KB Electronics KBRG-212D User Manual

INSTALLATION AND OPERATION MANUAL

REGENERATIVE DRIVE

MODEL KBRG-212D

Part No. 8819

VARIABLE SPEED SCR CONTROL

FULL WAVE 4–QUADRANT

M1M2L2L1

F-F+

Warning, on page 5.

However, the manufacturer retains the right to make changes in design, which may not be included herein.

See Safety

The information contained in this manual is intended to be accurate.

RoHS

(see back cover)

Section

Page

1 Quick-Start Instructions.........................................................................4

2 Safety Warning .....................................................................................5

3 Introduction ...........................................................................................6

4 Important Application Information .........................................................12

5 Mounting Instructions ............................................................................ 12

6 Electrical Connections........................................................................... 13

7 Setting Selectable Jumpers / Connector............................................... 19

8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot) ..... 23

9 Drive Operation ..................................................................................... 24

10 Trimpot Adjustments ............................................................................. 25

11 Diagnostic LED’s................................................................................... 30

12 Troubleshooting ....................................................................................30

TABLE OF CONTENTS

Limited Warranty ..................................................................... Back Cover

Table Page

1 Standard Features ................................................................................ 7

2 Selectable Jumpers............................................................................... 7

3 Trimpot Adjustments .............................................................................8

4 Electrical Ratings .................................................................................. 9

5 General Performance Specifications..................................................... 9

6 Terminal Block Wiring Information ........................................................ 13

7 Armature Fuse Chart............................................................................. 14

8 Field Connection ...................................................................................15

9 Jumper J2 Setting vs. Motor Horsepower ............................................. 19

10 Summary of Control (Regen) Operation ...............................................25

11 Troubleshooting Guide.......................................................................... 30

Figure Page

1 Control Layout ............................................. ......................................... 10

2 Mechanical Specifications........................... ......................................... 11

3 AC Line and Armature Connection ............. .........................................14

4 Full Voltage Field ........................................ .........................................15

5 Half Voltage Field........................................ ......................................... 15

6A Unidirectional Operation (Forward) ............. ......................................... 16

6B Unidirectional Operation (Reverse)............. ......................................... 16

6C Bidirectional Operation Reversing Contact . ......................................... 16

6D Bidirectional with Potentiometer.................. ......................................... 16

7A Voltage Following........................................ ......................................... 17

7B Current Following........................................ ......................................... 17

7C J17 Voltage Scale ....................................... ......................................... 18

7D J8 Current Scale ......................................... ......................................... 18

8A Enable Mode............................................... .........................................18

8B Inhibit Mode................................................. .........................................18

9 J1 Tach-Generator Connection................... ......................................... 19

10 J2 Armature Current Jumper ...................... ......................................... 19

11A J3 Armature Voltage (90V).......................... ......................................... 20

11B J3 Armature Voltage (180V)........................ ......................................... 20

12 J5 Speed /Torque........................................ ......................................... 20

13 Speed Mode vs. Motor Load ....................... ......................................... 20

14 Motor Speed vs. Applied Motor Load (Torque Mode) ........................... 21

15 J6 CTS / RTS Jumper ................................. .......................................2

Figure

Page

16 J8 15V / 10V Jumper .................................. .......................................22

17A J17 Analog Signal Input (Voltage Position). ....................................... 22

17B J17 Analog Signal Input (Current Position) . ....................................... 22

18 J9 Enable / Inhibit Jumper .......................... .......................................22

19 Typical Hi-Pot Test Setup ........................... .......................................24

20A Forward and Reverse Acceleration Trimpot Position............................ 26

20B ACCEL Trimpot Adjustment ........................ ....................................... 26

21 Maximum Speed Trimpot Position .............. .......................................26

22A Forward Current Trimpot Position ............... ....................................... 27

22B Reverse Current Trimpot Position............... .......................................27

23 IR Compensation Trimpot Position ............. .......................................27

24 Response Trimpot Position ......................... .......................................28

25A Deadband Trimpot Position......................... ....................................... 28

25B Deadband Trimpot Adjustment ................... .......................................28

26A Offset Trimpot Position................................ ....................................... 29

26B Offset Trimpot Adjustment .......................... .......................................29

27A Scale Trimpot Position ................................ ....................................... 29

27B Scale Trimpot Adjustment ........................... .......................................29

TABLE OF CONTENTS (Continued)

1 QUICK-START INSTRUCTIONS

Important: You must read these simplified instructions before proceeding. These instructions

are to be used as a reference only and are not intended to replace the details provided herein. You must read the SAFETY WARNING, on page 5, before proceeding.

1.1. Connections (See Figure 3, on page 14).

Note: There are no AC Line or Armature fuses supplied with this control. See Section,

1.1.2.

1.1.1 AC Line – Connect AC line voltage (115 or 230 VAC) to terminals L1 and L2.

Connect ground wire (earth) to the green ground screw.

1.1.2 Fusing – The KBRG-212D does not contain AC line or armature fusing. It is

recommended that a 20 Amp fuse or circuit breaker be installed on each AC line conductor not at ground potential. Do not fuse ground or neutral wires.

1.1.3 Ground Connection – Earth ground the control chassis using the green ground

screw that is provided on the control,s heat sink (near TB2).

1.1.4 Motor (See Figure 3, on page 14).

a. Permanent Magnet (PM Type). Connect motor armature leads to M1+ and

M2-.

Note: Motor performance and efficiency, including brush life, can be adversely affected

when using 90 volt motors with a 230 VAC line. Contact motor manufacturer for derating information.

b. Shunt Wound Motors. Connect motor armature leads as above. Connect

full voltage shunt field leads (90 volt motors with 100 volt fields and 180 volt with 200 volt fields) to F+ and F-. Connect half voltage field leads (90 volt motors with 50 volt fields and 180 volt motors with 100 volt fields) to F+ and L1.

1.2 ENABLE/INHIBIT– The control can be electronically stopped and started with this circuit

function. To “Stop” the control, Terminals must be connected in the required position, by selecting the type of mode, via J9. See Figure 8B and Section 6.10, on page 18.

In the Enable Mode, the control can also be started and stopped with an Enable circuit

(the Enable circuit functions opposite to that of the inhibit circuit; Inhibit: open to start, close to stop, Enable: open to stop, close to start). The Enable function can also be established by wiring a contact in series with the high side of the Main Speed Potentiometer lead connected to Terminal P3. See Figure 8A and Section 6.10, on page

18.

1.3 SPEED OR TORQUE MODE: Jumper J5 is factory set for Speed (SPD) control operation.

For torque control, set J5 to the Torque (TRQ) position. See Section 7.3, on page 20.

1.4 JUMPER SETTINGS: All jumpers are set for the KBRG-212D version. The control is factory jumpered for the Enabled mode. See Section 7, on page 19.

1.5 TRIMPOT SETTINGS – All trimpots have been factory set. See Figure 1, on page 10 and Section 10, on page 25.

1.6 SIGNAL INPUT – Connect potentiometer or analog input to TB1, terminals “-15,” “+15” “SIG,” and “COM” according to Section 6, on page 16.

2 SAFETY WARNING

Definition of Safety Warning Symbols

Electrical Hazard Warning Symbol: Failure to observe this warning could result in

electrical shock or electrocution.

Operational Hazard Warning Symbol: Failure to observe this warning could result in

serious injury or death.

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 electrical connections, mounting and adequate enclosure, fusing or other current protection, and grounding can reduce the chance of electrical shocks, and/or fires in this product or products used with this product, such as electric motors, switches, coils, solenoids, and/or relays. Do not use this drive in an explosion-proof application. Eye protection must be worn and insulated adjustment tools must be used when working with drive 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. The input circuits of this drive may not be isolated from the AC line. Be sure to read and follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product.

The drive may contain electronic start/stop circuits, which are used for "Start" and "Stop" functions. 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.

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 7/2009)

SAFETY WARNING! Please read carefully before proceeding.

This product complies with all CE directives pertinent at the time o manufacture. Contact our Sales Department for Declaration of Conformity. Installation of a CE approved RFI filter is required. Additional shielded cable and/or AC line cables may be required along with a signal isolator.

3 INTRODUCTION

Thank you for purchasing the KBRG-212D. KB Electronics is committed to providing total customer satisfaction by producing quality products that are easy to install and operate. The KBRG-212D is manufactured with Surface Mount Technology (SMT), incorporating advanced circuitry, components and technology.

The KBRG -212D has an Enable (EN) / Inhibit (INH) mode. The 212D version is factory set (J9 jumper) to Enable (EN). If the user requires the 213D Inhibit (INH) mode, the jumper, J9, is moved to that position.

The KBRG-212D is a full-wave regenerative drive capable of operating DC PM (Permanent Magnet) or Shunt motors in a bidirectional mode. Its 4-quadrant operation provides forward and reverse torque in both speed directions. This allows the control to maintain constant speed with overhauling loads and provides rapid instant reversing and controlled braking. Because of its excellent controllability and response time, the KBRG-212D can replace servos in many applications. The control is factory set for armature feedback, which can provide 1% load regulation over a motor base speed of 50:1. However, tachometer feedback is also available if superior regulation is required. By resetting mode jumper J5 to the “TRQ” position, the KBRG-212D can be changed from a speed control to a torque control.

In addition, the KBRG-212D is used to isolate, amplify, and condition DC voltage signals from any external source (power supplies, motors, tachometer generators, transducers, and potentiometers). The KBRG-212D also provides isolation for motor direction switching and an isolated power supply for transducer or potentiometer operation.

All input and signal connections are made via Terminal blocks and are electrically isolated from AC line and motor wiring.

The KBRG -212D features an Enable (EN) and Inhibit (INH) function (J9). Having both these features allows the drive to be used in applications that previously used the KBRG-212D (Enable) or the KBRG-213D (Inhibit). The control can be electronically stopped and started with the Enable / Inhibit circuit. (The Enable circuit functions opposite to that of the inhibit circuit; Inhibit: open to start, close to stop, Enable: open to stop, close to start).

The drive contains a variety of “selectable” jumpers and adjustment trimpots to allow for custom tailoring for exact requirements.

Another important feature is the LED indicators (PWR ON, OL), which indicate the mode of operation the drive is in, and also serves as a diagnostic tool.

Reliability of the KBRG-212D is further enhanced with the use of high speed current limiting and MOV transient protection. A 5kΩ remote potentiometer and full operating instructions are supplied. See Figures 1 and 2, on pages 10 and 11. In addition, see Tables 1 – 6, on pages 7 – 9.

OR ELECTROCUTION CAN RESULT DUE TO IMPROPER USE OF THIS PRODUCT. READ

WARNING! BE SURE TO FOLLOW ALL INSTRUCTIONS CAREFULLY. FIRE

SAFETY WARNING ON PAGE 5.

TABLE 1 – STANDARD FEATURES

Feature Description

Terminal Blocks

(See Section 6, on page 13.)

Connectors

(See Section 7, on page 19.)

Facilitates wiring of AC line, motor armature and field, TB1 (-15V, +15V, SIG, COM, EN), TB2 (L1, L2, M2, M1), TB3 (F+, F-). J1, Tach-Generator Input – Connection point for an external Tach-Generator. J2 - Motor Armature Current J3 - Motor Armature Voltage

Selectable Jumpers

(See Section 7, on page 19.)

J5 -SPD / TRQ – (Speed / Torque) J6 -CTS/RTS – (Coast to Stop / Regenerate to Stop) J8 -Signal Input Source (15V or 10V) J9 - Enable (EN) / Inhibit (INH) J17- Analog Signal Input (Voltage/Current) Provide adjustment for Forward Acceleration (FACC), Reverse

(See Section 10, on page 25.)

Trimpots

Acceleration (RACC), Maximum (MAX), Forward Current Limit (FCL), Reverse Current Limit (RCL), IR Compensation (IR), Response (RESP), Deadband (DB), Offset (OFFSET), and Scale (SCALE).

Diagnostic LEDs

(See Section 11, on page 30.)

For Power On (ON), and Current Limit (OL) indications. (Current Overload gives indication that the control will trip).

TABLE 2 – SELECTABLE JUMPERS (See Section 7, on page 19)

Feature Description

J2-Motor Current, Refer to Section 7.1, on page

19. J3 – Motor Armature Voltage, Refer to Section

7.2, on page 20. J5-SPD / TRQ, Speed or Torque, Refer to

Section 7.3, on page 20.

J6-CTS/RTS. Refer to Section 7.4, on page 21.

J8-Signal Input (15V or 10V). Refer to Section

7.5, on page 22.

J17-Signal Input. Refer to Section 7.6, on page

22.

J9-EN (Enable) / INH (Inhibit). Refer to Section

7.7, on page 22.

For selection of the motor current being used.

For selection of the motor voltage being used.

Jumper position is selectable for either Speed (SPD) or Torque (TRQ) modes.

For selection of Coast to Stop (CTS) and Regenerate to Stop (RTS). Works in conjunction with the Enable circuit.

Used for selection of potentiometer (15V) or use if the control is to be used from a 0 – ±10/±15VDC.

Input signal connection for the use with the Main Speed Potentiometer. Used for accepting a 0 – ±10V or 0 – ±25V signal or 4 – 20 ma.

For selection of electronically starting and stopping the motor. Used in conjunction with J6, CTS/RTS.

TABLE 3 – TRIMPOT ADJUSTMENTS (See Section 10, on pages 25)

Trimpot Description

Sets the amount of time for the motor to

Forward Acceleration (FACC). Refer to Section

10.1, page 25.

Reverse Acceleration (RACC). Refer to Section

10.1, on page 25.

Maximum Speed (MAX SPD). Refer to Section

10.2, on page 26.

Forward Current Limit (FCL). Refer to Section

10.3, on page 26. *

Reverse Current Limit (RCL) Refer to Section

10.3, on page 26. *

IR Comp (IR COMP). Refer to Section 10.4, page 27. Response (RESP). Refer to Section 10.5, on page 28.

Deadband (DB). Refer to Section 10.6, on page

28.

Offset (OFFSET). Refer to Section 10.7, on page 29.

Scale (SCALE). Refer to Section 10.8, on page

29.

* FCL and RCL also determine the maximum amount of regenerative breaking torque depending on which direction is braking.

accelerate from zero speed to full speed in the forward direction and the time it takes to decelerate in the reverse direction (FACC = Reverse Deceleration). Factory adjusted to 1 second. (Maximum of 15 seconds). Sets the amount of time for the motor to accelerate from zero speed to full speed in the reverse direction and the time it takes to decelerate in the forward direction (RACC = Forward Deceleration). Factory adjusted to 1 second. (Maximum of 15 seconds).

The MAX trimpot is used to set the maximum output voltage of the control which, in turn, sets the maximum speed of the motor. In the Torque Control Mode. The MAX trimpot setting

determines the unloaded motor speed. Sets the maximum amount of DC current that the motor can draw. This determines the amount of maximum motor torque in both the Speed Control Mode and Torque Mode. Sets the maximum amount of DC current that the motor can draw. This determines the amount of maximum motor torque in both the Speed Control Mode and Torque Mode. The IR Comp is used to stabilize motor speed under varying loads. This trimpot determines the dynamic response of the control. The DB trimpot sets the amount of main speed potentiometer rotation required to initiate control voltage output. It is factory set to approximately 0%. The DB trimpot also determines the amount of delay that will occur before regeneration starts. This trimpot determines the amount of bias in the forward or reverse direction. The trimpot is factory set to provide approximately zero offset, which means neither the forward nor the reverse speed is favored. This trimpot works in conjunction with the MAX potentiometer for fine tuning of the (voltage or current) of the incoming analog signal.

TABLE 4 B ELECTRICAL RATINGS

Input Voltage

(VAC)

115 12 0 – ±90 7.5 ¾, (0.5)

208/230 12 0 – ±180 7.5 1.5, (1)

AC Line Input Voltage (VAC, ±10%, 50/60 Hz) 115 or 208/230 208/230

Armature Voltage Range at 115 VAC Line (VDC) 0 – ±90 —

Armature Voltage Range at 230 VAC Line (VDC) 0 – ±90, 0 – ±180 0 – ±180

Maximum AC

Line Current (Amps RMS)

TABLE 5 B GENERAL PERFORMANCE SPECIFICATIONS

Parameter

Field Voltage at 115 VAC Line (VDC) 100 / 50

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

Max Load Capacity (% for 2 Minutes) 150 —

Ambient Temperature Range (ºC / °F) 0 – 40 / 32 – 104 —

Speed Range (Ratio) 50:1 —

Arm Feedback Load Regulation (% Base Speed) ±1 —

Tach Feedback Load Regulation (% Set Speed) ±1 —

AC Line Regulation (% Base Speed) ±0.5 —

Current Ranges (Amps DC) 1.7, 2.5, 5.0, 7.5 7.5

FWD and REV Accel Range (Seconds) 0.1 – 15 1

Deadband Range (% Base Speed) 0 – ±5 0

Max Speed Trimpot Range (% Base Speed) 55 – 110 100

IR Comp Range at 115 VAC Line (VDC) 0 – 20 5

IR Comp Range at 230 VAC Line (VDC) 0 – 40 10

FCL and RCL Range (% Range Setting) 0 – 175 150

Voltage Following Input Range (VDC) ±5 – ±25 0 – ±10, 0 – ±15

Voltage Following Linearity (% Base Speed) ±0.5 —

Output

Voltage

(Volts DC)

Maximum

DC Output

Current (ADC)

Specification Factory Setting

Maximum

Horsepower

HP, (KW)

—

FIGURE 1 B CONTROL LAYOUT

M1M2L1 L2

F-F+

+ 22 hidden pages