KBRG-212D (thru-hole) - KB Electronics, Inc.

KBRG-212D (thru-hole) - KB Electronics, Inc.
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
™
A COMPLETE LINE OF MOTOR DRIVES
© 1997 KB Electronics, Inc.
TABLE OF CONTENTS
Section
Page
i.
KBRG-212D Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ii.
Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I.
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
III.
Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IV.
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
V.
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VI.
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VIII. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IX.
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.
Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.
Summary of Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.
General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.
Jumper J3 Position vs Motor Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.
Relationship of AC Line Input and Motor Voltage with J1, J2 and J4 Positions . . . . . . . . . 4
6.
Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.
Field Connections (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.
Armature Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 16
1.
AC Line Voltage Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.
Motor Armature Voltage Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.
Jumper J5 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.
Speed Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.
Torque Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.
AC Line and Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TABLES
FIGURES
7A. Full Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7B. Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.
Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9.
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
KBRG-212D
II.
2
Input
Voltage
(VAC)
Max. AC
Current
(ARMS)
115
230
Output Voltage
(VDC)
Max. DC Output
Current (ADC)
Max. Horsepower
HP, (KW)
12
0 – ±90
7.5
3/4, (.5)
12
0 – ±180
7.5
1, (1)
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.
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
Type of
Operation
Motor Rotation
Direction
Motor Torque
direction
Applied Load
Direction
I
Motoring
CW
CW
CCW
II
Regeneration
CCW
CW
CCW
III
Motoring
CCW
CCW
CW
IV
Regeneration
CW
CCW
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)
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 (% Base Speed)
Line Regulation (% Base Speed)
Current Ranges (ADC)
FWD and REV Accel Range (Sec.)
Dead Band Range (% Base Speed)
Max Speed Trimpot Range (% Base Speed)
IR Comp Range at 115VAC Line (VDC)
IR Comp Range at 230VAC Line (VDC)
FWD and REV CL Range (% Range Setting)
Voltage Following Input Range (VDC)
Voltage Following Linearity (% Base Speed)
III.
Specification
115 or 230
50/60, 1
0 – ±90
0 – ±180, 0 – ±90
100/50
200/100
1.0
Continuous
150
0 – 50
50:1
±1
±1
±0.5
1.7, 2.5, 3.3 5.0, 7.5
0.1 – 15
0 – ±3
70 – 110
0 – 15
0 – 30
0 – 200
0 – ±10, 0 – ±15
±0.5
Factory
Setting
230
—
—
0 – ±180
—
—
—
—
—
—
—
—
—
—
7.5
1
0
100
5
10
150
0 – ±15
—
SETTING SELECTABLE JUMPERS.
The KBRG-212D has customer selectable jumpers which must be set before the control can
be used (refer to fig. 1, p. 4). Bold indicates factory setting. See fig. 8, p. 8 for location of
jumpers.
A. J1, J2 – Input AC Line Voltage – Select proper input line voltage, 115VAC or 230VAC,
by placing both J1 and J2 in the correct corresponding position, “115" or “230.” (See fig.
1.)
3
B. J3 – Armature Current – Select the J3 position (1.7, 2.5, 3.3, 5, 7.5) closest to the rated
motor current. (Note the maximum output current is set to 150% of the J3 position, which
may be readjusted using the FWD CL and REV CL trimpots.)
TABLE 4 – JUMPER J3 POSITION vs MOTOR HORSEPOWER
Jumper J3 Position
Motor Current
(DC Amps)
90VDC
7.5A
3/4
5.0A
1/2
1
3.3A
1/3
3/4
2.5A
2.5A
1/4
1/2
1.7A
1.7A
1/6
1/3
J3
7.5A
Motor Horsepower
180VDC
1
5.0A
3.3A
C. J4 – Motor Armature Voltage – Select the desired armature voltage by placing J4 in the
proper position, “A90" or “A180.” Note: For 115 volt AC Line input, the armature
voltage must be set to “90.” For 230 input, the armature voltage is normally set for
“180.” However, it is also possible to set the armature voltage to “90" for step-down
operation. (See fig. 2 and table 5.) Note: Jumper J4 is also used if tach-generator
feedback is to be used. (See fig. 2)
If a 7 volt per 1000 RPM tach-generator is used, place jumper J4 into the “T7" position.
For a 50 volt per 1000 RPM tach-generator, place the jumper into the “T50" position.
Note: When using tach-generator feedback, the IR Comp trimpot should be turned to a
minimum setting (full CCW).
FIG. 1 – AC LINE VOLTAGE
JUMPER SETTING
115VAC
FIG. 2 – MOTOR ARMATURE
VOLTAGE JUMPER SETTING
230VAC
90VDC
180VDC
TABLE 5 – RELATIONSHIP of AC LINE INPUT AND MOTOR
VOLTAGE with J1, J2 and J4 JUMPER POSITION
AC INPUT VOLTAGE
J1, J2 POSITION
J4 POSITION
MOTOR VOLTAGE
115
115
90
90
230
230
180
180
230
230
90*
90*
*A 90VDC motor can be used with a 230VAC line. However, speed range may be reduced and
motor derating may be required.
4
D. J5 – Analog Input Voltage –
Jumper J5 is set to the “15V”
position for potentiometer
operation. If the control is to be
operated from an isolated 0 –
±10VDC signal, set J5 to the
“10V” position. (See sec. V, F, p.
10.) (See fig. 3.)
FIG. 3 – JUMPER J5 SETTING
Potentiometer Operation
Signal Following
E. J6 – Control Mode – Speed (SPD) or Torque (TRQ). (Note: Factory setting of J6 is
Speed mode.) In the speed control mode (J6 set to SPD), the KBRG-212D will provide
variable speed control. The motor speed will be in direct proportion to the input signal.
Both forward and reverse torque are used to stabilize motor speed. (See fig. 4.)
FIG. 4 – SPEED CONTROL MODE
In the torque control mode (J6 set to TRQ), the KBRG-212D will vary the maximum motor
torque as a function of the voltage input to terminals “SIG” (signal) and “COM” (common).
This voltage can be derived from the wiper of the main potentiometer or from an isolated
analog input (voltage following). If the motor torque is greater than the load torque, the
motor will rotate. If no load is applied to the motor, the motor will rotate at a speed
proportional to the torque setting as set by the main potentiometer (see fig. 5, p. 6). By
using the ACCEL and DECEL trimpots, the application of torque can be made more
gradual or less gradual as required by the application. A maximum torque can be
established using the current selector jumper, J3, which can be further modified by using
the FWD and REV CL trimpots.
F. J7 – Coast to Stop (CTS), Regenerate to Stop (RTS) – This function operates in
conjunction with the Enable circuit, which is used to start and stop the control electronically. If the circuit connecting terminals “EN” and “COM” on terminal block TB1 is opened,
the control will cause the motor to stop. When jumper J7 is in the factory position (RTS),
the motor will regenerate to a stop. The stop time is controlled by the Forward
Acceleration (FWD ACC) and Reverse Acceleration (REV ACC) trimpots.
If J7 is changed to the coast to stop (CTS) position, the motor will coast to a stop when
the “EN” - “COM” circuit is opened. Note: Control will not run unless a jumper or
closed contact is connected between the “EN” and “COM” terminals.
5
FIG. 5 – TORQUE CONTROL MODE
IV.
MOUNTING.
Mount the KBRG-212D on a flat surface free of moisture, metal chips, or corrosive atmosphere.
See Mechanical Specifications fig. 9, p. 9. A 5K ohm remote speed potentiometer is provided
with each control. Install potentiometer using hardware provided. Be sure to install insulating
disk between potentiometer and inside of front panel.
Enclosure – When mounting the KBRG-212D in an enclosure, it must be large enough to allow
the proper heat dissipation. A 12"12"24" enclosure is suitable at full rating (7.5 Amps).
Smaller enclosures may be used if full rating is not required.
V.
WIRING.
Warning! Read Safety Warning before attempting to use this control.
Warning! To avoid erratic operation do not bundle AC Line and motor wires with
potentiometer, voltage following, enable, inhibit or other signal wiring. Use shielded
cables on all signal wiring over 12" (30 cm) – Do not ground shield.
Wire control in accordance with National Electrical Code requirements and other local codes
that apply. A “normal blo” 15 amp fuse or circuit breaker should be used on each AC line
conductor which is not at ground potential (do not fuse neutral or grounded conductors). (See
section VI, p. 11 for fuse information.) Wire control in accordance with connection diagrams
(see figures 6, 7A, 7B on page 7 and figures 10 - 12 on page 10). A separate AC Line switch
or contactor must be wired as a disconnect switch so that contacts open each ungrounded
conductor of the control. See table 6 for terminal block wiring information.
TABLE 6 – TERMINAL BLOCK WIRING INFORMATION
6
Supply Wire Gauge*
Terminal Block
Designation
Connection
Designation
Minimum
Maximum
Maximum Tightening
Torque (lbs inch)
TB1
Logic Connections
22
14
3.5
TB2
F+, F-
22
14
3.5
TB3
L1, L2, M2, M1
22
12
12
A. AC Line – Connect AC Line to terminals L1 and
L2. (Be sure jumpers J1 and J2 are set to match
the AC Line voltage used.) (See table 5, p. 4.)
FIG. 6 – AC LINE AND
ARMATURE CONNECTION
ARM
FUSE
B. Motor Armature – Connect motor armature to
terminal M1 and M2. (Be sure jumper J4 is set to
match motor voltage.) (See table 5, p. 4.)
F1
C. Ground – Be sure to ground (earth) control via
green screw located on chassis. Do not ground
any other terminals.
D. Field – For Shunt Wound motors only. Do not
use F+ and F- terminals for any other motor type.
Connect motor shunt field to terminals F+ and Ffor 90VDC motors with 100VDC fields and
180VDC motors with 200VDC fields. For motors
with half voltage fields, 90VDC motors with
50VDC fields and 180VDC motors with 100VDC
fields, connect field to terminals F+ and L1. See
table 7 for summary of field connections.
TB3
L1
L2
GROUND
(earth)
A
F
U
S
E
MOTOR
ARM
F
U
S
E
AC
LINE
CAUTION – Shunt-Wound motors may be
damaged if field remains powered without
motor rotating for an extended period of time.
FIG. 7A – FULL VOLTAGE FIELD
M1
M2
FIG. 7B – HALF VOLTAGE FIELD
ARM
FUSE
ARM
FUSE
F1
F1
TB2
TB3
TB2
TB3
L1
L2
M2
M1
F+
F-
L1 L2 M2
M1
F+
F-
A
A
FIELD
FIELD
AC
LINE
AC
LINE
ARM
ARM
TABLE 7 – FIELD CONNECTIONS (Shunt Wound Motors Only)
AC Line Voltage (VAC)
Motor Voltage
Field Voltage (VDC)
Field Connection
115
90
100
F+, F-
115
90
50
F+, L1
230
180
200
F+, F-
230
180
100
F+, L1
230
90*
100
F+, L1
*Step Down operation (see sec. III C, p. 4).
7
8
FIG. 8 – CONTROL LAYOUT
(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)
9
FIG. 9 – MECHANICAL SPECIFICATIONS
INCHES
[mm]
E. Main Speed Potentiometer – The main speed potentiometer can be connected in several
ways using terminals “COM,” “+15,” “SIG” and “-15.” A 5K ohm potentiometer is supplied
with control. (A 10K potentiometer can also be used.) (Warning! Terminals “COM,”
“+15,” “SIG” and “-15" are not isolated from AC line.) Note: Jumper J5 must be in
the “15V” position.
i. Unidirectional operation only – Connect potentiometer to terminals “COM,” “+15,”
“SIG" for forward direction. To operate in reverse direction, connect to “COM,” “SIG,”
and “-15.” See fig. 10.
ii. Bidirectional operation only – Connect to terminals “COM,” “+15,” “SIG,” and “-15"
when using reversing contacts. To operate with a potentiometer, connect to “+15,"
“SIG,” and “-15." See fig. 11.
FIG. 10 – MAIN SPEED POTENTIOMETER CONNECTIONS (Unidirectional)
Forward
Reverse
FIG. 11 – MAIN SPEED POTENTIOMETER CONNECTIONS (Bidirectional)
Bidirectional with Reversing Contact
Bidirectional with Speed Pot
-15V SIG +15V TACH COM EN
TB1
-15V SIG +15V TACH COM EN
TB1
*
MAIN SPEED
POTENTIOMETER
*Note: Arrow indicates increase in motor forward speed.
*
MAIN SPEED
POTENTIOMETER
FIG. 12 – VOLTAGE
FOLLOWING CONNECTION
F. Voltage Following – An isolated analog voltage can
be used in lieu of main speed potentiometer. Connect
signal to terminals “SIG" and “COM.” Note: Terminal
“COM" is common. A positive signal with respect to
terminal “RB1” will produce a positive output to motor.
A negative signal with respect to terminal “COM" will
produce a negative output. A 0 to ±10VDC is required
to operate control from 0 ± full output. (A bipolar
signal isolator, SI-4X [KB P/N 8801], is available as an
option from your distributor.) Note: Jumper J5 must be in the “10V” position. Note: An
isolated signal voltage must be used or catastrophic failure can result.
10
G. Enable Start/Stop Circuits – The KBRG-212D contains a 2-wire stop circuit (Enable)
which is used to electronically bring the motor to a “stop.” An isolated single contact
closure is required. If an isolated contact is not available, it may be necessary to use an
isolation relay.
WARNING! Do not use Start/Stop or Enable functions as a safety
disconnect. Use only an AC line disconnect for that purpose.
i.
Regen to a stop using terminals EN and
COM on terminal block TB1 – When a
contact is opened between terminals “EN”
and “COM”, with jumper J7 in the “RTS”
position, the motor will regeneratively brake to
a stop. The braking time can be controlled by
adjusting the REV ACC trimpot when the
motor is in the forward direction and the FWD
ACC trimpot when the motor is in the reverse
direction. See fig. 13.
ii. Coast to a stop using terminals “EN” and
“COM” on terminal block TB1 – If coast to
stop operation is required, move jumper J7 to
the coast to stop (CTS) position. When the
contact is opened between “EN” and “COM,”
the motor will coast to a stop. See fig. 14.
FIG. 13 – REGENERATE TO STOP
FIG. 14 – COAST TO STOP
H. Tach-generator Feedback – The KBRG-212D is
factory set for armature feedback which provides
good load regulation for most applications. For
superior load regulation analog tach-generator
feedback can be used.
Wire the tach-generator so that the polarity of the tach-generator is the same with respect
to the input signal polarity (see fig. 15). Note: If tach-generator is wired with reverse
polarity, the motor will run at full speed.
FIG. 15 – TACH-GENERATOR FEEDBACK
NOTE: Check tach voltage polarity with respect to
input signal if polarity does
not match reverse tach
leads.
Be sure AC line is
disconnected when
rewiring tach-generator.
VI.
FUSING.
Armature Fuse – An armature fuse (F1) rated 12A is provided with 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 (RMS/AVG current). Fuse
type should be Littlefuse 326 ceramic or Buss ABC, or equivalent. A fuse chart is presented
below which suggests appropriate armature fuse ratings. However, the specific application
may require larger fuse ratings based on ambient temperature, CL set point and duty cycle
of operation (see table 8, p. 12). Fuses may be purchased from your distributor.
11
TABLE 8 – ARMATURE FUSE CHART
Motor Horsepower
90VDC
180VDC
Approx. DC Motor
Current Amps
1/8
1/4
1.3
1/6
1/3
1.7
1/4
1/2
2.5
4
1/3
3/4
3.3
5
1/2
1
5.0
8
7.5
12
3/4
1
Fuse Rating
(AC Amps)
2
2
VII. TRIMPOT ADJUSTMENTS.
The KBRG-212D contains trimpots which have been factory adjusted for most applications.
See specifications for factory settings. (Note: Fig. 8 p. 8 presents the various trimpots with
their location. They are shown in the approximate adjustment position.) Some applications
may require readjustment of trimpots in order to tailor control to exact requirements. Readjust
trimpots as follows:
A. Forward Acceleration (FWD ACCEL) and Reverse Acceleration
(REV ACCEL) – The FWD ACCEL
trimpot determines the amount of
time it takes the control voltage to
reach full output in the forward direction. It also determines the
amount of time it takes for the control voltage, in the reverse direction, to reach zero output. (FWD
ACCEL is the Reverse Decel.)
FIG. 16 – ACCEL TRIMPOT ADJUSTMENT
The REV ACCEL trimpot determines the amount of time it takes
the control voltage to reach full
output in the reverse direction and
the time it takes for the control voltage, in the forward direction, to
reach zero output. (REV ACCEL is FIG. 17 – DEADBAND TRIMPOT ADJUSTMENT
the Forward Decel.)
The FWD and REV ACCEL
trimpots are factory adjusted to
approximately 1 second. The acceleration times are adjustable
over a range of 0.1 to 15 seconds.
See fig. 16 for graphical representation of ACCEL.
Note: The FWD and REV CL trimpots may override the rapid accel
and decel settings.
Note: A 4-quadrant
ACCEL/DECEL accessory module
(KB P/N 8803) is available as an
option. It provides separate control of FORWARD acceleration and
deceleration and REVERSE acceleration and deceleration.
12
B. Deadband Trimpot (DB) – The DB trimpot sets the amount of main speed potentiometer
rotation required to initiate control voltage output. It is factory adjusted to approximately
25% of rotation.
The DB trimpot also determines the amount of delay that will occur before regeneration
starts. Regeneration occurs when the applied load torque is in the same direction as the
motor rotation.
To readjust the DB to factory setting:
i. Set Main Speed pot to zero speed position.
ii. Set DB trimpot to full CCW position.
iii. Adjust DB trimpot CW until motor hum is eliminated. (See fig. 17, p. 12 for graphic
illustration of the DB trimpot.)
Note: If the deadband trimpot is set too low (CCW direction), the motor may oscillate
between forward and reverse. Adjust deadband trimpot CW until the instability
disappears. (Oscillation may also occur due to RESP and IR COMP trimpot settings.
See sec. VII, F p. 14.)
C. Forward Current Limit (FWD CL) and Reverse Current Limit (REV CL) Trimpots –
These trimpots are used to set the maximum amount of DC current that the motor can
draw in both the forward and reverse directions. The amount of DC current determines
the amount of maximum motor torque. They are factory set at 150% of the current
established by the jumper J3 setting.
Readjust the CL trimpot as follows:
i.
Turn CL trimpot to MIN (CCW) position. Be sure jumper J3 is in the proper position
approximately equal to the motor DC ampere rating.
ii. Wire in a DC ammeter in series with armature lead. Lock shaft of motor.
iii. Apply power. Rotate CL trimpot quickly until desired CL setting is reached (factory
setting is 1.5 times rated motor current). Be sure control is in forward direction for
FWD CL trimpot adjustment and likewise with REV CL.
Warning! To prevent motor damage, do not leave motor shaft locked for more
than 2 – 3 seconds.
Caution! Adjusting the CL above 150% of motor rating can cause overheating
and demagnetization of some PM motors. Consult motor manufacturer.
D. IR Compensation (IR Comp) – The IR Comp is used to stabilize motor speed under
varying loads.
Readjust the IR Comp trimpot as follows:
i.
ii.
Initially set trimpot to factory position (approximately 10 o’clock).
Run motor at approximately 30 – 50% of rated speed under no load and measure
actual speed.
iii. Load motor to rated current. Rotate IR Comp trimpot so that loaded speed is the
same as the unloaded speed measured in the previous step.
Control is now compensated so that minimal speed change will occur over a wide
range of motor load. Note: Excessive IR Comp will cause unstable (oscillatory)
operation.
E. Maximum Speed (MAX) – The MAX trimpot is used to set the maximum output voltage
of the control which, in turn, sets the maximum speed of the motor.
Adjust the MAX trimpot as follows:
i.
ii.
Rotate Main Speed potentiometer to full speed (CW).
Adjust MAX trimpot to desired maximum motor speed.
Note: Do not exceed maximum rated RPM of motor since unstable operation may
result.
13
F. Response Trimpot (RESP) – This trimpot determines the dynamic response of the
control. The factory setting is approximately 50% of full rotation. The setting may be
increased if a faster response is required. Note: If response is made too fast, unstable
operation may result.
VIII. FUNCTION INDICATOR LAMPS.
A. Power On (PWR ON) – Indicates that the drive is energized with the AC line.
B. Overload (OL) – Indicates the control has reached the current limit set point which has
been established by the position of jumper J3 and the FWD CL and REV CL trimpot
settings. In transient load applications it is normal for this light to blink.
IX.
KBRG-212D ACCESSORIES
•
•
•
14
Bipolar Signal Isolator
4-Quad Accel/Decel
Multi Speed Board
KB P/N 8801
KB P/N 8803
KB P/N 8814
IX – LIMITED WARRANTY
For a period of 18 months from date of original purchase, KB will repair or replace without
charge devices which our examination proves to be defective in material or workmanship.
This warranty is valid if the unit has not been tampered with by unauthorized persons,
misused, abused, or improperly installed and has been used in accordance with the
instructions and/or ratings supplied. The foregoing is in lieu of any other warranty or
guarantee, expressed or implied, and we are not responsible for any expense, including
installation and removal, inconvenience, or consequential damage, including injury to any
person, caused by items of our manufacture or sale. Some states do not allow certain
exclusions or limitations found in this warranty so that they may not apply to you. In any
event, KB's total liability, under all circumstances, shall not exceed the full purchase price
of this unit. (rev 4/88)
KB ELECTRONICS, INC.
12095 NW 39th Street, Coral Springs, FL 33065 • (954) 346-4900 • Fax (954) 346-3377
Outside Florida Call TOLL FREE (800) 221-6570 • E-mail – [email protected]
www.kbelectronics.com
(A40291) – Rev. B – 8/98
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