Pallet Wrapper 0550 Pup Manual

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INSTRUCTION
&
MAINTENANCE
MANUAL
MODEL 550
“PUP”
STRETCH WRAP
MACHINE
& OPTIONS
COUSINS PACKAGING INC.

105 Claireport Crescent, Etobicoke, Ontario M9W 6P7
Phone: (416) 743-1341 Fax: (416) 743-1831
www.cousinspackaging.com
NOTE - This document is formatted for 2-sided printing

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TABLE OF CONTENTS
1:0 BEFORE STARTING THE MACHINE......................................................... 5
2:0 SPECIFIC CAUTIONS AND WARNINGS ................................................... 7
3:0 MACHINE DESCRIPTION .......................................................................... 9

3:1 Machine Specifications .......................................................................... 9
4:0 INSTALLATION ........................................................................................ 11

4:1 Moving the Machine ............................................................................. 11
4:2 Unpacking and Inspection ................................................................... 12
4:3 Tower Installation (Optional) ............................................................... 12
4:4 Final Assembly and Inspection ........................................................... 13
4:5 General Power Requirements.............................................................. 14
5:0 SET-UP AND OPERATING PROCEDURES ............................................ 15

5:1 Operating Controls - Control Panel Door ........................................... 15
5:1:1 Power Pull Start – Push Stop Button ............................................. 16
5:1:2 Power On Indicator Light ............................................................... 16
5:1:3 Film Carriage Lower / Raise Switch ............................................... 16
5:1:4 Turntable Jog / Run Switch ............................................................ 16
5:1:5 Turntable Speed Control Potentiometer ........................................ 17
5:1:6 Carriage Speed Control Potentiometer .......................................... 17
5:2 Turntable Speed Set-Up ....................................................................... 17
5:3 Film Carriage Speed Set-Up ................................................................ 17
5:4 Film Roll Size ........................................................................................ 17
6:0 WRAPPING A LOAD ................................................................................ 19

6:1 Placing the Load on the Turntable ...................................................... 19
6:2 Loading the Stretch Wrap Film Roll .................................................... 19
6:3 Attaching the Stretch Wrap ................................................................. 19
6:4 Starting the Wrap Cycle ....................................................................... 19
6:5 Completing the Wrap............................................................................ 20
7:0 REMEDIAL ADJUSTMENT ...................................................................... 21

7:1 Turntable Soft-Start .............................................................................. 21
7:2 Load Toppling or Sliding ..................................................................... 21
7:3 Film Tearing & Puncturing ................................................................... 21
8:0 MAINTENANCE REQUIREMENTS .......................................................... 23

8:1 Lubrication ............................................................................................ 23
8:2 Maintenance Frequency Recommendations ...................................... 23
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9:0 MAINTENANCE AND ADJUSTMENTS ....................................................25

9:1 Turntable Removal & Installation.........................................................25
9:2 Turntable Drive Chain Adjustment ......................................................25
9:3 Turntable Support Rollers ....................................................................25
9:4 Carriage Lift Belt Tracking Adjustment ...............................................26
9:5 Carriage Limit Switch Lever Arm Adjustment ....................................27
9:6 Turntable Soft-Start (Acceleration) Adjustment .................................28
9:7 Turntable DC Motor Control (SCR) Card Adjustment ........................28
9:7:1 Acceleration Adjustment .................................................................30
9:7:2 Maximum Speed Adjustment..........................................................30
9:7:3 Minimum Speed Adjustment...........................................................30
9:7:4 Current Limit (Torque) Adjustment .................................................31
9:7:5 IR Compensation Adjustment .........................................................31
9:8 Film Carriage Lift DC Motor Control (SCR) Card Adjustment ...........31
9:8:1 Minimum Speed Adjustment...........................................................31
9:9 DC Motor Control (SCR) Card Settings ...............................................32
9:9:1 Turntable SCR Card (1SCR) ..........................................................32
9:9:2 Film Carriage Lift SCR Card (2SCR) ..............................................32
9:10 Gear-Motor Maintenance ......................................................................33
9:10:1 Gear-Motor Trouble-Shooting.........................................................33
9:10:2 Brush & Commutator Maintenance ................................................33
10:0 TROUBLE-SHOOTING..............................................................................35
11:0 PARTS LISTS ............................................................................................41
12:0 COMPONENT MANUALS
13:0 ELECTRICAL DRAWINGS
14:0 MECHANICAL DRAWINGS
15:0 SUPPLEMENTS
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1:0 BEFORE STARTING THE MACHINE
1. The machine must operate on a level floor or the life of certain parts will be
reduced substantially!
2. DO NOT START THE MACHINE BEFORE REMOVING THE PACKAGING

MATERIAL SECURING THE FILM CARRIAGE TO THE TOWER!
3. DO NOT START THE MACHINE BEFORE REMOVING THE TWO SHIPPING

TIE - STRAPS, located on the face of the Model 550 turntable, securing it to
the machine base!
4. Ensure that the Limit Switch Striker Bolt mounted on the film carriage operates
between the Upper and Lower Limit Switches. These Limit Switches define the
maximum travel of the carriage. WITHOUT THE LIMIT SWITCH STRIKER
BOLT CONTACTING THE TOP AND BOTTOM LIMIT SWITCHES TO TELL
THE CARRIAGE TO STOP, THE CARRIAGE WILL OVER-RUN ITS SAFE
OPERATING RANGE, POTENTIALLY CAUSING SERIOUS DAMAGE!
5. During the winter months, gear-motor lubricants will thicken when exposed to
cold weather during shipment. Allow the machine to warm up to room
temperature for 8 hours (minimum) before attempting to operate the machine.
FAILURE TO DO THIS MAY RESULT IN BLOWN FUSES OR DC MOTOR
CONTROL BOARD FAILURE!
6. If the machine is loaded by forklift truck, it is recommended that a stop block

be mounted to the floor in order to prevent the lift truck from colliding with
the turntable. (Suggestion: a 3” x 3” x 1/2” thick steel angle bolted to the
floor.)
7. READ THE MANUAL!

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2:0 SPECIFIC CAUTIONS AND WARNINGS
In the interest of promoting safe operating practices in the use of this equipment,
cautionary references are made throughout this manual in the format shown
below.
 NOTICE!
This designation indicates that a failure to observe can cause EQUIPMENT

MALFUNCTION!
 CAUTION!
This designation indicates that a failure to observe can cause DAMAGE TO

THE EQUIPMENT!
 WARNING!
This designation indicates that failure to observe can cause DAMAGE TO

THE EQUIPMENT AND / OR INJURY TO PERSONNEL!
We strongly recommend that all personnel involved in operating and

maintaining this equipment be fully trained in the operational and
maintenance procedures described in this manual, and that this manual be
kept accessible to those personnel as a source of reference information.
Cousins Packaging Inc. endeavors to manufacture the safest equipment

possible. Our intention to provide only safe, quality packaging equipment to our
customers is enhanced by our on-going Product Safety program.
Cousins Packaging has no means of controlling the safe use of our equipment
other than through the features designed and built into our machinery and the
recommendations made in this manual. Ultimately the end-user must assume
final responsibility for the safety performance of this equipment and for
maintaining a safe working environment!
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3:0 MACHINE DESCRIPTION
The 550 “PUP” low profile stretch wrap machine is a floor level (2-1/4” turntable
elevation), unit designed to be loaded either by fork-truck or by a pallet jack in
conjunction with the two-stage ramp (included). The machine operates on
standard 120 volt 15 amp electrical service.
The machines accept all commercial stretch films up to 1.2 mils thick wound on
3” diameter cores up to 10 inches in roll diameter, 12” – 20” width.
3:1 Machine Specifications
Power 120 Volt, 1 Phase, 15 Amp (unshared) line service required.

(20 Amp service preferable where other demands are made on
the same circuit.) A 14-gauge power cord complete with
standard 120 Volt 15 Amp 2-pole 3-wire grounding type plug is
provided.
Motors All gear-motors, unless otherwise specified, are 90 volts DC,

Permanent Magnet TEFC or TENV, fractional to 1/3 HP.
Speed Turntable speed is manually controlled from 0 to 9 RPM, by

adjustment of a potentiometer located on the control panel.
The Film Carriage Lift speed is manually controlled from

minimum stall to maximum speed by a potentiometer located on
the control panel.
Drive Train The Model 550 Turntable is driven from a 1/3 HP in-line gear-
motor and ANSI #50 direct chain drive. A center A-type
sprocket connects to the turntable using a plug & socket
arrangement.
The Film Carriage lift is driven from a 1/8 HP right-angle gear-

motor and flat belt.
Environment The Model 550 is designed for standard industrial environments

with operating temperature ranging from +55°F to +120°F.
Capacity Turntable loading of 3,000 pounds turning, and 8,000 pounds

static. Designed to handle pallet loads up to 48” square (68”
Maximum Diagonal dimension), to 80” overall height.
Film The Model 550 accepts “hand-wrap” or “machine” film wound on

a standard 3” core with a roll diameter of 10” maximum and 12”
– 20” width.
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4:0 INSTALLATION
4:1 Moving the Machine
The Model 550 stretch wrap machine may be fork-truck lifted from the rear using
the following procedure:
 CAUTION! The Loading Ramp and Ramp Contour 1/2

Moon Section are strapped to the top of the turntable for shipment
and must be removed before attempting to lift the machine!
1. Adjust the distance between the lift truck forks to suit the width of the back of
the machine (20”).
2. Lift the forks off the ground while tilting them forward. With the fork tips just
clear the ground; approach the machine from the rear (tower side). Move
forward until the lift truck fork tips are past the lifting angles affixed to the back
of the machine. Now lower the forks until they touch the ground and continue
moving forward until the fork tips slide under the turntable surround ring to a
minimum of 2 to 3 inches. Ensure that the insides of the lift truck forks are
touching the sides of the machine base.
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3. Tilt the lift truck forks back until the under-side of each fork touches the lifting
angles affixed to the back of the machine.
4. The machine can now be lifted vertically off the ground. The center of gravity
of the machine causes the lifting angles to press up against the underside of
the lift truck forks while the fork tips give support under the turntable surround
ring.
 WARNING! Be careful when lifting and moving the

machine to ensure that the lift truck forks do not spread apart
causing the machine to drop! Ensure that the machine does not
“bounce” off the lift truck forks when the lift truck is moving!
4:2 Unpacking and Inspection
Before applying power or operating the machine, a general inspection is

recommended to determine if any damage has taken place during transport.
IT IS THE END-USER’S RESPONSIBILITY TO REPORT ANY DAMAGE

INCURRED DURING SHIPMENT TO THE TRUCKING COMPANY!
In order to obtain a clear view of all elements of the machine, carefully remove all
packaging, strapping and blocking materials, as well as any shipping tie-straps.
The machine may be shipped in one piece, or with the tower “knocked-down” for
shipment.
4:3 Tower Installation (Optional)
Some machines may be shipped in “knocked-down” condition. Re-assemble the

tower to the machine base as follows:
1. Secure the necessary personnel, or other lifting device to erect the tower.
2. Lower the tower on to the machine base so that the tower shell fits over the
mounting angles on the machine base. Fasten the tower to the base
securely, using the hardware provided.
3. Remove the connection cover from the Turntable Drive Gear-Motor

connection box. Feed the turntable motor cable into the connection box and
tighten the cable gland. Connect the cable conductors to the turntable gear-
motor leads according to the markers at the wire ends, using the wire-nuts
provided. Re-install the cover on the Turntable Drive Gear-Motor connection
box.
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4:4 Final Assembly and Inspection
1. Remove any remaining packaging from the machine.
2. Cut the two plastic shipping tie-straps securing the turntable to the turntable
surround ring. Rotate the turntable clockwise and counter-clockwise
manually and verify that the rolling action is both smooth and quiet.
3. Locate the ramp contour section (1/2 moon), to the desired position, and
secure it to the machine base with the two bolts, two lock washers and six flat
washers provided. Ensure that four flat washers (2 per side) are positioned
as spacers between the 1/2 moon and the turntable surround ring. Install one
lock-washer and one flat washer under the head of each bolt.
 CAUTION! Two flat washers must be installed as spacers

on each side between the 1/2 moon and the turntable surround
ring! Failure to install these spacers may cause the ramp contour
section (1/2 moon) to buckle upwards in the center where it can
interfere with the rotation of the load!
4. Install the ramp onto the ramp contour section (1/2 moon), ensuring that the
pegs on the ramp mate with the sockets on the 1/2 moon. Rotate the
turntable through a 360° cycle manually and ensure that the edge of the
turntable sits proud of the ramp and that the turntable does not rub against
the ramp contour.
5. Inspect visible cables for damage or loose fittings.
6. Operate all control panel dials and switches. Their actions should be crisp
and free.
7. Check the upper and lower film carriage limit switch arms to ensure that they
will contact the striker bolt on the film carriage. Ensure that the limit switch
arms are secured tightly to the limit switches.
 CAUTION! The film carriage limit switch striker must

operate between the upper and lower limit switches to safely limit
the travel of the film carriage!
8. Ensure that the film carriage moves freely up and down the tower without
binding, and that there are no tight spots where the carriage may “hang-up”.
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4:5 General Power Requirements
Unless otherwise specified, the machine requires a 120 Volt, 1 Phase, 60 Hz., 15
Amp (unshared), line service.
 CAUTION! Power the system only from an adequately

fused wall socket of the correct voltage. Do not use an extension
cord as a severe line power drop may occur, resulting in damage
to the electronic circuits!
If it is necessary to use an extension cord temporarily, a #14 AWG (minimum),

grounded type flexible cord to a maximum length of 10 feet would be acceptable.
However, this is not recommended for permanent service.
The available line service voltage should be verified with a voltmeter at the
machine terminal strip, while the machine is operating under load, in order to
determine if the service is adequate.
The line voltage should not drop below 109 volts AC during full load
operation!
The line voltage should not exceed 126 volts AC at any time!
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5:0 SET-UP AND OPERATING PROCEDURES
5:1 Operating Controls - Control Panel Door
This section provides a description of the operator controls located on the

exterior panel of the control enclosure.
4 5 6 4 5 6
3 7 3 7
2 8 2 8
1 9 1 9
0 10 0 10
COUSINS
550
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5:1:1 Power Pull Start – Push Stop Button
This red two-position mushroom-head push-pull button is used to turn on the

control power. When pulled out to the START position, power is indicated by the
illumination of the red POWER ON light. Pushing the switch in to the STOP
position will interrupt power to the control and motor circuits and cause all
machine functions to come to an abrupt halt.
 WARNING! The interior of the control panel remains

powered even when the power switch is turned OFF. ALWAYS
unplug the machine before servicing the control enclosure!
5:1:2 Power On Indicator Light
This red neon pilot light, when lit, indicates that the power is “on”, and the
machine is ready to operate. Pushing in the Power Pull Start – Push Stop
button, or unplugging the machine will cause this light to turn off.
5:1:3 Film Carriage Lower / Raise Switch
This three-position momentary switch performs the following functions:
1. When turned to the RAISE position the film carriage will raise. This function
automatically stops when the carriage limit switch striker bolt comes in contact
with the upper limit switch actuator arm or when the switch is released.
2. When turned to the LOWER position the film carriage will lower. This function
automatically stops when the carriage limit switch striker bolt comes in contact
with the lower limit switch actuator arm or when the switch is released.
5:1:4 Turntable Jog / Run Switch
This three-position selector switch performs the following functions:
1. When turned to the JOG position the turntable will rotate. This function
automatically stops when the switch is released or when the Power Pull Start –
Push Stop button is pushed in.
2. When turned to the RUN position the turntable will rotate. The switch will
remain in this position after being released. This function stops when the
switch is turned back to the center position or when the Power Pull Start –
Push Stop button is pushed in.
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5:1:5 Turntable Speed Control Potentiometer
The Turntable Speed control allows adjustment of the turntable motor speed.
This is adjustable from 0 to 9 R.P.M. to suit loads of varying stability.
5:1:6 Carriage Speed Control Potentiometer
The Carriage Speed control allows adjustment of web overlap by varying the film
carriage lift motor speed. Adjustable from a slow crawl at zero to a maximum
speed to suit up to 20” wide film.
5:2 Turntable Speed Set-Up
Turntable speed is adjustable from approximately 0 RPM to 9 RPM to suit loads

of varying stability. Turn the Turntable Speed potentiometer clockwise or
counterclockwise to increase or decrease the turntable speed to the desired
level.
 WARNING! Do not increase the turntable speed above 9

RPM (7 seconds per revolution), as this may damage the turntable
gear-motor or DC drive circuit board!
5:3 Film Carriage Speed Set-Up
While the film carriage is raising or lowering, adjust the film carriage speed until
the desired film web overlap is achieved. (A four to six inch overlap between
layers is recommended for most applications.)
5:4 Film Roll Size
The 550 PUP is designed to accommodate “machine” film rolls up to 10”

diameter by 12” wide to a maximum 20” width.
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6:0 WRAPPING A LOAD
6:1 Placing the Load on the Turntable
Center the load to be wrapped on the turntable and ensure that it is securely
situated before proceeding.
When loading by forklift truck, avoid collisions between the lift truck and
the machine turntable or structure!
6:2 Loading the Stretch Wrap Film Roll
Raise the film carriage to a comfortable level and push the Power Pull On – Push
Off button in to the OFF position. Load a roll of stretch wrap material onto the
film spindle. Then, turn the film core lock actuating shaft hand knob in a
clockwise direction to securely engage the film core locking teeth into the film
core. To remove an empty core, reverse the procedure.
6:3 Attaching the Stretch Wrap
Draw approximately three to five feet of the stretch wrap from the carriage. Rope
the end of the stretch wrap material and attach to any convenient point on the
load or pallet.
6:4 Starting the Wrap Cycle
Set all wrap functions such as Turntable Speed, Carriage Speed and the Film
Tension to desired values. Start the wrap cycle by turning the Turntable Jog /
Run selector switch to the RUN position. As the pallet rotates, turn and hold the
Film Carriage Lower / Raise Switch to the RAISE position to elevate the film
carriage. While wrapping, adjust the Film Tension Adjusting Knob to fine-tune
the desired film tension level. When the film carriage has reached the desired
height, release the Film Carriage Lower / Raise Switch. Once the desired
amount of wrap has been applied to the top of the load, turn and hold the
Carriage Lower / Raise Switch to the LOWER position until the carriage reaches
the lower limit switch. Once the desired amount of wrap has been applied to the
base of the load, stop the wrap cycle by turning the Turntable Jog / Run Switch to
the center (Off), position.
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6:5 Completing the Wrap
At the completion of the wrap cycle, cut the film six to ten inches from the pallet
face and then wipe the film edge briskly at the corner of the load to WELD the
film layers together, or tuck the film tail under the layers of wrap. If necessary,
“jog” the turntable into the correct position for pick-up by turning the Turntable
Jog / Run Switch to the JOG position until the load on the turntable is aligned
with the ramp.
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7:0 REMEDIAL ADJUSTMENT
7:1 Turntable Soft-Start
Turntable Soft-Start (or acceleration) is controlled by the turntable DC drive

(SCR) electronic card.
Turntable start-up speed may be affected by a wide range of load weights and
stability factors. If the load twists, distorts, or spills during the first few moments
of turntable rotation, this may indicate that the acceleration time is set too low.
(Refer to Section 9:6 for corrective procedures.)
7:2 Load Toppling or Sliding
Lightweight loads may tend to slide off the turntable or topple due to the dragging
effect of the film.
A few modifications may be required in order to achieve satisfactory operation:
1. Select a stretch wrap material of thinner gauge requiring less tension to make
it elastic.
2. Select a stretch wrap material of softer composition that will behave in a more
gentle fashion.
3. To compensate for drag reduce the overall tension setting with the existing
stretch wrap material.
4. Lay a soft rubber floor mat on the turntable to increase the frictional force
between the pallet boards and the steel deck.
5. Increase the length of the starting loop of stretch wrap material to the first
corner of the load.
7:3 Film Tearing & Puncturing
1. If the film is tearing or puncturing, try decreasing the Tension level to allow the
film web to feed out with less compressive force.
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8:0 MAINTENANCE REQUIREMENTS
8:1 Lubrication
When operating in normal environments, based on single shift operation, the

machine will require periodic lubrication and maintenance as described in the
following section. Use standard industrial lubricants on a regular basis in
proportion to the usage of the machine and the cleanliness of the surroundings.
 Caution! Refer to the individual gear-motor maintenance

instructions for correct lubricant specifications.
8:2 Maintenance Frequency Recommendations
Item Operation Frequency

Turntable Support Rollers Inspect Quarterly
Turntable Drive Chain Lubricate & Adjust Tension Quarterly
Turntable Reducer Sprocket Inspect & Tighten Set- Quarterly
screws
Carriage Lift Belt Inspect Monthly
Carriage Lift Pulley Inspect & Tighten Set- Quarterly
screws
Carriage Limit Switches Inspect Quarterly
Film Core Locking Inspect Quarterly
Mechanism
 CAUTION! Inspect and tighten the turntable drive chain

after the first 100 operating hours. Follow the above-
recommended schedule thereafter.
 CAUTION! Recommended lubrication and inspection

frequency is based upon single shift operation. Adjust lubrication
and preventative maintenance accordingly for increased usage or
operation in a harsh environment.
 NOTICE! Some bearings are sealed-for-life rather than

regreasable. No maintenance is required or anticipated for the life
of the equipment.
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9:0 MAINTENANCE AND ADJUSTMENTS
9:1 Turntable Removal & Installation
The Model 550 turntable is fitted to the center sprocket assembly using three
1/2"UNC flat-head bolts.
To remove the turntable, first remove the three flat head bolts securing the
turntable to the center sprocket assembly. Install two 1/2”-13 UNC eye-bolts into
the tapped holes in the top of the turntable, hook up a two-way chain or cross
bar, and then raise the turntable with a fork-lift truck or chain fall.
To replace the turntable reverse the procedure, ensuring that the edge of the
turntable is aligned to the surrounding deck, and then slowly rotate the turntable
by hand, (holding the eye-bolts), until the holes in the turntable are aligned with
the tapped holes in the turntable center sprocket assembly. Reinstall the three
flat-head bolts and tighten securely.
9:2 Turntable Drive Chain Adjustment
A direct chain drive system is used to rotate the Model 550 turntable. To adjust
the chain, remove the turntable and loosen the four nuts holding the gear-motor
base plate. Turn the adjusting bolt (located on the back of the gear-motor
mounting plate), clockwise until the desired chain tension is achieved. The chain
should be taut, but not over-tight. Tighten the gear-motor base plate hardware
securely and then replace the turntable.
 CAUTION! Do not over-tighten the chain! Excessive

chain tension will overload the turntable gear-motor.
 CAUTION! Operate the turntable. It should be relatively

quiet and should rotate without excessive chain noise or slapping.
Readjust the chain tension as necessary.
9:3 Turntable Support Rollers
The Model 550 Turntable Support Rollers consist of a precision ball bearing
inserted into a plastic wheel cover, retained by an internal snap ring. The rollers
are installed in pairs, on a common axle bolt, in nine locations on a mounting ring
beneath the turntable. These rollers will require no maintenance unless
damaged by excessive impact loads or over-loading of the machine.
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To access the turntable support rollers, remove the turntable as previously

described. The support rollers can be removed in pairs by removing the axle bolt
lock nut and then sliding the axle bolt out of the mounting ring sideways. Spacer
washers are installed between the rollers and the mounting ring to prevent the
rollers from binding.
Replacement support rollers should be reinstalled by reversing the procedure.

Ensure that the proper quantity of spacer washers are installed between the
rollers and the mounting ring, and that after tightening the axle bolt nut the rollers
are able to turn freely.
9:4 Carriage Lift Belt Tracking Adjustment
The film carriage lift belt is made from woven nylon laminated to rubber, and
should be inspected on a monthly basis. Although a slight fraying of the flat belt
edges is a normal wear pattern, of more importance is the tracking (centering), of
the belt in the carriage lift belt take-up spool. If the carriage lift belt is allowed to
ride against the edges of the take-up spool, not only will the edge of the belt
become badly frayed, but the belt can also fold over onto itself resulting in a tear
or breakage of the belt.
If it is observed that the carriage lift belt tracking is out of adjustment, the problem
must be corrected as outlined below:
 WARNING! Adjustments to the carriage lift mechanism

should only be performed by a qualified technician!
1. Identify in which direction the carriage lift belt-tracking fault is occurring; i.e.
towards or away from the turntable.
2. Turn off the machine and unplug the power cord.
3. For carriage lift belt tracking-faults in the direction of the turntable adjust as
follows:
 CAUTION! Do not over tighten the bolts securing the

carriage lift gear motor mounting bracket to the tower top cap.
Excessive torque applied to the adjusting bolts will damage the
carriage lift gear-motor mounting bracket.
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4. Using a 1/2” wrench, loosen the 5/16” x 3/4” long hex head bolt securing the
carriage lift gear-motor mounting bracket to the tower top cap furthest away
from the turntable slightly. Then securely tighten the 5/16” x 3/4” long hex
head bolt closest to the turntable, approximately the same number of
degrees the first bolt was loosened. This will result in pivoting the carriage
lift gear-motor slightly, thus correcting the carriage lift belt tracking error.
5. For carriage lift belt tracking-faults away from the direction of the turntable:
 CAUTION! Do not over tighten the bolts securing the

carriage lift gear motor mounting bracket to the tower top cap.
Excessive torque applied to the adjusting bolts will damage the
carriage lift gear-motor mounting bracket.
6. Using a 1/2” wrench, loosen the 5/16” x 3/4” hex head bolt securing the
carriage lift gear-motor mounting bracket to the tower top cap closest to the
turntable slightly. Then securely tighten the 5/16” x 3/4” long hex head bolt
furthest away from to the turntable, approximately the same number of
degrees the first bolt was loosened. This will result in pivoting the carriage
lift gear-motor slightly, thus correcting the carriage lift belt tracking error.
7. Re-connect the power cord and turn the machine on.
8. Raise and lower the carriage several times to verify correct carriage lift belt
tracking, repeat the procedure only if a carriage lift belt-tracking fault is still
present.
9:5 Carriage Limit Switch Lever Arm Adjustment
The Film Carriage Limit Switches are mechanical limit switches of standard
design and may require some attention from time to time.
Position the arm on each switch so that is will travel through the appropriate
angle when struck, and not suffer from rebound or over-traveling.
Replace bent or broken lever arms. Check that all hardware securing the switch
components together and to the machine are intact, and tightly secured. Test the
switch for crisp action, and replace it if required.
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9:6 Turntable Soft-Start (Acceleration) Adjustment
The turntable drive uses a variable speed DC gear-motor that is controlled by an

electronic circuit board (SCR Card), located inside the control panel. Turntable
acceleration is adjustable from 1/2 to 4 seconds and is controlled by the trim-pot
labeled “ACCEL” on the Turntable SCR Card (1SCR). Turning the ACCEL trim-
pot to the fully clockwise position (maximum acceleration time) provides the
softest start and is recommended for all loads. (Refer to Section 9:6:1.)
 WARNING! Adjustments to DC Drive (SCR), Card trim-

pots should only be performed by a qualified technician!
 WARNING! All trim-pot settings have been pre-calibrated

at the factory and should not require adjustment.

unplug the machine before opening the control panel!
9:7 Turntable DC Motor Control (SCR) Card Adjustment
The Turntable is driven by variable speed DC gear-motor. This gear-motor is

controlled by an electronic circuit board (commonly known as an SCR Card),
located inside the control panel.

The SCR Card uses a Plug-In Horsepower Resistor to match the control to the
gear-motor horsepower and voltage. This Resistor must be installed in order for
the SCR Card to operate!
The SCR Card has five trim-pots that are used to control the speed, acceleration,
torque and load regulation characteristics of the gear-motor.
The following procedure, presented in order of trim-pot adjustment sequence,

should be used when readjusting all trim-pot functions.
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It is important to note that adjustments made to one trim-pot can affect the
setting of the other trim-pots. Therefore, do not attempt to change the
settings of the trim-pots unless absolutely necessary, since they are factory
adjusted to optimum settings.
 WARNING! All trim-pot settings have been pre-calibrated

at the factory and should not require any adjustment!
 WARNING! Adjustments to DC Drive (SCR) Card trim-

pots should only be performed by a qualified technician!
30
9:7:1 Acceleration Adjustment
Acceleration is adjustable from 1/2 to 4 seconds. If the acceleration needs to be

adjusted to a different time, adjust the ACCEL trim-pot on the SCR card to the
desired time according to the drawing.
9:7:2 Maximum Speed Adjustment
Turn the Turntable Speed Control Potentiometer to its maximum setting. Adjust
the MAX trim-pot on the SCR card to achieve the desired maximum speed
setting.
 CAUTION! Do not attempt to adjust the Maximum speed

above the rated motor RPM. Unstable gear-motor operation may
occur!
9:7:3 Minimum Speed Adjustment
If a higher than zero minimum speed is desired, readjust the minimum speed by
turning the Turntable Speed Control Potentiometer to its minimum setting. Then
adjust the MIN trim-pot on the SCR card to achieve the desired minimum speed
setting.
 NOTICE! Adjusting the MIN speed trim-pot will affect the

maximum speed setting. Therefore it will be necessary to readjust
the MAX speed trim-pot after setting the minimum speed, and it
may be necessary to repeat the sequence until both minimum and
maximum speeds are set to the desired levels.
31
9:7:4 Current Limit (Torque) Adjustment
The Current Limit circuitry is provided to protect the motor and control against
overloads and to limit the inrush current to a safe level during start-up. The CL
trim-pot is factory set to approximately 1.5 times the full load rating of the motor.
If the turntable is stalling under load, turning the CL trim-pot clockwise slightly
may increase the torque of the motor enough to prevent it from stalling.
 NOTICE! The correct value of Plug-in Horsepower

Resistor must be installed in order for the Current Limit and IR
Compensation to operate properly!
9:7:5 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
to a minimum level (approximately 1/4 of full setting). The IR trim-pot is factory
adjusted to approximately 3% regulation. If necessary, turning the IR trim-pot
slightly clock-wise will improve load regulation.
 NOTICE! Excessive IR Compensation will cause the

control to become unstable, which causes motor cogging!
9:8 Film Carriage Lift DC Motor Control (SCR) Card Adjustment
The film carriage lift drive uses a variable speed DC gear-motor that is controlled
by an electronic circuit board (SCR Card), located inside the control panel.

9:8:1 Minimum Speed Adjustment
If a higher than zero minimum speed is desired, readjust the minimum speed by
turning the Carriage Speed Control Potentiometer to its minimum setting. Then
adjust the MIN trim-pot on the SCR card to achieve the desired minimum speed
setting.
32
9:9 DC Motor Control (SCR) Card Settings
Typical factory settings for the DC Motor Control (SCR), cards are provided in
this section. Refer to the SCR Card drawing provided in Section 9:6 for
reference to the trim-pot “6 o’clock” position for 1SCR.
9:9:1 Turntable SCR Card (1SCR)
Typical settings for the Turntable SCR Card #1SCR are as follows:
TRIM-POT TRIM-POT VOLTAGE CONDITIONS FOR READING

NAME POSITION OR SETTING VOLTAGE
MAX 3 o’clock 90 Volts DC Turntable Speed Potentiometer
fully CW
MIN Fully CCW 0 Volts DC Turntable Speed Potentiometer
(8 o’clock) fully CCW
ACCEL Fully CW 4 seconds
(2 o’clock)
IR 10 o’clock
CL 2 o’clock
9:9:2 Film Carriage Lift SCR Card (2SCR)
Typical settings for the Film Carriage Lift SCR Card #2SCR are as follows:
TRIM-POT TRIM-POT VOLTAGE CONDITIONS FOR READING

NAME POSITION OR SETTING VOLTAGE
MIN 50% 6 Volts DC Carriage Speed Potentiometer
fully CCW
33
9:10 Gear-Motor Maintenance
The Turntable and Film Carriage are driven by variable speed DC gear-motors.
These gear-motors have permanent magnet brush-type motors, and will require
periodic inspection & maintenance in order to ensure uninterrupted service.
9:10:1 Gear-Motor Trouble-Shooting
Performance problems may result from something as simple as worn brushes.

Use the following chart as a guide to return the gear-motor to service.
PROBLEM DETECTED POSSIBLE CAUSE CORRECTIVE ACTION
1. Gear-Motor won’t run Worn brushes Replace brushes

Loose power leads Check wiring
Brush hung up Check brushes
Open armature Repair or replace gear-motor
or armature
2. Gear-Motor runs in wrong Power leads reversed Check lead polarity and
direction reconnect
3. Gear-Motor runs slow DC Motor Control current limit Adjust current limit (Refer to
adjustment incorrect Section 9:7:4)
4. Gear-Motor runs fast (no-load Possible over-current Repair or replace gear-motor
speed more than 15% higher) damage or open armature
5. Gear-Motor blows fuse or Shorted armature Repair or replace gear-motor
breaker or armature
Brush dust accumulation in Clean out dust thoroughly
motor
6. Gear-Motor blows fuse or Mechanical overload Check load throughout
breaker, runs hot
7. Gear-Motor blows breaker, Bad gear-motor bearing(s) Repair or replace gear-motor
runs hot, motor shaft hard to
turn
9:10:2 Brush & Commutator Maintenance
Motor brushes must be inspected periodically to establish a rate of wear.

Damage to the commutator may occur if the brushes are allowed to wear down
below a minimum length. It is recommended that the brushes and commutator
be inspected after 500 hours of use. The brush length after 500 hours versus the
length when new can be used to project an appropriate maintenance schedule.
Always clean out brush dust when inspecting or changing the brushes. When
inspecting the brushes, check the commutator for wear. If the commutator is
worn more than 0.031” (measured on the diameter), or is pitted, turning and
undercutting of the commutator is recommended. This can be accomplished by
a reputable motor repair facility. Usually three sets of brushes can be used for
one commutator turning.
34
To replace brushes, proceed as follows:
1. Disconnect motor from the power source.
2. Remove each brush cover.
3. Remove the brush by pulling the end of the brush shunt / spring from the top
of each brush until clear of the holder.
4. Carefully remove any brush dust accumulation from the inside of the gear-
motor. A soft brush and compressed air might be helpful.
5. Replace with new brushes and reinstall the brush covers.

35
10:0 TROUBLE-SHOOTING
In the event of a machine malfunction, the suggestions listed in this section will
assist in determining the cause of a failure and possible remedies.
Many of the corrective actions recommended here require technical ability. Only
qualified and fully trained personnel should perform the corrective actions
listed in this trouble-shooting guide!
1. Power On light is not Power Pull On – Push Off Pull the Power Pull On –
illuminated Button is pushed in to the Push Off Button out to the ON
OFF position position.
Machine is unplugged Plug in the machine.
Electrical Outlet supplying the Reset circuit breaker or
machine is dead replace fuse for electrical
outlet.
Machine requires a
dedicated, unshared line!
Main fuse #4FU is blown Replace fuse #4FU with one
of same type and rating.
(Normal-blow)
2. Turntable does not turn in run Turntable jammed Try rotating turntable by
or jog modes hand. If it will not move,
check for signs of mechanical
binding or jamming. Ensure
ramp does not interfere with
turntable.
Turntable Speed setting is too Increase Turntable Speed Pot
low setting. (Refer to Section
5:1:5)
Blown fuse #1FU Replace fuse #1FU with one
(Slow-blow)
Defective Turntable Speed Disconnect Turntable Speed
Potentiometer Pot and check with an
ohmmeter. Replace if
defective.
Plug-In H.P. Resistor not Install a Plug-In H.P. Resistor
installed in Turntable SCR of correct value in #1SCR.
Card #1SCR (Refer to Section 9:7)
Improperly calibrated Check calibration of #1SCR.
Turntable SCR Card #1SCR (Refer to Section 9:7 for SCR
Card Adjustment)
Defective Turntable SCR Check for DC voltage at
Card #1SCR terminals #A1 & #A2 on the
motor. If no voltage is
present during wrap cycle or
manual jog, replace #1SCR.
36
Turntable does not turn in run Turntable drive sprocket key If gear-motor appears to be
or jog modes missing, or chain has fallen running, but turntable does
…continued… off not rotate check that the key
between the turntable
sprocket and the gear-
reducer output shaft is intact.
Replace key if missing.
Ensure that turntable chain is
on.
Defective Turntable Gear- If gear-motor is running, but
Motor turntable does not rotate and
all keys and drive chain are
intact, replace gear-motor.
Defective Turntable Gear- Check for DC voltage at the
Motor motor terminals. If voltage is
present but gear-motor will
not run, repair or replace
gear-motor.
3. Turntable is noisy Turntable jamming Try rotating turntable by

hand. If it will not move,
check for signs of mechanical
binding or jamming. Ensure
ramp does not interfere with
turntable.
Machine is installed on an Relocate machine to a flat,
uneven surface clean, level surface.
Turntable drive chain too Adjust turntable drive chain
slack tension. (Refer to Section
9:2)
Turntable support rollers Replace rollers. (Refer to
damaged or worn out Section 9:3)
4. Turntable runs too slowly Turntable Speed setting is too Increase Turntable Speed Pot
Turntable stalls when low setting. (Refer to Section
wrapping a heavy load 5:1:5)
Load weight exceeds Do not wrap loads that
capacity of the machine exceed the rated weight
capacity of the machine!
Machine is installed on an Relocate machine to a flat,
uneven surface clean, level surface.
Card Adjustment)
Turntable SCR Card #1SCR Increase CL trim-pot setting
Current Limit (CL) trim-pot is on #1SCR slightly. (Refer to
set too low Section 9:7:4)
Turntable SCR Card #1SCR Install correct value Plug-in
has incorrect value of Plug-In H.P. Resistor in #1SCR.
H.P. Resistor installed (Refer to Section 9:7)
Turntable support rollers Replace rollers. (Refer to
damaged or worn out Section 9:3)
37
5. Turntable runs too fast and / Turntable Speed setting is too Decrease Turntable Speed
or speed cannot be varied fast Pot setting. (Refer to Section
5:1:5)
Card Adjustment)
Defective Turntable Speed Disconnect Turntable Speed
Potentiometer Pot and check with an
ohmmeter. Replace if
defective.
Defective Turntable SCR Check DC voltage at
Card #1SCR terminals #1 & #2 on control
panel terminal strip. If
voltage exceeds 100 VDC
and cannot be adjusted by
varying the Turntable Speed
Pot, replace #1SCR.
6. Turntable will not shut off Normally-Closed (NC) Replace contact block(s).
contact block(s) on Jog / Run
switch defective
Defective Turntable SCR Place a jumper across pins
Card #1SCR #I1 & #I2 on SCR Card. If
motor continues to run,
replace #1SCR.
7. Film Carriage will not raise or Carriage Speed setting is too Increase Carriage Speed Pot
lower low setting. (Refer to Section
5:1:6)
Carriage jammed Try moving carriage from side
to side and back and forth by
hand. There should be some
play between the carriage
guide wheels and the angles
on which they run. If the
carriage cannot be moved at
all, check for signs of
mechanical binding or
jamming.
(Slow-blow)
If fuse continues to blow and
temperature is cold, carriage
gear-motor lube may be
thickening. If so, replace
gear-motor gear-lube with
cold-temperature rated type
or place machine in a warmer
location.
(Normal-blow)
38
Film Carriage will not raise or Defective Carriage Speed Disconnect Carriage Speed
lower Potentiometer Pot and check with an
…continued… ohmmeter. Replace if
defective.
Defective Carriage SCR Card Check for DC voltage at
#2SCR terminals #3 & #4 on control
panel terminal strip. If no
voltage is present while trying
to raise or lower, replace
#2SCR.
Defective Carriage Gear- Check for DC voltage at the
Motor motor terminals. If voltage is
present but gear-motor will
not run, repair or replace
gear-motor.
Defective Film Carriage Inspect the Film Carriage
Lower / Raise Selector Switch Lower / Raise Selector Switch
and contacts. Replace
defective switch or contact
block(s).
8. Film Carriage raises and Carriage Speed setting is too Increase Carriage Speed Pot
lowers too slowly low setting. (Refer to Section
5:1:6)
Carriage SCR Card #2SCR (Refer to Section 9:8 for SCR
Card Adjustment)
9. Film Carriage raises and Carriage Speed setting is too Decrease Carriage Speed
lowers too fast and / or speed fast Pot setting. (Refer to Section
cannot be varied 5:1:6)
Defective Carriage SCR Card Check DC voltage at
#2SCR terminals #3 & #4 on control
panel terminal strip. If
voltage exceeds 100 VDC
and cannot be adjusted by
varying the Carriage Speed
Pot, replace #2SCR.
10. Film Carriage Lift movement Defective Carriage SCR Card If SCR output voltage is
is jerky #2SCR is causing motor to “cogging” or “hunting” replace
“cog” #2SCR.
Film Carriage V-wheels are Inspect V-wheels and ensure
binding in tower that they can turn freely on
their axle bolts. Adjust V-
wheel axle bolt position to
increase clearance between
wheels and tower. Replace
defective V-wheels.
Carriage Lift Belt not centered Adjust carriage lift belt
in the drive spool tracking. (Refer To Section
9:4)
39
11. Film Tension Mechanism will Film Core Locking Teeth not Adjust film core lock actuating
not hold setting - becomes positively engaged with the shaft knob.
tighter or looser during the film core
wrap cycle
Film Core Locking Teeth not Film core lock teeth broken or
positively engaged with film worn out. Replace teeth.
core
Film Tension Brake Pads Inspect film tension brake

slipping or binding on film pads and support weldment
support weldment for dirt or residue. Clean
pads or weldment with
Isopropanol as required.
Film Tension Brake Pads Film tension brake pads worn
slipping or binding on film out. Replace.
support weldment
40
41
11:0 PARTS LISTS
The parts lists shown in this section are for the end-user’s reference in identifying
components of the machine. When a malfunction is traced to a failed
component, the part number for that component will aid in the procurement of a
replacement part.
The description of each component in the parts list is generic. In order to identify
the item exactly, the manufacturer and manufacturer’s part number (along with
any other nameplate data) should be obtained from the item itself.
42
LOCATION QTY. PART No. DESCRIPTION
MACHINE BASE
ASSEMBLY
Base Weldment 1 G05003010100 Base Weldment

Turntable Gear-Motor 1 A137 Gear-Motor In-Line 1/3 HP 90VDC PM 43 RPM
Turntable Gear-Motor 1 G05003010200 Turntable Drive Mounting Plate Weldment
Mounting Plate
Turntable Gear-Motor Slide 1 G05003010300 Turntable Drive Gear-Motor Slide Plate
Plate Weldment
Turntable Gear-Motor 1 K214 Sprocket 50JA12 c/w QD Bushing Hub
Sprocket
Turntable Gear-Motor 1 Q100 QD Bushing Type JA c/w 3/4” Bore & Keyway
Sprocket
Turntable Support Rollers 18 S153 Turntable Support Wheel Assembly
Turntable Support Rollers 9 H811 Hex Cap Screw M12x1.75 x 60mm Long
Turntable Support Rollers 9 H765 Hex Nut M12x1.75 Plated
Turntable Support Rollers 54 H860 Spacer Washer M12
Turntable 1 C412-R1 Turntable Weldment 57” Diameter x 5/16” TK –
Bolt-On
Turntable Center Sprocket 1 K190-R1 Turntable Center Sprocket & Hub Weldment –
Bolt-On
Turntable Center Bearing 1 B126 Ball Bearing Double Row 30mm ID x 62mm OD
Turntable Drive Chain 9.6 ft. K120 Chain ANSI #50
Turntable Drive Chain 2 K121 Connecting Link ANSI #50
Turntable Drive Chain 1 K122 Offset (Half) Link ANSI #50
Turntable Drive Chain 1 G050030109 Turntable Drive Chain Access Cover
Access Cover
Turntable Drive Take-up 2 G050030110 Turntable Drive Take-up Nut-Bar
TOWER ASSEMBLY
Tower Weldment 1 G050030200 Tower Weldment

Tower Top Cap 1 C440 Tower Top Cap Weldment
Carriage Lift Drive 1 C439 Carriage Lift Drive Mounting Bracket Weldment
Mounting Bracket
Carriage Lift Gear-Motor 1 A138 Gear-Motor Right-Angle 1/8 HP 90VDC PM 30
RPM
Carriage Lift Belt Drive 1 M170 Carriage Lift Belt Drive Spool
Spool
Carriage Lift Drive Belt 1 K242 Carriage Lift Belt
Carriage Lift Drive Belt 1 H886 Flat Head Socket Screw 5/16”-18UNC x 2.75”
Spool Pin Long
Carriage Lift Safety Cable 1 C435 Carriage Lift Safety Cable Adapter Pulley
Carriage Lift Safety Cable 1 S157 Safety Cable Assembly 8’ Long c/w Eyes
FILM CARRIAGE
ASSEMBLY
Film Carriage Weldment G05004030100 Film Carriage Weldment

Tension Brake Disk 1 M172 Tension Brake Disk
Tension Brake Disk 2 B167 Bronze Plane Bearing 1.0” ID x 1.375” OD x
Bearings 1.0” Long
43
FILM CARRIAGE
ASSEMBLY
…continued…
Tension Brake / Mandrel 1 H881 Retaining Ring External for 1” Diameter Shaft
Retaining Ring
Upper Brake Pad 1 M173 Film Tension Brake – Brake Pad - Upper
Lower Brake Pad 1 M174 Film Tension Brake – Brake Pad - Lower
Lower Brake Pad 1 X141 Threaded Insert 9/16”-12UNC External Thread
x 3/8”-16UNC Internal Thread
Brake Pad Guide Pins 2 H882 Shoulder Screw 1/2” Dia. x 1-1/2" Long
Brake Pad Guide Pins 10 V117 Wave Spring Washer 0.531” ID x 0.734" OD x
0.009 TK - 0.050" High
Tension Adjusting Knob 1 X140 Hand Knob 4-Prong Black Plastic c/w 3/8”-
16UNC x 2” Long Stud
Tension Adjusting Knob 10 V118 Curved Spring Washer 0.395" ID x 0.735 OD x
0.011" TK - 0.129" High
Mandrel Body 1 M175 Mandrel Body 2.938” Dia. x 10” Long UHMW
Mandrel Top Cone 1 M176 Mandrel Top Cone
Mandrel Top Cone Stand- 4 C434 Mandel Top Cone Stand-Off
Off
Mandrel Top Cone Stand- 4 H884 Socket Head Cap Screw 1/4”-20UNC x 3” Long
Off Bolts
Film Core Lock Actuating 1 M178 Film Core Lock Actuating Shaft
Shaft
Film Core Lock Actuating 1 X139 Hand Knob Ball Type Black Phenolic 1.86” Dia.
Shaft
Film Core Lock Actuating 2 Q133 Shaft Collar Steel c/w Set-Screw 5/8” ID
Shaft
Film Core Lock Actuating 1 M177 Film Core Lock Actuating Nut
Nut
Film Core Lock Tooth 2 F249 Film Core Lock Tooth
Film Core Lock Tooth Pin 2 H880 Spring Pin Slotted 3/16” x 7/8” Long
Film Diverter Roller 1 W114 Roller Anodized Aluminum 0.75” Dia. x 21.88”
Long c/w 1/4” Dia. Spring-Loaded Axle 23”
Long
Carriage Guide Rollers 4 M171 Carriage Guide V-Wheel
Carriage Guide Roller Axle 4 H843 Shoulder Screw 5/8” Dia. x 1.25” Long
Carriage Guide Roller Axle 8 H833 Nylon Flat Washer 5/8” ID x 1” OD x 0.062” Tk.
Carriage Guide Roller Axle 4 H756 Nylon Insert Lock-Nut 1/2”-13UNC Plated
Carriage Side-Thrust 3 W162 Carriage Side-Thrust Rollers
Rollers
Carriage Side Thrust Roller 3 H879 Shoulder Screw 5/16” Dia. x 1/2" Long
Axle
Carriage Limit Switch 1 H841 Shoulder Screw 3/8” Dia. x 3-1/2” Long
Striker Bolt
Carriage Lift Belt Drive 1 C436 Carriage Lift Belt and Safety Cable Attachment
Attachment Bracket Weldment
Carriage Lift Drive Belt 1 F251 Carriage Lift Belt Attachment Bracket
Attachment
Carriage Lift Drive Belt 1 C438 Carriage Lift Belt Retainer
Attachment
44
FILM CARRIAGE
ASSEMBLY
…continued…
Carriage Lift Drive Belt 1 H885 Shoulder Screw 1/2” Dia. x 1/2" Long
Attachment
Carriage Lift Safety Cable 1 V119 Extension Spring 0.360” OD x 3-1/2” Long x
Spring 0.034” Wire Dia.
LOADING RAMP KIT
1/2 Moon Contour Section 1 G050030500 Ramp 1/2 Moon Platform Weldment
Ramp 1 G050030700 Ramp Weldment 40” Long x 60” Wide
Ramp Attaching Hardware 2 H717 Hex Cap Screw 3/8”-16UNC x 1” Long Grade 5
Plated
Ramp Attaching Hardware 2 H772 Lock Washer 3/8” Plated
Ramp Attaching Hardware 6 H771 Flat Washer 3/8” Bolt Size Plated
ELECTRICAL
CONTROLS
Control Panel
Control Panel Face Plate 1 G05003020300 Control Panel Face Plate Weldment
Control Panel Label 1 E836 Control Panel Label for Model 550
Power Pull Start - Push 1 E1812 Push-Pull Button Operator Red Mushroom-
Stop Button Head 2-Position Maintained
Power Pull Start - Push 1 E1813 Contact Body 1 x NC
Stop Button
Power On Light 1 E121 Light Red Neon 120VAC Glo-Dot
Turntable Jog/Run Switch 1 E1964 Selector Switch Operator 3-Position Spring-
Return Left to Center - Standard Lever
Turntable Jog/Run Switch 1 E2025 Contact Block Mounting Base
Turntable Jog/Run Switch 2 E1942 Contact Block NC Low Volts/Current
Film Carriage Lower/Raise 1 E1966 Selector Switch Operator 3-Position Spring-
Switch Return Both Sides to Center - Extended Lever
Film Carriage Lower/Raise 1 E1938 Contact Body 2 x NO
Switch
Film Carriage Speed 1 E373 SCR “Donut” Motor Speed Control 90VDC 4.0
Control - 2SCR Amps
Turntable Speed 1 E123 Potentiometer 5K ohm 2 Watt
Potentiometer
Turntable & Carriage 2 E143 Knob for 1/4” Dia. Potentiometer Shaft
Speed Potentiometers
Control Panel Inner Panel 1 G0500330 Control Panel Inner Panel
2MR & 2ML 2 E866 Relay 3PDT 10 Amp c/w 120VAC Coil
2MR & 2ML 2 E867 Relay Socket 3-Pole
2MR & 2ML 2 pr. E104 Relay Hold-Down Clip
1FU – 4FU 4/12 E133 Fuse Holder 12-Pole QD Type for 1/4”x1-1/4”
Fuse
1FU 1 E330 Fuse 4 Amp 250 Volt Slow-Blow 1/4”x1-1/4”
2FU 1 E335 Fuse 5 Amp 250 Volt Normal-Blow 1/4”x1-1/4”
45
ELECTRICAL
CONTROLS
Control Panel
…continued…
3FU 1 E833 Fuse 2.5 Amp 250 Volt Slow-Blow 1/4”x1-1/4”

1SCR 1 E137 SCR 90VDC Motor Control Card
1SCR 2 E140 Plug-In H.P. Resistor 1/3 H.P.
2 Ohm 25 Watt Resistor 1 E418 Resistor 2 ohm 25 Watt Wire-Wound
Carriage Dynamic Brake 1 E885 Resistor 10 ohm 10 Watt Wire-Wound c/w
Resistor Radial Leads
Terminal Strip 12 E159 Terminal Block 5mm Beige
Terminal Strip 3 E160 Terminal Block 5mm Green
Terminal Strip 1 E161 Terminal End Plate
Terminal Strip 2 E162 Terminal Center-Bridge Jumper Bar 3-pole
Terminal Strip 2 E163 Terminal End Clamp
Inner Panel to Face Plate 8 E561 Stand-Off #8-32 Male-Female x 2” Long
Stand-Offs
Machine Base
Turntable Gear-Motor 7 ft E183 Cable Type SJT #14 AWG 3-Conductor Black
Turntable Gear-Motor 1 E168 Strain Relief Connector w/o Lock-Nut 1/2” NPT
for Cable Dia. 0.236” - 0.472”
Turntable Gear-Motor 1 E146 Lock-Nut 1/2” Conduit
Tower
1LS & 2LS Carriage 2 E346 Limit Switch DPDT Side Rotary c/w Adjustable
Bottom & Top Limit Radius Arm & 1 Cable Entry 1/2" NPT
Switches
1LS & 2LS Carriage 2 E899 Strain Relief Connector w/o Lock-Nut PG11 for
Bottom & Top Limit Cable Dia. 0.200” - 0.394”
Switches
1LS Carriage Bottom Limit 5 ft E892 Cable Type SJT #18 AWG 2-Conductor Black
Switch
2LS Carriage Top Limit 4.5 ft E892 Cable Type SJT #18 AWG 2-Conductor Black
Switch
Power Cord 1 E182 Power Cord Assembly 14-3 SJT 120VAC 15A
Strain Relief Connectors 6 E168 Strain Relief Connector w/o Lock-Nut 1/2” NPT
for Cable Dia. 0.236” - 0.472”
Strain Relief Connectors 6 E146 Lock-Nut 1/2” Conduit
0550_pup_manual_newcarriage_r4.doc
12:0
C
O
M
P
O
N
E
N
T
M
A
N
U
A
L
S
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
2
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
1 115 0 - 90 0.5 1 50, 100

KBIC-240D 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* correct value. Plug-in CAUTION
® 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.
4
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.)
6
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
8
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
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
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
DC Motor Installation – Maintenance Instructions
When this motor is installed according to these instructions, it complies with
the EEC Machinery Directive. Electromagnetic Compatibility (EMC)
requirements for CE compliance are met when the incoming power is purely
sinusoidal. For other power source types, refer to MN1383 Recommended
Practices for Installation for EC Directive 89/336/EEC Relating to EMC".
These instructions are intended to complement, not replace, the information
in MN605 Installation and Operation manual for Integral Horsepower DC
Motor".
Handling
The weight of the motor and shipping container will vary. Use correct
material handling equipment to avoid injury.
Use caution when removing the motor from its packaging. Sharp corners
may exist on motor shaft, motor key, sheet metal and other surfaces.
Receiving
Inspect the motor for damage before accepting it. The Motor shaft should
rotate freely with no rubs. Report any damage immediately to the
commercial carrier that delivered your motor.
Safety Notice
Only qualified personnel trained in the safe installation and operation of this
equipment should install this motor. When improperly installed or used,
rotating equipment can cause serious or fatal injury. Equipment must be
installed in accordance with the National Electrical Code (NEC), local codes
and NEMA MG2 Safety Standards for Construction and Guide for Selection,
Installation and Use of Electric Motors and Generators. Observe the
following guidelines:
1. When eyebolts are provided, they must be fully tightened and are
intended to lift the motor and its included accessories only.
2. Ground the motor according to NEC and local codes.
3. Provide a permanent guard to prevent accidental contact of body parts
or clothing with rotating or moving parts or burns if motor is hot.
4. Shaft key must be secured before starting motor.
5. Do not apply power to the motor until the motor is securely mounted by
its mounting holes.
6. This motor must only be connected to the proper line voltage, line
frequency and load size.
7. Motors are not to be used for load holding or restraining unless a
properly sized brake is installed. If a motor mounted brake is installed,
provide proper safeguards for personnel in case of brake failure.
8. Disconnect all power services, stop the motor and allow it to cool before
servicing.
9. For single phase motors, discharge the start and/or run capacitors
before servicing.
10. Do not by-pass or render inoperative any safety device.
11. DC series wound motors must be protected from sudden loss of load
causing overspeed damage. DC shunt wound motors must be
protected from loss of field voltage which can result in damage.
12. Mounting bolts should be high tensile steel. Be sure to use a suitable
locking device on each bolt (spring washer or thread lock compound).
Guarding
After motor installation is complete, a guard of suitable dimensions
must be constructed and installed around the motor/gearmotor.
This guard must prevent personnel from coming in contact with
any moving parts of the motor or drive assembly but must allow
sufficient cooling air to pass over the motor.
If a motor mounted brake is installed, provide proper safeguards
for personnel in case of brake failure.
Brush inspection plates and electrical connection cover plates or
lids, must be installed before operating the motor.
Motor Enclosure
ODP, Open drip proof motors are intended for use in clean, dry locations with
adequate supply of cooling air. These motors should not be used in the
presence of flammable or combustible materials. Open motors can emit
flame and/or molten metal in the event of insulation failure.
TEFC, totally enclosed motors are intended for use where moisture, dirt
and/or corrosive materials are present in indoor and outdoor locations.
Explosion proof motors, as indicated by the Underwriters Laboratories, Inc.
label are intended for use in hazardous areas as specified by the NEC.
Mounting
Foot mounted machines should be mounted to a rigid foundation to prevent
excessive vibration. Shims may be used if location is uneven.
Flange mounted machines should be properly seated and aligned. Note: If
improper rotation direction is detrimental to the load, check rotation direction
prior to coupling the load to the motor shaft.
For V-belt drive, mount the sheave pulley close to the motor housing. Allow
clearance for end to end movement of the motor shaft. Do not overtighten
belts as this may cause premature bearing failure or shaft breakage.
Direct coupled machines should be carefully aligned and the shaft should
rotate freely without binding.
Wiring
Connect the motor as shown in the connection diagram. If this motor is
installed as part of a motor control drive system, connect and protect the
motor according to the control manufacturers diagrams. The wiring, fusing
and grounding must comply with the National Electrical Code and local
codes. When the motor is connected to the load for proper direction of
rotation and started, it should start quickly and run smoothly. If not, stop the
motor immediately and determine the cause. Possible causes are: low
voltage at the motor, motor connections are not correct or the load is too
heavy. Check the motor current after a few minutes of operation and
compare the measured current with the nameplate rating.
Adjustment
The neutral is adjustable on some motors.
Noise
For specific sound power or pressure level information, refer to the Acoustic
Performance of Standard Baldor TEFC or Super E TEFC motors in the Baldor
Mechanical Design Standard MD950. The information is from test results and
should be used with the national safety code for noise in the work place.
Vibration
This motor is balanced to NEMA MG1, Part 7 standard.
Lubrication
This is a ball or roller bearing motor. The bearings have been lubricated at
the factory. Motors that do not have regrease capability are factory
lubricated for the normal life of the bearings.
Lubricant
Baldor motors are pregreased, normally with Polyrex EM (Exxon Mobil). If
other greases are preferred, check with a local Baldor Service Center for
recommendations.
Relubrication Intervals (For motors with regrease capability)
New motors that have been stored for a year or more should be relubricated.
Lubrication is also recommended at these intervals:
Table 1 Relubrication Interval
NEMA (IEC) Rated Speed (RPM)
Frame Size 3600 1800 1200 900
Up to 210 incl. (132) 5500Hrs. 12000Hrs. 18000Hrs. 22000Hrs.
Over 210 to 280 incl. (180) 3600Hrs. 9500Hrs. 15000Hrs. 18000Hrs.
Over 280 to 360 incl. (225) *2200Hrs. 7400Hrs. 12000Hrs. 15000Hrs.
Over 360 to 5000 incl.(300) *2200Hrs. 3500Hrs. 7400Hrs. 10500Hrs.
* Lubrication interval for 6313 or 6314 bearings that are used in 360 through
5000 frame, 2 pole motors. If roller bearings are used, bearings must be
lubricated more frequently, divide the relubrication interval by 2.
Table 2 Service Conditions
Ambient Temperature Atmospheric
Severity of Service Type of Bearing
Maximum Contamination
Standard 40° C Clean, Little Corrosion Deep Groove Ball
Bearing
Severe 50° C Moderate dirt, Corrosion Ball Thrust, Roller
Extreme >50° C* or Severe dirt, Abrasive All Bearings
Class H Insulation dust, Corrosion
Low Temperature <-30° C **
* Special high temperature grease is recommended.

** Special low temperature grease is recommended.
Table 3 Lubrication Interval Multiplier

Severity of Service Multiplier
Standard 1.0
Severe 0.5
Extreme 0.1
Low Temperature 1.0
Table 4 Amount of Grease to Add

Bearing Description (Largest bearing in each frame size)
Frame Size NEMA Weight of Volume of grease to add
(IEC) OD Width
Bearing grease to add
D mm B mm inches3 teaspoon
ounce (gram)
Up to 210 incl. (132) 6307 80 21 0.30 (8.4) 0.6 2.0
Over 210 to 280 incl. (180) 6311 120 29 0.61 (17.4) 1.2 3.9
Over 280 to 360 incl. (225) 6313 140 33 0.81 (23.1) 1.5 5.2
Over 360 to 5000 incl.(300) NU322 240 50 2.12 (60.0) 4.1 13.4
Weight in grams = 0.005 DB
Procedure
Clean the grease fitting (or area around grease hole, if equipped with slotted
grease screws). If motor has a purge plug, remove it. Motors can be
regreased while stopped (at less than 80°C) or running.
Apply grease gun to fitting (or grease hole). Too much grease or injecting
grease to quickly can cause premature bearing failure. Slowly apply the
recommended amount of grease, taking 1 minute or so to apply. Operate
motor for 20 minutes, then reinstall purge plug if previously removed.
Caution: Keep grease clean. Mixing dissimilar grease is not recommended.
Sample Relubrication Determination

This sample determination is based on a NEMA 286T (IEC 180) motor
operating at 1750 RPM driving an exhaust fan in an ambient of 43°C
atmosphere that is moderately corrosive.
1. Table 1 list 9500 hours for standard conditions.
2. Table 2 classifies severity of service as Severe".
3. Table 3 lists a multiplier value of 0.5 for Severe conditions.
4. Table 4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.
Note: Smaller bearings in size category may require reduced amounts of
grease.
P.O. Box 2400
Fort Smith, AR 72902–2400 U.S.A.
(501) 646–4711
1/01 LB5029
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COUSINS PACKAGING INC.

NOTE - This document is formatted for 2-sided printing

1:0 BEFORE STARTING THE MACHINE......................................................... 5

2:0 SPECIFIC CAUTIONS AND WARNINGS ................................................... 7

3:0 MACHINE DESCRIPTION .......................................................................... 9

4:0 INSTALLATION ........................................................................................ 11

5:0 SET-UP AND OPERATING PROCEDURES ............................................ 15

6:0 WRAPPING A LOAD ................................................................................ 19

7:0 REMEDIAL ADJUSTMENT ...................................................................... 21

8:0 MAINTENANCE REQUIREMENTS .......................................................... 23

9:0 MAINTENANCE AND ADJUSTMENTS ....................................................25

11:0 PARTS LISTS ............................................................................................41

12:0 COMPONENT MANUALS

13:0 ELECTRICAL DRAWINGS

14:0 MECHANICAL DRAWINGS

1:0 BEFORE STARTING THE MACHINE

2. DO NOT START THE MACHINE BEFORE REMOVING THE PACKAGING

3. DO NOT START THE MACHINE BEFORE REMOVING THE TWO SHIPPING

6. If the machine is loaded by forklift truck, it is recommended that a stop block

7. READ THE MANUAL!

2:0 SPECIFIC CAUTIONS AND WARNINGS

This designation indicates that a failure to observe can cause EQUIPMENT

This designation indicates that a failure to observe can cause DAMAGE TO

This designation indicates that failure to observe can cause DAMAGE TO

We strongly recommend that all personnel involved in operating and

Cousins Packaging Inc. endeavors to manufacture the safest equipment

3:0 MACHINE DESCRIPTION

3:1 Machine Specifications

Power 120 Volt, 1 Phase, 15 Amp (unshared) line service required.

Motors All gear-motors, unless otherwise specified, are 90 volts DC,

Speed Turntable speed is manually controlled from 0 to 9 RPM, by

The Film Carriage Lift speed is manually controlled from

The Film Carriage lift is driven from a 1/8 HP right-angle gear-

Environment The Model 550 is designed for standard industrial environments

Capacity Turntable loading of 3,000 pounds turning, and 8,000 pounds

Film The Model 550 accepts “hand-wrap” or “machine” film wound on

4:1 Moving the Machine

 CAUTION! The Loading Ramp and Ramp Contour 1/2

 WARNING! Be careful when lifting and moving the

4:2 Unpacking and Inspection

Before applying power or operating the machine, a general inspection is

IT IS THE END-USER’S RESPONSIBILITY TO REPORT ANY DAMAGE

4:3 Tower Installation (Optional)

Some machines may be shipped in “knocked-down” condition. Re-assemble the

3. Remove the connection cover from the Turntable Drive Gear-Motor

4:4 Final Assembly and Inspection

1. Remove any remaining packaging from the machine.

 CAUTION! Two flat washers must be installed as spacers

5. Inspect visible cables for damage or loose fittings.

 CAUTION! The film carriage limit switch striker must

4:5 General Power Requirements

 CAUTION! Power the system only from an adequately

If it is necessary to use an extension cord temporarily, a #14 AWG (minimum),

5:0 SET-UP AND OPERATING PROCEDURES

5:1 Operating Controls - Control Panel Door

This section provides a description of the operator controls located on the

5:1:1 Power Pull Start – Push Stop Button

This red two-position mushroom-head push-pull button is used to turn on the

 WARNING! The interior of the control panel remains