Isolated Encoder Expansion Board Installation and Operating Manual

Isolated Encoder Expansion Board Installation and Operating Manual
Isolated Encoder
Expansion Board
Catalog No. EXB008A01
Installation and Operating Manual
6/98
MN1317
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
Expansion Board Description . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-15HP Size A and B Controls . . . . . . . . . . . . . . . . . . .
Single Expansion Board Installation . . . . . . . . . . . . .
Dual Expansion Board Installation . . . . . . . . . . . . . .
15HP Size C and Larger AC Controls . . . . . . . . . . . . .
Single Expansion Board Installation . . . . . . . . . . . . .
Dual Expansion Board Installation . . . . . . . . . . . . . .
SCR DC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Expansion Board Installation . . . . . . . . . . . . .
Dual Expansion Board Installation . . . . . . . . . . . . . .
Section 4
Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jumper Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-2
1-3
1-3
2-1
2-1
3-1
3-1
3-2
3-2
3-4
3-6
3-6
3-8
3-10
3-10
3-11
4-1
4-1
4-5
Table of Contents i
ii Table of Contents
Section 1
General Information
Introduction
The Baldor controls represent the latest technology in
microprocessor based motor controls. In addition to the user
programmable parameters available in every control, many
different expansion boards are available from Baldor to further
customize the control to most any application.
Expansion boards are categorized by compatibility into two
groups: Group 1 and Group 2, see Table 1-1. A board from
either group may be used alone in a control. If two boards are to
be used, one board must be from Group 1 and the other from
Group 2.
Note: Using two Group 1 or two Group 2 boards in the same
control is not allowed.
Table 1-1 Group 1 and Group 2 Board Categories
Group 1 Board Name
Catalog No.
Isolated Input Expansion Board
Master Pulse Reference/
Isolated Pulse Follower
DC Tachometer Interface
Isolated Encoder Expansion
Board
Resolver to Digital Interface
EXB003A01
EXB005A01
Baldor
Manual No.
MN1314
MN1312
EXB006A01
EXB008A01
MN1311
MN1317
EXB009A01
MN1313
EXB001A01
EXB002A01
MN1310
MN1310
EXB004A01
MN1315
EXB007A02
MN1316
EXB010A01
MN1319
Group 2 Board Name
RS-232 Serial Communication
RS-422/RS-485 High Speed
Serial Communication
Four Output Relays/3-15 PSI
Pneumatic Expansion Board
High Resolution Analog I/O
Expansion Board
2 Isolated Analog Output/ 3 Relay
Output Expansion Board
General Information 1-1
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. 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 or property caused by items of our manufacture
or sale. (Some states do not allow 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.
1-2 General Information
Safety Notice
This equipment contains voltages that may be as great 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.
Improper use can cause serious or fatal injury. Only qualified
personnel should attempt the start-up procedure or troubleshoot
this equipment.
PRECAUTIONS
WARNING: Do not touch any circuit board, power device
or electrical connection before you first
ensure that power has been disconnected
and there is no high voltage present from
this equipment or other equipment to which
it is connected. Electrical shock can cause
serious or fatal injury. Only qualified
personnel should attempt the start-up
procedure or troubleshoot this equipment.
WARNING: Be sure that you are completely familiar with
the safe operation of this equipment. This
equipment may be connected to other
machines that have rotating parts or parts
that are controlled by this equipment.
Improper use can cause serious or fatal
injury. Only qualified personnel should
attempt the start-up procedure or
troubleshoot this equipment.
General Information 1-3
WARNING: Be sure the system is properly grounded
before applying power. Do not apply AC
power before you ensure that all grounding
instructions have been followed. Electrical
shock can cause serious or fatal injury.
WARNING: Do not remove cover for at least five (5)
minutes after AC power is disconnected to
allow capacitors to discharge. Dangerous
voltages are present inside the equipment.
Electrical shock can cause serious or fatal
injury.
WARNING: Improper operation of control may cause
violent motion of the motor shaft and driven
equipment. Be certain that unexpected
motor shaft movement will not cause injury
to personnel or damage to equipment. Peak
torque of several times the rated motor
torque can occur during control failure.
WARNING: Motor circuit may have high voltage present
whenever AC power is applied, even when
motor is not rotating. Electrical shock can
cause serious or fatal injury.
Caution:
To prevent equipment damage, be certain
that the electrical service is not capable of
delivering more than the maximum line short
circuit current amperes listed in the
appropriate control manual, 230 VAC, 460
VAC or 575 VAC maximum per control rating.
1-4 General Information
Section 2
Expansion Board Description
Introduction
Isolated encoder expansion board
Catalog No. EXB008A01
Features:
Mounting Group 1
Electrically Isolated Encoder Inputs
Electrically Isolated Power Supply
Encoder Retransmit Signals
5, 12, or 15 VDC Power Supply
The isolated encoder expansion board optically isolates the
encoder signals from a non–isolated motor. This board also
provides an electrically isolated power source of 5, 12 or 15 VDC
for the encoder.
Encoder channel A, A, B, and B retransmit signals and index
channel inputs are jumper selectable. Retransmit signals are
transmitted as 5 VDC levels.
Table 2-1 describes the supply voltages and current, input and
output channels, retransmit voltage and connector types for the
isolated encoder expansion board.
Table 2-1 Characteristics
Encoder Supply Voltage
5 12
5,
12, or 15 VDC – Jumper Selectable
Encoder Supply Current
(Maximum)
300mA @ 5VDC, 100mA @ 12VDC and
100mA @ 15VDC
Encoder Input Channels
A, A, B, and B – Standard C and C –
Selectable
Encoder Retransmit Voltage
5 VDC
Encoder Output Channels
A, A – Standard
B, and B – Selectable
Connector
Screw Terminals
Terminal tightening torque is 7lb–in. (0.8Nm) maximum.
Description 2-1
2-2 Description
Section 3
Installation
Board Installation
This section describes the Expansion Board installation
procedure.
Caution:
Before you proceed, be sure to read and
become familiar with the safety precautions
at the beginning of this manual. Do not
proceed if you are unsure of the safety
precautions described. If you have any
questions, contact BALDOR before you
proceed.
1. Remove the expansion board from the shipping container.
2. Remove all packing material from the board.
Caution:
Be sure all packing materials are removed
from the board. Conductive foam may be
present on the connectors to prevent static
build up during shipping. This can prevent
proper circuit operation.
Installation differs between the 1-15 HP Size A and B controls
and the 15HP Size C and larger AC controls and the SCR DC
controls. If you are installing only one board, refer to the “Single
Expansion Board Installation” procedure. If you are installing two
expansion boards (or a second board) refer to the “Dual
Expansion Board Installation” procedure.
Installation 3-1
1-15HP Size A and B Controls
(For all 15H Inverter, 18H Vector, and 23H Servo).
Single Expansion Board Installation
Procedure:
1. Be sure drive operation is terminated and secured.
2. Remove all power sources from the control.
3. Wait at least 5 minutes for internal capacitors to discharge.
4. Remove the four (4) Phillips head screws that secure the
control cover.
5. Remove the control cover.
6. Remove the #6 screw at position MH1 (upper left on the
main circuit board. See Figure 3-1.
7. Install the long standoffs provided in the installation
hardware as shown in Figure 3-1. (Be sure the
Male/Female standoff is at position MH1. The other three
are Female/Female.)
8. Slide the expansion board male connector into the female
connector of the control board.
9. Securely mount the expansion board to the standoffs
installed in step 7 using #6 screws provided in the
installation hardware. See Figure 3-2.
10. The mechanical installation of the expansion board is now
complete. Refer to Section 4 of this manual and configure
the jumpers as desired. Also complete the wiring before
you proceed to step 11.
11. When complete, install the control cover using the four (4)
Phillips head screws.
12. Restore all power sources to the control.
13. Restore drive operation.
3-2 Installation
Figure 3-1 Single Expansion Board Installation
Expansion Board
Remove screw
(Labeled MH1 in
Main PCB Screen).
Install Male/Female
Standoff.
Main Control
Board
Install Female/Female
Aluminum Standoff.
Install Female/Female
Nylon Standoff.
Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.
Figure 3-2 Single Expansion Board Installation
#6 Screw
Group 1 or 2 Expansion Board
Long Aluminum or
Nylon Standoff
Female/Female shown. Use Male/Female
in place of (MH1) screw Figure 3-1.
Main Circuit Board
Installation 3-3
1-15HP Size A and B Controls (Continued)
Dual Expansion Board Installation
Procedure:
1. Be sure drive operation is terminated and secured.
2. Remove all power sources from the control.
3. Wait at least 5 minutes for internal capacitors to discharge.
4. Remove the four (4) Phillips head screws that secure the
control cover.
5. Remove the control cover.
6. Remove the #6 screw at position MH1 (upper left on the
main circuit board. See Figure 3-1.
7. Install the long standoffs provided in the installation
hardware as shown in Figure 3-1. (Be sure the
Male/Female standoff is at position MH1. The other three
are Female/Female.)
8. Slide the Group 1 board male connector into the female
connector of the control board. See Figure 3-3.
9. Securely mount the Group 1 expansion board to the
standoffs installed in step 7 using the 4 short aluminum
standoffs provided in the installation hardware. See Figure
3-3.
10. The mechanical installation of the Group 1 expansion board
is now complete. Refer to the manual for the Group 1 board
and configure the jumpers as desired. Also complete the
wiring before you proceed to step 11.
11. Install the Group 2 board on top of the previously installed
Group 1 board by plugging the female connector onto the
male connector of the Group 1 board as shown in Figure
3-3.
12. Secure this Group 2 board to the Group 1 board using the
#6 screws provided.
3-4 Installation
1-15HP Size A and B Controls
Dual Expansion Board Installation (Continued)
13. The mechanical installation of the first expansion board is
now complete. Refer to the manual for the Group 2 board
and configure any jumpers and switches as desired. Also
complete the wiring for this board before you install the
cover.
14. When complete, install the control cover using the four (4)
Phillips head screws.
15. Restore all power sources to the control.
16. Restore drive operation.
Figure 3-3 Dual Expansion Board Installation
#6 Screw
Group 2 Expansion Board
Female Connector
Short
Aluminum
Standoff
Male Connector
Group 1 Expansion Board
Long
Aluminum or
Nylon Standoff
Female/Female shown. Use Male/Female
in place of (MH1) screw (Figure 3-1).
Main Circuit Board
Installation 3-5
15HP Size C and Larger AC Controls
(For all 15H Inverter, 21H Line Regen Inverter, 18H Vector, 22H
Line Regen Vector and 23H Servo).
Single Expansion Board Installation
Procedure:
1. Be sure drive operation is terminated and secured.
2. Remove all power sources from the control.
3. Wait at least 5 minutes for internal capacitors to discharge.
4. Remove the four (4) Phillips head screws (1/4 turn) that
secure the control cover. (On floor mounted G size
enclosures, open the enclosure door).
5. Remove the control cover.
6. Slide the expansion board male connector into the female
connector of the control board. See Figure 3-4.
7. Securely mount the expansion board to the sheet metal
mounting plate using the #6 screws provided in the
installation hardware. See Figure 3-5.
8. The mechanical installation of the expansion board is now
complete. Refer to Section 4 of this manual and configure
the jumpers as desired. Also complete the wiring before
you proceed to step 9.
9. When complete, install the control cover using the four (4)
Phillips head screws (1/4 turn). (On floor mounted G size
enclosures, close the enclosure door).
10. Restore all power sources to the control.
11. Restore drive operation.
3-6 Installation
15HP Size C and Larger AC Controls
Single Expansion Board Installation (Continued)
Figure 3-4 Single Expansion Board Installation
Expansion Board
Motor Control Board
Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.
Figure 3-5 Single Expansion Board Installation
#6 Screw
Group 1 or 2 Expansion Board
Sheet Metal Mounting Plate
Installation 3-7
15HP Size C and Larger AC Controls (Continued)
Dual Expansion Board Installation
Procedure:
1. Be sure drive operation is terminated and secured.
2. Remove all power sources from the control.
3. Wait at least 5 minutes for internal capacitors to discharge.
4. Remove the four (4) Phillips head screws (1/4 turn) that
secure the control cover. (On floor mounted G size
enclosures, open the enclosure door).
5. Remove the control cover.
6. Slide the Group 1 expansion board male connector into the
female connector of the control board. See Figure 3-4.
7. Securely mount the Group 1 expansion board to the sheet
metal mounting plate using the short standoffs provided in
the installation hardware. See Figure 3-6.
8. The mechanical installation of the expansion board is now
complete. Refer to the manual for the Group 1 board and
configure the jumpers as desired. Also complete the wiring
before you proceed to step 9.
9. Install the Group 2 board on top of the previously installed
Group 1 board by plugging the female connector onto the
male connector of the Group 1 board as shown in Figure
3-6.
10. Secure this Group 2 board to the Group 1 board using the
#6 screws provided. See Figure 3-6.
11. The mechanical installation of the expansion board is now
complete. Refer to the manual for the Group 2 board and
configure any jumpers and switches as desired. Also
complete the wiring for this board before you install the
cover.
3-8 Installation
15HP Size C and Larger AC Controls
Dual Expansion Board Installation (Continued)
12. When complete, install the control cover using the four (4)
Phillips head screws (1/4 turn). (On floor mounted G size
enclosures, close the enclosure door).
13. Restore all power sources to the control.
14. Restore drive operation.
Figure 3-6 Dual Expansion Board Installation
#6 Screw
Group 2 Expansion Board
Female Connector
Short Aluminum
Standoff
Male Connector
Group 1 Expansion Board
Control Board Mounting Plate
Installation 3-9
SCR DC Controls
(For 19H and 20H SCR DC Controls).
Single Expansion Board Installation
Procedure:
1. Be sure drive operation is terminated and secured.
2. Remove all power sources from the control.
3. Wait at least 5 minutes for internal capacitors to discharge.
4. Slide the expansion board male connector into the female
connector of the control board. See Figure 3-4.
5. Securely mount the expansion board to the sheet metal
mounting plate using the #6 screws provided in the
installation hardware. See Figure 3-5.
6. The mechanical installation of the expansion board is now
complete. Refer to the Group 1 manual and configure the
jumpers as desired. Also complete the wiring before you
proceed to step 7.
7. Restore all power sources to the control.
8. Restore drive operation.
3-10 Installation
SCR DC Controls (Continued)
Dual Expansion Board Installation
Procedure:
1. Be sure drive operation is terminated and secured.
2. Remove all power sources from the control.
3. Wait at least 5 minutes for internal capacitors to discharge.
4. Slide the Group 1 board male connector into the female
connector of the control board. See Figure 3-4.
5. Securely mount the Group 1 expansion board to the sheet
metal mounting plate using the short standoffs provided in
the installation hardware. See Figure 3-6.
6. The mechanical installation of the expansion board is now
complete. Refer to the Group 1 manual and configure the
jumpers as desired. Also complete the wiring before you
proceed to step 7.
7. Install the Group 2 board on top of the previously installed
Group 1 board by plugging the female connector onto the
male connector of the Group 1 board as shown in Figure
3-6.
8. Secure this Group 2 board to the Group 1 board using the
#6 screws provided. See Figure 3-6.
9. The mechanical installation of the expansion board is now
complete. Refer to the manual for the Group 2 board and
configure any jumpers and switches as desired. Also
complete the wiring for this board before you proceed to
step 10.
10. Restore all power sources to the control.
11. Restore drive operation.
Installation 3-11
3-12 Installation
Section 4
Hardware Setup
Overview
Isolated Encoder Expansion Board
Catalog Number EXB008A01
Features:
Mounting Group 1
Electrically Isolated Encoder Inputs
Electrically Isolated Power Supply
Encoder Retransmit Signals
5, 12, or 15 VDC Power Supply
Important:
If the Isolated Encoder Expansion Board is installed in a Vector
control that has a feedback module installed, the feedback
module must be removed to prevent interference with the
expansion board. Figure 4-1 shows how to identify the feedback
module on the DSP Main Control Board. The main control board
is where the keypad plugs in.
Setup 4-1
Figure 4-1 Feedback Module Identification
Main
Control
Board
Feedback
Module
If your Vector control does not look like the one pictured in Figure
4-1, do not perform the feedback module removal procedure.
Instead, continue onto page 4-4.
4-2 Setup
Feedback Module Removal Procedure
If your Vector control looks like the one pictured in Figure 4-1,
perform the following procedure:
The resolver feedback module must be removed from the main
control board to change the JP1 position. Use the following
procedure.
1.
2.
Be sure drive operation is terminated and secured.
Remove all power sources from the control. Wait at least 5
minutes for internal capacitors to discharge.
3. Remove the control cover.
4. Use a grounded wrist strap connected to chassis ground.
5. Firmly grasp the Resolver Feedback Module and remove it
from its connectors on the main control board. Be careful
not to bend the pins by twisting or lifting the module
unevenly.
6. Place the Resolver Feedback Module in an antistatic bag
and store it in a clean area for future use.
7. Install the control cover.
Now there is no conflict between this module and the Resolver to
Digital expansion board signal inputs to the control board. The
Resolver to Digital expansion board will provide the input signals
for the control board to use. Continue on page 4-3.
Setup 4-3
Isolated Encoder Expansion Board Description
The isolated encoder expansion board provides electrically
isolated encoder signals from a non–isolated motor to the motor
control board. Also an electrically isolated encoder power
source of 5, 12 or 15 VDC is provided. Isolated encoder inputs
51–58 provides the motor encoder feedback that is normally
provided at main control board inputs 23–30 respectively
(located on the motor control board).
Encoder supply voltages of 5, 12 or 15 VDC are set by jumpers
on the expansion board. Encoder channel A, A, B, and B
retransmit signals are jumper selectable and are also available
on terminals 55, 56, 59 and 60 respectively. Terminals 55 and
56 may be used as index channel inputs or B channel
retransmits. Retransmit signals are transmitted as 5 VDC levels.
Please note the encoder retransmit signals on the main control
board are still available with the isolated encoder expansion
board installed.
4-4 Setup
Jumper Definitions
JMP1
Table 4-1 defines the 3 jumper positions to set the encoder
DC Voltage Level. Place JMP1 in the proper position for
desired encoder supply voltage.
JMP2
Table 4-2 defines the two positions of JMP2 that determine
the operation of terminal 56.
JMP3
Table 4-3 defines the two positions of JMP3 that determine
the operation of terminal 55.
Table 4-4 defines the 10 terminal connections at the expansion
board.
Table 4-1
Jumper – JMP1
DC Voltage Level
1–2
+ 15
3–4
+12
5–6
+5
Table 4-2
Jumper – JMP2
Terminal Function
1–2
B Channel Retransmit
3–4
C Channel Input
Table 4-3
Jumper – JMP3
Terminal Function
1–2
B Channel Retransmit
3–4
C Channel Input
Setup 4-5
Table 4-4 Terminal Connections
Terminal # and
Jumper Position
Jumper #2
Using C Channel
(Index) Input
3–4
Using B Channel
Retransmit
1–2
Jumper #3
3–4
1–2
51
A Input
A Input
52
A Input
A Input
53
B Input
B Input
54
B Input
B Input
55
C Input
B Retransmit
56
C Input
B Retransmit
57
VDC Ref (+)
VDC Ref (+)
58
VDC Ref (–)
VDC Ref (–)
59
A Retransmit
A Retransmit
60
A Retransmit
A Retransmit
Terminal tightening torque is 7lb–in. (0.8Nm) maximum.
4-6 Setup
Figure 4-2 Jumper and Terminal Locations
Terminal tightening torque is 7lb–in. (0.8Nm) maximum.
Setup 4-7
4-8 Setup
BALDOR ELECTRIC COMPANY
P.O. Box 2400
Fort Smith, AR 72902–2400
(501) 646–4711
Fax (501) 648–5792
 Baldor Electric Company
MN1317
Printed in USA
6/98 C&J2500
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