KB Electronics KBBC SERIES Data Sheet

KBBC SERIES

MICROPROCESSOR CONTROLLED

BATTERY POWERED DC/DC

Variable Speed Motor Control

for 12, 24, 36 and 48 Volt

PM and Series Wound DC Motors

thru 2HP Continuous Duty and 4HP Peak Duty

DATA SHEET D-905

TYPICAL APPLICATIONS

• Scooters • Personnel Carriers • Carts • Electric Boats

• Portable Pumps • Lifts • Floor Polishers

STANDARD FEATURES

• High Frequency PWM Operation: Reduces motor noise and

increases efficiency.

• Controlled Acceleration and Deceleration: Provides timed accel-

eration to set speed and deceleration to zero speed.

• Diagnostic LEDs: Provide indication of power on (PWR ON) and

control status (STATUS).

• Built-In Reversing Contactor: Provides forward/reverse operation

with a low power reversing switch or with a center-off throttle potentiometer (wigwag).

• Run Relay: Used to turn on or off equipment or signal a warning if

a fault has occurred.

• Brake Driver Circuit: Powers an optional electromechanical brake

(current regulated and short circuit protected).

• Key Switch Operation with Built-In Battery Power Contactor:

Allows the use of a low power switch to turn control on and off.

• Inhibit Circuit: Allows control to be turned off electronically with a

separate low power switch.

• Latching Circuit: Allows momentary switches to start, stop, and

reverse the control.

• Limit Switch Circuit (Stop Forward and Stop Reverse): Allows

limit switches to be used to immediately stop the control in forward or reverse directions.

• Single-Ended or Wigwag Potentiometer Control: Allows the

Main Speed Potentiometer to be used as single-ended (zero speed is at 0% rotation) or wigwag (zero speed is at 50% rotation).

PROTECTIVE FEATURES

• Electronic Current Limit: Protects the motor and control against

overload.

• Polarity Protected: Prevents control damage if the battery is wired

incorrectly.

• Short Circuit Protected: Protects main power transistor from fail-

ure due to a short at the motor.

• Overtemperature Protection: Reduces control output as the tran-

sistors reach maximum operating temperature.

• Overvoltage Protection: Will turn off the control if the battery volt-

age exceeds 125% of nominal.

• Undervoltage Protection: Will turn off the control if battery voltage

reduces below 65% of nominal.

SAFETY FEATURES

• Potentiometer Fault Circuit: Turns the control off if a short, open,

or ground occurs at the potentiometer.

• High Pedal Disable Function: Prevents control startup until the

potentiometer returns to zero.

Model KBBC-44M Shown (Part No. 9501)

DESCRIPTION

The KBBC series of battery powered variable speed controls are designed for 12, 24, 36, and 48 Volt PM and Series Wound DC motors. Microcontroller design provides superior performance and ease of tailoring to specific applications. Operating in a regenerative mode, precise and efficient control is obtained using stateof-the-art MOSFET technology. The KBBC operates at a switching frequency of 16 kHz, which provides high motor efficiency and quiet operation.

The KBBC contains many standard features such as current limit, short circuit protection, speed potentiometer fault detector, overtemperature sensing, and undervoltage/overvoltage protection. A variety of trimpots are provided, which can be used to tailor the control to exact specifications. The control also contains LEDs that indicate “power on” and “status.” A DC power contactor allows a low power switch to turn the control on and off. Reversing contactors provide arcless forward, stop, and reverse operation. In addition, a brake driver circuit is used to power an optional electromagnetic brake.

The KBBC can be controlled in several ways, such as singleended or wigwag speed potentiometer and 0 - 5 Volts DC signal following. The controls contain a built-in heat sink that also serves as a mounting base.

TRIMPOT ADJUSTMENTS

• Timed Brake Delay (T-BRK): Sets the delay time before the brake is

engaged.

• Current Limit (CL): Sets the current limit (overload), which limits the maxi-

mum current to the motor.

• IR Compensation (IR): Sets the amount of compensating voltage required

to keep the motor speed constant under changing loads.

• Deceleration (DECEL): Sets the amount of time for the motor to deceler-

ate from the set speed to zero speed.

• Acceleration (ACCEL): Sets the amount of time for the motor to acceler-

ate from zero speed to the set speed.

• Minimum Speed (MIN): Sets the minimum motor speed.

• Reverse Maximum Speed (RMAX): Sets the maximum motor speed in

the reverse direction (a % of FMAX setting).

• Forward Maximum Speed (FMAX): Sets the maximum motor speed in

the forward direction.

A Complete Line of Motor Drives

GENERAL PERFORMANCE SPECIFICATIONS

Parameter Specification Factory Setting

Input Voltage Range (% Nominal) 75 – 125 100 Intermittent Duty Operation (Minutes) 2 — Peak Duty Operation (Seconds) 7 — Overvoltage Shutdown (% Nominal Input Voltage) 125 — Undervoltage Warning (% Nominal Input Voltage, ± 10%) 85 — Undervoltage Shutdown (% Nominal Input Voltage) 65 — Nominal Carrier Frequency (kHz) 16 — Electromagnetic Brake Delay Trimpot (T-BRK) Range (Seconds) 0.2 – 2.5 1 CL Trimpot (CL) Range (% Range Setting) 0 – 200 150 IR Compensation Trimpot (IR) Range (% Nominal Battery Voltage) 0 – 25 4 Acceleration Trimpot (ACCEL) Range (% Base Speed) 0.1 – 15 2 Deceleration Trimpot (DECEL) Range (% Base Speed) 0.1 – 15 2 Minimum Trimpot (MIN) Range (% Base Speed) 0 – 30 0 Forward Maximum Speed Trimpot (FMAX) Range (% Base Speed)* 60 – 100 100 Reverse Maximum Speed Trimpot (RMAX) Range (% Forward Maximum Speed) 50 – 100 100 Electromagnetic Brake Current Rating (Amps DC) 1 — Heat Sink Overtemperature Protection Point (ºC) 100 — Deadband in Wigwag Throttle Mode (Volts DC) ± 0.3 — Wigwag Throttle Signal Input Voltage for Maximum Forward (Volts DC) 2.5 – 5.0 5 Wigwag Throttle Signal Input Voltage for Neutral (Volts DC) 1.2 – 2.5 2.5 Wigwag Throttle Signal Input Voltage for Maximum Reverse (Volts DC) 0 0 Single Ended Throttle Signal Range for Full Speed Forward or Reverse (Volts DC) 0 – 2.5 to 5.0 0 – 5 Timed Current Limit (TCL) Trip Time (Seconds) 7 — Run Relay Output Contact Rating (Amps at 30 Volts DC, Amps at 125 Volts AC) 1, 0.5 — Auxiliary Power Connector (P2) Rating (Maximum Amps DC) 10 — Operating Temperature Range (ºC / ºF) 0 – 40 / 32 – 104 —

*FMAX trimpot is also used as an input/output gain potentiometer.

ELECTRICAL RATINGS

Model No. Part No.

KBBC-24M 9500

KBBC-44M 9501

Note: Custom units are available with various voltages and currents with or without DC Power Contactor or Reversing Contactor.

Nominal

Battery Voltage

(Volts DC)

12 0 – 12 1/2 40 3/4 60 1 80 24 0 – 24 1 40 11⁄2 60 2 80 12 0 – 12 1/2 40 3/4 60 1 80 24 0 – 24 1 40 11⁄2 60 2 80 36 0 – 36 11⁄2 40 2 60 3 80 48 0 – 48 2 40 3 60 4 80

Nominal

Motor Voltage

(Volts DC)

Continuous Duty

Maximum

Amps

Intermittent Duty

(2 Minutes)

Maximum

Amps

Maximum

JUMPER SELECTABLE FEATURES

• JA - Battery Voltage (VOLTAGE - 12/24/36/48): Selects nominal battery voltage.

• JB - Motor Current (CURRENT - 10A/20A/30A/40A): Selects nominal motor current.

• J1 - Signal Type (SIG - VF/POT): Selects voltage following or potentiometer operation.

• J2 - Speed Potentiometer Mode (SPD - SE/WW): Selects single-ended or wigwag speed control.

• J3 - Current Limit Mode (TCL - NTCL/TCL): Selects non-timed current limit or timed current limit.

• J4 - High Pedal Mode (HPD - NHPD/HPD): Selects non-high pedal disable or high pedal disable.

• J5 - Deceleration Mode (STP - DEC/FIX): Selects adjustable or fixed (0.1 second) deceleration when a stop command is given.

• J6 - Direction Switch Type (LATCH - OFF/ON): Selects maintained or momentary direction commands.

• J7 - Cycling Mode (CYCL - OFF/ON): Selects cycling of relay which is used to brake the motor.

• J8 - Relay Output Contacts (RLY - NO/NC): Selects normally open or normally closed Run Relay contacts.

Peak Duty

(7 Seconds)

Amps

A Complete Line of Motor Drives

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