Baldor EXB003A02 User manual

Isolated Input
Expansion Board
Catalog No. EXB003A02
Catalog No. EXB003A03
Catalog No. EXB003A04
Catalog No. EXB003A05
Installation and Operating Manual
4/99 MN1314

Table of Contents
Table of Contents i
Section 1
General Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
Expansion Board Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Board Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Controls 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Expansion Board Installation 3-2. . . . . . . . . . . . . . . . . .
Dual Expansion Board Installation 3-4. . . . . . . . . . . . . . . . . . .
SCR DC Controls 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Expansion Board Installation 3-6. . . . . . . . . . . . . . . . . .
Dual Expansion Board Installation 3-7. . . . . . . . . . . . . . . . . . .
Section 4
Hardware Setup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii Table of Contents

Section 1
General Information
General Information 1-1
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. Manual No.
Isolated Input EXB003A0X MN1314
Master Pulse Reference/
Isolated Pulse Follower EXB005A0X MN1312
DC Tachometer Interface EXB006A0X MN1311
Isolated Encoder EXB008A0X MN1317
Resolver to Digital Interface EXB009A0X MN1313
Group 2 Board Name
RS-232 Serial EXB001A0X MN1310
RS-422/RS-485 Serial EXB002A0X MN1310
RS-232/485 Serial EXB012A0X MN1310
Four Output Relays/3-15 PSI
Pneumatic EXB004A0X MN1315
High Resolution Analog I/O EXB007A0X MN1316
2 Isolated Analog Output/ 3 Relay
Output EXB010A0X MN1319
Device Net EXB013A0X MN1320
Modbus Plus EXB015A0X MN1322
Profibus DP EXB014A0X MN1323

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 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.

General Information 1-3
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.

1-4 General Information
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.

Section 2
Expansion Board Description
Description 2-1
Isolated Input Expansion Board
Catalog No. EXB003A02
Catalog No. EXB003A03
Catalog No. EXB003A04 –Not compatible with 19H and 20H.
Catalog No. EXB003A05 –Not compatible with 19H and 20H.
Features:
Mounting Group 1
Optically Isolated Inputs
Table 2-1 defines the specifications of the Isolated Input Expansion
Board. Table 2-1 Specifications
Catalog No. No. of Inputs Input Voltage Input Freq. Input
Impedance
EXB003A02 810–30 VDC N.A. 10 KW
EXB003A03 870–130 VAC 48 - 62 Hz 10 KW
EXB003A04 910–30 VDC N.A. 10 KW
EXB003A05 970–130 VAC 48 - 62 Hz 10 KW
The Isolated Input Expansion Board converts high level AC or DC input
voltage levels to the proper range for the Motor Control Board. The
inputs are used to command the ON and OFF states of the digital
command inputs of the Motor Control Board.
The isolated inputs terminals automatically perform the programmed
function of the respective Motor Control Board inputs. See Figures 2-1
and 2-2. This means that when the Isolated Input Expansion Board is
installed, external connections to those Motor Control Board terminals is
not allowed.

2-2 Description
Figure 2-1 Expansion Board/Motor Control Board Relation
EXB003A02
EXB003A03
The external trip (Motor T–Stat)
on terminals 16 & 17 of the motor
control board is still available with
the expansion board installed.
Terminal tightening torque is 7 lb–in (0.8 Nm) maximum.
Figure 2-2 Expansion Board/Motor Control Board Relation
EXB003A04
EXB003A05
Terminal tightening torque is 7 lb–in (0.8 Nm) maximum.

Section 3
Installation
Installation 3-1
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.
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.

3-2 Installation
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 (1/4turn) that secure the
control cover. (For A & B size, remove four screws that secure the
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 3-1.
7. Securely mount the expansion board to the sheet metal mounting
plate using the #6 screws provided in the installation hardware.
See Figure 3-2.
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 (1/4turn). (For A & B size, install four screws that
secure the cover. On floor mounted G size enclosures, close the
enclosure door).
10. Restore all power sources to the control.
11. Restore drive operation.

Installation 3-3
AC Controls
Single Expansion Board Installation (Continued)
Figure 3-1 Single Expansion Board Installation
Expansion Board Motor Control Board
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
Sheet Metal Mounting Plate

3-4 Installation
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 (1/4turn) that secure the
control cover. (For A & B size, remove four screws that secure the
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 3-1.
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 3-3.
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 3-3.
10. Secure this Group 2 board to the Group 1 board using the #6
screws provided. See Figure 3-3.
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 or close the cover.

Installation 3-5
AC Controls
Dual Expansion Board Installation (Continued)
12. When complete, install the control cover using the four (4) Phillips
head screws (1/4turn). (For A & B size, install four screws that
secure the cover. On floor mounted G size enclosures, close the
enclosure door).
13. Restore all power sources to the control.
14. Restore drive operation.
Figure 3-3 Dual Expansion Board Installation
#6 Screw
Short
Aluminum
Standoff
Group 2 Expansion Board
Group 1 Expansion Board
Control Board Mounting Plate
Female Connector
Male Connector

3-6 Installation
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 3-1.
5. Securely mount the expansion board to the sheet metal mounting
plate using the #6 screws provided in the installation hardware.
See Figure 3-2.
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.

Installation 3-7
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 3-1.
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 3-3.
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 3-3.
8. Secure this Group 2 board to the Group 1 board using the #6
screws provided. See Figure 3-3.
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.

3-8 Installation

Section 4
Hardware Setup
Setup 4-1
Isolated Input Expansion Board
Figures 4-1 and 4-2 illustrates the external connections for DC or AC
voltage operation. No jumpers are required on this board.
Figure 4-3 illustrates the physical location of the terminals on the
expansion board.
Note: The diagnostic screens (Digital I/O) can be used to verify proper
operation of the inputs. Refer to the motor control manual.
Figure 4-1 Typical Connections EXB003A02 and A03
Figure 4-2 Typical Connections EXB003A04 and A05
(Not compatible with 19H and 20H)
Terminal tightening torque is 7 lb–in (0.8 Nm) maximum.

4-2 Setup
Figure 4-3 Terminal Locations
Terminal tightening torque is 7 lb–in (0.8 Nm) maximum.

BALDOR ELECTRIC COMPANY
P.O. Box 2400
Fort Smith, AR 72902–2400
(501) 646–4711
Fax [phone]
Baldor Electric Company Printed in USA
MN1314 4/99 C&J2500