Penta KB Power Penta-Drive KBPW-240D User manual

INSTALLATION AND OPERATION MANUAL
MODELKBPW-240D
KB Part No. 8401 (Black Case) •Part No. 8402 (White Case)
NEMA4X, 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
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.
BRK
REV
FWD
%100
90
80
70
60
50
40
30
20
10
0
NEMA-4X / IP-65
START
STOP
RUN
JOG
PWM DC MOTOR SPEED CONTROL
PENTA-DRIVE™
OLSTOPON
™
!
TM
A COMPLETE LINE OF MOTOR DRIVES
©2002 KB Electronics, Inc.
See back cover
See Safety Warning on Page 2
Spec Tech Industrial 203 Vest Ave. Valley Park, MO 63088 Phone: 888 SPECTECH
Email: [email protected] www.spectechind.com

TABLE OF CONTENTS
Sectio Page
i. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
I. Intro uction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
II. Simplifie Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
III. Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
IV. Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
V. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VI. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VII. AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VIII. Trimpot A justments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IX. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
X. Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
XI. Limite Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tables
1. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Fiel Connection (Shunt Woun Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Setting Motor Current (SCR & PWM Motor Horsepower Ratings) . . . . . . . . . . . . . . . . . . . 10
Figures
1. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Full Voltage Fiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Half Voltage Fiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Remote Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7A. Remote 3-Wire Start/Stop Switch with Normally Open Start Contact
an Normally Open Stop Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7B. Remote 3-Wire Start/Stop Switch with Normally Open Start Contact
an Normally Close Stop Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7C. Remote 2-wire Start/Stop Switch with Normally Open Start/Stop Contact . . . . . . . . . . . . . . 8
8. Start/Stop Function Eliminate (Jumper Installe ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9. Voltage Following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10. Inhibit Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11. Enable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
12. Enable Circuit Using Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
13. DC Tach-Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14. Motor Voltage Selection (J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
15. Motor Current Selection (J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
16. Removing Resistor R35 (for low current selection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
17. Current Limit Mo e Selection (J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
18. DC Tach-Generator Voltage Selection (J4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19. DC Tach-Generator with A ition of RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ii

20. Run Relay Output Mo e Selection (J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21. Stop Switch Type Selection (J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
22. Enable Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
23. ACCEL Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
24. DECEL Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
25. MAX Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
26. MIN Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
27. JOG Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
28. CL Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
29. TCL Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30. IR Trimpot Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
iii

1
I. INTRODUCTION
Thank you for purchasing the KBPW-240D. KB Electronics, Inc. is committe to provi ing total
customer satisfaction by pro ucing quality pro ucts that are easy to install an operate. The
KBPW-240D is manufacture with surface mount components incorporating a vance circuit-
ry an technology.
The KBPW-240D is a Pulse Wi th Mo ulate (PWM) control in a NEMA-4X / IP-65 watertight
an wash own enclosure esigne to operate PWM an SCR rate Permanent Magnet an
Shunt Woun motors ranging from 0.2 Amps DC to 7.5 Amps DC. It operates at a switching
frequency greater than 16kHz to provi e high motor efficiency an quiet operation. Special cir-
cuitry automatically accepts AC li e i put voltages of 115 Volts AC to 208/230 Volts AC
(±10%, 50/60Hz) without havi g to make a jumper selectio .
Stan ar panel mounte features inclu e iagnostic LEDs (power on, stop, an overloa ),
Start/Stop switch, an spee potentiometer. Other features inclu e barrier terminal blocks
(facilitate wiring of AC line, motor armature, motor fiel , tach-generator an run relay connec-
tions), a justable trimpots (acceleration, eceleration, maximum spee , minimum spee , jog
spee [use with optional Run/Jog switch], current limit, time current limit an IR Comp.)
i. SAFETY WARNING! Please read carefully
This pro uct shoul be installe an service by a qualifie technician, electrician, or electrical
maintenance person familiar with its operation an the hazar s involve . Proper installation, which
inclu es wiring, mounting in proper enclosure, fusing or other overcurrent protection, an groun ing
can re uce the chance of electrical shocks, fires, or explosion in this pro uct or pro ucts use with this
pro uct, such as electric motors, switches, coils, solenoi s, an /or relays. Eye protection must be worn
an insulate a justment tools must be use when working with control un er power. This pro uct is
constructe of materials (plastics, metals, carbon, silicon, etc.) which may be a potential hazar .
Proper shiel ing, groun ing, an filtering of this pro uct can re uce the emission of ra io frequency
interference (RFI) which may a versely affect sensitive electronic equipment. If further information is
require on this pro uct, contact the factory. It is the responsibility of the equipment manufacturer an
in ivi ual installer to supply this Safety Warning to the ultimate en user of this pro uct. (SW effective
11/1992.)
This control contains electronic Start/Stop circuits that can be use to start an stop the control.
However these circuits are never to be use as safety isconnects since they are not fail-safe. Use
only the AC line for this purpose.
Be sure to follow all instructions carefully. Fire an /or electrocution can result ue to improper use
of this pro uct.
!
PWM Safety War i g! This co trol co tai s a safety circuit which is desig ed to preve t
full speed ru away i the eve t the mai power tra sistor fails. However, this safety cir-
cuit is ot i fallible a d may itself fail to operate a d therefore allow a full speed ru away co -
ditio to exist. The i staller of this product should take proper precautio s to i clude other
mea s to protect the operator or the machi e i volved (such as mecha ical disco ects, war -
i g otices, etc.).
!
This pro uct complies with all CE irectives pertinent at the time of manufacture. Contact the
Sales Department for etaile installation an Declaration of Conformity. Installation of a CE
approve RFI filter (KBRF-200A [P/N 9945C] or equivalent) is require . A itional shiel e motor cable
an /or AC line cables may be require along with a signal isolator (KBSI-240D [P/N 9431] or equivalent).
Electrical Hazard War i g Symbol: Failure to observe this warning coul result in
electrical shock or electrocution.
Operatio al Hazard War i g Symbol: Failure to observe this warning coul result in
serious injury or eath.
!

Optional accessories inclu e On/Off AC Line Switch, FWD-BRK-REV Switch, Run-Stop-Jog
Switch, Signal Isolator, an Anti-Plug Reversing Mo ule. Quick-connect terminals are provi -
e for easy installation of all optional accessories. The control is available in black finish (P/N
8401) an FDA approve white finish (P/N 8402).
STANDARD FEATURES
•Short Circuit Protectio – Protects control from a short circuit at motor connections.
•Electro ic Motor Bur out Protectio – Time Current Limit shuts own the control if a pro-
longe overloa con ition exists.
•Active Bridge – Limits the AC line inrush current when power is turne on an also prevents
high spee runaway if the power transistor shorts.
•Heat Spreader – Allows power transistor to operate safely uring momentary overloa con i-
tions.
•Auto AC Li e Select – Control automatically a justs for 115 or 208/230 Volt AC line input.
•Start/Stop Switch – Provi es electronic start an stop functions.
•Diag ostic LEDs – For power on (ON), stop (STOP) an motor overloa (OL).
•Trimpots – Provi e a justment for acceleration (ACCEL), eceleration (DECEL), maximum
spee (MAX), minimum spee (MIN), jog spee (JOG), current limit (CL), time current limit
(TCL), an IR compensation (IR).
•Selectable Jumpers – Provi e settings for armature voltage or tach-generator fee back (J1),
motor current (J2), time or non-time current limit (J3), tach-generator voltage (J4), an run
relay output (J5).
•Barrier Termi al Blocks – Facilitate wiring of AC line, motor armature an fiel , tach-genera-
to, run relay output, an thermal or enable switch.
•Quick-Co ect Termi als – Facilitate connecting Start/Stop switch, Run-Stop-Jog switch,
FWD-BRK-REV switch, an Inhibit switch.
II. SIMPLIFIED OPERATING INSTRUCTIONS
A. Power Co ectio – Connect the AC line to L1 an L2 terminals of TB1 an the groun
wire (Earth) to the green groun screw as shown in Figure 3, on page 6, an as escribe
in Section IIIA, on page 6, an Section IIIB, on page 6.
B. Perma e t Mag et (PM) Motor Co ectio (Two-Wire Type) – Connect the motor arma-
ture to A1 (+) an A2 (-) terminals of TB1 as shown in Figure 3, on page 6, an as escribe
in Section IIIC, on page 6. Be sure that jumper J3 is set to the correspon ing motor voltage
position as escribe in Section IVA, on page 10. Do ot use F1 a d F2 termi als of TB2
for a y purpose other tha to power the field of a shu t wou d motor. Do ot use F1
a d F2 termi als for PM motors.
Note: Motor performance an efficiency, inclu ing brush life, may be a versely affecte
when operating the control in step own mo e (208/230 Volt AC line with 90/130 Volt DC
motors).
C. Shu t Wou d Motors (Four-Wire Type) – Connect the motor armature as escribe in
Section IIIC, on page 6. Connect full voltage fiel wires (90 Volt DC motors with 100 Volt
DC fiel an 180 Volt DC motors with 200 Volt DC fiel ) to F1 (+) an F2 (-) terminals of TB2
as escribe in Section IIID, on page 7. Connect half voltage fiel wires (90 Volt DC motors
with 50 Volt DC fiel an 180 Volt DC motors with 100 Volt DC fiel ) to F1 (+) terminal of
TB2 an L1 (-) terminal of TB1 as escribe in Section IIIE, on page 7.
Note: Do not connect motor armature lea s to F1 an F2 terminals.
2
IMPORTANT – You must rea these simplifie operating instructions before procee ing.
These instructions are to be use as a reference only an are not inten e to replace the
etaile instructions provi e herein. You must rea the Safety Warning, on page 1, before
procee ing.

D. Motor Curre t – Jumper J2 is factory set for 7.5 Amp motors. For lower current motors, set
jumper J2 to the correspon ing motor current as escribe in Section IVB, on page 10.
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 calibrate for 7.5 Amps).
E. Trimpot Setti gs – All trimpots have been factory set as shown in Figure 1, on page 4.
Trimpots may be rea juste as escribe in Section VIII, on page 13.
F. Diag ostic LEDs – After power has been applie , observe the LEDs to verify proper con-
trol function as escribe in Section IX, on page 14.
G. Start/Stop Switch – The control is supplie with a prewire Start/Stop switch as escribe
in Section IIIG, on page 7. This switch must be use to start the control each time the AC
power is lost or the control shuts own ue to TCL. To overri e this function, see Section
IIIG, on page 7.
1. For low current operation, remove resistor R35 as escribe in section IVB, on page 10
2. Step- own operation.
3
115
AC Li e Voltage
(±10%, 50/60 Hz)
(Volts AC)
Motor Voltage
(Volts DC)
Maximum AC
Li e Curre t
(Amps RMS)
Maximum
Load Curre t
(Amps DC)
Maximum Horsepower
HP, (kW)
SCR Rated
Motors
PWM Rated
Motors
3/4, (0.5)
208 – 230
0 – 90, 130 11.5 7.5 1, (0.75)
Field Voltage
(Volts DC)
200
100
7.5 2, (1.5)11⁄2, (1)11.50 – 180, 260
TABLE 1 – ELECTRICAL RATINGS
0
100
Specificatio Factory Setti gParameter
0 – 50
Operating Frequency (kHz)
0.5 – 10
Operating Temperature Range at Full Rating (ºC)
>16 –
Current Range (High Scale) (Amps DC)
0 – 50 –
1.7, 2.5, 3.5, 5.0, 7.5 7.5
Current Range (Low Scale) (Amps DC)1
ACCEL an DECEL Range (Secon s)
Jog Spee (% Base Spee )
MIN Spee Range (% Base Spee [90VDC & 180VDC Motors])
MAX Spee Range (% Base Spee [90VDC & 180VDC Motors])
IR Comp Range at 90 Volts DC Output (∆Volts DC at Full Loa )
IR Comp Range at 180 Volts DC Output (∆Volts DC at Full Loa )
CL Range (% Range Setting)
Time Current Limit (TCL) Range (Secon s)
AC Line Input Voltage (Volts AC, ±10%, 50/60 Hz)
Armature Voltage Range at 115 Volts AC Line Input (Volts DC)
Armature Voltage Range at 208/230 Volts AC Line Input (Volts DC)
Fiel Voltage at 115 Volts AC Line Input (Volts DC) –
–
Fiel Voltage at 208/230 Volts AC Line Input (Volts DC)
Spee Range (Ratio) 50:1
0.2, 0.3, 0.4, 0.5, 0.8
0.5 – 10
0 – 30
50 – 140
0 – 15
0 – 30
0 – 200
115 – 208/230
0 – 130
0 – 1302, 0 – 260
100/50
200/100
150
–
1
15
4
8
5
–
90
90
–
Voltage Following Linearity (% Base Spee ) ±0.5 –
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS
AC Line Regulation (% Base Spee ) 0.5 –
Armature Fee back Loa Regulation (% Base Spee ) 1 –
Tach-Generator Fee back Loa Regulation (% Set Spee ) 1–

4
WHITE
RED
BLACK
START/STOP SWITCH
WHITE
MAIN SPEED POTENTIOMETER
VIOLET
ORANGE
JOG
JOG
COM
STOP
STOP COM
INH1
INH1
INH2
START
INH2START
CON1
P1
TB3
P1
STOP
P3
P2
P2
P3
NC
NO
J6
BLU
DECELACCEL KBPW-240D MINMAX JOG CL IRTCL
To LED Boar
L1B
J7A
L1A L2A
J7B
L2B
ORN
WHT
RED BLK
F1 A1F2 A2 L2L1
TB2
CON2
A1B A2B
A1A A2A
BLU WHT WHT
TB1
TCL NTCL
J3
DECELACCEL MINMAX JOG CL IRTCL
RELAY
NC
J5
NO
180VT
90V
J1
AMP
J2
0.43.5
0.3
0.2
2.5
1.7
0.8
0.5
7.5
5.0
LH
T-
K2
K1
RELAY
EN1
50V7V
EN2
T+
TACH
ENABLE
EN
J7
J4
Enlarge view of trimpots
FIGURE 1 – CONTROL LAYOUT
(Illustrates Factory Setting of Jumpers an Approximate Trimpot Settings)

5
BRK
REV
FWD
%100
90
80
70
60
50
40
30
20
10
0
NEMA-4X / IP-65
START
STOP
RUN
JOG
PWM DC MOTOR SPEED CONTROL
PENTA-DRIVE™
OLSTOPON
™
CONTROL SHOWN WITH OPTIONAL FWD-BRK-REV AND RUN-STOP-JOG SWITCHES
5.89
8.88 8.23 9.49
5.00
127
241
209
225
5.47
139
150
0.36
9
FIGURE 2 – MECHANICAL SPECIFICATIONS (INCHES / mm)

III. WIRING INSTRUCTIONS
WARNING! Rea Safety
Warning, on page 1, before
using this control. Disconnect the AC
line before wiring.
Note: To avoi erratic operation, o not
bun le AC line an motor wires with wires
from signal following, start/stop switch,
inhibit, or any other signal wires. Use
shiel e cables on all signal wiring over
12” (30cm). Shiel shoul be Earth
groun e on the control si e only. Wire
the control in accor ance with the
National Electrical Co e requirements
an other co es that may apply to your area. See Figure 3, Table 3 an Table 4, on page 7.
Be sure to properly fuse each con uctor that is not at groun potential. Do ot fuse eutral
or grou ded co ductors. See Sectio VII, o page 13. A separate AC line switch or con-
tactor must be wire as a isconnect so that each ungroun e con uctor is opene . An acces-
sory On/Off AC Line Switch (P/N 9341) may be use in lieu of, or in a ition to, the Start/Stop
switch. The switch can be wire for single pole or ouble pole operation, as require .
To maintain the watertight integrity of the control, be sure to use suitable watertight connectors
an wiring which are appropriate for the application. Two 7/8” (22.2mm) knockout holes are
provi e for stan ar 1/2” knockout connectors (not supplie ) for wiring. A watertight plug is
provi e if only one knockout is require .
War i g! Do not wire switches or relays in series with the armature. Armature switching
can cause catastrophic failure of motor an /or control. To avoi erratic operation, o not
bun le AC line an motor wires with potentiometer wires, voltage following wires, Start/Stop
switch wires, inhibit wires, or any other signal wires. Use shiel e cables on all signal wiring
over 12” (30cm) long. Shiel shoul be Earth groun e on the control si e only. War i g! Do
ot use CON2 for a y purpose other tha to power the optio al A ti-Plug Reversi g
Module APRM-PC (P/N 9378A).
A. AC Li e Co ectio – Wire AC line input to L1 an L2 terminals of TB1 as shown in
Figure 3.
B. Grou d Co ectio – Earth groun the control chassis using the green groun screw that
is provi e on the insi e of the control to the right si e of TB1 as shown in Figure 3.
C. Perma e t Mag et (PM) Motor Co ectio – Wire the motor armature lea s to A1 (+) an
A2 (-) terminals of TB1 as shown in Figure 3. Be sure jumper J1 is set to the appropriate
motor voltage an that J3 is set to the appropriate motor current. For step- own operation
(230 Volt AC line input with 90 Volt DC SCR rate motor or 130 Volt DC PWM rate motor)
set jumper J1 to “90V” position. However, in step- own operation the motor may have
re uce brush life - consult motor manufacturer.
6
!
!
AC LINE
+
M
-
MOTOR GROUND
(EARTH)
TB2
L2A2A1 L1
F2F1
TB1
FIGURE 3 – POWER CONNECTION
3.5
12
Termi al
Block
TB1
TB1
TB2
TB3
Supply Wire Gauge
(AWG - Cu)
TB4
Desig atio Co ectio s
Maximum
Tighte i g Torque
(i -lbs)
L1 & L2
A1 & A2
F1 & F2
T+ & T-
K1 & K2
Mi imum Maximum
22
22
24
24
24
12
12
14
14
14
12
3.5
3.5
AC Line Input
Motor Armature
Motor Fiel (Shunt Woun Motors Only)
Tach-Generator
Run Relay
TABLE 3 – TERMINAL BLOCK WIRING INFORMATION

Note: Do not connect motor armature
lea s to F1 an F2 terminals. Do not
use F1 an F2 terminals for PM motors.
D. Full Voltage Field Co ectio (Shu t
Wou d Motors O ly) – Wire the motor
fiel lea s to F1 (+) an F2 (-) terminals
of TB2 as shown in Figure 4 & Table 4.
Note: Do not connect motor armature
lea s to F1 an F2 terminals.
War i g! Do ot use F1 a d F2 ter-
mi als of TB2 for a y purpose other
tha to power the field of a shu t
wou d motor.
E. Half Voltage Field Co ectio (Shu t
Wou d Motors O ly) – Wire the motor
fiel lea s to F1 (+) an L1 (-) terminals
of TB2, as shown in Figure 5 & Table 4.
Note: Do not connect motor armature
lea s to F1 an F2 terminals.
War i g! Do ot use F1 a d F2 ter-
mi als of TB2 for a y purpose other
tha to power the field of a shu t
wou d motor.
F. Remote Mai Speed Pote tiometer
Co ectio – The control is supplie with a
prewire main spee potentiometer mounte
on the front cover. To operate the control
from a remote potentiometer (5kΩ), remove
the white, orange, an violet potentiometer
lea s from P1, P2, an P3 terminals, respec-
tively. The lea s may be tape an left insi e
the control. The potentiometer assembly may be remove if a watertight seal is use to
cover the hole in the front cover. Connect the remote main spee potentiometer wires to
terminals P1 (low si e), P2 (wiper), an P3 (high si e) as shown in Figure 6.
G. Remote Start/Stop Switch Co ectio s – The control is supplie with a prewire
Start/Stop switch mounte on the front cover. To operate the control from a remote
Start/Stop switch (type: (ON)-OFF-ON, SPDT), remove the white, black, an re wires
from START, COM, an STOP terminals, respectively. The lea s may be tape an left in
the control. The switch itself may be remove if a watertight seal is use to cover the hole
7
M
+
-
MOTOR AC LINE
-
FIELD
L2L1A1 A2
TB2
TB1
F1 F2
+
GROUND
(EARTH)
FIGURE 4 – FULL VOLTAGE FIELD
AC LINE
-
-
+
+
MOTOR
M
(EARTH)
FIELD
GROUND
L2L1A2A1
TB2F1 F2
TB1
FIGURE 5 – HALF VOLTAGE FIELD
Field Co ectio s
F1 & L1
AC Li e Voltage
(Volts AC)
Armature Voltage
(Volts DC)
Field Voltage
(Volts DC)
90 – 130115
115
230 180 – 260
230
230
90 – 130
180 – 260
90 – 130
100
50
200
100
100
F1 & F2
F1 & L1
F1 & F2
F1 & L1
TABLE 4 – FIELD CONNECTION (Shu t Wou d Motors O ly)
(FRONT VIEW)
Wiper
Low Side
High Side
POTENTIOMETER
MAIN SPEED
P3
P2
P1
FIGURE 6 – REMOTE POTENTIOMETER

in the front cover. Connect the
remote Start/Stop switch wires to
START (momentary), COM
(common), an STOP (constant)
terminals as shown in Figure 7A.
After applying power, momentari-
ly set the Start/Stop switch to
“START” position. The motor will
operate at the set spee of the
main spee potentiome-
ter. To stop the motor,
set the Start/Stop switch
to “STOP” position.
For remote 3-wire
Start/Stop Switch with
normally open start con-
tact an normally close
stop contact, see
Figure 7B.
For remote 2-wire
Start/Stop Switch with
normally open start/stop contact,
see Figure 7C.
Note: For automatic start when
power is applie , the Start/Stop
function can be bypasse . This
can be accomplishe by installing
a jumper (provi e with control)
between the START an COM ter-
minals. Jumper J6 must be in the
“NO” position. See Figure 8.
CAUTION! Eliminating the Start/Stop function using
a jumper will cause the motor to run at the main
spee potentiometer setting when the AC line is applie .
H. Ru Relay Co ectio – Normally open (NO) or normal-
ly close (NC) relay output contacts are provi e at TB4,
which will change state when the Start/Stop switch is set
to “START” position or if the control shuts own an goes
into STOP mo e from TCL. The run relay is use to in i-
cate the state of the control (run or stop). Normally open
or normally close run relay contact outputs can be select-
e epen ing on the position of jumper J5. If nor-
mally open is selecte (J5 in “NO” position), the
run relay output contacts will close when the
Start/Stop switch is set to “START” position. If nor-
mally close is selecte (J5 set to “NC” position),
the run relay output contacts will open when the
Start/Stop switch is set to “START” position. When
the control shuts own an goes into STOP mo e
from TCL, or the Start/Stop switch is set to “STOP”
position, the Run Relay output contacts will return to their normal position.
Note: If relay output contacts are not require for your application, J5 may be in any position.
I. Voltage Followi g Co ectio – An isolate 0 - 10 Volt DC analog signal can also be use
to control motor spee . See Figure 9.
8
MOMENTARY
CONTACT
MAINTAINED
CONTACT
COM
STOP
START
Start
Stop
STOP
NO
NC
J6
FIGURE 7A – REMOTE 3-WIRE START/STOP SWITCH
WITH NORMALLY OPEN START CONTACT
AND NORMALLY OPEN STOP CONTACT
(ISOLATED)
0 - 10V DC
+-
P3
P1
P2
FIGURE 9 – VOLTAGE FOLLOWING
MOMENTARY
NORMALLY OPEN
CONTACT
MOMENTARY
N
ORMALLY CLOSED
CONTACT
COM
STOP
START
Start
Stop
STOP
NO
NC
J6
FIGURE 7B – REMOTE 3-WIRE START/STOP SWITCH WITH
NORMALLY OPEN START CONTACT
AND NORMALLY CLOSED STOP CONTACT
MAINTAINED
NORMALLY CLOSED CONTACT
(CLOSE TO RUN, OPEN TO STOP)
COM
STOP
START
STOP
NO
NC
J6
FIGURE 7C – REMOTE 2-WIRE START/STOP SWITCH
WITH NORMALLY OPEN START/STOP CONTACT
COM
STOP
START
STOP
NO
NC
J6
FIGURE 8 –START/STOP
FUNCTION ELIMINATED
(JUMPER INSTALLED)
!

Note: If an isolate signal voltage is not available, an
optional signal isolator can be installe (KBSI-240D,
P/N 9431). Connect the isolate signal voltage to P2
(+) an P1 (-) terminals. A justment of the MIN trim-
pot may be necessary to achieve a 0 Volt DC output.
J. I hibit Co ectio – The control is supplie with
inhibit terminals (INH1 an INH2) to con-
nect an Inhibit switch. See Figure 10.
These terminals are use to electronical-
ly stop the control. When the Inhibit
switch is close , the control will coast to
stop. When the Inhibit switch is
opene , the control will accelerate to the
main spee potentiometer setting.
War i g! Do ot use I hibit as a
safety disco ect. Use o ly the
AC li e for this purpose.
K. E able Co ectio – The Enable is
use to electronically start an stop the
control. When the Enable contact is
close , the control will accelerate to the
Main Spee Potentiometer setting.
When the Enable contact is opene , the
control will coast to stop. Wire the
Enable contacts to Terminals EN1 an
EN2 of Terminal Block TB3 as shown in
Figure 11. The contacts must be isolate
an Jumper J7 must be remove .
Note: The control can also be starte an
stoppe with an Enable contact in the
Main Spee Potentiometer circuit. The
Enable function is establishe by wiring a
switch in series with the violet Main Spee
Potentiometer lea which connects to the
P3 terminal. See Figure 12.
War i g! Do ot use E able as a
safety disco ect. Use o ly the
AC li e for this purpose. The E able
Circuit is ot isolated a d is ot to be
Earth grou ded.
L. DC Tach-Ge erator Co ectio – Wire
the tach-generator to T+ (+) an T- (-) ter-
minals of TB4 as shown in Figure 13.
Jumper J1 must be in “T” position. Jumper
J4 must be in “7V” position for 7 Volt per
1000 RPM tach-generators or “50V” posi-
tion for 50 Volt per 1000 RPM tach-gener-
ators. See section IVD on page 11.
Note: When using a tach-generator, the IR
trimpot shoul be set fully counterclockwise.
IV. SETTING SELECTABLE JUMPERS
The KBPW-240D has customer selectable jumpers which must be set before the control can
be use . See Figure 1, on page 4 for location of jumpers.
9
(CLOSE TO STOP)
(OPEN TO RUN)
INHIBIT
INH2
INH1
FIGURE 10 – INHIBIT CIRCUIT
!
(CLOSE TO RUN)
(OPEN TO STOP)
ENABLE
Orange
White
Violet
Potentiometer
Main Speed
P3
P2
P1
FIGURE 12 – ENABLE CIRCUIT
USING POTENTIOMETER
!
ENABLEEN
J7
DC TACH-GENERATOR
EN1
EN2
T-
T+
TACH
K2
RELAY
K1
TB3
G
FIGURE 13 – DC TACH-GENERATOR
ENABLEEN
J7
ENABLE
Note: Jumper J7 must be
removed for Enable to operate.
(CLOSE TO RUN)
(OPEN TO STOP)
EN1
EN2
T-
T+
TACH
K2
RELAY
K1
TB3
FIGURE 11 – ENABLE CONNECTION

10
A. Motor Voltage Selectio (J1) – Jumper
J1 is factory set to “90V” position for 90
Volt SCR rate motors (or 130 Volt PWM
rate motors). For 180 Volt SCR rate
motors (or 220 Volt PWM rate motors),
set jumper J1 to “180V” position. See
Figure 14.
Note: If jumper J1 is set to “T”
position, a tach-generator must
be wire to TB3. If a tach-gener-
ator is not use , jumper J1 must
be in either “90V” or “180V” posi-
tion. If jumper J1 is in “T” position
an a tach-generator is not use ,
the motor will accelerate to full
spee an the main spee poten-
tiometer will not control spee .
B. Motor Curre t Selectio (J2) –
Jumper J2 is factory set to “7.5A”
position for 7.5 Amp motors.
For motors of lower amper-
age, set Jumper J2 to the
correspon ing position for
the motor being use . See
Figure 15 an Table 5.
Note: For low (L) motor
current settings (0.8A, 0.5A,
0.4A, 0.3A, an 0.2A), it is
necessary to remove resis-
tor R35. Cut the lea s at
the locations shown in
Figure 16.
WARNING!
Disco ect AC li e
before cutti g out resistor R35. Use a i sulated cutter a d wear safety glasses.
!
TO REMOVE RESISTOR R35
CUT THE LEADS HERE
WHT WHTBLU BLU
L2AL1B L2BL1A
R35
J7B
Q5
BLK
J7A
RED WHT
A2A
J6B
TB1
A1A A2B
J6A
L1 L2A2A1
D6
CON2
D20
TB2
A1B
ORG Q4
F1 F2
FIGURE 16 – REMOVING RESISTOR R35
1/2, (0.37)
SCR Rated Motor Horsepower
HP, (kW)
PWM Rated Motor Horsepower
HP, (kW)
J2 Setti g
(Amps DC) 130 Volts DC Motors
1/4, (0.18)
1/2, (0.37)
90 Volts DC Motors 180 Volts DC Motors 220Volts DC Motors
7.5
5.0
3.5
2.5
1.7
0.8*
3/4, (0.5)
1/2, (0.37)
1/3, (0.25)
1/4, (0.18)
1/6, (0.1)
1/12, (0.06)
0.5*
0.4*
0.3*
0.2*
1/20, (0.04)
1/20, (0.04)
11⁄2, (1)
1/25, (0.03)
1/30, (0.02)
1/50, (0.01)
1, (0.75)
3/4, (0.5)
1/3, (0.25)
1/6, (0.1)
1/10, (0.08)
1/12, (0.06)
1/15, (0.05)
1/25, (0.03)
1, (0.75)
3/4, (0.5)
1/2, (0.37)
1/3, (0.25)
1/4, (0.18)
1/8, (0.09)
1/15, (0.05)
1/20, (0.04)
1/25, (0.03)
1/30, (0.02)
2, (1.5)
11⁄2, (1)
1, (0.75)
3/4, (0.5)
1/6, (0.1)
1/8, (0.09)
1/10, (0.08)
TABLE 5 – SETTING MOTOR CURRENT (SCR & PWM Motor Horsepower Rati gs)
*Note: For low (L) motor current range settings (0.8A, 0.5A, 0.4A, 0.3A an 0.2A), it is necessary to remove resistor R35 as
shown in figure 16.
90V
180V
T
J1
90V
J1
180V
T
J1 Set for 90 Volt Motors
(Factory Setting) J1 Set for 180 Volt Motors
FIGURE 14 – MOTOR VOLTAGE SELECTION
*Note: For low (L) motor current range settings (0.8A, 0.5A, 0.4A,
0.3A an 0.2A), it is necessary to remove resistor R35 by cutting it
out of the circuit as shown in figure 16 on page 10.
0.2
7.5
5.0
3.5
2.5
1.7
0.8
0.5
0.4
0.3
Low Scale
Curre t Ra ge*
(Amps DC)
High Scale
Curre t Ra ge
(Amps DC)
J2 Set for 7.5 Amp Motor
(Factory Setti g)
FIGURE 15 – MOTOR CURRENT SELECTION

11
C. Timed a d No -Timed Curre t Limit
Selectio (J3) – Jumper J3 is factory set
to “TCL” position for time current limiting
operation. See Figure 17. For non-time
current limiting operation, set jumper J3
to “NTCL” position.
TCL (Timed Curre t Limit) – When
Jumper J3 is in the “TCL” position, the
control will go into “STOP” after it is in
overloa for a pre etermine amount of
time (set by the TCL trimpot).
Resetti g the Co trol After TCL – To reset the control after it has gone into TCL, momen-
tarily set the Start/Stop switch to “START” position or isconnect an reconnect the AC line.
If an On/Off AC Line Switch is installe , set it to “OFF” position an then back to “ON” posi-
tion. If the Start switch is jumpere (START an COM terminals connecte ), the control
must be restarte by isconnecting an reconnecting the AC line.
NTCL (No -Timed Curre t Limit) – When jumper J3 is set to “NTCL” position, the control
will not go into “STOP” after it is in overloa .
Note: TCL trimpot will have no affect when jumper J3 is in “NTCL” position.
D. DC Tach-Ge erator Voltage Selectio (J1 a d J4) – For a tach-generator wire to TB3,
set jumper J1 to “T” position. See Figure 18. Jumper J4 is factory set to “7V” position for 7
Volt per 1000 RPM tach-generators wire to TB3. For a 50 Volt per 1000 RPM tach-gener-
ator, set jumper J4 to “50V” position.
Note: When using a tach-generator, the IR trimpot shoul be set fully counterclockwise.
Note: The tach-generator input is esigne for 7 Volt or 50 Volt per 1000 RPM tach-gen-
erators use with 1800 RPM motors. For tach-generators other than 7 Volt or 50 Volt per
1000 RPM or for motors other than 1800 RPM, an external 1/2 watt resistor (RT) must be
use . Install RTin series with the tach-generator as shown in Figure 19, on page 12.
Jumper J4 must be set to “7V” position.
The value of RTin Ω can be calculate using the following formula:
RT= (1.46 x VTx S) - 19,000
Where VTis the tach-generator voltage (in Volts per 1000 RPM) an S is the base spee of
the motor (in RPM).
J3 Set for TCL Mo e
(Time Current Limit)
(Factory Setting)
J3 Set for NTCL Mo e
(Non-Time Current Limit)
TCL NTCL
J3
J3
NTCLTCL
FIGURE 17 – CURRENT LIMIT
MODE SELECTION
50V
7V7V 50V
90V 180V
TJ1 J4 J4
90V
J1 180V
T
J1 Set for 90 Volt Motors
(Factory Setting)
J4 Set for 7V per 1000RPM
Tach-Generator Input
(Factory Setting) J4 Set for 50V per 1000RPM
Tach-Generator Input
J1 Set for
Tach-Generator Input
Jumper J1 Settings Jumper J4 Settings
FIGURE 18 – DC TACH-GENERATOR VOLTAGE SELECTION
Suppose you have a 20 Volt per 1000 RPM tach-generator with a 3600 RPM motor:
RT= (1.46 X 20 X 3600) - 19000 = 86120Ω.
Choose the closest 1/2W resistor value, which is 82000Ω (82kΩ) or 91000Ω (91kΩ).
Rea justment of the MAX trimpot may be necessary to achieve the esire maximum
output voltage.
Example:

E. Ru Relay Output Mode Selectio (J5)
–Jumper J5 is factory set to “NO” position
for normally open relay output at TB4. For
normally close relay output, set jumper
J5 to “NC” position. See Figure 20.
F. Stop Switch Type Selectio (J6) –
Jumper J6 is factory set to the “NO” position
for a normally open stop switch, as use on
the front cover. If a remote normally close
stop switch is use , set Jumper J6 to the
“NC” position. If a remote normally open
stop switch is use , set Jumper J6 to the
“NO” position. See Figure 21.
G. E able Selectio (J7) – Jumper J7 is fac-
tory installe to enable the control. If con-
necting Enable contacts to Terminals EN1
an EN2 of Terminal Block TB3, remove
Jumper J7. See Figure 22.
V. MOUNTING INSTRUCTIONS
War i g! The KBPW-240D is ot
desig ed to be used i a explo-
sio -proof applicatio .
It is recommen e that the control be mount-
e vertically on a flat surface with a equate
ventilation. Leave enough room below the
control to allow for AC line, motor connec-
tions, an any other wiring. Although the
control is esigne for out oor an wash-
own use, care shoul be taken to avoi
extreme hazar ous locations where physi-
cal amage can occur. If the control is
mounte in a close , unventilate location,
allow enough room for proper heat issipa-
tion. If operating the control at full rating, a
minimum enclosure size of 12”W x 24”H x
12”D is require . See Figure 2, on page 5.
The KBPW-240D is esigne with a hinge
case so that when the front cover is open,
all wiring stays intact. To open the cover, the four
screws must be loosene so they are no longer
engage in the case bottom. After mounting an
wiring, close the cover an make sure that wires will
not get caught or crimpe as the cover is close .
Tighten all four cover screws so that the gasket is
slightly compresse . Do ot over tighte .
VI. OPERATION
Cautio ! It is recommen e that the bus capacitors
be recon itione if this pro uct has been in storage for over one year. To recon ition the capac-
itors, apply the AC line, with the rive in Stop Mo e, for a minimum of one hour.
After the control has been properly set up (jumpers set to esire positions an wiring com-
plete ), the startup proce ure can begin. If AC power has been properly brought to the con-
trol, the ON an STOP LEDs will be illuminate . Before starting, be sure the main spee
12
ENABLEEN
J7
DC TACH-GENERATOR
RT
EN1
EN2
T-
T+
TACH
K2
RELAY
K1
TB3
G
FIGURE 19 – DC TACH-GENERATOR
WITH ADDITION OF RT
!J5 Set for Normally Open
(NO) Output Contacts
(Factory Setting) J5 Set for Normally Closed
(NC) Output Contacts
NC NO
J5
J5
NONC
FIGURE 20 – RUN RELAY OUTPUT
MODE SELECTION
J6 Set for
Normally Open Stop Switch
(Factory Setting) J6 Set for
Normally Closed Stop Switch
STOP
NO
NC
J6
STOP
NO
NC
J6
FIGURE 21 – STOP SWITCH
TYPE SELECTION
J7 Installed to
Enable the Control
(Factory Setting) J7 Removed to
Connect Enable Contacts
EN
J7
EN
J7
FIGURE 22 – STOP SWITCH
TYPE SELECTION

potentiometer is fully counterclockwise. To start the control, momentarily set the Start/Stop
switch to “START” position an release it. The STOP LED shoul no longer illuminate. The
motor shoul begin to rotate, as the main spee potentiometer is rotate clockwise.
Note: If the motor rotates in the incorrect irection, it will be necessary to isconnect the AC
line, reverse the motor lea s, an repeat the startup proce ure.
VII. AC LINE FUSING
This control oes not contain AC line fuses. Most electrical co es require that each ungroun -
e con uctor contain circuit protection. Installation of a 20 Amp fuse or circuit breaker in series
with each ungroun e con uctor is recommen e . Check all electrical co es that apply to the
application.
VIII. TRIMPOT ADJUSTMENTS
The KBPW-240D contains trimpots, which are factory set for most
applications. The trimpots are shown in the approximate calibrat-
e positions. Some applications may require rea justment of the
trimpots in or er to tailor the control for a specific requirement.
Rea just trimpots as escribe below.
War i g! If possible, do ot adjust trimpots with
mai power applied. If adjustme ts are made with
mai power applied, a i sulated adjustme t tool must be
used a d safety glasses must be wor . High voltage exists i
this co trol. Fire a d/or electrocutio ca result if cautio is
ot exercised. Safety War i g, o page 1, must be read a d
u derstood before proceedi g.
A. Acceleratio (ACCEL) – Sets the amount of time for the
motor to accelerate from minimum spee to maximum spee .
The ACCEL trimpot is factory set for one (1) secon , as
shown in Figure 23. For more rapi acceleration time, rotate
the trimpot counterclockwise. For longer acceleration time,
rotate the trimpot clockwise.
Note: Rapi acceleration settings may cause the current limit
circuit to activate, which will exten the acceleration time.
B. Deceleratio (DECEL) – Sets the amount of time for the
motor to ecelerate from maximum spee to minimum spee .
The DECEL trimpot is factory set for one (1) secon , as
shown in Figure 24. For more rapi eceleration time, rotate
the trimpot counterclockwise. For longer eceleration time,
rotate the trimpot clockwise.
Note: Deceleration time will not be shorter than the maximum
coast time of the motor un er actual loa .
C. Maximum Speed (MAX) – Sets maximum spee of the
motor. The MAX trimpot is factory set for 100% of base motor
spee , as shown in Figure 25. For a higher maximum spee
setting, rotate the trimpot clockwise. For a lower maximum
spee setting, rotate the trimpot counterclockwise.
D. Mi imum Speed (MIN) – Sets minimum spee of the motor.
The MIN trimpot is factory set for 0% spee , as shown in
Figure 26. For a higher minimum spee setting, rotate the
trimpot clockwise
13
!0.5 10
5
1
Secon s
FIGURE 23 – ACCEL
TRIMPOT RANGE
0.5 10
5
1
Seconds
FIGURE 24 – DECEL
TRIMPOT RANGE
5
0 140
95
100
% Base Speed
FIGURE 25 – MAX
TRIMPOT RANGE
030
15
% Base Speed
FIGURE 26 – MIN
TRIMPOT RANGE

E. Jog Speed (JOG) – Sets “jog” spee of the motor. The JOG
trimpot is factory set for 15% of motor base spee , as shown
in Figure 27 . For a higher jog setting, rotate the trimpot
clockwise. For a lower jog setting, rotate the trimpot counter-
clockwise.
Note: The Jog feature requires installation of the Run-Stop-Jog
Switch assembly (P/N 9340).
F. Curre t Limit (CL) – Sets current limit (overloa ), which limits
the maximum current to the motor. The current limit set point is
establishe by the setting of jumper J2 an the setting of the CL
trimpot. The CL trimpot is factory set for 150% of J2 range set-
ting, as shown in Figure 28. For a higher current limit setting,
rotate the trimpot clockwise. For a lower current limit setting,
rotate the trimpot counterclockwise. Two mo es of current lim-
iting operation are provi e : Non-Time Current Limit (NTCL)
an Time Current Limit (TCL). See Section IVC, on page 11.
CAUTION! A justing the CL above 150% of motor rating can
cause overheating an emagnetization of some PM motors.
Consult the motor manufacturer. Do not leave the motor in a
locke con ition for more than a few secon s since armature
amage may occur.
G. Timed Curre t Limit (TCL) – Sets the time for the control to
shut own after being in current limit (provi es electronic motor
overloa protection). The TCL trimpot is factory set for 5 sec-
on s, as shown in Figue 29. For increase TCL time, rotate the
trimpot clockwise. For ecrease TCL time, rotate the trimpot
counterclockwise. If the control remains in CL for a pre eter-
mine amount of time (set by the TCL trimpot an if jumper J3
is in the “TCL” position), the control will shut own. To reset the
control after it has shut own, momentarily set the start/stop
switch to the “START” position or isconnect an then recon-
nect the AC line.
War i g! When the control shuts own in TCL, the
AC line voltage is still present in the control.
H. No -Timed Curre t Limit (NTCL) – When jumper J3 is set to
“NTCL” position an an overloa con ition exists, the control
will remain in current limit an will not shut own.
I. IR Compe satio (IR) – Sets the amount of compensating
voltage require to keep the motor spee constant un er
changing loa s. The IR trimpot is factory set for 4 Volts (for
90 Volt DC output) an 8 Volts (for 180 Volt DC output), as
shwon in Figue 30. For higher compensating voltage, rotate the trimpot clockwise. For
lower compensating voltage, rotate the trimpot counterclockwise.
Note: If the IR compensation is set too high, unstable (oscillatory) operation will result. If
the control is use with a tach-generator, the IR trimpot shoul be set fully counterclockwise.
IX. DIAGNOSTIC LEDs
The KBPW-240D is esigne with LEDs mounte on the front cover to isplay the control’s
operational status.
A. Power O (ON) – The ON LED will illuminate green when the AC line is applie to the
control.
Note: When removing power to the control, the POWER LED will remain illuminate for a
few secon s until the DC bus voltage ischarges.
14
!
050
25
15
% Base Spee
FIGURE 27 – JOG
TRIMPOT RANGE
0 200
100
150
% Range Setting
FIGURE 28 – CL
TRIMPOT RANGE
0.5 10
5
Seconds
FIGURE 29 – TCL
TRIMPOT RANGE
0 15, 30
7.5, 15
4
, 8
Volts
FIGURE 30 – IR
TRIMPOT RANGE

B. Stop (STOP) – The STOP LED will illuminate yellow when the Start/Stop switch is set to
“STOP” position. When AC line is applie , this LED will also be illuminate until the
Start/Stop switch is set to “START” position.
C. Overload (OL) – The OL LED will illuminate re when the control goes into current limit, in i-
cating that the current limit set point has been reache (set by the CL trimpot an the posi-
tion of jumper J2). This LED will remain illuminate if the control times out in TCL (jumper
J3 set to “TCL” position). The control can be reset by either setting the start/stop switch to
“START” position or by isconnecting an reconnecting the AC line. If the overloa con i-
tion still exists when the control is restarte or AC line reapplie , the OL LED will illuminate
again. If the OL LED remains illuminate uring control operation, a fault con ition may
exist. Possible causes for this con ition are as follows:
• Motor is overloa e . Check motor current. If the motor is a shunt woun type, the fiel
may be open or not receiving proper voltage.
• Motor may be efective. Check motor for shorts or groun s.
• CL may be set too low. Check position of CL trimpot an setting of jumper J2.
Note: I some applicatio s, especially those requiri g the motor to cycle o a d off,
or from o e speed to a other, or from stop to high speeds, the OL LED may bli k,
i dicati g a tra sie t overload. This may be a ormal co ditio for the applicatio .
X. OPTIONAL ACCESSORIES
Complete instructions an connection iagrams are supplie with all accessories to facilitate
installation.
A. O /Off AC Li e Switch (P/N 9341) – Disconnects the AC line. Mounts on the enclosure
cover an is supplie with a switch seal to maintain watertight integrity.
B. FWD-BRK-REV Switch (P/N 9339) – Provi es motor reversing an ynamic braking. This
switch is equippe with a center off hesitation mechanism, which assures that the motor is
fully stoppe before it can be reverse . Mounts on the enclosure cover an is supplie with
a switch seal to maintain watertight integrity.
C. Ru -Stop-Jog Switch (P/N 9340) – Selects spee setting from either main potentiometer
or JOG trimpot. Mounts on the enclosure cover an is supplie with a switch seal to main-
tain watertight integrity.
D. Sig al Isolator KBSI-240D (P/N 9431) – Provi es isolation from non-isolate signal
sources. Mounts on the insi e of the enclosure cover.
E. Auto/Ma ual Switch (P/N 9377) – When use with the KBSI-240D (P/N 9431), it selects
either an isolate signal from the KBSI-240D or from the main spee potentiometer. Mounts
on the enclosure cover an is supplie with a switch seal to maintain watertight integrity.
F. A ti-Plug Reversi g Module APRM-PC (P/N 9378A) – Provi es electronic braking an
reversing. Mounts on the insi e of the enclosure cover.
Note: For use with this control, the APRM-PC must be Revision A or newer.
G. RFI Filters a d Chokes – RFI Filters an Chokes are available to provi e suppression for
con ucte ra io frequency interference (RFI). They comply with the CE Directive
89/336/EEC relating to the EMC Class A In ustrial Stan ar an Class B Resi ential
Stan ar . See RFI Filters an Chokes Selection Gui e (Publication No. D-321).
15

– NOTES –
16

XI. LIMITED WARRANTY
For a perio of 18 months from the ate of original purchase, KB Electronics, Inc. will repair or
replace, without charge, evices which our examination proves to be efective in material or
workmanship. This warranty is vali if the unit has not been tampere with by unauthorize per-
sons, misuse , abuse , or improperly installe an has been use in accor ance with the
instructions an /or ratings supplie . The foregoing is in lieu of any other warranty or guarantee,
expresse or implie . KB Electronics, Inc. is not responsible for any expense, inclu ing instal-
lation an removal, inconvenience, or consequential amage, inclu ing injury to any person,
cause by items of our manufacture or sale. Some states o not allow certain exclusions or lim-
itations foun in this warranty an therefore they may not apply to you. In any event, the total
liability of KB Electronics, Inc., un er any circumstance, shall not excee the full purchase price
of this pro uct. (rev 2/2000)
(A40360) – Rev. B – 8/2002
KB Electro ics, I c.
12095 NW 39th Street, Coral Springs, FL 33065-2516 • [phone] • Fax [phone]
Outsi e Flori a Call TOLL FREE [phone] • E-mail – [email protected]
www.kbelectronics.com
Copyright © 2002 by KB Electro ics, I c.
All rights reserve . In accor ance with the Unite States Copyright Act of 1976, no part of this
publication may be repro uce in any form or by any means without permission in writing from
KB Electronics, Inc. (8/22/02)