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 A COMPLETE LINE OF MOTOR DRIVES © 2002 KB Electronics, Inc. INSTALLATION AND OPERATION MANUAL KB Part No. 8833 Ñ Multi-Speed Board for KBMG Series Regenerative Drive The information contained in this manual is intended to be accurate. However, themanufacturer retains the right to make changes in design which may not be included herein. See Safety Warning on Page 1 T ABLE OF CONTENTS Section Page i.Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1I.Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2II.Setting Selectable Jumpers (Each Preset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3III.Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7IV.Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10V.Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11VI.Trimpot Adjustments (Each Preset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1VII.Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Tables1.General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.Terminal Block TB1 Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Figures1.Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.Presets 1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.Direction Selection (R/F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44.Speed Range Selection (HI/LO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.Enable Selection (J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46.Control Layout and Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.KBMG Multi-Speed Board and KBMG Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .68.Removing the KBMG Finger-Safe Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.Removing Terminal Block TB1 from the KBMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .810.Removing the KBMG Finger-Safe Cover Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911.Preset Speed Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1012.Enable Contact Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1013.Tach-Generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1114.Preset Trimpot Range (Each Preset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Definition of Safety Warning SymbolsElectrical Hazard Warning Symbol ÐFailure to observe this warning could result inelectrical shock or electrocution.Operational Hazard Warning Symbol ÐFailure to observe this warning could result i.SAFETY WARNING  This product should be installed and serviced by a qualified technician, electrician, orelectrical maintenance person familiar with its operation and the hazards involved.Proper installation, which includes wiring, mounting in proper enclosure, fusing or other over cur-rent protection, and grounding can reduce the chance of electrical shocks, fires, or explosion in thisproduct or products used with this product, such as electric motors, switches, coils, solenoids,and/or relays. Eye protection must be worn and insulated adjustment tools must be used whenworking with control under power. This product is constructed of materials (plastics, metals, car-bon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding, and filtering of thisproduct can reduce the emission of radio frequency interference (RFI) which may adversely affectsensitive electronic equipment. If further information is required on this product, contact the SalesDepartment. It is the responsibility of the equipment manufacturer and individual installer to supplythis Safety Warning to the ultimate end user of this product. (SW effective 11/1992).  This product complies with all CE directives pertinent at the time of manufacture.Contact the Sales Department for Declaration of Conformity. INSTALLATION AND OPERATION INSTRUCTIONSIMPORTANT ÐYou must read these installation and operation instructions beforeattempting to operate this control.I.INTRODUCTIONThank you for purchasing theKBMG Multi-Speed Board (PartNo. 8833). KB Electronics, Inc. iscommitted to providing total cus-tomer satisfaction by producingquality products that are easy toinstall and operate. The KBMGMulti-Speed Board is manufacturedincorporating advanced circuitryand technology.The KBMG Multi-Speed Board pro-vides four (4) user adjustable presetspeeds to control a motor connect-Regenerative Drive. A preset(Preset 1, Preset 2, Preset 3,Preset 4) is selected with a contactclosure or open collector. Motordirection is set by the position ofJumper R/F (reverse/forward) which is provided for each preset. 


 FIGURE 1 Ð CONTROL LAYOUT Speed range selection jumpers (HI, LO) and Enable jumper (ENABLE) are also provided.Other features include a barrier terminal block (TB1) to facilitate wiring and a connector(CON2) to connect a tach-generator (TACH) for the KBMG.STANDARD FEATURESFour (4) user Preset Speeds.Forward and Reverse ÐEach preset provides a selection of forward and reverse direction.Each preset provides expanded trimpot adjustments forProvides electronic Run/Stop function. PARAMETER SPECIFICATION Preset or Enable Switch Types Dry Contact* or Open Collector 1.5 Operating Temperature Range (¼C) 0 Ð50 *Contacts must be isolated from the AC line. TABLE 1 Ð GENERAL SPECIFICATIONS FIGURE 2 Ð PRESETS 1 THRU 4  
   
 II.SETTING SELECTABLEJUMPERS (each preset)The KBMG Multi-Speed Board has customerspecific application. See Figure 2. A.Direction Selection (R/F) ÐAll R/F Jumpers are fac-tory set to the ÒFÓ position for forward operation.For reverse operation, set the desired preset speedJumper to the ÒRÓ position. See Figure 3.B.Speed Range Selection (HI, LO) ÐJumpers are factory installed for full motor speedrange. For more precise adjustment over a nar-rower speed range (high, medium, or low) set theHI and LO jumpers as shown in Figure 4.C.Enable Selection (J1) Ðtory installed to enable the control. To con-nect an Enable Switch to Terminal BlockTB1, remove Jumper J1. See Figure 5 andFigure 12, on page 10.  Forward Direction(Factory Setting) FIGURE 4SELECTION(HI/LO) (Factory Setting)     % Base Speed FIGURE 3 Ð DIRECTIONSELECTION (R/F) (Factory Setting)  !"# !"# !#  & '()*) 


  
  -0/ FIGURE 6 Ð MECHANICAL SPECIFICATIONS (Inches/[mm]) KBMG2X #5-40UNC X 1/4" FINGER-SAFE BOARD FINGER-SAFE COVER 4X SNAPSON COVER FIGURE 7 Ð KBMG MULTI-SPEED BOARD & KBMG ASSEMBLY DIAGRAM III.MOUNTING INSTRUCTIONSSee Figure 7 on page 6. Note:Figure 7 is also supplied as a sep-WARNING! Makesure all power isdisconnected from the KBMGbefore proceeding.A.Removing the KBMG Finger-If a finger-safeKBMG, proceed to Section IIIB. If a finger-safe cover isremove the two (2) sockethead 5-40 X 1/4Ó screwslocated at the rear of the3/32Ó hex key. Also, removeÓ screwsTerminal Block TB1 of theKBMG. See Figure 8. "  Finger-Safe Screws FIGURE 8 Ð REMOVING THE KBMG FINGER-SAFE COVER B.Removing TerminalBlock TB1 from theRemove TerminalBlock TB1 from the KBMGby rocking it back and forthor using a flat blade screw-driver to gently pry it off. Theremoved terminal block willcarded. See Figure 9.C.Modifying the KBMGFinger-Safe Cover Ðthe KBMG finger-safe coveris removed, it has to be mod-KBMG Multi-Speed Board.Cut out the finger-safe covershown in Figure 10, on page9. Note: Some finger-safe covers may already have the cover removed.D.Installing the KBMG Finger-Safe Cover ÐOnce the KBMG finger-safe cover hasbeen modified, it can be installed onto the KBMG. Initially, use only the two (2) 5-40 X1/4Ó socket head screws, using the supplied 3/32Ó hex key. Do not over tighten thesescrews or damage may result to the KBMG finger-safe cover. See Figure 6 on page 6.  KBMG Terminal Block FIGURE 9 Ð REMOVINGTERMINAL BLOCK TB1 FROM THE KBMG finger-safe cover.E.Installing the KBMG Multi-speed Board onto theBoard plugs onto the six (6)header pins where TB1 wasremoved from the KBMG.Speed Board snap onto thefinger-safe cover. Use theÓ screws,that were previouslyremoved, to secure theKBMG Multi-Speed Boardto the KBMG. Do not overtighten these screws ordamage may result to theKBMG Multi-Speed Board and the KBMG. See Figure 7, on page 6. ! KBMG Finger-Safe Cover. Remove Panel(cut 7 places) to Install KBMG Multi-Speed Board. COVER PANEL IV. WIRING INSTRUCTIONSWARNING!Warning, on page 1,before using this control.Make sure all power isdisconnected from theKBMG before proceeding.Safety Warning!are not fail-safe. Use only the AC line for this purpose.A.Preset Speed Connection Ð Preset speed range,direction, and speed are selected by making a contactclosure between Terminals COM and either PS 1, PS 2, PS 3, or PS 4 of TerminalBlock TB1. See Figure 11.  Connection Designation Supply Wire Size (AWG Ð Cu) Recommended Tightening Torque Logic Connections 24 TABLE 2 Ð TERMINAL BLOCK TB1 WIRING INFORMATION  
 FIGURE 11 Ð PRESET  *)56
)37 CONTACT CONNECTION   B.Enable Switch Connection ÐRun/Stop function is required, removethe KBMG Multi-Speed Board JumperJ1 and wire a switch to Terminals ENand COM of Terminal Block TB1.When the switch is closed, the controlwill operate. When the switch isopened, the control will stop. Note:KBMG Multi-Speed Board Jumper J1must be installed or a connection must be made between Terminals EN and COM ofTerminal Block TB1 in order for the KBMG Multi-Speed Board to operate. See FigureC.Tach-Generator Connection ÐIf a tach-generator is to be used, wire a 7 Volt (or 50Volt) DC per 1000 RPM tach-generator to the KBMG Multi- Speed Board, connect thepositive (+) side of the tach-generator to Terminal T2 of CON2 and the negative (-) sideof the tach-generator to Terminal T1 of CON2. Note: If the positive (+) and negative (-)tach-generator connections are not as described above, the motor will run at full speedonly. See Figure 13. (Note: Refer to the KBMG instruction manual for tach-generatorV. OPERATIONAfter the KBMG Multi-Speed Board has been properly setup (jumpers and trimpots set todesired positions and wiring completed), the startup procedure can begin. If AC power hasbeen properly brought to the control, the power on (PWR) LED, on the KBMG, will illuminate.Select a preset, as described in Section IV A, on page 10. The motor will begin to run at thepreset speed selected. &
.8 FIGURE 13 Ð TACH-GENERATOR CONNECTION VI.TRIMPOT ADJUSTMENTS(Each Preset)The KBMG Multi-Speed Board contains trimpots which are factory set for approx. 50% ofbase motor speed. Readjustment of the trimpots will be required in order to tailor the con-trol for a specific application. If the HI and LO jumpers have been changed in accordancewith Figure 4, on page 4, the trimpot ranges will also change. Readjust trimpots as shownin Figure 14.WARNING!If adjustments are made with main power applied, an insulatedadjustment tool must be used and safety glasses must be worn. High voltageexists in this control. Fire and/or electrocution can result if caution is not exercised.Safety Warning, on page 1, must be read before proceeding.Preset 1, Preset 2, Preset 3, Preset 4 Ða higher speed setting, rotate the selected preset trimpot clockwise. For a lower speed set-ting, rotate the selected preset trimpot counterclockwise. See Figure 14.  69,
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,, 1 FIGURE 14 Ð PRESET TRIMPOT vs HI/LO JUMPER SETTING (EACH PRESET) Ð NOTES Ð  VII. LIMITED WARRANTYFor a period of 18 months from the date of original purchase, KB Electronics, Inc. will repairor replace, without charge, devices which our examination proves to be defective in mate-rial or workmanship. This warranty is valid if the unit has not been tampered with by unau-thorized persons, misused, abused, or improperly installed and has been used in accor-dance with the instructions and/or ratings supplied. The foregoing is in lieu of any other war-ranty or guarantee, expressed or implied. KB Electronics, Inc. is not responsible for anyexpense, including installation and removal, inconvenience, or consequential damage,including injury to any person, caused by items of our manufacture or sale. Some states donot allow certain exclusions or limitations found in this warranty and therefore they may notapply to you. In any event, the total liability of KB Electronics, Inc., under any circumstance,shall not exceed the full purchase price of this product. KB Electronics, Inc.12095 NW 39th Street, Coral Springs, FL 33065-2516 ¥ (954) 346-4900 ¥ Fax (954) 346-3377Outside Florida Call TOLL FREE (800) 221-6570 ¥ E-mail Ð info@kbelectronics.comwww.kbelectronics.com (A40401) Ð Rev. A Ð 7/2002