KBIC® SCR DC Motor Speed Controls Ultra Fast CL Circuit Prevents Demagnetization in PM Motors Installation and Operation Manual BASIC KBIC ® * See SAFETY WARNING * See CE information on page 5 This Manual Covers Models KBIC-120, 125, 240, 225, 240D, 240DS TABLE OF CONTENTS © 2008 KB Electronics, Inc.
TABLE OF CONTENTS Section Page 1 Quick-Start Instructions..................................................................................................................... 3 2 Safety ............................................................................................................................................... 5 3 Introduction ....................................................................................................................................... 6 4 Application Information .
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.
FIGURE 1.
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.
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.
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).
TABLE 1. FIELD CONNECTIONS (SHUNT-WOUND MOTORS ONLY) AC LINE FIELD VOLTAGE FIELD CAUTION VOLTAGE (VDC) CONNECTION Shunt-wound motors may be 115 100 F+, Fdamaged if field remains energized 115 50 F+, L1 with the motor stopped for an 230 200 F+, Fextended period of time, unless provided with external cooling. 230 100 F+, L1 FIELD TYPE Full Voltage Half Voltage Full Voltage Half Voltage TABLE 2. ELECTRICAL RATINGS Model No.
TABLE 3. MINIMUM SUPPLY WIRE SIZE REQUIREMENTS Maximum Motor Current (DC Amps) 6 12 16 Maximum Motor HP 90 V 0.5 1 1.5 Maximum Motor HP 180 V 1 2 3 Minimum Size Wire (AWG) Cu Only Max 50 Foot Run Max 100 Foot Run 16 14 14 12* 12 12 *Minimum recommended wire size. TABLE 4. FUSE SELECTION CHART* HORSEPOWER Approx. Fuse Rating Motor Current (AC Amps) 90 VDC 180 VDC Motor Motor (DC 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.
TABLE 5. 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) (seconds) 0.5 - 4.
TABLE 6. PLUG-IN HORSEPOWER RESISTOR CHART (1) Motor Horsepower (2) Armature Voltage ArmatureVoltage (90 VDC) (180 VDC) Approx. Motor Current (DC Amps) Plug-In Horsepower Resistor® Value (Ohms) Individual Plug-In Horsepower Resistor® P/N 9833 1/100 1/50 0.1 1.0 1/50 1/25 0.2 0.51 9834 1/30, 1/25 1/15 0.35 0.35 9835 9836 1/20 1/10 0.5 0.25 1/15, 1/12 1/6 0.8 0.18 9837 1/10, 1/8, 1/6 1/4 1.3 0.1 9838 1/4 1/2 2.5 0.05 9839 1/3 3/4 3.3 0.035 9840 1/2 1 5.0 0.
5 INSTALLATION, MOUNTING INSTRUCTIONS AND ELECTRICAL CONNECTIONS WARNING! DO NOT USE THIS DRIVE IN EXPLOSION-PROOF APPLICATIONS. BE SURE THE DRIVE IS SECURELY MOUNTED. 5.1 Location and Mounting – The KBIC® controls should be mounted on a flat surface and located in an area where it will not be exposed to contaminants such as water, metal chips, solvents or excessive vibration. When mounting in an enclosure, the air space should be large enough to provide adequate heat dissipation.
WARNING! IF CONTROL IS WIRED TO A TRANSFORMER, DO NOT SWITCH THE PRIMARY SIDE OF TRANSFORMER TO DISCONNECT POWER OR CATASTROPHIC FAILURE CAN RESULT. ALWAYS DISCONNECT CONTROL FROM SECONDARY SIDE OF TRANSFORMER. WARNING! ARMATURE SWITCHING. DO NOT SWITCH THE ARMATURE IN AND OUT OF CIRCUIT OR CATASTROPHIC FAILURE WILL RESULT. IF ARMATURE SWITCHING IS REQUIRED FOR DYNAMIC BRAKE OR REVERSING, USE MODEL KBRG, KBPB OR KBCC-R SUFFIX CONTROLS.
6 RECOMMENDED HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING (HI-POT) Testing agencies such as UL, CSA, etc., usually require that equipment undergo a hi-pot test. In order to prevent catastrophic damage to the control, which has been installed in the equipment, it is recommended that the following procedure be followed. A typical HI-POT test setup is shown in Figure 3, on page 15. All controls have been factory hi-pot tested in accordance with UL requirements.
FIGURE 3.
7 TRIMPOT ADJUSTMENTS AND CONTROL FUNCTIONS The KBIC® is factory adjusted to provide 0 to full speed range using a 5K potentiometer. Minimum and maximum speed trimpots are provided to change the speed range from other than 0 to full speed. An acceleration (ACCEL) trimpot (located directly behind the MIN trimpot) is factory set to provide motor acceleration from 0 to full speed over a time period of 2 seconds (approx.) each time the AC power is applied.
7.2 Maximum Speed Trimpot (MAX) The MAX Trimpot sets the maximum speed of the motor when the Main Speed Potentiometer is set fully clockwise. The MAX Trimpot is factory set to 100 % of base motor speed. To increase the maximum speed, rotate the MAX Trimpot clockwise. To decrease the maximum speed, rotate the MAX Trimpot counterclockwise. See Figure 5. FIGURE 5. MAX TRIMPOT RANGE 100 % Note: Do not attempt to adjust the MAX speed above the rated motor RPM, since unstable motor operation may occur.
7.4 Current Limit Trimpot (CL) The CL Trimpot sets the current limit (overload), which limits the maximum current (torque) to the motor. The CL also limits the AC line inrush current to a safe level during startup. The CL Trimpot is factory set to 1.5 times the full load rating of the motor. To increase the current limit, rotate the CL Trimpot clockwise (do not exceed 2 times (200%) motor current rating (maximum clockwise position)). To decrease the current limit, rotate the CL Trimpot counterclockwise.
7.5 IR Compensation Trimpot (IR): IR compensation is provided to substantially improve load regulation. If the load presented to the motor does not vary substantially, the IR adjustment may be set at a minimum level (approximately 1/4 of full setting). The control is factory adjusted to approximately 3% regulation. If superior performance is desired (less than 1% speed change of base speed from 0 to full load), then the IR compensation.
8 DIAGNOSTIC LED’S The KBIC™ is designed with PC board mounted LEDs to display the control's operational status. See Figure 1, on page 4, for the location of the LEDs. 9 8.1 Power On (PWR ON): The PWR ON LED will illuminate green when the AC line is applied to the control. 8.2 Current Limit (CL): The CL LED will illuminate red when the control goes into current limit, indicating that the current limit set point has been reached (set by the CL Trimpot). See Section 7.4, and Figure 7, on page 18.
WARNING! 1.THE INHIBIT CIRCUIT TERMINALS ("I1" AND "I2") IS NEVER TO BE USED AS A SAFETY DISCONNECT SINCE IT IS NOT FAIL-SAFE. USE ONLY THE AC LINE FOR THIS PURPOSE. 2. DO NOT DISCONNECT AND RECONNECT THE MOTOR ARMATURE WITH THE AC LINE APPLIED OR CATASTROPHIC FAILURE WILL RESULT. SEE ARMATURE SWITCHING (DYNAMIC BRAKING), ON PAGE 20. 9.3 Leader/Follower Connections - The KBIC® can be used with the KBSI® to drive multiple motors. Refer to Figure 10. FIGURE 10.
9.4 Voltage Following – All models can be controlled with an isolated analog reference voltage (0 -7 VDC) in lieu of the main speed potentiometer. The voltage is connected to P2 (+) and F-. The control output voltage will linearly follow the input voltage. The source impedance of the input should be 10K ohms or less. The Min and Max trimpots are rendered inoperative in the voltage following mode. Use auxiliary trimpots for scaling and to limit the control range.
9.6 Optional Overload Protection with KBAP-240D (Part No. 9106) The KBAP-240D® is a multipurpose DC Current Sensing Relay and Overload Protector. It is specifically designed for use with DC motors and speed controls from 1/8 - 3 HP. KBAP-240D® operates by sensing current in the armature circuit. When the preset level is reached, the output relay (RY1) trips. An adjustable time delay (0.2 15 secs.) is incorporated, which eliminates nuisance tripping.
OPTIONAL ACCESSORIES (CONTINUED) • DIN Rail Mounting Kit (Part No. 9995). • KBAP-240D Current Sensing Overload Protector (Part No. 9106): Provides overload current sensing and protection of DC motors and speed controls rated 1/8 - 3 HP by sensing armature current. Operates on 115 or 208/230 Volt AC line input. • KBEP-240D Electronic Potentiometer (Part No. 9108): Provides digital type control of motor speed.
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LIMITED WARRANTY For a period of 18 months from the date of original purchase, KB Electronics, Inc. will repair or replace without charge, devices which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied. The foregoing is in lieu of any other warranty or guarantee, expressed or implied.
