BC141, BC142, BC142-5 BC142

BC141, BC142, BC142-5 BC142
BC141, BC142, BC142-5 & BC142-6
DC Control
6/15
Installation & Operating Manual
MN704
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Important:
Be sure to check www.baldor.com to download the latest version of this manual in Adobe
Acrobat PDF format.
Table of Contents
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
MN704
i
ii
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 phaseto-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.
MN704
1-1
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.
1-2
MN704
Table 1-1 Electrical Ratings
Rating without Auxiliary Heat
Sink
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)
Field
VDC
(1.13
Amps
Max)
0-90
12
8
.75 (.6)
24
16
1.5 (1.1)
50, 100
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
0-90
9
6
.75 (.6)
18
12
1.5 (1.1)
50, 100
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
0-90
12
8
.75 (.6)
24
16
1.5 (1.1)
50, 100
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
Catalog
Number
AC Line
VAC
(±15%,
50/60Hz)
Motor
VDC
BC141
115
BC142
230
115
BC142-5
230
115
BC142-6
230
Rating with Auxiliary Heat Sink
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
—
MN704
1-3
1-4
MN704
Chapter 2
Installation
WARNING: Do not use this drive in an explosive environment. An explosion can cause serious or fatal injury.
This drive is not explosion proof.
MOUNTING INSTRUCTIONS
It is recommended that the control be mounted on a flat surface with adequate ventilation. Leave
enough room to allow for AC line, motor connection, and other wiring that is required. Care should
be taken to avoid extreme hazardous locations where physical damage can occur. When mounting
the control in an enclosure, the enclosure should be large enough to allow for proper heat dissipation
so that the ambient temperature does not exceed 40°C (104°F). If the optional Auxiliary Heat Sink
is used, mount the control in such a manner that there is unrestricted air flow through the heat sink
cooling fins. See Figure 2-1.
Figure 2-1 Mechanical Specifications (Inches/mm)
3.64
92.5
OPTIONAL AUXILIARY HEAT SINK
MAIN SPEED
POTENTIOMETER
(SUPPLIED)
.22
5.6
3.10
78.5
3/8"
.98
24.9
1/2"
CONTROL
MOUNTING "A"
6 SLOTS
3.00
76.2
4.30
109
FUSE HOLDER & FINGER-SAFE
COVER MOUNTING HOLES
TAPPED 6-32
(2 PLACES)
1.50
38.1
2.15
54.6
M O U N T IN G " D "
2 S LOTS
1/4" ROUND
SHAFT
MOUNTING "B"
TAPPED 10-32
(3 PLACES)
ANTIROTATION
PIN
.75
19.1
1.75
44.5
1.75
44.5
.25
6.4
.64
16.3
.18
4.6
5.63
143
7.00
178
3.11
(79.0)
3/8-32
BUSHING
5.63
142.9
.13
3.1
P1
.95
24.1
1.25
31.8
P3
.44
11.1
P2
.50
12.7
6.25
159
1.25
31.8
1.38
34.9
Electrical Connections
Important Application Note: To avoid erratic operation, do not bundle the AC line and motor wires with
signal or control wiring. Also, do not bundle motor wires from multiple controls in the same conduit.
Use shielded cables on all signal wiring over 12 (30 cm). The shield should be earth grounded on the
control side only. Wire the control in accordance with the National Electrical Code requirements and
other local codes that may apply.
Table 2-2 Minimum Supply Wire Size Requirements
Max Motor
Current (ADC)
90 - 130 VDC
Motors
(Max HP)
180 Volt DC
Motors (Max
HP)
Min Wire Size (Cu)
Maximum 50 Ft.
AWG
mm2
Maximum 100 Ft.
AWG
mm2
6
0.5
1
16
1.3
14
2.1
12
1
2
14
2.1
12*
3.3*
16
1.5
3
12*
3.3*
12*
3.3*
AC Line Fusing
A 25 Amp AC line fuse is factory installed in the AC line fuse holder. It is recommended that a 12 Amp AC line
fuse be installed for motors rated 7.5 Amps DC or less. Fuses should be normal blow ceramic 3AG, MDA,
or equivalent. For USA 230 Volt AC lines, separate branch circuit protection for each line must be used. The
optional Barrier Terminal Board (Catalog No. BC147) contains prewired AC line and armature fuse holders.
MN704
2-1
The AC Line Fuse protects the control against catastrophic failure. If the AC Line Fuse blows, the control is
miswired, the motor is shorted or grounded, or the control is defective.
Fuse holders and fuses not supplied with BC142-5.
Note: Fuse each AC line conductor that is not at ground potential.
Figure 2-2 Control Layout & General Connection Diagram (Catalog No. BC142-6 Shown)
R ed
B lue
25 Amp*
Line Fuse
Factory Installed
F-
A+
L1
Plug-In
Horsepower R esistor®
S upplied S eparately
L2
DEC EL
Armature Fuse*
S upplied S eparately
F+
B
J2
T
CL
AC C EL
EN
C ONN1
P2
P3
PWR ON
J1
Enable S witch
(C lose to R un)
(Open to S top)
Plug-In Horsepower
R esistor® and
Armature Fuse Kit
supplied separately
S ee S ection 9.
A-
I1
P1
I2
MAX
MIN
CL
+
High
Wiper
Low
AC Line
Input
Main S peed Potentiometer
(Front View)
Inhibit S witch
(Open to R un)
(C lose to S top)
-
Motor Field
(S hunt Motors Only)
IR
+
+
7V
1000
M
G
Motor Armature
DC Tach-Generator
(S et J 2 to "T" Position)
* Fuse holders and fuses not supplied with B C 142-5.
AC Line Connection
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.
The control can be turned “on” and “off” using the AC line disconnect. Auto-Inhibit® circuitry automatically
resets critical components each time the AC line is interrupted. This, along with Acceleration Start and CL,
provides a smooth start each time the AC line is applied.
Connect the AC line to Terminals L1 (Line Fuse)* and L2, Figure 2-2. For 115VAC connect neutral to L2.
Catalog No. BC141 operates on 115 Volt AC line input only.
Catalog No. BC142 operates on 208/230 Volt AC line input only.
Catalog BC142-5 and BC142-6 operates on 115 Volt AC line input when Jumper J1 is set to the 115 position
and operates on 208/230 Volt AC line input when Jumper J1 is set to the 230 position (factory setting).
* Fuse holders and fuses not supplied with BC142-5.
Note: When using a step-down transformer (460 Volts AC to 230 Volts AC), be sure the output current
rating of the transformer is at least 3 times the current rating of the motor. Do not switch the
primary side of the transformer to disconnect power or catastrophic failure can result.
Always disconnect the control from the secondary side of the transformer.
Ground Connection
Connect the ground wire (earth) to the control chassis.
2-2
MN704
Permanent Magnet (PM) Motor Connection
Connect the motor armature positive lead (+) to Terminal A+ (Armature Fuse*) and the negative lead
(-) to Terminal A-. On Catalog Nos. BC142, BC142-5 and BC142-6, be sure Jumper J2 is set to the
corresponding motor voltage. Be sure the correct Plug-In Horsepower Resistor® is installed.
* Fuse holders and fuses not supplied with BC142-5.
Motor Field Connection (Shunt Wound Motors Only) see Figure 2-2
CAUTION! Do not connect motor armature leads to Terminals F+ and F-. Do not use Terminals F+ and F- for any
purpose other than to power the field of a shunt wound motor. Shunt wound motors may be damaged
if the field remains energized without armature rotation for an extended period of time.
Full Voltage Field
Connect the field positive (+) lead to Terminal F+ and the negative lead (-) to Terminal F-.
Half Voltage Field
For 50 Volt DC with 100 Volt rated armature, use Terminal L1 and F+.
Table 2-3 Field Connection (Shunt Wound Motors Only)
Catalog
No.
Input Voltage
(VAC)
Armature Voltage
(VDC)
Field Voltage
(VDC)
Terminal
Connections
BC141
115
0 -90
100
50
F+, L1
208 / 230
0 -180
200
F+, F-
0 -90*
100
F+, L1
100
F+, F-
BC142
BC142-5
BC142-6
F+, F-
115
0 -90
50
F+, L1
208 / 230
0 -180
200
F+, F-
208 / 230
0 -90*
100
F+, L1
*Step-down operation.
PLUG-IN HORSEPOWER RESISTOR® & ARMATURE FUSE KIT*
The Plug-In Horsepower Resistor® and Armature Fuse are supplied as a prepackaged kit. Choose
the appropriate Plug-In Horsepower Resistor® and Armature Fuse based on motor horsepower and
voltage, see Table 2-4.
The Plug-In Horsepower Resistor® (supplied separately) must be installed to match the control to the
motor horsepower and voltage.
Install the Plug-In Horsepower Resistor® see Figure 2-2.
Notes:
1. The Plug-In Horsepower Resistor® is used to calibrate the IR Compensation and Current Limit
based on motor horsepower and voltage. The Plug-In Horsepower Resistor® eliminates the need
to recalibrate IR Compensation and Current Limit in most applications.
2. Be sure the Plug-In Horsepower Resistor® is inserted completely into the mating sockets.
8.2 Armature Fuse*
It is recommended that an Armature Fuse (supplied separately) be installed in the armature fuse
holder. Select the correct fuse. Fuses should be normal blow ceramic 3AG, MDA, or equivalent. The
optional Barrier Terminal Board (Catalog No. BC147) contains prewired AC line and armature fuse
holders. The Armature Fuse provides overload protection for the motor and control.
The Armature Fuse rating can be calculated by multiplying maximum DC Motor Current X 1.7.
* Fuse holders and fuses not supplied with BC142-5.
MN704
2-3
Table 2-4 Plug-In Horsepower Resistor® & Armature Fuse Kit Selection
90 -130 VDC
Motors (HP)
180 VDC
Motors (HP)
1/100
1/50
1/30
1/20
1/15
1/12
1/8
1/6
1/4
1/3
1/2
3/4
1*
1-1⁄2*
1/50
1/25
1/15
1/10
1/8
1/6
1/4
1/3
1/2
3/4
1
1-1⁄2
2*
3*
Approximate
Motor Current
(ADC)
0.2
0.3
0.33
0.5
0.8
0.85
1.3
2
2.5
3.3
5
7.5
10
15
Plug-In HP Resistor and
Armature Fuse Kit Cat.
No.
BR1000
BR0510
BR0350
BR0250
BR0251
BR0180
BR0100
BR0101
BR0050
BR0035
BR0025
BR0015
BR0010
BR0006
Plug-In HP
Resistor Value
(Ω)
1
0.51
0.35
0.25
0.25
0.18
0.1
0.1
0.05
0.035
0.025
0.015
0.01
0.006
Armature Fuse
Rating (Amps)
0.5
0.5
0.5
0.75
1
1.25
2
2.5
4
5
8
12
15
25
* Indicates an Auxiliary Heat Sink (Catalog No. BC143, or equivalent) must be used.
Remote Main Speed Potentiometer Connection
The control is supplied with a Main Speed Potentiometer to control motor speed. Connect the low side
of the potentiometer to Terminal P1. Connect the wiper of the potentiometer to Terminal P2. Connect
the high side of the potentiometer to Terminal P3.
Figure 2-3 Remote Main Speed Potentiometer Connection
Terminal "P3"
EN
C ONN1
P3
P2
Terminal "P2"
P1
Terminal "P1"
MAX
High
Wiper
Low
Voltage Following Connection
Main Speed Potentiometer
(Front View)
An isolated 0 - 9 Volt DC analog signal input can be used to control motor speed in lieu of the Main
Speed Potentiometer. The control output voltage will linearly follow the analog signal input. The signal
input must be isolated from the AC line. Connect the signal input positive lead (+) to Terminal P2 and
the negative lead (-) to Terminal P1. The source impedance of the signal input should be 10 kΩ or less.
The MAX Trimpot is not operational in voltage following mode. Set the MIN Trimpot, on the control, to
zero output (full counterclockwise rotation) and use auxiliary trimpots, if necessary, to scale and/or
limit the input voltage.
2-4
MN704
Figure 2-4 Voltage Following Connection
C ONN1
EN
P3
P2
Terminal "P2"
P1
Terminal "P1"
MAX
+
V
0 - 9 Volts DC
(Isolated)
-
Notes:
1. If an isolated signal input is not available, or if using a 4 - 20 mA DC signal input, install the
optional plug-on Catalog No. BC152 Signal Isolator. This will also allow direct connections to
process controllers and microprocessors.
2. If multiple follower motors are to be controlled from a single leader motor or a single Main Speed
Potentiometer, install the optional Catalog No. BC145 Signal Isolator.
3. Terminal F- may be used in lieu of Terminal P1.
Enable Circuit Connection
Opening the Enable Circuit will not stop the drive if the Min Trimpot and/or the Main Input Speed
Signal is not at Zero Setting.
The Enable Circuit is never to be used as a Safety Disconnect since it is not fail-safe.
The control can be started and stopped with an Enable Circuit (close to run), as follows.
Enable Switch or Contact Wired to the Enable Connector
Using the wired mating connector that is supplied with the control, connect the switch or contact to
the Enable connector (CONN1). When the switch or contact is closed, the motor will accelerate to the
Main Speed Potentiometer setting. When the switch or contact is opened, the motor will decelerate to
Stop. An open collector (PNP) can be used in lieu of a switch or contact.
Figure 2-5 Enable Switch Or Contact Wired To The Enable Connector
Remove this jumper to install
the Mating Connector
(Open to Stop)
C ONN1
MAX
EN
C ONN1
EN
C ONN1
EN
Enable Switch
or Contact
(Close to Run)
Open Collector
(On to Run)
)
MAX
MAX
Notes:
1. To use the Enable Circuit, remove the jumper that is factory installed on CONN1.
2. The deceleration time can only be made longer than the normal coasting time of the load.
Enable Switch or Contact Wired to the Main Speed Potentiometer
Connect the switch or contact in series with the Main Speed Potentiometer high side and Terminal P3
on the control. Be sure the jumper is installed on the Enable Connector (CONN1). When the switch or
contact is closed, the motor will accelerate to the Main Speed Potentiometer setting. When the switch
or contact is opened, the motor will decelerate to the MIN Trimpot setting (factory set to 0 Volts DC). If
the MIN Trimpot is set to other than 0 Volts DC, the motor will run at the MIN speed setting when the
switch or contact is opened. An open collector (PNP) can be connected in lieu of a switch or contact.
MN704
2-5
Notes:
1. The deceleration time can only be made longer than the normal coasting time of the load.
2. If the BC152, Signal Isolator option board is installed onto the BC141, or BC142 control, the
ENABLE circuit will not funciton as described. If an ENABLE feature is required for the application,
connect a N.O. (normally open), contact or switch between the speed adjust potentiometer wiper
lead, or voltage following input signal, and the SIG terminal of TB1. When the contact or switch is
closed, the motor will accelerate to set speed. When the contact or switch is opened, the motor will
decelerate to zero speed at a rate set with the DECEL trimpot.
Figure 2-6 Enable Switch Or Contact Wired To The Main Speed Potentiometer
Terminal "P3"
P1
C ONN1
P3
This jumper must
be installed
Terminal "P2"
EN
EN
C ONN1
P2
P3
Terminal "P1"
MAX
P2
P1
MAX
Enable Switch or Contact
(Close to Run)
(Open to Stop)
High
Wiper
Open Collector
(On to Run)
High
Wiper
Low
Low
Main Speed Potentiometer
(Front View)
Main Speed Potentiometer
(Front View)
Inhibit Circuit Connection
The control can be stopped and started with an Inhibit Circuit (close to stop). Wire the switch or
contact to Terminals I1 and I2. When the switch or contact is closed, the motor will coast to stop.
When the switch or contact is opened, the motor will accelerate to the Main Speed Potentiometer
setting. An open collector (NPN) can be connected in lieu of a switch or contact.
The Inhibit Circuit is never to be used as a Safety Disconnect since it is not fail-safe.
Figure 2-7 Inhibit Switch Or Contact Wired To The Inhibit Terminals
Terminal "I1"
Terminal "I2"
I1
I1
I2
MIN
Inhibit Switch or Contact
(Open to Run)
(Close to Stop)
I2
MIN
Open Collector
(On to Stop)
DC Tachometer Connection
A DC tachometer can be used for load regulation of 1% of the set speed.
Jumper J2 must be set to the T position for tachometer operation.
Notes
1. The tachometer input circuit is designed for a 7 Volt or 50 Volt per 1000 RPM DC tachometer used
with an 1800 RPM motor.
2. Initially set the IR Comp Trimpot fully counterclockwise. Once the tachometer is connected, the IR
Comp Trimpot may be increased for additional speed stabilization.
2-6
MN704
Seven (7) Volt per 1000 RPM Tachometer
Connect the tachometer positive lead (+) to Terminal T and the negative lead (-) to Terminal I2.
Figure 2-8 DC Tachometer Connection (7 Volts Per 1000 RPM)
Terminal "T"
J2
B
T
PWR ON
+
Terminal "I2"
7V
1000
G
I2
DC Tachometer
Fifty (50) Volt per 1000 RPM Tachometer
Connect the tachometer positive lead (+) to Terminal B and the negative lead (-) to Terminal I2.
Figure 2-9 DC Tachometer Connection (50 Volts Per 1000 RPM)
Terminal "B "
J2
B
T
PWR ON
+
G
50V
1000
DC Tachometer
I2
Other Tachometer Voltages
The tachometer input circuit is designed for a 7 Volt or 50 Volt per 1000 RPM DC tachometer used
with an 1800 RPM motor. For a tachometer other than 7 Volts or 50 Volts per 1000 RPM, or for a motor
other than 1800 RPM, an external 1/2 Watt resistor (RT) must be installed. Install RT in series with the
tachometer.
Connect one end of RT to Terminal T, connect the other end of RT to the tachometer positive lead (+),
and connect the negative lead (-) of the tachometer to Terminal I2.
The value of RT Ω can be calculated using the following formula: RT = (1.3 X VT X S) - 16000 Ω
VT is the tachometer voltage (in Volts per 1000 RPM) and S is the base speed of the motor (in RPM).
Example: If a 20 Volt per 1000 RPM tachometer is to be used with a 3600 RPM motor:
RT = (1.3 X 20 X 3600) - 16000 = 77600 Ω
Choose the closest 1/2 Watt resistor value, which is 75000 Ω (75 kΩ).
Figure 2-10 Other DC Tachometer Connection
J2
B
T
PWR ON
RT
+
G
I2
MN704
DC Tachometer
2-7
Armature Switching and Dynamic Braking
If the armature is to be disconnected and reconnected with the AC power applied, connect a relay (or
contactor) and a brake resistor (RB) in the armature circuit. The Inhibit Circuit must be simultaneously
activated when braking. Wire a double pole double throw (DPDT) mechanically ganged switch to the
Inhibit Terminals and the relay (or contactor) coil.
When the switch is in the “Brake” position, the relay is deenergized and allows the motor voltage,
through N.C. contact, to be dissipated through RB and dynamically brake the motor. Simultaneously,
the inhibit is activated and the control output is electronically “extinguished”, which eliminates arcing.
Figure 2-11 Typical Dynamic Braking Circuit Connection
Speed Control
A+
AC Line Input
N.O.
N.C.
L1
RB
L2
I1
I2
Run
Brake
A-
+
M
Motor
Armature
-
Double Pole Double Throw
Mechanically Ganged Switch
Run
Brake
Relay or
Contactor Coil
When the switch is in the “Run” position, the N.C. contact opens, the N.O. contact closes, the Inhibit is
deactivated, and the motor begins to accelerate (according to the setting of the ACCEL Trimpot) to the
Main Speed Potentiometer setting.
Startup & Adjustments
The control has selectable jumpers which must be set before it can be used.
J1, AC Line Input Voltage Selection (Catalog No. BC142-5 and BC142-6 only)
Jumper J1 is factory set to the 230 position for 208/230 Volt AC line input.
For 115 Volt AC line input, set Jumper J1 to the 115 position, Figure 2-2.
Note: When Jumper J1 is set to the 115 position, Jumper J2 must be set to the 90 position (or the
T position if using a tachometer).
J2, Motor Voltage and DC Tachometer Selection
Jumper J2 is factory set to the “90” position on Catalog No. BC141, for 90 Volt DC motors, and set
to the “180” position, on Catalog Nos. BC142, BC142-5 and BC142-6, for 180 Volt DC motors. To set
Catalog No. BC142, BC142-5 and BC142-6 for step-down operation (208/230 Volts AC line input and
90 Volt DC output), set Jumper J2 to the “90” position). To set the control for tachometer connection,
set Jumper J2 to the “T” position (all models). See Figure 2-11.
Notes:
1. Catalog No. BC141, the “180” position is not available on Jumper J2.
2. Catalog No. BC142-5 and BC142-6, do not set the output voltage to 180 Volts DC when the
AC line input is set to 115 Volts.
2-8
MN704
Figure 2-11 Motor Voltage & DC Tachometer Selection (Jumper J2)
Catalog No.BC141
J2 Set for
90 Volt Motor
(Factory Setting)
Catalog Nos. BC142, BC142-5 and BC142-6
J2 Set for
Tachometer
J2 Set for
180 Volt Motor
(Factory Setting)
J2 Set for
90 Volt Motor
(Step-Down)
J2 Set for
Tachometer
J2
J2
J2
J2
J2
Before power is applied,
1. Verify the Line voltage is correct for your control and is correctly connected.
2. Verify the Voltage Select Switch is correctly set.
3. Verify the correct line and armature fulses are installed and connected.
4. Verify the correct Plug-In Horsepower Resistor® is installed.
5. Verify the speed adjust potentiometer is set fully counterclockwise.
6. Verify the Forward-Brake-Reverse switch is correctly set (if installed).
7. Apply AC power.
8. Observe the Power ON LED indicator is illuminated. If not on, refer to troubleshooting.
9. Verify correct direction of motor rotation.
Start the control. The motor shaft should begin to rotate as the potentiometer knob is turned
clockwise, or the analog speed reference signal is increased.
Verify the motor shaft is rotating in the desired ‘forward’ direction.
If the direction of rotation is incorrect, stop the control and disconnect AC power.
Switch the motor lead connections at the A+ and A- terminals.
If a tachometer is connected, the leads may also need to be switched for correct signal polarity.
If the CL LED is on, refer to troubleshooting.
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.
TRIMPOT ADJUSTMENTS
The control contains trimpots which have been factory set for most applications. Some applications
may require readjustment of the trimpots in order to tailor the control for a specific requirement.
Acceleration Trimpot (ACCEL)
The ACCEL Trimpot is provided to allow for a smooth start over an adjustable time period each time
the AC power is applied or the Main Speed Potentiometer is adjusted to a higher speed. The ACCEL
Trimpot has been factory set to 2 seconds, which is the amount of time it will take for the motor to
accelerate from zero speed to full speed. To increase the acceleration time, rotate the ACCEL Trimpot
clockwise. To decrease the acceleration time, rotate the ACCEL Trimpot counterclockwise.
Deceleration Trimpot (DECEL)
The DECEL Trimpot controls the amount of ramp-down time when the Main Speed Potentiometer
is adjusted to a lower speed. The DECEL Trimpot has been factory set to 2 seconds, which is the
amount of time it will take for the motor to decelerate from full speed to zero speed. To increase the
deceleration time, rotate the DECEL Trimpot clockwise. To decrease the deceleration time, rotate the
DECEL Trimpot counterclockwise.
Note: The deceleration time cannot be less than the natural coast time of the motor and actual load.
Minimum Speed Trimpot (MIN)
The MIN Trimpot sets the minimum speed of the motor when the Main Speed Potentiometer is set
fully counterclockwise. The MIN Trimpot is factory set to 0 % of base motor speed. To increase the
minimum speed, rotate the MIN Trimpot clockwise. To decrease the minimum speed, rotate the MIN
Trimpot counterclockwise.
MN704
2-9
Note: Readjusting the MIN Trimpot will affect the maximum speed setting. Therefore, it is necessary
to readjust the MAX Trimpot if readjusting the MIN Trimpot. It may be necessary to repeat these
adjustments until both the minimum and maximum speeds are set to the desired levels.
Maximum Speed Trimpot (MAX)
The MAX Trimpot sets the maximum speed of the motor when the Main Speed Potentiometer is
set fully clockwise. The MAX Trimpot is factory set to 100 % of base motor speed. To increase the
maximum speed, rotate the MAX Trimpot clockwise. To decrease the maximum speed, rotate the MAX
Trimpot counterclockwise.
Do not set the maximum speed above the rated motor RPM since unstable motor operation may occur.
Current Limit Trimpot (CL)
The CL Trimpot sets the current limit (overload), which limits the maximum current (torque) to the
motor. The CL also limits the AC line inrush current to a safe level during startup. The CL Trimpot
is factory set to 1.5 times the full load rating of the motor. To increase the current limit, rotate the
CL Trimpot clockwise. To decrease the current limit, rotate the CL Trimpot counterclockwise. Some
applications require a lower torque limiting value so as not to damage the process material or the
drive train.
Note: The correct value Plug-In Horsepower Resistor® must be installed for the CL to operate properly.
Calibration of the CL Trimpot is normally not required when the proper Plug-In Horsepower
Resistor® is installed.
Caution: Adjusting the CL above 150% of motor rating can cause overheating and demagnetization of some PM
motors. Consult motor manufacturer.
To Recalibrate the CL Trimpot:
1. Disconnect the AC power and wire a DC ammeter in series with either motor armature lead.
Note: If only an AC ammeter is available, wire it in series with either AC line input lead.
2. Set the Main Speed Potentiometer to approximately 30 - 50 % clockwise position.
3. Set the CL Trimpot fully counterclockwise.
4. Load the motor shaft in accordance with application requirements.
5. Apply power and the CL LED will illuminate red. Rotate the CL Trimpot clockwise until the desired
current reading is observed on the ammeter. Factory Current Limit setting is 1.5 times the full load
rating of the motor (with a DC ammeter wired in series with the motor armature). If using an AC
ammeter wired in the AC line input, the factory Current Limit setting will read 0.75 times the full
load rating of the motor.
Note: On cyclical loads, it may be normal for the CL LED to momentarily flash.
IR Compensation Trimpot (IR)
The IR Trimpot sets the amount of compensating voltage required to keep the motor speed constant
under changing loads. If the load does not vary substantially, the IR Trimpot may be set to a minimum
level (approximately 1/4 of full clockwise rotation). The IR Trimpot is factory set to provide 3 Volts of
compensation for controls with 90 Volt DC output and 6 Volts of compensation for controls with 180
VDC output. To increase the amount of compensating voltage, rotate the IR Trimpot clockwise. To
decrease the amount of compensating voltage, rotate the IR Trimpot counterclockwise.
Notes:
1. The correct value Plug-In Horsepower Resistor® must be installed for the IR Compensation to
operate properly. Calibration of the IR Trimpot is normally not required when the proper Plug-In
Horsepower Resistor® is installed.
2. Excessive IR Compensation will cause the motor to become unstable, which causes cogging.
3. For tachometer feedback applications, set the IR Trimpot fully counterclockwise.
To Recalibrate the IR Trimpot:
1. Set the IR Trimpot to approximately 25% rotation.
2. Run the motor unloaded at approximately 1/3 speed and record the RPMs.
2-10
MN704
3. Run the motor with the maximum load and adjust the IR Trimpot so that the motor speed under
load equals the unloaded speed recorded in step 2.
4. Remove the load and recheck the RPMs.
5. If the unloaded RPM has changed, repeat steps 2 - 4 for more exact regulation. The control is now
compensated to provide minimal speed change due to changing loads.
Operation
Set the AC Line Switch to the ON position. Observe that the Pilot Light illuminates. Gradually increase
the Main Speed Potentiometer. The motor should smoothly come up to the desired speed and remain
stable.
Troubleshooting
The control has LEDs to display the control’s operational status.
Power On (PWR ON) LED and Pilot Light
When the AC power is applied to the control and the On/Off AC Line Switch is set ON, the PWR ON
LED, on the PC board, will illuminate green and the Pilot Light, on the front cover, will illuminate
orange.
Current Limit (CL) LED
The CL LED will illuminate red when the motor is overloaded, indicating that the current limit set point
has been reached (set by the CL Trimpot).
Table 2-4 provides information on symptoms, possible causes, and the suggested corrective action for
controls without optional forward-brake-reverse switch installed.
Table 2-4 Troubleshooting Guide (without Optional Forward-Brake-Reverse Switch)
Symptom
Possible Cause
Suggested Corrective Action
On/Off AC Line Switch in Off
Position.
Set On/Off Switch to On Position.
Blown Line fuse.
Replace Line Fuse.
Defective On/Off AC Line Switch,
Replace On/Off AC Line Switch.
Main Speed Potentiometer set fully
counterclockwise.
Rotate Main Speed potentiometer clockwise.
Defective motor.
Check for defective motor, worn brushes, etc.
Replace motor, if necessary.
Plug-In Horsepower Resistor® not
installed.
Install the correct Plug-In Horsepower
Resistor®.
Blown Armature Fuse.
Replace Armature Fuse.
CL Trimpot set fully
counterclockwise.
Set CL Trimpot
Motor hums, runs at very
low speed, or slows down
substantially when loaded.
Low AC line input voltage.
Check AC line input voltage.
Motor continues to run with
Main Speed Potentiometer
set fully counterclockwise.
MIN speed trimpot set higher than
0% of base speed.
Readjust the MIN Trimpot.
IR Comp trimpot set too high.
Readjust the IR Trimpot.
Motor runs in wrong
direction.
Motor armature leads are reversed.
Reconnect motor armature leads.
Motor is not running and
Pilot Light not illuminated.
Motor does not run and
Pilot Light is illuminated.
MN704
2-11
Table 2-4 Troubleshooting Guide (without Optional Forward-Brake-Reverse Switch)
Symptom
Motor will not run in Forward
or Reverse direction.
No braking action in brake
mode.
Erratic motor performance.
Possible Cause
Suggested Corrective Action
Faulty wiring or loose connections
to the reversing switch.
Check and correct connections.
Forward-Brake-Reverse Switch is
defective.
Replace Forward-Brake-Reverse Switch
assembly.
Faulty connections or loose
connections.
Check and correct connections.
Defective Brake Resistor.
Replace Forward-Brake-Reverse Switch
assembly.
Overload condition.
Remove overload.
Incorrect Plug-In Horsepower
Resistor®.
Install the correct Plug-In Horsepower
Resistor®.
CL and/or IR Trimpots may be set
incorrectly.
Readjust the CL and/or IR Trimpots
Defective speed control module.
Replace speed control.
Voltage Select Switch set to wrong
position.
Recheck line voltage and the correct setting of
the Voltage Select Switch.
Defective motor, worn brushes, etc.
Repair or replace motor.
Optional Accessories
1. Auxiliary Heat Sink (Catalog No. BC143) - Doubles the horsepower rating of the control.
2. Barrier Terminal Board (Catalog No. BC147) - Converts the quick-connect terminals of the control
to a barrier terminal block. Contains PC board mounted line and armature fuse holders (fuses
supplied separately). Plugs onto the quick-connect terminals of the control.
3. Signal Isolator (Catalog No. BC152) - Provides isolation between non-isolated signal sources and
the control. Plugs onto the quick-connect terminals of the control. May also use BC145 Signal
Isolater, separately mounted.
4. Dial Plate and Knob Kit (Catalog No. BC149) - Provides indication of the Main Speed Potentiometer
position (0 - 100 %).
5. DIN Rail Mounting Kit (Catalog No. BC218)
6. Current Sensing Overload Protector (Catalog No. BC146) - Provides overload current sensing and
protection of DC motors and speed controls rated 1/8 - 3 HP by sensing armature current.
Operates on 115 or 230 Volt AC line input.
7. RFI Filter (Catalog No. BC24-LF) - Provides RFI and EMI suppression. Rated 24 Amps at 230 Volts
AC, 50/60 Hz. Complies with CE Directive 89/336/EEC (EN55022 and/or EN55011) relating to the
EMC Class A Industrial Standard. Remote mountable.
2-12
MN704
Baldor District Offices
UNITED STATES
ARIZONA
PHOENIX
4211 S 43RD PLACE
PHOENIX, AZ 85040
PHONE: 602-470-0407
FAX: 602-470-0464
ARKANSAS
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CLARKSVILLE, AR 72830
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FAX: 479-754-9205
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COMMERCE, CA 90040
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FAX: 323-721-5859
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HAYWARD, CA 94545
PHONE: 510-785-9900
FAX: 510-785-9910
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DENVER
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DENVER, CO 80207
PHONE: 303-623-0127
FAX: 303-595-3772
CONNECTICUT
WALLINGFORD
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WALLINGFORD, CT 06492
PHONE: 203-269-1354
FAX: 203-269-5485
FLORIDA
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VIRGIN ISLANDS
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TAMPA, FL 33605
PHONE: 813-248-5078
FAX: 813-241-9514
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FAX: 770-772-7200
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BOLINGBROOK, IL 60440
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FAX: 630-226-9420
NEW YORK
AUBURN
ONE ELLIS DRIVE
AUBURN, NY 13021
PHONE: 315-255-3403
FAX: 315-253-9923
TENNESSEE
MEMPHIS
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MEMPHIS, TN 38118
PHONE: 901-365-2020
FAX: 901-365-3914
INDIANA
INDIANAPOLIS
5525 W. MINNESOTA STREET
INDIANAPOLIS, IN 46241
PHONE: 317-246-5100
FAX: 317-246-5110
NORTH CAROLINA
GREENSBORO
1220 ROTHERWOOD ROAD
GREENSBORO, NC 27406
PHONE: 336-272-6104
FAX: 336-273-6628
TEXAS
DALLAS
2920 114TH STREET SUITE 100
GRAND PRAIRIE, TX 75050
PHONE: 214-634-7271
FAX: 214-634-8874
IOWA
DES MOINES
1943 HULL AVENUE
DES MOINES, IA 50313
PHONE: 515-263-6929
FAX: 515-263-6515
OHIO
CINCINNATI
2929 CRESCENTVILLE ROAD
WEST CHESTER, OH 45069
PHONE: 513-771-2600
FAX: 513-772-2219
MARYLAND
BALTIMORE
7071A DORSEY RUN RD
ELKRIDGE, MD 21075
PHONE: 410-579-2135
FAX: 410-579-2677
OHIO (Continued)
CLEVELAND
8929 FREEWAY DRIVE
MACEDONIA, OH 44056
PHONE: 330-468-4777
FAX: 330-468-4778
UTAH
SALT LAKE CITY
2230 SOUTH MAIN STREET
SALT LAKE CITY, UT 84115
PHONE: 801-832-0127
FAX: 801-832-8911
MASSACHUSETTS
BOSTON
6 PULLMAN STREET
WORCESTER, MA 01606
PHONE: 508-854-0708
FAX: 508-854-0291
OKLAHOMA
TULSA
5555 E. 71ST ST., SUITE 9100
TULSA, OK 74136
PHONE: 918-366-9320
FAX: 918-366-9338
WISCONSIN
MILWAUKEE
1960 SOUTH CALHOUN ROAD
NEW BERLIN, WI 53151
PHONE: 262-784-5940
FAX: 262-784-1215
MICHIGAN
DETROIT
5993 PROGRESS DRIVE
STERLING HEIGHTS, MI 48312
PHONE: 586-978-9800
FAX: 586-978-9969
OREGON
PORTLAND
16201 SE 98TH AVENUE
CLACKAMAS, OR 97015
PHONE: 503-691-9010
FAX: 503-691-9012
INTERNATIONAL SALES
FORT SMITH, AR
P.O. BOX 2400
FORT SMITH, AR 72902
PHONE: 479-646-4711
FAX: 479-648-5895
MINNESOTA
MINNEAPOLIS
13098 GEORGE WEBER DR,
SUITE 400
ROGERS, MN 55374
PHONE: 763-428-3633
FAX: 763-428-4551
PENNSYLVANIA
PHILADELPHIA
103 CENTRAL AVENUE
SUITE 400B
MOUNT LAUREL, NJ 08054
PHONE: 856-840-8011
FAX: 856-840-0811
PITTSBURGH
159 PROMINENCE DRIVE
NEW KENSINGTON, PA 15068
PHONE: 724-889-0092
FAX: 724-889-0094
MISSOURI
ST LOUIS
13678 LAKEFRONT DRIVE
EARTH CITY, MO 63045
PHONE: 314-373-3032
FAX: 314-373-3038
KANSAS CITY
9810 INDUSTRIAL BLVD.
LENEXA, KS 66215
PHONE: 816-587-0272
FAX: 816-587-3735
HOUSTON
10355 W. LITTLE YORK ROAD
SUITE 300
HOUSTON, TX 77041
PHONE: 281-977-6500
FAX: 281-977-6510
MN704-0615
Baldor Electric Company
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
www.baldor.com
© Baldor Electric Company
MN704
All Rights Reserved. Printed in USA.
(A40249) - Rev D 6/15
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