Baldor MotiFlex e100 User manual

Contents i
MN1943
Contents
1 General Information 1-1.................................
2 Introduction 2-1........................................
2.1 MotiFlex 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..................................
2.4 Standards 2-4..............................................
2.4.1 Design and test standards 2-4.......................................
2.4.2 Environmental test standards: 2-4....................................
2.4.3 Marks 2-4........................................................
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 3-3...................................
3.2.1 Dimensions - 1.5 A ~ 16 A models 3-4................................
3.2.2 Dimensions - 21 A ~ 33.5 A models 3-5...............................
3.2.3 Dimensions - 48 A ~ 65 A models 3-6.................................
3.2.4 Mounting the MotiFlex e100 3-7......................................
3.2.5 Overtemperature trips and intelligent fan control 3-10.....................
3.3 Connector locations 3-11.....................................
3.3.1 Front panel connectors 3-11..........................................
3.3.2 Top panel connectors 3-12...........................................
3.3.3 Bottom panel connectors 3-13........................................
3.4 AC power connections 3-14...................................
3.4.1 Earthing / grounding 3-14............................................
3.4.2 AC input and regeneration resistor output wiring 3-15.....................
3.4.3 Earth leakage 3-16.................................................
3.4.4 AC power connections 3-17..........................................
3.4.5 AC power cycling 3-18..............................................
3.4.6 Inrush current 3-18.................................................
3.4.7 Phase loss detection 3-18............................................
3.4.8 Drive overload protection 3-18........................................
3.4.9 Input power conditioning 3-19.........................................
3.4.10 Power supply filters 3-20.............................................
3.4.11 Power disconnect and protection devices 3-21..........................
3.4.12 Recommended wire sizes 3-22.......................................

ii Contents MN1943
3.5 Sharing the DC bus 3-23.....................................
3.5.1 DC busbar connection 3-23..........................................
3.5.2 ‘Power ready’ input / output 3-24......................................
3.5.3 Line reactors 3-25..................................................
3.6 18 VDC out / 24 VDC in control circuit backup supply 3-26........
3.6.1 24 VDC backup supply 3-26..........................................
3.6.2 24 VDC control circuit backup supply wiring 3-27........................
3.7 Motor connections 3-28......................................
3.7.1 Motor cable shielding 3-30...........................................
3.7.2 Motor circuit contactor 3-31..........................................
3.7.3 Sinusoidal filter 3-31................................................
3.7.4 Motor power cable pin configuration - Baldor BSM rotary motors 3-32.......
3.7.5 Motor cable pin configuration - Baldor linear motors 3-33..................
3.7.6 Motor brake connection 3-34.........................................
3.7.7 Motor overtemperature input 3-35.....................................
3.7.8 Bottom panel wiring 3-35.............................................
3.8 Regeneration resistor (Dynamic Brake resistor) 3-36.............
3.8.1 Regeneration capacity 3-37..........................................
3.9 Regeneration resistor selection 3-38...........................
3.9.1 Required information 3-38............................................
3.9.2 Regenerative energy 3-39...........................................
3.9.3 Regenerative power and average power 3-39...........................
3.9.4 Resistor choice 3-40................................................
3.9.5 Resistor temperature derating 3-41....................................
3.9.6 Resistor pulse load rating 3-42........................................
3.9.7 Duty cycle 3-43....................................................
4 Feedback 4-1..........................................
4.1 Introduction 4-1............................................
4.1.1 Incremental encoder interface 4-2....................................
4.1.2 BiSS interface 4-7.................................................
4.1.3 SSI interface 4-9..................................................
4.1.4 SinCos interface 4-11...............................................
4.1.5 EnDat interface 4-13................................................
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 5-5..............................................
5.3.2 General purpose digital input DIN0 5-7................................
5.3.3 General purpose digital inputs DIN1 & DIN2 5-9........................
5.3.4 Special functions on inputs DIN1 & DIN2 5-10...........................
5.3.5 Motor overtemperature input 5-12.....................................

Contents iii
MN1943
5.3.6 General purpose / status digital output DOUT0 5-14......................
5.3.7 General purpose digital output DOUT1 5-16.............................
5.4 USB interface 5-17..........................................
5.4.1 USB 5-17.........................................................
5.5 RS485 interface 5-18........................................
5.5.1 RS485 (2-wire) 5-18................................................
5.6 Ethernet interface 5-19.......................................
5.6.1 TCP/IP 5-19.......................................................
5.6.2 Ethernet POWERLINK 5-20..........................................
5.6.3 Ethernet connectors 5-21............................................
5.7 CAN interface 5-22..........................................
5.7.1 CAN connector 5-22................................................
5.7.2 CAN wiring 5-22....................................................
5.7.3 CANopen 5-24.....................................................
5.8 Other I/O 5-25..............................................
5.8.1 Node ID selector switches 5-25.......................................
6 Configuration 6-1.......................................
6.1 Introduction 6-1............................................
6.1.1 Connecting the MotiFlex e100 to the PC 6-1...........................
6.1.2 Installing Mint Machine Center and Mint WorkBench 6-1.................
6.2 Starting the MotiFlex 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 Using the Commissioning Wizard 6-13.................................
6.4.5 Autotune Wizard 6-15...............................................
6.4.6 Further tuning - no load attached 6-16..................................
6.4.7 Further tuning - with load attached 6-18................................
6.4.8 Optimizing the velocity response 6-19..................................
6.4.9 Performing test moves - continuous jog 6-22............................
6.4.10 Performing test moves - relative positional move 6-23....................
6.5 Further configuration 6-24....................................
6.5.1 Parameters tool 6-24................................................
6.5.2 Spy window 6-25...................................................
6.5.3 Other tools and windows 6-26........................................

iv Contents MN1943
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 MotiFlex e100 7-1..................................
7.2 MotiFlex 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............................................
8.2 AC input 8-1...............................................
8.2.1 AC input voltage (X1) - all models 8-1.................................
8.2.2 AC input current (X1), DC bus not shared - all models 8-2................
8.2.3 AC input current (X1), DC bus sharing - all models 8-4...................
8.2.4 Recommended fuses and circuit breakers when sharing the DC bus 8-8....
8.2.5 Power, power factor and crest factor - 1.5 A ~ 16 A models 8-9............
8.2.6 Power, power factor and crest factor - 21 A model 8-12...................
8.2.7 Power, power factor and crest factor - 26 A & 33.5 A models 8-13..........
8.2.8 Power, power factor and crest factor - 48 A & 65 A models 8-14............
8.3 Motor output 8-15...........................................
8.3.1 Motor output power (X1) - 1.5 A ~ 16 A models 8-15......................
8.3.2 Motor output power (X1) - 21A ~ 33.5 A models 8-15.....................
8.3.3 Motor output power (X1) - 48 A ~ 65 A models 8-16......................
8.3.4 Motor output uprating and derating 8-17................................
8.3.5 Motor output rating adjustment - 1.5 A model 8-17........................
8.3.6 Motor output rating adjustment - 3 A model 8-18.........................
8.3.7 Motor output rating adjustment - 6 A model 8-19.........................
8.3.8 Motor output rating adjustment - 10.5 A model 8-20.......................
8.3.9 Motor output rating adjustment - 16 A model 8-21........................
8.3.10 Motor output rating adjustment - 21 A model 8-22........................
8.3.11 Motor output rating adjustment - 26 A model 8-23........................
8.3.12 Motor output rating adjustment - 33.5 A model 8-24.......................
8.3.13 Motor output rating adjustment - 48 A model 8-25........................
8.3.14 Motor output rating adjustment - 65 A model 8-26........................
8.4 Regeneration 8-27...........................................
8.4.1 Regeneration (X1) - 1.5 A ~ 16 A models 8-27...........................
8.4.2 Regeneration (X1) - 21 A ~ 33.5 A models 8-27..........................
8.4.3 Regeneration (X1) - 48 A ~ 65 A models 8-28...........................

Contents v
MN1943
8.5 18 VDC output / 24 VDC input 8-29............................
8.5.1 18 VDC output / 24 VDC control circuit backup supply input (X2) 8-29.......
8.5.2 Option card power supply 8-29.......................................
8.6 Input / output 8-31...........................................
8.6.1 Analog input - AIN0 (X3) 8-31.........................................
8.6.2 Digital inputs - drive enable and DIN0 general purpose (X3) 8-31...........
8.6.3 Digital inputs DIN1, DIN2 - high speed general purpose (X3) 8-31..........
8.6.4 Digital outputs DOUT0, DOUT1 - status and general purpose (X3) 8-32.....
8.6.5 Incremental encoder interface (X8) 8-32................................
8.6.6 SSI interface (X8) 8-32..............................................
8.6.7 BiSS interface (X8) 8-32.............................................
8.6.8 SinCos / EnDat interface (X8) 8-33....................................
8.6.9 Ethernet interface 8-33..............................................
8.6.10 CAN interface 8-33.................................................
8.6.11 RS485 interface (X6) 8-34...........................................
8.7 Weights and dimensions 8-34.................................
8.7.1 Weights and dimensions - 1.5 A ~ 16 A models 8-34......................
8.7.2 Weights and dimensions - 21 A ~ 33.5 A models 8-34.....................
8.7.3 Weights and dimensions - 48 A ~ 65 A models 8-34......................
8.8 Environmental 8-35..........................................
Appendices
A Accessories A-1........................................
A.1 Introduction A-1............................................
A.1.1 Busbars for DC bus sharing A-2......................................
A.1.2 AC supply (EMC) filters A-3.........................................
A.1.3 AC line reactors A-4................................................
A.1.4 Regeneration resistors A-5..........................................
A.1.5 Motor / power cable management bracket A-7..........................
A.1.6 Signal cable management bracket A-8................................
A.2 Cables A-9................................................
A.2.1 Motor power cables A-9.............................................
A.2.2 Feedback cable part numbers A-10....................................
A.2.3 Ethernet cables A-10................................................
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.......................................

vi Contents MN1943
C Mint Keyword Summary C-1.............................
C.1 Introduction C-1............................................
C.1.1 Keyword listing C-1................................................
D CE&UL D-1...........................................
D.1 Introduction D-1............................................
D.1.1 CE marking D-1...................................................
D.1.2 Declaration of conformity D-2........................................
D.1.3 Use of CE compliant components D-3.................................
D.1.4 EMC wiring technique D-3...........................................
D.1.5 EMC installation suggestions D-4.....................................
D.1.6 Wiring of shielded (screened) cables D-5..............................
D.2 UL file numbers D-6.........................................

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General Information 1-1MN1943
LT0279A03 Copyright Baldor (c) 2011. 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 MotiFlex® are registered trademarks of Baldor.
Windows XP, Windows Vista and Windows 7 are registered trademarks of the Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.
MotiFlex 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 MN1943
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 equipment is intended for installation in a suitable enclosure. The
enclosure must protect the equipment from exposure to excessive or corrosive moisture, dust and dirt or
abnormal ambient temperatures. The exact operating specifications are found in section 3 and section 8
of this manual. The installation, connection and control of drives is a skilled operation. This equipment
contains no user-serviceable parts; disassembly or repair must not be attempted. In the event that the
equipment 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.
After AC power has been removed from the MotiFlex e100, high voltages (greater than
50 VDC) can remain on power connections for up to 5 minutes, while the DC bus circuitry
discharges. Do not touch the DC bus, regeneration resistor, or other power connections
during this period.
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.
DANGER
DANGER
DANGER
DANGER
DANGER
WARNING

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General Information 1-3MN1943
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 MotiFlex e100, the
motor could begin to move immediately.
The metal heatsink on the left side of the MotiFlex e100 can become very hot during
normal operation.
The metal part of the MotiFlex e100 case incorporates prominent edges and corners that
may cause minor injury if the drive is handled without proper care and attention.
Take care when lifting. The 48 A and 65 A models weigh 12.45 kg (27.4 lb). Seek
assistance if necessary. When carrying, do not suspend the unit from the removable front
panels as they could detach and cause the unit to be dropped.
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.
To prevent equipment damage, be certain that the input power has correctly sized 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 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 (480 VAC):
Horsepower RMS Symmetrical Amperes
1-50 5,000
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE

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1-4 General Information MN1943
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.
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. If not installed in an electrical cabinet, barriers around the equipment are required.
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 MotiFlex 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.
Removing the cover will invalidate UL certification.
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE

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Introduction 2-1MN1943
2.1 MotiFlex e100 features
The MotiFlex 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:
1.5 A, 3 A, 6 A, 10.5 A, 16 A, 21 A, 26 A, 33.5 A, 48 A and 65 A.
HDirect connection to 230 - 480 VAC three-phase supplies.
HAbility to provide power to, or derive power from, a DC busbar
connection shared with neighboring drives.
HUniversal feedback interface supporting incremental encoder, BiSS,
EnDat, SSI or SinCos feedback.
HPosition, velocity and current control.
HAuto-tuning wizard (including position loop) and software oscilloscope
facilities provided by Mint WorkBench v5.5 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.
H1 motor temperature switch input.
H1 general purpose ±10 V analog input.
HUSB 1.1 serial interface (compatible with USB 2.0).
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.
MotiFlex e100 can operate 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
motors, please see the sales brochure BR1202 available from your local Baldor representative.
This manual is intended to guide you through the installation of MotiFlex e100. The sections
should be read in sequence.
The Basic Installation section describes the mechanical installation of the MotiFlex 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 MN1943
2.2 Receiving and inspection
When you receive your MotiFlex 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 MotiFlex e100.
2. Remove the MotiFlex 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 MotiFlex 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 MotiFlex e100 for external damage during shipment and report any damage to
the carrier that delivered your MotiFlex e100.
5. If MotiFlex 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 8.8.
Note: The 48 A and 65 A MotiFlex e100 have a recess at the rear of the product which is
filled with a block of packaging foam. Remove this foam before mounting the drive.
2.2.1 Identifying the catalog number
The MotiFlex 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 MFE460A003x:
Meaning Alternatives
MFE MotiFlex e100 family -
460 Requires an AC supply voltage of 230 - 480 Volts, 3Φ-
A003 Continuous current rating of 3 A
A001=1.5 A; A006=6 A;
A010=10.5 A; A016=16 A;
A021=21 A; A026=26 A;
A033=33.5 A; A048=48 A;
A065=65 A
xA letter indicating the hardware revision. This does not
affect the capabilities of the MotiFlex e100 unless
otherwise stated.
-

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Introduction 2-3MN1943
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.............
Kbit/s kilobits per second...........
LCD Liquid Crystal Display............
Mbit/s megabits per second...........
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 MN1943
2.4 Standards
The MotiFlex e100 has been designed and tested to comply with the following standards.
2.4.1 Design and test standards
HUL508C: Power Conversion Equipment.
HUL840: Insulation coordination including clearance and creepage distances for
electrical equipment.
HEN61800-5-1: Adjustable speed electrical power drive systems. Safety requirements.
Electrical, thermal and energy.
HEN50178: Electronic equipment for use in power installations.
HEN60529: Degrees of protection provided by enclosures.
HEN61800-3: When installed as directed in this manual, MotiFlex e100 conforms to the
category C3 emission limits and the ‘second environment’ immunity
requirements defined by this standard.
See also the CE certificate on page D-2.
2.4.2 Environmental test standards:
HEN60068-1: Environmental testing, general and guidance.
HEN60068-2-32: Environmental testing, Test Ed. Free Fall.
HEN60068-2-2: Environmental testing, Test B. Dry heat.
HEN60068-2-78: Environmental testing, Test cab. Damp heat, steady state.
2.4.3 Marks
See also Appendix D for general recommendations for CE compliance.

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Basic Installation 3-1MN1943
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 MotiFlex e100 in the
following stages:
HLocation considerations.
HMounting the MotiFlex e100.
HConnecting the AC power supply.
HConnecting the optional 24 VDC control circuit backup supply.
HConnecting the motor.
HInstalling a regeneration resistor (Dynamic Brake).
3.1.1 Power sources
A 230 - 480 VAC 3-phase power source (IEC1010 over-voltage category III or less) in the
installation area is required. An AC power filter is required to comply with the CE directive for
which the MotiFlex e100 was tested (see section 3.4.10).
The optional 24 VDC control circuit backup supply must be a regulated power supply with a
continuous current supply capability of up to 1.5 A, dependent on the number of option cards
fitted. See section 3.6 for details.
3.1.2 Hardware requirements
The components you will need to complete the basic installation are:
HAC power supply filter (for CE compliance).
HThe motor that will be connected to the MotiFlex 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) 24 VDC control circuit backup power supply.
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
MotiFlex e100 models have overvoltage sensing circuitry. Regeneration resistors may be
purchased separately - see section 3.8 and appendix A.
3Basic Installation 3

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3-2 Basic Installation MN1943
HA PC with the following minimum specification:
Minimum specification Recommended specification
Processor 32-bit Intel / AMD processor,
500 MHz
32-bit or 64-bit Intel / AMD dual-
core processor, 2 GHz or faster
RAM 256 MB 1GB
Hard disk space 100 MB 100 MB
Communication USB port (USB 1.1 full-speed), or
Ethernet port (100 Mbit/s, independent of office network)*
Screen 1024 x 768, 16-bit color 1280 x 1024, 16-bit color
Mouse A mouse or similar pointing device.
(Mint WorkBench does not support touch)
Operating
system
Windows XP Windows XP, Windows Vista, or
Windows 7 (32-bit or 64-bit)
* The Ethernet configuration used by a normal office PC is not suitable for direct
communication with the MotiFlex e100. It is recommended to install a separate dedicated
Ethernet adapter in the PC, which can be configured for use with the MotiFlex 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 2.5 mm (1/10 in) or less for connector X3.
HM5 screws or bolts for mounting the MotiFlex 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 3-3MN1943
3.2 Mechanical installation
It is essential that you read and understand this section before beginning the
installation.
Take care when lifting. The 48 A and 65 A models weigh 12.45 kg (27.4 lb). Seek
assistance if necessary. When carrying, do not suspend the unit from the
removable front panels as they could detach and cause the unit to be dropped.
Avoid locating the MotiFlex e100 immediately above or beside heat generating
equipment, or directly below water steam pipes.
Avoid locating the MotiFlex 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 MotiFlex e100 must be installed indoors, permanently fixed and located so that it can
only be accessed by service personnel using tools. When installed in a cabinet, the cabinet
must have a volume of at least 0.19 m3(6.84 cu.ft). If not installed in a cabinet, barriers
around the equipment are required.
HThe maximum suggested operating altitude is 1000 m (3300 ft).
HThe MotiFlex e100 must be installed where the pollution degree according to EN61800-5-1
shall not exceed 2.
HThe optional 24 VDC control circuit backup supply must be installed so that the 24 VDC
supplied to the unit is isolated from the AC supply either by using double or reinforced
insulation, or by using basic insulation with a protective earth.
HThe input of the control circuit must be limited to Extra Low Voltage circuits.
HBoth the AC supply and the optional 24 VDC control circuit backup 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 2004/108/EC an appropriate AC filter must be installed.
HThe MotiFlex e100 must be secured by the slots in the metal mounting flanges. The
protective earth/ground (the threaded studs on the top and bottom mounting flanges) 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 metal tab at the bottom of the case is used for attaching a cable clamp (section A.1.6).
HThe D-type connectors on the top and bottom panels of the MotiFlex 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).
HThe 48 A and 65 A MotiFlex e100 have a recess at the rear of the product which is filled
with a block of packaging foam. Remove this foam before mounting the drive.
CAUTION
NOTICE
NOTICE
NOTICE

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3-4 Basic Installation MN1943
3.2.1 Dimensions - 1.5 A ~ 16 A models
75
(2.95)
50
(1.97)
350
(13.78)
362
(14.25)
6
(0.24)
12.5
(0.49)
Mounting hole and slot detail
Dimensions shown as: mm (inches).
Depth: 260 mm (10.24 in)
Weight: 1.5 A: 1.90 kg (4.2 lb)
3A: 1.90kg(4.2 lb)
6A: 1.90kg(4.2 lb)
10.5A: 4.80kg(10.6 lb)
16 A: 5.80 kg (12.8 lb)
8
(0.31)
A
BC
A6mm
B12 mm
C12.7 mm
D6mm
E6mm
D
E
Note: The case is 76 mm wide, which
is 1 mm wider than the mounting plate.
For this reason, when mounting
multiple drives side-by-side for DC
bus sharing, it is advisable to use the
method described in section 3.2.4.1 to
avoid errors when marking hole
positions.
76
(2.99)
Figure 1 - Mounting and overall dimensions - 1.5 A ~ 16 A models