Baldor MN735 User Manual

Series 35D

Inverter Control

Installation & Operating Manual

8/02

MN735

Table of Contents

Section 1

Quick Start 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2

General Information 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CE Compliance 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limited Warranty 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Notice 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notice 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3

Receiving & Installation 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving & Inspection 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location and Mounting 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cover Removal 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Conditioning 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Grounding 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Impedance 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Reactors 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Reactors 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Disconnect 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective Devices 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reduced Input Voltage Derating 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Installation 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clamp Terminals 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Connections 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermistor Connections 3–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signal Connections 3–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Brake Resistor 3–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

User Relay 3–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applications/Modes 3–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Load an Application 3–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 – Keypad Mode 3–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 – Standard Run 3 Wire Mode 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 – 3 Speed 2 Wire Mode 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 – EPOT 3 Wire Mode 3–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 – EPOT 2 Wire Mode 3–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 – PID 2 Wire Mode 3–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iMN735

Section 4

Start–Up and Operation 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Description 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostics Menu 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu System 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Up 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Change a Parameter Value 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Menu Features 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Definitions 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PI Terms 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Related Parameter Values 4–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Routine Maintenance 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Saving Your Application Data 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disposal 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5

Troubleshooting 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trips 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Failures 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6

Specifications & Product Data 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Specifications 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Display 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Inputs 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Outputs 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Inputs 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Outputs 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relay Output 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ratings 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A

Dynamic Brake A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230VAC 1 & 3 Phase Controls A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

460VAC 3 Phase Controls A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Calculations A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RGA and RGJ Assemblies A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B

CE Guidelines B–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii Table of Contents MN735

Section 1
Quick Start

The basic steps for connection and setup are provided in this section.
Detailed descriptions of each step and parameter settings are provided
later in this manual. Be sure to comply with all applicable codes when
installing this control.

Minimum Connection Requirement

Power and Motor Connections

Figures 1-1and 1-2 show the minimum connections required at the power
connector.

Figure 1-1 Power Connections

Size 2 Shown

s Refer to Section 3 for cover removal procedure.

TH1A and TH1B must

be jumpered if

thermistor is not used

AC Line

Connections

Dynamic Brake

Connections

Motor

Connections

L1, L2, L3, GND

RL1A
RL1B

TH1A
TH1B

L1

L2/N

L3
DC+
DBR

M1/U

M2/V

M3/W

Use 2 Ground

Wires

Motor Cable

Mains Supply
Cable

Use a cable tie

in this area for

control wires.

10

9
8
7
6
5
4
3
2
1

Wire Retainer
(Channel)

Grounded
Cable Clamp

Dynamic Brake Cable

Thermistor Cable

Control Signal Cable

Quick Start 1–1MN735

Figure 1-2 Power Connections Continued

10

DIN4/DOUT2
9
8
7
6
5
4
3
2
1

DIN3
DIN2
DIN1

+24V

AOUT1

+10V Ref

AIN2
AIN1

0V

Feedback
Setpoint

See Applications/Modes

10k Speed
Setpoint

Connect 0V to PE (protective earth ground)
for single control installations only. If multiple
controls are used, connect 0V terminals
together and ground to PE at one point only.

Size 1 and 3 Terminal Strips

Size 1

TH1A
TH1B

AC

Line

Motor

L1

L2/N
M1/U
M2/V

M3/W

1φ 230VAC

AC Line

Dynamic

Brake

Motor

Volts or
0–20mA Input

Size 3

TH1A
TH1B

L1
L2

L3
DC+
DBR
DC–

M1/U
M2/V

M3/W

3φ 460VAC

Jumpers and Switches None
Control Terminal Connections See Table 1–2.

Local Mode

No connections are required.

Remote Mode

Control terminals 1 to 10 can be connected as shown in the application
modes described in Section 3 of this manual.

1–2 Quick Start MN735

Table 1–1 Power Connection Descriptions

idly t

2000Ω

this t

o

Range

above

380/460VAC±10%
with respect to L2, L3.

380/460VAC±10%
with respect to L1, L3.

emperature.

Terminal Description Function

RLY1 Relay Output Normally open, programmable

TH1A Thermistor Connection to motor thermistor It is good practice to protect motors by using

TH1B Thermistor Connection to motor thermistor

Reference
Terminal

L1 Power Input Single and three phase line

L2/NL2Power Input Single phase neutral (or L2 three

contact for a relay output.

Supply protective earth (PE). This terminal must be connected to a protective (earth)
ground for permanent ground.

connection

phase line connection)

230V 1–Phase 460V 3–Phase

Contact closes when the programmed
condition (see Section 4) is true.
No voltage is present on this contact. 6
conditions are available.

thermistors. A typical resistance (up to a
reference temperature of 125_C) is 200Ω,
rising rap
Connect devices in series between TH1A and
TH1B. Jumper TH1A and TH1B if temperature
sensors are not used.

220/240VAC±10%
with respect to L2/N.

220/240VAC±10%
with respect to L1.

L3 Power Input Three phase line connection Not applicable 380/460VAC±10%

DC- No user connection
DC+ Dynamic Brake Connection to external brake

DBR Dynamic Brake Connection to external brake

M1/U
M2/V
M3/W

Power Outputs 3-phase supply connection for

Reference
Terminal

resistor

resistor

motor

Supply protective earth (PE). This terminal must be connected to a protective (earth)
ground for permanent ground.

Not applicable Frame 2 (high volt

Not applicable Frame 2 (high volt

0 to 220/240VAC
0 to 240Hz

with respect to L1, L2.

only) & 3.
See Internal Dynamic
Brake Switch" table

only) & 3.
See Internal Dynamic
Brake Switch" table

0 to 380/460VAC
0 to 240Hz

Parameter Settings (for Keypad Operation)

The factory settings should be sufficient to operate the control using the
“Local” mode with the keypad. Only a few changes to the motor data
parameters must be made. Before any parameters can be changed, set
System::Configure I/O::Configure Enable to enable. All LEDs will blink
during configuration. After parameter values are changed to meet the
needs of your application, be sure to set System::Configure I/O::Configure
Enable to Disable and do the Parameter Save procedure.

Quick Start 1–3MN735

Table 1–2 Analog/Digital Signal Descriptions

U

Volt-f

0-250VAC/24VDC

Terminal

(SELV)

RL1A
RL1B

10 DIN4/

9 DIN3 Digital Input 3. 0-24V source

8 DIN2 Digital Input 2. 0-24V source

7 DIN1 Digital Input 1. 0-24V source

6 +24V 24V ć 24V supply for digital I/O 50mA max
5 AOUT1 Analog Output ć 10mA maximum 0-10V
4 10VREF 10V reference (10mA maximum loading) 10V
3 AIN2 Analog Input 2 0-10V, 4-20mA
2 AIN1 Analog Input 1 - Setpoint. If unused, connect to 0VDC. 0-10V
1 0V 0V - Reference for Analog/Digital I/O

Signal Name Description Range

ser Relay

DOUT2

ree contact - 4A maximum, non-inductive

Configurable I/O, Digital Input 4 or Digital Output 2. 0-24V source

For single control installations, connect pin 1 (0V) to
PE.
For multiple control installations, connect the 0V
terminals of each control together. Then connect only
one control to PE.

open collector

open collector

open collector

open collector

0V

1–4 Quick Start MN735

Section 2
General Information

Copyright Baldor  2002. All rights reserved.
This manual is copyrighted and all rights are reserved. This document may

not, in whole or in part, be copied or reproduced in any form without the
prior written consent of Baldor.

Baldor makes no representations or warranties with respect to the contents
hereof and specifically disclaims any implied warranties of fitness for any
particular purpose. The information in this document is subject to change
without notice. Baldor assumes no responsibility for any errors that may
appear in this document.

UL and cUL are registered trademarks of Underwriters Laboratories.

CE Compliance A custom unit may be required, contact Baldor. Compliance to

Directive 89/336/EEC is the responsibility of the system integrator. A
control, motor and all system components must have proper shielding,
grounding, and filtering as described in MN1383. Please refer to MN1383
for installation techniques for CE compliance. For additional information,
refer to Section 3 and Appendix B of this manual.

Limited Warranty

For a period of one (1) year 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.

General Information 2–1MN735

Product Notice Intended use:

These drives are intended for use in stationary ground based applications
in industrial power installations according to the standards EN60204 and
VDE0160. They are designed for machine applications that require variable
speed controlled three phase brushless AC motors.

These drives are not intended for use in applications such as:

– Home appliances
– Mobile vehicles
– Ships
– Airplanes

Unless otherwise specified, this drive is intended for installation in a
suitable enclosure. The enclosure must protect the control from exposure
to excessive or corrosive moisture, dust and dirt or abnormal ambient
temperatures.

In the event that a control fails to operate correctly, contact Baldor for return
instructions.

Safety Notice

: This equipment contains high voltages. 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.

– System documentation must be available at all times.
– Keep non-qualified personnel at a safe distance from this equipment.
– Only qualified personnel familiar with the safe installation, operation

and maintenance of this device should attempt start-up or operating
procedures.

– Always remove power before making or removing any connections to

this control.

PRECAUTIONS: Classifications of cautionary statements.

WARNING: Indicates a potentially hazardous situation which, if not avoided,

could result in injury or death.

Caution: Indicates a potentially hazardous situation which, if not avoided,

could result in damage to property.

Continued on next page.

2–2 General Information MN735

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.

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.

WARNING: Be sure all wiring complies with the National Electrical Code and

all regional and local codes or CE Compliance. Improper wiring
may cause a hazardous condition.

WARNING: Be sure the system is properly grounded before applying power.

Do not apply AC power before you ensure that grounds are
connected. Electrical shock can cause serious or fatal injury.

WARNING: Do not remove cover for at least five (5) minutes after AC power is

disconnected to allow capacitors to discharge. Electrical shock
can cause serious or fatal injury.

WARNING: Improper operation may cause violent motion of the motor and

driven equipment. Be certain that unexpected movement will not
cause injury to personnel or damage to equipment.

WARNING: Motor circuit may have high voltage present whenever AC power

is applied, even when motor is not moving. Electrical shock can
cause serious or fatal injury.

WARNING: If a motor is driven mechanically, it may generate hazardous

voltages that are conducted to its power input terminals. The
enclosure must be grounded to prevent a possible shock hazard.

WARNING: The user must provide an external hard-wired emergency stop

circuit to disable the control in the event of an emergency.

Continued on next page.

General Information 2–3MN735

Caution: To prevent equipment damage, be certain that the input power

has correctly sized protective devices installed as well as a power
disconnect.

Caution: Avoid locating the control immediately above or beside heat

generating equipment, or directly below water or steam pipes.

Caution: Avoid locating the control in the vicinity of corrosive substances

or vapors, metal particles and dust.

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

1.5–50 5,000
51–200 10,000
201–400 18,000
401–600 30,000
601–900 42,000

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: Logic signals are interruptible signals; these signals are removed

when power is removed from the drive.

Caution: The safe integration of the driver into a machine system is the

responsibility of the machine designer. Be sure to comply with
the local safety requirements at the place where the machine is to
be used. In Europe this is the Machinery Directive, the
ElectroMagnetic Compatibility Directive and the Low Voltage
Directive. In the United States this is the National Electrical code
and local codes.

Caution: Controls must be installed inside an electrical cabinet that

provides environmental control and protection. Installation
information for the drive is provided in this manual. Motors and
controlling devices that connect to the driver should have
specifications compatible to the drive.

Caution: Do not tin (solder) exposed wires. Solder contracts over time and

may cause loose connections.

Caution: Electrical components can be damaged by static electricity. Use

ESD (electro-static discharge) procedures when handling this
control.

2–4 General Information MN735

Section 3
Receiving & Installation

Receiving & Inspection

Baldor Controls are 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. Remove the control from the shipping container and remove all
packing materials. The container and packing materials may be
retained for future shipment.

3. Verify that the part number of the control you received is the same as
the part number listed on your purchase order.

4. Inspect the control for external physical damage that may have been
sustained during shipment and report any damage immediately to the
commercial carrier that delivered your control.

5. 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 humidity
and temperature specifications stated in this manual.

Location and Mounting

The location of the control is important. Installation should be in an area
that is protected from direct sunlight, corrosives, harmful gases or liquids,
dust, metallic particles, and vibration. Exposure to these can reduce the
operating life and degrade performance of the control.

Several other factors should be carefully evaluated when selecting a
location for installation:

To maintain compliance with European Electrical Safety Standard
VDE0160(1994)/EN50178 (1998) the control must be mounted inside an
enclosure that requires a tool for opening. The enclosure should provide
15dB attenuation to radiated emissions between 30–100MHz.
Mount the drive vertically on a solid, flat, non–flammable, vertical surface.
It can be panel–mounted, or rail–mounted on a rail complying with
EN50022 (35mm DIN). For DIN mount, hang the unit on the top DIN rail
and push the unit onto the bottom DIN rail until it snaps in to position.
Secure with a screw in the lower hole. See mounting drawing in Section 6
of this manual.

1. For effective cooling and maintenance, the control should be mounted
vertically on a smooth non-flammable surface.

2. At least 4.0 inches (100mm) top and bottom clearance must be
provided for air flow. At least 0.4 inches (10mm) clearance is required
between controls (each side).

3. Operating Altitude derating. Up to 3300 feet (1000 meters) no
derating required. Derate the continuous and peak output current by
1% for each 330 feet (100 meters) above 3300 feet. Maximum
operating altitude 16,500 feet (5,000 meters).

4. Operating Temperature derating. 0°C to 40°C ambient. Linear
derating to 50°C maximum ambient.

Receiving & Installation 3–1MN735

Table 3-1 Watts Loss Ratings

Catalog No.

Output

Current

(A)

Watts

Loss

(W)

Catalog No. Output

Current

(A)

Watts

Loss

ID35D8A1F5–CRH 1.5 26 ID35D4A1F5–CRH 1.5 26
ID35D8A2F2–CRH 2.2 32 ID35D4A02–CRH 2.0 32
ID35D8A03–CRH 3.0 41 ID35D4A2F5–CRH 2.5 40
ID35D8A04–CRH 4.0 52 ID35D4A4F5–CRH 4.5 61
ID35D8A07–CRH 7.0 82 ID35D4A5F5–CRH 5.5 70
ID35D8A10–CRH 10.5 116 ID35D4A09–CRH 9.0 100
ID35D8A16–CRH 16.5 181 ID35D4A12–CRH 12.0 140

ID35D4A16–CRH 16.0 180

Figure 3-1 Inverter Sizes

Size 3

Size 2

Size 1

3–2 Receiving & Installation MN735

Cover Removal To connect power and signal wires, the cover must be removed. This

1. Press in to
release cover

Power Conditioning

procedure describes how to access all terminal connections inside the
control.

Using your thumbs, press in and slide the cover down as shown in Figure
3-2.

Figure 3-2 Top Cover Removal

2. Slide cover down and remove.

System Grounding Baldor Controls are designed to be powered from standard

three phase power lines that are electrically symmetrical with respect to
ground. System grounding is an important step in the overall installation to
prevent problems.

Ungrounded Distribution System

With an ungrounded power distribution system it is possible to have a
continuous current path to ground through the MOV devices. To avoid
equipment damage, an isolation transformer with a grounded secondary is
recommended. This provides three phase AC power that is symmetrical
with respect to ground.

Input Power Conditioning

Baldor controls are designed for direct connection to standard three phase
lines that are electrically symmetrical with respect to ground. Certain
power line conditions must be avoided. An AC line reactor or an isolation
transformer may be required for some power conditions.

S If the feeder or branch circuit that provides power to the control has

permanently connected power factor correction capacitors, an input
AC line reactor or an isolation transformer must be connected
between the power factor correction capacitors and the control.

S If the feeder or branch circuit that provides power to the control has

power factor correction capacitors that are switched on line and off
line, the capacitors must not be switched while the control is
connected to the AC power line. If the capacitors are switched on line
while the control is still connected to the AC power line, additional
protection is required. TVSS (Transient Voltage Surge Suppressor) of
the proper rating must be installed between the AC line reactor or an
isolation transformer and the AC input to the control.

Receiving & Installation 3–3MN735

Line Impedance The Baldor control requires a 1% line impedance minimum . If

the impedance of the incoming power does not meet the requirement for
the control, a 3 phase line reactor can be used to provide the needed
impedance in most cases. Line reactors are optional and are available from
Baldor.

The input impedance of the power lines can be determined as follows:

Measure the line to line voltage at no load and at full rated load.
Use these measured values to calculate impedance as follows:

%Impedance +

(Volts

No Load Speed

(Volts

* Volts

No Load Speed

Full Load Speed

)

)

100

Line Reactors Three phase line reactors are available from Baldor. The line

reactor to order is based on the full load current of the motor (FLA). If
providing your own line reactor, use the following formula to calculate the
minimum inductance required.

0.03)

(V

L +

L* L

Ǹ

(I 3

377)

Where: L Minimum inductance in Henries.

V

L-L

0.03 Desired percentage of input impedance.

Input volts measured line to line.

I Input current rating of control.
377 Constant used with 60Hz power.

Use 314 if input power is 50Hz.

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:

S Protect the control from a short circuit at the motor.
S Limit the rate of rise of motor surge currents.
S 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.
Selection should be based on the motor nameplate FLA value.

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.

Protective Devices Recommended fuse sizes are based on the following:

115% of maximum continuous current for time delay.
150% of maximum continuous current for Fast or Very Fast action.

Note: These general size recommendations do not consider harmonic currents or

ambient temperatures greater than 40°C.
Be sure a suitable input power protection device is installed. Use the

recommended fuses and wire sizes shown in Table 3-2 is based on the use
of copper conductor wire rated at 75 °C. The table is specified for NEMA B
motors.

Reduced Input Voltage Derating All power ratings stated in Section 6 are for

the stated nominal AC input voltages (230 or 460VAC). The power rating of
the control must be reduced when operating at a reduced input voltage.
The amount of reduction is the ratio of the voltage change.

3–4 Receiving & Installation MN735

Examples:

A 5hp, 230VAC control operating at 208VAC has a reduced power rating of

4.5hp.

5HP

Likewise, a 3hp, 460VAC control operating at 380VAC has a reduced
power rating of 2.47hp.

3HP

Electrical Installation All interconnection wires between the control, AC power source,

motor, host control and any operator interface stations should be in metal
conduits or shielded cable must be used. Use 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.

Rubber

Grommet

Holes are required in the enclosure assembly to allow connections to be
made. Use the correct size rubber grommet, conduit coupling or 360
degree coupling.

Clamp Terminals To install a wire into a clamp terminal, first strip wire insulation

to 0.20–0.24 in. (5–6mm). Insert a flat–blade screwdriver, maximum blade
size 0.138 in. (3.5mm) into the adjacent hole. Do not twist or rotate the
screwdriver as this action may damage the terminal. A very slight
downward pressure on the screwdriver should open the terminals and allow
the wire to be inserted. Insert the wire into the clamp opening (Figure 3-4).
Remove the screwdriver. The terminal provides the correct force for a
secure connection.

208VAC
230VAC

380VAC
460VAC

Figure 3-3 Unshielded and Shielded Couplings

Metal

Coupling

+ 4.5hp

+ 2.47hp

360 Degree

Coupling

Figure 3-4 Clamp Terminal

360 Degree Coupling

Receiving & Installation 3–5MN735

Table 3-2 Wire Size

Output

Catalog

Number

ID35D8A1F5-CRH 1 1.5 2.3 12 2.5 12 2.5
ID35D8A2F2-CRH 1 2.2 3.3 12 2.5 12 2.5

ID35D8A03-CRH 1 3.0 4.5 12 2.5 12 2.5
ID35D8A04-CRH 1 4.0 6.0 12 2.5 12 2.5
ID35D8A07-CRH 2 7.0 10.5 12 2.5 12 2.5
ID35D2A10-CRH 3 10.5 15.8 10 2.5 10 2.5 12 2.5
ID35D2A16-CRH 3 16.5 24.8 10 2.5 10 2.5 12 2.5

ID35D4A1F5-CRH 2 1.5 2.3 12 2.5 12 2.5 12 2.5

ID35D4A02-CRH 2 2.0 3.0 12 2.5 12 2.5 12 2.5
ID35D4A2F5-CRH 2 2.5 3.8 12 2.5 12 2.5 12 2.5
ID35D4A4F5-CRH 2 4.5 6.8 12 2.5 12 2.5 12 2.5
ID35D4A5F5-CRH 2 5.5 8.3 12 2.5 12 2.5 12 2.5

ID35D4A09-CRH 3 9.0 13.5 10 2.5 10 2.5 12 2.5

ID35D4A12-CRH 3 12.0 18.0 10 2.5 10 2.5 12 2.5

ID35D4A16-CRH 3 16.0 24.0 10 2.5 10 2.5 12 2.5

Size

Current

Cont. Peak

(Amps) (Amps)

L1, L2, L3, N,

GND and Motor
AWG MM2AWG MM2AWG MM

Wire Size

DC+, DBR TH1A, TH1B

Note: All wire sizes based on 75°C copper wire, 40°C ambient temperature, 4-6

conductors per conduit or raceway.

Power Connections The signals are shown in Figure 3-5 and described in

Table 3-3.

1. Remove the cover, shown in Figure 3-2.

2. Loosen the grounded cable clamp, Figure 3-5.

3. Connect the Mains Cable, Motor Cable, Dynamic Brake Cable and
Thermistor Cable wires, if used to their proper clamp terminal, Figure
3-5. Be sure the shields of all shielded cables are in contact with the
grounded cable clamp.

Note: This control must have two separate mains earth grounds connected as

shown in Figures 3-5 and 3-6.

4. Tighten the grounded cable clamp screws to securely hold the cables.

2

3–6 Receiving & Installation MN735

Table 3-3 Power Connection Descriptions

idly t

2000Ω

this t

o

Range

above

380/460VAC±10%
with respect to L2, L3.

380/460VAC±10%
with respect to L1, L3.

emperature.

Terminal Description Function

RLY1 Relay Output Normally open, programmable

TH1A Thermistor Connection to motor thermistor It is good practice to protect motors by using

TH1B Thermistor Connection to motor thermistor

Reference
Terminal

L1 Power Input Single and three phase line

L2/NL2Power Input Single phase neutral (or L2 three

contact for a relay output.

Supply protective earth (PE). This terminal must be connected to a protective (earth)
ground for permanent ground.

connection

phase line connection)

230V 1–Phase 460V 3–Phase

Contact closes when the programmed
condition (see Section 4) is true.
No voltage is present on this contact. 6
conditions are available.

thermistors. A typical resistance (up to a
reference temperature of 125_C) is 200Ω,
rising rap
Connect devices in series between TH1A and
TH1B. Jumper TH1A and TH1B if temperature
sensors are not used.

220/240VAC±10%
with respect to L2/N.

220/240VAC±10%
with respect to L1.

L3 Power Input Three phase line connection Not applicable 380/460VAC±10%

DC- No user connection
DC+ Dynamic Brake Connection to external brake

DBR Dynamic Brake Connection to external brake

M1/U
M2/V

M3/W

Power Outputs 3-phase supply connection for

Reference
Terminal

resistor

resistor

motor

Supply protective earth (PE). This terminal must be connected to a protective (earth)
ground for permanent ground.

Not applicable Frame 2 (high volt

Not applicable Frame 2 (high volt

0 to 220/240VAC
0 to 240Hz

with respect to L1, L2.

only) & 3.
See Internal Dynamic
Brake Switch" table

only) & 3.
See Internal Dynamic
Brake Switch" table

0 to 380/460VAC
0 to 240Hz

Receiving & Installation 3–7MN735