KBIC® Solid State SCR DC Motor Speed Controls ® Patented Ultra Fast CL Circuit Prevents Demagnetization in PM Motors See table 2 page 4 for KBIC models covered by this manual Installation and Operating Instructions See SAFETY WARNING on page 4 Basic KBIC ® PATENTED *See Page 3 TM A COMPLETE LINE OF MOTOR DRIVES ©1996 KB ELECTRONICS, INC. TABLE OF CONTENTS Section i. ii. iii. I. II. III. IV. V. Page Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Simplified Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adjustments & Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Switching Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 TABLES 1. 2. 3. 4. 5. 6. 7. 8. Nominal Trimpot Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuse Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Plug-in Horsepower Resistor® Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Minimum Supply Wire Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FIGURES ® 1. 2. 3. 4. 5a. 5b. 5c. 6. 2 Basic KBIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCEL Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master/Slave Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dynamic Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7 8 10 12 13 13 14 i. SAFETY WARNING! 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 and/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 Inhibit circuits which 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, Inhibit) 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. This product complies with all CE directives pertinent at the time of manufacture. Contact factory for detailed installation instructions and Declaration of Conformity. ii. SIMPLIFIED INSTRUCTIONS ­ Read these simplified instructions before operating control. (See Safety Warning.) 1. Be sure input AC line voltage corresponds to control voltage. (See Electrical Rating chart, table 2 p. 4.) 2. Install the correct Plug-in Horsepower Resistor® according to armature voltage and motor horsepower (See chart, p. 5). 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.) 4. Nominal trimpot settings are as follows (expressed in % of full CW rotation): 5. It is recommended that both AC line and armature fuses should be installed in this product. (See sec. IID, p. 9.) TABLE 1 ­ NOMINAL TRIMPOT SETTINGS (For detailed instruction see Sec. III) MIN (minimum speed) MAX (maximum speed) IR (IR Compensation) 15% 60% 25% 3 CL (current limit/torque) ACCEL (acceleration start) 50% 50% TABLE 2 ­ ELECTRICAL RATINGS Model Number AC Line Voltage (VAC) ± 15% 50/60Hz 115 115 230 230 1 RATING WITHOUT AUXILIARY HEATSINK Motor Voltage 3 (VDC) Max. AC Load Current (RMS Amps) 9.0 12.0 9.0 12.0 9.0 9.0 Max. DC Load Current (Avg. Amps) 6.0 8.0 6.0 8.0 6.0 6.0 MAX HP 0.5 0.75 1 1.5 0.5 1 0.5 RATING WITH AUXILIARY HEATSINK Max. AC Load Current (RMS Amps) 18.0 24.0 18.0 24.0 18.0 18.0 Max. DC Load Current (Avg. Amps) 12.0 16.0 12.0 16.0 12.0 12.0 MAX HP 1 1.5 2 3 1 2 1 FIELD VOLTAGE (Shunt wound Motor Only) (VDC) 50, 100 50, 100 100, 200 100, 200 50, 100 100, 200 100 KBIC-120 KBIC-125 KBIC-240 KBIC-225 KBIC-240D 0 - 90 0 - 90 0 - 180 0 - 180 0 - 90 0 - 180 0 - 90 115 230 KBIC-240DS2 115 / 230 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 230 VAC line. (2) Model KBIC-240DS is designed to accept 115 or 230 VAC line input to provide 0-130 VDC with a 115 or 230 VAC line. (Also see Information Sheet A40058) (3) A higher output voltage can be reached by increasing MAX trimpot setting. TABLE 3 ­ 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) (secs) . . . . . . . . . . . . . . . . . 0.5 - 4.0 MIN Speed Trimpot Range (% full speed) . . . . . . . . . . . . . . . . . . . 0 - 30* MAX Speed Trimpot Range (% full speed) . . . . . . . . . . . . . . . . . 50 - 110* IR Compensation Trimpot Range (at specified full load) (volts) . . . . 0 - 24 Maximum Allowable Ambient Temperature at full rating (º C/º F) . . 45/113 Maximum Inrush Start Current (Peak DC amps) . . . . . 3 times CL Setting PLUG-IN HORSEPOWER RESISTOR® A Plug-in Horsepower Resistor ® must be installed to match the KBIC® to the motor horsepower and voltage. See table 4, p. 5 for the correct value. Plug-in ® Horsepower Resistors are stocked by your distributor. CAUTION Be sure Plug-in Horsepower Resistor® is inserted completely into mating socket. *Performance is for SCR rated PM motors only. Lower performance can be expected with other motor types. Factory setting is for 3% load regulation. To obtain superior regulation, see sec. III E, p. 11. 4 FIG. 1 ­ BASIC KBIC® *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. FIG. 1 ­ FEATURES AND FUNCTIONS Plug-in Horsepower Resistor® Mounting Holes for Armature and AC Line Fuses Trimpots: MIN, MAX, ACCEL, IR & CL Auxiliary Heatsink (optional) (see fig. 2, p. 7) (1) (2) (3) (4) TABLE 5 ­ PLUG-IN HORSEPOWER RESISTOR® CHART(1) Approx. Motor Armature Voltage Armature Voltage Current (DC Amps) 90VDC 180VDC Motor Horsepower(2) Plug-in Horsepower Resistor Value (Ohm) 1.0 0.51 0.35 0.25 0.18 0.1 0.05 0.035 0.025 0.015 0.01 0.006 Individual Plug-in Horsepower Resistor® P/N 9833 9834 9835 9836 9837 9838 9839 9840 9841 9842 9843 9850 TABLE 4. FUSE SELECTION CHART* 90 VDC Motor 180 VDC Motor HORSEPOWER 1/100 1/50 1/30 1/20 1/15 1/10 1/8 1/6 1/4 1/3 1/2 3/4 1 1 1/50 1/25 1/15 1/10 1/8 1/5 1/4 1/3 1/2 3/4 1 1 2 3 Approx. Motor Current (DC Amps) 0.1 0.2 0.3 0.5 0.7 1.0 1.3 1.7 2.5 3.3 5.0 7.5 10.0 15.0 Fuse Rating (AC Amps) 2/10 3/10 1/2 3/4 1 1 2 3 4 5 8 12 15 25 1/100 1/50 1/30, 1/25 1/20 1/15, 1/12 1/10, 1/8, 1/6 1/4 1/3 1/2 3/4 1 1 1/50 1/25 1/15 1/10 1/6 1/4 1/2 3/4 1 1 2 3 0.1 0.2 0.35 0.5 0.8 1.3 2.5 3.3 5.0 7.5 10.0 15.0 Notes: (1) Motor horsepower and armature voltage must be specified in order to select correct Plug-in Horsepower Resistor®. (2) For motor horsepower not indicated use lower value Plug-in Horsepower Resistor®. 5 iii. INTRODUCTION Thank you for purchasing the KBIC "Standard of the Industry" DC motor speed control. They 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 patented Direct-FedTM 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 Heatsink (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. A Barrier Terminal Board is available which incorporates both line and armature fuses. The InhibitTM circuit (Terminals I1 and I2) is provided to electronically disconnect the ...