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.