Baldor SIMG Instruction Manual Installation Directions

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Accessory for BC204 Regenerative Drive

Installation and Operating Manual

MOTORS AND DRIVES

SIGNAL ISOLATOR

4/2000 MN1387

TABLE OF CONTENTS

Section Page

i. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

II. Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

III. Connections to the BC215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

IV. Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

V. Installing the BC215 Finger-Safe Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

VI. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Tables

1. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2. Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. Resistor for Signal Following from Armature Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Figures

1. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2A. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2B. Mechanical Specifications (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. BC204/BC215 Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. Removing the BC204 Finger-Safe Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. Removing Terminal Block TB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6. Removing the BC204 Finger-Safe Cover Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7. Removing the BC204 Finger-Safe Cover Field Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9. Installing Field Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

10. Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

11. Main Speed Potentiometer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

12. Signal Following from Armature Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

13. Enable Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

14. Removing The BC215 Finger Safe Cover Field Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

ii

1

i. SAFETY WARNING! Please read carefully:

Be sure to follow all instructions carefully. Fire and/or electrocution can result due to

improper use of this product.

This product should be installed and serviced by a qualified technician, electrician, or

electrical maintenance person familiar with its operation and the hazard involved. Proper

installation, which includes wiring, mounting in proper enclosure, fusing or other over cur-

rent protection and grounding, can reduce the chance of electric shocks, fires, or explo-

sion in this product or products used with this product, such as electric motors, switches,

coils, solenoids, and relays. Eye protection must be worn and insulated adjustment tools

must be used when working with control under power. This product is constructed of

materials (plastics, metals, carbon, silicon, etc.) Which may be a potential hazard.

Proper shielding, grounding, and filtering of this product can reduce the emission of radio

frequency interference (RFI) which may adversely affect sensitive electronic equipment.

If information is required on this product, contact our factory. It is the responsibility of the

equipment manufacturer and individual installer to supply this safety warning to the ulti-

mate 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.

!

This product complies with all CE directives pertinent at the time of manufacture.

Contact factory for detailed installation instructions and Declaration of Conformity.

I. INTRODUCTION

Thank you for purchasing the BC215 Bipolar Signal Isolator. Baldor is com-

mitted to providing total customer satisfaction by producing quality products

that are easy to install and operate. The BC215 is manufactured with sur-

face mount components incorporating advanced circuitry and technology.

The BC215 provides input isolation and is used to isolate, amplify, and con-

dition DC voltage signals from any external source (power supplies, motors,

tachometer generators, transducers, and potentiometers). The isolated out-

put voltage of the BC215 provides input signals to the BC204 Regenerative

Drive. In also provides isolation for motor direction switching and an isolat-

ed power supply for transducer or potentiometer operation. The PWR LED

provides indication that power is applied.

All input connections (+15, -15, SIG, COM, and EN) are made via a barrier

terminal block and are isolated from AC line and motor wiring.

The BC215 is factory calibrated to accept a signal input voltage of -10V to

+10V DC. OFFSET and MAX trimpots are provided in order to recalibrate the

BC215 for specific applications.

2

FIGURE 1 – CONTROL LAYOUT

(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)

3

TACH

CON3

T1(-)

T2(+)

PWR TB1

L1

COM ENSIG

-15V+15V

L2

J1

ENABLE

A90

T7

A180

T50

F-

CON2

F+

1.7A

F-

OFFSET

2.5

5.0

7.5

10A

MAX

F+

F+

F-

M2

RACCMAXFCLIR RCL FACC

M1

DB RESP

FIGURE 2A – MECHANICAL SPECIFICATIONS (INCHES / mm)

(Shown Mounted onto BC204)

4

0.95

[24.21]

FIGURE 2B – MECHANICAL SPECIFICATIONS (INCHES / mm)

(Shown Mounted onto BC204)

5

L1 L2

M2

RACCMAXFCLIR RCL FACC

M1

DB RESP

2.67

[67.92]

0.48

[12.32]

3.80

[96.52]

4.68

[118.99]

0.19

[

4.83

]

TYP

3.80

[96.65]

2.50

[63.50]

0.75

[19.05]

TABLE 1 – GENERAL PERFORMANCE SPECIFICATIONS

II. INSTALLATION INSTRUCTIONS: Mounting the BC215 onto the BC204

See figure 3 on page 7. Note: This figure is also supplied as a separate drawing.

Warning! Make sure all power is disconnected from the BC204 before

proceeding.

A. Removing the BC204 Finger-Safe Cover

If a finger-safe cover is not installed on the BC204, proceed to section IIC (Modifying

the BC204 Finger-Safe cover). If a finger-safe cover is installed on the BC204,

remove the two (2) socket head 5-40 X 5/16” screws located at the rear of the BC204

using the supplied 3/32” hex key. Also, remove the two (2) 6-32 X 1-3/4” screws

located on either side of terminal block TB1. See figure 4 on page 8.

6

—

±5 to ±25

MAX Trimpot Range (with 10V DC Input) (% Speed)

Parameter Specification Factory Setting

Voltage Following Input Range (V DC) -10 to +10

Potentiometer Operation (kΩ) 5 —

OFFSET Trimpot Range (with 0V DC Input) (% Speed) ± 50 0

+15V DC and -15V DC Power Supply Max. Current Rating (mA DC)

0 – 110 100

25 —

Forward, Reverse, and Enable Input Switch Types Dry Contact or

Open Collector

Input/Output Linearity (%) 0.1 —

Thermal Drift (mV/ ºC) 0.4 —

Ambient Operating Temperature Range (ºC) 0 – 50

—

!

B. Removing Terminal Block

TB1 from the BC204

Remove terminal block TB1 from

the BC204 by rocking it back and

forth or using a screwdriver to gen-

tly pry it off. See figure 5 on page

9. The removed terminal block

TB1 will not be used and may be

discarded.

C. Modifying the BC204 Finger-

Safe Cover

Once the BC204 finger-safe cover

is removed, it has to be modified to

accommodate the BC215. Cut out

the finger-safe cover panel

at seven (7) places as

shown in figure 6 on page

9. (Note: Some finger-

safe covers may already

have the panel removed.)

To access the field termi-

nals (F+ and F- on the

BC204) cut out the field

tab of the BC204 finger-

safe cover at three (3)

places as shown in figure

7 on page 9.

7

FIGURE 3 – BC204/BC215 ASSEMBLY DIAGRAM

Snap on cover

(4 places)

BC215

Finger-Safe Cover

6-32 x 1-3/4" Screws

(2 places)

5-40 x 5/16"

Screws

(2 places)

Cable

Assembly

Note:

Yellow to F+

Brown to F-

BC215

BC204

Finger-Safe Cover

BC204

D. Installing the BC204 Finger-

Safe Cover

Once the BC204 finger-safe

cover has been modified, it

can be installed onto the

BC204. Initially, use only the

two (2) 5-40 X 5/16” socket

head screws, using the sup-

plied 3/32” hex key. Do not

over tighten these screws or

damage may result to the

BC204 finger-safe cover.

Note: All jumpers on the

BC204 must be set to their

appropriate positions

before installing the

BC204 finger-safe cover.

E. Installing the BC215 onto

the BC204

The terminal block located

on the bottom of the BC215

plugs onto the six (6) header

pins where TB1 was

removed from the BC204.

The two holes on the back of

the BC215 snap onto the fin-

ger-safe cover.

8

BC204

Finger-Safe

Cover

BC204

5-40 x 5/16"

Screws

6-32 x 1-3/4"

Screws

FIGURE 4 – REMOVING THE BC204

FINGER-SAFE COVER

Use the two (2) 6-32 X 1-3/4”

screws previously removed to

secure the BC215 to the BC204.

Do not over tighten these screws or

damage may result to the BC215

and BC204. See figure 3 on page 7.

9

BC204

Terminal Block

TB1

FIGURE 5 –

REMOVING

TERMINAL

BLOCK TB1

BC204 Finger-Safe Cover

Remove Panel (cut 7 places) to Install BC215.

FIGURE 6 – REMOVING THE BC204

FINGER-SAFE COVER PANEL

BC204 Finger-Safe Cover

Remove Tab (cut 3 places) to Access Field Terminals.

FIGURE 7 – REMOVING THE BC204

FINGER-SAFE FIELD TAB

FIGURE 8 – CONNECTION DIAGRAM

10

-

+

+

-

DC TACHOMETER

GENERATOR

-+

G

TACH

CON3

T1(-)

T2(+)

A90

T7

A180

T50

PWR TB1

J1

ENABLE

+15V -15V SIG COM EN

CON2

OFFSET

MAX

F+ F-

F+

F-

AC

LINE

L2

L1

GROUND

DB RESP

M1

ARMATURE

7.5

5.0

1.7A

2.5

RCL FCL MAX FACC

M2 F- F+

RACC

A

FIELD

(SHUNT MOTORS ONLY)

10A

IR

F. Wiring the BC215 to the BC204

See figure 8 on page 10.

The BC215 is powered from the BC204 with a connector that is installed from the

BC215 CON2 to the BC204 F+ and F- terminals. The yellow wire connects to the

BC204 F+ terminal and the brown wire connects to the BC204 F- terminal. When

the field connector is properly installed the wires should cross over each other. See

figure 9. If the connector is wired incorrectly, the BC215 PWR LED will not illuminate

and the control will not operate. Note: It is recommended that these wires be twist-

ed at least three (3) times to help reduce noise.

11

FIGURE 9 – INSTALLING

FIELD CONNECTOR

III. Connections to the BC215

Safety Warning! Do not use FWD-STOP-REV contacts as a safety discon-

nect since they are not fail-safe. Use only the AC line for this purpose.

Note: BC215 Enable jumper J1 must be installed, or a connection must be made

between EN and COM terminals of BC215 TB1 in order for the BC204 to operate.

A. Voltage Following – Uses a

voltage source to vary motor

speed. See figure 10. Connect

the voltage source to TB1 ter-

minals SIG and COM. When a

0V DC signal is applied, the

control will operate at the mini-

mum set speed (set by the

OFFSET trimpot on the

BC215). When a 10V DC sig-

nal is applied, the motor will

operate at the maximum set

speed (set by the MAX trimpot on the BC215).

Applying a positive (+) signal to SIG terminal, with respect to COM terminal, will oper-

ate the motor in the forward direction.

12

!

3.5

Connection Designation

Supply Wire Gauge (AWG – Cu) Maximum Tightening Torque

(in-lbs)

MaximumMinimum

Logic Connections 24 14

TABLE 2 – TERMINAL BLOCK (TB1) WIRING INFORMATION

(BC204 Jumper J4 in 10V Position)

(BC215 Enable Jumper J1 Installed)

± 10VDC

EN COM SIG -15 +15

J1

TB1

VDC

FIGURE 10 – VOLTAGE FOLLOWING

CONNECTION

Applying a negative (-) signal to SIG terminal, with respect to COM terminal, will

operate the motor in the reverse direction.

13

Unidirectional With Reversing Contact Bidirectional Potentiometer

J1

TB1

5K

REV

REV FWD

FWD

STOP

EN COM SIG -15 +15 EN COM SIG -15 +15

EN COM SIG -15 +15 EN COM SIG -15 +15

J1

TB1

J1

TB1

Forward Reverse

5K

5K

J1

TB1

5K

A. B.

D. C.

FIGURE 11 – MAIN SPEED POTENTIOMETER CONNECTIONS

(BC204 Jumper J4 in 15V Position, BC215 Enable Jumper J1 Installed)

B. Signal Following from

Armature Voltage – Uses

motor armature voltage as a

signal input. If the signal input

voltage applied to the BC215

is derived from a motor arma-

ture voltage output, it is neces-

sary to install a 1/4W resistor

in series with the signal lead

into the BC215. For a 90V DC

motor, install a 150K resistor.

for a 180V DC motor, install a

330K resistor.

C. Unidirectional Potentiometer

Operation (Forward) – Uses a

potentiometer to vary motor speed.

See figure 11A on page 13.

Connect the 5K potentiometer to

TB1 terminals marked “SIG” (wiper

of potentiometer), “+15V” (high side

of potentiometer), and “COM” (low

side of potentiometer). Use the

potentiometer to vary motor speed.

If the motor is not running in the

desired direction, either reconnect

the high side of the potentiometer to TB1 terminal marked “-15V” or reverse the

motor leads.

14

330K

Armature Voltage

Range (VDC) 1/4W Resistor (Ω)

0 – ± 90 150K

0 – ± 180

EN COM SIG -15 +15

J1

TB1

1/4W Resistor

(See Table 3)

Armature

+

-A

FIGURE 12 – SIGNAL FOLLOWING FROM

ARMATURE VOLTAGE

TABLE 3 – RESISTOR FOR

SIGNAL FOLLOWING FROM

ARMATURE VOLTAGE

D. Unidirectional Potentiometer Operation (Reverse) – Uses a potentiometer to vary

motor speed. See figure 11B on page 13. Connect the 5K potentiometer to TB1 ter-

minals marked “SIG” (wiper of potentiometer), “-15V” (high side of potentiometer),

and “COM” (low side of potentiometer). Use the potentiometer to vary motor speed

and the switching device to select motor direction. If the motor is not running in the

desired direction, either reconnect the high side of the potentiometer to TB1 terminal

marked “+15V” or reverse the motor leads.

E. Bidirectional Potentiometer Operation – Uses a potentiometer to vary motor

speed and direction. See figure 11C on page 13. Connect the 5K potentiometer to

TB1 terminals marked “SIG” (wiper of potentiometer), “+15V” (high side of poten-

tiometer), and “-15V” (low side of potentiometer). Use the potentiometer to vary

motor speed and direction.

When the potentiometer is in the center position, the control output can be set to

zero, using the OFFSET trimpot. Rotating the trimpot clockwise will cause the motor

to rotate in the forward direction. Rotating the potentiometer counterclockwise will

cause the motor to rotate in the reverse direction.

F. Unidirectional Potentiometer with Reversing Contacts – Uses a potentiometer to

vary motor speed. See figure 11D on page 13. Connect the 5K potentiometer to TB1

terminals marked “SIG” (wiper of potentiometer), “+15V” (high side of potentiometer),

and “COM” (low side of potentiometer). Use the potentiometer to vary motor speed

and the switching device to select motor direction. When the potentiometer is set to

0% (fully counterclockwise), the motor will operate at the minimum set speed (set by

the OFFSET trimpot on the BC215). When the potentiometer is set to 100% (fully

clockwise) the motor will operate at full speed (set by the MAX trimpot on the

BC215).

15

G. Enable Switch Connection

Safety Warning! Do

not use Enable or

Start/Stop contacts as a safety

disconnect since they are not

fail-safe. Use only the AC line

for this purpose. See figure 13.

If a Start/Stop function is

required, remove BC215

Enable jumper J1 and wire a

switch to EN and COM termi-

nals of BC215 TB1. When the

switch is opened, the control

will stop. When the switch is

closed, the control will operate.

H. Tachometer Generator Connection

See figure 8 on page 10. To wire a 7V or 50V per 1000RPM tachometer generator

to the BC215, connect the positive (+) side of the tachometer generator to terminal

“T2” and the negative (-) side of the tachometer generator to terminal “T1“ of the

BC215. Note: If the positive (+) and negative (-) tachometer generator connections

are not connected as described above, the motor will run at full speed only.

I. Motor Field Connection

If a shunt wound motor is used, the motor field wires connect to F+ and F- terminals

on the BC215. To access these terminals, cut out the field tab of the BC215 finger-

safe cover at three (3) places as shown in figure 14 on page 17.

16

EN COM SIG -15 +15

Enable

Open to Stop

J1

TB1

FIGURE 13 – ENABLE SWITCH CONNECTION

(BC215 Enable Jumper J1 Removed)

!

17

BC215 Finger-Safe Cover

Cut Out Tab (3 Places) to Access Field Terminals.

(For Shunt Wound Motors Only.)



FIGURE 14 – REMOVING THE BC215 FINGER-SAFE COVER FIELD TAB

IV. CALIBRATION PROCEDURE

(See Safety Warning, on page 1)

The BC215 is factory calibrated, but readjustments to the OFFSET and MAX trimpots

can be made to customize for a particular signal input requirement. It may be neces-

sary to repeat the calibration steps to achieve accurate settings.

A. Unidirectional Voltage Following Calibration

See figure 10 on page 12.

1. Apply 0V DC input signal (or connect SIG and COM terminals).

2. Monitor the BC204 output and adjust the OFFSET trimpot on the BC215 for the

desired minimum setting.

3. Apply the maximum voltage input signal.

4. Monitor the BC204 output voltage and adjust the MAX trimpot on the BC215 for

the desired maximum setting.

B. Unidirectional Potentiometer Operation Calibration:

See figure 11A, B or C on page 13.

1. Set potentiometer to 0% rotation (fully counterclockwise).

2. Monitor the BC204 output and adjust the OFFSET trimpot on the BC215 for the

desired minimum setting.

3. Set potentiometer to 100% rotation (fully clockwise).

4. Monitor the BC204 output voltage and adjust the MAX trimpot on the BC215 for

the desired maximum setting.

18

V. INSTALLING the BC215 FINGER-SAFE COVER

After all adjustments and wiring have been completed on the BC204 and the BC215,

install the BC215 finger-safe cover onto the BC204 finger-safe cover by snapping the

four (4) clips of the BC215 finger-safe cover into the four (4) slots of the BC204 finger-

safe cover.

Note: Ensure that the yellow and brown field wires (from CON2 of the BC215 to F+ and

F- terminals of the BC204) are within the shroud of the BC215 finger-safe cover. See

figure 3 on page 7.

19

– NOTES –

20

– NOTES –

21

(A40208) – Rev. A – 5/2000

VI. LIMITED WARRANTY

For a period of 2 years from date of original purchase, BALDOR will repair or replace without

charge controls which our examination proves to be defective in material or workmanship. This

warranty is valid if the unit has not been tampered with by unauthorized persons, misused,

abused, or improperly installed and has been used in accordance with the instructions and/or

ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or

implied. BALDOR shall not be held responsible for any expense (including installation and

removal), inconvenience, or consequential damage, including injury to any person, caused by

items of our manufacture or sale. (Some states do not allow the exclusion or limitation of inci-

dental or consequential damages, so the above exclusion may not apply.) In any event,

BALDOR’s total liability, under all circumstances, shall not exceed the full purchase price of the

control. Claims for purchase price refunds, repairs, or replacements must be referred to BAL-

DOR with all pertinent data as to the defect, the date purchased, the task performed by the con-

trol, and the problem encountered. No liability is assumed for expendable items such as fuses.

Goods may be returned only with written notification including a BALDOR Return Authorization

Number and any return shipments must be prepaid.

Baldor Electric Company

5711 R. S. Boreham, Jr. Street

Fort Smith, AR 72902-2400 U.S.A

(501) 646-4711 Fax (501) 648-5792

International Fax (501) 648-5895

MOTORS AND DRIVES