Baldor ZD18H201–E, ZD18H401–E, ZD18H501–E, ZD18H201–W, ZD18H401–W Installation & Operating Manual
...
VECTOR DRIVE
AC Flux Vector Control
SERIES 18H
Installation
9/97 MN718
& Operating Manual
Table of Contents
Section 1
Quick Start Guide
Overview 1-1
Quick
Quick
Section
General Information 2-1.
Section
Receiving & Installation
2
Overview 2-1
Limited Warranty 2-2.
Safety
Notice
3
Receiving
Physical
Control
Through
Optional
Electrical
Input
AC
Wire
AC
Optional
Encoder
Home
Buffered
Location
Installation
the W
Remote Keypad Installation
Installation
System
Line
Impedance
Line Reactors 3-7.
Load Reactors 3-7.
Current Requirements
Main Circuit
Protection Devices 3-10.
Power
Size and Protection Devices
Line Connections
380-400 VAC Configuration
Three
Single
Single
Size
A and B Single Phase Power Installation
Size
C and D Single Phase Power Installation
Size
E Single Phase Power Installation
Size
F Single Phase Power Installation
Dynamic Brake Hardware
Physical
Electrical
Installation
(Orient) Switch Input
Encoder Output
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Start Checklist
Start Procedure
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& Inspection
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all Mounting
Grounding
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Disconnect
Phase Input Power
Phase Input Power Considerations
Phase Control Derating
Installation
Installation
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1-1.
1-1.
1-2.
2-3.
3-1.
3-1.
3-1.
3-2.
3-2.
3-3.
3-4.
3-4.
3-6.
3-9.
3-10.
3-10.
3-10.
3-13.
3-13.
3-15.
3-18.
3-18.
3-18.
3-20.
3-22.
3-24.
3-26.
3-26.
3-27.
3-30.
3-32.
3-32.
MN718
Table
of Contents i
Section 1
General Information
Control Circuit Connections
Keypad
Standard
15
Fan
Fan
Bipolar
Process
Specific
Analog
Analog
Analog
External T
Opto-Isolated
Opto-Isolated
Pre-Operation
Power-Up
Section
Programming and Operation 4-1.
4
Overview 4-1
Display
Adjusting
Display
Display
Fault Log Access 4-5.
Program
Parameter
Changing
Reset
Initialize
Parameter
Mode Connections
Run 3 Wire Mode Connections
Speed 2-Wire Mode Connections
Pump 2 Wire Control Mode
Pump 3 Wire Control Mode
Speed and T
Mode Connections
Process Mode Outputs
Inputs and Outputs
Inputs
Outputs
rip Input
Inputs
Outputs
Procedure
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Mode
Mode Screens
Screens & Diagnostic Information Access
Mode
Parameters to Factory Settings
New Firmware
Definitions
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Checklist
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Display Contrast
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Blocks Access for Programming
Parameter V
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orque Mode Connections
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alues when Security Code Not Used
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3-33.
3-33.
3-35.
3-37.
3-39.
3-40.
3-41.
3-43.
3-45.
3-47.
3-47.
3-50.
3-51.
3-51.
3-53.
3-55.
3-56.
4-2.
4-2.
4-3.
4-4.
4-6.
4-6.
4-7.
4-8.
4-9.
4-10.
ii T
able of Contents
MN718
Section 1
General Information
Section 5
Troubleshooting 5-1.
No
Keypad Display - Display Contrast Adjustment
How
to Access the Fault Log
How
to Clear the Fault Log
How
Electrical
Causes
Special
Drive
Radio Transmitters 5-14.
Control
Special
Wiring Practices 5-16.
Optical
Plant
Section
Manual Tuning the Series 18H Control
Manually T
Isolation
Ground
6
Motor
Slip
Current
Current
Speed
Speed
PI
Controller
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to Access Diagnostic Information
Noise Considerations
and Cures
Drive Situations
Power Lines
Enclosures
Motor Considerations
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uning the Control
Mag Amps Parameter
Frequency Parameter
Prop Gain Parameter
Int Gain Parameter
Prop Gain Parameter
Int Gain Parameter
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5-1.
5-3.
5-3.
5-4.
5-11.
5-11.
5-14.
5-14.
5-15.
5-15.
5-17.
5-17.
6-1.
6-1.
6-1.
6-1.
6-1.
6-2.
6-2.
6-2.
6-3.
MN718
Table
of Contents iii
Section 1
General Information
Section 7
Specifications, Ratings & Dimensions
Specifications 7-1
Operating
Keypad
Control
Differential
Analog
Digital
Digital
Diagnostic
Ratings 7-4
Terminal T
Dimensions 7-10
Size
Size
Size
Size
Size
Size
Size
Size
Size
Size
Size
Appendix
Appendix
Appendix
A
Dynamic
RGA
RBA
RTA
B
Parameter Values B-1.
C
Remote
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Conditions
Display
Specifications
Analog Input
Outputs
Inputs
Outputs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ightening T
A Control
A Control – Through–W
B Control
B Control – Through–W
C Control
D Control
E Control
E Control – Through–W
F Control
F Control – Through–W
G Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking (DB) Hardware
Assemblies
Assemblies
Assemblies
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Keypad Mounting T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Indications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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orque Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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emplate C-2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
all Mounting
all Mounting
all Mounting
all Mounting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1.
7-1.
7-2.
7-2.
7-2.
7-3.
7-3.
7-3.
7-3.
7-6.
7-10.
7-11.
7-12.
7-13.
7-14.
7-15.
7-16.
7-17.
7-19.
7-20.
7-22.
A-1.
A-1.
A-4.
A-5.
A-6.
B-1.
C-1.
iv T
able of Contents
MN718
Section 1
Quick Start Guide
Overview
Quick Start Checklist
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
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
4.
Connect the motor, refer to Section 3 “Three Phase Input Power”.
5.
Connect the encoder
6.
Install Dynamic brake hardware, if required. Refer to Section 3 “Optional
Dynamic Brake Hardware”.
Check of electrical items.
CAUTION: After completing the installation but before you apply power
1. V
erify AC line voltage at source matches control rating.
2.
Inspect all power connections for accuracy
as compliance to codes.
3. V
erify 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.
. This will allow motor and control operation to be verified. This
, refer to Section 3 “AC Line Connections”.
, refer to Section 3 “Encoder Installation”.
, be
sure to check the following items.
, workmanship and torques as well
.
W
ARNING: 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. V
erify freedom of motion for all motor shafts and that all motor couplings are
tight without backlash.
2. V
erify the holding brakes if any, are properly adjusted to fully release and set to
the desired torque value.
MN718
Quick
Start Guide 1-1
Section 1
General Information
Quick Start Procedure
Initial Conditions
Be sure the Control, Motor and Dynamic Brake hardware are wired according to the
procedures described 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. V
erify that any enable inputs to J1-8 are open.
2. T
urn power on. Be sure there are no faults.
3.
Set the Level 1 Input block, Operating Mode to “KEYP
4.
Be sure the Level 2 Protection block, Local Enable INP parameter is OFF and
the Level 2 Protection block, External T
5.
Set the Level 2 Output Limits block, “OPERA
(STD CONST TQ, STD V
6.
Enter the following motor data in the Level 2 Motor Data block parameters:
Motor V
Motor Rated Amps (FLA)
Motor Rated Speed (base speed)
Motor Rated Frequency
Motor Mag Amps (no load current)
Encoder Counts
7.
Go to Level 2 Motor Data block, press ENTER, at CALC PRESETS select YES
(using the Y key) and let the control calculate preset values for the parameters
that are necessary for control operation.
8.
Disconnect the motor from the load (including coupling or inertia wheels). If the
load cannot be disconnected, refer to Section 6 and manually tune the control.
After manual tuning, perform steps 10, 1
oltage (input)
AR TQ, QUIET CONST TQ or QUIET V
rip parameter is OFF
TING ZONE” parameter as desired
1, 15, 16 and 17.
AD”.
.
AR TQ).
W
ARNING: The motor shaft will rotate during this procedure. Be certain that
unexpected motor shaft movement will not cause injury to
personnel or damage to equipment.
9.
Go to Level 2 Autotune block, and do the following tests:
CMD OFFSET TRIM
CUR LOOP COMP
STAT
OR R1
FLUX CUR SETTING
ENCODER TESTS
SLIP FREQ TEST
10.
Set the Level 2 Output Limits block, “MIN OUTPUT SPEED” parameter
11.
Set the Level 2 Output Limits block, “MAX OUTPUT SPEED” parameter
12.
Remove all power from the control.
13.
Couple the motor to its load.
14. T
urn power on. Be sure no errors are displayed.
15.
Go to Level 2 Autotune block and perform the SPD CNTRLR CALC test.
16.
Run the drive from the keypad using one of the following: the arrow keys for
direct speed control, a keypad entered speed or the JOG mode.
17.
Select and program additional parameters to suit your application.
The control is now ready for use the in keypad mode. If a dif
desired, refer to Section 3 Control Connections and Section 4 Programming and
Operation.
ferent operating mode is
.
.
1-2
Quick Start Guide
MN718
Section 2
General Information
Overview
The Baldor Series 18H PWM control uses flux vector technology
(sometimes referred to as Field Oriented Control) is a closed loop control scheme using
an algorithm to adjust the frequency and phase of voltage and current applied to a three
phase induction motor
torque producing components. These components are independently adjusted and
vectorially added to maintain a 90 degree relationship between them. This produces
maximum torque from base speed down to and including zero speed. Above base
speed, the flux component is reduced for constant horsepower operation. In addition to
the current, the electrical frequency must also be controlled. The frequency of the
voltage applied to the motor is calculated from the slip frequency and the mechanical
speed of the rotor
phasing in response to speed and position feedback from an encoder mounted to the
motors’ shaft.
The control’s rated horsepower is based on the use of a NEMA design B four pole motor
and 60Hz operation at nominal rated input voltage. If any other type of motor is used, the
control should be sized to the motor using the rated current stated on the motor
nameplate.
The Baldor Series 18H control may be used in many dif
programmed by the user to operate in four dif
constant torque or variable torque. It can also be configured to operate in a number of
modes depending upon the application requirements and user preference.
It is the responsibility of the user to determine the optimum operating zone and mode to
interface the control to the application. These choices are made with the keypad as
explained in Section 4 of this manual.
. The vector control separates the motor current into it’
. This provides instantaneous adjustment of the voltage and current
ferent applications. It may be
ferent operating zones; standard or quiet
. Flux vector technology
s flux and
MN718
General
Information 2-1
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
lieu of any other warranty or guarantee expressed or implied. BALDOR
shall not be held responsible for any expense (including installation and
removal),
person or property caused by items of our manufacture or sale. (Some
states do not allow exclusion or limitation of incidental or consequential
damages,
total liability, under all circumstances, shall not exceed the full purchase
price of the control. Claims for purchase price refunds, repairs, or
replacements
defect, the date purchased, the task performed by the control, and the
problem
fuses.
Goods may be returned only with written notification including a BALDOR
Return
with the instructions and/or ratings supplied.
inconvenience, or consequential damage, including injury to
so the above exclusion may not apply
.) In any event, BALDOR’
This warranty is in
any
must be referred to BALDOR with all pertinent data as to the
encountered. No liability is assumed for expendable items such as
Authorization Number and any return shipments must be prepaid.
s
2-2 General Information
MN718
Safety Notice This
can cause serious or fatal injury
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
qualified personnel should attempt the start–up procedure or troubleshoot this equipment.
PRECAUTIONS
equipment contains voltages that may be as high as 1000 volts! Electrical shock
. Only qualified personnel should attempt the start–up
. Only
W
ARNING:
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.
W
ARNING:
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.
W
ARNING: 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.
W
ARNING:
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
W
ARNING:
serious or fatal injury
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
W
ARNING: 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.
W
ARNING:
Motor circuit may have high voltage present whenever AC power is
applied, even when motor is not rotating. Electrical shock can
W
ARNING:
cause serious or fatal injury
Dynamic brake resistors may generate enough heat to ignite
.
combustible materials. Keep all combustible materials and
flammable vapors away from brake resistors.
W
ARNING: 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
MN718
General Information 2-3
Section 1
General Information
Caution: T
Caution: Disconnect motor leads (T1, T2 and T3) from control before you
Caution: Do not connect AC power to the Motor terminals T1, T2 and T3.
Caution: Baldor recommends not using “Grounded Leg Delta” transformer
Caution: Do not supply any power to the External Trip (motor thermostat)
o prevent equipment damage, be certain that the electrical service
is not capable of delivering more than the maximum line short
circuit current amperes listed for 230 V
control rating.
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.
Connecting AC power to these terminals may result in damage to
the control.
power leads that may create ground loops and degrade system
performance. Instead, we recommend using a four wire W
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.
AC, 460 V
AC or 575 V
ye.
AC
2-4
General Information
MN718
Section 3
Receiving & Installation
Receiving & Inspection The
for shipment. When you receive your control, there are several things you should do
immediately.
Physical Location The
from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and
vibration. Exposure to these elements can reduce the operating life and degrade
performance of the control.
Several other factors should be carefully evaluated when selecting a location for
installation:
Series 18H V
1.
Observe the condition of the shipping container and report any damage
immediately to the commercial carrier that delivered your control.
2. V
number listed on your purchase order
3.
If the control is to be stored for several weeks before use, be sure that it is
stored in a location that conforms to published storage specifications. (Refer to
Section 7 of this manual).
location of the 18H is important. It should be installed in an area that is protected
1.
For ef
on a flat, smooth, non-flammable vertical surface. T
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
may optionally be remote mounted up to 100 feet from the control.)
Controls installed in a floor mounted enclosure must be positioned with
clearance to open the enclosure door
suf
4. Altitude derating
3300 ft, derate the continuous and peak output current by 2% for each 1000 ft.
5. T
the continuous and peak output current by 2% per °C. Maximum ambient is
55°C.
ector Control is thoroughly tested at the factory and carefully packaged
erify that the part number of the control you received is the same as the part
.
fective cooling and maintenance, the control should be mounted vertically
ficient air space for cooling.
. Up to 3300 feet (1000 meters) no derating required. Above
emperature derating
. Up to 40°C no derating required. Above 40°C, derate
able 3-1 lists the W
. (The keypad
. This clearance will also provide
atts
.
Table 3-1 Series 18H Watts Loss Ratings
Enclosure
A and B
C, D, E, and F
MN718
Size
G
2.5KHz
PWM
14 W
Amp
12 W
Amp
230 V
atts/
atts/
AC
8.0KHz
PWM
17 W
15 W
atts/
Amp
atts/
Amp
2.5KHz
PWM
17 W
Amp
15 W
Amp
15 W
Amp
460 V
atts/
atts/
atts/
AC
8.0KHz
PWM
26 W
Amp
23Watts/
Amp
atts/
2.5KHz
PWM
18 W
atts/
Amp
19Watts/
Amp
Receiving
575 V
AC
8.0KHz
PWM
28 W
atts/
Amp
29 W
atts/
Amp
& Installation 3-1
Section 1
General Information
Control Installation The
control must be securely fastened to the mounting surface. Use the four (4)
mounting holes to fasten the control to the mounting surface or enclosure.
Shock Mounting
If the control will be subjected to levels of vibration greater than 0.5G at 10 to 60Hz, the
control should be shock mounted. Excessive vibration within the control could cause
internal connections to loosen and cause component failure or electrical shock hazard.
Through the Wall MountingControl
control through the wall, a Through the W
are:
Kit No. Description
KT0000A00
KT0001A00
V0083991
V0084001
Procedure:
1.
2.
3.
4.
5.
6.
sizes E and F are designed for panel or through the wall installation. T
all mounting kit must be purchased. These kits
Size A control through the wall mounting kit.
Size B control through the wall mounting kit.
Size E control through the wall mounting kit.
Size F control through the wall mounting kit.
Refer to Section 7 of this manual for drawings and dimensions of the through
the wall mounting kits. Use the information contained in these drawings to
layout the appropriate size hole on your enclosure and wall.
Cut the holes in your enclosure and wall.
Locate and drill holes for mounting hardware as shown in the drawings.
Cut foam tape and apply to perimeter of opening as shown.
Secure the four (4) brackets to the exterior of the customers panel with the
hardware provided.
Secure the control to the customers panel using the hardware provided.
o mount a
3-2
Receiving & Installation
MN718
Section 1
General Information
Optional Remote Keypad Installation
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 T
4X indoor rating.
Tools Required:
Mounting Instructions: For tapped mounting holes
Mounting Instructions:
For clearance mounting holes
The keypad may be remotely mounted using the optional Baldor keypad
•
Center punch, tap handle, screwdrivers (Phillips and straight) and crescent
wrench.
•
8-32 tap and #29 drill bit (for tapped mounting holes) or #19 drill (for clearance
mounting holes).
• 1-1/4″
• R
•
•
•
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
standard knockout punch (1-11/16″
TV 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.
Locate a flat 4″ wide x 5.5″ minimum high mounting surface. Material should
be suf
ficient thickness (14 gauge minimum).
Place the template on the mounting surface or mark the holes as shown.
Accurately center punch the 4 mounting holes (marked A) and the large
knockout (marked B).
Drill four #29 mounting holes (A). Thread each hole using an 8-32 tap.
Locate the 1-1/4″
instructions.
Debur knockout and mounting holes making sure the panel stays clean and flat.
Apply R
Assemble the keypad to the panel. Use 8–32 screws, nuts and lock washers.
From the inside of the panel, apply R
and nuts. Cover a 3/4″
encapsulate the nut and washer
Locate a flat 4″ wide x 5.5″ minimum high mounting surface. Material should
be suf
Place the template on the mounting surface or mark the holes as shown on the
template.
Accurately center punch the 4 mounting holes (marked A) and the large
knockout (marked B).
Drill four #19 clearance holes (A).
Locate the 1-1/4″
instructions.
Debur knockout and mounting holes making sure the panel stays clean and flat.
Apply R
Assemble the keypad to the panel. Use 8–32 screws, nuts and lock washers.
From the inside of the panel, apply R
and nuts. Cover a 3/4″
encapsulate the nut and washer
TV to the 4 holes marked (A).
ficient thickness (14 gauge minimum).
TV to the 4 holes marked (A).
ype 4X indoor enclosure, it retains the T
nominal diameter).
knockout center (B) and punch using the manufacturers
TV over each of the four mounting screws
area around each screw while making sure to completely
.
knockout center (B) and punch using the manufacturers
TV over each of the four mounting screws
area around each screw while making sure to completely
.
ype
MN718
Receiving
& Installation 3-3
Section 1
General Information
Electrical Installation Interconnection
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
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.
Caution: Baldor recommends not using “Grounded Leg Delta” transformer
Figure 3-1 Recommended System Grounding
wiring is required between the motor control, AC power source, motor
. Only Class 1 wiring should be
power leads that may create ground loops and degrade system
performance. Instead, we recommend using a four wire W
ye.
,
AC Main
Supply
Safety
Ground
Driven Earth
Ground Rod
(Plant Ground)
L1
L2
L3
Earth
Four Wire
“Wye”
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.
Optional
Line
Reactor
LOCAL
JOG
DISP
FWD
SHIFT
REV
RESET
STOP
Series H
L1
L2 L3 T1 T2 T3
PROG
ENTER
Note: Wiring shown for clarity of grounding
method only. Not representative of
actual terminal block location.
Optional
Load
Reactor
Ground
per NEC and
Local codes.
Connect all wires (including motor ground)
inside the motor terminal box.
3-4
Receiving & Installation
MN718
Section 1
General Information
Ungrounded Distribution System
With an ungrounded power distribution system it is possible to have a continuous current
path to ground through the MOV devices. T
transformer with a grounded secondary is recommended. This provides three phase AC
power that is symmetrical with respect ground.
Input Power Conditioning
Baldor controls are designed for direct connection to standard three phase lines that are
electrically symmetrical with respect to ground. Certain power line conditions must be
avoided. An AC line reactor or an isolation transformer may be required for some power
conditions.
S
Baldor Series H controls require a minimum line impedance of 3%. Refer to
“Line Impedance” for additional information.
S
If the feeder or branch circuit that provides power to the control has
permanently connected power factor correction capacitors, an input AC line
reactor or an isolation transformer must be connected between the power factor
correction capacitors and the control.
S
If the feeder or branch circuit that provides power to the control has power
factor correction capacitors that are switched on line and of
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 (T
Suppressor) of the proper rating must be installed between the AC line reactor
or an isolation transformer and the AC input to the control.
o avoid equipment damage, an Isolation
f line, the capacitors
ransient V
oltage Surge
MN718
Receiving
& Installation 3-5
Section 1
General Information
Line Impedance
The Baldor Series 18H control requires a minimum line impedance of 3% (voltage drop
across the reactor is 3% when the control draws rated input current). If the incoming
power line has less than 3% impedance, a 3 phase line reactor can be used to provide
the needed impedance in most cases. Line reactors are optional and are available from
Baldor.
The input impedance of the power lines can be determined in two ways:
1.
Measure the line to line voltage at no load and at full rated load.
Use these measured values to calculate impedance as follows:
(Volts
%Impedance+
2.
Calculate the short circuit current capacity of the power line. If the short circuit
NoLoadSpeed
(Volts
*Volts
NoLoadSpeed
FullLoadSpeed
)
)
100
current capacity is greater than the published maximum short circuit current
ratings for the control, a line reactor should be installed.
T
wo methods of calculating short circuit current capacity are provided:
A.
Method 1
Calculate short circuit current as follows:
SC
+
(KVA
I
Example: 50KV
SC
(50 1000 100)
+
B.
I
Method 2
Step 1: Calculate KV
KVA
SC
+
(%Z
A transformer with 2.75% impedance @ 460V
(2.75 460 3Ǹ)
1000 100)
XFMR
V
XFMR
A short circuit as follows:
(KVA
XFMR
%Z
XFMR
(
)
100
3Ǹ)
L*L
AC
+2282Amps
)
+
50
ǒ
.0275
Ǔ
+1818.2KVA
Step 2: Calculate short circuit current as follows:
SC
(KVASC 1000)
+
(V
L*L
3Ǹ)
I
1818.2 1000
+
460 3
+2282Amps
Ǹ
where:
KVA
XFMR
=T
ransformer KV
A
Isc=short circuit current
Z
=T
XFMR
V
L–L
ransformer Impedance
=Input volts measured line to line
3-6
Receiving & Installation
MN718
Section 1
General Information
Line Reactors
Load
Reactors
Three phase line reactors are available from Baldor
the *Quad Rated HP of the control. If providing your own line reactor
formula to calculate the minimum inductance required. T
. The line reactor to order is based on
, use the following
able 3-3 lists the input current
required for this calculation, for each control size.
(V
0.03)
L
LL
(I 3 377)
Where:
L Minimum inductance in Henries.
V
L–L
0.03 Desired percentage of input impedance.
I Input current rating of control.
377 Constant used with 60Hz power.
Line reactors may be used at the control output to the motor
Input volts measured line to line.
Use 314 if input power is 50Hz.
. When used this way
, they
are called Load Reactors. Load reactors serve several functions that include:
S
Protect the control from a short circuit at the motor
S
Limit the rate of rise of motor surge currents.
S
Slowing the rate of change of power the control delivers to the motor
.
.
Load reactors should be installed as close to the control as possible. Selection should be
based on the motor nameplate FLA value.
*Quad Rated HP of the control refers to the four (4) dif
ferent HP ratings of the control that
are based on operating in Standard (2.5KHz PWM) or Quiet (8.0KHz PWM) in either
Constant T
orque or V
ariable T
orque. The ratings are provided in Section 7 of this
manual.
MN718
Receiving
& Installation 3-7
Section 1
General Information
Table 3-2 Short Circuit Current Ratings
230VAC 460VAC 575VAC
Catalog Numbers Max. Line
Short Circuit
Amps
ZD18H201–E 250 ZD18H401–E 150 ZD18H501–E 50
ZD18H201–W 350 ZD18H401–W 200 ZD18H502–E 100
ZD18H202–E 350 ZD18H402–E 200 ZD18H503–E 150
ZD18H202–W 550 ZD18H402–W 300 ZD18H505–E 200
ZD18H203–E or W 550 ZD18H403–E or W 300 ZD18H507–E 300
ZD18H205–E 550 ZD18H405–E 300 ZD18H510–E 400
ZD18H205–W 1000 ZD18H405–W 500 ZD18H515–E, EO or ER 600
ZD18H207–E or W 1000 ZD18H407–E or W 500 ZD18H520–EO or ER 1000
ZD18H210–E 1000 ZD18H410–E 500 ZD18H525–EO or ER 1100
ZD18H210L–ER 1500 ZD18H410L–ER 800 ZD18H530–EO or ER 1500
ZD18H215–E, EO or ER 1900 ZD18H415–E, EO or ER 1000 ZD18H540–EO or ER 1800
ZD18H215L–ER 1900 ZD18H415L–ER 1000 ZD18H550–EO or ER 2200
ZD18H220–EO or ER 2400 ZD18H420–EO or ER 1200 ZD18H560–EO or ER 2700
ZD18H220L–ER 2100 ZD18H420L–ER 1200 ZD18H575–EO or ER 3300
ZD18H225–EO or ER 2800 ZD18H425–EO or ER 1400 ZD18H5100–EO or ER 4200
ZD18H225L–ER 2500 ZD18H425L–ER 1400 ZD18H5150V–EO or ER 4800
ZD18H230V–EO or ER 3600 ZD18H430V–EO or ER 1800
ZD18H230–EO or ER 3600 ZD18H430–EO or ER 1800
ZD18H230L–ER 3600 ZD18H430L–ER 1800
ZD18H240–MO or MR 4500 ZD18H440–MO or MR 2300
ZD18H240L–MR 4000 ZD18H440L–MR 2300
ZD18H250V–MO or MR 4500 ZD18H450–EO or ER 2800
ZD18H250–MO or MR 4500 ZD18H450L–ER 2800
Catalog Numbers Max. Line
Short Circuit
Amps
ZD18H460–EO or ER 3500
ZD18H460V–EO or ER 3500
ZD18H460L–ER 3500
ZD18H475–EO 4300
ZD18H475L–EO 4300
ZD18H4100–EO 5500
ZD18H4150V–EO 6200
ZD18H4150–EO 8300
ZD18H4200–EO 11000
ZD18H4250–EO 13800
ZD18H4300–EO 16600
ZD18H4350–EO 19900
ZD18H4400–EO 19900
ZD18H4450–EO 25000
Catalog Numbers Max. Line
Short Circuit
Amps
3-8
Receiving & Installation
MN718
Section 1
230 VAC Control
Input
460 VAC Control
Input
575 VAC Control
Input
General Information
Input Current Requirements
Table 3-3 Input Current Requirements
230 VAC Control Input 460 VAC Control Input 575 VAC Control Input
Catalog Numbers
ZD18H201-E or W 6.8 ZD18H401-E or W 3.4 ZD18H501-E 2.7
ZD18H202-E or W 9.6 ZD18H402-E or W 4.8 ZD18H502-E 4.0
ZD18H203-E or W 15.2 ZD18H403-E or W 7.6 ZD18H503-E 6.1
ZD18H205-E 15.2 ZD18H405-E or W 11 ZD18H505-E 11
ZD18H205-W 22 ZD18H407-E 11 ZD18H507-E 11
ZD18H207-E or W 28 ZD18H407-W 14 ZD18H510-E 11
ZD18H210-E 28 ZD18H410-E 21 ZD18H515-EO or ER 22
ZD18H210L-ER 42 ZD18H410L-ER 21 ZD18H520-EO or ER 27
ZD18H215-E 42 ZD18H415-E 21 ZD18H525-EO or ER 32
ZD18H215-EO or ER 54 ZD18H415-EO or ER 27 ZD18H530-EO or ER 41
ZD18H220-EO or ER 68 ZD18H415L-ER 27 ZD18H540-EO or ER 52
ZD18H220L-ER 60 ZD18H420-E or ER 34 ZD18H550-EO or ER 62
ZD18H225-EO or ER 80 ZD18H420L-ER 30 ZD18H560-EO or ER 62
ZD18H225L-ER 75 ZD18H425-EO or ER 40 ZD18H575-EO 100
ZD18H230-EO or ER 104 ZD18H425L-ER 38 ZD18H5100-EO 125
ZD18H230V-EO or ER 104 ZD18H430-EO or ER 52 ZD18H5150V-EO 145
ZD18H230L-ER 104 ZD18H430L-ER 52
ZD18H240-MO or MR 130 ZD18H430V-EO or ER 52
ZD18H240L-MR 115 ZD18H430L-ER 52
ZD18H250-MO or MR 130 ZD18H440-EO or ER 65
ZD18H250V-MR 130 ZD18H440L-ER 60
Amps
Catalog Numbers
ZD18H450-EO or ER 80
ZD18H450L-ER 80
ZD18H460-EO or ER 100
ZD18H460V-EO or ER 100
ZD18H460L-ER 100
ZD18H475-EO 125
ZD18H475L-EO 125
ZD18H4100-EO 160
ZD18H4150-EO 240
ZD18H4150V-EO 180
ZD18H4200-EO 310
ZD18H4250-EO 370
ZD18H4300-EO 420
ZD18H4350-EO 480
ZD18H4400-EO 540
ZD18H4450-EO 590
Amps
Catalog Numbers
Amps
MN718
Receiving
& Installation 3-9
Section 1
Control Output
I
I
Wi
p
p
General Information
AC Main Circuit
Protection Devices Be
Power Disconnect A
Wire Size and Protection Devices
Table 3-4 Wire Size and Protection Devices - 230 VAC Controls
sure a suitable input power protection device is installed. Use the recommended circuit
breaker or fuses listed in Tables 3-4 through 3-6 (Wire Size and Protection Devices). Wire
sizes
rating
power from the control will be less than the maximum, the sizes of the wire and protective
devices
Input
and output wire size is based on
table
is specified for NEMA B motors.
Circuit Breaker: 1 phase, thermal magnetic.
Fast Action Fuses: 230 VAC, Buss KTN
Very Fast Action: 230 VAC, Buss JJN
Time Delay Fuses: 230 VAC, Buss FRN
power
a
fail safe method to disconnect power
all
input power is removed from the control and the internal bus voltage is depleted.
and protective device specifications are based on the controls’ maximum output power
for the operating zone. Refer to Quad ratings in Section 7 of this manual.
may be adjusted accordingly
. Be sure to follow NEC, UL and other applicable codes.
If the output
the use of copper conductor wire rated at 75 °C. The
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 and 575 VAC.
460 VAC, Buss KTS to 600A (KTU 601 - 1200A)
575VAC, Buss FRS
460 VAC, Buss JJS
575 VAC, , Buss JJS
460 VAC, Buss FRS to 600A (KTU 601 - 1200A)
575 VAC, Buss FRS to 600A (KTU 601 - 1200A)
disconnect should be installed between the input power service and the control for
. The control will remain in a powered-up condition until
Note: All
Power Rating
1 5A 5A 5A 14 2.5
2 10A 10A 8A 14 2.5
3 15A 15A 12A 14 2.5
5 20A 25A 12.5A 14 2.5
7.5 25A 30A 25A 12 4
10 35A 40A 35A 10 10
15 50A 60A 50A 8 10
20 60A 80A 60A 4 25
25 80A 100A 80A 4 25
30 100A 125A 100A 3 30
40 125A 150A 125A 1 50
50 150A 200A 150A 2/0 70
nput Breaker
Fast Acting Time Delay AWG mm
wire sizes based on 75°C copper wire, 3% line impedance. Higher temperature smaller gauge wire may be
nput Fuse
re Gauge
used per NEC and local codes. Recommended fuses/breakers are based on 25°C ambient, maximum
continuous control output current and no harmonic current.
2
3-10
Receiving & Installation
MN718
Section 1
Control Output
I
I
Wi
p
p
General Information
Table 3-5 Wire Size and Protection Devices - 460 VAC Controls
Power Rating
1 4A 4A 3A 14 2.5
2 10A 5A 4A 14 2.5
3 10A 8A 6A 14 2.5
5 10A 12A 9A 14 2.5
7.5 15A 20A 15A 14 2.5
10 20A 25A 17.5A 12 4
15 25A 30A 25A 10 6
20 30A 40A 30A 8 10
25 40A 50A 40A 8 10
30 45A 60A 45A 6 16
40 60A 80A 60A 4 25
50 70A 100A 75A 4 25
60 90A 125A 90A 2 35
75 125A 150A 125A 1/0 54
100 150A 200A 150A 2/0 70
125 175A 250A 175A 2/0 70
150 200A 300A 200A 4/0 120
200 250A 350A 250A (2)1/0 (2)54
250 350A 450A 350A (2)3/0 (2)95
300 400A 500A 400A (2)4/0 (2)120
350 500A 600A 500A (3)4/0 (3)120
400 600A 800A 600A (3)250 mcm (3)125
450 600A 800A 600A (3)250 mcm (3)125
500 800A 1000A 800A (3)350 mcm (3)185
nput
Breaker
Fast Acting Time Delay AWG mm
nput Fuse
re Gauge
2
Note: All
wire sizes based on 75°C copper wire, 3% line impedance. Higher temperature smaller gauge wire may be
used per NEC and local codes. Recommended fuses/breakers are based on 25°C ambient, maximum
continuous control output current and no harmonic current.
Receiving
& Installation 3-1
1MN718
Section 1
Control Output
I
I
Wi
p
p
General Information
Table 3-6 Wire Size and Protection Devices - 575 VAC Controls
Note: All
Power Rating
1 5A 5A 4A 14 2.5
2 10A 5A 4A 14 2.5
3 10A 6A 5A 14 2.5
5 10A 10A 7A 14 2.5
7.5 10A 15A 10A 14 2.5
10 15A 15A 12A 14 2.5
15 20A 25A 20A 12 4
20 25A 35A 25A 10 6
25 30A 40A 30A 8 10
30 35A 50A 35A 8 10
40 45A 60A 45A 6 16
50 60A 80A 60A 4 25
60 70A 90A 70A 4 25
75 120A 150A 120A 3 27
100 120A 150A 120A 1/0 54
125 150A 200A 150A 2/0 70
150 175A 225A 175A 2/0 70
nput
Breaker
Fast Acting Time Delay AWG mm
wire sizes based on 75°C copper wire, 3% line impedance. Higher temperature smaller gauge wire may be
nput Fuse
re Gauge
used per NEC and local codes. Recommended fuses/breakers are based on 25°C ambient, maximum
continuous control output current and no harmonic current.
2
3-12
Receiving & Installation
MN718
Section 1
General Information
AC Line Connections Be
applied to the control, wait at least 5 minutes after power disconnect for residual voltage
across bus capacitors to discharge.
Reduced Input Voltage Derating
All
460 or 575V
reduced input voltage. The amount of reduction is the ratio of the voltage change.
Examples:
For example, a 10HP
of 9.04HP
10HP
Likewise, a 10HP
8.26HP
10HP
T
380-400 VAC Configuration
control modification is not necessary
Size C, D, E, F and G controls all require modification for operation on the reduced line
voltage (380-400V
T
sure all power to the control is disconnected before proceeding. If power has been
power ratings stated in Section 7 are for the stated nominal AC input voltages (230,
AC). The power rating of the control must be reduced when operating at a
, 230V
AC control operating at 208V
.
208VAC
230VAC
.
380VAC
460VAC
o obtain the full output rating of 10HP in either case requires a 15HP Control.
Size A and B controls may be used directly with a 380-400 V
ap Change Procedure
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
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
, 460V
AC control operating at 380V
8.26HP
.
AC).
(size C, D, E and F controls).
.
.
AC has a reduced power rating
AC has a reduced power rating of
AC power source,
MN718
Receiving
& Installation 3-13
Section 1
General Information
Figure 3-2 Configuring the Control Transformer Terminal Block for 380 - 400 VAC (Size G)
T
ap Change Procedure
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
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
(size G controls). See Figure 3-2.
.
.
460VAC 380-400VAC
3-14
Receiving & Installation
MN718
Section 1
General Information
Three Phase Input Power
Three
phase AC power and motor connections are shown in Figure 3-3. Overloads are
not required. The 18H 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.
Caution: Do not connect AC power to the Motor terminals T1, T2 and T3.
Connecting AC power to these terminals may result in damage to
the control.
Caution: Baldor recommends not using “Grounded Leg Delta” transformer
power leads that may create ground loops and degrade system
performance. Instead, we recommend using a four wire W
1.
Connect the incoming AC power wires from the protection devices to L1, L2
and L3 at the Main Circuit T
control is not phase sensitive.
2.
* Connect earth ground to the “ ” of the control. Be sure to comply with local
codes.
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.
erminals. The phase rotation is not important as the
ye.
3.
Connect the three phase power leads of the AC motor to terminals T1, T2, and
T3 of the Main Circuit T
4.
* Connect motor ground wire to the “
all applicable codes.
*
Grounding by using conduit or panel connection is not adequate. A separate
conductor of the proper size must be used as a ground conductor
erminals.
” of the control. Be sure to comply with
.
MN718
Receiving
& Installation 3-15
Section 1
General Information
Figure 3-3 Three Phase AC Power and Motor Connections
L1 L2 L3
Note 1
Note 2
* Circuit
Breaker
A1 B1 C1
Earth
Alternate *
Fuse
Connection
L1 L2 L3
Note 1
A1 B1 C1
Note 4
Note 2
Note 3
Note 4
Note 3
*Optional
Line
Reactor
*Optional
Load
Reactor
A2 B2 C2
L1 L2 L3
Baldor
Series
Control
T1 T2 T3
A1 B1 C1
A2 B2 C2
T2 T3
T1
18H
G
* Optional components not provided with 18H Control.
Notes:
1. See
2.
3.
4.
5.
“Protective Devices” described previously in this section.
Shield wires inside a metal conduit.
Metal conduit should be used to shield output wires (between
control and motor). Connect conduits so the use of Load Reactor
or RC Device does not interrupt EMI/RFI shielding.
See Line/Load Reactors described later in this section.
A motor circuit contactor is recommended to provide a positive
disconnect and prevent motor rotation which could pose a safety
hazard. Connect the M-Contactor as shown. The contactor
should open the enable input at J1-8 at least 20 msec before the
main M-contacts open to prevent arcing at contacts. This greatly
increases contactor life and allows use of IEC rated contactors.
Note 3
*Optional
Note 4
Load
Reactor
Note 3
M=Contacts of optional M-Contactor
3-16
Receiving & Installation
* AC Motor
T1 T2 T3
A1 B1 C1
A2 B2 C2
MMM
T2 T3
T1
* Motor
See Recommended Tightening Torques in Section 7.
Optional Connection of
Load Reactor and M-Contactor
G
To Power Source
(Rated Coil
Voltage)
J1
*
M Enable
7
8
9
Note 5
* M-Contactor
Note: Close “Enable”
after “M” contact closure.
* Optional
RC Device
Electrocube
RG1781-3
MN718
Section 1
p
p
p
p
General Information
Table 3-7 Single Phase Rating Wire Size and Protection Devices - 230 VAC Controls
Control Output
Power Rating
1 15A 5A 5A 14 2.5
2 15A 10A 10A 14 2.5
3 15A 15A 15A 14 2.5
5 30A 30A 30A 12 4
7.5 25A 25A 25A 14 2.5
10 40A 30A 30A 12 4
15 50A 45A 45A 10 6
20 60A 45A 45A 8 10
25 70A 70A 70A 8 10
30 80A 80A 80A 6 16
40 100A 100A 100A 4 25
50 125A 125A 125A 4 25
Input Breaker Input Fuse Wire Gauge
Fast Acting Time Delay AWG mm
2
Table 3-8 Single Phase Rating Wire Size and Protection Devices - 460 VAC Controls
Control Output
Power Rating
1 15A 4A 4A 14 2.5
2 15A 8A 8A 14 2.5
3 15A 10A 10A 14 2.5
5 15A 15A 15A 14 2.5
7.5 15A 15A 15A 14 2.5
10 20A 15A 15A 14 2.5
15 25A 25A 25A 14 2.5
20 30A 30A 30A 14 2.5
25 35A 30A 30A 14 2.5
30 40A 40A 40A 10 6
40 60A 50A 50A 8 10
50 70A 60A 60A 8 10
60 80A 80A 80A 6 16
Input Breaker Input Fuse Wire Gauge
Fast Acting Time Delay AWG mm
2
Note: All
wire sizes based on 75°C copper wire, 3% line impedance. Higher temperature smaller gauge wire may be
used per NEC and local codes. Recommended fuses/breakers are based on 25°C ambient, maximum
continuous control output current and no harmonic current.
MN718
Receiving
& Installation 3-17
Single
Phase Input Power Considerations
Caution: Do not connect AC power to the Motor terminals T1, T2 and T3.
Connecting AC power to these terminals may result in damage to
the control.
Caution: Baldor recommends not using “Grounded Leg Delta” transformer
power leads that may create ground loops and degrade system
performance. Instead, we recommend using a four wire W
Single phase AC input power can be used to power the control instead of three phase for
control sizes A, B, C, D, E and F
. Single phase operation of G size controls is not
possible. 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 T
ables 3-7 and 3-8.
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.
1-2 HP 230 and 460 V
AC controls:
No derating required.
2.
3-15 HP (Size B) 230 and 460 V
AC controls:
Derate HP by 40% of the nameplate rating.
3.
15 HP (Size C) and Larger 230 and 460 V
AC controls:
Derate HP by 50% of the nameplate rating.
ye.
Size A and B Single Phase Power Installation
Jumper Configuration
Size A and B controls, no jumper changes required.
Power and Control Connections
The
single phase power and motor connections are shown in Figure 3-4.
1.
Connect the incoming power wires to Main Circuit T
2.
Place a jumper across control power input terminals L2 and L3. Use the same
size wire for the jumper as the incoming power wires on L1 and L2.
3.
Connect earth ground to the “
codes.
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.
4.
Connect the three phase power leads of the AC motor to terminals T1, T2, and
T3 of the Main Circuit T
5.
Connect motor ground wire to the “
applicable codes.
Note:
In steps 3 and 5 grounding by using conduit or panel connection is not
adequate. A separate conductor of the proper size must be used as a ground
conductor.
erminals L1 and L2.
” of the control. Be sure to comply with local
erminals.
” of the control. Be sure to comply with all
3-18 Receiving & Installation
MN718
Section 1
General Information
Figure 3-4 Size A & B Single Phase 230/460VAC Power and Motor Connections
Note 1
* Circuit
Breaker
L1 L2
Earth
* Fuse
Connection
L1 L2
Note 1
Note 2
Note 4
Note 2
Note 3
Note 5
Note 3
*Optional
Line
Reactor
*Optional
Load
Reactor
A1 B1
A2 B2
L1 L2 L3
Baldor
Series
Control
T1 T2 T3
A1 B1 C1
A2 B2 C2
T2 T3
T1
18H
G
A1 B1
* Optional
components not provided with 18H Control.
Notes:
1. See
2.
3.
“Protective Devices” described previously in this section.
Shield wires inside a metal conduit.
Metal conduit should be used to shield output wires (between
control and motor).
4.
See “Line Impedance” described previously in this section.
5.
See Line/Load Reactors described previously in this section.
6.
A motor circuit contactor is recommended to provide a positive
disconnect and prevent motor rotation which could pose a safety
hazard. Connect the M-Contactor as shown. The contactor
should open the enable input at J1-8 at least 20 msec before the
main M-contacts open to prevent arcing at contacts. This greatly
increases contactor life and allows use of IEC rated contactors.
Note 3
Note 5
Note 3
M=Contacts of optional M-Contactor
*Optional
Load
Reactor
Note 6
MN718
* AC Motor
T1 T2 T3
A1 B1 C1
A2 B2 C2
MMM
T2 T3
T1
* Motor
See
Recommended T
Optional Connection of
Load Reactor and M-Contactor
To Power Source
Note 6
G
ightening T
M Enable
orques in Section 7.
(Rated Coil
Voltage)
*
Note 6
* M-Contactor
J1
7
8
9
* Optional
RC Device
Electrocube
RG1781-3
Note: Close “Enable”
after “M” contact closure.
Receiving & Installation 3-19
Size C and D Single Phase Power Installation
Figure 3-5
Place JP2 on pins 1 & 2 for control single phase operation.
Place JP3 in position B for fan single phase operation.
Gate Drive Circuit Board
Jumper Configuration
J2
J3
JP2
Pins 1 & 2 = Single Phase
Pins 2 & 3 = Three Phase
8380
J4 J5
R24
R27
JP2
1
JP3
Position A = Three Phase
Position B = Single Phase
R35
R36
R58
JP3
A
B
Power and Control Connections
The
single phase power and motor connections are shown in Figure 3-4.
1.
Connect the incoming power wires to Main Circuit T
2.
Place a jumper across control power input terminals L1 and L2. Use the same
size wire for the jumper as the incoming power wires on L2 and L3.
erminals L2 and L3.
1
JP1
J14J12
J13
AC INPUT
3.
Connect earth ground to the “
codes.
Note:
4.
Connect the three phase power leads of the AC motor to terminals T1, T2, and
T3 of the Main Circuit T
5.
Connect motor ground wire to the “
applicable codes.
Note:
3-20
Receiving & Installation
” of the control. Be sure to comply with local
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.
erminals.
” of the control. Be sure to comply with all
In steps 3 and 5 grounding by using conduit or panel connection is not
adequate. A separate conductor of the proper size must be used as a ground
conductor.
MN718
Section 1
General Information
Figure 3-6 Size C & D Single Phase 230/460VAC Power and Motor Connections
Note 1
* Circuit
Breaker
L1 L2
Earth
* Fuse
Connection
L1 L2
Note 1
Note 2
Note 4
Note 2
Note 3
Note 5
Note 3
*Optional
Load
Reactor
B1 C1
*Optional
Line
Reactor
B2 C2
L1 L2 L3
Baldor
Series
Control
T1 T2 T3
A1 B1 C1
A2 B2 C2
T1
18H
T2 T3
B1 C1
* Optional
components not provided with 18H Control.
Notes:
1. See
2.
3.
“Protective Devices” described previously in this section.
Shield wires inside a metal conduit.
Metal conduit should be used to shield output wires (between
control and motor).
4.
See “Line Impedance” described previously in this section.
5.
See Line/Load Reactors described previously in this section.
6.
A motor circuit contactor is recommended to provide a positive
disconnect and prevent motor rotation which could pose a safety
hazard. Connect the M-Contactor as shown. The contactor
should open the enable input at J1-8 at least 20 msec before the
main M-contacts open to prevent arcing at contacts. This greatly
increases contactor life and allows use of IEC rated contactors.
G
Note 3
Note 5
Note 3
M=Contacts of optional M-Contactor
*Optional
Load
Reactor
Note 6
MN718
* AC Motor
T1 T2 T3
A1 B1 C1
A2 B2 C2
MMM
T2 T3
T1
* Motor
See
Recommended T
Optional Connection of
Load Reactor and M-Contactor
To Power Source
Note 6
G
ightening T
M Enable
orques in Section 7.
(Rated Coil
Voltage)
*
Note 6
* M-Contactor
J1
7
8
9
* Optional
RC Device
Electrocube
RG1781-3
Note: Close “Enable”
after “M” contact closure.
Receiving & Installation 3-21
Size E Single Phase Power Installation
Place
JP1 on the High V
1
JP2
ANS
DUAL 230V
FANS
SINGLE
230V F
CNTRL XFMR
400V PRI
CNTRL XFMR
460V PRI
AC INPUT
J2
8470
Figure 3-7 Jumper Configuration
oltage Circuit Board across pins 1 and 2.
High Voltage Circuit Board
(100 - 150HP E Size)
1
JP1
JP1
Pins 1 & 2 = Single Phase
Pins 2 & 3 = Three Phase
J7
J8
Power and Control Connections
The
single phase power and motor connections are shown in Figure 3-8.
1.
Connect the incoming power wires to Main Circuit T
2.
Place a jumper across control power input terminals L2 and L3. Use the same
size wire for the jumper as the incoming power wires on L1 and L2.
3.
Connect earth ground to the “
” of the control. Be sure to comply with local
codes.
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.
4.
Connect the three phase power leads of the AC motor to terminals T1, T2, and
T3 of the Main Circuit T
5.
Connect motor ground wire to the “
erminals.
” of the control. Be sure to comply with all
applicable codes.
Note:
In steps 3 and 5 grounding by using conduit or panel connection is not
adequate. A separate conductor of the proper size must be used as a ground
conductor.
erminals L1 and L2.
3-22
Receiving & Installation
MN718
Section 1
General Information
Figure 3-8 Size E Single Phase 230/460VAC Power and Motor Connections
Note 1
* Circuit
Breaker
L1 L2
Earth
* Fuse
Connection
L1 L2
Note 1
Note 2
Note 4
Note 2
Note 3
Note 5
Note 3
*Optional
Line
Reactor
*Optional
Load
Reactor
A1 B1
A2 B2
L1 L2 L3
Baldor
Series
Control
T1 T2 T3
A1 B1 C1
A2 B2 C2
T2 T3
T1
18H
G
A1 B1
* Optional
components not provided with 18H Control.
Notes:
1. See
2.
3.
“Protective Devices” described previously in this section.
Shield wires inside a metal conduit.
Metal conduit should be used to shield output wires (between
control and motor).
4.
See “Line Impedance” described previously in this section.
5.
See Line/Load Reactors described previously in this section.
6.
A motor circuit contactor is recommended to provide a positive
disconnect and prevent motor rotation which could pose a safety
hazard. Connect the M-Contactor as shown. The contactor
should open the enable input at J1-8 at least 20 msec before the
main M-contacts open to prevent arcing at contacts. This greatly
increases contactor life and allows use of IEC rated contactors.
Note 3
Note 5
Note 3
M=Contacts of optional M-Contactor
*Optional
Load
Reactor
Note 6
MN718
* AC Motor
T1 T2 T3
A1 B1 C1
A2 B2 C2
MMM
T2 T3
T1
* Motor
See
Recommended T
Optional Connection of
Load Reactor and M-Contactor
To Power Source
Note 6
G
ightening T
M Enable
orques in Section 7.
(Rated Coil
Voltage)
*
Note 6
* M-Contactor
J1
7
8
9
* Optional
RC Device
Electrocube
RG1781-3
Note: Close “Enable”
after “M” contact closure.
Receiving & Installation 3-23
Size F Single Phase Power Installation
Place JP2 on the High Voltage Circuit Board across pins 1 and 2.
High Voltage Circuit Board
(150 - 250HP F Size)
Figure 3-9 Jumper Configuration
J5
JP1
JP2
1
JP2
Pins 1 & 2 = Single Phase
Pins 2 & 3 = Three Phase
J1 J4J3
Power and Control Connections
The
single phase power and motor connections are shown in Figure 3-10.
1.
Connect the incoming power wires to Main Circuit T
2.
Place a jumper across control power input terminals L1 and L3. Use the same
size wire for the jumper as the incoming power wires on L2 and L3.
erminals L2 and L3.
J2
3.
Connect earth ground to the “
codes.
Note:
4.
Connect the three phase power leads of the AC motor to terminals T1, T2, and
T3 of the Main Circuit T
5.
Connect motor ground wire to the “
applicable codes.
Note:
3-24
Receiving & Installation
” of the control. Be sure to comply with local
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.
erminals.
” of the control. Be sure to comply with all
In steps 3 and 5 grounding by using conduit or panel connection is not
adequate. A separate conductor of the proper size must be used as a ground
conductor.
MN718
Section 1
General Information
Figure 3-10 Size F Single Phase 230/460VAC Power and Motor Connections
Note 1
* Circuit
Breaker
L1 L2
Earth
* Fuse
Connection
L1 L2
Note 1
Note 2
Note 4
Note 2
Note 3
Note 5
Note 3
*Optional
Load
Reactor
B1 C1
*Optional
Line
Reactor
B2 C2
L1 L2 L3
Baldor
Series
Control
T1 T2 T3
A1 B1 C1
A2 B2 C2
T1
18H
T2 T3
B1 C1
* Optional
components not provided with 18H Control.
Notes:
1. See
2.
3.
“Protective Devices” described previously in this section.
Shield wires inside a metal conduit.
Metal conduit should be used to shield output wires (between
control and motor).
4.
See “Line Impedance” described previously in this section.
5.
See Line/Load Reactors described previously in this section.
6.
A motor circuit contactor is recommended to provide a positive
disconnect and prevent motor rotation which could pose a safety
hazard. Connect the M-Contactor as shown. The contactor
should open the enable input at J1-8 at least 20 msec before the
main M-contacts open to prevent arcing at contacts. This greatly
increases contactor life and allows use of IEC rated contactors.
G
Note 3
Note 5
Note 3
M=Contacts of optional M-Contactor
*Optional
Load
Reactor
Note 6
MN718
* AC Motor
T1 T2 T3
A1 B1 C1
A2 B2 C2
MMM
T2 T3
T1
* Motor
See
Recommended T
Optional Connection of
Load Reactor and M-Contactor
To Power Source
Note 6
G
ightening T
M Enable
orques in Section 7.
(Rated Coil
Voltage)
*
Note 60
* M-Contactor
J1
7
8
9
* Optional
RC Device
Electrocube
RG1781-3
Note: Close “Enable”
after “M” contact closure.
Receiving & Installation 3-25
Section 1
General Information
Optional Dynamic Brake Hardware
W
ARNING:
Resistors may generate enough heat to ignite combustible
materials. T
o avoid fire hazard, keep all combustible materials and
flammable vapors away from brake resistors.
Physical Installation Dynamic
surface to obtain ef
exceed 80
1.
Caution: If the DB hardware mounting is in any position other than vertical
2.
Figure 3-11 DB Hardware Installation
Brake (DB) Hardware must be installed on a flat, non-flammable, vertical
fective cooling and operation. The ambient temperature must not
°C.
Select a clean
VERTICAL
surface that is free from corrosive gasses, liquids,
vibration, dust and metallic particles.
(Figure 3-1
1), the DB hardware must be derated by 35% of its rated
capacity.
Mount the DB hardware as shown in Figure 3-1
Maximum
temperatures
near wall.
80°C
70°C
65°C
70°C
Maximum temperatures
above the enclosure.
85°C
115°C
115°C
200°C
12″
48″
36″
24″
1.
75°C
Heat shield inside RBA
units must be in this
vertical direction to
protect transistor and
circuit board.
3-26
Receiving & Installation
MN718
Section 1
General Information
Electrical Installation Terminal
(E, EO, ER or MO). See Figure 3-12 for terminal identification.
Figure 3-12 DB Terminal Identification
“E” or “W” suffix
“EO” or “MO” suffix
“ER” suffix
Figure 3-13 Wiring for RGA Assembly
MOTOR
GND
connections for DB hardware is determined by 18H Control model number suf
R2 B+/R1 B–
B+ B– GND D1 D2 GND
R2 B+/R1 B– GND
Control
Terminals
GND
R2
B+/R1
T3
T2
T1
T3
T2
T1
DB
Terminals
R2
R1
Optional
Dynamic Brake
(RGA)
fix
Optional Customer Supplied
Breaker or Fuse Protection -
Subject to Local Codes
50/60 Hz
3 Phase
Power
Note: Although
and motor leads.
L3
L2
L1
GND
See recommended Terminal Tightening Torques in Table 3-10.
not shown, metal conduit should be used to shield all power wires
MN718
Receiving
& Installation 3-27
Section 1
General Information
Figure 3-14 Wiring for RBA Assembly
Optional Customer Supplied
Breaker or Fuse Protection -
Subject to Local Codes
See recommended Terminal Tightening Torques in Section 7.
DB
Terminals
D1
D2
Dynamic Brake
B–
B+
MOTOR
GND
50/60 Hz
3 Phase
Power
Control
Terminals
T3
T2
T1
D1
D2
GND
B–
B+
T3
T2
T1
L3
L2
L1
Shielded
Twisted Pair
See recommended Terminal
Tightening Torques in Table 3-9.
Note: Although
GND
not shown, metal conduit should be used to shield all power wires
and motor leads.
Figure 3-15 Wiring for RTA Assembly
MOTOR
GND
D1
D2
GND
B–
B+
T3
T2
T1
Shielded
Twisted Pair
Control
Terminals
T3
T2
T1
DB
Terminals
D1
D2
B–
B+
Optional
(RBA)
Optional
Dynamic Brake
(RTA)
R2R1
R2R1
50/60 Hz
3 Phase
Power
Optional Customer Supplied
Breaker or Fuse Protection -
Subject to Local Codes
See recommended Terminal Tightening Torques in Section 7.
Note: Although
3-28
Receiving & Installation
L3
L2
L1
GND
not shown, metal conduit should be used to shield all power wires
and motor leads.
Optional
RGA
Assembly
See recommended Terminal
T
Tightening
orques in Table 3-10.
MN718
Section 1
Control
Braking
g
General Information
Table 3-9 Terminal Torques & Wire Size for Model No. Suffix E or W
Table 3-10 Terminal Torques & Wire Size for Model No. Suffix EO, MO, or ER
B+ / B– / R1 / R2 /
Control Voltage Rating
VAC
230, 460, 575 10 6 600 2.26 20
Wire SIze
AWG mm
Terminals
Volt
2
Tightening
Torque
Nm Lb–in
B+ / B– and R1 / R2 /
Control Braking
Voltage Rating
VAC
230 <10,000 10 6 600 2.26 32 20-22 0.5 600 0.4 3.5
230 >10,000 8 10 600 2.26 32 20-22 0.5 600 0.4 3.5
460 <20,000 10 6 600 2.26 32 20-22 0.5 600 0.4 3.5
460 >20,000 8 10 600 2.26 32 20-22 0.5 600 0.4 3.5
575 <20,000 10 6 600 2.26 32 20-22 0.5 600 0.4 3.5
575 >20,000 8 10 600 2.26 32 20-22 0.5 600 0.4 3.5
Option
Watts Rating
Terminals
Wire SIze
AWG mm
Tightening
Volt
2
Torque
Nm Lb–in AWG mm
Wire SIze
D1 / D2 /
Terminals
Volt
2
Table 3-11 DB Terminal Torques (All)
Tightening Torque
Nm Lb–in
2.26 32
Tightening
Torque
Nm Lb–in
MN718
Receiving
& Installation 3-29
Section 1
General Information
Encoder Installation
Electrical isolation of the encoder shaft and housing from the motor is required. Electrical
isolation prevents capacitive coupling of motor noise that will corrupt the encoder signals.
See electrical noise considerations in Section 7 of this manual.
Cable Preparation
Encoder wiring must be shielded twisted pairs, #22 A
200′
(60m) maximum, with an insulated overall shield.
Control End (See Figure 3-16.)
1.
Strip the outside jacket approximately 0.375″ (9.5mm) from the end.
2.
Solder a #22 A
3.
Connect all shields to J1-30. T
to the wire soldered to the braided shield in step 2.
4.
Insulate or tape of
conductors or ground.
Encoder End
1.
Strip the outside jacket approximately 0.375″ (9.5mm) from the end.
2.
Identify each of the four twisted pair and label or use the color codes shown in
Figure 3-17 for the optional Baldor Encoder Cable.
3.
Insulate or tape of
prevent contact with other conductors or ground.
CAUTION:
Do not connect any shields to the encoder case or motor frame.
The encoder +5VDC supply at J1-29 is referenced to circuit board
common. Do not connect any shields to ground or another power
supply or damage to the control may result.
WG (0.34mm2) wire to the braided shield.
o do this, solder a “Drain Wire” from each shield
f ungrounded end of shields to prevent contact with other
f ungrounded end of shields and unused conductors to
WG (0.34mm2) minimum size,
Figure 3-16 Encoder Cables
No.
9891
3-30
Receiving & Installation
MN718
Section 1
General Information
Figure 3-17 Encoder Connections
H
GJC
FED
No Connection
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
Encoder Cable Connection
Encoder cable must
wires. Encoder cables that cross power wires must cross at a 90° angle only
wires must be #22 A
have an overall shield.
Note:
Be careful not to pinch the wires’ insulation in J1 terminals as proper electrical
connection may not be made.
be separated by at least 3” (76mm) from parallel runs of power
WG (0.34mm2) minimum, 200 feet (60m) maximum length and must
AB
K
. Encoder
1.
Feed the control end of the cable through one of the “Knock-out” holes in the
control case so connections can be made inside the control.
2. Differential Connections
Connect the cable braided shield to J1-30 at control end.
Connect the cable ends as follows: (See Figure 3-17.)
Encoder End
Control End
A J1-23 (A)
H
J1-24 (A
)
B J1-25 (B)
J
C
K
D
F
E
3.
Single Ended Connections
Dif
ferential inputs are recommended for best noise immunity
J1–26 (B
)
J1–27 Index(C)
J1–28 Index(C
)
J1–29 (+5VDC)
J1–30 (Common)
No Connection
. If only single
ended encoder signals are available, connect them to A, B, and INDEX (C)
(J1-23, J1-25 and J1-27 respectively).
MN718
Receiving
& Installation 3-31
Section 1
General Information
Home (Orient) Switch InputThe
position. The homing function allows shaft rotation in the drive forward direction only
The home position is located when a machine mounted switch or the encoder “Index”
pulse is activated (closed). Home is defined by a rising signal edge at terminal J1-27.
The shaft will continue to rotate only in a “Drive Forward” direction for a user defined
of
fset value. The of
parameter
Miscellaneous Homing Speed parameter
A machine mounted switch may be used to define the Home position in place of the
encoder index channel. A dif
preferred for best noise immunity
J1-28.
A single ended solid-state switch or limit switch should be wired as shown in Figure 3-18.
Regardless of the type of switch used, clean rising and falling edges at J1-27 are required
for accurate positioning.
Figure 3-18 Typical Home or Orient Switch Connections
+5V Input
Output
Common
Home or Orient function causes the motor shaft to rotate to a predefined home
fset is programmed in the Level 2 Miscellaneous Homing Of
fset
. The speed at which the motor will “Home” or orient is set with the Level 2
.
ferential line driver output from a solid state switch is
. Connect this dif
Note:
Control requires dynamic brake hardware for Orient (Homing) function to
ferential output to terminals J1-27 and
work. Control will trip without dynamic brake hardware installed. Size A and B
controls ( “–E” suf
fix) are shipped with factory installed dynamic brake
hardware.
J1
27
28
29
30
INDEX
INDEX
+5V
Common
J1
27
28
29
30
INDEX
INDEX
+5V
Common
.
Buffered Encoder Output The
3-19. This output may be used by external hardware to monitor the encoder signals. It is
recommended that this output only drive one output circuit load.
From
Processor
Terminal
7 lb–in (0.8 Nm) maximum.
tightening torque is
Limit Switch (Closed at HOME).5VDC Proximity Switch
Terminal Tightening Torque = 7 Lb-in. (0.8 Nm).
control provides a buffered encoder output on pins J1-31 to J1-38 as shown in Figure
Figure 3-19 Buffered Encoder Output
J1
29
+5VDC
30
COMMON
31
A
IN A
IN
IN C
IN D
B
26LS31
E
A
A
B
B
C
C
D
D
E
32
33
34
35
36
37
38
A
B
B
INDEX
INDEX
Not Used
COMMON
Buffered
Encoder
Output
3-32
Receiving & Installation
MN718
Section 1
General Information
Control Circuit Connections
Eight dif
operating 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. A
ferent operating modes are available in the Series 18H vector control. These
vailable operating modes include:
•
Keypad Control
•
Standard Run, 3 Wire Control
•
15 Speed, 2 Wire Control
•
Fan Pump 2 Wire Control
•
Fan Pump 3 Wire Control
•
Bipolar Speed or T
•
Process Control
• Serial
Note:
The Serial operating mode requires one of the optional Serial Interface
expansion boards (RS232 or 422/485). 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.
orque
Keypad Mode Connections
To
to Keypad. In this mode, only the External T
2 Protection block, External T
active. Connections are made as shown in Figure 3-20.
operate in the Keypad mode, set the Level 1 Input block, Operating Mode parameter
rip Opto Input at J1-16 is active (if the Level
rip parameter is set to ON). Both analog outputs remain
The ST
S Press ST
S Press ST
OP key can operate in either of two ways:
OP key one time to brake or coast to stop (as set in the Level 1
Keypad Setup block, Keypad Stop Mode parameter).
OP key two times to disable control.
MN718
Receiving
& Installation 3-33
Section 1
J
General Information
Note 1
Notes:
1. Refer
2.
3.
4.
Programmable 0–5V Output (Factory Preset: Speed)
Programmable 0–5V Output (Factory Preset: Current)
to Analog Outputs.
Refer to Opto Isolated Outputs.
Refer to Encoder Installation.
Refer to Buf
fered Encoder Outputs.
Refer to Figure NO
Figure 3-20 Keypad Control Connection Diagram
1
No Connections
Required
No Connections
(Inactive)
TAG.
Note 2
ANALOG GND
ANALOG INPUT 1
POT REFERENCE
ANALOG INPUT +2
ANALOG INPUT –2
ANALOG OUT 1
ANALOG OUT 2
EXTERNAL TRIP
O INPUT COMMON
OPT
OPT
O OUT COMMON
OPTO OUT #1
OPTO OUT #2
OPTO OUT #3
OPTO OUT #4
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
ENABLE
INPUT #1
INPUT #2
INPUT #3
INPUT #4
INPUT #5
INPUT #7
1
23
2
24
3
25
4
26
5
27
6
28
7
29
8
30
9
31
10
32
11
33
12
34
13
6
35
14
36
15
37
16
38
17
39
18
40
19
41
20
42
21
43
22
44
A
A
B
B
INDEX
INDEX
+5VDC
COMMON
A
A
B
B
INDEX
INDEX
Not Used
COMMON
+24VDC
OPTO IN POWER
OPTO OUT #1 RETURN
OPTO OUT #2 RETURN
OPTO OUT #3 RETURN
OPTO OUT #4 RETURN
Encoder
Input
Note 3
Buffered
Encoder
Output
Note 4INPUT #1
J1-8 Optional, is active when Level 2 Protection block, Local Enable INP parameter is set to
ON.
OPEN disables the control and motor coasts to a stop.
CLOSED allows current to flow in the motor and produce torque.
J1-16 OPEN causes an external trip to be received by control. The control will disable and
J1-39 & 40 Jumper as shown to power the Opto Inputs from the internal +24VDC supply.
display external trip when programmed “ON”. When this occurs, the motor stop
command is issued, drive operation is terminated and an external trip fault is displayed
on the keypad display (also logged into the fault log).
If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”.
3-34
Receiving & Installation
MN718
Section 1
General Information
Standard Run 3 Wire Mode Connections
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 3-21 or logic signals from another device. The External T
active if connected as shown and the Level 2 Protection block, External Trip parameter is
set to ON.
rip opto input at J1-16 is
MN718
Receiving
& Installation 3-35
Section 1
General Information
Figure 3-21 Standard Run 3-Wire Connection Diagram
Note 1
Note 4
Note 2
Notes:
1. Refer
2.
3.
4.
5.
6.
Programmable 0–5V Output (Factory Preset: Speed)
Programmable 0–5V Output (Factory Preset: Current)
to Analog Inputs.
Refer to Analog Outputs.
Refer to Opto Isolated Outputs.
Refer to Figure NO TAG for 4-20mA.
Refer to Encoder installation.
Refer to Buf
fered Encoder Output.
Refer to Figure NO
5kW Command Pot
±5VDC, ±10VDC or 4-20mA
TAG.
Note 3
ANALOG GND
ANALOG INPUT 1
POT REFERENCE
ANALOG INPUT +2
ANALOG INPUT –2
ANALOG OUT 1
ANALOG OUT 2
FORWARD RUN
REVERSE RUN
ACCEL/DECEL
PRESET SPEED #1
FAULT RESET
EXTERNAL TRIP
O INPUT COMMON
OPT
OPT
O OUT COMMON
OPTO OUT #1
OPTO OUT #2
OPTO OUT #3
OPTO OUT #4
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
ENABLE
STOP
JOG
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
J1
23
A
24
A
B
25
B
26
INDEX
27
6
INDEX
28
+5VDC
29
30
COMMON
A
31
A
32
B
33
B
34
INDEX
35
INDEX
36
Not Used
37
38
COMMON
39
+24VDC
40
OPTO IN POWER
41
OPTO OUT #1 RETURN
42
OPTO OUT #2 RETURN
43
OPTO OUT #3 RETURN
44
OPTO OUT #4 RETURN
Encoder
Input
Note 5
Buffered
Encoder
Output
Note 6
J1-8 OPEN disables the control and motor coasts to a stop.
CLOSED allows current to flow in the motor and produce torque.
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 causes motor to decel to stop (depending on Keypad Stop Mode
parameter setting). Motor current continues to be applied to the motor.
J1-12 CLOSED places control in JOG mode, Forward and Reverse run are used to jog the
motor.
J1-13 OPEN selects ACC / DEC / S-CURVE group 1.
CLOSED selects group 2.
J1-14 CLOSED selects preset speed #1, (J1-12, will override this preset speed).
OPEN allows speed command from Analog input #1 or #2 or Jog.
J1-15 CLOSED to reset fault condition.
OPEN to run.
J1-16 OPEN causes an external trip to be received by control. The control will disable and
J1–39 & 40 Jumper as shown to power the Opto Inputs from the internal +24VDC supply.
display external trip when programmed “ON”. When this occurs, the motor stop
command is issued, drive operation is terminated and an external trip fault is displayed
on the keypad display (also logged into the fault log).
If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”.
3-36
Receiving & Installation
MN718
Section 1
General Information
15 Speed 2-Wire Mode Connections
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 3-22 or logic signals
from another device. The External T
shown and the Level 2 Protection block, External T
Switched inputs at J1-11 through J1-14 allow selection of 15 preset speeds and provide
Fault Reset as defined in T
Table 3-12 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
Switch T
ruth T
able is defined in T
able 3-12.
able 3-12.
rip Opto Input at J1-16 is active if connected as
rip parameter is set to ON.
MN718
Receiving
& Installation 3-37
Section 1
General Information
Figure 3-22 15 Speed 2-Wire Control Connection Diagram
Note 1
Notes:
1. Refer
2.
Refer to Opto Isolated Outputs.
3.
Refer to Encoder installation.
4.
Refer to Buf
* Refer to truth table, Table 3-12.
Programmable 0–5V Output (Factory Preset: Speed)
Programmable 0–5V Output (Factory Preset: Current)
Both CLOSED= Forward
Both OPEN = Stop
* All CLOSED= Fault
to Analog Outputs.
fered Encoder Output.
Refer to Figure NO
No Connections
Reset
TAG.
Note 2
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
ACC/DEC/“S” SELECT 1
EXTERNAL TRIP
O INPUT COMMON
OPT
OPT
O OUT COMMON
OPTO OUT #1
OPTO OUT #2
OPTO OUT #3
OPTO OUT #4
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
J1
23
A
24
A
B
25
B
26
INDEX
27
6
INDEX
28
+5VDC
29
30
COMMON
A
31
A
32
B
33
B
34
INDEX
35
INDEX
36
Not Used
37
38
COMMON
39
+24VDC
40
OPTO IN POWER
41
OPTO OUT #1 RETURN
42
OPTO OUT #2 RETURN
43
OPTO OUT #3 RETURN
44
OPTO OUT #4 RETURN
Encoder
Input
Note 3
Buffered
Encoder
Output
Note 4
J1-8 OPEN disables the control & motor coasts to a stop. CLOSED allows current to flow in
the motor and produce torque.
J1-9 CLOSED operates the motor in the Forward direction (with J1-10 open).
OPEN motor decels to stop (depending on Keypad Stop mode parameter setting).
J1-10 CLOSED operates motor in the Reverse direction (with J1-9 open).
OPEN motor decels to stop depending on Keypad Stop mode parameter setting.
J1-11 to Selects programmed preset speeds as defined
J1-14 in Table 3-12.
J1-15 Selects ACC/DEC group. OPEN selects group 1. CLOSED selects group 2.
J1-16 OPEN causes an external trip to be received by control. The control will disable and
J1-39 & Jumper as shown to power the Opto Inputs from the internal +24VDC supply.
40
display external trip when programmed “ON”. When this occurs, the motor stop
command is issued, drive operation is terminated and an external trip fault is displayed
on the keypad display (also logged into the fault log).
If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”.
3-38
Receiving & Installation
MN718
Section 1
General Information
Fan Pump 2 Wire Control Mode
Figure 3-23 Fan Pump, 2 Wire Control Connection Diagram
Note 1
Notes 1 and 2
Note 3
Notes:
1. Refer
2.
3.
4.
5.
6.
7.
Programmable 0–5v Output (Factory Preset: Speed)
Programmable 0–5v Output (Factory Preset: Current)
Both CLOSED=
Fault Reset
Note 4
Refer
Figure
to Analog Inputs.
NO T AG.
Refer to Figure NO TAG for
4-20mA.
Refer to Analog Outputs.
Refer to Opto Isolated Inputs.
Refer to Opto Isolated Outputs.
Refer to Encoder installation.
Refer to Buf
fered Encoder Output.
J1
ANALOG GND
0-10VDC or
5kW Command Pot
±5VDC, ±10VDC or 4-20mA
to
Note 5
J1-8 OPEN disables the control and motor coasts to a stop.
CLOSED allows current to flow in the motor.
J1-9 CLOSED starts motor operation in the Forward direction.
OPEN initiates Stop command.
J1-10 CLOSED starts motor operation in the Reverse direction.
OPEN initiates Stop command.
J1-11 OPEN selects setting of “Command Select” parameter. Closed selects Analog Input #1.
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 Run Command. OPEN selects STOP/START and Reset commands from Keypad.
CLOSED selects STOP/START and Reset commands from terminal strip.
J1-13 Speed Command. OPEN selects speed commanded from Keypad.
CLOSED selects terminal strip speed source (selected in the Level 1 Input block,
Command Select parameter).
Note: When changing from Keypad to Terminal Strip (J1-12 or J1-13) the motor speed and
direction will remain the same after the change.
J1-14 OPEN selects preset speed #1 regardless of the Speed Command input J1-13.
(FIRESTAT).
J1-15 OPEN selects preset speed #2 regardless of the Speed Command input J1-13.
(FREEZESTAT).
Note: If J1-14 and J1-15 are both Open, Preset Speed #1 is selected.
J1-16 OPEN causes an external trip to be received by control. The control will disable and
display external trip when programmed “ON”. When this occurs, the drive is disabled
and an external trip fault is displayed on the keypad display (also logged into the fault
log). If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”.
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
PRESET SPEED #1
PRESET SPEED #2
EXTERNAL TRIP
O INPUT COMMON
OPT
OPT
O OUT COMMON
OPTO OUT #1
OPTO OUT #2
OPTO OUT #3
OPTO OUT #4
1
23
A
2
24
A
3
25
B
4
26
B
5
27
INDEX
6
28
INDEX
7
29
+5VDC
8
30
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
COMMON
31
A
A
32
B
33
B
34
INDEX
35
INDEX
36
Not Used
37
38
COMMON
39
+24VDC
40
OPTO IN POWER
41
OPTO OUT #1 RETURN
42
OPTO OUT #2 RETURN
43
OPTO OUT #3 RETURN
44
OPTO OUT #4 RETURN
Encoder
Input
Note 6
Buffered
Encoder
Output
Note 7
MN718
Receiving
& Installation 3-39
Section
1
General Information
Fan Pump 3 Wire Control Mode
Figure 3-24 Fan Pump, 3 Wire Control Connection Diagram
Note 1
Notes 1 and 2
Note 3
Programmable 0–5v Output (Factory Preset: Speed)
Programmable 0–5v Output (Factory Preset: Current)
Note 4
Notes:
1. Refer
2.
to Analog Inputs.
Refer to Figure NO TAG for
4-20mA.
3.
Refer to Analog Outputs.
4.
Refer to Opto Isolated Inputs.
5.
Refer to Opto Isolated Outputs.
6.
Refer to Encoder installation.
7.
Refer to Buf
fered Encoder Output.
±5VDC, ±10VDC or 4-20mA.
Both CLOSED=
J1
ANALOG GND
0-10VDC or
5kW Command Pot
Fault Reset
Refer
to
Figure
NO T AG.
Note 5
J1-8 OPEN disables the control and motor coasts to a stop.
CLOSED allows current to flow in the motor.
J1-9 MOMENTARY CLOSED starts motor operation in the Forward direction.
J1-10 MOMENTARY CLOSED starts motor operation in the Reverse direction.
J1-11 When OPEN motor Decels to stop.
J1-12 Run Command. OPEN selects STOP/START and Reset commands from Keypad.
CLOSED selects STOP/START and Reset commands from terminal strip.
J1-13 Speed Command. OPEN selects speed commanded from Keypad.
CLOSED selects terminal strip speed source (selected in the Level 1 Input block,
Command Select parameter).
Note: When changing from Keypad to Terminal Strip (J1-12 or J1-13) the motor speed and
direction will remain the same after the change.
J1-14 OPEN selects preset speed #1 regardless of the Speed Command input J1-13.
(FIRESTAT)
J1-15 OPEN selects preset speed #2 regardless of the Speed Command input J1-13.
(FREEZESTAT)
Note: If J1-14 and J1-15 are both Open, Preset Speed #1 is selected.
J1-16 OPEN causes an external trip to be received by control. The control will disable and
display external trip when programmed “ON”. When this occurs, the drive is disabled
and an external trip fault is displayed on the keypad display (also logged into the fault
log). If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”.
ANALOG INPUT 1
POT REFERENCE
ANALOG INPUT +2
ANALOG INPUT –2
ANALOG OUT 1
ANALOG OUT 2
FORWARD RUN
REVERSE RUN
RUN COMMAND
SPEED COMMAND
PRESET SPEED #1
PRESET SPEED #2
EXTERNAL TRIP
O INPUT COMMON
OPT
OPT
O OUT COMMON
OPTO OUT #1
OPTO OUT #2
OPTO OUT #3
OPTO OUT #4
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
ENABLE
STOP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
A
A
B
B
INDEX
INDEX
+5VDC
COMMON
A
A
B
B
INDEX
INDEX
Not Used
COMMON
+24VDC
OPTO IN POWER
OPTO OUT #1 RETURN
OPTO OUT #2 RETURN
OPTO OUT #3 RETURN
OPTO OUT #4 RETURN
Encoder
Input
Note 6
Buffered
Encoder
Output
Note 7
3-40 Receiving & Installation
MN718
Section 1
General Information
Bipolar Speed and Torque Mode Connections
In
addition to individual motor bipolar speed or torque control, this mode of operation
allows the user to store up to four (4) different complete sets of operating parameters.
This is important if you wish to store and use dif
commands, jog speeds or to store tuning parameter values for dif
3-13 shows switch settings required to access each parameter table. 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:
Except for the Level 1 Operating Mode parameter, the control can be
programmed in the REMOTE mode with the drive enabled and switches
closed. The control must be disabled to change the operating mode
parameter.
1.
Set the Level 1 INPUT block, Operating Mode parameter value to BIPOLAR in
each of the parameter sets.
2.
Set switches J1-13 and J1-14 to Parameter T
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 T
3.
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 T
4.
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 T
5.
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 T
6.
Remember that to change the value of a parameter in one of the parameter
tables, you must first select the table using the switches. Y
value in a table until you have first selected that table.
Table 3-13 Bipolar Mode Table Select Truth Table
ferent acceleration rates, speed
ferent motors etc. T
able #0 (both switches open). Be
able#0.
able#1.
able#2.
able#3.
ou cannot change a
able
MN718
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: All
Note:
parameters except operating mode can be changed and saved for each
table.
Preset speed does not apply to table select.
Receiving
& Installation 3-41
Section 1
General Information
Figure 3-25 Bipolar Speed or Torque Connection Diagram
Note 1
Note 4
Note 2
Notes
1.
2.
3.
4.
5.
6.
Programmable 0–5V Output (Factory Preset: Speed)
Programmable 0–5V Output (Factory Preset: Current)
(for Figure 3-25):
Refer to Analog Inputs.
Refer to Analog Outputs.
Refer to Opto Isolated Outputs.
Refer to Figure NO TAG for 4-20mA.
Refer to Encoder installation.
Refer to Buf
fered Encoder Output.
* See Table 3-13.
±5VDC, ±10VDC or 4-20mA
Refer to Figure NO
5kW Command Pot
TAG.
Note 3
ANALOG GND
ANALOG INPUT 1
POT REFERENCE
ANALOG INPUT +2
ANALOG INPUT –2
ANALOG OUT 1
ANALOG OUT 2
FORWARD ENABLE
REVERSE ENABLE
CLOSED=ORIENT
SPEED/TORQUE
* TABLE SELECT
* TABLE SELECT
FAULT RESET
EXTERNAL TRIP
OPT
O INPUT COMMON
OPT
O OUT COMMON
OPTO OUT #1
OPTO OUT #2
OPTO OUT #3
OPTO OUT #4
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
ENABLE
10
11
12
13
14
15
16
17
18
19
20
21
22
J1
1
23
A
2
24
A
3
25
B
4
26
B
5
27
INDEX
6
28
INDEX
7
29
+5VDC
8
30
COMMON
9
A
31
A
32
B
33
B
34
INDEX
35
INDEX
36
Not Used
37
38
COMMON
39
+24VDC
40
OPTO IN POWER
41
OPTO OUT #1 RETURN
42
OPTO OUT #2 RETURN
43
OPTO OUT #3 RETURN
44
OPTO OUT #4 RETURN
Encoder
Input
Note 5
Buffered
Encoder
Output
Note 6
J1-8 OPEN disables the control & motor coasts to a stop.
CLOSED allows current to flow in the motor and produce torque.
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).
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).
J1-11 Causes the motor shaft to orient to a marker or external switch.
J1-12 CLOSED puts the control in torque mode.
OPEN puts the control in velocity mode.
J1-13 & Select from four parameter tables as defined
J1-14 in Table 3-13.
J1-15 Momentary CLOSED to reset fault condition.
OPEN to run,
J1-16 OPEN causes an external trip to be received by control. The control will disable and
J1-39 & Jumper as shown to power the Opto Inputs from the internal +24VDC supply.
40
display external trip when programmed “ON”. When this occurs, the motor stop
command is issued, drive operation is terminated and an external trip fault is displayed
on the keypad display (also logged into the fault log).
If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”.
3-42
Receiving & Installation
MN718
Section 1
General Information
Process Mode Connections
The process control mode provides an auxiliary closed loop general purpose PID set
point control that is shown in Figure 3-26. The process control loop may be configured in
either of two ways.
1.
Using two (2) inputs; a set point and a process feedback input. The error signal
(between the setpoint and the feedback signals) adjusts the speed or torque of
the motor to eliminate error
2.
Using three (3) inputs; a setpoint, process feedback and feedforward inputs.
Instead of waiting for an error signal to develop between the setpoint and the
process feedback signals, the feedforward signal adjusts the speed or torque of
the motor to reduce the amount of error that will develop between the feedback
and setpoint inputs.
The objective of either method is to force the process feedback to be as close to the
setpoint as possible and eliminate process error
Mode Input Signal Compatibility for the Setpoint Source, Process Feedback and
Feedforward signals. Be sure to use this information to select the signal types and
expansion boards for your application.
Two Input Configuration
For 2 input operation, several parameters must be set as follows:
1.
Level 2 Process Control block, “Process Feedback” parameter must be set to
the type of feedback signal used. The process feedback signal can be any
Analog input available at the J1 terminal strip or expansion board. Selections
are shown in Figure 3-26.
2.
Level 2 Process Control block, “Setpoint Source” parameter must be set to the
type of set point being used.
A.
A fixed value setpoint is a keypad programmed parameter value. T
program a fixed setpoint, do the following:
i.
Set the Level 2 Process Control block, “Setpoint Source” parameter
to Setpoint CMD.
ii.
Set the Level 2 Process Control block, “Setpoint CMD” parameter
to a value between –100% to +100% of the process feedback input.
B.
If a variable value setpoint is used, the Setpoint Source must be set to any
available terminal strip or expansion board input not being used for the
process feedback input. Selections are shown in Figure 3-26.
3.
Level 1 Input block “Command Select” parameter must be set to “None”.
Three Input Configuration
For 3 input operation, several parameters must be set as follows:
1.
Level 2 Process Control block “Process Feedback” parameter must be set to
the type of feedback signal used. The process feedback signal can be any
Analog input available at the J1 terminal strip or expansion board. Selections
are shown in Figure 3-26.
2.
Level 2 Process Control block “Setpoint Source” parameter must be set to the
type of set point being used.
A.
If a fixed value setpoint is used, set the Level 2 Process Control block,
Setpoint Source parameter to “Setpoint CMD”. Set the Level 2 Process
Control block “Setpoint Command” parameter to a value between –100%
to +100% of the process feedback.
B.
If a variable value setpoint is used, set the Level 2 Process Control block,
Setpoint Source parameter to any Analog1, Analog2 or expansion board
input not being used for the process feedback input. Selections are shown
in Figure 3-26.
.
. T
able 3-14 shows a matrix of Process
o
MN718
Receiving
& Installation 3-1
Section 1
General Information
Figure 3-26 Simplified Process Control Block Diagram
SETPOINT SOURCE
Available sources are:
Set Point Command
Potentiometer
± 10 Volts
± 5 Volts
4-20 mA
5 Volt EXB
10 Volt EXB
4-20mA EXB
3-15 PSI EXB
Tachometer EXB
None
3.
Level 1 Input block “Command Select” parameter must be set to the
feedforward signal type. This signal may be any Analog1, Analog2 or
expansion board input not being used for the process feedback or setpoint
source inputs. Selections are shown in Figure 3-26.
Note:
An input can only be used one time for Process Feedback, OR Setpoint
Source, OR Feedforward.
Baldor Series “H” Control
PROCESS FEEDBACK
Available sources are:
Potentiometer
± 10 Volts
± 5 Volts
4-20 mA
5 Volt EXB
10 Volt EXB
4-20mA EXB
3-15 PSI EXB
Tachometer EXB
None
PROCESS FEEDFORWARD
COMMAND SELECT
Available sources are:
Potentiometer
± 10 Volts
± 5 Volts
4-20 mA
10 V w/Torq FF
EXB Pulse Follower
5 Volt EXB
10 Volt EXB
4-20mA EXB
3-15 PSI EXB
Tachometer EXB
Serial
None
–
Auxiliary PID Control
Motor Control
ACC/DEC
S–Curve
Profiler
Differentiator
EXB Pulse
Follower Only
s
+
Proportional
∑
Closed When Process
Mode is Enabled (J1–13)
+
Proportional
+
∑
+
–
s
Differentiator
Gp
Differential
Gd s
Gp
Integral
Gi
s
Set Point adjustment limit
w/ integral clamp to max
limit value
Existing Baldor Control System
Differential
Gd s
+
+
+
∑
+
+
∑
Integral
Gi
s
+
Amp
Motor
Enc.
3-2
Receiving & Installation
MN718
Section 1
Setpoint
General Information
Table 3-14 Process Mode Input Signal Compatibility
or
Feedforward
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
Requires expansion board EXB004A01 (4 Output Relays/3-15 PSI Pneumatic Interface EXB).
Requires expansion board EXB006A01 (DC T
Requires expansion board EXB005A01 (Master Pulse Reference/Isolated Pulse Follower EXB).
Used for Feedforward only
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
J1-1 & 2 J1-4 & 5
5V EXB 10V EXB
expansion board EXB007A01 (High Resolution Analog I/O EXB).
achometer Interface EXB).
. Must not be used for Setpoint Source or Feedback.
4-20mA
EXB
3-15 PSI
EXB
DC
Tach EXB
Specific Process Mode Outputs
Process Mode Only
, Analog Monitoring Outputs
Name Description
Process FDBK Process Feedback scaled input. Useful for observing or tuning the
process control loop.
Setpoint CMD Setpoint Command scaled input. Useful for observing or tuning the
process control loop.
Speed Command Commanded Motor Speed. Useful for observing or tuning the output of
the control loop.
Process
Mode Only
, Opto Isolated Outputs
Name Description
Process Error CLOSED when the Process Feedback is within the specified tolerance
band. OPEN when the Process Feedback is greater than the specified
tolerance band. The width of the tolerance band is adjusted by the
Level 2 Process Control block Process ERR TOL parameter value.
MN718
Receiving
& Installation 3-3
Section 1
General Information
Note 4
Note 2
Notes:
1.
2.
3.
4.
5.
6.
Programmable 0–5V Output (Factory Preset: Speed)
Programmable 0–5V Output (Factory Preset: Current)
Refer to Analog Inputs.
Refer to Analog Outputs.
Refer to Opto Isolated Outputs.
Refer to Figure 3-30 for 4-20mA.
Refer to Encoder installation.
Refer to Buf
fered Encoder Output.
Refer
Figure 3-27 Process Mode Connection Diagram
ANALOG GND
Note 1
±5VDC, ±10VDC or 4-20mA
5kW Command Pot
to Figure 3-32.
Note 3
ANALOG INPUT 1
POT REFERENCE
ANALOG INPUT +2
ANALOG INPUT –2
ANALOG OUT 1
ANALOG OUT 2
Enable
Forward
Reverse
Table Select
Speed/Torque
Process Mode Enable
Jog
Fault Reset
External Trip
Opto Input Common
Opto Out Common
OPTO OUT #1
OPTO OUT #2
OPTO OUT #3
OPTO OUT #4
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
J1
23
A
24
A
25
B
26
B
INDEX
27
INDEX
28
+5VDC
29
30
COMMON
A
31
A
32
B
33
B
34
INDEX
35
INDEX
36
Not Used
37
38
COMMON
39
+24VDC
40
OPTO IN POWER
41
OPTO OUT #1 RETURN
42
OPTO OUT #2 RETURN
43
OPTO OUT #3 RETURN
44
OPTO OUT #4 RETURN
Encoder
Input
Note 5
Buffered
Encoder
Output
Note 6
J1-8 OPEN disables the control & motor coasts to a stop. Closed allows current to flow in the
motor and produce torque.
J1-9 CLOSED operates the motor in the Forward direction (with J1-10 open).
OPEN motor decels to stop (depending on Keypad Stop mode parameter setting).
J1-10 CLOSED operates motor in the Reverse direction (with J1-9 open).
OPEN motor decels to stop depending on Keypad Stop mode parameter setting.
J1-11 OPEN = TABLE 0, CLOSED = TABLE 1
J1-12 CLOSED, the control is in torque mode.
OPEN, the control is in 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 OPEN causes an external trip to be received by control. The control will disable and
J1-39 & Jumper as shown to power the Opto Inputs from the internal +24VDC supply.
40
display external trip when programmed “ON”. When this occurs, the motor stop
command is issued, drive operation is terminated and an external trip fault is displayed
on the keypad display (also logged into the fault log).
If J1-16 is connected, you must set Level 2 Protection block, External Trip to “ON”.
3-4
Receiving & Installation
MN718
Section 1
General Information
Analog Inputs and Outputs
Analog Inputs T
wo 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 #1 or #2 may be grounded
provided the common mode range is not exceeded. Either analog input may be selected
in the Level 1 INPUT block, Command Select parameter value. Analog input #1 is
selected if parameter value “Potentiometer” is selected. Analog input #2 is selected if
parameter value “+/–10V
olts, +/–5 V
olts or 4-20mA” is selected. Figure 3-29 shows the
equivalent circuits of the Analog Inputs.
Figure 3-28 Analog Inputs and Outputs
Analog Input #1
Command Pot
or
0-10VDC
±5VDC, ±10VDC
or 4-20 mA Input
Programmable 0-5VDC
(Factory Preset: Speed)
Programmable 0-5VDC
(Factory Preset: Current)
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
5KW
Analog Ground
Analog Input 1
Pot Reference
Analog Input +2
Analog Input -2
Analog Output 1
Analog Output 2
The single ended analog input #1 is used when the controller is set to Standard 3 Wire,
Fan Pump 2 or 3 Wire, Process, or Bipolar Control (not Keypad or 15 Speed 2 Wire
modes). When using a potentiometer as the speed command, process feedback or
setpoint source, the Level 1 Input block COMMAND SELECT parameter must be set to
“POTENTIOMETER”.
1.
Connect the wires from the 5KW pot as shown in Figure 3-28. One end of the
pot is connected to J1-1 (analog ground) and the other end is connected to J1-3
(reference voltage).
2.
Connect the wiper of the pot to J1-2. The voltage across terminals J1-1 and
J1-2 is the speed command input.
3.
A 0-10VDC speed command signal may be connected across J1-1 and J1-2
instead of a 5KW pot.
MN718
Receiving
& Installation 3-5
Section 1
General Information
Analog Input #2
Analog input #2 accepts a dif
operating mode is defined in the of the Level 1 Input block OPERA
parameter.
Note:
Analog Input #2 is used with Standard Run 3-Wire, Fan Pump 2 or 3 Wire or
Bipolar Control modes and not used for the Keypad or 15 Speed 2 Wire or the
Serial operating modes.
1.
Connect the Analog Input +2 wire to J1-4 and the –2 wire to J1-5.
2.
If using a 4-20 mA command signal, jumper JP1 located on the main control
board must be on pins 2 & 3. For all other modes, JP1 must be on pins 1 & 2.
Refer to Figure NO TAG for jumper position information.
Note:
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. The common mode voltage can be measured with a voltmeter
Apply the maximum command voltage to analog input 2 (J1A-4, 5). Measure
the AC and DC voltage across J1A-1 to J1A-4. Add the AC and DC readings
together
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. If the common mode
voltage range has been exceeded, the solution is either to change the
command voltage source or isolate the command voltage with a commercially
available signal isolator
. Measure the AC and DC voltage from J1A-1 to J1A-5. Add the AC
ferential command ±5VDC, ±10VDC or 4-20 mA. The
.
.
TING MODE
.
3-6
Receiving & Installation
MN718
Section 1
General Information
Figure 3-29 Analog Inputs Equivalent Circuits
J1
-15VDC
30KW
1
20KW
2
–
+
5.1V Zener
.033 mF
5KW
T
o Microprocessor
3
4
5
JP2
JP1
4-20mA
500W
X N/C
Notes:
123
1.96KW
+15VDC
10KW 10KW
+
–
10KW
+
–
Figure 3-30
T
o Microprocessor
10KW
All OP Amps are TL082 or TL084
Analog
Ground is separated from
Chassis Ground. Electrically
are separated by an RC network.
they
JP1
Jumper Jumper
JP1
JP2
MN718
123
Table 3-15 Control Board Jumper
Position
1–2 V
2–3
1–2
2–3
oltage Speed Command Signal. (Factory Setting)
4-20mA input at Analog #2
Factory Setting
Not used.
Description of Jumper Position Setting
Refer
to T
able 3-15
for jumper placement information.
Receiving
& Installation 3-7
Section 1
General Information
Analog Outputs T
From Microprocessor
.033 mf
wo 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
Table NO TAG
of 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.
1.
Connect the Output #1 wires to J1-6 and J1-1.
2.
Connect the Output #2 wires to J1-7 and J1-1.
Figure 3-31 Analog Outputs Equivalent Circuits
J1
1
10KW
+
–
10KW
50W
6
Notes:
From Microprocessor
10KW
.033 mf
+
–
10KW
50W
+
–
7
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
All OP Amps are TL082 or TL084
Analog
Ground is separated from
Chassis Ground. Electrically
are separated by an RC network.
they
3-8
Receiving & Installation
MN718
Section 1
General Information
External Trip Input Terminal
relay in all operating modes as shown in Figure 3-32. 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 T
and the N.O. contact is closed when power is applied to the relay and the motor is cold.
Connect the External T
same conduit as the motor power leads.
T
o activate the External T
Block must be set to “ON”.
Figure 3-32 Motor Temperature Relay
T1 T2 T3
External or remote motor
overload protection may
be required by National
Electrical Code or equivalent
MMM
T3
T2
T1
* Motor
Opto-Isolated Inputs The
equivalent circuit for the nine Opto inputs is shown in Figure 3-33. The function of
each input depends on the operating mode selected. Refer to the operating mode
connection diagrams shown previously in this section.
Figure 3-33 Opto-Input Equivalent Circuit (Using Internal Supply)
J1
J1-16 is available for connection to a normally closed thermostat or overload
rip fault. The optional relay (CR1) shown provides the isolation required
rip Input wires to J1-16 and J1-17. Do not place these wires in the
rip input, the External T
Customer Provided
Source Voltage
rip parameter in the Level 2 Protection
Note: Add appropriately rated
protective device for AC relay
(snubber) or DC relay (diode).
J1
*
G
Motor Thermostat Leads
CR1
Do not run these wires in
same conduit as motor
leads or AC power wiring.
Optional hardware. Must be ordered separately.
*
16
17
External Trip
Opto Input Common
+24VDC @ 200mA
(supply terminal 39).
Jumper terminals 39 to 40
(Factory Installed)
MN718
Opto Input 1
Opto Input 2
Opto Input 3
Opto Input 4
Opto Input 5
Opto Input 6
Opto Input 7
Opto Input 8
Opto Input 9
10
11
12
13
14
15
16
17
39
40
8
9
6.8K 6.8K 6.8K 6.8K 6.8K 6.8K 6.8K 6.8K
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
Receiving
6.8K
& Installation 3-9
Section
1
General Information
Figure 3-34 Opto-Input Equivalent Circuit (Using External Supply)
J1
J1
* User VCC (–)
Opto Inputs Closing to Ground Opto Inputs Closing to +VCC
Opto Input 1
Opto Input 2
Opto Input 3
Opto Input 4
Opto Input 5
Opto Input 6
Opto Input 7
Opto Input 8
Opto Input 9
* User VCC (+)
8
9
10
11
12
13
14
15
16
17
39
40
* User VCC = 10 - 30VDC
External Power Source
Opto Input 1
Opto Input 2
Opto Input 3
Opto Input 4
Opto Input 5
Opto Input 6
Opto Input 7
Opto Input 8
Opto Input 9
* User VCC (+)
* User VCC (–)
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
8
9
10
11
12
13
14
15
16
17
39
40
3-10 Receiving & Installation
MN718
Section 1
General Information
Opto-Isolated Outputs Four
See Figure 3-35. Each output may be programmed to represent one output condition.
The output conditions are defined in
The Opto-isolated outputs may be configured for sinking or sourcing 60 mA each.
However
common when active is 1.0 VDC (TTL compatible). The Opto-isolated outputs may be
connected in dif
Opto-isolated outputs is shown in Figure 3-36.
If the opto outputs are used to directly drive a relay
(IN4002) minimum should be connected across the relay coil. See Electrical Noise
Considerations in Section 5 of this manual.
Each Opto Output is programmed in the Output programming block.
Figure 3-35 Opto-isolated Output Configurations
24COM
Optional
Customer
Supplied
Relays
17
18
19
programmable Opto-isolated outputs are available at terminals J1-19 through J1-22.
Table NO TAG
of Section 4 of this manual.
, all must be configured the same. The maximum voltage from opto output to
ferent ways as shown in Figure 3-35. The equivalent circuit for the
, a flyback diode rated at 1A, 100 V
1.
Connect OPT
2.
Connect OPT
3.
Connect OPT
4.
Connect OPT
39
40
41
+24VDC
O OUT #1 wires to J1-19 and J1-41.
O OUT #2 wires to J1-20 and J1-42.
O OUT #3 wires to J1-21 and J1-43.
O OUT #4 wires to J1-22 and J1-44.
24COM
17
18
19
39
40
41
+24VDC
Optional
Customer
Supplied
Relays
Using Internal Supply
(Sinking the Relay Current)
–
Optional Customer Supplied
10VDC to 30VDC Source
+
Optional
Customer
Supplied
Relays
Using External Supply
(Sinking the Relay Current)
24COM
20
21
22
17
18
19
20
21
22
42
43
44
39
40
41
42
43
44
+24VDC
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
20
21
22
(Sourcing the Relay Current)
–
Optional Customer Supplied
10VDC to 30VDC Source
+
24COM
17
18
19
20
21
22
(Sourcing the Relay Current)
42
43
44
Using Internal Supply
+24VDC
39
40
41
42
43
44
Using External Supply
Customer
Optional
Supplied
Relays
Receiving
& Installation 3-1
1MN718
Section 1
General Information
PC865
50mA max
PC865
50mA max
Figure 3-36 Opto-Output Equivalent Circuit
J1
18
Opto Output 1
19
Opto Output 2
20
Opto Output 3
21
Opto Output 4
22
PC865
50mA max
Terminal Tightening Torque = 7 Lb-in (0.8 Nm).
PC865
50mA max
Opto Out 1 Return
41
Opto Out 2 Return
42
Opto Out 3 Return
43
Opto Out 4 Return
44
10
– 30VDC
Opto Outputs
3-12
Receiving & Installation
MN718
Section 1
General Information
Pre-Operation Checklist Check
CAUTION: After completing the installation but before you apply power
W
Check of Motors and Couplings
of Electrical Items
, be
sure to check the following items.
1. V
erify AC line voltage at source matches control rating.
2.
Inspect all power connections for accuracy
compliance to codes.
3. V
erify 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.
ARNING: Make sure that unexpected operation of the motor shaft during start
up will not cause injury to personnel or damage to equipment.
1. V
erify freedom of motion for all motor shafts and that all motor couplings are
tight without backlash.
2. V
erify the holding brakes if any, are properly adjusted to fully release and set to
the desired torque value.
.
, workmanship and tightness and
MN718
Receiving
& Installation 3-13
Section 1
General Information
Power-Up Procedure This procedure will help get your system up and running in the keypad mode quickly. This
will allow you to prove the motor and control operation. 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.
Initial Conditions
Be sure the Control, Motor and Dynamic Brake hardware are wired according to the
procedures described previously in this manual. Become familiar with the keypad
programming
1. Verify
2. T
3.
4.
5.
6.
7.
8.
It is not necessary to wire the terminal strip to operate
and keypad operation
that any enable inputs to J1-8 are open.
urn power on. Be sure there are no faults.
Set the Level 1 Input block, Operating Mode to “KEYP
Be sure the Level 2 Protection block, Local Enable INP parameter is OFF and
the Level 2 Protection block, External T
Set the Level 2 Output Limits block, “OPERA
(STD CONST TQ, STD V
Enter the following motor data in the Level 2 Motor Data block parameters:
Motor V
Motor Rated Amps (FLA)
Motor Rated Speed (base speed)
Motor Rated Frequency
Motor Mag Amps (no load current)
Encoder Counts
Go to 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.
Disconnect the motor from the load (including coupling or inertia wheels). If the
load cannot be disconnected, refer to Section 6 and manually tune the control.
After manual tuning, perform steps 10, 1
oltage (input)
of the control as described in Section 4 of this manual.
rip parameter is OFF
TING ZONE” parameter as desired
AR TQ, QUIET CONST TQ or QUIET V
1, 15, 16 and 17.
the motor in Keypad mode.
AD”.
.
AR TQ).
W
ARNING: The motor shaft will rotate during this procedure. Be certain that
unexpected motor shaft movement will not cause injury to
personnel or damage to equipment.
9.
Go to Level 2 Autotune block, and do the following tests:
CMD OFFSET TRIM
CUR LOOP COMP
STAT
OR R1
FLUX CUR SETTING
ENCODER TESTS
SLIP FREQ TEST
10.
Set the Level 2 Output Limits block, “MIN OUTPUT SPEED” parameter
11.
Set the Level 2 Output Limits block, “MAX OUTPUT SPEED” parameter
12.
Remove all power from the control.
13.
Couple the motor to its load.
14. T
urn power on. Be sure no errors are displayed.
15.
Go to Level 2 Autotune block and perform the SPD CNTRLR CALC test.
16.
Run the drive from the keypad using one of the following: the arrow keys for
direct speed control, a keypad entered speed or the JOG mode.
17.
Select and program additional parameters to suit your application.
The
control is now ready for use the in keypad mode. If a dif
refer
to Section 3 Control Connections and Section 4 Programming and Operation.
ferent operating
mode is desired,
.
.
3-14
Receiving & Installation
MN718
Section 4
Programming and Operation
Overview
The keypad is used to program the control parameters, operate the motor and monitor
the status and outputs of the control by accessing the display options, diagnostic menus
and the fault log.
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
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. This key is only
active in the Keypad or local mode.
REV - Press REV to initiate reverse
rotation of the motor. This key is active
only in the Keypad or local mode.
STOP - Press STOP one time to initiate
a stop sequence. Depending on the
setup of the control, the motor will either
ramp or coast to a stop. This key is
operational in all modes of operation
unless it has been disabled by the
Keypad Stop parameter in the Keypad
(programming) Setup Block. Press STOP
twice to disable control (coast to stop).
Note: If the control is operating in
remote mode and the stop key is
pressed the control will change to
the local mode when the stop
command is initiated. To resume
operation in the remote mode,
press the LOCAL key.
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.
Figure 4-1 Keypad
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.
Keypad Display -
information during Local or Remote
operation. It also displays information
during parameter setup and fault or
Diagnostic Information.
Displays status
PROG - Press PROG to enter the
program mode. While in the program
mode the PROG key is used to edit a
parameter setting.
Y - (UP Arrow).
Press Y to change the value of the
parameter being displayed. Pressing Y
increments the value to the next greater
value. Also, when the fault log or
parameter list is displayed, the Y key will
scroll upward through the list. In the
local mode pressing the Y 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.
B - (Down Arrow)
Press B to change the value of the
parameter being displayed. Pressing B
decrements the value to the next lesser
value. Also, when the fault log or
parameter list is displayed, the B key will
scroll downward through the list. In the
local mode pressing the B key will
decrease motor speed to the next lower
value.
MN718
Programming
& Operation 4-1
Section 1
General Information
Display Mode The
control is in the DISPLA
Y 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
The
DISPLA
Y MODE is used to view DIAGNOSTIC INFO and the F
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 Y or B Key
adjustment
Adjusts display intensity
Output Condition
Value and Units
AUL
T LOG. The
Press ENTER Saves level of contrast and exits
to display mode
Typical display
4-2
Programming & Operation
MN718
Section 1
General Information
Display Mode
Continued
Display Mode Screens
Action Description Display Comments
Apply Power Logo display for 5 seconds.
Display mode showing motor
speed.
Press DISP key Display mode custom unit output
rate (only if Level 2 Custom Units
block parameters are set).
Press DISP key Display Frequency First Display Mode Screen.
Press DISP key DIsplay Current
Press DISP key DIsplay Voltage
Press DISP key Combined DIsplay
Press DISP key Screen to enter Fault Log
No faults present. Local keypad
mode. If in remote/serial mode,
press local for this display.
Press DISP key Screen to enter Diagnostic Menu
Press DISP key Exit Display mode and return to
Motor Speed display
MN718
Programming
& Operation 4-3
Section 1
General Information
Display Mode
Continued
Display Screens & Diagnostic Information Access
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
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
screen
temperature.
voltage.
overload current remaining.
inputs & outputs states.
XXXV
No faults present. Local keypad
mode. If in remote/serial mode,
press local for this display.
Diagnostic Access screen.
screen.
Opto Inputs states (Left);
Opto Outputs states (Right).
Press DISP key Display mode showing actual
drive running time.
Press DISP key Display mode showing operating
zone, voltage and control type.
Press DISP key Display mode showing continuous
amps; PK amps rating; amps/volt
scale of feedback, power base ID.
Press DISP key Display mode showing which
Group1 or 2 expansion boards
are installed.
Press DISP key Display mode showing motor
shaft revolutions from the REV
home set point.
Press DISP key Display mode showing parameter
table selected.
Press DISP key Display mode showing firmware
version and revision installed in
the control.
Press DISP key Displays exit choice. Press ENTER to exit diagnostic
HR.MIN.SEC format.
Typical display.
ID is displayed as a hexadecimal
value.
information.
4-4
Programming & Operation
MN718
Section 1
General Information
Display Mode
Fault Log Access When
Continued
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 5 times 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 on.
fault occurred.
Scroll through fault messages.
Display mode.
Most recent fault displayed.
If no messages, the fault log exit
choice is displayed.
MN718
Programming
& Operation 4-5
Section 1
General Information
Program Mode The
Program Mode is used to:
1.
Enter motor data.
2.
Autotune the motor
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
parameter is selected for programming, the keypad display gives you the
following information:
Parameter
Parameter Status
Parameter
Status
left corner of the keypad display
value may be viewed but not changed while the motor is operating. 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.
Action Description Display Comments
Apply Power Keypad Display shows this
opening message.
.
. When a
Value and Units
. All programmable parameters are displayed with a “P:” in the lower
. If a parameter is displayed with a “V
Logo display for 5 seconds.
:”, the parameter
If no faults and programmed for
LOCAL operation.
If no faults and programmed for
REMOTE operation.
Press PROG key Press ENTER to access Preset
Press Y or B key
Press Y or B key
Press ENTER key First Level 2 block display.
Press Y or B key
Press ENTER key Return to display mode.
Scroll to the ACCEL/DECEL
block.
Scroll to the Level 2 Block.
Scroll to Programming Exit menu.
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.
4-6
Programming & Operation
MN718
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
Press PROG key Access programming mode.
Press Y or B key
Press ENTER key Access Input Block. Keypad mode shown is the
Press ENTER key Access Operating Mode
Press Y key
opening message.
If no faults and programmed for
LOCAL operation.
Scroll to Level 1 Input Block.
parameter.
Scroll to change selection.
Logo display for 5 seconds.
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.
.
Press ENTER Save selection to memory. Press ENTER to save selection.
Press Y key
Press ENTER key Return to Input Block.
Press DISP key Return to Display Mode. Typical display mode.
Scroll to menu exit.
MN718
Programming
& Operation 4-7
Section 1
General Information
Program Mode
Continued
Reset Parameters to Factory Settings
Sometimes
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).
Action Description Display Comments
Apply Power Keypad Display shows this
Press PROG key Enter program mode.
Press Y or B key
Press ENTER key Select Level 2 Blocks.
opening message.
If no faults and programmed for
LOCAL operation.
Scroll to Level 2 Blocks.
it is necessary to restore the parameter values to the factory settings. Follow
Note:
All specific application parameters already programmed will be lost when
resetting the control to factory settings.
Note:
After factory settings are restored, the drive must be auto tuned.
Logo display for 5 seconds.
Display mode. Stop LED on.
Press Y or B key
Press ENTER key Select Miscellaneous block.
Press Y key
Press ENTER key Access Factory Settings
Press Y key
Press ENTER key Restores factory settings. “Loading Presets” is first message
Press Y key
Press Y or B key
Press ENTER key Return to display mode. Display mode. Stop LED on.
Scroll to the Miscellaneous block.
Scroll to Factory Settings
parameter.
parameter.
Scroll to YES, to choose original
factory settings.
Scroll to menu exit.
Scroll to Programming exit.
V represents blinking cursor.
“Operation Done” is next
“No” is displayed last.
Exit Level 2 blocks.
Exit Programming mode and
return to Display mode.
4-8
Programming & Operation
MN718
Section 1
General Information
Program Mode
Continued
Initialize New Firmware
After
new firmware is installed, the control must be initialized to the new firmware version
and memory locations. Use the following procedure to Initialize the firmware.
Action Description Display Comments
Apply Power Keypad Display shows this
Press PROG key Enter program mode.
Press Y or B key
Press ENTER key Select Level 2 Blocks.
Press Y or B key
Press ENTER key Select Miscellaneous block.
opening message.
If no faults and programmed for
LOCAL operation.
Scroll to Level 2 Blocks.
Scroll to the Miscellaneous block.
Logo display for 5 seconds.
Display mode. Stop LED on.
Press Y key
Press ENTER key Access Factory Settings
Press Y key
Press ENTER key Restores factory settings. “Loading Presets” is first message
Press Y key
Press ENTER key Return to display mode. Display mode. Stop LED on.
Press DISP key several
times
Press ENTER key Access diagnostic information. Displays commanded speed,
Press DISP key Display mode showing firmware
Press DISP key Displays exit choice. Press ENTER to exit diagnostic
Scroll to Factory Settings
parameter.
parameter.
Scroll to YES, to choose original
factory settings.
Scroll to menu exit.
Scroll to diagnostic information
screen.
version and revision installed in
the control.
V represents blinking cursor.
“Operation Done” is next
“No” is displayed last.
If you wish to verify the firmware
version, enter diagnostic info.
direction of rotation, Local/
Remote and motor speed.
Verify new firmware version.
information.
MN718
Programming
& Operation 4-9
Section 1
General Information
Parameter Definitions To
make programming easier
the
PROG key to enter the programming
, parameters have been arranged as shown in T
mode and the “Preset Speeds” programming block
will be displayed. Use the Up (Y) and Down (B) arrows to scroll through the parameter
blocks.
Tables
Values
preset
Press ENTER to access parameters within a programing block.
4-2 and 4-3 provide an explanation of each parameter
. A complete Parameter Block
list is located at the end of this manual. This list defines the programmable range
value for each parameter and has space to record your settings for future reference.
Table 4-1 List of Parameters
LEVEL 1 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 DC Brake Current
Preset Speed #4 ANA CMD Offset PK Current Limit
Preset Speed #5 ANA 2 Deadband PWM Frequency Process Control
Preset Speed #6 ANA1 CUR Limit Current Rate Limit Process Feedback
Preset Speed #7 Process Inverse
Preset Speed #8 Output Custom Units Setpoint Source
Preset Speed #9 Opto Output #1 Decimal Places Setpoint Command
Preset Speed #10 Opto Output #2 Value at Speed Set PT ADJ Limit
Preset Speed #11 Opto Output #3 Units of Measure Process ERR TOL
Preset Speed #12 Opto Output #4 Process PROP Gain
Preset Speed #13 Zero SPD Set PT Protection Process INT Gain
Preset Speed #14 At Speed Band Overload Process DIFF Gain
Preset Speed #15 Set Speed External Trip Follow I:O Ratio
Analog Out #1 Local Enable INP Follow I:O Out
Accel / Decel Rate Analog Out #2 Following Error Master Encoder
Accel Time #1 Analog #1 Scale Torque Proving
Decel Time #1 Analog #2 Scale Communications
S-Curve #1 Position Band Miscellaneous Protocol
Accel Time #2 Restart Auto/Man Baud Rate
Decel Time #2 Vector Control Restart Fault/Hr Drive Address
S-Curve #2 Ctrl Base Speed Restart Delay
Feedback Filter Factory Settings Auto-Tuning
Jog Settings Feedback Align Homing Speed CALC Presets
Jog Speed Current PROP Gain Homing Offset
Jog Accel Time Current INT Gain CUR Loop Comp
Jog Decel Time Speed PROP Gain Security Control Stator R1
Jog S-Curve Time Speed INT Gain Security State Flux CUR Setting
Speed DIFF Gain Access Timeout Feedback Test
Keypad Setup Position Gain Access Code Slip Freq Test
Keypad Stop Key Slip Frequency SPD CNTRLR CALC
Keypad Stop Mode Stator R1 Motor Data
Keypad Run Fwd Stator X1 Motor Voltage
Keypad Run Rev Motor Rated Amps
Keypad Jog Fwd Motor Rated SPD
Keypad Jog Rev Motor Rated Freq
Motor Mag Amps
Encoder Counts
Resolver Speeds
CALC Presets
LEVEL 2 BLOCKS
CMD Of
fset Trim
able 4-1. Press
and
4-10
Programming & Operation
MN718
Section 1
Out ut Limits block.
S-C
2
S-C
direction (FWD or REV)
For Standard Run mode, close the JOG in ut (J1 12) at the
g
Jog Accel Time
Jog Accel Time changes the Accel Time to a new reset value for jog mode
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 during for jog. Jog can be initiated from the
Preset Speeds
#1 – #15
Allows selection of 15 predefined motor operating speeds.
Each speed may be selected using external switches connected to J1-11, J1-12,
J1-13 and J1-14 when Operating Mode is set to 15 Speed.
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.
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.
urve #1,
urve is a percentage of the total Accel and Decel time and provides smooth starts
p
p
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.
keypad or terminal strip. At the Keypad, press the JOG key then press and hold the
direction (FWD or REV). For Standard Run mode, close the JOG input (J1-12) at the
.
terminal strip then close and maintain the direction input (J1-9 or J1-10).
Jog Accel Time
Jog Decel Time
Jog S-Curve
0%
Curve
20
%
Output Speed
0
Accel Time
Accel S-Curves
40%
Curve
Process Control mode operation is different. If the terminal strip Process Mode
Enable input (J1-13) is closed, pressing the Keypad JOG key (or closing J1-14) will
cause the drive to move in the direction of the error (without pressing FWD or REV).
Jo
Accel Time changes the Accel Time to a new preset value for jog mode.
Jog Decel Time changes the Decel Time to a new preset value for jog mode.
Jog S-Curve changes the S-Curve to a new preset value for jog mode.
Figure 4-2 40% S-Curve Example
40%
Curve
20
%
20
%
Output Speed
0
Decel S-Curves
0%
Curve
Decel Time
20
%
.
Programming
& Operation 4-1
1MN718
Section 1
gqy
General Information
Table 4-2 Level 1 Parameter Block Definitions
Block Title Parameter Description
KEYPAD SETUP Keypad Stop Key
Keypad Stop Mode
Keypad Run FWD
Keypad Run REV
Keypad Jog FWD
Keypad Jog REV
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
Stop Key - Allows keypad “STOP” key to initiate motor stop during remote or serial
Stop Mode - Selects if the Stop command causes the motor to “COAST” to a stop or
Run FWD - ON makes the keypad “FWD” key active in Local mode.
Run REV - ON makes the keypad “REV” key active in Local mode.
Jog FWD - ON makes the keypad “FWD” key active in Local Jog mode.
Jog REV - ON makes the keypad “REV” key active in Local Jog mode.
Eight “Operating Modes” are available. Choices are: Keypad, Standard Run, 15SPD,
Fan Pump 2 Wire, Fan Pump 3 Wire, Serial, Bipolar, and Process. 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 or
±10VDC 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
without attenuation of the command signal.
10
VOL
T W/T
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.
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.
Note: When using the 4-20mA input, the JP1 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
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.
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.
- Continued
operation (if Stop key is set to Remote ON). If active, pressing “STOP”
automatically selects Local mode and initiates the stop command.
“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”.
at J1-4 and J1-5 should be considered. Current loop allows long cable lengths
ORQ FF - when a dif
must be moved to pins 2 and 3.
ferential command is present at J1-4 and
motor speed command
5, allows addi
-
4-12
Programming & Operation
MN718
Section 1
General Information
Table 4-2 Level 1 Parameter Block Definitions
Block Title Parameter Description
OUTPUT OPTO OUTPUT
#1 – #4
Zero SPD Set PT Sets
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 output frequency to motor is below the value of the
At Speed - Active when output speed is within the speed range defined by
At Set Speed - Active when output speed is at or above the Level 1 Output
Overload - A normally closed contact that is active (opens) during an
Keypad Control - Active when control is in Local keypad control.
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
the speed at which the Zero Speed opto output becomes active (turns on).
speed
is less than
ful 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.
- Continued
Level 1 Output “Zero SPD Set Pt” parameter.
the Level 1 Output “At Speed Band” parameter.
“Set Speed” parameter.
Overload fault caused by a time out when output current is
greater than Rated Current.
tolerance band defined by the At Speed Band parameter.
when FWD direction command received.
capable of producing torque).
Reverse direction.
position band parameter tolerance.
specified by the Level 2 Process Control block, AT Setpoint
Band parameter. Turns off when process feedback error is
eliminated.
when drive is Ready
received with FWD/REV direction issued.
the ZERO SPD SET PT
, Enabled, Speed or Torque command
, the Opto Output becomes active. This is use
When the
-
MN718
Programming
& Operation 4-13
Section 1
General Information
Table 4-2 Level 1 Parameter Block Definitions
Block Title Parameter Description
OUTPUT
(Continued)
Analog Output
#1 and #2
Analog Scale #1 Scale factor for the Analog Output voltage. Useful to set the zero value or full scale
Position Band Sets the acceptable range in digital counts (pulses) at which the AT Position Opto
Two Analog 0-5VDC linear outputs may be configured to represent any of 19 conditions
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 - Represents the actual portion of total current used for excitation.
CMD Flux CUR - Represents the calculated value for flux current.
Load Current - Represents the actual portion of total current used to produce torque
CMD Load Current - Represents the calculated value of load current.
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. Used to diagnose control problems.
Direct Voltage - Flux controller output. Used to diagnose control problems.
AC Voltage - A scaled AC waveform that represents the AC line to line motor
Bus Voltage - Bus voltage scaled to 0-5VDC. 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 1 Current - Sampled AC phase 1 motor current. 2.5V = zero amps,
Process Feedback - Represents the selected Process Feedback signal.
Position - Position within a single revolution. +5V = 1 complete revolution.
Setpoint Command - Represents the selected Setpoint Command signal.
range for external meters.
becomes active (turns on).
- Continued
as follows:
+5VDC = MAX RPM.
+5VDC = Torque at CURRENT LIMIT.
+5VDC = MAX RPM.
+5VDC = MAX AC Voltage.
5VDC= MAX flux current.
5VDC= MAX commanded flux current.
(CW and CCW torque).
5V = Max. CW torque, 0V = Max. CCW torque.
5V = Max. commanded load current.
5VDC = Rated Current.
current. 5VDC = Rated Current.
terminal voltage. 0V = Neg Peak PWM voltage. 2.5V centered.
5V = Pos Peak PWM voltage. At rated motor voltage, a full 0 to 5V
sinusoidal waveform should be present. This waveform should be at
or greater than the motor base frequency. (At half the motor base
frequency, a 1.25V to 3.75 sine wave is present.)
0V = Max negative torque.
power, +5V = Positive rated peak power.
+2.5V = Zero Speed, +5V = positive max RPM.
2
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.
2.5V centered, 5V = 100%, 0V = –100%.
The counter will reset to 0 every revolution.
2.5V centered, 5V = 100%, 0V = –100%.
4-14
Programming & Operation
MN718
Section 1
General Information
Table 4-2 Level 1 Parameter Block Definitions
Block Title Parameter Description
VECTOR CONTROL CTRL BASE Speed
Feedback Filter
Feedback Align
Current PROP
Gain
Current INT Gain
Speed PROP Gain
Speed INT Gain
Speed DIFF Gain
Position Gain
Slip Frequency
Stator R1 Stator resistance in ohms. If set too high, the motor will tend to stall at zero speed when
Stator X1 Stator leakage reactance, in ohms at 60Hz. This parameter has most impact when
LEVEL 2 BLOCK ENTERS LEVEL 2 MENU
Sets the speed in RPM at which the saturation voltage of the control is reached. Above
this RPM value the control will output constant voltage and variable frequency.
A larger value provides a more filtered signal but at the cost of reduced bandwidth.
Sets the encoder’s electrical direction of rotation to match that of the motor.
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.
Sets the rated slip frequency of the motor.
reversing or accelerating from low speed. Reducing this value will eliminate the
problem. When too low, speed regulation may suffer.
reversing motor rotation at full current limit. If set too low, the true decel time will tend
to increase.
- Continued
MN718
Programming
& Operation 4-15
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. V
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.
CUSTOM UNITS Decimal Places
Value At Speed
Units of Measure
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 that
Torque Proving When this parameter is set to ON the control looks for balanced output current in all
frequency. Two operating 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.
alues above 100% of the rated current
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 15 times the maximum output frequency of the
control. Ratios less than 15 will result in non-Sinusoidal current waveforms. See
Figure 4-3.
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 per RPM of motor speed. 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. The second number (right
most) is the motor RPM corresponding to the units in the first number. A decimal may
be inserted into the numbers by placing the flashing cursor over the up/down arrow.
Allows user specified 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.
(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” after an overload.
Note: The “Foldback” selection may not be available on some early versions of
the firmware.
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.
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.
three phases to the motor. If output current is unbalanced, the control will trip off
generating a torque proving fault. In a hoist application, for example, this is useful to
ensure that motor torque exists before the fail safe brake is released. “Drive On”
output, if programmed, will occur if torque proving fails.
4-16
Programming & Operation
MN718
Section 1
General Information
Figure 4-3 Maximum Output Frequency vs PWM Frequency
1000
It
is recommended that the PWM frequency parameter be set
to approximately16 times the maximum output frequency of
900
the control. The greater the ratio, the more sinusoidal the
output current waveform will be.
800
700
600
500
400
OUTPUT FREQUENCY
300
200
100
HZ
50
1.00KHz 8.00KHz 16.00KHz
Note:
The output current rating of the control must be derated for high PWM
frequency operation as follows:
Standard Constant T
orque and Standard V
ariable T
orque: Linearly
derate to 10% between 2.5 and 5.0KHz (10% derating at 5.0KHz).
Quiet Constant T
orque and Quiet V
ariable T
orque: Linearly derate to
30% between 8.0 and 16KHz (30% derating at 16KHz).
PWM FREQUENCY
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
Block Title Parameter Description
MISCELLANEOUS Restart Auto/Man Manual - If a fault or power loss occurs, the control must be manually reset to resume
operation.
Automatic - If a fault or power loss occurs, the control will automatically reset to
resume operation.
Restart Fault/Hr The maximum number of automatic restart attempts before requiring a manual restart.
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.
Restart Delay The amount of time allowed after a fault condition for an automatic restart to occur.
Useful to allow sufficient time to clear a fault before restart is attempted.
Factory Settings Restores factory settings for all parameter values. Select YES and press “ENTER” key
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.
Continued
MN718
Programming
& Operation 4-17
Section 1
General Information
Table 4-3 Level 2 Parameter Block Definitions
Block Title Parameter Description
MISCELLANEOUS
continued
SECURITY
CONTROL
MOTOR DATA Motor Voltage The rated voltage of the motor (listed on the motor nameplate).
Homing Speed In Bipolar and Serial modes, this parameter sets the speed that the motor shaft will
rotate to a “Home” position when the orient input switch is closed (J1-11).
Homing Offset In Bipolar and Serial modes, this parameter sets the number of digital encoder counts
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.
Security State Off - No security Access Code required to change parameter values.
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.
Access Timeout The time in seconds the security access remains enabled after leaving the programming
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 Code A 4 digit number code. Only persons that know the code can change secured Level 1
and Level 2 parameter values.
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.
Motor Rated Amps The rated current of the motor (listed on the motor nameplate). If the motor current
exceeds this value for a period of time, an Overload fault will occur.
Motor Rated SPD The rated speed of the motor (listed on the motor nameplate). If Motor Rated SPD =
1750 RPM and Motor Rated Freq = 60 Hz, the Keypad Display will show 1750 RPM
at 60 Hz and 875 RPM at 30Hz.
Motor Rated Freq The rated frequency of the motor (listed on the motor nameplate).
Motor Mag Amps The motor magnetizing current value (listed on the motor nameplate). Also called no
load current. Measure using a clamp on amp meter at the AC power line while the
motor is running at line frequency with no load connected to the motor shaft.
Encoder Counts The number of encoder feedback counts (lines per revolution).
Resolver Speed The speed of the resolver, if a resolver is used for feedback.
CALC Presets 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.
Continued
4-18
Programming & Operation
MN718
Section 1
General Information
Table 4-3 Level 2 Parameter Block Definitions
Block Title Parameter Description
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
DC Brake Current The amount of DC injection brake current. 0% = Flux current,
PROCESS
CONTROL
COMMUNICATIONS Protocol Sets the type of communication the control is to use, RS-232 or RS-485 ASCII (text)
Process Feedback
Process Inverse
Setpoint Source
Setpoint Command
Set PT ADJ Limit
Process ERR TOL
Process PROP
Gain
Process INT Gain
Process DIFF Gain
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.
Baldor for additional information.
Baldor for additional information.
100% = Motor rated current.
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 type to which the process feedback will be compared.
If “Setpoint CMD” is selected, the fixed value of the set point is entered
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.
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. Master:Follower ratio limits are (1-65,535) : (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 used only when Serial Communications 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.
protocol.
Continued
in the Setpoint
MN718
Programming
& Operation 4-19
Section 1
General Information
Table 4-3 Level 2 Parameter Block Definitions
Block Title Parameter Description
AUTO TUNING
CALC Presets
CMD Of
CUR Loop COMP
Stator R1
Flux CUR Setting
Feedback Tests
Slip FREQ Test
SPD CNTRLR
LEVEL 1 BLOCK ENTERS LEVEL 1 MENU
fset Trim
CALC
The Auto Tune procedure is used to automatically measure and calculate certain
parameter values. Dynamic Brake Hardware is required to perform “Slip Freq Test”
and “Spd Cntrlr Calc” autotuning test. Occasionally, the Auto Tune procedure cannot
be run due to various circumstances such as the load cannot be uncoupled from the
The control can be manually tuned by entering the parameter values based on
motor.
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 out voltage offsets for the differential analog input at J1-4 and J1-5.
Measures current response to pulses of one half the rated motor current.
Measures motor stator resistance.
Sets motor magnetizing current by running motor at near rated speed.
Checks the values for Encoder Lines per revolution and encoder alignment parameters
while the motor is running at near full rated speed. Test will automatically switch
encoder phasing to match motor rotational direction.
Calculates motor Slip Frequency during repeated motor accelerations.
Should be performed with the load coupled to the motor shaft. Sets the motor current to
acceleration ratio, Speed INT gain and Speed PROP 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 drive is loaded, adjust the PK
Current Limit parameter to a greater value and repeat this test.
Continued
4-20
Programming & Operation
MN718
Section 5
Troubleshooting
The Baldor Series 18H Control requires very little maintenance and should provide years
of trouble free operation when installed and applied correctly
inspection should be considered to ensure tight wiring connections and to avoid the build
up of any dust, dirt, or foreign debris which can reduce heat dissipation.
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 meg Ohm. In some
cases, an oscilloscope with 5 MHZ minimum bandwidth may be useful. Before consulting
the factory
recommendations given in this manual.
No Keypad Display - Display Contrast Adjustment
If there is no visible display
display.
Action Description Display Comments
Apply Power No visible display.
, check that all power and control wiring is correct and installed per the
. Occasional visual
, use the following procedure to adjust the contrast of the
Press DISP key Ensures control in Display mode. Display mode.
Press SHIFT key 2 times Allows display contrast
Press Y or B key
Press ENTER key Saves display contrast
adjustment.
Adjusts display contrast
(intensity).
adjustment level and exits to
display mode.
MN718
Troubleshooting
5-1
Table 5-1 Fault Messages
FAULT
Current Sens FL
MESSAGE
T
DC Bus High
DC Bus Low
Encoder Loss
External T
rip
Following Error
GND FLT
INT Over-Temp T
Invalid Base ID
Inverter Base ID
Line Regen FL
Logic Supply FL
T
T
Lost User Data
Low INIT Bus V
Memory Error
New Base ID
No Faults
No EXB Installed
Over Current FLT
Overload - 1 min
Overload - 3 sec
Over speed
m
P Reset
PWR Base FL
Regen R PWR FL
T
T
Resolver Loss
T
orque Prove FL
User Fault T
T
ext
DESCRIPTION
Defective phase current sensor or open circuit detected between control board and current
sensor.
Bus over voltage condition occurred.
Bus under voltage condition occurred.
Encoder coupling slipping or broken; noise on encoder lines, encoder power supply loss or
defective encoder
.
An external over temperature condition occurred or open circuit on J1-16.
Excessive following error detected between command and feedback signals.
Low impedance path detected between an output phase and ground.
emperature of control heatsink exceeded safe level.
Control does not recognize power base ID.
Control board installed on power base without current feedback.
Only applies to Series 21H and 22H Line Regen controls.
Logic power supply not working properly
.
Battery backed RAM parameters have been lost or corrupted.
When fault cleared (Reset), the control will reset to factory preset values.
Insuf
ficient bus voltage on startup.
EEPROM error occurred. Contact Baldor
.
Control board was changed since last operation.
Fault log is empty
.
Programmed operating mode requires an expansion board.
Instantaneous over current condition detected by bus current sensor
.
Output current exceeded 1 minute rating.
Output current exceeded 3 second rating.
Motor RPM exceeded 1
10% of programmed MAX Motor Speed.
Power cycled before the residual Bus voltage reached 0VDC.
Desaturation of power device occurred or bus current threshold exceeded.
Regen power exceeded DB resistor rating.
Resolver feedback problem is indicated (if resolver used).
Unbalanced current between all 3 motor phases.
Custom software operating fault occurred.
5-2 Troubleshooting MN718
Section 1
General Information
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. T
o access the fault log use the following procedure:
Action Description Display Comments
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 Y key
Press ENTER key Return to display mode. Display mode stop key LED is on.
How to Clear the Fault Log
Fault Log entry point.
fault occurred.
Scroll through fault messages.
Use the following procedure to clear the fault log.
Display mode.
Typical display.
If no messages, the fault log exit
choice is displayed.
Action Description Display Comments
Apply Power Logo display for 5 seconds.
Display mode showing output
frequency.
Press DISP key Press DISP to scroll to the Fault
Press ENTER key Displays most recent message.
Press SHIFT key
Press RESET key
Press SHIFT key
Press ENTER key Fault log is cleared. No faults in fault log.
Press Y or B key
Press ENTER key Return to display mode.
Log entry point.
Scroll Fault Log Exit.
Display mode.
MN718
Troubleshooting
5-3
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,
press local for this display.
Diagnostic Access screen.
screen.
XXXV
Press DISP key Display showing % overload
Press DISP key Display showing opto inputs &
Press DISP key Display showing actual drive
Press DISP key Display showing operating zone,
Press DISP key Display showing continuous
Press DISP key Display showing which Group1 or
current remaining.
outputs states.
running time.
voltage and control type.
amps; PK amps rating; amps/volt
scale of feedback, power base ID.
2 expansion boards are installed.
Opto Inputs states (Left);
Opto Outputs states (Right).
HR.MIN.SEC format.
ID is displayed as a hexadecimal
value.
Press DISP key Display showing motor shaft
Press DISP key Display mode showing parameter
Press DISP key Display showing software version
Press DISP key Displays exit choice. Press ENTER to exit diagnostic
revolutions from the REV home
set point.
table selected.
and revision installed in the
control.
information.
5-4 Troubleshooting MN718
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 Sec. 4.
Auto Tune
Encoder Test failed
Current Sense FLT Open circuit between control board
DC Bus High Excessive dynamic braking power. Increase the DECEL time.
DC Bus Low Input voltage too low. Disconnect dynamic brake hardware and repeat operation.
Encoder Loss Encoder power supply failure. Check 5VDC at J1-29 and J1-30.
Encoder miswired. Correct wiring problems.
Encoder coupling slipping, broken
or misaligned.
Excessive noise on encoder lines. Check the position counter in the Diagnostic Information for
and current sensor.
Defective current sensor. Replace current sensor.
Dynamic brake wiring problem. Check dynamic brake hardware wiring.
Input voltage too high. Verify proper AC line voltage.
Encoder coupling slipping, broken
or misaligned
Excessive noise on encoder lines. Check the position counter in the Diagnostic Information for
Verify fuses are good (or breaker is not tripped).
Verify connection of operator keypad.
Correct encoder to motor coupling.
jittering which will confirm an encoder problem.
Use recommended encoder cable.
Check encoder connections including shields.
Separate encoder leads from power wiring.
Cross encoder wires and power leads at 90°.
Electrically isolate encoder from motor.
Install optional Isolated Encoder Feedback expansion board.
Check connections between control board and current sensor.
Check dynamic brake watt and resistance parameter values.
Add optional dynamic braking hardware.
Use step down isolation transformer if needed.
Use line reactor to minimize spikes.
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.
Also check at encoder end pins D and F.
Correct or replace encoder to motor coupling.
jittering which will confirm an encoder problem.
Check encoder connections.
Separate encoder leads from power wiring.
Cross encoder wires and power leads at 90°.
Electrically isolate encoder from motor.
Install optional Isolated Encoder Feedback expansion board.
MN718
Troubleshooting
5-5
Section 1
General Information
Table 5-2 Troubleshooting
INDICATION POSSIBLE CAUSE CORRECTIVE ACTION
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.
Following ERR Speed proportional gain set too low. Following error tolerance band set too narrow.
Current limit set too low. Increase Current Limit parameter value.
ACCEL/DECEL time too short. Increase ACCEL/DECEL parameter time
Excessive load. Verify proper sizing of control and motor.
GND FLT Improper wiring.
Wiring shorted in conduit.
Motor winding shorted.
INT Over-Temp Motor Overloaded. Correct motor loading.
Ambient temperature too high. Relocate control to cooler operating area.
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
Voltage configuration.
current sensors being used.
Power was cycled before Bus
voltage reached 0VDC.
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.
Increase Speed PROP Gain parameter value.
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.
Press “RESET” key on keypad. If fault remains, call Baldor.
Replace power base with one that has output leg 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.
Continued
parameter to “OFF” if no connection made
5-6 Troubleshooting MN718
Section 1
General Information
Table 5-2 Troubleshooting
INDICATION POSSIBLE CAUSE CORRECTIVE ACTION
Motor has wrong
response to
Speed Command
Motor Shaft
Oscillates back
and forth
Motor Shaft
rotates at low
speed regardless
of commanded
speed
Motor Shaft
rotates in wrong
direction
Motor Will Not
Start
Motor Will Not
Reach Maximum
Speed
Motor Will Not
Stop Rotation
Analog input common mode voltage
may be excessive.
Incorrect encoder alignment
direction.
Incorrect encoder alignment
direction.
Incorrect encoder wiring. Reverse the A and A or B and B encoder wires at the J1 input to control
Not enough starting torque. Increase Current Limit setting.
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.
Max Output Speed set too low. Adjust MAX Output Speed parameter value.
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.
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.
Change the Feedback Align parameter in the Level 1 Vector Control block.
If it is Reverse, change it to Forward. If it is Forward, change it to Reverse.
Check encoder connections.
Change the Feedback Align parameter in the Level 1 Vector Control block.
If it is Reverse, change it to Forward. If it is Forward, change it to Reverse.
and change encoder direction in the Feedback Align parameter in the
Level 1 Vector Control block.
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.
Continued
MN718
Troubleshooting
5-7
Section 1
General Information
Table 5-2 Troubleshooting
INDICATION POSSIBLE CAUSE CORRECTIVE ACTION
New Base ID Software parameters are not
No EXB Installed Incorrect operating mode
Over Current FLT Current Limit parameter set lower
Overload - 3 Sec
FLT
Overload - 1 Min
FLT
Over Speed Motor exceeded 110% of MAX
initialized on newly installed
control board.
programmed.
Need expansion board. Install the correct expansion board for selected operating mode.
than drive rating.
ACCEL/DECEL time too short. Increase ACCEL/DEC parameters in the Level 1
Encoder coupling slipping, broken
or misaligned.
Encoder bearing failure. Replace and align encoder.
Excessive noise on encoder lines. Check the position counter in the Diagnostic Information for
Electrical noise from external DC
coils.
Electrical noise from external AC
coils.
Excessive load. Reduce the motor load.
Peak output current exceeded 3
second rating.
Encoder coupling slipping, broken
or misaligned.
Encoder bearing failure. Replace and align encoder.
Peak output current exceeded 1
minute rating.
Encoder coupling slipping, broken
or misaligned.
Encoder bearing failure. Replace and align encoder.
Speed parameter value.
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.
Change Operating Mode in the Level 1 Input block to one that does not
require the expansion board.
Increase PK Current Limit parameter in the Level 2
Output Limits block, not to exceed drive rating.
ACCEL/DECEL Rate block.
Correct or replace encoder to motor coupling.
jittering which will confirm an encoder problem.
Check encoder connections.
Separate encoder leads from power wiring.
Cross encoder wires and power leads at 90°.
Electrically isolate encoder from motor.
Install optional Isolated Encoder Feedback expansion board.
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 Section 5 of this manual.
Install RC snubbers on all external AC coils. See Electrical Noise
Considerations in Section 5 of this manual.
Verify proper sizing of control and motor.
Check PK Current Limit parameter in the Level 2
Output Limits block.
Change Overload parameter In the Level 2 Protection block
from Trip to Foldback.
Check motor for overloading.
Increase ACCEL time.
Reduce motor load.
Verify proper sizing of control and motor.
Correct or replace encoder to motor coupling.
Check PK Current Limit parameter in the Level 2
Output Limits block.
Change Overload parameter In the Level 2 Protection block
from Trip to Foldback.
Check motor for overloading.
Increase ACCEL/DECEL times.
Reduce motor load.
Verify proper sizing of control and motor.
Correct or replace encoder to motor coupling.
Check Max Output Speed in the Level 2 Output Limits block.
Increase Speed PROP Gain in the Level 1 Vector Control block.
Continued
5-8 Troubleshooting MN718
Section 1
General Information
Table 5-2 Troubleshooting
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
Excessive current usage.
Encoder coupling slipping, broken
or misaligned.
Encoder bearing failure. Replace and align encoder.
Excessive noise on encoder lines. Check encoder connections.
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
Resolver Loss Resolver defect. Check resolver to motor coupling (align or replace if needed).
Torque Prove FLT Unbalanced current in 3 motor
Unknown Fault Fault occurred but cleared before its
User Fault Text Fault detected by custom software. Refer to custom software fault list.
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.
phases.
source could be identified.
Be sure control has separate ground wire to earth ground.
Panel grounding or conduit connections is not sufficient.
Disconnect motor leads from control and retry test. If fault remains, call
Baldor.
Correct or replace encoder to motor coupling.
Separate encoder leads from power wiring.
Cross encoder wires and power leads at 90°.
Electrically isolate encoder from motor.
Install optional Isolated Encoder Feedback expansion board.
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 Section 7 of this manual.
Install RC snubbers on all external AC coils. See Electrical Noise
Considerations in Section 7 of this manual.
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.
Verify correct wiring. Refer to the Resolver to Digital
expansion board manual.
Electrically isolate resolver from motor.
Check continuity from control to motor windings and verify motor
connections.
Check AC line for high frequency noise.
Check input switch connections and switching noise.
Continued
MN718
Troubleshooting
5-9
Section 1
230VAC
460VAC
VAC
Catal
Catal
Catal
General Information
Table 5-3 Power Base ID - Series 18H
Power Base ID
FIF10 / FIF40 FIF20 / FIF24
og
Bus
No.
201–E 002 802 023 823 401–E 202 A02 23B A3B 501–E 602 E02 61A E1A
201–W 002 802 023 823 401–W 202 A02 23B A3B 501–W 602 E02 61A E1A
202–E 003 803 024 824 402–E 203 A03 23C A3C 502–E 603 E03 61B EIB
202–W 003 803 024 824 402–W 203 A03 23C A3C 502–W 603 E03 61B EIB
203–E 004 804 025 825 403–E 204 A04 23D A3D 503–E 604 E04 61C E1C
203–W 004 804 025 825 403–W 204 A04 23D A3D 503–W 604 E04 61C E1C
205–E 005 805 026 826 405–E 205 A05 241 A41 505–E 605 E05 61D E1D
205–W 005 805 02A 82A 405–W 205 A05 241 A41 505–W 605 E05 61D E1D
207–E 006 806 027 827 407–E 206 A06 23E A3E 507–E 606 E06 61E E1E
207–W 006 806 027 827 407–W 206 A06 23E A3E 507–W 606 E06 61E E1E
207L–E 001 801 407L–E 201 A01 510–E 607 E07 61F E1F
210–E 007 807 028 828 410–E 207 A07 207 A07 510–W 607 E07 61F E1F
210–W 028 828 410–W 207 A07 515–E 608 E08 620 E20
210L–E 02B 82B 410L–E 23F A3F 515–W 608 E08 620 E20
215–E 01A 81A 01A 81A 415–E 22C A2C 242 A42 510L
215–W 01A 81A 415–W 242 A42 515L
210L–ER 00C 80C 410L–ER 208 A08 520 611 E11
215V 008 808 415V 20E A0E 520L 60B EOB
215L 00A 80D 415L 20F A0F 525 612 E12
220 011 811 420 211 A11 525L 60C E0C
220L 00E 80E 420L 220 A20 530 613 E13
225 01D 81D 425 212 A12 530L 60D E0D
225V 009 809 425V 20B A0B 540 614 E14
225L 00F 80F 425L 221 A21 540L 60E E0E
230 013 813 430 213 A13 550 615 E15
230V 016 816 430V 20C A0C 550L 60F E0F
230L 017 817 430L 222 A22 560 616 E16
240 014 814 440 214 A14 575 617 E17
240L 018 818 440L 223 A23 5100 618 E18
250 015 815 450 215 A15 5150 E1A
250V 00A 80A 450L 21C A1C 5150V 619 E19
250L 01C 81C 460 216 A16 5200 E2A
275 829 460V 20A A0A 5250 E3A
Cur
Phase
Cur
Bus
Cur
Phase
Cur
Note: The
og
No.
460L 224 A24 5300 EA4
475 217 A17 5350 EA5
475L 21D A1D 5400 EA6
4100 218 A18
4100L A2F
4125L A30
4150 A9A
4150V 219 A19
4200 A9B
4250 AA5
4300 AAE
4350 AA6
4400 AA7
4450 AA9
Power Base ID number of a control is displayed in a Diagnostic
Information screen as a hexadecimal value.
Power Base ID
FIF10 / FIF40 FIF20 / FIF24
Bus
Cur
Phase
Cur
Bus
Cur
Phase
Cur
575
No.
Power Base ID
FIF10 / FIF40 FIF20 / FIF24
og
Bus
Phase
Cur
Cur
Bus
Cur
Phase
Cur
5-10 Troubleshooting MN718
Section 1
General Information
Electrical Noise Considerations
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 10 VDC 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.
Causes and Cures
Unwanted electrical noise can be produced by many sources. Depending upon the
source, various methods can be used to reduce the ef
coupling to sensitive circuits. All methods are less costly when designed into a system
initially than if added after installation.
Figure 5-1 shows an oscilloscope trace of noise induced (as the coil circuit is opened) in
a 1–ft. wire located next to a lead for a Size 2 contactor coil. Scope input impedance is
10KW
often enough noise to ruin the output of a productive machine.
All electronic devices including the Series 18H Control are vulnerable to significant
.
fects of this noise and to reduce the
for all scope traces. Maximum peak voltage is over 40V
. Unless well filtered this is
Figure 5-1 Electrical Noise Display
Relay and Contactor Coils
Among the most common sources of noise are the ever–present 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.
T
o suppress noise in these AC coils, add an R–C snubber across each relay and
contactor coil. A snubber consisting of a 33KW resistor in series with a 0.47mF capacitor
usually works well. The snubber reduces the rate of rise and peak voltage in the coil
when current flow is interrupted. This eliminates arcing and reduces the noise voltage
induced in adjacent wires. In our example, the noise was reduced from over 40 Vpeak to
about 16 Vpeak as shown in Figure 5-2.
Figure 5-2 R-C Snubber Circuit
Troubleshooting
5-1
1MN718
Section 1
General Information
Electrical Noise Considerations
Continued
Combining an R-C snubber and twisted-pair shielded cable keeps the voltage in a circuit
to less than 2 V for a fraction of a millisecond. The waveform shown in Figure 5-3 in
addition to the snubber across the coil, the adjacent wire is grounded in a twisted–pair
shielded cable. Note that the vertical scale is 1 V/div
., rather than the 20 V/div
. in figures
,
5-1 and 5-2. This shows that snubbers and twisted-pair shielded wire should be used for
sensitive circuits located adjacent to coil wires.
Figure 5-3 R-C Snubber Circuit & twisted-pair
A
reverse biased diode across a DC coil achieves the same result as adding an R–C
snubber across an AC coil, Figure 5-4.
Figure 5-4 AC & DC Coil Noise Suppression
RC snubber
+
AC Coil
0.47 mF
33 W
DC Coil
–
Diode
5-12 Troubleshooting MN718
Section 1
General Information
Electrical Noise Considerations
W
ires between Controls and Motors
Continued
Output leads from a typical 460 V
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 as shown in
Figure 5-5. For this waveform, a transient induced in 1 ft. of wire adjacent to motor lead
of a 10 hp, 460 V
AC drive. Scope is set at 5 V/div
AC drive controller contain rapid voltage rises created
. and 2
msec/div.
Figure 5-5 10HP, 460VAC Drive
If
the shielded pair cable is used, the coupling is reduced by nearly 90%, Figure 5-6.
Figure 5-6 10HP, 460VAC Drive, Shielded
The
motor leads of DC motors contain similar voltage transients. The switching rate is
about 360 times a second. These noise transients can produce about 2V of noise
induced in a wire adjacent to the motor lead. A 30HP
5-7. Scope is set at 1 V/div
. and 5
msec/div.
, 500VDC Drive, as shown in Figure
Figure 5-7 30HP, 500VDC Drive
Again,
Replacing a single wire with a shielded pair cable reduces the induced noise to
less than 0.3 V
, Figure 5-8.
Figure 5-8 30HP, 500VDC Drive, Shielded
MN718
Troubleshooting
5-13
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