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Downloaded from www.Manualslib.com manuals search engine
 Contents

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 MotiFlex e100 features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.1 Identifying the catalog number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4.1 Design and test standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4.2 Environmental test standards: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4.3 Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3 Basic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.3 Tools and miscellaneous hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.4 Other information needed for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1 Dimensions - 1.5 A ~ 16 A models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2 Dimensions - 21 A ~ 33.5 A models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.3 Dimensions - 48 A ~ 65 A models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.4 Mounting the MotiFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.5 Overtemperature trips and intelligent fan control . . . . . . . . . . . . . . . . . . . . . 3-10

3.3 Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.3.1 Front panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.3.2 Top panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3.3 Bottom panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.4 AC power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.4.1 Earthing / grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.4.2 AC input and regeneration resistor output wiring . . . . . . . . . . . . . . . . . . . . . 3-15
3.4.3 Earth leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.4.4 AC power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.4.5 AC power cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.4.6 Inrush current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.4.7 Phase loss detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.4.8 Drive overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.4.9 Input power conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.4.10 Power supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.4.11 Power disconnect and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.4.12 Recommended wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

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 3.5 Sharing the DC bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.5.1 DC busbar connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.5.2 ‘Power ready’ input / output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.5.3 Line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.6 18 VDC out / 24 VDC in control circuit backup supply . . . . . . . . 3-26

3.6.1 24 VDC backup supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.6.2 24 VDC control circuit backup supply wiring . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.7 Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.7.1 Motor cable shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.7.2 Motor circuit contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.3 Sinusoidal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.4 Motor power cable pin configuration - Baldor BSM rotary motors . . . . . . . 3-32
3.7.5 Motor cable pin configuration - Baldor linear motors . . . . . . . . . . . . . . . . . . 3-33
3.7.6 Motor brake connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.7.7 Motor overtemperature input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.7.8 Bottom panel wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3.8 Regeneration resistor (Dynamic Brake resistor) . . . . . . . . . . . . . 3-36

3.8.1 Regeneration capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.9 Regeneration resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.9.1 Required information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.9.2 Regenerative energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.9.3 Regenerative power and average power . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.9.4 Resistor choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.9.5 Resistor temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.9.6 Resistor pulse load rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.9.7 Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

4 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Incremental encoder interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 BiSS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.1.3 SSI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.1.4 SinCos interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.1.5 EnDat interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

5 Input / Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Analog input - X3 (demand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3.1 Drive enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.2 General purpose digital input DIN0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.3 General purpose digital inputs DIN1 & DIN2 . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.3.4 Special functions on inputs DIN1 & DIN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.3.5 Motor overtemperature input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

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 5.3.6 General purpose / status digital output DOUT0 . . . . . . . . . . . . . . . . . . . . . . 5-14
5.3.7 General purpose digital output DOUT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.4 USB interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.4.1 USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.5 RS485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.5.1 RS485 (2-wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.6 Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5.6.1 TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.6.2 Ethernet POWERLINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.6.3 Ethernet connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5.7 CAN interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.7.1 CAN connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.7.2 CAN wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.7.3 CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5.8 Other I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5.8.1 Node ID selector switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

6 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 Connecting the MotiFlex e100 to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Installing Mint Machine Center and Mint WorkBench . . . . . . . . . . . . . . . . . 6-1

6.2 Starting the MotiFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.1 Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Power on checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.3 Installing the USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.4 Configuring the TCP/IP connection (optional) . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 Mint Machine Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.3.1 Starting MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.4 Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.4.1 Help file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.2 Starting Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.3 Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.4.4 Using the Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.4.5 Autotune Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.4.6 Further tuning - no load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.4.7 Further tuning - with load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4.8 Optimizing the velocity response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.4.9 Performing test moves - continuous jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.4.10 Performing test moves - relative positional move . . . . . . . . . . . . . . . . . . . . 6-23

6.5 Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6.5.1 Parameters tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.5.2 Spy window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.5.3 Other tools and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

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 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Problem diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 SupportMe feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.3 Power-cycling the MotiFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 MotiFlex e100 indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2.1 STATUS LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2.2 CAN LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2.3 ETHERNET LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.5 Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.6 Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.7 Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.8 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.9 CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 AC input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2.1 AC input voltage (X1) - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2.2 AC input current (X1), DC bus not shared - all models . . . . . . . . . . . . . . . . 8-2
8.2.3 AC input current (X1), DC bus sharing - all models . . . . . . . . . . . . . . . . . . . 8-4
8.2.4 Recommended fuses and circuit breakers when sharing the DC bus . . . . 8-8
8.2.5 Power, power factor and crest factor - 1.5 A ~ 16 A models . . . . . . . . . . . . 8-9
8.2.6 Power, power factor and crest factor - 21 A model . . . . . . . . . . . . . . . . . . . 8-12
8.2.7 Power, power factor and crest factor - 26 A & 33.5 A models . . . . . . . . . . 8-13
8.2.8 Power, power factor and crest factor - 48 A & 65 A models . . . . . . . . . . . . 8-14

8.3 Motor output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

8.3.1 Motor output power (X1) - 1.5 A ~ 16 A models . . . . . . . . . . . . . . . . . . . . . . 8-15
8.3.2 Motor output power (X1) - 21A ~ 33.5 A models . . . . . . . . . . . . . . . . . . . . . 8-15
8.3.3 Motor output power (X1) - 48 A ~ 65 A models . . . . . . . . . . . . . . . . . . . . . . 8-16
8.3.4 Motor output uprating and derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.3.5 Motor output rating adjustment - 1.5 A model . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.3.6 Motor output rating adjustment - 3 A model . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.3.7 Motor output rating adjustment - 6 A model . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.3.8 Motor output rating adjustment - 10.5 A model . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.3.9 Motor output rating adjustment - 16 A model . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.3.10 Motor output rating adjustment - 21 A model . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.3.11 Motor output rating adjustment - 26 A model . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.3.12 Motor output rating adjustment - 33.5 A model . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.3.13 Motor output rating adjustment - 48 A model . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.3.14 Motor output rating adjustment - 65 A model . . . . . . . . . . . . . . . . . . . . . . . . 8-26

8.4 Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

8.4.1 Regeneration (X1) - 1.5 A ~ 16 A models . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.4.2 Regeneration (X1) - 21 A ~ 33.5 A models . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.4.3 Regeneration (X1) - 48 A ~ 65 A models . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

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 8.5 18 VDC output / 24 VDC input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.5.1 18 VDC output / 24 VDC control circuit backup supply input (X2) . . . . . . . 8-29
8.5.2 Option card power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

8.6 Input / output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

8.6.1 Analog input - AIN0 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.6.2 Digital inputs - drive enable and DIN0 general purpose (X3) . . . . . . . . . . . 8-31
8.6.3 Digital inputs DIN1, DIN2 - high speed general purpose (X3) . . . . . . . . . . 8-31
8.6.4 Digital outputs DOUT0, DOUT1 - status and general purpose (X3) . . . . . 8-32
8.6.5 Incremental encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.6.6 SSI interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.6.7 BiSS interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.6.8 SinCos / EnDat interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
8.6.9 Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
8.6.10 CAN interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
8.6.11 RS485 interface (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

8.7 Weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

8.7.1 Weights and dimensions - 1.5 A ~ 16 A models . . . . . . . . . . . . . . . . . . . . . . 8-34
8.7.2 Weights and dimensions - 21 A ~ 33.5 A models . . . . . . . . . . . . . . . . . . . . . 8-34
8.7.3 Weights and dimensions - 48 A ~ 65 A models . . . . . . . . . . . . . . . . . . . . . . 8-34

8.8 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

Appendices

A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1.1 Busbars for DC bus sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.1.2 AC supply (EMC) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.1.3 AC line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.1.4 Regeneration resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
A.1.5 Motor / power cable management bracket . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
A.1.6 Signal cable management bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

A.2 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

A.2.1 Motor power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
A.2.2 Feedback cable part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
A.2.3 Ethernet cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

B Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.1.1 Servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.1.2 Torque servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

MN1943 Contents v
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 C Mint Keyword Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1.1 Keyword listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

D CE & UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
D.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
D.1.1 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
D.1.2 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
D.1.3 Use of CE compliant components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
D.1.4 EMC wiring technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
D.1.5 EMC installation suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
D.1.6 Wiring of shielded (screened) cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

D.2 UL file numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6

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 1 General Information
1
www.baldormotion.com

LT0279A03 Copyright Baldor (c) 2011. All rights reserved.

This manual is copyrighted and all rights are reserved. This document or attached software may not, in
whole or in part, be copied or reproduced in any form without the prior written consent of Baldor.
Baldor makes no representations or warranties with respect to the contents hereof and specifically
disclaims any implied warranties of fitness for any particular purpose. The information in this document
is subject to change without notice. Baldor assumes no responsibility for any errors that may appear in
this document.

Mintt and MotiFlex® are registered trademarks of Baldor.

Windows XP, Windows Vista and Windows 7 are registered trademarks of the Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.

MotiFlex e100 is UL listed; file NMMS.E128059.

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

Baldor UK Ltd
Mint Motion Centre
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
Telephone: +44 (0) 1454 850000
Fax: +44 (0) 1454 859001
E-mail: motionsupport.uk@baldor.com
Web site: www.baldormotion.com

See rear cover for other international offices.

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Product notice
Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are controlled
by this equipment. Improper use can cause serious or fatal injury.

Safety Notice
Intended use: These drives are intended for use in stationary ground based applications in industrial
power installations according to the standards EN60204 and VDE0160. They are designed for machine
applications that require variable speed controlled three-phase brushless AC motors. These drives are
not intended for use in applications such as:

H Home appliances
H Medical instrumentation
H Mobile vehicles
H Ships
H Airplanes.
Unless otherwise specified, this equipment is intended for installation in a suitable enclosure. The
enclosure must protect the equipment from exposure to excessive or corrosive moisture, dust and dirt or
abnormal ambient temperatures. The exact operating specifications are found in section 3 and section 8
of this manual. The installation, connection and control of drives is a skilled operation. This equipment
contains no user-serviceable parts; disassembly or repair must not be attempted. In the event that the
equipment fails to operate correctly, contact the place of purchase for return instructions.

Precautions
Do not touch any circuit board, power device or electrical connection before you first
ensure that no high voltage is present at this equipment or other equipment to which it is
DANGER connected. Electrical shock can cause serious or fatal injury. Only qualified personnel
should attempt to start-up, program or troubleshoot this equipment.

The motor circuit might have high voltages present whenever AC power is applied, even
when the motor is not moving. Electrical shock can cause serious or fatal injury.
DANGER

After AC power has been removed from the MotiFlex e100, high voltages (greater than
50 VDC) can remain on power connections for up to 5 minutes, while the DC bus circuitry
DANGER discharges. Do not touch the DC bus, regeneration resistor, or other power connections
during this period.

If a motor is driven mechanically, it might generate hazardous voltages that are conducted
to its power terminals. The enclosure must be earthed/grounded to prevent possible shock
DANGER hazard.

Be sure the system is properly earthed/grounded before applying power. Do not apply AC
power before you ensure that earths/grounds are connected. Electrical shock can cause
DANGER serious or fatal injury.

Be sure that you are completely familiar with the safe operation and programming of this
equipment. This equipment may be connected to other machines that have rotating parts or
WARNING parts that are controlled by this equipment. Improper use can cause serious or fatal injury.

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MEDICAL DEVICE / PACEMAKER DANGER: Magnetic and electromagnetic fields in the

vicinity of current carrying conductors and industrial motors can result in a serious health
WARNING hazard to persons with cardiac pacemakers, internal cardiac defibrillators, neurostimulators,
metal implants, cochlear implants, hearing aids, and other medical devices. To avoid risk,
stay away from the area surrounding a motor and its current carrying conductors.
Be sure all wiring complies with the National Electrical Code and all regional and local
codes. Improper wiring may result in unsafe conditions.
CAUTION
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
CAUTION be used as appropriate.
Improper operation or programming of the drive may cause violent motion of the motor and
driven equipment. Be certain that unexpected motor movement will not cause injury to
CAUTION personnel or damage to equipment. Peak torque of several times the rated motor torque
can occur during control failure.
If the drive enable signal is already present when power is applied to the MotiFlex e100, the
motor could begin to move immediately.
CAUTION
The metal heatsink on the left side of the MotiFlex e100 can become very hot during
normal operation.
CAUTION
The metal part of the MotiFlex e100 case incorporates prominent edges and corners that
may cause minor injury if the drive is handled without proper care and attention.
CAUTION
Take care when lifting. The 48 A and 65 A models weigh 12.45 kg (27.4 lb). Seek
assistance if necessary. When carrying, do not suspend the unit from the removable front
CAUTION panels as they could detach and cause the unit to be dropped.

When operating a rotary motor with no load coupled to its shaft, remove the shaft key to
prevent it flying out when the shaft rotates.
CAUTION
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.
NOTICE
To prevent equipment damage, be certain that the input power has correctly sized protective
devices installed.
NOTICE
To prevent equipment damage, be certain that input and output signals are powered and
referenced correctly.
NOTICE
To ensure reliable performance of this equipment be certain that all signals to/from the drive
are shielded correctly.
NOTICE
Suitable for use on a circuit capable of delivering not more than the RMS symmetrical short
circuit amperes listed here, at the rated maximum voltage (480 VAC):
Horsepower RMS Symmetrical Amperes
NOTICE
1-50 5,000

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Avoid locating the drive immediately above or beside heat generating equipment, or directly
below water or steam pipes.
NOTICE
Avoid locating the drive in the vicinity of corrosive substances or vapors, metal particles and
dust.
NOTICE
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.
NOTICE
Baldor does not recommend using “Grounded Leg Delta” transformer power leads that may
create earth/ground loops and degrade system performance. Instead, we recommend using
a four wire Wye.
NOTICE
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.
NOTICE
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
NOTICE
Compatibility Directive and the Low Voltage Directive. In the United States this is the National
Electrical code and local codes.
Drives must be installed inside an electrical cabinet that provides environmental control and
protection. Installation information for the drive is provided in this manual. Motors and
controlling devices that connect to the drive should have specifications compatible to the
NOTICE
drive. If not installed in an electrical cabinet, barriers around the equipment are required.
Failure to meet cooling air flow requirements will result in reduced product lifetime and/or
drive overtemperature trips.
NOTICE
Violent jamming (stopping) of the motor during operation may damage the motor and drive.

NOTICE
Operating the MotiFlex e100 in Torque mode with no load attached to the motor can cause
the motor to accelerate rapidly to excessive speed.
NOTICE
Do not tin (solder) exposed wires. Solder contracts over time and may cause loose
connections. Use crimp connections where possible.
NOTICE
Electrical components can be damaged by static electricity. Use ESD (electrostatic
discharge) procedures when handling this drive.
NOTICE
If the drive is subjected to high potential (‘hipot’) testing, only DC voltages may be applied.
AC voltage hipot tests could damage the drive. For further information please contact your
local Baldor representative.
NOTICE
Ensure that encoder wires are properly connected. Incorrect installation may result in
improper movement.
NOTICE
Removing the cover will invalidate UL certification.

NOTICE

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 2 Introduction
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2.1 MotiFlex e100 features

The MotiFlex e100 is a versatile brushless servo drive, providing a flexible and powerful motion
control solution for rotary and linear motors. Standard features include:

H Single axis AC brushless drive.

H Range of models with continuous current ratings of:
1.5 A, 3 A, 6 A, 10.5 A, 16 A, 21 A, 26 A, 33.5 A, 48 A and 65 A.
H Direct connection to 230 - 480 VAC three-phase supplies.
H Ability to provide power to, or derive power from, a DC busbar
connection shared with neighboring drives.
H Universal feedback interface supporting incremental encoder, BiSS,
EnDat, SSI or SinCos feedback.
H Position, velocity and current control.
H Auto-tuning wizard (including position loop) and software oscilloscope
facilities provided by Mint WorkBench v5.5 configuration software
(supplied).
H 3 optically isolated general purpose digital inputs. Two inputs have
‘fast input’ capability, providing real-time position capture.
H 1 optically isolated drive enable input.
H 1 optically isolated general purpose digital output.
H 1 optically isolated digital output to indicate error conditions.
H 1 motor temperature switch input.
H 1 general purpose ±10 V analog input.
H USB 1.1 serial interface (compatible with USB 2.0).
H CANopen protocol for communication with Mint controllers and other
third party CANopen devices.
H Ethernet POWERLINK & TCP/IP support: Twin Ethernet ports with
integrated hub for communication with host PC or other Ethernet
POWERLINK devices.
H Programmable in Mint.
MotiFlex e100 can operate a large range of brushless rotary and linear servo motors. It can also
operate induction motors using closed-loop vector control. For information on selecting Baldor
motors, please see the sales brochure BR1202 available from your local Baldor representative.

This manual is intended to guide you through the installation of MotiFlex e100. The sections
should be read in sequence.

The Basic Installation section describes the mechanical installation of the MotiFlex e100, the
power supply connections and motor connections. The other sections require knowledge of the
low level input/output requirements of the installation and an understanding of computer software
installation. If you are not qualified in these areas you should seek assistance before proceeding.

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2.2 Receiving and inspection

When you receive your MotiFlex e100, there are several things you should do immediately:

1. Check the condition of the shipping container and report any damage immediately to the
carrier that delivered your MotiFlex e100.
2. Remove the MotiFlex e100 from the shipping container and remove all packing material. The
container and packing materials may be retained for future shipment.
3. Verify that the catalog number of the MotiFlex e100 you received is the same as the catalog
number listed on your purchase order. The catalog number is described in the next section.
4. Inspect the MotiFlex e100 for external damage during shipment and report any damage to
the carrier that delivered your MotiFlex e100.
5. If MotiFlex e100 is to be stored for several weeks before use, be sure that it is stored in a
location that conforms to the storage humidity and temperature specifications shown in
section 8.8.

Note: The 48 A and 65 A MotiFlex e100 have a recess at the rear of the product which is
filled with a block of packaging foam. Remove this foam before mounting the drive.

2.2.1 Identifying the catalog number

The MotiFlex e100 is available with different current ratings. The catalog number is marked on
the side of the unit. It is a good idea to look for the catalog number (sometimes shown as ID/No:)
and write it in the space provided here:

Catalog number: MFE_____________________

Installed at: ________________________ Date: ______

A description of a catalog number is shown here, using the example MFE460A003x:

Meaning Alternatives
MFE MotiFlex e100 family -
460 Requires an AC supply voltage of 230 - 480 Volts, 3Φ -
A001=1.5 A; A006=6 A;
A010=10.5 A; A016=16 A;
A003 Continuous current rating of 3 A A021=21 A; A026=26 A;
A033=33.5 A; A048=48 A;
A065=65 A
x A letter indicating the hardware revision. This does not
affect the capabilities of the MotiFlex e100 unless -
otherwise stated.

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2.3 Units and abbreviations

The following units and abbreviations may appear in this manual:

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

W .............. Watt
A ............... Ampere
Ω ............... Ohm
μF . . . . . . . . . . . . . . microfarad
pF . . . . . . . . . . . . . . picofarad
mH . . . . . . . . . . . . . millihenry

Φ............... phase
ms . . . . . . . . . . . . . . millisecond
μs . . . . . . . . . . . . . . microsecond
ns . . . . . . . . . . . . . . nanosecond

mm . . . . . . . . . . . . . millimeter
m............... meter
in . . . . . . . . . . . . . . . inch
ft . . . . . . . . . . . . . . . feet
lbf-in . . . . . . . . . . . . pound force inch (torque)
N·m . . . . . . . . . . . . . Newton meter (torque)

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

ASCII . . . . . . . . . . . American Standard Code for Information Interchange
AWG . . . . . . . . . . . . American Wire Gauge
CAL . . . . . . . . . . . . CAN Application Layer
CAN . . . . . . . . . . . . Controller Area Network
CDROM . . . . . . . . . Compact Disc Read Only Memory
CiA . . . . . . . . . . . . . CAN in Automation International Users and Manufacturers Group e.V.
CTRL+E . . . . . . . . . on the PC keyboard, press Ctrl then E at the same time.
DAC . . . . . . . . . . . . Digital to Analog Converter
DS301 . . . . . . . . . . CiA CANopen Application Layer and Communication Profile
DS401 . . . . . . . . . . CiA Device Profile for Generic I/O Devices
DS402 . . . . . . . . . . CiA Device Profile for Drives and Motion Control
DS403 . . . . . . . . . . CiA Device Profile for HMIs
EDS . . . . . . . . . . . . Electronic Data Sheet
EMC . . . . . . . . . . . . Electromagnetic Compatibility
EPL . . . . . . . . . . . . Ethernet POWERLINK
HMI . . . . . . . . . . . . . Human Machine Interface
ISO . . . . . . . . . . . . . International Standards Organization
Kbit/s . . . . . . . . . . . kilobits per second
LCD . . . . . . . . . . . . Liquid Crystal Display
Mbit/s . . . . . . . . . . . megabits per second
MB . . . . . . . . . . . . . megabytes
MMC . . . . . . . . . . . . Mint Machine Center
(NC) . . . . . . . . . . . . Not Connected
RF . . . . . . . . . . . . . . Radio Frequency
SSI . . . . . . . . . . . . . Synchronous Serial Interface
TCP/IP . . . . . . . . . . Transmission Control Protocol / Internet Protocol
UDP . . . . . . . . . . . . User Datagram Protocol

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2.4 Standards
The MotiFlex e100 has been designed and tested to comply with the following standards.

2.4.1 Design and test standards

H UL508C: Power Conversion Equipment.
H UL840: Insulation coordination including clearance and creepage distances for
electrical equipment.
H EN61800-5-1: Adjustable speed electrical power drive systems. Safety requirements.
Electrical, thermal and energy.
H EN50178: Electronic equipment for use in power installations.
H EN60529: Degrees of protection provided by enclosures.
H EN61800-3: When installed as directed in this manual, MotiFlex e100 conforms to the
category C3 emission limits and the ‘second environment’ immunity
requirements defined by this standard.
See also the CE certificate on page D-2.

2.4.2 Environmental test standards:

H EN60068-1: Environmental testing, general and guidance.
H EN60068-2-32: Environmental testing, Test Ed. Free Fall.
H EN60068-2-2: Environmental testing, Test B. Dry heat.
H EN60068-2-78: Environmental testing, Test cab. Damp heat, steady state.

2.4.3 Marks

See also Appendix D for general recommendations for CE compliance.

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3.1 Introduction
You should read all the sections in Basic Installation to ensure safe installation.
This section describes the mechanical and electrical installation of the MotiFlex e100 in the
following stages:

H Location considerations.
H Mounting the MotiFlex e100.
H Connecting the AC power supply.
H Connecting the optional 24 VDC control circuit backup supply.
H Connecting the motor.
H Installing a regeneration resistor (Dynamic Brake).

3.1.1 Power sources

A 230 - 480 VAC 3-phase power source (IEC1010 over-voltage category III or less) in the
installation area is required. An AC power filter is required to comply with the CE directive for
which the MotiFlex e100 was tested (see section 3.4.10).

The optional 24 VDC control circuit backup supply must be a regulated power supply with a
continuous current supply capability of up to 1.5 A, dependent on the number of option cards
fitted. See section 3.6 for details.

3.1.2 Hardware requirements

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

H AC power supply filter (for CE compliance).

H The motor that will be connected to the MotiFlex e100.
H A motor power cable.
H An incremental encoder feedback cable, SSI cable, or BiSS / EnDat / SinCos cable.
A separate Hall cable might also be required for linear motors.
H A USB cable.
H (Optional) 24 VDC control circuit backup power supply.
H (Optional) A regeneration resistor (Dynamic Brake) might be required, depending on the
application. Without the regeneration resistor, the drive may produce an overvoltage fault. All
MotiFlex e100 models have overvoltage sensing circuitry. Regeneration resistors may be
purchased separately - see section 3.8 and appendix A.

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H A PC with the following minimum specification:

Minimum specification Recommended specification

Processor 32-bit Intel / AMD processor, 32-bit or 64-bit Intel / AMD dual-
500 MHz core processor, 2 GHz or faster

RAM 256 MB 1 GB
Hard disk space 100 MB 100 MB
Communication USB port (USB 1.1 full-speed), or
Ethernet port (100 Mbit/s, independent of office network)*

Screen 1024 x 768, 16-bit color 1280 x 1024, 16-bit color

Mouse A mouse or similar pointing device.
(Mint WorkBench does not support touch)

Operating Windows XP Windows XP, Windows Vista, or

system Windows 7 (32-bit or 64-bit)

* The Ethernet configuration used by a normal office PC is not suitable for direct
communication with the MotiFlex e100. It is recommended to install a separate dedicated
Ethernet adapter in the PC, which can be configured for use with the MotiFlex e100. See
section 6.2.4.

3.1.3 Tools and miscellaneous hardware

H Your PC operating system user manual might be useful if you are not familiar with Windows.
H Small screwdriver(s) with a blade width of 2.5 mm (1/10 in) or less for connector X3.
H M5 screws or bolts for mounting the MotiFlex e100.

3.1.4 Other information needed for installation

This information is useful (but not essential) to complete the installation:

H The data sheet or manual provided with your motor, describing the wiring information of the
motor cables/connectors.
H Knowledge of whether the digital input signals will be ‘Active Low’ or ‘Active High’.

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3.2 Mechanical installation

It is essential that you read and understand this section before beginning the
installation.
Take care when lifting. The 48 A and 65 A models weigh 12.45 kg (27.4 lb). Seek
assistance if necessary. When carrying, do not suspend the unit from the
CAUTION removable front panels as they could detach and cause the unit to be dropped.
Avoid locating the MotiFlex e100 immediately above or beside heat generating
equipment, or directly below water steam pipes.
NOTICE
Avoid locating the MotiFlex e100 in the vicinity of corrosive substances or vapors,
metal particles and dust.
NOTICE
Failure to meet cooling air flow requirements will result in reduced product lifetime
and/or drive overtemperature trips.
NOTICE

The safe operation of this equipment depends upon its use in the appropriate environment.
The following points must be considered:

H The MotiFlex e100 must be installed indoors, permanently fixed and located so that it can
only be accessed by service personnel using tools. When installed in a cabinet, the cabinet
must have a volume of at least 0.19 m3 (6.84 cu.ft). If not installed in a cabinet, barriers
around the equipment are required.
H The maximum suggested operating altitude is 1000 m (3300 ft).
H The MotiFlex e100 must be installed where the pollution degree according to EN61800-5-1
shall not exceed 2.
H The optional 24 VDC control circuit backup supply must be installed so that the 24 VDC
supplied to the unit is isolated from the AC supply either by using double or reinforced
insulation, or by using basic insulation with a protective earth.
H The input of the control circuit must be limited to Extra Low Voltage circuits.
H Both the AC supply and the optional 24 VDC control circuit backup supply must be fused.
H The atmosphere must not contain flammable gases or vapors.
H There must not be abnormal levels of nuclear radiation or X-rays.
H To comply with CE directive 2004/108/EC an appropriate AC filter must be installed.
H The MotiFlex e100 must be secured by the slots in the metal mounting flanges. The
protective earth/ground (the threaded studs on the top and bottom mounting flanges) must
be bonded to a safety earth/ground using either a 25 A conductor or a conductor of three
times the peak current rating - whichever is the greater.
H The metal tab at the bottom of the case is used for attaching a cable clamp (section A.1.6).
H The D-type connectors on the top and bottom panels of the MotiFlex e100 are secured using
two hexagonal jack screws (sometimes known as “screwlocks”). If a jack screw is removed
accidentally or lost it must be replaced with a #4-40 UNC jack screw with an external male
threaded section no longer than 10 mm (0.4 in).
H The 48 A and 65 A MotiFlex e100 have a recess at the rear of the product which is filled
with a block of packaging foam. Remove this foam before mounting the drive.

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3.2.1 Dimensions - 1.5 A ~ 16 A models

75 8
(2.95) (0.31)

50 12.5
(1.97) (0.49)

(0.24)
6
Mounting hole and slot detail

A 6 mm
B B 12 mm
C
C 12.7 mm
D 6 mm
E 6 mm

D
E
(13.78)

(14.25)

Dimensions shown as: mm (inches).

350

362

Depth: 260 mm (10.24 in)

Weight: 1.5 A: 1.90 kg (4.2 lb)
3 A: 1.90 kg (4.2 lb)
6 A: 1.90 kg (4.2 lb)
10.5 A: 4.80 kg (10.6 lb)
16 A: 5.80 kg (12.8 lb)

Note: The case is 76 mm wide, which

is 1 mm wider than the mounting plate.
For this reason, when mounting
multiple drives side-by-side for DC
bus sharing, it is advisable to use the
method described in section 3.2.4.1 to
avoid errors when marking hole
positions.

76
(2.99)

Figure 1 - Mounting and overall dimensions - 1.5 A ~ 16 A models

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3.2.2 Dimensions - 21 A ~ 33.5 A models

127 8
(4.99) (0.31)

100 13.5
(3.94) (0.53)

(0.24)
6
Mounting hole and slot detail

A 6 mm
B B 12 mm
C
C 12.7 mm
D 6 mm
E 6 mm

D
E
(13.78)

(14.25)

Dimensions shown as: mm (inches).

350

362

Depth: 260 mm (10.24 in)

Weight: 21 A: 5.85 kg (12.9 lb)
26 A: 6.35 kg (14.0 lb)
33.5 A: 6.35 kg (14.0 lb)

Note: The case is 128 mm wide, which

is 1 mm wider than the mounting plate.
For this reason, when mounting
multiple drives side-by-side for DC
bus sharing, it is advisable to use the
method described in section 3.2.4.1 to
avoid errors when marking hole
positions.

128
(5.04)

Figure 2 - Mounting and overall dimensions - 21 A ~ 33.5 A models

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3.2.3 Dimensions - 48 A ~ 65 A models

212 8
(8.35) (0.31)

92.5 92.5 13.5

(3.64) (3.64) (0.53)

(0.24)
6
Mounting hole and slot detail

B
C

D
E

A 6 mm
(13.78)

(14.25)
B 12 mm
350

362

C 12.7 mm
D 6 mm
E 6 mm

Dimensions shown as: mm (inches)

Depth: 260 mm (10.24 in)

Weight: 48 A: 12.45 kg (27.4 lb)
65 A: 12.45 kg (27.4 lb)

Note: The case is 213 mm wide,

which is 1 mm wider than the
mounting plate. For this reason,
when mounting multiple drives
side-by-side for DC bus sharing, it
is advisable to use the method
described in section 3.2.4.1 to
avoid errors when marking hole
positions.

213
(8.39)

Figure 3 - Mounting and overall dimensions - 48 A ~ 65 A models

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3.2.4 Mounting the MotiFlex e100

Ensure you have read and understood the Mechanical installation and location requirements in
section 3.2. Mount the MotiFlex e100 vertically on its rear side, the side opposite the front panel.
M5 bolts or screws should be used to mount the MotiFlex e100. Detailed dimensions are shown
in section 3.2.1.
Note: The 48 A and 65 A MotiFlex e100 have a recess at the rear of the product which is
filled with a block of packaging foam. Remove this foam before mounting the drive.

For effective cooling, the MotiFlex e100 must be mounted upright on a smooth vertical metal
surface. The MotiFlex e100 is designed to operate in an ambient temperature of 0 °C to 45 °C
(32 °F to 113 °F). Output current must be derated between 45 °C (113 °F) and the absolute
maximum ambient temperature of 55 °C (131 °F). All models incorporate cooling fans and are
designed to operate without any additional cooling methods.

Temperature derating characteristics are shown in sections 8.3.5 to 8.3.14.

3.2.4.1 Mounting multiple drives for DC bus sharing

The MotiFlex e100 is designed to be mounted in close contact with other MotiFlex e100s, to allow
the optional DC busbar kits (Baldor parts OPT-MF-DC-A, -B, -C or -D) to be connected across
the top of the drives. Each busbar kit contains two busbars and the necessary screws. When
mounting drives for DC bus sharing it is essential that they are accurately positioned in contact
with the neighboring drive, otherwise the busbars will not fit.

Mount the rightmost drive first, but do not fully tighten the top left screw. Take the next drive and
hold it against the left side of the first drive. Slide it downwards until the alignment tab (see Figure
4) on the side of the mounting flange fits behind the matching cutout on the first drive’s mounting
flange. Tighten the first drive’s top left screw. Holding the second drive in place, mark its mounting
holes. Remove the second drive, finish the mounting holes and then remount the drive. Use the
same procedure to mount further drives to the left of the second drive.

3. ...and slide down until alignment

tab engages behind first drive.

Alignment tab

2. Press second drive

against the first drive...
1. Mount rightmost
drive first, leaving
top left screw
slightly loose.

FRONT

FRONT

Figure 4 - Mounting MotiFlex e100s for DC bus sharing

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3.2.4.2 Attaching the busbars for DC bus sharing

Busbars are supplied in kits, comprising a pair of busbars and all screws and washers required
for fitting. There are 4 different busbar sizes, allowing any combination of narrow bodied
MotiFlex e100 (1.5 A ~ 16 A models), wide bodied MotiFlex e100 (21 A ~ 33.5 A models) or
extended bodied MotiFlex e100 (48 A ~ 65 A models) to be connected, as shown in Figure 6. Size
3 and size 4 busbars have an insulating sleeve, since parts of them are exposed when fitted. See
also section 3.5 for details about sharing the DC bus.

Hazardous voltages exist underneath the drive’s hinged top cover! Before
lifting the cover ensure that AC power has been removed from the source
DANGER drive and at least 5 minutes have elapsed to allow the DC bus output
capacitors to discharge. Use only original Baldor busbar kits, parts
OPT-MF-DC-x.

Always observe the correct polarity. The busbar nearest the front of the
MotiFlex e100 is positive. The busbar at the rear is negative, as shown in Figure 5.
WARNING

1. Loosen the busbar cover retaining screw to reveal the busbar

mounting pads.
Rear

- -
+ +
Front

2. Attach the busbars using the supplied screws and washers.

Tighten screws to approximately 2 N·m (17.7 lb-in).
Rear

- - -
+ + +
Front

3. Close the busbar cover and tighten the retaining screw to

approximately 1 N·m (8.9 lb-in). Do not exceed 2 N·m (17.7 lb-in).

Figure 5 - Connecting busbars for DC bus sharing

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RIGHT

21 - 33.5 A
1.5 - 16 A

48 - 65 A
1.5 - 16 A

A A C
21 - 33.5 A
LEFT

B B D
48 - 65 A

B B D

Busbar selection: Size 1 busbar - kit OPT-MF-DC-A

1) From the LEFT column, select the

drive that will be on the left. 55 mm

2) From the RIGHT row, select the drive

that will be on the right. Size 2 busbar - kit OPT-MF-DC-B

3) The intersecting letter indicates the

busbar required to connect the 107 mm
selected drives.
Size 3 busbar - kit OPT-MF-DC-C
For example, B indicates that
OPT-MF-DC-B is required.
140.4 mm

Size 4 busbar - kit OPT-MF-DC-D

192 mm

Figure 6 - Busbar requirements according to drive combinations

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3.2.5 Overtemperature trips and intelligent fan control

The MotiFlex e100 contains internal temperature sensors that will cause it to trip and disable if
the control card or output power module temperatures exceed preset values. These values are
listed in the following table, and can also be read using the TEMPERATURELIMITFATAL
keyword - see the Mint help file for details.

MotiFlex e100 Maximum control card Maximum power module (PIM)

catalog number temperature temperature
MFE460A001
105 °C
MFE460A003
(221 °F)
F)
73 °C
MFE460A006
(163.4 °F)
F)
MFE460A010 115 °C
C
MFE460A016 (239 °F)
MFE460A021
62 °C 115 °C
MFE460A026
(143.6 °F)
F) (239 °F)
F)
MFE460A033
MFE460A048 62 °C
C 115 °C
C
MFE460A065 (143.6 °F) (239 °F)

Table 1 - Maximum internal trip temperatures

The MotiFlex e100 can detect problems with its cooling fan, such as disconnection (fan loss) or
overcurrent caused by stalling. The 10.5 A and 16 A models incorporate two cooling fans; one
fan operates continuously, but to increase overall lifetime and efficiency the second fan operates
only when necessary. Also, if a fault is detected on the first fan, the other one will turn on. The
48 A and 65 A models incorporate four cooling fans; none of the fans are required in normal
conditions, but all four will operate when necessary.

3.2.5.1 Effects of mounting surface and proximity

If the MotiFlex e100 is mounted above or below another MotiFlex e100 (or other obstruction),
there should be a minimum space of 90 mm to maintain effective cooling. Remember that when
a MotiFlex e100 is mounted above another MotiFlex e100 or heat source, it will be receiving air
that has been already heated by the device(s) below it.

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3.3 Connector locations

3.3.1 Front panel connectors
To remove the top cover, push on the center of the bottom edge, then pull
the top edge forwards. To refit, locate the cover over its intended position
and then push on until it snaps into place.

Option slot 1 retaining screw.

X6 RS485 (2-wire)
1 TXA
2 TXB
3 GND
4 +7V out
5 (NC)
6 (NC)
LEDs
The STATUS, CAN and ETHERNET
LEDs are described in section 7.2.1.

Node ID
These switches set the MotiFlex e100’s
node ID for Ethernet POWERLINK, and the
final value of the IP address when using
TCP/IP. See sections 5.8.1 and 6.2.4.

USB
1 (NC)
2 Data-
3 Data+
4 GND

To remove the bottom cover, push on the oval indentation and slide the
cover downwards. To refit, insert the two tabs, protruding from the cover’s
top edge, into the main body. Push on the Baldor label to snap into place.

X2 18 VDC output / 24 VDC backup input

18 V out / 24 V in
0V

X3 Input / Output
1 Status- 13 Status+
2 DGND 14 DGND
3 DOUT1- 15 DOUT1+
4 DIN2- 16 DIN2+
5 DGND 17 DGND
6 DIN1- 18 DIN1+
7 DIN0- 19 DIN0+
8 DGND 20 DGND
9 Drive enable- 21 Drive enable+
10 Shield 22 Shield
11 AGND 23 AGND
12 AIN0- 24 AIN0+

Option slot 2 retaining screw.

Tightening torque for terminal block connections (X2 & X3) is 0.5-0.6 N·m (4.4-5.3 lb-in).
Tightening torque for option slot 1/2 retaining screws is 0.7 N·m (6.2 lb-in).
Maximum wire / ferrule size (X2): 2.5 mm2 (14 AWG).
Maximum wire size (X3): 0.5 mm2 (20 AWG). Connector X3 is designed to accept bare wires only; do not use
bootlace ferrules.
(NC) = Not Connected. Do not make a connection to this pin.

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3.3.2 Top panel connectors

X1 AC power & regen X1 AC power & regen

(1.5 A ~ 16 A models) (21 A ~ 65 A models)

L1 AC Phase 1 L1 AC Phase 1
L2 AC Phase 2 L2 AC Phase 2
L3 AC Phase 3 L3 AC Phase 3
R1 Regeneration R1 Regeneration
R2 resistor
R2 resistor

Tightening torque: Tightening torque:

0.5-0.6 N·m (4.4-5.3 lb-in) L1/L2/L3: 1.7 N·m (15 lb-in)
Maximum wire / ferrule size: R1/R2: 1.7 N·m (15 lb-in)
X1: 4 mm2 (11 AWG). Maximum wire / ferrule size:
L1/L2/L3: 16 mm2 (5 AWG).
R1/R2: 16 mm2 (5 AWG).

Busbar cover retaining screw. Tightening torque is 1 N·m (8.9 lb-in).

CAN
1 (NC)
2 CAN-
3 CAN GND
4 (NC)
5 Shield
6 CAN GND
7 CAN+
8 (NC)
9 CAN V+

Option slot 1 cover

Ethernet
1 TX+ Both connectors have
2 TX- identical pinouts.
3 RX+
4 (NC)
5 (NC)
6 RX-
7 (NC)
8 Shield

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3.3.3 Bottom panel connectors

X8 Feedback In
Pin Incremental SinCos BiSS / SSI EnDat
1 CHA+ (NC) Data+ Data+
2 CHB+ (NC) Clock+ Clock+
3 CHZ+ (NC) (NC) (NC)
4 Sense Sense Sense Sense
5 Hall U- Sin- (NC) Sin-*
6 Hall U+ Sin+ (NC) Sin+*
7 Hall V- Cos- (NC) Cos-*
8 Hall V+ Cos+ (NC) Cos+*
9 CHA- (NC) Data- Data-
10 CHB- (NC) Clock- Clock-
11 CHZ- (NC) (NC) (NC)
12 +5V out +5V out +5V out +5V out
13 DGND DGND DGND DGND
14 Hall W- (NC) (NC) (NC)
15 Hall W+ (NC) (NC) (NC)
Shell Shield Shield Shield Shield
* EnDat v2.1 only. EnDat v2.2 does not use the Sin and
Cos signals.

Option slot 2 cover

X16 Motor temperature switch

1 TH1
2 TH2

Tightening torque: 0.5-0.6 N·m (4.4-5.3 lb-in).

Maximum wire size: 2.5 mm2 (14 AWG).

Cooling fan air inlet slots.

Ensure these slots remain free of obstructions at all times.

X17 Motor power out X17 Motor power out

(1.5 A ~ 16 A models) (21 A ~ 65 A models)

U Motor U out U Motor U out

V Motor V out V Motor V out
W Motor W out W Motor W out

Tightening torque: Tightening torque:

0.5-0.6 N·m (4.4-5.3 lb-in). 1.7 N·m (15 lb-in).
Maximum wire size: Maximum wire size:
4 mm2 (11 AWG). 16 mm2 (5 AWG).

IMPORTANT NOTE!
Motor power cables must be correctly bonded to earth.
See section 3.7.1 for details.

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3.4 AC power connections

This section provides instructions for connecting the AC power supply. For full specifications,
see section 8.
The installer of this equipment is responsible for complying with NEC (National Electric Code)
guidelines or CE (Conformite Europeene) directives and application codes that govern wiring
protection, earthing/grounding, disconnects and other current protection.

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
DANGER disconnected and there is no high voltage present from this equipment or
other equipment to which it is connected.
To prevent equipment damage, be certain that the input power has correctly rated
protective devices installed.
NOTICE
To prevent equipment damage, be certain that input and output signals are powered
and referenced correctly.
NOTICE
To ensure reliable performance of this equipment be certain that all signals to/from
the MotiFlex e100 are shielded correctly.
NOTICE

MotiFlex e100 drives are designed to be powered from standard three-phase lines that are
electrically symmetrical with respect to earth/ground. The power supply module within all
MotiFlex e100 models provides rectification, smoothing and current surge protection. Fuses or
circuit breakers are required in the input lines for cable protection.
Note: A Residual Current Device (RCD) must not be used for fusing the drive.
An appropriate type of circuit breaker or fuse must be used.
All interconnection wires should be in metal conduits between the MotiFlex e100, AC power
source, motor, host controller and any operator interface stations.

3.4.1 Earthing / grounding

Permanent earth/ground bonding points are provided on the mounting flanges, which must be
used as the protective earth. They are labeled with the protective earth symbol and do not form
any other mechanical function. Earthing methods are shown in section 3.4.4.
These protective earth/ground points prevent exposed metal parts of the MicroFlex e100 from
becoming live in the event of a wiring error or other failure. Connecting these points to earth does
not provide protection against electromagnetic contamination received or emitted by the drive
and its associated wiring. For example, the motor power output cable supplies a high frequency
high current waveform to the motor, so the cable’s shielding must be separately bonded to a
functional earth point to prevent the cable radiating electromagnetic contamination into the
surrounding area. Such contamination can cause spurious errors in apparently unrelated parts
of the installation, such as low voltage communication cables. See sections 3.4.2 and 3.7.1 for
detailed installation instructions that will help reduce electromagnetic contamination.

Note: When using unearthed/ungrounded distribution systems, an isolation transformer

with an earthed/grounded secondary is recommended. This provides three-phase
AC power that is symmetrical with respect to earth/ground and can prevent
equipment damage.

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3.4.2 AC input and regeneration resistor output wiring

The installation methods shown in Figure 7 will improve the reliability of the system, reduce
troubleshooting time, and optimize the EMC (electromagnetic compatibility) behavior of the
control system. The MotiFlex e100’s protective earth connection does not provide
electromagnetic compatibility. Its purpose is to prevent exposed metalwork becoming live in the
case of a serious failure. To avoid EMC coupled effects within the panel design:

1. Do not run AC filter input and output power cables in close proximity.
2. Do not run motor output power cables with any other cables, especially Ethernet, signal
cables, or ’clean’ AC power.
3. Do not run power and signal cables in the same trunking. If the cables must run in parallel,
they should be separated by 200 mm (8 in) or placed in separate metal trunking.
4. If any of the above cables must cross, they must do so at 90 degrees to minimize coupling.
5. Ensure all sources of electrical noise are suppressed, e.g. solenoids, relays, contactors.

Connect AC power cable shield to

metal panel, using conductive shield
earth/ground clamps.

AC power
from fuses
and reactor

AC power wires
should be as short as
Mount AC filter and
possible, typically
MotiFlex e100 on the
less than 0.3 m (1 ft).
same metal panel.
Longer wires must
be shielded as
shown.
Wire colors
Regeneration resistor. may vary
For long cables, use according
shielding as shown for AC to region.
power cables.

OPT-CM-001
CAUTION
DO NOT TOUCH!
Regeneration resistors can Drive
become extremely hot! earth
Locate away from vulnerable must be
components and wiring at least
10 mm2
(7 AWG)

Figure 7 - Panel layout best practice

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3.4.3 Earth leakage

The following table shows typical earth leakage figures for a MotiFlex e100 with a 20 m (66 ft)
motor cable, in combination with each of the recommended AC power filters (see section 3.4.10).

MotiFlex e100 with: Typical combined earth leakage

AC power filter Motor cable (mA)
None None 6.24
FI0035A00 (8 A) 20 m 28.6
FI0035A01 (16 A) 20 m 38.7
FI0035A02 (25 A) 20 m 38.7
FI0035A04 (50 A) 20 m 45.4
FI0035A05 (66 A) 20 m 60.0

If the MotiFlex e100 and filter are mounted in a cabinet, the minimum size of the protective
earthing conductor shall comply with the local safety regulations for high protective earthing
conductor current equipment. The conductor must be 10 mm2 or larger to satisfy EN61800-5-1.

3.4.3.1 Protection class

User protection has been achieved using Protective Class I, which requires an earth connection
to the unit whenever hazardous voltages are applied. The equipment provides protection against
electric shock by:
H Means of connection of protective earth to accessible live conductive parts.
H Basic insulation.

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3.4.4 AC power connections

Location Connector X1 (top panel)

Mating connector
1.5 A ~ 16 A models Phoenix POWER COMBICON PC 4/ 5-ST-7,62
21 A ~ 33 A models Phoenix POWER COMBICON PC 16/ 3-ST-10,16
48 A ~ 65 A models Phoenix POWER COMBICON SPC 16/ 3-ST-10,16
Nominal input voltage 230 VAC or 480 VAC, 3Φ line to line
Minimum input voltage 180 VAC, 3Φ line to line (see Note)
Maximum input voltage 528 VAC, 3Φ line to line

Note: The MotiFlex e100 will trip if the DC-bus voltage falls below 200 V or 60% of the
no-load voltage, whichever occurs first. The MotiFlex e100 will stop operating if the
DC-bus voltage falls below 150 VDC, unless a 24 VDC control circuit backup supply
is present (see section 3.6).

Connect the supply to L1, L2 and L3 as shown in Figure 8. For CE compliance, an AC filter must
be connected between the AC power supply and the MotiFlex e100. If local codes do not specify
different regulations, use at least the same gauge wire for earth/ground as is used for L1, L2 and
L3. The threaded studs protruding from the top and bottom case flanges can be used as the
earth/ground connection (PE).

For 1.5 A ~ 16 A models, tightening torque for X1 terminal block connections is 0.5-0.6 N·m
(4.4-5.3 lb-in). The 21 A ~ 65 A models use a spring cage connector. For all models, tightening
torque for the flange mounted PE connection is 2.5 N·m (22.1 lb-in).

Connect earth/ground
to protective earth on
drive flange.

AC Route L1, L2, L3 and Circuit breaker Optional AC line AC filter.*

Supply earth/ground together or fuses. See reactor. See See section
in conduit or cable section 3.4.11 section 3.4.9 3.4.10
Line (L1)
Line (L2)
Line (L3)
Isolating switch
AC power wires should be as
Incoming safety short as possible, typically less
earth/ground (PE) than 0.3 m (1 ft). Longer cables
must use shielded cable with
the outer shield bonded to the
STAR POINT unpainted backplane using a
metal P-clip.

* Mount filter and MotiFlex e100

on the same metal backplane.

Figure 8 - Three-phase power connections - 1.5 A ~ 16 A models

MN1943 Basic Installation 3-17

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Connect earth/ground
to protective earth on
drive flange.

AC Route L1, L2, L3 and Circuit breaker Optional AC line AC filter.*

Supply earth/ground together or fuses. See reactor. See See section
in conduit or cable section 3.4.11 section 3.4.9 3.4.10
Line (L1)
Line (L2)
Line (L3)
Isolating switch
AC power wires should be as
Incoming safety short as possible, typically less
earth/ground (PE) than 0.3 m (1 ft). Longer cables
must use shielded cable with
the outer shield bonded to the
STAR POINT unpainted backplane using a
metal P-clip.
* Mount filter and MotiFlex e100
on the same metal backplane.

Figure 9 - Three-phase power connections - 21 A ~ 65 A models

3.4.5 AC power cycling

After AC power has been removed, no delay is necessary before reapplying AC power. However,
note that after AC power has been removed from the MotiFlex e100, high voltages (greater than
50 VDC) can remain on power connections for up to 5 minutes, while the DC bus circuitry
discharges. Do not touch the DC bus, regeneration resistor, or other power connections during
this period.

3.4.6 Inrush current

The inrush current is limited by pre-charge circuitry and is lower than the maximum AC current
expected under full load conditions (see section 8), so it should not affect fusing or supply circuit
design.

3.4.7 Phase loss detection

The MotiFlex e100 requires all three phases to be present. If any phase is lost, the MotiFlex e100
will immediately trip and disable, reporting a phase loss error (error 10029). See the Mint help file
for details about handling errors.

3.4.8 Drive overload protection

The MotiFlex e100 will immediately trip and disable if there is an overload condition. The
parameters for managing drive overloads are configured automatically by the Commissioning
Wizard (see section 6.4.3). If they need to be changed, use the Parameters tool in Mint
WorkBench (see section 6.5.1).

3-18 Basic Installation MN1943

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3.4.9 Input power conditioning

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.

If the feeder or branch circuit that provides power to the MotiFlex e100 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 MotiFlex e100.

AC line reactors may also be required under certain conditions, for example:

H If the AC supply harmonic distortion is greater than 5%. Harmonic distortion typically
occurs in regions where the quality of the AC supply is poor, for example Israel or India,
and in heavy industry.
H The supply phases are imbalanced. An imbalanced supply typically occurs where one
phase of the local three-phase supply is being used more than the other phases.
H The supply contains commutation notches. These typically occur in heavy industry, and
are caused by the commutation of large power semiconductor devices in equipment such
as large thyristor converters.
H The MotiFlex e100 is sharing its DC bus with other drives (see section 3.5).

See section A.1.3 for a range of suitable line reactors.

If the feeder or branch circuit that provides power to the MotiFlex e100 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 MotiFlex e100.

MN1943 Basic Installation 3-19

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3.4.10 Power supply filters

To comply with EC directive 2004/108/EC, an AC power filter of the appropriate type must be
connected. This can be supplied by Baldor and will ensure that the MotiFlex e100 complies with
the CE specifications for which it has been tested. Ideally one filter should be provided for each
MotiFlex e100, except in DC bus sharing applications where only the source drive requires a
filter. Filters should not be shared between drives or other equipment. Table 2 lists the appropriate
filters:

MotiFlex e100 Recommended Filter Meets Meets

catalog Baldor AC current EN61000-6-4 EN61800-3
number power filters rating Industrial standard Drives Standard
(RMS) (class A)
FI0035A00 8A No Yes
MFE460A001
FI0035A01 16A No Yes
FI0035A00 8A No Yes
MFE460A003
FI0035A01 16A No Yes
MFE460A006 FI0035A01 16A No Yes
FI0035A01 16A No Yes
MFE460A010
FI0035A02 25A Yes Yes
MFE460A016 FI0035A02 25A Yes Yes
FI0035A03 36A Yes Yes
MFE460A021 FI0035A04 50A No Yes
FI0035A05 66A No Yes
FI0035A03 36A Yes Yes
MFE460A026 FI0035A04 50A No Yes
FI0035A05 66A No Yes
FI0035A04 50A No Yes
MFE460A033
FI0035A05 66A No Yes
MFE460A048 FI0035A05 66A Yes Yes
MFE460A065 FI0035A05 66A Yes Yes

Table 2 - Baldor filter part numbers

For filter earth leakage figures, see section 3.4.3.

Note: The MotiFlex e100 is not intended to be used on a low-voltage public network
which supplies domestic premises. Radio frequency interference is expected if
used on such a network.

3-20 Basic Installation MN1943

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3.4.11 Power disconnect and protection devices

A power disconnect should be installed between the input power supply and the MotiFlex e100
for a fail-safe method to disconnect power. The MotiFlex e100 will remain in a powered condition
until all input power is removed from the drive and the internal bus voltage has depleted. The
MotiFlex e100 must have a suitable input power protection device installed, preferably a fuse.

Recommended circuit breakers are thermal magnetic devices with characteristics suitable for
heavy inductive loads (C-type trip characteristic for 1.5 A ~ 16 A models, B-type trip
characteristic for 21 A ~ 65 A models. Circuit breaker or fuses are not supplied. See sections
8.2.2 to 8.2.4 for recommended ratings. For CE compliance, see Appendix D.

From Circuit Breaker From Fuses

supply supply

L1 L1 L1

L2 L2 L2

L3 L3 L3

Circuit breaker or fuse are not supplied.

For CE Compliance, see Appendix C.

Figure 10 - Circuit breaker and fuses

Note: Metal conduit or shielded cable should be used. Connect conduits so the use of a
line reactor or RC device does not interrupt EMI/RFI shielding.

3.4.11.1Discharge period

After AC power has been removed from the MotiFlex e100, high voltages
(greater than 50 VDC) can remain on power connections for up to 5 minutes,
DANGER while the DC bus circuitry discharges. Do not touch the DC bus,
regeneration resistor, or other power connections during this period.

MN1943 Basic Installation 3-21

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3.4.12 Recommended wire sizes

All wire sizes are based on 75 °C (167 °F) copper wire. Use copper conductors only. Higher
temperature smaller gauge wire may be used per National Electric Code (NEC) and local codes.

MotiFlex e100 AC input & motor output wire size

catalog number
AWG mm2
MFE..A001 14 2.5
MFE..A003 14 2.5
MFE..A006 14 2.5
MFE..A010 10 6.0
MFE..A016 10 6.0
MFE..A021 8 10.0
MFE..A026 8 10.0
MFE..A033 8 10.0
MFE..A048 4 20.0
MFE..A065 4 20.0

Table 3 - AC input and motor output wire sizes

3-22 Basic Installation MN1943

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3.5 Sharing the DC bus

The AC power supply is rectified and smoothed within the MotiFlex e100 to create a typical ‘DC
bus’ voltage of around 678 VDC (when using a 480 VAC supply). The DC bus voltage is then
switched by a power module to create the UVW output waveforms that drive the motor. The
MotiFlex e100 is capable of sharing its DC bus voltage with similar drives mounted beside it, using
solid metal busbar connections between the drives. In a group of drives, this significantly reduces
the amount of AC power supply wiring, filters, fuses and breakers, since these are only required
by the single drive that is generating the DC bus voltage (the source drive). Furthermore, only one
regeneration resistor is required for the group (see section 3.8). The DC bus outputs are
conditionally short-circuit proof according to EN61800-5-1, 6.2. When sharing the DC bus, revised
AC input current ratings apply. See section 8.

3.5.1 DC busbar connection

Hazardous voltages exist underneath the drive’s hinged top cover! Before
lifting the cover ensure that AC power has been removed from the source
DANGER drive and at least 5 minutes have elapsed to allow the DC bus output
capacitors to discharge.

Always observe the correct polarity. The busbar nearest the front of the
MotiFlex e100 is positive. The busbar at the rear is negative, as shown in Figure 5.
WARNING
When sharing the DC bus, special care must be taken to calculate the total peak and
continuous supply current requirement of the drives, since they will all derive power
NOTICE from the source drive’s DC bus.

Only the source drive must be connected to the AC power source so that it can
generate the DC bus voltage. The receiving drives sharing the DC bus must not be
NOTICE connected to the AC power source.

In the unlikely event that one of the MotiFlex e100’s DC bus capacitors should fail
with a short circuit, an internal fast-acting fuse will trip. These fuses are not user
NOTICE replaceable. Similar fuses in other drives sharing the DC bus are also likely to trip.

The top panel of the MotiFlex e100

incorporates a cover that conceals the DC
busbar output pads. To allow sharing of the
DC bus, optional busbar kits (Baldor parts
OPT-MF-DC-A, -B, -C or -D) must be
attached to these pads using the screws
supplied with the busbars. Lift the front
edge of the cover to access the DC bus
output pads. Since the busbars have a
fixed length, accurate positioning of
adjacent drives is critical to ensure the
busbars will fit. See section 3.2.4 for
details of busbars and fitting dimensions.

Figure 11 - Shared DC bus connections

MN1943 Basic Installation 3-23

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3.5.2 ‘Power ready’ input / output

A digital output on the source drive must be connected to a digital input on each of the receiving
drives (see Figure 12). This allows the source drive to inform the receiving drives when the DC
bus is ready for use. On each drive, the chosen output / input must also be configured as the power
ready output / input. Failure to connect and configure a ‘power ready’ signal will result in the
receiving drive reporting a ‘power base not ready’ error.

The configuration of the power ready output or input is performed in Mint WorkBench’s Drive Setup
Wizard, which appears as part of the Commissioning Wizard. This is explained in section 6.4.4.2.
The POWERREADYOUTPUT and POWERREADYINPUT keywords provide an alternative method for
assigning the power ready output and input. See the Mint help file for details.

The input and output must both be ‘active high’, and the input must also be level triggered (the
default settings).

MotiFlex e100 Customer

supplied
24VDC
SOURCE supply
DRIVE ‘X3’ +24VDC 0V
MotiFlex e100
‘X3’
15 DOUT1+
Mint RECEIVING
POWERREADYOUTPUT DRIVE 1
DOUT1- DIN1+
3 18
Mint
DIN1- POWERREADYINPUT
6

MotiFlex e100
‘X3’
RECEIVING
DRIVE 2
DIN1+
18
Mint
DIN1- POWERREADYINPUT
6

MotiFlex e100
‘X3’
RECEIVING
DRIVE 3
DIN1+
18
Mint
DIN1- POWERREADYINPUT
6

Figure 12 - ‘Power ready’ output and input connections

3-24 Basic Installation MN1943

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3.5.3 Line reactors

When a drive is sharing its DC bus, a line reactor must be fitted. This should be connected between
the source drive’s fuse (or circuit breaker) and the AC input filter (see Figure 8 on page 3-17).
See section A.1.3 for further details.

MotiFlex e100 Required line reactor Recommended

catalog inductance Baldor AC line
number (mH) reactor
MFE460A001
MFE460A003 1.2 LRAC02502
MFE460A006
MFE460A010
08
0.8 LRAC03502
MFE460A016
MFE460A021
MFE460A026 0.5 LRAC05502
MFE460A033
MFE460A048
04
0.4 LRAC08002
MFE460A065

Table 4 - Baldor line reactor part numbers

MN1943 Basic Installation 3-25

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3.6 18 VDC out / 24 VDC in control circuit backup supply

Location Connector X2
(Mating connector:
Phoenix COMBICON MVSTBR 2,5 HC/ 2-ST-5,08)
When operating as an 18 V output:
Nominal output voltage 15 VDC
Range 12-19 VDC
Output current
(maximum) 50 mA (limited by PTC)
When operating as a backup supply input:
Nominal input voltage 24 VDC
Range 20-30 VDC
Maximum input current 1.2 A
(max. @ 24V)

When the AC supply is present (section 3.4), connector X2 provides an 18 VDC output. This may
be used for various purposes such as:

H A permanent connection to the drive enable input in applications where an external

controller will not be used to enable the drive (see section 5.3.1).
H A source for creating a variable analog input voltage (see Figure 43 on page 5-3).
H To provide the source supply for digital outputs (see sections 5.3.6 and 5.3.7).

Take particular care not to exceed the 18 V supply’s maximum output current of 50 mA. Exceeding
this current will cause a self-resetting fuse to operate, which may take up to 20 seconds to reset
after the load has been removed. Tightening torque for terminal block connections is 0.5-0.6 N·m
(4.4-5.3 lb-in).

The 18 VDC output is fully short-circuit proof according to EN61800-5-1, 6.2.

3.6.1 24 VDC backup supply

Optionally, an external fused 24 VDC backup supply may be connected directly to connector X2
to power the controlling electronics. During normal operation, this supply is not used by the
MotiFlex e100. However, if AC power (or shared DC bus power) is lost or needs to be removed
from the drive, the controlling electronics will lose their internal supply. In this situation, the
external 24 VDC supply is employed to ensure the controlling electronics remain powered and
retain position and I/O information.

For detailed specifications of the 18 VDC out / 24 VDC in connection, see section 8.5.

3-26 Basic Installation MN1943

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3.6.2 24 VDC control circuit backup supply wiring

When multiple MotiFlex e100 are mounted side-by-side for DC bus sharing (see section 3.5), the
24 VDC backup supply wiring can be reduced. A channel and supporting tabs are built-in to the
front panel of the drive to allow easy ‘daisy-chaining’ of the 24 VDC backup supply, as shown in
Figure 13.

Customer
supplied
24 VDC
Fuse *
+24 V

GND

* Recommended fuse:
Bussman S504 20x5 mm anti-surge 2.5 A.

Figure 13 - ‘Daisy-chained’ 24 VDC backup supply wiring

MN1943 Basic Installation 3-27

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3.7 Motor connections

Location Connector X17 (bottom panel)
Mating connector
1.5 A ~ 16 A models Phoenix POWER COMBICON PC 4/ 3-ST-7,62
21 A ~ 33 A models Phoenix POWER COMBICON IPC 16/ 3-ST-10,16
48 A ~ 65 A models Phoenix POWER COMBICON ISPC 16/ 3-ST-10,16
AC supply voltage 230 VAC, 3Φ 480 VAC, 3Φ
Output voltage range 0-230 VAC, 3Φ 0-480 VAC, 3Φ

MotiFlex e100 will operate with a large number of brushless servo motors. For information on
selecting Baldor servo motors please see the sales brochure BR1202, available from your local
Baldor representative. The motor must be capable of being powered by an inverter PWM output
- see sections 8.3.1 to 8.3.3 for details. The motor can be connected directly to the MotiFlex e100
or through a motor contactor (M-Contactor). The motor outputs are fully short-circuit proof
according to EN61800-5-1, 6.2. Motors should ideally have a minimum inductance of 1 mH per
winding; for motors with lower inductance an output reactor may be fitted in series with the motor.

When using a Baldor motor, the parameters for managing motor overloads are configured
automatically by the Commissioning Wizard (see section 6.4.3). If they need to be changed, or
you are using an alternative motor, use the Parameters tool in Mint WorkBench (see section
6.5.1).

For full motor output specifications, see section 8.3.

Hazardous voltages can exist on the motor output connections. Do not

touch the motor output connections before you first ensure there is no high
DANGER voltage present.

The motor leads U, V and W must be connected to their corresponding U, V or W

terminal on the motor. Misconnection will result in uncontrolled motor movement.
NOTICE

Do not connect AC supply power to the MotiFlex e100 UVW outputs. This could
damage the MotiFlex e100.
NOTICE

For CE compliance, the motor earth/ground should be connected to the drive earth/ground, and
the motor power cable must be shielded; see section 3.7.1. The connector or gland used at the
motor must provide 360 degree shielding. The maximum recommended cable length is 30.5 m
(100 ft). See section 3.4.12 for recommended wire sizes.

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Motor
Optional motor
circuit contactor. Unshielded
lengths should
be as short as
U possible.

W
Connect motor
To earth/ground outer shield, use 360° clamps earth/ground to
connected to backplane. protective earth on
drive flange.
Earth

Figure 14 - Motor connections - 1.5 A ~ 16 A models

Motor
Optional motor
circuit contactor. Unshielded
lengths should
be as short as
U possible.

To earth/ground outer shield, use 360° clamps

connected to backplane.
Connect motor
Earth earth/ground to
protective earth on
drive flange.

Figure 15 - Motor connections - 21 A ~ 65 A models

For 1.5 A ~ 16 A models, tightening torque for X17 terminal block connections is 0.5-0.6 N·m
(4.4-5.3 lb-in). The 48 A ~ 65 A models use a spring cage connector. For all models, tightening
torque for the flange mounted PE connection is 2.5 N·m (22.1 lb-in).

MN1943 Basic Installation 3-29

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3.7.1 Motor cable shielding

It is essential that the motor cable shield is correctly bonded to a functional earth, typically the
same earthed metal backplane on which the MotiFlex e100 is mounted. The motor power output
cable carries a high frequency high current waveform to the motor, so the cable’s shielding must
be earthed to prevent the cable radiating electromagnetic contamination into the surrounding
area. Such contamination can cause spurious errors in apparently unrelated parts of the
installation, such as low voltage communication cables. To provide a low impedance path to earth
and effective shielding, the conductor must provide contact with a large proportion of the cable’s
circumference. Figure 16 shows two possible methods.

3.7.1.1 Exposing the cable shield

1. Make a single circular cut in the cable’s outer sheath, ensuring that the cable’s braided shield
is not damaged.
2. Slide the section of outer sheath towards the end of the cable to expose an area of braided
shield. Carefully remove the excess sheath at the end of the cable.
3. Attach the metal P-clip or clamp to the exposed area of braided shield.
4. Ensure that the P-clip (or Motor Cable Management Bracket) is securely attached to an
unpainted area of the metal backplane.

Looping the inner cores

allows easy insertion
and removal of the motor
power connector.
Motor On painted
UVW panels, remove
Motor paint to expose
protective earth bare metal
(PE)

Using the optional Using a metal P-clip

Motor Cable Management Bracket
OPT-CM-001 (recommended)

Figure 16 - Motor connections - physical cable arrangement

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3.7.1.2 Continuation of motor power cable shielding

When using a motor contactor, or extending the motor cable through a terminal box, ensure that
the motor cable shielding is continued all the way to the motor.

MotiFlex e100

Motor

Contactor

Terminal
box

Figure 17 - Continuation of motor power cable shielding

3.7.2 Motor circuit contactor

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 MotiFlex e100 (see
Figure 14). Opening the M-Contactor ensures that the MotiFlex e100 cannot drive the motor,
which may be necessary during equipment maintenance or similar operations. Under certain
circumstances, it may also be necessary to fit a brake to a rotary motor. This is important with
hanging loads where disconnecting the motor windings could result in the load falling. Contact
your local supplier for details of appropriate brakes. Ensure that shielding of the motor cable is
continued on both sides of the contactor.

If an M-Contactor is installed, the MotiFlex e100 must be disabled at least 20 ms

before the M-Contactor is opened. If the M-Contactor is opened while the
CAUTION MotiFlex e100 is supplying power to the motor, the MotiFlex e100 could be
damaged. Incorrect installation or failure of the M-Contactor or its wiring could
result in damage to the MotiFlex e100.

3.7.3 Sinusoidal filter

A sinusoidal filter is used to provide a better quality waveform to the motor, reducing motor noise,
temperature and mechanical stress. It will reduce or eliminate harmful dV/dt values (voltage rise
over time) and voltage doubling effects which can damage motor insulation. This effect occurs
most noticeably when using very long motor cables, for example 30.5 m (100 ft) or more. Baldor
motors intended to be used with drives are designed to withstand the effects of large dV/dt and
overvoltage effects. However, if very long motor cables are unavoidable and are causing
problems, then a sinusoidal filter may be beneficial.

MN1943 Basic Installation 3-31

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3.7.4 Motor power cable pin configuration - Baldor BSM rotary motors
Figure 18 shows the pin configuration for a typical Baldor motor cable, part number
CBL025SP-12:

Signal name Motor / cable pin Motor cable wire color

Motor U 1 Black, labeled ‘1’
Motor V 4 Black, labeled ‘2’
Motor W 3 Black, labeled ‘3’
Earth/ground 2 Green/Yellow
Thermal switch A Green
Thermal switch B White
Brake C Blue
Brake D Red

B C C B
Note:
Not all motors A D
D A
are fitted with
a brake so 4 4
pins C and D 1 3
might not be 3 1
connected. 2 2

Motor power connector Cable connector end view

(male) (female)

Figure 18 - Baldor motor power cable pin configuration

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3.7.5 Motor cable pin configuration - Baldor linear motors

The following table shows the pin colors used in a typical Baldor linear motor cable set, part
number AY1763A00:

Signal name Motor cable wire color

Motor U Black
Motor V Red
Motor W White
Motor ground Green
Thermal switch Blue
Thermal switch Orange

Signal name Hall cable wire color

Hall 1 (U) White
Hall 2 (V) Red
Hall 3 (W) Black
Hall ground Green
Hall +5 VDC Brown

MN1943 Basic Installation 3-33

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3.7.6 Motor brake connection

You might wish to wire a motor’s brake, via a relay, to a digital output on connector X3 (see
sections 5.3.6 and 5.3.7). This allows the MotiFlex e100 to control the motor’s brake. A typical
circuit is shown in Figure 19.

User User
supply supply
V+ GND
X3
C
from motor brake
DOUT1+ 15 connections
Relay D

DOUT1- 3

The inner shield

surrounding the
brake wires should
+24VDC 0V be earthed/grounded
The relay has normally open at one point only.
Separate
contacts and is shown deactivated
(contacts open, brake engaged). customer
supplied
24VDC supply

Figure 19 - Motor brake control circuit

The 24 VDC power supply must be a separate supply as shown in Figure 19.
Do not use the ‘user supply’ powering the MotiFlex e100 digital outputs, or the
WARNING internally generated 18 VDC supply. The brake wires often carry noise that
could cause erratic drive operation or damage. The brake contacts must never
be wired directly to the digital outputs. The relay and motor brake terminals
should be fitted with protective flyback diodes, as shown in Figure 19.

This circuit uses a special motor brake output, configured using MOTORBRAKEOUTPUT to appear
on DOUT1. The operation of the motor brake output is synchronized with the application of power
to the motor and the enabling / disabling of the drive. Configurable delays are included to allow
time for the relay contacts and the brake to engage or release (see MOTORBRAKEDELAY in the
Mint help file). This system allows controlled operation of suspended or tensioned loads that are
held by the brake. For example:

To engage the brake:

H The motor is brought to rest under normal control, but remains powered;
H The relay is deactivated, causing the brake to engage;
H Power is removed from the motor;
H The drive is disabled.

To disengage the brake:

H The drive is enabled;
H Power is applied to the motor to hold position under normal control;
H The relay is activated, causing the brake to be disengaged;
H Motion starts.

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3.7.7 Motor overtemperature input

The motor overtemperature input is a dedicated input which may be directly connected to the
motor’s thermal switch. When the motor overheats and triggers the overtemperature input, the
MotiFlex e100 is normally disabled. See section 5.3.5 for details.

3.7.8 Bottom panel wiring

It is important that signal cables are properly shielded. Optional bracket OPT-CM-002 / -003
allows easy screening and attachment of other signal cables. See section A.1.6.

The feedback connector on

Baldor cables provides the
required shield connection.
Baldor cables include an When using a cable that does
individually shielded pair not provide a shield at the
for the motor’s thermal connector, bond the shield to
switch output. earth using a conductive
Connect the shield to P-clip or optional bracket
earth using a conductive OPT-CM-002.
P-clip or optional bracket
OPT-CM-002.

Use spare slots in

bracket OPT-CM-002 to
secure other cables, When using the analog input,
such as drive enable use shielded twisted pair with
shown here. the shield connected to earth
using a conductive P-clip or
optional bracket OPT-CM-002.

Figure 20 - Bottom panel wiring using OPT-CM-002 / -003

MN1943 Basic Installation 3-35

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3.8 Regeneration resistor (Dynamic Brake resistor)

Location Connector X1 (top panel)
Mating connector
1.5 A ~ 16 A models Phoenix POWER COMBICON PC 4/ 5-ST-7,62)
21 A ~ 33 A models Phoenix POWER COMBICON IPC 16/ 2-ST-10,16)
48 A ~ 65 A models Phoenix POWER COMBICON ISPC 16/ 2-ST-10,16)

Electrical shock hazard. DC bus voltages may be present at these terminals.

Use a suitable heatsink (with fan if necessary) to cool the regeneration
DANGER resistor. The regeneration resistor and heatsink (if present) can reach
temperatures in excess of 80 °C (176 °F).
An optional regeneration resistor may be required to dissipate excess power from the DC bus
during motor deceleration. Care should be taken to select the correct resistor for the application
- see section 3.9. Suitable resistors are are listed in section A.1.4. The regeneration resistor
output is fully short-circuit proof according to EN61800-5-1, 6.2.

X1

Regeneration
resistor

STAR Earth/ground outer shield,

POINT using 360° conductive
clamp connected to
cabinet backplane.

Figure 21 - Regeneration resistor connections - 1.5 A ~ 16 A models

X1

Regeneration
resistor

STAR Earth/ground outer shield,

POINT using 360° conductive
clamp connected to
cabinet backplane.

Figure 22 - Regeneration resistor connections - 21 A ~ 65 A models

For 1.5 A ~ 16 A models, tightening torque for X1 terminal block connections is 0.5-0.6 N·m
(4.4-5.3 lb-in). The 48 A ~ 65 A models use a spring cage connector.

3-36 Basic Installation MN1943

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3.8.1 Regeneration capacity

The regeneration capacity of the MotiFlex e100 can be calculated from the following formula:


E = 0.5 × DC bus capacitance × ( Regen switching threshold ) − 2 × Supply voltage
2 2

where the Regen switching threshold is 800 V. This gives the following typical values:

MotiFlex e100 Regeneration capacity (J)

catalog number
DC bus 230 VAC supply 480 VAC supply
capacitance (μF)

MFE460A001 235 63 21
MFE460A003 235 63 21
MFE460A006 470 126 42
MFE460A010 470 126 42
MFE460A016 705 188 63
MFE460A021 960 256 86
MFE460A026 1280 342 115
MFE460A033 1280 342 115
MFE460A048 1350 360 121
MFE460A065 1350 360 121

Table 5 - Regeneration capacity

MN1943 Basic Installation 3-37

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3.9 Regeneration resistor selection

The following calculations can be used to estimate the type of regeneration resistor that will be
required for the application.

3.9.1 Required information

To complete the calculation, some basic information is required. Remember to use the worst-case
figures to ensure that the regeneration power is not underestimated. For example, use the
maximum possible motor speed, maximum inertia, minimum deceleration time and minimum
cycle time that the application might encounter.

Requirement Enter value here

a) Initial motor speed, before deceleration

begins, in radians per second.
Initial motor speed, U = _________ rad/s
Multiply RPM by 0.1047 to give radians
per second.

b) Final motor speed after deceleration is

complete, in radians per second.
Final motor speed, V = _________ rad/s
Multiply RPM by 0.1047 to get radians
per second. This value will be zero if the
load is going to be stopped.

c) The deceleration time from initial speed

to final speed, in seconds. Decel time, D = _________ s
See section 3.9.7.

d) The total cycle time (i.e. how frequently

the process is repeated), in seconds. Cycle time, C = _________ s
See section 3.9.7.

e) Total inertia.

This is the total inertia seen by the drive,

accounting for motor inertia, load inertia
and gearing. Use the Mint WorkBench
Autotune tool to tune the motor, with the
load attached, to determine the value.
This will be displayed in kg·m2 in the
Total inertia, J = ________ kg·m2
Autotune tool. If you already know the
motor inertia (from the motor spec.) and
the load inertia (by calculation) insert the
total here.

Multiply kg·cm2 by 0.0001 to give kg·m2.

Multiply lb-ft2 by 0.04214 to give kg·m2.
Multiply lb-in-s 2 by 0.113 to give kg·m2.

3-38 Basic Installation MN1943

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3.9.2 Regenerative energy

The regenerative energy to be dissipated, E, is the difference between the initial energy in the
system (before deceleration begins) and the final energy in the system (after deceleration has
finished). If the system is brought to rest then the final energy is zero.

The energy of a rotating object is given by the formula:

1
E= × J × ω2
2

where E is energy, J is the moment of inertia, and ω is the angular velocity.

The regenerative energy, which is the difference between the initial energy and the final energy,
is therefore:

E= 12 × J × U  − 12 × J × V 
2 2

1
= × J × (U 2−V2)
2

= ________________ J (joules)

Calculate E using the values for J, U and V entered in section 3.9.1. If E is less than the drive’s
regeneration capacity, shown in Table 5 on page 3-37, a regeneration resistor will not be required.

If E is greater than the drive’s regeneration capacity, then continue to section 3.9.3 to calculate
the regenerative and average power dissipation.

3.9.3 Regenerative power and average power

The regenerative power, Pr , is the rate at which the braking energy is dissipated. This rate is
defined by the deceleration period, D. The shorter the deceleration period, the greater the
regenerative power.

E
Pr =
D

= ________________ W (watts)

Although the resistors shown in Table 6 can withstand brief overloads, the average power
dissipation, Pav, must not exceed the stated power rating. The average power dissipation is
determined by the proportion of the application cycle time spent regenerating. The greater the
proportion of time spent regenerating, the greater the average power dissipation.

D
P av = P r ×
C

= ________________ W (watts)

MN1943 Basic Installation 3-39

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3.9.4 Resistor choice

Pav is the value to use when assessing which regeneration resistor to use. However, a safety
margin of 1.25 times is recommended to ensure the resistor operates well within its limits*, so:

Required resistor power rating = 1.25 × P av

= ________________ W (watts)

The range of suitable regeneration resistors for each MotiFlex e100 model is shown in Table 6.
Choose the resistor that has a power rating equal to or greater than the value calculated above.
The resistance must be not be less than the minimum resistance stated for the particular
MotiFlex e100 model.

MotiFlex e100 Minimum resistance

Suitable resistors
catalog Single stand-alone Sharing DC bus,
number (spec = Baldor part)
drive or duty > 0.2

MFE460A001 60 Ω, 100 W = RGJ160

60 Ω, 200 W = RGJ260
MFE460A003 60 Ω, 300 W = RGJ360
60 Ω 150 Ω
150 Ω, 100 W = RGJ1150
150 Ω,
Ω 200 W = RGJ2150
G
MFE460A006 150 Ω, 300 W = RGJ3150
MFE460A010
33 Ω 68 Ω 33 Ω, 500 W = RGJ533
MFE460A016 68 Ω, 300 W = RGJ368

MFE460A021
MFE460A026 15 Ω 60 Ω 15 Ω, 500 W = RGJ515
60 Ω, 300 W = RGJ360
MFE460A033
MFE460A048 10 Ω, 1.2 kW = RGA1210
75Ω
7.5 33 Ω 10 Ω,
Ω 22.4
4 kW = RGA2410
MFE460A065 10 Ω, 4.8 kW = RGA4810
Table 6 - Regeneration resistors

* The regeneration resistors listed in Table 6 can withstand a brief overload of 10 times the rated
power for 5 seconds.
Note that a greater minimum resistance is specified when sharing the DC bus or using
regeneration duty cycles greater than 0.2. This is because the drive to which the resistor is
connected will be required to switch the regeneration energy from all of the shared drives. The
shared drives could regenerate at different times, causing a greatly increased effective duty cycle
(see section 3.9.7). Alternatively, several drives could regenerate at the same time, causing large
peaks in regeneration energy. The greater minimum resistance allows for this extra loading and
provides protection for the host drive’s regeneration output circuitry.
Optionally, additional regeneration resistors may be connected to other drives in the group. Since
all MotiFlex e100 drives have approximately the same regeneration threshold voltage,
regeneration energy in the system will be shared proportionally (according to resistance) between
all drives fitted with a regeneration resistor. Each resistor must still meet the Sharing DC bus or
duty > 0.2 requirement, listed in Table 6, for the drive to which it is fitted.

3-40 Basic Installation MN1943

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3.9.5 Resistor temperature derating

The RGJ... regeneration resistors shown in Table 6 can achieve their stated power rating only
when mounted on a heatsink. In free air a derating must be applied. Furthermore, in ambient
temperatures greater than 25 °C (77 °F), a temperature derating must be applied - see Figure 23.

The RGA... regeneration resistors shown in Table 6 must operate in ambient temperatures not
exceeding 80°C (176°F). The resistor should be mounted vertically, as shown in section A.1.4.
If mounted in any other position, its power rating must be derated by 35%.

100 1

80 2
% of rated power

60 4

40

20

0
25 40 80 120 160 200 240 280
Ambient temperature (°C)

1 On heatsink: all models.

2 Free air: RGJ160, RGJ1150.
3 Free air: RGJ260, RGJ2150, RGJ3150, RGJ360, RGJ368.
4 Free air: RGJ515, RGJ533.

Typical heatsinks (metal plate):

RGJ160, RGJ1150: 200 mm x 200 mm x 3 mm
All other RGJ models: 400 mm x 400 mm x 3 mm

Figure 23 - Regeneration resistor temperature derating

The RGJ... regeneration resistors listed here do not provide a fail-safe safety
mechanism. For safety reasons and UL compliance, they will become
WARNING open-circuit in the event of failure. This will cause the MotiFlex e100 to trip due
to overvoltage, leaving the motor in an uncontrolled state. Further safety
mechanisms such as a motor brake will be required, especially for applications
involving suspended or tensioned loads.

MN1943 Basic Installation 3-41

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3.9.6 Resistor pulse load rating

The regeneration resistors shown in Table 6 can dissipate power levels greater than the stated
continuous power rating, provided the duty cycle (see section 3.9.7) is reduced, as shown in
Figure 24.

27000

24000

21000

18000

15000
Power (W)

12000

9000

6000
3
2
3000
1

0
absolute 0.08 0.17 0.25 0.33 0.42 0.5
on:off (s) 10:120 20:120 30:120 40:120 50:120 60:120
Duty cycle

1 100 W models: Maximum pulse 5 kW for 1 s, 120 s off.

2 300 W models: Maximum pulse 15 kW for 1 s, 120 s off.
3 500 W models: Maximum pulse 25 kW for 1 s, 120 s off.

Figure 24 - Regeneration resistor pulse load rating

3-42 Basic Installation MN1943

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3.9.7 Duty cycle

The regeneration duty cycle is the amount of time taken regenerating as a proportion of the overall
application cycle time. For example, Figure 25 shows a system which performs a trapezoidal
move profile, with regeneration during part of the deceleration phase. The regeneration duty is 0.2
(0.5 second regeneration / 2.5 second cycle time):

Decel time Regeneration active

v

0.5 s 0.5 s 0.5 s

2.5 s 2.5 s 2.5 s

(Cycle time) (Cycle time) (Cycle time)

Figure 25 - Duty cycle = 0.2

MN1943 Basic Installation 3-43

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3-44 Basic Installation MN1943

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 4 Feedback
4
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4.1 Introduction
MotiFlex e100 supports many feedback options for use with linear and rotary motors, including
incremental encoder, encoder with BiSS (Bi-directional Synchronous Serial interface), encoder
with SSI (Synchronous Serial Interface), EnDat absolute encoder or SinCos encoder. All suitable
types of feedback device can be connected to the universal feedback interface available on
connector X8 (bottom panel).

There are some important considerations when wiring the feedback device:

H The feedback device wiring must be separated from power wiring. The MotiFlex e100 has
been designed so that motor feedback wiring enters the bottom panel of the drive, well away
from the AC power wiring entering the top panel.
H Where feedback device wiring runs parallel to power cables, they must be separated by at
least 76 mm (3 in)
H Feedback device wiring must cross power wires at right angles only.
H To prevent contact with other conductors or earths/grounds, unearthed/ungrounded ends of
shields must often be insulated.
H Linear motors may use two separate cables (encoder and Hall). The cores of these two
cables will need to be wired to the appropriate pins of the 15-pin D-type mating connector.
H The inputs are not isolated.
H Baldor cables are recommended (see Appendix A). If alternative cables are used they must
be of an equivalent specification.

MN1943 Feedback 4-1

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4.1.1 Incremental encoder interface

The incremental encoder connections (ABZ channels and Hall signals) are made using the
15-pin D-type female connector X8. The encoder inputs (CHA, CHB and CHZ) accept differential
signals only. Twisted pairs must be used for each complementary signal pair e.g. CHA+ and
CHA-. The Hall inputs may be used as differential inputs (recommended for improved noise
immunity) or single ended inputs. When used as single ended inputs, leave the Hall U-, Hall V-
and Hall W- pins unconnected. The overall cable shield (screen) must be connected to the
metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to
detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the encoder
supply voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max).

Pin Incremental encoder function

1 CHA+
2 CHB+
3 CHZ+
4 Sense
5 Hall U-
6 Hall U+
7 Hall V-
1 9 8 Hall V+
9 CHA-
10 CHB-
15 11 CHZ-
8
12 +5V out
13 DGND
14 Hall W-
15 Hall W+

MotiFlex e100

to encoder signal loss detection

CHA+ 1

MAX3096
1nF 120R Differential to CPU
line receiver
CHA- 9

1nF

DGND

Figure 26 - Encoder channel input circuit - Channel A shown

4-2 Feedback MN1943

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MotiFlex e100
+5V

2k2 10k

Hall U+ 6

MAX3096
1nF Differential to CPU
line receiver
Hall U- 5

1nF 4k7

DGND

Figure 27 - Hall channel input circuit - U phase shown

4.1.1.1 Encoder cable configuration - Baldor rotary motors

Motor Twisted pairs X8

1 CHA+
9 CHA-
2 CHB+
Encoder 10 CHB-
Feedback 3 CHZ+ (INDEX)
11 CHZ- (INDEX)

12 +5V out
13 DGND
4 Sense

6 Hall U+
Hall 5 Hall U-
Feedback 8 Hall V+
7 Hall V-
15 Hall W+
14 Hall W-

Connect overall shield

to connector backshells.

Figure 28 - Encoder cable connections - rotary motors

Note: If the Hall inputs are used as single ended inputs, leave the Hall U-, Hall V- and
Hall W- pins unconnected; do not connect them to ground.

MN1943 Feedback 4-3

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4.1.1.2 Encoders without Halls

Incremental encoders without Hall feedback connections may be connected to the
MotiFlex e100. However, if Hall connections are not present, it will be necessary for the
MotiFlex e100 to perform an automatic phase search sequence the first time it is enabled after
power up. This will cause motor movement of up to 1 turn on rotary motors, or one pole-pitch on
linear motors.

Motor Twisted pairs X8

1 CHA+
9 CHA-
Encoder 2 CHB+
Feedback 10 CHB-
3 CHZ+ (INDEX)
11 CHZ- (INDEX)
12 +5V out
13 DGND
4 Sense

Connect overall shield

to connector backshells.

Figure 29 - Encoder cable connections without halls - rotary motors

4.1.1.3 Halls-only feedback devices

Feedback devices using only Hall sensors may be connected to the MotiFlex e100. However,
since there are no encoder connections, the MotiFlex e100 will not be able to perform smooth
speed control or accurate positioning control.

Motor X8

4 Sense
12 +5V out
13 DGND
6 Hall U+
5 Hall U-
Hall 15 Hall W+
Feedback 14 Hall W-
8 Hall V+
7 Hall V-

Connect overall shield

to connector backshells.

Figure 30 - Halls-only feedback cable connections - rotary motors

Note: If the Hall inputs are used as single ended inputs, leave the Hall U-, Hall V- and
Hall W- pins unconnected; do not connect them to ground.

4-4 Feedback MN1943

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4.1.1.4 Encoder cable pin configuration - rotary motors

Figure 31 shows the pin configuration for a typical Baldor encoder feedback cable, part
number CBL025SF-E2.

Signal name MotiFlex e100 Motor / cable Baldor encoder cable

X8 pin pin internal wire colors
CHA+ 1 3 Purple
CHA- 9 4 Purple / White
CHB+ 2 5 Green
CHB- 10 6 Green / White
CHZ+ 3 7 Brown
CHZ- 11 8 Brown / White
Hall U+ 6 10 Pink
Hall U- 5 11 Pink / Black
Hall V+ 8 12 Yellow
Hall V- 7 13 Yellow / Black
Hall W+ 15 14 Grey
Hall W- 14 15 Grey / Black
+5V 12 1 Red
DGND 13 2 Blue

11 1 1 11
10 12 2 2 12 10
16 13 13 16
9 3 3 9
Pins 9 and 16 15 14 14 15
8 4 4 8
are not
connected 7 5 5 7
6 6

Motor encoder connector Cable connector end view

(male) (female)

Figure 31 - Baldor rotary motor encoder cable pin configuration

The maximum recommended cable length is 30.5m (100ft).

MN1943 Feedback 4-5

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4.1.1.5 Encoder cable pin configuration - Baldor linear motors

Baldor linear motors use two separate cables (encoder and Hall). The cores of these two cables
must be wired to the appropriate pins of the 15-pin D-type mating connector (supplied):

Signal name MotiFlex e100 Encoder cable internal wire colors

X8 pin
CHA+ 1
CHA- 9
CHB+ 2 Please refer to MN1800 Linear Motors
CHB- 10 Installation & Operating Manual for details.
CHZ+ 3
CHZ- 11
Baldor Hall cable internal wire colors
Hall U+ 6 White
Hall V+ 8 Red
Hall W+ 15 Black
+5V out 12 Brown
Hall GND 13 Green

Motor Twisted pairs X8

1 CHA+
9 CHA-
2 CHB+
10 CHB-
Encoder CHZ+ (INDEX)
3
Feedback 11 CHZ- (INDEX)
12 +5V
13 DGND
4 Sense

6 Hall U+
Hall 5 Hall U-
15 Hall W+ Leave pins 5, 7 & 14
Feedback 14 Hall W- unconnected
8 Hall V+
7 Hall V-

Connect overall shield to

connector backshells.

Figure 32 - Encoder cable connections - linear motors

4-6 Feedback MN1943

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4.1.2 BiSS interface

The BiSS (Bi-directional Serial Synchronous interface) is an open-source interface that can be
used with many types of absolute encoder. The BiSS interface connections are made using the
15-pin D-type female connector X8. Twisted pair cables must be used for the complementary
signal pairs e.g. Data+ and Data-. The overall cable shield (screen) must be connected to the
metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to
detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the supply
voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max).

Pin BiSS function

1 Data+
2 Clock+
3 (NC)
4 Sense
5 Sin- Note: If your cable has Sin and Cos
6 Sin+ pairs they may be connected here.
However these signals are not
However,
7 Cos- required or used by the MotiFlex e100
1 9 8 Cos+ for BiSS operation.
9 Data-
10 Clock-
15 11 (NC)
8
12 +5V out
13 DGND
14 (NC)
15 (NC)

Motor X8
Twisted pairs
Absolute 1 Data+
Encoder 9 Data-
2 Clock+
Interface
BiSS

10 Clock-
12 +5V out
13 DGND
4 Sense Connect internal
shields to pin 13.
Chassis
Connect overall shield
to connector backshells.

Figure 33 - BiSS interface cable connections

MN1943 Feedback 4-7

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4.1.2.1 BiSS interface cable pin configuration

Figure 40 shows the pin configuration for a typical Baldor BiSS feedback cable, part number
CBL025SF-D2.

Signal name MotiFlex e100 Motor / cable Baldor BiSS / EnDat /

X8 pin pin SinCos cable internal
wire colors
Data- 9 1 Brown / White
Clock- 10 5 Pink / Black
Clock+ 2 7 Pink
Sense 4 9 Orange
+5V out 12 9 Red
DGND 13 10 Blue
Data+ 1 12 Brown

1 9 8 8 9 1

2 10 12 7 7 12 10 2

11 6 11 3
3 6
4 5 5 4

Motor BiSS interface connector Cable connector end view

(male) (female)

Figure 34 - Baldor rotary motor BiSS interface pin configuration

The maximum recommended cable length is 30.5 m (100 ft).

4-8 Feedback MN1943

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4.1.3 SSI interface

The SSI (Synchronous Serial Interface) is specifically designed for use with Baldor SSI motors,
which incorporate a custom Baumer SSI encoder. Correct operation with other SSI interfaces
cannot be guaranteed. The SSI interface connections are made using the 15-pin D-type female
connector X8. Twisted pair cables must be used for the complementary signal pairs e.g. Data+
and Data-. The overall cable shield (screen) must be connected to the metallic shell of the D-type
connector. Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage drop on long
cable runs. This allows the MotiFlex e100 to increase the supply voltage on pin 12 to maintain a
5 VDC supply at the encoder (200 mA max).

Pin SSI function

1 Data+
2 Clock+
3 (NC)
4 Sense
5 Sin- Note: If your cable has Sin and Cos
6 Sin+ pairs they may be connected here.
However these signals are not
However,
7 Cos- required or used by the MotiFlex e100
1 9 8 Cos+ for SSI operation.
9 Data-
10 Clock-
15 11 (NC)
8
12 +5V out
13 DGND
14 (NC)
15 (NC)

Motor X8
Twisted pairs
Absolute 1 Data+
Encoder 9 Data-
2 Clock+
Interface

10 Clock-
SSI

12 +5V out
13 DGND
4 Sense Connect internal
shields to pin 13.
Chassis
Connect overall shield
to connector backshells.

Figure 35 - SSI interface cable connections

MN1943 Feedback 4-9

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4.1.3.1 SSI cable pin configuration

Figure 36 shows the pin configuration for a typical Baldor SSI feedback cable, part number
CBL025SF-S2

Signal name MotiFlex e100 Motor / cable Baldor SSI cable

X8 pin pin internal wire colors
+5V out 12 1 Red
Sense 4 9 Orange
DGND 13 2 Blue
Clock+ 2 3 Green
Clock- 10 4 Yellow
Data+ 1 5 Pink
Data- 9 6 Grey

1 9 8 8 9 1

2 10 12 7 7 12 10 2
Pins 7-12
are not used 11 6 11 3
3 6
and may not
be present 4 5 5 4

Motor SSI connector Cable connector end view

(male) (female)

Figure 36 - Baldor rotary motor SSI interface pin configuration

The maximum recommended cable length is 30.5 m (100 ft).

4-10 Feedback MN1943

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4.1.4 SinCos interface

The SinCos interface connections (Sin and Cos incremental channels only) are made using the
15-pin D-type female connector X8. Twisted pair cables must be used for the complementary
signal pairs e.g. Sin+ and Sin-. The overall cable shield (screen) must be connected to the
metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to
detect the voltage drop on long cable runs. This allows the MotiFlex e100 to increase the supply
voltage on pin 12 to maintain a 5 VDC supply at the encoder (200 mA max). The Sin and Cos
channel input circuits accept a nominal 1 V pk-pk sine wave centered on a 2.5 V reference.

Pin SinCos function

1 (NC)
2 (NC)
3 (NC)
4 Sense
5 Sin-
6 Sin+
7 Cos-
1 9 8 Cos+
9 (NC)
10 (NC)

8
15 11 (NC)
12 +5V out
13 DGND
14 (NC)
15 (NC)

Motor X8
Twisted pairs
5 Sin-
6 Sin+
7 Cos-
SinCos 8 Cos+
Feedback 12 +5V out
13 DGND Connect internal
4 Sense shields to DGND.

Connect overall shield to

connector backshells.

Figure 37 - SinCos interface cable connections

MN1943 Feedback 4-11

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4.1.4.1 SinCos cable pin configuration

Figure 38 shows the pin configuration for a typical Baldor SinCos feedback cable, part number
CBL025SF-D2.

Signal name MotiFlex e100 Motor / cable Baldor BiSS / EnDat /

X8 pin pin SinCos cable internal
wire colors
(Not used) 9 1 Brown / White
Sin+ 6 2 Green
Cos+ 8 4 Purple
(Not used) 10 5 Pink / Black
(Not used) 2 7 Pink
Cos- 7 8 Purple / White
Sense 4 9 Orange
+5V out 12 9 Red
DGND 13 10 Blue
Sin- 5 11 Green / White
(Not used) 1 12 Brown

1 9 8 8 9 1

2 10 12 7 7 12 10 2

11 6 11 3
3 6

4 5 5 4

Motor SinCos connector Cable connector end view

(male) (female)

Figure 38 - Baldor rotary motor SinCos interface pin configuration

The maximum recommended cable length is 30.5 m (100 ft).

4-12 Feedback MN1943

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4.1.5 EnDat interface

The EnDat interface supports both incremental and absolute (multi and single turn) feedback
using EnDat technology. It is possible to read and write information to the encoder. The EnDat
interface connections are made using the 15-pin D-type female connector X8. Twisted pair
cables must be used for the complementary signal pairs e.g. Sin+ and Sin-. The overall cable
shield (screen) must be connected to the metallic shell of the D-type connector. Connector X8
includes a ‘Sense’ pin, which is used to detect the voltage drop on long cable runs. This allows
the MotiFlex e100 to increase the supply voltage on pin 12 to maintain a 5 VDC supply at the
encoder (200 mA max). The Sin and Cos channel input circuits accept a nominal 1 V pk-pk sine
wave centered on a 2.5 V reference. Version 2.2 EnDat encoders do not use the Sin and Cos
channels.

Pin EnDat function

1 Data+
2 Clock+
3 (NC)
4 Sense
5 Sin-
6 Sin+
7 Cos-
1 9 8 Cos+
9 Data-
10 Clock-
15 11 (NC)
8
12 +5V out
13 DGND
14 (NC)
15 (NC)

Motor X8
Twisted pairs
1 Data+
9 Data-
5 Sin-
6 Sin+
Absolute 7 Cos-
Encoder 8 Cos+
2 Clock+
10 Clock-
12 +5V out Connect internal
13 DGND shields to DGND.
4 Sense

Connect overall shield

to connector backshells.

Figure 39 - EnDat interface cable connections

MN1943 Feedback 4-13

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4.1.5.1 EnDat interface cable pin configuration

Figure 40 shows the pin configuration for a typical Baldor EnDat feedback cable, part number
CBL025SF-D2.

Signal name MotiFlex e100 Motor / cable Baldor BiSS / EnDat /

X8 pin pin SinCos cable internal
wire colors
Data- 9 1 Brown / White
Sin+ 6 2 Green
Cos+ 8 4 Purple
Clock- 10 5 Pink / Black
Clock+ 2 7 Pink
Cos- 7 8 Purple / White
Sense 4 9 Orange
+5V out 12 9 Red
DGND 13 10 Blue
Sin- 5 11 Green / White
Data+ 1 12 Brown

1 9 8 8 9 1

2 10 12 7 7 12 10 2

11 6 11 3
3 6

4 5 5 4

Motor EnDat connector Cable connector end view

(male) (female)

Figure 40 - Baldor rotary motor EnDat cable pin configuration

The maximum recommended cable length is 30.5 m (100 ft).

4-14 Feedback MN1943

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5.1 Introduction
This section describes the various digital input and output capabilities of the MotiFlex e100, with
descriptions of each of the connectors on the front panel.

The following conventions are used to refer to the inputs and outputs:

I/O . . . . . . . . . . . . . . Input / Output

AIN . . . . . . . . . . . . . Analog Input
DIN . . . . . . . . . . . . . Digital Input
DOUT . . . . . . . . . . . Digital Output

In the following sections, all connections to X2 and X3 assume stranded copper wire is used with
a temperature rating of at least 70 °C (158 °F). Use copper conductors only.

MN1943 Input / Output 5-1

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5.2 Analog I/O

The MotiFlex e100 provides as standard:

H 1 analog input on the connector block X3 (demand input)

5.2.1 Analog input - X3 (demand)

Location Connector X3, pins 12 & 24

(Mating connector: Weidmüller Minimate B2L 3.5/24 LH)
Name AIN0
Description Single ended or differential input.
Common mode voltage range: ±10 VDC.
Resolution: 12-bit (accuracy ±4.9 mV)
Common mode rejection: 40 dB
12 24 Input impedance: >30 kΩ
Sampling interval: 125 μs

The analog input can be connected as either a differential or a single ended input as shown in
Figure 42. The analog input is not optically isolated from internal power rails, so care must be taken
to avoid earth/ground loops and similar associated problems. The input buffers provide low pass
filtering of the applied voltage. To minimize the effects of noise, the analog input signal should be
connected to the system using an individually shielded twisted pair cable with an overall shield.
The overall shield should be connected to the chassis at one end only. No other connection should
be made to the shield.

MotiFlex e100 +15V

AIN0- 12

- Low pass
filter & level Mint
correction ADC(0)
+
LM258
AIN0+ 24

-15V
Internal reference

AGND 11

Figure 41 - AIN0 analog input (demand) circuit

When the MotiFlex e100 is connected to Mint WorkBench, the analog input value (expressed
as a percentage) can be viewed using the Spy window’s Monitor tab. Alternatively, the
command Print ADC(0) can be used in the command window to return the value of the
analog input. See the Mint help file for details.

5-2 Input / Output MN1943

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X3 X3

AIN0+ 24 AIN0+ 24

AIN0- 12 AIN0 12 AIN0

ADC(0) ADC(0)
11 GND 11

Differential connection Single ended connection

Figure 42 - AIN0 analog input wiring

+24 VDC

1.5 kΩ, 0.25 W *

X3

1 kΩ, 0.25 W
24
potentiometer
AIN0
0V 12 ADC(0)

11
* Note: If the MotiFlex e100’s 18 VDC source is to be used
(connector X2, see section 3.6), use a 1 kΩ fixed resistor
and a 1.5 kΩ potentiometer.

Figure 43 - Typical input circuit to provide 0-10 V (approx.) input from a 24 V source

NextMove ESB / controller MotiFlex e100

‘X13’ ‘X3’

- Demand0
1 24 AIN0+
+

AGND 2 12 AIN0-

11 AGND
Shield 3
Connect overall shield at
one end only

Figure 44 - Analog input - typical connection from a Baldor NextMove ESB

MN1943 Input / Output 5-3

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5.3 Digital I/O

The MotiFlex e100 provides as standard:

H 3 general purpose digital inputs.

H 1 dedicated drive enable input.
H 1 general purpose digital output.
H 1 general purpose / drive status output.
H 1 dedicated motor overtemperature trip input.

The general purpose digital inputs can be configured for typical input functions:

H Error input.
H Reset input.
H Stop input.
H Forward / reverse limit input.
H Home input - see important details in section 5.3.2.1 or 5.3.3.1.
H Power ready input (for DC bus sharing, see section 3.5.2).

The general purpose digital outputs can be configured for a variety of output functions:

H Drive enable indication.

H Global error indication.
H Motor brake output: controls the activation of the motor’s brake.
H Compare output: indicates when the axis is within a specified position range.

5-4 Input / Output MN1943

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5.3.1 Drive enable input

Location Connector X3, pins 9 & 21

(Mating connector: Weidmüller Minimate B2L 3.5/24 LH)
Name Drive enable
Description Dedicated drive enable input.
Nominal input voltage: 24 VDC
9 21 (input current not to exceed 50 mA)
Sampling interval: 1 ms

The drive enable input is buffered by a TLP280 opto-isolator, allowing the input signal to be
connected with either polarity.

MotiFlex e100 Vcc

3k3 Mint
Drive 21 DRIVEENABLESWITCH
Enable+

100R 74LVC14
Drive
9
Enable-
TLP280

DGND

Figure 45 - Drive enable input circuit

The drive enable input must be active and there must be no errors present before the
MotiFlex e100 can be enabled. Additional methods are required to enable the MotiFlex e100,
depending on the currently selected control reference source. The control reference source can
be selected on Mint WorkBench’s Motion toolbar. See also section 6.4.4.8.

H If the control reference source is set to ‘Direct’, the Mint WorkBench drive enable button
on the motion toolbar toggles the enable/disable status. Alternatively, the Mint command
DRIVEENABLE(0)=1 can be used in the command window to enable the MotiFlex e100;
DRIVEENABLE(0)=0 will disable the MotiFlex e100.
The Tools, Reset Controller menu item will also clear errors and enable the MotiFlex e100.
Alternatively, the Mint command RESET(0) can be used in the command window to perform
the same action.
H If the control reference source is set to ‘EPL’ or ‘CAN’, the respective fieldbus master
controls the drive enable status. Mint WorkBench cannot be used to control the drive enable
status until the control mode has been changed back to ‘Direct’.

The state of the drive enable input is displayed in the Mint WorkBench Spy window. Alternatively,
the state of the drive enable input can be read (but not set) using the Mint command Print
DRIVEENABLESWITCH(0) in the command window. See the Mint help file for details.

MN1943 Input / Output 5-5

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NextMove e100 / controller User MotiFlex e100

supply
‘X11’ 24 V
UDN2982
‘X3’
USR V+
9
Mint
DRIVEENABLEOUTPUT Drive
3k3
DOUT0 Enable+
1 21

Drive
Enable- 100R
10k 9

USR GND TLP280

10

User
supply
GND

Figure 46 - Drive enable input - typical connection from a Baldor NextMove e100

5-6 Input / Output MN1943

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5.3.2 General purpose digital input DIN0

Location Connector X3, pins 7 & 19

(Mating connector: Weidmüller Minimate B2L 3.5/24 LH)
Name DIN0
Description General purpose opto-isolated digital input.
7 19 Nominal input voltage: 24 VDC
(input current not to exceed 50 mA)
Sampling interval: 1 ms

This general purpose digital input is buffered by a TLP280 opto-isolator, allowing the input signal
to be connected with either polarity. The state of the digital input is displayed in the Mint
WorkBench Spy window. The input can be can be configured for different user definable
functions.

MotiFlex e100 Vcc

3k3
DIN0+ 19 Mint

100R 74LVC14
DIN0- 7
TLP280

DGND

Figure 47 - General purpose digital input circuit

When the MotiFlex e100 is connected to Mint WorkBench, the digital input can be configured
using the Digital I/O tool. Alternatively, Mint keywords including RESETINPUT, ERRORINPUT,
STOPINPUT, FORWARDLIMITINPUT, REVERSELIMITINPUT, POWERREADYINPUT and
HOMEINPUT can be used in the command window. The state of the digital input can be viewed
using the Mint WorkBench Spy window’s Axis tab. See the Mint help file for details.

5.3.2.1 Using a digital input as a home switch input

When the MotiFlex e100 is being controlled over EPL by a manager node (e.g. NextMove e100),
the home switch input must be wired to the MotiFlex e100, not the manager node. This is because
the manager node only triggers the homing sequence, which is then performed entirely by the
MotiFlex e100. It is therefore the MotiFlex e100 which must receive the home switch input signal,
otherwise it will not be able to complete its homing routine. Similarly, it is the MotiFlex e100’s own
HOME... keyword parameters that define the homing sequence.

MN1943 Input / Output 5-7

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NextMove e100 / controller User MotiFlex e100

supply
‘X11’ 24 V
UDN2982
‘X3’
USR V+
9
Mint
OUTX(0) 3k3
DOUT0 DIN0+
1 19

100R
10k DIN0-
7

USR GND TLP280

10

User
supply
GND

Figure 48 - Digital input - typical connection from a Baldor NextMove e100

5-8 Input / Output MN1943

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5.3.3 General purpose digital inputs DIN1 & DIN2

Location Connector X3, pins 6 & 18 (DIN1), 4 & 16 (DIN2)

(Mating connector: Weidmüller Minimate B2L 3.5/24 LH)

4 16 Name DIN1, DIN2

6 18 Description General purpose fast opto-isolated digital inputs.
Nominal input voltage: 24 VDC
(input current not to exceed 20 mA)
Maximum input frequency: 1 MHz maximum

These general purpose fast digital inputs are buffered by a TLP115 opto-isolator, allowing the
input signal to be connected with either polarity. The state of the digital input is displayed in the
Mint WorkBench Spy window. The inputs can be can be configured for different user definable
functions.

MotiFlex e100 Vcc

‘X3’

3k3
DIN1+ 18 Mint

74LVC14

TLP115A
100R
DIN1- 6
DGND

Figure 49 - General purpose fast digital input circuit

When the MotiFlex e100 is connected to Mint WorkBench, the digital input can be configured
using the Digital I/O tool. Alternatively, Mint keywords including RESETINPUT, ERRORINPUT,
STOPINPUT, FORWARDLIMITINPUT, REVERSELIMITINPUT, POWERREADYINPUT and
HOMEINPUT can be used in the command window. The state of the digital input can be viewed
using the Mint WorkBench Spy window’s Axis tab. See the Mint help file for details.

5.3.3.1 Using a digital input as a home switch input

When the MotiFlex e100 is being controlled over EPL by a manager node (e.g. NextMove e100),
the home switch input must be wired to the MotiFlex e100, not the manager node. This is because
the manager node only triggers the homing sequence, which is then performed entirely by the
MotiFlex e100. It is therefore the MotiFlex e100 which must receive the home switch input signal,
otherwise it will not be able to complete its homing routine. Similarly, it is the MotiFlex e100’s own
HOME... keyword parameters that define the homing sequence.

MN1943 Input / Output 5-9

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NextMove e100 / controller User MotiFlex e100

supply
‘X11’ 24 V
UDN2982
‘X3’
USR V+
9
Mint
OUTX(0)
DOUT0 DIN1+
1 18

10k DIN1-
6
USR
GND TLP115A
10
Shield
10

User
supply Connect overall
GND shield at one end only

Figure 50 - Digital input - typical connection from a Baldor NextMove e100

5.3.4 Special functions on inputs DIN1 & DIN2

DIN1 and DIN2 can be configured to perform special functions.

5.3.4.1 Step (pulse) and direction inputs

Using the MASTERSOURCE keyword, the MotiFlex e100 can be configured to use DIN1 and
DIN2 as step and direction inputs:

H DIN1 is used as the step input. The step frequency controls the speed of the motor.
H DIN2 is used as the direction input. The state of the direction input controls the direction of
motion. An active input will result in forward motion. An inactive input will result in motion in
the opposite direction.

5.3.4.2 Fast position capture

DIN1 or DIN2 can be configured using the LATCHTRIGGERCHANNEL keyword to become a fast
latch input. This allows the position of the axis to be captured in real-time and read using the Mint
keyword LATCHVALUE. The input can configured using the LATCHTRIGGEREDGE keyword to be
triggered either on a rising or falling edge. Further control of position capture is provided by other
keywords beginning with LATCH... . See the Mint help file for details.

The maximum latency to read the fast position depends on the feedback device. For an
incremental encoder, the latency is approximately 150 - 300 ns. For other feedback devices
latency may be up to 62.5 μs, resulting from the 16 kHz sampling frequency used for these types
of feedback device. The fast interrupt will be latched on a pulse width of about 30 μs, although a
width of 100 μs is recommended to ensure capture. To prevent subsequent inputs causing the
captured value to be overwritten, the interrupt is latched in software.

Note: The fast inputs are particularly sensitive to noise, so inputs must use shielded
twisted pair cable. Do not connect mechanical switches, relay contacts or other
sources liable to signal ‘bounce’ directly to the fast inputs. This could cause
unwanted multiple triggering.

5-10 Input / Output MN1943

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Incremental encoder MotiFlex e100

‘X3’
Twisted pairs
A+ 18 DIN1+ (Step)

A- 6 DIN1-

B+ 16 DIN2+ (Dir)

B- 4 DIN2-

5 DGND

24V 1 24V

GND 2 GND

‘X2’
Connect shields
at one end only
Drive Drive
supply supply
24V GND

Figure 51 - Step and direction inputs - typical connection from an incremental encoder

Note: When using an incremental encoder source, do not connect the A- or B- outputs;
leave them unconnected as shown in Figure 51.

MN1943 Input / Output 5-11

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5.3.5 Motor overtemperature input

Location Connector X16 (bottom panel)

(Mating connector:
Phoenix COMBICON MSTBT 2,5/ 2-ST-5,08)
Name Motor overtemperature switch in
Description Dedicated motor overtemperature input.
Trip: RTH1-TH2 > 3.0 kΩ typ. (2.9 kΩ - 3.2 kΩ)
Not tripped: RTH1-TH2 < 2.8 kΩ typ. (2.7 kΩ - 3.0 kΩ)
Sampling interval: Immediate

The motor overtemperature input is a dedicated input which may be directly connected to the
motor’s thermal switch. When the motor overheats and triggers the overtemperature input, the
MotiFlex e100 is normally disabled.

MotiFlex e100
TH 15V +5V

Mint
TH1
1 -

+ TLP281

TH2 2

TH GND

Figure 52 - Motor overtemperature input circuit

5.3.5.1 Connecting motors with normally closed switch contacts

Some motors contain a thermal switch with normally closed contacts. When the motor overheats
the switch contacts open. For this type of motor, connect the switch contact outputs directly to
TH1 and TH2, as shown in Figure 52.

5.3.5.2 Connecting motors with temperature dependent resistive output

Some motors contain a thermistor based resistive output. As the motor temperature increases,
the resistance between the thermal output connections increases. For this type of motor, the
thermal output connections may be connected directly to TH1 and TH2, but care must be taken
to ensure that the resistance will be sufficient to trigger the MotiFlex e100’s input circuit.

To ensure triggering of the input circuit, the resistance between TH1 and TH2 must exceed
3.2 kΩ. If the motor’s thermistor does not achieve this resistance at the required trip temperature,
it may be necessary to include an additional fixed resistor in the circuit, as shown in Figure 53.
The total resistance must fall to less than 2.8 kΩ (typical) to re-enable the drive.

5-12 Input / Output MN1943

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Example 1:
Motor MotiFlex e100 Motor maximum temp. = 130 °C

RT = 6 kΩ @ 130 °C
Rfixed RT > 3.2 kΩ, so Rfixed not required.
TH1
1

Example 2:
Motor maximum temp. = 130 °C
RT
RT = 2 kΩ @ 130 °C
Add Rfixed = 1.2 kΩ, so that RT + Rfixed >= 3.2 kΩ,
TH2 2

Note: To remove the trip, RT + Rfixed must reduce

to less than 2.8 kΩ.

Figure 53 - Using a thermistor controlled motor overtemperature output

Use a shielded twisted pair for the motor temperature connection, with the overall cable shield
(screen) connected to the metal backplane or signal cable management bracket (section A.1.6).

The state of the motor overtemperature input can be read using the
MOTORTEMPERATURESWITCH keyword. The resulting behavior of the MotiFlex e100 can be
controlled using the MOTORTEMPERATUREMODE keyword. See the Mint help file for details.

MN1943 Input / Output 5-13

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5.3.6 General purpose / status digital output DOUT0

Location Connector X3, pins 1 & 13

1 13 (Mating connector: Weidmüller Minimate B2L 3.5/24 LH)
Name Status / DOUT0
Description General purpose opto-isolated digital output
Output current: 100 mA maximum
User supply 28 VDC maximum
Update interval: 1 ms

The optically isolated general purpose / status output is designed to source current from the user
supply as shown in Figure 54. The TLP 127 has a maximum power dissipation of 150 mW at
25 °C. The maximum saturated voltage across the outputs when active is 1.0 VDC, so it can be
used as a TTL compatible output.

The output includes a self-resetting fuse that operates at approximately 200 mA. The fuse may
take up to 20 seconds to reset after the load has been removed. If the output is used to directly
drive a relay, a suitably rated diode must be fitted across the relay coil, observing the correct
polarity. This is to protect the output from the back-EMF generated by the relay coil when it is
de-energized. The sense of the output can be configured in Mint WorkBench, and its state is
displayed in the Spy window.
User supply
MotiFlex e100 V+

+3.3V
‘X3’
220R

Fuse
DOUT0+
13
200mA
[Error]
Load
TLP 127 (Relay with
diode shown)
DOUT0-
1

User supply
GND

Figure 54 - DOUT0 output circuit

By default, DOUT0 is configured as an error status output, which becomes inactive in the event
of an error. When the MotiFlex e100 is connected to Mint WorkBench, the active level of the
output can be configured using the Digital I/O tool. Alternatively, the Mint keyword
OUTPUTACTIVELEVEL can be used in the command window. Other Mint keywords such as
COMPAREOUTPUT, GLOBALERROROUTPUT, DRIVEENABLEOUTPUT and MOTORBRAKEOUTPUT
(see section 3.7.6) can also be used in the command window. The state of the digital output can
be viewed using the Mint WorkBench Spy window’s Axis tab. See the Mint help file for details.

5-14 Input / Output MN1943

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MotiFlex e100 User NextMove e100 / controller

‘X3’ supply ‘X9’
24 V
DOUT0+
13

DOUT0- DIN4 100R 6k2

1 8
TLP127
CREF1
9
TLP280
User
supply
GND

Figure 55 - DOUT0 - typical connections to a Baldor NextMove e100

MN1943 Input / Output 5-15

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5.3.7 General purpose digital output DOUT1

Location Connector X3, pins 3 & 15

(Mating connector: Weidmüller Minimate B2L 3.5/24 LH)
3 15 Name DOUT1
Description General purpose opto-isolated digital output
Output current: 100 mA maximum
User supply: 28 VDC maximum
Update interval: 1 ms

The optically isolated general purpose output is designed to source current from the user supply
as shown in Figure 54. The TLP 127 has a maximum power dissipation of 150 mW at 25 °C. The
maximum saturated voltage across the outputs when active is 1.0 VDC, so it can be used as a
TTL compatible output.

The output includes a self-resetting fuse that operates at approximately 200 mA. The fuse may
take up to 20 seconds to reset after the load has been removed. If the output is used to directly
drive a relay, a suitably rated diode must be fitted across the relay coil, observing the correct
polarity. This is to protect the output from the back-EMF generated by the relay coil when it is
de-energized. The sense of the output can be configured in Mint WorkBench, and its state is
displayed in the Spy window.

User supply
MotiFlex e100 V+
+3.3V
‘X3’
220R

Fuse
DOUT1+
15
200mA
[Error]
Load
TLP 127 (Relay with
diode shown)
DOUT1-
3

User supply
GND

Figure 56 - DOUT1 output circuit

When the MotiFlex e100 is connected to Mint WorkBench, the active level of the output can be
configured using the Digital I/O tool. Alternatively, the Mint keyword OUTPUTACTIVELEVEL can
be used in the command window. Other Mint keywords such as COMPAREOUTPUT,
GLOBALERROROUTPUT, DRIVEENABLEOUTPUT and MOTORBRAKEOUTPUT (see section 3.7.6)
can also be used in the command window. The state of the digital output can be viewed using the
Mint WorkBench Spy window’s Axis tab. See the Mint help file for details.

5-16 Input / Output MN1943

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MotiFlex e100 User NextMove e100 / controller

‘X3’ supply ‘X9’
24 V
DOUT1+
15

DOUT1- DIN4 100R 6k2

3 8
TLP127
CREF1
9
TLP280
User
supply
GND

Figure 57 - DOUT1 - typical connections to a Baldor NextMove e100

5.4 USB interface

5.4.1 USB

Location USB
Mating connector: USB Type B (downstream) plug

Pin Name Description

1 - (NC)
1 4 2 D- Data-
2 3
3 D+ Data+
4 GND Ground

The USB connector is used to connect the MotiFlex e100 to a PC running Mint WorkBench. The
MotiFlex e100 is a self-powered, USB 1.1 (12 Mbit/s) compatible device. If it is connected to a
slower USB1.0 host PC or hub, communication speed will be limited to the USB1.0 specification
(1.5 Mbit/s). If it is connected to a faster USB2.0 (480 Mbit/s) host PC or hub, communication
speed will remain at the USB1.1 specification of the MotiFlex e100.

Ideally, the MotiFlex e100 should be connected directly to a USB port on the host PC. If it is
connected to a hub shared by other USB devices, communication could be affected by the
activity of the other devices. A 2 m (6.5 ft) standard USB cable is supplied. The maximum
recommended cable length is 5 m (16.4 ft).

MN1943 Input / Output 5-17

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5.5 RS485 interface

5.5.1 RS485 (2-wire)

Location X6
Mating connector: RJ11 plug

Pin Name Description

1 TXA Transmit / receive +
2 TXB Transmit / receive -

1
3 GND Ground
6 4 +8 V out 8 V supply for Baldor accessories
5 (NC) -
6 (NC) -

The RS485 2-wire interface is used to connect third-party devices such as operator panels. The
Baldor Keypad and Baldor HMI panel range cannot be connected to this interface, since they
require a 4-wire RS485 connection. The 8 V supply on pin 4 is provided for future Baldor
accessories; care should be taken to ensure this supply will not damage connected devices. The
RS485 interface could be damaged if a USB plug is accidentally inserted while the drive is
powered.

The Mint keyword Print can be used to send characters to the attached device. The Mint
keyword InKey can be used to receive characters. The RS485 interface can also be used to
exchange data using the Baldor Host Comms Protocol (HCP/HCP2). See the Mint WorkBench
help file for details.

MicroFlex e100 ‘X6’ Operator panel

TXA TXA
1

TXB TXB
2

SN65HVD10D GND GND

3

Figure 58 - RS485 port - typical connections to an RS485 2-wire operator panel

5-18 Input / Output MN1943

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5.6 Ethernet interface

The Ethernet interface provides TCP/IP and Ethernet POWERLINK (EPL) networking capabilities.

5.6.1 TCP/IP
Transmission Control Protocol / Internet Protocol (TCP/IP) is a common set of protocols used to
transfer information between devices over a network, including the internet. TCP enables two
devices to establish a connection, and guarantees the delivery of packets (datagrams) of
information in the correct order. IP specifies the format of the individual packets (which includes
the destination address of the receiving device) but has no influence on whether the packet is
delivered correctly.

TCP/IP allows the MotiFlex e100 to support standard Ethernet communication with a host PC
running Mint WorkBench. The connection uses Baldor’s high level ICM (Immediate Command
Mode) protocol to allow Mint commands, Mint programs and even firmware to be sent to the
controller over the Ethernet network.

When operating in standard Ethernet mode, TCP/IP cannot be used to communicate with a
controller on a daisy-chained network. This is due to cumulative timing errors caused by each
controller’s internal hub. It is necessary to connect the host PC to the controller either directly or
via a switch or hub, as shown in Figure 59. A switch is preferable to a hub as it will provide faster
performance when there is a large amount of data being transmitted.
Host PC

MotiFlex e100 drives

Ethernet switch

Figure 59 - Connecting to drives using TCP/IP in standard Ethernet mode

When operating in EPL mode, in conjunction with an EPL compatible router, the host PC can use
TCP/IP to communicate with controllers on a daisy-chained network. In this situation, the router
will use TCP/IP only within EPL’s asynchronous time slots. See the Mint help file for further
details.
Host PC

NextMove e100
Master Node MotiFlex e100 drives
Ethernet POWERLINK
compatible router

Figure 60 - Connecting to daisy-chained drives using TCP/IP and EPL mode

MN1943 Input / Output 5-19

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5.6.2 Ethernet POWERLINK

MotiFlex e100 supports the deterministic Ethernet POWERLINK (EPL) protocol. This protocol
provides very precise and predictable ‘real-time’ communication over a 100 Mbit/s (100Base-T)
Fast Ethernet (IEEE 802.3u) connection. This makes it suitable for the transmission of control
and feedback signals between the MotiFlex e100 and other EPL enabled controllers such as
NextMove e100. The EPL protocol implemented in Mint is based on the CANopen DS402 Device
Profile for Drives and Motion Control.

MotiFlex e100 incorporates a built-in repeating hub, providing two ports for connection to other
equipment. This allows nodes to be connected as a ‘daisy-chain’ network of up to 5 nodes,
avoiding the need for additional hubs. If the network comprises more than 5 nodes an external
hub must be used, with up to 5 nodes per port. The structure of the physical network is informal
so does not need to reflect the logical relationship between nodes. Ethernet switches must not be
used in EPL networks as their timing cannot be guaranteed.

NextMove e100 MotiFlex e100 MotiFlex e100 MotiFlex e100 MotiFlex e100
Manager Node Drive Drive Drive Drive

‘Daisy chained’ network

Figure 61 - Simple daisy-chained EPL network

NextMove e100 Machine 1

Manager Node MotiFlex e100 Drives 1-5

1 2 3 4 5

External hub Machine 1

MotiFlex e100 Drives 6-10

6 7 8 9 10

NextMove e100 Machine 2

Controlled Node MotiFlex e100 Drives 11-14

11 12 13 14

Figure 62 - Example multi-branch EPL network

5-20 Input / Output MN1943

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5.6.3 Ethernet connectors

Ethernet connections are made using the identical RJ45 Ethernet receptacles.

Location E1 & E2 (top panel)

Pin Name Description

1 TX+ Transmit+
2 TX- Transmit-
3 RX+ Receive+
4 - (NC)
1
5 - (NC)
8
6 RX- Receive-
7 - (NC)
8 - (NC)

To connect the MotiFlex e100 to other EPL devices use CAT5e Ethernet cables - either S/UTP
(screened unshielded twisted pairs) or preferably S/FTP (screened fully shielded twisted pairs).

The MotiFlex e100 Ethernet interface is galvanically isolated from the rest of the MotiFlex e100
circuitry by magnetic isolation modules incorporated in each of the Ethernet connectors. This
provides protection up to 1.5 kV. The connector/cable screen is connected directly to the chassis
earth of the MotiFlex e100. Termination components are incorporated in each of the Ethernet
connectors, so no further termination is required. To ensure CE compliance, especially where
Ethernet cables are frequently unplugged, all Ethernet cables should be bonded to the metal
backplane using conductive clamps at one point at least (see section D.1.6). Cables longer than
3 m should be S/FTP cables bonded to the metal backplane at both ends. Do not run Ethernet
cables close to AC supply cables, motor power cables, or other sources of noise as this can
sometimes cause spurious errors to be reported.

Cables may be up to 100 m (328 ft) long. Two varieties of CAT5e cable are available; ‘straight’ or
‘crossed’. Straight cables have the TX pins of the connector at one end of the cable wired to the
TX pins of the RJ45 connector at the other end of the cable. Crossover cables have the TX pins
of the connector at one end of the cable wired to the RX pins of the RJ45 connector at the other
end of the cable. Provided the network consists of only Baldor EPL controllers and drives (and
any hub), straight or crossed cables may be used. This is because many Ethernet devices,
including hubs and all Baldor EPL products, incorporate Auto-MDIX switching technology which
automatically compensates for the wiring of the straight cable. However, if other manufacturers’
EPL nodes are included in the network, crossover cables should be used as recommended by
the Ethernet POWERLINK Standardization Group (EPSG). Similarly, if a host PC does not
provide Auto-MDIX on its Ethernet port, then a crossed cable will be essential for the connection
between the PC and an EPL router, e.g. OPT036-501.

The EPL network supports the 100Base-TX (100 Mbit/s) system only, so attempting to connect
slower 10Base-T (10 Mbit/s) nodes will cause a network error.

MN1943 Input / Output 5-21

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5.7 CAN interface

The CAN bus is a serial based network originally developed for automotive applications, but now
used for a wide range of industrial applications. It offers low-cost serial communications with very
high reliability in an industrial environment; the probability of an undetected error is 4.7x10-11.
It is optimized for the transmission of small data packets and therefore offers fast update of I/O
devices (peripheral devices) connected to the bus.

The CAN protocol only defines the physical attributes of the network, i.e. the electrical,
mechanical, functional and procedural parameters of the physical connection between devices.
The higher level network functionality on MotiFlex e100 is defined by the CANopen protocol, one
of the most used standards for machine control.

5.7.1 CAN connector

Location CAN (top panel)

Mating connector: 9-pin female D-type

Pin Name Description

1 - (NC)
2 CAN- CAN channel negative
3 CAN GND Ground/earth reference for CAN signals
4 - (NC)

5 5 Shield Shield connection

9
6 CAN GND Ground/earth reference for CAN signals

1
6 7 CAN+ CAN channel positive
8 - (NC)
9 CAN V+ CAN power V+ (12-24 VDC)

5.7.2 CAN wiring

A very low error bit rate over CAN can only be achieved with a suitable wiring scheme, so the
following points should be observed:
H The two-wire data bus line may be routed parallel, twisted and/or shielded, depending on
EMC requirements. Baldor recommend a twisted pair cable with the shield/screen
connected to the connector backshell, in order to reduce RF emissions and provide immunity
to conducted interference.
H The bus must be terminated at both ends only (not at intermediate points) with resistors of a
nominal value of 120 Ω. This is to reduce reflections of the electrical signals on the bus,
which helps a node to interpret the bus voltage levels correctly. If the MotiFlex e100 is at the
end of the network then ensure that a 120 Ω resistor is fitted (normally inside the D-type
connector).
H All cables and connectors should have a nominal impedance of 120 Ω. Cables should have
a length related resistance of 70 mΩ/m and a nominal line delay of 5 ns/m.

5-22 Input / Output MN1943

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H The maximum bus length depends on the bit-timing CAN Maximum

configuration (baud rate). The table opposite shows Baud Rate Bus Length
the approximate maximum bus length (worst-case),
assuming 5ns/m propagation delay and a total 1 Mbit/s 25 m
effective device internal in-out delay of 210 ns at 1 500 Kbit/s 100 m
Mbit/s, 300 ns at 500 - 250 Kbit/s, 450 ns at 125 Kbit/s 250 Kbit/s 250 m
and 1.5 ms at 50 - 10Kbit/s. 125 Kbit/s 500 m
(1) For bus lengths greater than about 1000 m, 100 Kbit/s 600 m
bridge or repeater devices may be needed. 50 Kbit/s 1000 m
20 Kbit/s 2500 m(1)
H The compromise between bus length and CAN baud 10 Kbit/s 5000 m(1)
rate must be determined for each application. The
CAN baud rate can be set using the BUSBAUD keyword. It is essential that all nodes on the
network are configured to run at the same baud rate.
H The wiring topology of a CAN network should be as close as possible to a single line/bus
structure. However, stub lines are allowed provided they are kept to a minimum (<0.3 m at
1 Mbit/s).
H The 0 V connection of all of the nodes on the network must be tied together through the CAN
cabling. This ensures that the CAN signal levels transmitted by MotiFlex e100 or CAN
peripheral devices are within the common mode range of the receiver circuitry of other nodes
on the network.

5.7.2.1 Opto-isolation
On the MotiFlex e100, the CAN channel is opto-isolated. A voltage in the range 12-24 VDC must
be applied between pin 9 (+24 V) and pin 3 or 6 (0 V) of the CAN connector. From this supply, an
internal voltage regulator provides the 5 V at 100 mA required for the isolated CAN circuit. To
allow easy connection of the 12-24 VDC supply, Baldor adaptor part OPT-CNV002 can be used,
allowing connection by ordinary CAT 5e Ethernet cables. The adaptor also provides flying lead
connections for the application of the CAN power supply.

Figure 63 - OPT-CNV002

Alternatively, a connector such as the Phoenix Contact SUBCON-PLUS F3 (part 2761871)

provides a 9-pin D-type female connector with easily accessible terminal block connections (see
Figure 64).
CAN cables supplied by Baldor are ‘category 5’ and have a maximum current rating of 1 A, so the
maximum number of MotiFlex e100 units that may be used on one network is limited to 10.

MN1943 Input / Output 5-23

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5.7.3 CANopen
Baldor have implemented a CANopen protocol in Mint (based on the ‘Communication Profile’ CiA
DS-301) which supports both direct access to device parameters and time-critical process data
communication. The MotiFlex e100 complies with CANopen slave device profile DS402, and can
be a DS401 or DS403 master device (with limited functionality). It is able to support and
communicate with a variety of devices including:

H Any third party digital and analog I/O device that is compliant with the ‘Device Profile for
Generic I/O Modules’ (CiA DS-401).
H Baldor HMI (Human Machine Interface) operator panels, which are based on the ‘Device
Profile for Human Machine Interfaces’ (DS403).
H Other Baldor controllers with CANopen support for peer-to-peer access using extensions to
the CiA specifications (DS301 and DS302).

The functionality and characteristics of all Baldor CANopen devices are defined in individual
standardized (ASCII format) Electronic Data Sheets (EDS) which can be found on the Baldor
Motion Toolkit CD supplied with your product, or downloaded from www.baldormotion.com.
Figure 64 shows a typical CANopen network with a NextMove e100 manager node, one
MotiFlex e100 slave node and a Baldor HMI operator panel:
Baldor HMI
Operator Panel NextMove e100 MotiFlex e100 End
CANopen D-type D-type node
D-type
7 7 7 7

2 2 2 2
TR TR
Twisted pair Twisted pairs
6 6 6 6

9 9 9

5 5 5

Phoenix
SUBCON-PLUS F3 ‘X2’
24 V
1
0V
2

Figure 64 - Typical CANopen network connections

Note: The MotiFlex e100 CAN channel is opto-isolated, so a voltage in the range
12-24 VDC must be applied between pin 9 and pin 6 of the CAN connector. See
section 5.7.2.1.

The configuration and management of a CANopen network must be carried out by a single node
acting as the network manager (for example NextMove e100), or by a third party CANopen
manager device. Up to 126 CANopen nodes (node IDs 2 to 127) can be added to the network by
the manager node using the Mint NODESCAN keyword. If successful, the nodes can then be
connected to using the Mint CONNECT keyword. Any network and node related events can then
be monitored using the Mint BUS1 event.
Note: All CAN related Mint keywords are referenced to CANopen using the bus parameter.
For CANopen the bus parameter must be set to 1. Please refer to the Mint help file
for further details on CANopen, Mint keywords and their parameters.

5-24 Input / Output MN1943

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5.8 Other I/O

5.8.1 Node ID selector switches
The MotiFlex e100 has two selector switches which determine the unit’s
node ID on EPL networks. Each switch has 16 positions, allowing selection
of the hexadecimal values 0 - F. In combination, the two switches allow node
IDs of 0 - 255 (hexadecimal FF) to be selected. The switch labelled ‘HI’ sets
the high nibble (half byte), and the switch labelled ‘LO’ sets the low nibble.
The following table lists all node IDs from 0 to 255 with the equivalent HI and
LO switch settings:

Node ID HI LO Node HI LO Node HI LO Node HI LO

ID ID ID

0 0 0 64 4 0 128 8 0 192 C 0
1 0 1 65 4 1 129 8 1 193 C 1

2 0 2 66 4 2 130 8 2 194 C 2
3 0 3 67 4 3 131 8 3 195 C 3

4 0 4 68 4 4 132 8 4 196 C 4
5 0 5 69 4 5 133 8 5 197 C 5

6 0 6 70 4 6 134 8 6 198 C 6
7 0 7 71 4 7 135 8 7 199 C 7

8 0 8 72 4 8 136 8 8 200 C 8
9 0 9 73 4 9 137 8 9 201 C 9

10 0 A 74 4 A 138 8 A 202 C A
11 0 B 75 4 B 139 8 B 203 C B
12 0 C 76 4 C 140 8 C 204 C C

13 0 D 77 4 D 141 8 D 205 C D

14 0 E 78 4 E 142 8 E 206 C E
15 0 F 79 4 F 143 8 F 207 C F
16 1 0 80 5 0 144 9 0 208 D 0

17 1 1 81 5 1 145 9 1 209 D 1

18 1 2 82 5 2 146 9 2 210 D 2
19 1 3 83 5 3 147 9 3 211 D 3

20 1 4 84 5 4 148 9 4 212 D 4

21 1 5 85 5 5 149 9 5 213 D 5
22 1 6 86 5 6 150 9 6 214 D 6

23 1 7 87 5 7 151 9 7 215 D 7
24 1 8 88 5 8 152 9 8 216 D 8

25 1 9 89 5 9 153 9 9 217 D 9
26 1 A 90 5 A 154 9 A 218 D A

27 1 B 91 5 B 155 9 B 219 D B

28 1 C 92 5 C 156 9 C 220 D C
29 1 D 93 5 D 157 9 D 221 D D

MN1943 Input / Output 5-25

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Node ID HI LO Node HI LO Node HI LO Node HI LO

ID ID ID

30 1 E 94 5 E 158 9 E 222 D E
31 1 F 95 5 F 159 9 F 223 D F

32 2 0 96 6 0 160 A 0 224 E 0

33 2 1 97 6 1 161 A 1 225 E 1

34 2 2 98 6 2 162 A 2 226 E 2

35 2 3 99 6 3 163 A 3 227 E 3
36 2 4 100 6 4 164 A 4 228 E 4

37 2 5 101 6 5 165 A 5 229 E 5

38 2 6 102 6 6 166 A 6 230 E 6

39 2 7 103 6 7 167 A 7 231 E 7

40 2 8 104 6 8 168 A 8 232 E 8

41 2 9 105 6 9 169 A 9 233 E 9

42 2 A 106 6 A 170 A A 234 E A

43 2 B 107 6 B 171 A B 235 E B

44 2 C 108 6 C 172 A C 236 E C

45 2 D 109 6 D 173 A D 237 E D

46 2 E 110 6 E 174 A E 238 E E
47 2 F 111 6 F 175 A F 239 E F

48 3 0 112 7 0 176 B 0 240 F 0

49 3 1 113 7 1 177 B 1 241 F 1

50 3 2 114 7 2 178 B 2 242 F 2

51 3 3 115 7 3 179 B 3 243 F 3

52 3 4 116 7 4 180 B 4 244 F 4

53 3 5 117 7 5 181 B 5 245 F 5

54 3 6 118 7 6 182 B 6 246 F 6

55 3 7 119 7 7 183 B 7 247 F 7

56 3 8 120 7 8 184 B 8 248 F 8

57 3 9 121 7 9 185 B 9 249 F 9

58 3 A 122 7 A 186 B A 250 F A

59 3 B 123 7 B 187 B B 251 F B

60 3 C 124 7 C 188 B C 252 F C

61 3 D 125 7 D 189 B D 253 F D

62 3 E 126 7 E 190 B E 254 F E

63 3 F 127 7 F 191 B F 255 F F

Figure 65 - Decimal node IDs and equivalent HI / LO hexadecimal switch settings

Note: If the node ID selector switches are set to FF, the node’s firmware will not run on
power up. However, Mint WorkBench will still be able to detect the MotiFlex e100
and download new firmware.

5-26 Input / Output MN1943

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In many networking environments, the node ID may also be referred to as the address. On EPL
networks, limitations apply to the node IDs that may be selected:

H Node ID 0 is reserved for special purposes and cannot be used.

H Setting the switches to select a node ID between 1 and 239 causes the node to become a
‘controlled node’, a node that will accept commands from the manager node.
H Node ID 240 is reserved for the EPL manager node (for example NextMove e100) so cannot
be used by MotiFlex e100.
H Node IDs between 241 and 255 are reserved for special purposes and cannot be used.

For all other communication channels such as CANopen and USB, the node ID is set in software.
Each channel can have a different node ID, selected using the Mint WorkBench Connectivity
Wizard or the Mint BUSNODE keyword. See the Mint help file for details.

MN1943 Input / Output 5-27

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5-28 Input / Output MN1943

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 6 Configuration
6
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6.1 Introduction
Before powering the MotiFlex e100 you will need to connect it to the PC using a USB or Ethernet
cable and install the supplied Mint Machine Center software. This software includes a number of
tools to allow you to configure and tune the MotiFlex e100. If you do not have experience of
software installation or Windows applications you may need further assistance for this stage of
the installation.

6.1.1 Connecting the MotiFlex e100 to the PC

The MotiFlex e100 can be connected to the PC using either USB (recommended) or TCP/IP.

To use USB, connect a USB cable between a PC USB port and the MotiFlex e100 USB port. The
PC must be running Windows XP, Windows Vista or Windows 7.

To use TCP/IP, connect a CAT5e Ethernet cable between the PC and one of the MotiFlex e100
Ethernet ports.
You cannot connect an ordinary office PC to the MotiFlex e100 without first altering
the PC’s Ethernet adapter configuration. However, if you have installed a second
Ethernet adapter dedicated for use with the MotiFlex e100, then this adapter’s
NOTICE
configuration can be altered without affecting the PC’s office Ethernet connection. If
you are unsure about making changes to your PC’s Ethernet adapter configuration,
or are prevented by user permission levels, ask your I.T. administrator to assist you.

If there is an EPL manager node (node ID 240) on the Ethernet network, then the
network will be operating in EPL mode. This means any TCP/IP connection from the
PC must pass through an EPL compatible router, e.g. Baldor part OPT036-501.
NOTICE

6.1.2 Installing Mint Machine Center and Mint WorkBench

You will need to install Mint Machine Center (MMC) and Mint WorkBench to configure and tune
the MotiFlex e100. Any previous version of Mint WorkBench must be uninstalled before
proceeding with this installation:

1. Insert the CD into the drive.

2. After a few seconds the setup wizard should start automatically. If the setup wizard does not
appear, select Run... from the Windows Start menu and type

d:\start

where d represents the drive letter of the CD device.

Follow the on-screen instructions to install MMC (including Mint WorkBench). The setup
wizard will copy the files to appropriate folders within the C:\Program Files folder, and place
shortcuts on the Windows Start menu.

MN1943 Configuration 6-1

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6.2 Starting the MotiFlex e100

If you have followed the instructions in the previous sections, you should now have connected all
the power sources, inputs and outputs, and the Ethernet cable or USB cable linking the PC to the
MotiFlex e100.

6.2.1 Preliminary checks

Before you apply power for the first time, it is very important to verify the following:

H Disconnect the load from the motor until instructed to apply a load. If this cannot be done,
disconnect the motor wires at connector X1.
H Verify that the AC line voltage (if connected) matches the specification of the MotiFlex e100.

Note: If the MotiFlex e100 is to be powered from a shared DC bus connection, ensure
that the busbars are securely fitted to the DC busbar pads under the top cover.
H Inspect all power connections for accuracy, workmanship and tightness.
H Verify that all wiring conforms to applicable codes.
H Verify that the MotiFlex e100 and motor are properly earthed/grounded.
H Check all signal wiring for accuracy.

6.2.2 Power on checks

If at any time the Status LED flashes red, the drive has detected a fault - see section 7.

1. Turn on the AC supply.

Note: If the MotiFlex e100 is to be powered from a shared DC bus connection, the
preliminary checks shown in section 6.2.1 must first be completed for the
MotiFlex e100 that will be supplying the DC bus voltage (the source drive). When
these checks have been completed AC power can be applied to the source drive.
2. Turn on the optional 24 VDC control circuit backup supply, if connected.
3. Within approximately 20-30 seconds, the test sequence should complete and the Status
LED should illuminate red. If the Status LED is not lit then re-check the power supply
connections. If the Status LED flashes red, this indicates that the MotiFlex e100 has detected
a fault - see section 7. Note that after downloading firmware, startup may take more than 1
minute.
4. If the motor wires were disconnected in section 6.2.1, turn off the AC supply and reconnect
the motor wires. Turn on the AC supply.
5. To allow the Commissioning Wizard to function, the drive enable signal will need to be
present on connector X3 to allow the MotiFlex e100 to be enabled (see section 5.3.1.). If you
do not wish to enable the MotiFlex e100 yet, the Commissioning Wizard will inform you when
this step is necessary.

6-2 Configuration MN1943

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6.2.3 Installing the USB driver

It is now necessary to install the USB driver. When the MotiFlex e100 is powered, Windows will
automatically detect the controller and request the driver.

1. Follow the on-screen instructions to select and install the driver. The driver files are available
on the supplied Baldor Motion Toolkit CD. If you are using a copy of the driver located on the
hard disk, USB stick, or another CD, the driver files must all be in the same folder.
2. During installation, Windows may report that the driver is ‘unsigned’. This is normal for the
MotiFlex e100 driver, so click the Continue Anyway button to continue with the installation.
When installation is complete, a new Motion Control category will be listed in Windows
Device Manager.

The MotiFlex e100 is now ready to be configured using Mint WorkBench.

Note: If the MotiFlex e100 is later connected to a different USB port on the host computer,
Windows may report that it has found new hardware. Either install the driver files
again for the new USB port, or connect the MotiFlex e100 to the original USB port
where it will be recognized in the usual way.

MN1943 Configuration 6-3

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6.2.4 Configuring the TCP/IP connection (optional)

If you have connected the MotiFlex e100 to the PC using the Ethernet connection, it will be
necessary to alter the PC’s Ethernet adapter configuration to operate correctly with the
MotiFlex e100.
You cannot connect an ordinary office PC to the MotiFlex e100 without first altering
the PC’s Ethernet adapter configuration. However, if you have installed a second
Ethernet adapter dedicated for use with the MotiFlex e100, then this adapter’s
NOTICE
configuration can be altered without affecting the PC’s office Ethernet connection. If
you are unsure about making changes to your PC’s Ethernet adapter configuration,
or are prevented by user permission levels, ask your I.T. administrator to assist you.

The following explanation assumes the PC is connected directly to the MotiFlex e100, and not
across an intermediate Ethernet network. If you wish to attempt the connection through an
intermediate Ethernet network, then the network administrator must be consulted to ensure that
the necessary IP addresses will be allowed and are not already allocated on the network. The
MotiFlex e100 has a fixed IP address of the format 192.168.100.xxx. The last number, xxx, is the
decimal value defined by the MotiFlex e100’s node ID selector switches (see section 5.8.1).

1. On the Windows Start menu, select Settings, Network Connections.

2. In the Network Connections Window, right-click the ‘Local Area Connection’ entry for the
required Ethernet adapter and choose Properties.
3. In the Local Area Connection Properties dialog, in the ‘This connection uses the following
items’ list, select the ‘Internet Protocol (TCP/IP)’ entry and click Properties.
4. In the Internet Protocol (TCP/IP) Properties dialog, on the General tab, make a note of the
existing settings. Click Advanced... and make a note of any existing settings. Click the
Alternate Configuration tab and make a note of any existing settings.
5. On the General tab, choose the ‘Use the following IP address’ option.
6. In the IP address box, enter the IP address 192.168.100.241. This is the IP address that will
be assigned to the Ethernet adapter. The value 241 is deliberately chosen as it is outside the
range that can be used by MotiFlex e100, so avoiding any chance of conflicts.
7. In the Subnet mask box, enter 255.255.255.0 and click OK.
Click OK to close the Local Area Connection Properties dialog.
8. On the Windows Start menu, select Command Prompt (often found under Accessories).
9. In the Command Prompt window, type PING 192.168.100.16, where the final value (16 in this
example) is the value selected by the MotiFlex e100’s node ID selector switches. In this
example, the MotiFlex e100’s switches would be set to HI=1 LO=0, which represents
hexadecimal 10, equivalent to decimal 16 (see section 5.8.1 for a list of hexadecimal /
decimal equivalents). A reply message should be returned.
10. It should now be possible to run Mint WorkBench and connect to the MotiFlex e100 using the
Ethernet / TCP/IP connection.

6-4 Configuration MN1943

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6.3 Mint Machine Center

The Mint Machine Center (MMC) is used to view the network of connected controllers in a
system. Individual controllers and drives are configured using Mint WorkBench.

Note: If you have only a single MotiFlex e100 connected to your PC, then MMC is
probably not required. Use Mint WorkBench (see section 6.4) to configure the
MotiFlex e100.

Toolbars

Menu system

Controller pane

Information pane

Figure 66 - The Mint Machine Center software

The Mint Machine Center (MMC) provides an overview of the controller network currently
accessible by the PC. The MMC contains a controller pane on the left, and an information pane
on the right. In the controller pane select the Host item, then in the information pane click Scan.
This causes MMC to scan for all connected controllers. Clicking once on a controller’s name
causes various options to be displayed in the information pane. Double-clicking on a controller’s
name launches an instance of Mint WorkBench that is automatically connected to the controller.

Application View allows the layout and organization of controllers in your machine to be modeled
and described on screen. Controllers can be dragged onto the Application View icon, and
renamed to give a more meaningful description, for example “Conveyor 1, Packaging Controller”.
Drives that are controlled by another product, such as a NextMove e100, can be dragged onto
the NextMove e100 icon itself, creating a visible representation of the machine. A text description
for the system and associated files can be added, and the resulting layout saved as an “MMC
Workspace”. When you next need to administer the system, simply loading the workspace
automatically connects to all the required controllers. See the Mint help file for full details of MMC.

MN1943 Configuration 6-5

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MintDrive II Mint WorkBench

RS232

MintDrive II Mint WorkBench

RS485/422

Host PC

Mint Machine Center

NextMove e100 Mint WorkBench

USB

MotiFlex e100 Mint WorkBench

Ethernet

MotiFlex e100 Mint WorkBench

USB

Figure 67 - Typical network visibility provided by Mint Machine Center

6-6 Configuration MN1943

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6.3.1 Starting MMC

1. On the Windows Start menu, select Programs, Mint Machine Center, Mint Machine Center.

2. In the controller pane, ensure that Host is

selected. In the information pane, click
Scan.

3. When the search is complete, click once

on ‘MotiFlex e100’ in the controller pane to
select it, then double click to open an
instance of Mint WorkBench. The
MotiFlex e100 will be already connected
to the instance of Mint WorkBench, ready
to configure.

MN1943 Configuration 6-7

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6.4 Mint WorkBench

Mint WorkBench is a fully featured application for commissioning and programming the
MotiFlex e100. The main Mint WorkBench window contains a menu system, the Toolbox and
other toolbars. Many functions can be accessed from the menu or by clicking a button - use
whichever you prefer. Most buttons include a ‘tool-tip’; hold the mouse pointer over the button
(don’t click) and its description will appear.

Menu system Toolbars

Control and
test area
Toolbox

Figure 68 - The Mint WorkBench software

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6.4.1 Help file

Mint WorkBench includes a comprehensive help file that contains information about every Mint
keyword, how to use Mint WorkBench and background information on motion control topics. The
help file can be displayed at any time by pressing F1. On the left of the help window, the Contents
tab shows the tree structure of the help file. Each book contains a number of topics . The
Index tab provides an alphabetic list of all topics in the file, and allows you to search for them by
name. The Search tab allows you to search for words or phrases appearing anywhere in the help
file. Many words and phrases are underlined and highlighted with a color (normally blue) to show
that they are links. Just click on the link to go to an associated keyword. Most keyword topics
begin with a list of relevant See Also links.

Figure 69 - The Mint WorkBench help file

For help on using Mint WorkBench, click the Contents tab, then click the small plus sign
beside the Mint WorkBench book icon. Double click a topic name to display it.

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6.4.2 Starting Mint WorkBench

Note: If you have already used MMC to start an instance of Mint WorkBench then the
following steps are unnecessary. Go to section 6.4.3 to continue configuration.

1. On the Windows Start menu, select Programs, Mint Machine Center, WorkBench v5.5.

2. In the opening dialog box, click Start New Project... .

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3. In the Select Controller dialog, click Scan to search for the MotiFlex e100. Mint WorkBench
will scan the PC’s ports for the MotiFlex e100.

When the search is complete, click ‘MotiFlex e100’ in the list to select it, then click Select.

This check box is already selected for you. When you

click Select, it means that the Commissioning Wizard
will start automatically.

Note: If the MotiFlex e100 is not listed, check the USB or Ethernet cable between the
MotiFlex e100 and the PC. Check that the MotiFlex e100 is powered correctly. Click
Scan to re-scan the ports.

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6.4.3 Commissioning Wizard

Each type of motor and drive combination has different performance characteristics. Before the
MotiFlex e100 can be used to control the motor accurately, the MotiFlex e100 must be ‘tuned’.
This is the process where the MotiFlex e100 powers the motor in a series of tests. By monitoring
the drive’s output and the feedback from the motor’s encoder, the MotiFlex e100 can make small
adjustments to the way it controls the motor. This information is stored in the MotiFlex e100 and
can be uploaded to a file if necessary.

The Commissioning Wizard provides a simple way to tune the MotiFlex e100 and create the
necessary configuration information for your drive/motor combination, so this is the first tool that
should be used. If necessary, any of the parameters set by the Commissioning Wizard can be
adjusted manually after commissioning is complete.

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6.4.4 Using the Commissioning Wizard

Each screen of the Commissioning Wizard requires you to enter information about the motor,
drive or application. Read each screen carefully and enter the required information. When you
have completed a screen, click Next > to display the next screen. If you need to change
something on a previous screen, click the < Back button. The Commissioning Wizard
remembers information that you have entered so you will not need to re-enter everything if you
go back to previous screens. If you need extra help, click Help or press F1.

6.4.4.1 Connectivity
If you wish to change a node ID or baud rate then click in the appropriate cell and select an
alternative value. When multiple controllers are to be connected on the same bus they must each
have a unique node ID. For example, if two MotiFlex e100s and a NextMove e100 are connected
to the PC using individual USB connections, they must each be assigned a unique USB node ID.

6.4.4.2 DC bus sharing

Refer to section 3.5, and in particular section 3.5.2, for important details about DC bus sharing.

If the drive is being used as a ‘standalone’ drive (it is not sharing its DC bus or deriving power from
another drive’s DC bus) it is not necessary to change anything on this screen. However, if the drive
is sharing its DC bus (it is a ‘source’ drive), or deriving its power from another drive’s DC bus (it
is a ‘receiving’ drive), this stage must be completed.

H For a source drive: Select the DC bus master option, then select the chosen ‘power ready’
digital output.
H For a receiving drive: Select the DC bus slave option, then select the chosen ‘power
ready’ digital input.

6.4.4.3 Select your Motor Type:

Select the type of motor that you are using (rotary or linear).

6.4.4.4 Select your Motor:

Carefully enter the details of your motor. If you are using a Baldor Motor, the catalog number or
spec. number can be found stamped on the motor’s nameplate. If you are using a motor with EnDat
feedback, are not using a Baldor motor, or need to enter the specification manually, select the
I would like to define a custom motor option.

6.4.4.5 Confirm Motor and Drive information:

If you entered the catalog or spec. number on the previous page, it is not necessary to change
anything on this screen; all the required data will be entered already. However, if you selected the
I would like to define a custom motor option, it will be necessary to enter the required information
before continuing.

6.4.4.6 Motor Feedback:

If you entered the catalog or spec. number on the previous page, it is not necessary to change
anything on this screen; the feedback resolution will be entered already. However, if you selected
the I would like to define a custom motor option, it will be necessary to enter the feedback
resolution before continuing.

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6.4.4.7 Drive Setup complete:

This screen confirms that drive setup is complete.

6.4.4.8 Select Operating Mode and Control Reference Source:

In the Operating Mode section, choose the required operating mode. In the Reference Source
section, choose the reference source that will be used to control the drive in its intended
application. For example, if the MotiFlex e100 will be eventually controlled over Ethernet
POWERLINK (EPL), the EPL reference source should be selected. If EPL or CAN is selected,
Mint WorkBench will ask for the reference source to be changed to Host/Mint during the remainder
of the commissioning process. This allows it to complete autotuning tests and enables further
initial testing to be performed. When the drive is next power cycled, the setting chosen in the Select
Operating Mode tool is always reinstated. In Mint WorkBench, the reference source can be
temporarily changed by using the Control Ref Source button on the motion toolbar, which also
displays the current operating mode.

6.4.4.9 Application Limits:

It may not be necessary to change anything on this screen. However, if you wish to adjust the
application peak current (App. Peak Current) and/or application maximum speed (App. Max.
Speed), then click in the appropriate box and enter a value.

6.4.4.10 Select Scale Factor:

It is not necessary to change anything on this screen. However, it is recommended to select a user
unit for position, velocity and acceleration. This allows Mint WorkBench to display distances,
speeds and accelerations using meaningful units, instead of encoder counts. For example,
selecting a Position User Unit of Revs (r) will mean that all position values entered or displayed
in Mint WorkBench will represent revolutions. The Position Scale Factor value will change
automatically to represent the required scale factor (the number of quadrature counts per
revolution). If you need to use an alternative unit, for example degrees, type “Degrees” in the
Position User Unit box and enter a suitable value in the Position Scale Factor box. Separate
velocity and acceleration units can also be defined. See the Mint help file for more information
about scale factors.

6.4.4.11 Profile Parameters:

Click in the appropriate boxes and enter values for the default profile parameters. A brief
description of each item is given at the bottom of the window. For further help, click the Help button.

6.4.4.12 Analog Input Parameters

This screen allows the analog input to be configured. This step is required only if the analog input
is to be used as a command reference source (previously selected in the Operating Mode screen),
or as a general purpose analog input.

6.4.4.13 Operation setup complete:

This screen confirms that operation setup is complete. All changed parameters have been saved
on the MotiFlex e100.

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6.4.5 Autotune Wizard

The Autotune Wizard tunes the MotiFlex e100 for optimal performance with the attached
motor. This removes the need for manual fine-tuning of the system, although in some critical
applications this still may be required.

Click Options... to configure optional autotuning parameters. These include Triggered

Autotune which allows the autotuning process to be delayed until the drive is enabled.

The motor will move during autotuning. For safety it is advisable to disconnect any
load from the motor during initial autotuning. The motor can be tuned with the load
CAUTION
connected after the Commissioning Wizard has finished.

Autotune:
Click START to begin the auto-tuning process. Mint WorkBench will take measurements from
the motor and then perform small test moves.

For further information about tuning with the load attached, see section 6.4.7.

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6.4.6 Further tuning - no load attached

The Autotune Wizard calculates many parameters that allow the MotiFlex e100 to provide good
control of the motor. In some applications, these parameters may need to be fine-tuned to provide
the exact response that you require.

1. Click the Fine-tuning icon in the Toolbox on the left of the screen.

The Fine-tuning window is displayed at the right of the screen.

This already shows some of the parameters that have been
calculated by the Commissioning Wizard.

The main area of the Mint WorkBench window displays the

capture window. When further tuning tests are performed, this will
display a graph representing the response.

2. The Fine-tuning window has a

number of tabs at the bottom.

Click on the Velocity tab.

Note: Some tabs may not be available depending on the configuration mode you selected
in the Commissioning Wizard.

3. In the Test Parameters area at the

bottom of the tab, click in the Move
Type drop down box and select
Forward.

In the Velocity and Distance boxes,

enter values to create a short move.
The values you enter depend on the
velocity scaling factor that was selected in the Commissioning Wizard. This example
assumes the velocity scaling factor was selected as Revs Per Minute (rpm), so entering a
value of 1000 here will create a move with a velocity of 1000 rpm. Similarly, assuming the
position scaling factor had been set to Revolutions (r), the value 10 will create a move
lasting for 10 revolutions of the motor.

4. Click Go to start the test move. Mint

WorkBench will perform the test move
and display a graph of the result.

5. Click on the graph labels to turn off

unwanted traces. Leave just Demand
Velocity and Measured Velocity turned
on.

Note: The graph that you see will not look exactly the same as the following graph!
Remember that each motor has a different response.

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Measured
velocity

Demand velocity

Figure 70 - Typical autotuned response (no load)

Figure 70 shows that the response reaches the demand quickly and only overshoots the
demand by a small amount. This can be considered an ideal response for most systems.

For further information about tuning with the load attached, see section 6.4.7.

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6.4.7 Further tuning - with load attached

To allow Mint WorkBench to adjust the basic tuning to compensate for the intended load, it is
necessary to attach the load to the motor and then perform the autotune procedure again.

1. Attach the load to the motor.

2. Click the Autotune icon in the Toolbox on the

left of the screen.

3. Click the Autotune on load check box.

4. Click START to begin the auto-tuning process.

Mint WorkBench will take measurements from
the motor and then perform small test moves.

5. Click the Fine-tuning icon in the Toolbox on the

left of the screen.

6. In the Velocity tab’s Test Parameters

area, ensure the same move
parameters are entered and then click
Go to start the test move.

Mint WorkBench will perform the test

move and display a graph of the
result.

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6.4.8 Optimizing the velocity response

It may be desirable to optimize the default autotuned response to better suit your application.
The following sections describe the two main tuning issues and how to correct them.

6.4.8.1 Correcting overshoot

Figure 71 shows a response where the measured velocity overshoots the demand by a
significant amount.

1. Go to the Fine-tuning window’s Velocity

tab.

To reduce the amount of overshoot, click

Calculate... and increase the bandwidth
using the slider control. Alternatively, type
a larger value in the Bandwidth box.

Click OK to close the Bandwidth dialog.

2. Click Go to start the test move. Mint

WorkBench will perform the test move
and display a graph of the result.

Measured
velocity

Demand velocity

Figure 71 - Velocity overshoots demand

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6.4.8.2 Correcting zero-speed noise in the velocity response

Figure 72 shows a response where there is very little overshoot but a significant amount of
zero-speed noise. This can cause undesirable humming or ringing in the motor.

1. Go to the Fine-tuning window’s Velocity

tab.

To reduce the amount of noise, click

Calculate... and decrease the bandwidth
using the slider control. Alternatively, type
a smaller value in the Bandwidth box.

Click OK to close the Bandwidth dialog.

2. Click Go to start the test move. Mint

WorkBench will perform the test move
and display a graph of the result.

Demand velocity

Noise in
measured
velocity at
zero-speed

Figure 72 - Zero-speed noise

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6.4.8.3 Ideal velocity response

Repeat the tests described in sections 6.4.8.1 and 6.4.8.2 until the optimal response is
achieved. Figure 73 shows an ideal velocity response. There is only a small amount of
overshoot and very little zero-speed noise.

Measured
velocity

Demand velocity

Figure 73 - Ideal velocity response

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6.4.9 Performing test moves - continuous jog

This section tests the basic operation of the drive and motor by performing a continuous jog.
Note: To stop a move in progress, click the red stop button or the drive enable button on
the toolbar. Alternatively, use the Mint WorkBench ‘Red Stop Button’ feature.

1. Check that the Drive enable button is

pressed (down).

2. In the Toolbox, click the Edit & Debug icon.

3. Click in the Command window.

4. Type:
JOG(0) = 10
This will cause the motor to move
continuously at 10 units per second. In Mint
WorkBench, look at the Spy window located
on the right of the screen. Check that the axis
tab is selected. The Spy window’s Velocity
display should show 10 (approximately). If there seems to be very little motor movement, it
is probably due to the scale factor. In the Commissioning Wizard, on the Select Scale Factor
page, if you did not adjust the scale factor then the current unit of movement is feedback
counts per second. Depending on the motor’s feedback device, 10 feedback counts per
second could equate to a very small velocity. Issue another JOG command using a larger
value, or use the Operating Mode Wizard to select a suitable scale factor (e.g. 4000 if the
motor has a 1000 line encoder, or 10,000 for a 2500 line encoder).
5. To stop the test, type:
STOP(0)

6. If you have finished testing click the Drive

Enable button to disable the drive.

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6.4.10 Performing test moves - relative positional move

This section tests the basic operation of the drive and motor by performing a positional move.

Note: To stop a move in progress, click the red stop button or the drive enable button on
the toolbar. Alternatively, use the Mint WorkBench ‘Red Stop Button’ feature.

1. Check that the Drive enable button is

pressed (down).

2. In the Toolbox, click the Edit & Debug icon.

3. Click in the Command window.

4. Type:
MOVER(0)=10
GO(0)
This will cause the motor to move to a
position 10 units from its current position.

The move will stop when completed.

5. If you have finished testing click the Drive

Enable button to disable the drive.

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6.5 Further configuration

Mint WorkBench provides a number of other tools for testing and configuring the MotiFlex e100.
Every tool is explained fully in the help file. Press F1 to display the help file, then navigate to the
Mint WorkBench book. Inside this is the Toolbox book.

6.5.1 Parameters tool

The Parameters tool can be used to view or change most of the drive’s parameters.

1. Click the Parameters icon in the Toolbox

on the left of the screen.

The main area of the Mint WorkBench

window displays the Parameters editor
screen.

Items listed with a grey icon are Read Only so cannot be changed.
Items listed with a green icon are currently set to their Factory Default value.
Items listed with a yellow icon have been altered from their factory default value, either
during the commissioning process or by the user.

2. In the parameters tree, scroll to the

required item. Click on the small + sign
beside the item’s name.

The list will expand to show all items in the

category.

Click on the item you wish to edit.

3. The adjacent table will list the chosen item.

Click in the Active Table cell and enter a

value. This immediately sets the
parameter, which will remain in the
MotiFlex e100 until another value is
defined. The icon to the left of the item will become yellow to indicate that the value has been
changed.

Many of the MotiFlex e100’s parameters are set automatically by the Commissioning Wizard,
or when tests are performed in the fine-tuning window.

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6.5.2 Spy window

The Spy window can be used to monitor and capture parameters in real-time. If you tried the test
moves in section 6.4.9 or 6.4.10 then you have already seen the Spy window, as it is displayed
in conjunction with Edit & Debug mode. See the Mint help file for full details of each tab.

1. Click the Edit & Debug icon in the Toolbox

on the left of the screen.

The Spy Window is displayed on the right

of the screen. Click on the tabs at the
bottom of the window to select the
required function.

2. The Axis tab displays the five most

commonly monitored parameters,
together with the state of special purpose
inputs and outputs.

3. The I/O tab displays the state of all the

digital inputs and outputs.

Clicking on an output LED will toggle the

output on/off.

4. The Monitor tab allows up to six

parameters to be selected for monitoring.

Click in a drop down box to select a

parameter.

At the bottom of the Monitor tab, real-time

data capture can be configured.

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6.5.3 Other tools and windows

Remember, for help on each tool just press F1 to display the help file, then navigate to the Mint
WorkBench book. Inside this is the Toolbox book.

H Edit & Debug Tool

This tool provides a work area including
the Command window and Output
window. The Command window can be
used to send immediate Mint
commands to the MotiFlex e100. If you
tried the test moves in section 6.4.9 or
6.4.10, then you have already used Edit
& Debug mode. Press Ctrl+N to open a
new Mint programming window.

H Scope Tool
Displays the capture screen. This screen is also shown when the Fine-tuning tool is
selected.

H Digital I/O
Allows you to configure the active states
and special assignments for all the digital
inputs and outputs.

See section 5.3.2.1 or 5.3.3.1 for

important details about using a digital
input as a home input.

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7.1 Introduction
This section explains common problems that may be encountered, together with possible
solutions. If you want to know the meaning of the LED indicators, see section 7.2.

7.1.1 Problem diagnosis

If you have followed all the instructions in this manual in sequence, you should have few
problems installing the MotiFlex e100. If you do have a problem, read this section first.
In Mint WorkBench, use the Error Log tool to view recent errors and then check the help file.
If you cannot solve the problem or the problem persists, the SupportMe feature can be used.

7.1.2 SupportMe feature

The SupportMe feature is available from the Help menu or by clicking the button on the motion
toolbar. SupportMe can be used to gather information which can then be e-mailed, saved as a
text file, or copied to another application. The PC must have e-mail facilities to use the e-mail
feature. If you prefer to contact Baldor technical support by telephone or fax, contact details are
provided at the front of this manual. Please have the following information ready:

H The serial number of your MotiFlex e100 (if known).

H Use the Help, SupportMe menu item in Mint WorkBench to view details about your system.
H The catalog and specification numbers of the motor that you are using.
H A clear description of what you are trying to do, for example trying to establish
communications with Mint WorkBench or trying to perform fine-tuning.
H A clear description of the symptoms that you can observe, for example the Status LED, error
messages displayed in Mint WorkBench, or errors reported by the Mint error keywords
ERRORREADCODE or ERRORREADNEXT.
H The type of motion generated in the motor shaft.
H Give a list of any parameters that you have setup, for example the motor data you
entered/selected in the Commissioning Wizard, the gain settings generated during the tuning
process and any gain settings you have entered yourself.

7.1.3 Power-cycling the MotiFlex e100

The term “Power-cycle the MotiFlex e100” is used in the Troubleshooting sections. This means:

H Remove the AC supply (or shared DC bus supply).

H Remove the 24 VDC backup supply (if connected).
H Wait for the MotiFlex e100 to power down completely (the Status LED will turn off).
H Re-apply power.

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7.2 MotiFlex e100 indicators

7.2.1 STATUS LED
The Status LED indicates general MotiFlex e100 status information.

Solid green:
Drive enabled (normal operation).
Flickering / blinking green:
Firmware download / update in progress.

Solid red:
Drive disabled, but no errors are latched.
Flashing red:
Powerbase fault or error(s) present. The number of flashes indicates which
error has occurred. For example, to display error 3 (overcurrent trip), the LED
flashes 3 times at 0.1 second intervals, followed by a 0.5 second pause. The
sequence is repeated continuously.

Error code Meaning

(no. of flashes)

1 ............... DC bus overvoltage trip.

2 ............... PIM (power integration module) trip.
3 ............... Overcurrent trip.
4 ............... Overspeed trip.
5 ............... Feedback trip.
6 ............... Motor overload (I2t) trip.
7 ............... Overtemperature trip.
8 ............... Drive overload (It) trip.
9 ............... Following error trip.
10 . . . . . . . . . . . . . . Error input triggered.
11 . . . . . . . . . . . . . . Phase search error.
12 . . . . . . . . . . . . . . All other errors, including: Internal supply error, encoder
supply error, parameter restore failure, power base not
recognized.

If multiple errors occur at the same time, the lowest numbered error code will be
flashed. For example, a MotiFlex e100 which has tripped on both feedback
error (code 5) and over-current error (code 3) will flash error code 3. If the drive
is already displaying an error code when a new error with a lower code occurs,
the drive will start flashing the new code. Note that undervoltage trip does not
appear in the table because it is already indicated by the green/red flashing
state. If an undervoltage trip occurs in conjunction with another error, the drive
will flash the code of the additional error.
Further details about error codes can be found in the Mint WorkBench help file.
Press F1 and locate the Error Handling book.
Alternate red/green flashing:
Undervoltage warning (low DC bus voltage), but no errors are latched.

The DC bus voltage has dropped below the powerbase undervoltage level (see
DRIVEBUSUNDERVOLTS). This error will only be generated if the drive is in the
enabled state. Check the AC power (or shared DC bus) is connected.

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7.2.2 CAN LEDs

The CAN LEDs display the overall condition of the CANopen interface,
once the startup sequence has completed. The LED codes conform to
the CAN in Automation (CiA) DR303_3 indicator standard. The green
LED indicates the state of the node’s internal CANopen ‘state machine’.
The red LED indicates the state of the physical CANopen bus.

Green (run)
Off: Node initializing or not powered.
X
1 flash: Node in STOPPED state.
3 flashes: Software is being downloaded to the node.
Continuous flashing: Node in PRE-OPERATIONAL state.
Flickering (very fast flashing): Auto-baudrate detection or LSS services in
progress; flickers alternately with red LED.
Continuously illuminated, not flashing: Node in OPERATIONAL state.

Red (error)
Off: No errors or not powered.
X
1 flash: Warning - too many error frames.
2 flashes: Guard event or heartbeat event has occurred.
3 flashes: The SYNC message has not been received within the time-out period.
Flickering (very fast flashing): Auto-baudrate detection or LSS services in
progress; flickers alternately with green LED.
Continuously illuminated, not flashing: The node’s CAN controller is in the BUS
OFF state, preventing it from taking part in any CANopen communication.

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7.2.3 ETHERNET LEDs

The ETHERNET LEDs display the overall condition of the Ethernet
interface once the startup sequence has completed. The LED codes
conform to the Ethernet POWERLINK Standardization Group (EPSG)
standard at the time of production.

Green (status)
Off: Node in NOT ACTIVE state. The controlled node is waiting to be triggered by
X the manager node.
1 flash: Node in PRE-OPERATIONAL1 state. EPL mode is starting.

2 flashes: Node in PRE-OPERATIONAL2 state. EPL mode is starting.

3 flashes: Node in READY TO OPERATE state. The node is signalling its

readiness to operate.

Blinking (continuous flashing): Node in STOPPED state. The controlled node has
been deactivated.

Flickering (very fast flashing): Node in BASIC ETHERNET state (EPL is not
operating, but other Ethernet protocols may be used).
Continuously illuminated, not flashing: Node in OPERATIONAL state. EPL is
operating normally.

Red (error)
Off: EPL is working correctly.
X
Continuously illuminated: An error has occurred.

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7.2.4 Communication
Status LED is off:
H Check that AC power (or shared DC bus supply) is present, or that the 24 VDC control circuit
backup supply (if present) is connected correctly to connector X2 and is switched on.
ETHERNET LEDs blinking green and red simultaneously:
H Does the MotiFlex e100 have firmware in it? If you tried to download new firmware and the
download failed, the controller may not have firmware. Download new firmware.
Mint WorkBench fails to detect the MotiFlex e100:
H Ensure that the MotiFlex e100 is powered and the Status LED is illuminated (see section
7.2.1).
H Check that the Ethernet or USB cable is connected between the PC and MotiFlex e100.
H Try an alternative cable or different port on the PC.
H In the “Search up to Nodexx“ option in Mint WorkBench’s Select Controller dialog, check that
the MotiFlex e100’s node ID is not higher than the selected value, or search up to a greater
node ID.
H For USB connections, check that the cable is properly connected. Check the USB connector
socket pins for damage or sticking. Check that the USB device driver has been installed; a
‘USB Motion Controller’ device should be listed in Windows Device Manager.
H Check that the PC’s Ethernet port has been correctly configured for TCP/IP operation (see
section 6.2.4).

7.2.5 Power on
The Status LED is flashing red:
H The MotiFlex e100 has detected a motion error. Click the Error button on the motion toolbar
to view a description of the error. Alternatively, select the Error Log tool to view a list of errors.

H Click the Clear Errors button on the motion toolbar.

7.2.6 Mint WorkBench

The Spy window does not update:
H The system refresh has been disabled. Go to the Tools, Options menu item, select the
System tab and then choose a System Refresh Rate (500 ms is recommended).
Cannot communicate with the controller after downloading firmware:
H After firmware download, always power cycle the MotiFlex e100.
Mint WorkBench loses contact with MotiFlex e100 while connected using USB:
H Check that the MotiFlex e100 is powered.
H Check that a ‘USB Motion Controller’ device is listed in Windows Device Manager. If not,
there could be a problem with the PC’s USB interface.

MN1943 Troubleshooting 7-5

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7.2.7 Tuning
Cannot enable the MotiFlex e100 because there is an error 10010:
H Check the drive enable input on connector X3 pins 9 and 19 is connected and powered
correctly.
When the MotiFlex e100 is enabled the motor is unstable:
H Check that the load is firmly coupled to the motor.
H Use the Mint WorkBench Drive Setup Wizard to confirm that the correct motor data has been
entered.
H Use the Mint WorkBench Autotune Wizard to retune the motor.
H If the motor is still unstable, select the Mint WorkBench Autotune Wizard once more. Click
Options.... On the Bandwidth tab, move the Current and/or Position and Speed Control
sliders to a slower position to select to a lower bandwidth. Click OK to exit and then start the
Autotune Wizard again.

7.2.8 Ethernet
Cannot connect to the drive over TCP/IP:
H Check that there is not an EPL manager node (for example NextMove e100 with node ID
240) on the network. If there is a manager node on the network, then an EPL compatible
router must be used to allow TCP/IP communication on the EPL network.
H Check that the PC’s Ethernet adapter has been correctly configured, as described in section
6.2.4.
The Ethernet POWERLINK network does not seem to be operating correctly:
H Confirm that only one device on the network is set to be the Ethernet POWERLINK manager
node (node ID 240, selector switches LO = F, HI = 0).
H Confirm that the reference source on all controlled nodes has been set to EPL in the Mint
WorkBench Operating Mode Wizard, and that the manager node has been configured
correctly. For a NextMove e100 manager node, this requires the System Config Wizard to be
used in Mint WorkBench.
H Confirm that each device on the network has a different node ID.
H Confirm that there are no more than 10 ‘daisy-chained’ devices on each branch of the
network.

7.2.9 CANopen
The CANopen bus is ‘passive’:
This means that the internal CAN controller in the MotiFlex e100 is experiencing a number of Tx
and/or Rx errors, greater than the passive threshold of 127. Check:
H 12-24 VDC is being applied between pin 9 (+24 V) and pin 6 or 3 (0 V) of the CAN connector,
to power the opto-isolators.
H There is at least one other CANopen node in the network.
H The network is terminated only at the ends, not at intermediate nodes.
H All nodes on the network are running at the same baud rate.
H All nodes have been assigned a unique node ID.
H The integrity of the CAN cables.

7-6 Troubleshooting MN1943

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The MotiFlex e100 should recover from the ‘passive’ state once the problem has been rectified
(this may take several seconds).

The CANopen bus is ‘off’:

This means that the internal CAN controller in the MotiFlex e100 has experienced a fatal number
of Tx and/or Rx errors, greater than the off threshold of 255. At this point the node will have
switched itself to a state whereby it cannot influence the bus. Check:
H 12-24 VDC is being applied between pin 9 (+24 V) and pin 6 or 3 (0 V) of the CAN connector,
to power the opto-isolators.
H There is at least one other CANopen node in the network.
H The network is terminated only at the ends, not at intermediate nodes.
H All nodes on the network are running at the same baud rate.
H All nodes have been assigned a unique node ID.
H The integrity of the CAN cables.
To recover from the ‘off’ state, the source of the errors must be removed and the bus then reset.
This can be done using the Mint BUSRESET keyword, or by resetting the MotiFlex e100.

The Manager node cannot scan / recognize a node on the network using the Mint
NODESCAN keyword:
Assuming that the network is working correctly (see previous symptoms) and the bus is in an
‘Operational’ state, check:
H Only nodes that conform to DS401, DS403 and other Baldor CANopen nodes are
recognized by the Mint NODESCAN keyword. Other types of node will be identified with a type
“unknown” (255) when using the Mint NODETYPE keyword.
H Check that the node in question has been assigned a unique node ID.
H The node must support the node guarding process. MotiFlex e100 does not support the
Heartbeat process.
H Try power-cycling the node in question.
If the node in question does not conform to DS401 or DS403 and is not a Baldor CANopen node,
communication is still possible using a set of general purpose Mint keywords. See the Mint help
file for further details.

The node has been successfully scanned / recognized by the Manager node, but
communication is still not possible:
For communication to be allowed, a connection must be made to a node after it has been
scanned:
H Baldor controller nodes are automatically connected to after being scanned.
H Nodes that conform to DS401, DS403 must have the connections made manually using the
Mint CONNECT keyword.
If a connection attempt using CONNECT fails then it may be because the node being connected
to does not support an object which needs to be accessed in order to setup the connection.

MN1943 Troubleshooting 7-7

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7-8 Troubleshooting MN1943

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 8 Specifications
8
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8.1 Introduction
This section provides technical specifications for the MotiFlex e100.

8.2 AC input

8.2.1 AC input voltage (X1) - all models

All models Unit AC input
3Φ, 50 Hz / 60 Hz
Nominal input voltage VAC 230 or 480
Minimum input voltage 180
Maximum input voltage 528
Nominal DC bus voltage VDC
@ 230 VAC input 325
@ 480 VAC input 678

MN1943 Specifications 8-1

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8.2.2 AC input current (X1), DC bus not shared - all models

Tables 7 and 8 show a range of typical AC input currents at typical motor output currents. The
Typical AC supply current at full load is calculated using an AC input power factor of 0.7 and a
motor output power factor of 0.85. It is highly recommended that fuses are used instead of circuit
breakers. Circuit breakers should only be used when absolutely necessary. Tables 7 and 8
describe the recommended fuses and circuit breakers to be used for AC power connections.

Full load output Typical Input fuse Circuit

current rating AC supply breaker
not exceeding current at (C type)
(C-type)
(A) full load
(A)
1.5 1.8 Ferraz Shawmut: 4A
A60Q5-2, 5 A (E217400)

3 3.6 Ferraz Shawmut: 6A

A60Q8-2, 8 A (T218425)

4 4.9 Ferraz Shawmut: 10 A

A60Q8-2, 8 A (T218425)

5.5 6.7 Ferraz Shawmut: 10 A

A60Q10-2, 10 A (Z212289)

8.5 10.3 Ferraz Shawmut: 16 A

A60Q15-2, 15 A (X213322)

9 10.9 Ferraz Shawmut: 16 A

A60Q15-2, 15 A (X213322)

10 12.1 Ferraz Shawmut: 16 A

A60Q20-2, 20 A (B214338)

11 13.4 Ferraz Shawmut: 20 A

A60Q20-2, 20 A (B214338)

13 15.8 Ferraz Shawmut: 20 A

A60Q25-2, 25 A (Z214842)

17.5 21.25 Ferraz Shawmut: 25 A

A60Q25-2, 25 A (Z214842)

18.5 22.5 Ferraz Shawmut: 25 A

A60Q25-2, 25 A (Z214842)

22 26.7 Ferraz Shawmut: 32 A

A60Q30-2, 30 A (E215859)

Table 7 - AC input current and protection device ratings - 1.5 A ~ 16 A models

8-2 Specifications MN1943

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Full load output AC supply Input fuse Circuit

current rating current at breaker
not exceeding full load (B-type)
(A) (A)
10 12.1 Ferraz Shawmut: 16 A
A60Q20-2, 20 A (B214338)

14 17 Ferraz Shawmut: 20 A
A60Q20-2, 20 A (B214338)
Ferraz Shawmut:
A60Q25-2, 25 A (Z214842)
15 18.2 25 A
or
6.600 CP URD 22x58/25 (B093956)
Ferraz Shawmut:
A60Q30-2, 30 A (E215859)
21 25.5 32 A
or
6.600 CP URD 22x58/32 (Z094828)
Ferraz Shawmut:
A60Q35-2, 35 A (J216369)
24 29 40 A
or
6.600 CP URD 22x58/32 (Z094828)
Ferraz Shawmut:
A60Q40-2, 40 A (N216879)
29 35.2 40 A
or
6.600 CP URD 22x58/40 (S094822)

33.5 40.7 Ferraz Shawmut: 50 A

6.600 CP URD 22x58/50 (W094779)

48 54.6 Cooper Bussmann: 80 A

LPN-RK-80SP

65 78.9 Cooper Bussmann: 80 A

LPN-RK-80SP

Table 8 - AC input current and protection device ratings - 21 A ~ 65 A models

MN1943 Specifications 8-3

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8.2.3 AC input current (X1), DC bus sharing - all models

When the MotiFlex e100 is sharing its DC bus, it becomes critical to consider the overall current
being derived from the drive’s internal power supply. This includes the current required to drive
its own motor (if present), and the current required by the other drives sharing its DC bus.

The following ratings assume that the source drive is itself driving a motor at the drive’s rated
current output.

8.2.3.1 Rating adjustment when sharing DC bus - 1.5 A model

Note: A 1.2 mH line reactor must be used when DC bus sharing.

Temperature Switching Maximum AC input supply current (RMS)

frequency
Continuous 3s 60 s
overload overload
4 kHz
45 °C
8 kHz 10 A
(113 °F)
F)
16 kHz
16 5 A
16.5 13 5 A
13.5
4 kHz
55 °C
8 kHz 7.5 A
(131 °F)
F)
16 kHz

Table 9 - Continuous current ratings for 1.5 A model, sharing DC bus

8.2.3.2 Rating adjustment when sharing DC bus - 3 A model

Note: A 1.2 mH line reactor must be used when DC bus sharing.

Temperature Switching Maximum AC input supply current (RMS)

frequency
Continuous 3s 60 s
overload overload
4 kHz
45 °C
8 kHz 10 A
(113 °F)
F)
16 kHz
16 5 A
16.5 13 5 A
13.5
4 kHz
55 °C
8 kHz 7.5 A
(131 °F)
F)
16 kHz

Table 10 - Continuous current ratings for 3 A model, sharing DC bus

8-4 Specifications MN1943

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8.2.3.3 Rating adjustment when sharing DC bus - 6 A model

Note: A 1.2 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload
4 kHz 14 A
45 °C
8 kHz 14 A
(113 °F)
F)
16 kHz 7.5 A
21 A 17 A
4 kHz 8.4 A
55 °C
8 kHz 8.4 A
(131 °F)
F)
16 kHz 4.5 A

Table 11 - Continuous current ratings for 6 A model, sharing DC bus

8.2.3.4 Rating adjustment when sharing DC bus - 10.5 A model

Note: A 0.8 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload
4 kHz 20 A
45 °C
8 kHz 18 A
(113 °F)
F)
16 kHz 13.5 A
36 A 27 A
4 kHz 17 A
55 °C
8 kHz 15 A
(131 °F)
F)
16 kHz 9A

Table 12 - Continuous current ratings for 10.5 A model, sharing DC bus

8.2.3.5 Rating adjustment when sharing DC bus - 16 A model

Note: A 0.8 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload
4 kHz 22 A
45 °C
8 kHz 20 A
(113 °F)
F)
16 kHz 13.5 A
42 A 33 A
4 kHz 18 A
55 °C
8 kHz 17.5 A
(131 °F)
F)
16 kHz 10 A

Table 13 - Continuous current ratings for 16 A model, sharing DC bus

MN1943 Specifications 8-5

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8.2.3.6 Rating adjustment when sharing DC bus - 21 A model

Note: A 0.5 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload
4 kHz 30 A 68 A 45 A
45 °C
8 kHz 26 A 60 A 39 A
(113 °F)
F)
16 kHz 19 A 57 A 30 A
4 kHz 23.8 A 47.6 A 31.5 A
55 °C
8 kHz 21 A 42 A 27.3 A
(131 °F)
F)
16 kHz 13.3 A 39.9 A 21 A

Table 14 - Continuous current ratings for 21 A model, sharing DC bus

8.2.3.7 Rating adjustment when sharing DC bus - 26 A model

Note: A 0.5 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload
4 kHz 34 A 80 A 51 A
45 °C
8 kHz 28 A 70 A 42 A
(113 °F)
F)
16 kHz 19 A 57 A 30 A
4 kHz 28 A 56 A 35.7 A
55 °C
8 kHz 24.5 A 49 A 29.4 A
(131 °F)
F)
16 kHz 13.3 A 39.9 A 21 A

Table 15 - Continuous current ratings for 26 A model, sharing DC bus

8.2.3.8 Rating adjustment when sharing DC bus - 33.5 A model

Note: A 0.5 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload
4 kHz 34 A 80 A 51 A
45 °C
8 kHz 28 A 70 A 42 A
(113 °F)
F)
16 kHz 19 A 57 A 30 A
4 kHz 28 A 56 A 35.7 A
55 °C
8 kHz 24.5 A 49 A 29.4 A
(131 °F)
F)
16 kHz 13.3 A 39.9 A 21 A

Table 16 - Continuous current ratings for 33.5 A model, sharing DC bus

8-6 Specifications MN1943

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8.2.3.9 Rating adjustment when sharing DC bus - 48 A model

Note: A 0.5 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload

45 °C
C 4 kHz 66 132 99
(113 °F) 8 kHz 66 132 99

55 °C
C 4 kHz 66 132 99
(131 °F) 8 kHz 66 132 99

Table 17 - Continuous current ratings for 48 A model, sharing DC bus

8.2.3.10 Rating adjustment when sharing DC bus - 65 A model

Note: A 0.5 mH line reactor must be used when DC bus sharing.
Temperature Switching Maximum AC input supply current (RMS)
frequency
Continuous 3s 60 s
overload overload

45 °C
C 4 kHz 66 132 99
(113 °F) 8 kHz 66 132 99

55 °C
C 4 kHz 66 132 99
(131 °F) 8 kHz 66 132 99

Table 18 - Continuous current ratings for 65 A model, sharing DC bus

MN1943 Specifications 8-7

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8.2.4 Recommended fuses and circuit breakers when sharing the DC bus
When a drive is being used as the source drive to power other drives linked by the DC bus (see
sections 3.2.4 and 3.5), the fuse rating will need to be increased to allow for the total input current.
This is summarized in the following table:

Max. cont. Input fuse for Circuit

AC input current maximum continuous breaker
less than (ARMS) input current (C-type)
10 A Ferraz Shawmut: 10 A
A60Q10-2, 10 A (Z212289)

14 A Ferraz Shawmut: 16 A
A60Q20-2, 20 A (B214338)

20 A Ferraz Shawmut: 25 A
A60Q25-2, 25 A (Z214842)

22 A Ferraz Shawmut: 25 A
A60Q25-2, 25 A (Z214842)
Table 19 - Protection device ratings when sharing the DC bus - 1.5 A ~ 16 A models

Max. cont. Input fuse for Circuit

AC input current maximum continuous breaker
less than (ARMS) input current (B-type)
14 A Ferraz Shawmut: 20 A
A60Q20-2, 20 A (B214338)
Ferraz Shawmut:
A60Q30-2, 30 A (E215859)
25 A 32 A
or
6.600 CP URD 22x58/32 (Z094828)
Ferraz Shawmut:
A60Q35-2, 35 A (J216369)
28 A 32 A
or
6.600 CP URD 22x58/32 (Z094828)
Ferraz Shawmut:
A60Q40-2, 40 A (N216879)
35 A 40 A
or
6.600 CP URD 22x58/40 (S094822)

40 A Ferraz Shawmut: 50 A
6.600 CP URD 22x58/50 (W094779)

80 A Cooper Bussmann: Not recommended.

LPN-RK-80SP

80 A Cooper Bussmann: Not recommended.

LPN-RK-80SP
Table 20 - Protection device ratings when sharing the DC bus - 21 A ~ 65 A models

Recommended fuses are based on 25 °C (77 °F) ambient, maximum continuous control output
current and no harmonic current. Earth/ground wires must be the same gauge, or larger, than the
Line wires.

UL compliance can only be achieved when using the recommended fuses. The use of circuit
breakers does not guarantee UL compliance and provides protection for the wiring only, not the
MotiFlex e100.

8-8 Specifications MN1943

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8.2.5 Power, power factor and crest factor - 1.5 A ~ 16 A models

The relationship between input current and power, power factor and crest factor is shown in
Figure 74 (with no line reactor) and Figures 75 to 78 (with line reactor).

50 4.0
45 3.6

Power Factor & Crest Factor

40 3.2
35 2.8
Power (kW)

30 2.4
25 2.0
20 1.6
15 1.2
10 0.8
5 0.4
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Supply current (ARMS)

Power Power factor Crest factor

Figure 74 - Power, power factor and crest factor (no line reactor) - 1.5 A ~ 16 A models

50 4.0
45 3.6

Power Factor & Crest Factor

40 3.2
35 2.8
Power (kW)

30 2.4
25 2.0
20 1.6
15 1.2
10 0.8
5 0.4
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Supply current (ARMS)

Power Power factor Crest factor

Figure 75 - Power, power factor and crest factor (1.2 mH line reactor) - 1.5 A & 3 A models

MN1943 Specifications 8-9

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50 4.0
45 3.6

Power Factor & Crest Factor

40 3.2
35 2.8
Power (kW)

30 2.4
25 2.0
20 1.6
15 1.2
10 0.8
5 0.4
0 0
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Supply current (ARMS)

Power Power factor Crest factor

Figure 76 - Power, power factor and crest factor (1.2 mH line reactor) - 6 A model

120 4.4
100 4.0
90 3.6

Power Factor & Crest Factor

80 3.2
70 2.8
Power (kW)

60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
0 5 10 15 20 25 30 35 40 45 50
Supply current (ARMS)

Power Power factor Crest factor

Figure 77 - Power, power factor and crest factor (0.8 mH line reactor) - 10.5 A model

8-10 Specifications MN1943

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120 4.4
100 4.0
90 3.6

Power Factor & Crest Factor

80 3.2
70 2.8
Power (kW)

60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
0 5 10 15 20 25 30 35 40 45 50
Supply current (ARMS)

Power Power factor Crest factor

Figure 78 - Power, power factor and crest factor (0.8 mH line reactor) - 16 A model

MN1943 Specifications 8-11

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8.2.6 Power, power factor and crest factor - 21 A model

The relationship between input current and power, power factor and crest factor is shown in
Figure 79 (with no line reactor) and Figure 80 (with 0.5 mH line reactor).

120 4.4
100 4.0
90 3.6

Power Factor & Crest Factor

80 3.2
70 2.8
Power (kW)

60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
0 5 10 15 20 25 30 35 40 45 50
Supply current (ARMS)

Power Power factor Crest factor

Figure 79 - Power, power factor and crest factor (no line reactor) - 21 A model

120 4.4
100 4.0
90 3.6

Power Factor & Crest Factor

80 3.2
70 2.8
Power (kW)

60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
35 40 45 50 55 60 65 70 75 80 85
Supply current (ARMS)

Power Power factor Crest factor

Figure 80 - Power, power factor and crest factor (0.5 mH line reactor) - 21 A model

8-12 Specifications MN1943

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8.2.7 Power, power factor and crest factor - 26 A & 33.5 A models
The relationship between input current and power, power factor and crest factor is shown in
Figure 81 (with no line reactor) and Figure 82 (with 0.5 mH line reactor).

120 4.4
100 4.0
90 3.6

Power Factor & Crest Factor

80 3.2
70 2.8
Power (kW)

60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
0 10 20 30 40 50 60 70 80 90 100
Supply current (ARMS)

Power Power factor Crest factor

Figure 81 - Power, power factor and crest factor (no line reactor) - 26 A & 33.5 A models

120 4.4
100 4.0
90 3.6

Power Factor & Crest Factor

80 3.2
70 2.8
Power (kW)

60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
0 5 10 15 20 25 30 35 40 45 50
Supply current (ARMS)

Power Power factor Crest factor

Figure 82 - Power, power factor and crest factor (0.5 mH line reactor) - 26 A & 33.5 A models

MN1943 Specifications 8-13

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8.2.8 Power, power factor and crest factor - 48 A & 65 A models

The relationship between input current and power, power factor and crest factor is shown in
Figure 83 (with no line reactor) and Figure 84 (with 0.5 mH line reactor).

140 4.8
120 4.4
100 4.0

Power Factor & Crest Factor

90 3.6
80 3.2
Power (kW)

70 2.8
60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
0 10 20 30 40 50 60 70
Supply current (ARMS)

Power Power factor Crest factor

Figure 83 - Power, power factor and crest factor (no line reactor) - 48 A & 65 A models

140 4.8
120 4.4
100 4.0

Power Factor & Crest Factor

90 3.6
80 3.2
Power (kW)

70 2.8
60 2.4
50 2.0
40 1.6
30 1.2
20 0.8
10 0.4
0 0
0 10 20 30 40 50 60 70
Supply current (ARMS)

Power Power factor Crest factor

Figure 84 - Power, power factor and crest factor (0.5 mH line reactor) - 48 A & 65 A models

8-14 Specifications MN1943

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8.3 Motor output

8.3.1 Motor output power (X1) - 1.5 A ~ 16 A models

Unit 1.5 A 3A 6A 10.5 A 16 A
Nominal phase current ARMS 1.5 3 6 10.5 16
Nominal output power kVA 1.08 2.16 4.31 7.55 11.50
@ 415 V

Output voltage range (line-line) VRMS 0 - 430

@ VDC-bus = 600 V

Output frequency Hz 0 - 2000

Output dV/dt kV/μs
at drive, phase-phase 2
at drive, phase-ground 1.1
at motor (using 20 m cable), phase-phase 1.9
at motor (using 20 m cable), phase-ground 1.8
Nominal switching frequencies kHz 4.0, 8.0, 16.0
Minimum motor inductance mH 1
(per winding)

Efficiency % >95

8.3.2 Motor output power (X1) - 21A ~ 33.5 A models

Unit 21 A 26 A 33.5 A
Nominal phase current ARMS 21 26 33.5
Nominal output power kVA 15.10 18.69 24.08
@ 415 V, 3Φ input

Output voltage range (line-line) VRMS 0 - 430

@ VDC-bus = 600 V

Output frequency Hz 0 - 2000

Output dV/dt kV/μs
at drive, phase-phase 2
at drive, phase-ground 1.1
at motor (using 20 m cable), phase-phase 1.9
at motor (using 20 m cable), phase-ground 1.8
Nominal switching frequencies kHz 4.0, 8.0, 16.0 *
Minimum motor inductance mH 1
(per winding)

Efficiency % >95

* 16 kHz not available on 33.5 A model.

MN1943 Specifications 8-15

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8.3.3 Motor output power (X1) - 48 A ~ 65 A models

Unit 48 A 65 A
Nominal phase current ARMS 48 65
Nominal output power kVA 32.5 46.72
@ 415 V, 3Φ input
Output voltage range (line-line) VRMS 0 - 430
@ VDC-bus = 600 V

Output frequency Hz 0 - 2000

Output dV/dt kV/μs
at drive, phase-phase 2
at drive, phase-ground 1.1
at motor (using 20 m cable), phase-phase 1.9
at motor (using 20 m cable), phase-ground 1.8
Nominal switching frequencies kHz 4.0, 8.0
Minimum motor inductance mH 1
(per winding)

Efficiency % >95

8-16 Specifications MN1943

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8.3.4 Motor output uprating and derating

The continuous output current available from the MotiFlex e100 will often differ from the nominal
value suggested by the model name. For example, depending on the chosen overload type and
switching frequency, the continuous output rating of a 16 A model can be derated to as little as
8.5 A, or uprated to as much as 22 A. When operating a motor at very low speeds or holding it
stationary, other ratings apply since these conditions represent abnormal operating modes for the
MotiFlex e100. In addition to these rating adjustments, if the MotiFlex e100 is operating in an
ambient temperature greater than 45 ºC (113 ºF), a further derating must be applied. The choice
of overload rating and switching frequency can be selected using the Drive Setup Wizard in Mint
WorkBench, or by using the DRIVERATINGZONE keyword. See the Mint help file for details.

8.3.5 Motor output rating adjustment - 1.5 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 21. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.
Servo motor Induction motor Low Stationary:
speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 1.15 A 1.7 A 2.2 A 3A 5.3 A 7.5 A (DC)

8 kHz 1.15 A 1.5 A 2A 2.7 A 4.25 A 6 A (DC)

16 kHz 1.15 A 1.5 A 2A 2.7 A 2.6 A 3.7 A (DC)

Table 21 - Continuous current ratings for 1.5 A model

The continuous current ratings shown in Table 21 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):
100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70 16 kHz
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 85 - Temperature derating for 1.5 A model

MN1943 Specifications 8-17

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8.3.6 Motor output rating adjustment - 3 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 22. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 2.75 A 4A 5A 5.5 A 5.3 A 7.5 A (DC)

8 kHz 2.75 A 3A 3.8 A 4.5 A 4.25 A 6 A (DC)

16 kHz 2.7 A 3A 3.8 A 4.5 A 2.6 A 3.7 A (DC)

Table 22 - Continuous current ratings for 3 A model

The continuous current ratings shown in Table 22 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70 16 kHz
65
60
55
50
45
40
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 86 - Temperature derating for 3 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

8-18 Specifications MN1943

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8.3.7 Motor output rating adjustment - 6 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 23. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 5A 7.5 A 9A 10 A 9.8 A 13.9 A (DC)

8 kHz 4.5 A 6A 7A 8A 8A 11.4 A (DC)

16 kHz 3A 4A 5A 5.5 A 5.2 A 7.4 A (DC)

Table 23 - Continuous current ratings for 6 A model

The continuous current ratings shown in Table 23 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70 16 kHz
65
60
55
50
45
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 87 - Temperature derating for 6 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

MN1943 Specifications 8-19

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8.3.8 Motor output rating adjustment - 10.5 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 24. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 8A 12 A 16 A 18.5 A 9.8 A 13.9 A (DC)

8 kHz 7.33 A 10.5 A 13 A 15 A 8A 11.4 A (DC)

16 kHz 5A 7.5 A 8.5 A 9.5 A 5.2 A 7.4 A (DC)

Table 24 - Continuous current ratings for 10.5 A model

The continuous current ratings shown in Table 24 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70 16 kHz
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 88 - Temperature derating for 10.5 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

8-20 Specifications MN1943

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8.3.9 Motor output rating adjustment - 16 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 25. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 12 A 18 A 20 A 22 A 17 A 24 A (DC)

8 kHz 12 A 16 A 16 A 17 A 13.8 A 19.5 A (DC)

16 kHz 8.5 A 10 A 9A 10 A 5.7 A 8.1 A (DC)

Table 25 - Continuous current ratings for 16 A model

The continuous current ratings shown in Table 25 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70 16 kHz
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 89 - Temperature derating for 16 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

MN1943 Specifications 8-21

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8.3.10 Motor output rating adjustment - 21 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 26. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 17 A 24 A 25 A 25 A 21 A* 31 A (DC)

8 kHz 15 A 21 A 23 A 23 A 20 A* 24 A (DC)

16 kHz 10 A 14 A 14 A 15 A 9 A* 13.8 A (DC)

* Estimated values

Table 26 - Continuous current ratings for 21 A model

The continuous current ratings shown in Table 26 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70 16 kHz
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 90 - Temperature derating for 21 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

8-22 Specifications MN1943

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8.3.11 Motor output rating adjustment - 26 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 27. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 20 A 29 A 29 A 29 A 25 A* 42 A (DC)

8 kHz 19 A 26 A 26 A 26 A 22 A* 32 A (DC)

16 kHz 12.5 A 12.5 A 12.5 A 12.5 A 8 A* 14 A (DC)

* Estimated values

Table 27 - Continuous current ratings for 26 A model

The continuous current ratings shown in Table 27 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70 16 kHz
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 91 - Temperature derating for 26 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

MN1943 Specifications 8-23

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8.3.12 Motor output rating adjustment - 33.5 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 28. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 24.5 A 33.5 A 33.5 A 33.5 A 28 A* 42 A (DC)

8 kHz 19 A 26 A 26 A 26 A 16 A* 32 A (DC)

* Estimated values

Table 28 - Continuous current ratings for 33.5 A model

The continuous current ratings shown in Table 28 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 92 - Temperature derating for 33.5 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

8-24 Specifications MN1943

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8.3.13 Motor output rating adjustment - 48 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 28. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 33 A 48 A 60 A 65 A 48 75

8 kHz 27 A 40 A 47 A 54 A 40 59

* Estimated values

Table 29 - Continuous current ratings for 48 A model

The continuous current ratings shown in Table 28 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 93 - Temperature derating for 48 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

MN1943 Specifications 8-25

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8.3.14 Motor output rating adjustment - 65 A model

The continuous current rating of the MotiFlex e100 is affected by the chosen overload type and
switching frequency, as shown in Table 28. These settings can be selected in the Mint
WorkBench Drive Setup Wizard - see the Mint help file for details.

Servo motor Induction motor Low Stationary:

speed DC output
300%, 3 s 200%, 3 s 150%, 60 s 110%, 60 s output (any phase)
overload overload overload overload (< 2 Hz)
4 kHz 43 A 65 A 65 A 65 A 65 75

8 kHz 35 A 48 A 52 A 58 A 48 59

* Estimated values

Table 30 - Continuous current ratings for 65 A model

The continuous current ratings shown in Table 28 must be derated if the drive is operating in an
ambient temperature between 45 °C (113 °F) and the absolute maximum operating temperature
of 55 °C (131 °F):

100
95
(% of continuous current rating)

90
85
Derated output

80 4 kHz
75 8 kHz
70
65
60
55
50
44 45 46 47 48 49 50 51 52 53 54 55 56
Ambient temperature (ºC)

Figure 94 - Temperature derating for 65 A model

When sharing the DC bus, it becomes critical to consider the overall power being
derived from the drive’s internal power supply. See section 8.2.3.
CAUTION

8-26 Specifications MN1943

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8.4 Regeneration

8.4.1 Regeneration (X1) - 1.5 A ~ 16 A models

Unit 1.5 A 3A 6A 10.5 A 16 A
Nominal switching threshold (typical) VDC on: 800, off: 775
Nominal power kW 1.07 1.94
(10% power cycle, standalone) (R = 60 Ω) (R = 33 Ω)
Peak power kW 10.7 19.4
(10% power cycle, standalone) (R = 60 Ω) (R = 33 Ω)
Maximum regeneration switching APK 13.3 24.2
current
Minimum load resistance Ω
‘standalone’ drive 60 33
sharing DC bus, or duty >0.2 150 68
Maximum load inductance μH 100

8.4.2 Regeneration (X1) - 21 A ~ 33.5 A models

Unit 21 A 26 A 33.5 A
Nominal switching threshold (typical) VDC on: 800, off: 775
Nominal power kW 4.27
(10% power cycle, R = 15 Ω)
Peak power kW 42.7
(10% power cycle, R = 15 Ω)
Maximum regeneration switching APK 53.3
current
Minimum load resistance Ω
‘standalone’ drive 15
sharing DC bus, or duty >0.2 60
Maximum load inductance μH 100

MN1943 Specifications 8-27

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8.4.3 Regeneration (X1) - 48 A ~ 65 A models

Unit 48 A 65 A
Nominal switching threshold (typical) VDC on: 800, off: 775
Nominal power kW 8.53
(10% power cycle, R = 15 Ω)
Peak power kW 85.3
(10% power cycle, R = 15 Ω)
Maximum regeneration switching APK 106
current
Minimum load resistance Ω
‘standalone’ drive 7.5
sharing DC bus, or duty >0.2 33
Maximum load inductance μH 100

8-28 Specifications MN1943

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8.5 18 VDC output / 24 VDC input

8.5.1 18 VDC output / 24 VDC control circuit backup supply input (X2)
When operating as an output: Unit All models
Nominal output voltage VDC 15
Minimum output voltage 12
Maximum output voltage 19
Maximum continuous output current mA 50
(limited by PTC)

When operating as in input:

Nominal input voltage VDC 24
Minimum input voltage 20
Maximum input voltage 30
Maximum ripple % ±10

Maximum continuous input current A

@24 VDC input:

powering encoder @ 250mA, no option cards fitted 0.8

powering encoder @ 250mA + option card(s) 1.2

8.5.2 Option card power supply

When using more than one option card, the power consumption of the option card combination
must be considered, since there is limited power available. The power requirements of the
various options are described in the following table:

Option Power requirement (max)

Resolver 3.8 W
Incremental Encoder 3.9 W
Analog I/O 2.9 W
Digital I/O 0.85 W
Mint 5W
Fieldbus Bus dependent: see option’s own installation manual.

MN1943 Specifications 8-29

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8.5.2.1 Derating option card power supply when AC supply is not present
The available power to the option cards depends on the ambient temperature and whether the
MotiFlex e100 is powered from the AC supply or from only the 24 VDC backup supply.

If the AC supply is present, a maximum of 10 W is available to power the option cards, at

temperatures up to 55 ºC (131 ºF).

If only the 24 VDC backup supply is present, the total power available to the option cards must
be derated as shown in Table 31:

Ambient Backup Maximum available Maximum

temperature supply additional current drawn power
not exceeding voltage from backup supply for available for
option cards option cards
35 ºC (95 ºF) 20 V 0.5 A 10 W
45 ºC (113 ºF) 30 V 0.33 A 10 W
20 V 0.35 A (0.5 A)* 7 W (10 W)*
55 ºC (131 ºF) 30 V 0.2 A (0.33 A)* 6 W (10 W)*
20 V 0.2 A (0.5 A)* 4 W (10 W)*
* Figures shown in brackets are for a maximum of 1 hour.

Table 31 - Derating option card power supply when AC supply is not present

8-30 Specifications MN1943

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8.6 Input / output

8.6.1 Analog input - AIN0 (X3)

Unit All models

Type Differential
Common mode voltage range VDC ±10
Input impedance kΩ 120
Input ADC resolution bits 12 (includes sign bit)

Equivalent resolution (±10 V input) mV ±4.9

Sampling interval μs 250

8.6.2 Digital inputs - drive enable and DIN0 general purpose (X3)
Unit All models
Type Opto-isolated inputs
Input voltage VDC
Nominal 24
Minimum 12
Maximum 30
Active > 12
Inactive <2

Input current (maximum, per input) mA 50

Sampling interval ms 1
Minimum pulse width μs 5

8.6.3 Digital inputs DIN1, DIN2 - high speed general purpose (X3)
Unit All models
Type Opto-isolated inputs
Input voltage VDC
Nominal 24
Minimum 12
Maximum 30
Active > 12
Inactive <2

Input current (maximum, per input) mA 20

Maximum input frequency MHz 1
Minimum pulse width ns 250

MN1943 Specifications 8-31

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8.6.4 Digital outputs DOUT0, DOUT1 - status and general purpose (X3)
Unit All models
User supply (maximum) V 28
Output current (max. continuous) mA 100
Fuse
Approximate trip current mA 200
Reset time s < 20
Update interval ms 1

8.6.5 Incremental encoder interface (X8)

Unit All models
Encoder interface RS422 A/B Differential, Z index
Maximum input frequency MHz 8
(quadrature)

Hall inputs RS422 A/B Differential

Output power supply to encoder 5 VDC (±7%), 200 mA max.
Maximum recommended cable length 30.5 m (100 ft)

8.6.6 SSI interface (X8)

Unit All models
SSI encoder interface Differential Data and Clock
Operating mode Single turn.
(Baldor motors) Positioning resolution up to 262144
counts/rev (18-bit)
Output power supply to encoder 5 VDC (±7%), 200 mA max.
Maximum recommended cable length 30.5 m (100 ft)

8.6.7 BiSS interface (X8)

Unit All models
BiSS encoder interface Differential Data and Clock
Operating mode Single or multi-turn.
A wide range of devices can be
supported. Contact Baldor technical
support before selecting a device.
Output power supply to encoder 5 VDC (±7%), 200 mA max.
Maximum recommended cable length 30.5 m (100 ft)

8-32 Specifications MN1943

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8.6.8 SinCos / EnDat interface (X8)

Unit All models
Absolute encoder interface EnDat / SinCos differential
inputs and data input

Sin+/- & Cos+/- differential pair

input voltage Centered on a 2.5 V reference:
Nominal 1 V p-p
Minimum 0.6 V p-p
Maximum 1.1 V p-p
Operating modes Single or multi-turn.
(Baldor motors) 512 or 2048 Sin/Cos cycles per turn,
with absolute positioning resolution of
up to 65536 steps.

(Many other encoder specifications

are supported - contact Baldor.)

Output power supply to encoder 5 VDC (±7%), 200 mA max.

Maximum recommended cable length 30.5 m (100 ft)

8.6.9 Ethernet interface

Description Unit All models
Signal 2 twisted pairs,
magnetically isolated

Protocols Ethernet POWERLINK

& TCP/IP

Bit rates Mbit/s 100

8.6.10 CAN interface

Description Unit All models
Signal 2-wire, isolated
Channels 1
Protocol CANopen
Bit rates Kbit/s 10, 20, 50, 100, 125,
250, 500, 1000

MN1943 Specifications 8-33

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8.6.11 RS485 interface (X6)

Description Unit Value
Signal RS485, 2-wire, non-isolated
Bit rates Baud 9600, 19200, 38400,
57600 (default), 115200

Nominal output voltage VDC 8.6

Minimum output voltage 8.1
Maximum output voltage 9
Maximum continuous output current mA 300

8.7 Weights and dimensions

8.7.1 Weights and dimensions - 1.5 A ~ 16 A models

Description 1.5 A 3A 6A 10.5 A 16 A

Weight 1.90 kg 1.90 kg 1.90 kg 4.80 kg 5.80 kg

(4.2 lb) (4.2 lb) (4.2 lb) (10.6 lb) (12.8 lb)

Nominal overall dimensions 362 mm x 76 mm x 260 mm

(H x W x D, mounted) (14.24 in x 2.99 in x 10.24 in)

8.7.2 Weights and dimensions - 21 A ~ 33.5 A models

Description 21 A 26 A 33.5 A

Weight 5.85 kg 6.35 kg 6.35 kg

(12.9 lb) (14.0 lb) (14.0 lb)

Nominal overall dimensions 362 mm x 128 mm x 260 mm

(H x W x D, mounted) (14.24 in x 5.04 in x 10.24 in)

8.7.3 Weights and dimensions - 48 A ~ 65 A models

Description 48 A 65 A

Weight 12.45 kg 12.45 kg

(27.4 lb) (27.4 lb)

Nominal overall dimensions 362 mm x 213 mm x 260 mm

(H x W x D, mounted) (14.25 in x 8.39 in x 10.24 in)

8-34 Specifications MN1943

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8.8 Environmental
All models Unit All models

Operating temperature range* °C °F

Minimum +0 +32
Maximum +45 +113
Derate See section 8.3.4 See section 8.3.4

Operating humidity range

maximum, non-condensing % 93 (ambient temp. < 45 °C / 113 °F)
70 (ambient temp. up to 55 °C / 131 °F)

Storage temperature range* -40 to +85 -40 to +185

Storage humidity Condensation on drive must be avoided.

Allow 2 hours acclimatization in installation area
before applying power.

Humidity
maximum, non-condensing* % 93

Maximum installation altitude m 1000

above m.s.l. Derate 1.1% / 100 m over 1000 m

ft 3300
Derate 1.1% / 330 ft over 3300 ft

Shock* 10 G

Vibration* 1 G, 10-150 Hz

IP rating IP20**

* MotiFlex e100 complies with the following environmental test standards:

BS EN60068-2-1:1993 low temperature operational 0 °C.

BS EN60068-2-2:1993 high temperature operational 45 °C.
BS EN60068-2-1:1993 low temperature storage/transportation -40 °C.
BS EN60068-2-2:1993 high temperature storage/transportation +85 °C.
BS EN60068-2-27:2009 Test “Ea” (shock)
BS EN60068-2-6:2008 Test “Fc” (vibration)

** MotiFlex e100 complies with EN60529, IP2x, provided connectors X1 and X17 are shrouded.
MotiFlex e100 complies with EN60529, IP3x, if it is either:

H mounted in a cabinet, or;

H connectors X1 and X17 are shrouded and objects are prevented from entering the
ventilation slots.

MN1943 Specifications 8-35

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8-36 Specifications MN1943

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 A Accessories
A
www.baldormotion.com

A.1 Introduction
This section describes accessories and options that you may need to use with your
MotiFlex e100. Shielded (screened) cables provide EMI / RFI shielding and are required for
compliance with CE regulations. All connectors and other components must be compatible with
the shielded cable.

MN1943 Accessories A-1

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A.1.1 Busbars for DC bus sharing

Plated copper busbars are required to allow the DC bus voltage to be shared between
neighboring MotiFlex e100 drives. The busbars are made from tin plated copper, and are
available in four different sizes. The required size depends upon the combination of drive types
and their relative positions. See Figure 6 on page 3-9 to determine which busbars are required.

Size 1 busbar - kit OPT-MF-DC-A

55 mm

Size 2 busbar - kit OPT-MF-DC-B

107 mm

Size 3 busbar - kit OPT-MF-DC-C

140.4 mm

Size 4 busbar - kit OPT-MF-DC-D

192 mm

Figure 95 - Using busbars for DC bus sharing

A-2 Accessories MN1943

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A.1.2 AC supply (EMC) filters

AC filters remove high frequency noise from the AC power supply, protecting the MotiFlex e100.
These filters also prevent high frequency signals from being transmitted back onto the power
lines and help meet EMC requirements. To select the correct filter, see section 3.4.10.

A.1.2.1 Catalog numbers

Baldor Rated volts Rated amps Weight
catalog number (VAC) @ 40 °C kg (lbs)
FI0035A00 520 8 0.58 (1.28)
FI0035A01 520 16 0.90 (1.98)
FI0035A02 520 25 1.1 (2.42)
FI0035A03 520 36 1.75 (3.85)
FI0035A04 520 50 1.75 (3.85)
FI0035A05 520 66 2.7 (5.95)

PE

F B M4 x 11mm

D E G

Terminal block connections - tightening torque and maximum wire size:

FI0035A00 / A01 / A02: 0.5 - 0.6 N·m (4.4 - 5.3 lb-in), 4 mm2.
FI0035A03 / A04 / A05: 1.2 - 1.5 N·m (10.6 - 13.3 lb-in), 10 mm2.

Dimensions mm (inches)
Dim. FI0035A00 FI0035A01 FI0035A02 FI0035A03 FI0035A04 FI0035A05
A 165 (6.49) 231 (9.09) 265 (10.43)
B 133.7 (5.26) 199.5 (7.85) 200 (7.87)
C 155 (6.10) 221 (8.70) 255 (10.04)
D 38 (1.50) 38 (1.50) 35 (1.38)
E 4.5 (0.18) 4.5 (0.18) 4.5 (0.18)
F 63 (2.48) 70 (2.76) 83 (3.27) 90 (3.54) 141.5 (5.57)
G 51.4 (2.02) 46.4 (1.83) 58 (2.28)

Figure 96 - Filter dimensions, types FI0035A00...A05

MN1943 Accessories A-3

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A.1.3 AC line reactors

AC line reactors provide bi-directional protection, reducing unwanted electrical noise, harmonics
and overvoltage trips. A line reactor should always be used when a MotiFlex e100 is sharing its
DC bus with other drives (see section 3.5).

A.1.3.1 Catalog numbers

Baldor Rated volts Rated Rated Impedance Inductance Weight
catalog (VAC) power current (%) (mH) kg (lbs)
number (kW) (A)
LRAC00802 380/400/415 3.7 8 3 3.0 3.6 (8)
LRAC02502 380/400/415 11.1 25 3 1.2 6.4 (14)
LRAC03502 575 14.9 35 3 0.8 7.3 (16)
LRAC05502 575 29.8 55 3 0.5 12.2 (27)
LRAC08002 380/400/415 37.2 80 3 0.4 14.5 (32)

Dimensions mm (inches)
Dimen- LRAC00802 LRAC02502 LRAC03502 LRAC05502 LRAC08002
sion
H 122 (4.8) 142 (5.6) 145 (5.7) 178 (7) 210 (8.25)
W 152 (6) 183 (7.2) 183 (7.2) 229 (9) 229 (9)
D 79 (3.1) 86 (3.4) 97 (3.8) 122 (4.8) 135 (5.3)

Figure 97 - Line reactor dimensions

A-4 Accessories MN1943

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A.1.4 Regeneration resistors

Depending on the application, MotiFlex e100 might require an external regeneration resistor to
be connected to pins R1 and R2 of connector X1. The regeneration resistor dissipates energy
during braking to prevent an over-voltage error occurring. See sections 3.8 and 3.9 for details
about choosing the correct resistor. The MotiFlex e100 is UL listed when using these resistors.

Electrical shock hazard. DC bus voltages may be present at these terminals.

Use a suitable heatsink (with fan if necessary) to cool the regeneration
DANGER
resistor. The regeneration resistor and heatsink (if present) can reach
temperatures in excess of 80 °C (176 °F). See section 3.9.5 for derating
information. The regeneration resistors listed here do not provide a fail-safe
safety mechanism. For safety reasons and UL compliance, they will become
open-circuit in the event of failure. This will cause the MotiFlex e100 to trip
due to overvoltage, leaving the motor in an uncontrolled state. Further
safety mechanisms such as a motor brake will be required, especially for
applications involving suspended or tensioned loads.

A C

Weights:
RGJ160: 215 g (7.6 oz)
F RGJ1150: 215 g (7.6 oz)
RGJ260: 447 g (15.8 oz)
RGJ2150: 447 g (15.8 oz)
E G RGJ360: 600 g (21.2 oz)
RGJ368: 600 g (21.2 oz)
RGJ3150: 600 g (21.2 oz)
D RGJ515: 980 g (34.6 oz)
RGJ523: 980 g (34.6 oz)
RGJ533: 980 g (34.6 oz)

Baldor Power Res. Dimensions mm (inches)

catalog W Ω
number A B C D E F G
RGJ160 100 60 165 41 22 152 12 10 4.3
RGJ1150 150 (6.49) (1.61) (0.87) (5.98) (0.47) (0.39) (0.17)
RGJ260 200 60 165 60 30 146 17 13 5.3
RGJ2150 150 (6.49) (2.36) (1.18) (5.75) (0.67) (0.51) (0.21)
RGJ360 300 60
215 60 30 196 17 13 53
5.3
RGJ368 68
(8.46)
(8 46) (2.36)
(2 36) (1.18)
(1 18) (7.72)
(7 72) (0.67)
(0 67) (0.51)
(0 51) (0.21)
(0 21)
RGJ3150 150
RGJ515 500 15
335 60 30 316 17 13 53
5.3
RGJ523 23
(13.19)
(13 19) (2.36)
(2 36) (1.18)
(1 18) (12.44)
(12 44) (0.67)
(0 67) (0.51)
(0 51) (0.21)
(0 21)
RGJ533 33
Figure 98 - Regeneration resistor dimensions - RGJ models

MN1943 Accessories A-5

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A
E D

F B C

Weights:
RGA1210: 5.9 kg (13 lb)
RGA2410: 9.1 kg (20 lb)
RGA4810: 11.8 kg (26 lb)

Baldor Pwr. Res. Dimensions mm (inches)

catalog W Ω
number A B C D E F G
RGA1210 1200 10 279 247.7 201.1 168.9 241.3 228.6 7
(11.0) (9.75) (7.92) (6.65) (9.5) (9.0) (0.28)
RGA2410 2400 10 279 400 353.6 270.5 241.3 381 7
RGA4210 4800 10 (11.0) (15.75) (13.92) (10.65) (9.5) (15.0) (0.28)

Figure 99 - Regeneration resistor dimensions - RGA models

A-6 Accessories MN1943

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A.1.5 Motor / power cable management bracket

The motor / power cable management bracket, part OPT-CM-001, provides a simple means of
clamping the outer screen of the motor’s power cable or AC supply cable. The bracket is supplied
with clamps suitable for typical motor power cables. The bracket can be mounted just below the
MotiFlex e100, as shown in Figure 100:

OPT-CM-001

Figure 100 - Motor cable management bracket

MN1943 Accessories A-7

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A.1.6 Signal cable management bracket

The signal cable management bracket, part OPT-CM-002 (for 1.5 A ~ 16 A models) and part
OPT-CM-003 (for 21 A ~ 65 A models), provides a simple means of clamping the outer screen of
the motor’s feedback cable or other shielded signal cables. The bracket is supplied with clamps
suitable for typical motor feedback cables. By using additional clamps, the bracket can hold other
signals cables too. The bracket must be attached to the metal tab that protrudes from the bottom
of the MotiFlex e100, as shown in Figure 101:

OPT-CM-002

OPT-CM-003

Figure 101 - Signal cable management brackets

A-8 Accessories MN1943

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A.2 Cables
A wide range of motor and feedback cables are available from Baldor.

A.2.1 Motor power cables

For easier installation, it is recommended that a color-coded motor power cable is used.
The Baldor part number for a BSM rotary motor power cable is derived as follows:

CBL 025 SP -12 S

m ft SP CE style threaded Current - Standard

motor connector (Amps) connector
1.5 5* (motor end only)
2.5 8.2 6 S Stainless
3.0 10* RP Raw cable 12 steel
5.0 16.4 (no connector) 20
6.1 20* 35
7.5 24.6 50
9.1 30* 90
10 32.8
15 49.2
15.2 50*
20 65.6
22.9 75*
30.5 100*
76 250*
152.5 500*
* North America only

Larger motors requiring 35 A cable or greater normally use terminal box connections, so a motor
power connector is not required. For this reason connectors are not available on 35 A - 90 A
cable.

Examples:

A 6.1 m cable, with a CE threaded standard connector, rated for 12 A has part number
CBL061SP-12.

A 30.5 m cable, with a CE threaded stainless steel connector, rated for 20 A has part number
CBL305SP-20S.

A 50 ft cable, with no connector, rated for 50 A has part number CBL152RP-50.

MN1943 Accessories A-9

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A.2.2 Feedback cable part numbers

The Baldor part number for a feedback cable is derived as follows:

CBL 020 SF -E 1 S

m ft SF Servo motor E Incremental - Raw cable - Standard

feedback cable encoder 1 FlexDriveII connector
0.5 1.6 with at least 1 D BiSS Flex+DriveII S
1.0 3.3 connector Stainless
EnDat MintDriveII steel
1.5 4.9 SinCos
2.0 6.6 RF Raw cable 2 e100 connector
5.0 16 (no connector) R Resolver
S SSI
Other lengths
available on
request.

Examples:

A 2 m encoder feedback cable for a MicroFlex e100 drive, with required connectors at both ends,
has part number CBL020SF-E2.

A 1 m EnDat cable for a MintDriveII, with drive connector and stainless steel motor connector,
has part number CBL010SF-D1S.

Baldor feedback cables have the outer shield tied to the connector housing(s). If you are not
using a Baldor cable with your chosen feedback device, be sure to obtain a cable that is a
shielded twisted pair 0.34 mm2 (22 AWG) wire minimum, with an overall shield. Ideally, the cable
should not exceed 30.5 m (100 ft) in length. Maximum wire-to-wire or wire-to-shield capacitance
is 50 pF per 300 mm (1 ft) length, to a maximum of 5000 pF for 30.5 m (100 ft).

A.2.3 Ethernet cables

The cables listed in this table connect MotiFlex e100 to other EPL nodes such as
NextMove e100, additional MotiFlex e100s, or other EPL compatible hardware. The cables are
standard CAT5e shielded twisted pair (S/UTP) ‘crossover’ Ethernet cables:

Length
Cable assembly description Baldor catalog number
m ft

CAT5e Ethernet cable CBL002CM-EXS 0.2 0.65

CBL005CM-EXS 0.5 1.6
CBL010CM-EXS 1.0 3.3
CBL020CM-EXS 2.0 6.6
CBL050CM-EXS 5.0 16.4
CBL100CM-EXS 10.0 32.8

A-10 Accessories MN1943

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B
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B.1 Introduction
The MotiFlex e100 can use two main control configurations:

H Servo (Position).
H Torque Servo (Current).

Each configuration supports different control modes, selected by using the Tools, Control Mode
menu item or by using the CONTROLMODE keyword in the Command window (see the Mint help
file). The control configurations are described in the following sections.

MN1943 Control System B-1

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B.1.1 Servo configuration

The servo configuration is the default configuration for the drive, allowing the motor control
system to operate as a torque controller, a velocity controller or a position controller. This
configuration comprises 3 nested control loops; a current control loop, a velocity control loop and
a position control loop, as shown in Figure 102.

The universal encoder interface reads rotor position from the encoder and estimates velocity.
The commutation block uses the position to calculate the electrical angle of the rotor. The current
sensor system measures U and V phase currents. These are fed into a current conversion block
that converts them into quantities representing torque producing and magnetizing currents (the
’vector’ currents which are locked to the rotor).

In the current control loop, a current demand and the final measured current values form the
inputs to a PI (Proportional, Integral) control system. This control system generates a set of
voltage demands that are fed into a PWM (pulse-width modulation) block. The PWM block uses
the space-vector modulation method to convert these voltage demands into a sequence of U, V
and W phase switching signals, which are applied to the output bridge of the drive. The PWM
block uses the measured DC bus voltage to compensate for variations in supply voltage.

The torque controller converts a torque demand into a current demand and compensates for
various load non-linearities. A 2-stage notch or low-pass filter allows the effects of load
compliance to be reduced. To avoid motor damage, a user-defined application current limit is also
applied, as well as individual positive and negative torque limits.

In the velocity control loop, a velocity demand and measured velocity form the inputs to a PI
control system. The output of the control system is a torque demand which, when the drive is
operating as a velocity controller, forms the input to the current control loop.

Finally, in the position control loop, a position demand and measured position form the inputs to
a PID (Proportional, Integral, Differential) control system incorporating velocity feedback,
velocity feed-forward and acceleration feed-forward. The output of the position control system is
a velocity demand which, when the drive is operating as a position controller, forms the input to
the velocity control loop.

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 MN1943
TORQUEDEMAND

ACCELDEMAND

VELDEMAND
DRIVEBUSVOLTS Bus Voltage
Torque control
Measurement
KPROP KACCEL

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KINT KIPROP
KVELFF KVPROP KIINT EFFORT
KINTMODE
KVINT Torque filters Limiting KITRACK
KINTLIMIT
VELERROR KVTRACK T
FOLERROR KDERIV
V + +
+ P,V PI + TF PWM
POSDEMAND + PI + TF
P --
PID -- +
+ + Control mode TORQUEFILTERTYPE TORQUELIMITPOS Current controllers Motor
-- -- Control mode Velocity controller switch TORQUEFILTERFREQ TORQUELIMITNEG
Position controller switch TORQUEFILTERBAND CURRENTLIMIT
TORQUEFILTERDEPTH
Electrical angle

Measured torque and

magnetizing currents U
Current Offset Current
CURRENTMEAS Comp V
Conv Sensors
Commutation
Temperature drift
compensation

VEL
KVEL
Universal
Encoder E
POS Interface
Encoder

Figure 102 - Servo configuration control structure

Control System B-3

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B.1.2 Torque servo configuration

Figure 103 shows the torque-servo control configuration. Here, the velocity loop has been
removed and the output of the position controller is fed into the current loop via the torque filters.

The torque servo configuration is useful when the drive is operating as a closed-loop position
controller and settling time must be minimized. Although the servo configuration tends to give
better velocity tracking when operating in position mode, settling times can be longer.

The control mode switch allows the drive to operate in either torque or position modes, but not
velocity mode.

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TORQUEDEMAND

ACCELDEMAND

VELDEMAND

DRIVEBUSVOLTS Bus Voltage

Torque control Measurement

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KPROP KVELFF KACCEL
KINT KIPROP
EFFORT
KINTMODE KIINT
KINTLIMIT Torque filters Limiting KITRACK
FOLERROR
KDERIV T
+ + +
POSDEMAND P PI + TF PWM
PID --
+ + + +
-- -- Control mode Current controllers Motor
TORQUEFILTERTYPE TORQUELIMITPOS
Position controller Control mode switch TORQUEFILTERFREQ TORQUELIMITNEG
switch TORQUEFILTERBAND CURRENTLIMIT
TORQUEFILTERDEPTH
Electrical angle

Measured torque and

magnetizing currents U
Current Offset Current
Comp V
CURRENTMEAS Conv Sensors
Commutation
Temperature drift
compensation

VEL
KVEL
Universal
Encoder E
POS
Interface
Encoder

Figure 103 - Torque Servo configuration control structure

Control System B-5

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B-6 Control System MN1943

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 C Mint Keyword Summary
C
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C.1 Introduction
The following table summarizes the Mint keywords supported by the MotiFlex e100. Note that
due to continuous developments of the MotiFlex e100 and the Mint language, this list is
subject to change. Check the latest Mint help file for full details of new or changed keywords.

C.1.1 Keyword listing

Keyword Description

ABORT To abort motion on all axes.

ABORTMODE To control the default action taken in the event of an

abort.

ABSENCODER To read the current EnDat encoder position.

ABSENCODERTURNS To set or read the number of turns of unique information

available on an absolute encoder.

ACCEL To define the acceleration rate of an axis.

ACCELDEMAND To read the instantaneous demand acceleration.

ACCELJERK To define the jerk rate to be used during periods of

acceleration.

ACCELJERKTIME To define the jerk rate to be used during periods of

acceleration.

ACCELSCALEFACTOR To scale axis encoder counts, or steps, into user defined

acceleration units.

ACCELSCALEUNITS To define a text description for the acceleration scale

factor.

ACCELTIME To define the acceleration rate of an axis.

ACCELTIMEMAX To define the acceleration rate of an axis.

AXISMODE To return the current mode of motion.

ADC To read an analog input value.

ADCDEADBAND To set the deadband to be applied to an ADC input.

ADCDEADBANDHYSTERESIS To set a hysteresis level for entering and leaving the

deadband on the ADC inputs.

ADCDEADBANDOFFSET To set the deadband offset to be applied to an ADC

input.

MN1943 Mint Keyword Summary C-1

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Keyword Description

ADCGAIN To set the gain to be applied to an ADC input.

ADCOFFSET To set the offset to be applied to an ADC input.

ADCOFFSETTRIM To zero (trim) the specified analog input.

ADCTIMECONSTANT To set the time constant of the low pass filter applied to
an ADC input.

AXISPOSENCODER To select the source of the position signal used in dual

encoder feedback systems.

AXISVELENCODER To select the source of the velocity signal used in dual

encoder feedback systems.

BUSBAUD To specify the bus baud rate.

BUSENABLE To enable or disable the operation of a fieldbus.

BUSEVENT Returns the next event in the bus event queue of a

specific bus.

BUSEVENTINFO Returns the additional information associated with a bus

event.

BUSNODE To set or read the node ID used by this node for the
specified bus.

BUSPROTOCOL To read the protocol currently supported on a particular

fieldbus.

BUSRESET Resets the bus controller.

BUSSTATE Returns the status of the bus controller.

CANCEL To stop motion and clear errors on an axis.

CANCELALL To stop motion and clear errors on all axes.

CAPTUREBUFFERSIZE To read the total size of the capture buffer.

CAPTURECOMMAND Controls the operation of capture.

CAPTUREDURATION To define the total duration of the data capture.

CAPTUREEVENT Configures capturing to stop on an event.

CAPTUREMODE To set or read the mode on a capture channel.

CAPTUREMODEPARAMETER To specify a parameter associated with CAPTUREMODE.

CAPTURENUMPOINTS To read the number of captured points per channel.

CAPTUREPERIOD To define the interval between data captures.

CAPTUREPRETRIGGER- To set the duration of the pre-trigger phase.

DURATION

C-2 Mint Keyword Summary MN1943

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Keyword Description

CAPTUREPROGRESS To return the progress of the pre-trigger or post-trigger

capture phase.

CAPTURESTATUS To return the progress of the capture.

CAPTURETRIGGER To generate a capture trigger.

CAPTURETRIGGERABSOLUTE To ignore the sign of the trigger value when triggering

from a capture channel source.

CAPTURETRIGGERCHANNEL To set the channel to be used as the reference source

for triggering.

CAPTURETRIGGERMODE To set the method used to evaluate the trigger source.

CAPTURETRIGGERSOURCE To set the reference source to be used for triggering.

CAPTURETRIGGERVALUE To set the trigger value when triggering from a capture

channel source.

COMMSINTEGER Accesses the reserved comms array, storing values as

integers.

COMPAREENABLE To enable/disable the position compare control of a

specific digital output.

COMPAREOUTPUT To specify the digital output used for position compare.

COMPAREPOS To write to the position compare registers.

CONFIG To set the configuration of an axis for different control

types.

CONNECT To enable a connection between two remote nodes to be

made or broken.

CONNECTSTATUS Returns the status of the connection between this node

and another node.

CONTROLMODE To set or read the control mode.

CONTROLMODESTARTUP To set or read the control mode used when the drive is
turned on.

CONTROLRATE To set the control loop and profiler sampling rates.

CONTROLREFCHANNEL To specify a channel for the source of the control

reference command.

CONTROLREFSOURCE To specify the source of the control reference command.

CONTROLREFSOURCESTARTUP To set or read the source of the control reference

command used when the drive is turned on.

CURRENTDEMAND To read the demands to the current controllers.

MN1943 Mint Keyword Summary C-3

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Keyword Description

CURRENTLIMIT To restrict the current output to a defined range.

CURRENTMEAS Reads the measured current.

CURRENTSENSORMODE To enable a current sensor temperature drift

compensation scheme.

DECEL To set the deceleration rate on the axis.

DECELJERK To define the jerk rate to be used during periods of

deceleration.

DECELJERKTIME To define the jerk rate to be used during periods of

deceleration.

DECELTIME To set the deceleration rate on the axis.

DECELTIMEMAX To define the deceleration rate of an axis.

DRIVEBUSNOMINALVOLTS To return the nominal value of the DC bus voltage for the
drive.

DRIVEBUSOVERVOLTS To set or return the overvoltage trip level for the drive.

DRIVEBUSUNDERVOLTS To set or return the undervoltage trip level for the drive.

DRIVEBUSVOLTS To return the current level of the DC bus.

DRIVEENABLE To enable or disable the drive for the specified axis.

DRIVEENABLEINPUTMODE To control the action taken in the event of the drive being
disabled from the drive enable input.

DRIVEENABLEOUTPUT To specify an output as a drive enable.

DRIVEENABLESWITCH To read the state of the drive enable input.

DRIVEID To define a text description for the drive.

DRIVEOVERLOADAREA Reads the extent of a drive overload condition.

DRIVEOVERLOADMODE Sets or reads the action taken in the event of a drive

overload condition.

DRIVEPEAKCURRENT Reads the peak current rating of the drive.

DRIVEPEAKDURATION Reads the duration for which peak drive current can be
sustained.

DRIVERATEDCURRENT Reads the continuous current rating for the drive.

DRIVESPEEDFATAL To define the overspeed trip level.

DRIVESPEEDMAX To set or read the maximum motor speed to be used.

EFFORT To read the instantaneous effort applied by the current

controllers.

C-4 Mint Keyword Summary MN1943

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Keyword Description

ENCODER To set or read the axis encoder value.

ENCODERCYCLESIZE To set or read the size of a sin/cos cycle on an encoder.

ENCODERMODE To make miscellaneous changes to the encoders.

ENCODEROFFSET To set or read the offset used to calculate encoder

position for absolute encoders.

ENCODEROUTCHANNEL To set or read the encoder channel to be output on a

simulated encoder output.

ENCODEROUTRESOLUTION To set or read the resolution of a simulated encoder

output.

ENCODERPRESCALE To scale down the encoder input.

ENCODERRESOLUTION To set or read the number of encoder lines

(pre-quadrature) for the motor.

ENCODERSCALE To set or read the scale factor for the encoder channel.

ENCODERTYPE To set or read the feedback type of the motor.

ENCODERVEL To read the velocity from an encoder channel.

ENCODERWRAP To set or read the encoder wrap range for the encoder
channel.

ENCODERZLATCH To get and reset the state of an axis’ encoder Z latch.

ERRCODE To return the last error code read from the error list.

ERRDATA To return data associated with the last error read from
the error list.

ERRLINE To return the line number of the last error read from the
error list.

ERRORCLEAR To clear all errors in the specified group.

ERRORCODEENABLE To allow or prevent specific errors to be created.

ERRORDECEL To set the deceleration rate on the axis for powered

stops, in the event of an error or stop input.

ERRORINPUT To set or return the digital input to be used as the error

input for the specified axis.

ERRORINPUTMODE To control the default action taken in the event of an

external error input.

ERRORPRESENT To determine if errors in a particular group are present in

the error list.

MN1943 Mint Keyword Summary C-5

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Keyword Description

ERRORREADCODE To determine if a particular error is present in the error

list.

ERRORREADNEXT Returns the next entry in the specified group from the
error list.

ERRORSWITCH To return the state of the error input.

ERRSTRING To return the error string for the last error code read from
the error list.

ERRTIME To return the time stamp for the last error code read
from the error list.

EVENTACTIVE To indicate whether an event is currently active.

EVENTDISABLE To selectively enable and disable Mint events.

EVENTPEND To manually cause an event to occur.

EVENTPENDING To indicate whether an event is currently pending.

FACTORYDEFAULTS To reset parameter table entries to their default values.

FIRMWARERELEASE To read the release number of the firmware.

FOLERROR To return the instantaneous following error value.

FOLERRORFATAL To set the maximum permissible following error before

an error is generated.

FOLERRORMODE To determine the action taken on the axis in the event of

a following error.

FOLLOW To enable encoder following with a specified gear ratio.

FOLLOWMODE To define the mode of operation of the FOLLOW keyword.

FOLLOWNUMERATOR To set or read the follow ratio’s numerator.

GLOBALERROROUTPUT Allows the user to specify a global error output which will
be deactivated in the event of an error.

GO To begin synchronized motion.

HALL To read the current Hall state on feedback devices

which use Hall sensors.

HALLFORWARDANGLE To define the electrical angles at which Hall states

change, when the motor is running in the forward
direction, for feedback devices which use Hall sensors.

HALLREVERSEANGLE To define the electrical angles at which Hall states

change, when the motor is running in the reverse
direction, for feedback devices which use Hall sensors.

HALLTABLE To define the Hall table for an encoder motor.

C-6 Mint Keyword Summary MN1943

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Keyword Description

HOME To find the home position on an axis.

HOMEACCEL To set the acceleration rate for the homing profile.

HOMEBACKOFF To set the home back-off speed factor.

HOMECREEPSPEED To set the creep speed for homing moves.

HOMEDECEL To set the deceleration rate for the homing profile.

HOMEINPUT To set a digital input to be the home switch input for the
specified axis. See section 5.3.2.1 or 5.3.3.1 for
important details about using a digital input as a home
input.

HOMEPHASE To find the phase of the homing sequence currently in

progress.

HOMEPOS To read the axis position at the completion of the homing

sequence.

HOMEREFPOS To define a reference position for homing moves.

HOMESPEED To set the speed for the initial seek phase of the homing
sequence.

HOMESTATUS To set or read the status of a homing sequence.

HOMESWITCH To return the state of the home input.

HOMETYPE To set the homing mode to be performed at start-up.

IDLE Indicates if a move has finished executing and the axis

has finished moving.

IDLEMODE To control the checks performed when determining if an

axis idle.

IDLEPOS Reads or sets the idle following error limit.

IDLESETTLINGTIME To read the time taken for an axis to become idle.

IDLETIME To specify the period for which the axis must meet its
idle conditions before becoming idle.

IDLEVEL Reads or sets the idle velocity limit.

IN To read the state of all the inputs on an input bank.

INCA To set up an incremental move to an absolute position.

INCR To set up an incremental move to a relative position.

INPUTACTIVELEVEL To set the active level on the digital inputs.

MN1943 Mint Keyword Summary C-7

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Keyword Description

INPUTMODE To set or return the sum of a bit pattern describing which

of the user digital inputs should be edge or level
triggered.

INPUTNEGTRIGGER To set or return the user inputs that become active on

negative edges.

INPUTPOSTRIGGER To set or return the user inputs that become active on

positive edges.

INSTATE To read the state of all digital inputs.

INSTATEX To read the state of an individual digital input.

INX To read the state of an individual digital input.

JOG To set an axis for speed control.

KACCEL To set the servo loop acceleration feed forward gain.

KDERIV To set the servo loop derivative gain on the servo axes.

KFINT To set or read the integral gain of the flux controller for
induction motor control.

KFPROP To set or read the proportional gain of the flux controller

for induction motor control.

KIINT To set the integral gain used by the current controller.

KINT To set the servo loop integral gain.

KINTLIMIT To restrict the overall effect of the integral gain KINT.

KINTMODE To control when integral action will be applied in the

servo loop.

KIPROP To set the proportional gain used by the current

controller.

KITRACK To set the tracking factor used by the current controller.

KPROP To set the proportional gain for the position controller.

KVEL To set the servo loop velocity feedback gain term.

KVELFF To set the velocity feedforward term for the position

controller.

KVINT To set the integral gain used by the speed controller.

KVPROP To set the proportional gain used by the speed

controller.

KVTIME To set the time constant of a low pass filter, applied to

measured speed.

C-8 Mint Keyword Summary MN1943

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Keyword Description

KVTRACK To set the tracking factor used by the speed controller.

LATCH To read the state of a fast latch channel.

LATCHENABLE Manually re-enables a fast latch channel.

LATCHINHIBITTIME To specify a period during which further fast triggers will

be ignored.

LATCHINHIBITVALUE To specify a range of values within which further fast

triggers will be ignored.

LATCHMODE To set the default action to be taken to clear a fast latch.

LATCHSOURCE To define the source of data to be latched by a fast latch

channel.

LATCHSOURCECHANNEL To define the channel of the source of data to be latched

by a fast latch channel.

LATCHTRIGGERCHANNEL To select which of the fast latch inputs (or outputs) will
trigger a fast latch channel.

LATCHTRIGGEREDGE To define which edge polarity should cause the fast latch
to be triggered.

LATCHTRIGGERMODE To select whether a fast latch is triggered by a digital

input or a digital output.

LATCHVALUE To return the instantaneous latch value that was

recorded by a fast latch.

LIFETIME Returns a lifetime counter for the drive.

LIMIT To return the state of the forward and reverse limit

switch inputs for the given axis.

LIMITFORWARD To return the state of the forward limit switch input for
the given axis.

LIMITFORWARDINPUT To set the user digital input configured to be the forward

end of travel limit switch input for the specified axis.

LIMITMODE To control the default action taken in the event of a

forward or reverse hardware limit switch input becoming
active.

LIMITREVERSE To return the state of the reverse limit switch input for
the given axis.

LIMITREVERSEINPUT To set the user digital input configured to be the reverse

end of travel limit switch input for the specified axis.

LOADDAMPING To define the equivalent viscous damping coefficient for

the motor and load.

MN1943 Mint Keyword Summary C-9

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Keyword Description

LOADINERTIA To define the combined inertia of the motor and load.

MASTERCHANNEL To set or read the channel of the input device used for
gearing.

MASTERSOURCE To set or read the source of the input device used for
gearing.

MOTORBRAKEDELAY To specify engage/disengage delays associated with

motor brake control.

MOTORBRAKEMODE To activate or deactivate motor brake control.

MOTORBRAKEOUTPUT To specify an output to be used as a control signal for a

braked motor.

MOTORBRAKESTATUS To determine the state of the motor brake control.

MOTORCATALOGNUMBER To return the catalog number of the motor.

MOTORDIRECTION To set or read the electrical direction of the motor.

MOTORFEEDBACKANGLE Reads the instantaneous value of commutation angle for

the motor.

MOTORFEEDBACKOFFSET To set or read the electrical angle at which the absolute

position read from an EnDat, BiSS or SSI encoder is
zero.

MOTORFLUX To set the motor’s magnetic flux level, to allow the drive
to accurately calculate motor torque and compensate for
back-EMF.

MOTORLINEARPOLEPITCH To set or read the distance between north poles on a

linear motor.

MOTORLS To set or read the motor leakage inductance.

MOTORMAGCURRENT To set or read the magnetizing current (Im) of an

induction motor.

MOTORMAGIND To set or read the magnetizing inductance (Lm) of an

induction motor.

MOTOROVERLOADAREA Reads the extent of an overload condition.

MOTOROVERLOADMODE To set or read the action taken in the event of a motor

overload condition.

MOTORPEAKCURRENT To set or read the peak current rating of the motor.

MOTORPEAKDURATION To set or read the duration for which peak motor current
can be sustained.

MOTORPOLES To set or read the number of motor poles.

C-10 Mint Keyword Summary MN1943

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Keyword Description

MOTORRATEDCURRENT To set or read the rated current of the motor.

MOTORRATEDFREQ To set or read the rated frequency of an induction motor.

MOTORRATEDSPEEDRPM To set or read the rated speed of an induction motor.

MOTORRATEDVOLTS To set or read the rated voltage of an induction motor.

MOTORROTORLEAKAGEIND To set or read the rotor leakage inductance of an

induction motor.

MOTORROTORRES To set or read the rotor resistance of an induction motor.

MOTORRS To set the motor stator resistance.

MOTORSLIP To read the slip of an induction motor.

MOTORSPECNUMBER To return the spec number of the motor.

MOTORSTATORLEAKAGEIND To set or read the stator leakage inductance of an

induction motor.

MOTORSTATORRES To set or read the stator resistance of an induction

motor.

MOTORTEMPERATUREMODE To set or read the action taken in the event of the motor
overtemperature trip input becoming active

MOTORTEMPERATURESWITCH To read the state of the motor overtemperature trip input.

MOTORTYPE To read or set the type of motor.

MOVEA To set up a positional move to an absolute position.

MOVEBUFFERFREE To return the number of free spaces in the move buffer

for the specified axis.

MOVEBUFFERSIZE To set or return the size of the move buffer allocated on

the specified axis.

MOVER To set up a positional move to a relative position.

NODELIVE To determine if a CAN node on the bus is currently live

or dead.

NODESCAN To scan a specific CAN bus for the presence of a

specific node.

NODETYPE To add or remove a CAN node to/from the CAN network.

Can also be read to determine the node type.

NUMBEROF To return information about the abilities of the controller.

OUT To set or read the state of all the outputs on an output

bank.

OUTPUTACTIVELEVEL To set the active level on the digital outputs.

MN1943 Mint Keyword Summary C-11

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Keyword Description

OUTX To set or read an individual digital output.

PHASESEARCHBACKOFF To select the back-off distance used to clear an end stop

during the phase search sequence.

PHASESEARCHBANDWIDTH To define the bandwidth used to design the ’debounce’

controller used during the initial alignment stage of the
phase search sequence.

PHASESEARCHCURRENT To select amount of current applied to the motor during

the phase search sequence.

PHASESEARCHINPUT To set or read the digital input to be used as the phase

search trigger input.

PHASESEARCHMODE To turn on the ‘debounce’ controller used during the

initial alignment stage of the phase search sequence.

PHASESEARCHOUTPUT To assign a digital output as the phase search output.

PHASESEARCHSPEED To select the speed of travel during the search sections

of a phase search sequence.

PHASESEARCHSTATUS To determine whether commutation is aligned on an

axis.

PHASESEARCHSWITCH To return the current state of the phase search input for
the axis.

PHASESEARCHTRAVEL To select the amount of travel during the search sections

of a phase search sequence.

PLATFORM To return the platform type.

POS To set or read the current axis position.

POSDEMAND To set or read the instantaneous position demand.

POSOFFSET To set or read the offset used to calculate axis position

for absolute encoders.

POSREMAINING To indicate the remaining move distance.

POSSCALEFACTOR To scale axis encoder counts, or steps, into user defined

position units.

POSSCALEUNITS To define a text description for the position scale factor.

POSTARGET Reads the target position of the current positional move.

POSTARGETLAST Reads the target position of the last move in the move
buffer.

POWERREADYINPUT To set or read the input used to inform a DC bus

receiving drive that mains power has been applied to the
source drive.

C-12 Mint Keyword Summary MN1943

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Keyword Description

POWERREADYOUTPUT To set or read the output used by a DC bus source drive

to inform a DC bus receiving drive that mains power has
been applied to the source drive.

PROFILEMODE To select the type of velocity profiler to use.

REMOTEADC To read the value of a remote analog input (ADC).

REMOTEADCDELTA To control the rate of change on a remote analog input

before a REMOTEADC message is sent.

REMOTECOMMS Accesses the reserved comms array on another

controller.

REMOTECOMMSINTEGER Accesses the reserved comms array on another

controller, storing values as integers.

REMOTEDAC To control the value of a remote analog output channel

(DAC). The value is a percentage (positive and
negative) of the full-scale output value.

REMOTEEMERGENCYMESSAGE Returns the error code from the last emergency

message received from a particular CANopen node.

REMOTEENCODER To read the value of a remote encoder channel.

REMOTEERROR Reads the CANopen error register information reported

within the last emergency message received from a
specific node.

REMOTEIN To read the state of all the digital inputs on a remote

CAN node.

REMOTEINBANK To read the state of a bank of digital inputs on a remote

CAN node.

REMOTEINHIBITTIME To set or read the CANopen PDO inhibit time.

REMOTEINX To read the state of individual digital inputs from a

remote CAN node.

REMOTEMODE To control the update mode for a remote node.

REMOTEOBJECT To access the Object Dictionary of any CANopen node

present on the network.

REMOTEOBJECTFLOAT To access ‘floating-point’ entries in the Object Dictionary

of a remote node present on the network.

REMOTEOBJECTSTRING To access ’Vis-String’ entries in the Object Dictionary of

any CANopen node present on the network.

REMOTEOUT To control the state of digital outputs on a remote CAN

node.

MN1943 Mint Keyword Summary C-13

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Keyword Description

REMOTEOUTBANK To read the state of a bank of digital outputs on a remote

CAN node.

REMOTEOUTX To control the state of individual digital outputs on a

remote CAN node.

REMOTEPDOIN To request data from a node in the form of a PDO

message.

REMOTEPDOOUT To force a Baldor controller node to transmit a variable

length PDO message with a specific COB-ID. The PDO
will contain up to 64 bits of data that can be passed in
the form of two 32-bit values.

REMOTESTATUS To set or read the status register on a remote CAN

node.

RESETINPUT To define the reset input for an axis.

SCALEFACTOR To scale axis encoder counts, or steps, into user defined

units.

SEXTANT To read the current sextant value for a motor using Hall
sensors.

SOFTLIMITFORWARD To set the forward software limit position on a specified

axis.

SOFTLIMITMODE To set or read the default action taken if a forward or

reverse software limit position is exceeded.

SOFTLIMITREVERSE To set or read the reverse software limit position on a

specified axis.

SPEED To set or read the slew speed of positional moves

loaded in the move buffer.

STOP To perform a controlled stop during motion.

STOPINPUT To set or read the digital input to be used as the stop

switch input for the specified axis.

STOPMODE To set or read the action taken when an axis is stopped.

STOPSWITCH To return the current state of the stop input for the axis.

SUSPEND To pause the current move.

SUSPENDINPUT To set or read the digital input to be used as the

suspend switch input for the specified axis.

SUSPENDSWITCH To return the current state of the suspend input for the
axis.

SYSTEMSECONDS To set or read a programmable system lifetime counter

for the drive.

C-14 Mint Keyword Summary MN1943

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Keyword Description

TEMPERATURE To report the internal drive temperature.

TEMPERATURELIMITFATAL To set or read the temperature fatal limit.

TORQUEDEMAND To return the instantaneous torque demand.

TORQUEFILTERBAND Defines the band of operation for a torque filter stage.

TORQUEFILTERDEPTH Defines the reduction in gain for a notch torque filter

stage.

TORQUEFILTERFREQ Defines a characteristic frequency for a torque filter

stage.

TORQUEFILTERTYPE Defines the type of characteristic used for the given

torque filter stage.

TORQUELIMITNEG To set or read the maximum negative torque limit.

TORQUELIMITPOS To set or read the maximum positive torque limit.

TORQUEREF To set or read a torque reference for torque (constant

current) mode on a servo axis.

TORQUEREFERRORFALLTIME To set or read the ’deceleration ramp’ for a torque profile

in the event of an error.

TORQUEREFFALLTIME To set or read the ’deceleration ramp’ for a torque

profile.

TORQUEREFRISETIME To set or read the ’acceleration ramp’ for a torque profile.

VEL To return the instantaneous axis velocity.

VELDEMAND To read the current instantaneous demand velocity.

VELERROR To report the velocity following error.

VELFATAL To set or read the threshold for the maximum difference

between demand and actual velocity.

VELFATALMODE To control the default action taken in the event of the

velocity threshold being exceeded.

VELREF To set or read a fixed point speed reference.

VELSCALEFACTOR To scale axis encoder counts, or steps, into user defined

velocity units.

VELSCALEUNITS To define a text description for the velocity scale factor.

VOLTAGEDEMAND To read the voltage demand outputs from the current

controllers.

MN1943 Mint Keyword Summary C-15

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C-16 Mint Keyword Summary MN1943

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 D CE & UL
D
www.baldormotion.com

D.1 Introduction
This section provides general information
regarding recommended methods of installation
for CE compliance. It is not intended as an
exhaustive guide to good practice and wiring
techniques. It is assumed that the installer of the
MotiFlex e100 is sufficiently qualified to perform
the task, and is aware of local regulations and
requirements. Baldor products that meet the EMC
directive requirements are indicated with a “CE”
mark. A duly signed CE declaration of conformity
is available from Baldor.

D.1.1 CE marking
The information contained herein is for your guidance only and does not guarantee that the
installation will meet the requirements of the Electromagnetic Compatibility Directive
2004/108/EC or the Low Voltage Directive 2006/95/EC.

The purpose of the EEC directives is to state a minimum technical requirement common to all the
member states within the European Union. In turn, these minimum technical requirements are
intended to enhance the levels of safety both directly and indirectly.

Council directive 2004/108/EC relating to Electro Magnetic Compliance (EMC) indicates that it is
the responsibility of the system integrator to ensure that the entire system complies with all
relative directives at the time of installing into service.

Motors and controls are used as components of a system, per the EMC directive. Hence all
components, installation of the components, interconnection between components, and
shielding and grounding of the system as a whole determines EMC compliance.

The CE mark informs the purchaser that the equipment has been tested and complies with the
appropriate standards. It rests upon the manufacturer or his authorized representative to ensure
the item in question complies fully with all the relative directives in force at the time of installing
into service, in the same way as the system integrator previously mentioned. Remember that it
is the instructions of installation and the product that should comply with the directive.

MN1943 CE & UL D-1

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D.1.2 Declaration of conformity

Date: 21/01/08 EC Declaration of Conformity Ref: DE00024-001

Manufacturer: Baldor UK Limited

Address: Mint Motion Centre, 6 Bristol Distribution Park, Hawkley Drive, Bristol, BS32 0BF, United Kingdom

Hereby declare that the product:

MotiFlex e100 Single and Multi-Axis Servo Drive, being one of:

MFE460A0xxx (where xxx = product variant)

when used in accordance with the guidance given in the corresponding MotiFlex e100 Installation Manual (MN1943)
conforms with the protection requirements of the following Council Directives, by application of the relevant harmonized
standards:

The Electromagnetic Compatibility Directive 2004/108/EC and its amending directives:

Standard: Title:
EN61800-3:2004 Adjustable speed electrical power drive systems Part 3: EMC Requirements and
specific test methods.

The Low Voltage Directive 2006/95/EC and its amending directives:

Standard: Title:
EN61800-5-1:2007 Adjustable speed electrical power drive systems. Safety requirements. Electrical,
thermal and energy.
EN61800-2:1998 Adjustable speed electrical power drive systems. General requirements. Rating
specifications for low voltage adjustable frequency a.c. power drive systems.
EN50178:1997 Electronic equipment for use in power installations.
EN60529:1991+A1 Specification for degrees of protection provided by enclosures (IP code).

EC Declaration of Incorporation
The Machinery Directive 98/37/EC and its amending directives:

The above product is intended to be incorporated into machinery or to be assembled with other machinery to constitute
machinery covered by directive 98/37/EC. As such it does therefore not in every respect comply with the provisions of
directive 98/37/EC.

User must follow the guidance given in this directive to meet all necessary protection requirements. All instructions,
warnings & safety information of the product manual MN1943 must be adhered to. User must follow the guidance given in
harmonized standard EN60204-1 (Safety of Machinery) to meet necessary protection requirements of this directive.

Furthermore it is declared that it may not be put into service before the machinery in which it will be incorporated is
declared to comply with the provisions of directive 98/37/EC, as amended.

Signed:

Dr. Gerry Boast

Engineering Manager

D-2 CE & UL MN1943

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D.1.3 Use of CE compliant components

The following points should be considered:

H Using CE approved components will not guarantee a CE compliant system!

H The components used in the drive, installation methods used, materials selected for
interconnection of components are important.
H The installation methods, interconnection materials, shielding, filtering and earthing /
grounding of the system as a whole will determine CE compliance.
H The responsibility of CE mark compliance rests entirely with the party who offers the end
system for sale (such as an OEM or system integrator).

D.1.4 EMC wiring technique

Cabinet
Using a typical electroplated zinc coated cabinet, connected to earth/ground, means that all parts
mounted on the back plane are connected to earth/ground and all outer shield (screen)
connections can be connected to earth/ground. Within the cabinet there should be a spatial
separation between power wiring (motor and AC power cables) and control wiring.

Shield (screen) connections

All connections between components must use shielded cables. The cable shields must be
connected to the cabinet. Use conductive clamps to ensure good earth/ground connection. With
this technique, a good earth/ground shield can be achieved.

EMC filters
The filter should be mounted next to the MotiFlex e100. The connections between the
MotiFlex e100 and the filter should use shielded (screened) cables. The cable shields should be
connected to shield clamps at both ends.

Earthing/grounding
For safety reasons (VDE0160), all Baldor components must be connected to earth/ground with
a separate wire. Earth/ground connections must be made from the central earth/ground (star
point) to the regeneration resistor enclosure/case and from the central earth/ground (star point)
to the power supply.

MN1943 CE & UL D-3

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D.1.5 EMC installation suggestions

To ensure electromagnetic compatibility (EMC), the following installation points should be
considered to help reduce interference:

H Earthing/grounding of all system elements to a central earth/ground point (star point)

H Shielding of all cables and signal wires
H Filtering of power lines.
A proper cabinet should have the following characteristics:

H All metal conducting parts of the cabinet must be electrically connected to the back plane.
These connections should be made with an earthing/grounding strap from each element to
a central earthing/grounding point (star point). *
H Keep the power wiring (motor and power cable) and control wiring separated. If these wires
must cross, be sure they cross at 90 degrees to minimize noise due to induction.
H The shield connections of the signal and power cables should be connected to the shield
rails or clamps. The shield rails or clamps should be conductive clamps fastened to the
cabinet. **
H The cable to the regeneration resistor must be shielded. The shield must be connected to
earth/ground at both ends.
H The location of the AC filter has to be situated close to the drive so the AC power wires are
as short as possible.
H Wires inside the cabinet should be placed as close as possible to conducting metal, cabinet
walls and plates. It is advised to terminate unused wires to chassis ground.*
H To reduce earth/ground current, use the largest suitable wire available for earth/ground
connections.

* Earthing/grounding in general describes all metal parts which can be connected to a

protective conductor, e.g. housing of cabinet, motor housing, etc. to a central earth/ground
point (star point). This central earth/ground point (star point) is then connected to the main
plant (or building) earth/ground.
** Or run as twisted pair at minimum.

D-4 CE & UL MN1943

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D.1.6 Wiring of shielded (screened) cables

Remove the outer insulation to expose the overall shield.

Clamp should ideally provide 360° contact with the cable.

P-type clamp
(preferred)

Flat clamp

Figure 104 - Earthing/grounding cable shields

MotiFlex e100 Encoder Connector

X8 Cable Housing
Twisted pairs
CHA+ 1
CHA- 9
CHB+ 2
CHB- 10
CHZ+ 3
CHZ- 11
+5V 12
DGND 13

Connect overall shield Connect overall shield

to connector backshell. to connector backshell.

Figure 105 - Encoder signal cable grounding

MN1943 CE & UL D-5

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D.2 UL file numbers

The following table lists UL file numbers for Baldor products and other accessories. Note that
UL file numbers for accessories not manufactured by Baldor are beyond Baldor’s control and
therefore subject to change without notice.

UL file Company Description

number

E128059 Baldor Electric Co. Drives

E46145 Baldor Electric Co. Motors

E212132 Renu Electronics PVT LTD Programmable Controllers for Use in Hazardous
Locations
(Baldor keypad KPD202-501)

E132956 Cabloswiss s.p.a. Power cables (6A, 12A, 20A, 25A, 50A, 90A)
Encoder cables
Resolver/SSI cables
EnDat cables

E192076 Unika Special Cables s.p.a Power cables (6A, 12A, 20A, 25A, 50A, 90A)
Encoder cables
Resolver/SSI cables
EnDat cables

E153698 Coninvers GmbH Connectors

E64388 Schaffner EMV AG AC filters

E70122 Epcos AG AC filters

E212934 Frizlen GmbH & Co. KG Regeneration (brake) resistors

E227820 RARA Electronics Corp. Regeneration (brake) resistors

D-6 CE & UL MN1943

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 Index

A Circuit breakers, 8-2

Abbreviations. See Units and Abbreviations Command window, 6-26
AC input current Commissioning Wizard, 6-12
DC bus not shared, 8-2 using, 6-13
DC bus sharing, 8-4 Configuration, 6-24
AC input voltage, 8-1 Connections
AC line reactors, 3-19, 3-25, 8-4 AC power, 3-14, 3-17
catalog numbers, A-4 feedback, 4-1
Accessories, A-1 motor, 3-28
AC line reactors, A-4 Connectors
AC supply (EMC) filters, A-3 CAN, 5-22
motor / power cable bracket, A-7 Ethernet, 5-19, 5-21
motor power cables, A-9 I/O, 5-5–5-14
regeneration resistors, A-5 locations, bottom, 3-13
signal cable bracket, A-8 locations, front, 3-11
Analog I/O, 5-2 locations, top, 3-12
analog input (demand), 5-2 RS485, 5-18
analog input AIN0, 8-31 USB, 5-17
Control system, B-1
servo configuration, B-2
B
torque servo configuration, B-4
Basic Installation, 3-1
Cooling
BiSS
intelligent fan control, 3-10
cable, 4-8
overtemperature trips, 3-10
interface, 4-7
Crest factor
specification, 8-32
1.5 A ~ 16 A models, 8-9
Busbars, 3-8, 3-23, A-2
21 A model, 8-12
26 A & 33.5 A models, 8-13
C 48 A & 65 A models, 8-14
CAN interface
CANopen, 5-24 D
connector, 5-22
DC bus sharing, 3-7, 3-8, 3-22, 3-23, A-2
introduction, 5-22
fuses & circuit breakers, 8-8
LEDs, 7-3
Demand input, 5-2
opto-isolation, 5-23
specifications, 8-33 Derating. See Rating
termination, 5-22 Digital I/O, 5-4
wiring, 5-22 digital input DIN0, 5-7, 8-31
Catalog number, identifying, 2-2 digital inputs DIN1 & DIN2, 5-9, 8-31
digital output DOUT0, 5-14, 8-32
CE Guidelines, D-1
digital output DOUT1, 5-16, 8-32
declaration of conformity, D-2

MN1943 Index
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 drive enable input, 5-5, 8-31 SSI, 4-9
fast position capture, 5-10 Filters
motor overtemperature input, 5-12 AC line reactors, 3-19, 3-25, A-4
special functions on DIN1 & DIN2, 5-10 AC supply (EMC), 3-20, A-3
step & direction, 5-10 catalog numbers, A-3
Dimensions, 3-4, 3-5, 3-6 sinusoidal, 3-31
Dynamic brake. See Regeneration resistor Fuses, 8-2

E G
Earthing (grounding) General Information, 1-1
leakage, 3-15, 3-16 Grounding. See Earthing (grounding)
protection class, 3-16
protective earth (PE), 3-14 H
Encoder, incremental Hardware requirements, 3-1
cable, 4-3, 4-5 Help file, 6-9
interface, 4-2
specification, 8-32
I
without Halls, 4-4
Incremental encoder
EnDat
cable, 4-3, 4-5
cable, 4-14
interface, 4-2
interface, 4-13
specification, 8-32
specification, 8-33
without Halls, 4-4
Environmental
Indicators
location, 3-3–3-4
CAN LEDs, 7-3
specification, 8-35
ETHERNET LEDs, 7-4
Ethernet interface
STATUS LED, 7-2
cables, A-10
Input / Output, 5-1
connector, 5-21
analog input, 5-2
ETHERNET Powerlink, 5-20
analog input AIN0, 8-31
introduction, 5-19
CAN interface, 5-22
LEDs, 7-4
digital input DIN0, 5-7, 8-31
specifications, 8-33
digital inputs DIN1 & DIN2, 5-9, 8-31
TCP/IP, 5-19
digital output DOUT0, 5-14, 8-32
digital output DOUT1, 5-16, 8-32
F drive enable input, 5-5, 8-31
Fan control & loss detection, 3-10 encoder interface, 4-1
Fast position capture, 5-10 Ethernet interface, 5-19
Features, 2-1 motor overtemperature input, 5-12
Feedback node ID selector switches, 5-25
BiSS, 4-7 RS485 interface, 5-18
connections, 4-1 USB interface, 5-17
encoder without Halls, 4-4 Installation
EnDat, 4-13 See also Basic Installation
Halls-only feedback, 4-4 dimensions, 3-4, 3-5, 3-6
incremental encoder, 4-2 mechanical, 3-3
SinCos, 4-11

Index MN1943
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 Mint Machine Center, 6-1 O
Mint WorkBench, 6-1 Operation, 6-1
mounting, 3-7 configuring the TCP/IP connection, 6-4
TCP/IP configuration, 6-4 connecting to the PC, 6-1
USB driver, 6-3 installing Mint Machine Center, 6-1
installing Mint WorkBench, 6-1
K installing the USB driver, 6-3
Keyword summary, C-1 power on checks, 6-2
preliminary checks, 6-2
L starting, 6-2
LED indicators Overloads
CAN LEDs, 7-3 drive, 3-18
ETHERNET LEDs, 7-4 motor, 3-28
STATUS LED, 7-2 overtemperature trips, 3-10
Line reactors, catalog numbers, A-4 Overtemperature input, 3-35, 5-12
Linear motor, cable configuration, 4-6
P
M Parameters tool, 6-24
Mint keyword summary, C-1 Power
Mint Machine Center (MMC), 6-5 18 V out / 24 V in control circuit supply, 3-26
starting, 6-7 reducing wiring, 3-27
Mint WorkBench, 6-8 AC line reactors, 3-19, 3-25, A-4
Commissioning Wizard, 6-12 AC supply, 3-14, 3-17
help file, 6-9 discharge period, 3-21
other tools and windows, 6-26 disconnect and protection devices, 3-21
parameters tool, 6-24 input conditioning, 3-19
spy window, 6-25 input cycling, 3-18, 7-1
starting, 6-10 inrush current, 3-18
Motor ready input, 3-24
bottom panel wiring, 3-35 ready output, 3-24
brake connections, 3-34 sources, 3-1
circuit contactor, 3-31 supply filters, 3-20, A-3
motor cable shielding, 3-30 Power factor
output connections, 3-28 1.5 A ~ 16 A models, 8-9
output specifications, 8-15–8-23 21 A model, 8-12
output uprating and derating, 8-17 26 A & 33.5 A models, 8-13
overtemperature input, 3-35, 5-12 48 A & 65 A models, 8-14
power cable, 3-32–3-33, A-9 Precautions, 1-2
sinusoidal filter, 3-31 Product Notice, 1-2
Mounting, 3-7
R
N Rating, AC input current
Node ID selector switches, 5-25 All models, DC bus not shared, 8-2

MN1943 Index
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 1.5 A model, DC bus sharing, 8-4 Specifications, 8-1
3 A model, DC bus sharing, 8-4 18 VDC output, 8-29
6 A model, DC bus sharing, 8-5 24 VDC backup supply, 8-29
10.5 A model, DC bus sharing, 8-5 AC input current, 8-2, 8-4
16 A model, DC bus sharing, 8-5 AC input voltage, 8-1
21 A model, DC bus sharing, 8-6 analog input AIN0, 8-31
26 A model, DC bus sharing, 8-6 BiSS interface, 8-32
33.5 A model, DC bus sharing, 8-6 CAN interface, 8-33
48 A model, DC bus sharing, 8-7 digital input DIN0, 8-31
65 A model, DC bus sharing, 8-7 digital input DIN1, 8-31
Rating, motor output current digital input DIN2, 8-31
1.5 A model, 8-17 digital output DOUT0, 8-32
3 A model, 8-18 digital output DOUT1, 8-32
6 A model, 8-19 drive enable input, 8-31
10.5 A model, 8-20 EnDat interface, 8-33
16 A model, 8-21 environmental, 8-35
21 A model, 8-22 ethernet interface, 8-33
26 A model, 8-23 incremental encoder interface, 8-32
33.5 A model, 8-24 motor output, 8-15, 8-16
48 A model, 8-25 1.5 A model, 8-17
65 A model, 8-26 3 A model, 8-18
Receiving and Inspection, 2-2 6 A model, 8-19
Regeneration 10.5 A model, 8-20
capacity, 3-37 16 A model, 8-21
duty cycle, 3-43 21 A model, 8-22
energy, 3-39 26 A model, 8-23
power, 3-39 33.5 A model, 8-24
resistor choice, 3-40 48 A model, 8-25
resistor, connection, 3-36 65 A model, 8-26
resistor, dimensions, A-5 uprating and derating, 8-17
resistor, duty cycle derating, 3-42 regeneration, 8-27, 8-28
resistor, selection, 3-38 RS485 interface, 8-34
resistor, temperature derating, 3-41 SinCos interface, 8-33
specification, 8-27, 8-28 SSI interface, 8-32
RS485 weights and dimensions, 8-34
interface, 5-18 Spy window, 6-25
specifications, 8-34 SSI
cable, 4-10
S interface, 4-9
specification, 8-32
Safety Notice, 1-2
Standards, 2-4
SinCos
cable, 4-12 Status LED, 7-2
interface, 4-11 Step & Direction
specification, 8-33 inputs DIN1/2, 5-10
specification, 8-31

Index MN1943
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 T load attached, 6-18
TCP/IP, configuring, 6-4 no load attached, 6-16
optimizing the velocity response, 6-19
Tools, 3-2
test moves, jog, 6-22
Troubleshooting, 7-1
test moves, positional, 6-23
CAN LEDs, 7-3
CANopen, 7-6
communication, 7-5
U
Ethernet, 7-6 UL file numbers, D-6
ETHERNET LEDs, 7-4 Units and abbreviations, 2-3
Mint WorkBench, 7-5 Uprating. See Rating
power cycling, 7-1 USB
power on, 7-5 installing the driver, 6-3
problem diagnosis, 7-1 interface, 5-17
STATUS LED, 7-2
SupportMe, 7-1 W
tuning, 7-6 Weights and dimensions, 8-34
Tuning WorkBench. See Mint WorkBench
autotune wizard, 6-15

MN1943 Index
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 Index MN1943
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 Comments

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