Baldor Outboard Motor BSC 7107 DC User Manual

BSC 7107  
DC Brushless Control  
Installation and Operating Manual  
9/97  
MN1231  
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Table of Contents  
Section 1  
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-1  
1-1  
1-2  
1-3  
1-3  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Section 2  
Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-1  
2-1  
2-1  
2-1  
2-1  
2-2  
2-2  
2-4  
2-5  
2-5  
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
AC Power Connection . . . . . . . . . . . . . . . . . . . . . . . . .  
Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . .  
Sensor and Motor Connections . . . . . . . . . . . . . . . . .  
Reverse Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Power Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .  
Section 3  
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-1  
3-1  
3-2  
3-2  
Current Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .  
Minimum Speed Adjustment . . . . . . . . . . . . . . . . . . . . . .  
Adjusting Closed Loop Gain . . . . . . . . . . . . . . . . . . . . . .  
Section 4  
Specifications and Data . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-1  
4-1  
4-1  
4-2  
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Hall Signal Timing Diagram . . . . . . . . . . . . . . . . . . . . . . .  
Table of Contents i  
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ii Table of Contents  
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Section 1  
General Information  
Introduction  
Baldor Series BSC 7107 control is a general purpose brushless DC  
motor control. This control commutates power into standard 3-phase  
brushless (BLDC) motors.  
The control input line voltage is 120 VAC ± 10%. This control provides  
up to 7 amperes of continuous current to the motor. Motors with Hall  
sensor spacings of 60 and 120 degrees can be used.  
The control has two PC boards-an upper and a lower, connected by  
ribbon cable. A 10-position terminal strip on the upper board connects  
the control to the motor sensors, the speedpot, and the forward/reverse  
control switch (optional). The control’s upper board also carries the  
trimpots for minimum speed, maximum speed, and current limit, as well  
as a means for selecting the sensor spacing.  
STANDARD FEATURES  
S
S
S
S
S
S
S
Closed loop control  
Quiet 15KHz PWM switching frequency  
MOSFET power devices  
Forward/Reverse direction control  
5Kspeedpot with leads, knob and dial for remote mounting  
Internal +6.25 VDC for motor hall-effect sensors  
Anodized chassis mount heatsink  
General Information 1-1  
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Limited Warranty  
For a period of one (1) year from the date of original purchase,  
BALDOR will repair or replace without charge controls and  
accessories 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 or property caused by items of our manufacture or  
sale. (Some states do not allow exclusion or limitation of  
incidental or consequential damages, so the above exclusion  
may not apply.) In any event, BALDOR’s total liability,  
under all circumstances, shall not exceed the full purchase  
price of the control. Claims for purchase price refunds,  
repairs, or replacements must be referred to BALDOR with  
all pertinent data as to the defect, the date purchased, the task  
performed by the control, and the problem encountered. No  
liability is assumed for expendable items such as fuses.  
Goods may be returned only with written notification  
including a BALDOR Return Authorization Number and any  
return shipments must be prepaid.  
1-2 General Information  
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Safety Notice  
This equipment contains voltages that may be as great as 1000 volts!  
Electrical shock can cause serious or fatal injury. Only qualified  
personnel should attempt the start-up procedure or troubleshoot this  
equipment.  
This equipment may be connected to other machines that have rotating  
parts or parts that are driven by this equipment. Improper use can  
cause serious or fatal injury. Only qualified personnel should attempt  
the start-up procedure or troubleshoot this equipment.  
PRECAUTIONS  
WARNING: Do not touch any circuit board, power device or  
electrical connection before you first ensure that power has  
been disconnected and there is no high voltage present  
from this equipment or other equipment to which it is  
connected. Electrical shock can cause serious or fatal  
injury. Only qualified personnel should attempt the start-up  
procedure or troubleshoot this equipment.  
WARNING: Be sure that you are completely familiar with the  
safe operation of this equipment. This equipment may be  
connected to other machines that have rotating parts or  
parts that are controlled by this equipment. Improper use  
can cause serious or fatal injury. Only qualified personnel  
should attempt the start-up procedure or troubleshoot this  
equipment.  
General Information 1-3  
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WARNING:  
Be sure the system is properly grounded before  
applying power. Do not apply AC power before you ensure  
that all grounding instructions have been followed.  
Electrical shock can cause serious or fatal injury.  
WARNING:  
Do not remove cover for at least five (5) minutes  
after AC power is disconnected to allow capacitors to  
discharge. Dangerous voltages are present inside the  
equipment. Electrical shock can cause serious or fatal  
injury.  
WARNING:  
Improper operation of control may cause violent  
motion of the motor shaft and driven equipment. Be certain  
that unexpected motor shaft movement will not cause injury  
to personnel or damage to equipment. Peak torque of  
several times the rated motor torque can occur during  
control failure.  
WARNING:  
Motor circuit may have high voltage present  
whenever AC power is applied, even when motor is not  
rotating. Electrical shock can cause serious or fatal injury.  
Caution: To prevent equipment damage, be certain that the  
electrical service is not capable of delivering more than the  
maximum line short circuit current amperes listed in the  
appropriate control manual, 120 VAC maximum per control  
rating.  
Caution: Keep the average continuous DC current draw  
under 7 amperes, and make sure the motor is rotating. A  
stalled brushless DC motor can quickly overheat the control  
and/or the motor resulting in damage to either or both  
devices.  
1-4 General Information  
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Section 2  
Receiving & Installation  
Receiving  
The control is thoroughly tested at the factory and carefully packaged for  
shipment. When you receive your control, there are several things you  
should do immediately.  
1. Observe the condition of the shipping container and report any  
damage immediately to the commercial carrier that delivered your  
control.  
2. Verify that the part number of the control you received is the same  
as the part number listed on your purchase order.  
3. If the control is to be stored for several weeks before use, be sure  
that it is stored in a location that conforms to published storage  
specifications.  
Physical Location  
The location of the control is important. It should be installed in an area  
that is protected from direct sunlight, corrosives, harmful gases or  
liquids, dust, metallic particles, and vibration. Exposure to these  
elements can reduce the operating life and degrade performance of the  
control.  
Installation  
Control Installation  
Refer to the mounting dimensions and hole locations shown in Figure  
2-1. Mount the control to the mounting surface using appropriate  
hardware (not provided).  
Receiving & Installation 2-1  
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Figure 2-1 Mounting Diagram  
9.00  
0.20  
7.50  
2.90  
6.30  
6.70  
7
/32 dia.  
(4 places)  
Top View  
End View  
AC Power Connection Refer to Figure 2-2.  
A fused 120 VAC power source is required. A 12 AMP fuse should be  
used.  
1. Be sure the AC source is disconnected (OFF).  
2. Be sure the appropriate fuse is installed at the source.  
3. Connect the AC power to P1 pins AC and AC.  
+
4. Connect plant earth ground to the chassis connection  
Speed Potentiometer Refer to Figure 2-2.  
1. Rotate the pot fully CCW (Counter clockwise). Measure the  
resistance between the wiper and each terminal.  
2. Connect the terminal with the most resistance (5KW) to Rmax (P4  
pin HI).  
3. Connect the terminal with the least resistance (0KW) to Rmin (P4  
pin LO).  
4. Connect the wiper to Wiper (P4 pin W).  
2-2 Receiving & Installation  
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Figure 2-2 Control Connection Locations  
Scaled motor current test point.  
110mV = 1A Motor Current.  
AC Line  
Rmin  
L
Wiper  
Rmax  
REV  
COM  
COM  
VR  
To Speed Pot.  
W
BLDC  
Motor  
Connection  
s.  
HI  
O
REV  
COM  
COM  
VR  
BLDC  
Sensor  
Connections  
.
S3  
S2  
S1  
S3  
S2  
S1  
GND  
Lower  
Board  
(Connect to  
plant “Earth”  
ground).  
60° / 120° Jumper  
Terminal tightening torque = 4 Lb-in (0.45 Nm)  
120°  
60°  
10K  
10K  
10K  
+
S1 (White)  
(Red)  
S2 (Yellow)  
S3 (Orange)  
Hall  
(Black)  
Receiving & Installation 2-3  
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Sensor and Motor Connections Refer to Figure 2-2.  
Brushless DC motors have eleven (11) wires: three (3) motor phase  
power wires, three (3) hall sensor wires, two (2) wires for hall sensor  
power and sensor common, one (1) wire for motor ground and two (2)  
wires for motor thermal switch.  
Note: Baldor BLDC motors have 120° Hall sensor spacing.  
1. Verify that the 60°/120° jumper is in the 120° position.  
2. Verify that the Speed Potentiometer is set to zero (5KW pot is set  
fully CCW).  
3. Place a 0-10A AC AMP meter in series with the source. This allows  
measurement of AC current during power up testing.  
4. Connect the three motor leads to P1 terminals as follows:  
BSM50A  
Lead Color  
Threaded  
Connector Pin #  
Motor Function  
P1 Terminal  
U
V
W
Φ1  
Φ3  
Φ2  
Red  
Black  
Blue  
1
4
3
5. Connect the motor ground to Earth.  
6. Connect the three hall sensor wires (S1, S2 and S3) to P4 terminals  
S1, S2 and S3 of on the upper board.  
7. Connect the sensor power lead (red) to P4 terminal strip pin VR on  
the upper board.  
8. Connect the sensor power common lead (black) to P4 terminal strip  
pin COM on the upper board.  
Note: The motor has an internal thermal switch (155°C ±5°C normally  
closed contact). The BSC7107 does not use this contact so no  
connection to the thermal switch leads is required.  
2-4 Receiving & Installation  
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Reverse Operation  
Terminal P4–REV is the forward/reverse control. You can reverse  
motor direction by connecting P4–REV to P4–COM. Use a jumper wire,  
switch, relay, or an open collector NPN transistor.  
Caution: Before reversing directions, make sure the motor is  
stopped. This control is not designed for plug reversing.  
Sometimes it may be necessary to reverse motor direction without using  
terminal P4–REV. This is done by stopping the motor and exchanging  
terminals P1–Φ1 with P1–Φ2 on the lower board, and terminals P4–S1  
with P4–S3 on the upper board.  
Receiving & Installation 2-5  
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1st Time Power Up Procedure (or after a motor is replaced)  
Caution: If full AC Voltage is applied and the motor  
connections are wrong, the control will be damaged. Apply  
10% of the input voltage to test motor lead connections at  
the first time power up or after a motor is replaced.  
It is strongly recommended that a Variac (AC Rheostat) be used for the  
first time power up procedure. If full AC power is applied to the control  
and the motor leads are incorrectly connected (wrong phase) the control  
will be damaged.  
1. Using a Variac (AC Rheostat) apply 10% of the rated AC input  
voltage to the control.  
2. Slowly turn the speedpot CW. Watch for erratic rotation or  
excessive source current. If either occurs, immediately return the  
speedpot fully CCW, and turn off the power.  
3. Try another phase combination of P1 Φ1, Φ2 and Φ3.  
There are six (6) combinations for connecting the three phase  
motor leads to P1 Φ1, Φ2 and Φ3.  
4. Apply power and test again. One combination will work. The correct  
combination will allow smooth rotation of the motor, and the lowest  
current draw from the AC source.  
5. Remove AC power.  
6. Remove the Variac.  
7. Connect normal AC input voltage at P1–AC and AC terminals.  
8. Apply power and check for proper motor operation.  
2-6 Receiving & Installation  
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Section 3  
Adjustments  
Current Limit Adjustment  
The current limit adjustment is factory set at 10 AMPS and you should  
not have to increase this setting for the Series BSC 7107 control.  
Rotating the I Limit potentiometer on the upper board CCW decreases  
the current limit.  
To calculate motor current, refer to Figure 2-2 and measure the voltage  
(VTP) at the “Scaled motor current test point”. The voltage should be  
770mV for a 7 AMP motor.  
VTP  
110mvńA  
770mv  
110mvńa  
+ MotorCurrent +  
+ 7A  
The correct setting of the I Limit potentiometer is 125% of the FLA rating  
of the motor.  
1. Preset the I Limit pot fully CW for maximum FLA.  
2. Apply power and run the motor at full or normal running speed.  
3. Load the motor to 125% of its FLA rating (or the desired maximum  
load).  
4. Rotate the I Limit pot CCW (clockwise) slowly until the measured  
motor current begins to decrease.  
5. Slowly rotate the I Limit pot CW to just obtain the 125% FLA  
measurement.  
Note: Do not use the Current Limit trimpot as a torque control or to  
reduce the speed of a motor.  
Caution: Keep the average continuous DC current draw  
under 7 amperes, and make sure the motor is rotating. A  
stalled brushless DC motor can quickly overheat the control  
and/or the motor resulting in damage to either or both  
devices.  
Adjustments 3-1  
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Minimum Speed Adjustment  
1. Set the Speed Pot to zero speed (fully CCW).  
2. Set the MIN pot on the upper board (Figure 2-2) fully CCW.  
3. Apply power to the control.  
4. Slowly rotate the MIN CW until the motor begins to rotate. Then  
turn the pot CCW until the motor just stops. The control will now  
run with a near–zero deadband.  
5. If a non–zero minimum speed is desired, rotate the MIN pot CW to  
the desired minimum speed setting.  
Adjusting Closed Loop Gain  
1. Set the MAX pot on the upper board (Figure 2-2) to the  
approximate position shown in the figure.  
2. Set the Speed Pot to maximum speed (fully CW).  
3. Set the “Closed Loop Gain” pot (Figure 2-2) to its’ fully  
CCW position.  
4. Apply power to the control. The motor should operate at full speed.  
If not, adjust the MAX pot setting until full motor speed is obtained.  
5. Adjust the “Closed Loop Gain” pot CW until the motor speed  
decreases slightly.  
Note: If the “Closed Loop Gain” pot is fully CW and the motor speed  
does not decrease, rotate the MAX pot CCW just enough to  
make the motor speed decrease slightly. Then adjust the  
“Closed Loop Gain” pot CCW just enough so the motor runs at  
full speed.  
3-2 Adjustments  
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Section 4  
Specifications and Data  
Specifications  
Input Voltage . . . . . . . . . . . . . . . . . . . . . 120 VAC±10%  
Output Voltage (Filtered Output) . . . . . 0 to 140 VDC  
Load Current (Continuous) . . . . . . . . . . . . . 7 Amperes  
Overload Current . . . . . . . . . . . . . 150% for 30 seconds  
Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50:1  
Max Speed Trimpot . . . . . . 70 to 100% of Input VAC  
Min Speed Trimpot . . . . Adjustable 0–30% OF MAX.  
Current Limit Trimpot . . . . . . . . . . . . . . . . . . Adjustable  
Acceleration . . . . . . . . . . . . . . . . . . . . Fixed, Fast Start  
Motor Hall Spacing (Electrical) Selectable 60° or 120°  
Closed Loop Speed Regulation ± 1/2% Of Base Speed  
Speed Control . . . . . . . . . . . . . . . . . . . . . 5KPot or  
0 - 6.2 VDC Isolated Signal  
Operating Temperature . . . . . 32° - 113°F ( 0° - 45°C )  
Dimensions  
Width . . . . . . . . . . . . . . . . . . . . . . . . . 6.75 in. (172 mm)  
Length . . . . . . . . . . . . . . . . . . . . . . . . 9.00 in. (228 mm)  
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . 2.90 in. (74 mm)  
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . 41 oz. (1.17 Kg)  
Specifications 4-1  
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Hall Signal Timing Diagram  
Brushless D.C. Commutation  
15 30 45 60 75 90 105 120 135 150 165 180 Ć 8 Pole Mechanical Degrees  
30 60 60 120 150 180 210 240 270 300 330 360 Ć 4 Pole Mechanical Degrees  
60 120 90 240 300 360 420 480 540 600 660 720 Ć Electrical Degrees  
0
0
0
Hall Sensor Leads  
(Hall generated signal)  
S1 (White)  
S2 (Yellow)  
S3 (Orange)  
Motor Leads  
(Motor generated EMF)  
F3 to F1  
F1 to F2  
F2 to F3  
4-2 Specifications  
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