Process Control Corporation • 6875 Mimms Drive • Atlanta, GA 30340

January 21, 2002 3:17 pm

Refeed Machine
User’s Guide
MD-0010-0000 Rev F
The information in this manual is subject to change without notice and should not be con-
strued as a commitment by Process Control. Process Control shall in no event be liable
for any loss of business, loss of use or data, interruptions in business or for damage of
any kind arising from any defect or errors in this publication or in the Process Control
hardware or software.

This material may not be reproduced in whole or in part by any means without permis-
sion from Process Control.

Copyright 2002 Process Control. All rights reserved.

Process Control Corporation

6875 Mimms Drive
Atlanta, GA 30340

Refeed Machine User’s Guide

Trademarks:

Gravitrol™ is a registered trademark of Process Control Corporation.

Original Printing - August 2001

Printed in the United States of America

 Special Icons and Text Styles
The following icons are used in this manual to indicate items of special interest.

Icon Type Description

Note The Note icon is used to draw the reader's attention to cru-
cial information within the manual. Ignoring a Note would
not cause equipment damage or personal injury, but could
result in wasted time or effort.
Electrical The Electrical icon is used to indicate the possibility of high
electrical current or electrostatic discharge. Use caution
when working around or handling this equipment.

Caution The Caution icon is used to denote the possibility of dam-

age to the equipment or a task requiring precautionary
measures.

Warning The Warning icon is only used when an action could result
in serious injury to personnel or severe damage to the
equipment. Always pay close attention to the warnings in
this manual.

Specific buttons on the console are represented by capitalized, bold text enclosed in
angle brackets. For example, “Press the <RECIPE> key.”

Revision History

Revision Page(s) Change

E All Complete rewrite.

F 2-6—2-7 Added auger drive linearization procedure.
Refeed Machine User’s Guide

Table of Contents
SECTION 1 - Introduction...................................................................... 1-1
1.1 The Process Control Automatic Scrap Recycle (ASR) System ........................ 1-2
1.2 Process Control Refeed Machines ................................................................... 1-3
1.2.1 How it Works ............................................................................................ 1-4
SECTION 2 - Installation........................................................................ 2-1
2.1 Receiving .......................................................................................................... 2-2
2.2 Handling ........................................................................................................... 2-2
2.3 Storing .............................................................................................................. 2-2
2.4 Assembly .......................................................................................................... 2-2
2.4.1 Supporting the Refeed Machine During Installation ................................ 2-3
2.4.2 Spool Piece (Extruder Inlet Transition) .................................................... 2-3
2.4.3 Electrical Connections .............................................................................. 2-4
2.4.4 Mechanical Connections .......................................................................... 2-6
2.4.5 Auger Drive Linearization ......................................................................... 2-6
2.4.6 Run-in Period ........................................................................................... 2-7
SECTION 3 - Accessories...................................................................... 3-1
3.1 Edge Trim Pick-Up System .............................................................................. 3-2
3.2 Roll Feeder ....................................................................................................... 3-2
3.3 Grinder .............................................................................................................. 3-2
3.4 Ground Scrap Blower ....................................................................................... 3-2
3.5 Vacuum Loading System .................................................................................. 3-2
3.6 Additive Feeder ................................................................................................ 3-2
3.7 System Control Panel ....................................................................................... 3-3
SECTION 4 - Operation.......................................................................... 4-1
4.1 Startup (Complete ASR System) ...................................................................... 4-2
4.2 Startup (Refeed Machine Only) ........................................................................ 4-3
4.3 Normal ASR System Operation Procedure ...................................................... 4-4
4.3.1 Starting the System .................................................................................. 4-4
4.3.2 Determining the Maximum Scrap Rate .................................................... 4-5
4.3.3 Adding Extra Scrap .................................................................................. 4-6
SECTION 5 - Troubleshooting .............................................................. 5-1
5.1 Reporting a Problem to Process Control .......................................................... 5-2
5.2 Fixing It Yourself ............................................................................................... 5-2
SECTION 6 - Preventive Maintenance.................................................. 6-1
6.1 Refeed Machine ............................................................................................... 6-2
6.1.1 Gearbox Lubrication ................................................................................. 6-2
6.1.2 High Level Switch ..................................................................................... 6-3
6.1.3 Bridge Breaker Assembly ......................................................................... 6-3
6.2 Other Devices ................................................................................................... 6-3

MD-0010-0000 Rev F TOC-1

 Refeed Machine User’s Guide
SECTION 7 - Spare Parts....................................................................... 7-1
7.1 RMR Parts List ................................................................................................. 7-2
7.2 RMB Parts List .................................................................................................. 7-3
7.3 RMT/RMS Parts List ......................................................................................... 7-4
7.4 Electrical Control Panel - Domestic Version ..................................................... 7-5
7.5 Electrical Control Panel - European (CE) Version ............................................ 7-6
SECTION 8 - Vendor Product Literature .............................................. 8-1
8.1 The KBSI-240D Signal Isolator ......................................................................... 8-2
8.2 KBIC ® Solid State SCR DC Motor Speed Controls ...................................... 8-18
8.3 Syrelec Voltage Control Relay ........................................................................ 8-25

TOC-2 Rev F MD-0010-0000

Refeed Machine User’s Guide

List of Figures
ASR System for Cast or Blown Film ....................................................................... 1-2
Mix and Feed Zone ................................................................................................. 1-4
Electrical Connections ............................................................................................ 2-5
RMR Refeed Machine ............................................................................................ 7-2
RMB Refeed Machine ............................................................................................ 7-3
RMT/RMS/RMX Refeed Machine ........................................................................... 7-4
Electrical Control Panel, Domestic Version ............................................................ 7-5
Electrical Control Panel, European (CE) Version ................................................... 7-6

MD-0010-0000 Rev F LOF-1

 Refeed Machine User’s Guide

LOF-2 Rev F MD-0010-0000

Refeed Machine User’s Guide

List of Tables
Table 1.1: Refeed Machine Models ............................................................................. 1-3
Table 2.1: Equipment Weights ..................................................................................... 2-6
Table 2.2: Oil Change Intervals ................................................................................... 2-8
Table 5.1: Troubleshooting .......................................................................................... 5-2
Table 6.1: Lubrication .................................................................................................. 6-2
Table 6.2: High Level Switch Maintenance .................................................................. 6-3
Table 6.3: Grinder Maintenance .................................................................................. 6-3
Table 6.4: Roll Feeder Maintenance ............................................................................ 6-4
Table 6.5: Inducer Maintenance .................................................................................. 6-4
Table 6.6: Additive Feeder Maintenance ..................................................................... 6-4
Table 6.7: Vacuum Loader Maintenance ..................................................................... 6-4
Table 7.1: RMR Parts .................................................................................................. 7-2
Table 7.2: RMB Parts ................................................................................................... 7-3
Table 7.3: RMT/RMS/RMX Refeed Machine Parts ...................................................... 7-4
Table 7.4: Domestic Control Panel Parts ..................................................................... 7-5
Table 7.5: European (CE) Control Panel Parts ............................................................ 7-7
Table 8.1: Vendor Documentation ............................................................................... 8-2

MD-0010-0000 Rev F LOT-1

 Refeed Machine User’s Guide

LOT-2 Rev F MD-0010-0000

SECTION 1 - Introduction

TOPICS DISCUSSED IN THIS CHAPTER

U The Process Control Automatic Scrap Recycle (ASR) System

U Process Control Refeed Machines

 Introduction
1.1 The Process Control Automatic Scrap Recycle (ASR) System

The terms “ground scrap” and “fluff” are used interchangeably in this manual.
Fluff is typically used when describing the equipment, such as “fluff auger”.

The Process Control Automatic Scrap Recycle (ASR) system recycles scrap directly
back to the extruder without the down-grading caused by additional heat history or con-
tamination from dirt or other scrap. The ASR system thus keeps the scrap at the original
virgin material value without the expense of repelletizing.

Virgin Material
G round Scrap
Air Elim inator
Trim

Refeed
Machine
Ref eed Machine
Con trol Panel
Spool Piece
ASR System Control Pa nel Film

Extrusion Line
Trim

Roll Scrap G rinder

Inducer

Figure 1 - 1 ASR System for Cast or Blown Film

A typical ASR system (shown above) consists of:

• one or more Inducers (vacuum/pressure power unit for conveying trim),

• an Air Eliminator (for separating the conveyed trim from the high velocity air),
• a Film Grinder (for size reduction of trim), and
• a Fan (for conveying ground trim to the Refeed Machine, which delivers the ground
trim to the extruder).

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Introduction
Section 1
In addition, most systems include a Roll Feed Unit for feeding off-line scrap rolls to the
Grinder. The refeed machine is the most important piece of equipment in the ASR sys-
tem.

1.2 Process Control Refeed Machines

The basic function of all models of refeed machine is the same. However, there are dif-
ferences between models, as shown below.

Table 1.1: Refeed Machine Models

Model Description

RMB The RMB model has a larger hopper for ground film scrap than does the
RMR. This larger hopper allows for more start-up surge of ground scrap.
RMT These all have
RMS •a lower virgin surge capacity for operation with Gravitrol™ extrusion
control systems, and
RMX
•an extended fluff auger.
RMS
These all have a fluff level switch for operation with roll scrap.
RMX

Actual production records show that

• virtually no production down time can be attributed to the system, and

• the system will handle very high scrap percentages while producing high quality film.
You can change the scrap recycle rate with no perceptible change in product.

MD-0010-0000 Rev F 1-3

 Introduction

Ground
Scrap

Mix and
Feed Zone Pellets

Extruder

Figure 1 - 2 Mix and Feed Zone

1.2.1 How it Works

1. The refeed machine is arranged to contain ground scrap in its upper compartment
and base material in its lower compartment. An auger bridge-breaker assembly
meters ground scrap consistently and uniformly, at the desired rate, through the base
material. The rate is selected by adjusting the variable speed drive system from the
ground scrap hopper.
2. The weight of the base material is sufficient to contain the ground scrap in the auger
flights. The base material in effect forms a retaining tube through which the ground
scrap is transported from the upper hopper tube to the extruder screw.
3. Base material flows by gravity through a clearance between the auger blades and the
lower tube. The scrap is therefore kept separated from the base material until the two
materials are combined and captured in the lower metal tube. This design eliminates
any possibility of stratification.
4. The auger moves the mix into the extruder throat. The clearance between the auger
blades and the lower tube wall is great enough to allow base material to flow by grav-
ity at a rate equal to the maximum extruder throughput.
5. Should the feed of ground scrap stop, base material automatically feeds at a rate suf-
ficient for production to continue with no perceptible change in film quality. No adjust-
ment to the extruder is needed.

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Introduction
Section 1
6. The refeed machine variable speed drive system is slaved to the extruder screw
speed. This feature assures that the ratio of scrap to base material remains constant
even as the extruder screw speed varies (assuming an adequate scrap supply).
7. When only edge trim is recycled, the refeed machine auger runs faster than required
to deliver all of the generated scrap to the extruder throat. As a result, the scrap com-
partment runs empty.
8. When either roll scrap or a combination of roll scrap and edge trim is recycled, the
ground scrap hopper normally runs full. A level control switch near the top of the
scrap compartment starts and stops the roll feeder, thus providing automatic opera-
tion.

When the refeed machine auger slows to a minimum level (or stops), a low
speed detector signals to stop the roll feeder or the ground scrap conveying
blower to prevent overfilling.

MD-0010-0000 Rev F 1-5

 Introduction

1-6 Rev F MD-0010-0000

SECTION 2 - Installation

TOPICS DISCUSSED IN THIS CHAPTER

U Receiving

U Handling

U Storing

U Assembly
 Installation
2.1 Receiving
Upon receiving any piece of equipment, always perform a thorough inspection of the
contents and compare it to the enclosed packing list. Make sure all parts listed are
present and that no visible damage exists.

Inspect the refeed machine in the presence of the freight carrier's repre-
sentative for damage in shipment. Note any damage on the delivery
receipt before signing it. If damage is evident, file a claim immediately
against the delivering carrier. It is the carrier's responsibility to pay for
any shipping damage.

If any part of the equipment was damaged during shipping, write up a report and take
photographs (if possible.) Send this information to the shipping company as soon as pos-
sible.

2.2 Handling
Handling of the equipment requires suitable lifting equipment. Installation requires the
use of hand and power tools, and an electrical power connection. Handling and installa-
tion of this equipment should be performed by personnel trained in each specific duty.

2.3 Storing
• The refeed machine is shipped crated and is secured with lagging screws to the pal-
let. To lift the refeed machine, use a fork lift to lift the pallet.
• Do not stack the crated refeed machine on top of another crate, and do not stack
other crates or pallets on it. (The wood crate is not strong enough to support other
items.) The crated refeed machine may be stored on a pallet rack of appropriate
design.
• Store the refeed machine in a dry location that is protected from the weather.
• Do not place the crated refeed machine in standing water - this can weaken the struc-
ture of the pallet.
• The refeed machine has an indefinite storage life.
• For storage of 6 months or more, fill the gear box completely with an approved oil
(see Table 6.1, “Lubrication,” on page 6-2 for recommended oils). Once each month,
rotate the input so that the output shaft rotates one revolution. Before starting the
refeed machine up, drain the storage oil and fill to the proper level.

2.4 Assembly
The refeed machine, which comes pre-assembled, requires mating with the throat of an
extruder. A transition or 'spool piece’ may be required for proper fit to the extruder and is
usually included with the refeed machine. Connect any other equipment that provides

2-2 Rev F MD-0010-0000

Installation
Section 2
material feed to the refeed machine after the refeed machine is securely fastened to the
extruder.

Process Control Corporation provides the fasteners needed to connect the refeed
machine to the spool piece. Contact the extruder manufacturer for the fasteners required
to connect the spool piece to the extruder inlet throat. See “Spool Piece (Extruder Inlet
Transition)” on page 2-3.

2.4.1 Supporting the Refeed Machine During Installation

The refeed machine is top heavy. Secure the refeed machine to an

appropriate lifting device, using the lifting points provided, before remov-
ing any mounting bolts from the transportation pallet. Serious injury to
personnel or damage to the equipment could result if the refeed machine
tips over.

1. Secure the refeed machine by its lifting points.

2. Support it from a suitable hoist or lift.
3. Carefully remove the palette lagging bolts.
4. Ensure that the lifting straps are stable.
5. Ensure that the refeed machine does not tip when lifted.
6. When the refeed machine is stable, lift it into place above the extruder inlet throat.

2.4.2 Spool Piece (Extruder Inlet Transition)

The spool piece is usually factory mounted on the discharge of the refeed machine, and
is designed to mate to the extruder throat inlet. If your spool piece is not mounted to your
refeed machine, bolt it to the discharge of the refeed machine now, using the fasteners
supplied. If your spool piece does not match your extruder inlet, contact your Process
Control representative.

Alternatively, the loose spool piece can be fastened to the extruder inlet. Process Control
Corporation does not supply the bolts/fasteners for this—consult the extruder manual for
bolt selection and torque specification. If the extruder manual does not give this informa-
tion, use the following as a guide:

• Use the largest bolts possible for the holes provided in the flanges.
• Use grade 5 (ISO Grade 8.8) or higher bolts.
• Do not use a gasket.

MD-0010-0000 Rev F 2-3

 Installation
• Pre-load the bolts to 90% of proof load.
Due to the variations in extruder inlet flange details, Process Control can not provide
complete bolt specifications. Contact the factory for specific applications.

2.4.3 Electrical Connections

1. The electrical components of the refeed machine are factory wired to a junction box
on the machine. Use the included electrical drawings to make the connections (for
motor power and controls) between the junction box and the control panel.
2. Mount the control panel in a convenient location.
3. Connect the control panel to the refeed machine.
4. Connect the control panel to the electrical source.
5. Check the motors and drives for correct rotation. The correct rotation of the drive for
the bridge-breaker auger assembly is counter-clockwise when looking down into the
fluff hopper.

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Installation
Section 2

Figure 2 - 1 Electrical Connections

MD-0010-0000 Rev F 2-5

Installation
Section 2
2.4.4 Mechanical Connections

Table 2.1: Equipment Weights

Equipment lbs kg

RMR 715 325

RMB 915 415
RMT/RMS 515 235
RMX 515 235
Cyclone, CY05 50 25
Cyclone, CY07 60 30
Cyclone, CY09 125 60
Control Panel 35 15

After the refeed machine is securely mounted to the extruder inlet, connect the equip-
ment (a cyclone for regrind, a blender or other type of feeder for virgin resin) to it.

1. Mount the cyclone directly to the top of the refeed machine. The refeed machine has
a four point clamp design for securing the cyclone.
2. Do not use the cyclone to support the duct/pipe that conveys the regrind to it—this
causes undesirable weight distributions.
3. The refeed machine can support a Gravitrol hopper, but larger feeders and blenders
need to be supported by the floor or a mezzanine structure.

2.4.5 Auger Drive Linearization

The Process Control refeed machine is designed to follow the extruder speed. In other
words, if the extruder speeds up, the refeed auger speeds up. If the extruder slows
down, the refeed auger slows down.

To link the extruder and refeed machine in this way, the refeed control panel must be
wired as shown in the attached electrical print. Notice that the SI1 signal isolator board
obtains the extruder speed from the extruder tach or DC armature.

After completing the electrical connection, follow the procedure below to linearize the
refeed auger so it accurately follows the speed of the extruder.

1. Set the extruder speed to zero.

MD-0010-0000 Rev F 2-6

Installation
Section 2
2. Remove all pellets and fluff from the refeed machine.
3. Set the speed on the ASR control panel to 10.
4. Connect a voltmeter to the refeed machine auger motor armature.
5. Set the voltage for maximum speed:
A. Slowly increase the extruder speed to maximum.
B. Adjust the maximum speed potentiometer on the KBSI signal isolator board for an
auger motor voltage of 170 volts dc. (See “The KBSI-240D Signal Isolator” on
page 8-2.)
6. Set the voltage for minimum speed:
A. Decrease the extruder speed to zero.
B. Adjust the minimum speed potentiometer on the KBSI signal isolator board for an
auger motor voltage of 0 volts dc. (See “The KBSI-240D Signal Isolator” on
page 8-2.)
7. Repeat steps 5 and 6 until the voltage is set properly.
8. Turn the speed dial on the front of the refeed machine to 4.
9. Start the extruder line and observe the load meter on the front of the refeed machine
control panel. The load will increase but must never oscillate up and down.
10. After the extruder is up to operating speed, adjust the speed control on the refeed
machine control panel until the load meter is stable (varying by no more than 5%).

Do not turn the speed dial too high as the load on the auger would be too
large.

2.4.6 Run-in Period

The gearmotor requires a run-in period before it can perform at maximum efficiency.
The run-in period is 2 to 4 hours for rated load, longer for lighter loads. During the run-in
period, you can expect

• higher than normal operating temperature,

• higher than normal motor currents, and
• lower output torque.

MD-0010-0000 Rev F 2-7

Installation
Section 2

Table 2.2: Oil Change Intervals

For this drain and refill the gearmotor

and then...
model... oil after the first...

RMR 100 hours of operation

RMT 100 hours of operation
after 2,500 hours of operation or every
RMS 100 hours of operation 6 months, whichever occurs first.
RMX 100 hours of operation
RMB 250 hours of operation

Refer to Table 6.1, “Lubrication,” on page 6-2 for oil type and capacity ratings.

MD-0010-0000 Rev F 2-8

Installation
Section 2

MD-0010-0000 Rev F 2-9

 Installation

2-10 Rev F MD-0010-0000

SECTION 3 - Accessories

TOPICS DISCUSSED IN THIS CHAPTER

U Edge Trim Pick-Up System

U Roll Feeder

U Grinder

U Ground Scrap Blower

U Vacuum Loading System

U Additive Feeder

U System Control Panel

 Accessories
The refeed machine is part of an overall refeed system. The other parts of the refeed
system are described below (see “ASR System for Cast or Blown Film” on page 1-2 to
locate parts of the system). Separate maintenance manuals are supplied with each com-
ponent.

3.1 Edge Trim Pick-Up System

The edge trim pick-up system consists of one or more manifolds connected to one or
more inducers. The system conveys the edge trim to the air eliminator mounted on top of
the grinder. The purpose of the air eliminator is to separate the edge trim from the air that
carries it.

3.2 Roll Feeder

The roll feeder takes roll scrap and feeds the rolls uniformly into the grinder. Forward/
Reverse controls are included and are interlocked with the grinder, the roll feeder door
switch in the forward direction, and the fluff hopper level switch. The feeder is connected
in series with the speed control relay in the refeed machine control panel. The low speed
switch disables the roll feeder when the extruder reaches the minimal speed.

3.3 Grinder
The grinder cuts the edge trim and roll scrap into fine particles dense enough to flow
through the refeed machine. Choose a grinder screen that maximizes the bulk density for
a given grinder rate. Locate the grinder as close to the source of scrap as possible—
ground scrap can be blown farther than edge trim can be conveyed.

3.4 Ground Scrap Blower

The bottom of a grinder contains a material handling blower. It blows the ground scrap to
a cyclone on top of the refeed machine.

3.5 Vacuum Loading System

Your system may come with a vacuum loading system to load the virgin resin into the vir-
gin compartment of the refeed machine. The loading system consists of a vacuum
receiver, a vacuum pump, and a pump control panel.

3.6 Additive Feeder

An additive feeder injects color or other additives into the virgin material stream. These
units mount to the spool piece.

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Accessories
Section 3
3.7 System Control Panel
The system control panel includes

• starters and all necessary control logic for your equipment, and
• Start/Stop controls for inducer fans.
It is recommended that the system control panel be located near the grinder, near the
start/stop controls for

• the grinder/ground scrap fan, and

• roll feeder.
The refeed machine has a separate control panel which is usually mounted near the
refeed machine.

MD-0010-0000 Rev F 3-3

 Accessories

3-4 Rev F MD-0010-0000

SECTION 4 - Operation

TOPICS DISCUSSED IN THIS CHAPTER

U Startup (Complete ASR System)

U Startup (Refeed Machine Only)

U Normal ASR System Operation Procedure

 Operation
This section describes equipment startup and normal system operation.

4.1 Startup (Complete ASR System)

Before attempting to operate the Automatic Scrap Recycle (ASR) system, make the fol-
lowing checks to verify that the field wiring is correct.

The follower circuitry requires input from the extruder tachometer to ensure
that the refeed machine rate varies in proportion to the extruder rate. Refer to
the refeed control panel schematic diagram for tachometer input wiring.

1. Remove motor fuses from the refeed machine power panel, leaving the transformer
fuses in place.
2. Turn power <ON> at the main disconnect (not provided by Process Control).
3. Push grinder and inducer <START> buttons. They should not light or pull in the start-
ers because the master control relay (MCR) in the refeed machine is not energized.
4. On the refeed machine control panel, set the auger speed to zero.
5. Push auger <START> push button. The indicator should light, however, the auger
should not rotate. This energizes the refeed machine MCR, enabling the grinder con-
trol panel.
6. Turn the roll feed selector to <FORWARD> and the roll feed speed potentiometer to
mid-position.
7. Pull the illuminated grinder <STOP> button. The material fan starter, grinder starter
and roll feed should be energized.
8. Push the inducer <START> push button. The inducer starter should be energized.
9. Push the inducer <STOP> push button.
10. Push the grinder <STOP> push button. All starters should be de-energized.
11. Repeat step 7.
12. On the refeed machine control panel, push the auger <STOP> push button. All start-
ers should be de-energized.
13. Repeat steps 3, 5 and 7.
14. Open the grinder knife access. All starters should be de-energized because the knife
access chamber electrical interlock disables the grinder control panel.
15. Close the knife access. Repeat step 7.
16. Open the roll feeder door. The roll feeder should be de-energized.
17. Turn the roll feed selector to <REVERSE>. Close the roll feeder door. The roll feeder
should be energized.

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Operation
Section 4
18. Deflect the paddle switch (or proximity switch) in the refeed machine fluff compart-
ment. The roll feeder should immediately de-energize. (This simulates a high level
condition in the fluff compartment which should disable the roll feeder.)
19. Return the paddle switch (or proximity switch) to its normal position. After a time
delay (adjustable at the refeed machine control panel from 1 to 4 minutes), the roll
feed should be re-energized.
20. Repeat step 10.
21. Turn the roll feed selector switch to <REVERSE>. The roll feed should be de-ener-
gized.
22. Turn the roll feed selector to <FORWARD>. The roll feed should be de-energized.
23. Turn the power off at the main disconnect. Replace the fuses.
24. Ensure that the low speed switch in the refeed machine control panel is set per the
schematic provided. Adjusting the threshold knob clockwise will prevent the roll
feeder from operating until the extruder speed is higher.
25. Tilt the hopper back to expose the rotor. Check all blade clearances (.002" minimum -
.004” maximum). Clear all foreign material from the chamber before energizing the
grinder.
The Automatic Scrap Recycle system is now ready to operate. Follow the instructions in
“Normal ASR System Operation Procedure” on page 4-4 for normal operation.

4.2 Startup (Refeed Machine Only)

Before attempting to operate the refeed system, make the following checks to assure
proper operation.

The follower circuitry requires input from the extruder tachometer to

ensure that the refeed machine rate varies in proportion to the extruder
rate. Refer to the refeed control panel schematic diagram for tachometer
input wiring.

1. Turn power ON at the main disconnect (not provided by Process Control). Ensure
that the extruder is stopped.
2. On the refeed machine control panel, turn the auger speed adjust potentiometer to
zero.
3. Push the auger <START> push button. The indicator should light but the auger
should not rotate.
4. If the refeed machine is part of a refeed system with a roll feeder, start the grinder.
After a time delay, the roll feeder should start.

MD-0010-0000 Rev F 4-3

 Operation
5. Deflect paddle switch (or cover proximity switch) in the refeed machine fluff compart-
ment. The roll feeder should de-energize.
6. Return the paddle switch to normal position (or uncover the proximity switch). After a
time delay, the roll feed should be re-energized.
7. Stop the grinder.
8. Introduce virgin into the virgin hopper.
9. Start the extruder and slowly ramp it to 1/4 speed.
10. Raise the refeed auger speed potentiometer to 4.
11. Check that the auger turns counterclockwise as viewed from above.
12. Set the refeed auger speed to zero and check that the auger stops.
13. Set the auger speed to 4.
14. Slow the extruder and check that the refeed auger slows.
15. Push the auger STOP button and check that the refeed auger stops.
The refeed machine is now ready to operate. Follow the instructions below for normal
operation.

4.3 Normal ASR System Operation Procedure

You can attach additional lights, alarms, etc. (as described in the electrical schematic) to
keep you informed about the status of the system. However, normal operation of the
ASR system is simple and automatic.

4.3.1 Starting the System

To start up the system, follow the procedure below.

1. Start the refeed auger. Do not exceed a potentiometer setting of 2.

2. Start the grinder.
3. Start the edge trim pick-up system.
4. Introduce scrap at a low rate, approximately 5 percent or less.

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Operation
Section 4
5. Monitor level of fluff through the level switch mounting plate hole in the hopper. If it is
rising, slowly increase the auger speed until it starts to fall.

GO SLOW! Remember, you are introducing a low bulk density material to a

steady state extrusion process. The extruder performance will probably
change—expect to see a reduction in extruder drive amps due to the lower
density material. Also, keep in mind that changes in the extruder feed section
won't become apparent at the die for several minutes.

Allow at least 15 minutes at each point for the system to stabilize.

4.3.2 Determining the Maximum Scrap Rate

At the maximum scrap rate the load meter is stable with a variation of no more than +/-
10%.

1. If you have an edge trim pick-up system, continue to add scrap while all edge trim is
being recovered. Increase the refeed auger speed to stay just ahead of your process-
ing requirements.

If you have an edge-trim-only system, run the fluff hopper dry while continuously
monitoring extruder RPM, die pressure, and product quality. If additional refeed
machine capacity is indicated and your product quality is acceptable, proceed to
increase scrap feed rates.

It is possible to deliver more scrap material to the extruder than your prod-
uct can tolerate. This can happen if your product is more demanding than
some of the other applications for which the refeed machine was designed.

Take care to avoid accidentally overfeeding. You know you are overfeeding
when you see large fluctuations on the refeed control panel load meter.
Small load variations of +/- 10% are normal and acceptable.

2. If you have a roll feed system, use it to add additional scrap.

Feeding multiple rolls at a low speed is preferable to feeding a single roll at

a high speed.

3. After starting the roll feed system, slow the auger down slightly and correspondingly
decrease scrap feed rate.

MD-0010-0000 Rev F 4-5

 Operation
4. Your refeed machine is now set at its maximum practical operating speed. Note your
maximum auger operating speed on the tachometer.

4.3.3 Adding Extra Scrap

Adding scrap to a system that is already at its maximum scrap rate causes the following
to happen:

1. The level of fluff in the hopper rises and activates the fluff high level switch.
2. This immediately stops the roll feeder and energizes a time delay relay.
3. After the fluff level subsides, the time delay begins counting down.
4. When the timer reaches zero, the roll feeder restarts.

4-6 Rev F MD-0010-0000

SECTION 5 - Troubleshooting

TOPICS DISCUSSED IN THIS CHAPTER

U Reporting a Problem to Process Control

U Fixing It Yourself
 Troubleshooting
This section describes general refeed machine and complete Automatic Scrap Recycling
(ASR) system problems along with their causes and solutions. Some solutions require
attention to other equipment; consult the manuals for that machine for proper proce-
dures.

5.1 Reporting a Problem to Process Control

To help us diagnose your problem and allow continual product improvement, please
report all troubles with the ASR system promptly to our service manager. The form on
page 5-5 specifies what information is most useful. For the best service, fill in a copy of
this form and fax it to Process Control.

We will make every effort to solve your problems while minimizing any interruptions to
your production.

5.2 Fixing It Yourself

Use the table below to help diagnose and correct the problem.

Table 5.1: Troubleshooting

Problem Cause Solution

Roll Feeder Rolls wrapping on the feed roll- •Close the slide doors on the
Stops ers. guide chute further or
•run more rolls at a slower rate.
Material Hangs Excessive air entering the •Throttle the inducer fan inlet or
up in Air Elimi- grinder.
•install perforated tubing
nator
between venturi and air elimi-
nator to exhaust excess air.
•If a dump wye is installed, open
the dump wider to release
more air.
Material Hangs •Rough surfaces or discontinui- •Smooth rough surfaces in the
up in Conveying ties in the tubing tubing.
Lines
•Insufficient air flow •Decrease fan back pressure.
Trims Not •Insufficient air flow •Decrease fan back pressure or
Picked Up
• Inadequate air velocity •use smaller conveying line.

5-2 Rev F MD-0010-0000

Troubleshooting
Section 5
Table 5.1: Troubleshooting (Continued)

Problem Cause Solution

Overfeeding •Reduce scrap input to grinder

or
•slow refeed auger speed.
Compaction in throat •Cool the auger throat.
Extruder Throat
•Check for a grooved feed
Bridging
throat.
•Check for a dual-flighted screw
in the feed section.
The auger is damaged and Repair or replace the auger.
unable to pass material.
•Low fluff bulk density (ground •Verify the grinder blade gap
scrap must exceed 5 pounds is.002 - .004 inches.
per cubic foot to feed properly)
•Verify that the grinder screen is
or
not clogged or broken.
•poor fluff geometry
Regrind too large. •Use smaller grinder outlet
screen,
Fluff Hopper Will
•open air intake below screen,
Not Empty
or
or
Fluff Turning As •reduce the grinder blade gap.
A Mass
The auger has filled and is turn- •Run the auger backwards, or
ing as a solid body. This can
•pour pellets in fluff hopper to
happen if it is run in overloaded
add weight.
condition for lengthy periods.

MD-0010-0000 Rev F 5-3

 Troubleshooting
Table 5.1: Troubleshooting (Continued)

Problem Cause Solution

•Fluff plugs in grinder. •Reduce scrap input to grinder.

See “Fluff Hopper Will Not
•Material plugging in material
Empty” on page 5-3.
handling fan.
•Sharpen bed knives.
•Instantaneous grinding rate.
•Reduce the air intake opening
•Bed knives dull.
below the screen.
•Air intake below the screen
open too much.
Fluff is dusty from excessive air Exhaust excess air by
Fluff Blows Out
in edge trim pick-up system.
Cyclone Top •throttling the inducer fan inlet or
•installing perforated tubing
between venturi and air elimi-
nator.
Grinder blades are set to incor- Verify the grinder blade gap is
rect blade gap. .002 - .004 inches.
Fluff high level switch or the
refeed auger speed relay does
not inhibit the optional grinder
roll feeder.

5-4 Rev F MD-0010-0000

Troubleshooting
Section 5

Trouble Report Form

Attn.: Service Manager
Please fill out this form and either fax it to (770) 449-5445, or call (770) 449-8810.

Nature/Symptoms of Problem

Operating Data

Extruder make, size Scrap throughput rate

run successfully
Die Size Scrap throughput rate
at which problem
occurs
Film Gauge Grinder model and
screen hole size
Total extrusion rate

Resin Data

Supplier number EVA level

Melt index Virgin pellet size
Slip coefficient

MD-0010-0000 Rev F 5-5

 Troubleshooting

5-6 Rev F MD-0010-0000

SECTION 6 - Preventive Maintenance

TOPICS DISCUSSED IN THIS CHAPTER

U Refeed Machine

U Other Devices
 Preventive Maintenance
The following are maintenance items for each part of an ASR system. For items other
than the refeed machine, consult the manual for that equipment for proper procedures.

All maintenance should be performed with

• the machine turned off,

• the electrical controls locked out at the control panel, and
• the local stop switch set.

6.1 Refeed Machine

Table 6.1: Lubrication

Ambient
Lubricant
Temperature

AGMA No. ISO Viscosity Grade

-30° to 225°F --- 320/460

-34° to 107°C
40°F to 90°F 7 or 7C 460
4.4° to 32.2°C
80°F to 125°F 8 or 8C 680
26.7° to 51.7°C

6.1.1 Gearbox Lubrication

The gearbox for all models is located on the top of the refeed machine. Check the oil
level monthly. If you find a leak in the oil seal, repair it immediately! Oil leaking from the
gearbox can contaminate your product.

Drain and refill the gearbox oil after 2,500 hours of operation or every 6 months, which-
ever occurs first. See Table 6.1 on page 6-2 for the appropriate oil type. Mobil Synthetic
SHC 634 is another suitable gearbox oil.

See “Run-in Period” on page 2-7 for initial gearbox start up considerations. See “Storing”
on page 2-2 for gearbox storage considerations.

6-2 Rev F MD-0010-0000

Preventive Maintenance
Section 6
6.1.2 High Level Switch
Whenever you perform any gearbox maintenance, inspect the high level switch through
the inner chamber access port on the top.

Table 6.2: High Level Switch Maintenance

Model Switch Location Maintenance

RMR and RMB on the top of the refeed Check the position to assure that the
machine (Not all models paddle is parallel with the bridge breaker
have high level switches.) assembly under the switch.
RMS and RMX on the side (see item 5 of Verify that the presence of fluff activates
figures 3, 4 and 5) the proximity switch. When sensitivity is
properly set, the proximity switch will
detect the Bridge Breaker at each revo-
lution. Proximity switch delay time must
be set long enough to ignore the bridge
breaker.
RMT no high level switch

6.1.3 Bridge Breaker Assembly

Whenever you perform any gearbox maintenance, inspect the bridge breaker for fluff
accumulation and clean it when necessary. The frequency of inspections depends on the
type of material used.

6.2 Other Devices

Your system can include other devices that require periodic maintenance. See the tables
below for maintenance procedures for each component of these devices.

Table 6.3: Grinder Maintenance

Component Maintenance

Rotor bearing Lube at specified intervals.

V-belts Check for wear and proper tension.
Blow-through Make sure vent is in proper position.
Grinder knives Check gap and edge condition; sharpen as required.
Grinder screen Check for obstructions.

MD-0010-0000 Rev F 6-3

 Preventive Maintenance

Table 6.4: Roll Feeder Maintenance

Component Maintenance

Gearbox, lubrication Check level; change at required intervals.

Rollers Clean any build-up of material from rollers.

Table 6.5: Inducer Maintenance

Component Maintenance

Venturi intake tube Adjust for best conveying and low motor load combination.

Table 6.6: Additive Feeder Maintenance

Component Maintenance

Gearbox, lubrication Check level; change at required intervals.

Table 6.7: Vacuum Loader Maintenance

Component Maintenance

Flapper valve Make sure valve seal is adequate, adjust if necessary.

Filter Clean or replace as required.
Filter gaskets Check for wear or tears, replace as required.

6-4 Rev F MD-0010-0000

SECTION 7 - Spare Parts

TOPICS DISCUSSED IN THIS CHAPTER

U RMR Parts List

U RMB Parts List

U RMT/RMS Parts List

U Electrical Control Panel - Domestic Version

U Electrical Control Panel - European (CE) Version

 Spare Parts
7.1 RMR Parts List

Figure 7 - 1 RMR Refeed Machine

Table 7.1: RMR Parts

Item Description RMR1 RMR2 RMR3 RMR4 RMR5

1 Motor, 1 HP, DC M0313 M0313 M0313 M0313 M0313
2 Gear Reducer, 20:1 G0424 G0424 G0424 G0424 G0424
Ratio
3 Auger Bridge Breaker AG189 AG190 AG191 AG192 AG201
Assembly
4 Auger Bridge Breaker AG187D AG187D AG187D AG187D AG187D
Tail
5 High Level Control 00332 00332 00332 00332 00332

7-2 Rev F MD-0010-0000

Spare Parts
Section 7
7.2 RMB Parts List

Figure 7 - 2 RMB Refeed Machine

Table 7.2: RMB Parts

Item Description RMB3 RMB4 RMB5 RMB6

1 Motor, 3 HP, DC M0137 M0137 M0137 M0137

2 Gear Reducer, 20:1 Ratio G0374 G0374 G0374 G0374
3 Auger Bridge Breaker Assembly AG160 AG161 AG162 AG163
5 High Level Control 00332 00332 00332 00332

MD-0010-0000 Rev F 7-3

 Spare Parts
7.3 RMT/RMS Parts List

Figure 7 - 3 RMT/RMS/RMX Refeed Machine

Table 7.3: RMT/RMS/RMX Refeed Machine Parts

Part Number
Item Description
RMT/RMS RMX - US RMX - Metric

1 Motor, 1 Hp, DC M0313 M0313 M0627M

2 Gear Reducer, 20:1 ratio G0424 G0530 G0531M
3 Auger Bridge Breaker Assembly (consult factory)
4 Auger Bridge Breaker Tail AG293D AG293D AG293D
5 High Level Control S1396 S1396 S1396

7-4 Rev F MD-0010-0000

Spare Parts
Section 7
7.4 Electrical Control Panel - Domestic Version

Control panel information is supplied for reference only. Some applications

may require special controls. Complete electrical schematics are suppled
with the control panel.

Figure 7 - 4 Electrical Control Panel, Domestic Version

Table 7.4: Domestic Control Panel Parts

Item Description RMR/RMT/RMS/RMX

1 Meter, DC Volts, 0-111% Speed M0353C

2 Meter, DC Amps, 0-112% Load M0362A
3 Controller, Signal Isolator C0911
4 Potentiometer, 1K Ohm P0186
5 Relay, 4PDT, 3 Amp R0310
6 Relay, Voltage Control R0353
7 Controller, DC Motor, 1 HP, 240 AC, 180 DC C0853E

MD-0010-0000 Rev F 7-5

 Spare Parts
Table 7.4: Domestic Control Panel Parts (Continued)

Item Description RMR/RMT/RMS/RMX

8 Starter, Motor, IEC, 18A S1305C

9 Timer, Relay, ON Delay, 1-30 seconds, DPDT T0399
10 Fuse, 1 Amp F0680
11 Fuse, 20 Amp F0495

7.5 Electrical Control Panel - European (CE) Version

Control panel information is supplied for reference only. Some applications

may require special controls. Complete electrical schematics are suppled
with the control panel.

Figure 7 - 5 Electrical Control Panel, European (CE) Version

7-6 Rev F MD-0010-0000

Spare Parts
Section 7

Table 7.5: European (CE) Control Panel Parts

Item Description RMR/RMS/RMT/RMX

1 Meter, Volts, 0-111% Speed M0353C

2 Meter, Amps, 0-112% Load M0362A
3 Controller, Signal Isolator C0911
4 Potentiometer, 1K Ohm P0470
5 Relay, 4PDT, 3 Amp R0310A
6 Auger Speed relay R0353A
7 Controller, DC Motor, 1 Hp C0853E
8 Starter, Motor, IEC, 12A S1536B
9 Timer, Relay, ON Delay, 1-30 seconds, DPDT T0399A
10 Breaker, Circuit, 1A, 1P B1010B
11 Breaker, Circuit, 15A, 1P B1044K
12 Breaker, Circuit, 15A, 1P B1044K

MD-0010-0000 Rev F 7-7

 Spare Parts

7-8 Rev F MD-0010-0000

SECTION 8 - Vendor Product Literature

TOPICS DISCUSSED IN THIS CHAPTER

U The KBSI-240D Signal Isolator

U KBIC ® Solid State SCR DC Motor Speed Controls

U Syrelec Voltage Control Relay

 Vendor Product Literature
This section contains the Installation and Operating Instructions for the KBSI-240D sig-
nal isolator, the KBIC ® solid state SCR DC motor speed controls, and the Syrelec Volt-
age Control Relay. All of these devices are used as components of Process Control
equipment.

Table 8.1: Vendor Documentation

PCC Part Vendor Part

Description Vendor Name Page
Number Number
C0911 DC signal isolator KBSI-240D KB [Link] page 8-2
C0853E 180 vdc motor con- KBIC-218pm- KB [Link] page 8-18
troller 1HP
K0353 voltage control relay DUR110A Syrelec

8.1 The KBSI-240D Signal Isolator

©2000 KB Electronics, Inc. Used by permission.

INSTALLATION AND OPERATING INSTRUCTIONS

MODEL KBSI-240D
Signal Isolator KB Part No. 9431

P1
KBSI-240D

J1
VOLT CUR

MAX MIN

1 2 3 4 5 6 7 8 9 10

! 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.

A COMPLETE LINE OF MOTOR DRIVES

© 2000 KB Electronics, Inc.

8-2 Rev F MD-0010-0000

Vendor Product Literature
Section 8

TABLE OF CONTENTS
Section Page
i. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
III. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IV. Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
V. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tables
1. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Voltage Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figures
1. Control Layout & Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2A. 115V Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2B. 230V Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Current Input Signal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Voltage Input Signal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5A. Master/Multiple Slave Voltage Following System (Single Main Motor) . . . . . . . . . . . . . . . . . . . . . . 9
5B. Master/Multiple Slave Voltage Following System (Single Main Potentiometer) . . . . . . . . . . . . . . . . 9
6A Master/Slave Voltage Following System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6B. Process Control with Auto/Manual Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6C. Process Control with Auto (Ratio Pot)/Manual Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6D. Auto/Manual Operation with Potentiometer on KBSI Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
ii

MD-0010-0000 Rev F 8-3

 Vendor Product Literature

i. SAFETY WARNING! Please read carefully:

!
Be sure to follow all instructions carefully. Fire and/or electrocution can result due to improper
use of this product.

This product should be installed and serviced by a qualified technician, electrician, or electrical
maintenance person familiar with its operation and the hazard involved. Proper installation,
which includes wiring, mounting in proper enclosure, fusing or other over current protection and
grounding, can reduce the chance of electric shocks, fires, or explosion in this product or prod-
ucts used with this product, such as electric motors, switches, coils, solenoids, and relays. Eye
protection must be worn and insulated adjustment tools must be used when working with con-
trol 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 warn-
ing to the ultimate user of this product. (SW effective 11/92)

This product complies with all CE directives pertinent at the time of manufacture. Contact
factory for detailed installation instructions and Declaration of Conformity.

8-4 Rev F MD-0010-0000

Vendor Product Literature
Section 8

I. INTRODUCTION
The KBSI-240D Signal Isolator is used to isolate, amplify and condition DC voltage and current
signals from any source (motors, tachs and transducers) which will drive most variable speed
motor controls with a voltage following input. The maximum output voltage of the isolator is 10
volts, which is a linear function of the input signal.
The KBSI-240D is versatile since it can accommodate a wide range of input voltages (0 - 25*,
0 - 120 and 0 - 550V DC) and, in addition, a wide range of input current signals (4 - 20 mA, 10
- 50 mA and 1 - 5 mA). The Voltage/Current (“VLT/CUR”) jumper is used to change the
KBSI-240D from a voltage to current input.
A built-in power supply enables the KBSI-240D to be controlled with a 5KΩ remote poten-
tiometer (connect potentiometer to terminals “P1,” “5” and “6” – see page 9). The potentiome-
ter can also be wired for Auto/Manual Operation.
*The input range of 0 - 25V is the maximum voltage that can be applied to terminals “5” and
“6”. The minimum input voltage is 0 - 5 volts, which can achieve an output voltage of 0 - 10
volts. The unit is factory calibrated so that a 0 - 10V DC input yields a 0 - 10V DC output.

II. MOUNTING
Mount the Signal Isolator using (4) 6-32 screws (not included). Use the Control Layout and
Mechanical Specifications drawing on page 3 to locate the mounting holes. The unit is
designed to be mounted in any position providing its components do not come in contact with
grounded or live wiring.

MD-0010-0000 Rev F 8-5

 Vendor Product Literature

FIGURE 1 – CONTROL LAYOUT & MECHANICAL SPECIFICATIONS (INCHES / [mm])

(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)

4.843
[123.00] 0.276
0.276 4.291 [7.00]
[7.00] [109.00]

P1

KBSI-240D
J1 2.244
VOLT CUR
[57.0]
MAX MIN 2.795
[71.0]

1 2 3 4 5 6 7 8 9 10
(4) mounting holes for #6 screws
3

8-6 Rev F MD-0010-0000

Vendor Product Literature
Section 8

TABLE 1 – GENERAL PERFORMANCE SPECIFICATIONS

AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 115 or 208 - 230V AC, 50/60 Hz (1)

Signal Input Voltage (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 25, 0 - 120, 0 - 550V DC
Signal Input Current (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5, 4 - 20, 10 - 50mA (3)
Maximum Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Volts
Maximum Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10mA
Range of “MIN” Trimpot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 3 Volts
Range of “MAX” Trimpot . . . . . . . . . . 0 to 2 times the input voltage with maximum of 10 Volts
Linearity (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 0.1%
Temperature Drift (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 mV per ºC
Temperature Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 50 ºC

Notes:
1. To achieve full specifications input voltage must be within ± 10% of nominal.
2. Floating (non-grounded) or grounded input signal may be used.
3. To change from 4 - 20mA to 1 - 5mA remove R3. To convert to 10 - 50mA add a 150Ω 1W resistor across
terminals “5” and “6.” See figure 3.
4. Specifications are based on an output of 10 volts.

MD-0010-0000 Rev F 8-7

 Vendor Product Literature

III. WIRING. FIGURE 2A – 115V CONNECTION

Warning! Read Safety Warning on page 1 1 2 3 4

! before attempting to use this control.

Warning! To avoid erratic operation do not bundle AC

Line and motor wires with potentiometer, voltage fol-
Jumper Jumper
lowing, enable, inhibit or other signal wiring. Use 1A
FUSE
shielded cables on all signal wiring over 12” (30 cm) –
Do not ground shield. 115V AC

A. AC Power – The KBSI-240D is powered with either 115

FIGURE 2B – 230V CONNECTION
or 230V AC, 50/60 Hz by arranging the jumpers
between terminals “1” to “4” properly. See figures 2A 1 2 3 4
and 2B. Be sure unit is wired in accordance with the
National Electric Code and other codes that may apply.
It is recommended that a 1 amp fuse be installed in
series with the AC line.
Jumper
B. Input Terminals – A voltage or current signal from a 1A
FUSE
microprocessor, tachometer, transducer, etc. is to be
connected to terminals “5” through “8.” The selection of 230V AC
the proper terminal is based on the maximum level of
the input signal. See figures 3 and 4.

8-8 Rev F MD-0010-0000

Vendor Product Literature
Section 8

i. Current Input Signal FIGURE 3 – CURRENT INPUT

SIGNAL CONNECTION
Warning! Read Safety Warning on Page 1
! before attempting to use this control. 5 6

Note: The Voltage/Current (VLT/CUR) jumper must be in “CUR”

position. Connect the negative current signal input to terminal “5”
and the positive to terminal “6.” The KBSI-240D is factory calibrat- 150Ω Resistor
ed so that a 4 - 20mA signal will provide a 0 - 9 Volt output. The Converts 4 - 20mA
to 10 - 50mA
input range can be converted to a 10 - 50mA range by attaching a – +
4 - 20mA
150Ω 1W resistor across the current input terminals “5” and “6.”
See figure 3. Control must be recalibrated when the 150Ω resistor is installed. The range of
signal input can be changed to 1 - 5mA by removing resistor R3 from the printed circuit board.
Recalibrate the Signal Isolator to follow a 4 - 20mA current signal input as follows:
1. Connect a 10V DC meter (digital DC meter is suggested) to terminals “9”(-) & “10” (+).
2. Apply the minimum input current (4mA) at terminals “5” and “6.”
3. Adjust the “MIN” trimpot to an output voltage of 0 volt DC.
4. Set the input current to 20mA and adjust the “MAX” trimpot so that the output voltage is at
the desired level (9V DC).
5. Repeat steps 3 and 4 if extreme accuracy is required. The Signal Isolator is now cali-
brated to provide 0 - 9V DC output with a 4 - 20mA input.
6. Use the “MIN” and “MAX” trimpot if other than 0 - 9V DC output is required with the respec-
tive input current range.
6

MD-0010-0000 Rev F 8-9

 Vendor Product Literature

ii. Voltage Input Signal

Warning! Read Safety Warning on Page 1
! before attempting to use this control.
Note: The Voltage/Current (VLT/CUR) jumper must be in the VLT position (factory setting).
The KBSI-240D is designed to accept a wide range of input voltage signals as follows:
TABLE 2 – VOLTAGE INPUT SIGNAL FIGURE 4 – VOLTAGE INPUT
Minimum Input Maximum Input SIGNAL CONNECTIONS
Input Terminals
Voltage Range Voltage Range
5, 6 0-5 0 - 25 5 6 7 8
5, 7 0 - 25 0 - 120
5, 8 0 - 120 0 - 550

Connect input voltage signal to proper input terminals as

+
0 - 25V
indicated in figure 4. – 0 - 120V
+
1. Connect a 10V DC meter (digital meter is suggested) +
0 - 550V
to terminals “9” (-) and “10” (+).
2. Apply the maximum input voltage that would be supplied from tach, transducer, etc.
3. Adjust the “MAX” trimpot to the desired output voltage.
Example: A slave motor is to follow the output of a main motor with an armature voltage
range of 0 - 90V.

8-10 Rev F MD-0010-0000

Vendor Product Literature
Section 8

a) Connect the armature of the main motor to the SI input terminals “5” (-) and “7” (+).
b) Set the armature voltage of the main motor to zero (0). Adjust the “MIN” trimpot so that
the output at terminals “9” and “10” reads zero (0) volts.
c) Reset the armature voltage of the main motor to 90V. Adjust the “MAX” trimpot so that
the output voltage is 9V DC.
Notes:
1. When setting the output voltage using the “MIN” and “MAX” trimpots the voltage or speed
of the driven motor can be read directly instead of using the output of the KBSI.
2. When readjusting the “MIN” and “MAX” trimpots, always set the minimum voltage first and
then the maximum voltage.
3. Trimpots allow approximately 20 turns for the full range of adjustment. If during the adjust-
ment procedure the output stops changing, try reversing the direction of rotation of trimpot.

IV. OUTPUT SIGNAL

The output signal from the SI is obtained from terminals “9” (-) and “10” (+). Connect the out-
put directly to the signal following input terminal of the speed control. For multiple slave motors,
several controls can be driven from a single KBSI-240D. Be sure the AC line connections to
the slave control are to the same phase (eg, L1 to L1 and L2 to L2 of all controls.)
The output from the KBSI-240D can be scaled to control the speed control over any desired
speed range. Adjust the “MIN” trimpot to provide the desired minimum speed and the “MAX”
trimpot to provide the desired maximum speed.
8

MD-0010-0000 Rev F 8-11

 Vendor Product Literature

FIGURE 5 – MASTER/MULTIPLE SLAVE VOLTAGE FOLLOWING SYSTEM

A) From a Single Main Motor
Main Motor Slave
10(+) Ratio 5KΩ
Motor #1
DC A(+) 7 P2 A(+)
Speed
Speed KBSI-240D 9(–) Control
Control A(–) 5 A(–)
F(–)
Isolation Diode Slave
Motor #2
P2 A(+)
Speed
A 10K ratio poten- Control
B) From a Single Main Potentiometer
tiometer is used to F(–) A(–)
control up to ten 10 (+) Slave
P1*
(10) slave motors. Motor #3
P2 A(+)
5K 6 Connect Speed
If a 5K ratio poten- Pot
KBSI-240D as above Control
tiometer is used, up A(–)
5 F(–)
to five (5) slave 9 (–)
motors can be con- *Connect high side of potentiometer
trolled. to terminal "P1" (1/4" QD) Additional
Slaves

WARNING! If Signal Isolator is connected to multiple speed controls;

1) Multiple controls must be powered from the same phase of AC line.
2) The positive input terminal to each speed control must be installed with a 1 amp - 600V isolation diode as
shown.
3) Multiple speed controls can not be used with PWM, Regenerative or Variable Frequency Drives (Inverters).

8-12 Rev F MD-0010-0000

Vendor Product Literature
Section 8

FIGURE 6A – MASTER/SLAVE VOLTAGE FOLLOWING SYSTEM

AC Line 90V DC AC Line AC Line

Main Motor Slave
10(+) P2 L1 L2 Motor #1
DC A(+) 7 A(+)
Speed
Speed KBSI-240D 9(–) F- Control
Control A(–) 5 A(–)

Speed
Pot

FIGURE 6B – PROCESS CONTROL WITH AUTO/MANUAL SWITCH

Manual
5K Pot
5K Speed Pot
The KBSI-240D can Auto/Man
be wired in an
Auto/Manual mode P3
which will allow man- Motor
10(+) P2 A(+)
ual override of an
automatic process. KB
KBSI-240D P1
See figure 6B. CONTROL
9(–) A(–)
F(–)

10

MD-0010-0000 Rev F 8-13

 Vendor Product Literature

FIGURE 6C – PROCESS CONTROL WITH AUTO (RATIO POT)/MANUAL SWITCH

The following circuit Auto

provides for dual pur- W/Ratio Manual
pose usage of the
speed pot. In the P3
“AUTO” mode it is Motor
10(+) A(+)
used for ratio control
P2 KB
and in the “MAN” KBSI-240D
CONTROL
mode it is used for
9(–) F(–) A(–)
manual speed adjust-
ment. 5K Pot

FIGURE 6D – AUTO/MANUAL OPERATION WITH POTENTIOMETER ON KBSI INPUT

Auto/Man 5K Pot
P1 Motor
Process 10(+) P2 A(+)
Signal KB
KBSI-240D
6 CONTROL
0 - 10V DC 5 9(–) F(–) A(–)

Note: The preceding circuit provides for the speed pot to be used in “MAN” mode only. In “AUT0”
mode, the process control signal is supplied directly to the signal isolator.
11

8-14 Rev F MD-0010-0000

Vendor Product Literature
Section 8

– NOTES –

12

MD-0010-0000 Rev F 8-15

 Vendor Product Literature

– NOTES –

13

8-16 Rev F MD-0010-0000

Vendor Product Literature
Section 8

V. LIMITED WARRANTY
For a period of 18 months from the date of original purchase, KB Electronics, Inc. will repair or
replace, without charge, devices which our examination proves to be defective in material or
workmanship. This warranty is valid if the unit has not been tampered with by unauthorized per-
sons, 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. KB Electronics, Inc. is not responsible for any expense, including instal-
lation and removal, inconvenience, or consequential damage, including injury to any person,
caused by items of our manufacture or sale. Some states do not allow certain exclusions or lim-
itations found in this warranty and therefore they may not apply 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.
(Rev 2/2000)

KB Electronics, Inc.
12095 NW 39th Street, Coral Springs, FL 33065-2516 • (954) 346-4900 • Fax (954) 346-3377
Outside Florida Call TOLL FREE (800) 221-6570 • E-mail – info@[Link]
[Link]

(A40255) – Rev. B – 5/2000

MD-0010-0000 Rev F 8-17

 Vendor Product Literature
8.2 KBIC ® Solid State SCR DC Motor Speed Controls
©1996 KB Electronics, Inc. Used by permission.

KBIC®
Solid State SCR
DC Motor Speed
Controls ®
See table 2 page 4 for KBIC
models covered by this manual

Patented Ultra Fast

CL Circuit Prevents
Demagnetization in
PM Motors

Installation and
®
Operating Basic KBIC
Instructions
PATENTED
See SAFETY WARNING on page 4
*See Page 3

A COMPLETE LINE OF MOTOR DRIVES

©1996 KB ELECTRONICS, INC.

TABLE OF CONTENTS
Section Page
i. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ii. Simplified Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
iii. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
I. Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
II. Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
III. Adjustments & Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
IV. Switching Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
V. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TABLES
1. Nominal Trimpot Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Fuse Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Plug-in Horsepower Resistor® Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Minimum Supply Wire Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7. Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FIGURES
1. Basic KBIC ® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. ACCEL Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5a. Master/Slave Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5b. Dynamic Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5c. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8-18 Rev F MD-0010-0000

Vendor Product Literature
Section 8

i. SAFETY WARNING!
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 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 which 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, 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.

ii. SIMPLIFIED INSTRUCTIONS – Read these simplified instructions before operating control. (See Safety Warning.)
1. Be sure input AC line voltage corresponds to control voltage. (See Electrical Rating chart, table 2 p. 4.)
2. Install the correct Plug-in Horsepower Resistor® according to armature voltage and motor horsepower (See chart, p. 5).
3. Recheck connections: AC line to L1 and L2, armature to A+ and A- and Field (Shunt motors only) to F+ and F-. (Note: if
motor runs in improper direction, interchange armature leads.)
4. Nominal trimpot settings are as follows (expressed in % of full CW rotation):
5. It is recommended that both AC line and armature fuses should be installed in this product. (See sec. IID, p. 9.)
TABLE 1 – NOMINAL TRIMPOT SETTINGS (For detailed instruction see Sec. III)

MIN (minimum speed) 15% CL (current limit/torque) 50%

MAX (maximum speed) 60% ACCEL (acceleration start) 50%

IR (IR Compensation) 25%

TABLE 2 – ELECTRICAL RATINGS

RATING WITHOUT AUXILIARY HEATSINK RATING WITH AUXILIARY HEATSINK
AC Line FIELD VOLTAGE
Motor
Model Voltage (Shunt wound
Voltage Max. AC Max. DC Max. AC Max. DC
Number (VAC) ± 15% 3 MAX MAX Motor Only)
(VDC) Load Current Load Current Load Current Load Current
50/60Hz HP HP (VDC)
(RMS Amps) (Avg. Amps) (RMS Amps) (Avg. Amps)

KBIC-120 115 0 - 90 9.0 6.0 0.5 18.0 12.0 1 50, 100

KBIC-125 115 0 - 90 12.0 8.0 0.75 24.0 16.0 1.5 50, 100
KBIC-240 230 0 - 180 9.0 6.0 1 18.0 12.0 2 100, 200
KBIC-225 230 0 - 180 12.0 8.0 1.5 24.0 16.0 3 100, 200
115 0 - 90 0.5 1 50, 100
KBIC-240D1 9.0 6.0 18.0 12.0
230 0 - 180 1 2 100, 200
KBIC-240DS2 115 / 230 0 - 90 9.0 6.0 0.5 18.0 12.0 1 100

Notes:
(1) Model KBIC-240D is designed to accept 115 or 230 VAC line input to provide 0 - 130 VDC with a 115 or 230 VAC line and 0 - 220 VDC
with a 230 VAC line.
(2) Model KBIC-240DS is designed to accept 115 or 230 VAC line input to provide 0-130 VDC with a 115 or 230 VAC line. (Also see
Information Sheet A40058)
(3) A higher output voltage can be reached by increasing MAX trimpot setting.

TABLE 3 – GENERAL PERFORMANCE SPECIFICATIONS PLUG-IN HORSEPOWER RESISTOR®

Speed Range (ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50:1 A Plug-in Horsepower

Load Regulation (% base speed) (0 - full load; 50:1 speed range) . . . . 1* Resistor ® must be
Line Voltage Regulation (% base speed at full load; 100 - 130 VAC) . 1/2* installed to match the
Control Linearity (% speed vs. dial rotation) . . . . . . . . . . . . . . . . . . . . . . 2 KBIC® to the motor
CL/Torque Range (% full load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 300 horsepower and voltage.
ACCEL Time Period (0 - full speed) (secs) . . . . . . . . . . . . . . . . . 0.5 - 4.0 See table 4, p. 5 for the
MIN Speed Trimpot Range (% full speed) . . . . . . . . . . . . . . . . . . . 0 - 30* CAUTION
correct value. Plug-in
® Be sure Plug-in
MAX Speed Trimpot Range (% full speed) . . . . . . . . . . . . . . . . . 50 - 110* Horsepower Resistors Horsepower
IR Compensation Trimpot Range (at specified full load) (volts) . . . . 0 - 24 are stocked by your Resistor® is
Maximum Allowable Ambient Temperature at full rating (º C/º F) . . 45/113 distributor. inserted completely
Maximum Inrush Start Current (Peak DC amps) . . . . . 3 times CL Setting into mating socket.

*Performance is for SCR rated PM motors only. Lower performance can be expected with other motor types. Factory setting is for 3% load
regulation. To obtain superior regulation, see sec. III E, p. 11.

MD-0010-0000 Rev F 8-19

 Vendor Product Literature

FIG. 1 – BASIC KBIC® *Note: Specific applications may require a different fuse value than
indicated. This is based on several factors such as ambient temperatures,
duty cycle, motor form factor and CL setpoint.

FIG. 1 – FEATURES AND FUNCTIONS

(1) Plug-in Horsepower Resistor®
(2) Mounting Holes for Armature and AC Line Fuses
(3) Trimpots: MIN, MAX, ACCEL, IR & CL
(4) Auxiliary Heatsink (optional) (see fig. 2, p. 7)

TABLE 5 – PLUG-IN HORSEPOWER RESISTOR® CHART(1)

Motor Horsepower(2) Approx. Plug-in Individual

Motor Horsepower Plug-in
Armature Voltage Armature Voltage Current Resistor Horsepower
90VDC 180VDC (DC Amps) Value (Ohm) Resistor® P/N
TABLE 4. FUSE SELECTION CHART*
1/100 1/50 0.1 1.0 9833
90 VDC Motor 180 VDC Motor Approx. Fuse Rating 1/50 1/25 0.2 0.51 9834
Motor Current (AC Amps)
HORSEPOWER 1/30, 1/25 1/15 0.35 0.35 9835
(DC Amps)
1/100 1/50 0.1 2/10 1/20 1/10 0.5 0.25 9836

1/50 1/25 0.2 3/10 1/15, 1/12 1/6 0.8 0.18 9837

1/30 1/15 0.3 1/2 1/10, 1/8, 1/6 1/4 1.3 0.1 9838

1/20 1/10 0.5 3/4 1/4 1/2 2.5 0.05 9839

1/15 1/8 0.7 1 1/3 3/4 3.3 0.035 9840

1/10 1/5 1.0 1 1/2 1 5.0 0.025 9841

1/8 1/4 1.3 2 3/4 1 7.5 0.015 9842

1/6 1/3 1.7 3 1 2 10.0 0.01 9843

1/4 1/2 2.5 4 1 3 15.0 0.006 9850

1/3 3/4 3.3 5 Notes:

1/2 1 5.0 8 (1) Motor horsepower and armature voltage must be specified in order
to select correct Plug-in Horsepower Resistor®.
3/4 1 7.5 12 (2) For motor horsepower not indicated use lower value Plug-in
1 2 10.0 15 Horsepower Resistor®.
1 3 15.0 25
5

iii. INTRODUCTION
®
Thank you for purchasing the KBIC "Standard of the Industry" DC motor speed control. They are designed for applications
demanding good performance, high reliability and low cost. The controls are fabricated with components that have proven reliability,
including MOV transient protection, which is used to protect the power bridge. Integrated circuitry is used to provide an uncomplicated
design with superior load and line voltage regulation. The patented Direct-Fed™ current limit circuit protects the motor and control
against overloads by limiting the maximum level of output current. It also prevents motor failure due to demagnetization of the magnets
of PM motors. Acceleration start (adjustable from 0.5 to 4 seconds) provides a smooth start each time the AC power is applied.
® ®
A unique feature of the KBIC control is the Plug-in Horsepower Resistor . It eliminates the need to recalibrate IR Comp. and CL
when the control is used over a wide range of motor horsepower. Additional versatility is achieved by using the Auxiliary Heatsink
(optional) which is used to double the horsepower rating of each model. The output of the control is a linear function of potentiometer
®
rotation. The KBIC can also be operated in a voltage following mode by supplying an isolated analog signal (0-7 VDC) to the input
terminals P2(+) and F-. If an isolated input signal is not available, the optional Barrier Terminal Board Signal Isolator (SI-5) can be used.
The controls are terminated as standard with Q-D terminals. A Barrier Terminal Board is available which incorporates both line and
armature fuses.
The Inhibit™ circuit (Terminals I1 and I2) is provided to electronically disconnect the armature output voltage. Another standard
®
feature is Auto Inhibit. This circuit prevents false starts and high surge currents when cycling the KBIC control with the AC line.
All models are UL Recognized for the USA and Canada and CE approved.
I. APPLICATION INFORMATION
®
A. Motor Type – The KBIC is designed for Permanent Magnet (PM), Shunt Wound and Universal (AC/DC) motors. Controls
operated on 115 volt AC inputs are designed for 90 volt SCR rated motors. Controls operated on 230 volt AC inputs are
designed for 180 volt SCR rated motors. Use of higher voltage motors will result in reduction of available MAX speed. Also,
if motor is not an SCR rated type, the actual AC line amperage at full load should not exceed the motor's DC nameplate
rating.
B. Torque Requirements – When replacing an AC induction motor with a DC motor and speed control, consideration must
be given to the maximum torque requirements. The full load torque rating of the DC motor must be equal to, or greater than,
that of the AC motor.
®
C. Acceleration Start – The KBIC contains an adjustable acceleration start feature which allows the motor to smoothly
accelerate from 0-full speed over a time period of 0.5-4 seconds. The "ACCEL" is factory set at 2 seconds.
®
D. Limitation in Use – The KBIC controls are designed for use on machine applications.
E. Armature Switching – Do not switch the armature without taking proper precautions. (See sec. IV, p. 11)

CAUTION
Consult factory before using on constant horsepower applications such as saws or drill presses. Do not use in
explosive atmosphere.
®
Be sure the KBIC is used within its maximum ratings. Follow all installation instructions carefully. (Refer to section II.)

8-20 Rev F MD-0010-0000

Vendor Product Literature
Section 8

FIG. 2 – MECHANICAL SPECIFICATIONS

POTENTIOMETER OPTIONAL AUXILIARY HEATSINK
0.982
3/8 1/2

0.500

CONTROL
1/4" ROUND
ALUM. SHAFT 5.625
7.000

3/8-32
ANTI- BUSHING
ROTATION 3.110
PIN

5.625
0.125 6.250
3
1.250
1 2
.438
1.375
DWG #:D2600-1-00281

II. INSTALLATION INSTRUCTIONS

A. Location and Mounting – The KBIC® controls should be mounted on a flat surface and located in an area where it will
not be exposed to contaminants such as water, metal chips, solvents or excessive vibration. When mounting in an
enclosure, the air space should be large enough to provide adequate heat dissipation. The maximum allowable ambient
temperature at full rating is 45 ºC/113 ºF. Consult factory if more information is required.
B. Initial Setup and Wiring.
1. Install proper size Plug-in Horsepower Resistor® (See chart).
2. The KBIC can be connected to a standard 115V or 230V (±15%) 50/60 Hz AC line based on model selected [Be sure
the AC input voltage corresponds to the control voltage rating and the motor rating (e.g. 90-130VDC motor on 115VAC
and 180VDC motor on 230VAC)].
3. Follow the recommended supply wire sizes as per table 6, p. 8.
4. Follow the NEC and other electrical codes that apply.
CAUTION: Separate branch protection must be provided on 240V circuits. Do not fuse neutral or grounded
conductors.
5. Connect control in accordance to connection diagram - See fig. 3, p. 8.
6. When using a step-down transformer (440 VAC to 220 VAC) be sure the VA rating of the transformer is at least 3 times
the VA rating of the motor. 7

MINIMUM WIRE SIZE (AWG) Cu only

MAX. MOTOR
TABLE 6 MAX. MOTOR MAX. MOTOR
CURRENT
HP 90V HP 180V MAX. 50 FOOT MAX. 100 FOOT
Minimum Supply Wire (DC AMPS)
RUN RUN
Size Requirements
6 0.5 1 16 14
*Minimum Recommended 12 1 2 14 12*
Wire Size
16 1.5 3 12 12

FIG. 3 – CONNECTION DIAGRAM

AC LINE VOLTAGE FIELD VOLTAGE (VDC) FIELD CONNECTION FIELD TYPE

TABLE 7
Field Connections (Shunt-wound Motors Only) 115 100 F+, F- Full Voltage

115 50 F+, L1 Half Voltage

Caution: Shunt-wound motors may be
damaged if field remains energized without 230 200 F+, F- Full Voltage
motor rotating for an extended period of time. 230 100 F+, L1 Half Voltage

MD-0010-0000 Rev F 8-21

 Vendor Product Literature

WARNING: If control is wired to a transformer, do not switch the primary side of transformer to disconnect power or catastrophic
failure can result. Always disconnect control from secondary side of transformer.

CAUTION: Do not bundle potentiometer connections (P1, P2, P3) and Inhibit™ connections (I1, I2) with AC line or motor wires.

WARNING: Armature Switching. Do not switch the armature in and out of circuit or catastrophic failure will result. If armature
switching is required for dynamic brake or reversing, use model KBRG, KBPB or KBCC-R suffix controls.

NOTE: (Shunt motors only) For 90V DC motors with 50VDC fields and 180VDC motors with 100VDC fields, use half voltage
field connections F+ and L1. (See table 7, p. 8)

C. Voltage Following – All models can be controlled with an isolated analog reference voltage (0-7 VDC) in lieu of the main
speed potentiometer. The voltage is connected to P2 (+) and F-. The control output voltage will linearly follow the input voltage.
The source impedance of the input should be 10K ohms or less. The Min and Max trimpots are rendered inoperative in the
voltage following mode. Use auxiliary trimpots for scaling and to limit the control range. If the input signal is not isolated, or
is a current signal (4 - 20 mA), the KBSI-240D or SI-5 Barrier Terminal Board Signal Isolator must be used. It will allow direct
connection to process controllers and microprocessors.

CAUTION:
1. The voltage feeding P2 and F- must be isolated from the AC line. Do not earth ground P2 or F- to setup a zero or ground
reference.
2. Do not bundle signal wires to P2 and F- with AC line or motor connections. If signal wires are over 18 inches, use shielded
cables.

®
D. Fusing – The KBIC has provision for adding a built-in AC line fuse and armature fuse*. The AC line fuse protects the control
against catastrophic failure. If the fuse blows, the control is miswired, the motor is shorted or grounded, or the KBIC® control
is defective. The armature fuse provides overload protection for the motor and control. Choose the proper size armature fuse
and AC line fuse (see fuse chart table 4, p. 5) by multiplying the maximum DC motor amps by 1.7. Armature and AC line fuse
kits are available from your distributor. On domestic 230 Volt AC lines, separate branch circuit protection for each line must
be used. All fuses should be normal blow ceramic 3AG or MDA or equivalent. The Barrier Terminal Kit (optional) contains
prewired AC line and armature fuses. *Contact your distributor.

III. ADJUSTMENTS AND CONTROL FUNCTIONS

The KBIC® is factory adjusted to provide 0 to full speed range using a 5K potentiometer. Minimum and maximum speed trimpots
are provided to change the speed range from other than 0 to full speed. An acceleration start (located directly behind the MIN
trimpot) is factory set to provide motor acceleration from 0 to full speed over a time period of 2 seconds (approx.) each time the
AC power is applied. The current limiting (CL, or torque output) adjustment is factory set to approximately one and a half times
the motor rating. The IR Compensation (IR) is factory adjusted to provide excellent motor regulation under normal operation.
®
NOTE: In order for the IR comp and CL trimpot settings to be correct, the proper Plug-in Horsepower Resistor must be
installed for the particular motor and input voltage being used. Do not attempt to change the settings of the trimpots
unless absolutely necessary since they are factory adjusted to near optimum settings.

IMPORTANT NOTE:
Readjusting the ACCEL time will affect the MAX speed and IR Comp. settings which will have to be readjusted (see
this Section). If the ACCEL time is decreased to the minimum time of 0.5 seconds (6 o'clock trimpot position), then
increase the IR trimpot 25% CW rotation and decrease the MAX trimpot 20% CCW rotation. If the ACCEL time is
increased to the maximum time of 4 seconds (full rotation), then decrease the IR and increase the MAX as per
above percentages of rotation.

The following procedure is presented in required order of adjustment. FIG. 4 – ACCEL TRIMPOT ADJUSTMENT
It should be followed when readjusting all trimpot functions:
A. Acceleration Start – (ACCEL trimpot is located directly behind the
MIN trimpot.) If the ACCEL is to be readjusted to different times,
adjust the trimpot to the desired time according to fig. 4.
B. Maximum Speed Adjustment – Set main speed pot to full speed
(maximum CW position). Adjust MAX speed trimpot to new desired
setting.
Note: Do not attempt to adjust the MAX speed above the rated motor
RPM since unstable motor operation may occur. For moderate
changes in the MAX speed, there will be a slight effect on the
MIN speed setting when the MIN speed is set at zero. There
may be significant variation in the MIN speed setting if the MIN
speed is at a higher than zero setting.
C. Minimum Speed Adjustment – If a higher than zero speed is desired, readjust the minimum speed by turning the main
speed potentiometer to zero setting (full CCW position). Then adjust the MIN speed trimpot to the desired setting.
10

8-22 Rev F MD-0010-0000

Vendor Product Literature
Section 8

Note: The MIN speed adjustment will affect the MAX speed setting. Therefore, it is necessary to readjust the MAX speed after
the MIN speed, and it may be necessary to repeat the sequence until both the MIN and the MAX speeds are set to the
desired levels.
D. Current Limit (CL/Torque Adjustment) – CL circuitry is provided to protect the motor and control against overloads. The
CL also limits the inrush current to a safe level during startup. The CL is factory set to approximately 1.5 times the full load
rating of the motor. (CL trimpot is nominally set to approx. 50% of full CW rotation.)
Note: The correct value Plug-in Horsepower Resistor® must be installed in order for the CL and IR comp. to operate properly.

Calibration of the CL & IR comp. is normally not required when the proper Plug-in Horsepower Resistor® is
installed.

To set the CL to factory specifications adjust as follows:

1. Set main speed potentiometer at approximately 30 - 50% CW rotation. Set CL trimpot to full CCW position.
2. Connect a DC ammeter in series with the armature lead.
3. Lock shaft of motor (be sure CL pot is in full CCW position). Apply power and rotate CL pot CW slowly until DC ammeter
reads 1.5 times motor rating (do not exceed 2 times motor rating). Note: Complete this step within 5 seconds to avoid
damaging motor.
Note: If only an AC ammeter is available, it can be installed in series with AC input line. Follow above instructions; however,
set AC amperage at 0.75 times motor rating.
E. IR Compensation Adjustment – IR compensation is provided to substantially improve load regulation. If the load presented
to the motor does not vary substantially, the IR adjustment may be set at a minimum level (approximately 1/4 of full setting).
The control is factory adjusted to approximately 3% regulation. If superior performance is desired (less than 1% speed
change of base speed from 0 to full load), then the IR comp. should be adjusted as follows:
Note: Excessive IR comp. will cause control to become unstable, which causes motor cogging.
1. Set IR comp. trimpot at approximately 25% of CW rotation. Run motor unloaded at approximately 1/3 speed and record
RPM.
2. Run motor with maximum load and adjust IR comp. trimpot so that the motor speed under load equals the unloaded speed
per step 1.
3. Remove load and recheck unloaded RPM. If unload RPM has shifted, repeat procedure for more exact regulation. The
control is now compensated to provide minimal speed change under large variations of applied load.

IV. SWITCHING CIRCUITS

A. AC Line Switching – The KBIC® can be safely turned "on" and "off" rapidly using the AC Line (no waiting time is required).
Auto Inhibit® circuitry contained in the KBIC® automatically resets critical components each time the AC line is interrupted.
This, along with Acceleration Start and CL, will provide a smooth start each time the AC line is connected.
11

Warning: Do not disconnect and reconnect the Armature with the AC line applied or catastrophic failure will result.

B. Armature Switching – If the armature is to be disconnected and reconnected with AC power applied, the Inhibit Circuit™ must
be simultaneously activated and deactivated. Connect I1 and I2 together to activate the Inhibit Circuit™. See fig. 5B for
dynamic brake circuit.
®
C. Reversing and Dynamic Braking – KB has developed the APRM * which provides anti-plug "instant" reversing and solid state
dynamic braking. The APRM® is built in as standard in all KBCC-R suffix models and in all KBPB™ models. *Patented.

FIG. 5 APPLICATIONS
A. Master/Slave Connections. The KBIC can be used with the KBSI to drive multiple motors:
(a) From a single main potentiometer
(b) From a single main motor.

FIG. 5A – MASTER SLAVE CIRCUIT

** connect high side of potentiometer

* A 10K ratio potentiometer is used to control up
to terminal “P” (” QD)
to (10) "slave" motors. If a 5K ratio
potentiometer is used, up to (5) "slave" motors
can be controlled.
1) Multiple KBIC® controls should be powered
from the same phase AC line.
2) The positive output terminal to each speed
control must be installed with a 1A-600PIV
isolation diode.

12

MD-0010-0000 Rev F 8-23

 Vendor Product Literature

FIG. 5B – DYNAMIC BRAKE CIRCUIT (Using Inhibit™)

Notes (Dynamic Brake Circuit)

* Choose RB resistance and wattage according to
braking requirements.
** Inhibit™ circuit extinguishes output of control during
brake. When the armature is reenergized, the Inhibit™
releases which allows for a smooth start.

C. Overload Protection with KBAP-240D (P/N 9106) (Optional)

The KBAP-240D is a multipurpose DC Current Sensing Relay and Overload Protector. It is specifically designed for
use with DC motors and speed controls from 1/8 - 3 HP. KBAP-240D operates by sensing current in the armature
circuit. When the preset level is reached, the output relay (RY1) trips. An adjustable time delay (0.2 - 15 secs.) is
incorporated, which eliminates nuisance tripping. Manual or automatic reset is provided at the user's option along
with a LED, which indicates when the preset current level has been reached. When an overload occurs, the KBAP-
240D can be used to shut the system down, sound an alarm, or initiate corrective action before damage occurs.

Internal Sensing. Wire the KBAP in accordance with the following wiring diagram.

13

V. – LIMITED WARRANTY - KBIC®

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, 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)

The information contained in this brochure is intended to be accurate. However, the manufacturer retains the right to make changes in design
which may not be included herein.

KB ELECTRONICS, Inc.
12095 NW 39th Street, Coral Springs, FL 33065 • (954) 346-4900 • Fax (954) 346-3377
Outside Florida Call TOLL FREE (800) 221-6570
A40202

8-24 Rev F MD-0010-0000

Vendor Product Literature
Section 8
8.3 Syrelec Voltage Control Relay

MD-0010-0000 Rev F 8-25

 Vendor Product Literature

8-26 Rev F MD-0010-0000

Refeed Machine User’s Guide

A Edge Trim Pick-Up System 3-2

Electrical Connections 2-4
Adding Extra Scrap 4-6
Electrical Control Panel - Domestic
Additive Feeder 3-2
Version 7-5
additive feeder 3-2
Electrical Control Panel - European
Additive Feeder Maintenance 6-4
(CE) Version 7-6
Air Eliminator 1-2, 5-2
air eliminator 3-2 Electrical icon 1-3
Assembly 2-2 Equipment Weights 2-6
auger bridge-breaker assembly 1-4 extruder rate 4-3
Auger Drive Linearization 2-6 extruder screw speed 1-5
auger speed 4-2, 4-5, 5-3 extruder speed 2-6
Automatic Scrap Recycle (ASR)
System 1-2 F
fax 5-5
B Film Grinder 1-2
Fixing It Yourself 5-2
base material 1-4
fluff 1-2, 4-3, 4-6, 5-3
blade clearances 4-3
Fluff Hopper 5-3
blender 2-6
fluff hopper 2-4, 3-2, 4-5
blower 3-2
follower circuitry 4-3
bolt specifications 2-4
fuses 4-2
bridge breaker 6-3
Bridge Breaker Assembly 6-3
bridge breaker assembly 6-3 G
bridge-breaker auger assembly 2-4 gear box 2-2
Bridging 5-3 Gearbox Lubrication 6-2
gearmotor 2-7
C Gravitrol hopper 2-6
Caution icon 1-3 Grinder 3-2
contamination 1-2 grinder blade gap 5-4
control panel 2-4, 3-3, 4-3, 6-2 Grinder Maintenance 6-3
Conveying Lines 5-2 grinder screen 3-2
crate 2-2 ground scrap 1-2, 1-4
Ground Scrap Blower 3-2
cyclone 2-6, 3-2

D H
damage in shipment 2-2 Handling 2-2
High Level Switch 6-3
high level switch 5-4, 6-3
E High Level Switch Maintenance 6-3
edge trim 1-5, 3-2, 4-5 hopper 4-6
How it Works 1-4

MD-0010-0000 Rev F Index-1

 Refeed Machine User’s Guide

I problems 5-2
proximity switch 4-3, 4-4, 6-3
inducer 4-2
Inducer Maintenance 6-4
Inducers 1-2 R
Receiving 2-2
K refeed auger 4-4
refeed auger speed relay 5-4
KBIC ® Solid State SCR DC Motor
Refeed Machine 1-2
Speed Controls 8-18
refeed machine 4-2, 4-5
KBSI-240D Signal Isolator 8-2
Refeed Machines 1-3
knives 5-4
repelletizing 1-2
Reporting a Problem to Process
L Control 5-2
lifting the Blender 2-2 RMB 1-3, 2-6, 2-8, 6-3
Linearization 2-6 RMB Parts List 7-3
loading system 3-2 RMR 2-6, 2-8, 6-3
low speed detector 1-5 RMR Parts List 7-2
low speed switch 3-2, 4-3 RMS 1-3, 2-6, 2-8, 6-3
RMT 1-3, 2-6, 2-8, 6-3
RMT/RMS Parts List 7-4
M RMX 1-3, 2-6, 2-8, 6-3
Maintenance of Refeed Machine 6-2 Roll Feed Unit 1-3
Maximum Scrap Rate 4-5 Roll Feeder 3-2, 5-2
maximum scrap rate 4-5, 4-6 roll feeder 3-2, 4-2, 5-4
Mechanical Connections 2-6 Roll Feeder Maintenance 6-4
Models 1-3 roll scrap 1-5
rotor 4-3
N Run-in Period 2-7
run-in period 2-7
Normal ASR System Operation
Procedure 4-4
Note icon 1-3 S
schematic 4-3, 4-4
O scrap 4-5
scrap feed rate 4-5
Oil Change Intervals 2-8 shipping damage 2-2
Overfeeding 5-3 spool piece 2-2, 3-2
overfeeding 4-5 Spool Piece (Extruder Inlet
Transition) 2-3
P Starting the System 4-4
paddle switch 4-3, 4-4 Startup (Complete ASR System) 4-2
pallet 2-2, 2-3 Startup (Refeed Machine Only) 4-3

Index-2 Rev F MD-0010-0000

Refeed Machine User’s Guide

storage life 2-2 tools 2-2

Storing 2-2
Storing the refeed machine 2-2 V
Supporting the Refeed Machine
During Installation 2-3 Vacuum Loader Maintenance 6-4
System Control Panel 3-3 Vacuum Loading System 3-2

T W
tachometer 4-6 Warning icon 1-3
time delay 4-3, 4-4, 4-6 weather 2-2

MD-0010-0000 Rev F Index-3

 Refeed Machine User’s Guide

Index-4 Rev F MD-0010-0000