INSTALLATION AND OPERATION MANUAL REGENERATIVE DRIVE MODEL KBRG-212D Part No. 8819 VARIABLE SPEED SCR CONTROL FULL WAVE 4–QUADRANT L1 L2 M2 M1 F+ F- See Safety Warning, on page 5. RoHS 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. © 2009 KB Electronics, Inc.
TABLE OF CONTENTS Section Page 1 Quick-Start Instructions......................................................................... 4 2 Safety Warning ..................................................................................... 5 3 Introduction ........................................................................................... 6 4 Important Application Information ......................................................... 12 5 Mounting Instructions ............................................
TABLE OF CONTENTS (Continued) Figure 16 17A 17B 18 19 20A 20B 21 22A 22B 23 24 25A 25B 26A 26B 27A 27B Page J8 15V / 10V Jumper .................................. ....................................... 22 J17 Analog Signal Input (Voltage Position). ....................................... 22 J17 Analog Signal Input (Current Position) . ....................................... 22 J9 Enable / Inhibit Jumper .......................... ....................................... 22 Typical Hi-Pot Test Setup .......
1 QUICK-START INSTRUCTIONS Important: You must read these simplified instructions before proceeding. These instructions are to be used as a reference only and are not intended to replace the details provided herein. You must read the SAFETY WARNING, on page 5, before proceeding. 1.1. Connections (See Figure 3, on page 14). Note: There are no AC Line or Armature fuses supplied with this control. See Section, 1.1.2. 1.1.1 AC Line – Connect AC line voltage (115 or 230 VAC) to terminals L1 and L2.
2 SAFETY WARNING Definition of Safety Warning Symbols Electrical Hazard Warning Symbol: Failure to observe this warning could result in electrical shock or electrocution. Operational Hazard Warning Symbol: Failure to observe this warning could result in serious injury or death. SAFETY WARNING! Please read carefully before proceeding. This product should be installed and serviced by a qualified technician, electrician, or electrical maintenance person familiar with its operation and the hazards involved.
3 INTRODUCTION Thank you for purchasing the KBRG-212D. KB Electronics is committed to providing total customer satisfaction by producing quality products that are easy to install and operate. The KBRG-212D is manufactured with Surface Mount Technology (SMT), incorporating advanced circuitry, components and technology. The KBRG -212D has an Enable (EN) / Inhibit (INH) mode. The 212D version is factory set (J9 jumper) to Enable (EN).
TABLE 1 – STANDARD FEATURES Description Facilitates wiring of AC line, motor armature and field, Terminal Blocks TB1 (-15V, +15V, SIG, COM, EN), TB2 (L1, L2, M2, M1), TB3 (See Section 6, on page 13.) (F+, F-). Connectors J1, Tach-Generator Input – Connection point for an external (See Section 7, on page 19.) Tach-Generator. J2 - Motor Armature Current J3 - Motor Armature Voltage J5 -SPD / TRQ – (Speed / Torque) Selectable Jumpers J6 -CTS/RTS – (Coast to Stop / Regenerate to Stop) (See Section 7, on page 19.
TABLE 3 – TRIMPOT ADJUSTMENTS (See Section 10, on pages 25) Trimpot Description Sets the amount of time for the motor to accelerate from zero speed to full speed in the Forward Acceleration (FACC). Refer to Section forward direction and the time it takes to 10.1, page 25. decelerate in the reverse direction (FACC = Reverse Deceleration). Factory adjusted to 1 second. (Maximum of 15 seconds). Sets the amount of time for the motor to accelerate from zero speed to full speed in the Reverse Acceleration (RACC).
TABLE 4 B ELECTRICAL RATINGS Maximum AC Output Maximum Line Current Voltage DC Output (Amps RMS) (Volts DC) Current (ADC) Input Voltage (VAC) Maximum Horsepower HP, (KW) 115 12 0 – ±90 7.5 ¾, (0.5) 208/230 12 0 – ±180 7.5 1.
FIGURE 1 B CONTROL LAYOUT L1 10 L2 M2 M1 F+ F-
FIGURE 2 B MECHANICAL SPECIFICATIONS (Inches / [mm]) 4.75 [120] 3.50 [88.9] 0.625 [15.9] 0.25 [6.35] 0.20 [5.08] 6.50 [165] L1 L2 M2 M1 F+ 7.00 [178] F- MAXIMUM HEIGHTS Without Accessory Boards With Accessory Boards 3.10 1.70 [78.7] [43.
4 IMPORTANT APPLICATION INFORMATION WARNING! DO NOT USE THIS DRIVE IN AN EXPLOSIVE ENVIRONMENT. AN EXPLOSION CAN CAUSE SERIOUS OR FATAL INJURY. THIS DRIVE IS NOT EXPLOSION PROOF. WARNING! BE SURE TO FOLLOW ALL INSTRUCTIONS CAREFULLY. FIRE OR ELECTROCUTION CAN RESULT DUE TO IMPROPER USE OF THIS PRODUCT. READ SAFETY WARNING ON PAGE 5. 4.1 Motor Type – The KBRG-212D is full-wave regenerative control, capable of operating a DC motor (Permanent Magnet (PM), or Shunt), in a Bi-Directional mode.
6 ELECTRICAL CONNECTIONS WARNING! READ SAFETY WARNING, ON PAGE 5, BEFORE USING THIS CONTROL. CAUTION! To avoid erratic operation, do not bundle AC line and motor connections with potentiometer connections, voltage following connections, Start/Stop switch connections, inhibit connections, or any other signal connections. Use shielded cables on all signal connections over 12” (30 cm) long. Shield should be earth grounded on the control side only.
FIGURE 3 – AC LINE AND ARMATURE CONNECTION TB2 L1 L2 M2 M1 F+ F- + FUSE FUSE FUSE GND (EARTH) TB3 M - AC LINE ARMATURE INPUT See Table 6, for Torque Requirements. 6.3 Fusing AC Line Fuse – The KBRG-212D does not contain an AC line fuse or fuse. It is recommended that a 20 Amp fuse or circuit breaker be each AC line conductor not at ground potential. In addition, refer to Table recommended Armature Fusing.
TABLE 8 – FIELD CONNECTIONS (Shunt Wound Motors Only) AC LINE FIELD VOLTAGE FIELD VOLTAGE FIELD CONNECTION VOLTAGE (VDC) (VDC) 115 90 100 F+, F115 90 50 F+, L1 230 180 200 F+, F230 180 100 F+, L1 230 *90 100 F+, L1 *Step down operation. See Section 7.2, on page 20. 6.7 Half Voltage Field Connection (Shunt Wound Motors Only) – Connect the motor field leads to F+, TB3 and L1 terminals of TB2, as shown in Figure 5, and Table 7, on page 14. CAUTION! TB3 terminals are not isolated from AC line.
6.8 Main Speed Potentiometer Connection – The main speed potentiometer can be connected in several ways. (A 5kΩ ohm potentiometer is supplied with control. A 10K potentiometer can also be used.) See Figures 6A – 6D. 6.8.1 Unidirectional operation (FORWARD) – Connect potentiometer to terminals “+15,” “SIG,” “COM” for forward direction as per Figure 6A. 6.8.2 Unidirectional operation (REVERSE) – Connect potentiometer to terminals “-15,” “SIG,” “COM” for reverse direction. As per Figure 6B. 6.8.
6.9 Signal Following – In this mode, a signal source is used to vary motor speed. 6.9.1 Voltage Following – Uses a voltage source to vary motor speed. Set J17 (See Section 7.7 on page 22 for jumper information) to “VOLT” position and connect the voltage source to TB1 terminals SIG (+) and COM (-) (See Figures 7A below and 7C, on page 18), Voltage Following Connection. Be sure the positive (+) signal is connected to “SIG” terminal and the negative (-) is connected to the “COM” terminal.
FIGURE 7C - J17 VOLTAGE SCALE 90V / 180 V J17 0 10 FIGURE 7D - J8 CURRENT SCALE J17 90V / 15 4 20mA 6.10 Enable / Inhibit – The control features an Enable / Inhibit function. The control can be electronically stopped and started with the Enable / Inhibit circuit. The Enable circuit functions opposite to that of the inhibit circuit. Inhibit: open to start, close to stop. Enable: open to stop, close to start. 6.10.
6.11 Tach-Generator Feedback, J1 – 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. Connect the tach-generator to J1, so that the polarity of the tach-generator is the same with respect to the input signal polarity. Note: If tach-generator is wired for reverse polarity, the motor will run at full speed. See Figure 9.
7.2 J3 – Armature Voltage Output and Tach-Generator Feedback – Select the desired armature voltage by placing J3 in the proper position, “A90" or “A180.” See Figure 11A. Note: FIGURE 11A – J3 ARMATURE VOLTAGE (90V) FIGURE 11B – J3 ARMATURE VOLTAGE (180V) (Default Position) For 115 volt AC line input, J3 must be set to “A90.” For 230 input, the armature voltage is normally set for “A180.” However, it is also possible to set the armature voltage to “A90" for stepdown operation. 7.2.
MOTOR SPEED (%) In the torque control mode FIGURE 14 - MOTOR SPEED vs. (J5 set to TRQ), the APPLIED MOTOR LOAD (TORQUE MODE) KBRG-212D will vary the maximum motor torque as 100 a function of the voltage input to terminals “SIG” 90 HIGHER TORQUE SETTING (signal) and “COM” 80 (common). This voltage 70 can be derived from the 60 wiper of the main 50 potentiometer or from an 40 analog input (voltage 30 following).
7.5 J8 – Analog (Signal) Input Voltage – The output of this control is normally controlled with the main potentiometer. However, an analog voltage (isolated) may also be used in place of a potentiometer. The control can be scaled for 0 – 10VDC by placing J8 in the appropriate position "15V" or "10V". The scaling can be further adjusted with the SCALE Trimpot. Refer to Section 6.9, (Signal Following) on page 17, and Figure 16, for additional information. 7.
8 RECOMMENDED HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING (HI-POT TESTING) WARNING! READ SAFETY WARNING ON PAGE 5 BEFORE ATTEMPTING TO OPERATE. SEVERE INJURY OR DEATH CAN RESULT. Testing agencies such as UL, CSA, etc., usually require that equipment undergo a hi-pot test. In order to prevent catastrophic damage to the drive, which has been installed in the equipment, the following procedure is recommended. A typical hi-pot test setup is shown in Figure 19, on page 24.
FIGURE 19 - TYPICAL HI-POT TEST SETUP HIGH VOLTAGE DIELECTRIC WITHSTAND TESTER (HI-POT TESTER) 1 LEAKAGE 2 0 3 0mA 10mA RETURN H. V. TEST VOLTAGE RESET ZERO MAX MOTOR SPEED CONTROL AUX. EQUPT. FRAME 9 DRIVE OPERATION WARNING! READ SAFETY WARNING ON PAGE 5 BEFORE ATTEMPTING TO OPERATE OR SEVERE INJURY OR DEATH CAN RESULT. The input voltage can be derived from the wiper of the Main Speed Potentiometer or from an analog input (voltage following mode).
The KBRG-212D can be operated as speed controls or torque controls by setting the position of jumper J5. The Main Speed Potentiometer controls the magnitude of the mode selected. Set jumper J5 to "SPD" for speed control or to "TRQ" for torque control. See Table 10.
FIGURE 20B – ACCEL TRIMPOT ADJUSTMENT CC FW D VA RE EL Time EL FW D CC AC CE L 0 VA RE Speed (%) 100 AC CE L FIGURE 20A – FORWARD AND REVERSE ACCELERATION TRIMPOT POSITIONS -100 10.2 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. The MAX Trimpot is factory setto100% of base speed. In the Torque Control Mode, the MAX Trimpot setting determines the unloaded motor speed. See Figure 21.
c. Apply power; Rotate CL trimpot CW until desired CL setting is reached (factory setting is 1.5 times rated motor current). Be sure control is in Forward direction for FCL trimpot adjustment and likewise with RCL. WARNING! DO NOT LEAVE MOTOR SHAFT LOCKED FOR MORE THAN 2 - 3 SECONDS, TO PREVENT MOTOR DAMAGE. CAUTION: Adjusting the CL above 150% of motor rating can cause overheating and demagnetization of some PM motors. Consult motor manufacturer.
10.5 Response (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. See Figure 24. FIGURE 24 –RESPONSE TRIMPOT POSITION Note: If response is made too fast, unstable operation may result. 10.6 Deadband (DB) - The DB trimpot sets the amount of Main Speed Potentiometer rotation required to initiate control voltage output. The DB Trimpot is factory set to 0%.
10.7 Offset (OFFSET) - This trimpot determines the amount of bias in the forward or reverse direction. The trimpot is factory set to provide approximately zero offset, which means neither the forward nor the reverse speed is favored. See Figures 26A and 26B. FIGURE 26A – OFFSET TRIMPOT POSITION FIGURE 26B – OFFSET TRIMPOT ADJUSTMENT 100 (%) SPEED b a c (%) 100 MAIN SPEED POT ROTATION -100 -100 CURVE OFFSET (a) None (b) Forward (c) Reverse 10.
11 DIAGNOSTIC LEDS The KBRG-212D is designed with LEDs mounted on the Control Board, to indicate the control=s operational status. See Figure 1, on page 10. 11.1 LED 1 Power On (PWR ON) -Indicates that the drive is energized with the AC line. 11.2 LED 2 Current Overload (OL) - Indicates that the drive is in Current Overload. 12 TROUBLESHOOTING WARNING! HIGH VOLTAGE IS PRESENT IN THIS DRIVE. DISCONNECT MAIN POWER BEFORE MAKING CONNECTIONS TO THE DRIVE.
Troubleshooting (Continued) Motor is overloaded. Check motor amps with DC ammeter in series with armature. (If motor is shunt type, field may be open or not receiving proper voltage.) Check motor for shorts or grounds. Motor may be defective. OL LED indicator is illuminated. Check position of RCL and FCL trimpots. The trimpots may be set too low. Rapid Acceleration change will cause the LED to illuminate. Verify potentiometer setting. Note: For any other problems, consult the factory representative.
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. The foregoing is in lieu of any other warranty or guarantee, expressed or implied.
