new kbmm manual - KB Electronics, Inc.
Contents
1. The value of RT Q can be calculated using the fol lowing formula RT 1 3 X VT X S 16000 Q Where VT is the tach generator 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 tach generator is to be used with a 3600 RPM motor RT 1 3 X 20 X 3600 16000 77600 Q Choose the closest 1 2 Watt resistor value which is 75000 Q 75 kQ 7 SETTING SELECTABLE JUMPERS The control has selectable jumpers which must be set before it can be used See Figure 1 on page 10 for the location of jumpers 7 1 AC Line Input Voltage Selection Jumper J1 Model KBMM 225D 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 See Figure 11 on page 20 Notes 1 Jumper J1 is installed on Model KBMM 225D only 2 When Jumper J1 is set to the 115 posi tion Jumper J2 must be set to the 90 position or the T position if using a tach generator 20 7 2 Motor Voltage and DC Tach Generator Selection FIGURE 11 AC LINE INPUT VOLTAGE SELECTION Jumper J2 is factory set to the 90 position on Model JUMPER 1 MODEL KBMM 225D ONLY KBMM 125 for 90 Volt DC motors and set to the J1 Set for J1 Set for 180 position on Models KBMM 225 225D for 180 20s aovo tac o q 115 Volt AC Line Input Factory Setting Volt DC mo2. Main Speed Potentiometer Front View Terminal P3 Terminal P2 Terminal P1 Open Collector On to Run Off to Stop Main Speed Potentiometer Front View of the load Inhibit Circuit Connection The control can be stopped and started with an Inhibit circuit close to stop open to run Wire the switch or contact to Terminals 11 and 12 as shown in Figure 7 When the switch or contact is closed the motor will coast to stop When the switch or contact is opened the motor will accelerate to the Main Speed Potentiometer setting An open collector NPN can be wired 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 7 INHIBIT SWITCH OR CONTACT WIRED TO THE INHIBIT TERMINALS Terminal 1 Terminal 12 Inhibit Switch or Contact Open Collector Open to Run Off to Run Close to Stop On to Stop 17 6 9 DC Tach Generator Connection A DC tach generator can be used for load regulation of 1 of the set speed Note Jumper J2 must be set to the T position for tach generator operation Connect the tach generator as follows Application Notes 1 The tach generator input circuit is designed for a 7 Volt or 50 Volt per 1000 RPM DC tach generator used with an 1800 RPM motor 2 Initially set the
3. 14 30 13 3 Reversing and Dynamic Braking The optional patented APRM provides anti plug instant reversing and solid state dynamic braking The APRME is built in as standard on Models KBCC R and KBPB Contact the Sales Department for more information OPTIONAL ACCESSORIES 14 1 14 2 14 3 14 4 14 5 14 6 14 7 14 8 14 9 Auxiliary Heat Sink Part No 9861 Doubles the horsepower rating of the control Barrier Terminal Accessory Kit Part No 9883 When used with the Auxiliary Heat Sink it converts the quick connect terminals of the control to a barrier terminal block Barrier Terminal Board Part No 9897 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 SI 6 Signal Isolator Part No 9444 Provides isolation between non isolated signal sources and the con trol Plugs onto the quick connect terminals of the control Run Brake Module Part No 9952 Used for applications that require rapid stopping of the motor Contains a barrier terminal block Dial Plate and Knob Kit Part No 9832 Provides indication of the Main Speed Potentiometer position O 100 Finger Safe Cover Part No 9564 Converts the control from open chassis to the IP 20 standard Fuse holders must be removed when installing the finger safe
4. 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 KB s Auxiliary Heat Sink4 Models KBMM 225 and KBMM 225D also allow operation of 90 Volt DC motors when used on 208 230 Volt AC line input gt The versatility of the control is confirmed by its extensive list of standard features such as selectable armature and tach feedback and adjustment trimpots for minimum speed maximum speed current limit IR compensation and linear acceleration and deceleration The control includes Auto Inhibit which eliminates surging during rapid AC line switching pulse transformer triggering which provides cogless operation at low speed and superior noise rejection circuitry which eliminates false starts and blown SCRs Enable normally closed and Inhibit normally open functions provide electronic switching of control output The output voltage of the control is a linear function of the Main Speed Potentiometer rotation In addition the control can be used in a voltage following mode by supplying an isolated analog input signal to Terminals P2 and P1 6 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 5 kQ
5. 0 Full Load 50 1 Speed Range Base Speed 1 Tach Generator Feedback Load Regulation 0 Full Load 50 1 Speed Range Set Speed 1 Line Voltage Regulation at Full Load 10 Line Variation Y Speed 0 5 Control Linearity Output Voltage vs Signal Input Voltage 2 Acceleration ACCEL Trimpot Range Seconds 0 2 10 2 Deceleration DECEL Trimpot Range Seconds 0 2 10 2 Maximum Speed MAX Trimpot Range Base Speed 50 110 100 Minimum Speed MIN Trimpot Range Base Speed 0 30 0 Current Limit CL Trimpot Range Full Load 0 200 150 IR Compensation IR Trimpot Range at Specified Full Load 90 180 Volts DC Output Volts DC 0 24 48 3 6 Notes 1 Step down operation motor may have reduced brush life Consult motor manufacturer 2 Performance is for SCR rated permanent magnet motors only Lower performance can be expected with other motor types Factory setting is for 3 load regulation To obtain superior regulation see Section 11 6 on page 27 FIGURE 1 CONTROL LAYOUT 8 GENERAL CONNECTION DIAGRAM Model KBMM 225D Shown Note Control is set for 208 230 VAC line input 0 180 VDC output with armature feedback Plug In AC Line Fuse Supplied Separately DON A DOT E Enable Switch Close to Run Open to Stop AC Line Main Speed Potentiometer Input Front View Inhibit Switch Open to Run Close to
6. 13 2 13 2 Armature Switching and Dynamic FIGURE 20 TYPICAL DYNAMIC BRAKE CIRCUIT CONNECTION Braking If the armature is to be dis connected and reconnected with the AC power applied wire a relay or contactor and a brake resistor RB in the armature circuit The Inhibit Circuit must be simul AC Line Input taneously activated when braking Wire a double pole double throw DPDT mechanically ganged switch to the Inhibit Terminals and the relay or contactor coil as shown in Figure 20 The resist ance and wattage of RB must be chosen according to braking requirements Speed Control Motor Armature Double Pole Double Throw Mechanically Ganged Switch Relay or Contactor Coil When the switch is in the Brake posi tion the relay is deenergized and allows the motor voltage via the 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 elimi nates arcing When the switch is in the Run position the N C contact opens the N O contact closes the Inhibit is deactivated and the motor begins to accelerate according to the setting of the ACCEL Trimpot to the Main Speed Potentiometer setting WARNING The Inhibit Circuit Terminals 11 and 12 is never to be used as a Safety Disconnect since it is not fail safe Use only the AC line for this purpose 29
7. 9 0 25 female crimp on termi nals 4 0 11 female crimp on terminals and an Enable harness CE Approved Product Information Card and Warranty Registration Card Items required to operate this control Plug In Horsepower Resistor AC Line Fuse and Armature Fuse Supplied through your distributor See Sections 8 and 9 on pages 20 22 3 1 SIMPLIFIED INSTALLATION INSTRUCTIONS IMPORTANT Read these simplified installation instructions before proceeding These instructions are to be used as a reference only and are not intended to replace the detailed instructions provided herein You must read the Safety Warning on page 6 before proceeding Note A Plug In Horsepower Resistor and AC Line and Armature Fuses supplied separately must be installed in order for this product to operate See Section 9 on page 21 Fuse Plug In Horsepower Resistor 1 1 1 2 1 3 1 4 AC Line Connection Wire the AC line to Terminals L1 Line Fuse and L2 as shown in Figure 1 on page 10 and as described in Section 6 1 on page 13 Model KBMM 125 is rated for 115 Volt AC line input only Model KBMM 225 is rated for 230 Volt AC line input only Model KBMM 225D is rated for 115 Volt AC line input Jumper J1 in the 115 position and 230 Volt AC line input Jumper J1 in the 230 position See Section 7 1 on page 19 Notes 1 The rated AC line voltage 115 208 230 of the control must match
8. 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 Set the Main Speed Potentiometer to approximately 30 50 clockwise position Set the CL Trimpot fully counterclockwise The CL LED will illuminate red Lock the motor shaft be sure the CL Trimpot is set fully counterclockwise Apply power and 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 the factory Current Limit setting will read 0 75 times the full load rating of the motor Do not exceed 2 times motor current rating maximum clockwise position Note On cyclical loads it may be normal for the CL LED to momentarily flash WARNING Do not leave motor shaft locked for more than 2 3 seconds or motor damage may result 11 6 IR Compensation Trimpot IR The IR Trimpot sets FIGURE 19 IR TRIMPOT RANGE the amount of compensating voltage required to keep the motor speed constant under changing loads If the load does not vary substantially the IR
9. IR Compensation and Current Limit based on motor horsepower and voltage The Plug In Horsepower Resistor eliminates the need to recali brate IR Compensation and Current Limit in most applications 2 Be sure the Plug In Horsepower Resistor is inserted completely into the mating sockets 21 TABLE 6 PLUG IN HORSEPOWER RESISTORO SELECTION 90 130 Volt DC Motors 180 Volt DC Motors Plug In Horsepower Resistor HP HP Value Ohms Part No 1 100 1 50 1 50 1 25 1 9833 1 50 1 30 1 25 1 15 51 9834 1 30 1 20 1 15 1 10 35 9835 1 20 1 12 10 1 6 25 9836 112 118 1 6 1 4 18 9837 1 8 1 5 1 4 1 3 A 9838 1 4 1 2 05 9839 1 3 3 4 035 9840 1 2 1 025 9841 3 4 1 015 9842 1 2 01 9843 1 3 006 9850 Indicates an Auxiliary Heat Sink Part No 9861 or equivalent must be used to achieve rating indicated 10 RECOMMENDED HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING Hi Pot Testing 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 recommended that the follow ing procedure be followed A typical hi pot test setup is shown in Figure 13 on page 23 Note All controls have been factory hi pot tested in accordance with UL requirements MA WARNING When performing the hi pot test disconnect the AC power 22 FIG
10. 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 KB Limited Warranty applies See page 32 3 Fuses and Plug In Horsepower Resistor supplied separately See Sections 8 and 9 on pages 20 22 4 Part No 9867 See Section 14 1 on page 30 5 Step Down operation 6 If an isolated signal input is not available or if using a 4 20 mA DC signal input install the optional plug on SI 6 Signal Isolator Part No 9444 3 1 Standard Features 1 10 11 12 13 14 Plug In Horsepower Resistor Eliminates the need to calibrate the control for IR Compensation and Current Limit when used on various horsepower motors Auto Inhibit Allows the control to be rapidly switched on and off using the AC line Inhibit and Enable Allows the control to be turned on and off using electronic switching Trimpots Minimum Speed MIN Maximum Speed MAX IR Compensation IR Current Limit CL Acceleration ACCEL and Deceleration DECEL Jumpers AC Line Input Voltage Selection J1 Model KBMM 225D only Motor Voltage and DC Tach Generator Selection J2 Protection Features MOV transient protection Short Circuit protected at motor only Diagnostic LEDs Power On PWR ON and Current Limit CL Model KBMM 125 operates on 115 Volt AC line input with 90 Volt DC motors Model KBMM 225 operates on 23
11. 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 war ranty or guarantee expressed or implied KB Electronics Inc is not responsible for any expense including instal lation 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 2000 COPYRIGHT 2004 by KB ELECTRONICS INC All rights reserved In accordance with the United States Copyright Act of 1976 no part of this publication may be repro duced in any form or by any means without permission in writing from KB Electronics Inc 8 22 02 KB Electronics Inc 4 12095 NW 39th Street Coral Springs FL 33065 2516 954 346 4900 e Fax 954 346 3377 Outside Florida Call TOLL FREE 800 221 6570 E mail info kbelectronics com www kbelectronics com A40209 Rev A 8 2004
12. the actual AC line input voltage 2 If one of the AC line inputs is a neutral N wire it to Terminal L2 Ground Connection Connect the ground wire earth to the control chassis Motor Connection Connect the motor to Terminals A Armature Fuse and A as shown in Figure 1 on page 10 and as described in Section 6 3 on page 14 Jumper Settings Jumper J1 on Model KBMM 225D only and Jumper J2 all models have been factory set for most applications as shown in Figure 1 on page 10 and as described in Section 7 on page 19 1 5 1 6 1 7 1 8 1 9 AC line Fusing It is required that an AC line fuse supplied separately be installed in the AC Line Fuse Holder as shown in Figure 1 on page 10 Select the correct AC Line Fuse as described in Section 8 on pages 20 and 21 Fuse each conductor that is not at ground potential Armature Fusing It is required that an Armature Fuse supplied separately be installed in the Armature Fuse Holder as shown in Figure 1 on page 10 Select the correct Armature Fuse as described in Section 8 on pages 20 and 21 Plug In Horsepower Resistor Install the correct Plug In Horsepower Resistor according to armature voltage and motor horsepower as shown in Figure 1 on page 10 Select the correct Plug In Horsepower Resistor as described in Section 9 on pages 21 and 22 Trimpot Settings All trimpots have been factory set for most applications as shown i
13. ture switching is required for reversing or dynamic braking use Model KBMG KBRG KBPB KBCC R 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 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 connections 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 45 C 113 F at full rating See Figure 2 on page 11 6 WIRING INSTRUCTIONS A WARNING Read Safety Warning on page 6 before using this control Disconnect the main power when making connections to the control To avoid electric shock be sure to properly ground control Important Application Note To avoid erratic operation do not bundle the AC line and motor wires with wires from signal following start stop contacts or any other signal wires Also do not bundle motor wires from mul
14. 0 for the location of trimpots 24 y Warning If possible do not adjust trimpots with the main power applied If adjustments are made with the main power applied an insulated adjustment tool must be used and safety glasses must be worn High voltage exists in this control Electrocution can result if caution is not exer cised Safety Warning on page 6 must be read and understood before proceeding 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 See Section 9 on page 21 FIGURE 14 11 1 Acceleration Trimpot ACCEL The ACCEL Trimpot is provided to allow for a ACCEL TRIMPOT RANGE 5 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 3n 8 Trimpot has been factory set to 2 seconds which is the amount of time it will 2 take for the motor to accelerate from zero speed to full speed To increase the 02 RE YA 10 acceleration time rotate the ACCEL Trimpot clockwise To decrease the accel Factory Set to 2 Seconds eration time rotate the ACCEL Trimpot counterclockwise See Figure 14 11 2 Deceleration Trimpot DECEL The DECEL Trimpot controls the amount of ramp down time when the Main Speed Potentiometer is adjusted to a lower speed The DECEL Trimpot ha
15. 0 Volt AC line input with 180 Volt DC motors or 90 Volt DC motors step down Jumper Selectable Model KBMM 225D 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 Armature or DC Tach Generator feedback Built in AC line and armature fusing Main Speed Potentiometer 5 kQ SMT construction TABLE 1 ELECTRICAL RATINGS AC Line Maximum Rating without Auxiliary Heat Sink Maximum Rating with Auxiliary Heat Sink Motor Field Part Voltage AC Line DC Load AC Line DC Load Model Voltage Voltage No 215 50 60H2 yoyo gt Current Current Horsepower Current Current Horsepower Volts a Volts AC RMS Amps Avg A ile Csr UPS ps Avg Amps RMS Amps Avg Amps KBMM 125 9449 115 0 90 12 0 8 0 75 6 24 0 16 0 1 5 1 1 50 100 0 180 12 0 8 0 1 5 1 1 24 0 16 0 3 2 3 100 200 KBMM 225 9450 230 0 90 12 0 8 0 75 6 24 0 16 0 1 5 1 1 100 115 0 90 12 0 8 0 75 6 24 0 16 0 1 5 1 1 50 100 KBMM 225D 9451 230 0 180 12 0 8 0 1 5 1 1 24 0 16 0 3 2 3 100 200 0 90 12 0 8 0 75 6 24 0 16 0 1 5 1 1 100 Step down operation TABLE 2 GENERAL PERFORMANCE SPECIFICATIONS Description Specification Factory Setting Speed Range Ratio 50 1 Armature Feedback Load Regulation
16. 0 and 90 Volt SCR rated motors Use of motors with higher rated voltage 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 and full speed should not exceed the motor s DC nameplate current rating 4 2 Torque Requirements The motor selected for the application must be capable of supplying the necessary torque In order to ensure the motor is not overloaded a DC ammeter should be connected in series with the armature Be sure the current under full load does not exceed the motor nameplate rating 4 3 4 4 4 5 4 6 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 Limitation In Use The control is designed for use on machine applications CAUTION Consult our Sales Department before using this control on constant horsepower applica tions such as saws and drill presses Do not use this control in an explosive atmosphere Be sure the control is used within its ratings Follow all instructions carefully Armature Switching Do not wire the control for armature switching without taking proper precautions See Section 13 2 on page 29 WARNING Do not switch the armature in and out of circuit or catastrophic failure will result If arma
17. AC Armature Voltage Volts DC Field Voltage Volts DC Terminal Connections 100 F F KBMM 125 115 0 90 50 F L1 0 180 200 F F KBMM 225 208 230 0 90 100 F L1 100 F F 115 0 90 50 F L1 KBMM 225D 208 230 0 180 200 F F 208 230 0 90 100 F L1 Step down operation 6 5 6 6 Remote Main Speed Potentiometer Connection The control is supplied with a Main Speed Potentiometer to control motor speed Wire the low side of the potentiometer to Terminal P1 Wire the wiper of the potentiometer to Terminal P2 Wire the high side of the potentiometer to Terminal P3 See Figure 3 Voltage Following Connection An isolated 0 9 Volt DC ana log 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 isolat ed from the AC line Connect the signal input positive lead to Terminal P2 and the negative lead to Terminal P1 as shown in Figure 4 The source impedance of the signal input should be 10 kQ or less The MAX Trimpot is not operational in voltage following mode Use the MIN trimpot to set an initial value of input signal If necessary use auxiliary trimpots to scale and or limit the input voltage A CAUTION Do not earth ground any input terminals Notes 1 If an isolated signal input is not available or if using
18. Connection Connect the ground wire earth to the control chassis 6 3 6 4 Permanent Magnet PM Motor Connection Wire the motor armature positive lead to Terminal A Armature Fuse and the negative lead to Terminal A as shown in Figure 1 on page 10 On Models KBMM 225 and KBMM 225D be sure Jumper J2 is set to the corresponding motor voltage as described in Section 7 2 on page 20 Be sure the correct Plug In Horsepower Resistor6 is installed as described in Section 9 on page 21 Motor Field Connection Shunt Wound Motors Only 6 4 1 Full Voltage Field Wire the field positive lead to Terminal F and the negative lead to Terminal F as shown in Figure 1 on page 10 and as described in Table 4 6 4 2 Half Voltage Field For 90 Volt DC motors with 50 Volt DC fields and 180 Volt DC motors with 100 Volt DC fields wire the field positive lead to Terminal F and the negative lead to Terminal L1 Line Fuse as described in Table 4 Notes 1 Do not connect motor armature leads to Terminals F and F 2 Do not use Terminals F and F for any purpose other than to power the field of a shunt wound motor 3 Shunt wound motors may be damaged if the field remains energized without armature rotation for an extended period of time TABLE 4 FIELD CONNECTION Shunt Wound Motors Only Model AC Line Input Voltage Volts
19. E O Factory Set to 0 of Base Speed FIGURE 17 MAX TRIMPOT RANGE Cy 50 KA 110 Factory Set to 100 of Base Speed wise To decrease the maximum speed rotate the MAX Trimpot counterclockwise See Figure 17 CAUTION Do not set the maximum speed above the rated motor RPM since unstable motor operation may occur 25 26 uy Warning If possible do not adjust trimpots with the main power applied If adjustments are made with the main power applied an insulated adjustment tool must be used and safety glasses must be worn High voltage exists in this control Electrocution can result if caution is not exer cised Safety Warning on page 6 must be read and understood before proceeding 11 5 Current Limit Trimpot CL The CL Trimpot sets the current limit FIGURE 18 overload which limits the maximum current torque to the motor The CL CL TRIMPOT RANGE also limits the AC line inrush current to a safe level during startup The CL 7 150 Trimpot is factory set to 1 5 times the full load rating of the motor To increase the current limit rotate the CL Trimpot clockwise do not exceed 2 times motor current rating maximum clockwise position I RJ 200 To decrease the current limit rotate the CL Trimpot counterclockwise Factory set to 150 of Full Load See Figure 18 Note The correct value Plug In Horsepower Resistor must be installed for the
20. IR Comp Trimpot fully counterclockwise Once the tach generator is connected the IR Comp Trimpot may be increased for additional speed stabilization 6 9 1 Seven 7 Volt per 1000 RPM Tach Generator Connect the tach generator positive lead to Terminal T and the negative lead to Terminal 12 as shown in Figure 8 6 9 2 Fifty 50 Volt per 1000 RPM Tach Generator Connect the tach generator positive lead to Terminal B and the negative lead to Terminal 12 as shown in Figure 9 6 9 3 Other Tach Generator Voltages The tach gener ator input circuit is designed for a 7 Volt or 50 Volt per 1000 RPM DC tach generator used with an 1800 RPM motor For a tach generator 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 FIGURE 8 DC TACH GENERATOR CONNECTION 7 VOLTS PER 1000 RPM Terminal T Terminal 12 DC Tach Generator FIGURE 9 DC TACH GENERATOR CONNECTION 50 VOLTS PER 1000 RPM Terminal B 50V 1000 DC Tach Generator tach generator Connect one end of RT to Terminal FIGURE 10 OTHER DC TACH GENERATOR T connect the other end of RT to the tach CONNECTION generator positive lead and connect the negative lead of the tach generator to Terminal 12 See Figure 10
21. Installation and Operation Manual KBMM Surface Mount Technology Solid State SCR DC Motor Speed Controls for Use with 1 100 3 HP 90 and 180 Volt Permanent Magnet and Shunt Wound DC Motors AC Line Input 115 and 208 230 Volts 50 60 Hz This Manual Covers Models KBMM 125 225 225D Ultra Fast Current Limit Circuit Prevents Demagnetization in Permanent Magnet Motors A See Safety Warning on page 6 amp 21 2 Mus ce See page 6 for CE Information PATENTED A Plug In Horsepower Resistor and AC Line and Armature Fuses supplied separately must be installed for this product to operate Auxiliary Heat Sink Part No 9861 is required to achieve maximum rating of control See Electrical Ratings Table 1 on page 9 The information contained in this manual is intended to be accurate However the manufacturer retains the right to make changes in design which may not be included herein PENTA E POWER Manufactured A COMPLETE LINE OF MOTOR DRIVES 2004 KB Electronics Inc in the USA See back cover TABLE OF CONTENTS Section Page fo SIMIPITSS installato Instructions senie gs ay ae EDI AA AA ae de 4 21 Safety WANO Za rata A A A A A as eta ayn ee 6 SN teja A A O A A O soe pated i i 7 A APICAL AOA
22. O ceso da Gs EAS AAA AN A EA 11 5 MOUNTING INStTUCIONS akioa AA A A A A A 12 VINILOS y IA AS A A A A Re NER A eee 13 T Setting Selectable Jumpers ii A A LA a da la 19 8 ACLine and Armature Fusing o oo oococcccco ene nee tenes 20 9 Plug In Horsepower ReSistor ia sia bk ida edad eae Gadd la pa cid ra baa a 21 10 Recommended High Voltage Dielectric Withstand Testing Hi Pot Testing 0 0000000000 22 Ta APIMPOt AGIUSHINENIS di enc seit aa is e Goto ee land caches ae PEM OS RAN Aiea Pete Hs Bort 24 12 Diagnostic EDS a A aa ee ae A AA a 28 he OWI CICUS A EN 28 14 Optional ACCESSOrIES gt tae cetera sean aura db or aio deine dsc HAP De Ratton AAA 30 Limited Warranty Exts a oe Bee il LAG be 32 Tables Ti Electrical Ratings ia la O A EA tale Dae e 9 2 General Performance Specifications 2 0 ec tenet ene 9 3 Minimum Supply Wire Size Requirements 0 00 ccc teen teens 13 4 Field Connection Shunt Wound Motors Only essea esasa aeaea 14 5 AC Line and Armature F se Selec Mass nus arcos ene ea a ELVA USSR re eee OR EE EE ASS 21 6 Plug In Horsepower Resistor Selection ce pans see dees eeu ay heehee SPER TIGRE ALN seb ee ea ee ee 22 T BRA SCHON als foci dl Minas hee tad a ENE A TAGE wed ke De eae N 31 TABLE OF CONTENTS Continued Figures Page 1 Control Layout and General Connection Diagram usas risa rt ee AA A ai OS 10 24 Mechanical Specifications o s cia a a SL Ea 11 3 Remote Main Sp
23. Stop Motor Field Shunt Motors Only Horsepower Resistor Supplied Separately TONS Armature Fuse Supplied Separately For Plug In Horsepower Resistor Line Fuse and Armature Fuse Selection See Sections 8 and 9 on pages 20 22 ESS Motor Armature DC Tach Generator Set J2 to T Position FIGURE 2 MECHANICAL SPECIFICATIONS Inches mm MAIN SPEED OPTIONAL AUXILIARY HEAT SINK se POTENTIOMETER cal 4 5 10 2 SUPPLIED i ma 78 5 l 0 U U U i 3 8 le 1 2 e A a E o 1 c 127 1 r MOUNTING A i CONTROL 6 SLOTS 1 i MOUNTING B 1 174 ROUND oo E S 15 TAPPED 10 32 1 SHAFT 7 00 8 PLACES 1a 3 00 4 30 762 109 Lo 3 8 32 mal FUSE HOLDER amp FINGER SAFE o AN Tron BUSHING EN 150 COVER MOUNTING HOLES 126 PIN 6 6 381 TAPPED 6 32 aie 130 8 2 PLACES 546 a 14297 628 7 1 159 1 13 i Lt 1 3 1 P3 125 o 1 25 i Y N N i f l 95 le P P z 75 1 75 64 25 EIA 1 2 191 P 44 5 163 64 24 1 44 le 138 i 1 75 18 1 25 _ aa 34 Ped z 445 ae 31 8 oe 4 APPLICATION INFORMATION 4 1 Motor Type The control is designed for permanent magnet PM and Shunt Wound DC motors Controls operated on 115 Volt AC line input are designed for 90 Volt SCR rated motors Controls operated on 230 Volt AC line input are designed for 18
24. Table 5 8 1 AC Line Fuse 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 8 2 Armature Fuse The Armature Fuse provides overload protection for the motor and control The Armature Fuse required can be calculated by multi plying the maximum DC Motor Current times 1 7 PLUG IN HORSEPOWER RESISTOR TABLE 5 AC LINE amp ARMATURE FUSE SELECTION Recommended Fuse Rating 90 130 Volt 180 Volt DC Motors DC Motors Amps HP HP AC Line Armature 1 100 1 50 1 50 1 25 12 1 3 1 50 1 30 1 25 1 15 12 1 2 1 30 1 20 1 15 1 10 12 3 4 1 20 1 12 1 0 1 6 12 1h 1 12 1 8 1 6 1 4 12 2 1 8 1 5 1 4 1 3 12 24 1 4 1 2 12 4 1 3 3 4 12 5 1 2 1 12 8 3 4 1 12 12 1 2 15 15 1 3 25 25 ed to Plug In Horsepower Resistor A Plug In Horsepower Resistor supplied separately must be insta match the control to the motor horsepower and voltage Plug In Horsepower Resistors are available from your distributor Install the Plug In Horsepower Resistor as shown in Figure 1 on page 10 Select the correct Plug In Horsepower Resistor as shown in Table 6 on page 22 Application Notes 1 The Plug In Horsepower Resistor is used to calibrate the
25. Trimpot 3 6 may be set to a minimum level approximately 1 4 of 0 REY 24 48 full clockwise rotation The IR Trimpot is factory set Factory set to 3 Volts DC for controls with 90 Volt DC Output to provide 3 Volts of compensation for controls with Factory set to 6 Volts DC for controls with 180 Volt DC Output 90 Volt DC output and 6 Volts of compensation for controls with 180 Volt DC output To increase the amount of compensating voltage rotate the IR Trimpot clockwise To decrease the amount of compensating voltage rotate the IR Trimpot counterclockwise See Figure 19 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 caus es cogging 3 For tach generator feedback applications set the IR Trimpot fully counterclockwise See Section 6 9 on page 18 To Recalibrate the IR Trimpot 1 Set the IR Trimpot to approximately 25 rotation 27 Y 4 Warning If possible do not adjust trimpots with the main power applied If adjustments are made with the main power applied an insulated adjustment tool must be used and safety glasses must be worn High voltage exists in this control Electrocution can result if caution is not exer cised Safety Warning on page 6 mus
26. URE 13 HI POT TEST SETUP High Voltage Dielectric Withstand Tester Hi Pot Tester RETURN TEST VOLTAGE e an ta HV RESET Connect all Speed Control O 1 Aj terminals together ZERO MAX 7 Motor Speed Control AC Line input Motor Wires Connect Hi Pot Tester to both AC Line inputs Auxiliary Equipment Chassis Machine or equipment frame 10 1 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 23 10 2 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 11 TRIMPOT ADJUSTMENTS The control contains trimpots which have been factory set for most applications Some applications may require readjustment of the trimpots in order to tailor the control for a specific requirement Readjust the trimpots as described below See Figure 1 on page 1
27. a 4 20 mA DC signal input install the optional plug on SI 6 Signal Isolator Part No 9444 This will also allow direct connections to process controllers and microprocessors 2 If multiple follower motors are to be controlled from a single lead motor or a single Main Speed Potentiometer install the optional KBSI 240D Signal FIGURE 3 REMOTE MAIN SPEED POTENTIOMETER CONNECTION Terminal P3 Terminal P2 Terminal P1 Main Speed Potentiometer Front View FIGURE 4 VOLTAGE FOLLOWING CONNECTION Terminal P2 Terminal P1 v 0 9 Volts DC Isolated Isolator Part No 9431 3 Terminal F may be used in lieu of Terminal P1 6 7 Enable Circuit Connection The control can be started and stopped with an Enable Circuit close to run open to stop as described below 6 7 1 6 7 2 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 Enable Switch or Contact Wired to the Enable Connector Using the wired mating connector that is supplied with the control wire the switch or contact to the Enable connector CONN1 as shown in Figure 5 When the switch or contact is closed the motor will accelerate to the Main Speed Potentiometer setting When the switch or contact is opened the motor will decelerate to stop An open collector PNP can be wired in li
28. cover DIN Rail Mounting Kit Part No 9995 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 230 Volt AC line input 14 10 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 Operates on 115 or 230 Volt AC line input 14 11 KBET 240D Electronic Tachometer Part No 9469 Provides an isolated tack feedback signal and an isolated voltage follower signal from an open collector Hall magnetic inductive optical or 2 wire inductive pickup encoder Operates on 115 or 230 Volt AC line input 14 12 RFI Filters Provide RFI and EMI suppression 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 under mount types See Table 7 TABLE 7 RFI FILTER SELECTION Model Part No Somer Mounting Class KBRF 200A 9945C 24 Remote A Industrial KBRF 250 9509 10 Undermount A Industrial KBRF 300 9484 16 Remote B Residential KBRF 350 9511 10 Undermount B Residential Also meets Industrial Standard 31 LIMITED WARRANTY For a period of 5 years from the date of original
29. eed Potentiometer Connectlon ok ba ee Pa eae cae 15 AY NGAGE POMO WI CONTEO oras ak ES AAA MEY Ral aterm E agii 15 5 Enable Switch or Contact Wired to the Enable Connector 00 eee 16 6 Enable Switch or Contact Wired to the Main Speed Potentiometer 0 0 0 0 eee eee 17 7 Inhibit Switch or Contact Wired to the Inhibit Terminals 0 sses asnes eee 17 8 DC Tach Generator Connection 7 Volts per 1000 RPM 0 ccc eects 18 9 DO Tach Generator Connection 50 Volts per 1000 RPM ansiada re AD A 18 10 Other DC Tach Generator Connection with Addition of RT 0 0 eect eee 19 11 AC Line Input Voltage Selection Jumper J1 Model KBMM 225D Only 0 02 eee eee 20 12 Motor Voltage and DC Tach Generator Selection Jumper J2 2 eee 20 The TEP OR Test Sep as A AA es seek eee Pedal aoa Seg bee eae 23 14 Acesielation Timpot ACCEL RANGE is ar aan aa Lee O O AUN 24 15 Deceleration Thmpor DECGEL RANGE src tab add ad cd e pda ORS 25 10 MINIT Speed Timp t MIN Rate as sa ri A AAN E AAA 25 17 Maximum Speed Trimpot MAX Range coat E A AI ata ora 25 18 Ourrent Limit Irimpot CH Range anen da 26 19 IR Compensation Trimpot IR Range 0 cette DEAL E EA 27 20 Typical Dynamic Brake Circuit Connections rss ex eae be EA ESA A e ei 29 Items Included in this package KBMM Speed Control KBMM Installation and Operation Manual Hardware Bag contains Main Speed Potentiometer with insulator and mounting hardware
30. eu of a switch or contact Notes 1 To use the Enable Circuit FIGURE 5 ENABLE SWITCH OR CONTACT WIRED TO THE ENABLE CONNECTOR remove the jumper Remove this jumper to install that is factory the Mating Connector installed on CONN1 2 The deceleration time Enable Switch Open Collector can only be made or Contact On to Run longer than the Close to Run Off to Stop Open to Stop normal coasting time of the load Enable Switch or Contact Wired to the Main Speed Potentiometer Wire the switch or contact in series with the Main Speed Potentiometer high side and Terminal P3 on the control as shown in Figure 6 on page 17 Be sure the jumper is installed on the Enable Connector CONN1 When the switch or contact is closed the motor will accelerate to the Main Speed Potentiometer setting When the switch or contact is opened the motor will decelerate to the MIN Trimpot setting factory set to O 6 8 Volts DC If the MIN Trimpot is set to other FIGURE 6 ENABLE SWITCH OR CONTACT WIRED TO THE MAIN SPEED POTENTIOMETER than O Volts DC the motor will run at that speed when the switch or contact is opened An open col lector PNP can be wired in lieu of a switch or contact This jumper must be installed Enable Switch or Contact Close to Run Open to Stop Note The decelera tion time can only be made longer than the normal coasting time
31. ial hazard Proper shielding grounding and filtering of this product can reduce the emission of radio frequency interference RFI which may adversely affect sensitive electronic equipment It is the responsibility of the equipment manufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product SW effective 11 1992 Be sure to follow all instructions care fully Fire and or electrocution can result due to improper use of this product Y y This product complies with all CE directives pertinent at the time of manufacture Contact the Sales C Department for Declaration of Conformity Installation of a CE approved RFI filter is required see Section 14 12 on page 30 Additional shielded cable and or AC line cables may be required along with a sig nal isolator SI 6 Part No 9444 3 INTRODUCTION Thank you for purchasing the KBMM Standard of the Industry full wave variable speed DC motor control now with SMT construction The control 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 shorts 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 KB s exclusive Plug In Horsepower Resistor
32. n Figure 1 on page 10 The trimpots may be readjusted as described in Section 11 on page 24 Diagnostic LEDs After power has been applied to the control observe the LEDs to verify proper control operation as described in Section 12 on page 28 1 10 Auxiliary Heat Sink Part No 9861 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 2 SAFETY WARNING Please read carefully Definition of Safety Warning Symbols y y Electrical Hazard Warning Symbol Failure to observe this warning could result in electrical shock or electrocution Operational Hazard Warning Symbol Failure to observe this warning could result in serious injury or death This product should be installed and serviced by a qualified technician electrician or electrical main tenance person familiar with its operation and the hazards involved Proper installation which includes wiring mounting in proper enclosure fusing or other over current protection and grounding can reduce the chance of electrical shocks fires or explosion in this product or products used with this product such as elec ric motors switches coils solenoids and or relays Eye protection must be worn and insulated adjustment tools must be used when working with control under power This product is constructed of materials plastics metals Carbon silicon etc which may be a potent
33. s been factory set to 2 seconds which is the amount of time it will take for the motor to decelerate from full speed to zero speed To increase the deceleration time rotate the DECEL Trimpot clockwise To decrease the deceleration time rotate the DECEL Trimpot counterclock wise See Figure 15 Note The deceleration time cannot be made less than the natural coast time of the motor and actual load 11 3 Minimum Speed Trimpot MIN The MIN Trimpot sets the minimum speed of the motor when the Main Speed Potentiometer is set fully coun terclockwise The MIN Trimpot is factory set to O 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 16 Note Readjusting the MIN Trimpot will affect the maximum speed set ting 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 11 4 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 clock FIGURE 15 DECEL TRIMPOT RANGE 5 3 8 02 RKR_Y 10 Factory Set to 2 Seconds FIGURE 16 MIN TRIMPOT RANG
34. t be read and understood before proceeding 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 12 DIAGNOSTIC LEDs The control is designed with PC board mounted LEDs to display the control s operational status See Figure 1 on page 10 for the location of the LEDs 12 1 Power On PWR ON The PWR ON LED will illuminate green when the AC line is applied to the control 12 2 Current Limit CL The CL LED will illuminate red when the control goes into current limit indicating that the current limit set point has been reached set by the CL Trimpot See Section 11 5 on page 26 13 SWITCHING CIRCUITS 13 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 28 WARNING Do not disconnect and reconnect the motor armature with the AC line applied or cata strophic failure will result See Section
35. tiple controls in the same conduit Use shielded cables on all signal wiring over 12 30 cm The shield should be earth grounded on the control side only Wire the control in accordance with the National Electrical Code requirements and other local codes that may apply TABLE 3 MINIMUM SUPPLY WIRE SIZE REQUIREMENTS Minimum Wire Size Cu rai ce 90 i E Ma ak on ies Maximum 50 Ft Maximum 100 Ft AWG mm2 AWG mm 6 5 1 16 1 3 14 2 1 12 1 2 14 21 12 3 3 16 1 5 3 12 3 3 12 3 3 6 1 AC Line Connection Wire the AC line to Terminals L1 Line Fuse and L2 as shown in Figure 1 on page 10 If one of the AC line inputs is a neutral N wire it to Terminal L2 CAUTION The rated AC line voltage 115 208 230 of the control must match the actual AC line input voltage See Section 7 1 on page 19 Model KBMM 125 operates on 115 Volt AC line input only Model KBMM 225 operates on 208 230 Volt AC line input only Model KBMM 225D 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 AC Line On Off Switch To remove power to the control a separate AC line switch should be used Use a single pole switch for hot and neutral AC supply lines and a double pole switch for 2 hot AC supply lines This switch can also be used as a Safety Disconnect 6 2 Ground
36. tors To set Models KBMM 225 225D for step down operation 208 230 Volt AC line input and S 90 Volt DC output set Jumper J2 to the 90 posi S tion To set the control for tach generator connection al set Jumper J2 to the T position all models See Figure 12 Notes 1 On Model KBMM 125 the 180 position is not available on Jumper J2 2 On Model KBMM 225D do not set the output voltage to 180 Volts DC when the AC line input is set to 115 Volts FIGURE 12 MOTOR VOLTAGE amp DC TACH GENERATOR SELECTION JUMPER J2 Model KBMM 125 Models KBMM 225 and KBMM 225D J2 Set for J2 Set for oa a USO Wels Lisi Sie Sgt Factory Setting Factory Setting S 5 5 S S 281 A 121 fe iH sip Al sp sif Pii 5 sl Sigl sifel Be sure jumper for 90 Volt DC output is installed in the two center pins as shown AC LINE AND ARMATURE FUSING All 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 Part No 9897 contains prewired AC line and armature fuse holders as described in Section 14 3 on page 30 An AC Line Fuse supplied separately must be installed in the AC line Fuse Holder and an Armature Fuse sup plied separately must be installed in the Armature Fuse Holder as shown in Figure 1 on page 10 Select the correct fuses as shown in
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