Baldor BC141, BC142, BC142-5, BC142-6 Installation & Operating Manual

5/17 Installation & Operating Manual MN704

BC141, BC142, BC142-5 & BC142-6
DC Control

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Important:
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Acrobat PDF format.

i

MN704

Chapter 1
Introduction

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

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

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

Chapter 2
Installation

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

Electrical Connections ........................................................ 2-1

AC Line Fusing .............................................................. 2-1

AC Line Connection .......................................................... 2-2

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

Permanent Magnet (PM) Motor Connection ........................................ 2-3

Motor Field Connection (Shunt Wound Motors Only) .................................. 2-3

Full Voltage Field ............................................................ 2-3

Plug-In Horsepower Resistor® & Armature Fuse Kit* ................................. 2-3

Armature Fuse* ............................................................. 2-3

Remote Main Speed Potentiometer Connection ..................................... 2-4

Voltage Following Connection .................................................. 2-4

Enable Circuit Connection ..................................................... 2-5

Inhibit Circuit Connection ...................................................... 2-6

DC Tachometer Connection .................................................... 2-6

Armature Switching and Dynamic Braking ........................................ 2-8

Startup & Adjustments ........................................................ 2-8

Trimpot Adjustments ......................................................... 2-9

Operation ................................................................. 2-11

Troubleshooting ............................................................ 2-11

Optional Accessories ........................................................ 2-12

Table of Contents

1-1

MN704

Chapter 1

Introduction

Introduction

Thank you for purchasing the BC141, BC142, BC142-5 or BC142-6 full-wave variable speed DC motor
control. The control, with Surface Mount (SMT) construction, offers the user the ultimate in reliability
and performance at an affordable price. The controls contain a unique patented super-fast Direct­Fed™ current limit circuit that protects the SCR power bridge against direct shorts1. The reliability of
the control is further enhanced with the use of high-surge, 25 Amp SCRs, and AC line and armature
fusing2,3. The control is designed with exclusive Plug-In Horsepower Resistor® 3, which eliminates
the need for recalibrating IR Comp and Current Limit when the control is used on various horsepower
motors. In addition, the rating of the control can be extended to 1.5 HP for controls with 90 Volt DC
output and 3 HP for controls with 180 Volt DC output, by the use of an Auxiliary Heat Sink4. Catalog
Nos. BC142, BC142-5 and BC142-6 also allow operation of 90 Volt DC motors when used on 208/230
Volt AC line input5.

The versatility of the control is confirmed by its extensive list of standard features, such as: selectable
armature or tach feedback and adjustment trimpots for minimum speed, maximum speed, current
limit, IR compensation, and linear acceleration and deceleration. The control includes Auto-Inhibit®,
which eliminates surging during rapid AC line switching; pulse transformer triggering, which provides
cogless operation at low speed; and superior noise rejection circuitry, which eliminates false starts
and blown SCRs. Enable (normally closed) and Inhibit (normally open) functions provide electronic
switching of control output.

The output voltage of the control is a linear function of the Main Speed Potentiometer setting. In
addition, the control can be used in a voltage following mode by supplying an isolated analog input
signal to Terminals P2 (+) and P1 (-). The control is compact in size (only 4.30 X 3.64 X 1.25) and
easily replaces all competitive speed controls. The control is supplied with a factory installed 25 Amp
AC line fuse, a 5 kΩ Main Speed Potentiometer and QD terminals. All models are UL Listed (USA and
Canada) and CE Approved.

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.

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MN704

SAFETY NOTICE Continued

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.

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.

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MN704

Table 1-1 Electrical Ratings

Catalog
Number

AC Line
VAC

(±15%,
50/60Hz)

Motor
VDC

Rating without Auxiliary Heat
Sink

Rating with Auxiliary Heat Sink

Field
VDC
(1.13
Amps
Max)

Max
AC Line
Current
Amps

Max DC
Load
Current

Amps

Max
Power
HP (kW)

Max
AC Line
Current
Amps

Max DC
Load
Current

Amps

Max
Power
HP (kW)

BC141 115 0-90 12 8 .75 (.6) 24 16 1.5 (1.1) 50, 100

BC142 230

0-180 12 8 1.5 (1.1) 24 16 3 (2.3) 100, 200

0-90* 12 8 .75 (.6) 24 16 1.5 (1.1) 100

BC142-5

115 0-90 9 6 .75 (.6) 18 12 1.5 (1.1) 50, 100

230

0-180 9 6 1.5 (1.1) 18 12 3 (2.3) 100, 200

0-90* 9 6 .75 (.6) 18 12 1.5 (1.1) 100

BC142-6

115 0-90 12 8 .75 (.6) 24 16 1.5 (1.1) 50, 100

230

0-180 12 8 1.5 (1.1) 24 16 3 (2.3) 100, 200

0-90* 12 8 .75 (.6) 24 16 1.5 (1.1) 100

Table 1-2 General Performance Specifications

Description Specification Factory

Setting

Speed Range (Ratio) 50:1 —

Armature Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (%
Base Speed)

1 —

Tachometer Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (%
Set Speed)

1 —

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

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 – 110 100

Minimum Speed (MIN) Trimpot Range (% Base Speed) 0 – 30 0

Current Limit (CL) Trimpot Range (% Full Load) 0 – 200 150

IR Compensation (IR) Trimpot Range (at Specified Full Load @ 90, 180 Volts DC
Output) (Volts DC)

0 – 24, 48 3, 6

Maximum Operating Ambient Temperature at Full Load - °C / °F 40 / 104 —