Series 35D Inverter Control Installation & Operating Manual 8/02 MN735
Table of Contents Section 1 Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 Start–Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu System . . . . . . . . . . . . . . . . .
Section 1 Quick Start The basic steps for connection and setup are provided in this section. Detailed descriptions of each step and parameter settings are provided later in this manual. Be sure to comply with all applicable codes when installing this control. Minimum Connection Requirements Refer to Section 3 for cover removal procedure. Power and Motor Connections Figures 1-1and 1-2 show the minimum connections required at the power connector.
Figure 1-2 Power Connections Continued 10 9 8 7 6 5 4 3 2 1 DIN4/DOUT2 DIN3 DIN2 DIN1 +24V AOUT1 +10V Ref Feedback AIN2 Setpoint AIN1 0V See Applications/Modes Volts or 0–20mA Input 10k Speed Setpoint Connect 0V to PE (protective earth ground) for single control installations only. If multiple controls are used, connect 0V terminals together and ground to PE at one point only.
Table 1–1 Power Connection Descriptions Terminal Description RLY1 Relay Output TH1A Thermistor TH1B Thermistor Reference Terminal L1 Power Input L2/N L2 Power Input L3 Range 230V 1–Phase 460V 3–Phase Normally open, programmable Contact closes when the programmed contact for a relay output. condition (see Section 4) is true. No voltage is present on this contact. 6 conditions are available. Connection to motor thermistor It is good practice to protect motors by using thermistors.
Table 1–2 Analog/Digital Signal Descriptions Terminal (SELV) RL1A RL1B 10 Signal Name User Relay Description Volt-free contact - 4A maximum, maximum non-inductive 9 DIN4/ DOUT2 DIN3 8 DIN2 Digital Input 2. 7 DIN1 Digital Input 1. 6 5 4 3 2 1 +24V AOUT1 10VREF AIN2 AIN1 0V 1–4 Quick Start Configurable I/O, Digital Input 4 or Digital Output 2. Digital Input 3.
Section 2 General Information Copyright Baldor 2002. All rights reserved. This manual is copyrighted and all rights are reserved. This document may not, in whole or in part, be copied or reproduced in any form without the prior written consent of Baldor. Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose. The information in this document is subject to change without notice.
Product Notice Intended use: These drives are intended for use in stationary ground based applications in industrial power installations according to the standards EN60204 and VDE0160. They are designed for machine applications that require variable speed controlled three phase brushless AC motors. These drives are not intended for use in applications such as: – Home appliances – Mobile vehicles – Ships – Airplanes Unless otherwise specified, this drive is intended for installation in a suitable enclosure.
PRECAUTIONS: WARNING: Do not touch any circuit board, power device or electrical connection before you first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury. WARNING: Be sure that you are completely familiar with the safe operation of this equipment.
Caution: To prevent equipment damage, be certain that the input power has correctly sized protective devices installed as well as a power disconnect. Caution: Avoid locating the control immediately above or beside heat generating equipment, or directly below water or steam pipes. Caution: Avoid locating the control in the vicinity of corrosive substances or vapors, metal particles and dust.
Section 3 Receiving & Installation Receiving & Inspection Baldor Controls are thoroughly tested at the factory and carefully packaged for shipment. When you receive your control, there are several things you should do immediately. 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control. 2. Remove the control from the shipping container and remove all packing materials.
Table 3-1 Watts Loss Ratings Catalog No. ID35D8A1F5–CRH ID35D8A2F2–CRH ID35D8A03–CRH ID35D8A04–CRH ID35D8A07–CRH ID35D8A10–CRH ID35D8A16–CRH Output Current (A) 1.5 2.2 3.0 4.0 7.0 10.5 16.5 Watts Loss (W) 26 32 41 52 82 116 181 Catalog No. ID35D4A1F5–CRH ID35D4A02–CRH ID35D4A2F5–CRH ID35D4A4F5–CRH ID35D4A5F5–CRH ID35D4A09–CRH ID35D4A12–CRH ID35D4A16–CRH Output Current (A) 1.5 2.0 2.5 4.5 5.5 9.0 12.0 Watts Loss 16.
Cover Removal To connect power and signal wires, the cover must be removed. This procedure describes how to access all terminal connections inside the control. Using your thumbs, press in and slide the cover down as shown in Figure 3-2. Figure 3-2 Top Cover Removal 1. Press in to release cover 2. Slide cover down and remove. Power Conditioning System Grounding Baldor Controls are designed to be powered from standard three phase power lines that are electrically symmetrical with respect to ground.
Line Impedance The Baldor control requires a 1% line impedance minimum . If the impedance of the incoming power does not meet the requirement for the control, a 3 phase line reactor can be used to provide the needed impedance in most cases. Line reactors are optional and are available from Baldor. The input impedance of the power lines can be determined as follows: Measure the line to line voltage at no load and at full rated load.
Examples: A 5hp, 230VAC control operating at 208VAC has a reduced power rating of 4.5hp. 5HP 208VAC + 230VAC 4.5hp Likewise, a 3hp, 460VAC control operating at 380VAC has a reduced power rating of 2.47hp. 3HP 380VAC + 460VAC 2.47hp Electrical Installation All interconnection wires between the control, AC power source, motor, host control and any operator interface stations should be in metal conduits or shielded cable must be used.
Table 3-2 Wire Size Catalog Number ID35D8A1F5-CRH ID35D8A2F2-CRH ID35D8A03-CRH ID35D8A04-CRH ID35D8A07-CRH ID35D2A10-CRH ID35D2A16-CRH ID35D4A1F5-CRH ID35D4A02-CRH ID35D4A2F5-CRH ID35D4A4F5-CRH ID35D4A5F5-CRH ID35D4A09-CRH ID35D4A12-CRH ID35D4A16-CRH Output Current Size 1 1 1 1 2 3 3 2 2 2 2 2 3 3 3 Cont. Peak (Amps) (Amps) 1.5 2.2 3.0 4.0 7.0 10.5 16.5 1.5 2.0 2.5 4.5 5.5 9.0 12.0 16.0 2.3 3.3 4.5 6.0 10.5 15.8 24.8 2.3 3.0 3.8 6.8 8.3 13.5 18.0 24.
Table 3-3 Power Connection Descriptions Terminal Description RLY1 Relay Output TH1A Thermistor TH1B Thermistor Reference Terminal L1 Power Input L2/N L2 Power Input L3 Range 230V 1–Phase 460V 3–Phase Normally open, programmable Contact closes when the programmed contact for a relay output. condition (see Section 4) is true. No voltage is present on this contact. 6 conditions are available. Connection to motor thermistor It is good practice to protect motors by using thermistors.
Figure 3-5 Power and Ground Connections Size 2 Shown RL1A RL1B TH1A and TH1B must be jumpered if thermistor is not used TH1A TH1B Use a cable tie in this area for control wires.
Figure 3-6 Power Connections Continued 10 9 8 7 6 5 4 3 2 1 DIN4/DOUT2 DIN3 DIN2 DIN1 +24V AOUT1 +10V Ref Feedback AIN2 Setpoint AIN1 0V See Applications/Modes Volts or 0–20mA Input 10k Speed Setpoint Connect 0V to PE (protective earth ground) for single control installations only. If multiple controls are used, connect 0V terminals together and ground to PE at one point only.
1. Connecting a jumper wire between the thermistor terminals TH1A and TH1B. or 2. Set the parameter Invert Thermistor Input to 1. TRIPS MENU Signal Connections Wire sizes between 12AWG and 28AWG (2.5mm2 to 0.08mm2) can be used. 1. With the cover removed, connect the analog and digital inputs and outputs as shown in Figure 3-5. The signals are described in Table 3-4. 2. Install the front cover.
External Brake Resistor Connect the dynamic brake resistor between terminals DC+ and DBR as shown in Figure 3-5 and 3-6. User Relay A customer provided, external DC or AC power supply must be used if relay output is to be used. Note: Contact is rated to 250V @ 4A Volts Control resistive (non–inductive). RL1A Contact is open when power is on and no faults are present. Load RL1B Customer Provided Load Applications/Modes There are 6 operating modes.
1 – Keypad Mode In Keypad mode, the control is operated by the keypad and opto isolated inputs and the analog command inputs are ignored. The analog output remain active. Figure 3-7 Keypad Connection Diagram 10 9 +24VDC Speed Output Pot Reference Analog Input 2 Analog Input 1 Analog GND Fault 8 7 6 5 4 3 2 1 RLY1A RLY1B 1 Analog GND. Reference for analog inputs. 2 Not used. 3 Not used. 4 +10VDC reference voltage for potentiometer. 5 Analog output that represents the commanded speed output.
2 – Standard Run 3 Wire Mode In Standard Run mode, the control is operated by the opto isolated inputs and the analog command input. The opto inputs can be switches as shown in Figure 3-8 or logic signals from another device.
3 – 3 Speed 2 Wire Mode In 3 speed 2 wire mode, the control is operated by the opto isolated inputs and the analog command input. The opto inputs can be switches as shown in Figure 3-9 or logic signals from another device.
4 – EPOT 3 Wire Mode (Electronic Potentiometer) In EPOT 3 wire mode, the control is operated by the opto isolated inputs and the analog command input. The opto inputs can be switches as shown in Figure 3-10 or logic signals from another device.
5 – EPOT 2 Wire Mode (Electronic Potentiometer) In EPOT 2 wire mode, the control is operated by the opto isolated inputs and the analog command input. The opto inputs can be switches as shown in Figure 3-11 or logic signals from another device.
6 – PID 2 Wire Mode In PID 2 wire mode, the control is operated by the opto isolated inputs and the analog command input. The opto inputs can be switches as shown in Figure 3-12 or logic signals from another device.
3–18 Receiving & Installation MN735
Section 4 Start–Up and Operation Keypad Description Figure 4-1 Keypad Description Display Local Run Local Stop Programming Keys Key Operation Description Escape Navigation – Displays the previous level’s menu Parameter – Returns to the parameter list Trip Acknowledge – Acknowledges displayed Trip or Error message Menu Navigation – Displays the next menu level, or the first parameter of the current Menu Parameter – Moves cursor to the left when the parameter is adjustable Increment Navigation – M
Display when in the Parameter menu Displays the units for the value: when in the Setup menu S for time in seconds, A for current in Amps when displaying an Alarm code V for voltage in Volts, % for percentage a negative parameter value Hz for frequency in Hertz Not Used Represents a rotating motor shaft: CW = forward rotation CCW = reverse rotation. Parameter numbers or values, trip information, error codes etc. See Drive Status Indications. Local mode. (Remote mode when hand is not visible.
Menu System There are three menu levels as shown in this diagram: Menu Level 1 Menu Level 2 Menu Level 3 Parameter Level Parameter Menu Remote Operation Hold for 1 sec Diagnostic Menu Hold for 2 sec Local Setpoint Inputs Menu SETUP MENU Outputs Menu Trips Menu Miscellaneous Setup Menu MN735 Start–Up and Operation 4–3
Power Up On initial power–up, the drive is in Local control mode and the keypad will display the Local Setpoint. . All parameters are at factory settings. Any changes to these conditions are automatically saved. The drive will initialize on subsequent power–ups with the previously saved settings and control mode. How to Change a Parameter Value You can change the values of parameters stored in the and menus. Refer to “Parameter Definitions” for further information.
Hold this key down until the display shows REMOTE Hold this key down until the display spells LOCAL Password Protection When activated, the password prevents unauthorized parameter modification by making all parameters “read–only”. Password protection is set–up using the Steps ACTIVATE Actions parameter.
Parameter Definitions You can program the Inverter for specific applications. The Inverter is supplied with pre–programmed applications that can be used as starting points for application–specific programming. Programming is simply selecting an application, changing some of the parameter values and finally saving the changes. Each application configures the terminal wiring for a differently. The Inverter retains the new settings during power–down.
Display Table 4-1 Parameter Definitions Continued Parameter Description Range NORMAL DUTY FIXED BOOST HEAVY DUTY: the current limit is set to 150% motor current, inverse time delay is set to 30s NORMAL DUTY: the current limit is set to 110% motor current, inverse time delay is set to 10s When P11 is changed from FAN to LINEAR, P12 is set to 0 (Heavy Duty) When P11 is changed from LINEAR to FAN, P12 is set to 1 (Normal Duty) P12 can be changed independently OUTPUT VOLTS 100% 25% 0% INCREASED TORQUE FLU
Display Table 4-1 Parameter Definitions Continued Parameter Description Range Parameters P501 and P502 are visible in the PAR menu when Application 5 is selected in parameter P1 PI P GAIN The PID P"roportional gain 0.00 to 100.00 Factory Setting 1.00 PI I GAIN The PID I"ntegral gain 0.00 to 100.00 0.00 PID D GAIN ~ The PID D"erivative gain 0.00 to 100.00 0.00 0.05 to 10.00s 0.05s -10.00 to 10.00 1.00 0.00 to 300.00% 0.00 -3.0000 to 3.0000 0.00 x.xx % x.xx % x.xx % x.
Display Table 4-1 Parameter Definitions Continued Parameter Description Range DIN 1 VALUE ~ DIN 2 VALUE ~ DIN 3 VALUE ~ DIN 4 VALUE ~ AIN 1 VALUE ~ AIN 2 VALUE ~ SET::IN Menu Continued The input signal after inversion (if any). Factory Setting 0 The analog input signal with scaling and offset. 0= False 1= True 0= False 1= True 0= False 1= True 0= False 1= True x.x% The analog input signal with scaling and offset. x.x% x.x% The input signal after inversion (if any).
Display Table 4-1 Parameter Definitions Continued Parameter Description Range RELAY INVERT True =Inverts the input signal. RELAY VALUE ~ The output signal that represents the OP31 choice.
Display Table 4-1 Parameter Definitions Continued Parameter Description Range Auto Restart Triggers+ Local MIN Speed ~ Enabled Keys ~ Application Lock ~ Detailed Menus MN735 Allows Auto Restart to be enabled for a selection of trip conditions. Refer to Section 5 The magnitude of the minimum setpoint that will Factory Setting 0x0000 to 0xFFFF 0x0000 0.0 to 100.0 % 0.0% 0 True prevents editing of parameter P1. True allows Full menu display.
PI Terms PI is used to control the response of any closed loop system. It is used specifically in system applications involving the control of drives to provide zero steady state error between Setpoint and Feedback, together with good transient performance. Proportional Gain (P501) This is used to adjust the basic response of the closed loop control system. The PI error is multiplied by the Proportional Gain to produce an output.
The gains should be set–up so that a critically damped response is achieved for a step change in setpoint. An underdamped or oscillatory system can be thought of as having too much gain, and an overdamped system has too little. To set up the P gain, set the I gain to zero. Apply a step change in setpoint that is typical for the System, and observe the response. Increase the gain and repeat the test until the system becomes oscillatory. At this point, reduce the P gain until the oscillations disappear.
Routine Maintenance Periodically inspect the Inverter for build–up of dust or obstructions that may affect cooling. Remove any build–up using dry air. Saving Your Application Data In the event of a repair, application data will be saved whenever possible. However, you should record your application settings before returning the unit. You should actually record the settings after programming. When a failure occurs, you may not be able to access the parameter values. Contact Baldor to arrange for the repair.
Section 5 Troubleshooting Trips The trip display message is briefly displayed repeatedly (flashing) on the screen to warn of an imminent trip. Some trip conditions need time to take effect. The warning can allow you time to resolve the situation. The message will clear when you use the keypad, but after a short time will reappear until the problem is resolved, or the drive trips. When a trip occurs, the control’s power stage is immediately disabled causing the motor and load to coast to a stop.
Display Trip Message and Meaning Possible Reason for Trip Motor loading too great FIXED BOOST level set too high DC LINK RIPPLE A dc link ripple alert Supply imbalance in a 3–phase system Poor supply regulation in a 1–phase system CURRENT LIMIT Software overcurrent trip See OVERCURRENT above TERMINAL 3 OVERLOAD AIN2 overload – overcurrent applied in Current mode TERMINAL 4 OVERLOAD +10V REF overload warning – 10mA maximum TERMINAL 5 OVERLOAD AOUT overload – 10mA maximum TERMINAL 9 OVERLOAD DIN
Section 6 Specifications & Product Data General Specifications: Enclosure: Enclosure rating: Europe North America / Canada Mounting method: Enclosure emissions: Horsepower: Voltage Range: 230 VAC Models 460 VAC Models Input Line Impedance: Service Factor: Duty: Ambient Operating Temperature: Cooling: Rated Storage Temperature: Humidity: Altitude: Shock: Vibration: Climatic conditions: Safety: Europe North America / Canada Overvoltage Category Pollution Degree EMC Compliance: Immunity: Radiated Emissions:
Control Specifications: Control method: Random carrier input, 0–240Hz PWM output. Output rating: Peak overload capacity of 150% for 30 seconds for constant torque; PWM Frequency: Random PWM for quiet motor operation. V/Hz Ratio: Linear squared reduced; base frequency; min frequency limit; max frequency limit. Torque Boost Adjustable 0–25% of input voltage. Brake Torque: Optional external braking resistors available for 460VAC controls.
Analog Outputs: Operating range 0–10VDC (no sign); maximum rated output current 10mA with short circuit protection 10 bits (1 in 1024) Bandwidth 15Hz Resolution Dynamic response Digital Inputs: Operating range Input impedance Rated output current 0–5VDC=OFF; 15–24VDC=ON (30VDC max.) 6k ohms 20mA Digital Outputs: DOut2 (DOut1 is reserved) Nominal open circuit output volts Nominal output impedance Rated output current 22.
Dimensions For Size 1 and 2 controls,the DIN clip can be repositioned to provide the upper mounting hole for wall mounting. B A3 A2 A4 DIN centerline A4 A3 DIN centerline A2 B DIN centerline A A1 C SIDE VIEW - Size 1 shown (Size 2 is similar) Size 1 2 3 A 5.6 (143) 7.9 (201) 10.2 (260) A1 5.2 (132) 7.4 (188) 9.5 (242) A1 B 2 B 2 REAR VIEW - Size 3 REAR VIEW - Size 1 shown (Size 2 is similar) A2 0.2 (6) 0.24 (6.5) 0.2 (6) 6–4 Specifications & Product Data Dimensions A3 A4 1.4 (35) 5.
Appendix A Dynamic Brake 230VAC 1 & 3 Phase Controls All controls are supplied without braking resistors. Size 1 and 2 – 230VAC 1 Phase Size 1 and 2 230VAC controls have no external dynamic brake capability. Size 3 – 230VAC 3 Phase Size 3 230VAC controls have internal brake circuit and can accept external brake resistor. 460VAC 3 Phase Controls Size 2 and 3 – 460VAC Size 2 and 3 460VAC controls have internal brake circuit and can accept external brake resistor.
Table A-1 External Brake Resistor Selection Input Volts 230 230 460 460 460 460 HP Size 3 5 0.5-1 2-3 5 7.5 - 10 3 3 2 2 3 3 Min Ohms 30 30 500 200 100 56 Continuous Rated Watts 100 200 300 RGJ130 RGJ230 RGJ330 RGJ130 RGJ230 RGJ330 RGJ1500 RGJ2500 RGJ1200 RGJ2200 RGJ3200 RGJ1120 RGJ2120 RGJ3120 RGJ160 RGJ260 RGJ360 600 RGA630 RGA630 RGA6200 RGA6120 RGA660 Contact Baldor for information on resistor kits that are not shown.
Appendix B CE Guidelines CE Declaration of Conformity Baldor indicates that the products are only components and not ready for immediate or instant use within the meaning of “Safety law of appliance”, “EMC Law” or “Machine directive”. The final mode of operation is defined only after installation into the user’s equipment. It is the responsibility of the user to verify compliance. The product conforms with the following standards: DIN VDE 0160 / 05.
Using CE approved components will not guarantee a CE compliant system! 1. The components used in the drive, installation methods used, materials selected for interconnection of components are important. 2. The installation methods, interconnection materials, shielding, filtering and grounding of the system as a whole will determine CE compliance. 3. The responsibility of CE mark compliance rests entirely with the party who offers the end system for sale (such as an OEM or system integrator).
EMC Installation Instructions To ensure electromagnetic compatibility (EMC), the following installation instructions should be completed. These steps help to reduce interference. Consider the following: • Grounding of all system elements to a central ground point • Shielding of all cables and signal wires • Filtering of power lines A proper enclosure should have the following characteristics: A) All metal conducting parts of the enclosure must be electrically connected to the back plane.
Input Signal Cable Grounding Control X3 Cable 1 2 3 7 9 10 11 B–4 CE Guidelines MN735
Baldor UK Limited Mint Motion Centre Hawkley Drive.
B–6 CE Guidelines MN735
BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72902–2400 (479) 646–4711 Fax (479) 648–5792 www.baldor.
