Baldor 18H Series Installation & Operating Manual
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Baldor 18H Series Installation & Operating Manual

Baldor 18H Series Installation & Operating Manual

Vector drive, ac flux vector control
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VECTOR DRIVE
SERIES 18H
AC Flux Vector Control
Installation & Operating Manual
9/97
MN718

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Summary of Contents for Baldor 18H Series

  • Page 1 VECTOR DRIVE SERIES 18H AC Flux Vector Control Installation & Operating Manual 9/97 MN718...

  • Page 2: Table Of Contents

    Table of Contents Section 1 Quick Start Guide ................Overview .
  • Page 3 Section 1 General Information Control Circuit Connections ..............3-33 Keypad Mode Connections .
  • Page 4 Section 1 General Information Section 5 Troubleshooting ................. No Keypad Display - Display Contrast Adjustment .
  • Page 5 Section 1 General Information Section 7 Specifications, Ratings & Dimensions ............. . Specifications .

  • 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: Quick Start Procedure

    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.

  • Page 8: General Information

    The Baldor Series 18H control may be used in many different applications. It may be programmed by the user to operate in four different operating zones; standard or quiet constant torque or variable torque.

  • 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 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 Wye.

  • Page 12: Receiving & Installation

    Section 3 Receiving & Installation Receiving & Inspection The Series 18H Vector Control is thoroughly tested at the factory and carefully packaged for shipment. 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.

  • Page 13: Control Installation

    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.

  • Page 14: Optional Remote Keypad Installation

    General Information 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 indoor enclosure, it retains the Type 4X indoor 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

    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.
  • Page 17 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.

  • Page 18: Line Reactors

    General Information Line Reactors Three phase line reactors are available from Baldor. The line reactor to order is based on the *Quad Rated HP of the control. If providing your own line reactor, use the following formula to calculate the minimum inductance required. Table 3-3 lists the input current required for this calculation, for each control size.
  • Page 19 Section 1 General Information Table 3-2 Short Circuit Current Ratings 230VAC 460VAC 575VAC Catalog Numbers Max. Line Catalog Numbers Max. Line Catalog Numbers Max. Line Short Circuit Short Circuit Short Circuit Amps Amps Amps ZD18H201–E ZD18H401–E ZD18H501–E ZD18H201–W ZD18H401–W ZD18H502–E ZD18H202–E ZD18H402–E ZD18H503–E...

  • Page 20: Input Current Requirements

    Section 1 General Information Input Current Requirements Table 3-3 Input Current Requirements 230 VAC Control 230 VAC Control Input Input 460 VAC Control 460 VAC Control Input Input 575 VAC Control 575 VAC Control Input Input Catalog Numbers Amps Catalog Numbers Amps Catalog Numbers Amps...

  • Page 21: Ac Main Circuit

    Section 1 General Information AC Main Circuit Protection Devices Be 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 and protective device specifications are based on the controls’ maximum output power rating for the operating zone.
  • Page 22 Section 1 General Information Table 3-5 Wire Size and Protection Devices - 460 VAC Controls Control O tp t Control Output Inp t Input Inp t F se Input Fuse Wire Ga ge Wire Gauge Power Rating R ti Breaker Fast Acting Time Delay 17.5A...
  • Page 23 Section 1 General Information Table 3-6 Wire Size and Protection Devices - 575 VAC Controls Control O tp t Control Output Inp t Input Inp t F se Input Fuse Wire Ga ge Wire Gauge Power Rating R ti Breaker Fast Acting Time Delay 120A...

  • Page 24: Ac Line Connections

    Section 1 General Information AC Line Connections Be sure all power to the control is disconnected before proceeding. If power has been 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 power ratings stated in Section 7 are for the stated nominal AC input voltages (230, 460 or 575VAC).
  • Page 25 Section 1 General Information Tap Change Procedure (size G controls). See Figure 3-2. Be sure drive operation is terminated and control is disabled. Remove all power sources from the control. If power has been applied, wait at least 5 minutes for bus capacitors to discharge. Remove or open the front cover.

  • Page 26: Three Phase Input Power

    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 Wye.
  • Page 27 Reactor Optional components not provided with 18H Control. Note 2 Notes: See “Protective Devices” described previously in this section. Baldor Shield wires inside a metal conduit. Series 18H Metal conduit should be used to shield output wires (between Control control and motor). Connect conduits so the use of Load Reactor or RC Device does not interrupt EMI/RFI shielding.
  • Page 28 Section 1 General Information Table 3-7 Single Phase Rating Wire Size and Protection Devices - 230 VAC Controls Control Output Input Breaker Input Fuse Wire Gauge Power Rating R ti Fast Acting Time Delay 100A 100A 100A 125A 125A 125A Table 3-8 Single Phase Rating Wire Size and Protection Devices - 460 VAC Controls Control Output Input Breaker...

  • Page 29: Single Phase Input Power Considerations

    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 Wye.
  • Page 30 Line Reactor * Optional components not provided with 18H Control. Note 2 Notes: Baldor See “Protective Devices” described previously in this section. Series 18H Control Shield wires inside a metal conduit. Metal conduit should be used to shield output wires (between control and motor).

  • Page 31: Size C And D Single Phase Power Installation

    Size C and D Single Phase Power Installation Figure 3-5 Jumper Configuration 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 Pins 1 & 2 = Single Phase Pins 2 &...
  • Page 32 Line Reactor * Optional components not provided with 18H Control. Note 2 Notes: Baldor See “Protective Devices” described previously in this section. Series 18H Control Shield wires inside a metal conduit. Metal conduit should be used to shield output wires (between control and motor).

  • Page 33: Size E Single Phase Power Installation

    Size E Single Phase Power Installation Figure 3-7 Jumper Configuration Place JP1 on the High Voltage Circuit Board across pins 1 and 2. High Voltage Circuit Board (100 - 150HP E Size) Pins 1 & 2 = Single Phase Pins 2 & 3 = Three Phase 8470 Power and Control Connections The single phase power and motor connections are shown in Figure 3-8.
  • Page 34 Line Reactor * Optional components not provided with 18H Control. Note 2 Notes: Baldor See “Protective Devices” described previously in this section. Series 18H Control Shield wires inside a metal conduit. Metal conduit should be used to shield output wires (between control and motor).

  • Page 35: Size F Single Phase Power Installation

    Size F Single Phase Power Installation Figure 3-9 Jumper Configuration Place JP2 on the High Voltage Circuit Board across pins 1 and 2. High Voltage Circuit Board (150 - 250HP F Size) Pins 1 & 2 = Single Phase Pins 2 & 3 = Three Phase Power and Control Connections The single phase power and motor connections are shown in Figure 3-10.
  • Page 36 Line Reactor * Optional components not provided with 18H Control. Note 2 Notes: Baldor See “Protective Devices” described previously in this section. Series 18H Control Shield wires inside a metal conduit. Metal conduit should be used to shield output wires (between control and motor).

  • Page 37: Optional Dynamic Brake Hardware

    Section 1 General Information Optional Dynamic Brake Hardware WARNING: Resistors may generate enough heat to ignite combustible materials. To avoid fire hazard, keep all combustible materials and flammable vapors away from brake resistors. Physical Installation Dynamic Brake (DB) Hardware must be installed on a flat, non-flammable, vertical surface to obtain effective cooling and operation.

  • Page 38: Electrical Installation

    Section 1 General Information Electrical Installation Terminal connections for DB hardware is determined by 18H Control model number suffix (E, EO, ER or MO). See Figure 3-12 for terminal identification. Figure 3-12 DB Terminal Identification “E” or “W” suffix B+/R1 B–...
  • Page 39 Section 1 General Information Figure 3-14 Wiring for RBA Assembly Control Shielded Terminals Terminals Twisted Pair Optional Dynamic Brake (RBA) B– B– MOTOR 50/60 Hz 3 Phase Power See recommended Terminal Tightening Torques in Table 3-9. Optional Customer Supplied Breaker or Fuse Protection - Subject to Local Codes See recommended Terminal Tightening Torques in Section 7.
  • Page 40 Section 1 General Information Table 3-9 Terminal Torques & Wire Size for Model No. Suffix E or W B+ / B– / R1 / R2 / Terminals Control Voltage Rating Control Voltage Rating Tightening Wire SIze Torque Volt Volt Lb–in 230, 460, 575 2.26 Table 3-10 Terminal Torques &...

  • Page 41: Encoder Installation

    Strip the outside jacket approximately 0.375 (9.5mm) from the end. 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. Insulate or tape off ungrounded end of shields and unused conductors to prevent contact with other conductors or ground.
  • Page 42 Section 1 General Information Figure 3-17 Encoder Connections No Connection Terminal Tightening Torque = 7 Lb-in (0.8 Nm). Encoder Cable Connection Encoder cable must be separated by at least 3” (76mm) from parallel runs of power wires. Encoder cables that cross power wires must cross at a 90 angle only. Encoder wires must be #22 AWG (0.34mm ) minimum, 200 feet (60m) maximum length and must have an overall shield.

  • Page 43: Home (Orient) Switch Input

    Section 1 General Information Home (Orient) Switch Input The Home or Orient function causes the motor shaft to rotate to a predefined home position. The homing function allows shaft rotation in the drive forward direction only. The home position is located when a machine mounted switch or the encoder “Index” pulse is activated (closed).

  • Page 44: Control Circuit Connections

    Section 1 General Information Control Circuit Connections Eight different operating modes are available in the Series 18H vector control. These 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.
  • Page 45 Section 1 General Information Figure 3-20 Keypad Control Connection Diagram ANALOG GND ANALOG INPUT 1 POT REFERENCE No Connections Required ANALOG INPUT +2 Encoder ANALOG INPUT –2 Input INDEX Note 3 ANALOG OUT 1 INDEX Programmable 0–5V Output (Factory Preset: Speed) Note 1 ANALOG OUT 2 +5VDC...

  • Page 46: Standard Run 3 Wire Mode Connections

    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.
  • Page 47 Section 1 General Information Figure 3-21 Standard Run 3-Wire Connection Diagram ANALOG GND ANALOG INPUT 1 Command Pot Note 1 POT REFERENCE ANALOG INPUT +2 Encoder Note 4 5VDC, 10VDC or 4-20mA Input ANALOG INPUT –2 INDEX Note 5 ANALOG OUT 1 Programmable 0–5V Output (Factory Preset: Speed) INDEX Note 2...

  • Page 48: Speed 2-Wire Mode Connections

    Section 1 General Information 15 Speed 2-Wire Mode Connections Switch Truth Table is defined in Table 3-12. 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.
  • Page 49 Section 1 General Information Figure 3-22 15 Speed 2-Wire Control Connection Diagram ANALOG GND ANALOG INPUT 1 POT REFERENCE No Connections ANALOG INPUT +2 Encoder ANALOG INPUT –2 Input INDEX Note 3 ANALOG OUT 1 Programmable 0–5V Output (Factory Preset: Speed) INDEX Note 1 ANALOG OUT 2...

  • Page 50: Fan Pump 2 Wire Control Mode

    Section 1 General Information Fan Pump 2 Wire Control Mode Figure 3-23 Fan Pump, 2 Wire Control Connection Diagram ANALOG GND 0-10VDC or ANALOG INPUT 1 Note 1 Command Pot POT REFERENCE ANALOG INPUT +2 Notes 1 and 2 Encoder 5VDC, 10VDC or 4-20mA ANALOG INPUT –2 Input...

  • Page 51: Fan Pump 3 Wire Control Mode

    Section 1 General Information Fan Pump 3 Wire Control Mode Figure 3-24 Fan Pump, 3 Wire Control Connection Diagram ANALOG GND ANALOG INPUT 1 0-10VDC or Note 1 POT REFERENCE Command Pot ANALOG INPUT +2 Encoder Notes 1 and 2 ANALOG INPUT –2 5VDC, 10VDC or 4-20mA.

  • Page 52: Bipolar Speed And Torque Mode Connections

    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 different acceleration rates, speed commands, jog speeds or to store tuning parameter values for different motors etc.
  • Page 53 Section 1 General Information Figure 3-25 Bipolar Speed or Torque Connection Diagram ANALOG GND ANALOG INPUT 1 Note 1 Command Pot POT REFERENCE ANALOG INPUT +2 Encoder Note 4 5VDC, 10VDC or 4-20mA Input ANALOG INPUT –2 INDEX Note 5 ANALOG OUT 1 Programmable 0–5V Output (Factory Preset: Speed) INDEX...

  • Page 54: Process Mode Connections

    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. Using two (2) inputs;...
  • Page 55 Selections are shown in Figure 3-26. Note: An input can only be used one time for Process Feedback, OR Setpoint Source, OR Feedforward. Figure 3-26 Simplified Process Control Block Diagram SETPOINT SOURCE Baldor Series “H” Control Available sources are: Set Point Command Potentiometer 10 Volts...

  • Page 56: Specific Process Mode Outputs

    Section 1 General Information Table 3-14 Process Mode Input Signal Compatibility Feedback Setpoint or Setpoint or 4-20mA 3-15 PSI J1-1 & 2 J1-4 & 5 5V EXB 10V EXB Feedforward Tach EXB J1-1 & 2 J1-4 & 5 Ë Ë Ë Ë Ë 5V EXB Ë...
  • Page 57 Section 1 General Information Figure 3-27 Process Mode Connection Diagram ANALOG GND ANALOG INPUT 1 Note 1 Command Pot POT REFERENCE ANALOG INPUT +2 Encoder Input Note 4 5VDC, 10VDC or 4-20mA ANALOG INPUT –2 INDEX Note 5 ANALOG OUT 1 Programmable 0–5V Output (Factory Preset: Speed) INDEX Note 2...

  • Page 58: Analog Inputs And Outputs

    Section 1 General Information Analog Inputs and Outputs 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 #1 or #2 may be grounded provided the common mode range is not exceeded.
  • Page 59 Section 1 General Information Analog Input #2 Analog input #2 accepts a differential command 5VDC, 10VDC or 4-20 mA. The operating mode is defined in the of the Level 1 Input block OPERATING MODE 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.
  • Page 60 Section 1 General Information Figure 3-29 Analog Inputs Equivalent Circuits 30KW 5.1V Zener -15VDC .033 mF 20KW – To Microprocessor 1.96KW +15VDC 10KW 10KW 4-20mA To Microprocessor – 10KW X N/C 10KW Notes: All OP Amps are TL082 or TL084 –...

  • Page 61: Analog Outputs

    Section 1 General Information 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 Table NO TAG of Section 4 of this manual.

  • Page 62: External Trip Input

    Section 1 General Information External Trip Input Terminal J1-16 is available for connection to a normally closed thermostat or overload relay in all operating modes as shown in Figure 3-32. 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 Trip fault.
  • Page 63 Section 1 General Information Figure 3-34 Opto-Input Equivalent Circuit (Using External Supply) Opto Input 1 Opto Input 1 Opto Input 2 Opto Input 2 Opto Input 3 Opto Input 3 Opto Input 4 Opto Input 4 Opto Input 5 Opto Input 5 Opto Input 6 Opto Input 6 Opto Input 7...

  • Page 64: Opto-Isolated Outputs

    Section 1 General Information Opto-Isolated Outputs Four programmable Opto-isolated outputs are available at terminals J1-19 through J1-22. See Figure 3-35. Each output may be programmed to represent one output condition. Table NO TAG The output conditions are defined in of Section 4 of this manual. The Opto-isolated outputs may be configured for sinking or sourcing 60 mA each.
  • Page 65 Section 1 General Information Figure 3-36 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...

  • Page 66: Pre-Operation Checklist

    Section 1 General Information Pre-Operation Checklist Check of Electrical Items CAUTION: After completing the installation but before you apply power, be sure to check the following items. Verify AC line voltage at source matches control rating. Inspect all power connections for accuracy, workmanship and tightness and compliance to codes.

  • Page 67: Power-Up Procedure

    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 &...

  • Page 68: Programming And Operation

    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. Figure 4-1 Keypad JOG - (Green) lights when Jog is active.

  • Page 69: 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 70: Display Mode Screens

    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 No faults present. Local keypad speed. mode. If in remote/serial mode, press local for this display. Press DISP key Display mode custom unit output rate (only if Level 2 Custom Units...

  • Page 71: Display Screens & Diagnostic Information Access

    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 No faults present. Local keypad speed. mode. If in remote/serial mode, press local for this display. Press DISP key 6 times Scroll to Diagnostic Information Diagnostic Access screen.

  • Page 72: 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 73: Program Mode

    Section 1 General Information Program Mode The Program Mode is used to: Enter motor data. Autotune the motor. 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 74: 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 75: 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 76: Initialize New Firmware

    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 Logo display for 5 seconds.

  • Page 77: Parameter Definitions

    Section 1 General Information Parameter Definitions To make programming easier, parameters have been arranged as 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 ( ) arrows to scroll through the parameter blocks.
  • Page 78 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 J1-11, J1-12, SPEEDS J1-13 and J1-14 when Operating Mode is set to 15 Speed.
  • Page 79 Section 1 General Information Table 4-2 Level 1 Parameter Block Definitions - Continued Block Title Parameter Description KEYPAD SETUP Keypad Stop Key Stop Key - Allows keypad “STOP” key to initiate motor stop during remote or serial operation (if Stop key is set to Remote ON). If active, pressing “STOP” automatically selects Local mode and initiates the stop command.
  • Page 80 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. Each output may be configured to any of the following conditions: #1 –...
  • Page 81 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 19 conditions (Continued) as follows: #1 and #2 Condition Description ABS Speed -...
  • Page 82 Section 1 General Information Table 4-2 Level 1 Parameter Block Definitions - Continued Block Title Parameter Description VECTOR CONTROL CTRL BASE Speed 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.
  • Page 83 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 operating modes are also selectable: Constant Torque and Variable Torque.
  • Page 84 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 the control. The greater the ratio, the more sinusoidal the output current waveform will be.
  • Page 85 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 86 BRAKE ADJUST Resistor Ohms The dynamic braking resistor value in ohms. Refer to dynamic braking manual or call Baldor for additional information. Resistor Watts The dynamic braking resistor watts rating. Refer to dynamic braking manual or call Baldor for additional information.
  • Page 87 Section 1 General Information Table 4-3 Level 2 Parameter Block Definitions Continued Block Title Parameter Description AUTO TUNING 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”...

  • Page 88: Troubleshooting

    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. Occasional visual 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.
  • Page 89 When fault cleared (Reset), the control will reset to factory preset values. Low INIT Bus V Insufficient bus voltage on startup. Memory Error EEPROM error occurred. Contact Baldor. New Base ID Control board was changed since last operation. No Faults Fault log is empty.

  • Page 90: How To Access The Fault Log

    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.

  • Page 91: 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, press local for this display. Press DISP key 6 times Scroll to Diagnostic Information Diagnostic Access screen.
  • Page 92 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. Verify fuses are good (or breaker is not tripped). Loose connections. Check input power termination. Verify connection of operator keypad. Adjust display contrast.
  • Page 93 Relocate control to cooler operating area. Add cooling fans or air conditioner to control cabinet. 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 leg current current sensors being used.
  • Page 94 Section 1 General Information Table 5-2 Troubleshooting Continued INDICATION POSSIBLE CAUSE CORRECTIVE ACTION Motor has wrong Analog input common mode voltage Connect control input source common to control common to minimize response to may be excessive. common mode voltage. Maximum common mode voltage at terminals Speed Command J1-4 and J1-5 is 15VDC referenced to chassis common.
  • Page 95 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 96 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 connections is not sufficient.
  • Page 97 Section 1 General Information Table 5-3 Power Base ID - Series 18H Power Base ID Power Base ID Power Base ID 230VAC 230VAC 460VAC 460VAC 575VAC 575VAC FIF10 / FIF40 FIF20 / FIF24 FIF10 / FIF40 FIF20 / FIF24 FIF10 / FIF40 FIF20 / FIF24 Catalog Catalog Catalog...

  • Page 98: Electrical Noise Considerations

    Section 1 General Information Electrical Noise Considerations All electronic devices including the Series 18H Control 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 99 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.
  • Page 100 Section 1 General Information Electrical Noise Considerations Continued Wires between Controls and Motors Output leads from a typical 460 VAC drive controller contain rapid voltage rises created by power semiconductors switching 650V in less than a microsecond, 1,000 to 10,000 times a second.

  • Page 101: Special Drive Situations

    PWM drives. For maximum benefit, the reactors should be mounted in the drive enclosure with short leads between the control and the reactors. Baldor offers a complete line of line and load reactors that will reduce ripple current and improve motor life.

  • Page 102: Control Enclosures

    Section 1 General Information Electrical Noise Considerations Continued Control Enclosures Motor controls mounted in a grounded enclosure should also be connected to earth ground with a separate conductor to ensure best ground connection. Often grounding the control to the grounded metallic enclosure is not sufficient. Usually painted surfaces and seals prevent solid metallic contact between the control and the panel enclosure.

  • Page 103: Wiring Practices

    Section 1 General Information Wiring Practices The type of wire used and how it is installed for specific applications makes the difference between obtaining reliable operation and creating additional problems. Power Wiring Conductors carrying power to anything (motor, heater, brake coil, or lighting units, for example) should be contained in conductive conduit that is grounded at both ends.

  • Page 104: Optical Isolation

    Section 1 General Information Optical Isolation Isolating electrical circuits with some form of light transmission reduces the electrical noise that is transmitted from one part of a circuit to another. That is, an electrical signal is converted to a light signal that is transmitted to a light receiver. This converts the light back to an electrical signal that has less noise than the input.
  • Page 105 Section 1 General Information 5-18 Troubleshooting MN718...

  • Page 106: Manual Tuning The Series 18H Control

    Section 6 Manual Tuning the Series 18H Control Manually Tuning the Control In some applications the drive cannot be accurately auto-tuned in an application. In these cases it is necessary to calculate the values needed to tune the drive and manually enter these calculated parameter values.

  • Page 107: Current Int Gain Parameter

    Section 1 General Information Current Int Gain Parameter The Current Int Gain parameter located in the Level 1 Vector Control Block is factory preset at 150 Hz. This setting is suitable for essentially all systems. DO NOT CHANGE WITHOUT FACTORY APPROVAL. Speed Prop Gain Parameter The Speed Prop Gain parameter located in the Level 1 Vector Control Block is factory set to 10.

  • Page 108: Pi Controller

    ) /s. The second equation shows that the ratio of K is a frequency in radians/sec. In the Baldor Series 18H AC Vector Control, the integral gain has been redefined to be, = (K ) / (2 ) Hz, and the transfer function is,...
  • Page 109 Section 1 General Information 6-4 Manual Tuning the Series 18H Control MN718...

  • Page 110: Specifications, Ratings & Dimensions

    Section 7 Specifications, Ratings & Dimensions Specifications: Horsepower 1-50 HP @ 230VAC 1-500 HP @ 460VAC 1-150 HP @ 575VAC Input Frequency 50/60 HZ Output Voltage 0 to Maximum Input VAC Output Current See Ratings Table Service Factor Duty Continuous Overload Capacity Constant Torque Mode: 170-200% for 3 secs...

  • Page 111: 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 112: Analog Outputs

    Section 1 General Information Other Analog Input: Full Scale Range 0 - 10 VDC Resolution 9 bits + sign Update Rate 500 s Analog Outputs: Analog Outputs 2 Assignable Full Scale Range 0 - 5 VDC Source Current 1 mA maximum Resolution 8 bits Update Rate...

  • Page 113: Ratings

    Section 1 General Information Ratings Series 18H Stock Products STANDARD 2.5 kHz PWM QUIET 8.0 kHz PWM CATALOG CATALOG INPUT INPUT SIZE SIZE CONSTANT TORQUE VARIABLE TORQUE CONSTANT TORQUE VARIABLE TORQUE VOLT VOLT ZD18H201–E, –W 0.75 0.75 0.56 0.75 ZD18H202–E, –W 0.75 ZD18H203–E, –W ZD18H205–E...
  • Page 114 Section 1 General Information Ratings Series 18H Custom High Peak Current Control STANDARD 2.5 kHz PWM QUIET 8.0 kHz PWM CATALOG CATALOG INPUT INPUT SIZE SIZE CONSTANT TORQUE VARIABLE TORQUE CONSTANT TORQUE VARIABLE TORQUE VOLT VOLT ZD18H210L–ER 11.1 11.1 ZD18H215L–ER 11.1 14.9 14.9...

  • Page 115: Terminal Tightening Torque Specifications

    Section 1 General Information Terminal Tightening Torque Specifications Table 7-4 Tightening Torque Specifications Tightening Torque Power TB1 Ground Control J1 D1/D2 B+/R1; B+; B–; or R2 230 VAC 230 VAC C t l Catalog No. Lb-in Lb-in Lb-in Lb-in Lb-in ZD18H201–E or W –...
  • Page 116 Section 1 General Information Table 7-4 Tightening Torque Specifications Continued Tightening Torque Power TB1 Ground Control J1 D1/D2 B+/R1; B+; B–; or R2 460 VAC 460 VAC C t l Catalog No. Lb-in Lb-in Lb-in Lb-in Lb-in ZD18H401–E or W –...
  • Page 117 Section 1 General Information Table 7-4 Tightening Torque Specifications Continued Tightening Torque 460 VAC 460 VAC Power TB1 Ground Control J1 D1/D2 Catalog No. B+/R1; B+; B–; or R2 Lb-in Lb-in Lb-in Lb-in Lb-in Continued ZD18H4100–EO ZD18H4150V–EO ZD18H4150–EO ZD18H4200–EO ZD18H4250–EO ZD18H4300–EO ZD18H4350–EO ZD18H4400–EO...
  • Page 118 Section 1 General Information Table 7-4 Tightening Torque Specifications Continued Tightening Torque Power TB1 Ground Control J1 D1/D2 B+/R1; B+; B–; or R2 575 VAC 575 VAC C t l Catalog No. Lb-in Lb-in Lb-in Lb-in Lb-in ZD18H501–E – – ZD18H502–E –...

  • Page 119: 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 7.70 (195.6mm) 7-10 Specifications, Ratings & Dimensions MN718...

  • Page 120: Size A Control - Through-Wall Mounting

    Section 1 General Information Size A Control – Through–Wall Mounting Steel Plate Gasket Standoffs 1/2 x 2-1/2 10–32 x 0.75 Truss screw & washer MN718 Specifications, Ratings & Dimensions 7-11...

  • Page 121: Size B 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 10.00 (254.0mm) 7-12 Specifications, Ratings & Dimensions MN718...

  • Page 122: Size B Control - Through-Wall Mounting

    Section 1 General Information Size B Control – Through–Wall Mounting Steel Plate Gasket Standoffs 1/2 x 2-1/2 10–32 x 0.75 Truss screw & washer MN718 Specifications, Ratings & Dimensions 7-13...

  • Page 123: Size C Control

    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 124: 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) CUSTOMER AIR INLET POWER CONNECTIONS 10.00 (254.0mm) 10.20 (259.0mm) MN718 Specifications, Ratings & Dimensions 7-15...

  • Page 125: Size E Control

    Section 1 General Information Dimensions Continued Size E Control Outlet Thru–wall Surface Mounting Flange Mounting Flange (9.5mm) 2 Places LOCAL PROG DISP SHIFT ENTER STOP RESET 30.00 (762mm) 5.75 6.25 2 Places (146mm) (159mm) (9.5mm) 17.70 (450mm) Air Inlet 7-16 Specifications, Ratings & Dimensions MN718...

  • Page 126: Size E Control - Through-Wall Mounting

    Section 1 General Information Dimensions Continued Size E Control – Through–Wall Mounting Mounting hole locations for Thru-Wall or surface mounting. Recommended hard- ware: 5/16 or M8. (4 Places) Mounting hole locations for Thru-Wall mounting using kit #0083991. Thru hole .218 (5.5mm) DIA. (4 Places) (716mm) 28.19 (711mm)
  • Page 127 Section 1 General Information Dimensions Continued Size E Control – Through–Wall Mounting Continued 14 Places Controller Assembly 4 Places Customer’s Panel Cut foam tape and apply to perimeter of opening (to seal installation of controller) Bracket 2 Places Bracket 2 Places Thru–Wall Mounting Kit No.

  • Page 128: Size F Control

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

  • Page 129: Size F Control - Through-Wall Mounting

    Section 1 General Information Dimensions Continued Size F Control – Through–Wall Mounting Mounting hole locations for Thru-Wall mounting Mounting hole locations for Thru-Wall mounting or without thru-wall mounting kit #0084001. using kit #0084001. Thru hole .218 (5.5mm) Thru hole .218 (5.5mm) DIA. (16 Places, DIA.
  • Page 130 Section 1 General Information Dimensions Continued Size F Control – Through–Wall Mounting Continued Controller 34 Places Assembly Customer’s Panel Cut foam tape and apply to perimeter of cutout (to seal installation of controller) Bracket 2 Places Bracket 2 Places Thru–Wall Mounting Kit No. V0084001 Parts List QTY Part No.

  • Page 131: Size G Control

    Section 1 General Information Dimensions Continued Size G Control 24.00 3.72 (609,6) (94,6) Removable Conduit Mounting Plates (Customer Power Connections) 8.63 (219) 8.63 (219) 12.41 (315) 2.66 (67,6) 31.50 (800) 23.63 (600) Outlet VECTOR DRIVE 90.55 (2300) 93.00 Intlet (2362) Grills (4) 47.25 (1200)

  • Page 132: 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 133 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 134 Section 1 General Information Dynamic Braking (DB) Hardware Continued 18H 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 135: 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 136: 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 137: 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 138: Parameter Values

    Appendix B Parameter Values 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 SPEEDS PRESET SPEED #2 1002 0-MAX Speed 0 RPM PRESET SPEED #3 1003...
  • Page 139 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 KEYPAD KEYPAD STANDARD RUN 15SPD FAN PUMP 2 WIRE FAN PUMP 3 WIRE SERIAL BIPOLAR PROCESS MODE...
  • Page 140 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 ABS SPEED (Continued) ABS TORQUE SPEED SPEED COMMAND PWM VOLTAGE FLUX CURRENT CMD FLUX CUR LOAD CURRENT...
  • Page 141 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 STD CONST TQ STD VAR TQ CONST TQ QUIET CONST TQ QUIET VAR TQ MIN OUTPUT SPEED 2002 0-MAX Speed...
  • Page 142 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 0-255 Ohms Factory Set ADJUST RESISTOR WATTS 2602 0-32767 Watts Factory Set DC BRAKE CURRENT 2603 0-100%...
  • Page 143 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 RS–232 ASCII, RS-485 ASCII RS–232 ASCII BAUD RATE 2802 9600, 19.2KB, 38.4KB, 57.6KB, 9600 115.2KB, 230.4KB DRIVE ADDRESS...

  • Page 144: Appendix C

    Appendix C MN718 Appendix C-1...

  • Page 145: Remote Keypad Mounting Template

    Section 1 General Information 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 C MN718...
  • Page 146 BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72902–2400 (501) 646–4711 Fax (501) 648–5792 Baldor Electric Company Printed in USA MN718 9/97 C&J 2500...

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