Baldor FPX A05T Installation & Operating Manual
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Baldor FPX A05T Installation & Operating Manual

Baldor FPX A05T Installation & Operating Manual

Flex+drive servo control
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SERVO DRIVE
Flex+Drive
Servo Control
Installation & Operating Manual
2/03
MN1276

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Summary of Contents for Baldor FPX A05T

  • Page 1 SERVO DRIVE Flex+Drive Servo Control Installation & Operating Manual 2/03 MN1276...

  • Page 2: Table Of Contents

    Table of Contents Section 1 General Information ............. CE Compliance .
  • Page 3 Section 5 Operation ............... Installing Software on your PC .
  • Page 4 Section 7 Specifications & Product Data ........... . Identification .
  • Page 5 iv Table of Contents MN1276...

  • Page 6: General Information

    For additional information, refer to Sections 3 and 8 of this manual. 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 which our examination proves to be defective in material or workmanship.

  • Page 7: Product Notice

    Product Notice Intended use: These drives are intended for use in stationary ground based applications in industrial power installations according to the standards EN60204 and VDE0160. They are designed for machine applications that require variable speed controlled three phase brushless AC motors. These drives are not intended for use in applications such as: Home appliances Medical instrumentation...
  • Page 8 PRECAUTIONS: WARNING: Do not touch any circuit board, 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. Electrical shock can cause serious or fatal injury.
  • Page 9 AC power to these terminals may result in damage to the control. Caution: Baldor recommends not using “Grounded Leg Delta” transformer power leads that may create ground loops and degrade system performance. Instead, we recommend using a four wire Wye.

  • Page 10: Product Overview

    The Flex+Drive can be integrated with Baldors’ motion controllers or to any industry standard motion controller. Motors Baldor servo controls are compatible with many motors from Baldor and other manufacturers. Motor parameters are provided with the PC software making the setup easy. Baldor compatible motors include:...
  • Page 11 Control Inputs Opto isolated inputs are single ended, user selectable and active high or low: Enable Machine Input 1 Quit Machine Input 2 Fault Reset Machine Input 3 Home Flag Machine Input 4 Trigger Control Outputs One normally closed relay contact provides a dedicated “Drive Ready” output. Two opto isolated outputs are single ended, active low and are current sinking.

  • Page 12: Receiving And Installation

    Section 3 Receiving and Installation Receiving & Inspection Baldor Controls are thoroughly tested at the factory and carefully packaged for shipment. When you receive your control, there are several things you should do immediately. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control.

  • Page 13: Electrical Installation

    Connectors are to be installed using crimp tool specified by the manufacturer of the connector. Only class 1 wiring should be used. System Grounding Baldor controls are designed to be powered from standard single and three phase lines that are electrically symmetrical with respect to ground. System grounding is an important step in the overall installation to prevent problems.
  • Page 14 Figure 3-3 Recommended System Grounding (1 phase) for UL Note: Control AC Main Wiring shown for clarity of grounding Supply method only. Not representative of actual terminal block location. Safety Earth Route all 3 wires L, N, and Earth Ground (Ground) together in conduit or cable.

  • Page 15: System Grounding

    AC power that is symmetrical with respect to ground. Input Power Conditioning Baldor controls are designed for direct connection to standard single and three phase lines that are electrically symmetrical with respect to ground. Certain power line conditions must be avoided. An AC line reactor or an isolation transformer may be required for some power conditions.

  • Page 16: X1 Power Connections

    Table 3-1 Wire Size and Protection Devices (for units with Power Supply) Catalog Number Incoming Power Input Input Wire Gauge Wire Gauge Contin o s Continuous Inp t Input Fuse Nominal Input Nominal Input Output Output Breaker Breaker Voltage Time Amps (RMS) Delay (A)
  • Page 17 Breaker Connection Note 2 Components not provided with Control. Notes: Baldor See “Protection Devices” described in this section. Control Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding.
  • Page 18 Connection Note 2 Components not provided with Control. Notes: See Protection Device description in this section. Baldor Metal conduit or shielded cable should be used. Connect Control conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding.
  • Page 19 Figure 3-9 Connector Locations (Single Phase Controls) X1 - Power Connector The holes in the top and Monitor bottom of the enclosure Earth are for cable clamps. Be Input Power AC Line sure to use an M4 bolt Neutral 12mm in length. Longer Motor lead “U”...
  • Page 20 Figure 3-10 Connector Locations (Three Phase Controls) The holes in the top and bottom of the X1 - Power Connector enclosure are for cable clamps. Be sure Earth to use an M4 bolt 12mm in length. Phase 1 Input Longer bolts may short circuit the Input Power Phase 2 Input electrical components inside the control.

  • Page 21: X1 Motor Connections

    Figure 3-11 Motor Connections for UL Notes: Metal conduit or shielded cable should be used. Connect Baldor conduits so the use of Load Reactor* or RC Device* does not Control interrupt EMI/RFI shielding. Use same gauge wire for Earth ground as is used for L and N.

  • Page 22: Motor Thermostat

    Figure 3-13 Optional M-Contactor Connections * RC Device * M-Contactor Electrocube To Power Source RG1781-3 (Rated Coil Voltage) For three phase controls, this is labeled “PE”. * Optional components not provided with control. Note 1 Note 2 M Enable Note: Close “Enable” * Motor after “M”...

  • Page 23: X1 +24Vdc Logic Supply

    X1 +24VDC Logic Supply For FPxAxxxx-xxx3 only. A separate 24VDC supply to the “Logic Power” input is required for operation. An external 24 VDC power source must be used. If bus power is lost, the logic circuits are still active if the 24VDC is present. This is important to maintain position reference, for example.
  • Page 24 X3 Digital Inputs Continued Table 3-3 Opto Input Signal Conditions Signal Switch = Closed (active) Switch = Open (not active) Number Name X3-9 Enable Drive enabled. Drive disabled. X3-10 MaI3 Machine Input 3 = Logical 1 Machine Input 3 = Logical 0 X3-11 MaI4 Machine Input 4 = Logical 1...
  • Page 25 X3 Digital Inputs Continued Figure 3-17 Positioning Mode Timing Diagram MaI1 - 4 Time Trigger Time See Table 3-4. Trajectory Time Motion Ready = Motion in Process Time Table 3-4 Process Duration for Resolver and Encoder Feedback Time Resolver Encoder %1ms &2ms &1.2ms...

  • Page 26: Factory Installed Settings

    Factory Installed Settings Absolute moves 15 predefined absolute moves have been programmed at the factory. These moves are defined in Table 3-5. Table 3-5 Machine Inputs and Position Move Definitions Machine Inputs Buffer Buffer Speed Speed Acceleration Acceleration Position Position (Move Number) (RPM) (RPM / ms)
  • Page 27 X3 Digital Outputs - Opto Isolated Outputs The control outputs are located on the X3 connector. A customer provided, external power supply must be used if digital outputs are to be used. The opto outputs provide status information and are not required for operation, Table 3-6. Figure 3-19 Fault Relay Connections Customer provided external power source: and Non-Inductive Load Relay...

  • Page 28: X6 Rs232 / 485 Connections

    X6 RS232 / 485 Connections RS232 A null modem cable (also called a modem eliminator cable) must be used to connect the control and the computer COM port. This will ensure that the transmit and receive lines are properly connected. Either a 9 pin or a 25 pin connector can be used at the computer, Figure 3-21.
  • Page 29 RS485 Standard RS485 connections are shown in Figure 3-24. Maximum cable length is 3280 ft (1000M). Figure 3-23 9 Pin RS-485 Cable Connections For UL Installations 9 Pin Connector TX-- RX-- Computer Control Port Signal (DCE) DGND DGND (DTE) Chassis DGND Figure 3-24 9 Pin RS-485 Cable Connections For CE Installations 9 Pin Connector...
  • Page 30 Figure 3-25 RS485 4 Wire Multi-Drop for UL Installations Host Computer = Twisted Pair RX-- TX-- DGND DGND Shields Use twisted pair shielded cable with an overall shield. TX-- is 120 W typical value. Terminating resistor T Only the PC and last control are terminated. DGND Shields Figure 3-26 RS485 4 Wire Multi-Drop for CE Installations...

  • Page 31: X7 Simulated Encoder Output

    X7 Simulated Encoder Output The control provides a simulated encoder output at connector X7. This output may be used by external hardware to monitor the encoder signals. It is recommended that this output only drive one circuit load (RS422 interface -- 28LS31 device).

  • Page 32: X8 Resolver Feedback

    X8 Resolver Feedback The resolver connections are the standard feedback on Flex+ drives and connections are made at the X8 connector as shown in Figure 3-27. The resolver cable must be shielded twisted pair #22 AWG (0.34mm ) wire minimum. The cable must also have an overall shield.

  • Page 33: X9 Encoder W/Hall Tracks

    X9 Encoder w/Hall Tracks Optional (Option E) Twisted pair shielded wire with an overall shield should be used. Figure 3-29 shows the electrical connections between the encoder and the encoder connector. Figure 3-29 Encoder with Hall Tracks Connections for UL Installations Encoder DGND Hall 1+...

  • Page 34: Switch Setting And Start-Up

    Section 4 Switch Setting and Start-Up Switch AS1 Settings Monitor AS1 switches are located on the front panel between X1 and the “Monitor” LED. Note: AS1--8 is shown in the “ON” position (Drive Enabled). All other switches are shown in the “OFF”...
  • Page 35 Setting of switches AS1-5 to AS1-8 The function of switches AS1-5 to AS1-8 are described in Table 4-2. Table 4-2 AS1-5 to AS1-8 Description Switch Function AS1-5 Not Used AS1-6 Hold-Position Hold-Position is active. Hold-Position is not active AS1-7 Offset Tuning Automatic Offset Tuning is Automatic Offset Tuning is not active.

  • Page 36: Start-Up Procedure

    Start-Up Procedure Power Off Checks Before you apply power, it is very important to verify the following: Disconnect the load from the motor shaft until instructed to apply a load. If this cannot be done, disconnect the motor wires at X1-U, V and W. Verify that switches AS1-5 to AS1-8 are set to OFF.
  • Page 37 4-4 Switch Setting & Start-Up MN1276...

  • Page 38: Operation

    Section 5 Operation Installing Software on your PC The setup software is Windows--based. The servo control connects to a serial port on your PC. The setup wizard will guide you through the necessary steps to set--up your servo control. Online--help to each topic is available. Minimum system requirements Hardware requirements (minimum): Processor: Intel 80486 / 33 MHz...
  • Page 39 Select “Binary Transfers” from the Settings pull down menu within Terminal program. Set the Binary Transfer protocol to XModem/CRC. Close menu and save the settings. Terminal Communications settings are now complete. Windows 95 Power up the Host and start Windows software. In “Control Panel”...

  • Page 40: Using The Setup Wizard

    Using The Setup Wizard The setup software wizard guides you through each step to set the basic parameters. This wizard is activated automatically after each start-up of the software. This automatic start of the Wizard can be turned off. It can be activated (and reset to automatic start) by Help ( Wizard.
  • Page 41 Figure 5-1 Flowchart of the Setup Wizard Setup Wizard Sequence 1: Skip Motor and Control Sequence 4: Skip Velocity Parameters General: -- App. Bus Voltage --Sim Enc. Output General: -- Max. Velocity -- Time to Motor: Max. Velocity -- Select the motor -- Min.

  • Page 42: Set Up Software

    Set up Software Opening menu. Click NEXT to go to the Set up Software. If you have already set up the parameters and saved them to a file, click FINISH then load the parameter file using the File ( Open selection. Start by selecting the Motor and Control and these parameters will be entered automatically for you by the software for a stock motor.

  • Page 43: Motor

    There are 7 parts to the setup procedure: Motor Select your motor from the list. First, select the general “Motor Type”. Then select your specific “Motor ID”. All of the parameters will be entered if your motor is on the list. If your motor is not on the list, you must define a motor and all of its parameters.

  • Page 44: Operating Mode

    After the motor and control are selected, click the General menu and note that the values are filed in. Operating Mode Select the operating mode of the control. Choices are: Current Mode Velocity Mode Positioning (15 preset point to point moves) Click “Download”...

  • Page 45: Current Parameter

    Current Parameter Nominal and peak current values are automatically entered for the motor type. For manual tuning only, set the control current limit value to a percentage of the continuous current rating. For example, if your control is rated for 5A continuous current and you desire to limit the output current to 4A, enter 80%.

  • Page 46: Positioning

    Positioning There are two ways to start a move: Software triggered or Hardware triggered. Software Triggered (Refer to Section 3 for information on how to setup a move). 1. From the Main menu select “Setup ) Operation Mode”. 2. Click on “Positioning Tab” and set Command Source to “Software”. 3.

  • Page 47: Home

    Home Starts a search for the machines absolute zero position. When home is found, the control will hold the position at absolute zero. There are three Homing types: Index channel, Capture and Actual Position. Index Channel causes the motor shaft to rotate to a predefined home position.

  • Page 48: Drift

    Drift If you know the input offset value of the control, you may enter the value manually. Otherwise, you may initiate automatic offset tuning and let the control measure and set this value. Click “Download” when finished. Figure 5-7 Drift Parameter Screen Autotune You may manually tune the control (see appendix) or use autotune to allow the control to tune itself.

  • Page 49: Main Menu Choice Descriptions

    Main Menu Choice Descriptions File Open a new editor window. Open an existing editor window. Close the active editor window. Close all editor windows. Save the active editor window to a file. Save the active editor window to a new file name . Save all editor windows.

  • Page 50: Tuning

    Tuning Allows manual or automatic tuning to remove offset drift. Allows manual or automatic tuning of velocity control parameters. Watch Show or hide the “symbols list bar”. Show or hide the “system parameters bar”. Show or hide the “system status bar”. Gather and plot motor data for two variables.

  • Page 51: Plc Program

    Alphabetic glossary listing of keywords. Search for help based on a keyword. Get help for a specific topic. Starts the setup wizard to configure a motor and control. Software version and release information. PLC Program At the main menu, select “Functions” then “PLC”. See Figure 5-9. Determine which event (listed under the THEN column) you wish to use.

  • Page 52: Troubleshooting

    Section 6 Troubleshooting Overview The system troubleshooting procedures involves observing the status of the “Ready” LED, the “DB On” LED and the “Monitor” 7 segment display. The tables in this section provide information related to the indications provided by these devices.
  • Page 53 Cause EEPROM checksum error. The personality must be downloaded to EEPROM and reset the control. If problem remains, contact Baldor. Velocity data in the EEPROM failed. The velocity data must be downloaded to EEPROM and reset the control. If problem remains, contact Baldor.

  • Page 54: Specifications & Product Data

    Section 7 Specifications & Product Data Identification - -R Servo Control Flex +Drive Logic Supply (Option) 0 = Internal 24VDC Supply 3 = External customer provided Input Voltage 24VDC required 1=115VAC 2=230VAC Serial Port Type (Option) 4=460/400VAC 2 = RS232 Current Rating 4 = RS485 A02 = 2 / 2.5 Amps...

  • Page 55: Specifications

    Specifications Description Unit FPX © FPX © FPX © FPX © A02T A05T A07T A02S A05S A010S A015S Input Voltage Range Nominal 115 / 230 Minimum 92 / 184 Maximum 132 / 265 50/60 "5% Input Frequency Nominal Output Bus Nominal 160 / 320 (@ 115 / 230 input)
  • Page 56 Specifications Continued Description Unit A02TB A05TB A07TB A15TR A20TR A27TR Input Voltage Range Nominal 460 @ 60Hz / 400 @ 50Hz Minimum 400 / 360 Maximum 528 / 480 50/60 "5% Input Frequency Nominal Output Bus Nominal 565 / 678 (@ 400 / 460 input) Minimum 509 / --...

  • Page 57: Vdc Logic Power Input

    24VDC Logic Power Input (Option FPxAxxxx--xxx3 ONLY) Description Unit A02T A05T A07T A02S A05S A10S A15S Input Voltage (maximum ripple = "10%) 20 -- 30 Input Current @ 24VDC 0.55 -- 0.8 ¡ Power On surge current (24VDC 100msec) ¡ Depends on installed options. 24VDC Logic Power Input (Option FP4Axxxx--xxx3 ONLY) Continued...

  • Page 58: Encoder Input

    Encoder Input (Handwheel or Feedback) Description Unit Signal Type RS422 Operating Mode A / B Quadrature Maximum Input Frequency Cycle Time msec Serial Interface (Option FPXAXXXX--XX2X) Description Unit Communication Type RS232C (not galvanically isolated) Transmission Rate Baud 9600 (not adjustable) Optional Interface (Option FPXAXXXX--XX4X) Communication Type RS485 (not galvanically isolated)

  • Page 59: Dimensions

    Dimensions Size E, G and H Size A, B and C 1.57' (40mm) 15.75 (400) 7.70' (195.5mm) 15.14 (385) 6.81' (173mm) 14.05 (357) Depth 0.2 (5.2) Dia. Size A, B, C = 6.0 (152) 4 Places 0.12 (3.0) Clearance Requirements (all sizes): 0.06' (15mm) top and bottom 0.04' (10mm) left and right side 0.374 (9.5)

  • Page 60: Section 8 Ce Guidelines

    Section 8 CE Guidelines CE Declaration of Conformity Baldor indicates that the products are only components and not ready for immediate or instant use within the meaning of “Safety law of appliance”, “EMC Law” or “Machine directive”. The final mode of operation is defined only after installation into the user’s equipment.
  • Page 61 (such as an OEM or system integrator). Baldor products which meet the EMC directive requirements are indicated with a “CE” mark. A duly signed CE declaration of conformity is available from Baldor. EMC Wiring Technique CABINET The drawing shows an electroplated zinc coated enclosure, which is connected to ground.

  • Page 62: Emc Installation Instructions

    EMC Installation Instructions To ensure electromagnetic compatibility (EMC), the following installation instructions should be completed. These steps help to reduce interference. Consider the following: Grounding of all system elements to a central ground point Shielding of all cables and signal wires Filtering of power lines A proper enclosure should have the following characteristics: All metal conducting parts of the enclosure must be electrically...
  • Page 63 Input Signal Cable Grounding Control Cable Simulated Encoder Output Cable Grounding Control Cable Controller Resolver Cable Grounding Control Resolver Connector Housing Cable Connection of shields to analog ground is optional. Encoder Cable Grounding Control Encoder Connector Cable Housing Connection of shields to digital ground is optional. 8-4 CE Guidelines MN1276...

  • Page 64: Section 9 Accessories And Options

    CE regulations. All connectors and other components used must be compatible with this shielded cable. Motor Power Cable Length Cable Assembly Cable Assembly Cable Rated C rrent Cable Rated Current Baldor Catalog N mber Baldor Catalog Number Description Feet Meters Power Cable Assembly CBL015SP--FHM Threaded connector...

  • Page 65: Emc Ac Mains Filter

    Resolver Feedback Cable Length Cable Assembly Cable Assembly Motor Type Motor Type Baldor Catalog Number Baldor Catalog Number Feet Meters Description Resolver Feedback Cable CBL015SF--ALM Assembly CBL030SF--ALM Threaded connector CBL046SF--ALM (Standard-Metric Style) CBL061SF--ALM CBL076SF--ALM CBL152SF--ALM 15.2 Resolver Feedback Cable CBL015SF--ALQ...
  • Page 66 For package size E, G and H (Model T -- 3 Phase Required for FP4xx) Rated Leakage Weight Filter Type Rated Volts Amps Baldor No. Current mA lbs (kg) @ 40#C FN 3258 - 30 - 47 184.7 2.64 (1.2)

  • Page 67: Regeneration Resistor

    Some controls are shipped with an internal regen resistor. If an internal resistor is not present, a regeneration resistor should be installed to dissipate energy during braking if a Fault “1” (over-voltage) occurs. Baldor Catalog Number 115VAC Controls 230VAC Controls...
  • Page 68 CAN Bus (Optional -- Not available for controls with encoder feedback) Controls that are supplied with the CAN bus option have two additional connectors, X10 and X11 (conform to DS102, version 2.0). These are shown in Figure 9-1. CAN is a factory installed option. Figure 9-1 CAN Bus Connectors Monitor Note: On some models, the width of the...
  • Page 69 NODE_ID may be changed by switch settings or serial command (e.g. command: CAN.ID = 50). Available addresses are 1 to 127. CAN Bus Features The following features are available with the Baldor CAN_OPEN structure: One SDO Two PDO’s; each for transmit and receive (synchronous or asynchronous)

  • Page 70: Getting Started With Can_Open

    Index Range The index range from 0x1000 to 0x100D is valid. The following index ranges are important: 0x1400 1st PDO receive (communication) 0x1402 2nd PDO receive (communication) 0x1600 1st PDO receive (mapping) 0x1602 2nd PDO receive (mapping) 0x1800 1st PDO transmit (communication) 0x1802 2nd PDO transmit (communication) 0x1A00...
  • Page 71 The default Baud rate is set to 125 kbit/second and the Node_ID is the drive address+1 (AS1 switches 1 to 4). Note: Every drive, connected to one CAN Bus system must have a different Node_ID. After power up you will receive an EMERGENCY message with two data bytes (0x00 and 0x00) to inform you that the CAN_DRIVE is now active.
  • Page 72 To read a parameter from the drive: PC Master Drive 0x40 Ind_lo Ind_hi ID = 0x600 + NODE_ID <-------------------------------------------- 0x60 Ind_lo Ind_hi 0x00 0x00 0x00 0x00 ID = 0x580 + NODE_ID <-------------------------------------------- Where: Don’t care Identifier Hexadecimal data format D0 - D7 Data byte 0 to 7 of CAN message Ind_lo Low byte of Index of Object dictionary...

  • Page 73: Identifiers And Object List

    Identifiers and object list The distribution of the identifiers of the supported objects conforms to Can Open (DS301, V 3.0, S. 8--12). Message / Object Function Code COB - Identifier Services Start_Remote_Node Stop_Remote_Node NMT Services 0 (broadcast) Pre-Operational-State NMT_Reset_Node NMT_Reset_Com 128 (broadcast) Synchronization Sync.
  • Page 74 Expedited domain download and initiate domain download Domain Protocols 7..5: 3..2:n = 1.byte up to 4 data bytes Expedited Domain Download ccs 001 (0 or n) =22, 2x1 multiplexor data to be Request scs 011 downloaded Confirm Initiate Domain Download ccs 001 =20, 2x2 multiplexor...
  • Page 75 Segmented domain upload Domain Protocols 7..5: 4: t 3..1:n = 1.byte up to 3+ up to 4 data bytes Upload Domain Segment ccs 001 0 / 1 =60 / 70 Reserved Request scs 000 0 / 1 =0E / 1E 7 data bytes to be downloaded Confirm End of Upload Domain Segment...
  • Page 76 Object Dictionary (CAN - Version: 23310D) Index (hex) Object Used 0000 not used 0001 -- 001F Static Data Types OBJECT_UNSIGNED8 0005 0020 -- 003F Complex Data Types 0040 -- 005F Manufacturer Specific Data Types 0060 -- 007F “Device Profile Specific Static Data Types” 00A0 -- 0FFF ”Reserved for future use ”...
  • Page 77 Continued Index (hex) Object Used PDO mappable parameters (2080 - - 2093): MANUFACT_POS 2080 MANUFACT_ABS_POS 2082 MANUFACT_VEL 2081 MANUFACT_VEL_COMMAND 2090 MANUFACT_CONTROL_COMMAND 2091 MANUFACT_TORQUE_COMMAND 2092 MANUFACT_POS_COMMAND 2093 Read only: MANUFACT_COM_ACTU 2100 MANUFACT_COM_ACTV 2101 MANUFACT_COM_ANAIN 2102 MANUFACT_COM_CUR 2103 MANUFACT_COM_FLT 2104 MANUFACT_COM_FEST 2105 MANUFACT_COM_LOG 2106 MANUFACT_COM_MODE...
  • Page 78 Subindexes to Index 2010 (CUR. Commands) ASCII Command Subindex Read/Write (RW), Read only (RO), Write only (WO) (Entries) 0x00 CUR.ACTV 0x01 CUR.ACTU 0x02 Reserved 0x03 CUR.IPEAK 0x04 CUR.INOM 0x05 Reserved 0x06 Reserved 0x07 Reserved 0x08 CUR.TOFR 0x09 CUR.TOSH 0x0A CUR.BEMF 0x0B CUR.SCAL 0x0C...
  • Page 79 Subindexes to Index 2012 (HW. Commands) ASCII Command Subindex Read/Write (RW), Read only (RO), Write only (WO) (Entries) 0x00 HW.GRFX 0x01 HW.GRSH 0x02 HW.PLCGEAR 0x03 HW.RES 0x04 HW.TYPE 0x05 Subindexes to Index 2013 (POS. Commands) ASCII Command Subindex Read/Write (RW), Read only (RO), Write only (WO) (Entries) 0x00 POS.FEWRN...
  • Page 80 Subindexes to Index 2015 (DRV. Commands) ASCII Command Subindex Read/Write (RW), Read only (RO), Write only (WO) (Entries) 0x00 DRV.BUSAPP 0x01 DRV.BUSOV 0x02 DRV.BUSV 0x03 DRV.I2T 0x04 DRV.ID 0x05 DRV.IDX 0x06 DRV.INOM 0x07 DRV.IPEAK 0x08 DRV.LIFE 0x09 Subindexes to Index 2016 (SYS. Commands) ASCII Command Subindex Read/Write (RW), Read only (RO), Write only (WO)
  • Page 81 Subindexes to Index 2018 (MOT. Commands) ASCII Command Subindex Read/Write (RW), Read only (RO), Write only (WO) (Entries) 0x00 MOT.ABSPOS 0x01 MOT.ACC 0x02 MOT.VEL 0x03 Reserved 0x04 MOT.TYPE 0x05 MOT.DWELL 0x06 MOT.INCCW 0x07 MOT.INCW 0x08 MOT.SRC 0x09 MOT.STATUS 0x0A MOT.TRIG 0x0B MOT.BUFTYPE 0x0C...

  • Page 82: Appendix A Manual Tuning

    Appendix A Manual Tuning TUNING This appendix presents guidelines for manual tuning the Control. Tuning is necessary, since a various loads (friction and inertia) will effect the drive response. Response may be defined as the time required for the drive to reach speed. Various software “tools”...

  • Page 83: Motor

    There are 7 parts to the setup procedure: Motor Select your motor from the library. First, select the general motor type. Then select your specific motor. All of the parameters will be entered if your motor is on the list. If your motor is not on the list, you may define a motor and all of its parameters.

  • Page 84: Operating Mode

    After the motor and control are selected, click the General menu and note that the values are filed in. Operating Mode Select the operating mode of the control. Choices are: Current Mode Velocity Mode Positioning (15 preset point to point moves) Click “Download”...

  • Page 85: Current Parameter

    Current Parameter Nominal and peak current values are automatically entered for the motor type. For manual tuning only, set the control current limit value to a percentage of the continuous current rating. For example, if your control is rated for 5A continuous current and you desire to limit the output current to 4A, enter 80%.

  • Page 86: Drift

    Drift If you know the input offset value of the control, you may enter the value manually. Otherwise, you may initiate automatic offset tuning and let the control measure and set this value. Click “Download” when finished. Figure A-8 Drift Parameter Screen Manual Tuning The first six steps of the manual tuning process is shown in Figure A-9.
  • Page 87 POLE PLACEMENT Pole placement provides a “no--overshoot response” when tuned for the correct inertia. This is the easiest and recommended method of adjustment. Inertia Click in the “Load” block and enter the value in Kg--cm . The range is from 0 to 133 Kg--cm If the inertia is under--estimated, the system will be stable.
  • Page 88 PI COMPENSATION PI method of adjustment allows adjustment of the acceleration ramp time and overshoot values. If “PI” Compensation is selected, you would enter values for GV--gain and GVI--gain. Select PI Compensation instead of Pole Placement on the menu shown in Figure A-9. This is an advanced method of adjustment for use by servo engineers.
  • Page 89 GV- -Gain This is the “proportional gain” of the velocity loop. It controls the gain of the velocity loop by adjusting the controls response to the error. The error is the difference between the commanded and actual velocity. The higher the gain, the smaller the difference (or error).

  • Page 90: Plotting Of Move

    Plotting of Move At any time after the setup parameters are downloaded to the control, you may proceed to the plotting routine. Plot allows you to verify that the parameter values you entered provide adequate system response. In this section, you will inform the software what move to perform. You will enter time (for the move), direction (CW or CCW) and speed.

  • Page 91: Pulse Follower Applications

    Pulse Follower Applications (Only used in “pulse follower” applications). Choose Tuning Select the “Manual tune” method as shown in Figure shown in Figure A-9. Position Parameters Click on the “Position Parameters” button. You will see parameters as shown in Figure A-13. Selecting “None Feedforward” allows you to enter Position Gain. Figure A-13 Position Control Menu Select Velocity feedforward allows you to enter Position Gain and Velocity, a parameter that is proportional to the desired velocity.

  • Page 92: Appendix B Command Set

    Appendix B Command Set Flex - - ASCII - - Command - - Set General Flex controls use the RS232 communication port (optional RS485) as the Interface. This document describes existing FlexDrive/Flex+Drive ASCII terminal commands for setup and control of the servo drive. There are three types of ASCII commands: Parameters.
  • Page 93 Upon receiving a command, the controller answers by sending the function parameter and variable list. General purpose commands are not prefixed. These commands only consist of the command identifier and therefore need the general structure “Command Identifier” [“Delimiter”]“Parameter list” [CR] With the non--prefixed commands, no delimiter is mandatory, but the blank space can be inserted optional.
  • Page 94 Start- -up with Terminal Communication and Command Examples Select the correct COM port NR. and set the following at your PC: -- Baud Rate: 9600 -- Protocol (Hardware, Xon/Xoff, None): OFF -- Data Length: 8 Bit --Stop Bit: 1 --Parity: NONE Set the control address.
  • Page 95 General Settings System Constants Command Description Range Common Lev I LevII SYS.POWER Queries dip switch ID, (see DRV.ID) SYS.FBACK Queries system feedback (encoder / resolver)as defined by ALTERA SYS.INFO SYS.INFO Queries firmware version with naming and Queries firmware version with naming and ASCII letters ASCII letters X ¡...
  • Page 96 Additional System parameters (mostly SYS.* prefixed) Velocity Feedback Parameters: Command Description Units Range Default / Par. set MTR.RPLS Resolver number of poles 1 : 65535 E / P SYS.ENCRES Queries / updates encoder feedback pulses/rev. 1 : 16384 E / P resolution for encoder motors (in pulses per revolution, i.e.
  • Page 97 PLC Parameters: Command Description Units Range Default / Par. set PLC.LINE Defines PLC statement :IF [input]=TRUE, num: 0 : 12 PLC disabled, E / P THEN [action] set/started, with sytax action: s. left all lines: PLC.LINE [num] [action] [input] [num] lines: input = false [action] -- PLC line number, and string...
  • Page 98 OCI Interface Parameters: Command Description Units Range Default / Par. set Significant CAN.BD (The range check is: Invalid execute 10 : 1000 context.) It should be: “Range error” CAN.ID (The range check is: Invalid execute 1 : 127 context.) Digital Interface Parameters: Command Description Units...
  • Page 99 System Variables General Variables: Command Description Units Range Default / Par. set DRV.LIFE Drive life time. Unsign.Word E / -- SYS.STTS Queries system status as a double word, Long Word -- / -- where Word High word is drive address (set by Dip switches) Low word: bit array “OR”ed with system status:...
  • Page 100 X1 Possible Faults -- Continued X1 Fault Display Description “FAULT_RELAY” when fault relay is closed. Displays ’9’. “EAF” “MISSING INT” “POWER_ID” DRV.ID != SYS.POWER. Displays small ’u’. “CW_CCW” Both limit switches are on. Displays ’L’. “DESIGN_FAILURE” Control design fail. Displays small ’c’. “EE_CLEARED”...
  • Page 101 Queries of System Variables, Status, Faults Single Values: Command Description Units Range Default / Par. set ACTU Query for actual current U 0.01 A -- / -- CUR.ACTU ACTV Query for actual current V 0.01 A -- / -- CUR.ACTV ANAIN Query for analog input -- / --...
  • Page 102 Description Parameter Range CLEAR Clear EEPROM content and drive life time variable by filling it with 0xFFFF (except code for Level I/II; Baldor/HD) EEDUMP Display all EEPROM data (256 words). Uploads EEPROM data to terminal (ASCII file) Operation Mode Control...
  • Page 103 Sys.mod 0: Current mode Parameters: Command Description Units Range Default / Par. set CUR.BEMF Back EMF voltage compensation, in 80 : 120 E / P percentage of nominal motor value Ke. CUR.IPEAK Queries / updates application peak current 0 : 1000 E / P in percentage of DRV.IPEAK CUR.INOM...
  • Page 104 Sys.mod 1 & Sys.mod 3 Velocity mode Parameters: Command Description Units Range Default / Par. set VEL.ACC Queries /updates velocity acceleration RPM/ms 0 : 7500 E / P limits ( time to max. velocity ). VEL.ADZON Queries / updates min. velocity in RPM 0 : Max_RPM E / P VEL.BW...
  • Page 105 Parameters: Command Description Units Range Default / Par. set JOG.TIME Jog time in milliseconds 3432448 E / -- JOG.TYPE 0 -- continuos, 1 -- step, 2 -- square wave 0 : 2 E / -- JOG.VEL Jog velocity in RPM, limited to maximum VEL.MXRPM E / -- velocity VEL.MXRPM.
  • Page 106 Position Controller Position Controller Parameters: Command Description Units Range Default / Par. set POS.FFA Queries/updates acceleration FF factor 25 : 100 E / P unsigned integer ranged 0..100 POS.FFTYPE Queries / updates FF type with position 0 : 2 E / P controller redesign 0 -- FF none, 1 -- velocity FF, 2 -- acceleration FF POS.FFV...
  • Page 107 Sys.mod 2: Pulse Follower (Handwheel respectively Pulse/Direction) Parameters: Command Description Units Range Default / Par. set HW.GRFX Queries/updates mantissa HW gear --32767 : E / P parameter, negative value means negative 32767 gear. HW.GRSH Queries/updates shift HW gear parameter 0 : 32767 E / P HW.PLC GEAR Queries/ updates PLC gear ratio...
  • Page 108 4.4.3Sys.mod 3: PTP mode Parameters: Command Description Units Range Default / Par. set MOT.ACC Motion acceleration and deceleration RPM / 10ms 1 : 65535 E / P MOT.BUF With parameters [line] [position] [velocity] line: -- line: 1 : 15 line: -- E / P [acceleration], the motion buffer is initialized pos:...
  • Page 109 Homing Parameters: Command Description Units Range Default / Par. set HOM.ACC Queries / updates HOME acceleration RPM / 10ms 1 : 65535 E / P2 HOM.VEL Queries / updates homing velocity --2500 : 2500 E / P2 HOM.TYPE Queries / updates HOME type: 1:3(resolver) E / P2 1 -- ZERO is found by Home Flag and...
  • Page 110 TEL: +39 11 562 4440 TEL: +61 29674 5455 TEL: +65 744 2572 TEL: +52 47 61 2030 FAX:+39 11 562 5660 FAX:+61 29674 2495 FAX:+65 747 1708 FAX:+52 47 61 2010 ! Baldor Electric Company Printed in UK MN1276 2/03...

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