BC140 / BC140

BC140 / BC140
BC140 / BC140-FBR DC CONTROL
6/15
Installation & Operating Manual
MN703
Any trademarks used in this manual are the property of their respective owners.
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
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permanent Magnet (PM) Motor Armature Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Field Connection (Shunt Wound Motors Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Full Voltage Field. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup & Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A
Options
Optional auxiliary heat sink (catalog no. BC143). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional forward -brake-reverse switch (catalog no. BC144)* . . . . . . . . . . . . . . . . . . . . . . . . . . .
MN703
2-1
2-1
2-2
2-2
2-2
2-2
2-2
2-2
2-3
2-3
2-4
2-5
2-5
2-7
2-7
A-1
A-1
i
ii
MN703
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 fieldproven 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 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.
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.
MN703
1-1
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)
115
90 – 130
230
180
Maximum Rating without Auxiliary Heat Sink
AC Current
(RMS Amps)
Maximum Rating with Auxiliary Heat Sink
DC Load
Current (Avg. Power
HP (kW)
Amps)
DC Load Current
(Avg. Amps)
Power
(HP, (kW))
AC Current
(RMS Amps)
12.0
6.0
0.75, (0.6)
16.0
12.0
1 (.75)
12.0
6.0
1.5, (1.1)
16.0
12.0
2 (1.5)
Table 1-2 General Performance Specifications
1
Description
Speed Range (Ratio)
Armature Feedback Load Regulation (0 - Full Load, 50:1 Speed Range)
(% Base Speed)
Line Voltage Regulation (at Full Load, ± 10% Line Variation) (% Base Speed)
Control Linearity (% Speed vs. Dial Rotation)
Acceleration (ACCEL) Trimpot Range (Seconds)
Deceleration (DECEL) Trimpot Range (Seconds)
Maximum Speed (MAX) Trimpot Range (% Base Speed)
Minimum Speed (MIN) Trimpot Range (% Base Speed)
CL/Torque Range (% Full Load)
IR Compensation (IR) Trimpot Range (at Specified Full Load at 90/180 Volts
Output) (Volts DC)
Operating Temperature Range without Optional Auxiliary Heat Sink
(Catalog
No. BC143) (°C / °F)
Specification
50:1
12
Factory Setting
—
—
0.52
2
0.2 - 10
0.2 - 10
50 - 1102
0 - 302
0 - 200
0 - 24 / 0 - 48
—
—
2
2
100
0
150
3/6
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.
1-2
MN703
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.
Introduction
The control is designed with a NEMA-1 / IP-40 enclosure for indoor use. It is recommended that the
control be mounted vertically on a flat surface with adequate ventilation. Leave enough room below
the control to allow for AC line and motor connections and any other connections that are required.
A mounting template is included to facilitate mounting of the control.
Control installation must ensure unrestricted air flow through the heatsink cooling fins.
Note: If drive is mounted in other than a vertical position, decrease maximum allowable ambient
temperature by 10°C.
Front Cover - The control is designed with a removable cover. To remove the cover, the two screws
must be removed.
After mounting the control and all connections are completed, install the cover and secure it with the
two screws. Tighten the screws to 5 lbs-in (6 kg-cm). Do not overtighten.
Figure 2-1 Mounting Hole Locations
Two (2) Knockouts
for Standard
3/4” Fittings
5.00
[127]
4.125
[105]
4X Ø
4.00
[102]
0.39
[9.91]
5.63 7.00
[143] [178]
0.35
9.0
4X Ø
Side View is Shown Dimensioned with
Cover Installed and Optional
Forward-Brake-Reverse Switch
0.2
[5.08]
Back View is Shown Dimensioned
without Cover Installed
Mounting
The control is designed with a NEMA-1 / IP-40 enclosure for indoor use. It is recommended that the
control be mounted vertically on a flat surface with adequate ventilation. Leave enough room below
the control to allow for AC line and motor connections and any other connections that are required.
A mounting template is included to facilitate mounting of the control. See Figure 2-1.
Care should be taken to avoid extreme hazardous locations where physical damage can occur.
The control should be located in an area where it will not be exposed to contaminants such as water,
metal chips, solvents or excessive vibration.
Without the Auxiliary Heat Sink, the temperature around the control must not exceed 50°C (122°F).
With the Auxiliary Heat Sink, the temperature around the control must not exceed 40°C (104 °F).
The control is designed with a removable cover. To remove the cover, the two screws must be
removed.
After mounting the control and all connections are completed, install the cover and secure it with the
two screws. Tighten the screws to 5 lbs-in (6 kg-cm). Do not overtighten.
MN703
2-1
Electrical Connections
Connection terminals are shown in Figure 2-2.
Figure 2-2 AC Line, Armature, Field*, and Ground Connections
Barrier
Terminal Block
A-
A+
F-
Armature
F+
L1
Field
L2
GND
115 or 208/230 Volts
AC Line Input
Ground (Earth)
DC Motor
Ground (Earth)
-
AC Power
Verify AC Line voltage matches to control voltage rating, (115/208/230VAC - 50/60 Hz. 1phase).
Connect AC Line to L1 and L2 terminals and tighten to correct torque (Table 2-1). The installer should
provide fuse protection for each ungrounded supply conductor. See Table 2-2.
The AC Line fuse is factory installed. The Armature fuse (supplied separately) must be installed in the
armature fuse holder, as shown in Figure 2-3.
Fuses are available from your distributor. All fuses should be normal blow ceramic 3AG, MDA, or
equivalent. On domestic 230 Volt AC lines, separate branch circuit protection for each line must be
used.
Table 2-1 Terminal Block Wire and Tightening Torque Specifications
Maximum Wire Size (Cu)
Maximum
Motor Current
(ADC)
90 – 130
VDC Motors
(Max HP)
180 VDC
Motors
(Max HP)
Maximum
50 Ft.
Maximum
100 Ft.
Recommended
Tightening Torque
AWG
mm2
AWG
mm2
lb-in
kg-cm
6
1/2
1
16
1.3
14
2.1
12
13.8
12
1
2
14
2.1
12
3.3
12
13.8
The AC Line Fuse acts as a disconnect in case of a catastrophic failure. If the AC Line Fuse blows, the
control is miswired, the motor is shorted or grounded, or the control is defective.
Ground Connection
Connect all ground wires (earth), of connections to the control, to the green ground screw on the
chassis, tighten to correct torque (Table 2-2).
Permanent Magnet (PM) Motor Armature Connection
Connect the motor armature positive lead (+) to Terminal A+ and negative lead (-) to Terminal A-, as
shown in Figure 2-1.
Motor Field Connection (Shunt Wound Motors Only)
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-, on the
Barrier Terminal Block (Table2-2).
Half Voltage Field
For 50 Volt DC with 100 Volt rated armature, use Terminal L1 and F+, on the terminal board (Table2-2).
2-2
MN703
Table 2-2 Armature and AC Line Fuse Chart
Motor Horsepower
90VDC
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*
Approximate Motor
Current (Amps DC)
180VDC
1/50
1/25
1/15
1/10
1/8
1/6
1/4
1/3
1/2
3/4
1
1½
2*
Fuse Selection
(AC Amps)
Armature
0.5
0.5
0.5
0.75
1
1.25
2
2.5
4
5
8
12
15
0.2
0.3
0.33
0.5
0.8
0.85
1.3
2
2.5
3.3
5.0
7.5
10
Line
12
12
12
12
12
12
12
12
12
12
12
12
25
*With optional Auxiliary Heat Sink (Catalog No. BC143).
Table 2-3 Field Connection (Shunt Wound Motors Only)
AC Input Voltage
(Volts AC)
Voltage Selector
Switch (Position)
Armature Voltage
(Volts DC)
115
115
0 – 90
208/230
230
0 – 180
0 – 90*
Field Voltage
(Volts DC)
100
50
200
100
Terminal
Connections
F+, FF+, L1
F+, FF+, L1
Plug-In Horsepower Resistor®
A Plug-In Horsepower Resistor® (supplied separately) must be installed to match the control to the
motor so the IR Compensation and Current Limit settings to be correct. Select the proper Plug-In
Horsepower Resistor® according to Table 2-3. Plug-In Horsepower Resistors® are available from
your distributor. Install the Plug-In Horsepower Resistor®, as shown in Figure 2-3.
Note: Be sure the Plug-In Horsepower Resistor® is inserted completely into the mating sockets.
Table 2-4 Plug-In Horsepower Resistor® and Armature Fuse Kit Information
Motor Horsepower
Armature
VDC
90 – 130
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*
MN703
Armature
VDC
180
1/50
1/25
1/15
1/10
1/8
1/6
1/4
1/3
1/2
3/4
1
1½
2*
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
Plug-In HP Resistor® and
Armature Fuse Kit
Plug-In HP
Resistor Value
(Ohms)
1.0
0.51
0.35
0.25
0.25
0.18
0.1
0.1
0.05
0.035
0.025
0.015
0.01
Armature Fuse Rating
(Amps)
Catalog No.
0.5
0.5
0.5
0.75
1
1.25
2
2.5
4
5
8
12
15
BR1000
BR0510
BR0350
BR0250
BR0251
BR0180
BR0100
BR0101
BR0050
BR0035
BR0025
BR0015SP
BR0010SP
2-3
Figure 2-3 Control Layout and Internal Connection Diagram
F-
A-
A+
ARMATURE
F-
F+
FIELD
L1
L2
LINE
GND
Important Considerations
Motor Type
The BC140 / BC140-FBR is designed for permanent magnet (PM) and Shunt Wound DC motors.
Controls operated on 115 Volt AC line input are designed for 90 Volt SCR rated motors. Controls
operated on 230 Volt AC line input are designed for 180 and 90 Volt (step-down) SCR rated motors.
Use of higher voltage motors will result in a reduction of the available maximum speed. Also, if motor
is not an SCR rated type, the actual AC line amperage of the control, at full load, should not exceed the
motor’s DC nameplate rating.
Torque Requirements
The motor selected for the application must be capable of supplying the necessary torque. To ensure
the motor is not overloaded, a DC ammeter should be connected in series with the armature. Be sure
the current under full load does not exceed the motor nameplate rating.
Acceleration Start
The BC140 / BC140-FBR contains an adjustable acceleration start feature which allows the motor to
smoothly accelerate from zero speed to full speed over a time period of 0.2-10 seconds.
The acceleration trimpot (ACCEL) is factory set for 2 seconds.
Limitation In Use
The BC140 / BC140-FBR control is designed for use on machine applications.
2-4
MN703
Startup & Adjustments
The Voltage Select Switch is located under the cover and must be set before applying power to the
control. Figure 2-4.
For 208/230 Volt AC Line Input
Set the Voltage Select Switch to the 230 position (factory setting). The switch toggle should be in the
lower position with 230 displayed at the top.
For 115 Volt AC Line Input
Set the Voltage Select Switch to the 115 position. The switch toggle should be in the upper position
with 115 displayed at the bottom.
Figure 2-4 Voltage Select Switch Setting
208/230 Volt AC Line Input
(Factory Setting)
115 Volt AC Line Input
After the control has been mounted properly and electrical connections have been completed,
1. Verify the speed adjust potentiometer is set fully counterclockwise.
2. Apply AC power.
3. Observe the Power ON LED indicator is illuminated. If not on, refer to troubleshooting.
4. 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 to tailor the control for a specific performance requirement.
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. The MIN Trimpot range is 0% – 30% of base motor speed.
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. The MAX Trimpot range is 50% – 110% of base motor speed.
Note: The MAX trimpot is inoperative in the voltage following mode.
Caution: Do not set the maximum speed above the rated motor RPM since unstable motor operation ay occur.
Note: Do not adjust the maximum speed above the rated motor RPM or unstable operation may occur.
MN703
2-5
For moderate changes in the maximum speed, there will be a slight effect on the minimum speed
setting when the minimum is set to zero. There may be significant variation in the minimum speed
setting if the minimum speed is at a higher than zero setting.
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 is 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. The ACCEL Trimpot
range is 0.2 – 10 seconds.
Deceleration Trimpot (DECEL)
The DECEL Trimpot controls the amount of rampdown time when the Main Speed Potentiometer is
adjusted to a lower speed. The DECEL Trimpot is 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. The DECEL Trimpot range is 0.2 – 10 seconds.
Current Limit Trimpot (CL)
The CL Trimpot is used to limit the maximum current (torque) to the motor. The CL also protects the
control from excessive current during startup. The CL Trimpot is factory set to 150% of the full load
current rating of the motor. To increase the current limit, rotate the CL Trimpot clockwise (do not
exceed 200% of the full load current rating of the motor (maximum clockwise position)). To decrease
the current limit, rotate the CL Trimpot counterclockwise. On cyclical loads, it may be normal for the
CL LED to momentarily flash.
(Visible only if the cover is removed.) The CL Trimpot range is 0% – 200% of the full load current
rating of the motor. Some application may require a lower value so as not to damage process material
or drive train components.
Note: For the Current Limit to operate properly, the correct Plug-In Horsepower Resistor® must be
installed for the particular motor and input voltage being used. Calibration of the CL Trimpot is
normally not required when the proper Plug-In Horsepower Resistor® is installed.
Caution: do not leave motor shaft locked for more than 2 – 3 seconds or motor damage may result.
To Recalibrate the CL Trimpot:
1. Disconnect the AC power and connect a DC ammeter in series with either motor armature lead.
If only an AC ammeter is available, connect 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. The CL LED will illuminate red.
4. Load the motor shaft in accordance with application requirements.
Apply power and rotate the CL Trimpot clockwise until the desired current reading is observed on the
DC ammeter. Factory Current Limit setting is 150% of the full load current rating of the motor. If using
an AC ammeter connected in the AC line input, the factory Current Limit setting will read 75% of the
full load current rating of the motor. Do not exceed 200% of the full load current rating of the motor
(maximum clockwise position).
IR Compensation Trimpot (IR)
The IR Trimpot sets the amount of compensating voltage required to keep the motor speed constant
under varying 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
Volt DC 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.
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.
2-6
MN703
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.
If the unloaded RPM has changed, repeat steps 2 and 4 for better 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 BC140 / BC140-FBR 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.
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.
Motor is not running and
Pilot Light not illuminated.
Motor does not run and
Pilot Light is illuminated.
Motor will not run in Forward
or Reverse direction.
MN703
2-7
Table 2-4 Troubleshooting Guide (without Optional Forward-Brake-Reverse Switch)
Symptom
No braking action in brake
mode.
Erratic motor performance.
Possible Cause
Suggested Corrective Action
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.
Table 2-5 Electrical Ratings
Line Voltage
(± 15%,
50/60 Hz)
(VAC)
2-8
Motor
Voltage
(VDC)
"Maximum Rating without Auxiliary
Heat Sink"
Maximum Rating with Auxiliary Heat Sink
Line Current
(RMS Amps)
Load Current
(ADC)
Power
HP (kW)
Line Current
(RMS Amps)
Load Current
(ADC)
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)
MN703
Appendix A
OPTIONAL AUXILIARY HEAT SINK (CATALOG NO. BC143)
The optional Auxiliary Heat Sink (Catalog No. BC143) is used to increase the rating of the control.
The control is mounted on the four (4) holes with four (4) mounting screws (supplied), Figure A-1.
Figure A-1 Optional Auxiliary Heat Si nk Mechanical Specifications
5.63 7.00
[143] [178]
5.61
[142]
6.29
[160]
1.375
[34.9]
OPTIONAL Forward -brake-reverse switch (CATALOG NO. BC144)*
The optional Forward-Brake-Reverse Switch (Catalog No. BC144)* is used to dynamically brake
the motor and reverse motor direction. The switch assembly is to be installed in the mounting hole
provided on the control.
See the installation instructions MN1372, provided with the Forward-Brake-Reverse Switch kit for
detailed information on mounting and connections.
Figure A-2 shows the connections of the Forward-Brake-Reverse Switch to the speed control and the
Barrier Terminal Block. * BC144 is factory installed on BC140-FBR model.
Figure A-2 Optional Forward-Brake- Reverse Switch Connections
MN703
A-1
Optional RFI Filter (BC24-LF)
Panel mount. Rated 24 Amps at 115 and 208/230 Volts AC, single phase. Complies with CE Directive
89/336/EEC (EN55022 and/or EN55011) relating to the EMC Class A Industrial Standard.
A-2
MN703
Baldor District Offices
UNITED STATES
ARIZONA
PHOENIX
4211 S 43RD PLACE
PHOENIX, AZ 85040
PHONE: 602-470-0407
FAX: 602-470-0464
ARKANSAS
CLARKSVILLE
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CLARKSVILLE, AR 72830
PHONE: 479-754-9108
FAX: 479-754-9205
CALIFORNIA
LOS ANGELES
6480 FLOTILLA STREET
COMMERCE, CA 90040
PHONE: 323-724-6771
FAX: 323-721-5859
HAYWARD
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HAYWARD, CA 94545
PHONE: 510-785-9900
FAX: 510-785-9910
COLORADO
DENVER
3855 FOREST STREET
DENVER, CO 80207
PHONE: 303-623-0127
FAX: 303-595-3772
CONNECTICUT
WALLINGFORD
65 SOUTH TURNPIKE ROAD
WALLINGFORD, CT 06492
PHONE: 203-269-1354
FAX: 203-269-5485
FLORIDA
TAMPA/PUERTO RICO/
VIRGIN ISLANDS
3906 EAST 11TH AVENUE
TAMPA, FL 33605
PHONE: 813-248-5078
FAX: 813-241-9514
GEORGIA
ATLANTA
62 TECHNOLOGY DRIVE
ALPHARETTA, GA 30005
PHONE: 770-772-7000
FAX: 770-772-7200
ILLINOIS
CHICAGO
340 REMINGTON BLVD.
BOLINGBROOK, IL 60440
PHONE: 630-296-1400
FAX: 630-226-9420
NEW YORK
AUBURN
ONE ELLIS DRIVE
AUBURN, NY 13021
PHONE: 315-255-3403
FAX: 315-253-9923
TENNESSEE
MEMPHIS
4000 WINCHESTER ROAD
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
MN703-0615
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
MN703
All Rights Reserved. Printed in USA.
(A40244B) - Rev E 6/15
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