Brushless DC Drive - Servo Systemsservosystems.com/pdf/baldor/dcadjustablespeed_install_manual.pdf · Contact your local Baldor District Office for Declaration of Conformity. Feature

For Catalog Nos. BMC6A01, BMC6A02,

BMC6A04, BMC6A05, BMC2A06, BMC2A09

Brushless DC Drive

Installation and Operating Manual

MN1365

TABLE OF CONTENTSSection Page1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Quick-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Finger-Safe Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Electrical Connections Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Baldor District Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Tables Page1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Performance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical Ratings and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Terminal Block Wire and Tightening Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 J1 Settings for AC Input Voltage and Motor Voltage Choices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2110 Motor Pole Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2311 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2912 Fault Recovery and Resetting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3013 Drive Operating Condition and Status LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figures Page1 Catalog Nos. BMC6A01, BMC6A02, BMC6A04, BMC6A05 Quick-Start Connection Diagram . . . . 92 Catalog Nos. BMC2A06, BMC2A09 Quick-Start Connection Diagram . . . . . . . . . . . . . . . . . . . . . . 103 Hall Isolator Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Catalog Nos. BMC6A01, BMC6A02 Mechanical Specifications and Drive Layout . . . . . . . . . . . . . 115 Catalog Nos. BMC6A04, BMC6A05 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Catalog Nos. BMC2A06, BMC2A09 Mechanical Specifications (Inches/mm) and Drive Layout . . . 137 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Hall Sensor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Unidirectional Operation Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 1810 Bidirectional Operation Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1811 Unidirectional Operation (Shown with Forward Run Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1812 Bidirectional Operation (Shown with Run Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1813 Automatic Start (Jumper Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1914 Manual Start Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1915 Forward-Stop-Reverse Switch (Shown with Main Speed Potentiometer) . . . . . . . . . . . . . . . . . . . . 2016 Form “C” Contact or Relay Forward-Stop-Reverse (Shown with Main Speed Potentiometer) . . . . . 2017 Open Collector Forward-Stop-Reverse Connection (Shown with Main Speed Potentiometer) . . . . 2018 Forward Run Switch Connection (Shown with Main Speed Potentiometer) . . . . . . . . . . . . . . . . . . 2119 Reverse Run Switch Connection (Shown with Main Speed Potentiometer) . . . . . . . . . . . . . . . . . . . 2120 Catalog Nos. BMC6A01, BMC6A02, BMC6A04 AC Line Input Voltage Selection . . . . . . . . . . . . . 2221 Catalog No. BMC6A05 AC Line Input Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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TABLE OF CONTENTS (Continued)Figures Page22 Removing J1 for Catalog No. BMC6A05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2223 Decel Extend Enable/Disable Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2224 Hall Sensor Phasing Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2325 Motor Poles Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2326 Coast-to-Stop (Non-Braking) During Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2327 Adjustable Braking During Deceleration (2Q Braking Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2428 Calibration in the 4Q Braking Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2529 Dynamic Braking During Deceleration (4Q Braking Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2530 Maximum Speed Trimpot Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2631 Main Speed Potentiometer Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2632 Acceleration Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2733 Deceleration Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2734 Response Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2735 Catalog No. BMC6A01 Current Limit Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2836 Catalog No. BMC6A02 Current Limit Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2837 Catalog No. BMC6A04 Current Limit Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2838 Catalog No. BMC6A05 Current Limit Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2839 Catalog No. BMC2A06 Current Limit Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2840 Catalog No. BMC2A09 Current Limit Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2841 Available Torque vs. Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

iii

4

1 INTRODUCTIONThank you for purchasing the Brushless DC Drive. This drive is UL Listed for US andcUL for Canada and is RoHS Compliant.

The Brushless DC Drive provides the best of DC control by providing extended constanttorque speed range, accurate speed control, fast response, and no brush wear for the BSMseries motors.

Signal isolation is standard on all Brushless DC Drives.

Adjustable speed control is provided for standard 160 Volt and 320 Volt Brushless DC motorsfrom sub fractional thru 3 hp. The Pulse Width Modulated (PWM) output operates at a carrierfrequency of 16 kHz, providing high motor efficiency, low motor heating, and low noise.Adjustable linear acceleration and deceleration are also provided for soft-start applications.

Adjusting the drive for a specific application is accomplished with selectable jumpers and trim-pots. However, for many applications no adjustments are necessary.

Main features of the Brushless DC Drives include adjustable RMS Current Limit and I2t MotorOverload Protection*. In addition, precision speed accuracy is possible over the extendedspeed range through the use of the Hall Feedback as an encoder. Electronic Inrush CurrentLimit (EICL™) eliminates harmful AC line inrush current. The drive is suitable for constanttorque or variable torque applications.

*UL approved as an overload protector for motors.

This product complies with all CE directives pertinent at the time of manufacture.Contact your local Baldor District Office for Declaration of Conformity.

Feature Description

Simple to Operate Trimpots and jumpers are factory set for most applications.

Industry Standard Mounting The drive has industry standard mounting dimensions.

Diagnostic LEDs Power on (PWR, IPWR), drive status (ST), and Drive Calibration (CAL).

Hall Sensor Feedback Standard Hall A, B, C, +5V, Common; 60/120 degree jumper selectable.

Jumper SelectionsLine Voltage, 4, 6, 8, 12 Pole, 60/120 Degree Hall Sensor Phasing, Automatic/ManualStart, Braking.

Trimpot AdjustmentsMaximum Speed, Current Limit, Response, Acceleration, Deceleration, Input SignalScaling, Input Signal Offset, Braking.

Finger-safe cover Meets IP-20 standard.

TABLE 1 – STANDARD FEATURES

Feature Description

High Torque Drive can maintain constant torque throughout the extended speed range.

Speed Control Accuracy Better than 0.5% with load and line.

Peak Current Two times rated current, continuous for 3 seconds.

Voltage Doubling Allows 320 Volt motors to be used on drives with 115 Volt AC line input.

Signal IsolationAll signal input connections, speed reference connections, and Hall Sensorconnections are isolated from the AC line.

Speed Command Accepts industry standard ±10 Volt DC bidirectional signal input.

OEM Applications Braking capability and PWM speed reference.

TABLE 2 – PERFORMANCE FEATURES

5

Feature Description

Motor Overload (I2t) with RMS Current LimitProvides motor overload protection which prevents motor burnout and eliminatesnuisance trips.

Electronic Inrush Current Limit (EICL™) Eliminates harmful inrush AC line current during startup.

Short Circuit Prevents drive failure if a short circuit occurs at the motor (phase-to-phase).

Hall Sensor Input Protection Protects the Hall Isolator Board from damage due to accidental miswiring.

Motor Filter Reduces harmful voltage spikes to the motor.

Undervoltage and Overvoltage Shuts down the drive if the AC line input voltage is outside the operating range.

MOV input transient suppression. Prevents failure of power devices caused by voltage spikes in the AC line.

TABLE 3 – PROTECTION FEATURES

Trimpot

Maximum Speed (MAX) Sets the maximum motor speed

Scaling (SCALE) Sets the scaling for the input signal

Input Offset (OFFSET) Sets the offset for the input signal

Acceleration (ACC) Sets the motor acceleration time (time to reach full speed)

Deceleration (DEC/B) Sets the motor deceleration time (time to reach zero speed)

Response (COMP) Sets the response time of the drive.

Current Limit (CL) Sets the current limit and limits the maximum current (torque) to the motor

Braking (% BRAKE) Sets the desired amount of braking (2Q Braking Mode only).

TABLE 4 – TRIMPOT ADJUSTMENTS

Accessory Description

Dynamic Brake Module(Catalog No. ID5RGA-1)

Provides up to 200 Watts of continuous braking for all models.

TABLE 5 – OPTIONAL ACCESSORIES

TABLE 6 – ELECTRICAL RATINGS AND FEATURES

CatalogNo.

AC Line Input Fuse orCircuitBreaker1

Rating(Amps)

Drive Output Features by Model2 Net Wt.

NominalVolts AC(50/60 Hz)

Phase(φ)

MaximumCurrent(Amps AC)

OutputVoltageRange(Volts AC)

MaximumContinuousLoad Current

(RMS mps/Phase)

MaximumHorsepower(HP (kW))

MotorFilter

AC LineandMotor

Connections Lbs. kg

BMC6A01115 1 6.0 10

0 – 320 1.5 1/4 (.18) S QC 1.8 0.8208/230 1 3.8 5

BMC6A02115 1 11.0 15

0 – 320 2.4 1/2 (.37) S QC 1.8 0.8208/230 1 7.0 10

BMC6A04115 1 16.0 20

0 – 320 4.0 1 (.75) S QC 2.7 1.2208/230 1 10.0 15

BMC6A05115 1 22.0 25

0 – 320 5.5 11⁄2 (1.13) S QC 3.4 1.5208/230 1 14.0 15

BMC2A06 208/230 1, 3 15.0 20 0 – 320 6.7 2 (1.5) N TB 4.1 1.9

BMC2A093 208/230 3 10.8 15 0 – 320 9.0 3 (2.25) N TB 5.4 2.4

Notes: 1. Recommended Fuse Type: Littelfuse 312/314, Buss ABC, or equivalent.

2. S = Standard Feature, N = Not Available, QC = Quick-Connect Terminals for AC line and motor connections,

TB = Terminal Block for AC line and motor connections.

3. Catalog No. BMC2A09 contains a built-in cooling fan.

6

Description Specification Factory Setting

115 Volt AC Line Input Voltage Operating Range (Volts AC)* 115 (±10%) —

208/230 Volt AC Line Input Voltage Operating Range (Volts AC)* 208 (-10%) / 230 (+10%) —

Maximum Load (% Current Overload for 1 Minute) 150 —

Switching Frequency (kHz) 16 —

Signal Following Input Voltage Range (Volts DC) ±25 0 – 5

Speed Range (RPM with 4-Pole Motor) 0 – 7000 0 – 4000

Maximum Speed Trimpot (MAX) Range (RPM) 1000 – 7000 4000

Acceleration Trimpot (ACC) and Deceleration Trimpot (DEC) Range (Seconds) 0.1 – 30 1.5

Input Scaling Trimpot (SCALE) ±25 0 – 5

Current Limit Trimpot (CL) Range (%Drive Rating) 75 – 230 200

Offset Trimpot (OFFSET) Range (% Signal Input) ±20 0

Response Trimpot (COMP) Range (Slow to Fast) (milliseconds (Hz)) 1000 – 200 (1 – 5) 700 (1.4)

Speed Range (Ratio) 150:1 —

Speed Regulation (% Base Speed) Better than 0.5 —

Overload Protector Trip Time for Stalled Motor (Seconds at 200% Load Current) 3 —

Operating Temperature Range (°C / °F) 0 – 45 / 32 – 113 —

TABLE 7 – GENERAL PERFORMANCE SPECIFICATIONS

*Do not operate the drive outside the specified AC line input voltage operating range.

SAFETY NOTICEA Warning statement indicates a potentially hazardous situation which, if not avoided, could resultin injury or death.

A Caution statement indicates a potentially hazardous situation which, if not avoided, could resultin damage to property.

A Note indicates additional information that is not critical to the installation or operation.

WARNING! This equipment may contain voltages as high as 1000 volts! Electricalshock can cause serious or fatal injury. Only qualified personnel should attempt the

start-up procedure or troubleshoot this equipment.

WARNING! Electrical shock can cause serious or fatal injury. Be sure that all power isdisconnected from drive before the finger-safe cover is removed. Removal of the

finger safe cover is required to make installation connections. Electrical shock can causeserious or fatal injury if the finger-safe cover is removed and power is still applied.

WARNING! Electrical shock can cause serious or fatal injury. Verify there is no volt-age 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 individualinstaller 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 resultdue to improper use of this product.

WARNING! Do not use this drive in an explosive environment. An explosion cancause serious or fatal injury. This drive is not explosion proof.

CAUTION!Disconnect motor leads (U, V and W) from control before performing a “LeakageResistance” test on the motor. Failure to disconnect motor from the control may result inextensive damage to the control. The control is tested at the factory for high voltage / leak-age resistance as part of Underwriters Laboratories requirements.

CAUTION!Suitable for use on a circuit capable of delivering not more than 5,000 RMS symmetricalshort circuit amperes listed here at rated voltage.

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

CAUTION!Do not use the “115V” position for 230 Volt AC line input voltage. Damage will occur to thedrive. The 115V position provides 2 times the AC input voltage to the motor.

7

8

2 QUICK-START INSTRUCTIONSThis procedure will help get your system up and running quickly and allows motor and controloperation to be verified.

WARNING! Electrical shock can cause serious or fatal injury. Be sure that allpower is disconnected from drive before the finger-safe cover is removed.

Removal of the finger safe cover is required to make installation connections. Electricalshock can cause serious or fatal injury if the finger-safe cover is removed and power isstill applied.

WARNING! Electrical shock can cause serious or fatal injury. Only qualifiedpersonnel should attempt installation, start-up procedure or to troubleshoot

this equipment.

2.1 Mount the drive. For instructions, see Section 3, on page 14

Note: Do not connect this drive to a Ground-Fault Circuit-Interrupter (GFCI). The PWMsignal to the motor produces slightly more leakage than normal. This will cause GFCI totrip. Filtering can reduce this leakage and GFCI trips.

2.2 Remove the finger-safe cover. For instructions, see Section 4, on page 14.

2.3 Connect AC power.

WARNING! Electrical shock can cause serious or fatal injury. Verify thereis 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 powermust be disconnected before proceeding.

A main power disconnect installed between the AC power lines and the control is recom-mended. Each AC Line wire that is not at neutral or ground potential must be protected.For the recommended fuse ratings, see Table 6, on page 5. Also see Section 5.1, onpage 15.

Connect the AC line wires to the control.

1. For Catalog Nos. BMC6A01, BMC6A02, BMC6A04, BMC6A05, connect thesingle-phase AC line input to terminals “L1” and “L2”, see Figure 1, on page 9.

2. For Catalog No. BMC2A06, connect the single-phase AC line input to terminals “L1”and “L2”, see Figure 2, on page 10.

3. For Catalog Nos. BMC2A06, BMC2A09, connect the 3-phase AC line input to termi-nals “L1”, “L2”, “L3”, see Figure 2, on page 10. Also see Section 5.1, on page 15.

2.4 Ground connection: Connect the ground (earth) conductor to the “Ground (Earth)”screw, shown in Figures 1 and 2, on pages 9 and 10.

2.5 Motor connection: Connect the motor wires to control terminals “U”, “V” and “W”, seeFigures 1 and 2, on pages 9 and 10. (Load reactors may be required for cable lengthsover 100 ft (30 m) – contact your local Baldor sales office).

2.6 Main speed potentiometer connection: For unidirectional speed operation, connect the5 KΩ potentiometer to TB2 terminals “COM” (low), “SIG” (wiper), “+5VI” (high). The MainSpeed Potentiometer can also be connected for bidirectional speed operation. SeeSection 5.5, on page 18.

9

2.7 Voltage following: A ±25 Volt DC analog signal input can be used to control motorspeed and direction. The drive output will linearly follow the analog signal input. Connectthe signal input positive lead (+) to TB2 terminal “SIG” and the negative lead (-) to TB2terminal “COM”. See Section 5.6, on pages 18 and 19.

2.8 AC line voltage and motor voltage selection: The drive is factory set for 230 Volt out-put (to operate 320 Volt motors with a 230 Volt AC line input). For connections to 160Volt motors and a 115 Volt AC line input, see Section 6.1, on page 21.

CAUTIONDo not use the “115V” position for 230 Volt AC line input voltage. Damage willoccur to the drive. The 115V position provides 2 times the AC input voltage to themotor.

Catalog Nos. BMC6A01, BMC6A02, BMC6A04: Jumper J1 is labeled “115V” and“230V”. Catalog No. BMC6A05: Jumper J1 is labeled “115VAC” and “230VAC”.

2.9 Hall Sensor Setting: Must be set prior to drive operation. See Section 6.3, on page 22.

2.10 Number of Motor Poles Setting: Must be set prior to drive operation. See Section 6.4,on page 23.

2.11 Trimpot Settings: Most trimpots have been factory set for typical applications, Figures 3and 4, on page 11. Some applications require adjustment of the trimpots in order to tailorthe drive for a specific requirement. See Section 7, on pages 25 – 27.

Note: The MAX trimpot must be set for the rated motor speed. See Section 7.1, onpage 26.

FIGURE 1 – CATALOG NOS. BMC6A01, BMC6A02, BMC6A04, BMC6A05 QUICK-START CONNECTION DIAGRAM*

see Section 6.2, on page 22.Decel Extend Enable/Disable

COMsee Section 5.2, on page 15.

see Section 5.3, on page 15.

Single-Phase AC Line Input:see Section 5.1, on page 15.

AC LINE

L2L1

Motor:

Motor

MOTOR

WV

U

PWR

J2

B+

CON1

X2X1

ST

CLM

AX

+Vcc+5V

W+

-Vcc

U+

B

A

0V

C

V+

Hall

TB1

230V

1

15V

B-

DEC/

B

J1

ACC

COM

P

Stop

Reverse

TB2

+5VI

-5VI

Forward

Wiper

FWD

COM

SIG

REV

Low High

see Section 6.1, on page 21AC Line Input Voltage Selection:

Ground (Earth): 5k

See Table 8, on page 15, for terminal block tightening torque specifications.

*Layout of Catalog Nos. BMC6A04, BMC6A05 varies slightly.

10

see

Sect

ion

5.2,

on

page

15.

Grou

nd (E

arth

):

see

Sect

ion

5.3,

on

page

15.

(Cat

alog

No.

BM

C2A0

6 On

ly):

see

Sect

ion

5.1,

on

page

15.

Sing

le-P

hase

AC

Line

Inpu

t:

3-Ph

ase A

C Li

ne In

put:

(Cat

alog

Nos

. BM

C2A0

6, B

MC2

A09)

:se

e Se

ctio

n 5.

1, o

n pa

ge 15

.

(Use

L1,

L2,

L3)

(Use

L1,

L2)M

otor

Mot

or:

-Vcc

LINE

Dece

l Ext

end

Enab

le/D

isabl

ese

e Se

ctio

n 6.

2, o

n pa

ge 2

2.

L3

CON1

X1 X2

CON3J2

U+ABC0V

V+

Hall

W+

5kCO

M

MOTOR AC L2L1WTB1 VU

DEC/B

TB2

ST

PWR

CLMAX

TB1 +5

V+V

cc

ACCCOMP

-5VI

+5VI

COM

Reve

rseSt

op

Low

FWD

REV

SIG

Wip

er

Forw

ard

High

FIGURE 2 – CATALOG NOS. BMC2A06, BMC2A09 QUICK-START CONNECTION DIAGRAM

SeeTable 8, on page 15, for terminal block tightening torque specifications.

11

96.5

5.35136

6.4

3.80

(2 Places)

0.25

FINGER-SAFE COVER RE TAINING CLIPS

Expanded View of Jumpers and TrimpotsB+

4.05103

CL

CON1

X2X1

J2

PWR ST

DEC/B ACC COMPMAX

230V 115V

J1

B-

76.2

5.10.2

AC LINE

L2

12.70.5

31.81.25

UVWL1MOTOR

(10 Places)

3.0099.03.90

PWR ST

J2

X1

CON1

X2

5.1

24.10.95

96.53.80

COMP

0.2

CL MAX DEC/B

J1

ACC

230V 115V

69.92.75

FIGURE 3 – HALL ISOLATOR BOARD LAYOUT

J1

4P6P

J2

120

60

J4

X1X2

J3

CON1

CON2

R S P2F P1

MODEBRAKE

CAL

OFF

ON

J6

ONOF

F

CAL% BRAKE

2Q

J7

4Q

TB1

A B C 0V +5V

Trimpot Not Used (Non-Functional)

IPW

R

SCALE

J5

PWM AN

OFFSE T

REV+5VI -5VI FWDCOM

TB2

COMSIG



FIGURE 4 – CATALOG NOS. BMC6A01, BMC6A02 MECHANICAL SPECIFICATIONS (INCHES/MM) AND DRIVE LAYOUT(Also See Figure 3)

(Top View Shown without Finger-Safe Cover Installed) (Side View Shown with Finger-Safe Cover Installed)

12

FING

ER-S

AFE

COVE

R RE

TAIN

ING

CLIP

S

FING

ER-S

AFE

COVE

R RE

TAIN

ING

CLIP

S

(2 P

lace

s)

DO N

OT

USE

RETA

ININ

G CL

IPS

THES

E FO

UR

0.4

10.2

(6 P

lace

s)

3.90

99.0

2.0

0.08

(2 P

lace

s)

66.5

2.62

1.87

47.5

111

4.37

Char

t ASe

e

103

4.05

0.2

5.1

Cata

log

No. B

MC2

A05

Cata

log

No. B

MC2

A05

FING

ER-S

AFE

COVE

R RE

TAIN

ING

CLIP

S

112

4.40

Char

t BSe

e

Cata

log

No. B

MC2

A04

Cha

rt A

- M

axim

um L

eng

thCa

talo

g No

. BM

C2A0

4

Cha

rt B

- M

axim

um H

eig

ht

5.35

6.75

4.70

119

127

5.00

136

114

4.50

172


FIGURE 5 – CATALOG NOS. BMC6A04, BMC6A05 MECHANICAL SPECIFICATIONS (INCHES/MM)

(Catalog No. BMC6A05 Shown with Finger-Safe Cover Installed)

(Also SeeFigure 3, on page 11) (SeeFigure 4, on Page 11, for Expanded View of Jumpers and Trimpots)

13

3.90

99.0

4.68

119

Max

imum

Heig

ht:

LINEL3UTB1 V W L2L1

AC MOTOR

12.7

0.5

1.25

31.8

76.2

3.00

191 (8 P

laces

)5.

1

7.00

178

0.2

7.50

8.55

217

PWR CON3

J2

X1 X2

CON1

COMP DEC/BACC MAX CL

ST

103

4.05

113

4.45


FIGURE 6 – CATALOG NOS. BMC2A06, BMC2A09 MECHANICAL SPECIFICATIONS (INCHES/MM) AND DRIVE LAYOUT

(Shown without Finger-Safe Cover Installed)

(Also SeeFigure 3, on page 11) (SeeFigure 4, on Page 11, for Expanded View of Jumpers and Trimpots)

3 MOUNTING INSTRUCTIONS

WARNING! Do not use this drive in an explosive environment. An explosioncan cause serious or fatal injury. This drive is not explosion proof.

3.1 Mounting the drive: This drive must be mounted in an enclosure. Avoid extreme haz-ardous locations where physical damage to the drive can occur due to moisture, metalchips, dust, and other contamination, including corrosive atmosphere that may be harm-ful. The enclosure must allow for proper heat dissipation so that the ambient temperaturedoes not exceed 45 °C (113 °F). Leave at least 2” of clearance between the top and bot-tom of the drive and the enclosure to allow for AC line, motor connection, and other con-nections that are required. See Figures 4 – 6, on pages 11 – 13.

3.2 Mounting The Main Speed Potentiometer: When mounting the Main SpeedPotentiometer, be sure to install the insulating disc between the potentiometer and thepanel. The Main Speed Potentiometer connects to the Hall Isolator Board terminal BlockTB2, as described in Section 5.5, on page 18.

4 FINGER-SAFE COVERThe drive is designed with an IP-20 finger-safe cover to protect against accidental contact withhigh voltage.



4.1 Removing the finger-safe cover: The finger-safe cover may have to be removed beforemaking electrical connections within the drive or setting selectable jumpers. All trimpotscan be adjusted with the finger-safe cover installed. Note the orientation of the finger-safecover before removing it.

To remove the finger-safe cover, gently lift up on the four retainer clips until the cover dis-engages from the heat sink base. See Figures 4 and 5, on pages 11 and 12.

Catalog BMC6A05, the inner bus capacitor support bracket does not have to beremoved.

4.2 Installing the finger-safe cover: To install the finger-safe cover, be sure to properly alignthe retainer clips. Gently push the finger-safe cover until the retainer clips are fullyengaged with the heat sink base.

5 ELECTRICAL CONNECTIONS INSTRUCTIONS



Note: Electrical noise can be induced in unshielded wires that run parallel to each other. Toavoid erratic operation, it is important to separately route the AC line wires, motor wires, motorfeedback wires, start/stop contact wires, or any other signal wires. Each set of wires must be

14

15

5.1 AC Line Connection:

WARNING! Electrical shock can cause serious or fatal injury. Verify thereis 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 powermust be disconnected before proceeding.

A main power disconnect installed between the AC power lines and the control is recom-mended and is required by most electrical codes. This provides a fail safe method to dis-connect power to the drive. Electrical codes require that suitable branch circuit protectionbe installed in each power conductor. Each AC Line wire that is not at neutral or groundpotential must be protected. For the recommended fuse ratings, see Table 6, on page 5.

AC Line Fuse: This drive does not contain AC line fuses. Most electrical codes requirethat each ungrounded wire contain circuit protection. Do not fuse neutral or groundedconnections. It is recommended to install a fuse (Littelfuse 312/314, Buss ABC, orequivalent) or a circuit breaker (Square D QUO, or equivalent) in series with eachungrounded wire. For the recommended fuse size, see Table 6, on page 5. Connect thedrive in accordance with the National Electrical Code requirements and other local codesthat may apply to the application.

Connect the AC line wires to the control.

1. For Catalog Nos. BMC6A01, BMC6A02, BMC6A04, BMC6A05, connect the single-phase AC line input to terminals “L1” and “L2”. See Figure 7, on page 16.

2. For Catalog No. BMC2A06 (single phase), connect the single-phase AC line input toterminals “L1” and “L2”. See Figure 7, on page 16.

3. For Catalog Nos. BMC2A06, BMC2A09, connect the 3-phase AC line input to termi-nals “L1”, “L2”, “L3”. See Figure 7, on page 16.

5.2 Ground Connection: Connect the ground wire (earth) to the green ground screw“Ground (Earth)” in Figure 7, on page 16. The ground screw is located on the heat sink.See Figure 7, on page 16.

5.3 Motor Connection: Connect the motor wires to terminals “U”, “V” and “W”. The termi-nals are located on the upper PC board. See Figure 7, on page 16. Motor cable lengthshould not exceed 100 ft. (30 m) – special reactors may be required. Do not fuse motorleads.

Terminal BlockMaximum

Wire Size (Cu)RecommendedTightening Torque

Designation Description Location AWG mm2 in-lbs kg-cm

TB1* AC Line Input and Motor Drive’s Upper PC Board 12 3.3 12 14

TB1 Hall Sensor Hall Isolator Board 16 2.1 3.5 4

TB2Signal Input, Direction Switch, and

Main Speed PotentiometerHall Isolator Board 16 2.1 3.5 4

TABLE 8 – TERMINAL BLOCK WIRE AND TIGHTENING TORQUE SPECIFICATIONS

*Catalog Nos. BMC2A06, BMC2A09 only. Catalog Nos. BMC6A01, BMC6A02, BMC6A04, BMC6A05 contain quick-connect terminals for AC

line and motor connections.

enclosed in a separate conduit or shielded cable bundle for all signal wires over 12” (30 cm). Do not bundle motor wires from multiple drives in the same conduit. The shield should beearth grounded on the drive side only.

16

Catalog Nos. BMC6A01, BMC6A02, BMC6A04, BMC6A05

(Single Ph

ase AC

Line Input)

Catalog No. BMC2A06

(Single-Ph

ase AC

Line Input)

Catalog No. BMC2A06, BMC2A09

(3-Phase AC Line In

put)

(Ear

th)

Grou

ndM

otor

Sing

le-Ph

ase,

50/

60 H

z11

5, 2

08/2

30 V

olt

AC L

ine

Inpu

t

UV

MOT

OR

WAC

LIN

E

L1L2

L3

208/

230

Volt

Mot

or(E

arth

)Gr

ound

Sing

le-Ph

ase,

50/

60 H

zAC

Lin

e In

put

(Use

L1,

L2

Only)

MOT

OR

UTB

1L2

L1W

V

AC

LINE

208/

230,

3-P

hase

50/6

0 Hz

AC

Line

Inpu

t(E

arth

)Gr

ound

Mot

or

AC

UTB

1V

MOT

OR

WL1

L2LINE

L3

FIGURE 7 – AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS

(Motor and AC Line Terminals are Located on the Drive’s Upper PC Board)


17

5.4 Hall Sensor Connection: Connect the HallSensor to TB1 terminals “A”, “B”, “C”,“0V”, “+5V” on the Hall Isolator Board ter-minal Block TB1, see Figure 8. Hall “U+” toTB1 terminal “A”, Hall “V+” to TB1 terminal“B”, Hall “W+” to TB1 terminal “C”, Hall“-Vcc” to TB1 terminal “0V”, and Hall“+Vcc” to TB1 terminal “+5V”. If the HallSensor phasing is unknown, use thefollowing procedure to determine phasingbefore making electrical connection to thedrive terminals. Baldor’s standard is 120degree Hall Sensor phasing.

If the Hall Sensor phasing is not known, it can be determined by using the following technique:

1. Verify that the AC power is disconnected from the drive.

2. Verify that the Hall sensor inputs are connected correctly, see Figure 8. Hall “U+” toTB1 terminal “A”, Hall “V+” to TB1 terminal “B”, Hall “W+” to TB1 terminal “C”, Hall“-Vcc” to TB1 terminal “0V”, and Hall “+Vcc” to TB1 terminal “+5V”.

3. Connect a DC voltmeter from Hall Sensor inputs “A” to “0V”.

4. Connect a DC voltmeter from Hall Sensor inputs “B” to “0V”.

5. Connect a DC voltmeter from Hall Sensor inputs “C” to “0V”.

6. Disconnect the motor wires from the drive (motor terminals “U”, “V” and “W”).

WARNING! Electrical shock can cause serious or fatal injury.Electrical shock can cause serious or fatal injury if power is still

applied while the finger-safe cover is removed.

WARNING! Electrical shock can cause serious or fatal injury. Onlyqualified personnel should attempt installation, start-up procedure

or to troubleshoot this equipment.

7. Apply the specified AC line input voltage to the drive.

8. Slowly rotate the motor shaft by hand through one revolution while monitoring the DCvoltmeter voltages on “A”, “B”, and “C”. If, at any position of the motor shaft, all threevoltages are either all high (+5V) or all low (0V), then the electrical phasing for the HallSensor is 60 degrees.

9. Disconnect the AC power from the drive.

10. Reconnect the motor to drive terminals “U”, “V” and “W”.

If Hall “U-”, “V-” and “W-” wires are also available, they are not to be used. Insulateany bare wires.

Note: The Hall Isolator Board can supply 20 mA max. for the Hall Sensor. Use an external isolated power supply for Hall Sensors that require more than 20 mA.

CBA 0V +5V

TB1

-Vcc+Vcc

Hall

U+V+W+

FIGURE 8 – HALL SENSOR CONNECTION

See Table 8, on page 15, for terminal block tighteningtorque specifications.

18

5.6 Voltage Following Connection: The factory setting is for a 0 to +5 Volt DC analog signalinput voltage to control motor speed instead of a Main Speed Potentiometer. The motorspeed will linearly follow the analog input signal. Other signal voltage ranges up to ±25Volts DC are allowed with the changes described in Section 7.1, on page 26.

1. Unidirectional Operation: For Zero Speed to Full Speed Operation, connect thesignal input positive lead (+) to terminal “SIG” and the negative lead (-) to terminal“COM”. See Figure 11.

Run Switch

-5VI+5VI COM

Wiper

High

5k

Low

SIGFWD REV COM

Jumper

TB2

FIGURE 10 – BIDIRECTIONAL OPERATIONMain Speed Potentiometer Connection

(Shown with Run Switch)

Wiper5k

+5VI -5VI

High

Low

COMREVFWDCOM

StopForward

Reverse

SIG

TB2

FIGURE 9 – UNIDIRECTIONAL OPERATIONMain Speed Potentiometer Connection

(Shown with Forward-Stop-Reverse Switch)

Jumper

+5VI -5VI FWDCOM

Run Switch

REV COMSIG

TB2

0 - ±25

V

Volts DC

FIGURE 12 – BIDIRECTIONAL OPERATION(Shown with Run Switch)

Forward Run Switch

+5VI -5VI FWDCOM REV COMSIG

TB2

0 - 25

-V+

Volts DC

FIGURE 11 – UNIDIRECTIONAL OPERATION(Shown with Forward Run Switch)

5.5 Main Speed Potentiometer Connection: A 5 kΩ Main Speed Potentiometer is provided.

1. Mount the potentiometer in a convenient location for speed control.

2. Connect the potentiometer wires.

a. Unidirectional Speed Control. For Zero Speed to Full Speed Operation, connectthe potentiometer to terminals “COM” (low), “SIG” (wiper), and “+5VI” (high).See Figure 9.

b. Bidirectional Speed Control. For Full Speed Reverse to Full Speed ForwardOperation, connect the potentiometer to terminals “-5VI” (low), “SIG” (wiper), and“+5VI” (high). Terminals “FWD” and “REV” must be jumpered. See Figure 10.



19

2. Bidirectional Operation: For Full Speed Reverse to Full Speed Forward Operation,connect the bipolar (+/-) signal input voltage to terminals “SIG” and “COM”. For for-ward motion, apply a positive (+) voltage to terminal “SIG”. For reverse motion, applya negative (-) voltage to terminal “SIG”. See Figure 12, on page 18.

5.7 Automatic Start (CON1): Connector CON1 is located onthe drives lower PC board. The drive is factory set forAutomatic Start (jumper installed onto CON1), see Figure13. The drive will automatically start when power isapplied and a run command is given. The drive willautomatically restart after a fault is cleared due toundervoltage, overvoltage, or short circuit (phase-to-phase at the motor).

For an I2t Trip, due to a prolonged overload, the drive must be manually restarted.See Section 9.2, on page 30. Also see Section 9.4, on page 30.

5.8 Manual Start Switch Connection (CON1): Factory installed jumper CON1 sets auto-matic start mode. For manual starting, the Manual Start Switch is used to manually startthe drive or restart the drive (reset) if a fault has occurred.

1. Remove the factory installed jumper on CON1

2. Install the 2-wire connector (supplied) on CON1 (located on the lower PC board).

3. Install a momentary switch or contact onto the 2-wire connector, see Figure 14.

In the Manual Start Mode, the drive will trip due to all faults (Overvoltage,Undervoltage, Short Circuit, and I2t) and remain tripped even when the fault iscleared. To Start/Reset the drive, the switch or contact must be manually closed.Also, the drive must be restarted each time the AC line is interrupted. See Section9.2, on page 30. Also see Section 9.4, on page 30.

5.9 Forward-Stop-Reverse Connection: To change motor direction, three choices areavailable. A maintained Forward-Stop-Reverse Switch, maintained Form “C” contactsor Open Collector line drivers may be used.

A/MCON1

FIGURE 13 – AUTOMATIC START(Jumper Installed)

Jumper Removed Connector Installed for Manual Start Switch

CON1A/M

Manual Start Switch

(Momentary Contacts)(Push to Run)

White

Black

CON1

FIGURE 14 – MANUAL START SWITCH CONNECTION

20

+5VI COM FWD-5VI COMSIGREV

High Forward

Low

5k Wiper

Reverse

TB2

FIGURE 16 – FORM “C” CONTACTOR RELAY FORWARD-STOP-REVERSE (Shown with Main Speed Potentiometer)

5k Wiper

+5VI -5VI

High

Low

COMREVFWDCOM

StopForward

Reverse

SIG

TB2

FIGURE 15FORWARD-STOP-REVERSE SWITCH

(Shown with Main Speed Potentiometer)


+5VI COM FWD-5VI COMSIGREV

ForwardHigh

Low

5k Wiper

Reverse

TB2

FIGURE 17 – OPEN COLLECTORFORWARD-STOP-REVERSE CONNECTION(Shown with Main Speed Potentiometer)


1. Connect the maintained switch contacts to terminals “FWD”, “COM”, “REV”, on theHall Isolator Board terminal Block TB2. See Figure 15.

OR

2. Connect the Form “C” contacts to terminals “FWD”, “COM”, “REV”, see Figure 16.

OR

3. Connect the open collector circuit to terminals “FWD”, “COM”, “REV”, see Figure 17.

5.10 Run Switch Connection: The drive can be started and stopped with a Run Switch(close to run, open to stop).

1. Forward Run/Stop Operation: Connect the switch to terminals “FWD” and “COM”,see Figure 18, on page 21.

2. Reverse Run/Stop Operation: Connect the switch to terminals “REV” and “COM”,see Figure 19, on page 21.

21

6 SETTING SELECTABLE JUMPERSThe drive and Hall Isolator Board have customer selectable jumpers which must be set beforethe drive can be used. For the location of the jumpers, see Figures 3 and 4, on page 11.See Section 4, on page 14, for instructions on removing and installing the finger-safe cover.


Removal of the finger safe cover is required to make installation connections. Electricalshock can cause serious or fatal injury. If the finger-safe cover is removed and power isstill applied.

For proper drive operation, the following jumpers must be set: Jumper J1 (Line Voltage onthe drive’s upper PC board), Jumper J2 (Hall Sensor Phasing on the Hall Isolator Board), andJumpers J1 and J4 (Motor Poles on the Hall Isolator Board).

6.1 AC Line Input Voltage Selection (J1): (located on the drive’s upper PC board.See Figure 1, on page 9.) Factory setting is the “230V” position for 230 Volt AC lineinput and 230 Volt AC output to a 320 Volt motor. For other settings, see Table 9.

The motor data sheet or nameplate should indicate the rated voltage (e.g., 160V or300V). The motor voltage may be expressed in Volts per RPM.

Motor Voltage = (RPM of the Application) X (Volts per RPM Rating of the Motor)

CAUTION!Do not use the “115V” position for 230 Volt AC line input voltage. Damage will occurto the drive. The 115V position provides 2 times the AC input voltage to the motor.

Catalog No. Input Volts Motor Rated Volts Jumper Position Figure Reference

BMC6A01, BMC6A02, BMC6A04

115VAC 160/320 VAC 230V

Figure 20,on page 22

115V

230VAC 160/320 VAC 230V

BMC6A05115VAC 160/320 VAC

230VFigures 21 and 22,

on page 22115V

230VAC 160/320 VAC 230V

TABLE 9 – J1 SETTINGS FOR AC INPUT VOLTAGE AND MOTOR VOLTAGE CHOICES

5k Wiper

+5VI -5VI

High

Low

COMREVFWDCOM

Reverse

SIG

TB2

FIGURE 19REVERSE RUN SWITCH CONNECTION

(Shown with Main Speed Potentiometer)

5k Wiper

+5VI -5VI

High

Low

COMREVFWDCOM

Forward

SIG

TB2

FIGURE 18FORWARD RUN SWITCH CONNECTION(Shown with Main Speed Potentiometer)


22

6.2 Decel Extend Enable/Disable Selection (J2): J2 is located on the drive’s lower PCboard. See Figures 1 and 2, on pages 9 and 10. Factory setting is the “X1” position toallow the Decel Extend Feature, prevents the drive from tripping on Overvoltage Faultswhen stopping with high inertial loads. To disable the Decel Extend Feature (to allow 4QBraking Mode), set J2 to the “X2” position. See Figure 23. 4Q Braking mode settings aredescribed in Section 6.5.2, on pages 24 and 25.

230 Volt AC Line Inputfor 230 Volt AC Output to a 320 Volt Motor

OR115 Volt AC Line Input

for115 Volt AC Output to a 160 Volt Motor(Factory Setting)

(J1 Installed in “230V” Position)

115 Volt AC Line Inputfor 230 Volt AC Output to a 320 Volt Motor

(J1 Installed in “115V” Position)

230V 115V

J1 J1

230V 115V

FIGURE 20 – CATALOG NOS. BMC6A01, BMC6A02, BMC6A04 AC LINE INPUT VOLTAGE SELECTION

230 Volt AC Line Input / 320 Volt MotorOR

115 Volt AC Line Input / 160 Volt Motor(J1 Installed in “230VAC” Position)

115 Volt AC Line Input / 320 Volt Motor(J1 Installed in “115VAC” Position)

install it onto the "115VAC" terminal.remove this terminal and

For 115 Volt AC Line Input,terminal.

"115VAC"

Do not removethis terminal.

115VAC

J1

230VAC

J1115VAC115VAC

230VAC

FIGURE 21 – CATALOG NO. BMC6A05 AC LINE INPUT VOLTAGE SELECTION

TerminalInstalled

TerminalRemoved

FIGURE 22 – REMOVING J1FOR CATALOG NO. BMC6A05

Decel Extend Enabled(Factory Setting)

Decel Extend Disabled(4Q Braking Mode)

X2X1

J2

X2X1

J2

FIGURE 23 – DECEL EXTENDENABLE/DISABLE SELECTION

23

6.3 Hall Sensor Phasing Selection (J2): JumperJ2 is located on the Hall Isolator Board. SeeFigure 3, on page 11. Jumper J2 is factory setto the “120” position for 120 degree Hall Sensorphasing. This is Baldor’s standard so it is notnecessary to move this jumper. For 60 degreeHall Sensor phasing, set Jumper J2 to the “60”position. See Figure 24.

6.4 Motor Poles Selection (J1, J4): Jumpers J1and J4 are located on the Hall Isolator Board.See Figure 3, on page 11. J1 and J4 must bothbe set for the appropriate number of motorpoles. See Table 10, for the motor pole count.

J1 is factory set to the “4P” position and J4 isfactory set to the “X1” position to operate4-pole motors. See Figure 25. For 6-pole motors, set J1 to the “6P” position and J4 to the“X1” position. For 8-pole motors, set J1 to the “4P” position and J4 to the “X2” position.

6.5 Braking Mode Selection (J3, J6, and J7): The drive isfactory set to coast-to-stop (non-braking) during decelera-tion or when a STOP command is given. For braking to astop when a STOP command is given, use the 2Q BrakingMode. For braking while following the deceleration setting,use the 4Q Braking Mode. J3, J6, J7 are located on theHall Isolator Board. See Figure 3, on page 11. J3 (CAL) isfactory set to the “OFF” position. J6 (BRAKE) is factory setto the “OFF” position. J7 (MODE) is factory set to the “2Q”position. See Figure 26.

1. 2Q Braking Mode: Set J6 to “ON” and J7 is set to the“2Q” for braking to a stop when a STOP command is given. The % BRAKE trimpot isused to adjust the desired amount of braking. See Figure 27, on page 24.

WARNING: The motor shaft may rotate during this procedure. Be certain thatunexpected motor shaft movement will not cause injury to personnel or dam-age to equipment.

Procedure to adjust for the desired braking in the 2Q Braking Mode:

a. Verify that the AC power is disconnected from the drive.

b. Connect a current meter in one of the motor wires.

120 Degree HallSensor Phasing(Baldor Standard)(Factory Setting)

60 Degree HallSensor Phasing

60

J2

120

60

J2

120

FIGURE 24 – HALL SENSORPHASING SELECTION

Motor Catalog No. Motor Poles

BSM 24 / 25 / 50 / 63 / 80 4

BSM 33 / F-Series 8

TABLE 10 – MOTOR POLE COUNT

4-Pole Motor Operation(Factory Setting) 6-Pole Motor Operation 8-Pole Motor Operation

4P

J1

X1

J4

6P X2

4P

J1

X1

J4

6P X2

4P

J1X1

J4

6P X2

FIGURE 25 – MOTOR POLES SELECTION

J3

ONOF

F

OFF

CAL

J6

ON

BRAKE

CAL

2Q

J7

4Q

MODE

FIGURE 26 – COAST-TO-STOP(NON-BRAKING)

DURING DECELERATION(Factory Setting)

24

2. 4Q Braking Mode: J2 on the drive’s lower PC board, must be set to “X2” position todisable the Decel Extend feature. See Figure 23, on page 22. The % Brake trimpot isnot operational in the 4Q Braking Mode. Do not operate the drive until completing thiscalibration procedure. For 4Q Braking Mode, the drive must be calibrated as follows:

Warning: The motor shaft may rotate during this procedure. Be certain thatunexpected motor shaft movement will not cause injury to personnel ordamage to equipment.

Note: Jumper J6 (BRAKE) is not functional in 4Q Mode because 4Q Mode hasregenerative braking.

4Q Braking Mode Calibration Procedure

a. Verify that AC power is disconnected from the drive.

b. Remove any load connected to the motor shaft.

c. Set J3 (CAL) to the “ON” position. Set J7 (MODE) to the “4Q” position.See Figure 28, on page 25.

d. Apply power and close terminals “FWD” and “COM”. The motor speed willincrease to maximum speed in approximately 20 seconds. Observe the red CALstatus LED (located on the Hall Isolator Board), is on steady.

Also observe the Status LED on the Main Board during the CAL procedure.

• Quick flash yellow while calibrating.

• Quick flash green when calibration has been completed successfully.

• Quick flash red if calibration fails.

J3

ONOF

F

OFF

CAL

J6

ON

BRAKE

CAL

2Q

J7

4Q

MODE

% BRAKE

FIGURE 27 – ADJUSTABLE BRAKING DURING DECELERATION (2Q BRAKING MODE)

c. Set the % BRAKE trimpot fully counterclockwise.

d. Apply AC line input voltage to the drive.

e. Run the drive to the maximum application speed.

f. Apply the STOP command, and monitor the peak current to the motor duringdeceleration.

g. For faster deceleration, adjust the % BRAKE trimpot clockwise and repeatsteps e through g. Increasing the % BRAKE trimpot setting until the requireddeceleration is achieved. The current must not exceed 200% of the drive rating.

h. If the required deceleration is not achieved or the drive trips on OvervoltageFaults, install the optional Dynamic Brake Module (DBM) (Catalog No. ID5RGA-1)to dissipate motor energy for braking with rapid, controlled deceleration (4QBraking Mode). The DBM is rated for up to 25% continuous braking torque and200% instantaneous braking torque (maximum 1 hp (0.75 kW)).

i. Disconnect the AC power from the drive.

25

Note: Jumper J6 (BRAKE) is not functional in 4Q Mode because 4Q Modehas regenerative braking.

6.6 SIGNAL INPUT TYPE (J5): Jumper J5 is located on the Hall Isolator Board. See Figure3, on page 11.

Jumper J5 is factory set to the “AN” position for analog signal inputs. For PWM signalinputs, contact your local Baldor District Office.

7 TRIMPOT ADJUSTMENTSSee Section 4, on page 14, for instructions on removing and installing the finger-safe cover.

The drive contains trimpots, which are factory set for most applications. See Figures 3 and 4,on page 11, for the location of the trimpots and their approximate factory calibrated positions.Some applications may require readjustment of the trimpots in order to tailor the drive for aspecific requirement. The trimpot adjustment procedures are as follows:



1. If the calibration fails, check the Hall Sensor connections and open Terminals“FWD” and “COM”. Set he ACC and DEC/B Trimpots fully clockwise. Repeatstep 2d, above, with different settings of the CL Trimpot to increase the likeli-hood that the calibration passes.

2. If the drive will also be operated in the reverse direction, this calibration must alsobe performed in the reverse direction (by closing terminals “REV” and “COM”).

e. Disconnect the AC power from the drive.

f. Set J3 (CAL) to the “OFF” position, see Figure 29. 4Q brake mode calibrationis complete.

g. If the required deceleration is not achieved or the drive trips on OvervoltageFaults, install the optional Dynamic Brake Module (DBM) (Catalog No. ID5RGA-1)to dissipate motor energy for braking with rapid, controlled deceleration (4QBraking Mode). The DBM is rated for up to 25% continuous braking torque and200% instantaneous braking torque (maximum 1 HP (0.75 kW)).

J3

ONOF

F

OFF

CAL

J6

ON

BRAKE

CAL

2Q

J7

4Q

MODE

FIGURE 28CALIBRATION IN THE4Q BRAKING MODE

J3

ONOF

F

OFF

CAL

J6ON

BRAKE

CAL

2Q

J7

4Q

MODE

FIGURE 29 – DYNAMIC BRAKINGDURING DECELERATION(4Q BRAKING MODE)

26

WARNING! If adjustments are made with the main power applied, an insulat-ed adjustment tool (provided) must be used and safety glasses (not provided)

must be worn. High voltage is present in this drive

7.1 MAXIMUM SPEED (MAX): Sets the maxi-mum speed of the motor. Range: 1000 -7000 RPM. The MAX trimpot is located onthe drive’s lower PC board. The motor datasheet or nameplate should indicate the ratedspeed at the application bus voltage. TheMAX trimpot is factory set to 4000 RPM.

To change the setting of the MAX trimpot,set it to the approximate motor nameplateRPM rating shown in Figure 30 and fine tune the adjustment using the MAX and SCALEtrimpot Calibration Procedure to eliminate any deadband on the Main SpeedPotentiometer when setting it for maximum speed output.

MAX and SCALE Trimpot Calibration Procedure:

1. Set the MAX trimpot on the drive’s main board for the closest motor nameplate RPMrating shown in Figure 30.

2. Set the Forward-Stop-Reverse Switch to the “FWD” or “REV” position.

3. Apply the desired maximum speed reference signal input voltage to the Hall IsolatorBoard or set the Main Speed Potentiometer fully clockwise.

4. Apply AC line input voltage to the drive.

5. Slowly rotate the SCALE trimpot, in the appropriate direction until the desired motorspeed is reached.

6. The MAX and SCALE trimpots are now calibrated.

7.2 Input Offset (Offset): Sets the input voltage offset. Range: ±20% of Signal Input.The multi-turn OFFSET trimpot located on the Hall Isolator Board is factory set for 0 Voltinput to produce zero speed output.

Adjust the OFFSET trimpot clockwise, if necessary for zero speed with a 0VDC input.

4750 RPM3250 RPM

1000 RPM

2500 RPM1750 RPM

MAX

5500 RPM6250 RPM7000 RPM

4000 RPM

FIGURE 30MAXIMUM SPEED TRIMPOT SETTING

with MAX and SCALE Trimpots Calibrated with MAX and SCALE Trimpots Not Calibrated

100%

Deadband

Effective areaof adjustment.

0%

area.

30%

10%

0%

20%

40%

70%

90%

100%

80%

60%50%

FIGURE 31 – MAIN SPEED POTENTIOMETER RANGE

27

7.3 Acceleration (ACC): Sets the time for the motor toaccelerate from zero speed to full speed. Range: 0.1 - 30Seconds. The ACC trimpot located on the drive’s lowerPC board is factory set to 1.5 seconds.

For longer acceleration time, rotate the ACC trimpotclockwise. For more rapid acceleration, rotate the ACCtrimpot counterclockwise. See Figure 32.

Note: Rapid acceleration settings may cause the currentlimit circuit to activate, which will extend the acceleration time.

7.4 Deceleration (DEC/B): Sets the time for the motor todecelerate from full speed to zero speed. Range: 0.1 – 30Seconds. The DEC/B trimpot located on the drive’s lowerPC board is factory set to 1.5 seconds.

For longer deceleration time, rotate the DEC/B trimpotclockwise. For more rapid deceleration, rotate the DEC/Btrimpot counterclockwise. See Figure 33.

Note: For high inertial loads, the decelerationmay automatically increase in time. This will slow down the rate of speed ofdecrease to prevent the bus voltage from risingto the Overvoltage Trip point. This function iscalled Regeneration Protection. It is recom-mended that for very high inertial loads that boththe ACC and DEC/B Trimpots should be set togreater than 10 seconds.

Note: For rapid stopping, install the optional Dynamic Brake Module(Catalog No. ID5RGA-1), as described in Section 6.5.2, on pages 24 and 25.

7.5 RESPONSE (COMP): Sets the response time. Range: 1000 - 200 milliseconds(1 – 5 Hz). The COMP trimpot is located on the drive’s lower PC board is factory set for700 milliseconds (1.4 Hz). See Figure 34.

For faster response, rotate the COMP trimpot clockwise. For slower response, rotate theCOMP trimpot counterclockwise.

7.6 Motor Overload (I2t) With RMS Current Limit (CL)*: The drive provides modified I2toverload protection. Range: 75% – 230%. The CL trimpot sets the current limit (overload)to limit the maximum motor current. This prevents motor burnout and eliminates nui-sance trips. The CL trimpot is factory set to 200% of the drive rating. To increase the cur-rent limit, rotate clockwise.To ensure that the motor is properly protected with the I2t fea-ture, the CL Trimpot must be set for 200% of the motor nameplate rating.

If the motor is overloaded to 125% of full load (63% of the CL setting), the I2t Timerstarts. If the motor continues to be overloaded at the 125% level, the timer will shutdown the drive after 1 minute. If the motor is overloaded to 200% of full load, the drivewill trip in 3 seconds.

*UL approved as an overload protector for motors.

1.5

ACC

0.1 30

7.5

15

23

FIGURE 32ACCELERATION TRIMPOT RANGE

1.5

DEC/B

0.1 30

7.5

15

23

FIGURE 33DECELERATION TRIMPOT RANGE

700 (1.4)800 (1.25)

1000 (1)COMP

200 (5)

600 (1.7)

400 (2.5)

FIGURE 34RESPONSE TRIMPOT RANGE

28

8 DRIVE OPERATIONAfter the drive has been properly setup (jumpers and trimpots set to the desired positions) andconnections completed, the status (ST) LED will indicate drive status, as described in Section9.4, on page 30. See Section 4, on page 14, for instructions on removing and installing thefinger-safe cover.

FIGURE 35CATALOG NO. BMC6A01

CURRENT LIMIT TRIMPOT RANGE(Shown Factory Set to 3.0 Amps)

1.7

1.1CL

3.4

2.3

3.0

Drive Rating: 1.5 Amps



2.8

1.8CL

5.5

3.7

4.8




4.6

3.0CL

9.2

6.1

8.0




6.3

4.1CL

12.6

8.4

11.0




7.6

5.0CL

15.4

10.2

13.4




10.3

6.8CL

20.7

13.8

18.0


Torq

ue (%

)

Speed (%)

020 Rated Speed

100

50

FIGURE 41 – AVAILABLE TORQUE VS. SPEED

29

9 TROUBLESHOOTING

WARNING! High voltage is present in this drive. Disconnect main powerbefore making connections to the drive. To prevent accidental contact with

high voltage, the Finger-Safe Cover must be properly installed after all setup, connec-tions, and adjustments are complete. This cover reduces electrical shock hazard.Failure to observe this warning could result in electrical shock or electrocution.

WARNING! High voltage is present in the drive. If possible, do not adjust trim-pots with the main power applied. If adjustments are made with the main

power applied, an insulated adjustment tool (provided) must be used and safety glassesmust be worn. Fire and/or electrocution can result if caution is not exercised.

9.1 Troubleshooting Guide:Table 11, provides information on symptoms, possible causes, and the suggestedtroubleshooting solutions for the drive. See Section 9.4, on page 30, for detailedinformation on LED status indicators. See Section 4, on page 14, for instructions onremoving and installing the finger-safe cover.

TABLE 11 – TROUBLESHOOTING GUIDE

Symptom Possible Cause Suggested Solution

Line fuse blows orcircuit breaker trips.

The line fuse or circuit breaker installedis the wrong rating.

See Table 6, on page 5, for the correct line fuse or circuitbreaker rating. Check for loose or damaged wiring. Check motorfor shorts or grounds. Motor may be defective.

Motor does not run.

The Main Speed Potentiometer is setto zero speed.

Set the Main Speed Potentiometer for the desired speed.

The Signal input is set to zero. Increase the signal input for the desired speed.

The Main Speed Potentiometer, signalinput, or motor connections are open.

Verify Main Speed Potentiometer, signal input, or motorconnections.

The Start/Stop Switch is set to the“STOP” position.

Set the Start/Stop Switch to the “START” position.

The Forward-Stop-Reverse Switch is setto the “STOP” position.

Set the Forward-Stop-Reverse Switch to the “FORWARD” or“REVERSE” position.

I2t Fault

The motor may be overloaded.

Check the motor current with an AC RMS responding ammeter.

The CL setting may be too low. See Section 7.6, on page 27.

The drive must be manually restarted by one of the followingmethods:

1. Disconnect and reconnect the AC power (the “ST” LED mustchange from quick flashing red to flashing red/yellow).

2. Set the Main Speed Potentiometer to zero(fully counter clockwise).

3. Open and close the Forward-Stop-Reverse Switch (or contact)or Run Switch (or contact). See Sections 5.9 and 5.10, onpages 19 and 20.

The Acceleration setting may be too fast.Reduce the ACCEL trimpot setting, as described in Section 7.3,on page 27.

Short Circuit Fault

The motor may be shorted. Verify motor.

The Hall Sensor may be incorrectly con-nected to the Hall Isolator Board.

Verify Hall Sensor Connections, as described in Section 5.4, onpage 17.

The Hall Sensor Phasing setting may beincorrect.

Verify proper Hall Sensor Phasing setting, as described in Section6.3, on page 22.

30

9.3 Starting The Drive After An I2t Fault Has Been Cleared: The drive can be restartedafter an I2t Fault has cleared by any of the following methods.

Note: If an I2t Fault occurs, the motor may be overloaded. Check the motor current withan AC RMS responding ammeter. Also, the CL setting may be set too low. See Section7.6, on page 27.

1. Disconnect the AC power. Wait 15 seconds. Reconnect the AC power. The “ST” LEDmust change from quick flashing red to quick flashing red/yellow.

2. Set the Main Speed Potentiometer to zero (fully counterclockwise).

3. Open and close either the Forward-Stop-Reverse Switch (or contact) or Run Switch(or contact). See Sections 5.9 and 5.10, on pages 19 and 20.

9.4 Diagnostic LEDs: The drive and Hall Isolator Board contain two diagnostic LEDs each todisplay operational status. See Figures 1 and 2, on pages 9 and 10, for the location ofthe “PWR” and “ST” LEDs on the drive. See Figure 3, on page 11, for the location of the“IPWR” and “CAL” LEDs on the Hall Isolator Board.

Power On: The “PWR” LED on the drive and the “IPWR” LED on the Hall Isolator Boardwill illuminate green when the AC line is applied to the drive.

Drive Status: The “ST” LED on the drive is a tricolor LED which provides indication ofa fault or abnormal condition. The information provided can be used to diagnose aninstallation problem such as incorrect input voltage, overload condition, and drive outputmiswiring. It also provides a signal which informs the user that all drive and microcon-troller operating parameters are normal. Table 13, on page 31, summarizes the “ST”LED functions.

*The fault must be cleared before the drive can be reset.

Fault Automatic Start Mode (Factory Setting)

UndervoltageDrive will automatically start after the bus voltage returns to the operational level or when the drive isfirst turned on (power up).

Overvoltage Drive will automatically start after the bus voltage returns to the operational level.

Short Circuit Drive will automatically start after the short circuit is removed.

I2t Drive must be manually restarted.

TABLE 12 – FAULT RECOVERY AND RESETTING THE DRIVE*

9.2 Fault Recovery: The drive monitors four faults (Undervoltage, Overvoltage, Short Circuitat the motor (phase-to-phase), and Overload). Table 12, describes how the drive willautomatically start (factory setting) after the fault has cleared.

Note: In Manual Start Mode, the drive must be manually reset for any fault. Use theManual Start Switch, as described in Section 5.8, on page 19. Also see Section 9.4.

31

9.5 Calibration Status LED: The Hall lsolator Board contains a “CAL” LED which indicatesthe calibration process is active while the drive is set for calibration in the 4Q BrakingMode, as described in Section 6.5.2, on pages 24 and 25.

Flash Sequence: Quick flash yellow while calibrating. Quick flash green when the calibration has been successfully completed. Quick flash red if calibration fails.

Notes: 1. Slow Flash = 1 second on and 1 second off. Quick Flash = 0.25 second on and 0.25 second off.

2. In Manual Start Mode, when the Overload is removed before the I2t times out and trips the drive, the “ST” LED will flash green.

3. In the Manual Start Mode: When the Undervoltage condition is corrected, the “ST” LED will quick flash red/yellow and then green.

When the Overvoltage condition is corrected, the “ST” LED will slow flash red/yellow and then green.

Drive Operating Condition Flash Rate1 and LED Color

Normal Operation (Run) Slow Flash Green

Overload (125% – 200% Full Load) Steady Red2

I2t (Drive Timed Out) Quick Flash Red

Short Circuit (At the Motor (Phase-to-Phase)) Slow Flash: Red

Undervoltage (AC Line Input) Quick Flash Red/Yellow3

Overvoltage (AC Line Input) Slow Flash Red/Yellow3

Stop Steady Yellow

TABLE 13 – DRIVE OPERATING CONDITION AND STATUS LED INDICATOR

32

Wiring Diagram

Documents

Brushless DC Drive - Servo Systemsservosystems.com/pdf/baldor/dcadjustablespeed_install_manual.pdf · Contact your local Baldor District Office for Declaration of Conformity. Feature