Baldor MicroFlex User manual

MicroFlex
Servo Control
SERVO DRIVE
Installation Manual
4/03 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 - 3A model 3-6................................
3.2.4 Derating characteristic - 6A model 3-7................................
3.2.5 Derating characteristic - 9A model 3-8................................
3.3 Connector locations 3-9.....................................
3.4 Power connections 3-10......................................
3.4.1 Single-phase or three-phase power connections 3-11.....................
3.4.2 Input power conditioning 3-12.........................................
3.4.3 Power disconnect and protection devices 3-13..........................
3.4.4 Wire sizes and protection device ratings 3-14...........................
3.4.5 Power supply filters 3-15.............................................
3.4.6 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..................
3.6 Regeneration resistor (Dynamic Brake resistor) 3-20.............
4 Feedback 4-1..........................................
4.1 Introduction 4-1............................................
4.1.1 Encoder feedback - X8 4-2..........................................
4.1.2 SSI feedback - X8 4-6..............................................
4.1.3 Encoder output - X7 4-7............................................

ii Contents MN1919
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 5-6.................................
5.3.3 Step (pulse) and direction inputs - X3 5-7..............................
5.3.4 Drive status output - X3 5-8.........................................
5.4 Serial port - X6 5-9.........................................
5.5 Connection summary - typical system wiring 5-10................
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 WorkBench v5 6-3..........................................
6.2.1 Help file 6-3......................................................
6.2.2 Starting WorkBench v5 6-4..........................................
6.2.3 Commissioning Wizard 6-6..........................................
6.2.4 Using the Commissioning Wizard 6-6.................................
6.3 Further configuration 6-7....................................
6.3.1 Fine-tuning tool 6-7................................................
6.3.2 Parameters tool 6-9................................................
6.3.3 Other tools and windows 6-10........................................
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........................................................

Contents iii
MN1919
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) 8-1............................
8.1.3 Motor output power (X1) 8-2.........................................
8.1.4 Regeneration (X1) 8-2..............................................
8.1.5 Analog input (X3) 8-2...............................................
8.1.6 Digital inputs - drive enable and general purpose (X3) 8-3................
8.1.7 Step and Direction inputs (X3) 8-3....................................
8.1.8 Drive status output (X3) 8-3.........................................
8.1.9 Incremental encoder feedback option (X8) 8-4..........................
8.1.10 SSI encoder feedback option (X8) 8-4................................
8.1.11 Encoder output (simulated) (X7) 8-4..................................
8.1.12 Serial RS232 interface (X6) 8-4......................................
8.1.13 Environmental 8-5.................................................
Appendices
A Accessories A-1........................................
A.1 Introduction A-1............................................
A.1.1 Motor power cables A-2.............................................
A.1.2 Motor power cable part numbers A-2..................................
A.1.3 Feedback cables A-2...............................................
A.1.4 EMC filters A-3....................................................
A.1.5 Regeneration resistors A-5..........................................
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 Guidelines C-1......................................
C.1 Outline C-1................................................
C.1.1 EMC Conformity and CE marking C-1.................................
C.1.2 Use of CE compliant components C-2.................................
C.1.3 EMC wiring technique C-2...........................................
C.1.4 EMC installation suggestions C-3.....................................
C.1.5 Wiring of shielded (screened) cables C-4..............................

iv Contents MN1919

General Information 1-1MN1919
Copyright Baldor (c) 2003. 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 95, Windows 98, Windows ME, Windows NT, Windows XP and Windows 2000 are
registered trademarks of the Microsoft Corporation. UL and cUL are registered trademarks of
Underwriters Laboratories.
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.
1General Information 1

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
WARNING: 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.
WARNING: 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.
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: Be sure all wiring complies with the National Electrical Code and all regional and
local codes. Improper wiring may result in unsafe conditions.

General Information 1-3MN1919
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: 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.
WARNING: 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.
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.
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
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.

1-4 General Information MN1919
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: 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: Do not tin (solder) exposed wires. Solder contracts over time and may cause
loose connections. Use crimp connections where possible.
CAUTION: Electrical components can be damaged by static electricity. Use ESD
(electro-static discharge) procedures when handling this drive.
CAUTION: Ensure that encoder wires are properly connected. Incorrect installation may
result in improper movement.
CAUTION: The threaded holes in the top and bottom of the enclosure 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 8mm.
CAUTION: Removing the cover will invalidate UL certification.

Introduction 2-1MN1919
2.1 MicroFlex features
The MicroFlex is a versatile compact control, providing a flexible and powerful solution for
single axis rotary systems. Standard features include:
HSingle axis AC brushless drive.
HRange of models with continuous current ratings of 3A, 6A or 9A.
HDirect connection to 115VAC or 230VAC single-phase or 230VAC three-phase supplies.
HSSI or incremental encoder feedback.
HVelocity and current control, with step and direction input for position control.
HAuto-tuning wizard (including position loop) and software oscilloscope facilities
H2 optically isolated digital inputs.
H1 optically isolated digital output.
H1 general-purpose analog input (can be used as a speed or torque command reference).
HRS232 communications.
MicroFlex will operate with a large number of brushless servo motors - for information on
selecting Baldor servo motors, please see the sales brochure BR1202 (BR1800 for linear
motors) available from your local Baldor representative.
This manual is intended to guide you through the installation of MicroFlex. The sections should
be read in sequence.
The Basic Installation section describes the mechanical installation of the MicroFlex, 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

2-2 Introduction MN1919
2.2 Receiving and inspection
When you receive your MicroFlex, 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.
2. Remove the MicroFlex 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 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 for external damage during shipment and report any damage to the
carrier that delivered your MicroFlex.
5. If MicroFlex is to be stored for several weeks before use, be sure that it is stored in a location
that conforms to the storage humidity and temperature specifications shown in section 8.1.13.
2.2.1 Identifying the catalog number
The MicroFlex 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: FMH______________-________
Installed at: ________________________ Date: ______
A description of a catalog number is shown here, using the example FMH2A03TR-EN23:
Meaning Alternatives
FMH MicroFlex family -
2Requires an AC supply voltage of 115-230 Volts, 1Φor 3Φ-
A03 Continuous current rating of 3A A06=6A; A09=9A
TBuilt in AC power supply -
RRequires external braking resistor -
ESupported feedback types are encoder or SSI -
NNo options specified -
2Serial port type is RS232 -
324VDC supply is required to power the control logic -

Introduction 2-3MN1919
2.3 Units and abbreviations
The following units and abbreviations may appear in this manual:
V Volt (also VAC and VDC)...............
AC Alternating current.............
DC Direct current.............
WWatt..............
A Ampere...............
ΩOhm...............
µF microfarad..............
pF picofarad..............
mH millihenry.............
Φphase...............
ms millisecond..............
µs microsecond..............
ns nanosecond..............
Kbaud kilobaud (the same as Kbit/s in most applications)...........
MB megabytes.............
CD Compact Disc.............
CTRL+E on the PC keyboard, press Ctrl then Eat the same time..........
mm millimeter.............
m meter...............
m/s meters per second.............
in inch...............
ft feet...............
ft/s feet per second..............
lb-in pound-inch (torque).............
Nm Newton-meter (torque).............
ADC Analog to Digital Converter............
DAC Digital to Analog Converter............
AWG American Wire Gauge............
SSI Synchronous Serial Interface.............
(NC) Not Connected............

2-4 Introduction MN1919

Basic Installation 3-1MN1919
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 in the
following stages:
HLocation considerations
HMounting the MicroFlex
HConnecting the AC power supply
HConnecting the 24VDC 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 230VAC 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 was tested (see section 3.4.5).
The 24VDC control circuit supply must be a regulated power supply with a continuous current
supply capability of 1A (4A power on surge).
3.1.2 Hardware requirements
The components you will need to complete the basic installation are:
HThe motor that will be connected to the MicroFlex.
HA motor power cable.
HAn encoder feedback cable (and Hall cable for linear motors).
HA serial cable. The serial connector on the MicroFlex (connector X6) is configured as an
RS232 port - see sections 5.4. A suitable cable is available from Baldor, catalog number
CBL001-501.
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 models have overvoltage sensing circuitry. Regeneration resistors may be
purchased separately - see Appendix A.
3Basic Installation 3

3-2 Basic Installation MN1919
HA PC with the following specification:
Minimum specification Recommended specification
Processor Intel Pentium 133MHz Intel Pentium 200MHz or faster
RAM 32MB 64MB
Hard disk space 40MB 60MB
CD-ROM ACD-ROMdrive
Serial port One free RS232 serial (COM) port
Screen 800 x 600, 256 colors 1024 x 768, 256 colors
Mouse A mouse or similar pointing device
Operating system Windows 95, Windows 98, Windows ME,
Windows NT, Windows XP or Windows 2000
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 3mm or less for connector X1, and 2.5mm (1/10
in) or less for connector X3.
HM5 screws or bolts for mounting the MicroFlex
HCrimping tool.
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 signal will be ‘Active Low’, ‘Active High’.

Basic Installation 3-3MN1919
3.2 Mechanical installation and cooling requirements
It is essential that you read and understand this section before beginning the
installation.
CAUTION: To prevent equipment damage, be certain that the input power has
correctly rated 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 MicroFlex are shielded correctly.
CAUTION: Avoid locating the MicroFlex immediately above or beside heat generating
equipment, or directly below water steam pipes.
CAUTION: Avoid locating the MicroFlex in the vicinity of corrosive substances or
vapors, metal particles and dust.
CAUTION: 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 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 1000m (3300ft).
HThe MicroFlex must be installed where the pollution degree according to IEC664 shall not
exceed 2.
HThe 24VDC control circuit supply must be installed so that the 24VDC 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 24VDC 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.
HThe MicroFlex must be secured by the slots in the flange. The protective earth/ground (the
threaded hole on the top of the MicroFlex) must be bonded to a safety earth/ground using
either a 25A conductor or a conductor of three times the peak current rating - whichever is
the greater.
HTo comply with CE directive 89/336/EEC an appropriate AC filter must be installed.
HThe threaded holes in the top and bottom of the enclosure are for cable clamps. The holes
are threaded for M4 bolts no longer than 11mm (0.43 in) in length.
HEach D-type connector on the front panel of the MicroFlex is 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 jack screw with an external male threaded section no
longer than 10mm (0.4 in).

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

Basic Installation 3-5MN1919
3.2.2 Mounting and cooling the MicroFlex
Ensure you have read and understood the Mechanical installation and location requirements in
section 3.2. Mount the MicroFlex vertically on its rear side, the side opposite the front panel.
M5 bolts or screws should be used to mount the MicroFlex. Detailed dimensions are shown in
section 3.2.1.
For effective cooling, the MicroFlex must be mounted upright on a smooth vertical metal
surface. The MicroFlex 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 3A model is designed to operate without any additional cooling methods. The 6A and 9A
models require a forced air flow, passing vertically from the bottom to the top of the MicroFlex
case, to allow full rated current at 45°C (113°F).
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.

3-6 Basic Installation MN1919
3.2.3 Derating characteristic - 3A model
The following derating characteristics are for model FMH2A03TR-EN23.
0
1
2
3
30 35 40 45 50 55
Ambient temperature (°C)
Rated output currrent (Arms)
Single-phase AC supply
Natural cooling
0.6m/s forced air
Natural cooling
0.6m/s forced air
0
1
2
3
30 35 40 45 50 55
Ambient temperature (°C)
Three-phase AC supply
Notes:
Load power factor = 0.75.
Characteristics shown above apply to a MicroFlex mounted on 3mm thick (or less) plate.
If MicroFlex is mounted on 6mm plate with 75mm clearance between other heat sources,
current characteristic may be increased by 12.5%.
If MicroFlex is mounted on 10mm plate with 150mm clearance between other heat sources,
current characteristic may be increased by 25%.
Overload limit for model FMH2A03TR-EN23 is 6A.
Rated output currrent (Arms)