BC140 / BC140-FBR DC CONTROL Installation and Operation Manual

11/11 MN703

SCR DC MOTOR CONTROL

SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.2 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.3 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.4 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.5 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152. Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.2 Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.3 AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.4 Armature Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.5 Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.6 Permanent Magnet (PM) Motor Armature Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.7 Motor Field (Shunt Wound Motors Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.8 Voltage Select Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.9 Trimpot Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.10 Diagnostic LEDS and Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.11 Optional Auxiliary Heat Sink (BC143) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.12 Optional Forward-Brake-Reverse Switch (BC144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.1 AC Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.2 Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.3 AC Line and Armature Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.4 AC Line Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.5 Armature Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.6 Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.7 Permanent Magnet (PM) Motor Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.8 Shunt Wound Motor Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.8.1 Full Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.8.2 Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Table of Contents

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5. Important Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.1 Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3 Acceleration Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.4 Limitation in Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316. Setting the Voltage Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1 For 208/230 Volt AC Line Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.2 For 115 Volt AC Line Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7.1 Acceleration Trimpot (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7.2 Deceleration Trimpot (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 7.3 Minimum Speed Trimpot (MIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 7.4 Maximum Speed Trimpot (MAX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 7.5 Current Limit Trimpot (CL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 7.6 IR Compensation Trimpot (IR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8.1 Set to the OFF Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8.2 Set the Voltage Select Switch to the correct position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8.3 Install the correct Armature Fuse and the correct Plug-In Horsepower Resistor®. . . . . . . . . . . . . . . . . . 40 8.4 Recheck all input AC line and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8.5 Set the Main Speed Potentiometer to 0% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8.6 Set the Forward-Brake-Reverse Switch (if installed) to the “FWD” or “REV” position . . . . . . . . . . . . . . 40 8.7 Set the On/Off AC Line Switch to the “ON” position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409. Diagnostics LEDS and Pilot Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 9.1 Power On (PWR ON) LED and Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 9.2 Current Limit (CL) LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4110. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4211. Optional Auxiliary Heat Sink (Catalog No. BC143) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4612. Optional Forward-Brake-Reverse Switch (Catalog No. BC144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Baldor District Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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WARNING! This product should be installed and serviced by a qualified technician, electrician or electrical maintenance person familiar with its operation and the hazards involved. Proper installation, which includes wiring, mounting in proper enclosure, fusing or other overcurrent protection and grounding, can reduce the chance of electric shocks, fires or explosion in the product or products used with this product, such as electric motors, switches, coils, solenoids or relays. Eye protection must be worn and insulated adjustment tools must be used when working with control under power. This product is constructed of materials (plastics, metals, carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding and filtering of this product can reduce the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic equipment. If information is required on this product, contact our factory. It is the responsibility of the equipment manufacturer and individual installer to supply this safety warning to the ultimate user of this product. (SW effective 11/92).

This control contains electronic Start/Stop and enable circuits that can be used to start and stop the control. However, these circuits are never to be used as safety disconnects since they are not fail-safe. Use only the AC line for this purpose.

The input circuits of this control (potentiometer, start/stop, enable) are not isolated from AC line.

Be sure to follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product.

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SAFETY NOTICES

WARNING - STATEMENT INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN INJURY OR DEATH.

CAUTION - Statement indicates a potentially hazardous situation which, if not avoided, could result in damage to property.

Note - Additional information that is not critical to the installation or operation.

WARNING! READ ALL SAFETY NOTICES BEFORE ATTEMPTING TO USE THIS CONTROL. DISCONNECT THE MAIN POWER BEFORE MAKING CONNECTIONS TO THE CONTROL. TO AVOID ELECTRIC SHOCK, BE SURE TO PROPERLY GROUND THE CONTROL. WIRE CONTROL IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE REQUIREMENTS AND OTHER LOCAL CODES THAT MAY APPLY. BE SURE TO FUSE EACH CONDUCTOR WHICH IS NOT AT GROUND POTENTIAL. DO NOT FUSE NEUTRAL OR GROUNDED CONDUCTORS.

WARNING! THIS EQUIPMENT MAY CONTAIN VOLTAGES AS HIGH AS 1000 VOLTS! ELECTRICAL SHOCK CAN CAUSE SERIOUS OR FATAL INJURY. ONLY QUALIFIED PERSONNEL SHOULD INSTALL AND PERFORM THE START-UP PROCEDURE OR TROUBLESHOOT THIS EQUIPMENT.

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WARNING! ELECTRICAL SHOCK CAN CAUSE SERIOUS OR FATAL INJURY. BE SURE THAT ALL POWER IS DISCONNECTED FROM THE CONTROL BEFORE THE COVER IS OPENED. OPENING OF THE COVER IS REQUIRED TO MAKE INSTALLATION CONNECTIONS. ELECTRICAL SHOCK CAN CAUSE SERIOUS OR FATAL INJURY IF THE COVER IS REMOVED AND POWER IS STILL APPLIED.

WARNING! ELECTRICAL SHOCK CAN CAUSE SERIOUS OR FATAL INJURY. VERIFY THERE IS NO VOLTAGE PHASE-TO-PHASE OR PHASE-TO-NEUTRAL AT THE AC LINE CONDUCTORS BEFORE TOUCHING THE AC INPUT WIRES. DO NOT TOUCH LIVE WIRES. ALL POWER MUST BE DISCONNECTED BEFORE PROCEEDING. WARNING! 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/FSC 5/2005) BE SURE TO FOLLOW ALL INSTRUCTIONS CAREFULLY. FIRE AND/OR ELECTROCUTION CAN RESULT DUE TO IMPROPER USE OF THIS PRODUCT. WARNING! DO NOT USE THIS CONTROL IN AN EXPLOSIVE ENVIRONMENT. AN EXPLOSION CAN CAUSE SERIOUS OR FATAL INJURY. THIS CONTROL IS NOT EXPLOSION PROOF.

WARNING! HIGH VOLTAGE IS PRESENT IN THE CONTROL. DISCONNECT MAIN POWER BEFORE MAKING CONNECTIONS TO THE CONTROL. DO NOT ADJUST TRIMPOTS WITH THE MAIN POWER APPLIED. IF ADJUSTMENTS ARE MADE WITH THE MAIN POWER APPLIED, AN INSULATED ADJUSTMENT TOOL (PROVIDED) MUST BE USED AND SAFETY GLASSES MUST BE WORN. FIRE AND/OR ELECTROCUTION CAN RESULT IF CAUTION IS NOT EXERCISED.

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WARNING! AUTOMATIC START: THE CONTROL WILL AUTOMATICALLY START WHEN THE POWER IS APPLIED AND THE ON/OFF AC LINE SWITCH IS SET TO THE “ON” POSITION.

WARNING! HIGH VOLTAGE IS PRESENT IN THIS CONTROL. DISCONNECT MAIN POWER BEFORE MAKING CONNECTIONS TO THE CONTROL. TO PREVENT ACCIDENTAL CONTACT WITH HIGH VOLTAGE, IT IS REQUIRED THAT THE COVER BE PROPERLY INSTALLED AFTER ALL SETUP, CONNECTIONS, AND ADJUSTMENTS ARE COMPLETE. THIS REDUCES ELECTRICAL SHOCK HAZARD. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ELECTRICAL SHOCK OR ELECTROCUTION.

WARNING! DO NOT DEPEND ON THE PILOT LIGHT OR THE PC BOARD MOUNTED LEDs FOR A GUARANTEED POWER OFF INDICATION. BE SURE ALL AC POWER IS “OFF” BEFORE SERVICING THE CONTROL TO AVOID ELECTRICAL SHOCK HAZARD.

WARNING! MAKE SURE THAT THE POTENTIOMETER IS SET FULLY COUNTERCLOCKWISE PRIOR TO APPLYING POWER. IF THIS IS NOT DONE, THE MOTOR WILL RUN AT THE SPEED SETTING AT POWER UP. THIS MAY CAUSE BODILY INJURY IF ONE IS IN CLOSE PROXIMITY OF MOVING PARTS.

WARNING! DO NOT SWITCH THE ARMATURE IN AND OUT OF CIRCUIT OR CATASTROPHIC FAILURE WILL RESULT. IF ARMATURE SWITCHING IS REQUIRED, USE THE OPTIONAL FORWARD-BRAKE-REVERSE SWITCH (CATALOG NO. BC144).

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CAUTION! Disconnect motor leads (A- and A+) from control before performing a “Leakage Resistance” test on the motor. Failure to disconnect motor from the control may result in extensive damage to the control. The control is tested at the factory for high voltage/leakage resistance as part of Underwriters Laboratories requirements.

CAUTION! Instantaneously applying the Hi-Pot voltage will cause irreversible damage to the control.

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! Proper shielding, grounding, and filtering of this product can reduce the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic equipment.

CAUTION! The Voltage Select Switch setting must match the actual AC line input voltage. Verify that the Voltage Select Switch is in the correct position (“115” position for 115 Volt AC line input and “230” position (factory setting) for 208/230 Volt AC line input). Do not use the “115V” position for 208/230 Volt AC line input voltage or damage will occur to the control.

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CAUTION! If the current limit is adjusted above 160% of the motor nameplate rating, this can cause overheating of the motor.

CAUTION! Do not leave the motor in a locked rotor condition for more than a few seconds since damage may occur.

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1. INTRODUCTIONThank 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 represent the latest in state-of-the-art design, surface mount technology, incorporating advanced circuitry and technology for variable speed DC motor controls. They are rugged and compact in size and are able to handle both 115 and 208/230 Volt AC line inputs by setting the built-in Dual Voltage Switch. In addition, one model can be used on a wide range of motors by selecting and inserting the appropriate Plug-in Horsepower Resistor®.

The standard model, BC140, controls all motors through 3/4 HP at 115 Volt AC line input and 1-1/2 HP at 230 Volt AC line input. By installing the Auxiliary Heat Sink (see Table 1-2), the horsepower range is increased to 1 HP at 115 Volt AC line input and 2 HP at 230 Volt AC line input. The versatility of the control is enhanced with the optional Forward-Brake-Reverse Switch Kit (Catalog No. BC144)*.*Note: Forward-Brake-Reverse Switch Kit, BC144, is factory installed on the BC140-FBR model.

The electronics for the BC140 and BC140-FBR consist of a patented speed control module. Its field-proven reliability is confirmed by over 100,000 controls presently in operation. The module is housed in a rugged metal enclosure not plastic. Keyhole slots facilitate mounting and an easily accessible terminal block simplifies connections.

WARNING! BE SURE TO FOLLOW ALL INSTRUCTIONS CAREFULLY. FIRE OR ELECTROCUTION CAN RESULT DUE TO IMPROPER USE OF THIS

PRODUCT. READ SAFETY NOTICES.

This product complies with all CE directives pertinent at the time of manufacture. Contact your local Baldor District Office for Declaration of Conformity. Installation of a CE approved RFI filter is required (see Table 1-2.)

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1.1 Standard FeaturesTable 1-1 outlines the Standard Features for the BC140 / BC140-FBR Control.

Table 1-1 Standard Features

Feature Description

Simple to Operate Does not require programming. Uses adjustable trimpots which are factory set for most applications.

AC Line Input Voltage (±15%, 50/60 Hz)

115 and 208/230 Volts AC

Dual Voltage Selection (Under the Front Cover)

Allows for selection of 115 Volt or 208/230 Volt AC line input. (Factory set to the "230" Volt position.)

Plug-In Horsepower Resistor® (Supplied Separately)*

Allows the control to be used on a wide range of motors.

Fusing* Built-In AC Line Fuse. Armature Fuse (Supplied Separately).

MOV Protection AC line input transient suppression.

Adjustable Trimpots Allow adjustment of Acceleration (ACCEL), Deceleration (DECEL), Minimum Speed (MIN), Maximum Speed (MAX), Current Limit (CL), and IR Compensation (IR).

Diagnostic LEDs Power On (PWR ON) and Current Limit (CL).

*Plug-In Horsepower Resistor® and armature fuse must be properly selected to accurately calibrate the control.

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1.2 Optional Accessories Table 1-2 outlines the optional accessories available to extend application versatility.

Table 1-2 Optional Accessories

Item Catalog No. Description

Auxiliary Heat Sink BC143 Extends the control's rating to 1 HP, at 115 Volts AC, and 2 HP, at 230 Volts AC. See Section 11.

Forward-Brake-Reverse Switch* BC144

Includes Forward-Brake-Reverse Switch with dynamic brake resistor. See Section 12.

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.

* Factory installed on the BC140-FBR model.

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1.3 Electrical RatingsTable 1-3 outlines the electrical ratings of the BC140 / BC140-FBR control.

Table 1-3 Electrical Ratings

AC Line Voltage (± 15%, 50/60 Hz)

(Volts AC)

Motor Voltage

(Volts DC)

Maximum Rating without Auxiliary Heat Sink

Maximum Rating with Auxiliary Heat Sink

AC Line Current

(RMS Amps)

DC Load Current

(Avg. Amps)

Horsepower (HP, (kW))

AC Line Current

(RMS Amps)

DC Load Current

(Avg. Amps)

Horsepower (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)

Notes: 1. The BC140 and BC140-FBR can be converted to the higher rating by installing the Auxiliary Heat Sink (Catalog No. BC143).2. The BC140 and BC140-FBR must be set for either 115 or 208/230 Volt AC line input by setting the Voltage Select Switch to the “115” or “230” position, respectfully. When the control is set for “115”, use only 90 – 130 Volt DC rated motors. When the control is set for “230”, use only 180 Volt DC rated motors.3. Field voltage is 100 Volt DC with 115 Volt AC line input and 200 Volts DC with 230 Volt AC line input. Maximum Field current is 1.0 Amps DC.

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1.4 Trimpot Adjustments Table 1-4 outlines the trimpot adjustments of the BC140 / BC140-FBR control.

Table 1-4 Trimpot Adjustments

Trimpot Description

Acceleration (ACCEL). See Section 7.1.

Sets the amount of time for the motor to accelerate from zero speed to full speed.

Deceleration (DECEL). See Section 7.2.

Sets the amount of time for the motor to decelerate from full speed to zero speed.

Minimum Speed (MIN). See Section 7.3.

Sets the minimum speed of the motor.

Maximum Speed (MAX). See Section 7.4.

Sets the maximum speed of the motor.

Current Limit (CL). See Section 7.5.

Sets the maximum amount of DC current that the motor can draw.

IR Compensation (IR). See Section 7.6.

Sets the required voltage compensation to the motor to provide improved load regulation.

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1.5 General Performance SpecificationsTable 1-5 outlines the general performance specifications of the BC140 / BC140-FBR control.

Table 1-5 General Performance Specifications1

Description SpecificationFactory Setting

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

12 —

Line Voltage Regulation (at Full Load, ± 10% Line Variation) (% Base Speed) 0.52 —Control Linearity (% Speed vs. Dial Rotation) 2 —Acceleration (ACCEL) Trimpot Range (Seconds) 0.2 - 10 2Deceleration (DECEL) Trimpot Range (Seconds) 0.2 - 10 2Maximum Speed (MAX) Trimpot Range (% Base Speed) 50 - 1102 100Minimum Speed (MIN) Trimpot Range (% Base Speed) 0 - 302 0CL/Torque Range (% Full Load) 0 - 200 150IR Compensation (IR) Trimpot Range (at Specified Full Load at 90/180 Volts Output) (Volts DC)

0 - 24 / 0 - 48 3 / 6

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

0 - 40 / 32 - 104 —

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

0 - 50 / 32 - 122 —

Notes: 1. CE Compliance requires BC24-LF RFI Filter. (See Optional Accessories, Table 1-2).2. Performance is for 90 Volt PM motors with 115 Volt AC line input and 180 Volt DC PM motors with 230 Volt AC line input.

16

Figure 1-1 Cover Layout

(%) SPEEDFWD

10

REV

RB

K Motor

Before to Stop

Reversing

Allow

0

3020

5040

ON

90

OFF

100

7080

60

Two (2) Cover ScrewsRecommended Tightening Torque: 5 lbs-in (6 kg-cm)

Main Speed Potentiometer

On/Off AC Line Switch

Pilot Light

Optional Forward-Brake-Reverse Switch

Note: See Section 6 for Voltage Select Switch (Located Under Cover)

17

Figure 1-2 Mechanical Specifications (Inches/[mm])

[178]7.00

0.2[5.08]

0.359.0 4X Ø

0.39[9.91]4X Ø

5.63[143]

5.00

[105]

[127]4.125

4.00[102]

Back View is Shown Dimensioned without Cover Installed

Side View is Shown Dimensioned with Cover Installed and Optional Forward-Brake-Reverse Switch

Two (2) Knockouts for Standard 3/4” Fittings

Note: See Section 11 for optional Auxiliary Heat Sink (Catalog No. BC143) Mechanical Specifications.

18

2. QUICK START

IMPORTANT – You must read these simplified operating instructions before you proceed. These instructions are to be used as a reference only and are not intended to replace the detailed instructions provided herein. You must read the Safety Warnings and Cautions before proceeding.

Note: A Plug-In Horsepower Resistor®, an AC Line Fuse, and an Armature Fuse (supplied separately), must be installed in order for this control to operate. See Section 4.

Figure 2-1

Plug-InFuse Horsepower Resistor®

Note: See Table 4-1 for Barrier Terminal Block wire size and recommended tightening torque specifications. See Table 4-4 for Field connections (Shunt Wound Motors only).

19

2.1 Connections AC Line Connection: Connect the AC line input to Terminals L1 (Line Fuse) and L2, of the Barrier Terminal Block, as shown in Figure 2-2 and as described in Section 4. The Voltage Select Switch position must match the AC line input voltage. See Section 6.

Note: See Table 4-2 for AC Line and Armature Fuse selection. These items must be installed for the control to operate.

Figure 2-2 AC Line, Armature, Field*, and Ground Connections

LINEFIELDARMATUREA- A+ F- F+ L1 L2 GND

-

BarrierTerminal Block

DC Motor

Ground (Earth)

Ground (Earth)Armature Field˙ 115 or 208/230 Volts AC Line Input

Note: *F- and F+ are Field connections for Shunt Wound Motors only.

2.2 Ground Connection Connect all ground wires (earth), of connections to the control, to the green ground screw on the chassis, as shown in Figure 2-2.

20

2.3 AC Line Fusing The control contains a built-in replaceable AC line fuse installed in the AC line fuse holder, as shown in Figure 2-3. Select the correct replacement AC Line Fuse, as described in Table 4-2.

Note: If fuse blows, check for wrong connections and shorted or grounded motor.

2.4 Armature Fusing Select an armature fuse (supplied separately) and install in the armature fuse holder, as shown in Figure 2-3. Select the correct Armature Fuse as shown in Table 4-2. (See note below.) 2.5 Plug-In Horsepower Resistor®

Select the correct Plug-In Horsepower Resistor® (supplied separately), according to armature voltage and motor horsepower information in Table 4-2. Install the correct Plug-In Horsepower Resistor® as shown in Figure 2-3. (See note below.)

Note: The Armature Fuse is supplied with the Plug-In Horsepower Resistor® Kit. See Table 4-3 for Catalog No. and ratings.

2.6 Permanent Magnet (PM) Motor Armature Connection Connect the motor armature to Terminals “A+” and “A-” of the Barrier Terminal Block, as shown in Figure 2-2.

2.7 Motor Field (Shunt Wound Motors Only) Connect the motor field (of the shunt wound motor) to the Barrier Terminal Block. For full voltage field, use Terminals F+ (positive) and F- (negative). For half voltage field, use Terminals F+ (positive) and L1 (negative). See Section 4.

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.

21

2.8 Voltage Select Switch The Voltage Select Switch must be set as described in Section 6. For 208/230 Volt AC line input, set the Voltage Select Switch to the “230” position (factory setting). For 115 Volt AC line input, set the Voltage Select Switch to the “115” position.

2.9 Trimpot Settings All trimpots have been factory set for most applications, as shown in Figure 2-3. The trimpots may be readjusted, as described in Section 7.

2.10 Diagnostic LEDs and Pilot Light After power has been applied to the control, observe the front panel indicator and the board mounted LEDs, to verify proper control operation, as described in Section 9.

2.11 Optional Auxiliary Heat Sink (BC143) Extends the horsepower rating of the control to 1 HP, with 115 Volts AC line input, and 2 HP, with 230 volts AC line input. See Table 1-2 and Section 11.

2.12 Optional Forward-Brake-Reverse Switch (BC144)* Used to dynamically brake the motor. It provides run/brake and forward-brake-reverse operations. See Table 1-2 and Section 12. * BC144 is factory installed on BC140-FBR model.

22

Figure 2-3 Control Layout and Internal Connection Diagram

A- A+ F- F+ L1 L2 GND

F-

ARMATURE FIELD LINE

23

3. INSTALLATION

3.1 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 1-2.

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.

24

4. ELECTRICAL CONNECTIONS

See Table 4-1 for Barrier Terminal Block wire size and recommended tightening torque specifications.

WARNING! READ SAFETY NOTICES BEFORE ATTEMPTING TO USE THIS CONTROL. DISCONNECT THE MAIN POWER BEFORE MAKING CONNECTIONS TO THE

CONTROL.

WARNING! TO AVOID ERRATIC OPERATION, DO NOT BUNDLE AC LINE AND MOTOR WIRES WITH WIRES FROM SIGNAL FOLLOWING, START/STOP CONTACTS, OR ANY OTHER SIGNAL WIRES. ALSO DO NOT BUNDLE MOTOR WIRES FROM MULTIPLE CONTROLS IN THE SAME CONDUIT. USE SHIELDED CABLES ON ALL SIGNAL CONNECTIONS OVER 12”, (30CM). THE SHIELD SHOULD BE EARTH GROUNDED ON CONTROL SIDE ONLY. WIRE THE CONTROL IN ACCORDANCE WITH NATIONAL ELECTRICAL CODE REQUIREMENTS AND OTHER LOCAL CODES THAT APPLY.

WARNING! DO NOT CONNECT SWITCHES OR RELAYS IN SERIES WITH ARMATURE OR CATASTROPHIC FAILURE WILL RESULT.

CAUTION! The Voltage Select Switch position must match the AC line input voltage (“115” position for 115 Volt AC line input and “230” position (factory setting) for 208/230 Volt AC line input).

CAUTION! If control is connected to a transformer, it is advisable to switch the secondary to disconnect power. If the primary is switched, additional snubber capacitors may have to be added across the transformer output to prevent damage to the power bridge.

25

Table 4-1 Barrier Terminal Block Wire and Tightening Torque Specifications

Maximum Motor

Current (Amps DC)

90 – 130 Volt DC Motors

(Maximum HP)

180 Volt DC Motors

(Maximum HP)

Maximum Wire Size (Cu) RecommendedTightening

TorqueMaximum

50 Ft. Maximum

100 Ft.

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

4.1 AC Line Connection Connect the AC Line to terminals L1 (Line Fuse) and L2, as shown in Figure 2-2. If one of the AC line inputs is a neutral (N), connect it to terminal L2.

Note: This control operates on 115 or 208/230 Volt AC line input and is factory set for 208/230 Volt AC line input (Voltage Select Switch is factory set to the “230” position). See Section 6.

4.2 Ground Connection Connect all ground wires (earth), of connections to the control, to the green ground screw on the chassis, as shown in Figure 2-2.

4.3 AC Line and Armature Fusing 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. Select the correct fuses, as shown in Table 4-2. 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.

26

Table 4-2 Armature and AC Line Fuse Chart

Motor Horsepower Approximate Motor Current

(Amps DC)

Fuse Selection(AC Amps)

90VDC 180VDC Armature Line

1/100 1/50 0.2 0.5 12

1/50 1/25 0.3 0.5 12

1/30 1/15 0.33 0.5 12

1/20 1/10 0.5 0.75 12

1/15 1/8 0.8 1 12

1/12 1/6 0.85 1.25 12

1/8 1/4 1.3 2 12

1/6 1/3 2 2.5 12

1/4 1/2 2.5 4 12

1/3 3/4 3.3 5 12

1/2 1 5.0 8 12

3/4 1½ 7.5 12 12

1* 2* 10 15 25

*With optional Auxiliary Heat Sink (Catalog No. BC143).

27

4.4 AC Line Fuse 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.

Note: Fuse each AC line conductor that is not at ground potential.

4.5 Armature Fuse The Armature Fuse acts as a diagnostic indicator. If the Armature Fuse blows, it indicates that there is a problem after the control’s output. The Armature Fuse required can be calculated by multiplying the maximum DC Motor Current times 1.7.

4.6 Plug-In Horsepower Resistor®

A Plug-In Horsepower Resistor® (supplied separately) must be installed to match the control to the motor horsepower and voltage in order for the IR Compensation and Current Limit settings to be correct. Select the proper Plug-In Horsepower Resistor® according to Table 4-3. Selecting the proper Plug-In Horsepower Resistor® is as important as selecting the proper Armature Fuse.

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.

28

Table 4-3 Plug-In Horsepower Resistor® and Armature Fuse Kit Information

Motor Horsepower

Approximate Motor Current

(Amps DC)

Plug-In Horsepower Resistor® and Armature Fuse Kit

Armature Voltage

90 – 130 Volts DC

Armature Voltage

180 Volts DC

Plug-InHorsepower

Resistor®

Value (Ohms)

Armature Fuse

Rating(Amps)

Catalog No.

1/100 1/50 0.2 1.0 0.5 BR1000

1/50 1/25 0.3 0.51 0.5 BR0510

1/30 1/15 0.33 0.35 0.5 BR0350

1/20 1/10 0.5 0.25 0.75 BR0250

1/15 1/8 0.8 0.25 1 BR0251

1/12 1/6 0.85 0.18 1.25 BR0180

1/8 1/4 1.3 0.1 2 BR0100

1/6 1/3 2 0.1 2.5 BR0101

1/4 1/2 2.5 0.05 4 BR0050

1/3 3/4 3.3 0.035 5 BR0035

1/2 1 5 0.025 8 BR0025

3/4 1½ 7.5 0.015 12 BR0015SP

1* 2* 10 0.01 15 BR0010SP

*With optional Auxiliary Heat Sink (Catalog No. BC143).

29

4.7 Permanent Magnet (PM) Motor Armature Connection Connect the motor armature positive lead (+) to Terminal “A+” and negative lead (-) to Terminal “A-”, on the Barrier Terminal Board, as shown in Figure 2-3. Be sure the correct Plug-In Horsepower Resistor® and Armature Fuse are installed, as described in Section 4.

4.8 Shunt Wound 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.

4.8.1 Full Voltage Field Connect the field positive (+) lead to Terminal “F+” and the negative lead (-) to Terminal “F-”, on the Barrier Terminal Block, and as described in Table 4-4. See Figure 2-3.

4.8.2 Half Voltage Field For 50 Volt DC with 100 Volt rated armature, use Terminal “L1” and F+, on the terminal board, as described in Table 4-4. See Figure 2-3.

Table 4-4 Field Connection (Shunt Wound Motors Only)

AC Input Voltage (Volts AC)

Voltage Selector Switch (Position)

Armature Voltage (Volts DC)

Field Voltage (Volts DC)

Terminal Connections

115 115 0 – 90

100 F+, F-

50 F+, L1

208/230 230 0 – 180 200 F+, F-

0 – 90* 100 F+, L1

*Step-down operation.

30

5. IMPORTANT APPLICATION INFORMATION WARNING! DO NOT USE THIS CONTROL IN AN EXPLOSIVE ENVIRONMENT. AN EXPLOSION CAN CAUSE SERIOUS OR FATAL INJURY. THIS CONTROL IS

NOT EXPLOSION PROOF.

WARNING! BE SURE TO FOLLOW ALL INSTRUCTIONS CAREFULLY. FIRE OR ELECTROCUTION CAN RESULT DUE TO IMPROPER USE OF THIS PRODUCT. READ SAFETY NOTICES.

5.1 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.

5.2 Torque Requirements The motor selected for the application must be capable of supplying the necessary torque. In order 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.

5.3 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.

31

5.4 Limitation In Use The BC140 / BC140-FBR control is designed for use on machine applications.

WARNING! DO NOT SWITCH THE ARMATURE IN AND OUT OF CIRCUIT OR CATASTROPHIC FAILURE WILL RESULT. IF ARMATURE SWITCHING IS REQUIRED, USE BC144 FORWARD-BRAKE-REVERSE SWITCH KIT.

CAUTION! Contact your local Baldor District Office before using this control on constant horsepower applications such as saws and drill presses. Do not use this control in an explosive atmosphere. Be sure the BC140 / BC140-FBR is used within its ratings. Follow all instructions carefully.

32

6. SETTING THE VOLTAGE SELECT SWITCH

WARNING! READ ALL SAFETY NOTICES BEFORE ATTEMPTING TO OPERATE THE CONTROL OR SEVERE INJURY OR DEATH CAN RESULT. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS, MAY RESULT IN ELECTRIC SHOCK, FIRE OR EXPLOSION.

The Voltage Select Switch is located under the cover and must be set before applying power to the control. See Figure 6-1.

6.1 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.

6.2 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 6-1 Voltage Select Switch Setting

208/230 Volt AC Line Input(Factory Setting) 115 Volt AC Line Input

33

7. TRIMPOT ADJUSTMENTSThe control contains trimpots which have been factory set for most applications. Figure 2-3 illustrates thelocation of the trimpots and their approximate factory set positions. Some applications may require readjustment of the trimpots in order to set the control for a specific requirement. See Table 1-5 for range and factory setting of all trimpots. The trimpots may be readjusted as follows.

WARNING! IF POSSIBLE, DO NOT ADJUST TRIMPOTS WITH THE MAIN POWER APPLIED. IF ADJUSTMENTS 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 EXERCISED. SAFETY NOTICES AND MUST BE READ AND UNDERSTOOD BEFORE PROCEEDING.

7.1 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. See Figure 7-1.

Figure 7-1 Accel Trimpot Range

34

7.2 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. See Figure 7-2.

Note: If the DECEL Trimpot is set to greater than the natural coast time of the motor and actual load, it will extend the deceleration time of the motor.

Figure 7-2 Decel Trimpot Range

7.3 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. See Figure 7-3.

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.

Figure 7-3 Min Trimpot Range

35

7.4 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.See Figure 7-4.

Note: Do not adjust the maximum speed above the rated motor RPM or unstable operation may occur. 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.

Figure 7-4 Max Trimpot Range

36

7.5 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.See Figure 7-5.

Note: In order 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, as described in Section 4. Calibration of the CL Trimpot is normally not required when the proper Plug-In Horsepower Resistor® is installed.

Figure 7-5 CL Trimpot Range

37

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).

WARNING! DO NOT LEAVE MOTOR SHAFT LOCKED FOR MORE THAN 2 – 3 SECONDS OR MOTOR DAMAGE MAY RESULT.

38

7.6 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. See Figure 7-6.

Note: In order for the IR Compensation to operate properly, the correct Plug-In Horsepower Resistor® must be installed for the particular motor and input voltage being used, as described in Section 4. Calibration of the IR Trimpot is normally not required when the proper Plug-In Horsepower Resistor® is installed. Excessive IR Compensation will cause the motor to become unstable, which causes cogging (“hunting” or “zooming”).

Figure 7-6 IR Trimpot Range

39

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.

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.

40

8. OPERATION

WARNING! READ SAFETY NOTICES BEFORE OPERATING THIS CONTROL OR SEVERE INJURY OR DEATH CAN RESULT.

8.1 With no AC power applied and the On/Off AC Line Switch set to the “OFF” position, remove the front cover by unscrewing the two cover screws. See Figure 1-1.

8.2 Set the Voltage Select Switch to the correct position, corresponding to the AC line input voltage. (“115” position for 115 Volt AC line input and “230” position (factory setting) for 208/230 Volt AC line input). See Figure 1-1.

8.3 Install the correct Armature Fuse, as shown in Table 4-2 and the correct Plug-In Horsepower Resistor® as shown in Table 4-3.

8.4 Recheck all input AC line and motor connections. See Figure 2-2.

8.5 Set the Main Speed Potentiometer to 0% (fully counterclockwise).

8.6 Set the Forward-Brake-Reverse Switch (if installed) to the “FWD” or “REV” position.

8.7 Set the On/Off 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.

41

9. DIAGNOSTIC LEDS AND PILOT LIGHT

The BC140 / BC140-FBR has PC board mounted LEDs, to display the control’s operational status and a panel-mounted Pilot Light. See Figure 2-3 for the location of the LEDs.

9.1 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.

9.2 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). See Section 7.

42

10. TROUBLESHOOTING Table 10-1 is a troubleshooting guide for controls without the optional Forward-Brake Reverse Switch installed. Table 10-2 is a troubleshooting guide for controls with the Forward-Brake-Reverse Switch installed. Both tables provide information on symptoms, their possible causes, and suggested corrective actions.

WARNING! HIGH VOLTAGE IS PRESENT IN THIS CONTROL. DISCONNECT MAIN POWER BEFORE MAKING CONNECTIONS TO THE CONTROL. THE COVER MUST BE PROPERLY SECURED, AFTER ALL SETUP CONNECTIONS, AND ADJUSTMENTS ARE COMPLETE. THIS REDUCES ELECTRICAL SHOCK HAZARD. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ELECTRICAL SHOCK OR ELECTROCUTION.

WARNING! HIGH VOLTAGE IS PRESENT IN THE CONTROL. IF POSSIBLE, DO NOT ADJUST TRIMPOTS WITH THE MAIN POWER APPLIED. IF ADJUSTMENTS

ARE MADE WITH THE MAIN POWER APPLIED, AN INSULATED ADJUSTMENT TOOL (PROVIDED) MUST BE USED AND SAFETY GLASSES MUST BE WORN. FIRE AND/OR ELECTROCUTION CAN RESULT IF CAUTION IS NOT EXERCISED.

43

Table 10-1 provides information on symptoms, possible causes, and the suggested corrective action for controls without optional forward-brake-reverse switch installed.

Table 10-1 Troubleshooting Guide for Controls without Optional Forward-Brake-Reverse Switch Installed

Symptom Possible Cause Suggested Corrective Action

Motor is not running and Pilot Light not illuminated.

On/Off AC Line Switch in “Off” Position.

Set On/Off Switch to “On” Position.

Blown Line fuse. Replace Line Fuse. See Table 4-2.

Defective On/Off AC Line Switch, Replace On/Off AC Line Switch.

Motor does not run and Pilot Light is illuminated.

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®. See Table 4-3.

Blown Armature Fuse. Replace Armature Fuse. See Table 4-2.

CL Trimpot set fully counterclockwise.

Set CL Trimpot, as described in Section 7.

Motor hums, runs at very low speed, or slows down substantially when load is applied.

Low AC line input voltage. Check AC line input voltage.

44

Symptom Possible Cause Suggested Corrective Action

Erratic motor performance.

Overload condition. Remove overload.

Incorrect Plug-In Horsepower Resistor®.

Install the correct Plug-In Horsepower Resistor®. See Table 4-3.

CL and/or IR Trimpots may be set incorrectly.

Readjust the CL and/or IR Trimpots, as described in Section 7.

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, as described in Section 6.

Defective motor, worn brushes, etc. Repair or replace motor.

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, as described in Section 7.

IR Comp trimpot set too high. Readjust the IR Trimpot, as described in Section 7.

Motor runs in wrong direction.

Motor armature leads are reversed. Reconnect motor armature leads.

Table 10-1 Troubleshooting Guide for Controls without Optional Forward-Brake-Reverse Switch Installed (Continued)

45

Table 10-2 provides information on symptoms, possible causes, and the suggested corrective action for controls with optional forward-brake-reverse switch installed.

Table 10-2 Troubleshooting Guide for Controls with Optional Forward-Brake-Reverse Switch Installed

Symptom Possible Cause Suggested Corrective Action

Motor will not run in Forward or Reverse direction.

Faulty wiring or loose connections to the reversing switch.

Correct the connections. See Figure 12-1.

Forward-Brake-Reverse defective. Switch is defective.

Replace Forward-Brake-Reverse Switch assembly.

No braking action in brake mode.

Faulty connections or loose connections.

Check and correct connections.

Defective Brake Resistor. Replace Forward-Brake-Reverse Switch assembly.

46

11. OPTIONAL AUXILIARY HEAT SINK (CATALOG NO. BC143) The optional Auxiliary Heat Sink (Catalog No. BC143) is used to increase the rating of the control. See Table 1-3.

The control is mounted on the four (4) holes with four (4) mounting screws (supplied), as shown in Figure 11-1.

Figure 11-1 Optional Auxiliary Heat Sink Mechanical Specifications

[34.9]1.375

6.29[160]

7.00[178]

[142]5.61

[143]5.63

47

12. OPTIONAL FORWARD-BRAKE-REVERSE SWITCH (CATALOG NO. BC144)*

WARNING! READ SAFETY NOTICES BEFORE USING THIS CONTROL. DISCONNECT THE MAIN POWER BEFORE MAKING CONNECTIONS TO THE CONTROL.

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 12-1 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 12-1 Optional Forward-Brake-Reverse Switch Connections

48

NOTES:

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49

LIMITED WARRANTY

For a period of 2 years from date of original purchase, BALDOR will repair or replace without charge controls which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or implied. BALDOR shall not be held responsible for any expense (including installation and removal), inconvenience, or consequential damage, including injury to person, caused by items of our manufacture 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 all pertinent data as to the defect, the date purchased, the task performed by the control, and the problem encountered. No liability is assumed for expendable items such as fuses.

Goods may be returned only with written notification including a BALDOR Return Authorization Number and any return shipments must be prepaid.

50

Baldor District Offices - United States LocationsMASSACHUSETTS BOSTON 6 PULLMAN STREET WORCESTER, MA 01606 PHONE: 508-854-0708 FAX: 508-854-0291

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UNITED STATES

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WISCONSIN MILWAUKEE 1960 SOUTH CALHOUN ROAD NEW BERLiN, Wi 53151 PHONE: 262-784-5940 FAX: 262-784-1215

51

Baldor District Offices - International LocationsINTERNATIONAL SALES FORT SMITH, AR P.O. BOX 2400 FORT SMiTH, AR 72902 PHONE: 479-646-4711 FAX: 479-648-5895 CANADA EDMONTON, ALBERTA 4053-92 STREET EDMONTON, ALBERTA T6E 6R8 PHONE: 780-434-4900 FAX: 780-438-2600

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VANCOUVER, BRITISH COLUMBIA 1538 kEBET WAy PORT COQUiTLAM, BRiTiSH COLUMBiA v3C 5M5 PHONE 604-421-2822 FAX: 604-421-3113

WINNIPEG, MANITOBA 54 PRiNCESS STREET WiNNiPEg, MANiTOBA R3B 1k2 PHONE: 204-942-5205 FAX: 204-956-4251

AUSTRALIA UNiT 3, 6 STANTON ROAD SEvEN HiLLS, NSW 2147, AUSTRALiA PHONE: (61) (2) 9674 5455 FAX: (61) (2) 9674 2495

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*703-1111*

© Baldor Electric CompanyMN703

All Rights Reserved. Printed in USA.(A40244B) - Rev D - 11/11

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 Baldor - Dodge

6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433www.baldor.com