Baldor mn792 User Manual

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Series 29

Digital DC Control

Installation & Operating Manual

9/03 MN792

Section 1

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

Minimum Connection Requirements 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power and Motor Connections 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference and Jumpers for Keypad Operation 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Settings (for Keypad Operation) 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference and Jumpers for Remote Operation 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Feedback 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial Link 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2

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

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

CE Compliance 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosure Sizes 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limited W arranty 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Notice 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Section 3

Getting Started 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Overview 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Loops 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control and Communications 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local and Remote Modes 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source / Destination Tags 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming Block 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4

Receiving and Installation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving & Inspection 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location Considerations 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cover Removal 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical Installation 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Vent Kit 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Electrical Installation 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Grounding 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Impedance 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Disconnect 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection Devices 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Isolation Transformer Sizing 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Phase Power 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Connections 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Logic Power 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Connections 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M-Contactor 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iMN792

Blower Motor Starter 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermal Protection 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Encoder Installation 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer Installation 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control I/O Signal Connections 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Inputs 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Outputs 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Inputs 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Outputs 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RS232 Connections 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Port (P3) Configuration 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5

Switch Setting and Start-Up 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre–Operation Checks 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power up in Local Mode with Armature Feedback 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power up in Remote Mode with Feedback 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Autotune 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Loop Adjustment 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping Methods 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upload/Download Procedure 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DUMP Procedure 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6

Programming 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu System 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Descriptions 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Inputs 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Outputs 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUX I/O 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Block Diagram 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configure Drive 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Loop 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Profile 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostics 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Inputs 6-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Outputs 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field Control 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alarms 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jog/Slack 6-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menus 6-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OP Station 6-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii Table of Contents MN792

Password 6-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PID 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raise/Lower 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ramps 6-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setpoint Sum 1 6-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Loop 6-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advanced 6-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standstill 6-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop Rates 6-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Port P3 6-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5703 Support 6-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEC Option 6-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7

Keypad Operation 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Keypad LED Status 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alarm Messages 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Menu 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

L/R Key 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROG Key 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu System 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Shortcuts and Special Key Combinations 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Tag Information 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restore Factory Settings 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 button reset 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Examples 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Select a Menu View Level 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Language Selection 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Password Protection 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deactivate a Password 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Save Settings 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8

Troubleshooting 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reset a Trip Condition 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Conditions 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial (P3) Errors 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alarm Messages 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Last Alarm 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Health Word 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Health Store 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Board LED Trip Information (Frame 4 and 5) 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iiiMN792

Manage Trips from the Keypad 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trip Messages 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbolic Alarm Messages 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self Test Alarms 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Trip Conditions 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing Trip Conditions 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inhibiting Alarms 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Points 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 9

Specifications & Product Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Display 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Specifications 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Encoder 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminal Tightening Torque 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ratings 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMC Filters 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A

CE Guidelines A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CE Declaration of Conformity A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMC – Conformity and CE – Marking A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMC Installation Instructions A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B

Parameter Table B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Values B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameters Listed by Tag Number B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameters Listed by Name B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameters Listed by Keypad Menu B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameters Listed by WB Block B-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C

Block Diagram C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv Table of Contents MN792

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. The Series 29 DC control is a one way control. That is, it is non–regen and cannot reverse direction. It operates in the forward direction only. All references to reverse operation or regen operation apply to the Series 30 DC Control only.

Minimum Connection Requirements Refer to Section 4 for cover removal procedure.

Power and Motor Connections

Figure 1-1 shows the minimum connections required at the power connector.

Figure 1-1 Power Connections

3 Phase

Power

L1 L2 L3 GND

Thermistor

For Size 1 & 2 controls, be sure the logic power jumper is in the correct position. Refer to Figure 4-9.

To 1 Phase 115VAC Control Power

(except units with internal

control transformer,

100hp and less)

or jumper TH1 to TH2 if

motor thermistor is not connected.

Armature

Reference and Jumpers for Keypad Operation

For keypad operation, the speed reference connections are not required. Speed is set at the keypad. Figure 1-2 shows the minimum connections required A, B and C signal connectors for Keypad operation.

Figure 1-2 Reference and Jumper Connections

If Optional Speed Feedback Board is used, refer to Speed Feedback at the end of this section.

Signal Connections

Minimum jumper connections:

A1 to A2 – 500 ohm jumper for 20mA input A6 to B3 – Analog Input 5 = +10VDC B8 to C9 – PROG Stop = +24VDC B9 to C9 – Coast Stop = +24VDC C4 to C9 – Enable = +24VDC C1 to C2 – No External Trip

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.

Note: To separate the various menu level designation, a double colon is used (System::Configure I/O).

500 ohm Jumper for 0-20mA

Field

0V 1

AnIn 1 2

500

Motor Starter on Size 1 & 2 controls.

AnIn 2 3

AnIn 3 4

AnIn 4 5

AnIn 5 6

AnOut 1 7

AnOut 2 8

0V 1

Not Used 2

Arm I Fbk 9

+10V Ref 3

DigOut 1 5

DigOut 2 6

DigOut 3 7

-10V Ref 4 Prog Stop 8

Coast Stop 9

Motor Blower connections when using optional

0V 1

Start 3

DigIn E 4

DigIn R 5

Ext Trip 2

+24V 9

DigIn 1 6

DigIn 2 7

DigIn 3 8

Quick Start 1-1MN792

Reference and Jumpers for Remote Operation

For remote operation, the speed reference and other connections are made at the terminal strip connector. Not all of these connections are shown in Figure 1-3.

Figure 1-3 Reference and Jumper Connections

Speed Reference connections:

A1 – one end of Pot B3 – one end of Pot A4 – wiper of Pot C1 to C2 – No External Trip

Minimum jumper connections:

A1 to A2 – 500 ohm jumper for 20mA input A6 to B3 – Analog Input 5 = +10VDC C4 to C9 – Enable = +24VDC C1 to C2 – No External Trip

Jumper if contacts are not used: B8 to C9 – PROG Stop = +24VDC B9 to C9 – Coast Stop = +24VDC

The Health relay (24VDC coil) may be installed between B6 and C1 to provide fault indication to an external device or circuit.

Signal Connections

500 ohm Jumper for 0-20mA

Optional Speed Feedback Board

0V 1

AnIn 1 2

AnIn 2 3

AnIn 3 4

AnIn 4 5

AnIn 5 6

AnOut 1 7

AnOut 2 8

500

0V 1

DigOut 1 5

Arm I Fbk 9

Not Used 2

DigOut 2 6

-10V Ref 4

+10V Ref 3

0V 1

Start 3

DigIn E 4

DigIn R 5

DigOut 3 7

Prog Stop 8

Coast Stop 9

Ext Trip 2

+24V 9

DigIn 1 6

DigIn 3 8

DigIn 2 7

Jog

Start

Health Relay

PROG Stop

Coast Stop

Speed Feedback The factory setting for speed feedback is Armature Voltage which does not require an optional feedback

board. If an optional board must be used, refer to its manual to install and set the board configuration.

Serial Link A PC COM port may be connected to the control at the System Port (P3). At Menu Level : Serial Links, all of

the parameters can be set for your application.

1-2 Quick Start MN792

 and  scroll the menu choices, and “M” goes to next level menu and “E” comes back up one menu level.

Action Description Display Comments

Apply Power Keypad Display shows this opening

Press “PROG” key

Press “M” key

Press “M” key Access the menus.

Press 

Press “M” key Access the Configure Drive Menu

Press “M” key Access Configure Enable.

Press  key

Press “E” key Return to the Configure Drive Menu

Press 

message.

Scroll to “Configure Drive” menu.

Change Disabled to Enabled.

Set the motor volts.

FORWARD REF: 0.00%

BALDOR DC DRIVE DC 4Q 15A

DC 4Q 15A MENU LEVEL

MENU LEVEL DIAGNOSTICS

MENU LEVEL CONFIGURE DRIVE

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE ENABLE DISABLED

CONFIGURE ENABLE ENABLED

CONFIGURE DRIVE CONFIGURE ENABLE

NOM MOTOR VOLTS

Local control display.

This message may be different for each control size.

Press M twice to go down 2 menu levels

Configure enable is disabled and no parameter value can be changed.

Configure enable must be enabled to allow a change to any parameter value. All LED’s on keypad are blinking to show it is enabled.

Use up and down arrows to set the motor voltage.

Press 

Set the armature current.

Set the field current (skip if field is in voltage mode.

Set the field control mode (voltage or current).

Field Volts Ratio= (field volts/AC supply)*100

Set the current limit (normally 100%).

Leave autotune off.

Select Armature Volts, Analog TACH or Encoder.

Set the pulses per REV of the encoder.

Set the encoder max speed (100% speed).

Change the polarity of the encoder signal if needed.

The Speed Loop Integral Gain.

ARMATURE CURRENT

FIELD CURRENT

FLD. CTRL MODE

FLD. VOLTS RATIO

MAIN CURR. LIMIT

AUTOTUNE

SPEED FBK SELECT

ENCODER LINES

ENCODER RPM

ENCODER SIGN

SPD INT TIME

Use up and down arrows to set. Press “E” when done.

Autotune after calibration is complete.

Use up and down arrows to set. Press “E” when done.

Press 

The Speed Loop Proportional Gain.

SPEED PROP GAIN

Use up and down arrows to set. Press “E” when done.

Quick Start 1-3MN792

Configure the drive parameters and block diagram connections.

Action Description Display Comments

Press “M” key

Press “M” key Access the menus.

Press  or 

Scroll to “Configure Drive” menu.

Setup Parameters

At Menu Level : Setup Parameters, several sub menus set values for your application: Ramps, AUX I/O, Op Station, Jog/Slack, Raise/Lower, Special Blocks, Field Control, Current Profile, Inverse

Time, Stop Rates, Calibration, Inhibit Alarms, Current Loop, Speed Loop, Standstill and Setpoint Sum 1.

Password

At Menu Level : Password, a password can be set to prevent unauthorized access to the setup and other parameters.

Configure I/O

At Menu Level : System : Configure I/O, make the connections using the Tags to configure the block diagram to your application.

Autotune At Menu Level : Configure Drive, set Autotune to On, press “E” to exit configure menu. At the keypad, press L/R for local mode. Press Run, the drive will autotune. When the drive stops and no error messages are displayed, autotune was successful. Repeat the Save Parameters procedure to ensure the new values are saved.

When completed, change the Configure Enable parameter from Enabled to Disabled.

DC 4Q 15A MENU LEVEL

MENU LEVEL DIAGNOSTICS

MENU LEVEL SETUP PARAMETERS

Press “E” when done.

Action Description Display Comments

Press  or 

Press “M” key Access the Configure Drive Menu

Press “M” key Access Configure Enable.

Press  key

Press “E” key 2 times Return to the Menu Level.

Scroll to “Configure Drive” menu.

Change Disabled to Enabled.

MENU LEVEL CONFIGURE DRIVE

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE ENABLE ENABLED

CONFIGURE ENABLE DISABLED

Press M twice to go down 2 menu levels

Configure enable is disabled and no parameter value can be changed.

Configure enable must be enabled to allow a change to any parameter value. All LED’s on keypad are blinking to show it is enabled.

MENU LEVEL CONFIGURE DRIVE

Save Parameters

At Menu Level : Save Parameters, save the settings you have programmed into the control. This will be the parameters that are restored for use after power up. If you do not save the parameters, the factory settings (or the last saved) will be used after a power up.

Action Description Display Comments

Start at Menu Level 1

Press 

Scroll to “PARAMETER SAVE” menu.

Press “M” key

Press  Press  to save parameters.

Press “E” key Exit one level

MENU LEVEL DIAGNOSTICS

MENU LEVEL PARAMETER SAVE

PARAMETER SAVE UP TO ACTION

PARAMETER SAVE REQUESTED

MENU LEVEL PARAMETER SAVE

Parameters are saved. Except the “Local Setpoint”.

Press “E” several times to return to the top level.

1-4 Quick Start MN792

Section 2 General Information

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.

Microsoft and MS–DOS are registered trademarks, and Windows is a trademark of Microsoft Corporation. UL and cUL are registered trademarks of Underwriters Laboratories.

Overview The Series 29 DC control is a one way control. That is, it is non–regen and cannot reverse direction. It

CE Compliance A custom unit may be required, contact Baldor. Compliance to Directive 89/336/EEC is the responsibility of the

Enclosure Sizes Five enclosure sizes are available:

operates in the forward direction only. All references to reverse operation or regen operation apply to the Series 30 DC Control only. The Baldor Digital DC control is a three phase, full wave, DC motor armature and field control. The SCR bridge converts three phase AC power to controlled DC to operate the DC motor armature. The AC input is also used for the reference transformer input to operate power supplies and synchronize to the AC input line. This control is of the NEMA Type C designation.

The control may also be used with permanent magnet field motors and DC spindle drive motors. In addition, standard feedback from armature may be used. An optional Encoder, Tachometer or resolver feedback is available with optional expansion boards. The control can 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 correct operating mode to use for the application. These choices are made using the keypad as explained in this manual.

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 4 and Appendix A of this manual.

Size 1 15A to 35A Size 2 40A to 165A Size 3 180A to 270A Size 4 380A to 830A Size 5 850A and larger

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 2-1MN792

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 MN792

PRECAUTIONS:

WARNING: Do not touch any circuit board, power device or electrical connection before you

WARNING: Be sure that you are completely familiar with the safe operation of this equipment.

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

WARNING: Be sure the system is properly grounded before applying power. Do not apply AC

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

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

WARNING: Motor circuit may have high voltage present whenever AC power is applied, even

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

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

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.

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.

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

power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury.

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

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

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

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

the control in the event of an emergency.

Continued on next page.

General Information 2-3MN792

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 drive 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.

Caution: This control is not designed for regenerative use with stabilized shunt or compound wound

motors. If stabilized shunt or compound wound are to be used, the series field must be isolated and not connected. Contact the motor manufacturer for motor derating specifications under these conditions.

2-4 General Information MN792

Section 3 Getting Started

Control Overview

Control Loops

In very simple terms, control of the DC motor is maintained by Control Loops. An inner Current Loop and an outer Speed Loop are used. These control loops are shown in the Block Diagram of Appendix C. From the keypad, you can select the control loops to be used by the Control to provide either:

Normally a current or speed feedback signal is applied to the appropriate loop to control the process. While current feedback sensors are built–in, speed feedback is normally provided directly from the armature sensing circuit (default), or by “Tachogenerator” or encoder connection to an option board.

• Current Control

• Speed Control (factory setting)

Figure 3-1 Speed Control

speed increase due to fieldweakening

Armature remains constant

Voltage 200V

Field Current 5.7A

field current reduced

base

speed

During speed control the speed of the motor can be increased by adjusting the motor field. Weakening the field current allows an increase in motor speed beyond that normally achieved for the motor rated armature voltage.

Control and Communications

Some of the internal blocks of this control must be connected for your application. This means that you must understand the application and how the software blocks should be connected to implement your design. The block diagram in Appendix C shows the factory set connections. These diagrams assist in understanding this concept and will be described next.

The Keypad (Operator Station) provides access to parameters, diagnostic messages, trip settings and full application programming. The heart of the control is a microprocessor that provides advanced features such as:

• Complex control algorithms not achievable by simple analog techniques.

• Software configured control circuitry that uses standard software blocks.

• Serial link communications with other drives or a PC for advanced process systems.

armature voltage

Speed

To customize drive performance for optimum use, you may need to configure, or reroute software connections to and from the drive’s inputs and outputs and to and from the drive’s software blocks. You can configure the drive and change software block parameter values either using the keypad or with a personal computer (PC) running the software package Workbench D (see MN794).

Getting Started 3-1MN792

Local and Remote Modes

Determine what operating mode is best for your application. Four modes are possible, see Figure 3-2.

Figure 3-2 Local and Remote Modes

Local: Keypad Setting (Factory Setting)

Remote: Terminal Strip Setting

Preset

Analog & Digital Inputs and Outputs

Remote: Serial Setting

Remote: COMMS Setting

For local operation, use the keypad to change parameters or control operation.

Process control and other applications may require the control to be used in remote mode with analog and digital input/output signals performing all control operations. The control is configured in this mode from the factory.

Remote Serial mode is used to initially setup and configure the parameters of the control. For applications that are controlled by a PC that is running suitable software. Workbench D is recommended.

For Baldor RS485/Modbus, Profibus DP and DeviceNet.

Two forms of control are in operation at all times: Start/Stop Control and Speed Control. These are operate by local or remote control.

Local

The keypad is used to set motor speed and other parameters. The Start, Stop and Jog keys then control motor rotation.

Remote

A speed reference signal (pot) and the various analog and digital inputs and outputs are used for speed control and rotation of the motor shaft.

3-2 Getting Started MN792

Source / Destination Tags

The control is very flexible because of the programming capability. The software block diagram of the control is shown in Appendix C. Each logic block has inputs and outputs. These I/O points are called “Tags” because they have a tag number associated with it and shown in brackets “[tag]” . Some tags are read only values and some are read/write. Besides setting the value of each parameter, its source or destination connections can be programmed. This means you can connect inputs and outputs of logic blocks as you desire to implement your application.

Destination Tag example

Consider Digital Input 1. The external connection (input) is made at the C connector pin 6. The block diagram of this input is shown in Figure 3-3. Tag [102] is the destination tag for the output signal. The destination is presently set to 90. This connects the output of Digital Input 1 to the Bipolar Clamps [90] input of the Current Loop Logic Block. The value of [102] Digital output is determined by the switch position, either the value of [103] or [104] will be applied to the output as the input changes from false to true.

Digital Input 1 – DIGIN 1 (C6)

Tag Parameter Setting

[102] Destination Tag 90 [104] Value for False 0.00%

Digital

[103] Value for True 0.01%

Input 1

Source Tag example

Consider Digital Output 1. The external connection (output) is made at the B connector pin 5. The block diagram of this input is shown in Figure 3-4. Tag [97] is the source tag for the input signal. The source is presently set to 77. This means that Digital output 1 receives its input signal from [77] At Zero Speed parameter from the Standstill Logic Block. To connect Digital Output 1 to the At Zero Setpoint parameter, simply change [97] Source Tag value from 77 to 78.

Standstill

[11] Standstill Logic [12] Zero Threshold

At Zero Setpoint [78][306] Source Tag

At Zero Speed [77]

At Standstill [79]

Figure 3-3 Digital Inputs

Current Loop

[102]

[71]

Diagnostic connection

[90] Bipolar Clamps Digital IN 1

[48] NEG I Clamp Analog IN 4

Figure 3-4 Digital Outputs

Digital Output 1 – DIOUT 1 (B5)

Tag Parameter [359] Inverted False [195] Threshold (>)

[97] Source Tag 77

[43] Modulus True

Setting

0.00%

ABS

[88] NEG I Clamp

-1

[87] POS I Clamp

Digital Output 1

From these examples, it is easy to see that several things are required to program the control.

1. First, you must understand the application and know how to implement it in the control parameters.

2. Second, layout all of the connections for your application using the block diagrams in Appendix C.

3. Third, program the connections and parameter preset values. To do this you will need to refer to the Parameter Values in Appendix B. This will tell you where in the keypad menu system you can locate each parameter value or [tag].

For example, find [97] in Appendix B, (see Figure 3-5). To locate [97] using the keypad, begin at the System menu, select Configure I/O menu, then select Digital Outputs menu, finally select Digital Output 1 (B5) parameter. Change the value of that parameter to the desired value.

Note: Tag number “[97]” is not shown at the keypad for the Digital Output 1 (B5) parameter value. To display

the [TAG] number of the parameter, display the parameter value then press the “M” key to show the parameters tag number. Appendix B and C are the key to programming your application.

Figure 3-5

Table B-1 Parameters Listed by Tag Number

Tag R/W Name Keypad Menu WB Block Range Factory Setting MN Notes

97 RW Source Tag SYSTEM::CONFIGURE I/O::DIGITAL

OUTPUTS::DIGOUT 1 (B5)

4. Select the next parameter and repeat step 3.

Digout 1 (B5) 0 to 549 77 cp 2, 3

Continued

Getting Started 3-3MN792

Programming Block A very important step to installing this control is to determine the configuration that will best implement your

application. Each input and output of each block has an assigned tag number. Tags are connected in software much like jumper wires are used in hardware. The control is shipped with a factory set software connection. This may be changed at any time. The method of changing these connections (source or destination tags) is described later in the programming Section 6 of this manual.

Note: It is important to correctly set the software to implement your application in the most efficient way. Some

parameters are Tags (connections) and others are programmed values. Be careful when programming to be sure the correct input or output is being set.

Example (View Analog Input 1 parameter settings) As an example, a portion of the block diagram is shown in Figure 3-6. The output of Analog Input 1 [246] is connected to [100] “Input 1” of Setpoint Sum 1 block. Each input and output shown on these diagrams is programmable.

Figure 3-6 Analog Input Example

Setpoint Sum 1

Analog Input 1

Analog Input 1 – ANIN 1 (A2)

Tag Parameter

[231] Max Value +100.00% [230] Calibration 1.0000

[232] Min Value -100.00% [246] Destination Tag 100

Factory Setting

[246]

Tag Parameter

[292] Sign 0 Positive [208] Ratio 0 1.0000 [309] Input 0 0.00% [420] Divider 0 1.0000 [423] Input 2 0.00% [6] Ratio 1 1.0000 [100] Input 1 0.00% [131] Deadband Width 0.00% [419] Divider 1 1.0000 [8] Sign 1 Positive [375] Limit 105.00%

Factory Setting

A/B

The parameter values for Analog Input 1 can be changed at the keypad. Figure 3-7 shows a partial map of the menu levels. The Analog Input 1 parameters are at Level 4 under the Level 3 Analog Inputs. The keypad operation is shown in Table 3-1. Figure 3-7 can be used to visualize the menu structure that is being navigated in Table 3-1.

Figure 3-7

1234

Diagnostics

Menu Levels

Configure Enable

System

Software Configure I/O

Analog Inputs ANIN1 (A2)

Calibration MAX Value MIN Value Destination Tag

Table 3-1 Set Analog Input 1 for 4–20mA

Action Description Display Comments

Apply Power Keypad Display shows this opening

message.

Press “PROG” key

Press M Access the menus.

Press  Scroll to System menu. Press 

several times.

Press M Access the System menus.

Press 

Scroll to Configure I/O menu.

Press M Access Configure I/O menu.

FORWARD REF: 0.00%

BALDOR DC DRIVE DC 4Q 35A

MENU LEVEL DIAGNOSTICS

MENU LEVEL SYSTEM

SYSTEM SOFTWARE

SYSTEM CONFIGURE I/O

CONFIGURE I/O CONFIGURE ENABLE

This message may be different for each control.

This is menu level 1. Refer to Figure 3-7 for a description of the menu levels.

This is menu level 1, System parameters.

This is menu level 2.

3-4 Getting Started MN792

Table 3-1 Set Analog Input 1 for 4–20mA Continued

Action

Description Display Comments

Press M Access Configure I/O menu.

Press 

Change Configure Enable to Enabled.

Press E Access Configure I/O menu.

Press 

Scroll to analog inputs menu.

Press M Access analog inputs 1 menu.

Press M Access Calibration menu.

Press M View or change the Calibration value.

Press E

Press 

Scroll to next menu.

Press M View or change the MAX Value menu.

Press E

Press 

Scroll to next menu.

Press M View or change the MIN Value menu.

Press E

Press 

Scroll to next menu.

Press M View or change the Destination tag

Value menu.

Press E Press “E” several times to return to

the Configure Enable menu.

Press M Access Configure I/O menu.

Press 

Change Configure Enable to Disabled.

Press E

CONFIGURE ENABLE DISABLE

CONFIGURE ENABLE ENABLED

CONFIGURE I/O CONFIGURE ENABLE

CONFIGURE I/O ANALOG INPUTS

ANALOG INPUTS ANIN1 (A2)

ANIN1 (A2) CALIBRATION

CALIBRATION

1.0000 ANIN1 (A2)

CALIBRATION ANIN1 (A2)

MAX VALUE MAX VALUE

100.00% ANIN1 (A2)

MAX VALUE ANIN1 (A2)

MIN VALUE MIN VALUE

–100.00% ANIN1 (A2)

MIN VALUE ANIN1 (A2)

DESTINATION TAG DESTINATION TAG

100 ANIN1 (A2)

DESTINATION TAG CONFIGURE I/O

CONFIGURE ENABLE CONFIGURE ENABLE

ENABLED

CONFIGURE ENABLE DISABLED

CONFIGURE I/O CONFIGURE ENABLE

This is menu level 3. Before any parameter values can be changed, Configure Enable must be “Enabled” (it is normally disabled”).

Note that the LED’s on Keypad are flashing until changed back to Disable.

Move back one menu level using the E key.

This is menu level 4.

Use the  and  keys to change the value. Press E when finished.

This is menu level 2.

This is menu level 3. Before the control can be used again, Configure Enable must be “Disabled”.

Note when  is pressed, the keypad will briefly display “calibrating” followed by Disabled and all Keypad LED’s stop blinking.

Press the “E” key several times to move back through the menu items or press “PROG” to return to control operation.

Note: When changing a numeric value, pressing the “M” key will change the cursor position one digit to the left.

Getting Started 3-5MN792

3-6 Getting Started MN792

Section 4 Receiving and 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 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 Considerations 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:

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

2. At least 1.0 inches (25mm) 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 1640 feet (500 meters) no derating required. Derate the continuous and peak output current by 1% for each 660 feet (200 meters) above 1640 feet. Maximum operating altitude 16,500 feet (5,000 meters).

4. Operating Temperature derating. 0°C to 45°C (Sizes 1, 2); 0°C to 40°C (Sizes 3,4,5) ambient. Above rated temperature, derate the continuous and peak output current by 2% per °C above rating. Maximum ambient is 55°C.

Table 4-1 Watts Loss Ratings

Catalog No. Output

Current (A)

BC29D7A35–CO7 35 117 BC29D7A380–CO1/CO2 380 1230

BC29D7A70–CO7 70 234 BC29D7A500–CO1/CO2 500 1590 BC29D7A110–CO7 110 354 BC29D7A725–CO1/CO2 725 2265 BC29D7A165–CO7 165 519 BC29D7A830–CO1/CO2 830 2580

BC29D7A243–CO1/CO2 243 840 BC29D7A1580–CO1/CO2 1580 4890

Watts Loss

(W)

Catalog No. Output

Current (A)

Watts Loss

(W)

Receiving & Installation 4-1MN792

Cover Removal To connect power and signal wires, the cover must be removed. This procedure describes how to access all

terminal connections inside the control.

1. Loosen the two cover screws shown in Figure 4-8, then lift and remove the cover as shown.

Figure 4-1 Top Cover Removal

Lift and remove cover

Cover Screws (2)

2. Locate the two 1/4 turn screws shown in Figure 4-2. Rotate each screw 1/4 turn CCW. This releases the control from the base.

Figure 4-2 Signal Connections

Feedback Expansion

Board location

1/4 Turn Screw 1/4 Turn Screw (1/4 turn to release,

Power Connections (Control and base must

be opened to view, see Figure 4-9)

Power Ground

Motor Ground

Communications Expansion Board location

Signal Connections

press screw into hole to close).

See Recommended Tightening Torques in Section 9.

4-2 Receiving & Installation MN792

Cover Removal Continued

3. The control and base are hinged and are opened as shown in Figure 4-3.

Figure 4-3 Hinged Assembly

Rubber

Grommet

The knock–out panel is part of the base assembly to allow connections to be made. Use the correct size rubber grommet, conduit coupling or 360 degree coupling.

Metal

Coupling

360 Degree Coupling

360 Degree

Coupling

Mechanical Installation

Mount the control to the mounting surface. The control must be securely fastened to the mounting surface by the control mounting holes. The location of the mounting holes is shown in Section 9 of this manual.

External Vent Kit (Size 4 & 5 controls only)

Raise the control to expose the base

Knock–out

panel

Hinge

Control

Base

Upper Housing

Foam gasket stretches over duct prior to attaching upper housing.

Duct slides down between duct clip and mounting panel and fits within the sides of the control housing.

Fit duct clip under fasteners at top of drive. Be sure it is tight against the mounting panel.

Receiving & Installation 4-3MN792

Optional Remote Keypad Installation (Enclosure rating of IP54 when correctly mounted). The keypad may be

remotely mounted using optional Baldor keypad extension cable.

Tools Required:

• Center punch, file and screwdrivers (Phillips and straight) and crescent wrench.

• #19 drill and drill motor .

Figure 4-4 Remote Keypad Installation

Mounting Instruction:

Keypad ACBD01A01

Bezel ACBD02A01

1. Locate a flat mounting surface. Place the template on the mounting surface (step 1).

2. Accurately center punch the mounting holes.

3. Drill holes for the two mounting screws.

4. Use the drill to remove metal for the 27 x 29 mm rectangular hole (step 2).

5. Debur the rectangular hole making sure the panel stays clean and flat.

6. Remove the protective film from the keypad gasket (step 3).

7. Assemble the keypad to the panel. Use two screws provided (step 4).

8. Connect the 10 ft. cable at the keypad and P3 of the control (step 5).

Figure 4-5 Template

CBLD030KP

4.09 (104)

1.90 (48.25)

3.78 (96.5)

3.40

(86.5)

5.22

(132.5)

1.57

1.06 (27)

(40)

1.97

(50)

1.14

0.16 (4.0) Dia.

(29)

Bottom

4 Places

4-4 Receiving & Installation MN792

Electrical InstallationAll interconnection wires between the control, AC power source, motor, host control and any operator

interface stations should be in metal conduits. 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.

System Grounding Baldor controls are designed to be powered from standard single and three phase lines that are electrically

symmetrical with respect to ground. System grounding is an important step in the overall installation. The recommended grounding method is shown in Figure 4-6.

Figure 4-6 Recommended System Grounding (3 phase) for UL

Note: Wiring shown for clarity of grounding method only. Not representative of actual terminal block location.

AC Supply (Mains)

Earth

Driven Earth Ground

(Facility Ground)

Disconnect

and Fuses

Four Wire “Wye”

Route all power wires L1, L2, L3 and Earth (Ground) together in conduit or cable.

L1 L2 L3

Control

TH1 TH2

A+ A– F+

F–

Motor

See Recommended Tightening Torques in Section 9.

Armature

Field

Thermistor

GND

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 single and 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.

• 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.

Line Impedance The control requires a 5% maximum line impedance (voltage drop across the reactor is 5% when the control

draws rated input current). 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

Power Disconnect A power disconnect should be installed between each input power source 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 voltage is depleted.

Protection Devices The control must have a suitable input power protection device installed. Input and output wire size is

based on the use of copper conductor wire rated at 75 °C. Table 4-3 describes the wire size to be used for power connections and Table 4-4 describes the ratings of the protection devices.

Recommended fuse sizes are based on the following:

UL 508C suggests a fuse size of four times the continuous output current of the control. Dual element, time delay fuses should be used to avoid nuisance trips due to inrush current when power is first applied.

Receiving & Installation 4-5MN792

Electrical Installation Continued

Isolation Transformer Sizing

Use the information in Table 4-2 to select the KVA rating of the transformer based on the HP rating of the control. The secondary voltage will be the input voltage to the control and the impedance should be 2% or less.

One exception to Table 4-2 is when the DC armature voltage is less than the AC input voltage. If this is the case, use the following formula:

KVA + 0.00163 VAC

Secondary

IDC

Secondary

Table 4-2 Isolation Transformer KVA Selection

HP 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300

KVA 7.5 11 14 20 27 34 40 51 63 75 93 118 145 175 220 275 330

Single Phase Power Since the control rectifies all three input power phases, operation from a single phase power source is

not possible.

Table 4-3 Wire Size

Armature

Maximum

Catalog Number

BC29D7A35-CO7 20 15 35 53 8 8.37 8 8.37 14 2.08 12-22 3.31-0.326

BC29D7A70-CO7 40 30 70 105 4 21.2 3 26.7 14 2.08 14 2.08 6-18 13.3-0.823 BC29D7A110-CO7 60 50 11 0 165 1 42.4 1/0 53.5 14 2.08 14 2.08 6-18 13.3-0.823 BC29D7A165-CO7 100 75 165 248 3/0 85.0 4/0 107.0 14 2.08 14 2.08 6-18 13.3-0.823

BC29D7A243-CO1/CO2 150 120 243 365 300kcmil 152 350kcmil 177 14 2.08 14 2.08 6-18 13.3-0.823 BC29D7A380-CO1/CO2 200 150 380 570 700kcmil 355 750kcmil 380 8 8.37 14 2.08 6-18 13.3-0.823 BC29D7A500-CO1/CO2 300 225 500 750 1250kcmil 634 1500kcmil 760 8 8.37 14 2.08 6-18 13.3-0.823 BC29D7A725-CO1/CO2 400 327 725 1088 1″x3″ BB* 1″x3″ BB* 8 8.37 14 2.08 6-18 13.3-0.823 BC29D7A830-CO1/CO2 500 335 830 1245 1″x3″ BB* 1″x4″ BB* 8 8.37 14 2.08 6-18 13.3-0.823

BC29D7A1580-CO1/CO2 900 650 1580 2370 2″x4″ BB* 2″x4″ BB* 8 8.37 14 2.08 6-18 13.3-0.823

Maximum Output **

HP kW

Current

Cont. Peak

(Amps) (Amps)

3 AC Input Armature

AWG MM

AWG MM2AWG MM2AWG MM2AWG MM

* BB is copper Bus Bar.

** Hp and kW are approximate at 500VDC Armature voltage.

Note: All wire sizes based on 75°C copper wire, 40°C ambient temperature, 4-6 conductors per conduit or raceway.

Wire Size

Field Power

Supply

Logic Power

Supply

BL1,BL2,BL3

Table 4-4 Protection Devices

Catalog

Number

BC29D7A35-CO7 A60Q40 A70QS50-14F 4 3 BC29D7A70-CO7 A50QS80-4R A70QS80 10 3

BC29D7A110-CO7 A50QS125-4R A70QS150 10 3

BC29D7A165-CO7 A50QS175-4R A70QS200 10 3 BC29D7A243-CO1/CO2 A50QS300-4R A70P350 10 3 BC29D7A380-CO1/CO2 A070URD32KI0400 A130URD73LI0450 30 3 BC29D7A500-CO1/CO2 A070URD32KI0630 A130URD73LI0700 30 3 BC29D7A725-CO1/CO2 A070URD32KI0800 A130URD73LI0900 30 3 BC29D7A830-CO1/CO2 A070URD32KI0900 14URD93TTF1250 30 3

BC29D7A1580-CO1/CO2 A070URD32KI0900 * 12.5URD94TDF2300M 30 3

3 AC Line

(Ferraz–Shawmut)

* 6 fuses per drive.

Fuse Rating

Armature

Field Supply (A) Logic Supply (A)

4-6 Receiving & Installation MN792

Electrical Installation Continued

Figure 4-7 Size 1–5 Power Terminal Locations

Size 1 and 2 Size 3

Power Connections

Size 4

Logic Supply,

Contactor &

Thermistor

Connections

Field

Connections

L1 L2 L3

AC Main Supply

Motor Ground

Logic Supply,

Contactor &

Thermistor

Connections

Field

Connections

L1 L2 L3

Earth from

Size 5

L1 L2 L3

D1, D2

A+

A–

THERM+ and THERM– are on separate bd. in door assembly

D3, D4

D1 = FL1 D2 = FL2 D3 = F– D4 = F+ D5 = 3 D6 = 4 D7 = N D8 = L

D7, D8

D5, D6

L1 L2 L3

A+

A-

A+

A-

See Recommended Tightening Torques in Section 9.

Table 4-5 Power Connector Signals

Terminal Description

L1, L2, L3 Main AC input power. A 3–phase AC contactor should be connected in the main AC power supply connections. A+, A– The motor armature is connected to busbar terminals A+ and A–. If a DC contactor is used the contactor poles F+, F– Connect the motor field (–) to terminal F– and field (+) to terminal F+. If the motor has no field connections, is a FL1, FL2 An external field supply may be used for Size 2–5 controls. Connect this supply to terminals FL1 and FL2. The

3, 4 Size 3–5, the AC Contactor coil can be connected between TB3–3 (line) and TB3–4 (neutral) and its purpose is to L, N Single phase AC power for logic circuits. The auxiliary supply must be connected directly to the incoming supply, TH1, TH2 Connection for motor thermal protection. Thermistors must have a combined working resistance of 750 ohms or

(AC Contactor is internal for Size 1 and 2 controls. For other sizes, use terminals 3 and 4). should be interposed between the control terminals and the motor terminals. permanent magnet motor, or if the field is derived externally, you must disable the Field Enable [170] parameter. voltage is determined by the desired field voltage. The supply must be protected externally with suitable fuses.

Always derive the supply from the Red and Yellow phases of the main power supply, with the Red phase connected to terminal FL1 and the Yellow phase connected to FL2.

provide AC power disconnection. Maximum coil inrush current must not exceed 3A. (disconnect only). (Logic Supply is internal for Size 1 and 2 controls). less, increasing to at least 4k ohms at over–temperature. The alarm is latched and the contol must be restarted.

Receiving & Installation 4-7MN792

Electrical Installation Continued

Power Connections Single phase operation of this control is not possible.

Power connections are shown in Figure 4-8. (The location of these terminals is shown in Figure 4-9).

Figure 4-8 3 Phase Power Connections

Note 1

Note 2

Start Contactor

Fuse

Connection

L1 L2 L3

Earth

Note 3 & 4

Note 6

Notes:

1. See Protection Device description in this section.

2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding.

3. Use the same gauge wire for Earth as used for L1, L2, L3 connections.

4. Use same gauge wire for Earth ground as is used for L and N, or L1, L2 L3. (VDE (Germany) requires 10mm 6AWG).

5. Reference EMC wiring in Appendix A for CE compliance.

6. AC Contactor is internal for size 1 and 2 controls. Size 3–5, the contactor can be connected between TB3–3 (line) and TB3–4 (neutral) and its purpose is to provide AC power disconnection. Maximum inrush current must not exceed 3A.

minimum,

TB3

Baldor Control

Figure 4-9 Size 1 & 2 Internal Logic Transformer Jumper Locations

TB1

Logic Trans. Location Size 1

FS7

Logic Trans. Location Size 2

This figure shows optional components not furnished with control.

See Recommended Tightening Torques in Section 9.

Size 1 control

Logic

Transformer

Conn1

Conn2

Conn3

Conn4

Conn5

Move the jumper to the correct voltage of the

480

L1,L2,L3 supply input.

400

Note: When the internal logic

230

208

transformer is installed, FS7 on the main board is removed. FS1 on the logic supply board is used.

FS1

Setting 480 400 230 208

Voltage Range 460–500 380–415 220–240 208

Size 2 control

208

230

400

480

Logic

Transformer

Power

Connections

AC Main Supply

Motor GroundEarth from

Move the jumper to the correct voltage of the L1,L2,L3 supply input. (480V position shown.)

See Recommended Tightening Torques in Section 9.

Logic Power For size 1 and 2 controls, the logic transformer is internal. The location is shown in Figure 4-9. Because the

logic transformer is powered from the L1,L2,L3 input AC power, the jumper must be placed in the location that corresponds to the AC line voltage.

For size 3, 4 and 5 controls the single phase logic power must be supplied by an external source. Normally 115VAC is applied at TB3 terminals L and N, see Figure 4-7 for the location. (Your control may have been ordered with 230VAC logic power. In that case, 230VAC is applied at TB3 terminals L and N.)

4-8 Receiving & Installation MN792

Electrical Installation Continued

Motor Connections Motor connections are shown in Figure 4-10. (The location of these terminals is shown in Figure 4-9).

Note: If your motor requires more than 85% of the line voltage as its DC input voltage, a step up transformer is

required. This is added between the incoming line terminals and the L1 and L2 terminals of the field supply module. This connection is phase sensitive with main input L1 and L2.

Figure 4-10 Motor Connections

Notes:

1. Shield wires inside a metal conduit.

2. Metal conduit should be used to shield output wires (between control and motor). Connect conduits for continuous EMI/RFI shielding.

See Recommended Tightening Torques in Section 9.

Control

TH1 TH2

A+ A– F+

F–

Motor

Armature

Field

Thermistor

GND

Note: The control may be connected to a permanent magnet field DC motor. In this case, the field supply is not

connected and the “Field Enable” [170] parameter must be set to “Disable”.

Shunt Wound

Typical shunt wound motor field connection 120/240V or 150/300V. Consult manufacturers specific motor data for details.

See Recommended Tightening Torques in Section 9.

External AC Field (Not available for size 1 controls)

The internal motor field is more widely used, it provides up to 90% of rated AC main voltage to the field windings. However if an external field supply is required (an application that requires more field voltage than 90% of AC main), terminals FL1 and FL2 can be used. The magnitude of this voltage is determined by the desired field voltage. The external supply must be protected with suitable fuses and disconnect. Always derive the supply from the Red and Yellow phases of the main power supply, with the Red phase connected to FL1 and the Yellow phase to FL2 (see jumpers in the External Field Connections diagrams).

Figure 4-11 External Field Connections

L1 L2 L3

Note 3 & 4

Earth

FL1 FL2

External

Field Supply

Note 1

Note 2

Start Contactor

Note 6

Fuse

Connection

TB3

Baldor Control

L1 L2 L3

TB1

F1 F2

F1 F4F2 F3

F3 F4

120V or 150V

Notes:

1. See Protection Device description in this section.

2. Metal conduit or shielded cable should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding.

3. Use the same gauge wire for Earth as used for L1, L2, L3 connections.

4. Use same gauge wire for Earth ground as is used for L and N. (VDE (Germany) requires 10mm

minimum, 6AWG).

5. Reference EMC wiring in Appendix A for CE compliance.

This figure shows optional components not furnished with control.

See Recommended Tightening Torques in Section 9.

240V or 300V

Receiving & Installation 4-9MN792

Electrical Installation Continued

External Field Terminal and Jumper Locations – Size 2

The position of the jumper selects the board to use either an internal or external motor field.

Figure 4-12 External Field Sensor Plug Jumper Settings

PLG1 to Power Board PLG2 to Power Board PLG3 to Power Board

External Field Selector Plug

FL1 FL2 F+ F– M1 M2 M3

Field Bridge

FL1 FL2

Jumper selecting external field supply Jumper selecting internal field supply

L1 L2

FL1 FL2

External Field Terminal and Jumper Locations – Size 3

Relocating the Red and Yellow phase wires (as shown in Figure 4-13) allows terminals D1 and D2 on the Power Board to be used as the external field AC supply connections. External fuse must not exceed 10A.

Figure 4-13 External Field Connections

Yellow

Red

F19

F16

Motor Vent Fan Circuit Breaker

Field Bridge

Power Board

F18

L N 3 4 TH1 TH2

Terminal Board

L1 L2

Connection No Connection

See Recommended Tightening Torques in Section 9.

F8 & F16 = Internal Field Supply. F18 & F19 = External Field Supply.

Red = FL1 Yellow = FL2

Procedure:

1. Remove the control board (2 screws secure it) to allow access to the power board.

2. Remove the red phase lead from connector “F16” on the left–hand side of the board.

3. Connect the red phase lead to connector “F19” located below D1.

4. Remove the yellow phase lead to connector “F8” on the left–hand side of the board.

5. Connect the yellow phase lead to connector “F18” located below D2.

6. Connect L1 to D1, and L2 to D2. When using an external AC input it is important to have the correct phase relationship on the terminals. The supply must be derived from L1 (Red) and L2 (Yellow) phases directly or indirectly through a single phase transformer. L1 must be connected to D1, and L2 connected to D2.

4-10 Receiving & Installation MN792

Electrical Installation Continued

External Field Terminal and Jumper Locations – Size 4 and 5

Relocating the Red and Yellow phase wires (as shown in Figure 4-14) allows terminals FL1 and FL2 to be used as the external field AC supply connections. External fuse must not exceed 30A.

Figure 4-14 External Field Connections

Red

red

F5 F6

F14

F13

F14

EX A– EX A+

Procedure:

1. Remove the control board (2 screws secure it) to allow access to the power board.

2. Remove the red phase lead from connector “F2” on the left–hand side of the board.

3. Connect the red phase lead to connector “F3” located near the EX L1 terminal.

4. Remove the yellow phase lead to connector “F5” on the left–hand side of the board.

5. Connect the yellow phase lead to connector “F6” located near the EX L2 terminal.

6. Connect L1 to FL1, and L2 to FL2. When using an external AC input it is important to have the correct phase relationship on the terminals. The supply must be derived from L1 (Red) and L2 (Yellow) phases directly or indirectly through a single phase transformer. L1 must be connected to FL1, and L2 connected to FL2.

EX L1

Yellow

ye llow

EX L2

FL1 FL2 F+ F–

FL1 F L2 F+ F–

F2 & F5 = Internal Field Supply. F3 & F6 = External Field Supply.

Red = FL1 Yellow = FL2

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 4-15.

Figure 4-15 Optional M–Contactor Connections

A+

A–F+ F–

F+

M=Contacts of optional M-Contactor

* M

F–

Control faults may occur if the control is enabled before the M Contactor is closed. The timing diagram shown in Figure 4-16 defines the correct operating sequence.

At Turn ON

Allow 20 milli seconds for the coil of the M contactor to energize and close the contactor before the Enable input at C–4 is issued.

At Turn OFF

Do not allow the M Contactor to open until motor shaft rotation has stopped and the Enable at C–4 has been removed. If this sequence does not occur, a TACH LOSS fault may be issued by the control.

Note: This example shows a “Drive ON” output to a PLC that is used to command the DC control and the

holding brake.

To Customer Provided

Power Source

(Rated Coil Voltage)

M Enable

* M-Contactor

3 4 5

Note: Close “Enable” after “M” contact closure.

See Recommended Tightening Torques in Section 9.

* Optional

RC Device

Electrocube

RG1781-3

Receiving & Installation 4-11MN792

Electrical Installation Continued

Figure 4-16 M Contactor Operation Sequence

Turn-ON

M Contact

20 msec.

Enable

Motor Flux

“Drive ON” Output

Mech. Brake Release (If user installed)

50 msec.

Speed/Torque Command

Blower Motor Starter Optional Size 1 and 2 controls only.

Size 1 and 2 controls can be equipped with an optional blower motor starter that uses a manual motor circuit controller to provide motor overload and branch circuit protection for a single or three phase AC blower motor. The starter assembly is fully wired and ready for site installation. This option offers

 Branch circuit protection  Instantaneous magnetic short circuit protection  Thermal overload protection, Class 10, with adjustable trip current settings  Start/Stop/Reset switching with “tripped“ pushbutton indication  Normally open auxiliary contact wired into the drive logic to indicate “Motor Overtemperature“ trip

Installation

1. Open the cover to view the fuse board (Figure 4-3).

2. Position the starter assembly horizontally across the top of the drive so that the harness points downward toward the power terminals.

3. Align the bracket with its mounting slots on the inside walls of the drive. Snap into place with a firm push until the tabs engage.

4. Locate the 14 pin header for the blower motor starter connections. For size 1, this connector is CONN 2, located at the top left corner of the fuse board. For size 2, this connector is CONN 44 located at the right edge of the terminal board.

5. This connector has a jumper installed at the right most two pins. Remove and save this jumper.

6. Plug the 14 pin connector from the blower motor starter onto this connector.

7. Use a small screwdriver to set the full load current of the blower motor on the dial of the blower motor starter.

8. Connect the blower motor leads to terminals BL1, BL2, BL3 (Figure 4-7).

9. Press the Start button on the blower motor starter. Installation is now complete.

Run Time

Turn-OFF

Brake Set Time

4-12 Receiving & Installation MN792

Electrical Installation Continued

Thermal Protection Terminals TB3 TH1 and TH2 are available for connection to a normally closed thermostat or overload

relay in all operating modes as shown in Figure 4-17. The thermostat or overload relay should be a dry contact type with no power available from the contact. If the motor thermostat or overload relay activates (opens), the control will automatically shut down and give an Thermistor fault. The optional relay (CR1) shown provides the isolation required and the N.O. contact is closed when power is applied to the relay and the motor is cold. If the motor thermostat is tripped, CR1 is de-energized and the N.O. contact opens.

Connect the motor thermal wires (N.O. relay contact) to TH1 and TH2. Do not place these wires in the same conduit as the motor power leads.

Figure 4-17 Motor Temperature Relay

If the motor thermostat is not used, TH1 and TH2 must be jumpered together to allow operation.

See recommended terminal

tightening torques in Section 9.

* Motor

Customer Provided

Source Voltage

CR1

Motor Thermostat Leads

Note: Add appropriately rated protective

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

TB3 TH1

TH2

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

* Optional hardware. Must be ordered separately.

Thermostat

See Recommended Tightening Torques in Section 9.

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. Table 4-6 defines the encoder connections to the encoder receiver expansion board. Figure 4-18 shows the electrical connections of the encoder. The expansion board is installed in the feedback EXB location shown in Figure 4-2.

1. Open the top cover (Figure 4-1).

2. Align the 10 pin connector on the board with the connector on the left side of the control.

3. Carefully push the encoder board into position being careful not to bend any pins. All four stand–offs should contact the control.

4. Connect the encoder wires to the expansion board, see Table 4-6 and Figure 4-18.

Table 4-6 Encoder Connection Descriptions

Description Encoder Connector

No.

A A 3 A A 4 B B 5 B B 6 C C C C +VCC Supply +VCC Supply 2 Not used (VCC Sensor) Not used (VCC Sensor) 0VDC 0VDC 1 Not used (0VDC Sensor) Cable Shield

Encoder Receiver Board Pin.

To Encoder

Figure 4-18 Differential Encoder Connections

Align the 10 pin connector to the 10 pin connector of the control (see Figure 4-2 for location). Carefully seat the board onto the pins until all four standoffs contact the control surface.

0VDC (Isolated) +VCC (Isolated) Channel A

Channel A Channel B Channel B

Encoder Case

Encoder Expansion Board

Potentiometer (VCC Adjust)

Torque to 3.5 lb-in (0.4Nm)

16-22AWG

Receiving & Installation 4-13MN792

Electrical Installation Continued

Tachometer Installation The tachometer expansion board can be used to connect either an AC Tach or a DC Tach to the

control (only one may be used). Shielded wire must be used for tachometer connection. Table 4-7 defines the tachometer connections to the tachometer expansion board. Figure 4-19 shows the electrical connections of the tachometer. Figure 4-20 shows the settings for this board.

Note: DC Tachometers provide speed and direction feedback. AC tachometers provide only speed feedback.

Table 4-7 Tachometer Connection Descriptions

Description Tachometer Receiver

AC Tach Input 1 AC Tach Input 2 DC Tach Input + 3 DC Tach Input – (0VDC) 4

Board Pin.

Figure 4-19 Tachometer Connections

Align the 10 pin connector to the 10 pin connector of the control (see Figure 4Ć2 for location). Carefully seat the board onto the pins until all four standoffs contact the control surface.

To AC Tach

To DC Tach

Tachometer Expansion Board

G1G2G3G

Torque to 5.3 lb-in (0.6Nm)

Figure 4-20 Switch Settings

Calibration Switches

The jumper is always used. It plugs onto the control PCB in just about the position shown. This jumper is where the actual scaled signal connects from the Tach board to the controller PCB.

For full speed tach voltages greater than 200V, an external resistor of value RE must be used in series with the DC Tach connection at G3. The value RE is calculated as follows:

SW1 = Ones calibration switches. SW2 = Tens calibration switches. SW3 = Down adds 100 VDC in the down position (100's position).

SW4 = Up for AC Tach; Down for DC Tach.

As shown, switches are set for 188VDC for a DC tach: (SW3 + SW2 + SW1 = 100 + 80 + 8 = 188)

SW1

SW2

SW4

SW3

SW4

1"

10"

100"

Jumper

RE ohms =

(Max Tach Volts * 200)

RE Watts = (Max Tach Volts * 200) 5 milliwatts

G1 G2 G3 G4

Torque to 5.3 lb-in (0.6Nm)

In general, the voltage output of an analog AC or DC tachometer generator is a function of speed and is rated in volts per 1000 RPM so that:

Speed Feedback Voltage

(volts) + Motor Speed

Max

(RPM) x Tach Rating

Max

The Tach Rating should be on the nameplate of the tachometer generator. Fine tuning is performed within the software (refer to the Speed Feedback Calibration). If the full speed feedback voltage exceeds 200 VDC, use an external resistive scaling network to drop the feedback voltage to within this range.

For AC tachometer generators, the switch settings will be about 1.3 times greater than the voltage measured at the input terminals G1 and G2 due to the rectifier offset. For example, for 90V feedback, the switch setting is:

Required Voltage Feedback + 2Ǹ 90 + 127V

4-14 Receiving & Installation MN792

Control I/O Signal Connections

All connections made to terminal blocks A, B and C must be isolated signal voltages. If in doubt a connection, contact Baldor. Only shielded, twisted pair cables should be use. Minimum wire size is 18AWG (0.75mm2). All cables should be installed using the appropriate coupling in the knock out panel, shown in Figure 4-3.

Analog Inputs Five analog inputs are available, AnIn1 – AnIn5 (AnIn4 and AnIn5 are factory set for current limits).

Connector

Terminal

A1 0V common reference point for all analog signals. A2 Analog Input 1. 0–20 or 4–20mA analog input speed input. Used as a unipolar 0–20mA ramped speed command

A3 Analog Input 2. ±10V analog input speed or torque reference without Accel/Decel ramps. +10V = maximum forward

A4 Analog Input 3. ±10V analog input speed or torque reference with Accel/Decel ramps.

A5 Analog Input 4. Optional Negative Current Clamp. Inactive until Bipolar Clamps parameter is set to Enable. When A6 Analog Input 5. External Current Limit / Optional Positive Current Clamp. A jumper is supplied from B3 (+10V Ref) to

Signal Description

channel. 4–20mA requires manually setting Min value to 25%, Max Value to 125% and setting Setpoint Sum1, Input 2 to (–)25%. These settings will provide the proper scaling and offset to set 4mA to zero command. Any input less than 4mA will result in a Min Value of 25% being added to (–)25% at the Setpoint Sum 1 summing junction.

speed demand. –10V = maximum reverse speed demand. Closing C8 (Digital Input 3) selects Torque Command Mode by enabling the IDMD Isolate input (Current Loop Block).

Opening C8 selects Speed Command Mode by disabling the IDMD Isolate input. In all cases this analog command channel bypasses the Ramps Block.

By closing the Reverse input at C5, the direction of the unipolar command can changed. Output of Ramps block is connected to Setpoint 1 of the Speed Loop block. Various voltage range, and bipolar or unipolar commands can be accepted by adjusting Calibration, Max Value, and Min Value parameters of Analog Input 3.

enabled, this input is the value of the negative current limit. A5 to allow full rated 150% current. When Bipolar Clamps parameter is set to Disabled, this input is the main current

limit value. When Bipolar Clamps parameter is set to Enable, this input value is the positive or forward current limit.

Note: The settings for AnIn1 – AnIn5 are factory set but can be changed to suit your application.

Speed Setpoint

The speed demand signal can be generated using an external 10K potentiometer as shown in Figure 4-21. The wiper is the speed reference.

0V 1

AnIn 1 2

AnIn 2 3

AnIn 3 4

Control I/O

AnIn 4 5

Connectors

0-20 mA or

4-20 mA Input

500

0–10VDC or ±10VDC Input

See Recommended Tightening Torques in Section 9.

AnIn1

Control

Figure 4-21 Analog Inputs

AnIn 5 6

AnOut 1 7

AnOut 2 8

0V 1

DigOut 1 5

Arm I Fbk 9

Not Used 2

DigOut 2 6

-10V Ref 4

+10V Ref 3

Multiple Speed Setpoints

A4 AnIn3 Speed Setpoint 2 (Ramped)

AnIn2 Speed Setpoint 1 (Non-Ramped)

Control

DigOut 3 7

Prog Stop 8

Coast Stop 9

Command Pot

0V 1

Ext Trip 2

10KW

Start 3

DigOut E 4

DigIn 1 6

DigIn 2 7

DigIn 3 8

DigOut R 5

Analog GND

Analog Input

Pot Reference

+24V 9

Setpoint Ramp Input

B3 +10VDC

AnIn3

Control

Receiving & Installation 4-15MN792

Control I/O Signal Connections Continued

Analog Outputs

Connector

Terminal

A7, A8, A9 Three analog outputs are available, AnOut1 – AnOut3. A1 is the 0V common reference point.

Signal Description

Figure 4-22 Analog Outputs

Analog Outputs

A10V

AnOut1

AnOut2

Control

A9Arm I Fbk

Analog Output 1 (±10VDC)

Analog Output 2 (±10VDC)

Analog Output 3 (±10VDC)

See Recommended Tightening Torques in Section 9.

Digital Inputs C4 (Enable) must be connected to C9 (+24V) to allow the drive to run when start command is given.

Connector

Terminal

B8 Program Stop. When opened runs a decel rate set by Stop Rates, Prog Stop Time. B9 Coast Stop. When opened disables the drive output. C2 External Trip. When opened disables the drive output and creates an External Trip Fault. C3 Start/Stop. Closed initiates a Start/Run forward sequence. When opened commands Stop and decels at Stop Rates,

C4 Enable. Closed enables the drive and allows output to the motor. C5 Reverse. Closed changes the slope of the speed command signal from Analog Input 1 and Analog Input 2.

C6 Jog / Slack.

C7 Jog/Slack Mode. See Jog/Slack description in Section 6 for description of modes. C8 Speed/Torque Select. Open selects speed (velocity) mode. Closed selects current (torque) mode.

Signal Description (factory settings)

Stop Time setting.

Accomplished by activating the “Ramp Invert” input of the Ramps block. If terminal C4 is closed and Start/Stop terminal C3 is open, motor will be commanded to run forward at Jog Speed 1.

If terminal C4 is closed and Start/Stop terminal C3 is closed, motor will be commanded to run forward at active speed

setpoint plus Jog/Slack Take Up 1 speed. Various Jog or Slack take–up functions Various Jog or Slack take–up functions are commanded depending on the various settings of terminals C3, C4 and Jog/Slack Mode C7.

Accel/Decel ramps are not used in Torque mode.

Start (C3), Enable (C4), Reverse (C5), Program Stop (B8) and Coast Stop (C9).

The basic Run/Start sequence is initiated by C3 (Start/Run). Other safeguards are provided by B8 (Program Stop) and B9 (Coast Stop). Assuming that the Program Stop and Coast Stop terminals are held TRUE, then a single contact connected between C9 (+24V) and C3 (Start/Run) when closed will cause the control to energize the Main Contactor and when C5 (Enable) is also TRUE the motor will rotate.

When the single contact to C3 (Start/Run) is opened, the controller will decelerate the motor to zero speed at a rate determined by the STOP TIME parameter value and the MAIN CURR. LIMIT value. If the load is to be serviced, the control must be securely disabled and isolated, do not rely on this mode.

4-16 Receiving & Installation MN792

Control I/O Signal Connections Continued

Figure 4-23 Run/Stop Connections

B8 Program Stop

B9 Coast Stop

Emergency Stop Relay (Optional)

(Shown in energized - Run position)

C5 Reverse

C8 Speed/Torque Select

Start

Enable

Jog/Slack

Jog/Slack Mode

+24VDC

Control

See Recommended Tightening Torques in Section 9.

A regenerative drive can be stopped using a Normal Stop, a Program Stop, or an Emergency Stop.

Normal Stop

If the +24V is removed from C3 during operation, the control will cause the motor to stop at a rate determined by Stop Limit, Stop Time and Curr. Limit.

Program Stop

If the +24V is removed from B8 during operation, the control will cause the motor to stop at a rate determined by Prog Stop I Lim, Prog Stop Limit and Prog Stop Time. If +24V is re–applied to B8, the motor remains stationary until a new Start command is applied to C3 (Start/Run).

Coast Stop

If the +24V is removed from B9 during operation, the control will remove power to the motor and the motor and load will coast to a stop.

Emergency Stop (Optional) When the “Emergency Stop Relay” is de–energized its contacts disconnect +24VDC from the inputs shown in Figure 4-23. The control will remove power to the motor and the motor and load will coast to a stop. The emergency stop relay should not be part of the normal sequencing of the system, but is an emergency operation when safety is the main concern. If the load is to be serviced, the control must be securely disabled and isolated, do not rely on this mode.

Digital Outputs

Connector

Terminal

B5, B6, B7 Three digital outputs are available, DigOut1 – DigOut3. B1 is the 0V common reference point.

Signal Description

These digital output terminals provide a +24VDC output signal under certain conditions. An LED, Lamp, Relay or other device can be connected at these outputs to indicate the condition of control operation. These are configurable outputs and can be used as required in the control system design, i.e. panel lamps, connection to a suitable PLC. Simply connect a 24VDC relay between the output and B1 (0VDC). Be sure to use a reverse biased diode or other noise elimination device across the relay coil, see Figure 4-24.

Figure 4-24 Optional Digital Output Relay Connection

Note: Add appropriately rated protective

CR1

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

Receiving & Installation 4-17MN792

RS232 Connections The keypad connector shown in Figure 4-25 is used for RS232 communications. Workbench D is the

1 SERIAL LINKS

2 SYSTEM PORT P3

block programming software for Windows PCs. It has a graphical user interface and drawing tools to allow you to create block programming diagrams quickly and easily.

Figure 4-25 System Port (P3) Keypad Connector

3 P3 SETUP

MODE P3 BAUD RATE

Control

(DCE)

1234

View into the connector.

A null modem cable (also called a modem eliminator cable) must be used to connect the control and the computer COM port. This will ensure that the transmit and receive lines are properly connected. Either a 9 pin or a 25 pin connector can be used at the computer, Figure 4-26. Maximum recommended length for RS232 cable is 10 ft. (3 meter).

Figure 4-26 9 & 25 Pin RS-232 Cable Connections

9 Pin Connector

25 Pin Connector

RXD

TXD

GND

Chassis

Null Modem Cable Connections

RXD TXD

GND

Computer

COM

Port

(DTE)

Pin Signal 2 RXD 3 TXD 5 GND

Pin Signal 3 RXD 2 TXD 7 GND

Table 4-8 Cable Connections

P3 Connector DB Connector Type and Pin Number

Pin Signal Name DB9 DB25

1 GND/0VDC 5 7 2 24VDC 3 RXD 2 3 4 TXD 3 2

System Port (P3) Configuration

The factory port settings are normally fine. These settings are:

9600 Baud 8 Bits 1 Stop Bit No Parity XON/XOFF Handshaking (fixed)

If the port settings must be changed, attach a keypad to the control and change the settings under the P3 SETUP menu. Refer to Keypad Operation for additional information to make these parameter value changes.

4-18 Receiving & Installation MN792

Section 5 Switch Setting and Start-Up

Pre–Operation Checks

Size 4 and 5 Only – Power Board Calibration

Power Board

IF CAL

SW2

When the installation is complete, several things should be verified before power is applied.

1. Be sure AC power is off at the main disconnect or circuit breakers.

2. Measure the main AC supply voltage (to the disconnect or breaker) and verify that it matches the nameplate rating of the control.

3. If the catalog number on the nameplate ends with “CO1”, an external 115VAC logic control supply is required (C02= 230VAC Logic). Verify Auxiliary power supply voltage is correct.

4. Verify the armature voltage and current ratings of the motor are correct.

5. Inspect all power connections (line and motor) for accuracy, workmanship tightness and compliance to codes.

6. Verify that the control and motor are grounded to each other and that the control is connected to earth ground.

7. Verify all signal wiring for accuracy and tightness.

8. Be certain that all contactor, brake or relay coils have noise suppression. This should be an RC filter for AC coils or a reverse biased diode for DC coils. MOV type transient suppression is not adequate.

9. Disconnect the load from the motor shaft if possible.

10. If possible, verify the motor shaft rotates freely.

11. Verify the cooling fan (blower) is free from obstruction.

12. Verify that the external run contacts are open.

13. Verify that external speed setpoints are all zero.

IA CAL – Armature Current Calibration Switch (SW1)

This switch is always set to LO on Frame 4 & 5 drives of less than 500A, and HI for drives greater than 500A.

F CAL – Field Current Calibration Switch (SW2)

This switch should always be set to HI for Frame 4 & 5 drives. The maximum field current calibration is 30A.

HI LO

IA CAL

SW1

HI LO

Power up in Local Mode with Armature Feedback

When pre–operation checks are complete, logic power can be applied to terminals L and N to setup the software parameters (catalog number C01=115VAC, C02=230VAC). For other catalog numbers (100hp and less), the logic power is provided internally so 3 phase power must be applied at this time.

(The start up mode is defined by Parameter [517] =True for keypad operation which is the same as “SETUP PARAMETERS::OP STATION::START UP VALUES::LOCAL = TRUE”.)

Note: To separate the various menu level designation, a double colon is used (SETUP PARAMETERS::OP

STATION).

1. Apply logic power.

2. Verify that the keypad and LED’s display correctly. If not, verify that the logic wiring is correct.

Action Description Display Comments

Apply Logic Power at terminals L and N

Keypad Display shows this opening message.

If [517] is True, local mode will be displayed (factory setting)

INITIALIZING

BALDOR DC DRIVE CALIBRATING

FORWARD REF: 0.00%

LED’s are all ON.

LED’s are flashing. After several seconds the next screen is displayed.

The OK, SEQ, REF, FWD and STOP LED’s are on.

Switch Setting & Start-Up 5-1MN792

Power up in Local Mode with Armature Feedback Continued

3. Set the parameter Configure Enable to “Enabled”.

Action Description Display Comments

Apply Logic Power Keypad Display shows this opening

message.

Press “PROG” key

Press “M” key

Press “M” key Access the menus.

Press 

Scroll to “Configure Drive” menu.

Press “M” key Access Configure Drive menu.

Press “M” key Access the Configure Enable

parameter.

Press 

Enable Configure Enable.

Press “E” key Returns to previous menu level.

FORWARD REF: 0.00%

BALDOR DC DRIVE DC 4Q 35A

DC 4Q 35A MENU LEVEL

MENU LEVEL DIAGNOSTICS

MENU LEVEL CONFIGURE DRIVE

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE ENABLE DISABLED

CONFIGURE ENABLE ENABLED

CONFIGURE DRIVE CONFIGURE ENABLE

LED’s are flashing. After several seconds the next screen is displayed.

All LED’s are now flashing. Press “E” when done.

4. Set the Nominal Motor Volts (Armature Voltage) in the Configure Drive menu.

Action Description Display Comments

Press 

Press “M” key Access the NOM Motor Volts

Press “PROG” key

Scroll to the NOM Motor volts parameter.

parameter

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE NOM MOTOR VOLTS

NOM MOTOR VOLTS

180 VOLTS

Press  to change to current control if desired. Press “E” when done.

5. Set the Armature Current. Note the maximum armature current from the motor name plate and set this value in the Armature Current parameter.

Action Description Display Comments

Press 

Press “M” key Access the Armature Current

Press “PROG” key

Scroll to the Armature Current parameter.

parameter

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE ARMATURE CURRENT

ARMATURE CURRENT

11.5 AMPS

Press  to change to current control if desired. Press “E” when done. Max value is hardware limited.

Note: Holding the M key scrolls the cursor the left most digit so it can be changed more quickly.

5-2 Switch Setting & Start-Up MN792

Power up in Local Mode with Armature Feedback Continued

6. Set the Field Current. Note the nominal field current from the motor rating plate and set this value in the Field Current parameter.

Action Description Display Comments

Press 

Press “M” key Access the Field Current parameter

Press “PROG” key

Action Description Display Comments

Press  several times

Press “M” key Access the field control mode

Press “PROG” key

Scroll to the Field Current parameter.

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE FIELD CURRENT

FIELD CURRENT

0.2 AMPS

Press  to change to current control if desired. Press “E” when done. Max value is hardware limited.

7. Set the Field Control Mode to Field Voltage or Field Current control. Refer to section 6 for more information. The factory setting is Voltage Control mode.

Scroll to the field control mode parameter.

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE FLD CTRL MODE

FLD CTRL MODE VOLTAGE CONTROL

Press  to change to current control if desired. Press “E” when done.

8. Set the Field Volts Ratio. Enter the calculated ratio into the parameter given by the equation: A setting of 90% is the maximum value obtainable, i.e. field output = 0.9 x VAC

FieldVolts (Nameplate)

100

Input Volts AC

RMS

Action Description Display Comments

Press 

Press “M” key

Press “M” key Access the menus.

Press 

Scroll to the field volts ratio parameter.

Scroll to “Configure Drive” menu.

CONFIGURE DRIVE FLD CTRL MODE

CONFIGURE DRIVE FLD VOLTS RATIO

FLD VOLTS RATIO

0.00%

CONFIGURE DRIVE FLD VOLTS RATIO

Press  to increase the value if desired. Press “E” when done.

9. Set the Configure Dive::Configure Enable parameter to disable (see step 3).

10. Save the settings.

Action Description Display Comments

Start at Menu Level 1

Press 

Scroll to “PARAMETER SAVE” menu.

Press “M” key

Press  Press  to save parameters.

Press “E” key Exit one level

MENU LEVEL DIAGNOSTICS

MENU LEVEL PARAMETER SAVE

PARAMETER SAVE UP TO ACTION

PARAMETER SAVE REQUESTED

MENU LEVEL PARAMETER SAVE

Parameters are saved. Except the “Local Setpoint”.

Press “E” several times to return to the top level.

Switch Setting & Start-Up 5-3MN792

Power up in Local Mode with Armature Feedback Continued

The control is now ready to run from the keypad using armature feedback.

1. The logic power is still applied, the keypad display is normal, the motor is connected but the load is removed.

2. Apply 3 phase power.

3. Verify that the keypad and LED displays are still normal, with no error messages.

4. Set the Speed Setpoint parameter to zero.

5. Verify that the Main CURR. Limit is set to 0.00%. View ANIN 5 (A6) parameter in the level 1 Diagnostics menu and verify it displays 0.00V.

6. Press JOG at the keypad. Verify that 3–phase mains is applied to Power Terminals L1, L2 and L3 and immediately check that the correct field voltage appears between the control supply terminals F+ and F–. If the field voltage is not correct, check one of the following:

Internally Supplied Field:

a. Check that 3–phase is applied to terminals L1, L2 and L3 when the main contactor is closed. b. Check that the fuses on the power board or supression board are healthy. c. Verify the Field Enable parameter is set to Enable. d. Is the FLD CTRL Mode parameter set to Voltage Control or Current Control?

If set to VOLTAGE CONTROL, check the value of the FLD. VOLTS RATIO parameter. Set this to 65% to obtain 300V fields from 460V lines. If set to CURRENT CONTROL, check the field current calibration. If the field volts are at maximum, check the field continuity. (The field current may initially be

less than the rated value due to a cold field.) Externally Supplied Field: (not available for size 1and 2 controls) a. Refer to Chapter 4 Installation, Motor Field Connections for conversion details. b. Check the voltage applied (externally fused) to terminals FL1 and FL2. c. Check the phasing of voltage applied to FL1 and FL2:

FL1 must be connected directly or indirectly to the Red phase on main power terminal L1.

FL2 must be connected directly or indirectly to the Yellow phase on main power terminal L2. d. Verify the Field Enable parameter is set to Enable. e. Is the FLD CTRL Mode parameter set to Voltage Control or Current Control?

If set to Voltage Control, check the value of the FLD. Volts Ratio parameter. Set this to 65% to

obtain 300V fields from 460V lines.

If set to Current Control, check the field current calibration set–up, refer to “Calibration”.

7. Verify that the OK and STOP LEDs are On, also either the FWD or REV LED.

This verifies keypad operation of the control and motor. The control may be used in this mode after the load is connected or additional wiring changes can be made for operation from the terminal strip.

5-4 Switch Setting & Start-Up MN792

Power up in Remote Mode with Feedback This procedure assumes that the terminal strip (connectors A, B C) are wired

according to the instructions provided in Section 4 and the feedback device is properly installed. (The start up mode is defined by Parameter [517] =False for remote operation which is the same as “SETUP PARAMETERS::OP STATION::START UP VALUES::LOCAL = FALSE”.)

When pre–operation checks are complete, logic power can be applied to setup the software parameters. At this point, 3 phase power should remain off, if possible.

1. Apply Logic power.

2. Verify the keypad and LED’s display correctly. If not, verify that the logic wiring is correct.

Action Description Display Comments

Apply Logic Power Keypad Display shows this opening

message. The local mode (keypad mode) is

displayed

BALDOR DC DRIVE CALIBRATING

FORWARD REF: 0.00%

3. Set the parameter Configure Enable to “Enabled”.

Action Description Display Comments

Apply Logic Power Keypad Display shows this opening

message.

Press “PROG” key

Press “M” key

Press “M” key Access the menus.

Press 

Scroll to “Configure Drive” menu.

Press “M” key Access Configure Drive menu.

Press “M” key Access the Configure Enable

parameter.

Press 

Enable Configure Enable.

Press “E” key Returns to previous menu level.

FORWARD REF: 0.00%

BALDOR DC DRIVE DC 4Q 35A

DC 4Q 35A MENU LEVEL

MENU LEVEL DIAGNOSTICS

MENU LEVEL CONFIGURE DRIVE

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE ENABLE DISABLED

CONFIGURE ENABLE ENABLED

CONFIGURE DRIVE CONFIGURE ENABLE

LED’s are flashing. After several seconds the next screen is displayed.

The OK, SEQ, REF, FWD and STOP LED’s are on.

LED’s are flashing. After several seconds the next screen is displayed.

All LED’s are now flashing. Press “E” when done.

4. Set the Nominal Motor Volts (Armature Voltage).

Action Description Display Comments

Press 

Press “M” key Access the NOM Motor Volts

Press “PROG” key

Scroll to the NOM Motor volts parameter.

parameter

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE NOM MOTOR VOLTS

NOM MOTOR VOLTS

180 VOLTS

Press  to change to current control if desired. Press “E” when done.

Switch Setting & Start-Up 5-5MN792

Power up in Remote Mode with Feedback Continued

5. Set the Armature Current. Note the maximum armature current from the motor name plate and set this value in the Armature Current parameter.

Action Description Display Comments

Press 

Press “M” key Access the Armature Current

Press “PROG” key

Action Description Display Comments

Press 

Press “M” key Access the Field Current parameter

Press “PROG” key

Scroll to the Armature Current parameter.

parameter

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE ARMATURE CURRENT

ARMATURE CURRENT

11.5 AMPS

Press  to change to current control if desired. Press “E” when done.

6. Set the Field Current. Note the nominal field current from the motor rating plate and set this value in the Field Current parameter.

Scroll to the Field Current parameter.

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE FIELD CURRENT

FIELD CURRENT

0.2 AMPS

Press  to change to current control if desired. Press “E” when done.

7. Set the Field Control Mode to Field Voltage or Field Current control. Refer to section 6 for more information. The factory setting is Voltage Control mode.

Action Description Display Comments

Press  several times

Press “M” key Access the field control mode

Press “PROG” key

Scroll to the field control mode parameter.

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE FLD CTRL MODE

FLD CTRL MODE VOLTAGE CONTROL

Press  to change to current control if desired. Press “E” when done.

8. Set the Field Volts Ratio. Enter the calculated ratio into the parameter given by the equation: A setting of 90% is the maximum value obtainable, i.e. field output = 0.9 x VAC

FieldVolts (Nameplate)

100

Input Volts AC

RMS

Action Description Display Comments

Press 

Press “M” key

Press “M” key Access the menus.

Press 

Scroll to the field volts ratio parameter.

Scroll to “Configure Drive” menu.

CONFIGURE DRIVE FLD CTRL MODE

CONFIGURE DRIVE FLD VOLTS RATIO

FLD VOLTS RATIO

0.00%

CONFIGURE DRIVE FLD VOLTS RATIO

Press  to increase the value if desired. Press “E” when done.

5-6 Switch Setting & Start-Up MN792

Power up in Remote Mode with Feedback Continued

9. Set the Configure Dive::Configure Enable parameter to disable (see step 3).

10. Save the settings.

Action Description Display Comments

Start at Menu Level 1

Press 

Scroll to “PARAMETER SAVE” menu.

Press “M” key

Press  Press  to save parameters.

Press “E” key Exit one level

The control is now ready to run the motor.

1. The logic power is still applied, the keypad display is normal, the motor is connected but the load is removed.

2. Apply 3 phase power.

3. Verify that the keypad and LED displays are still normal, no error messages.

4. Set the Speed Setpoint parameter to zero.

5. Verify that the Main CURR. Limit is set to 0.00%. View ANIN 5 (A6) parameter in the level 1 Diagnostics menu and verify it displays 0.00V.

6. Apply the Start/Run command and check that 3–phase mains is applied to Power Terminals L1, L2 and L3. Initiate “Enable” (C4) and immediately check that the correct field voltage appears between the control supply terminals F+ and F–. If the field voltage is not correct, check one of the following:

MENU LEVEL DIAGNOSTICS

MENU LEVEL PARAMETER SAVE

PARAMETER SAVE UP TO ACTION

PARAMETER SAVE REQUESTED

MENU LEVEL PARAMETER SAVE

Parameters are saved. Except the “Local Setpoint”.

Press “E” several times to return to the top level.

Internally Supplied Field:

f. Check that 3–phase is applied to terminals L1, L2 and L3 when the main contactor is closed. g. Check that the fuses on the power board or supression board are healthy. h. Verify the Field Enable parameter is set to Enable. i. Is the FLD CTRL Mode parameter set to Voltage Control or Current Control?

lower than the rated value due to a cold field.) Externally Supplied Field: (not available for size 1 and 2) a. Refer to Chapter 4 Installation, Motor Field Connections for conversion details. b. Check the voltage applied (externally fused) to terminals FL1 and FL2. c. Check the phasing of voltage applied to FL1 and FL2:

FL1 must be connected directly or indirectly to the Red phase on main power terminal L1.

If set to Voltage Control, check the value of the FLD. Volts Ratio parameter. Set this to 65% to

obtain 300V fields from 460V lines.

If set to Current Control, check the field current calibration set–up, refer back to “Calibration”.

7. Verify that the OK and STOP LEDs are On, also either the FWD or REV LED.

Switch Setting & Start-Up 5-7MN792

Power up in Remote Mode with Feedback Continued

8. Verify that C9 is +24VDC (reference to B1), and that B3 is –10VDC (reference to B1).

9. Select the Speed Feedback type.

Action Description Display Comments

Press 

Press “M” key Access Configure Drive menu.

Press “M” key Access the Configure Enable

Press 

Press “E” key Returns to previous menu level.

Press 

Press “M” key Access FBK select

Scroll to “Configure Drive” menu.

parameter. Enable Configure Enable.

Scroll to Speed FBK Select

MENU LEVEL CONFIGURE DRIVE

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE ENABLE DISABLED

CONFIGURE ENABLE ENABLED

CONFIGURE DRIVE CONFIGURE ENABLE

CONFIGURE DRIVE SPEED FBK SELECT

SPEED FBK SELECT ARM VOLTS FBK

10. If using a potentiometer for a setpoint, verify its operation as follows: a. Use the keypad to display the value of the Diagnostics::ANIN 3 (A4). b. Vary the setpoint potentiometer and observe the input voltage change on the keypad display. c. Additional Setpoint Inputs may also appear at ANIN 1 (A2) and ANIN 2 (A3).

Verify these if they are installed.

d. The sum of all the setpoints is given by the value of the Speed Setpoint parameter. This can be

verified from the keypad display.

11. Verify External Current Limit settings, if used. If using a single external clamp, A6 low (0V). Verify ANIN 5 (A6) is +10V or is adjustable up to +10V. If using dual external clamps, A6 high (+24V). Verify ANIN 5 (A6) is at +10V or is adjustable up to +10V and that ANIN 4 (A5) is at +10V.

12. Verify speed feedback device, if possible. a. Analog Tachometer – The voltage at G3 (DC Tach Input) should go positive when shaft is

rotated in the forward direction.

b. Encoder – The ENCODER parameter should give a positive reading when shaft is rotated in the

forward direction. Also check the Speed Feedback parameter is reading a positive value.

13. Set Main Current Limit to 0.00% to limit the motor current.

All LED’s are now flashing. Press “E” when done.

Press  to change to Analog Tach, Encoder or Encoder/Analog. Press “E” when done.

Action Description Display Comments

Press 

Press “M” key Access the Setup Parameters menus

Press 

Press “M” key Access Current Loop parameters

Press “M” key Access Main Current Limit parameter

Press 

Scroll to “Setup Parameters” menu

Scroll to Current Loop

MENU LEVEL DIAGNOSTICS

MENU LEVEL SETUP PARAMETERS

SETUP PARAMETERS CURRENT LOOP

CURRENT LOOP MAIN CUR LIMIT

MAIN CURR LIMIT

90.01%

MAIN CURR LIMIT

0.00%

Change the Main Current Limit to

0.00%. Press “E” when done

5-8 Switch Setting & Start-Up MN792

Power up in Remote Mode with Feedback Continued

14. Set the Configure Dive::Configure Enable parameter to disable (see step 9).

15. Save the settings.

Action Description Display Comments

Start at Menu Level 1

Press 

Scroll to “PARAMETER SAVE” menu.

Press “M” key

Press  Press  to save parameters.

Press “E” key Exit one level

16. With +24V present at terminals B8 and B9 (Program Stop and Coast Stop), do the following: a. Apply the “Start/Run” command to C3. The main 3–phase contactor should pull–in and remain

energized, (it may de–energize almost immediately due to the 3–phase fail alarm).

b. Remove the “Start/Run” command from C3. The main 3–phase contactor should drop–out and

remain de–energized.

If the above sequence does not function, remove the Logic power and check start/stop sequencing and contactor wiring.

If the contactor remains energized for an extended time during this check, the controller will detect that 3–phase is not connected and switch off the contactor, and the 3–phase alarm is displayed.

The main contactor should never be operated by any means other than the drive internal controls, nor should any additional circuitry be placed around the contactor coil circuit.

MENU LEVEL DIAGNOSTICS

MENU LEVEL PARAMETER SAVE

PARAMETER SAVE UP TO ACTION

PARAMETER SAVE REQUESTED

MENU LEVEL PARAMETER SAVE

Parameters are saved. Except the “Local Setpoint”.

Press “E” several times to return to the top level.

Do not continue unless the Start / Stop circuits are working correctly. If any problems were found during step 16, correct them or contact Baldor before continuing.

17. Apply 3 phase power.

18. Verify that the keypad and LED displays are still normal with no error messages.

19. Set the Speed Setpoint parameter to zero.

20. Verify that the Main CURR. Limit is set to 0.00%. View ANIN 5 (A6) parameter in the level 1 Diagnostics menu and verify it displays 0.00V.

21. Apply the Start/Run command and check that 3–phase mains is applied to Power Terminals L1, L2 and L3. Initiate “Enable” (C4) and immediately check that the correct field voltage appears between the control supply terminals F+ and F–. If the field voltage is not correct, check one of the following:

Internally Supplied Field:

c. Check that 3–phase is applied to terminals L1, L2 and L3 when the main contactor is closed. d. Check that the fuses on the power board or supression board are healthy. e. Verify the Field Enable parameter is set to Enable. f. Is the FLD CTRL Mode parameter set to Voltage Control or Current Control?

less than the rated value due to a cold field.) Externally Supplied Field: (not available for size 1) a. Refer to Chapter 4 Installation, Motor Field Connections for conversion details. b. Check the voltage applied (externally fused) to terminals FL1 and FL2. c. Check the phasing of voltage applied to FL1 and FL2:

FL1 must be connected directly or indirectly to the Red phase on main power terminal L1.

FL2 must be connected directly or indirectly to the Yellow phase on main power terminal L2. d. Verify the Field Enable parameter is set to Enable.

Switch Setting & Start-Up 5-9MN792

e. Is the FLD CTRL Mode parameter set to Voltage Control or Current Control?

If set to Voltage Control, check the value of the FLD. Volts Ratio parameter. Set this to 65% to obtain 300V fields from 460V lines. If set to Current Control, check the field current calibration set–up, refer to “Calibration”.

22. Verify that the OK and STOP LEDs are On, also either the FWD or REV LED. Note that all external interlocks that affect the Enable input C4 will affect the operation of the drive. Verify their connections and operation.

23. If the Setup Parameters::Standstill::Standstill Logic parameter is Enabled, temporarily set it to Disabled.

Be ready to stop the control should the motor try to over speed.

24. Set the Speed Setpoints so that the value of the Speed Setpoint is 5%, 0.5V at setpoint input.

25. Set Configure Dive::Configure Enable parameter to Enable.

26. Set the SPEED FBK SELECT parameter to ARM VOLTS FBK (because it is hard–wired and therefore the sign will be correct).

27. Slowly increase the MAIN CURR.LIMIT parameter to a maximum of 20%. The motor should begin to rotate if all connections are made correctly. The motor speed will settle at 5% of full speed if the motor is unloaded. Check the feedback from the Tach or Encoder using the appropriate Diagnostic menu. If the motor does not rotate, check the Current Feedback parameter to verify that current is flowing into the armature. If no current is flowing, disconnect all power and check the armature connections.

28. Stop the drive. Restore the correct Speed FBK Select parameter (if other than ARM Volts FBK) and perform the same test again.

29. If the test was successful perform a Parameter Save and continue with step 31. If just direction of rotation is wrong, perform a or b “Reversed Connections”.

a. Reversed Connections – Analog Tachometer:

Open the main contactor and switch off all supplies, then correct the connections.

 If the motor rotates in the correct direction, reverse the tachometer connections only.  If the motor rotates in the wrong direction, reverse the field connections only.

If the motor still runs out of control, check the tachometer and the wiring continuity.

b. Reversed Connections – Encoder

Open the main contactor.  If the motor rotates in the correct direction, change the Configure Drive::Encoder Sign

parameter.  If the motor rotates in the wrong direction, disconnect all power to the Control then reverse the

field connections only. c. Apply power (logic power then 3 phase power) and repeat step 29. d. If the drive trips on speed feedback alarm with tachometer feedback of the correct polarity,

check the armature voltage calibration. Check the SPEED FBK SELECT. This could be set

incorrectly allowing the drive to run open loop.

30. If 5% speed is exceeded and the motor continues to accelerate a reversed connection is implied, decrease the MAIN CURR.LIMIT parameter to zero.

Do not continue unless the control and motor are working correctly. If any problems were found during these steps, correct them or contact Baldor before continuing.

5-10 Switch Setting & Start-Up MN792

Power up in Remote Mode with Feedback Continued

Note: Reverse Operation is possible with the Series 30 REGEN Drives only.

31. With the MAIN CURR.LIMIT parameter set to 20% or the level required to achieve rotation, set the value of the Speed Setpoint to 10%, 1.0V at setpoint input. The motor will accelerate to this speed setting.

32. Adjust the Zero Speed parameter (Ensure Standstill is Disabled). a. Non–REGEN, non–reversing applications – Set the Speed Setpoint potentiometer to zero and

adjust the Zero Speed Offset parameter until the shaft is just rotating then reduce level until the shaft stops.

b. REGEN, non–reversing applications – Set the Speed Setpoint potentiometer to zero and adjust

the Zero Speed Offset parameter for minimum shaft rotation. (Series 30 REGEN Drives only).

c. REGEN, reversing applications – Set the Zero Speed Offset parameter to balance maximum

speed in forward and reverse directions. (Series 30 REGEN Drives only).

You can set the Standstill Logic parameter to Enable if a stationary shaft is required.

33. For reversing applications set the value of the Speed Setpoint to –10% and check that motor runs in the reverse direction.

34. Gradually increase the Speed Setpoints so that the value of the Speed Setpoint (Diagnostic menu) is at maximum. Verify that shaft speed is correct. If fine adjustment is required, adjust the calibration as appropriate to the speed feedback selection:

a. Armature Voltage feedback has a +2/–10% trim, greater changes outside this range require a

change of the calibration switches.

b. Analog tachometer has a +2/–10% trim, greater changes outside this range require a change of

the calibration switches.

c. An Encoder should give an absolute rotational speed for which adjustment is unnecessary .

Adjustment for Field Weakening.

If the drive is to run with a top speed greater than the base speed, “field weakening” is used to achieve the top speed. The field must be operating in Current Control mode. Select Current Control in the Configure Drive::FLD CTRL Mode parameter.

Note: Field weakening cannot be used if you have Armature Voltage feedback selected. Adjust the maximum

armature volts to the required scaled level by setting the MAX VOLTS parameter.

1. Operate the control at base speed and verify the motor volts are correct.

2. In the Level 4 FLD WEAK VARS menu, verify that field weakening is selected (FIELD WEAK ENABLE) and that the MIN FLD CURRENT parameter is set appropriately.

3. Increase the speed above the base speed. Verify that the armature volts remain constant while the field current reduces.

4. Gradually increase to maximum speed. Monitor the armature volts at maximum speed. If necessary, trim the speed feedback as previously detailed in Step 34 a, b or c.

5. Adjust the MIN FLD CURRENT parameter to the appropriate setting to limit maximum motor speed. PROCEED WITH CARE – Make Small Adjustments.

6. IR COMPENSATION (CALIBRATION function block) is also used in field weakening applications to improve dynamic response and speed holding stability. Set the IR Compensation as follows

a. Set Field Enable to Disabled (Field Control function block). b. Start the drive with a 5% speed command and ensure the ACTUAL POS I LIMIT is 100%

(diagnostic). This should stall the drive at zero speed and cause it to pass 100% current.

c. Monitor the BACK EMF diagnostic parameter and note the value (typically anything up to 17%

is normal).

d. Stop the drive and enter this value into IR Compensation parameter and repeat the test to

ensure that Back EMF is now zero.

e. Set Field Enable parameter to Enabled.

7. For reversing drives, check the maximum reverse speed. Imbalance in reversing applications can only be corrected by adjusting the ZERO SPD OFFSET parameter, which may be to the detriment of operation at Zero Setpoint.

Switch Setting & Start-Up 5-11MN792

Power up in Remote Mode with Feedback Continued

8. Reset the MAIN CURR. LIMIT to 100% to correspond to 100% full load current (FLC).

Note: The controller cannot achieve 200% current unless the CUR LIMIT/SCALER parameter is increased to

200% (from its factory setting of 100%). Until this is done, the External Current Clamp will limit the current to 100%.

a. If the current limit is set higher (maximum 200%) and the motor runs into an overload condition,

the current is automatically reduced from the current limit level down to 103% FLC (continual rating).

b. If the motor is overloaded, the controller will reduce the current to 103% of the current

calibration. (If the motor continues to rotate it may overheat and thermal protection should be provided).

c. If the motor is overloaded and the current provided by the controller is not enough to maintain

rotation, i.e. it stalls, the controller will trip out showing Stall Trip alarm, if enabled.

Autotune Performance adjustment of the following Current Loop parameters: PROP. Gain, INT. Gain, and Discontinuous.

Initial Conditions

1. Main contactor open, i.e. no Start/Run signal at terminal C3.

2. Set the AUTOTUNE parameter to OFF.

3. Program Stop (terminal B8) and Coast Stop (terminal B9) should be high, i.e. 24V.

4. If the motor field is supplied by an external supply, remove the field manually. (If the field is internally regulated, Autotune automatically quenches the field).

Note: The shaft may require clamping for certain motors to prevent rotation >20% during the Autotune

sequence. If using a permanent magnet motor, the shaft MUST be clamped.

5. Set the AUTOTUNE parameter to ON.

6. Close the main contactor, i.e. Start/Run signal to terminal C3.

7. Enable the control, terminal (C4).

8. The Autotune sequence is initiated. When complete (after approximately 10 seconds), the main contactor is opened automatically signalling the end of the sequence and the AUTOTUNE parameter is reset to OFF.

9. Save parameter settings.

10. If necessary, restore field connections and/or remove the mechanical clamp.

If autotune failed – Refer to the Manual Tuning appendix of this manual.

1. The keypad displays the message AUTOTUNE ABORTED. The Autotune sequence is aborted causing the main contactor to drop out if any of the Initial Conditions are not present, or if the Autotune sequence times out (after 2 minutes).

2. The Operator Station displays the message AUTOTUNE ERROR. The Autotune sequence is suspended causing the main contactor to drop out if the motor speed feedback is greater than 20% of rated speed, or the field current exceeds 6% of rated field current.

5-12 Switch Setting & Start-Up MN792

Speed Loop Adjustment You will need to adjust the Speed Loop for your application although in most cases the factory

settings are acceptable. The optimum Speed Loop performance is achieved by adjusting the PROP. Gain and INT. Time CONST. parameters.

1. Produce a small step–change to the speed setpoint and observe the response on the tachometer feedback or analog output set to speed feedback.

2. Adjust PROP. Gain and INT. Time CONST. parameters until you have rapid change of speed feedback between the setpoint values with minimum overshoot.

Incorrect Speed Response

Correct Response

Speed

Underdamped response causing overshoot or ringing

Starting and Stopping Methods

A Series 29 “non–regenerative” (2–quadrant) control coasts to a stop when the current demand reverses. A Series 30 “regenerative” (4–quadrant) control can stop faster because it uses energy from the load, i.e. reverse current is allowed to flow. The normal Stop and Program Stop are only relevant for a “regenerative” controller.

The parameters Stop Time and PROG Stop Time have associated timers which initiate a Coast Stop after the timed period. The Coast Stop has direct control of the Run relay with no intervening electronics. All associated parameters can be found in the Setup Parameters::Stop Rates menu.

Terminal

B8 Program Stop Motor decelerates at B9 Coast Stop Motor coasts to rest Overrides Program Stop C3 Start/Run

Description Function Parameter Priority

(Normal Stop)

Time

Speed

Overdamped response

Program Stop rate

Motor decelerates at Normal Stop rate

Speed

Time

Critically damped response with no more than 4% of max speed from 1st overshoot to first undersoot.

Time

PROG STOP TIME Overrides Normal Stop

and Normal Stop

STOP TIME

Switch Setting & Start-Up 5-13MN792

Starting and Stopping Methods Continued

Normal Stop

Action – Remove 24V from Terminal C3 to stop. The motor speed is brought to zero in a time defined by the Stop Time parameter.

Control Signals

Speed Demand

Speed Setpoint (100%)

Start/Run (C3)

Speed Demand

Normal Stop

100% = Speed Setpoint

Actual Speed

Enable

Control Signals

Speed Demand

Speed Feedback

Drive Enable = Enabled (Display Diagnostic)

Speed Setpoint

Start/Run (C3)

Speed Demand

Stop Time (10 Seconds)

=Speed Setpoint

Stop Zero Speed (2%)

Time Out in Normal Stop

Speed Setpoint

Actual stopping rate depends on load inertia, motor hp, and overload capability of the drive.

Drive is disabled below stop zero speed if set > 0.25%

Drive remains enabled for contactor delay if stop zero speed < 0.25%

Drive Enable = Disabled

Actual Speed

=Speed Setpoint

Stop Zero Speed (2%)

Stop Limit (60.0 Seconds)

Contactor will not drop out if Speed Feedback > Stop Zero Speed when stop limit timed out

5-14 Switch Setting & Start-Up MN792

Starting and Stopping Methods Continued

Program Stop (terminal B8)

Action – Remove 24V from Terminal B8 to stop. The motor speed is brought to zero by conditions defined in PROG. Stop Time (ramp rate) and PROG. Stop I Limit parameters.

Control Signals

Speed Demand

Actual Speed

Control Signals

Speed Demand

Speed Setpoint (100%)

Program Stop

Speed Demand

Speed Feedback

Speed Setpoint

Program Stop

Speed Demand

LED On (Program Stop False)

LED

(Program Stop is a latched funtion)

Off

Prog Stop Time (0.1 Seconds)

=Speed Setpoint

Stop Zero Speed (2%)

LED On (Program Stop False) LED Off

Program Stop Timing

100% = Speed Setpoint

Current Limit set by PROG Stop I Limit (100%)

Actual stopping rate depends on load inertia, motor hp, and overload capability of the drive.

Drive is disabled and contactor turns off below Stop Zero Speed

Time Out in Program Stop

Speed Setpoint

Actual Speed

Enable

Speed Feedback

Drive Run LED and Start Contactor Drive Enable = Enabled

Stop Zero Speed (2%)

Prog Stop Limit (60.0 Seconds)

Speed Setpoint

Contactor will not drop out if Speed Feedback > Stop Zero Speed when stop limit timed out

Drive Run LED and Start Contactor Drive Enable = Disabled

Switch Setting & Start-Up 5-15MN792

Starting and Stopping Methods Continued

Coast to Stop (terminal B9)

Action – Remove 24V from Terminal B8 to stop. The motor speed is brought to zero by conditions defined in the PROG. Stop Time (ramp rate) and PROG. Stop I Limit parameters.

The control output is automatically quenched and the contactor is opened. The motor coasts to a stop. The motor coast stop rate is dictated by the motor and load inertia – the drive does not control the motion.

Standstill

Standstill logic inhibits rotation during Zero Speed demand. threshold [12] and Standstill Logic [11] is enabled, the speed and current loops are disabled to prevent shaft oscillation around zero speed.

Trip Condition

When a trip condition is detected, the motor coasts to a stop. The motor coast stop rate is dictated by the motor and load inertia. The control cannot be enabled until the trip condition has been cleared and successfully reset.

Normal Starting Method

To achieve a normal start, two actions must occur:

1. Apply 24V to Terminal C4 (Enable).

2. Apply 24V to Terminal C3 (Start). The Control will not start if there are alarms present, or if Terminals B8 (Program Stop) or B9 (Coast Stop) are

low, 0V. Ensure that Program Stop and Coast Stop are valid before Start/Run is applied.

Advanced Starting Methods Jog

1. Apply 24V to Terminal C4 (Enable).

2. Apply 24V to Terminal C6 (Jog Mode) The Control will not start if there are alarms present. The control can be started using JOG SPEED 1, JOG

SPEED 2. Also refer to the STOP RATES function block: CONTACTOR DELAY parameter is used to prevent multiple operations of the main contactor from rapid use of the Jog switch. Refer to Section 6 JOG/SLACK for more information.

If the drive speed is less than the zero speed

Crawl

1. Apply 24V to Terminal C3 (Start).

2. Apply 24V to Terminal C6 (Jog Mode) The Control will not start if there are alarms present. Start the control using a crawl speed, in Forward. Refer to

Section 6 JOG/SLACK for more information.

5-16 Switch Setting & Start-Up MN792

Upload/Download Procedure (UDP)

Upload

This procedure will transfer the parameters from a file at the host computer to the non–volatile memory of the Control. This information is written directly to EEPROM, so all the drive’s settings are overwritten. The procedure is as follows:

1. Verify the Control is properly connected to the PC.

2. Use a standard communications software package installed at the PC. Set the COM port for 9600, 8, 1, None. Prepare the PC communications software to send a standard ASCII text file.

3. Set the Serial Links::System Port (P3)::P3 Setup::Mode parameter to DISABLE.

4. Start the upload. Use the keypad and select Serial Links::System Port (P3)::UDP XFER (RX) and press the UP () key, when instructed to start the upload.

5. When the keypad display shows RECEIVING, begin the file transfer.

6. The file ends in a :00000001FF which the Control uses to close the file.

7. As indicated, reset the Control by pressing the E key.

1 SERIAL LINKS

2 SYSTEM PORT P3

DUMP MMI (TX) UDP XFER (RX) UDP XFER (TX)

Download

This procedure will transfer the parameters from the Control to a file at the host computer. The procedure is as follows:

1. Verify the Control is properly connected to the PC.

2. Use a standard communications software package installed at the PC. Set the COM port for 9600, 8, 1, None. Prepare the software to receive a standard ASCII text file (Capture mode); use the file extension .UDP to differentiate it from .MMI format files.

3. Perform a PARAMETER SAVE of the Control’s settings. This ensures the Dump matches the Control’s settings, (the listing is of the Control’s currently saved settings, i.e. held in EEPROM).

4. Set the Serial Links::System Port (P3)::P3 Setup::Mode parameter to DISABLE.

5. Start the download at the Control by selecting Serial Links::System Port (P3)::UDP XFER ((TX) on the keypad and pressing the UP () key, when instructed.

6. The file ends in a Ctrl–z. With some software packages this automatically closes the downloaded file. If this is not the case, when the Control indicates it has finished and the host has stopped scrolling text, close the file at your PC. The last line should read :00000001FF

7. The ASCII file can now be stored like any other file on your disk drive.

Switch Setting & Start-Up 5-17MN792

DUMP ProcedureThis procedure will transfer the control’s settings in a text format that is clear and easy to read.

1. Verify the Control is properly connected to the PC.

2. Use a standard communications software package installed at the PC. Set the COM port for 9600, 8, 1, None. Prepare the PC communications software to receive a standard ASCII text file (Capture mode); use the file extension .UDP to differentiate it from .MMI format files.

3. Perform a PARAMETER SAVE of the Control’s settings. This ensures the Dump matches the Control’s settings, (the listing is of the saved settings held in EEPROM).

4. Set the Serial Links::System Port (P3)::P3 Setup::Mode parameter to DISABLE.

5. Start downloading on the Control by selecting Serial Links::System Port (P3)::Dump MMI (TX) on the keypad and pressing the UP () key, when instructed.

6. The file ends in a Ctrl–z. With some packages this automatically closes the file but if this is not the case, when the Control says it has finished and the host has stopped scrolling text, close the file.

7. The ASCII file can now be stored like any other file on your disk drive.

The following partial file was produced by performing a MMI DUMP (TX) to a PC, as described above. The file shows the Control default settings.

When printing this file, it is useful to select a Mono spaced font, such as Courier, so the text columns line–up. Note that in the list shown, ‘menus’ have been highlighted (bold) to make the list easier to use.

DIGITAL DC DRIVE ISSUE:X.X ..MENU LEVEL

....DIAGNOSTICS

......SPEED DEMAND [89 ] = 0.00 %

......SPEED FEEDBACK [207 ] = 0.00 %

......SPEED ERROR [297 ] = 0.00 %

......CURRENT DEMAND [299 ] = 0.00 %

......CURRENT FEEDBACK [298 ] = 0.00 %

......POS. I CLAMP [87 ] = 0.0 %

......NEG. I CLAMP [88 ] = 0.0 %

......ACTUAL POS I LIM [67 ] = 0.0 %

......ACTUAL NEG I LIM [61 ] = 0.0 %

......INVERSE TIME O/P [203 ] = 200.00 %

......AT CURRENT LIMIT [42 ] = FALSE

......AT ZERO SPEED [77 ] = TRUE

......AT ZERO SETPOINT [78 ] = TRUE

......AT STANDSTILL [79 ] = TRUE

......STALL TRIP [112 ] = OK

......RAMPING [113 ] = FALSE

......PROGRAM STOP [80 ] = TRUE

......DRIVE START [82 ] = OFF

......DRIVE ENABLE [84 ] = DISABLED

......OPERATING MODE [212 ] = STOP

......FIELD ENABLE [169 ] = DISABLED

......FIELD DEMAND [183 ] = 0.00 %

Example only

5-18 Switch Setting & Start-Up MN792

Section 6 Programming

Overview The shipping configuration allows the user to start up and run a DC motor in simple speed control. The flexibility

is having the ability to change configuration and to tune the control for optimum performance. The parameters most frequently adjusted for tuning and performance are in the Setup Parameters menu. They are categorized by submenus within the overall software block diagram.

This chapter describes each of these parameters. You can set the parameter values within the Setup Parameters submenu (keypad) or by using a Workbench D

(see Manual MN794). You can also configure the drive or connect and reconnect signals between drive function blocks and I/O terminals from the keypad or Workbench D. Parameters in this section are in the order of the keypad submenu.

The drive’s parameters and function block inputs and outputs are defined as either a percentage if they are continuous, or as boolean value (1 or 0) if they are discrete. Depending on how the drive is configured, these parameters can represent physical entities such as motor speed or current. Connecting inputs or outputs to software function blocks or to real world signals defines what the function block inputs or outputs represent. For example, the output (Destination Tag) from Raise/Lower can represent current demand if sent to the current loop or a speed setpoint if sent to the speed loop.

Menu System The menu system is divided into nine major selections, shown in Table 6-1. Each selection has a structure of

menus (Figure 6-1). At the keypad, press “M” to access the menus. Then press the  or  key to scroll through the menus. Refer to section 7 for more information on the keypad and menus.

Table 6-1 Keypad Display of the Main Menus

Action Description Display Comments

Apply Power Keypad Display shows this opening

message.

Press “PROG” key

FORWARD REF: 0.00%

BALDOR DC DRIVE DC 4Q 15A

Press “M”

Press “M” Access the menus.

Press 

Scroll to next menu.

DC 4Q 15A MENU LEVEL

MENU LEVEL DIAGNOSTICS

MENU LEVEL SETUP PARAMETERS

MENU LEVEL PASSWORD

MENU LEVEL ALARM STATUS

MENU LEVEL MENUS

MENU LEVEL PARAMETER SAVE

MENU LEVEL SERIAL LINKS

MENU LEVEL SYSTEM

MENU LEVEL CONFIGURE DRIVE

Press “M” key to access Diagnostic menus.

Press “M” key to access Setup Parameters menus.

Press “M” key to access Password menus.

Press “M” key to access Alarm Status menus.

Press “M” key to access Menus.

Press “M” key to access Serial Links menus.

Press “M” key to access System menus.

Press “M” key to access Configure Drive menus.

Menu Navigation

Remember, press “E” to return to the previous level of menus. Press “M” to enter the next level of menus. Press the  or  key to go to the previous or next menu item at the same level.

Programming 6-1MN792

Parameter Types

Each drive parameter is associated with a unique address, or “tag.” When “connecting” any parameter to drive inputs, outputs, or links, this tag is designated as the source or destination address. These drive parameters are listed by tag number, parameter name and menu group name in the appendix of this manual. There are only two types of parameters: logic or value.

Logic

Logic parameters are boolean – or either On (1) or Off (0). The keypad displays logic signals in a variety ways, each associated with the On and Off state like Enabled/ Disabled, True/False, Positive/Negative, or Even/Odd.

Value

Value parameters have a range of values depending on its function. The display is formatted appropriately (for example in percent). In all cases these values will not exceed five digits. For example, 100.00% is handled by the controller as 10000 and 30.00 as 3000. Other value parameters can be HEX numbers, ordinals, and lists. The ranges of these values depend on the parameter type.

Configuration Procedure

Before making any configuration changes with the keypad, you must set Configure Enable to Enabled. After completing the changes, set Configure Enable to Disabled to accept the changes then select “Parameter Save” to save to memory the changes you have made.

Note: Configuration changes are not allowed while running and will trip out on the alarm failure Configuration Make configuration changes from the keypad as follows:

1. Set parameter System::Configure I/O::Configure Enable to Enabled.

2. Find the input or output you want to change.

3. Change the source and/or destination tag as required.

4. Set the or analog or digital I/O parameter calibrations as needed.

5. Set parameter Configure Enable to Disabled.

6. Save Parameters.

Enabled if the drive is started while Configure Enable is Enabled.

6-2 Programming MN792

1234

Diagnostics

Setup Parameters

Password

Alarm Status

Menus

Ramps AUX I/O OP Station Jog / Slack Raise / Lower Special Blocks

Field Control

Stop Rates Calibration

Inhibit Alarms Current Loop

Speed Loop Standstill

Setpoint Sum 1

Figure 6-1

Setup Local Ramp Startup Values

PID

FLD Voltage VARS FLS Current VARSCurrent Profile

Advanced Setpoints

Menu Levels

FLD Weak VARS

Adaption Zero SPD Quench

Serial Links

System

Parameter Save

Configure Drive

Full & Reduced Views

Full View Only

TEC Option System Port (P3)

Software Configure I/O Peek

5703 Support Bisynch SupportP3 Setup

ANIN1 (A2) Configure Enable Analog Inputs

Analog Outputs ANOUT1 (A7)

Digital Inputs Digital Input (C4)

Digital Outputs DIGOUT1 (B5)

Block Diagram Internal Links Link 1

ANIN2 (A3)

ANIN3 (A4)

ANIN4 (A5)

ANIN5 (A6)

ANOUT2 (A8)

Digital Input (C5)

DIGIN1 (C6)

DIGIN2 (C7)

DIGIN3 (C8)

DIGOUT2 (B6)Configure 5703

DIGOUT3 (B7)

Link 10

ANOUT3 (A9) Armature Current is not displayed in menu

Programming 6-3MN792

Parameter Descriptions

Analog Inputs Five analog input blocks are used to scale and clamp the inputs for terminals A2 through A6.

1 SYSTEM

2 CONFIGURE I/O

3 ANALOG INPUTS

4 ANIN 1 (A2)

4 ANIN 2 (A3)

4 ANIN 3 (A4)

4 ANIN 4 (A5)

4 ANIN 5 (A6)

* ANIN 2 (A3) Notes:

1. ANIN 2 output [493] has two permanent connections: a. SETUP PARAMETERS:: SPEED LOOP::

SETPOINTS:: RATIO 2 (A3) input and

b. SETUP PARAMETER:: CURRENT LOOP:: I DMD.

ISOLATE switch.

If you do not want ANIN 2 output [493] to be in the Speed or Current Loops, set RATIO 2 (A3) [7] to zero, and set I DMD. ISOLATE [119] to DISABLED.

2. ANIN 2 (A3) is a direct input into the speed loop/current loop and is scanned synchronously with the current loop (typically every 3.33ms rather than every 7ms). Therefore ANIN 2 should be used for any signal whose response is critical.

3. Other tags can be connected to ANIN 2 output [493] for access to the calibrated final value of ANIN 2.

Diagnostic connection (tag accessible from the Diagnostic Menu) allows monitoring of the raw analog input signals from. within the Diagnostics parameter block.

Analog input 1 is the 0–20mA or 4–20mA input. Analog input 2 is the main speed loop input (without Accel/Decel ramps). Analog input 3 is Speed setpoint no. 3. Analog input 4 is the negative current clamp; this is only active if bipolar clamps are enabled; ANIN 5 – Main current limit (or positive current clamp if bipolar clamps are enabled. ANIN 4 is then the Negative current clamp input).

Analog Input 1 – ANIN 1 (A2)

Tag Parameter Factory Setting

[231] Max Value +100.00% [230] Calibration 1.0000

[232] Min Value [246] Destination Tag 100

Analog Input 2 – ANIN 2 (A3)

Tag Parameter Factory Setting

[234] Max Value [233] Calibration 1.0000

[235] Min Value

Analog Input 3 – ANIN 3 (A4)

Tag Parameter

[237] Max Value [236] Calibration 1.0000

[238] Min Value [249] Destination Tag 5

Analog Input 4 – ANIN 4 (A5)

Tag Parameter

[240] Max Value +100.00% [239] Calibration 1.0000

[241] Min Value -100.00% [250] Destination Tag 48

Analog Input 5 – ANIN 5 (A6)

Tag Parameter

[243] Max Value +100.00% [242] Calibration 1.0000

[244] Min Value -100.00% [247] Destination Tag 301

-100.00%

+100.00%

-100.00%

Factory Setting

+100.00%

-100.00%

Factory Setting

Calibration MAX Value MIN Value Destination Tag *

Analog Input 1

500

Analog Input 2

Analog Input 3

Analog Input 4

Analog Input 5

[246]

[493]

[249]

[250]

[247]

Factory Setting

Setpoint Sum 1

[100] Input 1

Diagnostic

[50]

connection

Fixed Outputs *

Speed Loop

[290] Setpoint 2 (A3)

Current Loop

[119] I DMD Isolate

Diagnostic

[51]

connection

Setpoint Sum 1

[309] Input 0

Diagnostic

[52]

connection

Current Loop

[48] Neg I Clamp

Diagnostic

[53]

connection

Current Loop

[301] POS I Clamp

Diagnostic

[54]

connection

Keypad Menu: System::Configure I/O::Analog Inputs::Block Title Block Title Parameter

ANIN1 (A2)

Calibration CALIBRATION ANIN2 (A3) ANIN3 (A4) ANIN4 (A5)

MAX Value ANIN5 (A6)

MIN Value

Description

The analog input scaling ratio (gain factor).

MAX VALUE

The maximum value of the scaled analog input (max voltage clamp).

MIN VALUE

The minimum value of the scaled analog input (min voltage clamp).

Destination Tag DESTINATION TAG [Output], (except ANIN 2)

The destination Tag No. to which the scaled analog input value is connected. The destination of Output [493] ANIN2 is fixed. It is a calibrated scaled value.

6-4 Programming MN792

Analog Inputs Continued

Input Description

Analog input 1 Terminal (A2)

Used as a unipolar 0–20mA ramped speed command channel. Output [246] is connected to Setpoint Sum 1, Input 1. To use 4–20mA requires setting the Min value to 25%, the Max Value to 125% and the Setpoint Sum1, Input 2 to (–)25%. These settings provide the proper scaling and offset to set 4mA to zero command. An input value less than 4mA results in a Min Value of 25% being summed with the (–)25% at the Setpoint Sum 1 summing junction. Output of Setpoint Sum 1 block is connected to the ramp input [5] of the Ramps block. Ramp invert [620] is controlled by C5, the reverse input. When C5 is closed, the ramp is inverted and the rotation direction is changed. This allows an Accel and Decel Rate limited command signal in either direction. Output of Ramps block is connected to Setpoint 1 of the Speed Loop block.

Analog input 2 Terminal (A3)

No Accel / Decel Ramp is provided for this input. Used as a non–ramped speed or torque command channel. Output [493] is connected to Speed Loop Setpoint 2 and Current Loop Input. Closing terminal C8 (Digital Input 3) selects Torque Command Mode (enables IDMD Isolate input of the Current Loop). Opening terminal C8 (Digital Input 3) selects Speed Command Mode by (disables the IDMD Isolate input of the Current Loop). In all cases this analog command channel bypasses the Ramps Block.

Analog input 3 Terminal (A4)

Used as a ramped ±10V speed command channel. Output [249] is connected to Setpoint Sum 1, Input 0. Output of Setpoint Sum 1 block is connected to the ramp input [5] of the Ramps block. Ramp invert [620] is controlled by C5, the reverse input. When C5 is closed, the ramp is inverted and the rotation direction is changed. This allows an Accel and Decel Rate limited command signal in either direction. Output of Ramps block is connected to Setpoint 1 of the Speed Loop block. Various voltage range, and bipolar or unipolar commands can be accepted by adjusting Calibration, Max Value , and Min Value parameters of Analog Input 3.

Analog input 4 Terminal (A5)

Analog input 5 Terminal (A6)

Not active if Bipolar Clamps parameter [90] is false. Used as an External Reverse (Negative) Current Limit if Bipolar Clamps parameter [90] is true.

Used as an External (Forward and Reverse) Current Limit. A hardwire jumper is supplied from terminal B3 (+10V Ref) to A5 to allow full rated 150% current. Used as an External Forward Current Limit if Bipolar Clamps parameter is set to Enabled.

When [90]=False, Analog IN 5 provides a bipolar current limit. When [90]=True, Analog IN 5 is the positive current limit (Analog IN 4 is the negative current limit).

Analog Inputs – Inputs can be connected to any writable parameter. The read/write status of each parameter is listed in

Appendix B. (RO is read only and RW is read/write.)

Example – Using analog input 1 as a 4–20mA input.

The parameter values for Analog Input 1 can be changed at the keypad. The 4–20mA source is connected to A2. Apply AC power to the control and observe the keypad display. The 500 ohm resistor at the A2 input converts a 0–20mA input current to 0 to 10 volt signal. So a 4–20mA input must be scaled so 4mA = 0VDC and 20mA = 10VDC. Analog Input 1 output terminal [246] is connected to Setpoint Sum 1, Input 1. 4–20mA requires the Min value = 25%, Max Value = 125% and setting Setpoint Sum1, Input 2 to (–)25%. These settings provide the proper scaling and offset to set 4mA to zero command. Any input less than 4mA will result in a Min Value of 25% being added to (–)25% at the Setpoint Sum 1 summing junction.

Setup Parameters::Setpoint Sum 1::

Analog Input 1

500

Analog Input 1 – ANIN 1 (A2)

Tag Parameter Setting

[231] Max Value 125.00% [230] Calibration 1.0000

[232] Min Value [246] Destination Tag 100

25.00%

Tag Parameter [292] Sign 0 Positive [208] Ratio 0 1.0000 [309] Input 0 0.00% [420] Divider 0 1.0000 [423] Input 2 -25.00% [6] Ratio 1 1.0000

[246]

[100] Input 1 0.00%

[131] Deadband Width [419] Divider 1 [8] Sign 1 Positive [375] Limit [86] Destination Tag 5

Setting

0.0%

1.0000

105.00%

4–20mA Direction Change

Output of Setpoint Sum 1 block is connected to the ramp input [5] of the Ramps block. Ramp invert [620] is controlled by C5, the reverse input. When C5 is closed, the ramp is inverted and the rotation direction is changed. This allows an Accel and Decel Rate limited command signal in either direction. Output of Ramps block is connected to Setpoint 1 of the Speed Loop block.

[86]

Programming 6-5MN792

Analog Outputs

1 SYSTEM

2 CONFIGURE I/O

3 ANALOG OUTPUTS

4 ANOUT 1 (A7)

% TO GET 10V MODULUS OFFSET SOURCE TAG

Speed Loop

Setpoints

Power Board

Arm

Calibration Board

Three Analog Outputs are available, A7, A8 and A9. A7 and A8 can be configured and the source of an analog output signal can be read from any parameter. It is important to remember that other parameters do not “send” signals to the output terminal. An output terminal “retrieves” the signal from the parameter described by

its Source Tag parameter. A9 is the armature current output and cannot be changed.

ANOUT 1 (A7)

Tag Parameter [464] Offset 0.00% [245] % to get to 10V +100.00%

[251] Source Tag[62] Speed Feedback

[362] Modulus

ANOUT 2 (A8)

Tag Parameter [465] Offset 0.00% [248] % to get to 10V

[252] Source Tag[63] Speed Setpoint

[363] Modulus False

ANOUT 3 (A9)

[25] Armature I (A9) Bipolar

Factory Setting

False

Factory Setting

+100.00%

UNI

ABS

[55]

[56]

Analog

Output 1

Diagnostic connection

Analog

Output 2

Diagnostic connection

Analog

Output 3

Arm I Fbk

Description

+10V= Full speed setpoint forward.

-10V = Full speed setpoint reverse.

+10V= Full speed setpoint forward.

-10V = Full speed setpoint reverse.

Bipolar Mode +10V= 200% output current forward.

-10V = 200% output current reverse. Unipolar Mode

+10V= 200% output current.

Parameter Descriptions INPUT

(SOURCE TAG) The source Tag No. of the output value.

% TO GET 10V (10V CAL) This value is based on the range of the source. It can be set positive or negative to set the sign of the output and scale the input to give a 10V output.

OFFSET

Offset value added to the input value after the scaler and before the modulus.

MODULUS

Modulus determines whether the output is bipolar or unipolar. False allows the input to pass through to the output (bipolar). When TRUE, the output is unipolar (will not go negative). Negative input values are made positive (absolute value).

ANOUT 1 & 2 (Read in Diagnostics Parameters) ANOUT 1 (A7)=scaled speed feedback. ANOUT 2 (A8)= Total speed setpoint.

Armature I (A9) (Armature Current only at Analog Output 3) Bipolar provides ±10V signal that represents armature current. Unipolar provides 0 to 10V signal that represents armature current.

Range: 0 to 549

Range: –300.00 to 300.00 %

Range: –100.00 to 100.00 % Range: 0 : False

1 : True

Range: xxx.xx Volts (h) Range: 0 : Bipolar

1 : Uniploar

6-6 Programming MN792

Analog Outputs Continued

Example 1 – Read the field current feedback using Analog Output 1.

The tag number for the field current feedback parameter is 300.

Setup Parameters::Calibration::

Tag Parameter [182] Field I CAL 1.0000

Calibration Board

[25] Armature I (A9)

Field

Power Board

Arm

Example 2 – Connect the serial link to Analog Output 1.

Allows analog output 1 to read values written by an external device to PNO 58 (ASCII 3A) which is AUX I/O Analog Out 1. The tag number for the AUX I/O::ANOUT 1 parameter is 128.

Setup Parameters::AUX I/O::

Tag Parameter Setting [94] AUX Digout 1 [95] AUX Digout 2 [96] AUX Digout 3 [128] AUX Anout 1 [129] AUX Anout 2

1. Set CONFIGURE I/O::CONFIGURE ENABLE to Enable.

2. Set ANALOG OUTPUTS::ANOUT 1 (A7):: SOURCE TAG to 300.

3. Set ANALOG OUTPUTS::ANOUT 1 (A7):: % TO GET 10 VDC to 100% (factory setting).

4. Set SETUP PARAMETERS::CALIBRATION::ARMATURE I (A9) to Bipolar (factory setting).

5. Reset CONFIGURE I/O::CONFIGURE ENABLE to Disable.

ANOUT 1 (A7)

Setting

Bipolar

UNI

[300]

[181]

Tag Parameter [464] Offset 0.00% [245] % to get to 10V

[251] Source Tag 300

[362] Modulus

To Field Control

Analog Output 3

Setting

+100.00%

ABS

False

1. Set CONFIGURE I/O::CONFIGURE ENABLE to Enable.

2. Set ANALOG OUTPUTS::ANOUT 1 (A7):: SOURCE TAG to 128.

3. Set ANALOG OUTPUTS::ANOUT 1 (A7):: % TO GET 10V to 100% (factory setting).

4. Reset CONFIGURE I/O::CONFIGURE ENABLE to Disable.

ANOUT 1 (A7)

OFF OFF OFF

0.00%

Tag Parameter [464] Offset 0.00% [245] % to get to 10V +100.00%

[251] Source Tag 128

[362] Modulus

Setting

ABS

False

Analog Output 1

Example 3 – Connect the current demand to Analog Output 2.

The tag number for the current demand parameter is 66.

1. Set CONFIGURE I/O::CONFIGURE ENABLE to Enable.

2. Set ANALOG OUTPUTS::ANOUT 2 (A8):: SOURCE TAG to 66.

3. Set ANALOG OUTPUTS::ANOUT 2 (A8):: % TO GET 10V to 200%.

4. Reset CONFIGURE I/O::CONFIGURE ENABLE to Disable.

Setting % TO GET 10V at 200% results in 5 volts output when current feedback is at 100%.

ANOUT 2 (A8)

Setup Parameters::Current Loop::

Tag Parameter Setting

[66] Current Demand N/A

Tag Parameter [465] Offset 0.00% [248] % to get to 10V

[252] Source Tag 66

[363] Modulus

Setting

+200.00%

False

ABS

Analog

Output 2

Programming 6-7MN792

AUX I/O The auxiliary I/O parameters allow an external computer (or PLC) to control the Start, Jog and Enable terminals.

Start, Enable and Jog digital input terminals C3, C4, C6 and C7 respectively connect directly to the AUX I/O block. Output signals are then sent to the drive start and drive enable logic and the Jog/Slack function block.

1 SETUP PARAMETERS

2 AUX I/O

AUX Start AUX Jog AUX Enable AUX Digout 1 AUX Digout 2 AUX Digout 3 ANOUT 1 ANOUT 2 Jog/Slack REM. SEQ. Enable REM Sequence SEQ Status Enable

Start

Dig In 1

Parameter Descriptions Start (C3) (Read in Diagnostics Parameters)

Start/Run terminal. ON initiates a start/run forward sequence. Off commands Stop and decels at Stop Rates, Stop Time setting.

Jog (C6 is set in Digital Input Parameters) Jog/Takeup slack terminal. If C6 = On and C7 is Off, motor is commanded to run forward at Jog Speed 1. If C6 is On and C7 is On, motor is commanded to run forward at active speed setpoint plus Jog/Slack, Take Up 1 speed. Various Jog or Slack takeup functions are commanded depending on the various settings of terminals C6, C7 and parameter Jog/Slack, Mode.

SEQ Status

A status word that groups important system flags together for use by remote device over a network. (Refer to “Remote Sequence”).

AUX Start

Software Start/Run command.

AUX Jog

Software Jog command.

AUX Enable

Software Enable command.

AUX DIGOUT 1

Software digital output 1.

AUX DIGOUT 2

Software digital output 2.

AUX DIGOUT 3

Software digital output 3.

ANOUT 1

Software analog output 1.

ANOUT 2

Software analog output 2. REM. Sequence (REM.SEQUENCE)

A control word that allows the device to be operated remotely. REM. SEQ. ENABLE must be True to enable this function. (Refer to “Remote Sequence”).

REM. SEQ. Enable (REM.SEQ.ENABLE) False disables REM.SEQUENCE, On enables REM.SEQUENCE.

[102]

AUX I/O

Tag Parameter

[161] AUX Start ON

[227] AUX Jog ON

[496] Jog/Slack

[535] REM SEQ Enable OFF

[536] REM Sequence OFF

[537] SEQ Status OFF

[94] AUX DIGOUT 1 OFF

[95] AUX DIGOUT 2 OFF [95] [96] AUX DIGOUT 3 OFF

[128] AUX ANOUT 1 0.00% [128]

[129] AUX ANOUT 2 0.00%

Setting

Range: 0 : OFF

Range: 0x0000 to 0xFFFF

Range: 0 : OFF Range: 0 : OFF Range: 0 : OFF Range: 0 : OFF Range: 0 : OFF Range: 0 : OFF Range: –100.00 to 100.00 % Range: –100.00 to 100.00 % Range: 0x0000 to 0xFFFF

Range: 0 : OFF

Start (To Jog/Slack)

Diagnostic

[68]

Connection

Jog (To Jog/Slack)

Diagnostic

[71]

Connection

[94]

[96]

[129]

1 : ON

1 : ON 1 : ON 1 : ON 1 : ON 1 : ON 1 : ON

1 : ON

6-8 Programming MN792

AUX I/O Continued Functional Description

The external device sends its signal directly to the required tag (PNO). In the case of auxiliary digital inputs AUX Start, AUX Jog and AUX Enable, the overall input will be the result of the “AND” gating of the normal terminal signal with the auxiliary signal from an external computer or PLC.

The remaining auxiliary outputs allow external computers to directly control the output terminals. These connections are set in SYSTEM::CONFIGURE I/O.

ANOUT 1 & 2 can also be used as a “jumper” for connecting inputs to outputs. Example: Use ANOUT1 [128] to connect Analog Input 1 (A2) [246] directly to Analog Output 1 (A7) [251].

Analog

Set Analog Input 1 Destination [246] = 128

Input 1

Remote Sequence Tag 536, Mnemonic “ow”, Factory setting = 0x0000

Reserved bits are undefined when read and should be set Zero when written.

Bit Number Mask Name Comment

0 (lsb) 0x0001 Remote Enable 1 0x0002 Remote Start 2 0x0004 Remote Jog 3 0x0008 Remote Jog Mode Selects Jog Speed 4 0x0010 Reserved 5 0x0020 Reserved 6 0x0040 Reserved 7 0x0080 Reserved 8 0x0100 Remote Alarm Ack Alarm Acknowledge 9 0x0200 Remote/Remote Trip Remote Trip (High for OK) 10 0x0400 Reserved 11 0x0800 Reserved 12 0x1000 Reserved 13 0x2000 Reserved 14 0x4000 Reserved 15 0x8000 Reserved

Analog Output 1

Set Analog Output 1 Source [251] = 128

SEQ Status Tag 537, Mnemonic “ox” (Read Only), Factory setting = OFF (Reserved bits are undefined when read.)

Bit Number Mask Name Comment

0 (lsb) 0x0001 Coast Stop Coast Stop demanded 1 0x0002 Program Stop Program (Fast) Stop demanded 2 0x0004 Disable Enable demanded 3 0x0008 Run Drive Start demanded 4 0x0010 Jog Drive Jog demanded 5 0x0020 Reserved Undefined 6 0x0040 Alarm Unacknowledged alarm (Health Store != 0) 7 0x0080 Reserved Undefined 8 0x0100 Running Contactor in and drive ready to be enabled 9 0x0200 Enabled Drive is enabled. 10 0x0400 Zero Speed Zero speed Output TAG 17 11 0x0800 Healthy Output Healthy Output TAG 12 12 0x1000 Ready Ready Output TAG 559 13 0x2000 Reserved Undefined 14 0x4000 Reserved Undefined 15 0x8000 Reserved Undefined

Programming 6-9MN792

AUX I/O Continued Example Bit Patterns

Sequence Status

0001 1011 0000 1011 Running 0000 0100 0100 1011 Tripped, Run High 0000 0100 0100 0111 Tripped, Run Low, Enable Low 0000 1100 0100 0111 Trip Acknowledged, Healthy o/p TRUE Alarm stays high until drive is restarted.

Example Serial commands using EI–ASCII – REM. SEQUENCE

Tag 536, Mnemonic “ow”, Factory setting = 0x0C07

Remote Trip

Start Drive 1 0 X 0 1 1 ow>0203 Stop Drive 1 0 X 0 0 1 ow>0201 Disable Drive 1 0 X X X 0 ow>0200 Jog Setpoint 1 1 0 0 1 0 1 ow>0205 Jog Setpoint 2 1 0 1 1 0 1 ow>020C Remote Trip 0 0 X X X X ow>0000 Reset Alarm a) 1 1 0 0 0 0 ow>0300 Reset Alarm b) Healthy Output Bit 11 Reset Alarm c) 1 0 50 0 0 0 ow>0200

Comment

Alarm Ack

Jog Mode

Jog Start Enable Command

Drive Enable To Enable the drive in remote mode the following parameters must be Drive Start To Start the drive in remote mode the following parameters must be Drive Jog To Jog the drive in remote mode the following parameters must be Jog Mode To select the jog setpoint in remote mode the following parameters must be TRUE:REM.SEQ.ENABLE[535] and ACK Alarm To Acknowledge an alarm the following parameter must be TRUE:REM SEQUENCE [536] BIT 8.

Remote Trip Alarm The Remote trip alarm is designed to signal a network fault to the drive. When using the Profibus interface,

REM TRIP INHIBIT [540]

Disable remote trip. Delay before trip becomes active after bit

TRUE: REM.SEQ.ENABLE[535] and REM SEQUENCE [536] BIT 1. TRUE: REM.SEQ.ENABLE[535] and REM SEQUENCE [536] BIT 0. TRUE: REM.SEQ.ENABLE[535] and REM SEQUENCE [536] BIT 3. REM SEQUENCE [536] BIT 4.

Note: If remote sequencing is not enabled then REM SEQUENCE [536] BIT 8 is forced TRUE. all outputs are set to zero on link fail. If one of the outputs is REM SEQUENCE [536 ] the drive will trip after a

delay specified by REM TRIP DELAY (541). The Drive will then need a low – > high transition on ACK Alarm and Start before the drive may run again.

REM TRIP DELAY [541] REMOTE TRIP [542]

being cleared.

Status of the Remote trip alarm, OK, Warning (Remote Seq Bit 9 FALSE and delay not expired), Active (Trip active, timer expired and remote not inhibited).

6-10 Programming MN792

Block Diagram

1 SYSTEM

2 CONFIGURE I/O

The Block Diagram parameters make the connections of input and output tags for the blocks identified on the

block diagrams of Appendix C. These connections are only executed when the destinations are connected to a non–zero tag. If a function is not required, set its destination tag to zero. A tag=0 causes the processor to ignore the function and reduces processor loading.

Note: Only the connections are described here. For information about an input or output, refer to the

description of that block described in this section.

3 BLOCK DIAGRAM [Block Name} I/O Signal Name

[Raise/Lower] Output Destination [Ramps] Ramp Output Destination [Setpoint Sum 1] SPT Sum Destination [PID] PID Output Destination [Current Loop] POS I Clamp Source [Current Loop] NEG I Clamp Source

Factory [Tag] Value Description [260] 0 Raise/Lower] Output Destination [293] 291 [Ramps] Ramp Output to Setpoint 3 of Speed Loop block. [294] 289 [Setpoint Sum 1] SPT Sum to Setpoint 1 of Speed Loop block. [400] 0 [PID] PID Output Destination [435] 0 [Current Loop] POS I Clamp Source [436] 0 [Current Loop] NEG I Clamp Source

Parameter Descriptions [Raise/Lower] Output Destination

Connects the output of the Raise/Lower bock to its destination tag.

[Ramps] Ramp Output Destination

Connects the Ramp Output of the Ramps bock to its destination tag.

[Setpoint Sum 1] SPT Sum Destination

Connects the SPT Sum Output of the Setpoint Sum 1 bock to its destination tag.

[PID] PID Output Destination

Connects the PID Output of the PID bock to its destination tag.

[Current Loop] POS I Clamp Source

Connects the POS 1 Clamp input of the Current Loop bock to its source tag.

[Current Loop] NEG I Clamp Source

Connects the NEG 1 Clamp input of the Current Loop bock to its source tag.

Range: 0 to 549 Range: 0 to 549 Range: 0 to 549 Range: 0 to 549 Range: 0 to 549 Range: 0 to 549

Programming 6-11MN792

Calibration

1 SETUP PARAMETERS

2 CALIBRATION

Configure Enable NOM Motor Volts Armature Current Field Current Armature V CAL IR Compensation Encoder RPM Encoder Lines Analog TACH CAL Zero SPD Offset Armature I (A9) SPDFBK Alarm Level Stall Threshold Stall Trip Delay REM Trip Delay Overspeed Level Field I CAL

This block contains parameters specific to the motor. Note: Control operation is suspended and all Keypad LEDs will flash while the Configure Enable = Enabled.

Calibration – Functional Diagram

These parameters can also be set in the Level 1 Configure Drive" menu.

From Power Board

Expasnion Board

Tachometer

Expansion Board

Armature

ACCT

Field

ACCT

Encoder

CAL Circuit

Tag Parameter

[10] Zero SPD Offset [24] Encoder Lines [22] Encoder RPM 1000 RPM

Encoder

[23] Analog TACH CAL

TACH

[20] Armature V CAL

Terminal Volts

[521] NOM Motor Volts [21] IR Compensation

[180] SPDFBK ALM Level [523] Armature Current [224] Stall Trip Delay [263] Stall Threshold

[25] Armature I (A9)

[182] Field I CAL

[524] Field Current

Factory Setting

0.00% 1000

1.0000

100 Volts

0.00%

50.0%

2.0 Amps

10.0 Sec

95.00%

Bipolar

1.0000

4.0 Amps

To Speed Loop Speed Feedback Selection

[59] [206]

[60]

BEMF

ABS

Field I FBK

To Field Regulator

Speed Feedback From Speed Loop

Speed Feedback Alarm To Inhibit Alarms

[112]

At Zero Speed From Standstill

[A9]

[59] [206]

Diagnostic connections

Diagnostic connection

Stall Trip To Inhibit Alarms

Armature Current 0-10V or ±10V

Diagnostic connections

Parameter Descriptions Terminal Volts (Read in Diagnostics Parameters)

Scaled terminal voltage. Tach Input (B2) (Read in Diagnostics Parameters)

Scaled analog tachogenerator feedback. Encoder (Read in Diagnostics Parameters)

Encoder speed feedback in RPM Back EMF (Read in Diagnostics Parameters)

Calculated motor back EMF including IR compensation. Field I Feedback (Read in Diagnostics Parameters)

Scaled field current feedback

Configuration Enable

When enabled, allow configuration changes but suspends control operation.

NOM Motor Volts

Set this value to match the armature volts rating of the motor.

Armature Current

Set this value to match the armature current rating of the motor.

Field Current

Set this value to match the Field Current rating of the motor.

Armature V CAL

Trim adjustment of the motor armature volts to give exactly 100% at the required actual voltage value (e.g. 460V etc.).

Note: Primary voltage calibration is achieved by adjusting VA calibration values using SW7.

IR Compensation

Compensation for motor IR drop to improve regulation when using armature voltage feedback as the speed feedback. This is also used in field weakening applications to improve dynamic response and speed holding stability, refer to “initial start–up routine”.

Range: xxx.xx % (h) Range: xxx.xx % (h) Range: xxxxx RPM Range: xxx.xx % (h) Range: xxx.xx % Range: 0 : Disabled

1 : Enabled

Range: 100 to 875 Volts Range: 2.0 to 15.0 AMPS Range: 0.2 to 4.0 AMPS Range: 0.9800 to 1.1000

Range: 0.00 to 100.00 %

6-12 Programming MN792

Calibration Continued

Parameter Descriptions Continued Encoder RPM

Max motor speed when using encoder feedback.

Encoder Lines

Sets the lines per revolution value of the encoder being used.

Analog TACH CAL

Trim adjustment of the motor speed to give exactly 100% at the required actual speed value (e.g. 1500 RPM etc). Note: Primary tachometer calibration is achieved by adjusting SW1 – 3 on the tachometer calibration board.

Zero SPD. Offset

If the speed feedback is not zero when the drive is stationary (possibly due to hardware offsets etc.), set this parameter value to result in a zero reading from the speed feedback.

Armature I (A9)

Selects bipolar or unipolar operation of the current meter output (terminal A9).

SPDFBK ALM LEVEL

The speed feedback alarm compares speed feedback to armature voltage. The alarm level is the maximum difference between the two signals before the alarm is activated.

Stall Threshold

Stall comparator current feedback threshold level.

Stall Trip Delay

Stall comparator time–out delay before stall output becomes true.

Speed Feedback > 0.25%

V/F Mode

Stall Trip Delay

Range: 0 to 6000 RPM Range: 10 to 5000 Range: 0.9800 to 1.1000

Range: –5.00 to 5.00 %

Range: 0 : Unipolar

1 : Bipolar

Range: 0.00 to 100.00 % (h)

Range: 0.00 to 200.00 % Range: 0.1 to 600.0

Seconds

Current Feedback

Comparator

Stall Threshold

Overspeed Level

Speed feedback level for overspeed alarm

FIELD I CAL

Trim adjustment of the motor field current to give exactly 100% at the required actual current value (e.g. 1.5A etc.).

Note: Primary field calibration is achieved by adjusting IF calibration using SW1 – 3.

Delay Stall Trip

Range: 0.00 to 200.00 % Range: 0.9800 to 1.1000

Programming 6-13MN792

Configure Drive

This menu contains many of the parameters required for configuring the drive. The Configure Drive menu is

only available at the keypad. Note: Control operation is suspended and all Keypad LEDs will flash while the Configure Enable = Enabled.

1 CONFIGURE DRIVE

Configure Enable NOM Motor Volts Armature Current Field Current Field Control Mode Field Volts Ratio Main Current Limit Autotune Speed Feedback Select Encoder Lines Encoder RPM Encoder Sign Speed INT Time Speed PROP Gain

Parameter Descriptions Configuration Enable

When enabled, allow configuration changes but suspends control operation.

NOM Motor Volts

Set this value to match the armature volts rating of the motor.

Armature Current

Set this value to match the armature current rating of the motor.

Field Current

Set this value to match the Field Current rating of the motor.

Zero CAL Inputs Range: 0 : Up to Action Field Control Mode Range: 0 : Voltage Control Field Volts Ratio Range: 0.00 to 100.00 % (h)

These parameters can also be set in the Calibration menus.

1 SETUP PARAMETERS

2 CALIBRATION

Range: 0 : Disabled

1 : Enabled

Range: 100 to 875 Volts Range: 2.0 to 15.0 AMPS Range: 0.2 to 4.0 AMPS

1 : Requested 1 : Current Control

Main Current Limit Range: 0.00 to 200.00 % Autotune Range: 0 : OFF

1 : ON

Speed Feedback Select Range: 0 : ARM Volts FDBK

1 : Analog Tach 2 : Encoder 3 : Encoder/Analog

Encoder Lines

Range: 10 to 5000

Sets the encoder lines per revolution.

Encoder RPM

Range: 0 to 6000 RPM

Max motor speed when using encoder feedback.

Encoder Sign

The polarity of the encoder signal.

Range: 0 : Negative

1 : Positive

Speed INT Time Range: 0.001 to 30.000

Seconds

Speed PROP Gain Range: 0.00 to 200.00

6-14 Programming MN792

Current Loop Allows parameters to be customized for the conventional current loop (torque loop) of the control.

1 SETUP PARAMETERS

2 CALIBRATION

Tag Parameter [18] Autotune Off [16] PROP Gain 45.00 [17] INT Gain 3.50 [137] Discontinuous 12.00 [201] REGEN Mode Enabled

[30] Additional DEM 0.00%

Setting

Analog IN 2

From Speed Loop

From Current Profile From Inverse Time Overload

Digital IN 3

PROG Stop I LIM (from Stop Rates)

Program Stop

Analog IN 4

ANALOG I/P 5

Armature Current Feedback

[356]

[119] I DMD Isolate

[421] Main Current Limit

-1

[90] Bipolar Clamps Disabled

[48] NEG I Clamp Analog IN 4

[301] POS I Clamp Analog IN 5

[65]

Digital IN 3

200.00%

[88] NEG I Clamp

[67] Actual POS I Limit [66] Current Demand [61] Actual NEG I Limit

-1

[87] POS I Clamp

Phase Angle Control

[42]

At Current Limit

To Speed Loop

Note 1: IDMD isolate removes speed loop demand and selects analog I/P 2 as current regulator demand.

IDMD isolate is overridden by program stop and stop to return drive to speed regulation.

Note 2: Regen mode disable prevents negative current demand. Series 29 Non–regenerative drives should have regen mode

disabled.

Programming 6-15MN792

Current Loop Continued

Parameter Descriptions At Current Limit (Read in Diagnostics Parameters)

True indicates that current demand equals or exceeds maximum current limit. IA Demand (Read in Diagnostics Parameters)

(IaDmd Unfiltered) IA Feedback (Read in Diagnostics Parameters)

(IaFbk Unfiltered) Current FBK.AMPS (Read in Diagnostics Parameters)

Scaled and filtered armature current in Amps. IF Feedback (Read in Diagnostics Parameters)

(Field I FBK.AMPS)

Autotune

This is the autotune function trigger input.

ILOOP Suspend

Reserved parameter.

Master Bridge

A diagnostic indicating currently active bridge; master = ON, slave = OFF.

Main CURR. Limit

Main current limit parameter which is independent of current limit scaler and in series with the other three current limit blocks.

PROP Gain

Proportional gain control for armature current pi loop. this parameter is set during the autotune function.

INT Gain

Integral gain control for armature current PI loop. This parameter is set during the autotune function.

Feed Forward

Set by Autotune but not used by the factory set I–Loop mode

Discontinuous

Discontinuous–to–continuous mean armature current boundary level. This parameter is set during the autotune function and affects the performance of the adaptive algorithm.

Additional DEM

Additional current demand input

Bipolar Clamps

Select input for bipolar (asymmetric) or unipolar (symmetric) current clamps for the 4 quadrants of operation. Factory setting of DISABLED means UNIPOLAR clamps selected.

Regen Mode – Series 30 controls only Set mode for regenerative (4–quadrant) or non–regenerative (2–quadrant) operation. Do not changed while the control is in operation.

POS. I Clamp

Positive current clamp in Bipolar Clamp mode.

NEG. I Clamp

Negative current clamp in Bipolar Clamp mode.

Note: Note bipolar current clamps in bipolar mode can cross over onto the same quadrant as

long as the POS. I Clamp is always algebraically greater than the NEG. I Clamp.

CUR. LIMIT/SCALER

Current limit scaler. It scales bipolar/unipolar clamps.

I DMD Isolate

Speed loop bypass: the current demand input is ANIN2 (A3). The following diagram shows that I DMD Isolate selects the controlling loop.

Current Feedback

Speed Demand

Speed Feedback

Analog I/P2 (A3)

Digital I/P3 (C8)

SPEED LOOP PI

I DMD ISOLATE

shown ENABLED

Current Demand

CURRENT LOOP PI

Motor

Range: 0 : False

1 : True

Range: xxx.xx % (h) Range: xxx.xx % (h) Range: xxx.xx AMPS Range: xxx.xx AMPS Range: 0 : Off

1 : On

Range: 0 : False

1 : True

Range: 0 : Off

1 : On

Range: 0.00 to 200.00 %

Range: 0.00 to 200.00

Range: 0.00 to 200.00 Range: 0.10 to 50.00 Range: 0.00 to 200.00 %

Range: –200.00 to 200.00 % Range: 0 : Disabled

1 : Enabled

Range: 0 : 2Q (Non–regen)

1 : 4Q (Regen) Range: –100.00 to 100.00 % Range: –100.00 to 100.00 %

Range: 0 to 200.00 % Range: 0 : Disabled

1 : Enabled

6-16 Programming MN792

Current Profile

When speed control is obtained by field weakening, the ability of the motor to commutate armature current is reduced at low field currents. Also some motors exhibit commutation limitations at higher speeds even with

rated field current.

1 SETUP PARAMETERS

2 CURRENT PROFILE

Speed Break 1 (Low) Speed Break 2 (High) IMAX Break 1 (SPD1) IMAX Break 2 (SPD2)

Current Profile

[32] SPD BRK 1 (Low)

100.0% [31] SPD BRK 2 (High)

100.0% [93] IMAX BRK 1 (SPD1)

200.0% [33] IMAX BRK 2 (SPD2)

200.0%

Parameter Descriptions SPD BRK 1 (LOW)

The motor speed at which current limit profiling begins.

SPD BRK 2 (HIGH)

The upper speed limit at which current limit profiling ends.

IMAX BRK 1 (SPD1)

This sets the current limit value at or below speed break–point 1, provided the other current limits are greater than this setting.

IMAX BRK 2 (SPD2)

This sets the current limit value at or above speed break–point 2, provided the other current limits are greater than this setting.

Functional Description

Current Limit

IMAX BRK 1 (SPD1)

IMAX BRK 2 (SPD2)

Range: 0.00 to 100.00 % (h) Range: 0.00 to 100.00 % (h) Range: 0.00 to 200.00 % (h)

Range: 0.00 to 200.00 % (h)

SPD BRK 1 (LOW)

SPD BRK 2 (HIGH)

Speed Demand

Programming 6-17MN792

Diagnostics This function block is used to monitor the status of the drive, internal variables, and its inputs and outputs.

1 DIAGNOSTICS

Speed Demand Speed Feedback Speed Error Speed Loop Output Current Demand Current Feedback Current FBK AMPS IaFBK Unfiltered IaDemand Unfiltered POS I Clamp NEG I Clamp Actual POS I LIM Actual NEG I LIM Inverse Time Output At Current Limit At Zero Speed At Zero Setpoint At Standstill Ramping Program Stop Coast Stop Drive Start Drive Enable

Operating Mode Field Enable Field Demand Field I FBK Field I FBK AMPS UNFIL Field FBK Field Firing Angle ANIN1 (A2) ANIN2 (A3) ANIN3 (A4) ANIN4 (A5) ANIN5 (A6) ANOUT 1 (A7) ANOUT 2 (A8) Start (C3) Digital Input C4 Digital Input C5 DIGIN 1 (C6) DIGIN 2 (C7) DIGIN 3 (C8) DIGOUT 1 (B5) DIGOUT 2 (B6) DIGOUT 3 (B7)

Raise/Lower Output PID Output PID Clamped PID Error Setpoint Sum Output Ramp Output Speed Setpoint Terminal Volts Back EMF TACH Input (B2) Raw TACH Input Encoder Raw Encoder RPM Raw Speed Feedback Raw Speed Error Contactor Closed Health LED Ready Drive Running System Reset

Parameter Descriptions Speed Feedback (Also set in Speed Loop Parameters)

Speed loop feedback. The speed feedback value from the source selected by Speed Feedback Select [47].

Speed Error (Diagnostics only) Speed Loop Error.

Current Demand (Diagnostics only) Current Loop Demand (speed error PI output or external current demand clamped by all the current limits).

Current Feedback (Diagnostics only) Scaled and filtered armature current.

POS. I Clamp (Diagnostics only) Positive current clamp.

NEG. I Clamp (Diagnostics only) Negative current clamp.

ACTUAL POS I LIM (Diagnostics only) Overall positive current limit value.

ACTUAL NEG I LIM (Diagnostics only) Overall negative current limit value.

DRIVE START (Diagnostics only) Controller start/run command.

Drive Enable (Diagnostics only) Drive speed and current loop are enabled/quenched.

FIELD I FBK (Diagnostics only) Scaled field current feedback

TACH INPUT (B2) (Diagnostics only) Scaled analog tachogenerator feedback.

ENCODER (Diagnostics only) Encoder speed feedback in RPM.

Speed Demand (shown in Stop Rates block) Speed loop total setpoint after the ramp–to–zero block.

Speed Loop Output (shown in Speed Loop block) Output from speed loop PI.

Current FBK. AMPS (shown in Current Loop block) Scaled and filtered armature current in Amps. (IA Feedback)

IaFBK Unfiltered (shown in Current Loop block) Scaled armature current.

IaDmd Unfiltered (shown in Current Loop block) Scaled demanded armature current.

Diagnostics

Speed Feedback [207] 0.06%

Speed Error [297]

Current Demand [299]

Current Feedback [298]

POS I Clamp [87] NEG I Clamp [88]

Actual POS I Limit [67]

Actual NEG I Limit [61]

Drive Start [82] OFF

Drive Enable [84] Field I Feedback [300] TACH Input (B2) [308]

Encoder [206]

Drive Running [376]

Contactor Closed [83]

0.06%

0.00%

100.0%

-100.0%

100.0%

-100.0%

Disabled

0.0%

0.2% 0 RPM

Range: xxx.xx %

Range: xxx.xx % Range: xxx.xx %

Range: xxx.xx % Range: xxx.xx % (h) Range: xxx.xx % (h) Range: xxx.xx % (h) Range: xxx.xx % (h) Range: 0 : Off Range: 0 : Disabled Range: xxx.xx % Range: xxx.xx % (h) xxxxx RPM Range: xxx.xx % Range: xxx.xx % Range: xxx.xx AMPS Range: xxx.xx % Range: xxx.xx %

1 : On 1 : Enabled

6-18 Programming MN792

Diagnostics Continued

Parameter Descriptions Inverse Time Output (shown in Current Loop block)

Inverse time clamp output level. At Current Limit (shown in Current Loop block)

Current demand is being restrained by the overall current limit. At Zero Speed (shown in Standstill block)

At zero speed feedback. At Zero Setpoint (shown in Standstill block)

At zero speed demand. At Standstill (shown in Standstill block)

At zero speed and at zero setpoint. Ramping (shown in Ramps block)

If the difference between the Ramp Input and The Ramp Output is greater than the Ramp Threshold, then Ramping is true.

Program Stop (shown in Stop Rates block) State of Program Stop (Terminal B8). When B8 is at 24V, then Program Stop is false and the Program Stop front panel LED is also on.

Coast Stop (Diagnostics only) State of Coast Stop (Terminal B9). When B9 is at 24V, then Coast Stop is False.

Operating Mode (shown in Jog/Slack block)

Sets the drive mode to Run, Jog 1....stop, etc.

0 : Stop 1 : Stop 2 : Jog Sp. 1 3 : Jog Sp. 2 4 : Run 5 : Take Up Sp. 1 6 : Take Up Sp. 2 7 : Crawl

Field Enabled (shown in Field Control block) Drive Field Loop Is Enabled/Quenched.

Field Demand (shown in Field Control block) The meaning of field demand depends upon which mode of field control is in force; in current control field demand is the current setpoint to the field loop, in voltage mode field demand is the voltage ratio to the field controller.

FIELD I FBK AMPS (shown in Current Loop block, IF Feedback) Scaled and filtered field current feedback in Amps.

Raw Field FBK

Scaled field current. FLD. Firing Angle (shown in Field Control block)

Field firing angle in degrees: 155 degrees is the value for back stop (min field) and 5 degrees is the value for front stop (max field).

ANIN 1 (A2) (shown in Analog Inputs block) Speed setpoint no. 1.

ANIN 2 (A3) (shown in Analog Inputs block) Speed setpoint no. 2/current demand.

ANIN 3 (A4) (shown in Analog Inputs block) Speed setpoint no. 3 (ramped).

ANIN 4 (A5) (shown in Analog Inputs block) Negative current clamp; this is only active if bipolar clamps are enabled (C6 = ON)

ANIN 5 (A6) (shown in Analog Inputs block) Main current limit or positive current clamp if C6 = on.

ANOUT 1 (A7) (shown in Analog Outputs block) Scaled speed feedback.

ANOUT 2 (A8) (shown in Analog Outputs block) Total speed setpoint.

Start (C3) (shown in AUX I/O block) Start/Run terminal.

Range: xxx.xx % Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 to 7

Range: 0 : Disabled

1 : Enabled

Range: xxx.xx %

Range: xxx.xx % Range: xxx.xx % Range: xxx.xx DEG

Range: xxx.xx Volts Range: xxx.xx Volts Range: xxx.xx Volts Range: xxx.xx Volts

Range: xxx.xx Volts Range: xxx.xx Volts Range: xxx.xx Volts Range: 0 : Off

1 : On

Programming 6-19MN792

Diagnostics Continued

Parameter Descriptions Digital Input C4

Enable terminal. Digital Input C5

Reverse terminal. DIGIN 1 (C6)

Jog/Slack terminal. DIGIN 2 (C7)

Jog/Slack Mode terminal. DIGIN 3 (C8)

Speed or Torque mode select terminal. DIGOUT 1 (B5) (shown in Digital Outputs block)

At zero speed. DIGOUT 2 (B6) (shown in Digital Outputs block)

Drive healthy. Health is also displayed on the front panel LED. DIGOUT 3 (B7) (shown in Digital Outputs block)

Drive ready to run (all alarms healthy and mains synchronization achieved). Raise/Lower Output (shown in Raise/Lower block)

(OUTPUT) Value of the raise/lower ramp function. PID Output (shown in PID block)

PID block output. PID Clamped (shown in PID block)

Logic output indicating whether the PID limits are active. PID Error (shown in PID block)

PID error = Input 1 – Input 2 SPT Sum Output (shown in Setpoint Sum 1 block)

Setpoint sum 1 output. Ramp Output (shown in Ramps block)

Setpoint ramp output. Speed Setpoint (shown in Speed Loop block)

Speed loop total setpoint including the ramp output before the ramp–to–zero function. Terminal Volts (shown in Calibration block)

Scaled terminal volts. Back EMF (shown in Calibration block)

Calculated motor back EMF including IR compensation. UNFIL TACH Input (shown in Calibration block)

Unfiltered analog tachogenerator feedback. Encoder (Diagnostics only)

Encoder speed feedback in RPM. Raw Encoder RPM (shown in Calibration block)

Unfiltered encoder speed feedback in RPM. UNFIL Speed FBK (shown in Speed Loop block)

Unfiltered speed feedback. UNFIL Speed Error (shown in Speed Loop block)

Unfiltered speed error. Contactor Closed (Diagnostics only)

Main contactor control signal. HEALTH LED (shown in Alarms block)

State of Health LED on Operator Station. READY (shown in Alarms block)

The drive is ready to accept an enable signal. DRIVE RUNNING (Diagnostics only)

Drive is enabled and may make current when TRUE. A diagnostic for those parameters that can only be written to when the drive is stopped (parameters marked with Note 2 in the Parameter Specification Table).

SYSTEM RESET (Diagnostics only) Set for one cycle as the drive is enabled.

Range: 0 : Off

1 : On

Range: 0 : Off

1 : On

Range: 0 : Off

1 : On

Range: 0 : Off

1 : On

Range: 0 : Off

1 : On

Range: 0 : Off

1 : On

Range: 0 : Off

1 : On

Range: 0 : Off

1 : On

Range: xxx.xx % Range: xxx.xx % Range: 0 : False

1 : True

Range: xxx.xx % Range: xxx.xx % Range: xxx.xx % Range: xxx.xx % Range: xxx.xx % (h) Range: xxx.xx % (h) Range: xxx.xx % (h) Range: xxxxx RPM Range: xxxxx RPM Range: xxx.xx % Range: xxx.xx % Range: 0 : Off

1 : On

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0 : False

1 : True

6-20 Programming MN792

Digital Inputs

1 SYSTEM

2 CONFIGURE I/O

3 DIGITAL INPUTS

4 DIGIN 1 (C6)

4 DIGIN 2 (C7)

4 DIGIN 3 (C8)

Destination Tag Value for True Value for False

Allows control of the digital operating parameters of the software. The digital input can be configured to point to a destination location and to set that destination true or false depending upon programmable values.

1 SYSTEM

2 CONFIGURE I/O

3 DIGITAL INPUTS

4 DIGITAL INPUT C4

4 DIGITAL INPUT C5

Destination Tag

 Optional DC contactor

“AM” auxiliary interlock with drive enable.



Digital Input 1

Digital Input 2

Digital Input 3

Digital Input 4

Enable

Digital Input 5

+24V

Digital Input 1 – DIGIN 1 (C6)

Tag Parameter

[102] Destination Tag 90 [104] Value for False 0.00% [103] Value for True 0.01%

Digital Input 2 – DIGIN 2 (C7)

Tag Parameter

[105] Destination Tag 118 [107] Value for False 0.00% [106] Value for True 0.01%

Digital Input 3 – DIGIN 3 (C8)

Tag Parameter

[108] Destination Tag 119 [110] Value for False 0.00% [109] Value for True 0.01%

Digital Input 4 – DIGIN E (C4)

Tag Parameter

[494] Destination Tag 497

Digital Input 5 – DIGIN R (C5)

Tag Parameter

[495] Destination Tag 392

Setting

[102]

[71]

[105]

[72]

[108]

[73]

[494]

[69]

[495]

[70]

AUX I/O

Diagnostic connection

Jog/Slack

Diagnostic connection

Current Loop

Diagnostic connection

AUX I/O

Diagnostic connection

Ramps

Diagnostic connection

[496] Jog/Slack

[228] Mode

[119] I DMD Isolate

[497] Enable

[620] Ramp Invert

Parameter Descriptions Destination Tag (Output)

The destination Tag No. assigned to the digital input.

Value for True

The value that output assumes when input is true.

Value for False

The value that output assumes when input is false. Digital Inputs 1, 2 , and 3 (Also see AUX I/O and Diagnostics blocks)

Refer to the diagnostics function block description. Digital Input C4 (Also see AUX I/O and Diagnostics Parameters).

Electronic enable/quench terminal (On=Enable). If terminal C4 is used for anything other than “Drive Enable” ([494] is not set to 497), then the enable parameter [497] must be set to ON or the drive will not run. Digital Inputs C4 and C5 have destination tags only.

Note: Value true is fixed at 0.01%, and value false is fixed at 0.00%.

Digital Input C5 (Also see AUX I/O and Diagnostics Parameters). Reverse is active when C5 is true. This causes [620] Ramp Invert to revese (change polarity) of the ramped output signal to Setpoint 1 [289] of the Speed Loop. Digital Inputs C4 and C5 have destination tags only.

Note: Value true is fixed at 0.01%, and value false is fixed at 0.00%.

Range: 0 to 549 Range: –300.00 to 300.00 % Range: –300.00 to 300.00 % Range: 0 : Off

1 : On

Range: 0 to 549

Programming 6-21MN792

Digital Inputs Continued Functional Description

Input

Digital input 1

Jog/Slack digital input. (See Jog/Slack description).

Terminal (C6) Digital input 2

Jog/Slack mode digital input. (See Jog/Slack description).

Terminal (C7) Digital input 3

Terminal (C8)

Speed/Torque select input. Closed allows a direct current output command from Analog Input 2. The bipolar signal from Analog 2 is direct acting without any accel or decel ramp rates. Connection from another command signal source is not possible.

The destination for a digital input can be any valid Tag number. This means that a digital input can be used to select one of two values for a given parameter. It is also possible to treat the values for true and false as destination tags from other functions or inputs. 0.00% = a Logic 0 and any other value = a Logic 1. This refers to the values set in both value for true and value for false parameters. Inverting the digital input is therefore simple; set value true to 0.00% and value false to 0.01% or any other non–zero number.

Description

Digital Inputs – Examples Digital inputs can be connected to read/write parameters only. These inputs are useful to control

logical parameters. Logical parameters are those whose ranges are On/Off, True/False, Enabled/Disabled, etc. They can also send two fixed values to a VALUE parameter as determined by the state of the input terminal.

Example 1 – Using an Analog Input as a Digital Input

It is possible to use an Analog Input as a Digital Input to extend the number of Digital Inputs available. Again,

0.00% is regarded as Logic 0 and any other value is regarded as Logic 1.

Analog Input 1 – ANIN 1 (A2)

Analog Input 1

Tag Parameter

[231] Max Value +100.00% [230] Calibration 1.0000

[232] Min Value [246] Destination Tag 100

0.00%

[246]

Current Loop

[90]

Bipolar Clamps

Diagnostic

[50]

connection

Example 2 – Using digital inputs with LOGIC parameters

The factory settings allow the digital inputs to switch LOGIC parameters. These are the connections from terminal C6 to tag 90 (Bipolar Clamps), C7 to tag 118 (Ramp Hold), and C8 to tag 119 (I DMD. Isolate). In each case, the state of the terminal switches the destination parameter on or off by sending a 1 or 0. Since the format of the Value For True and Value For False parameters is in percent, 0 is equal to 0.00% and 1 is equal to 0.01%.

Inverting the Input Signal

1. Set CONFIGURE I/O::CONFIGURE ENABLE To Enable.

2. Set DIGIN 1 (C6)::VALUE FOR TRUE to 0.00%.

3. Set Value for False to 0.01%.

4. Reset CONFIGURE I/O::CONFIGURE ENABLE To Disable.

6-22 Programming MN792

Digital Inputs Continued

Digital input 1 now sends a 0 when the input signal is true and 1 when it is false.

Digital Input 1

Digital Input 1 – DIGIN 1 (C6)

Tag Parameter

[102] Destination Tag 90 [104] Value for False 0.01% [103] Value for True 0.00%

Setting

[102]

From Speed Loop

Current Loop

Current Limit

Switch

[66]

Phase Angle Control

[90] Bipolar Clamps Digital IN 1

-1

Analog IN 4

ANALOG I/P 5

Armature Current Feedback

[48] NEG I Clamp Analog IN 4

[301] POS I Clamp Analog IN 5

[65]

Example 3 – Use Digital Input 1 to set Speed Loop PROP Gain

1. Set CONFIGURE I/O::CONFIGURE ENABLE to ENABLE.

2. Set DIGIN 1 (C6)::DESTINATION TAG to 14 (the speed loop prop gain parameter).

3. Set VALUE FOR TRUE to 10.00.

4. Set VALUE FOR FALSE to 30.00.

5. Reset CONFIGURE I/O::CONFIGURE ENABLE to DISABLE.

Digital input 1 now sets SPEED LOOP::PROP. GAIN to two values depending upon its state. When it is HIGH, PROP. GAIN is at 10.00 and when LOW, PROP. GAIN is at 30.00.

Digital Input 1 – DIGIN 1 (C6)

Tag Parameter

[102] Destination Tag 14 [104] Value for False 30.00%

Digital

[103] Value for True 10.00%

Input 1

Setting

[102]

Speed Loop

Tag Parameter Setting

[14] PROP Gain 10.00 [13] INT Time Constant [202] INT Defeat Off

[89] Speed Demand [207] Speed Feedback

0.500 Seconds

To Current Loop I DMD

[356]

Isolate switch input

Programming 6-23MN792

Digital Inputs Continued

Digital Input 1 – DIGIN 1 (C6)

Tag Parameter Setting

[102] Destination Tag 364 [104] Value for False 1.28%

Digital

[103] Value for True 1.29%

Input 1

Example 4 – Use Digital Input 1 to switch signal sources

1. Set CONFIGURE I/O::CONFIGURE ENABLE to ENABLE.

2. Set DIGIN 1 (C6)::DESTINATION TAG to 364 (Link 1 source tag parameter).

3. Set DIGIN 1 (C6)::VALUE FOR TRUE to 1.29% (tag number for AUX I/O::ANOUT 2=129).

4. Set DIGIN 1 (C6)::VALUE FOR FALSE to 1.28% (tag number for AUX I/O::ANOUT 1=128).

5. Set LINK 1::DESTINATION TAG to 309 (SETPOINT SUM::INPUT 0 parameter).

6. Set AUX I/O::ANOUT 1 to 10%.

7. Set AUX I/O::ANOUT 2 to 20%.

8. Reset CONFIGURE I/O::CONFIGURE ENABLE to Disable.

This example uses an internal link to route two signals to Input 0. The state of digital input 1 determines the number held by LINK 1 :: SOURCE TAG. When true, it is 129. When false, the tag is 128. LINK 1:: SOURCE TAG retrieves the value from ANOUT 1 or 2 depending on the tag and routes it to SETPOINT SUM 1:: INPUT 0. The signal switches between 10 and 20 percent. This is useful for switching between two jog setpoints.

System::Configure I/O::Link 1::

Tag Parameter Setting

[102]

[365] Destination Tag 309 [364] Source Tag 0

[365]

Setup Parameters::AUX I/O::

Tag Parameter

[128] AUX ANOUT 1 10.00%

[129] AUX ANOUT 2 20.00%

Setting

[128]

[129]

Setup Parameters::Setpoint Sum 1::

Tag Parameter

[292] Sign 0 Positive [208] Ratio 0 1.0000 [309] Input 0 0.00% A/B + / [420] Divider 0 1.0000 [423] Input 2 0.00% [100] Input 1 0.00%

Setting

[86]

6-24 Programming MN792

Digital Outputs

Digital outputs can read all parameters (the same as the analog outputs). When used with a VALUE parameter, MODULUS removes the sign from the value (so –100 becomes 100). The THRESHOLD (>) parameter determines when the output is HIGH or LOW. The input signal must exceed the Threshold value for the output to go HIGH. INVERTED, when TRUE, inverts the result of the output from the threshold test.

1 SYSTEM

2 CONFIGURE I/O

3 DIGITAL OUTPUTS

4 DIGOUT1 (B5)

4 DIGOUT2 (B6)

4 DIGOUT3 (B7))

Threshold (>) Modulus Source Tag Inverted

At Zero Speed

Healthy

Ready

Digital Output 1 – DIGOUT 1 (B5)

Tag Parameter [359] Inverted False [195] Threshold (>)

[97] Source Tag 77

[43] Modulus

Digital Output 2 – DIGOUT 2 (B6)

Tag Parameter [360] Inverted False [196] Threshold (>)

122

[98] Source Tag 122

[44] Modulus

Digital Output 3 – DIGOUT 3 (B7)

Tag Parameter [361] Inverted False [197] Threshold (>)

125

[99] Source Tag 125

[45] Modulus

Parameter Descriptions Threshold (>)

The threshold which the value must exceed to set the output to true.

Modulus

Output set TRUE for absolute or modulus of the tag no. value. Source Tag (Input)

Defines the source variable to control the digital output.

Inverted

Selects Inverted Output. DIGOUT 1, 2 , and 3 (Read in Diagnostics Parameters)

Refer to the diagnostics function block description.

Setting

0.00%

True

Setting

0.00%

True

Setting

0.00%

True

ABS

Digital

Output 1

Digital

Output 2

Digital

Output 3

Range: –300.00 to 300.00 % Range: 0 : False

1 : True

Range: 0 to 549 Range: 0 : False

1 : True

Range: 0 : Off

1 : On

Programming 6-25MN792

Field Control

This function block contains all the parameters for the field operating mode. It is viewed at the keypad in three submenus. In the Field Control menu, you select the field operating mode: open loop voltage control or closed loop current control.

In certain DC motor applications, high speeds can only be achieved by reducing the field current (torque). This is the constant horsepower region or field weakening region, and the speed at which it begins is known as the Base Speed.

1 SETUP PARAMETERS

2 FIELD CONTROL

Field Enable Field Control Mode Field Quench Delay Field Quench Mode

1 SETUP PARAMETERS

2 FIELD CONTROL

3 FLD VOLTAGE VARS

Field Volts Ratio

1 SETUP PARAMETERS

2 FIELD CONTROL

3 FLD CURRENT VARS

Setpoint PROP Gain INT Gain

1 CONFIGURE DRIVE

Field Control Mode Field Volts Ratio

1 SETUP PARAMETERS

2 FIELD CONTROL

3 FLD CURRENT VARS

4 FLD WEAK VARS

Field Weak Enable EMF Lead EMF Lag EMF Gain Min Field Current MAX Volts BEMF Feedback Lead BEMF Feedback Lag

Field Control Field Current VARS Field Weak VARS

Max Volts

Back EMF Feedback

PID

Field Demand

Field 1 Feedback

Parameter Descriptions Field Enabled (Read in Diagnostics Parameters)

Refer to the diagnostics function block description. Field Demand (Read in Diagnostics Parameters)

Refer to the diagnostics function block description. Field Firing Angle (Read in Diagnostics Parameters)

Refer to the diagnostics function block description.

Field Enable

Unquenches Field Current Loop. Field Control Mode Two modes are avaiable

(a) Field Voltage Control is an open loop phase angle control to give a certain voltage output. (b) Field Current Control is a closed loop current control for accurate field control or expansion to field

weakening.

Field Volts Ratio (Ratio Out/In) This parameter controls the output voltage from the open loop voltage control. The ratio is defined as the dc output voltage over the ac rms input voltage. The factory setting is equivalent to a single–phase diode rectifier.

Setpoint

Field Current Setpoint.

PROP. Gain

This is the proportional gain adjustment of the field current pi loop. The factory setting of 0.10 is equivalent to a real gain of 10.

INT. Gain

This is the integral gain adjustment of the field current PI loop.

Field Weak Enable

Activates the additional motor back emf PID loop for field weakening (field spillover) control.

EMF LEAD

With field weakening control enabled, a PID loop is brought into operation. This is the lead time constant adjustment of the field weakening PID loop. For a value of 2.00, the real time constant = 200ms.

EMF LAG

This is the lag time constant adjustment of the field weakening PID loop. For a value of 4.00, the real time constant = 4000ms.

EMF GAIN

This is the gain adjustment of the field weakening PID loop. For a value of 3.00, the real gain = 30.

MIN FIELD CURRENT

The field weakening loop reduces the field current to achieve speed control above base speed. At top speed the field reaches a minimum value. The Min Fld Current should be set below this minimum value to allow reasonable margin for transient control near the top speed but not lower than 6% as this could then cause the “Field Fail” alarm to operate.

Volts Ratio

Drive

Firing Angle

Run

Range: 0 : Disabled

1 : Enabled

Range: xxx.xx % Range: xxx.xx DEG Range: 0 : Disabled

1 : Enabled

Range: 0 : Voltage Control

1 : Current Control

Range: 0.00 to 100.00 % (h)

Range: 0.00 to 100.00 % Range: 0.00 to 100.00 %

Range: 0.00 to 100.00 % Range: 0 : Disabled

1 : Enabled

Range: 0.10 to 50.00

Range: 0.00 to 200.00

Range: 0.00 to 100.00 Range: 0.00 to 100.00 %

Phase Angle Control

6-26 Programming MN792

Field Control Continued

Parameter Descriptions MAX VOLTS

The voltage level at which field weakening begins. It is also known as “Spillover Bias”. The factory setting value is 100% of the nominal value as set by the armature voltage calibration value. For start–up this value can be set to a lower desirable level. It is advisable to return it to 100% for normal operation.

BEMF FBK LEAD

The lead time constant of the back EMF feedback filter used for reducing armature voltage overshoots when during fast acceleration through base speed.

BEMF FBK LAG

The lag time constant of the back EMF feedback filter. If active, the ratio of lead / lag should always be greater than 1 to give an overall lead action (reduces overshoot) and the ratio should be less than 3 for stable control. The factory values 100/100 = 1 make the filter inactive.

FLD. QUENCH DELAY

If dynamic braking is used, the field must be maintained for a period after the drive is disabled. The field quench delay is the period of time that the field is maintained.

FLD. QUENCH MODE

When the field quench delay has expired, the field can be entirely quenched or put into a standby mode at 50% of rated current or volts depending whether in current or voltage control mode respectively. (The factory value of 50% can be modified through the “SYSTEM / Reserved” Menu which is primarily for factory use only and requires the “super” password.)

Range: 0.00 to 100.00 %

Range: 10 to 5000

Range: 0.0 to 600.0

Seconds

Range: 0 : Quench

1 : Standby

Functional Description

Field Control

Tag# Parameter Factory Setting [170] Field Enable Enabled

[209] FLD CTRL Mode Voltage

Field Current VARS

[173] PROP Gain 0.10

[181]

Field Weak VARS

[174] FLD Weak Enable Disabled [175] EMF Lead 2.00 [176] EMF Lag 40.00 [177] EMF Gain 0.30 [191] BEMF FBK Lead 100 [192] BEMF FBK Lag 100

[60]

[178] MAX Volts 100.00% [179] MIN FLD Current 100.00%

[172] INT Gain 1.28

[171] Setpoint 100.00%

Motor

BEMF Filter

[183]

Field Demand

Field Enabled

Supply Alarms OK

Field Voltage VARS

[210] Ratio Out/In 90.00%

Field Regulator RMS Volts

Clamp

[184]

Field Firing Angle

Standby

X / 2

Quench

Tag# Parameter Factory Setting [186] Field Quench Mode Quench

[185] Field Quench Delay 0.00 Sec

Output In Voltage Mode

Supply Field OutputRatio

460V 460V

230V 230V

90% 67%

90%

67%

Drive Enable

410V 300V

200V 150V

[169]

Phase Angle Control

Programming 6-27MN792

Alarms

1 SETUP PARAMETERS

2 INHIBIT ALARMS)

Field Fail 5703 RCV Error Stall Trip Trip Reset Speed FBK Alarm Encoder Alarm REM Trip Inhibit

1 SETUP PARAMETERS

2 CALIBRATION

REM Trip Delay

This function block provides a view into the present and past trip conditions, and allows some trips to be disabled.

1 ALARM STATUS

It is viewed at the keypad in three menus.

Last Alarm Health Word Health Store Stall Trip Remote Trip

5703 in Slave Mode and COMMS Error

From Calibration Stall Delay and Stall Threshold

From Calibration SPD FBK Alarm Level

Encoder Feedback Selected and Error Detected

Field current less than 6%.

(Field fail threshold is 6% in Current

control, 12% in Voltage control.)

Drive Start

Inhibit Alarms

Tag Parameter Setting [19] Field Fail Enabled

[111] 5703 RCV Error Enabled

[28] Stall Trip Inhibited

[81] Speed FBK Alarm Enabled

[92] Encoder Alarm Enabled

[305] Trip Reset True

Parameter Descriptions Healthy (Read in Diagnostics Parameters)

Refer to the diagnostics function block description. Ready (Read in Diagnostics Parameters)

Refer to the diagnostics function block description.

Health Word

The hexadecimal sum of any alarms present. Refer to Troubleshooting for more information.

Health Store

The hexadecimal value of the first (or only) alarm. Refer to Troubleshooting for more information.

Remote Trip

The State Of Remote Trip.

Stall Trip

Armature current is above stall threshold and at zero speed but not at zero setpoint.

Last Alarm

The hexadecimal value of the last (or only) alarm. Refer to Troubleshooting for more information.

0x0000 : No Active Alarms 0x0080 : Encoder Failed 0x8000 : Accts Failed 0x0001 : Over Speed 0x0100 : Field Failed 0xf001 : Autotune Error 0x0002 : Missing Pulse 0x0200 : 3 Phase Failed 0xf002 : Autotune Aborted 0x0004 : Field Over I 0x0400 : Phase Lock 0xf200 : CONFIG Enabled 0x0008 : Heatsink Trip 0x0800 : 5703 Rcv Error 0xf400 : No Op–station (No Keypad) 0x0010 : Thermistor 0x1000 : Stall Trip 0xf006 : Remote Trip 0x0020 : Over Volts (Va) 0x2000 : Over I Trip 0xff05 : PCB Version 0x0040 : Spd Feedback 0xf005 : External Trip 0xff06 : Product Code

Field Fail

Inhibits the field fail alarm.

5703 RCV Error

Inhibits 5703 serial communications receive error. Only active in slave mode. Stall Trip

Inhibits the stall trip alarm from tripping the contactor out.

Trip Reset

When false, the faults are latched permanently and the healthy output remains inactive after changing the start input (C3) Off/On. The trip reset must then be set to true for the faults to be reset and the healthy output to go active (high) when C3 goes low. this feature can be used in applications where you want to reset the faults under your own control, rather than automatically with the start/run command.

Speed FBK Alarm

Inhibits the speed feedback alarm.

Encoder Alarm

Inhibits the encoder option board alarm.

REM Trip Inhibit

Inhibits the remote trip.

REM Trip Delay

The delay between the remote trip alarm being activated and the drive tripping.

Alarms

Field Fail

5703 RCV Error

Stall Trip

Speed FBK Alarm

Encoder Alarm

Health Reset

Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: 0x0000 to 0xFFFF Range: 0x0000 to 0xFFFF Range: 0 : OK

1 : Failed

Range: 0 : OK

1 : Failed

Range: 0x0000 to 0xff06

Range: 0 : Enabled

1 : Inhibited

Range: 0 : Enabled

1 : Inhibited

Range: 0 : Enabled

1 : Inhibited

Range: 0 : False

1 : True

Range: 0 : Enabled

1 : Inhibited

Range: 0 : Enabled

1 : Inhibited

Range: 0 : Enabled

1 : Inhibited

Range: 0 : Enabled

1 : Inhibited

6-28 Programming MN792

Jog/Slack These parameters control the Jog function of the control. (Also see “Ramps” description).

1 SETUP PARAMETERS

2 Jog/Slack

Jog Speed 1 Jog Speed 2 Take Up 1 Take Up 2 Crawl Speed Mode Ramp Rate

Parameter Descriptions OPERATING MODE (Read in Diagnostics Parameters)

Refer to the diagnostics function block description.

0 : STOP 2 : JOG SP. 1 4 : RUN 6 : TAKE UP SP. 2 1 : STOP 3 : JOG SP. 2 5 : TAKE UP SP. 1 7 : CRAWL

JOG SPEED 1

Jog speed 1 setpoint.

JOG SPEED 2

Jog speed 2 setpoint.

TAKE UP 1

Take–up slack speed setpoint 1.

TAKE UP 2

Take–up slack speed setpoint 2.

CRAWL SPEED

Crawl speed setpoint.

MODE

Jog/Slack operating mode select. MODE should be connected to a digital input.

RAMP RATE

The ramp rate used during Jog is independent of the main ramp rate during normal running. The acceleration and deceleration times in jog are always equal.

Functional Description

To fully use all the modes , Mode [228] must be connected to one of the digital inputs. “Setpoint” in the following table refers to the MIN Speed Input. Any direct setpoints that exist are added to this setpoint to make the total speed setpoint. If this is not desirable, for example during jog, the direct setpoints should be disconnected during the appropriate conditions.

DIG IN 1

[102][C6]

[105][C7]

Jog / Slack

Tag Parameter

[496] Jog/Slack Off

[228] Mode False

[212] Operating Mode

[253] Take Up 1 +5.00% [254] Take Up 2 -5.00% [218] Jog Speed 1 +5.00% [219] Jog Speed 2 -5.00% [225] Crawl Speed [355] Ramp Rate 1.0 Seconds

Factory Setting

Stop

10.00%

Operating Mode Stop Stop Run Take Up Slack 1 Take Up Slack 2 Jog 1 Jog 2 Crawl

Jog

Ramp Rate

Mode False True False False True False True True

Range: 0 to 7

Range: –100.00 to 100.00 % Range: –100.00 to 100.00 % Range: –100.00 to 100.00 % Range: –100.00 to 100.00 % Range: –100.00 to 100.00 % Range: 0 : False Range: 0.1 to 600.0

Jog Off Off Off On Off On On On

Run

O/P

Off

S/P

Off

S/P

S/P + Take Up 1

S/P + Take Up 2

Off

Jog Speed 1

Off

Jog Speed 2

Crawl Speed

1 : True Seconds

MIN Speed Input

Operating Mode Start (C3) Jog (C6) Mode (C7) Ramp Time Contactor

Setpoint Stop OFF OFF – factory setting OFF Setpoint Run ON OFF False factory setting ON Setpoint + Take–Up Slack 1 Take–Up Slack 1 ON ON False factory setting ON Setpoint + Take–Up Slack 2 Take–Up Slack 2 ON OFF True factory setting ON Crawl Speed Crawl ON ON True factory setting ON Jog Speed 1 Inch / Jog 1 OFF ON False Jog Accel/Decel Ramp ON Jog Speed 2 Inch / Jog 2 OFF ON True Jog Accel/Decel Ramp ON

MIN Speed Input

JOG (C4)

RUN (C3)

JOG (C4)

JOG SPEED 1

RAMP INPUT + TAKE UP 1

RAMP INPUT

RAMP RATE

set in JOG/SLACK

RAMP ACCEL TIME

set in RAMPS

RAMP DECEL TIME

set in RAMPS

Programming 6-29MN792

Menus

Allows selection of either the full menu structure, or a reduced menu structure. It also selects the language for the keypad display.

1 MENUS

Full Menus Language

1 SETUP PARAMETERS

Enabled

4 SPEED LOOP

Speed FBK Filter

Menus

[37] Full Menus [547] Speed FDBK Filter

0.000

English [304] Language

Parameter Descriptions FULL MENUS

When enabled, the full menu structure is displayed at the keypad.

LANGUAGE

Selects the display language. Other languages are available, please contact Baldor.

Range: 0 : Disabled

1 : Enabled

Range: 0 : English

1 : Other

SPEED FBK FILTER

A simple filter function that is applied to Speed Feedback to reduce ripple caused by encoders with low line count. A value of 0 diables the filter action. 1.00 is the maximum value. A typical value would be between 0.5 and 0.75. Increasing the filter value may make the speed loop unstable. The filter time constant “τ” in milliseconds is calculated as follows:

Log

3.3

tĂ +Ă

Where α is the Speed FBK Filter value. α = 0.5 indicates a filter time constant of 0.48 milliseconds,

0.8 to 14.7ms, and 0.9 to 31.2 ms.

Range: 0.000 to 1.000

6-30 Programming MN792

OP Station (Keypad) Local operation parameters are set using three menus.

1 SETUP PARAMETERS

2 OP-STATION

3 SETUP

Set Point JOG Setpoint Local Key Enable

1 SETUP PARAMETERS

2 OP-STATION

3 LOCAL RAMP

Ramp ACCEL Time Ramp DECEL Time

1 SETUP PARAMETERS

2 OP-STATION

3 START UP VALUES

Setpoint JOG Setpoint Forward Program Local

Note: Local Setpoint (only active when the drive is in Local mode)

Up Key

Down Key

Reset Value

Local Setpoint

Local Ramp

Accel Time

Decel Time

% S-Ramp

Parameter Descriptions Local Key Enable

Enables the “L/R” on the keypad. This must be set true to allow the operator to select local and remote modes.

Setpoint

Actual value of local setpoint.

Jog Setpoint

Actual value of local jog setpoint.

RAMP ACCEL TIME

Acceleration time used in Local mode.

RAMP DECEL TIME

Deceleration time used in Local mode. FORWARD (Initial FWD Direction)

Start–up mode of local direction on power–up. True = Forward. LOCAL (Initial Local)

Start–up mode of keypad L/R key on power–up. True = Local mode. Program (Initial Program)

Start–up mode of keypad PROG key on power–up. True = Program mode, to see the local setpoint. Setpoint (Initial Setpoint)

Value of local setpoint on power–up. JOG Setpoint (Initial Jog Setpoint)

Value of local jog setpoint on power up.

Stop Ramp

Range: 0 : False

1 : True Range: 0.00 to 100.00 % Range: 0.00 to 100.00 % Range: 0.1 to 600.0

Seconds Range: 0.1 to 600.0

Seconds Range: 0 : False

1 : True Range: 0 : False

1 : True Range: 0.00 to 100.00 %

Range: 0.00 to 100.00 %

Password This keypad menu activates or deactivates the password protection feature.

1 PASSWORD

Enter Password By-Pass Password Change Password

Parameter Descriptions Enter Password

Factory Setting = 0x0000 (No Password Is Set). BY–PASS PASSWORD Reserved parameter.

Factory Setting = FALSE

CHANGE PASSWORD

Factory Setting = 0x0000 (no change).

Range: 0x0000 to 0xFFFF Range: 0 : False

1 : True Range: 0x0000 to 0xFFFF

Programming 6-31MN792

PID This is a general purpose PID block which can be used for many closed loop control applications. PID feedback

can be loadcell tension, dancer position or any other transducer feedback such as pressure, flow etc.

1 SETUP PARAMETERS

2 SPECIAL BLOCKS

3 PID

PROP Gain INT Time CONST Derivative TC Positive Limit Negative Limit O/P Scaler (Trim) Input 1 Input 2 Ratio 1 Ratio 2 Divider 1 Divider 2 Enable INT Defeat Filter TC Mode MIN Profile Gain Profiled Gain

Parameter Descriptions PID Output (Read in Diagnostics Parameters)

Refer to the diagnostics function block description. PID Clamped (Read in Diagnostics Parameters)

Refer to the diagnostics function block description. PID Error (Read in Diagnostics Parameters)

Refer to the diagnostics function block description.

PROP. Gain

This is a pure gain factor which shifts the whole Bode PID transfer function up or down leaving the time constants unaffected. A value of P = 10.0 means that, for an error of 5%, the proportional part (initial step) of the PID output will be: 10 x [ 1 + (Td/Ti) ] x 5 % , i.e. approx. 50% for Td << Ti.

INT. TIME CONST (SPD.INT.TIME) The integrator time constant (Ti)

DERIVATIVE TC

The differentiator time constant (Td). When Td = 0 the transfer function of the block becomes a P+I.

Positive Limit

The upper limit of the pid algorithm. Negative Limit

The lower limit of the PID algorithm. Output Scaler (Trim) (Output Scaler Gain)

The ratio which the limited PID output is multiplied by in order to give the final PID Output. Normally this ratio would be between 0 and 1.

INPUT 1

This can be either a position/tension feedback or a reference/offset.

INPUT 2

This can be either a position/tension feedback or a reference/offset.

RATIO 1

The gain factor for Input 1 (Ratio 1).

RATIO 2

The gain factor for Input 2 (Ratio 2).

DIVIDER 1

This reduces (divides) Input 1 by a factor (Divider 1).

DIVIDER 2

This reduces (divides) Input 2 by a factor (Divider 2).

ENABLE

A digital input which resets the (total) PID Output as well as the integral term when false.

INT. DEFEAT

A digital input which resets the integral term when true. The block transfer function then becomes P+D only.

PID

Tag Parameter

[473] Mode 0 [404] PROP Gain 1

[474] MIN Profile Gain 20.00%

[401] Derivative TC 0.000 Seconds [402] INT Time Constant 5.00 Seconds [403] Filter TC 0.100 Seconds [412] Ratio 1 1.0000 [410] Input 1 0.00% [418] Divider 1 1.0000 [413] Ratio 2 1.0000 [411] Input 2 0.00% [414] Divider 2 1.0000 [409] INT Defeat Off [408] Enable Enabled [406] Negative Limit -100.00% [405] Positive Limit 100.00% [407] Output Scaler (Trim) 0.2000

Factory Setting

A/B

[475] Profile Gain

[415] PID Error

PID

Range: xxx.xx % Range: 0 : False

1 : True

Range: xxx.xx % Range: 0.0 to 100.0

Range: 0.01 to 100.00

Seconds

Range: 0.000 to 10.000

Seconds

Range: 0.00 to 105.00 % Range: –105.00 to 0.00 % Range: –3.0000 to 3.0000

Range: –300.00 to 300.00 % Range: –300.00 to 300.00 % Range: –3.0000 to 3.0000 Range: –3.0000 to 3.0000 Range: –3.0000 to 3.0000 Range: –3.0000 to 3.0000 Range: 0 : Disabled

1 : Enabled

Range: 0 : Off

1 : On

PID

Clamped

[416]

[417]

PID

Output

6-32 Programming MN792

PID Continued

Parameter Descriptions FILTER T.C.

To attenuate high–frequency noise, a first order filter is added in conjunction with the differentiator. The ratio k of the Derivative Time Constant (Td) over the Filter Time Constant (Tf) (typically 4 or 5) determines the high–frequency lift of the transfer function. For Tf = 0 this filter is disabled.

MODE

This determines the law which the profiler follows versus diameter. For Mode = 0, Profiled Gain = constant = P. For Mode = 1, Profiled Gain = A * (diameter – min diameter) + B. For Mode = 2, Profiled Gain = A * (diameter – min diameter)^2 + B. For Mode = 3, Profiled Gain = A * (diameter – min diameter)^3 + B.

For Mode = 4, Profiled Gain = A * (diameter – min diameter)^4 + B.

MIN PROFILE GAIN

This expresses the minimum gain required at min diameter (core) as a percentage of the (max) P gain at full diameter (100%).

PROFILED GAIN

The output of a profiler block which varies the gain versus diameter. This is primarily to be used with Speed Profiled Winders for compensation against varying diameter and therefore inertia. When MODE is not ZERO (see above) this overrides the P gain above.

Functional Description

The block diagram shows the internal structure of the PID block. PID is used to control the response of any closed loop system. It is used specifically in system applications involving the control of drives to allow zero steady state error between reference and feedback, together with good transient performance.

Proportional Gain (PROP. GAIN) Adjusts the basic response of the closed loop control system. It is defined as the portion of the loop gain that is fed back to make the complete control loop stable. The PID error is multiplied by the proportional gain to produce an output.

Integral (INT. TIME CONST.) The Integral term is used to give zero steady state error between the setpoint and feedback values of the PID. If the integral is set to a small value, this will cause an underdamped or unstable control system.

Derivative (DERIVATIVE TC) Corrects certain types of control loop instability and therefore improves response. Helpful when heavy or large

inertia rolls are being controlled. The derivative term has an associated filter to suppress high frequency signals. Parameter values should be selected to achieve a critically damped response, which allows the mechanics to

track as precisely as possible a step change on the setpoint.

Range: 0.000 to 10.000

Seconds

Range: 0 to 4

Range: 0.00 to 100.00 %

Range: xxxx.x

Critically Damped Response

Setpoint

Value

Setpoint

Underdamped

Overdamped

Critically damped

Time

Programming 6-33MN792

Raise/Lower

Provides a motor operated potentiometer (MOP) feature. Raise input [261], when true, increases the output at the rate determined by increase rate [256]. Lower input [262] decreases the output as determined by decrease rate [257]. MIN value and MAX value limits the total change by the amounts set. The output is not preserved

during power–down.

1 SETUP PARAMETERS

2 RAISE/LOWER

Reset Value Increase Rate Decrease Rate Raise Input Lower Input MIN Value MAX Value External Reset

Raise / Lower

Tag Parameter

[256] Increase Rate 10.0 Seconds [257] Decrease Rate 10.0 Seconds [261] Raise Input [262] Lower Input False [307] External Reset False [255] Reset Value 0.00% [258] MIN Value [259] MAX Value 100.00% [260] Destination Tag 0

Factory Setting

False

-100.00%

Digital MOP

Parameter Descriptions Raise/Lower Output (Read in Diagnostics Parameters)

Refer to the diagnostics function block description.

Reset Value

This reset value is preloaded directly into the output when External Reset is True, or at power–up. It Is clamped by min and max values.

Increase Rate

Rate of change of increasing output value.

Decrease Rate

Rate of change of decreasing output value.

Raise Input

Command to raise output.

Lower Input

Command to lower output.

MIN Value

Minimum ramp output clamp. This is a plain clamp, not a ramped “min speed” setting.

MAX Value

Maximum ramp output clamp.

External Reset

If External Reset = true, the output of the raise/lower block = the reset value.

Raise/Lower

Output

[260]

[264]

Diagnostic

Connection

Range: xxx.xx % Range: –300.00 to 300.00 %

Range: 0.1 to 600.0 Seconds Range: 0.1 to 600.0 Seconds Range: 0 : False

1 : True

Range: 0 : False

1 : True

Range: –300.00 to 300.00 % Range: –300.00 to 300.00 % Range: 0 : False

1 : True

Functional Description

These waveforms illustrate the raise/lower function. When External Reset is set true, the raise/lower output resets to reset value (default = 0.00%). When Raise Input is true, the output increases at increase rate. The output cannot exceed MAX Value. When Lower Input is true, the output is reduced at the decrease rate. The output cannot go below the MIN Value. Removing the raise or lower signal before the output reaches its maximum or minimum value leaves the output at its last value. Setting both raise input and lower input to true at the same time creates a ramp hold condition.

EXTERNAL RESET

RAISE/LOWER OUTPUT

RESET VALUE

DEFAULT=0%

RAISE INPUT

100%

INCREASE RATE

DEFAULT 10.0 SEC

LOWER INPUT

DECREASE RATE

DEFAULT 10.0 SEC

RAISE INPUT

6-34 Programming MN792

Ramps

1 SETUP PARAMETERS

2 RAMPS

Ramp ACCEL Time Ramp DECEL Time Constant ACCEL Ramp Hold % S-Ramp Ramping Thresh Auto Reset External Reset Reset Value MIN Speed

DIG IN 1

[102][C6]

DIG IN 2

[105][C7]

Tag Parameter

[496] Jog/Slack Off [228] Mode False

[212] Operating Mode

[253] Take Up 1 +5.00% [254] Take Up 2 -5.00% [218] Jog Speed 1 +5.00% [219] Jog Speed 2 -5.00% [225] Crawl Speed 10.00% [355] Ramp Rate 1.0 Seconds

This function block provides the facility to control the rate at which the control will respond to a changing setpoint.

RAMPS

Tag Parameter

[620] Ramp Invert False [5] Ramp Input 0.00% [126] Min Speed 0.00% [286] Ramping Threshold

O/P

[118] Ramp Hold Off [422] Reset Value 0.00% [288] External Reset Disabled [287] Auto Reset Enabled

[2] Ramp Accel Time 10.00 Sec [3] Ramp Decel Time 10.00 Sec [266] % S Ramp 2.50%

Ramp O/p Dest 291

[293]

Mode

Jog

False

Off

True

Off

False

Off

False

True

Off

False

True

S/Linear Ramp

Run Off Off On On On Off Off On

Factory Setting

0.50% +

O/P S/P S/P S/P S/P + Take Up 1 S/P + Take Up 2 Jog Speed 1 Jog Speed 2 Crawl Speed

S/P

[113]

[293]

Diagnostic connection

Jog / Slack

Factory Setting

Stop

DIG IN R

[C5]

Drive Enable

Operating Mode Stop Stop Run Take Up Slack 1 Take Up Slack 2 Jog 1 Jog 2 Crawl

Ramping

Ramp Output To Speed Loop

[85]

Jog

Ramp Rate

Jog Start

From

AUX I/O

O/PS/P

Parameter Descriptions Ramp Output (Read in Diagnostics Parameters)

Refer to the diagnostics function block description. Ramping (Read in Diagnostics Parameters)

Refer to the diagnostics function block description. Ramp Accel Time

Acceleration time (100% change) Ramp Decel Time

Deceleration time (100% change) Constant Accel

Reserved parameter. Ramp Hold

While ON, the ramp output is held at its last value. This is overridden by Ramp Reset. Ramp Input

Ramp input tag. % S–Ramp

Percentage of ramp with S–shaped rate of change. A value of zero is equivalent to a linear ramp. Changing this value affects the ramp times.

Ramping Thresh.

Ramping flag threshold level. The threshold is used to detect whether the ramp is active.

Auto Reset

If true, then the ramp is reset whenever System Reset is true, that is each time the speed/current loop is unquenched. (System Reset [374] is an internal flag that is set true for one cycle after the speed/current loop is enabled, i.e. every time the drive is started).

External Reset If true, then the ramp is held in reset. External reset does not depend on auto reset for its operation.

Range: xxx.xx % Range: 0 : False

1 : True

Range: 0.1 to 600.0 Seconds Range: 0.1 to 600.0 Seconds Range: 0 : Disabled

1 : Enabled

Range: 0 : Off

1 : On

Range: –105.00 to 105.00 % Range: 0.00 to 100.00 %

Range: 0.00 to 100.00 % Range: 0 : Disabled

1 : Enabled

Range: 0 : Disabled

1 : Enabled

Programming 6-35MN792

Ramps Continued

Parameter Descriptions Reset Value

This value is loaded into the output when Ramp Reset is true, or at power–up. To catch a spinning load smoothly (‘bumpless transfer’), connect Speed Feedback [62] (source) to Reset Value [422] (destination).

MIN. Speed The minimum speed clamp is fully bi–directional and operates with a 0.5% hysteresis. This clamp operates on the input to the ramp and it can therefore be overrridden by the Reset Value (as far as the ramp output is concerned).

Minimum Speed

Output

Range: –300.00 to 300.00 %

Range: 0.00 to 100.00 %

Functional Description

Ramp Input [5]

Min Speed [126]

Acceleration / Deceleration Rates

RAMP INPUT (+ 100%)

RAMP OUTPUT

+100%

Ramp Accel Time

(S Ramp 0%)

Actual Accel Time

with S Ramp

RAMP INPUT (-100%)

S/P O/P

Jog/Slack

Ramp Decel Time [3] Ramp Accel Time [2]

Ramp Hold [118] Auto Reset [287] External Reset [288] Reset Value [422]

RAMP DECEL TIME

(S RAMP 0%)

Actual Decel Time

with S Ramp

Input

Ramping Threshold [286]

% S Ramp [266] Input Output

S" Ramp

-0.5

0.5

Input

Output

Ramp Hold

Off

Ramp Output [293]

RAMP HOLD ON

RAMP OUTPUT

Ramp Input

Ramping [113]

Off

Ramp operation occurs when a ramp input is present. When Digital Input 2 is ON, Ramp Hold stops the ramp output from changing. Even when the ramp input signal is removed, Ramp Hold keeps the ramp output from changing. Once Ramp Hold is off, the ramp resumes.

RAMP OUTPUT

-100%

Ramp Accel Time

(S Ramp 0%)

Actual Accel Time

with S Ramp

RAMP DECEL TIME

(S RAMP 0%)

Actual Decel Time

with S Ramp

6-36 Programming MN792

Ramps Continued

Minimum Speed

100%

Ramp Input

100%

Ramp Output

Y% 0%

Drive Enabled

Ramp Input

This figure shows the effect of setting MIN. Speed above 0.00%. When the drive is enabled, the ramp output cannot decrease below the MIN. Speed value. Note the ramp rates are used when changing the

output from minimum speed to zero speed. Notice also that in this example the ramp output only increases to X% since the ramp input signal is limited to X%.

Auto Reset

100%

Ramp Input

100%

Ramp Output

External Reset

100%

Ramp Input

100%

Ramp Output

Y% 0%

Drive Enabled

Ramp Input

With Auto Reset enabled, the ramp output resets to reset value each time the drive is enabled. In this example, reset value is 0.00%. It does not reset if the drive is disabled.

The ramp input is set to X% at time t0 . The ramp output will increase at the ramp rate. While external reset is enabled, the ramp output resets to reset value. When external reset is disabled, the ramp output

continues to follow input signal.

Programming 6-37MN792

Setpoint Sum 1

Setpoint Sum 1 allows the summing and scaling of three analog inputs to produce SPT. Sum Output [294]. Note: This block is ignored by the drive unless [294] is connected to a nonzero destination tag.

Input 0 and Input 1 have individual ratio and divider scalers, and signs. Input 1 has an additional deadband function set by Deadband Width. When the input is within the deadband, the output clamps to zero to ignore any noise. This parameter is useful when digital setpoints are used (for example from a 5703, serial communications, or the Raise Lower function block). The inputs have symmetrical limits set by Limit. Input 2 has no scaling or limits. The output after Input 0, Input 1, and Input 2 are summed is also clamped by Limit before producing SPT. Sum Output.

1 SETUP PARAMETERS

2 SETPOINT SUM 1

Ratio 1 Ratio 0 Sign 1 Sign 0 Divider 1 Divider 0 Deadband Width Limit Input 2 Input 1 Input 0

Analog

Input 1

Setpoint Sum 1

Tag Parameter

Factory Setting

A/B

Parameter Descriptions SPT. Sum 1 Destination [294] (Set in Configure I/O::Block Diagram Parameters)

Refer to the diagnostics function block description. SPT. Sum Output [86] (Read in Diagnostics Parameters)

Refer to the diagnostics function block description.

Ratio 1

Analog input 1 scaling.

Ratio 0

Input 0 scaling.

Sign 1

Analog input 1 polarity.

Sign 0

Input 0 polarity.

Divider 1

Analog input 1 scaling. Dividing by 0 (zero) results in a zero output.

Divider 0

Input 0 scaling. Dividing by 0 (zero) results in a zero output.

Deadband Width

Analog input 1 deadband width. When Input 1 is within the deadband, the output clamps to zero to ignore any noise.

LIMIT

The Setpoint Sum 1 programmable limit is symmetrical and has the range of 0.00% to 200.00%. The limit is applied both to the intermediate results of the ratio calculation and the total ouput.

INPUT 2

Input 2 value. The factory settings do not connect this input to any analog input.

INPUT 1

Input 1 value. The factory settings connects this input to Analog Input 1 (A2).

INPUT 0

Input 0 value. The factory settings do not connect this input to any analog input.

SPT Sum

Destination

[294]

[86]

Diagnostic

Connection

Range: 0 to 549 Range: R/O Range: –3.0000 to 3.0000 Range: –3.0000 to 3.0000 Range: 0 : Negative

1 : Positive

Range: 0 : Negative

1 : Positive

Range: –3.0000 to 3.0000 Range: –3.0000 to 3.0000 Range: 0.00 to 100.00 % (h)

Range: 0 : False

1 : True Range: –200.00 to 200.00 % Range: –200.00 to 200.00 % Range: –200.00 to 200.00 %

6-38 Programming MN792

Speed Loop

Speed loop selects the speed feedback source and tunes the speed loop PI to produce a current demand. The parameters are set in several menus, some parameters can be set in multiple menus. Speed FBK Select determines the source of the speed feedback signal. The default, Arm Volts FBK, uses internal circuitry to derive speed feedback. The other selections require external devices to provide the feedback signal. Speed Demand is summed algebraically with Speed Feedback to yield Speed Error. When the drive is enabled, Speed Error is controlled by the PI loop. Proportional and integral values are set in the Advanced::Adaption block. The resulting current demand signal is sent to the Current Loop block and to the Advanced::Zero SPD. Quench block.

1 SETUP PARAMETERS

2 SPEED LOOP

Speed PROP Gain Speed INT Time INT Defeat Encoder Sign Speed FBK Select Speed FBK Filter

1 CONFIGURE DRIVE

Speed FBK Select Encoder Sign Speed INT Time Speed PROP Gain

Speed Loop

[119]

Analog Input 2

Tag# Parameter Factory Setting [7] Ratio 2 (A3) 1.0000 Sec

[9] Sign 2 (A3) Positive

[290] Setpoint 2 0.00% [41] Setpoint 4 1.0000 Sec [289] Setpoint 1 SPT Sum Out [291] Setpoint 3 Ramp Out [357] MAX Demand 105.00% [358] MIN Demand -105.00% [13] INT Time Constant 0.500 Sec [14] PROP Gain 10.00

Advanced Adaption

Tag# Parameter Factory Setting [270] SPD BRK2 (High) 5.00%

[269] SPD BRK2 (Low) 1.00% [268] Mode 0 [271] PROP Gain 5.00 [272] INT Time Constant 0.500 Sec

1 SETUP PARAMETERS

2 SPEED LOOP

3 SETPOINTS

Setpoint 1 Sign 2 (A3) Ratio 2 (A3) Setpoint 3 Setpoint 4 MAX Demand MIN Demand

I DMD Isolate (from Current Loop)

1 SETUP PARAMETERS

2 SPEED LOOP

3 ADVANCED

4 ADAPTION

Mode Speed BRK1 (Low) Speed BRK2 (High) PROP Gain

+ +

1 SETUP PARAMETERS

2 SPEED LOOP

3 ADVANCED

I Gain in Ramp POS Loop P Gain

+ / -

Zero SPD Quench

Tag# Parameter Factory Setting

[284] Zero SPD Level 0.50%

[285] Zero IAD Level 1.50%

1 SETUP PARAMETERS

2 SPEED LOOP

3 ADVANCED

4 ZERO SPD QUENCH

Zero SPD Level Zero IAD Level

Speed Setpoint

To IDMD Isolate Switch (To Current Loop)

Diagnostic

[63]

Connection

Armature SCR Firing Quench

[202] INT Defeat Off [89] Speed Demand

Speed Feedback Select

[47] Speed FBK Select Armature Volts

Analog Tach

Encoder

[49] Encoder Sign (+/-)

Zero SPD Offset

From Calibration Board

+ / -

Note: Encoder analog feedback selection uses analog Tach feedback for the proportional

term of the speed loop PI and encoder feedback for the Integral term. This feedback selection requires that the motor have an analog Tach/Encoder installed. This selection cannot be used with the switchable Tachogenerator board is installed.

Unfiltered Speed Error

Unfiltered Speed Feedback

Current Demand

To Current

[356]

Loop

Diagnostic

[64]

Connection

Diagnostic

[297]

Connection

Diagnostic

[62]

Connection

Diagnostic

[207]

Connection

Programming 6-39MN792

Speed Loop Continued

Parameter Descriptions Speed Loop Output SPD Loop Output (Read in Diagnostics Parameters)

Output from Speed Loop PI. Speed Feedback (Read in Diagnostics Parameters)

The speed feedback value from the source chosen by SPEED FBK SEL. Speed Setpoint (Read in Diagnostics Parameters)

Speed loop total setpoint including the ramp output before the ramp–to–zero function. Speed Error (Read in Diagnostics Parameters)

Speed loop error. Speed PROP. Gain (Can be set in Speed Loop or Configure Drive.)

Speed loop Pi proportional gain adjustment. Speed INT. Time (Can be set in Speed Loop or Configure Drive.)

Speed loop PI integral gain adjustment.

INT. DEFEAT

Inhibits the integral part of the speed loop PI to give proportional control only. Encoder Sign (Can be set in Speed Loop or Configure Drive.)

Since the encoder feedback cannot be reversed electrically, the signal polarity can be reversed by the control software.

Speed FBK Select (Can be set in Speed Loop or Configure Drive.) Four options are available:

0 : ARM Volts FBK 1 : Analog TACH 2 : Encoder 3 : Encoder/Analog

Setpoint 1

Speed Setpoint 1.

Sign 2 (A3)

Speed Setpoint 2 Sign.

Parameter Descriptions Ratio 2 (A3)

Speed Setpoint 2 Ratio. Setpoint 2 (A3) This is a fixed (non–configurable) input.

This setpoint is scanned synchronously with the current loop .

Setpoint 3

Speed Setpoint 3.

Setpoint 4

Speed Setpoint 4.

MAX Demand

Sets the maximum input to the speed loop. It is clamped at 105% to allow for overshoot in the external loops.

MIN Demand

Sets the minimum input to the speed loop. I Gain in Ramp Range:

Range: xxx.xx % Range: xxx.xx % Range: xxx.xx % Range: xxx.xx % Range: 0.00 to 200.00 Range: 0.001 to 30.000 Range: 0 : Off Range: 0 : Negative

Range: 0 to 3

Range: –105.00 to 105.00 % Range: 0 : Negative

Range: –3.0000 to 3.0000 Range: xxx.xx % Range: –105.00 to 105.00 % Range: –105.00 to 105.00 % Range: 0.00 to 105.00 %

Range: –105.00 to 105.00 %

Seconds

1 : On

1 : Positive

POS Loop P Gain Range: Zero SPD Level Range: Zero IAD Level Range:

Functional Description

Speed Loop PI Output – The PI output is available for connection using tag no. 356. This point is before the I Limit clamps

and the summing of the additional current demand. This tag is not visible at the keypad. Speed Loop PI with Current Demand Isolate – The speed loop output is still valid (active) with the I DMD. Isolate parameter

enabled.

1. The speed loop is reset by unquenching the speed loop/current loop.

2. I DMD. ISOLATE is overridden by Program Stop (B8) or Normal Stop (C3).

3. The speed loop PI holds the integral term as soon as the PI output reaches current limit. This is true even in Current

Demand Isolate mode where it may interfere depending on the way the speed PI is used. At the present time. this feature cannot be suppressed.

105% Speed Demands – The speed demand clamping allows the speed setpoint to reach 105%. This applies only to the final summing junction immediately before the speed loop and also to the Setpoint Sum 1 output. Individual speed setpoints are still clamped to 100%.

6-40 Programming MN792

Speed Loop Continued

Advanced This function block is shown in Speed Loop

Adaption Adjusts speed loop gain scheduling.

Zero SPD Quench Similar to Standstill logic (i.e. keeps the contactor in but motor current drops to zero) except

the speed loop stays enabled and will cause the current loop to unquench very quickly.

1 SETUP PARAMETERS

2 SPEED LOOP

3 ADVANCED

4 ADAPTION

Mode Speed BRK1 (Low) Speed BRK2 (High) PROP Gain SPD INT Time

2 SPEED LOOP

3 ADVANCED

I Gain in Ramp POS Loop P Gain

1 SETUP PARAMETERS

2 SPEED LOOP

3 ADVANCED

4 ZERO SPD QUENCH

Zero SPD Level Zero IAD Level

Parameter Descriptions Mode

0 – Disabled 1 – Speed Feedback Dependent 2 – Speed Error Dependent 3 – Current Demand Dependent

SPD BRK 1 (Low)

If Mode = 1 Then BRK–points correspond to speed feedback. If Mode = 2 Then BRK–points correspond to speed error. If Mode = 3 Then BRK–points correspond to current demand.

SPD BRK 2 (High)

Above SPD BRK 2 (HIGH) the normal gains (as per main menu above) prevail. Between the two breakpoints, a linear variation of the gains is implemented.

PROP. Gain

Prop gain used below SPD BRK 1 (LOW)

SPD INT Time

Integral time constant used below SPD BRK 1 (LOW)

I Gain IN Ramp

While the Ramping flag (Tag [113]) is true the integral gain is scaled by I GAIN IN RAMP. This can be used to help prevent integral windup while the drive is ramping (particularly with high inertia loads).

POS. LOOP P GAIN

Reserved parameter.

Zero SPD. Level

Sets the threshold of speed feedback below which Zero Speed Quench is active.

Zero IAD Level

Sets the threshold of current feedback below which Zero Speed Quench is active.

Range: 0 to 3

Range: 0.00 to 100.00 %

Range: 0.00 to 200.00 Range: 0.001 to 30.000

Seconds

Range: 0.0000 to 2.0000

Range: –200.00 to 200.00 % Range: 0.00 to 200.00 % Range: 0.00 to 200.00 %

Programming 6-41MN792

Standstill Standstill logic is used to inhibit rotation during Zero Speed demand. If the drive is below the zero speed

threshold [12] and Standstill Logic [11] is enabled, the speed and current loops are quenched to prevent shaft oscillation around zero speed. Standstill Logic is useful in maintaining absolute zero speed but can cause problems in web handling applications using tension feedback. At zero speed, the SCR’s turn off allowing web tension to pull the driven roll in reverse. When the drive no longer senses zero speed, the SCR’s turn on causing forward rotation and regulate tension. An oscillation condition can result as the drive SCR’s turn on and off trying to maintain a fixed position. A “not at standstill” signal is sent to the drive enable logic.

When Speed Feedback is less than Zero Threshold, the At Zero Speed output is On. At Zero Setpoint is on when Speed Setpoint is less than Zero Threshold. When both At Zero Speed and At Zero Setpoint are on, At Standstill is on to indicate the motor has stopped.

When Standstill Logic is enabled, the SCR firing circuits are disabled, the main contactor remains energized and the Run Led stays on when the drive is at standstill. The drive remains in this state until standstill drops out (the speed setpoint or speed feedback increase above the zero threshold value).

1 SETUP PARAMETERS

2 STANDSTILL

Standstill Logic Zero Threshold Source Tag

Speed Feedback from [62] Speed Loop

Speed Setpoint from [63] Speed Loop

Parameter Descriptions AT Zero Setpoint (Read in Diagnostics Parameters)

At zero speed demand. AT Zero Speed (Read in Diagnostics Parameters)

At zero speed feedback. AT Standstill (Read in Diagnostics Parameters)

At zero speed and zero setpoint. Source Tag (Zero Setpoint)

Reserved parameter. Standstill Logic

If true, the control is quenched (although the contactor remains in) when the speed feedback and speed setpoint values are less than zero threshold.

Zero Threshold

Threshold level which defines zero setpoint and zero speed diagnostic outputs and also controls the zero speed relay output.

Functional Description

Standstill logic inhibits the controller at zero setpoint and zero speed, i.e. at standstill. The main contactor remains in and the Run LED remains on.

Disabled

Standstill Logic

Speed Feedback

Speed Setpoint

2% 0%

-2%

Zero Treshold

Standstill

Tag# Parameter Factory Setting [306] Source Tag 89

[12] Zero Threshold 2.00% [11] Standstill Logic Disabled

Enabled

Speed Feedback

Curve depends on load characteristics

At Zero Speed

At Zero Setpoint

At Standstill

Diagnostic

Connection

Digital Output 1 (B5)97[77]

[78]

[79]

Not At Standstill" To Enable circuit

Range: 0 : False

1 : True Range: 0 : False

1 : True Range: 0 to 549

Range: 0 : Disabled

1 : Enabled Range: 0.00 to 100.00 %

Enabled

Drive Enable

Enabled

Disabled

6-42 Programming MN792

Stop Rates

Sets the stop method parameters for the control. A normal stop occurs when the Run signal is removed from terminal C3. It ramps the speed demand to zero at a rate set by Stop Time. Series 29 Non–regenerative drives will stop no faster than the coast stop rate. Series 30 Regenerative drives use Stop Time to set the duration of the stop. After the stop, the contactor de–energizes and the drive disables. The Stop Limit timer starts when C3 goes to zero volts. If the drive speed has not reached Stop Zero Speed within the Stop Limit time, the contactor de–energizes and the drive disables.

During normal stops, Contactor Delay delays de–energizing the contactor after the motor reaches zero speed. When Stop Zero Speed is set greater than 0.25%, the drive disables during the contactor delay. Below 0.25%, the drive disables after the contactor delay. This is useful when using the jog function to prevent multiple operations of the contactor. Contactor Delay is overridden when terminal C4 is at zero volts.

Program Stop provides a controlled fast stop using regenerative drives. The stop time is set by Program Stop Time. The timer starts when terminal B8 goes to zero volts. When the drive reaches Stop Zero Speed, the contactor de–energizes and the drive disables. Program Stop Limit sets the maximum time the program stop can take before the contactor de–energizes and the drive disables.

Prog Stop I Lim sets the current limit (current loop) during a program stop. Other current limits can override it.

1 SETUP PARAMETERS

2 STOP RATES

Stop Time Stop Limit Contactor Delay PROG Stop Time PROG Stop Limit PROG Stop I LIM Stop Zero Speed

Program Stop is true when terminal B8 is Low (Status LED Off).

Speed Setpoint from [62] Speed Loop

Drive Start

Speed Feedback from [63] Speed Loop

Program Stop

Stop Rates

Tag# Parameter Factory Setting [91] PROG Stop I Limit 100.00%

[27] Stop Time 10.0 Sec [26] PROG Stop Time 0.1 Sec

[217] Stop Limit 60.0 Sec [216] PROG Stop Limit 60.0 Sec

[82]

[29] Stop Zero Speed 2.00%

[302] Contactor Delay 1.0 Sec

Parameter Descriptions Speed Demand (Read in Diagnostics Parameters)

Speed loop total setpoint after the ramp–to–zero block. Program Stop (Read in Diagnostics Parameters)

State of Program Stop (Terminal B8). When B8 is at 24V, then Program Stop is false and the Program Stop front panel LED is also on.

Stop Time Time to reach zero speed from 100% set speed in normal stop mode (C3 Off).

Stop Limit Delay time limit to allow normal stop action (regenerative breaking) to achieve zero speed before drive quench and coast stop. The timer is triggered by Start command (C3) going low.

Contactor Delay This defines the time between the drive reaching Stop Zero Speed (Tag [29]) and the contactor being opened. This is particularly useful during the jog cycle to prevent multiple operations of the main contactor. If Stop Zero Speed is ≥ 0.25%, the drive will be quenched during the contactor delay time. The Contactor delay is overridden by Enable (C4).

Maintain zero speed during contactor delay.

If Stop Zero Speed is < 0.25%, the drive is not quenched until after the Contactor Delay time. PROG Stop Time

Time to reach zero speed from 100% set speed in program stop mode (B8 OFF). PROG Stop Limit

Delay time limit to allow program stop action (regenerative breaking) to achieve zero speed before drive quench and coast stop. The timer is triggered by program stop command (B8) going low.

PROG Stop I LIM

Main current limit level in program stop mode assuming current limit not overridden by I Profile or Inverse Time limits.

Stop Zero Speed

Zero speed level in program stop and normal stop modes at which the contactor delay timer starts timing out. At the end of this delay the contactor is de–energized.

PROG Stop I Limit

To Current Loop

Speed

[89]

Demand

To Coast Stop Logic

Range: xxx.xx % Range: 0 : False

1 : True

Range: 0.1 to 600.0

Seconds

Range: 0.0 to 600.0

Seconds

Range: 0.1 to 600.0

Seconds

Range: 0.1 to 600.0

Seconds

Range: 0.0 to 600.0

Seconds

Range:

Range: 0.00 to 100.00 %

Programming 6-43MN792

Stop Rates Continued Functional Description

Stop Hierarchy

Note: The Control’s reaction to commands is defined by a state machine. This determines which commands

Normal Stop Sequence

Stop Zero Speed settings less than 0.25% allow the control to remain enabled for the Contactor Delay Time after reaching Stop Zero Speed. This is useful for Jog applications.

100

Coast Stop – Terminal B9

• Disables the drive and opens the contactor using the pilot output

Enable – Terminal C4

• Suspends and resets the control loops

Program Stop – Terminal B8

• Independent ramp time

• Stop Timer

• Independent current limit may be greater than normal current limit

• Independent zero speed

Normal Run/Stop – Terminal C3

• Independent ramp time

• Contactor Delay

provide the demanded action, and in which sequence. Consequently, Coast Stop and Program Stop must be false (the Control is not in Coast or Program mode), before a Run signal is applied. Otherwise the control assumes a stop mode and remains disabled.

Start / Run (C3)

Speed Setpoint %

Speed Demand %

Speed Feedback %

Drive Enable

100

Stop Zero Speed 2.00%

Enabled

Stop Time

10.0 Seconds

Actual stop rate depends on load inertia, motor horse power and overload capacity of drive (motor + control)

Control is disabled below Stop Zero Speed if set>0.25%

Control remains enabled for the Contactor Delay if Stop Zero Speed <0.25%

Disabled

6-44 Programming MN792

Baldor mn792 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents