Kb Electronics KBRC-240D User Manual

5 (1)
INSTALLATION AND OPERATING INSTRUCTIONS
MODEL KBRC-240D
FULL-WAVE 4-QUADRANT REGENERATIVE DRIVE
NEMA 4X, IP-65
KB Part No. 8840 (Black Case) • Part No. 8841 (White Case)
Rated for 1/10 - 1 HP (90 Volts DC) @ 115 Volts AC, 50/60 Hz
and 1/5 - 2 HP (180 Volts DC) @ 208/230 Volts AC, 50/60 Hz
Washdown and Watertight for Indoor and Outdoor Use
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.
!
TM
A COMPLETE LINE OF MOTOR DRIVES
© 2003 KB Electronics, Inc.
TM
OLSTOPON
MANUAL
START
STOP
AUTO
REGENERATIVE
DC MOTOR SPEED CONTROL
PENTA-DRIVE
TM
REV
FWD
NEMA-4X / IP-65
100
90
80
70
60
40
30
20
10
0
50
%
Pending
TABLE OF CONTENTS
Section Page
i. Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
II. Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
III. Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IV. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
V. Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . 17
VI. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VII. AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
IX. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
X. Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XI. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tables
1. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3. Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. Run Relay Output Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. Setting Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figures
1. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2. Enlarged View of Trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Full Voltage Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . 10
6. Half Voltage Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . 10
7. Unidirectional Forward Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . 11
8. Unidirectional Reverse Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . 11
9. Bidirectional Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10. Bidirectional Main Speed Potentiometer Connection with Reversing Contacts . . . . . . . . 12
11. Remote Start/Stop Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12. Start/Stop Function Eliminated (Jumper Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
13. Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14. Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ii
15. DC Tach-Generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16. DC Tach-Generator Connection with Addition of R
T
. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
17. AC Line Input Voltage Selection (J1 and J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
18. Motor Voltage Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
19. DC Tach-Generator Voltage Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
20. Motor Current Selection (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21. Analog Input Signal Voltage Selection (J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
22. Control Mode Selection (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
23. Torque Mode Selection (J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
24. Current Limit Mode Selection (J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
25. Stop Mode Selection (J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
26. Run Relay Output Mode Selection (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
27. Enable Jumper (J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
28. Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
29. Linear Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
30. Non-Linear Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
31. Offset (OFFSET) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
32. Offset (OFFSET) Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
33. Forward Acceleration (FACC) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
34. Reverse Acceleration (RACC) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
35. Forward Acceleration (FACC) and Reverse Acceleration (RACC) Trimpot Adjustment . . 19
36. Maximum Speed (MAX) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
37. Forward Current Limit (FWDCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
38. Reverse Acceleration (REVCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
39. IR Compensation (IR) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
40. Response (RESP) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
41. Deadband (DB) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
42. Deadband (DB) Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
43. Timed Current Limit (TCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
iii
4
i. SIMPLIFIED OPERATING INSTRUCTIONS
A. Power Connection –
Connect the AC line to L1 and L2 terminals of Terminal Block
TB1 and the ground wire (earth) to the green ground screw, as shown in Figure 4, on
page 10 and as described in Section IIA, on page 10 and Section IIB on page 10.
Be sure Jumpers J1 and J2 are both set to the corresponding AC line input voltage
position, as described in Section IIIA, on page 14.
B. Permanent Magnet (PM) Motor Connection (Two Wire Type) – Connect the motor
armature to M1 (+) and M2 (-) terminals of Terminal Block TB1, as shown in Figure
4, on page 10 and as described in Section IIC, on page 10. Be sure that Jumper J3
is set to the corresponding motor voltage position, as described in Section IIIB, on
page 14 and Jumper J4 is set to the corresponding motor current, as described in
Section IIID, on page 15.
Note: Do not use F+ and F- terminals of Terminal Block TB2 for any purpose other
than to power the field of a shunt wound motor. Do not use F+ and F- terminals of
Terminal Block TB2 for PM motors. Do not use F1 and F2 quick-connect terminals
for any purpose other than to power the optional Signal Isolator SIRC (P/N 8842).
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
Volt DC motors).
C. Shunt Wound Motors (Four Wire Type) Connect the motor armature as described
in Section IIC, on page 10.
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 F+ and F- terminals of Terminal Block TB2, as
described in Section IID, on page 10.
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 F+ terminal of Terminal Block TB2 and L1 ter-
minal of Terminal Block TB1, as described in Section IIE, on page 11.
Note: Do not connect motor armature leads to F+ and F- terminals of Terminal Block
TB2 or to F1 and F2 quick-connect terminals. Do not use F1 and F2 quick-connect
terminals for any purpose other than to power the optional Signal Isolator SIRC (P/N
8842).
D. Start/Stop Switch The control is supplied with a prewired Start/Stop Switch, as
described in Section IIG, on page 12. This switch must be used to start the control
each time the AC power is lost or the control shuts down in TCL. To eliminate this
function, see Section IIG, on page 12.
E. Motor Current Jumper J4 is factory set for 10 Amp motors. For a lower current
motor, set Jumper J4 to the corresponding motor current, as described in Section
IIID, on page 15.
Note: The factory setting for Current Limit is 150% of the nominal current setting
(example: if Jumper J4 is set to the “10A” position, the CL trimpot is calibrated for 15
Amps).
F. Trimpot Settings – All trimpots have been factory set, as shown in Figure 2, on page
7. Trimpots may be readjusted, as described in Section VIII, on page 19.
G. Diagnostic LEDs – After power has been applied, observe the LEDs to verify prop-
er control function, as described in Section IX, on page 22.
IMPORTANT You must read these simplified operating instructions before pro-
ceeding. 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 5, before proceeding.
5
I. INTRODUCTION
Thank you for purchasing the KBRC-240D. KB Electronics, Inc. is committed to providing
total customer satisfaction by producing quality products that are easy to install and operate.
The KBRC-240D is manufactured with surface mount components incorporating advanced
circuitry and technology.
The KBRC-240D is a Full-Wave Regenerative Drive in a NEMA-4X / IP-65 washdown and
watertight enclosure. It is designed to operate 90 and 180 Volt Permanent Magnet and Shunt
Wound DC motors in a bidirectional mode. It provides 4-quadrant operation, which allows
forward and reverse torque in both speed directions. This allows the control to maintain con-
stant speed with overhauling loads and provides rapid instant reversing and controlled brak-
ing. Because of its excellent performance, the control can replace servo drives in many appli-
cations.
The KBRC-240D has a Regeneration Overspeed Protection Circuit, which prevents failure of
the power bridge in extreme overhauling conditions. Motor overload protection (I X t) will shut
down the control if the motor is overloaded for a predetermined amount of time. The exclu-
sive Auto-Inhibit
®
circuit allows safe, smooth starting during rapid cycling of the AC line.
Due to its user-friendly design, tailoring the KBRC-240D to specific applications is easily
accomplished via selectable jumpers and adjustable trimpots. However, for most applica-
tions, no adjustments are necessary.
The KBRC-240D can be operated from a two or three wire start/stop circuit or can be start-
ed from the AC line. A set of dedicated normally open or normally closed relay contacts are
provided (Run Relay), which are activated via the start/stop circuit. They can be used to turn
on or off equipment or to signal a warning if the control is put into Stop Mode or times out in
TCL.
The Main features of the KBRC-240D include Speed (SPD) or Torque (TRQ) control modes.
In the Linear Torque mode (S/L), speed and torque vary linearly as a function of Main Speed
ii. SAFETY WARNING! Please read carefully
This product should be installed and serviced by a qualified technician, electrician, or elec-
trical maintenance person familiar with its operation and the hazards involved. Proper instal-
lation, which includes wiring, mounting in proper enclosure, fusing or other over current pro-
tection, and grounding can reduce the chance of electrical shocks, fires, or explosion in this
product or products used with this product, such as electric motors, switches, coils, solenoids,
and/or relays. Eye protection must be worn and insulated adjustment tools must be used
when working with control under power. This product is constructed of materials (plastics,
metals, carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding
and filtering of this product can reduce the emission of radio frequency interference (RFI)
which may adversely affect sensitive electronic equipment. If further information is required
on this product, contact the Sales Department. It is the responsibility of the equipment man-
ufacturer and individual installer to supply this Safety Warning to the ultimate end user of this
product. (SW effective 9/2000).
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.
!
This product complies with all CE directives pertinent at the time of manufacture.
Contact factory for detailed installation and Declaration of Conformity. Installation of a
CE approved RFI filter (KBRF-200A [P/N 9945C] or equivalent) is required. Additional shield-
ed motor cable and/or AC line cables may be required along with a signal isolator (SIRC [P/N
8842] or equivalent).
6
Potentiometer rotation or input signal. In the Non-Linear Torque mode (NL), the torque is var-
ied by the Main Speed Potentiometer or input signal, and remains constant throughout the
motor’s entire speed range. In addition, Regenerate-to-Stop (RTS) or Coast-to-Stop (CTS)
stop modes are also provided.
Standard front panel features of the KBRC-240D include diagnostic LEDs (for Power On,
Stop and Overload), a Start/Stop Switch and a Main Speed Potentiometer. Other features
include Barrier Terminal Blocks (facilitates wiring of the AC line, motor armature and field,
tach-generator and run relay), adjustable trimpots (OFFSET, FACC, RACC, MAX, FWDCL,
REVCL, IR, RESP, DB and TCL), selectable jumpers (AC line voltage, motor voltage or tach
feedback, motor current, analog input voltage, control mode, torque mode, current limit
mode, stopping mode, run relay output contacts and enable) and PC Board mounted LEDs
(Power On, Overload, Forward Enable and Reverse Enable).
Optional accessories for the KBRC-240D include a Forward-Stop-Reverse Switch,
Auto/Manual Switch, Power On/Off Switch and a Signal Isolator. Quick-connect terminals are
provided for easy installation of all accessories. See Section X, on page 22.
10
Parameter Specification
Forward Acceleration Trimpot (FACC) Range (Seconds)
Forward Current Limit Trimpot (FWDCL) Range (% Range Setting)
Factory
Setting
AC Line Input Voltage (Volts AC, ±10%, 50/60 Hz) 115 and 208/230
Armature Voltage Range at 115 Volts AC Line (Volts DC) 0 – ±90
230
Armature Voltage Range at 208/230 Volts AC Line (Volts DC)
0 – ±90
1
, 0 – ±180
0 – ±180
Field Voltage at 115 Volts AC Line (Volts DC) 100/50
Field Voltage at 208/230 Volts AC Line (Volts DC) 200/100
Signal Following Input (Non-Isolated
2
) Range (Volts DC)
0 – ±10, 0 – ±15 0 – ±15
Signal Following Linearity (% Base Speed) 1
Line Regulation (% Base Speed) ±0.5
Armature Feedback Load Regulation (% Base Speed) ±1
Tach-Generator Feedback Load Regulation (% Set Speed) ±1
150
Maximum Load Capacity (% for 2 Minutes) 150
Current Ranges (Amps DC) 1.7, 2.5, 5, 7.5, 10
Speed Range (Ratio) 50:1
Operating Temperature Range (°C) 0 – 45
Offset Trimpot (OFFSET) Range (% Base Speed) 0 – ±10 0
Reverse Acceleration Trimpot (RACC) Range (Seconds) 0.2 – 15 1
0.2 – 15 1
0 – 200
Reverse Current Limit Trimpot (REVCL) Range (% Range Setting) 0 – 200 150
IR Compensation Trimpot (IR) Range at 90 Volts DC Output (Volts DC at Full Load) 0 – 15
IR Compensation Trimpot (IR) Range at 180 Volts DC Output (Volts DC at Full Load) 0 – 30 10
TABLE 1 – GENERAL PERFORMANCE SPECIFICATIONS
Maximum Speed Trimpot (MAX) Range (% Base Speed) 70 – 110 100
Deadband Trimpot (DB) Range (% Base Speed) 0 – ±3 0.5
Timed Current Limit Trimpot (TCL) Range (Seconds) 0 – 15 5
TABLE 2 – ELECTRICAL RATINGS
1, (0.75)
Maximum
Horsepower Rating
HP, (kW)
AC Line Input Voltage
(±10%, 50/60 Hz)
(Single Phase Volts AC)
Maximum Output
Load Current
(Amps DC)
115
Maximum AC Line
Input Current
(Amps AC)
15
Nominal Output
Voltage
(Volts DC)
0 – ±90 11
208/230
208/230
15
15
0 – ±180
0 – ±90
1
11
11
2, (1.5)
1, (0.75)
Notes: 1. Step-down operation: Motor may have reduced brush life. Consult motor manufacturer.
2. Requires an isolated signal. If a non-isolated signal is used, install the Signal Isolator SIRC (P/N 8842).
Note: 1. Step-down operation: Motor may have reduced brush life. Consult motor manufacturer.
7
TCLDBIR RESPFWDCLMAXRACC FACCOFFSET REVCL RELAYT- T+
TB3
J10
NO
NC
J8TCL
LED BOARD
PWR ON
OL
EN
EN
REV
FWD
NTCL
CON1
J5
15V
10V
STOP
CL
ON
G
B
Y
R
J7
S/L
NL
J6
J4
10A
SPD
T50
T7
A90
A180
1.7A
5A
2.5A
7.5A
TRQ
J3
J9
CTS
RTS
EN
J11
J1
J2
230V
KBRC
115V 230V 115V
L1BL1A
L2BL2A
L2
L1
F-
M1 M2F+
TB1
F2
F1
TB2
RET STOP-15V SIGCOMEN COM +15V START
FIGURE 1 – CONTROL LAYOUT
(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)
TCLDBIR RESPFWDCLMAXRACC FACCOFFSET REVCL
FIGURE 2 – ENLARGED VIEW OF TRIMPOTS
8
TM
RECOMMENDED MOUNTING SCREW: 1/4" (M6)
[127.00]
5.000
[138.99]
5.472
[149.50]
5.886
[9.07]
0.357
[208.94]
8.226
[225.45]
8.876
[241.00]
9.488
KBRC-240D SHOWN WITH OPTIONAL
FORWARD-BRAKE-REVERSE AND AUTO/MANUAL SWITCHES
OLSTOPON
MANUAL
START
STOP
AUTO
REGENERATIVE
DC MOTOR SPEED CONTROL
PENTA-DRIVE
TM
REV
FWD
NEMA-4X / IP-65
100
90
80
70
60
40
30
20
10
0
50
%
FIGURE 3 – MECHANICAL SPECIFICATIONS (Inches / [mm])
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