MODEL KBWD-15 Pulse Width Modulated (PWM) DC MOTOR SPEED CONTROL WHISPER DRIVETM INSTALLATION AND OPERATING INSTRUCTIONS See Safety Warning on Page 1 and Application Note Warning on Page 2 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. Model KBWD-15 Rated 5.0 ADC @ 115 VAC 50/60 Hz KB Part No. 8600 A COMPLETE LINE OF MOTOR DRIVES © 1999 KB ELECTRONICS, INC. TABLE OF CONTENTS Section Page i. Simplified Setup and Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 iii. Application Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 II. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 III. Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IV. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 V. DC Tachometer Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VI. Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 IX. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 X. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TABLES 1. Electrical Ratings & Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. Plug-in Horsepower Resistor® Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3. Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4. Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5. KBWD-15 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13, 14, 15, 16 FIGURES 1. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. AC Line and Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4A. Full Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4B. Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5. Remote Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6. Analog Voltage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7. Microprocessor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 8. Tachometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9. Inhibit Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10. KBWD-15 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ii i. 1. 2. SIMPLIFIED SETUP AND OPERATING INSTRUCTIONS IMPORTANT ­ You must read these simplified operating instructions before you proceed. Be sure AC line voltage is 115 VAC 50/60 Hz. Install the correct Plug-in Horsepower Resistor® according to motor current and/or horsepower. Note: Disregard the horsepower rating marked on the Plug-in Horsepower Resistor® since they are marked for SCR controls. See table 2, page 5. 3. Recheck connections: AC line to L1 and L2; armature to A+ and A- (use F+ and F- for shunt motor field connections only.) Note: If motor runs in improper direction, interchange armature leads. Nominal factory trimpot settings are as follows: (Expressed in % of full CW rotation). FACTORY SETTING OF TRIMPOTS 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 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 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 may contain electronic Start/Stop and Enable 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. The input circuits of this control (tachometer, start/stop, inhibit, enable) 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. See Application Note Warning on page 2. 1 This product complies with all CE directives pertinent at the time of manufacture. Contact factory for detailed installation instructions and Declaration of Conformity. Installation of a CE approved RFI filter (KBRF-200A, KB P/N 9945C or equivalent) is required. Additional shielded motor cable and/or AC line cables may be required along with a signal isolator (KBSI-240D, KB P/N 9431 or equivalent). iii. APPLICATION NOTE: WARNING! 1. PWM controls are designed with a single power transistor which is wired directly in series with the motor. If for some reason this transistor short circuits, a "runaway" condition could occur where the motor will almost instantaneously accelerate to full speed. This could cause physical harm to an operator or user of the machinery or equipment on which the control is installed. In some cases a proper sized fuse, when installed in series with the motor armature, will prevent this "runaway" condition. Use extreme caution when applying PWM controls to certain applications. 2. PWM controls emit substantial levels of radio frequency interference (RFI) compared to SCR controls. The KBWD contains a built-in RFI filter which suppresses most of the RFI that would normally be conducted and radiated via the AC line. However, some RFI can still be radiated and conducted from the control and through the motor wires. Shielded cables and other means of reducing the effect of RFI may have to be employed for some applications. 3. This control contains inhibit, enable and other circuits that can be used to turn the control "on" and "off." Do not use these circuits as a safety disconnect. Use only the AC line for that purpose. I. GENERAL INFORMATION The KBWD-15 Pulse Width Modulated (PWM) DC motor speed control provides excellent dynamic response to load variations. The efficient PWM waveform produces an almost pure DC current to the motor (form factor < 1.05) which has several advantages over a conventional SCR control. The PWM significantly lowers audible motor noise and provides longer brush life. It also produces less motor heating which allows a smaller, less costly motor to be used for most applications. Another advantage of PWM is higher output voltage which provides increased output speed. In addition, pulse-by-pulse current sensing provides short circuit protection. A unique feature of the KBWD-15 control is the Plug-in Horsepower Resistor®. It eliminates the need for recalibrating IR Comp and Current Limit when the control is used on various horsepower motors. The control is factory set for armature feedback which provides excellent load regulation. For applications that require superior performance, tachometer feedback is also provided. The KBWD-15 contains (I x t) overload protection which will shut the control down if the motor is overloaded for a predetermined time. Diagnostic LEDs for "Power On" and "Overload" (CL) indication are also provided. 2 RFI filtering is included as a standard feature. It greatly reduces conducted interference which could affect sensitive equipment. The control contains barrier terminals as standard; however, quick disconnect terminals can be provided as an option. A potentiometer (5K), isolated analog signal (0-10 VDC), or PWM microprocessor output can be used to vary the output of the control. TABLE 1 ­ ELECTRICAL RATINGS & MECHANICAL SPECIFICATIONS Model KBWD-15 Rated 5.0 Amps DC @ 115 VAC 50/60 Hz SPECIFICATIONS Output Voltage Range (VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 130 Speed Range (Ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50:1 Operating Frequency (kHz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >16 Form Factor (RMS / Avg Amps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <1.05 Ambient Operating Range Temp (°C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 45 Load Regulation (% Base Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1* Timed CL Trimpot Range (TCL) (Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 7 Acceleration Trimpot Range (ACCEL) (Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 ­ 15 Minimum Speed Trimpot Range (MIN) (VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 40 Maximum Speed Trimpot Range (MAX) (VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ­ 130 Current Limit Trimpot Range (CL) (% Range Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 200 IR Comp Trimpot Range (IR) (VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 15 AC Line Voltage Regulation (% Base Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...