INSTALLATION AND OPERATING INSTRUCTIONS REGENERATIVE DRIVE MODEL KBRG-255 (5HP) KB Part No. 8821 FULL WAVE · 4 QUADRANT FWD EN FWD REV ACCEL ACCEL DB MAX IR REV SPD RESP COMP CL FWD CL S/LT NLT OFFSET REV EN J8 TCL PWR ON CL R33 F1 TB1 1 2 3 4 5 6 7 8 9 10 11 12 13 (EARTH) TB1 GND F+ F- TB2 L1 L2 M1 M2 J1 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 © 1999 KB Electronics, Inc. TABLE OF CONTENTS Section Page i. Simplified Setup and Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ii. I. II. III. IV. V. VI. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Setting Mode of Drive (Speed or Torque Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 IX. X. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 TABLES Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Summary of Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Control State vs Relay Contact State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Current Limit Timer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Parts List (Power Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Parts List (Logic Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 16 FIGURES Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2A. Linear Torque Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2B. Non-Linear Torque Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3. AC Line and Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4A. Full Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4B. Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5. 6. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Main Speed Potentiometer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7A. Voltage Following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7B. Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7C. Start/Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7D. Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7E. Tach-generator Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 8. 9. Accel Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Offset Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 10. Deadband Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11. Power Board Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 12. Logic Board Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ii i. ! KBRG-255 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 (230VAC ±10%, 50/60 Hz). Connect ground wire (earth) to green ground screw. B. Motor. 1. Permanent Magnet (PM Type). Connect motor armature leads to M1+ and M2-. 2. Shunt Wound Motors. Connect motor armature as above. Connect full voltage shunt field wires (180 volt motors with 200 volt fields) to F+ and F-. Connect half voltage field wires (180 volt motors with 100 volt fields) to F+ and L1. 2. SPEED OR TORQUE MODE. Jumper J7 is factory set for speed control operation (SPD). For torque control, set J7 to TRQ position. Note: J8 must be set to "S/LT" position for speed control operation. TRIMPOT SETTINGS. All trimpots have been factory set in accordance with figure 1, page 3. FUSING. The KBRG-255 does not contain AC line or armature fusing. It is recommended that a 40 Amp fuse or circuit breaker be installed on each AC line conductor not at ground potential. Do not fuse ground or neutral wires. SIGNAL INPUT. Connect potentiometer or isolated analog input to terminal "10," "11," "12" and "13" according to section V, E and F, on pages 7 and 9. Do not ground (earth) signal inputs. Use a signal isolator when controlling multiple drives from a non isolated signal source. 3. 4. 5. 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. ! ii. SAFETY WARNING! -- PLEASE READ CAREFULLY 1 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 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-255 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 2. 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 KBRG-255 Part No. 8821 Input Voltage (VAC) 230 Max. AC Current (RMS) 38 Output Voltage (VDC) 0 ­ ±180 Max. DC Output Current (ADC) 25 Max. Horsepower HP, (KW) 5, (3.8) TABLE 2 ­ GENERAL PERFORMANCE SPECIFICATIONS Parameter AC Line Input Voltage (VAC ±10%,50/60 Hz) AC Line Frequency (Hz), # of Phases Arm Voltage Range at 230VAC Line (VDC) Field Voltage at 230VAC Line (VDC) Service Factor Duty Max Load Capacity (% for 2 minutes) Ambient Temperature Range (ºC) Speed Range (Ratio) Arm Feedback Load Regulation (% Base Speed) Tach Feedback Load Regulation (% Set Speed) Line Regulation (% Base Speed) FWD and REV Accel Range (Secs.) Dead Band Range (% Base Speed) Max Speed Trimpot Range (% Base Speed) IR Comp Range at 230VAC Line (VDC) FWD and REV CL Range (%) Timed CL Range (Sec.) Voltage Following Input Range (VDC) Voltage Following Linearity (% Base Speed) Tach-generator Voltage input (volts) Specification 230 50/60, 1 0 ­ ±180 200/100 1.0 Continuous 150 0 ­ 50(1) 50:1 ±1 ±1 ±0.5 0.1 ­ 15 0 ­ ±3 70 ­ 110 0 ­ 30 0 ­ 200 1 ­ 15 0 ­ ±10, 0 ­ ±15 ±0.5 7, 20/30, 50 Factory Setting 230 -- 0 ­ ±180 -- -- -- -- -- -- -- -- -- 1 0 100 10 150 5 0 ­ ±15 -- 50 Notes: Control mounted with colling fins in vertical position. Maximum ambient temperature in horizontal position is 45 ºC. 2 FIG. 1 ­ CONTROL LAYOUT Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings FWD EN FWD REV ACCEL ACCEL DB MAX IR REV SPD RESP COMP CL FWD CL S/LT NLT OFFSET REV EN J8 TCL PWR ON CL R33 F1 TB1 1 2 3 4 5 6 7 8 9 10 11 12 13 (EARTH) TB1 GND F+ F- TB2 L1 L2 M1 M2 J1 DWG#:C3900-2-00992 3 II. SETTING MODE OF DRIVE (SPEED OR TORQUE CONTROL). The KBRG-255 can be operated as a speed control or torque control by setting the position of jumper J7. The main speed potentiometer controls the magnitude of the mode selected. Set jumper J7 to "SPD" for speed control or to "TRQ" for torque control. (See fig. 1, p. 3.) A. Speed Control Mode ­ When jumper J7 is set to the "SPD" position, the KBRG-255 will vary the motor speed as a function of the voltage on input terminals "12" (signal) and "13" (common). IMPORTANT: When J7 is set for speed control ("SPD"), J8 must be set to "S/LT" position (factory setting). 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-255 is a 4-quadrant regenerative drive, the motor speed will follow both a positive and negative wiper 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. To understand the concept of a regenerative drive, the operation of an elevator can be used. If one were to enter the eleva ...