Baldor MN1274 User Manual

Installation

Installation

Manual

Manual

MN1274 06/2001

Copyright Baldor (c) 2001. All rights reserved.

Teleph

61296745455

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 and Windows 2000 are registered
trademarks of the Microsoft Corporation.

Limited Warranty
For a period of two (2) years from the date of original purchase, Baldor will repair or replace without charge
controls and accessories which our examination proves to be defective in material or workmanship. This warranty
is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed
and has been used in accordance with the instructions and/or ratings supplied. This warranty is in lieu of any
other warranty or guarantee expressed or implied. Baldor shall not be held responsible for any expense (including
installation and removal), inconvenience, or consequential damage, including injury to any person or property
caused by items of our manufacture or sale. (Some countries and U.S. states do not allow exclusion or limitation
of incidental or consequential damages, so the above exclusion may not apply.) In any event, Baldor’s total
liability, under all circumstances, shall not exceed the full purchase price of the control. Claims for purchase price
refunds, repairs, or replacements must be referred to Baldor with all pertinent data as to the defect, the date
purchased, the task performed by the control, and the problem encountered. No liability is assumed for
expendable items such as fuses. Goods may be returned only with written notification including a Baldor Return
Authorization Number and any return shipments must be prepaid.

Baldor UK Ltd
Mint Motion Centre
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Web site: www.baldor.co.uk

Baldor Electric Company
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Web site: www.baldor.com

Baldor ASR GmbH
Telephone: [phone]
Fax: [phone]

Baldor ASR AG
Telephone: [phone]
Fax: [phone]

Australian Baldor Pty Ltd

one: +

Fax: [phone]

Baldor Electric (F.E.) Pte Ltd
Telephone: [phone]
Fax: [phone]

Baldor Italia S.R.L
Telephone: [phone]
Fax: [phone]

iii

Safety 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 c an cause serious or fatal injury. Only qualified personnel should attempt to start-up,
program or troubleshoot this equipment.

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 grounded before applying power. Do not apply AC power

before you ensure that grounds are connected. Electrical shock can cause serious or fatal
injury.

WARNING: 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.

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 shaft

and driven equipment. Be certain that unexpected motor shaft movement will not cause
injury to personnel or damage to equipment. Peak torque of several times the rated motor
torque can occur during control failure.

WARNING: The motor circuit might have high voltages present whenever AC power is applied, even

when the motor is not rotating. 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 grounded to prevent possible shock hazard.

WARNING: When operating a 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.

iv

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
1-50 5,000

CAUTION: Avoid locating the drive immediately above or beside heat generating equipment, or directly

below water or steam pipes.

CAUTION: Avoid locating the drive in the vicinity of corrosive substances or vapors, metal particles and

dust.

CAUTION: Do not connect AC power to the drive terminals U, V and W. Connecting AC power to these

terminals may result in damage to the drive.

CAUTION: Baldor does not recommend using “Grounded Leg Delta” transformer power leads that may

create ground loops and degrade system performance. Instead, we recommend using a four
wire Wye.

RMS Symmetrical Amperes

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 s hould have specifications compatible to the
drive.

CAUTION: Violent jamming (stopping) of the motor shaft 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.

v

CAUTION: Ensure that resolver or encoder wires are properly connected. Incorrect installation may

result in improper rotation or incorrect commutation.

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.

vi

Contents

1 Introduction 1..............................................

1.1 MintDrive features 1.........................................................

1.2 Receiving and inspection 2...................................................

1.2.1 Identifying the catalog number 2.................................................

1.3 MintDrive indicators 3.......................................................

1.3.1 Monitor LED display 3..........................................................

1.3.2 CAN 1 and 2 LEDs 3...........................................................

1.3.3 Ready LED 3.................................................................

1.3.4 DB On (Regeneration Load) LED 3...............................................

1.4 Units and abbreviations 4....................................................

2 Basic Installation 5.........................................

2.1 Outline 5..................................................................

2.1.1 Hardware requirements 5.......................................................

2.1.2 RS485 / RS422 systems 7......................................................

2.1.3 Power sources 7..............................................................

2.1.4 Tools and miscellaneous hardware 7.............................................

2.1.5 Other information needed for installation 7.........................................

2.2 Mechanical installation and location requirements 8..............................

2.2.1 Dimensions and mounting 9.....................................................

2.3 Power connections 10........................................................

2.3.1 Grounding 11..................................................................

2.3.2 Input power conditioning 12......................................................

2.3.3 Power disconnect and protection devices 12........................................

2.3.4 Wire sizes 14..................................................................

2.3.5 Single phase connection to package size A or B 15..................................

2.3.6 Single phase connection to package size C 15......................................

2.3.7 Three phase connection to package size C 16......................................

2.3.8 24V control supply 16...........................................................

2.3.9 DC Bus power connections from package size C 17.................................

2.3.10 Power supply filters 18..........................................................

2.4 Motor connections 19.........................................................

2.4.1 Motor circuit contactors 20.......................................................

2.4.2 Regeneration resistor (Dynamic Brake resistor) 21...................................

2.5 Feedback connections 22.....................................................

2.5.1 Resolver option 23..............................................................

2.5.2 Encoder option 25..............................................................

2.6 Drive enable 26..............................................................

vii

3 Input / Output 27............................................

3.1 Outline 27..................................................................

3.2 Analog I/O 27...............................................................

3.2.1 Analog Input, Single Ended - X11 28...............................................

3.2.2 Analog Input, Differential - X11 29.................................................

3.2.3 Analog Inputs, Differential - X5 30.................................................

3.2.4 Analog Outputs, Bipolar - X11 32..................................................

3.2.5 Analog Outputs, Bipolar - X5 33...................................................

3.3 Digital I/O 34................................................................

3.3.1 Digital Inputs - X13 35...........................................................

3.3.2 Digital Inputs - X5 37............................................................

3.3.3 Digital Outputs - X13 39.........................................................

3.3.4 Digital Outputs - X5 40...........................................................

3.4 Other I/O 41................................................................

3.4.1 Simulated encoder output - X3 41.................................................

3.4.2 Master (auxiliary) encoder input - X6 42............................................

3.4.3 Serial port - X7 44..............................................................

3.4.4 Using RS232 cable 45...........................................................

3.4.5 Multidrop using RS485 / RS422 cable 46...........................................

3.4.6 Connecting Baldor HMI Operator Panels 47........................................

3.4.7 Optional breakout board for connector X5 48.......................................

3.4.8 CAN peripherals 48.............................................................

4 Tuning and Configuration 49..................................

4.1 Outline 49..................................................................

4.1.1 Connecting the MintDrive to the PC 49.............................................

4.1.2 Installing the software 49.........................................................

4.1.3 Starting the MintDrive 50.........................................................

4.2 Mint Configuration Tool Startup Wizard - coarse tuning 51.........................

4.3 MCT Startup Wizard - fine-tuning 54...........................................

4.3.1 An introduction to closed loop control 54...........................................

4.3.2 Fine-tuning the speed loop 56....................................................

4.3.3 Fine-tuning the position loop 57...................................................

4.3.4 Jog test 59.....................................................................

4.3.5 Completing the Startup Wizard 60.................................................

4.4 MCT Wizard - hardware configuration 61........................................

4.4.1 Digital input configuration 61.....................................................

4.4.2 Digital output configuration 62....................................................

4.4.3 Axis0 parameter configuration 63.................................................

4.4.4 Axis0 error configuration 63......................................................

4.4.5 Axis0 tuning configuration 64.....................................................

4.4.6 Miscellaneous configuration 64...................................................

4.4.7 Completing the configuration wizard 65............................................

viii

5 Mint WorkBench 67.........................................

5.1 Outline 67..................................................................

5.1.1 Completing configuration 67......................................................

5.2 Using WorkBench 68.........................................................

5.2.1 Selecting the controller 68.......................................................

5.2.2 Menus and buttons 68...........................................................

5.3 Watch window 70............................................................

5.3.1 Quick Watch tab 70.............................................................

5.3.2 Speed Loop tab 71..............................................................

5.3.3 Position Loop tab 72............................................................

5.3.4 Capture tab 73.................................................................

5.4 Editor windows 74...........................................................

5.4.1 Configuration window 74.........................................................

5.4.2 Program window 74.............................................................

5.4.3 Terminal window 75.............................................................

5.4.4 Useful commands for testing 75...................................................

5.4.5 Firmware update 77.............................................................

6 Specifications 79............................................

6.1 Outline 79..................................................................

6.1.1 General specifications 79........................................................

6.1.2 Power 80......................................................................

6.1.3 Rectifier and regeneration 81.....................................................

6.1.4 Resolver feedback 81...........................................................

6.1.5 Encoder feedback 82...........................................................

6.1.6 Control signals 82..............................................................

6.1.7 Environmental 83...............................................................

7 Troubleshooting 85..........................................

7.1 Outline 85..................................................................

7.1.1 Problem diagnosis 85...........................................................

7.1.2 Communication 86..............................................................

7.1.3 Power up 87...................................................................

7.1.4 Tuning 89.....................................................................

7.1.5 Mint gains 90..................................................................

7.1.6 Ready LED is red 91............................................................

7.1.7 CAN 94.......................................................................

ix

Appendices

A Tuning 97..................................................

A.1 Introduction 97..............................................................

A.1.1 Closed loop control 99...........................................................

A.1.2 Position loop 100................................................................

A.1.3 Speed loop 101..................................................................

A.1.4 Current loop 101.................................................................

A.1.5 MintDrive operational modes 101..................................................

A.1.6 Tuning the position loop for a velocity servo drive 102.................................

A.1.7 Tuning the position loop for a servo drive 102........................................

A.1.8 Tuning the position loop for a torque servo drive 105..................................

A.1.9 Saving tuning information 105.....................................................

B CAN 107....................................................

B.1 Outline 107..................................................................

B.1.1 MintDrive capabilities 107.........................................................

B.2 CAN 1 (CANopen) 109........................................................

B.2.1 CAN 1 (CANopen) - X9 109.......................................................

B.2.2 What is CANopen? 110...........................................................

B.2.3 Configuring nodes 111...........................................................

B.2.4 Network manager - node 1 111....................................................

B.2.5 Scanning nodes 111.............................................................

B.2.6 Connecting to nodes 112.........................................................

B.2.7 Monitoring CAN events 113.......................................................

B.2.8 Controller nodes 114.............................................................

B.2.9 I/O nodes 115...................................................................

B.2.10 HMI Operator Panels 117.........................................................

B.3 CAN 2 (Baldor CAN) 119.......................................................

B.3.1 CAN 2 (Baldor CAN) - X8 119.....................................................

B.3.2 Preparing the MintDrive 120.......................................................

B.3.3 Preparing the CAN peripheral 120..................................................

B.3.4 Connecting the PC, MintDrive and CAN peripheral 120................................

B.3.5 Node IDs 121...................................................................

B.3.6 Static configuration 121...........................................................

B.3.7 Adding the node to the network 122................................................

B.3.8 Monitoring CAN Bus communications 123...........................................

B.3.9 Controlling the CAN peripheral 123.................................................

B.3.10 Normal operation 123............................................................

B.3.11 KeypadNode 124................................................................

B.3.12 ioNode 24/24 125................................................................

B.3.13 Example CAN network 126........................................................

B.3.14 Mint CAN related keywords 127....................................................

x

C CE Guidelines 129...........................................

C.1 Outline 129..................................................................

C.1.1 Declaration of Conformity 129.....................................................

C.1.2 EMC Conformity and CE marking 130..............................................

C.1.3 Use of CE compliant components 130..............................................

C.1.4 EMC wiring technique 130........................................................

C.1.5 EMC installation suggestions 131..................................................

C.1.6 Wiring of shielded (screened) cables 132............................................

D Accessories and options 135..................................

D.1 Outline 135..................................................................

D.1.1 Cables 135.....................................................................

D.1.2 Resolver feedback cable 136......................................................

D.1.3 EMC mains filters 137............................................................

D.1.4 Regeneration resistors 139........................................................

D.1.5 Breakout board - X5 140..........................................................

xi

xii

1.1 MintDrive features

The MintDrive combines a powerful fully featured motion controller and brushless servo amplifier into a
compact package. This provides a flexible and powerful motion control solution for almost any single
axis positioning system. Programmable in Mintt, applications can be quickly realized. Using the
onboard CAN bus, drives can be connected together for loosely coupled multi-axis systems.

Features include:

H Single axis AC brushless drive with integrated Mint controller

H 2.5A to 15A continuous current ratings (model dependent)

H Direct on line connection to 115V or 230V single input or 230V three phase input (model dependent)

H Programmable in Mint

H Point to point moves, software cams and gearing

H 18 optically isolated digital inputs

H 9 optically isolated digital outputs

H 4 general purpose analog inputs

H 4 general purpose analog outputs

H CANopen protocol for peer-to-peer communications with other Mint v4 controllers, and other third

party devices.

H Proprietary CAN protocol for control of Baldor remote I/O devices

H RS232 and RS485 communications

H Flash memory for program and data storage.

1 Introduction

1

MintDrive will operate with a large number of brushless servo motors. For information on selecting
Baldor servo motors, please see the sales catalog BR1202.

This manual is intended to guide you through the installation of MintDrive, whether you are a novice in
the field of motion control or an experienced engineer.

The chapters should be read in sequence.

The Basic Installation section describes the mechanical installation of the MintDrive, the power supply
connections and motor connections. The following 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.

1

1.2 Receiving and inspection

When you receive your MintDrive, 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.

2. Remove the MintDrive 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 you received is the same as the catalog number listed
on your purchase order. The catalog/part number is described in the next section.

4. Inspect the MintDrive for external damage during shipment and report any damage to the carrier that
delivered your MintDrive.

5. If MintDrive 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 on page 83.

1.2.1 Identifying the catalog number

MintDrives are available with different current ratings and package sizes.
The catalog number describing the model is marked on a label on the side of the unit.
It is a good idea to look for the catalog number (sometimes shown as ID/No: ) and write it in the space
provided below.

Catalog number:

Installed at: ___________________________

A description of a catalog number is shown below, using the example number MD1A05TB-RC23:

Meaning Alternatives

MD The unit is a member of the MintDrive family. -

1 Requires an AC supply voltage of 115 Volts. 2=230V

A05 Continuous current rating of 5.0A.

T Built in mains power supply.

Dynamic Brake with a built in transistor and resistor

B

(available on 2.5A and 5A models only).

R Feedback option is a resolver. E=Encoder

C CAN Bus option (MintDrive is always fitted with CAN). -

2 Serial port type is combined RS232 / RS485. -

Additional 24VDC supply is required to power the

3

internal MintDrive logic*.

* An external 24VDC supply will always be required to operate the enable input and digital inputs on

connectors X13 and X5. See pages 26, 35 and 37.

MD_____________-_______

Date: ______

A02=2.5A; A07=7.5A;
A10=10A; A15=15A

S=Built in mains power supply with

DC out for powering other drives

R=Requires external braking resistor

0=Self generated internal 24VDC
logic supply*

2

1.3 MintDrive indicators

1.3.1 Monitor LED d isp lay

The 7 -segment Monitor LED display indicates general MintDrive status information:

Drive Disabled Driveinerror(seesection7)

Drive Enabled Follow mode

Jogging Local (see troubleshooting guide)

Positional Move i.e. MOVEA, MOVER Flying shear

Homing Cam

Incremental move i.e. INCA, INCR Speed Demand

Torque mode Firmware being updated by WorkBench

1.3.2 CAN 1 an d 2 LEDs

The CAN 1 and 2 LEDs refer to the independent CAN buses CAN1 and CAN2.

Green

Red/
Green

Red The bus is OFF (see page 94)

Off No primary power to the MintDrive

The bus is operational

The bus is passive (see page 94)

1.3.3 Ready LED

The front panel Ready LED indicates the general status of the MintDrive.

Green

Red An error condition exists (see page 91)

Off No primary power to the MintDrive

The MintDrive is operating normally

1.3.4 DB On (Regeneration Load) LED

The front panel DB On LED indicates regeneration activity.

Yellow

Off No regeneration occurring

Power is being dissipated into the regeneration resistor

3

1.4 Units and abbreviations

The following units and abbreviations are used in this manual:

V Volt (also VAC and VDC)............

WWatt............

A Ampere............

Ω Ohm............

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............

”inch.............

ft feet.............

lbin pound-inch (torque)...........

Nm Newton-meter (torque)...........

ADC Analog to Digital Converter..........

AWG American Wire Gauge.........

4

2.1 Outline

You must read all the sections in Basic Installation.

It is important that the correct steps are followed when installing the MintDrive. This section covers the
mechanical and electrical installation of the MintDrive, including the following steps:

H Location considerations

H Mounting the MintDrive

H Connecting the power supply

H Connecting the optional control supply

H Connecting the motor

H Installing a regeneration resistor

H Connecting the feedback signal

H Connecting the drive enable signal.

Each step should be followed in sequence.

2 Basic Installation

2

2.1.1 Hardware requirements

The components you will need to complete the basic installation are described below:

H Under some applications, such as those with high deceleration rates, there may be a requirement

for a dynamic brake (or regeneration) resistor.

Note: Without the braking resistor, the drive may produce an overvoltage fault.

All MintDrives have overvoltage sensing circuitry, but only the 2.5A and 5A units have an
integral regeneration resistor. For 7.5A, 10A and 15A units a regeneration resistor must be
purchased separately if required. See Appendix D.

H A PC that fulfills the following specification:

Processor Intel Pentium 133MHz Intel Pentium 200MHz or faster

RAM 32MB 64MB

Hard disk space 40MB 60MB

CD-ROM A CD-ROM drive is required

Screen 800 x 600, 256 colors 1024 x 768, 256 colors

Mouse A mouse or similar pointing device is required

Operating system Windows 95, Windows 98, Windows ME, Windows NT or Windows 2000

Minimum specification Recommended specification

5

H The servo motor that will be connected to the MintDrive.

H The appropriate motor cable. For easier installation it is recommended that a color-coded Baldor

motor power cable is used. A description of a Baldor motor power cable catalog number is shown
below, using the example number CBL030SP-MHM:

Meaning Alternatives

CBL The item is a cable. -

030 Indicates the length, in this example 3.0 meters. Various lengths are available

SP ThecableisaServo motor Power cable. -

M Current rating of 10A. F=20A; E=30A

H 8-pin connector -

M Metric style threaded connector CE=CE connector

Motor power cables are also available without connectors, in which case the last two letters (HM in
the example above) are not used.

H A resolver 9-core cable, 15-core if the MintDrive is fitted with the encoder option. A description of a

feedback cable catalog number is shown below, using the example number CBL030SF-ALM.

Meaning Alternatives

CBL The item is a cable. -

030 Indicates the length, in this example 3.0 meters. Various lengths are available

SF ThecableisaServo motor Feedback cable. -

A Suitable for resolver feedback

K=Suitable for Encoder / Hall

feedback

L 12-pin connector -

M Metric style threaded connector CE=CE connector

If you are not using a Baldor cable with your chosen feedback device, be sure to obtain a cable that
is a shielded twisted pair 22 AWG (0.34mm

2)

wire minimum, with an overall shield. Ideally, the cable
should not exceed 66ft (20m) in length. Maximum wire-to-wire or wire-to-shield capacitance is 50pF
per foot (300mm) (maximum of 7500pF for 150ft).

H An RS232 cable (Baldor order code CBL023-501), or the components to build one yourself.

Note: As the RS232 connector is shared with the RS485 port, a standard serial cable must not be

used as this may result in damage to the unit. See pages 44 and 45.

H (Optional) A break-out board (catalog number OPT017-501) for input/output from connector X5.

H A mains cable.

6

2.1.2 RS485 / RS422 systems

If your PC does not have an RS485 / RS422 connector, an RS232 to 4-wire RS485 / RS422 converter
will be required. This allows signals from the RS232 port to be converted to the signals necessary for
RS485 / RS422 communications. Appropriate converters are available from KK Systems Ltd
(www.kksystems.com).

Note: If this is the first time you are installing a MintDrive then it is strongly recommended that you

use RS232 to get started and use RS485 later. This will avoid any potential problems
involving the RS232-RS485 converter.
Also, MME (Mint Motion Engine) firmware can only be updated over RS232.

2.1.3 Power sources

If the MintDrive requires an external 24VDC for the logic supply then this must be a regulated power
supply with a minimum current supply capability of 1.6A. A 24V filter may be required to comply with
the CE directive for which the MintDrive was tested (see page 18).
A 24VDC power supply is required for the drive enable input, the digital outputs and the digital inputs;
24V cannot be sourced from the MintDrive unit itself.
A mains source (installation 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. A mains filter is
required to comply with the CE directive for which the MintDrive was tested (see page 18).

2.1.4 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 with a blade width less than 1/8” (3.5mm)
H Screws or bolts (depending on your own mounting requirements) with an M5 fixing
H Soldering equipment with suitable soldering tips.

2.1.5 Other information needed for installation

You will need the following information to complete the installation:

H The data sheet or manual provided with your motor, describing the wiring information of the motor

cables/connectors

H Whether digital inputs/outputs will be ’Active Low’ or ’Active High’ to meet the requirements and

specification of the system you are going to build.

7

2.2 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 are shielded correctly.

CAUTION: Avoid locating the MintDrive immediately above or beside heat generating

equipment, or directly below water steam pipes.

CAUTION: Avoid locating the MintDrive in 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 must be installed indoors, permanently fixed and located so that it is not accessible

by the operator and can only be accessed by service personnel using tools.

H The maximum suggested operating altitude is 3300ft (1000m).

Above 3300ft (1000m) de -rate output current 2% per 1000ft (300m).

H The MintDrive must be installed in an ambient temperature of 32°F to 104°F (0°C to 40°C).

De-rate output current 2.5% per 1.8°F (1°C) from 104°F (40°C) to 122°F (50°C) maximum.

H The MintDrive must be installed in relative humidity levels of less than 80% for temperatures up to

87°F (31°C) decreasing linearly to 50% relative humidity at 104°F (40°C) (non -condensing).

H The MintDrive must be installed where the pollution degree according to IEC664 shall not exceed 2.

H For MintDrives that require an external 24VDC for the logic supply, it must be installed so that the

24VDC supplied to the unit is isolated from the mains using double or reinforced insulation.

H The inputs and outputs of the control circuit must be confined to Safety Extra Low Voltage circuits.

H Both the mains supply and the external 24VDC supply must be fused.

H The atmosphere shall not contain flammable gases or vapors.

H There shall not be abnormal levels of nuclear radiation or X-rays.

H The MintDrive must be secured by the slots in the flange, with the protective earth stud bonded to a

safety earth by either a 25A conductor or a conductor of three times the peak current rating ­whichever is the greater.

H For effective cooling and maintenance, the MintDrive should be mounted on a smooth,

non-flammable vertical surface. The power handling capability is affected by the temperature of the
left hand side of the unit. Ensure a free flow of air is available to maintain the control electronics at a
suitable temperature.

H At least 2” (50mm) top and bottom clearance of the MintDrive must be provided for airflow.

8

H If multiple units are being mounted side by side, a spacing of 0.5” (13mm) must be provided

between the units and from the unit to the side of the cabinet / enclosure.

H To comply with CE directive 89/336/EEC an appropriate mains filter must be installed.

For MintDrives requiring the external 24VDC logic supply, a 24V filter must also be installed.
See page 18.

2.2.1 Dimensions and mounting

Ensure you have read and understood page 8. Mount the MintDrive on its rear side, the side opposite
to the front panel. The MintDrive 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 unit.

W

1

3

H

2

H

1

H

W

W

D

3

2

W

4

Package A

2.5A

Package C

10A / 15A

Package B

5A / 7.5A

Dimensions inches (mm) Weight

Package Current H1 H2 H3 W1 W2 W3 W4 D lb (kg)

A 2.5A 6.81

B 5A /

7.5A

C 10A /

15A

(173)

6.81

(173)

14.05
(357)

7.67

(195.5)

7.67

(195.5)

15.12
(384)

8.07

(205)

8.07

(205)

15.75
(400)

0.6

(15)

0.9

(23)

1.1

(27.5)

0.6

(15)

0.9

(23)

0.37

(9.5)

1.57
(40)

1.57
(40)

1.42
(36)

3.31
(84)

4.29

(109)

2.17
(55)

6.00

(152)

6.00

(152)

10.43
(265)

4.89

(2.22)

5.31

(2.41)

9.92
(4.5)

Figure 1 - Package dimensions

9

2.3 Power connections

This section provides instructions for connecting the mains supply. It is important that you refer to the
correct front panel for your MintDrive 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, 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 the MintDrive provides rectification, smoothing, regeneration capability
(built-in on 2.5A and 5A models only) and current surge protection.
The power stage is internally fused and therefore self protected, but fuses or circuit breakers may be
used in the input lines for cable protection.
A power disconnect should be installed between the mains supply and the input of the MintDrive for a
fail safe method to disconnect power. The MintDrive will remain in a powered condition until all input
power is removed from the MintDrive and the internal bus voltage is depleted.
On units without the self generated internal 24VDC logic supply (catalog number ends with 3), you
might wish the external 24VDC logic supply to remain connected to retain position and I/O information.
The MintDrive with package size C can accept either single phase direct (115V or 230V depending on
model) or 3 phase with transformer (250VAC max).

Note: A Residual Current Device (RCD) must not be used for fusing the drive.

10

All interconnection wires should be in metal conduits between the MintDrive, 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 ground. Due to the importance of system
grounding for increased reliability, grounding methods are shown in the following sections.

2.3.1 Grounding

Single phase units

AC Mains
Supply

Earth

Safety Ground

Driven Earth
Ground Rod

(Plant Ground)

L

N

Circuit breaker
or fuses.
See section

2.3.3.

MintDrive

VLN U W

Route all 3 wires L, N, and
Earth (Ground) together in
conduit or cable. Power
wires must be kept separate
from control signal wires.

Note: Wiring shown for clarity of

grounding method only.
Not representative of actual
terminal block location.

Ground as per
NEC and local codes.

Figure 2 - Recommended single phase system grounding

Note: For CE compliance, a 3-phase mains filter must be connected between the mains supply

and the MintDrive. The MintDrive and motor earths should be connected to the enclosure
backplane. (The enclosure backplane should be connected to the earth at the mains source.
There should be a separate connection from the earth at the mains source to the plant
ground rod).

Three phase units

AC Mains
Supply

Four Wire

“Wye”

L1

L2

L3

MintDrive

L3

Note: Wiring shown for clarity of

grounding method only.

VL1 L2 U W

Not representative of actual
terminal block location.

Safety

Ground

Driven Earth
Ground Rod

(Plant Ground)

Earth

Circuit breaker
or fuses.
See section

2.3.3.

Route wires L1, L2, L3 and
Earth (Ground) together in
conduit or cable. Power wires
must be kept separate from
control signal wires.

Ground as per
NEC and local codes.

Figure 3 - Recommended 3-phase system grounding

Note: For CE compliance, a 3-phase mains filter must be connected between the mains supply

and the MintDrive. The MintDrive and motor earths should be connected to the enclosure
backplane. (The enclosure backplane should be connected to the earth at the mains source.
There should be a separate connection from the earth at the mains source to the plant
ground rod).

11

Ungrounded distribution systems

L

To avoid equipment damage an isolation transformer with a grounded secondary is recommended.
This provides three phase AC power that is symmetrical with respect to ground.

2.3.2 Input power conditioning

Baldor drives are designed for direct connection to standard single and three phase lines that are
electrically symmetrical with respect to ground. Certain power line conditions must be avoided;
an AC line reactor, 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 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.

H If the feeder or branch circuit that provides power to the MintDrive 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.

2.3.3 Power disconn ect and protection devices

A power disconnect should be installed between the input power service and the MintDrive for a
fail-safe method to disconnect power. The MintDrive will remain in a powered condition until all input
power is removed from the drive and the internal bus voltage has depleted.

The MintDrive 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.
For CE installations the Gould Shawmut Cat. No. ATMR15 may be suitable, up to 15A.

Circuit
Breaker

N

LN

Earth

Fuse

Connection

LN

LN

MintDrive

Circuit breaker and fuse not supplied.
For CE Compliance, see Appendix C.

Figure 4 - Circuit breaker and fuse, single phase, package size A or B

12

L

N

L1L

L

LN

Earth

Circuit

Fuse

Connection

Breaker

L1 L2

MintDrive

L3

PE

Circuit breaker and fuse not supplied.
For CE Compliance, see Appendix C.

Figure 5 - Circuit breaker and fuse, single phase, package size C

2

3

Earth

Circuit

Fuse

Connection

Breaker

L1 L2

L3

PE

L1 L2

L1

L2 L3

L1 L2 L3

MintDrive

Circuit breaker and fuse not supplied.
For CE Compliance, see Appendix C.

Figure 6 - Circuit breaker and fuse, three phase, package size C

Note: Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor

or RC Device does not interrupt EMI/RFI shielding. If local codes do not specify different
regulations, use the same gauge wire for Earth ground as is used for L and N.
Connect earth to the backplane of the enclosure.

13

2.3.4 Wire sizes

g

Input

W

ireG

Nominal

Continuou

s

I

Input and output wire size is based on the use of copper conductor wire rated at 167°F (75°C).
The following tables describe the wire size to be used for power connections and the ratings of the
protection devices.

Catalog Number

Nominal Continuous

Input

Voltag e

MD1A02xx-xxxx 115V (1φ) 2.5A 6 6 14 2.5

MD2A02xx-xxxx 230V (1φ) 2.5A 6 6 14 2.5

MD1A05xx-xxxx 115V (1φ) 5A 10 10 14 2.5

MD2A05xx-xxxx 230V (1φ) 5A 10 10 14 2.5

MD1A07xx-xxxx 115V (1φ) 7.5A 16 16 14 2.5

MD2A07xx-xxxx 230V (1φ) 7.5A 16 16 14 2.5

MD1A10xx-xxxx 115V (1φ) 10A 20 20 14 2.5

MD2A10xx-xxxx 230V (3φ) 10A 20 20 14 2.5

MD1A15xx-xxxx 115V (1φ) 15A 32 32 12 2.5

MD2A15xx-xxxx 230V (3φ) 15A 32 32 12 2.5

Note: All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may

be used per NEC and local codes. Recommended fuses/breakers are based on 77°F (25°C)
ambient, maximum continuous control output current and no harmonic current.

Output

Amps

(RMS)

Incoming Power

D-Type

nput

Breaker

(A)

Input
Fuse

Time

Delay

(A)

auge

AWG mm

2

14

2.3.5 Single phase connection t o package size A or B

E

L

N

Location Connector X1, single or 2-part connector

Part number MD1A... MD2A...

Input voltage 115VAC, 1φ line to neutral 230VAC, 1φ line to neutral

Range 97-125VAC 220-250VAC

Note: For single phase connection, the voltage ripple on the DC-bus is 25Vp-p for 5A (the peak

current for a 2.5A MintDrive) and 50Vp-p for 10A (the peak current for a 5A MintDrive).
This can limit the maximum speed of the motor.
Tightening torque for terminal block connections is 4.4~5.3 lbin (0.5~0.6Nm).
The threaded holes in the top and bottom of the enclosure are for cable clamps (provided).
The holes are threaded for M4 bolts no longer than 0.47” (12mm) in length. Longer bolts
may short circuit the electrical components inside the MintDrive.

2.3.6 Single phase connection t o package size C

or

E

L

N

Earth stud

Location Connector X1, single or 2-part connector

Part number MD1A... MD2A...

Input voltage 115VAC, 1φ line to neutral 230VAC, 1φ line to neutral

Range 97-125VAC 220-250VAC

Note: For single phase connection, the voltage ripple on the DC-bus is 25Vp-p for 5A (the peak

current for a 2.5A MintDrive) and 50Vp-p for 10A (the peak current for a 5A MintDrive). This
can limit the maximum speed of the motor.
Tightening torque for terminal block connections is 4.4~5.3 lbin (0.5~0.6Nm).
The threaded holes in the top and bottom of the enclosure are for cable clamps (provided).
The holes are threaded for M4 bolts no longer than 0.47” (12mm) in length. Longer bolts
may short circuit the electrical components inside the MintDrive.

15

2.3.7 Three phase connection t o package size C

or

E

L1
L2
L3

Earth stud

Note: Tightening torque for terminal block connections is 4.4~5.3 lbin (0.5~0.6Nm).

The threaded holes in the top and bottom of the enclosure are for cable clamps (provided).
The holes are threaded for M4 bolts no longer than 0.47” (12mm) in length. Longer bolts
may short circuit the electrical components inside the MintDrive.

2.3.8 24V control supply

Depending on model, a 24VDC control supply may be required to provide power to the control
electronics when power is removed from the amplifier (see page 2). This is useful for safety where
power needs to be removed from the amplifier stage but the control electronics must be powered to
retain position and I/O information. The 24VDC supply is connected via X1.

Note: A 24VDC supply is always required for the drive enable input on connector X13.

Location Connector X1, single or 2-part connector

Part number MD2A...

Input voltage 230VAC, 3φ line to line

Range 220-250VAC

16

Location

Connector X1, single or 2-part connector

Part number MDxxxxxx-xxx3

Input voltage 24V

Input current 1.6A (maximum)

Range 20.4 - 28.8VDC

+24V

GND

Note: Tightening torque for terminal block connections is 4.4~5.3 lbin (0.5~0.6Nm)

2.3.9 DC Bus p o wer conn ections from package size C

Location Connector X1, single or 2-part connector

Part number MD1AxxSx... MD2AxxSx...

To external

drive(s)

with

Vcc inputs

Output voltage 160VDC 320VDC

Range 135-176VDC 306-350VDC

The MintDrive 10A and 15A variants are available with a DC bus supply output for powering other
drives that do not have their own internal mains power supplies. This power is available on the X1
connector pins Vcc+ and Vcc-.

MintDrive

External drive

External drive

(MD1AxxSx... )

Vcc+

Vcc-

R1

R2

Vcc+

Vcc-

Vcc+

Vcc-

Vcc+

Vcc-

Vcc+

Vcc-

Regeneration

Resistor

Note: It is important to ensure that the total current required by the powering drive, the

external drive(s) and their maximum combined loads does not exceed the current
rating of the powering drive.

Tightening torque for terminal block connections is 4.4~5.3 lbin (0.5~0.6Nm).
The threaded holes in the top and bottom of the enclosure are for cable clamps (provided).
The holes are threaded for M4 bolts no longer than 0.47” (12mm) in length. Longer bolts
may short circuit the electrical components inside the MintDrive.

17

2.3.10 Power supply filters

To comply with EEC directive 89/336/EEC, a mains filter of the appropriate type must be connected.
This will ensure that the unit complies with the CE specifications for which it has been tested. If the
MintDrive has the 24VDC input power supply option then a further filter will be necessary to comply with
CE specifications. Schaffner filters are recommended, with part numbers shown below:

MintDrive current rating 2.5A FN2070-10-06 FN9675-3-06

All models FN9675-3-06

Voltag e

230VAC, 1φ 115VAC, 1φ

5A FN2070-6-06 FN2070-10-06

7.5A FN2070-10-06

(Use FN2070-12-06 if 24V
option is fitted)

230VAC, 3φ -

10A FN351-36-33 -

15A FN351-50-33 -

24VDC

FN2070-12-06

18

Table 1 - Schaffner filter part numbers

See Appendix D, section D.1.3 for details of filter dimensions and Baldor catalog numbers.

2.4 Motor connections

This section provides instructions for connecting the motor.

Location

Connector X1, single or 2-part connector

Part number MD1A... MD2A...

Nominal output voltage 160VDC 320VDC

Range 135-176VDC 306-350VDC

(MintDrive 2.5A / 5A / 7.5A

X1 connector shown)

PE

Motor

U

V

W

M

M

M

Optional

motor circuit

contactors

U

V

W

CAUTION: Do not connect power to the MintDrive UVW outputs. The MintDrive 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. Mis-connection will result in uncontrolled motor movement.

All cables must be shielded. The maximum allowable cable length is 82ft (25m).

Note: For CE compliance the MintDrive and motor earth should be connected to the enclosure

backplane. (The enclosure backplane should be connected to the earth at the mains source.
There should be a separate connection from the earth at the mains source to the plant
ground rod).

19

2.4.1 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 (see page 19).
Opening the M-Contactor ensures that the MintDrive 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 the motor. This is important with
hanging loads where disconnecting the motor windings could result in the load falling. Contact Baldor
for details on appropriate brakes.

CAUTION: If an M-Contactor is installed, the MintDrive must be disabled at least 20ms before

the M-Contactor is opened. If the M -Contactor is opened while the MintDrive is
supplying voltage and current to the motor, the MintDrive may be damaged.
Incorrect installation or failure of the M -Contactor or its wiring may result in
damage to the MintDrive.

20

2.4.2 Regeneration resistor (Dynamic Brake resistor)

320

W

The 2.5A and 5A MintDrives both have internally fitted regeneration resistors*. For 7.5A, 10A and 15A
MintDrives, an external regeneration (Dynamic Brake) resistor must be installed to dissipate excess
power from the internal DC bus during motor deceleration.

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.

MintDrive current rating 230VAC 115VAC

R1
R2

Table 2 - Baldor regeneration resistor catalog numbers

All the regeneration resistors listed in section D.1.4 on page 139 are completely assembled and
enclosed in a IP21/NEMA 1 rated enclosure.

* Additional resistors connected to R1 and R2 will be connected in parallel with the internal resistor.

2.4.2.1 Regeneration resistor mounting

The regeneration resistor should be mounted near the top of an enclosure to maximize heat dissipation.
When the motor regenerates, the yellow DB On LED on the front panel of the MintDrive will illuminate
while the voltage is exceeding the safe limit. See section D.1.4 on page 139.

Location

Connector X1, single or 2-part connector

Voltag e Resistor

7.5A RG39 RG22 100W

10A RG10 RG4.7

15A RG10 RG4.7

power rating

21

2.5 Feedback connections

Two feedback options are available; a commutating encoder or a resolver, both using connector X2.
Check with the catalog number (see page 2) to ensure you are wiring the correct feedback device.

Resolver based MintDrives provide a simulated encoder output signal available on connector X3 for
master/slave type applications. Encoder based MintDrives duplicate the encoder signals entering X2.

The following points must be observed when wiring the feedback device:

H The feedback device wiring must be separated from power wiring

H Parallel runs of the device wiring must be separated from power cables by at least 3” (76mm)

H Power wires must be crossed at right angles only

H To prevent contact with other conductors or grounds, ungrounded ends of shields must be insulated.

22

2.5.1 Resolver op t io n

The resolver connections are made using the 15-pin D-type female connector X2.
Twisted pair cables must be used for the complementary signal pairs e.g. SIN+ and SIN-.
The overall cable screen/shield must be connected to the metallic shell of the D-type connector.

Location

Connector X2, 15 -pin D -type female connector

Pin Resolver function

1 SIN+

2 COS+

3 REF+

4~5 (not connected)

6 SIN-

10

15

11

5

1

6

7 COS-

8 REF-

9~10 (not connected)

11 External index

12 (not connected)

13 Analog ground

14~15 (not connected)

Baldor

R2

R1

S2

S4

S1S3

Motor

5

6

3

+

+

Twisted pairs

4

+

1

2

Connector
backshell

X2

+

1

6

+

2

7

+

3

8

13

SIN+

SIN-

COS+

COS-

REF+

REF- (Common)

AGND

Figure 7 - Resolver cable connections

23

2.5.1.1 Resolver cable pin configuration

The table and diagram below show the pin configuration for a typical Baldor Resolver Feedback cable,
part number CBL030SF-ALM.

Signal name

REF+ 3 1 Red

REF- 8 2 Blue

COS+ 2 3 Green

COS- 7 4 Yellow

SIN+ 1 5 Pink

SIN- 6 6 Grey

1

2

3

Motor resolver connector

101112

45

(male)

89

7

6

X2

pin

Pins 7~12 are

not used

Motor / cable

pin

Cable connector end view

89

7

12

6

Resolver cable wire

color

1

2

10

11

3

45

(female)

24

Figure 8 - Baldor motor resolver cable pin configuration

2.5.2 Encoder option

X

The encoder connections are made using the 15-pin D -type female connector X2. This provides the
ABZ channels and Hall signals. Twisted pair cables must be used for the complementary signal pairs
e.g. CHA+ and CHA -. The overall cable screen/shield must be connected to the metallic shell of the
D-type connector.

15

11

Encoder

Location

Connector X2, 15 -pin D -type female connector

Pin Encoder function

1 CHA+

2 CHB+

3 CHZ+

4 Hall U+

5 Hall U-

10

5

6 CHA-

7 CHB-

8 CHZ-

1

6

9 Hall W+

10 Hall V+

11 +5V

12 (not connected)

13 DGND

14 Hall W-

15 Hall V-

Twist ed p ai rs

2

CHA+

1
6

CHA­CHB+

2

CHB-

7

CHZ+ (INDEX)

3

CHZ- (INDEX)

8

11

+5V
DGND

13

4

Hall U+

5

Hall U-

9

Hall

Feedback

Connector backshell

Hall W+

14

Hall W­Hall V+

10

Hall V-

15
12 Not Used

Figure 9 - Encoder cable connections

25

2.6 Drive enable

To operate the MintDrive, the drive stage must be active and enabled. This requires an externally
generated 24VDC supply to be connected between pins 1 and 12. This 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 1, with the signal to pin 12 being hard -wired.

1

Note: The drive enable connection controls the s ense of the digital inputs

12

Location

Name Drive enable

Input voltage +24VDC (±20%)

DIN10 to DIN17 (see pages 35 to 37).

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 1 and
0V to pin 12.
Active low: To cause the digital inputs to be active low (active when
grounded) connect +24VDC to pin12 and 0V to pin 1.

The sense of the digital inputs can also be controlled through the Mint
software, using the keyword INPUTACTIVELEVEL.
For the drive to operate, it must be enabled using the Mint keyword
DRIVEENABLE or RESET.

Connector X13, pins 1 & 12

26

This completes the basic installation.

You should read the following sections in sequence before

attempting to start the MintDrive.

3.1 Outline

This section describes the various digital and analog input and output capabilities of the MintDrive,
together with descriptions of each of the associated 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........

3.2 Analog I/O

The MintDrive provides:

H 4 analog inputs, 2 on the block connector X11 and 2 on the 25 -pin D -type connector X5

H 4 analog outputs, 2 on the block connector X11 and 2 on the 25 -pin D -type connector X5.

3 Input / Output

3

None of the analog I/O are optically isolated from internal generated power rails, therefore care must be
taken to avoid earth loops and similar associated problems.
The input buffers do not offer any low pass filtering of the applied voltage. Any system noise presented
at the input will be reflected in the value read on conversion. Therefore, each analog input signal
should be connected to the system using individual screened/shielded cable (a twisted pair cable in the
case of the differential inputs) with an overall s hield in order to minimize these effects. The overall cable
shield should then be connected to the chassis at one end. No other connection should be made to the
cable shield. If any inputs are unused, then it is advisable to connect them to the AGND pin. Do not
leave the inputs unconnected (floating).

27

3.2.1 Analog Input, Single Ended - X11

1

2

Location Connector X11, pins 1 & 2

Name AIN2

Mint keyword ADC.2

Description Single ended input.

Range: 0 - ±10VDC.
Resolution: 9-bit with sign.
Input impedance: >4kΩ.
Sampling interval: 5ms.

Note: There is a +15V reference voltage supplied on X11 pin 3 from a 1.96kΩ resistor.

A linear command potentiometer of 5kΩ may be used, with X11 pin 2 connected to the wiper,
and the end terminations connected to pins 1 & 3, as shown below.

X11

5kΩ, 0.25W

potentiometer

or 0-10VDC

GND

Input

Reference

1

2

AIN2

(ADC.2)

3

28

Figure 10 - AIN2 analog input wiring

3.2.2 Analog Input, Differential - X11

Location Connector X11, pins 4 (+) & 5 (-)

Name AIN3

4

5

Description Differential input.

A typical input circuit is shown below:

+24VDC

1.5kΩ, 0.25W

1kΩ, 0.25W

potentiometer

0V

Mint keyword ADC.3

Common mode voltage range: ±10VDC.
Resolution: auto-selecting as follows:

12-bit with sign (<1V DC input)

9-bit with sign (>1V DC input)
Common mode rejection: 40dB
Input impedance: >5kΩ
Sampling interval: 5ms
Optional 4-20mA current mode (contact Baldor).

X11

Input+

Input-

4

AIN3

(ADC.3)

5

Figure 11 - AIN3 analog input

29

3.2.3 Analog Inputs, Differential - X5

Location Connector X5

Pins 8 (+) and 21 (-) 9 (+) and 22 (-)

Name AIN0 AIN1

Mint keyword ADC.0 ADC.1

Description Two independent differential inputs.

1

14

Common mode voltage range: ±10VDC.
Resolution: 12-bit with sign.
Common mode rejection: 40dB
Input impedance: >22kΩ
Sampling interval: 0.5ms - 20ms (depends upon servo
loop frequency).
Accuracy: better than 1%

13

25

Typical use for these may be analog sensor inputs or to provide a low cost joy -stick interface.
The guaranteed DC accuracy of the inputs is 2%. Each input is buffered individually, before being fed
into separate channels of the ADC, a Maxim MAX197. There is some input protection should the input
voltage exceed the maximum rating shown above, although this is for protection against transitional
over-voltage; long term over-voltages will cause permanent damage.
Each analog input signal should be connected to the system using a screened/shielded twisted pair
cable, and the cable s hield should be connected to the chassis at one end. Due to the differential
characteristics of these inputs, they can provide better rejection of common mode noise provided
normal good engineering practices are adhered to. No other connection should be made to the cable
shield.

Input +

Input -

GND

X5

21

20

8

AIN0 (ADC.0)

Input +

Input -

GND

X5

22

20

9

AIN1 (ADC.1)

30

Figure 12 - AIN0 and AIN1 analog inputs

If an input is unused, then it is advisable to connect it to the AGND pin. Do not leave the input
unconnected (floating).
The analog inputs can be read in Mint using the keywords ADC.0 and ADC.1. Mint will return the value
as a percentage where 0V=0%, -10V= -100% and +10V = 100%.

CAUTION: The isolation provided on the inputs, outputs, master encoder and CAN is

nominal. The primary function of the isolation is to break earth loops. Both sides
of the isolation boundary must still be kept at SELV potentials with respect to
ground, i.e. the difference in the 0V rail across the isolation boundary must not
exceed 30V.

31

3.2.4 Analog Outputs, Bipolar - X11

Location Connector X11

Pins 6 7

Name AOUT2 AOUT3

Mint keyword AUXDAC.2 AUXDAC.3

6

7

Two programmable analog outputs that can be used to provide real time status of various control
conditions. The voltage from the output buffer is supplied through a 50Ω resistor for short circuit
protection.

Description Two independent assignable outputs.

GND

Output range: ±10VDC.
Resolution: 8-bit with sign.
Output current: 1mA ma x imum.
Update interval: 2ms.

X11

1

32

Output 2

Output 3

6

7

AOUT2

AOUT3

(AUXDAC.2)

(AUXDAC.3)

Figure 13 - AOUT2 and AOUT3 analog outputs

CAUTION: Following power-up or a system reset, both outputs will initially be set at

approximately +10V. This condition will remain, for a short period, during the
software initialization process. For this reason, care should be taken if this output
is being used as a drive reference for a speed controller.

3.2.5 Analog Outputs, Bipolar - X5

Location Connector X5

Pins 19 7

Name AOUT0 AOUT1

Mint keyword AUXDAC.0 AUXDAC.1

Description Two independently controlled outputs.

Output range: ±10VDC.
Resolution: 8-bit
Output current: ±4mA maximum
Update interval: immediate, using Mint commands

1

13

14

25

The two analog 8 -bit outputs AOUT0 and AOUT1 are not isolated and are primarily intended for system
debugging. Output voltages in the range of ±10V are achievable with a DC accuracy of better than 3%.
They are derived from a high-frequency PWM pulse train from the main processor, which is
subsequently filtered. These signals are buffered by an operational amplifier in the MintDrive and are
capable of sinking or sourcing up to ±4mA. The outputs are protected by fast Schottky diodes against
excessively high transitional voltages of either polarity.

X5

Output 0

Output 1

GND

19

20

7

AOUT0

AOUT1

(AUXDAC.0)

(AUXDAC.1)

Figure 14 - AOUT0 and AOUT1 analog outputs

CAUTION: Following power-up or a system reset, both outputs will initially be set at

approximately +10V. This condition will remain, for a short period of time during
the software initialization process.

33

3.3 Digital I/O

The MintDrive provides:

H 8 general purpose inputs on block connector X13

H 4 general purpose outputs on block connector X13

H 10 general purpose inputs on 25-pin connector X5

H 5 general purpose outputs on 25-pin connector X5

A digital input can be used to support any of the following typical functions:

H Stop input

H Home input

H Forward limit

H Reverse limit

H Interrupts (controlled from Mint)

H General purpose use

DIN0 and DIN2 are also capable of special alternative functions:

H DIN0 and DIN2 are fitted with Schmitt trigger devices and can be configured using Mint for position

capture of the axis or the master or auxiliary encoder positions. See section 3.3.2.1 on page 38.

The following sections describe the digital I/O in more detail.

34

3.3.1 Digital Inputs - X13

1

9

The digital inputs DIN10 - DIN17 can be read individually using the associated Mint IN keyword (for
example IN.10) and can be configured for any number of user definable functions. These inputs are
sampled every 15.36ms. If a faster response is required, DIN0~DIN9 on connector X5 c an be used.

Each of the AC optically isolated digital inputs has one side connected internally via a current limiting
resistor to the signal on pin 12, CREF. The other side appears as a separate pin on connector X13, for
use by the end user.

External +24VDC supply

Active high: A=+24VDC

Active low: A=0V

Location Connector X13

Pin Name Mint keyword

1 Drive Enable -

2 DIN10 IN.10

3 DIN11 IN.11

4 DIN12 IN.12

5 DIN13 IN.13

6 DIN14 IN.14

7 DIN15 IN.15

8 DIN16 IN.16

9 DIN17 IN.17

Description Eight general purpose optically isolated AC digital inputs

(DIN10 to DIN17).
One committed drive enable input (Drive Enable).

X13

1

Enable

2

DIN10 (IN.10)

3

DIN11 (IN.11)

4

DIN12 (IN.12)

5

DIN13 (IN.13)

6

DIN14 (IN.14)

7

DIN15 (IN.15)

8

DIN16 (IN.16)

9

DIN17 (IN.17)

10

B=0V

B=+24VDC

A

B

(not connected)

11

(not connected)

12

CREF

Figure 15 - X13 Digital inputs

35

Pin 12 (CREF) controls the sense of all the digital inputs (X13 pins 1 to 9) and should be permanently
wired, dependent on the user requirements, as described below:

Active high: c onnect +24VDC to pin1 and 0V to pin 12.
The digital inputs will be active when a voltage of +24VDC (±20%) is applied to them and will sink a
maximum of 20mA.
Active low: connect +24VDC to pin12 and 0V to pin 1.
The digital inputs will be active when grounded and will source a maximum of 20mA.

The +24VDC supply mentioned above is from an externally generated 24VDC supply which should
have a current capability of at least 3A to fulfill all the current requirements of the above loads.

The sense of the inputs can also be controlled individually in Mint using the keyword
INPUTACTIVELEVEL. See also section 2.6 on page 26.

3.3.1.1 Thermal switch connection

It is recommended to wire the motor’s thermal switch, via a relay, to an input on connector X13.
Using suitable code, this provides a way for the Mint program to respond to motor overtemperature
conditions. A typical circuit, using DIN11 as the input, is shown below.

B

A

Motor

thermal switch

connections

Relay

+24VDC 0V

External

24VDC

supply

X13

1
2
3
4
5
6
7
8

9

12

DIN10 (IN.10)
DIN11 (IN.11)
DIN12 (IN.12)
DIN13 (IN.13)
DIN14 (IN.14)
DIN15 (IN.15)
DIN16 (IN.16)
DIN17 (IN.17)

CREF

36

Figure 16 - Motor thermal switch circuit

3.3.2 Digital Inputs - X5

X

Location Connector X5

Pin Name Mint keyword

1 DIN0 IN.0

2 DIN2 IN.2

3 DIN4 IN.4

4 DIN6 IN.6

5 DIN8 IN.8

1

14

14 DIN1 IN.1

15 DIN3 IN.3

16 DIN5 IN.5

17 DIN7 IN.7

13

25

Description Ten general purpose optically isolated AC digital inputs

18 DIN9 IN.9

(DIN0toDIN9).

The digital inputs DIN0 - DIN9 can be read individually using the associated Mint IN keyword (for
example IN.0) and can be configured for any number of user definable functions. These inputs are
sampled every servo loop (0.5ms to 2ms).

External +24VDC

supply

Active high: A=+24VDC

B=0V

Active low: A=0V

B=+24VDC

A

B

5

1
2
3
4
5
6
14
15
16
17
18

DIN0 (IN.0)
DIN2 (IN.2)
DIN4 (IN.4)
DIN6 (IN.6)
DIN8 (IN.8)

COM
DIN1 (IN.1)
DIN3 (IN.3)
DIN5 (IN.5)
DIN7 (IN.7)
DIN9 (IN.9)

Figure 17 - X5 Digital inputs

37

These inputs are isolated and share a single common line (COM). The entire input bank may be
configured for use in PNP mode (sinking current, where current flows in to the inputs) by connecting
COM to the negative rail of the externally generated power source. Alternatively the entire input bank
may be configured for use in NPN mode (current flows out of the inputs) sourcing current by connecting
COM to the positive rail of the externally generated power source.

The use of screened/shielded cable with the screen terminated on the D-shell is highly recommended
and will improve the inputs’ immunity to interference.

COM (pin 6) controls the sense of all the X5 digital inputs and should be permanently wired, dependent
on the user requirements, as described below:

Active high: Connect pin 6 to 0V.
The digital inputs will be active when a voltage of +24VDC (+10VDC to +30VDC) is applied to them and
will sink a maximum of 20mA.
Active low: Connect pin 6 to +24VDC.
The digital inputs will be active when grounded (less than 2VDC) and will source a maximum of 20mA.
(To eliminate any possible errors, designs should ideally provide a “grounded” voltage of less than 1V).

The +24VDC supply mentioned above is from an externally generated 24VDC supply with an adequate
current capability to fulfill all the current requirements of the above loads. The sense of the inputs can
also be controlled individually in Mint using the keyword INPUTACTIVELEVEL.

The inputs are compatible with mechanical switches or open-collector drivers. They are not, however,
compatible with external push-pull drivers unless an external diode is fitted, which effectively converts a
push-pull driver into an open collector driver.

There is a hardware propagation delay of 10µs or less between applying an external voltage and the
switch becoming active (ON). Similarly, there is a delay of 50µs or less for the device to switch OFF
when removing an external voltage.

3.3.2.1 Special functions on inputs DIN0 and DIN2

DIN0 and DIN2 can be configured using the FASTAUXSELECT keyword to perform special functions:

Input

Function

DIN0 Configurable as the fast interrupt (FASTIN) hardware position capture input. The

position of the axis is captured in real time and can be read using the Mint keyword
FASTPOS. DIN0 can also be configured to capture the auxiliary encoder input as well
as the axis position input. Fitted with a Schmitt trigger device.

DIN2 Similar to DIN0, but captures the master or auxiliary encoder input which can be

read using the Mint FASTAUXENCODER keyword.
Fitted with a Schmitt Trigger device.

3.3.2.2 Breakout board

Connector X5 can also be connected to an I/O supporting break-out board (giving screw-terminal type
connections and local filtering). The Baldor catalog number for this item is OPT017-501. See page 48.

38

3.3.3 Digital Outpu ts - X13

13

Location Connector X13

Pin Name Mint keyword

13 DOUT5- OUT.5

14 DOUT5+ OUT.5

15 DOUT6- OUT.6

16 DOUT6+ OUT.6

17 DOUT7- OUT.7

18 DOUT7+ OUT.7

19 DOUT8- OUT.8

20 DOUT8+ OUT.8

20

Description Four general purpose optically isolated digital outputs

(DOUT5 to DOUT8).

Each optically isolated output may be configured for either sinking or sourcing current up to a maximum
of 50mA on each output. The maximum saturated voltage across any of these outputs when active is

1.0VDC, so they can be used as TTL compatible outputs. These outputs can have a mixed
configuration, with some sinking current while others source current. However, 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 ensure that an output is protected from the back-EMF generated from the coil
when it is de-energized. The outputs are updated every 30.72ms and can be written to directly using
the Mint keyword OUT (for example OUT.5). If a faster response is required, DOUT0~DOUT4 on
connector X5 can be used.

Sink

Source

50mA

maximum

Typ ic al

50mA

maximum

DOUT+

DOUT-

DOUT+

Relay &
Flyback diode

USR V+

USR GND

USR V+

X13

13
14
15
16
17
18
19
20

DOUT5­DOUT5+
DOUT6­DOUT6+
DOUT7­DOUT7+
DOUT8­DOUT8+

OUT.5

OUT.6

OUT.7

OUT.8

Typ ic al

DOUT-

USR GND

Figure 18 - X13 Digital output circuit

39

3.3.4 Digital Outpu ts - X5

Location Connector X5

Pin Name Mint keyword

10 DOUT4 OUT.4

11 DOUT2 OUT.2

12 DOUT0 OUT.0

23 DOUT3 OUT.3

24 DOUT1 OUT.1

1

13

OUT.4

Description Five general purpose optically isolated digital outputs

14

(DOUT0 to DOUT4).

These general purpose optically isolated outputs can only be used to source
current from the USR V+ rail (pin 25). The output current source passes
through the load to USR GND (pin 13). The outputs are updated immediately
andcanbewrittentodirectlyusingtheMintkeywordOUT (for example OUT.4).

25

Note: The outputs have different current ratings!

DOUT0 is a high current output, rated at a maximum continuous current of 1A.
DOUT1~DOUT3 are lower current outputs, rated at a maximum continuous
current of 250mA on each output. There is no minimum current load
requirement for DOUT0~DOUT4.

D

S

VN330SP

output

driver

X5--25

X5--10

X5--13

USR V+

(250mA max)

Relay coil with
flyback diode

USR GND

X5

10

DOUT4 (OUT.4)
DOUT2 (OUT.2)

11

DOUT0 (OUT.0)

12

USR GND

13

DOUT3 (OUT.3)

23

DOUT1 (OUT.1)

24

USR V+

25

Figure 19 - X5 Digital output circuit

40

These MOSFET type outputs are driven from ST VN330SP devices and have a maximum ON
resistance of 0.4Ω. There are protection features built into each of the outputs. Under voltage sensing
means that when a USR V+ voltage of less than 10V is applied, the output will become inactive.
Thermal protection, for short circuit and over dissipation, also causes the output to become inactive.
If the combined current of all the X5 outputs exceeds 5A, there is the possibility of blowing an internal
SMD fuse, which is not easily replaceable and is non-serviceable. If a hardware fault is suspected on
these outputs, the condition can be checked (by the user’s program) using the Mint keyword
MISCERROR. If the outputs are used to directly drive a relay or an inductive load, a suitably rated flyback
diode must

be fitted across the relay coil, observing the correct polarity. This is to ensure that an output

is protected from the back-EMF generated from the coil when it is de-energized.

3.4 Other I/O

3.4.1 Simulated encod er output - X3

Location Connector X3

9

6

This output can be used for master slave situations where the axis movement can be transmitted to
another controller or MintDrive. It is recommended that this output only drives one output circuit load.
Driving multiple loads is not recommended. The encoder outputs are differential and conform to the
RS422 electrical specification. Shielded twisted pair cable is recommended.
If a resolver is fitted to the MintDrive, the output resolution is 1024 ppr (pulses per revolution). This is
equivalent to a 1024 line encoder, giving 4096 quadrature counts per rev. The simulated encoder also
supports an index or marker pulse.
If the MintDrive has the encoder feedback option, X3 duplicates the encoder signals entering X2

5

1

Description Simulated encoder output on a 9-pin female D -type

Pin Name

1 CHA+

2 CHB+

3 CHZ+

4 (not connected)

5 DGND

6 CHA-

7 CHB-

8 CHZ-

9 (not connected)

connector

.

CAUTION: Using connectors X3 and X6, multiple MintDrives can be ‘daisy-chained‘ together.

However, if another Mint based controller such as a NextMoveBX is to be
connected, a s pecial cable must be built, as shown below:

MintDrive

X3

1
6
3

8

2
7
5

Connector backshell

Figure 20 - MintDrive encoder output to other Mint controller encoder input

NextMoveBX

encoder input

5
9

2
6

8
3

7

41

3.4.2 Master (auxiliary) encoder input - X6

Location Connector X6

Pin Name

1 CHA+

2 CHB+

3 CHZ+

4 (not connected)

5 DGND

9

5

6 CHA-

7 CHB-

6

1

8 CHZ-

9 +5V

Description Optically isolated encoder input on a 9-pin female

D-type connector

The MintDrive provides an auxiliary (master or handwheel) encoder input which allows following of a
master encoder. An interface for a three channel, incremental encoder (CHA, CHB, CHZ) is provided.
The input receiver circuit allows only encoders with differential line drivers (RS422) to be used.
Single-ended operation is not supported. The interface also provides an isolated 5V supply for the
encoder electronics, capable of driving up to 100mA. These inputs are sampled every 0.5, 1 or 2ms.

CAUTION: The auxiliary encoder input does not conform to the standard on other Mint based

controllers such as NextMove.

Twisted pairs

Encoder

X6

CHA+

1

CHA--

6

CHB+

2

CHB--

7
3

CHZ+

8

CHZ--

9

+5V

5

DGND

42

Connector backshell

Figure 21 - Differential encoder connections

Connection of shields
to digital ground is optional.

Figure 22 - Auxiliary encoder circuit

43

3.4.3 Serial port - X7

6

9

X7 is a 9-pin male D-type connector, for the single MintDrive serial port.
The four-wire RS485 connections are also available on the this connector. See pages 45 and 46.
This port is configurable as either RS232 or RS485 / RS422 or both. Both X7 options are fully ESD
protected to IEC 1000-4-2 (15kV). Neither is isolated.

1

5

Location Connector X7

Pin RS232 Name RS485 / RS422 name

1 - RX+ (input)

2 RXD -

3 TXD -

4 - TX+ (output)

5 0V GND 0V GND

6 - RX- (input)

7 RTS -

8 CTS -

9 - TX- (output)

Description RS232 and RS485 / RS422 connections on a single

9-pin female D-type connector

44

3.4.4 Using RS232 cable

CAUTION: The serial connector on the MintDrive (X7) supports two serial channels, one

RS232 and one RS485 / RS422. The serial cable with catalog number
CBL001-501 must NOT be used with the MintDrive as this may result in damage
to the unit. Please use serial cable CBL023-501 or see this section for wiring
details.

The MintDrive has a full-duplex RS232 serial port with the following default 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

The MintDrive will transmit a line feed/carriage return (<LF><CR>) combination but only expects a
carriage return (<CR>) from the host terminal. The RS232 connections are brought out onto a 9-pin
male D-type connector (an identical pin configuration as a standard male 9-pin D-type connector, but
RS485 / RS422 signals are also taken to the unused pins). The RS232 port is configured as a DTE
(Data Terminal Equipment) unit so it is possible to operate the MintDrive with any DCE (Data
Communications Equipment) or DTE equipment. Both the output and input circuitry are single ended
and operate between ±12V. The port is capable of operation at up to 57.6Kbaud.

X7

RXD 2

MintDrive

(DCE)

TXD 3
RTS 7

CTS 8

GND 5

Connector
backshell

Figure 23 - RS232 serial port connections

Connector

backshell

COM

2RXD

3TXD
7RTS

8CTS

5GND

Computer
COM Port

(DTE)

45

3.4.5 Multidrop using RS485 / RS422 cable

Master

Controller

TX+

TX- 6RX-

RX+

RX-

T

DGND

Terminating resistors T
each have a typical value of 120Ω

R

Twisted pairs

R

Figure 24 - 4-wire RS485 multi-drop connections

ON

The MintDrive at the furthest end of the network from the transmitter should have
its RS485 DIP switch (located on the front panel of the MintDrive) set to the ’On’
position. This will connect a termination resistor, used to match the impedance of
the load to the impedance of the transmission line (cable).

MintDrive X7

1RX+

4TX+

9TX-

5DGND

GND

MintDrive X7

1RX+

T

R

6RX-

4TX+

9TX-

5DGND

GND

46

Each TX/RX network requires a termination resistor at the final RX connnection, but intermediate
devices must not be fitted with termination resistors. (An exception to this rule is where repeaters are
being used which may correctly contain termination resistors).

Unmatched impedance causes the transmitted signal to not be fully absorbed by the load. This causes
a portion of the signal to be reflected back into the transmission line (noise). If the Source impedance,
Transmission Line impedance, and Load impedance are all equal, these reflections (noise) are
eliminated. Termination does increase load current and sometimes changes the bias requirements and
increases the complexity of the system.

3.4.6 Connecting Baldor HMI Operator Panels

Baldor HMI Operator Panels use a 15-pin male D-type connector (marked PLC PORT), but the
MintDrive connector X7 is a 9-pin D-type connector. If you do not require hardware handshaking then
the following connections should be made:

Baldor HMI

PLC PORT

RXD 2

TXD 3

GND 5

1

MintDrive

X7

7RTS

8CTS

3TXD

2RXD

5GND

Figure 25 - Cable wiring if hardware handshaking is not required

If hardware handshaking is required then the following connections should be made:

Baldor HMI

PLC PORT

CTS 11

RTS 10

RXD 2

TXD 3

GND 5

1

MintDrive

X7

7RTS

8CTS

3TXD

2RXD

5GND

Figure 26 - Cable wiring if hardware handshaking is required

47

3.4.7 Optional breakout board for connector X5

An optional screw connection fitting is available should you wish to purchase a break-out board. The
break-out board, often referred to as a ’card’, mounts on a 35mm DIN rail. The board has two-part
screw terminals for all of the digital inputs, digital outputs, analog inputs and analog outputs of the
MintDrive’s X5 connector, together with indicator LEDs.

Figure 27 - Optional breakout board

The catalog number for the breakout board is OPT017-501. A 2m (6ft) cable is available with correctly
shielded cables (catalog number CBL022-501).

3.4.8 CAN peripherals

If you wish to make connections to a CAN network see Appendix B, before continuing with section 4.

This completes the input/output wiring.

You should read the following sections in sequence before

48

attempting to start the MintDrive.

4 T uning and Configuration

4.1 Outline

Before powering the MintDrive you will need to connect the PC to the MintDrive using a serial cable and
install the supplied software on the PC. The software provided includes a number of applications and
utilities to allow you to configure, tune and program the MintDrive. If you do not have experience of
software installation or Windows applications you will need to seek further assistance for this stage of
the installation. Please see the hardware section on page 5 to check that you have a suitable PC.

4.1.1 Connecting the MintDrive to the PC

Connect the serial cable between the PC serial port (often labeled as “COM”) to the MintDrive
connector X7 (RS232/RS485).

CAUTION: The serial connector on the MintDrive (X7) supports two serial channels, one

RS232 and one RS485. The serial cable with catalog number CBL001-501 must
not be used with the MintDrive as this may result in damage to the unit.
Please use serial cable CBL023 -501 or see pages 44 and 45.
If this is the first time you are installing a MintDrive then it is strongly
recommended that you use RS232 to get started and use RS485 later.

4

4.1.2 Installing the software

The CDROM containing the software can be found inside the rear cover of this manual or 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:\setup

where d is the drive letter of the CD-ROM device.

Follow the on-screen instructions to installthe Mint Configuration Tool and Mint Workbench. The set-up
Wizard will copy the files to appropriate folders on the hard drive. The default directory is C:\Mint v4,
although this can be changed during setup.

49

4.1.3 Starting the MintDrive

If you have followed the instructions in the previous sections, you should now have connected all the
power sources, your choice of I/O peripherals, CAN network connections (if required) and the serial
cable linking the PC with the MintDrive. It is advisable to check all of these connections before
proceeding.

You are now ready to power the MintDrive:

1. Turn on the mains supply.

2. If your MintDrive has an external 24VDC logic supply, turn this on.

The MintDrive’s Ready LED should be orange -green.

Note: If the Ready LED is red after powering the unit, turn off the power immediately.

This indicates that the drive has detected a fault - see section 7.1.3 on page 87.
If this is a severe error condition such as under or over-voltage the unit could be damaged.
Re-check the wiring in accordance with section 2.3 on page 10.
Power the unit again; if the Ready LED is still red then see the troubleshooting guide starting
on page 85.

3. After a couple of seconds theReady LED should turngreen andthe Monitor LED should display aminus
sign (

- ). If no LEDs are lit then re-check the power supply connections.

Both CAN LEDs shouldbe green,but ifyour MintDriveis configured as node 1 and no CANopen devices
are attached, the CAN1 LED will be red.

50

4.2 Mint Configuration Tool Startup Wizard - coarse tuning

Each type of motor and drive combination has a slightly different response. Before the MintDrive can be
used to control the motor accurately, the MintDrive must be “tuned”. This is the process where the
MintDrive powers the motor using a pre-defined set of moves. By monitoring the feedback from the
motor’s resolver or encoder, the MintDrive can make small adjustments to the way it controls the motor.
This information can then be stored in a configuration file, together with other information.

The Mint Configuration Tool (MCT) provides a simple way to tune the MintDrive and create the
configuration file, so this is the first application that should be used.

1. On the Windows Start menu,

select Programs, Mint v4,
Mint Configuration Tool.

The MCT will start and the
Startup Wizard Introduction
window will be shown.

2. Click Next > .
If you wish to enter some details
about the configuration, click in
the appropriate text boxes and
enter the information. You can
leave any or all of the boxes
blank if you wish.

51

3. Click Next > .
MCT will searchthe serial ports onthe PCuntil the MintDrive
is detected.
If the MintDrive is not found, check the serial connection and
click Rescan.

4. Click Next > .

Check that Axis-0 is highlighted.

Note: If you need to change the configuration, click on the

highlighted line to display the Axis Configuration dialog.

52

5. Click Next > .
The Wizard Axes Scale Parameterswindow allows you to setup
a scaling factor for later use when controlling the MintDrive.

Select Counts per revolution in the Scale to box.
This means that references to movement can be expressed in
revolutions, rather than encoder counts.

Note: Mint defines all positional and speed related motion

keywords in terms of encoder quadrature counts (for
servo motors) or steps for stepper motors. The scale
factor allows the system to be scaled to your own units
(called user units) to suit your application.
With a resolver or 1024 line encoder, a scale factor of
4096 gives a user unit of revolutions.

Note: Even though you may have a MintDrive with the resolver

option fitted, the input from the resolver is converted into
simulated encoder counts inside the MintDrive.

6. Click Next > .

The Axis Configuration Test Select frame provides two options.

Click PERFORM AXES CONFIGURATION TESTS.

The axis configuration tests allows MCT to tune the MintDrive
for use with the attached motor.

7. Using the drop-down boxes, select the exact motor
type. This information can be found stamped into the
label attached to the motor.

Important Note:
The following axis configuration tests must be
performed with the motor mechanically
disconnected from other machinery. The tests will
cause movement of the motor, so ensure that it is
safe for the motor to operate.

If it is safe for the motor to rotate, click
Coarse Tune Motor Parameters .

Click OK to confirm that you wish to begin the tests. MCT will begin the motor tests.

8. For the final test, the load should be connected to the motor.

Ensure that it is safe for the motor to operate when connected to the load.

If it is safe for the motor to operate, click OK. MCT will perform the final test.

9. Click Next > to continue with the tuning process.

Note: If an error occurs during any of the tests, an error number will appear on the error button at

the top of the window:

Click the button to see details of the error. When you have fixed the error, click Clear Errors
and then Coarse Tune Motor Parameters to restart the tests.

53

4.3 MCT Startup Wizard - fine-tuning

In the previous section, the motor response was ‘coarse tuned’. The following sections describe how to
fine tune the motor response. If you are familiar with closed loop servo control theory then you may
wish to proceed straight to section 4.3.2. If not, the following section provides an introduction to the
various factors involved, with simple analogies shown with [italics].

4.3.1 An introduction to closed loop control

When a demand is made to move the axis position, the MintDrive control software translates this into
motor currents. An encoder or resolver is used to measure the motor position, and every 1ms* the
MintDrive compares the demanded and measured positions and calculates the demand needed for the
motor to minimize the difference, the following error.
This system of constant measurement and correction is known as closed loop control.
[ For the analogy, imagine you are in your car waiting at an intersection. You are going to go straight on

when the lights change, just like the car standing next to you which is called Demand. You’re not going
to race Demand though - your job as the controller (MintDrive) is to stay exactly level with Demand,
looking out of the window to measure your position ].

The main term that the MintDrive uses to correct the error is called Proportional gain (KPROP).
A very simple proportional controller would s imply multiply the amount of error by the Proportional gain
and apply the result to the motor [ the further Demand gets ahead or behind you, the more you press or
release the gas pedal ].

If the Proportional gain is set too high overshoot will occur, resulting in the motor vibrating back and
forth around the desired position before it settles [ you press the gas pedal so hard you go right past
Demand. To try and stay level you ease off the gas, but end up falling behind a little. You keep

repeating this and after a few tries you end up level with Demand, travelling at a steady speed. This is
what you wanted to do but it has taken you a long time ].
If the Proportional gain is increased still further, the system becomes unstable [ you keep pressing and
then letting off the gas pedal so hard you never travel at a steady speed ].

54

To reduce the onset of instability, a term called Velocity Feedback gain (KVEL) is used. This resists
rapid movement of the motor and allows the Proportional gain to be set higher before vibration starts.
Another term called Derivative gain (KDERIV) can also be used to give a similar effect.

With Proportional gain and Velocity Feedback gain (or Derivative gain) it is possible for a motor to come
toastopwithasmallfollowingerror[Demandstopped so you stopped too, but not quite level ].
The MintDrive tries to correct the error, but because the error is so small the amount of torque
demanded might not be enough to overcome friction.

This problem is overcome by using a term called Integral gain (KINT). This sums the error over time,
so that the motor torque is gradually increased until the positional error is reduced to zero [ like a person
gradually pushing harder and harder on your car until they’ve pushed it level with Demand].
However, if there is large load on the motor (it is supporting a heavy suspended weight for example), it
is possible for the output to increase to 100% demand. This effect can be limited using the KINTLIMIT
keyword which limits the effect of KINT to a given percentage of the demand output. Another keyword
called KINTMODE can even turn off integral action when it’s not needed.

The final term to consider is Velocity Feed forward (KVELFF)whichcanbeusedtoincreasethe
response and reduce the following error, especially with velocity controlled servos.

In summary, the following rules can be used as a guide:

H KPROP: Increasing KPROP will speed up the response and reduce the effect of disturbances and

load variations. The side effect of increasing KPROP is that it also increases the overshoot, and if
set too high it will cause the system to become unstable. The aim is to set the Proportional gain as
high as possible without getting overshoot, instability or hunting on an encoder edge when
stationary (the motor will buzz).

H KVEL: This gain has a damping effect, and can be increased to reduce any overshoot. If KVEL

becomes too large it will amplify any noise on the velocity measurement and introduce osc illations.

H KINT: This gain has a de-stabilizing effect, but a small amount can be used to reduce any steady

state errors. By default, KINTMODE is set s o that the KINT term is ignored.

H KINTLIMIT: The integration limit determines the maximum value of the effect of integral action.

This is specified as a percentage of the full scale demand.

H KVELFF: This is a feed forward term and as such has a different effect on the servo system than the

previous gains. KVELFF is outside the closed loop and therefore does not have an effect on
system stability. This gain allows a faster response to demand speed changes with lower following
errors, for example you would increase KVELFF to reduce the following error during the slew
section of a trapezoidal move. The trapezoidal test move can be used to fine-tune this gain.

H KDERIV: This gain has a damping effect. The Derivative action has the same effect as the velocity

feedback if the velocity feedback and feedforward terms are equal, but scaled by a factor of 16.

In systems where precise positioning accuracy is required, it is often necessary to position within one
encoder count. Proportional gain, KPROP, is not normally able to achieve this because a very small
following error will only produce a small demand for the amplifier which may not be enough to overcome
mechanical friction (this is particularly so for current controlled systems). This error can be overcome
by applying some Integral gain.
The Integral gain, KINT, works by accumulating following error over time to produce a demand
sufficient to move the motor into the zero following error position. KINT can therefore also overcome
errors caused by gravitational effects, such as vertically moving linear tables, where with current
controlled drives a non -zero demand output is required to achieve zero following error.

For further details see Appendix A.

* The 1ms sampling interval can be changed using the LOOPTIME keyword.

55

4.3.2 Fine-tuning the speed loop

Before selecting the servo (position) loop gains, the speed loop gains might need to be fine tuned.

Note: MCT will have created starting values for the speed loop gains, so if you are not sure

which values to adjust, you can go straight to section 4.3.3 on page 57.

If you wish to change any of the speed loop gains:

1. Click the Speed Loop Tuning tab

2. The Speed Loop Tuning Parameters frame shows the
values of the terms.

3. MCT will have calculated suitable values during the
coarse tuning tests. However, in some systems you
may achieve better results using the theoretical
valueforKIPROP.Todothis,click<-Calculate.
The Calculate Current Proportional Gain dialog box
will appear.

56

Click Use this value to use the theoretical value.

The following information should be considered if you change any of the speed loop parameters.

The value for Current Integral gain (KIINT) is preset to 50Hz. This setting is suitable for almost every
system and should not need be changed.
The value for Speed Proportional gain (KVPROP) is set to a default value of 4. This gain may be
increased or decreased to suit the application. Increasing KVPROP will result in a faster response, but
excessive values will cause overshoot and oscillation.
The value for Speed Integral gain (KVINT) is set to a default value of 1 and should not be adjusted
unless you are an experienced user.
The value for Speed Differential gain (KVDIFF) has no effect on the MintDrive.

4.3.3 Fine-tuning the position loop

The following tuning methods involve adjusting the servo loop terms KVELFF, KPROP, KVEL and
KDERIV, which all have a default value of zero.

1. Click the Position Loop Tuning tab

2. The Tuning Parameters frame shows the values of the
terms.

3. The first value to enter is KVELFF. To do
this, click <-Calculate . The Calculate
Velocity Feedforward Gain dialog box
will appear.

Click Use this value to enter the value.

4. In the Shape Parameters frame, ensure the Move
Type box is set to Step.

Click in the Size (uu) box and enter a value of 0.2.

Note: The term “uu” means user units. Previously,

in the Wizard Axes Scale Parameters
window, you setup a scaling factor of 4096 ­equivalent to 1 count per revolution - so the
the user unit is now revolutions.
If you selected a different scaling factor the
value of 0.2 might not be suitable.

57

5. Click Start Move .

In the dialog box that appears, click GO .
The motor will now attempt to rotate 0.2 revolutions. MCT will upload the recorded (captured) data from
the MintDrive and the Tuning Graph tab will be shown. Below the graph, make sure that only the
Actual Position and Demand Position boxes are checked.

Note:

The graph that you see on your system will not look exactly the same as the graph shown below!
Remember that each motor has a slightly different response.

With only KVELFF defined, you will
get very little response.

The Proportional gain term,

Demand position

KPROP, should be used to
overcome the large following
error...

Measured position

6. Click thePosition Loop Tuning tab, click the KPROPbox and entera smallstartingvalue, for example 1.

Click Start Move .

In the dialog box that appears, click GO .

Adding the KPROP term has
improved the response, but it is still
quite slow.

Demand position

Measured position

58

As the value of KPROP increases,
the rise (response) time will
decrease. For example, the plot
opposite shows the effect of setting
KPROP to a value of 3.

Demand position

Measured position

If KPROP is increased too far,
overshoot or ringing will occur. The
plot opposite shows the effect of
setting KPROP to a value of 7.

Measured position

This overshoot and/or ringing can
be reduced by introducing a
damping term - either KVEL or
KDERIV...

7. The plot opposite shows how
applying a value of 0.25 to KVEL
(with KPROP set to 4.7), causes a
response with a small overshoot but
which settles quickly.

The ideal response is to have a
sharp (square) response with very
little overshoot and no oscillations.
The Step Response Statistics tab
shows measured values which can
be used as a further guide to tuning.

8. When you have tuned the motor,
click Next > to continue.

Demand position

Measured position

Demand position

4.3.4 Jog test

This tab allows you to perform a jog test on the motor. This will start the motor rotating at a preset speed
until it is stopped by you.

1. Set the demand speed and accelerations by clicking in
the bottom three boxes and typing the required values.

2. Click either Jog -ve or Jog +ve to perform the test.
The Stop button stops the movement.

The top two boxes show real-time information about the
jog move.

When you have completed your tests click Stop, followed
by Disable Drive .

3. Click Next > to continue.

59

4.3.5 Completing the Startup Wizard

The Startup Wizard is now complete. The next step is to continue with the configuration of other
parameters such as inputs and outputs.
If you have not used the MCT before, it is recommended that you continue using the Wizard mode to
guide you through all the stages of configuration. Manual mode is for experienced users only.

1. Click Mint Configuration
Tool in Wizard Mode .

2. Click Next > to continue.

60

4.4 MCT Wizard - hardware configuration

The next part of the Mint Configuration Tool allows you to setup the digital inputs and outputs, perform
further fine-tuning and configure many other parameters. At the bottom of the window, the help bar
shows guidance about the current options.

4.4.1 Digital input configuration

The Digital Input Configuration tab allows you to define how each digital input will be triggered and,
optionally, if it is to be allocated to a special function, for example the Forward Limit.
If you do not wish to configure any inputs at this stage, click Next > and go to section 4.4.2.
In the following example, digital input 1 (IN1) will be allocated to the forward limit input, triggered by a
falling edge.

1. Drag the Falling icon
the IN1 icon

This will setup IN1 to respond to
a falling edge.

2. Now drag the IN1 icon

onto the FWD Limit icon .

This will setup IN1 as the
Forward Limit input.

.

onto

61

3. Continue this process until you
have configured all the required
inputs.

Click Next > to continue.

The Undo Changes button can
be used to reset all the items on
the tab to their original values.

4.4.2 Digital output configuration

The Digital Output Configuration tab allows you to define how each digital output will operate and if it is
to be allocated to the drive enable output. If you do not wish to configure any outputs at this stage, click
Next > and go to section 4.4.3.

1. Drag the appropriate icons to
setup the digital outputs.

62

If you do not understand anitem,
click in its box and read the
information shown in the help
bar at the bottom of the window.
The Undo Changes button can
be used to reset all the items on
the tab to their original values.

When you have finished, click

Next > to continue.

Note: The purpose of the Drive Enable Output is to provide an indication of the MintDrive’s enabled

status. Its use is optional and it does not have to be assigned to an output for the MintDrive
to be operational.

4.4.3 Axis0 parameter configuration

The Axis0 Parameter Configuration tab allows you to setup various axis parameters.
If you do not wish to make any changes, click Next > and go to section 4.4.4.

1. Click in the appropriate boxes
and type the required values.

If you do not understand anitem,
click in its box and read the
information shown in the help
bar at the bottom of the window.
The Undo Changes button can
be used to reset all the items on
the tab to their original values.

When you have finished, click

Next > to continue.

4.4.4 Axis0 error configuration

The Axis0 Error Configuration tab allows you to setup various axis error parameters.
If you do not wish to make any changes, click Next > and go to section 4.4.5.

1. Click in the appropriate boxes
and type the required values.

If you do not understand anitem,
click in its box and read the
information shown in the help
bar at the bottom of the window.
The Undo Changes button can
be used to reset all the items on
the tab to their original values.

When you have finished, click

Next > to continue.

63

4.4.5 Axis0 tuning configuration

The Axis0 Tuning Configuration tab provides a further opportunity to make adjustments to the drive
tuning. The previous values that you set will already be entered in the boxes. If you do not wish to make
any changes, click Next > and go to section 4.4.6.

1. Click in the appropriate boxes
and type the required values.

If you do not understand anitem,
click in its box and read the
information shown in the help
bar at the bottom of the window.
The Undo Changes button can
be used to reset all the items on
the tab to their original values.

When you have finished, click

Next > to continue.

4.4.6 Miscellaneous configuration

The Miscellaneous Configuration tab allows you to setup miscellaneous parameters.
If you do not wish to make any changes, click Next > and go to section 4.4.7.

1. Click in the appropriate boxes
and type the required values.

If you do not understand anitem,
click in it’s box and read the
information shown in the help
bar at the bottom of the window.
The Undo Changes button can
be used to reset all the items on
the tab to their original values.

When you have finished, click

Next > to continue.

64

4.4.7 Completing the configuration wizard

The configuration must now be saved.
(If you wish to go back and make any further changes, click < Back .

1. Check that the drop down box is showing Mint Configuration
File Format. If it is not, then select this option.

Click Next > to continue.

2. The completed configuration file
will be shown.

Ifyouwishtogobackandmake
any further changes, click
< Back .

Click Finish to continue.

3. Check that the Launch Mint

Workbench and save the
project and configuration
files option is selected.

Click OK to continue.

65

4. The Save As dialog box will be shown.

The first file to save is the project file.
This file can be loaded into MCT and edited later.

Select a folder and enter a filename for the project file.

Click Save .

5. The second file to save is the configuration file.

This is the file that can be loaded into Mint Workbench
and sent to the MintDrive.

Select a folder and enter a filename for the
configuration file.

Click Save .

66

A number of things will now happen:

H The configuration file will be saved;

H MCT will be closed;

H Mint WorkBench will be started;

H The configuration file will be automatically loaded into WorkBench.

5.1 Outline

Mint WorkBench is the main application for programming and controlling the MintDrive.
The Terminal window allows you control the MintDrive in real-time, while the Program window allows
you to construct complex programs using the Mintt programming language. The Configuration window
allows you to view and alter the configuration file. For detailed information on Mint programming, see
the Mint v4 Programming Guide.

5.1.1 Completing configuration

To complete the configuration process, the configuration file must be downloaded to the MintDrive.

On the Standard toolbar, click
the download button

In the dialog box that appears,
click Yes to confirm download.

.

5 Mint WorkBench

5

Click the
of the Configuration Editor

window to close the window.

button at the top

This completes the configuration and tuning.

The remainder of this section in c lu d e s some simple motor

movement commands that can be useful for testing.

67

5.2 Using WorkBench

If you have not just completed the Mint Configuration Tool Wizard, you will need to start Mint
WorkBench manually. On the Windows Start menu, select Programs, Mint v4, Mint WorkBench.

5.2.1 Selecting the controller

Before WorkBench can communicate with the MintDrive, it must scan the PC’s serial ports to find where

it is connected. To do this, click Tools on the main menu and choose Select Controller... .

The Select Controller dialog box will appear and WorkBench will scan the serial ports until it finds the
MintDrive. When it has found the MintDrive, click OK .

Note: The MintDrive logic supply must be powered otherwise it will not be found.

If WorkBench was started automatically when you completed the MCT Wizard, you do not
need to do this step.

5.2.2 Menus and buttons

The main Mint WorkBench window contains a menu system and 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.

5.2.2.1 Standard toolbar functions

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

68

1 Controller reset (Not available on MintDrive).
2 Save Displays the save dialog box.
3PrintDisplays the print dialog box.
4CutCuts the text selected in the editor window and places it on the clipboard.
5 Copy Copies the text selected in the editor window and places it on the clipboard.
6 Paste Pastes the text on the clipboard into the editor window at the cursor location.
7 Undo Reverses the last editing action.
8 Watch window Turns the watch window on or off.
9 CAN window Turns the CAN window on or off.
10 Upload Uploads the current file from the MintDrive to WorkBench.
11 Download Downloads the current file to the MintDrive from WorkBench.
12 Run Runs the current configuration and program files in the MintDrive.
13 Stop Stops the current program running on the MintDrive.
14 DPR Watchwindow (Not available on MintDrive).
15 Terminal Displays the Terminal window (CTRL+T has the same effect).
16 Copy parameters Copies the current drive tuning parameters to the clipboard.
17 Digital I/O Displays the digital I/O watch window.
18 Platform information Displays the platform information window.
19 About Displays WorkBench version number information.

5.2.2.2 Motion toolbar functions

1 2 3 4567 8

1 Axis selection (Only Axis0 can be selected)
2 Jog (reverse) Causes the motor to start a reverse jog motion.
3 Jog speed Sets the jog speed (in user units per second)
4 Jog (forward) Causes the motor to start a forward jog motion.
5StopStops the jog motion.
6 Enable / Disable Enables (sending a CANCEL command first) or disables the drive.
7 Clear motion errors If an error occurs, clears the error condition so operation can continue.
8 Motion error Displays the error code bitmap when a motion error occurs. Click the button to

see a description of the error(s).

5.2.2.3 Macro toolbar functions

12

1 Configure macros Displays the Assign Macros to Function Keys F1..F12 dialog box.
2 Execute macro Starts the macro assigned to that button.

5.2.2.4 Status bar

The status bar provides information for the currently selected menu item or the status of WorkBench.
It provides a useful reminder of the meaning of each function. Double click on the center section to
display the Configure this Controller dialog.

5.2.2.5 CAN window

The CAN window shows the current status of the CAN ports. If the MintDrive is not connected to a CAN
network you can turn this window off by choosing View, CAN Window on the main menu or by clicking
the CAN window button on the standard toolbar.

4

123

1 Events Displays current CAN events
2 Nodes Displays node information for the CAN network.
3 Groups Displays grouping information for the CAN network
4ViewingSelects the CAN port to be monitored.

69

5.3 Watch window

The Watch window contains four tabs, providing real-time information and allowing tuning of the motor.
If a tab is not visible, click the

5.3.1 Quick Watch tab

The Quick Watch tab provides real-time information about various
WorkBench and motor parameters. Up to four user selectable parameters
canbemonitoredatthesametime.

To select a parameter to be monitored, click one of the parameter boxes
on the right of the QuickWatch tab.

In the drop down box that appears, click on the item you wish to monitor.

The value will appear in the line just below the drop down box.
Values are sampled, in turn, every 100ms although this can be changed
by clicking the arrows beside the Time Between QuickWatch Samples
(ms) box

The Capture The QuickWatch Channels frame allows the selected
parameters to be captured and shown on a graph. To select the sampling time, click the arrows beside
the Seconds box

buttons at the bottom of the window.

, then click the Capture button.

70

5.3.2 Speed Loop tab

The Speed Loop tab provides a further opportunity to tune the motor.
Click in the appropriate boxes and type the required values.

Click Start Move to perform the move.

The motor will now rotate, WorkBench will upload the recorded
(captured) data from the MintDrive and the Capture tab will be
shown.

Note: If an error occurs, the Error: button on the Motion toolbar

will show the error number. Click the button to see details
of the error. Depending on the type of error that occurred,
you might need to click the Clear Motion Errors button
before further moves can be performed.

Speed Step
maximum motor velocity entered in the Speed (% max motor) box.

Current Proportional Gain (KIPROP)
The gain is set by MCT during the tuning process. If you need to
recalculate this value, use the formula:

performs a step speed change to the percentage of



KIPROP =

where:
L = Line to neutral inductance of the motor in mH.
A/V = Amps / v olt scaling of the current feedback.
VAC = Nominal line voltage

Current Integral Gain (KIINT)
This gain is preset to 50Hz and should not need to be adjusted.

Speed Proportional Gain (KVPROP)
This gain will speed up the response and but excessive values will cause overshoot, and possible
instability.

Speed Integral Gain (KVINT)
Increasing the value of KVINT increases the low frequency gain and stiffness of the control, but
excessive values will cause overshoot for transient speed commands and may lead to oscillation.
If KVPROP and KVINT are set too high, an overshoot condition can also occur.

Speed differential gain (KVDIFF)
Theoretically this gain has a damping effect, although it is not implemented in the MintDrive.

For a full description of the tuning parameters, see Appendix A.

740 × L ×A∕V

VAC





71

5.3.3 Position Loop tab

The Position Loop tab provides a further opportunity to tune the motor
and perform test moves. Click in the appropriate boxes and type the
required values. For a full description of the position loop tuning
parameters, see Appendix A.

Click Start Move to perform the move.

The motor will now rotate, WorkBench will upload the recorded
(captured) data from the MintDrive and the Capture tab will be shown.

Note: If an error occurs, the Error: button on the Motion toolbar

will show the error number. Click the button to see details of
the error. Depending on the type of error that occurred, you
might need to click the Clear Motion Errors button before
further moves can be performed.

Depending on the type of move chosen in the MoveType box, different
options will appear below it:

Position Step
theStepSize(uu)box.

Position Trapezoid
the move is entered in the Move Distance (uu) box. When the move is
performed the demanded motor speed will increase at the rate entered
in the Acceleration box until the Slew Speed is reached. Towards the
end of the move, the demanded motor speed will decrease at the rate
entered in the Deceleration box.

performs a step position move of the distance entered in

performs a trapezoidal move. The total distance of

72

5.3.4 Capture tab

Each time a speed or position test move is performed using WorkBench,
the data from the move is automatically captured and uploaded in to
WorkBench. The Capture tab allows you to select the type of plot produced
from the captured data. Click in the appropriate boxes to select the
required data.

The Plot #1 and Plot #2 frames allow you to select which parameter(s) to
show on the graph and the color of the traces. Plot #2 is only available
after a Position move has been performed.

Normally, the graph will automatically scale itself to show the largest
maximum and minimum captured values for the selected plot types.
However, the Use the same axis as plot #1 check box forces the two
traces to be plotted using the scaling required for plot #1. This allows the
two sets of data to be compared with each other more easily.

The background color of the graph can be changed using the Background
Color drop down box, and the grid can be turned on or off using the Show
Grid check box. The Upload Captured Data From the Controller button
allows you to manually upload the data.

73

5.4 Editor windows

Mint WorkBench has three main editor windows; the Configuration window, the Program window and
the Terminal window.

5.4.1 Configuration window

If the configuration window is not visible,
select Window, Configuration from the main
menu.

The configuration window is used for writing
and editing the configuration file. Any file
downloaded from this window to the MintDrive
will be sent as the configuration file.

To view the current configuration stored in the
MintDrive, click the upload button on the
standard toolbar. After a couple of seconds,
the current configuration file will be displayed.

To download the configuration file to the
MintDrive, click the download button on the
standard toolbar.

In the dialog box that appears, click Yes to confirm download. Saved configuration files can also be
loaded into the configuration window using File, Open, Config... on the main menu.

5.4.2 Program window

If the program window is not visible, select
Window, Program from the main menu.

The program window is used for writing and
editing programs. Any file downloaded from
this window to the MintDrive will be sent as
the program file.

To view the current program stored in the
MintDrive, click the upload button on the
standard toolbar. After a couple of seconds,
the program file will be displayed. If there is no
program in the MintDrive, the window will
remain blank.

To download the program file to the MintDrive,
click the download button on the standard
toolbar.
In the dialog box that appears, click Yes to confirm download. Saved program files can also be loaded
into the program window using File, Open, Program... on the main menu.

74

5.4.3 Terminal window

If the terminal window is not visible, select
Tools, Termin al from the main menu.
(Alternatively, click the Terminal button on the
standard toolbar or press CTRL+T).

The Terminal window can be used for
controlling the MintDrive directly and for
monitoring output messages from programs.

On the PC keyboard, press the Enter key
once to display the C001> or P001> prompt.
Commands typed in the Terminal window will
have immediate effect on the MintDrive,
although the command line will not be
available while a program is running.

5.4.4 Useful co mmands for testing

The Terminal window can be a useful tool for performing simple tests. Before testing can begin, check
that the enable button

showing the

symbol.

on the motion toolbar is pressed; the MintDrive Monitor LED display should be

The following examples can now be typed in the Terminal window:

To start the motor turning slowly, type...

JOG=1 followed by the Enter key.

The motor will begin to rotate at a speed of 1 user unit per second. If you have followed all the previous
examples, this means the motor will rotate at one revolution per second.

To stop the motor turning, type...

STOP followed by the Enter key.

The motor will stop.

To start the motor turning in reverse, then change direction type...

JOG=-1 followed by the Enter key. Then type:

JOG=1 followed by the Enter key.

The motor will immediately change direction. Type:

STOP to stop the motor.

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To turn a distance of 5 turns, type...

MOVER=5 followed by the Enter k ey. Then type:
GO followed by the Enter key.

The keyword MOVER means “MOVE Relative”. In this example the motor will turn 5 units. If you have
followed all the previous examples, this means the motor will rotate five revolutions.

To change the speed, type...

SPEED=0.5 followed by the Enter key.

The motor will not turn, but the next time you use a MOVER command, the motor will now turn at half of
one revolution per second. To try it type:

MOVER=2 followed by the Enter key,
GO followed by the Enter key.

Combining commands on one line...

Commands can be combined on one line by separating them with colons. For example, type:

SPEED=2:MOVER=8:GO followed by the Enter key.

The motor will immediately turn for 8 revolutions at a speed of 2 revolutions per second.

76

To learn more about using these commands and how to incorporate them into programs, see the Mint
v4 Programming Guide. Using the Mint programming language, sophisticated programs can be written

that control the motor, set outputs and, most importantly, respond to external inputs.

5.4.5 Firmware update

Occasionally there may be updates to Mint to either fix problems or to add new features.
The Mint firmware is stored in Flash memory and can be updated using the RS232 serial port.
The RS485 port cannot be used for firmware update.

CAUTION: The state of the analog and digital outputs cannot be guaranteed while firmware is

being updated. Please disconnect any equipment which may be damaged.

CAUTION: It is recommended to remove any AUTO configuration file prior to updating

firmware. Changing the firmware may affect the way your Mint application works.

CAUTION: Updating firmware may destroy any program(s) held in the battery backed-up

RAM buffers. You should upload these into Mint WorkBench and save them
before updating the firmware.

CAUTION: Updating firmware will destroy any program(s) held in the Flash memory buffers.

You should upload these into Mint WorkBench and save them before updating the
firmware.

From the Tools menu, select Update Firmware and follow the instructions on screen.

Once the firmware has been updated, both the Configuration and Program flash buffers will need to be
reset. The Mint keyword BUFFERSTORE can be used to switch between battery backed -up RAM and
flash buffers. Typing:

BUFFERSTORE=0 will switch to the battery-backed RAM buffer. Typing:

BUFFERSTORE=1 will switch to the flash buffer.

With the flash buffer selected, type:

CON to select the configuration buffer (if it is not already selected).

A few report lines will be shown, followed by the C> prompt. Type:

NEW at the prompt to reset the buffer.

Now type:

PROG to select the program buffer.

A few report lines will be shown, followed by the P> prompt. Type:

NEW at the prompt to reset the buffer.

It is recommended to update the keyword tables supported by the controller after updating it with new
firmware. This allows the Mint WorkBench editor to identify keywords recognized by the controller.
To update the keyword tables, select Load Syntax from the Edit menu in Mint WorkBench.

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78

6.1 Outline

This section provides technical specifications of the MintDrive variants

6.1.1 General specificatio n s

The MintDrive is an integrated motion controller and brushless AC servo drive with internal power
supply.

H Five current output ratings are available: 2.5A, 5A, 7.5A, 10A and 15A

H Four voltage input ratings are available: 115VAC or 230VAC single-phase, with three-phase variants

available on the 10A and 15A units

H An optional internal 24V power supply for control electronics is available

H Resolver or encoder feedback

H 18 optically isolated digital inputs (12-24VDC ±20%), configurable for PNP or NPN operation.

Software configurable for forward limit, reverse limit, stop and home. Two inputs configurable for
high speed position latch (CAPT) on axis position and master encoder position

H 9 optically isolated digital outputs. Four outputs configurable for PNP or NPN operation. One output

rated at 1A, all others at 50mA.

H Four analog input channels:

One single ended input 0-10V, 10-bit resolution
One differential input: ±10V, auto selecting resolution - 12-bit below 1VDC, 10-bit above 1VDC
Two differential inputs: ±10V, 12-bit.

H Four analog output channels:

Two bipolar outputs: ±10V; 8-bit resolution, 1mA output
Two bipolar outputs: ±10V; 8-bit resolution, 4mA output

H Two channel serial interface: RS232 and 4-wire RS485

H Two channel CAN interface: CANopen DS401 master and Baldor CAN protocol

H Seven segment display for diagnostics.

6 Specifications

6

79

6.1.2 Power

Mains and motor output

Nominal input voltage (Vin=230VAC) VA C 230

Minimum input voltage 220

Maximum input voltage 250

Nominal DC-Bus voltage VDC 320

Minimum DC-Bus voltage 306

Maximum DC-Bus voltage 350

Nominal input voltage (Vin=115VAC) VAC 115

Minimum input voltage 97

Maximum input voltage 125

Nominal DC-Bus voltage VDC 160

Minimum DC-Bus voltage 135

Maximum DC-Bus voltage 176

Unit 2.5A 5A 7.5A 10A 15A

Output voltage (line-line)

V

RMS

0 ~ 230

@VDC-Bus=320V

Nominal phase current (±10%) A

Peak phase current (±10%)

A

RMS

RMS

2.5 5.0 7.5 10 15

5 10 15 20 30

for 2.4s (+0.5s / -0s)

Nominal output power kVA 1.01 2.17 2.99 4.33 6.51

Efficiency % >95

Output frequency Hz 0 ~ 500

Nominal switching frequency kHz 8.5

Optional 24V supply

Unit All models

Input voltage minimum

V

= 10% maximum

RIPPLE

Input current maximum

VDC 20

A

RMS

30

1.6

@24VDC

Surge current at power on

A

RMS

4

@24VDC for 100ms

80

6.1.3 Rectifier and regeneration

VDC

Rectifier

Input voltage (±15%, f=50~60Hz) Vin=230VAC Vin=115VAC

Unit All models

DC-Bus voltage (absolute) Minimum

Regeneration

Switching threshold Vin=230VAC

Nominal power kW 0.25 1.0

Peak power kW 2.7 15

Maximum regeneration
switching current

Maximum load inductance mH 100

*Note: 2.5A model contains an internal 320Ω, 20W resistor

5A model contains an internal 175Ω, 30W resistor.

6.1.4 Resolver feedback

Vin=115VAC

Nominal
Minimum
Maximum

Maximum

Unit 2.5A* 5A* 7.5A 10A 15A

A

RMS

VAC

VDC

on:373~383, off:362~372 on:373~383, off:362~372

on:188~195, off:183~188 on:188~195, off:183~188

10 40

230
190
265

270
360

115

90

130

125
175

Unit All models

Resolution

set automatically by software

Pole pairs - 1

Resolver winding ratio - 0.5

MintDrive resolver input accuracy counts ±2

Typical combined accuracy using
Baldor BSM series resolver motor

bits

counts ±4

Velocity <6100RPM: 14 b its
Velocity >6100RPM: 12 b its

81

6.1.5 Encoder feedback

Encoder input A/B Differential, Z index

Signal frequency (maximum) 1.5MHz (6MHz quadrature)

Hall inputs Single ended, 5V logic

6.1.6 Control signals

Encoder output (simulated)

Signal - RS422

Encoder resolution Resolver

Master (auxiliary) encoder input

Signal - RS422

Operating mode - A/B quadrature

Maximum input frequency (quadrature) MHz 8

Sample time ms Selectable: 0.5, 1, 2

Encoder

All models

Unit All models

- 1024ppr, simulated

1024ppr / 2500ppr (actual encoder lines)

(Baldor BSM series motor)

Unit All models

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Serial RS232 interface

Unit All models

Signal - RS232, non-isolated CTS/RTS

Bit rate Baud 9600, 19200, 57600

Serial RS485 interface

Unit All models

Signal - 4-wire RS485, non-isolated

Bit rate Baud 9600

CAN Bus interfaces

Signal - 2-wire, isolated

Channels - 2

Bit rate Kbit/s 10, 20, 50, 125, 250, 500, 1000

Protocols - CAN bus 1: CANopen

6.1.7 Environmental

Operating temperature range °C °F

Unit All models

(800 also available on CAN bus 1 only)

CAN bus 2: Baldor CAN

Unit All models

Minimum
Maximum
Derate

Storage temperature range -25 ~ +70 -13 ~ +158

Humidity

Maximum installation altitude

(above m.s.l.)

Shock - 10G according to

Vibration - 1G, 10~150Hz, according to

2.5% / °C between

40°C and 50°C (max)

%

m

ft

+5

+40

2.5% / 1.8°F between
40°C and 50°C (max)

10~90 non -condensing according to

DIN40 040 / IEC144

1000

Derate 1.1% / 100m over 1000m

3300

Derate 1.1% / 330ft over 3300ft

DIN IEC 68-2-6/2 9

DIN IEC 68-2-6/2 9

+41

+104

83

84

7.1 Outline

This section explains common problems that may be encountered and their solutions.
If you want to know the meaning of the LED Monitor display, see section 1.3 on page 3.

7.1.1 Problem diagnosis

If you have followed all the instructions in this manual in sequence, as instructed, you should have few
problems installing the MintDrive.

If you do have a problem, check through the diagnosis sections below. If you cannot solve the problem,
or the problem persists, contact details for Baldor Technical Support are provided at the front of this
manual.

Before contacting Technical Support, please have ready the following information (if available):

H The Serial Number of your MintDrive.

H The Catalog Number indicating the type of MintDrive you have.

H Assuming you have access to the command line, type VER and note down the software version

number and the build number.

H Assuming you have access to the command line, type VIEW HARDWARE and note down the

information given.

H The catalog number of the motor that you are using.

H The version of Mint WorkBench that you are using (click Help, About on the main menu).

H Give a clear description of what you are trying to do, for example trying to establish communications

with the Mint WorkBench, trying to run the Feedback Alignment test under the Drive Setup dialog or
trying to setup Mint gains.

H Give a clear description of the symptoms that you can observe, for example the current state of any

of the status indicators, error messages displayed, the current value of any of the Mint error
keywords AXISERROR, AXISSTATUS, MISCERROR, DRIVEFAULT, ERR and ERL.

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

from the ”Drive Setup” dialog, the gain settings generated by MCT during the tuning process and
any gain settings you have entered yourself.

7 T roubleshooting

7

Depending upon the nature of your problem you may be asked for some or all of the above
information.

The term “Power-cycle the MintDrive” is used in the following sections.
This means turn the MintDrive off, wait for it to power down completely, then turn it on again.

85

7.1.2 Communication

Problem Check

No LEDs are illuminated
(+24VDC models)

No LEDs are illuminated
(Mains only models)

Mint WorkBench fails to detect
the MintDrive - it detects another
controller

Mint WorkBench fails to detect
the MintDrive - it detects
“Controller with No Firmware” on
the serial port.

Cannot communicate with the
MintDrive over the RS232 port
(cannot get P> or C> prompt by
pressing Enter).

Check that the 24VDC power supply is connected on connector X1
and is switched on.

Check the mains supply is connected and switched on.

Mint WorkBench automatically attempts to re-select the last
controller to which it was connected. Select Tools, Select
Controller on the main menu. Check that MintDrive has been
selected in the drop-down. If not, select it.

Ensure that the MintDrive is powered and the LEDs are illuminated
(see section 1.3 on page 3).

Check that the RS232 cable is connected between the PC serial
port and to connector X7 on the MintDrive.

Check the wiring of the RS232 cable or try an alternate cable.

If available on the PC, try an alternative serial port.

Confirm that a mouse driver or other serial device is not conflicting
with Mint WorkBench.

Check that Mint WorkBench has detected the MintDrive, indicated
in the status bar at the bottom of the window.

Check that the MintDrive is still powered.

Check that the focus is on the Terminal window of the Mint
WorkBench (click in the Terminal window).

86

Check that there is not a program already running on the MintDrive
(press CTRL+E to abort the running program).

Check that a program hasn’t disabled the RS232 terminal using
the TERMINAL keyword (pressing CTRL+E will re-enable the
RS232 serial port).

Check that the Monitor LED is illuminated.

Power-cycle the MintDrive.

7.1.3 Power up

Problem Check

No LEDs are illuminated Check that the 24VDC power supply is connected on connector X1

and is switched on.
Check the mains supply is connected and switched on.

One or more of the Monitor,
Ready or CAN LEDs is not
illuminated

The ’Ready’ LED is red. The drive has detected an error.

A CAN LED is red or flashing
red.

The Ready LED is green and
the Monitor LED indicates ‘L’

The Ready LED is green and
the Monitor LED indicates ‘E’

The message Variables

corrupted. Use RELEASE.

is shown at power-up.

Check power connections. Power-cycle the MintDrive.

If the problem persists contact Baldor Technical Support.

Type PRINT DRIVEFAULT in the Terminal window or click the error
button on the motion toolbar to find the error code(s).
See section 7.1.6 on page 91.

See section 7.1.7 on page 94.

The drive has powered-up into ’Local’ mode.
Power-cycle the MintDrive.

If the problem persists then contact Baldor Technical Support.

The MintDrive has detected a motion error.
Type PRINT AXISERROR at the command line or click on the error
button on the motion toolbar to find the error code(s).
Click the Clear Motion Errors button on the motion toolbar.

Type RELEASE in the Terminal window to clear variables from the
variable stack.

If the problem persists then this indicates a battery problem.
Trickle charge the MintDrive’s battery by leaving the unit powered
for 24~48 hours.

If the problem still persists contact Baldor Technical Support.

The message Memory

Corruption. Use NEW to
clear buffers. is shown at

power-up.

Type NEW at the Configuration prompt (type CON to display C>).
Type NEW at the Program prompt (type PROG to display P>).
This will clear the corrupted programs from memory.

If the problem persists then this indicates a battery problem.
Trickle charge the MintDrive’s battery by leaving the unit powered
for 24~48 hours.

If the problem still persists contact Baldor Technical Support.

87

Problem Check

The message Lost User
Data: Defaulting to
Factory settings ­please wait... is shown at

power-up.

The message
Initialization Error is
shown at power-up.

The message Fatal
Initialization Error is
shown at power-up.

The message Processor
Reset Code = xx is shown at
power-up.

If this message is followed by You must now re-tune your
motor retune the MintDrive by either re-entering the gain settings
set earlier or by following the tuning setup (see section 4.2 on
page 51).

If this message is followed by Failed to automatically
reset Factory settings. power-cycle the MintDrive.
If the same message re-appears or the Ready LED stays red,
contact Baldor Technical Support. Otherwise, retune the MintDrive
by either re-entering the gain settings set earlier or by following the
tuning setup (see section 4.2 on page 51).

If this message is followed by Factory settings have been

reset, but failed to clear error flag. Try
clearing the error manually using CANCEL. type
CANCEL. and power-cycle the MintDrive. If the same message

re-appears or the Ready LED stays red, contact Baldor Technical
Support. Otherwise, retune the MintDrive by either re-entering the
gain settings set earlier or by following the tuning setup
(see section 4.2 on page 51).

Contact Baldor Technical Support.

Contact Baldor Technical Support.

If new firmware has just been downloaded this message may be
ignored.

If the MintDrive has been power-cycled, power-cycle the MintDrive
again. If the problem persists contact Baldor Technical Support.

88

If the firmware just reset without the unit being power-cycled,
contact Baldor Technical Support.