INSTALLATION AND OPERATING INSTRUCTIONS
REGENERATIVE DRIVE
MODEL KBMG-212D
KB Part No. 8831
Variable Speed SCR Control Designed for
Shunt Wound and PM DC Motors
FULL WAVE • 4 QUADRANT
See Safety Warning on Page 3
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
© 1999 KB Electronics, Inc.
TABLE OF CONTENTS
Section |
Page |
i.Simplified Setup and
Operating Instructions . . . . . . . . . . . . . . 1 ii. Safety Warning . . . . . . . . . . . . . . . . . . . 3 I. General Information . . . . . . . . . . . . . . . . 4 II. Operation . . . . . . . . . . . . . . . . . . . . . . . . 5 III. Setting Selectable Jumpers . . . . . . . . . . 8 IV. Mounting . . . . . . . . . . . . . . . . . . . . . . . 15 V. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 15 VI. Fusing . . . . . . . . . . . . . . . . . . . . . . . . . 24 VII. Trimpot Adjustments . . . . . . . . . . . . . . 25 VIII. Function Indicator Lamps . . . . . . . . . . . 30 IX. KBMG-212D Accessories . . . . . . . . . . 30 X. Limited Warranty . . . . . . . . . . . . . . . . . 34
TABLES
1. Electrical Ratings . . . . . . . . . . . . . . . . . . 5
2. Summary of Control Operation . . . . . . . 6
3.General Performance Specifications . 7,8
4.Jumper J2 Position vs
Motor Horsepower . . . . . . . . . . . . . . . . . 9
5.Relationship of AC Line Input and Motor
Voltage with J1A, J1B and J3 . . . . . . . 10 6. Terminal Block Wiring Information . . . . 15 7. Field Connections . . . . . . . . . . . . . . . . 18 8. Armature Fuse Chart . . . . . . . . . . . . . . 25
FIGURES Page
1. AC Line Voltage Jumper Setting . . . . . . . 10
2.Motor Armature Voltage
Jumper Setting . . . . . . . . . . . . . . . . . . . . 10
3. Jumper J4 Setting . . . . . . . . . . . . . . . . . . 11
4. Jumper J5 Setting . . . . . . . . . . . . . . . . . . 11
5. Jumper J6 Setting . . . . . . . . . . . . . . . . . . 12
6. Speed Control Mode . . . . . . . . . . . . . . . . 13
7. Torque Control Mode . . . . . . . . . . . . . . . 14
8. AC Line Connection . . . . . . . . . . . . . . . . 16
9. Armature Connection . . . . . . . . . . . . . . . 16
10A. Full Voltage Field . . . . . . . . . . . . . . . . . . 17
10B. Half Voltage Field . . . . . . . . . . . . . . . . . . 17
11.Main Speed Potentiometer
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Connections . . . . . . . . . . . . . . . . . . . . . . |
19 |
12. |
Control Layout . . . . . . . . . . . . . . . . . . . . |
20 |
13. |
Mechanical Specifications . . . . . . . . . . . |
21 |
14. |
Voltage Following Connection . . . . . . . . |
22 |
15. |
Regenerate to Stop . . . . . . . . . . . . . . . . . |
23 |
16. |
Coast to Stop . . . . . . . . . . . . . . . . . . . . . |
23 |
17. |
Tach-Generator Feedback . . . . . . . . . . . |
24 |
18. |
Accel Trimpot Adjustment . . . . . . . . . . . . |
26 |
19. |
Dead Band Trimpot Adjustment . . . . . . . |
27 |
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i. 
KBMG-212D 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 before proceeding.
1.CONNECTIONS.
A.AC Line – Wire AC line voltage to terminals L1 and L2. Be sure jumpers J1A and J1B are both set to the correct input line voltage 115 or 230 VAC. Connect ground wire (earth) to green ground screw.
B.Motor.
1.Permanent Magnet (PM Type). Connect motor armature leads to M1(+) and M2 (–). Be sure jumper J3 is set to the proper position “A90" for 90 volt DC motors and “A180" 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.
Note: Motor performance and efficiency, including brush life, can be adversely affected when using 90 volt motors with a 230 VAC line. Contact motor manufacturer for derating information.
2.Shunt Wound Motors. Connect motor armature leads as above. Connect full voltage shunt field leads (90 volt motors with 100 volt fields and 180 volt with 200 volt fields) to F+ and F-. Connect half voltage field leads (90 volt motors with 50 volt fields and 180 volt motors with 100 volt fields) to F+ and L1.
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2.MOTOR CURRENT.
Jumper J2 is factory set for 7.5 amp motors (7.5A). For lower amperage motors, place J2 in the proper position. If motor amperage is less than 1.7 amps, use the 1.7 amp position and readjust the IR and CL trimpots according to section VII, C and D on pages 28 and 29. Note: The factory setting for Current Limit is 150% of the nominal current setting (e.g., if J2 is selected for 5 amps, the actual CL setting will be 7.5 amps). Note: If the 10.0 amp setting (10.0A) is required, an auxiliary heatsink (KB P/N 9861) must be used.
3.TRIMPOT SETTINGS.
All trimpots have been factory set in accordance with figure 12, p. 20.
4.ENABLE.
A jumper must be connected between “EN” and “COM” terminals or control will not operate. (See sec. V, G, page 22.)
Note: For the location of jumpers and trimpots, see fig. 12, control layout, on page 20.
5.SPEED OR TORQUE MODE.
Jumper J5 is factory set for speed control operation (SPD). For torque control, set J5 to the “TRQ” position.
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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 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 enable 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, enable) 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.
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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 9945C or equivalent) is required. Additional shielded motor cable and/or AC line cables may be required along with a signal isolator (model SIMG, KB P/N
8832 or equivalent).
I.GENERAL INFORMATION.
The KBMG-212D is a full-wave regenerative control, capable of operating a DC motor (Permanent Magnet or Shunt) in a bidirectional mode. It provides 4-quadrant operation which allows forward and reverse torque in both speed directions. The drive offers excellent controllability, which closely approximates the performance of servo-type drives. Ratings and specifications are presented in tables 1 and 3. Be sure the drive is used within these ratings and specifications.
(Note: Regenerative drives normally produce more motor heating than standard unidirectional SCR speed controls, especially under low speed operation. This should be taken into consideration when specifying motor rating.)
WARNING! Be sure to follow all instructions carefully. Fire or
electrocution can result due to improper use of this product. Read Safety Warning.
4
TABLE 1 – ELECTRICAL RATINGS
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AC Line |
Motor |
Rating Without Auxiliary Heatsink |
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KB |
Voltage |
Max. AC |
Max. DC |
Maximum |
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Model No. |
Voltage |
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Part No. |
(VAC) ± 10% |
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(VDC) |
Load Current |
Load Current |
Horsepower |
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50/60 Hz |
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(RMS Amps) |
(Avg. Amps) |
HP, (KW) |
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KBMG-212D |
8831 |
115 |
0 – ± 90 |
12.0 |
8.0 |
0.75, (0.5) |
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230 |
0 – ± 180 |
12.0 |
8.0 |
1.5, (1.0) |
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AC Line |
Motor |
Rating With Auxiliary Heatsink (KB P/N 9861) |
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KB |
Voltage |
Max. AC |
Max. DC |
Maximum |
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Model No. |
Voltage |
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Part No. |
(VAC) ± 10% |
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(VDC) |
Load Current |
Load Current |
Horsepower |
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50/60 Hz |
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(RMS Amps) |
(Avg. Amps) |
HP, (KW) |
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KBMG-212D |
8831 |
115 |
0 – ± 90 |
16.0 |
11.0 |
1, (0.75) |
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230 |
0 – ± 180 |
16.0 |
11.0 |
2, (1.5) |
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II.OPERATION.
The KBMG-212D will vary motor speed or torque as a function of the signal voltage on input terminals “SIG" (signal) and “COM” (common). The input voltage can be derived from the wiper of the main speed potentiometer or from an isolated analog input (signal voltage following mode). Since the KBMG-212D is a 4-quadrant regenerative drive, the motor speed will follow both a positive and negative signal voltage and drive the motor in both the forward direction and reverse direction. In addition, it will apply both forward and reverse torque in order to stabilize motor speed.
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To understand the concept of a regenerative drive, the operation of an elevator can be used. If one were to enter the elevator on the first floor and press 10, the motor and control would have to lift the elevator against gravity. In this mode, the drive would operate like a conventional speed control which is called “motoring” (the applied load is opposite to the direction of motor rotation). When the elevator is at floor 10 and floor 1 is pressed, gravity will try to pull the elevator car down faster than the speed for which it is set. The control will then provide reverse torque to keep the car from falling faster than the set speed. This operation is regeneration (the applied load is in the same direction as the direction of motor rotation).
The table below summarizes the different modes of operation.
TABLE 2 – SUMMARY OF CONTROL OPERATION
Quadrant |
Type of Operation |
Motor Rotation |
Motor Torque |
Applied Load |
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Direction |
Direction |
Direction |
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I |
Motoring |
CW |
CW |
CCW |
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II |
Regeneration |
CCW |
CW |
CCW |
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III |
Motoring |
CCW |
CCW |
CW |
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IV |
Regeneration |
CW |
CCW |
CW |
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TABLE 3 – GENERAL PERFORMANCE SPECIFICATIONS
Parameter |
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Specification |
Factory |
|
Setting |
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AC Line Input Voltage (VAC ±10% 50/60 Hz) |
115 or 230 |
230 |
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AC Line Frequency (Hz) |
50/60 |
— |
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Armature Voltage Range 115VAC Line (VDC) |
0 |
– ± 90 |
— |
Armature Voltage Range 230VAC Line (VDC) |
0 |
– ± 90, 0 – ± 180 |
0 – ± 180 |
Field Voltage at 115VAC Line (VDC) |
100/50 |
— |
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Field Voltage at 230VAC Line (VDC) |
200/100 |
— |
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Max Load Capacity (% for 2 Minutes) |
150 |
— |
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Ambient Temperature Operating Range (ºC) |
0 |
– 50 |
— |
Speed Range (Ratio) |
50:1 |
— |
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Armature Feedback Load Regulation (% Base Speed) |
±1 |
— |
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Tach-generator Feedback Load Regulation (% Set Speed) |
±1 |
— |
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AC Line Regulation (% Base Speed) |
±0.5 |
— |
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Current Ranges (Amps DC) |
1.7, 2.5, 5.0, 7.5, 10* |
7.5 |
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Forward Accel (FACC) and Reverse Accel (RACC) Range (Sec.) |
0.1 – 15 |
1 |
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Dead Band Range (% Base Speed) |
0 |
– ±5 |
1 |
Max Speed Trimpot Range (% Base Speed) |
55 – 110 |
100 |
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IR Comp Range at 115VAC Line (VDC @ Full Load) |
0 |
– 20 |
5 |
IR Comp Range at 230VAC Line (VDC @ Full Load) |
0 |
– 40 |
10 |
Continued next page
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TABLE 3 – GENERAL PERFORMANCE SPECIFICATIONS (Continued)
Parameter |
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Specification |
Factory |
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Setting |
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Forward CL (FCL) and Reverse CL (RCL) Range (% Range Setting) |
0 |
– 175 |
150 |
Voltage Following Input Range (VDC)** |
0 |
– ±10, 0 – ±15 |
0 – ±15 |
Voltage Following Linearity (% Base Speed) |
±0.5 |
— |
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* Requires Auxiliary Heatsink KB P/N 9861. ** Requires isolated input or signal isolator.
III.SETTING SELECTABLE JUMPERS.
The KBMG-212D has customer selectable jumpers which must be set before the control can be used (refer to fig. 1, p. 10). Bold indicates factory setting. See fig. 12, p. 20 for location of jumpers.
A.J1A, J1B – Input AC Line Voltage – Select proper input line voltage, 115VAC or 230VAC, by placing both J1A and J1B in the correct corresponding position, “115" or “230.” (See fig. 1, p. 10.)
B.J2 – Armature Current – Select the J2 position (1.7, 2.5, 5.0, 7.5, 10) closest to the rated motor current. (Note: The maximum output current is set to 150% of the J2 position, which may be readjusted using the FWD CL and REV CL trimpots.)
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TABLE 4 – JUMPER J2 POSITION vs MOTOR HORSEPOWER
Jumper J2 Position |
Motor Horsepower HP, (KW) |
|
Motor Current |
90VDC |
180VDC |
(DC Amps) |
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10.0A* |
1.0, (0.75) |
2.0, (1.5) |
7.5A |
3/4, (0.5) |
1, (1.0) |
5.0A |
1/2, (0.37) |
1.0, (0.75) |
2.5A |
1/4, (0.18) |
1/2, (0.37) |
1.7A |
1/6, (0.12) |
1/3, (0.25) |
*10.0A setting requires auxiliary heatsink KB P/N 9861
C.J3 – Motor Armature Voltage – Select the desired armature voltage by placing J4 in the proper position, “A90" or “A180.” Note: For 115 volt AC line input, J3 must be set to “A90.” For 230 input, the armature voltage is normally set for “A180.” However, it is also possible to set the armature voltage to “A90" for stepdown operation. (See fig. 2 and table 5 on page 10.)
J3 – Tach-Generator Feedback (for use with 1800 RPM motors.) – Jumper J3 is also used if tach-generator feedback is to be used. (See fig. 2, p. 10) If a 7 volt per 1000 RPM tach-generator is used, set jumper J4 in the “T7" position. For a 50 volt per 1000 RPM tach-generator, set the jumper in the “T50" position. Note: When using tach-generator feedback, the IR Comp trimpot should be turned to a minimum setting (full CCW).
9
FIG. 1 – AC LINE VOLTAGE |
FIG. 2 – MOTOR ARMATURE VOLTAGE |
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JUMPER SETTING (J1A, J1B) |
JUMPER SETTING (J3) |
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115VAC |
230VAC |
90VDC |
180VDC |
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TABLE 5 – RELATIONSHIP of AC LINE INPUT AND MOTOR
VOLTAGE with J1A, J1B and J3 JUMPER POSITION
AC LINE INPUT VOLTAGE |
J1A, J1B POSITION |
J3 POSITION |
MOTOR VOLTAGE |
115 |
115 |
90 |
90 |
230 |
230 |
180 |
180 |
230 |
230 |
90* |
90* |
*A 90VDC motor can be used with a 230VAC line (J3 set in “A90" position). However, speed range may be reduced and motor derating may be required.
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