Baldor BC140, BC140-FBR Installation & Operating Manual

6/15 Installation & Operating Manual MN703

BC140 / BC140-FBR DC CONTROL

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Important:
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Acrobat PDF format.

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MN703

Chapter 1
Introduction

Introduction ................................................................ 1-1

Safety Notice ............................................................... 1-1

Receiving ................................................................. 1-2

Chapter 2
Installation

Introduction ................................................................ 2-1

Mounting .................................................................. 2-1

Electrical Connections ........................................................ 2-2

AC Power .................................................................. 2-2

Ground Connection .......................................................... 2-2

Permanent Magnet (PM) Motor Armature Connection ................................. 2-2

Motor Field Connection (Shunt Wound Motors Only) .................................. 2-2

Full Voltage Field .......................................................... 2-2

Half Voltage Field ......................................................... 2-3

Plug-In Horsepower Resistor® ................................................. 2-3

Important Considerations ...................................................... 2-4

Startup & Adjustments ........................................................ 2-5

Trimpot Adjustments ......................................................... 2-5

Operation .................................................................. 2-7

Troubleshooting ............................................................. 2-7

Appendix A
Options

Optional auxiliary heat sink (catalog no. BC143) ..................................... A-1

Optional forward -brake-reverse switch (catalog no. BC144)* .......................... A-1

Table of Contents

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Chapter 1

Introduction

Introduction

Thank you for purchasing the BC140™ / BC140-FBR, full-wave variable speed DC motor controls.

Baldor is committed to providing total customer satisfaction by producing quality products that are

easy to install and operate. The BC140 and BC140-FBR offer the user the ultimate in reliability and

performance at an affordable price.

The BC140 and BC140-FBR are able to handle both 115 and 208/230 Volt AC line inputs. In addition,

one model can be used on a wide range of motors by selecting and inserting the appropriate Plug-in

Horsepower Resistor®.

The standard model, BC140, controls all motors through 3/4 HP at 115 Volt AC line input and 1-1/2 HP

at 230 Volt AC line input. By installing the Auxiliary Heat Sink (see Table 1-2), the horsepower range

is increased to 1 HP at 115 Volt AC line input and 2 HP at 230 Volt AC line input. The versatility of the

control is enhanced with the optional Forward-Brake-Reverse Switch Kit (Catalog No. BC144)*.
*Note: Forward-Brake-Reverse Switch Kit, BC144, is factory installed on the BC140-FBR model.

The electronics for the BC140 and BC140-FBR consist of a patented speed control module. Its field-

proven reliability is confirmed by over 100,000 controls presently in operation. The module is housed

in a rugged metal enclosure not plastic. Keyhole slots facilitate mounting and an easily accessible

terminal block simplifies connections.

SAFETY NOTICE

A Warning statement indicates a potentially hazardous situation which, if not avoided, could result in

injury or death.

A Caution statement indicates a potentially hazardous situation which, if not avoided, could result in

damage to property.

A Note indicates additional information that is not critical to the installation or operation.

WARNING: This equipment may contain voltages as high as 1000 volts! Electrical shock can cause serious or fatal

injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

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: Electrical shock can cause serious or fatal injury. Be sure that all power is disconnected and there is

no voltage present from this equipment or equipment to which it is or will be connected. Electrical
shock can cause serious or fatal injury. Only qualified personnel should attempt the installation and
start-up procedures.

WARNING: Electrical shock can cause serious or fatal injury. Verify there is no voltage phase-to-phase or phase-

to-neutral at the motor leads before connecting motor to this control. Motor may have high voltage
present even when disconnected from this control.

WARNING: Do not use motor overload relays with an automatic reset feature. These are dangerous since the

process may injure someone if a sudden or unexpected automatic restart occurs. If manual reset
relays are not available, disable the automatic restart feature using external control wiring.

WARNING: This unit has an automatic restart feature that will start the motor whenever input power is applied

and a RUN (FWD or REV) command is issued. If an automatic restart of the motor could cause injury to
personnel, the automatic restart feature should be disabled.

WARNING: Using a jumper to eliminate the start/stop function will cause the motor to run at the Main Speed

Potentiometer setting when the AC line is applied.

WARNING: If possible, do not adjust trim pots with the main power applied. Electrical shock can cause serious or

fatal injury. If adjustments are made with the main power applied, an insulated adjustment tool must
be used to prevent shock hazard and safety glasses must be worn.

WARNING: Do not use this drive in an explosive environment. An explosion can cause serious or fatal injury.

This drive is not explosion proof.

WARNING: When the Enable jumper is installed, the drive and motor will start and run when AC power is applied,

when power is restored after a momentary power loss, or after an overload or TCL fault is reset. The
user must ensure that automatic start up of the driven equipment will not cause injury to operating
personnel or damage to the driven equipment. The user is responsible for providing suitable audible or
visual alarms or other devices to indicate that the drive may start at any moment. Failure to observe
this warning could result in severe bodily injury or loss of life.

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SAFETY NOTICE Continued

WARNING: Do not use start/stop, inhibit or enable functions as a safety disconnect. Use only an AC line disconnect

for that purpose. Failure to observe this warning could result in severe bodily injury or loss of life.

Caution: Disconnect motor leads (A1 and A2) from control before you perform a Dielectric Withstand test on the motor.

Failure to disconnect motor from the control will result in extensive damage to the control. The control is tested

at the factory for high voltage / leakage resistance as part of Underwriter Laboratory requirements.

Caution: Do not connect AC power to the Motor terminals A1 and A2. Connecting AC power to these terminals

may damage the control.

Caution: Baldor recommends not to use Grounded Leg Delta transformer power leads that may create ground

loops. Instead, we recommend using a four wire Wye.

Caution: Suitable for use on a circuit capable of delivering not more than 5,000 RMS symmetrical short circuit

amperes listed here at rated voltage.

Caution: Adjusting the current limit above 150% of the motor nameplate rating can cause overheating and

demagnetization of the PM motor.

Caution: Do not leave the motor in a locked rotor condition for more than a few seconds since motor damage may occur.
Caution: Shunt wound motors may be damaged if field windings remain energized for an extended period of

time without armature rotation.

Receiving

Each control is thoroughly tested at the factory and carefully packaged for shipment.
When you receive your control, there are several things you should do immediately.

1. Observe the condition of the shipping container and report any damage immediately to the
commercial carrier that delivered your control.

2. Verify that the part number you received is the same as the part number listed on your purchase order.

3. Do not unpack until ready for use.

Table Electrical Ratings

AC Voltage

(± 15%, 50/60 Hz)

(VAC)

Motor

Voltage

(VDC)

Maximum Rating without Auxiliary Heat Sink Maximum Rating with Auxiliary Heat Sink

AC Current

(RMS Amps)

DC Load Current

(Avg. Amps)

Power

(HP, (kW))

AC Current

(RMS Amps)

DC Load

Current (Avg.

Amps)

Power
HP (kW)

115 90 – 130 12.0 6.0 0.75, (0.6) 16.0 12.0 1 (.75)

230 180 12.0 6.0 1.5, (1.1) 16.0 12.0 2 (1.5)

Table 1-2 General Performance Specifications

1

Description Specification Factory Setting

Speed Range (Ratio) 50:1 —
Armature Feedback Load Regulation (0 - Full Load, 50:1 Speed Range)

(% Base Speed)

1

2

—

Line Voltage Regulation (at Full Load, ± 10% Line Variation) (% Base Speed) 0.5

2

—
Control Linearity (% Speed vs. Dial Rotation) 2 —
Acceleration (ACCEL) Trimpot Range (Seconds) 0.2 - 10 2
Deceleration (DECEL) Trimpot Range (Seconds) 0.2 - 10 2
Maximum Speed (MAX) Trimpot Range (% Base Speed) 50 - 110

2

100
Minimum Speed (MIN) Trimpot Range (% Base Speed) 0 - 30

2

0
CL/Torque Range (% Full Load) 0 - 200 150
IR Compensation (IR) Trimpot Range (at Specified Full Load at 90/180 Volts

Output) (Volts DC)

0 - 24 / 0 - 48 3 / 6

Operating Temperature Range without Optional Auxiliary Heat Sink
(Catalog
No. BC143) (°C / °F)

0 - 40 / 32 - 104 —

Operating Temperature Range with Optional Auxiliary Heat Sink
(Catalog No. BC143) (°C / °F)

0 - 50 / 32 - 122 —

1. CE Compliance requires BC24-LF RFI Filter. (See Optional Accessories, Table 1-2).

2. Performance is for 90 Volt PM motors with 115 VAC line input and 180 Volt DC PM motors with 230 VAC line input.