Baldor mn722 User Manual

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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

Section 1 General Information

-15VDC

Figure 3-13 Analog Inputs Equivalent Circuits

30KW

.033 mF

5.1V Zener

Notes:

–

All OP Amps are TL082 or TL084

5KW

20KW

1.96KW

10KW 10KW

JP1 4-20mA

500W

X N/C

10KW

–

+15VDC

–

To Microprocessor

See recommended terminal tightening torques in Section 7.

To Microprocessor

10KW

Analog Ground is separated from Chassis Ground. Electrically they are separated by an RC network.

Analog Outputs Two programmable analog outputs are provided on J1-6 and J1-7. See Figure 3-14.

These outputs are scaled 0 - 5 VDC (1mA maximum output current) and can be used to provide real-time status of various control conditions. The output conditions are defined in Table 4-4 of Section 4 of this manual.

The return for these outputs is J1-1 analog ground. Each output is programmed in the Level 1 Output block.

Figure 3-14 Analog Outputs Equivalent Circuits

Notes:

–

All OP Amps are TL082 or TL084

Analog Ground is separated from Chassis Ground. Electrically they are separated by an RC network.

See recommended terminal tightening torques in Section 7.

From Microprocessor

10KW

.033 mf

10KW

.033 mf

–

10KW

–

10KW

50W

3-20 Receiving & Installation MN722

Section 1 General Information

Control Circuit Connections

There are two control boards in a Series 22H Vector Control. The Converter Control Board is used to rectify and process the incoming power. The Inverter Control Board provides the inverting and power output functions. The keypad is normally connected to the Inverter Control Board. Each converter board has its own J1 terminal strip. The Inverter Control Board provides the user interface for most external connections.

Converter Control Board Connections

All necessary connections for the Converter Control Board have been made at the factory prior to shipment.

The jumper between J1-8 and J1-17 provides the enable signal to allow converter operation. The jumper between J1-39 and J1-40 provides +24VDC from the internal supply to allow the opto isolated input at J1-8 to operate. These jumpers should remain installed at all times.

Sometimes it is necessary to troubleshoot the converter section using the isolated opto outputs. Figure 3-15 shows how to connect external relays to the board to “Sink” or “Source” the relay current.

The function of each opto output is as follows: (these functions cannot be changed)

J1-19 Ready J1-20 At Voltage J1-21 Fault J1-22 Overtemperature Warning

24Com

Optional

Customer

Supplied

Relays &

Diodes

Using Internal Supply

(Sinking the Relay Current)

Note: Add appropriately rated

protective device for AC relay (snubber) or DC relay (diode).

Figure 3-15 Converter Control Board Opto Output Wiring

+24VDC

24Com

See recommended terminal tightening torques in Section 7.

Using Internal Supply

(Sourcing the Relay Current)

+24VDC

Optional

Customer

Supplied

Relays &

Diodes

Receiving & Installation 3-21MN722

Section 1 General Information

Inverter Control Board Connections

Ten operating modes are available in the Series 22H vector control. These operating modes define the basic motor control setup and the operation of the input and output terminals. After the circuit connections are completed, the operating mode is selected by programming the Level 1 Input block, Operating Mode parameter. Available operating modes include:

Each mode requires connections to the J1 terminal strip (except keypad and serial modes, all connections are optional). The J1 terminal strip is shown in Figure 3-16. The connection of each input or output signal is described in the following pages.

Refer to Analog Inputs

Refer to Analog Outputs

Refer to opto isolated Inputs

Refer to opto isolated Outputs

• Keypad Control

• Standard Run, 3 Wire Control

• 15 Speed, 2 Wire Control

• Three Speed, 2 Wire Control

• Three Speed, 3 Wire Control

• Serial

• Bipolar Speed or Torque

• Process Control

• EPOT, 2 Wire Control

• EPOT, 3 Wire Control

Figure 3-16 Control Signal Connections

Analog GND Analog Input 1 Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Input #1 Input #2 Input #3 Input #4 Input #5 Input #6 Input #7 Input #8 Input #9

Opto In Common

Opto Out #1

Opto Out #2

Opto Out #3

Opto Out #4

See recommended terminal tightening torques in Section 7.

INDEX

+5VDC

Common

INDEX

Not Used

Common

Opto Out #1 Return

Opto Out #2 Return

Opto Out #3 Return

Opto Out #4 Return

Refer to Encoder Installation

Refer to Buffered Encoder Output

+24VDC Opto In Power

J1-39 & 40 Jumper as shown to power

the opto inputs from the internal +24VDC supply.

Note: J1-18 and J1-41 are connected

together on the control circuit board.

Serial Mode The Serial operating mode requires one of the optional Serial Interface expansion boards

(RS232 or 422/485). Installation and operation information for these serial expansion boards is provided in Serial Communications expansion board manual MN1310. This manual is shipped with the serial expansion board.

3-22 Receiving & Installation MN722

Section 1 General Information

Keypad Mode Connections The Keypad operating mode allows the control to be operated from the keypad. This

mode requires no connections to J1. However, the Enable, Stop and External Trip inputs may optionally be used. All other opto inputs remain inactive. The analog outputs and opto-outputs remain active at all times. See Figure 3-17.

Parameter Selection

For operation in Keypad mode, set the Level 1 Input block, Operating Mode parameter to Keypad. The STOP key can operate in two ways:

 Press STOP key one time to brake or coast to stop.  Press STOP key two times to disable control.

To use the Enable input, J1-8 must be connected and the Local Enable INP parameter in the Level 2 Protection block must be set to ON. The Enable line is normally closed. When opened, the motor will COAST to a stop. When the enable line is again closed, the motor will not start until a new direction command is received from the keypad.

To use the Stop input, J1-11 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 Mode parameter value. Closing the input will immediately start the motor.

The External Trip input causes a fault condition during a motor over temperature condition (when normally closed input opens). The External Trip input (J1-16) must be connected and the External Trip parameter in the Level 2 Protection block must be set to “ON”. When J1-16 is opened, an external trip fault occurs. The control will disable and the motor coasts to a stop. An external trip fault is displayed on the keypad display (also logged into the fault log).

Figure 3-17 Keypad Control Connection Diagram

J1-8 If J1-8 is connected, you must set Level 2 Protection block, Local Enable INP

parameter to “ON” to activate the opto input. CLOSED allows normal operation. OPEN disables the control and motor coasts to a stop.

J1-11 If J1-11 is connected, you must set Level 1 Keypad Setup block,

Loc. Hot Start parameter to to “ON” to activate the opto input. CLOSED allows normal operation. OPEN motor decels to stop (depending on Keypad Stop mode). The motor will restart when J1-11 closes after open (if the keypad FWD or REV key is still pressed).

J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to

“ON” to activate the opto input. CLOSED allows normal operation. OPEN causes an external trip to be received by the control. The control will disable and display external trip. When this occurs, the motor stop command is issued, drive operation is terminated and an external trip fault is displayed on the keypad display (also logged into the fault log).

Refer to Figure 3-26.

See recommended terminal tightening torques in Section 7.

No Connection

Enable

Stop

External Trip

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Input #1 Input #2 Input #3 Input #4 Input #5 Input #6 Input #7 Input #8 Input #9

Opto In Common

Receiving & Installation 3-23MN722

Section 1 General Information

Standard Run 3 Wire Mode Connections

In Standard Run mode, the control is operated by the opto isolated inputs at J1-8 through J1-16 and the analog command input. The opto inputs can be switches as shown in Figure 3-18 or logic signals from another device. The external trip opto input at J1-16 is active if connected as shown and the Level 2 Protection block, External Trip parameter is set to ON.

For 4–20mA operation, refer to Table 3-10. Analog input 2 can then be used for 4–20mA operation.

Figure 3-18 Standard Run 3-Wire Connection Diagram

J1-8 CLOSED allows normal control operation.

OPEN disables the control and motor coasts to a stop.

J1-9 MOMENTARY CLOSED starts motor operation in the Forward direction.

In JOG mode (J1-12 CLOSED), continuous CLOSED jogs motor in the Forward direction.

J1-10 MOMENTARY CLOSED starts motor operation in the Reverse direction.

In JOG mode (J1-12 CLOSED), CONTINUOUS closed JOGS motor in the Reverse direction.

J1-11 MOMENTARY OPEN causes motor to decel to stop (depending on Keypad

Stop Mode parameter setting). Motor current continues to be applied to the motor.

J1-12 CLOSED places control in JOG mode, Forward and Reverse run are used

to jog the motor.

J1-13 CLOSED selects group 2.

OPEN selects ACC / DEC / S-CURVE group 1.

J1-14 CLOSED selects preset speed #1, (J1-12, will override this preset speed).

OPEN allows speed command from Analog input #1 or #2 or Jog.

J1-15 CLOSED to reset fault condition.

OPEN to run.

J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip

to “ON” to activate the opto input. CLOSED allows normal control operation. OPEN causes an external trip to be received by the control. The control will disable and display external trip. When this occurs, the motor stop command is issued, drive operation is terminated and an external trip fault is displayed on the keypad display (also logged into the fault log).

Command Pot or

0-10VDC

5KW

Programmable Output Programmable Output

Refer to Figure 3-26.

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Stop

Jog

Accel/Decel

Preset Speed #1

Fault Reset

External Trip

Opto In Common

3-24 Receiving & Installation MN722

Section 1 General Information

15 Speed 2-Wire Mode Connections Switch Truth Table is defined in Table 3-11.

Operation in the 15 Speed 2-Wire mode is controlled by the Opto Isolated inputs at J1-8 through J1-16. The Opto inputs can be switches as shown in Figure 3-19 or logic signals from another device.

Switched inputs at J1-11 through J1-14 allow selection of 15 preset speeds and provide Fault Reset as defined in Table 3-11.

Figure 3-19 15 Speed 2-Wire Control Connection Diagram

J1-8 CLOSED allows normal control operation. J1-9 CLOSED operates the motor in the Forward direction (with J1-10 open).

J1-10 CLOSED operates motor in the Reverse direction (with J1-9 open).

J1-11 to 14 Selects programmed preset speeds as defined in Table 3-11. J1-15 Selects ACC/DEC group. OPEN selects group 1. CLOSED selects

J1-16 If J1-16 is connected, you must set Level 2 Protection block, External

OPEN disables the control and motor coasts to a stop. OPEN motor decels to stop (depending on Keypad Stop mode parameter

setting). OPEN motor decels to stop depending on Keypad Stop mode parameter

setting.

group 2. Trip to “ON” to activate the opto input.

CLOSED allows normal control operation. OPEN causes an external trip to be received by the control. The control will disable and display external trip. When this occurs, the motor stop command is issued, drive operation is terminated and an external trip fault is displayed on the keypad display (also logged into the fault log).

See recommended terminal tightening torques in Section 7.

Programmable Output Programmable Output

No Connection

Refer to Figure 3-26.

Analog Input +2

Analog Input -2

Accel/Decel/S Select 1

Opto In Common

Analog GND

Analog Input 1

Pot Reference

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Switch 1 Switch 2 Switch 3 Switch 4

External Trip

Table 3-11 Switch Truth Table for 15 Speed, 2 Wire Control Mode

Function J1-11 J1-12 J1-13 J1-14

Preset 1 Open Open Open Open Preset 2 Closed Open Open Open Preset 3 Open Closed Open Open Preset 4 Closed Closed Open Open Preset 5 Open Open Closed Open Preset 6 Closed Open Closed Open Preset 7 Open Closed Closed Open Preset 8 Closed Closed Closed Open Preset 9 Open Open Open Closed

Preset 10 Closed Open Open Closed

Preset 11 Open Closed Open Closed Preset 12 Closed Closed Open Closed Preset 13 Open Open Closed Closed Preset 14 Closed Open Closed Closed Preset 15 Open Closed Closed Closed

Fault Reset Closed Closed Closed Closed

Receiving & Installation 3-25MN722

Section 1 General Information

3 Speed Analog 2 Wire Operating Mode

Allows selection of 3 preset speeds with 2 wire inputs. The opto inputs can be switches as shown in Figure 3-20 or logic signals from another device.

The values of the preset speeds are set in the Level 1 Preset Speeds block, Preset Speed #1, Preset Speed #2 and Preset Speed #3.

Figure 3-20 3 SPD ANA 2 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control and the motor coasts to a stop.

J1-9 CLOSED operates the motor in the Forward direction (with J1-10 open).

OPEN motor decels to stop (depending on Keypad Stop mode).

J1-10 CLOSED operates the motor in the Reverse direction (with J1-9 open).

OPEN motor decels to stop (depending on Keypad Stop mode).

Note: Closing both J1-9 and J1-10 at the same time will reset a fault condition.

J1-11 CLOSED selects Analog Input #1.

OPEN selects Level 1 Input block, Command Select parameter.

Note: If Command Select (Level 1 Input block) is set to Potentiometer, then Analog

Input #1 is always selected regardless of this switch position.

J1-12 CLOSED selects STOP/START and Reset commands from terminal strip.

OPEN selects STOP/START and Reset commands from Keypad.

J1-13 CLOSED selects Level 1 Input block, Command Select parameter.

OPEN selects speed commanded from Keypad.

Note: When changing from Terminal Strip to Keypad (J1-12 or J1-13) the motor speed

and direction will remain the same after the change.

J1-14 Selects preset speeds as defined in the Speed Select Table (Table 3-12). J1-15 Selects preset speeds as defined in the Speed Select Table (Table 3-12). J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”

to activate the opto input. CLOSED allows normal operation. OPEN causes an external trip to be received by the control. The control will disable and display external trip. When this occurs, the motor stop command is issued, drive operation is terminated and an external trip fault is displayed on the keypad display (also logged into the fault log).

Command Pot or

0-10VDC

5KW

Refer to Figure 3-26.

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Analog Input Select

Run Command

Speed Command

Switch 1 Switch 2

External Trip

Opto In Common

Table 3-12 Speed Select Table

J1-14 J1-15 Command

OPEN CLOSED

OPEN OPEN

CLOSED CLOSED

3-26 Receiving & Installation MN722

Analog Input (Command Select) Preset #1 Preset #2 Preset #3

Section 1 General Information

3 Speed Analog 3 Wire Operating Mode

Allows selection of 3 preset speeds with 3 wire inputs. The opto inputs can be switches as shown in Figure 3-21 or logic signals from another device.

The values of the preset speeds are set in the Level 1 Preset Speeds block, Preset Speed #1, Preset Speed #2 and Preset Speed #3.

Figure 3-21 3 SPD ANA 3 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control and the motor coasts to a stop. J1-9 MOMENTARY CLOSED starts motor operation in the Forward direction. J1-10 MOMENTARY CLOSED starts motor operation in the Reverse direction.

Note: Closing both J1-9 and J1-10 at the same time will reset a fault condition.

J1-11 Momentary OPEN motor decels to stop (depending on Keypad Stop mode). J1-12 CLOSED selects STOP/START and Reset commands from terminal strip.

OPEN selects STOP/START and Reset commands from Keypad. J1-13 CLOSED selects Level 1 Input block, Command Select parameter.

OPEN selects speed commanded from Keypad.

Note: When changing from Terminal Strip to Keypad (J1-12 or J1-13) the motor

speed and direction will remain the same after the change. J1-14 Selects preset speeds as defined in the Speed Select Table (Table 3-13).

J1-15 Selects preset speeds as defined in the Speed Select Table (Table 3-13). J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to

“ON” to activate the opto input.

CLOSED allows normal operation.

OPEN causes an external trip to be received by the control. The control will

disable and display external trip. When this occurs, the motor stop command

is issued, drive operation is terminated and an external trip fault is displayed on

the keypad display (also logged into the fault log).

Command Pot or

0-10VDC

5KW

Refer to Figure 3-26.

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Stop

Run Command

Speed Command

Switch 1 Switch 2

External Trip

Opto In Common

Table 3-13 Speed Select Table

J1-14 J1-15 Command

OPEN CLOSED

OPEN OPEN

CLOSED CLOSED

Analog Input (Command Select) Preset #1 Preset #2 Preset #3

Receiving & Installation 3-27MN722

Section 1 General Information

Bipolar Speed and Torque Mode Connections

Provides bipolar speed or torque control. Also, you may store up to four (4) complete sets of operating parameters. This is important if you wish to store and use different acceleration rates, speed commands, jog speeds or to store tuning parameter values for different motors etc. The opto inputs can be switches as shown in Figure 3-22 or logic signals from another device.

Figure 3-22 Bipolar Speed or Torque Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control & motor coasts to a stop.

J1-9 CLOSED to enable operation in the Forward direction.

OPEN TO DISABLE Forward operation (drive will brake to a stop if a Forward command is still present). Reverse operation is still possible if J1-10 is closed.

J1-10 CLOSED to enable operation in the Reverse direction.

OPEN to disable Reverse operation (drive will brake to a stop if a Reverse command is still present). Forward operation is still possible if J1-9 is closed.

Note: If J1-9 and J1-10 are both opened, the drive will brake to a stop.

J1-11 CLOSED causes the motor to rotate in the forward direction until the load

reaches a marker or external switch location. OPEN allows normal operation.

J1-12 CLOSED puts the control in torque command mode.

OPEN puts the control in speed (velocity) command mode.

Note: If a stop command is issued while in the torque (current) mode, the

control will stop but will not maintain position (zero current). This is different than zero speed operation for the velocity mode.

J1-13 & 14 Select from four parameter tables as defined in Table 3-14. J1-15 Momentary CLOSED to reset fault condition.

OPEN allows normal operation.

J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to

Command Pot or

0-10VDC

5KW

Refer to Figure 3-26.

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Enable

Reverse Enable

Homing

Speed/Torque

Switch 1 Switch 2

Fault Reset

External Trip

Opto In Common

Table 3-14 Bipolar Mode Table Select Truth Table

Function J1-13 J1-14

Parameter Table #0 Open Open Parameter Table #1 Closed Open Parameter Table #2 Open Closed Parameter Table #3 Closed Closed

Note: See multiple parameter sets.

3-28 Receiving & Installation MN722

Section 1 General Information

Multiple Parameter Sets

The following procedure allows you to program up to four complete sets of parameter values and to use these multiple parameter sets. When programming each parameter set, use the ENTER key to accept and automatically save parameter values.

Note: The control can be programmed in the REMOTE mode with the drive enabled.

The control must be disabled to change the operating mode parameter and the operating mode can not be stored in a parameter table.

1. If this is a new installation, do this procedure after the Pre-Operation Checklist and Power-Up Procedures at the end of this section.

2. Set the Level 1 INPUT block, Operating Mode parameter value to BIPOLAR in each of the parameter sets.

3. Set switches J1-13 and J1-14 to Parameter Table #0 (both switches open). Be sure switches J1-9 and J1-10 are OPEN, J1-8 is CLOSED. Enter all parameter values, and autotune as instructed in Section 3 of this manual. This creates and saves the first parameter set which is numbered Table#0.

4. Set switches J1-13 and J1-14 to Parameter Table #1. Be sure switches J1-9 and J1-10 are OPEN, J1-8 is CLOSED. Enter all parameter values, and autotune as instructed in Section 3 of this manual. This creates and saves the second parameter set which is numbered Table#1.

5. Set switches J1-13 and J1-14 to Parameter Table #2. Be sure switches J1-9 and J1-10 are OPEN, J1-8 is CLOSED. Enter all parameter values, and autotune as instructed in Section 3 of this manual. This creates and saves the third parameter set which is numbered Table#2.

6. Set switches J1-13 and J1-14 to Parameter Table #3. Be sure switches J1-9 and J1-10 are OPEN, J1-8 is CLOSED. Enter all parameter values, and autotune as instructed in Section 3 of this manual. This creates and saves the final parameter set which is numbered Table#3.

7. Remember that to change the value of a parameter in one of the parameter tables, you must first select the table using the switches. You cannot change a value in a table until you have first selected that table.

Note: Preset speed does not apply to table select.

Receiving & Installation 3-29MN722

Section 1

ËËËË

General Information

Process Mode Connections The process control mode provides an auxiliary closed loop general purpose PID set point

control. The process control loop may be configured in various ways and detailed descriptions of the process mode are given in MN707 “Introduction to Process Control”. The opto inputs can be switches as shown in Figure 3-23 or logic signals from another device.

Figure 3-23 Process Mode Connection Diagram

J1-8 CLOSED allows normal operation. J1-9 CLOSED to enable operation in the Forward direction.

J1-10 CLOSED to enable operation in the Reverse direction.

J1-11 CLOSED = TABLE 1, OPEN = TABLE 0. (See multiple parameter sets.) J1-12 CLOSED, the control is in torque command mode.

J1-13 CLOSED to enable the Process Mode. J1-14 CLOSED places control in JOG mode. The control will only JOG in the forward

J1-15 CLOSED to reset a fault condition. J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”

See recommended terminal tightening torques in Section 7.

OPEN disables the control & motor coasts to a stop. OPEN TO DISABLE Forward operation (drive will brake to a stop if a Forward

command is still present). Reverse operation is still possible if J1-10 is closed. OPEN to disable Reverse operation (drive will brake to a stop if a Reverse

command is still present). Forward operation is still possible if J1-9 is closed.

Note: If J1-9 and J1-10 are both opened, the drive will brake to a stop.

OPEN, the control is in speed (velocity) command mode.

Note: If a stop command is issued while in the torque (current) mode, the control

will stop but will not maintain position (zero current). This is different than zero speed operation for the velocity mode.

direction. OPEN to run. to activate the opto input.

CLOSED allows normal operation. OPEN causes an external trip to be received by the control. The control will disable and display external trip. When this occurs, the motor stop command is issued, drive operation is terminated and an external trip fault is displayed on the keypad display (also logged into the fault log).

Command Pot or

0-10VDC

5KW

Analog Input +2

Analog Input -2

Forward Enable Reverse Enable

Process Mode Enable

Opto In Common

Refer to Figure 3-26.

Table 3-15 Process Mode Input Signal Compatibility

Setpoint or

Feedforward

J1-1 & 2 J1-4 & 5 5V EXB 10V EXB 4-20mA EXB 3-15 PSI EXB DC Tach EXB EXB PULSE FOL   Serial EXB  

J1-1 & 2 J1-4 & 5

5V EXB 10V EXB

 Requires expansion board EXB007A01 (High Resolution Analog I/O EXB).  Requires expansion board EXB004A01 (4 Output Relays/3-15 PSI Pneumatic Interface EXB).  Requires expansion board EXB006A01 (DC Tachometer Interface EXB).  Requires expansion board EXB005A01 (Master Pulse Reference/Isolated Pulse Follower EXB).  Used for Feedforward only. Must not be used for Setpoint Source or Feedback.  Requires expansion board EXB001A01 (RS232 Serial Communication EXB). or

Requires expansion board EXB002A01 (RS422/RS485 High Speed Serial Communication EXB). or Requires expansion board EXB012A01 (RS232/RS485 Serial Communication EXB).

Conflicting inputs. Do not use same input signal multiple times. Conflicting level 1 or 2 expansion boards. Do not use!

Feedback

4-20mA

EXB



3-15 PSI

EXB



Analog GND

Analog Input 1

Pot Reference

Analog Out 1 Analog Out 2

Enable

Table Select

Speed/Torque

Fault Reset

External Trip

Tach EXB

Jog



3-30 Receiving & Installation MN722

Section 1 General Information

Electronic Pot 2 Wire Operating Mode

Provides speed Increase and Decrease inputs to allow EPOT operation with 2 wire inputs. The opto inputs can be switches as shown in Figure 3-24 or logic signals from another device. The values of the preset speeds are set in the Level 1 Preset Speeds block, Preset Speed #1 or Preset Speed #2.

Figure 3-24 EPOT, 2 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control and motor coasts to a stop.

J1-9 CLOSED starts motor operation in the Forward direction.

OPEN motor decels to stop (depending on Keypad Stop mode).

J1-10 CLOSED starts motor operation in the Reverse direction.

OPEN motor decels to stop (depending on Keypad Stop mode).

Note: Closing both J1-9 and J1-10 at the same time will reset a fault condition.

J1-11 Selects preset speeds as defined in the Speed Select Table (Table 3-16). J1-12 Selects preset speeds as defined in the Speed Select Table (Table 3-16). J1-13 CLOSED selects ACC / DEC / S-CURVE group 2.

OPEN selects ACC / DEC / S-CURVE group 1. J1-14 Momentary CLOSED increases motor speed while contact is closed. J1-15 Momentary CLOSED decreases motor speed while contact is closed. J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip

to “ON” to activate the opto input.

CLOSED allows normal operation.

OPEN causes an external trip to be received by the control. The control will

disable and display external trip. When this occurs, the motor stop

command is issued, drive operation is terminated and an external trip fault

is displayed on the keypad display (also logged into the fault log).

Command Pot or

0-10VDC

5KW

Refer to Figure 3-26.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Switch 1 Switch 2

Accel/Decel

Increase

Decrease

External Trip

Opto In Common

Table 3-16 Speed Select Table

J1-11 J1-12 Function

OPEN CLOSED OPEN CLOSED

* Command Select refers to the Level 1 Command Select parameter.

OPEN OPEN CLOSED CLOSED

Electronic Pot Command Select * Preset #1 Preset #2

See recommended terminal

tightening torques in Section 7.

Receiving & Installation 3-31MN722

Section 1 General Information

Electronic Pot 3 Wire Control Mode

Provides speed Increase and Decrease inputs to allow EPOT operation with 3 wire inputs. The opto inputs can be switches as shown in Figure 3-25 or logic signals from another device.

Figure 3-25 EPOT, 3 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control and motor coasts to a stop. J1-9 Momentary CLOSED starts motor operation in the Forward direction. J1-10 Momentary CLOSED starts motor operation in the Reverse direction.

Note: Closing both J1-9 and J1-10 at the same time will reset a fault condition.

J1-11 Momentary OPEN motor decels to stop (depending on Keypad Stop mode). J1-12 CLOSED selects Level 1 Command Select parameter value.

OPEN selects EPOT. J1-13 CLOSED selects ACC / DEC / S-CURVE group 2.

“ON” to activate the opto input.

CLOSED allows normal operation.

OPEN causes an external trip to be received by the control. The control will

disable and display external trip. When this occurs, the motor stop command

is issued, drive operation is terminated and an external trip fault is displayed

on the keypad display (also logged into the fault log).

Command Pot or

0-10VDC

Refer to Figure 3-26.

5KW

EPOT/Command Select

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Stop

Accel/Decel

Increase

Decrease

External Trip

Opto In Common

3-32 Receiving & Installation MN722

Section 1 General Information

External Trip Input To activate the External Trip input, the External Trip parameter in the programming

Protection Block must be set to “ON”. Terminal J1-16 is available for connection to a normally closed thermostat or overload

relay in all operating modes as shown in Figure 3-26. 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.

Connect the External Trip Input wires to J1-16 and J1-17. Do not place these wires in the same conduit as the motor power leads.

Figure 3-26 Motor Temperature Relay

T1 T2 T3

Customer Provided

Source Voltage

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

MMM

See recommended terminal tightening torques in Section 7.

* Motor

Motor Thermostat Leads

CR1

Do not run these wires in same conduit as motor leads or AC power wiring.

Optional hardware. Must be ordered separately.

16 17

External Trip

Opto-Isolated Inputs The equivalent circuit for the nine Opto inputs is shown in Figure 3-27. The function of

each input depends on the operating mode selected and are described previously in this section. This Figure also shows the connections using the internal opto input Supply.

Figure 3-27 Opto-Input Equivalent Circuit (Using Internal Supply)

J1 Opto In #1 Opto In #2 Opto In #3 Opto In #4 Opto In #5 Opto In #6 Opto In #7 Opto In #8 Opto In #9

Opto In Common

+24VDC @ 200mA

(supply terminal 39).

Jumper terminals 39 to 40

(Factory Installed)

6.8K 6.8K 6.8K 6.8K 6.8K 6.8K 6.8K 6.8K 6.8K

See recommended terminal tightening torques in Section 7.

Receiving & Installation 3-33MN722

Section 1 General Information

Figure 3-28 Opto-Input Equivalent Circuit (Using External Supply)

Opto In #1 Opto In #2 Opto In #3 Opto In #4 Opto In #5 Opto In #6 Opto In #7 Opto In #8 Opto In #9

* User VCC (-)

* User VCC (+)

Opto In #1 Opto In #2 Opto In #3 Opto In #4 Opto In #5 Opto In #6 Opto In #7 Opto In #8 Opto In #9

* User VCC (+)

* User VCC (-)

Opto Inputs Closing to Ground Opto Inputs Closing to +VCC

See recommended terminal

tightening torques in Section 7.

* User VCC = 10 - 30VDC

External Power Source

Opto-Isolated Outputs Four programmable Opto-isolated outputs are available at terminals J1-19 through J1-22.

See Figure 3-29. Each output may be programmed to represent one output condition. The output conditions are defined in Table 4-4 of Section 4 of this manual. The Opto-isolated outputs may be configured for sinking or sourcing 50 mA each. However, all must be configured the same. The maximum voltage from opto output to common when active is 1.0 VDC (TTL compatible). The Opto-isolated outputs may be connected in different ways as shown in Figure 3-29. The equivalent circuit for the Opto-isolated outputs is shown in Figure 3-30. If the opto outputs are used to directly drive a relay, a flyback diode rated at 1A, 100 V (IN4002) minimum should be connected across the relay coil. See Electrical Noise Considerations in Section 5 of this manual. Each Opto Output is programmed in the Output programming block.

Figure 3-29 Opto-isolated Output Configurations

Optional

Customer

Supplied Relays &

Diodes

Optional Customer Supplied

10VDC to 30VDC Source

Optional

Customer

Supplied

Relays &

Diodes

(Sinking the Relay Current)

24Com

Using Internal Supply

Using External Supply

See recommended terminal tightening torques in Section 7.

+24VDC

Optional Customer Supplied

10VDC to 30VDC Source

24Com

39 18

Using Internal Supply

(Sourcing the Relay Current)

Using External Supply

(Sourcing the Relay Current)

+24VDC

Optional

Customer

Supplied

Relays &

Diodes

Optional

Customer

Supplied

Relays &

Diodes

3-34 Receiving & Installation MN722

Section 1 General Information

Figure 3-30 Opto-Output Equivalent Circuit

PC865

50mA max

See recommended terminal tightening torques in Section 7.

PC865

50mA max

PC865

50mA max

PC865

50mA max

Opto Output 1

Opto Output 2

Opto Output 3

Opto Output 4

Opto Out 1 Return

Opto Out 2 Return

Opto Out 3 Return

Opto Out 4 Return

10 – 30VDC

Opto Outputs

Pre-Operation 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 tightness and 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.

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.

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

Receiving & Installation 3-35MN722

Section 1 General Information

Power-Up Procedure This procedure will help get your system up and running in the Keypad mode quickly.

This will allow you to prove the motor and control operation. 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 the motor in the Keypad mode.

Initial Conditions

Be sure the control and motor are wired according to the procedures described previously in 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 (STD CONST TQ, STD VAR TQ, QUIET CONST TQ or QUIET VAR TQ).

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 ENCODER 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.

3-36 Receiving & Installation MN722

Section 4 Programming and Operation

Overview The Series 22H Vector Line Regen Control has two control boards installed. The

“Converter Control Board” is used to rectify and process the incoming power. The “Inverter Control Board” provides the inverting and power output functions. Each control

board has its own J1 terminal strip. The Inverter Control Board normally has the keypad connected to it. The J1 terminal strip

of the Inverter Board provides the user interface for most external connections and software parameters. The Inverter Control board is mounted above the Converter Control Board.

The Converter Control Board is programmed at the factory and should not require program changes. However, you can change the values of several parameters within the firmware (refer to parameters in Appendix B). The J1 terminal strip of the Converter Control Board is factory wired for normal operation.

The keypad must be plugged into the Converter Control Board to change parameter values, or access the fault log or the diagnostic information of the Converter Control Board. A sheet metal panel separates the two control boards and there is a small access hole the the sheet metal panel to attach the keypad to the Converter Control Board. To attach the keypad to the Converter control board, use the following procedure:

Keypad Installation in the Converter Control Board

1. Be sure all power is disconnected from the Series 22H Control. Wait at least 5 minutes for the bus capacitors to discharge before you proceed.

2. Open the Series 22H cover.

3. Remove the keypad from the Inverter Control Board (secured by 4 screws).

4. Remove the extension ribbon cable from its retaining strap (secured to the sheet metal panel).

5. Connect one end of the ribbon cable into the keypad connector in the Converter Control Board (through the access hole in the sheet metal panel).

6. Connect the other end of the ribbon cable to the keypad.

The control can now be powered up and the Converter Control Board can be programmed or the fault log may be examined. To restore the keypad as factory installed, use the following procedure:

Keypad Installation in the Inverter Control Board

1. Be sure all power is disconnected from the Series 22H Control. Wait at least 5 minutes for the bus capacitors to discharge before you proceed.

2. Remove the keypad from the ribbon cable and remove the ribbon cable from the keypad connector in the Converter Control Board.

3. Store the extension ribbon cable in its retaining strap (secured to the sheet metal panel).

4. Install the keypad on Inverter Control Board (secured by 4 screws).

5. Close and secure the Series 22H cover.

Programming & Operation 4-1MN722

Section 1 General Information

Baldor Keypad The keypad is used to program the control parameters, operate the motor and monitor

the status and outputs of the control by accessing the display options, diagnostic menus and the fault log.

Figure 4-1 Keypad

JOG - (Green) lights when Jog is active. FWD - (Green) lights when FWD direction is commanded. REV - (Green) lights when REV direction is commanded. STOP - (Red) lights when motor STOP is commanded.

Indicator Lights

Keypad Display - Displays status

information during Local or Remote operation. It also displays information during parameter setup and fault or Diagnostic Information.

PROG - Press PROG to enter the

program mode. While in the Program mode the PROG key is used to edit a

JOG - Press JOG to select the

preprogrammed jog speed. After the JOG key has been pressed, use the FWD or REV keys to run the motor in the direction that is needed. The JOG key is only active in the Local mode.

FWD - Press FWD to initiate forward

rotation of the motor. This key is only active in the Keypad or Local mode.

REV - Press REV to initiate reverse

rotation of the motor. This key is active only in the Keypad or Local mode.

STOP - Press STOP one time to initiate

a stop sequence. Depending on the setup of the control, the motor will either ramp or coast to a stop. This key is operational in all modes of operation unless it has been disabled by the Keypad Stop parameter in the Keypad (programming) Setup Block. Press STOP twice to disable control (coast to stop).

LOCAL - Press LOCAL to change

between the local (keypad) and remote operation. When the control is in the local mode all other external commands to the J1 terminal strip will be ignored with the exception of the external trip input.

DISP - Press DISP to return to Display

mode from Programming mode. Provides operational status and advances to the next display menu item including the diagnostic screens.

SHIFT - Press SHIFT in the program

mode to control cursor movement. Pressing the SHIFT key once moves the blinking cursor one character position to the right. While in Program mode, a parameter value may be reset to the factory preset value by pressing the SHIFT key until the arrow symbols at the far left of the keypad display are flashing, then press an arrow key. In the Display mode the SHIFT key is used to adjust the keypad contrast.

RESET - Press RESET to clear all fault

messages (in local mode). Can also be used to return to the top of the block programming menu without saving any parameter value changes.

parameter setting.

 - (UP Arrow).

Press  to change the value of the parameter being displayed. Pressing  increments the value to the next greater value. Also, when the fault log or parameter list is displayed, the  key will scroll upward through the list. In the local mode pressing the  key will increase motor speed to the next greater value.

ENTER - Press ENTER to save

parameter value changes and move back to the previous level in the programming menu. In the Display mode the ENTER key is used to directly set the local speed reference. It is also used to select other operations when prompted by the keypad display.

 - (Down Arrow)

Press  to change the value of the parameter being displayed. Pressing  decrements the value to the next lesser value. Also, when the fault log or parameter list is displayed, the  key will scroll downward through the list. In the local mode pressing the  key will decrease motor speed to the next lower value.

4-2 Programming & Operation MN722

Section 1 General Information

Display Mode The control is in the DISPLAY MODE at all times except when parameter values are

changed (Programming mode). The Keypad Display shows the status of the control as in the following example.

Motor Status

Control Operation

Output Condition Value and Units

The DISPLAY MODE is used to view operating status, Diagnostic INFO and the Fault Log. The description of how to do these tasks are described on the following pages.

Adjusting Display Contrast When AC power is applied to the control, the keypad should display the status of the

control. If there is no visible display, use the following procedure to adjust the contrast of the display.

(Contrast may be adjusted in display mode when motor is stopped or running)

Action Description Display Comments

Apply Power No visible display

Press DISP Key Places control in display mode

Press SHIFT SHIFT Allows display contrast

Press  or  Key

Press ENTER Saves level of contrast and exits

adjustment Adjusts display intensity

Typical display

to display mode

Display Mode Screens

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing motor speed.

Press DISP key Display mode showing custom

unit output rate.

Press DISP key Display Frequency

Press DISP key DIsplay Current

Press DISP key DIsplay Voltage

Press DISP key Combined DIsplay

Press DISP key Screen to enter Fault Log

Press DISP key Screen to enter Diagnostic Menu

Press DISP key Exit Display mode and return to

Motor Speed display

No faults present. Local keypad mode. If in remote/serial mode, press local for this display.

Output rate display will only appear if Value At Speed parameter is entered.

Programming & Operation 4-3MN722

Section 1 General Information

Display Mode Continued

Display Screens & Diagnostic Information Access

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing motor speed.

Press DISP key 6 times Scroll to Diagnostic Information

Press ENTER key Access diagnostic information. First Diagnostic Information

Press DISP key Display mode showing control

Press DISP key Display mode showing bus

Press DISP key Display mode showing %

Press DISP key Display mode showing opto

Press DISP key Display mode showing actual

Press DISP key Display mode showing operating

Press DISP key Display mode showing continuous

Press DISP key Display mode showing which

Press DISP key Display mode showing motor

Press DISP key Display mode showing parameter

screen

temperature.

voltage.

overload current remaining.

inputs & outputs states. 0=OPEN, 1=CLOSED.

drive running time.

zone, voltage and control type.

amps; PK amps rating; amps/volt scale of feedback, power base ID.

Group1 or 2 expansion boards are installed and recognized.

shaft revolutions from the REV home set point.

table selected.

XXXV

No faults present. Local keypad mode. If in remote/serial mode, press local for this display.

Diagnostic Access screen.

screen.

Opto Inputs states (Left); Opto Outputs states (Right).

HR.MIN.SEC format.

Typical display.

ID is displayed as a hexadecimal value.

Press DISP key Display mode showing software

Press DISP key Displays exit choice. Press ENTER to exit diagnostic

version and revision installed in the control.

information.

4-4 Programming & Operation MN722

Section 1 General Information

Display Mode Continued

Fault Log Access When a fault condition occurs, motor operation stops and a fault code is displayed on the

Keypad display. The control keeps a log of up to the last 31 faults. If more than 31 faults have occurred the oldest fault will be deleted from the fault log to make room for the newest fault. To access the fault log perform the following procedure:

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing motor speed.

Press DISP key 5 times Scroll to the Fault Log screen Fault Log access screen.

Press ENTER key Display first fault type and time

Press  key

Press ENTER key Return to display mode. Display mode stop key LED is on.

fault occurred. Scroll through fault messages.

Display mode.

1=Most recent fault displayed. 2=Second most recent fault, etc.

If no messages, the fault log exit choice is displayed.

Programming & Operation 4-5MN722

Section 1 General Information

Program Mode The Program Mode is used to:

1. Enter motor data.

2. CALC Presets and Autotune the drive.

3. Customize the drive (Control and Motor) parameters to your application.

From the Display Mode press the PROG key to access the Program Mode.

Note: When a parameter is selected, alternately pressing the Disp and Prog keys

will toggle between the Display Mode and the selected parameter. When a parameter is selected for programming, the keypad display gives you the following information:

Parameter Parameter Status

Parameter Status. All programmable parameters are displayed with a “P:” in the lower left corner of the keypad display. If a parameter is displayed with a “V:”, the parameter value may be viewed but not changed while the control is enabled. If the parameter is displayed with an “L:”, the value is locked and the security access code must be entered before its’ value can be changed.

Parameter Blocks Access for Programming

Use the following procedure to access parameter blocks to program the control.

Value and Units

Action Description Display Comments

Apply Power Keypad Display shows this

Press PROG key Press ENTER to access Preset

Press  or  key

Press ENTER key First Level 2 block display.

Press  or  key

Press ENTER key Return to display mode.

opening message. If no faults and programmed for

LOCAL operation. If no faults and programmed for

REMOTE operation.

Scroll to the ACCEL/DECEL block.

Scroll to the Level 2 Block.

Scroll to Programming Exit menu.

Logo display for 5 seconds.

Display mode.

If fault is displayed, refer to the Troubleshooting section of this manual.

Speed parameters. Press ENTER to access Accel

and Decel rate parameters. Press ENTER to access Level 2

Blocks.

Press ENTER to return to Display mode.

4-6 Programming & Operation MN722

Section 1 General Information

Program Mode Continued

Changing Parameter Values when Security Code Not Used

Use the following procedure to program or change a parameter already programmed into the control when a security code is not being used.

The example shown changes the operating mode from Keypad to Bipolar.

Action Description Display Comments

Apply Power Keypad Display shows this

opening message.

Logo display for 5 seconds.

If no faults and programmed for LOCAL operation.

Press PROG key Access programming mode.

Press  or  key

Press ENTER key Access Input Block. Keypad mode shown is the

Press ENTER key Access Operating Mode

Press  key

Press ENTER Save selection to memory. Press ENTER to save selection.

Press  key

Press ENTER key Return to Input Block.

Press DISP key Return to Display Mode. Typical display mode.

Scroll to Level 1 Input Block.

parameter. Scroll to change selection.

Scroll to menu exit.

Display mode. Stop LED on.

Press ENTER to access INPUT block parameter.

factory setting. Keypad mode shown is the

factory setting. At flashing cursor, select desired

mode, BIPOLAR in this case.

Programming & Operation 4-7MN722

Section 1 General Information

Program Mode Continued

Reset Parameters to Factory Settings

Sometimes it is necessary to restore the parameter values to the factory settings. Follow this procedure to do so. Be sure to change the Level 2 Motor Data block “Motor Rated Amps” to the correct value after this procedure (restored factory setting is 999).

Note: All specific application parameters already programmed will be lost when

resetting the control to factory settings.

Note: After factory settings are restored, the drive must be re-tuned.

Action Description Display Comments

Apply Power Keypad Display shows this

opening message.

Logo display for 5 seconds.

If no faults and programmed for LOCAL operation.

Press PROG key Enter program mode.

Press  or  key

Press ENTER key Select Level 2 Blocks.

Press  or  key

Press ENTER key Select Miscellaneous block.

Press  key

Press ENTER key Access Factory Settings

Press  key

Press ENTER key Restores factory settings. “Loading Presets” is first message

Press  key

Scroll to Level 2 Blocks.

Scroll to the Miscellaneous block.

Scroll to Factory Settings parameter.

parameter. Scroll to YES, to choose original

factory settings.

Scroll to menu exit.

Display mode. Stop LED on.

 represents blinking cursor.

“Operation Done” is next “No” is displayed last.

Press ENTER key Return to Level 1 blocks. Exit Level 2 blocks.

Press  or  key

Press ENTER key Return to display mode. Display mode. Stop LED on.

Scroll to Programming exit.

Exit Programming mode and return to Display mode.

4-8 Programming & Operation MN722

Section 1 General Information

Program Mode Continued

Initialize New Firmware

After new firmware is installed, the control must be initialized to the new firmware version and memory locations. Use the following procedure to Initialize the firmware.

Action Description Display Comments

Apply Power Keypad Display shows this

opening message.

Logo display for 5 seconds.

If no faults and programmed for LOCAL operation.

Press PROG key Enter program mode.

Press  or  key

Press ENTER key Select Level 2 Blocks.

Press  or  key

Press ENTER key Select Miscellaneous block.

Press  key

Press ENTER key Access Factory Settings

Press  key

Press ENTER key Restores factory settings. “Loading Presets” is first message

Press  key

Scroll to Level 2 Blocks.

Scroll to the Miscellaneous block.

Scroll to Factory Settings parameter.

parameter. Scroll to YES, to choose original

factory settings.

Scroll to menu exit.

Display mode. Stop LED on.

 represents blinking cursor.

“Operation Done” is next “No” is displayed last.

Press ENTER key Return to display mode. Display mode. Stop LED on.

Press DISP key several times

Press ENTER key Access diagnostic information. Displays commanded speed,

Press DISP key Display mode showing software

Press DISP key Displays exit choice. Press ENTER to exit diagnostic

Scroll to diagnostic information screen.

version and revision installed in the control.

If you wish to verify the software version, enter diagnostic info.

direction of rotation, Local/ Remote and motor speed.

Verify new firmware version.

information.

Programming & Operation 4-9MN722

Section 1 General Information

Parameter Definitions

Converter Control Board Parameters

Converter section parameters are programmed at the factory. Table 4-1 is a list of the parameters that can be changed. However, to make any parameter adjustments the keypad must be installed in the Converter Control Board as described previously in this section. Each Converter section parameter is defined in Table 4-2.

Table 4-1 Converter Section Parameter List

LEVEL 1 BLOCKS

Miscellaneous

Factory Settings Line Inductor Bus Capacitance DAC Selection

Security Control

Security State Access Timeout Access Code

4-10 Programming & Operation MN722

Section 1 General Information

Table 4-2 Converter Control Board Parameter Definitions

Block Title Parameter Description

MISC Factory Settings Restores factory settings for converter section parameters. Select YES and press

Line Inductor

(Boost Regulator)

Bus Capacitance Sets the nominal DC Bus capacitance. This parameter sets the voltage loop gain for the

DAC Selection This parameter configures both Analog Outputs #1 (J1-6) and #2 (J1-7) at the same time

SECURITY CONTROL

Security State Off - No security Access Code required to change parameter values.

Access Timeout The time in seconds the security access remains enabled after leaving the programming

Access Code A 4 digit number code. Only persons that know the code can change secured Level 1

ENTER to restore factory parameter values. The Keypad Display will show “Operation Done” then return to “NO” when complete.

The value of the internal or external boost regulator inductor in “mH”. This parameter

sets the current loop gain of the converter section. This value is factory set and should not require adjustment.

converter section. This value is factory set and should not require adjustment unless more capacitance or more controls are added across the DC Bus.

for troubleshooting purposes.

AB BC Cross- This selection provides a scaled 0-5VDC signals at Outputs #1 and #2.

Analog Output #1 represents the Line-Line voltage (L1–L2). Analog Output #2 represents the Line-Line voltage (L2–L3).

DQ CONTRLR- This selection provides a scaled 0-5VDC signals at Outputs #1 and #2.

Analog Output #1 represents the Direct Control voltage. Analog Output #2 represents the Quadrature Control voltage.

DQ Currents- This selection provides a scaled 0-5VDC signals at Outputs #1 and #2.

Analog Output #1 represents the Direct Control current. Analog Output #2 represents the Quadrature Control current.

IQ Command-This selection provides a scaled 0-5VDC signals at Outputs #1 and #2.

Analog Output #1 represents the Quadrature Command signal. Analog Output #2 represents the Quadrature Feedback signal.

IB and IC- This selection provides a scaled 0-5VDC signals at Outputs #1 and #2.

Analog Output #1 represents the Phase B current feedback. Analog Output #2 represents the Phase C current feedback.

Va and Vb- This selection provides a scaled 0-5VDC signals at Outputs #1 and #2.

Analog Output #1 represents the PWM voltage for Phase A. Analog Output #2 represents the PWM voltage for Phase B.

Ia and Ib- This selection provides a scaled 0-5VDC signals at Outputs #1 and #2.

Analog Output #1 represents Phase A current. Analog Output #2 represents Phase B current.

Local - Requires security Access Code to be entered (using the keypad) before

parameter changes can be made using the Keypad.

Serial - Requires security Access Code to be entered (over the Serial Link) before

parameter changes can be made using the Serial Link.

Total - Requires security Access Code to be entered (using Keypad or Serial Link)

before parameter changes can be made using the Keypad or serial link.

Note: If security is set to Local, Serial or Total you can press PROG and scroll

through the parameter values and view their values but you are not allowed to change their values unless you enter the correct access code.

mode. If you exit and go back into the program Mode within this time limit, the security Access Code does not have to be re-entered. This timer starts when leaving the Program Mode (by pressing DISP).

Note: This feature is not available when using the Serial operating mode or if

power is cycled.

and Level 2 parameter values.

Note: Please record your access code and store it in a safe place. If you cannot

gain entry into parameter values to change a protected parameter, please contact Baldor. Be prepared to give the 5 digit code shown on the lower right side of the Keypad Display at the Security Control Access Code parameter prompt.

Programming & Operation 4-11MN722

Section 1 General Information

Inverter Control Board Parameters (Version 3.20)

To make programming easier, parameters have been arranged into the two level structure shown in Table 4-3. Press the PROG key to enter the programming mode and the “Preset Speeds” programming block will be displayed. Use the Up () and Down () arrows to scroll through the parameter blocks. Press ENTER to access parameters within a programing block.

Tables 4-4 and 4-5 provide an explanation of each parameter. A complete Parameter Block Values list is located at the end of this manual. This list defines the programmable range and factory preset value for each parameter. The list has a space to record your settings for future reference.

Table 4-3 Inverter Section Parameter List

LEVEL 1 BLOCKS

Preset Speeds Input Output Limits Motor Data – Continued

Preset Speed #1 Operating Mode Operating Zone Resolver Speeds Preset Speed #2 Command Select Min Output Speed CALC Presets Preset Speed #3 ANA CMD Inverse Max Output Speed Preset Speed #4 ANA CMD Offset PK Current Limit Brake Adjust Preset Speed #5 ANA 2 Deadband PWM Frequency Resistor Ohms Preset Speed #6 ANA1 CUR Limit CUR Rate Limit Resistor Watts Preset Speed #7 DC Brake Current Preset Speed #8 Output Custom Units Preset Speed #9 Opto Output #1 Decimal Places Process Control Preset Speed #10 Opto Output #2 Value at Speed Process Feedback Preset Speed #11 Opto Output #3 Units of Measure Process Inverse Preset Speed #12 Opto Output #4 Setpoint Source Preset Speed #13 Zero SPD Set PT Protection Setpoint Command Preset Speed #14 At Speed Band Overload Set PT ADJ Limit Preset Speed #15 Set Speed External Trip Process ERR TOL

Analog Out #1 Local Enable INP Process PROP Gain Accel / Decel Rate Analog Out #2 Following Error Process INT Gain Accel Time #1 Analog #1 Scale Torque Proving Process DIFF Gain Decel Time #1 Analog #2 Scale Follow I:O Ratio S-Curve #1 Position Band Miscellaneous Follow I:O OUT Accel Time #2 Restart Auto/Man Master Encoder Decel Time #2 Vector Control Restart Fault/Hr S-Curve #2 Ctrl Base Speed Restart Delay Communications Protocol

Feedback Filter Factory Settings Protocol Jog Settings Feedback Align Homing Speed Baud Rate Jog Speed Current PROP Gain Homing Offset Drive Address Jog Accel Time Current INT Gain Jog Decel Time Speed PROP Gain Security Control Auto-Tuning Jog S-Curve Time Speed INT Gain Security State CALC Presets

Speed DIFF Gain Access Timeout CMD Offset Trim Keypad Setup Position Gain Access Code CUR Loop Comp Keypad Stop Key Slip Frequency Flux CUR Setting Keypad Stop Mode Stator R1 Motor Data Feedback Test Keypad Run Fwd Stator X1 Motor Voltage Slip Freq Test Keypad Run Rev Prop Gain #1 Motor Rated Amps SPD CNTRLR CALC Keypad Jog Fwd Int Gain #1 Motor Rated SPD Keypad Jog Rev Motor Rated Freq Local Hot Start Motor Mag Amps

Encoder Counts

LEVEL 2 BLOCKS

4-12 Programming & Operation MN722

Section 1 General Information

Table 4-4 Inverter Control Board Level 1 Parameter Definitions

Block Title Parameter Description

PRESET SPEEDS

ACCEL/DECEL RATE

JOG SETTINGS Jog Speed Jog Speed is the programmed speed used during for jog. Jog can be initiated from the

Preset Speeds #1 – #15

Allows selection of 15 predefined motor operating speeds.

Each speed may be selected using external switches connected to J1-11, J1-12, J1-13 and J1-14 when Operating Mode is set to 15 Speed. For motor operation, a motor direction command must be given along with a preset speed command.

Accel Time #1,2 Accel time is the number of seconds required for the motor to increase at a linear rate

from 0 RPM to the RPM specified in the “Max Output Speed” parameter in the Level 2 Output Limits block.

Output Limits block.

Decel Time #1,2

Decel time is the number of seconds required for the motor to decrease at a linear rate

from the speed specified in the “Max Output Speed” parameter to 0 RPM.

S-Curve #1,2 S-Curve is a percentage of the total Accel and Decel time and provides smooth starts

and stops. Half of programmed S-Curve % applies to Accel and half to Decel ramps. 0% represents no “S” and 100% represents full “S” with no linear segment.

Note: Accel #1, Decel #1 and S-Curve #1 are associated together. Likewise,

Accel #2, Decel #2 and S-Curve #2 are associated together. These associations can be used to condition any Preset Speed or External Speed command.

Note: If drive faults occur during rapid Accel or Decel, selecting an S-curve may

eliminate the faults.

keypad or terminal strip. At the Keypad, press the JOG key then press and hold the FWD or REV. For Standard Run, close the JOG input (J1-12) then close and maintain the direction input (J1-9 or J1-10).

Jog Accel Time

Jog Decel Time

Jog S-Curve

Curve

Output Speed

Accel Time

Accel S-Curves

40%

Curve

Process Control mode operation is different. If the terminal strip Process Mode Enable input (J1-13) is closed, pressing the Keypad JOG key (or closing J1-14) will cause the drive to move in the direction of the error (without pressing FWD or REV).

Jog Accel Time changes the slope of the jog accel ramp. It is the time from zero speed to maximum speed programmed in seconds.

Jog Decel Time changes the slope of the jog decel ramp. It is the time from maximum speed to zero speed programmed in seconds.

Jog S-Curve changes the S-Curve to a preset value for jog mode.

Figure 4-2 40% S-Curve Example

40%

Curve

20 %

Output Speed

Decel S-Curves

Curve

Decel Time

20 %

Programming & Operation 4-13MN722

Section 1 General Information

Table 4-4 Inverter Control Board Level 1 Parameter Definitions - Continued

Block Title Parameter Description

KEYPAD SETUP Keypad Stop Key

Keypad Stop Mode

Keypad Run FWD Keypad Run REV Keypad Jog FWD Keypad Jog REV Loc. Hot Start

INPUT Operating Mode

Command Select

ANA CMD Inverse “OFF” will cause a low input voltage (e.g. 0VDC) to be a low motor speed command and

ANA CMD Offset Provides an offset to the Analog Input to minimize signal drift. For example, if the

ANA 2 Deadband

ANA 1 CUR Limit

Stop Key - Allows keypad “STOP” key to initiate motor stop during remote or serial

Stop Mode - Selects if the Stop command causes the motor to “COAST” to a stop or

Run FWD - ON makes the keypad “FWD” key active in Local mode. Run REV - ON makes the keypad “REV” key active in Local mode. Jog FWD - ON makes the keypad “FWD” key active in Local Jog mode. Jog REV - ON makes the keypad “REV” key active in Local Jog mode. Loc. Hot Start OFF disables the Stop input at J1-11 in the keypad operating mode.

Ten “Operating Modes” are available. Choices are: Keypad, Standard Run, 15SPD, 3

SPD ANA 2 Wire, 3 SPD ANA 3 Wire, Serial, Bipolar, Process, EPOT 2 Wire and EPOT 3 Wire. External connections to the control are made at the J1 terminal strip (wiring diagrams are shown in Section 3 “Operating Modes”).

Selects the external speed reference to be used. The easiest method of speed control is

to select POTENTIOMETER and connect a 5KW pot to J1-1, J1-2, and J1-3. ±5, ±10VDC or 4-20mA input command can be applied to J1-4 and J1-5.

If long distance is required between the external speed control and the control, the 4-20mA

selections at J1-4 and J1-5 should be considered. Current loop allows long cable lengths without attenuation of the command signal.

10 VOLT W/T ORQ FF - when a differential command is present at J1-4 and 5, allows addi-

tional 5V torque feedforward input at J1-1, 2 and 3 to set a predetermined amount of torque inside the rate loop with high gain settings.

EXB PULSE FOL - selects optional Master Pulse Reference/Isolated Pulse Follower ex-

pansion board if installed. 5VOLT EXB - selects optional High Resolution I/O expansion board if installed. 10VOLT EXB - selects optional High Resolution I/O expansion board if installed. 4–20mA EXB – selects the 4–20mA input of the optional High Resolution I/O expansion

board if installed. 3-15 PSI EXB selects optional 3-15 PSI expansion board if installed. Tachometer EXB- selects optional DC Tachometer expansion board if installed. Serial -selects optional Serial Communications expansion board if installed. None - Used in Process Control mode, two input configuration with no Feedforward input.

Note: When using the 4-20mA input, the JP1 jumper on the main control board

a maximum input voltage (e.g. 10VDC) to be a maximum motor speed command. “ON” will cause a low input voltage (e.g. 0VDC) to be a maximum motor speed command

and a maximum input voltage (e.g. 10VDC) to be a low motor speed command.

minimum speed signal is 1VDC (instead of 0VDC) the ANA CMD Offset can be set to

-10% so the minimum voltage input is seen by control as 0VDC.

Allows a defined range of voltage to be a deadband. A command signal within this

range will not affect the control output. The deadband value is the voltage above and

below the zero command signal level.

“OFF” Allows normal control operation. “ON” Allows the 5V input at J1-2 (referenced to J1-1) to be used for reduction of the

programmed current limit parameter for torque trimming during operation.

operation (if Stop key is set to Remote ON). If active, pressing “STOP” automatically selects Local mode and initiates the stop command.

“REGEN” to a stop. In COAST, the motor is turned off and allowed to coast to a stop. In REGEN, the voltage and frequency to the motor is reduced at a rate set by “Decel Time”.

ON enables the Stop input at J1-11 in the keypad operating mode.

must be moved to pins 2 and 3.

4-14 Programming & Operation MN722

Section 1 General Information

Table 4-4 Inverter Control Board Level 1 Parameter Definitions - Continued

Block Title Parameter Description

OUTPUT OPTO OUTPUT

#1 – #4

Zero SPD Set PT Sets the speed at which the Zero Speed opto output becomes active (turns on). When the

At Speed Band The At Speed Band serves two Opto Output Conditions and the Level 2 Protection block

Set Speed Sets the speed that the AT Set Speed opto output becomes active (turns on). When the

Four optically isolated digital outputs that have two operating states, logical High or Low.

Each output may be configured to any of the following conditions:

Condition Description

Ready - Active when power is applied and no faults are present. Zero Speed - Active when motor RPM is below the value of the Level 1 Output

At Speed - Active when output speed is within the speed range defined by

At Set Speed - Active when output speed is at or above the Level 1 Output

Overload - Active during an Overload fault caused by a time out when

Keypad Control - Active when control is in Local keypad control. Fault - Active when a fault condition is present. Following ERR - Active when the motor speed is outside the user specified

Motor Direction - Active High when REV direction feedback is sensed. Active Low

Drive On - Active when control is “Ready” (has reached excitation level and

CMD Direction - Active when Forward or Reverse is selected or enabled. Logical

AT Position - Active during an internal positioning command when control is

Over Temp Warn - Active when control heat sink is within 3°C of Int Overtemp. Process Error - Active when process feedback signal is outside the Level 2

Drive Run - Active when drive is Ready, Enabled, Speed or Torque command

Serial – Active when in Serial mode.

speed is less than the ZERO SPD SET PT, the Opto Output becomes active. This is useful when a motor brake is to interlock operation with a motor.

Following Error:

Sets the speed range in RPM at which the At Speed opto output turns on and remains

active within the range.

Sets the Following Error Tolerance Band for the Level 1 OUTPUT, Opto Output condition

Following ERR. The opto output is active if the motor speed is outside this band.

Sets the allowable following error speed band. This value is used by the Level 2

Protection block, Following Error parameter (if it is set to ON). If the drive speed falls out of this band, the Level 2 Protection block, Following Error parameter will shut down the drive (if it is set to ON).

speed is greater than the Level 1 Output SET SPEED parameter, the Opto Output becomes active. This is useful when another machine must not start or stop until the motor exceeds a predetermined speed.

“Zero SPD Set Pt” parameter.

the Level 1 Output “At Speed Band” parameter.

“Set Speed” parameter.

output current is greater than Rated Current.

tolerance band defined by the At Speed Band parameter.

when FWD direction feedback is sensed.

capable of producing torque).

output state indicates Forward or Reverse direction. High=FWD, Low=REV.

within the position band parameter tolerance.

Process Control block, PROC ERR TOL parameter value. Turns off when process feedback error is within tolerance.

received with FWD/REV direction issued.

Programming & Operation 4-15MN722

Section 1 General Information

Table 4-4 Inverter Control Board Level 1 Parameter Definitions - Continued

Block Title Parameter Description

OUTPUT (Continued)

Analog Output #1 and #2

Analog #1 Scale & Analog #2 Scale

Position Band Sets the acceptable range in digital counts (pulses) at which the AT Position Opto

Two Analog 0-5VDC linear outputs may be configured to represent any of 19 conditions

Condition Description

ABS Speed - Represents the absolute motor speed where 0VDC = 0 RPM and ABS Torque - Represents the absolute value of torque where Speed Command - Represents the absolute value of commanded speed where PWM Voltage - Represents the amplitude of PWM voltage where Flux Current - Represents the actual portion of total current used for excitation. CMD Flux CUR - Represents the calculated value for flux current. Load Current - Represents the actual portion of total current used to produce torque

CMD Load Current - Represents the calculated value of load current. Motor Current - Amplitude of continuous current including motor excitation current. Load Component - Amplitude of load current not including the motor excitation Quad Voltage - Load controller output. Used to diagnose control problems.

Direct Voltage - Flux controller output. Used to diagnose control problems. AC Voltage - A scaled AC waveform that represents the AC line to line motor

Bus Voltage - Bus voltage scaled to 0-5VDC. 5V = 1000VDC. Torque - Bipolar torque output. 2.5V centered, 5V = Max Positive Torque,

Power - Bipolar power output. 2.5V = Zero Power, 0V = negative rated peak Velocity - Represents motor speed scaled to 0V = negative max RPM, Overload - (Accumulated current)

PH 2 Current - Sampled AC phase 2 motor current. 2.5V = zero amps, PH 3 Current - Sampled AC phase 1 motor current. 2.5V = zero amps, Process Feedback - Represents the selected Process Feedback signal. Setpoint Command - Represents the selected Setpoint Command signal. Position - Position within a single revolution. +5V = 1 complete revolution. Serial – 0–5VDC level that indicates a value programmed by a serial

Scale factor for the Analog Output voltage. Useful to set the zero value or full scale range for external meters.

becomes active (turns on).

as follows:

+5VDC = MAX RPM. +5VDC = Torque at CURRENT LIMIT. +5VDC = MAX RPM. +5VDC = MAX AC Voltage. 5VDC= MAX flux current. 5VDC= MAX commanded flux current. (CW and CCW torque).

5V = Max. CW torque, 0V = Max. CCW torque. 5V = Max. commanded load current. 5VDC = Rated Current. current. 5VDC = Rated Current.

terminal voltage. 0V = Neg Peak PWM voltage. 2.5V centered. 5V = Pos Peak PWM voltage. At rated motor voltage, a full 0 to 5V sinusoidal waveform should be present. This waveform should be at or greater than the motor base frequency. (At half the motor base frequency, a 1.25V to 3.75 sine wave is present.)

0V = Max negative torque. power, +5V = Positive rated peak power. +2.5V = Zero Speed, +5V = positive max RPM.

0V = negative rated peak amps, +5V = positive rated peak amps. 0V = negative rated peak amps, +5V = positive rated peak amps.

2.5V centered, 5V = 100%, 0V = –100%.

2.5V centered, 5V = 100%, 0V = –100%. The counter will reset to 0 every revolution. command.

x (time), Overload occurs at +5V.

4-16 Programming & Operation MN722

Section 1 General Information

Table 4-4 Inverter Control Board Level 1 Parameter Definitions - Continued

Block Title Parameter Description

VECTOR CONTROL CTRL BASE Speed

Sets the speed in RPM at which the saturation voltage of the control is reached. Above this RPM value the control will output constant voltage and variable frequency.

Feedback Filter

Feedback Align Current PROP

Gain Current INT Gain Speed PROP Gain Speed INT Gain Speed DIFF Gain Position Gain Slip Frequency

Stator R1 Stator resistance in ohms. If set too high, the motor will tend to stall at zero speed when

Stator X1 Stator leakage reactance, in ohms at 60Hz. This parameter has most impact when

Prop Gain #1 The anti–saturation controller’s proportional gain. Leave the gain at the factory setting.

INT Gain #1 The anti–saturation controller’s integral gain. Leave the gain at the factory setting.

LEVEL 2 BLOCK ENTERS LEVEL 2 MENU

A larger value provides a more filtered signal but at the cost of reduced bandwidth.

Sets the encoder’s electrical direction of rotation to match that of the motor. Sets the current loop proportional gain.

Sets the current loop integral gain. Sets the speed (velocity) loop proportional gain. Sets the speed (velocity) loop integral gain. Sets the speed (velocity) loop differential gain. Sets the position loop proportional gain. Sets the rated slip frequency of the motor.

reversing or accelerating from low speed. Reducing this value may eliminate the problem. When too low, speed regulation may suffer.

reversing motor rotation at full current limit. If set too low, the decel time will tend to increase.

Do not change this gain unless authorized by Baldor.

Programming & Operation 4-17MN722

Section 1 General Information

Table 4-5 Inverter Control Board Level 2 Parameter Definitions

Block Title Parameter Description

OUTPUT LIMITS Operating Zone Sets the PWM operating zone to Standard 2.5KHz or Quiet 8.0KHz output carrier

MIN Output Speed Sets the minimum motor speed in RPM. During operation, the motor speed will not be

MAX Output Speed Sets the maximum motor speed in RPM. PK Current Limit The maximum output peak current to the motor. Values above 100% of the rated current

PWM Frequency The frequency that the output transistors are switched. PWM frequency is also referred

CUR Rate Limit Limits the rate of torque change in response to a torque command.

CUSTOM UNITS Decimal Places

Value At Speed

Units of Measure

PROTECTION Overload Sets the protection mode to Fault (trip off during overload condition) or to Foldback

External Trip OFF - External Trip is Disabled.

Local Enable INP OFF - Ignores J1-8 input when in the “LOCAL” mode. Following Error This parameter determines if the control is to monitor the amount of following error that

Torque Proving When this parameter is set to ON the control measures output current in all three

frequency. Two operating modes are also selectable: Constant Torque and Variable

Torque.

Constant Torque allows 170 - 200% for 3 seconds overload or 150% for 60 seconds

overload.

Variable Torque allows 115% peak overload for 60 seconds.

allowed to go below this value except for motor starts from 0 RPM or during dynamic

braking to a stop.

are available depending upon the operating zone selected.

to as “Carrier” frequency. PWM should be as low as possible to minimize stress on

the output transistors and motor windings. It is recommended that the PWM

frequency be set to approximately 15 times the maximum output frequency of the

control. Ratios less than 15 will result in non-Sinusoidal current waveforms. See

Figure 4-3.

The number of decimal places of the Output Rate display on the Keypad display. This

value will be automatically reduced for large values. The output rate display is only

available if the Value At Speed parameter value is non zero. Sets the desired output rate per RPM of motor speed. Two numbers are displayed on

the keypad display (separated by a slash “/”). The first number (left most) is the value

you want the keypad to display at a specific motor speed. The second number (right

most) is the motor RPM corresponding to the units in the first number. A decimal may

be inserted into the left numbers by placing the flashing cursor over the up/down

arrow and use the arrow keys. Allows user specified units of measure to be displayed on the Output Rate display. Use

the shift and arrow keys to scroll to the first and successive characters. If the

character you want is not displayed, move the flashing cursor over the special

up/down character arrow on the left side of the display. Use the up/down arrows and

the shift key to scroll through all 9 character sets. Use the ENTER key to save your

selection.

(automatically reduce the output current below the continuous output level) during an

overload. Foldback is the choice if continuous operation is desired. Fault will require

the control be “Reset” manually or automatically after an overload.

Note: The “Foldback” selection may not be available on some early versions of

the software.

ON - External Trip is enabled. If a normally closed contact at J1-16 is opened, an

External Trip fault will occur and cause the drive to shut down.

ON - Requires J1-8 input to be closed to enable the control when in the “LOCAL” mode.

occurs in an application. Following Error is the programmable tolerance for the AT

Speed Opto output as defined by the Level 1 Output block, AT Speed Band

parameter. Operation outside the speed range will cause a fault and the drive will

shut down.

phases to the motor. If output current is unbalanced, the control will trip off generating

a torque proving fault. In a hoist application, for example, this is useful to ensure that

motor torque exists before the fail safe brake is released. “Drive On” output, if

programmed, will not occur if torque proving fails.

4-18 Programming & Operation MN722

Section 1 General Information

Figure 4-3 Maximum Output Frequency vs PWM Frequency

It is recommended that the PWM frequency parameter be set to approximately16 times the maximum output frequency of the control. The greater the ratio, the more sinusoidal the output current waveform will be.

500

400

OUTPUT FREQUENCY

300

200

100

1.00KHz 8.00KHz 16.00KHz

Note: The output current rating of the control must be derated for high PWM

frequency operation as follows: Standard Constant Torque and Standard Variable Torque: Linearly derate to 10% between 2.5 and 5.0KHz (10% derating at 5.0KHz). Quiet Constant Torque and Quiet Variable Torque: Linearly derate to 30% between 8.0 and 16KHz (30% derating at 16KHz).

PWM FREQUENCY

Table 4-5 Inverter Control Board Level 2 Parameter Definitions - Continued

Block Title Parameter Description

MISCELLANEOUS Restart Auto/Man Manual - If a fault or power loss occurs, the control must be manually reset to resume

Restart Fault/Hr The maximum number of automatic restart attempts before requiring a manual restart.

Restart Delay The amount of time allowed after a fault condition for an automatic restart to occur.

Factory Settings Restores factory settings for all parameter values. Select YES and press “ENTER” key

Homing Speed In Bipolar and Serial modes, this parameter sets the speed that the motor shaft will

Homing Offset In Bipolar and Serial modes, this parameter sets the number of digital encoder counts

operation. Automatic - If a fault or power loss occurs, the control will automatically reset to resume operation.

After one hour without reaching the maximum number of faults or if power is turned off and on again, the fault count is rest to zero.

Useful to allow sufficient time to clear a fault before restart is attempted.

to restore factory parameter values. The keypad Display will show “Operation Done” then return to “NO” when completed.

Note: When factory settings are reset, the Motor Rated Amps value is reset to

999.9 amps. This Level 2 Motor Data block parameter value must be changed to the correct value (located on the motor rating plate) before attempting to start the drive.

rotate to a “Home” position when the orient command is issued.

past home at which the motor zero speed command is issued. Quadrature encoder pulses are 4 times the number of encoder lines per revolution. The recommended minimum number is 100 encoder counts to allow for deceleration distance to allow the motor to stop smoothly.

Note: Homing direction is always in the forward direction.

Programming & Operation 4-19MN722

Section 1 General Information

Table 4-5 Inverter Control Board Level 2 Parameter Definitions - Continued

Block Title Parameter Description

SECURITY CONTROL

MOTOR DATA Motor Voltage The rated voltage of the motor (listed on the motor nameplate).

Security State Off - No security Access Code required to change parameter values.

Local - Requires security Access Code to be entered (using the keypad) before

parameter changes can be made using the Keypad. Serial - Requires security Access Code to be entered (over the Serial Link) before

parameter changes can be made using the Serial Link. Total - Requires security Access Code to be entered (using Keypad or Serial Link)

before parameter changes can be made using the Keypad or serial link.

Note: If security is set to Local, Serial or Total you can press PROG and scroll

through the parameter values and view their values but you are not allowed to change their values unless you enter the correct access code.

Access Timeout The time in seconds the security access remains enabled after leaving the programming

mode. If you exit and go back into the program Mode within this time limit, the

security Access Code does not have to be re-entered. This timer starts when leaving

the Program Mode (by pressing DISP).

Note: This feature is not available when using the Serial operating mode or if

power is cycled.

Access Code A 4 digit number code. Only persons that know the code can change secured Level 1

and Level 2 parameter values.

Note: Please record your access code and store it in a safe place. If you cannot

Motor Rated Amps The full load current of the motor (listed on the motor nameplate). If the motor current

exceeds this value for a period of time, an Overload fault will occur.

Motor Rated SPD The rated speed of the motor (listed on the motor nameplate). If Motor Rated SPD =

1750 RPM and Motor Rated Freq = 60 Hz, the Keypad Display will show 1750 RPM

at 60 Hz and 875 RPM at 30Hz.

Motor Rated Freq The rated frequency of the motor (listed on the motor nameplate). Motor Mag Amps The motor magnetizing current value (listed on the motor nameplate). Also called no

load current. Measure using a clamp on amp meter at the AC power line while the

motor is running at line frequency with no load connected to the motor shaft.

Encoder Counts The number of encoder feedback counts (lines per revolution). Resolver Speed The speed of the resolver, if a resolver is used for feedback. CALC Presets This procedure loads preset values into memory that are required to perform Auto Tune.

Always run CALC Presets as the first step of Auto Tune.

4-20 Programming & Operation MN722

Section 1 General Information

Table 4-5 Inverter Control Board Level 2 Parameter Definitions - Continued

Block Title Parameter Description

BRAKE ADJUST Resistor Ohms The dynamic braking resistor value in ohms. Refer to dynamic braking manual or call

Resistor Watts DC Brake Current

PROCESS CONTROL

COMMUNICATIONS Protocol Sets the type of communication the control is to use, RS-232 ASCII, RS-485 ASCII,

Process Feedback Process Inverse

Setpoint Source

Setpoint Command

Set PT ADJ Limit

Process ERR TOL

Process PROP

Gain

Process INT Gain Process DIFF Gain Follow I:O Ratio

Follow I:O Out

Master Encoder

Baud Rate Sets the speed at which communication is to occur. Drive Address Sets the address of the control for communication.

Baldor for additional information.

The dynamic braking resistor watts rating. Refer to dynamic braking manual or call

Baldor for additional information.

The amount of DC injection brake current. 0% = Flux current, 100% = Motor rated

current. (Used during encoderless operation).

Sets the type of signal used for the process feedback signal. Causes the process feedback signal to be inverted. Used with reverse acting processes

that use a unipolar signal such as 4-20mA. If “ON”, 20mA will decrease motor speed and 4mA will increase motor speed.

Sets the source input signal to which the process feedback will be compared.

If “Setpoint CMD” is selected, the fixed value of the set point is entered in the Setpoint Command parameter value.

Sets the value of the setpoint the control will try to maintain by adjusting motor speed.

This is only used when the Setpoint Source is a fixed value “Setpoint CMD” under Setpoint Source.

Sets the maximum speed correction value to be applied to the motor (in response to the

maximum feedback setpoint error). For example, if the max motor speed is 1750 RPM, the setpoint feedback error is 100% and the setpoint adjustment limit is 10%, the maximum speed the motor will run in response to the setpoint feedback error is ±175 RPM. If at the process setpoint, the motor speed is 1500 RPM, the maximum speed adj limits is then 1325 to 1675 RPM.

Sets the width of the comparison band (% of setpoint) with which the process input is

compared. The result is that if the process input is within the comparison band the corresponding Opto Output will become active.

Sets the PID loop proportional gain. This determines how much adjustment to motor

speed or torque (within the Set PT ADJ Limit) is made to reduce process error.

Sets the PID loop Integral gain. This determines how quickly the motor speed or torque

is adjusted to correct long term error.

Sets the PID loop differential gain. This determines how much adjustment to motor

speed (within the Set PT ADJ Limit) is made for transient error.

Sets the ratio of the Master to the Follower in Master/Follower configurations. Requires

the Master Pulse Reference/ Isolated Pulse Follower expansion board. For example, the master encoder you want to follow is a 1024 count encoder. The follower motor you wish to control also has a 1024 count encoder on it. If you wish the follower to run twice the speed of the master, a 1:2 ratio is entered. Fractional ratios such as

0.5:1 are entered as 1:2. Ratio limits are (1-65,535) : (1-20). Note: The Master Encoder parameter must be defined if a value is entered in the

Follow I:O Ratio parameter.

Note: When using Serial Communications to operate the control, this parameter

value is the MASTER portion of the ratio. The FOLLOWER portion of the ratio is set in the Follow I:O Out parameter.

This parameter is used only when Serial Communications is used to operate the control.

A Master Pulse Reference/ Isolated Pulse Follower expansion board is required. This parameter represents the FOLLOWER portion of the ratio. The MASTER portion of the ratio is set in the Follow I:O Ratio parameter when using Serial operating mode.

Only used if an optional Master Pulse Reference/Isolated Pulse Follower expansion

board is installed. Defines the number of pulses per revolution of the master encoder. Programmed into follower drives only.

RS-232 BBP or RS-485 BBP protocol.

Programming & Operation 4-21MN722

Section 1 General Information

Table 4-5 Inverter Control Board Level 2 Parameter Definitions - Continued

Block Title Parameter Description

AUTO TUNING

CALC Presets

CMD Offset Trim CUR Loop COMP Flux CUR Setting Feedback Tests

Slip FREQ Test SPD CNTRLR

CALC

LEVEL 1 BLOCK ENTERS LEVEL 1 MENU

The Auto Tune procedure is used to automatically measure and calculate certain

parameter values. Dynamic Brake Hardware is required to perform “Slip Freq Test” and “Spd Cntrlr Calc” autotuning test. Occasionally, the Auto Tune procedure cannot be run due to various circumstances such as the load cannot be uncoupled from the motor. The control can be manually tuned by entering the parameter values based on calculations you have made. Refer to “Manually Tuning the Control” in the Troubleshooting section of this manual.

Loads operating values into memory. These values are based on information

programmed into the Level 2 Output Limits and Motor Data parameter values.

CALC Presets must be run before Autotuning or manually tuning the drive. This procedure trims out voltage offsets for the differential analog input at J1-4 and J1-5. Measures current response to pulses of one half the rated motor current. Sets motor magnetizing current by running motor at near rated speed. Checks the values for Encoder Lines per revolution and encoder alignment parameters

while the motor is running at near full rated speed. Test will automatically switch

encoder phasing to match motor rotational direction. Calculates motor Slip Frequency during repeated motor accelerations. Should be performed with the load coupled to the motor shaft. Sets the motor current to

acceleration ratio, Speed INT gain and Speed PROP gain values. If done under no

load, the Integral gain will be too large for high inertia loads if the PK Current Limit is

set too low. If the control is too responsive when the drive is loaded, adjust the PK

Current Limit parameter to a greater value and repeat this test.

4-22 Programming & Operation MN722

Section 5 Troubleshooting

Baldor Series 22H Controls require very little maintenance and should provide years of trouble free operation when installed and applied correctly. Occasional visual inspection should be considered to ensure tight wiring connections and to avoid the build up of any dust, dirt, or foreign debris which can reduce heat dissipation. The control should be mounted in a location that protects the internal circuits and external wiring from moisture or liquid contaminants.

When a fault condition occurs, motor operation stops and the fault is displayed on the Keypad Display. If a REGEN FLT is displayed, this indicates a fault in the converter section of the control. To determine the specific converter section fault, the keypad must be moved to the Converter Control Board keypad connector. The fault log can be examined and the specific faults will help to further isolate the failure. A list of possible Converter Control Board Fault Messages is given in Table 5-1. Other fault messages that pertain to the Inverter Control Board are given in Table 5-2.

When a fault has been identified, all input power must be removed from the control to avoid the possibility of electrical shock. The servicing of this equipment should be handled by a qualified electrical service technician experienced in the area of high power electronics.

It is important to familiarize yourself with the following information before attempting any troubleshooting or service of the control. Most troubleshooting can be performed using only a digital voltmeter having an input impedance exceeding 1 megOhm. In some cases, an oscilloscope with 5 MHZ minimum bandwidth may be useful. Before consulting the factory, check that all power and control wiring is correct and installed per the recommendations given in this manual.

No Keypad Display - Display Contrast Adjustment

If there is no visible display, use the following procedure to adjust the contrast of the display.

Action Description Display Comments

Apply Power No visible display.

Press DISP key Puts control in Display mode. Display mode with nothing visible.

Press SHIFT key 2 times Accesses display contrast

Press  or  key

Press ENTER key Saves display contrast

adjustment. Adjusts display contrast

(intensity).

adjustment level and exits to display mode.

When a Fault is Displayed When a fault is displayed, press “DISP” so that you can view the menu items (to go to

Diagnostic or Fault Log menus etc.). When you exit these menus, the fault message will again be displayed. The control must be reset to clear the fault message from the display.

Troubleshooting 5-1MN722

Section 1 General Information

Table 5-1 Converter Control Board Fault Messages

FAULT MESSAGE DESCRIPTION

Current Sens FLT Defective phase current sensor or open circuit detected between control board and current

sensor. DC Bus High Bus over voltage condition occurred. DC Bus Low Bus under voltage condition occurred. GND FLT Low impedance path detected between an output phase and ground. High INIT CUR Phasing between main power connections, zero crossing detectors, line reactor and

control does not match. ID:No Feedback Control board installed in power base that does not have current feedback and current

feedback is required. INT Over-Temp Temperature of control heatsink exceeded safe level. Invalid Base ID Control does not recognize power base ID. Logic Supply FLT Logic power supply not working properly. Lost AB Phase Lost BC Phase Lost User Data Battery backed RAM parameters have been lost or corrupted.

Low INIT Bus V Insufficient bus voltage on startup. Memory Error EEPROM error occurred. Contact Baldor. mP Reset New Base ID Control board sensed a different power base since last time it was powered up. No Faults Fault log is empty. Overcurrent FLT Instantaneous over current condition detected by bus current sensor. Overload Output current exceeded allowable rating. PWR Base FLT Desaturation of power device occurred or bus current threshold exceeded. Sync To Line Incorrect line phasing or frequency detected on startup.

Missing phase detected by mP.

When fault cleared (Reset), the control should reset to factory preset values.

Watchdog timer detected error.

5-2 Troubleshooting MN722

Section 1 General Information

Table 5-2 Inverter Control Board Fault Messages

FAULT MESSAGE DESCRIPTION

Current Sens FLT Defective phase current sensor or open circuit detected between control board and current

sensor. DC Bus High Bus over voltage condition occurred. DC Bus Low Bus under voltage condition occurred. Encoder Loss Encoder coupling slipping or broken; noise on encoder lines, encoder power supply loss or

defective encoder. External Trip An open circuit on J1-16 typically indicating an external over temperature condition. Following Error Excessive following error detected between command and feedback signals. GND FLT Low impedance path detected between an output phase and ground. INT Over-Temp Temperature of control heatsink exceeded safe level. Invalid Base ID Control does not recognize power base ID. Inverter Base ID Control board installed on power base without current feedback. Line Regen FLT Indicates a converter section fault. Logic Supply FLT Logic power supply not working properly. Lost User Data Battery backed RAM parameters have been lost or corrupted.

When fault cleared (Reset), the control should reset to factory preset values. Low INIT Bus V Insufficient bus voltage on startup. Memory Error EEPROM error occurred. Contact Baldor. New Base ID Control board sensed a different power base since last time it was powered up. No Faults Fault log is empty. No EXB Installed Programmed parameter requires an expansion board. Over Current FLT Instantaneous over current condition detected by bus current sensor. Overload - 1 min Output current exceeded 1 minute rating. Overload - 3 sec Output current exceeded 3 second rating. Over speed Motor RPM exceeded 110% of programmed MAX Motor Speed. mP Reset PWR Base FLT Desaturation of power device occurred or bus current threshold exceeded. Resolver Loss Resolver feedback problem is indicated (if resolver used). Torque Prove FLT Unbalanced current between all 3 motor phases. User Fault Text Custom software operating fault occurred.

Power cycled before the residual Bus voltage reached 0VDC.

Troubleshooting 5-3MN722

Section 1 General Information

How to Access the Fault Log When a fault condition occurs, motor operation stops and a fault code is displayed on

the keypad display. The control keeps a log of up to the last 31 faults. If more than 31 faults have occurred the oldest fault will be deleted from the fault log to make room for the newest fault. To access the fault log use the following procedure:

Action

Apply Power Logo display for 5 seconds.

Display mode showing output frequency

Press DISP key 5 times Use DISP key to scroll to the

Press ENTER key Display first fault type and time

Press  key

Press ENTER key Return to display mode. Display mode stop key LED is on.

Fault Log entry point.

fault occurred. Scroll through fault messages.

Description Display Comments

Display mode.

Typical display.

If no messages, the fault log exit choice is displayed.

5-4 Troubleshooting MN722

Section 1 General Information

How to Clear the Fault Log Use the following procedure to clear the fault log and reset the internal clock.

Action

Apply Power Logo display for 5 seconds.

Display mode showing output frequency.

Press DISP key Press DISP to scroll to the Fault

Press ENTER key Displays most recent message. 1=Most recent fault.

Press SHIFT key

Press RESET key

Press SHIFT key

Press ENTER key Fault log is cleared. No faults in fault log. Also resets

Press  or  key

Log entry point.

Scroll Fault Log Exit.

Description Display Comments

Display mode.

2=Second most recent fault, etc.

the internal clock.

Press ENTER key Return to display mode.

Troubleshooting 5-5MN722

Section 1 General Information

How to Access Diagnostic Information

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing motor speed.

Press DISP key 6 times Scroll to Diagnostic Information

screen

Press ENTER key Access diagnostic information. First Diagnostic Information

Press DISP key Display showing control

temperature.

Press DISP key Display showing bus voltage.

No faults present. Local keypad mode. In remote/serial mode, disable drive then press local for this display.

Diagnostic Access screen.

screen.

XXXV

Press DISP key Display showing % overload

Press DISP key Display showing opto inputs &

Press DISP key Display showing actual drive

Press DISP key Display showing operating zone,

current remaining.

outputs states. 0=OPEN, 1=CLOSED.

running time.

voltage and control type.

Opto Inputs states (Left); Opto Outputs states (Right).

HR.MIN.SEC format.

Press DISP key Display showing continuous

amps; PK amps rating; amps/volt scale of feedback, power base ID.

Press DISP key Display showing which Group1 or

2 expansion boards are installed and recognized.

Press DISP key Display showing motor shaft

revolutions from the REV home set point.

Press DISP key Display mode showing parameter

table selected.

Press DISP key Display showing software version

and revision installed in the control.

Press DISP key Displays exit choice. Press ENTER to exit diagnostic

ID is displayed as a hexadecimal value.

information.

5-6 Troubleshooting MN722

Section 1 General Information

Table 5-3 Converter Section Troubleshooting

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

Current Sense FLT Open circuit between control board

DC Bus High Incorrect setting of converter bridge

DC Bus Low Input voltage too low. Monitor power line fluctuations with date and time imprint

GND FLT Improper wiring. Disconnect wiring between control and motor. Retry test.

High INIT CUR Incorrect phasing between input

ID:No Feedback Control board is installed on wrong

INT Over-Temp Ambient temperature too high. Relocate control to a cooler area. Add cooling fans or air condition the

Invalid Base ID Control does not recognize

Logic Supply FLT Power supply malfunctioned. Replace logic power supply. Lost AB Phase Wire disconnected or phase lost. Check for input power on all 3 phases.

Lost BC Phase Wire disconnected or phase lost. Check for input power on all 3 phases.

Lost User Data Battery backed memory failure. Parameter data was erased. Disconnect power to control and

Low INIT Bus V Improper AC line voltage. Check input AC voltage level. Memory Error EEPROM memory fault occurred. Press “RESET” key on keypad. If fault remains, call Baldor. mP Reset

New Base ID Software parameters are not

and current sensor or defective current sensor.

parameter. Decel rate too fast. Increase Decel time parameter setting.

power, filter assembly and line reactors.

power base.

Drive overloaded. Verify proper sizing of control and motor. Correct loading of motor. Cooling fans or air path is clogged. Clean fans and air path.

converter power base.

Power was cycled before Bus voltage reached 0VDC.

initialized on newly installed control board.

Check control wires between control board and current feedback sensor.

Check Bus Capacitance value of converter section parameters.

to isolate power problem.

Check power line disturbances (sags caused by start up of

other equipment).

Use step up isolation transformer if needed.

If GND FLT is cleared, reconnect motor leads and retry the test. Rewire as necessary. Repair motor. If GND FLT remains, contact Baldor.

Check connections for proper phasing as detailed in Section 3 of this manual.

Change power base to one that has current feedback sensors.

cabinet.

Ensure fans are operating. Press “RESET” key on keypad. If fault remains, call Baldor.

Check wiring and correct errors in all output wiring and wiring between individual components on EK type controls. Press “RESET” key on keypad. If fault remains, call Baldor.

apply power (cycle power). Enter all parameters. Cycle power. If problem persists, contact Baldor.

Press “RESET” key on keypad.

Disconnect power and allow at least 5 minutes for Bus capacitors to discharge before applying power. If fault remains, call Baldor.

Press “RESET” key on keypad to clear the fault condition. Cycle power (turn power OFF then ON). Refer to Section 4 and initialize new software. Access diagnostics and compare power base ID number to list in Table 5-5 to ensure a match. Re-enter the Parameter Block Values you recorded in the User Settings at the end of this manual. Autotune the control. If fault remains, call Baldor.

Continued on next page.

Troubleshooting 5-7MN722

Section 1 General Information

Table 5-3 Converter Section Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

Over Current FLT Possible converter transistor failure. Check transistors for shorted junctions.

Incorrect inductance set in Line

Inductor parameter. Overload FLT Drive overloaded. Verify proper sizing of control and motor. PWR Base FLT Incorrect phase connections. Check connections for proper phasing of EK drive components as

Excessive current draw.

Power device saturated.

Electrical noise from DC coils. Install flyback diodes (reverse biased 1N4002 or equivalent)across all

Electrical noise from AC coils. Install RC snubbers on all external AC coils. Sync To Line Incorrect phase connections. Check connections for proper phasing as detailed in Section 3 of this

Incorrect frequency detected at

startup.

Check inductance parameter value.

detailed in Section 3 of this manual.

Disconnect motor wiring and retry test. If fault remains, call Baldor.

external DC relay coils..

manual. Check incoming line voltage and frequency.

5-8 Troubleshooting MN722

Section 1 General Information

Table 5-4 Inverter Section Troubleshooting

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

No Display Lack of input voltage. Check input power for proper voltage.

Loose connections. Check input power termination.

Bent pins in keypad to control connector.

Adjust display contrast. See Adjust Display Contrast in Sec. 4.

Auto Tune Encoder miswired. Correct wiring problems. Encoder Test failed

Current Sense FLT Open circuit between control board

DC Bus High Excessive regenerated power. Increase the DECEL time.

DC Bus Low Input voltage too low. Disconnect dynamic brake hardware and repeat operation.

Encoder Loss Encoder power supply failure. Check 5VDC at J1-29 and J1-30.

Encoder coupling slipping, broken or misaligned.

Excessive noise on encoder lines. Check the position counter in the Diagnostic Information for

Wrong parameter values for “Motor Base Speed”, “Frequency” or “Encoder Counts”.

Motor coupled to load. Disconnect load then autotune.

and current sensor. Defective current sensor. Replace current sensor.

Input voltage too high. Verify proper AC line voltage.

Encoder coupling slipping, broken or misaligned

Excessive noise on encoder lines. Check the position counter in the Diagnostic Information for

Verify fuses are good (or breaker is not tripped).

Verify connection of operator keypad. Check connector pins and straighten as required.

Correct encoder to motor coupling.

jittering which will confirm an encoder problem. Use recommended encoder cable. Check encoder connections including shields. Separate encoder leads from power wiring. Cross encoder wires and power leads at 90°. Electrically isolate encoder from motor. Install optional Isolated Encoder Feedback expansion board.

Enter correct parameter values.

Check connections between control board and current sensor.

Use step down isolation transformer if needed. Use line reactor to minimize spikes.

Verify proper AC line voltage. Use step up isolation transformer if needed. Check power line disturbances (sags caused by start up of

other equipment). Monitor power line fluctuations with date and time imprint

to isolate power problem.

Also check at encoder end pins D and F. Check encoder cable continuity.

Correct or replace encoder to motor coupling.

jittering which will confirm an encoder problem. Check encoder connections. Separate encoder leads from power wiring. Use Baldor encoder cable. Cross encoder wires and power leads at 90°. Electrically isolate encoder from motor. Install optional Isolated Encoder Feedback expansion board.

Continued on next page.

Troubleshooting 5-9MN722

Section 1 General Information

Table 5-4 Inverter Section Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

External Trip Motor ventilation insufficient. Clean motor air intake and exhaust.

Motor draws excessive current. Check motor for overloading.

No thermostat connected. Connect thermostat.

Poor thermostat connections. Check thermostat connections. External trip parameter incorrect. Verify connection of external trip circuit at J1-16.

Following ERR Speed proportional gain set too low. Following error tolerance band set too narrow.

Current limit set too low. Increase Current Limit parameter value. ACCEL/DECEL time too short. Increase ACCEL/DECEL parameter time Excessive load. Verify proper sizing of control and motor.

GND FLT Improper wiring.

Wiring shorted in conduit. Motor winding shorted.

INT Over-Temp Motor Overloaded. Correct motor loading.

Ambient temperature too high. Check that air flow path is clean and free of debris.

Invalid Base ID Control does not recognize HP and

Inverter Base ID Power base with no output phase

Logic Supply FLT Power supply malfunctioned. Replace logic power supply. Lost User Data Battery backed memory failure. Parameter data was erased. Disconnect power to control and

Low INIT Bus V Improper AC line voltage. Check input AC voltage level. Memory Error EEPROM memory fault occurred. Press “RESET” key on keypad. If fault remains, call Baldor. mP Reset

Voltage configuration.

current sensors being used.

Power was cycled before Bus voltage reached 0VDC.

Check external blower for operation. Verify motor’s internal fan is coupled securely. Verify correct line power to external blower.

Verify proper sizing of control and motor.

Verify connection of all external trip circuits used with thermostat. Disable thermostat input at J1-16 (External Trip Input).

Set external trip at J1-16.

Increase Speed PROP Gain parameter value.

Disconnect wiring between control and motor. Retry test. If GND FLT is cleared, reconnect motor leads and retry the test. Rewire as necessary. Repair motor. If GND FLT remains, contact Baldor.

Verify proper sizing of control and motor.

Relocate control to cooler operating area. Add cooling fans or air conditioner to control cabinet.

Press “RESET” key on keypad. If fault remains, access diagnostic info and compare power output section Power Base ID # with Table 5-5. If different, contact Baldor.

Replace power base with one that has output leg current

feedback. Contact Baldor.

apply power (cycle power). Enter all parameters. Cycle power. If problem persists, contact Baldor.

Press “RESET” key on keypad.

Disconnect power and allow at least 5 minutes for Bus capacitors to discharge before applying power. If fault remains, call Baldor.

parameter to “OFF” if no connection made

Continued on next page.

5-10 Troubleshooting MN722

Section 1 General Information

Table 5-4 Inverter Section Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

Motor has wrong response to Speed Command

Motor Shaft Oscillates back and forth

Motor Shaft rotates at low speed regardless of commanded speed

Motor Shaft rotates in wrong direction

Motor Will Not Not enough starting torque. Increase Current Limit setting. Start

Motor Will Not Max Output Speed set too low. Adjust Level 2 Output Limits block, MAX Output Speed parameter value. Reach Maximum Speed

Motor Will Not Stop Rotation

Analog input common mode voltage may be excessive.

Incorrect MIN or MAX speed settings.

Analog offset trim is incorrectly set. Re-run “Offset Trim” autotune test. Speed gain value is too large. Reduce the Level 1 Vector Control block, Speed PROP Gain and

Incorrect encoder alignment direction.

Incorrect encoder wiring. Reverse the A and A or B and B encoder wires at the J1 input to control

Motor overloaded. Check for proper motor loading.

Motor may be commanded to run below minimum speed setting.

Incorrect Command Select parameter.

Incorrect speed command. Verify control is receiving proper command signal at J1.

Motor overloaded. Check for mechanical overload. If unloaded motor shaft does not rotate

Improper speed command. Verify control is set to proper operating mode to receive speed command.

Speed potentiometer failure. Replace potentiometer. MIN Output Speed parameter set

too high. Improper speed command. Verify control is receiving proper command signal at input terminals.

Speed potentiometer failure. Replace potentiometer. Analog input common mode voltage

may be excessive.

Analog offset trim set incorrectly. Re-run “Offset Trim” autotune test.

Connect control input source common to control common to minimize common mode voltage. Maximum common mode voltage at terminals J1-4 and J1-5 is ±15VDC referenced to chassis common.

Check Level 2 Output Limits block, MIN Output Speed and MAX Output Speed parameter values and adjust as needed.

Speed INT Gain parameter values. Change the Feedback Align parameter in the Level 1 Vector Control block.

If Reverse, set to Forward. If Forward, set to Reverse.

Check encoder connections. Change the Feedback Align parameter in the Level 1 Vector Control block. If Reverse, set to Forward. If Forward, set to Reverse.

and change encoder direction in the Feedback Align parameter in the Level 1 Vector Control block.

Check couplings for binding. Verify proper sizing of control and motor.

Increase speed command or reduce minimum speed setting.

Change Command Select parameter to match wiring at J1.

freely, check motor bearings.

Verify control is receiving proper command signal at input terminals. Check velocity loop gains.

Adjust MIN Output Speed parameter value.

Verify control is set to receive speed command.

Connect control input source common to control common (J1-1) to minimize common mode voltage. Maximum common mode voltage at terminals J1-4 and J1-5 is ±15VDC referenced to chassis common.

Adjust the Level 1 Input block, ANA CMD Offset parameter to obtain zero speed.

Continued on next page.

Troubleshooting 5-11MN722

Section 1 General Information

Table 5-4 Inverter Section Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

New Base ID Software parameters are not

No EXB Installed Incorrect programmed parameter. Change the Level 1 Input block, Command Select parameter and the Level

Over Current FLT Current Limit parameter set lower

Overload - 3 Sec FLT

Overload - 1 Min FLT

Over Speed Motor exceeded 110% of MAX

initialized on newly installed control board.

Need expansion board. Install the correct expansion board for selected operating mode.

than drive rating. ACCEL/DECEL time too short. Increase the Level 1 ACCEL/DECEL Rate block ACCEL/DEC parameters. Encoder coupling slipping, broken

or misaligned. Encoder bearing failure. Replace encoder. Excessive noise on encoder lines. Check the position counter in the Diagnostic Information for

Electrical noise from external DC coils.

Electrical noise from external AC coils.

Excessive load. Reduce the motor load.

Peak output current exceeded 3 second rating.

Encoder coupling slipping, broken or misaligned.

Encoder bearing failure. Replace encoder. Peak output current exceeded 1

minute rating.

Encoder coupling slipping, broken or misaligned.

Encoder bearing failure. Replace encoder.

Speed parameter value.

Press “RESET” key on keypad to clear the fault condition. Reset parameter values to factory settings. Access diagnostics and compare power base ID number to list in Table 5-5 to ensure a match. Re-enter the Parameter Block Values you recorded in the User Settings at the end of this manual. Autotune the control.

2 Process Control block, Process Feedback and Setpoint Source parameters to a value that does not require an expansion board.

Increase the Level 2 Output Limits block, PK Current Limit parameter. Do not exceed drive rating.

Correct or replace encoder to motor coupling.

Install reverse biased diodes across all external DC relay coils as shown in the Opto Output circuit examples of this manual. See Electrical Noise Considerations in Section 5 of this manual.

Install RC snubbers on all external AC coils. See Electrical Noise Considerations in Section 5 of this manual.

Verify proper sizing of control and motor. Check the Level 2 Output Limits block PK Current Limit parameter.

Change the Level 2 Protection block Overload parameter from Trip to Foldback. Check motor for overloading. Increase Level 1 ACCEL/DECEL Rate block ACCEL/DEC parameters. Reduce motor load. Verify proper sizing of control and motor.

Correct or replace encoder to motor coupling.

Verify proper motor data has been entered. Check the Level 2 Output Limits block PK Current Limit parameter. Change the Level 2 Protection block Overload parameter from Trip to Foldback. Check motor for overloading. Increase Level 1 ACCEL/DECEL Rate block ACCEL/DEC parameters. Reduce motor load. Verify proper sizing of control and motor.

Correct or replace encoder to motor coupling.

Check the Level 2 Output Limits block Max Output Speed. Increase the Level 1 Vector Control block Speed PROP Gain.

Continued on next page.

5-12 Troubleshooting MN722

Section 1 General Information

Table 5-4 Inverter Section Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

Power Module Power supply failure. Press “RESET” key on keypad. If fault remains, call Baldor. PWR Base FLT Improper ground

Excessive current usage.

Encoder coupling slipping, broken or misaligned.

Encoder bearing failure. Replace encoder. Excessive noise on encoder lines. Check encoder connections.

Electrical noise from external DC coils.

Electrical noise from external AC coils.

Excessive load. Correct motor load.

Excessive power in dynamic brake circuit.

Regen PWR FLT Excessive input voltage. Verify proper AC Line voltage.

Resolver Loss Resolver defect. Check resolver to motor coupling (align or replace if needed).

Torque Prove FLT Unbalanced current in 3 motor

phases.

Unknown Fault Fault occurred but cleared before its

source could be identified.

User Fault Text Fault detected by custom software. Refer to custom software fault list.

Be sure control has separate ground wire to earth ground. Panel grounding or conduit connections is not sufficient. Disconnect motor leads from control and retry test. If fault remains, call Baldor.

Correct or replace encoder to motor coupling.

Separate encoder leads from power wiring. Use Baldor encoder cable. Cross encoder wires and power leads at 90°. Electrically isolate encoder from motor. Install optional Isolated Encoder Feedback expansion board.

Install reverse biased diodes across all external DC relay coils as shown in the Opto Output circuit examples of this manual. See Electrical Noise Considerations in Section 5 of this manual.

Install RC snubbers on all external AC coils. See Electrical Noise Considerations in Section 5 of this manual.

Verify proper sizing of control and motor. Verify proper Ohm and Watt parameters of Brake Adjust block.

Increase decel time.

Use step down transformer if needed. Use line reactor to minimize spikes.

Verify correct wiring. Refer to the Resolver to Digital

expansion board manual. Electrically isolate resolver from motor. Use Baldor Resolver cable.

Check continuity from control to motor windings and verify motor connections.

Check AC line for high frequency noise. Check input switch connections and switching noise.

Troubleshooting 5-13MN722

Section 1 General Information

Catalog Numbers Power

ZD22H210–EL 919 ZD22H410–EL B2D ZD22H215–EL 910 ZD22H415–EK B10 ZD22H220–EL 911 ZD22H420–EL B11 ZD22H225–EL 91D ZD22H425–EL B12 ZD22H230–EL 913 ZD22H430–EL B13 ZD22H240–EL 914 ZD22H440–EL B14 ZD22H250–EL 915 ZD22H450–EL B15

Table 5-5 Power Base ID - Series 22H

230VAC 460VAC

Catalog Numbers Power

Base

ID No.

ZD22H460–EK B16 ZD22H475–EK BAB ZD22H4100–EK B18 ZD22H4150–EK B9A ZD22H4200–EK B9B ZD22H4250–EL BC3 ZD22H4300–EL BAE ZD22H4350–EL BA6 ZD22H4400–EL BA7 ZD22H4450–EL BA9

Base

ID No.

Note: The Power Base ID number of a control is displayed in a Diagnostic

Information screen as a hexadecimal value.

Note: The power Base ID number is the same for both the converter and the

Inverter sections of the control.

5-14 Troubleshooting MN722

Section 1 General Information

Electrical Noise Considerations All electronic devices are vulnerable to significant electronic interference signals

(commonly called “Electrical Noise”). At the lowest level, noise can cause intermittent operating errors or faults. From a circuit standpoint, 5 or 10 millivolts of noise may cause detrimental operation. For example, analog speed and torque inputs are often scaled at 5 to 10 VDC maximum with a typical resolution of one part in 1,000. Thus, noise of only 5 mV represents a substantial error.

At the extreme level, significant noise can cause damage to the drive. Therefore, it is advisable to prevent noise generation and to follow wiring practices that prevent noise generated by other devices from reaching sensitive circuits. In a control, such circuits include inputs for speed, torque, control logic, and speed and position feedback, plus outputs to some indicators and computers.

Unwanted electrical noise can be produced by many sources. Various methods can be used to reduce the effects of this noise. All methods are less costly when designed into a system initially than if added after installation.

Relay and Contactor CoilsAmong the most common sources of noise are the ever–present coils of contactors and

relays. When these highly inductive coil circuits are opened, transient conditions often generate spikes of several hundred volts in the control circuit. These spikes can induce several volts of noise in an adjacent wire that runs parallel to a control–circuit wire.

Figure 5-1 illustrates noise suppression for AC and DC operated coils.

Figure 5-1 AC & DC Coil Noise Suppression

AC Coil

Wires between Controls and Motors

Output leads from a typical 460 VAC drive controller contain rapid voltage rises created by power semiconductors switching 650V in less than a microsecond, 1,000 to 10,000 times a second. These noise signals can couple into sensitive drive circuits. If shielded pair cable is used, the coupling is reduced by nearly 90% compared to unshielded cable.

Even input AC power lines contain noise and can induce noise in adjacent wires. In severe cases, line reactors may be required.

To prevent induced transient noise in signal wires, all motor leads and AC power lines should be contained in rigid metal conduit, or flexible conduit. Do not place line conductors and load conductors in same conduit. Use one conduit for 3 phase input wires and another conduit for the motor leads. The conduits should be grounded to form a shield to contain the electrical noise within the conduit path. Signal wires - even ones in shielded cable should never be placed in the conduit with motor power wires.

If flexible conduit is required, the wires should be shielded twisted-pair. Although this practice gives better protection than unshielded wires, it lacks the protection offered by rigid metal conduit.

RC snubber

0.47 mF 33 W

DC Coil

–

Diode

Troubleshooting 5-15MN722

Section 1 General Information

Electrical Noise Considerations Continued

Special Drive Situations

For severe noise situations, it may be necessary to reduce transient voltages in the wires to the motor by adding load reactors. Load reactors are installed between the control and motor.

Reactors are typically 3% reactance and are designed for the frequencies encountered in PWM drives. For maximum benefit, the reactors should be mounted in the drive enclosure with short leads between the control and the reactors. Baldor can deliver line and load reactors that will reduce ripple current and improve motor life.

Control Enclosures Motor controls mounted in a grounded enclosure should also be connected to earth

ground with a separate conductor to ensure best ground connection. Often grounding the control to the grounded metallic enclosure is not sufficient. Usually painted surfaces and seals prevent solid metallic contact between the control and the panel enclosure. Likewise, conduit should never be used as a ground conductor for motor power wires or signal conductors.

Special Motor Considerations

Motor frames must also be grounded. As with control enclosures, motors must be grounded directly to the control and plant ground with as short a ground wire as possible. Capacitive coupling within the motor windings produces transient voltages between the motor frame and ground. The severity of these voltages increases with the length of the ground wire. Installations with the motor and control mounted on a common frame, and with heavy ground wires less than 10 ft. long, rarely have a problem caused by these motor–generated transient voltages.

Sometimes motor frame transient voltages are capacitively coupled to feedback devices mounted on the motor shaft. To prevent this problem, add electrical isolation between the motor and the feedback device. The most simple isolation method, shown in Figure 5-2, has two parts: 1) A plate of electrical insulating material placed between the motor mounting surface and the feedback device. 2) An insulating coupling between motor shaft and the shaft of the feedback device.

Figure 5-2 Isolated Mounting Method

Insulating plate

Insulating Coupling

Encoder or other feedback device

5-16 Troubleshooting MN722

Mounting bracket

Section 6 Manual Tuning the Series 22H Control

Manually Tuning the Control In some applications the drive cannot be accurately auto-tuned in an application. In

these cases it is necessary to calculate the values needed to tune the drive and manually enter these calculated parameter values.

Motor Mag Amps Parameter This parameter is located in the Level 2, Motor Data Block. This parameter is

normally entered using the nameplate data (motor no load amps) or auto–tuned. If no other data is available, set Motor Mag Amps parameter to about 40% of the motor rated current stated on the nameplate.

The following procedure should be used for setting the Motor Mag Amps parameter with the motor coupled to the load:

1. Adjust the Motor Mag Amps Parameter to 40% of the motor nameplate full load current rating.

2. Give the controller a speed command input of 80% of the Base Speed on motor nameplate.

3. Select motor voltage on keypad display by pressing the DISP key until the motor voltage value is displayed.

4. Observe the motor voltage. Ideally, it should read 80% of motor nameplate voltage. By raising the Motor Mag Amps parameter value, the motor voltage will raise proportionally. Continuing to raise the Motor Mag Amps parameter value will eventually saturate the motor voltage. By lowering the Motor Mag Amps parameter value, the motor voltage will lower proportionally.

5. While the motor is running adjust the Motor Mag Amps parameter until the display indicates the proper voltage (80% of motor rated).

Slip Frequency Parameter This parameter is located in the Level 1, Vector Control Block. The slip frequency

may be calculated from nameplate data or auto tuned.

+ Rated Freq *

slip

(

Rated RPM x Number of Motor Poles

120

)

+ Rated Freq *

slip

Base Speed

Sync Speed

(

Rated Freq

)

Current Prop Gain Parameter This parameter is located in the Level 1, Vector Control Block. The Current Prop

Gain parameter is normally auto–tuned when motor inductance is not known. Where auto–tuning can’t be used, the proper manual setting for the proportional gain can be calculated by:

Current PROP Gain +

Where:

L = Line to neutral leakage inductance of the motor in mH VAC = Nominal line Volts A/V = The Amps/Volt scaling of the current feedback

Motor line to neutral leakage inductance can be obtained either from the motor manufacturer or by measuring the line–to–line inductance and dividing by two.

The A/V scaling for the controller can be found in the diagnostic information located in the DISPLAY MODE.

For most applications setting the Current Prop Gain parameter to a value of 20 will yield adequate performance.

740xLxǒAńV

VAC

Manual Tuning the Series 22H Control 6-1MN722

Section 1 General Information

Current Int Gain Parameter

Speed Prop Gain Parameter

Speed Int Gain Parameter

The Current Int Gain parameter located in the Level 1 Vector Control Block is factory preset at 150 Hz. This setting is suitable for essentially all systems. DO NOT CHANGE WITHOUT FACTORY APPROVAL.

The Speed Prop Gain parameter located in the Level 1 Vector Control Block is factory set to 10. This gain may be increased or decreased to suit the application. Increasing the Speed Prop Gain parameter will result in faster response, excessive proportional gain will cause overshoot and ringing. Decreasing the Speed Prop Gain parameter will cause slower response and decrease overshoot and ringing caused by excessive proportional gain.

The Speed Int Gain parameter located in the Level 1 Vector Control Block is set to 1 Hz and may be set at any value from zero to 9.99 Hz. See also, PI Controller later in this section.

Setting the Speed Int Gain parameter to 0Hz removes integral compensation that results in a proportional rate loop. This selection is ideal for systems where overshoot must be avoided and substantial stiffness (ability of the controller to maintain commanded speed despite varying torque loads) isn’t required.

Increasing values of the Speed Int Gain parameter increases the low frequency gain and stiffness of the controller, an excessive integral gain setting will cause overshoot for transient speed commands and may lead to oscillation. Typical setting is 4 Hz. If the Speed Prop Gain parameter and the Speed Int Gain parameter are set too high, an overshoot condition can also occur.

To manually tune the control, the following procedure is used:

1. Set the speed Int Gain parameter = 0 (remove integral gain).

2. Increase the Speed Prop Gain parameter setting until adequate response to step speed commands is attained.

3. Increase the Speed Int Gain parameter setting to increase the stiffness of the drive or its’ ability to maintain speed with dynamic load changes.

Note: It is convenient to monitor speed step response with a strip chart recorder or

storage oscilloscope connected to J1–6 or –7 with Level 1, Output Block Analog Out #1 or #2 set to ABS SPEED, 0 VDC = zero speed. See Section 3 for a discussion of analog outputs.

6-2 Manual Tuning the Series 22H Control MN722

Section 1 General Information

PI Controller

Both the current and rate control loops are of the Proportional plus Integral type. If “E” is defined to be the error signal,

E = Command – Feedback then the PI controller operated on “E” as

Output = (Kp * E) + (Ki s E dt) where Kp is the proportional gain of the system and Ki is the integral gain of the system. The transfer function (output /E) of the controller using 1/s (Laplace Operator) to denote

the integral, Output/E = Kp + KI / s = Kp (s + Ki/Kp) /s. The second equation shows that the ratio of Ki/Kp is a frequency in radians/sec. In the

Baldor Series 22H AC Vector Control, the integral gain has been redefined to be, KI = (Ki / Kp) / (2p) Hz, and the transfer function is, Output/E = Kp (s + 2pKI) / s. This sets the integral gain as a frequency in Hz. As a rule of thumb, set this frequency

about 1/10 of the bandwidth of the control loop. The proportional gain sets the open loop gain of the system, the bandwidth (speed of

response) of the system. If the system is excessively noisy, it is most likely due to the proportional gain being set too high.

Manual Tuning the Series 22H Control 6-3MN722

Section 1 General Information

6-4 Manual Tuning the Series 22H Control MN722

Section 7 Specifications, Ratings & Dimensions

Specifications:

Horsepower 10-50 HP @ 230VAC

10-450 HP @ 460VAC

Input Frequency 50/60 HZ ± 5%

Note: 50Hz operation requires a 15% control

derating. Output Voltage 0 to Maximum Input VAC Output Current See Ratings Table Service Factor 1.0 Duty Continuous Overload Capacity Constant Torque Mode: 170-200% for 3 secs

150% for 60 secs

Variable Torque Mode: 115% for 60 secs

Speed Command Potentiometer 5k or 10k ohm, 0.5 watt

Operating Conditions:

Voltage Range: 230 VAC Models

460 VAC Models

Input Line Impedance: 3% minimum Ambient Operating Temperature: 10 to +40 °C

Rated Storage Temperature: – 30 °C to +65 °C Enclosure: NEMA 1: EL (suffix) Control Module

Humidity: NEMA 1: 10 to 90% RH Non-Condensing Altitude: Sea level to 3300 Feet (1000 Meters)

Shock: 1G Vibration: 0.5G at 10Hz to 60Hz

Keypad Display:

Display Backlit LCD Alphanumeric Keys 12 key membrane with tactile response

Functions Output status monitoring

LED Indicators Forward run command

Remote Mount 100 feet (30.3m) max from control

180-264 VAC 3φ 60 Hz / 180-230 VAC 3φ 50 Hz 340-528 VAC 3φ 60 Hz / 340-460 VAC 3φ 50 Hz

Note: 50Hz operation requires a 15% control

derating.

Derate Output 2% per °C over 40 °C to 55 °C Max

NEMA 1: EK (suffix) Control Module NEMA 1: EK (suffix) Filter Assembly Open Chassis: EK 12% Boost Regulator

3% Line Reactor

Derate 2% per 1000 Feet (303 Meters) above 3300 Feet

2 Lines x 16 Characters

Digital speed control Parameter setting and display Diagnostic and Fault log display Motor run and jog Local/Remote toggle

Reverse run command Stop command Jog active

Specifications, Ratings & Dimensions 7-1MN722

Control Specifications:

Control Method PWM Velocity Loop Bandwidth Adjustable to 180 Hz Current Loop Bandwidth Adjustable to 1200 Hz Maximum Output Frequency 500 Hz Standard Frequency Version Full rating 1-2.5 KHz PWM frequency,

Adjustable to 5 KHz with linear derating (between 2.5 - 5KHz) by 10% at 5 KHz

Quiet Frequency Version Full rating 1-8 KHz PWM frequency,

Adjustable to 16 KHz with linear derating (between 8 - 16KHz) by 30% at 16 KHz

Selectable Operating Modes Keypad

Standard 3 Wire Control 15 Speed Two Wire Control 3 Speed, 2 Wire Control 3 Speed, 3 Wire Control Bipolar Speed/Torque Control Serial Process Control EPOT, 2 Wire Control EPOT, 3 Wire Control

Differential Analog Input:

Common Mode Rejection 40 db Full Scale Range ±5VDC, ±10VDC, 4-20 mA Resolution 9 bits + sign

Other Analog Input:

Full Scale Range 0 - 10 VDC Resolution 9 bits + sign

Analog Outputs:

Analog Outputs 2 Assignable Full Scale Range 0 - 5 VDC Source Current 1 mA maximum Resolution 8 bits

7-2 Specifications, Ratings & Dimensions MN722

Digital Inputs:

Opto-isolated Logic Inputs 9 Assignable Rated Voltage 10 - 30 VDC (closed contacts std) Input Impedance 6.8 K Ohms Leakage Current

10 mA maximum

Digital Outputs:

Opto-isolated Logic Outputs 4 Assignable ON Current Sink 50 mA Max ON Voltage Drop 2 VDC Max Maximum Voltage 30 VDC

Diagnostic Indications:

Inverter Section:

Current Sense Fault Over speed New Base ID DC Bus High Ground Fault Lost User Data Torque Proving DC Bus Low Over Current FLT Soft Start Fault Following Error External Trip Overload - 3 sec No EXB Installed Encoder Loss Int. Overtemp Low INIT Bus Volts Ready Logic Supply Fault Invalid Base ID Microprocessor Reset Memory Errors Power Base Fault Inverter Base ID Over temperature (Motor or Control) Overload - 1 min Line REGEN Fault Resolver Loss User Text Fault

Converter Section:

Current Sense Fault Invalid Base ID DC Bus Low Fault GND Fault ID No Feedback High Initial Current Fault Over Current Fault Power Base Fault Lost AB Phase Overload Fault Lost User Data Lost BC Phase New Base ID DC Bus High Low Init Bus Volts Microprocessor Reset Sync to Line Fault Memory Error Int Over temperature Logic Supply Fault

Specifications, Ratings & Dimensions 7-3MN722

Series 22H Vector Control Ratings

CATALOG

NO.

ZD22H210–EL 230 C+ 10 7.4 28 56 10 7.4 28 32 10 7.4 28 48 10 7.4 28 32 ZD22H215–EL 230 C+ 15 11.1 42 84 15 11.1 42 48 10 7.4 30 61 15 11.1 42 48 ZD22H220–EL 230 C+ 20 14.9 55 100 20 14.9 55 62 15 11.1 42 92 20 14.9 54 62 ZD22H225–EL 230 C+ 25 18.6 68 116 25 18.6 68 78 20 14.9 54 92 25 18.6 68 78 ZD22H230–EL 230 D+ 30 22.3 80 140 30 22.3 80 92 25 18.6 70 122 30 22.3 80 92 ZD22H240–EL 230 D+ 40 29.8 105 200 40 29.8 105 120 30 22.3 80 160 40 29.8 104 120 ZD22H250–EL 230 D+ 50 37.2 130 225 50 37.2 130 150 40 29.8 105 183 50 37.2 130 150

ZD22H410–EL 460 C+ 10 7.4 15 30 10 7.4 15 17 7.5 5.5 11 22 10 7.4 15 17 ZD22H415–EL 460 C+ 15 11.1 21 36 15 11.1 21 24 10 7.4 15 30 15 11.1 21 24 ZD22H420–EL 460 C+ 20 14.9 27 54 20 14.9 27 31 15 11.1 21 46 20 14.9 27 31 ZD22H425–EL 460 C+ 25 18.6 34 58 25 18.6 34 39 20 14.9 27 46 25 18.6 34 39 ZD22H430–EL 460 D+ 30 22.3 40 70 30 22.3 40 46 25 18.6 35 61 30 22.3 40 46 ZD22H440–EL 460 D+ 40 29.8 55 100 40 29.8 55 63 30 22.3 40 80 40 29.8 52 60 ZD22H450–EL 460 D+ 50 37.2 65 115 50 37.2 65 75 40 29.8 55 92 50 37.2 65 75 ZD22H460–EK 460 D 60 44.7 80 140 60 44.7 80 92 50 37.2 65 122 60 44.7 80 92 ZD22H475–EK 460 E 75 56 100 170 75 56 100 115 60 44.7 80 140 75 56 100 115 ZD22H4100–EK 460 E 100 75 125 220 100 75 125 144 75 56 100 180 100 75 125 144 ZD22H4150–EK 460 F 150 112 190 380 150 112 190 220 125 93 150 260 150 112 170 200 ZD22H4200–EK 460 F 200 149 250 500 200 149 250 290 150 112 190 380 175 131 210 240 ZD22H4250–EL 460 G+ 250 187 310 620 250 187 310 356 ZD22H4300–EL 460 G+ 300 224 370 630 300 224 370 425 ZD22H4350–EL 460 G+ 350 261 420 720 350 261 420 480 ZD22H4400–EL 460 G+ 400 298 480 820 400 298 480 552 ZD22H4450–EL 460 G+ 450 336 540 920 450 336 540 620

INPUT

VOLT

ENCLO- STANDARD 2.5 kHz PWM QUIET 8.0 kHz PWM

SURE

SIZE

CONSTANT TORQUE VARIABLE TORQUE CONSTANT TORQUE VARIABLE TORQUE

HP KW IC IP HP KW IC IP HP KW IC IP HP KW IC IP

IC = Continuous Output Current (in Amps) IP= Peak Output Current (in Amps) EL= NEMA 1 enclosure EK= Control, filter, and boost regulator shipped separately. Control and filter in NEMA1 enclosure.

Boost regulator and 3% line reactor are open chassis.

PWM Frequency Continuous and Peak Current Derating:

2.5KHz Ratings - Full rating from 1 - 2.5KHz Adjustable from 1 - 5KHz with linear derating to 90% current rating at 5KHz

8.0KHz Ratings - Full rating from 1 - 8.0KHz Adjustable from 1 - 16KHz with linear derating to 70% current rating at 16KHz

Custom Order. Not Available.

7-4 Specifications, Ratings & Dimensions MN722

Section 1 General Information

Table 7-6 Matched Component Matrix

Control

Catalog No.

ZD22H210–EL VE0574A00 LRAC03501 ZD22H215–EL VE0575A00 LRAC04501 ZD22H220–EL VE0576A00 LRAC05501 ZD22H225–EL VE0577A00 LRAC08001 ZD22H230–EL VE0568A00 LRAC08001 ZD22H240–EL VE0569A00 LRAC10001 ZD22H250–EL VE0570A00 LRAC13001 ZD22H410–EL VE0565A00 LRAC01802 LRAC01802 ZD22H415–EL VE0082A00 LRAC02502 LRAC02502 ZD22H420–EL VE0088A00 LRAC03502 LRAC03502 ZD22H425–EL VE0090A00 LRAC04502 LRAC03502 ZD22H430–EL VE0092A00 LRAC04502 LRAC04502 ZD22H440–EL VE0094A00 LRAC05502 LRAC05502 ZD22H450–EL VE0096A00 LRAC08002 LRAC08002 ZD22H460–EK VE0097A00 LRAC08002 LRAC08002 V2080709 LF1015 ZD22H475–EK VE0099A00 LRAC10002 LRAC10002 V2080710 LF1015 ZD22H4100–EK VE0077A00 LRAC13002 LRAC13002 V2080711 LF1015 ZD22H4150–EK VE0079A00 LRAC25003 LRAC20002 V2080712 LF2015 ZD22H4200–EK VE0084A00 LRAC32003 LRAC25002 V2080713 LF2015 ZD22H4250–EL VE0671A00 LRAC32002 LRAC32002 ZD22H4300–EL VE0631A00 LRAC40002 LRAC40002 ZD22H4350–EL VE0632A00 LRAC50002 LRAC50002 ZD22H4400–EL VE0633A00 LRAC60002 LRAC50002 ZD22H4450–EL VE0634A00 LRAC75003 LRAC60002

Control

Specification

No.

230 VAC

3% Line Reactor

Catalog No.

380-415 VAC

4% Line Reactor

Catalog No.

460 VAC

3% Line Reactor

Catalog No.

Boost Regulator

Specification No.

Included in “EL” Suffix

Catalog Numbers

Included in “EL” Suffix

Catalog Numbers

Included in “EL” Suffix

Catalog Numbers

FIlter

Specification No.

Included in EL Suffix Control Catalog Number. Not applicable.

Note: Line reactor, boost regulator, filter assembly and control must be ordered separately.

Specifications, Ratings & Dimensions 7-5MN722

Section 1 General Information

Terminal Tightening Torque Specifications

Table 7-7 Tightening Torque Specifications

Tightening Torque

Catalog No.

Power TB1 Ground Control J1 Interface J3 &

L1A, L2A, L3A

Lb-in Nm Lb-in Nm Lb-in Nm Lb-in Nm Lb-in Nm Lb-in Nm

ZD22H210–EL 35 4 50 5.6 7 0.8 ZD22H215–EL 35 4 50 5.6 7 0.8 ZD22H220–EL 35 4 50 5.6 7 0.8 ZD22H225–EL 35 4 50 5.6 7 0.8 ZD22H230–EL 35 4 50 5.6 7 0.8 ZD22H240–EL 35 4 50 5.6 7 0.8 ZD22H250–EL 35 4 50 5.6 7 0.8 ZD22H410–EL 35 4 50 5.6 7 0.8 ZD22H415–EL 35 4 50 5.6 7 0.8 ZD22H420–EL 35 4 50 5.6 7 0.8 ZD22H425–EL 35 4 50 5.6 7 0.8 ZD22H430–EL 35 4 22–26 2.5–3 7 0.8 ZD22H440–EL 22–26 2.5–3 22–26 2.5–3 7 0.8 ZD22H450–EL 22–26 2.5–3 22–26 2.5–3 7 0.8 ZD22H460–EK 22–26 2.5–3 22–26 2.5–3 7 0.8 7 0.8 7 0.8 50 5.6 ZD22H475–EK 22–26 2.5–3 50 5.6 7 0.8 7 0.8 7 0.8 50 5.6 ZD22H4100–EK 140 15 50 5.6 7 0.8 7 0.8 7 0.8 50 5.6 ZD22H4150–EK 275 31 275 31 7 0.8 7 0.8 7 0.8 50 5.6 ZD22H4200–EK 275 31 275 31 7 0.8 7 0.8 7 0.8 50 5.6 ZD22H4250–EL 275 31 275 31 7 0.8 ZD22H4300–EL 375 42 375 42 7 0.8 ZD22H4350–EL 375 42 375 42 7 0.8 ZD22H4400–EL 375 42 375 42 7 0.8 ZD22H4450–EL 375 42 375 42 7 0.8

Filter

J1 & J2

Line Reactor

Not Applicable.

7-6 Specifications, Ratings & Dimensions MN722

Section 1 General Information

Dimensions

Size C+ Control

0.40 (10.2)

0.50 (12.7)

28.32 (719.3)

11.50 (292.1)

5.25 (133.3)

0.31 (7.9)

AIR OUTLET

AIR OUTLET AIR OUTLET

JOG LOCAL PROG

FWD

DISP

REV SHIFT ENTER

RESETSTOP

12.20(309.9mm)

12.00(304.8) LIFTING

FLANGE

30.00 (762.0)

29.25 (743.0)

AIR INLET (Top)

AIR OUTLET

.31(7.9mm)

AIR INLET (Bottom)

Note: Allow 2 inches minimum clearance on all sides

for ventilation. An internal baffle divides the enclosure into two parts.

The upper and lower parts each have separate air inlets and outlets as shown.

AIR INLET (Bottom)

Specifications, Ratings & Dimensions 7-7MN722

Section 1 General Information

Dimensions Continued Size D+ Control

0.40(10.2)

36.00 (914.4)

35.25 (895.4)

0.50 (12.7)

34.08 (865.6)

14.50(368.3)

6.75 (171.5)

AIR OUTLET

AIR INLET (Top)

JOG LOCAL PROG

FWD

DISP

REV SHIFT ENTER

RESETSTOP

6.75 (171.5)

0.31 (7.9)

AIR OUTLET

12.20(309.9)

12.00(304.8)

LIFTING FLANGE

AIR INLET (Bottom)

AIR OUTLET

0.31 (7.9) WIDE

AIR INLET (Bottom)

Note: Allow 2 inches minimum clearance on all sides

for ventilation. An internal baffle divides the enclosure into two parts.

The upper and lower parts each have separate air inlets and outlets as shown.

7-8 Specifications, Ratings & Dimensions MN722

Section 1 General Information

Dimensions Continued

Size D Control

25.00

(635.0mm)

24.25

(616.0mm)

14.50

(368.5mm)

13.50

(343.0mm)

JOG LOCAL PROG

FWD

DISP

REV SHIFT ENTER

RESETSTOP

Air

Outlet

23.12

(587.0mm)

.31

(8.0mm)

CUSTOMER

POWER

CONNECTIONS

10.00

(254.0mm)

10.20

(259.0mm)

AIR INLET

Specifications, Ratings & Dimensions 7-9MN722

Section 1 General Information

Dimensions Continued

Size E Control

Air

Outlet

.38 (9.5mm)

2 Places

30.00

(762mm)

Thru–wall

Mounting Flange

R AM VO Hz

JOG LOCAL PROG

FWD

DISP

REV SHIFT ENTER

RESETSTOP

Surface

Mounting

Flange

.38

(9.5mm)

2 Places

17.70

(450mm)

5.75

(146mm)

6.25

(159mm)

Air Inlet

7-10 Specifications, Ratings & Dimensions MN722

Section 1 General Information

Dimensions Continued

Size E Control – Through–Wall Mounting

Mounting hole locations for Thru-Wall or surface mounting. Recommended hardware: 5/16″ or M8. (4 Places)

(716mm)

(711mm) (686mm) (672mm)

28.19

28.00

27.00

26.44

Mounting hole locations for Thru-Wall mounting using kit #0083991. Thru hole .218″ (5.5mm) DIA. (4 Places)

(552mm)

(343mm)

(133mm)

(14mm)

(25mm)

(30mm)

21.75

13.50

5.25

.56 .00

1.00

1.19 .00

.19

.79

(5mm)

(20mm)

Cutout for thru–wall mounting

1.25

(32mm)

6.00

(152mm)

10.75

(273mm)

16.94

16.75

15.50

(425mm)

(430mm)

(394mm)

17.54

(445mm)

Specifications, Ratings & Dimensions 7-11MN722

Baldor mn722 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents