Untitled art 2 - KB Electronics, Inc.
Contents
1. px pee a Note Armature fuse is not supplied and must be installed for control to operate 11 Vil 12 LOGIC FUNCTIONS AND WIRING Warning Do not use of the logic functions STP as an emergency stop since they are not fail safe Use only an AC line L1 L2 disconnect for that purpose To prevent erratic operation do not bundle logic wiring with AC line and motor wires Use shielded cables on logic wiring over 12 30 cm in length Do not ground or common shield The control contains several logic functions which are described in detail below All connections are made to terminal block TB3 See fig 1B p 5 for TB3 location A RUN A momentary contact closure between terminals RUN and RTN latches the control into a continuous run mode To stop the control the stop circuit must be activated by opening the contact between the STP and RTN terminals Note All momentary closures must be present for no less then 50 milliseconds and a normally closed NC contact must be maintained between the STP and RTN terminals in order for the drive to run FIG 7 RUN COMMAND RUN JOG STP RTN 24V COM Shield Do not ground ANORMALLY CLOSED CONTACT MUST BE INSTALLED BETWEEN RTN AND STOP ORDER FOR CONTROL TO START UNLESS JUMPER JW IS IN THE POSITION CLOSE TO START JOG Stop A mainta2. 1 13 9 mu dur Tc 22 23 26 27 FIGURES Control Layout Logic 2 4 1B Control Layout Main Board 1 5 2 Typical Indexing Performance 6 3 Mechanical Specifications 4 8 4 Line and Motor Connection 10 5 Remote Potentiometer Connection 11 6 Analog Voltage Connection 11 Run Commands s e eb pde EU aed 12 8 Jog Command i3 ib pe eh RD er eM 12 9 Command etna 12 10 Stop Command ic 5 ee ue uei ted PE titu at tcd 13 11 Jumper JR Operation x suras Ron Rae peor EE PEU RO SIR 14 12 Solid State Switching os cc eee p RE ERE ERE HEX 14 13 Contact Switching oce Rp PORE E D ORE LR RR 14 14 Correct Keyway Positions for Cam and Limit Switch Assemblies 15 15 Cycle Demand Wiring 1 16 16 Sequence of Cycle on Demand Operation 16 17 Reversing Logic Wiring Diagrams
3. 17 18 SCHEMALICS ooa ee dece 21 24 25 19 Internal Wiring 28 i AY SIMPLIFIED SETUP AND OPERATING PROCEDURES Before operating this control you must read these instructions They 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 before proceeding 1 Power Be sure jumpers and J2B on power board and jumper J1 on logic board are set to the correct positions to match the AC line input voltage See table 4 p 9 Connect AC power to terminal block TB1 terminals L1 and L2 When power is turned on LED 1 on main power board will light Be sure AC power is disconnected when making other connections to control Do not bundle AC power and motor wires with wires connected to TB3 terminals Motor Leads Connect the motor leads to terminal block TB2 terminals A1 and A2 Be sure motor nameplate voltage rating corresponds to control output voltage rating Do not use control with shunt wound motors DWG B4100 2 00532 Motor Current Setting Be sure Jumper J1 is set to the approximate rated motor B hob connect current 10A 5A 3 3A 2A INPUT ground wire to any MOTOR other terminal JUMPER J1 SETTING vs MOTOR HORSEPOWER Motor Horsepower Range Jumper Motor Horsepowe
4. 01 ZH 09 05 aequinN 21601 jue4inj peo peo oeJnjeuuv OVA Jo adAL Hed JOJOW eur SONILVY 1VOIHIO31l3 31 1 ees JO jo pue eur pue jo3u02 LNVLYOdINI FIG 1A CONTROL LAYOUT Logic Module Jt JUMPER SHOWN IN 240 VOLT POSITION LOGIC MODULE c cdd RUN JOG STOP SWITCH JUL FIG 1B CONTROL LAYO UT Main Board 9 P1 P2 sess pee e RUN REV 8 106 7 RUN FWD 6 JOG FWD 5 Q T 3 A MIN RTN 7 0 24V 2 E 1 B led Gee 7 95 4 B F JR J3 JUMPER SHOWN 180V 90V lt 1 IN 180VDC POSITION 120V J2A J2B 4 1 2 T J4B KBPI GND M INDEXER EARTH PWR ON 240V e SHOWN 1 IN 240VAC POSITION 2 fe GND TABLE 2 GENERAL PERFORMANCE SPECIFICATIONS Specifications Par
5. 13 Used to set the STOP function operation NC position Use a normally closed contact for open to stop operation NO position Use a normally open contact for close to stop operation Set to NC position Set according to model part numbers See table 1 p 3 Sets the operating AC line voltage for the logic module 120 240 VAC Determines the priority of the Run and Stop logic commands See table 8 p 13 Set to R position for cycle on demand Notes 1 Main Printed Circuit Board fig 1B p 5 2 Logic PC board fig 1A p 4 MOUNTING Mount the control in a vertical position on a flat surface Be sure to leave enough room below the bottom of the control to allow for the AC line and motor connections and other wiring that may be necessary Care should be taken to avoid extreme hazardous locations where physical damage can occur Note Do not use this control in an explosion proof application If the control is mounted in a closed unventilated cabinet remember to allow for proper heat dissipation If full rating is required a minimum enclosure size of 12 W x 24 H x 12 D should be used Front Cover The case is designed with a hinge so that when the front cover is open all wiring stays intact To open the cover the four cover screws must be loosened so they no longer are engaged in the case bottom Note that these screws are captive and the front cover holes are threaded A
6. The MAX trimpot is used to set the maximum voltage of the drive Adjust the MAX trimpot as follows 1 Rotate Main Potentiometer to maximum speed position full clockwise 2 Adjust MAX trimpot setting to desired setting of motor speed C Current Limit CL This trimpot is used to set the maximum amount of DC current that the motor can draw The amount of DC current determines the amount of motor torque The CL trimpot is factory set at 15096 of the current established by the jumper J1 selection Readjust the CL trimpot as follows 1 Turn CL trimpot to minimum CCW position Be sure jumper J1 is in proper position approximately equal to the motor DC ampere rating See sec IV p 9 2 Setthe main potentiometer at approximately 30 5090 rotation Wire in a DC ammeter in series with armature lead Lock shaft of motor 4 Apply power Rotate CL trimpot CW until desired CL setting is reached factory setting is 1 5 times rated motor current XII 19 CAUTION 1 Adjusting the CL above 15096 of motor rating can cause overheating and demagnetization of some PM motors Consult motor manufacturer 2 Do not leave the motor in a locked condition for more than a few seconds since armature damage may occur D IR Compensation The IR Comp circuit is used to stabilize motor speed under varying loads Readjust the IR trimpot as follows 1 Run the motor at approximately 30 5096 of rated speed under no load and measure
7. drive Do not ground both ends of the shield 3 Do not bundle logic wires with power carrying wires or other sources of electrical noise Never run speed adjustment potentiometer or voltage signal input wires in the same conduit as motor or AC line voltage wires 4 Connect earth ground to the earth ground screw provided the enclosure See fig 1B 5 for ground screw location Two 875 22 2 mm knockout holes are provided for a standard 1 2 knockout connector not supplied for wiring A plug is provided if only one knockout is required Be sure to use suitable connectors and wiring that are appropriate for the application A Line Connect AC Line to terminals L1 FIG 4 AC LINE AND MOTOR and L2 Be sure jumper J1 on the Logic CONNECTION DIAGRAM Board and jumpers J2A and J2B on the Power Board are set to the correct position to match the AC Line input voltage See table 4 p 9 B Motor Armature Connect motor armature to terminals A1 and A2 Be sure jumper J3 on the Power Board is set to the correct position 90V 180V to match the motor voltage See table 4 p 9 WARNING Do not wire switches or relays in series with the armature Armature MOTOR AC LINE switching can cause catastrophic failure of ARMATURE INPUT motor and or control Do not bundle AC line and motor wires with other wires e g potentiometer analog input Run Jog Stop etc since erratic operation may occur Do not
8. effective 11 92 This control contains Start Stop and Inhibit circuits that 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 potentiometer circuit P1 P2 P3 of this control is 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 C This product complies with all CE directives pertinent at the time of manufacture Contact factory for detailed installation instructions and Declaration of Conformity Installation of a CE approved RFI filter KBRF 200A KB P N 9945C or equivalent is required Additional shielded motor cable and or AC line cables may be required along with a signal isolator KBSI 240D KB P N 9431 or equivalent Special Instruction for Cycle on Demand Applications The camshaft of the Index drive should be in the middle of its dwell position This is the position in which the motor should receive its signal to start Connect the normally closed side of the cycling limit switch LS1 to the control s TB3 terminals STOP 4 and RTN 3 Note See fig 14 p 15 for information regarding the correct dwell position and cycling cam lobe positions GENERAL INFORMATION The KBPI INDEXER controls are packaged in a NEMA 4X enclosure which is ruggedly constructed of die cast aluminum The contr
9. is placed in position S the STOP command has priority over the RUN If the STOP is activated contact open the control cannot be started with the START command If jumper JW is in the R position factory setting the RUN command has priority over the STOP In this mode of operation the control can be started with the RUN command even though the STOP is activated contact open This setting of jumper JW in the R position is used for cycle on demand applications See table 8 for detailed information of jumper JW operation Warning Do not use as safety stop See Safety Warning on page 2 D TABLE 8 JUMPER JW OPERATION JUMPER JW SETTING DESCRIPTION CIRCUIT OPERATION Factory Setting Run has priority over Stop Control will run even if stop contact is open Use this setting for Cycle on Demand operation Stop has priority over Run Control will run only when STP contact is closed RUN JOG STP When start contact is made control will run with STP open If STP is closed and then reopened control will stop When start contact is made STP contact must be closed for control to run RETURN When Jumper JR is moved to position from the factory setting F it disables all of the command functions Run Jog Stop etc To enable these functions a contact must be placed between
10. INSTALLATION AND OPERATING INSTRUCTIONS KBPI SERIES SCR INDEXING amp CYCLING CONTROLS Designed for Indexing Applications FOR PM DC MOTORS RATED 1 6 1 HP 90VDC and 1 3 2 HP 180VDC ON STOP OL 000 Penta Drive DC MOTOR INDEXING CONTROL This control will not operate without installing the correct armature fuse supplied separately 65 See 2 This Manual Covers the Following Models KBPI 240DR Reversible 8501 See Safety Warning on Page 2 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 PENTA A POWER A COMPLETE LINE OF MOTOR DRIVES 1998 KB Electronics Inc 5 Section Page i Simplified Setup and Operating Procedures 1 ii Safety Warming ee hae ee a DARE E Mar 2 General Information 4 2 Mounting eee es Oe ie 7 Setting AC Line and Motor Voltage 1 9 IV Setting Motor Current Jumper 1 9 WIRING trices Se wai Mikes ai
11. PC board set to 120 Jumper J3 on main PC board set to 120 Jumper J1 on logic PC board set to 120 C 240 VOLTS AC LINE INPUT WITH 0 180 VDC OUTPUT STEP DOWN Jumpers J2A J2B on main PC board set to 240 Jumper J3 on main PC board set to 120 Jumper J1 on logic PC board set to 240 The above information is summarized in table 4 TABLE 4 Relationship of AC Line Input and Motor Voltage with Jumper J1 on Logic Board and Jumpers J2 and J3 on Power Board All Models AC Line Motor Voltage J1 Position J2A J2B Position Power J3 Position on VAC Logic Board 50 60Hz Voltage VDC 120V 120V 90V 90V 1 1 J2A J2B 240V 240V 1249 180V 180V 4 120V e J2A J2B 240V 240V 1249 90 90V e 120V e Power Board Denotes step down operation A 90 VDC motor used on a 240 VAC line input Note Motor performance and brush life may be affected IV SETTING MOTOR CURRENT JUMPER J1 Jumper J1 is used to set the range of armature current which can be further modified with the current limit CL trimpot The factory setting of J1 is 10 amps The CL trimpot is factory set to provide 150 of the J1 setting For example when J1 is in the 10 amp position the actual armature current is 15 amps When J1 is in the 5 amp position the control provides a maximum armature current of 7 5 amps The position of J1 should be set to the approxima
12. RAM USING EXTERNAL CONTACTS RUN REV 8 RUN REV JOG REV JOG REV RUN FWD RON EE JOG FWD JOG FWD STOP RTN 24V COM USE NORMALLY OPEN MAINTAINED CONTACTS FIG 17C CYCLE ON DEMAND FIG 17D FORWARD AND REVERSE WITH REVERSE CYCLE ON DEMAND LS2 NO REVERSE RUN REV RUN REV e RUN REV JOG REV JOG REV RUN FWD RUN FWD RUN FWD JOG FWD JOG FWD END OF CYCLE 9 STOP STOP REV STOP FWDe e s 181 U RTN RTN Shield Do not ground Shield Do not ground 17 X 18 WARNING Read Safety Warning page 2 before attempting to operate the control or severe injury or death can result Failure to follow the Safety Warning Instructions may result in electric shock fire or explosion After the control has been set up properly the jumpers set to the desired positions and the wiring completed the start up procedure can begin If AC power has been properly brought to the control the ON and the STOP indicators will be lighted Before starting control be sure the main potentiometer is set to approximately 15 rotation To start the control move the Run Jog Stop toggle to the Run position and release The Stop indicator should extinguish and the motor should rotate The motor will increase in speed as the potentiometer knob is rotated clockwise Note If the motor rotates in the wrong direction it will be ne
13. actual speed 2 Load the motor to rated current Rotate IR trimpot so that the loaded speed is the same as the unloaded speed measured in 1 Control is now compensated so that minimal speed change will occur over a wide range of motor load Note Too much IR Comp will cause unstable oscillatory operation FUNCTION INDICATOR LAMPS The control contains three LED Indicator Lamps on the front cover that reflect its operational status A Power On Indicator ON This lamp will glow GREEN when the AC line is connected to the control Note As a convenience an additional power on indicator Green is located on the main printed circuit board B Stop Indicator STOP This lamp will glow YELLOW when the control is placed in the STOP mode with the Run Jog Stop Switch or logic contact C Overload Indicator OL When the motor is loaded to the current limit setpoint CL setpoint is established by the setting of jumper J1 and the CL trimpot this lamp will glow RED If the OL indicator remains lit during control operation a fault condition may exist Possible causes for this condition are as follows 1 Motor is overloaded check motor amps with DC ammeter in series with armature 2 Motor may be defective check motor for shorts or grounds 3 The CL may be set too low check position of jumper J1 and CL trimpot Note In some applications especially those requiring the motor to cycle on and off or from one speed to another t
14. ameter Units Model No KBPI 240D P N 8500 amp Model No KBPI 240DR P N 8501 AG Une Input VAC 10 50 60 HZ Current Ranges ADC 2 3 3 5 10 to Min Speed Trimpot Range base spd o 939 Max Speed Trimpot Range 96 base spd __ ___ _ AC Line Voltage Regulation base spd i Voltage Following Linearity base spd _ __ __ _ e FIG 2 TYPICAL INDEXING PERFORMANCE Factory Setting P MOTOR RATED SPEED DECEL WITH BRAKE 1 1 1 6 100 4 250 Maximum Cycle Rate 30 cycles minute with typical 1 HP motor Total reflected inertia not to exceed 20 of armature inertia Acceleration time fixed at 1 sec may be extended when operating in Curent Limit TABLE 3 SELECTABLE JUMPER REFERENCE Establishes the range of maximum See sec IV p 9 armature current Set according to model part numbers See table 1 p 3 Sets the AC input line voltage 120 240 VAC for the main PC Board Set according to model part numbers See table 1 p 3 Sets the DC output voltage range to motor 90V 180V Used to activate the return RTN circuit F position RTN is jumpered to common Set to F position O position RTN used as logic disable See sec VII D p
15. cessary to disconnect the main AC power and reverse the armature wires To stop the motor move the Stop toggle to the Stop position If power is lost the control will not restart unless the Run Jog Stop toggle is moved to the position TRIMPOT ADJUSTMENTS The control contains trimpots which have been factory adjusted for most applications Figure 1B on page 5 illustrates the location of the trimpots and their approximate adjustment positions Some applications may require readjustment of the trimpots in order to tailor the control to exact requirements See table 2 p 6 for range and factory setting of trimpots Readjust trimpots as follows M WARNING Do not adjust trimpots with main power on if possible If adjustments are made with power on insulated adjustment tools must be used and safety glasses must be worn High voltage exists in this control Electrocution and or fire can result if caution is not exercised Safety Warning on page 2 must be read and understood before proceeding Failure to follow the Safety Warning Instructions may result in electric shock fire or explosion A Minimum Speed MIN The MIN trimpot is used to set minimum voltage of the drive This sets the minimum speed of the motor Adjust the MIN trimpot as follows 1 Rotate Main Potentiometer to minimum speed position full counterclockwise 2 Increase setting of MIN trimpot so that motor runs at desired minimum speed B Maximum Speed MAX
16. connects to P3 the wiper to P2 and the low side to See fig 5 2 Analog Input An isolated 0 10VDC analog voltage can also be used to drive the control Note If an isolated signal voltage is not available an optional signal isolator KB P N 9431 should be used Connect the isolated input voltage to terminal P2 positive and P1 negative See fig 6 Adjust the MIN trimpot clockwise to achieve 0 output voltage VI FUSING AC Line Fusing Most electrical codes require that each ungrounded conductor contain fusing Separate branch circuit fusing or circuit breaker may be required Check all electrical codes that may apply to the installation This control does not contain AC line fuses A 20 amp rated fuse or circuit breaker can be used B Armature Fusing The control contains a built in armature fuse holder An armature fuse rated 1 5 times higher than the full load of the motor must be installed before operating the control This fuse should not blow unless the motor is shorted or another catastrophic failure occurs An armature fuse replacement such as Littelfuse 326 or Buss ABC ceramic fuse or equivalent can be used Fuse supplied separately from your distributor See table 7 for armature fuse chart TABLE 7 ARMATURE FUSE CHART Motor Horsepower Approx DC Motor Fuse Rating 90VDC 180VDC Current Amps AC Amps 1 6 1 3
17. e ee oe a ee 10 FUSING since eee eee 11 Logic Functions Wiring 12 Application Wiring Diagrams 14 IX Application Wiring Diagrams Reversible Models 17 Me ks tke di 18 3Erimpot Adjustments as prep ey P ees 18 Function Indicator Lamps 19 Troubleshooting Guide 1 20 XIV Limited Warranty 30 TABLES 1 Electrical Ratings RR RERO edge pim 3 2 General Performance Specifications 6 3 Selectable Jumper Reference Chart 7 4 Relationship of AC Line Input and Motor Voltage with Jumper J1 on Logic Board and Jumpers J2 and J3 on Power Board All Models 9 5 Jumper J1 Setting vs Motor 9 6 Terminal Block Wiring Information 10 7 Armature Fuse 11 8 Jumper JW Operation
18. ection Contact Factory MOTOR WILL NOT RUN AT 1725 RPM 20 1 ak Improper setting of Max Speed trimpot rotate pot clockwise to increase speed Unit is in current limit OL LED is lighted See sec XI C p 18 Low line voltage Check AC line voltage 115VAC 10 or 230VAC 10 Verify motor nameplate voltage complies with control output voltage rating Contact Factory au EX 027 5 M C 600 2 00 vH pud ui un ed 14 Nee BY NNOO HAN vw uv ovAOgz NI 1 or or HOLIMS 4018 SOPINNY NOLLISOd OVAOSL NI NMOHS uar E e 5450 e 4015 NOLLOSNNNOO ofo nna 9 9 2 5 2 6918 SH ma as 5 OQ Q NALSWOLLNALOd 954 NS NOLLISOd LOA ObZ NI NMOHS ad nr NOILO3NNOO TVNYSLNI 61915 21 LIMITED WARRANTY For a period 18 months from date of original purchase KB will repair or replace with
19. fter mounting and wiring close the front cover making sure all wires are contained within the enclosure and the gasket is in place around the cover lip Tighten all four cover screws so that the gasket is slightly compressed Do not overtighten _ 00829 90225 Hld3d NANY i 1 9015 907 59 IA VIWAN 00772 88 6 0522 di 9 88 o 00 60z og 3028 oc 09 or TIOMINOO MOLON viNad 000 10 NO 1 05 69 d ELT weg 54405 520 are 05 9885 S3HONI SNOILV2IJI23dS IVOINVHO3M SIs SETTING AC LINE AND MOTOR VOLTAGE The is factory set to operate with a 230VAC 50 60 Hz AC line input and a 180 VDC PM motor By utilizing jumpers J2A J2B and J3 on the main PC board and Jumper J1 on the logic PC board different AC line voltage motor voltage combinations can be achieved A FACTORY SETTING 240 VOLTS AC LINE INPUT WITH 0 180 VDC OUTPUT Jumpers J2A J2B on main PC board set to 240 Jumper J3 on main PC board set to 240 Jumper J1 on logic PC board set to 240 B 120 VOLTS AC LINE INPUT WITH 0 90 VDC OUTPUT Jumpers J2A J2B on main
20. gnal cam may have to signal a stop some degrees before the indexer drive actually enters the dwell It is important that the motor is made to stop while in the dwell of the main cam Stopping in any other position could damage the control or the Indexer Drive See fig 14A 14B and 14C on page 15 FIG 14 CORRECT KEYWAY POSITION FOR CAM AND LIMIT SWITCH ASSEMBLIES A standard Roller Gear unit with FIG 14 ROLLER GEAR UNIT the CAM amp Limit Switch mounted on the correct keyway position directly opposite of the output shaft 90 clockwise from the CAM Lobe The CAM amp Limit Switch may also be mounted on the reducer If the unit has Type 1 motion a special Limit Switch CAM is needed with one extra Lobe 180 from the first Lobe as shown FIG 14B RIGHT ANGLE UNIT Keyway Type LOBE standard right angle unit with the 4 Limit Switch 4 mounted the housing has correct keyway position directly opposite of the CAM Lobe CAM amp Limit Switch may also be mounted on the reducer FIG 14C PARALLEL UNIT Keyway Keyway Vel A A standard parallel unit with the CAM amp Limit Switch mounted on the housing has a correct keyway position directly oppo
21. he OL indicator may blink indicating a transient overload This is a normal condition for the application TROUBLESHOOTING GUIDE MOTOR WILL RUN 1 oar Check control operation by placing RUN JOG STOP in RUN position Make sure disconnect fuses or circuit breaker in AC line are okay Check fuse on PC board and if open replace Check logic See Start up Procedures and Application Section Be sure speed pot is not set at zero Unit is in current limit See if OL indicator is lighted Check position of jumper J1 See table 5 p 9 and CL trimpot setting With power removed from unit and motor leads disconnected check motor for worn or improperly seated brushes Check for locked motor shaft Contact Factory FUSE BLOWING 1 Improper wiring check AC line and motor wiring Be sure ground wire is connected only to the Green ground screw Improper AC line voltage Be sure 120VAC is connected to 120VAC rated controls and 240VAC is connected to 240VAC rated controls Motor brushes worn or improperly seated Motor load is too heavy Check for machine jam up or excessive load OL LED is continuously lighted Contact Factory BRAKING NON FUNCTIONAL control may not stop 1 2 3 Improper logic wiring Motor brushes worn or improperly seated Contact Factory NO SPEED CONTROL 1 2 3 Speed pot miswired or wiring defective Control not set up properly see Application S
22. ined contact closure between terminals JOG and will cause the control to run continuously This is not a latching function The drive will run only as long as the contact is closed and stop when it is opened See fig 8 FIG 8 JOG COMMAND FIG 9 JOG COMMAND USED AS STOP RUN JOG STP 24V COM REN 100 SIP See 0000 0 Q0 0 0 Shield E TES Do not ground Do not ground CLOSE CONTACT NORMALLY OPEN TO RUN OPEN CONTACT CLOSE TO STOP TO STOP Shield Application Note The JOG can also be used as a normally open NO STOP command When the control is started with the momentary RUN command it can be stopped by connecting a momentary contact between the JOG and the RTN terminals See fig 9 Note The control can also be stopped by opening the STP contact STOP STP Use FIG 10 STOP COMMAND nor mally closed NC contact between terminals STP and RTN Opening the contact activates the control s Dynamic Brake producing a rapid stop Note A normally open NO limit switch or contact RUN JOG STP 24V COM 00000 0 Shield Do not ground NORMALLY CLOSED CONTACT OPEN TO STOP can also be used to activate the stop com mand To use a NO contact move jumper JS to the NO position See table 3 p 7 Application Note The setting of jumper JW establishes the priority a STOP command has over a RUN command If jumper JW
23. ion FIG 16 SEQUENCE OF CYCLE ON DEMAND OPERATION 151 CONTACT OPENS ROTATION 1 CLOSE START BUTTON TO INITIATE CYCLE MOMENTARY CLOSURE 151 CONTACT REMAINS CLOSED 3 CAM CONTINUES TO ROTATE THROUGH CYCLE LS1 REMAINS CLOSED 16 181 CONTACT CLOSES 2 CAM ROTATES LS1 CONTACT CLOSES 151 5 4 CAM ROTATES UNTIL LOBE OPENS 151 CONTACT DRIVE BRAKES TO A STOP CLOSE MOMENTARY START BUTTON TO INITIATE ANEW CYCLE APPLICATION WIRING DIAGRAMS Reversible Model KBPI 240DR 120 240 VAC Reversing models carry out the same functions as the unidirectional models except they can be made to index in both the forward and reverse direction A special circuit APRM provides a lockout feature that prevents catastrophic damage to the drive if a Reverse command is given during Forward operation and vice versa The reversing drives contain two additional positions on the terminal block Run Rev and Jog Rev The stop logic command is made with a normally closed NC contact Note The sense of the stop logic can be changed from normally closed NC to normally open NO by placing jumper JS in the NO position The following wiring diagrams illustrate typical logic circuits Many other configurations are possible Consult factory if help is needed FIG 17 SEQUENCE OF CYCLE ON DEMAND OPERATION FIG 17A GENERAL FIG 17B REVERSING CONNECTION DIAG
24. ols are designed specifically for cycling and indexing applications A variety of models provide different features and input voltage ratings see table 1 p 3 The controls provide the user with isolated logic functions STOP JOG and RUN Other functions such as cycle on demand can easily be obtained An important feature of the control is jumper J1 which is used for DC current selection It automatically presets the IR Compensation and Current Limit for safe operation on various motors Standard features include built in armature fusing and an LED indicator array for power stop and overload Part Number 8501 also contain logic input for Reverse Run Reverse Jog The controls contain trimpots that can be used to readjust Minimum and Maximum speed Current Limit and IR Compensation The front panel contains a built in 5K ohm speed potentiometer and a Run Jog Stop switch See table 3 p 7 for selectable jumper information pejoeyje ysn q pue 3 LON OVA uo pesn 9pA 06 89 0 Uny AE 1098 Uny MJ 5 uny AH uny jeuonoeumpiu 91 2 081 0 0098 sduv swe
25. out 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 and we are not responsible for any expense including installation and removal inconvenience or consequential damage including injury to any person caused by items of our manufacture or sale Some states do not allow certain exclusions or limitations found in this warranty so that they may not apply to you In any event KB s total liability under all circumstances shall not exceed the full purchase price of this unit rev 4 88 KB ELECTRONICS INC 8 12095 NW 39th Street Coral Springs FL 33065 954 346 4900 Fax 954 346 3377 Outside Florida Call TOLL FREE 800 221 6570 E mail info kbelectronics com www kbelectronics com A40285 Rev 1 99
26. r Range 90 VDC 180 VDC 1 4 1 3 1 2 3 4 Note Jumper J1 is shown the factory setting 4 Trimpot Settings Trimpots should be set to the approximate positon as shown 5 Main Speed Pot Turn the main speed pot on the front cover of the control to a 1596 or greater setting 4 ii SAFETY WARNING PLEASE READ CAREFULLY 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
27. site of the output shaft 90 clockwise from the CAM Lobe CAM amp Limit Switch may also be mounted on the reducer 15 The Cycle on Demand function is required for most indexing table applications control can be easily set for this operation as follows 1 Jumper JW must be in the R position factory setting see table 8 p 13 2 Jumper JR must be in the position factory setting see sec VII D p 13 3 Wire limit switch 151 normally closed and start switch normally open as shown The Cycle on Demand Operation begins with limit switch LS1 riding on the cam lobe Since LS1 is a normally closed switch it will be open when riding on the lobe The cycle is initiated by momentarily closing the start switch The drive will start even though LS1 is open Jumper JW is in the R position giving priority to the start switch which overrides the stop As the cam shaft rotates it moves off LS1 FIG 15 CYCLE ON DEMAND WIRING L START SWITCH N O o Te 181 Shield Do not ground which closes When the lobe rotates around back to LS1 LS1 now opens and the drive stops The drive is now ready to repeat the cycle by initiating another start command See fig 16 Note A normally open NO STOP contact can also be used To convert to a normally open STOP move jumper JS from the factory position NC to posit
28. state leakage current of less than 1 mA See fig 12 Warning Do not ground or short 24V to com or return on TB3 Do not use 24V for other than open collector sensors See fig 12 Example 2 For optimum operation contacts used on logic inputs should be rated for low level logic switching i e gold contacts See fig 13 FIG 12 SOLID STATE SWITCHING FIG 13 CONTACT SWITCHING RUN JOG STP 24 COM RUN JOG STP 24V o o o o o O si ea NOTE JUMPER JR MUST BE IN THE F POSITION NOTE JUMPER JR MUST BE IN THE O POSITION Output voltage provided can vary between 20 and 24VDC 14 Example 3 Cycle Demand Important Information In a Cycle on Demand application the Indexer Drive will make one complete cycle of movement of table or conveyor and then dwell until it receives an external signal from the machine s controller or operator to start again If motor receives a signal to start while the Indexer Drive is in its dwell position the motor will accelerate from a paused position to full speed during one half of the dwell of the main indexer cam When the motor has reached its maximum speed and is no longer accelerating the motion of the Indexer Drive can start As the Indexer re enters its dwell portion of the main cam the signal cam located on the camshaft of the Indexer Drive will actuate the limit switch to signal a stop Note Due to time delays the si
29. te DC motor current rating Table 5 is provided as a reference See fig 1b 5 for location of jumper J1 TABLE 5 JUMPER J1 SETTING vs MOTOR HORSEPOWER Motor Horsepower Range Jumper J1 90 VDC 180 VDC 69 e 1 4 1 3 1 2 3 4 Note Jumper J1 is shown in the factory setting V WIRING W WARNING Read Safety Warning on page 2 before attempting to use this control 2 Wire control in accordance with the National Electric Code requirements and other codes that apply Be sure to fuse each conductor which is not at ground potential Failure to follow the Safety Warning Instructions may result in electric shock fire or explosion Do not fuse neutral or grounded conductors Note See sec VI p 11 Fusing A separate AC line switch or contactor must be wired as a disconnect switch so that the contacts open each ungrounded conductor See fig 4 for AC Line and Armature connection Note Do not bundle AC or motor leads with logic leads or erratic operation may occur 1 Twistlogic wires speed adjustment potentiometer or voltage signal input wires to avoid picking up electrical noise If wires are longer than 18 use shielded cable 2 You may have to earth ground the shielded cable If noise is coming from devices other than the drive ground the shield at the drive end ground screw in enclosure If noise is generated by a device on the drive ground the shield at the end away from the
30. the RTN terminals Note Opening the return control will not stop the indexer if opened while indexer is running Warning Do not use as emergency or safety stop See Safety Warning on page 2 See fig 11 p 14 for jumper JR operation Failure to follow the Safety Warning Instructions may result in electric shock fire or explosion 13 FIG 11 JUMPER JR OPERATION Jumper JR F position factory setting RIN 0000 Q0 connects RTN to Jumper JR in O position opens the RTN to circuit allowing the use of an external disable contact This will not stop indexer in run mode OPEN TO DISABLE ALL RUN JOG STOP COMMANDS E 24 VDC SUPPLY The 24V terminal provides a nominal 24 VDC 12 mA output use with an external load such as one solid state 3 wire proximity switch F Common COM This terminal is referenced to all logic signals RUN JOG STOP through the Return RTN terminal The control is factory supplied with jumper JR in the position which connects the and COM terminals together Note Control will not operate unless jumper JR is in the F position APPLICATION WIRING DIAGRAMS Example 1 Solid state switching devices such as NPN transistors or proximity switches may be used for logic commands if they meet the following criteria Must be capable of switching 30 VDC at 24 mA with an off
31. use this control on shunt wound motors TABLE 6 TERMINAL BLOCK WIRING INFORMATION Connection Supply Wire Gauge Designation Terminal Block Designation Maximum Tightening Torque Ibs MINIMUM MAXIMUM Use Cu wire only AWG 10 Ground Be sure to ground earth the FIG 5 REMOTE POTENTIOMETER control by connecting a ground wire to the CONNECTION Green Ground Screw located to the right of the terminal block Do not connect ground wire to any other terminals on control D Main Potentiometer The control is supplied with the main potentiometer prewired However the control can also be operated from a remote potentiometer or from an isolated analog voltage for voltage FIG 6 ANALOG VOLTAGE following To operate from an external CONNECTION source remove white orange and violet USE AN ISOLATED VOLTAGE SOURCE potentiometer leads from terminals P1 P2 The leads be taped and left 0 10 F the control The potentiometer itself may VDC 0 emi be removed if a seal is used to cover the hole in the front cover Note Use Warning Do not ground earth shielded cable on all connections to P1 P1 or P2 connection P2 or P3 over 12 30cm in length Do not ground shield 1 Remote Potentiometer Connect remote potentiometer wires to terminals P1 P2 and P3 so that the high side of the potentiometer
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