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INSTALLATION AND OPERATION MANUAL

KBWA SERIES

HYBRID DRIVE™

Digital Drive with Analog Interface

KBWA-23D:

NEMA 1 / IP20 (Vented) Enclosure

KBWA-22D, 21D, 2P6D, 2P3D:

NEMA 1 / IP50 (Non Vented) Enclosure

Rated for 208 – 230 Volt 50 and 60 Hz

Subfractional thru 1/2 HP 3-Phase AC and PSC* Induction Motors

Operates from 115 and 208/230 Volt 50/60 Hz AC Line Input

Variable Speed / Soft Start

with Electronic Motor Overload Protection

Provision for

Forward-Stop-Reverse

Switch (supplied).

(See Sec. 6, on p. 18)

*Operation with

PSC Motors requires

factory programming.

RoHS

This Manual Covers Models KBWA-23D, 22D, 21D, 2P6D, 2P3D

SEE

SAFETY WARNING

ON PAGE 2

IMPORTANT

AC Line Input Voltage Setting:

The drive is factory set for

208/230 Volt AC Line input. For 115 Volt AC Line input, see
Section 7.1, on page 19.

Motor Frequency Setting:

The drive is factory set for 60 Hz

Motors. For 50 Hz Motors, see Section 4.1, on page 13.

KB Electronics, Inc.

(see back cover)

Summary of Contents for KBWA-21D

Page 1: ...Start with Electronic Motor Overload Protection Provision for Forward Stop Reverse Switch supplied See Sec 6 on p 18 Operation with PSC Motors requires factory programming RoHS This Manual Covers Models KBWA 23D 22D 21D 2P6D 2P3D SEE SAFETY WARNING ON PAGE 2 IMPORTANT AC Line Input Voltage Setting The drive is factory set for 208 230 Volt AC Line input For 115 Volt AC Line input see Section 7 1 on...

Page 2: ...nding and filtering of this product can reduce the emission of radio frequency interference RFI which may adversely affect sensitive electronic equipment 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 8 2012 The drive contains electronic Start Stop circuits which can be used to start and stop...

Page 3: ...st applications See Section 12 on pages 28 31 7 MOUNTING THE DRIVE See Section 8 on page 23 8 AC LINE INPUT MOTOR AND GROUND CONNECTIONS At Terminal Block TB1 wire the AC Line input to L1 and L2 the ground wire s to GND and the motor to U V and W See Section 10 on pages 24 26 9 FORWARD STOP REVERSE SWITCH SUPPLIED Install the switch if required See Section 6 on page 18 10 INSTALL THE COVER After t...

Page 4: ...EMOVING AND INSTALLING THE COVER 16 5 1 Removing the Cover 16 5 2 Installing the cover 17 6 INSTALLING THE SUPPLIED FORWARD STOP REVERSE SWITCH REQUIRED FOR MANUAL START MODE 18 7 SETTING SELECTABLE JUMPERS 19 7 1 AC Line Input Voltage Selection Jumper J3 19 7 2 60 Hz and 50 Hz Motor Operation and Drive Output Frequency Selection Jumpers J1 and J2 19 7 2 1 Setting the Drive for 60 Hz and 50 Hz Mot...

Page 5: ... Limit Trimpot CL 31 13 DRIVE OPERATION 32 13 1 Start Up Procedure 32 13 2 Fault Recovery 32 13 3 Restarting the Drive After An Overload Fault Has Cleared 33 14 DIAGNOSTIC INDICATORS 33 14 1 Illuminated On Off AC Line Switch 34 14 2 Power On LED PWR 34 14 3 Status LED ST 34 LIMITED WARRANTY Back Cover Table Page 1 Electrical Ratings 9 2 General Performance Specifications 9 3 Factory Setting of Cur...

Page 6: ...00 Hz Drive Output Frequency Selection 21 11 Automatic Start 21 12 Manual Start 22 13 Forward Reverse Speed Selection 22 14 Mechanical Specifications 23 15 AC Line Input Motor and Ground Connections 26 16 Typical Hi Pot Test Setup 28 17 Minimum Speed Trimpot MIN Range 29 18 Maximum Speed Trimpot MAX Range 29 19 Acceleration Trimpot ACC Range 29 20 Deceleration Trimpot DEC Range 30 21 Slip Compensa...

Page 7: ...re the AC Line input Motor and Ground connections See Figure 2 on page 8 Removing and Installing the Cover See Section 5 on pages 16 and 17 Forward Stop Reverse Switch Supplied See Section 6 on page 18 Selectable Jumpers See Section 7 on pages 18 22 Mounting See Section 8 on page 23 Electrical Connections See Section 10 on pages 24 26 Trimpot Adjustments See Section 12 on pages 28 31 Drive Operati...

Page 8: ...8 FIGURE 2 DRIVE LAYOUT SHOWN WITH COVER REMOVED ...

Page 9: ...06 Minimum Speed Trimpot MIN Range Frequency Setting 0 40 0 Maximum Speed Trimpot MAX Range Frequency Setting 70 110 100 Acceleration Trimpot ACC Range Seconds 0 3 20 1 5 Deceleration Trimpot DEC Range Seconds 0 3 20 1 5 Slip Compensation Trimpot COMP Range at Drive Rating Volts Hz 0 3 1 5 Current Limit Trimpot CL Range Drive Rating 60 190 160 Motor Frequency Setting Hz Jumper J1 50 60 60 Output F...

Page 10: ...stable RMS Current Limit and I 2 t Motor Overload Protection 2 Flux Vector Control with Static Auto Tune provides high torque and excellent load regulation over a wide speed range Power Start delivers over 200 motor torque to ensure startup of high frictional loads Electronic Inrush Current Limit EICL eliminates harmful AC line inrush current The drive is suitable for machine or variable torque HV...

Page 11: ...o times the rated RPM See Section 7 2 on pages 19 21 Jumper Selection for Automatic and Manual Start CON1 With the jumper installed the drive will automatically start after a fault has been cleared With the jumper removed the drive must be manually restarted after a fault has been cleared The supplied Forward Stop Reverse Switch must be installed for Manual Start Operation See Section 7 3 on pages...

Page 12: ...ion 7 2 2 on pages 20 and 21 J3 115V The drive is factory set for 230 Volt AC Line input J3 not installed For 115 Volt AC Line input install Jumper J1 supplied See Section 7 1 on page 19 CON1 A M Used to set the drive for Automatic or Manual Start Mode See Section 7 3 on pages 21 and 22 CON2 Forward Reverse Used to set the drive for forward or reverse speed operation See Section 7 4 on page 22 Als...

Page 13: ...position factory setting See Section 7 2 1 on pages 19 and 20 4 2 MOTOR CURRENT SETTING The Current Limit CL Trimpot is factory set to approximately 160 of the drive s Maximum Continuous Load Current Rating as shown in Table 3 In order for the Motor Overload Protection to operate properly for a lower motor rated current the CL Trimpot will have to be readjusted Do not exceed 160 of the drive s Max...

Page 14: ...verheating and winding failure under light load or no load conditions If the motor is operated in this manner for an extended period of time it is recommended that the unloaded motor current be checked from 1 5 Hz 30 150 RPM to ensure motor current does not exceed the nameplate rating Do not use motor if the motor current exceeds the nameplate rating It is recommended that the drive be used with I...

Page 15: ... the rated drive current The CL Trimpot is used to recalibrate the drive current from 60 thru 190 The Power Start circuit provides an overshoot function that allows most motors to develop more than 200 of starting torque and breakdown torque Standard I 2 t is undesirable because it causes nuisance tripping It allows a very high motor current to develop and will turn the drive off after a very shor...

Page 16: ... Trimpot Adjustments See Section 12 on pages 28 31 WARNING Disconnect the main power before removing or installing the cover WARNING After disconnecting the main power to the drive wait at least 30 seconds before removing the cover WARNING To prevent accidental contact with high voltage it is required that the cover be properly installed onto the drive after all wiring and setup is complete It off...

Page 17: ... 5 2 INSTALLING THE COVER After setting up the drive install the cover Be sure that the wires remain inside the drive so they do not get crimped while it is being installed Replace the two cover screws The screws should be tightened to 5 in lbs 5 76 kg cm do not overtighten ...

Page 18: ...wire toward REV 6 Push the switch through the cover hole until it snap mounts into position 7 Orient the connector red wire to R pin and white wire to F pin 8 Install the connector onto CON2 on the drive 9 Use the two wire ties supplied to secure the switch wires to the existing wires The wire ties should be placed next to the existing wire ties 10 Replace the cover as described in Section 5 2 on ...

Page 19: ...put FIGURE 7 AC LINE INPUT VOLTAGE SELECTION Drive Set for 208 230 Volt AC Line Input J3 Not Installed Factory Setting Drive Set for 115 Volt AC Line Input J3 Installed 7 2 60 Hz AND 50 Hz MOTOR OPERATION AND DRIVE OUTPUT FREQUENCY SELECTION JUMPERS J1 AND J2 Both Jumpers J1 and J2 must be set for the appropriate motor nameplate frequency rating 7 2 1 SETTING THE DRIVE FOR 60 Hz OR 50 Hz MOTOR OPE...

Page 20: ...Motor Operation J1 Installed in 50 Hz Position J2 Installed in X1 Position 7 2 2 SETTING THE DRIVE FOR TWO TIMES THE RATED MOTOR RPM The drive can also be used to operate the motor up to two times the rated RPM However constant horsepower will result when operating the drive in the X2 Mode See Figure 9 FIGURE 9 AVAILABLE TORQUE vs OUTPUT FREQUENCY ...

Page 21: ...TIC AND MANUAL START MODE CON1 CON1 is used to set the drive for Automatic or Manual Start Mode 7 3 1 AUTOMATIC START MODE The drive is factory set for Automatic Start Mode jumper installed onto CON1 See Figure 11 The drive will automatically start when power is applied The drive will also automatically restart after a recovered fault due to undervoltage or overvoltage After two Short Circuit Faul...

Page 22: ...o the drive must be restarted each time the AC line is interrupted To reset the drive after a Short Circuit Fault has cleared use the AC Line Switch 7 4 FORWARD REVERSE SPEED SELECTION CON2 The drive is factory set for Forward Speed Operation jumper installed in the F position of CON2 For reverse Speed Operation install the jumper in the R position See Figure 13 If the application requires that th...

Page 23: ...ous locations where physical damage can occur When mounting the drive in an enclosure the enclosure should be large enough to allow proper heat dissipation so that the ambient temperature does not exceed 40 C 104 F at full rating See Figure 14 WARNING DO NOT USE THIS DRIVE IN AN EXPLOSIVE ENVIRONMENT AN EXPLOSION CAN CAUSE SERIOUS OR FATAL INJURY THIS DRIVE IS NOT EXPLOSION PROOF FIGURE 14 MECHANI...

Page 24: ...gned with two 0 875 22 2 mm holes for standard 3 4 fittings for wiring the AC Line input motor and ground Note Wire the control in accordance with the National Electrical Code requirements and other local codes that may apply to the application WARNING HIGH VOLTAGE Read Safety Warning on page 2 before using the drive Disconnect the main power before making connections to the drive To avoid electri...

Page 25: ...230 Volt AC Line Input be sure that Jumper J3 is not installed For 115 Volt AC Line input install Jumper J3 supplied Applying 230 Volts to the drive set for 115 Volt AC Line input will cause catastrophic failure 10 2 MOTOR AND GROUND Connect the Motor to TB1 Terminals U V and W Connect the Ground earth to TB1 Terminal GND See Figure 15 on page 26 Motor cable length should not exceed 100 feet 30 m ...

Page 26: ...rive does not contain AC Line fuses For the recommended fuse or circuit breaker rating see Table 1 on page 9 Do not fuse motor leads Most electrical codes require that each ungrounded conductor contain circuit protection Do not fuse neutral or ground connections It is recommended to install a fuse Littelfuse 326 Buss ABC or equivalent or a circuit breaker Square D QOU or equivalent in series with ...

Page 27: ...ested Hi Pot Tester is Slaughter Model 2550 or equivalent Note If the Hi Pot Tester does not have automatic ramping then the hi pot output must be manually increased to the test voltage and then manually reduced to zero PROCEDURE Warning All equipment AC line inputs must be disconnected from the AC power before performing the Hi Pot Test 1 Set the Hi pot Tester to the appropriate voltage as shown ...

Page 28: ...nt of the trimpots in order to tailor the drive for a specific requirement The trimpots may be readjusted as follows WARNING If possible do not adjust trimpots with the main power applied If adjustments are made with the main power applied an insulated adjustment tool must be used and safety glasses must be worn High voltage exists in this drive Fire and or electrocution can result if caution is n...

Page 29: ...imum speed setting rotate the MAX Trimpot counterclockwise See Figure 18 12 3 ACCELERATION TRIMPOT ACC Sets the amount of time for the motor to accelerate from zero speed to full speed The ACC Trimpot is factory set to 1 5 seconds For longer acceleration time rotate the ACC Trimpot clockwise For more rapid acceleration rotate the ACC Trimpot counterclockwise See Figure 19 Note Rapid acceleration s...

Page 30: ...neration Protection It is recommended that for very high inertial loads that both the ACC and DEC Trimpots should be set to greater than 10 seconds 12 5 SLIP COMPENSATION TRIMPOT COMP Sets the amount of Volts Hz to maintain set motor speed under varying loads Used to fine tune the drive for improved load regulation The COMP Trimpot is factory set to 1 5 Volts Hz which provides excellent speed regu...

Page 31: ...rive s Maximum Continuous Load Current rating To increase the current limit rotate the CL Trimpot clockwise To decrease the current limit rotate the CL Trimpot counterclockwise See Figures 22 26 Note During normal operation if the ST LED illuminates red the CL Trimpot may be set too low or the motor may be overloaded Either increase the CL Trimpot setting or monitor the motor current to adjust the...

Page 32: ... illuminates green The PC board mounted Status LED ST will indicate the drive status as described in Section 14 3 on page 34 Note If the motor does not rotate in the desired direction either 1 Reverse any two motor leads with the AC Line disconnected and the motor stopped 2 Change the setting of the F S R Jumper on CON2 See Section 7 4 on page 22 3 If the Forward Stop Reverse Switch is installed r...

Page 33: ...r an Overload Fault has cleared by any of the following two methods Note If an Overload Trip occurs the motor may be overloaded Check the motor current with an AC RMS responding ammeter Also the CL setting may be set too low See Section 12 6 on page 31 1 Use the On Off AC Line Switch to turn the power off and on approximately 15 seconds If the cover is opened observe that the Status LED ST changes...

Page 34: ...orms the user that all drive and microcontroller operating parameters are normal Table 7 summarizes the ST LED functions TABLE 7 OPERATING CONDITION AND STATUS LED INDICATOR Status LED Operating Condition Flash Rate 1 Color Normal Operation Slow Green Overload 120 160 Full Load Steady Red 2 Overload Trip Drive Timed Out Quick Red 2 Short Circuit Slow Red Undervoltage Quick Red Yellow Undervoltage ...

Page 35: ...35 NOTES ...

Page 36: ...pressed or implied KB Electronics Inc is 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 and therefore they may not apply to you In any event the total liability of KB Electronics Inc und...

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