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  THIS FAQ AREA IS CONSTANTLY BEING REVIEWED AND UPDATED.
THIS FAQ AREA IS CONSTANTLY BEING REVIEWED AND UPDATED.
 
  THE INFORMATION IN THIS AREA IS NOT INTENDED TO CONTRADICT OR REPLACE INDUSTRY STANDARDS, CODES, OR ABSOLUTE DECREES
THE INFORMATION IN THIS AREA IS NOT INTENDED TO CONTRADICT OR REPLACE INDUSTRY STANDARDS, CODES, OR ABSOLUTE DECREES
 
 
General 
   
  What is FAQ


FAQ or Frequently Asked Questions is an area reserved for you, our valued customer. This area is designed to assist you in answering some basic technical questions regarding your KB Electronics and other motor controller issues. If you do not find your question here, use the Contact us Page and send us your question.


 
  When will I be able to use the Technical Information site


We apologize for the delay of this feature. We are in the process of evaluting the content that will be posted here. Please check back soon as this section is constantly being evaluted for content.


 
  I clicked on a link to view a document but the link doesn't work.


Most of our documents for download are in Adobe Acrobat.  In order to view the file you must have Adobe Acrobat Reader installed on your computer.  Adobe Acrobat Reader is a free application that allows you to view PDF files.  If you do not have Adobe Acrobat Reader, installed you can download it from Adobe by clicking the icon.


 
 
Installation 
   
  How do I hook up the KB drive?
All of the KB DC products have various terminals marked on the drive. Located in the ption and hookup diagram. But, to start with, the AC power is normally hooked to terminals marked L1 L2. The A+/A1 and A2/A are the connections for the motor armature. The terminals marked F1/Ft and F2/F are the shunt wound motors. The terminals marked P1, P2, P3 are hooked to the speed pot and should be in the 3 wire twisted shielded cable. The terminals marked I1 I2 are used for shutting the motor control off without disconnecting the in AC power connect. These wires with twisted shielded cable. A closed circuit will stop the drive.
 
  I have this KB drive and have hooked it up but it won’t run.
Have you installed the HP resistor in the drive? If the drive came without a HP resistor, then, temporarily, install a wire jumper in place of the resistor and the drive will probably run until you obtain a HP resistor (leaving the wire jumper will not protect the motor or drive from destructive currents. Check for fuses if applicable and install if missing.
 
  I hooked up my motor control to the motor but it runs the wrong direction.
To change the direction rotation, exchange the two wire motor leads. To change the shunt wound motor (4 wire) change either the wires attached to F1/Ft and F2/F1 and DO NOT exchange the A1/A+ and A2/A- leads.
 
  I have a DC motor that I want to use with my motor control but none of the wires are marked.
If the motor is a two wire type, connect these wires to all A1/A+ and A2/A- to run motor. If the motor has four wires or more, a DVM or multimeter has to be used to re-mark the motor wires.
 
  Do you have a wire diagram for the KBIC-120, KBIC-125, KBIC-240, KBIC-225, KBIC-240D, KBIC-240DS?


 
 
KB Products 
   
  What is the KB APRM module? ( P/N 9378 )
This module is used in the KBCC 125 R, KBCC 225R, KBPB 125, KBPB 225 and in the KBPC 240 D. The module allows the motor control to forward and reverse the motor direction with a simple SPDT toggle switch. The direction change can be near instantaneous.
 
 
Technical 
   
  KBIC TROUBLESHOOTING GUIDE
KBIC SIMPLIFIED TROUBLESHOOTING GUIDE

KBIC SIMPLIFIED TROUBLESHOOTING GUIDE
 

PART 1

Upon receiving a returned control from a customer, please follow the next few steps in order to determine if the control is in warranty.
EQUIPMENT NEEDED: Digital voltmeter (VOM) with diode test, alignment tool, potentiometer, line cord, 100 watt bulb

STEP I
Visually inspect the KBIC control for broken components. burn and/or smoke marks, or blown devices. These observations should be made known to the customer.

Broken Components are caused by mishandling of the control.

Burned or Smoke Marks are caused by miss wiring of the control.

Blown Devices such as SCR’s or flat pack diodes are caused by shorted or possibly grounded armature leads. Blown devices, such as MOV’s, are usually caused by an over line voltage condition or line surges greater than the MOV can tolerate.

If you receive the control and it has none of the obvious defects above, proceed to Step 2.

STEP 2
Set scale of VOM to diode scale. Remove Plug-In-Horsepower ® Resistor.

Check resistance across Li and L2. Reading should show infinite or open circuit. Be sure to reverse leads across Li and L2. Reading should still be infinite. Measurement values shown below are approximate only and reflect measurements made with a Beckman 310 digital VOM. Other meters will have different results. I suggest you use a known good control as your guide and compare its readings with the suspect control.
You may also substitute my readings with those of your meter. lf ”0” ohms is observed, check field diodes D4 and D7. With (+) lead on L2 and (-) lead on Li, if .66 ohms (( I your reading here) is observed, replace diode D7; if .56 ohms ( 1 your reading here) is observed, replace diode D2. With (+) lead on Li and (-) lead on L2. if .66 ohms ( ] your reading here) is observed, replace diode D4: if .56 ohms ( J) your reading here) is observed, replace power diode Dl.
 

Check resistance across Fi- and F-. With (±) lead on F— and (-) lead on F-. reading should be infinite. With reversed leads, reading should be 1.2 ohms ( your reading here If reading is less, check diodes D4 and D7.
 

Check resistance across A+ arid L2. Reading should be infinite. If reading is less than infinite, check SCR2.
 

Check resistance across A+ and Li. Reading should be infinite. If reading is less than infinite, check SCRI.
 

Check resistance from A+ to F-. With (+) lead on F- and (-) lead on A+, reading should be .55 ohms (11 ] your reading here). With leads reversed, reading should be infinite. If readings are “0” ohms, check power diode D3.
 

Change resistance scale to 10K or nearest selection. Check resistance from P3 to P1. Set MAX trim pot to 50% rotation. Resistance should read about 5,000 ohms. If resistance is infinite, MAX pot must be replaced.
 

Check resistance from P1 to 12. Set MIN trim pot to 50% rotation. Reading should be about 1200 ohms. If reading is “0” or infinite. MIN pot must be replaced.
 

Change scale back to diode scale. Check resistance across zener diode Z1. With (+) lead on stripped end and (-) lead on plain end, reading should be infinite. With reversed leads, resistance should be .7 ohms ([ ]) you’re reading here). If reading is “0” or infinite with leads this way, replace Z1.
 

Repeat Step (H) across Zener diode Z2.
 

Check the resistance across the Plug-In-Horsepower® Resistor. It should equal the value printed on the resistor, or at least indicate continuity, not an open.

STEP 3
 

On-Line Test. Connect 5K pot to P1, P2, P3. Connect 100W lamp to A+, A-. If testing a 120V control, be sure to use a 120V lamp. Likewise, use a 240V lamp for 240V controls or two 120V lamps in series. A 240V lamp may be used for 120V controls. However, the lamp brightness will be reduced.




In order to avoid any unnecessary damage to controls, I strongly recommend that you add a 100W lamp in series with the AC line,. This will protect the control from shorting in case any steps were overlooked. Also, add a simple SPST toggle switch in parallel with the lamp. This will allow you to put direct line voltage on the control. (See Fig. 1)


Be sure SPST switch is in OPEN position and 5K pot is set fully CCW. Be sure to replace plug-in-resistor. Apply line voltage. If control is good, lamps 1 and 2 should be dim or off. If lamp 1 is at full brightness, then there is a short circuit in the Power Bridge of the KBIC control. Remove control from test and repeat Step 2 (A)-(E).
If lamp 1 is dim or off, slowly rotate 5K pot. Lamps 1 and 2 should increase in brightness. If this is not the case, some voltage checks should be made.
 

Using the digital VOM, select the proper AC scale to measure the incoming AC voltage across Li and L2. This will verify that AC voltage is present at the control terminals. Next, change scales from AC to DC 250V range. Check voltage from F+ to F-. On 120V controls the reading should be approximately 1 O6VDC. Double that for 240V controls. On 240V controls the field voltage may vary depending on the actual line voltage. If field voltage is not present, or Y2 the required voltage, check diode D4 or D7. Next, measure the voltage from A+ to A-. Be sure to rotate 5K pot fully CW. Readings should be 90 or 1 8OVDC, depending on input line voltage. If voltage reading is low, adjust MAX trim pot to proper setting. If output is not adjustable either with MAX trim pot or with 5K pot, then check the following test points.

Reset scale on digital VOM to nearest range above 2OVDC. With (-) lead on F-, measure voltage at junction of R17 and Z2. Reading should be 18+ volts. If reading is below 20 (such as 15 or 12), then zener diode Z2 is wrong value and/or defective. It should be replaced with 22 volt, 1 watt device. If reading is “0”, then Z2 or Q3 may be shorted. Check resistance of Z2 with AC power off. If normal (infinite and .7), then with the power off clip out Q3 and retest.
If voltage is 1 8V, observe reading while removing AC power. Voltage should drop instantly to I .2V, then to “0” in 1 sec. This will confirm that the auto inhibit circuit (consisting of Q3 and Q2) is working.
If voltage is 20V, then check voltage on left terminal of MAX trim pot. It should read 12-15VDC.
If reading is less than or greater than this voltage, then Z 1 is defective. Next, measure voltage on P3, while varying the MAX trim pot. Voltage should vary from 12-15 to 7- 9VDC. If no reading is observed, MAX pot is open.
Next, adjust MIN pot to full CCW position. Measure voltage on P2 while varying the 5K pot. It should vary from 0 to 7+. The MAX voltage depends on where the MAX pot is set. If the voltage does not vary over this range, the MIN pot is open. While measuring the voltage on P2, vary the MIN pot. The voltage on P2 should increase smoothly. If it suddenly jumps to a higher value then the MIN pot is open.
 

Next, measure the voltage on Ii. Increase the 5K pot from 0 to full CW. The voltage on Ii should increase smoothly as a result of our controlled acceleration circuit (R5 & C101). Decreasing the 5K pot from full CW to 0 should cause the voltage to drop very quickly. This will confirm that diode Dl01 is OK.
 

This completes the simplified testing procedure that should help resolve 99% of all problems encountered.


 


 
  What is an IGBT?
An IGBT is a special transistor or solid-state component that converts DC voltage to AC voltage to run an AC motor. This process is also know as PWM See Pulse Width Modulated for explination.
 
  What is PWM?
PWM or Pulse Width Modulated Width is a process that uses DC voltage to mimic AC sign waves. However, it also can mimic DC level and length for DC motor applications.
 
  What is a Drive?
In the simplist terms, a drive is the electronics board which is used to control the speed of a motor. DC Drives (Converters) and AC Drives (Inverters) may use various techniques to control speed of motors.
 
  What is an SCR?
There are many interpetations and definitions of a SCR. Our explaintion is simply an electronic toggle switch controled by a input signal from some source to convert AC voltage to DC Voltage for motor armatures.
 
  What is PID Loop Control?
The most simple definition PID Loop control or Proportional-Integral-Derivative Loop Control would be "Regulated Control" or “Feedback Control” of a motor controller. Another explanation could also be referred to as a “dancer” circuit. A dancer circuit can detect surface tension on continuous manufacturing product. Machines such as news-paper presses, electrical wire making machines, paper towels and toilet paper roll making machines, are some examples. Feedback Control is also used in machines that rewind, unwind or also known as payoffs and even can be characterized as a sensor that can control air conditioning fan control.
 
  What is NEMA 7
NEMA 7, a standard from the National Electrical Manufacturers Association, is defined as an explosion-proof enclosure which surrounds an item and is used in areas classified as Class 1, Groups A, B. C or D, as specified in the National Electrical Code.
 
  What is IR compensation as used in a DC motor control?
The term IR compensation is an adjustable signal within the motor control to compensate for speed droop from load to no load that occurs with motors. This signal is not used when the motor control is connected for tach feedback.
 
  What is current limit?
Current limit signal used in motor controls is generated by measuring the voltage drop across a resistor (HP resistor used to set the HP range of the control) as a feedback to produce a threshold level to protect the control and motor from high currents.
 
  What is accel?
Accel is a shortened name for acceleration time. This time is the time that a loaded machine and the motor takes to reach the set speed from the reference set point.
 
  What is NEMA 12
NEMA 12 is an enclosure which surrounds an item that is defined as offering protection against falling dirt, circulating dust, and dripping non-corrosive liquids.
 
  What is NEMA 4X
NEMA which stands for National Electrical Manufacturers Association 4X is an enclosure which surrounds an item that is intended for indoor or outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water, and hose-directed water. It is also known as "washdown" for applications that require equipment to be rinsed. White NEMA 4X is typically found in food manufactuing equipment.
 
  What is NEMA 1?
NEMA 1 is a classification of enclosure that surrounds an item. Intended for indoor use the enclosure will provide a degree of protection against limited amount of falling dirt, fingers and other objects.
 
  What is the definition of "chassis?"
The term "chassis" or "open chassis" refers to an item that is not enclosed or self contained. A more laymen description could be if you can touch the "guts" its open chassis.
 
  How do I determine if my motor or my control is defective?
If the AC power protection components (fuses, circuit breaker) are blown or tripped, then the process of elimination is to begin, Remove the motor connections, both the armature and field wires, replacing or resetting the protection components. Reapply the AC power to the motor control. If all the protection components remain okay, the motor may be faulty. Next: with the power still applied to the motor control, advance the speed reference and measure the DC voltage with a test meter at A/A+ and A2/A connections. The meter will read some DC voltage value. Thus, confirming the motor control is okay. No DC voltage indicates the motor control is defective as will the possible blowing the power protection components.
 
  How do I determine if my motor is defective?
Do the protection devices (fuses, circuit breakers blow or trip when AC power is applied to motor control and the reference is advanced ? Yes/No Yes – remove all motor wire connections from motor control. Using a DVM or Multi meter. Measure a low resistance value connecting to the A1/A+ and A2 wire to the motor.
 
  What is the definition of "regen" or "regenative?"
Regen or regenative refers to a motor controllers capability to brake and reverse electronically.