Isolated Encoder Expansion Board - Baldor.com · Isolated Encoder Expansion Board Catalog No. EXB008A01 Installation and Operating Manual 6/98 MN1317

Isolated EncoderExpansion Board

Catalog No. EXB008A01

Installation and Operating Manual

6/98 MN1317

Table of Contents

Table of Contents i

Section 1General Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Warranty 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice: 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS: 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2Expansion Board Description 2-1. . . . . . . . . . . . . . . . . . .

Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Board Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15HP Size A and B Controls 3-2. . . . . . . . . . . . . . . . . . .

Single Expansion Board Installation 3-2. . . . . . . . . . . . . Dual Expansion Board Installation 3-4. . . . . . . . . . . . . .

15HP Size C and Larger AC Controls 3-6. . . . . . . . . . . . . Single Expansion Board Installation 3-6. . . . . . . . . . . . . Dual Expansion Board Installation 3-8. . . . . . . . . . . . . .

SCR DC Controls 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Expansion Board Installation 3-10. . . . . . . . . . . . . Dual Expansion Board Installation 3-11. . . . . . . . . . . . . .

Section 4Hardware Setup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumper Definitions 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii Table of Contents

Section 1General Information

General Information 1-1

IntroductionThe Baldor controls represent the latest technology inmicroprocessor based motor controls. In addition to the userprogrammable parameters available in every control, manydifferent expansion boards are available from Baldor to furthercustomize the control to most any application.Expansion boards are categorized by compatibility into twogroups: Group 1 and Group 2, see Table 1-1. A board fromeither group may be used alone in a control. If two boards are tobe used, one board must be from Group 1 and the other fromGroup 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. BaldorManual No.

Isolated Input Expansion Board EXB003A01 MN1314Master Pulse Reference/ Isolated Pulse Follower

EXB005A01 MN1312

DC Tachometer Interface EXB006A01 MN1311Isolated Encoder Expansion Board

EXB008A01 MN1317

Resolver to Digital Interface EXB009A01 MN1313

Group 2 Board NameRS-232 Serial Communication EXB001A01 MN1310RS-422/RS-485 High Speed Serial Communication

EXB002A01 MN1310

Four Output Relays/3-15 PSI Pneumatic Expansion Board

EXB004A01 MN1315

High Resolution Analog I/O Expansion Board

EXB007A02 MN1316

2 Isolated Analog Output/ 3 RelayOutput Expansion Board

EXB010A01 MN1319

1-2 General Information

Limited Warranty

For a period of two (2) years from the date of original purchase,BALDOR will repair or replace without charge controls andaccessories which our examination proves to be defective inmaterial or workmanship. This warranty is valid if the unit has notbeen tampered with by unauthorized persons, misused, abused, orimproperly installed and has been used in accordance with theinstructions and/or ratings supplied. This warranty is in lieu of anyother warranty or guarantee expressed or implied. BALDOR shallnot be held responsible for any expense (including installation andremoval), inconvenience, or consequential damage, includinginjury to any person or property caused by items of our manufactureor sale. (Some states do not allow exclusion or limitation ofincidental or consequential damages, so the above exclusion maynot apply.) In any event, BALDOR’s total liability, under allcircumstances, shall not exceed the full purchase price of thecontrol. Claims for purchase price refunds, repairs, orreplacements must be referred to BALDOR with all pertinent dataas to the defect, the date purchased, the task performed by thecontrol, and the problem encountered. No liability is assumed forexpendable items such as fuses.

Goods may be returned only with written notification including aBALDOR Return Authorization Number and any return shipmentsmust be prepaid.

General Information 1-3

Safety NoticeThis equipment contains voltages that may be as great as 1000volts! Electrical shock can cause serious or fatal injury. Onlyqualified personnel should attempt the start-up procedure ortroubleshoot this equipment.

This equipment may be connected to other machines that haverotating parts or parts that are driven by this equipment.Improper use can cause serious or fatal injury. Only qualifiedpersonnel should attempt the start-up procedure or troubleshootthis equipment.

PRECAUTIONS

WARNING: Do not touch any circuit board, power deviceor electrical connection before you firstensure that power has been disconnectedand there is no high voltage present fromthis equipment or other equipment to whichit is connected. Electrical shock can causeserious or fatal injury . Only qualifiedpersonnel should attempt the start-upprocedure or troubleshoot this equipment.

WARNING: Be sure that you are completely familiar withthe safe operation of this equipment. Thisequipment may be connected to othermachines that have rotating parts or partsthat are controlled by this equipment.Improper use can cause serious or fatalinjury. Only qualified personnel shouldattempt the start-up procedure ortroubleshoot this equipment.

1-4 General Information

WARNING: Be sure the system is properly groundedbefore applying power. Do not apply ACpower before you ensure that all groundinginstructions have been followed. Electricalshock can cause serious or fatal injury .

WARNING: Do not remove cover for at least five (5)minutes after AC power is disconnected toallow capacitors to discharge. Dangerousvoltages are present inside the equipment.Electrical shock can cause serious or fatalinjury.

WARNING: Improper operation of control may causeviolent motion of the motor shaft and drivenequipment. Be certain that unexpectedmotor shaft movement will not cause injuryto personnel or damage to equipment. Peaktorque of several times the rated motortorque can occur during control failure.

WARNING: Motor circuit may have high voltage presentwhenever AC power is applied, even whenmotor is not rotating. Electrical shock cancause serious or fatal injury .

Caution: T o prevent equipment damage, be certainthat the electrical service is not capable ofdelivering more than the maximum line shortcircuit current amperes listed in theappropriate control manual, 230 V AC, 460VAC or 575 VAC maximum per control rating.

Section 2Expansion Board Description

Description 2-1

IntroductionIsolated encoder expansion boardCatalog No. EXB008A01

Features:

Mounting Group 1Electrically Isolated Encoder InputsElectrically Isolated Power SupplyEncoder Retransmit Signals5, 12, or 15 VDC Power Supply

The isolated encoder expansion board optically isolates theencoder signals from a non–isolated motor. This board alsoprovides an electrically isolated power source of 5, 12 or 15 VDCfor the encoder.

Encoder channel A, A, B, and B retransmit signals and indexchannel inputs are jumper selectable. Retransmit signals aretransmitted as 5 VDC levels.

Table 2-1 describes the supply voltages and current, input andoutput channels, retransmit voltage and connector types for theisolated encoder expansion board.

Table 2-1 Characteristics

Encoder Supply Voltage 5 12 or 15 VDC – Jumper Selectable Encoder Supply Voltage 5, 12, or 15 VDC – Jumper Selectable

Encoder Supply Current (Maximum)

300mA @ 5VDC, 100mA @ 12VDC and100mA @ 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.

2-2 Description

Section 3Installation

Installation 3-1

Board InstallationThis section describes the Expansion Board installationprocedure.

Caution: Before you proceed, be sure to read andbecome familiar with the safety precautionsat the beginning of this manual. Do notproceed if you are unsure of the safetyprecautions described. If you have anyquestions, contact BALDOR before youproceed.

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 bepresent on the connectors to prevent staticbuild up during shipping. This can preventproper circuit operation.

Installation differs between the 1-15 HP Size A and B controlsand the 15HP Size C and larger AC controls and the SCR DCcontrols. If you are installing only one board, refer to the “SingleExpansion Board Installation” procedure. If you are installing twoexpansion boards (or a second board) refer to the “DualExpansion Board Installation” procedure.

3-2 Installation

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 theMale/Female standoff is at position MH1. The other threeare Female/Female.)

8. Slide the expansion board male connector into the femaleconnector of the control board.

9. Securely mount the expansion board to the standoffsinstalled in step 7 using #6 screws provided in theinstallation hardware. See Figure 3-2.

10. The mechanical installation of the expansion board is nowcomplete. Refer to Section 4 of this manual and configurethe jumpers as desired. Also complete the wiring beforeyou 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.

Installation 3-3

Figure 3-1 Single Expansion Board Installation

Remove screw(Labeled MH1 inMain PCB Screen).Install Male/FemaleStandoff.

Install Female/FemaleAluminum Standoff.

Install Female/FemaleNylon Standoff.

Main ControlBoard

Expansion Board

Terminal tightening torque is 7 lb-in (0.8 Nm) maximum.


#6 Screw

Long Aluminum orNylon Standoff

Group 1 or 2 Expansion Board

Female/Female shown. Use Male/Femalein place of (MH1) screw Figure 3-1.

Main Circuit Board

3-4 Installation

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 theMale/Female standoff is at position MH1. The other threeare Female/Female.)

8. Slide the Group 1 board male connector into the femaleconnector of the control board. See Figure 3-3.

9. Securely mount the Group 1 expansion board to thestandoffs installed in step 7 using the 4 short aluminumstandoffs provided in the installation hardware. See Figure3-3.

10. The mechanical installation of the Group 1 expansion boardis now complete. Refer to the manual for the Group 1 boardand configure the jumpers as desired. Also complete thewiring before you proceed to step 11.

11. Install the Group 2 board on top of the previously installedGroup 1 board by plugging the female connector onto themale connector of the Group 1 board as shown in Figure3-3.

12. Secure this Group 2 board to the Group 1 board using the#6 screws provided.

Installation 3-5

1-15HP Size A and B ControlsDual Expansion Board Installation (Continued)

13. The mechanical installation of the first expansion board isnow complete. Refer to the manual for the Group 2 boardand configure any jumpers and switches as desired. Alsocomplete the wiring for this board before you install thecover.

14. When complete, install the control cover using the four (4)Phillips head screws.


Figure 3-3 Dual Expansion Board Installation

#6 Screw

Female Connector

Male Connector

Group 2 Expansion Board


Main Circuit Board

Female/Female shown. Use Male/Femalein place of (MH1) screw (Figure 3-1).

ShortAluminumStandoff

LongAluminum or Nylon Standoff

3-6 Installation

15HP Size C and Larger AC Controls(For all 15H Inverter, 21H Line Regen Inverter, 18H Vector, 22HLine Regen Vector and 23H Servo).


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 sizeenclosures, 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 metalmounting plate using the #6 screws provided in theinstallation hardware. See Figure 3-5.

8. The mechanical installation of the expansion board is nowcomplete. Refer to Section 4 of this manual and configurethe jumpers as desired. Also complete the wiring beforeyou 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 sizeenclosures, close the enclosure door).


Installation 3-7

15HP Size C and Larger AC ControlsSingle 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.


#6 Screw

Group 1 or 2 Expansion Board

Sheet Metal Mounting Plate

3-8 Installation

15HP Size C and Larger AC Controls (Continued)


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 sizeenclosures, 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 inthe installation hardware. See Figure 3-6.

8. The mechanical installation of the expansion board is nowcomplete. Refer to the manual for the Group 1 board andconfigure the jumpers as desired. Also complete the wiringbefore you proceed to step 9.


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 nowcomplete. Refer to the manual for the Group 2 board andconfigure any jumpers and switches as desired. Alsocomplete the wiring for this board before you install thecover.

Installation 3-9

15HP Size C and Larger AC ControlsDual 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 sizeenclosures, close the enclosure door).


Figure 3-6 Dual Expansion Board Installation

#6 Screw

Short AluminumStandoff



Control Board Mounting Plate

Female Connector

Male Connector

3-10 Installation

SCR DC Controls(For 19H and 20H SCR DC Controls).


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 theinstallation hardware. See Figure 3-5.

6. The mechanical installation of the expansion board is nowcomplete. Refer to the Group 1 manual and configure thejumpers as desired. Also complete the wiring before youproceed to step 7.


Installation 3-11

SCR DC Controls (Continued)


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 inthe installation hardware. See Figure 3-6.

6. The mechanical installation of the expansion board is nowcomplete. Refer to the Group 1 manual and configure thejumpers as desired. Also complete the wiring before youproceed to step 7.


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 nowcomplete. Refer to the manual for the Group 2 board andconfigure any jumpers and switches as desired. Alsocomplete the wiring for this board before you proceed tostep 10.


3-12 Installation

Section 4Hardware Setup

Setup 4-1

OverviewIsolated Encoder Expansion Board

Catalog Number EXB008A01

Features:

Mounting Group 1Electrically Isolated Encoder InputsElectrically Isolated Power SupplyEncoder Retransmit Signals5, 12, or 15 VDC Power Supply

Important:If the Isolated Encoder Expansion Board is installed in a Vectorcontrol that has a feedback module installed, the feedbackmodule must be removed to prevent interference with theexpansion board. Figure 4-1 shows how to identify the feedbackmodule on the DSP Main Control Board. The main control boardis where the keypad plugs in.

4-2 Setup

Figure 4-1 Feedback Module Identification

FeedbackModule

MainControlBoard

If your Vector control does not look like the one pictured in Figure4-1, do not perform the feedback module removal procedure.Instead, continue onto page 4-4.

Setup 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 maincontrol board to change the JP1 position. Use the followingprocedure.

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 carefulnot to bend the pins by twisting or lifting the moduleunevenly.

6. Place the Resolver Feedback Module in an antistatic bagand 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 toDigital expansion board signal inputs to the control board. TheResolver to Digital expansion board will provide the input signalsfor the control board to use. Continue on page 4-3.

4-4 Setup

Isolated Encoder Expansion Board Description

The isolated encoder expansion board provides electricallyisolated encoder signals from a non–isolated motor to the motorcontrol board. Also an electrically isolated encoder powersource of 5, 12 or 15 VDC is provided. Isolated encoder inputs51–58 provides the motor encoder feedback that is normallyprovided 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 jumperson the expansion board. Encoder channel A, A, B, and Bretransmit signals are jumper selectable and are also availableon terminals 55, 56, 59 and 60 respectively. Terminals 55 and56 may be used as index channel inputs or B channelretransmits. Retransmit signals are transmitted as 5 VDC levels.Please note the encoder retransmit signals on the main controlboard are still available with the isolated encoder expansionboard installed.

Setup 4-5

Jumper DefinitionsJMP1 Table 4-1 defines the 3 jumper positions to set the encoder

DC Voltage Level. Place JMP1 in the proper position fordesired encoder supply voltage.

JMP2 Table 4-2 defines the two positions of JMP2 that determinethe operation of terminal 56.

JMP3 Table 4-3 defines the two positions of JMP3 that determinethe operation of terminal 55.

Table 4-4 defines the 10 terminal connections at the expansionboard.

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

4-6 Setup

Table 4-4 Terminal Connections

Terminal # and Using C Channel Using B ChannelTerminal # andJumper Position

Using C Channel(Index) Input

Using B ChannelRetransmit

Jumper #2 3 – 4 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


Setup 4-7

Figure 4-2 Jumper and T erminal Locations


4-8 Setup

BALDOR ELECTRIC COMPANYP.O. Box 2400

Fort Smith, AR 72902–2400(501) 646–4711

Fax (501) 648–5792

Baldor Electric Company Printed in USAMN1317 6/98 C&J2500

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Isolated Encoder Expansion Board - Baldor.com · Isolated Encoder Expansion Board Catalog No. EXB008A01 Installation and Operating Manual 6/98 MN1317