Penta KB Power KBMM-225 User manual

KBMM™
Installation and Operation Manual
Surface Mount Technology
Solid State SCR
DC Motor Speed Controls
J1
L1 A+ F-
ACCEL
DECEL
EN
CONN1
P2
PWR ON
I1
T
B
F+
A-
J2
CL
L2
P3
MAX
P1
MIN
I2
IR
CL
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
*
© 2004 KB Electronics, Inc.
(See back cover)
PATENTED
Manufactured
in the USA

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 – KBMM™ Speed Control, KBMM™ Installation and Operation Manual, Hardware
Bag (contains Main Speed Potentiometer with insulator and mounting hardware, (9) – 0.25” female crimp-on termi-
nals, (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

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.
1 SIMPLIFIED INSTALLATION INSTRUCTIONS
4
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.
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.
Fuse Plug-In Horsepower
Resistor®

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

6
This product should be installed and serviced by a qualified technician, electrician, or electrical main-
tenance 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 elec-
tric 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 care-
fully. Fire and/or electrocution can result due to improper use of this product.
!
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.
2 SAFETY WARNING – Please read carefully.
!
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 cables may be required along with a sig-
nal isolator (SI-6 (Part No. 9444)).

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 shorts1. The reliability of the control is further enhanced with the use of high-surge, 25
Amp SCRs, and AC line and armature fusing2, 3. The control is designed with KB’s exclusive Plug-In Horsepower
Resistor® 3, which eliminates the need for recalibrating IR Comp and Current Limit when the control is used on
various horsepower motors. In addition, the rating of the control can be extended to 1.5 HP for controls with 90
Volt DC output and 3 HP for controls with 180 Volt DC output, by the use of KB’s Auxiliary Heat Sink4. Models
KBMM-225 and KBMM-225D also allow operation of 90 Volt DC motors when used on 208/230 Volt AC line
input 5.
The versatility of the control is confirmed by its extensive list of standard features, such as: selectable armature
and tach feedback and adjustment trimpots for minimum speed, maximum speed, current limit, IR compensation,
and linear acceleration and deceleration. The control includes Auto-Inhibit®, which eliminates surging during rapid
AC line switching; pulse transformer triggering, which provides cogless operation at low speed; and superior noise
rejection circuitry, which eliminates false starts and blown SCRs. Enable (normally closed) and Inhibit (normally
open) functions provide electronic switching of control output.
The output voltage of the control is a linear function of the Main Speed Potentiometer rotation. In addition, the
control can be used in a voltage following mode by supplying an isolated analog input signal to Terminals “P2” (+)
and “P1” (-) 6. The control is compact in size (only 4.30” X 3.64” X 1.25”) and easily replaces all competitive speed
controls. The control is supplied with a 5 k ΩMain Speed Potentiometer and QD terminals. All models are UL
Listed (USA and Canada) and CE Approved.
Notes: 1. Short circuit protected at motor only. 2. KB Limited Warranty applies. See page 32. 3. Fuses and
Plug-In Horsepower Resistor® supplied separately. See Sections 8 and 9, on pages 20 - 22. 4. Part No. 9861.
See Section 14.1, on page 30. 5. Step-Down operation. 6. If an isolated signal input is not available, or if using a
4 - 20 mA DC signal input, install the optional plug-on SI-6 Signal Isolator (Part No. 9444).
7

3.1 Standard Features
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.
4 Trimpots – Minimum Speed (MIN), Maximum Speed (MAX), IR Compensation (IR), Current Limit (CL),
Acceleration (ACCEL), and Deceleration (DECEL).
5 Jumpers – AC Line Input Voltage Selection (J1 (Model KBMM-225D only)), Motor Voltage and DC
Tach-Generator Selection (J2).
6 Protection Features – MOV transient protection. Short Circuit protected (at motor only).
7 Diagnostic LEDs – Power On (PWR ON) and Current Limit (CL).
8Model KBMM-125 operates on 115 Volt AC line input with 90 Volt DC motors.
9Model KBMM-225 operates on 230 Volt AC line input with 180 Volt DC motors or 90 Volt DC motors
(step-down). - Jumper Selectable.
10 Model KBMM-225D can operate on 115 Volt AC line input with 90 Volt DC motors and 230 Volt AC
line input with 180 Volt DC motors or 90 Volt DC motors (step-down). - Jumper selectable.
11 Armature or DC Tach-Generator feedback.
12 Built-in AC line and armature fusing.
13 Main Speed Potentiometer (5 kΩ).
14 SMT construction.
8

Notes: 1. Step-down operation: motor may have reduced brush life. Consult motor manufacturer. 2. Performance is for SCR rated permanent magnet motors
only. Lower performance can be expected with other motor types. Factory setting is for 3% load regulation. To obtain superior regulation, see Section 11.6, on
page 27.
9
Model Part
No.
AC Line
Voltage
(±15%, 50/60Hz)
(Volts AC)
Motor
Voltage
(Volts DC)
Maximum Rating without Auxiliary Heat Sink Maximum Rating with Auxiliary Heat Sink
Field
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)
Horsepower
(HP (kw))
KBMM-125 9449 115 0 - 90 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 50, 100
KBMM-225 9450 230 0 - 180 12.0 8.0 1.5 (1.1) 24.0 16.0 3 (2.3) 100, 200
0 - 90* 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 100
KBMM-225D 9451
115 0 - 90 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 50, 100
230 0 - 180 12.0 8.0 1.5 (1.1) 24.0 16.0 3 (2.3) 100, 200
0 - 90* 12.0 8.0 .75 (.6) 24.0 16.0 1.5 (1.1) 100
TABLE 1 – ELECTRICAL RATINGS
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS
* Step-down operation.
Description Specification Factory Setting
Speed Range (Ratio) 50:1 —
Armature Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (% Base Speed) 1 —
Tach-Generator Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (% Set Speed) 1 —
Line Voltage Regulation (at Full Load, ± 10% Line Variation) (% Speed) 0.5 —
Control Linearity (% Output Voltage vs Signal Input Voltage) 2 —
Acceleration (ACCEL) Trimpot Range (Seconds) 0.2 – 10 2
Deceleration (DECEL) Trimpot Range (Seconds) 0.2 – 10 2
Maximum Speed (MAX) Trimpot Range (% Base Speed) 50 – 110 100
Minimum Speed (MIN) Trimpot Range (% Base Speed) 0 – 30 0
Current Limit (CL) Trimpot Range (% Full Load) 0 – 200 150
IR Compensation (IR) Trimpot Range (at Specified Full Load @ 90, 180 Volts DC Output) (Volts DC) 0 – 24, 48 3, 6

Motor ArmatureMotor Field
(Shunt Motors Only)
DC Tach-Generator
(Set J2 to "T" Position)
Main Speed PotentiometerAC Line
Input (Front View)
Inhibit Switch
(Close to Stop)
(Open to Run)
Enable Switch
(Open to Stop)
(Close to Run)
AC Line Fuse
Supplied Separately Supplied Separately
Armature Fuse
Wiper
Low
High
Horsepower Resistor®
Supplied Separately
Plug-In
L1
Blue
A+ F-
Red
ACCEL
DECEL
EN
-
+
M
-
+
CONN1
P2
G
-
+
1000
7V
PWR ON
I1
T
B
F+
A-
CL
L2
P3
MAX
P1
MIN
I2
IR
CL
For Plug-In Horsepower
Resistor®, Line Fuse,
and Armature Fuse
Selection See Sections
8 and 9, on pages 20-22.
J1
J2
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)

CONTROL
MOUNTING "D" 2 SLOTS
POTENTIOMETER
(SUPPLIED)
MAIN SPEED OPTIONAL AUXILIARY HEAT SINK
.95
24.1
1.25
31.8
.50
12.7
.98
24.9
5.63
143
3.11
(79.0)
5.63
142.9
6.25
159
1.25
31.8
1.38
34.9
7.00
178
1
ANTI-
ROTATION
PIN
3/8-32
BUSHING
3/8"
SHAFT
1/4" ROUND
1/2"
P2 P
3
P
.44
11.1
.13
3.1
MOUNTING "B"
TAPPED 10-32
(3 PLACES)
FUSE HOLDER & FINGER-SAFE
COVER MOUNTING HOLES
TAPPED 6-32
(2 PLACES)
MOUNTING "A"
6 SLOTS
3.64
92.5 3.10
78.5
.22
5.6
4.30
109
2.15
54.6
.25
6.4
.18
4.6
.64
16.3
1.75
44.5
1.75
44.5
.75
19.1
1.50
38.1
3.00
76.2
11
4 APPLICATION INFORMATION
4.1 Motor Type –The control is designed for permanent magnet (PM) and Shunt Wound DC motors. Controls
operated on 115 Volt AC line input are designed for 90 Volt SCR rated motors. Controls operated on 230 Volt
AC line input are designed for 180 and 90 Volt SCR rated motors. Use of motors with higher rated voltage will
result in a reduction of the available maximum speed. Also, if the motor is not an SCR rated type, the actual
AC line current at full load and full speed should not exceed the motor’s DC nameplate current rating.
4.2 Torque Requirements –The motor selected for the application must be capable of supplying the necessary
torque. In order to ensure the motor is not overloaded, a DC ammeter should be connected in series with
the armature. Be sure the current under full load does not exceed the motor nameplate rating.
FIGURE 2 –MECHANICAL SPECIFICATIONS (Inches/mm)

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 applica-
tions such as saws and drill presses. Do not use this control in an explosive atmosphere. Be sure the
control is used within its ratings. Follow all instructions carefully.
4.5 Armature Switching –Do not wire the control for armature switching without taking proper precautions.
See Section 13.2, on page 29.
WARNING! Do not switch the armature in and out of circuit or catastrophic failure will result. If arma-
ture switching is required for reversing or dynamic braking, use Model KBMG, KBRG, KBPB, KBCC-R.
4.6 Step-Down Transformer and AC Line Switching –When using a step-down transformer (460 Volts AC to
230 Volts AC), be sure the output current rating of the transformer is at least 3 times the current rating of the
motor. Do not switch the primary side of the transformer to disconnect power or catastrophic failure can
result. Always disconnect the control from the secondary side of the transformer.
5 MOUNTING INSTRUCTIONS
It is recommended that the control be mounted on a flat surface with adequate ventilation. Leave enough room to
allow for AC line, motor connections, and other wiring that is required. Care should be taken to avoid extreme
hazardous locations where physical damage can occur. When mounting the control in an enclosure, the enclosure
should be large enough to allow for proper heat dissipation so that the ambient temperature does not exceed
45 °C (113 °F) at full rating. See Figure 2, on page 11.
6 WIRING INSTRUCTIONS
WARNING! Read Safety Warning, on page 6, before using this control. Disconnect the main power
when making connections to the control. To avoid electric shock be sure to properly ground control.
12
!
!
!

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.
13
6.1 AC Line Connection –Wire the AC line to Terminals “L1” (Line Fuse) and “L2”, as shown in Figure 1, on
page 10. If one of the AC line inputs is a neutral (N), wire it to Terminal “L2”.
CAUTION! The rated AC line voltage (115, 208/230) of the control must match the actual AC line
input voltage. See Section 7.1, on page 19.
Model KBMM-125 operates on 115 Volt AC line input only. Model KBMM-225 operates on 208/230 Volt AC
line input only. Model KBMM-225D operates on 115 Volt AC line input when Jumper J1 is set to the “115”
position and operates on 208/230 Volt AC line input when Jumper J1 is set to the “230” position.
AC Line On/Off Switch –To remove power to the control, a separate AC line switch should be used. Use a
single pole switch for hot and neutral AC supply lines and a double pole switch for 2-hot AC supply lines.
This switch can also be used as a “Safety Disconnect”.
6.2 Ground Connection –Connect the ground wire (earth) to the control chassis.
Maximum Motor Current
(Amps DC)
90 - 130 Volt DC Motors
(Maximum HP)
180 Volt DC Motors
(Maximum HP)
Minimum Wire Size (Cu)
Maximum 50 Ft. Maximum 100 Ft.
AWG mm2AWG mm2
6.5 116 1.3 14 2.1
12 1 2 14 2.1 12 3.3
16 1.5 3 12 3.3 12 3.3
TABLE 3 –MINIMUM SUPPLY WIRE SIZE REQUIREMENTS
!

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)
6.4.1 Full Voltage Field –Wire the field positive (+) lead to Terminal “F+” and the negative lead (-) to
Terminal “F-”, as shown in Figure 1, on page 10, and as described in Table 4.
6.4.2 Half Voltage Field –For 90 Volt DC motors with 50 Volt DC fields and 180 Volt DC motors with 100
Volt DC fields, wire the field positive lead (+) to Terminal “F+” and the negative lead (-) to Terminal “L1”
(Line Fuse), as described in Table 4.
Notes: 1. Do not connect motor armature leads to Terminals “F+” and “F-”. 2. Do not use Terminals “F+”
and “F-” for any purpose other than to power the field of a shunt wound motor. 3. Shunt wound motors
may be damaged if the field remains energized without armature rotation for an extended period of time.
14
Model AC Line Input Voltage (Volts AC) Armature Voltage (Volts DC) Field Voltage (Volts DC) Terminal Connections
KBMM-125 115 0 - 90 100 F+, F-
50 F+, L1
KBMM-225 208 / 230 0 - 180 200 F+, F-
0 - 90* 100 F+, L1
KBMM-225D
115 0 - 90 100 F+, F-
50 F+, L1
208 / 230 0 - 180 200 F+, F-
208 / 230 0 - 90* 100 F+, L1
TABLE 4 –FIELD CONNECTION (Shunt Wound Motors Only)
* Step-down operation.

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.
6.6 Voltage Following Connection –An isolated 0 - 9 Volt DC ana-
log signal input can be used to control motor speed in lieu of the
Main Speed Potentiometer. The control output voltage will linearly
follow the analog signal input. The signal input must be isolat-
ed from the AC line. Connect the signal input positive lead (+) to
Terminal “P2” and the negative lead (-) to Terminal “P1”, as
shown in Figure 4. The source impedance of the signal input
should be 10 kΩor less. The MAX Trimpot is not operational in
voltage following mode. Use the MIN trimpot to set an initial value
of input signal. If necessary, use auxiliary trimpots to scale and/or
limit the input voltage.
CAUTION! Do not earth ground any input terminals.
Notes: 1. If an isolated signal input is not available, or if using a
4 - 20 mA DC signal input, install the optional plug-on SI-6 Signal
Isolator (Part No. 9444). This will also allow direct connections to
process controllers and microprocessors. 2. If multiple follower
motors are to be controlled from a single lead motor or a single
Main Speed Potentiometer, install the optional KBSI-240D Signal
Isolator (Part No. 9431). 3. Terminal “F-” may be used in lieu of Terminal “P1”.
15
(Front View)
Main Speed Potentiometer
EN
CONN1
P3
MAX
P1
P2
High
Wiper
Low
Terminal "P3"
Terminal "P1"
Terminal "P2"
FIGURE 3 –REMOTE MAIN SPEED
POTENTIOMETER CONNECTION
CONN1
P2
MAX
EN
P3 P1
V
-
+
0 - 9 Volts DC
(Isolated)
Terminal "P1"
Terminal "P2"
FIGURE 4 –VOLTAGE FOLLOWING
CONNECTION
!

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. When the switch or contact is closed, the motor will accelerate to the Main Speed
Potentiometer setting. When the switch or contact is opened, the motor will decelerate to stop. An
open collector (PNP) can be wired in lieu of a switch or contact.
Notes: 1. To use
the Enable Circuit,
remove the jumper
that is factory
installed on
CONN1. 2. The
deceleration time
can only be made
longer than the
normal coasting
time of the load.
6.7.2 Enable Switch or Contact Wired to the Main Speed Potentiometer –Wire the switch or contact in
series with the Main Speed Potentiometer high side and Terminal “P3” on the control, as shown in
Figure 6, on page 17. Be sure the jumper is installed on the Enable Connector (CONN1). When the
switch or contact is closed, the motor will accelerate to the Main Speed Potentiometer setting. When
the switch or contact is opened, the motor will decelerate to the MIN Trimpot setting (factory set to 0
16
!
(On to Run)
(Off to Stop)
Open Collector
CONN1
MAX
EN
(Open to Stop)
(Close to Run)
or Contact
Enable Switch
the Mating Connector
CONN1
MAX
EN
Remove this jumper to install
CONN1
MAX
EN
FIGURE 5 –ENABLE SWITCH OR CONTACT WIRED TO THE ENABLE CONNECTOR

Volts DC). If the MIN
Trimpot is set to other
than 0 Volts DC, the
motor will run at that
speed when the
switch or contact is
opened. An open col-
lector (PNP) can be
wired in lieu of a
switch or contact.
Note: The decelera-
tion time can only be
made longer than the
normal coasting time
of the load.
6.8 Inhibit Circuit Connection –The control can be stopped
and started with an Inhibit circuit (close to stop, open to run).
Wire the switch or contact to Terminals “I1” and “I2”, as
shown in Figure 7. When the switch or contact is closed, the
motor will coast to stop. When the switch or contact is
opened, the motor will accelerate to the Main Speed
Potentiometer setting. An open collector (NPN) can be wired
in lieu of a switch or contact.
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.
17
CONN1
Enable Switch or Contact
This jumper must
Main Speed Potentiometer
(Front View)
(Close to Run)
Low
High
Wiper
(Open to Stop)
be installed
MAX
EN
Terminal "P1"
Main Speed Potentiometer
(Front View)
(On to Run)
Low
High
Wiper
Open Collector
(Off to Stop)
MAX
CONN1
Terminal "P3"
Terminal "P2"
P3 P1
P2
EN
P3 P1
P2
FIGURE 6 –ENABLE SWITCH OR CONTACT WIRED TO THE
MAIN SPEED POTENTIOMETER
!
MIN
I1
I2
(Close to Stop)
Inhibit Switch or Contact
(Open to Run)
MIN
I2
I1
(On to Stop)
(Off to Run)
Open Collector
Terminal "I1"
Terminal "I2"
FIGURE 7 –INHIBIT SWITCH OR CONTACT
WIRED TO THE INHIBIT TERMINALS

6.9 DC Tach-Generator Connection –A DC tach-generator
can be used for load regulation of 1% of the set speed.
Note: Jumper J2 must be set to the “T” position for
tach-generator operation. Connect the tach-generator
as follows.
Application Notes –1. The tach-generator input circuit is
designed for a 7 Volt or 50 Volt per 1000 RPM DC tach-
generator used with an 1800 RPM motor. 2. Initially set the
IR Comp Trimpot fully counterclockwise. Once the tach-
generator is connected, the IR Comp Trimpot may be
increased for additional speed stabilization.
6.9.1 Seven (7) Volt per 1000 RPM Tach-Generator –
Connect the tach-generator positive lead (+) to
Terminal “T” and the negative lead (-) to Terminal
“I2”, as shown in Figure 8.
6.9.2 Fifty (50) Volt per 1000 RPM Tach-Generator –
Connect the tach-generator positive lead (+) to
Terminal “B” and the negative lead (-) to Terminal
“I2”, as shown in Figure 9.
6.9.3 Other Tach-Generator Voltages –The tach-gener-
ator input circuit is designed for a 7 Volt or 50 Volt
per 1000 RPM DC tach-generator used with an
1800 RPM motor. For a tach-generator other than 7
Volts or 50 Volts per 1000 RPM, or for a motor
other than 1800 RPM, an external 1/2 Watt resistor
(RT) must be installed. Install RT in series with the
18
B
PWR ON
I2
T
DC Tach-Generator
-
+
7V
G1000
Terminal "T"
Terminal "I2"
J2
FIGURE 8 –DC TACH-GENERATOR CONNECTION
(7 VOLTS PER 1000 RPM)
B
PWR ON
I2
T
1000
G50V
DC Tach-Generator
-
+
Terminal "B"
J2
FIGURE 9 –DC TACH-GENERATOR CONNECTION
(50 VOLTS PER 1000 RPM)

tach-generator. Connect one end of RT to Terminal
“T”, connect the other end of RT to the tach-
generator positive lead (+), and connect the negative
lead (-) of the tach-generator to Terminal “I2”. See
Figure 10.
The value of RT (Ω) can be calculated using the fol-
lowing 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).
Example: If a 20 Volt per 1000 RPM tach-generator
is to be used with a 3600 RPM motor:
RT = (1.3 X 20 X 3600) - 16000 = 77600 Ω
Choose the closest 1/2 Watt resistor value, which is 75000 Ω(75 kΩ).
7 SETTING SELECTABLE JUMPERS
The control has selectable jumpers which must be set before it can be used. See Figure 1, on page 10, for the
location of jumpers.
7.1 AC Line Input Voltage Selection (Jumper J1 (Model KBMM-225D Only)) –Jumper J1 is factory set to
the “230” position for 208/230 Volt AC line input. For 115 Volt AC line input, set Jumper J1 to the “115”
position. See Figure 11, on page 20.
Notes: 1. Jumper J1 is installed on Model KBMM-225D only. 2. When Jumper J1 is set to the “115” posi-
tion, Jumper J2 must be set to the “90” position (or the “T” position if using a tach-generator).
19
B
PWR ON
I2
T
G
DC Tach-Generator
-
+
RT
J2
FIGURE 10 –OTHER DC TACH-GENERATOR
CONNECTION