KBIC®
Solid State SCR DC Motor Speed Controls
See table 2 page 4 for KBIC® models covered by this manual
Patented Ultra Fast
CL Circuit Prevents
Demagnetization in
PM Motors
Installation and
Operating
Instructions
See SAFETY WARNING on page 4
Basic KBIC®
PATENTED
*See Page 3
™
A COMPLETE LINE OF MOTOR DRIVES
©1996 KB ELECTRONICS, INC.
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TABLE OF CONTENTS |
Section |
Page |
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i. |
Safety Warning . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 |
ii. |
Simplified Instructions . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 |
iii. |
Introduction . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 |
I. |
Application Information . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 |
II. |
Installation Instructions . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 |
III. |
Adjustments & Control Functions . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 |
IV. |
Switching Circuits . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 |
V. |
Limited Warranty . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 |
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TABLES |
1. |
Nominal Trimpot Settings . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 |
2. |
Electrical Ratings . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 |
3. |
General Performance Specifications . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 |
4. |
Fuse Selection Chart . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 |
5. |
Plug-in Horsepower Resistor® Chart . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 |
6. |
Minimum Supply Wire Requirements . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 |
7. |
Field Connections . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 |
8. |
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 |
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FIGURES |
1. |
Basic KBIC® . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 |
2. |
Mechanical Specifications . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 |
3. |
Connection Diagrams . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 |
4. |
ACCEL Trimpot Adjustment . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 |
5a. |
Master/Slave Circuit . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 |
5b. |
Dynamic Brake Circuit . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 |
5c. |
Overload Protection . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 |
6. |
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 |
2
i. SAFETY WARNING!
This product should be installed and serviced by a qualified technician, electrician or electrical maintenance person familiar with its operation and the hazards involved. Proper installation, which includes wiring, mounting in proper enclosure, fusing or other overcurrent protection and grounding, can reduce the chance of electric shocks, fires or explosion in this product or products used with this product, such as electric motors, switches, coils, solenoids and/or relays. Eye protection must be worn and insulated adjustment tools must be used when working with control under power. This product is constructed of materials (plastics, metals, carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding and filtering of this product can reduce the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic equipment. If information is required on this product, contact our factory. It is the responsibility of the equipment manufacturer and individual installer to supply this safety warning to the ultimate user of this product. (SW effective 11/92)
This control contains electronic Start/Stop and Inhibit circuits which can be used to start and stop the control. 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.
The input circuits of this control (potentiometer, Inhibit) are not isolated from AC line. Be sure to follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product.
This product complies with all CE directives pertinent at the time of manufacture. Contact factory for detailed
installation instructions and Declaration of Conformity.
ii.SIMPLIFIED INSTRUCTIONS – Read these simplified instructions before operating control. (See Safety Warning.)
1.Be sure input AC line voltage corresponds to control voltage. (See Electrical Rating chart, table 2 p. 4.)
2.Install the correct Plug-in Horsepower Resistor® according to armature voltage and motor horsepower (See chart, p. 5).
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.)
4.Nominal trimpot settings are as follows (expressed in % of full CW rotation):
5.It is recommended that both AC line and armature fuses should be installed in this product. (See sec. IID, p. 9.)
TABLE 1 – NOMINAL TRIMPOT SETTINGS (For detailed instruction see Sec. III)
MIN (minimum speed) |
15% |
CL (current limit/torque) |
50% |
MAX (maximum speed) |
60% |
ACCEL (acceleration start) |
50% |
IR (IR Compensation) |
25% |
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3
TABLE 2 – ELECTRICAL RATINGS
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AC Line |
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RATING WITHOUT AUXILIARY HEATSINK |
RATING WITH AUXILIARY HEATSINK |
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Motor |
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Model |
Voltage |
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Voltage |
Max. AC |
Max. DC |
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Max. AC |
Max. DC |
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Number |
(VAC) ± 15% |
MAX |
MAX |
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(VDC)3 |
Load Current |
Load Current |
Load Current |
Load Current |
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50/60Hz |
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(RMS Amps) |
(Avg. Amps) |
HP |
(RMS Amps) |
(Avg. Amps) |
HP |
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FIELD VOLTAGE (Shunt wound Motor Only)
(VDC)
KBIC-120 |
115 |
0 - 90 |
9.0 |
6.0 |
0.5 |
18.0 |
12.0 |
1 |
50, 100 |
KBIC-125 |
115 |
0 - 90 |
12.0 |
8.0 |
0.75 |
24.0 |
16.0 |
1.5 |
50, 100 |
KBIC-240 |
230 |
0 - 180 |
9.0 |
6.0 |
1 |
18.0 |
12.0 |
2 |
100, 200 |
KBIC-225 |
230 |
0 - 180 |
12.0 |
8.0 |
1.5 |
24.0 |
16.0 |
3 |
100, 200 |
KBIC-240D1 |
115 |
0 - 90 |
9.0 |
6.0 |
0.5 |
18.0 |
12.0 |
1 |
50, 100 |
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230 |
0 - 180 |
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1 |
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2 |
100, 200 |
KBIC-240DS2 |
115 / 230 |
0 - 90 |
9.0 |
6.0 |
0.5 |
18.0 |
12.0 |
1 |
100 |
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 230 VAC line.
(2)Model KBIC-240DS is designed to accept 115 or 230 VAC line input to provide 0-130 VDC with a 115 or 230 VAC line. (Also see Information Sheet A40058)
(3)A higher output voltage can be reached by increasing MAX trimpot setting.
TABLE 3 – GENERAL PERFORMANCE SPECIFICATIONS
Speed Range (ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
50:1 |
Load Regulation (% base speed) (0 - full load; 50:1 speed range) . . . . |
1* |
Line Voltage Regulation (% base speed at full load; 100 - 130 VAC) . 1/2*
Control Linearity (% speed vs. dial rotation) . . . . . . . . . . . . . . . . . |
. . . . . 2 |
CL/Torque Range (% full load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
0 - 300 |
ACCEL Time Period (0 - full speed) (secs) . . . . . . . . . . . . . . . . . |
0.5 - 4.0 |
MIN Speed Trimpot Range (% full speed) . . . . . . . . . . . . . . . . . . . |
0 - 30* |
MAX Speed Trimpot Range (% full speed) . . . . . . . . . . . . . . . . . |
50 - 110* |
IR Compensation Trimpot Range (at specified full load) (volts) . . . |
. 0 - 24 |
Maximum Allowable Ambient Temperature at full rating (º C/º F) . . |
45/113 |
Maximum Inrush Start Current (Peak DC amps) . . . . . 3 times CL Setting
PLUG-IN HORSEPOWER RESISTOR®
A Plug-in Horsepower Resistor® must be installed to match the KBIC® to the motor horsepower and voltage. See table 4, p. 5 for the correct value. Plug-in Horsepower Resistors® are stocked by your distributor.
CAUTION Be sure Plug-in Horsepower Resistor® is
inserted completely into mating socket.
*Performance is for SCR rated PM motors only. Lower performance can be expected with other motor types. Factory setting is for 3% load regulation. To obtain superior regulation, see sec. III E, p. 11.
4
FIG. 1 – BASIC KBIC®
TABLE 4. FUSE SELECTION CHART*
90 VDC Motor |
180 VDC Motor |
Approx. |
Fuse Rating |
HORSEPOWER |
Motor Current |
(AC Amps) |
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(DC Amps) |
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1/100 |
1/50 |
0.1 |
2/10 |
1/50 |
1/25 |
0.2 |
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 |
1/8 |
1/4 |
1.3 |
2 |
1/6 |
1/3 |
1.7 |
3 |
1/4 |
1/2 |
2.5 |
4 |
1/3 |
3/4 |
3.3 |
5 |
1/2 |
1 |
5.0 |
8 |
3/4 |
1 |
7.5 |
12 |
1 |
2 |
10.0 |
15 |
1 |
3 |
15.0 |
25 |
iii. INTRODUCTION
*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.
FIG. 1 – FEATURES AND FUNCTIONS
(1)Plug-in Horsepower Resistor®
(2)Mounting Holes for Armature and AC Line Fuses
(3)Trimpots: MIN, MAX, ACCEL, IR & CL
(4)Auxiliary Heatsink (optional) (see fig. 2, p. 7)
TABLE 5 – PLUG-IN HORSEPOWER RESISTOR® CHART(1)
Motor Horsepower(2) |
Approx. |
Plug-in |
Individual |
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Motor |
Horsepower |
Plug-in |
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Armature Voltage |
Armature Voltage |
Current |
Resistor |
Horsepower |
|
(DC Amps) |
Value (Ohm) |
Resistor® P/N |
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90VDC |
180VDC |
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1/100 |
1/50 |
0.1 |
1.0 |
9833 |
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1/50 |
1/25 |
0.2 |
0.51 |
9834 |
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1/30, 1/25 |
1/15 |
0.35 |
0.35 |
9835 |
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1/20 |
1/10 |
0.5 |
0.25 |
9836 |
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1/15, 1/12 |
1/6 |
0.8 |
0.18 |
9837 |
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1/10, 1/8, 1/6 |
1/4 |
1.3 |
0.1 |
9838 |
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1/4 |
1/2 |
2.5 |
0.05 |
9839 |
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1/3 |
3/4 |
3.3 |
0.035 |
9840 |
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1/2 |
1 |
5.0 |
0.025 |
9841 |
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3/4 |
1 |
7.5 |
0.015 |
9842 |
|
1 |
2 |
10.0 |
0.01 |
9843 |
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1 |
3 |
15.0 |
0.006 |
9850 |
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Notes:
(1)Motor horsepower and armature voltage must be specified in order to select correct Plug-in Horsepower Resistor®.
(2)For motor horsepower not indicated use lower value Plug-in Horsepower Resistor®.
5
Thank you for purchasing the KBIC® "Standard of the Industry" DC motor speed control. They 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 the power bridge. Integrated circuitry is used to provide an uncomplicated design with superior load and line voltage regulation. The patented 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 Heatsink (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. A Barrier Terminal Board is available which incorporates both line and armature fuses.
The Inhibit™ circuit (Terminals I1 and I2) is provided to electronically disconnect the armature output voltage. Another standard feature is Auto Inhibit. This circuit prevents false starts and high surge currents when cycling the KBIC® control with the AC line.
All models are UL Recognized for the USA and Canada and CE approved.
I.APPLICATION INFORMATION
A.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 MAX speed. 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.
B.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.
C.Acceleration Start – The KBIC® contains an adjustable acceleration start feature which 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.
D.Limitation in Use – The KBIC® controls are designed for use on machine applications.
E.Armature Switching – Do not switch the armature without taking proper precautions. (See sec. IV, p. 11)
CAUTION
Consult factory before 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 II.)
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