP-20*
CBL100SP-20
CBL150SP-20
CBL152SP-20*
CBL200SP-20
CBL229SP-20*
CBL052-501
1.5
2.5
3.0
5.0
6.1
7.5
9.1
10
15
15.2
20
22.9
5
8.2
10
16.4
20
24.6
30
32.8
49.2
50
65.6
75
Available by the meter or on
100m drum.
* Available in North and South America only.
A.1.6 Motor power cable part numbers
For easier installation, it is recommended that a color-coded motor power cable is used. A
description of a BSM rotary motor power cable catalog number is shown here, using the example
number CBL025SP-12:
Meaning
Alternatives
CBL
The item is a cable
-
025
Indicates the length, in this example 2.5 meters
Various: see section A.1.5.
SP
The cable is a Servo motor Power cable
-
12
Current rating of 12A
20=20A
Motor power cables include the motor power connector. Larger motors requiring 35A cable
normally use terminal box connections, so a motor power connector is not required.
A-8 Accessories
MN1942
www.supportme.net
A.1.7 SSI feedback cables
This table lists part numbers of feedback cables for use with the MicroFlex e100:
Cable assembly description
SSI Feedback Cable:
no connectors
Feedback Cable Assembly:
CE style threaded motor connector
and low density 15-pin D-type drive
connector
Catalog number
CBL044-501
CBL015SF-S2*
CBL025SF-S2
CBL030SF-S2*
CBL050SF-S2
CBL061SF-S2*
CBL075SF-S2
CBL091SF-S2*
CBL100SF-S2
CBL150SF-S2
CBL152SF-S2*
CBL200SF-S2
CBL229SF-S2*
Length
m
ft
Available by the meter
or on 100m drum.
1.5
2.5
3.0
5.0
6.1
7.5
9.1
10
15
15.2
20
22.9
5
8.2
10
16.4
20
24.6
30
32.8
49.2
50
65.6
75
* Available in North and South America only.
A.1.8 Encoder / Hall feedback cables
This table lists part numbers of encoder feedback cables for use with the MicroFlex e100:
Cable assembly description
Catalog number
Length
m
ft
Encoder Feedback Cable:
no connectors
CBL043-501
Feedback Cable Assembly:
CE style threaded motor connector
(motor end only)
CBL025SF-E
2.5
8.2
CBL015SF-E2*
CBL025SF-E2
CBL030SF-E2*
CBL050SF-E2
CBL061SF-E2*
CBL075SF-E2
CBL091SF-E2*
CBL100SF-E2
CBL150SF-E2
CBL152SF-E2*
CBL200SF-E2
CBL229SF-E2*
1.5
2.5
3.0
5.0
6.1
7.5
9.1
10
15
15.2
20
22.9
5
8.2
10
16.4
20
24.6
30
32.8
49.2
50
65.6
75
Feedback Cable Assembly:
CE style threaded motor connector
and low density 15-pin D-type drive
connector
Available by the meter
or on 100m drum.
* Available in North and South America only.
MN1942
Accessories A-9
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A.1.9 EnDat (absolute encoder) and SinCos feedback cables
Cable assembly description
Length
Baldor catalog number
Absolute encoder feedback cable:
no connectors
Absolute encoder
feedback cable assembly:
CE style threaded motor connector
and low density 15-pin D-type drive
connector
CBL045-501
m
ft
Available by the meter
or on 100m drum.
CBL015SF-D2*
CBL025SF-D2
CBL030SF-D2*
CBL050SF-D2
CBL061SF-D2*
CBL075SF-D2
CBL091SF-D2*
CBL100SF-D2
CBL150SF-D2
CBL152SF-D2*
CBL200SF-D2
CBL229SF-D2*
1.5
2.5
3.0
5.0
6.1
7.5
9.1
10
15
15.2
20
22.9
5
8.2
10
16.4
20
24.6
30
32.8
49.2
50
65.6
75
* Available in North and South America only.
A.1.10 Feedback cable part numbers
A description of a feedback cable catalog number is shown here, using the example number
CBL025SF-E2:
Meaning
Alternatives
CBL
The item is a cable
-
025
Indicates the length, in this example 2.5 meters
Various: see sections A.1.7 to
A.1.9.
SF
The cable is a Servo motor Feedback cable
-
E
Encoder feedback cable with motor connector
S=SSI feedback cable
D=EnDat/SinCos feedback cable
2
Drive connector included:
15-pin D-type connector for all feedback types
-
Note:
Feedback cables have the outer shield tied to the connector housing(s).
If you are not using a Baldor cable with your chosen feedback device, be sure to obtain a cable
that is a shielded twisted pair 0.34mm2 (22 AWG) wire minimum, with an overall shield. Ideally,
the cable should not exceed 30.5m (100ft) in length. Maximum wire-to-wire or wire-to-shield
capacitance is 50pF per 300mm (1ft) length, to a maximum of 5000pF for 30.5m (100ft).
A-10 Accessories
MN1942
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A.1.11 Ethernet cables
The cables listed in this table connect MicroFlex e100 to other EPL nodes such as
NextMove e100, additional MicroFlex e100s, or other EPL compatible hardware. The cables are
standard CAT5 ‘crossover’ Ethernet cables:
Cable assembly description
CAT5 Ethernet cable
MN1942
Baldor catalog number
CBL002CM-EXS
CBL005CM-EXS
CBL010CM-EXS
CBL020CM-EXS
CBL050CM-EXS
CBL100CM-EXS
Length
m
ft
0.2
0.5
1.0
2.0
5.0
10.0
0.65
1.6
3.3
6.6
16.4
32.8
Accessories A-11
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A-12 Accessories
MN1942
B
B
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Control System
B.1 Introduction
The MicroFlex e100 can use two main control configurations:
H
Servo (Position).
H
Torque Servo (Current).
Each configuration supports different control modes, selected by using the Tools, Control Mode
menu item or by using the CONTROLMODE keyword in the Command window (see the Mint help
file). The control configurations are described in the following sections.
MN1942
Control System B-1
www.supportme.net
B.1.1 Servo configuration
The servo configuration is the default configuration for the drive, allowing the motor control
system to operate as a torque controller, a velocity controller or a position controller. This
configuration comprises 3 nested control loops; a current control loop, a velocity control loop and
a position control loop, as shown in Figure 51.
The universal encoder interface reads rotor position from the encoder and estimates velocity.
The commutation block uses the position to calculate the electrical angle of the rotor. The current
sensor system measures U and V phase currents. These are fed into a current conversion block
that converts them into quantities representing torque producing and magnetizing currents (the
’vector’ currents which are locked to the rotor).
In the current control loop, a current demand and the final measured current values form the
inputs to a PI (Proportional, Integral) control system. This control system generates a set of
voltage demands that are fed into a PWM (pulse-width modulation) block. The PWM block uses
the space-vector modulation method to convert these voltage demands into a sequence of U, V
and W phase switching signals, which are applied to the output bridge of the drive. The PWM
block uses the measured DC bus voltage to compensate for variations in supply voltage.
The torque controller converts a torque demand into a current demand and compensates for
various load non-linearities. A 2-stage notch or low-pass filter allows the effects of load
compliance to be reduced. To avoid motor damage, a user-defined application current limit is also
applied, as well as individual positive and negative torque limits.
In the velocity control loop, a velocity demand and measured velocity form the inputs to a PI
control system. The output of the control system is a torque demand which, when the drive is
operating as a velocity controller, forms the input to the current control loop.
Finally, in the position control loop, a position demand and measured position form the inputs to
a PID (Proportional, Integral, Differential) control system incorporating velocity feedback,
velocity feed-forward and acceleration feed-forward. The output of the position control system
is a velocity demand which, when the drive is operating as a position controller, forms the input
to the velocity control loop.
B-2 Control System
MN1942
MN1942
POSDEMAND
+
--
FOLERROR
VELDEMAND
ACCELDEMAND
TORQUEDEMAND
Position controller
PID
KPROP
KINT
KINTMODE
KINTLIMIT
KDERIV
+
--
+
KVELFF
KVEL
Control mode
switch
P
V
+
--
POS
VEL
Velocity controller
PI + TF
KVPROP
KVINT
KVTRACK
+
+
TORQUELIMITPOS
TORQUELIMITNEG
CURRENTLIMIT
Limiting
+
--
CURRMEAS
Measured torque and
magnetising currents
TORQUEFILTERTYPE
TORQUEFILTERFREQ
TORQUEFILTERBAND
TORQUEFILTERDEPTH
Commutation
Electrical angle
Control mode
switch
P,V
T
Torque filters
Torque control
Figure 51 - Servo configuration control structure
VELERROR
KACCEL
EFFORT
Temperature drift
compensation
Current
Conv
Offset
Comp
PWM
Universal
Encoder
Interface
Current controllers
PI + TF
KIPROP
KIINT
KITRACK
DRIVEBUSVOLTS
V
U
Encoder
E
Current
Sensors
Motor
Bus Voltage
Measurement
www.supportme.net
Control System B-3
www.supportme.net
B.1.2 Torque servo configuration
Figure 52 shows the torque-servo control configuration. Here, the velocity loop has been
removed and the output of the position controller is fed into the current loop via the torque filters.
The torque servo configuration is useful when the drive is operating as a closed-loop position
controller and settling time must be minimized. Although the servo configuration tends to give
better velocity tracking when operating in position mode, settling times can be longer.
The control mode switch allows the drive to operate in either torque or position modes, but not
velocity mode.
B-4 Control System
MN1942
MN1942
POSDEMAND
VELDEMAND
ACCELDEMAND
TORQUEDEMAND
+
--
FOLERROR
Position controller
PID
KPROP
KINT
KINTMODE
KINTLIMIT
KDERIV
+
--
+
+
P
T
POS
+
TORQUELIMITPOS
TORQUELIMITNEG
CURRENTLIMIT
Limiting
--
EFFORT
Current
Conv
Universal
Encoder
Interface
Offset
Comp
PWM
DRIVEBUSVOLTS
Current controllers
PI + TF
KIPROP
KIINT
KITRACK
Temperature drift
compensation
CURRENTMEAS
Measured torque and
magnetising currents
TORQUEFILTERTYPE
TORQUEFILTERFREQ
TORQUEFILTERBAND
TORQUEFILTERDEPTH
Torque filters
Commutation
Electrical angle
Control mode
switch
VEL
KACCEL
Figure 52 - Torque Servo configuration control structure
KVEL
Control mode
switch
+
+
KVELFF
Torque control
V
U
Encoder
E
Current
Sensors
Motor
Bus Voltage
Measurement
www.supportme.net
Control System B-5
www.supportme.net
B-6 Control System
MN1942
C
C
www.supportme.net
CE Guidelines
C.1 Outline
This section provides general information
regarding recommended methods of installation
for CE compliance. It is not intended as an
exhaustive guide to good practice and wiring
techniques. It is assumed that the installer of the
MicroFlex e100 is sufficiently qualified to perform
the task, and is aware of local regulations and
requirements. Baldor products that meet the EMC
directive requirements are indicated with a “CE”
mark. A duly signed CE declaration of conformity
is available from Baldor.
C.1.1 EMC Conformity and CE marking
The information contained herein is for your guidance only and does not guarantee that the
installation will meet the requirements of the council directive 89/336/EEC.
The purpose of the EEC directives is to state a minimum technical requirement common to all the
member states within the European Union. In turn, these minimum technical requirements are
intended to enhance the levels of safety both directly and indirectly.
Council directive 89/336/EEC relating to Electro Magnetic Compliance (EMC) indicates that it is
the responsibility of the system integrator to ensure that the entire system complies with all
relative directives at the time of installing into service.
Motors and controls are used as components of a system, per the EMC directive. Hence all
components, installation of the components, interconnection between components, and
shielding and grounding of the system as a whole determines EMC compliance.
The CE mark informs the purchaser that the equipment has been tested and complies with the
appropriate standards. It rests upon the manufacturer or his authorized representative to ensure
the item in question complies fully with all the relative directives in force at the time of installing
into service, in the same way as the system integrator previously mentioned. Remember that it
is the instructions of installation and the product that should comply with the directive.
C.1.2 MicroFlex e100 compliance
When installed as directed in this manual, MicroFlex e100 units meet the emission limits for an
“industrial” environment, as defined by the EMC directives (EN61000-6-4: 2001). To meet the
more stringent emission limits of the “residential, commercial and light industrial” environment
(EN61000-6-3: 2001), the MicroFlex e100 must be mounted in a suitable metal cabinet
incorporating 360° screened cable glands.
MN1942
CE Guidelines C-1
www.supportme.net
C.1.3 Use of CE compliant components
The following points should be considered:
H
Using CE approved components will not guarantee a CE compliant system!
H
The components used in the drive, installation methods used, materials selected for
interconnection of components are important.
H
The installation methods, interconnection materials, shielding, filtering and earthing /
grounding of the system as a whole will determine CE compliance.
H
The responsibility of CE mark compliance rests entirely with the party who offers the end
system for sale (such as an OEM or system integrator).
C.1.4 EMC wiring technique
Cabinet
Using a typical electroplated zinc coated enclosure, connected to earth/ground, means that all
parts mounted on the back plane are connected to earth/ground and all outer shield (screen)
connections can be connected to earth/ground. Within the cabinet there should be a spatial
separation between power wiring (motor and AC power cables) and control wiring.
Shield (screen) connections
All connections between components must use shielded cables. The cable shields must be
connected to the enclosure. Use conductive clamps to ensure good earth/ground connection.
With this technique, a good earth/ground shield can be achieved.
EMC filters
The filter should be mounted next to the MicroFlex e100. The connections between the MicroFlex
e100 and the filter should use shielded (screened) cables. The cable shields should be
connected to shield clamps at both ends.
Earthing/grounding
For safety reasons (VDE0160), all Baldor components must be connected to earth/ground with
a separate wire. Earth/ground connections must be made from the central earth/ground (star
point) to the regeneration resistor enclosure and from the central earth/ground (star point) to the
power supply.
C-2 CE Guidelines
MN1942
www.supportme.net
C.1.5 EMC installation suggestions
To ensure electromagnetic compatibility (EMC), the following installation points should be
considered to help reduce interference:
H
Earthing/grounding of all system elements to a central earth/ground point (star point)
H
Shielding of all cables and signal wires
H
Filtering of power lines.
A proper enclosure should have the following characteristics:
H
All metal conducting parts of the enclosure must be electrically connected to the back plane.
These connections should be made with an earthing/grounding strap from each element to
a central earthing/grounding point (star point). *
H
Keep the power wiring (motor and power cable) and control wiring separated. If these wires
must cross, be sure they cross at 90 degrees to minimize noise due to induction.
H
The shield connections of the signal and power cables should be connected to the shield
rails or clamps. The shield rails or clamps should be conductive clamps fastened to the
cabinet. **
H
The cable to the regeneration resistor must be shielded. The shield must be connected to
earth/ground at both ends.
H
The location of the AC filter has to be situated close to the drive so the AC power wires are
as short as possible.
H
Wires inside the enclosure should be placed as close as possible to conducting metal,
cabinet walls and plates. It is advised to terminate unused wires to chassis ground.*
H
To reduce earth/ground current, use the largest suitable wire available for earth/ground
connections.
*
Earthing/grounding in general describes all metal parts which can be connected to a
protective conductor, e.g. housing of cabinet, motor housing, etc. to a central earth/ground
point (star point). This central earth/ground point (star point) is then connected to the main
plant (or building) earth/ground.
**
Or run as twisted pair at minimum.
MN1942
CE Guidelines C-3
www.supportme.net
C.1.6 Wiring of shielded (screened) cables
Remove the outer insulation
to expose the overall shield.
Clamp should provide 360°
contact with the cable.
Flat or p-type
conductive clamp
Figure 53 - Earthing/grounding cable shields
MicroFlex e100
X8
CHA+
CHACHB+
CHBCHZ+
CHZ+5V
DGND
Encoder Connector
Housing
Cable
Twisted pairs
1
9
2
10
3
11
12
13
Connect overall shield
to connector backshell.
Connect overall shield
to connector backshell.
Figure 54 - Encoder signal cable grounding
C-4 CE Guidelines
MN1942
Index
A
Abbreviations. See Units and Abbreviations
Accessories, A-1
EMC filters, A-4
fan tray, A-2
feedback cables, A-9, A-10
footprint filter, A-3
motor power cables, A-8
regeneration resistors, A-7
B
Basic Installation, 3-1
C
CAN interface
CANopen, 5-18
connector, 5-17
introduction, 5-17
LEDs, 7-3
opto-isolation, 5-18
specifications, 8-6
termination, 5-17
wiring, 5-17
Catalog number, identifying, 2-2
CE Guidelines, C-1
Circuit breakers, 3-15
Command window, 6-17
Commissioning Wizard, 6-11
using, 6-12
Configuration, 6-14
Connections
See also Input / Output
feedback, 4-1
motor, 3-18
power, 3-11, 3-12
Connectors
CAN, 5-17
Ethernet, 5-14, 5-16
I/O, 5-3–5-12
MN1942
locations, 3-9, 3-10
USB, 5-13
Control system, B-1
servo configuration, B-2
torque servo configuration, B-4
Cooling, 3-5, 3-6, 3-7, 3-8, A-2
overtemperature trips, 3-8
D
Demand outputs, 6-13
Derating, 3-6, 3-7, 3-8
Digital I/O, 5-2
digital input DIN0, 5-5, 8-4
digital inputs DIN1 & DIN2, 5-7, 8-4
digital output DOUT0, 5-9, 8-4
digital output DOUT1, 5-11, 8-4
drive enable input, 5-3, 8-4
special functions on DIN1 & DIN2, 5-8
Dimensions, 3-4
Dynamic brake. See Regeneration resistor
E
Earthing (grounding)
leakage, 3-11
protection class, 3-11
protective earth (PE), 3-11
Encoder, incremental
cable, 4-3, A-9
feedback, 4-2
specification, 8-5
without Halls, 4-4
EnDat (absolute) encoder
cable, 4-11
feedback, 4-10
specification, 8-5
Environmental
cooling, 3-3
location, 3-3–3-4
specification, 8-6
Index
Ethernet connector, 5-16
Ethernet interface
cables, A-11
connector, 5-16
ETHERNET Powerlink, 5-15
introduction, 5-14
LEDs, 7-4
specifications, 8-5
TCP/IP, 5-14
F
Features, 2-1
Feedback
cable, A-9–A-11
connections, 4-1
encoder without Halls, 4-4
EnDat (absolute), 4-10
Halls-only feedback, 4-4
incremental encoder, 4-2
SinCos, 4-8
SSI, 4-6
Filters
24V control circuit supply, 3-17
AC power (EMC), 3-16, A-4
catalog numbers, A-4
Footprint filter, A-3
Fuses, 3-15
G
General Information, 1-1
Grounding. See Earthing (grounding)
H
Hardware requirements, 3-1
Help file, 6-9
I
Incremental encoder
cable, 4-3, A-9
feedback, 4-2
specification, 8-5
without Halls, 4-4
Indicators
CAN LEDs, 7-3
ETHERNET LEDs, 7-4
Index
STATUS LED, 7-2
Input / Output, 5-1
CAN interface, 5-17
connection summary, 5-23
digital input DIN0, 5-5, 8-4
digital inputs DIN1 & DIN2, 5-7, 8-4
digital output DOUT0, 5-9, 8-4
digital output DOUT1, 5-11, 8-4
drive enable input, 5-3, 8-4
encoder interface, 4-1
Ethernet interface, 5-14
node ID selector switches, 5-20
serial port, 5-13
USB port, 5-13
Installation
See also Basic Installation
cooling, 3-5–3-8
dimensions, 3-4
mechanical, 3-3
Mint Machine Center, 6-1
Mint WorkBench, 6-1
mounting, 3-5
TCP/IP configuration, 6-3
USB driver, 6-2
L
LED indicators
CAN LEDs, 7-3
ETHERNET LEDs, 7-4
STATUS LED, 7-2
LED status indicator, 7-2
Linear motor, cable configuration, 4-5
M
Mint Machine Center (MMC), 6-5
starting, 6-7
Mint WorkBench, 6-8
Commissioning Wizard, 6-11
fine-tuning tool, 6-14
help file, 6-9
other tools and windows, 6-17
parameters tool, 6-16
starting, 6-10
Motor
circuit contactors, 3-19
MN1942
connections, 3-18
brake connection, 3-22
power cable, 3-19–3-20, A-8
sinusoidal filter, 3-20
thermal switch, 3-21
Mounting, 3-5
N
Node ID selector switches, 5-20
O
Operation, 6-1
configuring the TCP/IP connection, 6-3
connecting to the PC, 6-1
installing Mint Machine Center, 6-1
installing Mint WorkBench, 6-1
installing the USB driver, 6-2
power on checks, 6-2
preliminary checks, 6-2
starting, 6-2
Overloads
drive, 3-15
motor, 3-18
overtemperature trips, 3-8
P
Parameters tool, 6-16
Power
24V control circuit supply, 3-17
connections, 3-11
discharge period, 3-13
disconnect and protection devices, 3-14
input conditioning, 3-13
input cycling, 3-13, 7-1
inrush, 3-13
sources, 3-1
supply filters, 3-16, A-4
using a variac, 3-14
Precautions, 1-2
Product Notice, 1-2
R
Receiving and Inspection, 2-2
Regeneration
resistor, 3-23
specification, 8-3
MN1942
S
Safety Notice, 1-2
Servo axis, testing the demand output, 6-13
SinCos
cable, 4-9
feedback, 4-8
specification, 8-5
Specifications, 8-1
24VDC control supply, 8-3
AC input power and bus voltage, 8-1
CAN interface, 8-6
digital input DIN0, 8-4
digital input DIN1, 8-4
digital input DIN2, 8-4
digital output DOUT0, 8-4
digital output DOUT1, 8-4
drive enable input, 8-4
EnDat feedback, 8-5
environmental, 8-6
Ethernet interface, 8-5
incremental encoder feedback, 8-5
motor output, 8-3
regeneration, 8-3
SinCos feedback, 8-5
SSI encoder feedback, 8-5
weights and dimensions, 8-7
SSI
cable, 4-7, A-9
feedback, 4-6
specification, 8-5
Status LED, 7-2
Step & direction, specification, 8-4
T
Testing, demand output, 6-13
Thermal switch connection, 3-21
Tools, 3-2
Troubleshooting, 7-1
CAN LEDs, 7-3
CANopen, 7-6
communication, 7-5
Ethernet, 7-6
ETHERNET LEDs, 7-4
Mint WorkBench, 7-5
power cycling, 7-1
power on, 7-5
Index
problem diagnosis, 7-1
STATUS LED, 7-2
SupportMe, 7-1
tuning, 7-6
U
Units and abbreviations, 2-3
TCP/IP, configuring, 6-3
Index
USB
installing the driver, 6-2
port, 5-13
W
Weights and dimensions, 8-7
Wires sizes, 3-15
WorkBench. See Mint WorkBench
MN1942
Comments
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comments in the space provided below, remove this page from the manual and mail it to:
Manuals
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BS32 0BF
United Kingdom.
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[email protected]
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