Thank you for purchasing the Series 5 Adjustable Frequency Drive. This drive is UL Listed for
US and Canada, CE and is RoHS Compliant.
The Series 5 Adjustable Frequency Drives provide variable speed control for standard 3-phase
1
AC induction motors from 2 thru 5 HP
. This manual covers models with single-phase and 3phase AC line input. The sine wave coded Pulse Width Modulated (PWM) output operates at a
carrier frequency of 16 kHz, which provides high motor efficiency and low noise. Adjustable
linear acceleration and deceleration are provided, making the drive suitable for soft-start applications.
Adjusting the drive for a specific application is accomplished with selectable jumpers and trimpots. However, for most applications no adjustments are necessary.
Main features include adjustable RMS Current Limit and I2t Motor Overload Protection*. In
addition, Adjustable Slip Compensation with Static Auto-Tune and Boost provides high torque
and excellent load regulation over a wide speed range. Power Start™ delivers over 200%
motor torque to ensure startup of high frictional loads. Electronic Inrush Current Limit (EICL™)
eliminates harmful AC line inrush current. The drive is suitable for machine or variable torque
(HVAC) applications.
A Signal Isolator (built-in on Catalog Nos. ID5401-CO, ID5402-CO, ID5403-CO, ID5405-CO
and optional on Catalog Nos. ID5202-CO, ID5203-CO) can be used for unidirectional or bidirectional speed control and accepts voltage and current signal input.
UL approved as an electronic overload protector for motors.
*
This product complies with all CE directives pertinent at the time of manufacture.
Contact your local Baldor District Office for Declaration of Conformity.
TABLE 1 – STANDARD FEATURES
FeatureDescription
Simple to OperateTrimpots and jumpers are factory set for most applications.
Industry Standard MountingThe drive has industry standard mounting dimensions.
Diagnostic LEDsPower on (PWR, IPWR*) and drive status (ST). *On models with ID5SI-1
Built-In Cooling FanStandard on Catalog Nos. ID5203-CO and ID5405-CO
Jumper Selections of Drive Output
Frequency
Finger-safe coverMeets IP-20 standard.
Increases the motor speed up to two times the rated RPM.
TABLE 2 – PERFORMANCE FEATURES
FeatureDescription
Power Start™
Slip Compensation with
Static Auto-Tune and Boost
Speed Range60:1
(1) See Section 8, paragraph 8.1 for recommendations on motor type.
Provides more than 200% starting torque which ensures startup of high
frictional loads.
Provides excellent load regulation over a wide speed range.
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TABLE 3 – PROTECTION FEATURES
FeatureDescription
rovides motor overload protection which prevents motor burnout and eliminates
otor Overload (I
M
2
) with RMS Current Limit
t
P
nuisance trips. UL approved as an electronic overload protector for motors.
Electronic Inrush Current Limit (EICL™)Eliminates harmful inrush AC line current during startup.
hort CircuitPrevents drive failure if a short circuit occurs at the motor (phase-to-phase).
S
liminates nuisance tripping due to high bus overvoltage caused by rapid deceleration
Regeneration
ndervoltage and OvervoltageShuts down the drive if the AC line input voltage is outside the operating range.
U
OV input transient suppressionPrevents failure of power devices caused by voltage spikes in the AC line.
M
E
f high inertial loads.
o
MicrocontrollerSelf Monitoring and Auto-Reboot.
TABLE 4 – TRIMPOT ADJUSTMENTS
Trimpot
Minimum Speed (MIN)
Sets the minimum motor speed.
Offset (OFFSET) Sets the minimum motor speed.
Maximum Speed (MAX)Sets the maximum motor speed.
Acceleration (ACC)Sets the motor acceleration time (time to reach full speed).
Deceleration (DEC/B)Sets the motor deceleration time (time to reach zero speed).
Slip Compensation (COMP)
Boost (DEC/B)
Maintains set motor speed under varying loads.
Sets the Volts/Hz Curve for 50 Hz motors to obtain maximum performance.
Current Limit (CL)Sets the current limit and limits the maximum current (torque) to the motor.
TABLE 5 – OPTIONAL ACCESSORY
AccessoryDescription
Signal Isolator and Run/Fault Relay
(Catalog No. ID5SI-1)
Provides isolation between a non-isolated signal voltage (0 to ±25 Volts DC)
or current source (4 – 20 mA DC) and the drive. Mounts on the end of the drive. This
option is built-in on Catalog Nos. ID5401-CO, ID5402-CO, ID5403-CO, ID5405-CO.
Operating Temperature Range (°C / °F)0 – 45 / 32 – 113—
Notes: 1. Catalog Nos. ID5202-CO, ID5203-CO: if a non-isolated signal is used, or if using 0 to ±25 Volts DC or 4 – 20 mA DC signal input,
install the ID5SI-1 Signal Isolator. Catalog Nos. ID5401-CO, ID5402-CO, ID5403-CO, ID5405-CO contain built-in signal isolation. 2. Allows the
motor to operate up to two times the rated RPM. Constant motor horsepower will result when operating the drive in the “X2” mode above the
motor rated frequency. 3. Dependent on motor performance. 4. Do not operate the drive outside the specified AC line input voltage operating
range. 5. Catalog Nos. ID5403-CO, ID5405-CO.
Factory
Setting
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SAFETY NOTICE
A Warning statement indicates a potentially hazardous situation which, if not avoided, could result
in injury or death.
A Caution statement indicates a potentially hazardous situation which, if not avoided, could result
in damage to property.
A Note indicates additional information that is not critical to the installation or operation.
WARNING! This equipment may contain voltages as high as 1000 volts! Electrical
shock can cause serious or fatal injury. Only qualified personnel should attempt the
start-up procedure or troubleshoot this equipment.
WARNING! Electrical shock can cause serious or fatal injury. Be sure that all power is
disconnected from drive before the finger-safe cover is removed. Removal of the
finger safe cover is required to make installation connections. Electrical shock can cause
serious or fatal injury if the finger-safe cover is removed and power is still applied.
WARNING! Electrical shock can cause serious or fatal injury. Verify there is no volt-
age phase-to-phase or phase-to-neutral at the AC Line Conductors before touching
the AC Input wires. Do not touch live wires, all power must be disconnected before proceeding.
WARNING! It is the responsibility of the equipment manufacturer and individual
installer to supply this Safety Warning to the ultimate end user of this product.
(SW/FSC 5/2005) Be sure to follow all instructions carefully. Fire and/or electrocution can result
due to improper use of this product.
WARNING! Do not use this drive in an explosive environment. An explosion can
cause serious or fatal injury. This drive is not explosion proof.
CAUTION!
Disconnect motor leads (U, V and W) from control before performing a “Leakage
Resistance” test on the motor. Failure to disconnect motor from the control may result in
extensive damage to the control. The control is tested at the factory for high voltage / leakage resistance as part of Underwriters Laboratories requirements.
CAUTION!
Suitable for use on a circuit capable of delivering not more than 5,000 RMS symmetrical
short circuit amperes listed here at rated voltage.
CAUTION!
Proper shielding, grounding, and filtering of this product can reduce the emission of radio
frequency interference (RFI) which may adversely affect sensitive electronic equipment.
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2 QUICK-START INSTRUCTIONS
This procedure will help get your system up and running quickly and allows motor and control
operation to be verified.
WARNING! Electrical shock can cause serious or fatal injury. Be sure that all
power is disconnected from drive before the finger-safe cover is removed.
Removal of the finger safe cover is required to make installation connections. Electrical
shock can cause serious or fatal injury if the finger-safe cover is removed and power is
still applied.
WARNING! Electrical shock can cause serious or fatal injury. Only qualified
personnel should attempt installation, start-up procedure or to troubleshoot
this equipment.
2.1 Mount the drive. For instructions, see Section 3, on page 14
Note: Do not connect this drive to a Ground-Fault Circuit-Interrupter (GFCI). The PWM
signal to the motor produces slightly more leakage than normal. This will cause GFCI to
trip. Filtering can reduce this leakage and GFCI trips.
2.2 Remove the finger-safe cover. For instructions, see Section 4, on page 14.
2.3 Connect AC power.
WARNING! Electrical shock can cause serious or fatal injury. Verify there
is no voltage phase-to-phase or phase-to-neutral at the AC Line
Conductors before touching the AC Input wires. Do not touch live wires, all power
must be disconnected before proceeding.
A main power disconnect installed between the AC power lines and the control is recommended. Each AC Line wire that is not at neutral or ground potential must be protected.
For the recommended fuse ratings, see Table 6, on page 5. Also see Section 5.1, on
pages 15 and 16.
Connect the AC line wires to the control.
1. Catalog No. ID5202-CO: Connect the single-phase AC line input to terminals
“L1” and “L2”, or 3-phase AC line input to terminals “L1”, “L2” and “L3”.
See Figure 1, on page 10.
potentiometer to Terminals “COM1” (low), “SIG1” (wiper), “+5V” (high).
The Main Speed Potentiometer can also be connected for bidirectional speed operation.
See Section 5.4, on pages 16 and 17.
2.7 Signal Following: An analog signal input can be used to control motor speed instead of
the Main Speed Potentiometer. The drive output will linearly follow the analog signal input.
A Signal Isolator (ID5SI-1) is built-in on Catalog Nos. ID5401-CO, ID5402-CO, ID5403CO, ID5405-CO and optional on Catalog Nos. ID5202-CO, ID5203-CO.
1. Catalog Nos. ID5202-CO, ID5203-CO: Connect the isolated* 0 – 5 Volt DC signal
input positive lead (+) to Terminal “P2” and the negative lead (–) to Terminal “P1”.
See Section 5.5, on pages 17 and 18.
*If a non-isolated signal is used, install the ID5SI-1 Signal Isolator. The ID5SI-1
accepts voltage (0 to ±25 Volts DC) or current (4 – 20 mA DC) signal inputs.
See Table 5, on page 5.
Note: For signal following operation, the Minimum Speed Trimpot (MIN) must be set
fully counterclockwise.
WARNING! The signal input must be isolated from the AC line. Earth
grounding signal wiring will damage the drive and void the warranty.
It is highly recommended that the ID5SI-1 Signal Isolator and Run/Fault Relay
be installed when using signal following.
2. Catalog Nos. ID5401-CO, ID5402-CO, ID5403-CO, ID5405-CO: Connect the volt-
age (0 to ±25 Volt DC) or current (4 – 20 mA DC) signal input to Terminals “SIG1” (+)
and “COM1” (–) of Terminal Block TB1 on the ID5SI-1. For voltage following, be sure
Jumper J1 (on the ID5SI-1) is set to the “VOLT” position (factory setting). For current
following, set Jumper J1 (on the ID5SI-1) to the “CUR” position. A jumper must be
installed between Terminals “0V” and “FWD”, of Terminal Block TB1, in order for the
drive to operate.
2.8 60 Hz & 50 Hz Motor Operation (Jumpers J1 & J2 On the Lower PC Board): The
drive is factory set for 60 Hz motor operation (Jumper J1 set to the “60Hz” position and
Jumper J2 set to the “X1” position). For 50 Hz motor operation, set Jumper J1 to the
“50Hz” position and be sure Jumper J2 is set to the “X1” position. See Section 6.1, on
page 21.
2.9 Trimpot Settings: All trimpots have been factory set for most applications, as shown in
Figure 5, on page 14. Some applications require adjustments of the trimpots in order to
tailor the drive for a specific requirement. See Section 7, on pages 22 – 25.