Baldor NEMA-4X User manual

Installation and Operation Manual
NEMA-4X –IP65
For Catalog Numbers BC154, and BCWD140
MN705
SCR DC MOTOR CONTROL

2
TABLE OF CONTENTS
Section Page
1 Introduction ..........................................................................................................................4
Safety Notice ................................................................................................................. .....11
2 Quick-Start Instructions........................................................................................................13
3 Mounting Instructions...........................................................................................................15
4 Electrical Connections............................................................... ..........................................16
5 Important Application Information ........................................................................................23
6 Setting Selectable Jumpers .................................................................................................23
7 Start-Up and Adjustments....................................................................................................29
8 Drive Operation....................................................................................................................33
9 Diagnostic LED’s..................................................................................................................34
10 Troubleshooting ...................................................................................................................34
Appendix A - Modification for Subfractional Horsepower Motors.................................... ....36
Baldor District Offices...........................................................................................................39
Limited Warranty................................................................................................. Back Cover
Tables Page
1 Standard Features ...............................................................................................................5
2 Selectable Jumpers..............................................................................................................5
3 Trimpot Adjustments ............................................................................................................6
4 Optional Accessories ...........................................................................................................7
5 Electrical Ratings .................................................................................................................7
6 General Performance Specifications....................................................................................8
7 Armature Fuse Chart............................................................................................................17
8 Terminal Block Wiring..........................................................................................................17
9 Field Connections ................................................................................................................18
10 Drive Operating Condition and Run/Fault Relay Contact Status .........................................22
11 Relationship of AC Line Input and Motor Voltage with Jumper J2 and J3 Position .............27
12 Jumper J4 Setting vs. Motor Horsepower............................................................................27
13 Current Limit Settings with 0.5 Ohm Plug-In Horsepower Resistor Installed.......................28
14 Troubleshooting Guide.........................................................................................................34
Figures Page
1 Cover Layout......................................................................................................................9
2 Mechanical Specifications..................................................................................................10
3 Control Layout....................................................................................................................14
4 Captive Screw and Case....................................................................................................15
5 Connection Diagram ..........................................................................................................17
6A Full Voltage Field ...............................................................................................................18
6B Half Voltage Field...............................................................................................................18
7 Tachometer Connection Diagram ......................................................................................19
8A Remote Potentiometer Connection....................................................................................19
8B Analog Voltage Connection................................................................................................19
9 Remote Start/Stop Switch Connection...............................................................................20
10A Inhibit Circuit Wiring...........................................................................................................21
10B Enable Circuit Wiring..........................................................................................................21
11 Run/Fault Relay Connections ............................................................................................22

3
TABLE OF CONTENTS (Continued)
Figures Page
12 J1 Control Mode.................................................................................................................23
13 Motor Speed vs. Potentiometer Rotation (Speed Mode) ...................................................24
14 Preset Motor Speed vs. Motor Load (Speed Mode) ..........................................................24
15 Motor Output Torque vs. Potentiometer Rotation (Torque Mode) .....................................25
16 Motor Speed vs. Applied Motor Load (Torque Mode)........................................................25
17 Setting AC Line Voltage with Jumper J2A and J2B...........................................................26
18 Setting Armature Voltage with Jumper J3..........................................................................26
19 J5 Jumper Position ............................................................................................................27
20 J6 Jumper Position ............................................................................................................28
21 J7 Jumper Position ............................................................................................................29
22 Minimum Speed Trimpot Range ........................................................................................30
23 Maximum Speed Trimpot Range .......................................................................................30
24 Acceleration Trimpot Range ..............................................................................................30
25 Deceleration Trimpot Range..............................................................................................31
26 Current Limit Trimpot Range..............................................................................................31
27 IR Compensation Trimpot Range ......................................................................................32
28 Timed Current Limit Trimpot Range...................................................................................32
29 Jog Speed Trimpot Range.................................................................................................32

4
1 INTRODUCTION
Thank you for purchasing the BC154 / BCWD140 Series NEMA-4X (IP-65). The Baldor SCR DC
Motor, The BC154 / BCWD140 Series NEMA-4X (IP-65) SCR DC Motor Speed and Torque
Control is designed for applications requiring washdown watertight integrity. Its housing is
ruggedly constructed of die cast aluminum which is protected with an acrylic coating for the
ultimate in corrosion resistance. All switches are sealed with rubber boots and the main speed
potentiometer contains a shaft seal.
The electronics for the BC154 / BCWD140 are state-of-the-art and includes short circuit and
transient protection which provides the ultimate in reliability. Electronic overload protection
prevents motor burnout and demagnetization of PM motors. The control can be operated in either
the Speed or Torque mode via jumper selection. The current range, which is also jumper
selectable, eliminates the necessity for calibration of IR Compensation and Current Limit for most
applications. The BC154 / BCWD140 also contains jumper selections for AC line voltage
(230/115), DC armature voltage (180/90) and feedback type (Armature/Tach-Generator).
Standard features include armature fusing (fuse sold separately). electronic start/stop Switch, and
an LED indicator array for Power On, Stop and Overload. Although the BC154 / BCWD140 are
factory set for most applications, a variety of trimpots allow adjustment of the following
parameters: Minimum and Maximum Speed, Acceleration, Deceleration, Current Limit, IR Comp,
and Timed Current Limit. Optional features offered are: On/Off AC Line Switch, Forward-Brake-
Reverse Switch, Run-Stop-Jog Switch, Input Signal Isolation, RFI Filtering, and Electronic Run-
Brake Module. Refer to the following for further information; Figure 1, on page 9, Figure 2, on
page 10 and Tables 1 – 6, on pages 5 - 8.
WARNING! BE SURE TO FOLLOW ALL INSTRUCTIONS CAREFULLY. FIRE OR
ELECTROCUTION CAN RESULT DUE TO IMPROPER USE OF THIS PRODUCT. READ
SAFETY WARNING.
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 cable and/or AC line cables may be required
along with a signal isolator.

5
TABLE 1 - STANDARD FEATURES
Feature Description
Simple to Operate Does not require programming. Uses trimpots and
jumpers which are factory set for most applications.
AC Line Voltage -115/230 Volts operation Jumper selectable for 115 or 230 Volts input for 90 or
180 VDC output.
Electronic Overload Protection Adjustable with Current Limit Trimpot to prevent
motor burnout.
Diagnostic LED’s Panel mounted LED’s for Power on (ON), Overload
(OL) and Stop.
Start/Stop Switch Panel mounted. Used to START or STOP the drive.
Main Speed Potentiometer Panel mounted. Provides adjustment of motor speed.
Jumper Selections
Speed/Torque mode, Timed Current Limit (TCL), or
Non Timed Current Limit (NTCL), Armature Voltage
Feedback or tachometer Feedback, (T, 90, 180),
Tachometer Voltage level, (50V, 20/30V, 7V), if
Tachometer is used.
Adjustable Trimpots
For adjusting settings for Minimum Speed (MIN),
Maximum Speed (MAX), Current Limit (CL), IR
Compensation (IR), Acceleration (ACCEL),
Deceleration (DECEL), Timed Current Limit (TCL)
and Jog Speed (JOG).
TABLE 2 – SELECTABLE JUMPERS (See Section 6, on page 23)
Feature Description
J1, Speed / Torque Mode Jumper. Refer to
Section 6.1, on page 23.
In SPD position, the motor speed is adjustable in
accordance with the main speed potentiometer setting.
In TRQ position, the motor torque is adjustable in
accordance with the main speed potentiometer setting.
J2A, J2B, Input AC Line Voltage. Refer to
Section 6.2 on page 26. Selectable for 115VAC or 230VAC. Factory Set for 230VAC.
J3, Armature Voltage or Tachometer
Feedback. Refer to Section 6.3 on page 26. Factory set to 180V for Armature Voltage Feedback.
J4, Armature Current Feedback Scaling.
Refer to Section 6.4 on page 27. Selectable for 2.5A, 5A, 7.5A or 10A. Factory Set (10).
J5, Current Limit Mode. Refer to Section 6.5
on page 27.
In the TCL (Timed Current Limit), motor overload
protection is active. In the NTCL (Non Timed Current
Limit position), drive will run in current limit mode. In an
Overload condition, drive will trip on OL. Armature fuse
may clear.
J6, Tachometer Voltage. Refer to Section
6.6, on page 28. Selection for tachometer voltage in Volts/1000 RPM. Based on maximum motor speed.
J7, Analog Speed Reference Signal Input
Voltage. Refer to Section 6.7, on page 29.
Factory set to 10V for maximum speed. May be set to
5V for maximum speed. Speed range adjustable with
MIN and MAX speed trimpots.

6
TABLE 3 - TRIMPOT ADJUSTMENTS (See Section 7.2, on page 30)
Trimpot Description
Minimum Speed (MIN), Refer to Section
7.2.1, page 30. Sets the minimum speed of the motor. Range of adjustment 0 to 30% of base Speed.
Maximum Speed (MAX), Refer to Section
7.2.2, page 30. Sets the maximum speed of the motor. Range of adjustment 60% to 140% of base Speed.
Acceleration (ACCEL), Refer to Section
7.2.3, page 30. Sets the amount of time for the motor to accelerate from zero speed to full speed.
Deceleration (DECEL), Refer to Section
7.2.4, page 31. Sets the amount of time for the motor to decelerate from full speed to zero speed.
Current Limit (CL), Refer to Section 7.2.5, on
page 31.
Sets the maximum amount of DC current that the
motor can draw. This determines the amount of
maximum motor torque in both the Speed Control
Mode and Torque Mode.
IR Compensation (IR), Refer to Section 7.2.6,
page 32. Sets the IR Compensation circuit for stability (motor speed), under varying loads.
Timed Current Limit (TCL), Refer to Section
7.2.7, page 32. Sets the approximate amount of time the drive will stay in Current Limit before trip out...
JOG Speed, Refer to Section 7.2.8, page 32.
The JOG trimpot maybe adjusted to set JOG
speed. Adjustment of this trimpot has no effect
unless the optional RUN-STOP-JOG Switch
(BC157) is installed.

7
TABLE 4 - OPTIONAL ACCESSORIES
Description Catalog No.
Signal Isolator Board: Provides analog input isolation from non isolated
sources. Input signals can be 0-25Vdc 0r 0-250Vdc, or 1 – 5 mA, or 10 – 50
mA, (jumper selectable). Also contains an isolated enable input.
Note: Forward-Brake-Reverse Switch (P/N BC156) cannot be installed
with Signal Isolator.
BC145
Electronic Forward-Brake-Reverse Switch: Provides anti-plug instant
reverse and solid state dynamic braking. BC153
Forward-Brake-Reverse Switch: Special hesitation action with dynamic
braking to provide safe anti-plug reversing. BC156
RUN-STOP-JOG Switch: This switch provides a momentary jog speed that
can be used to index a machine into position. BC157
Auto/Manual Switch Kit: Allows for switching between Auto/Man mode
when the BC145, Signal isolator is installed. (BC145 sold separately) BC158
ON/OFF AC Line Switch: This option is desirable if a positive AC line
disconnect is required. The switch can be installed in lieu of the
START/STOP switch (which can be easily removed) or in place of the RUN-
STOP-JOG or FWD-BRK-REV switch. Installation is made via quick-connect
terminals.
BC159
RFI Filter: The filter meets the requirements of CE directives pertaining to RFI
filtering. BC24LF,
P/N WD3007A46
Note: All optional accessories are supplied with complete installation instructions.
TABLE 5 - ELECTRICAL RATINGS
Model
Number
Input
Line
Voltage
(VAC-
50/60 Hz)
Max. AC
Load
Current
(ARMS)
Output
Voltage
(VDC)
Max. DC
Output
Current
(ADC)
Max. Field
Current
(ADC)
Max.
Horsepower
HP, (KW)
115 15.0 0 – 90 10.2 1.5A 1, (.75)BC154,
BCWD140 230 15.0 0 – 180 10.2 1.5A 2, (1.5)

8
TABLE 6 - GENERAL PERFORMANCE SPECIFICATIONS
Description Specification
Factory
Settin
g
AC Line Input (VAC ± 10%) 115 / 230 230
AC Line frequency (Hz) 50 / 60 —
Armature Voltage Range at 115 VAC Line (VDC) 0 – 130* —
Armature Voltage Range at 230 VAC Line (VDC) 0 – 220* 180 VDC
Field Voltage at 115 VAC Line (VDC) 100/50 —
Field Voltage at 230 VAC Line (VDC) 200/100 —
Horsepower at 115 VAC 1/50 -1 —
Horsepower at 230 VAC 1/25 – 2 —
Ambient Temperature Range (ºC) 0 - 50 —
Speed Range 50:1 —
Speed Regulation (Armature Feedback, % Base Speed) ±1 —
Speed regulation (Tachometer Feedback, % Set Speed) ±1 —
AC Line Voltage Regulation ( % Base Speed) ±0.5 —
Current Ranges (ADC) 2.5, 5.0, 7.5, 10 —
ACCEL and DECEL Ranges (Seconds) 0.1 - 15 1
MIN SPEED Range ( % Base Speed) 0 - 30 0
MAX SPEED Range (% Base Speed) 60 - 140 100
IR COMP Range at 115 VAC input (VDC) 0 – 15 4
IR COMP Range at 230 VAC input (VDC) 0 – 30 8
Current Limit Range (%) 0 - 200 150
Timed Current Limit Range, (Seconds) 0.5 - 15 7
Voltage Following Linearity (% Base Speed) ±0.5 —
Notes: *Maximum recommended output voltage is 90 VDC for 115 VAC and 180 VDC for 230
VAC. Exceeding these output voltages may cause a reduction in load regulation performance.
**For shunt wound motor with a lower voltage field, use L1 and F1 connection.

9
FIGURE 1 – COVER LAYOUT
HOLE PLUG
(OPTIONAL RUN / JOG SWITCH) (TABLE 4, PAGE 7)
START / STOP SWITCH
(SECTION 4.7.3, PAGE 20)
HOLE PLUG
(OPTIONAL FWD-BRK-REV SWITCH) (TABLE 4, PAGE 7)
SPEED ADJUST
POTENTIOMETER
(SECTION 4.7, PAGE 19)
LED INDICATORS
(SECTION 9, PAGE 34)
DC MOTOR SPEED CONTROL
%
NEMA-4X / IP-65
100
90
80
70 60
50
0
10
20
30
40
FWD BRK REV
JOG
START
STOP
RUN

10
FIGURE 2 – MECHANICAL SPECIFICATIONS
ON STOP OL
DC MOTOR SPEED CONTROL
RUN
STOP
START
NEMA-4X / IP-65
0
10
20 30
40 50 60
70
80
90
100
%
JOG
REV
FWD
BRK
5.000
(127.00)
4.055
(103.00)
9.488
(241.00)
5.866
(
149.50)
5.472
(139.00)
8.228
(209.00) 8.875
(225.50) 9.488
(241.00)
0.25" Mounting Screws
Maximum Depth: 5.000
(127.00)
2.736
(69.50)

11
SAFETY NOTICE
WARNING - STATEMENT INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, COULD RESULT IN INJURY OR DEATH.
CAUTION - Statement indicates a potentially hazardous situation which, If not avoided, could result in
damage to property.
Note - Additional information that is not critical to the installation or operation.
WARNING! – READ SAFETY NOTICE ON PAGE 11 BEFORE ATTEMPTING TO USE
THIS CONTROL. WIRE CONTROL IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE
REQUIREMENTS AND OTHER CODES THAT APPLY. BE SURE TO FUSE EACH CONDUCTOR
WHICH IS NOT AT GROUND POTENTIAL. DO NOT FUSE NEUTRAL OR GROUNDED
CONDUCTORS.
WARNING! – DO NOT CONNECT SWITCHES OR RELAYS IN SERIES WITH THE
ARMATURE. ARMATURE SWITCHING CAN CAUSE CATASTROPHIC FAILURE OF MOTOR
AND/OR CONTROL.
WARNING! TO AVOID ERRATIC OPERATION DO NOT BUNDLE AC LINE AND
MOTOR WIRES WITH POTENTIOMETER, VOLTAGE FOLLOWING, ENABLE, INHIBIT OR
OTHER SIGNAL WIRING. USE SHIELDED CABLES ON ALL SIGNAL WIRING OVER 12" (30 CM)
– DO NOT GROUND SHIELD.
WARNING DO NOT USE START/STOP, INHIBIT OR ENABLE FUNCTIONS AS A
SAFETY DISCONNECT. USE ONLY AN AC LINE DISCONNECT FOR THAT PURPOSE.
WARNING! DO NOT USE THIS DRIVE IN AN EXPLOSIVE ENVIRONMENT. AN
EXPLOSION CAN CAUSE SERIOUS OR FATAL INJURY. THIS DRIVE IS NOT EXPLOSION
PROOF.
WARNING! DO NOT ADJUST TRIMPOTS WITH MAIN POWER ON IF POSSIBLE. IF
ADJUSTMENTS ARE MADE WITH POWER ON, INSULATED ADJUSTMENT TOOLS MUST BE
USED AND SAFETY GLASSES MUST BE WORN. HIGH VOLTAGE EXISTS IN THIS CONTROL.
ELECTROCUTION AND/OR FIRE CAN RESULT IF CAUTION IS NOT EXERCISED. SAFETY
WARNING MUST BE READ AND UNDERSTOOD BEFORE PROCEEDING.
WARNING! READ SAFETY NOTICE ON PAGE 11 BEFORE ATTEMPTING TO
OPERATE THE CONTROL OR SEVERE INJURY OR DEATH CAN RESULT. FAILURE TO
FOLLOW THE SAFETY NOTICE, MAY RESULT IN ELECTRIC SHOCK, FIRE OR EXPLOSION.

12
WARNING! HIGH VOLTAGE IS PRESENT IN THIS DRIVE. DISCONNECT MAIN
POWER BEFORE MAKING CONNECTIONS TO THE DRIVE. TO REDUCE ELECTRICAL SHOCK
HAZARD, THE COVER MUST BE INSTALLED AND SECURELY FASTENED, AFTER ALL SETUP
CONNECTIONS, AND ADJUSTMENTS ARE COMPLETE. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN ELECTRICAL SHOCK OR ELECTROCUTION.
WARNING! DO NOT DEPEND ON PANEL MOUNTED LED’S, AS A GUARANTEED
POWER OFF CONDITION. BE SURE THE MAIN POWER SWITCH OR CIRCUIT BREAKER IS IN
THE “OFF” POSITION BEFORE SERVICING THE DRIVE.
WARNING! BE SURE TO FOLLOW ALL INSTRUCTIONS CAREFULLY. FIRE OR
ELECTROCUTION CAN RESULT DUE TO IMPROPER USE OF THIS PRODUCT. READ SAFETY
WARNING.
CAUTION! -
1. Adjusting the CL above 150% of motor rating can cause overheating and possibly
demagnetization of some PM motors. Consult motor manufacturer.
2. Do not leave the motor in a locked condition for more than a few seconds since
armature damage may occur.
CAUTION! - Do not use in explosive atmosphere. Be sure the BC-154 / BCWD140 is used
within its maximum ratings. Follow all installation instructions carefully (Refer to Sections 3
and 4, on pages 15 and 16).
CAUTION! - Shunt-Wound motors may be damaged if field windings remain energized for an
extended period of time without armature rotation.

13
2 QUICK-START INSTRUCTIONS
Important: You must read these simplified instructions before proceeding. These instructions
are to be used as a reference only and are not intended to replace the details provided herein.
You must read the Safety Notice on, page 11, before proceeding.
2.1 Connections (See Figure 3, on page 14).
2.1.1 AC Line.
Connect AC line voltage to terminals L1 and L2. Be sure jumpers J2A and J2B are both
set to the correct input line voltage 115 or 230 VAC. Connect ground wire (earth) to
green ground screw on case.
2.1.2 Motor.
A. Permanent Magnet (PM) Type. Connect motor armature leads to A1 (+) and A2 (–).
Be sure jumper J3 is set to the proper position “90V" for 90 volt DC motors and
“180V" for 180 volt DC motors.
Note: 180 volt DC motors must be used with 230VAC line, 90 volt motors can be used
with a 230 VAC or 115 VAC line. See Section 6.3, on page 26.
B. Shunt Wound Motors. Connect motor armature as above. Connect full voltage
shunt field wires (90 volt motors with 100 volt fields and 180 volt motors with 200
volt fields) to F1 and F2. Connect half voltage field wires (90 volt motors with 50
volt fields and 180 volt motors with 100 volt fields) to F1 and L1. See Section 4,
on page 16.
2.2 Speed or Torque Mode – Jumper J1 is factory set for speed control operation ("SPD"). For
torque control, set J1 to "TRQ" position. See Section 6.1, on page 23.
2.3 Armature Current - Jumper J4 is factory set for 10 amp motors (10A). For lower amperage
motors, place J4 in the proper position. See section 6.4, on page 27 for details.
Note: The factory setting for Current Limit is 150% of the nominal current setting, e.g., if J4 is
selected for 10 amps, the actual CL setting will be 15 amps.
2.4 Trimpot Settings – All trimpots have been factory set in accordance with Figure 3, on page
14. See Table 3, page 6, for descriptions.
2.5 Diagnostic LEDs – After power is turned on, observe LED’s to verify proper control function.
See Section 9, on page 34.
2.6 Armature Fuse - The correct size armature fuse must be installed, depending on the rating
of the motor. Control will not operate if fuse is not installed. See Section 4.1.2, page 16 and
Table 7, on page 17.
2.7 START/STOP Switch - The BC154 / BCWD140 contains a built-in manual start/stop
switch. This switch must be used to start the control each time AC power is lost. To
override this function, see Section 4.7.3, on page 20.

14
FIGURE 3 – CONTROL LAYOUT
J3 - (Section 6)
T 90
180
I1 - (Section 4) I2 - (Section 4)
START - (Section 4)
COM - (Section 4)
STOP - (Section 4)
JOG - (Section 4)
P3 - (Section 4) P2 - (Section 4)
P1 - (Section 4)
TB2 - (Section 4)
Shunt Motors Only
F1 - (Section 4)
J6 - (Section 6)
T1 (Power Transformer)
AC LINE
F1 F2 A1 A2 L1 L2 -- (Section 4) --
FIELD MOTOR
CON2
J3
F1
TB1 - (Section 4)
Section6
Inset
L1B L1A A1B J2A A1A J2B A2B A2A
R69 (Horsepower Resistor)®
TB4 - (Section 4)
CON 1
-- (Section 7) --
JOG MAX MIN ACCEL DECEL TCL CL IR
(Section 4)
J7 J1 J5 J4
TB3 - (Section 4)
J4
K1 - (Section 4)

15
3 MOUNTING INSTRUCTIONS
WARNING! DO NOT USE THIS DRIVE IN AN EXPLOSIVE ENVIRONMENT. AN
EXPLOSION CAN CAUSE SERIOUS OR FATAL INJURY. THIS DRIVE IS NOT EXPLOSION
PROOF.
Mount the control in a vertical position on a flat surface. Be sure to leave enough room below
the bottom of the control to allow for the AC line and motor connections. Although the control
is designed for outdoor and washdown use, care should be taken to avoid extremely hazardous
locations where physical damage can occur.
Mount the control in such a manner that there is unrestricted air flow through the heatsink cooling
fins.
If the control is mounted in a closed, unventilated cabinet, remember to allow for proper heat
dissipation. If full rating is required, a minimum enclosure size of 12" W x 24" H x 12" D should be
used. See Figure 2, on page 10, for dimensional specifications.
Front Cover - The BC154 / BCWD140 case is designed with a hinge so that when the front cover
is open, all wiring stays intact. To open the cover, the four cover screws must be loosened, so
they no longer are engaged in the case bottom.
Note: Front cover screws are captive.
After mounting and wiring, close the front cover, making sure all wires are contained within the
enclosure and the gasket is in place around the cover lip. Tighten all four cover screws so that
the gasket is slightly compressed. Do not overtighten. See Figure 4.
FIGURE 4 – CAPTIVE SCREW AND CASE
Tighten the four case captive screws in the 1- 4 sequence.
Torque Specification: 12 lb-in (14 kg-cm)
Captive Screw
Cover
Gasket
Case
3
2
41
BC154 / BCWD140 Case
(Not to Scale)

16
4 ELECTRICAL CONNECTIONS
WARNING! – READ SAFETY NOTICE ON PAGE 11 BEFORE ATTEMPTING TO
USE THIS CONTROL. WIRE CONTROL IN ACCORDANCE WITH THE NATIONAL
ELECTRIC CODE REQUIREMENTS AND OTHER CODES THAT APPLY. BE SURE TO FUSE
EACH CONDUCTOR WHICH IS NOT AT GROUND POTENTIAL. DO NOT FUSE NEUTRAL
OR GROUNDED CONDUCTORS.
WARNING! TO AVOID ERRATIC OPERATION DO NOT BUNDLE AC LINE AND
MOTOR WIRES WITH POTENTIOMETER, VOLTAGE FOLLOWING, ENABLE, INHIBIT OR
OTHER SIGNAL WIRING. USE SHIELDED CABLES ON ALL SIGNAL WIRING OVER 12" (30
CM) – DO NOT GROUND SHIELD.
Connections to the control (BC-154 / BCWD140) should be in accordance with the National
Electric Code requirements, and other codes that apply. Be sure to fuse each conductor which
is not at ground potential. Do not fuse neutral or grounded conductors. Refer to the Section
4.1.
A separate AC line switch, or contactor, must be wired as a disconnect switch, so that the
contacts open each ungrounded conductor. An accessory ON/OFF AC Line Switch (KB P/N
9341) may be installed in this control in lieu of, or in addition to, the Start/Stop Switch normally
provided. The switch can be wired for double pole or single pole operation. (See Figure 5, on
page 17, for AC Line and Armature connection.)
To maintain the watertight integrity of the control, be sure to use suitable watertight connectors
and wiring, which are appropriate for the application. Two .875" (22.2 mm) knockout holes are
provided for a standard 1/2" knockout connector (not supplied) for wiring. A watertight plug is
provided if only one knockout is used.
4.1 Fusing
4.1.1 AC Line Fusing – Most electrical codes require that each ungrounded conductor
contain fusing. Separate branch circuit fusing or circuit breaker may be required.
Checkallelectrical codes that may apply to the installation. This control does not
contain AC line fuses. A 25 amp rated fuse or circuit breaker can be used.
4.1.2 Armature Fusing - The correct size armature fuse must be installed, depending
on the rating of the motor. Control will not operate if fuse is not installed. Fuse
type should be Littlefuse 326 ceramic, Buss ABC, or equivalent. A fuse chart is
presented below which suggests appropriate armature fuse ratings. However, the
specific application may require larger fuse ratings based on ambient temperature,
CL set point and duty cycle of operation. (See Table 7, on page 17.) (Fuse rating is
based upon 1.7 times the motor current rating.)

17
TABLE 7 - ARMATURE FUSE CHART
Motor Horsepower
90 VDC 180 VDC Approx. DC Motor
Current Amps Fuse Rating (AC Amps)
1/8 1/4 1.3 2
1/6 1/3 1.7
2 ½
1/4 1/2 2.5 4
1/3 3/4 3.3 5
1/2 1 5.0 8
3/4 1 ½7.5 12
1 2 10.0 20
Note:Armature fuse is not supplied and must be installed for control to operate.
4.2 AC Line – Connect AC Line to terminals L1 and L2. (Be sure that Jumpers J2A and J2B
are set to the correct position to match the AC line voltage. See Table 9 on page18 and
Figure 18, on page 26.
TABLE 8 - TERMINAL BLOCK WIRING INFORMATION
Supply Wire Gauge
(Copper Wire Only (AWG))
Terminal
Block
Designation
Connection
Designation Minimum Maximum
Maximum
Tightening
Torque (lb – in)
TB1 A1, A2, L1, L2 22 12 12
TB2 F1, F2 22 14 3.5
TB3 T+, T- 22 14 3.5
4.3 Ground – Be sure to ground (earth) the control by connecting a ground wire to the Green
Ground Screw located to the right of the terminal block. See Figure 5.
4.4 Motor Armature – Connect motor armature
leads to terminals A1 (+) and A2 (–). Be sure
that jumper. See Section 6, on page 23 for
Jumper J3 settings.
WARNING! – DO NOT CONNECT
SWITCHES OR RELAYS IN SERIES WITH
THE ARMATURE. ARMATURE
SWITCHING CAN CAUSE CATASTROPHIC
FAILURE OF MOTOR AND/OR CONTROL.
DO NOT BUNDLE AC AND MOTOR WIRES
WITH OTHER WIRES (e.g.,
POTENTIOMETER, ANALOG INPUT,
FORWARD-BRAKE-REVERSE, ETC.)
FIGURE 5 – CONNECTION DIAGRAM
GROUND
SCREW
A1 A2 L1 L2
TB1
M
+
-
ARMATURE AC LINE
INPUT
Torque Specification:
Refer to Table 8

18
4.5 Field [For Shunt Wound Motors Only]
Do not use terminals F1 and F2 for any other purpose than to power the field on a shunt
wound motor. Connect motor shunt field to terminals F1 and F2 for 180 VDC motors with
200 VDC fields. For motors with half voltage fields (180 VDC motors with 100 VDC fields),
connect field to terminals F1 and L1. See Table 10 for a summary of Field Connections.
See Figures 6A and 6B for field wiring diagrams.
CAUTION! Shunt-Wound motors may be damaged if field remains energized without
motor rotating for an extended period of time.
TABLE 9 – FIELD CONNECTIONS (Shunt Wound Motors Only)
AC LINE
VOLTAGE (VAC) MOTOR VOLTAGE FIELD VOLTAGE
(VDC) FIELD CONNECTION
115 90 100 F1, F2
115 90 50 F1, L1
230 180 200 F1, F2
230 180 100 F1, L1
230 90* 100 F1, L1
* Step Down Operation (See Section 6.3, on page 26)
FIGURE 6A – FULL VOLTAGE FIELD FIGURE 6B – HALF VOLTAGE FIELD
F1 F2
FIELD
+ -
+ -
ARMATURE AC LINE
INPUT
TB2 TB1
A1 A2 L1 L2
M
GROUND
SCREW
+ -
+ -
M
TB1
FIELD
TB2
AC LINE
INPUT
ARMATURE
F1 F2 GROUND
SCREW
A1 A2 L1 L2
Torque Specification: Refer to Table 8
4.6 DC Tach-Generator Input – If Tach-Generator feedback is required, an analog tach signal
must be connected to the terminal block TB3. See Figure 7, on page 19.
Note: For Tach-Generator feedback, Jumper J3 must be set to the "T" position, jumper J6
must be set for the proper tach voltage, and the IR COMP must be set to minimum
(ccw) position. See Section 6.6, on page 28.
Connect the Tach-Generator so that when the motor rotates the positive tach voltage lead is
connected to T+ and the negative tach lead is connected to T– (See Figure 7).

19
Note: If motor operates in the wrong
rotation, reverse the connection of
armature leads, A1 and A2.
WARNING! TO AVOID
ERRATIC OPERATION DO NOT
BUNDLE AC LINE AND MOTOR WIRES
WITH POTENTIOMETER, VOLTAGE
FOLLOWING, ENABLE, INHIBIT OR
OTHER SIGNAL WIRING. USE
SHIELDED CABLES ON ALL SIGNAL
WIRING OVER 12" (30 CM) – DO NOT
GROUND SHIELD.
4.7 Remote Speed Reference – The control
is supplied with the main potentiometer
prewired. However, the control can also
be operated from a remote potentiometer, or from an Isolated analog voltage for voltage
following. To operate from an external source remove white, orange and violet potentiometer
leads from terminals P1, P2 and P3. The leads may be taped and left in the control. The
potentiometer itself may be removed, provided a watertight seal is used to cover the hole in the
front cover.
4.7.1 Remote Potentiometer (5K) – Connect remote potentiometer wires to terminals P1,
P2 and P3, so that the "high" side of the potentiometer connects to P3, the "wiper" to
P2 and the "low" side to P1. See Figure 8A, on page 20.
4.7.2 Analog Input – An isolated 0 - 5 or 0 - 10 VDC analog voltage can also be used to
control speed. See Figure 8B, on page 20.
FIGURE 7 - TACHOMETER CONNECTION
DIAGRAM
TB3
T -
T + T
-
+
Torque Specification: Refer to Table 8
FIGURE 8A – REMOTE
POTENTIOMETER CONNECTION (5K)
P3
P2
P1
FIGURE 8B – ANALOG VOLTAGE
CONNECTION
Isolated Voltage
Source+P2
P1
-
0 - 5
0 - 10
VDC

20
Notes:
1.If the available analog speed reference signal voltage is not isolated, an optional Signal
Isolator Board, model BC145, may be installed. Reference: paragraph 4.8, page 21 for
Signal Isolator Connection information.
2. When using an external analog signal, the main speed potentiometer must be
disconnected from terminals P1, P2, and P3. The MIN trim pot may need to be adjusted to
achieve 0 output voltage.
Note:The Start/Stop function may be bypassed by connecting a jumper wire across the
"Start"and"Com"terminals.
4.7.3 Remote Start/Stop Switch - A remote
Start/Stop Switch may be installed by
disconnecting the wires from the "Start",
"Com", and "Stop" terminals, and reconnecting
the terminals toa remotely mounted switch.
See Figure 9.
WARNING! WHEN THIS JUMPER IS
INSTALLED, THE DRIVE AND MOTOR WILL START AND RUN WHEN AC SUPPLY POWER
IS APPLIED, WHEN POWER IS RESTORED AFTER A MOMENTARY POWER LOSS, OR
AFTER AN OVERLOAD OR TCL FAULT IS RESET. THE USER MUST ENSURE THAT
AUTOMATIC START UP OF THE DRIVEN EQUIPMENT WILL NOT CAUSE INJURY TO
OPERATING PERSONNEL OR DAMAGE TO THE DRIVEN EQUIPMENT. THE USER IS
RESPONSIBLE FOR PROVIDING SUITABLE AUDIBLE OR VISUAL ALARMS OR OTHER
DEVICES TO INDICATE THAT THE DRIVE MAY START AT ANY MOMENT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF
LIFE.
FIGURE 9 – REMOTE START/
STOP SWITCH CONNECTION
COM
STOP
START