SCR DC MOTOR CONTROL

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

Installation and Operation Manual

07/11 MN704
 Table of Contents
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Quick-Start Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 AC Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Jumper Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 AC Line Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Plug-In Horsepower Resistor® and Armature Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 Trimpot Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Diagnostic LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.9 Optional Auxiliary Heat Sink (Catalog No. BC143). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Acceleration Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Limitation In Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Armature Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Step-Down Transformer and AC Line Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 AC Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Permanent Magnet (PM) Motor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Motor Field Connection (Shunt Wound Motors Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.6 Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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 5.7 Enable Circuit Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.8 Inhibit Circuit Connection . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.9 DC Tachometer Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6. Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 AC Line Input Volage Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Motor Voltage and DC Tachometer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7. AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8. Plug-In Horsepower Resistor® and Armature Fuse Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Plug-In Horsepower Resistor®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.2 Armature Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.1 Acceleration Trimpot (ACCEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.2 Deceleration Trimpot (DECEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.3 Minimum Speed Trimpot (MIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.4 Maximum Speed Trimpot (MAX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.5 Current Limit Trimpot (CL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.6 IR Compensation Trimpot (IR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.1 Power On (PWR ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.2 Current Limit (CL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11. Switching Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.1 AC Line Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.2 Armature Switching and Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12. Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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SAFETY NOTICES
ELECTRICAL HAZARD WARNING - Statement indicates a potentially hazardous situation.
Failure to observe this warning could result in electrical shock or electrocution.

OPERATIONAL HAZARD WARNING - Statement indicates a potentially hazardous situation.

Failure to observe this warning could result in serious injury or death.

Note - Additional information that is not critical to the installation or operation.

WARNING! This product should be installed and serviced by a qualified technician,

electrician, or electrical maintenance person familiar with its operation and the
hazards involved. Proper installation, which includes wiring, mounting in proper
enclosure, fusing and 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 electric motors, switches, coils, solenoids, and/
or relays. 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.

WARNING! Follow all instructions carefully.

WARNING! Read all safety notices before attempting to use this control. Wire control in
accordance with the National Electrical Code requirements and other local
codes that may apply. Fuse each conductor which is not at ground potential.
Do not fuse neutral or grounded conductors.

WARNING! Do not use this drive in an explosive environment. Be sure the control is
operated within its ratings.

WARNING! Disconnect the main power before making connections to the control.
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WARNING! If possible, do not adjust trimpots with main power on. 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.

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.

WARNING! Do not disconnect and reconnect the motor armature with the AC line applied
or catastrophic failure will occur.

WARNING! The rated AC line voltage (115, 208/230) of the control must match the actual
AC line input voltage.

WARNING! Do not earth ground any input terminals.

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 his purpose.

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

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

This product complies with all CE directives pertinent at the time of manufacture.
Contact your local Baldor District Office for Declaration of Conformity. Installation of a
CE approved RFI filter is required. Additional shielded motor cable and/or AC line
cables may be required along with a signal isolator.

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1. QUICK-START INSTRUCTION
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.
Note: A Plug-In Horsepower Resistor® and Armature Fuse must be installed in order for this product to
operate. Fuse holders and fuses not supplied with BC142-5.

Fuse Plug-In Horsepower

Resitor®

1.1 AC Line Connection - Wire the AC line to Terminals “L1” (Line Fuse)* and “L2”.
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 are 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).
Notes: 1. The rated AC line voltage (115, 208/230) of the control must match the actual AC line input v
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-”.

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

1.5 AC line Fusing* – A 25 Amp AC line fuse is factory installed in the AC Line Fuse Holder. 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.

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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 in accordance with Table 8-1.

1.7 Trimpot Settings – All trimpots have been factory set for most applications. The trimpots may be
readjusted. See Section 9 - Trimpot Adjustments.

1.8 Diagnostic LEDs – After power has been applied to the control, observe the LEDs to verify proper
control operation. See Section 10 - Diagnostic LED’s.

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.

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2. 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 protects the SCR power bridge against direct shorts1. The reliability of the control is further
enhanced with the use of high-surge, 25 Amp SCRs, and AC line and armature fusing2,3. 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 controls with 90 Volt DC output and 3 HP for controls with 180
Volt DC output, by the use of an Auxiliary Heat Sink4. Catalog Nos. BC142, BC142-5 and BC142-6 also
allow operation of 90 Volt DC motors when used on 208/230 Volt AC line input5.
The versatility of the control is confirmed by its extensive list of standard features, such as: selectable
armature or 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 control 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 controls. The control is supplied with a factory installed 25 Amp AC line
fuse, a 5 kΩ 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.
3. Plug-In Horsepower Resistor® and Armature Fuse Kit supplied separately (Fuse holders and fuses not
supplied with BC142-5).
4. Catalog No. BC143.
5. Step-down operation.
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2.1 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 (except BC142-5, supplied without fuse holders).

13. Main Speed Potentiometer (5kΩ)

14. SMT construction

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 Table 2-1 Electrical Ratings
Rating without Auxiliary Heat Sink Rating with Auxiliary Heat Sink Field
AC Line
Motor Max. Voltage
Voltage Max. Max. DC Max.
Voltage DC (Volts
Catalog (±15%, AC Line Load Max. AC Line Max.
(Volts Load DC)
Number 50/60Hz) Current Current Horsepower Current Horsepower
DC) Current (1.13
(Volts (RMS (Avg. (HP (kw)) (RMS (HP (kw))
(Avg. Amps
AC) Amps) Amps) Amps)
Amps) Max)
BC141 115 0-90 12 8 .75 (.6) 24 16 1.5 (1.1) 50, 100
0-180 12 8 1.5 (1.1) 24 16 3 (2.3) 100, 200
BC142 230
0-90* 12 8 .75 (.6) 24 16 1.5 (1.1) 100
115 0-90 9 6 .75 (.6) 18 12 1.5 (1.1) 50, 100
BC142-5 0-180 9 6 1.5 (1.1) 18 12 3 (2.3) 100, 200
230
0-90* 9 6 .75 (.6) 18 12 1.5 (1.1) 100
115 0-90 12 8 .75 (.6) 24 16 1.5 (1.1) 50, 100
BC142-6 0-180 12 8 1.5 (1.1) 24 16 3 (2.3) 100, 200
230
0-90* 12 8 .75 (.6) 24 16 1.5 (1.1) 100

* Step-down operation.

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 Table 2-2 General Performance Specifications
Factory
Description Specification
Setting
Speed Range (Ratio) 50:1 —
Armature Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (%
1 —
Base Speed)
Tachometer Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (%
1 —
Set Speed)
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
0 – 24, 48 3, 6
Output) (Volts DC)
Maximum Operating Ambient Temperature at Full Load - °C / °F 40 / 104 —

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.

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 Figure 2-1 Control Layout & General Connection Diagram (Catalog No. BC142-6 Shown)

R ed Plug-In
Horsepower R esistor®
B lue S upplied S eparately

F-
L1 A+

25 Amp* DEC EL L2
Line Fuse Armature Fuse*
Factory Installed F+ S upplied S eparately

B
J2
T
CL
AC C EL Plug-In Horsepower
R esistor® and
Enable S witch J1
Armature Fuse Kit

PWR ON
(C lose to R un) A-
(Open to S top)
supplied separately
P2 S ee S ection 9.
C ONN1
EN

I1

P3 P1

I2
MAX MIN CL IR

+
+ +
High
Wiper 7V
M G
Low 1000
- - -
AC Line Main S peed Potentiometer Inhibit S witch Motor Field Motor Armature DC Tach-Generator
Input (Front View) (Open to R un) (S hunt Motors Only) (S et J 2 to "T" Position)
(C lose to S top)
* Fuse holders and fuses not supplied with B C 142-5.

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 Figure 2-2 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
(3 PLACES)

M O U N T IN G " D "
3.00 4.30
3.11
76.2 109 3/8-32 (79.0)
ANTI- BUSHING
FUSE HOLDER & FINGER-SAFE ROTATION

2 S LOTS
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
24.1
P1 .44 P2 1.38
19.1 44.5 16.3 6.4
1.75 .18 1.25 11.1 34.9
44.5 4.6 31.8

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3. application information
3.1 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.

3.2 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.

3.3 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.

3.4 Limitation In Use

The controls are designed for use on machine applications.

3.5 Armature Switching

Do not wire the control for armature switching without taking proper precautions.

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.

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3.6 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.

4. 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 hazardous 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 40°C (104°F). If the optional Auxiliary Heat Sink is used, mount the control in
such a manner that there is unrestricted air flow through the heat sink cooling fins.

15
5. wiring instructions
WARNING! Read the Safey Warnings before operating this control. Disconnect the main power
before 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 5-1 Minimum Supply Wire Size Requirements

Maximum 90 - 130 Volt 180 Volt DC Minimum Wire Size (Cu)

Motor Current DC Motors 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.

5.1 AC Line Connection

Wire the AC line to Terminals “L1” (Line Fuse)* and “L2”. 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.

16
 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.

5.2 Ground Connection

Connect the ground wire (earth) to the control chassis.

5.3 Permanent Magnet (PM) Motor Connection

Wire the motor armature positive lead (+) to Terminal “A+” (Armature Fuse*) and the negative lead (-)
to Terminal “A-”. On Catalog Nos. BC142, BC142-5 and BC142-6, be sure Jumper J2 is set to the
corresponding motor voltage. Be sure the correct Plug-In Horsepower Resistor® is installed.
* Fuse holders and fuses not supplied with BC142-5.

5.4 Motor Field Connection (Shunt Wound Motors Only)

5.4.1 Full Voltage Field

Wire the field positive (+) lead to Terminal “F+” and the field negative lead (-) to Terminal “F-”.

5.4.2 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).

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.

17
 Table 5-2 Field Connection (Shunt Wound Motors Only)
AC Line Input Voltage Armature Voltage Field Voltage Terminal
Catalog No.
(Volts AC) (Volts DC) (Volts DC) Connections
0 -90 100 F+, F-
BC141 115
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
*Step-down operation.

5.5 Remote Main Speed Potentiometer Connection

The control is supplied with a Main Speed Potentiometer to control motor speed. Connect the low side of
the potentiometer to Terminal “P1”. Connect the wiper of the potentiometer to Terminal “P2”. Connect the
high side of the potentiometer to Terminal “P3”.
Figure 5-1 Remote Main Speed Potentiometer Connection
Terminal "P3"
P2 Terminal "P2"
C ONN1
EN

P3 P1
Terminal "P1"

MAX

High
Wiper
Low

Main Speed Potentiometer

(Front View)

18
5.6 Voltage Following Connection
An isolated 0 - 9 Volt DC analog signal input can be used to control motor speed in lieu of the Main Speed
Potentiometer. The control output voltage will linearly follow the analog signal input. The signal input must
be isolated from the AC line. Connect the signal input positive lead (+) to Terminal “P2” and the negative
lead (-) to Terminal “P1”. The source impedance of the signal input should be 10 kΩ or less. The MAX
Trimpot is not operational in voltage following mode. Set the MIN Trimpot, on the control, to zero output
(full counterclockwise rotation) and use auxiliary trimpots, if necessary, to scale and/or limit the input
voltage.
Figure 5-2 Voltage Following Connection

P2 Terminal "P2"

C ONN1
EN
P3 P1
Terminal "P1"

MAX
+

0 - 9 Volts DC
V
(Isolated)
-

CAUTION! Do not earth ground any input terminals.

Notes:
1. If an isolated signal input is not available, or if using a 4 - 20 mA DC signal input, install the optional
plug-on Catalog No. BC152 Signal Isolator. This will also allow direct connections to process
controllers and microprocessors.
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”.

19
5.7 Enable Circuit Connection
The control can be started and stopped with an Enable Circuit (close to run), as described below.

WARNING! Opening the Enable Circuit will not stop the drive if the Min Trimpot and/or the
Main Input Speed Signal is not at Zero Setting.

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.

5.7.1 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). 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.
Figure 5-3 Enable Switch Or Contact Wired To The Enable Connector

Remove this jumper to install

the Mating Connector
C ONN1

C ONN1

C ONN1
EN

EN

EN
Enable Switch
Open Collector
or Contact
(On to Run)
(Close to Run)
(Off to Stop)
(Open to Stop)
MAX MAX MAX

Notes:
1. To use the Enable Circuit, remove the jumper that is factory installed on CONN1.
2. The deceleration time can only be made longer than the normal coasting time of the load.
20
5.7.2 Enable Switch or Contact Wired to the Main Speed Potentiometer
Connect the switch or contact in series with the Main Speed Potentiometer high side and Terminal “P3” on
the control. 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 setting. When the switch or contact
is opened, the motor will decelerate to the MIN Trimpot setting (factory set to 0 Volts DC). If the MIN
Trimpot is set to other than 0 Volts DC, the motor will run at the MIN speed setting when the switch or
contact is opened. An open collector (PNP) can be connected in lieu of a switch or contact.
Notes:
1. The deceleration time can only be made longer than the normal coasting time of the load.
2. If the BC152, Signal Isolator option board is installed onto the BC141, or BC142 control, the ENABLE
circuit will not funciton as described. If an ENABLE feature is required for the application, connect a
N.O. (normally open), contact or switch between the speed adjust potentiometer wiper lead, or voltage
following input signal, and the SIG terminal of TB1. When the contact or switch is closed, the motor
will accelerate to set speed. When the contact or switch is opened, the motor will decelerate to zero
speed at a rate set with the DECEL trimpot.
Figure 5-4 Enable Switch Or Contact Wired To The Main Speed Potentiometer

Terminal "P3"
P2 Terminal "P2" P2
C ONN1

C ONN1
EN

EN
P3 P1 P3 P1
This jumper must Terminal "P1"
be installed
MAX MAX

Enable Switch or Contact Open Collector

(Close to Run) (On to Run)
(Open to Stop) (Off to Stop)
High High
Wiper Wiper
Low Low

Main Speed Potentiometer Main Speed Potentiometer

(Front View) (Front View)

21
5.8 Inhibit Circuit Connection
The control can be stopped and started with an Inhibit Circuit (close to stop). Wire the switch or contact to
Terminals I1 and I2. 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. An open collector
(NPN) can be connected in lieu of a switch or contact.

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

Figure 5-5 Inhibit Switch Or Contact Wired To The Inhibit Terminals

Terminal "I1"
I1 Terminal "I2" I1

I2 I2
MIN MIN

Inhibit Switch or Contact Open Collector

(Open to Run) (Off to Run)
(Close to Stop) (On to Stop)

5.9 DC Tachometer Connection

A DC tachometer can be 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 as
follows.

Application Notes –
1. The tachometer input circuit is designed for a 7 Volt or 50 Volt per 1000 RPM DC tachometer used with
an 1800 RPM motor.
2. Initially set the IR Comp Trimpot fully counterclockwise. Once the tachometer is connected, the IR Comp
Trimpot may be increased for additional speed stabilization.
22
5.9.1 Seven (7) Volt per 1000 RPM Tachometer
Connect the tachometer positive lead (+) to Terminal “T” and the negative lead (-) to Terminal “I2”.
Figure 5-6 DC Tachometer Connection (7 Volts Per 1000 RPM)

Terminal "T" B

J2
T

PWR ON
Terminal "I2" +

7V
G
1000

I2 -
DC Tachometer

5.9.2 Fifty (50) Volt per 1000 RPM Tachometer

Connect the tachometer positive lead (+) to Terminal “B” and the negative lead (-) to Terminal “I2”.
Figure 5-7 DC Tachometer Connection (50 Volts Per 1000 RPM)

Terminal "B "

B
J2

T
PWR ON

50V
G
1000

I2 -
DC Tachometer

23
5.9.3 Other Tachometer Voltages
The tachometer 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 Volts per 1000 RPM, or for a motor other than
1800 RPM, an external 1/2 Watt resistor (RT) must be installed. Install RT in series with the tachometer.
Connect one end of RT to Terminal “T”, connect the other end of RT to the tachometer positive lead (+),
and connect the negative lead (-) of the tachometer to Terminal “I2”.

The value of RT Ω can be calculated using the following formula: RT = (1.3 X VT X S) - 16000 Ω
Where “VT” is the tachometer voltage (in Volts per 1000 RPM) and “S” is the base speed of the motor (in
RPM).
Example: If a 20 Volt per 1000 RPM tachometer is to be used with a 3600 RPM motor:
RT = (1.3 X 20 X 3600) - 16000 = 77600 Ω
Choose the closest 1/2 Watt resistor value, which is 75000 Ω (75 kΩ).

Figure 5-8 Other DC Tachometer Connection

J2
T PWR ON

RT

I2 -
DC Tachometer

24
6. SETTING SELECTABLE JUMPERS
The control has selectable jumpers which must be set before it can be used.

6.1 J1, AC Line Input Voltage Selection (Catalog No. BC142-5 and BC142-6 only)
Jumper J1 is factory 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.
Notes:
1. 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).

Figure 6-1 AC Line Input Voltage Selection (Jumper J1)

J1 Set for
J1 Set for
208/230 Volt AC Line Input
115 Volt AC Line Input
(Factory Setting)

J1

J1
6.2 J2, Motor Voltage and DC Tachometer Selection
Jumper J2 is factory set to the “90” position on Catalog No. BC141, for 90 Volt DC motors, and set to the
“180” position, on Catalog Nos. BC142, BC142-5 and BC142-6, for 180 Volt DC motors. To set Catalog
No. BC142, BC142-5 and BC142-6 for step-down 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).

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.

25
 Figure 6-2 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
7. AC LINE FUSING*
A 25 Amp AC line fuse is factory installed in the AC line fuse holder. 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 for each line must be used. The optional
Barrier Terminal Board (Catalog No. BC147) contains prewired AC line and armature fuse holders.

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

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

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

26
8. PLUG-IN HORSEPOWER RESISTOR® & ARMATURE FUSE KIT*
The appropriate Plug-In Horsepower Resistor® and Armature Fuse are supplied as a prepackaged kit.
Choose the Catalog No. containing the appropriate Plug-In Horsepower Resistor® and Armature Fuse
based on motor horsepower and voltage in accordance with values shown in Table 8-1.

8.1 Plug-In Horsepower Resistor®

The 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® in accordance with Figure 2-1.

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.

8.2 Armature Fuse*

It is recommended that an Armature Fuse (supplied separately) be installed in the armature fuse holder.
Select the correct fuse. 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. 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.

27
 Table 8-1 Plug-In Horsepower Resistor® & Armature Fuse Kit Selection
90 -130 180 Volt Plug-In Horsepower Plug-In Armature
Approximate
Volt DC Resistor® and Horsepower Fuse
Motor Current
DC Motors Motors Armature Resistor® Rating
(Amps DC)
(HP) (HP) 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.

28
9. 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.

WARNING! If possible, do not adjust trimpots with main power on. 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.

Note: In order for the IR Compensation and Current Limit settings to be correct, the proper Plug-In
Horsepower Resistor® must be installed for the particular motor and input voltage being used.

9.1 Acceleration Trimpot (ACCEL)

The ACCEL Trimpot is provided to allow for a smooth start over an adjustable time period each time the AC
power is applied or the Main Speed Potentiometer is adjusted to a higher speed. The 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 decrease
the acceleration time, rotate the ACCEL Trimpot counterclockwise.

Figure 9-1 ACCEL Trimpot Range

3 8
2
0.2 10
(Factory Set to 2 Seconds)

29
9.2 Deceleration Trimpot (DECEL) Figure 9-2 DECEL Trimpot
The DECEL Trimpot controls the amount of ramp-down time when the Main Range
Speed Potentiometer is adjusted to a lower speed. The DECEL Trimpot
has been factory set to 2 seconds, which is the amount of time it will take 5
for the motor to decelerate from full speed to zero speed. To increase the
3 8
deceleration time, rotate the DECEL Trimpot clockwise. To decrease the
deceleration time, rotate the DECEL Trimpot counterclockwise. 2
0.2 10
Note: The deceleration time cannot be made less than the natural coast time
of the motor and actual load. (Factory Set to 2 Seconds)

9.3 Minimum Speed Trimpot (MIN)

The MIN Trimpot sets the minimum speed of the motor when the Main Figure 9-3 MIN Trimpot
Speed Potentiometer is set fully counterclockwise. The MIN Trimpot is Range
factory set to 0 % of base motor speed. To increase the minimum speed,
rotate the MIN Trimpot clockwise. To decrease the minimum speed, rotate
the MIN Trimpot counterclockwise. 0
Note: Readjusting the MIN Trimpot will affect the maximum speed setting. 30
Therefore, it is necessary to readjust the MAX Trimpot if readjusting (Factory Set to 0 % of Base Speed)
the MIN Trimpot. It may be necessary to repeat these adjustments
until both the minimum and maximum speeds are set to the desired
levels.

9.4 Maximum Speed Trimpot (MAX) Figure 9-4 Max Trimpot

The MAX Trimpot sets the maximum speed of the motor when the Main Range
Speed Potentiometer is set fully clockwise. The MAX Trimpot is factory set
100
to 100 % of base motor speed. To increase the maximum speed, rotate the
MAX Trimpot clockwise. To decrease the maximum speed, rotate the MAX
Trimpot counterclockwise. 50 110
(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.
30
9.5 Current Limit Trimpot (CL)
Figure 9-5 CL Trimpot Range
The CL Trimpot sets the current limit (overload), which limits the maximum
current (torque) to the motor. The CL also limits the AC line inrush current 150
to a safe level during startup. The CL 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 0 200
counterclockwise. Some applications require a lower torque limiting value
so as not to damage the process material or the drive train. (Factory set to 150 % of Full Load)

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.

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.
4. Load the motor shaft in accordance with application requirements.
5. Apply power and the CL LED will illuminate red. 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.

31
9.6 IR Compensation Trimpot (IR)
The IR Trimpot sets 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 may be set to a minimum
level (approximately 1/4 of full clockwise rotation). The IR Trimpot is factory set to provide 3 Volts of
compensation for controls with 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.
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.
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.

Figure 9-6 IR Trimpot Range

3, 6
0 24, 48
(Factory set to 3 Volts DC for controls with 90 Volt DC Output)
(Factory set to 6 Volts DC for controls with 180 Volt DC Output)

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.
32
10. DIAGNOSTIC LEDs
The control is designed with PC board mounted LEDs to display the control’s operational status.

10.1 Power On (PWR ON)

The PWR ON LED will illuminate green when the AC line is applied to the control.

10.2 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).

11. SWITCHING CIRCUITS

11.1 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.

WARNING! Do not disconnect and reconnect the motor armature with the AC line applied or
catastrophic failure will result.

11.2 Armature Switching and Dynamic Braking - If the armature is to be disconnected and
reconnected with the AC power applied, connect a relay (or contactor) and a brake resistor (RB) in the
armature circuit. The Inhibit Circuit must be simultaneously activated when braking. Wire a double pole
double throw (DPDT) mechanically ganged switch to the Inhibit Terminals and the relay (or contactor) coil.

When the switch is in the “Brake” position, the relay is deenergized and allows the motor voltage, through
N.C. contact, to be dissipated through RB and dynamically brake the motor. Simultaneously, the inhibit is
activated and the control output is electronically “extinguished”, which eliminates arcing.

33
 Figure 11.1 Typical Dynamic Braking Circuit Connection

Speed Control
N.O.
A+
+
N.C.
L1
Motor
AC Line Input M
RB Armature
L2
-
I1 I2 A-
Run Double Pole Double Throw
Mechanically Ganged Switch
Brake

Run
Brake Relay or
Contactor Coil

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 his purpose.

34
12. optional accessories

1. Auxiliary Heat Sink (Catalog No. BC143) - Doubles the horsepower rating of the control.

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 separately). Plugs onto the quick-connect terminals of the control.

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. May also use BC145 Signal
Isolater, separately mounted.

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

5. DIN Rail Mounting Kit (Catalog No. BC218)

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

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.

35
 LIMITED WARRANTY

For a period of 2 years from date of original purchase, BALDOR will repair or replace without
charge controls which our examination proves to be defective in material or workmanship. This
warranty is valid if the unit has not been tampered with by unauthorized persons, misused,
abused, or improperly installed and has been used in accordance with the instructions and/
or ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or
implied. BALDOR shall not be held responsible for any expense (including installation and
removal), inconvenience, or consequential damage, including injury to person, caused by items
of our manufacture or sale. (Some states do not allow the 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.

36
 Baldor District Offices - United States Locations
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PHOENIX CHICAGO ST LOUIS PHILADELPHIA
4211 S 43RD PLACE 4 SAMMONS COURT 13678 Lakefront drivE 1035 THOMAS BUSCH
PHOENIX, AZ 85040 BOLINGBROOK, IL 60440 earth city, MO 63045 MEMORIAL HIGHWAY
PHONE: 602-470-0407 PHONE: 630-296-1400 PHONE: 314-373-3032 PENNSAUKEN, NJ 08110
FAX: 602-470-0464 FAX: 630-226-9420 FAX: 314-373-3038 PHONE: 856-661-1442
FAX: 856-663-6363
ARKANSAS INDIANA KANSAS CITY
CLARKSVILLE INDIANAPOLIS 1501 BEDFORD AVENUE PITTSBURGH
1001 COLLEGE AVE. 5525 W. MINNESOTA STREET NORTH KANSAS CITY, MO 64116 159 PROMINENCE DRIVE
CLARKSVILLE, AR 72830 INDIANAPOLIS, IN 46241 PHONE: 816-587-0272 NEW KENSINGTON, PA 15068
PHONE: 479-754-9108 PHONE: 317-246-5100 FAX: 816-587-3735 PHONE: 724-889-0092
FAX: 479-754-9205 FAX: 317-246-5110 FAX: 724-889-0094
NEW YORK
CALIFORNIA IOWA AUBURN TENNESSEE
LOS ANGELES DES MOINES ONE ELLIS DRIVE MEMPHIS
6480 FLOTILLA 1800 DIXON STREET, SUITE C AUBURN, NY 13021 4000 WINCHESTER ROAD
COMMERCE, CA 90040 DES MOINES, IA 50316 PHONE: 315-255-3403 MEMPHIS, TN 38118
PHONE: 323-724-6771 PHONE: 515-263-6929 FAX: 315-253-9923 PHONE: 901-365-2020
FAX: 323-721-5859 FAX: 515-263-6515 FAX: 901-365-3914
NORTH CAROLINA
HAYWARD MARYLAND GREENSBORO TEXAS
21056 FORBES STREET BALTIMORE 1220 ROTHERWOOD ROAD DALLAS
HAYWARD, CA 94545 6660 SANTA BARBARA RD. GREENSBORO, NC 27406 3040 QUEBEC STREET
PHONE: 510-785-9900 SUITE 22-24 PHONE: 336-272-6104 DALLAS, TX 75247
FAX: 510-785-9910 ELKRIDGE, MD 21075 FAX: 336-273-6628 PHONE: 214-634-7271
PHONE: 410-579-2135 FAX: 214-634-8874
COLORADO FAX: 410-579-2677 OHIO
DENVER CINCINNATI HOUSTON
3855 Forest Street MASSACHUSETTS 2929 CRESCENTVILLE ROAD 10355 W. Little York Rd.
Denver, CO 80207 BOSTON WEST CHESTER, OH 45069 Suite 300
PHONE: 303-623-0127 6 PULLMAN STREET PHONE: 513-771-2600 Houston, TX 77041
FAX: 303-595-3772 WORCESTER, MA 01606 FAX: 513-772-2219 PHONE: (281) 977-6500
PHONE: 508-854-0708 FAX: (281) 977-6510
CONNECTICUT FAX: 508-854-0291 CLEVELAND
WALLINGFORD 8929 FREEWAY DRIVE UTAH
65 SOUTH TURNPIKE ROAD MICHIGAN MACEDONIA, OH 44056 SALT LAKE CITY
WALLINGFORD, CT 06492 DETROIT PHONE: 330-468-4777 2230 SOUTH MAIN STREET
PHONE: 203-269-1354 5993 Progress Drive FAX: 330-468-4778 SALT LAKE CITY, UT 84115
FAX: 203-269-5485 STERLING HEIGHTS, MI 48312 PHONE: 801-832-0127
PHONE: 586-978-9800 OKLAHOMA FAX: 801-832-8911
FLORIDA FAX: 586-978-9969 TULSA
TAMPA/PUERTO RICO/ 7170 S. Braden, Suite 140 WISCONSIN
VIRGIN ISLANDS Tulsa, OK 74136 MILWAUKEE
3906 EAST 11TH AVENUE MINNESOTA PHONE: 918-366-9320 1960 SOUTH CALHOUN ROAD
TAMPA, FL 33605 MINNEAPOLIS FAX: 918-366-9338 NEW BERLIN, WI 53151
PHONE: 813-248-5078 21080 134TH AVE. NORTH PHONE: 262-784-5940
FAX: 813-247-2984 ROGERS, MN 55374 OREGON FAX: 262-784-1215
PHONE: 763-428-3633 PORTLAND
GEORGIA FAX: 763-428-4551 20393 SW AVERY COURT
ATLANTA TUALATIN, OR 97062
62 TECHNOLOGY DR. PHONE: 503-691-9010
ALPHARETTA, GA 30005 FAX: 503-691-9012
PHONE: 770-772-7000
FAX: 770-772-7200
 Baldor District Offices - International Locations
NTERNATIONAL SALES el salvador JAPAN
FORT SMITH, AR RESIDENCIAL PINARES DE SUIZA DIA BLDG 802, TAIWAN
P.O. BOX 2400 POL. 15 #44, 2-21-1 TSURUYA-CHO, 1F, No 126 Wenshan 3rd Street,
FORT SMITH, AR 72902 NVA. SAN SALVADOR, EL KANAGAWA-KU Nantun District,
PHONE: 479-646-4711 SALVADOR YOKOHAMA, 221-0835, JAPAN Taichung City 408
FAX: 479-648-5895 PHONE: +503 2288-1519 PHONE: 81-45-412-4506 Taiwan R.O.C
FAX: +503 2288-1518 FAX: 81-45-412-4507 PHONE: (886) 4 238 04235
CANADA FAX: (886) 4 238 04463
EDMONTON, ALBERTA CHILE MEXICO
4053-92 STREET Luis Thayer Ojeda 166, LEON, guanajuato UNITED KINGDOM
EDMONTON, ALBERTA T6E 6R8 of 402 - Providencia KM. 2.0 BLVD. AEROPUERTO 6 BRISTOL DISTRIBUTION PARK
PHONE: 780-434-4900 Santiago, Chile LEÓN 37545, GUANAJUATO, HAWKLEY DRIVE
FAX: 780-438-2600 Phone: +56 2 816 9900 MÉXICO BRISTOL BS32 0BF U.K.
PHONE: +52 477 761 2030 PHONE: +44 1454 850000
TORONTO CHINA FAX: +52 477 761 2010 FAX: +44 1454 859001
OAKVILLE, ONTARIO 160 Song SHENG road
2750 COVENTRY ROAD Songjiang INDUSTRY ZONE MIDDLE EAST & NORTH AFRICA Venezuela
OAKVILLE, ONTARIO L6H 6R1 Shanghai 201613, China VSE INTERNATIONAL CORP. Av. Roma. Qta el Milagro. Urb.
PHONE: 905-829-3301 PHONE: +86 21 5760 5335 P. O. BOX 5618 California Norte
FAX: 905-829-3302 Fax : +86 21 5760 5336 BUFFALO GROVE, IL 60089-5618 Caracas, 1070
PHONE: 847 590 5547 Venezuela
MONTREAL, QUEBEC GERMANY FAX: 847 590 5587 Phone/fax: +58 212 272 7343
5155, J.A. Bombardier DIESELSTRASSE 22 mobile: +58 414 114 8623
St-Hubert (Québec) Canada D-85551 KIRCHHEIM PANAMA
J3Z 1G4 MUNICH, GERMANY AVE. RICARDO J. ALFARO
PHONE: 514-933-2711 PHONE: +49 89 90 5080 EDIFICIO SUN TOWERS MALL
FAX: 514-933-8639 FAX: +49 89 90 50 8492 PISO 2, LOCAL 55
Ciudad de Panamá, Panamá
VANCOUVER, INDIA PHONE: +507 236-5155
BRITISH COLUMBIA 14, COMMERCE AVENUE Fax: +507 236-0591
1538 KEBET WAY MAHAGANESH COLONY
PORT COQUITLAM, PAUD ROAD
BRITISH COLUMBIA V3C 5M5 PUNE - 411038 SINGAPORE
PHONE 604-421-2822 MAHARASHTRA, INDIA 18 KAKI BUKIT ROAD 3, #03-09
FAX: 604-421-3113 PHONE: +91 20 25 45 27 17 / 18 ENTREPRENEUR BUSINESS
FAX: +91 20 25 45 27 19 CENTRE
SINGAPORE 415978
WINNIPEG, MANITOBA INDonesia PHONE: (65) 6744 2572
54 PRINCESS STREET FAX: (65) 6747 1708
Talavera Office Park,
WINNIPEG, MANITOBA R3B 1K2 28th Floor, Suite M18
PHONE: 204-942-5205 SWITZERLAND
JI. T.B. Simatupang, Kav. 22-26
FAX: 204-956-4251 POSTFACH 73
Jakarta 12430, Indonesia
PHONE: +62 21 7599 9879 SCHUTZENSTRASSE 59
AUSTRALIA FAX: + 62 21 7599 9878 CH-8245 FEUERTHALEN
UNIT 3, 6 STANTON ROAD SWITZERLAND
SEVEN HILLS, NSW 2147, AUSTRALIA PHONE: +41 52 647 4700
ITALY
PHONE: (61) (2) 9674 5455 FAX: +41 52 659 2394
Baldor ASR AG
FAX: (61) (2) 9674 2495 SUCCURSALE DI Mendrisio
Via Borromini, 20A
UNIT 8, 5 KELLETTS ROAD CH-6850 Mendrisio
ROWVILLE, VICTORIA, 3178 AUSTRALIA Switzerland
PHONE: (61) (3) 9753 4355 PHONE: 0041 91 640 99 50
FAX: (61) (3) 9753 4366 FAX: 0041 91 630 26 33
 *704-0711*

P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Baldor - Dodge
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com

© Baldor Electric Company All Rights Reserved. Printed in USA.

MN704 (A40249) - Rev C - 07/11