Baldor EXB009A01 User Manual

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Resolver to Digital

Expansion Board

Catalog No. EXB009A01

Installation and Operating Manual

6/98 MN1313

Section General Information 1-1.

Section Expansion Board Description

Section Installation 3-1.

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

Introduction 1-1 Limited Warranty 1-2. Safety

Precautions 1-3

Introduction 2–1 Specifications 2–1

Board 1-15HP

Single Dual

15HP

Single Dual

SCR

DC Controls Single Dual

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Notice

Installation

Size A and B Controls

Expansion Board Installation

Size C and Larger AC Controls

Expansion Board Installation

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Expansion Board Installation

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Expansion Board Installation

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1-3.

2–1.

3-1. 3-2. 3-2. 3-4. 3-6. 3-6.

3-8. 3-10. 3-10.

3-11.

Table of Contents i

Section Hardware Setup

Section Software Setup

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

Connections 4–3

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Configure

Series Series

Control Software

18H and 22H V

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

ector Controls

19H and 20H DC SCR Controls

. . . . . . . . . . .

. . . . . . . . .

4–1.

5–1. 5–1. 5–1. 5–1.

ii Table of Contents

Section 1 General Information

Introduction

The

Baldor controls represent the latest technology in microprocessor based motor controls. In addition to the user programmable parameters available in every control, many dif

ferent expansion boards are available from Baldor to further

customize the control to most any application. Expansion boards are categorized by compatibility into two

groups: Group 1 and Group 2, see T either group may be used alone in a control. If two boards are to be used, one board must be from Group 1 and the other from Group 2.

Note:

Using two Group 1 or two Group 2 boards in the same control is not allowed.

able 1-1 Group 1 and Group 2 Board Categories

able 1-1. A board from

Group 1 Board Name

Isolated Input Expansion Board Master Pulse Reference/

Isolated Pulse Follower DC T

achometer Interface

Isolated Encoder Expansion Board

Resolver to Digital Interface

Group 2 Board Name

RS-232 Serial Communication RS-422/RS-485 High Speed

Serial Communication Four Output Relays/3-15 PSI

Pneumatic Expansion Board High Resolution Analog I/O

Expansion Board 2 Isolated Analog Output/ 3 Relay

Output Expansion Board

Catalog No. Baldor

Manual No.

EXB003A01 MN1314 EXB005A01 MN1312

EXB006A01 MN1311 EXB008A01 MN1317

EXB009A01 MN1313

EXB001A01 MN1310 EXB002A01 MN1310

EXB004A01 MN1315 EXB007A02 MN1316 EXB010A01 MN1319

General Information 1-1

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 been improperly installed and has been used in accordance with the instructions other warranty or guarantee expressed or implied. BALDOR shall not be held responsible for removal), inconvenience, or consequential damage, including injury or sale. (Some states do not allow exclusion or limitation of incidental 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

or workmanship. This warranty is valid if the unit has not

tampered

with by unauthorized persons, misused, abused, or

and/or ratings supplied. This warranty is in lieu of any

any expense (including installation and

to any person or property caused

by items of our manufacture

or consequential damages, so the above exclusion may

items such as fuses.

Goods may be returned only with written notification including a BALDOR

Return Authorization

Number and any return shipments

must be prepaid.

1-2 General Information

Safety Notice

This

equipment contains voltages that may be as great as 1000 volts! Electrical shock can cause serious or fatal injury 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.

PRECAUTIONS

ARNING:

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

. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

ARNING:

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. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

. Only

General Information 1-3

ARNING:

Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury

Do not remove cover for at least five (5) minutes after AC power is disconnected to allow capacitors to discharge. Dangerous voltages are present inside the equipment. Electrical shock can cause serious or fatal injury.

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.

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

Caution: T

o prevent equipment damage, be certain that the electrical service is not capable of delivering more than the maximum line short circuit current amperes listed in the appropriate control manual, 230 V V

AC or 575 V

1-4 General Information

AC, 460

AC maximum per control rating.

Section 2 Expansion Board Description

Introduction

Resolver Catalog No. EXB009A01

Group 1 Expansion Board The Resolver to Digital Interface expansion board provides

closed loop operation for the Baldor Series 18H, 19H, 20H and 22H controls. The Resolver to Digital Interface can also be used for PID control.

Note:

The Resolver to Digital interface is used with a motor mounted resolver Baldor Control. The control can then monitor and control shaft position. The Buf still available from the control.

Resolver Reference Supply DIgital Resolution

Resolver Input Channels Resolver Impedance Resolver Return V Resolver T Resolver Speeds Connector Screw Terminals

to Digital Interface Expansion Board

When a Resolver to Digital Interface is used in a process control application, an encoder should be used to provide velocity feedback to the control.

Specifications

. This provides the correct feedback signals for the

fered Encoder Output (Retransmit) signals are

Resolver to Digital interface

4 V

olts, 25 mA maximum (@ 10KHz) 10, 12, 14, 16 bits (selectable)

Sine, ± Cosine

160 Ohms @ 10KHz minimum

oltage

ransformation Ratio

2 V

olts minimum 2:1 (0.5 TR) 1:128 (selectable)

Description 2-1

Maximum Motor Speed / Resolver Speed

pyp

Resolver Speed Type Maximum Motor Speed (RPM)

10 Bits 12 Bits 14 Bits 16 Bits

(2 Pole)

1 Speed Resolver

(4 Pole)

2 Speed Resolver

(6 Pole)

3 Speed Resolver

(8 Pole)

4 Speed Resolver

(10 Pole)

5 Speed Resolver

(12 Pole)

6 Speed Resolver

62,400 15,600 3,900 975 31,200 7,800 1,950 487 20,800 5,200 1,300 325 15,600 3,900 975 244 12,480 3,120 780 195 10,400 2,600 650 163

Maximum Resolver

Speed/Bit Resolution

2-2 Description

128

(256

Poles)

(128

Poles)

(64 Poles)8(16 Poles)

Section 3 Installation

Board Installation

This

section describes the Expansion Board installation

procedure.

Caution:

Remove the expansion board from the shipping container

Remove all packing material from the board.

Caution:

Installation dif and the 15HP Size C and larger AC controls and the SCR DC controls. If you are installing only one board, refer to the “Single Expansion Board Installation” procedure. If you are installing two expansion boards (or a second board) refer to the “Dual Expansion Board Installation” procedure.

Before you proceed, be sure to read and become familiar with the safety precautions at the beginning of this manual. Do not proceed if you are unsure of the safety precautions described. If you have any questions, contact BALDOR before you proceed.

Be sure all packing materials are removed from the board. Conductive foam may be present on the connectors to prevent static build up during shipping. This can prevent proper circuit operation.

fers between the 1-15 HP Size A and B controls

Installation 3-1

1-15HP Size A and B Controls

(For

all 15H Inverter

Single Expansion Board Installation

Procedure:

Be sure drive operation is terminated and secured.

Remove all power sources from the control.

3. W

ait at least 5 minutes for internal capacitors to discharge.

Remove the four (4) Phillips head screws that secure the control cover.

Remove the control cover

Remove the #6 screw at position MH1 (upper left on the main circuit board. See Figure 3-1.

Install the long standoffs provided in the installation hardware as shown in Figure 3-1. (Be sure the Male/Female standof are Female/Female.)

Slide the expansion board male connector into the female connector of the control board.

Securely mount the expansion board to the standof installed in step 7 using #6 screws provided in the installation hardware. See Figure 3-2.

10.

The mechanical installation of the expansion board is now complete. Refer to Section 4 of this manual and configure the jumpers as desired. Also complete the wiring before you proceed to step 1

11.

When complete, install the control cover using the four (4) Phillips head screws.

12.

Restore all power sources to the control.

13.

Restore drive operation.

, 18H V

ector

, and 23H Servo).

f is at position MH1. The other three

3-2 Installation

Figure

Remove screw (Labeled MH1 in Main PCB Screen). Install Male/Female Standoff.

Install Female/Female Aluminum Standoff.

Install Female/Female Nylon Standoff.

3-1 Single Expansion Board Installation

Expansion Board

Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.

Figure

3-2 Single Expansion Board Installation

Main Control

Board

#6 Screw

Long

Aluminum or

Nylon Standoff

Group 1 or 2 Expansion Board

Female/Female shown. Use Male/Female in place of (MH1) screw Figure 3-1.

Main Circuit Board

Installation 3-3

1-15HP Size A and B Controls (Continued)

Dual

Expansion Board Installation

Procedure:

Be sure drive operation is terminated and secured.

Remove all power sources from the control.

3. W

10.

11.

12.

ait at least 5 minutes for internal capacitors to discharge.

Remove the four (4) Phillips head screws that secure the control cover.

Remove the control cover

Remove the #6 screw at position MH1 (upper left on the main circuit board. See Figure 3-1.

Install the long standoffs provided in the installation hardware as shown in Figure 3-1. (Be sure the Male/Female standof

f is at position MH1. The other three

are Female/Female.) Slide the Group 1 board male connector into the female

connector of the control board. See Figure 3-3. Securely mount the Group 1 expansion board to the

standof standof

fs installed in step 7 using the 4 short aluminum fs provided in the installation hardware. See Figure

3-3. The mechanical installation of the Group 1 expansion board

is now complete. Refer to the manual for the Group 1 board and configure the jumpers as desired. Also complete the wiring before you proceed to step 1

Install the Group 2 board on top of the previously installed Group 1 board by plugging the female connector onto the male connector of the Group 1 board as shown in Figure 3-3.

Secure this Group 2 board to the Group 1 board using the #6 screws provided.

3-4 Installation

1-15HP Size A and B Controls

Dual

Expansion Board Installation

13.

The mechanical installation of the first expansion board is now complete. Refer to the manual for the Group 2 board and configure any jumpers and switches as desired. Also complete the wiring for this board before you install the cover.

14.

When complete, install the control cover using the four (4) Phillips head screws.

15.

Restore all power sources to the control.

16.

Restore drive operation.

Figure 3-3 Dual Expansion Board Installation

#6 Screw

Short Aluminum Standoff

Long Aluminum or Nylon Standoff

(Continued)

Group 2 Expansion Board

Female Connector

Male Connector

Group 1 Expansion Board

Female/Female shown. Use Male/Female in place of (MH1) screw (Figure 3-1).

Main Circuit Board

Installation 3-5

15HP Size C and Larger AC Controls

(For

all 15H Inverter, 21H Line Regen Inverter

Line Regen V

ector and 23H Servo).

Single Expansion Board Installation

Procedure:

Be sure drive operation is terminated and secured.

Remove all power sources from the control.

3. W

10.

11.

ait at least 5 minutes for internal capacitors to discharge.

Remove the four (4) Phillips head screws (1/4 turn) that secure the control cover enclosures, open the enclosure door).

Remove the control cover Slide the expansion board male connector into the female

connector of the control board. See Figure Securely mount the expansion board to the sheet metal

mounting plate using the #6 screws provided in the installation hardware. See Figure 3-5.

The mechanical installation of the expansion board is now complete. Refer to Section 4 of this manual and configure the jumpers as desired. Also complete the wiring before you proceed to step 9.

When complete, install the control cover using the four (4) Phillips head screws (1/4 turn). (On floor mounted G size enclosures, close the enclosure door).

Restore all power sources to the control. Restore drive operation.

. (On floor mounted G size

, 18H V

3-4.

ector

, 22H

3-6 Installation

15HP Size C and Larger AC Controls

Single Expansion Board Installation (Continued)

Figure

3-4 Single Expansion Board Installation

Expansion Board Motor Control Board

Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.

Figure

3-5 Single Expansion Board Installation

#6 Screw

Group 1 or 2 Expansion Board

Sheet Metal Mounting Plate

Installation 3-7

15HP Size C and Larger AC Controls (Continued)

Dual

Expansion Board Installation

Procedure:

Be sure drive operation is terminated and secured.

Remove all power sources from the control.

3. W

10.

11.

ait at least 5 minutes for internal capacitors to discharge.

Remove the four (4) Phillips head screws (1/4 turn) that secure the control cover

. (On floor mounted G size

enclosures, open the enclosure door). Remove the control cover

Slide the Group 1 expansion board male connector into the female connector of the control board. See Figure 3-4.

Securely mount the Group 1 expansion board to the sheet metal mounting plate using the short standof

fs provided in

the installation hardware. See Figure 3-6. The mechanical installation of the expansion board is now

complete. Refer to the manual for the Group 1 board and configure the jumpers as desired. Also complete the wiring before you proceed to step 9.

Install the Group 2 board on top of the previously installed Group 1 board by plugging the female connector onto the male connector of the Group 1 board as shown in Figure 3-6.

Secure this Group 2 board to the Group 1 board using the #6 screws provided. See Figure 3-6.

The mechanical installation of the expansion board is now complete. Refer to the manual for the Group 2 board and configure any jumpers and switches as desired. Also complete the wiring for this board before you install the cover.

3-8 Installation

15HP Size C and Larger AC Controls

Dual

Expansion Board Installation

12.

When complete, install the control cover using the four (4) Phillips head screws (1/4 turn). (On floor mounted G size enclosures, close the enclosure door).

13.

Restore all power sources to the control.

14.

Restore drive operation.

Figure 3-6 Dual Expansion Board Installation

#6 Screw

Short Aluminum Standoff

(Continued)

Group 2 Expansion Board

Group 1 Expansion Board

Control Board Mounting Plate

Female Connector

Male Connector

Installation 3-9

SCR DC Controls

(For 19H and 20H SCR DC Controls).

Single

Expansion Board Installation

Procedure:

Be sure drive operation is terminated and secured.

Remove all power sources from the control.

3. W

ait at least 5 minutes for internal capacitors to discharge.

Slide the expansion board male connector into the female connector of the control board. See Figure 3-4.

Securely mount the expansion board to the sheet metal mounting plate using the #6 screws provided in the installation hardware. See Figure 3-5.

The mechanical installation of the expansion board is now complete. Refer to the Group 1 manual and configure the jumpers as desired. Also complete the wiring before you proceed to step 7.

Restore all power sources to the control. Restore drive operation.

3-10 Installation

SCR DC Controls (Continued)

Dual

Expansion Board Installation

Procedure:

Be sure drive operation is terminated and secured.

Remove all power sources from the control.

3. W

10.

11.

ait at least 5 minutes for internal capacitors to discharge.

Slide the Group 1 board male connector into the female connector of the control board. See Figure 3-4.

Securely mount the Group 1 expansion board to the sheet metal mounting plate using the short standof

fs provided in

the installation hardware. See Figure 3-6. The mechanical installation of the expansion board is now

complete. Refer to the Group 1 manual and configure the jumpers as desired. Also complete the wiring before you proceed to step 7.

Install the Group 2 board on top of the previously installed Group 1 board by plugging the female connector onto the male connector of the Group 1 board as shown in Figure 3-6.

Secure this Group 2 board to the Group 1 board using the #6 screws provided. See Figure 3-6.

Restore all power sources to the control. Restore drive operation.

Installation 3-11

3-12 Installation

Section 4 Hardware Setup

Important:

the Resolver to Digital expansion board is installed in a V control that has a feedback module installed, the feedback module must be removed to prevent interference with the expansion board. Figure 4-1 shows how to identify the feedback module on the DSP Main Control Board. The main control board is where the keypad plugs in.

Figure 4-1 Feedback Module Identification

Main Control Board

Feedback Module

ector

Setup 4-1

your V

ector control does not look like the one pictured in Figure

4-1, do not perform the feedback module removal procedure. Instead, continue onto page 4-3.

Feedback Module Removal Procedure

If your V

ector control looks like the one pictured in Figure 4-1,

perform the following procedure: The resolver feedback module must be removed from the main

control board to change the JP1 position. Use the following procedure.

Be sure drive operation is terminated and secured.

Remove all power sources from the control. W

ait at least 5

minutes for internal capacitors to discharge.

Remove the control cover

Use a grounded wrist strap connected to chassis ground.

Firmly grasp the Resolver Feedback Module and remove it

from its connectors on the main control board. Be careful not to bend the pins by twisting or lifting the module unevenly.

Place the Resolver Feedback Module in an antistatic bag and store it in a clean area for future use.

Install the control cover

Now there is no conflict between this module and the Resolver to Digital expansion board signal inputs to the control board. The Resolver to Digital expansion board will provide the input signals for the control board to use. Continue on page 4-3.

4-2 Setup

Connections

ARNING:

Procedure: (Refer to Figure 4-1 and FIgure 4-2.)

Connect the resolver SINE+ wire to J1 terminal 51 of the Resolver to Digital expansion board.

Connect the resolver SINE– wire to J1 terminal 52 of the Resolver to Digital expansion board.

Connect the resolver COS+ wire to J1 terminal 53 of the Resolver to Digital expansion board.

Connect the resolver COS– wire to J1 terminal 54 of the Resolver to Digital expansion board.

Connect the resolver REFERENCE+ wire to J1 terminal 55 of the Resolver to Digital expansion board.

6. Connect

the

Resolver to Digital expansion board.

7. Connect cable shields to J1 terminal 56 of the Resolver to

Digital expansion board. Shields are to be connected at the expansion

Refer to T resolution you require.

High voltage is present on the Resolver to Digital expansion board. 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. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

the resolver REFERENCE– wire to J1 terminal 56

board. (Shields not connected at the Resolver).

able 4-1 and set the DIP switches for the

Setup 4-3

Figure

4-1 Switch and T

erminal Locations

DIP Switch

OFF

All switches

shown in OFF

position.

1234

51 52 53 54 55 56

Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.

4-4 Setup

Side View

Figure

S1S3

= T

4-2 Resolver Connections

wisted Pair

Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.

Table

4-1 Switch Settings

51 SINE+ 52 SINE– 53 COS+ 54 COS– 55 REF+ 56 REF–

(Common/ Shield)

Digital Resolution

(Bits)

1 2 3 4 5

DIP Switch Number

10 ON ON OFF OFF ON 12 ON OFF OFF OFF ON 14 OFF ON OFF ON OFF 16 OFF OFF ON OFF OFF

Setup 4-5

4-6 Setup

Section 5 Software Setup

Configure Control Software

After

the Resolver to Digital Interface board has been installed and the DIP switches are correctly set, the control software must be configured.

Series 18H and 22H V

Note:

When the Resolver to Digital Interface board is installed, the encoder inputs to the control are automatically disabled (J1 pins 23 to 30).

The value of the Level 2, MOT parameter (P2509) must be set to the correct speed value.

Procedure:

At the keypad, access the Level 2 Blocks.

Scroll to and access the Motor Data Block.

Access the Resolver Speed parameter Change its’ value to the Resolver Speed T Example: For a 2 pole Resolver Example: For a 6 pole Resolver

Series 19H and 20H DC SCR Controls

The value of the Level 2, MOT parameter (P2507) and “Resolver Speed” parameter (P2509) must be set.

Procedure:

At the keypad, access the Level 2 Blocks.

Scroll to and access the Motor Data Block.

3. Access the Feedback T

Change its’ value to RESOL

Access the Resolver Speed parameter Change its’ value to the Resolver Speed T Example: For a 2 pole Resolver Example: For a 6 pole Resolver

ector Controls

OR DATA Block, “Resolver Speed”

, enter 1 (1 Speed). , enter 3 (3 Speed).

OR DATA Block, “Feedback T

ype parameter

VER.

, enter 1 (1 Speed). , enter 3 (3 Speed).

ype.

ype”

Software 5-1

5-2 Software

BALDOR ELECTRIC COMPANY

P.O. Box 2400

Fort Smith, AR 72902–2400

(501) 646–4711

Fax (501) 648–5792



Baldor Electric Company Printed in USA

MN1313

6/98 C&J2500

Baldor EXB009A01 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents