Baldor MicroFlex Servo drive Installation Manual

SERVO DRIVE

MicroFlex

Servo Control

03/10

Installation Manual

MN1919

Contents

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

MicroFlex features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1

Identifying the catalog number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-1

2-2

2-2

2-3

3 Basic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1

Power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2

Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3

Tools and miscellaneous hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.4

Other information needed for installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Mechanical installation and cooling requirements . . . . . . . . . . . .

3.2.1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2

Mounting and cooling the MicroFlex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3

Derating characteristic - 1A model

3.2.4

Derating characteristic - 3A model

3.2.5

Derating characteristic - 6A model

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3.2.6

Derating characteristic - 9A model

3.2.7

Overtemperature trips

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3.3

Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1

Earthing / grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2

Single-phase or three-phase power connections . . . . . . . . . . . . . . . . . . . . .

3.4.3

Input power conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.4

Power disconnect and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.5

Recommended fuses and wire sizes

3.4.6

Drive overload protection

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3.4.7

Power supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.8

24V control circuit supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10

3-10

3-11

3-12

3-13

3-14

3-14

3-15

3-16

3.5

Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1

Motor circuit contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2

Motor power cable pin configuration - Baldor BSM rotary motors . . . . . . .

3.5.3

Motor cable pin configuration - Baldor linear motors

3.5.4

Sinusoidal filter

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3-17

3-18

3-18

3-19

3-19

3.6

Regeneration resistor (Dynamic Brake resistor)

3.6.1

Regeneration capacity

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3-20

3-20

3-3

3-4

3-5

3-6

3-6

3-7

3-8

3-8

3-9

3-1

3-1

3-1

3-1

3-2

3-2

MN1919

Contents i

3.7

Regeneration resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1

Required information

3.7.2

Regenerative energy

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3.7.3

Regenerative power and average power

3.7.4

Resistor choice

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3.7.5

Resistor derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-21

3-21

3-22

3-22

3-23

3-23

4 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1

Encoder feedback - X8

4.1.2

SSI feedback - X8

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4.1.3

Resolver feedback - X8

4.1.4

Encoder output - X7

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

4-1

4-2

4-7

4-9

4-11

5 Input / Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5-1

5.2

Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1

Analog input - X3 (demand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1

Drive enable input - X3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2

General purpose digital input - X3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3

Step (pulse) and direction inputs - X3

5.3.4

Status output - X3

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5.4

Serial port - X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1

Using RS232 cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2

Multidrop using RS485 / RS422 cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.3

Connecting serial Baldor HMI Operator Panels . . . . . . . . . . . . . . . . . . . . . .

5-14

5-14

5-15

5-16

5.5

Connection summary - recommended system wiring . . . . . . . . .

5-17

5-2

5-2

5-4

5-5

5-7

5-9

5-12

6 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1

Connecting the MicroFlex to the PC

6.1.2

Installing the software

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6.1.3

Starting the MicroFlex

6.1.4

Preliminary checks

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6.1.5

Power on checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2

Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1

Help file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2

Starting Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.3

Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.4

Using the Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1

Fine-tuning tool

6.3.2

Parameters tool

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6.3.3

Other tools and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-3

6-4

6-5

6-7

6-7

6-8

6-8

6-10

6-11

6-1

6-1

6-1

6-2

6-2

6-2

ii Contents

MN1919

7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1

Problem diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2

SupportMe feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.3

Power-cycling the MicroFlex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2

Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.1

Communication

7.2.2

Power on

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7.2.3

Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7-1

7-1

7-1

7-1

7-2

7-3

7-4

7-4

8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1

AC input power and DC bus voltage (X1)

8.1.2

24VDC control circuit supply input (X2)

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8.1.3

Motor output power (X1)

8.1.4

Regeneration (X1)

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8.1.5

Analog input (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.6

Digital inputs - drive enable and general purpose (X3)

8.1.7

Step and Direction inputs (X3)

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8.1.8

Status output (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.9

Incremental encoder feedback option (X8) . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.10 SSI encoder feedback option (X8)

8.1.11 Resolver feedback option (X8)

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.12 Encoder output (simulated) (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.13 Serial RS232/RS485 interface (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.14 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

8-1

8-5

8-5

8-5

8-5

8-6

8-6

8-6

8-1

8-3

8-3

8-3

8-4

8-4

8-4

Appendices

A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.1

Fan tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.2

Footprint filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.3

EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.4

Regeneration resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2.1

Motor power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2.2

Feedback cable part numbers

A.2.3

SSI feedback cables

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A.2.4

Encoder / Hall feedback cables

A.2.5

Resolver feedback cables

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1

A-1

A-2

A-3

A-4

A-7

A-8

A-8

A-10

A-10

A-11

A-12

MN1919

Contents iii

B Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1.1

Current (Torque) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1.2

Velocity (Speed) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1.3

Position (Step and Direction) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-1

B-1

B-2

B-3

B-4

C CE & UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.1

EMC Conformity and CE marking

C.1.2

MicroFlex compliance

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.3

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.4

Use of CE compliant components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.5

EMC wiring technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.6

EMC installation suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.7

Wiring of shielded (screened) cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.2

UL file numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C-1

C-1

C-1

C-1

C-2

C-3

C-3

C-4

C-5

C-6

iv Contents

MN1919

1

1

Copyright Baldor (c) 2010. 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 2000, Windows XP and Windows Vista are registered trademarks of the Microsoft

Corporation. UL and cUL are registered trademarks of Underwriters Laboratories.

MicroFlex 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:

Fax:

E-mail:

Web site:

+44 (0) 1454 850000

+44 (0) 1454 850001 [email protected]

www.baldormotion.com

See rear cover for other international offices

.

MN1919 General Information 1-1

www.baldormotion.com

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.

1-2 General Information MN1919

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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: MEDICAL DEVICE / PACEMAKER DANGER: Magnetic and electromagnetic fields in the vicinity of current carrying conductors and industrial motors can result in a serious health hazard to persons with cardiac pacemakers, internal cardiac defibrillators, neurostimulators, metal implants, cochlear implants, hearing aids, and other medical devices. To avoid risk, stay away from the area surrounding a motor and its current carrying conductors.

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. Baldor regeneration resistors are neither internally fused nor thermally protected and under extreme conditions, can cause a fire hazard if not suitably protected or rated for the application.

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

MN1919 General Information 1-3

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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.

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: If the drive is subjected to high potential (‘hipot’) testing, only DC voltages may be applied. AC voltage hipot tests could damage the drive. For further information please contact your local Baldor representative.

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 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, 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.

1-4 General Information MN1919

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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 can become very hot during normal operation.

MN1919 General Information 1-5

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1-6 General Information MN1919

2

2

2.1 MicroFlex features

The MicroFlex is a versatile brushless servo drive, providing a flexible and powerful motion control solution for rotary and linear motors. Standard features include:

H

Single axis AC brushless drive.

H

Range of models with continuous current ratings of 1A, 3A, 6A or 9A.

H

Direct connection to 115VAC or 230VAC single-phase or 230VAC three-phase supplies.

H

SSI, incremental encoder, or resolver feedback.

H

Velocity and current control, with step and direction input for position control.

H

Auto-tuning wizard (including position loop) and software oscilloscope facilities provided by Mint WorkBench configuration software (supplied).

H

2 optically isolated digital inputs (one enable input and one general purpose input).

H

1 optically isolated digital output to indicate error conditions.

H

1 general-purpose analog input (can be used as a speed or torque command reference).

H

RS232 or RS485 communications (model dependent) for setup and diagnostics.

MicroFlex 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. The sections should be read in sequence.

The Basic Installation section describes the mechanical installation of the MicroFlex, 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.

MN1919 Introduction 2-1

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2.2 Receiving and inspection

When you receive your MicroFlex, 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.

2. Remove the MicroFlex 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 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 for external damage during shipment and report any damage to the carrier that delivered your MicroFlex.

5. If MicroFlex 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 8.1.14.

2.2.1 Identifying the catalog number

The MicroFlex 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:

FMH______________-________

________________________

Date:

______

E

N

2

3

T

R

A description of a catalog number is shown here, using the example FMH2A03TR-EN23:

Meaning Alternatives

FMH MicroFlex family

2

Requires an AC supply voltage of 115-230 Volts, 1Φ or 3Φ

-

-

A03

Continuous current rating of 3A

A01=1A; A06=6A;

A09=9A

Built in AC power supply

Requires external braking resistor

Supported feedback types are encoder or SSI

No options specified

Serial port type is RS232

24VDC supply is required to power the control logic

-

-

R=Resolver feedback

-

4 = RS485

-

2-2 Introduction MN1919

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2.3 Units and abbreviations

The following units and abbreviations may appear in this manual:

A . . . . . . . . . . . . . . .

AC

DC

. . . . . . . . . . . . .

. . . . . . . . . . . . .

dB kW mA mH

. . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

mΩ pF

. . . . . . . . . . . . .

. . . . . . . . . . . . . .

V

W

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

μA

μH

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

μF

Ω

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

Ampere

Alternating current

Direct current decibel kilowatt milliampere millihenry milliohm picofarad

Volt (also VAC and VDC)

Watt microampere microhenry microfarad

Ohm

Hz kHz

. . . . . . . . . . . . . .

. . . . . . . . . . . . .

MHz ms

. . . . . . . . . . . .

. . . . . . . . . . . . . .

ns s

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

μs

Φ

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

hertz kilohertz megahertz millisecond nanosecond second microsecond phase

CD . . . . . . . . . . . . .

CTRL+E

Kbaud

. . . . . . . . .

. . . . . . . . . . .

MB . . . . . . . . . . . . .

Compact Disc on the PC keyboard, press Ctrl then E at the same time.

kilobaud (the same as Kbit/s in most applications) megabytes ft . . . . . . . . . . . . . . .

ft/s in

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

lb-in mm

. . . . . . . . . . . . .

. . . . . . . . . . . . .

m . . . . . . . . . . . . . . .

m/s . . . . . . . . . . . . .

Nm . . . . . . . . . . . . .

feet feet per second inch pound-inch (torque) millimeter meter meters per second

Newton-meter (torque)

ADC

AWG

DAC

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

SSI

(NC)

. . . . . . . . . . . . .

. . . . . . . . . . . .

Analog to Digital Converter

American Wire Gauge

Digital to Analog Converter

Synchronous Serial Interface

Not Connected

MN1919 Introduction 2-3

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2-4 Introduction MN1919

3

3

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 in the following stages:

H

Location considerations

H

Mounting the MicroFlex

H

Connecting the AC power supply

H

Connecting the 24VDC control circuit supply

H

Connecting the motor

H

Installing a regeneration resistor (Dynamic Brake)

H

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 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:

H

The motor that will be connected to the MicroFlex.

H

A motor power cable.

H

An encoder feedback cable (and Hall cable for linear motors), or resolver cable.

H

A serial cable connected as shown in section 5.4.

H

(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 models have overvoltage sensing circuitry. Regeneration resistors may be purchased separately - see Appendix A.

H

A cooling fan may be required to allow operation of the MicroFlex at full rated current (see section 3.2.2).

MN1919 Basic Installation 3-1

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H

A PC with the following specification:

Processor

RAM

Minimum specification

Intel Pentium 133MHz

Hard disk space

CD-ROM

Serial port

Recommended specification

Intel Pentium 200MHz or faster

32MB

40MB

64MB

60MB

A CD-ROM drive

RS232 or RS485 serial port (depending on MicroFlex model)

Screen

Mouse

Operating system

800 x 600, 256 colors 1024 x 768, 256 colors

A mouse or similar pointing device

Windows 95, Windows 98, Windows ME,

Windows NT, Windows XP or Windows 2000

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

H

Crimping tool.

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 signal will be ‘Active Low’ or ‘Active High’.

3-2 Basic Installation MN1919

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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 are shielded correctly.

CAUTION: Avoid locating the MicroFlex immediately above or beside heat generating equipment, or directly below water steam pipes.

CAUTION: Avoid locating the MicroFlex 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:

H

The MicroFlex must be installed indoors, permanently fixed and located so that it can only be accessed by service personnel using tools.

H

The maximum suggested operating altitude is 1000m (3300ft).

H

The MicroFlex must be installed where the pollution degree according to IEC664 shall not exceed 2.

H

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.

H

The input of the control circuit must be limited to Safety Extra Low Voltage circuits.

H

Both the AC supply and the 24VDC supply must be fused.

H

The atmosphere must not contain flammable gases or vapors.

H

There must not be abnormal levels of nuclear radiation or X-rays.

H

To comply with CE directive 89/336/EEC an appropriate AC filter must be installed.

H

The MicroFlex must be secured by the slots in the flange. The protective earth/ground (the threaded hole on the top of the MicroFlex) 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.

H

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.

H

Each D-type connector on the front panel of the MicroFlex is 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 jack screw with an external male threaded section no longer than 10mm (0.4 in).

MN1919 Basic Installation 3-3

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3.2.1 Dimensions

11

(0.4)

80

(3.2)

63.5

(2.5)

5

(0.2)

Mounting hole and slot detail

FRONT

PANEL

5.5 mm

Dimensions shown as: mm (inches).

Depth: 157 mm (6.2 in)

Weight: 1A: 1.45kg (3.2lb)

3A: 1.45kg (3.2lb)

6A: 1.50kg (3.3lb)

9A: 1.55kg (3.4lb)

3-4 Basic Installation

Figure 1 - Package dimensions

MN1919

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3.2.2 Mounting and cooling the MicroFlex

Ensure you have read and understood the Mechanical installation and location requirements in section 3.2. Mount the MicroFlex vertically on its rear side, the side opposite the front panel.

M5 bolts or screws should be used to mount the MicroFlex. Detailed dimensions are shown in section 3.2.1.

For effective cooling, the MicroFlex must be mounted upright on a smooth vertical metal surface. The MicroFlex 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 1A and 3A models are 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 case, to allow full rated current at 45°C (113°F).

Temperature derating characteristics are shown in sections 3.2.4 to 3.2.6.

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 to be UL listed.

3.2.2.1 Effects of mounting surface and proximity

The proximity of the MicroFlex to other components could affect cooling efficiency. If the MicroFlex is mounted beside another

MicroFlex (or other obstruction), there should be a minimum space of 15mm to maintain effective cooling.

If the MicroFlex is mounted above or below another MicroFlex (or other obstruction), there should be a minimum space of 90mm to maintain effective cooling. Remember that when a MicroFlex is mounted above another

MicroFlex or heat source, it will be receiving air that has been already heated by the device(s) below it. Multiple MicroFlex units mounted above each other should be aligned, not offset, to promote air flow across the heatsinks.

The derating characteristics assume the

MicroFlex is mounted on 3mm thick (or less) metal plate. If the MicroFlex is mounted on

10mm plate then the current characteristics shown in sections 3.2.4 to 3.2.6 may be increased by up to 7% if there is no forced air cooling, or 15% if forced air cooling is present.

It is recommended to allow approximately

60mm at the front to accommodate wiring and connectors.

Metal backplane

90mm

15mm

15mm

Fan Fan

Figure 2 - Cooling and proximity

MN1919 Basic Installation 3-5

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3.2.3 Derating characteristic - 1A model

The 1A model can be operated at maximum rated current at 55°C without any additional cooling. The output current does not need to be derated. The overload limit is 2A.

3.2.4 Derating characteristic - 3A model

The following derating characteristics are for model FMH2A03TR-EN23.

Single-phase AC supply

3

1m/s forced air

2

Natural cooling

1

0

30

3

35 40 45

Ambient temperature (°C)

50

Three-phase AC supply

55

1m/s forced air

2

Natural cooling

1

0

30 35 40 45

Ambient temperature (°C)

50

Notes:

Load power factor = 0.75.

Overload limit for model FMH2A03TR-EN23 is 6A.

3-6 Basic Installation

55

MN1919

3.2.5 Derating characteristic - 6A model

The following derating characteristics are for model FMH2A06TR-EN23.

Single-phase AC supply

6

5

1.5m/s forced air

4

3

1m/s forced air

2

1

0

30 35 40 45

Ambient temperature (°C)

50 55

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Natural cooling

Three-phase AC supply

6

5

4

3

2

1

0

30 35 40 45

Ambient temperature (°C)

50

Notes:

Load power factor = 0.75.

Overload limit for model FMH2A06TR-EN23 is 12A.

55

1.5m/s forced air

1m/s forced air

Natural cooling

MN1919 Basic Installation 3-7

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3.2.6 Derating characteristic - 9A model

The following derating characteristics are for model FMH2A09TR-EN23.

Single-phase AC supply

9

8

7

6

5

4

3

2

1

0

30 35 40 45

Ambient temperature (°C)

50 55

3.5m/s forced air

2.5m/s forced air

1.5m/s forced air

1m/s forced air

Natural cooling

Three-phase AC supply

7

6

5

4

9

8

3

2

1

0

30 35 40 45

Ambient temperature (°C)

50

Notes:

Load power factor = 0.78.

Overload limit for model FMH2A09TR-EN23 is 18A.

55

3.5m/s forced air

2.5m/s forced air

1.5m/s forced air

1m/s forced air

Natural cooling

3.2.7 Overtemperature trips

The MicroFlex contains internal temperature sensors that will cause it to trip and disable if the temperature exceeds 80°C on the 1A or 3A models, 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 MN1919

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3.3 Connector locations

X1 Power

Earth/Ground

Earth/Ground

(NC)

L1 AC Phase 1 / L

L2 AC Phase 2 / N

L3 AC Phase 3

U Motor U

V

W

Motor V

Motor W

R1 Regen

R2 Regen

L1

L2

L3

U

V

W

R1

R2

X1

X6

X7

X6 RS232

RS232

1 (NC)

2 RXD

3 TXD

4 (NC)

5 0V GND

6 (NC)

7 RTS

8 CTS

RS485/422

(NC)

RX-

TX-

(NC)

0V GND

(NC)

TX+

RX+

9 (NC - see

(NC) section 5.4)

X7 Encoder Out

1 CHA+

2 CHB+

3 CHZ+

4 (NC)

5 DGND

6 CHA-

7 CHB-

8 CHZ-

9 (NC)

X8

X2 Control circuit

0V

+24V

0V

+24V

X2

6

7

4

5

1

2

3

X3

8

9

10

11

12

13

14

X3 Input / Output

1 Shield

2 Status-

3 Status+

4 DIN0-

5 DIN0+

6 Drive enable-

7 Drive enable+

8 Shield

9 Dir

10 Step

11 DGND

12 AIN0-

13 AIN0+

14 AGND

Tightening torque for terminal block connections is

0.5-0.6Nm (4.4-5.3 lb-in). Maximum recommended cable size is 0.5mm

2

(20 AWG).

(NC)

= Not Connected. Do not make a connection to this pin.

X8 Feedback In

Incremental

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+

SSI

Data+

Clock+

(NC)

Sense

(NC)

(NC)

(NC)

(NC)

Data-

Clock-

(NC)

+5V out

DGND

(NC)

(NC)

Resolver

1 REF+

2 COS+

3 SIN+

4 (NC)

5 AGND

6 REF-

7 COS-

8 SIN-

9 Chassis

Left LED: Fault / signal loss

Right LED: Unused

MN1919 Basic Installation 3-9

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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 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 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, 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.

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 labelled 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 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 and filter are mounted in an enclosure, it is recommended the enclosure is earthed using a 10mm

2 conductor.

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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 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 between 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. 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.

Connect earth/ground to protective earth on top of drive AC

Supply

Line (L1)

Line (L2)

Line (L3)

Route L1, L2, L3 and earth/ground together in conduit or cable

Circuit breaker or fuses.

See section 3.4.4

AC filter.

See section

3.4.7

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

MN1919 Basic Installation 3-11

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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 has permanently connected power factor correction capacitors, a suitable input AC line reactor or an isolation transformer must be connected between the power factor correction capacitors and the MicroFlex to limit the maximum symmetrical short circuit current to 5000A.

H

If the feeder or branch circuit that provides power to the MicroFlex 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.

3.4.3.1 Input power-cycling and inrush

If AC power has been removed from the MicroFlex, it should remain disconnected for the period specified in Table 1, before it is reapplied.

MicroFlex current rating

1A, 3A

6A

9A

Minimum power cycle delay period

(seconds)

25

45

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.

3.4.3.2 Discharge period

DANGER: After AC power has been removed from the MicroFlex, high voltages

(greater than 50VDC) will remain on the regeneration resistor connections until the DC-bus circuitry has discharged. The high voltage will remain for the period specified in Table 2.

MicroFlex current rating

1A, 3A

6A

9A

Time for DC-bus to discharge to 50V or less

(maximum, seconds)

83

166

248

Table 2 - DC-bus discharge periods

3-12 Basic Installation MN1919

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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’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 for a fail-safe method to disconnect power. The MicroFlex will remain in a powered condition until all input power is removed from the drive and the internal bus voltage has depleted.

The MicroFlex must have a suitable input power protection device installed, preferably a fuse.

Recommended fuses are shown in section 3.4.5. 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. For CE compliance, see

Appendix C.

Circuit Breaker Fuse

From supply

L

N

L

N

From supply

L

N

L

N

Figure 4 - Circuit breaker and fuse, single-phase

From supply

L1

Circuit Breaker

L2

L3

L1

L2

L3

From supply

L1

L2

Fuses

L3

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. A two pole breaker must be used to isolate both lines. Fuses must be fitted in both lines.

MN1919 Basic Installation 3-13

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3.4.5 Recommended fuses and wire sizes

Table 3 describes the recommended fuses and suitable wires sizes to be used for power connections.

Catalog

Number

FMH1A03...

FMH2A03...

FMH2A09...

Continuous p

Amps

(RMS)

AC pp y

Input Fuse

(A)

1A

3A

9A

Ferraz Shawmut:

6x32 FA series, 10A (W084314P) or

BS88 2.5 URGS 10A (N076648)

Ferraz Shawmut:

6x32 FA series, 8A (V084313P) or

BS88 2.5 URGS, 7A (M076647)

Ferraz Shawmut:

6x32 FA series, 20A (A084318P) or

BS88 2.5 URGS, 20A (L097507)

Ferraz Shawmut:

6x32 FA series, 12.5A (X084315P) or

BS88 2.5 URGS, 12A (P076649)

Ferraz Shawmut:

BS88 2.5 URGS, 25A (R076651)

Ferraz Shawmut:

6x32 FA series, 20A (A084318P) or

BS88 2.5 URGS, 20A (L097507)

Table 3 - Protection device and wire ratings

Minimum

Wire Gauge

AWG mm

2

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 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

6.2.3). If they need to be changed, use the Parameters tool in Mint WorkBench (see section 6.3.2).

3-14 Basic Installation MN1919

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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 complies with the CE specifications for which it has been tested. Ideally, one filter should be provided for each MicroFlex; filters should not be shared between drives or other equipment. Table 4 lists the appropriate filters:

MicroFlex current rating 230VAC, 1Φ

Input voltages

1A, 3A FI0015A00 + line reactor

See sections 3.4.7.1 and 3.4.7.2.

or

FI0029A00 (see section A.1.2).

230VAC, 3Φ

FI0018A00

6A

FI0015A02 (see section 3.4.7.2)

or

FI0029A00 (see section A.1.2).

FI0018A00

9A FI0029A00 (see section A.1.2).

FI0018A03

Table 4 - Baldor filter part numbers

Maximum earth leakage from the MicroFlex 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 1A MicroFlex (part FMH1A03...) or 3A MicroFlex (part FMH2A03...) on a single-phase AC supply, a 13mH 4A rms

(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 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 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.

MN1919 Basic Installation 3-15

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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. 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 from the rest of the system. Alternatively, a ferrite sleeve may be attached to the supply cable near connector X2.

Location Connector X2

Nominal input voltage

24V

Range 20-30VDC

Input current

Maximum

Typical

1A continuous (4A typical power on surge, limited by NTC)

0.5A - 0.6A (no encoder power)

0.6A - 0.8A (if powering encoder)

Tightening torque for terminal block connections is 0.5-0.6Nm (4.4-5.3 lb-in).

Customer supplied

24VDC (fused)*

GND

+24V

24V filter

(optional)

Ferrite sleeve**

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

3-16 Basic Installation MN1919

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3.5 Motor connections

MicroFlex 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 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 6.2.3). If they need to be changed, or you are using an alternative motor, use the Parameters tool in Mint WorkBench (see section

6.3.2).

Location Connector X1

AC supply voltage 115VAC, 1Φ

Output voltage range 0-115VAC, 3Φ

230VAC, 1Φ

0-230VAC, 3Φ

230VAC, 3Φ

0-230VAC, 3Φ

Motor

To earth/ground outer shield, use 360° clamp connected to top of drive

Connect motor earth/ground to protective earth on top of drive

Earth

U

V

W

Optional motor circuit contactors

Unshielded lengths should be as short as possible.

To earth/ground outer shield, use 360° clamp connected to backplane

Figure 7 - Motor connections

CAUTION: Do not connect supply power to the MicroFlex UVW outputs. The

MicroFlex 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.

MN1919 Basic Installation 3-17

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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 (see section 3.5). Opening the M-Contactor ensures that the MicroFlex 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 must be disabled at least

20ms before the M-Contactor is opened. If the M-Contactor is opened while the MicroFlex is supplying voltage and current to the motor, the

MicroFlex may be damaged. Incorrect installation or failure of the

M-Contactor or its wiring may result in damage to the MicroFlex.

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:

Signal name

Motor U

Motor V

Motor W

Earth/ground

Thermal switch

Thermal switch

Brake

Brake

Motor / cable pin

1

4

3

2

A

B

C

D

Motor cable wire color

Black, labeled ‘1’

Black, labeled ‘2’

Black, labeled ‘3’

Green/Yellow

Green

White

Blue

Red

Note:

Not all motors are fitted with a brake so pins C and D might not be connected.

A

B C

D

4

1 3

2

Motor power connector

(male)

D

C

3

4

B

A

1

2

Cable connector end view

(female)

Figure 8 - Baldor motor power cable pin configuration

3-18 Basic Installation MN1919

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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 U

Motor V

Motor W

Motor ground

Thermal switch

Thermal switch

Motor cable wire color

Black

Red

White

Green

Blue

Orange

Signal name

Hall 1 (U)

Hall 2 (V)

Hall 3 (W)

Hall ground

Hall +5VDC

Hall cable wire color

White

Red

Black

Green

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.

MN1919 Basic Installation 3-19

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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, and an inductance of less than 100μH. Care should be taken to select the correct resistor for the application - see section 3.7. Suitable regeneration resistors are listed in section A.1.4. The regeneration resistor output is conditionally short-circuit proof.

Regeneration resistor

STAR

POINT

Earth/ground outer shield, using 360° conductive clamp connected to enclosure backplane

Figure 9 - Regeneration resistor connections

DANGER: 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.

3.6.1 Regeneration capacity

The regeneration capacity of the MicroFlex can be calculated from the following formula:

E

= 0.5 × DC bus capacitance ×



(Regen switching threshold)

2

−



2



2

 where the Regen switching threshold is 388 V. This gives the following typical values:

MicroFlex catalog number

Regeneration capacity (J)

115 VAC supply 230 VAC supply

FMH2A01/3...

FMH2A06...

FMH2A09...

DC bus capacitance (μF)

560

1120

1680

34.7

69.4

104.2

12.5

25

37.6

Table 5 - Regeneration capacity

3-20 Basic Installation MN1919

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3.7 Regeneration resistor selection

The following calculations can be used to estimate the type of regeneration resistor that will be required for the application.

3.7.1 Required information

To complete the calculation, some basic information is required. Remember to use the worst-case scenario to ensure that the regeneration power is not underestimated. For example, use the maximum possible motor speed, maximum inertia, minimum deceleration time and minimum cycle time that the application might encounter.

Enter value here Requirement

a) Initial motor speed, before deceleration begins, in radians per second.

Initial motor speed, U = _________ rad/s

Multiply RPM by 0.1047 to give radians per second.

b) Final motor speed after deceleration is complete, in radians per second.

Final motor speed, V = _________ rad/s

Multiply RPM by 0.1047 to get radians per second. This value will be zero if the load is going to be stopped.

c) The deceleration time from initial speed to final speed, in seconds.

d) The total cycle time (i.e. how frequently the process is repeated), in seconds.

e) Total inertia.

Decel time, D

Cycle time, C

= _________ s

= _________ s

This is the total inertia seen by the drive, accounting for motor inertia, load inertia and gearing. Use the Mint WorkBench

Autotune tool to tune the motor, with the load attached, to determine the value.

This will be displayed in kg·m

2 in the

Autotune tool. If you already know the motor inertia (from the motor spec.) and the load inertia (by calculation) insert the total here.

Multiply kg·cm

2 by 0.0001 to give kg·m

2

Multiply lb-ft

2 by 0.04214 to give kg·m

2

Multiply lb-in-s

2 by 0.113 to give kg·m

2

.

.

.

Total inertia, J = ________ kg·m

2

MN1919 Basic Installation 3-21

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3.7.2 Regenerative energy

The regenerative energy to be dissipated, E, is the difference between the initial energy in the system (before deceleration begins) and the final energy in the system (after deceleration has finished). If the system is brought to rest then the final energy is zero.

The energy of a rotating object is given by the formula:

E

=

1

2 ×

J

× ω

2 where E is energy, J is the moment of inertia, and ω is the angular velocity.

The regenerative energy, which is the difference between the initial energy and the final energy, is therefore:

E

=



1

2 ×

J

× U

2



−



1

2 ×

J

× V

2



=

1

2 ×

J

× (U

2

−V

2

)

= ________________ J (joules)

Calculate E using the values for J, U and V entered in section 3.7.1. If E is less than the drive’s regeneration capacity, shown in Table 5 on page 3-20, a regeneration resistor will not be required.

If E is greater than the drive’s regeneration capacity, then continue to section 3.7.3 to calculate the regenerative and average power dissipation.

3.7.3 Regenerative power and average power

The regenerative power, P r

, is the rate at which the braking energy is dissipated. This rate is defined by the deceleration period, D. The shorter the deceleration period, the greater the regenerative power.

P r

=

E

D

= ________________ W (watts)

Although the resistors shown in Table 6 can withstand brief overloads, the average power dissipation, P av

, must not exceed the stated power rating. The average power dissipation is determined by the proportion of the application cycle time spent regenerating. The greater the proportion of time spent regenerating, the greater the average power dissipation.

P av

= P

r

×

D

C

= ________________ W (watts)

3-22 Basic Installation MN1919

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3.7.4 Resistor choice

P av is the value to use when assessing which regeneration resistor to use. However, a safety margin of 1.25 times is recommended to ensure the resistor operates well within its limits, so:

Required resistor power rating

= 1.25 × P

av

= ________________ W (watts)

The range of suitable regeneration resistors is shown in Table 6. Choose the resistor that has a power rating equal to or greater than the value calculated above.

Baldor catalog number

RGJ139

RGJ160

RGJ260

RGJ360

Resistance

39 Ω

60 Ω

60 Ω

60 Ω

Power rating

100 W

100 W

200 W

300 W

Table 6 - Regeneration resistors

Dimensions are shown in section A.1.4.

* The regeneration resistors listed in Table 6 can withstand a brief overload of 10 times the rated power for 5 seconds. Please contact Baldor if larger power ratings are required.

3.7.5 Resistor derating

The regeneration resistors shown in Table 6 can achieve their stated power rating only when mounted on a heatsink. In free air a derating must be applied. Furthermore, in ambient temperatures greater than 25 °C (77 °F), a temperature derating must be applied.

Resistor

(Baldor part)

Nominal power rating

(W)

In free air On heatsink

RGJ139

RGJ160

RGJ260

100

200

Derate power linearly from:

80% @ 25 °C (77 °F) to

70% @ 55 °C (113 °F)

Derate power linearly from:

70% @ 25 °C (77 °F) to

Derate power linearly from:

100% @ 25 °C (77 °F) to

88% @ 55 °C (113 °F)

Typical heatsink:

200 mm x 200 mm x 3 mm

Derate power linearly from:

100% @ 25 °C (77 °F) to

RGJ360 300

Table 7 - Regeneration resistor derating

Typical heatsink:

400 mm x 400 mm x 3 mm

MN1919 Basic Installation 3-23

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3-24 Basic Installation MN1919

4

4

4.1 Introduction

Three feedback options are available for use with linear and rotary motors; incremental encoder, encoder with SSI (Synchronous Serial Interface), or resolver. 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 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.

An encoder output signal is available on connector X7 for supplying other equipment.

MN1919 Feedback 4-1

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4.1.1 Encoder feedback - X8

The encoder connections (ABZ channels and Hall signals) are made using the 15-pin D-type female connector X8. Twisted pair cables must be used for the complementary signal pairs 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 V- and 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 to increase the encoder supply voltage on pin 12 to maintain a 5V supply at the encoder.

1

8

9

15

Location Connector X8

15-pin D-type female connector (not high density)

Pin 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+

Description Incremental (UVW) encoder input, non-isolated. Pin 12 provides 5-11V for encoders requiring power (200mA max)

MicroFlex

+5V

CHA+

1

47pF

120R

AM26LS32

Differential line receiver to CPU

CHA-

9

47pF

DGND

4-2 Feedback

Figure 10 - Encoder channel input circuit - Channel A shown

MN1919

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MicroFlex

Hall U+

6

Hall U-

5

47pF

47pF

2k2

+5V

10k

4k7

DGND

AM26LS32

Differential line receiver to CPU

Figure 11 - 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+

CHA-

CHB+

CHB-

CHZ+ (INDEX)

CHZ- (INDEX)

12

13

4

6

5

15

14

8

7

+5V

DGND

Sense

Hall U+

Hall U-

Hall W+

Hall W-

Hall V+

Hall V-

Connect overall shield to connector backshells.

Figure 12 - Encoder cable connections - rotary motors

Note: 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.

MN1919 Feedback 4-3

Encoder

Feedback

Twisted pairs

www.baldormotion.com

4.1.1.2 Encoders without Halls

Incremental encoders without Hall feedback connections may be connected to the MicroFlex.

However, if Hall connections are not present, it will be necessary for the MicroFlex 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 X8

1

9

2

10

3

11

12

13

CHA+

CHA-

CHB+

CHB-

CHZ+ (INDEX)

CHZ- (INDEX)

+5V

DGND

4 Sense

Connect overall shield to connector backshells.

Figure 13 - 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. However, since there are no encoder connections, the MicroFlex will not be able to perform smooth speed control or accurate positioning control.

Hall

Feedback

Motor X8

4

12

13

6

5

15

14

8

7

Sense

+5V

DGND

Hall U+

Hall U-

Hall W+

Hall W-

Hall V+

Hall V-

Connect overall shield to connector backshells.

Figure 14 - Halls-only feedback cable connections - rotary motors

Note: 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.

4-4 Feedback MN1919

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4.1.1.4 Encoder cable pin configuration - rotary motors

Figure 15 shows the pin configuration for a typical Baldor encoder feedback cable, part number CBL025SF-E2.

Signal name

CHA+

CHA-

CHB+

CHB-

CHZ+

CHZ-

Hall U+

Hall U-

Hall V+

Hall V-

Hall W+

Hall W-

+5V

DGND

MicroFlex

X8 pin

1

9

8

7

6

5

2

10

3

11

15

14

12

13

Motor / cable pin

3

4

10

11

12

13

7

8

5

6

14

15

1

2

Baldor encoder cable internal wire colors

Purple

Purple / White

Green

Green / White

Brown

Brown / White

Pink

Pink / Black

Yellow

Yellow / Black

Grey

Grey / Black

Red

Blue

Pins 9 and 16 are not connected

9

10

11

16

15

8

12

13

14

1

7

6

5

2

4

3

Motor encoder connector

(male)

3

2

4

1

13

14

12

11

10

16

15

8

9

5

6

7

Cable connector end view

(female)

Figure 15 - Baldor rotary motor encoder cable pin configuration

The maximum recommended cable length is 30.5m (100ft).

MN1919 Feedback 4-5

www.baldormotion.com

4.1.1.5 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

CHA+

CHA-

CHB+

CHB-

CHZ+

CHZ-

MicroFlex

X8 pin

1

9

2

10

3

11

Encoder cable internal wire colors

Please refer to MN1800 Linear Motors

Installation & Operating Manual

for details.

Hall U+

Hall V+

Hall W+

+5V

Hall GND

6

8

15

12

13

Baldor Hall cable internal wire colors

White

Red

Black

Brown

Green

Encoder

Feedback

Motor

Twisted pairs

X8

1

9

2

10

3

11

12

13

4

CHA+

CHA-

CHB+

CHB-

CHZ+ (INDEX)

CHZ- (INDEX)

+5V

DGND

Sense

Hall

Feedback

6

5

15

14

8

7

Hall U+

Hall U-

Hall W+

Hall W-

Hall V+

Hall V-

Leave pins 5, 7 & 14 unconnected

Connect overall shield to connector backshells.

Figure 16 - Encoder cable connections - linear motors

4-6 Feedback MN1919

www.baldormotion.com

4.1.2 SSI feedback - X8

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 to increase the encoder supply voltage on pin 12 to maintain a 5V supply at the encoder.

1

8

9

15

Location Connector X8, 15-pin D-type female connector

Pin Encoder function

1 Data+

2 Clock+

3 (NC)

4 Sense

5 (NC)

6 (NC)

7 (NC)

8 (NC)

9 Data-

10 Clock-

11 (NC)

12 5-11V out

13 DGND

14 (NC)

15 (NC)

Description SSI encoder input, non-isolated. Pin 12 provides power to the encoder (200mA max).

Absolute

Encoder

Motor

Twisted pairs

Connect overall shield to connector backshells.

X8

1

9

2

10

Data+

Data-

Clock+

Clock-

12

13

+5V

DGND

4

Sense

Chassis

Connect internal shields to pin 13.

Figure 17 - SSI encoder cable connections

MN1919 Feedback 4-7

www.baldormotion.com

4.1.2.1 SSI cable pin configuration

Figure 18 shows the pin configuration for a typical Baldor SSI feedback cable, part number

CBL025SF-S2

Signal name

5-11V out

Sense

DGND

Clock+

Clock-

Data+

Data-

MicroFlex

X8 pin

12

4

13

2

10

1

9

Motor / cable pin

4

5

2

3

6

1

9

Baldor SSI cable internal wire colors

Red

Orange

Blue

Green

Yellow

Pink

Grey

Pins 7-12 are not used and may not be present

1 9

2

3

10

11

12

4 5

8

7

6

7

8 9

12 10

1

2

6

5

11

4

3

Motor SSI connector

(male)

Cable connector end view

(female)

Figure 18 - Baldor motor SSI feedback cable pin configuration

The maximum recommended cable length is 30.5m (100ft).

4-8 Feedback MN1919

www.baldormotion.com

4.1.3 Resolver feedback - X8

The resolver connections are made using the 9-pin D-type male 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. The resolver input is used to create an encoder signal inside the MicroFlex. This provides the MicroFlex with an equivalent resolution of 4096 pulses per revolution (ppr), although this can be reconfigured in the Mint WorkBench Commissioning Wizard to provide 1024 ppr. The

MicroFlex provides an input accuracy of ±3 counts. When used with a typical Baldor BSM series resolver motor the combined accuracy is ±11 counts (calculated with the input equivalent resolution set to the factory preset value of 4096 ppr). The left LED illuminates red if there is a fault or loss of the resolver signal; the right LED is unused.

5

1

9

6

Location Connector X7

Pin Name

1 REF+

2 COS+

3 SIN+

4 (NC)

5 AGND

6 REF-

7 COS-

8 SIN-

9 Chassis

Description Resolver input on a 9-pin male D-type connector

R2

R1

S3 S1

S2

S4

Baldor motor resolver connector

5

+

6

3

+

4

1 +

2

Twisted pairs

Connect overall shield to connector backshells.

X8

2

7

1

3

8

6

5

SIN+

SIN-

COS+

COS-

REF+

REF-

AGND

Connect internal shields to AGND.

Figure 19 - Resolver cable connections

MN1919 Feedback 4-9

www.baldormotion.com

4.1.3.1 Resolver cable pin configuration

Figure 18 shows the pin configuration for a typical Baldor resolver feedback cable, part number CBL025SF-R1.

Signal name

REF+

REF-

COS+

COS-

SIN+

SIN-

MicroFlex

X8 pin

3

8

2

7

1

6

Motor / cable pin

5

6

3

4

1

2

Baldor resolver cable internal wire colors

Red

Blue

Green

Yellow

Pink

Grey

Pins 7-12 are not used and may not be present

1 9

2

3

10

11

12

4 5

8

7

6

7

8 9

12 10

1

2

6

5

11

4

3

Motor resolver connector

(male)

Cable connector end view

(female)

Figure 20 - Baldor motor resolver cable pin configuration

The maximum recommended cable length is 30.5m (100ft).

4-10 Feedback MN1919

www.baldormotion.com

4.1.4 Encoder output - X7

1

5

6

9

Location Connector X7

Pin Name

1 CHA+

2 CHB+

3 CHZ+

4 (NC)

5 DGND

6 CHA-

7 CHB-

8 CHZ-

9 (NC)

Description Encoder output on a 9-pin female D-type connector

This output can be used for position feedback to a host positioner, or in master/slave situations where the axis movement can be transmitted to another controller. It is recommended that this output only drives one output circuit load. The encoder outputs are differential and conform to the RS422 electrical specification. Shielded twisted pair cable is recommended.

If the MicroFlex is configured for incremental encoder feedback, X7 duplicates the encoder signals entering X8. If operating in Halls-only mode, there will be no encoder output at X7.

If the MicroFlex is configured for SSI feedback, a simulated encoder output is produced at X7.

The default simulated encoder output resolution is 16384 counts per revolution, but this can be altered using the Drive Setup Wizard in Mint WorkBench. At 62.5 microsecond intervals (a

16kHz sampling rate), the simulated encoder output generates a burst of A and B pulses (and a Z pulse if required). The frequency and length of the burst is varied to represent the change in the input encoder’s position during the preceding 62.5 microsecond interval. See the keyword ENCODERLINESOUT in the Mint help file.

If the MicroFlex has resolver feedback, a simulated encoder output is produced at X7. If the resolver input has been configured to simulate an encoder input of 1024 pulses per revolution

(ppr), the output at X7 can be set to either 512 or 1024 ppr. If the resolver input has been configured to simulate an encoder input of 4096 ppr, output modes of 512, 1024, 2048 and

4096 ppr are possible. Note that these values represent actual encoder lines, not quadrature counts. The simulated encoder output is in the same direction as the resolver input. See the keyword ENCODERLINESOUT in the Mint help file.

MN1919 Feedback 4-11

www.baldormotion.com

CHA+

MicroFlex

X7

1

CHA6

CHZ+

CHZ-

3

8

CHB+

CHB-

DGND

2

7

5

NextMove BX

II

encoder input

1

6

3

8

2

7

5

Baldor cable parts

CBL0xxMF-E3B are recommended

(where xx represents a choice of available lengths).

Connect overall shield to connector backshells.

Figure 21 - MicroFlex encoder output to NextMoveBX

II

encoder input

Baldor cable parts

CBL0xxMF-E3B are recommended

(where xx represents a choice of available lengths).

CHA+

MicroFlex

X7

1

CHA6

CHZ+

CHZ-

CHB+

CHB-

DGND

3

8

2

7

5

Connect overall shield to connector backshells.

NextMove ES / ESB encoder input

1

6

3

8

2

Note: If NextMove ES is not being used in conjunction with a

Baldor backplane (part

BPL010-50x), the equivalent inputs on the card’s 96-pin edge connector are as follows:

7

5

CHA+ :

Enc0 Enc1

b7

CHA- : b10 c9

CHB+ : a7 a8 c7

CHB- : c10 a10

CHZ+ : b8

CHZ- :

DGND : b9 a3 c8 a9 a3 (or b3/c3)

Figure 22 - MicroFlex encoder output to NextMove ES / ESB encoder input

CAUTION: If a NextMove BX is to be connected, a different cable must be used, as shown in Figure 23:

CHA+

Microflex

X7

1

CHA-

CHZ+

CHZ-

6

3

8

CHB+

CHB-

DGND

2

7

5

NextMove BX encoder input

5

9

2

6

8

3

7

Baldor cable parts

CBL0xxMF-E3A are recommended

(where xx represents a choice of available lengths).

Connect overall shield to connector backshells.

Figure 23 - MicroFlex encoder output to NextMove BX encoder input

4-12 Feedback MN1919

5

5.1 Introduction

This section describes the various digital and analog input and output capabilities of the

MicroFlex, 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 . . . . . . . . . . . . . .

DIN . . . . . . . . . . . . .

DOUT . . . . . . . . . . .

AIN . . . . . . . . . . . . .

Input / Output

Digital Input

Digital Output

Analog Input

5

MN1919 Input / Output 5-1

www.baldormotion.com

5.2 Analog I/O

The MicroFlex provides as standard:

H

1 analog input on the connector block X3 (demand input)

5.2.1 Analog input - X3 (demand)

12

13

Location Connector X3, pins 12 & 13

(Mating connector: Weidmüller Minimate B2L 3.5/14)

Name AIN0

Description Single ended or differential input.

Common mode voltage range: ±10VDC.

Resolution: 12-bit (accuracy ±4.9mV)

Common mode rejection: 40dB

Input impedance: >30kΩ

Sampling interval: 125μs

The analog input can be connected as either a differential or a single ended input as shown in

Figure 25. The analog input is not optically isolated from internal power rails, so care must be taken to avoid earth/ground loops and similar associated problems. The input buffers provide low pass filtering of the applied voltage. To minimize the effects of noise, the analog input signal should be connected to the system using an individually shielded twisted pair cable with an overall shield. The overall shield should be connected to the chassis at one end only. No other connection should be made to the shield.

MicroFlex

+15V

10k

AIN0-

12

AIN0+

13

10k

47pF

10k

47pF

30k

30k

1nF

30k

30k

-

+

LM358

Low pass filter & level correction

Mint

ADC.0

-15V

Internal reference

AGND 14

Figure 24 - AIN0 analog input (demand) circuit

When the MicroFlex is connected to Mint WorkBench, the analog input value (expressed as a percentage) can be viewed using the Spy window’s Monitor tab. Alternatively, the command

Print ADC.0 can be used in the command window to return the value of the analog input.

See the Mint help file for details.

5-2 Input / Output MN1919

AIN0+

AIN0-

X3

13

12

14

AIN0

(ADC.0)

AIN0+

GND

www.baldormotion.com

X3

13

12

14

AIN0

(ADC.0)

Differential connection Single ended connection

Figure 25 - AIN0 analog input wiring

+24VDC

1.5kΩ, 0.25W

0V

1kΩ, 0.25W

potentiometer

X3

13

12

14

AIN0

(ADC.0)

Figure 26 - Typical input circuit to provide 0-10V (approx.) input from a 24V source

NextMove ESB / controller

‘X13’

-

+

Demand0

1

‘X3’

MicroFlex

13

AIN0+

AGND

2

Shield

3

12

AIN0-

14

AGND

Connect overall shield at one end only

Figure 27 - Analog input - typical connection from a Baldor NextMove ESB

MN1919 Input / Output 5-3

www.baldormotion.com

5.3 Digital I/O

The MicroFlex provides as standard:

H

1 dedicated drive enable input.

H

1 general purpose digital input.

H

Dedicated step and direction inputs.

H

1 dedicated drive status output.

The general purpose digital input can be configured for typical input functions:

H

Error input

H

Reset input

H

Stop input.

5-4 Input / Output MN1919

www.baldormotion.com

5.3.1 Drive enable input - X3

6

7

Location Connector X3, pins 6 & 7

(Mating connector: Weidmüller Minimate B2L 3.5/14)

Name Drive enable

Description Dedicated drive enable input.

Nominal input voltage: +24VDC

(input current not to exceed 50mA)

The drive enable input is buffered by a TLP280 opto-isolator, allowing the input signal to be connected with either polarity.

Drive

Enable+

Drive

Enable-

7

6

MicroFlex

4n7 4n7

100R

3k3

TLP280

10k

Vcc

74AHC14

Mint

DRIVEENABLE-

SWITCH

DGND

Figure 28 - Drive enable input circuit

In normal use, the drive enable input controls the enabled status of the drive. However, when the MicroFlex 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 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; DRIVEENABLE.0=0 will disable the MicroFlex.

H

The Tools, Reset Controller menu item will clear errors and enable the MicroFlex.

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.

MN1919 Input / Output 5-5

NextMove ESB / controller

UDN2982

MintMT

DRIVEENABLEOUTPUT

10k

www.baldormotion.com

‘X11’

9

USR V+

1

DOUT0

10

USR GND

User supply

24V

‘X3’

Drive

Enable+

7

Drive

Enable-

6

MicroFlex

100R

3k3

User supply

GND

TLP280

Figure 29 - Drive enable input - typical connection from a Baldor NextMove ESB

5-6 Input / Output MN1919

www.baldormotion.com

5.3.2 General purpose digital input - X3

4

5

Location Connector X3, pins 4 & 5

(Mating connector: Weidmüller Minimate B2L 3.5/14)

Name DIN0

Description General purpose optically isolated digital input.

Nominal input voltage: +24VDC

(input current not to exceed 50mA)

Sampling interval: 500μs

The 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.

DIN0+

5

DIN0-

4

MicroFlex

4n7 4n7

100R

3k3

TLP280

10k

Vcc

74AHC14

Mint

DGND

Figure 30 - General purpose digital input circuit

When the MicroFlex is connected to Mint WorkBench, the digital input can be configured using the Operating Mode Wizard. Alternatively, the Mint keywords RESETINPUT, ERRORINPUT and STOPINPUT can be used in the command window. See the Mint help file for details.

The state of the digital input can be viewed using the Spy window’s Axis tab.

MN1919 Input / Output 5-7

NextMove ESB / controller

UDN2982

MintMT

OUTX.0

10k

www.baldormotion.com

‘X11’

9

USR V+

1

DOUT0

10

USR GND

User supply

24V

MicroFlex

‘X3’

DIN0+

5

DIN0-

4

100R

3k3

User supply

GND

TLP280

Figure 31 - Digital input - typical connection from a Baldor NextMove ESB

5-8 Input / Output MN1919

www.baldormotion.com

5.3.3 Step (pulse) and direction inputs - X3

9

10

Location Connector X3, pins 9 & 10

(Mating connector: Weidmüller Minimate B2L 3.5/14)

Names Step and Dir

Description Dedicated step and direction inputs.

Input voltage: +5VDC

Maximum input frequency: 1 MHz maximum

When the MicroFlex control mode is set to position control, the step and direction inputs are used as the demand reference.

Pin 10 is the step input. The step frequency controls the speed of the motor.

Pin 9 is the direction input. The state of the direction input controls the direction of motion. If

+5V is present on pin 9, movement will be in the forward direction. If pin 9 is grounded, movement will be in the opposite direction.

MicroFlex

+5V

120R

Step

10

Mint

1nF

74AHC14

DGND

11

Figure 32 - Step and direction input circuit - Step shown

When the MicroFlex is connected to Mint WorkBench, the following ratio can be configured using the Operating Mode Wizard. Alternatively, the Mint keywords FOLLOWDENOM and

FOLLOWNUMERATOR can be used in the command window. See the Mint help file for details.

MN1919 Input / Output 5-9

www.baldormotion.com

NextMove ESB / controller

DS26LS31

Step

Output

DS26LS31

Dir

Output

GND

STEP0+

3

STEP0-

‘X2’

DIR0+

5

DIR0-

DGND

Shield

1

6

Twisted pairs

Connect shields at one end only

‘X3’

MicroFlex / drive amplifier

10

Step

11

DGND

9

Dir

Figure 33 - Stepper input - typical connection from a Baldor NextMove ESB

Note: When using a NextMove ESB’s STEP and DIR outputs, do not connect the

STEPx- or DIRx- outputs to ground; leave them unconnected as shown in

Figure 33.

Incremental encoder

B+

B-

A+

A-

GND

5V

Twisted pairs

‘X3’

MicroFlex / drive amplifier

10

Step

9

Dir

11

DGND

Connect shields at one end only

Encoder supply

5V

Encoder supply

GND

Figure 34 - Stepper input - typical connection from an incremental encoder

Note: When using an incremental encoder source, do not connect the A- or B- outputs; leave them unconnected as shown in Figure 34.

5-10 Input / Output MN1919

www.baldormotion.com

To allow connection of 24 V signals, it is recommended to use an intermediate circuit as shown in Figure 35. The circuit’s output voltage is determined by the pull-up voltage, Vcc.

Intermediate circuit

Input

24V

3k3

1k

Vcc

5V

MicroFlex

‘X3’

Step

10

120R

1nF

TLP115A

Input

GND

DGND

11

GND

Figure 35 - Step & direction - connection of 24V signals

MN1919 Input / Output 5-11

www.baldormotion.com

5.3.4 Status output - X3

2

3

Location Connector X3, pins 2 & 3

(Mating connector: Weidmüller Minimate B2L 3.5/14)

Name Status

Description Opto-isolated status output

Output current:

User supply

100mA maximum

30VDC maximum

Update interval: 500μs

The optically isolated status output is designed to source current from the user supply as shown in Figure 36. 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.

MicroFlex

User supply

V+

+5V

220R

Fuse

200mA

3

Status+

[Error]

NEC PS2562L-1

Load

(Relay with diode shown)

2

Status-

User supply

GND

Figure 36 - Drive status output circuit

When the MicroFlex is connected to Mint WorkBench, the active level of the output can be configured using the Operating Mode Wizard. Alternatively, the Mint keyword

OUTPUTACTIVELEVEL can be used in the command window. The output can also be configured using the Mint keywords DRIVEENABLEOUTPUT or GLOBALERROROUTPUT. See the Mint help file for details.

5-12 Input / Output MN1919

www.baldormotion.com

MicroFlex

NEC PS2562L-1

‘X3’

3

Status+

2

Status-

User supply

24V

‘X9’

DIN4

8

CREF1

9

NextMove ESB / controller

3k3

TLP280

User supply

GND

Figure 37 - Status output - typical connections to a Baldor NextMove ESB

MN1919 Input / Output 5-13

www.baldormotion.com

5.4 Serial port - X6

5

1

9

6

Location Connector X6

Pin RS232 name

1 (NC)

2 RXD

3 TXD

4 (NC)

5 0V GND

RS485 / RS422 name

(NC)

RX- (input)

TX- (output)

(NC)

0V DGND

6 (NC)

7 RTS

(NC)

TX+ (output)

8 CTS

9 (NC)

RX+ (input)

(NC)

Description RS232 or RS485 / RS422 connections on a 9-pin male

D-type connector

MicroFlex is available with either an RS232 or RS485 serial port (see section 2.2.1). The port is fully ESD protected to IEC 1000-4-2 (15kV).

5.4.1 Using RS232 cable

The MicroFlex has a full-duplex RS232 serial port with the following preset configuration:

H

57.6 Kbaud

H

1 start bit

H

8 data bits

H

1 stop bit

H

No parity

H

Hardware handshaking lines RTS and CTS must be connected.

MicroFlex

(DTE)

X6

RXD 2

TXD 3

GND 5

RTS 7

CTS 8

COM

2 RXD

3 TXD

5 GND

7 RTS

8 CTS

9-pin

Computer

COM Port

(DTE)

Connect overall shield to connector backshell.

Figure 38 - RS232 serial port connections

When the MicroFlex is connected to Mint WorkBench, the Tools, Options menu item can be used to configure the serial port. The configuration can also be changed using the Mint keyword SERIALBAUD (see the Mint help file for details).

5-14 Input / Output MN1919

www.baldormotion.com

The RS232 port is configured as a DTE (Data Terminal Equipment) unit. Both the output and input circuitry are single ended and operate between ±12V. The port is capable of operation at up to 57.6 Kbaud. The maximum recommended cable length is 3m (10ft) at 57.6 Kbaud (the factory preset rate). When using lower baud rates, longer cable lengths may be used up to maximum of 15m (49ft) at 9600 baud.

5.4.2 Multidrop using RS485 / RS422 cable

Multidrop systems allow one device to act as a ‘network master’, controlling and interacting with the other (slave) devices on the network. The network master can be a controller such as

MicroFlex, a host application such as Mint WorkBench (or other custom application), or a programmable logic controller (PLC). RS422 may be used for multi-drop applications as shown in Figure 39. Four-wire RS485 may be used for single point-to-point applications involving only one Baldor controller. If firmware is updated over RS485/RS422, it can only be downloaded to the drive that was chosen in the Select Controller dialog in Mint WorkBench.

Network master

TX+

TX-

RX+

RX-

T

R

DGND

Twisted pairs

Network slave

RX+

RX-

TX+

TX-

DGND

Master and final slave are shown with terminating resistors, T

R

120Ω.

, typical value

T

R

Network slave

RX+

RX-

TX+

TX-

DGND

Connect overall shield to connector backshell.

Figure 39 - 4-wire RS422 multi-drop connections

Each transmit/receive (TX/RX) network requires a termination resistor at the final RX connection, but intermediate devices must not be fitted with termination resistors. An exception is where repeaters are being used which may correctly contain termination resistors.

Termination resistors are used to match the impedance of the load to the impedance of the transmission line (cable) being used. Unmatched impedance causes the transmitted signal to not be fully absorbed by the load. This causes a portion of the signal to be reflected back into the transmission line as noise. If the source impedance, transmission line impedance, and load impedance are all equal, the reflections (noise) are eliminated. Termination resistors increase the load current and sometimes change the bias requirements and increase the complexity of the system.

MN1919 Input / Output 5-15

www.baldormotion.com

5.4.3 Connecting serial Baldor HMI Operator Panels

Serial Baldor HMI Operator Panels use a 15-pin male D-type connector (marked PLC PORT), but the MicroFlex connector X6 is a 9-pin male D-type connector. The MicroFlex may be connected with or without hardware handshaking, as shown in Figure 40:

Baldor HMI

PLC PORT

RXD 2

TXD 3

GND 5

1

Twisted pair

MicroFlex

X6

7 RTS

8 CTS

3 TXD

2 RXD

5 GND

Baldor HMI

PLC PORT

CTS 11

RTS 10

RXD 2

TXD 3

GND 5

1

Twisted pair

MicroFlex

X6

7 RTS

8 CTS

3 TXD

2 RXD

5 GND

Without hardware handshaking

Figure 40 - RS232 cable wiring

With hardware handshaking

Alternatively, the Baldor HMI panel may be connected using RS485/422, as shown in Figure 41:

Baldor HMI

PLC PORT

TX+ 14

TX- 6

RX+ 15

RX- 7

GND 5

1

Twisted pair

MicroFlex

X6

8 RX+

2 RX-

7 TX+

3 TX-

5 GND

Figure 41 - RS485/422 cable wiring

5-16 Input / Output MN1919

www.baldormotion.com

5.5 Connection summary - recommended system wiring

As an example, Figure 42 shows the recommended wiring necessary for the MicroFlex to control a motor, while conforming to the EMC requirements for ‘industrial’ environments.

AC power

From fuses

L1

L2

L3

L1

L2

L3

L1

L2

L3

AC power in

PE

Star point

Connect AC power cable shield to metal backplane using conductive shield clamp (see section C.1.7).

Shielded twisted pair, clamped to metal backplane near drive using conductive shield earth/ground clamp (see sections 3.6 and C.1.7).

Regen

Optional regen resistor

(Dynamic brake)

Motor feedback

Motor power U V W

Connect motor power cable shield to metal backplane using conductive shield clamp

Host PC

COM

Serial communication

Motor

+24V 0V

Control circuit supply.

Use twisted pair cable with a ferrite sleeve

(see section 3.4.8).

+24V 0V

Drive enable input

Demand input: ±10V analog input

(shown) or +5V step and direction inputs. Use shielded twisted pair(s) for demand input(s). Connect cable shield to the bottom of MicroFlex using conductive shield earth/ground clamp.

H

The MicroFlex should be mounted on an earthed metal backplane.

H

Ensure cables do not obstruct airflow to the heatsink.

H

Motor represents a typical Baldor BSM motor. Linear motors may also be controlled by MicroFlex.

H

Conductive shield earth/ground clamps are not supplied.

H

When using single phase supplies it may be necessary to reverse the AC power filter - see section 3.4.7.2.

Figure 42 - Recommended system wiring

MN1919 Input / Output 5-17

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5-18 Input / Output MN1919

6

6

6.1 Introduction

Before powering the MicroFlex you will need to connect it to the PC using a serial cable and install the supplied PC software Mint WorkBench. This software includes a number of tools to allow you to configure and tune the MicroFlex. 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 to the PC

Connect the serial cable between a PC serial port (often labeled as “COM”) and the MicroFlex connector X6. Mint WorkBench can scan all the COM ports, so you can use any port.

6.1.2 Installing the software

The Baldor Motion Toolkit CD containing the software can be found separately within the packaging.

1. Insert the CD into the PC’s 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 (use the correct letter for your installation).

Follow the on-screen instructions to install 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.

MN1919 Configuration 6-1

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6.1.3 Starting the MicroFlex

If you have followed the instructions in the previous sections, you should now have connected all the power sources, inputs and outputs, and the serial cable linking the PC to the MicroFlex.

6.1.4 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.

H

Inspect all power connections for accuracy, workmanship and tightness.

H

Verify that all wiring conforms to applicable codes.

H

Verify that the MicroFlex and motor are properly earthed/grounded.

H

Check all signal wiring for accuracy.

6.1.5 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. After a brief test sequence, the Status LED should be green.

If the LED is not lit then re-check the power supply connections.

4. If the motor wires were disconnected in section 6.1.4, 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 to be enabled (see section 5.3.1.). If you do not wish to enable the MicroFlex yet, the Commissioning Wizard will inform you when this step is necessary.

The MicroFlex is now ready to be commissioned using Mint WorkBench.

6-2 Configuration MN1919

www.baldormotion.com

6.2 Mint WorkBench

Mint WorkBench is a fully featured application for commissioning the MicroFlex. 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 Toolbars

Control and test area

Toolbox

Figure 43 - The Mint WorkBench software

MN1919 Configuration 6-3

www.baldormotion.com

6.2.1 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 & Mint Machine Center book icon. Double click a topic name to display it.

6-4 Configuration MN1919

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6.2.2 Starting Mint WorkBench

1. On the Windows Start menu, select Programs, Mint Machine Center, Mint WorkBench.

Mint WorkBench will start, and the Tip of the Day dialog will be displayed.

You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup.

Click Close to continue.

2. In the opening dialog box, click Start New Project... .

MN1919 Configuration 6-5

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3. In the Select Controller dialog, go to the drop down box near the top and select the PC serial port to which the MicroFlex is connected.

(If you are unsure which PC serial port is connected to the MicroFlex, select Scan all serial

ports).

Click Scan to search for the MicroFlex.

When the search is complete, click on MicroFlex in the list to select it, and click the Select button.

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 is not listed, check the serial lead between the MicroFlex and the

PC and that the MicroFlex is powered correctly. Click Scan to re-scan the ports.

6-6 Configuration MN1919

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6.2.3 Commissioning Wizard

Each type of motor and drive combination has different performance characteristics. Before the MicroFlex can be used to control the motor accurately, the MicroFlex must be “tuned”. This is the process where the MicroFlex 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 can make small adjustments to the way it controls the motor. This information is stored in the

MicroFlex and can be uploaded to a file if necessary.

The Commissioning Wizard provides a simple way to tune the MicroFlex and create the necessary configuration information for your drive/motor combination, so this is the first tool that should be used. However, if necessary any of the parameters set by the Commissioning

Wizard can be adjusted manually after commissioning is complete.

6.2.4 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.

If you need extra help, click the Help button 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’s 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’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; 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 to be reset.

MN1919 Configuration 6-7

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6.3 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. Three of the main tools used for tuning and configuring the MicroFlex 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.

6.3.1 Fine-tuning tool

The Commissioning Wizard calculates many parameters that allow the MicroFlex 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 three tabs at the bottom - Step, Speed and Current. 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.

6-8 Configuration MN1919

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6.3.1.1 Fine-tuning - Step tab

The Step 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. 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.

6.3.1.2 Fine-tuning - Speed tab

The Speed tab allows you to set speed 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. 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.

6.3.1.3 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. 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 as the Commissioning Wizard.

MN1919 Configuration 6-9

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6.3.2 Parameters tool

The Parameters tool can be used to setup many important parameters, such as a scaling factor for the feedback input, and the action to take when errors occur.

1. Click the Parameters icon in the Toolbox on the left of the screen.

The main area of the Mint WorkBench window displays the Controller Parameters screen.

2. The Controller Parameters screen has a number of tabs listed on the left. Click on a tab to select it.

If you need help with any of the options, just press F1 to display the help file.

Remember to click the tab’s Apply button to send the changes to the MicroFlex.

6-10 Configuration MN1919

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6.3.3 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.

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.

MN1919 Configuration 6-11

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6-12 Configuration MN1919

7

7

7.1 Introduction

This section explains common problems that may be encountered, together with possible solutions.

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. If you do have a problem, read this section first and check the help file in Mint WorkBench. 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 rear of this manual. Please have the following information ready:

H

The serial number of your MicroFlex.

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

Give 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

Give a clear description of the symptoms that you can observe, for example the Status

LED, error messages displayed in Mint WorkBench, or the current value of the Mint error keywords AXISERROR and DRIVEERROR.

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

The term “Power-cycle the MicroFlex” is used in the Troubleshooting sections. Remove the

24V supply, wait for the MicroFlex to power down completely (the Status LED will turn off), then re-apply the 24V supply.

MN1919 Troubleshooting 7-1

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7.2 Status LED

The Status LED indicates general MicroFlex status information.

Solid green:

Drive enabled (normal operation).

Flashing green:

Firmware download 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

5

6

3

4

7

1

2

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

8

9

10

11

12

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

DC bus overvoltage trip.

IPM (integrated power module) trip.

Overcurrent trip.

Overspeed trip.

Feedback trip.

Motor overload (I

2 t) 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 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 DRIVEERROR and AXISERROR keywords, or the Error

Handling

book.

Alternate red/green flashing:

Undervoltage warning (no AC power). The DC-bus voltage has dropped below the powerbase undervoltage level (see DRIVEBUSUNDERVOLTS). Check that

AC power is connected. This error will be automatically cleared when AC power is restored, so the MicroFlex does not need to be reset.

7-2 Troubleshooting MN1919

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7.2.1 Communication

Problem

Status LED is off

Mint WorkBench fails to detect the

MicroFlex - it detects “No controller found.

Communication fault on COMx”.

Check

Check that the 24VDC control circuit supply is connected correctly to connector X2 and is switched on.

Ensure that the MicroFlex is powered and the Status LED is illuminated (see section 7.2).

Check that the serial cable is connected between the PC’s COM port and connector X6 on the MicroFlex.

Check which PC COM port is being used, or use the “Scan all serial ports” option to locate the MicroFlex.

Check the wiring of the serial cable or try an alternate cable.

On the PC, try an alternative COM port.

Confirm that a mouse driver or other serial device is not conflicting

(using the same COM port) as Mint WorkBench.

Does the MicroFlex have firmware in it? If you tried to download new firmware and the download failed, the controller may not have firmware.

Check that the selected baud rate is supported by the PC and

MicroFlex.

If the “Only scan COMx” option is selected in Mint WorkBench, check that the correct COM port is selected.

If the “Search up to Nodexx“ option is selected in Mint WorkBench, check that the MicroFlex node number is not higher than this value, or search up to a greater node value.

Do you have multiple nodes on the bus? If so, they must all be set to the same baud rate. Mint WorkBench scans through all the node ID’s at different baud rates. When it finds a node, it will only continue to scan for other nodes at the same baud rate.

MN1919 Troubleshooting 7-3

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7.2.2 Power on

Problem

The Status LED is flashing.

Check

The MicroFlex has detected a motion error. Click the Error button on the motion toolbar to view a description of the error. Alternatively, type these commands in the Command window:

PRINT AXISERROR

PRINT DRIVEERROR

Click the Clear Errors button on the motion toolbar.

7.2.3 Tuning

Problem

Cannot enable the MicroFlex because AXISERROR has bit 13 set

When the MicroFlex is enabled the motor is unstable

Check

Check the drive enable input on connector X3 pins 6 and 7 is connected and powered correctly.

Check that the current loop has been tuned.

Check that the current loop was tuned with the correct motor data. If the motor is still unstable try reducing the Speed Proportional gain (KVPROP) and

Speed Integral gain (KVINT) on the Speed tab of the

Fine-tuning window.

7-4 Troubleshooting MN1919

8

8

8.1 Introduction

This section provides technical specifications for the MicroFlex.

8.1.1 AC input power and DC bus voltage (X1)

All models

Nominal input voltage

Minimum input voltage

Maximum input voltage

Nominal DC-bus voltage

Nominal input current

@ maximum rated output current

Unit

AC input

1Φ 3Φ

VAC

115 or 230

105*

VDC

250

305 321

1A 3A 6A 9A 1A 3A 6A 9A

A

2.5

7.5

15 22 1.3

4 8 12

* The MicroFlex 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

350

300

250

200

150

100

100

Three-phase AC supply

125

Single-phase AC supply

150 175 200

AC supply voltage (rms)

225 250

MN1919 Specifications 8-1

8.1.1.2 Effect of AC power supply voltage on DC-bus ripple

50

40

30

20

10

0

100 125

Single-phase AC supply

Three-phase AC supply

150 175 200

AC supply voltage (rms)

225 250

www.baldormotion.com

8.1.1.3 Effect of output current on DC-bus ripple voltage

40

35

30

25

20

15

10

60

55

50

45

Single-phase AC supply

Three-phase AC supply

5

0

20 30 40 50 60 70 80 90 100 110 120 130 140 150

% of Drive Rated Current

8-2 Specifications MN1919

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8.1.2 24VDC control circuit supply input (X2)

Unit

VDC Nominal input voltage

Minimum input voltage

Maximum input voltage

Maximum ripple

Maximum continuous current @24VDC

Power on surge current (typical)

@24VDC, 100ms

%

A

A

8.1.3 Motor output power (X1)

Unit

A

RMS

A

RMS

Nominal phase current

Peak phase current

for 3s

Nominal output

@ 230V, 3Φ

Output voltage range (line-line)

@VDC-bus=320V

Output frequency

Output dv/dt

at drive, phase-phase at drive, phase-ground at motor (using 20m cable), phase-phase at motor (using 20m cable), phase-ground

Nominal switching frequency

Minimum motor inductance (per winding)

Efficiency

8.1.4 Regeneration (X1)

V

RMS

Hz kV/μs kHz mH

%

1A

1A

1

2

VA

398

Unit

VDC kW

1A

Nominal switching threshold (typical)

Nominal power

(10% power cycle, R=57Ω)

Peak power

(10% power cycle, R=57Ω)

Maximum regeneration switching current

Minimum load resistance

Maximum load inductance kW

A

PK

Ω

μH

3A

3

6

3A

24

20

30

±10

0.6

4

6A

2

1.1

1.9

1.8

8.0

1

>95

10

39

100

6A

6

12

9A

9

18

1195 2390 3585

0 - 230

0 - 2000

3A 6A

on: 388, off: 376

0.25

2.7

9A

9A

MN1919 Specifications 8-3

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8.1.5 Analog input (X3)

Type

Common mode voltage range

Common mode rejection

Input impedance

Input ADC resolution

Equivalent resolution

Sampling interval

Unit

VDC dB kΩ bits mV

μs

All models

Differential

±10

>40

>30

12

±4.9

125

8.1.6 Digital inputs - drive enable and general purpose (X3)

Type

Input voltage

Unit

VDC

All models

Opto-isolated inputs

Input current (@ Vin=24V)

Sampling interval

Maximum pulse input frequency

Minimum pulse width

Nominal

Minimum

Maximum

mA ms

MHz

μs

0.5

1

5

24

12

30

6.7

8.1.7 Step and Direction inputs (X3)

Type

Input voltage

Input current (maximum, per input)

Maximum step input frequency

Minimum pulse width

Unit

VDC

μA

MHz ns

All models

Non-isolated DC inputs

5

20

1

250

8-4 Specifications MN1919

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8.1.8 Status output (X3)

User supply (maximum)

Output current (max. continuous)

Fuse

Approximate trip current

Reset time

Update interval

Unit

V mA mA s ms

8.1.9 Incremental encoder feedback option (X8)

Unit

Encoder input

Maximum input frequency

(quadrature)

MHz

Hall inputs

Output power supply to encoder

Maximum recommended cable length

8.1.10 SSI encoder feedback option (X8)

Unit

SSI encoder inputs

Operating mode

(Baldor motors)

Output power supply to encoder

Maximum recommended cable length

8.1.11 Resolver feedback option (X8)

Resolution

set automatically by software

Resolver winding ratio

MicroFlex resolver input accuracy

Typical accuracy

using Baldor BSM series resolver motor (with input set to simulate 4096 ppr)

Maximum recommended cable length

Unit bits counts counts

All models

30

100

200

<20

0.5

All models

A/B Differential, Z index

8

Single ended, 5V logic

5V (±7%), 200mA max.

30.5m (100ft)

All models

Differential Data and Clock

Single turn.

Positioning resolution up to

262144 counts/rev (18-bit)

5V (±7%), 200mA max.

30.5m (100ft)

All models

14

0.5

±3

±11

30.5m (100ft)

MN1919 Specifications 8-5

www.baldormotion.com

8.1.12 Encoder output (simulated) (X7)

Signal

Resolution

Unit All models

RS422 with encoder input on X8 with SSI encoder input on X8

Output is a copy of the input on

X8.

Adjustable simulated output.

See section 4.1.4.

8.1.13 Serial RS232/RS485 interface (X6)

Signal

Bit rate

Unit baud

All models

RS232, non-isolated CTS/RTS or

RS485, non-isolated

(model dependent)

9600, 19200, 38400,

57600 (default)

8.1.14 Environmental

All models

Operating temperature range*

Minimum

Maximum

Derate

Storage temperature range*

Humidity (maximum)*

Unit

°C

+0

+45

See sections

3.2.2 to 3.2.6

-40 to +85

%

1A, 3A

m/s None required

All models

93

6A

1

°F

+32

+113

See sections

3.2.2 to 3.2.6

-40 to +185

9A

2.5

Forced air cooling flow

(vertical, from bottom to top)

Maximum installation altitude

(above m.s.l.)

m

Shock*

Vibration*

IP rating ft

1000

Derate 1.1% / 100m over 1000m

3300

Derate 1.1% / 330ft over 3300ft

10G

1G, 10-150Hz

IP20**

8-6 Specifications MN1919

www.baldormotion.com

* MicroFlex 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 complies with EN61800-5-1:2003 part 5.2.2.5.3 (Impact Test), provided all front panel connectors are inserted.

MN1919 Specifications 8-7

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8-8 Specifications MN1919

A

A

A.1 Introduction

This section describes accessories and options that you may need to use with your MicroFlex.

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.

MN1919 Accessories A-1

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A.1.1 Fan tray

The fan tray (Baldor part FAN001-024) provides sufficient cooling for the 3A, 6A or 9A

MicroFlex. It requires 23 - 27.5VDC at 325mA, which may be sourced from the same filtered control circuit supply used for the MicroFlex. The MicroFlex 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

Fan tray dimensions

94

(3.7)

84

(3.3)

Assembled MicroFlex and fan tray

66

(2.6)

A-2 Accessories

Figure 45 - Fan tray

Position of fan tray mounting holes relative to MicroFlex

Bottom of MicroFlex

Fan tray

16

(0.63)

4.5

(0.18)

It is important that the fan tray is mounted in close proximity to the MicroFlex as shown above. Failure to do so will result in decreased cooling efficiency.

MN1919

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A.1.2 Footprint filter

The single-phase footprint AC power filter (Baldor part FI0029A00) provides mounting holes for the MicroFlex and fan tray. This allows the filter, fan tray and MicroFlex to use the minimum panel mounting space. See section A.1.3 for details of filter FI0029A00.

Footprint filter

FI0029A00

MicroFlex

MN1919

Fan tray

FAN001-024

Figure 46 - Assembled footprint filter, fan tray and MicroFlex

Accessories A-3

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A.1.3 EMC filters

AC filters remove high frequency noise from the AC power supply, protecting the MicroFlex.

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

FI0014A00

FI0015A00

FI0015A01

FI0015A02

FI0018A00

FI0018A03

FI0029A00

Rated volts

250

250

250

250

480

480

250

Rated amps

@ 40°C

3

6

10

12

7

16

22

Leakage current

(mA)

0.4

0.4

0.4

0.4

33

33

33

Weight kg (lbs)

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

190 (7.48)

FI0018A03

250 (9.84)

160 (6.30)

180 (7.09)

20 (0.79)

4.5 (0.18)

71 (2.80)

40 (1.57)

220 (8.66)

235 (9.25)

25 (0.98)

5.4 (0.21)

70 (2.76)

45 (1.77)

Figure 47 - Filter dimensions, types FI0018A00 and FI0018A03

A-4 Accessories MN1919

D E A

F

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L

H

C

G

K

B

J

Dimension

J

K

L

F

G

H

A

B

C

D

E

FI0014A00

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

113.5 (4.47)

94 (3.70)

103 (4.06)

4.4 (0.17)

FI0015A01

FI0015A02

156 (6.14)

57.5 (2.26)

46.6 (1.83)

130.5 (5.14)

143 (5.63)

25 (0.98)

12.4 (0.49)

32.4 (1.28)

6 (0.24)

15.5 (0.61)

5.3 (0.21)

Figure 48 - Filter dimensions, types FI0014A00, FI0015A00, FI0015A01, FI0015A02

MN1919 Accessories A-5

B

D

C A

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E

F

Mounting keyhole and slot detail

A

B

C

C A

A

A 5.5mm

B 11mm

C 10mm

D 5mm

D

Dimensions shown as: mm (inches).

Dimension

A

D

E

B

C

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 MN1919

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A.1.4 Regeneration resistors

Depending on the application, MicroFlex 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. See sections 3.6 and 3.7 for details about choosing the correct resistor.

WARNING: Electrical shock hazard. DC bus voltages may be present at these terminals. Use a suitable heatsink (with fan if necessary) to cool the regeneration resistor. The regeneration resistor and heatsink (if present) can reach temperatures in excess of 80 °C (176 °F).

B

A

C

F

E

G

D

Baldor catalog number

RGJ139

RGJ160

RGJ260

RGJ360

Power

W

100

100

200

300

Res.

Ω

39

60

60

60

A

165

(6.49)

165

(6.49)

165

(6.49)

215

(8.46)

B

41

(1.61)

41

(1.61)

60

(2.36)

60

(2.36)

Dimensions mm (inches)

C

22

(0.87)

22

(0.87)

30

(1.18)

30

(1.18)

D

152

(5.98)

152

(5.98)

146

(5.75)

196

(7.72)

Figure 50 - Regeneration resistor dimensions

E

12

(0.47)

12

(0.47)

17

(0.67)

17

(0.67)

F

10

(0.39)

10

(0.39)

13

(0.51)

13

(0.51)

G

4.3

(0.17)

4.3

(0.17)

5.3

(0.21)

5.3

(0.21)

MN1919 Accessories A-7

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A.2 Cables

A wide range of motor and feedback cables are available from Baldor.

A.2.1 Motor power cables

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

CBL

The item is a cable

Alternatives

-

025

Indicates the length, in this example 2.5 meters Various lengths are available.

SP

The cable is a Servo motor Power cable -

12

Current rating of 12A 20=20 A; 35=35 A

Motor power cables include the motor power connector. Larger motors requiring 35 A cable normally use terminal box connections, so a motor power connector is not required.

A.2.1.1 Cables available in North and South America

Cable rated current

12 Amps

20 Amps

35 Amps

Cable assembly description

Power cable: no connectors

Power cable assembly:

CE style threaded motor connector

(motor end only)

Power cable: no connector

Power cable assembly:

CE style threaded motor connector

(motor end only)

Power cable: no connector

CBL050-501

CBL015SP-12

CBL030SP-12

CBL061SP-12

CBL091SP-12

CBL152SP-12

CBL229SP-12

CBL051-501

CBL015SP-20

CBL030SP-20

CBL061SP-20

CBL091SP-20

CBL152SP-20

CBL229SP-20

CBL052-501

Length m ft

Available by the foot or on

100 m (328 ft) drum.

1.5

3.0

6.1

9.1

15.2

22.9

5

10

20

30

50

75

Available by the foot or on

100 m (328 ft) drum

1.5

3.0

6.1

9.1

15.2

22.9

5

10

20

30

50

75

Available by the foot or on

100 m (328 ft) drum.

A-8 Accessories MN1919

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A.2.1.2 Cables available in the rest of the world

Cable rated current

12 Amps

20 Amps

35 Amps

Cable assembly description

Power cable: no connectors

Power cable assembly:

CE style threaded motor connector

(motor end only)

Power cable: no connector

Power cable assembly:

CE style threaded motor connector

(motor end only)

Power cable: no connector

CBL050-501

CBL025SP-12

CBL050SP-12

CBL075SP-12

CBL100SP-12

CBL150SP-12

CBL200SP-12

CBL051-501

CBL025SP-20

CBL050SP-20

CBL075SP-20

CBL100SP-20

CBL150SP-20

CBL200SP-20

CBL052-501

Length m ft

Available by the meter or on

100 m drum.

2.5

5.0

7.5

10

15

20

8.2

16.4

24.6

32.8

49.2

65.6

Available by the meter or on

100 m drum.

2.5

5

7.5

10

15

20

8.2

16.4

24.6

32.8

49.2

65.6

Available by the meter or on

100 m drum.

MN1919 Accessories A-9

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A.2.2 Feedback cable part numbers

A description of a feedback cable catalog number is shown here, using the example number

CBL025SF-E2:

Meaning

CBL

The item is a cable

E

Encoder feedback cable with motor connector

Alternatives

-

025

Indicates the length, in this example 2.5 meters Various lengths are available.

SF

The cable is a Servo motor Feedback cable -

S=SSI feedback cable

R=Resolver feedback cable

2

Drive connector included:

15-pin D-type connector for all feedback types

1 = Drive connector included:

9-pin D-type connector (for

Resolver)

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 0.34 mm

2

(22 AWG) wire minimum, with an overall shield. Ideally, the cable should not exceed 30.5 m (100 ft) in length. Maximum wire-to-wire or wire-to-shield capacitance is 50 pF per 300 mm (1 ft) length, to a maximum of 5000 pF for 30.5 m (100 ft).

A.2.3 SSI feedback cables

A.2.3.1 Cables available in North and South America

SSI feedback cable: no connectors

Feedback cable assembly:

CE style threaded motor connector and low density 15-pin D-type drive connector

CBL044-501

CBL015SF-S2

CBL030SF-S2

CBL061SF-S2

CBL091SF-S2

CBL152SF-S2

CBL229SF-S2

Length m ft

Available by the foot or on 100 m (328 ft) drum.

1.5

3.0

6.1

9.1

15.2

22.9

5

10

20

30

50

75

A.2.3.2 Cables available in the rest of the world

SSI feedback cable: no connectors

Feedback cable assembly:

CE style threaded motor connector and low density 15-pin D-type drive connector

CBL044-501

CBL025SF-S2

CBL050SF-S2

CBL075SF-S2

CBL100SF-S2

CBL150SF-S2

CBL200SF-S2

Length m ft

Available by the meter or on 100 m drum.

2.5

5.0

7.5

10

15

20

8.2

16.4

24.6

32.8

49.2

65.6

A-10 Accessories MN1919

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A.2.4 Encoder / Hall feedback cables

A.2.4.1 Cables available in North and South America

Encoder feedback cable: no connectors

Feedback cable assembly:

CE style threaded motor connector

(motor end only)

Feedback cable assembly:

CE style threaded motor connector and low density 15-pin D-type drive connector

A.2.4.2 Cables available in the rest of the world

CBL043-501

CBL025SF-E

CBL015SF-E2

CBL030SF-E2

CBL061SF-E2

CBL091SF-E2

CBL152SF-E2

CBL229SF-E2

Length m ft

Available by the foot or on 100 m (328 ft) drum.

2.5

8.2

1.5

3.0

6.1

9.1

15.2

22.9

5

10

20

30

50

75

Encoder feedback cable: no connectors

Feedback cable assembly:

CE style threaded motor connector

(motor end only)

Feedback cable assembly:

CE style threaded motor connector and low density 15-pin D-type drive connector

CBL043-501

CBL025SF-E

CBL025SF-E2

CBL050SF-E2

CBL075SF-E2

CBL100SF-E2

CBL150SF-E2

CBL200SF-E2

Length m ft

Available by the meter or on 100 m drum.

2.5

8.2

2.5

5

7.5

10

15

20

8.2

16.4

24.6

32.8

49.2

65.6

MN1919 Accessories A-11

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A.2.5 Resolver feedback cables

A.2.5.1 Cables available in North and South America

Resolver Feedback Cable: no connectors

Feedback Cable Assembly:

CE style threaded motor connector

(motor end only)

Feedback Cable Assembly:

CE style threaded motor connector and 9-pin D-type drive connector

CBL044-501

CBL015SF-R

CBL030SF-R

CBL061SF-R

CBL091SF-R

CBL152SF-R

CBL229SF-R

CBL015SF-R1

CBL030SF-R1

CBL061SF-R1

CBL091SF-R1

CBL152SF-R1

CBL229SF-R1

Length m ft

Available by the foot or on 100 m (328 ft) drum.

1.5

3.0

6.1

9.1

15.2

22.9

1.5

3.0

6.1

9.1

15.2

22.9

5

10

20

30

50

75

5

10

20

30

50

75

A.2.5.2 Cables available in the rest of the world

Resolver Feedback Cable: no connectors

Feedback Cable Assembly:

CE style threaded motor connector

(motor end only)

Feedback Cable Assembly:

CE style threaded motor connector and 9-pin D-type drive connector

CBL044-501

CBL025SF-R

CBL050SF-R

CBL075SF-R

CBL100SF-R

CBL150SF-R

CBL200SF-R

CBL025SF-R1

CBL050SF-R1

CBL075SF-R1

CBL100SF-R1

CBL150SF-R1

CBL200SF-R1

Length m ft

Available by the meter or on 100 m drum.

2.5

5

7.5

10

15

20

2.5

5

7.5

10

15

20

8.2

16.4

24.6

32.8

49.2

65.6

8.2

16.4

24.6

32.8

49.2

65.6

A-12 Accessories MN1919

B

B.1 Introduction

The MicroFlex can be configured for three basic control modes:

H

Current (Torque) control.

H

Velocity (Speed) control.

H

Step and Direction following/gearing.

The mode you require is selected in Mint WorkBench using the Commissioning Wizard.

You can subsequently change between these control modes using the Tools, Control Mode menu item or by using the CONTROLMODE keyword in the Command window (see the Mint help file). Using the Parameter tool, you can define a mode for the drive to automatically select at start-up. The three control modes are described in the following sections.

B

MN1919 Control System B-1

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B.1.1 Current (Torque) control

Setting the control mode to Current Control configures the MicroFlex or MicroFlex as a torque amplifier, as shown in Figure 51. Here, a torque reference is obtained from a specified source:

H

Mint WorkBench

H

A host using the ActiveX control

H

Analog input

The source provides a signal that is fed into the Torque profiler.

The profiler generates a torque demand signal that smoothly changes between successive torque targets (reference values). This is achieved by specifying a rise time and fall time (see the WorkBench v5 Parameters tool). The torque demand signal is fed into the torque controller which determines the appropriate amount of current to apply to the windings of the motor.

This demand current is compared with the actual winding current measured from sensors, and a suitable pulse width modulation (PWM) signal is generated. This PWM signal is fed to the power electronics in the drive.

Torque reference

Host

Analog input

Torque profiler

Torque demand

Torque controller

PWM

Power stage

+ motor

Measured current

Figure 51 - Control structure in Current (Torque) control mode

The torque controller is a PI (Proportional Integral) controller. Gains are set using the Mint keywords KIPROP and KIINT. The torque demand is scaled into a current demand. This is compared with the measured current, obtained from the current sensors, and the error is fed into the PI control calculation. The resulting value forms the PWM signal that is fed through the power stage into the motor windings. The gain values KIPROP and KINT must be tuned for a specific motor. This is performed automatically by the Commissioning Wizard.

The feedback device is used to determine motor position and speed. Motor speed can be filtered to reduce measurement noise if necessary. The time constant of this filter is specified using the keyword KVTIME. By default the filter is turned off (KVTIME = 0). Note that introducing a filter on measured speed tends to reduce the stability of the speed controller.

This can make the tuning of the speed controller gains difficult if large values of KVTIME are used.

B-2 Control System MN1919

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B.1.2 Velocity (Speed) control

Setting the control mode to Velocity Control configures the MicroFlex as a speed amplifier, as shown in Figure 52. Here, a speed reference is obtained from a specified source:

H

Mint WorkBench

H

A host using the ActiveX control

H

Analog input

The source provides a signal that is fed into the Speed controller.

The profiler generates a speed demand signal that smoothly changes between successive speed targets (reference values). This is achieved by specifying acceleration and deceleration times (see the WorkBench v5 Parameters tool). The speed demand signal is fed into the speed controller and used, together with the speed measured from the feedback device, to generate a torque demand signal. If the speed controller is tuned correctly, the measured speed will accurately track the speed demand.

Finally, the torque demand signal is fed into a torque controller, which determines the appropriate amount of current to apply to the windings of the motor. This demand current is compared with the actual winding current measured from sensors, and a suitable pulse width modulation (PWM) signal is generated. This PWM signal is fed to the power electronics in the drive.

Speed reference

Host

Analog input

Speed profiler

Speed demand

Speed controller

Torque demand

Torque controller

PWM

Power stage

+ motor

Measured current

Measured speed

Figure 52 - Control structure in Velocity control mode

The speed controller is a PI (Proportional Integral) controller. Gains are set using the Mint keywords KVPROP, and KVINT. The speed is compared with the measured speed and the error is fed into the PI control calculation. The speed control calculation is performed every

250μs, and the result forms the torque demand for the torque controller. As with the position controller, the gain values KVPROP and KVINT must be tuned for each application.

This can either be performed automatically within the Commissioning Wizard, or manually using the Fine-tuning tool of Mint WorkBench.

MN1919 Control System B-3

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B.1.3 Position (Step and Direction) control

Setting the control mode to Position Control (Step and Direction) configures the MicroFlex as a positioning system, as shown in Figure 53, capable of following a position command signal.

The up down counter and gearing interpret the step and direction signals and use them to generate a position demand signal.

The position demand signal is fed into a position controller and used, together with the position measured from the feedback device, to generate a suitable speed demand signal. If the position controller is tuned correctly, the measured position will accurately track the position demand.

The speed demand signal from the position controller is fed into the speed controller and used, together with the speed measured from the feedback device, to generate a torque demand signal. If the speed controller is tuned correctly, the measured speed will accurately track the speed demand.

Finally, the torque demand signal is fed into a torque controller, which determines the appropriate amount of current to apply to the windings of the motor. This demand current is compared with the actual winding current measured from sensors, and a suitable pulse width modulation (PWM) signal is generated. This PWM signal is fed to the power electronics in the drive.

Position reference

Step

Direction

Up/down

Counter

Pulse count

Gearing

Position

Speed demand

Torque demand

PWM

Measured current

Measured speed

Measured position

Figure 53 - Control structure in Position control (Step and Direction)

B-4 Control System MN1919

C

C

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 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 compliance

When installed as directed in this manual, MicroFlex 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 must be mounted in a suitable metal cabinet incorporating

360° screened cable glands.

MN1919 CE & UL C-1

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C.1.3 Declaration of conformity

Date: 01/02/05

EC Declaration of Conformity

Ref: DE00014-001

Manufacturer:

Address:

Baldor UK Limited

Mint Motion Centre, Hawkley Drive, Bristol Distribution Centre, Bristol, BS32 0BF, United Kingdom

Hereby declare that the product:

MicroFlex Single-Axis Servo and Positioning Drive, being one of:

FMH2A01TR-xNy3 FMH2A03TR-xNy3

(where x = R or E, y = 4 or 2)

FMH2A06TR-xNy3 FMH2A09TR-xNy3 when used in accordance with the guidance given in the corresponding MicroFlex Installation Manual, MN1919, conforms with the protection requirements of the following Council Directives, by application of the relevant harmonized standards:

The Electromagnetic Compatibility Directive 89/336/EEC and its amending directives:

Standard:

EN61800-3:1996 + A11:2000

Title:

Adjustable speed electrical power drive systems Part 3: EMC Product standard, including test methods

.

Comments:

Emissions & Immunity comply with both 1st & 2nd environments.

The Low Voltage Directive 72/23/EEC and its amending directives:

Standard:

EN61800-5-1:2003

Title:

Adjustable speed electrical power drive systems. Safety requirements. Electrical, thermal and energy

.

EN61800-2:1998

EN50178:1998

EN60529:1992

Adjustable speed electrical power drive systems. General requirements. Rating specifications for low voltage adjustable frequency a.c. power drive systems

.

Electronic equipment for use in power installations

.

Specification for degrees of protection provided by enclosures (IP code)

.

EC Declaration of Incorporation

The Machinery Directive 98/37/EC and its amending directives:

The above product is intended to be incorporated into machinery or to be assembled with other machinery to constitute machinery covered by directive 98/37/EC. As such does therefore not in every respect comply with the provisions of directive 98/37/EC.

User must follow the guidance given in this directive to meet all necessary protection requirements. All instructions, warnings & safety information of the product manual MN1919 must be adhered to. User must follow the guidance given in harmonized standard EN60204-1 (Safety of Machinery) to meet necessary protection requirements of this directive.

and furthermore declare that it may not be put into service before the machinery in which it will be incorporated is declared to comply with the provisions of directive 98/37/EC, as amended.

Signed:

Dr. Gerry Boast

Engineering Manager

C-2 CE & UL MN1919

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C.1.4 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.1.5 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. The connections between the MicroFlex and the filter should use shielded (screened) cables. The cable shields should be connected to shield clamps at both ends. An exception to this is the analog command signal.

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.

MN1919 CE & UL C-3

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C.1.6 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.

C-4 CE & UL MN1919

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C.1.7 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 54 - Earthing/grounding cable shields

CHA+

CHA-

CHB+

CHB-

CHZ+

CHZ-

+5V

DGND

MicroFlex

X8

3

11

12

13

1

9

2

10

Cable

Twisted pairs

Encoder Connector

Housing

Connect overall shield to connector backshell.

Connect overall shield to connector backshell.

Figure 55 - Encoder signal cable grounding

MN1919 CE & UL C-5

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C.2 UL file numbers

The following table lists UL file numbers for Baldor products and other accessories. Note that

UL file numbers for accessories that are not manufactured by Baldor are beyond Baldor’s control and therefore subject to change without notice.

UL file number

E128059

E46145

Company

Baldor Electric Co.

Baldor Electric Co.

Description

Drives

Motors

E132956 Cabloswiss s.p.a.

Power cables (6A, 12A, 20A, 25A, 50A, 90A)

Encoder cables

Resolver/SSI cables

EnDat cables

E192076 Unika Special Cables s.p.a

Power cables (6A, 12A, 20A, 25A, 50A, 90A)

Encoder cables

Resolver/SSI cables

EnDat cables

E153698 Coninvers GmbH Connectors

E64388

E70122

Schaffner EMV AG

Epcos AG

E212934 Frizlen GmbH & Co. KG

E227820 RARA Electronics Corp.

AC filters

AC filters

Regeneration (brake) resistors

Regeneration (brake) resistors

C-6 CE & UL MN1919

Index

A

Abbreviations, 2-3

Accessories, A-1

EMC filters, A-4 fan-tray, A-2 feedback cables, A-10, A-11, A-12 footprint filter, A-3 motor power cables, A-8 regeneration resistors, A-7

Analog I/O, 5-2 analog input (demand), 5-2

B

Basic Installation, 3-1

C

Catalog number, identifying, 2-2

CE Guidelines, C-1 declaration of conformity, C-2

Command window, 6-11

Commissioning Wizard, 6-7 using, 6-7

Configuration, 6-8

Connections

See also

Input / Output feedback, 4-1 motor, 3-17 power, 3-10, 3-11

Connector, locations, 3-9

Control system, B-1 current (torque) control, B-2 position (step & direction) control, B-4 velocity (speed) control, B-3

Cooling, 3-5, 3-6, 3-7, 3-8, A-2 overtemperature trips, 3-8

D

Demand input, 5-2

Derating, 3-6, 3-7, 3-8

MN1919

Digital I/O, 5-4 drive enable input, 5-5 general purpose digital input, 5-7 status output, 5-12 step & direction inputs, 5-9

Dimensions, 3-4

Dynamic brake. See Regeneration resistor

E

Earthing (grounding) leakage, 3-10 protection class, 3-10 protective earth (PE), 3-10

Encoder cable, 4-3, 4-5 feedback, 4-2 specification, 8-5

SSI. See SSI without Halls, 4-4

Encoder, incremental, cable, A-11

Environmental cooling, 3-3 location, 3-3–3-4 specification, 8-6

F

Features, 2-1

Feedback cable, A-10–A-13 connections, 4-1 encoder, 4-2 encoder without Halls, 4-4

Halls-only feedback, 4-4

Resolver, 4-9

SSI, 4-7

Filters

24V control circuit supply, 3-16

AC power (EMC), 3-15, A-4 catalog numbers, A-4

Index

Footprint filter, A-3

Fuses, 3-14

G

General Information, 1-1

Grounding. See Earthing (grounding)

H

Hardware requirements, 3-1

Help file, 6-4

I

Incremental encoder, cable, A-11

Input / Output, 5-1 analog I/O, 5-2 analog input, 5-2, 8-4 connection summary, 5-17 digital I/O, 5-4 drive enable input, 5-5, 8-4 encoder output, 4-11, 8-6 general purpose digital input, 5-7, 8-4 serial port, 5-14, 8-6 multidrop using RS485/RS422 cable, 5-15 status output, 5-12, 8-5 step & direction inputs, 5-9, 8-4

Installation

See also

Basic Installation cooling, 3-5, 3-6, 3-7, 3-8 dimensions, 3-4 mechanical, 3-3 mounting, 3-5

L

LED indicator, 7-2

Linear motor, cable configuration, 4-6

M

Mint WorkBench, 6-3

Commissioning Wizard, 6-7 fine-tuning tool, 6-8 help file, 6-4 other tools and windows, 6-11 parameters tool, 6-10 starting, 6-5

Motor circuit contactors, 3-18 connections, 3-17 power cable, 3-18–3-19, A-8 sinusoidal filter, 3-19

Mounting, 3-5

O

Operation, 6-1 connecting to the PC, 6-1 installing software, 6-1 power on checks, 6-2 preliminary checks, 6-2 starting, 6-2

Operator panels, HMI operator panels, 5-16

Overloads drive, 3-14 motor, 3-17 overtemperature trips, 3-8

P

Power

24V control circuit supply, 3-16 connections, 3-10 discharge time, 3-12 disconnect and protection devices, 3-13 input conditioning, 3-12 input cycling, 3-12, 7-1 inrush, 3-12 sources, 3-1 supply filters, 3-15, A-4 using a variac, 3-13

Precautions, 1-2

Product Notice, 1-2

R

Receiving and Inspection, 2-2

Regeneration capacity, 3-20 energy, 3-22 power, 3-22 resistor, 3-20 resistor, selection, 3-21 specification, 8-3

Index

MN1919

Resolver, 4-9 cable, 4-10, A-12 specification, 8-5

RS232, 5-14 specification, 8-6

RS485, 5-15 multidrop using RS485/RS422 cable, 5-15

S

Safety Notice, 1-2

Serial port, 5-14 connecting serial Baldor HMI panels, 5-16

Simulated encoder output, 4-11

Specifications, 8-1

24V control supply, 8-3

AC input power and bus voltage, 8-1, 8-3 analog input, 8-4 digital input, 8-4 encoder feedback, 8-5 encoder output, 8-6 environmental, 8-6 regeneration, 8-3 resolver feedback, 8-5 serial RS232 interface, 8-6

SSI feedback, 8-5 status output, 8-5 step & direction inputs, 8-4

SSI, 4-7 cable, 4-8, A-10 specification, 8-5

Status LED, 7-2

Step & Direction, 5-9 specification, 8-4

T

Tools, 3-2

Troubleshooting, 7-1 communication, 7-3 power cycling, 7-1 power on, 7-4 problem diagnosis, 7-1

Status LED, 7-2

SupportMe, 7-1 tuning, 7-4

U

UL file numbers, C-6

Units and abbreviations, 2-3

W

Wires sizes, 3-14

MN1919

Index

Index

MN1919

Comments

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Manuals

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BS32 0BF

United Kingdom.

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Comment:

MN1919

continued...

Comments

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MN1919

Baldor Electric Company

P.O. Box 2400

Ft. Smith, AR 72902-2400

U.S.A.

Visit www.baldormotion.com for the latest documentation and software releases.

U.S.A. (Headquarters)

Baldor Electric Company

Tel: +1 479 646 4711

Fax: +1 479 648 5792

Australia

Australian Baldor PTY Ltd

Tel: +61 2 9674 5455

Fax: +61 2 9674 2495

Europe

Baldor ASR GmbH, Germany

Tel: +49 (0) 89 905 080

Fax: +49 (0) 89 905 08492

Europe (Southern)

Baldor ASR AG, Switzerland

Tel: +41 52 647 4700

Fax: +41 52 659 2394

Japan

Baldor Japan Corporation

Tel: +81 45 412 4506

Fax: +81 45 412 4507

Mexico

Baldor de Mexico

Tel: +52 477 761 2030

Fax: +52 477 761 2010

Singapore

Baldor Electric PTE Ltd

Tel: +65 6744 2572

Fax: +65 7474 1708

India

Baldor Electric India Pvt Ltd

Tel: +91 20 25 45 27 17

Fax: +91 20 25 45 27 19

United Kingdom

Baldor UK Ltd

Tel: +44 1454 850000

Fax: +44 1454 859001

For additional office locations visit www.baldor.com

Printed in UK

E

Baldor UK Ltd