INSTALLATION AND OPERATING INSTRUCTIONS KBPI SERIES SCR INDEXING & CYCLING CONTROLS -- Designed for Indexing Applications -- FOR PM DC MOTORS RATED (1/6 ­ 1 HP @ 90VDC) and (1/3 ­ 2 HP @ 180VDC) TM This control will not operate without installing the correct armature fuse ­ supplied separately. See Page 2 TM This Manual Covers the Following Models Model No. KBPI-240D KBPI-240DR Operation Unidirectional Reversible Part No. 8500 8501 See Safety Warning on Page 2 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. A COMPLETE LINE OF MOTOR DRIVES © 1998 KB Electronics, Inc. TABLE OF CONTENTS Section Page i. Simplified Setup and Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 II. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 III. Setting AC Line and Motor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 IV. Setting Motor Current (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 V. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VI. Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 VII. Logic Functions and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VIII. Application Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 IX. Application Wiring Diagrams, Reversible Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 X. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 XI. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 XII. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 XIII. Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 XIV. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TABLES 1. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. Selectable Jumper Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4. Relationship of AC Line Input and Motor Voltage with Jumper J1 on Logic Board and Jumpers J2 and J3 on Power Board (All Models) . . . . . . . . . . . . . . . . . . 9 5. Jumper J1 Setting vs Motor Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6. Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7. Armature Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8. Jumper "JW" Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 9. Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23, 26, 27 FIGURES 1A. Control Layout (Logic Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1B. Control Layout (Main Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2. Typical Indexing Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4. AC Line and Motor Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5. Remote Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6. Analog Voltage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 7. Run Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 8. Jog Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9. Jog Command Used as Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 10. Stop Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 11. Jumper "JR" Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 12. Solid State Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 13. Contact Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 14. Correct Keyway Positions for Cam and Limit Switch Assemblies . . . . . . . . . . . . . . . . . . . . . 15 15. Cycle on Demand Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 16. Sequence of Cycle on Demand Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 17. Reversing Logic Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 18. Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21, 24, 25 19. Internal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ii i. SIMPLIFIED SETUP AND OPERATING PROCEDURES Before operating this control you must read these instructions. They 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. AC Power ­ Be sure jumpers J2A and J2B on power board and jumper "J1" on logic board are set to the correct positions to match the AC line input voltage. (See table 4, p. 9.) Connect AC power to terminal block TB1 terminals L1 and L2. When power is turned on, LED 1 on main power board will light. . Be sure AC power is disconnected when making other connections to control. Do not bundle AC power and motor wires with wires connected to TB3 terminals. 2. Motor Leads ­ Connect the motor leads to terminal block TB2 terminals A1 and A2. Be sure motor nameplate voltage rating corresponds to control output voltage rating. Do not use control with shunt wound motors. 3. Motor Current Setting ­ Be sure Jumper J1 is set to the approximate rated motor current (10A, 5A, 3.3A, 2A). JUMPER J1 SETTING vs MOTOR HORSEPOWER Motor Horsepower Range Jumper J1* 90 VDC 10A 5A 3.3A 2A 3/4 ­ 1 1/4 ­ 1/3 1/6 180 VDC 1­2 1 1/2 ­ 3/4 1/3 *Note: Jumper J1 is shown in the factory setting. 4. Trimpot Settings ­ Trimpots should be set to the approximate positon as shown: 5. Main Speed Pot ­ Turn the main speed pot on the front cover of the control to a 15% or greater setting. 1 ii. 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 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 potentiometer circuit (P1, P2, P3) of this control is 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-200A, KB P/N 9945C 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). Special Instruction for Cycle on Demand Applications The camshaft of the Index drive should be in the middle of its dwell position. This is the position in which the motor should receive its signal to start. Connect the normally closed side of the cycling limit switch (LS1) to the control's TB3 terminals STOP (4) and RTN (3). Note: See fig. 14, p. 15 for information regarding the correct dwell position and cycling cam lobe positions. I. GENERAL INFORMATION. The KBPI INDEXER controls are packaged in a NEMA 4X enclosure which is ruggedly constructed of die cast aluminum. The controls are designed specifically for cycling and indexing applications. A variety of models provide different features and input voltage ratings (see table 1, p. 3). The controls provide the user with isolated logic functions: STOP, JOG and RUN. Other functions, such as cycle on demand, can easily be obtained. An important feature of the control is jumper J1 which is used for DC current selection. It automatically presets the IR Compensation and Current Limit for safe operation on various motors. Standard features include built-in armature fusing and an LED indicator array for "power on," "stop" and "overload." Part Number 8501 also contain logic input for "Reverse Run" and "Reverse Jog." The controls contain trimpots that can be used to readjust Minimum and Maximum speed, Current Limit and IR Compensation. The front panel contains a built-in 5K ohm speed potentiometer and a Run, Jog/Stop switch. (See table 3, p. 7 for selectable jumper information.) 2 IMPORTANT! Control part number and ratings must correspond to the AC Line voltage, motor voltage and type of operation (Unidirectional or Reversing). See table 1. TABLE 1 ­ ELECTRICAL RATINGS Input Line Voltage (VAC 50/60 Hz ±10%) Motor Armature Voltage (VDC) Type of Operation Unidirectional Unidirectional Unidirectional Reversing Reversing 1, (.75) Reversing 0 ­ 90 0 ­ 180 0 ­ 90* 0 ­ 90 0 ­ 180 0 ­ 90* 15.0 10/2 15.0 10.2 15.0 10.2 1, (.75) 2, (1.5) 15.0 10.2 1, (.75) 15.0 10.2 2, (1.5) 15.0 10.2 1, (.75) Maximum AC Load Current (RMS Amps) Maximum DC Load Current (DC Amps) Maximum Horsepower HP, (KW) 120 240 240 120 240 240 Logic Provided Run, Jog, Stop, Rtn Run, Jog, Stop, Rtn Run, Jog, Stop, Rtn Fwd Run. Fwd Jog, Stop, Rev Run, Rev Jog, Rtn Fwd Run. Fwd Jog, Stop, Rev Run, Rev Jog, Rtn Fwd Run. Fwd Jog, Stop, Rev Run, Rev Jog, Rtn Model Number Part Number KBPI-240D 8500 KBPI-240DR 8501 *Denotes step-down operation. A 90 Vdc motor used on a 240 VAC line input. NOTE: Motor performance and brush life may be affected. 3 FIG. 1A CONTROL LAYOUT (Logic Module) 4 FIG. 1B CONTROL LAYOUT (Main Board) P1 P2 P3 RUN REV (8) JOG REV ...