Kb Electronics KBPC-225 User Manual

INSTALLATION AND OPERATING INSTRUCTIONS

KBPC-225

SCR SPEED AND TORQUE CONTROL

NEMA 4X, IP-65

DESIGNED FOR SHUNT WOUND & PM DC MOTORS

RATED 3 HP @ 180 VDC

See Safety Warning on Page 3

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.

(Shown with optional Run-Stop-Jog Switch)

A COMPLETE LINE OF MOTOR DRIVES

TABLE OF CONTENTS

Section Page

i. Safety Warning .........................................................3

ii. Simplified Operating Instructions ............................................3

I. General Information .....................................................3

II. Setting Speed or Torque Mode of Drive (Jumper J1) ............................6

III. Setting Selectable Jumpers ...............................................6

IV. Mounting ..............................................................7

V. Wiring ................................................................8

VI. Fusing ...............................................................10

VII. Operation ............................................................11

VIII. Trimpot Adjustments ....................................................11

IX. Function Indicator Lamps ................................................12

X. Optional Accessories ...................................................13

XI. Limited Warranty .......................................................20

TABLES

1. Electrical Ratings .......................................................4

2. General Performance Specifications .........................................4

3. Field Connections (Shunt Wound Motors Only) ................................8

4. Parts List ............................................................16

FIGURES

1. Control Layout .........................................................5

2a. Motor Speed vs. Potentiometer Rotation ......................................6

2b. Preset Motor Speed vs. Motor Load .........................................6

3a. Motor Output Torque vs. Potentiometer Rotation ...............................6

3b. Motor Speed vs. Applied Motor Load ........................................6

4a. Captive Screw Tightened In Case ...........................................8

4b. Captive Screw Engaged In Front Cover ......................................8

5. Connection Diagram .....................................................8

6a. Full Voltage Field .......................................................9

6b. Half Voltage Field .......................................................9

7. Tachometer Connection Diagram ...........................................9

8a. Remote Potentiometer Connection .........................................10

8b. Analog Voltage Connection ...............................................10

9. Remote Start/Stop Switch Connection ......................................10

10a. Inhibit Circuit Wiring ....................................................10

10b. Enable Circuit Wiring ...................................................10

11. Mechanical Specifications ................................................14

12. Schematic ............................................................15

13. Internal Connection Diagram ..............................................17

14. Connection Diagrams KBPC-225 With KBSI-240D (Signal Isolator) ................18

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 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 effective 11/92)

This control contains electronic 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 input circuits of this control (potentiometer, start/stop, Inhibit) are 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.

This product complies with all CE directives pertinent at the time of manufacture. Contact

of a CE approved RFI filter (KBRF-200, KB P/N 9945 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).

factory for detailed installation instructions and Declaration of Conformity. Installation

ii. KBPC-225 SIMPLIFIED OPERATING INSTRUCTIONS

IMPORTANT – You must read these simplified operating instructions before you proceed. 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 before proceeding.

1. Connections.

A. AC Line. Wire AC line voltage (230 VAC - 50/60 Hz) to terminals L1 and L2. Connect ground

wire (earth) to Green Screw on case.

B. Motor.

a. Permanent Magnet (PM) Type: Connect motor armature leads to terminals A1(+) and

A2(–).

b. Shunt Wound Motors: Connect motor armature as above. Connect full voltage shunt field

wires (180 volt motors with 200 volt fields) to F1 and F2. Connect half voltage field wires (180 volt motors with 100 volt fields) to F1 and L1.

2. Speed or Torque Mode – Jumper J1 is factory set for speed control operation ("SPD"). For

torque control, set J1 to "TRQ" position.

3. Trimpot Settings – All trimpots have been factory set in accordance with Fig. 1 and Table 2.

4. Diagnostic LEDs – After power is turned on, observe LEDs to verify proper control function.

5. Fusing – Install 25 amp - 250 VAC fuses in both the AC Line and armature leads. See Section

VI (p. 10, 11).

I. GENERAL INFORMATION.

The KBPC Series Nema 4 X (IP-65) is a unidirectional SCR DC Motor Speed and Torque Control designed for applications requiring watertight integrity, including washdown. Its housing is ruggedly constructed of die cast aluminum, protected with an acrylic coating that provides excellent corrosion resistance. All switches are sealed with rubber boots and the main speed potentiometer contains a shaft seal.

The electronics for the KBPC is state-of-the-art and includes short circuit and transient protection which provides the ultimate in reliability. Electronic overload protection prevents motor burnout and demagnetization of PM motors. The control can be operated in either the Speed or Torque mode via jumper selection.

Standard features include electronic start/stop and an LED indicator array for Power On, Stop and Overload.

Although the KBPC is factory set for most applications, a variety of trimpots allow adjustment of the following parameters: Minimum and Maximum Speed, Acceleration, Deceleration, Current Limit, IR Comp, and Timed Current Limit. Optional features offered are: Run-Stop-Jog, and Input Signal Isolation.

TABLE 1 – ELECTRICAL RATINGS

Model

Number

KBPC-225 230 0 – 200 22.0 15 3 (2.25)

Input Line

Voltage

(VAC-50/60Hz)

Armature

Voltage

(VDC)

Maximum Ac

Load Current

(RMS Amps)

Maximum DC Load Current

(DC AMPS)

Maximum

Power HP (KW)

TABLE 2 – KBPC-225 GENERAL PERFORMANCE SPECIFICATIONS

PARAMETER (units) SPECIFICATIONS

AC Line Input (VAC ± 15%, 50/60 Hz) 230 —

Horsepower at 230 VAC Line (HP) [KW] 3 [2.25] —

Armature Voltage Range at 230 VAC Line (VDC) 0 - 200

Field Voltage at 230 VAC Line (VDC) 200/100

Ambient Temperature Range (ºC) 0 - 45 —

Speed Range (Ratio) 50:1

Load Regulation [Armature Feedback] (% Base Speed) ±1 —

Load Regulation [Tachometer Feedback] (% Set Speed) ±1 —

AC Line Voltage Regulation ( % Base Speed) ±0.5 —

ACCEL and DECEL Ranges (Seconds) 0.1 - 15 1

(1)

(2)

(3)

FACTORY

SETTING

180 VDC

—

MIN SPEED Range ( % Base Speed) 0 - 30 0

MAX SPEED Range (% Base Speed) 60 - 120 90

IR COMP Range at 230 VAC Line (VDC) 0 - 30 8

CL Range ( % Range Setting) 0 - 180 150

Timed CL Range (Seconds) 0.5 - 15 7

Voltage Following Linearity (% Base Speed) ±0.5

Notes:

(1) Maximum recommended output voltage is 180 VDC at 230 VAC. Exceeding this output

voltage will cause a reduction in load regulation performance. (2) For shunt wound motor with lower field voltage, use F1 and L1 connection. (3) Consult motor manufacturers for constant torque speed range of motor. (Typical speed

range for most 3 HP motor is 20:1)

—

FIG. 1 – CONTROL LAYOUT

Illustrates Approximate Factory Setting of Jumpers and Trimpots

STOP OL

SPDTRQ

CONN1

LED BOARD

TB3

START

COM

STOP

JOG

DECEL ACCEL

TT+

50V 20/30V 7V

KBPC

NTCLTCL

TCL

JOG

MAXMIN

5V10V

180V 90V T

R69

TB2

F+

F2F1

A1 A2 L1 L2

A1B J8A A1A

A2B J8B A2A

(1)

GND

(EARTH)

TB1

DWG#: B2800-1-00890

II. SETTING SPEED OR TORQUE MODE OF DRIVE (JUMPER J1)

A. Speed Control Mode – When Jumper J1 is placed in the "SPD" position the drive will

control motor speed as a linear function of the main potentiometer rotation or analog voltage input. The range of output speed can be adjusted with the MIN and MAX trimpots. The motor will maintain the preset speed as long as the maximum load does not exceed the current limit set point. If the motor load exceeds the current limit setting, the Overload LED will turn on and the motor will stall.

FIG. 2A – MOTOR SPEED vs.

POTENTIOMETER ROTATION

100

MOTOR

OUTPUT

SPEED

(%)

POTENTIOMETER ROTATION (%)

100

FIG. 2B – PRESET MOTOR SPEED vs.

MOTOR LOAD

100

PRESET

MOTOR

SPEED

(%)

100

MOTOR LOAD

150

CURRENT LIMIT STARTS LED LIGHTS

B. Torque Control Mode – When Jumper J1 is placed in the "TRQ" position, the drive will

control motor torque as a linear function of main potentiometer rotation. If the motor load exceeds the torque setting, the motor will stall, the Overload LED will light, and the drive will apply a constant preset torque based on the potentiometer setting. The Overload LED will light when the load torque approaches the current limit set point. The torque limits are set via the CL trimpot. Note: When operating in the Torque Mode, Jumper J5 must be in the "NTCL" position or drive will shut down when CL Timer times out.

FIG. 3A – MOTOR OUTPUT TORQUE vs.

POTENTIOMETER ROTATION

150

FIG. 3B – MOTOR SPEED vs. APPLIED

MOTOR LOAD

100

HIGHER TORQUE SETTING

TORQUE SETTING

100

MOTOR OUTPUT TORQUE

(%)

MOTOR

SPEED

(%)

LOWER TORQUE

POTENTIOMETER ROTATION (%)

100

SETTING

APPLIED MOTOR LOAD (%) TORQUE

III. SETTING SELECTABLE JUMPERS

This control has selectable jumpers which can be changed to accommodate various applications. Note: Jumpers J2 and J4 have not been installed in this control. Jumper J1

is set in accordance with Section II. Refer to Figure 1. C. Tachometer Feedback (J3) – The control is factory set for armature feedback which

provides good load regulation for most applications. If superior load regulation is required, tachometer feedback can provide over 1% load regulation over a 50:1 speed range. If tachometer feedback is to be used, J3 must be placed in the "TFB" position and an external DC tachometer must be connected. See Sections III C. (p. 7) and V E. (p. 9) for additional information. Note: IR Comp trimpot must be turned to minimum position (full ccw).

+ 11 hidden pages