Baldor Macro Drive Manual

SERVO DRIVE
MacroDrive
Servo Control
Installation & Operating Manual
10/00 MN1286
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Product Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 2
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MACRO Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Section 3
Receiving and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
X1 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
X1 Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
M-Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Motor Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
X1 Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
X1 +24VDC Logic Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
X3 – 8 pin Phoenix, Control Signals & Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
X7 – 15 pin Sub D, Simulated Encoder Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
X8 – 9 pin Sub D, Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
X8 – 15 pin Sub D, Encoder Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
X10 – 15 pin Sub D, User I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Section 4
Switch Setting and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Power Off Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Power On Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Continued on next page
MN1286 Table of Contents i

Section 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MacroDrive Node Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Rough and fine phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
8 Axis Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Monitor2 Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Using X10 (User I/O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Section 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Section 7
Specifications & Product Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
24VDC Logic Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Simulated Encoder Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Encoder Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Section 8
CE Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
EMC – Conformity and CE – Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
EMC Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Section 9
Accessories and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
EMC AC Mains Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Regeneration Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
ii Table of Contents MN1286

Section 1
General Information
Copyright Baldor  1999, 2000. All rights reserved.
This manual is copyrighted and all rights are reserved. This document may not, in
whole or in part, be copied or reproduced in any form without the prior written
consent of Baldor.
Baldor makes no representations or warranties with respect to the contents hereof
and specifically disclaims any implied warranties of fitness for any particular
purpose. The information in this document is subject to change without notice.
Baldor assumes no responsibility for any errors that may appear in this document.
Microsoft and MS–DOS are registered trademarks, and Windows is a trademark of
Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.
CE Compliance
A custom unit may be required, contact Baldor. Compliance to Directive
89/336/EEC is the responsibility of the system integrator. A control, motor and all
system components must have proper shielding, grounding, and filtering as
described in MN1383. Please refer to MN1383 for installation techniques for CE
compliance. For additional information, refer to Sections 3 and 8 of this manual.
Limited Warranty
For a period of two (2) years from the date of original purchase, BALDOR will repair or
replace without charge controls and accessories which our examination proves to be
defective in material or workmanship. This warranty is valid if the unit has not been
tampered with by unauthorized persons, misused, abused, or improperly installed and
has been used in accordance with the instructions and/or ratings supplied. This warranty
is in lieu of any other warranty or guarantee expressed or implied. BALDOR shall not be
held responsible for any expense (including installation and removal), inconvenience, or
consequential damage, including injury to any person or property caused by items of our
manufacture or sale. (Some states do not allow exclusion or limitation of incidental or
consequential damages, so the above exclusion may not apply.) In any event, 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.
MN1286 General Information 1-1

Product Notice Intended use:
These drives are intended for use in stationary ground based applications in
industrial power installations according to the standards EN60204 and VDE0160.
They are designed for machine applications that require variable speed controlled
three phase brushless AC motors.
These drives are not intended for use in applications such as:
– Home appliances
– Medical instrumentation
– Mobile vehicles
– Ships
– Airplanes
Unless otherwise specified, this drive is intended for installation in a suitable
enclosure. The enclosure must protect the control from exposure to excessive or
corrosive moisture, dust and dirt or abnormal ambient temperatures. The exact
operating specifications are found in Section 7 of this manual.
The installation, connection and control of drives is a skilled operation,
disassembly or repair must not be attempted.
In the event that a control fails to operate correctly, contact the place of purchase
for return instructions.
Safety Notice: This equipment contains high voltages. Electrical shock can cause serious or fatal
injury. Only qualified personnel should attempt the start–up procedure or
troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or
parts that are driven by this equipment. Improper use can cause serious or fatal
injury. Only qualified personnel should attempt the start–up procedure or
troubleshoot this equipment.
– System documentation must be available at all times.
– Keep non-qualified personnel at a safe distance from this equipment.
– Only qualified personnel familiar with the safe installation, operation and
maintenance of this device should attempt start-up or operating
procedures.
– Always remove power before making or removing any connections to
this control.
PRECAUTIONS: Classifications of cautionary statements.
WARNING: Indicates a potentially hazardous situation which, if not avoided,
could result in injury or death.
Caution: Indicates a potentially hazardous situation which, if not avoided,
could result in damage to property.
1-2 General Information MN1286

PRECAUTIONS:
WARNING: Do not touch any circuit board, power device or electrical
connection before you first ensure that power has been
disconnected and there is no high voltage present from this
equipment or other equipment to which it is connected.
Electrical shock can cause serious or fatal injury.
WARNING: Be sure that you are completely familiar with the safe operation
of this equipment. This equipment may be connected to other
machines that have rotating parts or parts that are controlled by
this equipment. Improper use can cause serious or fatal injury.
WARNING: Be sure all wiring complies with the National Electrical Code and
all regional and local codes or CE Compliance. Improper wiring
may cause a hazardous condition.
WARNING: Be sure the system is properly grounded before applying power.
Do not apply AC power before you ensure that grounds are
connected. Electrical shock can cause serious or fatal injury.
WARNING: Do not remove cover for at least five (5) minutes after AC power
is disconnected to allow capacitors to discharge. Electrical
shock can cause serious or fatal injury.
WARNING: Improper operation of control may cause violent motion of the
motor shaft and driven equipment. Be certain that unexpected
motor shaft movement will not cause injury to personnel or
damage to equipment. Peak torque of several times the rated
motor torque can occur during control failure.
WARNING: Motor circuit may have high voltage present whenever AC power
is applied, even when motor is not rotating. Electrical shock can
cause serious or fatal injury.
WARNING: If a motor is driven mechanically, it may generate hazardous
voltages that are conducted to its power input terminals. The
enclosure must be grounded to prevent a possible shock hazard.
WARNING: When operating a motor with no load coupled to its shaft,
remove the shaft key to prevent injury if it were to fly out when
the shaft rotates.
WARNING: A DB Resistor may generate enough heat to ignite combustible
materials. To avoid fire hazard, keep all combustible materials
and flammable vapors away from brake resistors.
WARNING: The user must provide an external hard-wired emergency stop
circuit to disable the control in the event of an emergency.
Caution: Suitable for use on a circuit capable of delivering not more than the RMS
symmetrical short circuit amperes listed here at rated voltage.
Horsepower RMS Symmetrical Amperes
1–50 5,000
Caution: To prevent equipment damage, be certain that the input power has
correctly sized protective devices installed as well as a power disconnect.
Continued on next page.
MN1286 General Information 1-3

Caution: Avoid locating control immediately above or beside heat generating
equipment, or directly below water or steam pipes.
Caution: Avoid locating control in the vicinity of corrosive substances or vapors,
metal particles and dust.
Caution: For UL installations, do not connect any resolver cable shields to the
motor frame. At a minimum, resolver signal integrity will be compromised
and damage to the control may result.
For CE installations, refer to CE guidelines stated in Sections 3 and 8 of
this manual.
Caution: Do not connect AC power to the control terminals U, V and W. Connecting
AC power to these terminals may result in damage to the control.
Caution: Baldor recommends not using “Grounded Leg Delta” transformer power
leads that may create ground loops and degrade system performance.
Instead, we recommend using a four wire Wye.
Caution: Logic signals are interruptible signals; these signals are removed when
power is removed from the drive.
Caution: Controls are intended to be connected to a permanent main power source,
not a portable power source. Suitable fusing and circuit protection devices
are required.
Caution: The safe integration of the drive into a machine system is the
responsibility of the machine designer. Be sure to comply with the local
safety requirements at the place where the machine is to be used. In
Europe this is the Machinery Directive, the ElectroMagnetic Compatibility
Directive and the Low Voltage Directive. In the United States this is the
National Electrical code and local codes.
Caution: Controls must be installed inside an electrical cabinet that provides
environmental control and protection. Installation information for the drive
is provided in this manual. Motors and controlling devices that connect to
the drive should have specifications compatible to the drive.
Caution: Violent jamming (stopping) of the motor shaft during operation may
damage the motor and control.
Caution: Do not tin (solder) exposed wires. Solder contracts over time and may
cause loose connections.
Caution: Electrical components can be damaged by static electricity. Use ESD
(electro-static discharge) procedures when handling this control.
Caution: Ensure that resolver or encoder wires are properly connected. Incorrect
installation may result in improper rotation or incorrect commutation.
Caution: The holes in the top and bottom of the enclosure are for cable clamps. Be
sure to use an M4 bolt 12mm in length. Longer bolts may short circuit the
electrical components inside the control.
Caution: If the I2T protection values are set incorrectly, a Series B motor can be
demagnetized.
1-4 General Information MN1286

Section 2
Product Overview
Overview The MacroDrive product is designed to serve the needs of machine designers and
manufacturers. Baldor products have both UL and CE approvals. The
MacroDrive is a servo amplifier for use with brushless servo motors.
The Motion Control with Macro (PMAC2) permits digital closure of the motor
current loops, mathematically creating phase voltage commands from numerical
registers representing commanded and actual current values. These numerical
phase voltage commands are converted to PWM format through digital
comparison to an up/down counter that creates a digital saw tooth waveform. The
analog current measurements are converted to digital signals with ADC’s for
closed loop feedback.
By using this direct PWM control of amplifiers, the Macro motion control performs
all of the control tasks for the motor, including commutation and digital current loop
closure. The MacroDrive only performs the power conversion task. In this mode,
the MacroDrive outputs a PWM voltage for each phase of the motor.
MACRO Defined ( Motion and Control Ring Optical ) is a digital interface for connection of
multi–axis motion controllers, amplifiers and other I/O devices on a fiber optic or
twisted pair copper (RJ45 connector) ring.
MACRO operates in a ring topology. Data is transmitted serially. Each station on
the ring has an “in” port for receiving data and an “out” port for transmitting data.
Nodes, residing at a station, can be amplifier axes, I/O banks or communication
interfaces to other devices. A station can have one or several nodes, allowing for
multi–axis amplifiers with a single “in” and single “out” port. Data packets, (groups
of 96 bits of serial data), from the motion controller or master node, are addressed
to a specific amplifier, or slave node. If the data packet is not for an amplifier, it is
passed on, unchanged. If it is for the node, it copies the contents of the data
packet (typically commands), places feedback data into a packet and transmits the
data packet.
MACRO’s advantages are:

1. Single–plug connections between controls and amplifiers. A single
fiber optic strand can provide a controller with: position feedback, flag
status (limits, home flag, registration prox status), amplifier status and
machine input status. This same strand can communicate to the
amplifier and other devices on the MACRO network (Amplifier enable &
amplifier command signals, machine outputs, commands to D/A
converters; all can be implemented with a single plug connection).
2. Noise Immunity. Fiber–optic cable transmits light, not electricity. Unlike
electricity light is immune to electromagnetic noise, capacitive coupling,
ground loops, and other wiring problems.
Continued on next page
MN1286 Product Overview 2-1

3. Speed. MACRO’s operation is 125 Mbits/second. This is at least 25
times faster than other digital motion control interfaces.
4. One ring, multiple masters. In a ring network, several motion
controllers (“masters”) can be on one ring. Each controller controls
several axes.
5. Simplicity. Transmission within the MACRO ring requires no software
intervention. The information sent to all nodes is written to a memory
location, and the MACRO hardware takes care of the rest.
Motors The MacroDrive servo control is compatible with many motors from Baldor and
other manufacturers. Baldor compatible motors include:
BSM–A–Series motors
BSM–B–Series motors (see I2T protection values in Figure 5-1).
BSM–N–Series motors
Refer to the Speed/Torque curves in the BR1202 catalog or contact your local
Baldor distributor or sales representative for assistance with motor sizing and
compatibility.
2-2 Product Overview MN1286

Section 3
Receiving and Installation
Receiving & Inspection Baldor Controls are thoroughly tested at the factory and carefully
packaged for shipment. When you receive your control, there are several things
you should do immediately.
1. Observe the condition of the shipping container and report any damage
immediately to the commercial carrier that delivered your control.
2. Remove the control from the shipping container and remove all packing
materials. The container and packing materials may be retained for
future shipment.
3. Verify that the part number of the control you received is the same as the
part number listed on your purchase order.
4. Inspect the control for external physical damage that may have been
sustained during shipment and report any damage immediately to the
commercial carrier that delivered your control.
5. If the control is to be stored for several weeks before use, be sure that it
is stored in a location that conforms to published storage humidity and
temperature specifications stated in this manual.
Location Considerations The location of the control is important. Installation should be in an area
that is protected from direct sunlight, corrosives, harmful gases or liquids, dust,
metallic particles, and vibration. Exposure to these can reduce the operating life
and degrade performance of the control.
Several other factors should be carefully evaluated when selecting a location for
installation:
1. For effective cooling and maintenance, the control should be mounted
on a smooth, non-flammable vertical surface.
2. At least 0.6 inches (15mm) top and bottom clearance must be provided
for air flow. At least 0.4 inches (10mm) clearance is required between
controls (each side).
3. Altitude derating. Up to 3300 feet (1000 meters) no derating required.
Derate the continuous and peak output current by 1.1% for each 330
feet (100 meters) above 3300 feet.
4. Temperature derating. From 0°C to 40°C ambient no derating
required. Above 40°C, derate the continuous and peak output current by
2.5% per °C above 40°C. Maximum ambient is 50°C.
Mechanical Installation
Mount the control to the mounting surface. The control must be securely fastened
to the mounting surface by the control mounting holes. The location of the
mounting holes is shown in Section 7 of this manual.
MN1286 Receiving & Installation 3-1

Electrical Installation All interconnection wires between the control, AC power source, motor,
motion controller and any operator interface stations should be in metal conduits.
Use listed closed loop connectors that are of appropriate size for wire gauge being
used. Connectors are to be installed using crimp tool specified by the
manufacturer of the connector. Only class 1 wiring should be used.
System Grounding Baldor controls are designed to be powered from standard single and three
phase lines that are electrically symmetrical with respect to ground. System
grounding is an important step in the overall installation to prevent problems. The
recommended grounding method is shown in Figure 3-1 and 3-3 for UL compliant
systems (Figure 3-2 and 3-4 for CE compliant systems).
Figure 3-1 Recommended System Grounding (3 phase) for UL
L1 Control Note:
Wiring shown for clarity of
AC Main L2 L1 L2 L3 PE U V W
grounding method only.
Supply Not representative of actual
terminal block location.
L3
Earth
Safety
Ground Four Wire Route all power wires L1, L2, L3 and Earth
“Wye” (Ground) together in conduit or cable.
Driven Earth
Ground Rod
(Plant Ground)
Note: Use shielded cable for control signal wires. Route

control signal wires in conduit. These wires must be
kept separate from power and motor wires. Ground per NEC and Local codes.
Figure 3-2 Recommended System Grounding (3 phase) for CE
AC Main L1 Control Note:

Supply Wiring shown for clarity of
L2 L1 L2 L3 PE U V W
grounding method only.
Not representative of actual
Four Wire
“Wye”
L3
Safety PE
Ground
Route all power wires
Motor
L1, L2, L3 and Earth
GND
(Ground) together in
conduit or cable.
All shields
Enclosure Backplane (see Section 8)

kept separate from power and motor wires.
3-2 Receiving & Installation MN1286

Figure 3-3 Recommended System Grounding (1 phase) for UL
L Note:
AC Main Control Wiring shown for clarity of grounding
Supply N L N U V W method only. Not representative of
actual terminal block location.
Safety Earth
Ground Route all 3 wires L, N, and Earth
(Ground) together in conduit or cable.
Driven Earth
Ground Rod
(Plant Ground)

kept separate from power and motor wires. Ground per NEC and Local codes.
Figure 3-4 Recommended System Grounding (1 phase) for CE

AC Main L1
Supply Control Note:
Wiring shown for clarity of
Four Wire L2 L N U V W grounding method only.
“Wye” Not representative of actual
L3
Safety
Ground Neutral
Route all power wires
PE Motor
together in conduit or
GND
cable.
All shields
Enclosure Backplane (see Section 8)

kept separate from power and motor wires.

System Grounding Continued
Ungrounded Distribution System
With an ungrounded power distribution system it is possible to have a continuous
current path to ground through the MOV devices. To avoid equipment damage, an
isolation transformer with a grounded secondary is recommended. This provides
three phase AC power that is symmetrical with respect to ground.
Input Power Conditioning
Baldor controls are designed for direct connection to standard single and three
phase lines that are electrically symmetrical with respect to ground. Certain power
line conditions must be avoided. An AC line reactor or an isolation transformer
may be required for some power conditions.
• If the feeder or branch circuit that provides power to the control has
permanently connected power factor correction capacitors, an input AC
line reactor or an isolation transformer must be connected between the
power factor correction capacitors and the control.
• If the feeder or branch circuit that provides power to the control has
power factor correction capacitors that are switched on line and off line,
the capacitors must not be switched while the control is connected to the
AC power line. If the capacitors are switched on line while the control is
still connected to the AC power line, additional protection is required.
TVSS (Transient Voltage Surge Suppressor) of the proper rating must be
installed between the AC line reactor or an isolation transformer and the
AC input to the control.
Power Disconnect A power disconnect should be installed between the input power service
and the control for a fail–safe method to disconnect power. The control will remain
in a powered-up condition until all input power is removed from the control and the
internal bus voltage is depleted.
Protection Devices The control must have a suitable input power protection device installed.
Input and output wire size is based on the use of copper conductor wire rated at
75 °C. Table 3-1 and 3-2 describes the wire size to be used for power connections
and the ratings of the protection devices. Use the recommended circuit breaker or
fuse types as follows:
Circuit Breaker: 1 phase, thermal magnetic.
Equal to GE type THQ or TEB for 115 or 230 VAC
3 phase, thermal magnetic.
Equal to GE type THQ or TEB for 230 VAC or
GE type TED for 460 VAC.
Time Delay Fuses: Buss FRN on 230 VAC or
Buss FRS on 460 VAC or equivalent.
Recommended fuse sizes are based on the following:
UL 508C suggests a fuse size of four times the continuous output
current of the control.
Dual element, time delay fuses should be used to avoid nuisance trips
due to inrush current when power is first applied.
For European installations, you may want to consider the following fast acting
fuse: Gould Shawmut Cat. No. ATMR15 for up to 15 amperes.

Table 3-1 Wire Size and Protection Devices (for units with Power Supply)
Catalog Number Incoming Power
Input
Continuous Input Wire Gauge
Nominal Input Fuse
Output Breaker
Voltage Time AWG mm2
Amps (RMS) (A) Delay (A) (USA) (Europe)
MA1A02SR-XXXX 115V (1f) 2.0A 8 8 14 2.5
MA2A02SR-XXXX 230V (3f) 2.5A 10 10 14 2.5
MA1A02TR-XXXX 115V (1f) 2.0A 8 8 14 2.5
MA2A02TR-XXXX 230V (1f) 2.5A 10 10 14 2.5
MA4A02TB-XXXX 400/460V (3f) 2.5A 10 10 14 2.5
MA1A05SR-XXXX 115V (1f) 5A 20 20 14 2.5
MA1A05SR-XXXX 230V (3f) 5A 20 20 14 2.5
MA1A05TR-XXXX 115V (1f) 5A 20 20 14 2.5
MA2A05TR-XXXX 230V (1f) 5A 20 20 14 2.5
MA4A05TB-XXXX 400/460V (3f) 5A 20 20 14 2.5
MA1A07TR-XXXX 115V (1f) 7.5A 30 30 14 2.5
MA2A07TR-XXXX 230V (1f) 7.5A 30 30 14 2.5
MA4A07TR-XXXX 400/460V (3f) 7.5A 30 30 14 2.5
MA1A10SR-XXXX 115V (1f) 10A 40 40 14 2.5
MA2A10SR-XXXX 230V (3f) 10A 40 40 14 2.5
MA1A15SR-XXXX 115V (1f) 15A 60 60 12 2.5
MA2A15SR-XXXX 230V (3f) 15A 60 60 12 2.5
MA4A15TR-XXXX 400/460V (3f) 15A 60 60 12 2.5
Table 3-2 Wire Size (for units without Power Supply)

Catalog Number Continuous Wire Gauge
Bus
Output AWG mm2
Voltage
Amps (USA) (Europe)
MA1A02PO-XXXX 160VDC 2.0A 14 2.5
MA1A10PO-XXXX 160VDC 10.0A 12 2.5
MA2A10PO-XXXX 300VDC 10.0A 12 2.5
MA1A15PO-XXXX 160VDC 15.0A 10 2.5
MA2A15PO-XXXX 300VDC 15.0A 10 2.5
Note: All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may
be used per NEC and local codes. Recommended fuses/breakers are based on 25°C
ambient, maximum continuous control output current and no harmonic current.
X1 Power Connections
Power connections are shown in Figures 3-5 through 3-8.

Figure 3-5 Single Phase AC Power Connections (MA1AxxT & MA2AxxT only)
L1 L2
Earth L1 L2
Note 1 * Circuit Alternate *

Note 3 & 4 Fuse Note 1
Breaker
Connection
Note 2
* Components not provided with Control.

L N
Notes:
Baldor 1. See “Protection Devices” described in this section.
Control 2. Metal conduit or shielded cable should be used. Connect
conduits so the use of a Reactor or RC Device does not
interrupt EMI/RFI shielding.
3. Use same gauge wire for Earth ground as is used for L and N.
(VDE (Germany) requires 10mm2 minimum). For CE
For CE Compliance, refer to Section 8 of this manual. Compliance, connect to the backplane of the enclosure.
4. Reference EMC wiring in Section 8.
Figure 3-6 Single Phase AC Power Connections (MA1AxxS only)

L1 L2
Earth L1 L2
Note 1 * Circuit Alternate *

Note 3 & 4 Fuse Note 1
Breaker
Connection
Note 2
L1 L2 L3 PE * Components not provided with Control.

Notes:
Baldor 1. See “Protection Devices” described in this section.
Control 2. Metal conduit or shielded cable should be used. Connect
conduits so the use of a Reactor or RC Device does not
interrupt EMI/RFI shielding.
(VDE (Germany) requires 10mm2 minimum). For CE
For CE Compliance, refer to Section 8 of this manual. Compliance, connect to the backplane of the enclosure.
Note: These MacroDrive versions are not designed for use with 400/460VAC
connections.

Figure 3-7 3 Phase Power Connections (MA2AxxS & MA4AxxT only)
L1 L2 L3
L1 L2 L3
Earth
Alternate *
Note 1 * Circuit Note 3 & 4 Fuse Note 1
Breaker Connection
Note 2
A1 B1 C1
L1 L2 L3 PE
* Components not provided with Control.
Notes:
Baldor 1. See Protection Device description in this section.
2. Metal conduit or shielded cable should be used. Connect
Control conduits so the use of a Reactor or RC Device does not interrupt
EMI/RFI shielding.
3. Use the same gauge wire for Earth as used for L1, L2, L3
connections.
For CE Compliance, refer to Section 8 of this manual. (VDE (Germany) requires 10mm2 minimum). For CE
compliance, connect “PE” to the backplane of the enclosure.
A shared supply configuration is shown in Figure 3-8. The first drive must have an
internal power supply such as an Option “S” control.
Figure 3-8 Shared Supply Power Connections
VCC+ VCC+ VCC+
VCC- VCC- VCC-
R1 VCC+ VCC+
R2 VCC- VCC-
Baldor Baldor Baldor

Option S Option P Option P
Control Control Control
To
Regen
Resistor

Figure 3-9 Connector Locations (Single Phase Controls)
X1 Ć Power Connector
X1 Monitor1 Monitor2 The holes in the top and
Earth bottom of the enclosure are
for cable clamps.
Input Power
L AC Line Be sure to use an M4 bolt
N Neutral NC 12mm in length. Longer
U Motor lead U" bolts may short circuit the
V Motor lead V" Motor L electrical components
W Motor lead W" N inside the control.
R1 Dynamic Brake Regen On Off
R2 Dynamic Brake Resistor U 1
+24V Customer
AS1
2
MAxAxxxxĆ V
0V Provided xx03 only
3
4
W
X6 Ć MacroDrive
R1 PWR WD 1 Reserved 19 Reserved
R2 2 Reserved 20 Reserved
Ready 3 ADC_CLK+ 21 ADC_CLK-
4 ADC_STB+ 22 ADC_STB-
Terminal tightening torque is 5 Current A+ 23 Current A-
0.5 lb-in (0.6Nm) +24V 6 Current B+ 24 Current B-
0V 7 AENA+ 25 AENA-
8 Fault+ 26 Fault-
9 PWM A+ 27 PWM A-
DB On 10 Reserved 28 Reserved
X3 Ć Control Signals & Digital I/O
In X9 Out
11 PWM B+ 29 PWM B-
1 +15VDC 12 Reserved 30 Reserved
2 Motor Overtemp + (Optocoupler) 13 PWM C+ 31 PWM C-
3 Motor Overtemp - (Optocoupler) 14 Reserved 32 Reserved
4 Ground 15 Ground 33 Ground
5 +15VDC 16 +5VDC 34 +5VDC
6 Hardware Enable + (Optocoupler) 17 Reserved 35 Reserved
7 Hardware Enable - (Optocoupler) 18 Reserved 36 Reserved
8 Ground
X10 Ć User I/O
X7 Ć Encoder Output 1 In Comm 9 Output 0
X6 2 Input 2 10 Output Pos.
1 CHA+ 9 Hall3+ 3 Home 11 Input 1
Encoder Out X7
2 CHB+ 10 Hall2+ 4 N.C. 12 Ext. Error In.

User I/O X10
3 CHC+ 11 +5VDC 5 Output 2 13 LIM. Sw. In+

4 Hall1+ 12 N.C. 6 Input 0 14 Output 1
5 Hall1- 13 Ground 7 Input 3 15 Out Comm.
6 CHAĆ 14 Hall3- 8 LIM. Sw. In-
7 CHBĆ 15 Hall2-
8 CHCĆ
X8 Ć Encoder Input
1 CHA+ 9 Hall3+
Res/Enc In X8
X8 Ć Resolver Input 2 CHB+ 10 Hall2+

3
SW1 SW2
1 REF+ 6 REF- (GND) 2 3 CHC+ 11 +5VDC

2 COS+ 7 COS-
1
0 4 Hall1+ 12 N.C.
3 SIN+ 8 SIN- 3 5 Hall1- 13 Ground
4 N.C. 9 N.C. 2 6 CHAĆ 14 Hall3-
1
5 Ground 0 7 CHBĆ 15 Hall2-
Off/On 8 CHCĆ
X3
Important:
MAxAxxxx-xx03 only.
A separate 24VDC supply to the “Logic Power” input is required for Note: Reserved means no connection is required
operation. An MAxAxxxx-xx03 control will not operate without 24VDC and no connection should be made to this
on this input. terminal. It is reserved for future use.

Figure 3-10 Connector Locations (Three Phase Controls)
X1 - Power Connector
The holes in the top and bottom of
PE Earth the enclosure are for cable clamps.
L1 Phase 1 Input Be sure to use an M4 bolt 12mm in
L2 Phase 2 Input Input Power
length. Longer bolts may short
L3 Phase 3 Input circuit the electrical components
U Motor lead “U” inside the control.
V Motor lead “V” Motor
W Motor lead “W”
R1 Dynamic Brake Dynamic Brake
R2 Dynamic Brake (Regen Resistor) X6 Ć MacroDrive
+24V Customer
0V Provided
MAxAxxxx-xxx3 1 Reserved 19 Reserved
only DB On 2 Reserved 20 Reserved
3 ADC_CLK+ 21 ADC_CLK-
Terminal tightening torque is 4 ADC_STB+ 22 ADC_STB-
0.5 lb-in (0.6Nm) 5 Current A+ 23 Current A-
6 Current B+ 24 Current B-
7 AENA+ 25 AENA-
8 Fault+ 26 Fault-
9 PWM A+ 27 PWM A-
10 Reserved 28 Reserved
11 PWM B+ 29 PWM B-
12 Reserved 30 Reserved
13 PWM C+ 31 PWM C-
X3 Ć Control Signals & Digital I/O 14 Reserved 32 Reserved
15 Ground 33 Ground
1 +15VDC 16 +5VDC 34 +5VDC
2 Motor Overtemp + (Optocoupler) 17 Reserved 35 Reserved
3 Motor Overtemp - (Optocoupler) 18 Reserved 36 Reserved
4 Ground
5 +15VDC X10 Ć User I/O
6 Hardware Enable + (Optocoupler) 1 In Comm 9 Output 0
7 Hardware Enable - (Optocoupler) 2 Input 2 10 Output Pos.
8 Ground 3 Home 11 Input 1
4 N.C. 12 Ext. Error In.
X7 Ć Encoder Output 5 Output 2 13 LIM. Sw. In+
6 Input 0 14 Output 1
1 CHA+ 9 Hall3+ 7 Input 3 15 Out Comm.
2 CHB+ 10 Hall2+ 8 LIM. Sw. In-
3 CHC+ 11 +5VDC
4 Hall1+ 12 N.C.
5 Hall1- 13 Ground
6 CHAĆ 14 Hall3-
7 CHBĆ 15 Hall2-
8 CHCĆ
X8 Ć Resolver Input X8 Ć Encoder Input

1 REF+ 6 REF- (GND) 1 CHA+ 9 Hall3+
2 COS+ 7 COS- 2 CHB+ 10 Hall2+
3 SIN+ 8 SIN- 3 CHC+ 11 +5VDC
4 N.C. 9 N.C. 4 Hall1+ 12 N.C.
5 Ground 5 Hall1- 13 Ground
6 CHAĆ 14 Hall3-
7 CHBĆ 15 Hall2-
8 CHCĆ
Important:
MAxAxxxx-xx03 only.
A separate 24VDC supply to the “Logic Power” input is required for Note: Reserved means no connection is required
operation. An MAxAxxxx-xx03 control will not operate without 24VDC and no connection should be made to this
on this input. terminal. It is reserved for future use.

X1 Motor Connections Motor connections are shown in Figure 3-11 and Figure 3-12.
It is important to connect the motor leads U, V and W correctly at the X1 connector
of the control. Incorrect wiring can cause erratic operation including moves at
peak force until the overcurrent limit trips. This will result in a display of “7” and a
“6” on the monitor. If erratic movement of the motor occurs, turn off power
immediately and check the connections of the motor, resolver or hall sensors and
encoder.
Figure 3-11 Motor Connections for UL
Notes:
Baldor 1. Metal conduit or shielded cable should be used. Connect
conduits so the use of Load Reactor* or RC Device* does not
Control interrupt EMI/RFI shielding.
(VDE (Germany) requires 10mm2 minimum, 6AWG).
U V W 3. Reference EMC wiring in Section 8.
4. Motor and resolver are phase sensitive. Connect only as
Note 1 instructed.
Note 2
V W For three phase controls, this is labeled “PE”.
U G * Optional components not provided with control.
* AC Servo Motor
Figure 3-12 Motor Connections for CE

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

Figure 3-13 Optional M-Contactor Connections
U V W * RC Device
To Power Source * M-Contactor Electrocube
(Rated Coil Voltage) RG1781-3
* M M M For three phase
controls, this is
labeled “PE”.
* Optional components not provided with control.
Note 1
V W
Note 2 * X3
U G M Enable
* Motor Note: Close “Enable”
6 after “M” contact closure.
M=Contacts of optional M-Contactor
Notes:
1. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm2 minimum, 6AWG).
2. For UL installations, connect motor ground to of the control as shown.
For CE installations, connect motor ground to the enclosure backplane (see Figure 3-12).
Motor Thermostat A relay contact can be used to isolate the motor thermostat leads for use with
other devices, shown in Figure 3-14. The thermostat or overload relay should be a
dry contact type with no power available from the contact. The optional relay
(CR1) shown provides the isolation required and the N.O. contact is open when
power is applied to the relay and the motor is cold. If the motor thermostat is
tripped, CR1 is de-energized and the N.O. contact closes.
Connect the External Trip Input wires (N.O. relay contact) to a PLC or other
device. Note that a machine input may be used and the PLC software of the
MacroDrive can define the thermal protection. Do not place these wires in the
same conduit as the motor power leads.
Figure 3-14 Motor Temperature Relay
Customer Provided Note: Add appropriately rated protective
Source Voltage device for AC relay (snubber)
or DC relay (diode).
*
CR1
External Trip
Note 1
V W G Do not run these wires in same conduit
as motor leads or AC power wiring.
U Motor Thermostat Leads
* Motor * Optional, customer supplied.
Note:
1. For UL installations, connect motor ground to of the control as shown.
For CE installations, connect motor ground to the enclosure backplane (see Figure 3-12).
X1 Dynamic Brake Resistor An external DB (dynamic brake or regen resistor) resistor may be
required to dissipate excess power from the DC bus during motor deceleration
operations. Some controls have an internal resistor. For selection of the DB
resistor, refer to the specifications located in Section 7 and the regeneration
resistor specifications in Section 9 of this manual. DB hardware is connected at
R1 and R2 terminals of the X1 connector, Figure 3-9 and 3-10.

X1 +24VDC Logic Supply For MAxAxxxx-xx03 only. A separate 24VDC supply to the “Logic
Power” input is required for operation. An external 24 VDC power source must be
used. If bus power is lost, the logic circuits are still active if the 24VDC is present.
This is important to maintain position reference, for example.
If the control was not ordered with this option, do not connect any voltage to these
pins.
X3 – 8 pin Phoenix, Control Signals & Digital I/O
Pin Signal Name

1 +15VDC
2 Motor Overtemperature + (Optocoupler)
3 Motor Overtemperature – (Optocoupler)
4 Ground
5 +15VDC
6 Hardware Enable + (Optocoupler)
7 Hardware Enable – (Optocoupler)
8 Ground
X7 – 15 pin Sub D, Simulated Encoder Feedback

Pin Signal Name
1 CHA+
2 CHB+
3 CHC+
4 SYNC_U+
5 Reserved
6 CHAĆ
7 CHBĆ
8 CHCĆ
9 SYNC_W+
10 SYNC_V+
11 +5VDC
12 N.C.
13 Ground
14 Reserved
15 Reserved

X8 – 9 pin Sub D, Resolver Feedback
The resolver connections are the standard feedback on Macro drives and
connections are made at the X8 connector as shown in Figure 3-15. The resolver
cable must be shielded twisted pair #22 AWG (0.34mm2) wire minimum. The
cable must also have an overall shield. Maximum wire-to-wire or wire-to-shield
capacitance is 50pf per foot. Maximum cable length is 80 ft (25 meters).
Resolver wiring must be separated from power wiring. Separate parallel runs of
resolver and power cables by at least 3″. Cross power wires at right angles only.
Insulate or tape ungrounded end of shields to prevent contact with other
conductors or ground.
Note: Motor and resolver are phase sensitive. Connect only as instructed.
Figure 3-15 Resolver Cable Connections for UL Installations

R2 S2 X8
P
3 SIN+
R1 S4
8 SIN-
P
S3 S1 2 COS+
7 COS-
P
1 REF+
P 6 REF- (Common)
= Twisted Pair Shields Shell (Chassis)
Figure 3-16 Resolver Cable Connections for CE Installations

R2 S2 X8
P
3 SIN+
R1 S4
8 SIN-
P
S3 S1 2 COS+
7 COS-
P
1 REF+
P 6 REF- (Common)
= Twisted Pair PE PE

X8 – 15 pin Sub D, Encoder Feedback
Twisted pair shielded wire with an overall shield should be used. Figure 3-17
shows the electrical connections between the encoder and the encoder connector.
Maximum cable length is 80 ft (25 meters).
Note: If the control was ordered with option E (Encoder/Hall feedback, catalog
MAxAxxxx-Exxx) it is not possible to connect the handwheel.
Figure 3-17 Encoder with Hall Tracks Connections for UL Installations

X8
1 A+
6 A–
Encoder 2 B+
7 B–
3 C+
8 C–
11 +5V
13 DGND
4 Hall1+
5 Hall1–
Hall 9 Hall3+
Feedback 14 Hall3–
10 Hall2+
15 Hall2–
Shell (Chassis)
Figure 3-18 Encoder with Hall Tracks Connections for CE Installations

X8
1 A+
6 A–
Encoder 2 B+
7 B–
3 C+
8 C–
11 +5V
13 DGND
4 Hall1+
5 Hall1–
Hall 9 Hall3+
Feedback 14 Hall3–
10 Hall2+
15 Hall2–
Shell (Chassis)

X10 – 15 pin Sub D, User I/O
These inputs operate from a customer provided 24VDC (20 – 30VDC @ 20mA)
power source.
Pin Signal Name
1 Input Ground
2 Input 2
3 Input Home
4 N.C.
5 Output 2
6 Input 0
7 Input 3
8 Limit Switch input (–)
9 Output 0
10 Output position
11 Input 1
12 External Error Input
13 Limit Switch input (+)
14 Output 1
15 Common High for all Outputs
Figure 3-19 MacroDrive System Connection Diagram

MacroDrive
Servo Control U, V, W Motor
Motion Control In
(with Macro) X9
Out Res./
X8
Out
Enc.
In
MacroDrive
In
X9
Out Res./
X8 Enc.
To Other MacroDrives & Devices
MacroDrive
In
X9
Out
X8 Res./
Enc.

Section 4
Switch Setting and Start-Up
Switch Settings
AS1 – Motor and Resolver Definition
On Off
1
AS1 switches are located on the front panel below the “Monitor” LEDs.
2 Note: All switches are shown in the “OFF” position.
3
4
AS1– Function
AS1
1 Pole Pair (only for resolver commutation).

Off Motor with 4 pole pairs, ie, 8 poles
On Motor with 2 pole pairs, ie, 4 poles
2 Resolver resolution (only for resolver commutation).
Off Resolver Resolution = 4096 counts / Rev
On Resolver Resolution = 1024 counts / Revolution
3 Motor with/without Over Temperature Sensor

Off Motor with Over Temperature Sensor
On Motor without Over Temperature Sensor
4 Not Used
SW1 (Servo Node) Description

3
Switch Number
SW1= 2 SW1 establishes how many servo nodes (0 – 15), and which
3 2 1 0
0 OFF OFF OFF OFF
1
0
servo nodes will be used on the MACRO station. It also
1 OFF OFF OFF ON Off On
establishes the mapping of MACRO node numbers to
2 OFF OFF ON OFF SW1 MACRO Station channel numbers. This mapping information
3 OFF OFF ON ON is important during software setup.
4 OFF ON OFF OFF
...
E ON ON ON OFF Note: All switches shown in “OFF” position.

F ON ON ON ON
SW2 (Master IC) Description

3
Switch Number
SW2= 2 SW2 establishes the “Master” number for communication with
3 2 1 0
0 OFF OFF OFF OFF
1
0
the MACRO station. The factory setting is 0, so the Macro
1 OFF OFF OFF ON Off On
station will respond to Master0.
2 OFF OFF ON OFF SW1
3 OFF OFF ON ON
4 OFF ON OFF OFF
...
E ON ON ON OFF Note: All switches shown in “OFF” position.

F ON ON ON ON
MN1286 Switch Setting & Start-Up 4-1

Node Number SW1 SW2
0 0 0 For MacroDrives with firmware version
1 1 0 2.114–24.01.00 or later. This table describes node
4 4 0 number settings using switches SW1 and SW2.
5 5 0
8 8 0 After switches SW1 and SW2 are set, go to the
9 9 0 terminal window of the MacroDrive Setup software
12 C 0 and set the variable
13 D 0 MSx,i942–$7FFFFE
MSx,i942 $7FFFFE
16 0 1 Other variables will be set by the setup software.
17 1 1
20 4 1 Note: This variable must be set after a reset
21 5 1 command is issued (MS$$$
(MS$$$***x,).x,).
24 8 1
25 9 1
28 C 1
29 D 1
32 0 2
33 1 2
36 4 2
37 5 2
40 8 2
41 9 2
44 C 2
... ... ...
4-2 Switch Setting & Start-Up MN1286

Start-Up Procedure
Power Off Checks
Before you apply power, it is very important to verify the following:
1. Disconnect the load from the motor shaft until instructed to apply a load.
If this cannot be done, disconnect the motor wires at X1-U, V and W.
2. Verify that switches AS1, SW1 and SW2 are set correctly.
3. Verify the AC line voltage at the source matches the control rated
voltage.
4. Verify the “Logic Power” is +24VDC (only if the option is present on your
MacroDrive).
5. Inspect all power connections for accuracy, workmanship and tightness.
6. Verify that all wiring conforms to applicable codes.
7. Verify that the control and motor are properly grounded to earth ground.
8. Check all signal wiring for accuracy.
Power On Checks
After successful power–up, the Monitor 1 and 2 LED’s should display the following:
d Monitor 1 LED display.
A Monitor 2 LED display (“A” or “O” depends on MSX, I18 setting. This is the
amplifier fault polarity within the PMAC2.)
Procedure:
1. Apply logic power (only if your control is equipped with this option).
2. Apply AC power.
3. Continue if the Monitor 1 and 2 LED’s display shows a successful
power–up. Otherwise disconnect AC power and refer to Section 6.
4. Start and run the setup program (P2–Setup or Turbo PMAC Setup
program version 1.3.0.0 or greater).
5. Disconnect AC power.
6. Connect the load to the motor shaft (or connect the motor wires at X1).
7. Apply AC power.
8. Program the motion control as required for the application.
Refer to Section 6 of this manual.
The drive is now ready for use.

Note: To protect the internal fuse, allow at least 1 minute after power down before
turning power on (power Off/On cycle).
MN1286 Switch Setting & Start-Up 4-3

Table of MacroDrive Variables
Node No. Node 0 Node 1 Node 4 Node 5 Node 8 Node 9 Node 12 Node 13
Motor No. 1 2 3 4 5 6 7 8
MI18 MS0, MI18 MS1, MI18 MS4, MI18 MS5, MI18 MS8, MI18 MS9, MI18 MS12, MI18 MS13, MI18
=$FF =$FF =$FF =$FF =$FF =$FF =$FF =$FF
=$10 =$11 =$10 =$11 =$10 =$11 =$10 =$11
=$11 =$10 =$11 =$10 =$11 =$10 =$11 =$10
=$12 =$13 =$12 =$13 =$12 =$13 =$12 =$13
=$13 =$12 =$13 =$12 =$13 =$12 =$13 =$12
=$14 =$15 =$14 =$15 =$14 =$15 =$14 =$15
=$15 =$14 =$15 =$14 =$15 =$14 =$15 =$14
=$16 =$17 =$16 =$17 =$16 =$17 =$16 =$17
=$17 =$16 =$17 =$16 =$17 =$16 =$17 =$16
Resolver:7 Resolver:7 Resolver:7 Resolver:7 Resolver:7 Resolver:7 Resolver:7 Resolver:7
Encoder:3 Encoder:3 Encoder:3 Encoder:3 Encoder:3 Encoder:3 Encoder:3 Encoder:3
=$1 =$1 =$1 =$1 =$1 =$1 =$1 =$1
=$0 =$0 =$0 =$0 =$0 =$0 =$0 =$0
=$7FFFFE =$7FFFFE =$7FFFFE =$7FFFFE =$7FFFFE =$7FFFFE =$7FFFFE =$7FFFFE
=$1 =$1 =$1 =$1 =$1 =$1 =$1 =$1
MI976 MS0, MI976 MS1, MI976 MS4, MI976 MS5, MI976 MS8, MI976 MS9, MI976 MS12, MI976 M13S, MI976
=$2222 =$1111 =$2222 =$1111 =$2222 =$1111 =$2222 =$1111
=$0 =$0 =$0 =$0 =$0 =$0 =$0 =$0
=$0080 =$0080 =$0080 =$0080 =$0080 =$0080 =$0080 =$0080
PWM Frequency 6.0kHz 8.0kHz

Phase Clock 6.0kHz 8.0kHz
Servo Clock 1.5kHz 2.0kHz
MSX, MI992 4914 3685
MSX, MI997 1 1
MSX, MI998 3 3
4-4 Switch Setting & Start-Up MN1286

Section 5
Operation
Introduction (Motion and Control Ring Optical ) is a digital interface for connection of multi–axis
motion controllers, amplifiers and other I/O devices on a fiber optic or twisted pair
copper (RJ45 connector) ring.
MACRO operates in a ring topology. Data is transmitted serially. Each station on
the ring has an “in” port for receiving data and an “out” port for transmitting data.
Nodes, residing at a station, can be amplifier axes, I/O banks or communication
interfaces to other devices. A station can have one or several nodes, allowing for
multi–axis amplifiers with a single “in” and single “out” port. Data packets, (groups
of 96 bits of serial data), from the motion controller or master node, are addressed
to a specific amplifier, or slave node. If the data packet is not for an amplifier, it is
passed on, unchanged. If it is for the node, it copies the contents of the data
packet (typically commands), places feedback data into a packet and transmits the
data packet.
MacroDrive Node Setup (P2–Setup program)
Several hardware and software operations must be performed in a specific
sequence when using the MacroDrive digital current loop closure, see Table 5-1.
Programming of the PMAC2 motion control must properly set the current loop and
direct the PWM output operation. This is quickly accomplished using the setup
software provided with the PMAC2 control.
Table 5-1 Motion Control Settings for MacroDrive
Menu Item Entry
Motion Type Selection: DC–Brushless
This Motor is: Rotary (on Macro)
Commutation Method: Digital Current Loop
PWM Frequency: 8kHz
Phase clock: 8kHz (Default)
Servo clock: 2kHz (Default)
PWM and Current Feedback Channel: This motor is assigned to Macro node ...
Set MI942 Set MI942 = $7FFFFE (in the terminal window).
Voltage Check: (Ixx66 will be modified) Enter the bus voltage of your MacroDrive
(160 or 300VDC).
Duty Cycle: Use 5% (Default). If problems occur, increase the
duty cycle in small increments (max = 10%).
On–Going Commutation feedback: Encoder: 1 (Default);
Quadrature default: 4 (Default).
Commutation size verification: (Counts per revolution) x 4. Depends on AS1
Counts per revolution: setting and resolution of feedback device. For
example, for high resolution resolver (AS1–2=OFF);
(4096 x 4) = 16384 counts per revolution.
Activate: autodetect the number of poles.
Motor 1 Input Channel: Flag Input Channel 1 (default)
Amplifier fault (A fault) signal is: High=True Amp
fault. Limit switches Disabled/Enabled depending on
system wiring.
MN1286 Operation 5-1

After current loop tuning, “Current Protection” is next.
Table 5-1 Motion Control Settings for MacroDrive Continued
Menu Item * Entry
Current Loop Tuning: Use autotune feature. Activate “Auto–Select
Bandwidth”. If problems occur, change “Test Scale
Factor”.
(Check Ixx66 after changing the “Test Scale Factor”)
What is the max time.... Enter the I2t time of the MacroDrive as follows:
2.5A / 5A = 2.88 seconds
7.5A = 15A = 1.25 seconds
Open Loop Test Perform this test with the default values.
Fine Phasing Calibration DO NOT perform the “Fine phasing calibration”!!!!
Skip this step by pressing “Continue”.
Applying the Phase Register Value: Incremental Encoder. (Hall effect)
Position Loop Feedback Sensor Setup: lncremental Encoder (default).
Position Encoder Channel Selection: Encoder Quadrature Decode *4 (default)
Velocity Loop Feedback Sensor Setup: lncremental Encoder (default)
Velocity Encoder Channel Selection: Encoder Quadrature Decode *4 (default)
Position Loop Tuning: Choose Autotuning. Select:
“Choose an initial bandwidth”
All other values as default.
Press “Begin PID Loop Autotuning”
Deactivate “Choose an initial bandwidth for me”
Increase the Desired Bandwidth by 2 or 3 times.
Damping Ratio = 0.7 and click “Autotune again”.
Activate “Auto–Select Velocity Feedforward” and
“Auto–Select Accel Feedforward”.
Choose the feature “l want my integral action to be”
Click Autotune again
Implement new gains and exit Autotune.
Motor Referencing (Homing) Setup: C–channel “high” (default). Use only when home
I will reference (home) on: limit switch is not wired. Otherwise it depends on
the limit switch wiring.
** Incremental Encoder Fine Phasing: Homing speed will be: 32 cts/msec (default)
The exact value for a Baldor Resolver is
Mx71= (I x 71) 0.5
The exact value for a Baldor Encoder is
Mx71= (I x 71) 0.333
* Refer to Figure 5-1 for I2t calculations.

** For this setting you could use the “TurboPMAC Setup” program. This is described on page 5–5 “Motor 1 Input
Channel” and “Incremental Encoder Fine Phasing”.
All parameters are set. Parameter values should be downloaded and saved.
To save the values, change to terminal mode and enter the “Save” command to store the value in PMAC flash
memory. Next, enter the “MSSAVEX” command to save all macro data to the macro flash memory. (X is the node
number for the MacroDrive you are setting up. This process must be repeated for each MacroDrive.)
5-2 Operation MN1286

Rough and fine phasing
Rough phasing is required for incremental encoders. PMAC must first perform
“rough phasing” after a reset (see PMAC2 software reference, variable IX80). The
setup program sets the variable to IX80=2, i.e. “phasing search on “$” command
only” is used. Setting of IX80=3 is not possible because during macro operation
no automatic “rough phasing” is possible upon power–up (see PMAC2 software
reference, IX80).
Variables IX73 and IX74 must be set to the correct values (motor under/without
load). Rough phasing must be manually performed by input of “#X00” (motor no.
X, 00 = enable) and by input of “#X$” (motor no. X, $ = rough phasing).
Now, the program for “fine phasing” may be started. Enter “I5=2” and “enable
plc1X” (X = motor no.), then the motor is ready to operate.
Using the function “upload PLC program” in the File menu of the program
PEWIN32, it is possible to edit the program “fine phasing” generated by the setup
program. In this program, by adding the following lines, after a reset, “rough
phasing” and “fine phasing” may be automatically executed:
The following lines have been inserted to perform automatic “rough phasing” and
“fine phasing” after reset, in this example: motor 1, node 0.
This PLC must in turn be downloaded, set I5=2 and store everything in PMAC.
This causes the necessary steps to be automatically executed after reset.
8 Axis Control Generally, 8 MacroDrives can be controlled by one motion controller (PMAC2).
SW1 is used to tell the MacroDrive which node it is (0, 1, 4, 5, 8, 9, 12 or 13).
Table 5-2 SW1 Node Definitions (For firmware 1.113 only).
SW1 Node
8 0 and 1
9 4 and 5
10 8 and 9
11 12 and 13
Nodes 0, 4, 8, 12 (For firmware 1.113 only).

1. First, connect 4 MacroDrives and the PMAC station into a macro ring.
Set each of the MacroDrives to a different node address (SW1 = 8, 9,
10, 11).
2. Now, the power supply is switched on for all terminals and all nodes are
enabled (in the setup program for motor 0, motor 4, motor 8 and motor
12, in each case execute step 1 “macro ring node”, in each case allocate
the preset values).
3. At the terminal, input “MS0, MI974=$1”, MS4,MI974=$1”,
MS8,MI974=$1”, MS12,MI974=$1”, then “MS0, MI976=$2”,
MS4,MI976=$20”, MS8,MI976=$200”, MS12,MI976=$2000”.
4. By inputting “MSSAVE0”, “MSSAVE4”, “MSSAVE8”, “MSSAVE12”, the
modifications are stored.
5. After reset by input of “MS$$$0”, “MS$$$4”, “MS$$$8”, “MS$$$12”, the
devices now react (depending on SW1) to the nodes 0, 4, 8, 12.

Nodes 1, 5, 9, 13 (For firmware 1.113 only).
1. First, connect 4 MacroDrives and the PMAC station into a macro ring.
Set each of the MacroDrives to a different node address (SW1 = 8, 9,
10, 11).
Note: As delivered, the MacroDrives are now at nodes 0, 4, 8, 12. This will be
changed later in this procedure.
2. Now, the power supply is switched on for all terminals and all nodes are
enabled (in the setup program for motor 0, motor 4, motor 8 and motor
12, in each case execute step 1 “macro ring node”, in each case allocate
the preset values).
3. At the terminal, input “MS0, MI974=$1”, MS4,MI974=$1”,
MS8,MI974=$1”, MS12,MI974=$1”, then “MS0, MI976=$1”,
MS4,MI976=$10”, MS8,MI976=$100”, MS12,MI976=$1000”.
4. Then, at the terminal, input “MS0, MI101=$11”, “MS0, MI102=$10”,
“MS4, MI103=$13”, “MS4, MI104=$12”, “MS8, MI105=$15”, “MS8,
MI106=$14” “MS12, MI107=$17”, “MS12, MI108=$16.
5. By inputting “MSSAVE0”, “MSSAVE4”, “MSSAVE8”, “MSSAVE12”, the
modifications are stored.
Reset each MacroDrive by input of “MS$$$0”, “MS$$$4”, “MS$$$8”,

“MS$$$12”, the devices are now nodes 1, 5, 9, 13.
Note: The MacroDrives are now at nodes 1, 5, 9, 13.
Now, all 8 devices may be controlled on a macro ring by one motion controller.
The PMAC2 may assign a different motor number than the node number. For
example, Motor 4 attached to Node 5 etc. (See Table 5-3).
Table 5-3 Motor Number vs Node Number

Motor Number Node Number
1 0
2 1
3 4
4 5
5 8
6 9
7 12
8 13

Monitor2 Error After correct and successful setup, Monitor2 still displays “A” amplifier fault
because its’ input is not used. To correct this, input “MS0, MI18=$FF” at the
terminal to set all error inputs to “high active”. After storing using “MSSAVEX”
(separately for each node X) and after reset using “MS$$$X”, the display of “A”
disappears on monitor 2.
Using X10 (User I/O)

To be able to use these inputs and outputs, the I/O states (high/low) must first be
configured.
Inputs limit+, limit–, fault_ext and home are set by the setup program (“Motor 1
Input Channel:” and “Incremental Encoder Fine Phasing:“), these inputs are
inverted (voltage at the input –> bit is low).
Motor 1 Input Channel: Flag Input Channel 1 (default)

My amplifier fault (A fault) signal is: High=True Amp
fault. Limit switches Disabled/Enabled depending on
system wiring.
Incremental Encoder Fine Phasing: My homing speed will be: 32 cts/msec (default)
(Firmware The inputs In0, In1, In2, In3 as well as the outputs Out0, Out1, Out2 are
1.113 and configured by entering the following commands at the terminal:
2.114 24.01.00)
Note: This must be separately executed for each node X address.
MS(node), MI198 = $40C085 ; Y:Memory, 8 bit, address $C085

MS(node), MI199 = $00FF ; Enable bits
MS(node), MI198 = $B0C081 ; X:Memory, 8 bit, address $C081
MS(node), MI199 = $00F0 ; Set inputs and outputs
MS(node), MI198 = $40C081 ; Y:Memory, 8 bit, address $C081
MS(node), MI199 ; Now, read or write the data bits. Remember the
upper bits are output and the lower bits are input.
The inputs are read using “MSX, MI199” (inputs are inverted, no voltage applied =
bit is high). The lower 4 bits (the smallest hex number) represent the 4 inputs.
Examples:
In 0 : low; In 1 : low; In 2: low; In 3: low –> MSX, MI199 –> $00000000000F
In 0 : low; In 1 : high; In 2: low; In 3: high –> MSX, MI199 –> $00000000000A
In 0 : high; In 1 : low; In 2: low; In 3: low –> MSX, MI199 –> $00000000000E
The outputs are read using the command “MSX, MI199=$Y0”. The lower 3 bits of
Y represent the outputs, binary coded, as a hex number:
Examples:
MSX,MI199=$10: Out 0: high; Out 1: low; Out 2: low
MSX,MI199=$10: Out 0: low; Out 1: high; Out 2: high

Using x10 (User I/O) – (Firmware 2.114 updated 12.04.00)
The I/O are now automatically set (IN0, IN1, IN2, IN3, OUT0, OUT1, OUT3).
MI980: Reading MI980 will input Macro Gates “I024 – I027” (IN).
MI982: Allows individual bit inversion of the Macro Gates “I024 – I027” (IN) data.
A bit value of “1” will invert the data read.
MI983: Setting MI981=1 will initialize the 4 bit I/O ports and set MI984 = MI985. It is automatically done at
$$$ and Ring Break. It can be done anytime and MI983 automatically clears – returns to zero.
MI984: Writing to MI984 will output to lines “I028 – I031” (OUT) of the Macro Gate.
MI985: MI985 is the value written to MI984 when MI983 is set to “1”.
MI986: Allows individual bit inversion of the Macro Gates “I028 – I031” (OUT).
A bit value of “1” will invert the data written.
Figure 5-1 I2t formula: Example of Current Protection Calculations
Note: ICont = Continuous Current of the Control
IPeak = Peak Current of the Control
(Choose the smallest ICont and IPeak values from the Control or Motor data, see example below)
IA/D = 1.25 x Ipeak (Current from the A/D Converter of the control)
I Cont Caution: If these I2T protection values are set
IX57Ă +Ă cos30° 32768
I AńD incorrectly, a Series B motor can be
demagnetized.
I Peak
IX69Ă +Ă cos30° 32768
I AńD
(IX69) 2Ă *Ă (IX57) 2
IX58Ă +Ă ServoĂupdateĂrateĂ(Hz) I 2tĂtimeĂ(seconds)
(32768) 2
(I ) 2Ă *Ă (I Cont) 2 2
IX58Ă +Ă Peak Ă ǒ cos 30° Ǔ Ă ServoĂupdateĂrateĂ(Hz) I 2tĂtimeĂ(seconds)
(I AńD) 2
(I ) 2Ă *Ă (I Cont) 2
IX58Ă +Ă Peak Ă Ă 0.75Ă ServoĂupdateĂrateĂ(Hz) I 2tĂtimeĂ(seconds)
(I AńD) 2
Example:
Control = MA2A07T . . .
ICont = 7.5A (RMS)
IPeak = 15A (RMS)
IA/D = 1.25 * 15A (RMS) = 18.75A (RMS)
I2t time = 1.25 seconds (for MA2A05 2.88 seconds) Choose smallest values
for ICont and IPeak
Motor = BSM 63A–333AA
ICont = 6.4A (RMS)
IPeak = 24A (RMS)
PMAC2Ultra–Lite: Servo update rate = 2000Hz, PWM Frequency = 8kHz. (I992=3685, I997=1, I998=3)
IX57Ă +Ă 6.4A cos30° 32768Ă +Ă 9686
18.75A
IX69Ă +Ă 15A cos30° 32768Ă +Ă 22702

18.75A
(15A) 2Ă *Ă (6.4A) 2
IX58Ă +Ă Ă Ă 0.75Ă 2000Ă(Hz) 1.25Ă +Ă 982
(18.75A) 2

Caution: Incorrect tuning of the Current Loop can cause current overshoot and a Series B
motor can be demagnetized. Verify calculated values with the TurboPMAC
Setup program. For best performance, you may select gain values up to 4 times
greater or less than the calculated values.
Figure 5-2 Setting PI Gains for PMAC Current Loop
IPD = Peak drive current (RMS)
lp–p = Motor phase to phase inductance (henries)
Rp–p = Motor phase to phase resistance (ohms)
1. Ixx66 = (1.1) x (I6800)
PWM Frequency = 8kHz
Bus Voltage = 320VDC
KiĂ +Ă ǒ 44.27297 x 10 *3Ă ǓĂ Ă L p*pĂ Ă ǒI4 Ă ǓĂ +Ă Ixx61
PD
KpĂ +Ă ǒI4 ǓĂ
PD
ƪ
Ă ǒ1.0522Ă Ă L p*pǓĂ *Ă ǒ1253.959
R p*p
ǓƫĂ +Ă Ixx62ĂorĂIxx76
2. Ixx66 = (1.1) x (I6800)
PD
KpĂ +Ă ǒI4 ǓĂ
PD
ƪ
Ă ǒ1.0522Ă Ă L p*pǓĂ *Ă ǒ1253.959
R p*p
3. Ixx66 = (1.1) x (I6800)
PD
KpĂ +Ă ǒI4 ǓĂ
PD
ƪ
Ă ǒ0.601Ă Ă L p*pǓĂ *Ă ǒ2194.364
R
p*p
4. Ixx66 = (1.1) x (I6800)

PD
KpĂ +Ă ǒI4 ǓĂ
PD
ƪ
Ă ǒ0.601Ă Ă L p*pǓĂ *Ă ǒ2194.364
R
p*p

Section 6
Troubleshooting
Overview The system troubleshooting procedures involves observing the status of the
“Ready” LED, the “DB On” LED and the “Monitor 2” 7 segment display. The tables
in this section provide information related to the indications provided by these
devices. If operation is normal, Monitor 1 should display a “d” or “.” and the Ready
LED is GREEN. If an error is detected, the Ready LED is RED.
Note: The “Ready” LED can display RED, YELLOW or GREEN color.
Table 6-1 LED Functions

LED Function
DB ON The “DB ON” LED is on whenever dynamic brake power is dissipated into
the db (dynamic brake) resistor. The DB resistor is also called a regen
resistor.
Ready If a PSM fault occurs, the “Ready” LED will be RED. If no faults are present,
the LED is GREEN.
PWR If voltage is applied to the control, the “PWR” LED is on.
WD The “WD” LED (software watch dog timer) is ON if a watchdog error
occurred.
Note: To protect the internal fuse, allow at least 1 minute after power down before
turning power on (power Off/On cycle).
It is important to connect the motor leads U, V and W correctly at the X1 connector

of the control. Incorrect wiring can cause erratic operation including moves at
peak force until the overcurrent limit trips. If erratic movement of the motor occurs,
turn off power immediately and check the connections of the motor, hall sensors
and encoder.
MN1286 Troubleshooting 6-1

Monitor 1 The Monitor 1 LED can display the error codes shown in Table 6-2.
Table 6-2 Monitor 1 Error Display
Error Code Description
1 Overvoltage – Amplifier DC Bus voltage too high.
2 BPS Fault – BPS Power Supply error.
3 Overcurrent – IPM error (IPM: overcurrent, overtemperature or power supply error)
4 Voltage Fault – Voltage fault in the logic supply.
5 Encoder/Resolver Fault
At encoder – Missing encoder signal (check connections).
At Resolver – Missing resolver connection (check connections).
or velocity is too high.
6 Overtemperature – Overtemperature of the power stage is detected.
7 Not applicable.
8 Overfrequency – PWM frequency is too high (> 10kHz).
9 Motor overtemperature – Motor temperature is too high.
(AS1–3 selects if temperature is to be monitored).
All errors except “2” are stored on the PWM interface card memory. Reset an
error with the Enable line or “o0” in the PMAC terminal program.
In addition to error codes, Table 6-3 lists the operation status that can be displayed
by the Monitor 1 display.
Table 6-3
Status Code Description
d Disabled – Amplifier is disabled (not active).
. Enabled – Amplifier is enabled (active).
Monitor 2 Display The Monitor 2 LED can display the error codes shown in Table 6-4.
Table 6-4 Monitor 2 Error Display
Error Code Description
A Amplifier Fault – Power stage fault (PWM card).
b Ring Break – Communication on the Macro Ring is broken.
C CPU Fault – Failure detected in RAM or PROM.
d Ring Error – Communication error detected on the Macro Ring.
E Encoder Fault – Error detected in the encoder feedback.
F Temporary Fault – No action taken.
In addition to error codes, Table 6-5 lists the operation status that can be displayed
by the Monitor 2 display.
Table 6-5 Monitor 2 Status Display
Status Code Description
0 0 axes are active.
1 1 axis is active.
6-2 Troubleshooting MN1286

Section 7
Specifications & Product Data
Identification
Servo Amplifier MA X A X X X X –R M 0 3
MacroDrive Logic Supply (Option)

0 = Internal 24VDC Supply
Input Voltage 3 = External customer provided
1=115VAC 24VDC required
2=230VAC
4=460/400VAC No Serial Port
Current Rating
A02 = 2 / 2.5 Amps
A05 = 5 Amps
A07 = 7.5 Amps Macro Bus
A10 = 10 Amps
A15 = 15 Amps
A20 = 20 Amps
Feedback Device (Option)
Enclosure Type R = Resolver
T= Panel Mount w/internal power supply E= Encoder
P= Panel Mount w/external power supply
S = Panel Mount w/internal power supply
(suitable for sharing with other controls).
Braking (Option)
R = Requires external regen resistor
B = Built-in regen resistor
O = No internal regen capability
MN1286 Specifications & Product Data 7-1

Specifications for 115 and 230VAC models only.
Description Unit MAx MAx MAx MAx MAx MAx MAx
A02T A05T A07T A02S A05S A010S A015S
Input Voltage Range Nominal VAC 115 / 230
Minimum 92 / 184
Maximum 132 / 265
Input Frequency Hz 50/60 ±5%
Nominal Output Bus Nominal VDC 160 / 320
(@ 115 / 230 input) Minimum 88 / 176
Maximum 180 / 360
Nominal Phase Current (±10%) ARMS 2.5 5.0 7.5 2.0 5.0 10 15
Peak Phase Current (±10%); for ARMS 5 10 15 4 10 20 30
2.4sec (+0.5s/–0sec) maximum
Nominal Output Power KVA 1.01 2.17 2.99 0.87 2.17 4.33 5.2
Output Frequency Hz 0 – 500
Efficiency % >95
Nominal Switching Frequency KHz 8.0 (software selectable)
Mounting – Panel
Package Size – A B C E E E E
Operating Altitude Feet To 3300 feet (1000 meters). Derate the continuous and
(Meters) peak output current by 1.1% for each 330 feet (100
meters) above 3300 feet.
Operating Temperature °C +0 to 40. Above 40°C, derate the continuous and peak
output current by 2.5% per °C above 40°C. Maximum
ambient is 50°C.
Rated Storage Temperature °C –25 to +70
Humidity % 10% to 90% non-condensing
Class of Protection (Enclosure) IP20
Shock 10G (according to DIN IEC 68–2–6/29)
Vibration 1G @ 10 – 150 Hz (according to DIN IEC 68–2–6/29)
Valid for zero current initial condition.

These specifications also apply to model MAXAxxP except it has DC input (no AC input).
All values at ambient temperature of 25°C unless otherwise stated.
7-2 Specifications & Product Data MN1286

Specifications Continued for 400/460VAC models only.
Description Unit MA4 A02TB MA4 A05TB MA4 A07TR MA4 A15TR MA4 A20TR
Input Voltage Range Nominal VAC 460 @ 60Hz / 400 @ 50Hz
Minimum 400 / 360
Maximum 528 / 480
Input Frequency Hz 50/60 ±5%
Nominal Output Bus Nominal VDC 565 / 678
(@ 400 / 460 input) Minimum 509 / –
Maximum – / 746
Nominal Phase Current (±10%) ARMS 2.5 5 7.5 15 20
Peak Phase Current (±10%); ARMS 5 10 15 30 40
2.4s +0.5s/–0s
Nominal Output Power KVA 1.9 3.8 5.7 11.4 15.2
Output Frequency Hz 0 – 500
Efficiency % >95
Nominal Switching Frequency KHz 8.0 (software selectable)
Mounting – Panel
Package Size – G G G H H
Operating Altitude Feet To 3300 feet (1000 meters). Derate the continuous and
(Meters) peak output current by 1.1% for each 330 feet (100
meters) above 3300 feet.
Operating Temperature °C +0 to 40. Above 40°C, derate the continuous and peak
output current by 2.5% per °C above 40°C. Maximum
ambient is 50°C.
Rated Storage Temperature °C –25 to +70
Humidity % 10% to 90% non-condensing
Class of Protection (Enclosure) IP20
Shock 10G (according to DIN IEC 68–2–6/29)
Vibration 1G @ 10 – 150 Hz (according to DIN IEC 68–2–6/29)
Valid for zero current initial condition.

All values at ambient temperature of 25°C unless otherwise stated.
For safe operation, allow a clearance distance between each control and on all sides of each control.

24VDC Logic Power Input (Option MAXAxxxx–xxx3 ONLY) for 115 and 230VAC models only.
A02T A05T A07T A02S A05S A10S A15S
Input Voltage (maximum ripple = ±10%) VDC 20 – 30
Input Current @ 24VDC ARMS 1.2 1.4
Power On surge current (24VDC 100msec) ARMS 4.0 4.0
Depends on installed options.

24VDC Logic Power Input Continued (Option MA4Axxxx–xxx3 ONLY)
Description Unit MA4 MA4 MA4 MA4 MA4
A02 A05 A07 A15 A20
Input Voltage (maximum ripple = ±10%) VDC 20 – 30
Input Current @ 24VDC ARMS 1.6 1.6 1.6 1.8 1.8
Power On surge current (24VDC 100msec) ARMS 4.0 4.0 4.0 4.0 4.0
Resolver Feedback
Description Unit All
Resolution bit Velocity < 6100RPM → Resolution 14 bits
(Depends on AS1 setting.) Velocity > 6100RPM → Resolution 12 bits
Pole Pairs 1
Resolver Winding Ratio 0.5
Simulated Encoder Output

Signal RS422
Encoder Resolution (set by switch AS1) ppr 1024, 4096
Encoder Input
Signal Type RS422
Operating Mode A / B Quadrature
Maximum Input Frequency kHz 125
Cycle Time msec 1
Factory Setting

Regeneration
A02T A05T A07T A02S A05S A10S A15S
Switching Threshold VDC ON: OFF: ON: OFF:
115VAC 188 - 195 183 - 188 180 200
230VAC 373 - 383 362 - 372 388 375
Nominal / Peak Power (10% Duty Cycle) kW 0.25 / 2.7

Maximum Regeneration Switching Current A 10
Maximum Load Inductance mH 100
Regeneration Continued
Description Unit MA4 MA4 MA4 MA4 MA4
A02 A05 A07 A15 A20
Switching Threshold 400/460VAC VDC ON: 794 OFF: 764
Nominal / Peak Power (10% Duty Cycle) kW 0.94 / 9.4 2.9 / 29 2.9 / 29
Maximum Regeneration Switching Current A 15 40 40
Maximum Load Inductance mH 100

Dimensions
Size A, B and C Size E, G and H
A 1.57″
(40mm)
W W
15.75
(400)
7.70″
(195.5mm)
15.14
6.81″ (385)
(173mm)
14.05
(357)
0.2 (5.2) Dia. Depth

4 Places Size A, B, C = 6.0 (152)
0.12 (3.0)
Clearance Requirements (all sizes):

0.06″ (15mm) top and bottom
0.04″ (10mm) left and right side 0.374 (9.5)
0.3 0.25 (6.5) Dia. 3 Places

(8.0)
Depth
Package Dimensions in (mm) Weight lb (kg)
Size E, G and H = 10.4 (265)
Size A W X
A 0.59 (15) 3.3 (84) – 2.73 (1.24)
B 0.90 (23) 4.3 (109) – 4.69 (2.13)
C 0.90 (23) 4.3 (109) – 4.8 (2.19)
E 1.08 (27.5) 2.17 (55) 1.42 (36) 11 (5)
G 1.28 (32.5) 2.6 (65) 1.81 (46 10.1 (4.6)
H 2.6 (65) 5.3(130) 4.37 (111) 20.9 (9.5)

Section 8
CE Guidelines
CE Declaration of Conformity
Baldor indicates that the products are only components and not ready for
immediate or instant use within the meaning of “Safety law of appliance”, “EMC
Law” or “Machine directive”.
The final mode of operation is defined only after installation into the user’s
equipment. It is the responsibility of the user to verify compliance.
The product conforms with the following standards:
DIN VDE 0160 / 05.88 Electronic equipment for use in electrical power
installations
DIN VDE 0100 Erection of power installations with nominal
voltages up to 1000V
DIN IEC 326 Teil 1 / 10.90 Design and use of printed boards
DIN VDE 0110Teil 1-2 / 01.89 Dimensioning of clearance and creepage
DIN VDE 0110Teil 20 / 08.90 distances
EN 60529 / 10.91 Degrees of protection provided by enclosures
EMC – Conformity and CE – Marking
The information contained herein is for your guidance only and does not
guarantee that the installation will meet the requirements of the council directive
89/336/EEC.
The purpose of the EEC directives is to state a minimum technical requirement
common to all the member states within the European Union. In turn, these
minimum technical requirements are intended to enhance the levels of safety both
directly and indirectly.
Council directive 89/336/EEC relating to Electro Magnetic Compliance (EMC)
indicates that it is the responsibility of the system integrator to ensure that the
entire system complies with all relative directives at the time of installing into
service.
Motors and controls are used as components of a system, per the EMC directive.
Hence all components, installation of the components, interconnection between
components, and shielding and grounding of the system as a whole determines
EMC compliance.
The CE mark does not inform the purchaser which directive the product complies
with. It rests upon the manufacturer or his authorized representative to ensure the
item in question complies fully with all the relative directives in force at the time of
installing into service, in the same way as the system integrator previously
mentioned. Remember, it is the instructions of installation and use, coupled with
the product, that comply with the directive.
Wiring of Shielded (Screened) Cables
Remove the outer insulation Conductive

to expose the overall screen. Clamp
MN1286 CE Guidelines 8-1

Using CE approved components will not guarantee a CE compliant system!
1. The components used in the drive, installation methods used, materials
selected for interconnection of components are important.
2. The installation methods, interconnection materials, shielding, filtering
and grounding of the system as a whole will determine CE compliance.
3. The responsibility of CE mark compliance rests entirely with the party
who offers the end system for sale (such as an OEM or system
integrator).
Baldor products which meet the EMC directive requirements are indicated with a
“CE” mark. A duly signed CE declaration of conformity is available from Baldor.
EMC Wiring Technique
1 CABINET
The drawing shows an electroplated zinc coated enclosure,
Y
which is connected to ground.
Capacitor
This enclosure has the following advantages:
– All parts mounted on the back plane are connected to ground.
– All shield (screen) connections are connected to ground.
Within the cabinet there should be a spatial separation between
power wiring (motor and AC power cables) and control wiring.
2 SCREEN CONNECTIONS
All connections between components must use shielded cables.
The cable shields must be connected to the enclosure. Use
conductive clamps to ensure good ground connection. With this
technique, a good ground shield can be achieved.
3 EMC – FILTER
The EMI or main filter should be mounted next to the power
supply (here BPS). For the connection to and from the main
filter screened cables should be used. The cable screens should
be connected to screen clamps on both sides. (Exception:
Analog Command Signal).
4 Grounding (Earth)
For safety reasons (VDE0160), all BALDOR components must
be connected to ground with a separate wire. The diameter of
the wire must be at minimum AWG#6 (10mm). Ground
connections (dashed lines) must be made from the central
ground to the regen resistor enclosure and from the central
ground to the Shared Power Supply.
5 Y–CAPACITOR
The connection of the regeneration resistor can cause RFI (radio
frequency interference) to be very high. To minimize RFI, a
Y–capacitor is used. The capacitor should only be connected
between the dynamic brake resistor housing and terminal pin R1
(lead from Flex).
Recommendation: 0,1µF / 250VAC Type: PME265
BALDOR–Ordering–No.: ASR27104
8-2 CE Guidelines MN1286

EMC Installation Instructions
To ensure electromagnetic compatibility (EMC), the following installation
instructions should be completed. These steps help to reduce interference.
Consider the following:
• Grounding of all system elements to a central ground point
• Shielding of all cables and signal wires
• Filtering of power lines
A proper enclosure should have the following characteristics:

A) All metal conducting parts of the enclosure must be electrically
connected to the back plane. These connections should be made with a
grounding strap from each element to a central grounding point .
B) Keep the power wiring (motor and power cable) and control wiring
separated. If these wires must cross, be sure they cross at 90 degrees to
minimize noise due to induction.
C) The shield connections of the signal and power cables should be
connected to the screen rails or clamps. The screen rails or clamps
should be conductive clamps fastened to the cabinet.
D) The cable to the regeneration resistor must be shielded. The shield must
be connected to ground at both ends.
E) The location of the AC mains filter has to be situated close to the drive
so the AC power wires are as short as possible.
F) Wires inside the enclosure should be placed as close as possible to
conducting metal, cabinet walls and plates. It is advised to terminate
unused wires to chassis ground.
G) To reduce ground current, use at least a 10mm2 (6 AWG) solid wire for
ground connections.
Grounding in general describes all metal parts which can be connected to a protective
conductor, e.g. housing of cabinet, motor housing, etc. to a central ground point. This
central ground point is then connected to the main plant (or building) ground.
Or run as twisted pair at minimum.
Cable Screens Grounding

Cable (Twisted Pair Conductors)
Conductive Clamp – Must contact bare cable shield

and be secured to metal backplane.
MN1286 CE Guidelines 8-3

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

Control Resolver Connector
X8 Housing
Cable
1 1
6 2
2 3
7 4
3 5
8 6
5
Connection of shields to analog ground is optional.
Encoder Cable Grounding

Control Encoder Connector
X9 Cable Housing
1
6
2
7
3
8
11
13
Connection of shields to digital ground is optional.
8-4 CE Guidelines MN1286

Section 9
Accessories and Options
Cables Shielded (Screened) cable provides EMI / RFI shielding and are required for
compliance to CE regulations. All connectors and other components used must
be compatible with this shielded cable.
Motor Power Cable
Length
Cable Rated Current Cable Assembly Baldor Catalog Number
Description Feet Meters
Power Cable Assembly CBL030SP–MHCE 10 3.0

CE Style Threaded CBL061SP–MHCE 20 6.1
Connector CBL091SP–MHCE 30 9.1
CBL152SP–MHCE 50 15.2
10 Amps
Power Cable CBL030SP–M 10 3.0
No Connectors CBL061SP–M 20 6.1
CBL091SP–M 30 9.1
CBL152SP–M 50 15.2
Power Cable Assembly CBL030SP–FHM 10 3.0
Threaded connector CBL061SP–FHM 20 6.1
(Standard-Metric Style) CBL091SP–FHM 30 9.1
CBL152SP–FHM 50 15.2
Power Cable Assembly CBL030SP–FHCE 10 3.0
CE Style Threaded CBL061SP–FHCE 20 6.1
20 Amps
Connector CBL091SP–FHCE 30 9.1
CBL152SP–FHCE 50 15.2
Power Cable CBL030SP–F 10 3.0
No Connectors CBL061SP–F 20 6.1
CBL091SP–F 30 9.1
CBL152SP–F 50 15.2
Power Cable CBL030SP–E 10 3.0
30 Amps No Connectors CBL061SP–E 20 6.1
CBL091SP–E 30 9.1
CBL152SP–E 50 15.2
Connectors
Mating Connector by connector number (for spare parts)
X1 – #ASR29714 (9 pin, Female) Phoenix Part No. MVSTBW2,5/9–ST
X1 – #ASR29715 (2 pin, Female) Phoenix Part No. MVSTBW2,5/2–ST
X3 – #ASR10467 (8 pin, Female) Phoenix Part No. MVSTBR2,5/8–ST
X6 – (Centronic 36 pin, Male) – Parallel Printer Connector
X7 – #ASR16215 (9 pin, Male)
X8 – #ASR23345 (9 pin, Female) Resolver
X8 – #ASR25828A (15 pin, Male) Encoder
X9 – Fiber Optic Connector (see your fiber optic installer)
MN1286 Accessories & Options 9-1

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

Rated Power
Amps Losses
Current mA lbs (kg)
@ 40°C Watts
FN 351 - 8 - 29 440 8 16 8.0 3.97 (1.8) ASR24667
FN 351 - 16 - 29 440 16 16 9.0 3.97 (1.8) ASR24668
FN 351 - 25 - 33 440 25 170 9.0 6.61 (3.0) ASR24669
FN 351 - 36 - 33 440 63 170 10.5 6.61 (3.0) ASR24670
FN 351 - 50 - 33 440 50 190 12.5 6.83 (3.1) ASR24671
9-2 Accessories & Options MN1286

For package size E, G and H (Model T – 3 Phase Required for MA4xx)
Rated
Amps
Current mA lbs (kg)
@ 40°C
FN 3258 - 30 - 47 480 30 184.7 2.64 (1.2) ASR30521
FN 3258 - 7 - 45 480 7 172.4 0.11 (0.5) ASR30522
AC Filter Dimensions Continued Depth = F 4.53 (115)

Dim. For For Filters: FN 351 -
FN350 8 Ć 29 16 Ć 29 25 Ć 33 36 Ć 33 50 Ć 33
A 5.4 8.6 9.45 9.84
(139) (220) (240) (250)
B 3.9 7.1 7.87 7.87
(99) (180) (200) (200) G
C 4.2 4.5 5.9 5.9
(105) (115) (150) (150 D
G C E
D 3.32 3.35 4.7 4.72
(84.5) (85) (119.5) (120)
E 3.73 3.93 5.31 5.31 H
(95) (100) (135) (135)
F 2.24 2.36 2.55 2.55
(57) (60) (65) (65)
G 0.39 0.39 0.39 0.78
(10) (10) (10) (20) M6
H 1.74 0.76 1.22 0.83 B
(19) (19.5) (31) (21) A
AC Filter Dimensions Continued

Dim. For Filters:
FN3358-7-45 FN3358-30-47
A 7.48 10.63
(190) (270) B
B 6.29 9.45 F
(160) (240)
C 7.08 10.04
(180) (255)
D 0.79 1.18 M5
(20) (30)
E 0.18 0.21
A
(4.5) (5.4)
F 2.75 3.35
(70) (85)
G
G 1.57 1.97 D E
(40) (50)
MN1286 Accessories & Options 9-3

Regeneration Resistor Some controls are shipped with an internal regen resistor. If an internal
resistor is not present, a regeneration resistor should be installed to dissipate
energy during braking if a Fault “1” (over-voltage) occurs.
Baldor Catalog Number

Control 115VAC Controls 230VAC Controls 400/460VAC Controls
Package
Rated Resistor Resistor Resistor
Size Resistor Resistor Resistor
Amps Catalog Catalog Catalog
Watts Watts Watts
No. No. No.
2.5 A RG27 44 RG56 44
5 B RG27 44 RG56 44
7.5 C RG22 100 RG39 100
2.5 G * RG68 320
5 G * RG68 320
7.5 G RG68 320
15 H RG27A 320
22.5 H RG23 640
2 E RG4.7 320 RG10 320
5 E RG4.7 320 RG10 320
10 E RG4.7 320 RG10 320
15 E RG4.7 320 RG10 320
* “TB” controls have a 200 ohm, 50 watt resistor installed.

“TR” controls require an external REGEN resistor (RG68).
1.7 (45)
3.9
(100) 3.54
(90)
L
M4 2.6 (65)
L = 5.5 (140) for 44 watt
8.9 (228) for 100 watt Clearance Requirements (all sizes):
13.2 (337) for 320/640 watt 2″ (51mm) top and bottom
1″ (26mm) left and right side
9-4 Accessories & Options MN1286

BALDOR ELECTRIC COMPANY
P.O. Box 2400
Ft. Smith, AR 72902–2400
(501) 646–4711
Fax (501) 648–5792
www.baldor.com
CH D UK F
TEL: +41 52 647 4700 TEL: +49 89 90 50 80 TEL: +44 1454 850000 TEL: +33 145 10 7902
FAX:+41 52 659 2394 FAX:+49 89 90 50 8491 FAX:+44 1454 850001 FAX:+33 145 09 0864
I AU CC MX
TEL: +39 11 562 4440 TEL: +61 29674 5455 TEL: +65 744 2572 TEL: +52 47 61 2030
FAX:+39 11 562 5660 FAX:+61 29674 2495 FAX:+65 747 1708 FAX:+52 47 61 2010
 Baldor Electric Company Printed in USA

MN1286 10/00 C&J 500
MacroDrive Servo Control MN1286

Baldor Macro Drive Manual

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SERVO DRIVE

Installation & Operating Manual

Continued on next page

MN1286 Table of Contents i

ii Table of Contents MN1286

MN1286 General Information 1-1

1-2 General Information MN1286

Continued on next page.

MN1286 General Information 1-3

1-4 General Information MN1286

MACRO’s advantages are:

Continued on next page

MN1286 Product Overview 2-1

2-2 Product Overview MN1286

MN1286 Receiving & Installation 3-1

Note: Use shielded cable for control signal wires. Route

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

AC Main L1 Control Note:

Note: Use shielded cable for control signal wires. Route

3-2 Receiving & Installation MN1286

Note: Use shielded cable for control signal wires. Route

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

Note: Use shielded cable for control signal wires. Route

MN1286 Receiving & Installation 3-3

3-4 Receiving & Installation MN1286

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

MN1286 Receiving & Installation 3-5

Note 1 * Circuit Alternate *

* Components not provided with Control.

Figure 3-6 Single Phase AC Power Connections (MA1AxxS only)

Note 1 * Circuit Alternate *

L1 L2 L3 PE * Components not provided with Control.

3-6 Receiving & Installation MN1286

Figure 3-8 Shared Supply Power Connections

VCC+ VCC+ VCC+

VCC- VCC- VCC-

Baldor Baldor Baldor

MN1286 Receiving & Installation 3-7

2 CHB+ 10 Hall2+ 4 N.C. 12 Ext. Error In.

3 CHC+ 11 +5VDC 5 Output 2 13 LIM. Sw. In+

X8 Ć Resolver Input 2 CHB+ 10 Hall2+

1 REF+ 6 REF- (GND) 2 3 CHC+ 11 +5VDC

3-8 Receiving & Installation MN1286

X8 Ć Resolver Input X8 Ć Encoder Input

MN1286 Receiving & Installation 3-9

Figure 3-12 Motor Connections for CE

3-10 Receiving & Installation MN1286

MN1286 Receiving & Installation 3-11

X3 – 8 pin Phoenix, Control Signals & Digital I/O

Pin Signal Name

X7 – 15 pin Sub D, Simulated Encoder Feedback

3-12 Receiving & Installation MN1286

Figure 3-15 Resolver Cable Connections for UL Installations

Figure 3-16 Resolver Cable Connections for CE Installations

MN1286 Receiving & Installation 3-13

Figure 3-17 Encoder with Hall Tracks Connections for UL Installations

Figure 3-18 Encoder with Hall Tracks Connections for CE Installations

3-14 Receiving & Installation MN1286

Figure 3-19 MacroDrive System Connection Diagram