Baldor MDH1A05TB-RC23 Installation Manual

Page 1
MintDrive
II
Servo & Position Control
SERVO DRIVE
Installation Manual
01/07 MN1901
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Page 3
MN1901
Contents
1 General Information 1-1.................................
2 Introduction 2-1........................................
2.1 MintDriveIIfeatures 2-1.....................................
2.2 Receiving and inspection 2-2................................
2.2.1 Identifying the catalog number 2-2....................................
2.3 Units and abbreviations 2-3..................................
3 Basic Installation 3-1....................................
3.1 Introduction 3-1............................................
3.1.1 Power sources 3-1................................................
3.1.2 Hardware requirements 3-1.........................................
3.1.3 RS485 / RS422 systems 3-2........................................
3.1.4 Tools and miscellaneous hardware 3-2................................
3.1.5 Other information needed for installation 3-3...........................
3.2 Mechanical installation and location requirements 3-4...........
3.2.1 Mounting the MintDrive
II
3-5.........................................
3.2.2 Dimensions 3-6...................................................
3.3 Connector locations 3-7.....................................
3.4 Power connections 3-8......................................
3.4.1 Single-phase connection to package sizes A, B, C, D 3-9................
3.4.2 Three-phase connection to package sizes E, G, H 3-10...................
3.4.3 Input power conditioning 3-11.........................................
3.4.4 Power disconnect and protection devices 3-11..........................
3.4.5 Power supply filters 3-12.............................................
3.4.6 Wire sizes and protection device ratings 3-13...........................
3.4.7 External customer supplied 24V control supply 3-14......................
3.5 Motor connections 3-15......................................
3.5.1 Motor circuit contactors 3-16.........................................
3.5.2 Motor power cable pin configuration - Baldor BSM rotary motors 3-16.......
3.5.3 Motor cable pin configuration - Baldor linear motors 3-17..................
3.5.4 Sinusoidal filter 3-17................................................
3.5.5 Thermal switch connection 3-18.......................................
3.5.6 Motor brake connection 3-19.........................................
3.6 Regeneration resistor (Dynamic Brake resistor) 3-20.............
3.6.1 Controlling regeneration 3-20.........................................
3.7 Feedback connections 3-21...................................
3.7.1 Resolver option - X8 3-22............................................
3.7.2 Encoder option - X8 3-24............................................
3.7.3 EnDat (absolute encoder) option - X8 3-27..............................
3.7.4 Hiperface (absolute encoder) option - X8 3-29...........................
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MN1901
3.8 Drive enable 3-31...........................................
3.8.1 Drive enable - X3 3-31..............................................
3.8.2 Drive enable - SW1 DIP switch 3-32...................................
3.8.3 Drive enable command 3-32..........................................
3.9 DIP switches - SW1 3-33.....................................
3.9.1 Switches 1-4 3-33..................................................
3.9.2 Switch 5 - Hold 3-34................................................
3.9.3 Switch 6 - RS485 terminator 3-34.....................................
3.9.4 Switch 7 - Offset tuning 3-34.........................................
3.9.5 Switch 8 - Enable 3-34..............................................
3.9.6 Switches 9 and 10 - RS232/RS485 select 3-35..........................
3.9.7 Factory settings 3-35................................................
3.9.8 Preventing a program running at startup 3-36...........................
4 Input / Output 4-1......................................
4.1 Introduction 4-1............................................
4.2 Analog I/O 4-1.............................................
4.2.1 Analog input - X3 (demand) 4-2......................................
4.2.2 Analog input - X4 4-4...............................................
4.2.3 Analog outputs, bipolar - X4 4-6......................................
4.3 Digital I/O 4-7..............................................
4.3.1 Digital inputs - X3 4-8..............................................
4.3.2 CREF and digital inputs 4-9.........................................
4.3.3 Special functions on inputs DIN4 and DIN5 4-9.........................
4.3.4 Digital outputs - X3 4-1 1.............................................
4.3.5 Relay output / digital output - X3 4-12..................................
4.4 Other I/O 4-13..............................................
4.4.1 Encoder output - X7 4-13............................................
4.4.2 Master (auxiliary) encoder input - X9 4-15..............................
4.4.3 Serial port - X6 4-17.................................................
4.4.4 Using RS232 cable 4-18.............................................
4.4.5 Multidrop using RS485 / RS422 cable 4-19.............................
4.4.6 Connecting Baldor HMI Operator Panels 4-20...........................
4.5 Connection summary - minimum system wiring 4-21.............
4.6 Option connectors 4-22......................................
5 Operation 5-1..........................................
5.1 Introduction 5-1............................................
5.1.1 Connecting the MintDriveIIto the PC 5-1..............................
5.1.2 Installing the software 5-1...........................................
5.1.3 Starting the MintDrive
II
5-2..........................................
5.1.4 Preliminary checks 5-2.............................................
5.1.5 Power on checks 5-2...............................................
5.1.6 Offset tuning (optional) 5-3..........................................
5.2 WorkBench v5 5-4..........................................
5.2.1 Help file 5-4......................................................
5.2.2 Starting WorkBench v5 5-5..........................................
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MN1901
5.2.3 Commissioning Wizard 5-7..........................................
5.2.4 Using the Commissioning Wizard 5-7.................................
5.2.5 Completing the Commissioning Wizard 5-7............................
5.2.6 Performing a test move 5-8.........................................
5.3 Further configuration 5-9....................................
5.3.1 Fine-tuning tool 5-9................................................
5.3.2 Parameters tool 5-11................................................
5.3.3 Digital I/O tool 5-12.................................................
5.3.4 Other tools and windows 5-12........................................
6 Preset Moves & PLC Task 6-1...........................
6.1 Introduction 6-1............................................
6.2 Preset moves 6-2..........................................
6.2.1 Defining a preset move 6-2..........................................
6.2.2 Testing a preset move 6-3...........................................
6.2.3 Using digital inputs to trigger a preset move 6-3........................
6.2.4 Controlling preset moves 6-6........................................
6.2.5 Using presets with the CAN & Auxiliary I/O option 6-6...................
6.3 PLC Task 6-7..............................................
6.3.1 Defining conditions 6-7.............................................
6.3.2 Enabling and downloading the actions 6-8.............................
6.3.3 Testing the PLC Task 6-9...........................................
6.4 Saving presets or PLC conditions 6-9.........................
7 Troubleshooting 7-1....................................
7.1 Introduction 7-1............................................
7.1.1 Problem diagnosis 7-1..............................................
7.1.2 SupportMe feature 7-1.............................................
7.1.3 Power-cycling the MintDrive
II
7-1....................................
7.2 MintDriveIIindicators 7-2....................................
7.2.1 Status display 7-2.................................................
7.2.2 DB On (Regeneration) LED 7-5......................................
7.2.3 Communication 7-5................................................
7.2.4 Power on 7-6.....................................................
7.2.5 Tuning 7-6........................................................
7.2.6 Status display shows a digit or ‘E.’ 7-6................................
8 Specifications 8-1......................................
8.1 Introduction 8-1............................................
8.1.1 AC input power and motor output - single-phase models 8-2..............
8.1.2 AC input power and motor output - 230V three-phase models 8-3..........
8.1.3 AC input power and motor output - 230-460V three-phase models 8-4......
8.1.4 Customer supplied 24VDC supply input 8-5............................
8.1.5 Regeneration 8-5..................................................
8.1.6 Analog input (X3) 8-6...............................................
8.1.7 Analog input (X4) 8-7...............................................
8.1.8 Analog outputs (X4) 8-7............................................
8.1.9 Digital inputs (X3) 8-8..............................................
8.1.10 Digital outputs (X3) 8-8.............................................
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MN1901
8.1.11 Relay / general purpose output (X3) 8-9...............................
8.1.12 Serial RS232 interface (X6) 8-9......................................
8.1.13 Serial RS485 interface (X6) 8-9......................................
8.1.14 Encoder output (simulated) (X7) 8-9..................................
8.1.15 Resolver feedback option (X8) 8-10...................................
8.1.16 Encoder feedback option (X8) 8-10....................................
8.1.17 EnDat (absolute encoder) feedback option (X8) 8-10.....................
8.1.18 Hiperface (absolute encoder) feedback option (X8) 8-11..................
8.1.19 Master (auxiliary) encoder input (X9) 8-11..............................
8.1.20 Pulse and direction input (X9) 8-11....................................
8.1.21 Environmental 8-12.................................................
Appendices
A Accessories A-1........................................
A.1 Introduction A-1............................................
A.1.1 Factory fitted options A-1...........................................
A.1.2 Motor power cables A-2.............................................
A.1.3 Motor power cable part numbers A-2..................................
A.1.4 Resolver feedback cables A-3.......................................
A.1.5 Encoder / Hall feedback cables A-4...................................
A.1.6 EnDat / Hiperface (absolute encoder) feedback cables A-4...............
A.1.7 Feedback cable part numbers A-5....................................
A.1.8 EMC filters A-6....................................................
A.1.9 Regeneration resistors A-9..........................................
B Control System B-1.....................................
B.1 Introduction B-1............................................
B.1.1 Positioning system with speed controller B-1...........................
B.1.2 Positioning system without speed controller B-2........................
B.1.3 Speed amplifier B-3................................................
B.1.4 Torque amplifier B-4................................................
B.2 Control system operation B-5................................
B.2.1 Position controller B-5..............................................
B.2.2 Speed controller B-6...............................................
B.2.3 Torque controller and feedback B-7...................................
C Mint Keyword Summary C-1.............................
C.1 Introduction C-1............................................
C.1.1 Keyword listing C-1................................................
D CE Guidelines D-1......................................
D.1 Introduction D-1............................................
D.1.1 EMC Conformity and CE marking D-1.................................
D.1.2 Declaration of conformity D-2........................................
D.1.3 Use of CE compliant components D-3.................................
D.1.4 EMC wiring technique D-3...........................................
D.1.5 EMC installation suggestions D-4.....................................
D.1.6 Wiring of shielded (screened) cables D-5..............................
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General Information 1-1MN1901
LT0159A03 Copyright Baldor (c) 2006. All rights reserved.
This manual is copyrighted and all rights are reserved. This document or attached software may not, in whole or in part, be copied or reproduced in any form without the prior written consent of Baldor. Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose. The information in this document is subject to change without notice. Baldor assumes no responsibility for any errors that may appear in this document. Mintt is a registered trademark of Baldor. Windows 95, Windows 98, Windows ME, Windows NT, Windows XP and Windows 2000 are registered trademarks of the Microsoft Corporation. UL and cUL are registered trademarks of Underwriters Laboratories. EnDat is a registered trademark of Heidenhain Corporation. Hiperface is a registered trademark of Max Stegmann GmbH.
Limited Warranty For a period of two (2) years from the date of original purchase, Baldor will repair or replace without charge controls and accessories that our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or implied. Baldor shall not be held responsible for any expense (including installation and removal), inconvenience, or consequential damage, including injury to any person or property caused by items of our manufacture or sale. (Some countries and U.S. states do not allow exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply.) In any event, Baldor’s total liability, under all circumstances, shall not exceed the full purchase price of the control. Claims for purchase price refunds, repairs, or replacements must be referred to Baldor with all pertinent data as to the defect, the date purchased, the task performed by the control, and the problem encountered. No liability is assumed for expendable items such as fuses. Goods may be returned only with written notification including a Baldor Return Authorization Number and any return shipments must be prepaid.
1 General Information
1
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1-2 General Information MN1901
Product Notice
Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to start-up, program or troubleshoot this equipment.
Safety Notice
Intended use: These drives are intended for use in stationary ground based applications in industrial power installations according to the standards EN60204 and VDE0160. They are designed for machine applications that require variable speed controlled three-phase brushless AC motors. These drives are not intended for use in applications such as:
H Home appliances
H Medical instrumentation
H Mobile vehicles
H Ships
H Airplanes.
Unless otherwise specified, this drive is intended for installation in a suitable enclosure. The enclosure must protect the drive from exposure to excessive or corrosive moisture, dust and dirt or abnormal ambient temperatures. The exact operating specifications are found in section 8 of this manual. The installation, connection and control of drives is a skilled operation, disassembly or repair must not be attempted. In the event that a drive fails to operate correctly, contact the place of purchase for return instructions.
Precautions
WARNING: Do not touch any circuit board, power device or electrical connection before you
first ensure that no high voltage is present at this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt to start-up, program or troubleshoot this equipment.
WARNING: Be sure the system is properly earthed/grounded before applying power. Do not
apply AC power before you ensure that earths/grounds are connected. Electrical shock can cause serious or fatal injury.
WARNING: Be sure that you are completely familiar with the safe operation and programming
of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to program, start-up or troubleshoot this equipment.
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General Information 1-3MN1901
WARNING: Be sure all wiring complies with the National Electrical Code and all regional and
local codes. Improper wiring may result in unsafe conditions.
WARNING: The stop input to this equipment should not be used as the single means of
achieving a safety critical stop. Drive disable, motor disconnect, motor brake and other means should be used as appropriate. Only qualified personnel should attempt to program, start-up or troubleshoot this equipment.
WARNING: Improper operation or programming of the drive may cause violent motion of the
motor and driven equipment. Be certain that unexpected motor movement will not cause injury to personnel or damage to equipment. Peak torque of several times the rated motor torque can occur during control failure.
WARNING: The motor circuit might have high voltages present whenever AC power is
applied, even when the motor is not moving. Electrical shock can cause serious or fatal injury.
WARNING: If a motor is driven mechanically, it might generate hazardous voltages that are
conducted to its power terminals. The enclosure must be earthed/grounded to prevent possible shock hazard.
WARNING: When operating a rotary motor with no load coupled to its shaft, remove the shaft
key to prevent it flying out when the shaft rotates.
WARNING: A regeneration resistor may generate enough heat to ignite combustible materials.
To avoid fire hazard, keep all combustible materials and flammable vapors away from the brake resistors.
CAUTION: To prevent equipment damage, be certain that the input power has correctly sized
protective devices installed.
CAUTION: To prevent equipment damage, be certain that input and output signals are
powered and referenced correctly.
CAUTION: To ensure reliable performance of this equipment be certain that all signals to/from
the drive are shielded correctly.
CAUTION: Suitable for use on a circuit capable of delivering not more than the RMS
symmetrical short circuit amperes listed here at rated voltage. Horsepower
RMS Symmetrical Amperes
1-50 5,000
CAUTION: Avoid locating the drive immediately above or beside heat generating equipment,
or directly below water or steam pipes.
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1-4 General Information MN1901
CAUTION: Avoid locating the drive in the vicinity of corrosive substances or vapors, metal
particles and dust.
CAUTION: Do not connect AC power to the drive terminals U, V and W. Connecting AC
power to these terminals may result in damage to the drive.
CAUTION: Baldor does not recommend using “Grounded Leg Delta” transformer power leads
that may create earth/ground loops and degrade system performance. Instead, we recommend using a four wire Wye.
CAUTION: Drives are intended to be connected to a permanent main power source, not a
portable power source. Suitable fusing and circuit protection devices are required.
CAUTION: The safe integration of the drive into a machine system is the responsibility of the
machine designer. Be sure to comply with the local safety requirements at the place where the machine is to be used. In Europe these are the Machinery Directive, the ElectroMagnetic Compatibility Directive and the Low Voltage Directive. In the United States this is the National Electrical code and local codes.
CAUTION: Drives must be installed inside an electrical cabinet that provides environmental
control and protection. Installation information for the drive is provided in this manual. Motors and controlling devices that connect to the drive should have specifications compatible to the drive.
CAUTION: If the drive is subjected to high potential (‘hipot’) testing, only DC voltages may be
applied. AC voltage hipot tests could damage the drive. For further information please contact your local Baldor representative.
CAUTION: Violent jamming (stopping) of the motor during operation may damage the motor
and drive.
CAUTION: Do not tin (solder) exposed wires. Solder contracts over time and may cause
loose connections. Use crimp connections where possible.
CAUTION: Electrical components can be damaged by static electricity. Use ESD
(electro-static discharge) procedures when handling this drive.
CAUTION: Ensure that resolver or encoder wires are properly connected. Incorrect
installation may result in improper movement.
CAUTION: The threaded holes in the top and bottom of the enclosure are for cable clamps.
Be sure to use a M4 bolt no longer than 12mm in length. Longer bolts might short-circuit the electrical components inside the drive.
CAUTION: Removing the cover will invalidate UL certification.
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Introduction 2-1MN1901
2.1 MintDriveIIfeatures
The MintDriveIIcombines a powerful fully featured motion controller and brushless servo control into a compact package. This provides a flexible and powerful motion control solution for single axis rotary and linear positioning systems. Programmable in Mint, applications can be quickly written and tested. Standard features include:
H Single axis AC brushless drive with integrated Mint controller
H Wide range of models with continuous current ratings from 2.5A to 27.5A
H Direct connection to 115V AC or 230VAC single-phase or 230-460VAC three-phase
supplies (model dependent)
H Resolver, encoder, EnDat or Hiperface feedback
H Programmable in Mint, with multi-tasking capability
H Position, velocity and current control, preset and point to point moves, software cams and
gearing
H Auto-tuning wizard (including position loop) and software oscilloscope facilities
H 8 optically isolated digital inputs
H 3 optically isolated digital outputs
H 2 general-purpose analog inputs (can be used as a speed or torque demand reference)
H 2 general-purpose analog outputs
H 1 control relay
H Selectable RS232 or RS485 communications
H Flash memory for program storage (128k)
H Non-volatile RAM.
Factory-fitted options expand the I/O capabilities of the MintDrive
II
and provide CAN bus,
DeviceNet or Profibus connectivity. See Appendix A for details about options. MintDrive
II
will operate with a large number of brushless servo motors - for information on selecting Baldor servo motors, please see the sales brochure BR1202 (BR1800 for linear motors) available from your local Baldor representative.
This manual is intended to guide you through the installation of MintDrive
II
. The sections
should be read in sequence.
The Basic Installation section describes the mechanical installation of the MintDrive
II
,the power supply connections and motor connections. The other sections require knowledge of the low level input/output requirements of the installation and an understanding of computer software installation. If you are not qualified in these areas you should seek assistance before proceeding.
2 Introduction
2
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2-2 Introduction MN1901
2.2 Receiving and inspection
When you receive your MintDriveII, there are several things you should do immediately:
1. Check the condition of the shipping container and report any damage immediately to the carrier that delivered your MintDrive
II
.
2. Remove the MintDrive
II
from the shipping container and remove all packing material. The
container and packing materials may be retained for future shipment.
3. Verify that the catalog number of the MintDrive
II
you received is the same as the catalog
number listed on your purchase order. The catalog number is described in the next section.
4. Inspect the MintDrive
II
for external damage during shipment and report any damage to the
carrier that delivered your MintDrive
II
.
5. If MintDrive
II
is to be stored for several weeks before use, be sure that it is stored in a location
that conforms to the storage humidity and temperature specifications shown in section 8.1.21.
2.2.1 Identifying the catalog number
The MintDriveIIis available with different current ratings and package sizes. The catalog number is marked on the front of the unit, just below the Baldor logo. It is a good idea to look for the catalog number (sometimes shown as ID/No: ) and write it in the space provided here:
Catalog number:
MDH______________-________
Installed at: ________________________
Date: ______
A description of a catalog number is shown here, using the example MDH1A05TB-RC23:
Meaning Alternatives
MDH MintDriveIIfamily -
1 Requires an AC supply voltage of 115 Volts, 1Φ
2=230V (1Φ or 3Φ); 4=230V-460V (3Φ)
A05 Continuous current rating of 5.0A
A02=2.5A; A07=7.5A; A15=15A; A20=20A; A27=27.5A
T Built in AC power supply -
B
Dynamic Brake with a built in transistor and resistor (available on 2.5A and 5A models only)
R= Requires external braking
resistor
R Feedback option is a resolver
E=Encoder (incremental); D=EnDat (absolute encoder); H=Hiperface (absolute encoder)
C Options: 1 CAN channel
B=CAN & Auxiliary I/O; D=DeviceNet; P=Profibus DP; N=No options specified
2 Serial port type is combined RS232 / RS485 -
3
Customer’s own 24VDC supply is required to power the internal MintDrive
II
logic
0= Internally generated 24VDC
supply*
Additional suffix letters may be used to indicate customer-specific builds. * An external 24VDC supply will always be required to operate the enable input, digital inputs and digital outputs on connectors X3 and X4. See sections 4.3.1 to 4.3.4.
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Introduction 2-3MN1901
2.3 Units and abbreviations
The following units and abbreviations are used in this manual:
V Volt (also VAC and VDC)...............
WWatt..............
A Ampere...............
Ohm...............
μF microfarad..............
pF picofarad..............
mH millihenry.............
Φ phase...............
ms millisecond..............
μs microsecond..............
ns nanosecond..............
Kbaud kilobaud (the same as Kbit/s in most applications)...........
MB megabytes.............
CDROM Compact Disc Read Only Memory.........
CTRL+E on the PC keyboard, press Ctrl then E at the same time..........
mm millimeter.............
m meter...............
in inch...............
ft feet...............
lb-in pound-inch (torque).............
Nm Newton-meter (torque).............
ADC Analog to Digital Converter............
DAC Digital to Analog Converter............
AWG American Wire Gauge............
(NC) Not Connected............
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2-4 Introduction MN1901
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Basic Installation 3-1MN1901
3.1 Introduction
You should read all the sections in Basic Installation to ensure safe installation.
This section describes the mechanical and electrical installation of the MintDrive
II
in the
following stages:
H Location considerations
H Mounting the MintDrive
II
H Connecting the AC power supply
H Connecting the optional customer supplied 24VDC control supply
H Connecting the motor
H Installing a regeneration resistor (Dynamic Brake resistor)
H Connecting the feedback device
H Connecting the drive enable input.
These stages should be read and followed in sequence.
3.1.1 Power sources
An AC power source (IEC1010 over-voltage category III or less) in the installation area is required. This will need to be single or three-phase depending upon the type of MintDrive
II
.
An AC power filter is required to comply with the CE directive for which the MintDrive
II
was
tested (see section 3.4.5).
If the MintDrive
II
requires an external (customer supplied) 24VDC logic supply then this must be a regulated power supply with a continuous current supply capability of 1.75A (4A power on surge). A 24V filter may be required to comply with the CE directive for which the MintDrive
II
was tested (see section 3.4.5).
3.1.2 Hardware requirements
The components you will need to complete the basic installation are:
H The motor that will be connected to the MintDrive
II
H A motor power cable
H A resolver or encoder feedback cable (and Hall cable for linear motors)
H With some applications there may be a requirement for a regeneration resistor (Dynamic
Brake).
Note: Without the regeneration resistor, the drive may produce an overvoltage fault.
All MintDrive
II
models have overvoltage sensing circuitry, but only 2.5A and 5A models (catalog numbers MDHxxxxxB-xxxx) have an internal regeneration resistor. For 7.5A, 15A, 20A and 27.5A models a regeneration resistor must be purchased separately if required. See Appendix A.
3 Basic Installation
3
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3-2 Basic Installation MN1901
H A serial cable.
Note: The serial connector on the MintDrive
II
(connector X6) can be configured as either RS232 or RS485 / RS422. Pin 9 is used to carry +8V for powering some Baldor keypad peripherals. Ensure that pin 9 is not connected to earth/ground or to equipment that could be damaged by the +8V supply. See sections 4.4.3 to 4.4.4. A suitable cable is available from Baldor, catalog number CBL001-501.
H A PC (with one free COM port) with the following specification:
Minimum specification Recommended specification
Processor Intel Pentium 500 MHz Intel PentiumIII 1 GHz or faster
RAM 64 MB 128 MB
Hard disk space 40 MB 40 MB
CD-ROM ACD-ROMdrive
Screen 1024 x 768, 16-bit color 1 152 x 864, 16-bit color
Mouse A mouse or similar pointing device
Operating
system
Windows 95, Windows 98, Windows ME,
Windows NT, Windows 2000 or Windows XP
3.1.3 RS485 / RS422 systems
If you will be using RS485 / RS422 and your PC does not have an RS485 / RS422 connector, an RS232 to 4-wire RS485 / RS422 converter will be required. These commercially available devices convert the signals from the RS232/RS485 port (connector X6) to the signals necessary for RS485 / RS422 communications. Special care must be taken with the pin assignment on all RS485 / RS422 devices, as this can differ between products. Connectors might need to be rewired to provide the correct pin assignment. The MintDrive
II
pin
assignment is shown in section 4.4.3.
Note: If this is the first time you are installing a MintDrive
II
then it is strongly recommended that you use RS232 to get started and try RS485 later. This will avoid any potential problems involving the RS232-RS485 converter. Selection of RS232 or RS485 is controlled using DIP switch 10 - see section 3.9.6.
3.1.4 Tools and miscellaneous hardware
H Your PC operating system user manual might be useful if you are not familiar with
Windows
H A small screwdriver (supplied) with a blade width less than 3mm (1/10 in).
H M5 screws or bolts for mounting the MintDrive
II
H Crimping tool.
A connector kit is supplied with your MintDrive
II
. This contains a number of useful connectors
and a screwdriver for tightening the connections.
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Basic Installation 3-3MN1901
3.1.5 Other information needed for installation
This information is useful (but not essential) to complete the installation:
H The data sheet or manual provided with your motor, describing the wiring information of
the motor cables/connectors
H Knowledge of which digital inputs/outputs will be ‘Active Low’, ‘Active High’ or edge
triggered.
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3-4 Basic Installation MN1901
3.2 Mechanical installation and location requirements
It is essential that you read and understand this section before beginning the installation
.
CAUTION: To prevent equipment damage, be certain that the input power has
correctly rated protective devices installed.
CAUTION: To prevent equipment damage, be certain that input and output signals
are powered and referenced correctly.
CAUTION: To ensure reliable performance of this equipment be certain that all
signals to/from the MintDrive
II
are shielded correctly.
CAUTION: Avoid locating the MintDriveIIimmediately above or beside heat
generating equipment, or directly below water steam pipes.
CAUTION: Avoid locating the MintDriveIIin the vicinity of corrosive substances or
vapors, metal particles and dust.
The safe operation of this equipment depends upon its use in the appropriate environment. The following points must be considered:
H The MintDrive
II
must be installed indoors, permanently fixed and located so that it can only
be accessed by service personnel using tools.
H The maximum suggested operating altitude is 1000m (3300ft).
Above 1000m (3300ft) de-rate output current 1.1% per 100m (330ft).
H The MintDrive
II
must operate in an ambient temperature of 0°C to 40°C (32°F to 104°F).
De-rate output current 2.5% per 1°C (1.8°F) from 40°C (104°F) to 50°C (122°F) maximum.
H The MintDrive
II
must operate in relative humidity levels of less than 90% for temperatures up to 31°C (87°F) decreasing linearly to 50% relative humidity at 40°C (104°F) (non-condensing).
H The MintDriveIImust be installed where the pollution degree according to IEC664 shall not
exceed 2.
H The external customer supplied 24VDC for the logic supply must be installed so that the
24VDC supplied to the unit is isolated from the AC supply using double or reinforced insulation.
H The inputs and outputs of the control circuit must be limited to Safety Extra Low Voltage
circuits.
H Both the AC supply and the external 24VDC supply must be fused.
H The atmosphere must not contain flammable gases or vapors.
H There must not be abnormal levels of nuclear radiation or X-rays.
H The MintDrive
II
must be secured by the slots in the flange, with the protective earth/ground stud bonded to a safety earth/ground by either a 25A conductor or a conductor of three times the peak current rating - whichever is the greater.
Page 19
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Basic Installation 3-5MN1901
H For effective cooling and maintenance, the MintDriveIIshould be mounted on a smooth,
non-flammable vertical surface. The power handling capability is affected by the temperature of the left side of the unit.
H At least 50mm (2 in) top and bottom clearance of the MintDriveIImust be provided for
airflow.
H If multiple MintDrive
II
are being mounted side by side there must be 13mm (0.5 in)
between them. The MintDrive
II
nearest the side of the cabinet / enclosure must be
separated from it by at least 13mm (0.5 in).
H To comply with CE directive 89/336/EEC an appropriate AC filter must be installed. The
external customer supplied 24VDC logic supply might also require a 24V filter. See section
3.4.7.
H The threaded holes in the top and bottom of the enclosure are for cable clamps. The holes
are threaded for M4 bolts no longer than 12mm (0.47 in) in length. Longer bolts may short circuit the electrical components inside the MintDrive
II
.
H Each D-type connector on the front panel of the MintDrive
II
is secured using two hexagonal jack screws (sometimes known as “screwlocks”). If a jack screw is removed accidentally or lost it must be replaced with an identical jack screw with an external male threaded section of 5mm (0.2 in). Jack screws with longer threads could damage or short circuit internal components.
3.2.1 Mounting the MintDrive
II
Ensure you have read and understood the Mechanical installation and location requirements in section 3.2. Mount the MintDrive
II
on its rear side, the side opposite to the front panel.
The MintDrive
II
must be mounted upright to ensure adequate cooling (you can check this by ensuring that the Hazardous Voltages warning information is clearly readable to you). M5 bolts or screws should be used to mount the MintDrive
II
.
There are seven different package sizes depending on the specification of the MintDrive
II
:
AC power
Current Factory fitted option Package size
Single-phase 2A without option A
with option B
5A without option C
with option D
7.5A without option D
with option D
230V Three-phase
15A with or without option E
230-460V
2.5A, 5A, 7.5A with or without option G
Three-phase
15A, 20A, 27.5A with or without option H
Detailed dimensions for each package are shown in section 3.2.2.
Page 20
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3-6 Basic Installation MN1901
3.2.2 Dimensions
H
1
H
2
H
W
D
W
2
W
1
W
3
Package size
H only.
W
4
Package sizes E, G & H only: W4=9.5mm.
All other sizes: W4=W
2
H3H
4
65mm
FRONT PANEL
H5H
6
Mounting keyhole and slot detail
A
B
C
A 5mm (package sizes E, G and H: 6.5mm) B 10mm (package sizes E, G and H: 12mm) C 9mm (package sizes E, G and H: 10mm)
A
Dimensions
mm / inches
Weight
Pack W W
1
W
2
W
3
H H
1
H
2
H
3
H
4
H
5
H
6
D kg / lb
A 67.5
2.66
15
1.25
2.76
B 84
3.31
40
1
5
0.59
40 173 195.5 205 23.5 6.5 8.5 3 152
1.55
3.42
C 92.5
3.64
4
0
1.57
23
4
0
1.57
173
6.81
195.5
7.70
205
8.07
2
3.5
0.93
6.5
0.26
8.5
0.3330.12
152
6.00
2.1
4.63
D 109
4.29
2
3
0.91
2.3
5.07
E 55
2.17361.42
27.5
1.08
- 263.5
10.37
3.3
7.28
G 65
2.56461.81
32.5
1.28
-
357
14.06
384
15.12
400
15.75
26.5
1.0480.31
16.5
0.6580.31
265.3
10.44
4.9
10.8
H 130
5.12
111
4.37
27.5
1.08752.95
265.3
10.44
9.05
19.95
Figure 1 - Package dimensions
Page 21
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Basic Installation 3-7MN1901
3.3 Connecto r locations
Earth NC (NC) LACLine N AC Neutral UMotorU VMotorV WMotorW R1 Regen Resistor R2 (Dynamic Brake)
- (NC) +24V Customer 0V supplied 24V
(MDHxxxxxx-xxx3
only)
Earth
Earth L1 AC Phase 1 L2 AC Phase 2 L3 AC Phase 3 UMotorU VMotorV WMotorW R1 Regen Resistor R2 (Dynamic Brake) +24V Customer supplied 24V 0V (MDH4xxxxx-xxx3 onl y)
1 AIN0+ (Demand+) 2 AIN0- (Demand-) 3AGND 4 Relay+ (DOUT3) 5 Relay­6UserV+ 7 CREF 8CGND 9 Drive Enable 10 DIN0 11 DIN1 12 DIN2 13 DIN3 14 DIN4 (Pulse) 15 DIN5 (Direction) 16 DIN6 17 DIN7 18 DOUT0 19 DOUT1 20 DOUT2
1 CHA+ 2 CHB+ 3 CHZ+ 4 (NC) 5DGND 6 CHA­7 CHB­8 CHZ­9 (NC)
RS232 RS485/422 1 (NC) (NC) 2RXD RX­3TXD TX­4 (NC) (NC) 5 0V GND 0V DGND 6 (NC) (NC) 7 RTS TX+ 8CTS RX+ 9 (NC - see secti on 4.4.3)
X3 General I/O
X6 RS232/RS485
X7 Encoder Out
X8 Feedback In
1REF+ 2COS+ 3SIN+ 4 (NC) 5AGND 6REF­7COS­8SIN­9 Chassis
Incremental EnDat Hiperface 1 CHA+ Data+ Data+ 2 CHB+ Data- Data­3 CHZ+ +5V +8V 4 Hall U+ +5V +8V 5 Hall U- DGND DGND 6 CHA- Shield Shield 7 CHB- Cos B- Cos B­8 CHZ- (NC) (NC) 9 Hall W+ Clock- (NC) 10 Hall V+ Clock+ (NC) 11 +5V DGND DGND 12 (NC) Sin A- Sin A­13 DGND Sin A+ Sin A+ 14 Hall W- Cos B+ Cos B+ 15 Hall V- (NC) (NC)
Resolver option
Encoder options
X1 / X1A Power
Single-phase models
Three-phase models, 230-460V
Tightening torque for terminal block connections is 0.5-0.6Nm (4.4-5.3 lb-in)
X9 Master Encoder
II
Options:
If there are other connectors on the front panel of your MintDriveII, then an option is fitted. See the other manuals supplied with your Mi ntDriv eII.
* Warning! High voltages are present on terminals labeled Vcc+ and Vcc-. Do not make a connection to these terminals.
(NC) = Not Connected. Do not make a connection to this pin.
Encoder Pulse & Dir. 1 CHA+ Pulse+ 2 CHB+ Dir.+ 3 CHZ+ (NC) 4 (NC) (NC) 5DGND (NC) 6 CHA- Pulse GND 7 CHB- Dir. GND 8 CHZ- (NC) 9+5V (NC)
1 Node 2 number 3 selection 4 5Hold 6 RS485 terminator 7 Offset tuning 8 Enable 9 (Reserved) 10 RS232/RS485
SW1 DIP switches
1 Chassis 2AIN1+ 3AIN1­4AOUT0 5AOUT1 6AGND
X4 Analog I/O
Earth
Earth L1 AC Phase 1 L2 AC Phase 2 L3 AC Phase 3 UMotorU VMotorV WMotorW Vcc+ (NC)* Vcc- (NC)* R1 Regen Resistor R2 (Dynamic Brake) +24V Customer supplied 24V 0V (MDH2xxxxx-xxx3 onl y)
Three-phase models, 230V
Page 22
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3-8 Basic Installation MN1901
3.4 Power connections
This section provides instructions for connecting the AC power supply. It is important that you refer to the correct front panel for your MintDrive
II
package.
The installer of this equipment is responsible for complying with NEC (National Electric Code) guidelines or CE (Conformite Europeene) directives and application codes that govern wiring protection, earthing/grounding, disconnects and other current protection.
WARNING: Electrical shock can cause serious or fatal injury. Do not touch any
power device or electrical connection before you first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected.
The power supply module within all MintDrive
II
models provides rectification, smoothing and current surge protection. On 2.5A and 5A models a regeneration resistor (Dynamic Brake resistor) is also built-in. The power stage is internally fused and therefore self protected, but fuses or circuit breakers are required in the input lines for cable protection (depending on local codes and regulations).
A power disconnect should be installed between the AC supply and the input of the MintDrive
II
for a fail safe method to disconnect mains power. On models with the internally generated 24VDC logic supply (catalog numbers MDHxxxxx-xxx0), the MintDrive
II
will remain operational until the internal bus voltage is depleted. Position and I/O information will then be lost. On models with an external customer supplied 24VDC logic supply (catalog numbers MDHxxxxx -xxx3), position and I/O information will be retained while the 24V supply is present.
Note: A Residual Current Device (RCD) must not be used for fusing the drive. A circuit
breaker or fuse must be used.
All interconnection wires should be in metal conduits between the MintDrive
II
, AC power source, motor, host controller and any operator interface stations. Use UL listed closed loop connectors that are of appropriate size for the wire gauge being used. Connectors are to be installed using only the crimp tool specified by the manufacturer of the connector. Only class 1 wiring should be used.
Baldor drives are designed to be powered from standard single and three-phase lines (depending on model) that are electrically symmetrical with respect to earth/ground. Due to the importance of system earthing/grounding for increased reliability, earthing/grounding methods are shown in sections 3.4.1 and 3.4.2.
Note: When using unearthed/ungrounded distribution systems, an isolation transformer
with an earthed/grounded secondary is recommended. This provides three-phase AC power that is symmetrical with respect to earth/ground and can prevent equipment damage.
MintDrive
II
may also be powered from a DC supply. However, details are not provided here since output current derating and other important limitations apply when using a DC supply. Please contact Baldor technical support for advice.
Page 23
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Basic Installation 3-9MN1901
3.4.1 Single-phase connection to package sizes A, B, C, D
Location Connector X1
(Mating connector: Phoenix COMBICON MVSTBW 2,5/9-ST, 5mm pitch)
Part number MDH1A... MDH2A...
Nominal input
voltage
115VAC, 1Φ line to neutral (U.S. single phase supply)
230VAC, 1Φ line to neutral (European single phase supply)*
Range 75-125VAC 75-250VAC
* The required 230VAC supply may also be derived from two phases of a U.S. 230VAC
3-phase supply, i.e. 230VAC line to line. Connect one phase to L and the other phase to N.
For single-phase connection, the voltage ripple on the DC-bus is 25Vp-p for 5A peak current rising to 50Vp-p for 10A peak current. This can limit the maximum speed of the motor. Tightening torque for terminal block connections is 0.5-0.6Nm (4.4-5.3 lb-in).
The threaded hole in the top of the enclosure is for protective earth/ground connections. The threaded hole in the bottom of the enclosure may be used as an additional functional earth/ground connection for signals on connector X3. It may also be used to attach strain relief clamps. The holes are threaded for M4 bolts no longer than 12mm (0.47 in) in length. Longer bolts may short circuit the electrical components inside the MintDrive
II
.
AC
Supply
Line (L)
Neutral (N)
Route L, N, and
earth/ground together
in conduit or cable
Circuit breaker or fuse.
See section 3.4.4
AC filter.
See section
3.4.5
STAR POINT
Incoming safety
earth/ground (PE)
Isolating switch
* If filter has no
output
earth/ground
terminal, earth
wire may be
connected directly
to star point.
*
If AC power wires
are shielded,
earth/ground
outer shield using
360º c lamps
connected to
backplane.
Figure 2 - Earthing/grounding for single-phase installations
Note: For CE compliance, a filter must be connected between the AC power supply and
the MintDrive
II
. If local codes do not specify different regulations, use at least the
same gauge wire for earth/ground as is used for L and N.
Page 24
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3-10 Basic Installation MN1901
3.4.2 Three-phase connection to package sizes E, G , H
Location Connector X1A
(Mating connector: Phoenix POWER COMBICON PC4/..-ST- 7.62)
Part number MDH2A15... MDH4A...
Nominal input
voltage
230VAC, 3Φ line to line 230-460VAC, 3Φ line to line
Range 75-253VAC 75-528VAC
Tightening torque for terminal block connections is 0.5-0.6Nm (4.4-5.3 lb-in). The threaded hole in the top of the enclosure is for protective earth/ground connections. The threaded hole in the bottom of the enclosure (if present) may be used as an additional functional earth/ground connection for signals on connector X3. It may also be used to attach strain relief clamps. The holes are threaded for M4 bolts no longer than 12mm (0.47 in) in length. Longer bolts may short circuit the electrical components inside the MintDrive
II
.
AC
Supply
Line (L1)
Route L1, L2, L3 and
earth/ground together
in conduit or cable
Circuit breaker or fuses.
See section 3.4.4
AC filter.
See section
3.4.5
Line (L2)
Line (L3)
STAR POINT
Incoming safety
earth/ground (PE)
Isolating switch
* If filter has no
output
earth/ground
terminal, earth
wire may be
connected
directly to star
point.
*
MDH4A... show n for illustration purposes
If AC power wires
are shielded, earth/ground
outer shield using
360º c lamps connected to
backplane.
Figure 3 - Earthing/grounding for three-phase installations
WARNING: Drives with part numbers MDH2A15... have two additional terminals
on the X1 connector labeled Vcc+ and Vcc-. The full DC bus output voltage is present on the these terminals so do not make any connection to them.
Note: For CE compliance, a three-phase AC filter must be connected between the AC
power supply and the MintDrive
II
. If local codes do not specify different regulations, use at least the same gauge wire for earth/ground as is used for L and N.
Page 25
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Basic Installation 3-11MN1901
3.4.3 Input power conditioning
Baldor drives are designed for direct connection to standard single and three-phase lines (depending on model) that are electrically symmetrical with respect to earth/ground. Certain power line conditions must be avoided; an AC line reactor, an isolation transformer or a step up/step down transformer may be required for some power conditions:
H If the feeder or branch circuit that provides power to the MintDrive
II
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 MintDrive
II
.
H If the feeder or branch circuit that provides power to the MintDrive
II
has power factor correction capacitors that are switched on line and off line, the capacitors must not be switched while the drive is connected to the AC power line. If the capacitors are switched on line while the drive is still connected to the AC power line, additional protection is required. A Transient Voltage Surge Suppressor (TVSS) of the proper rating must be installed between the AC line reactor (or isolation transformer) and the AC input to the MintDrive
II
.
3.4.3.1 Input power-cycling
If AC power has been removed from the MintDrive
II
, it should not be reapplied for at least one minute. This delay allows the input surge protection circuit to perform correctly. Power-cycling the drive more frequently could cause nuisance trips when power is reapplied and reduce the lifetime of the MintDrive
II
.
3.4.4 Power disconnect and protection devices
A power disconnect should be installed between the input power service and the MintDrive
II
for a fail-safe method to disconnect power. The MintDriveIIwill remain in a powered condition until all input power is removed from the drive and the internal bus voltage has depleted.
The MintDrive
II
must have a suitable input power protection device installed. Recommended circuit breakers are thermal magnetic devices (1 or 3 phase as required) with characteristics suitable for heavy inductive loads (D-type trip characteristic). Recommended time delay fuses are Buss FRN on 230VAC or equivalent, following the UL 508C recommendation of a fuse size of four times the continuous output current of the drive. Dual element, time delay fuses should be used to avoid nuisance trips due to inrush current when power is first applied.
Circuit Breaker
L
N
From
supply
L
N
From
supply
Fuse
L
N
L
N
Figure 4 - Circuit breaker and fuse, single-phase (package sizes A, B, C, D)
Page 26
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3-12 Basic Installation MN1901
Note: Power to single phase models may be derived by connecting two phases of an
appropriate three-phase supply (L1 and L2 for example). When supplying
AC
power in this way, the voltage between the two phases must not exceed the
rated
input voltage of the MintDrive
II
. A two pole breaker must be used to isolate both lines. Fuses must be fitted in both lines. Circuit breaker or fuse are not supplied. For CE compliance, see Appendix D.
Circuit Breaker
Circuit breaker or fuse are not supplied. For CE Compliance, see Appendix C.
L1
From
supply
Fuses
L2
L3
L1
L2
L3
From
supply
L1
L2
L3
Figure 5 - Circuit breaker and fuse, three-phase (package sizes E, G, H)
Note: Metal conduit or shielded cable should be used. Connect conduits so the use of a
line reactor or RC device does not interrupt EMI/RFI shielding.
3.4.5 Power supply filters
To comply with EEC directive 89/336/EEC, an AC power filter of the appropriate type must be connected. This can be supplied by Baldor and will ensure that the MintDrive
II
complies with
the CE specifications for which it has been tested. Table 1 lists the appropriate filters:
MintDrive
II
Input voltages
cu
r
rent
rating
115VAC, 1Φ 230VAC, 1Φ 230VAC, 3Φ 230-460VAC, 3Φ
2.5A FI0015A00 or FI0029A00 FI0018A00
5A FI0015A02 or FI0029A00
FI0018A00
7.5A FI0029A00 FI0018A00
15A FI0018A01 FI0018A01
20A FI0018A01
27.5A FI0018A01
Ta ble 1 - Baldor filter part numbers
All single-phase MintDrive
II
models can be mounted directly onto the body of filter FI0029A00,
reducing the amount of panel area required for filter and drive.
Page 27
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Basic Installation 3-13MN1901
3.4.6 Wire sizes and protection device ratings
Table 2 describes the wire size to be used for power connections and the ratings of the protection devices.
Incoming Power
Nominal
Continuous
D-Type
Time
Minimum
Catalog Number
Input
Output
y
p
Input
Dela
yMinimu
m
Wire Gauge
Vol
t
age
A
mps
(RMS)
B
reaker
(A)
I
npu
t
Fuse
(A)
AWG mm
2
MDH1A02xx-xxxx 115V (1Φ) 2.5A 6 6 14 2.0
MDH2A02xx-xxxx 230V (1Φ) 2.5A 6 6 14 2.0
MDH1A05xx-xxxx 115V (1Φ) 5A 10 10 14 2.0
MDH2A05xx-xxxx 230V (1Φ) 5A 10 10 14 2.0
MDH1A07xx-xxxx 115V (1Φ) 7.5A 16 16 14 2.0
MDH2A07xx-xxxx 230V (1Φ) 7.5A 16 16 14 2.0
MDH4A02xx-xxxx
230-460V
(3Φ)
2.5A 6 6 14 2.0
MDH4A05xx-xxxx
230-460V
(3Φ)
5A 10 10 14 2.0
MDH4A07xx-xxxx
230-460V
(3Φ)
7.5A 16 16 14 2.0
MDH2A15xx-xxxx 230V (3Φ) 15A 32 32 12 3.3
MDH4A15xx-xxxx
230-460V
(3Φ)
15A 32 32 12 3.3
MDH4A20xx-xxxx
230-460V
(3Φ)
20A 40 40 10 5.3
MDH4A27xx-xxxx
230-460V
(3Φ)
27.5A 60 60 10 5.3
Table 2 - Protection device and wire ratings
Note: All wire sizes are based on 75°C (167°F) copper wire. Higher temperature smaller
gauge wire may be used per National Electric Code (NEC) and local codes. Recommended fuses/breakers are based on 25°C (77°F) ambient, maximum continuous control output current and no harmonic current. Earth/ground wires must be the same gauge, or larger, than the Line and Neutral wires.
Page 28
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3-14 Basic Installation MN1901
3.4.7 External customer supplied 24V control supply
Depending on model (catalog numbers MDHxxxxx-xxx3) a 24VDC control supply must be provided to power the control electronics. This is useful for safety reasons where AC power needs to be removed from the power stage but the control electronics must remain powered to retain position and I/O information. It is recommended that a separate fused 24V supply is provided for the MintDrive
II
. If other devices are likely to be powered from the same 24V supply then a filter (Baldor catalog number FI0014A00) should be installed to isolate the MintDrive
II
from the rest of the system.
Location
Connector X1 / X1A
Part number MDHxxxxx -xxx3
Nominal input voltage 24V
Range 20.4-28.8VDC
Input current
(maximum)
1.75A continuous (4A power on surge)
Tightening torque for terminal block connections is 0.5-0.6Nm (4.4-5.3 lb-in)
Note: Connect 24V to connector X1 only if your model has this feature. Connecting 24V
to a model that does not require an external 24V supply (MDHxxxxx-xxx0) could damage the unit.
Note: The label on filter FI0014A00 correctly indicates that it is designed for connection
to AC power supplies. However, this filter has been tested and is suitable for use with a 24VDC input as indicated in Figure 6. Do not attempt to use an alternative AC power filter as a 24VDC input filter.
Customer s upplied
24VDC (fused)
+24V
24V filter * (optional)
GND
Single-phase model shown for illustration purposes
STAR
POINT
Incoming safety
earth/ground (PE)
If 24V wires are
shielded, earth/ground outer shields
using 360º
clamps connected
to backplane.
* An AC input voltage is indicated on the label of fi lter
FI0014A00, but it may also be used with a 24VDC input.
Figure 6 - Customer supplied 24V supply connections
Page 29
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Basic Installation 3-15MN1901
3.5 Motor connections
The motor can be connected directly to the MintDriveIIor through a motor contactor (M-Contactor).
Location
Connector X1 / X1A
Part number MDH1A... MDH2A... MDH2A15... MDH4A...
Nominal output voltage 160VDC 320VDC 320VDC 565/650V
Output voltage range 135-176VDC 306-350VDC 258-355VDC 254-746VDC
See section
3.5.5
V
W
U
Motor
To earth/ground outer shi eld, use 360° clamps connected to backplane
Thermal
switch
A
B
Brake
(if present)
C
D
See section
3.5.6
Unshielded
lengths should be
as short as
possible.
Optional motor
circuit contactors
Figure 7 - Motor connections
CAUTION: Do not connect supply power to the MintDriveIIUVW outputs.
The MintDrive
II
might be damaged.
CAUTION: The motor leads U, V and W must be connected to their corresponding U,
V or W terminal on the motor. Misconnection could result in uncontrolled motor movement.
The motor power cable must be shielded for CE compliance. The connector or gland used at the motor must provide 360 degree shielding. The maximum recommended cable length is
30.5m (100ft).
Note: For CE compliance the motor earth/ground should be connected to the drive
earth/ground.
Page 30
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3-16 Basic Installation MN1901
3.5.1 Motor circuit contactors
If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor) may be installed to provide a physical disconnection of the motor windings from the MintDrive
II
(see
section 3.5). Opening the M-Contactor ensures that the MintDrive
II
cannot drive the motor, which may be necessary during equipment maintenance or similar operations. Under certain circumstances it may also be necessary to fit a brake to a rotary motor. This is important with hanging loads where disconnecting the motor windings could result in the load falling. Contact your local supplier for details of appropriate brakes.
CAUTION: If an M-Contactor is installed, the MintDriveIImust be disabled at least
20ms before the M-Contactor is opened. If the M-Contactor is opened while the MintDrive
II
is supplying voltage and current to the motor, the
MintDrive
II
may be damaged. Incorrect installation or failure of the
M-Contactor or its wiring may result in damage to the MintDrive
II
.
Ensure that shielding of the motor cable is continued on both sides of the contactor.
3.5.2 Motor power cable pin configuration - Baldor BSM rotary motors
Figure 8 shows the pin configuration for a typical Baldor motor cable, part number CBL025SP-12:
Signal name
Motor / cable pin Motor cable wire color
Motor U 1 Black, labeled ‘1’
Motor V 4 Black, labeled ‘2’
Motor W 3 Black, labeled ‘3’
Earth/ground 2 Green/Yellow
Thermal switch A Green
Thermal switch B Whit e
Brake C Blue
Brake D Red
Cable connector end view
(female)
1
B
A
3
2
4
Motor power connector
(male)
1
B
A
3
2
4
C
D
C
D
Note: Not all motors arefittedwith a brake so pins C and D might not be connected.
Figure 8 - Baldor motor power cable pin configuration
Page 31
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Basic Installation 3-17MN1901
3.5.3 Motor cable pin configuration - Baldor linear motors
The following table shows the core colors used in a typical Baldor linear motor cable set, part number AY1763A00:
Signal name
Motor cable wire color
Motor U Black
Motor V Red
Motor W White
Motor ground Green
Thermal switch Blue
Thermal switch Orange
Signal name Hall cable wire color
Hall 1 (U) White
Hall 2 (V) Red
Hall 3 (W) Black
Hall ground Green
Hall +5VDC Brown
3.5.4 Sinusoidal filter
A sinusoidal filter is used to provide a better quality waveform to the motor, reducing motor noise, temperature and mechanical stress. It will reduce or eliminate harmful dV/dt values (voltage rise over time) and voltage doubling effects which can damage motor insulation. This effect occurs most noticeably when using very long motor cables, for example 30m (100 ft) or more. Baldor motors intended to be used with drives are designed to withstand the effects of large dV/dt and overvoltage effects. However, if very long motor cables are unavoidable and are causing problems, then a sinusoidal filter may be beneficial.
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3-18 Basic Installation MN1901
3.5.5 Thermal switch connection
You might wish to wire the motor’s thermal switch contacts (normally closed), using a relay, to a digital input on connector X3 (see section 4.3.1). Using the WorkBench v5 Digital I/O tool, the input can be configured to be the motor trip input. This allows the MintDrive
II
to respond to motor over-temperature conditions. The Mint keyword MOTORTEMPERATUREINPUT can also be used to configure a digital input for this purpose. A typical circuit, using DIN1 as the input, is shown in Figure 9.
A
B
motor
thermal
switch
CREF
X3
7
DIN0 (INX.0)
Relay
Customer
supplied
24VDC
supply
+24VDC 0V
10
11 12 13 14 15 16 17
DIN1 (INX.1)
DIN3 (INX.3)
DIN7 (INX.7)
DIN5 (INX.5)
DIN4 (INX.4)
DIN2 (INX.2)
DIN6 (INX.6)
Separate customer
supplied
24VDC supply
+24VDC 0V
Figure 9 - Motor thermal switch circuit
CAUTION: The 24VDC power supply connected to the thermal switch must be a
separate supply as shown in Figure 9. Do not use the 24V supply used for the drive enable signal, or the internally generated supply (if present). The thermal switch wires often carry noise that could cause erratic drive operation or damage. The thermal switch contacts must never be wired directly to a digital input.
The separate 24VDC supply used for the thermal switch may also be used for the motor brake circuit (section 3.5.6).
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Basic Installation 3-19MN1901
3.5.6 Motor brake connection
You might wish to wire a motor’s brake, via relays, to digital outputs on connector X3 (see section 4.3.1). This provides a way for the Mint program to control the motor’s brake. A typical circuit is shown in Figure 10.
C
D
from motor brake connections
Separate
customer
supplied
24VDC supply
X3
8
18 19
DOUT0 (OUTX.0) DOUT1 (OUTX.1)
CGND
Relay 2
Relay 1
+24VDC 0V
The inner shield surrounding the brake wi res should be earthed/grounded at one point only.
The relays have normally open contacts and are shown deactivated (contacts open, brake engaged).
Figure 10 - Motor brake control circuit
This circuit uses the drive enable signal (configured using DRIVEENABLEOUTPUT to appear on DOUT0) in conjunction with a brake output (configured using MOTORBRAKEOUTPUT to appear on DOUT1). With this configuration, the following sequences can be used to control the brake.
To engage the brake:
H The motor is brought to rest under normal control;
H Relay 2 is deactivated, causing the brake to engage;
H The drive is disabled. This removes power from the motor and causes Relay 1 to be
deactivated.
To disengage the brake:
H The drive is enabled, activating Relay 1;
H Power is applied to the motor to hold position under normal control;
H Relay 2 is activated, causing the brake to be disengaged.
It may be necessary to include a small delay, after Relay 2 has been activated, before starting motion. This delay will allow time for the relay contacts to engage and the brake to release.
CAUTION: The 24VDC power supply must be a separate supply as shown in Figure
10. Do not use the 24V supply powering the MintDrive
II
digital outputs, or the internally generated supply (if present). The brake wires often carry noise that could cause erratic drive operation or damage. The brake contacts must never be wired directly to the digital outputs. The relay(s) should be fitted with a protective flyback diode, as shown. The separate 24VDC supply used for the motor brake may also be used to power the relay in the thermal switch circuit (section 3.5.5).
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3-20 Basic Installation MN1901
3.6 Regeneration resistor (Dynamic Brake resistor)
The 2.5A and 5A MintDriveIIboth have an internally fitted regeneration resistor *. For 7.5A, 15A, 20A and 27.5A MintDrive
II
, an external regeneration resistor must be installed to dissipate excess power from the internal DC bus during motor deceleration. When regeneration causes the DC bus voltage to rise by more than about 10-50 volts (model dependent) above the maximum allowable DC bus voltage, the regeneration resistor is automatically connected. When this happens, the yellow DB On LED on the front panel of the MintDrive
II
will illuminate.
The MintDrive
II
has an additional emergency overvoltage trip system. However, this must not be used as a means of protecting the drive from regeneration, since the trip occurs at a much higher voltage than the regeneration switching voltage. Allowing regeneration to cause regular overvoltage trips increases the chance of permanent damage to the MintDrive
II
.
Suitable regeneration resistors are listed in section A.1.9.
WARNING: A regeneration resistor may generate enough heat to
ignite combustible materials. To avoid fire hazard, keep all combustible materials and flammable vapors away from the resistors. The regeneration resistor should be mounted near the top of an enclosure to maximize heat dissipation. Baldor regeneration resistors are neither internally fused nor thermally protected and, under extreme conditions, can cause a fire hazard if not suitably protected or rated for the application.
* If required by the application, additional external resistors connected to R1 and R2 will be
connected in parallel with the internal resistor.
3.6.1 Controlling regeneration
Some regeneration resistor assemblies include an overload switch to indicate when too much power is being dissipated by the resistor. This switch can be wired to a digital input on the MintDrive
II
. Using the WorkBench v5 Digital I/O tool, the input can be configured to be the
brake trip input. This allows the MintDrive
II
to respond to resistor overload conditions.
The Mint keyword DBEXTTRIPINPUT can also be used to configure a digital input for this purpose. On three-phase MintDrive
II
models, the operation of the regeneration resistor can be controlled by further Mint keywords. These also begin with the letters DB..., for example DBEXTPEAKPOWER. See the Mint help file for details.
R1 R2
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Basic Installation 3-21MN1901
3.7 Feed b ack connectio n s
Two feedback options are available for use with linear and rotary motors - commutating encoder or resolver. Confirm the catalog number of your MintDrive
II
(see section 2.2.1) to ensure you are wiring the correct feedback device. There are some important considerations when wiring the feedback device:
H The feedback device wiring must be separated from power wiring.
H Where feedback device wiring runs parallel to power cables, they must be separated by at
least 76mm (3 in).
H Feedback device wiring must cross power wires at right angles only.
H To prevent contact with other conductors or earth/grounds, unearthed/ungrounded ends of
shields must be insulated.
H Some larger D-type connector shells may be obstructed by neighboring connector X3.
H Linear motors use two separate cables (encoder and Hall). The cores of these two cables
will need to be wired to the appropriate pins of the 15-pin D-type mating connector (supplied).
An encoder output signal is available on connector X7 for supplying other equipment. MintDrive
II
models with the resolver option provide a simulated encoder output, while the
encoder based MintDrive
II
duplicates the encoder signals entering X8. See section 4.4.1 for
details.
MintDrive
II
models with the resolver or incremental encoder option are capable of dual encoder feedback, a technique where two encoders are used to control a single axis. The second feedback input is derived from the master (auxiliary) encoder input on connector X9 (section 4.4.2). See the Mint help file for details.
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3-22 Basic Installation MN1901
3.7.1 Resolver option - X8
The resolver connections are made using the 9-pin D-type male connector X8. Twisted pair cables must be used for the complementary signal pairs e.g. SIN+ and SIN-. The overall cable shield (screen) must be connected to the metallic shell of the D-type connector.
Location
Connector X8, 9-pin D-type male connector
Pin Resolver function
1 REF+
2 COS+
3 SIN+
4 (NC)
5 Analog Ground
6 REF-
7 COS-
8 SIN-
9 Chassis Ground
Description Resolver input with 14-bit resolution
The resolver input is used to create an encoder signal inside the MintDriveII. This provides the MintDrive
II
with an equivalent resolution of 4096 pulses per revolution (ppr), although this can be reconfigured in the WorkBench v5 Commissioning Wizard to provide 1024 ppr. The MintDrive
II
provides an input accuracy of ±3 counts. When used with a typical Baldor BSM series resolver motor the combined accuracy is ±1 1 counts (calculated with the input equivalent resolution set to the factory preset value of 4096 ppr).
1
6
2
7
3
8
5
R2
R1
S2
S4
S1S3
X8
SIN+
SIN-
COS+
COS-
REF+
REF-
AGND
+
Twi sted
pairs
Baldor motor
resolver connector
5
6
3
4
1
2
Connect overall shield
to connector backshells.
Connect internal shields to AGND.
+
+
Figure 11 - Resolver cable connections
1
5
6
9
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Basic Installation 3-23MN1901
3.7.1.1 Resolver cable pin configuration
Figure 12 shows the pin configuration for a typical Baldor resolver feedback cable, part number CBL025SF-R1.
Signal name
MintDrive
II
X8 pin
Motor / cable
pin
Baldor resolver cable
internal w ire colors
REF+ 1 1 Red
REF- 6 2 Blue
COS+ 2 3 Green
COS- 7 4 Yellow
SIN+ 3 5 Pink
SIN- 8 6 Grey
1
2
3
45
6
7
89
101112
Motor resolver connector
(male)
Pins 7-12 are not used and may not be present
1
2
3
45
6
7
89
10
11
12
Cable connector end view
(female)
Figure 12 - Baldor motor resolver cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
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3-24 Basic Installation MN1901
3.7.2 Encoder option - X8
The encoder connections (ABZ channels and Hall signals) are made using the 15-pin D-type female connector X8. Twisted pair cables must be used for the complementary signal pairs e.g. CHA+ and CHA-. The overall cable shield (screen) must be connected to the metallic shell of the D-type connector.
Location
Connector X8, 15-pin D-type female connector
Pin Encoder function
1 CHA+
2 CHB+
3 CHZ+
4 Hall U+
5 Hall U-
6 CHA-
7 CHB-
8 CHZ-
9 Hall W+
10 Hall V+
11 +5V out
12 (NC)
13 DGND
14 Hall W-
15 Hall V-
Description Commutating (UVW) encoder input, non-isolated. Pin 1 1
provides +5V for encoders requiring power (200mA max)
CHA+ CHA-
CHB+ CHB-
+5V
DGND
1 6
2 7 3 8
11
X8
CHZ+ (INDEX) CHZ- (INDEX)
4 5
9 14 10 15
13
Hall U+ Hall U-
Hall W+ Hall W­Hall V+ Hall V-
12 (NC)
Hall
Feedback
Connect overall shield
to connector backshells.
Twisted pairs
Encoder
Feedback
Motor
Figure 13 - Encoder cable connections - rotary motors
1
5
15
6
11
10
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Basic Installation 3-25MN1901
3.7.2.1 Encoder cable pin configuration - rotary motors
Figure 14 shows the pin configuration for a typical Baldor encoder feedback cable, part number CBL025SF-E1.
Signal name
MintDrive
II
X8 pin
Motor / cable
pin
Baldor encoder cable
internal w ire colors
CHA+ 1 3 Purple
CHA- 6 4 Purple / White
CHB+ 2 5 Green
CHB- 7 6 Green / White
CHZ+ 3 7 Brown
CHZ- 8 8 Brown / White
Hall U+ 4 10 Pink
Hall U- 5 11 Pink / Black
Hall V+ 10 12 Yellow
Hall V- 15 13 Yellow / Black
Hall W+ 9 14 Grey
Hall W- 14 15 Grey / Black
+5V 11 1 Red
DGND 13 2 Blue
Motor encoder connector
(male)
Pins 9 and 16 are not connected
1
2
3
4
5
6
7
8
9
10
11
12
13
1415
16
Cable connector end v iew
(female)
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15
16
Figure 14 - Baldor rotary motor encoder cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
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3-26 Basic Installation MN1901
3.7.2.2 Encoder cable connections - linear motors
CHA+ CHA-
CHB+ CHB-
+5V DGND
1 6
2 7 3 8
11
X8
Encoder
Feedback
CHZ+ (INDEX) CHZ- (INDEX)
4 5
9 14 10 15
13
Hall U+ Hall U-
Hall W+ Hall W­Hall V+ Hall V-
12 (NC)
Hall
Feedback
Connect overall shield to
connector backshells.
Twisted pairs
Connect internal shields to DGND.
Leave pins 5, 12, 14, 15 unconnected
Motor
Figure 15 - Encoder cable connections - linear motors
3.7.2.3 Encoder cable pin configuration - linear motors
Linear motors use two separate cables (encoder and Hall). The cores of these two cables must be wired to the appropriate pins of the 15-pin D-type mating connector (supplied):
Signal name
MintDrive
II
X8 pin
Encoder cable internal wire colors
CHA+ 1
CHA- 6
CHB+ 2
Please refer to MN1800 Linear Motors
CHB- 7
PleaserefertoMN1800
LinearMotor
s
Installation & Operating Manual for details.
CHZ+ 3
CHZ- 8
Baldor Hall cable internal wire colors
Hall U+ 4 White
Hall V+ 10 Red
Hall W+ 9 Black
+5V 11 Brown
Hall GND 13 Green
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Basic Installation 3-27MN1901
3.7.3 EnDat (absolute encoder) option - X8
The absolute encoder interface supports both incremental and absolute (multi and single turn) feedback using SinCos technology. It is possible to read and write information to the encoder. The absolute encoder connections are made using the 15-pin D-type female connector X8. Twisted pair cables must be used for the complementary signal pairs e.g. SinA+ and SinA-. The overall cable shield (screen) must be connected to the metallic shell of the D-type connector.
Location
Connector X8, 15-pin D-type female connector
Pin Encoder function
1 Data+
2 Data-
3 +5V out
4 +5V out
5 DGND
6 Shield
7 Cos B-
8 (Reserved - do not connect)
9 Clock-
10 Clock+
11 (Reserved - do not connect)
12 Sin A-
13 Sin A+
14 Cos B+
15 (Reserved - do not connect)
Description Absolute encoder input, non-isolated. Pin 4 provides
power to the encoder (200mA max)
Data+ Data-
Cos B­Cos B+
1 2
7
14
12 13
X8
Absolute Encoder
Sin A­Sin A+
6
Twisted pairs
109Clock+
Clock-
5DGND
Chassis
4 +5V out
Connect overall shield
to connector backshells.
Connect internal shields to pin 6.
Motor
Figure 16 - EnDat absolute encoder cable connections
1
5
15
6
11
10
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3-28 Basic Installation MN1901
3.7.3.1 Absolute encoder cable pin configuration
Figure 14 shows the pin configuration for a typical Baldor absolute encoder feedback cable, part number CBL025SF-D1.
Signal name
MintDrive
II
X8 pin
Motor / cable
pin
Baldor EnDat cable internal w ire colors
Data - 2 1 Brown / White
Sin A+ 13 2 Green
Cos B+ 14 4 Purple
Clock- 9 5 Pink / Black
Clock + 10 7 Pink
Cos B- 7 8 Purple / White
+5V 4 9 Red
DGND 5 10 Blue
Sin A- 12 11 Green / White
Data + 1 12 Brown
1
2
3
45
6
7
89
101112
Motor absolute encoder connector
(male)
1
2
3
45
6
7
89
10
11
12
Cable connector end view
(female)
Figure 17 - Baldor rotary motor absolute encoder cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
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Basic Installation 3-29MN1901
3.7.4 Hiperface (absolute encoder) option - X8
The Hiperface absolute encoder interface supports both incremental and absolute (multi and single turn) feedback using SinCos technology. It is possible to read and write information to the encoder. The absolute encoder connections are made using the 15-pin D-type female connector X8. Twisted pair cables must be used for the complementary signal pairs e.g. SinA+ and SinA-. The overall cable shield (screen) must be connected to the metallic shell of the D-type connector.
Location
Connector X8, 15-pin D-type female connector
Pin Encoder function
1 Data+
2 Data-
3 +8V out
4 +8V out
5 DGND
6 Shield
7 Cos B-
8 (Reserved - do not connect)
9 (Reserved - do not connect)
10 (Reserved - do not connect)
11 DGND
12 Sin A-
13 Sin A+
14 Cos B+
15 (Reserved - do not connect)
Description Hiperface absolute encoder input, non-isolated. Pin 3
provides power to the encoder (200mA max)
Data+ Data-
Cos B­Cos B+
1 2
7
14
12 13
X8
Hiperface Absolute Encoder
Sin A­Sin A+
6
Twisted pairs
5DGND
Chassis
3 +8V out
Connect overall shield
to connector backshells.
Connect internal shields to pin 6.
Motor
Figure 18 - Hiperface absolute encoder cable connections
1
5
15
6
11
10
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3-30 Basic Installation MN1901
3.7.4.1 Absolute encoder cable pin configuration
Figure 14 shows the pin configuration for a typical Baldor absolute encoder feedback cable, part number CBL025SF-D1.
Signal name
MintDrive
II
X8 pin
Motor / cable
pin
Baldor Hiperface
cable internal wire
colors
Data - 2 1 Brown / White
Sin A+ 13 2 Green
Cos B+ 14 4 Purple
Clock- 9 5 Pink / Black
Clock + 10 7 Pink
Cos B- 7 8 Purple / White
+8V 4 9 Red
DGND 5 10 Blue
Sin A- 12 11 Green / White
Data + 1 12 Brown
1
2
3
45
6
7
89
101112
Motor absolute encoder connector
(male)
1
2
3
45
6
7
89
10
11
12
Cable connector end view
(female)
Figure 19 - Baldor rotary motor absolute encoder cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
Page 45
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Basic Installation 3-31MN1901
3.8 Drive enable
Location Connector X3, pins 7 & 9 (Mating connector:
Phoenix MINI-COMBICON MC 1.5/20-ST-3,5)
Name Drive enable
Input voltage +24VDC (±20%)
To enable the MintDriveIIand allow motion, three actions are necessary:
H A customer supplied externally generated 24VDC supply must be
connected between pins 7 and 9 of connector X3.
H The drive enable DIP switch (switch 8) must be in the On position.
H A drive enable command must be received.
These actions are explained in the following sections.
3.8.1 Drive enable - X3
The wiring to the drive enable input can be connected in one of two ways. Because CREF is common to all the digital inputs, this has an effect on the sense of DIN0 to DIN7. Either method provides a suitable drive enable input:
Active high To cause the digital inputs to be active high (active when a voltage of +24VDC is applied to them) connect +24VDC to pin 9 and 0V to pin 7 (CREF).
Active low To cause the digital inputs to be active low (active when grounded) connect +24VDC to pin7 (CREF) and 0V to pin 9.
The drive enable connection can be wired directly or through an intermediate switch. If a switch is used it should always be used to switch the signal to pin 9, with the signal to pin 7 (CREF) being hard-wired.
The sense of the digital inputs can also be configured in WorkBench v5 using the Digital inputs tab of the Digital I/O tool. Alternatively, the Mint INPUTACTIVELEVEL keyword can be used to select the sense of all the digital inputs (except drive enable). The state of the drive enable input is displayed in the WorkBench v5 Spy window. It can also be checked (but not set) using the Mint keyword DRIVEENABLESWITCH. See the Mint help file for details.
The drive enable input is rising edge triggered, but is only sampled every 1ms. For the drive to become enabled, the input signal must have been inactive (off) for at least one sample, and active (on) at the next sample. Care must be taken to avoid signal bounce on the drive enable input, since any falling edge detected after the drive has become enabled will disable the drive immediately. The drive cannot then be re-enabled until the input has been inactive (off) for at least one sample, as described above.
ENABLE 9
CREF 7
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3-32 Basic Installation MN1901
3.8.2 Drive enable - SW1 DIP switch
To enable the MintDriveIIthe front panel DIP switch 8 must be set to On. This switch provides a local enable/disable switch that can be useful during testing.
The state of the drive enable DIP switch is displayed in the WorkBench v5 Spy window. It can also be checked (but not set) using the Mint keyword ENABLESWITCH. See the Mint help file for details.
See section 3.9 for full details of other DIP switch functions.
3.8.3 Drive enable command
The other action required to enable the MintDriveIIcan be controlled either by software or hardware.
Note: This method is explained here for your information, but cannot be completed until
you have installed the software and are ready to turn on AC power to the drive. Please continue to read all sections in sequence. Do not turn on AC power until you reach the appropriate instructions.
In software, a drive enable command must be issued. The easiest way to do this is by clicking
the Drive enable button
in WorkBench v5. Alternatively, the Mint commands RESET or
DRIVEENABLE=1 can be used. See the Mint help file for details.
In hardware, a digital input can be used to create the drive enable command. This can be configured in WorkBench v5 using the Digital inputs tab of the Digital I/O tool. Alternatively, the Mint keyword RESETINPUT can be used to select the required digital input. See the Mint help file for details. Digital inputs DIN0 - DIN7 are sampled every 2ms, so if one is used to provide the drive enable command it must be maintained for at least 2ms to ensure detection.
Another method is to use the Mint keyword DRIVEENABLEMODE. This allows the combination of DIP switch 8 and the dedicated drive enable input on pin 9 to create the drive enable command. Both inputs must become active. Provided one input is already on, as soon as the other input changes from off to on (active), the drive will be enabled. See the Mint help file for details.
On
8
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Basic Installation 3-33MN1901
3.9 DIP switches - SW1
Various functions of the MintDriveIIcan be controlled by the front panel SW1 DIP switches.
Location
Switch block SW1
Switch Function
1 8
2 4
Node number selection (serial and fieldbus networks)
3 2
Nodenumberselection(serialandfieldbusnetworks
)
Bit pattern values shown in italics
4 1
5 Hold
6 RS485 terminator
7 Offset tuning
8 Enable
9 (Reserved)
10 RS232/RS485 select
Description 10-way DIP switch module for major functions
3.9.1 Switches 1-4
Switches 1-4 set the network node number (address) after the next power off/on cycle. The switches can be used to select any node number from 1 to 14, as shown in Figure 20.
Switch
1
Switch
2
Switch
3
Switch
4
Node number
(address)
Off Off Off Off Set by Mint NODE keyword Off Off Off On 1 Off Off On Off 2 Off Off On On 3 Off On Off Off 4 Off On Off On 5 Off On On Off 6 Off On On On 7
On Off Off Off 8 On Off Off On 9 On Off On Off 10 On Off On On 11 On On Off Off 12 On On Off On 13 On On On Off 14
On On On On
Do not use!
See section 3.9.7
Figure 20 - Node number (address) switch settings
OnOff
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3-34 Basic Installation MN1901
If switches 1-4 are all in the Off position, the Mint NODE keyword can be used to set the node number. WorkBench v5 (see section 5.2) reads the MintDrive
II
node number (during the scan
process) and then uses it to direct commands to the MintDrive
II
.
Avoid accidentally setting switches 1-4 to the On position at the same time. In combination with DIP switch 8, this will reset the MintDrive
II
to its factory defaults. See section 3.9.7.
3.9.2 Switch 5 - Hold
Switch 5 stops the motor. In the Off position, normal operation is allowed. When switched to the On position, the motor decelerates to rest and maintains position. The switch position is sampled every 100ms.
3.9.3 Switch 6 - RS485 terminator
Switch 6 is used to connect a termination resistor to the RS485 network. In the Off position, the RS485 network is unterminated at the MintDrive
II
. In the On position, an internal 120
termination resistor is connected between the RX+ and RX- signals - see section 4.4.5. Switch 6 should remain in the Off position when using RS232.
3.9.4 Switch 7 - Offset tuning
Switch 7 is used to start offset tuning on analog (demand) input AIN0. The purpose of offset tuning is to remove DC offset voltages on analog input 0 (the demand reference input) to achieve a stationary motor shaft with 0VDC at the input. Confirm that the device supplying the AIN0 demand input is set to its intended zero output setting (nominally 0VDC) before starting offset tuning. When switch 7 is in the On position, offset tuning will start the next time Enable (switch 8) is changed from On to Off.
On
7
Wait for 1 second for offset tuning to be completed.
Off
7
1. 2. 3. 4.
Off
8
On
8
Figure 21 - Offset tuning using switch 7 and 8
Leave switch 7 Off in normal use. After offset tuning, remember to set switch 8 to the On position to allow the drive to be enabled. The switch positions are sampled every 100ms. The Mint keyword ADCOFFSETTRIM canbeusedtoperformthesameaction.
3.9.5 Switch 8 - Enable
Switch 8 must be set to On to allow the drive to be enabled. The switch positions are sampled every 100ms. However, two other actions are necessary to enable the MintDrive
II
:
H The enable input (see section 3.8) must be active.
H The drive must also be enabled by using a drive enable command (see section 3.8.3).
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Basic Installation 3-35MN1901
3.9.6 Switches 9 and 10 - RS232/RS485 select
Switch 9 is reserved for Baldor keypad selection.
Switch 10 selects RS232 communications (Off) or RS485/RS422 (On) the next time the MintDrive
II
is power-cycled.
3.9.7 Factory settings
If switches 1-4 are all in the On position and switch 8 is set to Off, the MintDriveIIwill be reset to its preset factory settings at power on (or whenever the processor is reset by WorkBench v5).
CAUTION: Use this function carefully - it will erase your drive setup information.
When using the SW1 DIP switches to reset the MintDrive
II
to its factory defaults, all parameters including the node number and serial communications baud rate will be reset. In WorkBench v5, this means it will be necessary to rescan for the MintDrive
II
(by starting a new
project) to enable communication. It will also be necessary to re-tune your motor and drive.
On
1
Reapply power.
1. 2.
On
2
On
3
On
4
MintDriveIIwill be res et to its preset factory settings.
3.
Off
8
Remove power.
4.
Figure 22 - Resetting the MintDriveIIto its factory default settings
The Mint keyword FACTORYDEFAULTS canalsobeusedtoresettheMintDrive
II
to its factory defaults. However, it will not reset the node number or serial communications baud rate. See the Mint help file for details.
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3-36 Basic Installation MN1901
3.9.8 Preventing a program running at startup
If switches 5 and 9 are set to On and switch 8 is set to Off, any program already in the MintDrive
II
that contains an Auto command will be prevented from running automatically at
startup.
On5
Reapply power. Mint program with Auto command will not run.
1. 2.
On9
3.
Off 8
Remove power.
Figure 23 - Preventing the Auto command from running a stored Mint program
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Input / Output 4-1MN1901
4.1 Introduction
This section describes the various digital and analog input and output capabilities of the MintDrive
II
, with descriptions of each of the connectors on the front panel.
The following conventions will be used to refer to the inputs and outputs:
I/O Input / Output..............
DIN Digital Input.............
DOUT Digital Output...........
AIN Analog Input.............
AOUT Analog Output...........
CH Encoder channel.............
4.2 Analo g I/O
The MintDriveIIprovides as standard:
H 1 analog input on the connector block X3 (demand input)
H 1 analog input on the connector block X4
H 2 analog outputs on the connector block X4
The analog inputs are not optically isolated from internal power rails, so care must be taken to avoid earth/ground loops and similar associated problems. The input buffers provide low pass filtering of the applied voltage.
To minimize the effects of noise, each analog input signal should be connected to the system using individual shielded/screened cable (a twisted pair cable in the case of the differential inputs) with an overall shield. The overall shield should then be connected to the chassis at one end only. No other connection should be made to the shield.
If any inputs are unused, then it is advisable to connect them to the AGND pin. Do not leave the inputs unconnected (floating).
4 Input / Output
4
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4-2 Input / Output MN1901
4.2.1 Analog input - X3 (demand)
Location Connector X3, pins 1-3
(Mating connector: Phoenix MINI-COMBICON MC 1.5/20-ST-3,5)
Name AIN0
Mint keyword ADC.0
Description Single ended or differential input.
Common mode voltage range: ±10VDC. Resolution: 14-bit with sign (accuracy ±1.2mV) Common mode rejection: 40dB Input impedance: >5k Sampling interval: 500μs - Software (Mint programs)
125μs - High speed demand
reference signal
Analog input X3 can be connected as either a differential or a single ended input as shown in Figure 25.
10k
LF412
AGND
Mint
ADC.0
MintDrive
II
10k
10k
10k
-15V+15V
-15V+15V
20k
-
+
20k
Low pass filter &
level correction
(inverts signal)
AIN0+
AIN0- 2
1
‘X3’
Figure 24 - AIN0 analog input circuit
1 2 3
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Input / Output 4-3MN1901
AIN0
(ADC.0)
X3
AIN0
(ADC.0)
1
2
3
X3
AIN0-
Differential connection Single ended connection
AIN0+
1
2
3
AIN0+
GND
Figure 25 - AIN0 analog input wiring
AIN0
1k, 0.25W
potentiometer
(ADC.0)2
1
X3
1.5k, 0.25W
0V
+24VDC
3
Figure 26 - Typical input circuit to provide 0-10V (approx.) input from a 24V source
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4-4 Input / Output MN1901
4.2.2 Analog input - X4
Location Connector X4, pins 2 & 3
(Mating connector: Phoenix MINI-COMBICON MC 1.5/6-ST-3,5)
Name AIN1
Mint keyword ADC.1
Description Single ended or differential input.
Common mode voltage range: ±10VDC. Resolution: 14-bit with sign (accuracy ±1.2mV) Common mode rejection: 40dB Input impedance: >5k Sampling interval: 500μs - Software (Mint programs)
500μs - Demand reference signal
Analog input X4 can be connected as either a differential or a single ended input as shown in Figure 28.
10k
LF412
AGND
Mint
ADC.1
MintDrive
II
10k
10k
10k
-15V+15V
-15V+15V
20k
-
+
20k
Low pass filter &
level correction
(inverts signal)
AIN1-
AIN1+ 2
3
‘X4’
Figure 27 - AIN1 analog input circuit
AIN1
(ADC.1)
2
3
6
X4
GND
AIN1
(ADC.1)
2
3
6
X4
AIN1-
Differential connection Single ended connec tion
AIN1+
AIN1+
Figure 28 - AIN1 analog input wiring
2 3
6
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Input / Output 4-5MN1901
AIN1
1k, 0.25W
potentiometer
(ADC.1)3
2
X4
1.5k, 0.25W
0V
+24VDC
6
Figure 29 - Typical input circuit to provide 0-10V (approx.) input from a 24V source
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4-6 Input / Output MN1901
4.2.3 Analog outputs, bipolar - X4
Location Connector X4
Pins 4 5
Name AOUT0 AOUT1
Mint keyword AUXDAC.0 AUXDAC.1
Description T wo independent assignable outputs.
Output range: ±10VDC. Resolution: 8-bit with sign (accuracy ±78mV). Output current: 1mA maximum. Update interval:
Immediate - Software (Mint programs) 1ms, 2ms - DAC monitoring
The two programmable analog outputs can be used to provide the status of various control conditions. DAC monitoring is the process where the value of a selected parameter can be monitored by the MintDrive
II
, and the analog output used to produce a voltage proportional to the value. DAC monitoring can be controlled by various Mint keywords. These begin with the letters DACMONITOR..., for example DACMONITORMODE. The update interval for DAC monitoring is affected by the Mint LOOPTIME keyword. See the Mint help file for details.
10k
LF412
AGND
MintDrive
II
68.1k
75k
-15V
+15V
300k
-
+
300k
0.47nF
Internal
2.5V
reference
AGND
PWM
signal
AOUT0
AGND
4
6
‘X4’
Figure 30 - X4 analog output circuit - AOUT0 shown
Note: When power is applied to the MintDrive
II
, or during firmware download, the analog
outputs may swing to +2V for a period of about 0.25s, before settling at 0V.
4 5 6
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Input / Output 4-7MN1901
4.3 Digital I/O
The MintDriveIIprovides as standard: *
H 8 general-purpose inputs on connector block X3
H 3 general-purpose outputs on connector block X3
H 1 relay / general-purpose output on connector block X3
A digital input can be used to support many typical input functions:
H Error input
H Reset input
H Stop input
H Home input
H Forward limit
H Reverse limit
H Interrupts (controlled from Mint)
H Regeneration resistor (Dynamic Brake) overtemperature input
H PLC Task input conditions
H Index selection and triggering for preset move types
H General purpose use.
DIN4 and DIN5 are also capable of special alternative functions:
H DIN4 and DIN5 are fitted with Schmitt trigger devices and can be configured using Mint for
position capture of the axis or the master/auxiliary encoder positions. See section 4.3.3.
H The main axis’ fast input (assigned using the Mint keyword FASTSELECT) can also be
used as a trigger for some motion types, for example CAM moves. See the Mint help file for details.
* Additional I/O is available on connector X12 if the CAN & Auxiliary I/O option is fitted. See
MN1908 CAN and I/O option for Flex+Drive
II
and MintDriveII.
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4-8 Input / Output MN1901
4.3.1 Digital inputs - X3
Location Connector X3
Pin Name Mint keyword
9 Drive Enable -
10 DIN0 INX.0
11 DIN1 INX.1
12 DIN2 INX.2
13 DIN3 INX.3
14 DIN4 INX.4
15 DIN5 INX.5
16 DIN6 INX.6
17 DIN7 INX.7
Description Eight general-purpose optically isolated AC digital inputs.
One committed drive enable input (Drive Enable). Sampling interval: 1ms - Drive Enable input
2ms - DIN0 - DIN7
The digital inputs DIN0 - DIN7 can be read individually using the associated Mint INX keyword (for example INX.7) and can be configured for many user definable functions. Each input circuit contains an opto-isolator as shown in Figure 31. Inputs DIN4 and DIN5 can also be used as fast inputs - see section 4.3.3. The state of each digital input is displayed in the WorkBench v5 Spy window.
Active high: DINx=+24VDC (±20%)
CREF=0V
4k7
1k 0.1μF
NECPS2565
DGND
Mint
INX.0
10k
Vcc
MintDrive
II
Active low: DINx=0V
CREF=+24VDC (±20%)
DIN0
CREF
10
7
‘X3’
Figure 31 - X3 digital input circuit - DIN0 shown
9
17
CREF 7
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Input / Output 4-9MN1901
4.3.2 CREF and digital inputs
Pin 7 (CREF) controls the sense of all the digital inputs (X3 pins 9 to 17) and should be permanently wired, dependent on the user requirements:
Active high: connect 0V to pin 7. The digital inputs will be active when a voltage of +24VDC (greater than 12VDC) is applied to them and will sink a current of approximately 5mA each.
Active low: connect +24VDC to pin7. The digital inputs will be active when grounded (less than 2V) and will source a current of approximately 5mA each.
The +24VDC supply is from a customer supplied 24VDC supply that should have a continuous current capability of 1.75A.
The sense of the inputs can be configured in WorkBench v5 or controlled individually in Mint using the keyword INPUTACTIVELEVEL.
See section 3.8 for more information about Drive Enable.
4.3.3 Special functions on inputs DIN4 and DIN5
In addition to being general purpose inputs, DIN4 and DIN5 are capable of special alternative functions.
4.3.3.1 Pulse and direction inputs - DIN4 and DIN5
DIN4 and DIN5 can be configured using the MASTERSOURCE keyword to behave as pulse and direction inputs:
H DIN4 is used as the pulse input. The pulse frequency controls the speed of the motor.
H DIN5 is used as the direction input. The state of the direction input controls the direction of
motion. A positive voltage will result in forward motion. If DIN5 is grounded, movement will be in the opposite direction.
Note: If DIN4 and DIN5 have been configured as pulse and direction inputs, the
alternative pulse and direction inputs, available on connector X9, cannot be used. See the Mint keyword MASTERSOURCE.
4.3.3.2 Fast inputs - DIN4 and DIN5
DIN4 and DIN5 can be configured using the FASTSELECT and FASTAUXSELECT keywords to perform special functions:
H Fast interrupt hardware position capture input. The position of the axis is captured in real
time and can be read using the Mint keyword FASTPOS.
H Master or auxiliary encoder input capture, read using the Mint keyword
FASTAUXENCODER (DIN5 only).
The maximum latency to read the fast position is approximately 1μs. The fast interrupt will be latched on a pulse width of about 30μs, although a width of 100μs is recommended to ensure
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4-10 Input / Output MN1901
capture. To prevent subsequent inputs causing the captured value to be overwritten, the interrupt is latched in software. It is necessary to clear the latch before subsequent interrupts can be detected. See the Mint help file. Both inputs are fitted with Schmitt trigger devices.
Note: The fast inputs are particularly sensitive to noise, so inputs must use shielded
twisted pair cable.
Do not connect mechanical switches, relay contacts or other sources liable to signal ‘bounce’ directly to the fast inputs. This could cause unwanted multiple triggering.
Active high: DINx=+24VDC (±20%)
CREF=0V
4k7
33pF
HCPL2231
to CPU
Vcc
MintDrive
II
Active low: DINx=0V
CREF=+24VDC (±20%)
1k
10k
DGND
DIN4
CREF
14
7
‘X3’
Figure 32 - X3 pulse and direction / fast digital input circuit
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Input / Output 4-11MN1901
4.3.4 Digital outputs - X3
Location Connector X3
Pin Name Mint keyword
18 DOUT0 OUTX.0
19 DOUT1 OUTX.1
20 DOUT2 OUTX.2
Description Three general-purpose optically isolated digital outputs.
Output current: 50mA maximum each output Update interval:
Immediate - Software (Mint programs)
2ms - DRIVEENABLEOUTPUT,
DRIVEOKOUTPUT and GLOBALERROROUTPUT functions
Programmable - PLC T ask functions
Each optically isolated PNP output is designed to source current from the USR V+ supply as shown in Figure 33. The maximum saturated voltage across any of the outputs when active is
1.0VDC, so they can be used as TTL compatible outputs. If the outputs are used to directly drive a relay, a suitably rated flyback diode must be fitted across the relay coil, observing the correct polarity. This is to protect the output from the back-EMF generated by the relay coil when it is de-energized. The outputs can be controlled directly using the Mint keyword OUTX (for example OUTX.2=1). The sense of the outputs can be configured in WorkBench v5, and their states are displayed in the Spy window.
OUTX.x
MintDrive
II
NEC P S2562L-1
Load (Relay with flyback diode shown)
USR V+
DOUT0
6
18
‘X3’
CGND
8
Figure 33 - X3 digital output circuit - DOUT0 shown
18
20
CGND 8
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4-12 Input / Output MN1901
4.3.5 Relay output / digital output - X3
Location Connector X3, pins 4 (+) & 5 (-)
Name General purpose relay
Mint keyword RELAY / OUTX.3
Description Relay switch contacts controlled by Mint, rated at 1A,
30VDC. Update interval: Immediate
The factory preset assignment for the relay is as the global error output signal (see the Mint keyword GLOBALERROROUTPUT). When an error occurs the relay is de-energized and the contacts open. When the error is cleared, the relay is re-energized and the contacts close. The relay can be also be controlled directly by the Mint keyword RELAY. When the relay is energized (RELAY=_on) the contacts close. When the relay is de-energized (RELAY=_off) the contacts open. The relay output may also be considered as a digital output, so can be controlled directly using the Mint keyword OUTX (for example OUTX.3=1).
Internal relay
MintDrive
II
Control
circuitry
Relay +
Relay -
4
5
‘X3’
Figure 34 - Relay contact outputs
Note: The internal relay has a limited lifetime and is not intended for continuous cyclical
operation. If relay operations are required more frequently than 4 - 5 times per hour, it is recommended to use one of the digital outputs to control a replaceable external relay.
4 5
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Input / Output 4-13MN1901
4.4 Other I/O
4.4.1 Encoder output - X7
Location Connector X7
Pin Name
1 CHA+
2 CHB+
3 CHZ+
4 (NC)
5 DGND
6 CHA-
7 CHB-
8 CHZ-
9 (NC)
Description Encoder output on a 9-pin female D-type connector
This output can be used for position feedback to a host positioner, or in master/slave situations where the axis movement can be transmitted to another controller or MintDrive
II
.Using
connectors X7 and X8, multiple MintDrive
II
units (with the encoder feedback option) can be ‘daisy-chained’ together. It is recommended that this output only drives one output circuit load. The encoder outputs are differential and conform to the RS422 electrical specification. Shielded twisted pair cable is recommended.
If the resolver feedback option is fitted, a simulated encoder output is produced at X7. If the resolver input has been configured to simulate an encoder input of 1024 pulses per revolution (ppr), the output at X7 can be set to either 512 or 1024 ppr. If the resolver input has been configured to simulate an encoder input of 4096 ppr, output modes of 512, 1024, 2048 and 4096 ppr are possible. Note that these values represent actual encoder lines, not quadrature counts. The simulated encoder output is in the same direction as the resolver input. See the keyword ENCODERLINESOUT in the Mint help file.
If the basic encoder feedback option is fitted, X7 duplicates the encoder signals entering X8. However, the simulated encoder output is in the opposite direction to the encoder input. When connecting the output to another Baldor controller, the ENCODERMODE or AUXENCODERMODE keywords can be used to re-invert the signal.
If the EnDat or Hiperface (absolute encoder) feedback option is fitted, a simulated encoder output is produced at X7. The output ppr is equal to the number of Sin/Cos cycles of the absolute encoder. For example, if a 2048 cycle absolute encoder is connected, the output at X7 will be equivalent to a 2048 ppr encoder. Note that this value represents actual encoder lines, not quadrature counts. For EnDat, the simulated encoder output is in the same direction as the encoder input. For Hiperface, the simulated encoder output is in the opposite direction to the encoder input.
The encoder output supports an index or marker pulse.
1
5
6
9
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4-14 Input / Output MN1901
1 6
3 8
5
2
7
1 6
3 8
5
2
7
MintDrive
II
X7
NextMove BX
II
encoder input
Connect overall shield
to connector backshells.
CHA+
CHA-
CHB+
CHB-
CHZ+
CHZ-
DGND
Baldor cable parts CBL0xxMF-E3B are recommended (where xx represents a choice of available lengths).
Figure 35 - MintDriveIIencoder output to NextMove BXIIencoder input
CAUTION: If the older model NextMove BX (which has a gray case) is to be
connected, a different cable must be used as shown in Figure 36:
5 9
2 6
7
8
3
1 6
3 8
5
2
7
MintDrive
II
X7
NextMove BX encoder input
Connect overall shield
to connector backshells.
CHA+
CHA-
CHB+
CHB-
CHZ+
CHZ-
DGND
Baldor cable parts CBL0xxMF-E3A are recommended (where xx represents a choice of available lengths).
Figure 36 - MintDriveIIencoder output to NextMove BX encoder input
1 6
3 8
5
2
7
1 6
3 8
5
2
7
MintDrive
II
X7
NextMove ES / ESB
encoder input
Connect overall shield
to connector backshells.
CHA+
CHA-
CHB+
CHB-
CHZ+
CHZ-
DGND
Note: If NextMove ES is not being used in conjunction with a Baldor backplane (part BPL010-50x), the equi valent inputs on the card’s 96-pin edge connector are as follows:
Enc0 Enc1
CHA+ : b7 a8 CHA- : b10 c9 CHB+ : a7 c7 CHB- : c10 a10 CHZ+ : b8 c8 CHZ- : b9 a9 DGND : a3 a3 (or b3/c3)
Baldor cable parts CBL0xxMF-E3B are recommended (where xx represents a choice of available lengths).
Figure 37 - MintDriveIIencoder output to NextMove ES / ESB encoder input
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Input / Output 4-15MN1901
4.4.2 Master (auxiliary) encoder input - X9
Location Connector X9
Pin Encoder name Pulse & direction name
1 CHA+ Pulse+
2 CHB+ Direction+
3 CHZ+ -
4 (NC) -
5 DGND -
6 CHA- Pulse GND
7 CHB- Direction GND
8 CHZ- -
9 +5V out -
Description Optically isolated encoder or pulse and direction input on
a 9-pin female D-type connector. Sampling interval: 1 or 2ms
The MintDriveIIprovides an auxiliary (master or handwheel) encoder input that allows it to follow a master encoder or pulse and direction inputs. An interface for a three-channel, incremental encoder (CHA, CHB, CHZ) is provided. The input receiver circuit allows only encoders with differential line drivers (RS422) to be used. The interface also provides an isolated 5V supply for the encoder electronics, capable of driving up to 100mA.
CAUTION: The master encoder input does not use the same pin configuration as
some Baldor controllers such as NextMove BX.
Vcc
MintDrive
II
1k51k5
3k3
AM26LS32 Differential line receiver
to CPU
EMIF01 ESD protection
150R
2.2nF
150R
CHA+
CHA-16
‘X3’
Figure 38 - Master encoder channel input circuit - Channel A shown
1
5
6
9
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4-16 Input / Output MN1901
CHA+ CHA--
CHB+
CHB--
+5V DGND
1 6
2 7 3 8 9 5
X9
CHZ+ CHZ --
Twisted pairs
Connect overall shield
to connector backshells.
Connect internal shields to DGND.
Master
Encoder
Figure 39 - Differential encoder connections
4.4.2.1 Dual encoder feedback
The master encoder input can be used as a second feedback input in dual encoder systems. The Mint keyword AXISPOSENCODER is used to select the master (auxiliary) encoder input as a feedback input. See the Mint help file for details.
4.4.2.2 Pulse and Direction following
The master encoder pulse and direction inputs accept 5V differential line driver (RS422) signals from an external source. The pulse frequency controls the speed, and the state of the direction signal controls the direction of motion. A positive direction voltage (greater than 200mV) will result in motion in one direction. A negative direction voltage (less than -200mV) will result in movement in the opposite direction.
The Mint keyword AUXENCODERMODE (bit 2) is used to configure X9 for pulse and direction operation. If necessary, the sense of the direction input can be reversed in software using the Mint keyword AUXENCODERMODE (bit 0). See the Mint help file for details.
Note: If X9 has been configured for pulse and direction input, the alternative pulse and
direction inputs, available on connector X3, cannot be used. See the Mint keyword MASTERSOURCE.
Pulse + Pulse - (GND) Direction+ Direction - (GND)
DGND
1 6 2 7
5
X9
Twisted pairs
Pulse and direction
source
Pulse
Direction
Connect overall shield
to connector backshells.
Connect internal shields to DGND.
Figure 40 - Pulse and direction connections
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Input / Output 4-17MN1901
4.4.3 Serial port - X6
Location Connector X6
Pin RS232 name RS485 / RS422 name
1 (NC) (NC)
2 RXD RX- (input)
3 TXD TX- (output)
4 (NC) (NC)
5 0V GND 0V DGND
6 (NC) (NC)
7 RTS TX+ (output)
8 CTS RX+ (input)
9 (Do not connect! See caution below)
Description RS232 or RS485 / RS422 connections on a single
9-pin male D-type connector
Connector X6 is a 9-pin male D-type connector. This port is configurable as either RS232 or 4-wire RS422 / RS485, using front panel DIP switch number 10 (see section 3.9.6). The Mint keyword SERIALBAUD is used to configure the port and is explained in the Mint help file. See also sections 4.4.4 and 4.4.5. The port is fully ESD protected to IEC 1000-4-2 (15kV).
When using RS485 / RS422 mode, front panel DIP switch number 6 may be used to connect an internal 120termination resistor between the RX+ and RX- signals. Switch 6 should remain in the Off position when using RS232.
CAUTION: Pin 9 is used to carry +8V for powering certain Baldor keypad peripherals.
Ensure that pin 9 is not connected to earth/ground or to equipment that could be damaged by the +8V supply.
1
5
6
9
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4-18 Input / Output MN1901
4.4.4 Using RS232 cable
CAUTION: The serial connector on the MintDriveII(X6) can be configured as either
RS232 or RS485 / RS422. Pin 9 is used to carry +8V for powering certain Baldor keypad peripherals. Ensure that pin 9 is not connected to earth/ground or to equipment that could be damaged by the +8V supply. A suitable cable is available from Baldor, catalog number CBL001-501.
Front panel DIP switch 10 must be in the Off position to select RS232 operation. The MintDrive
II
has a full-duplex RS232 serial port with the following preset configuration:
H 57.6Kbaud
H 1startbit
H 8 data bits
H 1stopbit
H No parity
H Hardware handshaking lines (RS232) RTS and CTS must be connected.
This configuration can be changed if required. The RS232 connections are brought out onto a 9-pin male D-type connector. The RS232 port is configured as a DTE (Data Terminal Equipment) unit. Both the output and input circuitry are single ended and operate between ±12V. The port is capable of operation at up to 57.6Kbaud.
MintDrive
II
(DTE)
9-pin
Computer
COM Port
(DCE / DTE)
X6
RXD 2
TXD 3
GND 5
2RXD
3TXD
5GND
RTS 7
CTS 8
7RTS
8CTS
COM
Connect overall
shield to connector
backshell.
Figure 41 - RS232 serial port connections
The maximum recommended cable length is 3m (10ft) at 57.6KBaud (the factory preset rate). When using lower Baud rates, longer cable lengths may be used up to maximum of 15m (49ft) at 9600 Baud.
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Input / Output 4-19MN1901
4.4.5 Multidrop using RS485 / RS422 cable
Multidrop systems allow one device to act as a ‘network master’, controlling and interacting with the other (slave) devices on the network. The network master can be a controller such as aMintDrive
II
, a host application such as WorkBench v5 (or other custom application), or a programmable logic controller (PLC). RS422 may be used for multi-drop applications as shown in Figure 42. Four-wire RS485 may be used for single point-to-point applications involving only one Baldor controller. If firmware is updated over RS485/RS422, it can only be downloaded to the drive that was chosen in the Select Controller dialog in WorkBench v5.
Master and final slave are shown with terminati ng resistors, TR, typical value 120Ω.
Front panel DIP switch 6 may be used to c onnect an internal 120terminating resistor
.
Network slave
T
R
RX-
DGND
RX+
TX+
TX- RX-
DGND
RX+
TX+
TX-
RX-
DGND
RX+
TX+
TX-
Twisted pairs
T
R
Connect overall shield to connector backshell.
Network slave
Network
master
DGND may be one wire from a third twisted pair.
Figure 42 - 4-wire RS422 multi-drop connections
Any MintDrive
II
on the network must have its SW1 DIP switch 10 (located on the front panel) set to the On position (see also section 3.9.6). This will set the serial port to RS422/RS485 mode after the next power off/on cycle. When SW1 DIP switch 6 is set to the On position, a 120termination resistor is connected between the RX+ and RX- signals.
Each TX/RX network requires a termination resistor at the final RX connection, but intermediate devices must not be fitted with termination resistors. An exception is where repeaters are being used which may
correctly contain termination resistors. Termination resistors are used to match the impedance of the load to the impedance of the transmission line (cable) being used. Unmatched impedance causes the transmitted signal to not be fully absorbed by the load. This causes a portion of the signal to be reflected back into the transmission line as noise. If the source impedance, transmission line impedance, and load impedance are all equal, the reflections (noise) are eliminated. Termination resistors increase the load current and sometimes change the bias requirements and increase the complexity of the system.
On10
On6
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4-20 Input / Output MN1901
4.4.6 Connecting Baldor HMI Operator Panels
Baldor HMI Operator Panels use a 15-pin male D-type connector (marked PLC PORT), but the MintDrive
II
connector X6 is a 9-pin male D-type connector. If you do not require hardware
handshaking then use the connections shown in Figure 43:
7RTS
8CTS
3TXD
2RXD
5GND
1
RXD 2
TXD 3
GND 5
Baldor HMI
PLC PORT
MintDrive
II
X6
Twisted pair
Figure 43 - Cable wiring if hardware handshaking is not required
If hardware handshaking is required then use the connections shown in Figure 44:
7RTS
8CTS
3TXD
2RXD
5GND
1
RXD 2
TXD 3
GND 5
Baldor HMI
PLC PORT
MintDrive
II
X6
CTS 11
RTS 10
Twisted pair
Figure 44 - Cable wiring if hardware handshaking is required
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Input / Output 4-21MN1901
4.5 Connection summary - minimum system wiring
As a guide, Figure 45 shows an example of the typical minimum wiring required to allow the MintDrive
II
to control a motor.
COM
II
Host PC
AC power
Filter
L N
PE
L
N E
Motor power UVW
Motor feedback
Serial communication
** Model shown: MDH2A07TR-RN23:
This model requires an external regeneration resistor and c ustomer supplied 24V supply - see sections 3.6 and 3.4.7. Some models contain an internal 24V supply and/or an internal regeneration resistor.
Motor represents a typical B aldor BS M motor. Linear motors may als o be controlled by MintDriveII. Shield earth/ground c lamps are not supplied.
To regen
resistor
(Dynamic
brake)**
Customer
supplied
24V**
Star point
Motor
Drive enable switch
Shield earth/ground c lamp attached to enclosure backplane
+24V 0V
+24V 0V
If the filter has no output
earth/ground terminal, earth
wire may be connected
directly to the star point.
AC power in
L
N E
Figure 45 - Example minimum system wiring
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4-22 Input / Output MN1901
4.6 Option connectors
If there are additional connectors on the front panel of your MintDriveIIthat have not been described in previous sections, these are part of a factory fitted option. You will need to refer to the extra manual supplied with your MintDrive
II
for details of the option’s connectors.
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Operation 5-1MN1901
5.1 Introduction
Before powering the MintDriveIIyou will need to connect it to the PC using a serial cable and install the supplied PC software WorkBench v5. This software includes a number of tools to allow you to configure, tune and program the MintDrive
II
. If you do not have experience of software installation or Windows applications you may need further assistance for this stage of the installation.
5.1.1 Connecting the MintDriveIIto the PC
Connect the serial cable between a PC serial port (often labeled as “COM”) to the MintDrive
II
connector X6 (RS232/RS485). WorkBench v5 can scan all the COM ports, so you can use any port.
CAUTION: The serial connector on the MintDriveII(X6) can be configured as either
RS232 or RS485 / RS422. If this is the first time you are installing a MintDrive
II
then it is strongly recommended that you use RS232 to get started (the preset factory setting) and use RS485 later. Pin 9 is used to carry +8V for powering a Baldor keypad peripheral. Ensure that pin 9 is not connected to earth/ground or to equipment that could be damaged by the +8V supply. A suitable cable is available from Baldor, catalog number CBL001-501.
5.1.2 Installing the software
The CDROM containing the software can be found separately within the packaging.
1. Insert the CDROM into the drive.
2. After a few seconds the setup wizard should start automatically. If the setup wizard does not
appear, select Run... from the Windows Start menu and type
d:\start
where d represents the drive letter of the CDROM device (use the correct letter for your installation).
Follow the on-screen instructions to install WorkBench v5. Files will normally be copied to a folder within the Program Files folder, although the destination can be changed during setup.
5 Operation
5
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5-2 Operation MN1901
5.1.3 Starting the MintDrive
II
If you have followed the instructions in the previous sections, you should now have connected all the power sources, your choice of inputs and outputs and the serial cable linking the PC with the MintDrive
II
.
5.1.4 Preliminary checks
Before you apply power for the first time, it is very important to verify the following:
H Disconnect the load from the motor until instructed to apply a load. If this cannot be done,
disconnect the motor wires at connector X1/X1A.
H Verify that the front panel DIP switches 1-9 are in the Off position.
It is recommended that you use RS232 communications to begin with, in which case DIP switch 10 must also be in the Off position. However, if you are using RS485/RS422 communication then DIP switch 10 must be in the On position (also DIP switch 6 if termination is required).
H Verify that the AC line voltage matches the specification of the MintDrive
II
.
H Inspect all power connections for accuracy, workmanship and tightness.
H Verify that all wiring conforms to applicable codes.
H Verify that the MintDrive
II
and motor are properly earthed/grounded.
H Check all signal wiring for accuracy.
5.1.5 Power on checks
If at any time the Status display shows a flashing symbol or ‘E.’ this indicates that the drive has detected a fault - see section 7.
1. Turn on the 24VDC supply (only for MintDrive
II
with catalog numbers MDHxxxxx-xxx3).
2. Turn on the AC supply.
3. After a brief test sequence, the Status display should show a minus sign (
).
If the display is not lit then re-check the power supply connections.
4. If the motor wires were disconnected in section 5.1.4, turn off the AC supply and reconnect the motor wires. Turn on the AC supply.
5. To allow the Commissioning Wizard to function, SW1 DIP switch 8 will need to be set to the On position to allow the MintDrive
II
to be enabled. If you do not wish to enable the MintDrive
II
yet, the Commissioning Wizard will inform you when this step is necessary.
6. To allow the Commissioning Wizard to function, the +24VDC drive enable signal will need to be present on connector X3 (between pins 7 and 9) to allow the MintDrive
II
to be enabled.
If you do not wish to enable the MintDrive
II
yet, the Commissioning Wizard will inform you
when this step is necessary.
The MintDrive
II
is now ready to be commissioned using WorkBench v5.
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Operation 5-3MN1901
5.1.6 Offset tuning (optional)
If the MintDriveIIwill be using analog input 0 (AIN0) as a demand reference input (or for any other purpose) you may wish to perform offset tuning before continuing. The purpose of offset tuning is to remove DC offset voltages on the demand reference input to achieve a stationary motor shaft with 0VDC at the input. Offset tuning is controlled by DIP switches 7 and 8.
Before starting, confirm that the device supplying the AIN0 demand input is set to its intended zero output setting (nominally 0VDC).
On
7
Wait for 1 second for offset tuning to be completed.
Off 7
1. 2. 3. 4.
Off
8
On
8
Figure 46 - Offset tuning using switch 7 and 8
After offset tuning, remember to set switch 8 to the On position to allow the drive to be enabled.
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5-4 Operation MN1901
5.2 WorkBench v5
WorkBench v5 is a fully featured application for programming and controlling the MintDriveII. The main WorkBench v5 window contains a menu system, the Toolbox and other toolbars. Many functions can be accessed from the menu or by clicking a button - use whichever you prefer. Most buttons include a ‘tool-tip’; hold the mouse pointer over the button (don’t click) and its description will appear.
5.2.1 Help file
WorkBench v5 includes a comprehensive help file that contains information about every Mint keyword, how to use WorkBench v5 and background information on motion control topics. The help file can be displayed at any time by pressing F1. On the left of the help window, the Contents tab shows the tree structure of the help file. Each book
contains a number of
topics
. The Index tab provides an alphabetic list of all topics in the file, and allows you to
search for them by name. The Search tab allows you to search for words or phrases appearing anywhere in the help file. Many words and phrases are underlined and highlighted with a color (normally blue) to show that they are links. Just click on the link to go to an associated keyword. Most keyword topics begin with a list of relevant See Also links.
Figure 47 - The WorkBench v5 help file
For help on using WorkBench v5, click the Contents tab, then click the small plus sign
beside the WorkBench v5 book icon. Double click a topic name to display it.
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Operation 5-5MN1901
5.2.2 Starting WorkBench v5
1. On the Windows Start menu, select Programs, WorkBench v5, WorkBench v5.
WorkBench v5 will start, and the Tip of the Day dialog will be displayed. You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup.
Click Close to continue.
2. In the opening dialog box, click Start New Project... .
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5-6 Operation MN1901
3. In the Select Controller dialog, go to the drop down box near the top and select the PC serial port to which the drive is connected. If you are unsure which PC serial port is connected to the drive, select Scan all serial ports.
Click Scan to search for the MintDrive
II
.
When the search is complete, click on MintDrive
II
in the list to select it, and click the Select
button.
This check box is already selected for you. When you click Select, it means that the Commissi oning Wizard will start automatically.
Note: If the MintDriveIIis not listed, check the serial lead between the MintDriveIIand
the PC and that the MintDrive
II
is powered correctly. Click Scan to re-scan the
ports.
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Operation 5-7MN1901
5.2.3 Commissioning Wizard
Each type of motor and drive combination has slightly different performance characteristics. Before the MintDrive
II
can be used to control the motor accurately, the MintDriveIImust be
“tuned”. This is the process where the MintDrive
II
powers the motor in a series of tests. By monitoring the feedback from the motor’s resolver or encoder and performing a number of calculations, the MintDrive
II
can make small adjustments to the way it controls the motor. This
informationisstoredintheMintDrive
II
EEPROM and can be uploaded to a file if necessary.
The Commissioning Wizard provides a simple way to tune the MintDrive
II
and create the necessary configuration information for your drive/motor combination, so this is the first tool that should be used.
5.2.4 Using the Commissioning Wizard
CAUTION: The motor will move during commissioning. For safety it is advisable to
disconnect any load from the motor during initial commissioning. The motor can be tuned with the load connected after the Commissioning Wizard has finished.
Each screen of the Commissioning Wizard requires you to enter information about the motor or drive. Read each screen carefully and enter the required information.
If you need extra help, click the Help button or press F1 to display the help file.
When you have completed a screen, click Next > to display the next screen. If you need to change something on a previous screen, click the < Back button. The Commissioning Wizard remembers information that you have entered so you will not need to re-enter everything if you go back to previous screens.
5.2.5 Completing the Commissioning Wizard
The final screen (Tuning) has a Finish button that is grayed out until the tuning tests have been completed. When the tuning tests have finished click Finish to complete the Commissioning Wizard.
The parameters that have been calculated by the Commissioning Wizard do not need to be downloaded to the MintDrive
II
. They are already in the MintDriveIIand will not be lost even
when it is powered down.
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5-8 Operation MN1901
5.2.6 Performing a test move
This section tests the basic operation of the drive and motor.
1. Check that the Drive enable button is pressed (down).
2. In the Toolbox, click the Edit & Debug icon.
3. Click in the Command window.
4. Type:
JOG.0 = 10
This will cause the motor to move continuously at 10 units per second. In WorkBench v5, look at the Spy window located on the right of the screen. The Spy window’s Velocity display should show 10 (approximately). If there seems to be very little motor movement, it is probably due to the scale factor. In the Commissioning Wizard, on the Position Control page, if you did not adjust the scale factor then the current unit of movement is feedback counts per second. Depending on the motor’s feedback device, 10 feedback counts per second could equate to a very small velocity. Issue another JOG command using a larger value, or use the Operating Mode Wizard to select a suitable scale factor (e.g. 4000 if the motor has a 1000 line encoder, or 10,000 for a 2500 line encoder).
5. To stop the test, type:
STOP.0
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Operation 5-9MN1901
5.3 Further configuration
WorkBench v5 provides a number of tools, each of which has an icon on the left of the screen. Click once on an icon to select the tool. Three of the main tools used for tuning and configuring the MintDrive
II
are briefly described here.
Every tool is explained fully in the help file. Press F1 to display the help file, then navigate to the WorkBench v5 book. Inside this is the Toolbox book.
5.3.1 Fine-tuning tool
The Commissioning Wizard calculates many parameters that allow the MintDriveIIto provide basic control of the motor. These parameters may need to be fine-tuned to provide the exact response that you require. The Fine-tuning screen allows you to do this.
1. Click the Fine-tuning icon in the Toolbox on the left of the screen.
The Fine-tuning window is displayed at the right of the screen. This already shows some of the parameters that have been calculated by the Commissioning Wizard.
The main area of the WorkBench v5 window displays the capture window. When further tuning tests are performed, this will display a graph representing the response.
2. The Fine-tuning window has three tabs at the bottom - Position, Speed and Current. Click on a tab to select it.
Click the tab for the type of tests you wish to perform.
Note: Some tabs may not be available depending on the configuration mode you
selected in the Commissioning Wizard.
5.3.1.1 Fine-tuning - Position tab
The position tab allows you to set position loop gains and perform test moves. The Commissioning Wizard may have already set some of these values, depending on the type of system selected on the mode screen.
Enter new values in the required boxes and then click Apply to download the values to the MintDrive
II
. To perform tests, go to the Test Parameters area at the bottom of the tab. Enter test values and then click Go to perform the test move. If you need help, just press F1 to display the help file.
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5-10 Operation MN1901
5.3.1.2 Fine-tuning - Speed tab
The speed tab allows you to set speed loop gains and perform test moves. The Commissioning Wizard may have already set some of these values, depending on the type of system selected on the mode screen.
Enter new values in the required boxes and then click Apply to download the values to the MintDrive
II
. To perform tests, go to the Test Parameters area at the bottom of the tab. Enter test values and then click Go to perform the test move. If you need help, just press F1 to display the help file.
5.3.1.3 Fine-tuning - Current tab
The current tab allows you to set current loop gains and perform test moves. The Commissioning Wizard may have already set some of these values, depending on the type of system selected on the mode screen.
Enter new values in the required boxes and then click Apply to download the values to the MintDrive
II
. To perform tests, go to the Test Parameters area at the bottom of the tab. Enter test values and then click Go to perform the test move. If you need help, just press F1 to display the help file.
The additional Measure and Feedback alignment buttons can be used to repeat the same measurement and alignment tests as the Commissioning Wizard.
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Operation 5-11MN1901
5.3.2 Parameters tool
The Parameters tool can be used to setup many important parameters, such as a scaling factor for the feedback input, and the action to take when errors occur.
1. Click the Parameters icon in the Toolbox on the left of the screen.
The main area of the WorkBench v5 window displays the Controller Parameters screen.
2. The Controller Parameters screen has a number of tabs listed on the left. Click on a tab to select it
If you need help with any of the options, just press F1 to display the help file.
Remember to click the tab’s Apply button to send the changes to the MintDrive
II
.
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5-12 Operation MN1901
5.3.3 Digital I/O tool
The Digital I/O tool allows you to define how each digital input and output will be triggered and if it is to be assigned to a special function, for example the forward limit or stop input.
1. Click the Digital I/O icon in the Toolbox on the left of the screen.
The main area of the WorkBench v5 window displays the Digital I/O screen. You can use a drag and drop method to assign triggering options to inputs and outputs and assign them to special purpose functions.
Remember to click the Apply button to send the changes to the MintDrive
II
. If you need help, just
press F1 to display the help file.
5.3.4 Other tools and windows
Each tool and window is explained fully in the help file, so is not described here in detail.
H Homing Tool
Allows you to setup homing moves.
H Edit & Debug Tool
This is the tool used for programming the MintDrive
II
. The tool provides a work area including the Command window and Output window. Multiple editing windows can be opened for entering program code.
H Scope Tool
Displays the capture screen. This screen is also shown when the Fine-tuning tool is selected.
H Presets T ool
Allows you to setup preset moves and the way in which they should be triggered. An interactive table of the moves is used to make changes.
H Jog Tool
Allows you to perform jog moves - useful for testing purposes.
H PLC Task Tool
Allows you to setup the PLC Task, a special task that can be used to check for a number of pre-defined conditions and then perform actions if they become true.
H Error Log Tool
Displays a list showing when errors occurred and when they were cleared.
H Spy window
Allows you to monitor all the important parameters for the axis, and shows the state of digital inputs and outputs, limit switches and comms locations.
Remember, for help on each tool just press F1 to display the help file, then navigate to the WorkBench v5 book. Inside this is the Toolbox book.
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Preset Moves & PLC Task 6-1MN1901
6.1 Introduction
Two of the important features introduced on the MintDriveIIare preset moves and the PLC task. Basic operation of these two features are described in the following sections.
6 Preset Moves & PLC Task
6
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6-2 Preset Moves & PLC Task MN1901
6.2 Preset moves
The standard MintDriveIIcan store 16 preset moves. If the CAN & Auxiliary I/O option is fitted, 256 preset moves can be stored. Presets can be selected and triggered using software (WorkBench v5 or a Mint program) or by using a combination of the digital inputs.
In WorkBench v5, the Presets tool displays an interactive table allowing you to set up the preset moves. WorkBench v5 reads the current preset data from the MintDrive
II
whenever you switch to the Presets tool. Preset tables can be saved in files on the PC and downloaded to the MintDrive
II
from WorkBench v5. For the following explanation, the MintDriveIImust be
connected, powered and ready to be enabled. The MintDrive
II
must also be in Position Control
Mode, which can be selected using the Operating Mode Wizard in WorkBench v5.
6.2.1 Defining a preset move
1. In the WorkBench v5 Toolbox, click Application then click the
Presets icon. Existing presets will be read from the MintDrive
II
and
displayed in the presets table.
2. Each preset is shown on a separate row in the table. To define (or
edit) a preset, click one of the preset numbers in the Index column.
3. On the selected row, click in the Type column. The drop-down box
allows you to select the type of move, which may be an absolute or relative positional move, a jog move, a homing move or a set position. The Value column will change accordingly.
4. Click in the Value column to set the appropriate value. Any values entered in the preset table
to specify a position, slew speed, acceleration, or deceleration are interpreted as user units.
H For an absolute move, the value represents the absolute position to which the axis will
move when the preset is used.
H For a relative move, the value represents the amount by which the axis will move
relative to its existing position when the preset is used.
H For a set position, the value represents the new axis position that will be set when the
preset is used. No movement will occur.
H For a jog move, the value represents the direction in which the axis will jog. H For a homing move, the value represents the type of homing move to be performed:
Pos index causes the axis to move forwards until a home input is triggered. Neg index causes the axis to move backwards until a home input is triggered. Pos index offset causes the axis to move forwards until a home input is triggered and
then continue forwards to an offset distance defined by HOMEOFFSET. Neg index offset causes the axis to move backwards until a home input is triggered and then continue backwards to an offset distance defined by HOMEOFFSET. Position search causes the axis to move towards a specific position defined by HOMEREFPOS.ThevalueofHOMEREFPOS may be set by a Mint program, or by using the Parameters tool in WorkBench v5.
5. Click in the Slew speed, Acceleration and Deceleration boxes to set appropriate values for
themoveprofile.
6. Click Apply to download the presets table to the MintDrive
II
.
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Preset Moves & PLC Task 6-3MN1901
6.2.2 Testing a preset move
For testing, WorkBench v5 can be used to trigger the preset moves.
1. At the bottom of the Presets window, ensure that the Software option is checked. This means that WorkBench v5 will be used to control the preset moves.
2. If the drive is not already enabled, click the drive enable
icon on the toolbar.
Just above the Presets table, click Enable to allow preset moves.
3. In the Index drop down box, select a preset number to test and click T est. The preset move will now be performed.
Note: The
button on the mode toolbar can also be used to enable or disable preset
moves, even if the Presets tool is not currently selected.
6.2.3 Using digital inputs to trigger a preset move
In normal operation preset moves can be selected and triggered by external equipment, using a combination of the digital inputs.
1. At the bottom of the Presets window, ensure that the Digital Inputs option is checked. This means the digital inputs will be used to control the preset index. Click Apply to send the changes to the MintDrive
II
.
The Use Trigger option should also be checked. This means that a digital input will be used to trigger the preset move.
Note: If the Use Trigger input is not checked, preset moves will be triggered instantly on
changing to the selected preset index. This mode should be used with care, as the change of state of digital inputs may not be synchronized. The Trigger pulse must have a duration of at least 2ms to ensure that it is recognized by the drive.
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6-4 Preset Moves & PLC Task MN1901
6.2.3.1 Configuring digital inputs to control presets
The default combination of digital inputs used for triggering presets is 6, 7, 0 and 1 to select the preset, and 5 to trigger the preset. However, this combination can be changed to use any four (or fewer) contiguous inputs, plus a trigger input. The inputs form a bit pattern that represents the preset to be selected. Consequently, if the application requires only a small number of different preset moves, you can reduce the number of inputs required to select the preset.
The following table shows the combinations of digital inputs that must be active to trigger each preset index move. The table shows 4 inputs being used (0 - 3), allowing 16 presets to be selected:
Preset index
(Bit pattern
sum)
Digital input 0
(Bit pattern
value: 1)
Digital input 1
(Bit pattern
value: 2)
Digital input 2
(Bit pattern
value: 4)
Digital input 3
(Bit pattern
value: 8)
0 0 0 0 0
1 1 0 0 0
2 0 1 0 0
3 1 1 0 0
4 0 0 1 0
5 1 0 1 0
6 0 1 1 0
7 1 1 1 0
8 0 0 0 1
9 1 0 0 1
10 0 1 0 1
11 1 1 0 1
12 0 0 1 1
13 1 0 1 1
14 0 1 1 1
15 1 1 1 1
Table 3 - Preset selection using digital inputs 0-3
For example, to select preset move 6, digital inputs 1 and 2 must be active. The choice of digital inputs is configured using the Digital I/O tool:
1. In the Toolbox, click Setup then click the Digital I/O icon.
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Preset Moves & PLC Task 6-5MN1901
2. At the bottom of the Digital I/O window, click in the Preset Inputs drop down box and select the number of inputs to be used for preset selection.
For example, if the application requires only four different preset moves, choose 2. This means only two digital inputs will be used to select preset moves, allowing 4 different combinations (moves) to be selected. Similarly, to allow selection of up to 8 different preset moves choose 3; for up to 16 different moves choose 4. Selecting fewer digital inputs will leave more free for other purposes.
3. If the default inputs shown by the Preset Sel icon are not suitable, drag a different IN icon onto the Preset Sel icon. This will set the lowest numbered input used for preset selection, with the other required inputs selected automatically. It is not possible to select a discontinuous range of inputs for preset selection, although the trigger input may be any input.
4. If the default input shown by the Preset Trig icon (the trigger input) is not suitable, drag a different IN icon onto the Preset Trig icon.
5. Click Apply to send the changes to the MintDrive
II
.
When you return to the Presets tool, the presets table (and the Addressable Presets box) will show the number of presets that can be selected by the chosen number of inputs.
Presets will now be selected and triggered when the appropriate digital inputs are active.
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6.2.4 Controlling preset moves
Additional options are available to control the operation of preset moves.
DwellTimecanbeusedtosetadelay period between the triggering of a preset move and its commencement.
If the Wait for Idle option is checked, the preset move will not begin until the previous one has been completed. If it is not checked, the new move will be started immediately. To allow this, the profile of the current move will be modified to smoothly adjust to the new move’s profile.
The Learn Current Position button can be used to read the current position and assign it to the Value / Position column for the currently selected preset. This function can only be used for Absolute moves; if the preset type is not already set to Absolute, it will be set automatically.
The configuration and operation of preset moves can also be controlled by a Mint program, using
a range of keywords beginning with PRESET.... See the Mint help file for details.
6.2.5 Using presets with the CAN & Auxiliary I/O option
If the CAN & Auxiliary I/O option is fitted (Option B) the additional digital inputs allow up to 256 presets to be selected.
The Extended tab below the presets table displays the preset table for presets 16 to 255. The Extended tab only appears if the CAN & Auxiliary I/O option is fitted.
Extended presets can only be used for Relative or Absolute moves, and they do not have unique Slew speed, Acceleration or Deceleration parameters. The extended presets are divided into groups of 16 presets (16-31, 32-47, 48-63 etc.), selected using the Group box. Each group of presets has unique parameters, set using the Slew S peed, Acceleration and Deceleration boxes.
In the Digital I/O tool, the number of inputs that may be selected in the Preset Inputs box also increases to 8, to allow up to 256 presets to be selected.
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6.3 PLC Task
The PLC Task is a special task that can be set up to monitor various events and act upon them if they become true. In WorkBench v5, the PLC Task tool allows you to enter conditional statements that respond to the events by performing a particular action. The statements can be downloaded to the MintDrive
II
if required. WorkBench v5 reads the current state of the PLC
Task table (from the MintDrive
II
) whenever you switch to PLC Task mode. For the following
explanation, the MintDrive
II
must be connected and powered.
6.3.1 Defining conditions
Each action is triggered as a result of the logical evaluation of one or two conditions, called Condition 1 and Condition 2. If the result of this logical comparison is true, the action is triggered. Condition 2 does not need to be defined if it is not required.
1. In the WorkBench v5 Toolbox, click Application then click the PLC Task icon. Existing actions will be read from the MintDrive
II
and displayed in the PLC Task table. Each action is shown on a separate row in the table.
2. Choose a row and click in the IF Condition 1 column. The word False will change into a drop down box.
3. Select a condition by clicking on its name in the list. For example, selecting Digital input will mean that a digital input will be monitored to check if it is active. A full description of each Condition is provided in the PLCCONDITION topic of the Mint help file.
4. Click in the adjacent Ch column and choose the related channel (if required). For example, if Digital input was selected, choose which digital input will be monitored.
6.3.1.1 Configuring Condition 2 (optional)
The Operator and Condition 2 columns need to be changed only if you want the action to depend on the logical evaluation of two conditions (Condition 1 and Condition 2). By leaving the Operator column set to OR, and the Condition 2 column set to False, the state of Condition 1 will be used to trigger the action. If you do not wish to configure the second condition, go to section 6.3.2.
5. Click in the Operator column. The word OR will change into a drop down box. Select a logical operator from the list. This operator will be used to evaluate the two conditions. If the result of the logical evaluation is true, the action will be performed.
6. Click in the Condition 2 column. The word False will change into a drop down box. Select a condition by clicking on its name in the list.
7. If necessary, click in the second Ch column and select the required channel.
6.3.1.2 Choosing the action to be performed
8. Click in the THEN Action column and choose the action that will performed when the conditions become true.
9. If necessary, click in the final Ch column and select the required channel.
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6-8 Preset Moves & PLC Task MN1901
6.3.2 Enabling and downloading the actions
Individual actions can be enabled by clicking in the appropriate check box in the Enable column. When the PLC Task is activated, only those actions that have been enabled will be evaluated.
1. Set the required check boxes in the Enable column.
Now that you have configured and enabled all the conditions you require, they must be downloaded to the MintDrive
II
.
2. Click Apply to download the conditions.
The Enable button above the table must be in the on (down) position to activate the PLC T ask. When the PLC Task is not in use it should be switched off to reduce processing power.
3. To activate the PLC Task, click Enable at the top of the screen.
Note: The
button on the mode toolbar can also be used to enable or disable PLC
Task, even if the PLC Task tool is not currently selected.
The controller will now monitor all the conditions for the enabled actions. If the logical result of any set of conditions becomes true, the corresponding action will be performed. An individual action can be disabled even while the PLC Task is running. T o disable an action that is not required, clear the action’s enable check box and click Apply. Remember to disable the PLC Task when it is not required, to reduce processing power.
6.3.2.1 Other functions
If the Auto-Enable PLC Task box is checked, the PLC Task will be enabled automatically every time the drive is reset. This option corresponds to the keyword PLCAUTOENABLE;seetheMint help file for details.
The value in the PLC Time box defines how often the PLC T ask is run. This may be set (in 5ms intervals) to a maximum value of 1 second (1000ms). If the evaluation of the PLC T ask is not critical in your application, it is advisable to set PLC Time to a large value. This will reduce the overall processing time taken by the PLC Task.
The Gear Factor defines the gear factor used by the Fast Gear action; see the Mint help file topic PLCGEARFACTOR for details.
The Jog Speed box can be used to enter a jog speed, expressed in user units. This value is used by the Jog positive and Jog negative actions. The value in this box is linked to the Velocity slider shown in Jog mode.
The Clear and Default buttons can be used to either clear or default all conditions.
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Preset Moves & PLC Task 6-9MN1901
6.3.3 Testing the PLC Task
There is no way to test the PLC Task other than causing the required conditions to occur. For example, if you have an action that is triggered by the condition Digital input 0, then activating digital input 0 will cause the corresponding action to occur.
6.4 Saving presets or PLC conditions
Preset tables and PLC conditions can be saved separately on the PC for later recall. For this purpose, Presets mode and PLC Task mode have Open, Save and Help icons just above their tables.
1. Click the Save icon just above the table.
2. In the Save As dialog, enter a filename.
Presets tables are saved with a .pre file extension. PLC Task tables are saved with a .plc file extension.
To open a file, click the open icon select the file and click Open. When the table has loaded, remember to click Apply to download the table to the MintDrive
II
.
Open Save Help
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Troubleshooting 7-1MN1901
7.1 Introduction
This section explains common problems that may be encountered, together with possible solutions.
7.1.1 Problem diagnosis
If you have followed all the instructions in this manual in sequence, you should have few problems installing the MintDrive
II
. If you do have a problem, read this section first. In WorkBench v5, use the Error Log tool to view recent errors and then check the help file. If you cannot solve the problem or the problem persists, the SupportMe feature can be used.
7.1.2 SupportMe feature
The SupportMe feature (on the Help menu) can be used to e-mail information to the Baldor representative from whom you purchased the equipment. If required, you can choose to add your program files as attachments. WorkBench v5 will automatically start up your e-mail program and begin a new message, with comprehensive system information and selected attachments already in place. Y ou can add any additional message of your own and then send the e-mail. The PC must have email facilities to use the SupportMe feature. If you prefer to contact Baldor technical support by telephone or fax, contact details are provided at the front of this manual. Please have the following information ready:
H The serial number of your MintDrive
II
.
H Use the Help, SupportMe menu item in WorkBench v5 to view details about your system.
H The catalog and specification numbers of the motor that you are using.
H Give a clear description of what you are trying to do, for example trying to establish
communications with WorkBench v5 or trying to perform fine-tuning.
H Give a clear description of the symptoms that you can observe, for example the Status
display, error messages displayed in WorkBench v5, or the current value of any of the Mint error keywords AXISERROR, AXISSTATUS, INITERROR, MISCERROR and DRIVEERROR.
H The type of motion generated in the motor shaft.
H Give a list of any parameters that you have setup, for example the motor data you
entered/selected in the Commissioning Wizard, the gain settings generated during the tuning process and any gain settings you have entered yourself.
7.1.3 Power-cycling the MintDrive
II
The term “Power-cycle the MintDrive
II
” is used in the Troubleshooting sections. On models
with a customer supplied 24V supply, remove the 24V supply, wait for the MintDrive
II
to power down completely (all Status LED segments will turn off), then re-apply the 24V supply. On models with an internally generated 24V supply, remove the AC power supply, wait for the MintDrive
II
to power down completely (all Status LED segments will turn off), then re-apply AC
power.
7 Troubleshooting
7
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7.2 MintDriveIIindicators
7.2.1 Status display
The Status LED display indicates general MintDriveIIstatus information. Some characters will flash to indicate an error.
Drive / comms watchdog. Interprocessor communications failure. This is potentially a severe problem if it occurs repeatedly. Communications failure could indicate a process locking out the interprocessor communications. Clear the error; if the problem persists then contact Baldor technical support.
Over volts. The DC Bus voltage has exceeded the powerbase overvolts level (see DRIVEBUSOVERVOLTS). Check the DC Bus level being fed into the system (see Mint keyword DRIVEBUSVOLTS). This should be close to the nominal voltage (see Mint keyword DRIVEBUSNOMINALVOLTS). Ensure that your input voltage is relevant to the voltage rating of your drive. If the input voltage is correct, then this error may be the result of high deceleration rates. If it is not possible to reduce the harshness of the deceleration rate, then a regeneration resistor should be used. To help you, use WorkBench v5 capture facility to monitor the DC Bus level during moves.
Integrated Power Module (IPM) trip. The unit’s powerbase has been overloaded. This should not happen in normal use if limits have been configured correctly. See the Mint keyword CURRENTLIMIT and related commands.
Current trip. Instantaneous over-current trip. One or more of the 3 motor phases has exceeded 300% of Drive Rated Current.
Under volts. The DC Bus voltage has dropped below the powerbase undervolts level (see DRIVEBUSUNDERVOLTS). This error will only be generated if the drive is in the enabled state. As with the overvolts error, check the input voltage being fed into the system. The error could also occur during high acceleration profiles.
Feedback trip. Can be enabled/disabled using FEEDBACKFAULTENABLE.Five consecutive errors (or five errors in any 500 servo tick period) will cause the drive to trip. This error indicates loss of encoder/resolver feedback and may indicate that the feedback cable has become detached or one of the signals has broken. Check the wiring in the Feedback cable; check for noise immunity; check the feedback device fitted to the motor (if possible).
Motor or Drive trip. The motor I2T or the drive I.T current protection algorithms have exceeded their limit and tripped the drive (disabled it). Check DRIVEERROR or the Error Log to determine which error has occurred. The motor and drive current limits are fixed according to the database parameters. The drive can demand peak current for a short duration (see DRIVEPEAKDURATION), thereafter it will trip or Foldback according to the setting of DRIVEOVERLOADMODE.The same is true for the motor (see MOTORPEAKDURATION and MOTOROVERLOADAREA). Use the Foldback option to automatically foldback the current to a level where the drive/motor can recover.
(Symbol not flashing) Motor I
2
T / It foldback. Motor I2T or Drive I.T algorithm has resulted in the demand current being folded back to a level where the drive/motor can recover. The motor / drive can run with demand currents greater than their rated value for a period of time; after that time the drive will either trip or automatically foldback the demand current.
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Troubleshooting 7-3MN1901
Overtemperature. The temperature of the drive or motor has exceeded a trip level (see Mint keyword TEMPERATURELIMITFATAL ) or the Motor overtemperature trip input has been activated (see Mint keyword MOTORTEMPERATUREINPUT).
Drive enabled. The drive is enabled (except where CONFIG = _cfVirtual, where it is not physically enabled).
Torque mode. The drive is in T orque mode. See the Mint keywords TORQUE, TORQUEREFSOURCE and related commands.
Hold to Analog. The axis is in Hold To Analog mode. See the Mint keyword HTA.
Auto tune test driving motor. Autotune is active and driving the motor. The motor may move.
Power base not ready. This error condition applies to 3-phase drives only. These drives have a pre-charge circuit which must activate after power-up before the drive can be enabled. If the drive is enabled prior to this then the error occurs. The error could also indicate the loss of one or more of the input phases.
Cam. A Cam profile is being profiled. See the Mint keyword CAM.
General error. See AXISERROR and DRIVEERROR. The motion toolbar displays the status of AXISERROR, which is a bit pattern of all latched errors. See also the Error Log topics in the help file.
Error input. The ERRORINPUT has been activated and generated an error.
Flying shear. A flying shear is being profiled. See the Mint keyword FLY.
Position or velocity following error. A following error has occurred. See the Mint keyword AXISERROR and associated keywords. Following errors could be caused by a badly tuned drive/motor. At higher acceleration and deceleration rates, the following error will typically be greater. Ensure that the drive/motor is adequately tuned to cope with these acceleration rates. The following error limit can be adjusted to suite your application (see Mint keywords FOLERRORFATAL and VELFATAL). Following error could also be the cause of encoder/resolver loss (see also Mint keyword FEEDBACKFAULTENABLE).
Follow mode. The drive is in Follow mode. See the Mint keyword FOLLOW.
Hold. The Hold DIP switch is active (see section 3.9.2) or the PLC Task has requested a Hold state. Motion will be ramped to zero demand and will then hold on position while the switch is active.
Homing. The drive is currently homing. See the Mint keyword HOME.
Preset Homing. The drive is currently homing. This motion has been triggered from a Preset move table.
Incremental move. An incremental move is being profiled. See the Mint keywords INCA and INCR.
Jog. The drive is jogging. In the Mint help file, see the topics JOG, JOGCOMMAND and Jog screen.
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7-4 Troubleshooting MN1901
Preset jog. The drive is jogging. The jog was triggered from a Preset jog table.
Overspeed. The measured speed of the motor has exceeded the trip level defined by DRIVESPEEDFATAL. Check that the trip level is set to a suitable value for your application. When accelerating to a demand speed close to the trip level, there will typically be a certain amount of overshoot. Using the Fine-tuning tool, check the amount of overshoot you get with the acceleration and demand speeds being used in your application.
Positional Move. The drive is performing a linear move. See the Mint keywords MOVEA and MOVER.
Preset positions. The drive is performing a linear move. This motion has been triggered from a Preset move table.
DB Overload. The regeneration resistor (Dynamic Brake) has been overloaded. See the Mint keyword DBEXTTRIPSWITCH and associated keywords.
Stop. A STOP command has been issued or the stop input is active.
Drive disabled. The drive must be enabled before operation can continue. See section
3.8. Click the Drive enable button in WorkBench v5.
Crash. The drive enable input or the Enable DIP switch have become inactive whilst the drive was in the enable state (or the drive was enabled whilst they were inactive) - bit 13 in AXISEERROR will be set. The drive can be programmed to ignore this state using the Mint keyword DRIVEENABLEINPUTMODE (see the Parameters tool).
Suspend. The SUSPEND command has been issued and is active. Motion will be ramped to zero demand whilst active.
Speed demand. The drive is under speed control. See the Mint keywords SPEEDREF, SPEEDREFSOURCE and related commands.
Reverse software or hardware limit. A reverse limit has been activated. See AXISERROR and/or AXISSTATUS to determine which applies.
Reverse software or hardware limit. A reverse limit has been activated, but no error has been generated. See AXISERROR and/or AXISSTATUS to determine which applies. This state can exist at the same time as a forward limit with no error, causing the resulting symbol to appear as H, the same symbol as Hold.
Forward software or hardware limit. A forward limit has been activated. See AXISERROR and/or AXISSTATUS to determine which applies.
Forward software or hardware limit. A forward limit has been activated, but no error has been generated. See AXISERROR and/or AXISSTATUS to determine which applies. This state can exist at the same time as a reverse limit with no error, causing the resulting symbol to appear as H, the same symbol as Hold.
Firmware being updated (horizontal bars appear sequentially). New firmware is being downloaded to the drive.
Initialization error. An initialization error has occurred at power on. See the Error Log or INITERROR topics in the help file. Initialization errors should not normally occur.
User defined symbols can be made to appear using the Mint keywords LED and LEDDISPLAY.
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Troubleshooting 7-5MN1901
7.2.2 DB On (Regeneration) LED
The front panel DB On LED indicates regeneration activity.
Yellow
Power is being dissipated into the regeneration resistor
Off No regeneration is occurring.
7.2.3 Communication
Problem Check
Status display is blank
Check that the customer supplied 24VDC power supply is connected correctly to connector X1 and is switched on. On models with an internally generated 24VDC supply, check that the AC power supply is connected correctly to connector X1 and is switched on.
WorkBenchv5fails to detect the MintDrive
II
-it detects “No controller found. Communication fault on COMx”.
Ensure that the MintDriveIIis powered and the Status display is illuminated (see section 7.2).
Check that the serial cable is connected between the PC’s COM port and connector X6 on the MintDrive
II
.
Check which PC COM port is being used, or use the “Scan all serial ports” option to locate the MintDrive
II
.
Check the wiring of the serial cable or try an alternate cable. Check that DIP switch 10 (RS232/RS422) is set correctly (see section 3.9.6).
On the PC, try an alternative COM port.
Confirm that a mouse driver or other serial device is not conflicting (using the same COM port) as WorkBench v5.
Does the MintDrive
II
have firmware in it? If you tried to download new firmware and the download failed, the controller may not have firmware. If this has happened, the Status display will show a minus sign (-) and flash the decimal point repeatedly.
Check that the selected Baud rate is supported by the PC and MintDrive
II
.
If the “Only scan COMx” option is selected in WorkBench v5, check that the correct COM port is selected.
If the “Search up to Nodexx“ option is selected in WorkBench v5, check that the MintDrive
II
node number is not higher than this value.
Do you have multiple nodes on the bus? If so, they must all be set to the same Baud rate. WorkBench v5 scans through all the node Id’s at different Baud rates. When it finds a node, it will only continue to scan for other nodes at the same Baud rate.
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7-6 Troubleshooting MN1901
7.2.4 Power on
Problem Check
The Status display is showing a flashing symbol with a static decimal point.
The MintDriveIIhas detected a motion error. Use the Error Log tool to view a list of recent errors, or click the Error button on the motion toolbar to view a description of the error. Alternatively, type any or all of these commands in the Command window:
PRINT AXISERROR PRINT DRIVEERROR PRINT MISCERROR PRINT INITERROR.
Click the Clear Errors button on the motion toolbar.
7.2.5 Tuning
Problem Check
Cannot enable the MintDrive
II
because
AXISERROR has bit 13 set
Check the drive enable input on connector X3 pins 7 and 9 is connected and powered correctly. Check that DIP switch 8 (enable) is set to the On position.
When the MintDriveIIis enabled the motor is unstable
Check that the current loop has been tuned. Check that the current loop was tuned with the correct motor data. If the motor is still unstable try reducing the Speed Proportional gain (KVPROP) and Speed Integral gain (KVINT) on the Speed tab of the Fine-tuning window.
I get a Following Error (AXISERROR bit 5 is set) and the drive disables when tuning the Mint gains
Set FOLERRORMODE to zero to ignore the following error while tuning the Mint gains.
I get a Software limit error (AXISERROR bits 3 or 4 set) and the drive disables when tuning the Mint gains
Set SOFTLIMITMODE to zero to ignore the software limit error while tuning the Mint gains.
I get a Hardware limit error (AXISERROR bits 1 or 2 set) and the drive disables when tuning the Mint gains
Set LIMITMODE to zero to ignore the hardware limit errors while tuning the Mint gains. Alternatively, disable the hardware limit inputs.
7.2.6 Status display shows a digit or ‘E.’
If the Status display shows a flashing digit, ‘E’, or the forward or reverse hardware limit symbol, use the Error Log tool to view a list of recent errors. Alternatively, type PRINT DRIVEERROR, PRINT AXISERROR and PRINT MISCERROR as separate commands in the WorkBench v5 Command window. Each of these commands will return an error code, a description of which can be found in the help file. Press F1 and locate the DRIVEERROR, AXISERROR and MISCERROR keywords. The Error Handling book contains topics listing the Status display indicators and basic error codes. Remember that many error codes are the sum of a bit pattern so may not be listed individually. For help on understanding bit pattern values, see the Bit pattern values topic in the Keywords book.
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