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kbpw-240d Instruction Manual

1. 82 DC TACH GENERATOR aE lt oD Fes IV SETTING SELECTABLE JUMPERS The KBPW 240D has customer selectable jumpers which must be set before the control can be used See Figure 1 on page 4 for location of jumpers A Motor Voltage Selection J1 Jumper J1 is factory set to 90V position for 90 Volt SCR rated motors or 130 Volt PWM rated motors For 180 Volt SCR rated motors or 220 Volt PWM rated motors set jumper J1 to 180V position FIGURE 14 MOTOR VOLTAGE SELECTION Figure 14 Note If jumper J1 is set to T position a tach generator must be wired to TBS If a tach gener ator is not used jumper J1 must be in either 90V or 180V posi tion If jumper J1 is in T position and a tach generator is not used the motor will accelerate to full Speed and the main speed poten tiometer will not control speed Motor Current Selection J2 Jumper J2 is factory set to 7 5A position for 7 5 Amp motors For motors of lower amper age set Jumper J2 to the J1 Set for 90 Volt MotorsO Factory Setting J1 Set for 180 Volt Motors J1 J1 See Tle EIE 10 gt sov 90V 90V FIGURE 15 MOTOR CURRENT SELECTION High Scale Low Scale SE pi Current Range Current Range ry g Amps DC Amps DC 7 5 0 8 5 0 0 5 3 5 0 4 Note
2. Gated Gr rE NE ia eni uri ds 18 IX Diagnostic LEDS s ema m nu studet ts une uf 14 X Optional Accessories o toda mies e e IO E EUIS EGG cee Cape ee esed prs 15 XI Limited Warranty 3 4 2 2 deer er ib e eot 16 Tables 14 Electrical RatingS 25 nt sete Ste d ibus dun pts 3 2 General Performance Specifications 3 3 Terminal Block Wiring Information 6 4 Field Connection Shunt Wound Motors 7 5 Setting Motor Current SCR amp PWM Motor Horsepower Ratings 10 Figures 1 Gontrol layout cs sere Con s te dac se eed eid 4 2 Mechanical Specifications hn 5 3 Power COnhectiori 2552 ipd Tue b aate 6 4 Full Voltage Field rere RR DER nib We uic ema ak 7 5 MHalt Voltage Field oc Diss cn uus tere 7 8 Remote Potentiometer soccer oe ee ae e GEO E ee 7 7A Remote 3 Wire Start Stop Switch with Normally Open Start Contact and Normally Open Stop Contact 8 7B Remote 3 Wire Start Stop Switch with Normally Open Start Contact and Normally Closed Stop Contact 8 7C Remote 2 wire Start Stop Switch with Normally O
3. Zeb 00 S LE 2 vanga sor 301 S9 dl XPWaN xD 68 S 60c 920 oor o c8 88 8 m o H OOO S 4015 95 0 _ LVS 091 WIRING INSTRUCTIONS j WARNING Read Safety 1 N Warning page 1 before using this control Disconnect the AC line before wiring Note To avoid erratic operation do not bundle AC line and motor wires with wires from signal following start stop switch inhibit or any other signal wires Use shielded cables on all signal wiring over 12 30cm Shield should be Earth grounded on the control side only Wire the control in accordance with the National Electrical Code requirements FIGURE 3 POWER CONNECTION Sese F1 F2 A1 A2 11 12 GROUND EARTH MOTOR AC LINE and other codes that may apply to your area See Figure 3 Table 3 and Table 4 on page 7 TABLE 3 TERMINAL BLOCK WIRING INFORMATION Supply Wire Gauge Maximum pal Designation Connections AWG Cu Tightening Torque Minimum Maximum in Ibs TB1 AC Line Input L1 amp L2 22 12 12 TB1 Motor Armature A1 amp A2 22 12 12 TB2 Motor Field Shunt Wound M
4. Jumper see Figurg 22 FIGURE 20 RUN RELAY OUTPUT MODE SELECTION MOUNTING INSTRUCTIONS J5 Set for Normally Open Warning The KBPW 240D is not NO Output Contacts J5 Set for Normally Closed designed to be used in an explo Factory Setting NC Output Contacts sion proof application J5 J5 It is recommended that the control be mount H z n ed vertically on a flat surface with adequate NC NO NC NO ventilation Leave enough room below the control to allow for AC line motor connec tions and any other wiring Although the control is designed for outdoor and wash down use care should be taken to avoid FIGURE 21 STOP SWITCH TYPE SELECTION extreme hazardous locations where physi J6 Set for cal damage can occur If the control is Newell Crem iep Factory Setting Normally Closed Stop Switch mounted in a closed unventilated location allow enough room for proper heat dissipa tion If operating the control at full rating a minimum enclosure size of 12 W x 24 H x 12 D is required See Figure 2 on page 5 The KBPW 240D is designed with a hinged case so that when the front cover is open all wiring stays intact To open the cover the four FIGURE 22 STOP SWITCH Screws must be loosened so they are no longer TYPE SELECTION engaged in the case bottom After mounting and wiring close the cover and make sure that wires will J7 Installed to not get caught or crimped as the cover is closed Ena
5. Wound Motors Only Wire the motor field leads to F1 and L1 terminals of TB2 as shown in Figure 5 amp Table 4 2 Fi Note Do not connect motor armature leads to F1 and F2 terminals F2 A1 A2 L1 4 Warning Do not use F1 and F2 ter minals of TB2 for any purpose other FIELD than to power the field of a shunt wound motor AC LINE GROUND EARTH MOTOR TABLE 4 FIELD CONNECTION Shunt Wound Motors Only WP COMI e Feta connections 115 90 130 100 F1 amp 22 115 90 130 50 F1 amp L1 230 180 260 200 F1 amp F2 230 180 260 100 F1 amp L1 230 90 130 100 F1 amp L1 F Remote Main Speed Potentiometer FIGURE 6 REMOTE POTENTIOMETER Connection The control is supplied with a prewired main speed potentiometer mounted on the front cover To operate the control from a remote potentiometer 5kQ remove the white orange and violet potentiometer leads from P1 P2 and P3 terminals respec FRONT VIEN tively The leads may be taped and left inside the control The potentiometer assembly may be removed if a watertight seal is used to cover the hole in the front cover Connect the remote main speed potentiometer wires to terminals P1 low side P2 wiper and P3 high side as shown in Figure 6 G Remote Start Stop Switch Connections The control is supplied with
6. INSTALLATION AND OPERATION MANUAL MODEL KBPW 240D KB Part No 8401 Black Case Part No 8402 White Case NEMA 4X IP 65 PWM DC Motor Speed Control For PM and Shunt Wound Motors Rated 7 5 Amps DC 11 5 Amps AC 115 230 VAC ON STOP OL OOO Penta Drive PWM DC MOTOR SPEED CONTROL F M NES EO 220 wy N 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 V POWER A COMPLETE LINE OF MOTOR DRIVES 2002 KB Electronics Inc See back cover TABLE OF CONTENTS Section Page i Safo Warning RINGS ULIS etra ees 1 Intr duction a x crt eret be b tes E 1 Simplified Operating Instructions 2 gt Wiring Instr ctions te ele AT ta niae AE 6 IV Setting Selectable lt 9 V Mounting Instructions 3 3 neun eet dh gud Ut qub us 12 VI esser Shed abe bony er fark rosae ipod opes ado aer ipu e Med 12 VII AC ios some zt L rco e og cti puberes qd ALT REOS 18 VIII Trimpot Adjustments
7. TRIMPOT ADJUSTMENTS The KBPW 240D contains trimpots which are factory set for most applications The trimpots are shown in the approximate calibrat ed positions Some applications may require readjustment of the trimpots in order to tailor the control for a specific requirement Readjust trimpots as described below Wy Warning If possible do not adjust trimpots with M4 5 main power applied adjustments are made with main power applied an insulated adjustment tool must be used and safety glasses must be worn High voltage exists in this control Fire and or electrocution can result if caution is not exercised Safety Warning on page 1 must be read and understood before proceeding A Acceleration ACCEL Sets the amount of time for the motor to accelerate from minimum speed to maximum speed The ACCEL trimpot is factory set for one 1 second as shown in Figure 23 For more rapid acceleration time rotate the trimpot counterclockwise For longer acceleration time rotate the trimpot clockwise Note Rapid acceleration settings may cause the current limit circuit to activate which will extend the acceleration time Deceleration DECEL Sets the amount of time for the motor to decelerate from maximum speed to minimum speed The DECEL trimpot is factory set for one 1 second as shown in Figure 24 For more rapid deceleration time rotate the trimpot counterclockwise For longer deceleration t
8. 1 3 0 25 1 4 0 18 1 2 0 37 0 8 1 12 0 06 1 6 0 1 1 8 0 09 1 4 0 18 0 5 1 20 0 04 1 10 0 08 1 15 0 05 1 6 0 1 0 4 1 25 0 03 1 12 0 06 1 20 0 04 1 8 0 09 0 3 1 30 0 02 1 15 0 05 1 25 0 03 1 10 0 08 0 2 1 50 0 01 1 25 0 03 1 30 0 02 1 20 0 04 Note For low L motor current range settings 0 8A 0 5A 0 4A 0 3A and 0 2 it is necessary to remove resistor R35 as shown in figure 16 10 C Timed and Non Timed Current Limit Selection 43 Jumper J3 is factory set to TCL position for timed current limiting operation See Figure 17 For non timed FIGURE 17 CURRENT LIMIT MODE SELECTION J3 Set for TCL ModeO Timed Current Limit O J3 Set for NTCL current limiting operation set jumper J3 Factory Setting Non Timed Current Limit to NTCL position J3 J3 TCL Timed Current Limit When a Jumper J3 is in the TCL position the TCL NTCL TCL NTCL control will go into STOP after it is in overload for a predetermined amount of time set by the TCL trimpot Resetting the Control After TCL To reset the control after it has gone into TCL momen tarily set the Start Stop switch to START position or disconnect and reconnect the AC line If an On Off AC Line Switch is installed set it to OFF position and then back to ON posi tion If the Start switch is jumpered START and COM ter
9. on page 12 Jumper J4 must be set to 7V position The value of RT in Q can be calculated using the following formula RT 1 46 x VT x S 19 000 Where VT is the tach generator voltage in Volts per 1000 RPM and S is the base speed of the motor in RPM Suppose you have a 20 Volt per 1000 RPM tach generator with a 3600 RPM motor RT 1 46 X 20 X 3600 19000 861200 Example Choose the closest 1 2W resistor value which is 820000 82kQ or 910000 91kQ Readjustment of the MAX trimpot may be necessary to achieve the desired maximum output voltage 11 Run Relay Output Mode Selection 45 FIGURE 19 DC TACH GENERATOR Jumper J5 is factory set to NO position WITH ADDITION OF Rr for normally open relay output at TB4 For normally closed relay output set jumper J5 to NC position See Figure 20 F Stop Switch Type Selection J6 Jumper J6 is factory set to the NO position for a normally open stop switch as used on the front cover If a remote normally closed Stop switch is used set Jumper J6 to the NC position If a remote normally open Stop switch is used set Jumper J6 to the NO position See Figure 21 2 EN ENABLE G Enable Selection 47 Jumper J7 is fac tory installed to enable the control If con necting Enable contacts to Terminals EN1 mH and EN2 of Terminal Block TB3 remove
10. For low L motor current range settings 0 8A 0 5 0 4A 0 3A and 0 2A it is necessary to remove resistor R35 by cutting it out of the circuit as shown in figure 16 on page 10 FIGURE 16 REMOVING RESISTOR R35 corresponding position for the motor being used See Figure 15 and Table 5 Note For low L motor current settings 0 8A 0 5A 0 4A 0 3A and 0 2A it is necessary to remove resis tor R35 Cut the leads at the locations shown in Figure 16 WARNING TO REMOVE RESISTOR R35 CUT THE LEADS HERE R35 BLU BLU WHT WHT 585 06 ORG RED WHT BLK LiB 12 128 Q4 E leg 66 Hy E jan TB1 F1 F2 A1 A2 11 L2 n n n ab B m Disconnect line before cutting out resistor R35 Use an insulated cutter and wear safety glasses TABLE 5 SETTING MOTOR CURRENT SCR amp PWM Motor Horsepower Ratings SCR Rated Motor Horsepower PWM Rated Motor Horsepower J2 Setting HP kW HP kW Amps DC 90 Volts DC Motors 180 Volts DC Motors 130 Volts DC Motors 220Volts DC Motors 75 3 4 0 5 1 1 1 0 75 2 1 5 5 0 1 2 0 37 1 0 75 3 4 0 5 1 1 3 5 1 3 0 25 3 4 0 5 1 2 0 37 1 0 75 2 5 1 4 0 18 1 2 0 37 1 3 0 25 3 4 0 5 17 1 6 0 1
11. be a normal condition for the application OPTIONAL ACCESSORIES Complete instructions and connection diagrams are supplied with all accessories to facilitate installation A On Off AC Line Switch P N 9341 Disconnects the AC line Mounts on the enclosure cover and is supplied with a switch seal to maintain watertight integrity FWD BRK REV Switch P N 9339 Provides motor reversing and dynamic braking This Switch is equipped with a center off hesitation mechanism which assures that the motor is fully stopped before it can be reversed Mounts on the enclosure cover and is supplied with a switch seal to maintain watertight integrity Run Stop Jog Switch P N 9340 Selects speed setting from either main potentiometer or JOG trimpot Mounts on the enclosure cover and is supplied with a switch seal to main tain watertight integrity Signal Isolator KBSI 240D P N 9431 Provides isolation from non isolated signal sources Mounts on the inside of the enclosure cover Auto Manual Switch P N 9377 When used with the KBSI 240D P N 9431 it selects either an isolated signal from the KBSI 240D or from the main speed potentiometer Mounts on the enclosure cover and is supplied with a switch seal to maintain watertight integrity Anti Plug Reversing Module APRM PC P N 9378A Provides electronic braking and reversing Mounts on the inside of the enclosure cover Note For use with this control the APRM PC mu
12. 3784 A AC Line Connection Wire AC line input to L1 and L2 terminals of TB1 as shown in Figure 3 B Ground Connection Earth ground the control chassis using the green ground screw that is provided on the inside of the control to the right side of TB1 as shown in Figure 3 C Permanent Magnet PM Motor Connection Wire the motor armature leads to A1 and 2 terminals of TB1 as shown in Figure Be sure jumper J1 is set to the appropriate motor voltage and that J3 is set to the appropriate motor current For step down operation 230 Volt AC line input with 90 Volt DC SCR rated motor or 180 Volt DC PWM rated motor set jumper J1 to 90V position However in step down operation the motor may have reduced brush life consult motor manufacturer Note Do not connect motor armature FIGURE 4 FULL VOLTAGE FIELD leads to F1 and F2 terminals Do not use F1 and F2 terminals for PM motors D Full Voltage Field Connection Shunt Wound Motors Only Wire the motor field leads to F1 and F2 terminals of TB2 as shown in Figure 4 amp Table 4 5 Note Do not connect motor armature leads to F1 and F2 terminals Warning Do not use F1 and F2 ter 1 minals of TB2 for any purpose other ASUNE G DUNO than to power the field of a shunt TINN wound motor E Half Voltage Field Connection Shunt FIGURE S HALF VOLTAGE MELD
13. ATED 0 10V DC from TCL or the Start Stop switch is set to STOP position the Run Relay output contacts will return to their normal position Note If relay output contacts are not required for your application J5 may be in any position Voltage Following Connection An isolated 0 10 Volt DC analog signal can also be used to control motor speed See Figure 9 Note If an isolated signal voltage is not available an optional signal isolator can be installed KBSI 240D FIGURE 10 INHIBIT CIRCUIT P N 9431 Connect the isolated signal voltage to P2 NTT and P1 terminals Adjustment of the MIN trim pot may be necessary to achieve a 0 Volt DC output Inhibit Connection The control is supplied with inhibit terminals INH1 and INH2 to con nect an Inhibit switch See Figure 10 These terminals are used to electronical ly stop the control When the Inhibit Switch is closed the control will coast to stop When the Inhibit switch is opened the control will accelerate to the main speed potentiometer setting Warning Do not use Inhibit as a safety disconnect Use only the AC line for this purpose Enable Connection The Enable is used to electronically start and stop the control When the Enable contact is closed the control will accelerate to the Main Speed Potentiometer setting When the Enable contact is opened the control will coast to stop Wire the Enable contacts to Ter
14. Type Connect the motor armature as described in Section on page 6 Connect full voltage field wires 90 Volt DC motors with 100 Volt DC field and 180 Volt DC motors with 200 Volt DC field to F1 and F2 terminals of TB2 as described in Section IIID on page 7 Connect half voltage field wires 90 Volt DC motors with 50 Volt DC field and 180 Volt DC motors with 100 Volt DC field to F1 4 terminal of TB2 and L1 terminal of TB1 as described in Section IIIE on page 7 Note Do not connect motor armature leads to F1 and F2 terminals D Motor Current Jumper J2 is factory set for 7 5 Amp motors For lower current motors set jumper J2 to the corresponding motor current as described in Section IVB on page 10 Note The factory setting for Current Limit is 15096 of the nominal current setting example if jumper J2 is set to 5A position the CL trimpot is calibrated for 7 5 Amps E Trimpot Settings All trimpots have been factory set as shown in Figure 1 on page 4 Trimpots may be readjusted as described in Section VIII on page 13 F Diagnostic LEDs After power has been applied observe the LEDs to verify proper con trol function as described in Section IX on page 14 Start Stop Switch The control is supplied with a prewired Start Stop switch as described in Section IIIG on page 7 This switch must be used to start the control each time the AC power is lost or the control shuts down due to TCL To o
15. a prewired Start Stop switch mounted on the front cover To operate the control from a remote Start Stop switch type ON OFF ON SPDT remove the white black and red wires from START COM and STOP terminals respectively The leads may be taped and left in the control The switch itself may be removed if a watertight seal is used to cover the hole 7 in the front cover Connect the remote Start Stop switch wires to START momentary COM common and STOP constant terminals as shown in Figure 7A After applying power momentari ly set the Start Stop switch to START position The motor will operate at the set speed of the main speed potentiome ter To stop the motor set the Start Stop switch to STOP position FIGURE 7A REMOTE 3 WIRE START STOP SWITCH WITH NORMALLY OPEN START CONTACT AND NORMALLY OPEN STOP CONTACT MOMENTARY CONTACT MAINTAINED CONTACT FIGURE 7B REMOTE 3 WIRE START STOP SWITCH WITH NORMALLY OPEN START CONTACT AND NORMALLY CLOSED STOP CONTACT For remote 3 wire Start Stop Switch with normally open start con tact and normally closed stop contact see Figure 7B MOMENTARY NORMALLY OPEN CONTACT MOMENTARY NORMALLY CLOSED CONTACT For remote 2 wire Start Stop Switch with normally open start stop contact see Figure 7C Note For automatic start when power is applied the Start Stop function can be bypassed T
16. adio frequency interference RFI which may adversely affect sensitive electronic equipment If further information is required on this product contact the factory 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 This control contains electronic Start Stop 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 Be sure to follow all instructions carefully Fire and or electrocution can result due to improper use of this product PWM Safety Warning This control contains a safety circuit which is designed to prevent full speed runaway in the event the main power transistor fails However this safety cir cuit is not infallible and may itself fail to operate and therefore allow a full speed runaway con dition to exist The installer of this product should take proper precautions to include other means to protect the operator or the machine involved such as mechanical disconnects warn ing notices etc This product complies with all CE directives pertinent at the time of manufacture Contact the C Sales Department for detailed installation and Declaration of Conformity Installation of a CE approved RFI filter KBRF 200A P N 9945C or equivalent is required Ad
17. ble au Tighten all four cover screws so that the gasket is rectory Setting Gone nane slightly compressed Do not over tighten car 2 2 A v OPERATION m Caution It is recommended that the bus capacitors be reconditioned if this product has been in storage for over one year To recondition the capac itors apply the AC line with the drive in Stop Mode for a minimum of one hour After the control has been properly set up jumpers set to desired positions and wiring com pleted the startup procedure can begin If AC power has been properly brought to the con trol the ON and STOP LEDs will be illuminated Before starting be sure the main speed potentiometer is fully counterclockwise To start the control momentarily set the Start Stop switch to START position and release it The STOP LED should no longer illuminate The motor should begin to rotate as the main speed potentiometer is rotated clockwise Note If the motor rotates in the incorrect direction it will be necessary to disconnect the AC line reverse the motor leads and repeat the startup procedure VII AC LINE FUSING This control does not contain AC line fuses Most electrical codes require that each unground ed conductor contain circuit protection Installation of a 20 Amp fuse or circuit breaker in series with each ungrounded conductor is recommended Check all electrical codes that apply to the application
18. ditional shielded motor cable and or AC line cables may be required along with a signal isolator KBSI 240D P N 9431 or equivalent INTRODUCTION Thank you for purchasing the KBPW 240D KB Electronics Inc is committed to providing total customer satisfaction by producing quality products that are easy to install and operate The KBPW 240D is manufactured with surface mount components incorporating advanced circuit ry and technology The KBPW 240D is a Pulse Width Modulated PWM control in a NEMA 4X IP 65 watertight and washdown enclosure designed to operate PWM and SCR rated Permanent Magnet and Shunt Wound motors ranging from 0 2 Amps DC to 7 5 Amps DC It operates at a switching frequency greater than 16kHz to provide high motor efficiency and quiet operation Special cir cuitry automatically accepts AC line input voltages of 115 Volts AC to 208 230 Volts AC 21096 50 60Hz without having to make a jumper selection Standard panel mounted features include diagnostic LEDs power on stop and overload Start Stop switch and speed potentiometer Other features include barrier terminal blocks facilitate wiring of AC line motor armature motor field tach generator and run relay connec tions adjustable trimpots acceleration deceleration maximum speed minimum speed jog speed used with optional Run Jog switch current limit timed current limit and IR Comp Optional accessories include On Off AC Line Switch FWD BRK REV Swi
19. esent in the control Non Timed Current Limit NTCL When jumper J3 is set to NTCL position and an overload condition exists the control will remain in current limit and will not shut down IR Compensation IR Sets the amount of compensating voltage required to keep the motor speed constant under changing loads The IR trimpot is factory set for 4 Volts for 90 Volt DC output and 8 Volts for 180 Volt DC output as FIGURE 27 JOG TRIMPOT RANGE 15 o4 50 Or Base Speed FIGURE 28 CL TRIMPOT RANGE 150 o4 200 Range Setting FIGURE 29 TCL TRIMPOT RANGE Or co e o a FIGURE 30 IR TRIMPOT RANGE 15 Volts shwon in Figue 30 For higher compensating voltage rotate the trimpot clockwise For lower compensating voltage rotate the trimpot counterclockwise Note If the IR compensation is set too high unstable oscillatory operation will result If the control is used with a tach generator the IR trimpot should be set fully counterclockwise DIAGNOSTIC LEDs The KBPW 240D is designed with LEDs mounted on the front cover to display the control s operational status A Power On ON The ON LED will illuminate green when the AC line is applied to the control Note When removing power to the control the POWER LED will remain illuminated for a few seconds u
20. his can be accomplished by installing a jumper provided with control between the START and COM ter minals Jumper J6 must be in the FIGURE 7C REMOTE 2 WIRE START STOP SWITCH WITH NORMALLY OPEN START STOP CONTACT MAINTAINED NORMALLY CLOSED CONTACT CLOSE TO RUN OPEN TO STOP NO position See Figure 8 CAUTION Eliminating the Start Stop function using a jumper will cause the motor to run at the main speed potentiometer setting when the AC line is applied Run Relay Connection Normally open NO or normal ly closed NC relay output contacts are provided at TB4 which will change state when the Start Stop switch is set to START position or if the control shuts down and goes into STOP mode from TCL The run relay is used to indi cate the state of the control run or stop Normally open or normally closed run relay contact outputs can be select ed depending on the position of jumper J5 If nor mally open is selected J5 in NO position the FIGURE 8 START STOP FUNCTION ELIMINATED JUMPER INSTALLED FIGURE 9 VOLTAGE FOLLOWING run relay output contacts will close when the Start Stop switch is set to START position If nor mally closed is selected J5 set to NC position the run relay output contacts will open when the Start Stop switch is set to START position When the control shuts down and goes into STOP mode ISOL
21. ime rotate the trimpot clockwise Note Deceleration time will not be shorter than the maximum coast time of the motor under actual load C Maximum Speed Sets maximum speed of the motor The MAX trimpot is factory set for 100 of base motor speed as shown in Figure 25 For a higher maximum speed setting rotate the trimpot clockwise For a lower maximum speed setting rotate the trimpot counterclockwise D Minimum Speed MIN Sets minimum speed of the motor The MIN trimpot is factory set for 0 speed as shown in Figure 26 For a higher minimum speed setting rotate the trimpot clockwise FIGURE 23 ACCEL TRIMPOT RANGE A 10 Seconds FIGURE 24 DECEL TRIMPOT RANGE E o a 5 a o o FIGURE 25 MAX TRIMPOT RANGE 95 100 O 504 140 Base Speed FIGURE 26 MIN TRIMPOT RANGE o 30 Base Speed 13 IX Jog Speed JOG Sets jog speed of the motor The JOG trimpot is factory set for 15 of motor base speed as shown in Figure 27 For a higher jog setting rotate the trimpot clockwise For a lower jog setting rotate the trimpot counter clockwise Note The Jog feature requires installation of the Run Stop Jog Switch assembly P N 9340 Current Limit CL Sets current limit overload which limits the maximum current to the motor The current limit se
22. mature and field tach genera to run relay output and thermal or enable switch Quick Connect Terminals Facilitate connecting Start Stop switch Run Stop Jog switch FWD BRK REV switch and Inhibit switch SIMPLIFIED OPERATING INSTRUCTIONS IMPORTANT You must read these simplified operating 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 1 before proceeding A Power Connection Connect the AC line to L1 and L2 terminals of TB1 and the ground wire Earth to the green ground screw as shown in Figure 3 on page 6 and as described in Section IIIA on page 6 and Section IIIB on page 6 B Permanent Magnet PM Motor Connection Two Wire Type Connect the motor arma ture to A1 and A2 terminals of TB1 as shown in Figure 3 on page 6 and as described in Section on page 6 Be sure that jumper J3 is set to the corresponding motor voltage position as described in Section IVA on page 10 Do not use F1 and F2 terminals of TB2 for any purpose other than to power the field of a shunt wound motor Do not use F1 and F2 terminals for PM motors Note Motor performance and efficiency including brush life may be adversely affected when operating the control in stepdown mode 208 230 Volt AC line with 90 130 Volt DC motors C Shunt Wound Motors Four Wire
23. minals EN1 and EN2 of Terminal Block TB3 as shown in Figure 11 The contacts must be isolated and Jumper J7 must be removed Note The control can also be started and stopped with an Enable contact in the Main Speed Potentiometer circuit The Enable function is established by wiring a switch in series with the violet Main Speed Potentiometer lead which connects to the P3 terminal See Figure 12 Warning Do not use Enable as a safety disconnect Use only the AC line for this purpose The Enable Circuit is not isolated and is not to be Earth grounded DC Tach Generator Connection Wire the tach generator to T and T ter minals of TB4 as shown in Figure 13 Jumper J1 must be in T position Jumper J4 must be in 7V position for 7 Volt per 1000 RPM tach generators or 50V posi tion for 50 Volt per 1000 RPM tach gener ators See section IVD on page 11 Note When using a tach generator the IR trimpot should be set fully counterclockwise CLOSE TO STOP OPEN TO RUN od K2 amp E ENABLE CLOSE TO RUN m od n Note Jumper J7 must be removed for Enable to operate FIGURE 12 ENABLE CIRCUIT USING POTENTIOMETER ENABLE CLOSE TO RUN OPEN TO STOP Violet Main Speed Potentiometer FIGURE 13 DC TACH GENERATOR
24. minals connected the control must be restarted by disconnecting and reconnecting the AC line NTCL Non Timed Current Limit When jumper J3 is set to NTCL position the control will not go into STOP after it is in overload Note TCL trimpot will have no affect when jumper J3 is in NTCL position D DC Tach Generator Voltage Selection J1 and J4 For a tach generator wired to TB3 set jumper J1 to T position See Figure 18 Jumper J4 is factory set to 7V position for 7 Volt per 1000 RPM tach generators wired to TB3 For a 50 Volt per 1000 RPM tach gener ator set jumper J4 to 50V position FIGURE 18 DC TACH GENERATOR VOLTAGE SELECTION Jumper J1 Settings Jumper J4 Settings J4 Set for 7V per 1000RPM Tach Generator Input Factory Setting J4 Set for 50V per 1000RPM Tach Generator Input J1 Set for 90 Volt Motors J1 Set for Factory Setting Tach Generator Input Ji Ji J4 J4 T 180v 180 LE 90V 7 50V 7V 50V Note When using a tach generator the IR trimpot should be set fully counterclockwise Note The tach generator input is designed for 7 Volt or 50 Volt per 1000 RPM tach gen erators used with 1800 RPM motors For tach generators other than 7 Volt or 50 Volt per 1000 RPM or for motors other than 1800 RPM an external 1 2 watt resistor RT must be used Install RT in series with the tach generator as shown in Figure 19
25. ntil the DC bus voltage discharges Stop STOP The STOP LED will illuminate yellow when the Start Stop switch is set to STOP position When AC line is applied this LED will also be illuminated until the Start Stop switch is set to START position Overload OL The OL LED will illuminate red when the control goes into current limit indi cating that the current limit set point has been reached set by the CL trimpot and the posi tion of jumper J2 This LED will remain illuminated if the control times out in TCL jumper J3 set to TCL position The control can be reset by either setting the start stop switch to START position or by disconnecting and reconnecting the AC line If the overload condi tion still exists when the control is restarted or AC line reapplied the OL LED will illuminate again If the OL LED remains illuminated during control operation a fault condition may exist Possible causes for this condition are as follows Motor is overloaded Check motor current If the motor is a shunt wound type the field may be open or not receiving proper voltage Motor may be defective Check motor for shorts or grounds CL may be set too low Check position of CL trimpot and setting of jumper J2 Note In some applications especially those requiring the motor to cycle on and off or from one speed to another or from stop to high speeds the OL LED may blink indicating a transient overload This may
26. od RE Eu a TASSE Nee ia 13 MIN 32 2 br an ecards ee ohn pne Paar 13 JOG Trimpot Ranger qup tk sete aaah vri 14 GTrimpot Bange dod te nisu aes 14 TOL Trimpot Range kha Se ae eae 14 IR Trimpot vad tad e ee 14 un 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 i 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 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 r
27. ordance with the United States Copyright Act of 1976 no part of this publication may be reproduced in any form or by any means without permission in writing from KB Electronics Inc 8 22 02 KB Electronics Inc 12095 NW 39th Street Coral Springs FL 33065 2516 954 346 4900 Fax 954 346 3377 4 Outside Florida Call TOLL FREE 800 221 6570 E mail info kbelectronics com www kbelectronics com A40360 Rev B 8 2002
28. otors Only F1 amp F2 24 14 3 5 TB3 Tach Generator T amp T 24 14 3 5 TB4 Run Relay 1 amp K2 24 14 3 5 Be sure to properly fuse each conductor that is not at ground potential Do not fuse neutral or grounded conductors See Section VII page 13 separate AC line switch or con tactor must be wired as a disconnect so that each ungrounded conductor is opened An acces sory On Off AC Line Switch P N 9341 may be used in lieu of or in addition to the Start Stop Switch The switch can be wired for single pole or double pole operation as required To maintain the watertight integrity of the control be sure to use suitable watertight connectors and wiring which are appropriate for the application Two 7 8 22 2mm knockout holes are provided for standard 1 2 knockout connectors not supplied for wiring A watertight plug is provided if only one knockout is required Warning Do not wire switches or relays in series with the armature Armature switching can cause catastrophic failure of motor and or control To avoid erratic operation do not bundle AC line and motor wires with potentiometer wires voltage following wires Start Stop Switch wires inhibit wires or any other signal wires Use shielded cables on all signal wiring over 12 30cm long Shield should be Earth grounded on the control side only Warning Do not use CON for any purpose other than to power the optional Anti Plug Reversing Module APRM PC P N 9
29. pen Start Stop Contact 8 8 Start Stop Function Eliminated Jumper Installed 8 9 Voltage Following Rer cere I per UI GR EA 8 10 Inhibit GIFCUIE E encode tegit Eat edita 9 11 Enable Connection eate op b ec te a bela stet ies 9 12 Enable Circuit Using 9 13 DC Tach Generator settee ATE DI eret Dp us baie 9 14 Motor Voltage Selection J1 10 15 Motor Current Selection J2 10 16 Removing Resistor R35 for low current selection 10 17 Current Limit Mode Selection J3 11 18 DC Tach Generator Voltage Selection J4 11 19 DC Tach Generator with Addition of RT 12 20 21 22 23 24 25 26 27 28 29 30 Run Relay Output Mode Selection J5 12 Stop Switch Type Selection J6 12 Enable Selectiony rers 12 ACCEL Trimpot Range 243 2 56a bbs b SES Edd E e eb gh tea 18 DECEI Tfimpot RANJE 2 qs us neta ea ect P ert AE 18 MAX Frimpot Range iem eee mo t
30. st be Revision A or newer RFI Filters and Chokes RFI Filters and Chokes are available to provide suppression for conducted radio frequency interference RFI They comply with the CE Directive 89 336 EEC relating to the EMC Class A Industrial Standard and Class B Residential Standard See RFI Filters and Chokes Selection Guide Publication No D 321 15 NOTES XI LIMITED WARRANTY For a period of 18 months from the date of original purchase KB Electronics Inc will repair or replace without 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 per sons 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 KB Electronics Inc is not responsible for any expense including instal lation 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 lim itations found in this warranty and therefore they may not apply to you In any event the total liability of KB Electronics Inc under any circumstance shall not exceed the full purchase price of this product rev 2 2000 Copyright 2002 by KB Electronics Inc All rights reserved In acc
31. t point is established by the setting of jumper J2 and the setting of the CL trimpot The CL trimpot is factory set for 150 of J2 range set ting as shown in Figure 28 For a higher current limit setting rotate the trimpot clockwise For a lower current limit setting rotate the trimpot counterclockwise Two modes of current lim iting operation are provided Non Timed Current Limit NTCL and Timed Current Limit TCL See Section IVC on page 11 CAUTION Adjusting the CL above 150 of motor rating can cause overheating and demagnetization of some PM motors Consult the motor manufacturer Do not leave the motor in a locked condition for more than a few seconds since armature damage may occur Timed Current Limit TCL Sets the time for the control to shut down after being in current limit provides electronic motor overload protection The TCL trimpot is factory set for 5 sec onds as shown in Figue 29 For increased TCL time rotate the trimpot clockwise For decreased TCL time rotate the trimpot counterclockwise If the control remains in CL for a predeter mined amount of time set by the TCL trimpot and if jumper J3 is in the TCL position the control will shut down To reset the control after it has shut down momentarily set the start stop switch to the START position or disconnect and then recon nect the AC line y 7 Warning When the control shuts down in TCL the AC line voltage is still pr
32. tch Run Stop Jog Switch Signal Isolator and Anti Plug Reversing Module Quick connect terminals are provid ed for easy installation of all optional accessories The control is available in black finish P N 8401 and FDA approved white finish P N 8402 STANDARD FEATURES Short Circuit Protection Protects control from a short circuit at motor connections Electronic Motor Burnout Protection Timed Current Limit shuts down the control if a pro longed overload condition exists Active Bridge Limits the AC line inrush current when power is turned on and also prevents high speed runaway if the power transistor shorts Heat Spreader Allows power transistor to operate safely during momentary overload condi tions Auto AC Line Select Control automatically adjusts for 115 or 208 230 Volt AC line input Start Stop Switch Provides electronic start and stop functions Diagnostic LEDs For power on ON stop STOP and motor overload OL Trimpots Provide adjustment for acceleration ACCEL deceleration DECEL maximum speed MAX minimum speed MIN jog speed JOG current limit CL timed current limit TCL and IR compensation IR Selectable Jumpers Provide settings for armature voltage or tach generator feedback J1 motor current J2 timed or non timed current limit J3 tach generator voltage J4 and run relay output J5 Barrier Terminal Blocks Facilitate wiring of AC line motor ar
33. ure Feedback Load Regulation Base Speed 1 Tach Generator Feedback Load Regulation Set Speed 1 Field Voltage at 115 Volts AC Line Input Volts DC 100 50 Field Voltage at 208 230 Volts AC Line Input Volts DC 200 100 Speed Range Ratio 50 1 Voltage Following Linearity Base Speed 0 5 1 For low current operation remove resistor R35 as described in section IVB on page 10 2 Step down operation FIGURE 1 CONTROL LAYOUT Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings START STOP SWITCH RED BLACK WHITE VIOLET ORANGE WHITE MAIN SPEED POTENTIOMETER 1 COM START INH2 INH STO lt 5 e To LED Board i START 8 a o com fe NC RELAY NO 1556999 BSc aS zl J7 ENABLE TACH RELAY EN 7V 50V BLU BLU WHT WHT ORN RED WHT BLK LIA LIB 12 128 b ____ 2 N2 3e gap TB2 F2 2 12 e view of FIGURE 2 MECHANICAL SPECIFICATIONS INCHES mm S3HOLIMS SOP dOLS NNY ANY A3821I88 QM IWNOILdO NMOHS 1OH LNOO
34. verride this function see Section on page 7 TABLE 1 ELECTRICAL RATINGS Maximum Horsepower 210 He Motor Voltage Lime Current Load Current TAN Field Voltage Volts AC Amps RMS Amps DC SCR Rated PWM Rated Volts DC Motors Motors 115 11 5 7 5 3 4 0 5 1 0 75 100 208 230 11 5 75 1 1 2 1 5 200 TABLE 2 GENERAL PERFORMANCE SPECIFICATIONS Parameter Specification Factory Setting Operating Frequency kHz gt 16 Operating Temperature Range at Full Rating 0 50 Current Range High Scale Amps DC 1 7 2 5 3 5 5 0 7 5 75 Current Range Low Scale Amps DC 1 0 2 0 3 0 4 0 5 0 8 ACCEL and DECEL Range Seconds 0 5 10 1 Jog Speed Base Speed 0 50 15 MIN Speed Range Base Speed 90VDC amp 180VDC Motors 0 30 0 MAX Speed Range Base Speed 90VDC amp 180VDC Motors 50 140 100 IR Comp Range at 90 Volts DC Output AVolts DC at Full Load 0 15 4 IR Comp Range at 180 Volts DC Output AVolts DC at Full Load 0 30 8 CL Range Range Setting 0 200 150 Timed Current Limit TCL Range Seconds 0 5 10 5 Line Input Voltage Volts AC 10 50 60 Hz 115 208 230 AC Line Regulation Base Speed 0 5 Armature Voltage Range at 115 Volts AC Line Input Volts DC 0 130 90 Armature Voltage Range at 208 230 Volts AC Line Input Volts DC 0 1302 0 260 90 Armat

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