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Baldor 22H series Installation & Operating Manual

Line regen ac flux vector control vector drive.
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VECTOR DRIVE
SERIES 22H
Line Regen
AC Flux Vector Control
Installation & Operating Manual
9/97
MN722
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Table of Contents

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   Summary of Contents for Baldor 22H series

  • Page 1 VECTOR DRIVE SERIES 22H Line Regen AC Flux Vector Control Installation & Operating Manual 9/97 MN722...

  • Page 2: Table Of Contents

    Table of Contents Section 1 Quick Start Guide ................Overview .
  • Page 3 ..................Baldor Keypad .
  • Page 4 Section 1 General Information Section 6 Manual Tuning the Series 22H Control ............. Manually Tuning the Control .
  • Page 5 Section 1 General Information iv Table of Contents MN722...

  • 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 22H control and motor 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: General Information

    DC Bus voltage is always controlled. Therefore, line voltage transients do not affect the output voltage to the motor. The Baldor Series 22H control may be used in many different applications. It may be programmed by the user to operate in different operating zones. It can also be configured to operate in a number of modes depending upon the application requirements and user preference.

  • 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 22H 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 Section 1 General Information Table 3-1 lists the Watts Loss ratings for Series 22H controls. Table 3-1 Series 22H Watts Loss Ratings. STD PWM BOOST STD PWM QUIET PWM CONTROL CONV & REG Loss Line Reactor Loss At Full Total QUIET PWM CONTROL CONV &...
  • Page 14 Section 1 General Information Table 3-1 Series 22H Watts Loss Ratings Continued STD PWM BOOST STD PWM QUIET PWM CONTROL CONV & REG Loss Line Reactor Loss At Full Total QUIET PWM CONTROL CONV & INV FIXED Load Total Losses At Full Losses Losses...

  • Page 15: 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. Through the Wall Mounting Control sizes E and F are designed for panel or through the wall installation. To mount a control through the wall, an optional Through the Wall mounting kit must be purchased.

  • Page 16: 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 17: 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 Figures 3-1 and 3-2.
  • Page 18 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 19: Load Reactors

    Section 1 General Information Load Reactors Line reactors may be used at the control output to the motor. When used this way, they are called Load Reactors. Load reactors serve several functions that include: Protect the control from a short circuit at the motor. Limit the rate of rise of motor surge currents.
  • Page 20 Section 1 General Information Current Requirements The input current for each control is given in Table 3-2 and the short circuit requirements are given in Table 3-3. The control may be damaged if input current exceeds ratings of Table 3-3. Table 3-2 Input Current Requirements 230VAC 460VAC...

  • Page 21: Protection Devices

    Section 1 General Information Protection Devices Be sure a suitable input power protection device is installed. Use the recommended circuit breaker or fuses listed in Table 3-5. Input and output wire size is based on the use of copper conductor wire rated at 75 C. The table is specified for NEMA B motors. Circuit Breaker: 3 phase, thermal magnetic.
  • Page 22 Section 1 General Information Wire Size and Protection Devices Table 3-5 lists the recommended wire size and the breaker or fuse size for each control. The specified wire sizes and protective devices are based on the maximum output power possible from the control. If the control is programmed for an operating zone that provides less output power, the wire size and the rating of the protective devices may be reduced but must meet NEC and other applicable codes.
  • Page 23 Section 1 General Information Single Phase Operation Single phase operation is not possible for Series 22H Line Regen Vector Controls. Operating the Control at a Reduced Input Voltage Series 22H Controls use a DC Bus regulation technique that provides full output voltage (240VAC for 230VAC Controls;...

  • Page 24: Hardware Changes For Reduced Voltage Input

    Section 1 General Information Hardware Changes for Reduced Voltage Input Size C+, D+,D, E, F and G+ controls all require modification for operation at a reduced line voltage (less than rated nominal). Table 3-8 defines the modifications for each enclosure size. Figure 3-1 shows the locations of the transformer locations for each enclosure size.
  • Page 25 Section 1 General Information Size C+, D, D+ E, and F size control procedure: Control Transformer Terminate drive operation and disable the control. 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 Section 1 General Information Size G+control procedure: (Refer to Figure 3-3.) Control Transformer 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 27: Ac Input Power & Motor Connections

    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 28 Note 2 Notes: See “Protective Devices” described previously in this section. Shield wires inside a metal conduit. Baldor Series 22HXXX-EL 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 29 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 Optional components not provided with 22H Control. 3% Line Note 4 Reactor Note 2 Phase Sensitive Inputs Boost Regulator L2A L3A Filter Baldor Series 22HXXX-EK Phase Sensitive Inputs Control Boost Regulator to Filter to Control Control Size Filter (5 ft. max.) (10 ft. max.) Note 3 D &...

  • Page 31: 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 3-7 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 32 J1–29 (+5VDC) J1–30 (Common) No Connection Note: Encoders other than a Baldor Standard Vector Encoder may require different connections. Refer to information provided by the manufacturer and connect the proper signals to the “Control End” J1 connections. Single Ended Connections Differential inputs are recommended for best noise immunity.

  • Page 33: Buffered Encoder Output

    Section 1 General Information Buffered Encoder Output The control provides a buffered encoder output on pins J1-31 to J1-38 as shown in Figure 3-8. This output may be used by external hardware to monitor the encoder signals. It is recommended that this output only drive one output circuit load. Figure 3-8 Buffered Encoder Output +5VDC COMMON...
  • Page 34 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 35: Control Circuit Connections

    Section 1 General Information Control Circuit Connections There are two control boards in a Series 22H Vector Control. The Converting Control Board is used to rectify and process the incoming power. The Power Output Control Board provides the inverting and power output functions. The keypad is normally connected to the Power Output Control Board.

  • Page 36: Power Output Control Board Connections

    Section 1 General Information Power Output Control Board Connections Eight operating modes are available in the Series 22H 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 Level 1 Input block, Operating Mode parameter.

  • Page 37: Keypad Mode Connections

    Section 1 General Information Keypad Mode Connections To operate in the keypad mode, set the Level 1 Input block, Operating Mode parameter to Keypad. In this mode, the External Trip input is active (if the Level 2 Protection block, External Trip parameter is set to ON), the Enable input is active (if the Level 2 Protection block, Local Enable INP is set to ON) and the Opto Outputs are active.
  • Page 38 Section 1 General Information Figure 3-11 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 39: 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 3-12 or logic signals from another device.
  • Page 40 Section 1 General Information Figure 3-12 Standard Run 3-Wire Connection Diagram ANALOG GND Command Pot ANALOG INPUT 1 Note 1 or 0-10VDC POT REFERENCE ANALOG INPUT +2 5VDC, 10VDC or Encoder Note 4 4-20mA Input ANALOG INPUT –2 INDEX Note 5 ANALOG OUT 1 Programmable 0–5V Output (Factory Preset: Speed) INDEX...

  • Page 41: Speed 2-wire Mode Connections

    Section 1 General Information 15 Speed 2-Wire Mode Connections Switch Truth Table is defined in Table 3-9. 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 3-13 or logic signals from another device.
  • Page 42 Section 1 General Information Figure 3-13 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 43 Section 1 General Information Fan Pump 2 Wire Control Mode Figure 3-14 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 5VDC, 10VDC or 4-20mA. Encoder ANALOG INPUT –2 Input...
  • Page 44 Section 1 General Information Fan Pump 3 Wire Control Mode Figure 3-15 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 5VDC, 10VDC or 4-20mA.

  • Page 45: 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 46 Section 1 General Information Figure 3-16 Bipolar Speed or Torque Connection Diagram ANALOG GND ANALOG INPUT 1 Command Pot Note 1 POT REFERENCE or 0-10VDC ANALOG INPUT +2 Encoder Note 4 5VDC or 10VDC or Input ANALOG INPUT –2 4-20mA INDEX Note 5 ANALOG OUT 1...

  • Page 47: 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 3-17. The process control loop may be configured in either of two ways. Using two (2) inputs;...
  • Page 48 Closed When Process Mode is Enabled (J1–13) Tachometer EXB Set Point adjustment limit None w/ integral clamp to max limit value PROCESS FEEDFORWARD Existing Baldor Control System Motor Control COMMAND SELECT Available sources are: Differential Potentiometer 10 Volts Gd s...

  • Page 49: Specific Process Mode Outputs

    Section 1 General Information Table 3-11 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 50 Section 1 General Information Figure 3-18 Process Mode Connection Diagram ANALOG GND Command Pot Note 1 ANALOG INPUT 1 or 0-10VDC POT REFERENCE ANALOG INPUT +2 Encoder 5VDC or 10VDC or Note 4 Input ANALOG INPUT –2 4-20mA INDEX Note 5 ANALOG OUT 1 Programmable 0–5V Output (Factory Preset: Speed) INDEX...
  • Page 51 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 3-19. Either analog input #1 or #2 may be grounded provided the common mode range is not exceeded.
  • Page 52 Section 1 General Information Analog Input #2 Analog input #2 accepts a 0-5VDC, 0-10VDC, 5VDC, 10VDC or 4-20 mA command input. 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, Bipolar or Process Control modes (not available for Keypad, 15 Speed 2 Wire or the Serial operating modes).
  • Page 53 Section 1 General Information Figure 3-20 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 54 Section 1 General Information Analog Outputs Two programmable analog outputs are provided on J1-6 and J1-7. See Figure 3-22. 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 55: External Trip Input

    Section 1 General Information External Trip Input To activate the External Trip input, the External Trip parameter in the programming Protection Block must be set to “ON”. Terminal J1-16 is available for connection to a normally closed thermostat or overload relay in all operating modes as shown in Figure 3-23.
  • Page 56 Section 1 General Information Figure 3-25 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 57: 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 3-26. 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 50 mA each.

  • Page 58: Pre-operation Checklist

    Section 1 General Information Figure 3-27 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 59: 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 and motor are correctly installed (see Section 3 for procedures) and that you have an understanding of the keypad programming &...

  • Page 60: Programming And Operation

    Section 4 Programming and Operation Overview The Series 22H Vector Line Regen Control has two control boards installed. The “Converting Control Board” is used to rectify and process the incoming power. The “Power Output Control Board” provides the inverting and power output functions. Each converter board has its own J1 terminal strip.

  • Page 61: Baldor Keypad

    Section 1 General Information Baldor Keypad 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 62: 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 63: 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 showing custom Output rate display will only...

  • Page 64: 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 65: 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 66: Program Mode

    Section 1 General Information Program Mode The Program Mode is used to: Enter motor data. CALC Presets and 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 67: 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 68: 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 69: 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 70: Parameter Definitions

    Section 1 General Information Parameter Definitions Converter Control Board Parameters Converting section parameters are programmed at the factory. Table 4-1 is a list of the parameters that can be changed. However,to make any parameter adjustments the keypad must be installed in the Converting Control Board as described previously in this section.
  • Page 71 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 72: Power Output Control Board Parameters

    Section 1 General Information Power Output Control Board Parameters To make programming easier, parameters have been arranged into the two level structure shown in Table 4-3. 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 73 Section 1 General Information Table 4-4 Level 1 Parameter Definitions Power Output Control Board 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 74 Section 1 General Information Table 4-4 Level 1 Parameter Definitions Power Output Control Board - 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).
  • Page 75 Section 1 General Information Table 4-4 Level 1 Parameter Definitions Power Output Control Board - 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 76 Section 1 General Information Table 4-4 Level 1 Parameter Definitions Power Output Control Board - 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...
  • Page 77 Section 1 General Information Table 4-4 Level 1 Parameter Definitions Power Output Control Board - 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.
  • Page 78 Section 1 General Information Table 4-5 Level 2 Parameter Definitions Power Output Control Board 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 79 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 80 Section 1 General Information Caution: If an automatic restart of the motor control could cause injury to personnel, the automatic restart feature should be disabled by changing the Level 2 Miscellaneous block, Restart Auto/Man parameter to manual. Table 4-5 Level 2 Parameter Definitions Power Output Control Board - Continued Block Title...
  • Page 81 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 82 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 83 Section 1 General Information Table 4-5 Level 2 Parameter Definitions Power Output Control Board - 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 84: Troubleshooting

    Section 5 Troubleshooting Baldor Series 22H Controls require very little maintenance and should provide years of trouble free operation when installed and applied correctly. Occasional visual inspection should be considered to insure tight wiring connections and to avoid the build up of any dust, dirt, or foreign debris which can reduce heat dissipation.
  • Page 85 When fault cleared (Reset), the control should reset to factory preset values. Low INIT Bus V Insufficient bus voltage on startup. Memory Error EEPROM error occurred. Contact Baldor. P Reset Watchdog timer detected error. New Base ID Control board sensed a different power base since last time it was powered up.
  • Page 86 When fault cleared (Reset), the control should reset to factory preset values. Low INIT Bus V Insufficient bus voltage on startup. Memory Error EEPROM error occurred. Contact Baldor. New Base ID Control board sensed a different power base since last time it was powered up. No Faults Fault log is empty.

  • Page 87: 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 88: How To Clear The Fault Log

    Section 1 General Information How to Clear the Fault Log Use the following procedure to clear the fault log and reset the internal clock. Action Description Display Comments Apply Power Logo display for 5 seconds. Display mode showing output Display mode. frequency.

  • Page 89: 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. In remote/serial mode, disable drive then press local for this display.
  • Page 90 Cooling fans or air path is clogged. Clean fans and air path. Ensure fans are operating. Invalid Base ID Control does not recognize Press “RESET” key on keypad. If fault remains, call Baldor. converter power base. Logic Supply FLT Power supply malfunctioned. Replace logic power supply.
  • Page 91 Section 3 of this manual. Excessive current draw. Disconnect motor wiring and retry test Disconnect motor wiring and retry test. If fault remains, call Baldor. If fault remains call Baldor Power device saturated. Electrical noise from DC coils.
  • Page 92 Check encoder connections. Separate encoder leads from power wiring. Use Baldor encoder cable. Cross encoder wires and power leads at 90 . Electrically isolate encoder from motor. Install optional Isolated Encoder Feedback expansion board.
  • Page 93 Improper AC line voltage. Check input AC voltage level. Memory Error EEPROM memory fault occurred. Press “RESET” key on keypad. If fault remains, call Baldor. P Reset Power was cycled before Bus Press “RESET” key on keypad. voltage reached 0VDC.
  • Page 94 Section 1 General Information Table 5-4 Power Output Section 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 Check encoder connections. Separate encoder leads from power wiring. Use Baldor encoder cable. Cross encoder wires and power leads at 90 . Electrically isolate encoder from motor. Install optional Isolated Encoder Feedback expansion 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 5-5 Power Base ID - Series 22H 230VAC 460VAC Catalog Numbers Power Catalog Numbers Power Base Base ID No. ID No. ZD22H210–EL ZD22H410–EL ZD22H215–EL ZD22H415–EK ZD22H220–EL ZD22H420–EL ZD22H225–EL ZD22H425–EL ZD22H230–EL ZD22H430–EL ZD22H240–EL ZD22H440–EL ZD22H250–EL ZD22H450–EL ZD22H460–EK ZD22H475–EK ZD22H4100–EK...

  • Page 98: Electrical Noise Considerations

    Section 1 General Information Electrical Noise Considerations All electronic devices including the Series 22H 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 5-22 Troubleshooting MN722...

  • Page 106: Manual Tuning The Series 22h Control

    Section 6 Manual Tuning the Series 22H 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 22H 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 22H Control MN722...

  • Page 110: Specifications, Ratings & Dimensions

    Section 7 Specifications, Ratings & Dimensions Specifications: Horsepower 10-50 HP @ 230VAC 10-450 HP @ 460VAC Input Frequency 50/60 HZ Note: 50Hz operation requires a 15% control derating. Output Voltage 0 to Maximum Input VAC Output Current See Ratings Table Service Factor Duty Continuous...

  • 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 sec Analog Outputs: Analog Outputs 2 Assignable Full Scale Range 0 - 5 VDC Source Current 1 mA maximum Resolution 8 bits Update Rate...

  • Page 113: Diagnostic Indications

    Section 1 General Information Diagnostic Indications: Power Output Section: Current Sense Fault Over speed New Base ID DC Bus High Ground Fault Lost User Data Torque Proving DC Bus Low Over Current FLT Soft Start Fault Following Error External Trip Overload - 3 sec No EXB Installed Encoder Loss...

  • Page 114: Series 22h Vector Control Ratings

    Section 1 General Information Series 22H Vector Control Ratings ENCLO- STANDARD 2.5 kHz PWM QUIET 8.0 kHz PWM CATALOG CATALOG INPUT INPUT SURE SURE CONSTANT TORQUE VARIABLE TORQUE CONSTANT TORQUE VARIABLE TORQUE VOLT SIZE ZD22H210–EL ZD22H215–EL 11.1 11.1 11.1 ZD22H220–EL 14.9 14.9 11.1...
  • Page 115 Section 1 General Information Table 7-6 Matched Component Matrix Control Control 230 VAC 380-415 VAC 460 VAC Boost Regulator FIlter Specification 3% Line Reactor 4% Line Reactor 3% Line Reactor Specification No. Specification No. Catalog No. Catalog No. Catalog No. Catalog No.

  • Page 116: Terminal Tightening Torque Specifications

    Section 1 General Information Terminal Tightening Torque Specifications Table 7-7 Tightening Torque Specifications Tightening Torque Power TB1 Ground Control J1 Interface J3 & Filter Line Reactor Catalog No. L1A, L2A, L3A J1 & J2 Lb-in Lb-in Lb-in Lb-in Lb-in Lb-in ZD22H210–EL ZD22H215–EL ZD22H220–EL...

  • Page 117: Dimensions

    Section 1 General Information Dimensions Size C+ Control 12.20(309.9mm) 11.50 0.40 (292.1) 12.00(304.8) (10.2) 5.25 0.50 5.25 0.31 LIFTING (12.7) (133.3) (133.3) FLANGE (7.9) AIR OUTLET AIR OUTLET AIR OUTLET LOCAL PROG DISP SHIFT ENTER STOP RESET 28.32 (719.3) AIR INLET (Top) 29.25 (743.0) 30.00...

  • Page 118: Size D+ Control

    Section 1 General Information Dimensions Continued Size D+ Control 0.40(10.2) 12.20(309.9) 14.50(368.3) LIFTING FLANGE 0.50 6.75 6.75 12.00(304.8) (12.7) (171.5) (171.5) 0.31 (7.9) AIR OUTLET AIR OUTLET AIR OUTLET LOCAL PROG DISP SHIFT ENTER STOP RESET 36.00 (914.4) AIR INLET (Top) 35.25 (895.4) 34.08...

  • Page 119: 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) 7-10 Specifications, Ratings & Dimensions MN722...

  • Page 120: 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 MN722 Specifications, Ratings &...

  • Page 121: 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 122 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 123: 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 124: 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 125 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 126: Size G+ Control

    Section 1 General Information Dimensions Continued Size G+ Control 35.18 [893.6] 3.72 24.00 [94.6] [609.6] Removable Conduit Mounting Plates (Customer Power COnnections) 8.63 [219] 8.63 12.41 [219] [315] 2.66 [67.6] 63.00 23.63 [1600] [600] Outlet Grills LINE REGEN 93.00 [2362] Inlet Grills (8) 90.55...

  • Page 127: Ek Controls - Filter Assembly

    Section 1 General Information EK Controls - Filter Assembly LF1015 LF2015 Dimension Dimension 7.75 196.9 10.25 260.3 4.00 101.6 5.00 127.0 1.81 46.0 3.31 84.1 15.25 387.4 18.00 457.2 3.52 89.4 3.65 92.7 2.00 50.8 2.00 50.8 0.92 23.3 0.92 23.3 7-18 Specifications, Ratings &...

  • Page 128: Ek Controls - Boost Regulators

    Section 1 General Information EK Controls - Boost Regulators STACK 0.380 4 PLACES X1 L2 X2 L3 “HR” Electrical Specification/Approximate Weight Dimensions - inches Baldor P/N Amps V2080709 1.20 11.75 2.25 5.50 9.25 4.50 12.25 5.75 0.50 1.50 .44” DIA X .75” LONG SLOT...
  • Page 129 EK Controls - Boost Regulators Continued .44” DIA X .75” LONG SLOT 4 PLACES TERMINAL BLOCK To Control J3 Connector STACK “HR” Electrical Specifications/Approximate Weight Dimensions - inches Baldor P/N Amps V2080712 0.50 18.00 2.50 9.50 4.50 8.25 13.56 12.00 0.63...

  • Page 130: Converter Section Parameter Values

    Appendix A Converter Section Parameter Values Table A-1 Converter Section Parameter Block Values Level 1 Level 1 Blocks Block Title Parameter Adjustable Range Factory User Setting Setting MISC FACTORY SETTINGS YES, NO LINE INDUCTOR CALC BUS CAPACITANCE 50 – 500% 100% DAC SELECTION AB BC CROSS...

  • Page 131: Power Output Section Parameter Values

    Section 1 General Information Power Output Section Parameter Values Table A-2 Power Output 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...
  • Page 132 Section 1 General Information Table A-2 Power Output 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...
  • Page 133 Section 1 General Information Table A-2 Power Output 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...
  • Page 134 Section 1 General Information Table A-3 Power Output 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...
  • Page 135 Section 1 General Information Table A-3 Power Output 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...
  • Page 136 Section 1 General Information Table A-3 Power Output Parameter Block Values Level 2 Continued Level 2 Blocks - Continued Block Title Parameter Adjustable Range Factory User Setting AUTO-TUNING CALC PRESETS 2508 YES, NO CMD OFFSET TRM Measures and trims out offset voltage at Analog Input #2 (J1-4 &...
  • Page 137 Section 1 General Information A-8 Appendix A MN722...
  • Page 138 Appendix B MN722 Appendix B-1...

  • Page 139: 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. B-2 Appendix B MN722...
  • Page 140 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 MN722 9/97 C&J2500...

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