KBRG-213D - KB Electronics, Inc.
Contents
1. Uwe ASLL LP aeLZ 9X8A E gt e E ZS S d x es gt 1 ap AP Zb AP alr AP Ar AP Joel R DE9 0 ww V sanon SNOILVOISIDAdS TVOINVHOAW Z 913 D Ground Be sure to ground earth control via green FIG 8 UNIDIRECTIONAL screw located on chassis OPERATION Forward E Main Speed Potentiometer The main speed potenti 15V SIG 15V MIN ometer can be connected in several ways using termi nals SO S1 S3 A 5K ohm potentiometer is supplied with control A 10K potentiometer can also be used Warning Terminals SO S1 S2 and S3 are not isolated from AC line Note Jumper J5 must be in the 15V position i Unidirectional operation only Connect potentiom eter to terminals SO S1 S2 for forward direction See fig 8 To operate in reverse direction connect to SO S2 and S3 See fig 9 ii Bidirectional operation using reversing contacts Connect to terminals SO S1 S2 and S3 as per fig 11 FIG 9 UNIDIRECTIONAL FIG 10 BIDIRECTIONAL FIG 11 BIDIRECTIONAL OPERATION Reverse OPERATION Reversing Contact OPERATION Potentiometer 15V SIG 15V MIN COM STP 15V SIG 15V MIN 15V SIG 15V F Voltage Following An analog voltage FIG 12 VOLTAGE FOLLOWING CONNECTION can be used in lieu of main speed poten tiometer Connect signal to terminals 15V_SIG 15V_MIN COM_STP S2 and RB1 Note Te2. 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 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 9945A or equivalent is required Additional shielded motor cable and or
3. terminal A1 and A2 Be sure jumper J3 is set to match motor voltage See table 4 p 3 C Field For Shunt Wound motors only Do not use F1 and F2 terminals for any other motor type Connect motor shunt field to terminals F1 and F2 for 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 F1 and L1 See table 6 for summary of field connections FIG 5A FULL VOLTAGE FIELD FIG 5B HALF VOLTAGE FIELD TABLE 6 FIELD CONNECTIONS Shunt Wound Motors Only MOTOR VOLTAGE FIELD VOLTAGE VDC FIELD CONNECTION F1 F2 So e BC RER RRE CL 100 180 2 F1 F2 gd ON AJYDOV GM4 AdS XVW dNOO I OLAZY DO AVLS dS NIN CHA lady OS LS ZS Co G eleele s dls WOO NIN ASI 9IS ASh erfi LNNOO 154 ASI PWR ON fer F1 O F2 a LL z z V dE LZ DUIA E y Ei 2 2 2 222222 zz besse zz zzz eessen 22222 LNOAVT TOULNOD 9 DIA WM SI GYYVOS AYOSSIIIV HLIM LHOISH WNWIXYWN E SI GUVOE ANOSSSOOV LNOHLIM LHSISH WNWIXVW SLON L922 006 8 oz 2 9 oles S9z 0 gd OC AC AMY dS vu dw MI OLAJ DL OM VIS Ode NIN cay LO OS LS ZS ES DEE sel R go s YA Se KS 020 513 Zeg e VS dlS WOO NIN ASI 9IS AL ech A LNNOO H ASI MOON AQ6 il er AL ege zr 6 88 GEIK ALL 00S NOEZ
4. 0 However it is also possible to set the armature voltage to 90 for step down operation See fig 2 and table 4 FIG 1 AC LINE VOLTAGE FIG 2 MOTOR ARMATURE JUMPER SETTING VOLTAGE JUMPER SETTING 115VAC 230VAC 90VDC 180VDC J1 J1 180V 180V sol el 90V 90V TABLE 4 RELATIONSHIP of AC LINE INPUT AND MOTOR VOLTAGE with J1 J2 and J3 JUMPER POSITION AC INPUT VOLTAGE J1 J2 POSITION J3 POSITION MOTOR VOLTAGE A 90VDC motor can be used with a 230VAC line However speed range may be reduced and motor overheating may result C J4 Armature Current Select the J4 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 J4 position which may be readjusted using the FWD CL and REV CL trimpots TABLE 5 JUMPER J4 POSITION vs MOTOR HORSEPOWER Jumper J4 Position Motor Current DC Amps D J5 Analog Input Voltage FIG 3 JUMPER J5 SETTING Jumper J5 is set to the 15V po Signal Following sition for potentiometer operation If the control is to be operated 15V 15V from an isolated 0 10VDC J5 SET J5 SET signal set J5 to the 10V posi EAA TAR tion See sec V F p 7 See fig 3 IV MOUNTING Mount the KBRG 213D on a flat surface free of moisture metal chips or corrosive atmosphere See Mechanical Specifications fig 7 p 6 A 5K ohm remote speed potentiometer is provided with each control I
5. AC line cables may be required along with a signal isolator SI 4X KB P N 8801 or equivalent GENERAL INFORMATION The KBRG 213D 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 provides dynamic response 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 Max AC Max Voltage Current Output Voltage Max DC Output Horsepower VAC RMS VDC Current ADC HP KW KBRG 213D Ta e lag i OPERATION The KBRG will vary the motor speed as a function of the signal voltage on input terminals S2 signal and RB1 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 is a 4 quadrant regenerative drive the m
6. INSTALLATION AND OPERATING INSTRUCTIONS REGENERATIVE DRIVE MODEL KBRG 213D KB Part No 8826 VARIABLE SPEED SCR CONTROL DESIGNED FOR SHUNT WOUND and PM DC MOTORS FULL WAVE 4 QUADRANT KS 213D Se Se Se q Ve aS aS aS Gu 180V i 90V E 3 S lS US tela H 909900000 S2_S1 S0 RB1 RB2 MINSPD emp FWDTQ REVTQ IRCOMP MAXSPD FWDACC REVACC DB 4 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 See Page 1 PENTA POWER A COMPLETE LINE OF MOTOR DRIVES 1998 KB Electronics Inc TABLE OF CONTENTS Section Page i EI Al WEE 1 l General Information ek i AEN A A A ie 1 IL Operation voii KEEN ens WENNT NEEN Se Re dd a a EOS ci 1 Ill Setting Selectable Jumpers 2 IVa Mounting 44 2 200044 isi steal ey doe A ae MEN AN 4 RN 4 Vip 2RUSING EE 8 VI Trimpot Adjustments veia Ss aes ee aod See Beane BAe Gas e AT ae EE 8 VIII Function Indicator Lamp eee eee 10 1D Limited Warranty ia A Sas ES aS oa tee ase ve ees 14 TABLES Tx Electrical Ratings EE 1 2 Summary of Control Operation 2 3 General Performance Specifications 2 4 Relationship of AC Line Input and Motor Voltage with J1 J2 and J3 Positions 3 5 Jumper J4 Position vs Motor Horsepower o o
7. d 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 J2 setting Readjust the CL trimpot as follows i Turn CL trimpot to MIN CCW position Be sure jumper J2 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 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 IR Compensation IR Comp The IR Comp is used to stabilize motor speed under varying loads Readjust the IR Comp trimpot as follows i Run motor at approximately 30 50 of rated speed under no load and measure actual speed ii Load motor to rated current Rotate IR Comp trimpot so that loaded speed is the same as the unloaded speed measured in i Control is now compensated so that minimal speed change will occur over a wide range of motor load Note Too much IR Comp will cause unstable oscillatory operation Maximum Speed MAX The MAX trim
8. e rapid braking when required can be accomplished by increasing the setting of the reverse current limit trimpot REV CL Note Increasing the CL beyond 200 of the E motor current rating can lead to premature motor failure REGENERATE Use an isolated contact as shown in fig 13 TO STOP ii Inhibit Coast to Stop using Conn 1 When a contact closure is made on the FIG 14 COAST TO STOP Conn 1 terminals the control will cause the motor to coast to a stop A 2 wire mating connector is supplied Use an E isolated contact as shown in fig 14 TO STOP 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 7 Fuses may be purchased from your distributor TABLE 7 ARMATURE FUSE CHART Motor Horsepower Approx DC Motor Fuse Rating 90VDC 180VDC Current Amps AC Amps RA TRIMPOT ADJUSTMENTS The KBRG contains trimpots which have been factory adjusted for most applications See specifications for factory settings N
9. ltage at 115VAC Line VDC 100 50 P GER Field Voltage at 230VAC Line VDC 200 100 Ss Service Factor 10 CN Duty Continuous Max Load Capacity for 2 minutes 150 Ambient Temperature Range C 0 50 as Speed Range Ratio 50 1 Arm Feedback Load Regulation Base Set CN Speed 40 5 fy Line Regulation Base Speed 1 7 25 335 0 7 5 75 Current Ranges ADC 01 G 15 eager S 1 FWD and REV Accel Range Sec o 43 0 Dead Band Range Base Speed 70 L1 10 100 Max Speed Trimpot Range Base Speed 0 15 5 IR Comp Range at 115VAC Line VDC 0 30 10 IR Comp Range at 230VAC Line VDC 0 150 150 FWD and REV CL Range Range Setting 0 10 0 15 0 15 Voltage Following Input Range VDC 0 5 g E Zeile Voltage Following Linearity Base Speed ic lll SETTING SELECTABLE JUMPERS The KBRG 213D has customer selectable jumpers which must be set before the control can be used refer to fig 1 p 3 Bold indicates factory setting See fig 6 p 5 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 p 3 B J3 Motor Armature Voltage Select the desired armature voltage by placing J3 in the proper position 90 or 180 Note For 115 volt AC Line input the armature voltage must be set to 90 For 230 input the armature voltage normally is set for 18
10. nstall potentiometer using hardware provided Be sure to install insulating disk between potentiometer and inside of front panel Enclosure When mounting the KBRG 213D in an enclosure it must be large enough to allow the proper heat dissipation A 12 12 24 enclosure is suitable at full rating Smaller enclosures may be used if full rating is not required V WIRING 4 4 Warning Read Safety Warning before attempting to use this 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 Electric Code require ments 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 FIG 4 AC LINE AND potential do not fuse neutral or grounded conductors See ARMATURE CONNECTION section VI p 8 for fuse information Wire control in accor dance with connection diagram see fig 6 p 5 A separate AC Line switch or contactor must be wired as a disconnect switch so that contacts open each ungrounded conductor of the control 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 4 p 3 B Motor Armature Connect motor armature to
11. occoccooccc eee 3 6 Field Connections Shunt Wound Motors Only 4 7 Armature Fuse Chart ooo ocooccoocc eee eee 8 FIGURES 1 AC Line Voltage Jumper Setting 3 2 Motor Armature Voltage Jumper Geng 3 de Jumper d5 Setting EE 3 4 AC Line and Armature Connection 4 5A Full Voltage Field e eed AS a ere E 4 5B Half Voltage Field Dren sects NEEN NN ts vue coe AANER SE NET ASS wip adie Ad 4 Bi Control Layout eect ret hs ee a Pe he eee Abate ek e 5 7 Mechanical Specifications 0 2 0 eee 6 8 Unidirectional Operation Forward oooooocccocccocoocre 7 9 Unidirectional Operation Reverse 0 0 eee 7 10 Bidirectional Operation Reversing Contact 7 11 Bidirectional Operation Potentiometer 7 12 Voltage Following Connection 0 0 000 cee eee 7 1357 Reget SlOp EEN 8 14 2 IS EE 8 15 Accel Trimpot Adjustment 0 0 0 0 ee eens 9 16 Minimum Speed Trimpot Adjustment 9 17 Deadband Trimpot Adjustment 9 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 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
12. 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 SS Outside Florida Call TOLL FREE 800 221 6570 Email info kbelectronics com www kbelectronics com A40282 Rev C 5 98
13. ote fig 6 p 5 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 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 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 15 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 is available as an option It provides separate control of FORWARD acceleration and deceleration and REVERSE acceleration and deceleration KB P N 8803 FIG 15 ACCEL TRIMPOT ADJUSTMENT Minimum Speed Trimpot MIN The MIN trimpot is used to pro
14. otor 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 regen operation TABLE 2 SUMMARY OF CONTROL OPERATION Operation Direction direction Direction Le CR CT beem cow cow on TABLE 3 GENERAL PERFORMANCE SPECIFICATIONS Parameter Specification Sang AC Line Input Voltage VAC 10 50 60 Hz AC Line Frequency Hz of Phases a 5 EE Arm Voltage Range at 115VAC Line VDC 0 90 WW Arm Voltage Range at 230VAC Line VDC 0 1 80 0 90 0 180 Field Vo
15. pot 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 Rotate Main Speed potentiometer to full speed CW ii Adjust MAX trimpot to desired maximum motor speed Note Do not exceed maximum rated RPM of motor since unstable operation may result Stability Trimpot STAB 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 FUNCTION INDICATOR LAMP LED 1 Power On PWR ON indicates that the drive is energized with the AC line Bipolar Signal Isolator 4 Quad Accel Decel Multi Speed Board IX KBRG 213D ACCESSORIES KB P N 8801 KB P N 8803 KB P N 8814 11 X 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
16. rminal RB1 is common A positive signal with respect to terminal RB1 will produce a positive output to motor A negative signal with S1 RB respect to terminal RB1 will produce a negative output A0 to 10VDC is re JUMPER quired to operate control from O full J5 output A bipolar signal isolator Sl 4X MUST BE KB P N 8801 is available as an option IN 10V from your distributor Note Jumper J5 THEN POSITION must be in the 10V position ISOLATED Ay Note An isolated signal voltage must be used or catastrophic failure can result G Start Stop Circuits The KBRG 213D contains two 2 wire stop circuits which are used to electronically bring the motor to a stop Both require an isolated single contact closure If an isolated contact is not available it may be necessary to use an isolation relay WARNING Do not use Start Stop or inhibit functions as a safety disconnect Use only an AC line disconnect for that purpose Vi Vil i Regen to stop using terminals RB1 and RB2 on terminal block TB3 When a contact closure is made the control will use FIG 13 REGEN TO STOP regenerative braking to bring the motor to a rapid stop In the forward direction the rate of braking can be slowed by increasing the setting of the reverse acceleration trimpot REV ACC The rate of braking can be made faster by decreasing the setting of the REV ACC trimpot to its full CCW position Mor
17. vide an adjustable minimum speed when the control is used with an external potentiometer See section V E p 7 FIG 16 MINIMUM SPEED TRIMPOT ADJUSTMENT CURVE ADJ MIN 4 aie haa TRIMPOT lt NONE RANGE b 10 MIN c 20 MIN T 100 MAIN SPEED POT ROTATION 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 FIG 17 DEADBAND TRIMPOT ADJUSTMENT CURVE a NO DEADBAND CURVE b MAX DEADBAND Vill 10 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 9 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 STAB trimpot setting See sec VII G 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 an
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