Baldor BC142, Installation And Operation Manual

Page 1: ...stic LEDs for Power On and Current Limit Now with SMT Construction 0 1 2 To use the Enable Circuit remove the jumper that is factory installed on CONN1 Note 1 For 50V 1000 tach generator connect to Terminals B and I2 Application Note When the control is stopped using Inhibit the motor will coast to stop When the control is stopped using Enable the motor will decelerate to stop The deceleration tim...

Page 2: ...DC DRIVE BC141 BC142 BC142 6 DC CONTROL 5 2004 MN704 Installation and Operation Manual ...

Page 3: ...electric Withstand Testing Hi Pot Testing 22 11 Trimpot Adjustments 24 12 Diagnostic LEDs 28 13 Switching Circuits 28 14 Optional Accessories 30 Limited Warranty 32 Tables 1 Electrical Ratings 9 2 General Performance Specifications 9 3 Minimum Supply Wire Size Requirements 13 4 Field Connection Shunt Wound Motors Only 14 5 Plug In Horsepower Resistor and Armature Fuse Kit Selection 22 Figures 1 Co...

Page 4: ...up 23 14 Acceleration Trimpot ACCEL Range 24 15 Deceleration Trimpot DECEL Range 25 16 Minimum Speed Trimpot MIIN Range 25 17 Maximum Speed Trimpot MAX Range 25 18 Current Limit Trimpot CL Range 26 19 IR Compensation Trimpot IR Range 27 20 Typical Dynamic Brake Circuit Connection 29 Items Included in this package Speed Control factory installed 25 Amp AC Line Fuse Installation and Operation Manual...

Page 5: ...8 230 of the control must match the actual AC line input voltage 2 If one of the AC line inputs is a neutral N wire it to Terminal L2 1 2 Ground Connection Connect the ground wire earth to the control chassis 1 3 Motor Connection Connect the motor to Terminals A Armature Fuse and A as shown in Figure 1 on page 10 and as described in Section 6 3 on page 14 1 4 Jumper Settings Jumper J1 on Catalog N...

Page 6: ...ly in a kit which is based on motor horsepower and voltage Select the correct kit as described in Section 9 on page 21 1 7 Trimpot Settings All trimpots have been factory set for most applications as shown in Figure 1 on page 10 The trimpots may be readjusted as described in Section 11 on page 24 1 8 Diagnostic LEDs After power has been applied to the control observe the LEDs to verify proper cont...

Page 7: ...e emission of radio frequency interference RFI which may adversely affect sensitive electronic equipment It is the responsibility of the equipment manufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product SW effective 11 1992 Be sure to follow all instructions care fully Fire and or electrocution can result due to improper use of this product Defi...

Page 8: ...ctable armature and tach feedback and adjustment trimpots for minimum speed maximum speed 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 rejec tion circuitry which eliminates false starts and blown SCRs Ena...

Page 9: ...ne Input Voltage Selection J1 Catalog No BC142 6 only Motor Voltage and DC Tach Generator Selection J2 6 Protection Features MOV transient protection Short Circuit protected at motor only 7 Diagnostic LEDs Power On PWR ON and Current Limit CL 8 Catalog No BC141 operates on 115 Volt AC line input with 90 Volt DC motors 9 Catalog No BC142 operates on 230 Volt AC line input with 180 Volt DC motors or...

Page 10: ...0 75 6 24 0 16 0 1 5 1 1 100 BC142 6 115 0 90 12 0 8 0 75 6 24 0 16 0 1 5 1 1 50 100 230 0 180 12 0 8 0 1 5 1 1 24 0 16 0 3 2 3 100 200 0 90 12 0 8 0 75 6 24 0 16 0 1 5 1 1 100 TABLE 1 ELECTRICAL RATINGS TABLE 2 GENERAL PERFORMANCE SPECIFICATIONS Step down operation Description Specification Factory Setting Speed Range Ratio 50 1 Armature Feedback Load Regulation 0 Full Load 50 1 Speed Range Base ...

Page 11: ... Fuse 25 Amp Factory Installed Supplied Separately Armature Fuse Wiper Low High Horsepower Resistor Supplied Separately Plug In L1 Blue A F Red ACCEL DECEL EN M CONN1 P2 G 1000 7V PWR ON 230V 115V I1 T B F A T 90V 180V J2 CL L2 P3 MAX P1 MIN I2 IR CL Plug In Horsepower Resistor and Armature Fuse Kit supplied separately See Section 9 on page 21 10 FIGURE 1 CONTROL LAYOUT GENERAL CONNECTION DIAGRAM ...

Page 12: ...nt 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 SCR rated motors Use of higher voltage motors will result in a reduction of the available maximum speed Also if the motor is not an SCR rated type the actual AC line current at full load should not ...

Page 13: ...r 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 CAUTION Do not use this control in an explosive atmosphere Be sure the control is used...

Page 14: ...to Terminals L1 Line Fuse and L2 as shown in Figure 1 on page 10 If one of the AC line inputs is a neutral N wire it to Terminal L2 CAUTION The rated AC line voltage 115 208 230 of the control must match the actual AC line input voltage See Section 7 1 on page 19 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 6 op...

Page 15: ... described in Table 4 6 4 2 Half Voltage Field For 90 Volt DC motors with 50 Volt DC fields and 180 Volt DC motors with 100 Volt DC fields wire the field positive lead to Terminal F and the negative lead to Terminal L1 Line Fuse as described in Table 4 Notes 1 Do not connect motor armature leads to Terminals F and F 2 Do not use Terminals F and F for any purpose other than to power the field of a ...

Page 16: ...t operational in voltage following mode Turn the MIN Trimpot on the control to zero output full counterclockwise rotation and use auxiliary trim pots if necessary to scale and or limit the input voltage CAUTION Do not earth ground any input terminals 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 Isola...

Page 17: ...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 6 7 2 Enable Switch or Contact Wired to the Main Speed Potentiometer Wire the switch or contact in series with the Main Speed Potentiometer high side and Terminal P3 on the control as shown in Figure 6 on page 17 Be sure th...

Page 18: ...Main Speed Potentiometer set ting An open collector NPN can be wired in lieu of a switch or contact WARNING The Inhibit Circuit is never to be used as a Safety Disconnect since it is not fail safe Use only the AC line for this purpose 17 CONN1 Enable Switch or Contact This jumper must Main Speed Potentiometer Front View Close to Run Low High Wiper Open to Stop be installed MAX EN Terminal P1 Main ...

Page 19: ... T and the negative lead to Terminal I2 as shown in Figure 8 6 9 2 Fifty 50 Volt per 1000 RPM Tach Generator Connect the tach generator positive lead to Terminal B and the negative lead to Terminal I2 as shown in Figure 9 6 9 3 Other Tach Generator Voltages The tach gener ator input circuit is designed for a 7 Volt or 50 Volt per 1000 RPM DC tach generator used with an 1800 RPM motor For a tach ge...

Page 20: ...t 1 2 Watt resistor value which is 75000 Ω 75 kΩ 7 SETTING SELECTABLE JUMPERS The control has selectable jumpers which must be set before it can be used See Figure 1 on page 10 for the location of jumpers 7 1 AC Line Input Voltage Selection Jumper J1 Catalog No BC142 6 Only Jumper J1 is factory set to the 230V position for 208 230 Volt AC line input For 115 Volt AC line input set Jumper J1 to the ...

Page 21: ... On Catalog No BC142 6 do not set the output voltage to 180 Volts DC when the AC line input is set to 115 Volts FIGURE 11 AC LINE INPUT VOLTAGE SELECTION JUMPER J1 8 AC LINE FUSING A 25 Amp AC line fuse is factory installed in the AC line fuse holder as shown in Figure 1 on page 10 It is rec ommended that a 12 Amp AC line fuse be installed for motors rated 7 5 Amps DC or less Fuses should be nor m...

Page 22: ...ll the Plug In Horsepower Resistor as shown in Figure 1 on page 10 Select the correct Plug In Horsepower Resistor as shown in Table 5 on page 22 Application 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 mo...

Page 23: ...onnect the AC power 22 90 130 Volt DC Motors HP 180 Volt DC Motors HP Approximate Motor Current Amps DC Plug In Horsepower Resistor and Armature Fuse Kit Catalog No Plug In Horsepower Resistor Value Ohms Armature Fuse Rating Amps 1 100 1 50 2 BR1000 1 5 1 50 1 25 3 BR0510 51 5 1 30 1 15 33 BR0350 35 5 1 20 1 10 5 BR0250 25 75 1 15 1 8 8 BR0251 25 1 1 12 1 6 85 BR0180 18 1 25 1 8 1 4 1 3 BR0100 1 2...

Page 24: ...nted 23 Motor Speed Control Motor Terminals Signal Inputs AC Line input Machine or P2 P3 P1 L2 L1 Auxiliary Equipment LEAKAGE H V RETURN 0mA MAX RESET TEST ZERO VOLTAGE High Voltage Dielectric Withstand Tester Hi Pot Tester 0 10mA AC KILOVOLTS 1 2 3 Chassis Motor Wires Frame terminals together Connect all Speed Control Connect Hi Pot Tester to both AC Line inputs equipment frame L1 L2 Chassis FIGU...

Page 25: ...s are made with the main power applied an insulated adjustment tool must be used and safety glasses must be worn High voltage exists in this control Electrocution can result if caution is not exer cised Safety Warning on page 6 must be read and understood before proceeding Note In order for the IR Compensation and Current Limit settings to be correct the proper Plug In Horsepower Resistor must be ...

Page 26: ...ockwise To decrease the minimum speed rotate the MIN Trimpot counterclockwise See Figure 16 Note Readjusting the MIN Trimpot will affect the maximum speed set ting 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 11 4 Maximum Speed Trimpot MAX ...

Page 27: ...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 The CL LED will illuminate red 4 Lock the motor shaft be sure the CL Trimpot is set fully counterclockwise 5 Apply power and rotate the CL Trimpot cloc...

Page 28: ...ion 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 See Figure 19 Notes 1 The correct value Plug In Horsepower Resistor must be installed for the IR Compensation to operate properly ...

Page 29: ...2 Current Limit CL The CL LED will illuminate red when the control goes into current limit indicating that the current limit set point has been reached set by the CL Trimpot See Section 11 5 on page 26 13 SWITCHING CIRCUITS 13 1 AC Line Switching The control can be turned on and off using the AC line no waiting time is required Auto Inhibit circuitry automatically resets critical components each t...

Page 30: ...llows the motor voltage through the N C con tact 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 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...

Page 31: ...n of the Main Speed Potentiometer position 0 100 14 5 DIN Rail Mounting Kit Catalog No BC218 14 6 Current Sensing Overload Protector Catalog No BC146 Provides overload current sensing and pro tection of DC motors and speed controls rated 1 8 3 HP by sensing armature current Operates on 115 or 230 Volt AC line input 14 7 Electronic Potentiometer Catalog No BC151 Provides digital type control of mot...

Page 32: ... NOTES 31 ...

Page 33: ...ry to any person caused by items of our manu facture or sale Some states do not allow the exclusion or limitation of incidental or consequential damages so the above exclusion may not apply In any event BALDOR s total liability under all circumstances shall not exceed the full purchase price of the control Claims for purchase price refunds repairs or replacements must be referred to BALDOR with al...