Baldor MicroFlex Installation Manual
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Baldor MicroFlex Installation Manual

Baldor MicroFlex Installation Manual

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SERVO DRIVE
MicroFlex
Servo Control
Installation Manual
03/10
MN1919

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Summary of Contents for Baldor MicroFlex

  • Page 1 SERVO DRIVE MicroFlex Servo Control Installation Manual 03/10 MN1919...

  • Page 3: Table Of Contents

    ......... 3-18 3.5.2 Motor power cable pin configuration - Baldor BSM rotary motors ..3-18 3.5.3...
  • Page 4 ..........6.1.1 Connecting the MicroFlex to the PC .......

  • Page 5: Feedback

    7.1.3 Power-cycling the MicroFlex ........
  • Page 6 C.1.2 MicroFlex compliance ......... . .

  • Page 7: General Information

    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.

  • Page 8: Safety Notice

    www.baldormotion.com Product notice Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Safety Notice Intended use: These drives are intended for use in stationary ground based applications in industrial power installations according to the standards EN60204 and VDE0160.
  • Page 9 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. 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.
  • Page 10 CAUTION: Violent jamming (stopping) of the motor during operation may damage the motor and drive. CAUTION: Operating the MicroFlex in Torque mode with no load attached to the motor can cause the motor to accelerate rapidly to excessive speed. CAUTION: If the drive enable signal is already present when power is applied to the MicroFlex, the motor could begin to move immediately.
  • Page 11 11.5 mm deep and accept M4 screws, which must be screwed in to a depth of at least 8mm. CAUTION: Removing the cover will invalidate UL certification. CAUTION: The metal heatsink on the left side of the MicroFlex can become very hot during normal operation. MN1919...
  • Page 12 www.baldormotion.com 1-6 General Information MN1919...

  • Page 13: Introduction

    1 general-purpose analog input (can be used as a speed or torque command reference). RS232 or RS485 communications (model dependent) for setup and diagnostics. MicroFlex will operate with a large range of brushless rotary and linear servo motors - for information on selecting Baldor servo motors, please see the sales brochure BR1202 available from your local Baldor representative.

  • Page 14: Receiving And Inspection

    4. Inspect the MicroFlex for external damage during shipment and report any damage to the carrier that delivered your MicroFlex. 5. If MicroFlex is to be stored for several weeks before use, be sure that it is stored in a location that conforms to the storage humidity and temperature specifications shown in section 8.1.14.

  • Page 15: Units And Abbreviations

    www.baldormotion.com 2.3 Units and abbreviations The following units and abbreviations may appear in this manual: ....Ampere ... . . Alternating current .
  • Page 16 www.baldormotion.com 2-4 Introduction MN1919...

  • Page 17: Basic Installation

    Without the regeneration resistor, the drive may produce an overvoltage fault. All MicroFlex models have overvoltage sensing circuitry. Regeneration resistors may be purchased separately - see Appendix A. A cooling fan may be required to allow operation of the MicroFlex at full rated current (see section 3.2.2). MN1919...

  • Page 18: Tools And Miscellaneous Hardware

    Hard disk space 40MB 60MB CD-ROM A CD-ROM drive Serial port RS232 or RS485 serial port (depending on MicroFlex model) Screen 800 x 600, 256 colors 1024 x 768, 256 colors Mouse A mouse or similar pointing device Operating system...

  • Page 19: Mechanical Installation And Cooling Requirements

    The MicroFlex must be secured by the slots in the flange. The protective earth/ground (the threaded hole on the top of the MicroFlex) must be bonded to a safety earth/ground using either a 25A conductor or a conductor of three times the peak current rating - whichever is the greater.

  • Page 20: Dimensions

    www.baldormotion.com 3.2.1 Dimensions (3.2) 63.5 (0.4) (2.5) (0.2) Mounting hole and slot detail 5.5 mm FRONT PANEL Dimensions shown as: mm (inches). Depth: 157 mm (6.2 in) Weight: 1A: 1.45kg (3.2lb) 3A: 1.45kg (3.2lb) 6A: 1.50kg (3.3lb) 9A: 1.55kg (3.4lb) Figure 1 - Package dimensions 3-4 Basic Installation MN1919...

  • Page 21: Mounting And Cooling The Microflex

    Ensure you have read and understood the Mechanical installation and location requirements in section 3.2. Mount the MicroFlex vertically on its rear side, the side opposite the front panel. M5 bolts or screws should be used to mount the MicroFlex. Detailed dimensions are shown in section 3.2.1.

  • Page 22: Derating Characteristic - 1A Model

    www.baldormotion.com 3.2.3 Derating characteristic - 1A model The 1A model can be operated at maximum rated current at 55°C without any additional cooling. The output current does not need to be derated. The overload limit is 2A. 3.2.4 Derating characteristic - 3A model The following derating characteristics are for model FMH2A03TR-EN23.

  • Page 23: Derating Characteristic - 6A Model

    www.baldormotion.com 3.2.5 Derating characteristic - 6A model The following derating characteristics are for model FMH2A06TR-EN23. Single-phase AC supply 1.5m/s forced air 1m/s forced air Natural cooling Ambient temperature (°C) Three-phase AC supply 1.5m/s forced air 1m/s forced air Natural cooling Ambient temperature (°C) Notes: Load power factor = 0.75.

  • Page 24: Derating Characteristic - 9A Model

    Overload limit for model FMH2A09TR-EN23 is 18A. 3.2.7 Overtemperature trips The MicroFlex contains internal temperature sensors that will cause it to trip and disable if the temperature exceeds 80°C on the 1A or 3A models, or 75°C on the 6A and 9A models. This limit can be read using the TEMPERATURELIMITFATAL keyword - see the Mint help file for details.

  • Page 25: Connector Locations

    www.baldormotion.com 3.3 Connector locations X1 Power Earth/Ground Earth/Ground (NC) AC Phase 1 / L AC Phase 2 / N AC Phase 3 Motor U X6 RS232 Motor V RS232 RS485/422 Motor W (NC) (NC) Regen Regen (NC) (NC) 0V GND 0V GND (NC) (NC)

  • Page 26: Power Connections

    AC power filter, which could be much larger (see section A.1.3). If the MicroFlex and filter are mounted in an enclosure, it is recommended the enclosure is earthed using a 10mm conductor.

  • Page 27: Single-Phase Or Three-Phase Power Connections

    For CE compliance, an AC filter must be connected between the AC power supply and the MicroFlex. If local codes do not specify different regulations, use at least the same gauge wire for earth/ground as is used for L1, L2 and L3.

  • Page 28: Input Power Conditioning

    MicroFlex to limit the maximum symmetrical short circuit current to 5000A. If the feeder or branch circuit that provides power to the MicroFlex has power factor correction capacitors that are switched on line and off line, the capacitors must not be switched while the drive is connected to the AC power line.

  • Page 29: Power Disconnect And Protection Devices

    L2 for example). When supplying AC power in this way, the voltage between the two phases must not exceed the rated input voltage of the MicroFlex. A two pole breaker must be used to isolate both lines. Fuses must be fitted in both lines.

  • Page 30: Recommended Fuses And Wire Sizes

    Line wires. 3.4.6 Drive overload protection The MicroFlex will immediately trip and disable if there is an overload condition. The parameters for managing drive overloads are configured automatically by the Commissioning Wizard (see section 6.2.3).

  • Page 31: Power Supply Filters

    To comply with EEC directive 89/336/EEC, an AC power filter of the appropriate type must be connected. This can be supplied by Baldor and will ensure that the MicroFlex complies with the CE specifications for which it has been tested. Ideally, one filter should be provided for each MicroFlex;...

  • Page 32: Control Circuit Supply

    I/O information. A separate fused 24V supply should be provided for the MicroFlex. If other devices are likely to be powered from the same 24V supply, a filter (Baldor catalog number FI0014A00) should be installed to isolate the MicroFlex from the rest of the system.
  • Page 33 Baldor representative. The motor must be capable of being powered by an inverter PWM output - see section 8.1.3 for details. The motor can be connected directly to the MicroFlex or through a motor contactor (M-Contactor). The motor outputs are conditionally short-circuit proof.

  • Page 34: Motor Circuit Contactors

    If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor) may be installed to provide a physical disconnection of the motor windings from the MicroFlex (see section 3.5). Opening the M-Contactor ensures that the MicroFlex cannot drive the motor, which may be necessary during equipment maintenance or similar operations.

  • Page 35: Motor Cable Pin Configuration - Baldor Linear Motors

    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...

  • Page 36: Regeneration Resistor (Dynamic Brake Resistor)

    A regeneration resistor may generate enough heat to ignite combustible materials. To avoid fire hazard, keep all combustible materials and flammable vapors away from the resistor. 3.6.1 Regeneration capacity The regeneration capacity of the MicroFlex can be calculated from the following formula:   ...
  • Page 37 www.baldormotion.com 3.7 Regeneration resistor selection The following calculations can be used to estimate the type of regeneration resistor that will be required for the application. 3.7.1 Required information To complete the calculation, some basic information is required. Remember to use the worst-case scenario to ensure that the regeneration power is not underestimated.
  • Page 38 www.baldormotion.com 3.7.2 Regenerative energy The regenerative energy to be dissipated, E, is the difference between the initial energy in the system (before deceleration begins) and the final energy in the system (after deceleration has finished). If the system is brought to rest then the final energy is zero. The energy of a rotating object is given by the formula: ×...

  • Page 39: Resistor Choice

    Dimensions are shown in section A.1.4. * The regeneration resistors listed in Table 6 can withstand a brief overload of 10 times the rated power for 5 seconds. Please contact Baldor if larger power ratings are required. 3.7.5 Resistor derating The regeneration resistors shown in Table 6 can achieve their stated power rating only when mounted on a heatsink.
  • Page 40 www.baldormotion.com 3-24 Basic Installation MN1919...

  • Page 41: Feedback

    www.baldormotion.com Feedback 4.1 Introduction Three feedback options are available for use with linear and rotary motors; incremental encoder, encoder with SSI (Synchronous Serial Interface), or resolver. There are some important considerations when wiring the feedback device: The feedback device wiring must be separated from power wiring. Where feedback device wiring runs parallel to power cables, they must be separated by at least 76mm (3 in) Feedback device wiring must cross power wires at right angles only.

  • Page 42: Encoder Feedback - X8

    D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows the MicroFlex to increase the encoder supply voltage on pin 12 to maintain a 5V supply at the encoder.
  • Page 43 AM26LS32 47pF to CPU Differential line receiver Hall U- 47pF DGND Figure 11 - Hall channel input circuit - U phase shown 4.1.1.1 Encoder cable configuration - Baldor rotary motors Motor Twisted pairs CHA+ CHA- CHB+ CHB- Encoder CHZ+ (INDEX)
  • Page 44 Incremental encoders without Hall feedback connections may be connected to the MicroFlex. However, if Hall connections are not present, it will be necessary for the MicroFlex to perform an automatic phase search sequence each time it is powered. This will cause motor movement of up to 1 turn on rotary motors, or one pole-pitch on linear motors.
  • Page 45 4.1.1.4 Encoder cable pin configuration - rotary motors Figure 15 shows the pin configuration for a typical Baldor encoder feedback cable, part number CBL025SF-E2. Signal name MicroFlex Motor / cable Baldor encoder cable X8 pin internal wire colors CHA+...
  • Page 46 4.1.1.5 Encoder cable pin configuration - Baldor linear motors Baldor linear motors use two separate cables (encoder and Hall). The cores of these two cables must be wired to the appropriate pins of the 15-pin D-type mating connector (supplied):...

  • Page 47: Ssi Feedback - X8

    D-type connector. Connector X8 includes a ’Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows the MicroFlex to increase the encoder supply voltage on pin 12 to maintain a 5V supply at the encoder.
  • Page 48 4.1.2.1 SSI cable pin configuration Figure 18 shows the pin configuration for a typical Baldor SSI feedback cable, part number CBL025SF-S2 Signal name MicroFlex Motor / cable Baldor SSI cable X8 pin internal wire colors 5-11V out Sense Orange...

  • Page 49: Resolver Feedback - X8

    (screen) must be connected to the metallic shell of the D-type connector. The resolver input is used to create an encoder signal inside the MicroFlex. This provides the MicroFlex with an equivalent resolution of 4096 pulses per revolution (ppr), although this can be reconfigured in the Mint WorkBench Commissioning Wizard to provide 1024 ppr.
  • Page 50 4.1.3.1 Resolver cable pin configuration Figure 18 shows the pin configuration for a typical Baldor resolver feedback cable, part number CBL025SF-R1. Signal name MicroFlex Motor / cable Baldor resolver cable X8 pin internal wire colors REF+ REF- Blue COS+...

  • Page 51: Encoder Output - X7

    X8. If operating in Halls-only mode, there will be no encoder output at X7. If the MicroFlex is configured for SSI feedback, a simulated encoder output is produced at X7. The default simulated encoder output resolution is 16384 counts per revolution, but this can be altered using the Drive Setup Wizard in Mint WorkBench.
  • Page 52 CHZ- : DGND : a3 (or b3/c3) Figure 22 - MicroFlex encoder output to NextMove ES / ESB encoder input CAUTION: If a NextMove BX is to be connected, a different cable must be used, as shown in Figure 23:...

  • Page 53: Input / Output

    5.1 Introduction This section describes the various digital and analog input and output capabilities of the MicroFlex, with descriptions of each of the connectors on the front panel. The following conventions are used to refer to the inputs and outputs: .

  • Page 54: Analog Input - X3 (Demand)

    AGND 14 Figure 24 - AIN0 analog input (demand) circuit When the MicroFlex is connected to Mint WorkBench, the analog input value (expressed as a percentage) can be viewed using the Spy window’s Monitor tab. Alternatively, the command Print ADC.0 can be used in the command window to return the value of the analog input.
  • Page 55 Figure 26 - Typical input circuit to provide 0-10V (approx.) input from a 24V source NextMove ESB / controller MicroFlex ‘X13’ ‘X3’ Demand0 AIN0+ AGND AIN0- AGND Shield Connect overall shield at one end only Figure 27 - Analog input - typical connection from a Baldor NextMove ESB MN1919 Input / Output 5-3...

  • Page 56: Digital I/O

    5.3 Digital I/O The MicroFlex provides as standard: 1 dedicated drive enable input. 1 general purpose digital input. Dedicated step and direction inputs. 1 dedicated drive status output. The general purpose digital input can be configured for typical input functions:...

  • Page 57: Drive Enable Input - X3

    In normal use, the drive enable input controls the enabled status of the drive. However, when the MicroFlex is connected to Mint WorkBench, additional methods are available for controlling the drive enable status. In all cases, the drive enable input must be active and there must be no errors present before the MicroFlex can be enabled.
  • Page 58 NextMove ESB / controller MicroFlex supply ‘X11’ UDN2982 ‘X3’ USR V+ MintMT Drive DRIVEENABLEOUTPUT 100R DOUT0 Enable+ Drive Enable- TLP280 USR GND User supply Figure 29 - Drive enable input - typical connection from a Baldor NextMove ESB 5-6 Input / Output MN1919...

  • Page 59: General Purpose Digital Input - X3

    DGND Figure 30 - General purpose digital input circuit When the MicroFlex is connected to Mint WorkBench, the digital input can be configured using the Operating Mode Wizard. Alternatively, the Mint keywords RESETINPUT, ERRORINPUT and STOPINPUT can be used in the command window. See the Mint help file for details.
  • Page 60 NextMove ESB / controller MicroFlex supply ‘X11’ UDN2982 ‘X3’ USR V+ MintMT OUTX.0 100R DOUT0 DIN0+ DIN0- TLP280 USR GND User supply Figure 31 - Digital input - typical connection from a Baldor NextMove ESB 5-8 Input / Output MN1919...

  • Page 61: Step (Pulse) And Direction Inputs - X3

    +5VDC Maximum input frequency: 1 MHz maximum When the MicroFlex control mode is set to position control, the step and direction inputs are used as the demand reference. Pin 10 is the step input. The step frequency controls the speed of the motor.
  • Page 62 Connect shields at one end only Figure 33 - Stepper input - typical connection from a Baldor NextMove ESB Note: When using a NextMove ESB’s STEP and DIR outputs, do not connect the STEPx- or DIRx- outputs to ground; leave them unconnected as shown in Figure 33.
  • Page 63 To allow connection of 24 V signals, it is recommended to use an intermediate circuit as shown in Figure 35. The circuit’s output voltage is determined by the pull-up voltage, Vcc. Intermediate circuit MicroFlex ‘X3’ Input 120R Step TLP115A...

  • Page 64: Status Output - X3

    User supply Figure 36 - Drive status output circuit When the MicroFlex is connected to Mint WorkBench, the active level of the output can be configured using the Operating Mode Wizard. Alternatively, the Mint keyword OUTPUTACTIVELEVEL can be used in the command window. The output can also be configured using the Mint keywords DRIVEENABLEOUTPUT or GLOBALERROROUTPUT.
  • Page 65 User MicroFlex NextMove ESB / controller ‘X3’ ‘X9’ supply Status+ Status- DIN4 NEC PS2562L-1 CREF1 TLP280 User supply Figure 37 - Status output - typical connections to a Baldor NextMove ESB MN1919 Input / Output 5-13...

  • Page 66: Using Rs232 Cable

    RS232 or RS485 / RS422 connections on a 9-pin male D-type connector MicroFlex is available with either an RS232 or RS485 serial port (see section 2.2.1). The port is fully ESD protected to IEC 1000-4-2 (15kV). 5.4.1 Using RS232 cable The MicroFlex has a full-duplex RS232 serial port with the following preset configuration: 57.6 Kbaud...

  • Page 67: Multidrop Using Rs485 / Rs422 Cable

    (slave) devices on the network. The network master can be a controller such as MicroFlex, a host application such as Mint WorkBench (or other custom application), or a programmable logic controller (PLC). RS422 may be used for multi-drop applications as shown in Figure 39.

  • Page 68: Connecting Serial Baldor Hmi Operator Panels

    Serial Baldor HMI Operator Panels use a 15-pin male D-type connector (marked PLC PORT), but the MicroFlex connector X6 is a 9-pin male D-type connector. The MicroFlex may be connected with or without hardware handshaking, as shown in Figure 40:...

  • Page 69: Connection Summary - Recommended System Wiring

    H The MicroFlex should be mounted on an earthed metal backplane. H Ensure cables do not obstruct airflow to the heatsink. H Motor represents a typical Baldor BSM motor. Linear motors may also be controlled by MicroFlex. H Conductive shield earth/ground clamps are not supplied.
  • Page 70 www.baldormotion.com 5-18 Input / Output MN1919...

  • Page 71: Configuration

    Configuration 6.1 Introduction Before powering the MicroFlex you will need to connect it to the PC using a serial cable and install the supplied PC software Mint WorkBench. This software includes a number of tools to allow you to configure and tune the MicroFlex. If you do not have experience of software installation or Windows applications you may need further assistance for this stage of the installation.

  • Page 72: Starting The Microflex

    5. To allow the Commissioning Wizard to function, the drive enable signal will need to be present on connector X3 to allow the MicroFlex to be enabled (see section 5.3.1.). If you do not wish to enable the MicroFlex yet, the Commissioning Wizard will inform you when this step is necessary.

  • Page 73: Mint Workbench

    6.2 Mint WorkBench Mint WorkBench is a fully featured application for commissioning the MicroFlex. The main Mint WorkBench window contains a menu system, the Toolbox and other toolbars. Many functions can be accessed from the menu or by clicking a button - use whichever you prefer. Most buttons include a ‘tool-tip’;...

  • Page 74: Help File

    www.baldormotion.com 6.2.1 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.

  • Page 75: Starting Mint Workbench

    www.baldormotion.com 6.2.2 Starting Mint WorkBench 1. On the Windows Start menu, select Programs, Mint Machine Center, Mint WorkBench. Mint WorkBench will start, and the Tip of the Day dialog will be displayed. You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup.
  • Page 76 (If you are unsure which PC serial port is connected to the MicroFlex, select Scan all serial ports). Click Scan to search for the MicroFlex. When the search is complete, click on MicroFlex in the list to select it, and click the Select button. This check box is already selected for you. When you click Select, it means that the Commissioning Wizard will start automatically.

  • Page 77: Commissioning Wizard

    MicroFlex can be used to control the motor accurately, the MicroFlex must be “tuned”. This is the process where the MicroFlex powers the motor in a series of tests. By monitoring the feedback from the motor’s encoder and performing a number of calculations, the MicroFlex can make small adjustments to the way it controls the motor.

  • Page 78: Further Configuration

    Mint WorkBench book. Inside this is the Toolbox book. 6.3.1 Fine-tuning tool The Commissioning Wizard calculates many parameters that allow the MicroFlex to provide basic control of the motor. These parameters may need to be fine-tuned to provide the exact response that you require.
  • Page 79 Enter new values in the required boxes and then click Apply to download the values to the MicroFlex. To perform tests, go to the Test Parameters area at the bottom of the tab. Enter test values and then click Go to perform the test move. If you need help, just press F1 to display the help file.

  • Page 80: Parameters Tool

    Click on a tab to select it. If you need help with any of the options, just press F1 to display the help file. Remember to click the tab’s Apply button to send the changes to the MicroFlex. 6-10 Configuration MN1919...

  • Page 81: Other Tools And Windows

    The Command window can be used send immediate Mint commands to the MicroFlex. Scope Tool Displays the capture screen. This screen is also shown when the Fine-tuning tool is selected. Spy window Allows you to monitor all the important parameters for the axis.
  • Page 82 www.baldormotion.com 6-12 Configuration MN1919...

  • Page 83: Troubleshooting

    If you have followed all the instructions in this manual in sequence, you should have few problems installing the MicroFlex. If you do have a problem, read this section first and check the help file in Mint WorkBench. If you cannot solve the problem or the problem persists, the SupportMe feature can be used.

  • Page 84: Status Led

    If multiple errors occur at the same time, the lowest numbered error code will be flashed. For example, a MicroFlex which has tripped on both feedback error (code 5) and over-current error (code 3) will flash error code 3. If the drive is already displaying an error code when a new error with a lower code occurs, the drive will start flashing the new code.

  • Page 85: Communication

    Confirm that a mouse driver or other serial device is not conflicting (using the same COM port) as Mint WorkBench. Does the MicroFlex have firmware in it? If you tried to download new firmware and the download failed, the controller may not have firmware.

  • Page 86: Power On

    7.2.2 Power on Problem Check The Status LED is flashing. The MicroFlex has detected a motion error. Click the Error button on the motion toolbar to view a description of the error. Alternatively, type these commands in the Command window:...

  • Page 87: Specifications

    Nominal input current @ maximum rated output current * The MicroFlex will operate at lower input voltages, although the drive will trip if the DC-bus voltage falls below 50V or 60% of the no-load voltage, whichever occurs first. 8.1.1.1 Effect of AC power supply voltage on DC-bus voltage...
  • Page 88 www.baldormotion.com 8.1.1.2 Effect of AC power supply voltage on DC-bus ripple Single-phase AC supply Three-phase AC supply AC supply voltage (rms) 8.1.1.3 Effect of output current on DC-bus ripple voltage Single-phase AC supply Three-phase AC supply 90 100 110 120 130 140 150 % of Drive Rated Current 8-2 Specifications MN1919...

  • Page 89: Vdc Control Circuit Supply Input (X2)

    www.baldormotion.com 8.1.2 24VDC control circuit supply input (X2) Unit Nominal input voltage Minimum input voltage Maximum input voltage Maximum ripple ±10 Maximum continuous current @24VDC Power on surge current (typical) @24VDC, 100ms 8.1.3 Motor output power (X1) Unit Nominal phase current Peak phase current for 3s Nominal output...

  • Page 90: Specifications

    www.baldormotion.com 8.1.5 Analog input (X3) Unit All models Type Differential Common mode voltage range ±10 Common mode rejection >40 Input impedance kΩ >30 Input ADC resolution bits Equivalent resolution ±4.9 Sampling interval μs 8.1.6 Digital inputs - drive enable and general purpose (X3) Unit All models Type...

  • Page 91: Status Output (X3)

    Resolver winding ratio MicroFlex resolver input accuracy counts ±3 Typical accuracy counts ±11 using Baldor BSM series resolver motor (with input set to simulate 4096 ppr) Maximum recommended cable length 30.5m (100ft) MN1919 Specifications 8-5...

  • Page 92: Encoder Output (Simulated) (X7)

    www.baldormotion.com 8.1.12 Encoder output (simulated) (X7) Unit All models Signal RS422 Resolution with encoder input on X8 Output is a copy of the input on with SSI encoder input on X8 Adjustable simulated output. See section 4.1.4. 8.1.13 Serial RS232/RS485 interface (X6) Unit All models Signal...
  • Page 93 BS EN60068-2-1:1993 low temperature storage/transportation -40°C. BS EN60068-2-2:1993 high temperature storage/transportation +85°C. BS 2011:part2.1 Cb: 1990: 45°C 93%RH humidity/high temperature operational. DIN IEC 68-2-6/29 ** MicroFlex complies with EN61800-5-1:2003 part 5.2.2.5.3 (Impact Test), provided all front panel connectors are inserted. MN1919 Specifications 8-7...
  • Page 94 www.baldormotion.com 8-8 Specifications MN1919...

  • Page 95: A.1 Introduction

    Accessories A.1 Introduction This section describes accessories and options that you may need to use with your MicroFlex. Shielded (screened) cables provide EMI / RFI shielding and are required for compliance with CE regulations. All connectors and other components must be compatible with the shielded cable.

  • Page 96: A.1.1 Fan Tray

    The fan tray (Baldor part FAN001-024) provides sufficient cooling for the 3A, 6A or 9A MicroFlex. It requires 23 - 27.5VDC at 325mA, which may be sourced from the same filtered control circuit supply used for the MicroFlex. The MicroFlex is UL listed (file NMMS.E128059) when used in conjunction with the fan tray, mounted exactly as shown in Figure 45.

  • Page 97: A.1.2 Footprint Filter

    The single-phase footprint AC power filter (Baldor part FI0029A00) provides mounting holes for the MicroFlex and fan tray. This allows the filter, fan tray and MicroFlex to use the minimum panel mounting space. See section A.1.3 for details of filter FI0029A00.

  • Page 98: A.1.3 Emc Filters

    A.1.3 EMC filters AC filters remove high frequency noise from the AC power supply, protecting the MicroFlex. These filters also prevent high frequency signals from being transmitted back onto the power lines and help meet EMC requirements. To select the correct filter, see sections 3.4.7 and 3.4.8.
  • Page 99 www.baldormotion.com Dimensions mm (inches) Dimension FI0014A00 FI0015A00 FI0015A01 FI0015A02 85 (3.35) 113.5 (4.47) 156 (6.14) 54 (2.13) 57.5 (2.26) 40 (1.57) 46.6 (1.83) 65 (2.56) 94 (3.70) 130.5 (5.14) 75 (2.95) 103 (4.06) 143 (5.63) 27 (1.06) 25 (0.98) 12 (0.47) 12.4 (0.49) 29.5 (1.16) 32.4 (1.28)
  • Page 100 www.baldormotion.com Mounting keyhole and slot detail A 5.5mm B 11mm C 10mm D 5mm Dimensions shown as: mm (inches). Dimensions mm (inches) Dimension FI0029A00 255 (10.04) 100 (3.94) 244.5 (9.63) 70 (2.76) 40 (1.57) 20 (0.79) Figure 49 - Filter dimensions, type FI0029A00 A-6 Accessories MN1919...

  • Page 101: A.1.4 Regeneration Resistors

    A.1.4 Regeneration resistors Depending on the application, MicroFlex might require an external regeneration resistor to be connected to pins R1 and R2 of connector X1. The regeneration resistor dissipates energy during braking to prevent an over-voltage error occurring. See sections 3.6 and 3.7 for details about choosing the correct resistor.

  • Page 102: A.2 Cables

    A.2 Cables A wide range of motor and feedback cables are available from Baldor. A.2.1 Motor power cables For easier installation, it is recommended that a color-coded motor power cable is used. A description of a BSM rotary motor power cable catalog number is shown here, using the...
  • Page 103 www.baldormotion.com A.2.1.2 Cables available in the rest of the world Length Cable Cable Cable assembly Cable assembly Catalog number Catalog number rated current description Power cable: CBL050-501 Available by the meter or on no connectors 100 m drum. CBL025SP-12 Power cable CBL050SP-12 16.4 12 Amps...

  • Page 104: A.2.2 Feedback Cable Part Numbers

    Resolver) Note: Feedback cables have the outer shield tied to the connector housing(s). If you are not using a Baldor cable with your chosen feedback device, be sure to obtain a cable that is a shielded twisted pair 0.34 mm (22 AWG) wire minimum, with an overall shield.

  • Page 105: A.2.4 Encoder / Hall Feedback Cables

    www.baldormotion.com A.2.4 Encoder / Hall feedback cables A.2.4.1 Cables available in North and South America Length Cable assembly description Cable assembly description Catalog number Catalog number Encoder feedback cable: CBL043-501 Available by the foot or no connectors on 100 m (328 ft) drum. Feedback cable assembly: CBL025SF-E CE style threaded motor connector...

  • Page 106: A.2.5 Resolver Feedback Cables

    www.baldormotion.com A.2.5 Resolver feedback cables A.2.5.1 Cables available in North and South America Length Cable assembly description Cable assembly description Catalog number Catalog number Resolver Feedback Cable: CBL044-501 Available by the foot or no connectors on 100 m (328 ft) drum. CBL015SF-R CBL030SF-R Feedback Cable Assembly:...

  • Page 107: B Control System

    Control System B.1 Introduction The MicroFlex can be configured for three basic control modes: Current (Torque) control. Velocity (Speed) control. Step and Direction following/gearing. The mode you require is selected in Mint WorkBench using the Commissioning Wizard. You can subsequently change between these control modes using the Tools, Control Mode menu item or by using the CONTROLMODE keyword in the Command window (see the Mint help file).

  • Page 108: Current (Torque) Control

    B.1.1 Current (Torque) control Setting the control mode to Current Control configures the MicroFlex or MicroFlex as a torque amplifier, as shown in Figure 51. Here, a torque reference is obtained from a specified source: Mint WorkBench A host using the ActiveX control Analog input The source provides a signal that is fed into the Torque profiler.

  • Page 109: Velocity (Speed) Control

    B.1.2 Velocity (Speed) control Setting the control mode to Velocity Control configures the MicroFlex as a speed amplifier, as shown in Figure 52. Here, a speed reference is obtained from a specified source: Mint WorkBench A host using the ActiveX control Analog input The source provides a signal that is fed into the Speed controller.

  • Page 110: Position (Step And Direction) Control

    B.1.3 Position (Step and Direction) control Setting the control mode to Position Control (Step and Direction) configures the MicroFlex as a positioning system, as shown in Figure 53, capable of following a position command signal. The up down counter and gearing interpret the step and direction signals and use them to generate a position demand signal.

  • Page 111: Cce & Ul

    C.1.2 MicroFlex compliance When installed as directed in this manual, MicroFlex units meet the emission limits for an ‘industrial’ environment, as defined by the EMC directives (EN61000-6-4: 2001). To meet the more stringent emission limits of the ‘residential, commercial and light industrial’ environment (EN61000-6-3: 2001), the MicroFlex must be mounted in a suitable metal cabinet incorporating 360°...

  • Page 112: Declaration Of Conformity

    (where x = R or E, y = 4 or 2) when used in accordance with the guidance given in the corresponding MicroFlex Installation Manual, MN1919, conforms with the protection requirements of the following Council Directives, by application of the relevant harmonized standards:...

  • Page 113: Use Of Ce Compliant Components

    With this technique, a good earth/ground shield can be achieved. EMC filters The filter should be mounted next to the MicroFlex. The connections between the MicroFlex and the filter should use shielded (screened) cables. The cable shields should be connected to shield clamps at both ends.

  • Page 114: Emc Installation Suggestions

    www.baldormotion.com C.1.6 EMC installation suggestions To ensure electromagnetic compatibility (EMC), the following installation points should be considered to help reduce interference: Earthing/grounding of all system elements to a central earth/ground point (star point) Shielding of all cables and signal wires Filtering of power lines.

  • Page 115: C.1.7 Wiring Of Shielded (Screened) Cables

    C.1.7 Wiring of shielded (screened) cables Remove the outer insulation to expose the overall shield. Clamp should provide 360° Flat or p-type contact with the cable. conductive clamp Figure 54 - Earthing/grounding cable shields MicroFlex Encoder Connector Cable Housing Twisted pairs CHA+ CHA- CHB+...

  • Page 116: Ul File Numbers

    C.2 UL file numbers The following table lists UL file numbers for Baldor products and other accessories. Note that UL file numbers for accessories that are not manufactured by Baldor are beyond Baldor’s control and therefore subject to change without notice.
  • Page 117 Index Digital I/O, 5-4 drive enable input, 5-5 Abbreviations, 2-3 general purpose digital input, 5-7 Accessories, A-1 status output, 5-12 EMC filters, A-4 step & direction inputs, 5-9 fan-tray, A-2 Dimensions, 3-4 feedback cables, A-10, A-11, A-12 Dynamic brake. See Regeneration resistor footprint filter, A-3 motor power cables, A-8 regeneration resistors, A-7...
  • Page 118 Footprint filter, A-3 Motor circuit contactors, 3-18 Fuses, 3-14 connections, 3-17 power cable, 3-18–3-19, A-8 sinusoidal filter, 3-19 General Information, 1-1 Mounting, 3-5 Grounding. See Earthing (grounding) Operation, 6-1 Hardware requirements, 3-1 connecting to the PC, 6-1 Help file, 6-4 installing software, 6-1 power on checks, 6-2 preliminary checks, 6-2...
  • Page 119 RS485/RS422 cable, 5-15 specification, 8-4 Safety Notice, 1-2 Tools, 3-2 Serial port, 5-14 Troubleshooting, 7-1 connecting serial Baldor HMI panels, 5-16 communication, 7-3 Simulated encoder output, 4-11 power cycling, 7-1 power on, 7-4 Specifications, 8-1 problem diagnosis, 7-1...
  • Page 120 Index MN1919...
  • Page 121 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...
  • Page 122 Thank you for taking the time to help us. Comments MN1919...
  • Page 124 Baldor Electric India Pvt Ltd Baldor UK Ltd Tel: +91 20 25 45 27 17 Tel: +44 1454 850000 Fax: +91 20 25 45 27 19 Fax: +44 1454 859001 For additional office locations visit www.baldor.com Printed in UK E Baldor UK Ltd...

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