KB Electronics KBWS-25D User Manual
INSTALLATION AND OPERATING INSTRUCTIONS
!
TM
Hi-Pot
Tes t e d
1500 VAC
KBWS WHISPER DRIVE
PULSE WIDTH MODULATED (PWM)
DC Motor Speed Control with Built-In
Input Signal Isolation
See Table 1 on page 10 for a list of KBWS
Models covered by this manual
The information contained
in this manual is intended to be accurate.
However, the manufacturer retains
the right to make changes in design
which may not be included herein.
Note: A Plug-In Horsepower Resistor®
must be installed for this product to
operate (supplied separately).
See Safety Warning on Page 5 before
installing and operating this control
A COMPLETE LINE OF MOTOR DRIVES
© 2001 KB Electronics, Inc.
TABLE OF CONTENTS
Section Page
i. Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
II. Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
III. Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IV. Setting Selectable Jumper (On Dual Voltage Models) . . . . . . . . . . . . . . . . . . . . 15
V. Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VI. Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . 16
VII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VIII.Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
IX. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
X. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XI. Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
XII. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tables
1. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. Plug-In Horsepower Resistor® Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Recommended AC Line Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ii
Figures Pages
1. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2A. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2B. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7. Inhibit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9. Motor Voltage Selection (J1) (Dual Voltage Models) . . . . . . . . . . . . . . . . . . . . . . 15
10. Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11. Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
12. Minimum Speed Trimpot (MIN) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
13. Acceleration Trimpot (ACC) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
14. Deceleration Trimpot (DEC) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
15. Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
16. IR Compensation Trimpot (IR) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
iii
i. SIMPLIFIED OPERATING INSTRUCTIONS
IMPORTANT –You must read these simplified operating instructions before proceed-
ing. These instructions are to be used as a reference only and are not intended to
replace the detailed instructions provided herein. You must read the Safety Warning
on page 5 before proceeding. See Application Note, Section VII, on page 18.
A. Power Connection – Connect the AC line to L1 and L2 terminals, as shown in
Figure 4, on page 13 and as described in Section IIIA, on page 13.
B. Permanent Magnet (PM) Motor Connection (Two Wire Type) – Connect the
motor armature to terminals A+ and A- as shown in Figure 4, on page 13 and as
described in Section IIIB, on page 13. On dual voltage models, be sure that
Jumper J1 is set to the corresponding motor voltage position, as described in
Section IV, on page 15.
C. Plug-In Horsepower Resistor® – Install the proper Plug-In Horsepower
Resistor® (supplied separately) according to motor current and horsepower.
See Table 3, on page 12.
D. Trimpot Settings – All trimpots have been factory set, as shown in Figure 1, on
page 8. Trimpots may be readjusted, as described in Section IX, on page 18.
E. Diagnostic LEDs – After power has been applied, observe the LEDs to verify
proper control function, as described in Section X, on page 22.
This product complies with all CE directives pertinent at the time of manufac-
ture. Contact the Sales Department for detailed installation and Declaration of
Conformity. Installation of a CE approved RFI filter (KBRF-300 [P/N 9484] or equivalent) is required. Additional shielded motor cable and/or AC line cables may also be
required.
4
ii. SAFETY WARNING! Please read carefully
!
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
over current protection, and grounding can reduce the chance of electrical 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 further information is required on this product, contact the Sales Department.
This control contains electronic Start/Stop circuits that 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.
Be sure to follow all instructions carefully. Fire and/or electrocution can result due
to improper use of this product.
This control does not contain protection circuitry to prevent full speed runaway in
the event of main power transistor failure. However, an optional Product Safety
Module (PSM) (P/N 9995) can be installed to prevent full speed runaway. If a PSM is
not used, the installer of this product should take proper precautions to include other
means, such as mechanical disconnects, warning notices, etc., to protect the operator
of the machine involved.
It is the responsibility of the equipment manufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product. (SW effective 1/2001).
5
I. INTRODUCTION
Thank you for purchasing the KBWS. KB Electronics, Inc. is committed to providing
total customer satisfaction by producing quality products that are easy to install and
operate. The KBWS is manufactured with surface mount components incorporating
advanced circuitry and technology.
The KBWS PWM (pulse width modulated) controls are designed to operate PWM
and SCR rated Permanent Magnet motors ranging from 1/50 HP to 1
1
⁄2 HP. They
operate at a switching frequency greater than 16 kHz to provide high motor efficiency and quiet operation. Another advantage of PWM is higher output voltage (up to
130 Volts DC for 115 Volt AC line and 220 Volts DC for 208/230 Volt AC line) which
provides increased motor speed.
The KBWS contains pulse-by-pulse current sensing, which provides short circuit
protection and prevents control damage due to commutator arcing. Permanent
magnet motor demagnetization is completely eliminated because current peaks are
reduced to safe levels. The controls contain an AC inrush current limiter (ICL) which
reduces the AC line surge current during cycling of the AC line.
Standard features of the KBWS include diagnostic LEDs for Power On and Current
Limit indication. Other features include adjustable trimpots for maximum speed,
minimum speed, acceleration, deceleration, current limit and IR compensation. Also
provided is a connector for an Inhibit Switch and quick-connect terminals for AC line,
motor armature and Main Speed Potentiometer. The KBWS can be operated from
a two wire start/stop circuit or can be started from the AC line.
Due to its user-friendly design, the KBWS can be easily tailored to specific applications. See Table 1 on page 10, for electrical ratings. The Plug-In Horsepower
Resistor® matches the motor characteristics to the control without having to recalibrate the Current Limit (CL) and IR Compensation (IR) trimpots. Therefore, for most
applications, no adjustments are necessary.
6
The KBWS contains built-in isolation for all signal inputs. This includes input signal
voltage, Main Speed Potentiometer terminals, Inhibit Circuit and +5VDC power supply. The dual voltage models contain a jumper to select motor voltage and special
circuitry which automatically accepts AC Line input voltages of 115 or 208/230 Volts
AC without having to make a jumper selection. See Application Note, Section VII,
on page 18.
Optional accessories for the KBWS include a DIN Rail Mounting Kit, a Product
Safety Module (PSM) and an AC Line Fuse Kit. See Section XI, on page 23.
STANDARD FEATURES
A. Plug-In Horsepower Resistor® – Automatically calibrates IR Compensation and
Current Limit.
B. Diagnostic LEDs – Power On (PWR ON) and Current Limit (CL).
C. Short Circuit Protection – Protects the control from a short circuit at the motor.
D. Isolated Signal Input Circuit – Eliminates the need for an external signal isolator.
E. Protection Features – Undervoltage protection. MOV input transient protection.
AC Inrush current limit protection.
F. Inhibit Circuit – Provides electronic coast-to-stop.
G. Auto AC Line Select – Control automatically adjusts for 115 or 208/230 Volt AC line
input (dual voltage models).
H. Motor Voltage Selection –Allows motor voltage to be set to 90/130 or 180 Volts DC
(dual voltage models).
7
Plug-In
Horsepower
Resistor®
(Supplied Separately)
KBWS
180V 90V
A+A-
L1
L2
CL
PWR ON
J1
P3 P2 P1
CON1
IRCLDECMIN ACCMAX
(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)
FIGURE 1 – CONTROL LAYOUT
8
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