Home

MicroFlex Servo Control

1. 3 21 3 7 2 Regenerative energy 3 22 3 7 3 Regenerative power and average power 3 22 3 7 4 Resistor Choice siio sdb b emnt bemus MP EN 3 23 3 7 9 Resistor deraling ce esce e ee ee 3 23 4 Feedback Mem 4 1 4 1 Introduction ooocccccco eh 4 1 4 1 1 Encoder feedback 8 4 2 4 1 2 SSlfeedback X8 benei e aa piat 4 7 4 1 3 Resolver feedback X8 4 9 41 4 Encoder output X7 0 2 00 teens 4 11 5 5 Input P DUIDUL ertet ete eee heats AA 5 1 Dil Introduction uio ER hb t e ee tee eran 5 1 5 2 Analog W O ni A eg SR a de 5 2 5 2 1 Analog input demand 5 2 5 3 Digital VO tai aa acini e TREES ace CIRC T oes 5 4 5 3 1 Drive enable input 5 5 5 3 2 General purpose digital input 5 7 5 3 3 Step pulse and direction inputs 5 9 5 8 44 Status output eee 5 12 5 4 Serial XO oe Le ee eee ep yp 5 14 5 4 1 Using RS232 5 14 5 4 2 Multidrop using RS485 RS422 cable 5 15 5 4 3 Connecting serial Baldor HMI
2. C 3 C 1 5 C 3 C 1 6 installation suggestions C 4 C 1 7 Wiring of shielded screened cables C 5 2 6 iv Contents MN1919 General Information 1 Copyright Baldor c 2010 All rights reserved This manual is copyrighted and all rights are reserved This document or attached software may not in whole or in part be copied or reproduced in any form without the prior written consent of Baldor Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose The information in this document is subject to change without notice Baldor assumes no responsibility for any errors that may appear in this document Mint is a registered trademark of Baldor Windows 2000 Windows XP and Windows Vista are registered trademarks of the Microsoft Corporation UL and cUL are registered trademarks of Underwriters Laboratories MicroFlex is UL listed file NMMS E128059 Limited Warranty For a period of two 2 years from the date of original purchase Baldor will repair or replace without charge controls and accessories that our examination proves to be defective in material or workmanship
3. 7 1 7 1 3 Power cycling the MicroFlex 7 1 7 2 Status LED iii ERE en e oca b edet 7 2 7T 2 1 Commu nicatiori siis hehe hk DET X RE RR Rae 7 3 1 2 2 POWER ON ciere erue ERR ee pan Y demi Sn RR URS Mei a Y 7 4 7 12 32 TUNING t eet eg E RA 7 4 8 SPECiHICAlIONS A salen Bot aie fed 8 1 82h Introduction ino re to uet te Nb ia 8 1 8 1 1 input power and DC bus voltage 1 8 1 8 1 2 24VDC control circuit supply input X2 8 3 8 1 3 Motor output power 1 8 3 8 1 4 Regeneration 1 8 3 81 9 Analog input X9 mero oer E RR ER KREISE Meet Need 8 4 8 1 6 Digital inputs drive enable and general purpose 8 4 8 1 7 Step and Direction inputs 8 4 8 1 8 Status output X3 wdc ce Oe a Mme ten 8 5 8 1 9 Incremental encoder feedback option 8 8 5 8 1 10 SSI encoder feedback option X8 8 5 8 1 11 Resolver feedback option X8 8 5 8 1 12 Encoder output simulated X7 8 6 8 1 13 Serial RS232 RS485 interface 8 6 8 31 14 Environmental ie a epe Reve Rt 8 6
4. From Circuit Breaker From Fuse supply supply L ON y L L L N N N N Figure 4 Circuit breaker and fuse single phase From Circuit Breaker From Fuses supply supply L1 T L1 L1 12 TN L2 L2 L3 L3 L3 Circuit breaker or fuse are not supplied For CE Compliance see Appendix C Figure 5 Circuit breaker and fuse three phase Note Metal conduit or shielded cable should be used Connect conduits so the use of a line reactor or RC device does not interrupt EMI RFI shielding 3 4 4 1 Using 2 phases of a 3 phase supply Power may be derived by connecting two phases of an appropriate three phase supply L1 and L2 for example When supplying AC power in this way the voltage between the two phases must not exceed the rated input voltage of the MicroFlex A two pole breaker must be used to isolate both lines Fuses must be fitted in both lines MN1919 Basic Installation 3 13 www baldormotion com 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 Output A Wire Gauge Amps RMS Ferraz Shawmut 6x32 FA series 10A W084314P or EMH1A03 BS88 2 5 URGS 10A N076648 FMH2A03 Ferraz Shawmut 6x32 FA series 8A V084313P or BS88 2 5 URGS 7A M076647 Ferraz Shawmut 6x32 FA series 20A A084318P
5. MicroFlex supply x11 24V UDN2982 x USR V MintMT Drive DRIVEENABLEOUTPUT DOUTO Enable Drive x Enable USR GND TLP280 User supply GND Figure 29 Drive enable input typical connection from a Baldor NextMove ESB 5 6 Input Output MN1919 www baldormotion com 5 3 2 General purpose digital input X3 aL Location Connector X3 pins 4 amp 5 Mating connector Weidm ller Minimate B2L 3 5 14 Description General purpose optically isolated digital input Nominal input voltage 24VDC input current not to exceed 50mA Sampling interval 500us The general purpose digital input is buffered by a TLP280 opto isolator allowing the input signal to be connected with either polarity The state of the digital input is displayed in the Mint WorkBench Spy window The input can be can be configured for different user definable functions MicroFlex DINO y Ny 74AHC14 DINO TLP280 Figure 30 General purpose digital input circuit When the MicroFlex is connected to Mint WorkBench the digital input can be configured using the Operating Mode Wizard Alternatively the Mint keywords RESETINPUT ERRORINPUT and STOPINPUT can be used in the command window See the Mint help file for details The state of the digital input can be viewed using the Spy window s Axis tab MN1919 Input Output 5 7 www bald
6. B a E D ER a F d TE Mounting keyhole and slot detail C JA C JA P ii A 5 5mm B 11mm C 10mm b D 5mm Dimensions shown as mm inches iento rim tres Dimension o 7 255 10 04 100 3 94 244 5 9 63 40 1 57 20 0 79 A 77079 Figure 49 Filter dimensions type FI0029A00 A 6 Accessories MN1919 www baldormotion com A 1 4 Regeneration resistors Depending on the application MicroFlex might require an external regeneration resistor to be connected to pins R1 and R2 of connector X1 The regeneration resistor dissipates energy during braking to prevent an over voltage error occurring See sections 3 6 and 3 7 for details about choosing the correct resistor IN WARNING Electrical shock hazard DC bus voltages may be present at these terminals Use a suitable heatsink with fan if necessary to cool the regeneration resistor The regeneration resistor and heatsink if present can reach temperatures in excess of 80 C 176 F o s 4 A n A Mem C F E G Baldor Power Res Dimensions mm inches catalog Q number A E A APA RGJ139 39 165 41 22 152 12 10 4 3 6 49 1 61 0 87 5 98 0 47 0 39 0 17 165 41 22
7. ActiveX See Also CONFIG Purpose To set or read the control mode Controllers Supported MicroFlex FlexDrive Flex Drive MintDrive Format CONTROLMODE axis lt expression gt v CONTROLMODE axis Dot Parameters Axis Axis No Attributes Controller Read Write Multi Scaled Default Range MicroFlex v v 2 1 3 FlexDrive v Y Defined by 1 3 y Figure 44 The Mint WorkBench help file For help on using Mint WorkBench click the Contents tab then click the small plus sign beside the Mint WorkBench amp Mint Machine Center book icon Double click a topic name to display it 6 4 Configuration MN1919 www baldormotion com 6 2 2 Starting Mint WorkBench 1 On the Windows Start menu select Programs Mint Machine Center Mint WorkBench Mint WorkBench will start and the Tip of the Day dialog will be displayed You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup Click Close to continue 2 In the opening dialog box click Start New Project MN1919 Configuration 6 5 www baldormotion com 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
8. 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 baldormotion com 6 3 2 Parameters tool The Parameters tool can be used to setup many important parameters such as a scaling factor for the feedback input and the action to take when errors occur 1 Click the Parameters icon in the Toolbox on the left of the screen The main area of the Mint WorkBench window displays the Controller Parameters screen 2 The Controller Parameters screen has a number of tabs listed on the left Click on a tab to select it If you need help with any of the options just press F1 to display the help file Remember to click the tab s Apply button to send the changes to the MicroFlex 6 10 Configuration MN1919 www baldormotion com 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 Edit 8 Debug Tool This tool provides a work area including the Command window and Output window The Command window can be used to send immediate
9. 5 3 8 3 3 Connector locations 0 0 0 ccc ete nes 3 9 3 4 3 10 3 4 1 Earthing grounding 3 10 3 4 2 Single phase or three phase power connections 3 11 3 4 3 Input power 3 12 3 4 4 Power disconnect and protection devices 3 13 3 4 5 Recommended fuses and wiresizes 3 14 3 4 6 Drive overload protection 3 14 3 4 7 lt 3 15 3 48 24 control circuit supply 3 16 3 5 Motor connections 3 17 3 5 1 Motor circuit contactors oi eomer e a e ea aa a a Ea 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 3 5 4 Sinusoidal filler sesi eere ea Me A E RR 3 19 3 6 Regeneration resistor Dynamic Brake resistor 3 20 3 6 1 Regeneration capacity 3 20 MN1919 Contents i 3 7 Regeneration resistor selection 3 21 3 7 1
10. C 4 CE 8 UL MN1919 www baldormotion com C 1 7 Wiring of shielded screened cables Remove the outer insulation to expose the overall shield Clamp should provide 360 o Ja i contact with the cable at or p type conductive clamp lt 30m 500mm max Figure 54 Earthing grounding cable shields MicroFlex Encoder Connector X8 Cable Housing CHA CHA CHB CHB CHZ CHZ 5V DGND NS Connect overall shield Connect overall shield to connector backshell to connector backshell Figure 55 Encoder signal cable grounding MN1919 CE amp UL C 5 www baldormotion com C 2 UL file numbers The following table lists UL file numbers for Baldor products and other accessories Note that UL file numbers for accessories that are not manufactured by Baldor are beyond Baldor s control and therefore subject to change without notice UL file Company Description number E132956 Cabloswiss s p a Power cables 6A 12A 20A 25A 50A 90A Encoder cables Resolver SSI cables EnDat cables E192076 Unika Special Cables s p a Power cables 6A 12A 20A 25A 50A 90A Encoder cables Resolver SSI cables EnDat cables RARA Electronics Corp C 6 CE 8 UL MN1919 A Abbreviations 2 3 Accessories A 1 EMC filters A 4 fan tray A 2 feedback cables A 10 A 11 A 12 footprint filter A 3 motor power cables A 8 regeneration resistors A 7 Analog I O 5
11. MicroFlex 8t CHA AM26LS32 Differential line receiver CHA Figure 10 Encoder channel input circuit Channel A shown 4 2 Feedback MN1919 www baldormotion com MicroFlex Hall U Hall U AM26LS32 Differential line receiver 4 1 1 1 Encoder cable configuration Baldor rotary motors Encoder Feedback Hall Feedback Motor Twisted pairs NN Connect overall shield Y to connector backshells Figure 11 Hall channel input circuit U phase shown CHA CHA CHB CHB CHZ INDEX CHZ INDEX 5V DGND Sense Hall U Hall U Hall W Hall W Hall V Hall V Figure 12 Encoder cable connections rotary motors Note If the Hall inputs are used as single ended inputs leave the Hall U Hall V and Hall W pins unconnected do not connect them to ground MN1919 Feedback 4 3 www baldormotion com 4 1 1 2 Encoders without Halls Incremental encoders without Hall feedback connections may be connected to the MicroFlex However if Hall connections are not present it will be necessary for the MicroFlex to perform an automatic phase search sequence each time it is powered This will cause motor movement of up to 1 turn on rotary motors or one pole pitch on linear motors Motor Twisted pairs CHA CHA
12. catalog number DC bus 115 VAC supply 230 VAC supply capacitance F Table 5 Regeneration capacity 3 20 Basic Installation MN1919 www baldormotion com 3 7 Regeneration resistor selection The following calculations can be used to estimate the type of regeneration resistor that will be required for the application 3 7 1 Required information To complete the calculation some basic information is required Remember to use the worst case scenario to ensure that the regeneration power is not underestimated For example use the maximum possible motor speed maximum inertia minimum deceleration time and minimum cycle time that the application might encounter a Initial motor speed before deceleration begins in radians per second Initial motor speed U Multiply RPM by 0 1047 to give radians per second b Final motor speed after deceleration is complete in radians per second Multiply RPM by 0 1047 to get radians motor speed per second This value will be zero if the load is going to be stopped c The deceleration time from initial speed Decel ti D to final speed in seconds ene _______ d The total cycle time i e how frequently the process is repeated in seconds Cycle time C S e Total inertia This is the total inertia seen by the drive accounting for motor inertia load inertia and gearing Use the Mint WorkBench Autotune tool to tune the motor
13. Appendices A ACCESSONGS ga d Oo eee ris A 1 AJ dntroductlonm iussis par tae RP saw DURER ne iA A 1 A Sean a ue Mb sot tut M oso d A 2 AJE2 Footprintsilter is 20 eb ipe eee E Ae a hae MEME NEG EUER A 3 AMS EMCHIISIS o e eibi all he bd A 4 A 1 4 Regeneration resistors A 7 A A A ied iet eat Aled tala A 8 A 2 1 Motor power cables rea remia ie eea aae Ea teens A 8 A 2 2 Feedback cable part numbers A 10 A23 SSlifeedback cables sarn oic rr A 10 A 2 4 Encoder Hall feedback cables A 11 A 2 5 Resolver feedback cables A 12 MN1919 Contents iii Control System 1 Bid Introd ctlOl oorr LER 1 B 1 1 Current Torque B 2 B 1 2 Velocity Speed control B 3 B 1 3 Position Step and Direction B 4 SCE E ore el C 1 G 1 OUNs nds C 1 1 1 EMC Conformity and CE marking C 1 C 1 2 MicroFlex C 1 C 1 3 Declaration of conformity C 2 C 1 4 Use of CE compliant components
14. Hardware requirements 3 1 Help file 6 4 Incremental encoder cable A 11 Input Output 5 1 analog l O 5 2 analog input 5 2 8 4 connection summary 5 17 digital I O 5 4 drive enable input 5 5 8 4 encoder output 4 11 8 6 general purpose digital input 5 7 8 4 serial port 5 14 8 6 multidrop using RS485 RS422 cable 5 15 status output 5 12 8 5 step 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 6 Mint WorkBench 6 3 Commissioning Wizard 6 7 fine tuning tool 6 8 help file 6 4 other tools and windows 6 11 parameters tool 6 10 starting 6 5 Motor circuit contactors 3 18 connections 3 17 power cable 3 18 3 19 A 8 sinusoidal filter 3 19 Mounting 3 5 Operation 6 1 connecting to the 6 1 installing software 6 1 power on checks 6 2 preliminary checks 6 2 starting 6 2 Operator panels HMI operator panels 5 16 Overloads drive 3 14 motor 3 17 overtemperature trips 3 8 P Power 24V control circuit supply 3 16 connections 3 10 discharge time 3 12 disconnect and protection devices 3 13 input conditioning 3 12 input cycling 3 12 7 1 inrush 3 12 Sources 3 1 supply filters 3 15 A 4 using a variac 3 13 Precautions 1 2 Product Notice 1 2 R Receiving and Inspection 2 2 Regeneration capacity 3 20
15. a Connect overall shield we to connector backshells NextMove ES ESB encoder input Note If NextMove ES is not being used in conjunction with a Baldor backplane part BPL010 50x the equivalent inputs on the card s 96 pin edge connector are as follows 0 1 b7 a8 CHA b10 c9 CHB a7 c7 CHB c10 a10 CHZ b8 c8 CHZ b9 a9 DGND a3 a3 or b3 c3 Figure 22 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 23 CHA CHA CHZ CHZ CHB CHB DGND Microflex encod 2 U U oy Connect overall shield p to connector backshells NextMove BX er input Baldor cable parts CBLOxxMF E3A are recommended where xx represents a choice of available lengths Figure 23 MicroFlex encoder output to NextMove BX encoder input 4 12 Feedback MN1919 5 1 Input Output 5 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 MO Input Output DIN ies Digital Input DOUT bs Digital Output AIN a scenes es Analog Input MN1919 Input Output 5 1 www baldormotion com 5 2 5 2 1 Analog I O The MicroFlex provides as standard m analog i
16. energy 3 22 power 3 22 resistor 3 20 resistor selection 3 21 specification 8 3 Index MN1919 Resolver 4 9 cable 4 10 A 12 specification 8 5 RS232 5 14 specification 8 6 RS485 5 15 multidrop using RS485 RS422 cable 5 15 S Safety Notice 1 2 Serial port 5 14 connecting serial Baldor HMI panels 5 16 Simulated encoder output 4 11 Specifications 8 1 24V control supply 8 3 AC input power and bus voltage 8 1 8 3 analog input 8 4 digital input 8 4 encoder feedback 8 5 encoder output 8 6 environmental 8 6 regeneration 8 3 resolver feedback 8 5 serial RS232 interface 8 6 SSI feedback 8 5 status output 8 5 Step amp direction inputs 8 4 SSI 4 7 cable 4 8 A 10 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 power cycling 7 1 power on 7 4 problem diagnosis 7 1 Status LED 7 2 SupportMe 7 1 tuning 7 4 U UL file numbers C 6 Units and abbreviations 2 3 Wires sizes 3 14 MN1919 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 manual and mail it to Manuals Baldor UK Ltd Mint Motion Centre 6 Bristol Distribution Park Hawkley Drive Bristol BS32 OBF United Kingdom Alternatively you
17. 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 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 3 10 Basic Installation MN1919 www baldormotion com 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 10 or 30 line to line Minimum input voltage 105VAC 10 or 30 line to line see Note Maximum input voltage 250VAC 10 or 30 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
18. with the load attached to determine the value This will be displayed in kg m in the Autotune tool If you already know the motor inertia from the motor spec and the load inertia by calculation insert the total here Total inertia J Multiply kg cm by 0 0001 to give kg m Multiply Ib ft by 0 04214 to give kg m Multiply Ib in s by 0 113 to give kg m MN1919 Basic Installation 3 21 www baldormotion com 3 7 2 3 7 3 Regenerative energy The regenerative energy to be dissipated E is the difference between the initial energy in the system before deceleration begins and the final energy in the system after deceleration has finished If the system is brought to rest then the final energy is zero The energy of a rotating object is given by the formula _1 2 E zxyJxo where E is energy J is the moment of inertia and w is the angular velocity The regenerative energy which is the difference between the initial energy and the final energy is therefore _ 1 2 _ 1 2 E xax U Ex ux vi x Jx U V J joules Calculate E using the values for J U and V entered in section 3 7 1 If E is less than the drive s regeneration capacity shown in Table 5 on page 3 20 a regeneration resistor will not be required If E is greater than the drive s regeneration capacity then continue to section 3 7 3 to calculate the regenerative and average power dissipation Regenerative power and ave
19. 152 12 10 4 3 6 49 1 61 0 87 5 98 0 47 0 39 0 17 165 60 30 146 17 13 5 3 6 49 2 36 1 18 5 75 0 67 0 51 0 21 215 60 30 196 17 13 5 3 8 46 2 36 1 18 7 72 0 67 0 51 0 21 Ww Figure 50 Regeneration resistor dimensions MN1919 Accessories A 7 www baldormotion com A 2 Cables A wide range of motor and feedback cables are available from Baldor A 2 1 Motor power cables For easier installation it is recommended that a color coded motor power cable is used A description of a BSM rotary motor power cable catalog number is shown here using the example number CBL025SP 12 025 Indicates the length in this example 2 5 meters Various lengths are available SP The cable is a Servo motor Power cable ENE 12 Current rating of 12A 20 20 A 35 35 A Motor power cables include the motor power connector Larger motors requiring 35 A cable normally use terminal box connections so a motor power connector is not required A 2 1 1 Cables available in North and South America Cable Cable assembly catal Length rated current description atalog number mo Power cable 1 050 501 Available by the foot or on no connectors 100 m 328 ft drum CBLO15SP 12 12 Amps Power cable CBLO30SP 12 assembly CE style threaded O Es motor connector CBL152SP 12 motor end only CBL229SP 12 Power cable CBL015SP 20 CBLO30SP 20 assembly CBL061SP 20
20. 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 Index Digital 1 O 5 4 drive enable input 5 5 general purpose digital input 5 7 status output 5 12 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 4 5 feedback 4 2 specification 8 5 SSI See SSI without Halls 4 4 Encoder incremental cable A 11 Environmental cooling 3 3 location 3 3 3 4 specification 8 6 F Features 2 1 Feedback cable A 10 A 13 connections 4 1 encoder 4 2 encoder without Halls 4 4 Halls only feedback 4 4 Resolver 4 9 SSI 4 7 Filters 24V control circuit supply 3 16 AC power EMC 3 15 A 4 catalog numbers A 4 MN1919 Index Footprint filter A 3 Fuses 3 14 G General Information 1 1 Grounding See Earthing grounding H
21. 32 F to 113 F Output current must be derated between 45 C 113 F and the absolute maximum ambient temperature of 55 C 131 F Within the ambient temperature range The 1A and 3A models are designed to operate without any additional cooling methods The 6A and 9A models require a forced air flow passing vertically from the bottom to the top of the MicroFlex case to allow full rated current at 45 C 113 F Temperature derating characteristics are shown in sections 3 2 4 to 3 2 6 Note Failure to meet cooling air flow requirements will result in reduced product lifetime and or drive overtemperature trips It is recommended to check periodically the operation of the cooling equipment Optional fan tray FANO01 024 mounted exactly as shown in section A 1 1 ensures that correct cooling is provided and allows the MicroFlex to be UL listed 3 2 2 1 Effects of mounting surface and proximity The proximity of the MicroFlex to other components could affect cooling efficiency If the MicroFlex is mounted beside another MicroFlex or other obstruction there should be a minimum space of 15mm to maintain effective cooling aseeeggs 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 heat
22. CE style threaded CBLO91SP 20 motor connector CBL152SP 20 motor end only CBL229SP 20 75 35 Amps Power cable 1 052 501 Available by the foot or on p no connector 100 m 328 ft drum Power cable 1 051 501 Available by the foot or on no connector 100 m 328 ft drum 20 Amps A 8 Accessories MN1919 www baldormotion com A 2 1 2 Cables available in the rest of the world Cable Cable assembly catal E ae rated current description atalog number Power cable 1 050 501 REN by meter or on no connectors 100 m drum 12 Amps CBLO25SP 12 NT CBLOSOSP 12 y CBLO75SP 12 CE style threaded CBL100SP 12 motor connector CBL150SP 12 motor end only CBL2008p j2 CBL025SP 20 E CBLOSOSP 20 CE style threaded CBLO7SSP 20 motor connector CBL100SP 20 CBL150SP 20 motor end only CBL200SP 20 35 Amps Power cable CBL052 501 Available by the meter or on p no connector 100 m drum Power cable 1 051 501 Available by the meter or on no connector 100 m drum 20 Amps MN1919 Accessories A 9 www baldormotion com A 2 2 Feedback cable part numbers A description of a feedback cable catalog number is shown here using the example number CBLO025SF E2 Alternatives 025 Indicates the length in this example 2 5 meters Various lengths are available SF The cable is a Servo motor Feedback cable We a a Encoder feedback cable with motor connector 37391 feedbac
23. Mint commands to the MicroFlex Scope Tool Displays the capture screen This screen is also shown when the Fine tuning tool is selected Axis 0 83 9 Current Plant Resistance 1 amp 06 Ohms Inductance 3320 mH Measure Flux Plant Vor Const 4 23 Measure Feedback Alignment Test Current Control Terms KIPROP 0 00 KIINT 000 Apply Calculate Test Parameters Time ms e x aaa Duration 50 00 ms 30 HS Measured magneticing curent Ames Speed Limit 2500 1 Havre cn aleh Current 0 Spy window wu PR Allows you to monitor all the important for the axis P oe Analog Input BI Chn 0 B Remember for help on each tool just press F1 to display the help file then navigate to the Mint WorkBench book Inside this is the Toolbox book Drive Bus Volts vy AxisO y MN1919 Configuration 6 11 www baldormotion com 6 12 Configuration MN1919 7 1 7 1 1 7 1 2 7 1 3 Troubleshooting 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 Mint WorkBench If you cannot solve the problem or the problem persists the SupportMe feature can be used SupportMe feature The SupportM
24. Operator Panels 5 16 5 5 Connection summary recommended system wiring 5 17 b COnmguravioniuss veut ioe metodo alto rer bb ox ess 6 1 INtrOduUCtiON i icr rec nx eto ad teenies 6 1 6 1 1 Connecting the MicroFlex to the PC 6 1 6 1 2 Installing the software 6 1 6 1 3 Starting the 6 2 6 1 4 Preliminary checks 0 0c cece eee ete tenes 6 2 6 1 5 Power on checks iano ane Wha eb eee IQ 6 2 6 2 Mint WorkBench 6 3 62 1 Helpile re phe ed eds THe tae ed eee be RR ya t EET S 6 4 6 22 Starting Mint WorkBench 6 5 6 23 Commissioning 6 7 6 24 Using the Commissioning Wizard 6 7 6 3 Further configuration 6 8 6 3 1 Fine tuning tool ul Ll Ei Sea ee AE RE 6 8 6 32 lt 1 6 10 6 3 3 Other tools and windows 6 11 ii Contents MN1919 7 Troubleshooting 7 1 T o troduction er art RR HIER ala 7 1 7 1 1 Problem diagnosis e rae r 7 1 7 1 2 SupportMe feature
25. Shield 8 Shield 15 Hall W NC 2 Status 9 Dir 3 Status 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 Left LED Fault signal loss NC Not Connected Do not make a connection to this pin Right LED Unused MN1919 Basic Installation 3 9 www baldormotion com 3 4 3 4 1 3 4 1 1 3 4 1 2 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 N 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 cir
26. The fan tray Baldor part FAN001 024 provides sufficient cooling for the 6A or 9A MicroFlex It requires 23 27 5VDC at 325mA which may be sourced from the same filtered control circuit supply used for the MicroFlex The MicroFlex is UL listed file NMMS E128059 when used in conjunction with the fan tray mounted exactly as shown in Figure 45 Fan tray Fan tray 2 MED ss FANO01 024 dimensions 84 3 3 g Y 98 0 sz nang 000000 ue 00000000 00000000 00000000 Do ago ago oo noa 0000 2000 2000 0000 ooo 95 G ZL Do oo 00000000 00000000 oo000000 OO0000 Assembled MicroFlex 0000 and fan tray 7 66 2 6 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 45 Fan tray A 2 Accessories MN1919 www baldormotion com A 1 2 Footprint filter The single phase footprint AC power filter Baldor part F10029A00 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 FANO01 024 Figure 46 Assembled fo
27. This warranty is valid if the unit has not been tampered with by unauthorized persons misused abused or improperly installed and has been used in accordance with the instructions and or ratings supplied This warranty is in lieu of any other warranty or guarantee expressed or implied Baldor shall not be held responsible for any expense including installation and removal inconvenience or consequential damage including injury to any person or property caused by items of our manufacture or sale Some countries and U S states do not allow exclusion or limitation of incidental or consequential damages so the above exclusion may not apply In any event Baldor s total liability under all circumstances shall not exceed the full purchase price of the control Claims for purchase price refunds repairs or replacements must be referred to Baldor with all pertinent data as to the defect the date purchased the task performed by the control and the problem encountered No liability is assumed for expendable items such as fuses Goods may be returned only with written notification including a Baldor Return Authorization Number and any return shipments must be prepaid Baldor UK Ltd Mint Motion Centre 6 Bristol Distribution Park Hawkley Drive Bristol BS32 OBF Telephone 44 0 1454 850000 Fax 44 0 1454 850001 E mail motionsupport uk baldor com Web site www baldormotion com See rear cover for other international offices MN191
28. as shown in Figure 53 capable of following a position command signal The up down counter and gearing interpret the step and direction signals and use them to generate a position demand signal The position demand signal is fed into a position controller and used together with the position measured from the feedback device to generate a suitable speed demand signal If the position controller is tuned correctly the measured position will accurately track the position demand The speed demand signal from the position controller is fed into the speed controller and used together with the speed measured from the feedback device to generate a torque demand signal If the speed controller is tuned correctly the measured speed will accurately track the speed demand Finally the torque demand signal is fed into a torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current measured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Position reference Pulse Up down count Counter Step SUL Direction l 7 Position Speed Position demand controller Torque Speed demand Torque PWM Power stagel controller controller motor na Measured speed Measured position Figure 53 Control structure in Po
29. can e mail your comments to manuals baldor co uk X continued MN1919 Comments Thank you for taking the time to help us Comments MN1919 BALDOR Baldor Electric Company P O Box 2400 Ft Smith AR 72902 2400 U S A Visit www baldormotion com for the latest documentation and software releases U S A Headquarters Baldor Electric Company Tel 1 479 646 4711 Fax 1 479 648 5792 Australia Japan Australian Baldor PTY Ltd Baldor Japan Corporation Tel 61 2 9674 5455 Tel 81 45 412 4506 Fax 61 2 9674 2495 Fax 81 45 412 4507 Europe Mexico Baldor ASR GmbH Germany Baldor de Mexico Tel 49 0 89 905 080 52 477 761 2030 Fax 49 0 89 905 08492 Fax 52 477 761 2010 Europe Southern Singapore Baldor ASR AG Switzerland Baldor Electric PTE Ltd Tel 41 52 647 4700 Tel 65 6744 2572 Fax 41 52 659 2394 Fax 65 7474 1708 India United Kingdom Baldor Electric India Pvt Ltd Baldor UK Ltd Tel 91 20 25 45 27 17 Tel 44 1454 850000 Fax 91 20 25 45 27 19 Fax 44 1454 859001 For additional office locations visit www baldor com Printed in UK Baldor UK Ltd
30. 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 threaded 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 3 4 7 Line L1 5 A Line L2 77 Line L3 Isolating switch Incoming safety earth ground PE To earth ground outer shield use 360 clamps connected to enclosure backplane STAR POINT Figure 3 Single or three phase power connections MN1919 Basic Installation 3 11 www baldormotion com 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 correcti
31. forced air 2 g 5 o Natural cooling 2 1 o o m ia 0 30 35 40 45 50 55 Ambient temperature Notes Load power factor 0 75 Overload limit for model FMH2A03TR EN23 is 6A 3 6 Basic Installation MN1919 www baldormotion com 3 2 5 Derating characteristic 6A model The following derating characteristics are for model FMH2A06TR EN23 Single phase AC supply 5 1 5m s forced air 1m s forced air Natural cooling Rated output currrent Arms 0 30 35 40 45 50 55 Ambient temperature Three phase AC supply 6 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 FMH2A06TR EN23 is 12A MN1919 Basic Installation 3 7 www baldormotion com 3 2 6 3 2 7 Derating characteristic 9A model The following derating characteristics are for model FMH2A09TR EN23 Single phase AC supply pu 3 5m s forced air 4 2 5m s forced air 1 5m s forced air 1m s forced air Rated output currrent Arms o N wo A N Natural cooling Ambient temperature Three phase AC supply 3 5m s forced air 2 5m s forced air 1 5m s forced air 1m s forced air Rated output currrent Arms Natural cooling Ambient temperature Notes Load power factor 0 78 Overload
32. in the Commissioning Wizard 6 8 Configuration MN1919 www baldormotion com 6 3 1 1 6 3 1 2 6 3 1 3 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 Fine tuning Speed tab The Speed tab allows you to set speed loop gains and perform test moves The Commissioning Wizard may have already set some of these values depending on the type of system selected on the mode screen Enter new values in the required boxes and then click Apply to download the values to the MicroFlex To perform tests go to the Test Parameters area at the bottom of the tab Enter test values and then click Go to perform the test move If you need help just press F1 to display the help file 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
33. 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 TEMPERATURELIMITFATAL keyword see the Mint help file for details 3 8 Basic Installation MN1919 www baldormotion com 3 3 Connector locations X1 Power Earth Ground Earth Ground NC L1 AC Phase 1 L L2 AC Phase 2 N L3 AC Phase 3 U Motor U V Motor V W Motor W RS232 RS485 422 1 NC NC R1 Regen 2 RXD RX R2 Regen 3 TXD TX cl o 4 NC NC L o 5 OV GND OV GND o 6 NC NC X6 o 7 RTS TX 59 8 CTS RX Bee re o 9 NC see NC po pO section 5 4 u v w R1 o o CHA m o llo CHB eZ CHZ x1 NC 25 DGND SATTA CHA BALDOR CHB Mer lex CHZ 9 NC 25 ie X2 Control circuit MM Incremental SSI 1 CHA Data 1 2 CHB ov ov oo to 3 CHZ NC 24V 24V gt m 4 Sense Sense 5 Hall U NC x2 14 6 Hall U NC 7 Hall V NC xs 8 Hall V NC 9 CHA Data 10 CHB Clock 11 CHZ NC 12 5V out 5V out X3 Input Output 13 DGND DGND 14 Hall W NC 1
34. 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 MENR IMEEM G HARO Table 2 DC bus discharge periods 3 12 Basic Installation MN1919 www baldormotion com 3 4 3 3 Supplying input power from a variac variable transformer 3 4 4 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 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
35. 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 baldormotion com 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 D type female connector not high density Encoder function 1 CHA 2 CHB 3 CHZ 4 Sense 5 Hall U Hall U 7 Hall V Hall V 10 CHB 11 CHZ 12 5V out 13 DGND 14 Hall W 15 Hall W Description Incremental UVW encoder input non isolated Pin 12 provides 5 11V for encoders requiring power 200mA max
36. was tuned with the correct motor data If the motor is still unstable try reducing the Speed Proportional gain KVPROP and Speed Integral gain KVINT on the Speed tab of the Fine tuning window 7 4 Troubleshooting MN1919 8 1 Specifications 8 Introduction This section provides technical specifications for the MicroFlex 8 1 1 AC input power and DC bus voltage X1 All models AC 30 Nominal input Nominal input voltage 230 8 1 1 1 ERI Nominal DC bus voltage Nominal input current maximum rated output current ER OOOO Ed The MicroFlex will operate at lower input voltages although the drive will trip if the DC bus voltage falls below 50V or 60 of the no load voltage whichever occurs first Effect of AC power supply voltage on DC bus voltage 350 300 1 zr Th hase AC deb ree phase supply Pa 200 A ingle phase AC supply DC bus voltage VDC a zc cR NUM NNI ot 10 250 K supply AM pu MN1919 Specifications 8 1 www baldormotion com 8 1 1 2 Effect of AC power supply voltage on DC bus ripple 8 1 1 3 DC bus ripple of DC bus voltage 40 30 20 o 00 1 AC supply voltage rms Effect of output current on DC bus ripple voltage DC bus ripple voltage Vpk pk 60 sd eec ESPA A aL TSTST ER EIE P P5 EA EUR ER ER RE ER RR d ER ES repe 10 hree
37. 19 Input Output 5 11 www baldormotion com 5 3 4 Status output X3 Location Connector X3 pins 2 amp 3 Mating connector Weidm ller Minimate B2L 3 5 14 Status 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 36 The PS2562L has a maximum power dissipation of 200mW at 25 C The maximum saturated voltage across the outputs when active is 1 0VDC so it can be used as a TTL compatible output The output includes a self resetting fuse that operates at approximately 200mA The fuse may take up to 20 seconds to reset after the load has been removed If the output is used to directly drive a relay a suitably rated diode must be fitted across the relay coil observing the correct polarity This is to protect the output from the back EMF generated by the relay coil when it is de energized The sense of the output can be configured in Mint WorkBench and its state is displayed in the Spy window MicroFlex User supply V Error V q La Load NEC PS2562L 1 Relay with diode shown User supply GND Figure 36 Drive status output circuit When the MicroFlex is connected to Mint WorkBench the active level of the output can be configured using the Operatin
38. 1919 Input Output 5 9 www baldormotion com Move ESB controller MicroFlex drive amplifier DS26LS31 STEPO Lee DS Twisted pairs DS26LS31 DIRO p DIRO DGND Shield Connect shields at one end only Figure 33 Stepper input typical connection from a Baldor NextMove ESB Note When using a NextMove ESB s STEP and DIR outputs do not connect the STEPx or DIRx outputs to ground leave them unconnected as shown in Figure 33 Incremental encoder MicroFlex drive amplifier Twisted pairs XX NS Connect shields at one end only Encoder Encoder supply supply 5V GND Figure 34 Stepper input typical connection from an incremental encoder Note When using an incremental encoder source do not connect the A or B outputs leave them unconnected as shown in Figure 34 5 10 Input Output MN1919 www baldormotion com To allow connection of 24 V signals it is recommended to use an intermediate circuit as shown in Figure 35 The circuit s output voltage is determined by the pull up voltage Vcc Intermediate circuit MicroFlex Input 24V A Input GND Figure 35 Step amp direction connection of 24V signals MN19
39. 3 1 Resolver cable pin configuration Figure 18 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 000 0BOO Pins 7 12 are not used 6 3 and may not be present 5 Motor resolver connector Cable connector end view male female Figure 20 Baldor motor resolver cable pin configuration The maximum recommended cable length is 30 5m 100ft 4 10 Feedback MN1919 www baldormotion com 4 1 4 Encoder output X7 3 CHZ m wo MAN CN CN DN This output can be used for position feedback to a host positioner or in master slave situations where the axis movement can be transmitted to another controller It is recommended that this output only drives one output circuit load The encoder outputs are differential and conform to the RS422 electrical specification Shielded twisted pair cable is recommended If the MicroFlex is configured for incremental encoder feedback X7 duplicates the encoder signals entering X8 If operating in Halls only mode there will be no encoder output at X7 If the MicroFlex is configured for SSI feedback a simulated encoder output is produced at X7 The default simulated encoder output resolution is 16384 counts per revolution but this can be altered using the Drive Setup Wizard in Mint WorkBench At 62 5 microsecond intervals a 16kHz
40. 9 General Information 1 1 www baldormotion com Product notice Only qualified personnel should attempt the start up procedure or troubleshoot this equipment This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment Improper use can cause serious or fatal injury Safety Notice Intended use These drives are intended for use in stationary ground based applications in industrial power installations according to the standards EN60204 and VDE0160 They are designed for machine applications that require variable speed controlled three phase brushless AC motors These drives are not intended for use in applications such as 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 specifications are found in section 8 of this manual The installation connection and control of drives is a skilled operation disassembly or repair must not be attempted In the event that a drive fails to operate correctly contact the place of purchase for return instructions Precautions DANGER Do not touch any circuit board power device or electrical connection before you first ensure that no high voltage is present at this equip
41. BALDOR SERVO DRIVE MicroFlex Servo Control Installation Manual 03 10 MN1919 Contents 1 General Information 1 1 z WMO GUCUON oo eeu odes ee 2 1 2 1 MicroFlex features 2 1 2 2 Receiving and inspection 2 2 2 2 1 Identifying the catalog 2 2 2 3 Units and abbreviations 2 3 3 Basic 5 3 1 A Introd ctlOh 4223 eee a ee e ia a RR ERG 3 1 Powe rssources ai AS 3 1 3 1 2 Hardware requirements 3 1 3 1 3 Tools and miscellaneous hardware 3 2 3 1 4 Other information needed for installation 3 2 3 2 Mechanical installation and cooling requirements 3 3 3 2 1 isis er baee e SUE E BR 3 4 3 2 2 Mounting and cooling the MicroFlex 3 5 3 23 Derating characteristic 1A model 3 6 3 24 Derating characteristic model 3 6 3 25 Derating characteristic 6A model 3 7 3 2 6 Derating characteristic 9A model 3 8 3 2 7 1
42. Encoder CHB Feedback CHB CHZ INDEX CHZ INDEX 5V DGND Sense NN Connect overall shield Y 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 NS Connect overall shield to connector backshells Figure 14 Halls only feedback cable connections rotary motors Note If the Hall inputs are used as single ended inputs leave the Hall U Hall V and Hall W pins unconnected do not connect them to ground 4 4 Feedback MN1919 www baldormotion com 4 1 1 4 Encoder cable pin configuration rotary motors Figure 15 shows the pin configuration for a typical Baldor encoder feedback cable part number CBLO25SF E2 X8 pin internal wire colors ae 3 poer J po el 2 s cm o s po en s 7 e mi 5 9 9 wm 5 eer wv 7 5 sese ow 5 8 99 aw a o WI e Pins 9 and 16 are not connected Motor encoder connector Cable connector end view male female Figure 15 Baldor rota
43. FMH2A09TR xNy3 where x y 4 or 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 Immunity 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
44. General Information MN1919 www baldormotion com 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 must 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 General Information 1 5 www baldormotion com 1 6 General Information MN1919 2 1 Introduction 2 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 Mint WorkBench configuration software supplied 2 optically isolated digital inputs one enable input and
45. LC PORT X6 PLC PORT X6 Without hardware handshaking With hardware handshaking Figure 40 RS232 cable wiring Alternatively the Baldor HMI panel may be connected using RS485 422 as shown in Figure 41 Baldor HMI MicroFlex PLC PORT X6 Figure 41 RS485 422 cable wiring 5 16 Input Output MN1919 www baldormotion com 5 5 Connection summary recommended system wiring As an example Figure 42 shows the recommended wiring necessary for the MicroFlex to control a motor while conforming to the EMC requirements for industrial environments AC power Connect motor Host PC F power cable shield rom L1 L1 L1 AC power in to metal backplane 0 uses 2 L2 812 using conductive 13 E 13 shield clamp Connect AC power cable shield to PE metal backplane using conductive Q Q shield clamp see section C 1 7 O Star 2 point Shielded twisted pair clamped to all fre ES metal backplane near drive using i lle conductive shield earth ground bs clamp see sections 3 6 and C 1 7 Serial OM communication v Regen w xt Optional regen resistor Dynamic brake ferm Motor feedback Motor power U V W dul x ER Motor 24V OV 24V OV Demand input 10V analog input Control circ
46. M port as Mint WorkBench Does the MicroFlex have firmware in it If you tried to download new firmware and the download failed the controller may not have firmware Check that the selected baud rate is supported by the PC and MicroFlex If the Only scan COMx option is selected in Mint WorkBench check that the correct COM port is selected If the Search up to Nodexx option is selected in Mint WorkBench check that the MicroFlex node number is not higher than this value or search up to a greater node value Do you have multiple nodes on the bus If so they must all be set to the same baud rate Mint WorkBench scans through all the node ID s at different baud rates When it finds a node it will only continue to scan for other nodes at the same baud rate MN1919 Troubleshooting 7 3 www baldormotion com 7 2 2 Power on 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 PRINT AXISERROR PRINT DRIVEERROR 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 AXISERROR 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
47. MN1919 Configuration 6 7 www baldormotion com 6 3 Further configuration Mint WorkBench provides a number of tools each of which has an icon on the left of the screen Click once on an icon to select the tool Three of the main tools used for tuning and configuring the MicroFlex are described in the following sections Every tool is explained fully in the help file Press F1 to display the help file then navigate to the Mint WorkBench book Inside this is the Toolbox book 6 3 1 Fine tuning tool The Commissioning Wizard calculates many parameters that allow the MicroFlex to provide basic control of the motor These parameters may need to be fine tuned to provide the exact response that you require The Fine tuning screen allows you to do this 1 Click the Fine tuning icon in the Toolbox on the left of the screen The Fine tuning window is displayed atthe right ofthe screen This already shows some of the parameters that have been calculated by the Commissioning Wizard Fine tuning The main area ofthe Mint WorkBench window displays the capture window When further tuning tests are performed this will display a graph representing the response 2 The Fine tuning window has three tabs at the bottom Step Speed and Current Click on a step Speed Y Current 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
48. 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 If the MicroFlex is not listed check the serial lead between the MicroFlex and the PC and that the MicroFlex is powered correctly Click Scan to re scan the ports 6 6 Configuration MN1919 www baldormotion com 6 2 3 6 2 4 Commissioning Wizard Each type of motor and drive combination has different performance characteristics Before the MicroFlex can be used to control the motor accurately the MicroFlex must be tuned This is the process where the MicroFlex powers the motor in a series of tests By monitoring the feedback from the motor s encoder and performing a number of calculations the MicroFlex can make small adjustments to the way it controls the motor This information is stored in the MicroFlex and can be uploaded to a file if necessary The Commissioning Wizard provides a simple way to tune the MicroFlex and create the necessary configuration information for your drive motor combination so this is the first tool that should be used However if necessary any of the parameters set by the Commissioning Wizard can be adjusted manually after com
49. N1919 www baldormotion com A 2 4 Encoder Hall feedback cables A 2 4 1 Cables available in North and South America Length Cable assembly description Catalog number Encoder feedback cable CBL043 501 Available by the foot or no connectors on 100 m 328 ft drum Feedback cable assembly CBLO25SF E 2 5 8 2 CE style threaded motor connector motor end only 5 10 CBLO15SF E2 Feedback cable assembly CBLO30SF E2 CE style threaded motor connector CBLOG1SF E2 i 20 and low density 15 pin D type drive CBLO91SF E2 connector CBL152SF E2 CBL229SF E2 A 2 4 2 Cables available in the rest of the world Length Cable assembly description Catalog number m Encoder feedback cable CBL043 501 Available by the meter no connectors or on 100 m drum Feedback cable assembly CBLO25SF E 2 5 8 2 CE style threaded motor connector motor end only 2 5 CBLO25SF E2 Feedback cable assembly CBLO50SF E2 CE style threaded motor connector CBLO75SF E2 and low density 15 pin D type drive CBL100SF E2 connector CBL150SF E2 CBL200SF E2 MN1919 Accessories A 11 www baldormotion com A 2 5 Resolver feedback cables A 2 5 1 Cables available in North and South America Length Cable assembly description Catalog number Resolver Feedback Cable CBL044 501 Available by the foot or no connectors on 100 m 328 ft drum CBLO15SF R Feedback Cable Assembly ene cee CE style threaded motor connector CBLO91SF R motor end
50. ON The motor leads U V and W must be connected to their corresponding U V or W terminal on the motor Misconnection will result in uncontrolled motor movement The motor power cable must be shielded for CE compliance The connector or gland used at the motor must provide 360 degree shielding The maximum recommended cable length is 30 5m 100ft Note For CE compliance the motor earth ground should be connected to the drive earth ground MN1919 Basic Installation 3 17 www baldormotion com 3 5 1 3 5 2 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 A 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 o
51. an achieve their stated power rating only when mounted on a heatsink In free air a derating must be applied Furthermore in ambient temperatures greater than 25 C 77 F a temperature derating must be applied Resistor Nominal Baldor power part rating w In free air Derate power linearly from Derate power linearly from 80 25 C 77 F 100 25 C 77 F to to RGJ139 o RGJ160 70 55 C 113 F 88 55 C 113 F Typical heatsink 200 mm x 200 mm x 3 mm Derate power linearly from Derate power linearly from RGJ260 70 25 C 77 F 100 25 C 77 F to to 62 55 C 113 F 88 55 C 113 F RGJ360 Typical heatsink 400 mm x 400 mm x 3 mm Table 7 Regeneration resistor derating MN1919 Basic Installation 3 23 www baldormotion com 3 24 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 only To prevent contact with other conductors or earths grounds unearthed ungrounded ends of
52. c fields in the vicinity of current carrying conductors and industrial motors can result in a serious health hazard to persons with cardiac pacemakers internal cardiac defibrillators neurostimulators metal implants cochlear implants hearing aids and other medical devices To avoid risk stay away from the area surrounding a motor and its current carrying conductors 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 Baldor regeneration resistors are neither internally fused nor thermally protected and under extreme conditions can cause a fire hazard if not suitably protected or rated for the application To prevent equipment damage be certain that the input power has correctly sized pro
53. characteristics kk 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 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 The shield connections of the signal and power cables should be connected to the shield rails or clamps The shield rails or clamps should be conductive clamps fastened to the cabinet The cable to the regeneration resistor must be shielded The shield must be connected to earth ground at both ends The location of the AC filter has to be situated close to the drive so the AC power wires are as short as possible 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 To reduce earth ground current use the largest suitable wire available for earth ground connections Earthing grounding in general describes all metal parts which can be connected to a protective conductor e g housing of cabinet motor housing etc to a central earth ground point star point This central earth ground point star point is then connected to the main plant or building earth ground Or run as twisted pair at minimum
54. cuit breakers are required in the input lines for cable protection Note AResidual Current Device RCD must not be used for fusing the drive An appropriate type of circuit breaker or fuse must be used All interconnection wires should be in metal conduits between the MicroFlex AC power Source motor host controller and any operator interface stations Use UL listed closed loop connectors that are of appropriate size for the wire gauge being used Connectors are to be installed using only the crimp tool specified by the manufacturer of the connector 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
55. d in sequence Power sources A 115 230VAC power source IEC1010 over voltage category III or less in the installation area is required This may be single phase or three phase An AC power filter is required to comply with the CE directive for which the MicroFlex was tested see section 3 4 7 The 24VDC control circuit supply must be a regulated power supply with a continuous current supply capability of 1A 4A power on surge 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 Acooling 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 baldormotion com A PC with the following specification A E e penton w Serial port RS232 or RS485 serial port depending on MicroFlex model Sereen 800 x 600 256 colors 1024 x 768 256 colors Mouse A mouse or similar pointing device Operat
56. d through the power stage into the motor windings The gain values KIPROP and KINT must be tuned for a specific motor This is performed automatically by the Commissioning Wizard The feedback device is used to determine motor position and speed Motor speed can be filtered to reduce measurement noise if necessary The time constant of this filter is specified using the keyword KVTIME By default the filter is turned off KVTIME 0 Note that introducing a filter on measured speed tends to reduce the stability of the speed controller This can make the tuning of the speed controller gains difficult if large values of KVTIME are used B 2 Control System MN1919 www baldormotion com B 1 2 Velocity Speed control Setting the control mode to Velocity Control configures the MicroFlex as a speed amplifier as shown in Figure 52 Here a speed reference is obtained from a specified source m Mint WorkBench m Ahost 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 co
57. 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 declared to comply with the provisions of directive 98 37 EC as amended Dr Gerry Boast Engineering Manager C 2 CE amp UL MN1919 www baldormotion com 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 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
58. e command Print ADC 0 can be used in the command window to return the value of the analog input See the Mint help file for details 5 2 Input Output MN 1919 www baldormotion com x3 x3 AINO 13 AINO 13 AINO 12 AINO 42 AINO 14 GND 14 Differential connection Single ended connection Figure 25 AINO analog input wiring 24VDC 1 5kQ 0 25W 1kQ 0 25W potentiometer AINO ov ADC 0 Figure 26 Typical input circuit to provide 0 10V approx input from a 24V source NextMove ESB controller MicroFlex NSS Connect overall shield at one end only Figure 27 Analog input typical connection from a Baldor NextMove ESB MN1919 Input Output 5 3 www baldormotion com 5 3 Digital I O The MicroFlex provides as standard m 1 dedicated drive enable input m general purpose digital input m Dedicated step and direction inputs m 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 baldormotion com 5 3 1 Drive enable input X3 Location Connector X3 pins 6 8 7 Mating connector Weidm ller Minimate B2L 3 5 14 Name Drive enable Ed 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 i
59. e feature is available from the Help menu or by clicking the BE 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 Use the Help SupportMe menu item in Mint WorkBench 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 Mint WorkBench or trying to perform fine tuning Give clear description of the symptoms that you can observe for example the Status LED error messages displayed in Mint WorkBench or the current value of the Mint error keywords AXISERROR and DRIVEERROR m The type of motion generated in the motor shaft Give a list of any parameters that you have setup for example the motor data you entered selected in the Commissioning Wizard the gain settings generated during the tuning process and any gain settings you have entered yourself 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 pow
60. ed by the device s below it Multiple MicroFlex units mounted Warm above each other should be aligned not offset to promote air flow across the heatsinks 0894068 derating characteristics assume the MicroFlex is mounted on 3mm thick or less metal plate If the MicroFlex is mounted on 10mm plate then the current characteristics shown in sections 3 2 4 to 3 2 6 may be increased by up to 7 if there is no forced air cooling or 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 Fee fe aaa 1 Figure 2 Cooling and proximity MN1919 Basic Installation 3 5 www baldormotion com 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 p 1m s forced air E 2 5 o gt g Natural cooling 8 1 o c ad 0 30 25 40 45 50 55 Ambient temperature C Three phase AC supply 3 1m s
61. em is the responsibility of the machine designer Be sure to comply with the local safety requirements at the place where the machine is to be used In Europe these are the Machinery Directive the ElectroMagnetic Compatibility Directive and the Low Voltage Directive In the United States this is the National Electrical code and local codes 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 If the drive is subjected to high potential hipot testing only DC voltages may be applied AC voltage hipot tests could damage the drive For further information please contact your local Baldor representative 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 1 4
62. er down completely the Status LED will turn off then re apply the 24V supply MN1919 Troubleshooting 7 1 www baldormotion com 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 I2t trip Overtemperature trip Drive overload It trip Following error trip Error input triggered Phase search error All other errors including Internal supply error encoder supply error parameter restore failure power base not recognized If multiple errors occur at the same time the lowest numbered error code will be flashed For example a MicroFlex 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
63. file Mint WorkBench includes a comprehensive help file that contains information about every Mint keyword how to use Mint WorkBench and background information on motion control topics The help file can be displayed at any time by pressing F1 On the left of the help window the Contents tab shows the tree structure of the help file Each book contains a number of topics The Index tab provides an alphabetic list of all topics in the file and allows you to search for them by name The Search tab allows you to search for words or phrases appearing anywhere in the help file Many words and phrases are underlined and highlighted with a color normally blue to show that they are links Just click on the link to go to an associated keyword Most keyword topics begin with a list of relevant See Also links E MintMT Ox PB E e S or Hide Locate Back Forward Print Options Update Help Contents nds Seach Favs Ar ROTIMODE CMD COMPAREOUTPUTICMO 2 COMPAREPOS CMP 2 CONFIGICF 2 CONNECT CNN 2 CONNECTSTATUS CNS 2 Const 2 Continue El 2 CONTOURANGLEICTA 2 CONTOURMODE CTM 2 CONTOURPARAMETERICT 2 CONTROLMODE CMD 2 2 Critical End Critical 2 CURRENTLIMT CL 2 CURRENTMEAS CMS 2 CURRENTSENSORMODE C pacioc 2 DACLIMTMAX DCX DACMODE DCM DACMONITORAXIS DMA DACMONITORGAIN DMG 2 DACMONITORMODE DMM a DACMONITOROFFSET DM w ee E
64. g Mode Wizard Alternatively the Mint keyword OUTPUTACTIVELEVEL can be used in the command window The output can also be configured using the Mint keywords DRIVEENABLEOUTPUT or GLOBALERROROUTPUT See the Mint help file for details 5 12 Input Output MN1919 www baldormotion com ALS User AUR MicroFlex supply X9 NextMove ESB controller 24V Status Status DIN4 NEC PS2562L 1 x CREF1 TLP280 User supply GND Figure 37 Status output typical connections to a Baldor NextMove ESB MN1919 Input Output 5 13 www baldormotion com 5 4 5 4 1 Serial port X6 Pm Rsrimme ROSAS ame EU 5 OV GND oV RC 777 CTS RX input Ng 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 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 RXD 2 2 RXD TXD 3 3 TXD 9 MicroFlex GND 5 5GND Computer DTE COM Port RTS 7 7 RTS DTE CTS8 8CTS y t N Connect overall shield A
65. he 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 IfMicroFlex is to be stored for several weeks before use be sure that itis stored in a location that conforms to the storage humidity and temperature specifications shown in section 8 1 14 Identifying the catalog number The MicroFlex is available with different current ratings The catalog number is marked on the side of the unit It is a good idea to look for the catalog number sometimes shown as ID No and write it in the space provided here Catalog number FMH Installed at Date A description of a catalog number is shown here using the example FMH2A03TR EN23 2 Requires an AC supply voltage of 115 230 Volts 1 or A01 1A A06 6A A03 Continuous current rating of A09 9A T Built in AC power supply r E 3 2 2 Introduction MN1919 www baldormotion com 2 3 Units and abbreviations The following units and abbreviations may appear in this manual Mr t RS Ampere AG idas Alternating current DG scene Direct current decibel kilowatt mA Lube milliampere iussi millihenry mQ s ccm nas
66. if very long motor cables are unavoidable and are causing problems then a sinusoidal filter may be beneficial MN1919 Basic Installation 3 19 www baldormotion com 3 6 Regeneration resistor Dynamic Brake resistor An optional external regeneration resistor may be required to dissipate excess power from the internal DC bus during motor deceleration The regeneration resistor must have a resistance of at least 390 and an inductance of less than 1004H Care should be taken to select the correct resistor for the application see section 3 7 Suitable regeneration resistors are listed in section A 1 4 The regeneration resistor output is conditionally short circuit proof Regeneration resistor Earth ground outer shield using 360 conductive clamp connected to enclosure backplane 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 6 1 Regeneration capacity The regeneration capacity of the MicroFlex can be calculated from the following formula 2 0 5 DC bus capacitance regen switching threshold v2 x Supply voltage where the Regen switching threshold is 388 V This gives the following typical values MicroFlex Regeneration capacity J
67. ing 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 X1 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 baldormotion com 3 2 Mechanical installation and cooling requirements It is essential that you read and understand this section before beginning the installation AN 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
68. is already indicated by the green red flashing state If an undervoltage trip occurs in conjunction with another error the drive will flash the code of the additional error Further details about error codes can be found in the Mint WorkBench help file Press F1 and locate the DRIVEERROR and AXISERROR keywords or the Error Handling book Alternate red green flashing Undervoltage warning no AC power The DC bus voltage has dropped below the powerbase undervoltage level see DRIVEBUSUNDERVOLTS Check that AC power is connected This error will be automatically cleared when AC power is restored so the MicroFlex does not need to be reset 7 2 Troubleshooting MN1919 www baldormotion com 7 2 1 Communication Status LED is off Check that the 24VDC control circuit supply is connected correctly to connector X2 and is switched on Mint WorkBench Ensure that the MicroFlex is powered and the Status LED is fails 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 CO
69. k cable R Resolver feedback cable 1 Drive connector included 9 pin D type connector for Resolver Drive connector included 15 pin D type connector for all feedback types Note Feedback cables have the outer shield tied to the connector housing s If you are not using a Baldor cable with your chosen feedback device be sure to obtain a cable that is a shielded twisted pair 0 34 mm 22 AWG wire minimum with an overall shield Ideally the cable should not exceed 30 5 m 100 ft in length Maximum wire to wire or wire to shield capacitance is 50 pF per 300 mm 1 ft length to a maximum of 5000 pF for 30 5 m 100 ft A 2 3 SSI feedback cables A 2 3 1 Cables available in North and South America Length SSI feedback cable CBL044 501 Available by the foot or no connectors on 100 m 328 ft drum CBLO15SF S2 Feedback cable assembly CBLO30SF S2 CE style threaded motor connector CBL061SF S2 and low density 15 pin D type drive CBLO91SF S2 connector CBL152SF S2 CBL229SF S2 Cable assembly description Catalog number A 2 3 2 Cables available in the rest of the world Length Cable assembly description Catalog number Cm SSI feedback cable CBL044 501 Available by the meter no connectors or on 100 m drum CBLO25SF S2 Feedback cable assembly CBLO50SF S2 CE style threaded motor connector CBLO75SF S2 and low density 15 pin D type drive CBL100SF S2 connector CBL150SF S2 CBL200SF S2 A 10 Accessories M
70. ll models p 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 Maximum installation altitude above m s l Derate 1 196 100m over 1000m 3300 Derate 1 196 330ft over 3300ft 8 6 Specifications MN1919 Forced air cooling flow None 2 5 vertical from bottom to top www baldormotion com MicroFlex complies with the following environmental test standards BS EN60068 2 1 1993 low temperature operational 0 C BS EN60068 2 2 1993 high temperature operational 45 C BS EN60068 2 1 1993 low temperature storage transportation 40 C BS EN60068 2 2 1993 high temperature storage transportation 85 C BS 2011 part2 1 Cb 1990 45 C 93 RH humidity high temperature operational DIN IEC 68 2 6 29 MicroFlex complies with EN61800 5 1 2003 part 5 2 2 5 3 Impact Test provided all front panel connectors are inserted MN1919 Specifications 8 7 www baldormotion com 8 8 Specifications 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 baldormotion com A 1 1 Fan tray
71. ment or other equipment to which it is connected Electrical shock can cause serious or fatal injury Only qualified personnel should attempt to start up program or troubleshoot this equipment DANGER The motor circuit might have high voltages present whenever AC power is applied even when the motor is not moving Electrical shock can cause serious or fatal injury conducted to its power terminals The enclosure must be earthed grounded to prevent possible shock hazard N DANGER motor is driven mechanically it might generate hazardous voltages that are DANGER 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 baldormotion com IN WARNING IN WARNING IN WARNING IN WARNING IN WARNING IN WARNING IN WARNING IN CAUTION CAUTION A AN CAUTION Be sure 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 MEDICAL DEVICE PACEMAKER DANGER Magnetic and electromagneti
72. milliohm PE Rel mens picofarad Maik m Ee noi Volt also VAC and VDC We Watt UA ac ceto de microampere p EN microhenry UE microfarad o Ohm HZ uiii hertz AA kilohertz megahertz Sii millisecond Mido nanosecond Sia second lS gerere microsecond Qa eee phase AIT Compact Disc CTRESE on the PC keyboard press Ctrl then E at the same time Kbaud kilobaud the same as Kbit s in most applications MB megabytes tasses etes feet A feet per second radar dass inch Ib in cu pound inch torque ITE sce th millimeter Iesse ers meter MS idad meters per second Nifi emer Newton meter torque ADC zb ivl Analog to Digital Converter American Wire Gauge DAG arcos Digital to Analog Converter SS cu ges ce Synchronous Serial Interface NC ie ees Not Connected MN1919 Introduction 2 3 www baldormotion com 2 4 Introduction MN1919 3 1 3 1 1 3 1 2 Basic Installation 3 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 followe
73. missioning is complete Using the Commissioning Wizard IN 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 lt Back button The Commissioning Wizard remembers information that you have entered so you will not need to re enter everything if you go back to previous screens During commissioning changed parameters are stored in the MicroFlex s volatile memory For this reason the Commissioning Wizard will occasionally prompt you to save the parameters Selecting Yes will cause the parameters to be saved in the MicroFlex s non volatile flash memory to be retained when power is removed If you select No you must remember to use the Save Drive Parameters function before removing power from the MicroFlex this function is available on the Tools menu or by clicking the button on the Mode toolbar Saving parameters into flash memory will cause the MicroFlex to be reset
74. mum recommended cable length is 30 5m 100ft 4 8 Feedback MN1919 www baldormotion com 4 1 3 Resolver feedback X8 The resolver conn ections are made using the 9 pin D type male connector X8 Twisted pair cables must be used for the complementary signal pairs e g SIN and SIN The overall cable shield screen must be connected to the metallic shell of the D type connector The resolver input is used to create an encoder signal inside the MicroFlex This provides the MicroFlex with an equivalent resolution of 4096 pulses per revolution ppr although this can be reconfigured in the Mint WorkBench Commissioning Wizard to provide 1024 ppr The MicroFlex provides an input accuracy of 3 counts When used with a typical Baldor BSM series resolver motor the combined accuracy is 11 counts calculated with the input equivalent resoluti on set to the factory preset value of 4096 ppr The left LED illuminates red if there is a fault or loss of the resolver signal the right LED is unused 3 S3 S1 e DEN CN DN CN Baldor motor Twisted pairs 52 resolver connector 5 S4 6 X8 SIN SIN COS COS REF REF Connect internal shields to AGND Connect overall shield to connector backshells Figure 19 Resolver cable connections MN1919 Feedback 4 9 www baldormotion com 4 1
75. nput on the connector block demand input 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 25 The analog input is not optically isolated from internal power rails so care must be taken to avoid earth ground loops and similar associated problems The input buffers provide low pass filtering of the applied voltage To minimize the effects of noise the analog input signal should be connected to the system using an individually shielded twisted pair cable with an overall shield The overall shield should be connected to the chassis at one end only No other connection should be made to the shield MicroFlex Low pass filter amp level correction o Internal reference Figure 24 AINO analog input demand circuit When the MicroFlex is connected to Mint WorkBench the analog input value expressed as a percentage can be viewed using the Spy window s Monitor tab Alternatively th
76. nput signal to be connected with either polarity MicroFlex Mint Drive I DRIVEENABLE Enable SWITCH i 74AHC14 Drive Enable TLP280 Figure 28 Drive enable input circuit In normal use the drive enable input controls the enabled status of the drive However when the MicroFlex is connected to Mint WorkBench additional methods are available for controlling the drive enable status In all cases the drive enable input must be active and there must be no errors present before the MicroFlex can be enabled m The drive enable button on the motion toolbar toggles the enable disable status Alternatively the Mint command DRIVEENABLE 0 1 can be used in the command window to enable the MicroFlex DRIVEENABLE 0 0 will disable the MicroFlex The Tools Reset Controller menu item will clear errors and enable the MicroFlex Alternatively the Mint command RESET 0 can be used in the command window to perform the same action The state of the drive enable input is displayed in the Mint WorkBench Spy window Alternatively the state of the drive enable input can be read but not set using the Mint command Print DRIVEENABLESWITCH in the command window See the Mint help file for details MN1919 Input Output 5 5 www baldormotion com NextMove ESB controller User
77. on 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 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 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 N DANGER After AC power has been removed from the MicroFlex high voltages greater than 50VDC will remain on the regeneration
78. 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 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 baldormotion com 2 2 2 2 1 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 t
79. only CBL152SF R CBL229SF R CBLO15SF R1 Feedback Cable Assembly CE style threaded motor connector CBLO91SF R1 and 9 pin D type drive connector CBL152SE R1 CBL229SF R1 A 2 5 2 Cables available in the rest of the world Length Cable assembly description Catalog number Resolver Feedback Cable CBL044 501 Available by the meter no connectors or on 100 m drum CBLO25SF R 2 5 8 2 Feedback Cable Assembly ss CE style threaded motor connector CBL100SF R motor end only CBL150SF R CBL200SF R CBLO25SF R1 Feedback Cable Assembly CE style threaded motor connector A CBL100SF R1 and 9 pin D type drive connector CBL150SE R1 CBL200SF R1 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 Mint WorkBench using the Commissioning Wizard You can subsequently change between these control modes using the Tools Control Mode menu item or by using the CONTROLMODE keyword in the Command window see the Mint help file Using the Parameter tool you can define a mode for the drive to automatically select at start up The three control modes are described in the following sections MN1919 Control System B 1 www baldormotion com B 1 1 Current Torque control Setting the c
80. onnection between components and shielding and grounding of the system as a whole determines EMC compliance The CE mark informs the purchaser that the equipment has been tested and complies with the appropriate standards It rests upon the manufacturer or his authorized representative to ensure the item in question complies fully with all the relative directives in force at the time of installing into service in the same way as the system integrator previously mentioned Remember that it is the instructions of installation and the product that should comply with the directive 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 amp UL C 1 www baldormotion com C 1 3 Declaration of conformity BALDOR CE Date 01 0205 EC Declaration of Conformity Ref DE00014 001 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
81. ontrol mode to Current Control configures the MicroFlex or MicroFlex as a torque amplifier as shown in Figure 51 Here a torque reference is obtained from a specified source Mint WorkBench m 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 targets reference values This is achieved by specifying a rise time and fall time see the WorkBench v5 Parameters tool The torque demand signal is fed into the torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current measured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Torque Torque reference profiler Torque Host demand Analog input e Torque PWM Power stage controller motor Measured current Figure 51 Control structure in Current Torque control mode The torque controller is a Proportional Integral controller Gains are set using the Mint keywords KIPROP and KIINT The torque demand is scaled into a current demand This is compared with the measured current obtained from the current sensors and the error is fed into the PI control calculation The resulting value forms the PWM signal that is fe
82. or BS88 2 5 URGS 20A L097507 Ferraz Shawmut 6x32 FA series 12 5A X084315P or BS88 2 5 URGS 12A P076649 Ferraz Shawmut BS88 2 5 URGS 25A R076651 Ferraz Shawmut 6x32 FA series 20A A084318P or BS88 2 5 URGS 20A L097507 Table 3 Protection device and wire ratings Note All wire sizes are based on 75 C 167 F copper wire Higher temperature smaller gauge wire may be used per National Electric Code NEC and local codes Recommended fuses are based on 25 C 77 F ambient maximum continuous control output current and no harmonic current Earth ground wires must be the same gauge or larger than the Line wires 3 4 6 Drive overload protection The MicroFlex will immediately trip and disable if there is an overload condition The parameters for managing drive overloads are configured automatically by the Commissioning Wizard see section 6 2 3 If they need to be changed use the Parameters tool in Mint WorkBench see section 6 3 2 3 14 Basic Installation MN1919 www baldormotion com 3 4 7 3 4 7 1 3 4 7 2 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 lis
83. or vapors metal particles and dust IN 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 depends upon its use in the appropriate environment The following points must be considered 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 whicheve
84. ormotion com User NextMove ESB controller supply MicroFlex x11 24V UDN2982 USR V MintMT OUTX 0 DOUTO PY USR GND TLP280 User supply GND Figure 31 Digital input typical connection from a Baldor NextMove ESB 5 8 Input Output MN1919 www baldormotion com 5 3 3 Step pulse and direction inputs X3 Location Connector X3 pins 9 amp 10 o Mating connector Weidm ller Minimate B2L 3 5 14 Names Step and Dir E Dedicated step and direction inputs Input voltage 5VDC Maximum input frequency 1 MHz maximum When the MicroFlex control mode is set to position control the step and direction inputs are used as the demand reference Pin 10 is the step input The step frequency controls the speed of the motor Pin 9 is the direction input The state of the direction input controls the direction of motion If 5V is present on pin 9 movement will be in the forward direction If pin 9 is grounded movement will be in the opposite direction MicroFlex i 74AHC14 Figure 32 Step and direction input circuit Step shown When the MicroFlex is connected to Mint WorkBench the following ratio can be configured using the Operating Mode Wizard Alternatively the Mint keywords FOLLOWDENOM and FOLLOWNUMERATOR can be used in the command window See the Mint help file for details MN
85. otprint filter fan tray and MicroFlex MN1919 Accessories A 3 www baldormotion com 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 Lm FI0014A00 0 FI0015A00 0 0 FI0015A02 0 FI0018A00 FI0018A03 3 3968 5 04 073160 250 250 250 250 80 80 250 3 4 4 10 4 12 4 4 7 33 4 16 33 2 33 Dimensions mm inches FOGAU 257080 2200890 255 925 25 055 51021 77079 40 0 1 57 45 1 77 Figure 47 Filter dimensions types 0018 00 and FI0018A03 A 4 Accessories MN1919 www baldormotion com Dimensions mm inches A Dimensions ARETES G FI0015A02 mom gt 13 57 5 2 26 40 1 57 46 6 1 83 5 se 13051510 5 2 95 103 a 4 06 143 5 63 7 1 06 25 0 98 12 0 47 12 4 0 49 29 5 1 16 32 4 1 28 A A 6 3 0 25 0 24 13 5 0 53 15 5 0 61 Figure 48 Filter dimensions types FI0014A00 FI0015A00 FI0015A01 FI0015A02 MN1919 Accessories A 5 www baldormotion com
86. 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 2 s mj 7 Ng 7 NC Data ooo iver eS E 12 5 11V out 13 DGND wp 7 Description SSI encoder input non isolated Pin 12 provides power to the encoder 200mA max Motor X8 Twisted pairs Data Data Clock Clock 5V DGND Sense Connect internal shields to pin 13 Absolute Encoder SSI Interface U Y NA Connect overall shield 77 to connector backshells Chassis Figure 17 SSI encoder cable connections MN1919 Feedback 4 7 www baldormotion com 4 1 2 1 SSI cable pin configuration Figure 18 shows the pin configuration for a typical Baldor SSI feedback cable part number CBLO25SF S2 Signal name MicroFlex Motor cable Baldor SSI cable X8 pin pin internal wire colors 5 11V out 1 3 1 000 0BOO Pins 7 12 are not used 6 e and may not be present o Motor SSI connector Cable connector end view male female Figure 18 Baldor motor SSI feedback cable pin configuration The maxi
87. phase supply ades eser si 3 s 20 30 40 50 60 70 80 90 100 110 120 130 140 150 96 of Drive Rated Current 25 150 175 200 225 250 8 2 Specifications MN1919 www baldormotion com 8 1 2 24VDC control circuit supply input X2 10 VDC i A i A Nominal input voltage Maximum continuous current 24VDC Power on surge current typical 24VDC 100ms 8 1 3 Motor output power X1 A 1 Peak phase current 2 230V 3 Output voltage range line line 0 230 VDC bus 320V Output frequency 0 2000 Output dv dt kV us at drive phase phase at drive phase ground at motor using 20m cable phase phase at motor using 20m cable phase ground Nominal switching frequency Minimum motor inductance per winding 8 1 4 Regeneration X1 A o Nominal switching threshold typical VDC on 388 off 376 Nominal power 0 25 10 power cycle 570 EN Peak power 10 power cycle 570 Maximum regeneration switching current Minimum load resistance Maximum load inductance MN 1919 Specifications 8 3 www baldormotion com 8 1 5 Analog input X3 T me e S A Me Smogon 8 1 6 Digital inputs drive enable and general purpose X3 Input voltage VDC Nominal Minimum Maximum Type Non isolated DC inputs Input voltage Input current maximum per input Maximum step input frequency Minimum pulse wid
88. r 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 as screwlocks If a jack screw is removed accidentally or lost it must be replaced with a jack screw with an external male threaded section no longer than 10mm 0 4 in MN1919 Basic Installation 3 3 www baldormotion com 3 2 1 Dimensions 80 lt 3 2 gt BET 63 5 5 LIS 2 5 gt 02 oN A AA No se 8 Y s Figure 1 Package dimensions 7 1 Mounting hole and slot detail Dimensions shown as mm inches Depth 157 mm 6 2 in Weight 1A 1 45kg 3 2 b 1 45kg 3 2 b 6A 1 50kg 3 3 b 9A 1 55kg 3 416 3 4 Basic Installation MN1919 www baldormotion com 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
89. r 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 MIC ae wow me 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 3 18 Basic Installation MN1919 www baldormotion com 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 AY 1763A00 woj Wax S AA 8 amp 4 Wemasdh Signal name Hall cable wire color Hair uj O rats 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
90. rage power The regenerative power P is the rate at which the braking energy is dissipated This rate is defined by the deceleration period D The shorter the deceleration period the greater the regenerative power E W watts Although the resistors shown in Table 6 can withstand brief overloads the average power dissipation Pay must not exceed the stated power rating The average power dissipation is determined by the proportion of the application cycle time spent regenerating The greater the proportion of time spent regenerating the greater the average power dissipation Pa PIX Z W watts 3 22 Basic Installation MN1919 www baldormotion com 3 7 4 Resistor choice 3 7 5 Pay is the value to use when assessing which regeneration resistor to use However a safety margin of 1 25 times is recommended to ensure the resistor operates well within its limits so Required resistor power rating 1 25 X Pay W watts The range of suitable regeneration resistors is shown in Table 6 Choose the resistor that has a power rating equal to or greater than the value calculated above Table 6 Regeneration resistors Dimensions are shown in section A 1 4 The regeneration resistors listed in Table 6 can withstand a brief overload of 10 times the rated power for 5 seconds Please contact Baldor if larger power ratings are required Resistor derating The regeneration resistors shown in Table 6 c
91. re The Baldor Motion Toolkit CD containing the software can be found separately within the packaging 1 Insert the CD into the PC s drive 2 After a few seconds the setup wizard should start automatically If the setup wizard does not appear select Run from the Windows Start menu and type d start where d represents the drive letter of the CD device use the correct letter for your installation Follow the on screen instructions to install Mint WorkBench The setup wizard will copy the files to appropriate folders within the C Program Files folder and place shortcuts on the Windows Start menu MN1919 Configuration 6 1 www baldormotion com 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 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 Po
92. rk slave Twisted pairs Network slave Master and final slave are shown with terminating resistors Tg typical value 1200 Connect overall shield to connector backshell Figure 39 4 wire RS422 multi drop connections Each transmit receive TX RX network requires a termination resistor at the final RX connection but intermediate devices must not be fitted with termination resistors An exception is where repeaters are being used which may correctly contain termination resistors Termination resistors are used to match the impedance of the load to the impedance of the transmission line cable being used Unmatched impedance causes the transmitted signal to not be fully absorbed by the load This causes a portion of the signal to be reflected back into the transmission line as noise If the source impedance transmission line impedance and load impedance are all equal the reflections noise are eliminated Termination resistors increase the load current and sometimes change the bias requirements and increase the complexity of the system MN1919 Input Output 5 15 www baldormotion com 5 4 3 Connecting serial Baldor HMI Operator Panels Serial Baldor HMI Operator Panels use a 15 pin male D type connector marked PLC PORT but the MicroFlex connector X6 is a 9 pin male D type connector The MicroFlex may be connected with or without hardware handshaking as shown in Figure 40 Baldor HMI MicroFlex Baldor HMI MicroFlex P
93. rrectly the measured speed will accurately track the speed demand Finally the torque demand signal is fed into a torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current measured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Speed Speed reference profiler Speed Torque demand Host Analog input e Speed Torque PWM Power stage controller controller motor Measured speed Figure 52 Control structure in Velocity control mode The speed controller is a PI Proportional Integral controller Gains are set using the Mint keywords KVPROP and KVINT The speed is compared with the measured speed and the error is fed into the PI control calculation The speed control calculation is performed every 250us and the result forms the torque demand for the torque controller As with the position controller the gain values KVPROP and KVINT must be tuned for each application This can either be performed automatically within the Commissioning Wizard or manually using the Fine tuning tool of Mint WorkBench MN1919 Control System B 3 www baldormotion com 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
94. ry motor encoder cable pin configuration The maximum recommended cable length is 30 5m 100ft MN1919 Feedback 4 5 www baldormotion com 4 1 1 5 Encoder cable pin configuration Baldor linear motors Baldor linear motors use two separate cables encoder and Hall The cores of these two cables must be wired to the appropriate pins of the 15 pin D type mating connector supplied Signal name MicroFlex Encoder cable internal wire colors X8 pin E Please refer to MN 1800 Linear Motors Installation amp Operating Manual for details CHZ 3 gt O NECE mi IAN WW ww 8E Lee LE 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 1 xd SS Connect overall shield to 7 connector backshells Figure 16 Encoder cable connections linear motors 4 6 Feedback MN1919 www baldormotion com 4 1 2 SSI feedback X8 The SSI Synchronous Serial Interface encoder interface is specifically designed for use with Baldor SSI motors which incorporate a custom Baumer SSI encoder Correct operation with other SSI interfaces cannot be guaranteed The SSI encoder connections are made using the 15 pin D type female connector X8 Twisted pair cables must be used for the complementary signal pairs e g Data and Data The
95. sampling rate the simulated encoder output generates a burst of A and B pulses and a Z pulse if required The frequency and length of the burst is varied to represent the change in the input encoder s position during the preceding 62 5 microsecond interval See the keyword ENCODERLINESOUT in the Mint help file If the MicroFlex has resolver feedback a simulated encoder output is produced at X7 If the resolver input has been configured to simulate an encoder input of 1024 pulses per revolution ppr the output at X7 can be set to either 512 or 1024 ppr If the resolver input has been configured to simulate an encoder input of 4096 ppr output modes of 512 1024 2048 and 4096 ppr are possible Note that these values represent actual encoder lines not quadrature counts The simulated encoder output is in the same direction as the resolver input See the keyword ENCODERLINESOUT in the Mint help file MN1919 Feedback 4 11 www baldormotion com CHA CHA CHZ CHZ CHB CHB DGND MicroFlex U U SS Connect overall shield zt to connector backshells NextMove BX encoder input Baldor cable parts CBLOxxMF E3B are recommended where xx represents a choice of available lengths Figure 21 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 U
96. screen connections can be connected to earth ground Within the cabinet there should be a spatial Separation between power wiring motor and AC power cables and control wiring Shield screen connections All connections between components must use shielded cables The cable shields must be connected to the enclosure Use conductive clamps to ensure good earth ground connection With this technique a good earth ground shield can be achieved EMC filters The filter should be mounted next to the MicroFlex The connections between the MicroFlex and the filter should use shielded screened cables The cable shields should be connected to shield clamps at both ends An exception to this is the analog command signal Earthing grounding For safety reasons VDE0160 all Baldor components must be connected to earth ground with a separate wire Earth ground connections must be made from the central earth ground star point to the regeneration resistor enclosure and from the central earth ground star point to the power supply MN1919 CE amp UL C 3 www baldormotion com C 1 6 EMC installation suggestions To ensure electromagnetic compatibility EMC the following installation points should be considered to help reduce interference Earthing grounding of all system elements to a central earth ground point star point Shielding of all cables and signal wires Filtering of power lines A proper enclosure should have the following
97. sition control Step and Direction B 4 Control System MN1919 C 1 C 1 1 C 1 2 CE amp UL Outline This section provides general information regarding recommended methods of installation for CE compliance It is not intended as an exhaustive guide to good practice and wiring techniques It is assumed that the installer of the MicroFlex is sufficiently qualified to perform the task and is aware of local regulations and requirements Baldor products that meet the EMC directive requirements are indicated with a CE mark A duly signed CE declaration of conformity is available from Baldor 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 interc
98. tective devices installed To prevent equipment damage be certain that input and output signals are powered and referenced correctly To ensure reliable 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 MN1919 General Information 1 3 www baldormotion com CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION AN AN AN AN AS AN AN AN AN AN AN AN 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 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 syst
99. th 8 4 Specifications MN1919 www baldormotion com 8 1 8 Status output X3 Approximate trip current 200 Reset time lt 20 8 1 9 Incremental encoder feedback option X8 Encoder input mm A B Differential Z index Maximum input frequency quadrature Output power supply to encoder EE 5V 796 200mA max Maximum recommended cable length EXE 30 5m 100ft 8 1 10 SSI encoder feedback option X8 All models Differential Data and Clock Operating mode Single turn Baldor motors Positioning resolution up to 262144 counts rev 18 bit Output power supply to encoder 5V 796 200mA max Maximum recommended cable length 30 5m 100ft 8 1 11 Resolver feedback option X8 All models Resolution 14 set automatically by software Typical accuracy 11 using Baldor BSM series resolver motor with input set to simulate 4096 ppr Maximum recommended cable length 30 5m 100ft MN 1919 Specifications 8 5 www baldormotion com 8 1 12 Encoder output simulated X7 TI Ames RN RUN NM Resolution with encoder input on X8 Output is a copy of the input on X8 with SSI encoder input on X8 Adjustable simulated output See section 4 1 4 8 1 13 Serial RS232 RS485 interface X6 RS232 non isolated CTS RTS or RS485 non isolated model dependent Bit rate 9600 19200 38400 57600 default 8 1 14 Environmental All models Operating temperature range A
100. tion com 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 l O information A separate fused 24V supply should be provided for the MicroFlex If other devices are likely to be powered from the same 24V supply a filter Baldor catalog number FI0014A00 should be installed to isolate the MicroFlex from the rest of the system Alternatively a ferrite sleeve may be attached to the supply cable near connector X2 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 baldormotion com 3 5 Motor connections MicroFlex will operate with a large number of brushless servo motors For informa
101. tion on selecting Baldor servo motors please see the sales brochure BR1202 available from your local Baldor representative The motor must be capable of being powered by an inverter PWM output see section 8 1 3 for details The motor can be connected directly to the MicroFlex or through a motor contactor M Contactor The motor outputs are conditionally short circuit proof Motors should ideally have a minimum inductance of 1mH per winding for motors with lower inductance an output reactor may be fitted in series with the motor When using a Baldor motor the parameters for managing motor overloads are configured automatically by the Commissioning Wizard see section 6 2 3 If they need to be changed or you are using an alternative motor use the Parameters tool in Mint WorkBench see section 6 3 2 Location Connector X1 AC supply voltage 115VAC 10 230VAC 10 230VAC 30 Output voltage range 0 115VAC 30 0 230VAC 0 230VAC Motor Connect motor earth ground to protective earth on top of To earth ground outer shield use 360 clamp connected to top of drive rnm Unshielded lengths should be as short as Optional motor possible circuit contactors IK To earth ground outer shield use 360 clamp connected to backplane Figure 7 Motor connections IN CAUTION Do not connect supply power to the MicroFlex UVW outputs The MicroFlex might be damaged IN CAUTI
102. to connector backshell Figure 38 RS232 serial port connections When the MicroFlex is connected to Mint WorkBench the Tools Options menu item can be used to configure the serial port The configuration can also be changed using the Mint keyword SERIALBAUD see the Mint help file for details 5 14 Input Output MN 1919 www baldormotion com 5 4 2 The RS232 port is configured as a DTE Data Terminal Equipment unit Both the output and input circuitry are single ended and operate between 12V The port is capable of operation at up to 57 6 Kbaud The maximum recommended cable length is 3m 10ft at 57 6 Kbaud the factory preset rate When using lower baud rates longer cable lengths may be used up to maximum of 15m 49ft at 9600 baud Multidrop using RS485 RS422 cable Multidrop systems allow one device to act as a network master controlling and interacting with the other slave devices on the network The network master can be a controller such as MicroFlex a host application such as Mint WorkBench or other custom application or a programmable logic controller PLC RS422 may be used for multi drop applications as shown in Figure 39 Four wire RS485 may be used for single point to point applications involving only one Baldor controller If firmware is updated over RS485 RS422 it can only be downloaded to the drive that was chosen in the Select Controller dialog in Mint WorkBench Network master Netwo
103. ts the appropriate filters MicroFlex Input voltages current rating 230VAC 10 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 a FI0015A02 see section 3 4 7 2 Maximum earth leakage from the MicroFlex is 3 4mA per phase 230V 50Hz supply This value does not include the earth leakage from the AC power filter which could be much larger see section A 1 3 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 Reversing the filter When using filters FI0015A00 or FI0015A02 as specified in Table 4 they must be reversed to ensure that the MicroFlex complies with the CE specifications for which it has been tested The AC power supply should be connected to the filter terminals marked as the outputs with the MicroFlex connected to the filter terminals marked as the inputs N WARNING This recommendation applies only to filters FI0015A00 and FI0015A02 Alternative filters or protection devices must be connected as specified by the manufacturer MN1919 Basic Installation 3 15 www baldormo
104. uit 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 Ensure cables do not obstruct airflow to the heatsink Motor represents a typical Baldor BSM motor Linear motors may also be controlled by MicroFlex Conductive shield earth ground clamps are not supplied m When using single phase supplies it may be necessary to reverse the AC power filter see section 3 4 7 2 Figure 42 Recommended system wiring MN1919 Input Output 5 17 www baldormotion com 5 18 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 Mint WorkBench This software includes a number of tools to allow you to configure and tune the MicroFlex If you do not have experience of software installation or Windows applications you may need further assistance for this stage of the installation Connecting the MicroFlex to the PC Connect the serial cable between a PC serial port often labeled as COM and the MicroFlex connector X6 Mint WorkBench can scan all the COM ports so you can use any port Installing the softwa
105. wer on checks If at any time the Status LED flashes red the drive has detected a fault see section 7 1 2 3 Turn on the 24VDC supply Turn on the AC supply After a brief test sequence the Status LED should be green If the LED is not lit then re check the power supply connections If the motor wires were disconnected in section 6 1 4 turn off the AC supply and reconnect the motor wires Turn on the AC supply 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 do not wish to enable the MicroFlex yet the Commissioning Wizard will inform you when this step is necessary The MicroFlex is now ready to be commissioned using Mint WorkBench 6 2 Configuration MN1919 www baldormotion com 6 2 Mint WorkBench Mint WorkBench is a fully featured application for commissioning the MicroFlex The main Mint WorkBench window contains a menu system the Toolbox and other toolbars Many functions can be accessed from the menu or by clicking a button use whichever you prefer Most buttons include a tool tip hold the mouse pointer over the button don t click and its description will appear wkBench v5 fruitmachine wbx Fine tuning Toolbars Control and test area Toolbox Figure 43 The Mint WorkBench software MN1919 Configuration 6 3 www baldormotion com 6 2 1 Help

MicroFlex Servo Control

Contents

Download Pdf Manuals

Related Search

Related Contents