Baldor BC140-FBR DC CONTROL Operating instructions

BC140 / BC140-FBR DC CONTROL

Installation and Operation Manual

11/11 MN703

SCR DC MOTOR CONTROL

SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. 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 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. 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

2

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6. Setting the Voltage Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.1 For 208/230 Volt AC Line Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.2 For 115 Volt AC Line Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7. 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9. Diagnostics LEDS and Pilot Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9.1 Power On (PWR ON) LED and Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9.2 Current Limit (CL) LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

11. Optional Auxiliary Heat Sink (Catalog No. BC143) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

12. Optional Forward-Brake-Reverse Switch (Catalog No. BC144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Baldor District Ofces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3

WARNING! This product should be installed and serviced by a qualied 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, res 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 ltering 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.

4

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.

5

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.

6

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).

7

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.

8

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.

9

10

1. 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 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 eld-proven

reliability is conrmed 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

simplies 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 Ofce for Declaration of Conformity. Installation of a

CE approved RFI lter is required (see Table 1-2.)

11

1.1 Standard Features

Table 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.

12

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.

13

1.3 Electrical Ratings

Table 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.

14

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.

15

1.5 General Performance Speciﬁcations

Table 1-5 outlines the general performance specications of the BC140 / BC140-FBR control.

Table 1-5 General Performance Speciﬁcations

1

Description Speciﬁcation

Factory

Setting

Speed Range (Ratio) 50:1 —

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

Base Speed)

1

2

—

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

2

—

Control Linearity (% Speed vs. Dial Rotation) 2 —

Acceleration (ACCEL) Trimpot Range (Seconds) 0.2 - 10 2

Deceleration (DECEL) Trimpot Range (Seconds) 0.2 - 10 2

Maximum Speed (MAX) Trimpot Range (% Base Speed) 50 - 110

2

100

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

2

0

CL/Torque Range (% Full Load) 0 - 200 150

IR Compensation (IR) Trimpot Range (at Specied 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

(%) SPEED

FWD

1

0

REV

R

B

K

Motor

Before

to Stop

Reversing

Allow

0

3

0

20

50

4

0

ON

90

OFF

1

0

7

0

80

6

0

Two (2) Cover Screws

Recommended 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]

0.35

9.0

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-In

Fuse 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

LINEFIELDARMATURE

A- A+ F- F+ L1 L2 GND

-

Barrier

Terminal Block

DC Motor

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 eld (of the shunt wound motor) to the Barrier Terminal Block. For full voltage

eld, use Terminals F+ (positive) and F- (negative). For half voltage eld, 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.

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