Baldor Modbus Plus User manual

Modbus Plus
Expansion Board
Catalog No. EXB015A01
Installation and Operating Manual
8/03 MN1322

Table of Contents
Table of Contents i
Section 1
General Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice 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. . . . . . . . . . . . . . . . . . .
Section 4
Hardware Setup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIP Switch Settings 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Connection 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powerup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Indicators 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Terminal Strip Connections 4-5. . . . . . . . . . . . . . . . . . . . .
Section 5
Register Map for Modbus Plus 5-1. . . . . . . . . . . . . . . . . . . .

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
Profibus EXB014A0X MN1323
Modbus Plus EXB015A0X MN1322

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
Introduction
The Modbus Plus expansion board is a Group 2 expansion board. It
allows a Series H control to communicate as a node on the Modbus
Plus network. It has a DB9 connector to make connection to the network
simple.
Group 2 board
Modbus Plus Expansion Board
Catalog No. EXB015A01
A good resource document is the “Modicon Plus Network Planning and
Installation Guide”. Refer to that guide for planning your network and
details such as cable specifications etc.

2-2 Description

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

Section 4
Hardware Setup
Hardware Setup 4-1
A good resource document is the “Modicon Plus Network Planning and
Installation Guide”. Refer to that guide for planning your network and
details such as cable specifications etc.
DIP Switch Settings
This procedure will configure the Modbus Plus Expansion Board for
communication with a computer or terminal. Reference Figure 4-1 and
Table 4-1 for the following procedure.
1. Set DIP switches 1 through 6 for the desired board address.
2. Switches 7 and 8 are not used and may be left in either position.
3. Be sure a jumper is installed at J1.
4. Be sure no jumper is installed at J3 or J4.
5. Install the expansion board in the Series H control as instructed in
Section 3 of this manual.
Note: The switch settings can be changed after the board is powered
up. However, switch changes will not take effect until the board
is reset (by turning power off then on).
Cable Connection
Connect the Modbus cable to the DB 9 connector on the expansion
board (shown in Figure 4-1).
Powerup
When the Modbus Plus expansion board is powered up it will do the
following:
1. Perform a self test.
2. Check the switch settings for configuration information.
3. Verify communications with the Series H control board.
4. Check for power from the Series H control.
5. Perform a duplicate ID (address) check to determine if any other
devices on the network have the same ID number.
6. Go online.
Refer to the LED description in this section of the manual.

4-2 Hardware Setup
Figure 4-1 Board Configuration
Modbus Plus Expansion Board Catalog No. EXB015A01
All switches shown in ON (Down) position.
12345678
12345678
J2
S1
D1 Modbus Plus Status LED
J1
DB9
Connector
Pin Description
1 Chassis Ground
2 TxA
3 TxB
D1
J4
Circuit Board
J3
PB1
PB1 Reset switch (Processor only)
To reset the board, turn control off then on
(cycle power).
D5
D4
D3
D2
D5 Power LED
D2 Error LED
D3 Status LED
D4 Status LED
ON

Hardware Setup 4-3
Table 4-1 Switch Settings
S1 Switch Position
Modbus Plus Address 123456
1 000000
2 100000
3 010000
4 110000
5 001000
6 101000
7 011000
8 111000
9 000100
10 100100
11 010100
12 110100
13 001100
14 101100
15 011100
16 111100
17 000010
18 100010
19 010010
20 110010
21 001010
22 101010
23 011010
24 111010
25 000110
26 100110
27 010110
28 110110
29 001110
30 101110
31 011110
32 111110
33 000001
. . . . . . . . . . . . . . . . . . . . .
63 111111

4-4 Hardware Setup
LED Indicators
Five LED’s are located on the Modbus Plus expansion board (see
Figure 4-1 for their locations).
D1 Modbus Plus Status LED
D1 displays the operational status of the Modbus Plus Interface
expansion board (EXB). When power is first applied, the LED will
pause, then flash slowly 8 times while it checks the network. If a valid
Modbus Plus connection is established, D1 will flash continuously.
Otherwise, it flash an error code as shown in Table 4-2.
Table 4-2
LED State Status Description
OFF No power is applied to the EXB.
2 Flashes
then pause The network is active, but the token is never passed to this node. The node may have a bad transmitter.
3 flashes
then pause No other nodes on the network.
4 flashes
then pause Duplicate node numbers on the network.
D2 Error LED
D2 will flash 4 times then pause if any errors are encountered that would
prevent correct operation of the board. If this error occurs, turn the
control off, then on (cycle power). If error continues, the trouble could
be the expansion board, motor control board, or software version.
Correct the problem as required, and if the error remains, contact
Baldor.
D3 and D4 Status LED
D3 will flash to indicate that firmware is correctly loaded and running.
D4 will flash to indicate that the interface circuits between Modbus Plus
expansion board and the Series H control is running correctly. These
LEDs flash at different rates and, if flashing, indicate proper operation.
D5 Power LED
D5 indicates that the expansion board is receiving power from the
Series H control.

Hardware Setup 4-5
Control Terminal Strip Connections
For Serial Mode operation, the Input/Output terminal strip of the control
(J1 of the Vector and DC controls and J4 of the Inverters) is wired as
shown in Figure 4-2. Connect the Enable, Forward Enable Switch,
Reverse Enable Switch, External Trip and Opto Common connections
as shown.
Note: All opto-isolated outputs and analog outputs remain active while
operating in the Serial Mode.
When these connections are complete, refer to Section 5 of this manual
and set the software for Serial Mode.
Figure 4-2 Serial Opto Input Connections
8
9
10
16
17
Common
J1*
8
9
10
16
17
Common
J4**
Enable
Forward
Enable
Reverse
Enable
External
Trip
Enable
Forward
Enable
Reverse
Enable
External
Trip
* Series 18H, 22H and 23H controls.
** Series 15H and 21H controls.