KB Electronics KBIC-240DS User Manual

TABLE OF CONTENTS

KBIC

SCR

DC Motor

Speed Controls

Ultra Fast CL Circuit Prevents Demagnetization in

PM Motors

Installation and

Operation Manual

See SAFETY WARNING

* See CE information on page 5

This Manual Covers Models

KBIC-120

125, 240, 225, 240D, 240DS

(See back cover)

BASIC KBIC

TABLE OF CONTENTS

Section Page

1 Quick-Start Instructions.....................................................................................................................3

2 Safety...............................................................................................................................................5

3 Introduction.......................................................................................................................................6

4 Application Information ..................................................................................................................... 6

5 Installation, Mounting Instructions and Electrical Connections .......................................................... 12

6 Recommended High Voltage Dielectric Withstand Testing (HI-POT) ............................................... 14

7 Trimpot Adjustments.........................................................................................................................16

8 Diagnostic LED’s...............................................................................................................................20

9 Control Functions..............................................................................................................................20

10 Optional Accessories ........................................................................................................................ 23

Table Page

1 Field Connections (Shunt-Wound Motors Only) ................................................................................ 8

2 Electrical Ratings..............................................................................................................................8

3 Minimum Supply Wire Size Requirements........................................................................................ 9

4 Fuse Selection Chart ........................................................................................................................ 9

5 General Performance Specifications................................................................................................. 10

6 Plug-In-Horsepower Resistor Chart .................................................................................................. 11

7 RFI Filter Selection ........................................................................................................................... 24

Figure

Page

1 General Connection Diagram............................................................................................................4

2 Mechanical Specifications.................................................................................................................7

3 HI-POT Test Setup ........................................................................................................................... 15

4 ACCEL Trimpot Range..................................................................................................................... 16

5 MIN Trimpot Range........................................................................................................................... 17

6 MAX Trimpot Range.........................................................................................................................17

7 CL Trimpot Range............................................................................................................................. 18

8 IR Trimpot Range..............................................................................................................................19

9 Dynamic Braking ............................................................................................................................... 20

10 Master / Follower Circuit Connection ................................................................................................ 21

11 Connection Methods ......................................................................................................................... 22

12 Internal Sensing................................................................................................................................ 23

1 QUICK-START INSTRUCTIONS

Important: You must read these simplified instructions before proceeding. These instructions are to be

used as a reference only and are not intended to replace the details provided herein. You must read the Safety Warning on, page 5, before proceeding.

See Figure 1, on page 4. Also see Section 3 - Application Information, on pages 6 and 7.

WARNING! Disconnect main power before making connections to the speed control.

1.1 Be sure the AC input line voltage corresponds to the control voltage. See Table 2, on page 8.

1.2 Install the correct Plug-In Horsepower Resistor

according to armature voltage and motor

horsepower. See Table 6, on page 11.

1.3 Recheck connections: AC line to L1 and L2, armature to A+ and A- and Field (Shunt motors only) to F+ and F-. (Note: If motor runs in improper direction, interchange armature leads with Main Power disconnected.) See Figure 1, on page 4.

1.4 It is recommended that both AC line and armature fuses be installed. See Table 4, on page 9.

FIGURE 1. GENERAL CONNECTION DIAGRAM

(Shunt Motors Only)

2 SAFETY WARNING

Definition of Safety Warning Symbols

Electrical Hazard Warning Symbol: Failure to observe this warning could result in electrical shock

or electrocution.

Operational Hazard Warning Symbol: Failure to observe this warning could result in serious injury or

death.

This product should be installed and serviced by a qualified technician, electrician, or electrical maintenance person familiar with its operation and the hazards involved. Proper installation, which includes electrical connections, fusing or other current protection, and grounding, can reduce the chance of electrical shocks, and/or fires, in this product or products used with this product, such as electric motors, switches, coils, solenoids, and/or relays. Do not use this drive in an explosion-proof application. Eye protection must be worn and insulated adjustment tools must be used when working with drive under power. This product is constructed of materials (plastics, metals, carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding, and filtering of this product can reduce the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic equipment. It is the responsibility of the equipment manufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product. (SW 1/2006)

his drive contains electronic Start/Stop circuits, which can be used to start and stop the drive. However, these circuits are never to be used as safety disconnects since they are not fail-safe. Use only the AC line for this purpose.

Be sure to read and follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product.

This product complies with all CE directives pertinent at the time of manufacture. Contact the Sales Department for Declaration of Conformity. Installation of a CE approved RFI filter is required (see Table 7, on page 24). Additional shielded cable and/or AC line cables may be required along with a signal isolator (SI-5 (Part No. 9443)).

3 INTRODUCTION

Thank you for purchasing the KBIC

"Standard of the Industry" DC motor speed controls. The speed

controls are designed for applications demanding good performance, high reliability and low cost. The controls are fabricated with components that have proven reliability, including MOV transient protection, which is used to protect the Power Bridge. Integrated circuitry is used to provide an uncomplicated design with superior load and line voltage regulation. The Direct-Fed™ current limit circuit protects the motor and control against overloads by limiting the maximum level of output current. It also prevents motor failure due to demagnetization of the magnets of PM motors. Acceleration start (adjustable from 0.5 to 4 seconds) provides a smooth start each time the AC power is applied.

A unique feature of the KBIC

control is the Plug-in Horsepower Resistor

. It eliminates the need to recalibrate IR Comp. and CL when the control is used over a wide range of motor horsepower. Additional versatility is achieved by using the Auxiliary Heat Sink (optional) which is used to double the horsepower rating of each model. The output of the control is a linear function of potentiometer rotation. The KBIC

can also be operated in a voltage following mode by supplying an isolated analog signal (0-7 VDC) to the input terminals P2 (+) and F-. If an isolated input signal is not available, the optional Barrier Terminal Board Signal Isolator (SI-5) can be used. The controls are terminated as standard with Q-D terminals provided. A Barrier Terminal Board is available, which includes both line and armature fuse holders.

The Inhibit™ circuit (Terminals I1 and I2) are 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 Listed for the USA and Canada and

are CE approved.

4 APPLICATION INFORMATION

4.1 Motor Type – The KBIC

is designed for Permanent Magnet (PM), Shunt Wound and Universal (AC/DC) motors. Controls operated on 115 volt AC inputs are designed for 90 volt SCR rated motors. Controls operated on 230 volt AC inputs are designed for 180 volt SCR rated motors. Use of higher voltage motors will result in reduction of available maximum (MAX) speed (Trimpot Adjustment). Also, if motor is not an SCR rated type, the actual AC line amperage at full load should not exceed the motor's DC nameplate rating.

4.2 Torque Requirements – When replacing an AC induction motor with a DC motor and speed control, consideration must be given to the maximum torque requirements. The full load torque rating of the DC motor must be equal to, or greater than, that of the AC motor.

4.3 Acceleration Start – The KBIC

contains an adjustable acceleration start feature that allows the motor to smoothly accelerate from 0-full speed over a time period of 0.5-4 seconds. The "ACCEL" is factory set at 2 seconds.

4.4 Limitation in Use – The KBIC

controls are designed for use on machine applications.

4.5 Armature Switching – Do not switch the armature without taking proper precautions. (Refer to Armature Switching and Dynamic Braking, Section 9.2 on page 20).

CAUTION! Consult factory before using on constant horsepower applications such as saws or drill presses. Do not use in explosive atmosphere. Be sure the KBIC

is used within its maximum ratings.

Follow all installation instructions carefully (Refer to Section 5, on page 12).

FIGURE 2. MECHANICAL SPECIFICATIONS

OPTIONAL AUXILIARY HEATSINK

POTENTIOMETER

MOUNTING "A" 6 SLOTS

CONTROL

MOUNTING "B" TAPPED 6-32 (3 PLACES)

FUSE MOUNTING TAPPED 6-32 (2 PLACES)

ANTI-ROTATION PIN

Note: All dimensions are shown in inches.

TABLE 1. FIELD CONNECTIONS (SHUNT-WOUND MOTORS ONLY)

AC LINE

VOLTAGE

FIELD VOLTAGE

(VDC)

FIELD

CONNECTION

FIELD TYPE

115 100 F+, F- Full Voltage 115 50 F+, L1 Half Voltage 230 200 F+, F- Full Voltage

CAUTION

Shunt-wound motors may be damaged if field remains energized with the motor stopped for an extended period of time, unless provided with external cooling.

230 100 F+, L1 Half Voltage

TABLE 2. ELECTRICAL RATINGS

RATING WITHOUT

AUXILLARY HEAT SINK

RATING WITH

AUXILLARY HEAT SINK

Model

No.

Part

No.

Line

Voltage

(VAC)

+/- 15%

50/60

Motor

Voltage

(VDC)

(3)

Max.

Load

Current

(RMS

Amps)

Max.

Load

Current

(Avg.

Amps)

Max.

Load

Current

(RMS

Amps)

Max.

Load

Current

(Avg.

Amps)

Max.

Field

Voltage

(Shunt Wound

Motor Only) (VDC)

KBIC-

120

9429 115 0 – 90 9.0 6.0 0.5 18.0 12.0 1 50, 100

KBIC-

125

9433 115 0 – 90 12.0 8.0 0.75 24.0 16.0 1.5 50, 100

KBIC-

240

9428 208/230 0 – 180 9.0 6.0 1 18.0 12.0 2 100, 200

KBIC-

225

9432 208/230 0 – 180 12.0 8.0 1.5 24.0 16.0 3 100, 200

115 0 – 90 0.5 1 50, 100

KBIC-

240D

(1)

9464

208/230 0 – 180

9.0 6.0 1

18.0

12.0 2 100, 200

KBIC240DS

(2)

9423 115,

208/230

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 208/230 VAC line. (2) Model KBIC-240DS is designed to accept 115 or 208/230 VAC line input to provide 0-130 VDC with a 115 or 208/230 VAC line. (3) A higher output voltage can be reached by increasing MAX trimpot setting.

TABLE 3. MINIMUM SUPPLY WIRE SIZE REQUIREMENTS

Minimum Size Wire (AWG)

Cu Only

Maximum Motor

Current

(DC Amps)

Maximum

Motor

HP 90 V

Maximum

Motor

HP 180 V

Max 50 Foot Run Max 100 Foot Run

6 0.5 1 16 14 12 1 2 14 12* 16 1.5 3 12 12

*Minimum recommended wire size.

TABLE 4. FUSE SELECTION CHART*

HORSEPOWER

90 VDC

Motor

180 VDC

Motor

Approx.

Motor Current

(DC Amps)

Fuse Rating

(AC Amps)

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 –1/2

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 –1/2 7.5 12

1 2 10.0 15

1 –1/2 3 15.0 25 *Note: Specific applications may require a different fuse value than indicated. This is based on several factors such as ambient temperatures, duty cycle, motor form factor and CL setpoint.

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