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mn722
User Manual
121 pgs1.07 Mb0

Baldor mn722 User Manual

SERIES 22H
Line Regen
AC Flux Vector Control
Installation & Operating Manual
8/03 MN722

Table of Contents

Section 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.
Table of Contents iMN722
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
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
CONTROL
NOT
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
• 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.
L1
Line Reactor
Four Wire
“Wye”
L2
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
L1
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.
L1
L2
L3
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
L1
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
Size
C+
D+
D
E
F
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
3
/
A
10
500VAC
3
/
A
10
500VAC
3
/
A
10
500VAC
3
/
A
10
500VAC
3A
600VAC
FLQ-
3
/
10
Equiv.
FLQ-
3
/
10
Equiv.
FLQ-
3
/
10
Equiv.
FLQ-
3
/
10
Equiv.
or
or
or
or
5A
500VAC
5A
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
2
2
2
2
2
MDA-
2
/
3
Equiv.
MDA-
2
/
3
Equiv.
MDA-
2
/
3
Equiv.
MDA-
2
/
3
Equiv.
KTK-3 or
Equiv.3A600VAC
FNQ-
A
1
/
3 Equiv.
FNQ-
A
1
/
3 Equiv.
FNQ-
A
1
/
3 Equiv.
FNQ-
A
1
/
3 Equiv.
FNQ-
A
1
/
3 Equiv.
or
10
or
10
or
10
1
/
A
or
10
2
250VAC
ABC 1/
or Equiv.
2
KTK-3 or
Equiv.
or
2
or
2
or
2
or
2
or
2
4A
500VAC
4A
500VAC
4A
500VAC
4A
500VAC
4A
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
Input Breaker
(Amps)
Input Fuse (Amps) Wire Gauge
Fast Acting Time Delay AWG mm
2
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
2
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
F
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
C2
L1 L2
L3
L1A L2A L3A
Filter to Control (10 ft. max.)
14AWG (2.08 mm
2
)
10AWG (5.26 mm
X1
X2 X3
J1 J2
1 2
3
2
)
2
)
* Optional components not provided with 22H Control.
Phase Sensitive Inputs
Filter
1 2
3
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
E
Input
Contactor
Control Size
F
Contactor
Transformer
Transformer
Control
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)
H1
380VAC
440VAC
H2
550VAC
H3
600VAC
H4
H5
Frequency 50 / 60
Hz
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
T1
* AC Motor
G
* 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
T1
* Motor
To Power Source
(Rated Coil Voltage)
J1
*
M Enable
G
7
Note: Close “Enable”
8
after “M” contact closure.
9
* 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
A
24
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
J1
J1
27
+5V Input
Output Common
See recommended terminal tightening torques in Section 7.
28 29
30
INDEX INDEX +5V Common
Limit Switch (Closed at HOME).5VDC Proximity Switch
27 28 29
30
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
J1
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”.
1
2
3
4
5
Analog Input 1
Analog Input 2
Analog Input #2 Analog input #2 accepts a differential command 0-5VDC, 0-10VDC, ±5VDC, ±10VDC or
(Differential) 4-20 mA. If pin J1-4 is positive with respect to pin 5, the motor will rotate in the forward
direction. If pin J1-4 is negative with respect to pin 5, the motor will rotate in the reverse direction. JP1 must be set for voltage or current operation as required. Analog Input #2 can be connected for single ended operation by grounding either of the inputs, provided the common mode voltage range is not exceeded.
Note: The common mode voltage can be measured with a voltmeter. Apply the
maximum command voltage to analog input 2 (J1-4, 5). Measure the AC and DC voltage across J1-1 to J1-4. Add the AC and DC readings together. Measure the AC and DC voltage from J1-1 to J1-5. Add the AC and DC readings together.
If either of these measurement totals exceeds a total of ±15 volts, then the common mode voltage range has been exceeded. To correct this condition, either change the command source or isolate the command signal with a signal isolator.
Receiving & Installation 3-19MN722
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