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Installation Manual

1. sem p Description Optically isolated encoder or pulse and direction input on a 9 pin female D type connector Sampling interval 1 or 2ms 1 The FlexDrive provides an auxiliary master or handwheel encoder input that allows it to follow a master encoder or pulse and direction inputs An interface for a three channel incremental encoder CHA CHB CHZ is provided The input receiver circuit allows only encoders with differential line drivers RS422 to be used The interface also provides an isolated 5V supply for the encoder electronics capable of driving up to 100mA AN CAUTION The master encoder input does not use the same pin configuration as some Baldor controllers such as NextMove BX FlexDrive EMIFO1 AM26LS32 ESD 150R Differential protection line receiver Figure 36 Master encoder channel input circuit Channel A shown MN1902 Input Output 4 13 www baldormotion com x9 Twisted pairs CHA CHA CHB Master CHB Encoder CHZ CHZ 45V DGND Connect internal shields to DGND aAOowWmMWwnNnD N Connect overall shield P to connector backshells Figure 37 Differential encoder connections 4 4 2 1 Dual encoder feedback The master encoder input can be used as a second feedback input in dual encoder systems The Mint keyword AXISPOSENCODER is used to select the master auxiliary e
2. 2 At the bottom of the Digital I O window click in the Preset Inputs drop down box Preset Inputs vw x and select the number of inputs to be used for preset selection For example if the application requires only four different preset moves choose 2 This means only two digital inputs will be used to select preset moves allowing 4 different combinations moves to be selected Similarly to allow selection of up to 8 different preset moves choose 3 for up to 16 different moves choose 4 Selecting fewer digital inputs will leave more free for other purposes 3 If the default inputs shown by the Preset Sel icon are not suitable drag a different a IN icon onto the Preset Sel icon This will IN X set the lowest numbered input used for preset selection with the other required Mot rip inputs selected automatically It is not possible to select a discontinuous range of inputs for preset selection although the Lr Ex trigger input may be any input Preset Trig Preset Sel INS IN 2 3 4 4 Ifthe default input shown by the Preset Trig icon the trigger input is not suitable X drag a different IN icon onto the Preset na Motor Tri Trig icon otor Trip IN 1 pw A Preset Trig Preset Sel IN 1 IN 2 3 4 5 Click Apply to send the changes to the FlexDrivel Apply When you return to the Presets tool the presets table and the Addressable Presets box will show the number of presets that can be selected by the chosen number
3. 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 34mm 22 AWG wire minimum with an overall shield Ideally the cable should not exceed 30 5m 100ft in length Maximum wire to wire or wire to shield capacitance is 50pF per 300mm 1ft length to a maximum of 5000pF for 30 5m 100ft MN1902 Accessories A 5 www baldormotion com A 1 8 EMC filters AC filters remove high frequency noise from the AC power supply protecting the FlexDrive These filters also prevent high frequency signals from being transmitted back onto the power lines and help meet CE requirements To select the correct filter see section 3 4 5 A 1 8 1 Catalog numbers Baldor Rated amps Leakage Weight catalog number Rated volts 40 C current mA kg Ibs FIOOT ADO 027 08 FIOOTSROO 250 8 04 045059 FIOOTEROZ 075 81 FTOOTEAOO ost FOOTER 12085 FI028A00 5068 Lait B Sio I Dimensions mm inches FI0018A00 FI0018A01 190 7 48 270 10 63 160 6 30 240 9 45 180 7 09 255 10 04 20 0 79 30 1 18 4 5 0 18 5 4 0 21 71 2 80 85 3 35 0 40 1 57 50 1 97 Figure 46 Filter dimensions types FI0018A00 and FI0018A01 A 6 Accessories MN1902 www baldormotion com Dimensions mm inches ae 5A02 TET
4. disabled from the drive enable input enable DIP switch To specify an output as a drive enable To read the state of the drive enable input DRIVEERROR To report errors on the drive or to clear current drive errors DRIVEOVERLOADMODE Sets or reads the action taken in the event of a drive overload condition Reads the peak current rating of the drive DRIVEPEAKDURATION Reads the duration for which peak drive current can be sustained DRIVERATEDCURRENT Reads the continuous current rating for the drive DRIVESPEEDFATAL To define the overspeed trip level DRIVESPEEDMAX To set or read the maximum motor speed to be used EFFORT To read the instantaneous effort applied by the current controllers To read the state of the Drive Enable DIP switch To set or read the axis encoder value ENCODERLINESIN To set or read the number of encoder lines pre quadrature for the drive feedback ENCODERLINESINSPEEDMAX To read the maximum allowable speed when using a resolver feedback device C 6 Mint Keyword Summary MN1902 www baldormotion com ENCODERWRAP To set or read the encoder wrap range for the encoder channel To get and reset the state of an axis encoder Z latch ERRORDECEL To set the deceleration rate on the axis for powered Stops in the event of an error or stop input ERRORINPUT To set or return the digital input to be used as the error input for the specified axis ERRORINPUTMODE To control the default action tak
5. Units and abbreviations The following units and abbreviations are used in this manual Me Ses Volt also VAC and VDC Weed sou EN RA Y Watt B Selbcpxge Eus Ampere Q ls pP Ohm PIP anus microfarad PR ettees baad wel picofarad MH 22 ieikzes millihenry Quse eS phase m nete es millisecond UL Spi MU Mn E MT microsecond TS oco Ste otis nanosecond Kbaud kilobaud the same as Kbit s in most applications MB IR megabytes CDROM Compact Disc Read Only Memory CTRL E nii on the PC keyboard press Ctrl then E at the same time MMS ier cones millimeter E T meter P E inch IU atia feet IAI sez pound inch torque Nm ee aed Newton meter torque ADC xs testa Analog to Digital Converter DAG pix Ies Digital to Analog Converter AWG iene chad bees American Wire Gauge NC eee Not Connected MN1902 Introduction 2 3 www baldormotion com 2 4 Introduction MN1902 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 FlexDrive in the following stages Location considerations Mounting the FlexDrive Connecting the AC power supply Connecting the optional customer supplied 24VDC control supply Connecting the motor Installing a regeneration resistor Dynamic Brake resistor Connecting the feedback device Connecting
6. 5 Hold 3 34 6 RS485 terminator 3 34 7 Offset tuning 3 34 5 3 8 Enable 3 34 9 amp 10 RS232 RS485 select 3 35 factory settings 3 35 preventing a program running 3 36 Drive enable command 3 32 DIP switch 8 3 32 X3 CREF 3 31 Dual encoder feedback following 4 14 Dynamic brake See Regeneration resistor Encoder absolute See Absolute encoder cable 3 25 A 4 Hiperface See Absolute encoder option 3 24 MN1902 Index specification 8 9 EnDat See Absolute encoder Environmental location 3 4 3 5 specification 8 11 F Factory fitted options A 1 Factory settings 3 35 Features 2 1 Feedback absolute encoder 3 27 3 29 cable A 3 A 5 connections 3 21 encoder 3 24 resolver 3 22 Filters 24V control supply 3 14 AC power EMC 3 12 A 6 catalog numbers A 6 G General Information 1 1 H Hardware requirements 3 1 Help file 5 4 Hiperface See Absolute encoder Indicators 7 2 DB On LED 7 5 Status display 7 2 Input Output 4 1 analog I O 4 1 analog input X3 4 2 8 6 connection summary 4 19 digital I O 4 4 digital inputs X3 4 5 8 7 digital outputs X3 4 9 4 10 8 7 encoder output X7 4 11 8 9 master encoder input X9 4 13 8 10 option connectors 4 20 relay X3 4 10 8 8 serial port X6 4 15 8 8 connecting Baldor HMI panels 4 18 multidrop using RS485 RS422 cable 4 17 using RS232 cable 4 16 Installation See also Basic Installatio
7. 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 D 6 CE amp UL MN1902 A Abbreviations See Units and Abbreviations Absolute encoder cable 3 28 3 30 A 4 Hiperface option 3 29 option 3 27 specification 8 10 Accessories A 1 EMC filters A 6 feedback cables A 3 A 4 motor power cables A 2 regeneration resistors A 9 Analog I O 4 1 analog input X3 demand 4 2 B Basic Installation 3 1 C Catalog number identifying 2 2 CE Guidelines D 1 declaration of conformity D 2 Commissioning Wizard 5 7 completing 5 7 using 5 7 Configuration 5 9 performing a test move 5 8 Connections See also Input Output feedback 3 21 motor 3 15 motor brake 3 19 power 3 8 single phase 3 9 three phase 3 10 thermal switch 3 18 Connector locations 3 7 Control system B 1 current torque control B 2 Index operation position controller B 6 speed controller B 7 torque controller and feedback B 8 position control B 5 position control pulse amp direction B 4 velocity speed control B 3 DB On LED 7 5 Digital I O 4 4 CREF 4 6 digital inputs X3 4 5 digital outputs X3 4 9 4 10 pulse amp direction 4 6 special functions 4 8 Dimensions 3 6 DIP switches 3 33 1 4 Node select 3 33
8. Package size H only Mounting keyhole and slot detail FRONT PANEL A 5mm package sizes E G and H 6 5mm B 10mm package sizes E G and H 12mm C 9mm package sizes E G and H 10mm Package sizes E G amp H only W479 5mm All other sizes W4 W2 Dimensions mm inches ENEEEJEBHEBSESESEZESESEOEEL 1 25 2 71 15 84 0 59 1 55 31 42 33 40 40 173 195 5 205 152 925 1 57 157 681 770 8 07 amp 00 24 64 4 3 6 is 63 0 91 2 3 5 07 55 36 27 5 263 5 3 3 2 17 1 42 1 08 10 37 7 28 65 46 32 5 357 384 400 8 16 5 8 265 3 4 9 2 56 1 81 1 28 14 06 15 12 15 75 0 31 0 65 0 31 10 44 10 8 130 111 27 5 75 265 3 9 05 5 12 4 37 1 08 2 95 10 44 19 95 Figure 1 Package dimensions 3 6 Basic Installation MN1902 www baldormotion com 3 3 Connector locations X1 X1A Power X9 Master Encoder Single ph del y Encoder Pulse amp Dir ingle phase models Sm E e TH Puber E 2 CHB Dir jj Fon X 3 CHZ NC D o Lina s DB A U i N AC Neutral v by Og 6 CHA Pulse GND U Motor U w A 7 CHB Dir GND V Motor V R1 a 8 CHZ NC B Motor a R2 2 9 5V NC egen Resistor WS O aw 07 X6 RS232 RS485 NC ov ET RS232 RS485 422 24V Customer wo O C 8 NO NO OV Jsupplied 24V 3 TXD TX FDHxxxxxx xxx3 8 4 NC NC FPHxxxxxx xxx3 Fiex Drive x Box 5 OVGND OV DGND BALDOR lt 2 NO quo
9. expressed in user units This value is used by the Jog positive and Jog negative actions The value in this box is linked to the Velocity slider shown in Jog mode The Clear and Default buttons can be used to either clear or default all conditions 6 8 Preset Moves amp PLC Task MN1902 www baldormotion com 6 3 3 Testing the PLC Task 6 4 There is no way to test the PLC Task other than causing the required conditions to occur For example if you have an action that is triggered by the condition Digital input 0 then activating digital input O will cause the corresponding action to occur Saving presets or PLC conditions Preset tables and PLC conditions can be saved separately on the PC for later recall For this purpose Presets mode and PLC Task mode have Open Save and Help icons just above their tables 1 Click the Save icon just above the table 2 Inthe Save As dialog enter a filename Presets tables are saved with a pre file extension PLC Task tables are saved with a plc file Open Save Help extension To open a file click the open icon select the file and click Open When the table has loaded remember to click Apply to download the table to the FlexDrive MN1902 Preset Moves amp PLC Task 6 9 www baldormotion com 6 10 Preset Moves amp PLC Task MN1902 7 1 7 1 1 7 1 2 7 1 3 Troubleshooting f Introduction This section explains common problems that may be encountered to
10. www baldormotion com A serial cable Note The serial connector on the FlexDrive connector X6 can be configured as either RS232 or RS485 RS422 Pin 9 is used to carry 8V for powering some Baldor keypad peripherals Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply See sections 4 4 3 and 4 4 4 A suitable cable is available from Baldor catalog number CBL001 501 APC with one free COM port with the following specification Trina sesiteaton Recommander speciation Intel PentiumIII Intel PentiumIII 4 or equivalent 500 MHz or faster 1 GHz or faster Sc A CD ROM drive 1024 x 768 16 bit color 1152 x 864 16 bit color Mouse A mouse or similar pointing device Operating Windows 2000 Windows XP or Windows Vista system 3 1 3 RS485 RS422 systems If you will be using RS485 RS422 and your PC does not have an RS485 RS422 connector an RS232 to 4 wire RS485 RS422 converter will be required These commercially available devices convert the signals from the RS232 RS485 port connector X6 to the signals necessary for RS485 RS422 communications Special care must be taken with the pin assignment on all RS485 RS422 devices as this can differ between products Connectors might need to be rewired to provide the correct pin assignment The FlexDrive pin assignment is shown in section 4 4 3 Note If this is the first time you are installing a FlexDri
11. 0 1 57 46 6 1 83j 65 2 56 130 5 5 14 75 2 95 103 1 06 143 5 63 E fa eee To oT m0 7 1 06 25 0 98 12 0 47 12 4 0 49 29 5 1 16 32 4 1 28 TA 995m 6 3 0 25 0 24 13 5 0 53 15 5 0 61 Figure 47 Filter dimensions types Fl0014A00 Fl0015A00 and FI0015A02 MN1902 Accessories A 7 www baldormotion com B a E D ER _ F d TE A Mounting keyhole and slot detail R rl C JA C JA P ii APS A 5 5mm B 11mm C 10mm o b D 5mm o Oo Oo o Dimensions shown as mm inches E Bimensions rim tres Dmewimn o 255 10 04 100 3 94 244 5 9 63 40 1 57 20 0 79 ae AD Figure 48 Filter dimensions type FI0029A00 A 8 Accessories MN1902 www baldormotion com A 1 9 Regeneration resistors Some FlexDrive models 2 5A and 5A are fitted with an internal regeneration resistor see sections 2 2 1 and 8 1 5 Additional external regeneration resistors can be fitted to these models using the R1 and R2 pins of connector X1 X1A Resistors connected in this way will be in parallel with the internal resistor If an internal resistor is not present a regeneration resistor should be installed to dissipate energy during braking to prevent an over voltage error occurring 115VAC 230VAC 230VAC 230 460VAC FlexDrive 1
12. 1 Encoder cable pin configuration rotary motors Figure 14 shows the pin configuration for a typical Baldor encoder feedback cable part number CBLO25SF E1 X8 pin internal wire colors a rr cem 2 s Gm o cm 7 s e wm 4 9 9 a rna ewe o J 99 ww a e o SA 8 Pins 9 and 16 are not connected Motor encoder connector Cable connector end view male female Figure 14 Baldor rotary motor encoder cable pin configuration The maximum recommended cable length is 30 5m 100ft MN1902 Basic Installation 3 25 www baldormotion com 3 7 2 2 Encoder cable connections linear motors Motor Twisted pairs 1 CHA 6 CHA 2 CHB Encoder 7 CHB Feedback 3 CHZ INDEX 8 CHZ INDEX 11 5V 13 DGND Connect internal shields to DGND Hall U Hall U E ET Hall W Leave pins Hall W 5 12 14 15 Hall V unconnected Hall V Y NC L SS Connect overall shield to connector backshells Figure 15 Encoder cable connections linear motors 3 7 2 3 Encoder cable pin configuration linear motors 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 FlexDrive Encoder cable internal wire colors X8 pin CHA 1 a Eigass rorat ta MN TROC Linea Moire CHB 7
13. 9 8 1 15 EnDat absolute encoder feedback option X8 05 8 10 8 1 16 Hiperface absolute encoder feedback option X8 8 10 8 1 17 Master auxiliary encoder input X9 sssssesessseesseens 8 10 8 1 18 Pulse and direction input X9 000 eee 8 11 8 1 19 Environmental or ose Re ER EUER ebb eS 8 11 Appendices A ACCESSES Taaa bee eres pua dad bs iraq d nd NA ad a Ea A 1 A 1 Introduction 2 0 ccc A 1 A 1 1 Factory fitted options 0 eee A 1 A 1 2 Motor power cables 000 c cece eens A 2 A 1 3 Motor power cable part numbers 22 000 0c eee eee eee A 2 A 1 4 Resolver feedback cables 00 0 0 cece eee A 3 A 1 5 Encoder Hall feedback cables 0 00 eee A 4 A 1 6 EnDat Hiperface absolute encoder feedback cables A 4 A 1 7 Feedback cable part numbers 00 0 cee ee eee eee A 5 ARS EMG filters cous Lern redeem nU A depu pot AA dti A 6 A 1 9 Regeneration resistors 060 00 e eee eee eee A 9 B Control SySIelm 22 5224 cae eee eto i eae eee id B 1 B 1 Introduction 0 0 0 c eee eee B 1 B 1 1 Current Torque control liiiseeesesessseseeeeseeseeee B 2 B 1 2 Velocity Speed control 0 eee ee B 3 B 1 3 Position control Pulse and Direction 00 0 0c eee ee eee B 4 B 1 4 Position Control i oe ahs Satie es eene n de
14. CAN node to from the CAN network Can also be read to determine the node type To return information about the abilities of the controller To return information about the abilities of the controller To perform a positional offset move Define the mode of operation on the OFFSET keyword To read the status of the previous offset move To set or read the state of all the outputs on an output bank To set the active level on the digital outputs To set or read an individual digital output PARAMSAVEMODE To allow parameters to be stored in EEPROM during run time PHASESEARCHBACKOFF To select the back off distance used to clear an end stop during the phase search sequence C 14 Mint Keyword Summary MN1902 www baldormotion com PHASESEARCHBANDWIDTH To define the bandwidth used to design the debounce controller used during the initial alignment stage of the phase search sequence PHASESEARCHCURRENT To select amount of current applied to the motor during the phase search sequence PHASESEARCHMODE To turn on the debounce controller used during the initial alignment stage of the phase search sequence PHASESEARCHSPEED To select the speed of travel during the search sections of a phase search sequence PHASESEARCHSTATUS To determine whether commutation is aligned on an axis PHASESEARCHTRAVEL To select the amount of travel during the search sections of a phase search sequence To read the action assigned to a PLC
15. Check that the Drive enable button is pressed down 2 Inthe Toolbox click the Edit amp Debug icon n E is Edit amp Debug 3 Click in the Command window 4 Type JOG 0 10 This wil cause the motor to move continuously at 10 units per second In Mint WorkBench look at the Spy window located on the right of the screen The Spy window s Velocity display should show 10 approximately If there seems to be very little motor movement it is probably due to the scale factor In the Commissioning Wizard on the Position Control page if you did not adjust the scale factor then the current unit of movement is feedback counts per second Depending on the motor s feedback device 10 feedback counts per second could equate to a very small velocity Issue another JOG command using a larger value or use the Operating Mode Wizard to select a suitable scale factor e g 4000 if the motor has a 1000 line encoder or 10 000 for a 2500 line encoder 5 To stop the test type STOP 0 5 8 Operation MN1902 www baldormotion com 5 3 5 3 1 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 FlexDrive 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 Mi
16. Enable switch 8 is changed from On to Off 3 Wait for 1 second 4 for offset tuning to be completed On On Off Oft Off Figure 21 Offset tuning using switch 7 and 8 Leave switch 7 Off in normal use After offset tuning remember to set switch 8 to the On position to allow the drive to be enabled The switch positions are sampled every 100ms The Mint keyword ADCOFFSETTRIM can be used to perform the same action Switch 8 Enable Switch 8 must be set to On to allow the drive to be enabled The switch position is sampled every 100ms However two other actions are necessary to enable the FlexDrive m The enable input see section 3 8 must be active The drive must also be enabled by using a drive enable command see section 3 8 3 3 34 Basic Installation MN1902 www baldormotion com 3 9 6 3 9 7 3 9 8 Switch 9 MODBUS select Switch 9 enables the MODBUS serial protocol the next time the FlexDrive is power cycled This affects the value of the Mint keyword SERIALPROTOCOL Enabling MODBUS disables the Host Comms Protocol HCP so attempts to access the drive s comms array over the serial connection using a serial HMI panel for example will no longer work Switch 10 RS232 RS485 select Switch 10 selects RS232 communications Off or RS485 RS422 On the next time the FlexDrive is power cycled Factory settings If switches 1 4 are all in the On position and switch 8 is set to Off t
17. Figure 33 FlexDrive encoder output to NextMove BX encoder input AN CAUTION Ifthe older model NextMove BX which has a gray case is to be connected a different cable must be used as shown in Figure 34 FlexDrive X7 CHA CHA CHZ CHZ CHB CHB DGND encod a U U Ne Connect overall shield ut to connector backshells NextMove BX er input Baldor cable parts CBLOxxMF E3A are recommended where xx represents a choice of available lengths Figure 34 FlexDrive encoder output to NextMove BX encoder input Baldor cable parts CBLOxxMF E3B are recommended where xx represents a choice of available lengths FlexDrive CHA CHA CHZ CHZ CHB CHB DGND enco Q U U SS Connect overall shield Pd to connector backshells NextMove ES ESB der 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 EncO Enc1 CHA b7 a8 CHA b10 c9 CHB a7 c7 CHB c10 a10 CHZ b8 c8 CHZ b9 a9 DGND a3 a3 or b3 c3 Figure 35 FlexDrive encoder output to NextMove ES ESB encoder input 4 12 Input Output MN1902 www baldormotion com 4 4 2 Master auxiliary encoder input X9 Pin Encodername Pulse recon name a e 35 E pow Bs o Ic frr a GB e 5 DGND gon se meo sm
18. 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 Network slave Twisted pairs DGND may be one wire from a third twisted pair Network slave Master and final slave are shown with terminating resistors Tg typical value 1200 Front panel DIP switch 6 may be used to connect an internal 1200 terminating resistor Connect overall shield to connector backshell Figure 40 4 wire RS422 multi drop connections Any FlexDrive on the network must have its SW1 DIP switch 10 located on the front panel set to the On position see also section 3 9 7 This will set the serial port to RS422 RS485 mode after the next power off on cycle When SW1 DIP switch 6 is set to the On position a 1200 termination resistor is connected between the RX and RX signals Each 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
19. Task channel PLCACTIONPARAMETER To read the associated parameter for an action assigned to a PLC Task channel PLCAUTOENABLE To specify whether the PLC Task will be automatically enabled on power up PLCGEARFACTOR To set or read the gear factor used by the Fast Gear PLC action To read the operator for a PLC Task channel PLCPARAMETER To read the associated parameter used by a PLC Task channel s condition MN1902 Mint Keyword Summary C 15 www baldormotion com To read the target position of the last move in the move buffer POSWRAP To set or read the position wrap range for the axis PRESETCANCEL To set up a preset move to perform a cancel command PRESETDWELLTIME To specify a dwell time between a hardware trigger and the preset move starting To set up a homing type preset move To read the current preset index or set a new index PRESETINDEXMODE To set the controller s response to changes in a preset index PRESETINDEXSOURCE To define the source for preset index changes PRESETINPUTSMAX To define the number of preset moves available in the preset table PRESETINPUTSTATE To read the current state of digital inputs representing the preset index C 16 Mint Keyword Summary MN1902 www baldormotion com To assign the input to be used as the preset index trigger PULSEDIRMODE To set the control mode for the step pulse amp direction digital inputs PULSEOUTX To activate a digital output f
20. Windows Start menu MN1902 Operation 5 1 www baldormotion com 5 1 3 Starting the FlexDrive If you have followed the instructions in the previous sections you should now have connected all the power sources your choice of inputs and outputs and the serial cable linking the PC with the FlexDrive l 5 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 X1A Verify that the front panel DIP switches 1 9 are in the Off position It is recommended that you use RS232 communications to begin with in which case DIP Switch 10 must also be in the Off position However if you are using RS485 RS422 communication then DIP switch 10 must be in the On position also DIP switch 6 if termination is required Verify that the AC line voltage matches the specification of the FlexDrive l Inspect all power connections for accuracy workmanship and tightness Verify that all wiring conforms to applicable codes Verify that the FlexDrive and motor are properly earthed grounded Check all signal wiring for accuracy 5 1 5 Power on checks If at any time the Status display shows a flashing symbol or E this indicates that the drive has detected a fault see section 7 1 Turn on the 24VDC supply only for FlexDrive with catalog numbers FDH
21. aw NC Connect overall shield MNA to connector backshells Figure 18 Hiperface absolute encoder cable connections MN1902 Basic Installation 3 29 www baldormotion com 3 7 4 1 Absolute encoder cable pin configuration Figure 19 shows the pin configuration for a typical Baldor absolute encoder feedback cable part number CBLO25SF D1 Signal name FlexDrive Motor cable Baldor Hiperface X8 pin i cable internal wire colors IEEE Bow While 000 9 6 00 o 9 o o0 Motor absolute encoder connector Cable connector end view male female Figure 19 Baldor rotary motor absolute encoder cable pin configuration The maximum recommended cable length is 30 5m 100ft 3 30 Basic Installation MN1902 www baldormotion com 3 8 Drive enable X3 Location Connector X3 pins 7 amp 9 Mating connector Phoenix MINI COMBICON MC 1 5 20 ST 3 5 Warne Dive enable 0 ae Input voltage 24VDC 420 ENABLE 9 To enable the FlexDrive and allow motion three actions are necessary A customer supplied externally generated 24VDC supply must be connected between pins 7 and 9 The drive enable DIP switch switch 8 must be in the On position A drive enable command must be received These actions are explained in the following sections 3 8 1 Drive enable X3 The wiring to the drive enable input can be connected in one of two ways Because CREF is common to all the digital inputs thi
22. between the AC line reactor or isolation transformer and the AC input to the FlexDrive Input power cycling If AC power has been removed from the FlexDrive it should not be reapplied for at least one minute This delay allows the input surge protection circuit to perform correctly Power cycling the drive more frequently could cause nuisance trips when power is reapplied and reduce the lifetime of the FlexDrive Power disconnect and protection devices A power disconnect should be installed between the input power service and the FlexDrive for a fail safe method to disconnect power The FlexDrive will remain in a powered condition until all input power is removed from the drive and the internal bus voltage has depleted The FlexDrive must have a suitable input power protection device installed Recommended circuit breakers are thermal magnetic devices 1 or 3 phase as required with characteristics suitable for heavy inductive loads D type trip characteristic Recommended time delay fuses are Buss FRN on 230VAC or equivalent Dual element time delay fuses should be used to avoid nuisance trips due to inrush current when power is first applied From Circuit Breaker From Fuse supply supply L CON L L L N N N N Figure 4 Circuit breaker and fuse single phase package sizes A B C D MN1902 Basic Installation 3 11 www baldormotion com Note Power to single phase models may be derived
23. bit 5 is set and the drive disables error while tuning the Mint gains when tuning the Mint gains get a Software limit error Set SOFTLIMITMODE to zero to ignore the software AXISERROR bits 3 or 4 set and the limit error while tuning the Mint gains drive disables when tuning the Mint gains get a Hardware limit error Set LIMITMODE to zero to ignore the hardware limit AXISERROR bits 1 or 2 set and the errors while tuning the Mint gains Alternatively drive disables when tuning the Mint disable the hardware limit inputs gains 7 2 6 Status display shows a digit or E If the Status display shows a flashing digit E or the forward or reverse hardware limit symbol use the Error Log tool to view a list of recent errors Alternatively type PRINT DRIVEERROR PRINT AXISERROR and PRINT MISCERROR as separate commands in the Mint WorkBench Command window Each of these commands will return an error code a description of which can be found in the help file Press F1 and locate the DRIVEERROR AXISERROR and MISCERROR keywords The Error Handling book contains topics listing the Status display indicators and basic error codes Remember that many error codes are the sum of a bit pattern so may not be listed individually For help on understanding bit pattern values see the Bit pattern values topic in the Keywords book 7 6 Troubleshooting MN1902 Specifications 8 8 1 Introduction This section provides technical speci
24. cables Remove the outer insulation d o Flat or p type to expose the overall shield or conductive a Clamp should provide 360 l contact with the cable j O ane am M x30mr7 500r m max FlexDrive Resolver Connector X8 Cable Housing REF Twisted pairs bul O ES E NS Connect overall shield Connect overall shield to connector backshell to connector backshell Figure 58 Resolver cable grounding FlexDrive X8 Cable Encoder Connector Housing CHA CHA CHB CHB CHZ CHZ 5V DGND N Connect overall shield Connect overall shield to connector backshell to connector backshell Figure 59 Encoder signal cable grounding FlexDrive x9 Cable Auxiliary Encoder Housing O CHA pairs CHA CHB CHB CHZ CHZ 5V 102 10 12 DGND D ONNO NS Connect overall shield Connect overall shield A to connector backshell to connector backshell Figure 60 Auxiliary Encoder cable grounding MN1902 CE amp UL D 5 www baldormotion com D 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
25. colors E 1 seriis A a a 99m ed a n Gek s s Bak C 1 0 7 m pen uci Lon Motor absolute encoder connector Cable connector end view male female Figure 17 Baldor rotary motor absolute encoder cable pin configuration The maximum recommended cable length is 30 5m 100ft 3 28 Basic Installation MN1902 www baldormotion com 3 7 4 Hiperface absolute encoder option X8 The Hiperface absolute encoder interface supports both incremental and absolute multi and single turn feedback using SinCos technology It is possible to read and write information to the encoder The absolute encoder connections are made using the 15 pin D type female connector X8 Twisted pair cables must be used for the complementary signal pairs e g SinA and SinA The overall cable shield screen must be connected to the metallic shell of the D type connector Connector X8 15 pin D type female connector Encoder function 1 Data 2 Data 3 8V out 4 8V out 5 DGND Shield 7 Cos B FT Reserved do not connect 9 Reserved do not connect Reserved do not connect Reserved do not connect Descript escription Hiperface absolute encoder input non isolated Pin 3 provides power to the encoder 200mA max Data Data Na 12 Sin A 13 Sin A Hiperface 7 Cos B Absolute P Cos B 8Vout Connect internal DGND shields to DGND Encoder
26. following a position demand signal The profiler interprets the pulse and direction signals and uses them to generate corresponding position speed and acceleration demand signals The position and speed demand signals are 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 To improve the tracking performance of the speed controller the profiler acceleration demand is fed in at this point 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 Profi Pulse and Direction Profiler Acn nnn Speed Torque peed Position demand Speed demandf Torque PWM Power stagel controller controller controller moto
27. 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 MN1902 Input Output 4 17 www baldormotion com 4 4 6 Connecting Baldor HMI Operator Panels Baldor HMI Operator Panels use a 15 pin male D type connector marked PLC PORT but the FlexDrive connector X6 is a 9 pin male D type connector If you do not require hardware handshaking then use the connections shown in Figure 41 Baldor HMI FlexDrive PLC PORT Figure 41 Cable wiring if hardware handshaking is not required If hardware handshaking is required then use the connections shown in Figure 42 Baldor HMI FlexDrive PLC PORT X6 Figure 42 Cable wiring if hardware handshaking is required 4 18 Input Output MN1902 www baldormotion com 4 5 Connection summary minimum system wiring As a guide Figure 43 shows an example of the typical minimum wiring required to allow the FlexDrive to control a motor AC power Host PC Filter L L AC N N N power E E in If the filter has no output earth ground terminal earth Shield earth ground clamp wire may be connected attached to enclosure backplane directly to the star point Star PE point x z gem e T e Motor power UVW s 0800 O FiexDrive Se
28. input voltage 253 Nominal input current maximum rated output current Nominal DC Bus voltage Minimum operating DC Bus voltage Maximum operating DC Bus voltage Overvoltage safety trip Output voltage line line VDC Bus 320V Nominal phase current 11096 Peak phase current 11096 for 1 25s 0 5s 0s Nominal output power Efficiency Output frequency Nominal switching frequency As input voltage decreases DC Bus ripple voltage increases This can cause a deterioration of drive performance MN1902 Specifications 8 3 www baldormotion com 8 1 3 AC input power and motor output 230 460V three phase models 230 460VAC 50 60Hz 2 5A 7 5A 27 5A Catalog number FDH4 FPH4 Nominal input Nominal input voltage VAC P 22040 Minimum input UII MESE a a ee 75 recommended absolute Maximum input Maximum input voltage EU I input current Arms Scene NES 5 6 5 10 20 27 36 5 max rated output current Nominal DC Bus Nominal DC Bus voltage VDC 325 325 230VAC input 650 460VAC input input 650 460VAC input MEM operating Maximum operating DC Bus voltage Overvoltage safety trip safety trip 840 oa voltage line line VRMS 0 353 VDC Bus 500V Nominal Nominal phase current 1096 current 11096 20 27 5 5 Piel eee eae phase current 410 Arms 10 15 30 40 E for 1 25s 0 5s 0s 3 8 Nominal output power 19 9 Efficiency ae gt 9
29. of inputs Presets will now be selected and triggered when the appropriate digital inputs are active MN1902 Preset Moves amp PLC Task 6 5 www baldormotion com 6 2 4 Controlling preset moves Additional options are available to control L C t Positi the operation of preset moves Spe UME He AUIS 2 al Dwell Time can be used to set a delay period between the triggering of a preset Addressable Presets move and its commencement E j Current Active Preset Index If the Wait for Idle option is checked the preset move will not begin until the previous one has been completed If it is not checked the new move will be started Wait for Ide immediately To allow this the profile of the current move will be modified to smoothly adjust to the new move s profile Dwell Time T Flex Drive only The Learn Current Position button can be used to read the current position and assign it to the Value Position column for the currently selected preset This function can only be used for Absolute moves if the preset type is not already set to Absolute it will be set automatically The configuration and operation of preset moves can also be controlled by a Mint program using a range of keywords beginning with PRESET See the Mint help file for details Using presets with the CAN amp Auxiliary I O option Flex Drive only If the CAN amp Auxiliary I O option is fitted Option B the additional digit
30. pre trigger or post trigger capture phase C 4 Mint Keyword Summary MN1902 www baldormotion com Returns the progress of the capture CAPTURETRIGGERABSOLUTE To ignore the sign of the trigger value when triggering from a capture channel source CAPTURETRIGGERCHANNEL Sets the channel to be used as the reference source for triggering CAPTURETRIGGERMODE Sets the method used to evaluate the trigger source CAPTURETRIGGERSOURCE Sets the reference source to be used for triggering CAPTURETRIGGERVALUE Sets the trigger value when triggering from a capture channel source COMMISSIONED To set or read whether the axis drive has been commissioned COMMS Accesses the reserved comms array COMMSINTEGER Accesses the reserved comms array storing values as integers To define the data type of a comms element COMMSMAPMODE To set or read the comms mapping for a comms element COMMSMAPPARAMETER To set or read the associated parameter for a mapped comms element Selects comms use over either RS485 or CANopen CONFIG To set the configuration of an axis for different control types CONNECTSTATUS Returns the status of the connection between this node and another node DPREVENT To interrupt the host PC and generate a trappable event using the Dual Port RAM DPR MN1902 Mint Keyword Summary C 5 www baldormotion com DRIVEBUSNOMINALVOLTS To return the nominal value of the DC bus voltage for the drive
31. read from an EnDat or Hiperface encoder is zero C 12 Mint Keyword Summary MN1902 www baldormotion com MOTORFEEDBACKPROTOCOL To read the type of feedback error when using a ERROR Hiperface encoder MOTORFEEDBACKPROTOCOL To set or read the number of retries to attempt when an RETRIES error occurs on a Hiperface encoder MOTORFEEDBACKSTATUS To read the current status of the EnDat or Hiperface encoder MOTORFLUX To set the motor s magnetic flux level to allow the drive to accurately calculate motor torque and compensate for back EMF MOTORLINEARENCODER To set the resolution of the encoder on a linear motor RESOLUTION MOTORLINEARPOLEPITCH To set or read the distance between north poles on a linear motor To set or read the motor leakage inductance MOTOROVERLOADAREA Reads the extent of an overload condition To set or read the action taken in the event of a motor overload condition MOTOROVERLOADMODE MOTORPEAKCURRENT To set or read the peak current rating of the motor MOTORPEAKDURATION To set or read the duration for which peak motor current can be sustained MOTORPOLES To set or read the number of motor poles MOTORPOWERMEASURED To read the instantaneous electrical power applied to the motor MOTORRATEDCURRENT To set or read the rated current of the motor MOTORRESOLVEROFFSET To set the feedback alignment for a resolver motor To set the motor stator resistance MOTORSPECNUMBER To return the spec
32. sections 3 4 1 and 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 FlexDrive may also be powered from a DC supply However details are not provided here since output current derating and other important limitations apply when using a DC supply Please contact Baldor technical support for advice 3 8 Basic Installation MN1902 www baldormotion com 3 4 4 Single phase connection to package sizes A B C D Location Connector X1 Mating connector Phoenix COMBICON MVSTBW 2 5 9 ST 5mm pitch FDH 1A FPH1A FDH2A FPH2A 230VAC 19 line to neutral European single phase supply Nominal input 115VAC 16 line to neutral voltage U S single phase supply 75 125VAC 75 250VAC The required 230VAC supply may also be derived from two phases of a U S 280VAC 3 phase supply i e 230VAC line to line Connect one phase to L and the other phase to N For single phase connection the voltage ripple on the DC bus is 25Vp p for 5A peak current rising to 50Vp p for 10A peak current This can limit the maximum speed of the motor Tightening torque for terminal block connections is 0 5 0 6Nm 4 4 5 3 Ib in The threaded hole in the top of the enclosure is for protective earth ground connections The threade
33. 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 Violent jamming stopping of the motor during operation may damage the motor and drive Do not tin solder exposed wires Solder contracts over time and may cause loose connections Use crimp connections where possible Electrical components can be damaged by static electricity Use ESD electro static discharge procedures when handling this drive Ensure that resolver or encoder wires are properly connected Incorrect installation may result in improper movement The threaded holes in the top and bottom of the enclosure are for cable clamps Be sure to use a M4 bolt no longer than 12mm in length Longer bolts might short circuit the electrical components inside the drive Removing the cover will invalidate UL certification 1 4 General Information MN1902 2 1 Introduction 2 FlexDrive features Throughout this manual both the FlexDrive and the Flex Drive will be referred to simply as FlexDrive Where there is a difference in specification it will be clearly marked The FlexDrive is a versatile compact control providing a flexible and powerful solution for single axis rotary systems Standard features include Single axis AC brushless dri
34. than this 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 MN1902 Troubleshooting 7 5 www baldormotion com 7 2 4 Power on The Status display is The FlexDrive has detected a motion error Use the Error showing a flashing symbol Log tool to view a list of recent errors or click the Error with a static decimal point button on the motion toolbar to view a description of the error Alternatively type any or all of these commands in the Command window PRINT AXISERROR PRINT DRIVEERROR PRINT MISCERROR PRINT INITERROR Click the Clear Errors button on the motion toolbar 7 2 5 Tuning Cannot enable the FlexDrive Check the drive enable input on connector X3 pins 7 because AXISERROR has bit 13 set and 9 is connected and powered correctly Check that DIP switch 8 enable is set to the On position When the FlexDrive is enabled the Check that the current loop has been tuned motor is unstable Check that the current loop was tuned with the correct motor data If the motor is still unstable try reducing the Speed Proportional gain KVPROP and Speed Integral gain KVINT on the Speed tab of the Fine tuning window get a Following Error AXISERROR Set FOLERRORMODE to zero to ignore the following
35. the Mint NODE keyword can be used to set the node number Mint WorkBench see section 5 2 reads the FlexDrive node number during the scan process and then uses it to direct commands to the FlexDrive l Avoid accidentally setting switches 1 4 to the On position at the same time In combination with DIP switch 8 this will reset the FlexDrive to its factory defaults See section 3 9 8 Switch 5 Hold Switch 5 stops the motor In the Off position normal operation is allowed When switched to the On position the motor decelerates to rest and maintains position The switch position is sampled every 100ms Switch 6 RS485 terminator Switch 6 is used to connect a termination resistor to the RS485 network In the Off position the RS485 network is unterminated at the FlexDrive In the On position an internal 1200 termination resistor is connected between the RX and RX signals see section 4 4 5 Switch 6 should remain in the Off position when using RS232 Switch 7 Offset tuning Switch 7 is used to start offset tuning on analog demand input AINO The purpose of offset tuning is to remove DC offset voltages on analog input 0 the demand reference input to achieve a stationary motor shaft with OVDC at the input Confirm that the device supplying the AINO demand input is set to its intended zero output setting nominally OVDC before starting offset tuning When switch 7 is in the On position offset tuning will start the next time
36. 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 MN1902 Operation 5 9 www baldormotion com 5 3 1 2 5 3 1 3 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 FlexDrive 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 Enter new values in the required boxes and then click Apply to download the values to the FlexDrive 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 5 10 Operation MN1902 www baldormo
37. the first tool that should be used Using the Commissioning Wizard AN 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 Completing the Commissioning Wizard The final screen Tuning has a Finish button that is grayed out until the tuning tests have been completed When the tuning tests have finished click Finish to complete the Commissioning Wizard The parameters that have been calculated by the Commissioning Wizard do not need to be downloaded to the FlexDrive They are already in the FlexDrive and will not be lost even when it is powered down MN1902 Operation 5 7 www baldormotion com 5 2 6 Performing a test move This section tests the basic operation of the drive and motor 1
38. tuned drive motor At higher acceleration and deceleration rates the following error will typically be greater Ensure that the drive motor is adequately tuned to cope with these acceleration rates The following error limit can be adjusted to suite your application see Mint keywords FOLERRORFATAL and VELFATAL Following error could also be the cause of encoder resolver loss see also Mint keyword FEEDBACKFAULTENABLE Follow mode The drive is in Follow mode See the Mint keyword FOLLOW Hold The Hold DIP switch is active see section 3 9 2 or the PLC Task has requested a Hold state Motion will be ramped to zero demand and will then hold on position while the switch is active Homing The drive is currently homing See the Mint keyword HOME Preset Homing The drive is currently homing This motion has been triggered from a Preset move table Incremental move An incremental move is being profiled See the Mint keywords INCA and INCR Jog The drive is jogging In the Mint help file see the topics JOG JOGCOMMAND and Jog screen Preset jog The drive is jogging The jog was triggered from a Preset jog table 8 K e KE 3 K h u MN1902 Troubleshooting 7 3 www baldormotion com Overspeed The measured speed of the motor has exceeded the trip level defined by DRIVESPEEDFATAL Check that the trip level is set to a suitable value for your application When accelerating to a demand speed close to the trip level
39. uses the drive enable signal configured using DRIVEENABLEOUTPUT to appear on DOUTO in conjunction with DOUT1 With this configuration the following sequences can be used to control the brake To engage the brake The motor is brought to rest under normal control m Relay 2 is deactivated causing the brake to engage m The drive is disabled This removes power from the motor and causes Relay 1 to be deactivated To disengage the brake m The drive is enabled activating Relay 1 Power is applied to the motor to hold position under normal control m Relay 2 is activated causing the brake to be disengaged It may be necessary to include a small delay after Relay 2 has been activated before starting motion This delay will allow time for the relay contacts to engage and the brake to release AN CAUTION The 24VDC power supply must be a separate supply as shown in Figure 10 Do not use the 24V supply powering the FlexDrive digital outputs or the internally generated supply if present The brake wires often carry noise that could cause erratic drive operation or damage The brake contacts must never be wired directly to the digital outputs The relay s should be fitted with a protective flyback diode as shown The separate 24VDC supply used for the motor brake may also be used to power the relay in the thermal switch circuit section 3 5 5 MN1902 Basic Installation 3 19 www baldormotion com 3 6 3 6 1 Regene
40. 0 models 1 models 30 models 30 models current Baldor Power Baldor Power Baldor Power Baldor Power rating catalog rating catalog rating catalog rating catalog rating no W no W no W no W Internal Interi Internal A nal RG2 ross wo Rees A 27 5A RG11 640 Note Where the required dissipation could exceed 320W resistor RG23 rated at 640W can be used instead gt gt s GHI 0457 DERREN 90 CLERI ote D je L jy Ler 2 L 123 4 3 for 44 watts M4 2 228 8 9 for 100 watts 63129 337 13 2 for 320 640 watt Dimensions mm inches Figure 49 Regeneration resistor dimensions all types N WARNING A regeneration resistor may generate enough heat to ignite combustible materials To avoid fire hazard keep all combustible materials and flammable vapors away from the brake resistors Ensure that the resistor has clearance of at least 50mm 2 in above and below and 26mm 1 in left and right 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 MN1902 Accessories A 9 www baldormotion com A 10 Accessories MN1902 B 1 Control System B Introductio
41. 000 4 2 1995 ElectroStatic Discharge EN 61000 4 3 1995 Radiated Field Immunity EN 61000 4 4 1995 EFT Bursts EN 61000 4 5 1995 Surge Immunity EN 61000 4 6 1996 Conducted Immunity and with the protection requirements of Council Directive 72 23 EEC amended by 93 68 EEC relating to Low Voltage Equipment by following the guidance found in the following standard Standard Title EN50178 1997 Electronic equipment for use in power installations Signed m Dr Gerry Boast Engineering Manager D 2 CE amp UL MN1902 www baldormotion com D 1 3 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 D 1 4 EMC wiring technique Cabinet Using a typical electroplated zinc coated enclosure connected to earth ground means that all parts mounted on the back plane are connected to earth ground and all outer shield screen connections can be connected to earth ground Within the cabinet there should be
42. 1902 www baldormotion com Overtemperature The temperature of the drive or motor has exceeded a trip level see Mint keyword TEMPERATURELIMITFATAL or the Motor overtemperature trip input has been activated see Mint keyword MOTORTEMPERATUREINPUT Drive enabled The drive is enabled except where CONFIG cfVirtual where it is not physically enabled Torque mode The drive is in Torque mode See the Mint keywords TORQUE TORQUEREFSOURCE and related commands Auto tune test driving motor Autotune is active and driving the motor The motor may move Power base not ready This error condition applies to 3 phase drives only These drives have a pre charge circuit which must activate after power up before the drive can be enabled If the drive is enabled prior to this then the error occurs The error could also indicate the loss of one or more of the input phases Cam A Cam profile is being profiled See the Mint keyword CAM General error See AXISERROR and DRIVEERROR The motion toolbar displays the status of AXISERROR which is a bit pattern of all latched errors See also the Error Log topics in the help file c Error input The ERRORINPUT has been activated and generated an error Flying shear A flying shear is being profiled See the Mint keyword FLY Position or velocity following error A following error has occurred See the Mint keyword AXISERROR and associated keywords Following errors could be caused by a badly
43. 4 4 Power disconnect and protection devices ssusssss 3 11 34 5 Power supply fillers see iN vend Sade Rer Rega ERES 3 12 3 4 0 Wire sizes and protection device ratings 0000 eee eee 3 13 3 4 7 External customer supplied 24V control supply 05 3 14 3 5 Motor connections sssssssslss eee 3 15 3 5 4 Motor circuit contactors 00 sese 3 16 3 5 2 Motor power cable pin configuration Baldor BSM rotary motors 3 16 3 5 3 Motor cable pin configuration Baldor linear motors 3 17 3 5 4 Sinusoidal filter cc ce eked Sa Seas Sead MESES ee teen 3 17 3 5 5 Thermal switch connection 00 0 cece eee ees 3 18 3 5 6 Motor brake connection 00 000 c eee eee 3 19 3 6 Regeneration resistor Dynamic Brake resistor 3 20 3 6 1 Controlling regeneration 0 00 cee 3 20 3 7 Feedback connections 000 cece eee es 3 21 3 71 Resolver option X8 eraann iam aa teens 3 22 3 42 Encoder option X8 Sei eraeun y rex b hehe hoes 3 24 3 73 EnDat absolute encoder option X8 0 0c cee eee eee 3 27 3 7 4 Hiperface absolute encoder option X8 0 0 00 eceeeeeee 3 29 MN1902 Contents i 3 8 Drive enable X3 000s 3 31 3 8 1 Driveenable X9 six ibl d ope wes dee bbe PERDERE 3 31 3 82 Drive enable SW1 DIP switch sisse 3 32 3 8 3 Drive en
44. 5 Output frequency Hz 0 500 Nominal switching frequency As input voltage decreases DC Bus ripple voltage increases This can cause a deterioration of drive performance 8 4 Specifications MN1902 www baldormotion com 8 1 4 Customer supplied 24VDC supply input 24VDC Catalog numbers 27 5A FDHXxxxxx xxx3 and FPHxxxxx xxx3 Nominal input voltage EL Minimum input Minimum input voltage Maximum input voltage 28 8 Maximum ripple a MMC PO Maximum continuous current 1 75 24VDC Power on surge current 24VDC 100ms 8 1 5 Regeneration vA Cage OH ont zea 6A T4 eme WTO Peak power Peak power 10 power cycle power cycle Peak power 10 power cyce KWL switching current eimumioedinanee Note 2 5A models FDH1A02 and FPH1A02 contain an internal 1750 20W resistor 5A models FDH1A05 and FPH1AQ05 contain an internal 900 40W resistor Switching threshold mim on 373 383 off 362 372 EI regeneration Arms 10 switching current Note 2 5A models FDH2A02 and FPH2A02 contain an internal 1750 20W resistor 5A models FDH2A05 and FPH2AQ05 contain an internal 900 40W resistor MN1902 Specifications 8 5 www baldormotion com 230VAC three phase models ic GEN Catalog number FDH2A15 FPH2A15 Nomina power io owerevaey ww panom wT Maximum regeneration Arms 40 switching current Ls x E Maximum load induc
45. 5 5 my wo AE Em E r my i la 1a i Brake C 7 T T E See if present ui 53 section d 7 me To earth ground outer shield use 360 clamps connected to backplane Figure 7 Motor connections AN CAUTION Do not connect supply power to the FlexDrive UVW outputs The FlexDrive might be damaged AN CAUTION The motor leads U V and W must be connected to their corresponding U V or W terminal on the motor Misconnection will result in uncontrolled motor movement The motor power cable must be shielded for CE compliance The connector or gland used at the motor must provide 360 degree shielding The maximum recommended cable length is 30 5m 100ft For recommended motor power cable sizes see section 3 4 6 Note For CE compliance the motor earth ground should be connected to the drive earth ground MN1902 Basic Installation 3 15 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 FlexDrive see section 3 5 Opening the M Contactor ensures that the FlexDrive 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 t
46. 5 O g Three phase models 230 460V E 8 CTS RX Q Earth 8 9 NC see section 4 4 3 Earth 3 L1 AC Phase 1 o X7EncoderOut L2 AC Phase 2 7 i 1 CHA L3 ACPhase3 9 bi 2 CHB U Motor U amp F E 3 CHZ V Motor V NC W _ MotorW 1 TEJ 5 DGND R1 Regen Resistor Qm ES Mas R2 Dynamic Brake 8 CHZ od ceed supplied 24V 9 NC OV J FDH4xxxxx xxx3 FPHAxxxxx xxx3 SW1 DIP switches X8 Feedback In SWI 1 4 Node Resolver option NS 2 number 1 REF Three phase models 230V 3 f selection 2 COS 4 3 SIN Earth EES 5 Hold 4 NC Earth E 6 RS485 terminator 5 AGND L1 AC Phase 1 7 Offset tuning 6 REF L2 AC Phase 2 8 Enable 7 COS L3 AC Phase 3 9 Reserved 8 SIN U Motor U 10 RS232 RS485 9 Chassis V Motor V Encbd m W Motor W ncoder options Vcc NC X3 General I O Incremental EnDat Hiperface Vcc NC AINO Demand E 1 CHA Data Data AINO Demand P 2 CHB Data Data R1 Regen Resistor AGND S CHZ 45V BV R2 Dynamic Brake Relay DOUT3 fJ 4 HallU 5V BV Mo Re al supplied 24V Relay Ki 5 HallU DGND DGND OV J FDH2xxxxx xxx3 User V Li 6 CHA Shield Shield FPH2 xxxxx xxx3 CREF 7 CHB CosB Cos B i CGND 8 CHZ NC NC Warning High voltages are present on Drive Enable 9 Hall W Clock NC terminals labeled Vcc and Vcc Do not DINO 10 Hall V Clock NC make a connection to these terminals DIN1 11 45V DGND DGND DIN2 12 NC SinA Sin A DIN3 13
47. BALDOR e SERVO DRIVE FlexDrive Flex Drive Servo Controls Installation Manual 03 10 MN1902 Contents 1 General Information 0c eee eee ee 1 1 2 InrOOdUCllon user nl lLPLr temen iii erc icing 2 1 2 1 FlexDrive features xri oec aca de dee wink dou a ae see aora xa 2 1 2 2 Receiving and inspection 0 eee ee 2 2 2 2 1 Identifying the catalog number 0000 c cece eee 2 2 2 3 Units and abbreviations 2 00 0 cece eee 2 3 3 Basic Installalgri ss aoo 0p 923 890 929 009 9208 UPS as 3 1 3 1 Introduction asii oe ee Le RP Pins 3 1 3 11 Power SOUIC6S o esee eere ER RE ER ES 3 1 3 1 2 Hardware requirements 0 00 eee ces 3 1 3 4 3 RS485 RS422 systems 0 cece eee eee 3 2 3 1 4 Tools and miscellaneous hardware 000 cece eee eens 3 2 3 1 5 Other information needed for installation 02 000 00 3 3 3 2 Mechanical installation and location requirements 3 4 3 2 1 Mounting the FlexDrive lelleeelsssssss esee 3 5 3 22 Dimensions i esee eer qe eub a eee ae ees 3 6 3 3 Connector locations 0 0 ccc eens 3 7 3 4 Powerconnections 0 cece eee eee ee 3 8 3 4 1 Single phase connection to package sizes A B C D 3 9 3 4 2 Three phase connection to package sizes E G H 3 10 3 4 3 Input power conditioning s es saaana 3 11 3
48. DGND SinA Sin A DIN4 Pulse 14 Hall W Cos B Cos B DIN5 Direction 15 Hall V NC NC NC Not Connected Do not make a DIN Options connection to this pin DOUTO If there are other connectors on the DOUT1 front panel of your FlexDrive then an Tightening torque for terminal block DOUT2 option is fitted See the other manuals connections is 0 5 0 6Nm 4 4 5 3 Ib in supplied with your FlexDrive MN1902 Basic Installation 3 7 www baldormotion com 3 4 Power connections This section provides instructions for connecting the AC power supply It is important that you refer to the correct front panel for your FlexDrive package 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 AN WARNING 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 The power supply module within all FlexDrive models provides rectification smoothing and current surge protection On 2 5A and 5A models a regeneration resistor Dynamic Brake resistor is also built in The power stage is internally fused and therefore self p
49. Drive Enable 4 3 3 Special functions on DIN4 and DIN5 pulse and direction inputs DIN4 and DIN5 can be configured using the MASTERSOURCE keyword to behave as pulse and direction inputs m DIN4 is used as the pulse input The pulse frequency controls the speed of the motor m DIN5 is used as the direction input The state of the direction input controls the direction of motion A positive voltage will result in forward motion If DIN5 is grounded movement will be in the opposite direction Note If DIN4 and DIN5 have been configured as pulse and direction inputs the alternative pulse and direction inputs available on connector X9 cannot be used See the Mint keyword MASTERSOURCE FlexDrive Active high DINx 24VDC 420 Active low DINx 0V CREF 0V CREF 24VDC 420 Figure 28 X3 pulse and direction fast digital input circuit 4 6 Input Output MN1902 www baldormotion com Incremental encoder FlexDrive Twisted pairs XX DIN4 Pulse i i DIN5 Dir Y V l SS Connect shields at one end only s Drive 4 Drive supply supply GND 24V Figure 29 Pulse and direction inputs typical connection from an incremental encoder FlexDrive with external 24V supply option active h
50. ETINPUT To define the reset input for an axis SCALEFACTOR To scale axis encoder counts or steps into user defined units SENTINEL To set up sentinel channels SENTINELLATCH To determine whether a sentinel channel has become true since it was last checked SENTINELSOURCE To read the source used by a sentinel channel SENTINELSOURCEPARAMETER To read the source parameter used by a sentinel channel SENTINELTRIGGERABSOLUTE To read the absolute parameter used by a sentinel channel SENTINELTRIGGERMODE To read the mode parameter used by a sentinel channel SENTINELTRIGGERVALUE To read the lowVal or highVal parameter used by a sentinel channel To set the baud rate of the RS232 RS485 422 port SEXTANT To read the current sextant value for a motor using Hall sensors SOFTLIMITFORWARD To set the forward software limit position on a specified axis SOFTLIMITMODE To set or read the default action taken if a forward or reverse software limit position is exceeded SOFTLIMITREVERSE To set or read the reverse software limit position on a specified axis SPEED To set or read the slew speed of positional moves loaded in the move buffer SPEEDERROR To return the error between the demanded speed and the measured speed SPEEDERRORFATAL To set or read the trip limit for the error between demanded and measured speed C 18 Mint Keyword Summary MN1902 www baldormotion com SPEEDREFERRORDECELTIME Sets a decelerat
51. ION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION 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 system is the responsibility of the machine designer Be sure to comply with the local safety requirements at the place where the machine is to be used In Europe these are the Machinery Directive the ElectroMagnetic Compatibility Directive and the Low Voltage Directive In the United States this is the National Electrical code and local codes 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
52. Installation amp Operating Manual for details Baldor Hall cable internal wire colors Www 9 mex waemo 5 Gem 3 26 Basic Installation MN1902 www baldormotion com 3 7 3 EnDat absolute encoder option X8 The absolute encoder interface supports both incremental and absolute multi and single turn feedback using SinCos technology It is possible to read and write information to the encoder The absolute encoder connections are made using the 15 pin D type female connector X8 Twisted pair cables must be used for the complementary signal pairs e g SinA and SinA The overall cable shield screen must be connected to the metallic shell of the D type connector Connector X8 15 pin D type female connector Encoder function 1 Data 2 Data 3 5V out 4 5V out 5 DGND Shield 7 Cos B Description Absolute encoder input non isolated Pin 4 provides power to the encoder 200mA max Motor z Twisted pairs ND NN Absolute Encoder P o e Connect internal shields to DGND af NI Connect overall shield 7 to connector backshells Figure 16 EnDat absolute encoder cable connections MN1902 Basic Installation 3 27 www baldormotion com 3 7 3 1 Absolute encoder cable pin configuration Figure 17 shows the pin configuration for a typical Baldor absolute encoder feedback cable part number CBLO25SF D1 X8 pin internal wire
53. The FlexDrive is available with different current ratings and package sizes The catalog number is marked on the front of the unit just below the Baldor logo 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 F_H Installed at Date A description of a catalog number is shown here using the example FDH1A05TB RC23 FDH FlexDrive family FPH Flex Drive Requires an AC supply voltage of 115 Volts 1 PEN ea A02 2 5A A07 7 5A A15 15A Continuous current rating of 5 0A A20 20A A27 27 5A Dynamic Brake with a built in transistor and R Requires external braking resistor available on 2 5A and 5A models only resistor E Encoder incremental Feedback option is a resolver D EnDat absolute encoder H Hiperface absolute encoder B CAN amp Auxiliary I O Flex Drive only D DeviceNet P Profibus DP N No options specified Serial port type is combined RS232 RS485 ie 3 Customer s own 24VDC supply is required to 0 Internally generated 24VDC power the internal FlexDrive logic supply Additional suffix letters may be used to indicate customer specific builds An external 24VDC supply will always be required to operate the enable input digital inputs and digital outputs on connector X3 See sections 4 3 1 to 4 3 5 Option fitted 1 CAN channel 2 2 Introduction MN1902 www baldormotion com 2 3
54. X PULSEOUTX functions Equivalent to LOOPTIME 1ms default or 2ms PLC Task functions Programmable lt g o MN1902 Specifications 8 7 www baldormotion com 8 1 9 Relay general purpose output X3 All models Unit All models Contacts Normally closed Contact rating resistive 1A 30VDC or 0 5A 125VAC Maximum carrying current Maximum switching power Maximum switching voltage Maximum switching current 5 Capacitance 0 between open contacts at 1kHz Update interval Software Mint programs Immediate DRIVEOKOUTPUT Equivalent to LOOPTIME DRIVEENABLEOUTPUT 1ms default or 2ms GLOBALERROROUTPUT MOVEOUT MOVEOUTX MOVEPULSEOUTX PULSEOUTX functions PLC Task functions Programmable 8 1 10 Serial RS232 interface X6 All models All models 8 1 11 Serial RS485 interface X6 All models All models 8 8 Specifications MN1902 www baldormotion com 8 1 12 Encoder output simulated X7 All models Unit All models Bw E Resolution with resolver input on X8 Simulated 512 1024 2048 4096 Only available if resolver input is set to simulate a 4096ppr source with encoder input on X8 Output is a copy of the input on X8 with absolute encoder input on X8 Output ppr equals the number of Sin Cos cycles per revolution of the input See section 4 4 1 8 1 13 Resolver feedback option X8 Catalog numbers All models FDHxxxxxx Rxxxx FPHxxxx
55. a single 9 pin male D type connector Connector X6 is a 9 pin male D type connector This port is configurable as either RS232 or 4 wire RS422 RS485 using front panel DIP switch number 10 see section 3 9 7 The Mint keyword SERIALBAUD is used to configure the port and is explained in the Mint help file See also sections 4 4 4 and 4 4 5 The port is fully ESD protected to IEC 1000 4 2 15kV When using RS485 RS422 mode front panel DIP switch number 6 may be used to connect an internal 120Q termination resistor between the RX and RX signals Switch 6 should remain in the Off position when using RS232 N CAUTION Pin 9 is used to carry 8V for powering certain Baldor keypad peripherals Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply MN1902 Input Output 4 15 www baldormotion com 4 4 4 Using RS232 cable AN CAUTION The serial connector on the FlexDrive X6 can be configured as either RS232 or RS485 RS422 Pin 9 is used to carry 8V for powering certain Baldor keypad peripherals Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply A suitable cable is available from Baldor catalog number CBL001 501 Front panel DIP switch 10 must be in the Off position to select RS232 operation The FlexDrive has a full duplex RS232 serial port with the following preset configuration 57 6Kbaud 1 start bit 8 da
56. 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 FlexDrive The connections between the FlexDrive 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 demand 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 MN1902 CE amp UL D 3 www baldormotion com D 1 5 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 characteristics kk All metal conducting parts of the enclosure must be electricall
57. able command isiissssssssssssss esee 3 32 3 9 DIP switches SW1 uuusessssssssssss esses 3 33 3 9 1 Switches 1 4 sche ox LER EPI d X EPrb X Pu Y 3 33 3 92 Switcli 5 Hold i uescdenbberate tbe tbe HERREN S MIRA m RIS 3 34 3 9 3 Switch 6 RS485 terminator 00 eee 3 34 3 9 4 Switch 7 Offset tuning 0 00 eee 3 34 3 9 5 Switch Ss Enable octets yr Y tI E e Be wes en ale eer 3 34 3 9 6 Switch 9 MODBUS select 0 3 35 3 9 7 Switch 10 RS232 RS485 select 000 3 35 3 9 8 Factory setlingS 25 osse aan onde wae eta ee Rena ursi EL 3 35 3 9 9 Preventing a program running at startup 002 0 eee eee 3 36 4 Jnput Outpub 2524805 a2 EX yaa ERA Dus oa are fh 4 1 AT Introduction ec ib ern eov euet ets 4 1 42 Analog I Q 5i ie dto ime epkeIE EN eei 4 1 4 2 1 Analog input X3 demand 0 00 eee eee ee 4 2 4 3 Digital 4 sod el sie high hd aden A 4 4 4 3 1 Digital inputs X3 eenaa aneian teens 4 5 4 3 3 CREF and digital inputs 0 0 eee 4 6 4 3 8 Special functions on DIN4 and DIN5 pulse and direction inputs 4 6 4 3 4 Special functions on DIN4 and DIN5 fast inputs 4 8 4 3 5 Digital outputs X8 sssssssssssssssess eh 4 9 4 3 6 Relay output digital output X3 0 eee 4 10 44 Otherl O ssesseee e me 4 11 4 4 1 Encoderoutput XZ sssssssssssese
58. al and will provide optimum loop closure 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 Mint WorkBench 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 profiler Torque demand Torque Torque PWM Power stage controller motor High speed torque reference Figure 50 Control structure in Current Torque control mode B 2 Control System MN1902 www baldormotion com B 1 2 Velocity Speed control Setting the control mode to Velocity Control configures the FlexDrive or Flex Drive as a speed amplifier as shown in Figure 51 Here a speed reference is obtained from a specified source m M Mint host command profiled High speed analog input not profiled m Analog input profiled m Fieldbus profiled The source provides a signal that can either be fed directly into the Speed controller only when using the high speed analog input source or through a profiler The high speed reference source is ideal for connecting to a motion controlle
59. al inputs allow up to 256 presets to be selected The Extended tab below the presets table displays the preset table for presets 16 to 255 The Extended tab only appears if the CAN amp Auxiliary I O option is fitted Extended presets can only be used for Relative or Absolute moves and they do not have unique Slew speed Acceleration or Deceleration parameters The extended presets are divided into groups of 16 presets 16 31 32 47 48 63 etc selected using the Group box Each group of presets has unique parameters set using the Slew Speed Acceleration and Deceleration boxes In the Digital I O tool the number of inputs that may be selected in the Preset Inputs box also increases to 8 to allow up to 256 presets to be selected 6 6 Preset Moves amp PLC Task MN1902 www baldormotion com 6 3 6 3 1 6 3 1 1 PLC Task The PLC Task is a special task that can be set up to monitor various events and act upon them if they become true In Mint WorkBench the PLC Task tool allows you to enter conditional statements that respond to the events by performing a particular action The statements can be downloaded to the FlexDrive if required Mint WorkBench reads the current state of the PLC Task table from the FlexDrive whenever you switch to PLC Task mode For the following explanation the FlexDrive must be connected and powered Defining conditions Each action is triggered as a result of the logical evaluation of one
60. and 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 Profiler Speed Position demand Speed demand Torque PWM Power stage controller controller motor Measured speed Measured position Figure 53 Control structure in Position control mode MN1902 Control System B 5 www baldormotion com B 2 B 2 1 Control system operation The following sections describe the operation of the position speed and torque controllers Position controller The position controller shown below is a typical proportional integral derivative PID controller with gains set by the Mint keywords KPROP KINT and KDERIV The position demand from the profiler is compared with the measured position and the error is fed into the PID control calculation The resulting value forms the basic speed or torque demand depending on the CONFIG setting The effect of the integral term can be changed using the KINTLIMIT and KINTMODE keywords KINTLIMIT sets the maximum value of the effect of integral action as a percentage of the full scale demand KINTMODE can be used to specify the circumstances under which the integral term is applied As an al
61. ay not be synchronized The Trigger pulse must have a duration of at least 2ms to ensure that it is recognized by the drive MN1902 Preset Moves amp PLC Task 6 3 www baldormotion com 6 2 3 1 Configuring digital inputs to control presets The default combination of digital inputs used for triggering presets is 6 7 O and 1 to select the preset and 5 to trigger the preset However this combination can be changed to use any four or fewer contiguous inputs plus a trigger input The inputs form a bit pattern that represents the preset to be selected Consequently if the application requires only a small number of different preset moves you can reduce the number of inputs required to select the preset The following table shows the combinations of digital inputs that must be active to trigger each preset index move The table shows 4 inputs being used 0 3 allowing 16 presets to be selected Preset index Digital input 0 Digital input 1 Digital input 2 Digital input 3 Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern value 1 value 2 value 4 value 8 Table 3 Preset selection using digital inputs 0 3 For example to select preset move 6 digital inputs 1 and 2 must be active The choice of digital inputs is configured using the Digital I O tool 1 Inthe Toolbox click Setup then click the Digital I O icon Digital 1 0 6 4 Preset Moves amp PLC Task MN1902 www baldormotion com
62. by connecting two phases of an appropriate three phase supply L1 and L2 for example When supplying AC ower in this way the voltage between the two phases must not exceed the rated input voltage of the FlexDrive A two pole breaker must be used to isolate both lines Fuses must be fitted in both lines Circuit breaker or fuse are not supplied For CE compliance see Appendix D From Circuit Breaker From Fuses supply supply L1 T L1 L1 L2 ZUM L2 L2 i L3 f L3 E3 Circuit breaker or fuse are not supplied For CE Compliance see Appendix C Figure 5 Circuit breaker and fuse three phase package sizes E G H 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 5 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 FlexDrive complies with the CE specifications for which it has been tested Table 1 lists the appropriate filters FlexDrive Input voltages current rating 115VAC 1 230VAC 10 230VAC 30 230 460VAC 36 FI0015A00 or FI0029A00 FI0018A00 FI0015A02 or FI0029A00 FI0018A00 7 5A FI0029A00 FI0018A00 FI0018A01 FI0018A01 FI0018A01 FI0018A01 Table 1 Baldor filter part numbers All single phase FlexDrive models can be mounted d
63. connector CBLO75SF E1 and high density 15 pin D type drive CBLO91SF E1 connector CBL100SF E1 CBL150SF E1 CBL152SF E1 CBL200SF E1 CBL229SF E1 Available in North and South America only A 1 6 EnDat Hiperface absolute encoder feedback cables This table lists part numbers of Baldor absolute encoder feedback cables for use with the FlexDrive Length Cable assembly description Baldor catalog number Absolute Encoder Feedback Cable CBL045 501 i no connectors CBLO15SF D1 CBLO25SF D1 CBLO30SF D1 CBLOSOSF D1 CBLO61SF D1 CBLO75SF D1 CBLO91SF D1 CBL100SF D1 CBL150SF D1 CBL152SF D1 CBL200SF D1 CBL229SF D1 Absolute Encoder Feedback Cable Assembly CE style threaded motor connector and high density 15 pin D type drive connector Available in North and South America only A 4 Accessories MN1902 www baldormotion com A 1 7 Feedback cable part numbers A description of a Baldor feedback cable catalog number is shown here using the example number CBL025SF R1 Indicates the length in this example 2 5 meters Mela See Serions n en The cable is a Servo motor Feedback cable Me na a cable Drive connector included 9 pin D type connector resolver 15 pin D type connector Encoder Hall amp EnDat Hiperface E Encoder Hall feedback cable Resolver feedback cable with motor connector D EnDat Hiperface feedback Note Feedback cables have the outer shield tied to the connector housing s
64. connector X8 Twisted pair cables must be used for the complementary signal pairs e g SIN and SIN The overall cable shield screen must be connected to the metallic shell of the D type connector Connector X8 9 pin D type male connector Resolver function p eM 2 COS C 7 sme 0 A see 70 s Chassis Ground Resolver input with 14 bit resolution The resolver input is used to create an encoder signal inside the FlexDrive This provides the FlexDrive 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 FlexDrive provides an input accuracy of 3 counts When used with a typical Baldor BSM series resolver motor the combined accuracy is 11 counts calculated with the input equivalent resolution set to the factory preset value of 4096 ppr Baldor motor R2 52 resolver connector Twisted X8 pairs R1 S4 SIN SIN S3 S1 COS COS REF REF AGND Connect internal 7 shields to AGND Connect overall shield to connector backshells Figure 11 Resolver cable connections 3 22 Basic Installation MN1902 www baldormotion com 3 7 1 1 Resolver cable pin configuration Figure 12 shows the pin configuration for a typical Baldor resolver feedback cable part number CBLO25SF R1 Signal name FlexDri
65. d hole in the bottom of the enclosure may be used as an additional functional earth ground connection for signals on connector X3 It may also be used to attach strain relief clamps The holes are threaded for M4 bolts no longer than 12mm 0 47 in in length Longer bolts may short circuit the electrical components inside the FlexDrive AC Route L N and Circuit breaker or fuse AC filter Supply earth ground together See section 3 4 4 See section in conduit or cable 3 4 5 Line Ll _ Neutral N 1 Isolating switch Incoming safety earth ground PE STAR POINT If filter has no output earth ground terminal earth wire may be connected directly to star point If AC power wires are shielded earth ground outer shield using 360 clamps connected to backplane Figure 2 Earthing grounding for single phase installations Note For CE compliance a filter must be connected between the AC power supply and the FlexDrive If local codes do not specify different regulations use at least the same gauge wire for earth ground as is used for L and N MN1902 Basic Installation 3 9 www baldormotion com 3 4 2 Three phase connection to package sizes E G H Location Connector X1A Mating connector Phoenix POWER COMBICON PC4 ST 7 62 FDH2A15 FPH2A15 FDHAA FPHAA didit 230VAC 3 line to line 230 460VAC 30 line to l
66. de for the specified bus BUSPROCESSDATAIN To configure the drive for the type of process data that will be received from the master BUSPROCESSDATAIN To configure the data type for process data that will be DATATYPE received from the master BUSPROCESSDATAIN To define the associated parameter for items received in PARAMETER process data telegrams BUSPROCESSDATAOUT To configure the type of process data that will be sent by the drive BUSPROCESSDATAOUT To configure the data type for process data that will be DATATYPE sent by the drive MN1902 Mint Keyword Summary C 3 www baldormotion com INTERVAL process data telegrams PARAMETER process data telegrams CAPTURECOMMAND Controls the operation of capture CAPTUREBUFFERSIZE To read the total size of the capture buffer CAPTURECHANNELINTEGER To allow an entire channel of captured data values to be UPLOAD uploaded as integer data into an array CAPTURECHANNELUPLOAD To allow an entire channel of captured data values to be uploaded into an array To define the total duration of the data capture CAPTUREHSMODE To set or read the mode of a high speed capture channel CAPTUREINTERVAL To define the interval between data captures relative to the servo frequency CAPTUREPOINTINTEGER To allow individual capture values to be read as integer values CAPTUREPRETRIGGER Sets the duration of the pre trigger phase DURATION CAPTUREPROGRESS Returns the progress of the
67. detail Edit amp Debug Tool This tool provides a work area including the Command window and Output window The Command window can be used to send immediate Mint commands to both the FlexDrive and Flex Drive Scope Tool Displays the capture screen This screen is also shown when the Fine tuning tool is selected Jog Tool Allows you to perform jog moves useful for testing purposes PLC Task Tool Allows you to setup the PLC Task a special task that can be used to check for a number of pre defined conditions and then perform actions if they become true Error Log Tool Displays a list showing when errors occurred and when they were cleared Spy window Allows you to monitor all the important parameters for the axis and shows the state of digital inputs and outputs limit switches and comms locations Flex Drive only Edit amp Debug also provides the environment for programming the Flex Drive Multiple editing windows can be opened for entering program code Presets Tool Allows you to setup preset moves and the way in which they should be triggered An interactive table of the moves is used to make changes Homing Tool Allows you to setup homing moves 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 5 12 Operation MN1902 Preset Moves amp PLC Task 6 6 1 Introduction Two of the important features intr
68. digital input o 9 a H z x JOGTIME To return the remaining jog time before deceleration C 10 Mint Keyword Summary MN1902 www baldormotion com KINTMODE To control when integral action will be applied in the Servo loop KIPROP To set the proportional gain used by the current controller To set the proportional gain for the position controller To set the derivative gain used by the speed controller KVDERIVTCONST To set the time constant used by the filter on the derivative gain term of the speed controller To set the servo loop velocity feedback gain term KVELFF To set the velocity feedforward term for the position controller To set the integral gain used by the speed controller KVPROP To set the proportional gain used by the speed controller KVTIME To set the time constant of a low pass filter applied to measured speed LED To set or read the display mode for the seven segment display To set or read the value for the seven segment display Returns a lifetime counter for the drive LIMIT To return the state of the forward and reverse limit Switch inputs for the given axis LIMITFORWARD To return the state of the forward limit switch input for the given axis LIMITFORWARDINPUT To set the user digital input configured to be the forward end of travel limit switch input for the specified axis LIMITMODE To control the default action taken in the event of a forward or reverse hardware limit swi
69. dor 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 MN1902 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 Only qualified personnel should attempt to start up program or troubleshoot this equipment 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 re
70. dormotion com 8 12 Specifications MN1902 A 1 A 1 1 Accessories A Introduction This section describes accessories and options that you may need to use with your FlexDrive 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 Factory fitted options The FlexDrive can be supplied with a number of factory fitted options Each option is described in a separate manual that will be supplied with your product as necessary MN1908 CAN amp Auxiliary I O Option for Flex Drive and MintDrivel Option B provides CANopen and additional input output capabilities If this option is fitted the Flex Drive front panel will include connectors X10 X11 and X12 MN1909 CAN Option for FlexDrive Flex Drive and MintDrive Option C provides CANopen capabilities If this option is fitted the FlexDrive front panel will include connectors X10 and X11 MN1910 DeviceNet Option for FlexDrive Flex Drive and MintDrivel Option D provides DeviceNet capabilities If this option is fitted the FlexDrive front panel will include connector X15 MN1911 PROFIBUS DP Option for FlexDrive Flex Drive and MintDrivel Option P provides Profibus capabilities If this option is fitted the FlexDrive front panel will include connector X14 MN1902 Accessories A 1 www baldorm
71. e clamps The holes are threaded for M4 bolts no longer than 12mm 0 47 in in length Longer bolts may short circuit the electrical components inside the FlexDrive m Each D type connector on the front panel of the FlexDrive 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 an identical jack screw with an external male threaded section of 5mm 0 2 in Jack screws with longer threads could damage or short circuit internal components Mounting the FlexDrive Ensure you have read and understood the Mechanical installation and location requirements in section 3 2 Mount your FlexDrive on its rear side the side opposite to the front panel The FlexDrive must be mounted upright to ensure adequate cooling you can check this by ensuring that the Hazardous Voltages warning information is clearly readable to you M5 bolts or screws should be used to mount the FlexDrive There are seven different package sizes depending on the specification of the FlexDrive Single phase 2A with option 230V 15A with or without option Three phase 230 460V 2 5A 5A 7 5A with or without option Three phase 15A 20A 27 5A with or without option Detailed dimensions for each package are shown in section 3 2 2 reine ELEM E EN mum 9 3 px um t MN1902 Basic Installation 3 5 www baldormotion com 3 2 2 Dimensions 65mm
72. e e Rte B 5 B 2 Control system operation 000 eee eee ee B 6 B 2 1 Position controller sessa secie c eee eee nnn B 6 B 2 2 Speed controller vy ies cs sone een be SE t Xe as Ree has B 7 B 2 3 Torque controller and feedback 0 00 cece eee eee eee B 8 C Mint Keyword Summary 0 0 0c eee eee C 1 Cir SIMTOGUGION 525 ae Le e era faa e ER Reed C 1 C 1 1 Keyword listinig secr c2 N coded s er xk RR p fet erates C 1 iv Contents MN1902 D CE amp UL ER RU TT RUE D 1 DA Introduction one mRERIDLEEPIGHRUORGer4keRe EPA D 1 D 1 1 EMC Conformity and CE marking 0 200 cece eee eee eee D 1 D 1 2 Declaration of conformity 00 00 cece ee D 2 D 1 3 Use of CE compliant components 0 00 ccc eee eee eee D 3 D 1 4 EMC wiring technique 0 2000s D 3 D 1 5 EMC installation suggestions 000 00 cece eee D 4 D 1 6 Wiring of shielded screened cables 000 cece eee eee D 5 D 2 UL Tile n mbers tee bmedeand POP PH Eb D 6 MN1902 Contents v vi Contents MN1902 General Information 1 LT0160A05 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 conten
73. e enabled until the input has been inactive off for at least one sample as described above MN1902 Basic Installation 3 31 www baldormotion com 3 8 2 Drive enable SW1 DIP switch To enable the FlexDrive the front panel DIP switch 8 must be set to On This switch provides a local enable disable switch that can be useful during testing The state of the drive enable DIP switch is displayed in the Mint WorkBench Spy window It can also be checked but not set using the Mint keyword ENABLESWITCH See the Mint help file for details See section 3 9 for full details of other DIP switch functions 3 8 3 Drive enable command The other action required to enable the FlexDrive can be controlled either by software or hardware Note This method is explained here for your information but cannot be completed until you have installed the software and are ready to turn on AC power to the drive Please continue to read all sections in sequence Do not turn on AC power until you reach the appropriate instructions In software a drive enable command must be issued The easiest way to do this is by clicking the Drive enable button a in Mint WorkBench Alternatively the Mint commands RESET or DRIVEENABLE 1 can be used See the Mint help file for details In hardware a digital input can be used to create the drive enable command This can be configured in Mint WorkBench using the Digital inputs tab of the Digital I O tool Alterna
74. ed fuses breakers 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 and Neutral wires MN1902 Basic Installation 3 13 www baldormotion com 3 4 7 External customer supplied 24V control supply Depending on model catalog numbers FDHxxxxx xxx3 and FPHxxxxx xxx3 a 24VDC control supply must be provided to power the control electronics This is useful for safety reasons where AC power needs to be removed from the power stage but the control electronics must remain powered to retain position and I O information It is recommended that a separate fused 24V supply is provided for the FlexDrive If other devices are likely to be powered from the same 24V supply then a filter Baldor catalog number F10014A00 should be installed to isolate the FlexDrive from the rest of the system Location Connector X1 X1A FDHXxxxx xxx3 or FPHxxxxx xxx3 Nominal input 24V voltage Range 20 4 28 8VDC Input current 1 75A continuous 4A power on surge maximum Tightening torque for terminal block connections is 0 5 0 6Nm 4 4 5 3 Ib in Note Connect 24V to connector X1 only if your model has this feature Connecting 24V to a model that does not require an external 24V supply FDHxxxxx xxx0 and FPHxxxxx xxx0 could damage the unit Note The label on filter FI0014A00 correctly indicates that it is designed for c
75. ed to the unit is isolated from the AC supply using double or reinforced insulation The inputs and outputs of the control circuit must be limited to Safety Extra Low Voltage circuits Both the AC supply and the external 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 The FlexDrive must be secured by the slots in the flange with the protective earth ground stud bonded to a safety earth ground by either a 25A conductor or a conductor of three times the peak current rating whichever is the greater 3 4 Basic Installation MN1902 www baldormotion com 3 2 1 For effective cooling and maintenance the FlexDrive should be mounted on a smooth non flammable vertical surface The power handling capability is affected by the temperature of the left side of the unit Atleast 50mm 2 in top and bottom clearance of the FlexDrive must be provided for airflow m f multiple FlexDrive are being mounted side by side there must be 13mm 0 5 in between them The FlexDrive nearest the side of the cabinet enclosure must be separated from it by at least 13mm 0 5 in m To comply with CE directive 89 336 EEC an appropriate AC filter must be installed The external customer supplied 24VDC logic supply might also require a 24V filter See section 3 4 7 m The threaded holes in the top and bottom of the enclosure are for cabl
76. ements 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 interconnection between components and shielding and grounding of the system as a whole determines EMC compliance The CE mark informs the purchaser that the equipment has been tested and complies with the appropriate standards It rests upon the manufacturer or his authorized representative to ensure the item in question complies fully with all the relative directives in force at the time of installing into service in the same way as the system integrator
77. en in the event of an external error input FASTAUXENABLE To manually clear the auxiliary encoder s fast position latch FASTAUXENCODER To return the instantaneous auxiliary encoder value that was recorded on the fast interrupt To read the auxiliary encoder fast interrupt latch FASTAUXLATCHDISTANCE To specify the distance over which further auxiliary encoder latch edges will be ignored FASTAUXLATCHEDGE To select the capture edge for fast capture on the auxiliary encoder FASTAUXLATCHMODE Sets the default action to be taken to clear the auxiliary encoder s fast position latch FASTAUXSELECT To select which of the fast position capture inputs will capture an auxiliary encoder channel MN1902 Mint Keyword Summary C 7 www baldormotion com Manually clears the encoder s fast position latch FASTENCODER To return the instantaneous encoder value that was recorded on the fast interrupt To read the axis fast interrupt latch FASTLATCHEDGE To define which edge polarity should cause the fast position to be captured FASTLATCHMODE To set the default action to be taken to clear the encoders fast position latch FASTPOS To return the instantaneous axis position that was recorded on the fast interrupt FASTSELECT To select which of the fast position capture inputs or outputs will cause axis position to be captured To enable or disable detection of motor feedback faults FEEDRATE To set the slew speed of an indiv
78. ess eee 4 11 4 4 2 Master auxiliary encoder input X9 00 0c cece ee eee ee 4 13 AAS Serial port X0 Loses tie ana Ux bibere Ehe nian IURE E 4 15 444 Using RS232cable ssssssssseeeeee nnn 4 16 4 4 5 Multidrop using RS485 RS422 cable ssssssssssse 4 17 4 4 6 Connecting Baldor HMI Operator Panels ssselssssusse 4 18 4 5 Connection summary minimum system wiring 4 19 4 6 Option connectors sssssessees eh 4 20 5 Operation t5 rait Ad sao ca ES pA eda adt 5 1 5 1 Introduction masei i eai a a a ara ee 5 1 5 1 1 Connecting the FlexDrive to the PC 2 cece cece eee 5 1 5 1 2 Installing the software 0 0 ccc eee 5 1 5 1 3 Starting the FlexDrive 2 00 0 cece een nee 5 2 5 1 4 Preliminary checks 0 000 cece eect eet eens 5 2 5 115 Power ON CHECKS iso tot war hos eae ae aE REG ee eee 5 2 5 14 63 ORSESEIUNING ory censere roe Ree do es eee Beale hese 5 3 ii Contents MN1902 5 2 Mint WorkBench sussssssessssss eese 5 4 5 2 1 Help tile setae ia La i ERG PERDE I SR E PERDERE 5 4 5 22 Starting Mint WorkBench 0000 cece eee eens 5 5 5 23 Commissioning Wizard ususse aeaaaee 5 7 5 24 Using the Commissioning Wizard 0002 c eee eee eee 5 7 5 25 Completing the Commissioning Wizard 00200e eee eee 5 7 5 2 6 Performing a test move 0 0c cece tees 5 8 5 3 Furt
79. ess locking out the interprocessor communications Clear the error if the problem persists then contact Baldor technical support Over volts The DC Bus voltage has exceeded the powerbase overvolts level see DRIVEBUSOVERVOLTS Check the DC Bus level being fed into the system see Mint keyword DRIVEBUSVOLTS This should be close to the nominal voltage see Mint keyword DRIVEBUSNOMINALVOLTS Ensure that your input voltage is relevant to the voltage rating of your drive If the input voltage is correct then this error may be the result of high deceleration rates If it is not possible to reduce the harshness of the deceleration rate then a regeneration resistor should be used To help you use Mint WorkBench capture facility to monitor the DC Bus level during moves Integrated Power Module IPM trip The unit s powerbase has been overloaded This should not happen in normal use if limits have been configured correctly See the Mint keyword CURRENTLIMIT and related commands j Current trip Instantaneous over current trip One or more of the 3 motor phases has exceeded 300 of Drive Rated Current Under volts The DC Bus voltage has dropped below the powerbase undervolts level see DRIVEBUSUNDERVOLTS This error will only be generated if the drive is in the enabled state As with the overvolts error check the input voltage being fed into the system The error could also occur during high acceleration profiles Feedback trip Can be enab
80. fications for the various FlexDrive models MN1902 Specifications 8 1 www baldormotion com 8 1 1 AC input power and motor output single phase models 115VAC CRE number FDH1 FPH1 E Minimum input voltage recommended absolute 97 75 Maximum input Maximum input voltage 125 eS input current Arms 12 maximum rated output current P85 He Minimum operating DC Bus Minimum operating DC Bus voltage Maximum operating DC Bus BU r safety trip Nominal input voltage Minimum input voltage recommended absolute Maximum input voltage o 20 EIL NEFF EU RN maximum rated output current Minimum operating DC Bus Minimum operating DC Bus voltage ME Maximum operating DC Bus BU EE OOOO epum DE UY Rm safety trip As input voltage decreases DC Bus ripple voltage increases This can cause a deterioration of drive performance All single phase models Catalog numbers FDH1 FPH1 and FDH2 FPH2 Output voltage line line VDC Bus 320V Peak phase current 10 Arms 5 10 15 2 5A amp 5A for 2 4s 0 5s 0s 7 5A for 1 25s 0 5s Os em a Output frequency Hn 0 500 8 2 Specifications MN1902 www baldormotion com 8 1 2 AC input power and motor output 230V three phase models 230VAC 50 60Hz Catalog numbers FDH2A15 and FPH2A15 Nominal input voltage Minimum input voltage recommended absolute Maximum
81. g the AINO demand input is set to its intended zero output setting nominally OVDC 3 Wait for 1 second for offset tuning to be completed Cull Figure 44 Offset tuning using switch 7 and 8 After offset tuning remember to set switch 8 to the On position to allow the drive to be enabled MN1902 Operation 5 3 www baldormotion com 5 2 5 2 1 Mint WorkBench Mint WorkBench is a fully featured application for programming Flex Drive only and controlling the FlexDrive 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 Help file Mint WorkBench includes a comprehensive help file that contains information about every Mint keyword how to use Mint WorkBench and background information on motion control topics The help file can be displayed at any time by pressing F1 On the left of the help window the Contents tab shows the tree structure of the help file Each book contains a number of topics 2 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 co
82. gether with possible solutions Problem diagnosis If you have followed all the instructions in this manual in sequence you should have few problems installing the FlexDrive If you do have a problem read this section first In Mint WorkBench use the Error Log tool to view recent errors and then check the help file If you cannot solve the problem or the problem persists the SupportMe feature can be used SupportMe feature The SupportMe feature on the Help menu can be used to e mail information to the Baldor representative from whom you purchased the equipment If required you can choose to add your program files as attachments Mint WorkBench will automatically start up your e mail program and begin a new message with comprehensive system information and selected attachments already in place You can add any additional message of your own and then send the e mail The PC must have email facilities to use the SupportMe feature If you prefer to contact Baldor technical support by telephone or fax contact details are provided at the front of this manual Please have the following information ready m The serial number of your FlexDrive l m Use the Help SupportMe menu item in Mint WorkBench to view details about your System The catalog and specification numbers of the motor that you are using Give a clear description of what you are trying to do for example trying to establish communications with Mint WorkBench or trying to
83. hat have rotating parts or parts that are controlled by this equipment Improper use can cause serious or fatal injury Only qualified personnel should attempt to program start up or troubleshoot this equipment 1 2 General Information MN1902 www baldormotion com AN WARNING AN WARNING AN WARNING AN WARNING AN WARNING AN WARNING AN WARNING AN WARNING AN CAUTION CAUTION AN AN CAUTION MEDICAL DEVICE PACEMAKER DANGER Magnetic and electromagnetic fields in the vicinity of current carrying conductors and industrial motors can result in a serious health hazard to persons with cardiac pacemakers internal cardiac defibrillators neurostimulators metal implants cochlear implants hearing aids and other medical devices To avoid risk stay away from the area surrounding a motor and its current carrying conductors Be sure all wiring complies with the National Electrical Code and all regional and local codes Improper wiring may result in unsafe conditions 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 Only qualified personnel should attempt to program start up or troubleshoot this equipment 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 ca
84. he FlexDrive will be reset to its preset factory settings at power on or whenever the processor is reset by Mint WorkBench AN CAUTION Use this function carefully it will erase your drive setup information When using the SW1 DIP switches to reset the FlexDrive to its factory defaults all parameters including the node number and serial communications baud rate will be reset In Mint WorkBench this means it will be necessary to rescan for the FlexDrive by starting a new project to enable communication It will also be necessary to re tune your motor and drive 1 Remove 3 Reapply 4 FlexDrive will power power be reset to its preset factory settings Figure 22 Resetting the FlexDrive to its factory default settings The Mint keyword FACTORYDEFAULTS can also be used to reset the FlexDrive to its factory defaults However it will not reset the node number or serial communications baud rate See the Mint help file for details MN1902 Basic Installation 3 35 www baldormotion com 3 9 9 Preventing a program running at startup Flex Drive only If switches 5 and 9 are set to On and switch 8 is set to Off any program already in the Flex Drive that contains an Auto command will be prevented from running automatically at startup It is possible for normal Baldor Binary Protocol serial communication to be lost if bit 5 of the Mint keyword COMMSMODE has been set This can occur when alternative communication
85. he load falling Contact your local supplier for details of appropriate brakes N CAUTION If an M Contactor is installed the FlexDrive must be disabled at least 20ms before the M Contactor is opened If the M Contactor is opened while the FlexDrive is supplying voltage and current to the motor the FlexDrive may be damaged Incorrect installation or failure of the M Contactor or its wiring may result in damage to the FlexDrive 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 Wet ae wow 3 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 16 Basic Installation MN1902 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 WawU Wax S AA 8 amp 4 a E Su Signal name Hall cable wire color Hair uj mm Rm O rats Sinusoidal filter A sinusoidal filter is used to provide a better quality waveform to the motor reducing motor noise temperature and mechanica
86. her configuration 2 0 00 eee eee eee 5 9 5 3 4 Fine tuning tool a aA eens 5 9 5 3 2 lt Parameters tool ene su eei ene Se eee See Me Lee Se ae 5 11 5 3 9 Digital OtOO xp MEE aan Sos Mata aaa eta 5 12 5 3 4 Other tools and windows sssseeeeeee eee ee 5 12 6 Preset Moves amp PLC Task uuuu 6 1 6 1 Introduction i oor rede tenerte Sea eR E uS 6 1 6 2 Preset moves sia ossaa ratia aa ma a a ess 6 2 6 21 Defining a preset move ssiuisssssssssseeseess ere 6 2 6 22 Testing a preset Move 0 0 cece sere 6 3 6 2 3 Using digital inputs to trigger a preset move ssuuuusss 6 3 6 24 Controlling preset moves 0 0 cece 6 6 6 25 Using presets with the CAN amp Auxiliary I O option 6 6 6 3 PLC Task cnr t test aieo aa ula ees t elo C 6 7 6 3 1 Defining conditions uses RPTUEHIM REA REB 6 7 6 3 2 Enabling and downloading the actions lsslllisellsssss 6 8 6 3 8 Testing the PLC Task ridind eane ta i A eee eee 6 9 6 4 Saving presets or PLC conditions 0 cease 6 9 7 Troubleshooting 2 559 2255695 eu sds bes S vec ek Ai 7 1 Fel sIntroduction i oa ter e E Renee RH n 7 1 7 1 1 Problem diagnosis 000 00 cece eect eee eee 7 1 74 2 SupportMe feature cosmos vie e oe ED peer EXPERS ER eee 7 1 7 1 3 Power cycling the FlexDrive lli cece eee eee 7 1 7 2 FlexDrive indicato
87. idual move loaded in the move buffer FEEDRATEMODE To control the use of slew speed acceleration deceleration and feedrate override FOLERRORFATAL To set the maximum permissible following error before an error is generated FOLERRORMODE To determine the action taken on the axis in the event of a following error FOLERRORWARNING Sets the following error threshold before an axis warning is generated To enable encoder following with a specified gear ratio To define the mode of operation of the FOLLOW keyword FOLLOWNUMERATOR To set or read the follow ratio s numerator GLOBALERROROUTPUT Allows the user to specify a global error output which will be deactivated in the event of an error To begin synchronized motion C 8 Mint Keyword Summary MN1902 www baldormotion com GROUPCOMMS To write to the comms arrays of all the nodes within a specified group GROUPMASTERSTATUS To determine whether the current node is master of the group GROUPSTATUS To determine whether the current node is a member of the group To read the current Hall state on feedback devices which use Hall sensors HALLFORWARDANGLE To define the electrical angles at which Hall states change when the motor is running in the forward direction for feedback devices which use Hall sensors ALLREVERSEANGLE To define the electrical angles at which Hall states change when the motor is running in the reverse direction for feedback devices which use Hall
88. igh inputs Incremental encoder FlexDrive Twisted pairs 14 DIN4 Pulse i i 15 DIN5 Dir Pei MV U NC Connect shields at one end only l Encoder 4 4 Encoder supply supply 24V GND Figure 30 Pulse and direction inputs typical connection from an incremental encoder FlexDrive with internally generated 24V supply option active high inputs Note When using an incremental encoder source do not connect the A or B outputs leave them unconnected as shown in Figures 29 and 30 MN1902 Input Output 4 7 www baldormotion com 4 3 4 Special functions on DIN4 and DIN5 fast inputs Flex Drive only DIN4 and DIN5 can be configured using the FASTSELECT keyword to perform special functions m Fast interrupt hardware position capture input The position of the axis is captured in real time and can be read using the Mint keyword FASTPOS Master or auxiliary encoder input capture read using the Mint keyword FASTAUXENCODER DIN5 only The maximum latency to read the fast position is approximately 1us The fast interrupt will be latched on a pulse width of about 30us although a width of 100us is recommended to ensure capture To prevent subsequent inputs causing the captured value to be overwritten the interrupt is latched in software It is necessary to clear the latch before subsequent i
89. igure 9 Motor thermal switch circuit The 24VDC power supply connected to the thermal switch must be a separate supply as shown in Figure 9 Do not use the 24V supply used for the drive enable signal or the internally generated supply if present The thermal switch wires often carry noise that could cause erratic drive operation or damage The thermal switch contacts must never be wired directly to a digital input The separate 24VDC supply used for the thermal switch may also be used for the motor brake circuit section 3 5 6 3 18 Basic Installation MN1902 www baldormotion com 3 5 6 Motor brake connection You might wish to wire a motor s brake via relays to digital outputs on connector X3 see section 4 3 1 This provides a way for the Mint program to control the motor s brake A typical circuit is shown in Figure 10 Flex Drive only MOTORBRAKEOUTPUT and associated keywords may be used to configure the motor brake output X3 S c T from motor brake CGND 8 1 D connections V Relay 1 lr The inner shield surrounding the brake wires should be earthed grounded at one point only Relay 2 DOUTO ourx 0 18 y DOUT1 ouzx 1 19 24VDC OV Separate The relays have normally open customer contacts and are shown deactivated supplied contacts open brake engaged 24VDC supply Figure 10 Motor brake control circuit This circuit
90. in the Type column The drop down box O allows you to select the jog move type Flex Drive only an PETS resets absolute relative positional move homing move or set position may also be selected The Value column will change accordingly 4 Click in the Value column to set the appropriate value Any values entered in the preset table to specify a position slew speed acceleration or deceleration are interpreted as user units Fora jog move the value represents the direction in which the axis will jog Flex Drive only Foran absolute move the value represents the absolute position to which the axis will move when the preset is used Fora relative move the value represents the amount by which the axis will move relative to its existing position when the preset is used m Fora set position the value represents the new axis position that will be set when the preset is used No movement will occur For a homing move the Homing settings window is displayed Choose the required settings for the homing move and click OK The value column will display the corresponding value of the HOME keyword for the chosen settings Press F1 to display the Mint help file for details of the HOME keyword 5 Click in the Slew speed Acceleration and Deceleration boxes to set appropriate values for the move profile 6 Click Apply to download the presets table to the FlexDrive 6 2 Preset Moves amp PLC Task MN1902 www baldor
91. ine 75 253VAC 75 528VAC Tightening torque for terminal block connections is 0 5 0 6Nm 4 4 5 3 Ib in The threaded hole in the top of the enclosure is for protective earth ground connections The threaded hole in the bottom of the enclosure if present may be used as an additional functional earth ground connection for signals on connector X3 It may also be used to attach strain relief clamps The holes are threaded for M4 bolts no longer than 12mm 0 47 in in length Longer bolts may short circuit the electrical components inside the FlexDrive AC Route L1 L2 L3 and Circuit breaker or fuses AC filter Supply earth ground together See section 3 4 4 See section in conduit or cable 3 4 5 Line L1 7 1 i gt Line L2 7 3 4 7 7 Line L3 oO Isolating switch Incoming safety If filter has no If AC power wires earth ground PE output are shielded earth ground earth ground STAR POINT terminal earth outer shield using wire may be 360 clamps connected connected to directly to star backplane point FDHAA shown for illustration purposes Figure 3 Earthing grounding for three phase installations N WARNING Drives with part numbers FDH2A15 or FPH2A15 have two additional terminals on the X1 connector labeled Vcc and Vcc The full DC bus output voltage is present on the these terminals s
92. ion ramp for a speed profile in the event of an error SPEEDREFSOURCE To specify the source of the speed reference command SRAMP Sets the percentage of S ramping applied to linear moves To perform a controlled stop during motion STOPINPUT To set or read the digital input to be used as the stop Switch input for the specified axis STOPINPUTMODE To set or read the action taken in the event of a stop input becoming active To return the current state of the stop input for the axis SYSTEMDEFAULTS To reset parameter table entries to their default values and erase the Mint program NVRAM and error log SYSTEMSECONDS To set or read a programmable system lifetime counter for the drive SYSTEMTIMEMODE To specify whether system time data is stored to non volatile memory TEMPERATURE To report the internal drive temperature TEMPERATURELIMITFATAL To set or read the temperature fatal limit TEMPERATURELIMITWARNING To read the temperature warning limit To set or read the device type associated with a given terminal TERMINALMODE To set or read handshaking modes for a terminal TERMINALPORT To set or read the communication port associated with a given terminal TIMEREVENT To set or read the rate of the timer event TIMESCALE To scale speed related values into user time units MN1902 Mint Keyword Summary C 19 www baldormotion com TORQUEREF To set or read a torque reference for torque constant current mode on a ser
93. ion should be made to the shield If the input is unused then it is advisable to connect it to the AGND pin Do not leave the input unconnected floating MN1902 Input Output 4 1 www baldormotion com 4 2 1 Analog input X3 demand Connector X3 pins 1 3 Location Mating connector Phoenix MINI COMBICON MC 1 5 20 ST 3 5 Description Single ended or differential input Common mode voltage range 10VDC Resolution 14 bit with sign accuracy 1 2mV Common mode rejection 40dB Input impedance 5kO Sampling interval 500us Software Mint programs 125us High speed demand reference signal Analog input X3 can be connected as either a differential or a single ended input as shown in Figure 24 FlexDrive 15V x3 10k AINO Low pass filter amp level correction inverts signal AINO Figure 24 AINO analog input circuit 4 2 Input Output MN1902 www baldormotion com x3 AINO 1 AINO 2 AINO AINO ADC 0 aDC 0 3 Differential connection Single ended connection Figure 25 AINO analog input wiring 24VDC 1 5kQ 0 25W AINO ov ADC 0 Figure 26 Typical input circuit to provide 0 10V approx input from a 24V source MN1902 Input Output 4 3 www baldormotion com 4 3 Digital I O The FlexDrive provides as standard m 8 general purpose input
94. irectly onto the body of filter FI0029A00 reducing the amount of panel area required for filter and drive 3 12 Basic Installation MN1902 www baldormotion com 3 4 6 Wire sizes and protection device ratings Table 2 describes the wire sizes to be used for AC input power and motor output connections together with the ratings for protection devices FDH1A02xx xxxx FPH1A02xx xxxx 115V 19 2 FDH2A02xx xxxx FPH2A02xx xxxx SOV AP 2 FDH1A05xx xxxx FPH1A05xx xxxx 115V 1 FDH2A05xx xxxx FPH2A05xx xxxx 220v CI FDH1A07 xx xxxx FPH1A07xx xxxx 115V 16 y FDH2A07xx xxxx FPH2A07 xx xxxx 230V 1 i FDH4A02xx xxxx 230 460V 2 FPH4A02xx xxxx 30 FDH4A05xx xxxx 230 460V FPH4A05xx xxxx 30 FDH4A07 xx xxxx 230 460V 7 FPH4A07 xx xxxx 30 FDH2A15xx xxxx FPH2A15xx xxxx 230V 30 FDH4A15xx xxxx 230 460V FPH4A15xx xxxx 30 FDH4A20xx xxxx 230 460V 40 FPH4A20xx xxxx 30 FDH4A27xx xxxx 230 460V 5 FPHA4A27 xx xxxx 30 ncoming Power Nominal Continuous D Type i Minimum Catalog Number Input Output Input Wire Gauge Voltage Amps Breaker Note SA SA 5A 5A SA SA SA 5A SA 15A 15A 20A 14 14 14 14 14 14 14 14 14 12 12 10 10 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 3 3 3 3 5 3 3 Table 2 Protection device and wire ratings 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 Recommend
95. issioning Wizard The feedback device e g an encoder or resolver 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 Proportional gain term f KIINT Feedback KIPROP device e g en ii Power Motor resolver Current Integral gain term A PWM value stage Torque demand demand mr EFFORT Interna scaling Feedback interface Measured current Filter KVTIME Measured speed VEL Measured position POS Figure 56 Torque control system B 8 Control System MN1902 Mint Keyword Summary C 1 Introduction The following table summarizes the Mint keywords supported by the FlexDrive and Flex Drive Note that due to continuous developments of the FlexDrive Flex Drive and the Mint language this list is subject to change Check the latest Mint help file for a complete list of new keywords changed keywords and those used for controlling program flow C 1 1 Keyword listing Keywords marked with are supported on Flex Drive only ABORTMODE To control the default action taken in the eve
96. l stress It will reduce or eliminate harmful dV dt values voltage rise over time and voltage doubling effects which can damage motor insulation This effect occurs most noticeably when using very long motor cables for example 30m 100 ft or more Baldor motors intended to be used with drives are designed to withstand the effects of large dV dt and overvoltage effects However if very long motor cables are unavoidable and are causing problems then a sinusoidal filter may be beneficial MN1902 Basic Installation 3 17 www baldormotion com 3 5 5 Thermal switch connection You might wish to wire the motor s thermal switch contacts normally closed using a relay to a digital input on connector X3 see section 4 3 1 Using the Mint WorkBench Digital I O tool the input can be configured to be the motor trip input This allows the FlexDrive to respond to motor over temperature conditions The Mint keyword MOTORTEMPERATUREINPUT can also be used to configure a digital input for this purpose A typical circuit using DIN1 as the input is shown in Figure 9 switch AN CAUTION X3 10 DINO INX 0 11 DIN1 INX 1 k 12 DIN2 INX 2 13 DIN3 INX 3 14 DIN4 INX 4 El Rela n ZN i 15 DIN5 INX 5 LB u 16 DING zNX 6 ME DIN7 INX 7 24VDC ov 24VDC oV 7 CREE Separate Customer m customer supplied supplied 24VDC 24VDC supply supply F
97. led disabled using FEEDBACKFAULTENABLE Five consecutive errors or five errors in any 500 servo tick period will cause the drive to trip This error indicates loss of encoder resolver feedback and may indicate that the feedback cable has become detached or one of the signals has broken Check the wiring in the Feedback cable check for noise immunity check the feedback device fitted to the motor if possible Motor or Drive trip The motor 12T or the drive I T current protection algorithms have exceeded their limit and tripped the drive disabled it Check DRIVEERROR or the Error Log to determine which error has occurred The motor and drive current limits are fixed according to the database parameters The drive can demand peak current for a short duration see DRIVEPEAKDURATION thereafter it will trip or Foldback according to the setting of DRIVEOVERLOADMODE The same is true for the motor see MOTORPEAKDURATION and MOTOROVERLOADAREA Use the Foldback option to automatically foldback the current to a level where the drive motor can recover Symbol not flashing Motor I T It foldback Motor I T or Drive I T algorithm has resulted in the demand current being folded back to a level where the drive motor can recover The motor drive can run with demand currents greater than their rated value for a period of time after that time the drive will either trip or automatically foldback the demand current D 7 2 Troubleshooting MN
98. lor 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 Mint MT mE x a RE ec o amp amp Hide Locate Back Forwed Print Options Contents Index Search JOGMODE JGM See Also JOG JOGSPEED JOGCOMMAND JOGDURATION Purpose Specifies the control mode for profiling a jog move Controllers Supported FlexDrives Flex Drivel7 MintDriveIT Format JOGMODE axes expression lt expression gt v JOGMODE axis Dot Parameters Axis Axis No Dak ail CE EA EA EA EA ps poser a Figure 45 The Mint WorkBench help file For help on using Mint WorkBench click the Contents tab then click the small plus sign beside the Mint WorkBench book icon Double click a topic name to display it 5 4 Operation MN1902 www baldormotion com 5 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 Inthe opening dialog box click Start New Project MN1902 Operation 5 5 www baldormotion com 3 Inthe Select Controller dialog go to the drop down box near the top and selec
99. ment damage be certain that input and output signals are powered and referenced correctly signals to from the FlexDrive are shielded correctly CAUTION Avoid locating the FlexDrive immediately above or beside heat generating equipment or directly below water steam pipes AN CAUTION To ensure reliable performance of this equipment be certain that all CAUTION Avoid locating the FlexDrive in the vicinity of corrosive substances or vapors metal particles and dust The safe operation of this equipment depends upon its use in the appropriate environment The following points must be considered The FlexDrive 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 Above 1000m 3300ft de rate output current 1 196 per 100m 330ft The FlexDrive must operate in an ambient temperature of 0 C to 40 C 32 F to 104 F De rate output current 2 5 per 1 C 1 8 F from 40 C 104 F to 50 C 122 F maximum The FlexDrive must operate in relative humidity levels of less than 90 for temperatures up to 31 C 87 F decreasing linearly to 50 relative humidity at 40 C 104 F non condensing The FlexDrive must be installed where the pollution degree according to IEC664 shall not exceed 2 The external customer supplied 24VDC for the logic supply must be installed so that the 24VDC suppli
100. motion com 6 2 2 Testing a preset move For testing Mint WorkBench can be used to trigger the preset moves At the bottom of the Presets window ensure that the Software option is checked This means that Mint WorkBench will be used to control the preset moves If the drive is not already enabled click the drive enable x4 icon on the toolbar Just above the Presets table click Enable to allow preset moves Iv Use Trigger b c Sce oe In the Index drop down box select a preset number to test and click Test The preset move will now be performed Note The B button on the mode toolbar can also be used to enable or disable preset moves even if the Presets tool is not currently selected 6 2 3 Using digital inputs to trigger a preset move In normal operation preset moves can be selected and triggered by external equipment using a combination of the digital inputs f At the bottom of the Presets window ensure that the Digital Inputs option is checked This means the digital inputs will be used to control the preset index Click Apply to send the changes to the FlexDrive The Use Trigger option should also be checked This means that a digital input will be used to trigger the preset move Note Ifthe Use Trigger input is not checked preset moves will be triggered instantly on changing to the selected preset index This mode should be used with care as the change of state of digital inputs m
101. n The FlexDrive can be configured for three basic control modes m Current Torque control m Velocity Speed control m Position Control Pulse and Direction following gearing The Flex Drive can be configured for three basic control modes Current Torque control Velocity Speed control Position Control 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 four control modes are described in the following sections MN1902 Control System B 1 www baldormotion com B 1 1 Current Torque control Setting the control mode to Current Control configures the FlexDrive or Flex Drive as a torque amplifier as shown in Figure 50 Here a torque reference is obtained from a specified source m Mint host command profiled m High speed analog input not profiled m Analog input profiled m Fieldbus profiled The source provides a signal that can either be fed directly into the Torque controller only when using the high speed analog input source or through a profiler The high speed reference source is ideal for connecting to a motion controller e g NextMove PCI that will have already profiled the sign
102. n dimensions 3 6 mechanical 3 4 mounting 3 5 K Keyword summary C 1 L LED indicators DB On 7 5 Status display 7 2 M Mint keyword summary C 1 Mint WorkBench 5 4 Commissioning Wizard 5 7 digital I O tool 5 12 fine tuning tool 5 9 help file 5 4 other tools and windows 5 12 parameters tool 5 11 starting 5 5 Motor circuit contactors 3 16 connections 3 15 power cable 3 16 3 17 A 2 sinusoidal filter 3 17 Motor brake connection 3 19 Mounting 3 5 O Operation 5 1 connecting to the PC 5 1 installing software 5 1 offset tuning 3 34 5 3 power on checks 5 2 preliminary checks 5 2 starting 5 2 Options A 1 P PLC Task 6 7 defining conditions 6 7 enabling and downloading 6 8 Index MN1902 saving conditions 6 9 testing 6 9 Power 24V control supply 3 14 connections 3 8 disconnect and protection devices 3 11 input conditioning 3 11 input cycling 3 11 7 1 Sources 3 1 supply filters 3 12 A 6 Precautions 1 2 Preset moves 6 2 CAN amp Auxiliary I O option 6 6 controlling 6 6 defining 6 2 saving 6 9 testing 6 3 using digital inputs 6 3 Product Notice 1 2 Pulse amp Direction following 4 14 specification 8 7 8 11 X3 DIN4 5 4 6 X9 4 13 R Receiving and Inspection 2 2 Regeneration controlling 3 20 resistor 3 20 specification 8 5 X6 4 15 4 18 S Safety Notice 1 2 Specifications 8 1 115V 230V single phase models 8 2 230V
103. n the PLC Task is not in use it should be switched off to reduce processing power 3 Toactivate the PLC Task click Enable at the top of the screen Note The Plc button on the mode toolbar can also be used to enable or disable PLC Task even if the PLC Task tool is not currently selected The controller will now monitor all the conditions for the enabled actions If the logical result of any set of conditions becomes true the corresponding action will be performed An individual action can be disabled even while the PLC Task is running To disable an action that is not required clear the action s enable check box and click Apply Remember to disable the PLC Task when it is not required to reduce processing power Other functions If the Auto Enable PLC Task box is checked the PLC Task will be enabled automatically every time the drive is reset This option corresponds to the keyword PLCAUTOENABLE see the Mint help file for details The value in the PLC Time box defines how often the PLC Task is run This may be set in 5ms intervals to a maximum value of 1 second 1000ms If the evaluation of the PLC Task is not critical in your application it is advisable to set PLC Time to a large value This will reduce the overall processing time taken by the PLC Task The Gear Factor defines the gear factor used by the Fast Gear action see the Mint help file topic PLCGEARFACTOR for details The Jog Speed box can be used to enter a jog speed
104. ncoder input as a feedback input See the Mint help file for details 4 4 2 2 Pulse and Direction following The master encoder pulse and direction inputs accept 5V differential line driver RS422 signals from an external source The pulse frequency controls the speed and the state of the direction signal controls the direction of motion A positive direction voltage greater than 200mV will result in motion in one direction A negative direction voltage less than 200mV will result in movement in the opposite direction The Mint keyword AUXENCODERMODE bit 2 is used to configure X9 for pulse and direction operation If necessary the sense of the direction input can be reversed in software using the Mint keyword AUXENCODERMODE bit 0 See the Mint help file for details Note If X9 has been configured for pulse and direction input the alternative pulse and direction inputs available on connector X3 cannot be used See the Mint keyword MASTERSOURCE Pulse and direction Source Twisted pairs x9 Pulse Pulse GND Direction Direction GND DGND Connect internal shields to DGND bos Connect overall shield iim to connector backshells Figure 38 Pulse and direction connections 4 14 Input Output MN1902 www baldormotion com 4 4 3 Serial port X6 Pin aaee nsssrnsszmame 5 OV GND OV DGND FT Do not connect See caution below Description RS232 or RS485 RS422 connections on
105. nt WorkBench book Inside this is the Toolbox book Fine tuning tool The Commissioning Wizard calculates many parameters that allow the FlexDrive to provide basic control of the motor These parameters may need to be fine tuned to provide the exact response that you require The Fine tuning screen allows you to do this 1 Click the Fine tuning icon in the Toolbox on the left of the screen The Fine tuning window is displayed at the right ofthe screen This a 1 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 Position Speed and Current Click on Position Speed Current a tab to select it Click the tab for the type of tests you wish to perform Note Some tabs may not be available depending on the configuration mode you selected in the Commissioning Wizard 5 3 1 1 Fine tuning Position tab The position tab allows you to set position 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 FlexDrive To perform tests go to the Test Parameters area at
106. nt of an abort ABSENCODER To read the current EnDat or Hiperface encoder position ADCDEADBANDHYSTERESIS To set a hysteresis level for entering and leaving the deadband on the ADC inputs To set the deadband offset to be applied to an ADC input To read back the analog inputs currently in error ADCERRORMODE Controls the default action taken in the event of an ADC limit being exceeded on an associated channel To set the gain to be applied to an ADC input MN1902 Mint Keyword Summary C 1 www baldormotion com ADCMAX Sets the upper analog limit value for the specified analog input Sets the lower analog limit value for the specified analog input ADCMONITOR Specifies the analog inputs that an axis will monitor for analog limit checking To set the offset to be applied to an ADC input To zero trim the specified analog input ADCTIMECONSTANT To set the time constant of the low pass filter applied to an ADC input ASYNCERRORPRESENT To determine whether an asynchronous error is present To automatically execute a program on power up AUTOHOMEMODE To set the autohome mode for the specified configuration To set the autostart mode for the specified configuration To set or read the auxiliary encoder input AUXENCODERMODE To make miscellaneous changes to the auxiliary encoders AUXENCODERROLLOVER To count the number of wraps of the auxiliary encoder value AUXENCODERSCALE To set or read the scale factor for
107. nterrupts can be detected See the Mint help file Both inputs are fitted with Schmitt trigger devices Note The fast inputs are particularly sensitive to noise so inputs must use shielded twisted pair cable Do not connect mechanical switches relay contacts or other sources liable to signal bounce directly to the fast inputs This could cause unwanted multiple triggering 4 8 Input Output MN1902 www baldormotion com 4 3 5 Digital outputs X3 Connector X3 Pi Wme Wes Description Three general purpose optically isolated digital outputs Output current 50mA maximum each output Update intervals Immediate Software Mint programs LOOPTIME default 1ms DRIVEENABLEOUTPUT 18 DRIVEOKOUTPUT and GLOBALERROROUTPUT functions 20 Outputs controlled by functions MOVEOUT MOVEOUTX MOVEPULSEOUTX PULSEOUTX Programmable PLC Task functions Each optically isolated PNP output is designed to source current from the USR V supply as shown in Figure 31 The maximum saturated voltage across any of the outputs when active is 1 0VDC so they can be used as TTL compatible outputs If the outputs are used to directly drive a relay a suitably rated flyback 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 outputs can be written to directly using the Mint keyword OUTX for exam
108. number of the motor MOTORTEMPERATUREINPUT To assign a digital input as the motor overtemperature trip input MOTORTEMPERATURESWITCH To read the state of the motor overtemperature trip input z z o o o o Z Zu a E n n z o lt za D To set up a positional move to an absolute position MOVEBUFFERFREE To return the number of free spaces in the move buffer for the specified axis To attach or read back a 16 bit identifier from the move buffer MOVEBUFFERID MN1902 Mint Keyword Summary C 13 www baldormotion com To read a 16 bit identifier from the move buffer MOVEBUFFERLOW To set or return the number of free spaces in the move buffer before a move buffer low event is generated MOVEBUFFERSIZE To set or return the size of the move buffer allocated on the specified axis To return information about the move buffer To load a dwell move into the move buffer To load a digital output bit pattern into the move buffer MOVEOU To load a change of state for a specific digital output into the move buffer MOVEPULSEOUTX To load a pulsed change of state for a specific digital output into the move buffer MOVER To set up a positional move to a relative position MOVESTATUS To return information about the progress of the current move To set or read the node ID used by this node NODELIVE To determine if a CAN node on the bus is currently live or dead NODETYPE To add or remove a
109. o do not make any connection to them Note For CE compliance a three phase AC filter must be connected between the AC power supply and the FlexDrive If local codes do not specify different regulations use at least the same gauge wire for earth ground as is used for L and N 3 10 Basic Installation MN1902 www baldormotion com 3 4 3 3 4 3 1 3 4 4 Input power conditioning Baldor drives are designed for direct connection to standard single and three phase lines depending on model that are electrically symmetrical with respect to earth ground 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 FlexDrive has permanently connected power factor correction capacitors an input AC line reactor or an isolation transformer must be connected between the power factor correction capacitors and the FlexDrive m f the feeder or branch circuit that provides power to the FlexDrive 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
110. oduced on the FlexDrive are preset moves and the PLC task Basic operation of these two features are described in the following sections MN1902 Preset Moves amp PLC Task 6 1 www baldormotion com 6 2 6 2 1 Preset moves The FlexDrive can store 16 preset moves Flex Drive only If the CAN amp Auxiliary I O option is fitted 256 preset moves can be stored Presets can be selected and triggered using software Mint WorkBench or a Mint program or by using a combination of the digital inputs In Mint WorkBench the Presets tool displays an interactive table allowing you to set up the preset moves Mint WorkBench reads the current preset data from the FlexDrive whenever you switch to the Presets tool Preset tables can be saved in files on the PC and downloaded to the FlexDrive from Mint WorkBench For the following explanation the FlexDrive must be connected powered and ready to be enabled The FlexDrive must also be in Position Control Mode which can be selected using the Operating Mode Wizard in Mint WorkBench Defining a preset move 1 In the Mint WorkBench Toolbox click Application then click the Presets icon Existing presets will be read from the FlexDrive and Application displayed in the presets table For Help pres J 2 Each preset is shown on a separate row in the table To define or edit a preset click one of the preset numbers in the Index column gt 3 Onthe selected row click
111. oftware installation or Windows applications you may need further assistance for this stage of the installation Connecting the FlexDrive to the PC Connect the serial cable between a PC serial port often labeled as COM to the FlexDrive connector X6 RS232 RS485 Mint WorkBench can scan all the COM ports so you can use any port AN CAUTION The serial connector on the FlexDrive X6 can be configured as either RS232 or RS485 RS422 If this is the first time you are installing a FlexDrive then it is strongly recommended that you use RS232 to get started the preset factory setting and use RS485 later Pin 9 is used to carry 8V for powering a Baldor keypad peripheral Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply A suitable cable is available from Baldor catalog number CBL001 501 Installing the software The CDROM containing the software can be found separately within the packaging Insert the CDROM into the drive 2 After a few seconds the setup wizard should start automatically If the setup wizard does not appear select Run from the Windows Start menu and type d start where d represents the drive letter of the CDROM 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
112. olumn The word OR will change into a drop down box Select a logical operator from the list This operator will be used to evaluate the two conditions If the result of the logical evaluation is true the action will be performed 6 Click in the Condition 2 column The word False will change into a drop down box Select a condition by clicking on its name in the list 7 If necessary click in the second Ch column and select the required channel 6 3 1 2 Choosing the action to be performed 8 Click in the THEN Action column and choose the action that will performed when the conditions become true 9 If necessary click in the final Ch column and select the required channel MN1902 Preset Moves amp PLC Task 6 7 www baldormotion com 6 3 2 6 3 2 1 Enabling and downloading the actions Individual actions can be enabled by clicking in the appropriate check box in the Enable column When the PLC Task is activated only those actions that have been enabled will be evaluated 1 Setthe required check boxes in the Enable Golum Enable IF Condition 1 0 Digital Input Chn 3 D 9 Hardware Limit Fwd Axis 0 2 QOnldle Aie CJ 3 False Ol 4 False Now that you have configured and enabled all the conditions you require they must be downloaded to the FlexDrive l 2 Click Apply to download the conditions Apply The Enable button above the table must be in the on down position to activate the PLC Task Whe
113. omments www baldormotion com Thank you for taking the time to help us Comments MN1902 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 1479 646 4711 Fax 1 479 648 5792 Australia Japan Australian Baldor PTY Ltd Baldor Japan Corporation Tel 61 2 9674 5455 Tel 8145 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 Tel 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 Il Il Printed in UK LT0160A05 Baldor UK Ltd
114. onnection to AC power supplies However this filter has been tested and is suitable for use with a 24VDC input as indicated in Figure 6 Do not attempt to use an alternative AC power filter as a 24VDC input filter Customer supplied 24V filter 24VDC fused optional 24V GND If 24V wires are Incoming safety shielded earth ground PE earth ground outer shields using 360 clamps connected to backplane Single phase model An AC input voltage is indicated on the label of filter shown for illustration FI0014A00 but it may also be used with a 24VDC input purposes Figure 6 Customer supplied 24V supply connections 3 14 Basic Installation MN1902 www baldormotion com 3 5 Motor connections The motor can be connected directly to the FlexDrive or through a motor contactor M Contactor Location Connector X1 X1A Part number FDHTA FDH2A FDH2A15 FDH4A art number FPHAA FPH2A FPH2A15 FPH4A Nominal output voltage 160VDC j920VDC j9320VDC 565 650V Output voltage range 135 176VDC e 350VDC SO 355VDC a 746VDC Motor Se a ee ee Ree SCS s E Unshielded E lengths should be nie a tad as short as E ea possible Psy E 1 E Fog a uM 1 log oy A i D 1 1 i Optional motor eg t circuit contactors j 5 E See Thermal T adi switch g E es i i 3
115. optional filter is included The time constant of this filter can be set using keyword KVDERIVTCONST By default the filter is turned off with KVDERIVTCONST set to zero When the FlexDrive is set to positioning mode CONFIG is _cf SERVO the profiler acceleration is fed forward by gain KACCEL to give a contribution to the final torque demand The speed control calculation is performed every 250us As with the position controller the gain values KVPROP KVINT KVDERIV and KACCEL 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 Profiler acceleration Acceleration feedforward term Position control Velocity Speed demand Torque demand KVDERIVTCONST Measured speed VEL Figure 55 Speed control system MN1902 Control System B 7 www baldormotion com B 2 3 Torque controller and feedback The torque controller shown in Figure 56 is a PI controller Gains are set using the Mint keywords KIPROP and KIINT The torque demand is scaled into a current demand This is compared with the measured current obtained from the current sensors and the error is fed into the PI control calculation The resulting value forms the PWM signal that is fed through the power stage into the motor windings The gain values KIPROP and KINT must be tuned for a specific motor This is performed automatically by the Comm
116. or a specified number of milliseconds To enable or disable the relay To read the value of a remote analog input ADC REMOTEADCDELTA To control the rate of change on a remote analog input before a REMOTEADC message is sent REMOTEIN To read the state of all the digital inputs on a remote CAN node REMOTEINBANK To read the state of a bank of digital inputs on a remote CAN node To set or read the CANopen PDO inhibit time REMOTEINX To read the state of individual digital inputs from a remote CAN node To control the update mode for a remote node REMOTEOBJECT To access the Object Dictionary of any CANopen node present on the network REMOTEOUT To control the state of digital outputs on a remote CAN node REMOTEOUTBANK To read the state of a bank of digital outputs on a remote CAN node REMOTEOUTX To control the state of individual digital outputs on a remote CAN node REMOTEPDOIN To request data from a node in the form of a PDO message REMOTEPDOOUT To force a Baldor controller node to transmit a variable length PDO message with a specific COB ID The PDO will contain up to 64 bits of data that can be passed in the form of two 32 bit values MN1902 Mint Keyword Summary C 17 www baldormotion com REMOTESTATUS To set or read the status register on a remote CAN node RESET To clear motion errors set the position to zero and re enable the drive RESETALL To perform a reset on all axes RES
117. or two conditions called Condition 1 and Condition 2 If the result of this logical comparison is true the action is triggered Condition 2 does not need to be defined if it is not required 1 In the Mint WorkBench Toolbox click Application then click the PLC Task icon Existing actions will be read from the FlexDrive Application and displayed in the PLC Task table Each action is shown on a For Help pres separate row in the table 2 Choose a row and click in the IF Condition 1 column The word False will change into a drop down box y Ls 3 Select a condition by clicking on its name in the list For example PLC Task selecting Digital input will mean that a digital input will be monitored to check if it is active A full description of each Condition is provided in the PLCCONDITION topic of the Mint help file 4 Click in the adjacent Ch column and choose the related channel if required For example if Digital input was selected choose which digital input will be monitored Configuring Condition 2 optional The Operator and Condition 2 columns need to be changed only if you want the action to depend on the logical evaluation of two conditions Condition 1 and Condition 2 By leaving the Operator column set to OR and the Condition 2 column set to False the state of Condition 1 will be used to trigger the action If you do not wish to configure the second condition go to section 6 3 2 5 Click in the Operator c
118. otion com A 1 2 Motor power cables Cable Cable assembly Baldor catalog ode rated current description number Power Cable CBL050 501 EE by se meter or on no connectors 100m drum CBLO15SP 12 CBLO25SP 12 CBLO30SP 12 CBLO50SP 12 12 Amps Power Cable CBLO61SP 12 Assembly CE style threaded CBLO75ST 12 motor connector CBL100SP 12 motor end only CBL150SP 12 CBL152SP 12 CBL200SP 12 CBL229SP 12 Power Cable CBL051 501 Available by the meter or on no connector 100m drum CBL015SP 20 CBL025SP 20 CBLO30SP 20 CBL050SP 20 20 Amps ESAME CBLO61SP 20 CE style threaded CBLOTSSP 20 CBL091SP 20 motor connector CBL100SP 20 motor end only CBL150SP 20 CBL152SP 20 CBL200SP 20 CBL229SP 20 35 Amps Power Cable CBL052 501 Available by the meter or on p no connector 100m drum Available in North and South America only A 1 3 Motor power cable part numbers For easier installation it is recommended that a color coded Baldor motor power cable is used A description of a Baldor rotary motor power cable catalog number is shown here using the example number CBL025SP 12 The item is a cable 025 Indicates the length in this example 2 5 meters Various see section A 1 2 SP The cable is a Servo motor Power cable ae o 12 Current rating of 12A 20 20A Motor power cables include the motor power connector Larger motors requiring 35A cable normally use terminal box connections
119. perform fine tuning Give a clear description of the symptoms that you can observe for example the Status display error messages displayed in Mint WorkBench or the current value of any of the Mint error keywords AXISERROR AXISSTATUS INITERROR MISCERROR and DRIVEERROR m The type of motion generated in the motor shaft m Give alist of any parameters that you have setup for example the motor data you entered selected in the Commissioning Wizard the gain settings generated during the tuning process and any gain settings you have entered yourself Power cycling the FlexDrive The term Power cycle the FlexDrive is used in the Troubleshooting sections On models with a customer supplied 24V supply remove the 24V supply wait for the FlexDrive to power down completely all Status LED segments will turn off then re apply the 24V supply On models with an internally generated 24V supply remove the AC power supply wait for the FlexDrive to power down completely all Status LED segments will turn off then re apply AC power MN1902 Troubleshooting 7 1 www baldormotion com 7 2 FlexDrive indicators 7 2 1 Status display The Status LED display indicates general FlexDrive status information Some characters will flash to indicate an error Drive comms watchdog Interprocessor communications failure This is potentially a severe problem if it occurs repeatedly Communications failure could indicate a proc
120. ple OUTX 271 The sense of the outputs can be configured in Mint WorkBench and their states are displayed in the Spy window FlexDrive X3 Load USR V Relay with Va A flyback diode iis shown NEC PS2562L 1 OUTX x Figure 31 X3 digital output circuit DOUTO shown MN1902 Input Output 4 9 www baldormotion com 4 3 6 Relay output digital output X3 Note Connector X3 pins 4 amp 5 Name General purpose relay Description Relay switch contacts controlled by Mint rated at 1A 30VDC Update intervals Immediate Software Mint programs LOOPTIME default 1ms DRIVEENABLEOUTPUT DRIVEOKOUTPUT and GLOBALERROROUTPUT functions Outputs controlled by functions MOVEOUT MOVEOUTX MOVEPULSEOUTX PULSEOUTX Programmable PLC Task functions The factory preset assignment for the relay is as the global error output signal see the Mint keyword GLOBALERROROUTPUT When an error occurs the relay is de energized and the contacts open When the error is cleared the relay is re energized and the contacts close The relay can be also be controlled directly by the Mint keyword RELAY When the relay is energized RELAY on the contacts close When the relay is de energized RELAY off the contacts open The relay output may also be considered as a digital output so can be controlled directly using the Mint keyword OUTX for example OUTX 3 1 FlexD
121. previously mentioned Remember that it is the instructions of installation and the product that should comply with the directive MN1902 CE amp UL D 1 www baldormotion com D 1 2 Declaration of conformity C BALDOR CE Date 01 0602 EC Declaration of Conformity Ref DE00011 001 Manufacturer Baldor UK Limited Address Mint Motion Centre Hawkley Drive Bristol Distribution Centre Bristol BS32 OBF United Kingdom This is to certify that MintDrive FlexDrive and Flex Drive single axis Servo and Positioning Drives being one of MDH1Axxxx xxxx FPH1AXxxx Xxxx FDH1Axxxx xxxx MDH2Axxxx xxxx FPH2AXXXX XXxx FDH2AXxxx xxxx MDH4Axxxx xxxx FPHAAXXXxx Xxxx FDHAAxxxx xxxx built after the 1st January 2002 when used in accordance with the guidance given in the corresponding Installation Manuals MN1901 MintDrive or MN1902 FlexDrive and Flex Drive conforms with the protection requirements of Council Directive 89 336 EEC relating to Electromagnetic Compatibility by the application of the following standards Standard Title Comments EN61800 3 1996 Adjustable speed electrical power drive Emissions amp Immunity comply systems Part 3 EMC Product standard with both the first domestic and second including specific test methods industrial environments and in detail with the following basic standards Standard Title EN 61800 3 1996 Conducted Emissions EN 61800 3 1996 Radiated Emissions EN 61
122. protected or rated for the application If required by the application additional external resistors connected to R1 and R2 will be connected in parallel with the internal resistor Controlling regeneration Some regeneration resistor assemblies include an overload switch to indicate when too much power is being dissipated by the resistor This switch can be wired to a digital input on the FlexDrive Using the Mint WorkBench Digital I O tool the input can be configured to be the brake trip input This allows the FlexDrive to respond to resistor overload conditions The Mint keyword DBEXTTRIPINPUT can also be used to configure a digital input for this purpose On three phase FlexDrive models the operation of the regeneration resistor can be controlled by further Mint keywords These also begin with the letters DB for example DBEXTPEAKPOWER See the Mint help file for details Alternatively a thermostatic switch on the regeneration resistor can be used to disconnect the circuit breaker on the drive s ACpower input This will prevent the drive from operating if the regeneration resistor overheats 3 20 Basic Installation MN1902 www baldormotion com 3 7 Feedback connections Two feedback options are available for use with linear and rotary motors commutating encoder or resolver Confirm the catalog number of your FlexDrive see section 2 2 1 to ensure you are wiring the correct feedback device There a
123. protocols have been used This DIP switch procedure will clear bit 5 restoring normal serial communication 1 Remove 2 3 Reapply power Mint program power with Auto command will not run 5 On Off 8 9 On Figure 23 Preventing the Auto command from running a stored Mint program or restoring normal serial communication 3 36 Basic Installation MN1902 Input Output 4 4 1 Introduction This section describes the various digital and analog input and output capabilities of the FlexDrive with descriptions of each of the connectors on the front panel The following conventions will be used to refer to the inputs and outputs VO ctiilxc6ie nM Input Output DIN Digital Input DOUT ns Digital Output AIN sce hers ots Analog Input AOUT ee Analog Output CH aces eth Encoder channel 4 2 Analog I O The FlexDrive provides as standard m 1 analog input on the connector block X3 demand input 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 individual shielded screened cable a twisted pair cable in the case of differential operation with an overall shield The overall shield should then be connected to the chassis at one end only No other connect
124. quire 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 AN WARNING Do not touch any circuit board power device or electrical connection before you first ensure that no high voltage is present at this equipment or other equipment to which it is connected Electrical shock can cause serious or fatal injury Only qualified personnel should attempt to start up program or troubleshoot this equipment AN WARNING Be sure the system is properly earthed grounded before applying power Do not apply AC power before you ensure that earths grounds are connected Electrical shock can cause serious or fatal injury AN WARNING Be sure that you are completely familiar with the safe operation and programming of this equipment This equipment may be connected to other machines t
125. r Measured speed Measured position Figure 52 Control structure in Position control Pulse and Direction B 4 Control System MN1902 www baldormotion com B 1 4 Position control Flex Drive only Setting the control mode to Position Control configures the Flex Drive as a full positioning system as shown in Figure 53 Here the Flex Drive can be used to command many different position profiles Preset moves Absolute or relative moves Incremental absolute or relative moves Jog control Following Gearing Homing The profiler generates a position demand signal that smoothly changes between successive targets The profile also generates corresponding speed and acceleration demand signals The position and speed demand signals are 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 To improve the tracking performance of the speed controller the profiler acceleration demand is fed in at this point Finally the torque dem
126. r e g NextMove PCI that will have already profiled the signal and will provide optimum loop closure 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 Mint WorkBench Parameters tool The speed demand signal is fed into the speed controller and used together with the speed measured from the feedback device to generate a torque demand signal If the speed controller is tuned correctly the measured speed will accurately track the speed demand Finally the torque demand signal is fed into a torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current measured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Speed profiler Speed Torque Speed demand Speed demand reference gt controller Torque PWM Power stage controller motor High speed Measured speed speed reference Figure 51 Control structure in Velocity control mode MN1902 Control System B 3 www baldormotion com B 1 3 Position control Pulse and Direction Setting the control mode to Position Control Pulse and Direction configures the FlexDrive 7 as a positioning system as shown in Figure 52 capable of
127. ration resistor Dynamic Brake resistor The 2 5A and 5A FlexDrive both have an internally fitted regeneration resistor For 7 5A 15A 20A and 27 5A FlexDrive an external regeneration resistor must be installed to dissipate excess power from the internal DC bus during motor deceleration When regeneration causes the DC bus voltage to rise by more than about 10 50 volts model dependent above the maximum allowable DC bus voltage the regeneration resistor is automatically connected When this happens the yellow DB On LED on the front panel of the FlexDrive will illuminate The FlexDrive has an additional emergency overvoltage trip system However this must not be used as a means of protecting the drive from regeneration since the trip occurs at a much higher voltage than the regeneration switching voltage Allowing regeneration to cause regular overvoltage trips increases the chance of permanent damage to the FlexDrive Suitable regeneration resistors are listed in section A 1 9 AN WARNING A regeneration resistor may generate enough heat to ignite combustible materials To avoid fire hazard keep all combustible materials and flammable vapors away from the resistors The regeneration resistor should be mounted near the top of an enclosure to maximize heat dissipation Baldor regeneration resistors are neither internally fused nor thermally protected and under extreme conditions can cause a fire hazard if not suitably
128. rdware limit A reverse limit has been activated but no error has been generated See AXISERROR and or AXISSTATUS to determine which applies This state can exist at the same time as a forward limit with no error causing the resulting symbol to appear as H the same symbol as Hold 4 Forward software or hardware limit A forward limit has been activated See AXISERROR and or AXISSTATUS to determine which applies 4 Forward software or hardware limit A forward limit has been activated but no error has been generated See AXISERROR and or AXISSTATUS to determine which applies This state can exist at the same time as a reverse limit with no error causing the resulting symbol to appear as H the same symbol as Hold Firmware being updated horizontal bars appear sequentially New firmware is being downloaded to the drive Initialization error An initialization error has occurred at power on See the Error Log or INITERROR topics in the help file Initialization errors should not normally occur li g i 2 a i S B User defined symbols can be made to appear using the Mint keywords LED and LEDDISPLAY 7 4 Troubleshooting MN1902 www baldormotion com 7 2 2 DB On Regeneration LED Bo The front panel DB On LED indicates regeneration activity Power is being dissipated into the regeneration resistor 7 2 3 Communication Status display is Check that the customer supplied 24VDC power supply is connected blank correctl
129. re 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 shields must be insulated Some larger D type connector shells may be obstructed by neighboring connector X3 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 supplied An encoder output signal is available on connector X7 for supplying other equipment FlexDrive models with the resolver option provide a simulated encoder output while the encoder based FlexDrive duplicates the encoder signals entering X8 See section 4 4 1 for details FlexzDrive only Flex Drive models with the resolver or incremental encoder option are capable of dual encoder feedback a technique where two encoders are used to control a single axis The second feedback input is derived from the master auxiliary encoder input on connector X9 section 4 4 2 See the Mint help file for details MN1902 Basic Installation 3 21 www baldormotion com 3 7 1 Resolver option X8 The resolver connections are made using the 9 pin D type male
130. read individually using the associated Mint keyword INX for example INX 7 and can be configured for many user definable functions Each input circuit contains an opto isolator as shown in Figure 27 Inputs DIN4 and DIN5 can also be used as fast inputs see section 4 3 4 The state of each digital input is displayed in the Mint WorkBench Spy window FlexDrive he NECPS2565 Active high DINx 24VDC 420 Active low DINx 0V CREF 0V CREF 24VDC 420 Figure 27 X3 digital input circuit DINO shown MN1902 Input Output 4 5 www baldormotion com 4 3 2 CREF and digital inputs Pin 7 CREF controls the sense of all the digital inputs X3 pins 9 to 17 and should be permanently wired dependent on the user requirements Active high connect OV to pin 7 The digital inputs will be active when a voltage of 24VDC greater than 12VDC is applied to them and will sink a current of approximately 5mA each Active low connect 24VDC to pin7 The digital inputs will be active when grounded less than 2V and will source a current of approximately 5mA each The 24VDC supply is from a customer supplied 24VDC supply that should have a continuous current capability of 1 75A The sense of the inputs can be configured in Mint WorkBench or controlled individually in Mint using the keyword INPUTACTIVELEVEL See section 3 8 for more information about
131. rial communication 424 ov BALDOR gt Customer supplied Toregen 24V resistor Dynamic 2 Drive brake enable switch 24V OV Demand input Motor Model shown FDH2A07TR RN23 This model requires an external regeneration resistor and customer supplied 24V supply see sections 3 6 and 3 4 7 Some models contain an internal 24V supply and or an internal regeneration resistor Demand input may be differential or single ended See section 4 2 1 The encoder output X7 would normally be connected to a motion controller not shown Motor represents a typical Baldor BSM motor Linear motors may also be controlled by FlexDrive Shield earth ground clamps are not supplied Figure 43 Example minimum system wiring MN1902 Input Output 4 19 www baldormotion com 4 6 Option connectors If there are additional connectors on the front panel of your FlexDrive that have not been described in previous sections these are part of a factory fitted option You will need to refer to the extra manual supplied with your FlexDrive for details of the option s connectors 4 20 Input Output MN1902 5 1 5 1 1 5 1 2 Operation 5 Introduction Before powering the FlexDrive 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 FlexDrive If you do not have experience of s
132. rive Internal relay Control circuitry Figure 32 Relay contact outputs The internal relay has a limited lifetime and is not intended for continuous cyclical operation If relay operations are required more frequently than 4 5 times per hour it is recommended to use one of the digital outputs to control a replaceable external relay 4 10 Input Output MN1902 www baldormotion com 4 4 Other I O 4 4 1 Encoder output X7 Pin Ram 7000 Encoder Out X7 sje sje o 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 or FlexDrive Using connectors X7 and X8 multiple FlexDrive units with the encoder feedback option can be daisy chained together 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 resolver feedback option is fitted 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
133. rotected but fuses or circuit breakers are required in the input lines for cable protection depending on local codes and regulations A power disconnect should be installed between the AC supply and the input of the FlexDrive for a fail safe method to disconnect power On models with the internally generated 24VDC logic supply catalog numbers FDHxxxxx xxx0 and FPHxxxxx xxx0 the FlexDrive will remain operational until the internal bus voltage is depleted Position and I O information will then be lost On models with an external customer supplied 24VDC logic supply catalog numbers FDH xxxxx xxx3 and FPHxxxxx xxx3 position and I O information will be retained while the 24V supply is present Note AResidual Current Device RCD must not be used for fusing the drive A circuit breaker or fuse must be used All interconnection wires should be in metal conduits between the FlexDrive 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 Baldor drives are designed to be powered from standard single and three phase lines depending on model that are electrically symmetrical with respect to earth ground Due to the importance of system earthing grounding for increased reliability earthing grounding methods are shown in
134. rs css cov tens Le ee EP ev 7 2 72 1 Status display sos oo ERA wa hae Se he EUM es Ee Shi uU 7 2 7 2 2 DB On Regeneration LED 000 c cece eee 7 5 7 2 3 Communication iiie perg Rega er Ee RR EROR 7 5 7 24 POWO ON Loir XEM BEA ES DEER OOM ADE ote eee Ad RE e 7 6 1 2 5 TUNING i32 obese be Wowace hou ade bu EA REB seed 7 6 7 2 0 Status display shows a digit or E 2 2 eee 7 6 SPECIICAHONS uiia one fedes sed taal ee een ates 8 1 8 1 Introduction s iaia aa ees 8 1 8 1 1 AC input power and motor output single phase models 8 2 8 1 2 AC input power and motor output 230V three phase models 8 3 8 1 3 AC input power and motor output 230 460V three phase models 8 4 MN1902 Contents iii 8 1 4 Customer supplied 24VDC supply input 000 00 ee 8 5 8 1 5 Regeneration issuer R eee ha Na a Ge ee EE 8 5 8 1 6 Analog input XB x oc cee des ste pee e ER Si crac bye bre e Ge 8 6 8 17 Digital inputs X3 0 eee eee eee 8 7 8 1 8 Digital outputs X3 ii a tenes 8 7 8 1 9 Relay general purpose output X3 000 2 eee eee 8 8 8 1 10 Serial RS232 interface X6 6 eee eee 8 8 8 1 11 Serial RS485 interface X6 6 eee ee 8 8 8 1 12 Encoder output simulated X7 00 0 0 eee 8 9 8 1 13 Resolver feedback option X8 06 0 0 cece eee eee 8 9 8 1 14 Encoder feedback option X8 0 000 eects 8
135. s cycles per turn with absolute positioning resolution of 2048 or 4096 steps Hiperface Sin Cos differential inputs and data input Many other encoder specifications are supported contact Baldor 7V 11V supply dependent 200mA max 30 5m 100ft Output power supply to encoder Maximum recommended cable length 8 1 17 Master auxiliary encoder input X9 All models All models Operating mode A B quadrature Sampling interval Software selectable 1 2 Output power supply to encoder 5V 100mA max 8 10 Specifications MN1902 Eme m E Maximum input frequency 2 5 Bec mo E m www baldormotion com 8 1 18 Pulse and direction input X9 All models Unit All models Pulse and direction signals mH RS422 Sampling interval ms Software selectable 1 2 8 1 19 Environmental All models Unit All models Minimum 0 32 Maximum 40 104 Derate 2 5 C between 2 5 1 8 F between 40 C and 50 C max 104 F and 122 F max Storage temperature range ir 25 to 70 13 to 158 Humidity 10 90 non condensing according to DIN40 040 IEC144 Above 31 C 87 F derate linearly to 50 relative humidity at 40 C 104 F Maximum installation altitude 1000 above m s l Derate 1 1 100m over 1000m 3300 Derate 1 1 330ft over 3300ft 10G according to DIN IEC 68 2 6 29 Vibration 1G 10 150Hz according to DIN IEC 68 2 6 29 MN1902 Specifications 8 11 www bal
136. s has an effect on the sense of DINO to DIN7 Either method provides a suitable drive enable input Active high To cause the digital inputs to be active high active when a voltage of 24VDC is applied to them connect 24VDC to pin 9 and OV to pin 7 CREF Active low To cause the digital inputs to be active low active when grounded connect 24VDC to pin7 CREF and OV to pin 9 The drive enable connection can be wired directly or through an intermediate switch If a Switch is used it should always be used to switch the signal to pin 9 with the signal to pin 7 CREF being hard wired The sense of the digital inputs can also be configured in Mint WorkBench using the Digital inputs tab of the Digital I O tool Alternatively the Mint INPUTACTIVELEVEL keyword can be used to select the sense of all the digital inputs except drive enable The state of the drive enable input is displayed in the Mint WorkBench Spy window It can also be checked but not set using the Mint keyword DRIVEENABLESWITCH See the Mint help file for details The drive enable input is rising edge triggered but is only sampled every 1ms For the drive to become enabled the input signal must have been inactive off for at least one sample and active on at the next sample Care must be taken to avoid signal bounce on the drive enable input since any falling edge detected after the drive has become enabled will disable the drive immediately The drive cannot then be r
137. s on connector block X3 m 3 general purpose outputs on connector block X3 m 1 relay general purpose output on connector block X3 A digital input can be used to support many typical input functions Error input Reset input Stop input Forward limit Reverse limit Interrupts controlled from Mint Regeneration resistor Dynamic Brake overtemperature input PLC Task input conditions General purpose use Flex Drive only Home input Index selection and triggering for preset move types wm DIN4 and DIN5 are fitted with Schmitt trigger devices and can be configured using Mint for position capture of the axis or the master auxiliary encoder positions See section 4 3 4 The main axis fast input assigned using the Mint keyword FASTSELECT can also be used as a trigger for point to point move types See the Mint help file for details Additional I O is available on connector X12 if the CAN amp Auxiliary I O option is fitted See MN1908 CAN amp Auxiliary I O option for Flex Drive and MintDrivel 4 4 Input Output MN1902 www baldormotion com 4 3 1 Digital inputs X3 Pin Name Tatars S pwEmh 1 we mes Description Eight general purpose optically isolated AC digital inputs One committed drive enable input Drive Enable Sampling interval Drive Enable input 1ms DINO DIN7 Equivalent to LOOPTIME default 1ms d o The digital inputs DINO DIN7 can be
138. sensors ee D HOMEINPUT To set a digital input to be the home switch input for the specified axis Apply an offset to the homing sequence HOMEPHASE To find the phase of the homing sequence currently in progress HOMEPOS To read the axis position at the completion of the homing sequence To define a reference position for homing moves HOMESPEED To set the speed for the initial seek phase of the homing sequence To set or read the status of a homing sequence To return the state of the home input To set the homing mode to be performed at start up MN1902 Mint Keyword Summary C 9 www baldormotion com IDLE Indicates if a move has finished executing and the axis has finished moving IDLEMODE To control the checks performed when determining if an axis idle idle conditions before becoming idle INITWARNING Returns the sum of a bit pattern describing initialization warnings generated at start up UTACTIVELEVEL To set the active level on the digital inputs UTMODE To set or return the sum of a bit pattern describing which of the user digital inputs should be edge or level triggered UTNEGTRIGGER To set or return the user inputs that become active on negative edges UTPOSTRIGGER To set or return the user inputs that become active on positive edges INSTATE To read the state of all digital inputs INSTATEX To read the state of an individual digital input To read the state of an individual
139. so a motor power connector is not required A 2 Accessories MN1902 www baldormotion com A 1 4 Resolver feedback cables This table lists part numbers of Baldor resolver feedback cables for use with the FlexDrive Length Cable assembly description Catalog number Lom wm Resolver Feedback Cable CBL044 501 Available by the meter no connectors or on 100m drum CBLO15SF R CBLO25SF R CBLO30SF R CBLOSOSF R CBLO61SF R CBLO75SF R CBLO91SF R CBL100SF R CBL150SF R CBL152SF R CBL200SF R CBL229SF R Feedback Cable Assembly CE style threaded motor connector motor end only CBLO15SF R1 CBLO25SF R1 CBLO30SF R1 CBLOSOSF R1 CBLO61SF R1 CBLO75SF R1 CBLO91SF R1 CBL100SF R1 CBL150SF R1 CBL152SF R1 CBL200SF R1 CBL229SF R1 Feedback Cable Assembly CE style threaded motor connector and 9 pin D type drive connector Available in North and South America only MN1902 Accessories A 3 www baldormotion com A 1 5 Encoder Hall feedback cables This table lists part numbers of Baldor encoder feedback cables for use with the FlexDrive Cable assembly description Baldor catalog number Encoder Feedback Cable CBL043 501 Available ae ae the meter no connectors or on 100m drum Feedback Cable Assembly CBLO25SF E 2 5 8 2 CE style threaded motor connector motor end only CBLO15SF E1 CBLO25SF E1 CBLOSOSF E1 CBLO50SF E1 Feedback Cable Assembly CBL061SF E1 CE style threaded motor
140. t the PC serial port to which the drive is connected If you are unsure which PC serial port is connected to the drive select Scan all serial ports Click Scan to search for the FlexDrive When the search is complete click on FlexDrive 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 FlexDrive is not listed check the serial lead between the FlexDrive and the PC and that the FlexDrive is powered correctly Click Scan to re scan the ports 5 6 Operation MN1902 www baldormotion com 5 2 3 5 2 4 5 2 5 Commissioning Wizard Each type of motor and drive combination has slightly different performance characteristics Before the FlexDrive can be used to control the motor accurately the FlexDrive must be tuned This is the process where the FlexDrive powers the motor in a series of tests By monitoring the feedback from the motor s resolver or encoder and performing a number of calculations the FlexDrive can make small adjustments to the way it controls the motor This information is stored in the FlexDrive EEPROM and can be uploaded to a file if necessary The Commissioning Wizard provides a simple way to tune the FlexDrive and create the necessary configuration information for your drive motor combination so this is
141. ta bits 1 stop bit No parity Hardware handshaking lines RS232 RTS and CTS must be connected This configuration can be changed if required The RS232 connections are brought out onto a 9 pin male D type connector 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 6Kbaud X6 COM RXD 2 2 RXD TXD 3 3 TXD 9 pin FlexDrive GND 5 5GND Computer DTE COM Port RTS 7 7RTS DCE DTE CTS 8 8CTS Connect overall shield to connector backshell Figure 39 RS232 serial port connections The maximum recommended cable length is 3m 10ft at 57 6KBaud the factory preset rate When using lower Baud rates longer cable lengths may be used up to maximum of 15m 49ft at 9600 Baud 4 16 Input Output MN1902 www baldormotion com 4 4 5 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 a FlexDrive 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 40 Four wire RS485 may be used for single point to point applications involving only one Baldor controller
142. tance 230 460VAC three phase models 7 5A 27 5A Catalog number FDHA FPH4 Switching threshold Vin 400VAC VDC on off 750 on off 750 Vin 460VAC Wewepmwe powers ww oe ee C mr 9 3 LC MENU switching current WemumbeiRemwe Wi 09 Note 2 5A models FDH4A02 and FPH4A02 contain an internal 2000 300W resistor 5A models FDH4A05 and FPH4A05 contain an internal 2000 300W resistor 8 1 6 Analog input X3 All models Unit All models Type Differential Common mode voltage range 10 Common mode rejection 40 Input impedance Equivalent resolution Sampling interval Software Mint programs High speed demand reference signal ES oew e includes sign bit 8 6 Specifications MN1902 www baldormotion com 8 1 7 Digital inputs X3 All models Input voltage Active high Nominal Minimum All models Opto isolated DC inputs 24 12 Input voltage Active low VDC Nominal 0 Maximum 2 5 1 50 Input current approximate per input Sampling interval Maximum pulse input frequency DIN4 pulse and direction mode Minimum pulse width DIN4 DIN5 pulse and direction mode 8 1 8 Digital outputs X3 All models Output current maximum each output Update interval Software Mint programs Equivalent to LOOPTIME 1ms default or 2ms All models Immediate DRIVEOKOUTPUT DRIVEENABLEOUTPUT GLOBALERROROUTPUT MOVEOUT MOVEOUTX MOVEPULSEOUT
143. tch input becoming active MN1902 Mint Keyword Summary C 11 www baldormotion com LIMITREVERSE To return the state of the reverse limit switch input for the given axis LIMITREVERSEINPUT To set the user digital input configured to be the reverse end of travel limit switch input for the specified axis LOADDAMPING To define the equivalent viscous damping coefficient for the motor and load To define the combined inertia of the motor and load To set the servo loop update interval in microseconds To set or read the channel of the input device used for gearing MASTERDISTANCE To set the distance on the master axis over which the slave will travel for a segment in master slave move types To set or read the source of the input device used for gearing MAXSPEED To set a limit for the speed demanded on an axis MISCERROR To read or clear the miscellaneous error flag MISCERRORDISABLE To enable or disable miscellaneous errors calling the error event MOTORBRAKE To manually override motor brake control MOTORBRAKEDELAY To specify engage disengage delays associated with motor brake control MOTORBRAKEMODE To activate or deactivate motor brake control MOTORBRAKEOUTPUT To specify an output to be used as a control signal for a braked motor To set or read the number of encoder lines pre quadrature for the motor MOTORFEEDBACKOFFSET To set or read the electrical angle at which the absolute position
144. ternative to the derivative term a velocity feedback term is available by setting keyword KVEL To improve the tracking performance of the position controller the profiler speed is fed forward by gain KVELFF to give a contribution to the final speed or torque demand The profiler acceleration is fed forward by gain KACCEL to give a contribution to the final speed demand The position control calculation is performed every 500us The gain values KPROP KINT KDERIV KVEL KVELFF and KACCEL must be tuned for each application This can either be performed automatically within the Commissioning Wizard or manually using the Fine tuning tool in Mint WorkBench Profiler speed Velocity feedforward term VELDEMAND KPROP Following rror Profiler position T FOLERROR POSDEMAND Integral gain term t KINT f O gt Derivative gain term d KDERIV dt Speed demand it Velocity feedback term Measured speed VEL Measured position POS Figure 54 Position control system B 6 Control System MN1902 www baldormotion com B 2 2 Speed controller The speed controller shown in Figure 55 is also a PID controller Gains are set using the Mint keywords KVPROP KVINT and KVDERIV The speed is compared with the measured speed and the error is fed into the PID control calculation The result forms the torque demand for the torque controller To improve the performance of the derivative term an
145. the auxiliary encoder input AUXENCODERSPEED Specifies a virtual speed reference for the auxiliary encoder To read the velocity of the auxiliary encoder input AUXENCODERWRAP To set or read the encoder wrap range for the auxiliary encoder input AUXENCODERZEROENABLE To re enable Z pulse capturing on the auxiliary encoder AUXENCODERZEROLATCHMODE To control the latching mechanism for the auxiliary encoder s Z latch AUXENCODERZEROPOSITION To read the auxiliary encoder position at the last Z capture To read the state of the auxiliary encoder s Z latch C 2 Mint Keyword Summary MN1902 www baldormotion com To read back the motion error To return the current mode of motion encoder feedback systems AXISWARNINGDISABLE Allows individual axis warnings to be enabled and disabled To enable or disable bridge circuit compensation BRIDGEERRORCURRENT To set the current parameter used when compensating for non linearities in the drive s PWM bridge BRIDGEERRORVOLTAGE To set the voltage parameter used when compensating for non linearities in the drive s PWM bridge To specify which fieldbus is to be used as the default BUSCOMMANDMASK Defines a bit mask for CANopen DeviceNet and PROFIBUS Command telegrams BUSEVENT Returns the next event in the bus event queue of a specific bus BUSEVENTINFO Returns the additional information associated with a bus event BUSNODE To set or read the node ID used by this no
146. the drive enable input These stages should be read and followed in sequence Power sources An AC power source IEC1010 over voltage category III or less in the installation area is required This will need to be single or three phase depending upon the type of FlexDrive An AC power filter is required to comply with the CE directive for which the FlexDrive was tested see section 3 4 5 If the FlexDrive requires an external customer supplied 24VDC logic supply then this must be a regulated power supply with a continuous current supply capability of 1 75A 4A power on surge A 24V filter may be required to comply with the CE directive for which the FlexDrive was tested see section 3 4 5 Hardware requirements The components you will need to complete the basic installation are The motor that will be connected to the FlexDrive A motor power cable A resolver or encoder feedback cable and Hall cable for linear motors With some applications there may be a requirement for a regeneration resistor Dynamic Brake Note Without the regeneration resistor the drive may produce an overvoltage fault All FlexDrive models have overvoltage sensing circuitry but only 2 5A and 5A models catalog numbers FDHxxxxxB xxxx and FPHxxxxxB xxxx have an internal regeneration resistor For 7 5A 15A 20A and 27 5A models a regeneration resistor must be purchased separately if required See Appendix A MN1902 Basic Installation 3 1
147. there will typically be a certain amount of overshoot Using the Fine tuning tool check the amount of overshoot you get with the acceleration and demand speeds being used in your application Positional Move The drive is performing a linear move See the Mint keywords MOVEA and MOVER Preset positions The drive is performing a linear move This motion has been triggered from a Preset move table DB Overload The regeneration resistor Dynamic Brake has been overloaded See the Mint keyword DBEXTTRIPSWITCH and associated keywords Stop A STOP command has been issued or the stop input is active Drive disabled The drive must be enabled before operation can continue See section 3 8 Click the Drive enable button in Mint WorkBench r Crash The drive enable input or the Enable DIP switch have become inactive whilst the drive was in the enable state or the drive was enabled whilst they were inactive bit 13 in AXISEERROR will be set The drive can be programmed to ignore this state using the Mint keyword DRIVEENABLEINPUTMODE see the Parameters tool Suspend The SUSPEND command has been issued and is active Motion will be ramped to zero demand whilst active Speed demand The drive is under speed control See the Mint keywords SPEEDREF SPEEDREFSOURCE and related commands Reverse software or hardware limit A reverse limit has been activated See AXISERROR and or AXISSTATUS to determine which applies Reverse software or ha
148. three phase models 8 3 230V 460V three phase models 8 4 24V control supply 8 5 absolute encoder feedback X8 8 10 analog input X3 8 6 digital inputs X3 8 7 digital outputs X3 8 7 encoder feedback X8 8 9 encoder output X7 8 9 environmental 8 11 Hiperface feedback X8 8 10 master encoder input X9 8 10 pulse amp direction inputs X9 8 11 regeneration 8 5 relay output X3 8 8 resolver feedback X8 8 9 serial RS232 interface X6 8 8 serial RS485 interface X6 8 8 Status display 7 2 T Thermal switch connection 3 18 Tools 3 2 Troubleshooting 7 1 communication 7 5 Relay DB On LED 7 5 output 4 10 power cycling 7 1 specification 8 8 power on 7 6 Resolver problem diagnosis 7 1 cable 3 23 A 3 Status display 7 2 option 3 22 SupportMe 7 1 specification 8 9 tuning 7 6 RS232 U e UL file numbers D 6 specification 8 8 X6 4 15 Units and abbreviations 2 3 RS485 RS422 W specification 8 8 ise dn Systems 3 2 MN1902 Index Index MN1902 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 can e mail your comments to manuals baldor co uk X continued MN1902 C
149. tion com 5 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 FlexDrive MN1902 Operation 5 11 www baldormotion com 5 3 3 Digital I O tool The Digital I O tool allows you to define how each digital input and output will be triggered and if itis to be assigned to a special function for example the forward limit or stop input i Click the Digital I O icon in the Toolbox on the left of the screen displays the Digital I O screen You can use a drag and drop method to assign triggering options to inputs and outputs and assign them to special purpose functions Digital 1 0 The main area of the Mint WorkBench window Remember to click the Apply button to send the changes to the FlexDrive If you need help just press F1 to display the help file 5 3 4 Other tools and windows Each tool and window is explained fully in the help file so is not described here in
150. tion of FlexDrive The sections should be read in sequence The Basic Installation section describes the mechanical installation of the FlexDrive 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 MN1902 Introduction 2 1 www baldormotion com 2 2 2 2 1 Receiving and inspection When you receive your FlexDrive 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 FlexDrive l 2 Remove the FlexDrive from the shipping container and remove all packing material The container and packing materials may be retained for future shipment 3 Verify that the catalog number of the FlexDrive you received is the same as the catalog number listed on your purchase order The catalog number is described in the next section 4 Inspectthe FlexDrive for external damage during shipment and report any damage to the carrier that delivered your FlexDrive l 5 If FlexDrive is to be stored for several weeks before use be sure that itis stored in a location thatconforms to the storage humidity and temperature specifications shown in section 8 1 19 Identifying the catalog number
151. tively the Mint keyword RESETINPUT can be used to select the required digital input See the Mint help file for details Digital inputs DINO DIN7 are sampled every 2ms so if one is used to provide the drive enable command it must be maintained for at least 2ms to ensure detection Another method is to use the Mint keyword DRIVEENABLEMODE This allows the combination of DIP switch 8 and the Drive Enable input to create the drive enable command Both inputs must become active Provided one input is already on as soon as the other input changes from off to on active the drive will be enabled See the Mint help file for details 3 32 Basic Installation MN1902 www baldormotion com 3 9 DIP switches SW1 Various functions of the FlexDrive can be controlled by the front panel SW1 DIP switches 1 2 3 4 5 7 8 9 1 RS485 terminator Enable MODBUS select RS232 RS485 select 10 way DIP switch module for major functions 3 9 1 Switches 1 4 Switches 1 4 set the network node number address after the next power off on cycle The switches can be used to select any node number from 1 to 14 as shown in Figure 20 ee Node number address oro or at by MISTRODE FeyWor Oo M Do not use See section 3 9 8 Figure 20 Node number address switch settings MN1902 Basic Installation 3 33 www baldormotion com 3 9 2 3 9 3 3 9 4 3 9 5 If switches 1 4 are all in the Off position
152. ts 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 2000 are registered trademarks of the Microsoft Corporation UL and cUL are registered trademarks of Underwriters Laboratories EnDat is a registered trademark of Heidenhain Corporation Hiperface is a registered trademark of Max Stegmann GmbH Limited Warranty For a period of two 2 years from the date of original purchase Baldor will repair or replace without charge controls and accessories that our examination proves to be defective in material or workmanship This warranty is valid if the unit has not been tampered with by unauthorized persons misused abused or improperly installed and has been used in accordance with the instructions and or ratings supplied This warranty is in lieu of any other warranty or guarantee expressed or implied Baldor shall not be held responsible for any expense including installation and removal inconvenience or consequential damage including injury to any person or property caused by items of our manufacture or sale Some countries and U S states do not allow exclusion or limitation of incidental or consequential damages so the above exclusion may not apply In any event Bal
153. use injury to personnel or damage to equipment Peak torque of several times the rated motor torque can occur during control failure 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 If a motor is driven mechanically it might generate hazardous voltages that are conducted to its power terminals The enclosure must be earthed grounded to prevent possible shock hazard When operating a rotary motor with no load coupled to its shaft remove the shaft key to prevent it flying out when the shaft rotates A regeneration resistor may generate enough heat to ignite combustible materials To avoid fire hazard keep all combustible materials and flammable vapors away from the brake resistors To prevent equipment damage be certain that the input power has correctly sized protective devices installed To prevent equipment damage be certain that input and output signals are powered and referenced correctly To ensure 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 MN1902 General Information 1 3 www baldormotion com p pepper qo ee qeu eS CAUTION CAUTION CAUT
154. 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 If the basic encoder feedback option is fitted X7 duplicates the encoder signals entering X8 However the simulated encoder output is in the opposite direction to the encoder input When connecting the output to another Baldor controller the ENCODERMODE or AUXENCODERMODE keywords can be used to re invert the signal If the EnDat or Hiperface absolute encoder feedback option is fitted a simulated encoder output is produced at X7 The output ppr is equal to the number of Sin Cos cycles of the absolute encoder For example if a 2048 cycle absolute encoder is connected the output at XT will be equivalent to a 2048 ppr encoder Note that this value represents actual encoder lines not quadrature counts For EnDat the simulated encoder output is in the same direction as the encoder input For Hiperface the simulated encoder output is in the opposite direction to the encoder input The encoder output supports an index or marker pulse MN1902 Input Output 4 11 www baldormotion com FlexDrive CHA CHA CHZ CHZ CHB CHB DGND 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
155. ve then it is strongly recommended that you use RS232 to get started and try RS485 later This will avoid any potential problems involving the RS232 RS485 converter Selection of RS232 or RS485 is controlled using DIP switch 10 see section 3 9 7 3 1 4 Tools and miscellaneous hardware m Your PC operating system user manual might be useful if you are not familiar with Windows A small screwdriver supplied with a blade width less than 3mm 1 10 in m M5 screws or bolts for mounting the FlexDrive m Crimping tool A connector kit is supplied with your FlexDrive This contains a number of useful connectors and a screwdriver for tightening the connections 3 2 Basic Installation MN1902 www baldormotion com 3 1 5 Other information needed for installation This information is useful but not essential to complete the installation m The data sheet or manual provided with your motor describing the wiring information of the motor cables connectors m Knowledge of which digital inputs outputs will be Active Low Active High or edge triggered MN1902 Basic Installation 3 3 www baldormotion com 3 2 Mechanical installation and location 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 equip
156. ve Motor cable Baldor resolver cable X8 pin pin internal wire colors 5 000 QOO Pins 7 12 are not used 6 Q9 e and may not be present o 4 Motor resolver connector Cable connector end view male female Figure 12 Baldor motor resolver cable pin configuration The maximum recommended cable length is 30 5m 100ft MN1902 Basic Installation 3 23 www baldormotion com 3 7 2 Encoder option 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 overall cable shield screen must be connected to the metallic shell of the D type connector Pm Ewor mto OOO OOOO s 7 0 E994 5V out zog E L s Description Commutating UVW encoder input non isolated Pin 11 provides 5V for encoders requiring power 200mA max 7 1 1 Motor Twisted pairs CHA CHA CHB CHB CHZ INDEX CHZ INDEX 5V DGND Encoder Feedback OWNND a Hall U Hall U Hall W Hall W Hall V Hall V NC Hall Feedback L9 NS Connect overall shield d to connector backshells Figure 13 Encoder cable connections rotary motors 3 24 Basic Installation MN1902 www baldormotion com 3 7 2
157. ve Wide range of models with continuous current ratings from 2 5A to 27 5A Direct connection to 115VAC or 230VAC single phase or 230 460VAC three phase supplies model dependent Resolver encoder EnDat or Hiperface feedback Velocity and current control with pulse and direction input for position control Auto tuning wizard including position loop and software oscilloscope facilities 8 optically isolated digital inputs 3 optically isolated digital outputs 1 general purpose analog input can be used as a speed or torque demand reference 1 control relay Selectable RS232 or R8485 communications Flex Drive only m Integrated motion controller for rotary and linear positioning systems Programmable in Mint m Up to 16 programmable preset moves expandable to 256 with factory fitted CAN and I O option Position control using preset moves software gearing and point to point moves Flash memory for program storage 64k Motion controller for rotary and linear positioning systems Factory fitted options expand the I O capabilities of the FlexDrive and provide CANopen DeviceNet or Profibus connectivity See Appendix A for details about options FlexDrive will operate with a large number of brushless servo motors for information on selecting Baldor servo motors please see the sales brochure BR1202 BR1800 for linear motors available from your local Baldor representative This manual is intended to guide you through the installa
158. vo axis TORQUEREFENABLE To set the drive into torque command mode TORQUEREFERRORFALLTIME To set or read the deceleration ramp for a torque profile in the event of an error TORQUEREFFALLTIME To set or read the deceleration ramp for a torque profile TORQUEREFRISETIME To set or read the acceleration ramp for a torque profile TORQUEREFSOURCE To specify the source of the torque reference command Controls the channel used as the trigger source TRIGGERINPUT To specify the input used for triggering when triggering on a digital input Controls the triggering of a move USERPARAMETER To provide access to user programmable parameters stored in EEPROM VELFATAL To set or read the threshold for the maximum difference between demand and actual velocity VELFATALMODE To control the default action taken in the event of the velocity threshold being exceeded To set or read the maximum limit of a velocity band To set the minimum limit of a velocity band These keywords are supported on Flex Drive only C 20 Mint Keyword Summary MN1902 D 1 D 1 1 CE amp UL D Introduction 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 FlexDrive is sufficiently qualified to perform the task and is aware of local regulations and requir
159. xx Hxxxx Resolution set automatically by software LoT en M EET n Resolver Resolver winding ratio ratio Typical accuracy counts 11 using Baldor BSM series resolver motor with input set to simulate 4096 ppr Maximum recommended cable length 30 5m 100ft 8 1 14 Encoder feedback option X8 Catalog numbers All models FDHXxxxxx Exxxx FPHxxxxxx Exxxx Encoder Encoder input AB Differential Zindex Differential Z index Maximum input Cee NN quadrature att inputs S f Single ended 5V logic Output power supply to encoder d i 5V 5 200mA max Maximum recommended cable length 30 5m 100ft MN1902 Specifications 8 9 www baldormotion com 8 1 15 EnDat absolute encoder feedback option X8 All models Catalog numbers FDHxxxxxx Dxxxx FPHxxxxxx Dxxxx Absolute encoder input E Operating modes Single or multi turn Baldor motors 512 or 2048 Sin Cos cycles per turn with absolute positioning resolution of EnDat Sin Cos differential inputs and data input up to 65536 steps Many other encoder specifications are supported contact Baldor 5 2V 596 200mA max 30 5m 100ft Output power supply to encoder Maximum recommended cable length 8 1 16 Hiperface absolute encoder feedback option X8 Catalog numbers All models FDHxxxxxx Hxxxx FPHxxxxxx Hxxxx Absolute encoder input NE Operating modes Single or multi turn 512 or 1024 Sin Co
160. xxxxx xxx3 FPHxxxxx xxx3 Turn on the AC supply After a brief test sequence the Status display should show a minus sign If the display is not lit then re check the power supply connections If the motor wires were disconnected in section 5 1 4 turn off the AC supply and reconnect the motor wires Turn on the AC supply To allow the Commissioning Wizard to function SW1 DIP switch 8 will need to be set to the On position to allow the FlexDrive to be enabled If you do not wish to enable the FlexDrive yet the Commissioning Wizard will inform you when this step is necessary To allow the Commissioning Wizard to function the 24VDC drive enable signal will need to be present on connector X3 between pins 7 and 9 to allow the FlexDrive to be enabled If you do not wish to enable the FlexDrive yet the Commissioning Wizard will inform you when this step is necessary The FlexDrive is now ready to be commissioned using Mint WorkBench 5 2 Operation MN1902 www baldormotion com 5 1 6 Offset tuning If the FlexDrive will be using analog input 0 AINO as a demand reference input or for any other purpose you may wish to perform offset tuning before continuing The purpose of offset tuning is to remove DC offset voltages on the demand reference input to achieve a stationary motor shaft with OVDC at the input Offset tuning is controlled by DIP switches 7 and 8 Before starting confirm that the device supplyin
161. y 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 D 4 CE amp UL MN1902 www baldormotion com D 1 6 Wiring of shielded screened
162. y to connector X1 and is switched on On models with an internally generated 24VDC supply check that the AC power supply is connected correctly to connector X1 and is Switched on Mint WorkBench Ensure that the FlexDrive is powered and the Status display is fails to detect the illuminated see section 7 2 FlexDrive it detects No Check that the serial cable is connected between the PC s COM port controller found and connector X6 on the FlexDrive Communication fault on COMX Check which PC COM port is being used or use the Scan all serial ports option to locate the FlexDrive l Check the wiring of the serial cable or try an alternate cable Check that DIP switch 10 RS232 RS422 is set correctly see section 3 9 7 On the PC try an alternative COM port Confirm that a mouse driver or other serial device is not conflicting using the same COM port as Mint WorkBench Does the FlexDrive have firmware in it If you tried to download new firmware and the download failed the controller may not have firmware If this has happened the Status display will show a minus sign and flash the decimal point repeatedly Check that the selected Baud rate is supported by the PC and FlexDrive l 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 FlexDrive node number is not higher

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