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 TM TM 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 © 1998 KB Electronics, Inc. TABLE OF CONTENTS Section i. ii. I. II. III. IV. V. VI. Page Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Setting Speed or Torque Mode of Drive (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 IX. X. XI. 1. 2. 3. 4. 1. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 TABLES Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Field Connections (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FIGURES 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 2 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 factory for detailed installation instructions and Declaration of Conformity. Installation 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). 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. 3 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 Input Line Voltage (VAC-50/60Hz) 230 Armature Voltage (VDC) 0 ­ 200 Maximum Ac Load Current (RMS Amps) 22.0 Maximum DC Load Current (DC AMPS) 15 Maximum Power HP (KW) 3 (2.25) TABLE 2 ­ KBPC-225 GENERAL PERFORMANCE SPECIFICATIONS PARAMETER (units) AC Line Input (VAC ± 15%, 50/60 Hz) Horsepower at 230 VAC Line (HP) [KW] Armature Voltage Range at 230 VAC Line (VDC) Field Voltage at 230 VAC Line (VDC) Ambient Temperature Range (ºC) Speed Range (Ratio) Load Regulation [Armature Feedback] (% Base Speed) Load Regulation [Tachometer Feedback] (% Set Speed) AC Line Voltage Regulation ( % Base Speed) ACCEL and DECEL Ranges (Seconds) MIN SPEED Range ( % Base Speed) MAX SPEED Range (% Base Speed) IR COMP Range at 230 VAC Line (VDC) CL Range ( % Range Setting) Timed CL Range (Seconds) Voltage Following Linearity (% Base Speed) SPECIFICATIONS 230 3 [2.25] 0 - 200 (1) FACTORY SETTING -- -- 180 VDC -- -- -- -- -- -- 1 0 90 8 150 7 200/100(2) 0 - 45 50:1(3) ±1 ±1 ±0.5 0.1 - 15 0 - 30 60 - 120 0 - 30 0 - 180 0.5 - 15 ±0.5 -- Notes: (1) (2) (3) 4 Maximum recommended output voltage is 180 VDC at 230 VAC. Exceeding this output voltage will cause a reduction in load regulation performance. For shunt wound motor with lower field voltage, use F1 and L1 connection. 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 J5 TCL I1 I2 START COM STOP JOG P3 P2 P1 TB3 TT+ MIN DECEL KBPC NTCL TCL 10V 5V J7 ON STOP OL LED BOARD CL JOG IR TRQ SPD J1 ACCEL CONN1 MAX J3 180V 90V T R69 50V 20/30V 7V J6 T1 A1B J8A (1) A1A A2B J8B (1) F+ A2A GND TB2 F1 F2 A1 A2 L1 L2 TB1 (EARTH) DWG#: B2800-1-00890 5 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 FIG. 2B ­ PRESET MOTOR SPEED vs. MOTOR LOAD 100 100 MOTOR OUTPUT SPEED (%) PRESET MOTOR SPEED (%) 0 0 POTENTIOMETER ROTATION (%) 100 100 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 FIG. 3B ­ MOTOR SPEED vs. APPLIED MOTO ...