INSTALLATION AND OPERATING INSTRUCTIONS MODEL KBRC-240D FULL-WAVE 4-QUADRANT REGENERATIVE DRIVE NEMA 4X, IP-65 KB Part No. 8840 (Black Case) · Part No. 8841 (White Case) Rated for 1/10 - 1 HP (90 Volts DC) @ 115 Volts AC, 50/60 Hz and 1/5 - 2 HP (180 Volts DC) @ 208/230 Volts AC, 50/60 Hz Washdown and Watertight for Indoor and Outdoor Use ON STOP OL TM PENTA-DRIVE REGENERATIVE DC MOTOR SPEED CONTROL 40 30 20 10 0 50 60 70 80 90 % FWD 100 REV NEMA-4X / IP-65 START AUTO STOP MANUAL TM Pending ! See Safety Warning on Page 5 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 © 2003 KB Electronics, Inc. TABLE OF CONTENTS Section i. ii. I. II. III. Page Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 IV. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 V. Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . 17 VI. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VII. AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 IX. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 X. Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 XI. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Tables 1. 2. 3. 4. 5. 6. 7. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Run Relay Output Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Setting Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Figures 1. 2. 3. 4. 5. 6. 7. 8. 9. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Enlarged View of Trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Full Voltage Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . 10 Half Voltage Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . 10 Unidirectional Forward Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . 11 Unidirectional Reverse Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . 11 Bidirectional Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 10. Bidirectional Main Speed Potentiometer Connection with Reversing Contacts . . . . . . . . 12 11. Remote Start/Stop Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12. Start/Stop Function Eliminated (Jumper Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 13. Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 14. Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ii 15. DC Tach-Generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 16. DC Tach-Generator Connection with Addition of RT . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 17. AC Line Input Voltage Selection (J1 and J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 18. Motor Voltage Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 19. DC Tach-Generator Voltage Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20. Motor Current Selection (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 21. Analog Input Signal Voltage Selection (J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 22. Control Mode Selection (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 23. Torque Mode Selection (J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 24. Current Limit Mode Selection (J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 25. Stop Mode Selection (J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 26. Run Relay Output Mode Selection (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 27. Enable Jumper (J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 28. Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 29. Linear Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 30. Non-Linear Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 31. Offset (OFFSET) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 32. Offset (OFFSET) Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 33. Forward Acceleration (FACC) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 34. Reverse Acceleration (RACC) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 35. Forward Acceleration (FACC) and Reverse Acceleration (RACC) Trimpot Adjustment . . 19 36. Maximum Speed (MAX) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 37. Forward Current Limit (FWDCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 38. Reverse Acceleration (REVCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 39. IR Compensation (IR) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 40. Response (RESP) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 41. Deadband (DB) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 42. Deadband (DB) Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 43. Timed Current Limit (TCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 iii i. SIMPLIFIED OPERATING INSTRUCTIONS IMPORTANT ­ You must read these simplified operating instructions before proceeding. 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, on page 5, before proceeding. A. Power Connection ­ Connect the AC line to L1 and L2 terminals of Terminal Block TB1 and the ground wire (earth) to the green ground screw, as shown in Figure 4, on page 10 and as described in Section IIA, on page 10 and Section IIB on page 10. Be sure Jumpers J1 and J2 are both set to the corresponding AC line input voltage position, as described in Section IIIA, on page 14. B. Permanent Magnet (PM) Motor Connection (Two Wire Type) ­ Connect the motor armature to M1 (+) and M2 (-) terminals of Terminal Block TB1, as shown in Figure 4, on page 10 and as described in Section IIC, on page 10. Be sure that Jumper J3 is set to the corresponding motor voltage position, as described in Section IIIB, on page 14 and Jumper J4 is set to the corresponding motor current, as described in Section IIID, on page 15. Note: Do not use F+ and F- terminals of Terminal Block TB2 for any purpose other than to power the field of a shunt wound motor. Do not use F+ and F- terminals of Terminal Block TB2 for PM motors. Do not use F1 and F2 quick-connect terminals for any purpose other than to power the optional Signal Isolator SIRC (P/N 8842). Note: Motor performance and efficiency, including brush life, may be adversely affected when operating the control in stepdown mode (208/230 Volt AC line with 90 Volt DC motors). C. Shunt Wound Motors (Four Wire Type) ­ Connect the motor armature as described in Section IIC, on page 10. Connect full voltage field wires (90 Volt DC motors with 100 Volt DC field and 180 Volt DC motors with 200 Volt DC field) to F+ and F- terminals of Terminal Block TB2, as described in Section IID, on page 10. Connect half voltage field wires (90 Volt DC motors with 50 Volt DC field and 180 Volt DC motors with 100 Volt DC field) to F+ terminal of Terminal Block TB2 and L1 terminal of Terminal Block TB1, as described in Section IIE, on page 11. Note: Do not connect motor armature leads to F+ and F- terminals of Terminal Block TB2 or to F1 and F2 quick-connect terminals. Do not use F1 and F2 quick-connect terminals for any purpose other than to power the optional Signal Isolator SIRC (P/N 8842). D. Start/Stop Switch ­ The control is supplied with a prewired Start/Stop Switch, as described in Section IIG, on page 12. This switch must be used to start the control each time the AC power is lost or the control shuts down in TCL. To eliminate this function, see Section IIG, on page 12. E. Motor Current ­ Jumper J4 is factory set for 10 Amp motors. For a lower current motor, set Jumper J4 to the corresponding motor current, as described in Section IIID, on page 15. Note: The factory setting for Current Limit is 150% of the nominal current setting (example: if Jumper J4 is set to the "10A" position, the CL trimpot is calibrated for 15 Amps). F. Trimpot Settings ­ All trimpots have been factory set, as shown in Figure 2, on page 7. Trimpots may be readjusted, as described in Section VIII, on page 19. G. Diagnostic LEDs ­ After power has been applied, observe the LEDs to verify proper control function, as described in Section IX, on page 22. 4 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 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. ...