Baldor mn792 User Manual

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

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Baldor mn792 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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