Baldor mn722 User Manual

SERIES 22H

Line Regen

AC Flux Vector Control

Installation & Operating Manual

8/03 MN722

Section 1

Quick Start Guide 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Start Checklist 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Start Procedure 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2

General Information 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limited W arranty 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notice 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3

Receiving & Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving & Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Physical Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Installation 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Through the Wall Mounting 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Remote Keypad Installation 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Installation 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Reactors 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Grounding 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection Devices 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Fuses 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Size and Protection Devices 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Phase Input Power Connections 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware Changes for Reduced Voltage Input 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Connections 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M-Contactor 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Encoder Installation 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Buffered Encoder Output 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Home (Orient) Switch Input 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Board Jumpers 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Inputs 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Outputs 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Continued on next page.

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Control Circuit Connections 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converting Control Board Connections 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inverter Control Board Connections 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial Mode 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Mode Connections 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Run 3 Wire Mode Connections 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 Speed 2-Wire Mode Connections 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Speed Analog 2 Wire Operating Mode 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Speed Analog 3 Wire Operating Mode 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bipolar Speed and Torque Mode Connections 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multiple Parameter Sets 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process Mode Connections 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Pot 2 Wire Operating Mode 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Pot 3 Wire Control Mode 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Trip Input 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opto-Isolated Inputs 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opto-Isolated Outputs 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Operation Checklist 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power-Up Procedure 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4

Programming and Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Baldor Keypad 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Mode 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Display Contrast 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Mode Screens 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Screens & Diagnostic Information Access 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Log Access 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Mode 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Blocks Access for Programming 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Parameter Values when Security Code Not Used 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reset Parameters to Factory Settings 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initialize New Firmware 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Definitions 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converter Control Board Parameters 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inverter Control Board Parameters 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Continued on next page.

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Section 5

Troubleshooting 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No Keypad Display - Display Contrast Adjustment 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When a Fault is Displayed 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Access the Fault Log 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Clear the Fault Log 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Access Diagnostic Information 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Noise Considerations 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Drive Situations 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Enclosures 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Motor Considerations 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6

Manual Tuning the Series 22H Control 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manually Tuning the Control 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Mag Amps Parameter 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slip Frequency Parameter 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Prop Gain Parameter 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Int Gain Parameter 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Prop Gain Parameter 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Int Gain Parameter 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PI Controller 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Continued on next page.

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Section 7

Specifications, Ratings & Dimensions 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Conditions 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Display 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Specifications 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Analog Input 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Outputs 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Inputs 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Outputs 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Indications 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Series 22H Vector Control Ratings 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminal Tightening Torque Specifications 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size C+ Control 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size D+ Control 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size D Control 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size E Control 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size E Control – Through–Wall Mounting 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size F Control 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size F Control – Through–Wall Mounting 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size G+ Control 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size H Control 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EK Controls - Filter Assembly 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EK Controls - Boost Regulators 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converter Section Parameter Values A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Output Section Parameter Values A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Keypad Mounting Template B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv Table of Contents MN722

Section 1 Quick Start Guide

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. This will allow motor and control operation to be verified. This procedure 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 procedures. It is not necessary to wire the terminal strip to operate in the keypad mode, if Level 2 Protection block parameters “External Trip” and “Local Enable INP” are set to off. 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 Location” procedure.

3. Connect AC power. Refer to Section 3, “AC Input Power Connections”.

4. Connect the motor. Refer to Section 3, “Motor Connections”.

5. Connect the encoder. Refer to Section 3, “Encoder Installation ”.

Quick Start Checklist Check of electrical items.

CAUTION: After completing the installation but before you apply power, be

sure to check the following items.

1. Verify AC line voltage at source matches control rating.

2. Inspect all power connections for accuracy, workmanship and torques as well as compliance to codes.

3. Verify 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.

WARNING: Make sure that unexpected operation of the motor shaft during start

up will not cause injury to personnel or damage to equipment.

Check of Motor and Coupling

1. Verify freedom of motion of motor shaft.

2. Verify that motor coupling is tight without backlash.

2. Verify the holding brakes if any, are properly adjusted to fully release and set to the desired torque value.

Quick Start Guide 1-1MN722

Section 1 General Information

Quick Start Procedure

Initial Conditions

Be sure the 22H control and motor are installed and wired according to the procedures in Section 3 of this manual. Become familiar with the keypad programming and keypad operation of the control as described in Section 4 of this manual.

1. Disconnect the load (including coupling or inertia wheels) from the motor shaft if possible.

2. Verify that all enable inputs to J1-8 are open.

3. Turn power on. Be sure no errors are displayed.

4. Set the Level 1 Input block, Operating Mode parameter to “KEYPAD”.

5. Set the Level 2 Output Limits block, “OPERATING ZONE” parameter as desired.

6. Enter the following motor data in the Level 2 Motor Data block parameters: Motor Voltage (Nameplate, VOLTS) Motor Rated Amps (Nameplate, FLA) Motor Rated Speed (Nameplate, RPM) Motor Rated Frequency (Nameplate, HZ) Motor Mag Amps (Nameplate, NLA) Encoder Counts

7. At the Level 2 Motor Data, go to CALC Presets and select YES (using the up arrow key). Press ENTER and let the control calculate the preset values for the parameters that are required for control operation.

8. Disconnect the motor from the load (including coupling or inertia wheels). If the load can not be disconnected, refer to Section 6 and manually tune the control. After manual tuning, perform steps 10, 11, 15, 16 and 17.

WARNING: The motor shaft will rotate during this procedure. Be certain that

unexpected motor shaft movement will not cause injury to personnel or damage to equipment.

9. At the Level 2 Autotune block, perform the following tests:

CMD OFFSET TRIM CUR LOOP COMP STATOR R1 FLUX CUR SETTING FEEDBACK TESTS SLIP FREQ TEST

10. Set the Level 2 Output Limits block, “MIN OUTPUT SPEED” parameter.

11 Set the Level 2 Output Limits block, “MAX OUTPUT SPEED” parameter.

12. Remove all power from the control.

13. Couple the motor to its load.

14. Turn power on. Be sure no errors are displayed.

15. Go to Level 2 Autotune block, and perform the SPD CNTRLR CALC test.

16. Run the drive from the keypad using one of the following: the arrow keys for direct speed control, keypad entered speed or the JOG mode.

17. Select and program additional parameters to suit your application.

The control is now ready for use the in keypad mode. If a different operating mode is desired, refer to Section 3 for control connection diagrams and Section 4 Programming and Operation.

1-2 Quick Start Guide MN722

Section 2 General Information

Overview The Baldor Series 22H Line Regen Vector Control provides full motoring and line

regeneration to the AC power mains with a near unity power factor. The control uses PWM controlled by IGBT power transistors in both the converter and inverter sections of the control to provide 3 phase power to the motor and Regen power to the line. Flux vector technology (sometimes referred to as Field Oriented Control) is a closed loop control scheme that adjusts the frequency and phase of voltage and current applied to a three phase induction motor. The vector control separates the motor current into it’s flux and torque producing components. These components are independently adjusted and vectorially added to maintain a 90 degree relationship between them. This produces maximum torque from base speed down to and including zero speed. Above base speed, the flux component is reduced for constant horsepower operation. In addition to the current, the electrical frequency must also be controlled. The frequency of the voltage applied to the motor is calculated from the slip frequency and the mechanical speed of the rotor. This provides instantaneous adjustment of the voltage and current phasing in response to speed and position feedback from an encoder mounted on the motors’ shaft.

The Line Regen vector control provides several advantages over non-regenerative drives:

Regenerated energy from the motor is returned to the power source. The control can provide regenerated energy absorption up to it’s full rating on a continuous basis.

Input current is controlled to be a near unity power factor at rated load. Line harmonic distortion is reduced. DC Bus voltage is always controlled. Therefore, line voltage transients do not

affect the output voltage to the motor.

The Baldor Series 22H control may be used in many different applications. It may be programmed by the user to operate in different operating zones. It can also be configured to operate in a number of modes depending upon the application requirements and user preference.

It is the responsibility of the user to determine the optimum operating zone and mode to interface the control to the application. These choices are made with the keypad as explained in the programming section of this manual.

General Information 2-1MN722

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 MN722

Safety Notice This equipment contains voltages that may be 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.

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: 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. If an automatic restart of the motor could cause injury to personnel, the automatic restart feature should be disabled by changing the Level 2 Miscellaneous block, 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 all grounding instructions have been followed. 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. Dangerous voltages are present inside the equipment. 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. Certain failure modes of the control can produce peak torque of several times the rated motor torque.

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: The motor shaft will rotate during the autotune procedure. Be

certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment.

Continued on next page

General Information 2-3MN722

Section 1 General Information

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 51–200 10,000 201–400 18,000 401–600 30,000 601–900 42,000

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 Underwriter Laboratory requirements.

Caution: Do not supply any power to the External Trip (motor thermostat)

leads at J1-16 and 17. Power on these leads can damage the control. Use a dry contact type that requires no external power to operate.

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 and degrade system performance. Instead, we recommend using a four wire Wye.

Caution: Do not use power factor correction capacitors at the input power

lines to the 22H Line Regen control. Installing power factor correction capacitors may damage the control.

2-4 General Information MN722

Section 3 Receiving & Installation

Receiving & Inspection The Series 22H Vector 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 part number of the control you received is the same as the part number 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 7 of this manual).

Physical Location The location of the 22H 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 vertically on a flat, smooth, non-flammable vertical surface. Size G+ are floor standing NEMA 1 enclosures.

2. At least two inches clearance must be provided on all sides for air flow.

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. (The keypad may optionally be remote mounted up to 100 feet from the control.)

Controls installed in a floor mounted enclosure must be positioned with clearance to open the enclosure door. This clearance will also provide sufficient air space for cooling.

4. Altitude derating. Up to 3300 feet (1000 meters) no derating required. Above 3300 ft, derate the continuous and peak output current by 2% for each 1000 ft.

5. Temperature derating. Up to 40°C no derating required. Above 40°C, derate the continuous and peak output current by 2% per °C. Maximum ambient is 55°C.

6. 50Hz Operation derating. For operation on 50Hz input power, derate the continuous and peak output current by 15%.

7. Shock Mounting. The control is designed to withstand 0.5G at 10 to 60 Hz shock during normal operation.

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.

Receiving & Installation 3-1MN722

Section 1

CONTROL

NOT

General Information

Table 3-1 lists the Watts Loss ratings for Series 22H controls.

Table 3-1 Series 22H Watts Loss Ratings.

STD PWM

CONTROL

MODEL No. SIZE INPUT VAC

ZD22H210-EL C+ 230 268 315 102 80 LRAC03501 49 499 546

ZD22H215-EL C+ 230 397 311 102 109 LRAC04501 54 662 576

ZD22H220-EL C+ 230 527 458 102 136 LRAC05501 64 829 760

ZD22H225-EL C+ 230 690 611 102 137 LRAC08001 82 1011 932

ZD22H230-EL D+ 230 571 768 170 164 LRAC08001 82 987 1184

ZD22H240-EL D+ 230 1095 942 170 187 LRAC10001 94 1546 1393

ZD22H250-EL D+ 230 1437 1286 170 225 LRAC13001 108 1940 1789

ZD22H410-EL C+ 460 240 326 102 80 LRAC01802 43 465 551

ZD22H415-EL C+ 460 336 259 102 86 LRAC02502 52 576 499

ZD22H420-EL C+ 460 432 379 102 11 0 LRAC03502 54 698 645

ZD22H425-EL D+ 460 544 504 102 134 LRAC03502 54 834 794

ZD22H430-EL D+ 460 640 740 170 158 LRAC04502 62 1030 1130

ZD22H440-EL D+ 460 880 738 170 228 LRAC05502 67 1345 1203

ZD22H450-EL D+ 460 1040 1023 170 217 LRAC08002 86 1513 1496

ZD22H460-EK D+ 460 1280 1236 100 299 LRAC08002 86 1765 1721

ZD22H475-EK E 460 2400 2322 153 395 LRAC10002 84 3032 2954

ZD22H4100-EK E 460 3000 2928 153 420 LRAC13002 180 3753 3681

ZD22H4150-EK F 460 3610 191 750 LRAC20002 168 4719

ZD22H4200-EK F 460 4750 191 850 LRAC25002 231 6022

ZD22H4250-EL G+ 460 6200

ZD22H4300-EL G+ 460 8140

ZD22H4450-EL G+ 460 8400

ZD22H4400-EL G+ 460 10560 1000 1750 LRAC50002 340 13650

ZD22H4450-EL G+ 460 11880 1000 1850 LRAC60002 414 15144

CONV &

INV

Losses

(Watts) (Watts) (Watts) (Watts) Cat. No. (Watts) (Watts) (Watts)

QUIET PWM CONV & INV

Losses

CONTROL

RATINGS

AVAILABLE

CONTROL

FIXED

Losses

1000 900 LRAC32002 264 8364

1000 1620 LRAC40002 333 11093

1000 1650 LRAC50002 340 11390

BOOST

REG Loss

At Full

Load

Line Reactor Loss At Full

Load

STD PWM

Total

Losses

QUIET PWM

Total Losses

CONTROL

RATINGS

AVAILABLE

3-2 Receiving & Installation MN722

Section 1 General Information

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.

Through the Wall MountingControl sizes E and F are designed for panel or through the wall installation. To mount a

control through the wall, an optional Through the Wall mounting kit must be purchased. These kits are:

Kit No. Description

V0083991 Size E control Through the Wall mounting kit. V0084001 Size F control Through the Wall mounting kit.

Procedure:

1. Refer to Section 7 of this manual for drawings and dimensions of the Through the Wall mounting kits. Use the information contained in these drawings to layout the appropriate size hole on your enclosure and wall.

2. Cut the holes in your enclosure and wall.

3. Locate and drill holes for mounting hardware as shown in the drawings.

4. Cut foam tape and apply to perimeter of opening as shown.

5. Secure the four (4) brackets to the exterior of the panel with the hardware provided.

6. Secure the control to the panel using the hardware provided.

Receiving & Installation 3-3MN722

Section 1 General Information

Optional Remote Keypad Installation The keypad may be remotely mounted using the optional Baldor keypad

extension cable. The keypad assembly (white - DC00005A-01; grey - DC00005A-02) comes complete with the screws 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-

• RTV sealant.

• (4) 8-32 nuts and lock washers.

• Extended 8-32 screws (socket fillister) are required if the mounting surface is

• Remote keypad mounting template. A tear out copy is provided at the end of

Mounting Instructions: For tapped mounting holes

1. Locate a flat 4″ wide x 5.5″ minimum high mounting surface. Material should

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

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

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

Mounting Instructions: For clearance mounting holes

1. Locate a flat 4″ wide x 5.5″ minimum high mounting surface. Material should

2. Place the template on the mounting surface or mark the holes as shown on the

3. Accurately center punch the 4 mounting holes (marked A) and the large

4. Drill four #19 clearance holes (A).

5. Locate the 1-1/4″ knockout center (B) and punch using the manufacturers

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

/4″ standard knockout punch (1-11/16″ nominal diameter).

thicker than 12 gauge and is not tapped (clearance mounting holes). this manual for your convenience.

be sufficient thickness (14 gauge minimum).

knockout (marked B).

instructions.

and nuts. Cover a 3/4″ area around each screw while making sure to completely encapsulate the nut and washer.

be sufficient thickness (14 gauge minimum). template. knockout (marked B).

instructions.

and nuts. Cover a 3/4″ area around each screw while making sure to completely encapsulate the nut and washer.

3-4 Receiving & Installation MN722

Section 1 General Information

Electrical Installation Interconnection wiring is required between the motor control, AC power source, motor,

host control and any operator interface stations. Use only UL (cUL) 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.

Baldor Series 22H controls feature UL approved adjustable motor overload protection suitable for motors rated at no less than 50% of the output rating of the control. Other governing agencies such as NEC may require separate over–current protection. The installer of this equipment is responsible for complying with the National Electric Code and any applicable local codes which govern such practices as wiring protection, grounding, disconnects and other current protection.

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 that include:

 Protect the control from a short circuit at the motor.  Limit the rate of rise of motor surge currents.  Slowing the rate of change of power the control delivers to the motor.

Load reactors should be installed as close to the control as possible. Select the load reactor that matches the full load amperes (FLA) stated on the nameplate of the motor you are using.

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 Figures 3-1 and 3-2.

Figure 3-1 Recommended System Grounding – EL

Safety

Ground

AC Main Supply

Driven Earth Ground Rod

(Plant Ground)

Note: A line reactor is required and

must be ordered separately.

Line Reactor

Four Wire

“Wye”

L3 Earth

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 cable.

Connect all wires (including motor ground) inside the motor terminal box.

LOCAL

JOG

DISP

FWD

SHIFT

REV

RESET

STOP

Series H

L2 L3 T1 T2 T3

PROG

ENTER

Note: Wiring shown for clarity of grounding

method only. Not representative of actual terminal block location.

Note: A load reactor is highly recommended

and must be ordered separately.

Optional

Load

Reactor

Ground per NEC and Local codes.

Receiving & Installation 3-5MN722

Section 1 General Information

Figure 3-2 Recommended System Grounding – EK

LOCAL

PROG

JOG

DISP

FWD

SHIFT

ENTER

REV

RESET

STOP

Note: A boost regulator is required and

provided with each model EK control.

Note: A line reactor is required and

must be ordered separately.

AC Main Supply

Safety

Ground

Driven Earth

Ground Rod

(Plant Ground)

Earth

Four Wire

“Wye”

Series H

Note: Wiring shown for clarity of grounding

method only. Not representative of actual terminal block location.

Note: A load reactor is highly recommended

and must be ordered separately.

Load

Ground per NEC and Local codes.

Line

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 cable.

Connect all wires (including motor ground) inside the motor terminal box.

Boost

Regulator

L2 L3 T1 T2 T3

Optional

Reactor

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 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.

 Baldor Series H controls require a minimum line impedance of 3%. Refer to

“Line Impedance” for additional information.

 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.

3-6 Receiving & Installation MN722

Section 1 General Information

Catalog Numbers Input

ZD22H210–EL 24 ZD22H410–EL 13 ZD22H215–EL 36 ZD22H415–EK 18 ZD22H220–EL 47 ZD22H420–EL 23 ZD22H225–EL 58 ZD22H425–EL 29 ZD22H230–EL 68 ZD22H430–EL 34 ZD22H240–EL 90 ZD22H440–EL 47 ZD22H250–EL 111 ZD22H450–EL 56

Current Requirements

The input current for each control is given in Table 3-2 and the short circuit requirements are given in Table 3-3. The control may be damaged if input current exceeds ratings.

Table 3-2 Input Current Requirements

230VAC 460VAC

Amps

Catalog Numbers Input

Amps

ZD22H460–EK 68 ZD22H475–EK 85 ZD22H4100–EK 107 ZD22H4150–EK 162 ZD22H4200–EK 213 ZD22H4250–EL 264 ZD22H4300–EL 315 ZD22H4350–EL 357 ZD22H4400–EL 408 ZD22H4450–EL 459

Table 3-3 Short Circuit Current Ratings

230VAC 460VAC

Catalog Numbers Short Circuit

Amps

ZD22H210–EL 240 ZD22H410–EL 130 ZD22H215–EL 360 ZD22H415–EK 180 ZD22H220–EL 470 ZD22H420–EL 230 ZD22H225–EL 580 ZD22H425–EL 290 ZD22H230–EL 680 ZD22H430–EL 340 ZD22H240–EL 890 ZD22H440–EL 470 ZD22H250–EL 1110 ZD22H450–EL 550

Catalog Numbers Short Circuit

Amps

ZD22H460–EK 680 ZD22H475–EK 850 ZD22H4100–EK 1060 ZD22H4150–EK 1620 ZD22H4200–EK 2130 ZD22H4250–EL 2640 ZD22H4300–EL 3150 ZD22H4350–EL 3570 ZD22H4400–EL 4080 ZD22H4450–EL 4590

Receiving & Installation 3-7MN722

Section 1 General Information

Protection Devices Be sure a suitable input power protection device is installed. Use the recommended

circuit breaker or fuses listed in Table 3-5 and 3-6. 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.

Circuit Breaker: 3 phase, thermal magnetic.

Equal to GE type THQ or TEB for 230 VAC or GE type TED for 460 VAC

Fast Action Fuses: 230 VAC, Buss KTN

460 VAC, Buss KTS to 600A (KTU 601 - 1200A)

Very Fast Action: 230 VAC, Buss JJN

460 VAC, Buss JJS

Time Delay Fuses: 230 VAC, Buss FRN

460 VAC, Buss FRS to 600A (KLU 601 - 1200A)

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.

Internal Fuses

Table 3-4 Internal Fuses

Control

Size

C+

D+

G+ 250HP

G+300HP

G+350HP

G+400HP

G+450HP

Zero Crossing

(Input Interface

Board)

Filter Fuses

(Filter Board)

Control

Transformer

Soft Start

Transformer

Fan Control Transformer

Rating Type Rating Type Rating Type Rating Type Rating Type

500VAC

600VAC

FLQ-

Equiv.

FLQ-

Equiv.

FLQ-

Equiv.

FLQ-

Equiv.

500VAC

10A

600VAC

10A

600VAC

ATM-3

or Equiv.3A500VAC

50A

600VAC

50A

600VAC

60A

600VAC

70A

600VAC

70A

600VAC

FNQ-5 or

Equiv.

FNQ-5 or

Equiv.

KTK-10

or Equiv.

KTK-10

or Equiv.

3.2A

250VAC

3.2A

250VAC

3.2A

250VAC

3.2A

250VAC

KTK-3 or

Equiv.3A600VAC

JJS or

Equiv.

JJS or

Equiv.

JJS or

Equiv.

JJS or

Equiv.

JJS or

Equiv.

31/

500VAC

31/

500VAC

31/

500VAC

31/

500VAC

31/

500VAC

MDA-

Equiv.

MDA-

Equiv.

MDA-

Equiv.

MDA-

Equiv.

KTK-3 or

Equiv.3A600VAC

FNQ-

3 Equiv.

FNQ-

3 Equiv.

FNQ-

3 Equiv.

FNQ-

3 Equiv.

FNQ-

3 Equiv.

250VAC

ABC 1/

or Equiv.

KTK-3 or

Equiv.

500VAC

FNQ-4 or

Equiv.3A500VAC

FNQ-4 or

Equiv.3A500VAC

FNQ-4 or

Equiv.3A500VAC

FNQ-4 or

Equiv.3A500VAC

FNQ-4 or

Equiv.3A500VAC

FNQ-3 or

Equiv.

FNQ-3 or

Equiv.

FNQ-3 or

Equiv.

FNQ-3 or

Equiv.

FNQ-3 or

Equiv.

Not applicable.

3-8 Receiving & Installation MN722

Section 1 General Information

Wire Size and Protection Devices

Table 3-5 230VAC Controls (3 Phase) Wire Size and Protection Devices

Control Rating

Amps HP

3 0.75 7 5 4 14 2.5 4 1 7 6 5 14 2.5

7 2 15 12 9 14 2.5 10 3 15 15 12 14 2.5 16 5 20 25 20 12 3.31 22 7.5 30 35 30 10 5.26 28 10 40 45 35 8 8.37 42 15 60 70 60 6 13.3 54 20 70 80 70 6 13.3 68 25 90 100 90 4 21.2 80 30 100 125 110 3 26.7

104 40 150 175 150 1 42.4 130 50 175 200 175 1/0 53.5 145 60 200 225 200 2/0 67.4 192 75 250 300 250 4/0 107.0

Input Breaker

(Amps)

Input Fuse (Amps) Wire Gauge

Fast Acting Time Delay AWG mm

Table 3-6 460VAC Controls (3 Phase) Wire Size and Protection Devices

Control Rating Input Breaker Input Fuse (Amps) Wire Gauge

Amps HP

2 0.75 3 2 2 14 2.5

2 1 3 3 2.5 14 2.5

4 2 7 5 4.5 14 2.5

5 3 7 8 6.3 14 2.5

8 5 15 12 10 14 2.5 11 7.5 15 17.5 15 14 2.5 14 10 20 20 17.5 12 3.31 21 15 30 30 25 10 5.26 27 20 40 40 35 10 5.26 34 25 50 50 45 8 8.37 40 30 50 60 50 8 8.37 52 40 70 80 70 6 13.3 65 50 90 100 90 4 21.2 77 60 100 125 100 3 26.7 96 75 125 150 125 2 33.6

124 100 175 200 175 1/0 53.5 156 125 200 250 200 2/0 67.4 180 150 225 300 250 3/0 85.0 240 200 300 350 300 (2) 2/0 (2) 67.4 302 250 400 450 400 (2) 4/0 (2) 107.0 361 300 450 600 450 (3) 2/0 (3) 67.4 414 350 500 650 500 (3) 3/0 (3) 85.0 477 400 600 750 600 (3) 4/0 (3) 107.0 515 450 650 800 700 (3) 250MCM (3) 127.0 590 500 750 900 800 (3) 300MCM (3) 152.0

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 40°C ambient, maximum continuous control output current and no harmonic current.

(Amps)

Fast Acting Time Delay AWG mm

Receiving & Installation 3-9MN722

Section 1 General Information

Three Phase Input Power Connections

AC power and motor connections are different for controls that have a model number suffix of “EL” and “EK”. Be sure to use the correct procedure for your control.

Note: “EK” Controls are input phase sensitive. Be sure all connections are correct.

“EL” suffix

The AC power and motor connections are shown in Figure 3-3. Overloads are not required. The 22H control has an electronic I2t 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.

1. Connect the incoming AC power wires from the protection devices to terminals

2. Connect A2, B2 and C2 3% line reactor terminals to the L1, L2 and L3 power

3. * Connect earth ground to the “ ” of the control. Be sure to comply with local

* Grounding by using conduit or panel connection is not adequate. A separate

A1, B1 and C1 at the 3% line reactor.

input terminals of the control.

codes.

conductor of the proper size must be used as a ground conductor.

Note 1

Note 2

Note 3

Note 2

* Circuit Breaker

Line

Reactor

Figure 3-3 “EL” Control 3 Phase AC Power and Motor Connections

L1 L2 L3

A1 B1 C1

A2 B2 C2

L1 L2 L3

Baldor

Series 22HXXX-EL

Control

Earth

Alternate *

Fuse

Connection

* Optional components not provided with 22H Control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Shield wires inside a metal conduit.

3. 3% Line Reactor is required at input.

L1 L2 L3

Note 1

A1 B1 C1

See Recommended Tightening Torques in Section 7.

3-10 Receiving & Installation MN722

Section 1 General Information

Figure 3-4 “EK” Control 3 Phase AC Power and Motor Connections (Size D, E & F)

L1 L2 L3

Note 1

Note 2

* Circuit Breaker

A1 B1 C1

“EK” suffix (“EK” Controls are input phase sensitive. Check all connections).

The AC power and motor connections are shown in Figure 3-4. Overloads are not required. The 22H control has an electronic I2t 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.

1. Connect the incoming AC power wires from the protection devices to terminals A1, B1 and C1 of the 3% line reactor.

2. Connect A2, B2 and C2 3% line reactor terminals to the L1, L2 and L3 of the boost regulator.

3. Connect X1, X2 and X3 boost regulator terminals to X1, X2 and X3 of the control.

4. * Connect earth ground to the “ ” of the control. Be sure to comply with local codes.

5. Connect boost regulator terminals L1A, L2A and L3A to Filter terminals J1-1, J1-2 and J1-3.

6. Connect filter terminals J2-1, J2-2 and J2-3 to control terminals L1A, L2A and L3A.

* Grounding by using conduit or panel connection is not adequate. A separate

conductor of the proper size must be used as a ground conductor.

Earth

Alternate *

Fuse

Connection

L1 L2 L3

Note 1

A1 B1 C1

Note 3

Note 2

Notes:

1. See “Protective Devices” described previously in this section.

2. Shield wires inside a metal conduit.

3. 3% Line Reactor is required at input.

Control Size

D & E

See Recommended Tightening Torques in Section 7.

3% Line

Reactor

A2 B2

Boost

Regulator

Phase Sensitive Inputs

Boost Regulator to Filter (5 ft. max.)

14AWG (2.08 mm2) 10AWG (5.26 mm

L1 L2

L1A L2A L3A

Filter to Control (10 ft. max.)

14AWG (2.08 mm

)

10AWG (5.26 mm

X2 X3

J1 J2

1 2

)

* Optional components not provided with 22H Control.

Phase Sensitive Inputs

Filter

1 2

X1 X2 X3 L1A L2A

Series 22HXXX-EK

L3A

Baldor

Control

Receiving & Installation 3-11MN722

Section 1 General Information

Single Phase Operation

Single phase operation is not possible for Series 22H Line Regen Vector Controls.

Operating the Control at a Reduced Input Voltage

Series 22H Controls use a DC Bus regulation technique that provides full output voltage (240VAC for 230VAC Controls; or 480VAC for 460VAC controls) for the full input voltage range. However, at reduced input voltages the output current of the control may have to be derated. Table 3-7 lists the % derating of the output current for various motor voltage ratings and input power voltage levels to the control.

Table 3-7 Output Current Derating at Reduced Input Voltages (2.5KHz PWM)

Input Voltage % of Output Current after Derating

230VAC Control 460VAC Control 240/480VAC Motor 230/440VAC Motor 208/400VAC Motor

180VAC 340VAC 77% 84% 93% 190VAC 360VAC 82% 89% 98% 208VAC 400VAC 90% 99% 100% 230VAC 440VAC 100% 100% 100% 240VAC 480VAC 100% 100% 100%

For example: A 460VAC Control that has a 400VAC input line can provide 90% of the rated current to a 480VAC motor. In the Section 6 specifications we find our example 10HP control is ZD22H410-EL has a continuous current rating of 15 Amps. The derated current can be calculated as follows: 15A x 90% = 13.5A derated value.

Hardware Changes for Reduced Voltage Input

Size C+, D+,D, E, F and G+ controls all require modification for operation at a reduced line voltage (less than rated nominal). Table 3-8 defines the modifications for each enclosure size. Figure 3-1 shows the locations of the transformer locations for each enclosure size.

Table 3-8 Hardware changes for 380-400VAC operation

Enclosure

Size

C+ Yes No D+ Yes No

D Yes No E Yes Yes F Yes Yes

G+ No Yes Yes

Transformer

Tap Change

Control

Contactor

Transformer

Tap Change

Fuse Block

Connection

Change

3-12 Receiving & Installation MN722

Section 1 General Information

Figure 3-1 Control and Contactor Transformer Locations

Control Sizes

C+, D, D+

Logic Control

Board

Control Size

Input

Contactor

Control Size

Contactor

Transformer

Control

Transformer

Control Size

G+

Fuse Block

Swing out panel

xfmr xfmr

Contactor

Fan

Transformers

Contactor

Transformer

Input

Contactor

Transformer

Input

Contactor

Control

Transformer

Not drawn to scale or proportion

Size C+, D, D+ E, and F size control procedure:

Control Transformer

1. Terminate drive operation and disable the control.

2. Remove all power sources from the control. If power has been applied, wait at least 5 minutes for bus capacitors to discharge.

3. Remove or open the front cover and locate the control transformer (Figure 3-2).

4. Remove the wire from terminal 5 of the control transformer.

5. Place the wire that was removed from terminal 5 onto terminal 4.

6. Install or close the front cover.

Receiving & Installation 3-13MN722

Figure 3-2 Configuring the Control Transformer for 380 - 400 VAC Installation

Contactor Transformer

Only size E and F controls require a change of the contactor transformer tap. See Figure 3-3. Use the taps (H1 to H5) that are correct for the input voltage.

Figure 3-3 Contactor Transformer Tap Change (380 -400VAC Input)

380VAC

440VAC

550VAC

600VAC

Frequency 50 / 60

Voltage Taps 380

440-460 550 600

H1 – H2 H1 – H3 H1 – H4 H1 – H5

Size G+and H control procedure: (Refer to Figure 3-4.)

Control Transformer

1. Be sure drive operation is terminated and control is disabled.

2. Remove all power sources from the control. If power has been applied, wait at least 5 minutes for bus capacitors to discharge.

3. Remove or open the front cover. Locate the control transformer fuse block (see Figure 3-1).

4. Remove the wires from the two right side terminals (460VAC connection).

5. Place the wires on the center terminals as shown (380VAC connection).

6. Install or close the front cover.

Figure 3-4 Configuring the Control Transformer Fuse Block for 380 - 400 VAC Installation

For Fuse Block, location refer to Figure 3-1.

460VAC Connection

380-400VAC Connection

3-14 Receiving & Installation MN722

Section 1 General Information

Motor Connections Motor connections are shown in Figure 3-5.

Figure 3-5 Motor Connections

Notes:

1. Metal conduit should be used. Connect conduits so the use of Load

Baldor

Series 22H

Control

T1 T2 T3

Note 1

A1 B1 C1

Reactor or RC Device does not interrupt EMI/RFI shielding.

2. See Line/Load Reactors described previously in this section.

3. Use same gauge wire for Earth ground as for L1, L2 and L3.

Note 2

Note 1

*Optional

Load

Reactor

A2 B2 C2

T2 T3

* AC Motor

* Optional components not provided with 22H Control.

Note 3

See recommended terminal tightening torques in Section 7.

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 3-6.

Figure 3-6 Optional M-Contactor Connections

T1 T2 T3

MMM

M=Contacts of optional M-Contactor

T2 T3

* Motor

To Power Source

(Rated Coil Voltage)

M Enable

Note: Close “Enable”

after “M” contact closure.

* M-Contactor

See recommended terminal tightening torques in Section 7.

* Optional

RC Device

Electrocube

RG1781-3

Receiving & Installation 3-15MN722

Section 1 General Information

Encoder Installation Electrical isolation of the encoder shaft and housing from the motor is required. Electrical

isolation prevents capacitive coupling of motor noise that will corrupt the encoder signals. Baldor provides shielded wire for encoder connection. Figure 3-7 shows the electrical connections between the encoder and the encoder connector. Figure 3-8 shows the connections between the encoder connector and J1 of the control.

Figure 3-7 Encoder Connections

J1 23

Electrically

Isolated

Encoder

Figure 3-8 Control Connections

Encoder End Control End

A J1-23 A J1-24 B J1-25 B J1-26 Index(C) J1-27 Index(C) J1-28 +5VDC J1-29 Common J1-30 Shield J1-30

25 26 27 28 29 30

A B B C C +5V COMMON

See recommended terminal tightening torques in Section 7.

Single Ended Connections

Differential inputs are recommended for best noise immunity. If only single ended encoder signals are available, connect them to A, B, and INDEX (C) (J1-23, J1-25 and J1-27 respectively).

Buffered Encoder Output The control provides a buffered encoder output on pins J1-31 to J1-38. This output may

be used by external hardware to monitor the encoder signals. It is recommended that this output only drive one output circuit load (a 26LS31 type device drives this output).

3-16 Receiving & Installation MN722

Section 1 General Information

Home (Orient) Switch Input The Home or Orient function is active in the Bipolar and Serial modes and causes the

motor shaft to rotate to a predefined home position. The homing function allows shaft rotation in the drive forward direction only. The home position is located when a machine mounted switch or the encoder “Index” pulse is activated (closed). Home is defined by a rising signal edge at terminal J1-27. The shaft will continue to rotate only in a “Drive Forward” direction for a user defined offset value. The offset is programmed in the Level 2 Miscellaneous Homing Offset parameter. The speed at which the motor will “Home” or orient is set with the Level 2 Miscellaneous Homing Speed parameter.

A machine mounted switch may be used to define the Home position in place of the encoder index channel. A differential line driver output from a solid state switch is preferred for best noise immunity. Connect this differential output to terminals J1-27 and J1-28.

A single ended solid-state switch or limit switch should be wired as shown in Figure 3-9. Regardless of the type of switch used, clean rising and falling edges at J1-27 are required for accurate positioning.

Note: A control may require dynamic brake hardware for Orient (Homing) function to

work. The control may trip without dynamic brake hardware installed.

Figure 3-9 Typical Home or Orient Switch Connections

+5V Input

Output Common

See recommended terminal tightening torques in Section 7.

28 29

INDEX INDEX +5V Common

Limit Switch (Closed at HOME).5VDC Proximity Switch

27 28 29

INDEX INDEX +5V Common

Example:

If the drive is operating in the forward direction when the “Orient” J1-11 input is closed, the drive will decel at “DECEL #1” speed. Then continue in the forward direction at the “Homing Speed” until the index pulse is received. The drive will continue past the int index in the forward direction by the amount of the “Homing Offset”. The drive will then stop and maintain position.

Receiving & Installation 3-17MN722

Control Board Jumpers Converter Section Control Board

Figure 3-10 Converter Control Board Jumper JP1 Location

Expansion Board Motor Control Board

Keypad

Connector

321

JP1

See recommended terminal tightening torques in Section 7.

Table 3-9 Converter Control Board Jumper

Jumper Jumper Position Description of Jumper Position Setting

JP1

1–2 Voltage Speed Command Signal. (Factory Setting) 2–3 4–20mA Speed Command Signal.

Inverter Section Control Board

Figure 3-11 Inverter Control Board Jumper Locations

JP2

123

Refer to Table 3-10 for jumper placement information.

123

JP1

See recommended terminal tightening torques in Section 7.

Table 3-10 Inverter Control Board Jumper

Jumper Jumper Position Description of Jumper Position Setting

JP1

JP2

3-18 Receiving & Installation MN722

1-2 Voltage Speed Command Signal. (Factory Setting) 2-3 4-20mA input at Analog #2 1-2 Factory Setting 2-3 Not used.

Section 1 General Information

Analog Inputs Two analog inputs are available: analog input #1 (J1-1 and J1-2) and analog input #2

(J1-4 and J1-5) as shown in Figure 3-12. Either analog input may be selected in the Level 1 INPUT block, Command Select parameter value. Analog input #1 is selected if the parameter value is “Potentiometer”. Analog input #2 is selected if the parameter value is “+/-10Volts, +/-5 Volts or 4-20mA”. Figure 3-13 shows the equivalent circuits of the Analog Inputs.

Figure 3-12 Analog Inputs and Outputs

Analog GND

Command Pot or

0-10VDC

±5VDC, ±10VDC or 4-20 mA Input

5KW

See recommended terminal tightening torques in Section 7.

Analog Input 1 Pot Reference

Analog Input +2

Analog Input -2

Analog Input #1 When using a potentiometer as the speed command, process feedback or setpoint (Single Ended) source, the Level 1 Input block COMMAND SELECT parameter must be set to

“POTENTIOMETER”.

Note: A potentiometer value of 5kW to 10kW, 0.5 watt may be used.

Parameter Selection

The single ended analog input #1 can be used in one of three ways:

1. Speed or Torque command (Level 1 Input block, Command Select=Potentiometer).

2. Process Feedback (Level 2 Process Control block, Process Feedback=Potentiometer).

3. Setpoint Source (Level 2 Process Control block, Setpoint Source=Potentiometer). When using Analog Input #1, the respective parameter must be set to

“POTENTIOMETER”.

Analog Input 1

Analog Input 2

Analog Input #2 Analog input #2 accepts a differential command 0-5VDC, 0-10VDC, ±5VDC, ±10VDC or

(Differential) 4-20 mA. If pin J1-4 is positive with respect to pin 5, the motor will rotate in the forward

direction. If pin J1-4 is negative with respect to pin 5, the motor will rotate in the reverse direction. JP1 must be set for voltage or current operation as required. Analog Input #2 can be connected for single ended operation by grounding either of the inputs, provided the common mode voltage range is not exceeded.

Note: The common mode voltage can be measured with a voltmeter. Apply the

maximum command voltage to analog input 2 (J1-4, 5). Measure the AC and DC voltage across J1-1 to J1-4. Add the AC and DC readings together. Measure the AC and DC voltage from J1-1 to J1-5. Add the AC and DC readings together.

If either of these measurement totals exceeds a total of ±15 volts, then the common mode voltage range has been exceeded. To correct this condition, either change the command source or isolate the command signal with a signal isolator.

Receiving & Installation 3-19MN722

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