Manual

ManualsBrandsKB Electronics ManualsSoftwareKBMM-225D

KBMM

™

Installation and Operation Manual

Surface Mount Technology

Solid State SCR

DC Motor Speed Controls

A+

F-

ACCEL

DECEL

CONN1

PWR ON

F+

A-

MAX

MIN

for Use with 1/100 – 3 HP, 90 and 180 Volt

Permanent Magnet and Shunt Wound DC Motors*

AC Line Input: 115 and 208/230 Volts, 50/60 Hz

This Manual Covers Models KBMM-125, 225, 225D

Ultra Fast Current Limit Circuit Prevents

Demagnetization in Permanent Magnet Motors

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 Plug-In Horsepower Resistor® and AC Line

and Armature Fuses, supplied separately,

must be installed for this product to operate.

*Auxiliary Heat Sink (Part No. 9861) is required

to achieve maximum rating of control. See

Electrical Ratings, Table 1, on page 9.

See Safety Warning on page 6.

A COMPLETE LINE OF MOTOR DRIVES

*See page 6

for CE

Information

(See back cover)

PATENTED

Manufactured

in the USA

Summary of content (32 pages)

PAGE 1
Installation and Operation Manual KBMM™ FA+ L1 Surface Mount Technology DECEL L2 Solid State SCR DC Motor Speed Controls F+ J2 B T CL for Use with 1/100 – 3 HP, 90 and 180 Volt Permanent Magnet and Shunt Wound DC Motors* ACCEL P3 PWR ON J1 CONN1 EN AC Line Input: 115 and 208/230 Volts, 50/60 Hz P2 A- I1 P1 I2 This Manual Covers Models KBMM-125, 225, 225D MIN MAX CL IR PATENTED Ultra Fast Current Limit Circuit Prevents Demagnetization in Permanent Magnet Motors * ! See Safety W
PAGE 2
TABLE OF CONTENTS Section Page 1 Simplified Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 3
TABLE OF CONTENTS (Continued) Figures Page 1 Control Layout and General Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4
1 SIMPLIFIED INSTALLATION INSTRUCTIONS IMPORTANT – Read these simplified installation instructions before proceeding. 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 6, before proceeding. Note: A Plug-In Horsepower Resistor® and AC Line and Armature Fuses, supplied separately, must be installed in order for this product to operate. See Section 9, on page 21.
PAGE 5
1.5 AC line Fusing – It is required that an AC line fuse (supplied separately) be installed in the AC Line Fuse Holder, as shown in Figure 1, on page 10. Select the correct AC Line Fuse, as described in Section 8, on pages 20 and 21. Fuse each conductor that is not at ground potential. 1.6 Armature Fusing – It is required that an Armature Fuse (supplied separately) be installed in the Armature Fuse Holder, as shown in Figure 1, on page 10.
PAGE 6
2 SAFETY WARNING – Please read carefully. 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.
PAGE 7
3 INTRODUCTION Thank you for purchasing the KBMM™ “Standard of the Industry” full-wave variable speed DC motor control, now with SMT construction. The control offers the user the ultimate in reliability and performance at an affordable price. The controls contain a unique patented super-fast Direct-Fed™ current limit circuit that protects the SCR power bridge against direct shorts 1.
PAGE 8
3.1 Standard Features 8 1 Plug-In Horsepower Resistor® – Eliminates the need to calibrate the control for IR Compensation and Current Limit when used on various horsepower motors. 2 Auto-Inhibit® – Allows the control to be rapidly switched “on” and “off” using the AC line. 3 Inhibit and Enable – Allows the control to be turned “on” and “off” using electronic switching.
PAGE 9
TABLE 1 – ELECTRICAL RATINGS Part No. AC Line Voltage (±15%, 50/60Hz) (Volts AC) KBMM-125 9449 115 KBMM-225 9450 230 Model 115 KBMM-225D 9451 230 Maximum Rating without Auxiliary Heat Sink Maximum Rating with Auxiliary Heat Sink Motor Voltage (Volts DC) AC Line Current (RMS Amps) DC Load Current (Avg. Amps) Horsepower (HP (kw)) AC Line Current (RMS Amps) DC Load Current (Avg. Amps) Field Horsepower Voltage (HP (kw)) (Volts DC) 0 - 90 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.
PAGE 10
FIGURE 1 – CONTROL LAYOUT & GENERAL CONNECTION DIAGRAM (Model KBMM-225D Shown) (Note: Control is set for 208 / 230 VAC line input, 0 -180 VDC output with armature feedback) Red Blue Plug-In Horsepower Resistor® Supplied Separately FA+ L1 DECEL L2 AC Line Fuse Supplied Separately Armature Fuse Supplied Separately F+ B J2 T CL For Plug-In Horsepower Resistor®, Line Fuse, and Armature Fuse Selection See Sections 8 and 9, on pages 20-22.
PAGE 11
FIGURE 2 – MECHANICAL SPECIFICATIONS (Inches/mm) 3.64 92.5 OPTIONAL AUXILIARY HEAT SINK MAIN SPEED POTENTIOMETER (SUPPLIED) .22 5.6 3.10 78.5 3/8" .98 24.9 1/2" .50 12.7 CONTROL MOUNTING "A" 6 SLOTS 4.30 109 3.00 76.2 FUSE HOLDER & FINGER-SAFE COVER MOUNTING HOLES TAPPED 6-32 (2 PLACES) 1.50 38.1 2.15 54.6 MOUNTING "D" 2 SLOTS 1/4" ROUND SHAFT MOUNTING "B" TAPPED 10-32 (3 PLACES) ANTIROTATION PIN 1.75 44.5 1.75 44.5 4 .64 16.3 .18 4.6 .25 6.4 .95 24.1 1.25 31.8 3.11 (79.
PAGE 12
4.3 Acceleration Start – The control contains an adjustable acceleration start feature which allows the motor to smoothly accelerate from zero speed to full speed over a time period of 0.2 - 10 seconds. The acceleration trimpot (ACCEL) is factory set for 2 seconds. 4.4 Limitation In Use – The control is designed for use on machine applications. CAUTION! Consult our Sales Department before using this control on constant horsepower applications such as saws and drill presses.
PAGE 13
Important Application Note: To avoid erratic operation, do not bundle the AC line and motor wires with wires from signal following, start/stop contacts, or any other signal wires. Also, do not bundle motor wires from multiple controls in the same conduit. Use shielded cables on all signal wiring over 12” (30 cm). The shield should be earth grounded on the control side only. Wire the control in accordance with the National Electrical Code requirements and other local codes that may apply.
PAGE 14
6.3 Permanent Magnet (PM) Motor Connection – Wire the motor armature positive lead (+) to Terminal “A+” (Armature Fuse) and the negative lead (-) to Terminal “A-”, as shown in Figure 1, on page 10. On Models KBMM-225 and KBMM-225D, be sure Jumper J2 is set to the corresponding motor voltage, as described in Section 7.2, on page 20. Be sure the correct Plug-In Horsepower Resistor® is installed, as described in Section 9, on page 21. 6.4 Motor Field Connection (Shunt Wound Motors Only) 6.4.
PAGE 15
FIGURE 3 – REMOTE MAIN SPEED POTENTIOMETER CONNECTION Terminal "P3" CONN1 EN 6.5 Remote Main Speed Potentiometer Connection – The control is supplied with a Main Speed Potentiometer to control motor speed. Wire the low side of the potentiometer to Terminal “P1”. Wire the wiper of the potentiometer to Terminal “P2”. Wire the high side of the potentiometer to Terminal “P3”. See Figure 3. P2 P3 6.
PAGE 16
6.7 Enable Circuit Connection – The control can be started and stopped with an Enable Circuit (close to run, open to stop), as described below. ! WARNING! The Enable Circuit is never to be used as a Safety Disconnect since it is not fail-safe. Use only the AC line for this purpose. 6.7.1 Enable Switch or Contact Wired to the Enable Connector – Using the wired mating connector that is supplied with the control, wire the switch or contact to the Enable connector (CONN1), as shown in Figure 5.
PAGE 17
Terminal "P3" P1 High Wiper Low WARNING! The Inhibit Circuit is never to be used as a Safety Disconnect since it is not fail-safe. Use only the AC line for this purpose. P1 MAX MAX Main Speed Potentiometer (Front View) P2 P3 Terminal "P1" Enable Switch or Contact (Close to Run) (Open to Stop) High Wiper 6.8 Inhibit Circuit Connection – The control can be stopped and started with an Inhibit circuit (close to stop, open to run).
PAGE 18
Terminal "T" B T PWR ON Application Notes – 1. The tach-generator input circuit is designed for a 7 Volt or 50 Volt per 1000 RPM DC tachgenerator used with an 1800 RPM motor. 2. Initially set the IR Comp Trimpot fully counterclockwise. Once the tachgenerator is connected, the IR Comp Trimpot may be increased for additional speed stabilization. FIGURE 8 – DC TACH-GENERATOR CONNECTION (7 VOLTS PER 1000 RPM) J2 6.
PAGE 19
FIGURE 10 – OTHER DC TACH-GENERATOR CONNECTION B J2 tach-generator. Connect one end of RT to Terminal “T”, connect the other end of RT to the tachgenerator positive lead (+), and connect the negative lead (-) of the tach-generator to Terminal “I2”. See Figure 10. T PWR ON The value of RT (Ω) can be calculated using the following formula: RT = (1.3 X VT X S) - 16000 Ω Where “VT” is the tach-generator voltage (in Volts per 1000 RPM) and “S” is the base speed of the motor (in RPM).
PAGE 20
7.2 Motor Voltage and DC Tach-Generator Selection – Jumper J2 is factory set to the “90” position on Model KBMM-125, for 90 Volt DC motors, and set to the “180” position, on Models KBMM-225, 225D, for 180 Volt DC motors. To set Models KBMM-225, 225D for step-down operation (208/230 Volt AC line input and 90 Volt DC output), set Jumper J2 to the “90” position). To set the control for tach-generator connection, set Jumper J2 to the “T” position (all models). See Figure 12.
PAGE 21
An AC Line Fuse (supplied separately) must be installed in the AC line Fuse Holder and an Armature Fuse (supplied separately) must be installed in the Armature Fuse Holder, as shown in Figure 1, on page 10. Select the correct fuses, as shown in Table 5. 8.1 AC Line Fuse – The AC Line Fuse protects the control against catastrophic failure. If the AC Line Fuse blows, the control is miswired, the motor is shorted or grounded, or the control is defective.
PAGE 22
TABLE 6 – PLUG-IN HORSEPOWER RESISTOR® SELECTION Plug-In Horsepower Resistor® 90 - 130 Volt DC Motors (HP) 180 Volt DC Motors (HP) Value (Ohms) Part No. 1/100 – 1/50 1/50 – 1/25 1 9833 1/50 – 1/30 1/25 – 1/15 .51 9834 1/30 – 1/20 1/15 – 1/10 .35 9835 1/20 – 1/12 1/10 – 1/6 .25 9836 1/12 – 1/8 1/6 – 1/4 .18 9837 1/8 – 1/5 1/4 – 1/3 .1 9838 1/4 1/2 .05 9839 1/3 3/4 .035 9840 1/2 1 .025 9841 3/4 11⁄2 .015 9842 1* 2* .01 9843 11⁄2* 3* .
PAGE 23
FIGURE 13 – HI-POT TEST SETUP High Voltage Dielectric Withstand Tester (Hi-Pot Tester) 1 LEAKAGE 2 0 3 AC KILOVOLTS 0mA 10mA RETURN TEST H. V. RESET VOLTAGE Connect all Speed Control terminals together MAX ZERO Motor Speed Control AC Line input L1 L2 Motor Terminals Motor Wires Frame Connect Hi-Pot Tester to both AC Line inputs Auxiliary Equipment P1 L1 P2 L2 Chassis Machine or equipment frame Signal Inputs P3 Chassis 10.
PAGE 24
10.2 The Hi-Pot Tester must have an automatic ramp-up to the test voltage and an automatic ramp-down to zero voltage. Note: If the Hi-Pot Tester does not have automatic ramping, then the hi-pot output must be manually increased to the test voltage and then manually reduced to zero. This procedure must be followed for each machine to be tested. A suggested Hi-Pot Tester is Slaughter Model 2550. CAUTION! Instantaneously applying the hi-pot voltage will cause irreversible damage to the control.
PAGE 25
11.2 Deceleration Trimpot (DECEL) – The DECEL Trimpot controls the amount of ramp-down time when the Main Speed Potentiometer is adjusted to a lower speed. The DECEL Trimpot has been factory set to 2 seconds, which is the amount of time it will take for the motor to decelerate from full speed to zero speed. To increase the deceleration time, rotate the DECEL Trimpot clockwise. To decrease the deceleration time, rotate the DECEL Trimpot counterclockwise. See Figure 15.
PAGE 26
Warning! If possible, do not adjust trimpots with the main power applied. If adjustments are made with the main power applied, an insulated adjustment tool must be used and safety glasses must be worn. High voltage exists in this control. Electrocution can result if caution is not exercised. Safety Warning, on page 6, must be read and understood before proceeding. ! 11.5 Current Limit Trimpot (CL) – The CL Trimpot sets the current limit (overload), which limits the maximum current (torque) to the motor.
PAGE 27
wired in series with the motor armature). If using an AC ammeter wired in the AC line input, the factory Current Limit setting will read 0.75 times the full load rating of the motor. Do not exceed 2 times motor current rating (maximum clockwise position). Note: On cyclical loads, it may be normal for the CL LED to momentarily flash. ! WARNING! Do not leave motor shaft locked for more than 2-3 seconds or motor damage may result. FIGURE 19 – IR TRIMPOT RANGE 11.
PAGE 28
Warning! If possible, do not adjust trimpots with the main power applied. If adjustments are made with the main power applied, an insulated adjustment tool must be used and safety glasses must be worn. High voltage exists in this control. Electrocution can result if caution is not exercised. Safety Warning, on page 6, must be read and understood before proceeding. ! 2 Run the motor unloaded at approximately 1/3 speed and record the RPMs.
PAGE 29
! WARNING! Do not disconnect and reconnect the motor armature with the AC line applied or catastrophic failure will result. See Section 13.2. 13.2 Armature Switching and Dynamic Braking – If the armature is to be disconnected and reconnected with the AC power applied, wire a relay (or contactor) and a brake resistor (RB) in the armature circuit. The Inhibit Circuit must be simultaneously activated when braking.
PAGE 30
13.3 Reversing and Dynamic Braking – The optional patented APRM® provides anti-plug “instant” reversing and solid state dynamic braking. The APRM® is built-in as standard on Models KBCC-R™ and KBPB™. Contact the Sales Department for more information. 14 OPTIONAL ACCESSORIES 14.1 Auxiliary Heat Sink (Part No. 9861) – Doubles the horsepower rating of the control. 14.2 Barrier Terminal Accessory Kit (Part No.
PAGE 31
14.10 KBEP-240D Electronic Potentiometer (Part No. 9108) – Provides digital type control of motor speed. Replaces a standard rotary potentiometer with a set of customer supplied momentary push buttons or membrane switches. Operates on 115 or 230 Volt AC line input. 14.11 KBET-240D Electronic Tachometer (Part No. 9469) – Provides an isolated tack-feedback signal and an isolated voltage follower signal from an open collector (Hall, magnetic, inductive, optical) or 2-wire inductive pickup (encoder).
PAGE 32
LIMITED WARRANTY For a period of 5 years 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.