Manual - KB Electronics, Inc.
Contents
1. Machine or equipment frame 15 TRIMPOT ADJUSTMENTS AND CONTROL FUNCTIONS The KBIC is factory adjusted to provide O to full speed range using a 5K potentiometer Minimum and maximum speed trimpots are provided to change the speed range from other than O to full speed An acceleration ACCEL trimpot located directly behind the MIN trimpot is factory set to provide motor acceleration from 0 to full speed over a time period of 2 seconds approx each time the AC power is applied The current limiting CL or torque output adjustment is factory set to approximately one and a half times the motor rating The IR Compensation IR is factory adjusted to provide excellent motor regulation under normal operation See Figure 1 on page 4 for trimpot locations Note In order for the IR comp and CL trimpot settings to be correct the proper Plug in Horsepower Resistor must be installed for the particular motor and input voltage being used Do not attempt to change the settings of the trimpots unless absolutely necessary since they are factory adjusted to near optimum settings IMPORTANT NOTE Readjusting the ACCEL time will affect the MAX speed and IR Comp settings that will have to be readjusted see this Section If the ACCEL time is decreased to the minimum time of 0 5 seconds 6 o clock trimpot position then increase the IR trimpot 25 CW rotation and decrease the MAX trimpot 20 CCW rotation If the ACCEL time is i2. Plug In Horsepower Resistor Supplied Separately Armature Fuse Holder Kit and Fuse Supplied Separately POT Symbol ACCEL MAX MIN IR CL CLLED Will illuminate red when the motor is in overload Indicates that the Current Limit setpoint has been reached set by the CL Trimpot Notes 1 Mounting Holes for Armature and AC Line Fuses A 2 Auxillary Heatsink optional ae a An See Figure 2 Page 7 Inhibit Switch Motor Field Motor Armature Open to Run Shunt Motors Only Close to Stop 2 SAFETY WARNING 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 HA 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 electrical connections fusing or other current protection and grounding can reduce the chance of electrical shocks and or fires in this product or products used with this product such as electric motors switches coils solenoids and or relays Do not use this drive in an explosion proof application Eye protection must be worn and insulated adjustment tools must be used when working with drive under power This product is
3. 5 Ifthe 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 20 DIAGNOSTIC LED S The KBIC is designed with PC board mounted LEDs to display the control s operational status See Figure 1 on page 4 for the location of the LEDs 8 1 8 2 9 1 9 2 Power On PWR ON The PWR ON LED will illuminate green when the AC line is applied to the control 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 7 4 and Figure 7 on page 18 CONTROL FUNCTIONS 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 Armature Switching If the armature is to be disconnected and reconnected with AC power applied the Inhibit Circuit must be simultaneously activated and deactivated Connect 11 and I2 together to activate the Inhibit Circuit See Figure 9 FIGURE 9 DYNAMIC BRAKING CIRCUIT Notes Dynamic Brake Circuit Choose RB resistance and wattage according to braking requirements Inhibit circu
4. motor current rating maximum 0 clockwise position To decrease the current limit rotate the CL Trimpot counterclockwise See Figure 7 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 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 3 4 5 Re Apply power Set the Main Speed Potentiometer to approximately 30 50 clockwise position Set the CL Trimpot fully counterclockwise Lock the motor shaft The CL LED will illuminate red NWARNING DO NOT LEAVE MOTOR SHAFT LOCKED FOR MORE THAN 2 3 SECONDS OR MOTOR DAMAGE MAY RESULT 6 Rotate the CL Trimpot clockwise until the desired current reading is observed on the DC 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 set the CL 0 75 times the full load rating of the motor Do not exceed 2 times motor current rating Refer to Figure 7 Note On cyclical loads it may be normal for the CL LED to momentarily flash 7 5 IR Compensation Trimpot I
5. F Consult factory if more information is required Initial Setup and Wiring a Install proper size Plug in Horsepower Resistor See Table 6 on page 11 b The KBIC can be connected to a standard 115V or 230V 11596 50 60 Hz AC line based on model selected Be sure the AC input voltage corresponds to the control voltage rating and the motor rating e g 90 130VDC motor on 115VAC and 180VDC motor on 230VAC c Follow the recommended supply wire sizes as per Table 3 on page 9 d Follow the NEC and other electrical codes that apply CAUTION Separate branch protection must be provided on 230V circuits Do not fuse neutral or grounded conductors e Connect control in accordance to connection diagram See Figure 1 on page 4 f When using a step down transformer 440 VAC to 230 VAC be sure the VA rating of the transformer is at least 3 times the VA rating of the motor A WARNING READ SAFETY WARNING ON PAGE 5 BEFORE USING THE DRIVE DISCONNECT MAIN POWER BEFORE MAKING CONNECTIONS TO THE DRIVE TO AVOID ELECTRIC SHOCK BE SURE THE DRIVE AND MOTOR ARE PROPERLY GROUNDED EAA WARNING IF CONTROL IS WIRED TO A TRANSFORMER DO NOT SWITCH THE PRIMARY SIDE OF TRANSFORMER TO DISCONNECT POWER OR CATASTROPHIC FAILURE CAN RESULT ALWAYS DISCONNECT CONTROL FROM SECONDARY SIDE OF TRANSFORMER EA WARNING ARMATURE SWITCHING DO NOT SWITCH THE ARMATURE IN AND OUT OF CIRCUIT OR CATASTROPHIC FAILURE WILL RESULT IF ARMATURE SWITCHI
6. 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 1 2006 his drive contains electronic Start Stop circuits which can be used to start and stop the drive However these circuits are never to be used as safety disconnects since they are not fail safe Use only the AC line for this purpose Be sure to read and follow all instructions carefully Fire and or electrocution can result due to improper use of this product Ethis product complies with all CE directives pertinent at the time of manufacture Contact the Sales Department for Declaration of Conformity Installation of a CE approved RFI filter is required see Table 7 on page 24 Additional shielded cable and or AC line cables may be required along with a signal isolator INTRODUCTION Thank you for purchasing the KBIC Standard of the Industry DC motor speed controls The speed controls are designed for applications demanding good performance high reliability and low cost The controls are fabricated with components that have proven reliability including MOV transient protection which is used to protect t
7. 3 4 3 3 5 1 2 1 5 0 8 3 4 1 1 2 7 5 12 1 2 10 0 15 1 1 2 3 15 0 25 Note Specific applications may require a different fuse value than indicated This is based on several factors such as ambient temperatures duty cycle motor form factor and CL setpoint TABLE 5 GENERAL PERFORMANCE SPECIFICATIONS Speed Range ratio 50 1 Load Regulation base speed 0 full load 50 1 speed range T Line Voltage Regulation base speed at full load 100 130 VAC 12 Control Linearity speed vs dial rotation 2 CL Torque Range full load 0 300 ACCEL Time Period 0 full speed seconds 0 5 4 0 MIN Speed Trimpot Range 96 full speed 0 30 MAX Speed Trimpot Range 96 full speed 50 140 IR Compensation Trimpot Range at specified full load volts 0 24 Maximum Allowable Ambient Temperature at full rating C F 45 113 Maximum Inrush Start Current Peak DC amps 3 times CL Setting Note Performance is for the SCR rated PM motors only Lower performance can be expected with other motor types Factory setting is for 396 load regulation To obtain superior regulation See Section 7 paragraph 7 5 on page 19 TABLE 6 PLUG IN HORSEPOWER RESISTOR CHART 1 Motor Horsepower 2 Plug In Individual Armature Voltage ArmatureVoltage e j Horse pawar Pic cu 90 VDC 180 VDC Amps Value Ohms Resistor P N 1 100 1 50 0 1 1 0 98
8. 33 1 50 1 25 02 0 51 9834 1 30 1 25 1 15 0 35 0 35 9835 1 20 1 10 0 5 0 25 9836 1 15 112 1 6 0 8 0 18 9837 1 10 1 8 1 6 1 4 1 3 0 1 9838 1 4 1 2 2 5 0 05 9839 1 3 3 4 3 3 0 035 9840 1 2 1 5 0 0 025 9841 3 4 1 1 2 75 0 015 9842 1 2 10 0 0 01 9843 1 1 2 3 15 0 0 006 9850 Notes 1 Motor horsepower and armature voltage must be specified in order to selec correct Plug In Horsepower Resistor 2 For motor horsepower not indicated use lower value Plug In Horsepower Resistor A Plug In Horsepower Resistor must be installed to match the KBIC to the motor horsepower and voltage See Table 6 above for the correct value Plug In Horsepower Resistors are stocked by your distributor Plug In Horsepower Resistor CAUTION Be sure Plug In Horsepower Resistor is inserted completely into the mating socket 11 INSTALLATION MOUNTING INSTRUCTIONS AND ELECTRICAL CONNECTIONS EAA WARNING DO NOT USE THIS DRIVE IN EXPLOSION PROOF APPLICATIONS BE SURE THE DRIVE IS SECURELY MOUNTED 5 1 5 2 AA Location and Mounting The KBIC controls should be mounted on a flat surface and located in an area where it will not be exposed to contaminants such as water metal chips solvents or excessive vibration When mounting in an enclosure the air space should be large enough to provide adequate heat dissipation The maximum allowable ambient temperature at full rating is 45 C 113
9. 84 16 Remote B Residential KBRF 350 9511 10 Undermount B Residential Also meets industrial standard Notes 25 26 Notes Notes 27 LIMITED WARRANTY For a period of 18 months from the date of original purchase KB Electronics Inc will repair or replace without charge devices 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 The foregoing is in lieu of any other warranty or guarantee expressed or implied KB Electronics Inc is not responsible for any expense including installation and removal inconvenience or consequential damage including injury to any person caused by items of our manufacture or sale Some states do not allow certain exclusions or limitations found in this warranty and therefore they may not apply to you In any event the total liability of KB Electronics Inc under any circumstance shall not exceed the full purchase price of this product rev 2 2002 COPYRIGHT 2008 KB Electronics Inc All rights reserved In accordance wi
10. KBIC SCR DC Motor Speed Controls Ultra Fast CL Circuit Prevents el Demagnetization in PM Motors Brier M Installation and BASIC KBIC Operation Manual ZA Qu ce See SAFETY WARNING See CE information on page 5 This Manual Covers Models KBIC 120 125 240 225 240D 240DS PENTA POWER A COMPLETE LINE OF MOTOR DRIVES 2008 KB Electronics Inc See back cover Section OONAN o Table 1 TM JODADN Q oo o0o00nN igure TABLE OF CONTENTS Quick Start Instructions Safety Introduction Application Information Installation Mounting Instructions and Electrical Connections Recommended High Voltage Dielectric Withstand Testing HI POT Trimpot Adjustments Diagnostic LED s Control Functions Optional Accessories Field Connections Shunt Wound Motors Only Electrical Ratings ssssssss Minimum Supply Wire Size Requirements Fuse Selection Chart General Performance Specifications Plug In Horsepower Resistor Chart RFI Filter Selection General Connection Diagram Mechanical Specifications HI POT Test Setup ACCEL Trimpot Range MIN Trimpot Range MAX Trimpot Range CL Trimpot Range IR Trimpot Range Dynamic Braking Master Follower Circuit Connection Connection Methods Internal Sensing 1 QUICK START INSTRUCTIONS Important You must r
11. NG IS REQUIRED FOR DYNAMIC BRAKE OR REVERSING USE MODEL KBRG KBPB OR KBCC R SUFFIX CONTROLS CAUTION Do not bundle potentiometer connections P1 P2 P3 and Inhibit connections I1 12 with AC line or motor wires Note Shunt motors only For 90VDC motors with 50VDC fields and 180VDC motors with 100VDC fields use half voltage field connections F and L1 See Table 1 on page 8 5 3 Fusing AC Line and Armature The AC line fuse protects the control against catastrophic failure If the fuse blows the control is mis wired the motor is shorted or grounded or the KBIC control is defective The armature fuse provides overload protection for the motor and control Choose the proper size armature fuse and AC line fuse by multiplying the maximum DC motor amps by 1 7 Armature and AC line fuse kits are available from your distributor On domestic 230 Volt AC lines separate branch circuit protection for each line must be used All fuses should be normal blow ceramic 3AG or MDA or equivalent See Fuse Chart Table 4 on page 9 Note Also available the Barrier Terminal Kit optional which contains pre wired AC line and armature fuseholders Contact your distributor 13 RECOMMENDED HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING HI POT Testing agencies such as UL CSA etc usually require that equipment undergo a hi pot test In order to prevent catastrophic damage to the control which has been installed in the equipment it is
12. R IR compensation is provided to substantially improve load regulation If the load presented to the motor does not vary substantially the IR adjustment may be set at a minimum level approximately 1 4 of full setting The control is factory adjusted to approximately 3 regulation If superior performance is desired less than 1 speed change of base speed from 0 to full load then the IR compensation should be adjusted See Figure 8 as follows Note Excessive IR comp will cause control to become 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 Actual Comp voltage depends on the value of the Horsepower Resistor 2 Excessive IR Compensation will cause the motor to become unstable which causes unstable which causes motor cogging cogging To Recalibrate the IR Trimpot 1 Set the IR Trimpot to approximately 25 rotation FIGURE 8 IR TRIMPOT RANGE 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 2 Run the motor unloaded at approximately 1 3 speed and record the RPMs 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
13. RMS Avg RMS Avg VDE Amps Amps Amps Amps pg 9429 115 0 90 9 0 6 0 0 5 18 0 12 0 1 50 100 pug 9433 115 0 90 12 0 8 0 0 75 24 0 16 0 15 50 100 5s 9428 208 230 0 180 9 0 6 0 1 18 0 12 0 2 100 200 s 9432 208 230 0 180 12 0 8 0 1 5 24 0 16 0 3 100 200 KBIC E AUD E 115 0 90 9 0 e 0 5 T 120 1 50 100 1 208 230 0 180 1 2 100 200 KBIC 240DS 9423 115 0 90 9 0 6 0 0 5 18 0 12 0 1 100 2 208 230 Notes 1 Model KBIC 240D is designed to accept 115 or 230 VAC line input to provide 0 130 VDC with a 115 or 230 VAC line and 0 220 VDC with a 208 230 VAC line 2 Model KBIC 240DS is designed to accept 115 or 208 230 VAC line input to provide 0 130 VDC with a 115 or 208 230 VAC line 3 A higher output voltage can be reached by increasing MAX trimpot setting TABLE 3 MINIMUM SUPPLY WIRE SIZE REQUIREMENTS Maximum Motor Maximum Maximum Minimum Size Wire AWG Current Motor Motor Cu Only DC Amps HP 90 V HP 180 V Max 50 Foot Run Max 100 Foot Run 6 0 5 1 16 14 12 1 2 14 12 16 1 5 3 12 12 Minimum recommended wire size TABLE 4 FUSE SELECTION CHART HORSEPOWER Approx Fuse Rating 90 VDC 180 VDC Motor Current AC Amps Motor Motor DC Amps 1 100 1 50 0 1 2 10 1 50 1 25 02 3 10 1 30 1 15 0 3 1 2 1 20 1 10 0 5 3 4 1 15 1 8 0 7 1 1 10 1 5 1 0 1 1 2 1 8 1 4 1 3 2 1 6 1 3 1 7 3 1 4 1 2 2 5 4 1 3
14. ead 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 Warning on page 5 before proceeding See Figure 1 on page 4 Also see Section 3 Application Information on pages 6 and 7 EAA WARNING Disconnect main power before making connections to the speed control 1 1 Be sure the AC input line voltage corresponds to the control voltage See Table 2 on page 8 1 2 Install the correct Plug In Horsepower Resistor according to armature voltage and motor horsepower See Table 6 on page 11 1 3 Recheck connections AC line to L1 and L2 armature to A and A and Field Shunt motors only to F and F Note If motor runs in improper direction interchange armature leads with Main Power disconnected See Figure 1 on page 4 1 4 Itis recommended that both AC line and armature fuses be installed See Table 4 on page 9 FIGURE 1 GENERAL CONNECTION DIAGRAM Blue U PWR ON AC L3 Fuse Holder Ki Supplied Separately MO CIE 1 2 mm a Line and Fuse AC Line Input MAX High a m Wc D Dl Main Speed Potentiometer Supplied Front View Wiper Low
15. ge is connected to P2 and F The control output voltage will linearly follow the input voltage The source impedance of the input should be 10K ohms or less The Min and Max trimpots are rendered inoperative in the voltage following mode Use auxiliary trimpots for scaling and to limit the control range If the input signal is not isolated or is a current signal 4 20 mA the KBSI 240D or SI 5 Barrier Terminal Board Signal Isolator must be used It will allow direct connection to process controllers and microprocessors CAUTION The voltage feeding P2 and F must be isolated from the AC line Do not earth ground P2 or F to setup a zero or ground reference 2 Do not bundle signal wires to P2 and F with AC line or motor connections If signal wires are over 18 inches use shielded cables 9 5 Connection Methods Additional methods for motor connections may be used See Figure 11 FIGURE 11 CONNECTION METHODS KBIC WITH BARRIER TERMINAL L1 L2 A1 A2 F F P1 P2 P3 alos N lalalala O i i P i AC ARMATURE FIELD POTENTIOMETER AC DC MOTOR CONNECTION Le 22 10 9 6 Optional Overload Protection with KBAP 240D Part No 9106 The KBAP 240D is a multipurpose DC Current Sensing Relay and Overload Protector It is specifically designed for use with DC motors and speed controls from 1 8 3 HP KBAP 240D operates by sensing cu
16. he Power Bridge Integrated circuitry is used to provide an uncomplicated design with superior load and line voltage regulation The Direct Fed current limit circuit protects the motor and control against overloads by limiting the maximum level of output current It also prevents motor failure due to demagnetization of the magnets of PM motors Acceleration start adjustable from 0 5 to 4 seconds provides a smooth start each time the AC power is applied A unique feature of the KBIC control is the Plug in Horsepower Resistor It eliminates the need to recalibrate IR Comp and CL when the control is used over a wide range of motor horsepower Additional versatility is achieved by using the Auxiliary Heat Sink optional which is used to double the horsepower rating of each model The output of the control is a linear function of potentiometer rotation The KBIC can also be operated in a voltage following mode by supplying an isolated analog signal 0 7 VDC to the input terminals P2 and F If an isolated input signal is not available the optional Barrier Terminal Board Signal Isolator SI 5 can be used The controls are terminated as standard with Q D terminals provided A Barrier Terminal Board is available which includes both line and armature fuse holders The Inhibit circuit Terminals 11 and 12 are provided to electronically disconnect the armature output voltage Another standard feature is Auto Inhibit This circuit prevents false s
17. it extinguishes output of control during brake When the armature is reenergized the inhibit releases which allows for a smooth start A WARNING 1 THE INHIBIT CIRCUIT TERMINALS I1 AND I2 IS NEVER TO BE USED AS A SAFETY DISCONNECT SINCE IT IS NOT FAIL SAFE USE ONLY THE AC LINE FOR THIS PURPOSE 2 DO NOT DISCONNECT AND RECONNECT THE MOTOR ARMATURE WITH THE AC LINE APPLIED OR CATASTROPHIC FAILURE WILL RESULT SEE ARMATURE SWITCHING DYNAMIC BRAKING ON PAGE 20 9 3 Leader Follower Connections The KBIC can be used with the KBSI to drive multiple motors Refer to Figure 10 FIGURE 10 LEADER FOLLOWER b SINGLE MAIN MOTOR RATIO MAIN MOTOR 5K OHM KBIC o B A FOLLOWER ISOLATION DIODE A FOLLOWER 5K CONNECT POT AS ABOVE FOLLOWER MOTOR 3 Connect the high side of the ADDITIONAL potentiometer to the terminal FOLLOWER p 4 QD A 10K ratio potentiometer is used to control up to 10 Follower motors If a 5K ratio potentiometer is used up to 5 Follower motors can be used 1 Multiple KBIC controls should be powered from the same phase AC line 2 The positive output terminal to each speed must be installed with a 1A 600PIV isolation diode 21 9 4 Voltage Following All models can be controlled with an isolated analog reference voltage 0 7 VDC in lieu of the main speed potentiometer The volta
18. ncreased to the maximum time of 4 seconds full rotation then decrease the IR and increase the MAX as per above percentages of rotation The following procedure is presented in required order of adjustment It should be followed when readjusting all trimpot functions 7 1 Acceleration Trimpot ACCEL FIGURE 4 ACCEL TRIMPOT The ACCEL Trimpot is provided to allow for a smooth RANGE start over an adjustable time period each time the AC power is applied or the Main Speed Potentiometer is 3SEC SLOW4SEC adjusted to a higher speed A FACTORY The ACCEL Trimpot has been factory set to 2 seconds SETTING do which is the amount of time it will take for the motor to 2 SEC accelerate from zero speed to full speed To increase the acceleration time rotate the ACCEL Trimpot clockwise 1 SEC To decrease the acceleration time rotate the ACCEL Trimpot counterclockwise See Figure 4 Do Not rotate the Accel Trimpot into L he shaded area 7 2 Note 7 3 Note Maximum Speed Trimpot MAX The MAX Trimpot sets the maximum speed of the motor when the Main Speed Potentiometer is set fully clockwise The MAX Trimpot is factory set 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 See Figure 5 Do not attempt to adjust the MAX speed above the rated motor RPM since unstable motor opera
19. recommended that the following procedure be followed A typical HI POT test setup is shown in Figure 3 on page 15 All controls have been factory hi pot tested in accordance with UL requirements 4 A WARNING WHEN PERFORMING THE HI POT TEST DISCONNECT THE AC POWER 6 1 6 2 Connect all equipment AC power input lines together and connect them to the H V lead of the HI POT Tester Connect the RETURN of the HI POT Tester to the frame on which the control and other auxiliary equipment are mounted Refer to Figure 3 on page 15 for further information The HI POT Tester must have an automatic ramp up to the test voltage and an automatic ramp down to zero voltage Note If the Hi Pot Tester does not have automatic ramping then the HI POT output must be manually increased to the test voltage and then manually reduced to zero This procedure must be followed for each machine to be tested A suggested HI POT Tester is Slaughter Model 2550 CAUTION Instantaneously applying the HI POT voltage will cause irreversible damage to the control FIGURE 3 HI POT TEST SETUP High Voltage Dielectric Withstand Tester Hi Pot Tester LEAKAGE AC KILOVOLTS RETURN TEST VOLTAGE e E H V RESET Connect all Speed Control e terminals together aes ZERO MAX Speed Control AC Line input Motor Wires Connect Hi Pot Tester Auxiliary Equipment to both AC Line inputs 1 12 Chassis
20. rmature Fuse Kit Part No 9849 Provides fusing for the AC line input and armature Includes wired fuse holders and mounting screws Fuses supplied separately 23 24 OPTIONAL ACCESSORIES CONTINUED DIN Rail Mounting Kit Part No 9995 e KBAP 240D Current Sensing Overload Protector Part No 9106 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 208 230 Volt AC line input e KBEP 240D Electronic Potentiometer Part No 9108 Provides digital type control of motor speed Replaces a standard rotary potentiometer with a set of customer supplied momentary push buttons or membrane switches e KBET 240D Electronic Tachometer Part No 9469 Provides an isolated tach feedback signal and an isolated voltage follower signal from an open collector Hall magnetic inductive and optical or 2 wire inductive pickup encoder Operates on 115 or 208 230 Volt AC line input e RFI Filters Provide RFI and EMI suppression Rated for 208 230 Volt 50 60 Hz AC Complies with CE Council Directive 89 336 EEC relating to the Class A Industrial Standard and Class B Residential Standard Filters are available in remote or undermount types See Table 7 TABLE 7 RFI FILTER SELECTION Model No Part No pony Mounting CE Class KBRF 200A 9945C 24 Remote A Industrial KBRF 250 9509 10 Undermount A Industrial KBRF 300 94
21. rrent in the armature circuit When the preset level is reached the output relay RY1 trips An adjustable time delay 0 2 15 secs is incorporated which eliminates nuisance tripping Manual or automatic reset is provided at the user s option along with a LED which indicates when the preset current level has been reached When an overload occurs the KBAP 240D can be used to shut the system down sound an alarm or initiate corrective action before damage occurs Refer to Figure 12 FIGURE 12 INTERNAL SENSING Internal Sensing Circuit Wire the KBAP in accordance with this wiring diagram OPTIONAL ACCESSORIES e Auxiliary Heat Sink Part No 9861 Doubles the horsepower rating of the control e Barrier Terminal Accessory Kit Part No 9863 When used with the Auxiliary Heat Sink it converts the quick connect terminals of the control to a barrier terminal block e Barrier Terminal Board Part No 9884 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 e SI 5 Signal Isolator Part No 9443 Provides isolation between non isolated signal sources and the control Plugs onto the quick connect terminals of the control e Dial Plate amp Knob Kit Part No 9832 Provides indication of the Main Speed Potentiometer position 0 100 96 e AC Line amp A
22. tarts and high surge currents when cycling the KBIC control with the AC line All models are UL Listed for the USA and Canada and are CE approved APPLICATION INFORMATION 4 1 Motor Type The KBIC is designed for Permanent Magnet PM Shunt Wound and Universal AC DC motors Controls operated on 115 volt AC inputs are designed for 90 volt SCR rated motors Controls operated on 230 volt AC inputs are designed for 180 volt SCR rated motors Use of higher voltage motors will result in reduction of available maximum MAX speed Trimpot Adjustment Also if motor is not an SCR rated type the actual AC line amperage at full load should not exceed the motor s DC nameplate rating 4 2 Torque Requirements When replacing an AC induction motor with a DC motor and speed control consideration must be given to the maximum torque requirements The full load torque rating of the DC motor must be equal to or greater than that of the AC motor 4 3 Acceleration Start The KBIC contains an adjustable acceleration start feature that allows the motor to smoothly accelerate from 0 full speed over a time period of 0 5 4 seconds The ACCEL is factory set at 2 seconds 4 4 Limitation in Use The KBIC controls are designed for use on machine applications 4 5 Armature Switching Do not switch the armature without taking proper precautions Refer to Armature Switching and Dynamic Braking Section 9 2 on page 20 CAUTION Consult factory before
23. th the United States Copyright Act of 1976 no part of this publication may be reproduced in any form or by any means without permission in writing from KB Electronics Inc 8 2002 The information contained in this brochure is intended to be accurate However the manufacturer retains the right to make changes in design which may not be included herein KB ELECTRONICS Inc 4 12095 NW 39 Street Coral Springs FL 33065 954 346 4900 Fax 954 346 3377 Outside Florida Call TOLL FREE 800 221 6570 Email info kbelectronics com www kbelectronics com A40202 Rev A 1 2008
24. tion may occur For moderate changes in the MAX speed there will be a slight effect on the MIN speed setting when the MIN speed is set at zero There may be significant variation in the MIN speed setting if the MIN speed is at a higher than zero setting Minimum Speed Trimpot MIN The MIN speed trimpot sets the minimum speed of the motor when the Main Speed Potentiometer is set fully counterclockwise The MIN Trimpot is 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 See Figure 6 Readjusting the MIN Trimpot will affect the maximum speed setting Therefore it is necessary to readjust 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 FIGURE 5 MAX TRIMPOT RANGE Factory Set to 100 Base Speed FIGURE 6 MIN TRIMPOT RANGE 0 Factory Set to 0 Base Speed 17 7 4 Current Limit Trimpot CL The CL Trimpot sets the current limit overload which FIGURE 7 CL TRIMPOT RANGE limits the maximum current torque to the motor The CL also limits the AC line inrush current to a safe level 150 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 do not exceed 2 times 200
25. using on constant horsepower applications such as saws or drill presses Do not use in explosive atmosphere Be sure the KBIC is used within its maximum ratings Follow all installation instructions carefully Refer to Section 5 on page 12 FIGURE 2 MECHANICAL SPECIFICATIONS OPTIONAL AUXILIARY HEATSINK POTENTIOMETER Ic gunt q ha 3T Eoo 3H Ue Iu a CONTROL L MOUNTING A 6 SLOTS MOUNTING B TAPPED 6 32 3 PLACES 1 FUSE MOUNTING TAPPED 6 32 2 PLACES 2 ET Ls poh E gt l 1 438l Note All dimensions are shown in inches H WINN IT L TABLE 1 FIELD CONNECTIONS SHUNT WOUND MOTORS ONLY CAUTION AC LINE FIELD VOLTAGE FIELD FIELD TYPE Shunt wound motors may be VOLTAGE VDC CONNECTION damaged if field remains energized 115 100 F F Full Voltage with the motor stopped for an 115 50 F L1 Half Voltage extended period of time unless 230 200 F F Full Voltage provided with external cooling 230 100 F L1 Half Voltage TABLE 2 ELECTRICAL RATINGS RATING WITHOUT RATING WITH shin d d sd AUXILLARY HEAT SINK AUXILLARY HEAT SINK oo k E oltage Voltage VDC pos eg es as Shunt VAC 3 Wound 15 Load Load Max Load Load Max Motor 50 60 Current Current HP Current Current HP Only HE
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