Baldor ID15J202-ER, ID15J101-ER, ID15J1F33-ER, ID15J1F75-ER, ID15J201F5-ER Installation And Operating Manual
...
Series 15J
Inverter Control
7/04 MN715J
Installation and Operating Manual
Table of Contents
MN715J Table of Contents i
Section 1
Quick Start 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Start Checklist 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-up Procedure 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
General Information 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CE Compliance 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Receiving and Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving & Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Remote Keypad Installation 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Installation 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Grounding 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Impedance 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Reactors 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Reactors 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Current Requirements 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Removal 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Identification 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Line Connections 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reduced Input Voltage Derating 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Disconnect 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Devices 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Phase Wire Size and Protection Devices 3-8. . . . . . . . . . . . . . . . . . .
3 Phase Installation 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115VAC 1 Phase Wire Size and Protection Devices 3-10. . . . . . . . . . . . . . . .
230VAC Single Phase Derating for Three Phase Controls 3-11. . . . . . . . . .
Motor Brake Connections 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Dynamic Brake Hardware 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inputs and Outputs 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Inputs 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Output 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Outputs 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Trip Input 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents MN715J
Selection of Operating Mode 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keypad Connection 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Run 3 Wire Connection 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Speed Connection 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Pump 2 Wire Connection 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Pump 3 Wire Connection 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process Control Connection 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Speed Analog 2 Wire Connection 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Speed Analog 3 Wire Connection 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EPOT 2 Wire Connection 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EPOT 3 Wire Connection 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Operation Checklist 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-up Procedure 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4
Programming and Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation Examples 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Control from the Keypad 4-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing the Keypad JOG Command 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Adjustment using Local Speed Reference 4-4. . . . . . . . . . . . . . . . . .
Speed Adjustment using Arrow Keys 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Mode 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Display Contrast 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Screens 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Log Access 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information Access 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Mode 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter Blocks Access for Programming 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Parameter Values 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Parameters to Factory Settings 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter Definitions 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter Block Definitions 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5
Troubleshooting 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Keypad Display - Display Contrast Adjustment 5-1. . . . . . . . . . . . . . . . . . . . . .
Wrong Language Selection 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information Access 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Access the Fault Log 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Clear the Fault Log 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Noise Considerations 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay and Contactor Coils 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wires between Controls and Motors 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Drive Situations 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Motor Considerations 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Signal Wires 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MN715J Table of Contents iii
Section 6
Specifications and Product Data 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications: 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Conditions: 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keypad Display: 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Specifications: 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Inputs: 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Output: 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Inputs: 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Outputs: 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Indications: 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Tightening Torque Specifications 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Dimensions 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A
Dynamic Brake Hardware A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B
Parameter Values B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix C
Remote Keypad Mounting Template C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv Table of Contents MN715J
Section 1
Quick Start
MN715J Quick Start 1-1
Overview
If you are an experienced user of Baldor controls, you are probably already
familiar with the keypad programming and keypad operation methods. If so,
this quick start guide has been prepared for you. This procedure will help get
your system up and running in the keypad mode quickly and will allow motor
and control operation to be verified. It assumes that the Control and Motor
are correctly installed (see Section 3 for procedures) and that you have an
understanding of the keypad programming & operation. It is not necessary to
wire the terminal strip to operate in the Keypad mode (Section 3 describes
how to wire the terminal strip).
The quick start procedure is as follows:
1. Read the Safety Notice and Precautions in section 2 of this manual.
2. Mount the control. Refer to Section 3, “Physical Installation” procedure.
3. Connect AC power. Refer to Section 3, “AC Line Connections”.
4. Connect the motor. Refer to Section 3, “AC Line Connections”.
Quick Start Checklist Check of electrical items.
1. Verify that the AC line voltage at the source matches the control rating.
2. Inspect all power connections for accuracy, workmanship and tightness
as well as compliance to codes.
3. Verify that the control and motor are grounded to each other and the
control is connected to earth ground.
4. Check all signal wiring for accuracy.
5. Be certain all brake coils, contactors and relay coils have noise
suppression. This should be an R-C filter for AC coils and reverse
polarity diodes for DC coils. MOV type transient suppression is not
adequate.
Check of Motors and Couplings
1. Verify freedom of motion of motor shaft.
2. Verify that all motor couplings are tight without backlash.
3. If holding brakes are used, verify they are properly adjusted to fully
release and set to the desired torque value.
1-2 Quick Start MN715J
WARNING: Make sure that unexpected operation of the motor shaft during start
up will not cause injury to personnel or damage to equipment.
Power-up Procedure
1. Turn power on. Be sure no faults are displayed on the keypad display.
2. Set the Level 1 Input block, Operating Mode to “Keypad”.
3. Set the Level 2 Output Limits block, “MIN Output FREQ” parameter.
4. Set the Level 2 Output Limits block, “MAX Output FREQ” parameter.
5. If the desired peak current limit setting is not correct, set the Level 2
Output Limits block, “PK Current Limit” parameter as desired.
6. Enter the following motor data in the Level 2 Motor Data block
parameters:
Motor Rated Amps (FLA)
Motor Rated Speed (base speed)
Motor Rated Frequency (Nameplate)
7. If External Dynamic Brake hardware is used, set the Level 2 Brake
Adjust block parameters as desired.
8. Set the Level 1 V/HZ Boost block, “V/HZ Profile” parameter for the
correct V/Hz ratio for your application.
9. If the load is a high initial starting torque type, the torque boost and accel
time may need to be increased. Set the Level 1 V/HZ Boost block,
“Torque Boost” and the Level 1 Accel/Decel Rate block, “Accel Time #1”
as required.
10. Select and program additional parameters to suit your application.
The control is now ready for use in keypad mode. The terminal strip wiring
may be changed and different parameter values used for another operating
mode.
Section 2
General Information
MN715J General Information 2-1
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.
Overview
The Baldor Series 15J control is a PWM inverter motor control. The control
operates by converting AC line power into fixed DC power. The DC power is
then pulse width modulated into synthesized three-phase AC line voltage for
the motor. In this way, the control converts the fixed input frequency to
variable output frequency to cause the motor to have variable speed
operation.
The rated horsepower of the control is based on a NEMA design B four pole
motor and 60Hz operation at nominal rated input voltage. If any other type of
motor is used, or input voltage other than 230 or 460 VAC is applied to the
input terminals, the control should be sized to the motor using the rated output
current of the control.
The Baldor Series 15J control may be used in many different applications. It
can be programmed to operate in a number of operating modes, PWM rates
and output current levels for custom operation.
It is the responsibility of the user to determine the optimum operating mode for
the application. These choices are programmed using the keypad as
explained in the programming section 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.
2-2 General Information MN715J
Safety Notice:
This equipment contains voltages that may be as great as 1000 volts!
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.
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. Only qualified personnel
should attempt the start–up procedure or troubleshoot this
equipment.
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. Only
qualified personnel should attempt the start–up procedure or
troubleshoot this equipment.
WARNING: Do not use motor overload relays with an automatic reset feature.
These are dangerous since the process may injure someone if a
sudden or unexpected automatic restart occurs. If manual reset
relays are not available, disable the automatic restart feature using
external control wiring.
WARNING: This unit has an automatic restart feature that will start the motor
whenever input power is applied and a RUN (FWD or REV) command
is issued and maintained. If an automatic restart of the motor could
cause injury to personnel, the automatic restart feature should be
disabled by changing the “Restart Auto/Man” parameter to
MANUAL.
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.
Continued on next page.
MN715J General Information 2-3
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: Dynamic brake resistors may generate enough heat to ignite
combustible materials. Keep all combustible materials and
flammable vapors away from brake resistors.
Caution: Suitable for use on a circuit capable of delivering not more than
5,000 RMS symmetrical amperes, at rated voltage.
Caution: Do not supply any power on the External Trip (motor thermostat)
leads at J4-17 or J4-18 as the control may be damaged. Use a dry
contact type that requires no external power to operate.
Caution: Disconnect motor leads (T1, T2 and T3) from control before you
perform a “Megger” test on the motor. Failure to disconnect motor
from the control will result in extensive damage to the control. The
control is tested at the factory for high voltage / leakage resistance
as part of Underwriters Laboratories Inc. requirements.
Caution: Do not connect AC power to the motor terminals T1, T2 and T3.
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. Instead, we recommend
using a four wire Wye.
2-4 General Information MN715J
Section 3
Receiving and Installation
MN715J Receiving and Installation 3-1
Receiving & Inspection
The Series 15J Inverter Control is 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. Verify that the control you received is the same as listed on your
purchase order.
3. 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 specifications.
(Refer to Section 6 of this manual).
Physical Installation
The mounting location of the 15J is important. It should be installed in an area
that is protected from direct sunlight, corrosives, harmful gases or liquids,
dust, metallic particles, and vibration. Exposure to these elements 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. Table 3-1 lists the Watts
Loss ratings for enclosure sizing.
2. At least two inches clearance must be provided on all sides for airflow.
3. Front access must be provided to allow the control cover to be opened
or removed for service and to allow viewing of the Keypad Display.
4. Altitude derating. Up to 3300 feet (1000 meters), no derating required.
Above 3300 feet, derate output current by 2% for each 1000 feet above
3300 feet.
5. Temperature derating. Up to 40°C, no derating required. Above 40°C,
derate output current by 2% per °C above 40°C.
Maximum ambient is 55°C.
Table 3-1 Series 15J Watts Loss Ratings
115VAC 230VAC 460VAC
2.5kHz
PWM
7.5kHz
PWM
2.5kHz
PWM
7.5kHz
PWM
2.5kHz
PWM
7.5kHz
PWM
17 Watts/
Amp
20 Watts/
Amp
17 Watts/
Amp
20 Watts/
Amp
19 Watts/
Amp
28 Watts/
Amp
Control Installation
The control must be securely fastened to the mounting surface. Use the four
(4) mounting holes to fasten the control to the mounting surface or enclosure.
Shock Mounting
If the control will be subjected to levels of shock greater than 1G or vibration
greater than 0.5G at 10 to 60Hz, the control should be shock mounted.
Excessive vibration within the control could cause internal connections to
loosen and cause component failure or electrical shock hazard.
3-2 Receiving and Installation MN715J
Optional Remote Keypad Installation
Note: Requires phone jack connector on the control board. Some models may not
have a phone jack installed. If the phone jack is not installed and you wish to
connect a remote keypad, contact Baldor.
A separate keypad may be remotely mounted using an optional Baldor
keypad extension cable (in addition to the keypad within the control). Keypad
assembly (CBLSM015KP - 5 ft, CBLSM046KP - 15 ft or CBLSM091KP - 30 ft)
comes complete with the extension cable and gasket required to mount it to
an enclosure. When the keypad is properly mounted to a NEMA Type 4X
indoor enclosure, it retains the Type 4X indoor rating.
Tools Required:
• Center punch, tap handle, screwdrivers (Phillips and straight) and
crescent wrench.
• 8-32 tap and #29 drill bit (for tapped mounting holes) or #19 drill
(for clearance mounting holes).
• 1-
1
/4″ standard knockout punch (1-11/16″ nominal diameter).
• RTV sealant.
• (4) 8-32 nuts and lock washers.
• Extended 8-32 screws (socket fillister) are required if the mounting
surface is thicker than 12 gauge and is not tapped (clearance mounting
holes).
• Remote keypad mounting template. A tear out copy is provided at the
end of this manual for your convenience. (Photo copy or tear out.)
Mounting Instruction: For tapped mounting holes
1. Locate a flat 4″ wide x 5.5″ minimum height mounting surface. Material
should have sufficient thickness (14 gauge minimum).
2. Place the template on the mounting surface or mark the holes as shown.
3. Accurately center punch the 4 mounting holes (marked A) and the large
knockout (marked B).
4. Drill four #29 mounting holes (A). Thread each hole using an 8-32 tap.
5. Locate the 1-
1
/4″ knockout center (B) and punch using the manufacturers
instructions.
6. Debur knockout and mounting holes making sure the panel stays clean
and flat.
7. Apply RTV to the 4 holes marked (A).
8. Assemble the keypad to the panel. Use 8-32 screws, nuts and lock
washers.
9. From the inside of the panel, apply RTV over each of the four mounting
screws and nuts. Cover a
3
/4″ area around each screw while making
sure to completely encapsulate the nut and washer.
MN715J Receiving and Installation 3-3
Mounting Instructions: For clearance mounting holes
1. Locate a flat 4″ wide x 5.5″ minimum high mounting surface. Material
should have sufficient thickness (14 gauge minimum).
2. Place the template on the mounting surface or mark the holes as shown
on the template.
3. Accurately center punch the 4 mounting holes (marked A) and the large
knockout (marked B).
4. Drill four #19 clearance holes (A).
5. Locate the 1-
1
/4″ knockout center (B) and punch using the manufacturers
instructions.
6. Debur knockout and mounting holes making sure the panel stays clean
and flat.
7. Apply RTV to the 4 holes marked (A).
8. Assemble the keypad to the panel. Use 8-32 screws, nuts and lock
washers.
9. From the inside of the panel, apply RTV over each of the four mounting
screws and nuts. Cover a
3
/4″ area around each screw while making
sure to completely encapsulate the nut and washer.
Electrical Installation
Interconnection wiring is required between the motor control, AC power
source, motor, host control and any operator interface stations. Use listed
closed loop connectors that are of appropriate size for the 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 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.
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 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.
S 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 should be connected between the
power factor correction capacitors and the control.
3-4 Receiving and Installation MN715J
S 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 should
be installed between the AC line reactor or an isolation transformer and
the AC input to the control.
Line Impedance
The Baldor Series 15J control requires a minimum line impedance of 1%. The
input impedance of the power lines can be determined as follows:
Measure the line to line voltage at no load and at full rated load. Use
these measured values to calculate impedance as follows:
%Impedance +
(Volts
NoLoad
* Volts
FullLoad
)
(Volts
NoLoad
)
100
Line Reactors
3 phase line reactors are available from Baldor. The size of the line reactor to
use is based on the maximum continuous load. If providing your own line
reactor, use the following formula to calculate the minimum inductance
required. Table 3-3 lists the input current required for this calculation.
L +
(V
L*L
0.01)
(I 3Ǹ 377)
Where: L Minimum inductance in henrys.
V
L-L
Input volts measured line to line.
0.01 Desired percentage of input impedance (1% shown).
I Input current rating of control.
377 Constant used with 60Hz power.
Use 314 with 50Hz power.
Table 3-2 Recommended Line Reactors
230VAC, 60Hz, 3% Impendance 460VAC, 60Hz, 3% Impendance
Catalog No. HP Amps Inductance
(mH)
Catalog No. HP Amps Inductacne
(mH)
LRAC00401 1 4 3 LRAC00202 1 2 12
LRAC00801 1.5 8 1.15 LRAC00202 1.5 2 12
LRAC00801 2 8 1.15 LRAC00402 2 4 6.5
LRAC01201 3 12 1.25 LRAC00402 3 4 6.5
LRAC01801 5 18 0.8 LRAC00802 5 8 3.0
LRAC3501 7.5 25 0.5 LRAC01202 7.5 12 2.5
LRAC01802 10 18 1.5
Load Reactors
Line reactors may be used at the control output to the motor. When used this
way, they are called Load Reactors. Load Reactors serve several functions.
S Protect the control from a short circuit at the motor.
S Limit the rate of rise of motor surge currents.
S Slow the rate of change of power the control delivers to the motor.
Load reactors should be installed as close to the control as possible.
MN715J Receiving and Installation 3-5
Figure 3-1 Recommended System Grounding
L1
AC Main Supply
Safety
Ground
Driven earth ground
rod (plant ground)
Four Wire
“Wye”
L1
L2
L3
Earth
L2L3 T1 T3
Line
Reactor
Load
Reactor
Route all 4 wires L1, L2, L3 and Earth
(ground) together in conduit or cable.
Route all 4 wires T1, T2, T3 and motor ground
together in conduit or shielded cable.
Connect all wires (including
motor ground) inside the
motor terminal box.
Ground per NEC and Local codes.
Note: A line reactor is recommended
and must be ordered separately.
Note: A load reactor is
recommended and must
be ordered separately.
Baldor Control
T2
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.
3-6 Receiving and Installation MN715J
Input Current Requirements
Table 3-3 Input Current Requirements for Stock Products
115VAC - 1f 230VAC - 3f 460VAC - 3f
Catalog
Numbers
Input
Amps
Catalog
Numbers
Input
Amps
Catalog
Numbers
Input
Amps
ID15J1F33-ER 3.5 ID15J201-ER 5.0 ID15J401-ER 2.5
ID15J1F50-ER 5.0 ID15J201F5-ER 7.0 ID15J401F5-ER 3.5
ID15J1F75-ER 7.5 ID15J202-ER 8.0 ID15J402-ER 4.0
ID15J101-ER 10.0 ID15J203-ER 11.0 ID15J403-ER 5.5
ID15J205-ER 15.0 ID15J405-ER 9.0
ID15J407-ER 10.0
ID15J410V-ER 13.0
Cover Removal
The cover is made of plastic and could be damaged during removal if handled
roughly. Refer to Figure 3-2. Insert a screwdriver or small blade tool and pry
cover outward as shown to release the side.
When both sides are released, remove the cover.
Figure 3-2 Cover Removal
Use small screwdriver or suitable
tool to pry cover slightly outward
to release cover from catch.
Use small screwdriver or suitable
tool to pry cover slightly outward
to release cover from catch.
MN715J Receiving and Installation 3-7
Terminal Identification
The terminals for signal, AC power and motor connections are shown in
Figure 3-3. Separate ground connections are provided for power and
motor grounds.
Figure 3-3 Terminal Identification
J4 Control Terminal Strip
J5 Power Terminal Strip
Power
GND
Motor
GND
L1 L2 L3 T1 T2 T3BĆR2
R1/
B+
120
Shown with cover removed.
Note: J5 is accessible with the cover on.
Keypad may be plugged in or removed
while control is ON. If remote keypad is
plugged into J5, the main keypad is
automatically disabled.
J5 Connector for Optional Remote Keypad
AC Line Connections
Be sure all power to the control is disconnected before proceeding. If power
has been applied to the control, wait at least 5 minutes after power disconnect
for residual voltage across the bus capacitors to discharge.
Reduced Input Voltage Derating
All power ratings stated in Section 6 are for the nominal AC input voltages
(115, 230, or 460). The power rating of the control must be reduced when
operating at a reduced input voltage. The amount of reduction is the ratio of
the voltage change.
Examples:
A 5hp, 230VAC control operating at 208VAC has a reduced power rating of
4.52hp.
5HP
208VAC
230VAC
+ 4.52hp
Likewise, a 5hp, 460VAC control operating at 380VAC has a reduced power
rating of 4.13hp.
5HP
380VAC
460VAC
+ 4.13hp
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 discharged.
3-8 Receiving and Installation MN715J
Protective Devices
Recommended fuse sizes are based on the following:
115% of maximum continuous current for time delay.
150% of maximum continuous current for Fast or Very Fast action.
Note: These general size recommendations do not consider harmonic currents or
ambient temperatures greater than 40°C.
Be sure a suitable input power protection device is installed. Use the
recommended fuses listed in Tables 3-4 and 3-5. Input and output wire size is
based on the use of copper conductor wire rated at 75°C. The table is
specified for NEMA B motors.
Fast Action Fuses: 230VAC, Buss KTN
460VAC, Buss KTS
Very Fast Action: 230VAC, Buss JJN
460VAC, Buss JJS
Time Delay Fuses: 230VAC, Buss FRN
460VAC, Buss FRS
Three Phase Wire Size and Protection Devices
Table 3-4 Three Phase Wire Size and Protection Devices 230VAC Controls
Control Power
I
nput Fuse
Wire G
auge
Control Power
Output Rating
Fast Acting Time Delay AWG mm
2
1 6 5 14 2.08
1.5 8 7 14 2.08
2 12 9 14 2.08
3 15 12 14 2.08
5 25 20 12 3.31
Table 3-5 Three Phase Wire Size and Protection Devices 460VAC Controls
Control Power
I
nput Fuse
Wire G
auge
Control Power
Output Rating
Fast Acting Time Delay AWG mm
2
1 3 2.5 14 2.08
1.5 4 3.5 14 2.08
2 5 4.5 14 2.08
3 8 6.3 14 2.08
5 12 10 14 2.08
7.5 17.5 15 14 2.08
10 20 17.5 12 3.31
Note: All wire sizes are based on 75°C copper wire, 1% line impedance. Higher
temperature, smaller gauge wire may be used per NEC and local codes.
Recommended fuses are based on 40°C ambient, maximum continuous
control output current and no harmonic current.
MN715J Receiving and Installation 3-9
3 Phase Installation
The AC power and motor connections are shown in Figure 3-4. The 15J
control has electronic I
2
t motor overload protection. If motor overloads are
desired, they should be sized according to the manufacturers specifications
and installed between the motor and the T1, T2 and T3 terminals of the
control. Refer to Figure 3-3 for terminal locations.
Figure 3-4 3 Phase AC Power and Motor Connections
L1 L2 L3
L1 L2 L3
Earth
* AC Motor
Note 2
Note 3
Baldor
Series 15J
Control
*Optional
Line
Reactor
Note 1
Note 3
Note 3
A1 B1 C1
A2 B2 C2
T1 T2 T3
Note 4
T1
T2 T3
G
Notes:
1. See Protection Devices described in this section.
2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.
3. Metal conduit should be used. Connect conduits so the use of a reactor or RC device
does not interrupt EMI/RFI shielding.
4. See Line/Load Reactors described previously in this section.
* Optional components not
provided with 15J Control.
*Optional
Fusing
3-10 Receiving and Installation MN715J
115VAC 1 Phase Wire Size and Protection Devices
Table 3-6 Wire Size and Protection Devices - 1 phase
I
nput Fuse
Wire G
auge
C
ontro
l O
utput
Rating HP
Fast Acting
Amps
Time Delay
Amps
AWG mm
2
0.33 10 10 14 2.08
0.5 10 10 14 2.08
0.75 15 10 14 2.08
1.0 20 15 14 2.08
Note: All wire sizes are based on 75°C copper wire, 1% line impedance. Higher
temperature, smaller gauge wire may be used per NEC and local codes.
Recommended fuses are based on 40°C ambient, maximum continuous
control output current and no harmonic current.
Figure 3-5 Single Phase AC Power and Motor Connections
L1 N
Earth
* AC Motor is not provided with control.
Baldor Series 15J Control
Metal conduit should be used to shield
output wires (from T1, T2, T3 of control to
T1, T2, T3 of motor).
T1 T2 T3
T1
T2 T3
G
Shield wires inside
a metal conduit.
Motor wire should be sized using the 3
phase information in Table 3Ć4.
* Optional components not
provided with 15J Control.
L1 L2 L3
*Optional
Fusing
MN715J Receiving and Installation 3-11
230VAC Single Phase Derating for Three Phase Controls
Single phase AC input power can be used to power a three phase control.
However, the continuous and peak current ratings of the control must be
reduced by 35% (derated).
I
nput Fuse
Wire G
auge
C
ontro
l O
utput
Rating HP
Fast Acting
Amps
Time Delay
Amps
AWG mm
2
0.75 10 9 14 2.08
1 12 10 14 2.08
1.5 15 15 14 2.08
2 20 17.5 14 2.08
3 25 25 12 3.31
Note: All wire sizes are based on 75°C copper wire, 1% line impedance. Higher
temperature, smaller gauge wire may be used per NEC and local codes.
Recommended fuses are based on 40°C ambient, maximum continuous
control output current and no harmonic current.
Figure 3-6 Single Phase 230VAC Power and Motor Connections
L1 L2
L1 L2 L3
Earth
* AC Motor is not provided with control.
Baldor Series 15J Control
Metal conduit should be used to
shield output wires (from T1, T2, T3
of control to T1, T2, T3 of motor).
T1 T2 T3
T1
T2 T3
G
Shield wires inside
a metal conduit.
Motor wire should be sized using the
3 phase information in Table 3Ć4.
* Optional components not
provided with 15J Control.
*Optional
Fusing
3-12 Receiving and Installation MN715J
Motor Brake Connections
For motors with spring set brakes, connect the brake power leads and the
motor power leads separately. Because the inverter has variable voltage
output to the motor, the inverter may not supply enough power at low
frequencies for proper brake operation. If using a motor with an internally
connected brake, the brake power leads must be connected to a separate
power source for proper brake operation.
Optional Dynamic Brake Hardware
Dynamic Brake (DB) Hardware must be installed on a flat, non-flammable,
vertical surface for effective cooling and operation. See Figure 3-7 for
terminal identification.
See Appendix A of this manual for additional information.
Note: Although not shown, metal conduit should be used to shield all power wires
and motor leads.
Figure 3-7 Wiring for RGA Assembly
See recommended Terminal
Tightening Torques in Section 6.
* Optional Customer Supplied
Fuse Protection Ć
Subject to Local Codes
50/60 Hz
3 Phase
Power
Motor GND
BĆ
R1/B+
T3
T2
T1
L3
L2
L1
Power GND
GND
T1
T2
T3
* Optional
Dynamic Brake
Resistor
J5 Power Terminal Strip
DB
Terminals
R1
R2
R2
* Motor
Optional hardware. Must
be ordered separately.
MN715J Receiving and Installation 3-13
Inputs and Outputs (Refer to Figure 3-8).
Analog Inputs
Two analog inputs are available: analog input #1 (J4-5 and J4-4) and analog
input #2 (J4-7 and J4-8) as shown. Either analog input #1 or #2 may be
grounded provided the common mode range is not exceeded. Either analog
input may be selected in the Level 1 INPUT block, ANA CMD Select
parameter value. Analog input #1 is selected if parameter value
“Potentiometer” is selected. Analog input #2 is selected if parameter value
“0-10Volts, 0-5 Volts, 4-20mA or 0-20mA” is selected.
Figure 3-8 Analog Inputs and Outputs
8
9
10
Analog Input 2Ć
Analog Output 1Ć
J4
N.O.
Relay Common
N.C.
Analog Ground
Analog Input 1
Pot Reference
Analog Input 2+
Analog Output 1+
1
2
3
4
5
6
7
5kΩ
Command Pot
Programmable Relay Outputs
0Ć5VDC, 0Ć10VDC,
4Ć20mA or 0Ć20mA
0Ć5VDC, 0Ć10VDC,
4Ć20mA or 0Ć20mA
See recommended Terminal
Tightening Torques in Section 6.
Analog Input #1
The single ended analog input #1 can be used when the controller is set to
Standard Run, 7 Speed, Fan Pump 2 Wire, Fan Pump 3 Wire, Process
Control, 3 SPD ANA 2Wire, 3 SPD ANA 3Wire, EPOT 2Wire or EPOT 3Wire
(not Keypad).
The single ended analog input #1 can be used as a Speed command (Level 1
Input block, ANA CMD Select=Potentiometer).
Note: A potentiometer value of 5kW to 10kW, 0.5 watt may be used.
1. Connect the wires from the 5KW pot at the J4 terminal strip. One end of
the pot is connected to J4-4 (analog ground) and the other end is
connected to J4-6 (reference voltage).
2. Connect the wiper of the pot to J4-5. The voltage across terminals J4-4
and J4-5 is the speed command input.
Analog Input #2
Analog input #2 accepts a differential command 0-5VDC, 0-10VDC, 4-20 mA
or 0-20 mA. The (Differential) command mode is defined in the Level 1 Input
block ANA CMD Select parameter.
Note: Analog Input #2 can be used with Standard Run, 7 Speed, Fan Pump 2 Wire,
Fan Pump 3 Wire, Process Control, 3 SPD ANA 2Wire or 3 SPD ANA 3Wire,
EPOT 2Wire or EPOT 3Wire (not Keypad).
1. Connect the Analog Input + wire to J4-7 and the - wire to J4-8.
2. If using a 0-20 mA or 4-20 mA command signal, “Level 1 Input block,
ANA CMD Select” parameter should be set to 0-20 mA or 4-20 mA.
3-14 Receiving and Installation MN715J
Analog Output
One programmable analog output is provided at J4-10 and J4-9. The output
is scaled 0 - 5 VDC, 0 - 10 VDC, 4-20mA or 0-20mA. The output function is
programmed in the Level 1 Output block, Analog Out parameter value. The
scaling of the output is programmed in the Level 1 Output block, Analog
Scale.
Relay Outputs
One normally open (N.O.) and one normally closed (N.C.) relay contact is
available at terminals J4-1, J4-2 and J4-3. J4-2 is relay common. The output
is programmable in the Level 1 Output block, Relay Output parameter.
1. Connect the N.O. contact to another circuit by attaching the wires to J4-1
and J4-2.
2. Connect the N.C. contact to another circuit by attaching the wires to J4-3
and J4-2.
External Trip Input
Terminal J4-17 is available for connection to a normally closed thermostat or
overload relay in some operating modes as shown in Figure 3-9. The
thermostat or overload relay should be a dry contact type with no power
available from the contact. If the motor thermostat or overload relay activates,
the control will automatically shut down and give an external trip fault.
The optional relay (CR1) shown provides the isolation required. The N.O.
contact is closed when power is applied to the relay and the motor is cold.
Connect the external trip input wires to J4-17 and J4-18. Do not place these
wires in the same conduit as the motor power leads.
To activate the external trip input, the external trip parameter in the Level 2
Protection Block must be set to “ON”.
Figure 3-9 External Trip Input Connection
T1 T2 T3
T1
T2
T3
G
* Motor
17
18
J4
Do not run these wires in
same conduit as motor leads
or AC power wiring.
Customer supplied
source voltage
Motor Thermostat Leads
CR1
*
*
Optional hardware. Must be ordered separately.
See recommended terminal tightening torque in section 6.
Note: Add appropriately rated protective device
for AC relay (snubber) or DC relay (diode).
External or remote motor overload
protection may be required by National
Electrical Code or equivalent
MN715J Receiving and Installation 3-15
Selection of Operating Mode (and Connection Diagram)
Several operating modes are available that define the basic motor control
setup and the operation of the input and output terminals. These operating
modes are selected by programming the Operating Mode parameter in the
Level 1 Input programming Block. Available operating modes include:
• Keypad
• Standard Run, 3 Wire
• 7 Speed
• Fan Pump 2 Wire
• Fan Pump 3 Wire
• Process Control
• 3 Speed Analog 2 Wire
• 3 Speed Analog 3 Wire
• Electronic Potentiometer 2 Wire
• Electronic Potentiometer 3 Wire
Each mode requires connections to the J4 terminal strip (except that all J4
connections are optional in the keypad mode).
Note: J4-19 and J4-20 are not to be used. These terminals are reserved for
manufacturing use only.
3-16 Receiving and Installation MN715J
Keypad Connection
The Keypad operating mode allows the control to be operated from the
keypad. In this mode, no control connection wiring is required. However, the
Stop, Accel/Decel select and External Trip inputs may optionally be used. All
other digital inputs are inactive. The analog output and relay outputs remain
active at all times.
For operation in Keypad mode, set the Level 1 Input block, Operating Mode
parameter to Keypad.
To use the Stop input, J4-13 must be connected and the Level 1 Keypad
Setup block, LOC. Hot Start parameter must be set to ON. The Stop line is
normally closed. When opened, the motor will COAST or REGEN to a stop
depending upon the setting of Level 1 Keypad Setup block Keypad Stop Key
parameter value. Closing the input will immediately start the motor if a run
command was given before the stop line was opened.
The Accel/Decel select input is used to select ACC / DEC / S-CURVE group 1
or group 2. This connection is made at J4-14.
The External Trip input is used to cause a fault condition during a motor
over-temperature condition. The External Trip input (J4-17) must be
connected and the External Trip parameter in the Level 2 Protection block
must be set to ON. When J4-17 is opened, the motor will coast to a stop and
an External Trip fault will be displayed on the keypad display.
Figure 3-10 Keypad Connection Diagram
11
12
13
14
15
16
17
18
Accel/Decel Select
External Trip
J4
Input Common
Refer to Figure 3Ć9.
See recommended terminal
tightening torques in Section 6.
Stop
Keypad Only Connection
J4-13 If J4-13 is connected, you must set Level 1 Keypad Setup block, LOC. Hot Start
parameter to “ON” to activate the opto input.
CLOSED allows normal control operation.
OPEN disables the control and the motor will coast or brake to a stop. The motor
will restart when J4-13 closes after open.
J4-14 OPEN selects ACC / DEC / S-CURVE group 1.
CLOSED selects group 2.
J4-17 If J4-17 is connected, you must set Level 2 Protection block, External Trip to
“ON” to activate the opto input.
OPEN causes an external trip fault. The control will disable and the motor
coasts to a stop. An external trip fault is displayed (also logged in the fault log).
CLOSED allows normal operation.
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