User Manual

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G. Remote Start/Stop Switch Connections

The control is supplied with a prewired Start/Stop Switch with a normally open "NO"

stop contact. Jumper J6 is factory set to the "NO" position.

For remote 3-wire Start/Stop Switch with a normally closed "NC" stop contact, connect

the switch as shown in Figure 7A, below. Set Jumper J6 to the "NC" position.

Figure 7A

Remote 3-Wire Start/Stop Switch

with Normally Closed Stop Contact

START

STOP

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K. Enable Connection

Wire the Enable contact to Terminals "EN1" and "EN2" of Terminal Block TB3 as

shown in Figure 10A, below.

The Enable is used to electronically start and stop the control. When the Enable

contact is closed, the control will accelerate to the Main Speed Potentiometer setting.

When the Enable contact is opened, the control will coast to stop.

Note: The contact must be isolated from the AC line and Jumper J7 must be removed.

Figure 10A

Enable Switch Connection

WARNING! Disconnect main power when making connections to the drive.

The following information and instructions are to be used as a supplement to the

KBPW-240D Installation and Operation Manual Rev. A (Part No. A40360). The manual

must be read and understood before attempting to operate this control.

The PC board has been upgraded to include provision for normally open or normally

closed stop contacts and to connect an Enable switch. The General Performance

Specifications have not changed.

Jumper J6 (Stop Switch type "NO" or "NC" Selection) and Jumper J7 (Enable

Selection) have been added. Enable terminals have been added to Terminal Block

TB3. Also, Figures 7A and 10A have been added.

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Figure

Page

7A Remote 3-Wire Start/Stop Switch with Normally Closed Stop Contact ..................8

10A Enable Switch Connection .....................................................................................9

ENABLE SWITCH

Page 1 of 2 Page 2 of 2

KB Electronics, Inc.

(A42140) - Rev. A00 - 3/22/2005 - Z3570A00

Summary of content (19 pages)

PAGE 1
.%3: ' ,QVWDOODWLRQ DQG 2SHUDWLRQ 0DQXDO 5HY $ 6XSSOHPHQWDO ,QIRUPDWLRQ &KDQJHV WR :LULQJ 6HFWLRQ ,,, * RQ 3DJH G. Remote Start/Stop Switch Connections The control is supplied with a prewired Start/Stop Switch with a normally open "NO" stop contact. Jumper J6 is factory set to the "NO" position. WARNING! Disconnect main power when making connections to the drive. For remote 3-wire Start/Stop Switch with a normally closed "NC" stop contact, connect the switch as shown in Figure 7A, below.
PAGE 2
INSTALLATION AND OPERATING INSTRUCTIONS MODEL KBPW-240D KB Part No. 8401 (Black Case) • Part No. 8402 (White Case) NEMA 4X, IP-65 PWM DC Motor Speed Control For PM and Shunt Wound Motors Rated 7.5 Amps DC, 11.5 Amps AC @ 115/230 VAC ON STOP OL PENTA-DRIVE™ PWM DC MOTOR SPEED CONTROL 50 40 60 70 30 20 80 10 90 0 100 % FWD BRK REV NEMA-4X / IP-65 START RUN STOP JOG ™ Pending ! See Safety Warning on Page 2 The information contained in this manual is intended to be accurate.
PAGE 3
TABLE OF CONTENTS Section Page i. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 II. Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 III. Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4
i. ! 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.
PAGE 5
Optional accessories include On/Off AC Line Switch, FWD-BRK-REV Switch, Run-Stop-Jog Switch, Signal Isolator, and Anti-Plug Reversing Module. Quick-connect terminals are provided for easy installation of all optional accessories. The control is available in black finish (P/N 8401) and FDA approved white finish (P/N 8402). STANDARD FEATURES • Short Circuit Protection – Protects control from a short circuit at motor connections.
PAGE 6
D. Motor Current – Jumper J2 is factory set for 7.5 Amp motors. For lower current motors, set jumper J2 to the corresponding motor current as described in Section IVB, on page 9. Note: The factory setting for Current Limit is 150% of the nominal current setting (example: if jumper J2 is set to “5A” position, the CL trimpot is calibrated for 7.5 Amps). E. Trimpot Settings – All trimpots have been factory set as shown in Figure 1, on page 4. Trimpots may be readjusted as described in Section VIII, on page 12.
PAGE 7
FIGURE 1 – CONTROL LAYOUT (Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings) ACCEL DECEL MAX MIN JOG CL TCL IR START/STOP SWITCH RED CON1 J3 TCL NTCL INH1 ON START BLACK STOP CL YG R B INH2 WHITE KBPW 240D A57440 COM LED BOARD C56 STOP K1 JOG VIOLET J5 P2 P1 K2 K1 TB3 TT+ RELAY TB4 C55 J1 180V T 90V J2 H L AMPS 7.5 0.8 5.0 0.5 3.5 0.4 TACH WHITE MAIN SPEED POTENTIOMETER NC NO P3 ORANGE Q3 T2 2.5 0.3 1.7 0.
PAGE 8
.876 [225.45] 0.357 [9.07] STOP OL FWD 60 0 RUN JOG START STOP NEMA-4X / IP-65 REV ™ 100 10 BRK 80 90 20 % 70 50 30 40 PWM DC MOTOR SPEED CONTROL PENTA-DRIVE™ ON 9.488 [241.00] 5.000 [127.00] CONTROL SHOWN WITH OPTIONAL FWD-BRK-REV AND RUN-STOP-JOG SWITCHES 8.226 [208.94] 5.886 [149.50] 5.472 [138.
PAGE 9
III. WIRING INSTRUCTIONS ! control. wiring. Warning! Read Safety Warning, on page 1, before using this Disconnect the AC line before FIGURE 3 – POWER CONNECTION TB1 Note: To avoid erratic operation, do not bundle AC line and motor wires with wires from signal following, start/stop switch, inhibit, or any other signal wires. Use shielded cables on all signal wiring over 12” (30cm). Shield should be Earth grounded on the control side only.
PAGE 10
operation (230 Volt AC line input with 90 Volt DC SCR rated motor or 130 Volt DC PWM rated motor) set jumper J1 to “90V” position. However, in step-down operation the motor may have reduced brush life - consult motor manufacturer. FIGURE 4 – FULL VOLTAGE FIELD TB1 TB2 F1 Note: Do not connect motor armature leads to F1 and F2 terminals. Do not use F1 and F2 terminals for PM motors. A1 F2 A2 L1 L2 + + FIELD M D.
PAGE 11
G. Remote Start/Stop Switch Connections – The control is supplied with a prewired Start/Stop switch mounted on the front cover. To operate the control from a remote Start/Stop switch (type: (ON)-OFF-ON, SPDT), remove the white, black, and red wires from START, COM, and STOP terminals, respectively. The leads may be taped and FIGURE 7 – REMOTE START/STOP SWITCH left in the control. The switch itself may be removed if a watertight seal is used to cover the hole in the front cover.
PAGE 12
T+ FIGURE 11 – DC TACH-GENERATOR P3 P2 P1 TT+ IV. SETTING SELECTABLE JUMPERS The KBPW-240D has customer selectable jumpers which must be set before the control can be used. See Figure 1, on page 4 for location of jumpers. A. Motor Voltage Selection (J1) – Jumper J1 is factory set to “90V” position for 90 Volt SCR rated motors (or 130 Volt PWM rated motors). For 180 Volt SCR rated motors (or 220 Volt PWM rated motors), set jumper J1 to “180V” position. See Figure 12.
PAGE 13
FIGURE 14 – REMOVING RESISTOR R35 For motors of lower amperage, set jumper J2 to the corresponding position for the motor being used. See Figure 13 on page 9 and Table 5. TO REMOVE RESISTOR R35 CUT THE LEADS HERE R35 ! A1B D20 CON2 L2A L2B Q4 J6B ORG RED WHT BLK L1A L1B J6A Note: For low (L) motor current settings (0.8A, 0.5A, 0.4A, 0.3A, and 0.2A), it is necessary to remove resistor R35 by cutting it out of the circuit. Cut the leads at the locations shown in Figure 14.
PAGE 14
NTCL (Non-Timed Current Limit) – When jumper J3 is set to “NTCL” position, the control will not go into “STOP” after it is in overload. Note: TCL trimpot will have no affect when jumper J3 is in “NTCL” position. D. DC Tach-Generator Voltage Selection (J1 and J4) – For a tach-generator wired to TB3, set jumper J1 to “T” position. See Figure 16. Jumper J4 is factory set to “7V” position for 7 Volt per 1000 RPM tach-generators wired to TB3.
PAGE 15
The KBPW-240D is designed with a hinged case so that when the front cover is open, all wiring stays intact. To open the cover, the four screws must be loosened so they are no longer engaged in the case bottom. After mounting and wiring, close the cover and make sure that wires will not get caught or crimped as the cover is closed. Tighten all four cover screws so that the gasket is slightly compressed. Do not over tighten.
PAGE 16
D. Minimum Speed (MIN) – Sets minimum speed of the motor. The MIN trimpot is factory set for 0% speed. For a higher minimum speed setting, rotate the trimpot clockwise. E. Jog Speed (JOG) – Sets “jog” speed of the motor. The JOG trimpot is factory set for 15% of motor base speed. For a higher jog setting, rotate the trimpot clockwise. For a lower jog setting, rotate the trimpot counterclockwise. Note: The Jog feature requires installation of the Run-Stop-Jog Switch assembly (P/N 9340). F.
PAGE 17
(jumper J3 set to “TCL” position). The control can be reset by either setting the start/stop switch to “START” position or by disconnecting and reconnecting the AC line. If the overload condition still exists when the control is restarted or AC line reapplied, the OL LED will illuminate again. If the OL LED remains illuminated during control operation, a fault condition may exist. Possible causes for this condition are as follows: • Motor is overloaded. Check motor current.
PAGE 18
XI. LIMITED WARRANTY For a period of 18 months from the date of original purchase, KB Electronics, Inc. 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.
PAGE 19
RECONDITIONING THE BUS CAPACITORS If this drive has been in storage for over one year it is necessary to recondition the power supply bus capacitors. To recondition the bus capacitors, apply the AC Line, with the drive in the Stop Mode, for a minimum of one hour. Not following this procedure will cause the bus capacitors to fail. (A40194) – Rev.