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MicroFlex Servo Control

1. Figure 29 General purpose digital input circuit When the MicroFlex is connected to WorkBench v5 the digital input can be configured using the Operating Mode Wizard Alternatively the Mint keywords RESETI NPUT ERRORI NPUT and STOPI NPUT 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 t www supportme net NextMove ESB controller MicroFlex UDN2982 MintMT QUTX 0 ZA Na TLP280 Figure 30 Digital input typical connection from a Baldor NextMove ESB 5 8 Input Output MN1919 www supportme net 5 3 3 Step pulse and direction inputs X3 Location Connector X3 pins 9 amp 10 Mating connector Weidmuller Minimate B2L 3 5 14 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 t
2. fr 2 RXD RS485 RS422 name NC RX input TXD TX output NC NC OV GND OV DGND jm NC RTS TX output CTS 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 9 1 3 4 5 7 5 4 1 Using RS232 cable The MicroFlex has a full duplex RS232 serial port with the following preset configuration 57 6 Kbaud 1 start bit 8 data bits 1 stop bit No parity Hardware handshaking lines RTS and CTS must be connected X6 COM TXD 3 3 TXD 9 pin MicroFlex GND 5 5 GND Computer DTE COM Port RTS 7 7RTS DTE CTS 8 8 CTS N Connect overall shield P d to connector backshell Figure 35 RS232 serial port connections When the MicroFlex is connected to WorkBench v5 the Tools Options menu item can be used to configure the serial port The configuration can also be changed using the Mint keyword SERI ALBAUD see the Mint help file for details MN1919 Input Output 5 13 www supportme net 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 l
3. 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 Aux Encoder 6 10 Configuration MN1919 www supportme net 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 m Edit amp 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 V DITE It m Scope Tool Displays the capture screen This screen is also shown when the Fine tuning tool is selected a x dvds O E F Current Plant Resistance 16 06 Ohms Inicuclance 33 zu mH Measure Flux Plant Wok Const Ed 73 Measure Feedback Alignment Test Current Control Terma KIPR F 0 00 FJINT 0 00 Apply Calculate Test Parameters f Type Statiner m Time ms Cunent cu m RE EE ETETE Duration 50 00 mz E HS Measured magnetizing current Amps Speed Limit zo a F Heirat ees TS Current m Spy window ee gt Allows you to monitor all the important arameters for the axis P Analog Input E Cho 0 Remember for help on each tool just press F1 to display the help file then navigate to the WorkBench v5 book Inside this is the Toolbox book Drive
4. BALDOR MOTION PRODUCTS SERVO DRIVE MicroFlex Servo Control Installation Manual 01 06 MN1919 Contents 1 General Information 0 0 0 0 cc eee eee 1 1 2 NTOAUCION 3 339 50 sticks Soe oc eb e CA E Ue M dosi 2 1 2 1 MicroFlexfeatures 0 0 cc eens 2 1 2 2 Receiving and inspection 0 ccc ees 2 2 2 2 1 Identifying the catalog number 0 00 cee eee 2 2 2 3 Units and abbreviations 0 0 0 ccc ees 2 3 3 Basic Installation as 03 2458 ROCA ORO EXE HEAD Bees 3 1 oc AOtFfoOUue lO educ dh aer S cn UR BURCH ERR 28 RC UR He a8 3 1 SA dIPOWSLRSOUICOS 273 1324 Ano EAS died Med bates ad ed ssa stades 3 1 3 1 2 Hardware requirements 000 cece eee eee 3 1 3 1 3 Tools and miscellaneous hardware 000 cece eens 3 2 3 1 4 Other information needed for installation 3 2 3 2 Mechanical installation and cooling requirements 3 3 32 1 DIMENSIONS samedis dut Sei E cece DES Ere gd usada 3 4 3 2 2 Mounting and cooling the MicroFlex 0 0 00 cece ees 3 5 3 2 8 Derating characteristic 1A model 0 2 00 c eee ees 3 6 3 2 4 Derating characteristic 3A model 0 0 0 cee eee 3 6 3 2 5 Derating characteristic 6A model 00 cc eee es 3 7 3 2 0 Derating characteristic 9A model 0 000 cee ees 3 8 3 2 7 Overtemperature trips 0 0 eee ren 3 8 3 3 C
5. A 9 A 11 connections 4 1 encoder 4 2 encoder without Halls 4 4 Halls only feedback 4 4 Resolver 4 8 SSI 4 6 Filters 24V control circuit supply 3 16 AC power EMC 3 15 A 4 catalog numbers A 4 Footprint filter A 3 Fuses 3 14 Index G General Information 1 1 Grounding See Earthing grounding H Hardware requirements 3 1 Help file 6 4 Input Output 5 1 analog I O 5 2 analog input 5 2 8 4 connection summary 5 16 digital I O 5 4 drive enable input 5 5 8 4 encoder output 4 10 8 6 general purpose digital input 5 7 8 4 serial port 5 13 8 6 multidrop using RS485 RS422 cable 5 14 status output 5 11 8 5 step amp 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 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 Index Operator panels HMI operator panels 5 15 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
6. 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 Fan tray FANOO1 024 Figure 43 Assembled footprint filter fan tray and MicroFlex MN1919 Accessories A 3 www supportme net A 1 3 EMC filters AC filters remove high frequency noise from the AC power supply protecting the MicroFlex 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 K bs 327 5 45 035 73 1 61 73 1 61 0 5 1 1 0 8 1 76 xm 3 3968 0 0 0 Hos 0 9 94 3 10 12 7 16 2 FI0018A03 FI0029A00 4 4 4 4 33 33 33 Dimensions mm inches FI0018A00 190 7 48 160 6 30 180 7 09 20 0 79 4 5 0 18 71 2 80 40 1 57 FI0018A03 250 9 84 220 8 66 235 9 25 25 0 98 5 4 0 21 70 2 76 45 1 77 Figure 44 Filter dimensions types FI0018A00 and FI0018A03 A 4 Accessories MN1919 www supportme net T Dimensions rim me FI0015A02 A ses 35847 ee es 8882 o sew xem 195
7. 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 resistor 3 20 specification 8 3 Resolver 4 8 cable 4 9 A 10 specification 8 5 RS232 5 13 specification 8 6 RS485 5 14 multidrop using RS485 RS422 cable 5 14 S Safety Notice 1 2 Serial port 5 13 connecting serial Baldor HMI panels 5 15 Simulated encoder output 4 10 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 MN1919 environmental 8 6 regeneration 8 3 resolver feedback 8 5 serial RS232 interface 8 6 SSI feedback 8 5 status output 8 5 step amp direction inputs 8 4 SSI 4 6 cable 4 7 A 9 specification 8 5 Status LED 7 2 Step amp Direction 5 9 specification 8 4 T Tools 3 2 Troubleshooting 7 1 communication 7 3 MN1919 power cycling 7 1 power on 7 4 problem diagnosis 7 1 Status LED 7 2 SupportMe 7 1 tuning 7 4 U Units and abbreviations 2 3 W Wires sizes 3 14 WorkBench v5 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 Index Index MN1919 Comments If you have any suggestions for improvements to this manual please let us know Write your comments in the space provided below remove this page from the ma
8. E E m Dedicated step and direction inputs a 1 dedicated drive status output The general purpose digital input can be configured for typical input functions m Error input m Reset input m Stop input 5 4 Input Output MN1919 www supportme net 5 3 1 Drive enable input X3 Location Connector X3 pins 6 amp 7 Mating connector Weidmuller Minimate B2L 3 5 14 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 MicroFlex Mint Drive I DRI VEENABLE Enable SW TCH A ak 74AHC14 Drive Enable TLP280 Figure 27 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 WorkBench v5 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 m The drive enable button 4 on the motion toolbar toggles the enable disable status Alternatively the Mint command DRI VEENABLE O 1 can be used in the command window to enable the MicroFlex DRI VEENABLE 0 290 will disable the MicroFlex m he Tools Reset Contro
9. 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 Mint is a registered trademark of Baldor Windows 95 Windows 98 Windows ME Windows NT Windows XP and Windows 2000 are registered trademarks of the Microsoft Corporation UL and cUL are registered trademarks of Underwriters Laboratories MicroFlex 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 pu
10. at least 50mm 2 in above and below and 26mm 1 in left and right MN1919 Accessories A 7 www supportme net A 1 5 Motor power cables Length Cable Cable assembly rated current description Power Cable CBLO50 501 no connectors CBLO015SP 12 CBLO25SP 12 CBLO30SP 12 power Cable SBLOSOSE 12 ad Assembly CBLO75SP 12 CE style threaded y CBL091SP 12 motor connector CBL100SP 12 motor end only CBL150SP 12 CBL152SP 12 CBL200SP 12 CBL229SP 12 Catalog number Power Cable CBLO51 501 Availa no connector CBLO15SP 20 CBLO25SP 20 CBLO30SP 20 Power Cable a EAE E dii Assembly CBLO75SP 20 CE style threaded i i y CBLO091SP 20 motor connector CBL100SP 20 motor end only CBL150SP 20 CBL152SP 20 CBL200SP 20 CBL229SP 20 35 Amps Power Cable CBL052 501 Available by the meter or on P no connector 100m drum Available in North and South America only A 1 6 Motor power cable part numbers For easier installation it is recommended that a color coded motor power cable is used A description of a BSM rotary motor power cable catalog number is shown here using the example number CBL025SP 12 Indicates the length in this example 2 5 meters Various see section A 1 5 SP The cable is a Servo motor Power cable me sd 32 7 Current rating of 12A 20 20A Motor power cables include the motor power connector Larger motors requiring 35A cable normally use terminal box connections so a motor power c
11. be connected to the shield rails or clamps The shield rails or clamps should be conductive clamps fastened to the cabinet m The cable to the regeneration resistor must be shielded The shield must be connected to earth ground at both ends m The location of the AC filter has to be situated close to the drive so the AC power wires are as short as possible m 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 m Toreduce 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 kk Or run as twisted pair at minimum C 4 CE Guidelines MN1919 www supportme net 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 is Due amp pP es 3 mo S5O0rrm max lI Figure 51 Earthing grounding cable shields MicroFlex Encoder Connector X8 Cable Housing CHA CHA CHB CHB CHZ CHZ 5V DGND RK Connect overall shield to co
12. 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 conductor Basic Installation MN1919 www supportme net 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 19 or 36 line to line Minimum input voltage 105VAC 1 or 30 line to line see Note Maximum input voltage 250VAC 19 or 36 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 Ib 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 th
13. 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 WorkBench v5 6 2 Configuration MN1919 www supportme net 6 2 WorkBench v5 WorkBench v5 is a fully featured application for commissioning the MicroFlex The main WorkBench v5 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 J a WorkBenc h ws Iruibmiachine T Fine tuning EA T E3 a Lj 0 Menu system 5n 100 Toolbars 450 D z on pu c P eames Control and test area Toolbox 025 Time msi Figure 40 The WorkBench v5 software MN1919 Configuration 6 3 www supportme net 6 2 1 Help file WorkBench v5 includes a comprehensive help file that contains information about every Mint keyword how to use WorkBench v5 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 F 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 appe
14. 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 www supportme net 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
15. 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 Minimum power cycle delay period current rating seconds 25 65 BENE T 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 ON 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 Time for DC bus to discharge to 50V or less current rating maximum seconds 83 248 Table 2 DC bus discharge periods 3 12 Basic Installation MN1919 www supportme net 3 4 3 3 Supplying in
16. window is displayed at the right of the screen This d already shows some of the parameters that have been calculated by the Commissioning Wizard Fine tuning The main area of the WorkBench v5 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 JA Step 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 www supportme net 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
17. 1 and 2 5mm 1 10 in or less for connector X3 M5 screws or bolts for mounting the MicroFlex Crimping tool 3 1 4 Other information needed for installation This information is useful but not essential to complete the installation The data sheet or manual provided with your motor describing the wiring information of the motor cables connectors Knowledge of whether the digital input signal will be Active Low or Active High 3 2 Basic Installation MN1919 www supportme net 3 2 Mechanical installation and cooling requirements It is essential that you read and understand this section before beginning the installation N 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 equipment or directly below water steam pipes CAUTION Avoid locating the MicroFlex in the vicinity of corrosive substances or vapors metal particles and dust N CAUTION Avoid locating the MicroFlex immediately above or beside heat generating 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 depe
18. 11 t www supportme net 4 12 Feedback MNf919 5 1 Input Output D 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 V D p Input Output DIN sad V sen Digital Input DOU PT ous ex dm Digital Output AIN Analog Input MN1919 Input Output 5 1 www supportme net 5 2 Analog I O The MicroFlex provides as standard m 1 analog input on the connector block X3 demand input 5 2 1 Analog input X3 demand Location Connector X3 pins 12 amp 13 Mating connector Weidm ller Minimate B2L 3 5 14 Description Single ended or differential input Common mode voltage range 10VDC Resolution 12 bit accuracy 4 9mV Common mode rejection 40dB Input impedance gt 30kQ Sampling interval 125us The analog input can be connected as either a differential or a single ended input as shown in Figure 24 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 sh
19. 4 8 41 4 Encoder OUIDULAAL arere iumewkx n EPYWETIWES RETIuMPEWETSuSSu 4 10 o TOPU QUIDUL x 12599 94 3 44 Wd RE ARCA REDE ERE 5 1 Ost Introduction s ovp MEI RUDEESeETEUPRPTMEOXUEPRPRFeR eU PPM 5 1 5 2 Analog IO ieu dare e E pd Sates Bede ebat 5 2 5 2 1 Analog input X3 demand 0 0c eee 5 2 9 9 DIG HADE saree boe ae EPA d END E 5 4 538 1 Drive enable Input X9 oues teianei aa AE EE ARES EY 5 5 5 3 2 General purpose digital input X3 a an anaa aana aeaaea 5 7 5 3 3 Step pulse and direction inputs X32 6 es 5 9 5 3 4 Status output X3 0 rr 5 11 924 Seral poks KO cureranno bis eee d 5 13 5 4 1 Using RS232 Cable xn secet x anaana 5 13 5 4 2 Multidrop using RS485 RS422 cable llus 5 14 5 4 3 Connecting serial Baldor HMI Operator Panels 5 15 5 5 Connection summary recommended system wiring 0 16 stress TE T m 6 1 O T IAMOGUCTIONG 2 rode a EE AUR ae ihe Eat ERR E Red RRS 6 1 6 1 1 Connecting the MicroFlex to the PC ullllllssllseslen 6 1 6 1 2 Installing the software anaana cc e 6 1 6 1 3 Starting the MicroFlex 0 0 ccc eee e 6 2 6 1 4 Preliminary Checks os iu equi x El eR doe Oe ar e Hee dod 6 2 o L5 ROWEROMCNECKS avidos Sieonticid atis ang ete alk acid eee ee dint hee dpa 6 2 62 WOrKBench Vou aie See eee aes baie totes ee eee bere ees 6 3 S T HEME xa teres ie tras t cedet datas Wig de at
20. 6 E588 mew TBS F 2 9 8 uan 3404 H 594 3028 530027 K 3052 882 Figure 45 Filter dimensions types FI0014A00 FI0015A00 FI0015A01 FI0015A02 MN1919 Accessories A 5 www supportme net OE E e Bb uai E ND US aF E Mounting keyhole and slot detail D m d A EC AA J O O O o Rcs cu C IA C IA A gt D A 5 5mm B 11mm C 10mm O O D 5mm O O O O L f f Figure 46 Filter dimensions type FI0029A00 A 6 Accessories MN1919 www supportme net 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 Baldor part number RG56 is recommended 56O 44W However if the required dissipation is greater than this Baldor part number RG39 may be used rated at 100W RG56 140 5 5 RG39 226 8 9 Dimensions mm inches Figure 47 Regeneration resistor dimensions N WARNING A regeneration resistor may generate enough heat to ignite combustible materials To avoid fire hazard keep all combustible materials and flammable vapors away from the brake resistors Ensure that the resistor has clearance of
21. Ace Pe oe eas 6 4 6 2 2 Starting WorkBench v5 0 ccc eee eee eens 6 5 6 2 3 Commissioning Wizard 0 0 ccc eee eens 6 7 6 2 4 Using the Commissioning Wizard 00 cee eee 6 7 6 3 Further configuration 0 0 00 cee eee 6 8 6 91 IMG TUNING IOO soa elio teh ea inks ANE aw oer deta e elo edes bo Boke e c alae 6 8 0392 Parameters 00 wks sent ine weet aes ees Goes aed ahs ees See ee 6 10 6 3 3 Other tools and windows 00 c cee eee eens 6 11 ii Contents MN1919 7 Troubleshooting 0 0 ccc cee ee ees 7 1 et OUOGHCIOD uas puesto oan qoe RR RUP E RR oe heey a 1 1 TAST Problem diagnosis xx Sexo io aed EE aoe sea RADICE RUE P VEI ORAS 7 1 7 1 2 SupportMe feature eelslleeeee n 7 1 7 1 3 Power cycling the MicroFlex 00 renen mI 7 1 Peo SOUS E 23g eed a Avie er es oe aes ih ons dot Maven REE 7 2 724 COMMUNICAIION i061 at older n er EE Rs BUR CR ORA RUBER ELLE 7 3 23 POWSPON grensen Su sae DEER DER DINES KER DEERE RUE Sud dus 1 4 529 TUNNO LA MEAD She NNE aede unice ledn chante Bilas eerie ahve a r tos doct 1 4 Or ODECHICAUONS desi ori ace sd seaweed aa aes i do 8 1 Sol dJnipogduellOi 3 2 2 dew o Mete pO Ey qo bt as Bees 8 1 8 1 1 AC input power and DC bus voltage X1 0 cee ees 8 1 8 1 2 24VDC control circuit supply input X2 0 0 0 eee 8 3 8 153 Motoroutpub DOWER OX T 13d ee tack AUR bare hk
22. Bus Volts jassi m MN1919 Configuration 6 11 www supportme net 6 12 Configuration MN1919 7 1 7 1 1 7 1 2 7 1 3 Troubleshooting f Introduction This section explains common problems that may be encountered together with possible solutions 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 WorkBench v5 If you cannot solve the problem or the problem persists the SupportMe feature can be used 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 m The serial number of your MicroFlex m Use the Help SupportMe menu item in WorkBench v5 to view details about your system m The catalog and specification numbers of the motor that you are using m Give a clear description of what you are trying to do for example trying to establish communications with WorkBench v5 or trying to perform fine tuning m Give a clear descri
23. The Status LED is flashing 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 PRI NT AXI SERROR PRI NT DRI VEERROR Click the Clear Errors button on the motion toolbar 7 2 3 Tuning Cannot enable the MicroFlex Check the drive enable input on connector X3 pins 6 because AXI SERROR has bit 13 set and 7 is connected and powered correctly When the MicroFlex is enabled the Check that the current loop has been tuned motor is unstable 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 KVI NT on the Speed tab of the Fine tuning window 7 4 Troubleshooting MN1919 Specifications 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 ni Nominal input voltage 115 or 230 AC input 105 Minimum input voltage Maximum input voltage Nominal DC bus voltage D Nominal input current Q maximum rated output current The MicroFlex will operate at lower input voltages although the drive will trip if the DC bus voltage falls below 50V or 6096 of the no load voltage whichever occurs first 8 1 1 1 Effect of AC power supply voltage on DC bus voltage 350 300 LLL A 55h ree phase su
24. able performance of this equipment be certain that all signals to from the drive are shielded correctly 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 Avoid locating the drive immediately above or beside heat generating equipment or directly below water or steam pipes Avoid locating the drive in the vicinity of corrosive substances or vapors metal particles and dust 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 General Information 1 3 www supportme net CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION pBPDPpPpPbPEPPPPbPPP PPS 1 4 General Information CAUTION CAUTION 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 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 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
25. argets 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 Torque reference profiler Torque demand Host Analog input e Torque PWM Power stage controller motor Measured current Figure 48 Control structure in Current Torque control mode The torque controller is a PI Proportional Integral controller Gains are set using the Mint keywords KI PROP and KI NT 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 KI PROP and KI NT 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 KVTI ME By default the fil
26. aring 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 E MintMT _ El s Hide Locate Back Forward Print Options Supportide Update Help Contents Index Search Favorites CONTROLMODE CMD COMPAREOUTPUTCMO a ee COMPAREPOS CMP RR See Also COHFIG CONNECT CNN CONNECTSTATLIS CNS Const Continue CONTOURANGLEICTA CONTOLIRMODE CTM Purpose Fi To set or read the control mode Controllers Supported MicroFlex FlexDrme Flex Onve MintDrme Format Critical End Critical COHTROLHODE axis lt expression gt CURRENTLIMITACL v CONTROLMODE axis CURRENTMEASICMS CURRENTSENSORMODEJC Dot Parameters DACDC Axis Axis Mo DACLIMITMAXIDCX DACMODE DCM Attributes Po M ONTIESE UR Controller Read Write Multi Scaled Default Range DACMONITORGAINOMG Aziz DACMONITORMODE DMM m MicroFlex v vi J T Frej d FlexDrive Y v Defined by 1 3 mi Figure 41 The WorkBench v5 help file For help on using WorkBench v5 click the Contents tab then click the small plus sign beside the WorkBench v5 book icon Double click a topic name to display it 6 4 Configuration MN1919 www supportme net 6 2 2 Starting WorkBench v5 1 On the Windows Start m
27. ase 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 FANOO1 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 Metal backplane 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 Hot gaeceggs gaeceggs 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 Warm 884e99gs V The derating characteristics assume the MicroFlex is mounted on 3mm thick or less metal
28. 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 FMH Installed ate Date A description of a catalog number is shown here using the example FMH2A03TR EN23 Requires an AC supply voltage of 115 230 Volts 1 or 36 eo i A01 1A A06 6A Continuous current rating of 3A A09 9A T emmers O R Reesswmdbemgmssr O E Supported feedback types are encoderor SSI ReResoherledbuck N No options specified EA ES 24VDC supply is required to power the control logic 2 2 Introduction MN1919 www supportme net 2 3 Units and abbreviations The following units and abbreviations may appear in this manual a E AA AET E Ampere AG a e m Alternating current DES aaa a Direct current dB EAEE wire meee er decibel VV au suse sopa uss kilowatt M uis nea oes milliampere MEL BET M m millihenry MO M milliohm DF coe eet serene picofarad ere re eee ee Volt also VAC and VDC MM S aen de ant esa gyre eee Watt WA microampere IU x NN EN microhenry HE occa aos oe deb microfarad oS Ohm Ia adios cubos rd As hertz kHz kilohertz MHz megahertz MOSE SEE millisecond AS eee sne nanosecond Sr RENEE d ad ee second US annunin microsecond Dra a nn phase Si Bere ee eee ere Compact Disc CUREE era on the PC keyboard pre
29. ave 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 WorkBench v5 see section 6 3 2 AC supply voltage 115VAC 16 230VAC 10 230VAC 30 Output voltage range 0 115VAC 36 0 230VAC 30 0 230VAC 36 Motor Connect motor To earth ground outer earth ground I I shield use 360 to protective I damp seeding to earth on top of mme Eme a deme dno cmo do ee oer ERR a emo ums wem deme Rue a mmy D Gem UEM Dem Unshielded lengths should E be as short as Optional motor possible circuit contactors i 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 co
30. d 2 Black labeled 3 Green Yellow Earth ground Green White c D Note Not all motors are fitted with a brake so pins C and D might not be connected Motor power connector Cable connector end view male female Figure 8 Baldor motor power cable pin configuration Basic Installation MN1919 www supportme net 3 5 3 3 5 4 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 nar Be Muay ke aa te o Hall cable wire color al 1 faz Re iar 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 www supportme net 3 6 Regeneration resistor Dynamic Brake resistor An optional external regeneration resistor may be required to dissipate excess power from the inter
31. d Do not make a connection to this pin Left LED Fault signal loss Right LED Unused Basic Installation 3 9 www supportme net 3 4 3 4 1 3 4 1 1 3 4 1 2 3 10 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 ON 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 lis
32. d to comply with the provisions of directive 98 37 EC as amended Signed Dr Gerry Boast Engineering Manager C 2 CE Guidelines MN1919 www supportme net C 1 4 Use of CE compliant components The following points should be considered m Using CE approved components will not guarantee a CE compliant system m The components used in the drive installation methods used materials selected for interconnection of components are important m The installation methods interconnection materials shielding filtering and earthing grounding of the system as a whole will determine CE compliance m 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 mou
33. e 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 The motor that will be connected to the MicroFlex A motor power cable An encoder feedback cable and Hall cable for linear motors or resolver cable A serial cable connected as shown in section 5 4 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 m 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 www supportme net A PC with the following specification Min petition Wesommendeispecicson Serial port RS232 or RS485 serial port depending on MicroFlex model 0 Screen 800 x 600 256 colors 1024 x 768 256 colors Mouse A mouse or similar pointing device Operating system Windows 95 Windows 98 Windows ME Windows NT Windows XP or Windows 2000 3 1 3 Tools and miscellaneous hardware Your PC operating system user manual might be useful if you are not familiar with Windows Small screwdriver s with a blade width of 3mm or less for connector X
34. ectly 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 Pulse Up down count Counter Step TUUL Direction 7 Position Speed Torque Position demand s controller peed demand Torque PWM Power stage controller controller motor c Loans Measured speed Figure 50 Control structure in Position control Step and Direction B 4 Control System MN1919 CE Guidelines C 1 Outline This section provides general information regarding recommended methods of installation for CE compliance It is not intended as an exhaustive guide to good practice and wiring techniques It is assumed that the installer of the MicroFlex is sufficiently qualified to perform the task and is aware of local regulations and requirem
35. ectronics in the drive Speed Speed reference profiler Speed demand Torque demand Host Analog input e Speed Torque PWM Power stage controller controller motor Measured speed Figure 49 Control structure in Velocity control mode The speed controller is a PI Proportional Integral controller Gains are set using the Mint keywords KVPROP and KVI NT 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 250us and the result forms the torque demand for the torque controller As with the position controller the gain values KVPROP and KVI NT must be tuned for each application This can either be performed automatically within the Commissioning Wizard or manually using the Fine tuning tool of WorkBench v5 MN1919 Control System B 3 www supportme net 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 50 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 Ifthe position controller is tuned corr
36. ed re MM EENU GG x D Resolver input on a 9 pin male D type connector Twisted X8 Baldor motor SIN f i resolver connector SIN COS REF REF AGND Connect internal shields to AGND Connect overall shield to connector backshells Figure 18 Resolver cable connections 48 Feedback 1 1 1 MN1919 www supportme net 4 1 3 1 Resolver cable pin configuration Figure 17 shows the pin configuration for a typical Baldor resolver feedback cable part number CBLO25SF R1 Signal name MicroFlex Motor cable Baldor resolver cable X8 pin pin internal wire colors re ow qoc 1 1 O O O Pins 7 12 9 e are not used Q D eee 60 Motor resolver connector Cable connector end view male female Figure 19 Baldor motor resolver cable pin configuration The maximum recommended cable length is 30 5m 100ft MN1919 Feedback 4 9 www supportme net 4 1 4 Encoder output X7 E eee 5 DGND SEA T 1 2 3 4 CHZ BENE cCENMNNEENEEINEEMEENMEEMM 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 elect
37. ed during setup MN1919 Configuration 6 1 www supportme net 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 m Disconnect the load from the motor until instructed to apply a load If this cannot be done disconnect the motor wires at connector X1 Verify that the AC line voltage matches the specification of the MicroFlex Inspect all power connections for accuracy workmanship and tightness Verify that all wiring conforms to applicable codes Verify that the MicroFlex and motor are properly earthed grounded 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 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 Ifthe 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 Toallow 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
38. en using single phase supplies it may be necessary to reverse the AC power filter see section 3 4 7 2 Figure 39 Recommended system wiring 5 16 Input Output MN1919 6 1 6 1 1 6 1 2 Configuration 6 Introduction Before powering the MicroFlex you will need to connect it to the PC using a serial cable and install the supplied PC software WorkBench v5 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 Connecting the MicroFlex to the PC Connect the serial cable between a PC serial port often labeled as COM and the MicroFlex connector X6 WorkBench v5 can scan all the COM ports so you can use any port Installing the software The Baldor Motion Toolkit CD containing the software can be found separately within the packaging 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 WorkBench v5 The setup wizard will copy the files to appropriate folders on the hard drive The default folder is C Program Files WorkBench v5 although this can be chang
39. ents 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 inte
40. enu select Programs WorkBench v5 WorkBench WorkBench v5 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 ol Werken 1 Fe ede View Tode Window He 2 Inthe opening dialog box click Start New Project IworkBench v5 Open Hecent Project MN1919 Configuration 6 5 www supportme net 3 Inthe 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 Select Controller This check box is already selected for you When you click Select it means that the Commissioning Wizard will start automatically Note Ifthe 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 www supportme net 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 w
41. es 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 WorkBench v5 and its state is displayed in the Spy window User supply V MicroFlex Yeh g Load NEC PS2562L 1 Relay with diode shown Error User supply GND Figure 33 Drive status output circuit When the MicroFlex is connected to WorkBench v5 the active level of the output can be configured using the Operating Mode Wizard Alternatively the Mint keyword OUTPUTACTI VELEVEL can be used in the command window The output can also be configured using the Mint keywords DRI VEENABLEOUTPUT or GLOBALERROROUTPUT See the Mint help file for details MN1919 Input Output 5 11 www supportme net FEER User e MicroFlex x3 supply x9 NextMove ESB controller 24V Status Status DIN4 NEC PS2562L 1 CREF1 TLP280 User supply GND Figure 34 Status output typical connections to a Baldor NextMove ESB 5 12 Input Output MN1919 www supportme net 5 4 Serial port X6
42. f919 MicroFlex CHA CHA CHZ CHZ CHB CHB DGND SS Connect overall shield P d to connector backshells www supportme ne NextMove BX enco der input Baldor cable parts CBLOxxMF E3B are recommended where xx represents a choice of available lengths Figure 20 MicroFlex encoder output to NextMoveBX encoder input Baldor cable parts CBLOxxMF E3B are recommended where xx represents a choice of available lengths MicroFlex CHA CHA CHZ CHZ CHB CHB DGND U SR Connect overall shield P d to connector backshells NextMove ES ESB encoder input a Note If NextMove ES is not being used in conjunction with a Baldor backplane part BPLO10 50x the equivalent inputs on the card s 96 pin edge connector are as follows Enc0 Enct CHA b7 a8 CHA b10 c9 CHB a7 c7 CHB c10 a10 CHZ b8 c8 CHZ b9 a9 DGND a3 a3 or b3 c3 Figure 21 MicroFlex encoder output to NextMove ES ESB encoder input N CAUTION If a NextMove BX is to be connected a different cable must be used as shown in Figure 22 CHA CHA CHZ CHZ CHB CHB DGND Microflex X7 to connector backshells SX Connect overall shield P d NextMove BX encoder input Baldor cable parts CBLOxxMF E3A are recommended where xx represents a choice of available lengths Figure 22 MicroFlex encoder output to NextMove BX encoder input MN1919 Feedback 4
43. 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 www supportme net 3 4 5 Recommended fuses and wire sizes Table 3 describes the recommended fuses and suitable wires sizes to be used for power connections Continuous Input Fuse Minimum Catalog Output A Wire Gauge Number Amps Dus wo Ferraz Shawmut 10 6x32 FA series m W084314P 4 20 2 0 0 O FMH1A03 BS88 2 5 URGS 10A N076648 A FMH2A03 Ferraz Shawmut 30 6x32 FA eae i V084313P 14 BS88 2 5 URGS 7A M076647 14 Ferraz Shawmut 30 6x32 FA series gt m X084315P 44 BS88 2 5 URGS 12A P076649 Ferraz Shawmut 1o BS88 2 5 URGS 25A R076651 Ferraz Shawmut 30 6x32 FA Ses lad A084318P 44 2 BS88 2 5 URGS 20A L097507 Table 3 Protection device and wire ratings Ferraz Shawmut 10 6x32 FA series 20A A084318P Or BS88 2 5 URGS 20A L097507 FMH2A06 ES Note All wire sizes are based on 75 C 167 F copper wire H
44. grator 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 Guidelines C 1 www supportme net C 1 3 Declaration of conformity ge RR M CE BALDOR C Manufacturer Baldor UK Limited Address Mint Motion Centre Hawkley Drive Bristol Distribution Centre Bristol BS32 OBF United Kingdom Hereby declare that the product MicroFlex Single Axis Servo and Positioning Drive being one of FMH2A01TR xNy3 FMH2A03TR xNy3 FMH2A06TR xNy3 FMH2A09TR xNy3 where x RorE y 4or 2 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 Title Comments EN61800 3 1996 A11 2000 Adjustable speed electrical power drive Emissions amp Imm
45. he Mint help file for details 3 8 Basic Installation MN1919 www supportme net 3 3 Connector locations X1 Power Earth Ground Earth Ground NC L1 AC Phase 1 L L2 ACPhase2 N L3 AC Phase 3 OO U Motor U X6 RS232 V Motor V W Motor W RS232 RS485 422 NC NC MEL RXD RX R2 Regen TXD TX fe o NC NC J OV GND OV GND a o NC NC X6 o RTS TX s 3 CTS RX ile gt NC see NC ES T V section 5 4 U fo cu A V WwW R1 a CHA R2 9 A Eg CHB oa CHZ X1 NC EUR DGND BALDOR CHA CHB MicroF lex CHZ NC 0000000 00000000 X2 Control circuit Incremental SSI 1 CHA Data E es 2 CHB Clock OV 3 oo to 3 CHZ NC 24V 24V 4 jooj ff 4 Sense Sense AE 5 Hall U NC x 7 14 6 HallU NC 7 Hall V NC d 8 HallV NC 9 CHA Data 10 CHB Clock 11 CHZ NC 12 5V out 5V out X3 Input Output 13 DGND DGND 14 HallW NC 1 Shield 8 Shield 15 HallW NC 2 Status 9 Dir 3 Statust 10 Step 4 DINO 11 DGND Resolver 5 DINO 12 AINO 2 COS 6 Drive enable 13 AINO 3 SIN 7 Drive enable 14 AGND 4 NC 5 AGND Tightening torque for terminal block connections is 6 REF 0 5 0 6Nm 4 4 5 3 Ib in Maximum recommended 7 COS cable size is 0 5mm 20 AWG 8 SIN 9 Chassis MN1919 NC Not Connecte
46. he opposite direction MicroFlex p 74AHC14 Figure 31 Step and direction input circuit Step shown When the MicroFlex is connected to WorkBench v5 the following ratio can be configured using the Operating Mode Wizard Alternatively the Mint keywords FOLLOWDENOMand FOLLOWNUNMERAT OR can be used in the command window See the Mint help file for details MN1919 Input Output 5 9 www supportme net NextMove ESB controller DS26LS31 SED E 5 Q STEPO DS26LS31 bikes p Q DIRO DGND Shield po E NS Connect shields at one end only Figure 32 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 32 5 10 Input Output MN1919 www supportme net 5 3 4 Status output X3 Location Connector X3 pins 2 amp 3 Mating connector Weidm ller Minimate B2L 3 5 14 Description Opto isolated status output Output current 100mA maximum User supply 30VDC maximum Update interval 500us The optically isolated status output is designed to source current from the user supply as shown in Figure 33 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 includ
47. here 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 gt 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 previo
48. ield should be connected to the chassis at one end only No other connection should be made to the shield MicroFlex Low pass filter amp level correction Internal reference Figure 23 AINO analog input demand circuit When the MicroFlex is connected to WorkBench v5 the analog input value expressed as a percentage can be viewed using the Spy window s Monitor tab Alternatively the command Print ADC O 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 www supportme net X3 X3 AINO 13 AINO 13 AINO 12 AINO 49 AINO x BEE ie 14 GND 14 Differential connection Single ended connection Figure 24 AINO analog input wiring 24VDC 1 5kQ 0 25W li 1kQ 0 25W potentiometer OV Figure 25 Typical input circuit to provide 0 10V approx input from a 24V source MicroFlex NextMove ESB controller AGND Shield ee NS Connect overall shield at one end only Figure 26 Analog input typical connection from a Baldor NextMove ESB MN1919 Input Output 5 3 www supportme net 5 3 Digital I O The MicroFlex provides as standard 1 dedicated drive enable input 1 general purpose digital input
49. igher 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 WorkBench v5 see section 6 3 2 3 14 Basic Installation MN1919 www supportme net 3 4 7 Power supply filters To comply with EEC directive 89 336 EEC an AC power filter of the appropriate type must be connected This can be supplied by Baldor and will ensure that the MicroFlex 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 Input voltages current rating 230VAC 16 230VAC 30 FI0015A00 line reactor FI0018A00 See sections 3 4 7 1 and 3 4 7 2 or FI0029A00 see section A 1 2 Or FI0018A00 FI0029A00 see section A 1 2 FI0029A00 see section A 1 2 FI0018A03 Table 4 Baldor filter part numbers ow FI0015A02 see section 3 4 7 2 Maximum earth leakage f
50. ions MN1919 Accessories 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 www supportme net A 1 1 Fan tray The fan tray Baldor part FAN001 024 provides sufficient cooling for the 3A 6A or 9A MicroFlex 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 42 Fan tray Fan tray MED s FAN001 024 dimensions 84 3 3 i P UE O Brem O d 5 S Assembled MicroFlex and fan tray 66 2 6 i Mo Position of fan tray mounting holes relative to MicroFlex Bottom of MicroFlex 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 Figure 42 Fan tray A 2 Accessories MN1919 www supportme net A 1 2 Footprint filter
51. k MN1919 www supportme net 4 1 2 1 SSI cable pin configuration Figure 17 shows the pin configuration for a typical Baldor SSI feedback cable part number CBLO25SF S2 Signal name MicroFlex Motor cable Baldor SSI cable X8 pin pin internal wire colors 1 000 Pins 7 12 9 are not used Q D e be present 60 Motor SSI connector Cable connector end view male female Figure 17 Baldor motor SSI feedback cable pin configuration The maximum recommended cable length is 30 5m 100ft MN1919 Feedback 4 7 www supportme net 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 WorkBench v5 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 unus
52. ller menu item will clear errors and enable the MicroFlex Alternatively the Mint command RESET O can be used in the command window to perform the same action The state of the drive enable input is displayed in the WorkBench v5 Spy window Alternatively the state of the drive enable input can be read but not set using the Mint command Pri nt DRI VEENABLESW TCH in the command window See the Mint help file for details MN1919 Input Output 5 5 www supportme net NextMove ESB controller MicroFlex UDN2982 DRI VEENABLEOUTPUT M Enable LA Na TLP280 Figure 28 Drive enable input typical connection from a Baldor NextMove ESB 5 6 Input Output MN1919 www supportme ne 5 3 2 General purpose digital input X3 Location Connector X3 pins 4 amp 5 Mating connector Weidmuller Minimate B2L 3 5 14 Description General purpose optically isolated digital input Nominal input voltage 24VDC input current not to exceed 50mA sampling interval o00us 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 WorkBench v5 Spy window The input can be can be configured for different user definable functions MicroFlex TLP280
53. ly 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 Nominal input 24V voltage Input current Maximum 1A continuous 4A typical power on surge limited by NTC Typical 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 Ib in Customer supplied 24V filter Ferrite 24VDC fused optional sleeve GND 24V Use a twisted pair cable with ferrite sleeve attached close to connector X2 Incoming safety earth ground PE 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 www supportme net 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 h
54. mpliance the motor earth ground should be connected to the drive earth ground MN1919 Basic Installation 3 17 www supportme net 3 5 1 3 5 2 3 18 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 N 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 Motor power cable pin configuration Baldor BSM rotary motors Figure 8 shows the pin configuration for a typical Baldor motor cable part number CBLO25SP 12 Motor cable wire color Black labeled 1 Black labele
55. nal DC bus during motor deceleration The regeneration resistor must have a resistance of at least 390 and an inductance of less than 100pH Suitable regeneration resistors are listed in section A 1 4 The regeneration resistor output is conditionally short circuit proof Regeneration resistor Connect outer shield to resistor body Earth ground outer shield using 360 conductive clamp connected to STAR enclosure backplane POINT Figure 9 Regeneration resistor connections N 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 20 Basic Installation MN1919 Feedback 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 The feedback device wiring must be separated from power wiring Where feedback device wiring runs parallel to power cables they must be separated by at least 76mm 3 in Feedback device wiring must cross power wires at right angles onl
56. nds upon its use in the appropriate environment The following points must be considered MN1919 The MicroFlex must be installed indoors permanently fixed and located so that it can only be accessed by service personnel using tools The maximum suggested operating altitude is 1000m 3300ft The MicroFlex must be installed where the pollution degree according to IEC664 shall not exceed 2 The 24VDC control circuit supply must be installed so that the 24VDC supplied to the unit is isolated from the AC supply using double or reinforced insulation The input of the control circuit must be limited to Safety Extra Low Voltage circuits Both the AC supply and the 24VDC supply must be fused The atmosphere must not contain flammable gases or vapors There must not be abnormal levels of nuclear radiation or X rays To comply with CE directive 89 336 EEC an appropriate AC filter must be installed The MicroFlex 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 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 Each D type connector on the front panel of the MicroFlex is secured using two hexagonal jack screws sometimes known a
57. 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 www supportme net 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 WorkBench v5 window displays the Controller Parameters screen nre m n il p
58. nnector backshell Connect overall shield T to connector backshell Figure 52 Encoder signal cable grounding MN1919 CE Guidelines C 5 www supportme net C 6 CE Guidelines MN1919 A Abbreviations 2 3 Accessories A 1 EMC filters A 4 fan tray A 2 feedback cables A 9 A 10 footprint filter A 3 motor power cables A 8 regeneration resistors A 7 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 amp 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 Index Digital I O 5 4 drive enable input 5 5 general purpose digital input 5 7 status output 5 11 step amp 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 A 9 feedback 4 2 specification 8 5 SSI See SSI without Halls 4 4 Environmental cooling 3 3 location 3 3 3 4 specification 8 6 F Features 2 1 Feedback cable
59. nted 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 Guidelines C 3 www supportme net C 1 6 EMC installation suggestions To ensure electromagnetic compatibility EMC the following installation points should be considered to help reduce interference m Earthing grounding of all system elements to a central earth ground point star point m Shielding of all cables and signal wires m Filtering of power lines A proper enclosure should have the following characteristics m 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 m 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 m The shield connections of the signal and power cables should
60. nual and mail it to Manuals Baldor UK Ltd Mint Motion Centre 6 Bristol Distribution Park Hawkley Drive Bristol BS32 OBF United Kingdom Alternatively you can e mail your comments to manuals baldor co uk continued MN1919 Comments Thank you for taking the time to help us Comments MN1919 BALDOR MOTORS DRIVES amp GENERATORS Baldor Electric Company P O Box 2400 Ft Smith AR 72902 2400 U S A Visit www supportme net for the latest documentation and software releases 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 08491 Europe Southern Baldor ASR AG Switzerland Tel 41 52 647 4700 Fax 41 52 659 2394 Japan Baldor Japan Corporation Tel 8145 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 65 744 2572 Fax 65 747 1708 United Kingdom Baldor UK Ltd Tel 44 1454 850000 Fax 44 1454 859001 U S A Headquarters Baldor Electric Company Tel 1479 646 4711 Fax 1479 648 5792 For additional office locations visit www baldor com Printed in UK Baldor UK Ltd
61. oet aad adt 8 3 9 1 4 Regeneration X T ia sire ient ee RR RUE d e DPA OR E wed ate d 8 3 8 1 5 Analog Input X9 a sala donc dope RR RR ee ea dee eR abd ae kone edna s 8 4 8 1 6 Digital inputs drive enable and general purpose X3 8 4 8 1 7 Step and Direction inputs X3 0 0 0 ees 8 4 8 1 8 Status output X3 s qud as dena a ESL RERUM ER FASES enken S PR ERRARE Slee 8 5 8 1 9 Incremental encoder feedback option X8 anaana araara 8 5 8 1 10 SSI encoder feedback option X8 0 ces 8 5 8 1 11 Resolver feedback option X8 0 ccc eens 8 5 8 1 12 Encoder output simulated X7 2 0 anaana aaaea 8 6 8 1 13 Serial RS232 RS485 interface X6 llle 8 6 SkA En VviIronrmebtdl sceosecaraxote dta ice Qaeda ce ducite dance dui testa dulce disc Porn 8 6 Appendices As ACCESSOS ox arose eso EDER wed AUS bas we SERRE A 1 ACT o IBIFOQUGIIOD 42x uc ep aS EROS A eie SEEMS A 1 AAG Fantay eese eicere el eode bene ca ee eod wed amas A 2 FEV EOS DER EINE cca Dau lun rc ceca De Rage ce e atra AGRO ed d Rd A 3 Bd EME IUS Ra ores Piden ERE ERR OE EAD hes Dn B ECL Sec dotata A 4 A 1 4 Regeneration resistors 0 cet A 7 Ako MOOR power CabDl68 oa nind ata Ps Beta ce a ae a Ea che A 8 A 1 6 Motor power cable part numbers 0 0 0 0 cece A 8 A 1 7 SSI feedback cables nnana 0c eee enna A 9 A 1 8 Encoder Hall feedback cables 0 00 cee nes A 9 A 1 9 Re
62. ommended cable length MN1919 Specifications 8 5 www supportme net 8 1 12 Encoder output simulated X7 All models Output is a copy of the input on X8 Adjustable simulated output See section 4 1 4 All models RS232 non isolated CTS RTS Or RS485 non isolated model dependent 9600 19200 38400 5 600 default 8 1 14 Environmental All models Operating temperature range All models ae 32 45 113 See sections See sections 3 2 2 to 3 2 6 3 2 2 to 3 2 6 40 to 85 40 to 185 Minimum Maximum Derate Storage temperature range Humidity maximum 1000 Derate 1 1 100m over 1000m Maximum installation altitude above m s l 3300 Derate 1 1 330ft over 3300ft 8 6 Specifications MN1919 Forced air cooling flow None ne m 5 vertical from bottom to top www supportme net MicroFlex complies with the following environmental test standards BS EN60068 2 1 1993 low temperature operational O 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 38 7 www supportme net 8 8 Specificat
63. on WorkBench v5 fails Ensure that the MicroFlex is powered and the Status LED is to detect the illuminated see section 7 2 MicroFlex it detects No Check that the serial cable is connected between the PC s COM port controller found and connector X6 on the MicroFlex Communication fault on COMx 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 WorkBench v5 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 WorkBench v5 check that the correct COM port is selected If the Search up to Nodexx option is selected in WorkBench v5 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 WorkBench v5 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 www supportme net 7 2 2 Power on
64. onnector is not required A 8 Accessories MN1919 www supportme net A 1 7 SSI feedback cables This table lists part numbers of feedback cables for use with the MicroFlex Length Cable assembly description Catalog number HEDE SSI Feedback Cable CBL044 501 Available by the meter no connectors or on 100m drum 1 5 5 CBLO15SF S2 CBLO25SF S2 CBLO30SF S2 CBLOS50SF S2 Feedback Cable Assembly CBLOG1SF S2 CE style threaded motor connector CBLO75SF S2 and low density 15 pin D type drive CBLO91SF S2 connector CBL100SF S2 CBL150SF S2 CBL152SF S2 CBL200SF S2 CBL229SF S2 Available in North and South America only A 1 8 Encoder Hall feedback cables This table lists part numbers of encoder feedback cables for use with the MicroFlex Cable assembly description Catalog number es Encoder Feedback Cable CBL043 501 Available by the meter no connectors or on 100m drum Feedback Cable Assembly CBLO25SF E 2 5 0 2 CE style threaded motor connector motor end only CBLO15SF E2 CBLO25SF E2 CBLO30SF E2 CBLO50SF E2 Feedback Cable Assembly CBLOG1SF E2 CE style threaded motor connector CBLO75SF E2 and low density 15 pin D type drive CBLO91SF E2 connector CBL100SF E2 CBL150SF E2 CBL152SF E2 CBL200SF E2 CBL229SF E2 Available in North and South America only MN1919 Accessories A 9 www supportme net A 1 9 Resolver feedback cables This table lists part numbers of Baldor resolve
65. onnector locations kolde Bars kl aa eee 3 9 39 4 Power connections iid Spe ERE nie oe eine ool EG A 3 10 3 4 1 Earthing grounding i22 Aes 6 o s SOROR een CS aeos SCRI ks Ks 3 10 3 4 2 Single phase or three phase power connections 3 11 4449 Inputpower CONGITIONING acera cse dede ted a eek Ae es Dole ee ERA a hs 3 12 3 4 4 Power disconnect and protection devices 3 13 3 4 5 Recommended fuses and wire sizes lsusls 3 14 3 4 6 Drive overload protection 0 00 ces 3 14 34 7 Power supply fillers 53 TASKE EEG ERDBEEETGGQEPYERETGGePULES 3 15 SAG 24V controleireult SUDDIV xe eal Oe ale a Pee tis 3 16 3 5 Motor connections 0 eee 3 17 OT MOO CIFGUIV COMACIOIS sd ahr ble dose ed eie acide dope v de t o 3 18 3 5 2 Motor power cable pin configuration Baldor BSM rotary motors 3 18 3 5 3 Motor cable pin configuration Baldor linear motors 3 19 ood SKS OGS ANER 09 aud uo La darte d E ouam tu ded d eda et s 3 19 3 6 Regeneration resistor Dynamic Brake resistor 3 20 MN1919 Contents i 4 Feedback ua Be ase Ear rar etr Stute Roe erar Sek ae dox 4 1 41 JntrodliellOl xs axe pacte n euch ee whee RAE RO ERR 4 1 4 1 Encoder feedback XO s atr a Shes dec P RER ERR EVERT RSS 4 2 4 1 2 SSI feedback X8 0 eee eee eee eee e ene 4 6 4 1 3 Resolver feedback X8 0 0 ccc eee enn
66. ower 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 WorkBench v5 or other custom application or a programmable logic controller PLC RS422 may be used for multi drop applications as shown in Figure 36 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 WorkBench v5 Network master i i Network slave Twisted pairs Master and final slave are shown with terminating resistors TR typical value 1200 Connect overall shield to connector backshell Figure 36 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 transmi
67. pairs CHA CHA CHB CHB CHZ INDEX CHZ INDEX 5V DGND Sense Hall U Hall Hall U Feedback Hall W Leave pins 5 7 amp 14 Hall W unconnected Hall V Hall V Encoder Feedback NS Connect overall shield to A connector backshells Figure 15 Encoder cable connections linear motors MN1919 Feedback 4 5 www supportme net 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 Connector X8 15 pin D type female connector ws 12 5 11V out Motor X8 Data Data Clock Clock 5V DGND Sense Connect internal shields to pin 13 Absolute Encoder SSI Interface Chassis Connect overall shield Da to connector backshells Figure 16 SSI encoder cable connections 46 Feedbac
68. pairs CHA CHA Encoder CHB Feedback CHB CHZ INDEX CHZ INDEX 5V DGND Sense NKS Connect overall shield A 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 Motor Sense 5V DGND Hall U Hall U Hall W Hall W Hall V Hall V Hall Feedback SSG Connect overall shield P to connector backshells Figure 14 Halls only feedback cable connections rotary motors Note Ifthe 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 44 Feedback MN1919 www supportme net 4 1 1 4 Encoder cable pin configuration Baldor linear motors Baldor linear motors use two separate cables encoder and Hall The cores of these two cables must be wired to the appropriate pins of the 15 pin D type mating connector supplied Signal name MicroFlex Encoder cable internal wire colors X8 pin CHA CHA CHB a NENNEN Please refer to MN1800 Linear Motors Installation amp Operating Manual for details CHZ OT BaorHalisabieimtermal wie colors mu 9 We 0 ar Re Web 5 on 1 2 CHB 10 3 Motor Twisted
69. pecifications 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 ZN 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 Ifa 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 www supportme net WARNING WARNING WARNING WARNING WARNING WARNING CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION ppp ppp pnm mm po CAUTION MN1919 Be s
70. 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 1596 if forced air cooling is present Forced air flow Cool It is recommended to allow approximately 60mm at the front to accommodate wiring and connectors Figure 2 Cooling and proximity MN1919 Basic Installation 3 5 www supportme net 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 4 1m s forced air z 5 2 5 O 5 i Natural cooling O 4 O 2 ad 0 30 35 40 45 50 55 Ambient temperature C Three phase AC supply 3 m 1m s forced air E g 2 5 O Natural cooling a 1 O O 2 a4 0 30 35 40 45 50 55 Ambient temperature C Notes Load power factor 0 75 Overload limit for model FMH2AOS3TR EN23 is 6A 3 6 Basic Installation MN1919 www supportme net 3 2 5 Derating characteristic 6A model The following derating characteristics are for model FMH2A06TR EN23 Single phase AC supply 1 5m
71. pply pd O Q i P Oo F 200 AT Single phase AC supply 2 Q O QO 150 100 10 250 1 supply uL Tn MN1919 Specifications 8 1 www supportme net 8 1 1 2 Effect of AC power supply voltage on DC bus ripple DC bus ripple of DC bus voltage 100 125 150 175 200 225 250 AC supply voltage rms 8 1 1 3 Effect of output current on DC bus ripple voltage DC bus ripple voltage Vpk pk 20 30 40 50 60 70 80 90 100 110 120 130 140 150 of Drive Rated Current 8 2 Specifications MN1919 www supportme net 8 1 2 24VDC control circuit supply input X2 10 Power on surge current typical 24VDC 100ms Nominal input voltage VDC 7 8 1 3 Motor output power X1 Nominal phase current Peak phase current for 3s vA ER Nominal output 398 1195 2390 3585 230V 36 Output voltage range line line VRMS 0 230 VDC bus 320V Output frequency 0 2000 Output dv dt kV us at drive phase phase 2 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 Nominal switching threshold typical VDC Nominal power 10 power cycle R 57Q 1 gt 95 Peak power 10 power cycle R 57Q Maximum regeneration switching current Minimum load resistance Maximum load inductance MN1919 Specifications 8 3 e NO C1 www s
72. ption of the symptoms that you can observe for example the Status LED error messages displayed in WorkBench v5 or the current value of the Mint error keywords AXI SERROR and DRI VEERRCR m The type of motion generated in the motor shaft m Give alist 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 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 www supportme net 7 2 Status LED The Status LED indicates general MicroFlex status information Solid green Drive enabled normal operation Flashing green Firmware download in progress 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 Meaning no of flashes DC bus overvoltage trip IPM integrated power module trip Overcurrent trip Overspeed trip Feedback trip Motor overload It trip Overtemperature trip Drive overload It t
73. put 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 From Circuit Breaker From Fuse supply supply L L I t N N N Figure 4 Circuit breaker and fuse single phase From Circuit Breaker From Fuses supply supply L1 Tx L1 L1 I I L2 Av L2 L H I I L3 Y L3 L3 4 I Circuit breaker or fuse are not supplied For CE Compliance see Appendix C Figure 5 Circuit breaker and
74. r feedback cables for use with the MicroFlex Length Cable assembly description Baldor catalog number bu Resolver Feedback Cable CBL044 501 Available by the meter no connectors or on 100m drum CBLO15SF R CBLO25SF R CBLO30SF R CBLOSOSF R CBLO61SF R CBLO75SF R CBLO91SF R CBL100SF R CBL150SF R CBL152SF R CBL200SF R CBL229SF R CBLO15SF R1 CBLO25SF R1 CBLO30SF R1 CBLOSOSF R1 CBLO061SF R1 CBLO75SF R1 CBLO91SF R1 CBL100SF R1 CBL150SF R1 CBL152SF R1 CBL200SF R1 CBL229SF R1 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 Available in North and South America only A 1 10 Feedback cable part numbers A description of a feedback cable catalog number is shown here using the example number CBLO25SF E2 Indicates the length in this example 2 5 meters Hebe SES SECHONS ED END The cable is a Servo motor Feedback cable aes 1 Drive connector included 9 pin D type connector Resolver Drive connector included 15 pin D type connector Encoder Hall amp SSI R Resolver feedback cable ca Encoder feedback cable with motor connector S SSI feedback cable A 10 Accessories MN1919 www supportme net 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
75. r in to metal backplane OR tuses 5 sji2 2 12 using conductive L3 jL3 131 shield clamp COM la Connect AC power cable shield to PE metal backplane using conductive O shield clamp see section C 1 7 O Star O point Shielded twisted pair clamped to metal backplane near drive using conductive shield earth ground ie clamp see sections 3 6 and C 1 7 Serial Optional communication regen resistor Regen Dynamic In MEG brake Z a Motor feedback Motor power U V W Motor T 24V OV 24V OV Demand input 10V analog input Control circuit supply Drive enable shown or 5V step and direction Use twisted pair cable input inputs Use shielded twisted pair s for with a ferrite sleeve demand input s Connect cable shield see section 3 4 8 to the bottom of MicroFlex using conductive shield earth ground clamp m The MicroFlex should be mounted on an earthed metal backplane m Ensure cables do not obstruct airflow to the heatsink Motor represents a typical Baldor BSM motor Linear motors may also be controlled by MicroFlex m Conductive shield earth ground clamps are not supplied m Wh
76. rchase 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 MN1919 General Information 1 1 www supportme net 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 VDEO0160 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 Home appliances Medical instrumentation Mobile vehicles Ships 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 s
77. readed for M4 bolts no longer than 11mm 0 43 in in length Connect earth ground to protective earth on top of AC Route L1 L2 L3 and Circuit breaker or fuses AC filter drive Supply earth ground together See section 3 4 4 See section in conduit or cable I cf Ode cg UO Gem a CNN Line L1 Line L2 Line L3 77 I 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 www supportme net 3 4 3 Input power conditioning Certain power line conditions must be avoided an AC line reactor an isolation transformer or a step up step down transformer may be required for some power conditions m 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 m 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
78. rical 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 WorkBench v5 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 ENCODERLI NESOUT 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 ENCODERLI NESOUT in the Mint help file 440 Feedback MN
79. rip 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 WorkBench v5 help file Press F1 and locate the DRI VEERROR and AXI SERROR keywords or the Error Handling book Alternate red green flashing Undervoltage warning no AC power but no errors are latched The DC bus voltage has dropped below the powerbase undervoltage level see DRI VEBUSUNDERVOLTS This error will only be generated if the drive is in the enabled state Check the AC power is connected 7 2 Troubleshooting MN1919 www supportme net 7 2 1 Communication Status LED is off Check that the 24VDC control circuit supply is connected correctly to connector X2 and is switched
80. rom 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 4Arms 10A peak line reactor is required to ensure compliance with EN61000 3 2 2000 class A limits when the total equipment supply load is less than 1kW 3 4 7 2 Reversing the filter When using filters F10015A00 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 JN WARNING This recommendation applies only to filters FI10015A00 and FI0015A02 Alternative filters or protection devices must be connected as specified by the manufacturer MN1919 Basic Installation 3 15 www supportme net 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 like
81. s 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 Basic Installation 3 3 www supportme net 3 2 1 Dimensions 5 0 2 l Mounting hole and slot detail 00 9 l 5 5 mm gt N 5o Sx Dimensions shown as mm inches Depth 157 mm 6 2 in Weight 1A 1 45kg 3 2Ib 3A 1 45kg 3 2 b 6A 1 50kg 3 3 b 9A 1 55kg 3 4 b Figure 1 Package dimensions 3 4 Basic Installation MN1919 www supportme net 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 c
82. s forced air 1m s forced air Natural cooling Rated output currrent Arms Ambient temperature C Three phase AC supply 1 5m s forced air 1m s forced air Natural cooling Rated output currrent Arms Ambient temperature C Notes Load power factor 0 75 Overload limit for model FMH2AO06TR EN23 is 12A MN1919 Basic Installation 3 7 www supportme net 3 2 6 3 2 7 Derating characteristic 9A model The following derating characteristics are for model FMH2A09TR EN23 Single phase AC supply e eem 3 5m s forced air 2 5m s forced air om s forced air 1m s forced air Rated output currrent Arms LL Natural cooling LULA _ Eo o re EE O re SENE Ed FE 30 35 40 45 50 55 Ambient temperature C Three phase AC supply Em qu 3 5m s forced air 2 5m s forced air 1 5m s forced air 1m s forced air Rated output currrent Arms O gt N O A a Q N 0 CO Natural cooling mm oe ee e See ER pas ea Gees BEER es es m UU UU 30 35 40 45 50 55 Ambient temperature C Notes Load power factor 0 78 Overload limit for model FMH2A09TR EN23 is 18A 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 TEMPERATURELI M TFATAL keyword see t
83. shielded twisted pair 0 34mm 22 AWG wire minimum with an overall shield Ideally the cable should not exceed 30 5m 100ft in length Maximum wire to wire or wire to shield capacitance is 50pF per 300mm 1ft length to a maximum of 5000pF for 30 5m 100ft MN1919 Accessories A 11 www supportme net A 12 Accessories MN1919 B 1 Control System B Introduction The MicroFlex can be configured for three basic control modes m Current Torque control m Velocity Speed control m Step and Direction following gearing The mode you require is selected in WorkBench v5 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 MN1919 Control System B 1 www supportme net 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 48 Here a torque reference is obtained from a specified source m WorkBench v5 m A host using the ActiveX control m 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 t
84. solver feedback cables 0 0c ccc eee nes A 10 A 1 10 Feedback cable part numbers 0 000 ees A 10 MN1919 Contents iii D Control System ausa pu ke eua ph e SUPE Ne ERR ET IS B 1 Bt INrodUCHON presses 209 9 2 9 206 oce Md 0 LM d eI D Mt Re B 1 B 1 1 Gurrent Torque control d usi andre ads ER OL RADIO E DERE ORA B 2 B 1 2 Velocity Speed control 0 0 0 teens B 3 B 1 3 Position Step and Direction control 0 cee eee B 4 C CE GuidGiineS sux vae bp E ESAME REESE EARS C 1 EA CJ T v m C 1 C 1 1 EMC Conformity and CE marking 0 000 cece eee eens C 1 Q2 MicroFPlex compliance po PEOR ace eee een eed eee eis C 1 C 1 3 Declaration of conformity 0 c cee C 2 C 1 4 Use of CE compliant components 0 0 0 C 3 Cro EMC WinhG IEEE AUS iiss die tae vh a aue iee a a ole ih er abes to ai C 3 C 1 6 EMC installation suggestions 0 ccs C 4 C 1 7 Wiring of shielded screened cables 0 000 cee eee ees C 5 iv Contents MN1919 General Information 1 Copyright Baldor c 2006 All rights reserved This manual is copyrighted and all rights are reserved This document or attached software may not in whole or in part be copied or reproduced in any form without the prior written consent of Baldor Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims
85. ss Ctrl then E at the same time Ibat boa e el kilobaud the same as Kbit s in most applications ME oa sd xA RAS megabytes NP TM eden tats feet TUS a puris eder ds feet per second y EM Rm inch ID a me RR ERES pound inch torque MM 20 te tenses millimeter Mig ieee See DERE meter M S 2 22 each iss meters per second NIM ost Sees PERS Newton meter torque ADO 340 a a a Analog to Digital Converter AWG American Wire Gauge DAC is eneret uy Digital to Analog Converter vil MENTEM Synchronous Serial Interface NC Not Connected MN1919 Introduction 2 3 www supportme net 2 4 Introduction MN1919 Basic Installation 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 Location considerations Mounting the MicroFlex Connecting the AC power supply Connecting the 24VDC control circuit supply Connecting the motor Installing a regeneration resistor Dynamic Brake Connecting the feedback device These stages should be read and followed in sequence 3 1 1 Power sources A 115 230VAC power source IEC1010 over voltage category III or less in the installation area is required This may be single phase or three phase An AC power filter is required to comply with the CE directive for which the MicroFlex was tested see section 3 4 7 Th
86. ted closed loop connectors that are of appropriate size for the wire gauge being used Connectors are to be installed using only the crimp tool specified by the manufacturer of the connector Only class 1 wiring should be used 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 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 m Means of connection of protective earth to accessible live conductive parts m Basic insulation 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
87. ter is turned off KVTI ME 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 KVTI ME are used B 2 Control System MN1919 www supportme net B 1 2 Velocity Speed control Setting the control mode to Velocity Control configures the MicroFlex as a speed amplifier as shown in Figure 49 Here a speed reference is obtained from a specified source m WorkBench v5 m A host using the ActiveX control m 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 el
88. tted 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 5 14 Input Output MN1919 www supportme net 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 37 Baldor HMI MicroFlex Baldor HMI MicroFlex PLC PORT X6 PLC PORT X6 Without hardware handshaking With hardware handshaking Figure 37 RS232 cable wiring Alternatively the Baldor HMI panel may be connected using RS485 422 as shown in Figure 38 Baldor HMI MicroFlex PLC PORT X6 Figure 38 RS485 422 cable wiring MN1919 Input Output 5 15 www supportme net 5 5 Connection summary recommended system wiring As an example Figure 39 shows the recommended wiring necessary for the MicroFlex to control a motor while conforming to the EMC requirements for industrial environments AC power Connect motor HostPC power cable shield From L1 1 AC powe
89. uiring power 200mA max MicroFlex CHA AM26LS32 Differential line receiver CHA Figure 10 Encoder channel input circuit Channel A shown 42 Feedback MN1919 www supportme net MicroFlex Hall U AM26LS32 Differential line receiver Hall U Figure 11 Hall channel input circuit U phase shown 4 1 1 1 Encoder cable configuration Baldor rotary motors Motor Twisted pairs m CHA i hes m FJER de EEUU l CHB Encoder CHB Feedback FEE amp SE ee En CHZ INDEX 5V TE LX ee ee T Hall U es Sali Re I E LL ew a a ed Hall V SERENE EN SES E dena AN Connect overall shield P to connector backshells Figure 12 Encoder cable connections rotary motors Note Ifthe 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 www supportme net 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 Twisted
90. unity comply systems Part 3 EMC Product standard with both 1st amp 2nd environments including test methods The Low Voltage Directive 72 23 EEC and its amending directives Standard Title EN61800 5 1 2003 Adjustable speed electrical power drive systems Safety requirements Electrical thermal and energy EN61800 2 1998 Adjustable speed electrical power drive systems General requirements Rating specifications for low voltage adjustable frequency a c power drive systems EN50178 1998 Electronic equipment for use in power installations EN60529 1992 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 amp 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 declare
91. upportme net 8 1 5 Analog input X3 Common mode voltage range VDC V t gt gt 4 9 8 1 6 Digital inputs drive enable and general purpose X3 10 40 30 12 125 All models Opto isolated inputs Input voltage VDC Nominal 24 Minimum Maximum 8 1 7 Step and Direction inputs X3 m 12 30 F Es 1 5 mA All models Non isolated DC inputs VDC 8 4 Specifications MN1919 www supportme net 8 1 8 Status output X3 User supply maximum Output current max continuous Approximate trip current Reset time Update interval 8 1 9 Incremental encoder feedback option X8 Encoder input A B Differential Z index Maximum input frequency quadrature Single ended 5V logic SV 200mA max 30 5m 100ft Output power supply to encoder Maximum recommended cable length 8 1 10 SSI encoder feedback option X8 All models Differential Data and Clock Single turn Positioning resolution up to 262144 counts rev 18 bit 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 5V 200mA max 30 5m 100ft MicroFlex resolver input accuracy Typical accuracy using Baldor BSM series resolver motor with input set to simulate 4096 ppr Hul um MK wm Aim EINE LL E M Maximum rec
92. ure all wiring complies with the National Electrical Code and all regional and local codes Improper wiring may result in unsafe conditions 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 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 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 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 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 To prevent equipment damage be certain that the input power has correctly sized protective devices installed To prevent equipment damage be certain that input and output signals are powered and referenced correctly To ensure reli
93. us 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 lel button on the Mode toolbar Saving parameters into flash memory will cause the MicroFlex to be reset MN1919 Configuration 6 7 www supportme net 6 3 Further configuration WorkBench v5 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 WorkBench v5 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
94. 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 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 Failure to meet cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips Violent jamming stopping of the motor during operation may damage the motor and drive Operating the MicroFlex in Torque mode with no load attached to the motor can cause the motor to accelerate rapidly to excessive speed If the drive enable signal is already present when power is applied to the MicroFlex the motor could begin to move immediately Do not tin solder exposed wires Solder contracts over time and may cause loose connections Use crimp connections where possible Electrical components can be damaged by static electricity Use ESD electrostatic discharge procedures when handling this drive Ensure that encoder wires are properly connected Incorrect installation may result in improper movement 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 m
95. ust be screwed in to a depth of at least 8mm Removing the cover will invalidate UL certification The metal heatsink on the left side of the MicroFlex can become very hot during normal operation MN1919 Introduction 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 Single axis AC brushless drive Range of models with continuous current ratings of 1A 3A 6A or 9A Direct connection to 115VAC or 230VAC single phase or 230VAC three phase supplies SSI incremental encoder or resolver feedback Velocity and current control with step and direction input for position control Auto tuning wizard including position loop and software oscilloscope facilities provided by WorkBench v5 configuration software supplied 2 optically isolated digital inputs one enable input and one general purpose input 1 optically isolated digital output to indicate error conditions 1 general purpose analog input can be used as a speed or torque command reference 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
96. y To prevent contact with other conductors or earths grounds unearthed ungrounded ends of shields must be insulated 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 www supportme net 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 Location Connector X8 15 pin nails female connector not high density Pin fEncoderfuncton OOOO ENNNIL MN fee fa aa ae TT m 9 NEN 9 E Description Incremental UVW encoder input non isolated Pin 12 provides 5 11V for encoders req

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