Baldor BC142 User manual

Baldor Electric Company, P. O. Box 2400, Ft. Smith, AR 72902-2400, [phone], Fax [phone]
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Part No. MN704-SUP
(A42130) - Rev. A03 - 5/21/2004 - Z2993A03 Page 1 of 1
IMPORTANT: The following information and instructions are to be used as a supplement to the Installation and Operation
Manual (Part No. MN704). The manual must be read and understood before attempting to operate this control.
• The General Performance Specifications, Electrical Ratings, and Mechanical Specifications of these controls have not changed •
• Jumper J2 (DC Output Voltage / Tach Selection) and Enable Connector (EN) have been added •
• Diagnostic LEDs for Power On and Current Limit • Now with SMT Construction •
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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 time can only be made longer than the
normal coasting time of the load.
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Jumper J2 (DC Output Voltage / Tach Selection)
Catalog No.
90 Volts DC
180 Volts DC
T
BC141
(Factory Setting) (Tach-Generator)
BC142
(Step-Down) (Factory Setting) (Tach-Generator)
Notes: 1. The 180V position, on Jumper J2, is not available on Catalog No. BC141. 2. The control
will run at full speed, if Jumper J2 is in the "T" position and the tach-generator is miswired.

DC DRIVE
BC141, BC142 & BC142-6 DC CONTROL
5/2004 MN704
Installation and Operation Manual

TABLE OF CONTENTS
Section Page
1 Simplified Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Plug-In Horsepower Resistor® and Armature Fuse Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 Recommended High Voltage Dielectric 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 Control Layout and General Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2

TABLE OF CONTENTS (Continued)
Figures Page
4 Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Enable Switch or Contact Wired to the Enable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Enable Switch or Contact Wired to the Main Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Inhibit Switch or Contact Wired to the Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 DC Tach-Generator Connection (7 Volts per 1000 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9 DC Tach-Generator Connection (50 Volts per 1000 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10 Other DC Tach-Generator Connection (with Addition of RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11 AC Line Input Voltage Selection (Jumper J1 (Catalog No. BC142-6 Only)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12 Motor Voltage and DC Tach-Generator Selection (Jumper J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13 Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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, Hardware Bag (contains Main Speed Potentiometer with insulator and mounting hardware, (9) – 0.25” female
crimp-on terminals, (4) – 0.11” female crimp-on terminals, and an Enable harness), CE Approved Product Information
Card, and Warranty Registration Card.
Items required to operate this control – Plug-In Horsepower Resistor® and Armature Fuse Kit. Supplied through
your distributor. See Section 9, on page 21.
3

Note: A Plug-In Horsepower Resistor® and Armature Fuse
Kit must be installed in order for this product to operate.
See Section 9, on page 21.
1 SIMPLIFIED INSTALLATION INSTRUCTIONS
4
1.1 AC Line Connection – Wire the AC line to Terminals “L1” (Line Fuse) and “L2”, as shown in Figure 1, on
page 10 and as described in Section 6.1, on page 13.
Catalog No. BC141 is rated for 115 Volt AC line input only. Catalog No. BC142 is rated for 230 Volt AC line
input only. Catalog No. BC142-6 is rated for 115 Volt AC line input (Jumper J1 in the “115V” position) and
230 Volt AC line input (Jumper J1 in the “230V” position). See Section 7.1, on page 19.
Notes: 1. The rated AC line voltage (115, 208/230) 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 No. BC142-6 only) and Jumper J2 (all models) have been facto-
ry set for most applications, as shown in Figure 1, on page 10, and as described in Section 7, on page 19.
IMPORTANT – Read these simplified installation instructions before proceeding. 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 Warning, on page 6, before proceeding.
Fuse Plug-In Horsepower
Resitor®

1.5 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 recommended that this fuse be changed to a 12 Amp fuse for motors rated 7.5 Amps
DC or less. Fuse each conductor that is not at ground potential.
1.6 Plug-In Horsepower Resistor® and Armature Fuse – It is required that a Plug-In Horsepower Resistor®
and Armature Fuse be installed. These are supplied separately 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 control
operation, as described in Section 12, on page 28.
1.9 Auxiliary Heat Sink (Catalog No. BC143) – Extends the horsepower rating of the control to 1.5 HP for
controls with 90 Volt DC output and 3 HP for controls with 180 Volt DC output.
5

6
This product should be installed and serviced by a qualified technician, electrician, or electrical main-
tenance person familiar with its operation and the hazards involved. Proper installation, which includes
wiring, mounting in proper enclosure, fusing or other over current protection, and grounding can reduce the
chance of electrical shocks, fires, or explosion in this product or products used with this product, such as elec-
tric motors, switches, coils, solenoids, and/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. 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.
!
Definition of Safety Warning Symbols:
Electrical Hazard Warning Symbol – Failure to observe this warning could result in electrical shock
or electrocution.
Operational Hazard Warning Symbol – Failure to observe this warning could result in serious injury
or death.
2 SAFETY WARNING – Please read carefully.
!
This product complies with all CE directives pertinent at the time of manufacture. Installation of a CE
approved RFI filter is required (see Section 14.8, on page 30). Additional shielded cable and/or AC
line cables may be required along with a signal isolator (Catalog No. BC152).

3 INTRODUCTION
Thank you for purchasing the BC141, BC142, or BC142-6 full-wave variable speed DC motor control, now with
SMT construction. The control offers the user the ultimate in reliability and performance at an affordable price. The
controls contain a unique patented super-fast Direct-Fed™ current limit circuit that protects the SCR power
bridge against direct shorts1. The reliability of the control is further enhanced with the use of high-surge, 25 Amp
SCRs, and AC line and armature fusing2, 3. The control is designed with exclusive Plug-In Horsepower
Resistor® 3, which eliminates the need for recalibrating IR Comp and Current Limit when the control is used on
various horsepower motors. In addition, the rating of the control can be extended to 1.5 HP for controls with 90
Volt DC output and 3 HP for controls with 180 Volt DC output, by the use of an Auxiliary Heat Sink4. Catalog Nos.
BC142 and BC142-6 also allow operation of 90 Volt DC motors when used on 208/230 Volt AC line input 5.
The versatility of the control is confirmed by its extensive list of standard features, such as: selectable 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. Enable (normally closed) and Inhibit (normally open)
functions provide electronic switching of control output.
The output voltage of the control is a linear function of the Main Speed Potentiometer rotation. In addition, the
control can be used in a voltage following mode by supplying an isolated analog input signal to Terminals “P2” (+)
and “P1” (-). The control is compact in size (only 4.30” X 3.64” X 1.25”) and easily replaces all competitive speed
controls. The control is supplied with a factory installed 25 Amp AC line fuse and a 5 k ΩMain Speed
Potentiometer and QD terminals. All models are UL Listed (USA and Canada) and CE Approved.
Notes: 1. Short circuit protected at motor only. 2. Baldor Limited Warranty applies. See page 32. 3. Plug-In
Horsepower Resistor® and Armature Fuse Kit supplied separately. See Sections 8 and 9, on pages
20 - 22. 4. Catalog No. BC143. See Section 14.1, on page 30. 5. Step-Down operation.
7

3.1 Standard Features
1 Plug-In Horsepower Resistor® – Eliminates the need to calibrate the control for IR Compensation
and Current Limit when used on various horsepower motors.
2 Auto-Inhibit® – Allows the control to be rapidly switched “on” and “off” using the AC line.
3 Inhibit and Enable – Allows the control to be turned “on” and “off” using electronic switching.
4 Trimpots – Minimum Speed (MIN), Maximum Speed (MAX), IR Compensation (IR), Current Limit (CL),
Acceleration (ACCEL), and Deceleration (DECEL).
5 Jumpers – AC Line 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).
8Catalog No. BC141 operates on 115 Volt AC line input with 90 Volt DC motors.
9Catalog No. BC142 operates on 230 Volt AC line input with 180 Volt DC motors or 90 Volt DC motors
(step-down). - Jumper Selectable.
10 Catalog No. BC142-6 can operate on 115 Volt AC line input with 90 Volt DC motors and 230 Volt AC
line input with 180 Volt DC motors or 90 Volt DC motors (step-down). - Jumper selectable.
11 Armature or DC Tach-Generator feedback.
12 SMT construction.
8

Notes: 1. Step-down operation: motor may have reduced brush life. 2. Performance is for SCR rated permanent magnet motors only. Lower performance can be
expected with other motor types. Factory setting is for 3% load regulation. To obtain superior regulation, see Section 11.6, on page 27.
9
Catalog
Number
AC Line
Voltage
(±15%, 50/60Hz)
(Volts AC)
Motor
Voltage
(Volts DC)
Rating without Auxiliary Heat Sink Rating with Auxiliary Heat Sink
Field Voltage
(Volts DC)
Maximum AC
Line Current
(RMS Amps)
Maximum DC
Load Current
(Avg. Amps)
Maximum
Horsepower
(HP (kw))
Maximum AC
Line Current
(RMS Amps)
Maximum DC
Load Current
(Avg. Amps)
Maximum
Horsepower
(HP (kw))
BC141 115 0 - 90 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 50, 100
BC142 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
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 Speed) 1 —
Tach-Generator Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (% Set Speed) 1 —
Line Voltage Regulation (at Full Load, ± 10% Line Variation) (% Speed) 0.5 —
Control Linearity (% Speed vs. Dial Rotation) 2 —
Acceleration (ACCEL) Trimpot Range (Seconds) 0.2 – 10 2
Deceleration (DECEL) Trimpot Range (Seconds) 0.2 – 10 2
Maximum Speed (MAX) Trimpot Range (% Base Speed) 50 – 110 100
Minimum Speed (MIN) Trimpot Range (% Base Speed) 0 – 30 0
Current Limit (CL) Trimpot Range (% Full Load) 0 – 200 150
IR Compensation (IR) Trimpot Range (at Specified Full Load @ 90, 180 Volts DC Output) (Volts DC) 0 – 24, 48 3, 6