Resolver to Digital
Expansion Board
Catalog No. EXB009A01
Installation and Operating Manual
6/98
MN1313
Table of Contents
Section
1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-2
1-3
1-3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited
Safety Notice
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section
2
Expansion Board Description
.
. . . . . . . . . . . . . . . . . . .
2–1
2–1
2–1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section
3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
Board Installation
1-15HP Size A and B Controls
Single Expansion Board Installation
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
. . . . . . . . . . . . .
.
3-2
.
3-2
Dual Expansion Board Installation
15HP Size C and Larger AC Controls
Single Expansion Board Installation
.
3-4
.
.
. . . . . . . . . . . .
. . . . . . . . . . . .
3-6
3-6
Dual Expansion Board Installation
SCR DC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Expansion Board Installation . . . . . . . . . . . .
Dual Expansion Board Installation . . . . . . . . . . . . .
.
. . . . . . . . . . . . .
3-8
.
3-10
3-10
3-11
.
.
Table of Contents i
Section
4
Hardware Setup
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
4–3
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section
5
Software Setup
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
Series 18H and 22H Vector Controls . . . . . . . . . . .
Series 19H and 20H DC SCR Controls . . . . . . . . .
5–1
5–1
5–1
5–1
Configure Control Software
.
.
.
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.
Baldor
Manual No.
Isolated Input Expansion Board
Master Pulse Reference/
Isolated Pulse Follower
EXB003A01
EXB005A01
MN1314
MN1312
DC Tachometer Interface
Isolated Encoder Expansion
Board
EXB006A01
EXB008A01
MN1311
MN1317
Resolver to Digital Interface
EXB009A01
MN1313
Group 2 Board Name
RS-232 Serial Communication
RS-422/RS-485 High Speed
Serial Communication
EXB001A01
EXB002A01
MN1310
MN1310
Four Output Relays/3-15 PSI
Pneumatic Expansion Board
High Resolution Analog I/O
Expansion Board
2 Isolated Analog Output/ 3 Relay EXB010A01
Output Expansion Board
EXB004A01
EXB007A02
MN1315
MN1316
MN1319
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
W
ARNING: 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.
W
ARNING: 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
W
ARNING: 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
.
W
ARNING: 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.
W
ARNING: 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.
W
ARNING: 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
Resolver to Digital Interface Expansion Board
Catalog No. EXB009A01
Group 1 Expansion Board
The Resolver to Digital Interface expansion board provides
closed loop operation for the Baldor Series 18H, 19H, 20H and
22H controls. The Resolver to Digital Interface can also be used
for PID control.
Note: When a Resolver to Digital Interface is used in a process
control application, an encoder should be used to provide
velocity feedback to the control.
Specifications
The Resolver to Digital interface is used with a motor mounted
resolver. This provides the correct feedback signals for the
Baldor Control. The control can then monitor and control shaft
position. The Buffered Encoder Output (Retransmit) signals are
still available from the control.
Resolver to Digital interface
Resolver Reference Supply
4 Volts, 25 mA maximum
(@ 10KHz)
DIgital Resolution
10, 12, 14, 16 bits (selectable)
Resolver Input Channels
Resolver Impedance
Resolver Return Voltage
±
Sine,
±
Cosine
160 Ohms @ 10KHz minimum
2 Volts minimum
Resolver Transformation Ratio 2:1 (0.5 TR)
Resolver Speeds
Connector
1:128 (selectable)
Screw Terminals
Description 2-1
Maximum Motor Speed / Resolver Speed
Resolver Speed Type Maximum Motor Speed (RPM)
10 Bits
12 Bits
14 Bits
16 Bits
(2 Pole)
62,400
15,600
3,900
975
1 Speed Resolver
(4 Pole)
2 Speed Resolver
(6 Pole)
3 Speed Resolver
(8 Pole)
4 Speed Resolver
(10 Pole)
5 Speed Resolver
31,200
20,800
15,600
12,480
10,400
7,800
5,200
3,900
3,120
2,600
1,950
1,300
975
487
325
244
195
163
780
(12 Pole)
650
6 Speed Resolver
Maximum Resolver
Speed/Bit Resolution
128
(256
64
(128
32
8
(64 Poles) (16 Poles)
Poles)
Poles)
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
Female/Female shown. Use Male/Female
in place of (MH1) screw Figure 3-1.
Long Aluminum or
Nylon Standoff
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
Female/Female shown. Use Male/Female
Aluminum or
in place of (MH1) screw (Figure 3-1).
Nylon Standoff
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.
1
4. Remove the four (4) Phillips head screws (
/
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)
1
Phillips head screws (
/
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.
1
4. Remove the four (4) Phillips head screws (
/
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)
1
Phillips head screws (
/
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
Important:
If the Resolver to Digital 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.
Figure 4-1 Feedback Module Identification
Main
Control
Board
Feedback
Module
Setup 4-1
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 4-3.
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. Be sure drive operation is terminated and secured.
2. 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.
4-2 Setup
Connections
W
ARNING: High voltage is present on the Resolver to
Digital expansion board. 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.
Procedure: (Refer to Figure 4-1 and FIgure 4-2.)
1. Connect the resolver SINE+ wire to J1 terminal 51 of the
Resolver to Digital expansion board.
2. Connect the resolver SINE– wire to J1 terminal 52 of the
Resolver to Digital expansion board.
3. Connect the resolver COS+ wire to J1 terminal 53 of the
Resolver to Digital expansion board.
4. Connect the resolver COS– wire to J1 terminal 54 of the
Resolver to Digital expansion board.
5. Connect the resolver REFERENCE+ wire to J1 terminal 55
of the Resolver to Digital expansion board.
6. Connect the resolver REFERENCE– wire to J1 terminal 56 of
the Resolver to Digital expansion board.
7. Connect cable shields to J1 terminal 56 of the Resolver to
Digital expansion board. Shields are to be connected at the
expansion board. (Shields not connected at the Resolver).
8. Refer to Table 4-1 and set the DIP switches for the
resolution you require.
Setup 4-3
Figure 4-1 Switch and Terminal Locations
DIP Switch
OFF
ON
All switches
hown in OFF
position.
Side View
51 52 53 54 55 56
J1
Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.
4-4 Setup
Figure 4-2 Resolver Connections
R2
R1
S2
P
51
SINE+
SINE–
COS+
COS–
REF+
S4
52
P
53
S3
S1
54
55
56
P
REF–
(Common/
Shield)
P
= Twisted Pair
Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.
Table 4-1 Switch Settings
DIP Switch Number
Digital Resolution
(Bits)
1
2
3
4
5
10
12
14
16
ON
ON
OFF
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
OFF
Setup 4-5
4-6 Setup
Section 5
Software Setup
Configure Control Software
After the Resolver to Digital Interface board has been installed
and the DIP switches are correctly set, the control software must
be configured.
Series 18H and 22H Vector Controls
Note: When the Resolver to Digital Interface board is installed,
the encoder inputs to the control are automatically
disabled (J1 pins 23 to 30).
The value of the Level 2, MOTOR DATA Block, “Resolver Speed”
parameter (P2509) must be set to the correct speed value.
Procedure:
1. At the keypad, access the Level 2 Blocks.
2. Scroll to and access the Motor Data Block.
3. Access the Resolver Speed parameter
.
Change its’ value to the Resolver Speed Type.
Example: For a 2 pole Resolver, enter 1 (1 Speed).
Example: For a 6 pole Resolver, enter 3 (3 Speed).
Series 19H and 20H DC SCR Controls
The value of the Level 2, MOTOR DATA Block, “Feedback Type”
parameter (P2507) and “Resolver Speed” parameter (P2509)
must be set.
Procedure:
1. At the keypad, access the Level 2 Blocks.
2. Scroll to and access the Motor Data Block.
3. Access the Feedback Type parameter
.
Change its’ value to RESOLVER.
4. Access the Resolver Speed parameter
.
Change its’ value to the Resolver Speed Type.
Example: For a 2 pole Resolver, enter 1 (1 Speed).
Example: For a 6 pole Resolver, enter 3 (3 Speed).
Software 5-1
5-2 Software
|