BSC Series 1000/1100

Servo Control
for Brushless AC Motors

Installation & Operating Manual

7/01 MN1202
 Table of Contents

Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Section 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
M-Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
BUS Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
24VDC Logic Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Simulated Encoder Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
X2 Control I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Section 4
Switch Setting and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Potentiometer Initial Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Identity Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Start–up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Power Off Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Power On Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

MN1202 Table of Contents i

Section 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
BPS Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Noise Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Section 6
Specifications and Product Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Dimensions & Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Section 7
CE Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
EMC – Conformity and CE – Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
EMC Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

ii Table of Contents MN1202

Section 1
General Information

Copyright Baldor  1997, 1999, 2000, 2001. All rights reserved.

This manual is copyrighted and all rights are reserved. This document may not, in whole
or in part, be copied or reproduced in any form without the prior written consent of Baldor.
Baldor makes no representations or warranties with respect to the contents hereof and
specifically disclaims any implied warranties of fitness for any particular purpose. The
information in this document is subject to change without notice. Baldor assumes no
responsibility for any errors that may appear in this document.
Microsoft and MS–DOS are registered trademarks, and Windows is a trademark of
Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.

CE Compliance
A custom unit may be required, contact Baldor. Compliance to Directive 89/336/EEC is
the responsibility of the system integrator. A control, motor and all system components
must have proper shielding, grounding, and filtering as described in MN1383. Please
refer to MN1383 for installation techniques for CE compliance. For additional information,
refer to Sections 3 and 7 of this manual.

Limited Warranty

For a period of two (2) years 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.

MN1202 General Information 1-1

Product Notice Intended use:
These drives are intended for use in stationary ground based applications in industrial
power installations according to the standards EN60204 and VDE0160. They are
designed for machine applications that require variable speed controlled three phase
brushless AC motors.
These drives are not intended for use in applications such as:
– Home appliances
– Medical instrumentation
– Mobile vehicles
– Ships
– Airplanes
Unless otherwise specified, this drive is intended for installation in a suitable enclosure.
The enclosure must protect the control from exposure to excessive or corrosive moisture,
dust and dirt or abnormal ambient temperatures. The exact operating specifications are
found in Section 6 of this manual.
The installation, connection and control of drives is a skilled operation, disassembly or
repair must not be attempted.
In the event that a control fails to operate correctly, contact the place of purchase for
return instructions.
Safety Notice: This equipment contains high voltages. 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.
– System documentation must be available at all times.
– Keep non-qualified personnel at a safe distance from this equipment.
– Only qualified personnel familiar with the safe installation, operation and
maintenance of this device should attempt start-up or operating procedures.
– Always remove power before making or removing any connections to this
control.
PRECAUTIONS: Classifications of cautionary statements.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury
or death.

Caution: Indicates a potentially hazardous situation which, if not avoided, could result in damage
to property.

Continued on next page.

1-2 General Information MN1202

 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.

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.

WARNING: Be sure all wiring complies with the National Electrical Code and all regional and local codes
or CE Compliance. Improper wiring may cause a hazardous condition.

WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power
before you ensure that grounds are connected. 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. 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.

WARNING: If a motor is driven mechanically, it may generate hazardous voltages that are conducted to
its power input terminals. The enclosure must be grounded to prevent a possible shock
hazard.

WARNING: When operating a motor with no load coupled to its shaft, remove the shaft key to prevent
injury if it were to fly out when the shaft rotates.

WARNING: The motor shaft will rotate during the autotune procedure. Be certain that unexpected motor
shaft movement will not cause injury to personnel or damage to equipment.

WARNING: A DB Resistor may generate enough heat to ignite combustible materials. To avoid fire
hazard, keep all combustible materials and flammable vapors away from brake resistors.

WARNING: The user must provide an external hard-wired emergency stop circuit to disable the control
in the event of an emergency.
Caution: Suitable for use on a circuit capable of delivering not more than the RMS symmetrical short
circuit amperes listed here at rated voltage.
Horsepower RMS Symmetrical Amperes
1–50 5,000
Caution: To prevent equipment damage, be certain that the input power has correctly sized protective
devices installed as well as a power disconnect.

Continued on next page.

MN1202 General Information 1-3

 Caution: Avoid locating control immediately above or beside heat generating equipment, or directly
below water or steam pipes.
Caution: Avoid locating control in the vicinity of corrosive substances or vapors, metal particles and
dust.
Caution: For UL installations, do not connect any resolver cable shields to the motor frame. At a
minimum, resolver signal integrity will be compromised and damage to the control may
result.
For CE installations, refer to CE guidelines stated in Sections 3 and 7 of this manual.
Caution: Do not connect AC power to the control terminals U, V and W. Connecting AC power to these
terminals may result in damage to the control.
Caution: Baldor recommends not using “Grounded Leg Delta” transformer power leads that may
create ground loops and degrade system performance. Instead, we recommend using a four
wire Wye.
Caution: Logic signals are interruptible signals; these signals are removed when power is removed
from the drive.
Caution: Controls are intended to be connected to a permanent main power source, not a portable
power source. Suitable fusing and circuit protection devices are required.
Caution: The safe integration of the drive into a machine system is the responsibility of the machine
designer. Be sure to comply with the local safety requirements at the place where the
machine is to be used. In Europe this is the Machinery Directive, the ElectroMagnetic
Compatibility Directive and the Low Voltage Directive. In the United States this is the
National Electrical code and local codes.
Caution: Controls must be installed inside an electrical cabinet that provides environmental control
and protection. Installation information for the drive is provided in this manual. Motors and
controlling devices that connect to the drive should have specifications compatible to the
drive.
Caution: Violent jamming (stopping) of the motor shaft during operation may damage the motor and
control.
Caution: Do not tin (solder) exposed wires. Solder contracts over time and may cause loose
connections.
Caution: Electrical components can be damaged by static electricity. Use ESD (electro-static
discharge) procedures when handling this control.
Caution: Ensure that resolver or encoder wires are properly connected. Incorrect installation may
result in improper rotation or incorrect commutation.
Caution: The holes in the top and bottom of the enclosure are for cable clamps. Be sure to use an M4
bolt 12mm in length. Longer bolts may short circuit the electrical components inside the
control.

1-4 General Information MN1202

Section 2
Product Overview

Overview The BSC product is designed to serve the needs of machine designers and manufacturers. Baldor
products have both UL and CE approvals.
Motors Baldor servo controls are compatible with many motors from Baldor and other manufacturers. Motor
parameters are provided with the PC software making the setup easy. Baldor compatible motors
include:

BSM–4R / 63A / 80A / 80B Series motors

BSM–6R Series motors

BSM–4F / 6F / 8F / 90A / 90B Series motors

General Information The BSC1000/1100 is a resolver based servo control designed to be used with brushless
servo motors. The control accepts a standard ±10 VDC to control brushless servo motors
in either a velocity or current (torque) loop. The standard BSC 1100 series includes an
internal power supply; the standard BSC 1000 series requires an external supply.
Physically, the two units are identical.

MN1202 Product Overview 2-1

2-2 Product Overview MN1202
Section 3
Installation

Receiving & Inspection Baldor Controls are 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. Remove the control from the shipping container and remove all packing
materials. The container and packing materials may be retained for future
shipment.
3. Verify that the part number of the control you received is the same as the part
number listed on your purchase order.
4. Inspect the control for external physical damage that may have been sustained
during shipment and report any damage immediately to the commercial carrier
that delivered your control.
5. 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 humidity and
temperature specifications stated in this manual.
Location Considerations The location of the control is important. Installation should be in an area that is protected
from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and
vibration. Exposure to these can reduce the operating life and degrade performance of
the control.
Several other factors should be carefully evaluated when selecting a location for
installation:
1. For effective cooling and maintenance, the control should be mounted on a
smooth, non-flammable vertical surface.
2. At least 0.6 inches (15mm) top and bottom clearance must be provided for air
flow. Refer to Section 6 for mounting dimensions.
3. Altitude derating. Up to 3300 feet (1000 meters) no derating required. Derate
the continuous and peak output current by 1.1% for each 330 feet (100 meters)
above 3300 feet.
4. Temperature derating. From 5°C to 45°C ambient no derating required.
Above 45°C, derate the continuous and peak output current by 2.9% per °C
above 45°C. Maximum ambient is 55°C.

Mechanical Installation Mount the control to the mounting surface. The control must be securely fastened to the
mounting surface by the control mounting holes. The location of the mounting holes is
shown in Section 6 of this manual.

Power Loss Ratings

Control Type 1002 1005 1010 1015
Power Loss (Watts)
19 19 54 85
(For BSC11XX units, add 55Watts)

MN1202 Installation 3-1

Electrical Installation All interconnection wires between the control, AC power source, motor, host control and any
operator interface stations should be in metal conduits. Use listed closed loop connectors that are of
appropriate size for wire gauge being used. Connectors are to be installed using crimp tool specified
by the manufacturer of the connector. Only class 1 wiring should be used.
System Grounding Baldor controls are designed to be powered from standard single and three phase lines that are
electrically symmetrical with respect to ground. System grounding is an important step in the overall
installation to prevent problems. The recommended grounding method is shown in Figure 3-1 for UL
compliant systems (Figure 3-2 for CE compliant systems).

Figure 3-1 Recommended System Grounding (3 phase) for UL

L1 Control Note:
Wiring shown for clarity of
AC Main L2 L1 L2 L3 PE U V W grounding method only.
Supply Not representative of actual
terminal block location.
L3

Earth
Safety
Ground Four Wire Route all power wires L1, L2, L3 and Earth
“Wye” (Ground) together in conduit or cable.
Driven Earth
Ground Rod
(Plant Ground)

Note: Use shielded cable for control signal wires. Route

control signal wires in conduit. These wires must be
kept separate from power and motor wires. Ground per NEC and Local codes.

Figure 3-2 Recommended System Grounding (3 phase) for CE

AC Main L1 Control Note:

Supply Wiring shown for clarity of
L2 L1 L2 L3 PE U V W grounding method only.
Not representative of actual
Four Wire
terminal block location.
“Wye”
L3

Safety PE
Ground
Route all power wires
Motor
L1, L2, L3 and Earth
GND
(Ground) together in
conduit or cable.

All shields
Enclosure Backplane (see Section 6)

Note: Use shielded cable for control signal wires. Route

control signal wires in conduit. These wires must be
kept separate from power and motor wires.

3-2 Installation MN1202

 System Grounding Continued
Ungrounded Distribution System
With an ungrounded power distribution system it is possible to have a continuous current path to
ground through the MOV devices. To avoid equipment damage, an isolation transformer with a
grounded secondary is recommended. This provides three phase AC power that is symmetrical with
respect to ground.
Input Power Conditioning
Baldor controls are designed for direct connection to standard single and three phase lines that are
electrically symmetrical with respect to ground. Certain power line conditions must be avoided. An
AC line reactor or an isolation transformer may be required for some power conditions.
• If the feeder or branch circuit that provides power to the control has permanently connected
power factor correction capacitors, an input AC line reactor or an isolation transformer must
be connected between the power factor correction capacitors and the control.
• If the feeder or branch circuit that provides power to the control has power factor correction
capacitors that are switched on line and off line, the capacitors must not be switched while
the control is connected to the AC power line. If the capacitors are switched on line while
the control is still connected to the AC power line, additional protection is required. TVSS
(Transient Voltage Surge Suppressor) of the proper rating must be installed between the AC
line reactor or an isolation transformer and the AC input to the control.

Power Disconnect A power disconnect should be installed between the input power service and the control for a
fail–safe method to disconnect power. The control will remain in a powered-up condition until all input
power is removed from the control and the internal bus voltage is depleted.

Protection Devices The control must have a suitable input power protection device installed. Input and output
wire size is based on the use of copper conductor wire rated at 75 °C. Table 3-1 describes the wire
size to be used for power connections and the ratings of the protection devices.

Table 3-1 Wire Size and Protection Devices

Catalog Number Incoming Power
Continuous Input Fuse Wire Gauge
Nominal Input
Output AWG mm2
Voltage (A)
Amps (RMS) (USA) (Europe)
BSC1002  – 2 6 14 2.5
BSC1102 115V (3f) 2 6 14 2.5
BSC1105–1 115V (1f) 5 10 14 2.5
BSC1005  – 5 10 14 2.5
BSC1105 230V (3f) 5 10 14 2.5
BSC1110–1 115V (1f) 10 20 12 2.5
BSC1010  – 10 20 12 2.5
BSC1110 230V (3f) 10 20 12 2.5
BSC1115–1 115V (1f) 15 30 10 5.26
BSC1015  – 15 30 10 5.26
BSC1115 230V (3f) 15 30 10 5.26
Note: All wire sizes are based on 75°C copper wire. Higher temperature smaller gauge wire may be used per NEC
and local codes. Recommended fuses/breakers are based on 25°C ambient, maximum continuous control
output current and no harmonic current.
 Requires separate DC Bus input voltage. No AC input or internal power supply available in this model.

MN1202 Installation 3-3

 AC Power Connections The location of the X7 connector is shown in Figure 3-6.
Each BSC control must be fused separately. All interconnection wires between the
control, AC power source, motor and any operator interface stations should be in metal
conduits. Only class 1 wiring should be used.
Wire and Fuses should be of the correct size specified in Table 3-1. Connect the AC
power connections as shown in Figures 3-3 (three phase) or 3-4 (single phase). For
single phase installations, do not connect any wires to L3.
Figure 3-3 3 Phase Power Connections
L1 L2 L3
Earth
Note 1 Note 3 & 4
* Fuse Notes: * Components not provided with Control.
Connections 1. See Protection Device description in this section.
Note 2 2. Metal conduit or shielded cable should be used. Connect
conduits so the use of a Reactor or RC Device does not interrupt
L1 L2 L3 PE EMI/RFI shielding.
3. Use the same gauge wire for Earth as used for L1, L2, L3
connections.
Baldor 3. Use same gauge wire for Earth ground as is used for L and N.
(VDE (Germany) requires 10mm2 minimum). For CE
Control compliance, connect “PE” to the backplane of the enclosure.
4. Reference EMC wiring in Section 7.

Figure 3-4 Single Phase Power Connections (115V 1f only)

L N
Earth
Note 1 Note 3 & 4
* Fuse * Components not provided with Control.
Connections Notes:
1. See Protection Device description in this section.
Note 2
2. Metal conduit or shielded cable should be used. Connect
L1 L2 L3 PE conduits so the use of a Reactor or RC Device does not interrupt
EMI/RFI shielding.
3. Use the same gauge wire for Earth as used for L1 and L2
connections.
Baldor 3. Use same gauge wire for Earth ground as is used for L and N.
Control (VDE (Germany) requires 10mm2 minimum). For CE
compliance, connect “PE” to the backplane of the enclosure.
4. Reference EMC wiring in Section 7.

3-4 Installation MN1202

 Figure 3-5 Single Phase Power Connections (230V 1f only)
L1 L2
Earth
Note 1 Note 3 & 4
* Fuse * Components not provided with Control.
Connections Notes:
1. See Protection Device description in this section.
Note 2
2. Metal conduit or shielded cable should be used. Connect
L1 L2 L3 PE conduits so the use of a Reactor or RC Device does not interrupt
EMI/RFI shielding.
3. Use the same gauge wire for Earth as used for L1 and L2
connections.
Baldor 3. Use same gauge wire for Earth ground as is used for L and N.
Control (VDE (Germany) requires 10mm2 minimum). For CE
compliance, connect “PE” to the backplane of the enclosure.
4. Reference EMC wiring in Section 7.

MN1202 Installation 3-5

 Figure 3-6 Connector Locations

PE (Power Ground)
X7
X1 - Power Connector L1
PE Earth Ground L2
L1 Phase 1 Input L3
L2 Phase 2 Input AC Input Power
L3 Phase 3 Input U
U Motor lead “U” V
V Motor lead “V” Motor Connections W
W Motor lead “W” vcc+
VCC+ Bus Power Bus power for vcc-
VCC– Bus Power BSC1000 etc. R1
R1 Dynamic Brake Dynamic Brake
R2 Dynamic Brake R2
(Regen Resistor)
+24V Customer +24V
0V Provided Logic Power input * 0V
Reg. load
* Only connect 24VDC to logic power input
if option is installed. If option is not installed,
connecting 24VDC to these terminals can
cause damage to the control.
Monitor

Enable
ON

ID
Off

1 2 3 4

Current limit switches are accessed through a hole in the

side panel in the approximate area shown.

P
1 Ref Input gain

X3 – Resolver X3 3 Velocity gain

1 Ref+ 5 Sine+
2 Ref– 6 Sine– 4 Velocity balance
3 Cos+ 7 Not Used
4 Cos– 8 DGND 5 Velocity loop gain

ON
6 Peak current
1

X2 – Control I/O X2 DIP Switches (Motor select)

2
3

1 CMD+ 11 CWLimit
4 5 6

2 CMD– 12 CCWLimit X5 – Simulated Encoder Output

3 AGND 13 Current C 1 Not Used 6 CHB–
4 +15VDC 14 CREF X5
2 Not Used 7 CHA+
5 –15VDC 15 Fault+ 3 CHC– 8 CHB+
6 Speed 16 Fault– 4 CHC+ 9 DGND
7 DCurrent 17 Warn_C 5 CHA–
8 Icmd 18 Warn_E
9 Enable 19 Reset
10 EMStop 20 DGND

Signal Ground (Shields)

3-6 Installation MN1202

 Motor Connections Motor connections are shown in Figure 3-7. (Connections U, V and W are shown in
Figure 3-6). If connected wrong, erratic operation including moves at peak force may
occur until the overcurrent limit trips. If erratic movement of the motor occurs, turn off
power immediately and check the connections of the motor.
Figure 3-7 Motor Connections for U.L.
Notes: 1. Metal conduit or shielded cable should be used. Connect
Baldor conduits so the use of Load Reactor* or RC Device* does
Control not interrupt EMI/RFI shielding.
2. Use same gauge wire for Earth ground as is used for the
L1, L2 and L3. (VDE (Germany) requires 10mm2 minimum,
U V W PE 6AWG). For CE compliance, connect motor ground to the
Note 1 backplane of the enclosure.
3. Reference EMC wiring in Section 7.
4. Motor and resolver are phase sensitive. Connect only as
Note 2
V W instructed.
U G This is the ground post on the top cover.

* Optional components not provided with control.

* AC Servo Motor

Figure 3-8 Motor Connections for CE

Notes: 1. Metal conduit or shielded cable should be used. Connect
conduits so the use of Load Reactor* or RC Device* does
not interrupt EMI/RFI shielding.
Baldor
Control 2. Use same gauge wire for Earth ground as is used for
This is the
the L1, L2 and L3. (VDE (Germany) requires 10mm2
ground post on minimum, 6AWG). For CE compliance, connect motor
U V W PE the top cover. ground to the backplane of the enclosure.
Note 1 3. Reference EMC wiring in Section 7.
4. Motor and resolver are phase sensitive. Connect only as
instructed.
V W
Note 2
U G Enclosure Backplane (see Section 7)
* Optional components not provided with control.
* AC Servo Motor

Note: For CE compliant installations, connect unused leads within the motor cable
to “PE” on both ends of the cable.

MN1202 Installation 3-7

 M-Contactor If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor)
may be installed. However, incorrect installation or failure of the M-contactor or wiring
may damage the control. If an M-Contactor is installed, the control must be disabled for
at least 20msec before the M-Contactor is opened or the control may be damaged.
M-Contactor connections are shown in Figure 3-9.
Figure 3-9 Optional M-Contactor Connections
U V W * RC Device
To Power Source * M-Contactor Electrocube
(Rated Coil Voltage) RG1781-3
* M M M
This is the
ground post on
the top cover.
* Optional components not provided with control.
Note 1 and 2
V W
* X2
U G M Enable
* Motor Note: Close “Enable”
9 after “M” contact closure.
M=Contacts of optional M-Contactor
Notes:
1. Use same gauge wire for Earth ground as is used for the BPS L1, L2 and L3. (VDE
(Germany) requires10mm2 minimum, 6AWG).
2. For UL installations, connect motor ground to of the control as shown.
For CE installations, connect motor ground to the enclosure backplane (see Figure 3-8).

BUS Power For multi–axis applications, the second control may not have an internal supply. Bus
power for the second control can be connected as shown in Figure 3-10.
Figure 3-10
A control with an internal supply can provide bus power to a
BSC1100 BSC1000
maximum of one control that requires an external power X7 X7
source. Simply connect the X7 VCC+ of the first control to
vcc+ vcc+
the VCC+ of the second control. Then connect the X7 VCC– vcc- vcc-
of the first control to the VCC– of the second control.

Internal Power Requires External Power

Dynamic Brake Resistor An external DB (dynamic brake or regen resistor) resistor is required to dissipate excess
power from the DC bus during motor deceleration operations. An external 320 watt
resistor must be connected at the X7 terminals R1 and R2.
Refer to Section 6 for selection information or contact Baldor.

24VDC Logic Power If the control is equipped with the internal 24VDC logic power circuit (BSC1XXX–24–X),
24VDC may be connected to this input to maintain voltage on the logic circuits at all
times. An external 24VDC (20V to 60V source) supply must be used. This supply must
remain on when AC power to the control is disconnected. Connect the power supply
leads to X7 input terminals +24V and 0V.
Note: All units are marked 24V and 0V. Do not connect an external 24VDC source
to these terminals unless the control is equipped with the internal 24VDC logic
power circuit (BSC1XXX–24–X).

3-8 Installation MN1202

 Resolver Feedback The resolver connections are made at the X3 connector as shown in Figure 3-11 or 3-12.
The resolver cable must be shielded twisted pair #22 AWG (0.34mm2) wire minimum.
The cable must also have an overall shield. Maximum wire-to-wire or wire-to-shield
capacitance is 50pf per foot.
Resolver wiring must be separated from power wiring. Separate parallel runs of resolver
and power cables by at least 3″. Cross power wires at right angles only. Insulate or tape
ungrounded end of shields to prevent contact with other conductors or ground.
Note: Motor and resolver are phase sensitive. Connect only as instructed.
Figure 3-11 Resolver Cable Connections for UL Installations
R2 S2 X3
P
5 SIN+
R1 S4
6 SIN-
P
S3 S1 3 COS+
4 COS-
P
1 REF+
P 2 REF- (Common)
= Twisted Pair Shields Shell (Chassis)

Figure 3-12 Resolver Cable Connections for CE Installations

R2 S2 X3
P
5 SIN+
R1 S4
6 SIN-
P
S3 S1 3 COS+
4 COS-
P
1 REF+
P 2 REF- (Common)
= Twisted Pair PE PE

Simulated Encoder Output

The control provides a simulated encoder output at connector X5. This output may be used by
external hardware to monitor the encoder signals. It is recommended that this output only drive one
circuit load. Refer to Table 3-2.
Table 3-2 Simulated Encoder Output at X5 Connector
X5 Pin Signal Name
1 Not Used
2 Not Used
3 CHC–
4 CHC+
5 CHA–
6 CHB–
7 CHA+
8 CHB+
9 DGND
Shell * Chassis (Cable Shield)
* For UL Installations ONLY. For CE Installations, connect the outer shield on each end
of the cable to the signal ground (shields) at the bottom of the control.

MN1202 Installation 3-9

 X2 Control I/O Connections 18AWG wire is sufficient for all X2 connections.
Analog I/O
Command Input X3 pins 1, 2 and 3 allows connection of an external analog command input. This input
can accept a 0-10VDC or ±10VDC signal and can be wired as a single ended or
differential input, shown in Figure 3-13.
Figure 3-13 Control Input Wiring
Single Ended Connection Differential Connection
X2 X2
+
1 CMD+ 1 CMD+
Single Ended Signal Signal
CW operation Source 2 CMD- Source 2 CMD-
as shown 3 AGND 3 AGND

15VDC Output X2 pins 4 and 5 provide 15VDC output @100mA maximum. (X2–3 is common).
Speed Output X2 pins 6 provides a motor velocity test point. (X2–3 is common).
Motor RPM = VDC X 600
Output Current X2 pins 7 provides a test point to measure actual motor current. (X2–3 is common).
Scaled 0 to 10VDC (where 10VDC = Ipeak)
Icmd X2 pins 7 provides a test point to measure commanded motor current. (X2–3 is common).
Scaled ±10VDC (where ±10VDC = Ipeak)

Figure 3-14 Reset Wiring

X2

Close X2–19 to reset an over voltage, under

19 Reset voltage, over current, over temperature,
resolver fault or electronic fusing (I2T) fault.
20 DGND

3-10 Installation MN1202

 Digital I/O
X2 Digital Inputs - (uses CREF, X2-14)
Active High (Sourcing) - If pin X2-14 is grounded, an input is active when it is at
+24VDC (+12VDC to +30VDC).
Active Low (Sinking) - If pin X2-14 is at +24VDC (+12VDC to +30VDC), an input is
active when it is grounded.
Logic input connections are made at terminal strip X2. Input connections can be wired as
active High or active Low as shown in Figure 3-15. X2 pin 14 is the Control Reference
point (CREF) for the Isolated Input signals.
Note: An internal 24VDC power supply connection is not available from the control
to power the Input circuits. A customer provided external power source must
be used as indicated in Figure 3-15.
Figure 3-15 Active HIGH /LOW Relationship
Active Low Active High Input Note: All inputs are referenced to CREF, X2-14.
(Sink) (Source) X2
+24VDC GND A 14 CREF

B Input 9 ENABLE
GND +24VDC
10 EMStop
A
11 CW-ENABLE
20mA 20mA
12 CCW-ENABLE
+24VDC 9 - 17 GND 9 - 17 B
B B 13 Current C

GND 7 +24VDC 7
A A
Typical Typical

Control Control
Source Sink

Table 3-1 Digital Input Signal Conditions

Pin Signal
Switch = Closed (active) Switch = Open (not active)
Number Name
X2-9 Enable Drive enabled. Drive disabled.
X2-10 EMStop (Emergency Stop) Motor enabled. Motor disabled.
X2-11 CW-Enable Clockwise rotation enabled. Clockwise rotation disabled.
X2-12 CCW-Enable Counter-clockwise rotation enabled. Counter-clockwise rotation disabled.
X2-13 Current C (Torque/Velocity) Current mode (Torque). Velocity mode.

Current C Use Current mode (X2–13 Closed) for positioning applications.

Use Velocity mode (X2–13 Open) for speed control applications.

Signal Name Digital Input Signal Definition

Enable CLOSED allows normal operation.
OPEN disables the control and motor coasts to a stop.
EMStop CLOSED allows normal operation.
OPEN commands zero velocity and motor coasts to a stop.
CW-Enable CLOSED allows normal operation in the CW direction.
OPEN to disable CW rotation. The motor decels to a stop.
CCW-Enable CLOSED allows normal operation in the CCW direction.
OPEN to disable CCW rotation. The motor decels to a stop.
Current C CLOSED current mode operation is enabled.
OPEN velocity mode operation is enabled.

MN1202 Installation 3-11

 X2 Digital Outputs The control outputs are located on the X2 connector. A customer provided, external
power supply must be used if digital outputs are to be used. The outputs provide status
information and are not required for operation.
Figure 3-16 Fault Relay Connections
15
Customer provided external power source: and Non-Inductive Load
Relay 110VAC @ 0.3A maximum or
16 24VDC @ 0.8A maximum

Contact is closed when power is on Note:

and no faults are present.
After a fault, the output is reset by closing
Control Customer provided interface circuit the reset switch (X2–19 to X2–20).

Figure 3-17 Warning “C” and “E” Output Connections

+
Note:
VCC Source
RL Customer must use a current limiting
(+12VDC to +30VDC)
resistor (RL). The minimum value of
RL can be calculated as follows:
17, 18 Output Signal OR R L minimum + VCC Source
0.04
20 Relay
Typical CGND
35mA
Maximum Control Customer Provided Interface Circuit

Table 3-2 Output Signal Conditions

Pin Signal
Switch = Closed (active) Switch = Open (not active)
Number Name
X2-15 Fault + Drive OK - no faults detected. Fault is detected.
X2-16 Fault - Drive OK - no faults detected. Fault is detected.
X2-17 WarnC No Overcurrent fault detected. I2T Overcurrent condition is detected.
X2-18 WarnE No Over temperature fault detected. Over temperature condition is detected.

Fault Relay A normally closed relay contact that opens if a fault occurs. The contact is rated:
24VDC @ 0.8A maximum or 110VAC @ 0.3A maximum.
WarnC Over Current limit (I2T electronic fusing warning). Output can be connected to an external alarm
circuit. Each output is rated 30VDC @ 35mA maximum.
WarnE Overtemperature warning. Output can be connected to an external alarm circuit.
This output is rated 30VDC @ 35mA maximum.

3-12 Installation MN1202

Section 4
26M
Switch Setting and Start-Up

Introduction These procedures are performed with the power off. Do not apply power until you are instructed to do
so. This means AC power and 24VDC Logic power must both be disconnected.

DIP Switch Settings (Refer to Section 3 for location)

Motor Select (on front panel)
ON
Six DIP switches are located on the front panel. Refer to Table 4-1 to determine the correct setting
1 2 3 4 5 6

of these switches.

Note: All switches are shown in the “ON” position.

Table 4-1 Control Address Setting

Switch
Description
1 2 3 4 5 6
ON OFF OFF For motors BSM 4R / 63A / 80A / 80B
OFF ON OFF For motor BSM 6R
ON ON OFF For motors BSM 4F / 6F / 8F / 90A / 90B
OFF OFF Encoder Simulation of 1024 Pulse per Revolution
ON OFF Encoder Simulation of 1000 Pulse per Revolution
OFF ON Encoder Simulation of 500 Pulse per Revolution
ON ON Encoder Simulation of 250 Pulse per Revolution
OFF Off = Integral part of the velocity loop is active.
ON On = Proportional loop only (no integral part).

Current Limit (on side panel)

ON

Current limit switches are accessed through a hole in the side panel. These switches reduce both
Off

1 2 3 4
the continuous and peak current by the same ratio.

Table 4-2 Current Limit Setting

Switch
Description
1 2 3 4
OFF OFF OFF OFF 25% of full rated output current
ON ON OFF OFF 50% of full rated output current
OFF OFF ON ON 75% of full rated output current
ON ON ON ON 100% of full rated output current

Potentiometer Initial Settings

The potentiometers must be pre–set. Refer to Section 3 for location. Set the
potentiometers to the pre–set positions indicated in Table 4-3.
Table 4-3 Potentiometer Initial Preset Positions
Potentiometer Function Initial Setting (Factory settings)
P1 Reference Input Gain CW for maximum input gain
P3 Velocity Feedback Gain CW for maximum gain
P4 Velocity Balance (Drift Adjustment) Standstill at zero point command
P5 Velocity Loop Gain (Prop Gain) CCW for minimum gain
P6 Peak Current CCW for reduced current

MN1202 Switch Setting and Start-Up 4-1

Identity Module The Identity Module must be fully inserted into its socket to allow control operation.
Several components are mounted on this module. Refer to Figure for their location and to
Table 4-4 for their description.
Note: If the Identity Module is not completely inserted, the unit will not operate.
Figure 4-1 Identity Module Component Locations

Table 4-4 Identity Module Component Descriptions

Component Description Factory Value
R38 Speed Scaling (4000 RPM)  4.99 kΩ
D401 Plug–in protection –
R94 P–gain for velocity loop 100 kΩ
C19 I–gain for velocity loop 47 nF
R22 I2T–switching threshold (nom. current)  –
R765 Special function 26.7 kΩ
R43 P–gain for current loop phase U 150 kΩ
C17 I–gain for current loop phase U 4.7 nF
R44 P–gain for current loop phase V 150 kΩ
C11 I–gain for current loop phase V 4.7 nF
D402 Plug–in protection –
RES Reserved for special applications –
 R38 is used to set the maximum speed of the control/motor combination. The standard
factory value is a 4.99 kΩ resistor for 4000 RPM. If the motor’s maximum speed for a
given application is not 4000 RPM, this resistor should be replaced with one of the
following resistor values below depending on the maximum required speed:
0 Ω for 6000 RPM
4.99 kΩ for 4000 RPM
10 kΩ for 3000 RPM
20 kΩ for 2000 RPM
Contact Baldor for applications over 6000 RPM.
 R22 is used to limit the continuous current of the control (without affecting peak current).
The standard factory arrangement is to not insert R22. If an I2T limit is desired, the value
of R22 can be determined from Table 4-5.

4-2 Switch Setting and Start-Up MN1202

 Table 4-5 Current Limit Value Determination
Value of R22 BSC 1002/1102 BSC 1005/1105 BSC 1010/1110 BSC 1015/1115
Ohms Ipeak = 4A Ipeak = 10A Ipeak = 20A Ipeak = 30A
Open ( ∞ ) Icont = 2.0A Icont = 5.0A Icont = 10.0A Icont = 15.0A
20kΩ Icont = 1.6A Icont = 4.0A Icont = 8.0A Icont = 12.0A
10kΩ Icont = 1.3A Icont = 3.3A Icont = 6.7A Icont = 10.0A
5kΩ Icont = 1.0A Icont = 2.5A Icont = 5.0A Icont = 7.5A

Start–up Procedure
Power Off Checks Before you apply power, it is very important to verify the following:
1. Disconnect the load from the motor shaft until instructed to apply a load. If this
cannot be done, disconnect the motor wires at X7-U, V and W.
2. Verify that switches are set correctly.
3. Verify the AC line voltage at the source matches the control rated voltage.
4. Inspect all power connections for accuracy, workmanship and tightness.
5. Verify that all wiring conforms to applicable codes.
6. Verify that the control and motor are properly grounded to earth ground.
7. Check all signal wiring for accuracy.
Power On Checks If using a transformer, switch the primary side only, and check that the secondary voltage
is 115 VAC for single phase units and between 115 VAC and 230 VAC for three phase
units.
1. Temporarily disconnect the input speed command signal (±10 VDC) from the
Control Signal Connector X2 inputs CMD + (pin 1) and CMD – (pin 2) and
jumper the CMD + and CMD – inputs together.
2. Switch on the main power. The motor may run away “out of control” if the
resolver wires are connected incorrectly. Turn power off immediately and check
resolver wires. If the motor shaft rotates in the wrong direction, check the
wiring of the motor and the resolver. Turn power on.
3. Verify that the “READY” LED is green, and the Status Monitor LED display on
the front panel shows a decimal point on the bottom right. This verifies that
power is applied, and the unit is enabled. If the motor is slowly rotating, adjust
the Velocity Balance pot P4 for no rotation.
4. Adjust P6 Peak Current CW (clockwise), and verify that the motor has holding
torque. If the motor has no holding torque, make sure that the Identity Module is
fully inserted, and check the wiring of the Control Signal Connector X2 pins:
CW limit (pin 11), CCW limit (pin 12), ENABLE (pin 9), EMStop (pin 10). If the
motor runs away or if Error 5 or 7 is displayed on the Status Monitor, switch off
the main power immediately and check the resolver and motor wiring.
5. Again, switch off the main power, and reconnect the input speed command
signal (±10 VDC) to the CMD + and CMD – inputs. Switch on the main power
and apply a small input speed command (5V or less is suggested). Positive
command voltage will cause CW shaft rotation and negative command voltage
will cause CCW (counterclockwise) shaft rotation.
Note: When using single ended input, positive voltage input to CMD + causes
CW shaft rotation, and positive voltage input to CMD – causes
CCW shaft rotation.

MN1202 Switch Setting and Start-Up 4-3

Adjustment Procedure The following procedure yields proper potentiometer adjustment for optimum servo
control operation. For best results, read the entire procedure before making adjustments.
1. Apply a signal input command between 0 and 10 VDC at the Control Signal
Connector X2 inputs CMD + (pin 1) and CMD – (pin 2). +5 VDC (for CW shaft
rotation) or –5 VDC (for CCW shaft rotation) is suggested. If the motor shaft
rotates in the wrong direction for a given polarity of the signal input voltage,
check the wiring of the motor and resolver. If the shaft still rotates in the wrong
direction, reverse the CMD + and CMD – inputs.
Note: When using single–ended input, positive voltage input to CMD + causes CW
shaft rotation, and positive voltage input to CMD – causes CCW shaft rotation.
2. Slowly turn the Peak Current (P6) pot 1/4 turn CW, observing that the motor
shaft speed may increase and stabilize.
3. If connected, verify that the CW and CCW limit switches properly inhibit the
machine travel in the direction defined.
4. If the motor shaft drifts, or rotates when sent a zero velocity (“don’t move“)
command, slowly adjust the Velocity Balance (P4) pot to eliminate any motor
shaft rotation.
Note: The setting of potentiometers P1 and P3 must allow the control to reach the
maximum velocity for the command input before P5 can be correctly adjusted.
Begin with both P1 and P3 set fully CW.
5. The adjustment of the Velocity Loop Gain (P5) pot may be accomplished by
either of two methods:
a. Slowly turn the Velocity Loop Gain pot CW until the axis becomes unstable
and then turn the pot back 1/8 turn CCW.
b. Using a step input command with an amplitude of 10% of full desired
speed and a suggested duration of 1 second on/1 second off, adjust the
Velocity Loop Gain pot CW while monitoring the speed test point signal
(Control Signal Connector X2 pin 6) on a scope until the desired response
is obtained. Refer to Figure 4-2 for typical responses.
Note: If the servo control is unstable at all pot settings there is probably a
mechanical resonance.
6. If the motor shaft overshoots when stopping, turn the Tacho Gain (P3) pot CCW
CCW, being careful not to turn to full CCW. Full CCW on the Tacho Gain pot
may cause the motor shaft speed to become uncontrollable.
7. The Input Gain (P1) pot can now be used to “fine tune” and optimize the
maximum response for the given signal input voltage range. Note that steps 4
thru 6 may have to be repeated.
Figure 4-2 Typical Response

4-4 Switch Setting and Start-Up MN1202

Section 5
Troubleshooting

Overview The BSC Control requires very little maintenance and should provide years of trouble free
operation when installed and applied correctly. Occasional visual inspection and cleaning
should be considered to ensure tight wiring connections and to remove dust, dirt, or
foreign debris which can reduce heat dissipation.
Operational failures called “Faults” will be displayed as they occur. A comprehensive list
of these faults, their meaning and related information is provided in this section.
Before attempting to service this equipment, all input power should be removed to avoid
the possibility of electrical shock. The servicing of this equipment should be handled by a
qualified electrical service technician experienced in the area of high power electronics.
It is important to familiarize yourself with the following information before attempting any
troubleshooting or service of the control. Most troubleshooting can be performed using
only a digital voltmeter having an input impedance exceeding 1 megohm. In some cases,
an oscilloscope with 5 MHZ minimum bandwidth may be useful. Before consulting the
factory, check that all power and control wiring is correct and installed per the
recommendations given in this manual.
BPS Troubleshooting Procedure
BPS LEDs’ The system troubleshooting procedures involves observing the status of the “Enable”
Display LED, the “Reg. Load” LED and the “Monitor” 7 segment display. Table 5-1 provides
Identification information related to the indications provided by these devices.
Table 5-1 Status and Fault Indications
Enable Monitor Status
OFF OFF BSC is powered off
Green Decimal Normal operation, Control enabled and no faults
Point
Red 1 Bus overvoltage
Red 2 Bus undervoltage
Red 3 Over current
Red 4 Overtemperature
Red 5 Resolver fault
Red 6 Electronic fusing
Green 7 I2T warning. After 2–3 seconds, control switches off then
monitor displays “6”

“Reg. Load” LED The Reg Load LED is located on the panel. The Reg Load LED is on (green) whenever
DB (Dynamic Brake) power is dissipated into the DB resistor. The DB resistor is also
called a Regen resistor.

MN1202 Troubleshooting 5-1

 Table 5-2 Troubleshooting Information
Symptom Corrective Action
Decimal point does not appear. Make sure that power is applied to the unit.
Check wiring and polarity of the ENABLE line (Connector X2, pin 9, pin
14).
Make sure Identity Module (ID) is fully inserted. (Remove power, remove
ID module, Re–insert ID module, apply power)
Motor shaft accelerates when main power is switched on. Check wiring of the Resolver (Connector X3).
Motor has no holding torque. Make sure Identity Module (ID) is fully inserted. (Remove power, remove
ID module, re–insert ID module, apply power).
Check the wiring and polarity of the Connector X2 pins:
CW limit (pin 11)
CCW limit (pin 12)
ENABLE (pin 9)
EMStop (pin 10)
Reference (pin 14)
Motor does not reach rated speed. Check Motor Voltage Phase connections (Connector X3 terminals U2,
V2, W2).
Refer to Section 3 (Identity Module) to check the value of R38 on the
Identity Module (ID).
Refer to Table 4–1 and Table 4–2 to check the DIP Switch settings.
Check that potentiometers P1 and P3 are set to allow the control to reach
the maximum velocity for the command input.
Monitor displays a 1 during deceleration. Increase decel time or add a Regeneration Resistor.

Electrical Noise Considerations All electronic devices are vulnerable to significant electronic interference signals
(commonly called “Electrical Noise”). At the lowest level, noise can cause intermittent
operating errors or faults. From a circuit standpoint, 5 or 10 millivolts of noise may cause
detrimental operation. For example, analog speed and torque inputs are often scaled at 5
to 10 VDC maximum with a typical resolution of one part in 1,000. Thus, noise of only 5
mV represents a substantial error.
At the extreme level, significant noise can cause damage to the drive. Therefore, it is
advisable to prevent noise generation and to follow wiring practices that prevent noise
generated by other devices from reaching sensitive circuits. In a control, such circuits
include inputs for speed, torque, control logic, and speed and position feedback, plus
outputs to some indicators and computers.
Relay and Contactor Coils Among the most common sources of noise is the coil of a contactor or a relay. When
these highly inductive coil circuits are opened, transient conditions often generate spikes
of several hundred volts in the control circuit. These spikes can induce several volts of
noise in an adjacent wire that runs parallel to a control–circuit wire.
Figure 5-1 illustrates noise suppression for AC and DC operated coils.
Figure 5-1 AC & DC Coil Noise Suppression

RC snubber +

0.47 mF
AC Coil DC Coil Diode
33 W

5-2 Troubleshooting MN1202

Section 6
Specifications and Product Data

Identification
Servo Control BSC 1 0 XX – XX – X

Brushless
Servo Control (Applies to 10 and 15 Amp controls only:)
Blank = 3φ Input Power
Enclosure Size 1 = 1φ or 3φ Input Power

Blank = 24V Logic option is not installed.

0 = Requires external Bus supply 24 = 24V Logic option is installed.
1 = No external Bus supply required
Note: If 24V Logic option is not installed, do not
connect 24VDC to X7 terminals.
Control Current Rating
02 = 2 Amps
05 = 5 Amps
10 = 10 Amps
15 = 15 Amps
27 = 27.5 Amps

MN1202 Specifications and Product Data 6-1

Specifications:

BSC Servo Control Specifications: (115 / 230VAC)

Description Unit 1002 / 1105–1 1005 / 1110–1 1010 / 1115–1 1015 /
1102 1105 1110 1115
Input voltage 115VAC (100–120) VAC 115–1φ / 115–1φ 230–3φ 115–1φ 230–3φ 115–1φ 230–3φ
230VAC (200–250) 230–3φ φ   
Nominal Bus Volts 160 (140–170) VDC 160 / 300 160 300 160 300 160 300
300 (280–350)
Continuous Bus Current ARMS 2 5 10 15
Peak Bus Current (1.5s ±.5s) ARMS 4 10 20 30
Recommended Fuse Size  A 6 10 20 30
Continuous Output Power Rating kVA 0.87 1.0 2.1 2.1 4.3 3.1 6.5
Simulated Encoder Output ppr 250/500/1000/1024
Efficiency % >95
Nominal Switching Frequency kHz 8.5
Minimum Load Inductance µH 200
Analog Command Input VDC ±10
Speed Command Potentiometer 5kΩ or 10kΩ, 0.5watt
Balance (Offset Drift) RPM Adjustable to 0
Resolver Signal Resolution Bits 12
Mounting – Panel
Weight lb (kg) 10.0 (4.54)
Operating Altitude ft(M) To 3300ft (1000M). Above 3300 ft, derate 11% per 3300ft (1000M).
Operating Shock G 1G according to DIN IEC 68–2–6/ 29
Operating Vibration G 1.0G (10-60Hz) according to DIN IEC 68–2–6/ 29
Operating Temperature Range °C 5 to 45 °C 
Humidity % 10–90 Non–Condensing; according to IEC 68–2–38
Storage Temperature Range °C –25 to +70°C
Class of Protection IP20

All values at ambient temperature of 25°C unless otherwise stated.

Notes:
 When a 3φ is connected to a 1φ input, derate the output power to 5A, to avoid excessive ripple.
 Standard fuse sizes are determined as follows:
Single unit IFUSE = 1.25 x ICONT.
Multiple units IFUSE = the sum of the ICONT of all the linked units.
 Derate output current by 2.9% per °C over 45°C to a maximum ambient temperature of 55°C .
 All BSC11XX units have internal power supplies capable of 15 Amps continuous and 30 Amps peak.

DB (Regen) Resistor
Description Unit 1002 / 1105–1 1005 / 1110–1 1010 / 1115–1 1015 /
1102 1105 1110 1115
Switching Threshold 155VAC controls VDC 188–195
230VAC controls 370–410
Nominal Peak Power kW 7.5–15
Maximum Inductive Load µH 100
Regen Switching Current (maximum) A 40
Regen Resisor Value (320watt) Ω 18 18 18 10  18  4.7 10 
Resistor Part Number RG18 RG18 RG18 RG10  RG18  RG4.7 RG10 

Note:
 Recommended regeneration resistor/part number for single axis operation only.

6-2 Specifications and Product Data MN1202

24VDC Option (Logic Power)
Description Unit 1002 / 1105–1 1005 / 1110–1 1010 / 1115–1 1015 /
1102 1105 1110 1115
Input Voltage Range VDC 20–60
Input Current at 24VDC A 1.4
Surge Current at Power On A 2.5 for 100ms

Bus Supply Voltage

Description Unit 1002 1005 1010 1015
Nominal Bus Voltage VDC 160 300 300 300
Bus Voltage Range (absolute Minimum/Maximum) VDC 50/170 50/350 50/350 50/350
Bus Voltage Range with 24VDC option (absolute Min./Max.) VDC 0/170 0/350 0/350 0/350

MN1202 Specifications and Product Data 6-3

Section 1
General Information

Dimensions & Mounting

6-4 Specifications and Product Data MN1202

Section 7
CE Guidelines

CE Declaration of Conformity
Baldor indicates that the products are only components and not ready for immediate or
instant use within the meaning of “Safety law of appliance”, “EMC Law” or “Machine
directive”.
The final mode of operation is defined only after installation into the user’s equipment. It
is the responsibility of the user to verify compliance.
The product conforms with the following standards:
DIN VDE 0160 / 05.88 Electronic equipment for use in electrical power
installations
DIN VDE 0100 Erection of power installations with nominal voltages up
to 1000V
DIN IEC 326 Teil 1 / 10.90 Design and use of printed boards
DIN VDE 0110Teil 1-2 / 01.89 Dimensioning of clearance and creepage
DIN VDE 0110Teil 20 / 08.90 distances
EN 60529 / 10.91 Degrees of protection provided by enclosures
EMC – Conformity and CE – Marking
The information contained herein is for your guidance only and does not guarantee that
the installation will meet the requirements of the council directive 89/336/EEC.
The purpose of the EEC directives is to state a minimum technical requirement common
to all the member states within the European Union. In turn, these minimum technical
requirements are intended to enhance the levels of safety both directly and indirectly.
Council directive 89/336/EEC relating to Electro Magnetic Compliance (EMC) indicates
that it is the responsibility of the system integrator to ensure that the entire system
complies with all relative directives at the time of installing into service.
Motors and controls are used as components of a system, per the EMC directive. Hence
all components, installation of the components, interconnection between components,
and shielding and grounding of the system as a whole determines EMC compliance.
The CE mark does not inform the purchaser which directive the product complies with. It
rests upon the manufacturer or his authorized representative to ensure the item in
question complies fully with all the relative directives in force at the time of installing into
service, in the same way as the system integrator previously mentioned. Remember, it is
the instructions of installation and use, coupled with the product, that comply with the
directive.
Wiring of Shielded (Screened) Cables

Remove the outer insulation Conductive

to expose the overall screen. Clamp

MN1202 CE Guidelines 7-1

 Using CE approved components will not guarantee a CE compliant system!
1. The components used in the drive, installation methods used, materials
selected for interconnection of components are important.
2. The installation methods, interconnection materials, shielding, filtering and
grounding of the system as a whole will determine CE compliance.
3. The responsibility of CE mark compliance rests entirely with the party who
offers the end system for sale (such as an OEM or system integrator).
Baldor products which meet the EMC directive requirements are indicated with a “CE”
mark. A duly signed CE declaration of conformity is available from Baldor.
EMC Wiring Technique

1 CABINET
The drawing shows an electroplated zinc coated enclosure, which is connected to
Y
ground.
Capacitor
This enclosure has the following advantages:
– All parts mounted on the back plane are connected to ground.
– All shield (screen) connections are connected to ground.
Within the cabinet there should be a spatial separation between power wiring (motor
and AC power cables) and control wiring.

2 SCREEN CONNECTIONS
All connections between components must use shielded cables. The cable shields
must be connected to the enclosure. Use conductive clamps to ensure good ground
connection. With this technique, a good ground shield can be achieved.

3 EMC – FILTER
The EMI or main filter should be mounted next to the power supply (here BPS). For the
connection to and from the main filter screened cables should be used. The cable
screens should be connected to screen clamps on both sides. (Exception: Analog
Command Signal).

4 Grounding (Earth)
For safety reasons (VDE0160), all BALDOR components must be connected to ground
with a separate wire. The diameter of the wire must be at minimum AWG#6 (10mm).
Ground connections (dashed lines) must be made from the central ground to the regen
resistor enclosure and from the central ground to the Shared Power Supply.

5 Y–CAPACITOR
The connection of the regeneration resistor can cause RFI (radio frequency
interference) to be very high. To minimize RFI, a Y–capacitor is used. The capacitor
should only be connected between the dynamic brake resistor housing and terminal pin
R1 (lead from Flex).
Recommendation: 0,1µF / 250VAC Type: PME265
BALDOR–Ordering–No.: ASR27104

7-2 CE Guidelines MN1202

EMC Installation Instructions
To ensure electromagnetic compatibility (EMC), the following installation instructions
should be completed. These steps help to reduce interference. Consider the following:
• Grounding of all system elements to a central ground point
• Shielding of all cables and signal wires
• Filtering of power lines
A proper enclosure should have the following characteristics:
A) All metal conducting parts of the enclosure must be electrically connected to the
back plane. These connections should be made with a grounding strap from
each element to a central grounding point . 
B) Keep the power wiring (motor and power cable) and control wiring separated. If
these wires must cross, be sure they cross at 90 degrees to minimize noise due
to induction.
C) The shield connections of the signal and power cables should be connected to
the screen rails or clamps. The screen rails or clamps should be conductive
clamps fastened to the cabinet. 
D) The cable to the regeneration resistor must be shielded. The shield must be
connected to ground at both ends.
E) The location of the AC mains filter has to be situated close to the drive so the
AC power wires are as short as possible.
F) Wires inside the enclosure should be placed as close as possible to conducting
metal, cabinet walls and plates. It is advised to terminate unused wires to
chassis ground. 
G) To reduce ground current, use at least a 10mm2 (6 AWG) solid wire for ground
connections.
 Grounding in general describes all metal parts which can be connected to a
protective conductor, e.g. housing of cabinet, motor housing, etc. to a central
ground point. This central ground point is then connected to the main plant (or
building) ground.
 Or run as twisted pair at minimum.

Cable Screens Grounding

Cable (Twisted Pair Conductors)

Conductive Clamp – Must contact bare cable shield

and be secured to metal backplane.

MN1202 CE Guidelines 7-3

 Input Signal Cable Grounding
Control
X3
Cable
1
2
3
7
9
10
11

Simulated Encoder Output Cable Grounding

Control
X7 Cable

1
6
2
7 To
3 Controller
8
11
13

Resolver Cable Grounding

Control Resolver Connector
X8 Housing
Cable
1 1
6 2
2 3
7 4
3 5
8 6
5
Connection of shields to analog ground is optional.

7-4 CE Guidelines MN1202

 BALDOR ELECTRIC COMPANY
P.O. Box 2400
Ft. Smith, AR 72902–2400
(501) 646–4711
Fax (501) 648–5792

CH D UK F
TEL: +41 52 647 4700 TEL: +49 89 90 50 80 TEL: +44 1454 850000 TEL: +33 145 10 7902
FAX:+41 52 659 2394 FAX:+49 89 90 50 8491 FAX:+44 1454 850001 FAX:+33 145 09 0864
I AU CC MX
TEL: +39 11 562 4440 TEL: +61 29674 5455 TEL: +65 744 2572 TEL: +52 47 61 2030
FAX:+39 11 562 5660 FAX:+61 29674 2495 FAX:+65 747 1708 FAX:+52 47 61 2010

 Baldor Electric Company Printed in USA

MN1202 7/01 PS 200