INSTALLATION AND OPERATING INSTRUCTIONS 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 TM Hi-Pot Tested 1500 VAC A COMPLETE LINE OF MOTOR DRIVES © 2001 KB Electronics, Inc. TABLE OF CONTENTS Section i. ii. I. II. Page Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 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. AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 IX. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 X. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 XI. Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 XII. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Tables 1. 2. 3. 4. ii Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Plug-In Horsepower Resistor® Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Recommended AC Line Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Figures 1. Pages Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2A. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2B. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3. 4. 5. 6. 7. 8. 9. Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inhibit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 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 proceeding. 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 manufacture. 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 11/2 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 FIGURE 1 ­ CONTROL LAYOUT (Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings) 180V 90V J1 KBWS A+ Plug-In Horsepower Resistor® (Supplied Separately) MAX MIN ACC DEC CL IR 8 PWR ON L2 CL L1 A- P3 P2 P1 CON1 FIGURE 2A ­ MECHANICAL SPECIFICATIONS (Inches / [mm]) 4.30 [109.2] 0.48 [12.3] 180V 90V J1 KBWS A+ 1.23 [31.4] A- P3 P2 P1 2.98 [75.8] 3.62 [92.1] MAX MIN ACC DEC CL IR 3.80 [96.5] PWR ON L2 CL L1 CON1 9 FIGURE 2B ­ MECHANICAL SPECIFICATIONS (Inches / [mm]) Ø0.19 [Ø4.83] 8 PLACES KBWS-12: KBWS-15: KBWS-22D: 0.95 [24.1] 1.25 [31.8] KBWS-25D: 2.19 [55.5] 1.99 [50.5] 2.19 [55.5] 3.17 [80.5] 3.80 96.5 TABLE 1 ­ ELECTRICAL RATING Model Part No. AC Line Input Voltage (±10%, 50/60 Hz) (Single Phase Volts AC) Motor Voltage (Volts DC) Maximum Maximum AC Line Load Current Current (Amps AC) (Amps DC) Maximum Horsepower Rating HP, (kW) SCR Rated Motors PWM Rated Motors KBWS-12 KBWS-15 9490 9491 115 115 115 0 - 90, 130 0 - 90, 130 0 - 90, 130 0 - 180, 220 0 - 90, 130 0 - 90, 130 0 - 180, 220 0 - 90, 130 4.0 8.0 4.0 4.0 4.0 8.0 8.0 8.0 2.5 5.0 2.5 2.5 2.5 5.0 5.0 5.0 1/4, (0.18) 1/2, (0.37) 1/4, (0.18) 1/2, (0.37) 1/4, (0.18) 1/2, (0.37) 1, (0.75) 1/2, (0.37) 1/3, (0.25) 3/4, (0.5) 1/3, (0.25) 3/4, (0.5) 1/3, (0.25) 3/4, (0.5) 11/2, (1) 3/4, (0.5) KBWS-22D* 9492 208/230 208/230 115 KBWS-25D* 9493 208/230 208/230 * See Sections 1G an ...