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Flexi PRO - FPRO_QSG_Rev_5.6_fw144

1. CAN In C5 RJ45 STO Safe Torque Off P1 Molex 26 28 AWG 1 24 VDC STO enable 2 Ground 24 VDC return 3 4 Mating Connector type Crimp Housing PN 436450400 MPC PN xxxxxxxxxx 4x Crimp PN 0430300001 MPC PN xxxxxxxxxx Wired STO MPC PN xxxxxxxxxx Controller I F EtherCAT Out C8 0 1 IDC Female C2 MDR 36 Plug 24 28 AWG A EOS 1 24 VDC return 119 24 VDC OR Gh al n Common output Bie Common input ni CAN Out ee Digital output 1 20 Digital input 2 C6 RJ45 2 PO ZE i Equivalent encoder 22 Equivalent encoder 3 RXD output A output A 4 GND 5 Equivalent encoder 23 Equivalent encoder RS232 5 TXD o o output B output B C7 4p4c 6 GND 9 6 Equivalentencoder 24 Eguivalent encoder 1 RX 7 output Z u output Z 7 ana 5 7 25 Ground 3 TX 9 8 Analog input 1 26 Analog input 1 4 1 9 Direction input 27 Direction input Secondary encoder B Secondary encoder B 10 Ground 28 Pulse input Secondary encoder A 11 Pulse input 29 Ground Secondary encoder A 12 30 13 Ground 31 Digital input 3 14 Digital input 4 132 Digital input 5 15 Digital input 6 33 Digital output 2 16 Digital output 3 34 17 o 35 Analog input 2 18 E Analog input 2 36 Analog output Logic Power AC Input P2 Phoenix 16 AWG L1C AC Phase 1 2 L2C AC Phase 2 Mating Connector PN FKC 2 5 2 STF 5 1873207
2. Controller I F C2 MDR 36 Plug 24 28 AWG 1 24 VDC return 19 24 VDC Common output H Common input 2 Digital output 1 20 Digital input 2 Digital input 1 21 Equivalent encoder 22 Equivalent encoder output A output A 5 Equivalent encoder 23 Equivalent encoder output B output B 6 Equivalent encoder 24 Equivalent encoder output Z output Z 7 25 Ground 8 Analog input 1 26 Analog input 1 t 9 Direction input 27 Direction input Secondary encoder B Secondary encoder B al E 10 Ground 28 Pulse input Secondary encoder A Secondary encoder A 11 Pulse input 29 Ground 12 30 13 Ground 31_ Digital input 3 14 Digital input 4 32 Digital input 5 15 Digital input 6 33 Digital output 2 16 Digital output 3 34 17 35 Analog input 2 Analog input 2 36 Analog output 3M Solder Plug Junction Shell Secondary encoder A 11 Mating Connector 3M Solder Plug Connector PN 10136 3000PE MPC PN xxxxxxxxxx PN 10336 52F0 008 MPC PN xxxxxxxxxx Secondary encoder A Pulse input Pulse input 2 Secondary encoder B 12 Secondary encoder B Direction input Direction input Secondary encoder Z Secondary encoder Z
3. ALAR RER ERYL R cnn rre rr rr 54 O CG GN YY A A tas UY Y Fi eae YN 55 Motore Pilla ia 56 5 Software 57 FLEX SUITE Installation 57 POWEFY Doc 57 Drive Conta ura cOn a 58 6 Drive Status 59 Normal Operation Cole add 59 Warming ana Faule COGES ndo 60 Quick Start Guide 5 FLEXI PRO Quick Start Guide FLEXI PRO Introduction 1 Introduction FLEXI PRO Documentation This manual is part of a documentation set The entire set consists of the following m FLEXI PRO Quick Start Guide Basic setup and operation of the drive m FLEXI PRO User Manual Hardware installation configuration and operation m FLEXI PRO VarCom Reference Manual Parameters and commands used to program the FLEXI PRO m FLEXI PRO CANopen for CAN and EtherCAT Drives Reference Manual FLEXI PRO implementation of CANopen protocol for CAN and EtherCAT Safety Only qualified persons may perform the installation procedures You do not need to be an expert in motion control to install and operate the drive system However you must have a basic understanding of electronics computers mechanics and safety practices The FLEXI PRO utilizes hazardous voltages Be sure the drive is properly grounded Before you install the FLEXI PRO review the safety instructions in this manual The manual is available as a PDF file that can be downloaded from the Motor Power Company website Failure to follow the safety instructions may result in personal inju
4. FLEXI PRO Servo Drive Quick Start Guide Revision 5 6 Firmware 1 4 4 SEE IT BEFORE IT HAPPENS MOTOR POWER COMPANY FLEXI PRO Revision History Doc Rev 5 6 5 4a 5 4b 5 4 5 3 5 2 5 0 5 1 4 3 Firmware Revision 1 4 4 Date Remarks Oct 2013 Updated ordering info pin assignments diagrams controller and machine interface wiring diagrams EnDat wiring faults July 2013 Miscellaneous corrections and updates Mar 2013 Miscellaneous corrections and updates Dec 2012 Added and revised faults and warnings Dec 2012 Added wiring for FLEXI PRO 020 FLEXI PRO 024 models Nov 2012 Includes 120 240 VAC and 400 480 VAC models Aug 2012 Warnings and faults updated Software GUI Revision 1 4 4 x Note If an earlier firmware revision is installed in you drive contact your Account Manager or Technical Support Important Notice 2013 Motor Power Company s r l All rights reserved No part of this work may be reproduced or transmitted in any form or by any means without prior written permission of Motor Power Company Disclaimer The information in this manual was accurate and reliable at the time of its release Motor Power Company s r l reserves the right to change the specifications of the product described in this manual without notice at any time Trademarks CANopen and CiA are registered trademarks of the CAN in Automation User s Group EtherCAT is a registered
5. 15 Incremental encoder B SSI encoder clock SSI encoder clock Incremental encoder Z 6 Incremental encoder Z Hall U 7 Hall V Hall W 8 AF EC PN Models 8V supply 9 Resolver sine Resolver cosine 0 Resolver cosine Resolver reference O DOAN Oo OH SAS W Sine encoder sine 2 Sine encoder sine 10 Sine encoder cosine 3 Sine encoder cosine 11 5V supply Resolver sine 4 Ground 5V 8V return 1 1 1 1 2 21 Resolver reference 2 2 2 2 12 Motor temperature sensor 13 5V supply 26 Shield 5 Motor temperature sensor Quick Start Guide 33 Control Board FLEXI PRO Feedback Wiring Guidelines The following tables present the most common feedback variations If your motor feedback does not match any one of the following contact technical support The tables present the wiring pin layout Use the User Motor Pin column in these tables to record the pin numbers of your specific motor for future reference Notes for Wiring Tables A If the motor does not support a temperature sensor do not connect pins 12 and 25 B If the motor has an additional temperature sensor connect pins 12 and 25 E Halls are single ended signals To use differential Hall signals refer to the relevant wiring tables D Incremental encoders with Hall sensors and index pulse A Band Z signals use the same wiring as Hall sensors U V and W On power up feedback briefly sends Hall readings and then
6. MPC PN xxxxxxxxxx 4x Crimp PN 0430300001 MPC PN xxxxxxxxxx Wired STO MPC PN xxxxxxxxxx Logic Power 24V Input P2 Molex 26 28 AWG 1 24 VDC logic in Housing PN 436450200 MPC PN xxxxxxxxxx 2x Crimp PN 0430300001 MPC PN xxxxxxxxxx AC Input and Regeneration P3 Phoenix 12 14 AWG 2 Ground 24 VDC retum Mating Connector Type Crimp TX B o m e L1 AC Phase 1 L2 AC Phase 2 L3 AC Phase 3 B1 DC Bus B2 Regen Bus 6 B3 DC Bus Mating Connector MPC PN xxxxxxxxxx PN SPC 5 6 STCL 7 62 1718520 Brake P4 Phoenix 14 17 AWG 1 BR Motor Brake 2 BR Mating Connector MPC PN xxxxxxxxxx Functional Ground PE Terminal M4 M4 ring or spade terminal Motor Brake PN SPC 5 2 STCL 7 62 1718481 Motor P5 Phoenix 12 14 AWG 1 lU Motor Phase U Motor Phase V 2N 3 lw Motor Phase W Mating Connector MPC PN xxxxxxxxxx PN SPC 5 3 STCL 7 62 1718494 Refer to ordering information CAN and EtherCAT models only O OI NID on BR wl n Machine I F EtherCAT models only Motor Power Company Highlighted PN Supplied with FPRO Crimping tool 4 40 insert threads on C2 C3 C4 18 owe ae Molex 0638190000 P1 P2 19
7. Quick Start Guide FLEXI PRO Control Board Feedback Wiring Differential Halls Only Pin Twisted Pair User Motor Pin Signal Description 9 22 10 23 3 16 12 25 11 24 26 Twisted Pair Hall U Hall U Hall V Hall V Hall W Hall W Motor Temperature Sensor Motor Temperature Sensor 5 VDC O VDC Shield Notes A Feedback Wiring Incremental Tamagawa Pin Twisted Pair User Motor Pin Signal Description 1 Twisted Pair 14 Twisted Pair 15 Twisted Pair 16 11 24 26 Incremental Encoder A Hall U Incremental Encoder A Hall U Incremental Encoder B Hall V Incremental Encoder B Hall V Incremental Encoder Z Hall W Incremental Encoder Z Hall W 5 VDC O VDC Shield Notes B D Quick Start Guide 37 Control Board FLEXI PRO 38 Feedback Wiring Sine Encoder Pin Twisted Pair User Motor Pin 9 22 10 23 11 24 26 Notes B E Twisted Pair Twisted Pair Signal Description Sine Encoder Sine Sine Encoder Sine Sine Encoder Cosine Sine Encoder Cosine 5VDC OVDC Shield Feedback Wiring Sine Encoder with Halls Pin Twisted Pair User Motor Pin Signal Description Twisted Pair 22 10 23 Twisted Pair 17 11 24 26 Note B Sine Encoder Sine Sine Encoder Sine Sine Encoder Cosine Sine Encoder Cosine Hall U Hall V Hall W 5 VDC O VDC Shield Quick Start Guide FLEXI
8. exceeded the position error limit PEMAX The velocity error VE has exceeded the velocity error limit VEMAX Positive hardware limit switch is activated Negative hardware limit switch is activated Positive and negative hardware limit switches are both activated Positive software limit switch is activated PFB gt POSLIMPOS and POSLIMMODE 1 Negative software limit switch is activated PFB lt POSLIMNEG and POSLIMMODE 1 Positive and negative software limit switches are activated PFB gt POSLIMPOS and PFB lt POSLIMNEG and POSLIMMODE 1 The STO signal is not connected when drive enabled The STO signal is not connected when drive disabled Action Required Reestablish the connection between controller and drive Clear the fault and allow the controller to send new commands Check that the drive is configured properly using THERMODE THERMTYPE THERMTHRESH and THERMTIME and that the motor temperature sensor is properly connected to the drive if needed If the drive is configured and wired properly check whether the motor is under sized for the application Check that VLIM is set to match the application requirements Using velocity loop tuning check for excessive overshoot Change drive tuning to improve position tracking or increase PEMAX to allow a greater position error Change drive tuning to improve velocity tracking or increase VEMAX to allow a grea
9. L2 L3 L1C LC2 Pin Label L1 L2 L3 L1C LC2 Function AC Phase 1 AC Phase 2 Logic AC Phase 1 Logic AC Neutral Function AC Phase 1 AC Phase 2 AC Phase 3 Logic AC Phase 1 Logic AC Neutral Function AC Phase 1 AC Phase 2 AC Phase 3 Logic AC Phase 1 Logic AC Neutral Function AC Phase 1 AC Phase 2 AC Phase 3 Logic AC Phase 1 Logic AC Neutral 51 Power Board 400 480 VAC FLEXI PRO 4 Power Board 400 480 VAC Overview A On all FLEXI PRO 400 480 VAC models the power board has the following interfaces E STO P1 m Logic Power 24 VDC P2 m AC Input and Regeneration P3 m Brake P4 m Motor P5 Make sure the main voltage rating matches the drive specification Applying incorrect voltage may cause drive failure Do not apply power until all hardware connections are complete Safe Torque Off STO P1 52 STO uses interface P1 on all FLEXI PRO 400 480 VAC models Safe torque off STO is a safety function that prevents the drive from delivering power to the motor which can generate torque STO Enable and STO Return must be connected to enable FLEXI PRO operation The STO Enable signal voltage must be 24 VDC Note If the application does not require STO control jumper pin 4 to pin 1 and pin 3 to pin 2 to bypass the STO STO Bypass STO Interface Pin Pin Label Function 1 24V STO Enable 2 GND 24 VDC Return 3 4 Quick Start Guide FLEXI PRO Power Board 4
10. 05V KX 6 esolver sine 9 Resolver sine MPC PN xxxxxxxxxx 7 Resolver cosine 20 Resolver cosine 5x Crimp PN SF3F 71GF P2 0 8 Resolver reference 21 Resolver reference MPC PN xxxxxxxxxx Mating Connector type Spring 9 Sine encoder sine 22 Sine encoder sine PN 05JFAT SBXGF I 10 Sine encoder cosine 23 Sine encoder cosine NEE BNO 11 5V supply 24 Ground 5V 8V return Functional Ground 12 Motor temperature 25 Motor temperature PE T inal M4 sensor sensor rmin a EEE i i 13 5V supply 26 Shield i i efer to ordering information impi l ME or spade Ermina a Camping too MOE IE Mating Connector 3M Solder Plug Connector CAN and EtherCAT models only Crimping tool YRF 1070 P2 P3 P4 PN 10126 3000PE MPC PN xxxxxxxxxx EtherCAT models only Extraction tool EJ JFAJ3 3M Solder Plug Junction Shell PN 10326 52F0 008 MPC PN xxxxxxxxxx Motor Power Compan i w Bed Key for spring GU Mating Cable MPC PN xxxxxxxxxx Highlighted PN Supplied with FPRO connector 4 40 insert threads on C2 C3 C4 FLEXI PRO 4D5 FLEXI PRO 006 Pin Assignments 120 240 VAC Quick Start Guide 15 16 Introduction FLEXI PRO Mains Three Phase 120 240 VAC L L Daisy Chain RS232 EtherCAT OUT Rotary Switches or CAN s Drive addressing Circuit Breaker HS STO Sant or Fuses Safe Torque Off i Connect to 24 VDC power supply Connect to PC or use bypa
11. 10336 52F0 008 MPC PN xxxxxxxxxx MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx Secondary encoder A Logic Power 24V Input P2 Molex 26 28 AWG 24 VDC logic in Machine I F C3 MDR 20 Plug 24 28 AWG 1 11 Secondary encoder A 2 Secondary encoder B 12 Secondary encoder B Direction input Secondary encoder Z 13 Secondary encoder Z Secondary encoder 5V 14 Secondary encoder ground Digital input 8 Digital input 9 16 Digital input 10 Digital output 4 2 Ground 24 VDC return Mating Connector Type Crimp Housing PN 436450200 MPC PN 000000000 2x Crimp PN 0430300001 MPC PN xxxxxxxxxx AC Input and Regeneration P3 Phoenix 12 14 AWG Machine I F 3 4 5 6 7 ee EON 8 Digital output 5 18 Digital output 6 igital outpu igitai outpu ee WORE 8 Digital output5 18 Digital outp 9 24 VDC 19 24 VDC return 3 L3 AC Phase 3 za reses Common output Common input 4 B1 DC Bus 10 Fault relay 1 Fault relay 2 5 B2 Regen Bus Mating Connector 3M Solder Plug Connector 6 E Porn PN 10120 3000PE MPC PN xxxxxxxxxx Mating Connector PN SPC 5 6 STCL 7 62 1718520 MPC PN xxxxxxxxxx 3M Solder Plug Junction Shell PN 10320 52F0 008 MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx Brake Feedback P4 Phoenix 14 17 AWG C4 MDR
12. C1 gam 234 6 244 7 235 Feedback MMechinelF 8 Controller UF 4 Lo Fd 4 i a 193 5 E FLEXI PRO 020 FLEXI PRO 024 120 240 VAC Dimensions mm 10 Quick Start Guide FLEXI PRO Introduction D4 5 3pls for screws M4 or UN 8 163 2 FLEXI PRO 003 FLEXI PRO 006 400 480 VAC Dimensions mm _3pls for screws M4 or UN 8 FLEXI PRO 012 400 480 VAC Dimensions mm Quick Start Guide 11 Introduction FLEXI PRO FLEXI PRO Wiring and Pin Assignments Mains Daisy Chain Single Phase 120 240 VAC RS232 EtherCAT Rotary Switches or CAN Drive addressing Circuit Breaker lalalala STO or Fuses Safe Torque Off Connect to 24 VDC power supply Connect to PC or use bypass plug USB mini B cable Line Filter K l optional i ge esistor optional Connect to Host Controller Voltage reference input Pulse and direction input 6x digital inputs 3x digital outputs Magnetic 1x analog output Contactor 8 8 6 Connect to Additional IOs 2 I 5x digital inputs n am fc 3x digital outputs Z Nin 1x fault relay i c Secondary feedback Motor Feedback Functional Ground Motor Brake Rela 24 VDC Power Suppl optional PPY Motor Power Brake Output To be supplied by customer Refer to EMI Suppression in the user man
13. Company Highlighted PN Supplied with FPRO E 3M Solder Plug Junction Shell Crimping tool YRF 1130 P2 P3 P4 PN 10326 52F0 008 MPC PN xxxxxxxxxx UEM ES Mating Cable MPC PN xxxxxxxxxx Extraction tool EJ JFAJ4 P2 P3 P4 EJ JFAJ3 P5 4 40 insert threads on C2 C3 C4 FLEXI PRO 008 FLEXI PRO 010 FLEXI PRO 013 Pin Assignments 120 240 VAC Quick Start Guide 17 Introduction FLEXI PRO Mains Three Phase 120 240 VAC L L Daisy Chain RS232 Circuit Breaker MY EtherCAT our or CAN or Fuses IN Rotary Switches Drive addressing Line Filter optional STO Safe Torque Off Connect to 24 VDC power supply S or use bypass plug g lt gt Magnetic sc Contactor Connect to PC USB mini B cable Machine WF Connect to Host Controller Voltage reference input Pulse and direction input 6x digital inputs 3x digital outputs 1x analog output Regenerative Resistor optional of i Connect to Additional lOs 5x digital inputs 3x digital outputs Li a 1x fault relay Secondary feedback Functional Ground Motor Feedback Motor Brake Rela 24 VDC optional y Power Supply Motor Power Brake Output To be supplied by customer Refer to EMI Suppression in the user manual FLEXI PRO 020 FLEXI PRO 024 Servo System Wiring 120 240 VAC 3 Phase 18 Quick Start Guide FLEXI PRO Introduction EtherCAT In C5 RJ45 OR
14. Pao Daisy Chain Line Filter m 4 optional bn RS232 EtherCAT OUT Rotary Switches or CAN IN _ Drive addressing Magnetic Contactor STO Safe Torque Off Connect to 24 VDC power supply or use bypass plug Connect to PC USB mini B cable Logic PS 24 VDC 3 5A Connect to Host Controller Voltage reference input Pulse and direction input 6x digital inputs 3x digital outputs 1x analog output Regenerative Resistor optional Connect to Additional lOs 5x digital inputs 3x digital outputs 1x fault relay Secondary feedback Functional Ground Motor Feedback Motor Power Motor Brake 24 VDC 1 3A max Internal 472 300W For higher power external regen resistor is required refer to the user manual v uN Refer to EMI Suppression in the user manual FLEXI PRO 003 FLEXI PRO 006 Servo System Wiring 400 480 VAC 3 Phase 20 Quick Start Guide FLEXI PRO Introduction EtherCAT In C5 RJ45 OR CAN In C5 RJ45 EtherCAT Out C6 RJ45 CAN Out C6 RJ45 RS232 C7 4p4c RX Daisy Chain C8 0 1 IDC Female NELTRON 4401 10SR OR COXOC 304A 10PSAAA03 MPC PN 1000000000 DC Shield RXD GND GND ISO STO Safe Torque Off P1 Molex 26 28 AWG 1 24 VDC STO enable 2 Ground 24 VDC return EN EM Mating Connector type Crimp Housing PN 436450400
15. Resolver Sine Resolver Sine Resolver Cosine Resolver Cosine Resolver Reference Resolver Reference Motor Temperature Sensor Motor Temperature Sensor Optional Internal shield of each twisted pair sine cosine reference Cable Shield Feedback Wiring Incremental Encoder A Quad B Index Pulse and Halls Pin Twisted Pair Twisted Pair Twisted Pair Twisted Pair 26 Notes A C Quick Start Guide Twisted Pair User Motor Pin Signal Description Incremental Encoder A Incremental Encoder A Incremental Encoder B Incremental Encoder B Incremental Encoder Z Incremental Encoder Z Hall U Hall V Hall W Motor Temperature Sensor Motor Temperature Sensor 5 VDC O VDC Shield 35 Control Board FLEXI PRO Feedback Wiring Single Ended Halls Only Pin Twisted Pair User Motor Pin Signal Description 4 17 5 11 24 26 Hall U Hall V Hall W 5 VDC O VDC Shield Notes A C Feedback Wiring Incremental Encoder A Quad B Index Pulse and Differential Halls Pin Twisted Pair Twisted Pair 15 9 22 10 23 3 16 12 25 11 24 26 Twisted Pair Twisted Pair User Motor Pin Signal Description Incremental Encoder A Incremental Encoder A Incremental Encoder B Incremental Encoder B Hall U Hall U Hall V Hall V Hall W Hall W Motor Temperature Sensor Motor Temperature Sensor 5 VDC O VDC Shield Notes A I 36
16. Secondary encoder 5V Secondary encoder ground Digital input 7 Digital input 9 Digital input 10 Digital input 8 Digital input 11 Digital output 4 Digital output 5 24 VDC O O NX O TOI A O Digital output 6 24 VDC return Common output Common input Fault relay 1 3M Solder Plug Junction Shell Mating Connector 3M Solder Plug Connector PN 10120 3000PE MPC PN 000000000 PN 10320 52F0 008 MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx Fault relay 2 C4 MDR 26 Plug Feedback 24 28 AWG Incremental encoder A 14 Incremental encoder A SSI encoder data SSI encoder data ai Incremental encoder B 15 Incremental encoder B SSI encoder clock SSI encoder clock 4 Incremental encoder Z 16 Incremental encoder Z Hall U 17 Hall V Hall W 18 8V supply Resolver sine 19 Resolver sine JL Resolver cosine 20 Resolver cosine Resolver reference 21 Resolver reference Jl Sine encoder sine 22 Sine encoder sine 10 Sine encoder cosine 23 Sine encoder cosine 11 5v supply 24 Ground 5V 8V return sensor 12 Motor temperature 25 5V su
17. encoder aA 4 C7 4p4c 6 GND output Z output Z 5 5 1 RX 7 7 25 Ground 6 6e 2 GNDISO 8 8 Analog input 1 26 Analog input 1 7 FGND 7 FGND 3 ITX 9 9 Direction input 27 Direction input 8 8 4 10 5 ca Secondary encoder B Secondary encoder B i ESSI 10 Ground 28 Pulse input Secondary encoder A 11 Pulse input 29 Ground Secondary encoder A STO Safe Torque Off U P1 Molex 26 28 AWG iF 13 Ground 31 Digital input 3 24 VDC STO enable T 14 Digital input 4 32 Digital input 5 2 Ground 24 VDC return FF 2 15 Digital input 6 33 Digital output 2 L 7 16 Digital output 3 34 17 35 Analog input 2 Mating Connector type Crimp T Housing PN 436450400 USB 18 Analog input 2 36 Analog output MPC PN xXXXXXXXXXX car C1 Mini B Mating Connector 3M Solder Plug Connector 4x Crimp PN 0430300001 ESS y i PN 10136 3000PE MPC PN xxxxxxxxxx MPC HN 3M Solder Plug Junction Shell Wired STO 9 Er PN 10336 52F0 008 MPC PN xxxxxxxxxx MPC PN xxxxxxxxxx 4 a Mating Cable MPC PN xxxxxxxxxx Motor SS o UE Machine I F oe gt In P2 JST J300 16 AWG 3 MU achine E Sa C3 MDR 20 Plug 24 28 AWG PE Functional Ground gt U YC 4 Sa 1 Secondary encoder A 11 Secondary encoder A i Pulse input Pulse input 2 E S E 2 Secondary encoder B 12 Secondary encoder B 4 W Motor Phase W Y EEE I 3 E dor Direction input Direction in
18. finding parameters are set correctly for the application Check that the wiring to the encoder is correct Check that all signals to the P amp D inputs are properly connected to the drive Check the battery voltage and feedback wiring Make sure the motor did not move ata high velocity during encoder initialization Check the wiring of the motor phases Quick Start Guide FLEXI PRO Drive Status Display Light Type Name Description Action Required r28 Fault Resolver The drive could not detect the Check resolver wiring and Initialization Failed proper gain setting or sampling gain value point for the sine cosine signals r29 Fault Absolute Encoder An error bit indicating a battery Replace battery then reset Battery Low problem was detected in data drive If battery is replaced Voltage from the drive while drive is on position information is retained r34 Fault PFB Off Checksum The calculated checksum of the If required by the application Invalid PFB backup data does not home the machine match the expected checksum r35 Fault PFB Off Data Multiturn data of the PFB cannot If required by the application Mismatch be restored due to axis home the machine movement r36 Fault No PFB Off Data PFB backup memory is empty If required by the application home the machine r37 Fault Encoder Phase In normal incremental encoder Set MENCAOBFILT to 0 to Error operation quadrature inputs A remove the filter on A and B and B are 90 degrees
19. half the value of those used to declare a fault Although the system may continue to function these values indicate the existence of a problem which may worsen over time Communication problem between the drive and the EnDat encoder Mismatch between calculated and actual encoder guadrature information The sine cosine calibration parameters are out of range This fault is related to resolver and sine encoder feedback Action Reguired Increase the value of the regen resistor Turn off the specific input Make sure the power brake load cables are connected properly and are not damaged Replace the power brake the motor Check whether a regen resistor is reguired for the application The drive probably needs repair Contact technical support The drive probably needs repair Contact technical support May occur during power off If occurs otherwise contact technical support Check for a short circuit on the motor connection Check for excessive overshoot in the current loop Check the encoder and associated hardware These values suggest some degradation in either electronics e g encoder drive or wiring e g increased wire resistance increased leakage between wires The problem must be analyzed and repaired Check that the data and clock signals to the EnDat encoder are connected properly The cable must be shielded Check the feedback device wiring Check that the corr
20. operation the display shows a steadily lit single digit indicating the operation mode Display Name Description Drive Drive Enabled Disabled Drive enabled a 0 OPMODE O Serial velocity control mode a A 1 OPMODE 1 Analog velocity control mode a a 2 OPMODE 2 Serial current control mode 2 Z 3 OPMODE 3 Analog current control mode 3 3 4 OPMODE 4 Master slave gearing control mode H H 8 OPMODE 8 Position control mode A A Quick Start Guide 59 Drive Status FLEXI PRO Display Name Description Drive Drive Enabled Disabled E Ember Mode Drive is in Ember mode firmware is being downloaded to the drive Warning and Fault Codes The following table will help you interpret the warning and fault codes and respond appropriately m Display is the code that appears on the drive s 7 segment display m Light distinguishes between a steadily lit character for warnings or a flashing character for faults Type specifies a warning or a fault Name is the text message displayed in FLEXI SUITE Display Light Type Flash Fault 1 Fault 5 Fault A4 Fault b Flash Fault b Steady Warning b1 Fault C1 Fault e Flash Fault E Flash Fault e101 Fault 60 Name Watchdog Fault Not Configured Motor Setup Failed CAN Supply Fault Drive Locked Tamagawa Battery Low Voltage PLL phase locked loop Synchronization Failed CAN Heartbeat Lost Parameter Memory Checksum Failure Failure Writi
21. out of signals If problem persists it phase The phase error occurs may be due to a faulty when edge transition is detected encoder simultaneously on the A and B signals r38 Fault Differential Halls Line break in differential Hall Make sure HALLSTYPE Line Break sensors matches the Hall sensors in use single ended or differential Check whether all signals from the differential Hall sensors are properly connected to the drive r4 Fault A B Line Break One of the primary feedback Check whether all signals signals is not connected This from the primary feedback fault occurs in incremental device are properly connected encoder resolver and sine to the drive encoder feedback types r5 Fault Index Line Break Encoder index line is not Check that the drive is connected configured for working with the index signal using MENCTYPE and check if the index signal is connected r6 Fault Illegal Halls The drive has detected either Check that the Hall signals 000 or 111 state on the Hall are all properly connected feedback signals While turning the motor read the Halls state using HALLS to see which signal is not connected If the feedback type is Tamagawa check that the feedback wiring is correct r8 Fault A B Out of Range Feedback analog signal is out of Check the amplitudes of the Ouick Start Guide range This fault is related to resolver and sine encoder feedback The drive checks that the amplitudes of the sine and cosine sig
22. 00 480 VAC Logic Power 24V Input P2 Logic Power 24V uses interface P2 on all FLEXI PRO 400 480 VAC models This interface is used to connect an external power supply 24V 3 15A max that provides the logic voltage to the control board and to the motor brake circuit GND 24V h Logic Power 24V Interface Pin Pin Label Function 1 24V Logic In 2 GND 24 VDC Return Quick Start Guide 53 Power Board 400 480 VAC FLEXI PRO AC Input and Regeneration Resistor P3 AC Input and Regen Resistor use interface P3 on all FLEXI PRO 400 480 VAC models 1 Connect the AC input voltage ground wire to the PE terminal located on the FLEXI PRO front panel Use an M4 ring or spade terminal Connect L1 L2 and L3 for the AC power input If the application requires a regeneration regen resistor connect the regen resistor between terminals B1 and B2 AC Input and Regeneration Resistor Interface Pin Pin Label Function 1 L1 AC Phase 1 2 L2 AC Phase 2 3 L3 AC Phase 3 4 B1 DC Bus 5 B2 Regen Bus 6 B3 DC Bus 54 Quick Start Guide FLEXI PRO Power Board 400 480 VAC Brake P4 Brake uses interface P4 on all FLEXI PRO 400 480 VAC models This is the power output for the electric motor brake system P3 Brake Interface Pin Pin Label Function 1 BR Motor Brake 2 BR Motor Brake Quick Start Guide 55 Power Board 400 480 VAC FLEXI PRO Motor P5 Motor uses interface P5 on
23. 1 F EtherCAT In EtherCAT Out C8 0 1 IDC Female C2 MDR 36 Plug 24 28 AWG C5 RJ45 C6 RJ45 NELTRON 4401 10SR OR _ 2 24 VDC COXOC 304A 10PSAAA03 7 Common output Common input OR OR MPC PN xxxxxxxxxx 2 Digital output 1 Digital input 2 CAN In CAN Out 1 igital outpu igital inpu Digital input 1 C5 RJ45 C6 RJ45 2 igital inpu Equivalent encoder Equivalent encoder NI CAN 2 output A output A 2 CANL 2 CANL 5 Equivalent encoder Equivalent encoder 3 FGND 3 FGND RS232 5 TXD g output B output B 4 E C7 4p4c 6 6 Equivalent encoder Equivalent encoder output Z output Z 5 ax IA fe fa foso fs 7 7 FGND 3 TX a 8 Analog input 1 Analog input 1 8 8 4 9 Direction input Direction input Secondary encoder B Secondary encoder B Ground Pulse input Secondary encoder A Pulse input Ground STO Safe Torque Off P1 Molex 26 28 AWG 30 24 VDC STO enable y 13 Ground Digital input 3 Ground 24 VDC return 14 Digital input 4 Digital input 5 EN 1 El iS Digital input 6 33 Digital output 2 4 a E 16 Digital output 3 34 Mating Connector type Crimp AE Analog input 2 Housing PN 436450400 5 18 Analog input 2 Analog output MPC PN xxxxxxxxxx 4x Crimp PN 0430300001 Mating Connector 3M Solder Plug Connector PN 10136 3000PE MPC PN xxxxxxxxxx MPC PN xxxxxxxxxx Wired STO 3M Solder Plug Junction Shell PN
24. 11 17 Digital output 4 Housing PN F32FSS 04V KX 7 MPC PN xxxxxxxxxx Digital output 5 18 i Digital output 6 4x Crimp PN SF3F 71GF P2 0 24 VDC 19 24 VDC return Common output _ E Common input 10 Fault relay 1 20 Fault relay 2 Mating Connector 3M Solder Plug Connector wes i N PN 10120 3000PE MPC PN xxxxxxxxxx AC Input and 3 H 3M Solder Plug Junction Shell Regeneration TE PN 10320 52F0 008 MPC PN xxxxxxxxxx P3 JST J300 18 AWG i Mating Cable MPC PN xxxxxxxxxx DC Bus T Regen Bus 2 my Feedback l AC Phase 1 i C4 MDR 26 Plug 24 28 AWG MPC PN xxxxxxxxxx Mating Connector type Spring PN 04JFAT SBXGF I MPC PN xxxxxxxxxx AC Phase 2 a Incremental encoder A 14 Incremental encoder A Logic AC Phase 1 2 ed SSI encoder data l ES encoder data 7 J Logic AC Phase 2 2 Incremental encoder B 115 Incremental encoder B Mating Connector Type Crimp 4 SSI encoder clock n T ssi encoder clock Housing PN F32FSS 06V KX i 5 3 Incremental encoder ze En 146 Incremental encoder ZE MPC PN xxxxxxxxxx sa Bag gt 6x Crimp PN SF3F 71GF P2 0 4 Hall U haz Hall V MPC PN xxxxxxxxxx 5 Hall W 18 8V supply _ Mating Connector Type Spring all zi 7 PN 06JFAT SBXGF I 6 Resolver
25. 26 Plug 24 28 AWG E e 2 SS encoder cook _ SSl encoder cook 1 B Motor Brake B 2 R Motor Brake Mating Connector PN SPC 5 2 STCL 7 62 1718481 MPC PN xxxxxxxxxx 3 Incremental encoder Z Functional Ground 4 HallU PE Terminal M4 S5 Hall W 18 8V supply M4 ring or spade terminal 6 Resolver sine 7 Resolver cosine Motor 8 Resolver reference 121 Resolver reference P5 Phoenix 12 14 AWG 9 Sine encoder sine Motor Phase U 11 5V supply 24 Ground 5V 8V return 1 12 Motor temperature 25 Motor temperature sensor sensor 13 1 U Mating Connector PN SPC 5 3 STCL 7 62 1718494 5V supply 26 Shield MPC PN Xxxxxxxxxx Bolero ordering information Mating Connector 3M Solder Plug Connector CAN and EtherCAT models only PN 10126 3000PE MPC PN xxxxxxxxxx EtherCAT models only 3M Solder Plug Junction Shell 7 PN 10326 52F0 008 MPC PN xxxxxxxxxx Motor Power Company Crimping tool Molex 0638190000 P1 P2 Mating Cable MPC PN xxxxxxxxxx Highlighted PN Supplied with FPRO 4 40 insert threads on C2 C3 C4 FLEXI PRO 012 Pin Assignments 400 480 VAC Quick Start Guide 23 Control Board FLEXI PRO 2 Control Board Overview The control board has the same interfaces on all FLEXI PRO models USB Communication C1 Exception AP models do not have a USB port Controller I Os C2 Machine I Os C3 M
26. MPC PN xxxxxxxxxx 3M Solder Plug Junction Shell PN 10320 52F0 008 MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx ELI Fault relay 1 Fault relay 2 Feedback Incremental encoder A SS encoder data SSI encoder data Incremental encoder B Incremental encoder B 15 l ssi encoder clock ss encoder clock i Incremental encoder Z Hall U Hall W Resolver s sine Incremental encoder Z Hall V 8V supply Resolver sine Resolver cosine Resolver cosine Resolver reference Resolver reference dao Sine encoder sine Sine encoder sine 10 Sine encoder cosine Sine encoder cosine Ground 5V 8V return 25 Motor temperature sensor Shield Mating Connector 3M Solder Plug Connector PN 10126 3000PE MPC PN xxxxxxxxxx 3M Solder Plug Junction Shell 11 5V supply 12 Motor temperature sensor 13 5V supply Refer to ordering information CAN and EtherCAT models only PN 10326 52F0 008 MPC PN xxxxxxxxxx EtherCAT models only Mating Cable MPC PN xxxxxxxxxx Motor Power Company Crimping tool Molex 0638190000 P1 Highlighted PN Supplied with FPRO 4 40 insert threads on C2 C3 C4 FLEXI PRO 020 FLEXI PRO 024 Pin Assignments 120 240 VAC Quick Start Guide 19 Introduction FLEXI PRO Mains Three Phase Max 528 VAC L L Circuit Breaker or Fuses
27. MPC PN xxxxxxxxxx AC Phase 1 L2 AC Phase 2 L3 AC Phase 3 Mating Connector PN SPC 5 3 STCL 7 62 1718494 MPC PN xxxxxxxxxx Motor P4 Phoenix 10 11 AWG Functional Ground Motor Phase U Motor Phase V Motor Phase W Mating Connector PN SPC 5 4 STCL 7 n 1718504 MPC PN 000000000 Regeneration P5 Phoenix 14 AWG Regen Bus 2 B1 DC Bus Mating Connector PN SPC 5 2 STCL 7 62 1718481 MPC PN 000000000 Functional Ground PE Terminal M4 M4 ring or spade terminal Mating Connector 3M Solder Plug Connector PN 10136 3000PE MPC PN xxxxxxxxxx 3M Solder Plug Junction Shell PN 10336 52F 0 008 MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx Machine I F C3 MDR 20 Plug 24 28 AWG 1 Secondary encoder A 11 Secondary encoder A Controller I F Pulse input Pulse input 2 Secondary encoder B 12 Secondary encoder B Direction input Direction input E E Secondary encoder Z 13 Secondary encoder Z 4 Secondary encoder 5V 14 Secondary encoder ground Y 5 Digital input 7 15 Digital input 8 2 6 Digital input 9 16 Digital input 10 7 Digital input 11 17 Digital output 4 8 Digital output 5 18 Digital output 6 9 24 VDC 19 Pos Common output 24 VDC return cv Common input 20 Mating Connector 3M Solder Plug Connector PN 10120 3000PE
28. MPC PN xxxxxxxxxx Secondary encoder Z 4x Crimp PN SJ4F 71GF M3 0 MPC PN xxxxxxxxxx Regeneration 1 P3 JST J400 14 AWG 1 B1 DC Bus 2 Regen Bus Mating Connector Type Crimp Housing PN J42FSC 02V KX MPC PN xxxxxxxxxx 2x Crimp PN SJ4F 71GF M3 0 1 MPC PN xxxxxxxxxx Main AC Input P4 JST J400 14 AWG Mating Connector Type Crimp Housing PN J43FSS 03V KX MPC PN xxxxxxxxxx 3x Crimp PN SJ4F 71GF M3 0 1 MPC PN xxxxxxxxxx Machine I F Feedback C4 MDR 26 Plug 24 28 AWG 1 14 Incremental encoder A di 2 Incremental encoder B 15 Incremental encoder B HalW Hall W 8V supply Resolver sine 19 Resolver sine Resolver cosine Resolver reference Sine encoder sine 0 Sine encoder cosine 4 Feedback Logic Power AC Input P5 JST J300 16 AWG 1 LiC AC Phase 1 2 L2C AC Phase 2 Mating Connector type Crimp Housing PN F32FSS 02V KX MPC PN xxxxxxxxxx 2x Crimp PN SF3F 71GF P2 0 MPC PN xxxxxxxxxx 11 5V supply Ground 5V 8V return 12 Motor temperature 25 Motor temperature sensor sensor 13 5V supply 26 Shield Mating Connector 3M Solder Plug Connector Crimping tool Molex 0638190000 P1 UU MMPS EN essers Functional Ground PE Terminal M4 Refer to ordering information CAN EtherCAT 1 l M4 ring or spade terminal GAN aNg P A OERO EtherCAT models only Motor Power
29. PRO Control Board Feedback Wiring Sine Encoder with Index Pin Twisted Pair User Motor Pin Signal Description 9 22 10 23 3 16 11 24 26 Note B Twisted Pair Twisted Pair Twisted Pair Sine Encoder Sine Sine Encoder Sine Sine Encoder Cosine Sine Encoder Cosine Sine Encoder Z Sine Encoder Z 5 VDC O VDC Shield Feedback Wiring Sine Encoder with Index and Halls Pin Twisted Pair User Motor Pin Signal Description 9 22 10 23 3 16 A 17 5 11 24 26 Note B Quick Start Guide Twisted Pair Twisted Pair Twisted Pair Sine Encoder Sine Sine Encoder Sine Sine Encoder Cosine Sine Encoder Cosine Sine Encoder Z Sine Encoder Z Hall U Hall V Hall W 5 VDC O VDC Shield 39 Control Board FLEXI PRO 40 Feedback Wiring Sick 5V Hiperface Protocol and Sine Signal Pin Twisted Pair User Motor Pin Signal Description 1 14 9 22 10 23 11 24 26 Note B Twisted Pair Twisted Pair Twisted Pair SSI Data SSI Data Sine Encoder Sine Sine Encoder Sine Sine Encoder Cosine Sine Encoder Cosine 5 VDC O VDC Shield Feedback Wiring Sick 8V Hiperface Protocol and Sine Signal Pin Twisted Pair User Motor Pin Signal Description 1 14 9 22 10 23 18 24 26 Note B Twisted Pair Twisted Pair Twisted Pair SSI Data SSI Data Sine Encoder Sine Sine Encoder Sine Sine Encoder Cosine S
30. RLY2 RS422 RECEIVER pe E AWPULSEs AMD ii DES Besos i EYDIREGTION SECONDARY ENCODER a Za OR PULSE amp DIRECTION Machine Interface Wiring AP AF Models Quick Start Guide 31 Control Board FLEXI PRO mn CONN INPUT SOURCE MODE 10nF Puma wr 10 lt HIGH y NK EE lata D E e ANIN1 INPUT 10V COMN GND OUT_COMM 1 BW eg A 8 HIGH OUTPUT SOURCE MODE oars lt i o TX Low i ANIN2 OPTIONAL 10V 24V NND 16 2 10nF eels E cwl GND OUTPUT SINK MODE RS422 TRANSMITER S_ eb Xx NO E EQVIVALENT ENCODER OUTPUT OUT COMM ci pa 26 WD RS422 RECEIVER e YSA gt DIRECTION a O Direcmon 8 PULSE amp DIRECTION GND R 28h PULSE A OR SECONDARY ENCODER E sax Machine Interface Wiring EC PN Models 32 Quick Start Guide FLEXI PRO Control Board Motor Feedback C4 Motor Feedback uses interface C4 on all FLEXI PRO models Wire the motor feedback interface according to the type of feedback device to be used in your application Refer to the guidelines following the pinout table below Pins 1 2 14 and 15 have dual functionality Pin 25 for the motor temperature sensor is connected internally in the drive to FLEXI PRO ground Unused pins must remain unwired Fr 14 13 26 Motor Feedback Interface Pin Function Pin Function 1 Incremental encoder A 14 Incremental encoder A SSI encoder data SSI encoder data 2 Incremental encoder B
31. STO Safe Torque Off eas faa P1 Molex 26 28 AWG 24 VDC STO enable Ground Pulse input Secondary encoder A all o 31 Digital input 3 14 15 16 17 14 Digital input 4 32 Digital input 5 Digital input 6 33 Digital output 2 Make niy Digital output 3 34 Mating Connector type Crimp Analog input 2 36 Analog output Housing PN 436450400 MPC PN xxxxxxxxxx 4 Mating Connector 3M Solder Plug Connector MPC PN xxxxxxxxxx Y SM Solder Plug Junction Shell Wired STO PN 10336 52F0 008 MPC PN xxxxxxxxxx MPC PN xxxxxxxxxx Te a i Mating Cable MPC PN xxxxxxxxxx g 3 Wr Motor Machine I F P2 JST J400 14 AWG C3 MDR 20 Plug 24 28 AWG U Motor Phase U ge Pulse input Secondary encoder B wa 2 Secondary encoder B 12 Secondary encoder Z 13 4 Secondary encoder 5V 14 Secondary encoder ground 5 Digital input 7 15 Digital input 8 5 Digital input 18 Digiatipuito Digital output 4 8 Digitaloutput5 18 Digital output 6 19 24 VDC return a Common output Common input 10 Fault relay 1 20 Fault relay 2 Mating Connector 3M Solder Plug Connector PN 10120 3000PE MPC PN 0000000000 3M Solder Plug Junction Shell PN 10320 52F0 008 MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx Direction input Controller I F Mating Connector Type Crimp Housing PN J43FSS 04V KX
32. Shield Notes B G Feedback Wiring Tamagawa 17 bit Multi Turn Pin Twisted Pair User Motor Pin Signal Description 1 14 11 24 26 Twisted Pair Serial Data Serial Data 5 VDC O VDC Shield Battery Voltage Battery Ground Notes B F H Quick Start Guide FLEXI PRO Control Board Fieldbus Devices C5 and C6 All FLEXI PRO models have the same RJ45 connectors CANopen Communication 1 Be sure the required EDS file is installed in the controller You can download the file from the Motor Power Company website or contact Technical Support Termination Resistor Switch 2 Note the Termination Resistor switch located on the top of the drive next to the daisy chain connector C8 Use a small slotted screwdriver or similar tool to set the switch position m Towards T default 1209 termination resistor not in use m Away from T Used when the drive is the last drive in a chain The drive provides the 120Q termination resistor between CAN high and CAN low 3 Using any RJ45 cables m Connect the host to the drive on interface C5 m Connect the next node to interface C6 EtherCAT Communication 1 Be sure you have installed the required XML file You can download the file from the Motor Power Company website or contact Technical Support 2 Using any RJ45 cables m Connect the host to the drive on interface C5 m Connect the next node to interface C6 Quick Start Guide 43 Contr
33. al display provides various indications of drive operation such as operation modes drive enable status and fault conditions For more information refer to the section Drive Status Drive Configuration 1 In FLEXI SUITE select the Setup Wizard option from the navigation menu 2 Follow the prompts to configure the FLEXI PRO for your particular motor and application Note The wizard performs a basic drive configuration For more advanced configuration options and procedures refer to the user manual 58 Quick Start Guide FLEXI PRO Drive Status 6 Drive Status The 7 segment display provides various indications of drive status such as operation modes drive enable status and fault conditions The display uses the following conventions Decimal point Enable Disable status if displayed the drive is enabled Steadily lit digit Operation mode OPMODE Steadily lit letter Warning Sequential display of letters and digits Fault with some exceptions Flashing Fault Other Status Indications W During the motor setup procedure three characters are displayed in sequence At1 m The state of the software and hardware limit switches are indicated by a sequential display of characters L1 L2 L3 L4 m During the encoder initialization a digit flashing at half second intervals indicates the operation mode OPMODE currently in effect Normal Operation Codes After the drive is configured and ready for
34. all 400 480 VAC models Motor Interface Pin Pin Label Function 1 U Motor Phase U 2 V Motor Phase V 3 W Motor Phase W 56 Quick Start Guide FLEXI PRO Software 5 Software FLEXI SUITE Installation Use FLEXI SUITE software to configure the drive for your application 1 Install FLEXI SUITE on the host computer 2 When installation is complete start FLEXI SUITE pai Flexi PRO Software Suite o 0 CDHD 0084DAF1 00 Orive Peak Current 25 4 A 18Arms Soria Nemo PE AN Drive Continuous Current 8 4 A GArms FPGA Version Power Up 1 After completing the hardware connections turn on power to the drive The first time the drive is connected to the host computer on the USB port Windows detects the device and displays a Found New Hardware wizard Browse to and select the Drivers folder The path will vary depending on the computer s operating system and the location selected for software installation for example m Program Files x86 Motor Power Company FLEXI SUITE Drivers m Program Files Motor Power Company FLEXI SUITE Drivers The wizard will automatically select and install the driver file 3 Look at the 7 segment display on the FLEXI PRO front panel Upon initial power up the status display shows a flashing e indicating that drive parameters are not yet configured This fault will be cleared once the drive is configured Quick Start Guide 57 Software FLEXI PRO LO The digit
35. and save the parameters Contact technical support Contact technical support Quick Start Guide FLEXI PRO Drive Status Display Light e105 e106 e107 e108 e109 e120 e121 F1 F2 F3 Fb1 Fb2 Steady Type Fault Fault Fault Fault Fault Fault Fault Warning Fault Fault Fault Fault Fault Ouick Start Guide Name Self Test Fail Control EEPROM Fault Power EEPROM Fault Vbus Measure Circuit Fail Current Sensors Offset Out of Range FPGA Version Mismatch Internal Error Foldback Drive Foldback Motor Foldback Stall Fault Fieldbus Target position exceeds velocity limit Fieldbus Target position exceeds acceleration deceleration limits Description The power up self test failed Fatal fault drive cannot be operated A problem accessing the EEPROM on the control board Fatal fault drive cannot be operated A problem accessing the EEPROM on the power board Fatal fault drive cannot be operated A failure occurred in the circuit that measures bus voltage The calculated offsets for the current sensors are out of range FPGA version does not match the firmware version Internal error due to an endless while loop or a numerical issue Drive fold current dropped below the drive fold current warning threshold MIFOLDWTHRESH Or motor fold current dropped below the motor fold current warning thre
36. as the ground path for the outputs Note AP AF Models The 24 VDC supply and return can be connected on either the Controller interface C2 or the Machine interface C3 but it is not necessary to connect it to both Notes EC PN Models Common output on the Controller interface C2 and the Machine interface C3 are connected internally Common input on the Controller interface C2 and the Machine interface C3 are connected internally m User can connect outputs as source or sink m User can connect inputs as source or sink m Refer to the Machine Interface Wiring schematic diagram for EC PN Models below and the FLEXI PRO System Wiring Pin Assignments diagram for EC PN Models at the end of this manual 10 20 Ouick Start Guide 29 Control Board FLEXI PRO Pin Function 1 Oy N 00 Machine I O Interface Secondary encoder A Description High side of the secondary encoder input signal A RS422 Pulse input High side of the pulse Secondary signal High side of the encoder B Secondary encoder input Direction input Secondary encoder Z Secondary encoder 5V Digital input 7 Digital input 9 Digital input 11 Digital output 5 24 VDC Common output Signal B RS422 High side of the direction Signal High side of the secondary encoder input index RS422 5 VDC supply for the secondary encoder Opto isolated programmable digital i
37. continuously sends the A B and Z signals On every power up the phase find procedure must be executed Encoder backup battery is external to the FLEXI PRO drive Voltage must be more than 3 6 VDC The recommended battery is lithium ER3V 3 6V 1000mAh manufactured by Toshiba Corp G A serial digital data encoder A single turn absolute encoder transmits absolute position data at 17 bit per revolution 131 072 count per rev H A serial digital data encoder This is a full absolute encoder with 17 bit per revolution resolution and xx bit multi turn counting When the battery is disconnected it functions as a full absolute encoder that transmits absolute position data at 17 bit per revolution I To use differential Halls with A quad B and index connect the Halls to the Machine interface as follows Hall U to Machine I F pin 1 Hall U to Machine I F pin 11 Hall V to Machine I F pin 2 Hall V to Machine I F pin 12 Hall W to Machine I F pin 3 Hall W to Machine I F pin 13 Connect the encoder A B I and power supply to the Motor Feedback connector Use the FLEXI SUITE Motor Setup procedure and the Feedback screens to define motor feedback type resolution and other parameters 34 Quick Start Guide FLEXI PRO Control Board Feedback Wiring Resolver Pin Twisted User Motor Pair Pin 6 Twisted 19 Pair 7 Twisted 20 Pair 8 Twisted ji Pair 12 Twisted 25 Pair 24 Ground 26 Note A Signal Description
38. dditional lOs 5x digital inputs 3x digital outputs 1x fault relay Secondary feedback Motor Feedback Functional Ground 24 VDC Power Supply Motor Power Brake Output To be supplied by customer Refer to EMI Suppression in the user manual FLEXI PRO 4D5 FLEXI PRO 006 Servo System Wiring 120 240 VAC 1 Phase 14 Quick Start Guide FLEXI PRO Introduction Controller I F Daisy Chain C2 MDR 36 Plug 24 28 AWG EtherCAT In EtherCAT Out C8 0 1 IDC Female _ a 1 24 VDC return 19 24 VDC C5 RJ45 C6 RJ45 NELTRON 4401 10SR OR Ten ae a COXOC 304A 10PS 03 Common output Common input OR OR MPC PN xxxxxxxx 2 Digital output 1 20 Digital input 2 CAN In CAN Out 1 DC Shield 3 Digital input 1 21 C5 RJ45 C6 RJ45 2 Equivalent encoder 22 Equivalent encoder output A output A 1 CANH 1 CANH 3 RXD z m 5 Equivalent encoder 23 Equivalent encoder 2 CANL 2 CANL 4 GND 2 g output B output B 3 FGND 3 FGND RS232 5 TXD 6 Equivalent encoder 24 Equivalent
39. e detected HIPERFACE device is not supported HIPERFACE encoder type information is not recognized Phase difference is reguired to initialize the commutation angle Action Reguired Check the parameters used for setting up the eguivalent encoder output If using a sine encoder check the ENCOUTRES parameter settings Check if the ambient temperature exceeds the drive specification Otherwise contact technical support Check if the ambient temperature exceeds the drive specification Otherwise contact technical support Check if the ambient temperature exceeds the drive specification Otherwise contact technical support Check if the ambient temperature exceeds the drive specification Otherwise contact technical support Check that the main AC voltage supply is connected to the drive and is switched on The under voltage limit can be read with the UVTHRESH command Check that the main AC voltage supply is connected to the drive and is switched on Verify that the setting of UVMODE is correct Enter the correct resolution MENCRES value Contact technical support Contact technical support Perform phase find Quick Start Guide FLEXI PRO Servo Drive Quick Start Guide Revision 5 6 Motor Power Company s r l Via Leonardo Da Vinci 4 42024 Castelnovo Sotto Reggio Emilia Italia Tel 39 0522 682710 Fax 39 0522 683552 Website www motorpowerco com
40. ect encoder type MENCTYPE is selected Re execute the sine cosine calibration process 63 Drive Status FLEXI PRO Display Light r16 r17 r18 r19 r20 r21 r23 r24 r25 r26 r27 64 Type Fault Fault Fault Fault Fault Fault Fault Fault Fault Fault Fault Name Feedback 5V Over Current Secondary Feedback Index Break Secondary Feedback A B Line Break Secondary Feedback 5V Over Current Feedback Communication Error Nikon Encoder Operational Fault Phase Find Failed Tamagawa Init Failed Pulse amp Direction Input Line Break Tamagawa Abs Operational Fault Motor Phases Disconnected Description The current supplied by the drive on the 5V primary encoder supply has exceeded the preset current limit The drive allows this fault to occur up to 3 times in succession After 3 faults the drive forces a delay of 1 minute before it can be reenabled Secondary encoder index line not connected One of the secondary feedback Signals is not connected The preset current limit for current supplied by the drive on the 5 V secondary encoder supply has been exceeded Communication with the feedback device did not initialize correctly Communication with the Nikon MAR A40A feedback device did not initialize correctly Commutation initialization has failed This fault occurs in systems that do not have commutation inf
41. gital output 1 Digital input 1 Equivalent encoder output A Equivalent encoder output B Equivalent encoder output Z Analog input 1 Direction input Secondary encoder B Quick Start Guide Description AP AF Models Return of the user supplied 24 VDC 19 EC PN Models Opto isolated programmable digital output Read using OUT1 Opto isolated programmable digital input Read using IN1 Low side of the equivalent encoder output signal A RS422 Low side of the equivalent encoder output signal B RS422 Low side of the equivalent 24 encoder output index RS422 25 High side of the 26 differential analog command input 10 VDC High side of the direction Signal RS422 or High side of the down count signal High side of the Secondary encoder input Signal B RS422 27 36 Pin Function 24 VDC Common input Digital input 2 Equivalent encoder output A Equivalent encoder output B Equivalent encoder output Z Ground Analog input 1 Direction input Secondary encoder B Description AP AF Models User supplied 24V for I O biasing EC PN Models Opto isolated programmable digital input Read using IN2 High side of the equivalent encoder output signal A RS422 High side of the equivalent encoder output signal B RS422 High side of the equivalent encoder output index RS422 Digital ground Low side of the differe
42. hree Phase 120 240 L L VAC 10 15 50 60 Hz AC Input Power Supply Input Three Phase 400 L L VAC 10 15 50 60 Hz Input Three Phase 480 L L VAC 10 15 50 60 Hz 24 VDC input for control board power supply Quick Start Guide FLEXI PRO Contents 1 Introduction 7 FLEX PRO DOCUMenta ON scans e E ARIA HYDD O 7 SMC AAA A A A OS 7 Required Hardware and TOO Sita 7 Required Computer SISTE iaa 8 ELEXE PRO Installation Procedur ew Gu GW yn EA 8 FLEXT PRO DIMENSIONS and MOUNTING ri e 9 FLEXI PRO Wiring and Pin Assignments comica nds 12 2 Control Board 24 OV CUNO Co lies ias 24 Controller I Oc Ce E E E E A E E E 24 Controller Interface Wisin a 27 Machine l79s ES sta a cana 29 Machine Internac WIN Oasis rindas 31 MOCtOrFeedback C4 trata aaa 33 Feedback Wiring Guideline S ana 34 RIeldbus DEVICES C5 and Co eni A E A AS 43 CANoOpen ComnnunicauoTiie en ND AA o 43 EtnerCAlr Communication a as 43 most Compuler C C o ISA GG RR ORAR 44 Bay Cholnr Co lilla einen 45 Drive Address SWITCHES anu Y T 46 3 Power Board 120 240 VAC 47 OVCNICW AC rata ari YY Y Y NF NN Y 47 Sale TO due Of STO Patada 47 Mi a YR ai 48 Regeneration RESISEOR PS eu rai ini da ddn oe DA ote dwU UI God 49 AC Input P5 APS iPS uan a e a 50 4 Power Board 400 480 VAC 52 OV Ch VIO Wii da Garber 52 Sa Torque Off LU LO JP Eu iad a eta 52 Logic POWer 24V Thput P ee ands eae teas GN rie O cana 53 AC Input and Regeneration Resistor P3
43. ill not install it automatically FLEXI PRO Installation Procedure Perform the following steps to install and setup a FLEXI PRO system 1 Mount the FLEXI PRO 2 Make all electrical connections m Controller I Os and or Machine I Os Motor feedback Fieldbus devices if required Safe torque off STO or bypass using jumpers Motor Motor brake if required Regeneration resistor if required AC input voltage Set the drive address using the rotary switches Connect the drive to the PC Power up the drive and the PC Install FLEXI SUITE software Using FLEXI SUITE configure and test the drive a a 8 Quick Start Guide FLEXI PRO Introduction FLEXI PRO Dimensions and Mounting Using the bracket on the back of the FLEXI PRO mount the FLEXI PRO on a grounded conductive metal panel D4 7 _ 2pls for screws M4 or UN 8 152 4 Cosa FLEXI PRO 1D5 FLEXI PRO 003 120 240 VAC Dimensions mm Note FLEXI PRO 003 has fan DA4 6 _ 2 pls for screws M4 or UN 8 Ay at CAA noun FLEXI PRO 4D5 FLEXI PRO 006 120 240 VAC Dimensions mm Ouick Start Guide Introduction FLEXI PRO 4 6 2pls for screws M4 or 8 i i 173 185 194 3 l FLEXI PRO 008 FLEXI PRO O10 FLEXI PRO 013 120 240 VAC Dimensions mm D4 5 3 pls for screws M4 or 48 AA A a ET par I t AN AR ef amp Lo IE
44. ine Encoder Cosine 8 VDC O VDC Shield Feedback Wiring Heidenhain EnDat 2 x Communication Only Pin Twisted Pair User Motor Pin Signal Description 1 14 2 15 11 24 26 Note B Twisted Pair Twisted Pair SSI Data SSI Data SSI Clock SSI Clock 5 VDC O VDC Shield Quick Start Guide FLEXI PRO Control Board Feedback Wiring Heidenhain EnDat 2 x with Sine Cosine Pin Twisted Pair User Motor Pin 1 14 2 15 9 22 10 23 11 24 26 Note B Twisted Pair Twisted Pair Twisted Pair Twisted Pair Signal Description SSI Data SSI Data SSI Clock SSI Clock Sine Encoder Sine Sine Encoder Sine Sine Encoder Cosine Sine Encoder Cosine 5 VDC O VDC Shield Feedback Wiring Nikon 17 bit Single Turn Pin Twisted Pair User Motor Pin Signal Description 1 14 11 24 26 Notes B Twisted Pair Serial Data Serial Data 5 VDC O VDC Shield Feedback Wiring Nikon 17 bit Multi Turn Pin Twisted Pair User Motor Pin Signal Description 1 14 11 24 26 Twisted Pair Notes B F Quick Start Guide Serial Data Serial Data 5 VDC O VDC Shield Battery Voltage Battery Ground 41 Control Board FLEXI PRO 42 Feedback Wiring Incremental Tamagawa 17 bit Single Turn Pin Twisted Pair User Motor Pin Signal Description 1 14 11 24 26 Twisted Pair Serial Data Serial Data 5 VDC O VDC
45. lated programmable digital output Read using OUT2 Low side of the second differential analog input 10 VDC Analog output referenced to digital ground 0 10 VDC Quick Start Guide FLEXI PRO Control Board Controller Interface Wiring de E a n EOVIVALENT ENCODER OUTPUT Bi ESd422 RECEIVER a r TH Wd DIRECTION i wb XX mee PULSE amp DIRECTION z PULSE siha OR SECONDARY ENCODER DAA GND Controller Interface Wiring AP AF Models Quick Start Guide 27 Control Board FLEXI PRO mn CONN INPUT SOURCE MODE al 10nF OR mw 10 eL HIGH y NK EE lata D E e ANIN1 INPUT 10V COMN GND OUT_COMM 1 BW eg A 8 HIGH OUTPUT SOURCE MODE oars lt i o TX Low i ANIN2 OPTIONAL 10V 24V NN y3 16 2 10nF pa Y E cwl GND OUTPUT SINK MODE RS422 TRANSMITER SAA Shs S a CX ai EQVIVALENT ENCODER OUTPUT OUT COMM ni pa 26 WD RS422 RECEIVER i YSA gt DIRECTION a O Direcmon 8 PULSE amp DIRECTION E sax Controller Interface Wiring EC PN Models 28 Quick Start Guide FLEXI PRO Control Board Machine I Os C3 Machine I Os are connected through interface C3 on all FLEXI PRO models Wire the machine inputs and outputs according to the requirements of your application Unused pins must remain unwired To preserve isolation of the digital I Os connect a 24 VDC source to pin 9 Connect the return of the 24 VDC supply to pin 19 which functions
46. nals are correct based on the calculation sin2 cos2 1 sine and cosine signals 65 Drive Status FLEXI PRO Display Light r9 tl t2 t3 66 Steady Flash Steady Type Fault Warning Fault Fault Fault Fault Warning Warning Warning Warning Warning Warning Warning Name Encoder Simulation Freg Too High Over Temperature Power Stage Over Temperature Power Module Over Temperature Control Board Over Temperature Under Voltage Under Voltage Description The computed eguivalent encoder output freguency exceeds the upper limit for this signal which is 4 MHz The temperature on the power board and or on the control board has exceeded the preset limit The temperature on the power board has exceeded the preset limit The temperature inside the integrated power module has exceeded the preset limit The temperature on the control board has exceeded the preset limit The bus voltage is below the minimum value The bus voltage is below the minimum value Encoder Hall Switch Hall switch not yet detected Not Found Encoder Index Not Detected HIPERFACE Encoder Resolution Mismatch HIPERFACE Device Not Supported HIPERFACE Device Unknown Phase Find Reguired Index not yet detected Encoder resolution as determined from the detected HIPERFACE device information is different from the current settings of MENCRES Th
47. ng to Flash Memory FPGA Config Fail Description Generally occurs due to an unforeseen circumstance The drive is inoperable until power is cycled Drive configuration required Motor Setup procedure failed MOTORSETUPST will show the reason A problem with the internal voltage supply for the CAN bus Security code and key do not match Fatal fault drive cannot be operated Battery voltage is nearing fault level Action Required Contact technical support Set drive parameters and execute CONFIG Check phase and motor wiring Make sure to choose the correct feedback type and follow the hints in MOTORSETUPST The drive probably needs repair Contact technical Support Contact technical support Prepare to replace battery soon Controller synchronization signal Check if controller provide is missing or not stable The fault is detected only when synchronization is enabled by SYNCSOURCE command Drive detected disconnection between CAN master and drive The non volatile memory used to store drive parameters is empty or the data is corrupted An internal problem accessing the flash memory Fatal fault drive cannot be operated The code for the FPGA did not load Fatal fault drive cannot be operated synchronization signal Check the cable connection and wiring Reconnect master and slave and power cycle the drive Reconfigure the drive or download the parameter set
48. nput Read using IN7 Opto isolated programmable digital input Read using IN9 Fast opto isolated programmable digital input Read using IN11 Opto isolated programmable digital output Read using OUT5 AP AF Models User supplied 24V for I O biasing EC PN Models 10 Fault relay 1 Terminal 1 of the dry 30 contact fault relay Pin Function 11 Secondary encoder A Pulse input 12 Secondary encoder B Direction input 13 Secondary encoder Z 14 Secondary encoder ground 15 Digital input 8 16 Digital input 10 17 Digital output 4 18 Digital output 6 19 24 VDC return Common input Description Low side of the secondary encoder input signal A RS422 Low side of the pulse signal Low side of the secondary encoder input signal B RS422 Low side of the direction signal Low side of the secondary encoder input index RS422 Ground of the 5 VDC supply for the secondary encoder Opto isolated programmable digital input Read using IN8 Opto isolated programmable digital input Read using IN10 Opto isolated programmable digital output Read using OUT4 Fast opto isolated programmable digital output Read using OUT6 AP AF Models Return of the user supplied 24 VDC EC PN Models 20 Fault relay 2 Terminal 2 of the dry contact fault relay Quick Start Guide Control Board FLEXI PRO Machine Interface Wiring MAS FL ALY Fault Relay SS FLT_
49. ntial analog command input 10 VDC Low side of the direction Signal RS422 or Low side of the down count signal Low side of the secondary encoder input Signal B RS422 25 Control Board FLEXI PRO Pin Function 10 Ground 11 Pulse input Secondary encoder A 12 13 Ground 14 Digital input 4 15 Digital input 6 16 Digital output 3 17 18 Analog input 2 Description Pin Function Digital ground 28 Pulse input Secondary encoder A Low side of the pulse 29 Ground Signal RS422 or Low side of the master encoder signal A or Low side of the up count Signal Low side of the secondary encoder input signal A RS422 30 Digital ground 31 Digital input 3 Opto isolated 32 Digital programmable digital input 5 input Read using IN4 Fast opto isolated 33 Digital input Read using IN6 Fast opto isolated 34 programmable digital output Read using OUT3 35 Analog programmable digital output 2 input 2 High side of the second 36 Analog differential analog input output 10 VDC Optional see ordering information 26 Description High side of the pulse signal RS422 or High side of the master encoder signal A or High side of the up count signal High side of the secondary encoder input signal A RS422 Digital ground Opto isolated programmable digital input Read using IN3 Fast opto isolated programmable digital input Read using IN5 Opto iso
50. ol Board FLEXI PRO Host Computer C1 C7 On all FLEXI PRO models the drive can be connected to the host computer through either one of the following interfaces m USB port The interface is labeled C1 on all FLEXI PRO models Exception AP models do not have a USB port Use a USB 2 0 A to Mini B cable m RS232 port The interface is labeled C7 on all FLEXI PRO models Use a 4p4c plug RS232 Interface 4P4C Pin Pin Label Function 1 RX Receive 2 GND ISO Ground 3 TX Transmit 4 Unused 44 Quick Start Guide FLEXI PRO Control Board Daisy Chain C8 The FLEXI PRO can be addressed and controlled on a daisy chained RS 232 line In a daisy chain RS 232 configuration all drives must be daisy chained through the C8 connector Each drive must have a unique address to enable its identification on the network A daisy chained drive can be assigned an address from 1 to 99 by setting the rotary switches on the drive When configuring a daisy chain address O cannot be used Daisy Chain Daisy Chain Interface Pin Function 1 DC Shield 2 Unused 3 RXD 4 GND 5 TXD 6 GND 7 10 Unused Quick Start Guide 45 Control Board FLEXI PRO Drive Address Switches 46 On all FLEXI PRO models two rotary switches are used to set the drive address for both CAN and serial communication Use a small slotted screwdriver or similar tool to set the switches Each switch has 10 positions m The upper switch p
51. ormation e g Hall signals in the motor feedback device The initialization process with the Tamagawa feedback device has failed One of the Pulse amp Direction Signals is not connected Several faults are indicated by the feedback device and include one or more of the following battery low error over speed counting error multi turn error One of the motor phases is disconnected The current of one of the motor phases is effectively zero for more than 160 electrical degrees while the current command is greater than 100 Action Required The FLEXI PRO can source a maximum current of 250 mA to the primary encoder Check for a short circuit at the encoder Check if the encoder is drawing more than the current limit Check whether the drive is configured for working with the index signal on the secondary encoder and check if the index signal is connected Check that all signals from the secondary encoder are properly connected to the drive The FLEXI PRO can source a maximum current of 250 mA to the secondary encoder Check for a short circuit at the encoder Check if the encoder is drawing more than the current limit Check that the feedback device is wired correctly Check that the correct encoder type MENCTYPE is selected Check that the feedback device is wired correctly Check that the correct encoder type MENCTYPE is selected Check whether the motor feedback type and the phase
52. ositions are set as tens 10 20 30 90 m The lower switch positions are set as ones 0 1 2 9 Each drive on the network must have a unique address Note If two or more drives are connected to the network address 0 cannot be used A single drive may have the address 0 Quick Start Guide FLEXI PRO Power Board 120 240 VAC 3 Power Board 120 240 VAC Overview A On most FLEXI PRO 120 240 VAC models the power board has the following interfaces m STO P m Motor P2 P4 on FLEXI PRO 020 024 m Regeneration Resistor P3 P5 on FLEXI PRO 020 024 m AC Input Voltage P3 P4 P2 P3 on FLEXI PRO 020 024 Make sure the main voltage rating matches the drive specification Applying incorrect voltage may cause drive failure Do not apply power until all hardware connections are complete Safe Torque Off STO P1 STO uses interface P1 on all FLEXI PRO 120 240 VAC models Safe torque off STO is a safety function that prevents the drive from delivering power to the motor which can generate torque STO Enable and STO Return must be connected to enable FLEXI PRO operation The STO Enable signal voltage must be 24 VDC Note Ifthe application does not require STO control jumper pin 4 to pin 1 and pin 3 to pin 2 to bypass the STO 24V GND STO Bypass STO Interface Pin Pin Label Function 1 24V STO Enable 2 GND STO Return 3 24V Return provided by the drive for use with emergency stop circ
53. otor Feedback C4 Fieldbus Devices optional C5 and C6 RS232 Communication C7 Daisy Chain C8 Drive Address Rotary Switches Controller I Os C2 Controller I Os are connected through interface C2 on all FLEXI PRO models Wire the digital and analog inputs and outputs according to the reguirements of your application Unused pins must remain unwired To preserve isolation of the digital I Os connect a 24 VDC source to pin 19 Connect the return of the 24 VDC supply to pin 1 which functions as the ground path for the outputs Note AP AF Models The 24 VDC supply and return can be connected on either the Controller interface C2 or the Machine interface C3 but it is not necessary to connect it on both Notes EC PN Models Common output on the Controller interface C2 and the Machine interface C3 are connected internally Common input on the Controller interface C2 and the Machine interface C3 are connected internally m User can connect outputs as source or sink m User can connect inputs as source or sink m Refer to the Controller Interface Wiring schematic diagram for EC PN Models below and the FLEXI PRO System Wiring Pin Assignments diagram for EC PN Models at the end of this manual 24 Quick Start Guide FLEXI PRO Control Board Pin K si q A i LA Controller I F 18 Controller I O Interface Function 24 VDC return Common output Di
54. pply 26 Shield Mating Connector 3M Solder Plug Connector PN 10126 3000PE MPC PN xxxxxxxxxx 3M Solder Plug Junction Shell PN 10326 52F0 008 MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx FLEXI PRO 003 FLEXI PRO 006 Pin Assignments 400 480 VAC Quick Start Guide 21 Introduction FLEXI PRO Mains ca aa A Three Phase Max 528 VAC L L Daisy Chain RS232 Circuit Breaker all EtherCAT OUT or CAN IN or Fuses eS Se sit fl Rotary Switches STO Drive addressing Safe Torque Off Connect to 24 VDC Line Filter optional power Sappy or use bypass plug Logic PS 24 VDC 3 5A x E Magnetic Contactor DS Connect to PC USB mini B cable Machine I F Connect to Host Controller Voltage reference input Pulse and direction input 6x digital inputs 3x digital outputs 1x analog output Regenerative Resistor optional CISISSIISEIICISIII LISI CIS GILICIZIZAII Connect to Additional lOs 5x digital inputs 3x digital outputs 1x fault relay Secondary feedback Functional Ground Motor Feedback Motor Power Motor Brake 24 VDC 1 3A max Internal 4722 300W For higher power external regen resistor is required refer to the user manual Refer to EMI Suppression in the user manual FLEXI PRO 0012 Servo System Wiring 400 480 VAC 3 Phase 22 Quick Start Guide FLEXI PRO Introduction Daisy Chain Controller
55. put Mating Connector type Crimp we JE Housing PN F32FSS 04V KX o 2 Q 3 Secondary encoder Z 13 Secondary encoder Z ro a 2 4 Secondary encoder 5V 14 Secondary encoder ground MPC PN xxxxxxxxxx 2 C 5 Digital input 7 15 Digital input 8 ci Tzal Mating Connector type Spring o 6 Digital input 9 16 Digital input 10 PN 04JFAT SBXGF I arr MPC PN xxxxxxxxxx 7 Digital input 11 J17 Digital output 4 8 Digital output 5 18 Digital output 6 T Regeneration 9 24VDC 19 24 VDC return P3 JST J300 16 AWG Common output Common input 1 Bl DCBus 1 10 Fault relay 1 20 Fault relay 2 2 B2 Regen Bus Mating Connector 3M Solder Plug Connector 3 gt gt PN 10120 3000PE MPC PN xxxxxxxxxx Mating Connector Type Crimp 2 UL E ON F 3M Solder Plug Junction Shell Housing PN F32FSS 02V KX 2x Crimp PN SF3F 71GF P2 0 So Mating Cable MPC PN xxxxxxxxxx MPC PN xxxxxxxxxx Mating Connector Type Spring a Not available 3 Feedback bi C4 MDR 26 Plug 24 28 AWG AC Input 1 M 1 Incremental encoder A 14 Incremental encoder A P4 JST J300 16 AWG SSI encoder data SSI encoder data 1 M _ AC Phase 1 2 Incremental encoder B 15 Incremental encoder B 2 _ l2 AC Phase 2 SSI encoder clock SSI encoder clock 3 L3 AC Phase 3 3 Incremental encoder Z 16 Incremental encoder Z E A O HO 2 o 4 HallU 17 Hall V Mating Connector Type Crimp Tr I nac 1 Resol ine Housing PN F32FSS
56. rs a connector for bus power uses interface P4 and another connector for logic power uses interface P5 m FLEXI PRO 020 024 Two connectors a connector for bus power uses interface P3 and another connector for logic power uses interface P2 Make the following connections 1 Connect the AC input voltage ground wire to the PE terminal located on the FLEXI PRO front panel Use an M4 ring or spade terminal 2 Connect L1 L2 and L3 for bus power m If the main voltage is from a single phase source connect line and neutral to L1 and L2 m If the main voltage is from a three phase source connect the phases to Li L2 and L3 3 Connect L1C and L2C for logic power m If the main voltage is from a single phase source connect line and neutral to LLC and L2C m If the main voltage is from a three phase source connect any two phases to L1C and L2C 50 Quick Start Guide FLEXI PRO Power Board 120 240 VAC AC Input Voltage Interface Note On models FLEXI PRO 1D5 and FLEXI PRO 003 Regen and AC Input Voltage are combined on one connector FLEXI PRO 1D5 FLEXI PRO 003 P3 FLEXI PRO 4D5 FLEXI PRO 006 P4 FLEXI PRO OOS FLEXI PRO O10 FLEXI PRO O13 P4 P5 FLEXI PRO 020 FLEXI PRO 024 P3 P2 Quick Start Guide Pin 3 4 5 6 Pin UO BR O N Pin N Fl WwW N e Pin N BIO N FP Pin Label L1 L2 LIC LC2 Pin Label L1 L2 L3 L1C LC2 Pin Label L1
57. ry or equipment damage Reguired Hardware and Tools All required hardware and tools are specified in the diagrams in the section FLEXI PRO Wiring and Pin Assignments The connectors and tools that are supplied with the FLEXI PRO are also indicated in those diagrams In addition you will need a small slotted screwdriver for setting switches To connect the FLEXI PRO to the host computer via serial communication you will need one of the following m USB 2 0 A to Mini B cable USB interface E 4p4c plug and cable RS232 interface To connect the FLEXI PRO to the host computer or host PLC via fieldbus you will need m RJ45 cables CAN interface or EtherCAT Quick Start Guide 7 Introduction FLEXI PRO Required Computer System The following computer system and software are required m 2 GHz CPU E 1 MB RAM 1000 MB available on hard drive after net 4 is installed E USB or RS232 port for connecting to the drive according to FLEXI PRO model m Operating system Windows XP SP3 or Windows 7 E Recommended screen resolution for FLEXI SUITE is 1280x800 Minimal resolution is1024x768 m FLEXI SUITE the graphical software interface for configuring and testing the drive Download from the Motor Power Company website or contact Technical Support m Net4 for details refer to NET Framework System Requirements If NET 4 is not installed on the computer FLEXI SUITE will guide you through the installation but w
58. shold IFOLDWTHRESH Drive fold current dropped below the drive fold current fault threshold MIFOLDFTHRESH Motor fold current dropped below the motor fold current fault threshold IFOLDFTHRESH A stall fault occurred because the motor was in a stalled state for too long that is I gt MICONT and I gt 0 9 ILIM and V lt STALLVEL for time gt STALLTIME Action Reguired Contact technical support Contact technical support Contact technical support Reset faults If the fault persists the drive probably needs repair Contact technical support Reset faults If the fault persists the drive probably needs repair Contact technical support Update either the FPGA version or drive version Contact technical support Check the drive motor sizing This warning can occur if the drive or the motor is under sized under powered for the application Check motor drive sizing This fault can occur if the drive is under sized under powered for the application Check that the commutation angle is correct i e commutation is balanced Check MIFOLDFTHRESH and MIFOLDWTHRESH values Check the drive motor sizing This fault can occur if the motor is under sized under powered for the application Check IFOLDFTHRESH and IFOLDWTHRESH values Remove the stall condition and take care to prevent stall conditions A target position command from Enable the drive and send controller
59. sine 19 Resolver sine 7 Resolver cosine 20 Resolver cosine 8 Resolver reference 21 Resolver reference 9 Sine encoder sine 22 Sine encoder sine 4 10 Sine encoder cosine 23 Sine encoder cosine 11 5V supply 24 Ground 5V 8V return 12 Motor temperature 25 Motor temperature sensor sensor 3 BV supply 26 Shield Refer to ordering information Crimping tool Molex 0638190000 P1 Mating Connector 3M Solder Plug Connector Can Er men Cimini _ va PE PO i EtherCAT models only i Extraction tool EJ JFAJ3 Pa P3 PN 10326 52F0 008 MPC PN xxxxxxxxxx Motor Power Company Key for spring J FAT OT Mating Cable MPC PN xxxxxxxxxx Highlighted PN Supplied with FPRO connector 4 40 insert threads on C2 C3 C4 FLEXI PRO 1D5 FLEXI PRO 003 Pin Assignments 120 240 VAC Quick Start Guide 13 Introduction FLEXI PRO Mains Daisy Chain Single Phase RS232 120 240 VAC EtherCAT 5 or CAN iN Rotary Switches Drive addressing Circuit Breaker a STO or Fuses Safe Torque Off Connect to 24 VDC power supply or use bypass plug as adi Line Filter Regenerative optional Resistor optional 7 Connect to Host Controller Voltage reference input Pulse and direction input 6x digital inputs 3x digital outputs Magnetic 1x analog output Contactor Connect to A
60. ss pl e ec U Y da USB mini B cable Line Filter Fat Regenerative optional te Resistor optional Controller I F Connect to Host Controller Voltage reference input Pulse and direction input 6x digital inputs 3x digital outputs 1x analog output Magnetic Contactor Machine WF Connect to Additional lOs 5x digital inputs 3x digital outputs 1x fault relay Secondary feedback Feedback Motor Feedback Functional Ground Motor Brake optional 24 VDC Power Supply Motor Powe Brake Output To be supplied by customer Refer to EMI Suppression in the user manual FLEXI PRO 008 FLEXI PRO 010 FLEXI PRO 013 Servo System Wiring 120 240 VAC 3 Phase Quick Start Guide FLEXI PRO Introduction Controller I F Daisy Chain C2 MDR 36 Plug 24 28 AWG EtherCAT In EtherCAT Out Sans 1 19 24 VDC C5 RJ45 C6 RJ45 NELTRON 4401 10SR OR si Common input 20 COXOC 304A 10PSAAA03 19 N Digital input 2 OR Digital output 1 SI SO 3 Digitalinput1 CAN In CAN Out DC Shield 4 Eguivalent encoder 22 Equivalent encoder C5 RJ45 C6 RJ45 2a output A CANH 5 Equivalent encoder Equivalent encoder a4 output B output B a a 16 Equivalent encoder 24 Equivalent encoder 5 TXD 8 l Analog input 1 26 Analog input 1 Direction input 27 Direction input Secondary encoder B Secondary encoder B 28 fee 8 10 gt hd
61. ter velocity error Check that the STO connector P1 is wired correctly Check that the STO connector P1 is wired correctly Quick Start Guide FLEXI PRO Drive Status Display Light Type ni Fault n3 Fault n41 Fault n42 Fault O Flash Fault 015 Fault 0 15 Fault 05 Fault P Fault r Steady Warning r10 Fault r14 Fault r15 Fault Ouick Start Guide Name Regen Over Current Emergency Stop Issued Power Brake Open Load Power Brake Short Over Voltage Plus 15V Out of Range Minus 15V Out of Range 5V Out of Range Over Current Offset and or Gain Adjustment Values Detected After SININIT Sine Feedback Communication Fail Sine Encoder Guadrature Fault Sin Cos Calibration Invalid Description The preset current limit for regen current has been exceeded The input defined as emergency stop has been activated Open load on the power brake output Short circuit on the power brake output The bus voltage exceeded the maximum value The internal 15 V supply is out of range The internal 15 V supply is out of range 5V is low or powering off Over current at the drive output has been detected The drive allows this fault to occur up to 3 times in succession After 3 faults the drive forces a delay of 1 minute before it can be reenabled Significant offset and or gain adjustment values were detected after SININIT The values that trigger this warning are
62. trademark and patented technology licensed by Beckhoff Automation GmbH EnDat is a registered trademark of Dr Johannes Heidenhain GmbH HIPERFACE is a registered trademark of Sick Stegmann Gmbh Windows is a registered trademark of Microsoft Corporation Ouick Start Guide FLEXI PRO Contact Information Motor Power Company s r l Via Leonardo Da Vinci 4 42024 Castelnovo Sotto Reggio Emilia Italia Tel 39 0522 682710 Fax 39 0522 683552 Website www motorpowerco com Technical Support If you need assistance with the installation and configuration of the FLEXI PRO drive contact Motor Power Company technical support info motorpowerco it Part Number FPRO 006 2A AP 1 FLEXI PRO Servo Drive 120 240 VAC Cont Peak A rms Arms 1 5 4 5 3 9 18 18 28 28 28 48 400 480 VAC Cont Peak Arms Arms 48 AC and Controller Input Power Supply Power block One analog input 16 bit Two analog inputs 14 bit each Interface Options AP Analog Voltage Pulse Train Ref USB RS232 AF Analog Voltage Pulse Train Ref CANopen USB RS232 EC EtherCAT USB RS232 PB PWM Power Block Standard configuration with one analog input Standard configuration with two analog inputs PBO and PWM power block do not have analog input option Input Single Phase 120 L L VAC 10 15 50 60 Hz Input Single Phase 240 L L VAC 10 15 50 60 Hz Input T
63. ual FLEXI PRO 1D5 FLEXI PRO 003 Servo System Wiring 120 240 VAC 1 Phase 12 Quick Start Guide FLEXI PRO Introduction Daisy Chain Controller I F EtherCAT In EtherCAT Out C8 0 1 IDC Female C2 MDR 36 Plug 24 28 AWG C5 RJ45 C6 RJ45 NELTRON 4401 10SR OR E gt 24 VDC return 119 24 VDC COXOC 304A 10PSAAA03 O MPC PN E Common output Common input CAN In CAN Out 1 DC Shield 2 Digital output 1 Es Digital input 2 C5 RJ45 C6 RJ45 Digital input 1 21 Equivalent encoder 22 Equivalent encoder output A output A 5 Equivalent encoder 23 Equivalent encoder RS232 output B output B C7 4p4c Equivalent encoder 24 Equivalent encoder RX output Z output Z GND iso 25 Ground a ales input 1 26 Analog input 1 Direction input 27 Direction input Secondary encoder B Secondary encoder B Ground 28 Pulse input Secondary encoder A 11 Pulse input 29 Ground Secondary encoder A Ground si Digital input 3 14 Digital input 4 32 Digitalinp
64. uit 4 24V Supply provided by the drive for use with emergency stop circuit Quick Start Guide 47 Power Board 120 240 VAC FLEXI PRO Motor P2 Motor uses interface P2 on all FLEXI PRO 120 240 models Exception Motor uses P4 on FLEXI PRO 020 024 Motor Interface Pin Pin Label 1 PE 2 U 2 V 4 W 48 s lt ceR Function Protective ground motor housing Motor Phase U Motor Phase V Motor Phase W Quick Start Guide FLEXI PRO Power Board 120 240 VAC Regeneration Resistor P3 Regen uses interface P3 on all FLEXI PRO 120 240 VAC models Exception Regen uses P5 FLEXI PRO 020 024 Note On models FLEXI PRO 1D5 and FLEXI PRO 003 Regen and AC Input Voltage are combined on one connector If the application requires a regeneration regen resistor connect the regen resistor between terminals B1 and B2 Regen Interface Pin Pin Label Function 1 B1 DC bus 2 B2 Regen bus Regen Interface on FLEXI PRO 020 024 Pin Pin Label Function 1 B2 Regen bus 2 B1 DC bus Quick Start Guide 49 Power Board 120 240 VAC FLEXI PRO AC Input P3 P4 P5 The AC Input interfaces and connectors vary among FLEXI PRO 120 240 VAC models m FLEXI PRO 1D5 and FLEXI PRO 003 One connector for bus power and logic power uses interface P3 m FLEXI PRO 4D5 and FLEXI PRO 006 One connector for bus power and logic power uses interface P4 m FLEXI PRO 008 CHDH O10 andFLEXI PRO 013 Two connecto
65. ut 5 15 Digital input 6 33 Digital output 2 16 Digital output 3 aab 17 35 Analog input 2 Analog input 2 STO Safe Torque Off P1 Molex 26 28 AWG 24 VDC STO enable Goons 24 VDC retum n C1 Mini B Analog output Mating Connector 3M Solder Plug Connector PN 10136 3000PE MPC PN xxxxxxxxxx 3M Solder Plug Junction Shell PN 10336 52F0 008 MPC PN xxxxxxxxxx Mating Cable MPC PN xxxxxxxxxx Machine I F C3 MDR 20 Plug 24 28 AWG 1 Secondary encoder A 11 Secondary encoder A o m e Mating Connector type Crimp Housing PN 436450400 MPC PN xxxxxxxxxx 4x Crimp PN 0430300001 MPC PN xxxxxxxxxx Wired STO MPC PN xxxxxxxxxx Motor P2 JST J300 18 AWG PE Functional Ground U Motor Phase U 1 v Motor Phase v Pulse input Pulse input 12 Secondary encoder B af Secondary encoder B Direction input Direction input Secondary encoder Z 13 Secondary encoder Z Secondary encoder 5V 14 Secondary encoder ground Digital input 7 E 15 Digital input 8 8 Digital input 9 16 Digital input 10 1 2 3 Er iw i Motor Phase W o E ojo n o Mating Connector type Crimp Digital input
66. was rejected because it would cause the motor to exceed the velocity limit valid position commands A target position command from Enable the drive and send controller was rejected because it would cause the motor to exceed the acceleration deceleration limit valid position commands 61 Drive Status FLEXI PRO Display Light Type Name Fb3 Fault EtherCAT Cable disconnected Fb4 Fault Fieldbus Target Command Lost H Flash Fault Motor Over Temperature H Steady Warning Motor Over Temperature j Flash Fault Velocity Over Speed Exceeded J1 Fault Exceeded Maximum Position Error J2 Fault Exceeded Maximum Velocity Error L1 Warning Hardware positive limit switch is open L2 Warning Hardware negative limit switch is open L3 Warning Hardware positive and negative limit switches are open L4 Warning Software positive limit switch is tripped L5 Warning Software negative limit switch is tripped L6 Warning Software limit Switches are tripped n Flash Fault STO Fault n Steady Warning STO 62 Description The connection between controller and drive was removed The fieldbus controller has not sent a target command in 3 consecutive instances Either the motor has overheated or the drive is not set up correctly for the motor temperature sensor Motor is overheated Actual velocity exceeded 1 2 times the velocity limit The velocity limit is set using VLIM The position error PE has

Flexi PRO - FPRO_QSG_Rev_5.6_fw144

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