INSTALLATION AND OPERATING INSTRUCTIONS REGENERATIVE DRIVE MODEL KBRG-212D KB Part No. 8819 VARIABLE SPEED SCR CONTROL DESIGNED FOR SHUNT WOUND and PM DC MOTORS FULL WAVE · 4 QUADRANT ! 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. See Page 2 TM A COMPLETE LINE OF MOTOR DRIVES © 1997 KB Electronics, Inc. TABLE OF CONTENTS Section i. ii. I. II. III. IV. V. VI. Page KBRG-212D Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 VII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VIII. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 IX. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 3. 4. 5. 6. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TABLES Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Summary of Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Jumper J3 Position vs Motor Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Relationship of AC Line Input and Motor Voltage with J1, J2 and J4 Positions . . . . . . . . . 4 Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Field Connections (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Armature Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 16 FIGURES AC Line Voltage Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Motor Armature Voltage Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Jumper J5 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Speed Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 AC Line and Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7A. Full Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7B. Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 8. 9. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 10. Main Speed Potentiometer Connections (Unidirectional) . . . . . . . . . . . . . . . . . . . . . . . . . 10 11. Main Speed Potentiometer Connections (Bidirectional) . . . . . . . . . . . . . . . . . . . . . . . . . . 10 12. Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 13. Regenerate to Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 14. Coast to Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 15. Tach-generator Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 16. Accel Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 17. Deadband Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 18. Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ii i. KBRG-212D 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 on page 2 before proceeding. 1. CONNECTIONS. A. AC Line ­ Wire AC line voltage to terminals L1 and L2. Be sure jumpers J1 and J2 are both set to the correct input line voltage 115 or 230 VAC. Connect ground wire (earth) to green ground screw. B. Motor. 1. Permanent Magnet (PM Type). Connect motor armature leads to M1(+) and M2(-). Be sure jumper J4 is set to the proper position "A90" for 90 volt DC motors and "A180" for 180 volt DC motors. Note: 180 volt DC motors must be used with 230 VAC line, 90 volt motors can be used with a 230 VAC or 115 VAC line. Note: Motor performance and efficiency, including brush life, can be adversely affected when using 90 volt motors with a 230 VAC line. (Note: Contact motor manufacturer for derating information.) 2. Shunt Wound Motors. Connect motor armature as above. Connect full voltage shunt field wires (90 volt motors with 100 volt fields and 180 volt with 200 volt fields) to F+ and F-. Connect half voltage field wires (90 volt motors with 50 volt fields and 180 volt motors with 100 volt fields) to F+ and L1. 2. SPEED OR TORQUE MODE. Jumper J6 is factory set for speed control operation (SPD). For torque control, set J6 to TRQ position. 3. MOTOR CURRENT. Jumper J3 is factory set for 7.5 amp motors (7.5A). For lower amperage motors, place J3 in the proper position. If motor amperage is less than 1.7 amps, use the 1.7 amp position and readjust the IR and CL trimpots according to section VII, C and D on page 13. Note: The factory setting for Current Limit is 150% of the nominal current setting (e.g., if J3 is selected for 5 amps, the actual CL setting will be 7.5 amps). 4. TRIMPOT SETTINGS. All trimpots have been factory set in accordance with figure 8, p. 8. 5. ARMATURE FUSE. An armature fuse (F1) rated 12A is installed, which has a rating equal to the maximum RMS rating of the control. It is recommended that the correct size armature fuse be installed depending on the rating of the motor and form factor. See table 8, page 12. 6. ENABLE. A jumper must be connected between "EN" and "COM" terminals or control will not operate. (See sec. V, G, page 11.) 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 electronic Start/Stop and enable 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 failsafe. 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-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 (SI-4X, KB P/N 8801 or equivalent). I. GENERAL INFORMATION. The KBRG-212D is a full-wave regenerative control, capable of operating a DC motor (Permanent Magnet or Shunt) in a bidirectional mode. It provides 4-quadrant operation which allows forward and reverse torque in both speed directions. The drive offers excellent controllability, which closely approximates the performance of servo-type drives. Ratings and specifications are presented in tables 1 and 3. Be sure the drive is used within these ratings and specifications. (Note: Regenerative drives normally produce more motor heating than standard unidirectional SCR speed controls, especially under low speed operation. This should be taken into consideration when specifying motor rating.) WARNING! Be sure to follow all instructions carefully. Fire or electrocution can result due to improper use of this product. Read Safety Warning. TABLE 1 ­ ELECTRICAL RATINGS Model Input Voltage (VAC) 115 230 Max. AC Current (ARMS) 12 12 Output Voltage (VDC) 0 ­ ±90 0 ­ ±180 Max. DC Output Current (ADC) 7.5 7.5 Max. Horsepower HP, (KW) 3/4, (.5) 1, (1) KBRG-212D II. OPERATION. The KBRG-212D will vary motor speed or torque as a function of the signal voltage on input terminals "SIG" (signal) and "COM" (common). The input voltage can be derived from the wiper of the main speed potentiometer or from an isolated analog input (voltage following mode). Since the KBRG-212D is a 4-quadrant regenerative drive, the motor speed will follow both a positive and negative signal voltage and drive the motor in both the forward direction and reverse direction. In addition , it will apply both forward and reverse torque in order to stabilize motor speed. 2 To understand the concept of a regenerative drive, the operation of an elevator can be used. If one were to enter the elevator on the first floor and press 10, the motor and control would have to lift the elevator against gravity. In this mode, the drive would operate like a conventional speed control which is called "motoring" (the applied load is opposite to the direction of motor rotation). When the elevator is at floor 10 and floor 1 is pressed, gravity will try to pull the elevator car down faster than the speed for which it is set. The control will then provide reverse torque to keep the car form falling faster than the set speed. This operation is regeneration (the applied load is in the same direction as the direction of motor rotation). The table below summarizes the different modes of regenerative operation. TABLE 2 ­ SUMMARY OF CONTROL OPERATION Quadrant I II III IV Type of Operation Motoring Regeneration Motoring Regeneration Motor Rotation Direction CW CCW CCW CW Motor Torque direction CW CW CCW CCW Applied Load Direction CCW CCW CW CW TABLE 3 ­ GENERAL PERFORMANCE SPECIFICATIONS Parameter AC Line Input Voltage (VAC ±10%,50/60 Hz) AC Line Frequency (Hz), # of Phases Arm Voltage Range at 115VAC Line (VDC) Arm Voltage Range at 230VAC Line (VDC) Field Voltage at 115VAC Line (VDC) Field Voltage at 230VAC Line (VDC) Serv ...