Baldor MicroFlex e100 User manual

Contents i
MN1942
Contents
1 General Information 1-1.................................
2 Introduction 2-1........................................
2.1 MicroFlex e100 features 2-1.................................
2.2 Receiving and inspection 2-2................................
2.2.1 Identifying the catalog number 2-2....................................
2.3 Units and abbreviations 2-3..................................
3 Basic Installation 3-1....................................
3.1 Introduction 3-1............................................
3.1.1 Power sources 3-1................................................
3.1.2 Hardware requirements 3-1.........................................
3.1.3 Tools and miscellaneous hardware 3-2................................
3.1.4 Other information needed for installation 3-2...........................
3.2 Mechanical installation and cooling requirements 3-3............
3.2.1 Dimensions 3-4...................................................
3.2.2 Mounting and cooling the MicroFlex e100 3-5..........................
3.2.3 Derating characteristic - 3 A model 3-6................................
3.2.4 Derating characteristic - 6 A model 3-7................................
3.2.5 Derating characteristic - 9 A model 3-8................................
3.2.6 Overtemperature trips 3-8...........................................
3.3 Connector locations 3-9.....................................
3.3.1 Front panel connectors 3-9..........................................
3.3.2 Top panel connectors 3-10...........................................
3.4 Power connections 3-11......................................
3.4.1 Earthing / grounding 3-11............................................
3.4.2 Single-phase or three-phase power connections 3-12.....................
3.4.3 Input power conditioning 3-13.........................................
3.4.4 Power disconnect and protection devices 3-14..........................
3.4.5 Recommended fuses, circuit breakers and wire sizes 3-15................
3.4.6 Drive overload protection 3-15........................................
3.4.7 Power supply filters 3-16.............................................
3.4.8 24 V control circuit supply 3-17.......................................
3.5 Motor connections 3-18......................................
3.5.1 Motor circuit contactors 3-19.........................................
3.5.2 Motor power cable pin configuration - Baldor BSM rotary motors 3-19.......
3.5.3 Motor cable pin configuration - Baldor linear motors 3-20..................
3.5.4 Sinusoidal filter 3-20................................................
3.5.5 Thermal switch connection 3-21.......................................
3.5.6 Motor brake connection 3-22.........................................
3.6 Regeneration resistor (Dynamic Brake resistor) 3-23.............
3.6.1 Regeneration capacity 3-23..........................................

ii Contents MN1942
3.7 Regeneration resistor selection 3-24...........................
3.7.1 Required information 3-24............................................
3.7.2 Regenerative energy 3-25...........................................
3.7.3 Regenerative power and average power 3-25...........................
3.7.4 Resistor choice 3-26................................................
3.7.5 Resistor derating 3-26...............................................
4 Feedback 4-1..........................................
4.1 Introduction 4-1............................................
4.1.1 Incremental encoder feedback 4-2...................................
4.1.2 BiSS interface 4-7.................................................
4.1.3 SSI feedback 4-9..................................................
4.1.4 SinCos feedback 4-11...............................................
4.1.5 EnDat (absolute encoder) feedback 4-13...............................
5 Input / Output 5-1......................................
5.1 Introduction 5-1............................................
5.2 Digital I/O 5-2..............................................
5.2.1 Drive enable input 5-3..............................................
5.2.2 General purpose digital input DIN0 5-5................................
5.2.3 General purpose digital inputs DIN1 & DIN2 5-7........................
5.2.4 Special functions on inputs DIN1 & DIN2 5-8...........................
5.2.5 General purpose / status output DOUT0 5-10...........................
5.2.6 General purpose output DOUT1 5-12..................................
5.3 USB communication 5-14....................................
5.3.1 USB port 5-14.....................................................
5.4 RS485 communication 5-14..................................
5.4.1 RS485 port (2-wire) 5-14.............................................
5.5 Ethernet interface 5-16.......................................
5.5.1 TCP/IP 5-16.......................................................
5.5.2 ETHERNET Powerlink 5-17..........................................
5.5.3 Ethernet connectors 5-18............................................
5.6 CAN interface 5-19..........................................
5.6.1 CAN connector 5-19................................................
5.6.2 CAN wiring 5-19....................................................
5.6.3 CANopen 5-20.....................................................
5.7 Other I/O 5-22..............................................
5.7.1 Node ID selector switches 5-22.......................................
5.8 Connection summary - recommended system wiring 5-25.........
6 Configuration 6-1.......................................
6.1 Introduction 6-1............................................
6.1.1 Connecting the MicroFlex e100 to the PC 6-1..........................
6.1.2 Installing Mint Machine Center and Mint WorkBench 6-1.................

Contents iii
MN1942
6.2 Starting the MicroFlex e100 6-2..............................
6.2.1 Preliminary checks 6-2.............................................
6.2.2 Power on checks 6-2...............................................
6.2.3 Installing the USB driver 6-3.........................................
6.2.4 Configuring the TCP/IP connection (optional) 6-4.......................
6.3 Mint Machine Center 6-5....................................
6.3.1 Starting MMC 6-7..................................................
6.4 Mint WorkBench 6-8........................................
6.4.1 Help file 6-9......................................................
6.4.2 Starting Mint WorkBench 6-10........................................
6.4.3 Commissioning Wizard 6-12..........................................
6.4.4 Further tuning - no load attached 6-15..................................
6.4.5 Further tuning - with load attached 6-17................................
6.4.6 Optimizing the velocity response 6-18..................................
6.4.7 Performing test moves - continuous jog 6-21............................
6.4.8 Performing test moves - relative positional move 6-22....................
6.5 Further configuration 6-23....................................
6.5.1 Fine-tuning tool 6-23................................................
6.5.2 Parameters tool 6-25................................................
6.5.3 Spy window 6-26...................................................
6.5.4 Other tools and windows 6-27........................................
7 Troubleshooting 7-1....................................
7.1 Introduction 7-1............................................
7.1.1 Problem diagnosis 7-1..............................................
7.1.2 SupportMe feature 7-1.............................................
7.1.3 Power-cycling the MicroFlex e100 7-1................................
7.2 MicroFlex e100 indicators 7-2................................
7.2.1 STATUS LED 7-2..................................................
7.2.2 CAN LEDs 7-3....................................................
7.2.3 ETHERNET LEDs 7-4..............................................
7.2.4 Communication 7-5................................................
7.2.5 Power on 7-5.....................................................
7.2.6 Mint WorkBench 7-5...............................................
7.2.7 Tuning 7-6........................................................
7.2.8 Ethernet 7-6......................................................
7.2.9 CANopen 7-6.....................................................
8 Specifications 8-1......................................
8.1 Introduction 8-1............................................
8.1.1 AC input power and DC bus voltage (X1) 8-1...........................
8.1.2 24 V control circuit supply input (X2) 8-3...............................
8.1.3 Motor output power (X1) 8-3.........................................
8.1.4 Regeneration (X1) 8-3..............................................
8.1.5 Digital inputs - drive enable and DIN0 general purpose (X3) 8-4...........
8.1.6 Digital inputs DIN1, DIN2 - high speed general purpose (X3) 8-4..........
8.1.7 Digital outputs DOUT0, DOUT1 - status and general purpose (X3) 8-4.....
8.1.8 Incremental encoder feedback option (X8) 8-5..........................

iv Contents MN1942
8.1.9 BiSS interface (X8) 8-5.............................................
8.1.10 SSI encoder feedback option (X8) 8-5................................
8.1.11 SinCos / EnDat encoder feedback option (X8) 8-6......................
8.1.12 Ethernet interface 8-6..............................................
8.1.13 CAN interface 8-6.................................................
8.1.14 RS485 interface 8-6................................................
8.1.15 Environmental 8-7.................................................
8.1.16 Weights and dimensions 8-7........................................
Appendices
A Accessories A-1........................................
A.1 Introduction A-1............................................
A.1.1 Fan tray A-2......................................................
A.1.2 Footprint filter (single-phase only) A-3.................................
A.1.3 24 V power supplies A-3............................................
A.1.4 EMC filters A-4....................................................
A.1.5 Regeneration resistors A-7..........................................
A.2 Cables A-8................................................
A.2.1 Motor power cables A-8.............................................
A.2.2 Feedback cable part numbers A-10....................................
A.2.3 SSI feedback cables A-10............................................
A.2.4 Encoder / Hall feedback cables A-11...................................
A.2.5 BiSS, EnDat and SinCos feedback cables A-12..........................
A.2.6 Ethernet cables A-12................................................
B Control System B-1.....................................
B.1 Introduction B-1............................................
B.1.1 Servo configuration B-2.............................................
B.1.2 Torque servo configuration B-4.......................................
C Mint Keyword Summary C-1.............................
C.1 Introduction C-1............................................
C.1.1 Keyword listing C-1................................................
D CE&UL C-1...........................................
D.1 Outline C-1................................................
D.1.1 EMC Conformity and CE marking C-1.................................
D.1.2 MicroFlex e100 compliance C-1......................................
D.1.3 Declaration of conformity C-2........................................
D.1.4 Use of CE compliant components C-3.................................
D.1.5 EMC wiring technique C-3...........................................
D.1.6 EMC installation suggestions C-4.....................................
D.1.7 Wiring of shielded (screened) cables C-5..............................
D.2 UL file numbers C-6.........................................

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General Information 1-1MN1942
LT0262A03 Copyright Baldor (c) 2010. All rights reserved.
This manual is copyrighted and all rights are reserved. This document or attached software may not, in
whole or in part, be copied or reproduced in any form without the prior written consent of Baldor.
Baldor makes no representations or warranties with respect to the contents hereof and specifically
disclaims any implied warranties of fitness for any particular purpose. The information in this document
is subject to change without notice. Baldor assumes no responsibility for any errors that may appear in
this document.
Minttand MicroFlextare registered trademarks of Baldor.
Windows 2000, Windows XP, Windows Vista and Windows 7 are registered trademarks of the Microsoft
Corporation. UL and cUL are registered trademarks of Underwriters Laboratories.
MicroFlex 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.
This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused,
or improperly installed and has been used in accordance with the instructions and/or ratings supplied.
This warranty is in lieu of any other warranty or guarantee expressed or implied. Baldor shall not be held
responsible for any expense (including installation and removal), inconvenience, or consequential
damage, including injury to any person or property caused by items of our manufacture or sale. (Some
countries and U.S. states do not allow exclusion or limitation of incidental or consequential damages, so
the above exclusion may not apply.) In any event, Baldor’s total liability, under all circumstances, shall not
exceed the full purchase price of the control. Claims for purchase price refunds, repairs, or replacements
must be referred to Baldor with all pertinent data as to the defect, the date purchased, the task performed
by the control, and the problem encountered. No liability is assumed for expendable items such as fuses.
Goods may be returned only with written notification including a Baldor Return Authorization Number and
any return shipments must be prepaid.
Baldor UK Ltd
Mint Motion Centre
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
Telephone: [phone]
Fax: [phone]
E-mail: [e-mail]
Web site: www.baldormotion.com
See rear cover for other international offices.
1General Information 1

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1-2 General Information MN1942
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. They are designed for machine
applications that require variable speed controlled three-phase brushless AC motors. These drives are
not intended for use in applications such as:
HHome appliances
HMedical instrumentation
HMobile vehicles
HShips
HAirplanes.
Unless otherwise specified, this drive is intended for installation in a suitable enclosure. The enclosure
must protect the drive from exposure to excessive or corrosive moisture, dust and dirt or abnormal
ambient temperatures. The exact operating specifications are found in section 8 of this manual. The
installation, connection and control of drives is a skilled operation, disassembly or repair must not be
attempted. In the event that a drive fails to operate correctly, contact the place of purchase for return
instructions.
Precautions
Do not touch any circuit board, power device or electrical connection before you first
ensure that no high voltage is present at this equipment or other equipment to which it is
connected. Electrical shock can cause serious or fatal injury. Only qualified personnel
should attempt to start-up, program or troubleshoot this equipment.
The motor circuit might have high voltages present whenever AC power is applied, even
when the motor is not moving. Electrical shock can cause serious or fatal injury.
If a motor is driven mechanically, it might generate hazardous voltages that are conducted
to its power terminals. The enclosure must be earthed/grounded to prevent possible shock
hazard.
Be sure the system is properly earthed/grounded before applying power. Do not apply AC
power before you ensure that earths/grounds are connected. Electrical shock can cause
serious or fatal injury.
Be sure that you are completely familiar with the safe operation and programming of this
equipment. This equipment may be connected to other machines that have rotating parts or
parts that are controlled by this equipment. Improper use can cause serious or fatal injury.
WARNING
WARNING
WARNING
WARNING
WARNING

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General Information 1-3MN1942
MEDICAL DEVICE / PACEMAKER DANGER: Magnetic and electromagnetic fields in the
vicinity of current carrying conductors and industrial motors can result in a serious health
hazard to persons with cardiac pacemakers, internal cardiac defibrillators, neurostimulators,
metal implants, cochlear implants, hearing aids, and other medical devices. To avoid risk,
stay away from the area surrounding a motor and its current carrying conductors.
Be sure all wiring complies with the National Electrical Code and all regional and local
codes. Improper wiring may result in unsafe conditions.
The stop input to this equipment should not be used as the single means of achieving a
safety critical stop. Drive disable, motor disconnect, motor brake and other means should
be used as appropriate.
Improper operation or programming of the drive may cause violent motion of the motor and
driven equipment. Be certain that unexpected motor movement will not cause injury to
personnel or damage to equipment. Peak torque of several times the rated motor torque
can occur during control failure.
If the drive enable signal is already present when power is applied to the MicroFlex e100, the
motor could begin to move immediately.
The metal heatsink on the left side of the MicroFlex e100 can become very hot during
normal operation.
When operating a rotary motor with no load coupled to its shaft, remove the shaft key to
prevent it flying out when the shaft rotates.
A regeneration resistor may generate enough heat to ignite combustible materials.
To avoid fire hazard, keep all combustible materials and flammable vapors away from the
brake resistors. 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
To prevent equipment damage, be certain that the input power has correctly sized protective
devices installed.
To ensure reliable performance of this equipment be certain that all signals to/from the drive
are shielded correctly.
Suitable for use on a circuit capable of delivering not more than the RMS symmetrical short
circuit amperes listed here, at the rated maximum voltage:
Horsepower RMS Symmetrical Amperes
1-50 5,000
Avoid locating the drive immediately above or beside heat generating equipment, or directly
below water or steam pipes.
Avoid locating the drive in the vicinity of corrosive substances or vapors, metal particles and
dust.
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE

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1-4 General Information MN1942
Do not connect AC power to the drive terminals U, V and W. Connecting AC power to these
terminals may result in damage to the drive.
Baldor does not recommend using “Grounded Leg Delta” transformer power leads that may
create earth/ground loops and degrade system performance. Instead, we recommend using
a four wire Wye.
Drives are intended to be connected to a permanent main power source, not a portable
power source. Suitable fusing and circuit protection devices are required.
The safe integration of the drive into a machine system is the responsibility of the machine
designer. Be sure to comply with the local safety requirements at the place where the
machine is to be used. In Europe these are the Machinery Directive, the ElectroMagnetic
Compatibility Directive and the Low Voltage Directive. In the United States this is the National
Electrical code and local codes.
Drives must be installed inside an electrical cabinet that provides environmental control and
protection. Installation information for the drive is provided in this manual. Motors and
controlling devices that connect to the drive should have specifications compatible to the
drive.
Failure to meet cooling air flow requirements will result in reduced product lifetime and/or
drive overtemperature trips.
Violent jamming (stopping) of the motor during operation may damage the motor and drive.
Operating the MicroFlex e100 in Torque mode with no load attached to the motor can cause
the motor to accelerate rapidly to excessive speed.
Do not tin (solder) exposed wires. Solder contracts over time and may cause loose
connections. Use crimp connections where possible.
Electrical components can be damaged by static electricity. Use ESD (electrostatic
discharge) procedures when handling this drive.
If the drive is subjected to high potential (‘hipot’) testing, only DC voltages may be applied.
AC voltage hipot tests could damage the drive. For further information please contact your
local Baldor representative.
Ensure that encoder wires are properly connected. Incorrect installation may result in
improper movement.
The threaded holes in the top and bottom of the case are for cable clamps. The holes are
11.5 mm deep and accept M4 screws, which must be screwed in to a depth of at least 8 mm.
Removing the cover will invalidate UL certification.
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE

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Introduction 2-1MN1942
2.1 MicroFlex e100 features
The MicroFlex e100 is a versatile brushless servo drive, providing a flexible and powerful motion
control solution for rotary and linear motors. Standard features include:
HSingle axis AC brushless drive.
HRange of models with continuous current ratings of 3 A, 6 A
or 9 A.
HDirect connection to 115 VAC or 230 VAC single-phase or
230 VAC three-phase supplies.
HUniversal feedback interface supporting incremental
encoder, BiSS, SSI, EnDat or SinCos feedback.
HPosition, velocity and current control.
HAuto-tuning wizard (including position loop) and software
oscilloscope facilities provided by Mint WorkBench
configuration software (supplied).
H3 optically isolated general purpose digital inputs. Two
inputs have ‘fast input’ capability, providing real-time
position capture.
H1 optically isolated drive enable input.
H1 optically isolated general purpose digital output.
H1 optically isolated digital output to indicate error
conditions.
HUSB 1.1 serial port (compatible with USB2.0).
HCANopen protocol for communication with Mint controllers
and other third party CANopen devices.
HETHERNET Powerlink & TCP/IP support: Twin Ethernet
ports with integrated hub for communication with host PC
or other ETHERNET Powerlink devices.
HProgrammable in Mint.
MicroFlex e100 will operate with 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 servo motors, please see the sales brochure BR1202 available from your local Baldor
representative.
This manual is intended to guide you through the installation of MicroFlex e100. The sections
should be read in sequence.
The Basic Installation section describes the mechanical installation of the MicroFlex e100, the
power supply connections and motor connections. The other sections require knowledge of the
low level input/output requirements of the installation and an understanding of computer software
installation. If you are not qualified in these areas you should seek assistance before proceeding.
2Introduction 2

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2-2 Introduction MN1942
2.2 Receiving and inspection
When you receive your MicroFlex e100, there are several things you should do immediately:
1. Check the condition of the shipping container and report any damage immediately to the
carrier that delivered your MicroFlex e100.
2. Remove the MicroFlex e100 from the shipping container and remove all packing material.
The container and packing materials may be retained for future shipment.
3. Verify that the catalog number of the MicroFlex e100 you received is the same as the catalog
number listed on your purchase order. The catalog number is described in the next section.
4. Inspect the MicroFlex e100 for external damage during shipment and report any damage to
the carrier that delivered your MicroFlex e100.
5. If MicroFlex 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 8.1.15.
2.2.1 Identifying the catalog number
The MicroFlex e100 is available with different current ratings. The catalog number is marked on
the side of the unit. It is a good idea to look for the catalog number (sometimes shown as ID/No:)
and write it in the space provided here:
Catalog number: MFE_____________________
Installed at: ________________________ Date: ______
A description of a catalog number is shown here, using the example MFE230A003x:
Meaning Alternatives
MFE MicroFlex e100 family -
230 Requires an AC supply voltage of 115-230 Volts, 1Φor 3Φ-
A003 Continuous current rating of 3 A A006=6 A; A009=9 A
xA letter indicating the hardware revision.
This does not affect the capabilities of the MicroFlex e100
unless otherwise stated.
-

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Introduction 2-3MN1942
2.3 Units and abbreviations
The following units and abbreviations may appear in this manual:
V Volt (also VAC and VDC)...............
WWatt..............
A Ampere...............
ΩOhm...............
μF microfarad..............
pF picofarad..............
mH millihenry.............
Φphase...............
ms millisecond..............
μs microsecond..............
ns nanosecond..............
mm millimeter.............
m meter...............
in inch...............
ft feet...............
lbf-in pound force inch (torque)............
N·m Newton meter (torque).............
ADC Analog to Digital Converter............
ASCII American Standard Code for Information Interchange...........
AWG American Wire Gauge............
CAL CAN Application Layer............
CAN Controller Area Network............
CDROM Compact Disc Read Only Memory.........
CiA CAN in Automation International Users and Manufacturers Group e.V..............
CTRL+E on the PC keyboard, press Ctrl then Eat the same time..........
DAC Digital to Analog Converter............
DS301 CiA CANopen Application Layer and Communication Profile..........
DS401 CiA Device Profile for Generic I/O Devices..........
DS402 CiA Device Profile for Drives and Motion Control..........
DS403 CiA Device Profile for HMIs..........
EDS Electronic Data Sheet............
EMC Electromagnetic Compatibility............
EPL ETHERNET Powerlink............
HMI Human Machine Interface.............
ISO International Standards Organization.............
Kbaud kilobaud (the same as Kbit/s in most applications)...........
LCD Liquid Crystal Display............
Mbps megabits/s...........
MB megabytes.............
MMC Mint Machine Center............
(NC) Not Connected............
RF Radio Frequency..............
SSI Synchronous Serial Interface.............
TCP/IP Transmission Control Protocol / Internet Protocol..........
UDP User Datagram Protocol............

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2-4 Introduction MN1942

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Basic Installation 3-1MN1942
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 MicroFlex e100 in the
following stages:
HLocation considerations
HMounting the MicroFlex e100
HConnecting the AC power supply
HConnecting the 24 VDC control circuit supply
HConnecting the motor
HInstalling a regeneration resistor (Dynamic Brake)
HConnecting the feedback device
These stages should be read and followed in sequence.
3.1.1 Power sources
A 115 - 230 VAC power source (IEC1010 over-voltage category III or less) in the installation area
is required. This may be single-phase or three-phase. An AC power filter is required to comply
with the CE directive for which the MicroFlex e100 was tested (see section 3.4.7).
The 24 VDC control circuit supply must be a regulated power supply with a continuous current
supply capability of 1 A (4 A power on surge).
3.1.2 Hardware requirements
The components you will need to complete the basic installation are:
H24 VDC power supply.
HAC power supply filter (for CE compliance).
HThe motor that will be connected to the MicroFlex e100.
HA motor power cable.
HAn incremental encoder feedback cable, SSI cable, or BiSS / EnDat / SinCos cable.
A separate Hall cable might also be required for linear motors.
HA USB cable.
H(Optional) A regeneration resistor (Dynamic Brake) might be required, depending on the
application. Without the regeneration resistor, the drive may produce an overvoltage fault. All
MicroFlex e100 models have overvoltage sensing circuitry. Regeneration resistors may be
purchased separately - see Appendix A.
HA cooling fan may be required to allow operation of the MicroFlex e100 at full rated current
(see section 3.2.2).
3Basic Installation 3

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3-2 Basic Installation MN1942
HA PC with the following specification:
Minimum specification Recommended specification
Processor Intel PentiumIII
500 MHz
Intel PentiumIII / 4 or equivalent
1 GHz or faster
RAM 128 MB 1GB
Hard disk space 50 MB 50 MB
CD-ROM ACD-ROMdrive
Communication USB port or Ethernet* port
Screen 1024 x 768, 16-bit color 1152 x 864, 16-bit color
Mouse A mouse or similar pointing device
Operating
system
Windows 2000, Windows XP or Windows Vista
* The Ethernet configuration used by a normal office PC is not suitable for direct
communication with the MicroFlex e100. It is recommended to install a separate dedicated
Ethernet adapter in the PC, which can be configured for use with the MicroFlex e100. See
section 6.2.4.
3.1.3 Tools and miscellaneous hardware
HYour PC operating system user manual might be useful if you are not familiar with Windows.
HSmall screwdriver(s) with a blade width of 3 mm or less for connector X1, and 2.5 mm
(1/10 in) or less for connector X3.
HM5 screws or bolts for mounting the MicroFlex e100.
3.1.4 Other information needed for installation
This information is useful (but not essential) to complete the installation:
HThe data sheet or manual provided with your motor, describing the wiring information of the
motor cables/connectors.
HKnowledge of whether the digital input signals will be ‘Active Low’ or ‘Active High’.

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Basic Installation 3-3MN1942
3.2 Mechanical installation and cooling requirements
It is essential that you read and understand this section before beginning the
installation.
To prevent equipment damage, be certain that the input power has correctly rated
protective devices installed.
To prevent equipment damage, be certain that input and output signals are powered
and referenced correctly.
To ensure reliable performance of this equipment be certain that all signals to/from
the MicroFlex e100 are shielded correctly.
Avoid locating the MicroFlex e100 immediately above or beside heat generating
equipment, or directly below water steam pipes.
Avoid locating the MicroFlex e100 in the vicinity of corrosive substances or vapors,
metal particles and dust.
Failure to meet cooling air flow requirements will result in reduced product lifetime
and/or drive overtemperature trips.
The safe operation of this equipment depends upon its use in the appropriate environment.
The following points must be considered:
HThe MicroFlex e100 must be installed indoors, permanently fixed and located so that it can
only be accessed by service personnel using tools.
HThe maximum suggested operating altitude is 1000 m (3300 ft).
HThe MicroFlex e100 must be installed where the pollution degree according to IEC664 shall
not exceed 2.
HThe 24 VDC control circuit supply must be installed so that the 24 VDC supplied to the unit
is isolated from the AC supply using double or reinforced insulation.
HThe input of the control circuit must be limited to Safety Extra Low Voltage circuits.
HBoth the AC supply and the 24 VDC supply must be fused.
HThe atmosphere must not contain flammable gases or vapors.
HThere must not be abnormal levels of nuclear radiation or X-rays.
HTo comply with CE directive 89/336/EEC an appropriate AC filter must be installed.
HThe MicroFlex e100 must be secured by the slots in the flange. The protective earth/ground
(the threaded hole on the top of the MicroFlex e100) must be bonded to a safety earth/ground
using either a 25 A conductor or a conductor of three times the peak current rating -
whichever is the greater.
HThe threaded holes in the top and bottom of the case are for cable clamps. The holes are
threaded for M4 bolts no longer than 11 mm (0.43 in) in length.
HThe D-type connectors on the front panel of the MicroFlex e100 are secured using two
hexagonal jack screws (sometimes known as “screwlocks”). If a jack screw is removed
accidentally or lost it must be replaced with a #4-40 UNC jack screw with an external male
threaded section no longer than 10 mm (0.4 in).
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE

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3-4 Basic Installation MN1942
3.2.1 Dimensions
80
(3.2)
63.5
(2.5)
11
(0.4)
167.7
(6.6)
180
(7.1)
6
(0.24)
6
(0.24)
5
(0.2)
Mounting hole and slot detail
5.5 mm
Dimensions shown as: mm (inches).
Depth: 157 mm (6.2 in)
Weight: 3 A: 1.45 kg (3.2 lb)
6A:1.50kg(3.3 lb)
9A:1.55kg(3.4 lb)
Figure 1 - Mounting and overall dimensions

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Basic Installation 3-5MN1942
3.2.2 Mounting and cooling the MicroFlex e100
Ensure you have read and understood the Mechanical installation and location requirements in
section 3.2. Mount the MicroFlex e100 vertically on its rear side, the side opposite the front panel.
M5 bolts or screws should be used to mount the MicroFlex e100. Detailed dimensions are shown
in section 3.2.1.
For effective cooling, the MicroFlex e100 must be mounted upright on a smooth vertical metal
surface. The MicroFlex e100 is designed to operate in an ambient temperature of 0 °C to 45 °C
(32 °F to 113 °F). Output current must be derated between 45 °C (113 °F) and the absolute
maximum ambient temperature of 55 °C (131 °F). Within the ambient temperature range:
The 3 A model is designed to operate without any additional cooling methods.
The 6 A and 9 A models require a forced air flow, passing vertically from the bottom to the top of
the MicroFlex e100 case, to allow full rated current at 45 °C (113 °F).
Temperature derating characteristics are shown in sections 3.2.3 to 3.2.5.
Note: Failure to meet cooling air flow requirements will result in reduced product lifetime
and/or drive overtemperature trips. It is recommended to check periodically the
operation of the cooling equipment. Optional fan tray FAN001-024, mounted exactly
as shown in section A.1.1., ensures that correct cooling is provided and allows the
MicroFlex e100 to be UL listed.
3.2.2.1 Effects of mounting surface and proximity
The proximity of the MicroFlex e100 to other
components could affect cooling efficiency. If
the MicroFlex e100 is mounted beside another
MicroFlex e100 (or other obstruction), there
should be a minimum space of 15 mm to
maintain effective cooling.
If the MicroFlex e100 is mounted above or
below another MicroFlex e100 (or other
obstruction), there should be a minimum space
of 90 mm to maintain effective cooling.
Remember that when a MicroFlex e100 is
mounted above another MicroFlex e100 or
heat source, it will be receiving air that has
been already heated by the device(s) below it.
Multiple MicroFlex e100 units mounted above
each other should be aligned, not offset, to
promote air flow across the heatsinks.
The derating characteristics assume the
MicroFlex e100 is mounted on 3 mm thick (or
less) metal plate. If the MicroFlex e100 is
mounted on 10 mm plate then the current
characteristics shown in sections 3.2.3 to 3.2.5
may be increased by up to 7% if there is no
forced air cooling, or 15% if forced air cooling
is present.
It is recommended to allow approximately
60 mm at the front to accommodate wiring and
connectors.
Forced air flow
Fan Fan
15 mm
15 mm
90 mm
Figure 2 - Cooling and proximity
Metal backplane
Cool Warm Hot

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3-6 Basic Installation MN1942
3.2.3 Derating characteristic - 3 A model
The following derating characteristics are for model MFE230A003.
0
1
2
3
30 35 40 45 50 55
Ambient temperature (°C)
Rated output current (Arms)
Single-phase AC supply
Natural cooling
Natural cooling
0
1
2
3
30 35 40 45 50 55
Ambient temperature (°C)
Three-phase AC supply
Notes:
Load power factor = 0.75.
Overload limit for model MFE230A003 is 6 A.
Rated output current (Arms)
1 m/s forced air
1 m/s forced air