B503 SERIES

SENSORLESS VECTOR CONTROL CONTROLLER

INSTRUCTION MANUAL

GUANGZHOU BEDFORD ELECTRIC EQUIPMENT.CO.,LTD.

V1.0.0
 CONTENTS

SAFETY PRECAUTIONS ...................................................................................1

1 INTRODUCTION ...........................................................................................1
1.1 Technology Features ...................................................................................................1
1.2 Description of Name Plate..........................................................................................2
1.3 Selection Guide............................................................................................................3
1.4 Parts Description.........................................................................................................4
1.5 External Dimension ....................................................................................................6
2 INSPECTION ..................................................................................................8

3 INSTALLATION .............................................................................................8
3.1 Environmental Requirement .....................................................................................9
3.2 Installation Space ......................................................................................................10
3.3 Dimension of External Keypad................................................................................ 11
3.4 Disassembly ...............................................................................................................12
4 WIRING.........................................................................................................14
4.1 Connection of Peripheral Devices............................................................................15
4.2 Terminal Configuration............................................................................................16
4.3 Typical Wiring Diagram...........................................................................................17
4.4 Specifications of Breaker, Cable, Contactor and Reactor.....................................18
4.5 Wiring Main Circuits................................................................................................19
4.5.1 Wiring at input side of main circuit ..................................................................19
4.5.2 Wiring at controller side of main circuit ...........................................................20
4.5.3 Wiring at motor side of main circuit .................................................................20
4.5.4 Wiring of regenerative unit ...............................................................................21
4.5.5 Wiring of Common DC bus ..............................................................................21
4.5.6 Ground Wiring (PE)..........................................................................................22
4.6 Wiring Control Circuits ...........................................................................................22
4.6.1 Precautions........................................................................................................22
4.6.2 Control circuit terminals ...................................................................................23
4.6.3 Jumpers on control board..................................................................................23
4.7 Installation Guideline to EMC Compliance ...........................................................24
4.7.1 General description of EMC .............................................................................24
4.7.2 EMC features of controller ...............................................................................24

5 OPERATION .................................................................................................26
5.1 Keypad Description ..................................................................................................26

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 5.1.1 Keypad schematic diagram ...............................................................................26
5.1.2 Key function description...................................................................................27
5.1.3 Indicator light description .................................................................................27
5.2 Operation Process .....................................................................................................28
5.2.1 Parameter setting...............................................................................................28
5.2.2 Fault reset..........................................................................................................29
5.2.3 Motor parameter autotuning .............................................................................29
5.2.4 Password setting................................................................................................30
5.3 Running State ............................................................................................................30
5.3.1 Power-on initialization......................................................................................30
5.3.2 Stand-by ............................................................................................................30
5.3.3 Motor parameter autotuning .............................................................................30
5.3.4 Operation...........................................................................................................30
5.3.5 Fault ..................................................................................................................31
5.4 Quick Testing.............................................................................................................31
6 DETAILED FUNCTION DESCRIPTION....................................................32
6.1 F0 Group--Basic Function........................................................................................32
6.2 F1 Group--Start and Stop Control ..........................................................................38
6.3 F2 Group--Motor Parameters..................................................................................41
6.4 F3 Group—Vector Control ......................................................................................42
6.5 F4 Group-- V/F Control............................................................................................43
6.6 F5 Group--Input Terminals .....................................................................................45
6.7 F6 Group--Output Terminals...................................................................................50
6.8 F7 Group--Display Interface....................................................................................51
6.9 F8 Group--Enhanced Function................................................................................55
6.10 F9 Group--PID Control ..........................................................................................59
6.11 FA Group-- Multi-step Speed Control...................................................................63
6.12 FB Group-- Protection Function ...........................................................................64
6.13 FC Group--Serial Communication........................................................................68
6.14 FD Group--Supplementary Function....................................................................70
6.15 FE Group--Factory Setting ....................................................................................72
7 TROUBLE SHOOTING ...............................................................................73
7.1 Fault and Trouble shooting ......................................................................................73
7.2 Common Faults and Solutions.................................................................................75
8 MAINTENANCE ..........................................................................................76
8.1 Daily Maintenance ....................................................................................................76
8.2 Periodic Maintenance ...............................................................................................77
8.3 Replacement of wearing parts .................................................................................78
9 LIST OF FUNCTION PARAMETERS ........................................................78
9.1 Function Parameters of B503 ..................................................................................79

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10 SPECIFICATION OF BRAKING UNIT AND BRAKING RESISTOR......94

11 COMMUNICATION PROTOCOL ...............................................................95

11.1 Interfaces..................................................................................................................95
11.2 Communication Modes...........................................................................................95
11.3 Protocol Format ......................................................................................................95
11.4 Protocol function .....................................................................................................97
11.5 Note.........................................................................................................................100
11.6 CRC Check ............................................................................................................100
11.7 Example..................................................................................................................101

III
SAFETY PRECAUTIONS

Please read this operation manual carefully before installation, operation, maintenance
or inspection.
In this manual, the safety precautions were sorted to “WARNING” or “CAUTION”.

! WARNING Indicates a potentially hazardous situation which, if not, will result in

death or serious injury.

! CAUTION Indicates a potentially hazardous situation which, if not avoided, will

result in minor or moderate injury and physical damage. This sign is
also used for alert of any unsafe operation.
In some cases, the contents of “CAUTION” could cause serious accident. Please follow
these important precautions in any situation.
★NOTE is the necessary step to ensure the proper operation.
Warning marks were shown on the front keypad of controllers.
Please follow these indications when using the controller.
WARNING
z May cause injury or electric shock.
z Please follow the instructions in the manual before installation or operation.
z Disconnect all power line before opening front cover of unit. Wait at least 5 minute until
DC Bus capacitors discharge.
z Use proper grounding techniques.
z Never connect AC power to output UVW terminals

1 INTRODUCTION

1.1 Technology Features

● Input & Output
◆Input Voltage Range: 380/220V ±15%
◆Input Frequency Range: 47~63Hz
◆Output Voltage Range: 0~rated input voltage
◆Output Frequency Range: 0~600Hz
● I/O features
◆Programmable Digital Input: Provide 4 terminals which can accept ON-OFF inputs
◆Programmable Analog Input: AI1can accept input of 0~10V;AI2 can accept of 0~10V
or 0/4~20mA.
◆Programmable Open Collector Output: Provide 1 output terminal (open collector output
or high-speed pulse output)
◆Relay Output: Provide 1 output terminal.
◆Analog Output: Provide 1 analog output terminal, whose output scope can be 0/4~20

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 mA or 0~10 V, as chosen.
● Main Control Function
◆Control Mode: Sensorless Vector Control (SVC), V/F Control.
◆Overload Capacity: 60s with 150% of rated current, 10s with 180% of rated current.
◆Starting Torque: 150% of rated torque at 0.5Hz (SVC).
◆Speed Adjusting Range: 1:100 (SVC)
◆Speed Accuracy: ± 0.5% of maximum speed (SVC)
◆Carrier Frequency: 0.5kHz ~15.0kHz.
◆Reference Frequency Source: keypad, analog input, serial communication, multi-step
speed, PID and so on. The combination of multi- modes and switching between
different modes can be realized.
◆Torque Control Function: Provide multiple torque setting source.
◆PID Control Function
◆Multi-Step Speed Control Function: 8 steps speed can be set.
◆Traverse Control Function
◆Non-Stop when power is instantaneously cut off.
◆Speed trace Function: Start the running motor smoothly.

◆ Key: User defined shortcut key can be realized.

◆Automatic Voltage Regulation (AVR) Function:
◆Automatically keep the output voltage stable when input voltage fluctuating.
◆Up to 25 fault protections:
◆Protect from over current, over voltage, under voltage, over heat, phase failure, over
load etc.

1.2 Description of Name Plate

B503-4010G/4015P G: Constant Torque

P: Variable Torque
Current Vector Control
Power Symbol
010—10HP/7.5kw
015—15HP/11kw
Voltage Class
4—380V
2—220V

Figure1.1 Nameplate of controller

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1.3 Selection Guide

Rated Rated Motor

Rated Input
Model No. Output Output Power Size
Current
Power Current (KW)
1AC 220V ±15%
B503-2001 0.75 8.2 4.5 0.75 A
B503-2002 1.5 14.2 7.0 1.5 B
B503-2003 2.2 23.0 10 2.2 B
3AC 220V ±15%
B503-2001 0.75 5.0 4.5 0.75 A
B503-2002 1.5 7.7 7 1.5 B
B503-2003 2.2 11.0 10 2.2 B
B503-2005 3.7 17.0 16 3.7 C
B503-2007 5.5 21.0 20 5.5 C
B503-2010 7.5 31.0 30 7.5 D
B503-2015 11.0 43.0 42 11.0 E
B503-2020 15 56.0 55 15.0 E
B503-2025 18.5 71.0 70 18.5 E
B503-2030 22.0 81.0 80 22.0 F
B503-2040 30.0 112.0 110 30.0 F
B503-2050 37.0 132.0 130 37.0 F
B503-2060 45.0 163.0 160 45.0 G
3AC 380V±15%
B503-4001 0.75 3.4 2.5 0.75 B
B503-4002 1.5 5.0 3.7 1.5 B
B503-4003 2.2 5.8 5 2.2 B
B503-4005G/4007P 4.0/5.5 10/15 9/13 4.0/5.5 C
B503-4007G/4010P 5.5/7.5 15/20 13/17 5.5/7.5 C
B503-4010G/4015P 7.5/11.0 20/26 17/25 7.5/11.0 D
B503-4015G/4020P 11/15 26/35 25/32 11/15 D
B503-4020G/4025P 15/18.5 35/38 32/37 15/18.5 D
B503-4025G/4030P 18.5/22 38/46 37/45 18.5/22 E
B503-4030G/4040P 22/30 46/62 45/60 22/30 E
B503-4040G/4050P 30/37 62/76 60/75 30/37 E
B503-4050G/4060P 37/45 76/90 75/90 37/45 F
B503-4060G/4075P 45/55 90/105 90/110 45/55 F
B503-4075G/4100P 55/75 105/140 110/150 55/75 F
B503-4100G/4120P 75/90 140/160 150/176 75/90 G

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 Rated Rated Motor
Rated Input
Model No. Output Output Power Size
Current
Power Current (KW)
B503-4120G/4150P 90/110 160/210 176/210 90/110 G
B503-4150G/4180P 110/132 210/240 210/250 110/132 G
B503-4180G/4215P 132/160 240/290 250/300 132/160 H
B503-4215G/4250P 160/185 290/330 300/340 160/185 H
B503-4250G/4270P 185/200 330/370 340/380 185/200 I
B503-4270G/4300P 200/220 370/410 380/415 200/220 I
B503-4300G/4340P 220/250 410/460 415/470 220/250 I
B503-4340G/4380P 250/280 460/500 470/520 250/280 I
B503-4380G/4430P 280/315 500/580 520/600 280/315 I
B503-4430G/4470P 315/350 580/620 600/640 315/350 I
B503-4470 350 620 640 350 -
B503-4540 400 670 690 400 -
B503-4680 500 855 860 500 -
B503-4760 560 920 950 560 -
B503-4860 630 1050 1100 630 -

1.4 Parts Description

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Figure 1.2 Parts of controllers(15KW and below)

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 Figure 1.3 Parts of controllers (18.5KW and above)

1.5 External Dimension

Figure 1.4 Dimension(0.75~15KW) Figure 1.5 Dimension(18.5~110KW)

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 Figure 1.6 Dimension(132~315KW)

Figure 1.7 Dimension(350~630KW)

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 A(mm) B(mm) H(mm) W(mm) D(mm) Installation
Power(KW) Size
Installation Dimension External Dimension Hole (mm)
0.75~2.2 B 110.4 170.5 180 120 140 5
4~5.5 C 147.5 236 250 160 183 5
7.5~15 D 206 305.5 322 220 183 6.0
18.5~30 E 175 455 472 295 222 6.5
37~55 F 230 564.5 580 380 270 7.0
75~110 G 320 738.5 755 465 330 9.0
H(without
270 1233 1275 490 395 13.0
base)
132~185
H(with
- - 1490 490 395 -
base)
I(without
500 1324 1358 750 402 12.5
base)
200~315
I(with
- - 1670 750 402 -
base)
350~630 Refer to Figure 1.7 for the specific size

2 INSPECTION

! CAUTION
z Don’t install or use any controller that is damaged or have fault part, otherwise may
cause injury
Check the following items when unpacking the controller.
1、Inspect the entire exterior of the Controller to ensure there are no scratches or other
damage caused by the transportation.
2、Ensure there is operation manual and warranty card in the packing box.
3、Inspect the nameplate and ensure it is what you ordered.
4、Ensure the optional parts are what you need if have ordered any optional parts.

Please contact the local agent if there is any damage in the controller or optional parts.

3 INSTALLATION

! WARNING
z The person who without passing the training manipulate the device or any rule in the
“Warning” being violated, will cause severe injury or property loss. Only the person, who
has passed the training on the design, installation, commissioning and operation of the
device and gotten the certification, is permitted to operate this equipment.
z Input power cable must be connected tightly, and the equipment must be grounded
securely.

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z Even if the controller is not running, the following terminals still have dangerous
voltage:
—Power Terminals: R,S,T
—Motor Connection Terminals: U,V,W.
z When power off, should not install the controller until 5 minutes after, which can ensure
the device discharge completely.
z The section area of grounding conductor must be no less than that of power supply cable.

! CAUTION
z When moving the controller please lift by its base and don’t lift by the panel, otherwise
may cause the main unit fall off which may result in personal injury.
z Install the controller on the fireproofing material (such as metal) to prevent fire.
z When need install two or more controllers in one cabinet, cooling fan should be provided
to make sure that the air temperature is lower than 45℃.Otherwise it could cause fire or
damage the device.

3.1 Environmental Requirement

3.1.1 Temperature & Humidity
Environment temperature range: -10℃~+40℃，Controller will be derated if ambient
temperature exceeds 40℃.
Less than 90% RH, without dewfall.
3.1.2 Altitude
Controller can output the rated power when installed with altitude of lower than 1000m.
It will be derated when the altitude is higher than 1000m. For details, please refer to the
following figure:

Figure 3.1 Relationship between output current and altitude

3.1.3 Others environmental requirements
It is not allowed that the controller falls down or suffers from fierce impact or the
controller installed at the place that oscillation frequently. The maximum swing should less
than 5.8m/Ss2 (0.6g).

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3.1.5 Electromagnetic radiation
Keep away from the electromagnetic radiation source.
3.1.6 Water
Do not install the controller at the wringing or dewfall place.
3.1.7 Air pollution
Keep away from air pollution such as dusty, corrosive gas.
3.1.8 Storage
Do not store the controller in the environment with direct sunlight, vapor, oil fog and
vibration.

3.2 Installation Space

Figure 3.2 Safe space.

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 Figure 3.3 Installation of multiple controllers.
Notice: Add the air deflector when apply the up-down installation.

3.3 Dimension of External Keypad

Figure 3.4 Dimension of small keypad.

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 Figure 3.5 Dimension of big keypad.

3.4 Disassembly

Figure 3.6 Dimension of plastic keypad.

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Figure 3.7 Dimension of metal plate cover.

Figure 3.8 Open controller cabinet.

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4 WIRING

! WARNING
z Wiring must be performed by the person certified in electrical work.
z Forbid testing the insulation of cable that connects the controller with high-voltage
insulation testing devices.
z Cannot install the controller until discharged completely after the power supply is
switched off for 5 minutes.
z Be sure to ground the ground terminal.
(200V class: Ground resistance should be 100Ω or less, 400V class: Ground resistance
should be 10Ω or less,660Vclass:Ground resistance should be 5Ω or less ). Otherwise , it
might cause electric shock or fire.
z Connect input terminals(R,S,T)and output terminals (U,V,W) correctly. Otherwise it will
cause damage the inside part of controller.
z Do not wire and operate the controller with wet hands. Otherwise there is a risk of
electric shock.

! CAUTION
z Check to be sure that the voltage of the main AC power supply satisfies the rated voltage
of the Controller.
z Injury or fire can occur if the voltage is not correct.
z Connect power supply cables and motor cables tightly.

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4.1 Connection of Peripheral Devices

Power supply

Circuit breaker

Contactor

AC reactor

Braking resistor
Input EMC filter

DC reactor

Controll

Ground

Output reactor

Output EMC filter

Motor

Ground
Figure 4.1 Connection of peripheral devices

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4.2 Terminal Configuration
4.2.1 Main Circuit Terminals (380V AC)
（+） PB L N U V W
Figure 4.2 Main circuit terminals (0.75~2.2KW 1AC 220V)
R S T U V W
(+) PB
POWER MOTOR
Figure 4.3 Main circuit terminals (1.5~2.2KW)
R S T U V W
(+) PB (-)
POWER MOTOR
Figure 4.4Main circuit terminals (3.7~5.5KW)
R S T U V W
(+) PB (-)
POWER MOTOR
Figure 4.5Main circuit terminals (7.5~15KW)
R S T U V W
P1 (+) (-)
POWER MOTOR
Figure 4.6Main circuit terminals (18.5~110KW)
R S T U V W
POWER MOTOR

P1 (+) (-)

Figure 4.7Main circuit terminals (132~315KW)

U V W
R S T
PE P1 (+) (-)
Figure 4.8Main circuit terminals (350~500KW)
Main circuit terminal functions are summarized according to the terminal to the terminal
symbols in the following table. Wire the terminal correctly for the desired purposes.
Terminal Symbol Function Description
R、S、T Terminals of 3 phase AC input
(+)、(-) Spare terminals of external braking unit
(+)、PB Spare terminals of external braking resistor
P1、(+) Spare terminals of external DC reactor
(-) Terminals of negative DC bus
U、V、W Terminals of 3 phase AC output
Terminals of ground

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 4.2.2 Control Circuit Terminals

485+ 485- +10V AO COM Y +24V ROA ROB ROC

AI1 GND AI2 S1 S2 S3 S4
Figure 4.9 Control circuit terminals (0.75~2.2KW)
485+ 485- AO AI1 GND AI2 +10V S1 S2 S3 S4 COM Y +24V ROA ROB ROC
Figure 4.10 Control terminals (4.0KW and above)

4.3 Typical Wiring Diagram

Figure4. 2 Wiring diagram

Notice:
1. Controllers between 18.5KW and 90KW have built-in DC reactor which is used to
improve power factor. For controllers above 110KW, it is recommended to install DC
reactor between P1 and (+).
2. Controllers below 15KW have built-in braking unit. If need braking, only need to

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 install braking resistor between PB and (+).
3. For controllers above 18.5KW, If need braking, should install external braking unit
between (+) and (-).

4.4 Specifications of Breaker, Cable, Contactor and Reactor

4.4.1 Specifications of breaker, cable and contactor
Input/ Output Cable
Model No. Circuit Breaker (A) AC Contactor (A)
( mm 2 )
1AC 220V ±15%
B503-2001 16 2.5 10
B503-2002 20 4 16
B503-2003 32 6 20
3AC 220V ±15%
B503-2001 16 2.5 10
B503-2002 20 4 16
B503-2003 32 6 20
B503-2005 40 6 25
B503-2007 63 6 32
B503-2010 100 10 63
B503-2015 125 25 95
B503-2020 160 25 120
B503-2025 160 25 120
B503-2030 200 35 170
B503-2040 200 35 170
B503-2050 200 35 170
B503-2060 250 70 230
3AC 380V ±15%
B503-4001 10 2.5 10
B503-4002 16 2.5 10
B503-4003 16 2.5 10
B503-4005G/4007P 25 4 16
B503-4007G/4010P 25 4 16
B503-4010G/4015P 40 6 25
B503-4015G/4020P 63 6 32
B503-4020G/4025P 63 6 50
B503-4025G/4030P 100 10 63
B503-4030G/4040P 100 16 80
B503-4040G/4050P 125 25 95
B503-4050G/4060P 160 25 120
B503-4060G/4070P 200 35 135
B503-4075G/4100P 200 35 170
B503-4100G/4120P 250 70 230
B503-4120G/4150P 315 70 280

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