1275 203

SERVO DRIVE
FlexDrive Servo Control
Installation & Operating Manual
2/03
MN1275
Table of Contents
Section 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 Receiving and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X1 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X1 Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X1 Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X1 +24VDC Logic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X3 Control Inputs & Digital I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X6 RS232 / 485 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X7 Simulated Encoder Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X8 Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X9 Handwheel (Encoder) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X9 Encoder w/Hall Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4 Switch Setting and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch AS1 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Off Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power On Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-2 2-1 3-1 3-1 3-1 3-1 3-2 3-2 3-4 3-4 3-5 3-10 3-10 3-11 3-11 3-12 3-12 3-15 3-18 3-18 3-19 3-21 4-1 4-1 4-3 4-3 4-3
MN1275
Table of Contents i
Section 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Software on your PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum system requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Host Ccommunications Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using The Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set up Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Velocity Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu Choice Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 7 Specifications & Product Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24VDC Logic Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simulated Encoder Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse / Direction Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Encoder Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 5-1 5-1 5-1 5-1 5-3 5-5 5-6 5-6 5-7 5-8 5-8 5-9 5-9 5-10 5-10 5-10 5-10 5-11 5-11 5-11 5-11 5-11 5-12 6-1 7-1 7-1 7-2 7-4 7-4 7-4 7-4 7-4 7-5 7-5 7-5 7-5 7-6
ii Table of Contents
MN1275
Section 8 CE Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC -- Conformity and CE -- Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9 Accessories and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMC AC Mains Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regeneration Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Getting Started with CAN_OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identifiers and object list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Velocity Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plotting of Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse Follower Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix B Command Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1 8-1 8-1 8-3 9-1 9-1 9-1 9-2 9-4 9-5 9-7 9-10 A-1 A-2 A-2 A-3 A-4 A-4 A-5 A-5 A-9 A-10 B-1
MN1275
Table of Contents iii
iv Table of Contents
MN1275
Section 1 General Information

Copyright Baldor ! 1999, 2000. All rights reserved. This manual is copyrighted and all rights are reserved. This document 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. Microsoft and MS--DOS are registered trademarks, and Windows is a trademark of Microsoft Corporation. UL and cUL are registered trademarks of Underwriters Laboratories.
CE Compliance
A custom unit may be required, contact Baldor. Compliance to Directive 89/336/EEC is the responsibility of the system integrator. A control, motor and all system components must have proper shielding, grounding, and filtering as described in MN1383. Please refer to MN1383 for installation techniques for CE compliance. For additional information, refer to Sections 3 and 8 of this manual.
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 which 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 states do not allow exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply.) In any event, BALDORs 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.
MN1275
General Information 1-1
Product 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 control 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 control fails to operate correctly, contact the place of purchase for return instructions. Safety Notice: This equipment contains high voltages. Electrical shock can cause serious or fatal injury. 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 driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start--up procedure or troubleshoot this equipment. -System documentation must be available at all times. -Keep non-qualified personnel at a safe distance from this equipment. -Only qualified personnel familiar with the safe installation, operation and maintenance of this device should attempt start-up or operating procedures. -Always remove power before making or removing any connections to this control. PRECAUTIONS: Classifications of cautionary statements. WARNING: Caution: Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Indicates a potentially hazardous situation which, if not avoided, could result in damage to property.
Continued on next page.
1-2 General Information
MN1275
Do not touch any circuit board, 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. Electrical shock can cause serious or fatal injury. WARNING: Be sure that you are completely familiar with the safe operation of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. WARNING: Be sure all wiring complies with the National Electrical Code and all regional and local codes or CE Compliance. Improper wiring may cause a hazardous condition. WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury. WARNING: Do not remove cover for at least five (5) minutes after AC power is disconnected to allow capacitors to discharge. Electrical shock can cause serious or fatal injury. WARNING: Improper operation of control may cause violent motion of the motor shaft and driven equipment. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment. Peak torque of several times the rated motor torque can occur during control failure. WARNING: Motor circuit may have high voltage present whenever AC power is applied, even when motor is not rotating. Electrical shock can cause serious or fatal injury. WARNING: If a motor is driven mechanically, it may generate hazardous voltages that are conducted to its power input terminals. The enclosure must be grounded to prevent a possible shock hazard. WARNING: When operating a motor with no load coupled to its shaft, remove the shaft key to prevent injury if it were to fly out when the shaft rotates. WARNING: The motor shaft will rotate during the autotune procedure. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment. WARNING: A DB Resistor may generate enough heat to ignite combustible materials. To avoid fire hazard, keep all combustible materials and flammable vapors away from brake resistors. WARNING: The user must provide an external hard-wired emergency stop circuit to disable the control in the event of an emergency. Caution: Suitable for use on a circuit capable of delivering not more than the RMS symmetrical short circuit amperes listed here at rated voltage. Horsepower RMS Symmetrical Amperes 1-50 5,000 Caution: To prevent equipment damage, be certain that the input power has correctly sized protective devices installed as well as a power disconnect. Continued on next page. MN1275 General Information 1-3
WARNING:
Caution: Caution: Caution:
Caution: Caution:
Caution: Caution:
Caution:
Caution:
Caution: Caution: Caution: Caution: Caution:
Avoid locating control immediately above or beside heat generating equipment, or directly below water or steam pipes. Avoid locating control in the vicinity of corrosive substances or vapors, metal particles and dust. For UL installations, do not connect any resolver cable shields to the motor frame. At a minimum, resolver signal integrity will be compromised and damage to the control may result. For CE installations, refer to CE guidelines stated in Sections 3 and 8 of this manual. Do not connect AC power to the control terminals U, V and W. Connecting AC power to these terminals may result in damage to the control. Baldor recommends not using Grounded Leg Delta transformer power leads that may create ground loops and degrade system performance. Instead, we recommend using a four wire Wye. Logic signals are interruptible signals; these signals are removed when power is removed from the drive. Controls are intended to be connected to a permanent main power source, not a portable power source. Suitable fusing and circuit protection devices are required. The safe integration of the drive into a machine system is the responsibility of the machine designer. Be sure to comply with the local safety requirements at the place where the machine is to be used. In Europe this is 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. Controls must be installed inside an electrical cabinet that provides environmental control and protection. Installation information for the drive is provided in this manual. Motors and controlling devices that connect to the drive should have specifications compatible to the drive. Violent jamming (stopping) of the motor shaft during operation may damage the motor and control. Do not tin (solder) exposed wires. Solder contracts over time and may cause loose connections. Electrical components can be damaged by static electricity. Use ESD (electro-static discharge) procedures when handling this control. Ensure that resolver or encoder wires are properly connected. Incorrect installation may result in improper rotation or incorrect commutation. The holes in the top and bottom of the enclosure are for cable clamps. Be sure to use an M4 bolt 12mm in length. Longer bolts may short circuit the electrical components inside the control.
1-4 General Information
MN1275
Section 2 Product Overview

Overview The FlexDrive product is designed to serve the needs of machine designers and manufacturers. Baldor products have both UL and CE approvals. The FlexDrive is a flexible versatile compact control for brushless servo motors. This digital servo control can be tailored to suit many applications. It can accept 0--10VDC input, standard "10VDC input, current loop input, pulse and direction input or electronic handwheel input. Some flexible options are CAN bus interface (for resolver feedback only), internal or external regen, or with customer provided 24VDC to maintain logic power. The FlexDrive can be integrated with Baldors motion controllers or to any industry standard motion controller. Motors Baldor servo controls are compatible with many motors from Baldor and other manufacturers. Motor parameters are provided with the PC software making the setup easy. Baldor compatible motors include: S BSM--A--Series motors S BSM--B--Series motors S BSM--F--Series motors S BSM--N--Series motors Refer to the Speed/Torque curves in the BR1202 catalog or contact your local Baldor distributor or sales representative for assistance with motor sizing and compatibility. Custom motors or motors not manufactured by Baldor may be used. Please contact your local Baldor distributor or sales representative for assistance. Command Source In the analog mode (current or velocity), the control requires a variable 0-10VDC or "10VDC external analog signal. Suitable sources can be a PLC or motion controller. Pulse and Direction In the pulse and direction mode, two opto isolated inputs are provided for pulse input and direction input. The software identifies the command source: A leads B or Pulse Follower. Serial Communications Interface A serial port allows external communication. This means that the FlexDrive can interface to a PC (for configuration and control) or to other user--supplied equipment such as: S Host computers S PLCs S PCs S Motion controllers The serial communication interface supports: S RS232 and the four wire RS--485 communication standards S Baud rate: 9600
MN1275
Product Overview 2-1
Control Inputs Opto isolated inputs are single ended, user selectable and active high or low: Enable CW Enable Hold CCW Enable Fault Reset Machine Input 1 Pulse Machine Input 2 Direction Control Outputs One normally closed relay contact provides a dedicated Drive Ready output. Two opto isolated outputs are single ended, active low and are current sinking. Either output can be assigned to one of the following: In Position Machine Input 1 CW Warning Machine Input 2 CCW Warning I2t Warning Following Error Flag Drive Over Temperature Following Error Warning Simulated Encoder Output Resolver Feedback The resolver feedback signal is converted to PPR (pulses per revolution) by a Resolver to Digital Converter. A position controller uses position feedback The resolution of the simulated encoder output is software controlled with the following available resolutions: 512 PPR, 1024 PPR, 2048 PPR or 4096 PPR Note: For speeds above 6000 RPM, resolution is limited to 1024PPR maximum. Encoder Feedback When encoder feedback is used, the encoder input signal is buffered and provided at the simulated encoder output.
2-2 Product Overview
MN1275
Section 3 Receiving and Installation

Receiving & Inspection
Baldor Controls are thoroughly tested at the factory and carefully packaged for shipment. When you receive your control, there are several things you should do immediately. 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control. 2. Remove the control from the shipping container and remove all packing materials. The container and packing materials may be retained for future shipment. 3. Verify that the part number of the control you received is the same as the part number listed on your purchase order. 4. Inspect the control for external physical damage that may have been sustained during shipment and report any damage immediately to the commercial carrier that delivered your control. 5. If the control is to be stored for several weeks before use, be sure that it is stored in a location that conforms to published storage humidity and temperature specifications stated in this manual. Location Considerations The location of the control is important. Installation should be in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these can reduce the operating life and degrade performance of the control. Several other factors should be carefully evaluated when selecting a location for installation: 1. For effective cooling and maintenance, the control should be mounted on a smooth, non-flammable vertical surface. 2. At least 0.6 inches (15mm) top and bottom clearance must be provided for air flow. At least 0.4 inches (10mm) clearance is required between controls (each side). 3. Altitude derating. Up to 3300 feet (1000 meters) no derating required. Derate the continuous and peak output current by 1.1% for each 330 feet (100 meters) above 3300 feet. 4. Temperature derating. From 0#C to 40#C ambient no derating required. Above 40#C, derate the continuous and peak output current by 2.5% per #C above 40#C. Maximum ambient is 50#C. 5. The control must be installed where the pollution degree according to IEC664 shall not exceed 2.
Mechanical Installation
Mount the control to the mounting surface. The control must be securely fastened to the mounting surface by the control mounting holes. The location of the mounting holes is shown in Section 7 of this manual.
MN1275
Receiving & Installation 3-1
Electrical Installation All interconnection wires between the control, AC power source, motor, host
control and any operator interface stations should be in metal conduits. Use listed closed loop connectors that are of appropriate size for wire gauge being used. Connectors are to be installed using crimp tool specified by the manufacturer of the connector. Only class 1 wiring should be used. System Grounding Baldor controls are designed to be powered from standard single and three phase lines that are electrically symmetrical with respect to ground. System grounding is an important step in the overall installation to prevent problems. The recommended grounding method is shown in Figure 3-1 and 3-3 for UL compliant systems (Figure 3-2 and 3-4 for CE compliant systems).
Figure 3-1 Recommended System Grounding (3 phase) for UL

L1 AC Main Supply L2 L3 Safety Ground Driven Earth Ground Rod (Plant Ground) Earth Four Wire Wye Route all power wires L1, L2, L3 and Earth (Ground) together in conduit or cable.
Control
L1 L2 L3 PE U V W
Note: Wiring shown for clarity of grounding method only. Not representative of actual terminal block location.
Note:
Use shielded cable for control signal wires. Route control signal wires in conduit. These wires must be Ground per NEC and Local codes. kept separate from power and motor wires.
Figure 3-2 Recommended System Grounding (3 phase) for CE

AC Main Supply Four Wire Wye Safety Ground PE Route all power wires L1, L2, L3 and Earth (Ground) together in conduit or cable. All shields Enclosure Backplane (see Section 8) Motor GND L1 L2 L3
Control
L1 L2 L3 PE U V W
Note:
Use shielded cable for control signal wires. Route control signal wires in conduit. These wires must be kept separate from power and motor wires.
3-2 Receiving & Installation
MN1275
Figure 3-3 Recommended System Grounding (1 phase) for UL

L AC Main Supply
Control
N
L N U V W
Safety Ground
Earth Driven Earth Ground Rod (Plant Ground)
Route all 3 wires L, N, and Earth (Ground) together in conduit or cable.
Note:
Ground per NEC and Local codes.
Figure 3-4 Recommended System Grounding (1 phase) for CE

AC Main Supply Four Wire Wye L1 L2 L3 Safety Ground PE Neutral Route all power wires together in conduit or cable. Motor GND
L N
Control
U V W
All shields
Enclosure Backplane (see Section 8)
Note:
MN1275
System Grounding Continued Ungrounded Distribution System With an ungrounded power distribution system it is possible to have a continuous current path to ground through the MOV devices. To avoid equipment damage, an isolation transformer with a grounded secondary is recommended. This provides three phase AC power that is symmetrical with respect to ground. Input Power Conditioning Baldor controls are designed for direct connection to standard single and three phase lines that are electrically symmetrical with respect to ground. Certain power line conditions must be avoided. An AC line reactor or an isolation transformer may be required for some power conditions. $ If the feeder or branch circuit that provides power to the control 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 control. $ If the feeder or branch circuit that provides power to the control has power factor correction capacitors that are switched on line and off line, the capacitors must not be switched while the control is connected to the AC power line. If the capacitors are switched on line while the control is still connected to the AC power line, additional protection is required. TVSS (Transient Voltage Surge Suppressor) of the proper rating must be installed between the AC line reactor or an isolation transformer and the AC input to the control. Power Disconnect A power disconnect should be installed between the input power service and the control for a fail--safe method to disconnect power. The control will remain in a powered-up condition until all input power is removed from the control and the internal bus voltage is depleted. Protection Devices The control must have a suitable input power protection device installed. Input and output wire size is based on the use of copper conductor wire rated at 75 #C. Table 3-1 and 3-2 describes the wire size to be used for power connections and the ratings of the protection devices. Use the recommended circuit breaker or fuse types as follows: Circuit Breaker: 1 phase, thermal magnetic. Equal to GE type THQ or TEB for 115 or 230 VAC 3 phase, thermal magnetic. Equal to GE type THQ or TEB for 230 VAC or GE type TED for 460 VAC. Time Delay Fuses: Buss FRN on 230 VAC or Buss FRS on 460 VAC or equivalent. Recommended fuse sizes are based on the following: UL 508C suggests a fuse size of four times the continuous output current of the control. Dual element, time delay fuses should be used to avoid nuisance trips due to inrush current when power is first applied. For European installations, you may want to consider the following fast acting fuse: Gould Shawmut Cat. No. ATMR15 for up to 15 amperes.
MN1275
Table 3-1 Wire Size and Protection Devices (for units with Power Supply)
Catalog g Number Nominal Input Voltage FD1A02SR-XXXX FD2A02SR-XXXX FD1A02TR-XXXX FD2A02TR-XXXX FD4A02TB-XXXX FD1A05SR-XXXX FD1A05SR-XXXX FD1A05TR-XXXX FD2A05TR-XXXX FD4A05TB-XXXX FD1A07TR-XXXX FD2A07TR-XXXX FD4A07TR-XXXX FD1A10SR-XXXX FD2A10SR-XXXX FD1A15SR-XXXX FD2A15SR-XXXX FD4A15TR-XXXX FD4A20TR-XXXX FD4A27TR-XXXX 115V (1) 230V (3) 115V (1) 230V (1) 400/460V (3) 115V (1) 230V (3) 115V (1) 230V (1) 400/460V (3) 115V (1) 230V (1) 400/460V (3) 115V (1) 230V (3) 115V (1) 230V (3) 400/460V (3) 400/460V (3) 400/460V (3) Continuous Contin o s Output Amps (RMS) 2.0A 2.5A 2.0A 2.5A 2.5A 5A 5A 5A 5A 5A 7.5A 7.5A 7.5A 10A 10A 15A 15A 15A 20A 27.5A Incoming Power Input Inp t Input Fuse Breaker Time (A) Delay (A) 7.5 8 7 4.5 7.5 8 5 4.5 7 4 7.5 8 7 8 7.5 8 7.5 7 7 7.5 10 10 10 10 15 12 12.5 15 15 15 20 20 20 25 20 20 30 35 40 45 Wire Gauge AWG (USA) 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 12 12 12 10 10 mm2 (Europe) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 5.26 5.26
Table 3-2 Wire Size (for units without Power Supply)

Catalog g Number Bus Voltage 160VDC 300VDC 160VDC 300VDC 160VDC 300VDC 160VDC 300VDC Contin o s Continuous Output Amps 2.0A 2.5A 5.0A 5.0A 10.0A 10.0A 15.0A 15.0A Wire Gauge AWG mm2 (USA) (Europe) 14 2.5 14 2.5 14 2.5 14 2.5 12 2.5 12 2.5 10 2.5 10 2.5
FD1A02PO-XXXX FD2A02PO-XXXX FD1A05PO-XXXX FD2A05PO-XXXX FD1A10PO-XXXX FD2A10PO-XXXX FD1A15PO-XXXX FD2A15PO-XXXX
Note: All wire sizes are based on 75#C copper wire. Higher temperature smaller gauge wire may be used per NEC and local codes. Recommended fuses/breakers are based on 25#C ambient, maximum continuous control output current and no harmonic current. X1 Power Connections Power connections are shown in Figures 3-5 through 3-8. MN1275 Receiving & Installation 3-5
Figure 3-5 Single Phase AC Power Connections (FD1AxxT & FD2AxxT only)
L1 Note 1 Note 2 * Circuit Breaker L2 Earth Note 3 & 4 Alternate * Fuse Connection L1 L2 Note 1
* Components not provided with Control.

Notes: 1. See Protection Devices described in this section. 2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. 3. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum). For CE Compliance, connect to the backplane of the enclosure. 4. Reference EMC wiring in Section 8.
Baldor Control
For CE Compliance, refer to Section 8 of this manual.
Figure 3-6 Single Phase AC Power Connections (FD1AxxS only)

L1 Note 1 Note 2 * Circuit Breaker L2 Earth Note 3 & 4 Alternate * Fuse Connection L1 L2 Note 1
L1
L2
L3
PE

Notes: 1. See Protection Devices described in this section. 2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. 3. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum). For CE Compliance, connect to the backplane of the enclosure. 4. Reference EMC wiring in Section 8.
Baldor Control
Note: These FlexDrive versions are not designed for use with 400/460VAC connections.
MN1275
Figure 3-7 3 Phase Power Connections (FD2AxxS & FD4AxxT only)

L1 L2 L3
Earth
Note 1
Note 2 L1 L2 L3
L1 Alternate * Fuse Connection A1
L2
L3 Note 1
* Circuit Breaker
Note 3 & 4
PE
B1
C1
Baldor Control
Notes: 1. See Protection Device description in this section. 2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. 3. Use the same gauge wire for Earth as used for L1, L2, L3 connections. 3. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum). For CE compliance, connect PE to the backplane of the enclosure. 4. Reference EMC wiring in Section 8.
A shared supply configuration is shown in Figure 3-8. The first drive must have an internal power supply such as an Option S control.
Figure 3-8 Shared Supply Power Connections

VCC+ VCCVCC+ VCCVCC+ VCC-
R1 R2
VCC+ VCC-
VCC+ VCC-
Baldor Option S Control To Regen Resistor
Baldor Option P Control
Baldor Option P Control
MN1275
Figure 3-9
X1 - Power Connector Earth L N U V W R1 R2 +24V 0V AC Line Neutral Motor lead U Motor lead V Motor lead W Dynamic Brake Dynamic Brake Customer Provided Input Power
Connector Locations (Single Phase Controls)

X1 Monitor AS1
1 2 3 4 5 6 7 8 Off/On
NC Motor Dynamic Brake (Regen Resistor) FDxAxxxx-xxx3 only L N U V W R1 R2
The holes in the top and bottom of the enclosure are for cable clamps. Be sure to use an M4 bolt 12mm in length. Longer bolts may short circuit the electrical components inside the control.
X9 - Handwheel Input (Encoder) 1 2 3 4 5 6 7 8 CHA+ CHB+ CHC+ Hall 1+ Hall 1-CHACHBCHC9 10 11 12 13 14 15 Hall 3+ Hall 2+ +5VDC N.C. DGND Hall 3-Hall 2--
Ready Encoder In X9
Terminal tightening torque is 0.5 lb-in (0.6Nm)
+24V 0V
X6 - RS232 / 485 1 2 3 4 5 6 7 8 9 RS232 Reserved Rx Data Tx Data DTR DGND DSR RTS CTS +5V 1 2 3 4 5 6 7 8 9 RS485 TXTX+ RX+ RXDGND RTSRTS+ CTS+ CTSRS232 / 485 X6 Encoder Out X7
DB On
X3 - Control Signals & Digital I/O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CMD+ CMDAGND Fault Relay+ Fault RelayCIV CREF CGND Enable CW - Enable CCW - Enable Hold Fault Reset Pulse Direction MaI1 MaI2 MaO1 MaO2 DrOK
X7 - Simulated Encoder Output 1 2 3 4 5 CHA+ CHB+ CHC+ Reserved DGND 6 7 8 9 CHA-CHB-CHC-Reserved
X8 - Resolver Input Resolver In X8 1 2 3 4 5 REF+ COS+ SIN+ Reserved AGND 6 7 8 9 REF-COS-SIN-Reserved
Note:
Important: X3 FDxAxxxx-xxx3 only. A separate 24VDC supply to the Logic Power input is required for operation. An FDxAxxxx-xxx3 control will not operate without 24VDC on this input.
Reserved means no connection is required and no connection should be made to this terminal. It is reserved for future use.
MN1275
Figure 3-10
X1 - Power Connector PE L1 L2 L3 U V W R1 R2 +24V 0V Earth Phase 1 Input Phase 2 Input Phase 3 Input Motor lead U Motor lead V Motor lead W Dynamic Brake Dynamic Brake Customer Provided Input Power Motor
Connector Locations (Three Phase Controls)

The holes in the top and bottom of the enclosure are for cable clamps. Be sure to use an M4 bolt 12mm in length. Longer bolts may short circuit the electrical components inside the control.
Dynamic Brake (Regen Resistor) FDxAxxxx-xxx3 only
X9 - Handwheel Input (Encoder) 1 2 3 4 5 6 7 8 CHA+ CHB+ CHC+ Hall 1+ Hall 1-CHACHBCHC9 10 11 12 13 14 15 Hall 3+ Hall 2+ +5VDC N.C. DGND Hall 3-Hall 2--
Terminal tightening torque is 0.5 lb-in (0.6Nm)
X6 - RS232 / 485 1 2 3 4 5 6 7 8 9 RS232 Reserved Rx Data Tx Data DTR DGND DSR RTS CTS +5V 1 2 3 4 5 6 7 8 9 RS485 TXTX+ RX+ RXDGND RTSRTS+ CTS+ CTS-
X3 - Control Signals & Digital I/O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CMD+ CMDAGND Fault Relay+ Fault RelayCIV CREF CGND Enable CW - Enable CCW - Enable Hold Fault Reset Pulse) Direction MaI1 MaI2 MaO1 MaO2 DrOK
X7 - Simulated Encoder Output 1 2 3 4 5 CHA+ CHB+ CHC+ Reserved DGND 6 7 8 9 CHA-CHB-CHC-Reserved
X8 - Resolver Input 1 2 3 4 5 REF+ COS+ SIN+ Reserved AGND 6 7 8 9 REF-COS-SIN-Reserved
Note:
Important: FDxAxxxx-xxx3 only. A separate 24VDC supply to the Logic Power input is required for operation. An FDxAxxxx-xxx3 control will not operate without 24VDC on this input.
Reserved means no connection is required and no connection should be made to this terminal. It is reserved for future use.
MN1275
X1 Motor Connections Motor connections are shown in Figure 3-11. It is important to connect the motor leads U, V and W correctly at the X1 connector of the control. Incorrect wiring can cause erratic operation including moves at peak force until the overcurrent limit trips. This will result in a display of 7 and a 6 on the monitor. If erratic movement of the motor occurs, turn off power immediately and check the connections of the motor, hall sensors and encoder.
Figure 3-11 Motor Connections for U.L.

Baldor Control
Notes: 1. Metal conduit or shielded cable should be used. Connect conduits so the use of Load Reactor* or RC Device* does not interrupt EMI/RFI shielding. 2. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum, 6AWG). For CE compliance, connect motor ground to the backplane of the enclosure. 3. Reference EMC wiring in Section 8. 4. Motor and resolver are phase sensitive. Connect only as instructed. Note 2 V U * AC Servo Motor W G For three phase controls, this is labeled PE.
U Note 1
* Optional components not provided with control.
Figure 3-12 Motor Connections for CE

Baldor Control
Notes: 1. Metal conduit or shielded cable should be used. Connect conduits so the use of Load Reactor* or RC Device* does not interrupt EMI/RFI shielding. 2. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum, 6AWG). For CE compliance, connect motor ground to the backplane of the enclosure. 3. Reference EMC wiring in Section 8. 4. Motor and encoder are phase sensitive. Connect only as instructed. Note 2 Enclosure Backplane (see Section 8)
U Note 1
V U * AC Servo Motor
W G
M-Contactor
Note: For CE compliant installations, connect unused leads within the motor cable to PE on both ends of the cable. If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor) may be installed. However, incorrect installation or failure of the M-contactor or wiring may damage the control. If an M-Contactor is installed, the control must be disabled for at least 20msec before the M-Contactor is opened or the control may be damaged. M-Contactor connections are shown in Figure 3-13.
MN1275
Figure 3-13 Optional M-Contactor Connections

U V W To Power Source (Rated Coil Voltage) * M-Contactor * RC Device Electrocube RG1781-3
For three phase controls, this is labeled PE. Note 1 and 2 * M Enable

X3 9 Note: Close Enable after M contact closure.
V U
W G
* Motor M=Contacts of optional M-Contactor
Notes: 1. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires10mm2 minimum, 6AWG). 2. For UL installations, connect motor ground to of the control as shown. For CE installations, connect motor ground to the enclosure backplane (see Figure 3-12).
Motor Thermostat A relay contact can be used to isolate the motor thermostat leads for use with other devices, shown in Figure 3-14. The thermostat or overload relay should be a dry contact type with no power available from the contact. The optional relay (CR1) shown provides the isolation required and the N.O. contact is open when power is applied to the relay and the motor is cold. If the motor thermostat is tripped, CR1 is de-energized and the N.O. contact closes. Connect the External Trip Input wires (N.O. relay contact) to a PLC or other device. Note that a machine input may be used and the PLC software of the FlexDrive can define the thermal protection. Do not place these wires in the same conduit as the motor power leads.
Figure 3-14 Motor Temperature Relay

Customer Provided Source Voltage
Note: Add appropriately rated protective device for AC relay (snubber) or DC relay (diode).
*
CR1
External Trip V W G U * Motor Motor Thermostat Leads
Do not run these wires in same conduit as motor leads or AC power wiring.
* Optional hardware, customer supplied. X1 Dynamic Brake Resistor An external DB (dynamic brake or regen resistor) resistor may be required to dissipate excess power from the DC bus during motor deceleration operations. Some controls have an internal resistor. For selection of the DB resistor, refer to the specifications located in Section 7 and the regeneration resistor specifications in Section 9 of this manual. DB hardware is connected at R1 and R2 terminals of the X1 connector, Figure 3-9 and 3-10.
MN1275
X1 +24VDC Logic Supply For FDxAxxxx-xxx3 only. A separate 24VDC supply to the Logic Power input is required for operation. An external 24 VDC power source must be used. If bus power is lost, the logic circuits are still active if the 24VDC is present. This is important to maintain position reference, for example. If the control was not ordered with this option, do not connect any voltage to these pins. X3 Control Inputs & Digital I/O Connections Control Inputs X3 pins 1 and 2 allows connection of an external analog command input. This input can accept a 0-10VDC or "10VDC signal and can be wired as a single ended or differential input, shown in Figure 3-15.
Figure 3-15 Control Input Wiring

Single Ended Connection
X3
Signal Source
Differential Connection
X3 1 2 3
CMD+ CMDAGND
1 2 3
CMD+ CMDAGND
Signal Source
X3 Digital Inputs - Opto Isolated Inputs (uses CREF, X3-7) Active High (Sourcing) - If pin X3-7 is grounded, an input is active when it is at +24VDC (+12VDC to +30VDC). Active Low (Sinking) - If pin X3-7 is at +24VDC (+12VDC to +30VDC), an input is active when it is grounded. Logic input connections are made at terminal strip X3. Input connections can be wired as active High or active Low as shown in Figure 3-16. X3 pin 7 is the Control Reference point (CREF) for the Opto Isolated Input signals. Note: An internal 24VDC power supply connection is not available from the control to power the Opto Input circuits. A customer provided external power source must be used as indicated in Figure 3-16.
Figure 3-16 Active HIGH /LOW Relationship

Active Low (Sink) +24VDC GND Active High (Source) GND +24VDC
20mA
Input A B
Note:
All Opto inputs are referenced to CREF, X3-7. Input A B
X3 7 8 9 10 11 12 13 14 15
CREF CGND ENABLE CW-ENABLE CCW-ENABLE HOLD FAULT RESET PULSE DIRECTION MAI1 MAI2
20mA
+24VDC
9 - 17 7
Typical
GND
9 - 17 7
Typical
GND
+24VDC
Control Source Sink
Control
16 17
MN1275
X3 Digital Inputs Continued
Table 3-3 Opto Input Signal Conditions

Pin Number X3-9 X3-10 X3-11 X3-12 X3-13 X3-14 X3-15 X3-16 X3-17 Signal Name Enable CW-Enable CCW-Enable Hold Fault Reset Pulse Direction MaI1 MaI2 Switch = Closed (active) Drive enabled. Clockwise rotation enabled. Counter-clockwise rotation enabled. HOLD function is active. Fault Reset is active (reset control). See Pulse & Direction Definition. See Pulse & Direction Definition. Machine Input 1 = Logical 1 Machine Input 2 = Logical 1 Switch = Open (not active) Drive disabled. Clockwise rotation disabled. Counter-clockwise rotation disabled. HOLD function is not active. Fault Reset is not active. See Pulse & Direction Definition. See Pulse & Direction Definition. Machine Input 1 = Logical 0 Machine Input 2 = Logical 0
Signal Name Opto Input Signal Definition

Enable CLOSED allows normal operation. OPEN disables the control and motor coasts to a stop. CW-Enable CLOSED allows normal operation in the CW direction. OPEN to disable CW rotation. The motor decels to a stop. CCW-Enable CLOSED allows normal operation in the CCW direction. OPEN to disable CCW rotation. The motor decels to a stop. Hold CLOSED causes the motor to decelerate (at maximum deceleration rate) to rest and maintain a constant position (to prevent drift in velocity mode only). OPEN allows normal operation. Fault Reset CLOSED allows the control to be cleared or Reset for any of the following four fault conditions (provided that the cause of the fault has been removed): $ Overvoltage $ Electronic Fusing $ Undervoltage $ Resolver Fault OPEN allows normal operation. Pulse & Direction The pulse and direction inputs allow the control to change speed and direction based on these signals. The frequency of the signal at the pulse input determines the motor velocity. The logic state of the signal applied at the direction input determines the direction of rotation (CW = 1; CCW = 0). The input voltage for both pulse and direction is 12 - 29VDC at 20mA.
Figure 3-17 Pulse & Direction Timing Diagram

4m s Pulse Time Tmin = 8ms 4m s Direction Time
MN1275
X3 Digital Inputs Continued MaI1 & 2 Two machine inputs are provided. These inputs are used with the internal PLC software program. The internal PLC software can cause an event to occur based on the presence of one or both inputs. X3 Digital Outputs - Opto Isolated Outputs The control outputs are located on the X3 connector. A customer provided, external power supply must be used if digital outputs are to be used. The opto outputs provide status information and are not required for operation, Table 3-4.
Figure 3-18 Fault Relay Connections

4 Relay 5 Contact is closed when power is on and no faults are present. Control Customer Provided Interface Circuit Customer provided external power source: and Non-Inductive Load 110VAC @ 0.3A maximum or 24VDC @ 0.8A maximum
Figure 3-19 Opto Output Connections

6 CIV 18, 19, 20 CGND 8 Control Customer Provided Interface Circuit Output Signal
(+12VDC to +30VDC)
OR
Relay
Typical
35mA Maximum
Table 3-4 Opto Output Signal Conditions

Pin Number X3-4 X3-5 X3-18 X3-19 X3-20 Signal Name Fault + Fault MAO1 MAO2 DrOK Switch = Closed (active) Drive OK - no faults detected Drive OK - no faults detected Machine Output 1 = Logical 1 Machine Output 2 = Logical 1 Drive OK - no faults detected Switch = Open (not active) Fault is detected Fault is detected Machine Output 1 = Logical 0 Machine Output 2 = Logical 0 Fault is detected
Fault Relay MaO1 & 2
DrOK
A normally closed relay contact that opens if a fault occurs. The contact is rated: 24VDC @ 0.8A maximum or 110VAC @ 0.3A maximum. Two machine outputs are provided. Either output can be set to one of the following conditions: CW Warning, CCW Warning, In Position, Error Flag, Following Error Warning, MAI1-2, Drive Overtemperature or I2T Warning. Each output is rated 30VDC @ 35mA maximum. This output is active when the control is ready for operation. This output is rated 30VDC @ 35mA maximum.
MN1275
X6 RS232 / 485 Connections RS232 A null modem cable (also called a modem eliminator cable) must be used to connect the control and the computer COM port. This will ensure that the transmit and receive lines are properly connected. Either a 9 pin or a 25 pin connector can be used at the computer, Figure 3-20. Maximum recommended length for RS232 cable is 3 ft. (1 meter).
Figure 3-20 9 & 25 Pin RS-232 Cable Connections for UL Installations

9 Pin Connector Pin 2 3 5 Signal RXD TXD GND 25 Pin Connector Pin 2 3 7 X6 RXD Control (DCE) TXD GND Chassis Null Modem Cable Connections Signal RXD TXD GND
RXD TXD GND
Computer COM Port (DTE)
Figure 3-21 9 & 25 Pin RS-232 Cable Connections for CE Installations

X6 RXD Control (DCE) TXD GND PE PE Null Modem Cable Connections
RXD TXD GND
Computer COM Port (DTE)
Note: For CE installations, connect the overall shield at each end of the cable to PE. The voltage potential between the PE points at each end of the cable must be Zero Volts.
MN1275
RS485 Standard RS485 connections are shown in Figure 3-23. Maximum cable length is 3280 ft (1000M).
Figure 3-22 9 Pin RS-485 Cable Connections For UL Installations

X6 9 Pin Connector Control Pin 1 2 3 4 5 Signal TXTX+ RX+ RXDGND (DCE) RX+ RX-TX+ TXDGND Chassis TX+ TX-RX+ RXDGND Computer COM Port (DTE)
Figure 3-23 9 Pin RS-485 Cable Connections For CE Installations

X6 9 Pin Connector Control Pin 1 2 3 4 5 Signal TXTX+ RX+ RXDGND (DCE) RX+ RX-TX+ TXDGND Chassis PE PE TX+ TX-RX+ RXDGND Computer COM Port (DTE)
Note: For CE installations, connect the overall shield at each end of the cable to PE. The voltage potential between the PE points at each end of the cable must be Zero Volts. RS485 Multi-Drop Connections What does termination or a termination resistor do? Termination resistance is 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 (noise). If the Source impedance, Transmission Line impedance, and Load impedance are all equal, these reflections (noise) are eliminated. Termination does increase load current and sometimes changes the bias requirements and increases the complexity of the system. What is a termination resistor? A resistor is added in parallel with the receiver input to match the impedance of the cable being used. Typically, the resistor value that is used is 100 ohm or 120 ohm. Resistors with 90 ohms or less should never be used. Where are these resistors placed? Terminators or Termination resistors are placed in parallel with the receiver at both ends of a transmission line. This means that you should never have more than two terminators in the system (unless repeaters are being used). How many resistors should my system have? Terminators or Termination resistors are placed in parallel with the receiver at both ends of a transmission line. This means that you should never have more than two terminators in the system (unless repeaters are being used). 3-16 Receiving & Installation MN1275
Figure 3-24 RS485 4 Wire Multi-Drop for UL Installations

Host Computer
P
RX+
* TR * TR
P
X6
P
TX+ TX-RX+ RXDGND

Shields
= Twisted Pair
RX-TX+ TXDGND GND
GND
Use twisted pair shielded cable with an overall shield. * Terminating resistor TR is 120 W typical value. Only the PC and last control are terminated.
Shields
*TR *TR
X6 TX+ TX-RX+ RXDGND GND
Figure 3-25 RS485 4 Wire Multi-Drop for CE Installations

Host Computer
P
RX+
* TR * TR
P
X6
P
TX+ TX-RX+ RXDGND PE PE PE GND X6 TX+ TX--
= Twisted Pair
RX-TX+ TXDGND GND
Use twisted pair shielded cable with an overall shield. * Terminating resistor TR is 120 W typical value. Only the PC and last control are terminated.
PE
*TR *TR
RX+ RXDGND GND
Note: For CE installations, connect the overall shield at each end of the cable to PE. The voltage potential between the PE points at each end of the cable must be Zero Volts. See Section 4 of this manual for the description of switch AS1-1 to AS1-4 for address settings for multi-drop applications.
MN1275
X7 Simulated Encoder Output The control provides a simulated encoder output at connector X7. This output may be used by external hardware to monitor the encoder signals. It is recommended that this output only drive one circuit load (RS422 interface -28LS31 device). Refer to Table 3-5. The simulated Encoder Output is set by software control in General Motor & Control.
Table 3-5 Simulated Encoder Output at X7 Connector

X7 Pin 1 2 3 4 5 6 7 8 9 Shell Signal Name A+ B+ C+ Reserved DGND A-B-C-Reserved * Chassis (Cable Shield)
* For UL Installations ONLY. For CE Installations, connect the outer shield on each end of the cable to the enclosure backplane PE. X8 Resolver Feedback The resolver connections are the standard feedback on Flex drives and connections are made at the X8 connector as shown in Figure 3-26. The resolver cable must be shielded twisted pair #22 AWG (0.34mm2) wire minimum. The cable must also have an overall shield. Maximum wire-to-wire or wire-to-shield capacitance is 50pf per foot. Resolver wiring must be separated from power wiring. Separate parallel runs of resolver and power cables by at least 3%. Cross power wires at right angles only. Insulate or tape ungrounded end of shields to prevent contact with other conductors or ground. Note: Motor and resolver are phase sensitive. Connect only as instructed.
Figure 3-26 Resolver Cable Connections for UL Installations

R2 S2
P
R1 S4
X8 3
P
SIN+ SINCOS+ COSREF+ REF- (Common) Shell (Chassis)
8 2 7 1 6
S3
S1
P P
= Twisted Pair
Shields
MN1275
Figure 3-27 Resolver Cable Connections for CE Installations

R2 S2
P
R1 S4
X8 3
P
SIN+ SINCOS+ COSREF+ REF- (Common) AGND

Connect internal shields to AGND
8 2 7 1 6 5
S3
S1
= Twisted Pair
Connect overall shield to connector backshells
X9 Handwheel (Encoder) Installation Handwheel Mode (Standard Encoder) Twisted pair shielded wire with an overall shield should be used. Figure 3-28 shows the electrical connections between the encoder and the encoder connector. Note: If the control was ordered with option E (Encoder/Hall feedback, catalog FDxAxxxx-Exxx) it is not possible to connect the handwheel.
Figure 3-28 Differential Encoder Connections for UL Installations

X9 1 6 2 7 3 8 11 13 A+ A-B+ B-C+ C-+5V DGND Shell (Chassis)
Encoder
Single Ended Connections Differential inputs are recommended for best noise immunity. If only single ended encoder signals are available, connect them to A, B, and C as shown in Figure 3-29.
Figure 3-29 Single Ended Encoder Connections for UL Installations

X9 1 6 2 7 3 8 11 13 A B C +5V DGND Shell (Chassis)
Encoder
MN1275
Figure 3-30 Differential Encoder Connections for CE Installations

X9 1 6 2 7 3 8 11 13 A+ A-B+ B-C+ C-+5V DGND
Encoder
PE
Connection of shields to digital ground is optional.
Figure 3-31 Single Ended Encoder Connections for CE Installations

X9 1 6 2 7 3 8 11 13 PE Connection of shields to digital ground is optional. A B C +5V DGND
Encoder
MN1275
X9 Encoder w/Hall Tracks Optional (Option E) Twisted pair shielded wire with an overall shield should be used. Figure 3-32 shows the electrical connections between the encoder and the encoder connector. Note: If the control was ordered with option E (Encoder/Hall feedback, catalog FDxAxxxx-Exxx) it is not possible to connect the handwheel.
Figure 3-32 Encoder with Hall Tracks Connections for UL Installations

X9 1 6 2 7 3 8 11 13 4 5 9 14 10 15 12 A+ A-B+ B-C+ C-+5V DGND Hall 1+ Hall 1-Hall 3+ Hall 3-Hall 2+ Hall 2-Not Used Shell (Chassis)
Encoder
Hall Feedback
Figure 3-33 Encoder with Hall Tracks Connections for CE Installations

X9 1 6 2 7 3 8 11 13 4 5 9 14 10 15 12 A+ A-B+ B-C+ C-+5V DGND Hall 1+ Hall 1-Hall 3+ Hall 3-Hall 2+ Hall 2-Not Used Shell (Chassis)
Encoder
Hall Feedback
MN1275
MN1275
Section 4 Switch Setting and Start-Up

Switch AS1 Settings
AS1
1 2 3 4 5 6 7 8
Monitor
AS1 switches are located on the front panel between X1 and the Monitor LED. Note: AS1--8 is shown in the ON position (Drive Enabled). All other switches are shown in the OFF position.
Off / On
Address Setting, AS1-1 to AS1-4 (for Multi-Drop Applications) Each control address can be set using switches AS1-1 to AS1-4 of each control. Each control must have a unique address. Refer to Table 4-1.
Table 4-1 Control Address Setting

AS1-1 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON AS1-2 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON AS1-3 OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON AS1-4 OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON Control Address (Hexadecimal) 0 (Factory Setting) 1 2 3 4 5 6 7 8 9 A B C D E F
MN1275
Switch Setting & Start-Up 4-1
Setting of switches AS1-5 to AS1-8 The function of switches AS1-5 to AS1-8 are described in Table 4-2.
Table 4-2 AS1-5 to AS1-8 Description

Switch AS1-5 AS1-6 AS1-7 AS1-8 Function ON Not Used Hold-Position Hold-Position is active. Offset Tuning Automatic Offset Tuning is active. Enable Control is enabled (Enable is active) OFF Hold-Position is not active Automatic Offset Tuning is not active. Control is disabled (Enable is not active)
Hold-Position OFF allows normal operation. ON causes the motor to quickly decelerate to rest and maintain a constant position (in current or velocity modes). (Time to max velocity = 0 with the Hold function.) Offset Tuning OFF allows normal operation. ON causes Offset Tuning to automatically start the next time Enable is changed from ON to OFF. The purpose of Offset Tuning is to remove DC offset voltages (on the command input X3-1 and X3-2) and achieve a stationary motor shaft with 0VDC at the command input. Leave this switch OFF when not in use. See Figure 4-1 for additional information. Enable OFF disables the control and the motor coasts to a stop. ON allows normal operation. Note: AS1-8 and X3-9 must both be enabled to allow control operation.
Figure 4-1 Automatic Offset Tuning Timing Diagram

Main Power
On Off Time On On or Off Off On On Time
Enable Switch AS1-8
Offset Tuning Switch AS1-7
Off On
On or Off
On Time
Automatic Offset Tuning
Off
Start Offset Tuning
Offset Tuning Done Time
Note: It is important that you set the analog command to 0VDC before the Automatic Offset Tuning is started.
4-2 Switch Setting & Start-Up
MN1275
Start-Up Procedure
Power Off Checks Before you apply power, it is very important to verify the following: 1. Disconnect the load from the motor shaft until instructed to apply a load. If this cannot be done, disconnect the motor wires at X1-U, V and W. 2. Verify that switches AS1-5 to AS1-8 are set to OFF. 3. Verify the AC line voltage at the source matches the control rated voltage. 4. Inspect all power connections for accuracy, workmanship and tightness. 5. Verify that all wiring conforms to applicable codes. 6. Verify that the control and motor are properly grounded to earth ground. 7. Check all signal wiring for accuracy. Power On Checks When power is first applied, the Monitor LED display will show four indications if there is no failure found. 8. All segments and decimal point are on. 0 Display test. 1 Option number of test (1, 2 etc.). d Final display with no decimal point (control disabled because AS1-8 = OFF). Procedure: 1. Apply AC power. 2. Apply logic power (only if your control is equipped with this option). 3. Verify the Monitor LED power on sequence. If d is displayed, continue otherwise disconnect AC power and refer to the Troubleshooting procedure. 4. Disconnect AC power. 5. Connect the load to the motor shaft (or connect the motor wires at X1). 6. Apply Logic Power (24VDC) if option is present. 7. Apply AC power. 8. Set switches AS1-7 and AS1-8 to ON. 9. Set switch AS1-8 to OFF (initiate offset tuning). 10. Set switch AS1-7 to OFF. 11. Configure the control using the Setup Software provided. Refer to Section 5 of this manual. 12. Set switch AS1-8 to ON (drive enabled). 13. Perform System Tuning. The drive is now ready for use. Note: To protect the internal fuse, allow at least 1 minute after power down before turning power on (power Off/On cycle).
MN1275
Switch Setting & Start-Up 4-3
4-4 Switch Setting & Start-Up
MN1275
Section 5 Operation
Installing Software on your PC
The setup software is Windows--based. The servo control connects to a serial port on your PC. The setup wizard will guide you through the necessary steps to set--up your servo control. Online--help to each topic is available. Minimum system requirements Hardware requirements (minimum): Processor: Intel 80486 / 33 MHz RAM: 8 MB Hard Disk Space: 50 MB Screen: 600 x 480 (minimum) Recommended: Intel Pentium, 16 MB RAM, 133 MHz, 100 MB Free Space Software requirements: Operating system: Windows 3.1x (minimum) Recommended: Win95 or Windows NT Installation The following procedure will install the setup software on your computers hard disk: 1. Start Windows. Make sure that no other programs are running during this installation. 2. Place installation Disk #1 in your computers floppy drive. 3. Run A:\Setup.exe (if A:\ is your floppy drive) or double click the file Setup.exe from My computer, 3.5 inch Floppy (A:). 4. Follow the instructions and insert the other installation disks as required. After the installation process is finished, a program manager group for Flex with a Flex progman icon is created. Double clicking this icon will start the setup program. A file Readme.txt is included in the master directory of the software. This file contains installation instructions, change notices from previous revisions and information that became available after this manual was printed.
Host Ccommunications Setup

Be sure the communications port of the PC is correctly set for communications with the Drive software. The following examples assume COM1 of the PC is used. If you are using COM2 -- 4, substitute the correct COM port number in the example. Windows 3.1 Terminal Emulation 1. Power up the Host and start Windows software. 2. In the Windows Accessories Group select Terminal ICON. 3. Select Communications from the Settings pull down menu within Terminal program. 4. Set the communications settings for: 9600 Baud rate 8 Data Bits 1 Stop Bit No Parity Xon/Xoff Flow Control COM1
MN1275
Operation 5-1
5. 6. 7. 8.
Select Binary Transfers from the Settings pull down menu within Terminal program. Set the Binary Transfer protocol to XModem/CRC. Close menu and save the settings. Terminal Communications settings are now complete.
Windows 95 1. Power up the Host and start Windows software. 2. In Control Panel select and open System. 3. Open Ports, select the COM port you are using then click properties.
Figure 5-2
4.
Be sure the port settings are as: Bits per second=9600, Data bits=8, Parity=none, Stop bits=1 and Flow control=Xon/Xoff.
Windows NT 1. Power up the Host and start Windows software. 2. In Control Panel, select and open Ports then click Settings.
Figure 5-3
3.
Be sure the port settings are as: Bits per second=9600, Data bits=8, Parity=none, Stop bits=1 and Flow control=Xon/Xoff.
5-2 Operation
MN1275
Using The Setup Wizard

The setup software wizard guides you through each step to set the basic parameters. This wizard is activated automatically after each start-up of the software. This automatic start of the Wizard can be turned off. It can be activated (and reset to automatic start) by Help & Wizard. Figure 5-1 shows the flowchart of the Setup Wizard. All selected parameters can be stored in a file. To save the configuration, select Setup & Save Configuration. To restore these parameter values or to configure a several controls with the same parameter sets, select the Setup & Restore Configuration.
MN1275
Operation 5-3
Figure 5-1 Flowchart of the Setup Wizard

Setup Wizard
Skip
Sequence 1: Motor and Control Skip General: -- App. Bus Voltage --Sim Enc. Output Motor: -- Select the motor Control: -- Control is selected automatically Download Sequence 4: Velocity Parameters
General: -- Max. Velocity -- Time to Max. Velocity -- Min. Velocity -- Scaling Factor Download Skip Sequence 5: Drift Offset
Skip
Sequence 2: Operating Mode
Auto Tune
Offset Value (mV) Download Close
General: -- Current -- Velocity -- Pulse Follow Download Skip Sequence 3: Current Parameters
Sequence 6: Auto tuning
Auto Tuning Procedure
General: -- App. Peak Amps --App. Nom. Amps --BEMF Compensation --Scaling Factor
Done
Sequence 4:
5-4 Operation
MN1275
Set up Software Opening menu. Click NEXT to go to the Set up Software. If you have already set
up the parameters and saved them to a file, click FINISH then load the parameter file using the File & Open selection.
Start by selecting the Motor and Control and these parameters will be entered automatically for you by the software for a stock motor. For a custom motor, the motor parameters must be entered on the general menu. First, click on Motor and then select User Models in the Library menu. Then, click General to return to this menu and enter all parameters.
MN1275
Operation 5-5
There are 7 parts to the setup procedure: Motor Select your motor from the list. First, select the general Motor Type. Then select your specific Motor ID. All of the parameters will be entered if your motor is on the list. If your motor is not on the list, you must define a motor and all of its parameters. If your motor is not listed, select User Models in the Library menu and enter the motor parameters. Click Download when finished.
Figure 5-2 Motor Selection Screen
Control
The Control ID is automatically selected. All of the parameters will be entered if your control is on the list. Click Download when finished.
Figure 5-3 Control Selection Screen
5-6 Operation
MN1275
After the motor and control are selected, click the General menu and note that the values are filed in.
Operating Mode Select the operating mode of the control. Choices are: 1. Current Mode 2. Velocity Mode 3. Pulse Follower Mode (Pulse & direction or Electronic Handwheel) Click Download when finished. Note: If an encoder with hall feedback is plugged into X9, the handwheel cannot be used. Only one device may be plugged into X9.
Figure 5-4 Operating Mode Selection Screen
MN1275
Operation 5-7
Current Parameter Nominal and peak current values are automatically entered for the motor type. For manual tuning only, set the control current limit value to a percentage of the continuous current rating. For example, if your control is rated for 5A continuous current and you desire to limit the output current to 4A, enter 80%. If you wish to use the full output power of the control, enter 100%. Click Download when finished.
Figure 5-5 Current Parameter Screen
Velocity Parameter Set the velocity parameters of the control: 1. Scale factor - ratio of the input voltage to output RPM. 2. Minimum velocity 3. Time to maximum velocity Click Download when finished.
Figure 5-6 Velocity Parameter Screen
5-8 Operation
MN1275
Drift
If you know the input offset value of the control, you may enter the value manually. Otherwise, you may initiate automatic offset tuning and let the control measure and set this value. Click Download when finished.
Figure 5-7 Drift Parameter Screen
Autotune
You may manually tune the control (see appendix) or use autotune to allow the control to tune itself. Click Download when finished.
Figure 5-8 Autotune Screen
MN1275
Operation 5-9
Main Menu Choice Descriptions

File
Open a new editor window. Open an existing editor window. Close the active editor window. Close all editor windows. Save the active editor window to a file. Save the active editor window to a new file name . Save all editor windows. Print the contents of the active editor window. Exit and close the Set up software.
Edit
Cut the selected text in the active editor window to the clipboard. Copy the selected text in the active editor window to the clipboard. Paste text from the clipboard at the cursor location in the active editor window. Erase the contents of the active window. Select everything in the active window. Save the active editor window to a new file name .
Setup
Allows selection of the motor being used. Allows selection of Current, Velocity or Pulse Follower modes. Allows PC to read the control configuration and save the parameters to a file. Allows PC to read a configuration file and download parameters to the control. Save the contents of the motion buffer to a file. Restore a motion buffer file and downloads the parameters to the control. Select a control for communication (8 maximum in daisy chain). Not available for this control. Not available for this control.
5-10 Operation
MN1275
Tuning
Allows manual or automatic tuning to remove offset drift. Allows manual or automatic tuning of velocity control parameters.
Watch
Show or hide the symbols list bar. Show or hide the system parameters bar. Show or hide the system status bar. Gather and plot motor data for two variables. View the error log. View the available options for the selected control.
Functions
Enable the control. Disable the control --
Active: Motor decels to stop then control disables. Passive: Motor coasts to stop. Cause motor to stop and maintain position. Allow you to Jog the position of the motor. Define up to 12 PLC statements (logical association of input / output conditions).
Terminal
Allows communication with selected control using command set (see Appendix B). Configure PC COM port 1, 2, 3 or 4 to communicate with the selected control.
Windows
Cascade display of all open software windows. Tile display of all open software windows.
Alphabetic glossary listing of keywords. Search for help based on a keyword. Get help for a specific topic. Starts the setup wizard to configure a motor and control. Software version and release information.
MN1275
Operation 5-11
PLC Program
At the main menu, select Functions then PLC. See Figure 5-9. 1. Determine which event (listed under the THEN column) you wish to use. 2. Next, click in the IF column on the same ROW as the desired event. For example, If you are to use the MAO1 output, click in row 1 in the IF column as shown. 3. Choose the condition for the desired event. 4. Set other event conditions as desired. 5. Activate the PLC by selecting Enable on PLC Status. 6. Select Download to update the parameter values in the control. 7. Select Close when finished. Note: To reset all IF conditions to False, select Clear located just below the Download selection. This will clear all condition choices.
Figure 5-9 PLC Program Menu
5-12 Operation
MN1275
Section 6 Troubleshooting
Overview
The system troubleshooting procedures involves observing the status of the Ready LED, the DB On LED and the Monitor 7 segment display. The tables in this section provide information related to the indications provided by these devices. Note: The Ready LED can display RED, YELLOW or GREEN color. Table 6-1 Operating Mode Indications
Ready Monitor Status OFF OFF Control Disabled Green Decimal Control Enabled Point Red 1 Over-voltage fault (DC Bus) Red 3 Cause No Fault. Normal operating mode. No Fault.
Red Red Red Red
4 5 6 7
Red Red Green
9 0
(
'
Green Green
-l l-
Missing, damaged or wrong REGEN resistor. Input voltage too high. Over-current fault. Motor leads shorted or control failure. (More than 2X peak current) Load exceeds motor rating (too much current). Accel time set too short. Over or Under-voltage fault. Internal 15VDC supply fault. Resolver fault (or encoder fault). Resolver or cable short circuit or resolver not connected (open circuit). Electronic fusing Control current over-load detected by (also see fault 7) software. I2t limit reached. After a fault is detected, Cycle time between Acceleration and control will run at nominal output current for Deceleration is too short. 2.5 seconds then stop. The control is disabled and the Monitor will first display 7 fault then the 6 fault. Control Over-Temperature Control should be relocated to cooler area. Add fans or air conditioning to control cabinet. User defined fault (see PLC). Processor Watchdog timeout Reset control (turn off AC power, wait 1 minute then turn power on). Move Command not accepted. More than two move commands have been sent to the control. To return to normal status, send a Quit or a new move command to the control. A non-initialized buffer line has been called by the Machine inputs. To return to normal status, call an initialized buffer line by MA1-4 or send a Quit to the control. CW Enable switch activated. CW limit reached. Check X3-10 input. CCW Enable switch activated. CCW limit reached. Check X3-11 input.
Note: To protect the internal fuse, allow at least 1 minute after power down before turning power on (power Off/On cycle).
MN1275
Troubleshooting 6-1
Table 6-1 Operating Mode Indications Continued

Ready Monitor Status Red A EEPROM checksum error. Red Green Red Green Green c C C d E Velocity data in the EEPROM failed. CAN bus problem detected. CAN bus problem detected. Control Disabled. Following Error. Cause The personality must be downloaded to EEPROM and reset the control. If problem remains, contact Baldor. The velocity data must be downloaded to EEPROM and reset the control. If problem remains, contact Baldor. (C blinking) A communication error on the CAN bus exists. The control is still connected to the CAN bus. (C blinking) A communication error on the CAN bus exists. The control will attempt resynchronization to establish the CAN bus. Disable mode activated by hardware or software. The following error exceeded the user defined value of the Following Error Band. This error is not stored and goes away when the following error is reduced to within limits. The following error exceeded the user defined value of the Following Fatal Error. The following error preset level is Operation Mode & Pulse Follower This error is stored and must be cleared by the operator, but operation continues as long as the error is less than "215 ("32768). Hold mode activated by hardware or software. Jog mode activated by hardware or software. Defective or missing limit switch or wiring. The following error is less than the user defined preset value. The personality must be downloaded to EEPROM and reset the control. The personality must be downloaded to EEPROM and reset the control.
Green
Fatal Following Error.
Green Green Red Green Red Red
H J L P U u
Hold-Position mode. Jog mode. Both limit switches active. In Position. EPROM version fault. EEPROM version fault.
It is important to connect the motor leads U, V and W correctly at the X1 connector of the control. Incorrect wiring can cause erratic operation including moves at peak force until the overcurrent limit trips. This will result in a display of 7 and a 6 on the monitor. If erratic movement of the motor occurs, turn off power immediately and check the connections of the motor, hall sensors and encoder.
6-2 Troubleshooting
MN1275
Section 7 Specifications & Product Data

Identification
Servo Control -R C 4 3 FD X A X X X X -
Flex Drive Input Voltage 1=115VAC 2=230VAC 4=460/400VAC Current Rating A02 = 2 / 2.5 Amps A05 = 5 Amps A07 = 7.5 Amps A10 = 10 Amps A15 = 15 Amps A20 = 20 Amps A27 = 27.5 Amps Enclosure Type T= Panel Mount w/internal power supply P= Panel Mount w/external power supply S = Panel Mount w/internal power supply (suitable for sharing with other controls). Braking (Option) R = Requires external regen resistor B = Built-in regen resistor O = No internal regen capability
Logic Supply (Option) 0 = Internal 24VDC Supply 3 = External customer provided 24VDC required Serial Port Type (Option) 2 = RS232 4 = RS485 Bus (Option) N = None C= CAN Bus * Feedback Device (Option) R = Resolver E= Encoder
CAN Bus is only available for controls with resolver feedback. Controls that have encoder feedback may not have CAN Bus.
MN1275
Specifications & Product Data 7-1
Specifications
Description Unit FDX A02T FDX A05T FDX A07T FDX A02S FDX A05S FDX A010S FDX A015S
Input Voltage Range
Nominal Minimum Maximum Nominal Minimum Maximum
VAC
115 / 230 92 / 184 132 / 265 50/60 "5% 160 / 320 88 / 176 180 / 360 2.5 5 1.01 5.0 10 2.17 7.5 15 2.99 2.0 4 0.87 0 -- 500 >95 8.5 1200 10 to 200 (software selectable) Panel A B C E E E E 5.0 10 2.17 10 20 4.33 15 30 5.2
Input Frequency Nominal Output Bus (@ 115 / 230 input)
Hz VDC
Nominal Phase Current ("10%) Peak Phase Current ("10%); for 2.4sec (+0.5s/--0sec) maximum Nominal Output Power Output Frequency Efficiency Nominal Switching Frequency Current Loop Bandwidth Velocity Loop Bandwidth Mounting Package Size Operating Altitude
ARMS ARMS KVA Hz % KHz Hz Hz --Feet (Meters) #C
To 3300 feet (1000 meters). Derate the continuous and peak output current by 1.1% for each 330 feet (100 meters) above 3300 feet. +0 to 40. Above 40#C, derate the continuous and peak output current by 2.5% per #C above 40#C. Maximum ambient is 50#C.
--25 to +70 10% to 90% non-condensing IP20 10G (according to DIN IEC 68--2--6/29) 1G @ 10 -- 150 Hz (according to DIN IEC 68--2--6/29)
Operating Temperature
Rated Storage Temperature Humidity Class of Protection (Enclosure) Shock Vibration
#C %
Valid for zero current initial condition. These specifications also apply to model FDxAxxP except it has DC input (no AC input).
All values at ambient temperature of 25#C unless otherwise stated. For safe operation, allow a clearance distance between each control and on all sides of each control.
7-2 Specifications & Product Data
MN1275
Specifications Continued
Description Unit FD4 A02TB FD4 A05TB FD4 A07TB FD4 A15TR FD4 A20TR FD4 A27TR
Input Voltage Range
Nominal Minimum Maximum Nominal Minimum Maximum
VAC
460 @ 60Hz / 400 @ 50Hz 400 / 360 528 / 480 50/60 "5% 565 / 678 509 / --- / 746 2.5 5 1.9 5 10 3.8 7.5 15 5.7 >95 8.0 1200 10 to 200 (software selectable) Panel G G G H H H 15 30 11.4 0 -- 500 20 40 15.2 27.5 55 20.9
Input Frequency Nominal Output Bus (@ 400 / 460 input)
Hz VDC
Nominal Phase Current ("10%) Peak Phase Current ("10%); 1.25s +0.25s/--0s Nominal Output Power Output Frequency Efficiency Nominal Switching Frequency Current Loop Bandwidth Velocity Loop Bandwidth Mounting Package Size Operating Altitude
ARMS ARMS KVA Hz % KHz Hz Hz ---
Feet To 3300 feet (1000 meters). Derate the continuous and (Meters) peak output current by 1.1% for each 330 feet (100
meters) above 3300 feet.

Operating Temperature #C
+0 to 40. Above 40#C, derate the continuous and peak output current by 2.5% per #C above 40#C. Maximum ambient is 50#C.
--25 to +70 10% to 90% non-condensing IP20 10G (according to DIN IEC 68--2--6/29) 1G @ 10 -- 150 Hz (according to DIN IEC 68--2--6/29)
Rated Storage Temperature Humidity Class of Protection (Enclosure) Shock Vibration
#C %
Valid for zero current initial condition.
All values at ambient temperature of 25#C unless otherwise stated. For safe operation, allow a clearance distance between each control and on all sides of each control.
MN1275
24VDC Logic Power Input (Option FDxAxxxx--xxx3 ONLY)

Description Input Voltage (maximum ripple = "10%) Input Current @ 24VDC Power On surge current (24VDC 100msec) Unit VDC ARMS ARMS FDX A02T FDX A05T FDX A07T FDX FDX FDX A02S A05S A10S 20 -- 30 1.4 2.5 FDX A15S
0.55 -- 0.8 4.0
Depends on installed options.
24VDC Logic Power Input (Option FD4Axxxx--xxx3 ONLY) Continued

Description Input Voltage (maximum ripple = "10%) Input Current @ 24VDC Power On surge current (24VDC 100msec) Unit VDC ARMS ARMS FD4 A02 0.8 FD4 A05 1.0 FD4 FD4 A7 A15 20 -- 30 1.0 1.4 4.0 FD4 A20 1.6 FD4 A27 1.6
Velocity Control
Description Command Input Command Signal Resolution Update Rate Unit VDC bit msec All 0 to 10; or "10 12 500
Resolver Feedback
Description Resolution (Automatically set by software. Depends on maximum speed.) Pole Pairs Resolver Winding Ratio Unit bit Velocity < 6100RPM & Velocity > 6100RPM & All Resolution 14 bits Resolution 12 bits 1 0.5
Simulated Encoder Output

Description Signal Encoder Resolution Unit ppr All RS422 512 / 1024 / 2048 / 4096 Factory Setting
Pulse / Direction Input

Description Signal Operating Mode Maximum Input Frequency Cycle Time Unit VDC kHz msec All 12 -- 29 / Opto Isolated Pulse and Direction 125 1
7-4 Specifications & Product Data
MN1275
Encoder Input (Handwheel or Feedback)

Description Signal Type Operating Mode Maximum Input Frequency Cycle Time kHz msec Unit All RS422 A / B Quadrature 125 1
Serial Interface (Option FDXAXXXX--XX2X)

Description Communication Type Transmission Rate Baud Unit All RS232C (not galvanically isolated) 9600 (not adjustable)
Optional Interface (Option FDXAXXXX--XX4X)

Communication Type Transmission Rate Baud RS485 (not galvanically isolated) 9600 (not adjustable)
Regeneration (115 / 230VAC)

Description Switching Threshold 115VAC 230VAC Nominal / Peak Power (10% Duty Cycle) Maximum Regeneration Switching Current Maximum Load Inductance kW A mH Unit VDC FDX A02T FDX A05T FDX A07T FDX A02S
ON: 180 388
FDX A05S
FDX A10S
FDX A15S
ON: 188 - 195 373 - 383
OFF: 183 - 188 362 - 372
OFF: 200 375
0.25 / 2.7 10 100
Regeneration (400 / 460VAC)

Description Switching Threshold 400/460VAC Unit VDC kW A mH FD4 A02 ON: 794 FD4 A05 0.94 / 9.4 15 100 45 FD4 A07 FD4 A15 ON: 794 FD4 A20 2.9 / 29 40 80 FD4 A27
OFF: 787
OFF: 764
Nominal / Peak Power (10% Duty Cycle) Maximum Regeneration Switching Current Maximum Load Inductance
MN1275
Dimensions
Size A, B and C
A 1.57% (40mm)
Size E, G and H
7.70% (195.5mm)
15.75 (400)
6.81% (173mm)
15.14 (385)
14.05 (357) Depth Size A, B, C = 6.0 (152)
0.2 (5.2) Dia. 4 Places 0.12 (3.0)
Clearance Requirements (all sizes): 0.06% (15mm) top and bottom 0.04% (10mm) left and right side
0.374 (9.5) X
0.3 (8.0) Package Size A A w/CAN option B B w/CAN option C E G H A 0.59 (15) 0.59 (15) 0.90 (23) 0.90 (23) 0.90 (23) 1.08 (27.5) 1.28 (32.5) 2.6 (65) Dimensions in (mm) W 2.6 (67.5) 3.3 (84.0) 3.6 (92.5) 4.3 (109) 4.3 (109) 2.17 (55) 2.6 (65) 5.3(130) Weight lb (kg) X -----1.42 (36) 1.81 (46) 4.37 (111) 2.73 (1.24) 3.17 (1.44) 4.69 (2.13) 5.06 (2.3) 4.8 (2.19) 11 (5) 10.1 (4.6) 20.9 (9.5)
0.25 (6.5) Dia. 3 Places Depth Size E, G and H = 10.4 (265)
For safe operation, allow a clearance distance between each control and on all sides of each control. 7-6 Specifications & Product Data MN1275
Section 8 CE Guidelines
CE Declaration of Conformity
Baldor indicates that the products are only components and not ready for immediate or instant use within the meaning of Safety law of appliance, EMC Law or Machine directive. The final mode of operation is defined only after installation into the users equipment. It is the responsibility of the user to verify compliance. The product conforms with the following standards: DIN VDE 0160 / 05.88 Electronic equipment for use in electrical power installations DIN VDE 0100 Erection of power installations with nominal voltages up to 1000V DIN IEC 326 Teil 1 / 10.90 Design and use of printed boards DIN VDE 0110Teil 1-2 / 01.89 Dimensioning of clearance and creepage DIN VDE 0110Teil 20 / 08.90 distances EN 60529 / 10.91 Degrees of protection provided by enclosures
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 grounding of the system as a whole determines EMC compliance. The CE mark does not inform the purchaser which directive the product complies with. 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, it is the instructions of installation and use, coupled with the product, that comply with the directive.
Wiring of Shielded (Screened) Cables

Remove the outer insulation to expose the overall screen.
Conductive Clamp
MN1275
CE Guidelines 8-1
Using CE approved components will not guarantee a CE compliant system! 1. The components used in the drive, installation methods used, materials selected for interconnection of components are important. 2. The installation methods, interconnection materials, shielding, filtering and grounding of the system as a whole will determine CE compliance. 3. The responsibility of CE mark compliance rests entirely with the party who offers the end system for sale (such as an OEM or system integrator). Baldor products which meet the EMC directive requirements are indicated with a CE mark. A duly signed CE declaration of conformity is available from Baldor. EMC Wiring Technique
1
Y Capacitor
CABINET The drawing shows an electroplated zinc coated enclosure, which is connected to ground. This enclosure has the following advantages: -- All parts mounted on the back plane are connected to ground. -- All shield (screen) connections are connected to ground. Within the cabinet there should be a spatial separation between power wiring (motor and AC power cables) and control wiring. SCREEN CONNECTIONS All connections between components must use shielded cables. The cable shields must be connected to the enclosure. Use conductive clamps to ensure good ground connection. With this technique, a good ground shield can be achieved. EMC - FILTER The EMI or main filter should be mounted next to the power supply (here BPS). For the connection to and from the main filter screened cables should be used. The cable screens should be connected to screen clamps on both sides. (Exception: Analog Command Signal). Grounding (Earth) For safety reasons (VDE0160), all BALDOR components must be connected to ground with a separate wire. The diameter of the wire must be at minimum AWG#6 (10mm@). Ground connections (dashed lines) must be made from the central ground to the regen resistor enclosure and from the central ground to the Shared Power Supply. Y-CAPACITOR The connection of the regeneration resistor can cause RFI (radio frequency interference) to be very high. To minimize RFI, a Y--capacitor is used. The capacitor should only be connected between the dynamic brake resistor housing and terminal pin R1 (lead from Flex). Recommendation: 0,1)F / 250VAC Type: PME265 BALDOR--Ordering--No.: ASR27104
8-2 CE Guidelines
MN1275
EMC Installation Instructions

To ensure electromagnetic compatibility (EMC), the following installation instructions should be completed. These steps help to reduce interference. Consider the following: $ Grounding of all system elements to a central ground point $ Shielding of all cables and signal wires $ Filtering of power lines A proper enclosure should have the following characteristics: A) All metal conducting parts of the enclosure must be electrically connected to the back plane. These connections should be made with a grounding strap from each element to a central grounding point . B) 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. C) The shield connections of the signal and power cables should be connected to the screen rails or clamps. The screen rails or clamps should be conductive clamps fastened to the cabinet. D) The cable to the regeneration resistor must be shielded. The shield must be connected to ground at both ends. E) The location of the AC mains filter has to be situated close to the drive so the AC power wires are as short as possible. F) 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. G) To reduce ground current, use at least a 10mm2 (6 AWG) solid wire for ground connections. 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 ground point. This central ground point is then connected to the main plant (or building) ground. Or run as twisted pair at minimum.
Cable Screens Grounding

Cable (Twisted Pair Conductors)
Conductive Clamp -- Must contact bare cable shield and be secured to metal backplane.
MN1275
CE Guidelines 8-3
Input Signal Cable Grounding

Control X3
1 2 3 7 9 10 11
Cable
Simulated Encoder Output Cable Grounding

Control X7
1 6 2 7 3 8 11 13
Cable
To Controller
Resolver Cable Grounding

Control X8
1 6 2 7 3 8 5
Cable
Resolver Connector Housing

1 2 3 4 5 6
Connection of shields to analog ground is optional.
Encoder Cable Grounding

Control X9
1 6 2 7 3 8 11 13
Cable
Encoder Connector Housing
Connection of shields to digital ground is optional.
8-4 CE Guidelines
MN1275
Section 9 Accessories and Options

Cables
Shielded (Screened) cable provides EMI / RFI shielding and are required for compliance to CE regulations. All connectors and other components used must be compatible with this shielded cable. Motor Power Cable
Cable Assembly Description Power Cable Assembly Threaded connector (Standard-Metric Style) Length Baldor Catalog Number N mber CBL015SP--FHM CBL030SP--FHM CBL046SP--FHM CBL061SP--FHM CBL076SP--FHM CBL152SP--FHM CBL015SP--FHQ CBL030SP--FHQ CBL046SP--FHQ CBL061SP--FHQ CBL076SP--FHQ CBL152SP--FHQ CBL030SP--FHCE CBL061SP--FHCE CBL091SP--FHCE CBL152SP--FHCE CBL030SP--F CBL046SP--F CBL061SP--F CBL076SP--F CBL091SP--F CBL152SP--F CBL030SP--E CBL046SP--E CBL061SP--E CBL091SP--E CBL152SP--E
Feet Meters
Cable Rated Current C rrent
Power Cable Assembly Quick Connect Style
20 Amps Power Cable Assembly CE Style Threaded Connector Power Cable No Connectors
Power Cable No Connectors 30 Amps
5 10 15 20 25 50 5 10 15 20 25 50 10 20 30 50 10 15 20 25 30 50 10 15 20 30 50
1.5 3.0 4.6 6.1 7.6 15.2 1.5 3.0 4.6 6.1 7.6 15.2 3.0 6.1 9.1 15.2 3.0 4.6 6.1 7.6 9.1 15.2 3.0 4.6 6.1 9.1 15.2
Connectors
Mating Connector by connector number (for spare parts) X1 -- #ASR29714 (9 pin, Female) Phoenix Part No. MVSTBW2,5/9--ST X1 -- #ASR29715 (2 pin, Female) Phoenix Part No. MVSTBW2,5/2--ST X3 -- #ASR16000 (20 pin, Female) Phoenix Part No. MVSTBR2,5/20--ST X6 -- #ASR16215 (9 pin, Male) X7 -- #ASR16215 (9 pin, Male) X8 -- #ASR23345 (9 pin, Female) X9 -- #ASR25828A (15 pin, Male)
MN1275
Accessories & Options 9-1
Resolver Feedback Cable

Motor Type Cable Assembly Description Resolver Feedback Cable Assembly Threaded connector (Standard-Metric Style) Resolver Feedback Cable Assembly Quick Connect Style Baldor Catalog Number CBL015SF--ALM CBL030SF--ALM CBL046SF--ALM CBL061SF--ALM CBL076SF--ALM CBL152SF--ALM CBL015SF--ALQ CBL030SF--ALQ CBL046SF--ALQ CBL061SF--ALQ CBL076SF--ALQ CBL152SF--ALQ CBL030SF--ALCE CBL061SF--ALCE CBL091SF--ALCE CBL152SF--ALCE CBL030SF--A CBL061SF--A CBL091SF--A CBL152SF--A Length
Feet Meters
BSM 50/63/80/90/100
Resolver Feedback Cable Assembly CE Style Threaded Connector Resolver Feedback Cable No Connector
BSM 50/63/80/90/100
5 10 15 20 25 50 5 10 15 20 25 50 10 20 30 50 10 20 30 50
1.5 3.0 4.6 6.1 7.6 15.2 1.5 3.0 4.6 6.1 7.6 15.2 3.0 6.1 9.1 15.2 3.0 6.1 9.1 15.2
EMC AC Mains Filter AC filters remove high frequency noise to protect the control. These filters
also prevent high frequency signals from being transmitted back onto the power lines and help meet CE requirements. To select the proper filter, you must know the voltage and current used by the drive and the impedance of the AC line. For package size A, B and C (Model T -- 1 Phase)
Filter Type FN 2070 - 12 Rated Volts 250 Rated Amps @ 40#C 12 Leakage Current mA 0.4 Weight lbs (kg) 1.61 (0.73) Baldor No. 30548
For package size E, G and H (Model S -- 3 Phase)

Filter Type FN 351 - 8 - 29 FN 351 - 16 - 29 FN 351 - 25 - 33 FN 351 - 36 - 33 FN 351 - 50 - 33 Rated Volts 440 440 440 440 440 Rated Amps @ 40#C 8 16 25 36 50 Leakage Current mA 16 16 170 170 190 Power Losses Watts 8.0 9.0 9.0 10.5 12.5 Weight lbs (kg) 3.97 (1.8) 3.97 (1.8) 6.61 (3.0) 6.61 (3.0) 6.83 (3.1) Baldor No. ASR24667 ASR24668 ASR24669 ASR24670 ASR24671
9-2 Accessories & Options
MN1275
For package size E, G and H (Model T -- 3 Phase Required for LD4xx)

Filter Type FN 3258 - 30 - 47 FN 3258 - 7 - 45 Rated Volts 480 480 Rated Amps @ 40#C 30 7 Leakage Current mA 184.7 172.4 Weight lbs (kg) 2.64 (1.2) 0.11 (0.5) Baldor No. ASR30521 ASR30522
AC Filter Dimensions Continued

Dim. A B C D E F G H For FN350 5.4 (139) 3.9 (99) 4.2 (105) 3.32 (84.5) 3.73 (95) 2.24 (57) 0.39 (10) 1.74 (19) 8 - 29 8.6 (220) 7.1 (180) 4.5 (115) 3.35 (85) 3.93 (100) 2.36 (60) 0.39 (10) 0.76 (19.5) For Filters: FN 351 16 - 29 25 - 33 36 - 33 50 - 33 9.45 9.84 (240) (250) 7.87 7.87 (200) (200) 5.9 5.9 (150) (150 4.7 4.72 (119.5) (120) 5.31 5.31 (135) (135) 2.55 2.55 (65) (65) 0.39 0.78 (10) (20) 1.22 0.83 (31) (21)
Depth = F
4.53 (115)
G G H D C E
M6
B A
AC Filter Dimensions
Dim. A B C D E F G
Continued
For Filters: FN3358- 7- 45 FN3358- 30- 47 7.48 10.63 (190) (270) 6.29 9.45 (160) (240) 7.08 10.04 (180) (255) 0.79 1.18 (20) (30) 0.18 0.21 (4.5) (5.4) 2.75 3.35 (70) (85) 1.57 1.97 (40) (50)
B F
M5 A G
MN1275
Regeneration Resistor
A regeneration resistor should be installed to dissipate energy during braking if a Fault 1 (over-voltage) occurs.
Baldor Catalog Number 230VAC Controls Resistor Resistor Catalog Watts No. RG56 44 RG56 44 RG39 100
Control Rated Amps 2.5 5 7.5 2.5 5 7.5 15 20 27.5 2 5 10 15
Control Size A B C G G G H H H E E E E
115VAC Controls Resistor Resistor Catalog Watts No. RG27 44 RG27 44 RG22 100
400/460VAC Controls Resistor Resistor Catalog Watts No.
* RG68 * RG68 RG68 RG27A RG11 RG11 RG4.7 RG4.7 RG4.7 RG4.7 320 320 320 320 RG10 RG10 RG10 RG10 320 320 320 320
320 320 320 320 640 640
These controls have a 200 ohm, 50 watt resistor installed (internal). An RG68 resistor can be installed in parallel for additional capability.
1.7 (45) 3.9 (100) 3.54 (90)
L
M4 L = 5.5 (140) for 44 watt 8.9 (228) for 100 watt 13.2 (337) for 320/640 watt 2.6 (65)
Clearance Requirements (all sizes): 2% (51mm) top and bottom 1% (26mm) left and right side
For safe operation, allow a clearance distance between each control and on all sides of each control.
MN1275
CAN Bus (Optional -- Not available for controls with encoder feedback.)
Controls that are supplied with the CAN bus option have two additional connectors, X10 and X11 (conform to DS102, version 2.0). These are shown in Figure 9-1. CAN is a factory installed option.
Figure 9-1 CAN Bus Connectors

X1 Monitor AS1
1 2 3 4 5 6 7 8 Off/On
NC L N U V W R1 R2 +24V 0V
Note: On some models, the width of the control may increase slightly when equipped with the CAN option.
Ready Encoder In X9 Encoder Out X7 RS232 / 485 X6
DB On
CAN X10
X10 - CAN Bus 1 2 3 4 5 Reserved CAN_L GND Reserved Reserved 6 7 8 9 GND CAN_H Reserved VCC
X11 - CAN Bus Resolver In X8 CAN X11 1 2 3 4 5 Reserved CAN_L GND Reserved Reserved 6 7 8 9 GND CAN_H Reserved VCC
X3
MN1275
Figure 9-2 CAN Bus Interconnections CAN MASTER
Flex Control X10 X11 X10
Flex Control X11
X10-7 X10-2 CAN_H CAN_L
X11-7 CAN_H
X11-2 CAN_L
X10-7 X10-2 X10-3 CAN_H CAN_L GND
X11-7 CAN_H
X11-2 CAN_H CAN_L CAN_L
X10-3 GND
X10-3 GND GND
120W
120W
Terminate the last drive
Terminate the Master
CAN Bus Protocol Baldor uses CAN_OPEN, DS 301 protocol. Baud rate is preset to 125kbit/second may be changed by AS1 switch settings or serial command (e.g. command: CAN.BD = 1000 for 1Mbit/sec). Available baud rates are: 10, 20, 50, 100, 125, 250, 500, 800, and 1000kbit/sec. NODE_ID may be changed by switch settings or serial command (e.g. command: CAN.ID = 50). Available addresses are 1 to 127. CAN Bus Features The following features are available with the Baldor CAN_OPEN structure: One SDO S S Two PDOs; each for transmit and receive (synchronous or asynchronous) S SYNC message S EMERGENCY object S Default and variable PDO mapping S All IDs can be set with SDO S Node guarding S Simple boot-up
MN1275
Index Range
The index range from 0x1000 to 0x100D is valid. The following index ranges are important:
0x1400 0x1402 0x1600 0x1602 0x1800 0x1802 0x1A00 0x1A02 1st PDO receive (communication) 2nd PDO receive (communication) 1st PDO receive (mapping) 2nd PDO receive (mapping) 1st PDO transmit (communication) 2nd PDO transmit (communication) 1st PDO transmit (mapping) 2nd PDO transmit (mapping)
Object Entries The following object entries are available with PDO:
----Read position (absolute and resolver position) Read and write velocity Read status Write torque
The following object entries are available with SDO:

-- Variables and commands
Getting Started with CAN_OPEN

The CAN message transmission consists of an address (=Identifier = ID) followed by 0 to 8 Data bytes. CAN drives use the following addresses (according to CAN_OPEN, DS301):
PDO1 (Receive, Master to Drive): 0x200 + Node_ID PDO2 (Receive, Master to Drive): 0x300 + Node_ID PDO1 (Transmit, Drive to Master): 0x180 + Node_ID PDO2 (Transmit, Drive to Master): 0x280 + Node_ID NMT: 0x000 SYNC: 0x80 EMERGENCY: 0x80 + Node_ID SDO (Master to Drive): 0x600 + Node_ID SDO (Drive to Master): 0x580 + Node_ID PDO = Process data transfer, fast communication ex: velocity command. SDO = Service data transfer, slow communication to access all parameters inside the drive. NMT = Network management task, to switch the PDOs free and to reset the drive. SYNC = Specific CAN_OPEN message to do some synchronization. EMERGENCY: The drive will send this message automatically if a fatal drive error occurs Node_ID: Special setting (= drive number) for each drive. Range : 1 to 127
MN1275
The default Baud rate is set to 125 kbit/second and the Node_ID is the drive address+1 (AS1 switches 1 to 4). Note: Every drive, connected to one CAN Bus system must have a different Node_ID. After power up you will receive an EMERGENCY message with two data bytes (0x00 and 0x00) to inform you that the CAN_DRIVE is now active. Now you will have access to all commands via SDO. If you want to give a command or set a parameter, you have to put the following message on the CAN_BUS: To send a command or set a parameter in the drive:
PC Master D0 0x20 0x20 D1 Ind_lo Ind_lo D2 Ind_hi Ind_hi D3 Sub Sub D4 XXX XXX D5 XXX XXX D6 XXX XXX Drive D7 XXX XXX
ID = 0x600 + NODE_ID <-------------------------------------------ID = 0x580 + NODE_ID <-------------------------------------------Where: X ID 0x D0 - D7 Ind_lo Ind_hi Sub Data bytes (to write a parameter) Identifier Hexadecimal data format Data byte 0 to 7 of CAN message Low byte of Index of Object dictionary High byte of Index of Object dictionary Subindex of Object dictionary. If Object has only one entry, Subindex must always be 0
Note: If the first data byte in the returned message from the drive = 0x80, the commanded action failed.
MN1275
To read a parameter from the drive:

PC Master D0 0x40 0x60 D1 Ind_lo Ind_lo D2 Ind_hi Ind_hi D3 Sub Sub D4 XXX 0x00 D5 XXX 0x00 D6 XXX 0x00 Drive D7 XXX 0x00
ID = 0x600 + NODE_ID <-------------------------------------------ID = 0x580 + NODE_ID <-------------------------------------------Where: X ID 0x D0 - D7 Ind_lo Ind_hi Sub P_lsb P_msb Dont care Identifier Hexadecimal data format Data byte 0 to 7 of CAN message Low byte of Index of Object dictionary High byte of Index of Object dictionary Subindex of Object dictionary. If Object has only one entry, Subindex must always be 0 Low byte of requested parameter High byte of requested parameter
Note: If the first data byte in the returned message from the drive = 0x80, the commanded action failed. To send a velocity command to the drive: 1. Verify that the correct motor and drive parameters and operating mode are set. This is done by CAN or RS232 communications. 2. Send the following CAN messages to the drive.
ID 0x601 0x581 0x601 0x581 0x601 0x581 D0 0x20 0x60 0x20 0x60 0x20 0x60 D1 0x8F 0x8F 0x83 0x8F 0x90 0x8F D2 0x21 0x21 0x21 0x21 0x20 0x21 D3 0x00 0x00 0x00 0x00 0x00 0x00 D4 0x08 0x00 XXX 0x00 Vl 0x00 D5 XXX 0x00 XXX 0x00 Vm 0x00 D6 XXX 0x00 XXX 0x00 XXX 0x00 D7 XXX 0x00 XXX 0x00 XXX 0x00 Description Select CAN card for velocity command. Drive response with OK. Enable drive. Drive response with OK. Velocity command (Vl=lsb; Vm=msb. Scaling=bits/msec) Drive response with OK.
Note: Every command is answered by the drive. Allow time for the response. Summary: With a CAN_OPEN master you dont need to know each data byte. Therefore you only should be informed about the object dictionary, which you will find in the Appendix. Appendix: Object dictionary ASCII command set description
MN1275
Identifiers and object list

The distribution of the identifiers of the supported objects conforms to Can Open (DS301, V 3.0, S. 8--12).
Message / Object Function Code COB - Identifier Services Start_Remote_Node Stop_Remote_Node Pre-Operational-State NMT_Reset_Node NMT_Reset_Com Synchronization Emergency (fault) Transmit PDO (asynchronous) Receive PDO (asynchronous) Transmit PDO (synchronous) Receive PDO (synchronous) Transmit SDO Receive SDO NMT node guarding
NMT Services
0 (broadcast)
Sync. Emergency PDO1 (tx) PDO1 (rx) PDO2 (tx) PDO2 (rx) SDO (tx) SDO (rx) Node guarding
1 1
128 (broadcast) 128 + Node_ID 384 + Node_ID 512 + Node_ID 640 + Node_ID 768 + Node_ID 1408 + Node_ID 1536 + Node_ID 1760
Node_ID is the node identifier, which is the card--address (set by switch AS1--4). SDO Protocols (CMS Multiplexed Domain Protocols) In CiA/DS202--2 CMS protocol specification, the following specifications of the SDO COB identifier. This protocol specifies the meaning of the content of the 8 data bytes transferred within a CAN Message for the different domain protocols.
Byte 1 Protocol Control Bits index, lsb Byte 2 Byte 3 Multiplexer or Data Bytes index, msb sub-index Byte 4 Byte5 to Byte 8 up to 4 Data Bytes Data (byte 5 is lsb; byte 8 is msb)
Multiplexed: Same identifier, message indication by Index + Subindex Expedited: Used, if data to be transported is less or equal 4 byte (long int, 32 Bit) The following tables list the meaning / setting of the control bits of first byte (x = not used, always 0) to select the protocol and the correspondent meaning of the further 7 data bytes of the CAN frame.
MN1275
Expedited domain download and initiate domain download

Domain Protocols Expedited Domain Download Request Confirm Initiate Domain Download Request Confirm 7..5: ccs 001 scs 011 ccs 001 scs 011 4: x x x x 3..2:n (0 or n) x x x 1:e 1 x 0 x 0:s s x s x = 1.byte =22, 2x1 =60 =20, 2x2 =60 m up to 4 data bytes multiplexor data to be downloaded multiplexor if s=1: number of data reserved
n:
If e=1 & s=1, n indicates the number of bytes, which do not contain data (therefore only valid for expedited protocol) s: Data set size is not indicated / indicated: 0 / 1 1 If s=1, the 1.byte contains: 23 or (n shifted 2 left) 2 If s=1, the 4 data bytes contain the number of data bytes to be transferred in the segmented domain. Segmented domain download
Domain Protocols Download Domain Segment Request Confirm End of Download Domain Segment Request Confirm 7..5: ccs 000 scs 001 ccs 000 scs 001 4: t 0/1 0/1 0/1 0/1 3..1:n n x n x 0:c 0 x 1 x = 1.byte =00 / 10 =20 / 30 =0X / 1X3 =20 / 30 up to 3+ up to 4 data bytes 7 data bytes to be downloaded Reserved <7 data bytes to be downloaded Reserved
t: n: c:
3
Toggle bit of segmented domain, with first download domain segment t=0 n indicates the number of bytes, which do not contain data 1 if last segment to be downloaded, else 0 The 1. byte contains: 01 or (n shifted 1 left)
Expedited domain upload and initiate domain upload

Domain Protocols Expedited Domain Upload Request Confirm Initiate Domain Upload Request Confirm 7..5: ccs 001 scs 010 ccs 001 scs 010 4: t x x x x 3..1:n x (0 or n) x 0 1:e X 1 x 0 0:c x s x s = 1.byte =40 =42,4X4 =40 =40, 41 m up to 4 data bytes multiplexor reserved data to be downloaded multiplexor reserved if s=1: number of data
n: s:
If e=1 & s=1, n indicates the number of bytes, which do not contain data Data set size is not indicated / indicated: 0 / 1, in the case of expedited protocol s indicates that n gives the number of non--data bytes, in the case of initiate protocol s indicates that the four data bytes 5. data byte 5 .. 8. data byte contain the total number of bytes to be uploaded. If s=1, the 1.byte contains: 43 or (n shifted 2 left)
MN1275
Segmented domain upload

Domain Protocols Upload Domain Segment Request Confirm End of Upload Domain Segment Request Confirm 7..5: ccs 001 scs 000 ccs 011 scs 000 4: t 0/1 0/1 0/1 0/1 3..1:n x n x n 0:c x 0 x 1 = 1.byte =60 / 70 =0E / 1E =60 / 70 =0X / 1X5 up to 3+ up to 4 data bytes Reserved 7 data bytes to be downloaded Reserved <7 data bytes to be downloaded
t: n: c:
5
Toggle bit of segmented domain, with first upload domain segment t=0 n indicates the number of bytes, which do not contain data 1 if last segment to be uploaded, else 0 The 1. byte contains: 01 or (n shifted 1 left)
Abort Domain Transfer (Unconfirmed)

Domain Protocols Expedited Domain Upload Request 7..5: c100 4.0 x
80
1.byte
up to 4 data bytes
multiplexor reason for the abort
MN1275
Object Dictionary (CAN - Version: 23310D)

Index (hex) 0000 0001 -- 001F 0020 -- 003F 0040 -- 005F 0060 -- 007F 00A0 -- 0FFF 1000 -- 1FFF Object not used Static Data Types Complex Data Types Manufacturer Specific Data Types Device Profile Specific Static Data Types Reserved for future use Communication Profile Area DEVICE_TYPE ERROR_REGISTER MANUFACT_STATUS_REGISTER PREDEFINED_ERROR_FIELD NUMBER_OF_PDOS COB_ID_SYNC_MSG COMMUNI_CYCLE_PERIODE SYNCHRON_WINDOW_LENGTH MANUFACT_DEVICE_NAME MANUFACT_HW_VERSION MANUFACT_SW_VERSION NODE_ID GUARD_TIME LIFE_TIME_FACTOR RECEIVE_PDO_2_COMMUNI_PARAM RECEIVE_PDO_1_COMMUNI_PARAM RECEIVE_PDO_2_MAPPING_PARAM RECEIVE_PDO_1_MAPPING_PARAM TRANSMIT_PDO_2_COMMUNI_PARAM TRANSMIT_PDO_1_COMMUNI_PARAM TRANSMIT_PDO_2_MAPPING_PARAM TRANSMIT_PDO_1_MAPPING_PARAM MANUFACT_NODI_ID MANUFACT_BAUD_RATE Objects with Subindexes (2010 - 2020): MANUFACT_CUR_CONTROLLER MANUFACT_VEL_CONTROLLER MANUFACT_HANDWHEEL_PARAM MANUFACT_POS_CONTROLLER MANUFACT_MOTOR_PARAM MANUFACT_DRIVE_PARAM MANUFACT_SYS_PARAM MANUFACT_JOG_PARAM MANUFACT_MOT_PARAM MANUFACT_HOM_PARAM MANUFACT_LIM_PARAM MANUFACT_COM_JOG MANUFACT_COM_MOV MANUFACT_COM_GO MANUFACT_COM_LRN 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 100A 100B 100C 100D 1400 1402 1600 1602 1800 1802 1A00 1A02 2000 2001 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2050 2051 2052 2053 OBJECT_UNSIGNED8 0005 Used
2000 -- 5FFF
Manufacturer Specific Profile Area
MN1275
Continued
Index (hex) Object Used PDO mappable parameters (2080 - 2093): MANUFACT_POS MANUFACT_ABS_POS MANUFACT_VEL MANUFACT_VEL_COMMAND MANUFACT_CONTROL_COMMAND MANUFACT_TORQUE_COMMAND MANUFACT_POS_COMMAND Read only: MANUFACT_COM_ACTU MANUFACT_COM_ACTV MANUFACT_COM_ANAIN MANUFACT_COM_CUR MANUFACT_COM_FLT MANUFACT_COM_FEST MANUFACT_COM_LOG MANUFACT_COM_MODE MANUFACT_COM_MPFE MANUFACT_COM_MVFE MANUFACT_COM_PFE MANUFACT_COM_VFE MANUFACT_COM_POS MANUFACT_COM_PREF MANUFACT_COM_RFOFS MANUFACT_COM_VEL MANUFACT_COM_VREF MANUFACT_COM_WRN MANUFACT_COM_ABSPOS Write only: MANUFACT_COM_CLEAR 2180 MANUFACT_COM_DIS MANUFACT_COM_ENA MANUFACT_COM_DISA MANUFACT_COM_FRST MANUFACT_COM_GRST MANUFACT_COM_HOLD MANUFACT_COM_IADJ MANUFACT_COM_ICLC MANUFACT_COM_JS MANUFACT_COM_LOGRST MANUFACT_COM_PRST MANUFACT_COM_ABS MANUFACT_COM_HOME MANUFACT_COM_INC MANUFACT_COM_CALC MANUFACT_COM_QUIT MANUFACT_COM_CONT MANUFACT_COM_STOP MANUFACT_COM_PLOAD MANUFACT_COM_PSAVE 6000 -- 9FFF A000-- FFFF Standardized Device Profile Area Reserved 2080 2082 2081 2090 2091 2092 2093 2100 2101 2102 2103 2104 2105 2106 2107 2108 2109 210A 210B 210C 210D 210E 210F 2110 2111 2112 2180 2181 2182 2183 2184 2185 2186 2187 2188 2189 218A 218B 218C 218D 218E 2190 2191 2192 2193 2194 2195
MN1275
Subindexes to Index 2010 (CUR. Commands)

ASCII Command (Entries) CUR.ACTV CUR.ACTU Reserved CUR.IPEAK CUR.INOM Reserved Reserved Reserved CUR.TOFR CUR.TOSH CUR.BEMF CUR.SCAL CUR.VOLT Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x09 0x0A 0x0B 0x0C 0x0D Read/Write (RW), Read only (RO), Write only (WO) RO RO RO RW RW
RW RW RW RW RW
Subindexes to Index 2011 (VEL. Commands)

ASCII Command (Entries) VEL.ACC VEL.ADZON VEL.BW Reserved VEL.MXRPM VEL.VEL Reserved VEL.VREF VEL.CTRL VEL.TRKFCT VEL.GV VEL.GVI Reserved Reserved Reserved VEL.INRT VEL.SCAL VEL.VOLT Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x09 0x0A 0x0B 0x0C 0x0D 0x0E 0x0F 0x10 0x11 0x12 Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RW RO RO RO RW RW RW RW
RW RW RW
MN1275
Subindexes to Index 2012 (HW. Commands)

ASCII Command (Entries) HW.GRFX HW.GRSH HW.PLCGEAR HW.RES HW.TYPE Subindex 0x00 0x01 0x02 0x03 0x04 0x05 Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RW RW RW
Subindexes to Index 2013 (POS. Commands)

ASCII Command (Entries) POS.FEWRN POS.FEFAT POS.FEST POS.FFA POS.FFTYPE POS.FFV POS.IPOS POS.KP POS.MPFE POS.REF POS.PFE POS.POS Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x09 0x0A 0x0B 0x0C Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RO RW RW RW RW RW RO RO RO RO
Subindexes to Index 2014 (MTR. Commands)

ASCII Command (Entries) MTR.IDX MTR.IND MTR.INOM MTR.IPEAK MTR.JM MTR.MPLS MTR.RPLS MTR.RES MTR.KT MTR.KV MTR.NAME Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x09 0x0A 0x0B Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RW RW RW RW RW RW RW RW RW
MN1275
Subindexes to Index 2015 (DRV. Commands)

ASCII Command (Entries) DRV.BUSAPP DRV.BUSOV DRV.BUSV DRV.I2T DRV.ID DRV.IDX DRV.INOM DRV.IPEAK DRV.LIFE Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x09 Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RW RW RW RW RW RW RO
Subindexes to Index 2016 (SYS. Commands)

ASCII Command (Entries) SYS.ANAIN SYS.ANA2 SYS.ENC SYS.ENCRES SYS.FAULT SYS.FBACK SYS.INFO SYS.MOD SYS.OPT SYS.POWER SYS.RFOFS SYS.POS SYS.STTS SYS.VER SYS.WRN Reserved SYS.ENCINDX SYS.LEVEL Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x09 0x0A 0x0B 0x0C 0x0D 0x0E 0x0F 0x10 0x11 0x12 Read/Write (RW), Read only (RO), Write only (WO) RO RO RO RW RW (encoder system only) RO RW RO RW RO RO RW RO RO RO RO RW RO
Subindexes to Index 2017 (JOG. Commands)

ASCII Command (Entries) JOG.TIME JOG.TYPE JOG.VEL Subindex 0x00 0x01 0x02 0x03 Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RW
MN1275
Subindexes to Index 2018 (MOT. Commands)

ASCII Command (Entries) MOT.ABSPOS MOT.ACC MOT.VEL Reserved MOT.TYPE MOT.DWELL MOT.INCCW MOT.INCW MOT.SRC MOT.STATUS MOT.TRIG MOT.BUFTYPE MOT.GENPOS Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 0x08 0x09 0x0A 0x0B 0x0C 0x0D Read/Write (RW), Read only (RO), Write only (WO) RO RO RW RW RW RW RW RW RW RO RW RW RO
Subindexes to Index 2019 (HOM. Commands)

ASCII Command (Entries) HOM.ACC Reserved HOM.VEL HOM.TYPE HOM.OFFSET HOM.POLR HOM.STATUS Subindex 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RW RW RW RO
Subindexes to Index 2020 (LIM. Commands)

ASCII Command (Entries) LIM.CW LIM.CCW LIM.ON LIM.LRN Subindex 0x00 0x01 0x02 0x03 0x04 Read/Write (RW), Read only (RO), Write only (WO) RO RW RW RW RW
MN1275
Appendix A Manual Tuning

TUNING This appendix presents guidelines for manual tuning the Control. Tuning is necessary, since a various loads (friction and inertia) will effect the drive response. Response may be defined as the time required for the drive to reach speed. Various software tools are available to make tuning easier, such as: Internal libraries (easy definition of parameters), pole placement (the software calculates a no--overshoot response), plotting routine (the drive response is displayed on a screen). This information is as a guide only and the exact response is entirely up to the individual performing the tuning. TUNING GUIDELINES The Flex control is easily tuned using a laptop computer and Flex software. The autotuning procedure provides a stable and responsive drive, by adjusting the parameter values for velocity loop tuning. The autotuning procedure will work for most applications. Manual tuning however may be desirable when very tight response is required. These guidelines provide a basic reference starting point for any additional adjustments. General Tuning Rules Tune the velocity loop first, and then tune the position loop (when using pulse/direction, or position follower mode). The velocity loop should always be tuned before the position loop, as velocity loop tuning affects the position loop response. To reduce mechanical resonance, use a stiffer mechanical coupling or decrease the low--pass filter value. Manual Tuning Manual tuning may be used to adjust the response of the control. Two types of manual tuning are possible: velocity tuning and position tuning (for a system which has been set up to operate in either the pulse/direction, or position follower mode). Initial Settings Required Before manual tuning can begin, the motor, control, and operating mode must be set. Make sure that these parameters have been selected and downloaded.
MN1275
Manual Tuning A-1
There are 7 parts to the setup procedure: Motor Select your motor from the library. First, select the general motor type. Then select your specific motor. All of the parameters will be entered if your motor is on the list. If your motor is not on the list, you may define a motor and all of its parameters. Click Download when finished.
Figure A-3 Motor Selection Screen
Control
The Control ID is automatically selected. All of the parameters will be entered if your control is on the list. Click Download when finished.
Figure A-4 Control Selection Screen
A-2 Manual Tuning
MN1275
After the motor and control are selected, click the General menu and note that the values are filed in.
Operating Mode Select the operating mode of the control. Choices are: 1. Current Mode 2. Velocity Mode 3. Pulse Follower Mode (Pulse & direction or Electronic Handwheel) Click Download when finished.
Figure A-5 Operating Mode Selection Screen
MN1275
Manual Tuning A-3
Current Parameter Nominal and peak current values are automatically entered for the motor type. For manual tuning only, set the control current limit value to a percentage of the continuous current rating. For example, if your control is rated for 5A continuous current and you desire to limit the output current to 4A, enter 80%. If you wish to use the full output power of the control, enter 100%. Click Download when finished.
Figure A-6 Current Parameter Screen
Velocity Parameter Set the velocity parameters of the control: 1. Scale factor - ratio of the input voltage to output RPM. 2. Minimum velocity 3. Time to maximum velocity Click Download when finished.
Figure A-7 Velocity Parameter Screen
A-4 Manual Tuning
MN1275
Drift
If you know the input offset value of the control, you may enter the value manually. Otherwise, you may initiate automatic offset tuning and let the control measure and set this value. Click Download when finished.
Figure A-8 Drift Parameter Screen
Manual Tuning The first six steps of the manual tuning process is shown in Figure A-9.
Figure A-9 Select Manual Tuning
1 Select Tuning
4 5 Select Pole Placement Enter either Inertia or Inertia Ratio (the other value is automatically entered). 3 Select OK 6 Enter a value for Bandwidth 7 Click on Download
2 Select Manual Tuning
If Pole Placement method of adjustment is selected, you would enter values for inertia or inertia ratio. Enter either one, and the other value will automatically be entered. This is the easiest and recommended method of adjustment. If PI method of adjustment is selected, you would enter values for GV--gain and GVI--gain. This is an advanced method of adjustment, and is more difficult. Both methods of adjustment provide identical results. PI method is described later in this section. MN1275 Manual Tuning A-5
POLE PLACEMENT Pole placement provides a no--overshoot response when tuned for the correct inertia. This is the easiest and recommended method of adjustment. Inertia Click in the Load block and enter the value in Kg--cm2. The range is from 0 to 133 Kg--cm2. If the inertia is under--estimated, the system will be stable. If the inertia is over--estimated, the system will vibrate or oscillate due to too much system gain. If the load inertia is unknown, estimate low. It is recommended to start with load inertia = 0.2, which represents a stable condition. If you entered the inertia ratio, you should enter a value representing the ratio of reflected load inertia to motor inertia. The range is from 0 to 100. Response Move to the Response block and place the cursor in the bandwidth window, and click on it. The bandwidth is a measure of the range over which the system can respond. It is expressed in frequency or Hertz. This parameter controls the rise time of the system. It does not effect overshoot. It is recommended that bandwidth is increased only if higher dynamic response is required. Increase the bandwidth and observe (go to plotting of move) the velocity and command current, until current reaches maximum value, then back off to 80%. The range is from 10--200. The next step, would be to verify that the value you entered, provides for adequate system response. You can check this out, by having the software move the equipment and plot the response. Proceed to Plotting of Move.
Figure A-10 Inertia and Load Response Examples

Over--Estimated
1500 1500
Under--Estimated
1500
Good Response Velocity (RPM)
Velocity (RPM)
Velocity (RPM)
1000 500 0 --500
1000 500 0 --500
1000 500 0 --500
Time Velocity Command / Velocity
Tracking factor The tracking factor parameter controls the amount of tracking versus overshoot. The range is 0 to 200. A tracking factor of 0 generates no overshoot. A tracking factor of 200 results in a PI equivalent control (i.e. with overshoot). The next step, would be to verify that the values you entered, provides for adequate system response. You can check this out, by having the software move the equipment and plot the response. Proceed to Plotting of Move. Click in the Tracking block and enter the desired adjustment value. This adjustment is used for applications that require improved tracking (or following) capability, to improve (or reduce) following error.
A-6 Manual Tuning
MN1275
PI COMPENSATION PI method of adjustment allows adjustment of the acceleration ramp time and overshoot values. If PI Compensation is selected, you would enter values for GV--gain and GVI--gain. Select PI Compensation instead of Pole Placement on the menu shown in Figure A-9. This is an advanced method of adjustment for use by servo engineers. The pole placement method is easier to use for most applications and is recommended.
Figure A-11 PI Compensation Menu
GVI-Gain
The Integral Gain (GVI) is the integral gain of the velocity loop. It controls 1) the stiffness (the ability to reject load disturbances), and 2) the amount of offset, or following error, during steady state conditions (velocity command or load does not change). The adjustable range is from 0 to 32767. 1. Click on the Integral Gain (GVI) box and enter a value. You may want to begin with the default values click on the default button and answer yes. To increase stiffness, increase the GVI--gain setting. It rejects load disturbance and compensates for system friction. To reduce following error, or offset, during steady state running conditions, increase the GVI--gain setting. To reduce the overshoot, reduce the GVI--gain setting. Note: As you increase the value for GVI, the system will become unstable, i.e. oscillate. You may hear an audible noise. Decrease the GVI value immediately. Continue to decrease the value until the noise is no longer heard, then decrease it another 10%. 2. Next, verify that the value you entered provides adequate system response. To verify, have the software move the equipment and plot the response. Proceed to Plotting of Move.
MN1275
Manual Tuning A-7
GV-Gain
This is the proportional gain of the velocity loop. It controls the gain of the velocity loop by adjusting the controls response to the error. The error is the difference between the commanded and actual velocity. The higher the gain, the smaller the difference (or error). The adjustable range is from 0 to 32767. 1. Click in the Proportional Gain (GV) box. Enter a value for GV. You may want to begin with the default values click on the default button and answer yes. Note: The default values may not be best for all applications, it may be too high. If the system is noisy (displays an audible noise) decrease this value immediately. To obtain a faster rise time, increase the GV--gain setting. The ramp up time (to operating speed) will be faster. As you increase the value for GV, the system may have very large overshoots and become unstable. Decrease the GV value immediately. Then decrease it another 10%. 2. Next, verify that the value you entered provides adequate system response. You can check this out, by having the software move the equipment and plot the response. Proceed to Plotting of Move.
A-8 Manual Tuning
MN1275
Plotting of Move At any time after the setup parameters are downloaded to the control, you may proceed to the plotting routine. Plot allows you to verify that the parameter values you entered provide adequate system response. In this section, you will inform the software what move to perform. You will enter time (for the move), direction (CW or CCW) and speed. It is recommended that you start with low speeds (i.e. 100 RPM) and short time periods (i.e. 0.5 sec) until you get a feel for your system. Control Window Enter the parameter values using the Pole Placement menu and click the Download button. Refer to Figure A-9 for details.
Figure A-12 Record & Plot Menu
2 Select 1P variable
3 Select 2P variable
1.0
Overshoot 4 Enter Jog values
Velocity (RPM)
0.8 0.6 0.4 0.2 0 0.04 0.08 0.13 0.17 0.21 0.25 0.29 0.33 0.38 0.42
Good Response (Constant Acceleration)
1 Click Record
Time (sec)
5 Click on CW or CCW
Graphic Screen Click on the Record button to activate a graphic screen. Move the cursor to the plot variable window (1P and 2P windows = 1st and 2nd Plot windows) and choose one or two variables which will be drawn on the plot (such as velocity, velocity command, etc.). Jog Block Click on velocity in the Jog window. Enter a value to run the motor. A low speed (i.e. 100 RPM) is recommended. Click on duration in the Jog window. Choose a duration time. Recommend that you use a short time period (i.e. 0.5 sec). Initiate Move Click on either the CW or CCW button. This selects the direction of movement and the software will plot the variables you selected. Observe the performance plot. If it meets your expectations, you are done. If you wish to alter parameters and view another plot, repeat the above procedure. MN1275 Manual Tuning A-9
Pulse Follower Applications (Only used in pulse follower applications). Choose Tuning Select the Manual tune method as shown in Figure shown in Figure A-9. Position Parameters Click on the Position Parameters button. You will see parameters as shown in Figure A-13. Selecting None Feedforward allows you to enter Position Gain.
Figure A-13 Position Control Menu
Select Velocity feedforward allows you to enter Position Gain and Velocity, a parameter that is proportional to the desired velocity. Increasing this gain, compensates for damping (brings actual velocity closer to desired velocity). It is not within the servo loop, so it does not effect stability. The adjustable range is from 25 to 100%. Select Acceleration feedforward allows you to enter Position Gain and Velocity and Acceleration. Acceleration is a parameter that is proportional to the desired acceleration. Increasing this gain, compensates for inertia (brings desired acceleration closer to actual acceleration). It is not within the servo loop, so it does not effect stability. Inertia resists acceleration. The adjustable range is from 25 to 100%. Initiate Move To verify that the parameter values are correct, you must cause the system to move. This would be accomplished by having the host controller, or indexer, or computer output a string of pulses. During movement, observe the Monitor (7--segment display) on the front panel. If a P is observed on the Monitor display, the drive is within the in--position band which has been set. If a P is not observed, then the drive is outside the band, or window. This would occur, for example, with a high friction system. Either the gain or feedforward term must be adjusted, or the in--position band must be opened (until a P is observed). Note: To change the in--position band or window, you have to choose Setup (from the toolbar at top of the screen). In the box, choose Operation Mode. You will see choices of general, current, velocity, and pulse. Select pulse tab. This will open the window showing the following error limits. You may enter and modify (open) the in--position bands.
A-10 Manual Tuning
MN1275
Appendix B Command Set

Flex - ASCII - Command - Set General Flex controls use the RS232 communication port (optional RS485) as the Interface. This document describes existing FlexDrive/Flex+Drive ASCII terminal commands for setup and control of the servo drive. There are three types of ASCII commands: 1. Parameters. Without parameters, these commands are handled as queries. To modify the value of a parameter, the value to be set is added to the command. Some parameters may only be modified under special drive conditions. Query is not restricted to special drive conditions. 2. Variables or system constants. System variables are internally updated in the control, and can not be changed by the user. System constants are fixed (e.g. by hardware) system properties. Query of variables or constants is not restricted to special drive conditions. 3. Methods support control of the system. Methods may or may not require a parameter. Commanding a method to be executed is in some cases also restricted to special drive conditions. Each command is defined as a special mnemonic, which is used for query of parameters, variables and constants as well as for parameter less methods. Modifying a parameter respectively commanding a parameterized method is done by simply adding the parameter value to the mnemonic. Syntax General structure of the ASCII command Each ASCII command is structured in principle according to Mnemonic Delimiter Parameter List. Syntax allows multiple commands in the same string separated by blank space delimiter. Each command string is terminated by a carriage return. i.e. generally, a command string looks like:
Mnemonic1 Delimiter Parameter List1... MnemonicN Delimiter Parameter ListN [CR]
Up to 80 characters are allowed at the command prompt. For each correct command the control returns a > sign (ASCII 3E hex) as an acknowledge. If a command is not accepted, the reason for the command revision is sent instead of the acknowledge. Mnemonics The mnemonics are not case sensitive. Most of the ASCII commands are grouped into functional groups. The Mnemonics of the commands of parameters, variables and methods of these function groups have a prefix, which indicate the function and, separated by the dot, the command identifier. The general structure of Function Group Commands is as follows:
Functional Group.Command Identifier DelimiterParameter list [CR]. e.g.SYS.MOD 1
All prefixed commands are drive parameters. The delimiter between mnemonic and parameter of these commands is either blank space or equal sign (one of both is mandatory). To query all parameters and variables of a function group, the function group prefix followed by dot and asterisk can be used:
Functional Group.* e.g.SYS.*
MN1275
Command Set B-1
Upon receiving a command, the controller answers by sending the function parameter and variable list. General purpose commands are not prefixed. These commands only consist of the command identifier and therefore need the general structure
Command Identifier [Delimiter]Parameter list [CR]
With the non--prefixed commands, no delimiter is mandatory, but the blank space can be inserted optional. Parameters and Units The parameters used within the ASCII commands are integers of different sizes: INTEGER: 16 bit value ranged 8000.. 7FFF hex ( --215.. +215--1 dec. ) UNSIGNED INT: 16 bit value ranged 0.. FFFF hex (0..216--1 dec.) LONG: 32 bit value ranged 80000000.. 7FFFFFFF hex ( --231.. +231--1 dec.) UNSIGNED LONG: 32 bit value ranged 0.. FFFFFFFF hex ( 0.. +232--1 dec.) STRINGS: Strings of ASCII characters (0 .. FF hex). A string parameter is preceded and terminated with double quote character (%)! Commands, which accept or require more than one parameter, use parameter lists which are composed of the sequence of parameters necessary, with the delimiters blank space or comma between. The number of the parameter can be given as decimal value or as hexadecimal value. Hexadecimal values are preceded by one or more 0--character (30 hex), while decimal values are taken as default without indicator. The ASCII command set description below, also shows the units of the parameters respectively indicate parameters with no units. For best resolution within the accepted range, the units of the parameters are not chosen according to SI, but most of the units used are SI units multiplied with potentials of 10. In some cases, units are related to system properties and can therefore not be same for all applications. The following is an example of how to calculate Counts and Limits, used with positioning and homing: Resolver
max. < 1500 < 6100 < 6100 RPM Resolution 216 214 212 Counts/rev. 216 216 216 Limits " 229--1 " 229--1 " 229--1
Encoder
Pulses/rev. 1000 1500 2000 2500 5000 6000 Resolution 4000 6000 8000 10000 20000 24000 Counts/rev. 64000 48000 64000 40000 40000 48000 Limits 225--1 226--1 226--1 227--1 228--1 228--1
The resolution of all (Resolver or Encoder) is between " 213 and " 214. B-2 Command Set MN1275
Start-up with Terminal Communication and Command Examples 1. Select the correct COM port NR. and set the following at your PC: -- Baud Rate: 9600 -- Protocol (Hardware, Xon/Xoff, None): OFF -- Data Length: 8 Bit --Stop Bit: 1 --Parity: NONE 2. Set the control address. The address is set by switch AS1-1 to AS1-4. To locate a control, type A then the control address, e.g. A3 (searches for a control with address 3). If a drive with address 3 is running and connected to the PC COM, this drive answers with the prompt sign > to indicate that communication to the drive is established. Additional command may be sent to the A3 control. Entering an address command with another address number, will terminate communication with control A3. If more than one drive is connected to the PC COM port, typing the address of another drive connected, will change communication path to this one. 3. Communication is now established and the ASCII commands may be used. Note: If more than one drive is connected to the PC port, correct communication can only be established if all drives have different addresses. 4. Error messages (from the control) If the syntax and the values of the ASCII command string are correct, the control accepts the command and answers by sending < as acknowledge. If any error within the transferred command was found, the control rejects the command by sending a correlated error string. There are following terminal--reported errors : -- SYNTAX ERROR: invalid character; -- EXECUTION ERROR: invalid command; -- RANGE ERROR: invalid parameter value; -- INVALID EXE CONTEXT: invalid command or operation mode; -- control DESIGN FAILURE: invalid control design; -- INPUT BUFFER OVERFLOW: command line exceeded 80 char.; -- TOO MANY PARAMETERS: too many parameters; -- REQ. PARAMETER MISSED: not enough parameters; In case of an error, the event protocol will return a NAK ( negative acknowledge ) to a user. The error check can only provide a syntax and range check for each command. Error checking will not check a wrong parameter value that may degrade system performance.
MN1275
Command Set B-3
General Settings System Constants

Command SYS.POWER SYS.FBACK SYS.INFO (SYS.VER) SYS.LEVEL SYS.OPT SYS.STTS (COM.ADDR) Description Queries dip switch ID, (see DRV.ID) Queries system feedback (encoder / resolver)as defined by ALTERA Queries firmware version with naming and version number as ASCII string Queries level version Queries ALTERA option(s)X Most Significant--Word of SYS.STTS gives control address of (LS--Word s. below). Control Address is set per Dip Switch Firmware versions RES--1.xx, Range 0:1 ASCII letters 1:2 0:7 (MS-Word of SYS.STTS) Common X X X X X Lev I LevII
ENC--1.xx SYS.VER is equal to SYS.INFO , downward versions: answer to SYS.VER is unsigned integer version number only Firmware versions RES--1.xx, ENC--1.xx only (no version)
Basic System Parameters Motor Parameters (MTR. prefixed)

Command MTR.IDX MTR.IND MTR.INOM MTR.IPEAK MTR.JM MTR.MPLS MTR.RES MTR.KT MTR.KV MTR.NAME Description D3S/FlexDrive/Flex+Drive Setup library defined Motor Index Motor inductance Motor nominal current Motor peak Motor Inertia Motor number of poles Motor resistance Motor torque constant (torque to RMS phase current) Motor bemf constant Motor string name in ASCII characters Units Range Unsign Int. 1 : 65535 1 : 65535 1 : 65535 1 : 65535 1 : 65535 1 : 65535 1 : 65535 1 : 65535 ASCII char Default E2 / Par. set E/P E/P E/P E/P E/P E/P E/P E/P E/P E/P
0.01 H 0.1 A 0.1 A 0.01 Kg-cm2 0.01 Ohm 0.001 Nm/A V/1000RPM
Drive Parameters (typical DRV. prefixed)

Command DRV.BUSAPP DRV.BUSOV DRV.BUSV DRV.I2T DRV.ID DRV.IDX DRV.INOM DRV.IPEAK Description Application bus voltage Application bus over voltage Drive Bus voltage I2t warning time Drive ID (EEPROM value) to be checked against power ID ( dip switch ) in case of Version Error ( U ) FlexDrive/Flex+Drive Setup library index Drive nominal current Drivepeak current Units V V V 0.01 s Range Unsign. Int. Unsign. Int. Unsign. Int. 100 : 300 Unsign. Int. Unsign. Int. Unsign. Int. Unsign. Int. Default E2 / Par. set E/P E/P E/P E/P E/P E/P E/P E/P
0.1 A 0.1 A
B-4 Command Set
MN1275
Additional System parameters (mostly SYS.* prefixed) Velocity Feedback Parameters:

Command MTR.RPLS SYS.ENCRES Description Resolver number of poles Queries / updates encoder feedback resolution for encoder motors (in pulses per revolution, i.e. before quadrature) Queries encoder motor hall table type. Units -pulses/rev. Range 1 : 65535 1 : 16384 Default E2 / Par. set E/P E/P
SYS.ENCTBL
--
0:2
E/P
Firmware versions RES-1.xx, ENC-1.xx only Encoder Simulation Output Parameter:

Command SYS.ENC Description Encoder simulation resolution. Range depends on maximum velocity (VEL.MXRPM) Up to 1500 RPM: 512 :4096; above 1500 RPM: 512 only. Downward versions to 80112d1000, (incl.) also provide the decimal values. Units Puls/Rev. Range 512 : 1024 (2048 : 4096) (500, 1000 1250, 1500) Default E2 / Par. set E/
Software Limit Switches Parameters:

Command LIM.CCW Description Absolute Position of Software Limit Switch CCW (related to1 Home, activated after Homing only) LIM.CW Absolute Position of Software Limit Switch CW (related to1 Home, activated after Homing only) LIM.ON Deactivate / activate Software Limit Switches (independent from Hardware Limit Switches) 1 Counts and Limits depend on Resolver and Encoder resolution Units Counts 1 Range --Limit:Limit 1 Default 0 E2 / Par. set E/
Counts 1
--Limit:Limit 1
E/
--
0 (off) 1 (on)
E/
Variables: NONE Software Limit Switches Methods:

Command LIM.LRN Description Take actual position as software limit for CW respectively CCW Parameter 0: CW 1: CCW Units -Range 0:1
MN1275
Command Set B-5
PLC Parameters:
Command PLC.LINE Description Defines PLC statement :IF [input]=TRUE, THEN [action] set/started, with sytax PLC.LINE [num] [action] [input] [num] [action] -- PLC line number, and string parameter for PLC action, fixed to line number: 0 ENABLE (PLC enable) 1 MAO1 (Digital Input MAO1) 2 MAO2 (Digital Input MAO2) 3 MAO3 (Digital Input MAO3, if available) 4 MAO4 (Digital Input MAO4, if available) 5 RELAY ( 6 USRERR (Error 9) 7 FRST (Fault Reset) 8 DISA (Disable active, s. 0) 9 DISP (Disable active, s. 0) 10 HOLD (Hold--status, s. 0) 11 JOG (JOG function, s. 0) 12 GEAR [input] -- string parameter with enumerated values: FALSE: Always false, i.e. switched off CW, CCW: Hardware or Software Limit Switches MAI1, MAI2 : Digital Inputs MAI3, MAI4: Digital Inputs (if available) DRVOT,MTROT: Drive respectively motor overtemperature I2tWRN: I2T--warning (error 7) TRUE: Always true, i.e. switched ON INPOS, FEWRN, FEFAT: Flags of Position Controller in position, following error warning, following error limit (s. 0) BADMOV: Not initialized motion buffer line commanded (s. 0) MOTRDY, MOTNRDY: Positioning finished respectively in process Units num: 0 : 12 action: s. left lines: input: s. left lines: Range PLC disabled, all lines: input = false Default E2 / Par. set E/P
Note: Choice of Inputs and Outputs is not completely available in all configurations Variables: NONE PLC Methods:
Command PLC Description Enables (on) / disables (off) / clears and disables (clr) PLC. PLC on and off command is stored in PLC buffer line 0. Parameter on, (off), clr Units Range
B-6 Command Set
MN1275
OCI Interface Parameters:

Command CAN.BD CAN.ID Description (The range check is: Invalid execute context.) It should be: Range error (The range check is: Invalid execute context.) Units Hz -Range 10 : 1000 1 : 127 Default Significant OK OK E2 / Par. set
Digital Interface Parameters:

Command MOT.INCCW MOT.INCW Description Defines digital Input CCW/MAI4 as CCW (0) or as MAI4 (1) for positioning Defines digital Input CW/MAI3 as CW (0) or as MAI3 for positioning Units --Range 0:1 0:1 Default 0 0 E2 / Par. set E/P E/P
Analog Interface Parameters:

Command SYS.RFOFS (RFOFS) Description Query / updates system reference offset of the analog input, with analog input range "10V (RFOFS only supports query) Units mV Range --100000 : 100000 Default 0 E2 / Par. set E / --
Note: Scaling of the analog input command is offered with firmware versions RES--1.xx, ENC--1.xx. Because scaling parameters are different for current mode and velocity mode, these parameters are described under 0 (current command scaling) respectively 0 (velocity command scaling).
MN1275
Command Set B-7
System Variables General Variables:

Command DRV.LIFE SYS.STTS Description Drive life time. Queries system status as a double word, where Word High word is drive address (set by Dip switches) Low word: bit array ORed with system status: 0x0001: Disable SW 0x0002: Disable HW 0x0004: CW 0x0008: CCW 0x0010: Fault exists 0x0020: Warning exits 0x0040: Hold mode 0x0080: Burn in Status 0x0100: Jog Status 0x0200: Enable 0x0400: Jog Non Zero Velocity 0x0800: n/a 0x1000: HW source for Disable HW: 0x2000: PLC active Units Hrs -Range Unsign.Word Long Word Default E2 / Par. set E / --- / --
Queries / modifications of Fault Listing Variables:

Command FAULT FLT LOG, LG LG WRN SYS.FAULT SYS.WRN Description Gets system fault string list, response is multiple string X1 Gets system fault string list, response is error numberX1 Gets system fault log list X1 Gets system fault log number list X1 Gets system warning list as multiple strings Queries system fault as ID of the most significant fault Queries system warnings. The most important warning will be reported as ID X1 Possible Faults Display USER ERROR OVERCURRENT OVERVOLTAGE FEEDBACK POWER_FAIL BPS OVER_15_VOLTAGE UNDER_15_VOLTAGE EEPROM_ERROR EPROM_ERROR RAM_ERROR Units -------Range Default E2 / Par. set -- / --- / -----/ / / / -----
X1 X1
-- / --
X1 Fault 1 2 3 4 5 6 7 8 9 10 11
Description PLC user generated error. Displays 9. Over current. Displays 3. Bus over voltage. Displays 1. Resolver/encoder position feedback error. Displays 5. Power fail. Displays 2. BPS fail. Displays 2. "15v over voltage. +15v line is more then 17v or --15v line is more than --17v. Displays 4. "15v under voltage. +15v line is less then 12v or --15v line is less than --12v. Displays 4. N.I N.I RAM integrity error. Displays 9.
B-8 Command Set
MN1275
X1 Fault 12 13 14 15 16 17 18 19 20 21 22 23
X1 Possible Faults -- Continued Display FAULT_RELAY EAF MISSING INT POWER_ID CW_CCW DESIGN_FAILURE EE_CLEARED EE_INTEGRITY EAF Drive Temp EAF Motor Temp EAF Drive I2T EAF Motor I2T
Description when fault relay is closed. Displays 9. N.I N.I DRV.ID != SYS.POWER. Displays small u. Both limit switches are on. Displays L. Control design fail. Displays small c. EEPROM header stamp was not detected. Displays U EEPROM footer stamp was not detected. Displays A. EAF drive over temperature error. Displays 6. EAF motor over temperature error. Displays 6. EAF drive I2T error. Displays 6. EAF motor I2T error. Displays 6.
Methods:
Command FRST LOGRST Description Resets system faults if allowed. Reset is not allowed, if error is still pending. Resets system fault log Parameter --Units --Range ---
Communication Settings Parameter:

Command ECHO PROMPT TALK Description Disable / enable echoing for input characters Enables / disables terminal prompt Enables / Disables terminal error notification Units ---Range ON/OFF ON/OFF ON/OFF Default ON ON ON E2 / Par. set -- / --- / --- / --
Variable:
Command COM.STTS Description Queries the most recent communication handler error Units -Range 0:65535 Default E2 / Par. set -- / --
Methods:
Command B Description Opens communication to the drive, called by its address (the addresses a constant, which can be queried by COM.ADDR or SYS.STTS) Parameter Address Units -Range 0:7
MN1275
Command Set B-9
Queries of System Variables, Status, Faults Single Values:

Command ACTU CUR.ACTU ACTV CUR.ACTV ANAIN SYS.ANAIN POS, RPOS, SYS.POS POS.POS VEL VEL.VEL Description Query for actual current U Query for actual current V Query for analog input Queries motor position Resolver bits / encoder counts Query feedback velocity RPM Units 0.01 A 0.01 A mV Range Default E2 / Par. set -- / --- / --- / --- / --- / --
Data Record ( REC. prefixed ) Parameters:

Command REC.GAP REC.TIME REC.VAR1, REC.VAR2 Description Specify gap between recording samples in number of servo loops (0.5 ms) Specify recording time Specify recording variable: POS: position, REF: velocity command, VEL: velocity, CUR: current command, ACTU: current U, ACTV: current V, FE: position following error. Units -0.5 ms -Range 0 : 65535 1:65535 s. left Default 1 1000 POS VEL E2 / Par. set E / --- / --- / --
Data Record ( REC. prefixed ) Variable:

Command REC.VFREE1 REC.VFREE1 Description Specify recording address for REC.VAR1 Specify recording address for REC.VAR2 Units --Range Unsign.Long Unsign.Long Default E2 / Par. set -- / --- / --
Methods:
Command GETD GETX REC Description Gets data from recording buffer in decimal form. Gets data from recording buffer in hex form, data buffer is cleared afterwards Starts(on) / stops (off) recording process Parameter --start / stop Units ---Range --on, off
B-10 Command Set
MN1275
Memory related methods (Queries / modifications): RAM related:

Command BDUMP BMEMH BMEMD WDUMP WMEMH WMEMD Description Gets hexadecimal memory dump in bytes Query / Update memory byte in hex Query / Update memory byte in dec Get hexadecimal memory dump in words Query / update hexadecimal word memory location Query / update decimal word memory Parameter Memory address Memory address Memory address Memory address Memory address Memory address Range Unsign.Int. Unsign.Int. Unsign.Int. Unsign.Int. Unsign.Int. Unsign.Int.
EEPROM related:
Command CLEAR Description Clear EEPROM content and drive life time variable by filling it with 0xFFFF (except code for Level I/II; Baldor/HD) Display all EEPROM data (256 words). Uploads EEPROM data to terminal (ASCII file) Parameter Range
EEDUMP UP
Operation Mode Control Normal Modes Parameters:

Command SYS.MOD MODE Description Queries / updates system operating mode Where 0 -- current, 1 -- velocity, 2 -- position Units -Range 0:3 Default 1 E2 / Par. set E/P
Normal Modes Variables:

Command STATUS Description Queries drive status: DIS_HW, DIS_SW, ENABLE, BURN_IN, FAULT Units -Range Default E2 / Par. set -- / --
Normal Modes Methods:

Command DIS DISA ENA HOLD QUIT STOP CONT Description Disables drive passively Disables drive actively, brake to stop, then disable control Enables drive Stops drive and maintains position after stop Stops drive and maintains position after stop Stops drive and maintains position after stop (CONT will resume the interrupted move) Continues interrupted move (interrupted by STOP) Parameter Units Range
Note: In velocity and current mode, braking is with acceleration=zero. In positioning mode (SYS.MOD 3), braking is with acceleration=MOT.ACC.
MN1275
Command Set B-11
Sys.mod 0: Current mode Parameters:

Command CUR.BEMF CUR.IPEAK CUR.INOM CUR.TOFR Description Back EMF voltage compensation, in percentage of nominal motor value Ke. Queries / updates application peak current in percentage of DRV.IPEAK Queries / updates application nominal current in percentage of DRV.IPEAK Queries / updates mantissa of Torque Optimizer: Phase Advance or BEMF Compensation Queries / updates Torque Optimizer Shift coefficient Corresponding current value to analog input voltage CUR.VOLT for setting of analog input scaling Corresponding analog input voltage to current value CUR.SCAL for setting of analog input scaling Units % % % Range 80 : 120 0 : 1000 0 : 500 0x0f00 : 0x1100 16 0.1 % of CUR.IP 0.1 VEAK 100 : 10000 1000 Default 100 100 50 E2 / Par. set E/P E/P E/P E/P
CUR.TOSH CUR.SCAL
E/P E/P
CUR.VOLT
1 : 100
100
E/P
Current mode Variables:

Command CUR.CUR CUR Description Query for actual current command Units Range 0 : 65535 Default E2 / Par. set E / --
Current mode Methods:

Command CALC T TS Description Calculate current control parameters from MTR.*, DRV.* and CUR.* parameters. Commanding digital current command (torque equivalent) Stops current commanded motion (started by Tcommand) Parameter torque equivalent Units mV Range --10000 : 10000
B-12 Command Set
MN1275
Sys.mod 1 & Sys.mod 3 Velocity mode Parameters:

Command VEL.ACC VEL.ADZON VEL.BW VEL.CTRL VEL.GV VEL.GVI VEL.INRT VEL.LPFA VEL.LPFB VEL.LPFMOD Description Queries /updates velocity acceleration limits ( time to max. velocity ). Queries / updates min. velocity in RPM Queries / updates velocity control band width Queries / updates velocity control type Queries / updates velocity control proportional gain Queries / updates velocity control integral gain Load inertial, set in % of motor inertia MTR.JM Bandwidth of single velocity control filter. Second Bandwidth of double velocity control filter (First s. VEL.LPFA). Type of velocity control filter (0: no filter, 1: filter with bandwidth VEL.LPFA, 2: double filter with bandwidths VEL.LPFA and VEL.LPFB Queries / updates velocity control tracking factor Queries / updates velocity control MAX RPM value. The limit for this value is internally calculated by the Application Bus Voltage and the Motor Voltage Constant. Absolute limit for velocity is 7500 RPM. Corresponding velocity value to analog input voltage VEL.VOLT for setting of analog input scaling. Corresponding analog input voltage to velocity value VEL.SCAL for setting of analog input scaling Units RPM/ms RPM Hz Range 0 : 7500 0 : Max_RPM 10 : 200 0, 2 0 : 32767 0 : 32767 % Hz Hz -0 : 10000 20 : 800 20 : 800 0 : 20 500 500 0 Default E2 / Par. set E/P E/P E/P E/P E/P E/P E/P E/P E/P E/P
VEL.TRKFCT VEL.MXRPM
--32768 : 32767 RPM 1000 : (7500)
E/P E/P
VEL.SCAL
RPM
100 : 32767
E/P
VEL.VOLT
0.1 V
1 : 100
E/P
Velocity mode Variables:

Command VEL.VREF VREF Description Queries velocity reference, commanded at analog input Units RPM Range Default E2 / Par. set -- / --- / --
Velocity mode Methods:

Command VCRST Description Velocity controller parameters reset to default values: Pole Placement controller: BW = 20 Hz, TRFCT = 0 , INRT = 0; PI controller: GV, GVI equivalent to Bandwidth 20 Hz Parameter Units Range
MN1275
Command Set B-13
Jog Parameters:
Command JOG.TIME JOG.TYPE JOG.VEL Description Jog time in milliseconds 0 -- continuous, 1 -- step, 2 -- square wave Jog velocity in RPM, limited to maximum velocity VEL.MXRPM. Units ms -Range 3432448 0:2 VEL.MXRPM Default E2 / Par. set E / -E / -E / --
Methods:
Command JOG JS Description Commanding a Jog according to JOG.* parameters, with Stops jog and returns to previous operation mode Parameter Direction -Units --Range +, -- --
B-14 Command Set
MN1275
Position Controller Position Controller Parameters:

Command POS.FFA POS.FFTYPE Description Queries/updates acceleration FF factor unsigned integer ranged 0..100 Queries / updates FF type with position controller redesign 0 -- FF none, 1 -velocity FF, 2 -- acceleration FF Queries / updates velocity FF factor unsigned integer ranged within 0..100 Queries / updates position gain unsigned integer ranged within 25.. 200 Queries / updates FE warning limits resolver: 1/4096 of revolution, encoder: 1/(4*SYS. encres) of revolution integer, > 0 (< 0: disabled) Queries / updates FE fatal limits 1/4096 of revolution, integer, Queries / updates FE in position limits 1/4096 of revolution, integer, > 0 (< 0: disabled) Units --Range 25 : 100 0:2 Default E2 / Par. set E/P E/P
POS.FFV POS.KP POS.FEWRN
--1/4096 (resolver) 1/(4*SYS. encres) encoder 1/4096 of revolution 1/4096 of revolution
25 : 100 25 : 100 --32768 : 32767
E/P E/P E/P
POS.FEFAT POS.IPOS
--32768 : 32767 --32768 : 32767
E/P E/P
Variables:
Command POS.MPFE MPFE POS.PFE PFE PREF POS.REF POS.FEST FEST Description Queries maximum position following error Queries position following error Queries for position reference Queries position controller reference, 1/4096 of revolution Returns follow error status: 0 -- normal, 1 -- in position, 2 --warning, 3 -- error Units 1/4096 of rev. 1/4096 of rev. 1/4096 of rev. 1/4096 of rev. -0:3 Range Default E2 / Par. set -- / --- / --- / --- / --- / --- / --- / --- / --
Methods:
Command PRST Description Resets position following error Parameter -Units -Range --
MN1275
Command Set B-15
Sys.mod 2: Pulse Follower (Handwheel respectively Pulse/Direction) Parameters:

Command HW.GRFX Description Queries/updates mantissa HW gear parameter, negative value means negative gear. Queries/updates shift HW gear parameter GEAR Queries/ updates PLC gear ratio Queries / updates HW resolution in pulses per revolution (only necessary for Queries / updates HW type: 0 -- None, 1 -Pulse and Direction at connector X3, 2 -- A leads B at connector X9, 3 -- B leads A respectively, Pulse and Direction at connector X92, 4 -- A leads B at connector X32 Units Range --32767 : 32767 0 : 32767 0 : 65535 --32768 : 32767 Default E2 / Par. set E/P
HW.GRSH HW.PLC HW.RES HW.TYPE
pulses/rev.
E/P E/P E/P E/P
B-16 Command Set
MN1275
BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72902-2400 (479) 646-4711 Fax (479) 648-5792 www.baldor.com
CH TEL: +41 52 647 4700 FAX:+41 52 659 2394 I TEL: +39 11 562 4440 FAX:+39 11 562 5660 D TEL: +49 89 90 50 80 FAX:+49 89 90 50 8491 AU TEL: +61 29674 5455 FAX:+61 29674 2495 UK TEL: +44 1454 850000 FAX:+44 1454 850001 CC TEL: +65 744 2572 FAX:+65 747 1708 F TEL: +33 145 10 7902 FAX:+33 145 09 0864 MX TEL: +52 47 61 2030 FAX:+52 47 61 2010
! Baldor Electric Company MN1275
Printed in UK 2/03

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SERVO DRIVE

FlexDrive Servo Control

Installation & Operating Manual

Table of Contents iii

Section 1 General Information

General Information 1-1

Continued on next page.

1-2 General Information

Caution: Caution: Caution:

Caution: Caution: Caution: Caution: Caution:

1-4 General Information

Section 2 Product Overview

Product Overview 2-1

2-2 Product Overview

Section 3 Receiving and Installation

Receiving & Installation 3-1

Figure 3-1 Recommended System Grounding (3 phase) for UL

Figure 3-2 Recommended System Grounding (3 phase) for CE

3-2 Receiving & Installation

Figure 3-3 Recommended System Grounding (1 phase) for UL

Earth Driven Earth Ground Rod (Plant Ground)

Route all 3 wires L, N, and Earth (Ground) together in conduit or cable.

Ground per NEC and Local codes.

Figure 3-4 Recommended System Grounding (1 phase) for CE

Enclosure Backplane (see Section 8)

Receiving & Installation 3-3

3-4 Receiving & Installation

Table 3-2 Wire Size (for units without Power Supply)

FD1A02PO-XXXX FD2A02PO-XXXX FD1A05PO-XXXX FD2A05PO-XXXX FD1A10PO-XXXX FD2A10PO-XXXX FD1A15PO-XXXX FD2A15PO-XXXX

* Components not provided with Control.

For CE Compliance, refer to Section 8 of this manual.

Figure 3-6 Single Phase AC Power Connections (FD1AxxS only)

* Components not provided with Control.

For CE Compliance, refer to Section 8 of this manual.

3-6 Receiving & Installation

Figure 3-7 3 Phase Power Connections (FD2AxxS & FD4AxxT only)

L1 Alternate * Fuse Connection A1

For CE Compliance, refer to Section 8 of this manual.

* Components not provided with Control.

Figure 3-8 Shared Supply Power Connections

Baldor Option S Control To Regen Resistor

Baldor Option P Control

Baldor Option P Control

Receiving & Installation 3-7

Connector Locations (Single Phase Controls)

NC Motor Dynamic Brake (Regen Resistor) FDxAxxxx-xxx3 only L N U V W R1 R2

Terminal tightening torque is 0.5 lb-in (0.6Nm)

X7 - Simulated Encoder Output 1 2 3 4 5 CHA+ CHB+ CHC+ Reserved DGND 6 7 8 9 CHA-CHB-CHC-Reserved

X8 - Resolver Input Resolver In X8 1 2 3 4 5 REF+ COS+ SIN+ Reserved AGND 6 7 8 9 REF-COS-SIN-Reserved

3-8 Receiving & Installation

Connector Locations (Three Phase Controls)

Dynamic Brake (Regen Resistor) FDxAxxxx-xxx3 only

Terminal tightening torque is 0.5 lb-in (0.6Nm)

X7 - Simulated Encoder Output 1 2 3 4 5 CHA+ CHB+ CHC+ Reserved DGND 6 7 8 9 CHA-CHB-CHC-Reserved

X8 - Resolver Input 1 2 3 4 5 REF+ COS+ SIN+ Reserved AGND 6 7 8 9 REF-COS-SIN-Reserved

Receiving & Installation 3-9

Figure 3-11 Motor Connections for U.L.

* Optional components not provided with control.

Figure 3-12 Motor Connections for CE