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.........................................

www.baldormotion.com
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

www.baldormotion.com
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

www.baldormotion.com
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

www.baldormotion.com
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