Installation and Operation Manual KBMMTM Surface Mount Technology Solid State SCR DC Motor Speed Controls for Use with 1/100 ­ 3 HP, 90 and 180 Volt Permanent Magnet and Shunt Wound DC Motors* EN FL1 A+ DECEL L2 F+ B T CL J2 ACCEL J1 PWR ON A- P2 I1 P1 CONN1 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 MAX P3 I2 MIN CL IR PATENTED 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. *See page 6 for CE Information 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. Manufactured in the USA A COMPLETE LINE OF MOTOR DRIVES © 2004 KB Electronics, Inc. (See back cover) TABLE OF CONTENTS Section Page 1 Simplified Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4 Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6 Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 7 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 8 AC Line and Armature Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 9 Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 10 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 11 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 12 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 13 Switching Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 14 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Tables 1 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3 Minimum Supply Wire Size Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4 Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5 AC Line and Armature Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6 Plug-In Horsepower Resistor® Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7 RFI Filter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2 TABLE OF CONTENTS (Continued) Figures Page 1 Control Layout and General Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4 Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5 Enable Switch or Contact Wired to the Enable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6 Enable Switch or Contact Wired to the Main Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7 Inhibit Switch or Contact Wired to the Inhibit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 8 DC Tach-Generator Connection (7 Volts per 1000 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 9 DC Tach-Generator Connection (50 Volts per 1000 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 10 Other DC Tach-Generator Connection (with Addition of RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 11 AC Line Input Voltage Selection (Jumper J1 (Model KBMM-225D Only)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 12 Motor Voltage and DC Tach-Generator Selection (Jumper J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 13 Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 14 Acceleration Trimpot (ACCEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 15 Deceleration Trimpot (DECEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 16 Minimum Speed Trimpot (MIN) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 17 Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 19 IR Compensation Trimpot (IR) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 20 Typical Dynamic Brake Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Items Included in this package ­ KBMMTM Speed Control, KBMMTM Installation and Operation Manual, Hardware Bag (contains Main Speed Potentiometer with insulator and mounting hardware, (9) ­ 0.25" female crimp-on terminals, (4) ­ 0.11" female crimp-on terminals, and an Enable harness), CE Approved Product Information Card, and Warranty Registration Card. Items required to operate this control ­ Plug-In Horsepower Resistor®, AC Line Fuse and Armature Fuse. Supplied through your distributor. See Sections 8 and 9, on pages 20 - 22. 3 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. Fuse Plug-In Horsepower Resistor® 1.1 AC Line Connection ­ Wire the AC line to Terminals "L1" (Line Fuse) and "L2", as shown in Figure 1, on page 10 and as described in Section 6.1, on page 13. Model KBMM-125 is rated for 115 Volt AC line input only. Model KBMM-225 is rated for 230 Volt AC line input only. Model KBMM-225D is rated for 115 Volt AC line input (Jumper J1 in the "115" position) and 230 Volt AC line input (Jumper J1 in the "230" position). See Section 7.1, on page 19. Notes: 1. The rated AC line voltage (115, 208/230) of the control must match the actual AC line input voltage. 2. If one of the AC line inputs is a neutral (N), wire it to Terminal "L2". 1.2 Ground Connection ­ Connect the ground wire (earth) to the control chassis. 1.3 Motor Connection ­ Connect the motor to Terminals "A+" (Armature Fuse) and "A-", as shown in Figure 1, on page 10, and as described in Section 6.3, on page 14. 1.4 Jumper Settings ­ Jumper J1 (on Model KBMM-225D only) and Jumper J2 (all models) have been factory set for most applications, as shown in Figure 1, on page 10, and as described in Section 7, on page 19. 4 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. Select the correct Armature Fuse as described in Section 8, on pages 20 and 21. 1.7 Plug-In Horsepower Resistor® ­ Install the correct Plug-In Horsepower Resistor® according to armature voltage and motor horsepower, as shown in Figure 1, on page 10. Select the correct Plug-In Horsepower Resistor®, as described in Section 9, on pages 21 and 22. 1.8 Trimpot Settings ­ All trimpots have been factory set for most applications, as shown in Figure 1, on page 10. The trimpots may be readjusted, as described in Section 11, on page 24. 1.9 Diagnostic LEDs ­ After power has been applied to the control, observe the LEDs to verify proper control operation, as described in Section 12, on page 28. 1.10 Auxiliary Heat Sink (Part No. 9861) ­ Extends the horsepower rating of the control to 1.5 HP for controls with 90 Volt DC output and 3 HP for controls with 180 Volt DC output. 5 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. Proper installation, which includes wiring, mounting in proper enclosure, fusing or other over current protection, and grounding can reduce the chance of electrical 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. 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 effective 11/1992). 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 the Sales Department for Declaration of Conformity. Installation of a CE approved RFI filter is required (see Section 14.12, on page 30). Additional shielded cable and/or AC line ca ...