SCR DC MOTOR CONTROL

BC141, BC142, BC142-5 & BC142-6 DC CONTROL

Installation and Operation Manual

10/2008 MN704
 TABLE OF CONTENTS
Section Page
1 Simplified Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Plug-In Horsepower Resistor® and Armature Fuse Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
11 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
12 Switching Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Baldor District Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 – 31
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tables
1 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Minimum Supply Wire Size Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Plug-In Horsepower Resistor® and Armature Fuse Kit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figures
1 Control Layout and General Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2
 TABLE OF CONTENTS (Continued)
Figures Page
4 Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Enable Switch or Contact Wired to the Enable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Enable Switch or Contact Wired to the Main Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Inhibit Switch or Contact Wired to the Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 DC Tachometer Connection (7 Volts per 1000 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9 DC Tachometer Connection (50 Volts per 1000 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10 Other DC Tachometer Connection (with Addition of RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11 AC Line Input Voltage Selection (Jumper J1 (Catalog No. BC142-6 Only)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12 Motor Voltage and DC Tachometer Selection (Jumper J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13 Acceleration Trimpot (ACCEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
14 Deceleration Trimpot (DECEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15 Minimum Speed Trimpot (MIIN) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
16 Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
17 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
18 IR Compensation Trimpot (IR) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
19 Typical Dynamic Brake Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Items Included in this package – Speed Control, factory installed 25 Amp AC Line Fuse*, Installation and Operation
Manual, Hardware Bag (contains Main Speed Potentiometer with insulator and mounting hardware, (9) – 0.25” female
crimp-on terminals, (4) – 0.11” female crimp-on terminals, and an Enable harness), CE Approved Product Information
Card, and Warranty Registration Card.

Items required to operate this control – Plug-In Horsepower Resistor® and Armature Fuse Kit*. Supplied through
your distributor. See Section 9, on page 21.

* Fuse holders and fuses not supplied with BC142-5.

3
1 SIMPLIFIED INSTALLATION INSTRUCTIONS

IMPORTANT – Read these simplified installation instructions before proceeding. These instructions are to be
used as a reference only and are not intended to replace the detailed instructions provided herein. You must
read the Safety Warning, on page 6, before proceeding.

Note: A Plug-In Horsepower Resistor® and Armature Fuse

Kit must be installed in order for this product to operate.
See Section 9, on page 21. Fuse holders and fuses not
Fuse Plug-In Horsepower
supplied with BC142-5.
Resitor®

1.1 AC Line Connection – Wire the AC line to Terminals “L1” (Line Fuse)* and “L2”, as shown in Figure 1,
on page 10 and as described in Section 6.1, on page 13.

Catalog No. BC141 is rated for 115 Volt AC line input only. Catalog No. BC142 is rated for 230 Volt AC line
input only. Catalog No. BC142-5 and BC142-6 is rated for 115 Volt AC line input (Jumper J1 in the “115”
position) and 230 Volt AC line input (Jumper J1 in the “230” position). See Section 7.1, on page 19.

Notes: 1. The rated AC line voltage (115, 208/230) of the control must match the actual AC line input
voltage. 2. If one of the AC line inputs is a neutral (N), wire it to Terminal “L2”.

1.2 Ground Connection – Connect the ground wire (earth) to the control chassis.

1.3 Motor Connection – Connect the motor to Terminals “A+” (Armature Fuse)* and “A-”, as shown in Figure 1,
on page 10, and as described in Section 6.3, on page 14.

1.4 Jumper Settings – Jumper J1 (on Catalog No. BC142-5 and BC142-6) and Jumper J2 (all models) have
been factory set for most applications, as shown in Figure 1, on page 10, and as described in Section 7,
on page 19.

* Fuse holders and fuses not supplied with BC142-5.

4
1.5 AC line Fusing* – A 25 Amp AC line fuse is factory installed in the AC Line Fuse Holder, as shown in Figure
1, on page 10. It is recommended that this fuse be changed to a 12 Amp fuse for motors rated 7.5 Amps
DC or less. Fuse each conductor that is not at ground potential.

1.6 Plug-In Horsepower Resistor® and Armature Fuse* – It is required that a Plug-In Horsepower Resistor®
and Armature Fuse be installed. These are supplied separately in a kit which is based on motor horsepower
and voltage. Select the correct kit as described in Section 9, on page 21.

1.7 Trimpot Settings – All trimpots have been factory set for most applications, as shown in Figure 1, on page
10. The trimpots may be readjusted, as described in Section 10, on page 22.

1.8 Diagnostic LEDs – After power has been applied to the control, observe the LEDs to verify proper control
operation, as described in Section 11, on page 26.

1.9 Optional Auxiliary Heat Sink (Catalog No. BC143) – Extends the horsepower rating of the control to 1.5
HP for controls with 90 Volt DC output and 3 HP for controls with 180 Volt DC output.

* Fuse holders and fuses not supplied with BC142-5.

5
2 SAFETY WARNING – Please read carefully.
Definition of Safety Warning Symbols:

Electrical Hazard Warning Symbol – Failure to observe this warning could result in electrical shock
or electrocution.

Operational Hazard Warning Symbol – Failure to observe this warning could result in serious injury
! or death.

This product should be installed and serviced by a qualified technician, electrician, or electrical main-
! tenance person familiar with its operation and the hazards involved. Proper installation, which includes
wiring, mounting in proper enclosure, fusing or other over current protection, and grounding can reduce the
chance of electrical shocks, fires, or explosion in this product or products used with this product, such as elec-
tric motors, switches, coils, solenoids, and/or relays. Eye protection must be worn and insulated adjustment tools
must be used when working with control under power. This product is constructed of materials (plastics, metals,
carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding, and filtering of this product
can reduce the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic
equipment. It is the responsibility of the equipment manufacturer and individual installer to supply this Safety
Warning to the ultimate end user of this product. (SW effective 11/1992). Be sure to follow all instructions care-
fully. Fire and/or electrocution can result due to improper use of this product.

This product complies with all CE directives pertinent at the time of manufacture. Installation of a CE
approved RFI filter is required (see Section 13.7, on page 28). Additional shielded cable and/or AC
line cables may be required along with a signal isolator (Catalog No. BC152).

6
3 INTRODUCTION
Thank you for purchasing the BC141, BC142, BC142-5 or BC142-6 full-wave variable speed DC motor control.
The control, with Surface Mount, (SMT) construction, offers the user the ultimate in reliability and performance at
an affordable price. The controls contain a unique patented super-fast Direct-Fed™ current limit circuit that pro-
tects the SCR power bridge against direct shorts 1. The reliability of the control is further enhanced with the use of
high-surge, 25 Amp SCRs, and AC line and armature fusing 2, 3. The control is designed with exclusive Plug-In
Horsepower Resistor® 3, which eliminates the need for recalibrating IR Comp and Current Limit when the control
is used on various horsepower motors. In addition, the rating of the control can be extended to 1.5 HP for con-
trols with 90 Volt DC output and 3 HP for controls with 180 Volt DC output, by the use of an Auxiliary Heat Sink 4.
Catalog Nos. BC142, BC142-5 and BC142-6 also allow operation of 90 Volt DC motors when used on 208/230
Volt AC line input 5.

The versatility of the control is confirmed by its extensive list of standard features, such as: selectable armature
and tach feedback and adjustment trimpots for minimum speed, maximum speed, current limit, IR compensation,
and linear acceleration and deceleration. The control includes Auto-Inhibit®, which eliminates surging during rapid
AC line switching; pulse transformer triggering, which provides cogless operation at low speed; and superior noise
rejection circuitry, which eliminates false starts and blown SCRs. Enable (normally closed) and Inhibit (normally
open) functions provide electronic switching of control output.

The output voltage of the control is a linear function of the Main Speed Potentiometer setting. In addition, the con-
trol can be used in a voltage following mode by supplying an isolated analog input signal to Terminals “P2” (+) and
“P1” (-). The control is compact in size (only 4.30” X 3.64” X 1.25”) and easily replaces all competitive speed con-
trols. The control is supplied with a factory installed 25 Amp AC line fuse 3 and a 5 k Ω Main Speed Potentiometer
and QD terminals. All models are UL Listed (USA and Canada) and CE Approved.

Notes:
1. Short circuit protected at motor only.
2. Baldor Limited Warranty applies. See page 32.
3. Plug-In Horsepower Resistor® and Armature Fuse Kit supplied separately (Fuse holders and fuses not
supplied with BC142-5). See Sections 8 and 9, on pages 20 - 22.
4. Catalog No. BC143. See Section 13.1, on page 28.
5. Step-Down operation.
7
 3.1 Standard Features
1 Plug-In Horsepower Resistor® – Eliminates the need to calibrate the control for IR Compensation
and Current Limit when used on various horsepower motors.

2 Auto-Inhibit® – Allows the control to be rapidly switched “on” and “off” using the AC line.

3 Inhibit and Enable – Allows the control to be turned “on” and “off” using electronic switching.

4 Trimpots – Minimum Speed (MIN), Maximum Speed (MAX), IR Compensation (IR), Current Limit (CL),
Acceleration (ACCEL), and Deceleration (DECEL).

5 Jumpers – AC Line Input Voltage Selection (J1 (Catalog No. BC142-5 and BC142-6)), Motor Voltage
and DC Tachometer Selection (J2).

6 Protection Features – MOV transient protection. Short Circuit protected (at motor only).

7 Diagnostic LEDs – Power On (PWR ON) and Current Limit (CL).

8 Catalog No. BC141 operates on 115 Volt AC line input with 90 Volt DC motors.

9 Catalog No. BC142 operates on 230 Volt AC line input with 180 Volt DC motors or 90 Volt DC motors
(step-down). - Jumper Selectable.

10 Catalog No. BC142-5 and BC142-6 can operate on 115 Volt AC line input with 90 Volt DC motors and
230 Volt AC line input with 180 Volt DC motors or 90 Volt DC motors (step-down). - Jumper selectable.

11 Armature or DC Tachometer feedback.

12 Built-in AC line and armature fusing.

13 Main Speed Potentiometer (5 kΩ).

14 SMT construction.

8
 TABLE 1 – ELECTRICAL RATINGS
AC Line Rating without Auxiliary Heat Sink Rating with Auxiliary Heat Sink
Motor
Catalog Voltage Maximum AC Maximum DC Maximum Maximum AC Maximum DC Maximum Field Voltage
Voltage
Number (±15%, 50/60Hz) Line Current Load Current Horsepower Line Current Load Current Horsepower (Volts DC)
(Volts DC)
(Volts AC) (RMS Amps) (Avg. Amps) (HP (kw)) (RMS Amps) (Avg. Amps) (HP (kw))
BC141 115 0 - 90 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 50, 100
0 - 180 12.0 8.0 1.5 (1.1) 24.0 16.0 3 (2.3) 100, 200
BC142 230
0 - 90* 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 100
115 0 - 90 9.0 6.0 .75 (.6) 18.0 12.0 1.5 (1.1) 50, 100
BC142-5 0 - 180 9.0 6.0 1.5 (1.1) 18.0 12.0 3 (2.3) 100, 200
230
0 - 90* 9.0 6.0 .75 (.6) 18.0 12.0 1.5 (1.1) 100
115 0 - 90 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 50, 100
BC142-6 0 - 180 12.0 8.0 1.5 (1.1) 24.0 16.0 3 (2.3) 100, 200
230
0 - 90* 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 100
* Step-down operation.

TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS

Description Specification Factory Setting
Speed Range (Ratio) 50:1 —
Armature Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (% Base Speed) 1 —
Tachometer Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (% Set Speed) 1 —
Line Voltage Regulation (at Full Load, ± 10% Line Variation) (% Speed) 0.5 —
Control Linearity (% Speed vs. Dial Rotation) 2 —
Acceleration (ACCEL) Trimpot Range (Seconds) 0.2 – 10 2
Deceleration (DECEL) Trimpot Range (Seconds) 0.2 – 10 2
Maximum Speed (MAX) Trimpot Range (% Base Speed) 50 – 110 100
Minimum Speed (MIN) Trimpot Range (% Base Speed) 0 – 30 0
Current Limit (CL) Trimpot Range (% Full Load) 0 – 200 150
IR Compensation (IR) Trimpot Range (at Specified Full Load @ 90, 180 Volts DC Output) (Volts DC) 0 – 24, 48 3, 6

Notes:
1. Step-down operation: motor may have reduced brush life.
2. Performance is for SCR rated permanent magnet motors only. Lower performance can be expected with other motor types. Factory setting is for 3% load
regulation. To obtain superior regulation, see Section 10.6, on page 25. 9
 FIGURE 1 – CONTROL LAYOUT & GENERAL CONNECTION DIAGRAM (Catalog No. BC142-6 Shown)

Red Plug-In
Horsepower Resistor®
Blue Supplied Separately

F-
L1 A+

25 Amp* DECEL L2
Line Fuse Armature Fuse*
Factory Installed F+ Supplied Separately

B
J2
T
CL
ACCEL
Plug-In Horsepower
Resistor® and
Enable Switch J1
Armature Fuse Kit

PWR ON
(Close to Run) A-
(Open to Stop)
supplied separately
P2 See Section 9,
CONN1
EN

I1 on page 21.

P3 P1

I2
MAX MIN CL IR

+
+ +
High
Wiper 7V
M G
Low 1000
- - -
AC Line Main Speed Potentiometer Inhibit Switch Motor Field Motor Armature DC Tach-Generator
Input (Front View) (Open to Run) (Shunt Motors Only) (Set J2 to "T" Position)
(Close to Stop)
* Fuse holders and fuses not supplied with BC142-5.
10
 FIGURE 2 – MECHANICAL SPECIFICATIONS (Inches/mm)

MAIN SPEED OPTIONAL AUXILIARY HEAT SINK

3.64 POTENTIOMETER .98
92.5 24.9
3.10 .22 (SUPPLIED)
78.5 5.6
3/8" 1/2"
.50
12.7
MOUNTING "A" CONTROL
6 SLOTS
1/4" ROUND 5.63
MOUNTING "B" 7.00 143
SHAFT
TAPPED 10-32 178

MOUNTING "D"
(3 PLACES)
3.00 4.30
3.11
76.2 109 3/8-32 (79.0)
ANTI- BUSHING
FUSE HOLDER & FINGER-SAFE

2 SLOTS
ROTATION
1.50 COVER MOUNTING HOLES PIN
38.1 TAPPED 6-32 2.15 5.63
54.6 142.9 6.25
(2 PLACES)
159
.13
3.1 1.25
P3
31.8
.75 1.75 .64 .25 .95 P1 P2
19.1 44.5 16.3 6.4 24.1 .44 1.38
1.75 .18 1.25 11.1 34.9
44.5 4.6 31.8

4 APPLICATION INFORMATION
4.1 Motor Type – The control is designed for permanent magnet (PM) and Shunt Wound DC motors. Controls
operated on 115 Volt AC line input are designed for 90 Volt SCR rated motors. Controls operated on 230
Volt AC line input are designed for 180 and 90 Volt SCR rated motors. Use of higher voltage motors will
result in a reduction of the available maximum speed. Also, if the motor is not an SCR rated type, the actual
AC line current at full load should not exceed the motor’s DC nameplate current rating.

4.2 Torque Requirements – The motor selected for the application must be capable of supplying the necessary
torque. In order to ensure the motor is not overloaded, a DC ammeter should be connected in series with
the armature. Be sure the current under full load does not exceed the motor nameplate rating.
11
 4.3 Acceleration Start – The control contains an adjustable acceleration start feature which allows the motor to
smoothly accelerate from zero speed to full speed over a time period of 0.2 - 10 seconds. The acceleration
trimpot (ACCEL) is factory set for 2 seconds.

4.4 Limitation In Use – The controls are designed for use on machine applications.

4.5 Armature Switching – Do not wire the control for armature switching without taking proper precautions.
See Section 12.2, on page 27.

WARNING! Do not switch the armature in and out of circuit or catastrophic failure will result. If armature
! switching is required for reversing or dynamic braking, use Catalog Nos. BC204, BC200, or BC201.

4.6 Step-Down Transformer and AC Line Switching – When using a step-down transformer (460 Volts AC to
230 Volts AC), be sure the output current rating of the transformer is at least 3 times the current rating of the
motor. Do not switch the primary side of the transformer to disconnect power or catastrophic failure can
result. Always disconnect the control from the secondary side of the transformer.

CAUTION! Do not use this control in an explosive atmosphere. Be sure the control is used within its
! ratings. Follow all instructions carefully.

5 MOUNTING INSTRUCTIONS
It is recommended that the control be mounted on a flat surface with adequate ventilation. Leave enough room to
allow for AC line, motor connection, and other wiring that is required. Care should be taken to avoid extreme haz-
ardous locations where physical damage can occur. When mounting the control in an enclosure, the enclosure
should be large enough to allow for proper heat dissipation so that the ambient temperature does not exceed
45 °C (113 °F). See Figure 2, on page 11. If the optional Auxiliary Heatsink is used, mount the control in such a
manner that there is unrestricted air flow through the heatsink cooling fins.

12
6 WIRING INSTRUCTIONS

WARNING! Read Safety Warning, on page 6, before using this control. Disconnect the main power
! when making connections to the control.

Important Application Note: To avoid erratic operation, do not bundle the AC line and motor wires with
signal or control wiring. Also, do not bundle motor wires from multiple controls in the same conduit. Use
shielded cables on all signal wiring over 12” (30 cm). The shield should be earth grounded on the control
side only. Wire the control in accordance with the National Electrical Code requirements and other local
codes that may apply.

TABLE 3 – MINIMUM SUPPLY WIRE SIZE REQUIREMENTS

Minimum Wire Size (Cu)
Maximum Motor Current 90 - 130 Volt DC Motors 180 Volt DC Motors
Maximum 50 Ft. Maximum 100 Ft.
(Amps DC) (Maximum HP) (Maximum HP)
AWG mm2 AWG mm2
6 .5 1 16 1.3 14 2.1
12 1 2 14 2.1 12* 3.3*
16 1.5 3 12* 3.3* 12* 3.3*

* Maximum recommended wire size.

6.1 AC Line Connection – Wire the AC line to Terminals “L1” (Line Fuse)* and “L2”, as shown in Figure 1, on
page 10. If one of the AC line inputs is a neutral (N), wire it to Terminal “L2”.

CAUTION! The rated AC line voltage (115, 208/230) of the control must match the actual AC line
! input voltage. See Section 7.1, on page 19.

Catalog No. BC141 operates on 115 Volt AC line input only. Catalog No. BC142 operates on 208/230 Volt
AC line input only. Catalog BC142-5 and BC142-6 operates on 115 Volt AC line input when Jumper J1 is
set to the “115” position and operates on 208/230 Volt AC line input when Jumper J1 is set to the “230”
position (factory setting).

* Fuse holders and fuses not supplied with BC142-5. 13

 6.2 Ground Connection – Connect the ground wire (earth) to the control chassis.
6.3 Permanent Magnet (PM) Motor Connection – Wire the motor armature positive lead (+) to Terminal “A+”
(Armature Fuse*) and the negative lead (-) to Terminal “A-”, as shown in Figure 1, on page 10. On Catalog
Nos. BC142, BC142-5 and BC142-6, be sure Jumper J2 is set to the corresponding motor voltage, as
described in Section 7.2, on page 20. Be sure the correct Plug-In Horsepower Resistor® is installed, as
described in Section 9, on page 21.
* Fuse holders and fuses not supplied with BC142-5.
6.4 Motor Field Connection (Shunt Wound Motors Only)
6.4.1 Full Voltage Field – Wire the field positive (+) lead to Terminal “F+” and the field negative lead (-) to
Terminal “F-”, as shown in Figure 1, on page 10, and as described in Table 4.
6.4.2 Half Voltage Field – For 90 Volt DC motors with 50 Volt DC fields and 180 Volt DC motors with 100
Volt DC fields, wire the field positive lead (+) to Terminal “F+” and the negative lead (-) to Terminal “L1”
(Line Fuse*), as described in Table 4.
Notes:
1. Do not connect motor armature leads to Terminals “F+” and “F-”.
2. Do not use Terminals “F+” and “F-” for any purpose other than to power the field of a shunt
wound motor.
3. Shunt wound motors may be damaged if the field remains energized without armature rotation for
an extended period of time.
TABLE 4 – FIELD CONNECTION (Shunt Wound Motors Only)
Catalog No. AC Line Input Voltage (Volts AC) Armature Voltage (Volts DC) Field Voltage (Volts DC) Terminal Connections
100 F+, F-
BC141 115 0 - 90
50 F+, L1
0 - 180 200 F+, F-
BC142 208 / 230
0 - 90* 100 F+, L1
100 F+, F-
115 0 - 90
BC142-5 50 F+, L1
BC142-6 208 / 230 0 - 180 200 F+, F-
208 / 230 0 - 90* 100 F+, L1
14 * Step-down operation.
6.5 Remote Main Speed Potentiometer Connection – The control FIGURE 3 – REMOTE MAIN SPEED
is supplied with a Main Speed Potentiometer to control motor POTENTIOMETER CONNECTION
speed. Connect the low side of the potentiometer to Terminal Terminal "P3"
“P1”. Connect the wiper of the potentiometer to Terminal “P2”. P2 Terminal "P2"

CONN1
EN
Connect the high side of the potentiometer to Terminal “P3”.
See Figure 3.
P3 P1
Terminal "P1"
6.6 Voltage Following Connection – An isolated 0 - 9 Volt DC ana-
log signal input can be used to control motor speed in lieu of the MAX

Main Speed Potentiometer. The control output voltage will linearly

follow the analog signal input. The signal input must be isolat- High
Wiper
ed from the AC line. Connect the signal input positive lead (+) to Low
Terminal “P2” and the negative lead (-) to Terminal “P1”, as
shown in Figure 4. The source impedance of the signal input Main Speed Potentiometer
(Front View)
should be 10 k Ω or less. The MAX Trimpot is not operational in
voltage following mode. Turn the MIN Trimpot, on the control, to zero output (full counterclockwise rotation)
and use auxiliary
FIGURE 4 – VOLTAGE FOLLOWING
trimpots, if necessary, to scale and/or limit the input voltage.
CONNECTION

! CAUTION! Do not earth ground any input terminals. P2 Terminal "P2"

CONN1
EN
Notes:
1. If an isolated signal input is not available, or if using a 4 - 20 P3 P1
Terminal "P1"
mA DC signal input, install the optional plug-on Catalog No.
BC152 Signal Isolator. This will also allow direct connections +
MAX

to process controllers and microprocessors. 0 - 9 Volts DC

V
(Isolated)
2. If multiple follower motors are to be controlled from a single -
leader motor or a single Main Speed Potentiometer, install the
optional Catalog No. BC145 Signal Isolator.

3. Terminal “F-” may be used in lieu of Terminal “P1”.

15
 6.7 Enable Circuit Connection – The control can be started and stopped with an Enable Circuit (close to run),
as described below.

WARNING! The Enable Circuit is never to be used as a Safety Disconnect since it is not
! fail-safe. Use only the AC line for this purpose.

6.7.1 Enable Switch or Contact Wired to the Enable Connector – Using the wired mating connector that
is supplied with the control, connect the switch or contact to the Enable connector (CONN1), as
shown in Figure 5. When the switch or contact is closed, the motor will accelerate to the Main Speed
Potentiometer setting. When the switch or contact is opened, the motor will decelerate to stop. An
open collector (PNP) can be used in lieu of a switch or contact.

Notes: 1. To use FIGURE 5 – ENABLE SWITCH OR CONTACT WIRED TO THE ENABLE CONNECTOR
the Enable Circuit,
remove the jumper Remove this jumper to install
that is factory the Mating Connector

installed on CONN1

CONN1

CONN1
EN

EN

EN
CONN1. 2. The
deceleration time Enable Switch
Open Collector
can only be made or Contact
(On to Run)
(Close to Run)
longer than the (Off to Stop)
(Open to Stop)
normal coasting MAX MAX MAX
time of the load.

6.7.2 Enable Switch or Contact Wired to the Main Speed Potentiometer – Connect the switch or con-
tact in series with the Main Speed Potentiometer high side and Terminal “P3” on the control, as
shown in Figure 6, on page 17. Be sure the jumper is installed on the Enable Connector (CONN1).
When the switch or contact is closed, the motor will accelerate to the Main Speed Potentiometer set-
ting. When the switch or contact is opened, the motor will decelerate to the MIN Trimpot setting

16
 (factory set to 0 Volts FIGURE 6 – ENABLE SWITCH OR CONTACT WIRED TO THE
MAIN SPEED POTENTIOMETER
DC). If the MIN
Trimpot is set to other Terminal "P3"
than 0 Volts DC, the P2 Terminal "P2" P2

CONN1

CONN1
EN

EN
motor will run at the
MIN speed setting P3 P1 P3 P1
This jumper must Terminal "P1"
when the switch or be installed
contact is opened. An MAX MAX

open collector (PNP) Enable Switch or Contact Open Collector

(Close to Run) (On to Run)
can be connected in (Open to Stop) (Off to Stop)
High High
lieu of a switch or Wiper Wiper
contact. Low Low

Note: The decelera- Main Speed Potentiometer Main Speed Potentiometer

(Front View) (Front View)
tion time can only be
made longer than the normal coasting time of the load.
FIGURE 7 – INHIBIT SWITCH OR CONTACT
6.8 Inhibit Circuit Connection – The control can be stopped WIRED TO THE INHIBIT TERMINALS
and started with an Inhibit circuit (close to stop). Wire the
switch or contact to Terminals I1 and I2, as shown in Figure Terminal "I1"
I1 Terminal "I2" I1
7. When the switch or contact is closed, the motor will coast
to stop. When the switch or contact is opened, the motor
will accelerate to the Main Speed Potentiometer setting. I2 I2
An open collector (NPN) can be connected in lieu of a MIN MIN

switch or contact.

WARNING! The Inhibit Circuit is never to be used

! as a Safety Disconnect since it is not fail-safe. Use
Inhibit Switch or Contact
(Open to Run)
(Close to Stop)
Open Collector
(Off to Run)
(On to Stop)
only the AC line for this purpose.

17
 6.9 DC Tachometer Connection – A DC tachometer can be FIGURE 8 – DC TACHOMETER CONNECTION
(7 VOLTS PER 1000 RPM)
used for load regulation of 1% of the set speed. Note:
Jumper J2 must be set to the “T” position for
tachometer operation. Connect the tachometer Terminal "T" B

J2
as follows. T

Application Notes – 1. The tachometer input circuit is

designed for a 7 Volt or 50 Volt per 1000 RPM DC

PWR ON
tachometer used with an 1800 RPM motor. 2. Initially set
the IR Comp Trimpot fully counterclockwise. Once the Terminal "I2" +

tachometer is connected, the IR Comp Trimpot may be 7V

G
increased for additional speed stabilization. 1000

I2 -
DC Tachometer
6.9.1 Seven (7) Volt per 1000 RPM Tachometer –
Connect the tachometer positive lead (+) to Terminal
“T” and the negative lead (-) to Terminal
“I2”, as shown in Figure 8. FIGURE 9 – DC TACHOMETER CONNECTION (50
VOLTS PER 1000 RPM)
6.9.2 Fifty (50) Volt per 1000 RPM Tachometer –
Terminal "B"
Connect the tachometer positive lead (+) to Terminal B

J2
“B” and the negative lead (-) to Terminal “I2”, as
T
shown in Figure 9.

6.9.3 Other Tachometer Voltages – The tachometer

PWR ON
input circuit is designed for a 7 Volt or 50 Volt per
1000 RPM DC tachometer used with an 1800 RPM
+
motor. For a tachometer other than 7 Volts or 50
50V
Volts per 1000 RPM, or for a motor other than G
1000
1800 RPM, an external 1/2 Watt resistor I2 -
DC Tachometer
(RT) must be installed. Install RT in series with the
18
 tachometer. Connect one end of RT to Terminal “T”, FIGURE 10 – OTHER DC TACHOMETER
CONNECTION
connect the other end of RT to the tachometer pos-
itive lead (+), and connect the negative lead (-) to
Terminal “I2”. See Figure 10. B

J2
The value of RT (Ω) can be calculated using the fol- T
lowing formula: RT = (1.3 X VT X S) - 16000 Ω
Where “VT” is the tachometer voltage (in Volts per

PWR ON
1000 RPM) and “S” is the base speed of the motor RT
(in RPM).
+
Example: If a 20 Volt per 1000 RPM tachometer is
G
to be used with a 3600 RPM motor:
I2 -
RT = (1.3 X 20 X 3600) - 16000 = 77600 Ω DC Tachometer

Choose the closest 1/2 Watt resistor value, which is

75000 Ω (75 kΩ).

7 SETTING SELECTABLE JUMPERS

The control has selectable jumpers which must be set before it can be used. See Figure 1, on page 10, for the
location of jumpers.

7.1 AC Line Input Voltage Selection (Jumper J1 (Catalog No. BC142-5 and BC142-6)) – Jumper J1 is fac-
tory set to the “230” position for 208/230 Volt AC line input. For 115 Volt AC line input, set Jumper J1 to the
“115” position. See Figure 11, on page 20.

Notes:
1. Jumper J1 is installed on Catalog No. BC142-5 and BC142-6 only.

2. When Jumper J1 is set to the “115” position, Jumper J2 must be set to the “90” position
(or the “T position if using a tachometer).

19
 7.2 Motor Voltage and DC Tachometer Selection – FIGURE 11 – AC LINE INPUT VOLTAGE SELECTION
Jumper J2 is factory set to the “90” position on (JUMPER J1)
Catalog No. BC141, for 90 Volt DC motors, and set to J1 Set for
J1 Set for
the “180” position, on Catalog Nos. BC142, BC142-5 208/230 Volt AC Line Input
115 Volt AC Line Input
and BC142-6, for 180 Volt DC motors. To set Catalog (Factory Setting)
No. BC142, BC142-5 and BC142-6 for step-down

J1

J1
operation (208/230 Volts AC line input and 90 Volt DC
output), set Jumper J2 to the “90” position). To set the
control for tachometer connection, set Jumper J2 to
the “T” position (all models). See Figure 12.

Notes:
1. On Catalog No. BC141, the “180” position is not available on Jumper J2.
2. On Catalog No. BC142-5 and BC142-6, do not set the output voltage to 180 Volts DC when the AC line
input is set to 115 Volts.

FIGURE 12 – MOTOR VOLTAGE & DC TACHOMETER SELECTION (JUMPER J2)

Catalog No. BC141 Catalog Nos. BC142, BC142-5 and BC142-6
J2 Set for J2 Set for J2 Set for
J2 Set for J2 Set for
90 Volt Motor 180 Volt Motor 90 Volt Motor
Tachometer Tachometer
(Factory Setting) (Factory Setting) (Step-Down)

J2

J2

J2
J2

J2

8 AC LINE FUSING*
A 25 Amp AC line fuse is factory installed in the AC line fuse holder as shown in Figure 1, on page 10. It is
recommended that a 12 Amp AC line fuse be installed for motors rated 7.5 Amps DC or less. Fuses should be
normal blow ceramic 3AG, MDA, or equivalent. On domestic 230 Volt AC lines, separate branch circuit protection
* Fuse holders and fuses not supplied with BC142-5.
20
 for each line must be used. The optional Barrier Terminal Board (Catalog No. BC147) contains prewired AC line
and armature fuse holders, as described in Section 13.2, on page 28.

The AC Line Fuse protects the control against catastrophic failure. If the AC Line Fuse blows, the control is mis-
wired, the motor is shorted or grounded, or the control is defective.

Note: Fuse each AC line conductor that is not at ground potential.

9 PLUG-IN HORSEPOWER RESISTOR® & ARMATURE FUSE KIT*

The appropriate Plug-In Horsepower Resistor® and Armature Fuse are supplied as a prepackaged kit as shown
in Table 5, on page 22. Choose the Catalog No. containing the appropriate Plug-In Horsepower Resistor® and
Armature Fuse based on motor horsepower and voltage.
9.1 Plug-In Horsepower Resistor® – A Plug-In Horsepower Resistor® (supplied separately) must be installed
to match the control to the motor horsepower and voltage. Install the Plug-In Horsepower Resistor® as
shown in Figure 1, on page 10. Select the correct Plug-In Horsepower Resistor® as shown in Table 5, on
page 22.

Application Notes:
1. The Plug-In Horsepower Resistor® is used to calibrate the IR Compensation and Current Limit based on
motor horsepower and voltage. The Plug-In Horsepower Resistor® eliminates the need to recalibrate IR
Compensation and Current Limit in most applications.
2. Be sure the Plug-In Horsepower Resistor® is inserted completely into the mating sockets.

9.2 Armature Fuse* – It is recommended that an Armature Fuse (supplied separately) be installed in the arma-
ture fuse holder as shown in Figure 1, on page 10. Select the correct fuse as shown in Table 5, on page 22.
Fuses should be normal blow ceramic 3AG, MDA, or equivalent. The optional Barrier Terminal Board
(Catalog No. BC147) contains prewired AC line and armature fuse holders, as described in Section 13.2,
on page 28.

The Armature Fuse provides overload protection for the motor and control. The Armature Fuse required can
be calculated by multiplying the maximum DC Motor Current times 1.7.

* Fuse holders and fuses not supplied with BC142-5. 21

 TABLE 5 – PLUG-IN HORSEPOWER RESISTOR® & ARMATURE FUSE KIT SELECTION
90 - 130 Volt 180 Volt Approximate Plug-In Horsepower Plug-In Horsepower Armature
DC Motors DC Motors Motor Current Resistor® and Armature Resistor® Fuse Rating
(HP) (HP) (Amps DC) Fuse Kit Catalog No. Value (Ohms) (Amps)
1/100 1/50 .2 BR1000 1 .5
1/50 1/25 .3 BR0510 .51 .5
1/30 1/15 .33 BR0350 .35 .5
1/20 1/10 .5 BR0250 .25 .75
1/15 1/8 .8 BR0251 .25 1
1/12 1/6 .85 BR0180 .18 1.25
1/8 1/4 1.3 BR0100 .1 2
1/6 1/3 2 BR0101 .1 2.5
1/4 1/2 2.5 BR0050 .05 4
1/3 3/4 3.3 BR0035 .035 5
1/2 1 5 BR0025 .025 8
3/4 11⁄2 7.5 BR0015 .015 12
1* 2* 10 BR0010 .01 15
11⁄2* 3* 15 BR0006 .006 25

* Indicates an Auxiliary Heat Sink (Catalog No. BC143, or equivalent) must be used.

10 TRIMPOT ADJUSTMENTS
The control contains trimpots which have been factory set for most applications. Some applications may require
readjustment of the trimpots in order to tailor the control for a specific requirement. Readjust the trimpots as
described below. See Figure 1, on page 10, for the location of trimpots.

Warning! If possible, do not adjust trimpots with the main power applied. If adjustments are
!
made with the main power applied, an insulated adjustment tool must be used and safety
glasses must be worn. High voltage exists in this control. Electrocution can result if caution is not exer-
cised. Safety Warning, on page 6, must be read and understood before proceeding.

22
Note: In order for the IR Compensation and Current Limit settings to be correct, the FIGURE 13
ACCEL TRIMPOT RANGE
proper Plug-In Horsepower Resistor® must be installed for the particular motor and
input voltage being used. 5
See Section 9, on page 21.
3 8
10.1 Acceleration Trimpot (ACCEL) – The ACCEL Trimpot is provided to allow for 2
a smooth start over an adjustable time period each time the AC power is 0.2 10
applied or the Main Speed Potentiometer is adjusted to a higher speed. The (Factory Set to 2 Seconds)
ACCEL Trimpot has been factory set to 2 seconds, which is the amount of
time it will take for the motor to accelerate from zero speed to full speed. To
increase the acceleration time, rotate the ACCEL Trimpot clockwise. To FIGURE 14
decrease the acceleration time, rotate the ACCEL Trimpot counterclockwise. DECEL TRIMPOT RANGE
See Figure 13. 5
10.2 Deceleration Trimpot (DECEL) – The DECEL Trimpot controls the amount of
3 8
ramp-down time when the Main Speed Potentiometer is adjusted to a lower
2
speed. The DECEL Trimpot has been factory set to 2 seconds, which is the
0.2 10
amount of time it will take for the motor to decelerate from full speed to zero
(Factory Set to 2 Seconds)
speed. To increase the deceleration time, rotate the DECEL Trimpot clockwise.
To decrease the deceleration time, rotate the DECEL Trimpot counterclockwise.
See Figure 14. FIGURE 15
MIN TRIMPOT RANGE
Note: The deceleration time cannot be made less than the natural coast
time of the motor and actual load.
0
10.3 Minimum Speed Trimpot (MIN) – The MIN Trimpot sets the minimum
30
speed of the motor when the Main Speed Potentiometer is set fully coun-
terclockwise. The MIN Trimpot is factory set to 0 % of base motor speed. (Factory Set to 0 % of Base Speed)
To increase the minimum speed, rotate the MIN Trimpot clockwise. To
decrease the minimum speed, rotate the MIN Trimpot counterclockwise. See Figure 15.
23
 Note: Readjusting the MIN Trimpot will affect the maximum speed setting. Therefore, it is necessary to read-
just the MAX Trimpot if readjusting the MIN Trimpot. It may be necessary to repeat these adjustments until
both the minimum and maximum speeds are set to the desired levels.

10.4 Maximum Speed Trimpot (MAX) – The MAX Trimpot sets the maximum FIGURE 16
MAX TRIMPOT RANGE
speed of the motor when the Main Speed Potentiometer is set fully
clockwise. The MAX Trimpot is factory set to 100 % of base motor 100
speed. To increase the maximum speed, rotate the MAX Trimpot clock-
wise. To decrease the maximum speed, rotate the MAX Trimpot counter- 50 110
clockwise. See Figure 16.
(Factory Set to 100 % of Base Speed)
CAUTION! Do not set the maximum speed above the rated motor RPM
since unstable motor operation may occur.

10.5 Current Limit Trimpot (CL) – The CL Trimpot sets the current limit FIGURE 17
CL TRIMPOT RANGE
(overload), which limits the maximum current (torque) to the motor. The CL
also limits the AC line inrush current to a safe level during startup. The CL 150
Trimpot is factory set to 1.5 times the full load rating of the motor. To
increase the current limit, rotate the CL Trimpot clockwise. To decrease
the current limit, rotate the CL Trimpot counterclockwise. Some applica- 0 200
tions require a lower torque limiting value so as not to damage the process (Factory set to 150 % of Full Load)
material or the drive train. See Figure 17.

Note: The correct value Plug-In Horsepower Resistor® must be installed for the CL to operate properly.
Calibration of the CL Trimpot is normally not required when the proper Plug-In Horsepower Resistor® is
installed.

CAUTION! Adjusting the CL above 150% of motor rating can cause overheating and demagnetization
of some PM motors. Consult motor manufacturer.

24
 To Recalibrate the CL Trimpot:
1 Disconnect the AC power and wire a DC ammeter in series with either motor armature lead.
Note: If only an AC ammeter is available, wire it in series with either AC line input lead.
2 Set the Main Speed Potentiometer to approximately 30 - 50 % clockwise position.
3 Set the CL Trimpot fully counterclockwise. The CL LED will illuminate red.
4 Load the motor shaft in accordance with application requirements.
5 Apply power and rotate the CL Trimpot clockwise until the desired current reading is observed on the
ammeter. Factory Current Limit setting is 1.5 times the full load rating of the motor (with a DC ammeter
wired in series with the motor armature). If using an AC ammeter wired in the AC line input, the factory
Current Limit setting will read 0.75 times the full load rating of the motor.

Note: On cyclical loads, it may be normal for the CL LED to momentarily flash.

10.6 IR Compensation Trimpot (IR) – The IR Trimpot sets FIGURE 18 – IR TRIMPOT RANGE
the amount of compensating voltage required to keep
the motor speed constant under changing loads. If
the load does not vary substantially, the IR Trimpot 3, 6
may be set to a minimum level (approximately 1/4 of 0 24, 48
full clockwise rotation). The IR Trimpot is factory set
(Factory set to 3 Volts DC for controls with 90 Volt DC Output)
to provide 3 Volts of compensation for controls with (Factory set to 6 Volts DC for controls with 180 Volt DC Output)
90 Volt DC output and 6 Volts of compensation for
controls with 180 Volt DC output. To increase the
amount of compensating voltage, rotate the IR Trimpot clockwise. To decrease the amount of compensating
voltage, rotate the IR Trimpot counterclockwise. See Figure 18.

Notes:
1. The correct value Plug-In Horsepower Resistor® must be installed for the IR Compensation to operate
properly. Calibration of the IR Trimpot is normally not required when the proper Plug-In Horsepower
Resistor® is installed. 25
 2. Excessive IR Compensation will cause the motor to become unstable, which causes cogging.

3. For tachometer feedback applications, set the IR Trimpot fully counterclockwise. See Section 6.9, on
page 18.

To Recalibrate the IR Trimpot:

1 Set the IR Trimpot to approximately 25 % rotation.

2 Run the motor unloaded at approximately 1/3 speed and record the RPMs.

3 Run the motor with the maximum load and adjust the IR Trimpot so that the motor speed under load
equals the unloaded speed recorded in step 2.

4 Remove the load and recheck the RPMs.

5 If the unloaded RPM has changed, repeat steps 2 - 4 for more exact regulation. The control is now
compensated to provide minimal speed change due to changing loads.

11 DIAGNOSTIC LEDs
The control is designed with PC board mounted LEDs to display the control’s operational status. See Figure 1, on
page 10, for the location of the LEDs.

11.1 Power On (PWR ON) – The PWR ON LED will illuminate green when the AC line is applied to the control.

11.2 Current Limit (CL) – The CL LED will illuminate red when the control goes into current limit, indicating that
the current limit set point has been reached (set by the CL Trimpot). See Section 10.5, on page 24.

12 SWITCHING CIRCUITS
12.1 AC Line Switching – The control can be turned “on” and “off” using the AC line (no waiting time is
required). Auto-Inhibit® circuitry automatically resets critical components each time the AC line is interrupted.
This, along with Acceleration Start and CL, provides a smooth start each time the AC line is applied.
26
 WARNING! Do not disconnect and reconnect the motor armature with the AC line applied or cata-
! strophic failure will result. See Section 12.2.

12.2 Armature Switching and Dynamic Braking – If the armature is to be disconnected and reconnected with
the AC power applied, connect a relay FIGURE 19 – TYPICAL DYNAMIC BRAKE CIRCUIT CONNECTION
(or contactor) and a brake resistor (RB) in
the armature circuit. The Inhibit Circuit Speed Control
N.O.
must be simultaneously activated when A+
+
braking. Wire a double pole double throw L1
N.C.
Motor
(DPDT) mechanically ganged switch to AC Line Input M
Armature
L2 RB
the Inhibit Terminals and the relay (or -
contactor) coil, as shown in Figure 19. I1 I2 A-
Run Double Pole Double Throw
When the switch is in the “Brake” posi- Mechanically Ganged Switch
Brake
tion, the relay is deenergized and allows
the motor voltage, through the N.C. con- Run
tact, to be dissipated through RB and Brake Relay or
Contactor Coil
dynamically brake the motor.
Simultaneously, the Inhibit is activated
and the control output is electronically
“extinguished”, which eliminates arcing.

When the switch is in the “Run” position, the N.C. contact opens, the N. O. contact closes, the Inhibit is
deactivated, and the motor begins to accelerate (according to the setting of the ACCEL Trimpot) to the Main
Speed Potentiometer setting.

WARNING! The Inhibit Circuit (I1, I2) is never to be used as a Safety Disconnect since it is not
! fail-safe. Use only the AC line for this purpose.

27
13 OPTIONAL ACCESSORIES
13.1 Auxiliary Heat Sink (Catalog No. BC143) – Doubles the horsepower rating of the control.

13.2 Barrier Terminal Board (Catalog No. BC147) – Converts the quick-connect terminals of the control to a
barrier terminal block. Contains PC board mounted line and armature fuse holders (fuses supplied separate-
ly). Plugs onto the quick-connect terminals of the control.

13.3 Signal Isolator (Catalog No. BC152) – Provides isolation between non-isolated signal sources and the
control. Plugs onto the quick-connect terminals of the control.

13.4 Dial Plate and Knob Kit (Catalog No. BC149) – Provides indication of the Main Speed Potentiometer
position (0 - 100 %).

13.5 DIN Rail Mounting Kit (Catalog No. BC218)

13.6 Current Sensing Overload Protector (Catalog No. BC146) – Provides overload current sensing and pro-
tection of DC motors and speed controls rated 1/8 - 3 HP by sensing armature current. Operates on 115 or
230 Volt AC line input.

13.7 RFI Filter (Catalog No. BC24-LF) – Provides RFI and EMI suppression. Rated 24 Amps at 230 Volts AC,
50/60 Hz. Complies with CE Directive 89/336/EEC (EN55022 and/or EN55011) relating to the EMC Class A
Industrial Standard. Remote mountable.

28
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PHONE: 586-978-9800
COLORADO
INDIANA FAX: 586-978-9969 NORTH CAROLINA
DENVER
INDIANAPOLIS GREENSBORO
2520 W BARBERRY PLACE GRAND RAPIDS
5525 W. MINNESOTA STREET 1220 ROTHERWOOD ROAD
DENVER, CO 80204 668 3 MILE ROAD NW
INDIANAPOLIS, IN 46241 GREENSBORO, NC 27406
PHONE: 303-623-0127 GRAND RAPIDS, MI 49504
PHONE: 317-246-5100 P O BOX 16500
FAX: 303-595-3772 PHONE: 616-785-1784
FAX: 317-246-5110 GREENSBORO, NC 27416
FAX: 616-785-1788
800-428-4141 PHONE: 336-272-6104
FAX: 336-273-6628

29
OHIO TENNESSEE INTERNATIONAL SALES
CINCINNATI MEMPHIS FORT SMITH, AR
2929 CRESCENTVILLE ROAD 4000 WINCHESTER ROAD P.O. BOX 2400
WEST CHESTER, OH 45069 MEMPHIS, TN 38118 FORT SMITH, AR 72902
PHONE: 513-771-2600 PHONE: 901-365-2020 PHONE: 479-646-4711
FAX: 513-772-2219 FAX: 901-365-3914 FAX: 479-648-5895

CLEVELAND TEXAS CANADA

8929 FREEWAY DRIVE HOUSTON EDMONTON, ALBERTA
MACEDONIA, OH 44056 4647 PINE TIMBERS 4053-92 STREET
PHONE: 330-468-4777 SUITE # 135 EDMONTON, ALBERTA T6E 6R8
FAX: 330-468-4778 HOUSTON, TX 77041 PHONE: 780-434-4900
PHONE: 713-895-7062 FAX: 780-438-2600
OKLAHOMA FAX: 713-690-4540
TULSA OAKVILLE, ONTARIO
2 EAST DAWES DALLAS 2750 COVENTRY ROAD
BIXBY, OK 74008 3040 QUEBEC OAKVILLE, ONTARIO L6H 6R1
PHONE: 918-366-9320 DALLAS, TX 75247 PHONE: 905-829-3301
FAX: 918-366-9338 PHONE: 214-634-7271 FAX: 905-829-3302
FAX: 214-634-8874
OREGON MONTREAL, QUEBEC
PORTLAND UTAH 1844 WILLIAM STREET
20393 SW AVERY COURT SALT LAKE CITY MONTREAL, QUEBEC H3J 1R5
TUALATIN, OR 97062 2230 SOUTH MAIN STREET PHONE: 514-933-2711
PHONE: 503-691-9010 SALT LAKE CITY, UT 84115 FAX: 514-933-8639
FAX: 503-691-9012 PHONE: 801-832-0127
FAX: 801-832-8911 VANCOUVER,
PENNSYLVANIA BRITISH COLUMBIA
PHILADELPHIA WISCONSIN 1538 KEBET WAY
1035 THOMAS BUSCH MILWAUKEE PORT COQUITLAM, BC V3C 5M5
MEMORIAL HIGHWAY 2725 SOUTH 163RD STREET PHONE 604-421-2822
PENNSAUKEN, NJ 08110 NEW BERLIN, WI 53151 FAX: 604-421-3113
PHONE: 856-661-1442 PHONE: 262-784-5940
FAX: 856-663-6363 FAX: 262-784-1215 WINNIPEG, MANITOBA
54 PRINCESS STREET
PITTSBURGH WINNIPEG, MANITOBA R3B 1K2
616H BEATTY ROAD PHONE: 204-942-5205
MONROEVILLE, PA 15146 FAX: 204-956-4251
PHONE: 412-380-7244
FAX: 412-380-7250
30
AUSTRALIA INDIA MIDDLE EAST & NORTH AFRICA
UNIT 3, 6 STANTON ROAD 14, COMMERCE AVENUE VSE INTERNATIONAL CORP.
SEVEN HILLS, NSW 2147, MAHAGANESH COLONY 3233 NORTH ARLINGTON HEIGHTS
AUSTRALIA PAUD ROAD SUITE 100W
PHONE: (61) (2) 9674 5455 PUNE - 411 038 ARLINGTON HEIGHTS, IL 60004
FAX: (61) (2) 9674 2495 MAHARASHTRA, INDIA PHONE: 847 590 5547
PHONE: 91 20 25 45 95 30
UNIT 8, 5 KELLETTS ROAD FAX: 91 20 5 4 95 30 SINGAPORE
ROWVILLE, VICTORIA, 3178 51 KAKI BUKIT ROAD 2
AUSTRALIA ITALY K B WAREHOUSE COMPLEX
PHONE: (61) (3) 9753 4355 BALDOR ASR AG SINGAPORE 417863
FAX: (61) (3) 9753 4366 SUCCURSALE DI MENDRISIO PHONE: (65) 6 744 2572
VIA BORROMINI, 20A FAX: (65) 6 747 1708
América DEL SUR CH-6850 MENDRISIO
APTDO. 9109 0818 ZONA 6 SWITZERLAND SWITZERLAND
BETHANIA, PHONE: 41 91 640 9952 POSTFACH 73
CIUDAD DE PANAMÁ, PANAMÁ FAX: 41 91 630 2633 SCHUTZENSTRASSE 59
PHONE: +507 261-5347 CH-8245 FEUERTHALEN
FAX: +507 261-5355 JAPAN SWITZERLAND
DIA BLDG 802, PHONE: (41) (52) 6474700
CENTRO AMÉRICA Y CARIBE 2-21-1 TSURUYA-CHO, FAX: (41) (52) 6592394
RESIDENCIAL PINARES DE SUIZA KANAGAWA-KU
POL. 15 #44, YOKOHAMA, 221-0835, JAPAN TAIWAN
NVA. SAN SALVADOR, EL SALVADOR PHONE: 81-45-412-4506 4F, NO. 25, SEC. 1,
PHONE: +503 2288-1519 FAX: 81-45-412-4507 TUNHUA S ROAD,
FAX: +503 2288-1518 TAIPEI 10557, TAIWAN, R.O.C.
KOREA PHONE: (886-2) 2577-4352
CHINA ROOM 208-37 FAX: (886-2) 2577-4157
SHANGHAI JIAHUA BUSINESS CENTER INCHEON INDUSTRIAL GOODS
ROOM NO. A-8421 CIRCULATING CENTER UNITED KINGDOM
808 HONG QIAO ROAD SONGHYEON 3-DONG, DONG-GU 6 BRISTOL DISTRIBUTION PARK
SHANGHAI 200030 INCHEON. KOREA, 401-705 HAWKLEY DRIVE
PHONE: 86-21-64473060 PHONE: 82 32 588 3253 BRISTOL BS32 0BF U.K.
FAX: 86-21-64078620 FAX: 82 32 588 3254 PHONE: 44 1454 859000
FAX: 44 1454 8590019
GERMANY MÉXICO
DIESELSTRASSE 22 KM. 2.0 BLVD. AL AEROPUERTO
D-85551 KIRCHHEIM LEÓN 37545, GUANAJUATO,
MUNICH, GERMANY MÉXICO
PHONE: (49) (89) 90508 0 PHONE: 52 477 761 2030
FAX: (49) (89) 90508 492 FAX: 52 477 761 2010 31
 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 guaran-
tee 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 manu-
facture or sale. (Some states do not allow the exclusion or limitation of incidental or consequentialdamages, 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 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

P.O. Box 2400
Ft. Smith, AR 72902-2400
(479) 646-4711
Fax (479) 648-5792

(A40249) – Rev. B – 10/2008