ACCRA-WIRE CONTROLS, INC.

Rockford, MI

ACCRA-BOTIC DEREELER
Model D-30
Patent #4,899,945

Contents
SPECIFICATIONS .................................................................................... 3
CAUTIONS ............................................................................................... 5
DEREELER SETUP PROCEDURES ....................................................... 6
CONTROL DESCRIPTION ........................................................................ 7
CONTROL TROUBLESHOOTING ............................................................. 9
VISUAL INSPECTION ............................................................................ 10
MOTOR CHECKS .................................................................................. 10
CONTROL PROBLEMS ......................................................................... 11
VOLTAGE CHECK ................................................................................. 12
SETUP OF SWITCHES, JUMPERS, AND POTENTIOMETERS ............. 13
TB1 CONNECTIONS .............................................................................. 13
VOLTAGE CHECK TABLE BY LOCATION & FUNCTION ........................ 14
TRIMPOT ADJUSTMENTS ..................................................................... 15
WIRING DIAGRAM ................................................................................ 19
CONTROL BOARD ................................................................................ 20
POTENTIOMETER SETTINGS ............................................................... 20
PARTS LIST ........................................................................................... 22
 Specifications
Serial No.: _____________________

Capacity: _____________________
3,000 lbs

110 VAC/1 Ph/60Hz

Voltage: _____________________

41
RPM: _____________________

WARRANTY VOID IF CUSTOMER

MACHINE SHUTOFF IS NOT
CONNECTED TO DEREELER LIMIT
SWITCH.

NOTE:
Chain should be adjusted after several
hours of use.

3
 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945

CAUTIONS

1. Keep hands, feet, clothing, etc. away from spool and motor drive before turning
on power.

2. DANGER: The National Electrical Code (publication NFPA No. 70) requires
that a fused main disconnect switch be installed between the incoming AC line
and this drive system or, if used, the power transformer. Serious injury or death
could result if a disconnect switch is not provided.

3. DANGER: The control is at line voltage when AC power is connected to the

unit. The main power feed must be disconnected by a switch or unplug the
service cord before it is safe to touch the internal parts.

4. DANGER: When this unit is being used, it should be installed, started up,
adjusted and serviced only by qualified personnel who are familiar with the
operation of all major components in the system. Serious personal injury or
death, and/or equipment damage, may result if this procedure is not followed.

5. DANGER: The user is responsible for the installation of the entire system, in
accordance with the National Electrical Code, Publication NFPA No. 70; with
Electrical Standards for Metal-working Machine Tools, NFPA No. 79; and
with all local and national codes which apply. Serious personal injury or death,
and/or equipment damage could result if this procedure is not followed.

6. CAUTION: If it becomes necessary to service the motor or controller, follow

the wiring diagram provided on page 14. When connecting the motor, pay
particular attention to the marking on the motor leads. It is possible to damage
the controller and motor if incorrect connections are made.

7. DANGER: High voltages may, in some installations with interconnection to

other equipment, exist in the enclosure even after the main unit switch is turned
off (or service cord unplugged). Wiring codes dictate the use of yellow
insulation on wires not controlled by the switch (or cord). Find the source for
those wires, and remove power. Serious personal injury or death can result if
this caution is not followed.

5
 DEREELER SETUP PROCEDURES

1. Make sure power to unit is off (unplug service cord or open disconnect switch).

2. Position wire guides (optional) to accommodate desired core center for loose
packs. Center all wire on the table.

3. Position the hold-down ring over wire then tighten down the wing nut. (Hold-
down ring optional)

CAUTION: Keep hands, feet, clothing, etc. away from wire and motor drive
before turning on power!
Make sure you plug the service cord into 115 VAC receptacle outlet (or open
breaker). Turn on the unit. (Make sure the unit is turning in the correct direction)
Use the movable arm to begin paying off wire.

Feed the wire as shown below on the wire threading

diagram.

This machine has a top speed stop located on the timing

belt. This should be set at top speed so that the motor will
not exceed maximum RPM. A B
For heavier wire, adjust Spring B as shown for more tension. Spring A
is only necessary for smaller diameter wire.

ALWAYS TURN OFF POWER BEFORE RELOADING ANY UNIT!

9
#4 4
1
3 4 5
#1 CONTROL ARM
3
8
CONTROL ARM 6
2 7

2
5
1 9

#2 4 5 #5 8 1 2
1
4
CONTROL ARM
CONTROL ARM

3 2 3
6
7

#3 3 9
7 7
8
4
2
CONTROL ARM #6 7

7 CONTROL ARM 2
1 5
6 4 3 5
6 1

NOTE: The wiring diagrams shown above are recommended for most efficient
dereeling of wire. Other combinations such as adding more pulleys will add to your
accumulation.
For more wiring information please consult AWC
6
 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945

CONTROL DESCRIPTION

NOTE: This dereeler has been setup and tested after assembly, and should
provide satisfactory operation when installed. The unit should only require
connection to proper 120 volt power receptacle by a service cord, or by user
provided connection to suitable power source in accordance with local and
national codes and safety requirements. Please read, understand and
follow the "Setup Procedures" when using this unit to assure trouble free
satisfactory operation.

A wiring diagram and a control board diagram showing switch and jumper
settings for standard operation and voltage are included. A table describing
jumpers, switches and terminal connections is also included. This table
describes the adjustments on the board, and the usual settings. If it
becomes necessary to replace a board, this table should be used as a guide
to aid in getting the system setup as close as possible prior to actually
loading a full spool to fine tune the system.

The control consists of several functional circuits:

1. Speed Reference: A voltage source to supply the max. speed, dancer and speed
pots. This bidirectional control system permits unidirectional speed control
(with regeneration during deceleration).

2. Acceleration/Deceleration: This circuit provides controlled and independently

adjustable linear rate of acceleration and deceleration to or from operating
speed. Forward acceleration control adjusts the acceleration in the "positive"
motoring direction and deceleration in the "negative" motoring direction.
Reverse acceleration control adjusts the acceleration in the "negative" motoring
direction and deceleration in the "positive" motoring direction.

3. Armature Voltage Scaling: This circuit provides a scaled voltage proportional

to the motor's armature voltage to permit a closed loop speed control.

4. Speed Loop Regulator and IR Comp: This circuit sums the command and
feedback signals. The resulting voltage is amplified and modified and provides
input to the current regulator. The IR compensation circuit modifies the
command signal to compensate for IR drop in the armature caused by load
current. The output of the speed loop regulating circuit is limited by the settings
of the FORWARD and REVERSE LIMIT pots.

7
CONTROL DESCRIPTION (Cont.)

5. Current Regulator: This circuit sums the signals from the Feed Loop and
Current Feedback circuits, amplifies, stabilizes and outputs a signal to the firing
circuits.

6. Firing Circuits: These provide firing pulses to the SCR's to produce output
power. This circuit properly phases these pulses and prevents one SCR bridge
from firing while current is flowing through the motor armature from the other
bridge. This signal is called the Lockout Signal.

7. Enable Circuit: Prevents system operation unless "Enable" signal is present.

(Jumper TB1-8 to TB-9)

8. Overspeed Circuit: This circuit electronically locks out the regenerative circuits
if the motor armature voltage exceeds a safe value or if the AC line input voltage
falls below a safe level. This prevents a malfunction called "Inversion Fault"
which may cause fuse blowing.

8
 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945

CONTROL TROUBLESHOOTING

SAFETY PROCEDURES:

Certain basic safety procedures must always be practiced when troubleshooting

equipment. Do not assume the procedures listed here form a complete safety
list. They are only a basic starting point.

1. Always use appropriate high-voltage safety techniques when working on the

equipment.
2. Visually check for possible short circuits before applying power. Accidental
shorts may result in extremely high current. They may also cause serious
personal injury and even death.
3. Use padlocks to ensure that power remains OFF at the main machine disconnect
switch.
4. Use personal safety equipment. Wear safety clothing, eye protection, rubber
soled shoes (without nails).
5. Keep one hand in a pocket when servicing live equipment and avoid bracing
yourself on the unit.
6. Check for presence of suitable "equipment ground". This should include a
continuous ground conductor from power source ("grounding" plug or connec-
tion) to ground connection screw in control.

RECOMMENDED INSTRUMENTS

The following troubleshooting instruments are recommended:

1. Multimeter (VOM): Simpson 260, Triplett 630, or equivalent meter with a

minimum sensitivity of 20,000 ohms/volt.
2. DC Ammeter: Various Mfgr. Shunt type capable of 150% of rated armature
current, as indicated on the motor nameplate.
3. Oscilloscope: Choose an isolated type scope, if possible. While a scope is not
essential to the installation, start-up or maintenance of the system, it may be
useful.

9
 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945

VISUAL INSPECTION

The following checks are to be made with the power OFF, and locked out. Using
a VOM, check the high voltage area to make sure no voltages are present in the
control.

1. Inspect AC power connections to fuse terminals to insure that they are secure
and tight.
2. Inspect the control for possible physical damage and to insure connections are
secure.
3. Inspect control for foreign matter and remove any found.
4. Check jumper conditions on board against control diagram and table.
5. Check wiring diagram against control connections.
6. Check fuse for continuity and seating.
7. Check for indication of a shorted or grounded wire.

INCOMING AC LINE

The following are typical problems located in the incoming AC line:

1. AC line voltage is not within -0 to +10% range of nameplate rating of the system.
2. AC line is incorrectly matched for the specific system.

MOTOR CHECKS

CAUTION: Do not use an ohmmeter to check for motor grounds unless the motor
wiring to the control is completely disconnected. Damage to the circuitry will
result if this procedure is not followed.

1. Armature: Check continuity through the armature and brushes. Use the A1/
A2 conductors at the control terminals.
2. Brushes: When replacing worn brushes, use parts identical to the original
equipment. Excessively worn brushes cause a loss of spring tension and
subsequent malfunction.
3. Commutator: Inspect the condition of the commutator. A shiny and light brown
surface generally indicates good condition. If oil, grease, or other foreign
matter is noted, clean thoroughly. Brush carbon is to be removed with a
commutator stone. Do not use any other type of abrasive.

10
 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945

MOTOR CHECKS (Cont.)

4. Bearing, gear box: Inspect these two areas for proper lubricant levels. (Refer
to manufacturer's recommendations for type and frequency.)
5. Mounting, coupling: Inspect mounting hardware for tightness. The coupling
between the motor and the gear box, and the drive pulleys should be checked
for tightness, alignment and physical condition.

CONTROL PROBLEMS

The most common problem experienced with this type of control is fuse blowing.
When the fuses blow, there is not always a problem with the control. Fuse blowing
in a good drive control can be caused by one of the following problems:

1. Fuse blowing can be caused by the AC line voltage dropping below the rated
input voltage while the drive is regenerating at or near maximum speed.

A. This voltage drop can be caused by general low line conditions, a brownout
or by the momentary inrush loading caused by some other piece of
equipment being started or operated.
B. The sizing and length of the power wiring can also cause line voltage drop.

2. Fuse blowing can be caused by a momentary power loss while the drive is
regenerating. A power loss as short as 1/2 Hertz can cause the failure.

A. In some areas, the power companies use fast-acting switching gear which
sometimes interrupts the power for a period of between 1/2 and several
Hertz.

3. Fuse blowing can be caused by the maximum motor speed being set too high.
This causes the same problem as a drive at rated speed being supplied from a
low voltage line.

4. Fuse blowing can also be caused by an overload of the drive or lubrication failure
of the gear box.

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 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945

CONTROL PROBLEMS (Cont.)

5. It is difficult to determine if fuse blowing is being caused by a drive malfunction

or by improper operating conditions. Since improper operating conditions are
the cause of most fuse blowing incidents, it is important to check the following
before assuming the drive is defective:

A. Check the AC power line with an accurate voltmeter to make sure it is not
more than 10% above the nominal AC line voltage or below the rated line
voltage.

NOMINAL -10% 10%

LINEVOLTAGE LINE HIGHLINE

110VAC 99VAC 121VAC

B. Check that the motor maximum speed never exceeds 1750 RPM.
If the control is still thought to be malfunctioning after above checks, the
controls may be tested by following the procedures outlined below:

WARNING: During the following tests, frequent application and removal of the
AC input voltage is required. It is essential that the troubleshooter
has sufficient knowledge to do so at the appropriate times.

VOLTAGE CHECK

Using a VOM, check the voltages listed in the table on the next page. Take great
care when connecting a meter to the points described to avoid short circuiting
adjacent terminals.

12
 SETUP OF SWITCHES, JUMPERS, AND POTENTIOMETERS

NAME DESCRIPTION REMARKS

J1A Line Voltage 115/230 To suit installation120V

J1B Line Voltage 115/230 To suit installation120V
J2 Armature Current Use Speed Position
J3 Armature Voltage 90/180 To suit motor 90V
J4 Tach Voltage Use .3-3 Range A
J5 Feedback Type Use Armature Feedback
J6 Current Limit Mode Use C position
SW1 Speed Control Mode Use armature position
R52 IR Comp 3/4 CW (Adjusted at assembly)
R58 Response Max Adj back to smooth operat.
R61 REV Current Limit Max Adj back to smooth operat.
R62 FWD Current Limit Max Adj back to smooth operat.
R69 Deadband Adj deadband w/0 ref. volts to
prevent motor rotation
R92 Max Speed Full CW
R101 Offset FACTORY SET-DO NOT ADJUST
R112 FWD Accel/REV Dec Full CW (Adjusted w/ full spool)
R113 REV Accel/FWD Dec Full CW (Adjusted w/ full spool)

TB1 CONNECTIONS

NAME DESCRIPTION REMARKS

1 -DC Tach NOT USED

2 +DC Tach NOT USED
3 Alarm Contact NOT USED
4 Alarm Contact NOT USED
5 Stop One side of N.C. STOP SWITCH
6 Start/Stop Common To SEAL POWER FAIL RELAY
7 Start One side of N.O. Start Switch
8 Enable Must have jumper to TB1-9
9 Enable Must have jumper to TB1-8
10 Speed Control +10VDC
11 REV Selector -10VDC
12 Speed Control Speed pot wiper
13 Dancer GR & speed pot OR
(Control System Common)

13
 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945

VOLTAGE CHECK TABLE BY LOCATION & FUNCTION

TYPICAL VOLTAGE READINGS VOLTAGE

LOCATION FUNCTION 110 VAC

POWER

L1 - L2 AC line input 99 to121 VAC

A1 - A2 Armature output 0 to ±90 VDC

F1 - F2 Field output not used

CONTROL

TB-13 to TB-9 +20 VDC supply +19 to +20 VDC

enabled

TB-13 to TB-10 +10 VDC supply +9 to +10 VDC

TB-13 to TB-11 -10 VDC supply -9 to -10 VDC

TB-13 to TB-12 Reference input 0 to +10 VDC

TB-13 to TB-9 -20 VDC supply -19 to -21 VDC

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 TRIMPOT ADJUSTMENTS

The KBRG contains many trimpots which have been factory adjusted for most
applications. Some applications may require readjustment of trimpots in order
to tailor control to exact requirements. Readjust trimpots as follows:

A. Forward Acceleration (FWD ACCEL) and Reverse Acceleration (REV

ACCEL) – The FWD ACCEL trimpot determines the amount of time it takes
the control voltage to reach full output in the forward direction. It also
determines the amount of time it takes for the control voltage, in the reverse
direction, to reach zero output. (FWD ACCEL also sets the Reverse Decel.)
The REV ACCEL trimpot determines the amount of time it takes the control
voltage to reach full output in the reverse direction and the time it takes for
the control voltage, in the forward direction, to reach zero output. (REV
ACCEL is the Forward Decel.)
The FWD and REV ACCEL trimpots are factory adjusted to 1 second. The
acceleration times are adjustable to a maximum of 15 seconds.
Note: The FWD and REV CL trimpots settings may override the rapid accel
and decel settings.
Note: A 4-quadrant ACCEL/DECEL accessory module is available as an
option. It provides separate control of FORWARD acceleration and decel-
eration and REVERSE acceleration and deceleration.

B. Offset (OFFSET) – This trimpot determines the amount of bias in the

forward or reverse direction. The trimpot is factory set to provide approxi-
mately zero offset, which means neither the forward nor the reverse speed
is favored.

C. Deadband (DB) – The DB trimpot sets the amount of main speed

potentiometer rotation required to initiate control voltage output. It is factory
adjusted to approximately 25% of rotation. The DB trimpot also determines
the amount of delay that will occur before regeneration starts. (Regenera-
tion occurs when the applied load torque is in the same direction as the
motor rotation.)
To readjust the DB to factory setting:
i. Set Main Speed pot to zero speed position.
ii. Set DB trimpot to full CCW position.
iii. Adjust DB trimpot CW until motor hum is eliminated.

15
Note: If the deadband trimpot is set too low (CCW direction), the motor may
oscillate between forward and reverse. Adjust deadband trimpot CW until
the instability disappears. (Oscillation may also occur due to response
setting

D. Forward Current Limit (FWD CL) and Reverse Current Limit (REV CL)
Trimpots – These trimpots are used to set the maximum amount of DC
current that the motor can draw in both the forward and reverse directions.
The amount of DC current determines the amount of maximum motor torque
in both the Speed Control Mode and Torque Control Mode. They are factory
set at 150% of the current established by the jumper J2 setting.
Readjust the CL trimpots as follows:
i. Turn CL trimpot to MIN (CCW) position. Be sure jumper J2 is in proper
position approximately equal to the motor DC ampere rating.
ii. Wire in a DC ammeter in series with armature lead. Lock shaft of
motor.
iii. Apply power. Rotate CL trimpot CW until desired CL setting is
reached (factory setting is 1.5 times rated motor current). Be sure
control is in Forward direction for FWD CL trimpot adjustment and
likewise with REV CL.

WARNING! Do not leave motor shaft locked for more than 2 – 3 seconds to
prevent motor damage.
CAUTION: Adjusting the CL above 150% of motor rating can cause overheat-
ing and demagnetization of some PM motors. Consult motor manufacturer.

E. IR Compensation (IR Comp) – The IR Comp is used to stabilize motor

speed under varying loads. (Note: If control is in Tach Feedback mode, the
IR Comp should be set to minimum - CCW.)
Readjust the IR Comp trimpot as follows:
i. Run motor at approximately 30-50% of rated speed under no load and
measure actual speed.
ii. Load motor to rated current. Rotate IR Comp trimpot so that loaded
speed is the same as the unloaded speed measured in the previous
step. Control is now compensated so that minimal speed change will
occur over a wide range of motor load. [Note: Too much IR Comp will
cause unstable (oscillatory) operation.]
F. Maximum Speed (MAX) – The MAX trimpot is used to set the maximum
output voltage of the control which, in turn, sets the maximum speed of the
motor. In the Torque Control Mode, the MAX trimpot setting determines the

16
 unloaded motor speed. Adjust the MAX trimpot as follows:
i. Rotate Main Speed potentiometer to full speed (CW).
ii. Adjust MAX trimpot to desired maximum motor speed. (Note: Do not
exceed maximum rated RPM of motor since unstable operation may
result.)
G. Response (RESP) Trimpot – This trimpot determines the dynamic
response of the control. The factory setting is approximately 50% of full
rotation. The setting may be increased if a faster response is required.
(Note: If response is made too fast, unstable operation may result.)
H. Timed Current Limit (TCL) Trimpot – Trimpot is functional only when
control is wired for 3-wire Start/Stop and J6 is in the TCL position. The TCL
trimpot sets the delay time for the Timed Current Limit.

17
 Model D-30
Wiring Diagram

120 VAC

19
ACCRA-BOTIC DEREELER
MODEL D-30

CONTROL BOARD

POTENTIOMETER SETTINGS

20
 ACCRA-BOTIC DEREELER
MODEL D-30
PATENT #4,899,945
PARTS LIST

Part #: Description Qty

BASE0830AD-30 Base 1
MTR0250P 1 hp Motor 1
RED0405P Reducer 1
ASM0845F Gearbox Spacer Plates 1
ASM2815F Red. & Mtr. Adj. Screws 1
CTL0765P Controller 1
ELE2211P Relay 1
ELE2150P Socket for Relay 1
ELE0500P Enclosure for Controller 1
ELE0530P Controller Mounting Plate 1
ASM4100F Drive Shaft 1
BRG0500P Table Bearing 1
BRG0625P Shaft Bearing 1
SPK0390P 15 Tooth #50 Drive Sprocket 1
BSH0150P Bushing for drive sprocket 1
SPK0550P 32 Tooth #50 Driven Sprocket 1
BSH0500P Bushing for Driven Sprocket 1
CHN0200P #50 Chain 5
CHN0606P #50 Connecting Link 1
ELE2143P Ultrasonic Analog Prox 1
PUL0100P Prox Pulley, 10 tooth. 1
ASM1001A Prox Belt Hardware 1
ASM0980F Prox Guard 1
ELE0100P Limit Switch 1
ELE0200P Trip Arm for Limit Switch 1
ASM1050F Control Plate - Plate Style 1
Forward Stop Bolt 1
HDW1930P Spring for Forward Stop 1
Rear Stop Bolt 1
SPR0610P Spring for Rear Stop 1
ASM0815F Spring Tension T-Mount 1
Eyebolts 4
ASM0891F Control Arm Tube w/ steel bushing 1
ASM0810F Control Arm Slide Tube 1

22
Part #: Description Qty
ASM0820F Spring Tension Mount 1
Eyebolts 4
Eyebolt for Rear Tension 1
ASM0825F Stationary Arm Slide Piece 1
ASM0800F Vertical Tube for Stationary Arm 1
ASM0900F Steel Rollers Assembly 1
SHD6050F Shield for Control Arm End 1
SHD6001F Shield for Stationary-arm End 1
TBL0900P 50" x 3/8" Table 1
OPT0475F Side Pickup Arm w/spring loaded pulley 1
OPT1250F Spider Hold Down 1
OPT2505F Table ring for 50" Table 1
OPT 36" Table Stems 1
ELE0585P Operator Controls Enclosure 1
ELE1260P Speed Control Potentiometer 1
ELE1280P Speed Pot. Knob 1
ELE1270P Speed Pot. Plate 1
ELE0950P Forward / Reverse Switch 1
ELE0800P On/Off Switch 1
ELE3005P Start/Stop Push-button Switch 1
MISC Table Riser (Set of 4) 1

23