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FlexDrive II / Flex+Drive II Installation Manual - Q-TECH

1. might be damaged N CAUTION The motor leads U V and W must be connected to their corresponding U V or W terminal on the motor Misconnection will result in uncontrolled motor movement The motor power cable must be shielded for CE compliance The connector or gland used at the motor must provide 360 degree shielding The motor cable shield can be clamped to the FlexDrive using the earth ground clamp at the top or bottom of the drive if this is more convenient The maximum recommended cable length is 30 5m 100ft Note For CE compliance the motor earth ground should be connected to the drive earth ground 3 14 Basic Installation MN1902 3 5 1 Motor circuit contactors If required by local codes or for safety reasons an M Contactor motor circuit contactor may be installed to provide a physical disconnection of the motor windings from the FlexDrive see section 3 5 Opening the M Contactor ensures that the FlexDrive cannot drive the motor which may be necessary during equipment maintenance or similar operations Under certain circumstances it may also be necessary to fit a brake to a rotary motor This is important with hanging loads where disconnecting the motor windings could result in the load falling Contact your local supplier for details of appropriate brakes IN CAUTION If an M Contactor is installed the FlexDrive must be disabled at least 20ms before the M Contactor is opened If the M Contactor is opened wh
2. To perform tests go to the Test Parameters area at the bottom of the tab Enter test values and then click Go to perform the test move If you need help just press F1 to display the help file Fine tuning Current tab The current tab allows you to set current loop gains and perform test moves The Commissioning Wizard may have already set some of these values depending on the type of system selected on the mode screen Enter new values in the required boxes and then click Apply to download the values to the FlexDrive To perform tests go to the Test Parameters area at the bottom of the tab Enter test values and then click Go to perform the test move If you need help just press F1 to display the help file The additional Measure and Feedback alignment buttons can be used to repeat the same measurement and alignment tests as the Commissioning Wizard 5 8 Operation MN1902 5 3 2 Parameters tool The Parameters tool can be used to setup many important parameters such as a scaling factor for the feedback input and the action to take when errors occur 1 Click the Parameters icon in the Toolbox on the left of the screen The main area of the WorkBench v5 window displays the Controller Parameters screen Dap Co For Help press F1 2 The Controller Parameters screen has a number of tabs listed on the left Click on a tab to select it If you need help with any of the options just press F1 to display the
3. You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup Click Close to continue In the opening dialog box click Start New Project WorkBench v5 MN1902 Operation 5 5 5 2 3 5 2 4 3 In the Select Controller dialog go to the Select Controller BE drop down box near the top and select Click Scan or choose a controller from the list For a controller with the PC ag port to which the drive is cut ob dake amare S aleet is roplacedeah Update mwere connected Only scan COM1 v Scan Add Specific Controller If you are unsure which PC serial port is Search up to Node 30 connected to the drive select Scan all serial ports Scanning serial ports done Controllers found Click Scan to search for the FlexDrive Flex Drive ll Node 2 on COM R5232 at 57600 Baud When the search is complete click on FlexDrive in the list to select it and click the Select button Note If the FlexDrive is not listed check the serial lead between the FlexDrive and the PC and that Micro A zm the FlexDrive is powered wizard correctly Click Scan to re scan the ports This check box is already selected for you When you click Select it means that the Commissioning Wizard will start automatically Commissioning Wizard Each type of motor and drive combination has slightly different pe
4. If you do not have experience of software installation or Windows applications you may need further assistance for this stage of the installation Connecting the FlexDrive to the PC Connect the serial cable between a PC serial port often labeled as COM to the FlexDrive connector X6 RS232 RS485 WorkBench v5 can scan all the COM ports so you can use any port IN CAUTION The serial connector on the FlexDrive X6 can be configured as either RS232 or RS485 RS422 If this is the first time you are installing a FlexDrive then it is strongly recommended that you use RS232 to get started the preset factory setting and use RS485 later Pin 9 is used to carry 8V for powering a Baldor keypad peripheral Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply A suitable cable is available from Baldor catalog number CBL001 501 Installing the software The CDROM containing the software can be found separately within the packaging 1 Insert the CDROM into the drive 2 After a few seconds the setup wizard should start automatically If the setup wizard does not appear select Run from the Windows Start menu and type d start where d represents the drive letter of the CDROM device use the correct letter for your installation Follow the on screen instructions to install WorkBench v5 The setup wizard will copy the files to appropriate folders on the hard drive The default
5. Encoder Out X7 10 o lo o lo Feedback n X8 Customer supplied 24V X3 General I O X3 1 ze 2 AINO Command 3 AGND 4 Relay 5 Relay 6 User V 7 CREF 8 CGND 9 Drive Enable 10 DINO 11 DIN1 12 DIN2 13 DIN3 14 DIN4 Pulse 15 DIN5 Direction 16 DING 17 DIN7 18 DOUTO 19 DOUT1 20 DOUT2 AINO Command X9 Master Encoder ME 1 CHA 2 CHB 3 CHZ 4 NC 5 DGND 6 CHA 7 CHB 8 CHZ 9 5V X6 RS232 RS485 z RS232 RS485 422 1 NC NC 2 RXD RX ET 3 TXD TX Ei 4 NC NC E 5 OVGND OVDGND B 6 NC NC x 7 RTS TX m4 8 CTS RX 9 NC see section 4 4 3 X7 Encoder Out CHA CHB CHZ NC DGND CHA CHB CHZ NC Encoder Out X ODBNODORWNH X8 Feedback In Resolver option LIVE REF COS SIN NC AGND REF COS SIN Chassis OMNODARWNH CHA CHB CHZ Hall U Hall U CHA CHB CHZ Hall W Hall V 5V NC DGND Hall W Hall V Feedback In X8 3 6 Basic Installation MN1902 3 4 Power connections This section provides instructions for connecting the AC power supply It is important that you refer to the correct front panel for your FlexDrive package The installer of this equipment is responsible for complying with NEC National Electric Code guidelines or CE Conformite Europeene directives and application codes that govern wiring protection earthing grounding disconnec
6. The threaded holes in the top and bottom of the enclosure are for earth ground clamps provided The holes are threaded for M4 bolts no longer than 12mm 0 47 in in length Longer bolts may short circuit the electrical components inside the FlexDrive AC Route L N and Circuit breaker or fuse AC filter Supply earth ground together See section 3 4 4 See section 3 4 5 in conduit or cable Line L 7 34 L Neutral N Isolating switch f filter has no output To earth ground outer Incoming safety earth ground terminal earth shields use 360 earth ground PE wire may be connected clamps connected to directly to star point backplane or FlexDrive case STAR POINT See section 4 5 1 Figure 2 Earthing grounding for single phase installations Note For CE compliance a filter must be connected between the AC power supply and the FlexDrive If local codes do not specify different regulations use at least the same gauge wire for earth ground as is used for L and N 3 8 Basic Installation MN1902 3 4 2 Three phase connection to package sizes G H Location Connector X1A Mating connector Phoenix POWER COMBICON PC4 ST 7 62 FDHAA FPH4A Nominal input voltage 230 460VAC 30 line to line 80 528VAC Tightening torque for terminal block connections is 0 5 0 6Nm 4 4 5 3 Ib in The threaded hole
7. d Figure 26 FlexDrive encoder output to Mint controller encoder input 4 10 Input Output MN1902 4 4 2 Master auxiliary encoder input X9 Location Connector X9 sp 34 s DN 1 o CIC 7 C RN A AN Optically isolated encoder or pulse and direction input on a Description 9 pin female D type connector Sampling interval 1 or 2ms x Ci E o z The FlexDrive provides an auxiliary master or handwheel encoder input that allows it to follow a master encoder or pulse and direction inputs An interface for a three channel incremental encoder CHA CHB CHZ is provided The input receiver circuit allows only encoders with differential line drivers RS422 to be used Single ended operation is not supported The interface also provides an isolated 5V supply for the encoder electronics capable of driving up to 100mA A CAUTION The master encoder input does not use the same pin configuration as some Baldor controllers such as NextMoveBX Twisted pairs CHA CHA CHB Master CHB Encoder CHZ CHZ 5V DGND Connect internal shields to DGND Oc1d000 1n0 R Connect overall shield to A connector backshells Figure 27 Differential encoder connections MN1902 Input Output 4 11 4 4 2 1 Pulse and Direction following The master encoder input accepts 5V pulse and direction signals from an external source The
8. is applied to them and will sink a current of approximately 5mA each Active low connect 24VDC 20 to pin7 and OV to pin 9 The digital inputs will be active when grounded less than 2V and will source a current of approximately 5mA each The 24VDC supply is from a customer supplied 24VDC supply that should have a continuous current capability of 1 75A The sense of the inputs can be configured in WorkBench v5 or controlled individually in Mint using the keyword INPUTACTIVELEVEL See section 3 8 for more information about Drive Enable Special functions on DIN4 and DIN5 pulse and direction inputs DIN4 and DIN5 can be configured using the MASTERSOURCE keyword to behave as pulse and direction inputs m DIN4 is used as the pulse input The pulse frequency controls the speed of the motor m DIN5 is used as the direction input The state of the direction input controls the direction of motion A positive voltage will result in forward motion If DIN5 is grounded movement will be in the opposite direction Note If DIN4 and DIN5 have been configured as pulse and direction inputs the alternative pulse and direction inputs available on connector X9 cannot be used See the Mint keyword MASTERSOURCE MN1902 Input Output 4 7 Special functions on DIN4 and DIN5 fast inputs Flex Drive only DIN4 and DIN5 can be configured using the FASTSELECT keyword to perform special functions m Fastinterrupt hardware pos
9. om No regeneration is occurring 6 4 Troubleshooting MN1902 6 2 3 Communication Status display is blank WorkBench v5 fails to detect the FlexDrive it detects Controller with No Firmware on the serial port Check that the customer supplied 24VDC power supply is connected correctly to connector X1 and is switched on On models with an internally generated 24VDC supply check that the AC power supply is connected correctly to connector X1 and is Switched on Ensure that the FlexDrive is powered and the Status display is illuminated see section 6 2 Check that the serial cable is connected between the PC s COM port and connector X6 on the FlexDrive Check which PC COM port is being used or use the Scan all serial ports option to locate the FlexDrive Check the wiring of the serial cable or try an alternate cable Check that DIP switch 10 RS232 RS422 is set correctly see section 3 9 5 On the PC try an alternative COM port Confirm that a mouse driver or other serial device is not conflicting using the same COM port as WorkBench v5 Does the FlexDrive have firmware in it If you tried to download new firmware and the download failed the controller may not have firmware If this has happened the Status display will show a minus sign and flash the decimal point repeatedly Check that the selected Baud rate is supported by the PC and FlexDrive If the Only scan COMx optio
10. which error has occurred The motor and drive current limits are fixed according to the database parameters The drive can demand peak current for a short duration see DRIVEPEAKDURATION thereafter it will trip or Foldback according to the setting of DRIVEOVERLOADMODE The same is true for the motor see MOTORPEAKDURATION and MOTOROVERLOADAREA Use the Foldback option to automatically foldback the current to a level where the drive motor can recover Symbol not flashing Motor IT It foldback Motor I T or Drive I T algorithm has resulted in the demand current being folded back to a level where the drive motor can recover The motor drive can run with demand currents greater than their rated value for a period of time after that time the drive will either trip or automatically foldback the demand current Overtemperature The temperature of the drive or motor has exceeded a trip level see Mint keyword TEMPERATURELIMITFATAL or the Motor overtemperature trip input has been activated see Mint keyword MOTORTEMPERATUREINPUT 6 2 Troubleshooting MN1902 Drive enabled The drive is enabled except where CONFIG cfVirtual where it is not physically enabled Torque mode The drive is in Torque mode See the Mint keywords TORQUE TORQUEREFSOURCE and related commands Auto tune test driving motor Autotune is active and driving the motor The motor may move Power base not ready This error condition applies to 3 phase drives o
11. 7 6 7 1 10 Serial RS485 interface X6 lili teens 7 6 7 1 11 Encoder output simulated X7 sllislssssssssssssles eh 7 6 7 1 12 Resolver feedback option X8 00 0 ccc n 7 7 7 1 13 Encoder feedback option X8 0 0 cece etn 7 7 7 1 14 Master auxiliary encoder input XQ 6 ete eee 7 7 7 1 15 Pulse and direction input X9 o oooccoococcccccoccor teens 7 8 1116 Environmental tenia prie acai we pede tb Roi ds al 7 8 MN1902 Contents iii Appendices A ACCESSOS ai 22542 mie eios ot Saee LE ao A 1 AV Jatreduction e soe eese a oe triad takes qeu ipsos nuda etos o ticis mae A 1 AAT Factory fitted Options ss terors reveni a SER a RES Ys A 1 A 1 2 Motor power Cables o ooooocococono hara A 2 A 1 3 Motor power cable part numbers 00 00 cece teen tenn eee ens A 2 A 1 4 Feedback cables ooccoccoccccccncc sr A 3 A 1 5 Resolver cable part numbers 0 00 ccc eee teen eee eens A 4 A 4 6 EMC fille s i orsi e Ra ue rec ae ci A 5 A 1 7 Regeneration resistors 0 00 c ccc tent n A 8 B Control Systeme so ox etc bee eR kde SRI UE UT LES EE E CES B 1 B T Introduction asis nta dE Aa e B 1 B 1 1 Current Torque control oooooocccccoccco o B 2 B 1 2 Velocity Speed control oocooccccccccooco es B 3 B 1 3 Position control Pulse and Direction 0 000 cece teens B 4 B 1 4 Position control ss crer rena a Se ee ve peo ee a B 5 B 2 C
12. Bit pattern values topic in the Keywords book 6 6 Troubleshooting MN1902 Specifications f T 1 Introduction This section provides technical specifications for the various FlexDrive models MN1902 Specifications 7 1 7 1 1 AC input power and motor output single phase models 115VAC Catalog number FDH1 FPH1 EEE E 97 Minimum input voltage Coo oh Maximum input voltage Nominal DC Bus voltage VDC Minimum DC Bus voltage bo 85 p O Maximum DC Bus voltage T n n Pi EA Nominal input voltage Minimum input voltage Maximum input voltage 250 Nominal DC Bus voltage 320 Minimum DC Bus voltage 306 Maximum DC Bus voltage 350 All single phase models Catalog numbers FDH1 FPH1 and FDH2 FPH2 VDC Bus 320V Nominal phase current Nominal phase current 10 Ams 25 50 Peak rus TE 10 ARMS 10 15 cme e E Nominetouputpower RA EU 29 Eme Cd CO A AI NominarswichingFequeney f w 7 2 Specifications MN1902 7 1 2 AC input power and motor output three phase models 230 460VAC 50 60Hz 20A 27 5A Catalog number FDH4 FPHA Nominal input Nominal input voltage 230 460 Maximum input Maximum input voltage Nominal DC Bus voltage 325 230VAC input 650 460VAC input Minimum DC Bus Minimum DC Bus voltage 746 Programmable using Mint keyword DRIVEBUSOVERVOLTS Maximum DC Bus voltage Output voltage line line VRMS 0 353 VDC Bus 5
13. COM Port RTS 7 Ws 7RTS DCE DTE CTS 8 8CTS ld l Su Connect overall shield ger to connector backshell Figure 29 RS232 serial port connections The maximum recommended cable length is 3m 10ft at 57 6KBaud the factory preset rate When using lower Baud rates longer cable lengths may be used up to maximum of 15m 49ft at 9600 Baud 4 14 Input Output MN1902 4 4 5 Multidrop using RS485 RS422 cable Multidrop systems allow one device to act as a network master controlling and interacting with the other slave devices on the network The network master can be a controller such as a FlexDrive a host application such as WorkBench v5 or other custom application or a programmable logic controller PLC Network master Network slave Final slave shown with terminating resistor Tr typical value 1200 Connect overall shield to connector backshell Figure 30 4 wire RS485 multi drop connections E Any FlexDrive on the network must have its SW1 DIP switch 10 located on the front panel set to the On position see also section 3 9 5 This will set the serial port to RS485 mode after the next power off on cycle Each TX RX network requires a termination resistor at the final RX connection but intermediate devices must not be fitted with termination resistors An exception is where repeaters are being used which may correctly contain termination resistors Termination resistors
14. IN CAUTION IN CAUTION IN CAUTION IN CAUTION 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 The motor circuit might have high voltages present whenever AC power is applied even when the motor is not moving Electrical shock can cause serious or fatal injury If a motor is driven mechanically it might generate hazardous voltages that are conducted to its power terminals The enclosure must be earthed grounded to prevent possible shock hazard 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 circ
15. See sections 4 4 3 and 4 4 4 A suitable cable is available from Baldor catalog number CBL001 501 m APC with one free COM port with the following specification To Mmmumspesheaon Recommendeispecicston M mw 98 9B C IE ZEN te AmMwewSrmGdeE Operating system Windows 95 Windows 98 Windows ME Windows NT Windows XP or Windows 2000 RS485 RS422 systems If you will be using RS485 RS422 and your PC does not have an RS485 RS422 connector an RS232 to 4 wire RS485 RS422 converter will be required These commercially available devices convert the signals from the RS232 RS485 port connector X6 to the signals necessary for RS485 RS422 communications Special care must be taken with the pin assignment on all RS485 RS422 devices as this can differ between products Connectors might need to be rewired to provide the correct pin assignment The FlexDrive pin assignment is shown in section 4 4 3 Note If this is the first time you are installing a FlexDrive then it is strongly recommended that you use RS232 to get started and try RS485 later This will avoid any potential problems involving the RS232 RS485 converter Firmware updates can only be performed over RS232 Selection of RS232 or RS485 is controlled using DIP switch 10 see section 3 9 5 Tools and miscellaneous hardware m Your PC operating system user manual might be useful if you are not familiar with Windows m Asmallscrewdriver supplied
16. X3 CGND 8 Three general purpose optically isolated digital outputs Output current 50mA maximum each output Update interval Immediate Software Mint programs 2ms DRIVEENABLEOUTPUT DRIVEOKOUTPUT and GLOBALERROROUTPUT functions Programmable PLC Task functions Description 18 20 Each optically isolated PNP output is designed to source current from the USR V supply as shown in Figure 25 The maximum saturated voltage across any of the outputs when active is 1 0VDC so they can be used as TTL compatible outputs If the outputs are used to directly drive a relay a suitably rated flyback diode must be fitted across the relay coil observing the correct polarity This is to protect the output from the back EMF generated by the relay coil when it is de energized The outputs can be written to directly using the Mint keyword OUTX for example OUTX 2 71 The sense of the outputs can be configured in WorkBench v5 and their states are displayed in the Spy window FlexDrive Load RUE es USRV Relay with E Pin 6 flyback diode Y E 4 shown NEC PS2562L 1 DOUTx AN y Pins 18 20 CGND Pin 8 Figure 25 X3 digital output circuit MN1902 Input Output 4 9 4 4 Other I O 4 4 4 Encoder output X7 Connector X7 7 E UU END AAA gt E x 5 Bey E O O o El 5 Encoder output on a 9 pin female D type connector This output can be
17. cect I a 3 10 3 4 4 Power disconnect and protection devices 0 cc cent eee 3 10 3 4 5 Power supply filters oocooococccocoocoocoorrr I I eee 3 11 3 4 6 Wire sizes and protection device ratings 0 cece ett 3 12 3 4 7 External customer supplied 24V control supply 6 000 cee eee eee eee 3 13 3 5 Motor connections o 3 14 3 5 1 Motor circuit contactors socrii r RR n 3 15 3 5 2 Motor power cable pin configuration Baldor BSM rotary motors 3 15 3 5 3 Motor cable pin configuration Baldor linear motors 0000e eee reese 3 16 3 5 4 Thermal switch connection 00 0 RR IRR 3 17 3 6 Regeneration resistor Dynamic Brake resistor 0 0 0 cece eee eee eee 3 18 3 6 1 Controlling regeneration 000 ccc tenet a 3 18 3 7 Feedback connections 0 0 cc eee een eee n eens 3 19 3 7 1 Resolver option X8 s eeri a aa a ehh 3 20 3 7 2 Eneoderoption a X8 A ue eer a sas soe a ERRORI e A ORA 3 22 MN1902 Contents i 3 8 Drive enable X39 coii tUe vene CUIU Ie idee PEE AS 3 25 3 8 1 Drive enable X3 c cat Aenea a Keay Miele Bled b emet xe tet md eq 3 25 3 8 2 Drive enable SW1 DIP switch 2 0 III 3 26 3 8 3 Drive enable command oooocccocccc ee mnt 3 26 3 9 BIP switehes SWT x ics ve Ee a Rcs ds VE death cen Nd A es 3 27 3 94 Switches 14 eere EXER C RERO RU E ee RO RA ee Ra 3 27 3 92 Switch Hold o e AE Ede ER
18. equipment has been tested and complies with the appropriate standards It rests upon the manufacturer or his authorized representative to ensure the item in question complies fully with all the relative directives in force at the time of installing into service in the same way as the system integrator previously mentioned Remember that it is the instructions of installation and the product that should comply with the directive MN1902 CE Guidelines C 1 C 1 2 C 1 3 Use of CE compliant components The following points should be considered m Using CE approved components will not guarantee a CE compliant system m The components used in the drive installation methods used materials selected for interconnection of components are important m Theinstallation methods interconnection materials shielding filtering and earthing grounding of the system as a whole will determine CE compliance m Theresponsibility of CE mark compliance rests entirely with the party who offers the end system for sale such as an OEM or system integrator EMC wiring technique Cabinet Using a typical electroplated zinc coated enclosure connected to earth ground means that all parts mounted on the back plane are connected to earth ground and all outer shield screen connections can be connected to earth ground Within the cabinet there should be a spatial separation between power wiring motor and AC power cables and control wiring Shield s
19. in the top of the enclosure is for the earth ground clamp provided The hole is threaded for M4 bolts no longer than 12mm 0 47 in in length Longer bolts may short circuit the electrical components inside the FlexDrive AC Route L1 L2 L3 and Circuit breaker or fuses AC filter Supply earth ground together See section 3 4 4 See section 3 4 5 in conduit or cable Line L1 Line L2 Line L3 7 Isolating switch To earth ground outer shields use 360 If filter has no output earth ground terminal Incoming safety earth wire may be clamps connected to earth ground PE connected directly to backplane or star point FlexDrive case STAR POINT See section 4 5 1 Figure 3 Earthing grounding for three phase installations Note For CE compliance a three phase AC filter must be connected between the AC power supply and the FlexDrive If local codes do not specify different regulations use at least the same gauge wire for earth ground as is used for L and N MN1902 Basic Installation 3 9 3 4 3 3 4 4 Input power conditioning Baldor drives are designed for direct connection to standard single and three phase lines depending on model that are electrically symmetrical with respect to earth ground Certain power line conditions must be avoided an AC line reactor an isolation transformer or a step up step do
20. of the FlexDrive 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 MN1902 Introduction 2 1 2 2 Receiving and inspection When you receive your FlexDrive 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 FlexDrive 2 Remove the FlexDrive 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 FlexDrive you received is the same as the catalog number listed on your purchase order The catalog part number is described in the next section 4 Inspect the FlexDrive for external damage during shipment and report any damage to the carrier that delivered your FlexDrive 5 f FlexDrive 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 7 1 16 2 2 1 Identifying the catalog number The FlexDrive is available with different current ratings and package sizes The catalog number is marked on the front of the unit just below
21. on position while the switch is active Homing The drive is currently homing See the Mint keyword HOME Preset Homing The drive is currently homing This motion has been triggered from a Preset move table Incremental move An incremental move is being profiled See the Mint keywords INCA and INCR Jog The drive is jogging In the Mint help file see the topics JOG JOGCOMMAND and Jog screen Preset jog The drive is jogging The jog was triggered from a Preset jog table Overspeed The measured speed of the motor has exceeded the trip level defined by DRIVESPEEDFATAL Check that the trip level is set to a suitable value for your application When accelerating to a demand speed close to the trip level there will typically be a certain amount of overshoot Using the Fine tuning tool check the amount of overshoot you get with the acceleration and demand speeds being used in your application Positional Move The drive is performing a linear move See the Mint keywords MOVEA and MOVER n m Pu E K B B a E dE E MN1902 Troubleshooting 6 3 6 2 2 Preset positions The drive is performing a linear move This motion has been triggered from a Preset move table DB Overload The regeneration resistor Dynamic Brake has been overloaded See the Mint keyword DBEXTTRIPSWITCH and associated keywords 5 Stop A STOP command has been issued or the stop input is active Drive disabled The drive must be enabled
22. pulse frequency controls the speed and the state of the direction signal controls the direction of motion A positive voltage 5V on pin 2 will result in forward motion If pin 2 is grounded movement will be in the opposite direction The Mint keyword AUXENCODERMODE bit 2 is used to configure X9 for pulse and direction operation If necessary the sense of the direction input can be reversed in software using the Mint keyword AUXENCODERMODE bit 0 See the Mint help file for details Note If X9 has been configured for pulse and direction input the alternative pulse and direction inputs available on connector X3 cannot be used See the Mint keyword MASTERSOURCE Pulse and direction source x9 Twisted pairs Pulse Pulse GND Direction Direction GND DGND Connect internal shields to DGND Se Connect overall shield to A connector backshells Figure 28 Pulse and direction connections 4 12 Input Output MN1902 4 4 3 Serial port X6 Connector X6 CI m fr 1 4 5 A s A RS232 RS485 X6 9 Do not connect See caution below Description RS232 or RS485 RS422 connections on a single 9 pin female D type connector Connector X6 is a 9 pin male D type connector This port is configurable as either RS232 or 4 wire RS422 RS485 using front panel DIP switch number 10 see section 3 9 5 The Mint keyword SERIALBAUD is used to configure the port and is explained in the
23. signals The position and speed demand signals are fed into a position controller and used together with the position measured from the feedback device to generate a suitable speed demand signal If the position controller is tuned correctly the measured position will accurately track the position demand The speed demand signal from the position controller is fed into the speed controller and used together with the speed measured from the feedback device to generate a torque demand signal If the speed controller is tuned correctly the measured speed will accurately track the speed demand To improve the tracking performance of the speed controller the profiler acceleration demand is fed in at this point Finally the torque demand signal is fed into a torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current measured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Position reference Pulse and Direction Profiler A Speed Torque Speed Position demand demand controller Speed controller Torque PWM Power stage controller motor ai current Measured speed Measured position Figure 43 Control structure in Position control Pulse and Direction B 4 Control System MN1902 Position contr
24. the position controller the profiler speed is fed forward by gain KVELFF to give a contribution to the final speed or torque demand The profiler acceleration is fed forward by gain KACCEL to give a contribution to the final speed demand The position control calculation is performed every 500us The gain values KPROP KINT KDERIV KVEL KVELFF and KACCEL must be tuned for each application This can either be performed automatically within the Commissioning Wizard or manually using the Fine tuning tool in WorkBench v5 Profiler speed Velocity feedforward term VELDEMAND KVELFF Proportional gain term Following error FOLERROR Profiler position POSDEMAND Speed demand Velocity feedback term Measured speed VEL Measured position Figure 45 Position control system B 6 Control System MN1902 B 2 2 Speed controller The speed controller shown in Figure 46 is also a PID controller Gains are set using the Mint keywords KVPROP KVINT and KVDERIV The speed is compared with the measured speed and the error is fed into the PID control calculation The result forms the torque demand for the torque controller To improve the performance of the derivative term an optional filter is included The time constant of this filter can be set using keyword KVDERIVTCONST By default the filter is turned off with KVDERIVTCONST set to zero When the FlexDrive is set to positioning mode CONFIG i
25. used for position feedback to a host positioner or in master slave situations where the axis movement can be transmitted to another controller or FlexDrive It is recommended that this output only drives one output circuit load The encoder outputs are differential and conform to the RS422 electrical specification Shielded twisted pair cable is recommended If a resolver is connected to the FlexDrive a simulated encoder output is produced at X7 If the resolver input has been configured to simulate an encoder input of 1024 pulses per revolution ppr the output at X7 can be set to either 512 or 1024 ppr If the resolver input has been configured to simulate an encoder input of 4096 ppr output modes of 512 1024 2048 and 4096 ppr are possible Note that these values represent actual encoder lines not quadrature counts See the keyword ENCODERLINESOUT in the Mint help file If the FlexDrive is fitted with the basic encoder feedback option X7 duplicates the encoder signals entering X8 The encoder output supports an index or marker pulse IN CAUTION Using connectors X7 and X8 multiple FlexDrive units can be daisy chained together However if another Mint based controller such as a NextMoveBX is to be connected a special cable must be built as shown FlexDrive NextMoveBX X7 encoder input CHA CHA CHZ CHZ CHB CHB Connect internal shields to DEND DGND Connect overall shield U 55s to connector backshells
26. you have entered yourself Power cycling the FlexDrive The term Power cycle the FlexDrive is used in the Troubleshooting sections On models with a customer supplied 24V supply remove the 24V supply wait for the FlexDrive to power down completely all Status LED segments will turn off then re apply the 24V supply On models with an internally generated 24V supply remove the AC power supply wait for the FlexDrive to power down completely all Status LED segments will turn off then re apply AC power MN1902 Troubleshooting 6 1 6 2 FlexDrive indicators 6 2 1 Status display The Status LED display indicates general FlexDrive status information 3 a Drive comms watchdog Interprocessor communications failure This is potentially a severe problem if it occurs repeatedly Communications failure could indicate a process locking out the interprocessor communications Clear the error if the problem persists then contact Baldor technical support Over volts The DC Bus voltage has exceeded the powerbase overvolts level see DRIVEBUSOVERVOLTS Check the DC Bus level being fed into the system see Mint keyword DRIVEBUSVOLTS This should be close to the nominal voltage see Mint keyword DRIVEBUSNOMINALVOLTS Ensure that your input voltage is relevant to the voltage rating of your drive If the input voltage is correct then this error may be the result of high deceleration rates If itis not possible to r
27. 00V Nominal phase current 10 15 27 54 5A Peak phase current 10 EE 10 15 for 2 4s 0 5s 0s Roninatoupuipower WA Ts 3s 5r wa 52 m5 AA All three phase models 5A 7 5A 15A 20A 27 5A Catalog numbers FDH4 FPHA Efficiency Output frequency Hz 0 500 Nominal switching frequency kHz 7 1 3 Customer supplied 24VDC supply 24VDC 20A 27 5A Catalog number FDHxxxxx xxx3 and FPHxxxxx xxx3 Nominal input voltage Minimum input Minimum input voltage o 88 SES 8 ee input Maximum input voltage Maximum continuous current 1 75 24VDC Power on surge current 4 24VDC 100ms MN1902 Specifications 7 3 7 1 4 Regeneration Switching threshold voc on 188 195 off 183 188 Nominal power 10 power cycle 0 25 Peak Peak power 10 power cycle Peak power 10 power cycle 0 power cycle Maximum regeneration SSS awe current Note 2 5A models FDH1A02 and FPH1A02 contain an internal 1750 20W resistor 5A models FDH1A05 and FPH1A05 contain an internal 900 40W resistor Switching threshold voc on 373 383 off 362 372 Peak Peak power 10 power cycle Peak power 10 power cycle 0 power cycle Maximum regeneration A ae switching current Maximum load inductance Note 2 5A models FDH2A02 and FPH2A02 contain an internal 1750 20W resistor 5A models FDH2A05 and FPH2A05 contain an internal 900 40W resi
28. 14 06 10 31 1 81 1 28 15 12 15 75 10 8 130 357 328 111 27 5 75 384 400 9 05 5 12 14 06 12 91 4 37 108 295 15 12 15 75 19 95 Figure 1 Package dimensions MN1902 Basic Installation 3 5 3 3 Connector locations X1 X1A Power Single phase models Q Earth NC NC L AC Line N AC Neutral U Motor U V Motor V Ww Motor W R1 Regen Resistor R2 J Dynamic Brake z NC 24V Customer OV supplied 24V FDHXxxxxxx xxx3 FPHXxxxxxx xxx3 Three phase models Earth Earth L1 AC Phase 1 L2 AC Phase 2 L3 AC Phase 3 U Motor U V Motor V Ww Motor W R1 Regen Resistor R2 Dynamic Brake 24 OV J FDHXxxxxx xxx3 FPHxxxxxx xxx3 SW1 DIP switches 1 Node number selection ee E 20 uo nano S Reserved Hold Offset tuning Enable Reserved 0 RS232 RS485 SPOONnNoanhWND Tightening torque for terminal block connections is 0 5 0 6Nm 4 4 5 3 Ib in NC Not Connected Do not make a connection to this pin Options If there are other connectors on the front panel of your FlexDrive then an option is fitted See the other manuals supplied with your FlexDrive Swi x1 y Status e 3 4 NC L N 8 9 U 10 V Off On oie 7 gt o Ri R2 E e c gt 24V O ov Og Boa Q wn E q e N E O FlexDrive xs BALDOR lt
29. 30VAC single phase or 230 460VAC three phase supplies model dependent Resolver or encoder feedback Velocity and current control with pulse and direction input for position control Auto tuning wizard including position loop and software oscilloscope facilities 8 optically isolated digital inputs 3 optically isolated digital outputs 1 general purpose analog input can be used as a speed or torque command reference 1 control relay Selectable RS232 or RS485 communications Flex Drive only Integrated motion controller for rotary and linear positioning systems Programmable in Mint Up to 16 programmable preset moves expandable to 256 with factory fitted CAN and I O option Position control using preset moves software gearing and point to point moves Flash memory for program storage 16k Motion controller for rotary and linear positioning systems Factory fitted options expand the I O capabilities of the FlexDrive and provide CANopen DeviceNet or Profibus connectivity See Appendix A for details about options FlexDrive 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 FlexDrive The sections should be read in sequence The Basic Installation section describes the mechanical installation
30. AY off the contacts open An axis can use the relay as its drive enable output signal This can be configured in WorkBench v5 or by using the Mint keyword DRIVEENABLEOUTPUT This prevents access by RELAY but means that the relay can be used to monitor the state of the DRIVEENABLE keyword See the Mint help file for details FlexDrive Internal relay Relay Pin 4 Control circuitry Relay Pin 5 Figure 22 Relay contact outputs 4 4 Input Output MN1902 4 3 Digital I O The FlexDrive provides as standard 8 general purpose inputs on connector block X3 3 general purpose outputs on connector block X3 A digital input can be used to support many typical input functions Error input Reset input Stop input Forward limit Reverse limit Interrupts controlled from Mint Regeneration resistor Dynamic Brake trip input PLC Task input conditions General purpose use Flex Drive only Home input Index selection and triggering for preset move types DIN4 and DIN5 are fitted with Schmitt trigger devices and can be configured using Mint for position capture of the axis or the master auxiliary encoder positions See section 4 3 4 The main axis fast input assigned using the Mint keyword FASTSELECT can also be used as a trigger for point to point move types See the Mint help file for details Additional I O is available on connector X12 if the option
31. B is fitted See MN1908 CAN and I O option for FlexDrive Flex Drive and MintDrive MN1902 Input Output 4 5 4 3 1 Digital inputs X3 Connector X3 fF 9 Drive Enable 10 DINO INX 0 Mint keyword Description Eight general purpose optically isolated AC digital inputs One committed drive enable input Drive Enable Sampling interval 2ms The digital inputs DINO DIN7 can be read individually using the associated Mint keyword INX for example INX 7 and can be configured for many user definable functions Each input circuit contains an opto isolator as shown in Figure 23 Inputs DIN4 and DIN5 can also be used as fast inputs see section 4 3 4 The state of each digital input is displayed in the WorkBench v5 Spy window 1 1 1 1 FlexDrive Vee 10k DINx Ak7 Pins 10 13 2 E amp 16 17 x 1k 0 1pF Ne CREF DGND Pin 7 Y NECPS2565 Active high DINx 24VDC 420 Active low DINx 0V CREF 0V CREF 24VDC 20 Figure 23 X3 digital input circuit 4 6 Input Output MN1902 4 3 2 4 3 3 CREF and digital inputs Pin 7 CREF controls the sense of all the digital inputs X3 pins 9 to 17 and should be permanently wired dependent on the user requirements Active high connect 24VDC to pin 9 and OV to pin 7 The digital inputs will be active when a voltage of 24VDC greater than 12VDC
32. BALDOR MOTORS AND DRIVES SERVO DRIVE FlexDrive Flex Drive Servo Controls Installation Manual 11 01 MN1902 Contents 1 General Information aot AA 1 1 2 MINO UCI sc qe sed SOI CR 2 1 2 4 FlexDrive features 2 1 2 2 Receiving and inspection 00 0 cect eee tees 2 2 2 2 1 Identifying the catalog number 0 unane nanana 2 2 2 3 Units and abbreviations 0 0 ccc RR es 2 3 3 Basic Installallon sx vase benc DA base cede ewes ER M REV AES 3 1 3 4 Introduction edu ex ee e ice EN RC ICE A e RICE SEA C HAC EA C EA e 3 1 3 14 POWerSQUICES ox eia dacs coud ave coc ose E bt dao ad ER CER Whe Be poke dln do odes 3 1 3 1 2 Hardware requirements ea da 3 1 3 1 3 RS4857 RS422 systems oie oes hie eee ee a ig Mie neh RTS 3 2 3 1 4 Tools and miscellaneous hardware 0 000 cece eee nent eens 3 2 3 1 5 Other information needed for installation 0 0 teens 3 2 3 2 Mechanical installation and location requirements 0 000020e o 3 3 3 2 1 Mounting the FlexDrive 20 0 nee n 34 322 DIMENSIONS td A reto i e PALA Gee A s aka siete AC QC eT VERNA OR 3 5 3 9 Connector loCatlonis cca 6 4i A et odes ILE 3 6 3 4 Power connections o 3 7 3 4 1 Single phase connection to package sizes A B C D iiiuiuiiullilllsslluss 3 8 3 4 2 Three phase connection to package sizes G H 0 0 c cece eee 3 9 3 4 8 Input power conditioning 0 0 0
33. CE CBL229SF KPCE CBL305SF KPCE CBLO30SF K CBLO61SF K CBLO91SF K CBL152SF K CBL213SF K CBL305SF K Accessories A 3 A 1 5 Resolver cable part numbers A description of a Baldor feedback cable catalog number is shown here using the example number CBLO030SF ALCE The item is a cable 030 Indicates the length in this example 3 0 meters Various lengths are available Sr Tre cable Tsa Servo motor Feedback eae A Resolver feedback cae e cae Note Feedback cables terminated with a CE connector catalog numbers CBLxxxxx xxCE have shields tied to the connector housing If you are not using a Baldor cable with your chosen feedback device be sure to obtain a cable that is a shielded twisted pair 0 34mm 22 AWG wire minimum with an overall shield Ideally the cable should not exceed 30 5m 100ft in length Maximum wire to wire or wire to shield capacitance is 50pF per 300mm 1ft length to a maximum of 5000pF for 30 5m 100ft A 4 Accessories MN1902 A 1 6 EMC filters AC filters remove high frequency noise from the AC power supply protecting the FlexDrive These filters also prevent high frequency signals from being transmitted back onto the power lines and help meet CE requirements To select the correct filter see section 3 4 5 A 1 6 1 Catalog numbers FI0015A00 250 6 04 045 9 FI0015A01 250 0 73 1 61 FI0015A02 250 0 73 1 61 FI0017A03 440 3 0 6 61 FI0017A04 440 3 1 6 83 F
34. DH4A27 xx xxxx 230 460V Table 2 Protection device and wire ratings A A A A A A A A A A Note All wire sizes are based on 75 C 167 F copper wire Higher temperature smaller gauge wire may be used per National Electric Code NEC and local codes Recommended fuses breakers are based on 25 C 77 F ambient maximum continuous control output current and no harmonic current Earth ground wires must be the same gauge or larger than the Line and Neutral wires 3 12 Basic Installation MN1902 3 4 7 External customer supplied 24V control supply Depending on model catalog numbers FDHxxxxx xxx3 and FPHxxxxx xxx3 a 24VDC control supply must be provided to power the control electronics This is useful for safety reasons where AC power needs to be removed from the power stage but the control electronics must remain powered to retain position and I O information It is recommended that a separate fused 24V supply is provided for the FlexDrive If other devices are likely to be powered from the same 24V supply then a filter Baldor catalog number FI0014A00 should be installed to isolate the FlexDrive from the rest of the system Location Connector X1 X1A FDHxxxxx xxx3 or FPHxxxxx xxx3 Nominal input voltage 24V nput current 1 75A continuous 4A power on surge maximum Tightening torque for terminal block connections is 0 5 0 6Nm 4 4 5 3 Ib in Note Connect 24V to connector X1 only if your model has th
35. ENE contact with the cable pe amp S 30mm 500mm mox Figure 48 Earthing grounding cable shields FlexDrive Cable Resolver Connector X8 Housing REF REF COS COS SIN SIN AGND NS Connect overall shield Connect overall shield to connector backshell to connector backshell Figure 49 Resolver cable grounding FlexDrive Encoder Connector x8 Cable Housing Twisted pairs CHA CHA CHB CHB CHZ CHZ 5V DGND 00 YJNO PN Connect overall shield Connect overall shield dT to connector backshell to connector backshell Figure 50 Encoder signal cable grounding C 4 CE Guidelines MN1902 FlexDrive x9 CHA CHA CHB CHB CHZ CHZ 5V DGND aowownnod Cable gt Auxiliary Encoder Housing Connect overall shield to connector backshell Figure 51 Auxiliary Encoder cable grounding Connect overall shield A to connector backshell MN1902 CE Guidelines C 5 C 6 CE Guidelines MN1902 BALDOR MOTORS AND DRIVES Baldor Electric Company P O Box 2400 Ft Smith AR 72902 2400 Tel 501 646 4711 Fax 501 648 5792 www baldor com Il Printed in UK MN1902 11 2001 Baldor UK Ltd
36. I0018A00 480 0 5 1 1 FI0018A01 480 1 2 2 65 Dimensions mm inches FI0018A00 FI0018A01 CN 190 7 48 270 10 63 160 6 30 240 9 45 20 0 79 30 1 18 4 5 0 18 5 4 0 21 71 2 80 85 3 35 o ons oom Figure 37 Filter dimensions types FI0018A00 and FI0018A01 MN1902 Accessories A 5 Dimensions mm inches FI0015A00 FI0015A01 FI0015A02 A mssuan 566 arene 46 6 t a 5 aem 89 D E 103 d K 123 5 83 E 25 038 e 124 049 32 4 1 28 el 6 0 24 55 081 Figure 38 Filter dimensions types FI0015A00 FI0015A01 FI0015A02 A 6 Accessories MN1902 npes i4 F Depth E gt p Far FI0017A04 65 2 55 20 0 78 20 21 0 83 Figure 39 Filter dimensions types FI0017A03 and FI0017A03 MN1902 Accessories A 7 A 1 7 Regeneration resistors Some FlexDrive models 2 5A and 5A are fitted with an internal regeneration resistor see sections 2 2 1 and 7 1 4 Additional external regeneration resistors can be fitted to these models using the R1 and R2 pins of connector X1 X1A Resistors connected in this way will be in parallel with the
37. LESWITCH See the Mint help file for details MN1902 Basic Installation 3 25 3 8 2 3 8 3 Drive enable SW1 DIP switch at To enable the FlexDrive the front panel DIP switch 8 must be set to On This switch provides a local enable disable switch that can be useful during testing The state of the drive enable DIP switch is displayed in the WorkBench v5 Spy window It can also be checked but not set using the Mint keyword ENABLESWITCH See the Mint help file for details 1 2 3 4 Ly 6 7 8 9 1 o See section 3 9 for full details of other DIP switch functions Drive enable command The other action required to enable the FlexDrive can be controlled either by software or hardware Note This method is explained here for your information but cannot be completed until you have installed the software and are ready to turn on AC power to the drive Please continue to read all sections in sequence Do not turn on AC power until you reach the appropriate instructions In software a drive enable command must be issued The easiest way to do this is by clicking the Drive enable button Yau in WorkBench v5 Alternatively the Mint commands RESET or DRIVEENABLE 1 can be used See the Mint help file for details In hardware a digital input can be used to create the drive enable command This can be configured in WorkBench v5 using the Digital inputs tab of the Digital I O tool Alternatively the Mint keyword RESETI
38. M UE 10 I oi Oi Sm Figure 16 Offset tuning using switch 7 and 8 Leave switch 7 Off in normal use The switch positions are sampled every 100ms The Mint keyword ADCOFFSETTRIM can be used to perform the same action Switch 8 Enable Switch 8 must be set to On to allow the drive to be enabled The switch position is sampled every 100ms However two other actions are necessary to enable the FlexDrive m The enable input see section 3 8 must be active m The drive must also be enabled by using a drive enable command see section 3 8 3 3 28 Basic Installation MN1902 3 9 5 3 9 6 Switches 9 and 10 RS232 RS485 select Switch 9 is reserved for Baldor keypad selection Switch 10 selects RS232 communications Off or RS485 RS422 On the next time the FlexDrive is power cycled Factory settings If switches 1 4 are all in the On position and switch 8 is set to Off the FlexDrive will be reset to its preset factory settings at power on or whenever the processor is reset by WorkBench v5 IN CAUTION Use this function carefully it will erase your drive setup information When using the SW1 DIP switches to reset the FlexDrive to its factory defaults all parameters including the node number and serial communications baud rate will be reset In WorkBench v5 this means it will be necessary to rescan for the FlexDrive by starting a new project to enable communication It will also be nec
39. Mint help file See also sections 4 4 4 and 4 4 5 The port is fully ESD protected to IEC 1000 4 2 15kV AN CAUTION Pin 9 is used to carry 8V for powering certain Baldor keypad peripherals Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply MN1902 Input Output 4 13 4 4 4 Using RS232 cable IN CAUTION The serial connector on the FlexDrive X6 can be configured as either RS232 or RS485 RS422 Pin 9 is used to carry 8V for powering certain Baldor keypad peripherals Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply A suitable cable is available from Baldor catalog number CBL001 501 Front panel DIP switch 10 must be in the Off position to select RS232 operation The FlexDrive has a full duplex RS232 serial port with the following preset configuration 57 6Kbaud 1 start bit 8 data bits 1 stop bit No parity Hardware handshaking lines RS232 RTS and CTS must be connected This configuration can be changed if required The RS232 connections are brought out onto a 9 pin male D type connector The RS232 port is configured as a DTE Data Terminal Equipment unit Both the output and input circuitry are single ended and operate between 12V The port is capable of operation at up to 57 6Kbaud X6 COM RXD 2 d 2 RXD TXD3 8 TXD n 9 pin EE GND 5 SGND Computer
40. Mint keyword MOTORTEMPERATURINPUT can also be used to configure a digital input for this purpose A typical circuit using DIN1 as the input is shown in Figure 9 Relay DINO INX 0 from motor A DIN1 INX 1 thermal switch DIN2 INX 2 connections E DIN3 INX 3 K DIN4 INX 4 DIN5 INX 5 DING INX 6 DIN7 INX 7 24VDC OV eer Customer e supplied 24VDC supply Figure 9 Motor thermal switch circuit IN CAUTION The thermal switch contacts must never be wired directly to a digital input the wires might carry induced voltages and noise that could damage the input The relay should be fitted with a protective flyback diode as shown Wires should not run in the same conduit as motor leads or AC power wiring MN1902 Basic Installation 3 17 3 6 3 6 1 Regeneration resistor Dynamic Brake resistor The 2 5A and 5A FlexDrive both have an internally fitted regeneration resistor For 7 5A 15A 20A and 27 5A FlexDrive an external regeneration resistor must be installed to dissipate excess power from the internal DC bus during motor deceleration Suitable regeneration resistors are listed in section A 1 7 IN 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 resistors R1 The regeneration resistor should be mount
41. NPUT can be used to select the required digital input See the Mint help file for details Another method is to use the Mint keyword DRIVEENABLEMODE This allows the combination of DIP Switch 8 and the Enable input to create the drive enable command Both inputs must become active Provided one input is already on as soon as the other input changes from off to on active the drive will be enabled See the Mint help file for details 3 26 Basic Installation MN1902 3 9 DIP switches SW1 Various functions of the FlexDrive can be controlled by the front panel SW1 DIP switches Switch block SW1 Cis Node number selection serial and CANopen networks Bit pattern values shown in italics TT i 53 i i sm OONAMRWN 3 9 1 Switches 1 4 Switches 1 4 set the network node number address after the next power off on cycle The switches can be used to select any node number from 1 to 14 as shown in Figure 15 A c a address or OF SetbyMmtNopEKeywori E o o on o 2 A A A B S or 00 o o 4 on o o J BG 9m Do not use See section 3 9 6 Figure 15 Node number address switch settings MN1902 Basic Installation 3 27 3 9 2 3 9 3 3 9 4 If switches 1 4 are all in the Off position the Mint NODE keyword can be used to set the node number WorkBench v5 see section 5 2 reads the FlexDriv
42. P and Speed Integral gain KVINT on the Speed tab of the Fine tuning window get a Following Error Set FOLERRORMODE to zero to ignore the following error while AXISERROR bit 5 is set and the tuning the Mint gains drive disables when tuning the Mint gains get a Software limit error Set SOFTLIMITMODE to zero to ignore the software limit error while AXISERROR bits 3 or 4 set and tuning the Mint gains the drive disables when tuning the Mint gains get a Hardware limit error Set LIMITMODE to zero to ignore the hardware limit errors while AXISERROR bits 1 or 2 set and tuning the Mint gains Alternatively disable the hardware limit the drive disables when tuning inputs the Mint gains 6 2 6 Status LED shows a digit or E If the Status display shows a flashing digit E or the forward or reverse hardware limit symbol use the Error Log tool to view a list of recent errors Alternatively type PRINT DRIVEERROR PRINT AXISERROR and PRINT MISCERROR as separate commands in the WorkBench v5 Command window Each of these commands will return an error code a description of which can be found in the help file Press F1 and locate the DRIVEERROR AXISERROR and MISCERROR keywords The Error Handling book contains topics listing the Status display indicators and basic error codes Remember that many error codes are the sum of a bit pattern so may not be listed individually For help on understanding bit pattern values see the
43. REUR E RARE RE Bataan 3 28 3 9 3 Switch 7 Offset tuning 000 cect a 3 28 3 9 4 Swilch 8 En ble ek e RE da 3 28 3 9 5 Switches 9 and 10 RS232 RS485 select 0 3 29 3 9 6 Factory SetiNgS rie epe poro eee Rep a EE potra dag 3 29 3 9 7 Preventing a program running at startup ssseseese e 3 30 4 dpt Outpt iot a Foto ns An RAS 4 1 41 Introduction nente ebo be t bh der Ped Dabo ye tete coe ox ebd 4 1 42 MAA EL e iR I a ias 4 1 4 2 1 Analog input X3 command oocoocccccocc n 4 2 4 2 2 Relay output X3 a a aaea e sh rs 4 4 43 Digitall O 1 2 e RR e peek ex Rue eR EO RD UR Reg EAQUE ba e Ran 4 5 43 1 Digital inputs X9 voce eee a gWniefbuceier jkr PUese bes des 4 6 4 3 2 CREF and digital inputs Ani reresesorrre enese ue teadet e eireta teenies 4 7 4 3 3 Special functions on DIN4 and DIN5 pulse and direction inputs 4 7 4 3 4 Special functions on DIN4 and DIN5 fast inputs 0 0 00 ccs 4 8 43 5 Digital outputs X3 ee cei ri a add 4 9 AVA Omer VO a A den Weg t ey Uta auc eee reges Vat s 4 10 4 44 Encoderoutp bsXZ uc xeon hae ee he ae es ee PLO REE SN 4 10 4 4 2 Master auxiliary encoder input X9 0 0600s 4 11 4 43 Seal port XO eure ge he PIU Pe Seed Oe Ps aS SENS 4 13 4 44 Using RS232 cable isis ere a 4 14 4 4 5 Multidrop using RS485 RS422 cable 0 00 0 4 15 4 4 6 Connecting Baldor HMI Operator Panels 00 00 c cece
44. US a microsecond MS Dedos nanosecond Kbaud kilobaud the same as Kbit s in most applications MB uu megabytes CDROM Compact Disc Read Only Memory CTRL E on the PC keyboard press Ctrl then E at the same time mm millimeter Mons meter ia sa els inch Ah ete tna he atte feet Ib in pound inch torque Nm oce Newton meter torque ADG iaa Analog to Digital Converter DAC sees Digital to Analog Converter AWG American Wire Gauge NC cs eem Not Connected MN1902 Introduction 2 3 2 4 Introduction MN1902 3 1 3 1 1 3 1 2 Basic Installation Introduction You should read all the sections in Basic Installation to ensure safe installation This section describes the mechanical and electrical installation of the FlexDrive in the following stages Location considerations Mounting the FlexDrive Connecting the AC power supply Connecting the optional customer supplied 24VDC control supply Connecting the motor Installing a regeneration resistor Dynamic Brake resistor Connecting the feedback device Connecting the drive enable input These stages should be read and followed in sequence Power sources An AC power source IEC1010 over voltage category III or less in the installation area is required This will need to be single or three phase depending upon the type of FlexDrive An AC power filter is required to comply with the CE directive f
45. and X12 m MN1909 CAN option for FlexDrive Flex Drive and MintDrive Option C provides CANopen capabilities If this option is fitted the FlexDrive front panel will include connectors X10 and X11 m MN1910 DeviceNet option for FlexDrive Flex Drive and MintDrive Option D provides DeviceNet capabilities If this option is fitted the FlexDrive front panel will include connector X15 m MN1911 Profibus option for FlexDrive Flex Drive and MintDrive Option P provides Profibus capabilities If this option is fitted the FlexDrive front panel will include connector X14 MN1902 Accessories A 1 A 1 2 Motor power cables Cable Cable assembly CBL015SP MHCE 5 CBLO30SP MHCE Power Cable Assembly CBL061SP MHCE 10 Amps CE Style Threaded CBL091SP MHCE Connector CBL152SP MHCE CBL229SP MHCE CBL305SP MHCE CBL015SP FHM CBLO30SP FHM CBLO61SP FHM CBLO76SP FHM CBL091SP FHM CBL152SP FHM CBL229SP FHM CBL305SP FHM Power Cable Assembly E CE Style Threaded CBL091SP FHCE Connector CBL152SP FHCE CBLO30SP F CBLO46SP F Power Cable CBL061SP F No Connectors CBLO76SP F CBL091SP F CBL152SP F CBLO30SP E CBLO46SP E 30 Amps T CBLOG1SP E CBLO91SP E CBL152SP E A 1 3 Motor power cable part numbers 8Naiocos Power Cable Assembly Threaded connector Standard Metric Style com 8 Nono al ONDARY al ODKRY al For easier installation it is recommended that a color coded Bal
46. arameters that E have been calculated by the Commissioning Wizard E The main area of the WorkBench v5 window displays the capture window When further tuning tests are performed this will display a graph representing the response 2 The Fine tuning window has three tabs at the bottom Position Speed and Current Click on a tab to select it Position Speed Current Click the tab for the type of tests you wish to perform Note Some tabs may not be available depending on the configuration mode you selected in the Commissioning Wizard MN1902 Operation 5 7 5 3 1 1 5 3 1 2 5 3 1 3 Fine tuning Position tab The position tab allows you to set position loop gains and perform test moves The Commissioning Wizard may have already set some of these values depending on the type of system selected on the mode screen Enter new values in the required boxes and then click Apply to download the values to the FlexDrive To perform tests go to the Test Parameters area at the bottom of the tab Enter test values and then click Go to perform the test move If you need help just press F1 to display the help file Fine tuning Speed tab The speed tab allows you to set speed loop gains and perform test moves The Commissioning Wizard may have already set some of these values depending on the type of system selected on the mode screen Enter new values in the required boxes and then click Apply to download the values to the FlexDrive
47. are used to match the impedance of the load to the impedance of the transmission line cable being used Unmatched impedance causes the transmitted signal to not be fully absorbed by the load This causes a portion of the signal to be reflected back into the transmission line as noise If the source impedance transmission line impedance and load impedance are all equal the reflections noise are eliminated Termination resistors increase the load current and sometimes change the bias requirements and increase the complexity of the system 0030 0 0N E E Le De Un ur LIS ue gt en is loft MN1902 Input Output 4 15 4 4 6 Connecting Baldor HMI Operator Panels Baldor HMI Operator Panels use a 15 pin male D type connector marked PLC PORT but the FlexDrive connector X6 is a 9 pin male D type connector If you do not require hardware handshaking then use the connections shown in Figure 31 Baldor HMI FlexDrive PLC PORT X6 Figure 31 Cable wiring if hardware handshaking is not required If hardware handshaking is required then use the connections shown in Figure 32 Baldor HMI FlexDrive PLC PORT P Twisted pair Figure 32 Cable wiring if hardware handshaking is required 4 16 Input Output MN1902 4 5 Connection summary minimum system wiring As a guide Figure 33 shows an example of the typical minimum wiring required to allow the FlexDrive to contro
48. asured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Profiler Speed demand Torque demand Position reference data Position Speed controller controller Torque PWM Power stage controller motor Measured current Measured speed Measured position Figure 44 Control structure in Position control mode MN1902 Control System B 5 B 2 B 2 1 Control system operation The following sections describe the operation of the position speed and torque controllers Position controller The position controller shown below is a typical proportional integral derivative PID controller with gains set by the Mint keywords KPROP KINT and KDERIV The position demand from the profiler is compared with the measured position and the error is fed into the PID control calculation The resulting value forms the basic speed or torque demand depending on the CONFIG setting The effect of the integral term can be changed using the KINTLIMIT and KINTMODE keywords KINTLIMIT sets the maximum value of the effect of integral action as a percentage of the full scale demand KINTMODE can be used to specify the circumstances under which the integral term is applied As an alternative to the derivative term a velocity feedback term is available by setting keyword KVEL To improve the tracking performance of
49. ate interval 7 1 9 Serial RS232 interface X6 All models All models RS232 non isolated CTS RTS Baud 9600 19200 38400 57600 115200 7 1 10 Serial RS485 interface X6 All models 7 1 11 Encoder output simulated X7 All models All models Resolution with resolver input on X8 Simulated 512 1024 2048 4096 All models Only available if resolver input is set to simulate a 4096ppr source See section 4 4 1 with encoder input on X8 Output is a copy of the input on X8 7 6 Specifications MN1902 7 1 12 Resolver feedback option X8 Catalog numbers FDHxxxxxx Rxxxx All models FPH xxxxxx Rxxxx Resolution set automatically by software Resolver winding ratio Pf OK Typical accuracy using Baldor BSM counts 11 series resolver motor with input set to simulate 4096 ppr Maximum recommended cable length 30 5m 100ft 7 1 13 Encoder feedback option X8 Catalog numbers FDHxxxxxx Exxxx All models FPHxxxxxx Exxxx Encoder input it A B Differential Z index Hall inputs E Single ended 5V logic Output power supply to encoder HEN 5V 200mA max Maximum recommended cable length 30 5m 100ft 7 1 14 Master auxiliary encoder input X9 All models Unit All models Operating mode a A B quadrature Sampling interval ms Software selectable 1 2 Output power supply to encoder HE 5V 100mA max MN1902 Specifications 7 7 7 1 15 Pulse and direction in
50. before operation can continue See section 3 8 Click the Drive enable button in WorkBench v5 Crash The drive enable input or the Enable DIP switch have become inactive whilst the drive was in the enable state or the drive was enabled whilst they were inactive bit 13 in AXISEERROR will be set The drive can be programmed to ignore this state using the Mint keyword DRIVEENABLEINPUTMODE see the Parameters tool Suspend The SUSPEND command has been issued and is active Motion will be ramped to zero demand whilst active Speed demand The drive is under speed control See the Mint keywords SPEEDREF SPEEDREFSOURCE and related commands Reverse software or hardware limit A reverse software limit has been activated See AXISERROR and or AXISSTATUS to determine which applies Forward software or hardware limit A forward software limit has been activated See AXISERROR and or AXISSTATUS to determine which applies Firmware being updated horizontal bars appear sequentially New firmware is being downloaded to the drive Initialization error An initialization error has occurred at power on See the Error Log or INITERROR topics in the help file Initialization errors should not normally occur ok User defined symbols can be made to appear using the Mint keywords LED and LEDDISPLAY DB On Regeneration LED oo The front panel DB On LED indicates regeneration activity Power is being dissipated into the regeneration resistor
51. central earthing grounding point star point Keep the power wiring motor and power cable and control wiring separated If these wires must Cross be sure they cross at 90 degrees to minimize noise due to induction The shield connections of the signal and power cables should be connected to the shield rails or clamps The shield rails or clamps should be conductive clamps fastened to the cabinet The cable to the regeneration resistor must be shielded The shield must be connected to earth ground at both ends The location of the AC filter has to be situated close to the drive so the AC power wires are as short as possible Wires inside the enclosure should be placed as close as possible to conducting metal cabinet walls and plates It is advised to terminate unused wires to chassis ground To reduce earth ground current use the largest suitable wire available for earth ground connections Earthing grounding in general describes all metal parts which can be connected to a protective conductor e g housing of cabinet motor housing etc to a central earth ground point star point This central earth ground point star point is then connected to the main plant or building earth ground Orrun as twisted pair at minimum MN1902 CE Guidelines C 3 C 1 5 Wiring of shielded screened cables Remove the outer insulation to Ju O expose the overall shield nductiv Clamp should provide 360 a e V
52. creen connections All connections between components must use shielded cables The cable shields must be connected to the enclosure Use conductive clamps to ensure good earth ground connection With this technique a good earth ground shield can be achieved EMC filters The filter should be mounted next to the FlexDrive The connections between the FlexDrive and the filter should use shielded screened cables The cable shields should be connected to shield clamps at both ends An exception to this is the analog command signal Earthing grounding For safety reasons VDE0160 all Baldor components must be connected to earth ground with a separate wire Earth ground connections must be made from the central earth ground star point to the regeneration resistor enclosure and from the central earth ground star point to the power supply C 2 CE Guidelines MN1902 C 1 4 EMC installation suggestions To ensure electromagnetic compatibility EMC the following installation points should be considered to help reduce interference Earthing grounding of all system elements to a central earth ground point star point Shielding of all cables and signal wires Filtering of power lines A proper enclosure should have the following characteristics All metal conducting parts of the enclosure must be electrically connected to the back plane These connections should be made with an earthing grounding strap from each element to a
53. demarks 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 MN1902 General Informa
54. dor motor power cable is used A description of a Baldor motor power cable catalog number is shown here using the example number CBL030SP MHCE Fe Tr 030 indicates the Tengin misserampe 30 mem Varouslengtheareavalable SP Tre cabe isa Servo motor Powercatle w Curentraing OA REA CI Motor power cables are also available without connectors in which case the final letters HCE in the example above are not used A 2 Accessories MN1902 A 1 4 Feedback cables This table lists part numbers of Baldor resolver feedback cables for use with the FlexDrive Feedback Cable assembly type description Feedback Cable Assembly Threaded connector Standard Metric Style Feedback Cable Assembly CE Style Threaded Connector Resolver Feedback Cable No Connector Feedback Cable Assembly Threaded connector Standard Metric Style Feedback Cable Assembly CE Style Threaded Connector Encoder Hall Feedback Cable No Connector Baldor catalog number CBLO30SF ALM CBLO61SF ALM CBLO91SF ALM CBL152SF ALM CBL229SF ALM CBL305SF ALM CBLO15SF ALCE CBLO30SF ALCE CBLO61SF ALCE CBL091SF ALCE CBL152SF ALCE CBL229SF ALCE CBL305SF ALCE CBLO30SF A CBLO61SF A CBLO91SF A CBL152SF A CBL213SF A CBL305SF A CBLO15SF KPM CBLO30SF KPM CBLO61SF KPM CBLO91SF KPM CBL152SF KPM CBL229SF KPM CBL305SF KPM CBLO15SF KPCE CBLO30SF KPCE CBLO61SF KPCE CBLO91SF KPCE CBL152SF KP
55. e node number during the scan process and then uses it to direct commands to the FlexDrive If the node number is changed from the Command window subsequent commands sent by WorkBench v5 will have no effect To rescan for the FlexDrive you will need to start a new project in WorkBench v5 Avoid accidentally setting switches 1 4 to the On position at the same time In combination with DIP Switch 8 this will reset the FlexDrive to its factory defaults See section 3 9 6 Switch 6 Hold Switch 6 stops the motor In the Off position normal operation is allowed When switched to the On position the motor decelerates to rest and maintains position The switch position is sampled every 100ms Switch 7 Offset tuning Switch 7 is used to start offset tuning on analog command input AINO The purpose of offset tuning is to remove DC offset voltages on analog input 0 the command reference input to achieve a stationary motor shaft with OVDC at the input Confirm that the device supplying the AINO command input is set to its intended zero output setting nominally OVDC before starting offset tuning When switch 7 is in the On position offset tuning will start the next time Enable switch 8 is changed from On to Off 1 2 SWI 3 Wait for 1 second 4 MS de for offset tuning to d i V4 be completed 2 r v 33 ae 3 E 3 4 ae 4 5 me 5 es 6 6 6 7 7 On m 7 Off 74 7 8 8 On Off L WM I s e s 9 o a
56. e used to check for a number of pre defined conditions and then perform actions if they become true Spy window Allows you to monitor all the important parameters for the axis and shows the state of digital inputs and outputs limit switches and comms locations Flex Drive only Edit amp Debug also provides the environment for programming the Flex Drive Multiple editing windows can be opened for entering program code Presets Tool Allows you to setup preset moves and the way in which they should be triggered An interactive table of the moves is used to make changes Homing Tool Allows you to setup homing moves Remember for help on each tool just press F1 to display the help file then navigate to the WorkBench v5 book Inside this is the Toolbox book 5 10 Operation MN1902 6 1 6 1 1 6 1 2 6 1 3 Troubleshooting Introduction This section explains common problems that may be encountered together with possible solutions Problem diagnosis If you have followed all the instructions in this manual in sequence you should have few problems installing the FlexDrive If you do have a problem read this section first In WorkBench v5 use the Error Log tool to view recent errors and then check the help file If you cannot solve the problem or the problem persists the SupportMe feature can be used SupportMe feature The SupportMe feature on the Help menu can be used to e mail information to
57. e values This is achieved by specifying a rise time and fall time see the WorkBench v5 Parameters tool The torque demand signal is fed into the torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current measured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Torque profiler Torque demand Torque Torque Power stage reference controller motor Measured current High speed torque reference Figure 41 Control structure in Current Torque control mode B 2 Control System MN1902 B 1 2 Velocity Speed control Setting the control mode to Velocity Control configures the FlexDrive or Flex Drive as a speed amplifier as shown in Figure 42 Here a speed reference is obtained from a specified source Mint host command profiled High speed analog input not profiled Analog input profiled Fieldbus profiled The source provides a signal that can either be fed directly into the Speed controller only when using the high speed analog input source or through a profiler The high speed reference source is ideal for connecting to a motion controller e g NextMove PCI that will have already profiled the signal and will provide optimum loop closure The profiler generates a speed demand signal that sm
58. ector X8 Twisted pair cables must be used for the complementary signal pairs e g CHA and CHA The overall cable shield screen must be connected to the metallic shell of the D type connector X y x 18 o Q O D o uu Encoder Feedback Hall Feedback Pin Encoderfunction ooo 4 Hall U 5 Hall U MC 8 10 Hall V 7 E Farw Hal vV o V A UVW encoder input non isolated Pin 11 provides 5V for encoders requiring power 200mA max Twisted pairs e s 1 CHA L SA a n a e 2 CHB CE CIR ov e Q A 3 CHZ INDEX d CX 1LD s cuz INDEX A A 11 5V Connect internal CX HU loe a A ON E shields to DGND L po me A A Hall U i xc DE E meu Q A Hall W p CX IM y TT Hall W A A Hall V im el i NC NS Connect overall shield A to connector backshells Figure 12 Encoder cable connections rotary motors 3 22 Basic Installation MN1902 3 7 2 1 Encoder cable pin configuration rotary motors Figure 13 shows the pin configuration for a typical Baldor encoder feedback cable part number CBLO30SF KCE Slanaliname FlexDrive Motor cable Baldor encoder cable 9 X8 p pin internal wire colors CHA 9 1 a ERR INN ER Eco e 8 Pme 7 Smew ree Hall U Hall V Hall V Hall W Pins 9 and 16 are not connected Motor encod
59. ed near the top of an enclosure to maximize heat dissipation When the motor regenerates the yellow DB On LED on the front panel of the FlexDrive will illuminate If required by the application additional external resistors connected to R1 and R2 will be connected in parallel with the internal resistor Controlling regeneration Some regeneration resistor assemblies include an overload switch to indicate when too much power is being dissipated by the resistor This switch can be wired to a digital input on the FlexDrive Using the WorkBench v5 Digital I O tool the input can be configured to be the brake trip input This allows the FlexDrive to respond to resistor overload conditions The Mint keyword DBEXTTRIPINPUT can also be used to configure a digital input for this purpose On three phase FlexDrive models the operation of the regeneration resistor can be controlled by further Mint keywords These also begin with the letters DB for example DBEXTPEAKPOWER See the Mint help file for details 3 18 Basic Installation MN1902 3 7 Feedback connections Two feedback options are available for use with linear and rotary motors commutating encoder or resolver Confirm the catalog number of your FlexDrive see section 2 2 1 to ensure you are wiring the correct feedback device There are some important considerations when wiring the feedback device The feedback device wiring must be separated from power w
60. educe the harshness of the deceleration rate then a regeneration resistor should be used To help you use WorkBench v5 capture facility to monitor the DC Bus level during moves Integrated Power Module IPM trip The unit s powerbase has been overloaded This should not happen in normal use if limits have been configured correctly See the Mint keyword CURRENTLIMIT and related commands Current trip Instantaneous over current trip One or more of the 3 motor phases has exceeded 300 of Drive Rated Current Under volts The DC Bus voltage has dropped below the powerbase undervolts level see DRIVEBUSUNDERVOLTS This error will only be generated if the drive is in the enabled state As with the overvolts error check the input voltage being fed into the system The error could also occur during high acceleration profiles Feedback trip Can be enabled disabled using FEEDBACKFAULTENABLE Five consecutive errors or five errors in any 500 servo tick period will cause the drive to trip This error indicates loss of encoder resolver feedback and may indicate that the feedback cable has become detached or one of the signals has broken Check the wiring in the Feedback cable check for noise immunity check the feedback device fitted to the motor if possible Motor or Drive trip The motor 12T or the drive I T current protection algorithms have exceeded their limit and tripped the drive disabled it Check DRIVEERROR or the Error Log to determine
61. eee eee aes 4 16 4 5 Connection summary minimum system wiring 000 eee eee eee eee 4 17 4 5 1 Connection summary shield clamps ssseese ee 4 18 4 6 Option Connectors oes yr raras pla eie ced bra 4 18 SEES DIM CERTI ET 5 1 51 Introduction ooo UL aa aaia AY DES bb e oro bb b eds 5 1 5 1 1 Connecting the FlexDrive to the PC 2 0 nn ee 5 1 5 1 2 Installing the software 6 00 ccc a 5 1 5 1 3 Starting the FlexDrive 2 0 nn 5 2 5 1 4 Preliminary checks sssssssssssssses es hn 5 2 5 15 Power ON Checks 2053 05 A A a RF interes 5 2 5 1 6 Offset tuning 2 ote tL tke we eas a cece mte yt ale RE ie E P e edes 5 3 ii Contents MN1902 5 2 WorkBench v5 aea RCM WEE Ue TM e IER st x 5 4 52 1 H elp fil ses scares hee ptt ede AN ATA tesa d a e edem aec aos 5 4 5 2 2 Starting WorkBench V5 0 0 eet tenn nee ene 5 5 5 2 3 Commissioning Wizard censeo a iioii eurer ee ee ee 5 6 5 2 4 Using the Commissioning Wizard 0 cece tenets 5 6 5 2 5 Completing the Commissioning Wizard ies 5 7 537 Further configuration ui ea 5 7 roe Fe IM ea 6 1 01 tGOL i a ne ERIS obe 5 7 5 3 2 Parameters tO0lls ose v O a eer ee Rn dst 5 9 9 3 3 Digital O to0l ca bs sse es 5 10 5 3 4 Other tools and windows sess HH 5 10 b Troubleshooting cates acsi cene Ses paca acta satan denna Dec pr d 6 1 0 1 Introduction tier ee e Eos a Met
62. enable the FlexDrive and allow motion three actions are necessary m Acustomer supplied externally generated 24VDC supply must be connected between pins 7 and 9 m The drive enable DIP switch switch 8 must be in the On position m A drive enable command must be received These actions are explained in the following sections 3 8 4 Drive enable X3 The wiring to the drive enable input can be connected in one of two ways This has an effect on the sense of the digital inputs DINO to DIN7 Either method provides a suitable drive enable input Active high To cause the digital inputs to be active high active when a voltage of 24VDC is applied to them connect 24VDC to pin 9 and OV to pin 7 CREF Active low To cause the digital inputs to be active low active when grounded connect 24VDC to pin7 CREF and OV to pin 9 The drive enable connection can be wired directly or through an intermediate switch If a switch is used it should always be used to switch the signal to pin 9 with the signal to pin 7 CREF being hard wired The sense of the digital inputs can also be configured in WorkBench v5 using the Digital inputs tab of the Digital I O tool Alternatively the Mint INPUTACTIVELEVEL keyword can be used to select the sense of all the digital inputs except drive enable The state of the drive enable input is displayed in the WorkBench v5 Spy window It can also be checked but not set using the Mint keyword DRIVEENAB
63. enter everything if you go back to previous screens 5 6 Operation MN1902 5 2 5 5 3 Completing the Commissioning Wizard The final screen Tuning has a Finish button that is grayed out until the tuning tests have been completed When the tuning tests have finished click Finish to complete the Commissioning Wizard The parameters that have been calculated by the Commissioning Wizard do not need to be downloaded to the FlexDrive They are already in the FlexDrive and will not be lost even when it is powered down Further configuration WorkBench v5 provides a number of tools each of which has an icon on the left of the screen Click once on an icon to select the tool Three of the main tools used for tuning and configuring the FlexDrive are described in the following sections Every tool is explained fully in the help file Press F1 to display the help file then navigate to the WorkBench v5 book Inside this is the Toolbox book 5 3 1 Fine tuning tool The Commissioning Wizard calculates many parameters that allow the FlexDrive to provide basic control of the motor These parameters may need to be fine tuned to provide the exact response that you require The Fine tuning screen allows you to do this 1 Click the Fine tuning icon in the Toolbox on the left of the screen File Edit view T NON Bu Z The Fine tuning window is displayed at the right of the screen This already shows some of the p
64. er connector Cable connector end view male female Figure 13 Baldor rotary motor encoder cable pin configuration The maximum recommended cable length is 30 5m 100ft MN1902 Basic Installation 3 23 3 7 2 2 Encoder cable connections linear motors Twisted pairs te J y 6 CHA n A 2 CHB Eidos A 7 CHB Feedback a a 3 CHZ INDEX RHN 8 CHz INDEX A 11 5V UL XxX Lp toy 13 DGND Connect internal shields to DGND e l O O Hall U ds Pal Leave pins Feedback Hall W 515 la 15 Hall W unconnected Hall V Hall V NC Ls NS Connect overall shield A to connector backshells Figure 14 Encoder cable connections linear motors 3 7 2 3 Encoder cable pin configuration linear motors Linear motors use two separate cables encoder and Hall The cores of these two cables will need to be wired to the appropriate pins of the 15 pin D type mating connector supplied FlexDrive Signal name X8 pin Encoder cable internal wire colors CHA CHA CHB CHB 4 Please refer to MN1800 Linear Motors Installation amp Operating Manual for details Hall U Baldor Hall cable internal wire colors Hall V Raw prance 3 24 Basic Installation MN1902 3 8 Drive enable X3 Location Connector X3 pins 7 amp 9 Mating connector Phoenix MINI COMBICON MC 1 5 20 ST 3 5 Name Dive enable O Input voltage 24VDC 420 To
65. essary to re tune your motor and drive 1 Remove i 3 Reapply 4 FlexDrive will be power power reset to its preset factory settings SS a aad Lj Ld ae Un Us ue Ue ue Figure 17 Resetting the FlexDrive to its factory default settings The Mint keyword FACTORYDEFAULTS can also be used to reset the FlexDrive to its factory defaults However it will not reset the node number or serial communications baud rate See the Mint help file for details MN1902 Basic Installation 3 29 3 9 7 Preventing a program running at startup Flex Drive only If switches 6 and 9 are set to On and switch 8 is set to Off any program already in the Flex Drive that contains an Auto command will be prevented from running automatically at startup 1 Remove 2 FL SWI 3 Reapply power Mint program power ilii with Auto command will not run E 1 3 B 2 B 3 Gm 4 am 5 6 T 6 On L 7 Off a d 8 9 31 a On EN 10 On Figure 18 Preventing the Auto command from running a stored Mint program This completes the basic installation You should read the following sections in sequence before attempting to start the FlexDrive 3 30 Basic Installation MN1902 4 1 4 2 Input Output Introduction This section describes the various digital and analog input and output capabilities of the FlexDrive with descriptions of each of the connectors on the front panel The following conventions wil
66. exDrive with an equivalent resolution of 4096 pulses per revolution ppr although this can be reconfigured in the WorkBench v5 Commissioning Wizard to provide 1024 ppr The FlexDrive provides an input accuracy of 3 counts When used with a typical Baldor BSM series resolver motor the combined accuracy is 11 counts calculated with the input equivalent resolution set to the factory preset value of 4096 ppr Baldor motor R2 s2 resolver connector X8 Twisted pairs 5 3 SIN R1 S4 6 8 SIN bs TA an 2 po 4 7 COS 1 1 REF 2 6 REF O 5 AGND Connect internal shields to AGND La So Connect overall shield P a we to connector backshell Figure 10 Resolver cable connections 3 20 Basic Installation MN1902 3 7 1 1 Resolver cable pin configuration Figure 11 shows the pin configuration for a typical Baldor resolver feedback cable part number CBLO30SF ALCE vell Signal name FlexDrive Motor cable Baldor resolver cable X8 pin pin internal wire colors Pins 7 12 ot ssa dd 9 o tb n o 90 Motor resolver connector Cable connector end view male female Figure 11 Baldor motor resolver cable pin configuration The maximum recommended cable length is 30 5m 100ft MN1902 Basic Installation 3 21 3 7 2 Encoder option X8 The encoder connections ABZ channels and Hall signals are made using the 15 pin D type female conn
67. folder is C Program Files Baldor MintMT although this can be changed during setup MN1902 Operation 5 1 5 1 3 Starting the FlexDrive If you have followed the instructions in the previous sections you should now have connected all the power sources your choice of inputs and outputs and the serial cable linking the PC with the FlexDrive 5 1 4 Preliminary checks Before you apply power for the first time it is very important to verify the following Disconnect the load from the motor until instructed to apply a load If this cannot be done disconnect the motor wires at connector X1 X1A Verify that the front panel DIP switches 1 9 are in the Off position It is recommended that you use RS232 communications to begin with in which case DIP switch 10 must also be in the Off position However if you are using RS485 RS422 communication then DIP Switch 10 must be in the On position Verify that the AC line voltage matches the specification of the FlexDrive Inspect all power connections for accuracy workmanship and tightness Verify that all wiring conforms to applicable codes Verify that the FlexDrive and motor are properly earthed grounded Check all signal wiring for accuracy 5 1 5 Power on checks If at any time the Status display shows a flashing symbol or E this indicates that the drive has detected a fault see section 6 1 Turn on the 24VDC supply only for FlexDrive with catalog numbers FDH
68. help file Remember to click the tab s Apply button to send the changes to the FlexDrive MN1902 Operation 5 9 5 3 3 Digital I O tool The Digital I O tool allows you to define how each digital input and output will be triggered and if it is to be assigned to a special function for example the forward limit or stop input 1 Click the Digital I O icon in the Toolbox on the left of the Screen The main area of the WorkBench v5 window displays the Digital I O screen You can use a drag and drop method to X assign triggering options to inputs and outputs and assign them to special purpose functions If you need help just press F1 to display the help file Digital 1 0 Remember to click the Apply button to send the changes to the FlexDrive 5 3 4 Other tools and windows Each tool and window is explained fully in the help file so is not described here in detail Error Log Tool Displays a list showing when errors occurred and when they were cleared Scope Tool Displays the capture screen This screen is also shown when the Fine tuning tool is selected Jog Tool Allows you to perform jog moves useful for testing purposes Edit amp Debug Tool This tool provides a work area including the Command window and Output window The Command window can be used to send immediate Mint commands to both the FlexDrive and Flex Drive PLC Task Tool Allows you to setup the PLC Task a special task that can b
69. ile the FlexDrive is supplying voltage and current to the motor the FlexDrive may be damaged Incorrect installation or failure of the M Contactor or its wiring may result in damage to the FlexDrive Ensure that shielding of the motor cable is continued on both sides of the contactor 3 5 2 Motor power cable pin configuration Baldor BSM rotary motors Figure 8 shows the pin configuration for a typical Baldor motor cable part number CBLO30SP MHCE Meter Toto ae ed o o 9 o oO o Motor power connector Cable connector end view male female Note Not all motors are fitted with a brake so pins C and D might not be connected Figure 8 Baldor motor power cable pin configuration MN1902 Basic Installation 3 15 3 5 3 Motor cable pin configuration Baldor linear motors The following table shows the pin colors used in a typical Baldor linear motor cable set part number AY1763A00 oto Bak O DINA RM AN MawW ano S C emase B Hall cable wire color Raro VI IE Fals Hall DC 3 16 Basic Installation MN1902 3 5 4 Thermal switch connection You might wish to wire the motor s thermal switch contacts normally open via a relay to a digital input on connector X3 see section 4 3 1 Using the WorkBench v5 Digital I O tool the input can be configured to be the motor trip input This allows the FlexDrive to respond to motor over temperature conditions The
70. input is set to its intended zero output setting nominally OVDC o 1 gems 2 ERES 3 Wait for 1 second 4 MUS 13 ye for offset tuning to de V4 be completed 2 3 we 4 De 51 L 6 E 7 7 On a off 7 8 8 On off Te 8 9 ur 1 ue Figure 35 Offset tuning using switch 7 and 8 MN1902 Operation 5 3 5 2 5 2 1 WorkBench v5 WorkBench v5 is a fully featured application for programming Flex Drive only and controlling the FlexDrive The main WorkBench v5 window contains a menu system the Toolbox and other toolbars Many functions can be accessed from the menu or by clicking a button use whichever you prefer Most buttons include a tool tip hold the mouse pointer over the button don t click and its description will appear Help file WorkBench v5 includes a comprehensive help file that contains information about every Mint keyword how to use WorkBench v5 and background information on motion control topics The help file can be displayed at any time by pressing F1 On the left of the help window the Contents tab shows the tree structure of the help file Each book contains a number of topics 2 The Index tab provides an alphabetic list of all topics in the file and allows you to search for them by name The Search tab allows you to search for words or phrases appearing anywhere in the help file Many words and phrases are underlined and highlighted with a color normally blue to show tha
71. internal resistor If an internal resistor is not present a regeneration resistor should be installed to dissipate energy during braking to prevent an over voltage error occurring FlexDrive 115VAC 10 models 230VAC 10 models 230 460VAC 3 models exDrive current Baldor Power Baldor Power Baldor Power rating catalog rating catalog rating catalog rating number W number W number W Internal Internal Internal REED REID RGS 5A RG27A RG27A E Ren Note Where the required dissipation could exceed 320W resistor RG23 rated at 640W can be used instead i T FEED Jeon CIA 3 9 O on a L RSEN gt O o Pe 80 EE os M4 L 65 2 6 337 13 2 for 320 640 watt Dimensions mm inches Figure 40 Regeneration resistor dimensions all types IN 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 Ensure that the resistor has clearance of at least 50mm 2 in above and below and 26mm 1 in left and right A 8 Accessories MN1902 B 1 Control System Introduction The FlexDrive can be configured for three basic control modes m Current Torque control m Velocity Speed control m Po
72. iring m Where feedback device wiring runs parallel to power cables they must be separated by at least 76mm 3 in m Feedback device wiring must cross power wires at right angles only To prevent contact with other conductors or earths grounds unearthed ungrounded ends of shields must be insulated m Some larger D type connector shells may be obstructed by neighboring connector X3 m Linear motors use two separate cables encoder and Hall The cores of these two cables will need to be wired to the appropriate pins of the 15 pin D type mating connector supplied An encoder output signal is available on connector X7 for supplying other equipment FlexDrive 7 models with the resolver option provide a simulated encoder output while the encoder based FlexDrive duplicates the encoder signals entering X8 See section 4 4 1 for details MN1902 Basic Installation 3 19 3 7 1 Resolver option X8 The resolver connections are made using the 9 pin D type male connector X8 Twisted pair cables must be used for the complementary signal pairs e g SIN and SIN The overall cable shield screen must be connected to the metallic shell of the D type connector C Pm Rememdon i 5 Analog Ground Analog Ground PRE 898 essem Resolver input with 14 bit resolution The resolver input is used to create an encoder signal inside the FlexDrive This provides the Fl
73. is equipment depends upon its use in the appropriate environment The following points must be considered m The FlexDrive must be installed indoors permanently fixed and located so that it can only be accessed by service personnel using tools m The maximum suggested operating altitude is 1000m 3300ft Above 1000m 3300ft de rate output current 1 196 per 100m 330ft m The FlexDrive must operate in an ambient temperature of 0 C to 40 C 32 F to 104 F De rate output current 2 5 per 1 C 1 8 F from 40 C 104 F to 50 C 122 F maximum m The FlexDrive must operate in relative humidity levels of less than 90 for temperatures up to 31 C 87 F decreasing linearly to 50 relative humidity at 40 C 104 F non condensing m The FlexDrive must be installed where the pollution degree according to IEC664 shall not exceed 2 m The external customer supplied 24VDC for the logic supply must be installed so that the 24VDC supplied to the unit is isolated from the AC supply using double or reinforced insulation The inputs and outputs of the control circuit must be limited to Safety Extra Low Voltage circuits Both the AC supply and the external 24VDC supply must be fused The atmosphere must not contain flammable gases or vapors There must not be abnormal levels of nuclear radiation or X rays The FlexDrive must be secured by the slots in the flange with the protective earth ground stud bonded to a safety earth gr
74. is feature Connecting 24V to a model that does not require an external 24V supply FDHxxxxx xxx0 and FPHxxxxx xxx0 could damage the unit Customer supplied 24V filter 24VDC fused optional 24V GND i tt xs To earth ground outer shield use 360 clamps connected to Incoming safety e ackplane earth ground PE STAR POINT omma Re ome Rue m mE ees Single phase model shown for illustration purposes Figure 6 Customer supplied 24V supply connections MN1902 Basic Installation 3 13 3 5 Motor connections The motor can be connected directly to the FlexDrive or through a motor contactor M Contactor Partnumber FDH1A FPH1A FDH2A FPH2A FDH4A FPH4A Nominal output voltage 160VDC 320VDC 565 650V Output voltage range 135 176VDC 306 350VDC 254 746VDC i PAR 1 TT ys Ld ER AU ME my be i Unshielded lengths should 1 be as short as possible 1 _ E zT EN DET 1 1 1 T 1 n i 1 1 1 D 1 I 1 1 1 NN ro ZT 1 1 i 1 1 1 l 1 1 1 i 1 1 1 1 D 1 1 i T i pa na See Thermal i INN T S i section Switch AN a m 3 5 4 Brake i Li v P E Customer supplied i brake control circuit if present To earth ground outer shields use 360 clamps connected to backplane Figure 7 Motor connections A CAUTION Do not connect supply power to the FlexDrive UVW outputs The FlexDrive
75. ition capture input The position of the axis is captured in real time and can be read using the Mint keyword FASTPOS Master or auxiliary encoder input capture read using the Mint keyword FASTAUXENCODER DIN5 only The maximum latency to read the fast position is approximately 1us The fast interrupt will be latched on a pulse width of about 30us although a width of 100us is recommended to ensure capture To prevent subsequent inputs causing the captured value to be overwritten the interrupt is latched in software It is necessary to clear the latch before subsequent interrupts can be detected See the Mint help file Both inputs are fitted with Schmitt trigger devices Note The fast inputs are particularly sensitive to noise so inputs must use shielded twisted pair cable The inputs are not opto isolated Do not connect mechanical switches relay contacts or other sources liable to signal bounce directly to the fast inputs This could cause unwanted multiple triggering DINx Pins 14 15 CREF Pin 7 FlexDrive Vee 10k 4k7 1k to CPU 33pF ha HCPL2231 alls DGND Active high DINx 24VDC 420 Active low DINx 0V CREF 0V CREF 24VDC 420 Figure 24 X3 pulse and direction fast digital input circuit 4 8 Input Output MN1902 4 3 5 Digital outputs X3 Connector
76. l a AC power L N PE Motor power UVW motor Shield earth ground clamp attached to enclosure backplane L L N Filter N If the filter has no output earth ground terminal earth wire may be connected directly to the star point in Host PC Diagram shows AC power cable shield clamped to FlexDrive case Motor power and regen resistor cables should also be clamped to FlexDrive case if possible See section 4 5 1 LO Shield earth ground clamps see section 4 5 1 Customer supplied 24V To regen resistor Dynamic brake Motor feedback resistor Motor Flex Drive ov BALDOR Model shown FDH1A05TR RN23 Status Master Enc X9 Serial communication Drive enable switch Command input 24V OV This model requires an external regeneration resistor and customer supplied 24V supply see sections 3 6 and 3 4 7 Some models contain an internal 24V supply and or an internal regeneration Command input may be differential shown or single ended See section 4 2 1 Motor represents a typical Baldor BSM motor Linear motors may also be controlled by FlexDrive Figure 33 Example minimum system wiring MN1902 Input Output 4 17 4 5 1 Connection summary shield clamps Ideally shield clamps should be attached to the top surface of
77. l be used to refer to the inputs and outputs Ou rk Input Output DIN Digital Input DOUT Digital Output AIN Cr Is Analog Input AOUT Analog Output CH erre Encoder channel Analog I O The FlexDrive provides as standard m 1 analog input on the connector block X3 command input The analog input is not optically isolated from internal power rails so care must be taken to avoid earth ground loops and similar associated problems The input buffers provide low pass filtering of the applied voltage To minimize the effects of noise the analog input signal should be connected to the system using individual shielded screened cable a twisted pair cable in the case of differential operation with an overall shield The overall shield should then be connected to the chassis at one end only No other connection should be made to the shield If the input is unused then it is advisable to connect it to the AGND pin Do not leave the input unconnected floating MN1902 Input Output 4 1 4 2 4 Analog input X3 command Connector X3 pins 1 3 Location Mating connector Phoenix MINI COMBICON MCVR 1 5 ST Description Single ended or differential input Common mode voltage range 10VDC Resolution 14 bit with sign accuracy 4 9mV Common mode rejection 40dB Input impedance gt 5kQ Sampling interval 500us Software Mint programs 125us High speed command reference signal Analog in
78. l compensates for the voltage drop due to stator resistance set using the MOTORRS keyword and stator leakage inductance set using the MOTORLS keyword It also compensates for the back EMF of the motor with the voltage constant of the motor being set using the MOTORFLUX keyword Values for MOTORRS MOTORLS and MOTORFLUX are set automatically by the Commissioning Wizard The torque control calculation is performed every 125us The feedback device e g an encoder or resolver is used to determine motor position and speed Motor speed can be filtered to reduce measurement noise if necessary The time constant of this filter is specified using the keyword KVTIME By default the filter is turned off KVTIME 0 Note that introducing a filter on measured speed tends to reduce the stability of the speed controller This can make the tuning of the speed controller gains difficult if large values of KVTIME are used Proportional gain term KIPROP Integral gain term Feedback device e g encoder Motor resolver Power PWM value Stage Current demand Torque demand Internal scaling MOTORRS MOTORLS MOTORFLUX Voltage model Measured current Feedback interface Filter KVTIME Measured speed VEL Measured position POS Figure 47 Torque control system B 8 Control System MN1902 CE Guidelines C 1 C 1 1 Outline This section provides general informati
79. n is selected in WorkBench v5 check that the correct COM port is selected If the Search up to Nodexx option is selected in WorkBench v5 check that the FlexDrive node number is not higher than this value Do you have multiple nodes on the bus If so they must all be set to the same Baud rate WorkBench v5 scans through all the node ld s at different Baud rates When it finds a node it will only continue to scan for other nodes at the same Baud rate MN1902 Troubleshooting 6 5 6 2 4 Poweron The Status display is showing a The FlexDrive has detected a motion error Use the Error Log tool flashing symbol with a static to view a list of recent errors or click the Error button on the motion decimal point toolbar to view a description of the error Alternatively type any or all of these commands in the Command window PRINT AXISERROR PRINT DRIVEERROR PRINT MISCERROR PRINT INITERROR Click the Clear Errors button on the motion toolbar 6 2 5 Tuning Cannot enable the FlexDrive Check the drive enable input on connector X3 pins 7 and 9 is because AXISERROR has bit 13 connected and powered correctly Check that DIP switch 8 set enable is set to the On position When the FlexDrive is enabled Check that the current loop has been tuned the motor is unstable Check that the current loop was tuned with the correct motor data If the motor is still unstable try reducing the Speed Proportional gain KVPRO
80. nly These drives have a pre charge circuit which must activate after power up before the drive can be enabled If the drive is enabled prior to this then the error occurs The error could also indicate the loss of one or more of the input phases Cam A Cam profile is being profiled See the Mint keyword CAM General error See AXISERROR and DRIVEERROR The motion toolbar displays the status of AXISERROR which is a bit pattern of all latched errors See also the Error Log topics in the help file Error input The ERRORINPUT has been activated and generated an error Flying shear A flying shear is being profiled See the Mint keyword FLY Position or velocity following error A following error has occurred See the Mint keyword AXISERROR and associated keywords Following errors could be caused by a badly tuned drive motor At higher acceleration and deceleration rates the following error will typically be greater Ensure that the drive motor is adequately tuned to cope with these acceleration rates The following error limit can be adjusted to suite your application see Mint keywords FOLERRORFATAL and VELFATAL Following error could also be the cause of encoder resolver loss see also Mint keyword FEEDBACKFAULTENABLE Follow mode The drive is in Follow mode See the Mint keyword FOLLOW Hold The Hold DIP switch is active see section 3 8 or the PLC Task has requested a Hold state Motion will be ramped to zero demand and will then hold
81. ol Flex Drive only Setting the control mode to Position Control configures the Flex Drive as a full positioning system as shown in Figure 44 Here the Flex Drive can be used to command many different position profiles Preset moves Absolute or relative moves Incremental absolute or relative moves Jog control Following Gearing Homing The profiler generates a position demand signal that smoothly changes between successive targets The profile also generates corresponding speed and acceleration demand signals The position and speed demand signals are fed into a position controller and used together with the position measured from the feedback device to generate a suitable speed demand signal If the position controller is tuned correctly the measured position will accurately track the position demand The speed demand signal from the position controller is fed into the speed controller and used together with the speed measured from the feedback device to generate a torque demand signal If the speed controller is tuned correctly the measured speed will accurately track the speed demand To improve the tracking performance of the speed controller the profiler acceleration demand is fed in at this point Finally the torque demand signal is fed into a torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current me
82. on regarding recommended methods of installation for CE compliance It is not intended as an exhaustive guide to good practice and wiring techniques It is assumed that the installer of the FlexDrive is sufficiently qualified to perform the task and is aware of local regulations and requirements Baldor products that meet the EMC directive requirements are indicated with a CE mark A duly signed CE declaration of conformity is available from Baldor EMC Conformity and CE marking The information contained herein is for your guidance only and does not guarantee that the installation will meet the requirements of the council directive 89 336 EEC The purpose of the EEC directives is to state a minimum technical requirement common to all the member states within the European Union In turn these minimum technical requirements are intended to enhance the levels of safety both directly and indirectly Council directive 89 336 EEC relating to Electro Magnetic Compliance EMC indicates that it is the responsibility of the system integrator to ensure that the entire system complies with all relative directives at the time of installing into service Motors and controls are used as components of a system per the EMC directive Hence all components installation of the components interconnection between components and shielding and earthing grounding of the system as a whole determines EMC compliance The CE mark informs the purchaser that the
83. ontrol system operation 0 0 cc rr B 6 B 2 1 Position controllet el ii ei B 6 B 2 2 gt Speed controller i v e e ee oad B 7 B 2 3 Torque controller and feedback 0 ccc ccc tenet e B 8 CG CE GuldelineS cuneate cet abre teak eta xb dudo C 1 Cid enn wer C 1 C 1 1 EMC Conformity and CE marking ssessseeeee I C 1 C 1 2 Use of CE compliant components sssssssssssss sn C 2 C 1 3 EMC wiring technique 0 eee ee II un C 2 C 1 4 EMC installation suggestions 0 cette eens C 3 C 1 5 Wiring of shielded screened cables 0 000 c eect teeta C 4 iv Contents MN1902 General Information Copyright Baldor c 2001 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 Mint is 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 tra
84. oothly changes between successive speed targets reference values This is achieved by specifying acceleration and deceleration times see the WorkBench v5 Parameters tool The speed demand signal is fed into the speed controller and used together with the speed measured from the feedback device to generate a torque demand signal If the speed controller is tuned correctly the measured speed will accurately track the speed demand Finally the torque demand signal is fed into a torque controller which determines the appropriate amount of current to apply to the windings of the motor This demand current is compared with the actual winding current measured from sensors and a suitable pulse width modulation PWM signal is generated This PWM signal is fed to the power electronics in the drive Speed profiler Speed Torque Speed reference gt Speed Torque Power stage controller controller motor Measured current High speed Measured speed speed reference Figure 42 Control structure in Velocity control mode MN1902 Control System B 3 B 1 3 Position control Pulse and Direction Setting the control mode to Position Control Pulse and Direction configures the FlexDrive as a positioning system as shown in Figure 43 capable of following a position command signal The profiler interprets the pulse and direction signals and uses them to generate corresponding position speed and acceleration demand
85. or which the FlexDrive was tested see section 3 4 5 If the FlexDrive requires an external customer supplied 24VDC logic supply then this must be a regulated power supply with a continuous current supply capability of 1 75A 4A power on surge A 24V filter may be required to comply with the CE directive for which the FlexDrive was tested see section 3 4 5 Hardware requirements The components you will need to complete the basic installation are The motor that will be connected to the FlexDrive A motor power cable A resolver or encoder feedback cable and Hall cable for linear motors With some applications there may be a requirement for a regeneration resistor Dynamic Brake Note Without the regeneration resistor the drive may produce an overvoltage fault All FlexDrive models have overvoltage sensing circuitry but only 2 5A and 5A models catalog numbers FDHxxxxxB xxxx and FPHxxxxxB xxxx have an internal regeneration resistor For 7 5A 15A 20A and 27 5A models a regeneration resistor must be purchased separately if required See Appendix A MN1902 Basic Installation 3 1 3 1 3 3 1 4 3 1 5 A serial cable Note The serial connector on the FlexDrive connector X6 can be configured as either RS232 or RS485 RS422 Pin 9 is used to carry 8V for powering some Baldor keypad peripherals Ensure that pin 9 is not connected to earth ground or to equipment that could be damaged by the 8V supply
86. ound by either a 25A conductor or a conductor of three times the peak current rating whichever is the greater m For effective cooling and maintenance the FlexDrive should be mounted on a smooth non flammable vertical surface The power handling capability is affected by the temperature of the left side of the unit m Atleast 50mm 2 in top and bottom clearance of the FlexDrive must be provided for airflow MN1902 Basic Installation 3 3 3 2 1 If multiple FlexDrive are being mounted side by side there must be 13mm 0 5 in between them The FlexDrive nearest the side of the cabinet enclosure must be separated from it by at least 13mm 0 5 in To comply with CE directive 89 336 EEC an appropriate AC filter must be installed The external customer supplied 24VDC logic supply might also require a 24V filter See section 3 4 7 The threaded holes in the top and bottom of the enclosure are for cable clamps provided The holes are threaded for M4 bolts no longer than 12mm 0 47 in in length Longer bolts may short circuit the electrical components inside the FlexDrive Each D type connector on the front panel of the FlexDrive 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 an identical jack screw with an external male threaded section of 5mm 0 2 in Jack screws with longer threads could damage or short circui
87. put X9 All models Unit All models Sampling interval ms Software selectable 1 2 7 1 16 Environmental Minimum 0 32 Maximum 40 104 Derate 2 5 C between 2 5 1 8 F between 40 C and 50 C max 104 F and 122 F max Storage temperature range 25 to 70 13 to 158 Humidity 10 90 non condensing according to DIN40 040 IEC 144 Above 31 C 87 F derate linearly to 50 relative humidity at 40 C 104 F Maximum installation altitude 1000 above m s l Derate 1 1 100m over 1000m 3300 Derate 1 1 330ft over 3300ft 10G according to DIN IEC 68 2 6 29 Vibration 1G 10 150Hz according to DIN IEC 68 2 6 29 7 8 Specifications MN1902 A 1 A 1 1 Accessories Introduction This section describes accessories and options that you may need to use with your FlexDrive Shielded screened cables provide EMI RFI shielding and are required for compliance with CE regulations All connectors and other components must be compatible with the shielded cable Factory fitted options The FlexDrive can be supplied with a number of factory fitted options Each option is described in a separate manual that will be supplied with your product as necessary m MN1908 CAN amp Auxiliary I O option for Flex Drive and MintDrive Option B provides CANopen and additional input output capabilities If this option is fitted the Flex Drive front panel will include connectors X10 X11
88. put X3 can be connected as either a differential or a single ended input as shown in Figure 19 X3 AINO 1 AINO AINO 2 AINO AINO ADC 0 ADC 0 3 GND Differential connection Single ended connection Figure 19 AINO analog input wiring 4 2 Input Output MN1902 24VDC 1 5kQ 0 25W il 1kQ 0 25W potentiometer OV Figure 20 Typical input circuit to provide 0 10V approx input from a 24V source FlexDrive 15V 15V HAHAHA 20k AINO 10k 10k Pin 2 Low pass filter 8 Mint level correction ADC 0 AINO 10k 10k i inverts signal End LF412 x o HS KIL 4 15V 15V AGND Figure 21 AINO analog input circuit MN1902 Input Output 4 3 4 2 2 Relay output X3 Connector X3 pins 4 amp 5 Name General purpose relay Description Relay switch contacts controlled by Mint rated at 1A 30VDC Normally closed Update interval Immediate The factory preset assignment for the relay is as the global error output signal see the Mint keyword GLOBALERROROUTPUT When an error occurs the relay is de energized and the normally closed relay contacts are opened When the error is cleared the relay is re energized and the contacts are closed The relay can be also be controlled directly by the Mint keyword RELAY When the relay is de energized REL
89. rformance characteristics Before the FlexDrive can be used to control the motor accurately the FlexDrive must be tuned This is the process where the FlexDrive powers the motor in a series of tests By monitoring the feedback from the motor s resolver or encoder and performing a number of calculations the FlexDrive can make small adjustments to the way it controls the motor This information is stored in the FlexDrive EEPROM and can be uploaded to a file if necessary The Commissioning Wizard provides a simple way to tune the FlexDrive and create the necessary configuration information for your drive motor combination so this is the first tool that should be used Using the Commissioning Wizard IN CAUTION The motor will move during commissioning For safety it is advisable to disconnect any load from the motor during initial commissioning The motor can be tuned with the load connected after the Commissioning Wizard has finished Each screen of the Commissioning Wizard requires you to enter information about the motor or drive Read each screen carefully and enter the required information If you need extra help click the Help button or press F1 to display the help file When you have completed a screen click Next gt to display the next screen If you need to change something on a previous screen click the Back button The Commissioning Wizard remembers information that you have entered so you will not need to re
90. rive AC power source motor host controller and any operator interface stations Use UL listed closed loop connectors that are of appropriate size for the wire gauge being used Connectors are to be installed using only the crimp tool specified by the manufacturer of the connector Only class 1 wiring should be used Baldor drives are designed to be powered from standard single and three phase lines depending on model that are electrically symmetrical with respect to earth ground Due to the importance of system earthing grounding for increased reliability earthing grounding methods are shown in sections 3 4 1 and 3 4 2 Note When using unearthed ungrounded distribution systems an isolation transformer with an earthed grounded secondary is recommended This provides three phase AC power that is symmetrical with respect to earth ground and can prevent equipment damage MN1902 Basic Installation 3 7 3 4 4 Single phase connection to package sizes A B C D Location Connector X1 Mating connector Phoenix COMBICON MVSTBW 2 5 9 ST 5mm pitch FDH1A FPH1A FDH2A FPH2A Input voltage 115VAC 10 line to neutral 230VAC 10 line to neutral 97 125VAC 220 250VAC For single phase connection the voltage ripple on the DC bus is 25Vp p for 5A peak current rising to 50Vp p for 10A peak current This can limit the maximum speed of the motor Tightening torque for terminal block connections is 0 5 0 6Nm 4 4 5 3 Ib in
91. rst 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 A 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 IN 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 Only qualified personnel should attempt to program start up or troubleshoot this equipment AN WARNING Be sure all wiring complies with the National Electrical Code and all regional and local codes Improper wiring may result in unsafe conditions A 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 Only qualified personnel should attempt to program start up or troubleshoot this equipment 1 2 General Information MN1902 IN WARNING IN WARNING IN WARNING IN WARNING IN WARNING IN CAUTION IN CAUTION IN CAUTION IN CAUTION IN CAUTION
92. s are Buss FRN on 230VAC or equivalent following the UL 508C recommendation of a fuse size of four times the continuous output current of the drive Dual element time delay fuses should be used to avoid nuisance trips due to inrush current when power is first applied Circuit Breaker Fuse From From supply supply L se L L L N N N N Figure 4 Circuit breaker and fuse single phase package sizes A B C D Note Power to single phase models may be derived by connecting two phases of an appropriate three phase supply L1 and L2 for example When supplying AC power in this way the voltage between the two phases must not exceed the rated input voltage of the FlexDrive l A two pole breaker must be used to isolate both lines Fuses must be fitted in both lines Circuit breaker or fuse are not supplied For CE compliance see Appendix C 3 10 Basic Installation MN1902 3 4 5 Circuit Breaker Fuses From From supply supply L1 L1 L1 L2 L2 L2 L3 L3 L3 Circuit breaker or fuse are not supplied For CE Compliance see Appendix C Figure 5 Circuit breaker and fuse three phase package sizes G H Note Metal conduit or shielded cable should be used Connect conduits so the use of a line reactor or RC device does not interrupt EMI RFI shielding Power supply filters To comply with EEC directive 89 336 EEC an AC power filter of the appropriate
93. s c SERVO the profiler acceleration is fed forward by gain KACCEL to give a contribution to the final torque demand The speed control calculation is performed every 250ys As with the position controller the gain values KVPROP KVINT KVDERIV and KACCEL must be tuned for each application This can either be performed automatically within the Commissioning Wizard or manually using the Fine tuning tool of WorkBench v5 Acceleration feedforward term Profiler acceleration Position control Proportional gain term KVPROP Integral gain term Velocity error Torque demand Speed demand KVDERIVTCONST Measured speed VEL Figure 46 Speed control system MN1902 Control System B 7 B 2 3 Torque controller and feedback The torque controller shown in Figure 47 is a Pl controller Gains are set using the Mint keywords KIPROP and KIINT The torque demand is scaled into a current demand This is compared with the measured current obtained from the current sensors and the error is fed into the PI control calculation The resulting value forms the PWM signal that is fed through the power stage into the motor windings The gain values KIPROP and KINT must be tuned for a specific motor This is performed automatically by the Commissioning Wizard Although the PI control alone can achieve adequate current tracking if tuned correctly performance is increased using a feedforward voltage model This mode
94. sition Control Pulse and Direction following gearing The Flex Drive can be configured for three basic control modes m Current Torque control m Velocity Speed control m Position Control The mode you require is selected in WorkBench v5 using the Commissioning Wizard You can subsequently change between these control modes using the Tools Control Mode menu item or by using the CONTROLMODE keyword in the Command window see the Mint help file Using the Parameter tool you can define a mode for the drive to automatically select at start up The four control modes are described in the following sections MN1902 Control System B 1 B 1 1 Current Torque control Setting the control mode to Current Control configures the FlexDrive or Flex Drive as a torque amplifier as shown in Figure 41 Here a torque reference is obtained from a specified source Mint host command profiled High speed analog input not profiled Analog input profiled Fieldbus profiled The source provides a signal that can either be fed directly into the Torque controller only when using the high speed analog input source or through a profiler The high speed reference source is ideal for connecting to a motion controller e g NextMove PCI that will have already profiled the signal and will provide optimum loop closure The profiler generates a torque demand signal that smoothly changes between successive torque targets referenc
95. stor All three phase models 27 5A Catalog number FDHA FPHA Switching threshold Vin 400VAC on 794 off 787 on 794 off 764 Vin 460VAC Peak Peak power 10 power cycle Peak power 10 power cycle 0 power cycle Maximum regeneration Wu switching current Maximum load inductance load inductance Note 2 5A models FDH4A02 and FPH4A02 contain an internal 2000 300W resistor 5A models FDH4A05 and FPH4A05 contain an internal 2000 300W resistor 7 4 Specifications MN1902 7 1 5 Analog input X3 All models All models Coa me LL E eem Input ADC resolution bits 14 includes sign bit Sampling interval Software Mint programs 500 High speed command reference signal 125 7 1 6 Digital inputs X3 All models All models Input voltage Active high VDC Nominal 24 Minimum 12 Input voltage Active low Nominal 0 Maximum 2 7 1 7 Digital outputs X3 All models Unit All models Update interval Software Mint programs Immediate DRIVEENABLEOUTPUT and 2ms GLOBALERROROUTPUT functions PLC Task functions Programmable MN1902 Specifications 7 5 7 1 8 Relay output X3 All models All models Normally closed 1A 30VDC or 0 5A 125VAC Contact rating resistive Lus Mni uL E WeiensemWpoer MSAN Maximum wicking votaoe GMALEMDO iman soto ant AL us IAS haa Lus E Capacitance between open contacts at 1KHz Upd
96. t internal components Mounting the FlexDrive Ensure you have read and understood the Mechanical installation and location requirements in section 3 2 Mount your FlexDrive on its rear side the side opposite to the front panel The FlexDrive must be mounted upright to ensure adequate cooling you can check this by ensuring that the Hazardous Voltages warning information is clearly readable to you M5 bolts or screws should be used to mount the FlexDrive There are six different package sizes depending on the specification of the FlexDrive Factory fitted option Package size with option without option Detailed dimensions for each package are shown in section 3 2 2 Mas ACI 3 A Basic Installation MN1902 3 2 2 Dimensions Package size H only Additional mounting hole positioned centrally between outer mounting holes Package sizes G amp H W4 9 5mm All other sizes W4 W2 Dimensions mm inches A 67 5 173 152 40 15 40 195 5 205 1 25 2 66 6 81 6 00 1 57 059 157 7 70 807 2 76 84 173 152 40 15 40 195 5 205 1 55 3 31 6 81 6 00 1 57 0 59 157 7 70 8 07 342 92 5 173 152 40 23 40 195 5 205 2 1 3 64 6 81 6 00 1 57 091 157 7 70 8 07 4 63 109 173 152 40 23 40 195 5 205 2 3 4 29 6 81 600 1 57 091 157 7 70 8 07 5 07 65 357 262 46 32 5 384 400 4 9 2 56
97. t they are links Just click on the link to go to an associated keyword Most keyword topics begin with a list of relevant See Also links A EA E Mint MT Xo c o g amp Hide Locate Back Forward Print Options JOGMODE JGM Contents Index Search 2 INPUTPOSTRIG 2 INSTATEAS 2 INSTATEX ISX 2 Int 2 INx IX 2 IPend IP 2 JOGAG 2 JOGCOMMAND See Also JOG JOGSPEED JOGCOMMAND JOGDURATION Purpose Specifies the control mode for profiling a jog move Controllers Supported FlexDrivel Flex Drivei7 MintDriveIr 2 JOGS Format JOGMODE axes lt expression gt lt expression gt v JOGMODE axis 2 JOGTIME JGT 2 KACCEL KA nl 2 KDERIV KD 2 KEYPADNODE 2 KEYS 2 KIINT KII 2 KINT KI 2 KINTLIMITZKIL 2 KINTMODE KIM 2 KIPROP KIP 2 KPROP KP Dot Parameters Axis Axis No Attributes Controller Write Multi Axis Scaled Default scum Y 0 Figure 36 The WorkBench v5 help file For help on using WorkBench v5 click the Contents tab then click the small plus sign El beside the WorkBench v5 book icon Double click a topic name to display it 5 4 Operation MN1902 5 2 2 Starting WorkBench v5 f On the Windows Start menu select Programs WorkBench v5 WorkBench WorkBench v5 will start and the Tip of the Day dialog will be displayed
98. the Baldor representative from whom you purchased the equipment If required you can choose to add your program files as attachments WorkBench v5 will automatically start up your e mail program and begin a new message with comprehensive system information and selected attachments already in place You can add any additional message of your own and then send the e mail The PC must have email facilities to use the SupportMe feature If you prefer to contact Baldor technical support by telephone or fax contact details are provided at the front of this manual Please have the following information ready The serial number of your FlexDrive Use the Help SupportMe menu item in WorkBench v5 to view details about your system The catalog and specification numbers of the motor that you are using Give a clear description of what you are trying to do for example trying to establish communications with WorkBench v5 or trying to perform fine tuning m Give a clear description of the symptoms that you can observe for example the Status display error messages displayed in WorkBench v5 or the current value of any of the Mint error keywords AXISERROR AXISSTATUS INITERROR MISCERROR and DRIVEERROR m Thetype of motion generated in the motor shaft Give a list of any parameters that you have setup for example the motor data you entered selected in the Commissioning Wizard the gain settings generated during the tuning process and any gain settings
99. the Baldor logo 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 F_H Installed at Date A description of a catalog number is shown here using the example number FDH1A05TB RC23 Alternatives FlexDrive family FPH Flex Drive Requires an AC supply voltage of 115 Volts 10 2 230V 10 4 230V 460V 30 A02 2 5A A07 7 5A A15 15A A20 20A A27 27 5A Dynamic Brake with a built in transistor and resistor _ available on 2 5A and 5A models only R Requires external braking resistor Continuous current rating of 5 0A Feedback option is a resolver E Encoder B CAN amp Auxiliary I O Flex Drive Option fitted 1 CAN channel only D DeviceNet P Profibus DP NzNo options specified Serial port type is combined RS232 RS485 Pe E Customer s own 24VDC supply is required to power E the internal FlexDrive logic 0 Internally generated 24VDC supply An external 24VDC supply will always be required to operate the enable input digital inputs and digital outputs on connector X3 See sections 4 3 1 to 4 3 5 2 2 Introduction MN1902 2 3 Units and abbreviations The following units and abbreviations are used in this manual Mer hia fae ts Volt also VAC and VDC Wins Watt BY testati o DAS Ampere Q sss ssnes Ohm UE ost ves microfarad DE aeree picofarad millc I millihenry Queue oS phase ms i ski millisecond
100. the FlexDrive as shown in Figure 34 Use brass P clamps not supplied attached using the earth ground bolt Multiple P clamps may be used to clamp the AC power motor and regeneration resistor cables Brass metal P clamp provides 360 shielding Earth ground d bolt WT Status 2 FlexDrive top pane FlexDrive front panel Im Master Enc X9 RS232 RS485 X6 Figure 34 Attaching shield clamps 4 6 Option connectors If there are additional connectors on the front panel of your FlexDrive that have not been described in previous sections these are part of a factory fitted option You will need to refer to the extra manual supplied with your FlexDrive for details of the option s connectors This completes the input output wiring You should read the following sections in sequence before attempting to start the FlexDrive 4 18 Input Output MN1902 5 1 5 1 1 5 1 2 Operation Introduction Before powering the FlexDrive you will need to connect it to the PC using a serial cable and install the supplied PC software WorkBench v5 This software includes a number of tools to allow you to configure and tune the FlexDrive
101. tion 1 1 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 Only qualified personnel should attempt to start up program or troubleshoot this equipment 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 Home appliances Medical instrumentation Mobile vehicles Ships Airplanes 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 7 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 IN WARNING Do not touch any circuit board power device or electrical connection before you fi
102. tion 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 Violent jamming stopping of the motor during operation may damage the motor and drive 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 electro static discharge procedures when handling this drive Ensure that resolver or encoder wires are properly connected Incorrect installation may result in improper movement The threaded holes in the top and bottom of the enclosure are for cable clamps Be sure to use a M4 bolt no longer than 12mm in length Longer bolts might short circuit the electrical components inside the drive Removing the cover will invalidate UL certification 1 4 General Information MN1902 Introduction 2 14 FlexDrive features Throughout this manual both the FlexDrivel and the Flex Drivel will be referred to simply as FlexDrive Where there is a difference in specification it will be clearly marked The FlexDrive is a versatile compact control providing a flexible and powerful solution for single axis rotary systems Standard features include Single axis AC brushless drive Wide range of models with continuous current ratings from 2 5A to 27 5A Direct connection to 115VAC or 2
103. ts and other current protection IN WARNING Electrical shock can cause serious or fatal injury Do not touch any power device or electrical connection before you first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected The power supply module within all FlexDrive models provides rectification smoothing and current surge protection On 2 5A and 5A models a regeneration resistor Dynamic Brake resistor is also built in The power stage is internally fused and therefore self protected but fuses or circuit breakers are required in the input lines for cable protection depending on local codes and regulations A power disconnect should be installed between the AC supply and the input of the FlexDrive for a fail safe method to disconnect power On models with the internally generated 24VDC logic supply catalog numbers FDHxxxxx xxx0 and FPHxxxxx xxx0 the FlexDrive will remain operational until the internal bus voltage is depleted Position and I O information will then be lost On models with an external customer supplied 24VDC logic supply catalog numbers FDHxxxxx xxx3 and FPHxxxxx xxx3 position and I O information will be retained while the 24V supply is present Note A Residual Current Device RCD must not be used for fusing the drive A circuit breaker or fuse must be used All interconnection wires should be in metal conduits between the FlexD
104. type must be connected This can be supplied by Baldor and will ensure that the FlexDrive complies with the CE specifications for which it has been tested Table 1 lists the appropriate filters FlexDrive Input voltages current rating 230VAC 10 115VAC 10 230 460VAC 30 FI0015A01 FI0014A00 FI0018A00 FI0015A00 FI0015A01 FI0018A00 FI0015A01 FI0015A02 FI0018A00 FI0018A01 27 5A FI0018A01 Table 1 Baldor filter part numbers If this model requires a customer supplied 24V control supply catalog numbers FDH2A07T x xxx3 or FPH2A07Tx xxx3 use filter FI0015A02 For further details of power supply filters see section A 1 6 MN1902 Basic Installation 3 11 3 4 6 Wire sizes and protection device ratings Table 2 describes the wire size to be used for power connections and the ratings of the protection devices ncoming Power F Continuous D Type Minimum Catalog Number Nominal Output Input Time Delay wire Gauge Input Breaker Input Fuse Tams mw FDH1A02xx xxxx FPH1A02xx xxxx 119V 09 FDH2A02xx xxxx FPH2A02xx xxxx 230V 19 25 FDH1A05xx xxxx FPH1A05xx xxxx 115V 10 5 FDH2A05xx xxxx FPH2A05xx xxxx 230V 19 5 FDH1A07 xx xxxx FPH1A07 xx xxxx 115V 10 ES FDH2A07 xx xxxx FPH2A07 xx xxxx 230V 10 15 FDH4A02xx xxxx 230 460V 25 FPH4A02xx xxxx 30 FDH4A05xx xxxx 230 460V 5 FPH4A05xx xxxx 30 FDH4A07 xx xxxx 230 460V 7 5 FPH4A07 xx xxxx 30 i FDH4A15xx xxxx 230 460V FDH4A20xx xxxx 230 460V F
105. u eu dre ORTA cdas 6 1 6 11 Problem diagnosis cse rite Had eee ek eb ee EI E t Rer d tert 6 1 6 1 2 SupportMe feature 5 1 viuis he Rs dle pqube orbr e gala de Ses e led EU gode 6 1 6 1 3 Power cycling the FlexDrive lleiisiissssssssssssss een 6 1 b 2 JBl xbinve IndiCatOES ii ova Cana Pauca ur apaga ad ada 6 2 6 21 Status display x cie eer eR eee e RERO oe pm au Eben eacus 6 2 6 2 2 DB On Regeneration LED 00 ccc cece s 6 4 6 2 3 CommuricaliOT s one heri ORC RE READ DR EROGO GE E Ce eae REUS 6 5 6 24 POWEL OD nene ER RA e EE RE GER anes RUF REA aet PEE Red dtt 6 6 6 2 57 TUNING sea A E AM eti e Aor A A omes 6 6 6 2 6 Status LED shows a digit or E 2 1 0 0 0 0 6 6 7 Specifications beer e Da woe URBE UR eR UR 7 1 4 Introduction xxx Bee Roce tu o RS be a A dte eti bb ee 7 1 7 1 1 AC input power and motor output single phase models ssuuussuus 7 2 7 1 2 AC input power and motor output three phase models 00sec eee eens 7 3 7 1 3 Customer supplied 24VDC supply sssssssssssss I 7 3 7 1 4 Regeneration edu eR ERRARE a EE REGERE FR RR dates 7 4 7 1 5 Analog input X3 a e rra 7 5 LA Digital inputs X3 cse Re REM RE REESE RE e ER PEE 7 5 11 1 Digital o tputs X3 ia Geek Ee ees CDI EU SU ER ee s 7 5 17 1 8 Relay output X3 sesta a ake e bedienen dag dialed UR qos 7 6 7 1 9 Serial RS232 interface X6 00 0 ee nn
106. uit amperes listed here at rated voltage Horsepower RMS Symmetrical Amperes 1 50 5 000 Avoid locating the drive immediately above or beside heat generating equipment or directly below water or steam pipes Avoid locating the drive in the vicinity of corrosive substances or vapors metal particles and dust 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 MN1902 General Information 1 3 IN CAUTION IN CAUTION IN CAUTION IN CAUTION IN CAUTION IN CAUTION IN CAUTION IN 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 Drives must be installed inside an electrical cabinet that provides environmental control and protection Installa
107. with a blade width less than 3mm 1 10 in m M5 screws or bolts for mounting the FlexDrive m Crimping tool A connector kit is supplied with your FlexDrive This contains a number of useful connectors and a screwdriver for tightening the connections Other information needed for installation This information is useful but not essential to complete the installation m The data sheet or manual provided with your motor describing the wiring information of the motor cables connectors m Knowledge of which digital inputs outputs will be Active Low Active High or edge triggered 3 2 Basic Installation MN1902 3 2 Mechanical installation and location requirements It is essential that you read and understand this section before beginning the installation AN CAUTION To prevent equipment damage be certain that the input power has correctly rated protective devices installed IN CAUTION To prevent equipment damage be certain that input and output signals are powered and referenced correctly IN CAUTION To ensure reliable performance of this equipment be certain that all signals to from the FlexDrive are shielded correctly IN CAUTION Avoid locating the FlexDrive immediately above or beside heat generating equipment or directly below water steam pipes IN CAUTION Avoid locating the FlexDrive in the vicinity of corrosive substances or vapors metal particles and dust The safe operation of th
108. wn transformer may be required for some power conditions m If the feeder or branch circuit that provides power to the FlexDrive has permanently connected power factor correction capacitors an input AC line reactor or an isolation transformer must be connected between the power factor correction capacitors and the FlexDrive m If the feeder or branch circuit that provides power to the FlexDrive has power factor correction capacitors that are switched on line and off line the capacitors must not be switched while the drive is connected to the AC power line If the capacitors are switched on line while the drive is still connected to the AC power line additional protection is required A Transient Voltage Surge Suppressor TVSS of the proper rating must be installed between the AC line reactor or isolation transformer and the AC input to the FlexDrive Power disconnect and protection devices A power disconnect should be installed between the input power service and the FlexDrive for a fail safe method to disconnect power The FlexDrive will remain in a powered condition until all input power is removed from the drive and the internal bus voltage has depleted The FlexDrive must have a suitable input power protection device installed Recommended circuit breakers are thermal magnetic devices 1 or 3 phase as required with characteristics suitable for heavy inductive loads D type trip characteristic Recommended time delay fuse
109. xxxxx xxx3 FPH xooxx xxx3 2 Turn on the AC supply After a brief test sequence the Status display should show a minus sign If the display is not lit then re check the power supply connections If the motor wires were disconnected in section 5 1 4 turn off the AC supply and reconnect the motor wires Turn on the AC supply To allow the Commissioning Wizard to function SW1 DIP switch 8 will need to be setto the On position to allow the FlexDrive to be enabled If you do not wish to enable the FlexDrive yet the Commissioning Wizard will inform you when this step is necessary To allow the Commissioning Wizard to function the 24VDC drive enable signal will need to be present on connector X3 between pins 7 and 9 to allow the FlexDrive to be enabled If you do not wish to enable the FlexDrive yet the Commissioning Wizard will inform you when this step is necessary The FlexDrive is now ready to be commissioned using WorkBench v5 5 2 Operation MN1902 5 1 6 Offset tuning If the FlexDrive will be using analog input 0 AINO as a command reference input or for any other purpose you may wish to perform offset tuning before continuing The purpose of offset tuning is to remove DC offset voltages on the command reference input to achieve a stationary motor shaft with OVDC at the input Offset tuning is controlled by DIP switches 7 and 8 Before starting confirm that the device supplying the AINO command

FlexDrive II / Flex+Drive II Installation Manual - Q-TECH

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