Page 3: Table Of Contents
3.2.4 Mounting the MotiFlex e100 ........
Page 4 ..........3-31 3.7.4 Motor power cable pin configuration - Baldor BSM rotary motors ..3-32 3.7.5...
Page 5 ..........6.1.1 Connecting the MotiFlex e100 to the PC ......
Page 6 ..........7.1.3 Power-cycling the MotiFlex e100 ........
Page 7 18 VDC output / 24 VDC input ......8-29 8.5.1 18 VDC output / 24 VDC control circuit backup supply input (X2) .
Page 8 C Mint Keyword Summary ......Introduction ..........C.1.1 Keyword listing .
Page 9: General Information
MotiFlex e100 is UL listed; file NMMS.E128059. Limited Warranty For a period of two (2) years from the date of original purchase, Baldor will repair or replace without charge controls and accessories that our examination proves to be defective in material or workmanship.
Page 10 Electrical shock can cause serious or fatal injury. DANGER After AC power has been removed from the MotiFlex e100, high voltages (greater than 50 VDC) can remain on power connections for up to 5 minutes, while the DC bus circuitry discharges.
Page 11 Peak torque of several times the rated motor torque CAUTION can occur during control failure. If the drive enable signal is already present when power is applied to the MotiFlex e100, the motor could begin to move immediately. CAUTION The metal heatsink on the left side of the MotiFlex e100 can become very hot during normal operation.
Page 12 Violent jamming (stopping) of the motor during operation may damage the motor and drive. NOTICE Operating the MotiFlex e100 in Torque mode with no load attached to the motor can cause the motor to accelerate rapidly to excessive speed. NOTICE Do not tin (solder) exposed wires.
Page 13: Introduction
POWERLINK devices. Programmable in Mint. MotiFlex e100 can operate a large range of brushless rotary and linear servo motors. It can also operate induction motors using closed-loop vector control. For information on selecting Baldor motors, please see the sales brochure BR1202 available from your local Baldor representative.
Page 14: Receiving And Inspection
MotiFlex e100. 5. If MotiFlex e100 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 8.8.
Page 15: Units And Abbreviations
www.baldormotion.com 2.3 Units and abbreviations The following units and abbreviations may appear in this manual: ....Volt (also VAC and VDC) ....Watt .
Page 16: Standards
2.4 Standards The MotiFlex e100 has been designed and tested to comply with the following standards. 2.4.1 Design and test standards UL508C: Power Conversion Equipment. UL840: Insulation coordination including clearance and creepage distances for electrical equipment. EN61800-5-1: Adjustable speed electrical power drive systems. Safety requirements.
Page 17: Basic Installation
Basic Installation 3.1 Introduction You should read all the sections in Basic Installation to ensure safe installation. This section describes the mechanical and electrical installation of the MotiFlex e100 in the following stages: Location considerations. Mounting the MotiFlex e100.
Page 18: Tools And Miscellaneous Hardware
* The Ethernet configuration used by a normal office PC is not suitable for direct communication with the MotiFlex e100. It is recommended to install a separate dedicated Ethernet adapter in the PC, which can be configured for use with the MotiFlex e100. See section 6.2.4.
Page 19: Mechanical Installation
10 mm (0.4 in). The 48 A and 65 A MotiFlex e100 have a recess at the rear of the product which is filled with a block of packaging foam. Remove this foam before mounting the drive.
Page 20: Dimensions - 1.5 A ~ 16 A Models
www.baldormotion.com 3.2.1 Dimensions - 1.5 A ~ 16 A models (2.95) (0.31) 12.5 (1.97) (0.49) Mounting hole and slot detail 6 mm 12 mm 12.7 mm 6 mm 6 mm Dimensions shown as: mm (inches). Depth: 260 mm (10.24 in) Weight: 1.5 A: 1.90 kg (4.2 lb)
Page 21: Dimensions - 21 A ~ 33.5 A Models
www.baldormotion.com 3.2.2 Dimensions - 21 A ~ 33.5 A models (4.99) (0.31) 13.5 (3.94) (0.53) Mounting hole and slot detail 6 mm 12 mm 12.7 mm 6 mm 6 mm Dimensions shown as: mm (inches). Depth: 260 mm (10.24 in) Weight: 21 A: 5.85 kg (12.9 lb)
Page 22: Dimensions - 48 A ~ 65 A Models
www.baldormotion.com 3.2.3 Dimensions - 48 A ~ 65 A models (8.35) (0.31) 92.5 92.5 13.5 (3.64) (3.64) (0.53) Mounting hole and slot detail 6 mm 12 mm 12.7 mm 6 mm 6 mm Dimensions shown as: mm (inches) Depth: 260 mm (10.24 in) Weight: 48 A: 12.45 kg (27.4 lb) 65 A:...
Page 23: Mounting The Motiflex E100
M5 bolts or screws should be used to mount the MotiFlex e100. Detailed dimensions are shown in section 3.2.1. Note: The 48 A and 65 A MotiFlex e100 have a recess at the rear of the product which is filled with a block of packaging foam. Remove this foam before mounting the drive.
Page 24 There are 4 different busbar sizes, allowing any combination of narrow bodied MotiFlex e100 (1.5 A ~ 16 A models), wide bodied MotiFlex e100 (21 A ~ 33.5 A models) or extended bodied MotiFlex e100 (48 A ~ 65 A models) to be connected, as shown in Figure 6. Size 3 and size 4 busbars have an insulating sleeve, since parts of them are exposed when fitted.
Page 25 www.baldormotion.com RIGHT Busbar selection: Size 1 busbar - kit OPT-MF-DC-A 1) From the LEFT column, select the drive that will be on the left. 55 mm 2) From the RIGHT row, select the drive that will be on the right. Size 2 busbar - kit OPT-MF-DC-B 3) The intersecting letter indicates the 107 mm...
Page 26: Overtemperature Trips And Intelligent Fan Control
90 mm to maintain effective cooling. Remember that when a MotiFlex e100 is mounted above another MotiFlex e100 or heat source, it will be receiving air that has been already heated by the device(s) below it.
Page 27: Connector Locations
To remove the bottom cover, push on the oval indentation and slide the cover downwards. To refit, insert the two tabs, protruding from the cover’s top edge, into the main body. Push on the Baldor label to snap into place. X2 18 VDC output / 24 VDC backup input...
Page 28: Top Panel Connectors
www.baldormotion.com 3.3.2 Top panel connectors X1 AC power & regen X1 AC power & regen (1.5 A ~ 16 A models) (21 A ~ 65 A models) AC Phase 1 AC Phase 1 AC Phase 2 AC Phase 2 AC Phase 3 AC Phase 3 Regeneration Regeneration...
Page 29: Bottom Panel Connectors
www.baldormotion.com 3.3.3 Bottom panel connectors X8 Feedback In Incremental SinCos BiSS / SSI EnDat CHA+ Data+ Data+ (NC) CHB+ Clock+ Clock+ (NC) CHZ+ (NC) (NC) (NC) Sense Sense Sense Sense Hall U- Sin- Sin-* (NC) Hall U+ Sin+ Sin+* (NC) Hall V- Cos- Cos-*...
Page 30: Ac Power Connections
MotiFlex e100 are shielded correctly. NOTICE MotiFlex e100 drives are designed to be powered from standard three-phase lines that are electrically symmetrical with respect to earth/ground. The power supply module within all MotiFlex e100 models provides rectification, smoothing and current surge protection. Fuses or circuit breakers are required in the input lines for cable protection.
Page 31: Ac Input And Regeneration Resistor Output Wiring
The installation methods shown in Figure 7 will improve the reliability of the system, reduce troubleshooting time, and optimize the EMC (electromagnetic compatibility) behavior of the control system. The MotiFlex e100’s protective earth connection does not provide electromagnetic compatibility. Its purpose is to prevent exposed metalwork becoming live in the case of a serious failure.
Page 32: Earth Leakage
3.4.3 Earth leakage The following table shows typical earth leakage figures for a MotiFlex e100 with a 20 m (66 ft) motor cable, in combination with each of the recommended AC power filters (see section 3.4.10). MotiFlex e100 with:...
Page 33: Ac Power Connections
Maximum input voltage 528 VAC, 3Φ line to line Note: The MotiFlex e100 will trip if the DC-bus voltage falls below 200 V or 60% of the no-load voltage, whichever occurs first. The MotiFlex e100 will stop operating if the DC-bus voltage falls below 150 VDC, unless a 24 VDC control circuit backup supply is present (see section 3.6).
Page 34: Ac Power Cycling
3.4.7 Phase loss detection The MotiFlex e100 requires all three phases to be present. If any phase is lost, the MotiFlex e100 will immediately trip and disable, reporting a phase loss error (error 10029). See the Mint help file for details about handling errors.
Page 35: Input Power Conditioning
See section A.1.3 for a range of suitable line reactors. If the feeder or branch circuit that provides power to the MotiFlex e100 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 36: Power Supply Filters
To comply with EC directive 2004/108/EC, an AC power filter of the appropriate type must be connected. This can be supplied by Baldor and will ensure that the MotiFlex e100 complies with the CE specifications for which it has been tested. Ideally one filter should be provided for each MotiFlex e100, except in DC bus sharing applications where only the source drive requires a filter.
Page 37: Power Disconnect And Protection Devices
A power disconnect should be installed between the input power supply and the MotiFlex e100 for a fail-safe method to disconnect power. The MotiFlex e100 will remain in a powered condition until all input power is removed from the drive and the internal bus voltage has depleted. The MotiFlex e100 must have a suitable input power protection device installed, preferably a fuse.
Page 38: Recommended Wire Sizes
All wire sizes are based on 75 °C (167 °F) copper wire. Use copper conductors only. Higher temperature smaller gauge wire may be used per National Electric Code (NEC) and local codes. MotiFlex e100 AC input & motor output wire size...
Page 39: Sharing The Dc Bus
3.5 Sharing the DC bus The AC power supply is rectified and smoothed within the MotiFlex e100 to create a typical ‘DC bus’ voltage of around 678 VDC (when using a 480 VAC supply). The DC bus voltage is then switched by a power module to create the UVW output waveforms that drive the motor.
Page 40: Power Ready' Input / Output
See the Mint help file for details. The input and output must both be ‘active high’, and the input must also be level triggered (the default settings). Customer MotiFlex e100 supplied 24VDC supply SOURCE ‘X3’...
Page 41: Line Reactors
Required line reactor Recommended catalog inductance Baldor AC line number (mH) reactor MFE460A001 MFE460A003 LRAC02502 MFE460A006 MFE460A010 LRAC03502 LRAC03502 MFE460A016 MFE460A021 MFE460A026 LRAC05502 MFE460A033 MFE460A048 LRAC08002 LRAC08002 MFE460A065 Table 4 - Baldor line reactor part numbers MN1943 Basic Installation 3-25...
Page 42: Vdc Out / 24 Vdc In Control Circuit Backup Supply
During normal operation, this supply is not used by the MotiFlex e100. However, if AC power (or shared DC bus power) is lost or needs to be removed from the drive, the controlling electronics will lose their internal supply. In this situation, the external 24 VDC supply is employed to ensure the controlling electronics remain powered and retain position and I/O information.
Page 43: Vdc Control Circuit Backup Supply Wiring
3.6.2 24 VDC control circuit backup supply wiring When multiple MotiFlex e100 are mounted side-by-side for DC bus sharing (see section 3.5), the 24 VDC backup supply wiring can be reduced. A channel and supporting tabs are built-in to the front panel of the drive to allow easy ‘daisy-chaining’...
Page 44: Motor Connections
Baldor representative. The motor must be capable of being powered by an inverter PWM output - see sections 8.3.1 to 8.3.3 for details. The motor can be connected directly to the MotiFlex e100 or through a motor contactor (M-Contactor). The motor outputs are fully short-circuit proof according to EN61800-5-1, 6.2.
Page 45 www.baldormotion.com Motor Optional motor Unshielded circuit contactor. lengths should be as short as possible. Connect motor earth/ground to To earth/ground outer shield, use 360° clamps protective earth on connected to backplane. drive flange. Earth Figure 14 - Motor connections - 1.5 A ~ 16 A models Motor Optional motor Unshielded...
Page 46: Motor Cable Shielding
It is essential that the motor cable shield is correctly bonded to a functional earth, typically the same earthed metal backplane on which the MotiFlex e100 is mounted. The motor power output cable carries a high frequency high current waveform to the motor, so the cable’s shielding must be earthed to prevent the cable radiating electromagnetic contamination into the surrounding area.
Page 47: Motor Circuit Contactor
This effect occurs most noticeably when using very long motor cables, for example 30.5 m (100 ft) or more. Baldor motors intended to be used with drives are designed to withstand the effects of large dV/dt and overvoltage effects.
Page 48: Motor Power Cable Pin Configuration - Baldor Bsm Rotary Motors
3.7.4 Motor power cable pin configuration - Baldor BSM rotary motors Figure 18 shows the pin configuration for a typical Baldor motor cable, part number CBL025SP-12: Signal name Motor / cable pin Motor cable wire color Motor U Black, labeled ‘1’...
Page 49: Motor Cable Pin Configuration - Baldor Linear Motors
3.7.5 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 50: Motor Brake Connection
You might wish to wire a motor’s brake, via a relay, to a digital output on connector X3 (see sections 5.3.6 and 5.3.7). This allows the MotiFlex e100 to control the motor’s brake. A typical circuit is shown in Figure 19.
Page 51: Motor Overtemperature Input
The motor overtemperature input is a dedicated input which may be directly connected to the motor’s thermal switch. When the motor overheats and triggers the overtemperature input, the MotiFlex e100 is normally disabled. See section 5.3.5 for details. 3.7.8 Bottom panel wiring It is important that signal cables are properly shielded.
Page 52: Regeneration Resistor (Dynamic Brake Resistor)
www.baldormotion.com 3.8 Regeneration resistor (Dynamic Brake resistor) Location Connector X1 (top panel) Mating connector 1.5 A ~ 16 A models Phoenix POWER COMBICON PC 4/ 5-ST-7,62) 21 A ~ 33 A models Phoenix POWER COMBICON IPC 16/ 2-ST-10,16) 48 A ~ 65 A models Phoenix POWER COMBICON ISPC 16/ 2-ST-10,16) Electrical shock hazard.
Page 53: Regeneration Capacity
3.8.1 Regeneration capacity The regeneration capacity of the MotiFlex e100 can be calculated from the following formula:      × Supply voltage ( Regen switching threshold ) E = 0.5 × DC bus capacitance × −...
Page 54: Regeneration Resistor Selection
www.baldormotion.com 3.9 Regeneration resistor selection The following calculations can be used to estimate the type of regeneration resistor that will be required for the application. 3.9.1 Required information To complete the calculation, some basic information is required. Remember to use the worst-case figures to ensure that the regeneration power is not underestimated.
Page 55: Regenerative Energy
www.baldormotion.com 3.9.2 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 56: Resistor Choice
Required resistor power rating = 1.25 × P = ________________ W (watts) The range of suitable regeneration resistors for each MotiFlex e100 model is shown in Table 6. Choose the resistor that has a power rating equal to or greater than the value calculated above.
Page 57: Resistor Temperature Derating
The RGJ... regeneration resistors listed here do not provide a fail-safe safety mechanism. For safety reasons and UL compliance, they will become open-circuit in the event of failure. This will cause the MotiFlex e100 to trip due WARNING to overvoltage, leaving the motor in an uncontrolled state. Further safety mechanisms such as a motor brake will be required, especially for applications involving suspended or tensioned loads.
Page 58: Resistor Pulse Load Rating
www.baldormotion.com 3.9.6 Resistor pulse load rating The regeneration resistors shown in Table 6 can dissipate power levels greater than the stated continuous power rating, provided the duty cycle (see section 3.9.7) is reduced, as shown in Figure 24. 27000 24000 21000 18000 15000...
Page 59: Duty Cycle
www.baldormotion.com 3.9.7 Duty cycle The regeneration duty cycle is the amount of time taken regenerating as a proportion of the overall application cycle time. For example, Figure 25 shows a system which performs a trapezoidal move profile, with regeneration during part of the deceleration phase. The regeneration duty is 0.2 (0.5 second regeneration / 2.5 second cycle time): Regeneration active Decel time...
Page 60 www.baldormotion.com 3-44 Basic Installation MN1943...
Page 61: Feedback
Feedback 4.1 Introduction MotiFlex e100 supports many feedback options for use with linear and rotary motors, including incremental encoder, encoder with BiSS (Bi-directional Synchronous Serial interface), encoder with SSI (Synchronous Serial Interface), EnDat absolute encoder or SinCos encoder. All suitable types of feedback device can be connected to the universal feedback interface available on connector X8 (bottom panel).
Page 62: Incremental Encoder Interface
D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the encoder supply voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max).
Page 63 Hall U+ MAX3096 to CPU Differential line receiver Hall U- DGND Figure 27 - 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 64 MotiFlex e100. However, if Hall connections are not present, it will be necessary for the MotiFlex e100 to perform an automatic phase search sequence the first time it is enabled after power up. This will cause motor movement of up to 1 turn on rotary motors, or one pole-pitch on linear motors.
Page 65 4.1.1.4 Encoder cable pin configuration - rotary motors Figure 31 shows the pin configuration for a typical Baldor encoder feedback cable, part number CBL025SF-E2. Signal name MotiFlex e100 Motor / cable Baldor encoder cable X8 pin internal wire colors...
Page 66 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 67: Biss Interface
D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the supply voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max).
Page 68 4.1.2.1 BiSS interface cable pin configuration Figure 40 shows the pin configuration for a typical Baldor BiSS feedback cable, part number CBL025SF-D2. Signal name MotiFlex e100 Motor / cable Baldor BiSS / EnDat / X8 pin SinCos cable internal...
Page 69: Ssi Interface
Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the supply voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max).
Page 70 4.1.3.1 SSI cable pin configuration Figure 36 shows the pin configuration for a typical Baldor SSI feedback cable, part number CBL025SF-S2 Signal name MotiFlex e100 Motor / cable Baldor SSI cable X8 pin internal wire colors +5V out Sense...
Page 71: Sincos Interface
D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the supply voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max). The Sin and Cos channel input circuits accept a nominal 1 V pk-pk sine wave centered on a 2.5 V reference.
Page 72 4.1.4.1 SinCos cable pin configuration Figure 38 shows the pin configuration for a typical Baldor SinCos feedback cable, part number CBL025SF-D2. Signal name MotiFlex e100 Motor / cable Baldor BiSS / EnDat / X8 pin SinCos cable internal wire colors...
Page 73: Endat Interface
‘Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the supply voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max). The Sin and Cos channel input circuits accept a nominal 1 V pk-pk sine wave centered on a 2.5 V reference.
Page 74 4.1.5.1 EnDat interface cable pin configuration Figure 40 shows the pin configuration for a typical Baldor EnDat feedback cable, part number CBL025SF-D2. Signal name MotiFlex e100 Motor / cable Baldor BiSS / EnDat / X8 pin SinCos cable internal...
Page 75: Input / Output
Input / Output 5.1 Introduction This section describes the various digital input and output capabilities of the MotiFlex e100, with descriptions of each of the connectors on the front panel. The following conventions are used to refer to the inputs and outputs: .
Page 76: Analog I/O
AGND 11 Figure 41 - AIN0 analog input (demand) circuit When the MotiFlex e100 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 77 AIN0 ADC(0) * Note: If the MotiFlex e100’s 18 VDC source is to be used (connector X2, see section 3.6), use a 1 kΩ fixed resistor and a 1.5 kΩ potentiometer. Figure 43 - Typical input circuit to provide 0-10 V (approx.) input from a 24 V source...
Page 78: Digital I/O
5.3 Digital I/O The MotiFlex e100 provides as standard: 3 general purpose digital inputs. 1 dedicated drive enable input. 1 general purpose digital output. 1 general purpose / drive status output. 1 dedicated motor overtemperature trip input. The general purpose digital inputs can be configured for typical input functions: Error input.
Page 79 DRIVEENABLE(0)=1 can be used in the command window to enable the MotiFlex e100; DRIVEENABLE(0)=0 will disable the MotiFlex e100. The Tools, Reset Controller menu item will also clear errors and enable the MotiFlex e100. Alternatively, the Mint command RESET(0) can be used in the command window to perform the same action.
Page 80 24 V ‘X11’ UDN2982 ‘X3’ USR V+ Mint Drive DRIVEENABLEOUTPUT DOUT0 Enable+ Drive 100R Enable- TLP280 USR GND User supply Figure 46 - Drive enable input - typical connection from a Baldor NextMove e100 5-6 Input / Output MN1943...
Page 81: General Purpose Digital Input Din0
When the MotiFlex e100 is being controlled over EPL by a manager node (e.g. NextMove e100), the home switch input must be wired to the MotiFlex e100, not the manager node. This is because the manager node only triggers the homing sequence, which is then performed entirely by the MotiFlex e100.
Page 82 NextMove e100 / controller MotiFlex e100 supply 24 V ‘X11’ UDN2982 ‘X3’ USR V+ Mint OUTX(0) DOUT0 DIN0+ 100R DIN0- TLP280 USR GND User supply Figure 48 - Digital input - typical connection from a Baldor NextMove e100 5-8 Input / Output MN1943...
Page 83: General Purpose Digital Inputs Din1 & Din2
When the MotiFlex e100 is being controlled over EPL by a manager node (e.g. NextMove e100), the home switch input must be wired to the MotiFlex e100, not the manager node. This is because the manager node only triggers the homing sequence, which is then performed entirely by the MotiFlex e100.
Page 84: Special Functions On Inputs Din1 & Din2
DIN1 and DIN2 can be configured to perform special functions. 5.3.4.1 Step (pulse) and direction inputs Using the MASTERSOURCE keyword, the MotiFlex e100 can be configured to use DIN1 and DIN2 as step and direction inputs: DIN1 is used as the step input. The step frequency controls the speed of the motor.
Page 85 Incremental encoder MotiFlex e100 ‘X3’ Twisted pairs DIN1+ (Step) DIN1- DIN2+ (Dir) DIN2- DGND ‘X2’ Connect shields at one end only Drive Drive supply supply Figure 51 - Step and direction inputs - typical connection from an incremental encoder Note: When using an incremental encoder source, do not connect the A- or B- outputs;...
Page 86: Motor Overtemperature Input
TH1 and TH2, but care must be taken to ensure that the resistance will be sufficient to trigger the MotiFlex e100’s input circuit. To ensure triggering of the input circuit, the resistance between TH1 and TH2 must exceed 3.2 kΩ.
Page 87 (screen) connected to the metal backplane or signal cable management bracket (section A.1.6). state motor overtemperature input read using MOTORTEMPERATURESWITCH keyword. The resulting behavior of the MotiFlex e100 can be controlled using the MOTORTEMPERATUREMODE keyword. See the Mint help file for details. MN1943 Input / Output 5-13...
Page 88: General Purpose / Status Digital Output Dout0
By default, DOUT0 is configured as an error status output, which becomes inactive in the event of an error. When the MotiFlex e100 is connected to Mint WorkBench, the active level of the output can be configured using the Digital I/O tool. Alternatively, the Mint keyword OUTPUTACTIVELEVEL can be used in the command window.
Page 89 User MotiFlex e100 NextMove e100 / controller ‘X3’ ‘X9’ supply 24 V DOUT0+ 100R DOUT0- DIN4 TLP127 CREF1 TLP280 User supply Figure 55 - DOUT0 - typical connections to a Baldor NextMove e100 MN1943 Input / Output 5-15...
Page 90: General Purpose Digital Output Dout1
User supply Figure 56 - DOUT1 output circuit When the MotiFlex e100 is connected to Mint WorkBench, the active level of the output can be configured using the Digital I/O tool. Alternatively, the Mint keyword OUTPUTACTIVELEVEL can be used in the command window. Other Mint keywords such as COMPAREOUTPUT, GLOBALERROROUTPUT, DRIVEENABLEOUTPUT and MOTORBRAKEOUTPUT (see section 3.7.6)
Page 91: Usb Interface
USB1.1 specification of the MotiFlex e100. Ideally, the MotiFlex e100 should be connected directly to a USB port on the host PC. If it is connected to a hub shared by other USB devices, communication could be affected by the activity of the other devices.
Page 92: Rs485 Interface
Baldor Keypad and Baldor HMI panel range cannot be connected to this interface, since they require a 4-wire RS485 connection. The 8 V supply on pin 4 is provided for future Baldor accessories; care should be taken to ensure this supply will not damage connected devices. The RS485 interface could be damaged if a USB plug is accidentally inserted while the drive is powered.
Page 93: Ethernet Interface
TCP/IP allows the MotiFlex e100 to support standard Ethernet communication with a host PC running Mint WorkBench. The connection uses Baldor’s high level ICM (Immediate Command Mode) protocol to allow Mint commands, Mint programs and even firmware to be sent to the controller over the Ethernet network.
Page 94: Ethernet Powerlink
Fast Ethernet (IEEE 802.3u) connection. This makes it suitable for the transmission of control and feedback signals between the MotiFlex e100 and other EPL enabled controllers such as NextMove e100. The EPL protocol implemented in Mint is based on the CANopen DS402 Device Profile for Drives and Motion Control.
Page 95: Ethernet Connectors
(NC) (NC) To connect the MotiFlex e100 to other EPL devices use CAT5e Ethernet cables - either S/UTP (screened unshielded twisted pairs) or preferably S/FTP (screened fully shielded twisted pairs). The MotiFlex e100 Ethernet interface is galvanically isolated from the rest of the MotiFlex e100 circuitry by magnetic isolation modules incorporated in each of the Ethernet connectors.
Page 96: Can Interface
120 Ω. This is to reduce reflections of the electrical signals on the bus, which helps a node to interpret the bus voltage levels correctly. If the MotiFlex e100 is at the end of the network then ensure that a 120 Ω resistor is fitted (normally inside the D-type connector).
Page 97 9-pin D-type female connector with easily accessible terminal block connections (see Figure 64). CAN cables supplied by Baldor are ‘category 5’ and have a maximum current rating of 1 A, so the maximum number of MotiFlex e100 units that may be used on one network is limited to 10.
Page 98: Canopen
24 V Figure 64 - Typical CANopen network connections Note: The MotiFlex e100 CAN channel is opto-isolated, so a voltage in the range 12-24 VDC must be applied between pin 9 and pin 6 of the CAN connector. See section 5.7.2.1.
Page 99: Other I/O
5.8 Other I/O 5.8.1 Node ID selector switches The MotiFlex 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.
Page 100 Figure 65 - Decimal node IDs and equivalent HI / LO hexadecimal switch settings Note: If the node ID selector switches are set to FF, the node’s firmware will not run on power up. However, Mint WorkBench will still be able to detect the MotiFlex e100 and download new firmware.
Page 101 ‘controlled node’, a node that will accept commands from the manager node. Node ID 240 is reserved for the EPL manager node (for example NextMove e100) so cannot be used by MotiFlex e100. Node IDs between 241 and 255 are reserved for special purposes and cannot be used.
Page 102 www.baldormotion.com 5-28 Input / Output MN1943...
Page 103: Configuration
Configuration 6.1 Introduction Before powering the MotiFlex 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 MotiFlex e100. If you do not have experience of software installation or Windows applications you may need further assistance for this stage of the installation.
Page 104: Starting The Motiflex E100
5. To allow the Commissioning Wizard to function, the drive enable signal will need to be present on connector X3 to allow the MotiFlex e100 to be enabled (see section 5.3.1.). If you do not wish to enable the MotiFlex e100 yet, the Commissioning Wizard will inform you when this step is necessary.
Page 105: Installing The Usb Driver
1. Follow the on-screen instructions to select and install the driver. The driver files are available on the supplied Baldor Motion Toolkit CD. If you are using a copy of the driver located on the hard disk, USB stick, or another CD, the driver files must all be in the same folder.
Page 106: Configuring The Tcp/Ip Connection (Optional)
10, equivalent to decimal 16 (see section 5.8.1 for a list of hexadecimal / decimal equivalents). A reply message should be returned. 10. It should now be possible to run Mint WorkBench and connect to the MotiFlex e100 using the Ethernet / TCP/IP connection.
Page 107: 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 MotiFlex e100 connected to your PC, then MMC is probably not required. Use Mint WorkBench (see section 6.4) to configure the MotiFlex e100.
Page 108 MintDrive Mint WorkBench RS232 MintDrive Mint WorkBench RS485/422 Host PC Mint Machine Center NextMove e100 Mint WorkBench MotiFlex e100 Mint WorkBench Ethernet MotiFlex e100 Mint WorkBench Figure 67 - Typical network visibility provided by Mint Machine Center 6-6 Configuration MN1943...
Page 109: Starting Mmc
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 ‘MotiFlex e100’ in the controller pane to select it, then double click to open an instance Mint WorkBench.
Page 110: Mint Workbench
Mint WorkBench is a fully featured application for commissioning and programming the MotiFlex 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.
Page 111: Help File
www.baldormotion.com 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.
Page 112: Starting Mint Workbench
www.baldormotion.com 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.
Page 113 3. In the Select Controller dialog, click Scan to search for the MotiFlex e100. Mint WorkBench will scan the PC’s ports for the MotiFlex e100. When the search is complete, click ‘MotiFlex 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.
Page 114: Commissioning Wizard
MotiFlex e100 can be used to control the motor accurately, the MotiFlex e100 must be ‘tuned’. This is the process where the MotiFlex e100 powers the motor in a series of tests. By monitoring the drive’s output and the feedback from the motor’s encoder, the MotiFlex e100 can make small adjustments to the way it controls the motor.
Page 115: Using The Commissioning Wizard
6.4.4.4 Select your Motor: Carefully enter the details of your motor. If you are using a Baldor Motor, the catalog number or spec. number can be found stamped on the motor’s nameplate. If you are using a motor with EnDat feedback, are not using a Baldor motor, or need to enter the specification manually, select the I would like to define a custom motor option.
Page 116 For example, if the MotiFlex e100 will be eventually controlled over Ethernet POWERLINK (EPL), the EPL reference source should be selected. If EPL or CAN is selected, Mint WorkBench will ask for the reference source to be changed to Host/Mint during the remainder of the commissioning process.
Page 117: Autotune Wizard
6.4.5 Autotune Wizard The Autotune Wizard tunes the MotiFlex e100 for optimal performance with the attached motor. This removes the need for manual fine-tuning of the system, although in some critical applications this still may be required. Click Options... to configure optional autotuning parameters. These include Triggered Autotune which allows the autotuning process to be delayed until the drive is enabled.
Page 118: Further Tuning - No Load Attached
6.4.6 Further tuning - no load attached The Autotune Wizard calculates many parameters that allow the MotiFlex e100 to provide good control of the motor. In some applications, these parameters may need to be fine-tuned to provide the exact response that you require.
Page 119 www.baldormotion.com Measured velocity Demand velocity Figure 70 - Typical autotuned response (no load) Figure 70 shows that the response reaches the demand quickly and only overshoots the demand by a small amount. This can be considered an ideal response for most systems. For further information about tuning with the load attached, see section 6.4.7.
Page 120: Further Tuning - With Load Attached
www.baldormotion.com 6.4.7 Further tuning - with load attached To allow Mint WorkBench to adjust the basic tuning to compensate for the intended load, it is necessary to attach the load to the motor and then perform the autotune procedure again. 1.
Page 121: Optimizing The Velocity Response
www.baldormotion.com 6.4.8 Optimizing the velocity response It may be desirable to optimize the default autotuned response to better suit your application. The following sections describe the two main tuning issues and how to correct them. 6.4.8.1 Correcting overshoot Figure 71 shows a response where the measured velocity overshoots the demand by a significant amount.
Page 122 www.baldormotion.com 6.4.8.2 Correcting zero-speed noise in the velocity response Figure 72 shows a response where there is very little overshoot but a significant amount of zero-speed noise. This can cause undesirable humming or ringing in the motor. 1. Go to the Fine-tuning window’s Velocity tab.
Page 123 www.baldormotion.com 6.4.8.3 Ideal velocity response Repeat the tests described in sections 6.4.8.1 and 6.4.8.2 until the optimal response is achieved. Figure 73 shows an ideal velocity response. There is only a small amount of overshoot and very little zero-speed noise. Measured velocity Demand velocity...
Page 124: Performing Test Moves - Continuous Jog
www.baldormotion.com 6.4.9 Performing test moves - continuous jog This section tests the basic operation of the drive and motor by performing a continuous jog. Note: To stop a move in progress, click the red stop button or the drive enable button on the toolbar.
Page 125: Performing Test Moves - Relative Positional Move
www.baldormotion.com 6.4.10 Performing test moves - relative positional move This section tests the basic operation of the drive and motor by performing a positional move. Note: To stop a move in progress, click the red stop button or the drive enable button on the toolbar.
Page 126: Further Configuration
6.5 Further configuration Mint WorkBench provides a number of other tools for testing and configuring the MotiFlex e100. 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.
Page 127: Spy Window
www.baldormotion.com 6.5.2 Spy window The Spy window can be used to monitor and capture parameters in real-time. If you tried the test moves in section 6.4.9 or 6.4.10 then you have already seen the Spy window, as it is displayed in conjunction with Edit &...
Page 128: Other Tools And Windows
The Command window can be used send immediate Mint commands to the MotiFlex e100. If you tried the test moves in section 6.4.9 or 6.4.10, then you have already used Edit & Debug mode. Press Ctrl+N to open a new Mint programming window.
Page 129: Troubleshooting
If you have followed all the instructions in this manual in sequence, you should have few problems installing the MotiFlex e100. If you do have a problem, read this section first. In Mint WorkBench, use the Error Log tool to view recent errors and then check the help file.
Page 130: Motiflex E100 Indicators
If multiple errors occur at the same time, the lowest numbered error code will be flashed. For example, a MotiFlex e100 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 131: Can Leds
www.baldormotion.com 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.
Page 132: Ethernet Leds
www.baldormotion.com 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) Off: Node in NOT ACTIVE state.
Page 133: Communication
Try an alternative cable or different port on the PC. In the “Search up to Nodexx“ option in Mint WorkBench’s Select Controller dialog, check that the MotiFlex e100’s node ID is not higher than the selected value, or search up to a greater node ID.
Page 134: Tuning
7.2.9 CANopen The CANopen bus is ‘passive’: This means that the internal CAN controller in the MotiFlex e100 is experiencing a number of Tx and/or Rx errors, greater than the passive threshold of 127. Check: 12-24 VDC is being applied between pin 9 (+24 V) and pin 6 or 3 (0 V) of the CAN connector, to power the opto-isolators.
Page 135 Try power-cycling the node in question. If the node in question does not conform to DS401 or DS403 and is not a Baldor CANopen node, communication is still possible using a set of general purpose Mint keywords. See the Mint help file for further details.
Page 136 www.baldormotion.com 7-8 Troubleshooting MN1943...
Page 137: Specifications
Specifications 8.1 Introduction This section provides technical specifications for the MotiFlex e100. 8.2 AC input 8.2.1 AC input voltage (X1) - all models Unit AC input All models 3Φ, 50 Hz / 60 Hz Nominal input voltage 230 or 480...
Page 138: Ac Input Current (X1), Dc Bus Not Shared - All Models
www.baldormotion.com 8.2.2 AC input current (X1), DC bus not shared - all models Tables 7 and 8 show a range of typical AC input currents at typical motor output currents. The Typical AC supply current at full load is calculated using an AC input power factor of 0.7 and a motor output power factor of 0.85.
Page 139 www.baldormotion.com Full load output AC supply Input fuse Circuit current rating current rating current at current at breaker breaker not exceeding full load (B-type) Ferraz Shawmut: 12.1 16 A A60Q20-2, 20 A (B214338) Ferraz Shawmut: 20 A A60Q20-2, 20 A (B214338) Ferraz Shawmut: A60Q25-2, 25 A (Z214842) 18.2...
Page 140: Ac Input Current (X1), Dc Bus Sharing - All Models
8.2.3 AC input current (X1), DC bus sharing - all models When the MotiFlex e100 is sharing its DC bus, it becomes critical to consider the overall current being derived from the drive’s internal power supply. This includes the current required to drive its own motor (if present), and the current required by the other drives sharing its DC bus.
Page 141 www.baldormotion.com 8.2.3.3 Rating adjustment when sharing DC bus - 6 A model Note: A 1.2 mH line reactor must be used when DC bus sharing. Temperature Switching Maximum AC input supply current (RMS) frequency frequency Continuous 60 s overload overload 4 kHz 14 A 45 °C...
Page 142 www.baldormotion.com 8.2.3.6 Rating adjustment when sharing DC bus - 21 A model Note: A 0.5 mH line reactor must be used when DC bus sharing. Temperature Switching Maximum AC input supply current (RMS) frequency frequency Continuous 60 s overload overload 4 kHz 30 A 68 A...
Page 143 www.baldormotion.com 8.2.3.9 Rating adjustment when sharing DC bus - 48 A model Note: A 0.5 mH line reactor must be used when DC bus sharing. Temperature Switching Maximum AC input supply current (RMS) frequency frequency Continuous 60 s overload overload 4 kHz 45 °C 45 C...
Page 144: Recommended Fuses And Circuit Breakers When Sharing The Dc Bus
Earth/ground wires must be the same gauge, or larger, than the Line wires. UL compliance can only be achieved when using the recommended fuses. The use of circuit breakers does not guarantee UL compliance and provides protection for the wiring only, not the MotiFlex e100. 8-8 Specifications MN1943...
Page 145: Power, Power Factor And Crest Factor - 1.5 A ~ 16 A Models
www.baldormotion.com 8.2.5 Power, power factor and crest factor - 1.5 A ~ 16 A models The relationship between input current and power, power factor and crest factor is shown in Figure 74 (with no line reactor) and Figures 75 to 78 (with line reactor). 9 10 11 12 13 14 15 16 17 18 19 20 Supply current (A...
Page 146 www.baldormotion.com 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Supply current (A Power Power factor Crest factor Figure 76 - Power, power factor and crest factor (1.2 mH line reactor) - 6 A model Supply current (A Power Power factor...
Page 147 www.baldormotion.com Supply current (A Power Power factor Crest factor Figure 78 - Power, power factor and crest factor (0.8 mH line reactor) - 16 A model MN1943 Specifications 8-11...
Page 148: Power, Power Factor And Crest Factor - 21 A Model
www.baldormotion.com 8.2.6 Power, power factor and crest factor - 21 A model The relationship between input current and power, power factor and crest factor is shown in Figure 79 (with no line reactor) and Figure 80 (with 0.5 mH line reactor). Supply current (A Power Power factor...
Page 149: Power, Power Factor And Crest Factor - 26 A & 33.5 A Models
www.baldormotion.com 8.2.7 Power, power factor and crest factor - 26 A & 33.5 A models The relationship between input current and power, power factor and crest factor is shown in Figure 81 (with no line reactor) and Figure 82 (with 0.5 mH line reactor). Supply current (A Power Power factor...
Page 150: Power, Power Factor And Crest Factor - 48 A & 65 A Models
www.baldormotion.com 8.2.8 Power, power factor and crest factor - 48 A & 65 A models The relationship between input current and power, power factor and crest factor is shown in Figure 83 (with no line reactor) and Figure 84 (with 0.5 mH line reactor). Supply current (A Power Power factor...
Page 151: Motor Output
www.baldormotion.com 8.3 Motor output 8.3.1 Motor output power (X1) - 1.5 A ~ 16 A models Unit 1.5 A 10.5 A 16 A Nominal phase current 10.5 Nominal output power 1.08 2.16 4.31 7.55 11.50 @ 415 V Output voltage range (line-line) 0 - 430 @ VDC-bus = 600 V Output frequency...
Page 152: Motor Output Power (X1) - 48 A ~ 65 A Models
www.baldormotion.com 8.3.3 Motor output power (X1) - 48 A ~ 65 A models Unit 48 A 65 A Nominal phase current Nominal output power 32.5 46.72 @ 415 V, 3Φ input Output voltage range (line-line) 0 - 430 @ VDC-bus = 600 V Output frequency 0 - 2000 Output dV/dt...
Page 153: Motor Output Uprating And Derating
MotiFlex e100. In addition to these rating adjustments, if the MotiFlex e100 is operating in an ambient temperature greater than 45 ºC (113 ºF), a further derating must be applied. The choice of overload rating and switching frequency can be selected using the Drive Setup Wizard in Mint WorkBench, or by using the DRIVERATINGZONE keyword.
Page 154: Motor Output Rating Adjustment - 3 A Model
8.3.6 Motor output rating adjustment - 3 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 22. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 155: Motor Output Rating Adjustment - 6 A Model
8.3.7 Motor output rating adjustment - 6 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 23. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 156: Motor Output Rating Adjustment - 10.5 A Model
8.3.8 Motor output rating adjustment - 10.5 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 24. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 157: Motor Output Rating Adjustment - 16 A Model
8.3.9 Motor output rating adjustment - 16 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 25. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 158: Motor Output Rating Adjustment - 21 A Model
8.3.10 Motor output rating adjustment - 21 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 26. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 159: Motor Output Rating Adjustment - 26 A Model
8.3.11 Motor output rating adjustment - 26 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 27. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 160: Motor Output Rating Adjustment - 33.5 A Model
8.3.12 Motor output rating adjustment - 33.5 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 28. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 161: Motor Output Rating Adjustment - 48 A Model
8.3.13 Motor output rating adjustment - 48 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 28. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 162: Motor Output Rating Adjustment - 65 A Model
8.3.14 Motor output rating adjustment - 65 A model The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and switching frequency, as shown in Table 28. These settings can be selected in the Mint WorkBench Drive Setup Wizard - see the Mint help file for details.
Page 163: Regeneration
www.baldormotion.com 8.4 Regeneration 8.4.1 Regeneration (X1) - 1.5 A ~ 16 A models Unit 1.5 A 10.5 A 16 A Nominal switching threshold (typical) on: 800, off: 775 Nominal power 1.07 1.94 (10% power cycle, standalone) (R = 60 Ω) (R = 33 Ω) Peak power 10.7...
Page 164: Regeneration (X1) - 48 A ~ 65 A Models
www.baldormotion.com 8.4.3 Regeneration (X1) - 48 A ~ 65 A models Unit 48 A 65 A Nominal switching threshold (typical) on: 800, off: 775 Nominal power 8.53 (10% power cycle, R = 15 Ω) Peak power 85.3 (10% power cycle, R = 15 Ω) Maximum regeneration switching current Minimum load resistance...
Page 165: Vdc Output / 24 Vdc Input
www.baldormotion.com 8.5 18 VDC output / 24 VDC input 8.5.1 18 VDC output / 24 VDC control circuit backup supply input (X2) Unit All models When operating as an output: Nominal output voltage Minimum output voltage Maximum output voltage Maximum continuous output current (limited by PTC) When operating as in input: Nominal input voltage...
Page 166 The available power to the option cards depends on the ambient temperature and whether the MotiFlex e100 is powered from the AC supply or from only the 24 VDC backup supply. If the AC supply is present, a maximum of 10 W is available to power the option cards, at temperatures up to 55 ºC (131 ºF).
Page 167: Input / Output
www.baldormotion.com 8.6 Input / output 8.6.1 Analog input - AIN0 (X3) Unit All models Type Differential Common mode voltage range ±10 Input impedance kΩ Input ADC resolution bits 12 (includes sign bit) Equivalent resolution (±10 V input) ±4.9 Sampling interval μs 8.6.2 Digital inputs - drive enable and DIN0 general purpose (X3) Unit...
Page 168: Digital Outputs Dout0, Dout1 - Status And General Purpose (X3)
Differential Data and Clock Operating mode Single or multi-turn. A wide range of devices can be supported. Contact Baldor technical support before selecting a device. Output power supply to encoder 5 VDC (±7%), 200 mA max. Maximum recommended cable length 30.5 m (100 ft)
Page 169: Sincos / Endat Interface (X8)
512 or 2048 Sin/Cos cycles per turn, with absolute positioning resolution of up to 65536 steps. (Many other encoder specifications are supported - contact Baldor.) Output power supply to encoder 5 VDC (±7%), 200 mA max. Maximum recommended cable length 30.5 m (100 ft)
Page 170: Rs485 Interface (X6)
www.baldormotion.com 8.6.11 RS485 interface (X6) Unit Value Description Signal RS485, 2-wire, non-isolated Bit rates Baud 9600, 19200, 38400, 57600 (default), 115200 Nominal output voltage Minimum output voltage Maximum output voltage Maximum continuous output current 8.7 Weights and dimensions 8.7.1 Weights and dimensions - 1.5 A ~ 16 A models 1.5 A 10.5 A 16 A...
Page 171: Environmental
BS EN60068-2-2:1993 high temperature storage/transportation +85 °C. BS EN60068-2-27:2009 Test “Ea” (shock) BS EN60068-2-6:2008 Test “Fc” (vibration) ** MotiFlex e100 complies with EN60529, IP2x, provided connectors X1 and X17 are shrouded. MotiFlex e100 complies with EN60529, IP3x, if it is either: mounted in a cabinet, or;...
Page 172 www.baldormotion.com 8-36 Specifications MN1943...
Page 173: A.1 Introduction
This section describes accessories and options that you may need to use with your MotiFlex 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.
Page 174: A.1.1 Busbars For Dc Bus Sharing
Plated copper busbars are required to allow the DC bus voltage to be shared between neighboring MotiFlex e100 drives. The busbars are made from tin plated copper, and are available in four different sizes. The required size depends upon the combination of drive types and their relative positions.
Page 175: A.1.2 Ac Supply (Emc) Filters
A.1.2 AC supply (EMC) filters AC filters remove high frequency noise from the AC power supply, protecting the MotiFlex 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 section 3.4.10.
Page 176: A.1.3 Ac Line Reactors
A.1.3 AC line reactors AC line reactors provide bi-directional protection, reducing unwanted electrical noise, harmonics and overvoltage trips. A line reactor should always be used when a MotiFlex e100 is sharing its DC bus with other drives (see section 3.5).
Page 177: A.1.4 Regeneration Resistors
See sections 3.8 and 3.9 for details about choosing the correct resistor. The MotiFlex e100 is UL listed when using these resistors. Electrical shock hazard. DC bus voltages may be present at these terminals.
Page 178 Weights: RGA1210: 5.9 kg (13 lb) RGA2410: 9.1 kg (20 lb) RGA4810: 11.8 kg (26 lb) Dimensions mm (inches) Baldor Pwr. Res. catalog catalog Ω Ω number RGA1210 1200 247.7 201.1 168.9 241.3 228.6 (11.0) (9.75) (7.92) (6.65) (9.5) (9.0)
Page 179: A.1.5 Motor / Power Cable Management Bracket
AC supply cable. The bracket is supplied with clamps suitable for typical motor power cables. The bracket can be mounted just below the MotiFlex e100, as shown in Figure 100: OPT-CM-001...
Page 180: A.1.6 Signal Cable Management Bracket
By using additional clamps, the bracket can hold other signals cables too. The bracket must be attached to the metal tab that protrudes from the bottom of the MotiFlex e100, as shown in Figure 101: OPT-CM-002...
Page 181: 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. The Baldor part number for a BSM rotary motor power cable is derived as follows: SP CE style threaded Current...
Page 182: A.2.2 Feedback Cable Part Numbers
CBL010SF-D1S. Baldor 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 183: B Control System
Control System B.1 Introduction The MotiFlex e100 can use two main control configurations: Servo (Position). 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).
Page 184: B.1.1 Servo Configuration
www.baldormotion.com 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 102.
Page 185 www.baldormotion.com MN1943 Control System B-3...
Page 186: B.1.2 Torque Servo Configuration
www.baldormotion.com B.1.2 Torque servo configuration Figure 103 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.
Page 187 www.baldormotion.com MN1943 Control System B-5...
Page 188 www.baldormotion.com B-6 Control System MN1943...
Page 189: C.1 Introduction
The following table summarizes the Mint keywords supported by the MotiFlex e100. Note that due to continuous developments of the MotiFlex e100 and the Mint language, this list is subject to change. Check the latest Mint help file for full details of new or changed keywords.
Page 190 www.baldormotion.com Keyword Description To set the gain to be applied to an ADC input. ADCGAIN To set the offset to be applied to an ADC input. ADCOFFSET To zero (trim) the specified analog input. ADCOFFSETTRIM To set the time constant of the low pass filter applied to ADCTIMECONSTANT an ADC input.
Page 191 www.baldormotion.com Keyword Description To return the progress of the pre-trigger or post-trigger CAPTUREPROGRESS capture phase. CAPTURESTATUS To return the progress of the capture. To generate a capture trigger. CAPTURETRIGGER To ignore the sign of the trigger value when triggering CAPTURETRIGGERABSOLUTE from a capture channel source.
Page 192 www.baldormotion.com Keyword Description To restrict the current output to a defined range. CURRENTLIMIT Reads the measured current. CURRENTMEAS To enable a current sensor temperature drift CURRENTSENSORMODE compensation scheme. To set the deceleration rate on the axis. DECEL To define the jerk rate to be used during periods of DECELJERK deceleration.
Page 193 www.baldormotion.com Keyword Description To set or read the axis encoder value. ENCODER To set or read the size of a sin/cos cycle on an encoder. ENCODERCYCLESIZE To make miscellaneous changes to the encoders. ENCODERMODE To set or read the offset used to calculate encoder ENCODEROFFSET position for absolute encoders.
Page 194 www.baldormotion.com Keyword Description To determine if a particular error is present in the error ERRORREADCODE list. ERRORREADNEXT Returns the next entry in the specified group from the error list. To return the state of the error input. ERRORSWITCH To return the error string for the last error code read from ERRSTRING the error list.
Page 195 www.baldormotion.com Keyword Description To find the home position on an axis. HOME To set the acceleration rate for the homing profile. HOMEACCEL To set the home back-off speed factor. HOMEBACKOFF To set the creep speed for homing moves. HOMECREEPSPEED To set the deceleration rate for the homing profile. HOMEDECEL To set a digital input to be the home switch input for the HOMEINPUT...
Page 196 www.baldormotion.com Keyword Description To set or return the sum of a bit pattern describing which INPUTMODE of the user digital inputs should be edge or level triggered. To set or return the user inputs that become active on INPUTNEGTRIGGER negative edges. INPUTPOSTRIGGER To set or return the user inputs that become active on positive edges.
Page 197 www.baldormotion.com Keyword Description To set the tracking factor used by the speed controller. KVTRACK To read the state of a fast latch channel. LATCH Manually re-enables a fast latch channel. LATCHENABLE To specify a period during which further fast triggers will LATCHINHIBITTIME be ignored.
Page 198 www.baldormotion.com Keyword Description To define the combined inertia of the motor and load. LOADINERTIA To set or read the channel of the input device used for MASTERCHANNEL gearing. To set or read the source of the input device used for MASTERSOURCE gearing.
Page 199 www.baldormotion.com Keyword Description To set or read the rated current of the motor. MOTORRATEDCURRENT To set or read the rated frequency of an induction motor. MOTORRATEDFREQ To set or read the rated speed of an induction motor. MOTORRATEDSPEEDRPM To set or read the rated voltage of an induction motor. MOTORRATEDVOLTS To set or read the rotor leakage inductance of an MOTORROTORLEAKAGEIND...
Page 200 www.baldormotion.com Keyword Description To set or read an individual digital output. OUTX To select the back-off distance used to clear an end stop PHASESEARCHBACKOFF during the phase search sequence. To define the bandwidth used to design the ’debounce’ PHASESEARCHBANDWIDTH controller used during the initial alignment stage of the phase search sequence.
Page 201 www.baldormotion.com Keyword Description To set or read the output used by a DC bus source drive POWERREADYOUTPUT to inform a DC bus receiving drive that mains power has been applied to the source drive. To select the type of velocity profiler to use. PROFILEMODE To read the value of a remote analog input (ADC).
Page 202 To request data from a node in the form of a PDO REMOTEPDOIN message. To force a Baldor controller node to transmit a variable REMOTEPDOOUT length PDO message with a specific COB-ID. The PDO will contain up to 64 bits of data that can be passed in the form of two 32-bit values.
Page 203 www.baldormotion.com Keyword Description To report the internal drive temperature. TEMPERATURE To set or read the temperature fatal limit. TEMPERATURELIMITFATAL To return the instantaneous torque demand. TORQUEDEMAND Defines the band of operation for a torque filter stage. TORQUEFILTERBAND Defines the reduction in gain for a notch torque filter TORQUEFILTERDEPTH stage.
Page 204 www.baldormotion.com C-16 Mint Keyword Summary MN1943...
Page 205: D.1 Introduction
CE compliance. It is not intended as an exhaustive guide to good practice and wiring techniques. It is assumed that the installer of the MotiFlex 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”...
Page 206: D.1.2 Declaration Of Conformity
MotiFlex e100 Single and Multi-Axis Servo Drive, being one of: MFE460A0xxx (where xxx = product variant) when used in accordance with the guidance given in the corresponding MotiFlex e100 Installation Manual (MN1943) conforms with the protection requirements of the following Council Directives, by application of the relevant harmonized...
Page 207: D.1.3 Use Of Ce Compliant Components
EMC filters The filter should be mounted next to the MotiFlex e100. The connections between the MotiFlex e100 and the filter should use shielded (screened) cables. The cable shields should be connected to shield clamps at both ends. Earthing/grounding For safety reasons (VDE0160), all Baldor components must be connected to earth/ground with a separate wire.
Page 208: D.1.5 Emc Installation Suggestions
www.baldormotion.com D.1.5 EMC installation suggestions To ensure electromagnetic compatibility (EMC), the following installation points should be considered to help reduce interference: Earthing/grounding of all system elements to a central earth/ground point (star point) Shielding of all cables and signal wires Filtering of power lines.
Page 209: D.1.6 Wiring Of Shielded (Screened) Cables
D.1.6 Wiring of shielded (screened) cables Remove the outer insulation to expose the overall shield. Clamp should ideally provide 360° contact with the cable. P-type clamp (preferred) Flat clamp Figure 104 - Earthing/grounding cable shields MotiFlex e100 Encoder Connector Cable Housing Twisted pairs CHA+ CHA-...
Page 210: D.2 Ul File Numbers
D.2 UL file numbers The following table lists UL file numbers for Baldor products and other accessories. Note that UL file numbers for accessories not manufactured by Baldor are beyond Baldor’s control and therefore subject to change without notice.
Page 211 Index Circuit breakers, 8-2 Command window, 6-26 Abbreviations. See Units and Abbreviations Commissioning Wizard, 6-12 AC input current using, 6-13 DC bus not shared, 8-2 Configuration, 6-24 DC bus sharing, 8-4 Connections AC input voltage, 8-1 AC power, 3-14, 3-17 AC line reactors, 3-19, 3-25, 8-4 feedback, 4-1 catalog numbers, A-4...
Page 212 drive enable input, 5-5, 8-31 SSI, 4-9 fast position capture, 5-10 Filters motor overtemperature input, 5-12 AC line reactors, 3-19, 3-25, A-4 special functions on DIN1 & DIN2, 5-10 AC supply (EMC), 3-20, A-3 step & direction, 5-10 catalog numbers, A-3 Dimensions, 3-4, 3-5, 3-6 sinusoidal, 3-31 Dynamic brake.
Page 213 Mint Machine Center, 6-1 Mint WorkBench, 6-1 Operation, 6-1 mounting, 3-7 configuring the TCP/IP connection, 6-4 TCP/IP configuration, 6-4 connecting to the PC, 6-1 USB driver, 6-3 installing Mint Machine Center, 6-1 installing Mint WorkBench, 6-1 installing the USB driver, 6-3 Keyword summary, C-1 power on checks, 6-2 preliminary checks, 6-2...
Page 214 1.5 A model, DC bus sharing, 8-4 Specifications, 8-1 3 A model, DC bus sharing, 8-4 18 VDC output, 8-29 6 A model, DC bus sharing, 8-5 24 VDC backup supply, 8-29 10.5 A model, DC bus sharing, 8-5 AC input current, 8-2, 8-4 16 A model, DC bus sharing, 8-5 AC input voltage, 8-1 21 A model, DC bus sharing, 8-6...
Page 215 load attached, 6-18 no load attached, 6-16 TCP/IP, configuring, 6-4 optimizing the velocity response, 6-19 Tools, 3-2 test moves, jog, 6-22 Troubleshooting, 7-1 test moves, positional, 6-23 CAN LEDs, 7-3 CANopen, 7-6 communication, 7-5 UL file numbers, D-6 Ethernet, 7-6 Units and abbreviations, 2-3 ETHERNET LEDs, 7-4 Uprating.
Page 216 Index MN1943...
Page 217 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 218 www.baldormotion.com Thank you for taking the time to help us. Comments MN1943...

Baldor MotiFlex e100 Installation Manual

1 General Information

2 Introduction

3 Basic Installation

4 Feedback

5 Input / Output

6 Configuration

7 Troubleshooting

8 Specifications

B Control System

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