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KBRCInstruction Manual INSTALLATION AND OPERATING INSTRUCTIONS
MODEL KBRC-240D
FULL-WAVE 4-QUADRANT REGENERATIVE DRIVE
NEMA 4X, IP-65
KB Part No. 8840 (Black Case) Part No. 8841 (White Case)
Rated for 1/10 - 1 HP (90 Volts DC) @ 115 Volts AC, 50/60 Hz
and 1/5 - 2 HP (180 Volts DC) @ 208/230 Volts AC, 50/60 Hz
Washdown and Watertight for Indoor and Outdoor Use
See Safety Warning on Page 5
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
© 2000 KB Electronics, Inc.
TM
OL
STOP
ON
MANUAL
START
STOP
AUTO
REGENERATIVE
DC MOTOR SPEED CONTROL
PENTA-DRIVE
TM
REV
FWD
NEMA-4X / IP-65
100
90
80
70
60
40
30
20
10
0
50
%
Pending TABLE OF CONTENTS
Section
Page
i.
Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ii.
Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
II.
Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
III.
Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IV.
Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
V.
Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . .
17
VI. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VII. AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
IX. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
X.
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XI. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tables
1.
General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.
Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.
Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.
Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.
Run Relay Output Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.
Setting Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.
Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figures
1.
Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.
Enlarged View of Trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.
Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.
Full Voltage Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . 10
6.
Half Voltage Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . 10
7.
Unidirectional Forward Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . 11
8.
Unidirectional Reverse Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . 11
9.
Bidirectional Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10. Bidirectional Main Speed Potentiometer Connection with Reversing Contacts . . . . . . . . 12
11. Remote Start/Stop Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12. Start/Stop Function Eliminated (Jumper Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
13. Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14. Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ii 15. DC Tach-Generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16. DC Tach-Generator Connection with Addition of RT . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
17. AC Line Input Voltage Selection (J1 and J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
18. Motor Voltage Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
19. DC Tach-Generator Voltage Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
20. Motor Current Selection (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21. Analog Input Signal Voltage Selection (J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
22. Control Mode Selection (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
23. Torque Mode Selection (J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
24. Current Limit Mode Selection (J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
25. Stop Mode Selection (J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
26. Run Relay Output Mode Selection (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
27. Enable Jumper (J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
28. Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
29. Linear Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
30. Non-Linear Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
31. Offset (OFFSET) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
32. Offset (OFFSET) Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
33. Forward Acceleration (FACC) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
34. Reverse Acceleration (RACC) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
35. Forward Acceleration (FACC) and Reverse Acceleration (RACC) Trimpot Adjustment . . 19
36. Maximum Speed (MAX) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
37. Forward Current Limit (FWDCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
38. Reverse Acceleration (REVCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
39. IR Compensation (IR) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
40. Response (RESP) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
41. Deadband (DB) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
42. Deadband (DB) Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
43. Timed Current Limit (TCL) Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
iii 4
i.
SIMPLIFIED OPERATING INSTRUCTIONS
A. Power Connection Connect the AC line to L1 and L2 terminals of Terminal Block
TB1 and the ground wire (Earth) to the green ground screw, as shown in Figure 4, on
page 10 and as described in Section IIA, on page 10 and Section IIB on page 10.
Be sure Jumpers J1 and J2 are both set to the corresponding AC line input voltage
position, as described in Section IIIA, on page 14.
B. Permanent Magnet (PM) Motor Connection (Two Wire Type) Connect the motor
armature to M1 (+) and M2 (-) terminals of Terminal Block TB1, as shown in Figure
4, on page 10 and as described in Section IIC, on page 10. Be sure that Jumper J3
is set to the corresponding motor voltage position, as described in Section IIIB, on
page 14 and Jumper J4 is set to the corresponding motor current, as described in
Section IIID, on page 15.
Note: Do not use F+ and F- terminals of Terminal Block TB2 for any purpose other
than to power the field of a shunt wound motor. Do not use F+ and F- terminals of
Terminal Block TB2 for PM motors. Do not use F1 and F2 quick-connect terminals
for any purpose other than to power the optional Signal Isolat