“The Right Control for Your Application.” 12095 NW 39 Street, Coral Springs, FL 33065-2516
Telephone: 954-346-4900; Fax: 954-346-3377
KB Electronics, Inc. www.kbelectronics.com
KBPC-240D (Part Nos. 9338 and 9342) Installation and Operation Manual Supplement
This supplement is for Model KBPC-240D Installation and Operation Manual (Part No. A40400) until the new manual is available. The manual
must be read and understood before operating this drive. For further assistance, contact our Sales Department at 954-346-4900 or Toll Free
at 800-221-6570 (outside Florida).
PRODUCT UPDATES
z Run Relay Added z SMT Construction
This drive has been converted to Surface Mount Technology (SMT). All trimpots have been moved and aligned at the top of the PC board.
A Run Relay has been added, which can be used to turn equipment "on" or "off" as a function of drive status (Off, Stop, Run). The General
Performance Specifications, Electrical Ratings, Mechanical Specifications, and Connection Diagrams have not changed. The Parts List (Table
11, on pages 17 and 18) and Schematic (Figure 16, on page 19) in the manual no longer apply to this drive and should not be used. See
Figure 1 for the location of the Run Relay Output Contacts, Trimpots, and Jumpers (replaces Figure 1, on page 3, in the manual). See Figure
1 for the Run Relay Output Contacts ratings. See Table 1 for the drive operating conditions and Run Relay Output Contacts status.
FIGURE 1 – DRIVE LAYOUT
TABLE 1 – DRIVE OPERATING CONDITION AND RUN RELAY OUTPUT CONTACTS STATUS
Drive Operating Condition Description Normally Open Contact Normally Closed Contact
Power Off Main Power Disconnected Open Closed
Run Mode Normal Drive Operation Closed Open
Stop Mode Selected by Operator Open Closed
Trip Drive Tripped Open Closed
(A42144) – Rev. D00 – 1/6/2010 Page 1 of 1
INSTALLATION AND OPERATING INSTRUCTIONS
MODEL KBPC-240D
KB Part No. 9338 (Black Case) • Part No. 9342 (White Case)
NEMA 4X, IP-65
SCR Speed and Torque Control Designed
For DC Motors Rated
1/50 – 1 HP @ 90VDC, 1/25 – 2 HP @ 180VDC
T
This control will
not operate
without installing
the correct
armature fuse –
supplied
separately.
See Page 2
Note: Product
illustration is
shown with
optional ForwardBrake-Reverse
and Run-Jog
options.
See Safety Warning on Page 2
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.
A COMPLETE LINE OF MOTOR DRIVES
™
© 1998 KB Electronics, Inc.
TABLE OF CONTENTS
Section Page
i. KBPC-240D Simplified Operating Instructions ..................................1
ii. Safety Warning .........................................................2
I. General Information .....................................................2
II. Setting Selectable Jumpers ...............................................5
III. Mounting ..............................................................9
IV. Wiring ...............................................................10
V. Fusing ...............................................................13
VI. Operation ............................................................13
VII. Trimpot Adjustments ....................................................14
VIII. Function Indicator Lamps ................................................15
IX. Optional Accessories ...................................................15
X. Limited Warranty .......................................................22
TABLES
1. Electrical Ratings .......................................................5
2. General Performance Specifications .........................................5
3. Setting AC Line Voltage with Jumper J2A and J2B ..............................7
4. Setting Armature Voltage with Jumper J3 .....................................8
5. Jumper J4 vs Motor Horsepower ...........................................8
6. Current Limit Settings with .05 Ohm Plug-In-Horsepower Resistor Installed ...........8
7. Terminal Block Wiring Information .........................................10
8. Relationship of AC Line Input and Motor Voltage with J2 and J3 Jumper Position .....10
9. Field Connections (Shunt Wound Motors Only) ...............................11
10. Armature Fuse Chart ...................................................13
11. Parts List .........................................................17, 18
FIGURES
1. Control Layout .........................................................3
2. Mechanical Specifications .................................................4
3. Motor Speed vs Potentiometer Rotation ......................................6
4. Preset Motor Speed vs Motor Load ..........................................6
5. Motor Output Torque vs Potentiometer Rotation ................................7
6. Motor Speed vs Applied Motor Load .........................................7
7A. Captive Screw Tightened in Case ..........................................10
7B. Captive Screw Engaged in Front Cover .....................................10
8. Connection Diagram ....................................................10
9A. Full Voltage Field ......................................................11
9B. Half Voltage Field ......................................................11
10. Tach-generator Connection Diagram .......................................11
11. Remote Potentiometer ..................................................12
12. Analog Voltage ........................................................12
13. Remote Start/Stop Switch ................................................12
14. Inhibit Circuit ..........................................................12
15. Enable Circuit .........................................................13
16. Schematic ............................................................19
17. Connection Diagram for KBPC-240D with KBSI-240D Signal Isolator ...............20
18. Internal Connection Diagram ..............................................21
19. Connection Diagrams for Available Options ..................................21
ii
i. KBPC-240D SIMPLIFIED OPERATING INSTRUCTIONS
IMPORTANT – You must read these simplified operating
instructions before you proceed. 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 2 before proceeding.
1. CONNECTIONS.
A. AC Line – Wire AC line voltage to terminals L1 and L2. Be sure jumpers J2A and J2B
are both set to the correct input line voltage 115 or 230 VAC. Connect ground wire
(earth) to green ground screw on case.
B. Motor.
1. Permanent Magnet (PM) Type. Connect motor armature leads to A1(+) and A2(–).
Be sure jumper J3 is set to the proper position “90V" for 90 volt DC motors and
“180V" for 180 volt DC motors. Note: 180 volt DC motors must be used with 230
VAC line, 90 volt motors can be used with a 230 VAC or 115 VAC line. See sec.
II, C, on page 7.
2. Shunt Wound Motors. Connect motor armature as above. Connect full voltage
shunt field wires (90 volt motors with 100 volt fields and 180 volt motors with 200
volt fields) to F1 and F2. Connect half voltage field wires (90 volt motors with 50
volt fields and 180 volt motors with 100 volt fields) to F1 and L1. See sec. IV, C,
on page 11.
2. SPEED OR TORQUE MODE.
Jumper J1 is factory set for speed control operation (SPD). For torque control, set J1 to
TRQ position. See sec. II, A, on page 5.
3. MOTOR CURRENT.
Jumper J4 is factory set for 10 amp motors (10A). For lower amperage motors, place J4
in the proper position. See section II, D, on page 8 for details. Note: The factory setting
for Current Limit is 150% of the nominal current setting, e.g., if J4 is selected for 10 amps,
the actual CL setting will be 15 amps.
4. TRIMPOT SETTINGS.
All trimpots have been factory set in accordance with figure 1, page 3 and table 1, page 5.
5. DIAGNOSTIC LED’s.
After power is turned on, observe LED’s to verify proper control function. See sec. VIII on
page 15.
6. ARMATURE FUSE.
The correct size armature fuse must be installed, depending on the rating of the motor.
Control will not operate if fuse is not installed. See section V, B on page 13 and table 6 on
page 12.
7. START/STOP SWITCH.
The KBPC contains a built-in manual start/stop switch. This switch must be used to start
the control each time AC power is lost. To override this function see sec IV, G, p. 12.
1
ii. SAFETY WARNING! — PLEASE READ CAREFULLY
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 that 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, start/stop, 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.
Installation of a CE approved RFI filter (KBRF-200A, KB P/N 9945A or equivalent) is required.
Additional shielded motor cable and/or AC line cables may be required along with a signal
isolator (KBSI-240D, KB P/N 9431 or equivalent).
I. GENERAL INFORMATION.
The KBPC Series Nema 4 X (IP-65) is a unidirectional SCR DC Motor Speed and Torque Control
designed for applications requiring watertight integrity, including washdown. Its housing is
ruggedly constructed of die cast aluminum, protected with an acrylic coating that provides
excellent corrosion resistance. All switches are sealed with rubber boots and the main speed
potentiometer contains a shaft seal.
The electronics for the KBPC is state-of-the-art and includes short circuit and transient protection
which provides the ultimate in reliability. Electronic overload protection prevents motor burnout
and demagnetization of PM motors. The control can be operated in either the Speed or Torque
mode via jumper selection. The current range, which is also jumper selectable, eliminates the
necessity for calibration of IR Compensation and Current Limit for most applications. The KBPC
also contains jumper selections for AC line voltage (230/115), DC armature voltage (180/90) and
feedback type (armature/Tach-generator).
Standard features include armature fusing*, electronic start/stop and an LED indicator array for
Power On, Stop and Overload (*fuse supplied separately).
Although the KBPC is factory set for most applications, a variety of trimpots allow adjustment of
the following parameters: Minimum and Maximum Speed, Acceleration, Deceleration, Current
Limit, IR Comp, and Timed Current Limit. Optional features offered are: On/Off AC Line Switch,
Forward-Brake-Reverse, Run-Stop-Jog, Input Signal Isolation, RFI Filtering, and Electronic RunBrake Module.
WARNING! Be sure to follow all instructions carefully. Fire or electrocution
can result due to improper use of this product. Read Safety Warning.
2
FIG. 1 – CONTROL LAYOUT
(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)
3
[mm]
INCHES
TM
FIG. 2 – MECHANICAL SPECIFICATIONS
TM
4
Model
TABLE 1 – ELECTRICAL RATINGS
Input
Voltage
(VAC)
115 15.0 0 – 90 10.2 1, (.75)
Max. AC
Current
(ARMS)
Output Voltage
(VDC)
Max. DC Output
Current (ADC)
HP, (KW)
Max.
KBPC-240D
230 15.0 0 – 180 10.2 2, (1.5)
230 15.0 0 – 90 10.2 1, (.75)
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS
Parameter Specification
AC Line Input Voltage (VAC ±10%,50/60 Hz)
AC Line Frequency (Hz), # of Phases
Arm Voltage Range at 115VAC Line (VDC)
Arm Voltage Range at 230VAC Line (VDC)
Field Voltage at 115VAC Line (VDC)
Field Voltage at 230VAC Line (VDC)
Horsepower Range at 115 VAC HP, (KW)
Horsepower Range at 230 VAC HP, (KW)
Ambient Temperature Range (ºC)
Speed Range (Ratio)
Arm Feedback Load Regulation (% Base Speed)
Tach Feedback Load Regulation (% Set Speed)
Line Regulation (% Base Speed)
Current Ranges (ADC)
ACCEL and DECEL Ranges (Sec.)
MIN Speed Range (% Base Speed)
MAX Speed Range (% Base Speed)
IR Comp Range at 115VAC Line (VDC)
IR Comp Range at 230VAC Line (VDC)
CL Range (% Range Setting)
Timed CL Range (Sec.)
Voltage Following Linearity (% Base Speed)
115 or 230
50/60, 1
0 – 90
0 – 180, 0 – 90
100/50
200/100
1/50 – 1, (.015 – .75)
1/25 – 2, (.03 – 1.5)
0 – 50
50:1
±1
±1
±0.5
2.5, 5.0, 7.5, 10
0.1 – 15
0 – 30
60 – 140
0 – 15
0 – 30
0 – 200
0.5 – 15
±0.5
Factory
Setting
230
—
—
0 – 180
—
—
—
—
—
—
—
—
—
10
1
0
100
4
8
150
7
—
II. SETTING SELECTABLE JUMPERS.
The KBPC-240D has customer selectable jumpers which must be set before the control can
be used. Bold indicates factory setting. See fig. 1, page 3 for location of jumpers.
A. Control Mode – Speed (SPD) or Torque (TRQ). Note: Factory
setting for J1 is Speed mode. When Jumper J1 is placed in the
"SPD" position the drive will control motor speed as a linear
function of the main potentiometer rotation, or analog voltage
input. The range of output speed can be adjusted with the MIN
and MAX trimpots. The motor will maintain the preset speed as long as the maximum
load does not exceed the current limit set point. If the motor load exceeds the current limit
setting, the Overload LED will turn on and the motor will stall.
TRQ
SPD
5
FIG. 3 – MOTOR SPEED vs POTENTIOMETER ROTATION – [SPEED MODE]
FIG. 4 – PRESET MOTOR SPEED vs MOTOR LOAD – [SPEED MODE]
When Jumper J1 is placed in the "TRQ" position, the drive will control motor torque as a
linear function of main potentiometer rotation. If the motor load exceeds the torque
setting, the motor will stall, the Overload LED will light, and the drive will apply a constant
preset torque based on the potentiometer setting. The Overload LED will light when the
load torque approaches the current limit set point. The torque limits are set via jumper
J4 and the CL trimpot. (Note: When operating in the Torque Mode, Jumper J5 must be
in the "NTCL" position or drive will shut down when CL Timer times out.)
6
FIG. 5 – MOTOR OUTPUT TORQUE vs POTENTIOMETER ROTATION – [TORQUE MODE]
FIG. 6 – MOTOR SPEED vs APPLIED MOTOR LOAD – [TORQUE MODE]
B. J2A, J2B – Input AC Line Voltage –
Select proper input line voltage
115VAC or 230VAC by placing both
J2A and J2B in the correct
corresponding positions, "115V" or
“230V.”
C. J3 – Armature Voltage Output and
Tach-generator Feedback – Select
the desired armature voltage by
placing J3 in the proper position “90V”
for 90 – 130VDC motors and “180V"
for 180 – 220 VDC motors. For
115VAC line input the armature voltage must be set to “90V.”
TABLE 3 – SETTING AC LINE VOLTAGE
WITH JUMPER J2A and J2B
Control Set for 230 VAC
(Factory Setting)
Control Set for 115 VAC
7
For 230VAC line input, the
armature voltage is normally set
to"180V". However, it is also
possible to operate in a Step-
TABLE 4 – SETTING ARMATURE
VOLTAGE WITH JUMPER J3
Control Set for 180 VDC
(Factory Setting)
Control Set for 90 VDC
Down Mode (90 – 130VDC motor
with a 230VAC line) by setting J3
to "90". However, reduced
performance may result.
180V
90V
180V
90V
If tach-generator feedback is to be
used, J3 must be placed in the "T"
position and an external DC tachgenerator must be connected. See section II, F, p. 9, and section IV, E on page 11 for
additional information.
D. J4 – Armature Current – Select the J4 position (2.5A, 5A, 7.5A, 10A) closest to the rated
motor current. Note that the output is factory set to 150% of the J4 position (e.g. 15 amps
in the 10A position and 11 amps in the 7.5 position, etc.). This setting can be readjusted
using the CL trimpot (see section VII, E on page 14).
TABLE 5 – JUMPER J4 SETTING vs MOTOR HORSEPOWER
JUMPER J4*
10.0 Amps 1 2
7.5 Amps 3/4 1
Motor Horsepower Range
90 VDC 180 VDC
5.0 Amps 1/3 – 1/2 3/4 – 1
2.5 Amps 1/6 – 1/4 1/3 – 1/2
Note: Jumper J4 is shown in the factory setting.
Application Note – Subfractional Horsepower Motors. For subfractional motors with
current ratings below 2.5 amps, the KBPC can be modified as follows. Note: Before
making this modification you must have a .05 ohm Plug-in Horsepower Resistor® (KB P/N
9839). Carefully clip out the large power resistor R69 on the printed circuit board. The
resistor location is indicated in fig. 1, p. 3.) Insert the .05 ohm Plug-in Horsepower
Resistor® into the two (2) pins located under the resistor R69. Each of the current
selection values are now divided by 10. See table 6 below.
TABLE 6 – CURRENT LIMIT SETTINGS with .05 OHM
PLUG-IN HORSEPOWER RESISTOR INSTALLED
Original J4 Current
Jumper Selection
10.0 Amps 1.0 Amps 0 – 2.0 Amps 1.50 Amps
7.5 Amps 0.75 Amps 0 – 1.5 Amps 1.13 Amps
5.0 Amps 0.5 Amps 0 – 1.0 Amps 0.75 Amps
2.5 Amps 0.25 Amps 0 – 0.5 Amps 0.38 Amps
New J4 Current
Jumper Selection
New Current Limit
Trimpot Range
New Current Limit Trimpot
Factory Setting
E. J5 – Current Limit Mode – (Factory set for "TCL") This control contains electronic
current limiting which limits the maximum DC current to the motor
(the current limit set point is established with the selection of the
J4 position and the setting of the CL trimpot). Two modes of
current limit operation are provided:
8
1. Timed current limit "TCL": In this mode the drive will turn off after being in current limit
for a preset time. The time period is adjustable with the TCL trimpot from 0.5-15
seconds and is factory set for approximately seven (7) seconds. TCL provides
electronic motor overload protection.
Application Note: After the control times out in TCL, it can be reset using the Start
Switch by setting the switch to the "STOP" position and then to "START," or by
disconnecting and reconnecting the AC line. If the Start Switch is jumpered out, the
control can be restarted after timing out in TCL, by disconnecting and reconnecting the
AC line. Note, the Overload lamp will remain lighted until the control is reset.
2. Non-Timed Current Limit "NTCL": In this mode the drive will reach the preset current
limit during overload and stay at that level until a fuse blows or the drive is manually
turned off. If non-timed CL operation is desired, move jumper J5 from the factory set
"TCL" position to the "NTCL" position. The NTCL position must be used when
operating in the Torque Mode. See section II, A on page 5.
F. J6 – Tach-generator voltage – (Note: Selection of this jumper
position is not required if tach-generator feedback is not used.) If
tach-generator feedback is used, select the J6 position (7V, 20/30V,
50V) which corresponds to the tach-generator voltage in Volts/1000
RPM. The selection of J6 position is based on a maximum motor
speed of 1800 RPM. If other than standard tach-generator voltages
and motor speeds are used, an external resistor (RT) may be used
(1/2 watt rating).
1. Install resistor (RT) in series with either tach-generator lead.
2. Place J6 in "7V" position.
3. Calculate the value of (RT) as follows:
J6
50V
20/30V
7V
RT = [(1.64 x VT x S) - 20,000] ohms
Note: For tach-generator feedback, Jumper J3 must be in the "T" position.
G. J7 – Signal Input Voltage – The output of this control is normally controlled with the main
potentiometer. However, an Isolated analog voltage may also be used in place of a
potentiometer. The control can be scaled for either a 0-5VDC or 010VDC by placing J7 in the appropriate position "5V" or "10V". The
scaling can be further adjusted with the "Max" trimpot. See section IV,
F 2, on page 12 for wiring information.
Note: If an Isolated input signal is not available an accessory Signal Isolator Model KBSI240D (KB P/N-9431) can be installed. The KBSI-240D accepts a wide range of signal voltage
and current. An Installation Kit containing Auto/Man Switch and required wiring is also
available (P/N 9377).
III. MOUNTING
Mount the control in a vertical position on a flat surface. Be sure to leave enough room below
the bottom of the control to allow for the AC line and motor connections. Although the control
is designed for outdoor and washdown use, care should be taken to avoid extremely
hazardous locations where physical damage can occur. Note: Do not use this control in
an explosion proof application. If the control is mounted in a closed, unventilated cabinet,
remember to allow for proper heat dissipation. If full rating is required, a minimum enclosure
size of 12" W x 24" H x 12" D should be used.
Front Cover - The KBPC case is designed with a hinge so that when the front cover is open,
all wiring stays intact. To open the cover, the four cover screws must be loosened, so they
no longer are engaged in the case bottom. Note that these screws are captive and the front
cover holes are threaded. After mounting and wiring, close the front cover, making sure all
wires are contained within the enclosure and the gasket is in place around the cover lip.
Tighten all four cover screws so that the gasket is slightly compressed. Do not overtighten.
VT = Tach Voltage in Volts/1000 RPM
{
S = Base speed of motor in RPM
10V
9
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