Baldor SD23H2A03–E, SD23H2A04–E, SD23H2A04–W, SD23H2A07–E, SD23H2A10–E Installation & Operating Manual

...

Download

SERIES 23H

AC Servo Control

Installation & Operating Manual

9/03 MN723

Table of Contents

Section 1

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

Section 2

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

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

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

Safety Notice 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3

Receiving & Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving & Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Physical Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Installation 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Installation Procedure 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Remote Keypad Installation 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Installation 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Grounding 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Impedance 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Reactors 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Reactors 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Main Circuit Considerations 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection Devices 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Disconnect 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Size and Protection Devices 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Line Connections 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reduced Input Voltage Derating 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

380-400 VAC Operation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Phase Input Power 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Phase Input Power Considerations 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Phase Control Derating 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size A, B and B2 Single Phase Power Installation 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size C2 Single Phase Power Installation 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size C and D Single Phase Power Installation 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size D2 Single Phase Power Installation 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size E Single Phase Power Installation 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size F Single Phase Power Installation 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Connections 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M-Contactor 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Dynamic Brake Hardware 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Installation 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resolver Feedback 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Simulated Encoder Output 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Home (Orient) Switch Input 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iMN723

Operating Modes 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Inputs 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Outputs 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial Operating Mode 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Operating Mode 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Run 3 Wire Operating Mode 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 Speed 2-Wire Operating Mode 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Speed Analog 2 Wire Operating Mode 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Speed Analog 3 Wire Operating Mode 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bipolar Speed or Torque Operating Mode 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multiple Parameter Sets 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process Operating Mode 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Pot 2 Wire Operating Mode 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Pot 3 Wire Control Mode 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Trip Input 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opto-Isolated Inputs 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opto-Isolated Outputs 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Operation Checklist 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power-Up Procedure 3-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4

Programming and Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Display Contrast 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Mode Screens 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Information Access 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Log Access 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Mode 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Blocks Access for Programming 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Parameter Values when Security Code Not Used 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reset Parameters to Factory Settings 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initialize New Software 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Definitions 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii Table of Contents MN723

Section 5

Troubleshooting 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No Keypad Display - Display Contrast Adjustment 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Access Diagnostic Information 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Access the Fault Log 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Clear the Fault Log 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resolver Troubleshooting 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Noise Considerations 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relay and Contactor Coils 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wires between Controls and Motors 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Drive Situations 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Enclosures 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Motor Considerations 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Signal Wires 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6

Manual Tuning the Series 23H Control 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manually Tuning the Control 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Prop Gain Parameter 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current INT Gain Parameter 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Prop Gain Parameter 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Int Gain Parameter 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PI Controller 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7

Specifications, Ratings & Dimensions 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Conditions 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resolver Feedback 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Display 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Specifications 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Analog Input 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Outputs 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Inputs 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Outputs 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Indications 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ratings 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminal Tightening Torque Specifications 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iiiMN723

Dimensions 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size A Control 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size B Control 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size B2 Control 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size C Control 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size C2 Control 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size C2 Control – Through–Wall Mounting 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size D Control 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size D2 Control 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size D2 Control – Through–Wall Mounting 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size E Control 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size F Control 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size G Control 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dynamic Braking (DB) Hardware A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RGA Assemblies A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RBA Assemblies A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RTA Assemblies A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Appendix C C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Keypad Mounting Template C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv Table of Contents MN723

Section 1 Quick Start Guide

Overview If you are an experienced user of Baldor controls, you are probably already familiar with

the keypad programming and keypad operation methods. If so, this quick start guide has been prepared for you. This procedure will help get your system up and running in the Keypad mode quickly. This will allow motor and control operation to be verified. This procedure assumes that the control, motor and dynamic brake hardware are correctly installed (see Section 3 for procedures) and that you have an understanding of the keypad programming & operation procedures. It is not necessary to wire the terminal strip to operate in the keypad mode (Section 3 describes terminal strip wiring procedures). The quick start procedure is as follows:

1. Read the Safety Notice and Precautions in section 2 of this manual.

2. Mount the control. Refer to Section 3 “Physical Location” procedure.

3. Connect AC power, refer to Section 3 “Three Phase Motor and Control Connections”.

4. Connect the motor, refer to Section 3 “Three Phase Motor and Control Connections”.

5. Connect the resolver, refer to Section 3 “Resolver Feedback”.

6. Install dynamic brake hardware, if required. Refer to Section 3 “Optional Dynamic Brake Hardware”.

7. Connect the keypad to the keypad connector of the main control board. Refer to Section 3 “Keypad Installation Procedure”.

Quick Start Checklist Check of electrical items.

CAUTION: After completing the installation but before you apply power, be

sure to check the following items.

1. Verify AC line voltage at source matches control rating.

2. Inspect all power connections for accuracy, workmanship and torque as well as compliance to codes.

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

4. Check all signal wiring for accuracy.

5. Be certain all brake coils, contactors and relay coils have noise suppression. This should be an R-C filter for AC coils and reverse polarity diodes for DC coils. MOV type transient suppression is not adequate.

WARNING: Make sure that unexpected operation of the motor shaft during start

up will not cause injury to personnel or damage to equipment.

Check of Motors and Couplings

1. Verify freedom of motion of the motor shaft.

2. Verify that all motor couplings are tight without backlash.

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

Quick Start Guide 1-1MN723

Section 1 General Information

Quick Start Procedure

Initial Conditions

Be sure the 23H control, motor and dynamic brake hardware are installed and wired according to the procedures in Section 3 of this manual. Become familiar with the keypad programming and keypad operation of the control as described in Section 4 of this manual.

1. Disconnect the load (including coupling or inertia wheels) from the motor shaft, if possible.

2. Verify that any enable inputs to J1-8 are open. Be sure Level 2 Protection block, Local Enable INP is OFF and Level 2 Protection block, External Trip is OFF.

3. Turn power on. Be sure no errors are displayed.

4. Set the Level 1 Input block, Operating Mode parameter to “KEYPAD”.

5. Set the Level 2 Output Limits block, “OPERATING ZONE” parameter as desired (STD CONST TQ, STD VAR TQ, QUIET CONST TQ or QUIET VAR TQ).

6. Enter the following motor data in the Level 2 Motor Data block parameters: Motor Rated Amps (IC) Motor Poles Resolver Speeds (Pre-set is one speed)

7. If external dynamic brake hardware is used, set the Level 2 Brake Adjust block “Resistor Ohms” and “Resistor Watts” parameters.

8. If the load was not disconnected in step 1, refer to Section 6 and manually tune the control. After manual tuning, perform steps 11 and 12 then continue with step 16.

9. At the Level 2 Motor Data block, press ENTER, at CALC PRESETS select YES (using the  key) and let the control calculate preset values for the parameters that are necessary for control operation.

WARNING: The motor shaft will rotate during the autotune procedure. Be

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

10. Go to Level 2 Autotune block, and perform the following tests:

CMD OFFSET TRIM CUR LOOP COMP RESOLVER ALIGN

11. Set the Level 2 Output Limits block, “MIN OUTPUT SPEED” parameter.

12. Set the Level 2 Output Limits block, “MAX OUTPUT SPEED” parameter.

13. Remove all power from the control.

14. Couple the motor to its load.

15. Turn power on. Be sure no errors are displayed.

16. Perform the SPD CNTRLR CALC test in the Level 2 Autotune block.

17. Run the drive from the keypad using the arrow keys for direct speed control, a keypad entered speed or the JOG mode.

18. Select and program additional parameters to suit your application.

The control is now ready for use the in keypad mode. If a different operating mode is desired, refer to Section 3 Control Connections and Section 4 Programming and Operation.

1-2 Quick Start Guide MN723

Section 2 General Information

Overview The Baldor Series 23H PWM control uses a closed loop control scheme using an

algorithm to adjust the phase of voltage and current applied to a three phase permanent magnet synchronous motor. The servo control adjusts the motor current to produce maximum torque from base speed down to and including zero speed. The frequency of the voltage applied to the motor follows the electrical cycles per revolution based on the mechanical speed of the rotor. This provides instantaneous adjustment of the voltage and current phasing in response to speed and position feedback from a resolver mounted to the motors’ shaft.

General Information 2-1MN723

Limited Warranty

For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without charge controls and accessories which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or implied. BALDOR shall not be held responsible for any expense (including installation and removal), inconvenience, or consequential damage, including injury to any person or property caused by items of our manufacture or sale. (Some states do not allow exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply.) In any event, BALDOR’s total liability, under all circumstances, shall not exceed the full purchase price of the control. Claims for purchase price refunds, repairs, or replacements must be referred to BALDOR with all pertinent data as to the defect, the date purchased, the task performed by the control, and the problem encountered. No liability is assumed for expendable items such as fuses.

Goods may be returned only with written notification including a BALDOR Return Authorization Number and any return shipments must be prepaid.

2-2 General Information MN723

Safety Notice This equipment contains voltages that may be as high as 1000 volts! Electrical shock

can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

PRECAUTIONS

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

connection before you first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

WARNING: This unit has an automatic restart feature that will start the motor

whenever input power is applied and a RUN (FWD or REV) command is issued. If an automatic restart of the motor could cause injury to personnel, the automatic restart feature should be disabled by changing the Level 2 Miscellaneous block, Restart Auto/Man parameter to Manual.

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

disconnected to allow capacitors to discharge. Dangerous voltages are present inside the equipment. Electrical shock can cause serious or fatal injury.

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

this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

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

Do not apply AC power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury.

WARNING: Improper operation of control may cause violent motion of the

motor shaft and driven equipment. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment. Certain failure modes of the control can produce peak torque of several times the rated motor torque.

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

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

WARNING: Dynamic brake resistors may generate enough heat to ignite

combustible materials. Keep all combustible materials and flammable vapors away from brake resistors.

WARNING: The motor shaft will rotate during the autotune procedure. Be

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

Continued on next page

General Information 2-3MN723

Section 1 General Information

Caution: Disconnect motor leads (T1, T2 and T3) from control before you

perform a “Megger” test on the motor. Failure to disconnect motor from the control will result in extensive damage to the control. The control is tested at the factory for high voltage / leakage resistance as part of Underwriter Laboratory requirements.

Caution: Suitable for use on a circuit capable of delivering not more than the

RMS symmetrical short circuit amperes listed here at rated voltage. Horsepower rms Symmetrical Amperes 1–50 5,000 51–200 10,000 201–400 18,000 401–600 30,000 601–900 42,000

Caution: Do not supply any power to the External Trip (motor thermostat)

leads at J1-16 and 17. Power on these leads can damage the control. Use a dry contact type that requires no external power to operate.

Caution: Do not connect AC power to the Motor terminals T1, T2 and T3.

Connecting AC power to these terminals may result in damage to the control.

Caution: Baldor recommends not using “Grounded Leg Delta” transformer

power leads that may create ground loops. Instead, we recommend using a four wire Wye.

Caution: If the DB hardware mounting is in any position other than vertical,

the DB hardware must be derated by 35% of its rated capacity.

Caution: If an M-Contactor is installed, the control must be disabled for at

least 20msec before the M-Contactor is opened. If the M-Contactor is opened while the control is supplying voltage and current to the motor, the control may be damaged.

Caution: Do not connect any shields to the motor frame. At a minimum,

resolver signal integrity will be compromised and damage to the control may result. The resolver shields must be connected at J1-28 only.

2-4 General Information MN723

Section 3 Receiving & Installation

Receiving & Inspection When you receive your control, there are several things you should do immediately.

1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control.

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

3. If the control is to be stored for several weeks before use, be sure that it is stored in a location that conforms to published storage temperature and humidity specifications. (Refer to Section 7 of this manual).

Physical Location The mounting location of the control is important. It should be installed in an area that is

protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, shock and vibration.

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

1. For effective cooling and maintenance, the control should be mounted vertically on a flat, smooth, non-flammable vertical surface. Table 3-1 lists the Watts Loss ratings for enclosure sizing.

2. At least two inches clearance must be provided on all sides for air flow.

3. Front access must be provided to allow the control cover to be opened or removed for service and to allow viewing of the Keypad Display.

Controls packaged in a floor mounted enclosure must be positioned with clearance to open the enclosure door. This clearance will also provide sufficient air space for cooling.

4. Altitude derating. Up to 3300 feet (1000 meters) no derating required. Above 3300 ft, derate the continuous and peak output current by 2% for each 1000 ft.

5. Temperature derating. Up to 40°C no derating required. Above 40°C, derate the continuous and peak output current by 2% per °C. Maximum ambient is 55°C.

Table 3-1 Series 23H Watts Loss Ratings

Enclosure Size 230 VAC 460 VAC

2.5KHz PWM

A, B and B2 14 Watts/

Amp

C, C2, D, D2, E, and F 12 Watts/

Amp

G 15 Watts/

8.0KHz PWM

17 Watts/

Amp

15 Watts/

Amp

2.5KHz PWM

17 Watts/

Amp

15 Watts/

Amp

8.0KHz PWM

26 Watts/

Amp

23Watts/

Amp

Receiving & Installation 3-1MN723

Control Installation The control must be securely fastened to the mounting surface at the mounting holes.

Shock Mounting

If the control will be subjected to levels of shock greater than 1G or vibration greater than

0.5G at 10 to 60Hz, the control should be shock mounted.

Keypad Installation Procedure

1. Refer to the optional remote keypad installation procedure and mount the keypad.

2. Connect the keypad cable to the keypad connector on the main control board. Refer to Figure 3-30 for the connector location.

3-2 Receiving & Installation MN723

Optional Remote Keypad Installation The keypad may be remotely mounted using the optional Baldor keypad

extension cable. The keypad assembly (white - DC00005A-01; grey - DC00005A-02) comes complete with the screws and gasket required to mount it to an enclosure. When the keypad is properly mounted to a NEMA Type 4X enclosure, it retains the Type 4X rating.

Tools Required:

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

• 8-32 tap and #29 drill bit (for tapped mounting holes) or #19 drill (for clearance mounting holes).

• 1-

/4″ standard knockout punch (1-11/16″ nominal diameter).

• RTV sealant.

• (4) 8-32 nuts and lock washers.

• Extended 8-32 screws (socket fillister) are required if the mounting surface is

thicker than 12 gauge and is not tapped (clearance mounting holes).

• Remote keypad mounting template. A tear out copy is provided at the end of this manual for your convenience.

Mounting Instructions: For tapped mounting holes

1. Locate a flat 4″ wide x 5.5″ minimum high mounting surface. Material should be sufficient thickness (14 gauge minimum).

2. Place the template on the mounting surface or mark the holes as shown.

3. Accurately center punch the 4 mounting holes (marked A) and the large knockout (marked B).

4. Drill four #29 mounting holes (A). Thread each hole using an 8-32 tap.

5. Locate the 1-1/4″ knockout center (B) and punch using the manufacturers instructions.

6. Debur knockout and mounting holes making sure the panel stays clean and flat.

7. Apply RTV to the 4 holes marked (A).

8. Assemble the keypad to the panel. Use 8–32 screws, nuts and lock washers.

9. From the inside of the panel, apply RTV over each of the four mounting screws and nuts. Cover a 3/4″ area around each screw while making sure to completely encapsulate the nut and washer.

Mounting Instructions: For clearance mounting holes

1. Locate a flat 4″ wide x 5.5″ minimum high mounting surface. Material should be sufficient thickness (14 gauge minimum).

2. Place the template on the mounting surface or mark the holes as shown on the template.

3. Accurately center punch the 4 mounting holes (marked A) and the large knockout (marked B).

4. Drill four #19 clearance holes (A).

5. Locate the 1-1/4″ knockout center (B) and punch using the manufacturers instructions.

6. Debur knockout and mounting holes making sure the panel stays clean and flat.

7. Apply RTV to the 4 holes marked (A).

8. Assemble the keypad to the panel. Use 8–32 screws, nuts and lock washers.

9. From the inside of the panel, apply RTV over each of the four mounting screws and nuts. Cover a 3/4″ area around each screw while making sure to completely encapsulate the nut and washer.

Receiving & Installation 3-3MN723

Electrical Installation Interconnection wiring is required between the motor control, AC power source, motor,

host control and any operator interface stations. 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.

Baldor Series H controls feature UL approved adjustable motor overload protection suitable for motors rated at no less than 50% of the output rating of the control. Other governing agencies such as NEC may require separate over–current protection. The installer of this equipment is responsible for complying with the National Electric Code and any applicable local codes which govern such practices as wiring protection, grounding, disconnects and other current protection.

System Grounding Baldor Controls are designed to be powered from standard three phase lines that are

electrically symmetrical with respect to ground. System grounding is an important step in the overall installation to prevent problems. The recommended grounding method is shown in Figure 3-1.

Figure 3-1 Recommended System Grounding

LOCAL

PROG

JOG

DISP

FWD

SHIFT

ENTER

REV

RESET

STOP

AC Main Supply

Safety

Ground

Note: A line reactor is recommended

and must be ordered separately.

L3 Earth

Four Wire

“Wye” Driven Earth Ground Rod

(Plant Ground)

Route all 4 wires L1, L2, L3 and Earth (Ground) together in conduit or cable.

Route all 4 wires T1, T2, T3 and Motor Ground together in conduit or cable.

Series H

L2 L3 T1 T2 T3

Optional Line Reactor

Connect all wires (including motor ground) inside the motor terminal box.

Note: Wiring shown for clarity of grounding

method only. Not representative of actual terminal block location.

Ground per NEC and Local codes.

3-4 Receiving & Installation MN723

System Grounding Continued

Ungrounded Distribution System

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

Input Power Conditioning

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

 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 Baldor control requires a minimum line impedance. 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.

Control Size A, B, C, D, E B2, C2, D2, F, G Line Impedance Required 3% 1%

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

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

%Impedance +

(Volts

No Load Speed

(Volts

* Volts

No Load Speed

Full Load Speed

)

100

Line Reactors Three phase line reactors are available from Baldor. The line reactor to order is based on

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

0.03)

L +

L*L

(I 3Ǹ 377)

Where: L Minimum inductance in Henries.

L-L

0.03 Desired percentage of input impedance. I Input current rating of control. 377 Constant used with 60Hz power.

Input volts measured line to line.

Use 314 if input power is 50Hz.

Load Reactors Line reactors may be used at the control output to the motor. When used this way, they

are called Load Reactors. Load reactors serve several functions that include:

 Protect the control from a short circuit at the motor.  Limit the rate of rise of motor surge currents.  Slowing the rate of change of power the control delivers to the motor.

Load reactors should be installed as close to the control as possible. Selection should be based on the motor nameplate FLA value.

Receiving & Installation 3-5MN723

AC Main Circuit Considerations

Protection Devices Be sure a suitable input power protection device is installed. Use the recommended

circuit breaker or fuses listed in Tables 3-2 through 3-3 (Wire Size and Protection Devices). Input and output wire size is based on the use of copper conductor wire rated at 75 °C. The table is specified for NEMA B motors.

Circuit Breaker: 1 phase, thermal magnetic.

Equal to GE type THQ or TEB for 230 VAC 3 phase, thermal magnetic.

Equal to GE type THQ or TEB for 230 VAC or GE type TED for 460 VAC.

Fast Action Fuses: 230 VAC, Buss KTN

460 VAC, Buss KTS to 600A (KTU 601 - 1200A)

Very Fast Action: 230 VAC, Buss JJN

460 VAC, Buss JJS

Time Delay Fuses: 230 VAC, Buss FRN

460 VAC, Buss FRS to 600A (KLU 601 - 1200A)

Power Disconnect A power disconnect should be installed between the input power service and the control

for a fail safe method to disconnect power. The control will remain in a powered-up condition until all input power is removed from the control and the internal bus voltage is depleted.

Wire Size and Protection Devices

Table 3-2 230VAC Controls (3 Phase) Wire Size and Protection Devices

Control Output Rating

Amps HP

3 0.75 5 4 14 2.5 4 1 6 5 14 2.5

7 2 10 9 14 2.5 10 3 15 12 14 2.5 16 5 25 20 12 3.31 22 7.5 30 30 10 5.26 28 10 40 45 35 8 8.37 42 15 60 70 60 6 13.3 54 20 70 80 70 6 13.3 68 25 90 100 90 4 21.2 80 30 100 125 110 3 26.7

104 40 150 175 150 1 42.4 130 50 175 200 175 1/0 53.5 145 60 200 225 200 2/0 67.4 192 75 250 300 250 4/0 107.0

Input Breaker

(Amps)

Input Fuse (Amps) Wire Gauge

Fast Acting Time Delay AWG mm

Note: All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may be used per NEC

and local codes. Recommended fuses/breakers are based on 40°C ambient, maximum continuous control output current and no harmonic current.

3-6 Receiving & Installation MN723

T able 3-3 460VAC Controls (3 Phase) Wire Size and Protection Devices

Control Output Rating Input Breaker Input Fuse (Amps) Wire Gauge

Amps HP

2 0.75 2 2 14 2.5 2 1 3 2.5 14 2.5 4 2 6 5 14 2.5 5 3 8 7 14 2.5 8 5 12 10 14 2.5

11 7.5 20 15 14 2.5 14 10 25 20 12 3.31 21 15 30 30 25 10 5.26 27 20 40 40 35 10 5.26 34 25 50 50 45 8 8.37 40 30 50 60 50 8 8.37 52 40 70 80 70 6 13.3 65 50 90 100 90 4 21.2 77 60 100 125 100 3 26.7 96 75 125 150 125 2 33.6

124 100 175 200 175 1/0 53.5

(Amps)

Fast Acting Time Delay AWG mm

Note: All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may be used per NEC

and local codes. Recommended fuses/breakers are based on 40°C ambient, maximum continuous control output current and no harmonic current.

Receiving & Installation 3-7MN723

AC Line Connections

Reduced Input Voltage Derating All power ratings stated in Section 7 are for the stated nominal AC input

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

Examples:

A 10HP, 230VAC control operating at 208VAC has a reduced power rating of 9.04HP.

10HP

Likewise, a 10HP, 460VAC control operating at 380VAC has a reduced power rating of

8.26HP. 10HP

To obtain the full output rating of 10HP in either case requires a 15HP Control.

380-400 VAC Operation Size A, B, B2, C2 and D2 460VAC controls may be used directly with a 380-400 VAC

power source, control modification is not necessary. Size C, D, E, F and G 460VAC controls all require modification for operation on the

reduced line voltage. Specifically, the control transformer must have the wire on terminal 5 (for 460V) moved to terminal 4 (for 380-400V).

208VAC 230VAC

380VAC 460VAC

1. Be sure drive operation is terminated and secured.

2. Remove all power sources from the control. If power has been applied, wait at least 5 minutes for bus capacitors to discharge.

3. Remove or open the front cover.

4. Remove the wire from terminal 5.

5. Place the wire that was removed from terminal 5 onto terminal 4.

6. Install or close the front cover.

+ 9.04HP

+ 8.26HP

Figure 3-2 Control Transformer Identification

3-8 Receiving & Installation MN723

Tap Change Procedure (size G controls). See Figure 3-3.

Figure 3-3 Size G - Control Transformer Terminal Block

460VAC 380-400VAC

Three Phase Input Power

Three phase AC power connections are shown in Figure 3-4. The 23H control has an electronic I2t motor overload protection. If motor overloads are desired, they should be sized according to the manufacturers specifications and installed between the motor and the T1, T2 and T3 terminals of the control.

1. Be sure drive operation is terminated and control is disabled.

2. Remove all power sources from the control. If power has been applied, wait at least 5 minutes for bus capacitors to discharge.

3. Remove or open the front cover and locate the control transformer (Figure 3-3).

4. Remove the wires from the two right side terminals.

5. Place the wires on the center terminals as shown.

6. Install or close the front cover.

Note: Use same gauge wire for earth ground as is used for L1, L2 and L3

connections. Refer to the wire size and protection devices tables shown previously in this section.

Note 1

Note 3

Note 4

Note 3

* Circuit Breaker

*Optional

Line

Reactor

L1 L2 L3

A1 B1 C1

A2 B2 C2

L1 L2 L3

Baldor

Series 23H

Control

Figure 3-4 Three Phase AC Power Connections

Earth

Note 2

Alternate *

Fuse

Connection

L1 L2 L3

Note 1

A1 B1 C1

* Optional components not provided with control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.

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

4. See Line/Load Reactors described previously in this section.

See Recommended Tightening Torques in Section 7.

Receiving & Installation 3-9MN723

Table 3-4 and 3-5 list the wire size for the input AC power wires. Motor leads should be sized from the 3 phase tables.

Table 3-4 Single Phase Rating Wire Size and Protection Devices - 230 VAC Controls*

Control Output Rating

Amps HP

6.9 0.75 10 9 14 2.5

8.0 1 12 10 14 2.5 12 2 20 17.5 14 2.5 17 3 25 25 12 3.31 28 5 45 35 10 5.26 40 7.5 60 50 8 8.37 50 10 70 80 70 6 13.3 68 15 90 110 90 4 21.2 88 20 110 150 125 3 26.7

110 25 150 175 150 2 33.6 136 30 175 200 175 1/0 53.5 176 40 225 250 250 3/0 85.0 216 50 275 350 300 (2) 1/0 (2) 53.5

Input Breaker

(Amps)

Input Fuse (Amps) Wire Gauge

Fast Acting Time Delay AWG mm

Table 3-5 Single Phase Rating Wire Size and Protection Devices - 460 VAC Controls*

Control Output Rating

Amps HP

3.5 0.75 5 5 14 2.5

4.0 1 6 5.6 14 2.5

6.0 2 10 8 14 2.5

8.5 3 15 12 14 2.5 14 5 20 20 12 3.31 20 7.5 30 25 10 5.26 25 10 40 30 10 5.26 34 15 45 50 45 8 8.37 44 20 60 70 60 8 8.37 55 25 70 80 70 6 13.3 68 30 90 100 90 4 21.2 88 40 110 150 125 3 26.7

108 50 150 175 150 2 33.6

Input Breaker

(Amps)

Input Fuse (Amps) Wire Gauge

Fast Acting Time Delay AWG mm

*Note:All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may be used per NEC

and local codes. Recommended fuses/breakers are based on 40°C ambient, maximum continuous control output current and no harmonic current.

3-10 Receiving & Installation MN723

Single Phase Input Power Considerations Single phase operation of G and H size controls is not possible.

Single phase AC input power can be used to power the control instead of three phase for control sizes A, B, B2, C, C2, D, D2, E and F. The specifications and control sizes are listed in Section 7 of this manual. If single phase power is to be used, the rated Horsepower of the control may have to be reduced (derated). In addition, power wiring and jumper changes are required.

Single phase rating wire size and protection devices are listed in Tables 3-4 and 3-5.

Single Phase Control Derating: Single phase power derating requires that the continuous and peak current ratings

of the control be reduced by the following percentages:

1. 3–10A 230 and 2–5A 460 VAC controls: No derating required.

2. 15–28A (Size B and B2) 230 and 5–15A 460 VAC controls: Derate HP by 40% of the nameplate rating.

3. 42–55A (Size C) and Larger 230 and 460 VAC controls: Derate HP by 50% of the nameplate rating.

Size A, B and B2 Single Phase Power Installation (See Figure 3-5.)

Jumper Configuration

Size A, B and B2 controls, no jumper changes required.

Note 1

Note 3

Note 4

Note 3

Figure 3-5 Size A, B and B2 Single Phase 230/460VAC Power Connections

* Circuit

Breaker

*Optional

Line

Reactor

L1 L2

A1 B1

A2 B2

L1 L2 L3

Baldor

Control

Earth

L1 L2

* Fuse

Connection

Note 2

A1 B1

* Optional components not provided with control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.

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

4. See Line/Load Reactors described previously in this section.

See Recommended Tightening Torques in Section 7.

Note 1

Receiving & Installation 3-11MN723

Size C2 Single Phase Power Installation (See Figure 3-7.)

Jumper Configuration

Locate the Interface board, and place JP7 on pins 2 & 3 for single phase operation.

Figure 3-6 Jumper Configuration

Control Board

Bend plastic insulator upward to access the Interface Board.

L1 L2

Note 1

Note 3

Note 4

Note 3

* Circuit

Breaker

*Optional

Line

Reactor

A1 B1

A2 B2

L1 L2 L3

JP7

Interface Board

JP7 Pins 1 & 2 = Three Phase Pins 2 & 3 = Single Phase

Figure 3-7 Size C2 Single Phase 230/460VAC Power Connections

Baldor

Control

Earth

* Fuse

Connection

Note 2

* Optional components not provided with control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.

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

4. See Line/Load Reactors described previously in this section.

L1 L2

Note 1

A1 B1

See Recommended Tightening Torques in Section 7.

3-12 Receiving & Installation MN723

Size C and D Single Phase Power Installation (See Figure 3-9.)

Figure 3-8 Jumper Configuration

Place JP2 on pins 1 & 2 for control single phase operation.

Place JP3 in position B for fan single phase operation.

Note 1

Note 3

Note 4

Note 3

JP2 Pins 1 & 2 = Single Phase Pins 2 & 3 = Three Phase

Figure 3-9 Size C & D Single Phase 230/460VAC Power Connections

L1 L2

* Circuit

Breaker

B1 C1

*Optional

Line

Reactor

B2 C2

L1 L2 L3

Baldor

Control

JP3

Position A = Three Phase Position B = Single Phase

JP2 1

JP3

Earth

Note 2

* Fuse

Connection

L1 L2

Note 1

B1 C1

* Optional components not provided with control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.

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

4. See Line/Load Reactors described previously in this section.

See Recommended Tightening Torques in Section 7.

Receiving & Installation 3-13MN723

Size D2 Single Phase Power Installation (see Figure 3-11)

Jumper Configuration

Locate the Interface board, and place J100 on pins 2 & 3 for single phase operation.

Figure 3-10 Jumper Configuration

Note 1

Note 3

Note 4

Note 3

* Circuit

Breaker

*Optional

Line

Reactor

J100 Pins 1 & 2 = Three Phase Pins 2 & 3 = Single Phase

1 2 3

J100

Figure 3-11 Size D2 Single Phase 230/460VAC Power Connections

L1 L2

A1 B1

A2 B2

L1 L2 L3

Baldor

Control

Earth

L1 L2

* Fuse

Connection

Note 2

A1 B1

* Optional components not provided with control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.

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

4. See Line/Load Reactors described previously in this section.

Note 1

See Recommended Tightening Torques in Section 6.

3-14 Receiving & Installation MN723

Size E Single Phase Power Installation (See Figure 3-13.)

Figure 3-12 Jumper Configuration

Place JP1 on the High Voltage Circuit Board across pins 1 and 2.

Note 1

Note 3

Note 4

Note 3

* Circuit Breaker

*Optional

Line

Reactor

JP1

Pins 1 & 2 = Single Phase Pins 2 & 3 = Three Phase

JP1

Figure 3-13 Size E Single Phase 230/460VAC Power Connections

L1 L2

A1 B1

A2 B2

L1 L2 L3

Baldor

Control

Earth

L1 L2

* Fuse

Connection

A1 B1

Note 1

* Optional components not provided with control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.

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

4. See Line/Load Reactors described previously in this section.

See Recommended Tightening Torques in Section 7.

Receiving & Installation 3-15MN723

Size F Single Phase Power Installation (See Figure 3-15.)

Figure 3-14 Jumper Configuration

Place JP2 on the High Voltage Circuit Board across pins 1 and 2.

Figure 3-15 Size F Single Phase 230/460VAC Power Connections

Note 1

L1 L2

* Circuit Breaker

Earth

Note 2

* Fuse

Connection

JP2

Pins 1 & 2 = Single Phase Pins 2 & 3 = Three Phase

L1 L2

Note 1

Note 3

Note 4

Note 3

B1 C1

*Optional

Line

Reactor

B2 C2

L1 L2 L3

Control

Baldor

B1 C1

* Optional components not provided with control.

Notes:

1. See “Protective Devices” described previously in this section.

2. Use same gauge wire for Earth ground as is used for L1, L2 and L3.

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

4. See Line/Load Reactors described previously in this section.

See Recommended Tightening Torques in Section 7.

3-16 Receiving & Installation MN723

Motor Connections Motor connections are shown in Figure 3-16.

Figure 3-16 Motor Connections

Notes:

1. Metal conduit should be used. Connect conduits so the use of Load Reactor or RC Device does not interrupt EMI/RFI shielding.

2. See Line/Load Reactors described previously in this section.

3. Use same gauge wire for Earth ground and motor leads (from the 3 phase wire size tables).

4. Motors are phase sensitive. If the motor leads are labeled 1, 2, 3 then lead 1 must be connected to T1 etc. If the motor leads are labeled U, V, W then lead U must be connected to T1 etc.

5. Connect the motor ground lead to the of the control.

Note 1

Note 2

Note 1

*Optional

Load

Reactor

Baldor

Control

T1 T2 T3

A1 B1 C1

A2 B2 C2

* Optional components not provided with control.

T2 T3

Note 3

See Recommended Tightening Torques in Section 7.

* AC Motor

M-Contactor If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor)

may be installed. However, incorrect installation or failure of the M-contactor or wiring may damage the control. If an M-Contactor is installed, the control must be disabled for at least 20msec before the M-Contactor is opened or the control may be damaged. M-Contactor connections are shown in Figure 3-17.

Figure 3-17 Optional M-Contactor Connections

T1 T2 T3

MMM

M=Contacts of optional M-Contactor

T2 T3

* Motor

To Power Source

(Rated Coil Voltage)

M Enable

Note: Close “Enable”

after “M” contact closure.

* M-Contactor

See Recommended Tightening Torques in Section 7.

* Optional

RC Device

Electrocube

RG1781-3

Receiving & Installation 3-17MN723

Optional Dynamic Brake Hardware

Dynamic Brake (DB) Hardware must be installed on a flat, non-flammable, vertical surface for effective cooling and operation. Refer to MN701 (for RGA, RBA and RTA assemblies) or MN782 (for RUA assemblies) for additional information.

Electrical Installation Terminal connections for DB hardware is determined by the control model number suffix

(E, EO, ER or MO). See Figure 3-18 for terminal identification. Refer to Tables 3-6 and 3-7 for wire size information.

Figure 3-18 DB Terminal Identification Figure 3-19 Wiring for RGA Assembly (–E, –W, –ER)

“E” or “W” suffix

Note: Although not shown, metal conduit should be used to shield all

R2 B+/R1 B-

power wires and motor leads.

“EO” or “MO” suffix

B+ B- GND D1 D2 GND

(May be labeled GND or )

MOTOR

GND

Control

Terminals

GND

B+/R1

T3 T2

DB Terminals

Optional

Dynamic Brake

R2 R1

(RGA)

“ER” suffix

R2 B+/R1 B- GND

50/60 Hz 3 Phase Power

Optional Customer Supplied Breaker or Fuse Protection -

Subject to Local Codes

L3 L2 L1

GND

See recommended Terminal Tightening Torques in Section 7.

Figure 3-20 Wiring for RBA Assembly (–EO, –MO) Figure 3-21 Wiring for RTA Assembly (–EO, –MO)

DB Assembly

Terminals

D1 D2

Dynamic Brake

B-

B+

Optional

(RTA)

R2R1

Optional

RGA

Assembly

(May be labeled GND or )

MOTOR

GND

50/60 Hz 3 Phase Power

Optional Customer Supplied Breaker or Fuse Protection -

Subject to Local Codes

Control

Terminals

D1 D2

GND

B-

B+

T3 T2

L3 L2 L1

GND

Shielded Twisted Pair

DB Assembly

Terminals

D1 D2

Dynamic Brake

B-

B+

Optional

(RBA)

Note: Although not shown, metal conduit should be used to shield all power wires and motor leads.

See recommended Terminal Tightening Torques in Section 7.

(May be labeled GND or )

MOTOR

GND

50/60 Hz 3 Phase Power

Optional Customer Supplied Breaker or Fuse Protection -

Subject to Local Codes

Control

Terminals

D1 D2

GND

B-

B+

T3 T2

L3 L2 L1

GND

Shielded Twisted Pair

See recommended Terminal Tightening Torques in Section 7.

3-18 Receiving & Installation MN723

Control

Assembly

Control Terminals

See recommended Terminal Tightening Torques in Section 7.

The RUA Dynamic Brake assembly is designed for controls that have built in dynamic brake hardware. Be sure to disconnect the internal resistor wires from control terminals. These factory installed wires must be removed and the wire ends insulated with electrical tape to prevent contact with other components. The braking capability may also need to be disabled in software. For Baldor controls, reduce the resistor ohms to the lowest value and increase the resistor watts to greatest value. Be sure to select the proper size kit based on the dissipation rating of the resistor(s) to handle the average watts of the overhauling or cyclic load.

Figure 3-22 Wiring for RUA Assembly

Use Baldor cables:

LD5157A05 – 5 Ft. LD5157A10 – 10 Ft. LD5157A20 – 20 Ft. LD5157A30 – 30 Ft. LD5157A50 – 50 Ft.

GND

B–B+/R1R2

NC Thermal NC Thermal

Chassis must be grounded to Earth.

B+ S+

No Connection S– B–

200°C Thermal Switch Normally Closed contact (mounted on chassis).

Dynamic

Brake

Assembly

Note: Sense lines S+ and S– must be shielded, twisted pair wire.

Terminate shields at control end only.

Table 3-6 Terminal Torques & Wire Size for RUA Assemblies

Braking

Control

Rating

VAC

Braking

Option

Watts

Max.

AWG mm

230 746 16 1.31 300 9 1 20 0.51 300 9 1 230 1492 16 1.31 300 9 1 20 0.51 300 9 1 230 1865 16 1.31 300 9 1 20 0.51 300 9 1 230 2238 14 2.08 300 9 1 20 0.51 300 9 1 230 3730 14 2.08 300 9 1 20 0.51 300 9 1 230 5600 14 2.08 300 9 1 20 0.51 300 9 1 460 746 16 1.31 600 9 1 20 0.51 600 9 1 460 1492 16 1.31 600 9 1 20 0.51 600 9 1 460 1865 16 1.31 600 9 1 20 0.51 600 9 1 460 2238 16 1.31 600 9 1 20 0.51 600 9 1 460 3730 14 2.08 600 9 1 20 0.51 600 9 1 460 5600 14 2.08 600 9 1 20 0.51 600 9 1

B+ and B– Terminals S+ and S– Terminals

Shielded

Wire Size

Volt

Tightening

Torque

Lb–in Nm AWG mm

Shielded

Wire Size

See recommended Terminal Tightening Torques and wire sizes in Table 3-6.

Volt

Tightening

Torque

Lb–in Nm

Receiving & Installation 3-19MN723

Table 3-7 Dynamic Brake Wire Size for RGA, RBA and RTA Assemblies

Control

Voltage Rating

VAC

Braking Option

Watts Rating

B+ / B- and R1 / R2 / Terminals

Wire Size Wire Size

AWG mm

Volt

AWG mm

D1 / D2 /

Terminals

Volt

230 <2,000 16 1.31 600 20-22 0.5 600 230 2,100 – 5,000 14 2.08 600 20-22 0.5 600 230 5,100 – 10,000 10 6 600 20-22 0.5 600 230 >10,000 8 10 600 20-22 0.5 600 460 <4,000 16 1.31 600 20-22 0.5 600 460 4,100 – 10,000 14 2.08 600 20-22 0.5 600 460 10,100 – 20,000 10 6 600 20-22 0.5 600 460 >20,000 8 10 600 20-22 0.5 600

Resolver Feedback The resolver connections are made at the J1 connector as shown in Figure 3-23. The

resolver cable must be shielded twisted pair #22 AWG (0.34mm2) wire minimum. The cable must also have an overall shield and not exceed 150 feet (45m) in length. Maximum wire-to-wire or wire-to-shield capacitance is 50pf per foot (maximum of 7500pf for 150 ft). See electrical noise considerations in Section 5 of this manual.

Resolver wiring must be separated from power wiring. Separate parallel runs of resolver and power cables by at least 3″. Cross power wires at right angles only. Insulate or tape ungrounded end of shields to prevent contact with other conductors or ground.

Figure 3-23 Resolver Cable Connections

= Twisted Pair

See recommended Terminal Tightening Torques in Section 7.

S1S3

J1 23 SINE+ 24 SINE– 25 COSINE+ 26 COSINE– 27 EXCITATION + 28 EXCITATION –

Figure 3-24 Baldor Resolver Cable Lead Identification

Red EXCITATION+ Blue EXCITATION– Green COSINE+ Shield EXCITATION– Yellow COSINE– Pink SINE+ Gray SINE–

3-20 Receiving & Installation MN723

Simulated Encoder Output The control provides a simulated encoder output at connector J1 as shown in Figure

3-25. This output provides position information to the host controller. Use twisted pair wire with an overall shield.

This output simulates a 1024 ppr encoder with quadrature outputs. Counting in quadrature will provide 4096 ppr with one index marker (CHC) per revolution. It is recommended that this output only drive one circuit load. Driving multiple loads is not recommended (to avoid ground loops).

Figure 3-25 Simulated Encoder Output

From Processor

IN A IN B IN C IN D

26LS31

A A B

B C C

32 33 34 35 36 38

A B B C C DGND

See recommended Terminal Tightening Torques in Section 7.

To Host Position

Controller

= Twisted Pair

Receiving & Installation 3-21MN723

Home (Orient) Switch InputTo use the internally generated index pulse for homing, no external connections are

required. However, to use an external index input a jumper must be moved and the external index signal must be connected to J1-29 and 30.

External Index Jumper

Refer to Figure 3-30. The resolver feedback module must be removed from the main control board to change the JP1 position. Use the following procedure.

1. Use a grounded wrist strap.

2. Firmly grasp the Resolver Feedback Module and remove it from its connectors on the main control board. Be careful not to bend the pins by twisting or lifting the module unevenly.

3. Place the jumper in the desired position, refer to Figure 3-30.

4. Insert the Resolver Feedback Module back into its connectors on the main control board. Be careful not to bend the pins by twisting or lifting the module unevenly. Be sure the module is fully seated (pushed into) the connectors.

Connections for External Index Signal

The Home or Orient function causes the motor shaft to rotate to a predefined home position. The homing function allows shaft rotation in the drive forward direction only. The home position is located when a machine mounted switch or “Index” pulse is activated (closed). Home is defined by a rising signal edge at terminal J1-29. The shaft will continue to rotate only in a “Drive Forward” direction for a user defined offset value. The offset is programmed in the Level 2 Miscellaneous Homing Offset parameter. The speed at which the motor will “Home” or orient is set with the Level 2 Miscellaneous Homing Speed parameter.

A machine mounted switch may be used to define the Home position or “index” channel. A differential line driver output from a solid state switch is preferred for best noise immunity. Connect this differential output to terminals J1-29 and J1-30.

A single ended solid-state switch or limit switch should be wired as shown in Figure 3-26. Regardless of the type of switch used, clean rising and falling edges at J1-29 are required for accurate positioning.

Note: Control requires dynamic brake hardware for Orient (Homing) function to

work. Control will trip without dynamic brake hardware installed. Size A and B controls ( “–E” suffix) are shipped with factory installed dynamic brake hardware.

Figure 3-26 Typical Home or Orient Switch Connections

Customer Provided +5VDC to +12VDC

Limit Switch (Closed at HOME).

3-22 Receiving & Installation MN723

INDEX

Common

See recommended Terminal Tightening

Torques in Section 7.

Operating Modes Ten operating modes are available. These modes define the basic motor control setup

and the operation of the input and output terminals. After the circuit connections are completed, the operating mode is selected by programming the Operating Mode parameter in the Level 1 Input Programming Block. Operating modes include:

• Keypad

• Standard Run, 3 Wire

• 15 Speed, 2 Wire

• 3 SPD ANA 2 Wire

• 3 SPD ANA 3 Wire

• Bipolar Speed or Torque

• Process Control

• Serial

• Electronic Pot 2 Wire

• Electronic Pot 3 Wire

Each mode requires connections to the J1 terminal strip (except the keypad mode, all connections are optional). The J1 terminal strip is shown in Figure 3-27. The connection of each input or output signal is described in the following pages.

Figure 3-27 Control Signal Connections

Refer to Analog Inputs

Refer to Analog Outputs

Refer to opto isolated Inputs

Refer to opto isolated Outputs

See recommended terminal tightening torques in Section 7.

Analog GND

Analog Input 1 Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

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

Opto In Common

Opto Out #1 Return

Opto Out #1 Opto Out #2 Opto Out #3 Opto Out #4

Sine

Cosine

Excitation

Index

Common

INDEX

Not Used

Common

Opto Out #1 Return

Opto Out #2 Return

Opto Out #3 Return

Opto Out #4 Return

Refer to Resolver Installation

Refer to Home Switch Input

Refer to Simulated Encoder Output

+24VDC Opto In Power

J1-39 & 40 Jumper as shown to power the opto inputs

from the internal +24VDC supply.

Note: J1-18 and J1-41 are connected together

on the control circuit board.

Receiving & Installation 3-23MN723

Analog Inputs Two analog inputs are available: analog input #1 (J1-1 and J1-2) and analog input #2

(J1-4 and J1-5) as shown in Figure 3-28. Either analog input may be selected in the Level 1 INPUT block, Command Select parameter value. Analog input #1 is selected if the parameter value is “Potentiometer”. Analog input #2 is selected if the parameter value is “+/-10Volts, +/-5 Volts or 4-20mA”. Figure 3-29 shows the equivalent circuits of the Analog Inputs.

Figure 3-28 Analog Inputs

Analog GND

Command Pot or

0-10VDC

±5VDC, ±10VDC or 4-20 mA Input

5KW

See recommended terminal tightening torques in Section 7.

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Input #1 When using a potentiometer as the speed command, process feedback or setpoint (Single Ended) source, the Level 1 Input block COMMAND SELECT parameter must be set to

“POTENTIOMETER”.

Note: A potentiometer value of 5kW to 10kW, 0.5 watt may be used.

Parameter Selection

The single ended analog input #1 can be used in one of three ways:

1. Speed or Torque command (Level 1 Input block, Command Select=Potentiometer).

2. Process Feedback (Level 2 Process Control block, Process Feedback=Potentiometer).

3. Setpoint Source (Level 2 Process Control block, Setpoint Source=Potentiometer). When using Analog Input #1, the respective parameter must be set to

“POTENTIOMETER”.

Analog Input 1

Analog Input 2

Analog Input #2 Analog input #2 accepts a differential command ±5VDC, ±10VDC or 4-20 mA.

(Differential) If pin J1-4 is positive with respect to pin 5, the motor will rotate in the forward direction.

If pin J1-4 is negative with respect to pin 5, the motor will rotate in the reverse direction. JP1 must be set for voltage or current operation as required. Analog Input #2 can be connected for single ended operation by grounding either of the inputs, provided the common mode voltage range is not exceeded.

Note: The common mode voltage can be measured with a voltmeter. Apply the

maximum command voltage to analog input 2 (J1-4, 5). Measure the AC and DC voltage across J1-1 to J1-4. Add the AC and DC readings together. Measure the AC and DC voltage from J1-1 to J1-5. Add the AC and DC readings together.

If either of these measurement totals exceeds a total of ±15 volts, then the common mode voltage range has been exceeded. To correct this condition, either change the command source or isolate the command signal with a signal isolator.

3-24 Receiving & Installation MN723

Figure 3-29 Analog Inputs Equivalent Circuits

–

.033 mF

5KW

Notes:

To Microprocessor

–

All OP Amps are TL082 or TL084

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

-15VDC

30KW

20KW

3 4

(on main control board)

Refer to Table 3-8 for jumper placement information.

(on main control board)

Resolver Feedback Module

JP2

JP1

JP1 4-20mA

X N/C

123

1.96KW

500W

+15VDC

10KW 10KW

–

10KW

To Microprocessor

See recommended terminal tightening torques in Section 7.

Figure 3-30 Control Board Jumper Locations

JP1 (on bottom side of resolver

123

feedback module)

1–2 Internal Index 2–3 External Index

Jumper Jumper Position Description of Jumper Position Setting

JP1

JP2

See recommended terminal tightening torques in Section 7.

Table 3-8 Control Board Jumper

1-2 Voltage Speed Command Signal. (Factory Setting) 2-3 4-20mA Speed Command input at Analog #2 1-2 Factory Setting 2-3 Not used.

Receiving & Installation 3-25MN723

Analog Outputs Two programmable analog outputs are provided on J1-6 and J1-7. See Figure 3-31.

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

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

Figure 3-31 Analog Outputs Equivalent Circuits

From Microprocessor

Serial Operating Mode

10KW

.033 mf

10KW

.033 mf

–

10KW

–

10KW

50W

Notes:

See recommended terminal tightening torques in Section 7.

–

All OP Amps are TL082 or TL084

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

The Serial operating mode requires one of the optional Serial Interface expansion boards (RS232, RS422 or RS485). Installation and operation information for these serial expansion boards is provided in Serial Communications expansion board manual MN1310. This manual is shipped with the serial expansion boards.

3-26 Receiving & Installation MN723

Keypad Operating Mode

The Keypad operating mode allows the control to be operated from the keypad. This mode requires no connections to J1. However, the Enable, Stop and External Trip inputs may optionally be used. All other opto inputs remain inactive. The analog outputs and opto-outputs remain active at all times.

Parameter Selection

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

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

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

To use the Stop input, J1-11 must be connected and the Level 1 Keypad Setup block, LOC. Hot Start parameter must be set to ON. The Stop line is normally closed. When opened, the motor will COAST or REGEN to a stop depending upon the setting of Level 1 Keypad Setup block Keypad Stop Mode parameter value. Closing the input will immediately start the motor.

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

Figure 3-32 Keypad Control Connection Diagram

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

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

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

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

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

“ON” to activate the opto input. CLOSED allows normal operation. OPEN causes an external trip fault. The control will disable and the motor coasts to a stop. An external trip fault is displayed (also logged in the fault log).

Refer to Figure 3-41.

See recommended terminal tightening torques in Section 7.

No Connection

Programmable Output Programmable Output

Enable

Stop

External Trip

Analog GND

Analog Input 1 Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

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

Opto In Common

Receiving & Installation 3-27MN723

Standard Run 3 Wire Operating Mode

In Standard Run mode, the control is operated by the opto isolated inputs at J1-8 through J1-16 and the analog command input. The opto inputs can be switches as shown in Figure 3-33 or logic signals from another device.

Figure 3-33 Standard Run 3-Wire Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control and motor coasts to a stop.

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

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

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

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

J1-11 MOMENTARY OPEN motor decels to stop (depending on Keypad Stop

mode).

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

jog the motor.

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

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

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

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

J1-15 CLOSED to reset fault condition.

OPEN to run.

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

Command Pot or

0-10VDC

5KW

Programmable Output Programmable Output

Refer to Figure 3-41.

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable Forward Run Reverse Run

Stop

Jog

Accel/Decel

Preset Speed #1

Fault Reset

External Trip

Opto In Common

3-28 Receiving & Installation MN723

15 Speed 2-Wire Operating Mode

Operation in the 15 Speed 2-Wire mode is controlled by the opto isolated inputs at J1-8 through J1-16. The opto inputs can be switches as shown in Figure 3-34 or logic signals from another device.

Switched inputs at J1-11 through J1-14 allow selection of 15 preset speeds and provide Fault Reset as defined in Table 3-9.

Figure 3-34 15 Speed 2-Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control and motor coasts to a stop.

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

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

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

OPEN motor decels to stop (depending on Keypad Stop mode). J1-11-14 Selects programmed preset speeds as defined in Table 3-9. J1-15 CLOSED selects ACC / DEC / S-CURVE group 2.

OPEN selects ACC / DEC / S-CURVE group 1. J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to

“ON” to activate the opto input.

CLOSED allows normal operation.

OPEN causes an external trip fault. The control will disable and the motor

coasts to a stop. An external trip fault is displayed (also logged in the fault log).

See recommended terminal tightening torques in Section 7.

No Connection

Programmable Output Programmable Output

Refer to Figure 3-41.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Switch 1 Switch 2 Switch 3 Switch 4

Accel/Decel

External Trip

Opto In Common

Table 3-9 Switch Truth Table for 15 Speed, 2 Wire Control Mode

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

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

Preset 9 Open Open Open Closed Preset 10 Closed Open Open Closed Preset 11 Open Closed Open Closed Preset 12 Closed Closed Open Closed Preset 13 Open Open Closed Closed Preset 14 Closed Open Closed Closed Preset 15 Open Closed Closed Closed

Fault Reset Closed Closed Closed Closed

Receiving & Installation 3-29MN723

3 Speed Analog 2 Wire Operating Mode

Allows selection of 3 preset speeds with 2 wire inputs. The opto inputs can be switches as shown in Figure 3-35 or logic signals from another device.

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

Figure 3-35 3 SPD ANA 2 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

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

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

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

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

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

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

J1-11 CLOSED selects Analog Input #1.

OPEN selects Level 1 Input block, Command Select parameter.

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

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

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

OPEN selects STOP/START and Reset commands from Keypad.

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

OPEN selects speed commanded from Keypad.

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

and direction will remain the same after the change.

J1-14 Selects preset speeds as defined in the Speed Select Table (Table 3-10). J1-15 Selects preset speeds as defined in the Speed Select Table (Table 3-10). J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”

to activate the opto input. CLOSED allows normal operation. OPEN causes an external trip fault. The control will disable and the motor coasts to a stop. An external trip fault is displayed (also logged in the fault log).

Programmable Output Programmable Output

Command Pot or

0-10VDC

5KW

Refer to Figure 3-41.

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable Forward Run Reverse Run

Analog Input Select

Run Command

Speed Command

Switch 1 Switch 2

External Trip

Opto In Common

Table 3-10 Speed Select Table

J1-14 J1-15 Command

OPEN CLOSED OPEN CLOSED

OPEN OPEN CLOSED CLOSED

3-30 Receiving & Installation MN723

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

3 Speed Analog 3 Wire Operating Mode

Allows selection of 3 preset speeds with 3 wire inputs. The opto inputs can be switches as shown in Figure 3-36 or logic signals from another device.

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

Figure 3-36 3 SPD ANA 3 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

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

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

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

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

OPEN selects speed commanded from Keypad.

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

speed and direction will remain the same after the change. J1-14 Selects preset speeds as defined in the Speed Select Table (Table 3-11).

J1-15 Selects preset speeds as defined in the Speed Select Table (Table 3-11). J1-16 If J1-16 is connected, you must set Level 2 Protection block, External Trip to

“ON” to activate the opto input.

CLOSED allows normal operation.

OPEN causes an external trip fault. The control will disable and the motor coasts

to a stop. An external trip fault is displayed (also logged in the fault log).

Command Pot or

0-10VDC

5KW

Programmable Output Programmable Output

Refer to Figure 3-41.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Stop

Run Command

Speed Command

Switch 1 Switch 2

External Trip

Opto In Common

Table 3-11 Speed Select Table

J1-14 J1-15 Command

OPEN CLOSED OPEN CLOSED

OPEN OPEN CLOSED CLOSED

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

See recommended terminal

tightening torques in Section 7.

Receiving & Installation 3-31MN723

Bipolar Speed or Torque Operating Mode

Provides bipolar speed or torque control. Also, you may store up to four (4) complete sets of operating parameters. This is important if you wish to store and use different acceleration rates, speed commands, jog speeds or to store tuning parameter values for different motors etc. The opto inputs can be switches as shown in Figure 3-37 or logic signals from another device.

Note: In Bipolar mode, the pot input can only be used in the forward direction.

To operate in either direction, Analog Input 2 must be used.

Figure 3-37 Bipolar Speed or Torque Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control & motor coasts to a stop.

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

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

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

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

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

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

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

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

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

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

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

J1-13 & 14 Select from four parameter tables as defined in Table 3-12. J1-15 Momentary CLOSED to reset fault condition.

OPEN allows normal operation.

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

Command Pot or

0-10VDC

5KW

Programmable Output Programmable Output

Refer to Figure 3-41.

See recommended terminal

tightening torques in Section 7.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable Forward Enable Reverse Enable

Homing

Speed/Torque

Switch 1 Switch 2

Fault Reset

External Trip

Opto In Common

Table 3-12 Bipolar Mode Table Select Truth Table

Function J1-13 J1-14

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

Note: See multiple parameter sets.

3-32 Receiving & Installation MN723

Multiple Parameter Sets

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

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

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

Note: Preset speed does not apply to table select.

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

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

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

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

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

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

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

Receiving & Installation 3-33MN723

Process Operating Mode

ËËËË

Figure 3-38 Process Mode Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control & motor coasts to a stop.

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

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

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

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

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

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

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

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

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

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

direction.

J1-15 CLOSED to reset a fault condition.

OPEN to run.

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

See recommended terminal tightening torques in Section 7.

Command Pot or

0-10VDC

5KW

Programmable Output Programmable Output

Process Mode Enable

Refer to Figure 3-41.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable Forward Enable Reverse Enable

Table Select

Speed/Torque

Jog

Fault Reset

External Trip

Opto In Common

Table 3-13 Process Mode Input Signal Compatibility

Setpoint or

Feedforward

J1-1 & 2 J1-4 & 5

5V EXB 10V EXB

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

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

Requires expansion board EXB002A01 (RS422/RS485 High Speed Serial Communication EXB). Conflicting inputs. Do not use same input signal multiple times. Conflicting level 1 or 2 expansion boards. Do not use!

Feedback

4-20mA

EXB

3-15 PSI

EXB

Tach EXB

3-34 Receiving & Installation MN723

Electronic Pot 2 Wire Operating Mode

Provides speed Increase and Decrease inputs to allow EPOT operation with 2 wire inputs. The opto inputs can be switches as shown in Figure 3-39 or logic signals from another device. The values of the preset speeds are set in the Level 1 Preset Speeds block, Preset Speed #1 or Preset Speed #2.

Figure 3-39 EPOT, 2 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

OPEN disables the control and motor coasts to a stop.

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

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

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

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

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

J1-11 Selects preset speeds as defined in the Speed Select Table (Table 3-14). J1-12 Selects preset speeds as defined in the Speed Select Table (Table 3-14). J1-13 CLOSED selects ACC / DEC / S-CURVE group 2.

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

to “ON” to activate the opto input.

CLOSED allows normal operation.

OPEN causes an external trip fault. The control will disable and the motor

coasts to a stop. An external trip fault is displayed (also logged in the fault

log).

Command Pot or

0-10VDC

5KW

Programmable Output Programmable Output

Refer to Figure 3-41.

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Switch 1 Switch 2

Accel/Decel

Increase

Decrease

External Trip

Opto In Common

Table 3-14 Speed Select Table

J1-11 J1-12 Function

OPEN CLOSED OPEN CLOSED

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

OPEN OPEN CLOSED CLOSED

Electronic Pot Command Select * Preset #1 Preset #2

See recommended terminal

tightening torques in Section 7.

Receiving & Installation 3-35MN723

Electronic Pot 3 Wire Control Mode

Provides speed Increase and Decrease inputs to allow EPOT operation with 3 wire inputs. The opto inputs can be switches as shown in Figure 3-40 or logic signals from another device.

Figure 3-40 EPOT, 3 Wire Control Connection Diagram

J1-8 CLOSED allows normal operation.

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

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

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

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

“ON” to activate the opto input.

CLOSED allows normal operation.

OPEN causes an external trip fault. The control will disable and the motor

coasts to a stop. An external trip fault is displayed (also logged in the fault log).

See recommended terminal

tightening torques in Section 7.

Command Pot or

0-10VDC

Programmable Output Programmable Output

Refer to Figure 3-41.

5KW

EPOT/Command Select

Analog GND

Analog Input 1

Pot Reference

Analog Input +2

Analog Input -2

Analog Out 1 Analog Out 2

Enable

Forward Run

Reverse Run

Stop

Accel/Decel

Increase

Decrease

External Trip

Opto In Common

External Trip Input Terminal J1-16 is available for connection to a normally closed thermostat or overload

relay in all operating modes as shown in Figure 3-41. The thermostat or overload relay should be a dry contact type with no power available from the contact. If the motor thermostat or overload relay activates, the control will automatically shut down and give an External Trip fault. The optional relay (CR1) shown provides the isolation required and the N.O. contact is open 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 closes.

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

To activate the External Trip input, the External Trip parameter in the Level 2 Protection Block must be set to “ON”.

Figure 3-41 Motor Temperature Relay

See recommended terminal

tightening torques in Section 7.

* Motor

Motor Thermostat Leads

Customer Provided

Source Voltage

CR1

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

Note: Add appropriately rated protective

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

External Trip

* Optional hardware. Must be ordered separately.

3-36 Receiving & Installation MN723

Opto-Isolated Inputs The equivalent circuit of the nine opto inputs is shown in Figure 3-42. The function of

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

Figure 3-42 Opto-Input Connections (Using Internal Supply)

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

Opto In Common

+24VDC @ 200mA

(supply terminal 39).

Jumper terminals 39 to 40

(Factory Installed)

Figure 3-43 Opto-Input Connections (Using External Supply)

* User VCC (-)

* User VCC (+)

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

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

See recommended terminal tightening torques in Section 7.

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

* User VCC (+)

* User VCC (-)

Opto Inputs Closing to Ground Opto Inputs Closing to +VCC

* User VCC = 10 - 30VDC External Power Source

See recommended terminal

tightening torques in Section 7.

Receiving & Installation 3-37MN723

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

See Figure 3-44. Each output may be programmed to represent one output condition. The output conditions are defined in Section 4 of this manual.

The opto isolated outputs may be configured for sinking or sourcing 60 mA each, as shown in Figure 3-44. However, all must be configured the same. The maximum voltage from opto output to common when active is 1.0 VDC (TTL compatible). The equivalent circuit for the opto isolated outputs is shown in Figure 3-45.

If the opto outputs are used to directly drive a relay, a flyback diode rated at 1A, 100 V (IN4002 or equivalent) minimum should be connected across the relay coil.

Each opto output is programmed in the Output programming block.

Figure 3-44 Opto-isolated Output Configurations

Optional

Customer

Supplied Relays &

Diodes

(Sinking the Relay Current)

Optional Customer Supplied

10VDC to 30VDC Source

Optional

Customer

Supplied Relays &

Diodes

(Sinking the Relay Current)

24Com

Using Internal Supply

Using External Supply

See recommended terminal tightening torques in Section 7.

+24VDC

Optional Customer Supplied

10VDC to 30VDC Source

24Com

39 18

Using Internal Supply

(Sourcing the Relay Current)

Using External Supply

(Sourcing the Relay Current)

+24VDC

Optional

Customer

Supplied

Relays &

Diodes

Optional

Customer

Supplied

Relays &

Diodes

3-38 Receiving & Installation MN723

PC865

50mA max

Figure 3-45 Opto-Output Equivalent Circuit

Opto Output 1

Opto Output 2

Opto Output 3

Opto Output 4

PC865

50mA max

See recommended Terminal Tightening Torques in Section 7.

PC865

50mA max

PC865

50mA max

Opto Out 1 Return

Opto Out 2 Return

Opto Out 3 Return

Opto Out 4 Return

10 – 30VDC

Opto Outputs

Pre-Operation Checklist Check of Electrical Items

1. Verify AC line voltage at source matches control rating.

2. Inspect all power connections for accuracy, workmanship and torque as well as compliance to codes.

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

4. Check all signal wiring for accuracy.

Check of Motors and Couplings

1. Verify freedom of motion of the motor shaft.

2. Verify that the motor coupling is tight without backlash.

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

Receiving & Installation 3-39MN723

Power-Up Procedure Be sure the 23H control, motor and dynamic brake hardware are installed and wired

according to the procedures in Section 3 of this manual. Become familiar with the keypad programming and keypad operation of the control as described in Section 4 of this manual.

1. Disconnect the load (including coupling or inertia wheels) from the motor shaft, if possible.

2. Verify that any enable inputs to J1-8 are open. Be sure Level 2 Protection block, Local Enable INP is OFF and Level 2 Protection block, External Trip is OFF.

3. Turn power on. Be sure no errors are displayed.

4. Set the Level 1 Input block, Operating Mode parameter to “KEYPAD”.

5. Set the Level 2 Output Limits block, “OPERATING ZONE” parameter as desired (STD CONST TQ, STD VAR TQ, QUIET CONST TQ or QUIET VAR TQ).

6. Enter the following motor data in the Level 2 Motor Data block parameters: Motor Rated Amps (IC) Motor Poles Resolver Speeds (Pre-set is one speed)

7. If external dynamic brake hardware is used, set the Level 2 Brake Adjust block “Resistor Ohms”, “Resistor Watts” and “DC Brake Current” parameters.

8. If the load was not disconnected in step 1, refer to Section 6 and manually tune the control. After manual tuning, perform steps 11 and 12 then continue with step 16.

WARNING: The motor shaft will rotate during the autotune procedure. Be

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

10. Go to Level 2 Autotune block, and perform the following tests:

CMD OFFSET TRIM CUR LOOP COMP RESOLVER ALIGN

11. Set the Level 2 Output Limits block, “MIN OUTPUT SPEED” parameter.

12. Set the Level 2 Output Limits block, “MAX OUTPUT SPEED” parameter.

13. Remove all power from the control.

14. Couple the motor to its load.

15. Turn power on. Be sure no errors are displayed.

16. Perform the SPD CNTRLR CALC test in the Level 2 Autotune block.

17. Run the drive from the keypad using the arrow keys for direct speed control, a keypad entered speed or the JOG mode.

18. Select and program additional parameters to suit your application.

The control is now ready for use the in keypad mode. If a different operating mode is desired, refer to Section 3 Control Connections and Section 4 Programming and Operation.

3-40 Receiving & Installation MN723

Section 4 Programming and Operation

Overview The keypad is used to program the control parameters, to operate the motor and to

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

Figure 4-1 Keypad

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

Keypad Display - Displays status

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

PROG - Press PROG to enter the

JOG - Press JOG to select the

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

FWD - Press FWD to initiate forward

rotation of the motor.

REV - Press REV to initiate reverse

rotation of the motor.

STOP - Press STOP one time to initiate

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

LOCAL - Press LOCAL to change

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

DISP - Press DISP to return to display

mode from programming mode. Provides operational status and advances to the next display menu item including the Diagnostic Screens.

SHIFT - Press SHIFT in the program

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

RESET - Press RESET to clear all fault

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

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

 - (UP Arrow).

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

ENTER - Press ENTER to save

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

 - (Down Arrow)

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

Programming & Operation 4-1MN723

Section 1 General Information

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

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

Motor Status

Control Operation

Output Condition Value and Units

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

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

control. If there is no visible display, use the following procedure to adjust the contrast of the display. Contrast may be adjusted in display mode when motor is stopped or running.

Action Description Display Comments

Apply Power No visible display

Press DISP Key Places control in display mode

Press SHIFT SHIFT Allows display contrast

Press  or  Key

Press ENTER Saves level of contrast and exits

adjustment Adjusts display intensity

Typical display

to display mode

Display Mode Screens

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing motor speed.

Press DISP key Display Frequency First Display Mode Screen.

Press DISP key Display Current

Press DISP key Display Voltage

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

Press DISP key Combined Display

Press DISP key Screen to enter Fault Log

Press DISP key Screen to enter Diagnostic Menu

4-2 Programming & Operation MN723

Section 1 General Information

Display Mode Continued

Diagnostic Information Access

Action Description Display Comments

Press DISP key Scroll to Diagnostic Information

screen

Diagnostic Access screen.

Press ENTER key Access diagnostic information. First Diagnostic Information

Press DISP key Display mode showing control

Press DISP key Display mode showing bus

Press DISP key Display mode showing %

Press DISP key Display mode showing opto

Press DISP key Display mode showing actual time

Press DISP key Display mode showing operating

Press DISP key Display mode showing continuous

Press DISP key Display mode showing which

Press DISP key Display mode showing position

temperature.

voltage.

overload current remaining.

inputs & outputs states. (0=Open, 1=Closed.)

the drive has been powered up.

zone, voltage and control type.

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

Group1 or 2 expansion boards are installed and recognized.

counter contents.

XXXV

screen.

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

HR.MIN.SEC format.

Typical display.

In this case, no expansion boards are installed.

Press DISP key Display mode showing parameter

Press DISP key Display mode showing software

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

table selected.

version and revision installed in the control.

information.

Programming & Operation 4-3MN723

Section 1 General Information

Display Mode Continued

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

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

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing motor speed.

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

Press ENTER key Display first fault type and time

Press  key

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

fault occurred. Scroll through fault messages.

Display mode.

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

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

on.

4-4 Programming & Operation MN723

Section 1 General Information

Program Mode The Program Mode is used to:

1. Enter motor data.

2. Autotune the drive.

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

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

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

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

Parameter Parameter Status

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

Parameter Blocks Access for Programming

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

Value and Units

Action Description Display Comments

Apply Power Keypad Display shows this

Press PROG key Press ENTER to access Preset

Press  or  key

Press ENTER key First Level 2 block display.

Press  or  key

Press ENTER key Return to display mode.

opening message. If no faults and programmed for

LOCAL operation. If no faults and programmed for

REMOTE operation.

Scroll to the ACCEL/DECEL block.

Scroll to the Level 2 Block.

Scroll to Programming Exit menu.

Logo display for 5 seconds.

Display mode.

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

Speed parameters. Press ENTER to access Accel

and Decel rate parameters. Press ENTER to access Level 2

Blocks.

Press ENTER to return to Display mode.

Programming & Operation 4-5MN723

Section 1 General Information

Program Mode Continued

Changing Parameter Values when Security Code Not Used

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

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

Action Description Display Comments

Apply Power Keypad Display shows this

opening message.

Logo display for 5 seconds.

If no faults and programmed for LOCAL operation.

Press PROG key Access programming mode.

Press  or  key

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

Press ENTER key Access Operating Mode

Press  key

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

Press  key

Press ENTER key Return to Input Block.

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

Scroll to Level 1 Input Block.

parameter. Scroll to change selection.

Scroll to menu exit.

Display mode. Stop LED on.

Press ENTER to access INPUT block parameter.

factory setting. Keypad mode shown is the

factory setting. At flashing cursor, select desired

mode, BIPOLAR in this case.

4-6 Programming & Operation MN723

Section 1 General Information

Program Mode Continued

Reset Parameters to Factory Settings

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

Note: All parameter values are changed when the control is reset to factory settings. Note: After factory settings have been restored, the drive must again be tuned.

Action Description Display Comments

Apply Power Keypad Display shows this

opening message.

Logo display for 5 seconds.

If no faults and programmed for LOCAL operation.

Press PROG key Enter program mode.

Press  or  key

Press ENTER key Select Level 2 Blocks.

Press  or  key

Press ENTER key Select Miscellaneous block.

Press  key

Press ENTER key Access Factory Settings

Press  key

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

Press  key

Scroll to Level 2 Blocks.

Scroll to the Miscellaneous block.

Scroll to Factory Settings parameter.

parameter. Scroll to YES, to choose original

factory settings.

Scroll to menu exit.

Display mode. Stop LED on.

 represents blinking cursor.

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

Exit Level 2 blocks.

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

Press  or  key

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

Scroll to Programming exit.

Exit Programming mode and return to Display mode.

Programming & Operation 4-7MN723

Section 1 General Information

Program Mode Continued

Initialize New Software

When new software is installed, the control must be initialized to the new software version and memory locations. Use the following procedure to initialize the software.

Note: All parameter values are changed when the control is reset to factory settings. Note: After factory settings have been restored, the drive must again be tuned.

Action Description Display Comments

Apply Power Keypad Display shows this

opening message.

Logo display for 5 seconds.

If no faults and programmed for LOCAL operation.

Press PROG key Enter program mode.

Press  or  key

Press ENTER key Select Level 2 Blocks.

Press  or  key

Press ENTER key Select Miscellaneous block.

Press  key

Press ENTER key Access Factory Settings

Press  key

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

Press  key

Scroll to Level 2 Blocks.

Scroll to the Miscellaneous block.

Scroll to Factory Settings parameter.

parameter. Scroll to YES, to choose original

factory settings.

Scroll to menu exit.

Display mode. Stop LED on.

 represents blinking cursor.

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

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

Press  key

Press ENTER key Access diagnostic information. Displays commanded speed,

Press DISP key Display mode showing software

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

Scroll to diagnostic info block.

version and revision installed in the control.

direction of rotation, Local/ Remote and motor speed.

Verify new software version.

XXX-X.XX

information.

4-8 Programming & Operation MN723

Section 1 General Information

Parameter Definitions To make programming easier, parameters have been arranged into the two level

structure shown in Table 4-1. Press the PROG key to enter the programming mode and the “Preset Speeds” programming block will be displayed. Use the Up () and Down () arrows to scroll through the parameter blocks. Press ENTER to access parameters within a programming block.

Tables 4-2 and 4-3 provide an explanation of each parameter. A complete Parameter Block Values list is located at the end of this manual. This list defines the programmable range and factory preset value for each parameter. The list has a space to record your settings for future reference.

Table 4-1 List of Parameters (Version 3.12)

LEVEL 1 BLOCKS LEVEL 2 BLOCKS

Preset Speeds Input Output Limits Brake Adjust

Preset Speed #1 Operating Mode Operating Zone Resistor Ohms Preset Speed #2 Command Select Min Output Speed Resistor Watts Preset Speed #3 ANA CMD Inverse Max Output Speed Preset Speed #4 ANA CMD Offset PK Current Limit Process Control Preset Speed #5 ANA 2 Deadband PWM Frequency Process Feedback Preset Speed #6 ANA1 CUR Limit CUR Rate Limit Process Inverse Preset Speed #7 Setpoint Source Preset Speed #8 Output Custom Units Setpoint Command Preset Speed #9 Opto Output #1 Max. Decimal Places Set PT ADJ Limit Preset Speed #10 Opto Output #2 Value at Speed Process ERR TOL Preset Speed #11 Opto Output #3 Units of Measure Process PROP Gain Preset Speed #12 Opto Output #4 Process INT Gain Preset Speed #13 Zero SPD Set PT Protection Process DIFF Gain Preset Speed #14 At Speed Band Overload Follow I:O Ratio Preset Speed #15 Set Speed External Trip Follow I:O OUT

Analog Out #1 Local Enable INP Master Encoder Accel / Decel Rate Analog Out #2 Following Error Accel Time #1 Analog #1 Scale Communications Decel Time #1 Analog #2 Scale Miscellaneous Protocol S-Curve #1 Position Band Restart Auto/Man Baud Rate Accel Time #2 Restart Fault/Hr Drive Address Decel Time #2 Brushless Control Restart Delay S-Curve #2 Resolver Align Factory Settings Auto-Tuning

Speed Filter Homing Speed CALC Presets Jog Settings Feedback Align Homing Offset CMD Offset Trim Jog Speed Current PROP Gain CUR Loop Comp Jog Accel Time Current INT Gain Security Control Feedback Align Jog Decel Time Speed PROP Gain Security State SPD CNTRLR Calc Jog S-Curve Time Speed INT Gain Access Timeout

Speed DIFF Gain Access Code Keypad Setup Position Gain Keypad Stop Key Motor Data Keypad Stop Mode Motor Rated Amps Keypad Run Fwd Motor Poles Keypad Run Rev Resolver Speeds Keypad Jog Fwd CALC Presets Keypad Jog Rev Local Hot Start

Programming & Operation 4-9MN723

Section 1 General Information

Table 4-2 Level 1 Parameter Block Definitions

Block Title Parameter Description

PRESET SPEEDS

ACCEL/DECEL RATE

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

Preset Speeds #1 – #15

Allows selection of 15 predefined motor operating speeds.

Each speed may be selected using external switches connected to terminals at J1. For motor operation, a motor direction command must be given along with a preset speed command.

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

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

Output Limits block.

Decel Time #1,2

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

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

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

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

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

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

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

eliminate the faults.

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

Jog Accel Time

Jog Decel Time

Jog S-Curve

Curve

Output Speed

Accel Time0Max

Accel S-Curves

40%

Curve

In Process Mode, if the Jog key is pressed or J1-12 is closed the drive will move in the direction of the error without pressing FWD or REV.

Jog Accel Time changes the Slope of the Jog Accel ramp. It is the time in seconds from zero speed to maximum speed.

Jog Decel Time changes the Slope of the Jog Decel ramp. It is the time in seconds from maximum speed to zero speed.

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

Figure 4-2 40% S-Curve Example

40%

Curve

Output Speed

Decel S-Curves

Curve

Decel Time0Max

4-10 Programming & Operation MN723

Section 1 General Information

Table 4-2 Level 1 Parameter Block Definitions - Continued

Block Title Parameter Description

KEYPAD SETUP Keypad Stop Key

Keypad Stop Mode

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

INPUT Operating Mode

Command Select

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

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

ANA 2 Deadband Allows a defined range of voltage to be a deadband. A command signal within this

ANA 1 CUR Limit Allows the 5V input at J1-2 (referenced to J1-1) to be used for reduction of the

Allows keypad STOP key to initiate motor stop during remote or serial operation (if Stop

key is set to Remote ON in Standard Run, 15 Speed, Bipolar, Serial and Process Control modes). If active, pressing STOP automatically selects Local mode and initiates the stop command.

Selects if the Stop command causes the motor to COAST to a stop or REGEN to a stop.

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

age and frequency to the motor is reduced at a rate set by Decel Time. ON makes the keypad FWD key active in Local mode. ON makes the keypad REV key active in Local mode. ON makes the keypad FWD key active in Local Jog mode. ON makes the keypad REV key active in Local Jog mode. The STOP input at J1-11 in the Keypad mode is enabled (when ON).

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

Serial, Bipolar, Process, 3 SPD ANA 2 wire, 3 SPD ANA 3 wire, EPOT - 2 Wire and

EPOT - 3 Wire. External connections to the control are made at the J1 terminal strip

(wiring diagrams are shown in Section 3 “Control Circuit Connections”). Selects the external speed reference to be used. The easiest method of speed control is to select POTENTIOMETER and connect a 5KW

pot to J1-1, J1-2, and J1-3. ±5, ±10VDC or 4-20mA input command can be applied to J1-4 and J1-5. If long distance is required between the external speed control and the control, the 4-20mA

selections at J1-4 and J1-5 should be considered. Current loop allows long cable lengths

without attenuation of the command signal. 10 VOLT W/T ORQ FF - when a differential command is present at J1-4 and 5, allows addi-

tional 5V torque feedforward input at J1-1, 2 and 3 to set a predetermined amount of

torque inside the rate loop with high gain settings. EXB PULSE FOL - selects optional Master Pulse Reference/Isolated Pulse Follower ex-

pansion board if installed. 5VOLT EXB - selects optional High Resolution I/O expansion board if installed. 10VOLT EXB - selects optional High Resolution I/O expansion board if installed. 4-20mA EXB - selects optional High Resolution I/O expansion board if installed. 3-15 PSI EXB selects optional 3-15 PSI expansion board if installed. Tachometer EXB- selects optional DC Tachometer expansion board if installed. Serial -selects optional Serial Communications expansion board if installed. None - Used in Process Control mode, two input configuration with no Feedforward input.

Note: When using the 4-20mA input, the JP2 jumper on the main control board

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

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

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

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

parameter is automatically adjusted during Autotune “CMD Offset Trim” test.

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

below the zero command signal level.

programmed current limit parameter for torque trimming during operation.

must be moved to the left two pins “A”.

Programming & Operation 4-11MN723

Section 1 General Information

Table 4-2 Level 1 Parameter Block Definitions - Continued

Block Title Parameter Description

OUTPUT OPTO OUTPUT

#1 – #4

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

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

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

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

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

Condition Description

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

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

Note: In the torque command mode, the At Speed opto output is always in the

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

Keypad Control - Active when control is in Local keypad control. At Set Speed - Active when output speed is at or above the Level 1 Output

Fault - Active when a fault condition is present. Following ERR - Active when the motor speed is outside the user specified

Motor Direction - Active High when REV direction command received. Active Low

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

CMD Direction - Active at all times. Logical output state indicates Forward or

At Position - Active during a positioning command when control is within the

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

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

Serial - Active when drive is in the Serial mode.

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

Following Error:

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

active within the range.

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

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

Sets the no fault operating speed range of the drive. This value is used by the Level 2

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

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

“Zero SPD Set Pt” parameter.

the Level 1 Output “At Speed Band” parameter.

“OFF” state.

output current is greater than Rated Current.

“Set Speed” parameter.

tolerance band defined by the At Speed Band parameter.

when FWD direction command received.

capable of producing torque).

Reverse direction. High=FWD, Low=REV.

position band parameter tolerance.

specified by the Level 2 Process Control block, AT Setpoint Band parameter. Turns off when process feedback error is eliminated.

received with FWD/REV direction issued.

4-12 Programming & Operation MN723

Section 1 General Information

Table 4-2 Level 1 Parameter Block Definitions - Continued

Block Title Parameter Description

OUTPUT (Continued)

Analog Output

Two Analog 0-5VDC linear outputs may be configured to represent any of the following

#1 and #2

Condition Description

ABS Speed - Represents the absolute motor speed where 0VDC = 0 RPM and ABS Torque - Represents the absolute value of torque where Speed Command - Represents the absolute value of commanded speed where PWM Voltage - Represents the amplitude of PWM voltage where Flux Current - Flux Current Feedback. Useful with CMD Flux CUR.

CMD Flux CUR - Commanded Flux Current. Load Current - Load current feedback is 2.5V centered, 5V = maximum peak

CMD Load Current - Commanded load current 2.5V centered, 5V = maximum peak Motor Current - Amplitude of continuous current including motor excitation current. Load Component - Amplitude of load current not including the motor excitation

Quad Voltage - Load controller output. Useful when diagnosing control problems. Direct Voltage - Flux controller output. AC Voltage - PWM control voltage which is proportional to AC line to line motor

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

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

PH 2 Current - Sampled AC phase 2 motor current. 2.5V = zero amps, PH 3 Current - Sampled AC phase 3 motor current. 2.5V = zero amps, Process Feedback - Represents the selected Process Feedback scaled input. 2.5V

Position - Position within a single revolution +5V = 1 Complete Revolution. Setpoint Command - Represents the selected Setpoint Command scaled. 2.5V

Serial - 0-5VDC level that represents a value programmed by a serial

Analog Scale #1 Scale factor for the Analog Output voltage. Useful to set the zero value or full scale

range for external meters.

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

becomes active (turns on).

conditions:

+5VDC = MAX RPM. +5VDC = Torque at CURRENT LIMIT and 0VDC=0 Torque. +5VDC = MAX RPM and 0VDC=0 RPM +5VDC = MAX AC Voltage.

positive load current, 0V = maximum peak negative load current. positive load current, 0V = maximum peak negative load current.

2.5V = rated Current, 0VDC=0 Current and 5VDC=Peak Current. current. 2.5V = rated Current, 0VDC=MAG Current and

5VDC=Peak Current.

terminal voltage. 2.5V centered.

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

x (time), Overload occurs at +5V. 0V = negative rated peak amps, +5V = positive rated peak amps. 0V = negative rated peak amps, +5V = positive rated peak amps. centered, 5V = maximum positive feedback, 0V = maximum

negative feedback. The counter is reset to 0 each revolution. centered, 5V = maximum positive setpoint command, 0V =

maximum negative setpoint command. command.

Programming & Operation 4-13MN723

Section 1 General Information

Table 4-2 Level 1 Parameter Block Definitions - Continued

Block Title Parameter Description

Brushless Control Resolver Align

Speed Filter

Feedback Align

Current Prop Gain Current Int Gain Speed Prop Gain Speed Int Gain Speed Diff Gain Position Gain

LEVEL 2 BLOCK ENTERS LEVEL 2 MENU

A numerical alignment value. The autotune procedure aligns the motor and resolver

positions. 22.3 degrees is correct for all Baldor BSM motors.

The number of input samples taken by the control microprocessor over which to filter

and determine the resolver speed. It is automatically set to suit the resolver resolution. The preset filter may be reduced to obtain smoother slow speed operation. The greater the number, the more filtered the signal becomes and the bandwidth is also reduced.

Sets the electrical direction of rotation of the resolver.

May be set to forward or reverse to match the motor rotation. Sets the current loop proportional gain. Sets the current loop integral gain. Sets the speed (velocity) loop proportional gain. Sets the speed (velocity) loop integral gain. Sets the speed (velocity) loop differential gain. Sets the position loop proportional gain.

4-14 Programming & Operation MN723

Section 1 General Information

Table 4-3 Level 2 Parameter Block Definitions

Block Title Parameter Description

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

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

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

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

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

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

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

overload.

Variable Torque allows 115% peak overload for 60 seconds.

allowed to go below this value except for motor starts from 0 RPM or during dynamic braking to a stop or in Process mode.

are available depending upon the operating zone selected.

to as “Carrier” frequency. PWM should be as low as possible to minimize stress on the output transistors and motor windings. It is recommended that the PWM frequency be set to approximately 16 times the maximum output frequency of the control. Ratios less than 16 will result in non-Sinusoidal current waveforms. See Figure 4-3.

Figure 4-3 Maximum Output Frequency vs PWM Frequency

It is recommended that the PWM frequency parameter be set to approximately16 times the maximum output frequency of

500

400

300

OUTPUT FREQUENCY

200

100

1.00KHz 8.00KHz 16.00KHz

the control. The greater the ratio, the more sinusoidal the output current waveform will be.

Note: The output current rating of the control must be

derated for operation between 8KHz and 16KHz PWM frequency. Derating is 10% from 2.5kHz to 5kHz and is linear from 10% at 8KHz to a 30% reduction of rated output current at 16KHz PWM operation.

PWM FREQUENCY

Programming & Operation 4-15MN723

Section 1 General Information

Table 4-3 Level 2 Parameter Block Definitions Continued

Block Title Parameter Description

CUSTOM UNITS Max Decimal

Places

Value At Speed

Value DEC Places Value Speed REF Units of Measure

Units of MEAS 2

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

External Trip OFF - External Trip is Disabled.

Local Enable INP OFF - Ignores J1-8 switched input when in the “LOCAL” mode.

Following Error This parameter determines if the control is to monitor the amount of following error

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

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

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

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

want the keypad to display at a specific motor speed (second number, right most). A

decimal may be inserted into the numbers by placing the flashing cursor over the

up/down arrow. Serial Only. * Serial Only. * Allows you to specify units of measure to be displayed on the Output Rate display. Use

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

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

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

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

selection. Serial Only. *

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

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

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

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

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

ON - Requires J1-8 Enable input to be closed to enable the control when in the

“LOCAL” mode.

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

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

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

shut down.

* Note: Serial Commands. When using the serial command option, the “Value AT Speed”, “Value DEC Places”, and “Value

Speed REF” parameters must be set. The Value AT Speed parameter sets the desired output rate per increment of motor speed. The Value DEC Places sets the desired number of decimal places of the Value AT Speed number. The Value Speed REF sets the increment of motor speed for the desired output rate.

The Units of Measure parameter sets the two left-most characters of the custom units display while the Units of MEAS 2 parameter sets the two right most characters. For example, if “ABCD” is the custom units, “AB” is set in the Level 2 Custom Units block, Units of Measure parameter and “CD” is set in the Level 2 Custom Units block, Units of MEAS 2 parameter.

Note: Custom Display Units. The output rate display is only available if the Value AT Speed parameter has been changed

from a value of 0 (zero). To access the Output Rate display, use the DISP key to scroll to the Output Rate display.

4-16 Programming & Operation MN723

Section 1 General Information

Caution: If an automatic restart of the motor control could cause injury to

personnel, the automatic restart feature should be disabled by changing the Level 2 Miscellaneous block, Restart Auto/Man parameter to manual.

Table 4-3 Level 2 Parameter Block Definitions Continued

Block Title Parameter Description

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

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

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

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

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

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

SECURITY CONTROL

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

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

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

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

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

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

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

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

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

rotate to a “Home” position when the orient input switch is closed (J1-11).

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

Note: Homing direction is always forward.

Local - Requires security Access Code to be entered before changes can be made

using the Keypad.

Serial - Requires security Access Code to be entered before changes can be made

using the Serial Link.

Total - Requires security Access Code to be entered before changes can be made

using the Keypad or serial link.

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

through the parameter values that are programmed but you are not allowed to change them unless you enter the correct access code.

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

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

power is cycled.

and Level 2 parameter values. A loss of power to the control will automatically require the secured access code for parameter adjustments.

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

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

Programming & Operation 4-17MN723

Section 1 General Information

Table 4-3 Level 2 Parameter Block Definitions Continued

Block Title Parameter Description

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

Motor Poles The number of motor poles. Factory setting is 4 poles. The values shown here are for

Resolver Speed The resolver speed. All standard BSM motors use 1 speed resolvers. CALC Presets Loads operating values into memory. These values are based on information

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

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

PROCESS CONTROL

Process Feedback Process Inverse

Setpoint Source

Setpoint Command

Set PT ADJ Limit

Process ERR TOL

Process PROP

Gain

Process INT Gain Process DIFF Gain

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

standard Baldor BSM motors.

MOTOR

BSM63, BSM80 4

BSM90, BSM100 8

BSM4F, BSM6F, BSM8F 8

BSM2R, BSM3R, BSM4R 4

BSM6R 6

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

CALC Presets must be run before Autotuning or manually tuning the drive.

Baldor for additional information.

Baldor for additional information. Sets the type of signal used for the process feedback signal.

Causes the process feedback signal to be inverted. Used with reverse acting processes

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

and 4mA will increase motor speed. Sets the source input signal to which the process feedback will be compared.

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

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

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

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

maximum feedback setpoint error). For example, if the max motor speed is 1750

RPM, the setpoint feedback error is 100% and the setpoint adjustment limit is 10%,

the maximum speed the motor will run in response to the setpoint feedback error is

±175 RPM. If at the process setpoint, the motor speed is 1500 RPM, the maximum

speed adj limits is then 1325 to 1675 RPM. Sets the width of the comparison band (% of setpoint) with which the process input is

compared. The result is that if the process input is within the comparison band the

corresponding Opto Output will become active. Sets the PID loop proportional gain. This determines how much adjustment to motor

speed (within the Set PT ADJ Limit) is made to move the analog input to the setpoint. Sets the PID loop Integral gain. This determines how quickly the motor speed is

adjusted to correct long term error. Sets the PID loop differential gain. This determines how much adjustment to motor

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

NUMBER OF

POLES

4-18 Programming & Operation MN723

Section 1 General Information

Table 4-3 Level 2 Parameter Block Definitions Continued

Block Title Parameter Description

PROCESS CONTROL (Continued)

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

AUTO TUNING

LEVEL 1 BLOCK ENTERS LEVEL 1 MENU

Follow I:O Ratio

Follow I:O Out

Master Encoder

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

CALC Presets CMD Offset Trim

CUR Loop COMP Resolver Align

SPD CNTRLR

CALC

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

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

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

Follow I:O Ratio parameter.

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

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

This parameter is visible for use only when Serial Communication is used to operate the

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

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

board is installed. Defines the number of pulses per revolution of the master encoder. Only used for follower drives.

RS-232 BBP or RS-485 BBP protocol.

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

parameter values. Occasionally, the Auto Tune procedure cannot be run due to various circumstances such as the load cannot be uncoupled from the motor. The control can be manually tuned by entering the parameter values based on calculations you have made. Refer to “Manually Tuning the Control” in the Troubleshooting section of this manual.

This procedure loads preset values into memory that are required to perform Auto Tune.

Always run CALC Presets as the first step of Auto Tune. This procedure trims offset voltage at the differential analog input at J1A-4 and J1A-5. Measures current response while running motor at one half the rated motor current. This procedure checks the electrical alignment of the resolver with respect to the motor

stator. This test locks the motor rotor into a reference position and proceeds to check

are re-adjust if necessary. Should be performed with the load coupled to the motor shaft. Sets the motor current to

acceleration ratio, Integral gain and Differential gain values. If done under no load,

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

low. If the control is too responsive when the motor is loaded, adjust the PK Current

Limit parameter to a greater value and repeat this test.

Programming & Operation 4-19MN723

Section 1 General Information

4-20 Programming & Operation MN723

Section 5 Troubleshooting

Overview

The Baldor Series 23H Control requires very little maintenance and should provide years of trouble free operation when installed and applied correctly. Occasional visual inspection and cleaning should be considered to ensure tight wiring connections and to remove dust, dirt, or foreign debris which can reduce heat dissipation.

Operational failures called “Faults” will be displayed on the Keypad Display as they occur. A comprehensive list of these faults, their meaning and how to access the fault log and diagnostic information is provided later in this section. Troubleshooting information is provided later in this section.

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

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

No Keypad Display - Display Contrast Adjustment

At power up, the display may be blank if the contrast is improperly set. Use the following procedure to adjust the display contrast.

Action Description Display Comments

Apply Power No visible display.

Press DISP key Ensures control in Display mode. Display mode.

Press SHIFT key 2 times Allows display contrast

Press  or  key

Press ENTER key Saves display contrast

adjustment. Adjusts display contrast

(intensity).

adjustment level and exits to display mode.

Troubleshooting 5-1MN723

Section 1 General Information

How to Access Diagnostic Information

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing motor speed.

Press DISP key 6 times Scroll to Diagnostic Information

screen

Press ENTER key Access diagnostic information. First Diagnostic Information

Press DISP key Display showing control

temperature.

Press DISP key Display showing bus voltage.

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

Diagnostic Access screen.

screen.

XXXV

Press DISP key Display showing % overload

Press DISP key Display showing real time opto

Press DISP key Display showing actual drive

Press DISP key Display showing operating zone,

current remaining.

input & output states. (0=Open, 1=Closed).

running time.

voltage and control type.

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

HR.MIN.SEC format.

Press DISP key Display showing continuous

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

Press DISP key Display showing which Group1 or

2 expansion boards are installed and recognized.

Press DISP key Display showing software version

and revision installed in the control.

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

ID is a hexadecimal value.

In this case, no expansion boards are installed.

information.

5-2 Troubleshooting MN723

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

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

Action

Apply Power Logo display for 5 seconds.

Display mode showing output frequency

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

Press ENTER key Display first fault type and time

Press  key

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

Fault Log entry point.

fault occurred. Scroll through fault messages.

Description Display Comments

Display mode.

Typical display.

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

on.

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

Action Description Display Comments

Apply Power Logo display for 5 seconds.

Display mode showing output frequency.

Display mode.

Press DISP key Press DISP to scroll to the Fault

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

Press SHIFT key

Press RESET key

Press SHIFT key

Press ENTER key Fault log is cleared. No faults in fault log and the

Press  or  key

Press ENTER key Return to display mode.

Log entry point.

2 = second most recent fault, etc.

internal clock is reset.

Scroll Fault Log Exit.

Troubleshooting 5-3MN723

Table 5-1 Fault Messages

FAULT MESSAGE DESCRIPTION

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

sensor. DC Bus High Bus over voltage condition occurred. DC Bus Low Bus under voltage condition occurred. External Trip An open circuit on J1-16 typically indicating an external over temperature condition

occurred. GND FLT Low impedance path detected between an output phase and ground. INT Over-Temp Temperature of control heatsink exceeded safe level. Invalid Base ID Control does not recognize power base ID. Inverter Base ID Control board installed on power base without current feedback. Line Regen FLT Only applies to Series 21H and 22H Line Regen controls. Logic Supply FLT Logic power supply not working properly. Lost User Data Battery backed RAM parameters have been lost or corrupted.

When fault cleared (Reset), the control should reset to factory preset values. Low INIT Bus V Insufficient bus voltage on startup. Memory Error EEPROM error occurred. Contact Baldor. New Base ID Control board sensed a different power base since last time it was powered up. No Faults Fault log is empty. No EXB Installed Programmed operating parameter requires an expansion board that is not installed or is

not recognized. Over Current FLT Instantaneous over current condition detected by bus current sensor. Overload - 1 min Output current exceeded 1 minute rating. Overload - 3 sec Output current exceeded 3 second rating. Over speed Motor RPM exceeded 110% of programmed MAX Motor Speed. mP Reset PWR Base FLT Desaturation of power device occurred or bus current threshold was exceeded. (On B2

Regen R PWR FLT Regen power exceeded DB resistor rating. User Fault Text Custom software operating fault occurred. Co–Processor Fault Co-Processor hardware fault occurred. Contact Baldor.

Power cycled before the residual Bus voltage reached 0VDC.

size controls, a desat error can indicate any of the following: low line impedance, brake

transistor failure or excessive internal temperature at the output transistors.)

5-4 Troubleshooting MN723

Section 1 General Information

Resolver Troubleshooting

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Continuous Overspeed Fault displayed on keypad.

Intermittent Overspeed Fault displayed on keypad.

When commanded to run, the motor will not rotate and the keypad current display is in excess of the motor rated amps. Resolver coupling has failed.

Resolver wiring connection is disconnected, a wire broken or miswired. Missing or miswired shield.

Resolver wiring connection is intermittent. Missing or miswired shield. Resolver signal is outside of specification.

The resolver has failed or is not connected properly. Resolver is not aligned properly.

Inspect and repair the resolver wiring. Terminate shield properly @ J1–28

Inspect and repair the resolver wiring. Terminate shield properly @ J1–28.

The resolver output Sine and Cosine maximum voltage must be 2VAC RMS ±10% at the J1 terminal strip. This high frequency voltage (5kHz) can only be measured with a Fluke 87 or equivalent meter or an oscilloscope. Rotate the resolver to find the max voltage.

Verify the resolver is connected and wired properly. Disable control and rotate motor by hand. If the position display in the keypad diagnostic menu shows a position change, then the resolver is probably working. Run the auto tune test to align the resolver.

Replace resolver coupling.

The fourth auto–tuning step (Resolver Align) can be used to effectively troubleshoot the system. The purpose of the test procedure is to adjust the electrical alignment of the resolver with respect to the motor stator. There are four steps that the auto tuning procedure performs:

1 . This test initially displays the calculated number of counts per motor pole pair. For example, if using a

BSM4F motor, with the MOTOR POLES parameter set to 8 and a standard 1 speed resolver, the initial keypad display will be 1024. The equation is: [4096 counts / (8 motor poles/2) = 1024].

HELPFUL HINT: If the resolver speed (or poles) is unknown, a simple test can be useful to determine the number of resolver speed. Temporarily set the resolver speed parameter to 10. With the resolver wired to the motor control, apply power to the motor control. Go to the diagnostic menu and select the position display. Rotate the motor shaft by hand until the display indicates approximately 0000:0000. Rotate the motor shaft by hand exactly 1 revolution. If the keypad display shows approximately 4096, the resolver is a 1 speed resolver, approximately 8,192 = 2 speed, approximately 12,288 = 3 speed and 16,192 = 4 speed, etc. in multiples of 4096. When the resolver speed is known, set the resolver speed parameter to the proper number before starting the auto–tune test.

2. The control then locks the motor rotor into a reference position using 50% of motor rated current and then proceeds to check and re–adjust if necessary, the factory setting of the resolver alignment parameter. This is similar to setting a clock to the local time. This parameter is scaled in degrees.

3. From the reference position, the control slowly rotates the motor through a 360° electrical cycle of current using 50% motor rated current. The number of counts from the resolver is compared against the number calculated in step 1. From the above example with the BSM4F motor, if the control receives approximately 1024 counts (±10%) from the resolver, then the test will pass. This portion of the test will take approximately 6 to 12 seconds.

HELPFUL HINT: If the motor poles are unknown, this test can be useful to determine the number of motor poles. A 2 pole motor will mechanically rotate the motor shaft 360°, a 4 pole motor will rotate 180°, a 6 pole motor will rotate 120°, a 8 pole motor will rotate 90°. Observing the mechanical rotation will indicate the number of motor poles.

4. As part of step 3, the resolver rotation is determined and the feedback alignment parameter is adjusted to the appropriate direction, FWD or REV.

Troubleshooting 5-5MN723

Section 1 General Information

Table 5-2 Troubleshooting

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

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

Loose connections. Check input power termination.

Adjust display contrast. See Adjust Display Contrast in this section.

Current Sense FLT Open circuit between control board

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

DC Bus High Excessive dynamic braking power. Increase the DECEL time.

Dynamic brake wiring problem. Check dynamic brake hardware wiring. Input voltage too high.

Too fast a Decel rate.

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

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

Motor draws excessive current. Check motor for overloading.

No thermostat connected. Connect thermostat.

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

GND FLT Improper wiring.

Wiring shorted in conduit. Motor winding shorted.

INT Over-Temp Drive Overloaded. Correct motor loading.

Ambient temperature too high. Relocate control to cooler operating area.

Cooling fans clogged or restricted air path.

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

Verify connection of operator keypad.

Check connections between control board and current sensor.

Check dynamic brake watt and resistance parameter values. Add optional dynamic braking hardware.

Verify proper AC line voltage. Use step down isolation transformer if needed. Use line reactor to minimize spikes. Increase Decel time parameter value.

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

other equipment).

Monitor power line fluctuations with date and time imprint

to isolate power problem.

Check external blower for operation. Verify motor’s internal fan is coupled securely.

Verify proper sizing of control and motor.

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

Set external trip at J1-16.

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

Verify proper sizing of control and motor.

Add cooling fans or air conditioner to control cabinet. Clean fans and air path.

parameter to “OFF” if no connection made

5-6 Troubleshooting MN723

Section 1 General Information

Table 5-2 Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

Invalid Base ID Control does not recognize HP and

Inverter Base ID Power base with no output phase

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

Low INIT Bus V Improper AC line voltage. Disconnect Dynamic Brake hardware and retry test.

Memory Error EEPROM memory fault occurred. Press “RESET” key on keypad. If fault remains, call Baldor. mP Reset

Motor has wrong response to Speed Command

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

Motor Will Not Max Output Speed set too low. Adjust MAX Output Speed parameter value. Reach Maximum Speed

Motor Will Not Stop Rotation

Voltage configuration.

current sensors being used.

Power was cycled before Bus voltage reached 0VDC.

Analog input common mode voltage may be excessive.

Motor overloaded. Check for proper motor loading.

Control not in local mode of operation.

Motor may be commanded to run below minimum frequency setting.

Incorrect Command Select parameter.

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

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

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

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

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

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

may be excessive.

Analog offset trim set incorrectly. Adjust the Level 1 Input block, ANA CMD Offset parameter value to obtain

Press “RESET” key on keypad. If fault remains, call Baldor.

Replace power base with one that has output phase current

feedback. Contact Baldor.

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

Check input AC voltage level.

Press “RESET” key on keypad.

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

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

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

Place control in local mode.

Increase speed command or lower minimum frequency setting.

Change Command Select parameter to match wiring at J1.

freely, check motor bearings.

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

Adjust MIN Output Speed parameter value.

Verify control is set to receive speed command.

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

zero speed with a zero value input command.

Troubleshooting 5-7MN723

Section 1 General Information

Table 5-2 Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

New Base ID Software parameters are not

No EXB Installed Parameter incorrectly set. Change Level 1 Input block, Command Select parameter and Level 2

Over Current FLT Current Limit parameter set lower

Overload - 3 Sec FLT

Overload - 1 Min FLT

initialized on newly installed control board.

Need expansion board. Install the correct expansion board for selected operating mode. Incorrect software Revision Software does not support the revision level of the board installed. Update

than drive rating. ACCEL/DECEL time too short. Increase ACCEL/DEC parameters in the Level 1

Electrical noise from external DC coils.

Electrical noise from external AC coils.

Excessive load. Reduce the motor load.

Excessive motor current. Verify motor leads are properly connected to control. (Motor is phase

Peak output current exceeded 3 second rating.

Excessive motor current. Verify motor leads are properly connected to control. (Motor is phase

Peak output current exceeded 1 minute rating.

Excessive motor current. Verify motor leads are properly connected to control. (Motor is phase

Press “RESET” key on keypad to clear the fault condition. Cycle power (turn power OFF then ON). Reset parameter values to factory settings. Access diagnostics and compare power base ID number to list in Table 5-3 to ensure a match. Re-enter the Parameter Block Values you recorded in the User Settings at the end of this manual. Autotune the control.

Process Control block, Process Feedback and Setpoint Source parameters, to selections that do not require an expansion board.

software. Increase PK Current Limit parameter in the Level 2

Output Limits block, not to exceed drive rating.

ACCEL/DECEL Rate block. Install reverse biased diodes across all external DC relay coils as shown in

the Opto Output circuit examples of this manual. See Electrical Noise Considerations in this Section.

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

Verify proper sizing of control and motor.

sensitive, refer to Section 3 for connection information). Check PK Current Limit parameter in the Level 2

Output Limits block.

Change Overload parameter In the Level 2 Protection block

from Fault to Foldback. Check motor for overloading. Increase ACCEL time. Reduce motor load. Verify proper sizing of control and motor.

sensitive, refer to Section 3 for connection information). Verify Level 2 Motor Data is correct.

Check PK Current Limit parameter in the Level 2

Output Limits block. Change Overload parameter In the Level 2 Protection block

from Fault to Foldback. Check motor for overloading. Increase ACCEL/DECEL times. Reduce motor load. Verify proper sizing of control and motor.

sensitive, refer to Section 3 for connection information).

5-8 Troubleshooting MN723

Section 1 General Information

Table 5-2 Troubleshooting Continued

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

Power Module Power supply failure. Press “RESET” key on keypad. If fault remains, call Baldor. PWR Base FLT Improper ground Be sure control has separate ground wire to earth ground.

Excessive current. Disconnect motor leads from control and retry test. If fault remains, call

Electrical noise from external DC coils.

Electrical noise from external AC coils.

Excessive load. Correct motor load.

Excessive power in dynamic brake circuit.

Regen R PWR FLT

Unknown Fault Fault occurred but cleared before its

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

Fault

Incorrect dynamic brake parameter. Check Resistor Ohms and Resistor Watts parameters in the Level 2 Brake

Regen power exceeded dynamic brake resistor rating.

Input voltage too high. Verify proper AC line voltage.

source could be identified.

Fault detected. Contact Baldor.

Panel grounding or conduit connection is not sufficient.

Baldor. Install reverse biased diodes across all external DC relay coils as shown in

the Opto Output circuit examples of this manual. See Electrical Noise Considerations in this Section.

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

Verify proper sizing of control and motor. Verify proper Ohm and Watt parameters of DC Injection Braking.

Increase decel time. Add optional dynamic braking hardware.

Adjust block. Add optional dynamic braking hardware.

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

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

Troubleshooting 5-9MN723

Section 1 General Information

Table 5-3 Power Base ID - Series 23H

230VAC 460VAC

Catalog

No.

2A03–E A 823 4A04–E A A3D 2A04–E A 824 4A05–E A A41 2A04–W A 824 4A08–E A A3E 2A07–E A 833 4A11–E B A07 2A10–E A 826 4A11–E B2 A4A 2A10–W A 826 4A14–E B A42 2A15–E B2 82D 4A14–E B2 A4B 2A16–E B 827 4A15–E B A42 2A16–E B2 82D 4A15–E B2 A4B 2A22–E B 828 4A15–ER C A10 2A22–E B2 82E 4A21–E B2 A4C 2A28–E B 81A 4A21–EO C2 A11 2A28–E B2 82F 4A22–ER C 8A11 2A30–ER C 4810 4A27–ER C2 A12 2A42–E B2 830 4A30–ER C 4A0B 2A42–EO C2 811 2A45–ER C 2811 2A54–ER C2 81D 2A55–ER C 6809

Size

Power

Base ID

Catalog

No.

Size

Power

Base ID

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

Information screen as a hexadecimal value.

5-10 Troubleshooting MN723

Section 1 General Information

Electrical Noise Considerations

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

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

Relay and Contactor Coils

Among the most common sources of noise are the coils of contactors and relays. When these highly inductive coil circuits are opened, transient conditions often generate spikes of several hundred volts in the control circuit. These spikes can induce several volts of noise in an adjacent wire that runs parallel to a control-circuit wire. Figure 5-1 illustrates noise suppression for AC and DC relay coils.

Figure 5-1 AC and DC Coil Noise Suppression

AC Coil

Wires between Controls and Motors

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

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

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

RC snubber

0.47 mf 33 W

DC Coil

Diode

Troubleshooting 5-11MN723

Section 1 General Information

Special Drive Situations

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

Reactors are typically 3% reactance and are designed for the frequencies encountered in PWM drives. For maximum benefit, the reactors should be mounted in the drive enclosure with short leads between the control and the reactors.

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

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

Special Motor Considerations

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

Analog Signal Wires Analog signals generally originate from speed and torque controls, plus DC tachometers

and process controllers. Reliability is often improved by the following noise reduction techniques:

• Use twisted-pair shielded wires with the shield grounded at the drive end only.

• Route analog signal wires away from power or control wires (all other wiring types).

• Cross power and control wires at right angles (90°) to minimize inductive noise

coupling.

5-12 Troubleshooting MN723

Section 6 Manual Tuning the Series 23H Control

Manually Tuning the Control In some applications the drive cannot be accurately auto-tuned. In these cases, it is

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

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

Prop Gain parameter is normally autotuned when motor inductance is not known. Where autotuning can’t be used, the proper manual setting for the proportional gain can be calculated by:

Current PROP Gain +

Where:

L = Line to neutral leakage inductance of the motor in mH VAC = Nominal line volts A/V = The amps/volt scaling of the current feedback

Motor line to neutral leakage inductance can be obtained either from the motor manufacturer or for WYE connected motors, by measuring the line–to–line inductance and dividing the measured value by two.

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

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

Current INT Gain Parameter This parameter is located in the Level 1, Brushless Control Block. The factory setting is

suitable for essentially all systems. Do not change without factory approval.

Speed Prop Gain Parameter

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

740xLxǒAńV

VAC

Manual Tuning the Series 23H Control 6-1MN723

Section 1 General Information

Speed Int Gain Parameter

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

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

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

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

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

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

3. Increase the Speed Int Gain parameter setting to increase the stiffness of the drive.

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

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

PI Controller

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

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

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

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

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

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

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

6-2 Manual Tuning the Series 23H Control MN723

Section 7 Specifications, Ratings & Dimensions

Specifications:

Power 0.75 - 37.2kW (1-50 HP) @ 230VAC

0.75 - 186.5kW (1-250 HP) @ 460VAC Input Frequency 50/60 HZ ± 5% Output Voltage 0 to Maximum Input VAC Output Current See Ratings Table Service Factor 1.0 Duty Continuous Overload Capacity Constant Torque Mode: 170-200% for 3 secs

150% for 60 secs

Variable Torque Mode: 115% for 60 secs

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

Operating Conditions:

Voltage Range: 230 VAC Models

460 VAC Models

Input Line Impedance: Size A, B, C, D, E requires 3% Minimum

Ambient Operating Temperature: –10 to +40 °C

Rated Storage Temperature: – 30 °C to +65 °C Enclosure: NEMA 1: E and EO (suffix) Models

Humidity: NEMA 1: 10 to 90% RH Non-Condensing

Altitude: Sea level to 3300 Feet (1000 Meters)

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

180-264 VAC 3f 60 Hz / 180-230 VAC 3f 50 Hz 340-528 VAC 3f 60 Hz / 380-415 VAC 3f 50 Hz

Size B2, C2, D2, F and G requires 1% Minimum

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

NEMA 4X: W (suffix) Models

NEMA 4X: To 100% RH

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

Resolver Feedback:

Sine & Cosine Inputs 2V Excitation (Reference Voltage) 4V Resolver Transformation Ratio TR = 0.5 only

±10% (Maximum Coupled)

RMS

@ 10kHz

RMS

Specifications, Ratings & Dimensions 7-1MN723

Section 1 General Information

Keypad Display:

Display Backlit LCD Alphanumeric

2 Lines x 16 Characters Keys 12 key membrane with tactile response Functions Output status monitoring

Digital speed control

Parameter setting and display

Diagnostic and Fault log display

Motor run and jog

Local/Remote toggle LED Indicators Forward run command

Reverse run command

Stop command

Jog active Remote Mount 100 feet (30.3m) max from control

Control Specifications:

Control Method PWM Command Input ±10VDC Command Signal Resolution 9 bits + Sign Feedback Resolution 12 bit Velocity Loop Bandwidth Adjustable to 30 Hz Current Loop Bandwidth Adjustable to 1500 Hz Maximum Output Frequency 500 Hz Quiet PWM Frequency Setting Full rating 1-8 kHz PWM frequency,

Adjustable to 16 kHz with linear derating (between 8 - 16kHz)

to 30% at 16 kHz Standard PWM Frequency Setting Full rating 1-2.5 kHz PWM frequency,

Adjustable to 5 kHz with linear derating (between 2.5 - 5kHz)

to 10% at 5 kHz Selectable Operating Modes Keypad

Standard Run

15 SPD

3SPD ANA 2 Wire

3SPD ANA 3 Wire

Serial

Bipolar Speed

Process

EPOT 2 Wire

EPOT 3 Wire

Differential Analog Input:

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

7-2 Specifications, Ratings & Dimensions MN723

Section 1 General Information

Other Analog Input:

Full Scale Range 0 - 10 VDC (0 to –10VDC and 0 to +10VDC are valid inputs) Resolution 9 bits + sign

Analog Outputs:

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

Digital Inputs:

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

10 mA maximum

Digital Outputs:

Opto-isolated Logic Outputs 4 Assignable ON Current Sink 60 mA Max ON Voltage Drop 2 VDC Max Maximum Voltage 30 VDC

Diagnostic Indications:

No Faults No EXB Installed Current Sense Fault Overload - 1 minute Logic Supply Fault Ground Fault Overload - 3 seconds Invalid Base ID

Overcurrent FLT Inverter Base ID Line Power Loss DC Bus High New Base ID Microprocessor Reset DC Bus Low PWR Base FLT Coprocessor Fault Lost User Data Regen R PWR FLT Over temperature (Motor or Control) Low INIT Bus V Line Regen FLT Over speed Memory Error User FLT T ext

Note: All specifications are subject to change without notice.

Specifications, Ratings & Dimensions 7-3MN723

Section 1 General Information

Ratings Series 23H Stock Products

CATALOG

NO.

NO. VOLT

SD23H2A03–E 230 A 3 6 .56 .75 4 5 .75 1 4 8 .75 1 7 8 1.5 2 SD23H2A04–E, W 230 A 4 8 .75 1 7 8 1.5 2 7 14 1.5 2 10 12 2.2 3 SD23H2A07–E 230 A 7 14 1.5 2 10 12 2.2 3 10 20 2.2 3 16 19 3.7 5 SD23H2A10–E, W 230 A 10 20 2.2 3 16 19 3.7 5 16 32 3.7 5 22 25 5.5 7.5 SD23H2A16–E 230 B 16 32 3.7 5 22 25 5.5 7.5 22 44 5.5 7.5 28 32 7.4 10 SD23H2A22–E 230 B 22 44 5.5 7.5 28 32 7.4 10 28 56 7.4 10 42 48 11.1 15 SD23H2A28–E 230 B 28 56 7.4 10 42 48 11.1 15 42 84 11.1 15 42 48 11.1 15 SD23H2A42–EO 230 C2 42 92 11.1 15 54 62 14.9 20 55 110 14.9 20 68 78 18.6 25 SD23H2A54–ER 230 C2 54 92 14.9 20 68 78 18.6 25 68 116 18.6 25 80 92 22.3 30

SD23H4A04–E 460 A 4 8 1.5 2 5 6 2.2 3 5 10 2.2 3 8 10 3.7 5 SD23H4A05–E 460 A 5 10 2.2 3 8 10 3.7 5 8 16 3.7 5 11 13 5.5 7.5 SD23H4A08–E 460 A 8 16 3.7 5 11 13 5.5 7.5 11 22 5.5 7.5 14 17 7.4 10 SD23H4A11–E 460 B 11 22 5.5 7.5 14 16 7.4 10 14 28 7.4 10 21 24 11.1 15 SD23H4A15–E 460 B 15 30 7.4 10 21 24 11.1 15 21 42 11.1 15 SD23H4A21–EO 460 C2 21 46 11.1 15 27 31 14.9 20 27 50 14.9 20 34 39 18.6 25 SD23H4A27–ER 460 C2 27 46 14.9 20 34 39 18.6 25 34 58 18.6 25 40 46 22.3 30

INPUT

VOLT

SIZE

CONSTANT TORQUE VARIABLE TORQUE CONSTANT TORQUE VARIABLE TORQUE

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

QUIET 8.0 kHz PWM STANDARD 2.5 kHz PWM

Note: –E, –EO= NEMA 1 Enclosure

–W= NEMA 4X Enclosure –MO= Protected Chassis (not NEMA1)

7-4 Specifications, Ratings & Dimensions MN723

Section 1 General Information

Terminal Tightening Torque Specifications

Table 7-4 Tightening Torque Specifications

230VAC

Catalog Numbers

Size

SD23H2A03–E A SD23H2A04–E A SD23H2A04–W A SD23H2A07–E A SD23H2A10–E A SD23H2A10–W A SD23H2A15–E B2 SD23H2A16–E B SD23H2A16–E B2 SD23H2A22–E B SD23H2A22–E B2 SD23H2A28–E B SD23H2A28–E B2 SD23H2A30–ER C SD23H2A42–E B2 SD23H2A42–EO C2 SD23H2A45–ER C SD23H2A54–ER C2 SD23H2A55–ER C

460VAC

Catalog Numbers

Size

SD23H4A04–E A SD23H4A05–E A SD23H4A08–E A SD23H4A11–E B SD23H4A11–E B2 SD23H4A14–E B SD23H4A14–E B2 SD23H4A15–E B SD23H4A15–E B2 SD23H4A15–ER C SD23H4A21–E B2 SD23H4A21–EO C2 SD23H4A22–ER C SD23H4A27–ER C2 SD23H4A30–ER C

Power TB1 Ground Control J1

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

8 0.9 15 1.7 4.5 0.5 8 0.9 8 0.9 15 1.7 4.5 0.5 8 0.9 8 0.9 15 1.7 4.5 0.5 8 0.9 8 0.9 15 1.7 4.5 0.5 8 0.9 8 0.9 15 1.7 4.5 0.5 8 0.9

8 0.9 15 1.7 4.5 0.5 8 0.9 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 35 4.0 35 4.0 4.5 0.5 50 5.6 32 3.6 20 2.5 15 1.7 4.5 0.5 20 2.5 50 5.6 50 5.6 4.5 0.5 50 5.6 32 3.6 35 4.0 35 4.0 4.5 0.5 50 5.6 32 3.6 50 5.6 50 5.6 4.5 0.5 50 5.6 32 3.6 35 4.0 35 4.0 4.5 0.5 50 5.6 32 3.6

Power TB1 Ground Control J1

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

8 0.9 15 1.7 4.5 0.5 8 0.9

8 0.9 15 1.7 4.5 0.5 8 0.9 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 20 2.5 15 1.7 4.5 0.5 20 2.5 35 4.0 35 4.0 4.5 0.5 50 5.6 32 3.6 20 2.5 15 1.7 4.5 0.5 20 2.5 50 5.6 50 5.6 4.5 0.5 50 5.6 32 3.6 35 4.0 35 4.0 4.5 0.5 50 5.6 32 3.6 50 5.6 50 5.6 4.5 0.5 50 5.6 32 3.6 35 4.0 35 4.0 4.5 0.5 50 5.6 32 3.6

Tightening Torque

B+/R1; B+; B–;

or R2

B+/R1; B+; B–;

or R2

D1/D2

Specifications, Ratings & Dimensions 7-5MN723

Section 1 General Information

Dimensions

Size A Control

7.20

(182.9mm)

LOCAL

JOG

DISP

FWD

SHIFT

REV

RESET

STOP

Air

7.120

0.25

(180.8mm)

(6.4mm)

PROG

ENTER

11.50 (292.1mm)

Outlet

12.00

(304.8mm)

KP5000

.25

(6.4mm)

7.20

(182.9mm)

Air Inlet

0.88 Dia. (22.35 mm)

7.70

(195.6mm)

7-6 Specifications, Ratings & Dimensions MN723

Section 1 General Information

Dimensions Continued

Size B Control

9.25

(225.0mm)

JOG

FWD

REV

STOP

0.28 TYP (7.1mm)

LOCAL

PROG

DISP

SHIFT

ENTER

RESET

7.120

(180.9mm)

Air

Outlet

14.65 (372.1mm)

15.40

(391.2mm)

0.88 Dia. (22.35 mm)

KP5002

.28 TYP (7.1mm)

9.25

(235.0mm)

Air Inlet

1.12 Dia. (28.45 mm)

10.00

(254.0mm)

Specifications, Ratings & Dimensions 7-7MN723

Section 1 General Information

Dimensions Continued

Size B2 Control

7.20

(182.9mm)

JOG

FWD

REV

STOP

0.28 TYP (7.1mm)

LOCAL

PROG

DISP

SHIFT

ENTER

RESET

Air Outlet

8.73

(221.7mm)

12.15

(308.6mm)

.28 TYP

(7.1mm)

1.12 Dia. (28.45 mm)

7.20

(182.9mm)

11.50

(292.1mm)

Air Inlet

7.20

(182.9mm)

8.07

(205.0mm)

10.92

(277.5mm)

8.00

11.50

(292.1mm)

Cutout for through

wall mounting

(203.2mm)

8.70

(221.0mm)

0.280 (7mm) Dia. hole through wall 4 Places

OM0001A15

7-8 Specifications, Ratings & Dimensions MN723

Section 1 General Information

Dimensions Continued

Size C Control

.38

(9.5 mm)

.38

(9.5 mm)

18.50

(470.0 mm)

17.75

(451 mm)

17.00

(433.0 mm)

11.50

(292.0 mm)

10.75

(273.0 mm)

JOG

FWD

REV

STOP

9.50

(241.5 mm)

9.50

(241.5 mm)

.28 (7.0mm)

Air

Outlet

2 Places

LOCAL

PROG

DISP

SHIFT

ENTER

RESET

V8525

0.875 Dia. (22.23 mm)

1.734 Dia. (44.04 mm)

.28 (7.0mm) 2 Places

0.50 Dia. (12.70 mm)

0.875 Dia. (22.23 mm)

One or Two Fan(s) (119mm)

Customer

Power Connections

Air Inlet

Specifications, Ratings & Dimensions 7-9MN723

Section 1 General Information

Dimensions Continued

Size C2 Control

0.000

0.916

16.568

16.075

15.665

0.280 Dia. 2 Places

LOCAL

JOG

DISP

FWD

SHIFT

REV

RESET

STOP

Air Outlet

8.675

PROG

ENTER

16.98 (431.3)

0.903

0.493

0.00

2.207 Dia. (56.06 mm)

1.734 Dia. (44.04 mm)

OM0012A00D1 EH0073A00D1

0.000

0.260

0.916

10.50 (266.7)

0.250 Dia. 2 Places

8.675

9.340

4.95 (125.7)

4.71 (119.6)

9.66 (245.4)

0.875 Dia. (22.23 mm)

0.5 Dia (12.7 mm)

Through Wall Mtg. Flange

Wall Mount Mtg. Flange

Air Inlet

7-10 Specifications, Ratings & Dimensions MN723

Section 1 General Information

Dimensions Continued

Size C2 Control – Through–Wall Mounting

0.00

15.50 (393,7)

15.25 (387,4)

14.91 (378,1)

0.00

0.33 (8,4)

Note: Throughwall mounting provides NEMA 4 protection.

1.00 (25,4)

AB AB

0.280 Dia. hole through wall 4 Places coded “A”

Cutout for through

wall mounting

0.280 Dia. hole through wall 4 Places coded “B”

ABAB

0.00

1.00 (25,4)

2.75 (69,8)

For clarity, cover and inside components not shown.

9.76 (247,9)

8.76 (222,5)

7.01 (178.0)

8.76 (222,5)

1/4-20 or M6 self sealing bolt and flat washer 4 places each (holes coded “A”)

Control Assembly

Customer’s Panel (Cutout)

Cut single coated vinyl foam tape (3M #4726–0.4062x36 yds.) and apply to the perimeter to seal installation of the drive assembly.

Specifications, Ratings & Dimensions 7-11MN723

Section 1 General Information

Dimensions Continued

Size D Control

25.00

(635.0mm)

24.25

(616.0mm)

14.50

(368.5mm)

13.50

(343.0mm)

Air

Outlet

LOCAL

PROG

JOG

DISP

FWD

SHIFT

ENTER

REV

RESET

STOP

23.12

(587.0mm)

0.875 Dia. (22.23 mm)

.31

(8.0mm)

2.469 Dia. (62.71 mm)

0.50 Dia. (12.70 mm)

0.875 Dia. (22.23 mm)

CUSTOMER

POWER

CONNECTIONS

10.00

(254.0mm)

10.20

(259.0mm)

AIR INLET

V8526 EH0001A38

7-12 Specifications, Ratings & Dimensions MN723

Dimensions Continued

Size D2 Control

24.00 (607)

23.00 (585)

13.00 (330)

9.50 (241)

0.375 Dia. 4 Places

21.00 (535)

9.09 (231)

Through Wall

Mounting Flange

OM0001A01 EH0001A16

2.45 Dia. 2 Places

Wall Mounting

Flange

6.09 (155)

3.09 (78)

11.035 (280)

2.00 Dia.

12.24 (311)

11.91 (303)

0.50 Dia.

6.885 (175)

0.875 Dia. 2 Places

7.864 (200)

8.464 (215)

9.114 (232)

10.00 (254)

10.33 (263)

Specifications, Ratings & Dimensions 7-13MN723

Dimensions Continued

Size D2 Control – Through–Wall Mounting

22.25 (565)

21.50 (546)

Mounting hole locations for Thru-Wall or surface mounting. Recommended .31 – 18 Tap. (4 Places)

Cutout for thru–wall mounting

.00

0.75 (19)

.00

1.50 (38)

11.00 (280)

12.50 (317)

7-14 Specifications, Ratings & Dimensions MN723

Section 1 General Information

Dimensions Continued

Size E Control

Air

Outlet

30.00

(762mm)

.38 (9.5mm)

2 Places

.38 (9.5mm) 2 Places

17.70

(450mm)

Thru–wall

Mounting Flange

(146mm)

5.75

Surface

Mounting

Flange

6.25

(159mm)

2.469 Dia. (62.71 mm)

0.875 Dia. (22.23 mm) 3 places

V8316 EH0001A43

Air Inlet

0.50 Dia. (12.70 mm)

0.875 Dia. (22.23 mm)

Specifications, Ratings & Dimensions 7-15MN723

Baldor SD23H2A03–E, SD23H2A04–E, SD23H2A04–W, SD23H2A07–E, SD23H2A10–E Installation & Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual