Baldor 23H Series Installation & Operating Manual
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Baldor 23H Series Installation & Operating Manual

Baldor 23H Series Installation & Operating Manual

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SERIES 23H
AC Servo Control
Installation & Operating Manual
9/03
MN723

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  • Page 1 SERIES 23H AC Servo Control Installation & Operating Manual 9/03 MN723...

  • Page 2: Table Of Contents

    Table of Contents Section 1 Quick Start Guide ................Section 2 General Information .
  • Page 3 Operating Modes ................3-23 Analog Inputs .
  • Page 4 Section 5 Troubleshooting ................. Overview .
  • Page 5 Dimensions ................. . Size A Control .

  • Page 6: Quick Start Guide

    Quick Start Guide Overview If you are an experienced user of Baldor controls, you are probably already familiar with the keypad programming and keypad operation methods. If so, this quick start guide has been prepared for you. This procedure will help get your system up and running in the Keypad mode quickly.

  • Page 7: General Information

    Section 1 General Information Quick Start Procedure Initial Conditions Be sure the 23H control, motor and dynamic brake hardware are installed and wired according to the procedures in Section 3 of this manual. Become familiar with the keypad programming and keypad operation of the control as described in Section 4 of this manual.

  • Page 8: Overview

    General Information Overview The Baldor Series 23H PWM control uses a closed loop control scheme using an algorithm to adjust the phase of voltage and current applied to a three phase permanent magnet synchronous motor. The servo control adjusts the motor current to produce maximum torque from base speed down to and including zero speed.

  • Page 9: Limited Warranty

    Limited Warranty For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without charge controls and accessories which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied.

  • Page 10: Safety Notice

    Safety Notice This equipment contains voltages that may be as high as 1000 volts! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment.
  • Page 11 Do not connect AC power to the Motor terminals T1, T2 and T3. Connecting AC power to these terminals may result in damage to the control. Caution: Baldor recommends not using “Grounded Leg Delta” transformer power leads that may create ground loops. Instead, we recommend using a four wire Wye. Caution: If the DB hardware mounting is in any position other than vertical, the DB hardware must be derated by 35% of its rated capacity.

  • Page 12: Receiving & Installation

    Section 3 Receiving & Installation Receiving & Inspection When you receive your control, there are several things you should do immediately. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control. Verify that the part number of the control you received is the same as the part number listed on your purchase order.

  • Page 13: Control Installation

    Control Installation The control must be securely fastened to the mounting surface at the mounting holes. Shock Mounting If the control will be subjected to levels of shock greater than 1G or vibration greater than 0.5G at 10 to 60Hz, the control should be shock mounted. Keypad Installation Procedure Refer to the optional remote keypad installation procedure and mount the keypad.

  • Page 14: Optional Remote Keypad Installation

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

  • Page 15: Electrical Installation

    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.

  • Page 16: Line Impedance

    No Load Speed Line Reactors Three phase line reactors are available from Baldor. The line reactor to order is based on the full load current of the motor (FLA). If providing your own line reactor, use the following formula to calculate the minimum inductance required.

  • Page 17: Ac Main Circuit Considerations

    AC Main Circuit Considerations Protection Devices Be sure a suitable input power protection device is installed. Use the recommended circuit breaker or fuses listed in Tables 3-2 through 3-3 (Wire Size and Protection Devices). Input and output wire size is based on the use of copper conductor wire rated at 75 °C.
  • Page 18 Table 3-3 460VAC Controls (3 Phase) Wire Size and Protection Devices Control Output Rating Input Breaker Input Fuse (Amps) Wire Gauge (Amps) Amps Fast Acting Time Delay 0.75 3.31 5.26 5.26 8.37 8.37 13.3 21.2 26.7 33.6 53.5 Note: All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may be used per NEC and local codes.

  • Page 19: Ac Line Connections

    AC Line Connections Reduced Input Voltage Derating All power ratings stated in Section 7 are for the stated nominal AC input voltages (230 or 460VAC). The power rating of the control must be reduced when operating at a reduced input voltage. The amount of reduction is the ratio of the voltage change.

  • Page 20: Three Phase Input Power

    Use same gauge wire for Earth ground as is used for L1, L2 and L3. Metal conduit should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. Baldor See Line/Load Reactors described previously in this section. Series 23H Control See Recommended Tightening Torques in Section 7.
  • Page 21 Table 3-4 and 3-5 list the wire size for the input AC power wires. Motor leads should be sized from the 3 phase tables Table 3-4 Single Phase Rating Wire Size and Protection Devices - 230 VAC Controls* Control Output Rating Input Fuse (Amps) Wire Gauge Input Breaker...

  • Page 22: Single Phase Input Power Considerations

    Notes: See “Protective Devices” described previously in this section. Use same gauge wire for Earth ground as is used for L1, L2 and L3. Baldor Metal conduit should be used. Connect conduits so the use of a Control Reactor or RC Device does not interrupt EMI/RFI shielding.

  • Page 23: Size C2 Single Phase Power Installation

    Notes: See “Protective Devices” described previously in this section. Use same gauge wire for Earth ground as is used for L1, L2 and L3. Baldor Metal conduit should be used. Connect conduits so the use of a Control Reactor or RC Device does not interrupt EMI/RFI shielding.

  • Page 24: Size C And D Single Phase Power Installation

    See “Protective Devices” described previously in this section. Use same gauge wire for Earth ground as is used for L1, L2 and L3. Metal conduit should be used. Connect conduits so the use of a Baldor Reactor or RC Device does not interrupt EMI/RFI shielding. Control See Line/Load Reactors described previously in this section.

  • Page 25: Size D2 Single Phase Power Installation

    Notes: See “Protective Devices” described previously in this section. Use same gauge wire for Earth ground as is used for L1, L2 and L3. Baldor Metal conduit should be used. Connect conduits so the use of a Control Reactor or RC Device does not interrupt EMI/RFI shielding.

  • Page 26: Size E Single Phase Power Installation

    Use same gauge wire for Earth ground as is used for L1, L2 and L3. Metal conduit should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. Baldor See Line/Load Reactors described previously in this section. Control See Recommended Tightening Torques in Section 7.

  • Page 27: Size F Single Phase Power Installation

    Use same gauge wire for Earth ground as is used for L1, L2 and L3. Metal conduit should be used. Connect conduits so the use of a Reactor or RC Device does not interrupt EMI/RFI shielding. Baldor See Line/Load Reactors described previously in this section. Control See Recommended Tightening Torques in Section 7.

  • Page 28: Motor Connections

    Notes: Metal conduit should be used. Connect conduits so the use of Load Reactor or RC Device does not interrupt EMI/RFI shielding. Baldor See Line/Load Reactors described previously in this section. Control Use same gauge wire for Earth ground and motor leads (from the 3 phase wire size tables).

  • Page 29: Optional Dynamic Brake Hardware

    Optional Dynamic Brake Hardware Dynamic Brake (DB) Hardware must be installed on a flat, non-flammable, vertical surface for effective cooling and operation. Refer to MN701 (for RGA, RBA and RTA assemblies) or MN782 (for RUA assemblies) for additional information. Electrical Installation Terminal connections for DB hardware is determined by the control model number suffix (E, EO, ER or MO).
  • Page 30 The braking capability may also need to be disabled in software. For Baldor controls, reduce the resistor ohms to the lowest value and increase the resistor watts to greatest value. Be sure to select the proper size kit based on the dissipation rating of the resistor(s) to handle the average watts of the overhauling or cyclic load.

  • Page 31: Resolver Feedback

    Figure 3-23 Resolver Cable Connections SINE+ SINE– COSINE+ COSINE– = Twisted Pair EXCITATION + EXCITATION – See recommended Terminal Tightening Torques in Section 7. Figure 3-24 Baldor Resolver Cable Lead Identification EXCITATION+ Blue EXCITATION– Green COSINE+ Shield EXCITATION– Yellow COSINE–...

  • Page 32: Simulated Encoder Output

    Simulated Encoder Output The control provides a simulated encoder output at connector J1 as shown in Figure 3-25. This output provides position information to the host controller. Use twisted pair wire with an overall shield. This output simulates a 1024 ppr encoder with quadrature outputs. Counting in quadrature will provide 4096 ppr with one index marker (CHC) per revolution.

  • Page 33: Home (Orient) Switch Input

    Home (Orient) Switch Input To use the internally generated index pulse for homing, no external connections are required. However, to use an external index input a jumper must be moved and the external index signal must be connected to J1-29 and 30. External Index Jumper Refer to Figure 3-30.

  • Page 34: Operating Modes

    Operating Modes Ten operating modes are available. These modes define the basic motor control setup and the operation of the input and output terminals. After the circuit connections are completed, the operating mode is selected by programming the Operating Mode parameter in the Level 1 Input Programming Block.

  • Page 35: Analog Inputs

    Analog Inputs Two analog inputs are available: analog input #1 (J1-1 and J1-2) and analog input #2 (J1-4 and J1-5) as shown in Figure 3-28. Either analog input may be selected in the Level 1 INPUT block, Command Select parameter value. Analog input #1 is selected if the parameter value is “Potentiometer”.
  • Page 36 Figure 3-29 Analog Inputs Equivalent Circuits .033 mF 30KW Notes: -15VDC All OP Amps are TL082 or TL084 – 20KW Analog Ground is separated from – Chassis Ground. Electrically they To Microprocessor are separated by an RC network. 1.96KW +15VDC 10KW 10KW 4-20mA...

  • Page 37: Analog Outputs

    Analog Outputs Two programmable analog outputs are provided on J1-6 and J1-7. See Figure 3-31. These outputs are scaled 0 - 5 VDC (1mA maximum output current) and can be used to provide real-time status of various control conditions. The output conditions are defined in Section 4 of this manual.

  • Page 38: Keypad Operating Mode

    Keypad Mode Operating The Keypad operating mode allows the control to be operated from the keypad. This mode requires no connections to J1. However, the Enable, Stop and External Trip inputs may optionally be used. All other opto inputs remain inactive. The analog outputs and opto-outputs remain active at all times.
  • Page 39 Standard Run 3 Wire Mode Operating In Standard Run mode, the control is operated by the opto isolated inputs at J1-8 through J1-16 and the analog command input. The opto inputs can be switches as shown in Figure 3-33 or logic signals from another device. Figure 3-33 Standard Run 3-Wire Connection Diagram J1-8 CLOSED allows normal operation.
  • Page 40 15 Speed 2-Wire Mode Operating Operation in the 15 Speed 2-Wire mode is controlled by the opto isolated inputs at J1-8 through J1-16. The opto inputs can be switches as shown in Figure 3-34 or logic signals from another device. Switched inputs at J1-11 through J1-14 allow selection of 15 preset speeds and provide Fault Reset as defined in Table 3-9.
  • Page 41 3 Speed Analog 2 Wire Mode Operating Allows selection of 3 preset speeds with 2 wire inputs. The opto inputs can be switches as shown in Figure 3-35 or logic signals from another device. The values of the preset speeds are set in the Level 1 Preset Speeds block, Preset Speed #1, Preset Speed #2 and Preset Speed #3.
  • Page 42 3 Speed Analog 3 Wire Mode Operating Allows selection of 3 preset speeds with 3 wire inputs. The opto inputs can be switches as shown in Figure 3-36 or logic signals from another device. The values of the preset speeds are set in the Level 1 Preset Speeds block, Preset Speed #1, Preset Speed #2 and Preset Speed #3.
  • Page 43 Bipolar Speed or Torque Mode Operating Provides bipolar speed or torque control. Also, you may store up to four (4) complete sets of operating parameters. This is important if you wish to store and use different acceleration rates, speed commands, jog speeds or to store tuning parameter values for different motors etc.

  • Page 44: Multiple Parameter Sets

    Multiple Parameter Sets The following procedure allows you to program up to four complete sets of parameter values and to use these multiple parameter sets. When programming each parameter set, use the ENTER key to accept and automatically save parameter values. Note: The control can be programmed in the REMOTE mode with the drive enabled.

  • Page 45: Process Operating Mode

    Process Operating Mode Figure 3-38 Process Mode Connection Diagram J1-8 CLOSED allows normal operation. Analog GND OPEN disables the control & motor coasts to a stop. Command Pot or Analog Input 1 J1-9 CLOSED to enable operation in the Forward direction. 0-10VDC Pot Reference OPEN TO DISABLE Forward operation (drive will brake to a stop if a Forward...

  • Page 46: Electronic Pot 2 Wire Operating Mode

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

  • Page 47: Electronic Pot 3 Wire Control Mode

    Electronic Pot 3 Wire Control Mode Provides speed Increase and Decrease inputs to allow EPOT operation with 3 wire inputs. The opto inputs can be switches as shown in Figure 3-40 or logic signals from another device. Figure 3-40 EPOT, 3 Wire Control Connection Diagram J1-8 CLOSED allows normal operation.

  • Page 48: Opto-Isolated Inputs

    Opto-Isolated Inputs The equivalent circuit of the nine opto inputs is shown in Figure 3-42. The function of each input depends on the operating mode selected and are described previously in this section. This Figure also shows the connections using the internal opto input Supply. Figure 3-42 Opto-Input Connections (Using Internal Supply) Opto In #1 Opto In #2...

  • Page 49: Opto-Isolated Outputs

    Opto-Isolated Outputs Four programmable opto isolated outputs are available at terminals J1-19 through J1-22. See Figure 3-44. Each output may be programmed to represent one output condition. The output conditions are defined in Section 4 of this manual. The opto isolated outputs may be configured for sinking or sourcing 60 mA each, as shown in Figure 3-44.

  • Page 50: Pre-Operation Checklist

    Figure 3-45 Opto-Output Equivalent Circuit Opto Output 1 Opto Output 2 Opto Output 3 Opto Output 4 10 – 30VDC Opto Outputs PC865 PC865 PC865 PC865 50mA max 50mA max 50mA max 50mA max Opto Out 1 Return Opto Out 2 Return Opto Out 3 Return Opto Out 4 Return See recommended Terminal Tightening Torques in Section 7.

  • Page 51: Power-Up Procedure

    Power-Up Procedure Be sure the 23H control, motor and dynamic brake hardware are installed and wired according to the procedures in Section 3 of this manual. Become familiar with the keypad programming and keypad operation of the control as described in Section 4 of this manual. Disconnect the load (including coupling or inertia wheels) from the motor shaft, if possible.

  • Page 52: Programming And Operation

    Section 4 Programming and Operation Overview The keypad is used to program the control parameters, to operate the motor and to monitor the status and outputs of the control by accessing the display options, the diagnostic menus and the fault log. Figure 4-1 Keypad JOG - (Green) lights when Jog is active.

  • Page 53: Display Mode

    Section 1 General Information Display Mode The control is in the DISPLAY MODE at all times except when parameter values are changed (Programming mode). The Keypad Display shows the status of the control as in the following example. Motor Status Output Condition Control Operation Value and Units...

  • Page 54: Diagnostic Information Access

    Section 1 General Information Display Mode Continued Diagnostic Information Access Action Description Display Comments Press DISP key Scroll to Diagnostic Information Diagnostic Access screen. screen Press ENTER key Access diagnostic information. First Diagnostic Information screen. Press DISP key Display mode showing control temperature.

  • Page 55: Fault Log Access

    Section 1 General Information Display Mode Continued Fault Log Access When a fault condition occurs, motor operation stops and a fault code is displayed on the Keypad display. The control keeps a log of up to the last 31 faults. If more than 31 faults have occurred, the oldest fault will be deleted from the fault log to make room for the newest fault.

  • Page 56: Program Mode

    Section 1 General Information Program Mode The Program Mode is used to: Enter motor data. Autotune the drive. 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.

  • Page 57: Changing Parameter Values When Security Code Not Used

    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...

  • Page 58: Reset Parameters To Factory Settings

    Section 1 General Information Program Mode Continued Reset Parameters to Factory Settings Sometimes it is necessary to restore the parameter values to the factory settings. Follow this procedure to do so. Be sure to change the Level 2 Motor Data block “Motor Rated Amps”...

  • Page 59: Initialize New Software

    Section 1 General Information Program Mode Continued Initialize New Software When new software is installed, the control must be initialized to the new software version and memory locations. Use the following procedure to initialize the software. Note: All parameter values are changed when the control is reset to factory settings. Note: After factory settings have been restored, the drive must again be tuned.

  • Page 60: Parameter Definitions

    Section 1 General Information Parameter Definitions To make programming easier, parameters have been arranged into the two level structure shown in Table 4-1. Press the PROG key to enter the programming mode and the “Preset Speeds” programming block will be displayed. Use the Up (Y) and Down (B) arrows to scroll through the parameter blocks.
  • Page 61 Section 1 General Information Table 4-2 Level 1 Parameter Block Definitions Block Title Parameter Description PRESET Preset Speeds Allows selection of 15 predefined motor operating speeds. #1 – #15 Each speed may be selected using external switches connected to terminals at J1. SPEEDS For motor operation, a motor direction command must be given along with a preset speed command.
  • Page 62 Section 1 General Information Table 4-2 Level 1 Parameter Block Definitions - Continued Block Title Parameter Description KEYPAD SETUP Keypad Stop Key Allows keypad STOP key to initiate motor stop during remote or serial operation (if Stop key is set to Remote ON in Standard Run, 15 Speed, Bipolar, Serial and Process Control modes).
  • Page 63 Section 1 General Information Table 4-2 Level 1 Parameter Block Definitions - Continued Block Title Parameter Description OUTPUT OPTO OUTPUT Four optically isolated digital outputs that have two operating states, logical High or Low. #1 – #4 Each output may be configured to any of the following conditions: Condition Description Ready -...
  • Page 64 Section 1 General Information Table 4-2 Level 1 Parameter Block Definitions - Continued Block Title Parameter Description OUTPUT Analog Output Two Analog 0-5VDC linear outputs may be configured to represent any of the following (Continued) #1 and #2 conditions: Condition Description ABS Speed - Represents the absolute motor speed where 0VDC = 0 RPM and...
  • Page 65 Resolver Align A numerical alignment value. The autotune procedure aligns the motor and resolver positions. 22.3 degrees is correct for all Baldor BSM motors. Speed Filter The number of input samples taken by the control microprocessor over which to filter and determine the resolver speed.
  • Page 66 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 frequency. Two output power modes are also selectable: Constant Torque and Variable Torque.
  • Page 67 Section 1 General Information Table 4-3 Level 2 Parameter Block Definitions Continued Block Title Parameter Description CUSTOM UNITS Max Decimal The number of decimal places of the Output Rate display on the Keypad display. This Places value will be automatically reduced for large values. The output rate display is only available if the “Value At Speed”...
  • Page 68 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.
  • Page 69 The full load motor current (listed on the motor nameplate). If the motor current exceeds this value for a period of time, an Overload fault will occur. Motor Poles The number of motor poles. Factory setting is 4 poles. The values shown here are for standard Baldor BSM motors. NUMBER OF MOTOR POLES...
  • Page 70 Section 1 General Information Table 4-3 Level 2 Parameter Block Definitions Continued Block Title Parameter Description PROCESS Follow I:O Ratio Sets the ratio of the Master to the Follower in Master/Follower configurations. Requires CONTROL the Master Pulse Reference/ Isolated Pulse Follower expansion board. For example, (Continued) the master encoder you want to follow is a 1024 count encoder.
  • Page 71 Section 1 General Information 4-20 Programming & Operation MN723...

  • Page 72: Troubleshooting

    Section 5 Troubleshooting Overview The Baldor Series 23H Control requires very little maintenance and should provide years of trouble free operation when installed and applied correctly. Occasional visual inspection and cleaning should be considered to ensure tight wiring connections and to remove dust, dirt, or foreign debris which can reduce heat dissipation.

  • Page 73: How To Access Diagnostic Information

    Section 1 General Information How to Access Diagnostic Information Action Description Display Comments Apply Power Logo display for 5 seconds. Display mode showing motor No faults present. Local keypad speed. mode. If in remote/serial mode, disable drive then press local for this display.

  • Page 74: How To Access The Fault Log

    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.
  • Page 75 Regen R PWR FLT Regen power exceeded DB resistor rating. User Fault Text Custom software operating fault occurred. Co–Processor Fault Co-Processor hardware fault occurred. Contact Baldor. 5-4 Troubleshooting MN723...

  • Page 76: Resolver Troubleshooting

    Section 1 General Information Resolver Troubleshooting SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Continuous Overspeed Fault displayed on Resolver wiring connection is Inspect and repair the resolver wiring. keypad. disconnected, a wire broken or miswired. Missing or miswired shield. Terminate shield properly @ J1–28 Intermittent Overspeed Fault displayed on Resolver wiring connection is intermittent.
  • Page 77 If GND FLT is cleared, reconnect motor leads and retry the test. Wiring shorted in conduit. Rewire as necessary. Motor winding shorted. Repair motor. If GND FLT remains, contact Baldor. INT Over-Temp Drive Overloaded. Correct motor loading. Verify proper sizing of control and motor.
  • Page 78 POSSIBLE CAUSE CORRECTIVE ACTION Invalid Base ID Control does not recognize HP and Press “RESET” key on keypad. If fault remains, call Baldor. Voltage configuration. Inverter Base ID Power base with no output phase Replace power base with one that has output phase current current sensors being used.
  • Page 79 Section 1 General Information Table 5-2 Troubleshooting Continued INDICATION POSSIBLE CAUSE CORRECTIVE ACTION New Base ID Software parameters are not Press “RESET” key on keypad to clear the fault condition. Cycle power initialized on newly installed (turn power OFF then ON). Reset parameter values to factory settings. control board.
  • Page 80 POSSIBLE CAUSE CORRECTIVE ACTION Power Module Power supply failure. Press “RESET” key on keypad. If fault remains, call Baldor. PWR Base FLT Improper ground Be sure control has separate ground wire to earth ground. Panel grounding or conduit connection is not sufficient.
  • Page 81 Section 1 General Information Table 5-3 Power Base ID - Series 23H 230VAC 460VAC Catalog Power Catalog Power Size Size Base ID Base ID 2A03–E 4A04–E 2A04–E 4A05–E 2A04–W 4A08–E 2A07–E 4A11–E 2A10–E 4A11–E 2A10–W 4A14–E 2A15–E 4A14–E 2A16–E 4A15–E 2A16–E 4A15–E 2A22–E...

  • Page 82: Electrical Noise Considerations

    Section 1 General Information Electrical Noise Considerations All electronic devices are vulnerable to significant electronic interference signals (commonly called “Electrical Noise”). At the lowest level, noise can cause intermittent operating errors or faults. From a circuit standpoint, 5 or 10 millivolts of noise may cause detrimental operation.

  • Page 83: Special Drive Situations

    Section 1 General Information Special Drive Situations For severe noise situations, it may be necessary to reduce transient voltages in the wires to the motor by adding load reactors. Load reactors are installed between the control and motor. Reactors are typically 3% reactance and are designed for the frequencies encountered in PWM drives.

  • Page 84: Manual Tuning The Series 23H Control

    Section 6 Manual Tuning the Series 23H Control Manually Tuning the Control In some applications the drive cannot be accurately auto-tuned. In these cases, it is necessary to calculate the values needed to tune the drive and manually enter these calculated parameter values.

  • Page 85: Speed Int Gain Parameter

    (s + K ) /s. The second equation shows that the ratio of K is a frequency in radians/sec. In the Baldor Control, the integral gain has been redefined to be, = (K ) / (2p) Hz, and the transfer function is,...

  • Page 86: Specifications, Ratings & Dimensions

    Section 7 Specifications, Ratings & Dimensions Specifications: Power 0.75 - 37.2kW (1-50 HP) @ 230VAC 0.75 - 186.5kW (1-250 HP) @ 460VAC 50/60 HZ ± 5% Input Frequency Output Voltage 0 to Maximum Input VAC Output Current See Ratings Table Service Factor Duty Continuous...

  • Page 87: Keypad Display

    Section 1 General Information Keypad Display: Display Backlit LCD Alphanumeric 2 Lines x 16 Characters Keys 12 key membrane with tactile response Functions Output status monitoring Digital speed control Parameter setting and display Diagnostic and Fault log display Motor run and jog Local/Remote toggle LED Indicators Forward run command...

  • Page 88: Analog Outputs

    Section 1 General Information Other Analog Input: Full Scale Range 0 - 10 VDC (0 to –10VDC and 0 to +10VDC are valid inputs) Resolution 9 bits + sign Analog Outputs: Analog Outputs 2 Assignable Full Scale Range 0 - 5 VDC Source Current 1 mA maximum Resolution...

  • Page 89: Ratings

    Section 1 General Information Ratings Series 23H Stock Products QUIET 8.0 kHz PWM STANDARD 2.5 kHz PWM CATALOG INPUT SIZE CONSTANT TORQUE VARIABLE TORQUE CONSTANT TORQUE VARIABLE TORQUE VOLT VOLT SD23H2A03–E SD23H2A04–E, W SD23H2A07–E SD23H2A10–E, W SD23H2A16–E SD23H2A22–E 11.1 SD23H2A28–E 11.1 11.1 11.1...

  • Page 90: Terminal Tightening Torque Specifications

    Section 1 General Information Terminal Tightening Torque Specifications Table 7-4 Tightening Torque Specifications Tightening Torque 230VAC B+/R1; B+; B–; Power TB1 Ground Control J1 D1/D2 Size or R2 Catalog Numbers Catalog Numbers Lb-in Lb-in Lb-in Lb-in Lb-in SD23H2A03–E SD23H2A04–E SD23H2A04–W SD23H2A07–E SD23H2A10–E SD23H2A10–W...

  • Page 91: Dimensions

    Section 1 General Information Dimensions Size A Control Outlet 7.120 7.20 0.25 (180.8mm) (182.9mm) (6.4mm) LOCAL PROG DISP SHIFT ENTER STOP RESET 12.00 11.50 (304.8mm) (292.1mm) (6.4mm) 7.20 (182.9mm) Air Inlet 0.88 Dia. (22.35 mm) 7.70 KP5000 (195.6mm) 7-6 Specifications, Ratings & Dimensions MN723...

  • Page 92: Size C2 Control

    Section 1 General Information Dimensions Continued Size B Control 9.25 Outlet 0.28 TYP 7.120 (225.0mm) (7.1mm) (180.9mm) LOCAL PROG DISP SHIFT ENTER STOP RESET 14.65 15.40 (372.1mm) (391.2mm) .28 TYP 9.25 (7.1mm) (235.0mm) Air Inlet 1.12 Dia. 0.88 Dia. (28.45 mm) (22.35 mm) 10.00 KP5002...
  • Page 93 Section 1 General Information Dimensions Continued Size B2 Control Air Outlet 7.20 0.28 TYP 8.73 (182.9mm) (7.1mm) (221.7mm) LOCAL PROG DISP SHIFT ENTER STOP RESET 11.50 12.15 (292.1mm) (308.6mm) 7.20 .28 TYP Air Inlet (7.1mm) (182.9mm) 7.20 (182.9mm) 1.12 Dia. (28.45 mm) 8.07 (205.0mm)
  • Page 94 Section 1 General Information Dimensions Continued Size C Control 11.50 9.50 (292.0 mm) (241.5 mm) 10.75 9.50 (9.5 mm) (273.0 mm) (241.5 mm) Outlet (9.5 mm) .28 (7.0mm) 2 Places 18.50 (470.0 mm) LOCAL PROG DISP 17.75 SHIFT ENTER (451 mm) STOP RESET 17.00...
  • Page 95 Section 1 General Information Dimensions Continued Size C2 Control Air Outlet 16.568 16.075 15.665 0.280 Dia. 2 Places LOCAL PROG DISP SHIFT ENTER STOP RESET 16.98 (431.3) 0.250 Dia. 0.903 2 Places 0.493 0.00 Air Inlet 10.50 (266.7) 0.875 Dia. (22.23 mm) 4.95 (125.7)

  • Page 96: Size C2 Control - Through-Wall Mounting

    Section 1 General Information Dimensions Continued Size C2 Control – Through–Wall Mounting Control 1/4-20 or M6 self sealing Assembly bolt and flat washer 4 places 15.50 (393,7) each (holes coded “A”) 15.25 (387,4) 14.91 (378,1) 0.280 Dia. hole through wall 4 Places coded “A”...

  • Page 97: Size D Control

    Section 1 General Information Dimensions Continued Size D Control 14.50 (368.5mm) Outlet 13.50 (343.0mm) LOCAL PROG 25.00 DISP SHIFT ENTER (635.0mm) STOP RESET 24.25 (616.0mm) 23.12 (587.0mm) (8.0mm) 0.50 Dia. CUSTOMER (12.70 mm) AIR INLET 2.469 Dia. POWER (62.71 mm) CONNECTIONS 10.00 (254.0mm)

  • Page 98: Size D2 Control

    Dimensions Continued Size D2 Control 13.00 (330) 9.50 (241) 0.375 Dia. 4 Places 24.00 (607) 23.00 (585) 21.00 (535) 11.91 (303) 10.00 (254) 11.035 (280) 10.33 (263) 9.09 (231) 0.50 6.09 (155) 2.00 Dia. Dia. 0.875 Dia. 3.09 (78) 2 Places 2.45 Dia.

  • Page 99: Size D2 Control - Through-Wall Mounting

    Dimensions Continued Size D2 Control – Through–Wall Mounting Mounting hole locations for Thru-Wall or surface mounting. Recommended .31 – 18 Tap. (4 Places) 22.25 (565) 21.50 (546) Cutout for thru–wall mounting 0.75 (19) 7-14 Specifications, Ratings & Dimensions MN723...

  • Page 100: Size E Control

    Section 1 General Information Dimensions Continued Size E Control Outlet Surface Thru–wall Mounting Mounting Flange Flange (9.5mm) 2 Places 30.00 (762mm) 5.75 6.25 .38 (9.5mm) 2 Places (146mm) (159mm) 17.70 (450mm) Air Inlet 2.469 Dia. 0.50 Dia. (62.71 mm) (12.70 mm) 0.875 Dia.

  • Page 101: Size F Control

    Section 1 General Information Dimensions Continued Size F Control 22.75 (577.9mm) Air Outlet .38 (9.5mm) Surface 3 Places Thru–wall Mounting Flange Mounting Flange 45.00 (1143mm) 44.00 (1117.6mm) 0.38 (9.5mm) 3 Places 11.38 11.38 (28.9mm) (28.9mm) Air Inlet 27.00 6.24 6.76 (686mm) (158mm) (172mm)

  • Page 102: Size G Control

    Section 1 General Information Dimensions Continued Size G Control 24.00 3.72 Removable Conduit Mounting Plates (609,6) (94,6) (Customer Power Connections) 8.63 (219) 8.63 (219) 12.41 (315) 2.66 (67,6) 31.50 (800) 23.63 (600) Outlet 90.55 (2300) 93.00 Inlet (2362) Grills (4) 47.25 (1200) 4.00...
  • Page 103 Section 1 General Information 7-18 Specifications, Ratings & Dimensions MN723...

  • Page 104: Dynamic Braking (Db) Hardware

    Identify the control model number and determine which braking hardware is required based on the model number suffix: E, EO, ER, MO or MR. Select appropriate braking hardware from Baldor 501 Catalog or Tables A-2, A-3 and A-4. Hoisting Load Calculations...
  • Page 105 Section 1 General Information Dynamic Braking (DB) Hardware Continued General Machinery Load Calculations: Calculate braking duty cycle: Braking Time Duty Cycle + Total Cycle Time Calculate deceleration torque: RPM change * Friction Decel (Lb.Ft.) time where: = Deceleration torque in Lb.-ft. Decel = Inertia in Lb.ft.
  • Page 106 Section 1 General Information Dynamic Braking (DB) Hardware Continued Catalog Numbers with an “E” Suffix These controls are equipped with a factory installed dynamic brake transistor and brake resistor(s). Size A controls have 400 watts and size B controls have 800 watts of dissipation.

  • Page 107: Rga Assemblies

    Section 1 General Information Dynamic Braking (DB) Hardware Continued RGA Assemblies RGA Assemblies include braking resistors completely assembled and mounted in a NEMA 1 enclosure. A listing of available RGA assemblies is provided in Table A-2. The minimum resistance “Minimum Ohms” shown in the table is the minimum resistor value that can be connected to the control without causing damage to the internal dynamic brake transistor for E, ER and MR controls.

  • Page 108: Rba Assemblies

    Section 1 General Information Dynamic Braking (DB) Hardware Continued RBA Assemblies An RBA Assembly includes a dynamic brake transistor and resistors completely assembled and mounted in a NEMA 1 enclosure. The are designed for EO and MO controls. Select the RBA based on the voltage rating of the control and the dynamic brake watt capacity required.

  • Page 109: Rta Assemblies

    Section 1 General Information Dynamic Braking (DB) Hardware Continued RTA Assemblies RTA assemblies include a dynamic brake transistor and gate driver circuit board completely assembled and mounted in a NEMA 1 enclosure. Brake resistors are not included in the RTA assembly. Each RTA assembly is designed to be used with an RGA dynamic brake resistor assembly.

  • Page 110: Parameter Values

    Appendix B Parameter Values (Version 3.12) Table B-1 Parameter Block Values Level 1 Level 1 Blocks Block Title Parameter Adjustable Range Factory User Setting Setting PRESET PRESET SPEED #1 1001 0-MAX Speed 0 RPM SPEEDS PRESET SPEED #2 1002 0-MAX Speed 0 RPM PRESET SPEED #3 1003...
  • Page 111 Section 1 General Information Table B-1 Parameter Block Values Level 1 Continued Level 1 Blocks - Continued Block Title Parameter Adjustable Range Factory User Setting INPUT OPERATING MODE 1401 1–KEYPAD KEYPAD 2–STANDARD RUN 3–15SPD 4–3SPD ANA 2 WIRE 5–3SPD ANA 3 WIRE 6–SERIAL 7–BIPOLAR 8–PROCESS MODE...
  • Page 112 Section 1 General Information Table B-1 Parameter Block Values Level 1 Continued Level 1 Blocks - Continued Block Title Parameter Adjustable Range Factory User Setting OUTPUT ANALOG OUT #1 1508 0–ABS SPEED (Continued) 1–ABS TORQUE SPEED 2–SPEED COMMAND 3–PWM VOLTAGE 4–FLUX CURRENT 5–CMD FLUX CUR 6–LOAD CURRENT...
  • Page 113 Section 1 General Information Table B-2 Parameter Block Values Level 2 Level 2 Blocks Block Title Parameter Adjustable Range Factory User Setting OUTPUT LIMITS OPERATING ZONE 2001 1–STD CONST TQ QUIET 2–STD VAR TQ CONST TQ 3–QUIET CONST TQ 4–QUIET VAR TQ MIN OUTPUT SPEED 2002 0-2500...
  • Page 114 Section 1 General Information Table B-2 Parameter Block Values Level 2 Continued Level 2 Blocks - Continued Block Title Parameter Adjustable Range Factory User Setting BRAKE RESISTOR OHMS 2601 0-250 OHMS 30.0 OHM ADJUST RESISTOR WATTS 2602 0-360KW 0.40 KW PROCESS PROCESS FEEDBACK 2701...
  • Page 115 Section 1 General Information Table B-2 Parameter Block Values Level 2 Continued Level 2 Blocks - Continued Block Title Parameter Adjustable Range Factory User Setting COMMUNICATIONS PROTOCOL 2801 0–RS–232 ASCII, 1–RS-485 ASCII, RS–485 2–RS–232 BBP, 3–RS-485 BBP ASCII BAUD RATE 2802 0–9600, 9600...

  • Page 116: Appendix C

    Appendix C MN723 Appendix C-1...

  • Page 117: Remote Keypad Mounting Template

    Remote Keypad Mounting Template 4.00 2.500 Four Places Tapped mounting holes, use #29 drill and 8-32 tap (Clearance mounting holes, use #19 or 0.166″ drill) ″ diameter hole Use 1.25″ conduit knockout 1.250 Note: Template may be distorted due to reproduction. C-2 Appendix MN723...
  • Page 118 TEL: +39 11 562 4440 TEL: +61 29674 5455 TEL: +65 744 2572 TEL: +52 477 761 2030 FAX:+39 11 562 5660 FAX:+61 29674 2495 FAX:+65 747 1708 FAX:+52 477 761 2010  Baldor Electric Company Printed in USA MN723 9/03 C&J 1500...
  • Page 120 BALDOR ELECTRIC COMPANY MOTION CONTROL APPLICATION NOTES MN1200...
  • Page 121 Application Notes TABLE OF CONTENTS BASICS OF MOTION ... . . 13 CONVERSION TABLES... 26 DRIVE TECHNOLOGY ... 1 INERTIA MATCHING .
  • Page 122 Application Notes Page 2...
  • Page 123 , which this wire provides, results in longer motor life, reduced down time, and better overall value. All Baldor motors include the above features, designed in as standard. If the application has high inertial loads, a line regeneration (“line regen”) vector control should be considered.
  • Page 124 Application Notes Vector drives are used in high-performance adjustable-speed applications, machine tool spindles, and industrial test stands just to mention a few applications. Line regen units are used in winders, hoist/crane, presses, HVAC, and other applications. For positioning applications, vector drives are used with existing programmable position controllers.
  • Page 125 Application Notes Figure 1 represents a summary of vector and servo drive technology comparisons. Figure 1. DRIVE TECHNOLOGY COMPARISON (1 HP AT 1800 RPM) VECTOR BRUSHLESS SERVO SERVO Std Inertia Low Inertia Speed Traditional Traditional Higher Speeds are possible Acceleration Traditional Fast Very Fast...
  • Page 126 Application Notes Advantages of linear motors include high acceleration (up to 10 g’s), low speed (0.0001 inch/second) and high speed (100 inch/second) capability, small strokes (0.01 inch) and long strokes (excess of 25 feet), and sub-micron position accuracy (with appropriate feedback device). Only one moving part leads to simplicity and high reliability, with no backlash and very high stiff- ness.
  • Page 127 Application Notes Mechanics This application note presents formulas for calculating reflected load parameters. The mechanical systems used in motion control applications can be divided into four basic categories: direct, gear, belt-pulley and leadscrew. Reflecting parameters back to the motor shaft eases the calculations necessary for sizing and selecting.
  • Page 128 Application Notes The inertia of complex concentric rotating parts is calculated by breaking the part up into simple rotating cylinders, calculating their individual inertia, and adding them together. Material Densities Material lb/in Aluminum 0.096 Brass 0.300 Bronze 0.295 Copper 0.322 Steel (cold rolled) 0.280 Plastic...
  • Page 129 Application Notes Gear Loads in a gear application have to be reflected back to the motor shaft by the gear ratio, or the gear ratio squared. The inertia of the gears have to be included in the calculations. Gear inertia may be calculated using the formula for cylinder.
  • Page 130 Application Notes Leadscrew The load has to be reflected back to the motor shaft. The leadscrew inertia has to be included (can use the formula for inertia of a cylinder). If preloading is used the torque must be included since it may be significant.
  • Page 131 Application Notes Matched Performance The information in this application note explains how to read the speed-torque curves. Baldor provides “matched performance ”curves to simplify the process of selecting both a motor and control for a specific application. Curves In constant speed applications, motors are defined in terms of horsepower (which is torque at a “base”...
  • Page 132 Application Notes Example An application requires a continuous torque of 30 lb-in at a speed of 3750 RPM. The peak torque required for acceleration is 80 lb-in. The curve shows a motor which will work in this application. The bus voltage required is 300 VDC. The continuous and peak currents required are 7 and 18 amps.
  • Page 133 Application Notes Basics of Motion The following will show you how to easily determine the right motor and control for any electromechanical positioning application. Once the mechanics of the appli- cation have been analyzed, and Figure 1. Basic Motion System the friction and inertia of the load are known, the next step is to determine the torque levels...
  • Page 134 Application Notes Movement Profile A movement profile defines the desired acceleration rate, run time, speed, and deceleration rate of the load. For example, suppose with a system at rest (time=0, Figure 2), the programmable motion controller issues a command to start motion. At this instant, the motor has not yet started to move, there is no feedback signal, and the error signal is large.
  • Page 135 Application Notes Figure 3. Example Application Duty Cycle Torque In addition to acceleration torque, the motor must be able to provide sufficient torque over the entire duty cycle or movement profile. This includes a certain amount of constant torque during the run phase, and deceleration torque during the stopping phase.
  • Page 136 Application Notes 7.73 = 1.61 A Power Requirements The control must supply sufficient power for both the acceleration portion of the movement profile, as well as for the duty-cycle requirements. The two aspects of power requirements include (1) power to move the load, P , and (2) power losses dissipated in the motor, P diss Power delivered to move the load is:...
  • Page 137 Application Notes Is It DC or AC Brushless The brushless motor can be driven by either a DC control or an AC control. However the torque developed by the package is different. The torque developed by a brushless motor depends on the control technology used. The same motor can be driven by either a DC control or an AC control scheme.
  • Page 138 Application Notes this process is repeated (i.e. current is removed from winding T at 270° and applied to winding S) the shaft will continue to rotate. By continuation of the scheme, rotation is continued. DC Control The electrical windings will be energized near the peak of the waveform, to obtain maximum torque from the motor.
  • Page 139 Application Notes Thus, the expression for torque, with a floating neutral, becomes: T = K φφ I (Torque in N-m, K T = 0.955 K in v/r/s) (10) The back-EMF or voltage constant is measured phase to phase, and current is the DC level thru the winding.
  • Page 140 Application Notes Using these equations we arrive at: φ I [sin φ + sin (φ +120) + sin (φ + 240)] (17) φ I x 1.5 (18) With this commutation scheme, there is no difference between the maximum and minimum torque developed.
  • Page 141 Application Notes tions and current is calculated from the relationship: T = K where K is the torque constant from Figure 5. Figure 5. Relationship between KE and KT for a brushless motor when driven with a DC control versus an AC control Voltage constant is measured as V/KRPM peak (phase to phase).
  • Page 142 Application Notes Inertia Matching Consider matching load and motor inertia. The following presents some points to consider. System performance depends upon the load and motor coupling, and the ratio selected. These determine response, mechanical resonance, and power dissipated. Response Typical system response with “relatively good inertial matching” is shown in Figure 1. As the load to motor mismatch is increased, oscillations occur, and it takes longer to settle in position (Figure 1b).
  • Page 143 Application Notes minimal power dissipation. For a mismatch of 2:1 the energy increases by 56%. System power dissipation is minimized with inertia matching. Inertia ratio ranges, by markets, traditionally are: 1:1 to 3:1 for robotics type applications 4:1 to 7:1 for machine tool type applications 5:1 to 10:1 for other X-Y positioning type applications Conclusion Thus recommendations would be: 1) whenever there is a choice between two motor frame sizes,...
  • Page 144 Application Notes Figure 2. Additional energy dissipation for mis-matched load/motor inertia. Page 24...
  • Page 145 Application Notes Conversion Tables Rotary inertia (To convert from A to B, multiply by entry in table) lb-ft-s gm-cm oz-in gm-cm-s kg-cm lb-in oz-in-s lb-ft Kg-cm-s lb-in-s slug-ft gm-cm 5.46x10 1.01x10 3.417x10 1.41x10 2.37x10 1.01x10 8.85x10 7.37x10 oz-in 182.9 0.186 0.182 0.0625 2.59x10...
  • Page 146 Application Notes Conversion Tables Multiply To Obtain Length Angstrom units 3.937 x 10 0.3937 0.30480 in. (U.S.) 2.5400058 in. (British) 0.9999972 in. (U.S.) Angstrom units 3.280833 39.37 1.09361 6.2137 x 10 miles (U.S. statute) 0.91440 miles (U.S. statute) 5,280 Area cir mils 7.854 x 10 1.07639 x 10...
  • Page 147 Application Notes Page 27...
  • Page 148 Application Notes Page 28...
  • Page 149 BALDOR ELECTRIC COMPANY P. O. BOX 2400 Fort Smith, Arkansas 72901-2400 (501) 646-4711 Fax (501) 648-5792 www.baldor.com © 99 Baldor Electric Company Printed in U.S.A. MN1200 2/99 FARR 5000...

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