ADJUSTABLE SPEED DRIVE
Series 5 Inverter
NEMA 4X, IP-65
Installation & Operating Manual
8/01
MN781B
TABLE OF CONTENTS
Section
Page
i.
Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ii.
Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II.
Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
III.
Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IV. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
V.
Recommended High Voltage Dielectric Withstand Testing (Hi-Pot) . . . . . . . . . . . . . . . . . 8
VI. Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VII. AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
IX. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
X.
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XI. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tables
1.
Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.
General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.
Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.
Fault Recovery and Resetting the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.
Control Mode and Status LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5
Figures
1.
Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.
Enlarged View of Trimpot Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.
Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.
Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.
Remote Start/Stop Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.
Start/Stop Function Eliminated (Jumper Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8.
Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.
Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10. AC Line Input Voltage Selection (J1 and J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11. Motor Horsepower Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12. Reset Mode Selection (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
13. Motor Frequency Selection (J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14. Motor Frequency Multiplier Selection (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
15. Boost Mode Selection (J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
16. Hi-Pot Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17. MAX Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
18. MIN Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
19. ACCEL Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
20. DECEL Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21. COMP Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
22. CL Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
23. I2t Trip Time vs Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
24. BOOST Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ii
i.
SIMPLIFIED OPERATING INSTRUCTIONS
IMPORTANT – You must read these simplified operating instructions before proceeding.
These instructions are to be used as a reference only and are not intended to replace the
detailed instructions provided herein. You must read the Safety Warning below before
proceeding.
!
WARNING! Disconnect main power when making connections to the control.
A. AC Line Connection – Connect the AC line to L1 and L2 terminals of Terminal Block TB1
and the ground wire (Earth) to the green ground screw as shown in Figure 4, on page 6, and
as described in Section IIA, on page 6, and Section IIB, on page 6. Set Jumpers J1 and J2
to the corresponding AC line input voltage (115 or 208/230 Volts AC).
B. Motor Connection – Connect the motor to U, V and W terminals of Terminal Block TB1
as shown in Figure 4, on page 6, and as described in Section IIC, on page 6.
C. Start/Stop Switch – The control is supplied with a prewired Start/Stop Switch as
described in Section IIE, on page 6, which is used to start and stop the control. In Manual
Start Mode, this switch must be used to start the control each time the AC power is lost or
the control shuts down due to a fault.
D. Jumper Settings – All jumpers are factory set for most applications. Be sure Jumper J3
is set to the correct motor HP. See Section IIIB, on page 7.
E. AC Line Fusing – Install a fuse or circuit breaker in the AC line. Fuse each conductor
that is not at ground potential. See Section VII, on page 10, for recommended fuse size.
F. Trimpot Settings – All trimpots have been factory set as shown in Figure 2, on page 3.
Trimpots may be readjusted as described in Section VIII, on page 10.
G. Diagnostic LEDs – After power has been applied, observe the LEDs to verify proper control operation as described in Section IX, on page 13.
ii.
!
SAFETY WARNING! Please read carefully
This product should be installed and serviced by a qualified technician, electrician, or electrical maintenance person familiar with its operation and the hazards involved. Proper installation, which includes wiring, mounting in proper enclosure, fusing or other overcurrent protection,
and grounding can reduce the chance of electrical shocks, fires, or explosion in this product or
products used with this product, such as electric motors, switches, coils, solenoids, and/or
relays. Eye protection must be worn and insulated adjustment tools must be used when working with control under power. This product is constructed of materials (plastics, metals, carbon,
silicon, etc.) which may be a potential hazard. Proper shielding, grounding, and filtering of this
product can reduce the emission of radio frequency interference (RFI) which may adversely
affect sensitive electronic equipment. If further information is required on this product, contact
the factory. It is the responsibility of the equipment manufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product. (SW effective 11/1992.)
This control contains electronic Start/Stop circuits that can be used to start and stop the control. However these circuits are never to be used as safety disconnects since they are not failsafe. Use only the AC line for this purpose.
Be sure to follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product.
This product complies with all CE directives pertinent at the time of manufacture.
Contact factory for detailed installation and Declaration of Conformity. Installation of a
CE approved RFI filter is required. Additional shielded motor cable and/or AC line cables may
be required along with a signal isolator (ID5SI-2).
1
I.
INTRODUCTION
The Baldor ID5601-BO Adjustable Speed Drive is a variable speed control in a NEMA-4X / IP65 and watertight enclosure. It is designed to operate 208 - 230 Volt 3-phase AC induction
motors through 3.6 Amps RMS. The sine wave coded Pulse Width Modulated (PWM) output,
which operates at a frequency of 8 kHz, provides high motor torque, high efficiency and low
noise. The control operates from 115 or 208/230 Volt 50/60 Hz single phase AC line input.
Due to its user friendly design, tailoring to specific applications is easily accomplished via
selectable jumpers and trimpot adjustments. However, for most applications no adjustments
are necessary.
Main features include adjustable RMS Current Limit and I2t Motor Overload Protection. In
addition, Adjustable Slip Compensation provides excellent load regulation over a wide speed
range. Electronic Inrush Current Limiting eliminates harmful AC line inrush current and
Adjustable Linear Acceleration and Deceleration make the drive suitable for soft-start applications. Additional features include holding torque at zero speed and ride-through which provides a smooth recovery to the previous set speed during a momentary power loss.
Standard front panel features include diagnostic LEDs for power on and control status, a
Start/Stop Switch, Power On/Off Switch and a Main Speed Potentiometer. Other features include
a Barrier Terminal Block to facilitate wiring of the AC line and motor, adjustable trimpots (MAX, MIN,
ACCEL, DECEL, COMP, CL, BOOST) and selectable jumpers (line voltage, motor horsepower,
auto or manual reset modes, motor frequency, frequency multiplier, fixed or adjustable boost).
Optional accessories include a Forward-Stop-Reverse Switch, Signal Isolator, and Auto/Manual
Switch. Quick-connect terminals are provided for easy installation of all accessories.
STANDARD FEATURES
•
Motor Overload Protection (I2t)* – Provides motor overload protection which prevents motor
burnout and eliminates nuisance trips.
•
Electronic Inrush Current Limiting – Eliminates harmful inrush AC line current during startup.
•
Dual Voltage Input – The control operates from 115 or 208/230 Volt 50/60 Hz single phase
AC line Input.
•
Horsepower Selection – The control contains a horsepower selection jumper which eliminates the need to recalibrate the CL trimpot for different motors.
•
Short Circuit Protection – Shuts down the control if a short circuit occurs at the motor
(phase-to-phase).
•
Regeneration Protection – Eliminates tripping due to bus overvoltage caused by rapid
deceleration of high inertial loads.
•
Slip Compensation with Boost – Provides excellent load regulation over a wide speed range.
•
Start/Stop Switch – Provides electronic start and stop.
•
Power On/Off Swiitch – Disconects the AC line.
•
Ride-Through – Provides smooth recovery to the previous set speed during a momentary
power loss.
•
Diagnostic LEDs – Power on (POWER) and control status (STATUS).
•
Barrier Terminal Block – Facilitates wiring of motor and AC line.
•
Protection Features – Undervoltage and overvoltage protection. MOV input transient protection. Microcontroller self-monitoring and auto reboot. Short circuit protected phase-tophase at motor.
•
Industrial Duty Die-Cast Aluminum Case.
•
Holding Torque at Zero Speed – Resists motor shaft rotation when the control is in stop mode.
Note: * UL approved as an electronic overload protector for motors.
2
FIGURE 1 – CONTROL L AYOUT
(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)
WHITE
ORANGE
VIOLET
MAIN SPEED POTENTIOMETER
(BACK VIEW)
MAX
CON1
P2
CL
P1
FWD
R
Y
STATUS
REV
J7
POWER
B
G
STOP
START/STOP SWITCH
(BACK VIEW)
BOOST
J6
RUN
J5
COM
LED BOARD
RED
STOP
J4
FIX
BOOST
ADJ
1X
MULT J3
2X
60HZ
FREQ
50HZ
AUTO
1HP
3/4
1/2
1/4
230V
P3
MIN ACCEL DECEL COMP
MAN
115V
J2
R/F
BLACK
WHITE
NOTES:
1. REV TERMINAL IS USED
FOR OPTIONAL
FWD-STOP-REV SWITCH.
2. R/F, B- AND B+ TERMINALS
ARE USED FOR OPTIONAL
ID5SI-2 SIGNAL ISOLATOR.
J1
B-
BC-
BC0 BC+ B+
115V 230V
POWER ON/OFF SWITCH
BLUE
WHITE
L1A
L1B
L2A
L2B
TB1
MOTOR
BLUE
U
V
W
L1
L2
AC LINE
WHITE
FIGURE 2 – ENLARGED VIEW OF TRIMPOT SETTINGS
MAX
MIN ACCEL DECEL COMP
CL
BOOST
3
4
[241.96]
9.53
8.82
[224.00]
STOP
MANUAL
AUTO
90
100
0
STOP
START
STATUS
POWER
NEMA-4X / IP-65
POWER
OFF
ON
2.53
[64.35]
ADJUSTABLE SPEED DRIVE
REVERSE
FORWARD
80
10
% SPEED
70
60
20
50
30
40
5.06
[128.59]
5.86
[148.94]
RECOMMENDED MOUNTING SCREW: 1/4" (M6)
SHOWN WITH OPTIONAL AUTO/MANUAL AND FORWARD-STOP-REVERSE
8.20
[208.17]
0.31
[7.97]
5.51
[139.97]
FIGURE 3 – MECHANICAL SPECIFICATIONS (Inches / [mm])
TABLE 1 – ELECTRICAL RATINGS
AC Line Input Voltage
±10%, 50/60 Hz
(Single Phase Volts AC)
Maximum
Nominal
AC Line Input Current Output Voltage
(Amps AC)
(Volts AC)
Maximum Continuous
Output Load Current
(RMS Amps/Phase)
Maximum
Horsepower Rating
HP, (kW)
115
16
0 – 230
3.6
1, (0.75)
208/230
10
0 – 230
3.6
1, (0.75)
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS
Parameter
AC Line Input Voltage (Volts AC, ±10%, 50/60 Hz)
Maximum Load Capacity (% for 2 Minutes)
Switching Frequency (kHz)
Signal Following (Non-Isolated Input1) Input Voltage (Volts DC)
Signal Following Input Resolution (Bits)
Maximum Speed Trimpot (MAX) Range (% of Frequency Setting)
Minimum Speed Trimpot (MIN) Range (% of Frequency Setting)
Specification
Factory Setting
115 or 208/230
208/230
150
—
8
—
0–5
—
8
—
70 – 110
100
0 – 40
0
Acceleration Trimpot (ACCEL) Range (Seconds)
0.3 – 20
1.5
Deceleration Trimpot (DECEL) Range (Seconds)
0.3 – 20
1.5
Slip Compensation Trimpot (COMP) Range (Volts/Hz/Amp)
0–3
1.5
Current Limit Trimpot (CL) Range (% Range Setting)
0 – 200
160
Boost Trimpot (BOOST) Range for 50 Hz Output Frequency (Volts AC)
0 – 70
—
Boost Trimpot (BOOST) Range for 60 Hz Output Frequency (Volts AC)
0 – 35
5
Motor Horsepower Selection (HP)
1/4, 1/2, 3/4, 1
1
Output Frequency (Hz)
0 – 50, 0 – 60
0 – 60
Frequency Multiplier (1X, 2X)
Minimum Operating Frequency at Motor (Hz)
1, 2
1
1
—
Speed Regulation (30:1 Speed Range) (% Base Speed)2
2.5
—
Speed Range (Ratio)
60:1
—
0 – 45
—
Operating Temperature Range (°C)
Notes: 1. Requires an isolated signal. If a non-isolated signal voltage is used, install the ID5SI-2 Signal Isolator.
2. Dependent on motor performance.
II.
WIRING INSTRUCTIONS
!
WARNING! Read Safety Warning, on page 1, before using this control.
Disconnect the AC line before wiring.
Note: To avoid erratic operation, do not bundle AC line and motor wires with wires from signal following, Start/Stop Switch or any other signal wires. Use shielded cables on all signal
wiring over 12” (30cm). Shield should be Earth grounded on the control side only. Wire the
control in accordance with the National Electrical Code requirements and other codes that
may apply to your area. See Table 3 and Figure 4, on page 6.
Be sure to properly fuse each AC line conductor that is not at ground potential. Do not fuse neutral or grounded conductors. See Section VII, on page 10. A separate AC line switch or contactor must be wired as a disconnect so that each ungrounded conductor is opened. A Power
On/Off Switch may be used in lieu of, or in addition to, the Start/Stop Switch. The switch can be
wired for single pole or double pole operation, as required.
To maintain the watertight integrity of the control, be sure to use suitable watertight connectors and wiring which are appropriate for the application. Two 7/8” (22.2mm) knockout holes
are provided for standard 1/2” knockout connectors (not supplied) for wiring. A watertight
plug is provided if only one knockout is required.
The enclosure is designed with a hinged case so that when the front cover is open, all wiring
stays intact. To open the cover, the four screws must be loosened so they are no longer
engaged in the case bottom. After mounting and wiring, close the cover making sure that the
wires do not get caught or crimped as the cover is closed. Tighten all four cover screws so
that the gasket is slightly compressed. Do not over tighten.
5
TABLE 3 – TERMINAL BLOCK WIRING INFORMATION
Designation
Connection
Supply Wire Gauge (AWG - Cu)
Minimum
Maximum
Maximum Tightening Torque
(in-lbs)
AC Line Input
L1, L2
22
12
12
Motor
U, V, W
22
12
12
A. AC Line Connection – Wire the
AC line input to L1 and L2 terminals
of Terminal Block TB1 as shown in
Figure 4. Be sure both Jumpers J1
and J2 are set to the “115V” position for 115 Volt AC line input or to
the “230V” position for 208/230 Volt
AC line input.
FIGURE 4 – POWER CONNECTIONS
TB1
MOTOR U
B. Ground Connection – Earth
ground the control chassis using
the green ground screw that is provided on the inside of the control to
the right side of Terminal Block TB1
as shown in Figure 4.
C. Motor Connection – Wire the
motor leads to U, V and W terminals of Terminal Block TB1 as
shown in Figure 4. Be sure
Jumper J3 is set to the corresponding motor horsepower rating.
V
W
MOTOR
L1
L2 AC LINE
GROUND
(EARTH)
AC LINE
FIGURE 5 – REMOTE MAIN SPEED
POTENTIOMETER CONNECTION
WHITE (LOW)
ORANGE (WIPER)
VIOLET (HIGH)
CON1
MAIN SPEED POTENTIOMETER
D. Remote Main Speed
(BACK VIEW)
P3
P2
P1
Potentiometer Connection –
The control is supplied with a
prewired Main Speed
FIGURE 6 – REMOTE START/STOP
Potentiometer mounted on the front cover. To
SWITCH CONNECTION
operate the control from a remote potentiometer
(5kΩ), remove the white, orange, and violet
START/STOP SWITCH
potentiometer leads from P1, P2 and P3 termiWHITE
RUN
START
nals. The leads may be taped and left inside the
BLACK
COM
control.
RED
STOP
STOP
The potentiometer assembly may be removed if a
watertight seal is used to cover the hole in the front
cover. Connect the remote main speed potentiometer wires to P1 (low side), P2 (wiper) and P3
(high side) terminals as shown in Figure 5.
R/F
E. Remote Start/Stop Switch Connections – The control is FIGURE 7 – START/STOP
supplied with a prewired Start/Stop switch, mounted on the FUNCTION ELIMINATED
(JUMPER INSTALLED)
front cover. To operate the control from a remote Start/Stop
Switch (type (ON)-OFF-ON, SPDT), remove the white, black
and red wires from RUN, COM and STOP terminals. The
RUN
leads may be taped and left in the control. The switch
COM
assembly may be removed if a watertight seal is used to
STOP
cover the hole in the front cover. Connect the remote
R/F
Start/Stop Switch wires to RUN (momentary), COM (common) and STOP (constant) terminals as shown in Figure 6.
After applying power, momentarily set the Start/Stop Switch
to the "START" position. The motor will operate at the set speed of the Main Speed
Potentiometer. To stop the motor, set the Start/Stop Switch to the "STOP" position.
6
Note: To eliminate the Start/Stop function, connect RUN and COM terminals with the
jumper that is provided. See Figure 7, on page 6.
CAUTION! Using a jumper to eliminate the Start/Stop function will cause the motor to run
at the Main Speed Potentiometer setting when the AC line is applied.
F. Voltage Following Connection – An isolated 0 - 5
Volt DC analog signal can also be used to control
motor speed. See Figure 8.
FIGURE 8 – VOLTAGE
FOLLOWING CONNECTION
0 - 5V DC
(ISOLATED)
+
-
Note: If an isolated signal voltage is not available,
an optional signal isolator can be installed (ID5SI-2).
Connect the isolated signal voltage to P2 (+) and
P1 (-) terminals. The MIN trimpot must be set fully
counterclockwise.
CON1
P3
P2
P1
G. Enable Circuit Connection – The control can also be
started and stopped with an Enable circuit (close to
start). See Figure 9. The Enable
FIGURE 9 – ENABLE CIRCUIT CONNECTION
function is established by wiring a
switch in series with the orange
ENABLE
Main Speed Potentiometer lead
SWITCH OR RELAY
(CLOSE TO START)
WHITE (LOW)
which connects to P2 terminal.
ORANGE (WIPER)
When the Enable switch is closed,
VIOLET (HIGH)
the control will accelerate to the
Main Speed Potentiometer setting.
CON1
MAIN SPEED POTENTIOMETER
When the Enable switch is opened,
(BACK VIEW)
P3
P2
P1
the motor will coast to stop.
III.
SETTING SELECTABLE JUMPERS
The control circuit board has customer selectable jumpers which must be set before the
motor control can be used. See Figure 1, on page 3, for location of jumpers.
Note: Disconnect the AC line before changing position of jumpers.
A. AC Line Voltage Selection (J1 and J2) – Jumpers J1 and J2 are both factory set to the
“230V” position, for 208/230 Volt AC line input. For 115 Volt AC line input, set both
Jumpers J1 and J2 to the “115V” position. See Figure 10.
FIGURE 10 – AC LINE INPUT VOLTAGE SELECTION
Control Set for 208/230 Volt AC Line Input
(Factory Setting)
J1 Set for 208/230 Volt
AC Line Input
J2 Set for 208/230 Volt
AC Line Input
Control Set for 115 Volt AC Line Input
J1 Set for 115 Volt
AC Line Input
J2 Set for 115 Volt
AC Line Input
230V
230V
J1
J1
115V 230V
115V 230V
J2
J2
115V
B. Motor Horsepower Selection (J3) – Jumper J3
is factory set to the “1HP” position, for 1HP
motors. For motors of lower horsepower, set
Jumper J3 to the corresponding position for the
motor being used. See Figure 11.
115V
FIGURE 11 – MOTOR
HORSEPOWER SELECTION
J3 Set for 1 HP Motor Motor Horsepower
(Factory Setting)
HP, (kW)
1, (0.75)
C. Reset Mode Selection (J4) – Jumper J4 is factory set to the "MAN" position, for manual resetting
of the control every time the AC line is applied or
after a fault condition has occurred (undervoltage,
overvoltage, phase-to-phase short circuit and I2t
3/4, (0.5)
1/2, (0.37)
1/4, (0.18)
7
fault). To set the control to automatically reset after a
fault has been cleared, set Jumper J3 to the "AUTO"
position. See Figure 12. (Also see section VIB, on page
9 and Table 4, on page 10.)
WARNING!
The motor will automatically
restart when the AC line is applied, if Jumper
J4 is set to the "AUTO" or “MAN” position and the
Start/Stop Switch is eliminated with a jumper
installed between the RUN and COM terminals.
FIGURE 12 – RESTART
MODE SELECTION
J4 Set for Manual
Reset Mode
(Factory Setting)
!
D. Motor Frequency Selection (J5) – Jumper J5 is factory set to the “60Hz” position, for 60 Hz motors. For 50
Hz motors, set Jumper J5 to the “50Hz” position. See
Figure 13.
E. Motor Frequency Multiplier Selection (J6) – Jumper
J6 is factory set to the “1X” position, for motor frequency
corresponding to the frequency setting of Jumper J5 (50
or 60 Hz). To double the output frequency to the motor,
set Jumper J6 to the “2X” position (100 or 120 Hz). See
Figure 14.
Note: When doubling the motor frequency, the motor
will produce full torque up to its base speed. The torque
will be linearly reduced to 50% at the maximum doubled
frequency.
F. Boost Mode Selection (J7): Jumper J7 is factory set to
the "FIX" position, for fixed boost voltage. For adjustable
boost voltage, using the BOOST trimpot, set Jumper J7
to the "ADJ" position. See Figure 15. (See section
VIIIG, on page 12).
J4 Set for Auto
Reset Mode
AUTO
AUTO
J4
MAN
J4
FIGURE 13 – MOTOR
FREQUENCY SELECTION
J5 Set for
60 Hz Motors
(Factory Setting)
J5 Set for
50 Hz Motors
60 Hz
60 Hz
FREQ
FREQ
J5
50 Hz
J5
J6 Set for 1X
J6 Set for 2x
Motor Frequency
Motor Frequency
(Factory Setting)
1X
!
It is recommended that the control be mounted vertically on
a flat surface with adequate ventilation. Leave enough room
below the control to allow for AC line, motor connections and
any other wiring. Although the control is designed for outdoor
and wash down use, care should be taken to avoid extreme
hazardous locations where physical damage can occur. If
the control is mounted in a closed, unventilated location,
allow enough room for proper heat dissipation. If operating
the control at full rating, a minimum enclosure size of 12”W X
24”H X 12”D is required. See Figure 3, on page 4.
1X
MULT
J6
2X
MULT
J6
2X
FIGURE 15
BOOST MODE SELECTION
J7 Set for
J7 Set for
Fixed Boost
Adjustable Boost
(Factory Setting)
FIX
FIX
BOOST
J7
V.
50 Hz
FIGURE 14
MOTOR FREQUENCY
MULTIPLIER SELECTION
IV. MOUNTING INSTRUCTIONS
WARNING! This motor control is not designed to
be used in an explosion-proof application.
MAN
ADJ
BOOST
J7
ADJ
RECOMMENDED HIGH VOLTAGE DIELECTRIC
WITHSTAND TESTING (HI-POT)
Testing agencies such as UL, CSA, VDE, etc., usually require that equipment undergo a hipot test. In order to prevent catastrophic damage to the speed control, which has been
installed in the equipment, it is recommended that the following procedure be followed.
Figure 16, on page 9 shows a typical hi-pot test setup.
Note: All equipment AC line inputs must be disconnected from the AC power.
A. Connect all equipment AC power input lines together and connect them to the H.V. lead
of the hi-pot tester. Connect the RETURN lead of the hi-pot tester to the frame on which
the control and other auxiliary equipment are mounted.
8
B. The hi-pot tester must have an automatic ramp-up to the test voltage and an automatic
ramp-down to zero voltage.
Note: If the hi-pot tester does not have automatic ramping, then the hi-pot output must
be manually increased to the test voltage and then manually reduced to zero. This procedure must be followed for each machine to be tested. A suggested hi-pot tester is
Slaughter Model 2550.
WARNING! Instantaneously applying the hi-pot voltage will cause irreversible damage to the speed control.
!
C. The hi-pot test voltage should be set in accordance to the testing agency standards and
the leakage current should be set as low as possible without causing nuisance trips.
D. To eliminate motor speed control damage due to auxiliary equipment hi-pot failure, it is
also recommended that all signal inputs be wired together and connected to the AC input
lines as shown.
FIGURE 16 – HI-POT SETUP
HIGH VOLTAGE DIELECTRIC WITHSTAND TESTER
(HI-POT TESTER)
1
LEAKAGE
2
0
3
AC KILOVOLTS
0mA
10mA
RETURN
TEST
H. V.
RESET
VOLTAGE
CONNECT ALL SPEED CONTROL
TERMINALS TOGETHER
(MAIN POWER DISCONNECTED)
MAX
ZERO
MOTOR SPEED CONTROL
AC LINE INPUT
L1
L2
CONNECT HI-POT
TO BOTH
AC LINE INPUTS
AUXILIARY EQUIPMENT
L1
MOTOR
TERMINALS
MOTOR WIRES
FRAME
SIGNAL INPUTS
P1
L2
P2
CHASSIS
P3
CHASSIS
MACHINE OR EQUIPMENT FRAME
VI. CONTROL OPERATION
A. Start-Up Procedure – After the control has been properly setup (jumpers and trimpots
set to desired positions and wiring completed), the startup procedure can begin. If the AC
power has been properly brought to the control, the POWER LED will be illuminated
green once the Power On/Off Switch is set to the “ON” position. The STATUS LED will
indicate control status as described in Section IX, on page 13. To start the control,
momentarily set the Start/Stop Switch to the "START" position. The motor will begin to
accelerate to the set speed.
Note: If the motor rotates in the incorrect direction, it will be necessary to disconnect the
AC line, reverse any two motor leads, and repeat the startup procedure.
B. Fault Recovery – The control has four fault states – undervoltage, overvoltage, short circuit at the motor (phase-to-phase) and I2t overload protection. To recover from any fault,
it is necessary to momentarily set the Start/Stop Switch to the "START" position.
If the Start/Stop function has been eliminated by installing a jumper between RUN and
COM terminals, then it will be necessary to either disconnect the AC line until the STATUS LED indicates an undervoltage fault (approximately 20 seconds) or use the
Start/Stop Switch (if installed).
9
TABLE 4 – FAULT RECOVERY & RESETTING THE CONTROL*
Auto Mode
Manual Mode
Auto or Manual Mode
with Start/Stop Switch Installed with Start/Stop Switch Installed with Start/stop Switch Removed
Fault
Undervoltage Control will automatically reset.
Reset the control with the
Start/Stop Switch.
Control will automatically reset.
Overvoltage Control will automatically reset.
Reset the control with the
Start/Stop Switch.
Control will automatically reset.
Short Circuit Control will automatically reset.
Reset the control with the
Start/Stop Switch.
Control will automatically reset.
Reset the control with the
Start/Stop Switch.
Disconnect and reconnect the AC
line.
Reset the control with the
Start/Stop Switch.
It
2
*Fault must be cleared before the control can be reset.
WARNING! The motor will automatically start when the AC line is applied or a
fault is cleared, if Jumper J4 is set to the “AUTO” or “MAN” position and the
Start/Stop Switch is eliminated.
!
VII. AC LINE FUSING
This control does not contain AC line fuses. Most electrical codes require that each
ungrounded conductor contain circuit protection. It is recommended to install a 20 Amp fuse
(Littelfuse 326, Buss ABC or equivalent) or a circuit breaker in series with each ungrounded
conductor. Check all electrical codes that apply to the application. Do not fuse motor leads.
VIII. TRIMPOT ADJUSTMENTS
The control circuit board contains trimpots, which are factory set
for most applications. Figure 2, on page 3 illustrates the location
of the trimpots and their approximate factory calibrated positions.
Some applications may require readjustment of the trimpots in
order to tailor the control for a specific requirement. Readjust
trimpots as described below.
WARNING! If possible, do not adjust trimpots with
the main power applied. If adjustments are made
with the main power applied, an insulated adjustment tool
must be used and safety glasses must be worn. High voltage exists in this control. Fire and/or electrocution can
result if caution is not exercised. Safety Warning, on page 1,
must be read before proceeding.
!
A. Maximum Speed (MAX): Sets the maximum speed of the
motor. The MAX trimpot is factory set for 100% of base motor
speed. For a higher maximum speed setting, rotate the MAX
trimpot clockwise. For a lower maximum speed setting,
rotate the MAX trimpot counterclockwise. See Figure 17.
FIGURE 17
MAX TRIMPOT RANGE
80
75
90
100
70
110
Percent of Frequency Setting
(Shown Factory Set to 100%)
FIGURE 18
MIN TRIMPOT RANGE
30
15
35
0
40
Percent of Frequency Setting
(Shown Factory Set to 0%)
B. Minimum Speed (MIN): Sets the minimum speed of the
motor. The MIN trimpot is factory set for 0% speed. For a
FIGURE 19
higher minimum speed setting, rotate the MIN trimpot clockACCEL TRIMPOT RANGE
wise. See Figure 18.
C. Acceleration (ACCEL): Sets the amount of time for the
motor to accelerate from zero speed to max speed. The
ACCEL trimpot is factory set for 1.5 seconds acceleration.
For more rapid acceleration time, rotate the ACCEL trimpot
counterclockwise. For longer acceleration time, rotate the
ACCEL trimpot clockwise. See Figure 19.
Note: Rapid acceleration settings may cause the current limit
circuit to activate, which will extend the acceleration time.
5
2.5
12.5
1.5
0.3
20
Seconds
(Shown Factory Set to 1.5 Seconds)
D. Deceleration (DECEL): Sets the amount of time for the motor to decelerate from max
speed to zero speed. The DECEL trimpot is factory set for 1.5 seconds deceleration. For
10
FIGURE 20
more rapid deceleration time, rotate the DECEL trimpot counterclockwise. For longer deceleration time, rotate the DECEL DECEL TRIMPOT RANGE
trimpot clockwise. See Figure 20.
5
Note: To provide increased resolution of the ACCEL and
DECEL trimpots, 50% rotation covers 0.3 - 5 seconds.
2.5
Application Note: On applications with high inertial loads,
the deceleration may automatically increase in time. This will
slow down the rate of speed decrease to prevent the bus voltage from rising to the overvoltage trip point. This function is
called regeneration protection. It is recommended that for
very high inertial loads that both the ACCEL and DECEL
trimpots should not be set to less than ten (10) seconds.
0.3
2. Run the motor and set the unloaded speed to approximately 50%.
20
Seconds
(Shown Factory Set to 1.5 Seconds)
FIGURE 21
COMP TRIMPOT RANGE
E. Slip Compensation (COMP) – Sets the amount of
Volts/Hz/Amp to maintain set motor speed under varying
loads. The COMP trimpot is factory set for 1.5 Volts/Hz/Amp.
The slip compensation may be adjusted by the COMP trimpot as described below. See Figure 21.
1. Wire an ammeter in series with one motor phase.
12.5
1.5
1.5
0.8
2.3
0
3
Volts/Hz/Amp
Shown Factory Set to 1.5 Volts/Hz/Amp
FIGURE 22
CL TRIMPOT RANGE
3. Load the motor to the rated motor nameplate current
(Amps AC).
120
4. Adjust the COMP trimpot so that the loaded RPM is equal
to the unloaded RPM.
80
160
5. The motor is now compensated to provide constant
speed under varying loads.
40
200
F. Current Limit with I t Shutdown (CL) – Sets the current
limit (overload), which limits the maximum current to the
motor. The current limit set point is established by the setting
of Jumper J3 and the setting of the CL trimpot. See Figure 22.
2
Percent of Range Setting
(Shown Factory Set to 160%)
FIGURE 23 – I2t TRIP TIME vs MOTOR CURRENT
50
10
I2t TRIP TIME
(minutes)
FACTORY CL
SETTING (160%)
1.0
0.1
110
120
130
140
MOTOR CURRENT (%)
150
160
NOTES: 1. The CL set point is factory set to 160% of nominal motor current.
2. I2t Will not trip below 120% of the CL setting.
11
The CL trimpot is factory set for 160% of Jumper J3 range setting. For a higher current
limit setting, rotate the CL trimpot clockwise. For a lower current limit setting, rotate the
CL trimpot counterclockwise. The current limit also contains I2t trip function. The control
will trip according to a predetermined current vs. time function. The trip curve is directly
related to the CL set point and can be changed with the CL trimpot. See Figure 23 on
page 11.
CAUTION! Adjusting the CL above 160% of the motor rating may cause overheating of
the motor. Do not leave the motor in a locked rotor condition for more than a few seconds since motor damage may occur.
G. Boost (BOOST) – Sets the amount of boost voltage to the
FIGURE 24
motor. Jumper J7 is factory set to the "FIX" position, which BOOST TRIMPOT RANGE
provides a predefined amount of boost voltage for 50 Hz and
16
60 Hz motors. To adjust the amount of boost voltage to the
9
23
motor, set Jumper J7 to the "ADJ" position. The amount of
boost voltage may be adjusted by the BOOST trimpot as
5
described below. See Figure 24.
0
35
1. Connect an analog AC ammeter in series with one of the
motor leads.
Volts
(Shown Factory Set to 5 Volts)
Note: Generally, digital or clamp-on ammeters do not
yield accurate readings.
2. Run the motor unloaded at approximately 4 Hz (or 120 RPM).
Note: An unloaded motor with excessive boost will draw more current than a partially loaded motor.
3. Adjust the BOOST trimpot until the ammeter reading reaches the motor nameplate
rating.
4. Using the Main Speed Potentiometer, slowly adjust the motor speed over a 0 - 15 Hz
(0 - 450 RPM) range. If the motor current exceeds the nameplate rating, lower the
boost setting.
WARNING! TO AVOID MOTOR WINDING OVERHEATING AND FAILURE, DO
NOT OVERBOOST THE MOTOR.
TABLE 5 – CONTROL MODE AND STATUS LED INDICATION
Status LED Information
Control Mode
Flash Rate
Run
Stop
Color Sequence
Illumination Duration Seconds
Slow Flash
Green
1 Sec On - 1 Sec Off
Constant
Steady
Yellow
Stand-By1
Slow Flash
Yellow
1 Sec On - 1 Sec Off
Short Circuit
Slow Flash
Red
1 Sec On - 1 Sec Off
I2t Fault
Quick Flash
Red
0.25 Sec On - 0.25 Sec Off
Steady
Red
Constant
Overload
Undervoltage
Quick Flash
Red - Yellow
0.25 Sec Red - 0.25 Sec Yellow
Overvoltage
Slow Flash
Red - Yellow
1 Sec Red - 1 Sec Yellow
Recovered Undervoltage2
Quick Flash
Red - Yellow - Off - Green - Off
0.25 Sec Red - 0.25 Sec Yellow 0.5 Sec Off - 1 Sec Green - 0.5 Sec Off
Recovered Overvoltage2
Slow Flash
Red - Yellow - Off - Green - Off
1 Sec Red - 1 Sec Yellow - 0.5 Sec Off 1 Sec Green - 0.5 Sec Off
Notes: 1. Only if the Forward-Stop-Reverse Switch is installed
2. Only if the control is in Manual Reset Mode (Jumper J4 set to the “MAN” position).
12
IX. DIAGNOSTIC LEDs
The motor control is designed with LEDs mounted on the front cover to display the control’s
operational status.
A. Power On (ON) – Indicates the presence of bus voltage.
B. Status (STATUS) – The Status LED is a tricolor LED that provides indication of the control’s operational status including installation problems such as incorrect input voltage,
overvoltage, undervoltage and control miswiring. It also provides a "normal" indication if
all control and microcontroller operating parameters are proper. See Table 5 on page 12.
X.
OPTIONAL ACCESSORIES
Complete instructions and connection diagrams are supplied with all accessories to facilitate
installation.
A. Forward-Stop-Reverse Switch (ID5FSR-1) – Provides motor reversing and stop functions. Mounts on the enclosure cover and is supplied with a switch seal to maintain watertight integrity.
B. Signal Isolator/Run Relay (ID5SI-2) – Provides isolation between a non-isolated signal
voltage source and the drive and contains a Run Relay which can be used to turn on or
off equipment or to signal a warning if the control is put into the Stop Mode or a fault has
occured.
C. Auto/Manual Switch (ID5AMS-1) – When used with the ID5SI-2, it either selects an isolated signal from the ID5SI-2 or the Main Speed Potentiometer. Mounts on the enclosure
cover and is supplied with a switch seal to maintain watertight integrity.
13
XI. LIMITED WARRANTY
For a period of 2 years from date of original purchase, BALDOR will repair or replace without
charge controls 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. This warranty is in lieu of any other warranty or guarantee expressed
or implied. BALDOR shall not be held responsible for any expense (including installation and
removal), inconvenience, or consequential damage, including injury to any person, caused by
items of our manufacture or sale. (Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply.) In any event,
BALDOR’s total liability, under all circumstances, shall not exceed the full purchase price of
the control. Claims for purchase price refunds, repairs, or replacements must be referred to
BALDOR with all pertinent data as to the defect, the date purchased, the task performed by
the control, and the problem encountered. No liability is assumed for expendable items such
as fuses.
Goods may be returned only with written notification including a BALDOR Return
Authorization Number and any return shipments must be prepaid.
Baldor Electric Company
P.O. Box 2400
Ft. Smith, AR 72902-2400
(501) 646-4711
Fax (501) 648-5792
(A40299) – Rev. A – 3/2001
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