INSTALLATION AND OPERATION MANUAL KBMG MULTI-SPEED BOARD KB Part No. 8833 -- Multi-Speed Board for KBMG Series Regenerative Drive Pending ! See Safety Warning on Page 1 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 © 2002 KB Electronics, Inc. TABLE OF CONTENTS Section Page i. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 II. Setting Selectable Jumpers (Each Preset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 III. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 IV. Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 V. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 VI. Trimpot Adjustments (Each Preset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VII. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Tables 1. General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. Terminal Block TB1 Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Figures 1. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. Presets 1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3. Direction Selection (R/F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4. Speed Range Selection (HI/LO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5. Enable Selection (J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6. Control Layout and Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7. KBMG Multi-Speed Board and KBMG Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8. Removing the KBMG Finger-Safe Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9. Removing Terminal Block TB1 from the KBMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 10. Removing the KBMG Finger-Safe Cover Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 11. Preset Speed Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 12. Enable Contact Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 13. Tach-Generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 14. Preset Trimpot Range (Each Preset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ii i. 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 wiring, mounting in proper enclosure, fusing or other over current 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 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 manufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product. (SW effective 11/1992). This product complies with all CE directives pertinent at the time of manufacture. Contact the Sales Department for Declaration of Conformity. 1 INSTALLATION AND OPERATION INSTRUCTIONS IMPORTANT ­ You must read these installation and operation instructions before attempting to operate this control. I. INTRODUCTION Thank you for purchasing the KBMG Multi-Speed Board (Part No. 8833). KB Electronics, Inc. is committed to providing total customer satisfaction by producing quality products that are easy to install and operate. The KBMG Multi-Speed Board is manufactured with surface mount components incorporating advanced circuitry and technology. FIGURE 1 ­ CONTROL LAYOUT ENABLE J1 LO R/F HI LO R/F HI LO PRESET 3 PRESET 2 PRESET 1 The KBMG Multi-Speed Board proR/F vides four (4) user adjustable preset speeds to control a motor connectHI ed to the KBMG Series PRESET 4 LO Regenerative Drive. A preset R/F (Preset 1, Preset 2, Preset 3, HI Preset 4) is selected with a contact closure or open collector. Motor direction is set by the position of Jumper R/F (reverse/forward) which is provided for each preset. 2 PS 4 PS 3 PS 2 PS 1 COM EN TB1 Speed range selection jumpers (HI, LO) and Enable jumper (ENABLE) are also provided. Other features include a barrier terminal block (TB1) to facilitate wiring and a connector (CON2) to connect a tach-generator (TACH) for the KBMG. STANDARD FEATURES · Multi-Speed Operation ­ Four (4) user Preset Speeds. · Forward and Reverse ­ Each preset provides a selection of forward and reverse direction. · Speed Range Settings ­ Each preset provides expanded trimpot adjustments for motor speed range (0-100, 50-100, 0-50, 33-66 % base speed). · Enable ­ Provides electronic Run/Stop function. TABLE 1 ­ GENERAL SPECIFICATIONS PARAMETER Preset or Enable Switch Types Maximum Operating Current per Preset (milliamps DC) Operating Temperature Range (ºC) *Note: Contacts must be isolated from the AC line. SPECIFICATION Dry Contact* or Open Collector 1.5 0 ­ 50 II. SETTING SELECTABLE JUMPERS (each preset) The KBMG Multi-Speed Board has customer selectable jumpers which can be set for a specific application. See Figure 2. Note: Disconnect the AC line before changing position of jumpers. FIGURE 2 ­ PRESETS 1 THRU 4 PRESET 1 PRESET 2 PRESET 3 PRESET 4 R/F R/F LO R/F R/F LO LO LO HI HI HI HI 3 A. Direction Selection (R/F) ­ All R/F Jumpers are factory set to the "F" position for forward operation. For reverse operation, set the desired preset speed Jumper to the "R" position. See Figure 3. B. Speed Range Selection (HI, LO) ­ All HI and LO Jumpers are factory installed for full motor speed range. For more precise adjustment over a narrower speed range (high, medium, or low) set the HI and LO jumpers as shown in Figure 4. HI/LO Set for Full Speed Range (Factory Setting) FIGURE 4 SPEED RANGE SELECTION (HI/LO) R/F R/F FIGURE 3 ­ DIRECTION SELECTION (R/F) R/F Set for Forward Direction R/F Set for (Factory Setting) Reverse Direction HI/LO Set for High Speed Setting HI/LO Set for Low Speed Setting HI/LO Set for Med. Speed Setting R/F R/F LO LO LO LO HI HI HI % Base Speed 0 - 100 50 - 100 0 - 50 33 - 66 C. Enable Selection (J1) ­ Jumper J1 is factory installed to enable the control. To connect an Enable Switch to Terminal Block TB1, remove Jumper J1. See Figure 5 and Figure 12, on page 10. 4 FIGURE 5 ­ ENABLE SELECTION (J1) J1 Set for Enabling of Control (Factory Setting) J1 Removed for Enable Switch HI FIGURE 6 ­ MECHANICAL SPECIFICATIONS (Inches/[mm]) 3.80 [97] L1 L2 ENABLE J1 TB1 3.80 [97] 4.68 [119] PRESET 1 PRESET 2 PRESET 3 R/F R/F R/F PRESET 4 R/F LO LO LO LO HI HI HI HI DB RESP IR RCL FCL MAX FACC RACC M1 M2 T1 (-) TACH T2 (+) CON2 PS 4 PS 3 PS 2 PS 1 COM EN Maximum Height 2.67 [68] 5 FIGURE 7 ­ KBMG MULTI-SPEED BOARD & KBMG ASSEMBLY DIAGRAM ACCESSORIES FINGER-SAFE COVER 2X #6-32 UNC X 1-3/4" 4X SNAPS ON COVER KBMG MULTI SPEED BOARD 2X #5-40 UNC X 1/4" 6 KBMG FINGER-SAFE KBMG III. MOUNTING INSTRUCTIONS See Figure 7 on page 6. Note: Figure 7 is also supplied as a separate drawing. WARNING! Make sure all power is disconnected from the KBMG before proceeding. FIGURE 8 ­ REMOVING THE KBMG FINGER-SAFE COVER 5-40 x 1/4" Screws ! 6-32 x 1-3/4" A. Removing the KBMG FingerSafe Cover ­ If a finger-safe cover is not installed on the KBMG, proceed to Section III B. If a finger-safe cover is installed on the KBMG, remove the two (2) socket head 5-40 X 1/4" screws located at the rear of the KBMG using the supplied 3/32" hex key. Also, remove the two (2) 6-32 X 13/4" screws located on either side of Terminal Block TB1 of the KBMG. See Figure 8. KBMG Finger-Safe Cover KBMG 7 B. Removing Terminal Block TB1 from the KBMG ­ Remove Terminal Block TB1 from the KBMG by rocking it back and forth or using a flat blade screwdriver to gently pry it off. The removed terminal block will not be used and may be discarded. See Figure 9. FIGURE 9 ­ REMOVING TERMINAL BLOCK TB1 FROM THE KBMG Terminal Block TB1 C. Modifying the KBMG Finger-Safe Cover ­ Once the KBMG finger-safe cover is removed, it has to be modified to accommodate the KBMG Multi-Speed Board. Cut out the finger-safe cover panel at seven (7) places as shown in Figure 10, on page 9. Note: Some finger-safe covers may already have the cover removed. KBMG D. Installing the KBMG Finger-Safe Cover ­ Once the KBMG finger-safe cover has been modified, it can be installed onto the KBMG. Initially, use only the two (2) 5-40 X 1/4" socket head screws, using the supplied 3/32" hex key. Do not over tighten these screws or damage may result to the KBMG finger-safe cover. See Figure 6 on page 6. 8 Note: All jumpers on the KBMG must be set before installing the KBMG finger-safe cover. FIGURE 10 ­ REMOVING KBMG FINGER-SAFE COVER PANEL E. Installing the KBMG Multispeed Board onto the KBMG ­ The terminal block located on the bottom of the KBMG Multi-Speed Board plugs onto the six (6) header pins where TB1 was removed from the KBMG. The two (2) holes on the back of the KBMG MultiSpeed Board snap onto the finger-safe cover. Use the two (2) 6-32 X 13/4" screws, that were previously removed, to secure the KBMG Finger-Safe Cover. Remove Panel KBMG Multi-Speed Board (cut 7 places) to Install KBMG Multi-Speed Board. to the KBMG. Do not over tighten these screws or damage may result to the KBMG Multi-Speed Board and the KBMG. See Figure 7, on page 6. Installation is now complete. 9 TABLE 2 ­ TERMINAL BLOCK TB1 WIRING INFORMATION Connection Designation Logic Connections Supply Wire Size (AWG ­ Cu) Minimum 24 Maximum 14 FIGURE 12 ­ ENABLE CONTACT CONNECTION Jumper Removed ENABLE Recommended Tightening Torque (in-lbs) 3.5 FIGURE 11 ­ PRESET SPEED CONNECTION TB1 EN Close to Run Open to Stop COM IV. WIRING INSTRUCTIONS WARNING! Read Safety Warning, on page 1, before using this control. Make sure all power is disconnected from the KBMG before proceeding. ! J1 Close to Run Open to Stop Safety Warning! Do not use the PRESET TB1 or ENABLE contacts as a safety disconnect since they are not fail-safe. Use only the AC line for this purpose. EN COM COM PS 1 ! PS 2 PS 3 PS 4 A. Preset Speed Connection ­ Preset speed range, direction, and speed are selected by making a contact closure between Terminals COM and either PS 1, PS 2, PS 3, or PS 4 of Terminal Block TB1. See Figure 11. 10 FIGURE 13 ­ TACH-GENERATOR CONNECTION B. Enable Switch Connection ­ If a Run/Stop function is required, remove the KBMG Multi-Speed Board Jumper DC TACH-GENERATOR J1 and wire a switch to Terminals EN + T1 (-) G and COM of Terminal Block TB1. TACH When the switch is closed, the control T2 (+) will operate. When the switch is opened, the control will stop. Note: KBMG Multi-Speed Board Jumper J1 mus ...