Contents 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 MicroFlex e100 features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2.1 2.3 3 Identifying the catalog number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1.1 4.1.2 4.1.3 4.1.4 4-2 4-6 4-8 4-10 Input / Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Digital I/O . . . . . . . . . . . . . . .
6.4 6.5 Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.4.1 6.4.2 6.4.3 6.4.4 6-9 6-10 6-11 6-13 Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.5.1 6.5.2 6.5.3 7 Fine-tuning tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendices A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1.1 A.1.2 A.1.3 A.1.4 A.1.5 A.1.6 A.1.7 A.1.8 A.1.9 A.1.10 A.1.11 A-2 A-3 A-4 A-7 A-8 A-8 A-9 A-9 A-10 A-10 A-11 Fan tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Footprint filter (single-phase only) . . . . . . . . . .
1 1 www.supportme.net General Information Copyright Baldor (c) 2006. All rights reserved. This manual is copyrighted and all rights are reserved. This document or attached software may not, in whole or in part, be copied or reproduced in any form without the prior written consent of Baldor. Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose.
www.supportme.net Product notice Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Safety Notice Intended use: These drives are intended for use in stationary ground based applications in industrial power installations according to the standards EN60204 and VDE0160.
www.supportme.net WARNING: Be sure all wiring complies with the National Electrical Code and all regional and local codes. Improper wiring may result in unsafe conditions. WARNING: Be sure that you are completely familiar with the safe operation and programming of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury.
www.supportme.net CAUTION: Baldor does not recommend using “Grounded Leg Delta” transformer power leads that may create earth/ground loops and degrade system performance. Instead, we recommend using a four wire Wye. CAUTION: Drives are intended to be connected to a permanent main power source, not a portable power source. Suitable fusing and circuit protection devices are required. CAUTION: The safe integration of the drive into a machine system is the responsibility of the machine designer.
2 2 www.supportme.net Introduction 2.1 MicroFlex e100 features The MicroFlex e100 is a versatile brushless servo drive, providing a flexible and powerful motion control solution for rotary and linear motors. Standard features include: H H H H H H H H H H H H H Single axis AC brushless drive. Range of models with continuous current ratings of 3A, 6A or 9A. Direct connection to 115VAC or 230VAC single-phase or 230VAC three-phase supplies.
www.supportme.net 2.2 Receiving and inspection When you receive your MicroFlex e100, there are several things you should do immediately: 1. Check the condition of the shipping container and report any damage immediately to the carrier that delivered your MicroFlex e100. 2. Remove the MicroFlex e100 from the shipping container and remove all packing material. The container and packing materials may be retained for future shipment. 3.
www.supportme.net 2.3 Units and abbreviations The following units and abbreviations are used in this manual: V ............... W .............. A ............... Ω ............... µF . . . . . . . . . . . . . . pF . . . . . . . . . . . . . . mH . . . . . . . . . . . . . Volt (also VAC and VDC) Watt Ampere Ohm microfarad picofarad millihenry Φ............... ms . . . . . . . . . . . . . . µs . . . . . . . . . . . . . . ns . . . . . . . . . . . . . . phase millisecond microsecond nanosecond mm . . . . .
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3 3 www.supportme.net Basic Installation 3.1 Introduction You should read all the sections in Basic Installation to ensure safe installation.
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www.supportme.net 3.2 Mechanical installation and cooling requirements It is essential that you read and understand this section before beginning the installation. CAUTION: To prevent equipment damage, be certain that the input power has correctly rated protective devices installed. CAUTION: To prevent equipment damage, be certain that input and output signals are powered and referenced correctly.
www.supportme.net 3.2.1 Dimensions 80 (3.2) 5 (2.5) (0.2) 6 63.5 Mounting hole and slot detail (0.24) 11 (0.4) 180 (7.1) (6.6) 167.7 5.5 mm Dimensions shown as: mm (inches). 6 (0.24) Depth: 157 mm (6.2 in) Weight: 3A: 1.45kg (3.2lb) 6A: 1.50kg (3.3lb) 9A: 1.55kg (3.
www.supportme.net 3.2.2 Mounting and cooling the MicroFlex e100 Ensure you have read and understood the Mechanical installation and location requirements in section 3.2. Mount the MicroFlex e100 vertically on its rear side, the side opposite the front panel. M5 bolts or screws should be used to mount the MicroFlex e100. Detailed dimensions are shown in section 3.2.1. For effective cooling, the MicroFlex e100 must be mounted upright on a smooth vertical metal surface.
www.supportme.net 3.2.3 Derating characteristic - 3A model The following derating characteristics are for model MFE230A003. Single-phase AC supply Rated output current (Arms) 3 1m/s forced air 2 Natural cooling 1 0 30 35 40 45 50 55 Ambient temperature (°C) Three-phase AC supply 3 Rated output current (Arms) 1m/s forced air 2 Natural cooling 1 0 30 35 40 45 50 55 Ambient temperature (°C) Notes: Load power factor = 0.75. Overload limit for model MFE230A003 is 6A.
www.supportme.net 3.2.4 Derating characteristic - 6A model The following derating characteristics are for model MFE230A006. Single-phase AC supply Rated output current (Arms) 6 1.5m/s forced air 5 4 1m/s forced air 3 2 Natural cooling 1 0 30 35 40 45 50 55 Ambient temperature (°C) Three-phase AC supply Rated output current (Arms) 6 1.5m/s forced air 5 4 1m/s forced air 3 2 Natural cooling 1 0 30 35 40 45 50 55 Ambient temperature (°C) Notes: Load power factor = 0.75.
www.supportme.net 3.2.5 Derating characteristic - 9A model The following derating characteristics are for model MFE230A009. Single-phase AC supply 9 Rated output current (Arms) 8 7 3.5m/s forced air 6 2.5m/s forced air 5 1.5m/s forced air 4 1m/s forced air 3 2 Natural cooling 1 0 30 35 40 45 50 55 Ambient temperature (°C) Three-phase AC supply 9 Rated output current (Arms) 8 3.5m/s forced air 7 2.5m/s forced air 6 1.
www.supportme.net 3.3 Connector locations 3.3.1 Front panel connectors X1 Power LEDs Earth/Ground The STATUS, CAN and ETHERNET LEDs are described in section 7.2.1. Earth/Ground (NC) L1 AC Phase 1 / L L2 AC Phase 2 / N L3 AC Phase 3 U Motor U V Motor V W Motor W R1 Regen R2 Regen Node ID These switches set the MicroFlex e100’s node ID for ETHERNET Powerlink, and the final value of the IP address when using TCP/IP. See sections 5.6.1 and 6.2.4.
www.supportme.net 3.3.2 Top panel connectors CAN 1 2 3 4 5 6 7 8 9 (NC) CANCAN GND (NC) Shield CAN GND CAN+ (NC) CAN V+ Ethernet 1 2 3 4 5 6 7 8 3-10 Basic Installation TX+ TXRX+ (NC) (NC) RX(NC) (NC) Both connectors have identical pinouts.
www.supportme.net 3.4 Power connections This section provides instructions for connecting the AC power supply. The installer of this equipment is responsible for complying with NEC (National Electric Code) guidelines or CE (Conformite Europeene) directives and application codes that govern wiring protection, earthing/grounding, disconnects and other current protection. DANGER: Electrical shock can cause serious or fatal injury.
www.supportme.net 3.4.2 Single-phase or three-phase power connections Location Connector X1 (Mating connector: Phoenix COMBICON MSTB 2,5HC/11-ST-5,08) Nominal input voltage 115VAC or 230VAC, 1Φ or 3Φ line to line Minimum input voltage 105VAC, 1Φ or 3Φ line to line (see Note*) Maximum input voltage 250VAC, 1Φ or 3Φ line to line Note: * The MicroFlex e100 will operate at lower input voltages, although performance could be impaired.
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www.supportme.net 3.4.3.3 Supplying input power from a variac (variable transformer) When AC power is supplied from a variac, the MicroFlex e100’s pre-charge circuit may not operate correctly. To ensure that the pre-charge circuitry operates correctly, increase the variac voltage to the desired level and then power cycle the 24VDC control circuit supply. This will restart the pre-charge circuit and allow it to operate correctly. 3.4.
www.supportme.net 3.4.5 Recommended fuses, circuit breakers and wire sizes Table 3 describes the recommended fuses, circuit breakers and suitable wires sizes to be used for power connections. Catalog Number MFE A003 MFE..A003 MFE..A006 MFE..A009 Cont. Output p A Amps (RMS) AC Supply pp y T Type Input Fuse Circuit breaker (C t (C-type) ) Minimum Wire Gauge AWG mm2 1Φ Ferraz Shawmut: 6x32 FA series, 10A (W084314P) or BS88 2.5 URGS 10A (N076648) 10A 14 20 2.
www.supportme.net 3.4.7 Power supply filters To comply with EEC directive 89/336/EEC, an AC power filter of the appropriate type must be connected. This can be supplied by Baldor and will ensure that the MicroFlex e100 complies with the CE specifications for which it has been tested. Ideally, one filter should be provided for each MicroFlex e100; filters should not be shared between drives or other equipment.
www.supportme.net 3.4.8 24V control circuit supply A 24VDC supply must be provided to power the controlling electronics. This is useful for safety reasons where AC power needs to be removed from the power stage but the controlling electronics must remain powered to retain position and I/O information. A separate fused 24V supply should be provided for the MicroFlex e100.
www.supportme.net 3.5 Motor connections MicroFlex e100 will operate with a large number of brushless servo motors. For information on selecting Baldor servo motors please see the sales brochure BR1202, available from your local Baldor representative. The motor must be capable of being powered by an inverter PWM output - see section 8.1.3 for details. The motor can be connected directly to the MicroFlex e100 or through a motor contactor (M-Contactor). The motor outputs are conditionally short-circuit proof.
www.supportme.net 3.5.1 Motor circuit contactors If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor) may be installed to provide a physical disconnection of the motor windings from the MicroFlex e100 (see section 3.5). Opening the M-Contactor ensures that the MicroFlex e100 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.
www.supportme.net 3.5.3 Motor cable pin configuration - Baldor linear motors The following table shows the pin colors used in a typical Baldor linear motor cable set, part number AY1763A00: Signal name Motor cable wire color Motor U Black Motor V Red Motor W White Motor ground Green Thermal switch Blue Thermal switch Orange Signal name Hall 1 (U) Hall cable wire color White Hall 2 (V) Red Hall 3 (W) Black Hall ground Green Hall +5VDC Brown 3.5.
www.supportme.net 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 3.3.1). Using the Mint WorkBench Digital I/O tool, the input can be configured to be the motor trip input. This allows the MicroFlex e100 to respond to motor over-temperature conditions. The Mint keyword MOTORTEMPERATUREINPUT can also be used to configure a digital input for this purpose.
www.supportme.net 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 3.3.1). This provides a way for the MicroFlex e100 to control the motor’s brake. A typical circuit is shown in Figure 10. ‘X3’ User supply V+ 11 13 1 3 DOUT0+ The relays have normally open contacts and are shown deactivated (contacts open, brake engaged).
www.supportme.net 3.6 Regeneration resistor (Dynamic Brake resistor) An optional external regeneration resistor may be required to dissipate excess power from the internal DC bus during motor deceleration. The regeneration resistor must have a resistance of at least 39Ω, an inductance of less than 100µH, and a minimum power rating of 44W. Suitable regeneration resistors are listed in section A.1.4. The regeneration resistor output is conditionally short-circuit proof.
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4 4 www.supportme.net Feedback 4.1 Introduction MicroFlex e100 supports many feedback options for use with linear and rotary motors, including incremental encoder, encoder with SSI (Synchronous Serial Interface), SinCos encoder, or EnDat absolute encoder. All suitable types of feedback device can be connected to the universal feedback interface available on connector X8.
www.supportme.net 4.1.1 Incremental encoder feedback The incremental encoder connections (ABZ channels and Hall signals) are made using the 15-pin D-type female connector X8. The encoder inputs (CHA, CHB and CHZ) accept differential signals only. Twisted pairs must be used for each complementary signal pair e.g. CHA+ and CHA-. The Hall inputs may be used as differential inputs (recommended for improved noise immunity) or single ended inputs.
www.supportme.net MicroFlex e100 +5V 2k2 Hall U+ 10k 6 MAX3096 Differential line receiver 1nF Hall U- to CPU 5 1nF 4k7 DGND Figure 13 - Hall channel input circuit - U phase shown 4.1.1.1 Encoder cable configuration - Baldor rotary motors Motor Twisted pairs Encoder Feedback Hall Feedback X8 1 9 2 10 3 11 CHA+ CHACHB+ CHBCHZ+ (INDEX) CHZ- (INDEX) 12 13 4 +5V out DGND Sense 6 5 15 14 8 7 Hall U+ Hall UHall W+ Hall WHall V+ Hall V- Connect overall shield to connector backshells.
www.supportme.net 4.1.1.2 Encoders without Halls Incremental encoders without Hall feedback connections may be connected to the MicroFlex e100. However, if Hall connections are not present, it will be necessary for the MicroFlex e100 to perform an automatic phase search sequence each time it is powered. This will cause motor movement of up to 1 turn on rotary motors, or one pole-pitch on linear motors.
www.supportme.net 4.1.1.4 Encoder cable pin configuration - Baldor linear motors Baldor linear motors use two separate cables (encoder and Hall). The cores of these two cables must be wired to the appropriate pins of the 15-pin D-type mating connector (supplied): Signal name MicroFlex e100 X8 pin CHA+ 1 CHA- 9 CHB+ 2 CHB- 10 CHZ+ 3 CHZ- 11 Hall U+ 6 Encoder cable internal wire colors Please refer to MN1800 Linear Motors Installation & Operating Manual for details.
www.supportme.net 4.1.2 SSI feedback The SSI (Synchronous Serial Interface) encoder interface is specifically designed for use with Baldor SSI motors, which incorporate a custom Baumer SSI encoder. Correct operation with other SSI interfaces cannot be guaranteed. The SSI encoder connections are made using the 15-pin D-type female connector X8. Twisted pair cables must be used for the complementary signal pairs e.g. Data+ and Data-.
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www.supportme.net 4.1.3 SinCos feedback The SinCos connections (Sin and Cos incremental channels only) are made using the 15-pin D-type female 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 includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs.
www.supportme.net 4.1.3.1 SinCos cable pin configuration Figure 21 shows the pin configuration for a typical Baldor SinCos feedback cable, part number CBL025SF-D2.
www.supportme.net 4.1.4 EnDat (absolute encoder) feedback The absolute encoder interface supports both incremental and absolute (multi and single turn) feedback using EnDat 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. Sin+ and Sin-.
www.supportme.net 4.1.4.1 Absolute encoder cable pin configuration Figure 23 shows the pin configuration for a typical Baldor absolute encoder feedback cable, part number CBL025SF-D2.
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5 5 www.supportme.net Input / Output 5.1 Introduction This section describes the various digital input and output capabilities of the MicroFlex e100, with descriptions of each of the connectors on the front panel. The following conventions are used to refer to the inputs and outputs: I/O . . . . . . . . . . . . . . Input / Output DIN . . . . . . . . . . . . . Digital Input DOUT . . . . . . . . . . .
www.supportme.net 5.2 Digital I/O The MicroFlex e100 provides as standard: H 3 general purpose digital inputs. H 1 dedicated drive enable input. H 1 general purpose digital output. H 1 general purpose / drive status output. The general purpose digital inputs can be configured for typical input functions: H Error input H Reset input H Stop input H Forward / reverse limit input H Home input.
www.supportme.net 5.2.1 Drive enable input Location Name Description 9 19 Connector X3, pins 9 & 19 (Mating connector: Weidmüller Minimate B2L 3.5/20) Drive enable Dedicated drive enable input. Nominal input voltage: +24VDC (input current not to exceed 50mA) Sampling interval: 1ms The drive enable input is buffered by a TLP280 opto-isolator, allowing the input signal to be connected with either polarity.
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www.supportme.net 5.2.2 General purpose digital input DIN0 Location Connector X3, pins 7 & 17 (Mating connector: Weidmüller Minimate B2L 3.5/20) Name DIN0 7 17 Description General purpose opto-isolated digital input. Nominal input voltage: +24VDC (input current not to exceed 50mA) Sampling interval: 1ms This general purpose digital input is buffered by a TLP280 opto-isolator, allowing the input signal to be connected with either polarity.
www.supportme.net NextMove e100 / controller ‘X11’ User supply 24V UDN2982 9 Mint OUTX.
www.supportme.net 5.2.3 General purpose digital inputs DIN1 & DIN2 Location Connector X3, pins 6 & 16 (DIN1), 4 & 14 (DIN2) (Mating connector: Weidmüller Minimate B2L 3.5/20) 4 14 6 16 Name DIN1, DIN2 Description General purpose fast opto-isolated digital inputs.
www.supportme.net NextMove e100 / controller ‘X11’ User supply 24V MicroFlex e100 UDN2982 9 Mint OUTX.0 1 ‘X3’ USR V+ DOUT0 DIN1+ DIN1- 10k 10 USR GND 16 6 TLP115A Shield User supply GND 10 Connect overall shield at one end only Figure 29 - Digital input - typical connection from a Baldor NextMove e100 5.2.4 Special functions on inputs DIN1 and DIN2 DIN1 and DIN2 can be configured to perform special functions. 5.2.4.
www.supportme.net 5.2.5 General purpose / status output DOUT0 1 11 Location Connector X3, pins 1 & 11 (Mating connector: Weidmüller Minimate B2L 3.5/20) Name Status / DOUT0 Description General purpose opto-isolated digital output Output current: 100mA maximum User supply +28VDC maximum Update interval: 1ms The optically isolated general purpose / status output is designed to source current from the user supply as shown in Figure 30. The PS2562L has a maximum power dissipation of 200mW at 25°C.
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www.supportme.net 5.2.6 General purpose output DOUT1 3 13 Location Connector X3, pins 3 & 13 (Mating connector: Weidmüller Minimate B2L 3.5/20) Name DOUT1 Description General purpose opto-isolated digital output Output current: 100mA maximum User supply: +28VDC maximum Update interval: 1ms The optically isolated general purpose output is designed to source current from the user supply as shown in Figure 30. The PS2562L has a maximum power dissipation of 200mW at 25°C.
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www.supportme.net 5.3 USB communication 5.3.1 USB port Location 1 2 4 3 USB Mating connector: USB Type B (downstream) plug Pin Name Description 1 VBUS USB +5V 2 D- Data- 3 D+ Data+ 4 GND Ground The USB connector is used to connect the MicroFlex e100 to a PC running Mint WorkBench. The MicroFlex e100 is a self-powered, USB 1.1 (12Mbps) compatible device. If it is connected to a slower USB1.0 host PC or hub, communication speed will be limited to the USB1.0 specification (1.5Mbps).
www.supportme.net 5.4 Ethernet interface The Ethernet interface provides TCP/IP and ETHERNET Powerlink (EPL) networking capabilities. 5.4.1 TCP/IP Transmission Control Protocol / Internet Protocol (TCP/IP) is a common set of protocols used to transfer information between devices over a network, including the internet. TCP enables two devices to establish a connection, and guarantees the delivery of packets (datagrams) of information in the correct order.
www.supportme.net 5.4.2 ETHERNET Powerlink MicroFlex e100 supports the deterministic ETHERNET Powerlink (EPL) protocol. This protocol provides very precise and predictable ‘real-time’ communication over a 100Mbit/s (100Base-T) Fast Ethernet (IEEE 802.3u) connection. This makes it suitable for the transmission of control and feedback signals between the MicroFlex e100 and other EPL enabled controllers such as NextMove e100.
www.supportme.net 5.4.3 Ethernet connectors Ethernet connections are made using the identical RJ45 Ethernet receptacles. Location E1 & E2 Pin Name 1 8 Description 1 TX+ Transmit+ 2 TX- Transmit- 3 RX+ Receive+ 4 - (NC) 5 - (NC) 6 RX- Receive- 7 (NC) - 8 Shield Shield connection To connect the MicroFlex e100 to other EPL devices, ordinary shielded CAT5 Ethernet cables are used. Cables may be up to 100m (328 ft) long. Two varieties of CAT5 cable are available; ‘straight’ or ‘crossed’.
www.supportme.net 5.5 CAN interface The CAN bus is a serial based network originally developed for automotive applications, but now used for a wide range of industrial applications. It offers low-cost serial communications with very high reliability in an industrial environment; the probability of an undetected error is 4.7x10-11. It is optimized for the transmission of small data packets and therefore offers fast update of I/O devices (peripheral devices) connected to the bus.
www.supportme.net H The maximum bus length depends on the bit-timing configuration (baud rate). The table opposite shows the approximate maximum bus length (worst-case), assuming 5ns/m propagation delay and a total effective device internal in-out delay of 210ns at 1Mbit/s, 300ns at 500 - 250Kbit/s, 450ns at 125Kbit/s and 1.5ms at 50 - 10Kbit/s. (1) For bus lengths greater than about 1000m, bridge or repeater devices may be needed.
www.supportme.net Baldor HMI Operator Panel CANopen D-type 7 Power supply terminal block 24V 0V 2 6 Twisted pairs CAN+ CAN- TR 0V 24V 1 2 NextMove e100 D-type 5 7 End node MicroFlex e100 D-type Twisted pairs 7 7 2 2 6 6 6 9 9 9 5 5 TR 2 Figure 38 - Typical CANopen network connections Note: The MicroFlex e100 CAN channel is opto-isolated, so a voltage in the range 12-24V must be applied between pin 9 and pin 6 of the CAN connector.
www.supportme.net 5.6 Other I/O 5.6.1 Node ID selector switches The MicroFlex e100 has two selector switches which determine the unit’s node ID on EPL networks. Each switch has 16 positions, allowing selection of the hexadecimal values 0 - F. In combination, the two switches allow node IDs of 0 - 255 (hexadecimal FF) to be selected. The switch labelled ‘HI’ sets the high nibble (half byte), and the switch labelled ‘LO’ sets the low nibble.
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www.supportme.net In many networking environments, the node ID may also be referred to as the address. On EPL networks, limitations apply to the node IDs that may be selected: H Node ID 0 is reserved for special purposes and cannot be used. H Setting the switches to select a node ID between 1 and 239 causes the node to become a ‘controlled node’, a node that will accept commands from the manager node.
www.supportme.net 5.7 Connection summary - recommended system wiring As an example, Figure 40 shows the recommended wiring necessary for the MicroFlex e100 to control a motor, while conforming to the EMC requirements for ‘industrial’ environments.
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6 6 www.supportme.net Configuration 6.1 Introduction Before powering the MicroFlex e100 you will need to connect it to the PC using a USB or Ethernet cable and install the supplied Mint Machine Center software. This software includes a number of tools to allow you to configure and tune the MicroFlex e100. If you do not have experience of software installation or Windows applications you may need further assistance for this stage of the installation. 6.1.
www.supportme.net 6.2 Starting the MicroFlex e100 If you have followed the instructions in the previous sections, you should now have connected all the power sources, inputs and outputs, and the Ethernet cable or USB cable linking the PC to the MicroFlex e100. 6.2.1 Preliminary checks Before you apply power for the first time, it is very important to verify the following: H Disconnect the load from the motor until instructed to apply a load.
www.supportme.net The MicroFlex e100 is now ready to be configured using Mint WorkBench. Note: If the MicroFlex e100 is later connected to a different USB port on the host computer, Windows may report that it has found new hardware. Either install the driver files again for the new USB port, or connect the MicroFlex e100 to the original USB port where it will be recognized in the usual way. 6.2.
www.supportme.net 7. In the Subnet mask box, enter 255.255.255.0 and click OK. Click OK to close the Local Area Connection Properties dialog. 8. On the Windows Start menu, select Command Prompt (often found under Accessories). 9. In the Command Prompt window, type PING 192.168.100.16, where the final value (16 in this example) is the value selected by the MicroFlex e100’s node ID selector switches.
www.supportme.net 6.3 Mint Machine Center The Mint Machine Center (MMC) is used to view the network of connected controllers in a system. Individual controllers and drives are configured using Mint WorkBench. Note: If you have only a single MicroFlex e100 connected to your PC, then MMC is probably not required. Use Mint WorkBench (see section 6.4) to configure the MicroFlex e100.
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www.supportme.net 6.3.1 Starting MMC 1. On the Windows Start menu, select Programs, Mint Machine Center, Mint Machine Center. 2. In the controller pane, ensure that Host is selected. In the information pane, click Scan. 3. When the search is complete, click once on ‘MicroFlex e100’ in the controller pane to select it, then double click to open an instance of Mint WorkBench. The MicroFlex e100 will be already connected to the instance of Mint WorkBench, ready to configure.
www.supportme.net 6.4 Mint WorkBench Mint WorkBench is a fully featured application for commissioning the MicroFlex e100. 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.
www.supportme.net 6.4.1 Help file Mint WorkBench includes a comprehensive help file that contains information about every Mint keyword, how to use Mint WorkBench and background information on motion control topics. The help file can be displayed at any time by pressing F1. On the left of the help window, the Contents tab shows the tree structure of the help file. Each book contains a number of topics .
www.supportme.net 6.4.2 Starting Mint WorkBench Note: If you have already used MMC to start an instance of Mint WorkBench then the following steps are unnecessary. Go to section 6.4.3 to continue configuration. 1. On the Windows Start menu, select Programs, Mint Machine Center, WorkBench v5.5. 2. In the opening dialog box, click Start New Project... .
www.supportme.net 3. In the Select Controller dialog, click Scan to search for the MicroFlex e100. Mint WorkBench will scan the PC’s ports for the MicroFlex e100. When the search is complete, click ‘MicroFlex e100’ in the list to select it, then click Select. This check box is already selected for you. When you click Select, it means that the Commissioning Wizard will start automatically. Note: If the MicroFlex e100 is not listed, check the USB or Ethernet cable between the MicroFlex e100 and the PC.
www.supportme.net 6.4.3.1 Using the Commissioning Wizard CAUTION: The motor will move during commissioning. For safety it is advisable to disconnect any load from the motor during initial commissioning. The motor can be tuned with the load connected after the Commissioning Wizard has finished. Each screen of the Commissioning Wizard requires you to enter information about the motor or drive. Read each screen carefully and enter the required information.
www.supportme.net 6.4.4 Performing a test move This section tests the basic operation of the drive and motor. 1. Check that the Drive enable button is pressed (down). 2. In the Toolbox, click the Edit & Debug icon. 3. Click in the Command window. 4. Type: JOG.0 = 10 This will 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).
www.supportme.net 6.5 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. Two of the main tools used for tuning and configuring the MicroFlex e100 are described in the following sections. Every tool is explained fully in the help file. Press F1 to display the help file, then navigate to the Mint WorkBench book. Inside this is the Toolbox book. 6.5.
www.supportme.net 6.5.1.3 Fine-tuning - Current tab The Current tab allows you to set current loop gains and perform test moves. The Commissioning Wizard may have already set some of these values, depending on the type of system selected on the mode screen. Normally, it should not be necessary to alter these values. Enter new values in the required boxes and then click Apply to download the values to the MicroFlex e100. To perform tests, go to the Test Parameters area at the bottom of the tab.
www.supportme.net 6.5.2 Parameters tool The Parameters tool can be used to view or change most of the drive’s parameters. 1. Click the Parameters icon in the Toolbox on the left of the screen. The main area of the Mint WorkBench window displays the Parameters editor screen. 2. In the parameters tree, scroll to the required item. Click on the small + sign beside the item’s name. 3. The adjacent table will list the parameters for the chosen item. Scroll to the required entry.
www.supportme.net 6.5.3 Other tools and windows Each tool and window is explained fully in the help file, so is not described here in detail. H Edit & Debug Tool This tool provides a work area including the Command window and Output window. The Command window can be used to send immediate Mint commands to the MicroFlex e100. If you tried the test move in section 6.4.4, then you have already used Edit & Debug mode. H Scope Tool Displays the capture screen.
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7 7 www.supportme.net Troubleshooting 7.1 Introduction This section explains common problems that may be encountered, together with possible solutions. If you want to know the meaning of the LED indicators, see section 7.2. 7.1.1 Problem diagnosis If you have followed all the instructions in this manual in sequence, you should have few problems installing the MicroFlex e100. If you do have a problem, read this section first.
www.supportme.net 7.2 MicroFlex e100 indicators 7.2.1 STATUS LED The Status LED indicates general MicroFlex e100 status information. Solid green: Drive enabled (normal operation). Flickering / blinking green: Firmware download / update in progress. Solid red: Drive disabled, but no errors are latched. Flashing red: Powerbase fault or error(s) present. The number of flashes indicates which error has occurred. For example, to display error 3 (overcurrent trip), the LED flashes 3 times at 0.
www.supportme.net 7.2.2 CAN LEDs The CAN LEDs display the overall condition of the CANopen interface, once the startup sequence has completed. The LED codes conform to the CAN in Automation (CiA) DR303_3 indicator standard. The green LED indicates the state of the node’s internal CANopen ‘state machine’. The red LED indicates the state of the physical CANopen bus. Green (run) X Off: Node initializing or not powered. 1 flash: Node in STOPPED state. 3 flashes: Software is being downloaded to the node.
www.supportme.net 7.2.3 ETHERNET LEDs The ETHERNET LEDs display the overall condition of the Ethernet interface once the startup sequence has completed. The LED codes conform to the ETHERNET Powerlink Standardization Group (EPSG) standard at the time of production. Green (status) X Off: Node in NOT ACTIVE state. The controlled node is waiting to be triggered by the manager node. 1 flash: Node in PRE-OPERATIONAL1 state. EPL mode is starting. 2 flashes: Node in PRE-OPERATIONAL2 state. EPL mode is starting.
www.supportme.net 7.2.4 Communication Status LED is off: H Check that the 24VDC control circuit supply is connected correctly to connector X2 and is switched on. ETHERNET LEDs blinking green and red simultaneously: H Does the MicroFlex e100 have firmware in it? If you tried to download new firmware and the download failed, the controller may not have firmware. Download new firmware.
www.supportme.net 7.2.7 Tuning Cannot enable the MicroFlex e100 because there is an error 10010: H Check the drive enable input on connector X3 pins 9 and 19 is connected and powered correctly. When the MicroFlex is enabled the motor is unstable: H Check that the load is firmly coupled to the motor. H Use the Mint WorkBench Drive Setup Wizard to confirm that the correct motor data has been entered. H Use the Mint WorkBench Autotune Wizard to retune the motor.
www.supportme.net H The integrity of the CAN cables. The MicroFlex e100 should recover from the ‘passive’ state once the problem has been rectified (this may take several seconds). The CANopen bus is ‘off’: This means that the internal CAN controller in the MicroFlex e100 has experienced a fatal number of Tx and/or Rx errors, greater than the off threshold of 255. At this point the node will have switched itself to a state whereby it cannot influence the bus.
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8 8 www.supportme.net Specifications 8.1 Introduction This section provides technical specifications for the MicroFlex e100. 8.1.1 AC input power and DC bus voltage (X1) All models AC input Unit 1Φ Nominal input voltage 3Φ 115 or 230 VAC Minimum input voltage 105* Maximum input voltage 250 Nominal DC-bus voltage @230VAC input VDC Nominal input current @ maximum rated output current A 305 321 3A 6A 9A 3A 6A 9A 7.
www.supportme.net 8.1.1.2 Effect of AC power supply voltage on DC-bus ripple DC-bus ripple (% of DC-bus voltage) 50 40 30 Single-phase AC supply 20 10 Three-phase AC supply 0 100 125 150 175 200 225 250 AC supply voltage (rms) 8.1.1.
www.supportme.net 8.1.2 24VDC control circuit supply input (X2) Unit Nominal input voltage 3A 6A VDC 9A 24 Minimum input voltage 20 Maximum input voltage 30 Maximum ripple % ±10 Maximum continuous current @24VDC A 0.6 Power on surge current (typical) @24VDC, 100ms A 4 8.1.
www.supportme.net 8.1.5 Digital inputs - drive enable and DIN0 general purpose (X3) Unit Type All models Opto-isolated inputs Input voltage VDC Nominal Minimum Maximum 24 12 30 Input current (maximum, per input) mA 50 Sampling interval ms 1 Minimum pulse width µs 5 8.1.
www.supportme.net 8.1.8 Incremental encoder feedback option (X8) Unit Encoder input Maximum input frequency (quadrature) All models RS422 A/B Differential, Z index MHz 8 Hall inputs RS422 A/B Differential Output power supply to encoder 5V, 200mA max. Maximum recommended cable length 30.5m (100ft) 8.1.9 SSI encoder feedback option (X8) Unit All models SSI encoder inputs Differential Data and Clock Operating mode (Baldor motors) Single turn.
www.supportme.net 8.1.12 CAN interface Description Unit Value Signal 2-wire, isolated Channels 1 Protocol CANopen Bit rates Kbit/s 10, 20, 50, 100, 125, 250, 500, 1000 8.1.13 Environmental All models Unit All models Operating temperature range* Minimum Maximum Derate Storage temperature range* Humidity (maximum)* Forced air cooling flow (vertical, from bottom to top) Maximum installation altitude (above m.s.l.) Shock* Vibration* IP rating °C °F +0 +45 See sections 3.2.2 to 3.2.
www.supportme.net 8.1.14 Weights and dimensions Description Weight Nominal overall dimensions MN1942 3A 6A 9A 1.45kg (3.2 lb) 1.5kg (3.3 lb) 1.55kg (3.4 lb) 180mm x 80mm x 157mm (7.1in x 3.2in x 6.
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A A www.supportme.net Accessories A.1 Introduction This section describes accessories and options that you may need to use with your MicroFlex e100. 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.
www.supportme.net A.1.1 Fan tray The fan tray (Baldor part FAN001-024) provides sufficient cooling for the 3A, 6A or 9A MicroFlex e100. It requires 23 - 27.5VDC at 325mA, which may be sourced from the same filtered control circuit supply used for the MicroFlex e100. The MicroFlex e100 is UL listed (file NMMS.E128059) when used in conjunction with the fan tray, mounted exactly as shown in Figure 45. Fan tray FAN001-024 94 (3.7) Fan tray dimensions 84 (3.3) 21.5 (0.85) 142.5 (5.6) 66 (2.
www.supportme.net A.1.2 Footprint filter (single-phase only) The single-phase footprint AC power filter (Baldor part FI0029A00) provides mounting holes for the MicroFlex e100 and fan tray. This allows the filter, fan tray and MicroFlex e100 to use minimal panel mounting space. See section A.1.3 for details of filter FI0029A00.
www.supportme.net A.1.3 EMC filters AC filters remove high frequency noise from the AC power supply, protecting the MicroFlex e100. These filters also prevent high frequency signals from being transmitted back onto the power lines and help meet EMC requirements. To select the correct filter, see sections 3.4.7 and 3.4.8. A.1.3.
www.supportme.net L H D E C A G F K J B Dimension FI0014A00 A B C D E F G H J K L 85 (3.35) 54 (2.13) 40 (1.57) 65 (2.56) 75 (2.95) 27 (1.06) 12 (0.47) 29.5 (1.16) 5.3 (0.21) 6.3 (0.25) 13.5 (0.53) Dimensions mm (inches) FI0015A00 FI0015A01 FI0015A02 113.5 (4.47) 156 (6.14) 57.5 (2.26) 46.6 (1.83) 94 (3.70) 103 (4.06) 130.5 (5.14) 143 (5.63) 25 (0.98) 12.4 (0.49) 32.4 (1.28) 4.4 (0.17) 5.3 (0.21) 6 (0.24) 15.5 (0.
www.supportme.net B E D F Mounting keyhole and slot detail G H C A C A J G G H J K K 5.5mm 11mm 10mm 5mm Dimensions shown as: mm (inches). Dimension A B C D E F Dimensions mm (inches) FI0029A00 255 (10.04) 100 (3.94) 244.5 (9.63) 70 (2.76) 40 (1.57) 20 (0.
www.supportme.net A.1.4 Regeneration resistors Depending on the application, MicroFlex e100 might require an external regeneration resistor to be connected to pins R1 and R2 of connector X1. The regeneration resistor dissipates energy during braking to prevent an over-voltage error occurring. Baldor part number RG56 is recommended (56Ω, 44W). However, if the required dissipation is greater than this, Baldor part number RG39 may be used, rated at 100W. 45 (1.7) 100 (3.9) 90 (3.54) RG56: 140 (5.
www.supportme.net A.1.5 Motor power cables Cable rated current Cable assembly description Power Cable: no connectors 12 Amps Power Cable Assembly: CE style threaded motor connector (motor end only) Power Cable: no connector 20 Amps 35 Amps Length Catalog number Power Cable Assembly: CE style threaded motor connector (motor end only) Power Cable: no connector CBL050-501 m ft Available by the meter or on 100m drum.
www.supportme.net A.1.
www.supportme.net A.1.9 EnDat (absolute encoder) and SinCos feedback cables Cable assembly description Length Baldor catalog number Absolute encoder feedback cable: no connectors Absolute encoder feedback cable assembly: CE style threaded motor connector and low density 15-pin D-type drive connector CBL045-501 m ft Available by the meter or on 100m drum.
www.supportme.net A.1.11 Ethernet cables The cables listed in this table connect MicroFlex e100 to other EPL nodes such as NextMove e100, additional MicroFlex e100s, or other EPL compatible hardware. The cables are standard CAT5 ‘crossover’ Ethernet cables: Cable assembly description CAT5 Ethernet cable MN1942 Baldor catalog number CBL002CM-EXS CBL005CM-EXS CBL010CM-EXS CBL020CM-EXS CBL050CM-EXS CBL100CM-EXS Length m ft 0.2 0.5 1.0 2.0 5.0 10.0 0.65 1.6 3.3 6.6 16.4 32.
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B B www.supportme.net Control System B.1 Introduction The MicroFlex e100 can use two main control configurations: H Servo (Position). H Torque Servo (Current). Each configuration supports different control modes, selected by using the Tools, Control Mode menu item or by using the CONTROLMODE keyword in the Command window (see the Mint help file). The control configurations are described in the following sections.
www.supportme.net B.1.1 Servo configuration The servo configuration is the default configuration for the drive, allowing the motor control system to operate as a torque controller, a velocity controller or a position controller. This configuration comprises 3 nested control loops; a current control loop, a velocity control loop and a position control loop, as shown in Figure 51. The universal encoder interface reads rotor position from the encoder and estimates velocity.
MN1942 POSDEMAND + -- FOLERROR VELDEMAND ACCELDEMAND TORQUEDEMAND Position controller PID KPROP KINT KINTMODE KINTLIMIT KDERIV + -- + KVELFF KVEL Control mode switch P V + -- POS VEL Velocity controller PI + TF KVPROP KVINT KVTRACK + + TORQUELIMITPOS TORQUELIMITNEG CURRENTLIMIT Limiting + -- CURRMEAS Measured torque and magnetising currents TORQUEFILTERTYPE TORQUEFILTERFREQ TORQUEFILTERBAND TORQUEFILTERDEPTH Commutation Electrical angle Control mode switch P,V T Torque filt
www.supportme.net B.1.2 Torque servo configuration Figure 52 shows the torque-servo control configuration. Here, the velocity loop has been removed and the output of the position controller is fed into the current loop via the torque filters. The torque servo configuration is useful when the drive is operating as a closed-loop position controller and settling time must be minimized.
MN1942 POSDEMAND VELDEMAND ACCELDEMAND TORQUEDEMAND + -- FOLERROR Position controller PID KPROP KINT KINTMODE KINTLIMIT KDERIV + -- + + P T POS + TORQUELIMITPOS TORQUELIMITNEG CURRENTLIMIT Limiting -- EFFORT Current Conv Universal Encoder Interface Offset Comp PWM DRIVEBUSVOLTS Current controllers PI + TF KIPROP KIINT KITRACK Temperature drift compensation CURRENTMEAS Measured torque and magnetising currents TORQUEFILTERTYPE TORQUEFILTERFREQ TORQUEFILTERBAND TORQUEFILTERDEPTH
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C C www.supportme.net CE Guidelines C.1 Outline This section provides general information regarding recommended methods of installation for CE compliance. It is not intended as an exhaustive guide to good practice and wiring techniques. It is assumed that the installer of the MicroFlex e100 is sufficiently qualified to perform the task, and is aware of local regulations and requirements. Baldor products that meet the EMC directive requirements are indicated with a “CE” mark.
www.supportme.net C.1.3 Use of CE compliant components The following points should be considered: H Using CE approved components will not guarantee a CE compliant system! H The components used in the drive, installation methods used, materials selected for interconnection of components are important. H The installation methods, interconnection materials, shielding, filtering and earthing / grounding of the system as a whole will determine CE compliance.
www.supportme.net C.1.5 EMC installation suggestions To ensure electromagnetic compatibility (EMC), the following installation points should be considered to help reduce interference: H Earthing/grounding of all system elements to a central earth/ground point (star point) H Shielding of all cables and signal wires H Filtering of power lines. A proper enclosure should have the following characteristics: H All metal conducting parts of the enclosure must be electrically connected to the back plane.
www.supportme.net C.1.6 Wiring of shielded (screened) cables Remove the outer insulation to expose the overall shield. Clamp should provide 360° contact with the cable. Flat or p-type conductive clamp Figure 53 - Earthing/grounding cable shields MicroFlex e100 X8 CHA+ CHACHB+ CHBCHZ+ CHZ+5V DGND Encoder Connector Housing Cable Twisted pairs 1 9 2 10 3 11 12 13 Connect overall shield to connector backshell. Connect overall shield to connector backshell.
Index A Abbreviations.
Ethernet connector, 5-16 Ethernet interface cables, A-11 connector, 5-16 ETHERNET Powerlink, 5-15 introduction, 5-14 LEDs, 7-4 specifications, 8-5 TCP/IP, 5-14 F Features, 2-1 Feedback cable, A-9–A-11 connections, 4-1 encoder without Halls, 4-4 EnDat (absolute), 4-10 Halls-only feedback, 4-4 incremental encoder, 4-2 SinCos, 4-8 SSI, 4-6 Filters 24V control circuit supply, 3-17 AC power (EMC), 3-16, A-4 catalog numbers, A-4 Footprint filter, A-3 Fuses, 3-15 G General Information, 1-1 Grounding.
connections, 3-18 brake connection, 3-22 power cable, 3-19–3-20, A-8 sinusoidal filter, 3-20 thermal switch, 3-21 Mounting, 3-5 N Node ID selector switches, 5-20 O Operation, 6-1 configuring the TCP/IP connection, 6-3 connecting to the PC, 6-1 installing Mint Machine Center, 6-1 installing Mint WorkBench, 6-1 installing the USB driver, 6-2 power on checks, 6-2 preliminary checks, 6-2 starting, 6-2 Overloads drive, 3-15 motor, 3-18 overtemperature trips, 3-8 P Parameters tool, 6-16 Power 24V control circu
problem diagnosis, 7-1 STATUS LED, 7-2 SupportMe, 7-1 tuning, 7-6 U Units and abbreviations, 2-3 TCP/IP, configuring, 6-3 Index USB installing the driver, 6-2 port, 5-13 W Weights and dimensions, 8-7 Wires sizes, 3-15 WorkBench.
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 0BF United Kingdom. Alternatively, you can e-mail your comments to: manuals@baldor.co.uk Comment: continued...
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