Baldor MicroFlex User manual

MicroFlex
Servo Control
SERVO DRIVE
Installation Manual
03/10 MN1919

Contents i
MN1919
Contents
1 General Information 1-1.................................
2 Introduction 2-1........................................
2.1 MicroFlex 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 3-5...............................
3.2.3 Derating characteristic - 1A model 3-6................................
3.2.4 Derating characteristic - 3A model 3-6................................
3.2.5 Derating characteristic - 6A model 3-7................................
3.2.6 Derating characteristic - 9A model 3-8................................
3.2.7 Overtemperature trips 3-8...........................................
3.3 Connector locations 3-9.....................................
3.4 Power connections 3-10......................................
3.4.1 Earthing / grounding 3-10............................................
3.4.2 Single-phase or three-phase power connections 3-11.....................
3.4.3 Input power conditioning 3-12.........................................
3.4.4 Power disconnect and protection devices 3-13..........................
3.4.5 Recommended fuses and wire sizes 3-14..............................
3.4.6 Drive overload protection 3-14........................................
3.4.7 Power supply filters 3-15.............................................
3.4.8 24V control circuit supply 3-16........................................
3.5 Motor connections 3-17......................................
3.5.1 Motor circuit contactors 3-18.........................................
3.5.2 Motor power cable pin configuration - Baldor BSM rotary motors 3-18.......
3.5.3 Motor cable pin configuration - Baldor linear motors 3-19..................
3.5.4 Sinusoidal filter 3-19................................................
3.6 Regeneration resistor (Dynamic Brake resistor) 3-20.............
3.6.1 Regeneration capacity 3-20..........................................

ii Contents MN1919
3.7 Regeneration resistor selection 3-21...........................
3.7.1 Required information 3-21............................................
3.7.2 Regenerative energy 3-22...........................................
3.7.3 Regenerative power and average power 3-22...........................
3.7.4 Resistor choice 3-23................................................
3.7.5 Resistor derating 3-23...............................................
4 Feedback 4-1..........................................
4.1 Introduction 4-1............................................
4.1.1 Encoder feedback - X8 4-2..........................................
4.1.2 SSI feedback - X8 4-7..............................................
4.1.3 Resolver feedback - X8 4-9.........................................
4.1.4 Encoder output - X7 4-11............................................
5 Input / Output 5-1......................................
5.1 Introduction 5-1............................................
5.2 Analog I/O 5-2.............................................
5.2.1 Analog input - X3 (demand) 5-2......................................
5.3 Digital I/O 5-4..............................................
5.3.1 Drive enable input - X3 5-5..........................................
5.3.2 General purpose digital input - X3 5-7.................................
5.3.3 Step (pulse) and direction inputs - X3 5-9..............................
5.3.4 Status output - X3 5-12..............................................
5.4 Serial port - X6 5-14.........................................
5.4.1 Using RS232 cable 5-14.............................................
5.4.2 Multidrop using RS485 / RS422 cable 5-15.............................
5.4.3 Connecting serial Baldor HMI Operator Panels 5-16......................
5.5 Connection summary - recommended system wiring 5-17.........
6 Configuration 6-1.......................................
6.1 Introduction 6-1............................................
6.1.1 Connecting the MicroFlex to the PC 6-1...............................
6.1.2 Installing the software 6-1...........................................
6.1.3 Starting the MicroFlex 6-2...........................................
6.1.4 Preliminary checks 6-2.............................................
6.1.5 Power on checks 6-2...............................................
6.2 Mint WorkBench 6-3........................................
6.2.1 Help file 6-4......................................................
6.2.2 Starting Mint WorkBench 6-5........................................
6.2.3 Commissioning Wizard 6-7..........................................
6.2.4 Using the Commissioning Wizard 6-7.................................
6.3 Further configuration 6-8....................................
6.3.1 Fine-tuning tool 6-8................................................
6.3.2 Parameters tool 6-10................................................
6.3.3 Other tools and windows 6-11........................................

Contents iii
MN1919
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 7-1.....................................
7.2 Status LED 7-2............................................
7.2.1 Communication 7-3................................................
7.2.2 Power on 7-4.....................................................
7.2.3 Tuning 7-4........................................................
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 24VDC 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 Analog input (X3) 8-4...............................................
8.1.6 Digital inputs - drive enable and general purpose (X3) 8-4................
8.1.7 Step and Direction inputs (X3) 8-4....................................
8.1.8 Status output (X3) 8-5..............................................
8.1.9 Incremental encoder feedback option (X8) 8-5..........................
8.1.10 SSI encoder feedback option (X8) 8-5................................
8.1.11 Resolver feedback option (X8) 8-5...................................
8.1.12 Encoder output (simulated) (X7) 8-6..................................
8.1.13 Serial RS232/RS485 interface (X6) 8-6................................
8.1.14 Environmental 8-6.................................................
Appendices
A Accessories A-1........................................
A.1 Introduction A-1............................................
A.1.1 Fan tray A-2......................................................
A.1.2 Footprint filter A-3..................................................
A.1.3 EMC filters A-4....................................................
A.1.4 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 Resolver feedback cables A-12.......................................

iv Contents MN1919
B Control System B-1.....................................
B.1 Introduction B-1............................................
B.1.1 Current (Torque) control B-2.........................................
B.1.2 Velocity (Speed) control B-3.........................................
B.1.3 Position (Step and Direction) control B-4...............................
C CE&UL C-1...........................................
C.1 Outline C-1................................................
C.1.1 EMC Conformity and CE marking C-1.................................
C.1.2 MicroFlex compliance C-1...........................................
C.1.3 Declaration of conformity C-2........................................
C.1.4 Use of CE compliant components C-3.................................
C.1.5 EMC wiring technique C-3...........................................
C.1.6 EMC installation suggestions C-4.....................................
C.1.7 Wiring of shielded (screened) cables C-5..............................
C.2 UL file numbers C-6.........................................

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General Information 1-1MN1919
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.
Minttis a registered trademark of Baldor.
Windows 2000, Windows XP and Windows Vista are registered trademarks of the Microsoft
Corporation. UL and cUL are registered trademarks of Underwriters Laboratories.
MicroFlex 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 MN1919
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
DANGER: 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.
DANGER: 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.
DANGER: 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.
DANGER: 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.

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General Information 1-3MN1919
WARNING: Be sure all wiring complies with the National Electrical Code and all regional and
local codes. Improper wiring may result in unsafe conditions.
WARNING: 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: 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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
WARNING: A regeneration resistor may generate enough heat to ignite combustible materials.
To avoid fire hazard, keep all combustible materials and flammable vapors away
from the brake resistors. Baldor regeneration resistors are neither internally fused
nor thermally protected and under extreme conditions, can cause a fire hazard if
not suitably protected or rated for the application.
CAUTION: To prevent equipment damage, be certain that the input power has correctly sized
protective devices installed.
CAUTION: To prevent equipment damage, be certain that input and output signals are
powered and referenced correctly.
CAUTION: To ensure reliable performance of this equipment be certain that all signals to/from
the drive are shielded correctly.
CAUTION: Suitable for use on a circuit capable of delivering not more than the RMS
symmetrical short circuit amperes listed here at rated voltage.
Horsepower RMS Symmetrical Amperes
1-50 5,000

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1-4 General Information MN1919
CAUTION: Avoid locating the drive immediately above or beside heat generating equipment,
or directly below water or steam pipes.
CAUTION: Avoid locating the drive in the vicinity of corrosive substances or vapors, metal
particles and dust.
CAUTION: 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.
CAUTION: 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.
CAUTION: 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.
CAUTION: 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.
CAUTION: 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.
CAUTION: 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.
CAUTION: Failure to meet cooling air flow requirements will result in reduced product lifetime
and/or drive overtemperature trips.
CAUTION: Violent jamming (stopping) of the motor during operation may damage the motor
and drive.
CAUTION: Operating the MicroFlex in Torque mode with no load attached to the motor can
cause the motor to accelerate rapidly to excessive speed.
CAUTION: If the drive enable signal is already present when power is applied to the
MicroFlex, the motor could begin to move immediately.
CAUTION: Do not tin (solder) exposed wires. Solder contracts over time and may cause
loose connections. Use crimp connections where possible.