KB Electronics KBWS-12 Page 2 Installation And Operating Instructions Manual Download

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TABLE OF CONTENTS

Section

Page

Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ii.

Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

II.

Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

III. Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

IV. Setting Selectable Jumper (On Dual Voltage Models) . . . . . . . . . . . . . . . . . . . 15

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

Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Plug-In Horsepower Resistor® Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Recommended AC Line Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Summary of Contents for KBWS-12

Page 1: ...urate However the manufacturer retains the right to make changes in design which may not be included herein 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 TM A COMPLETE LINE OF MOTOR DRIVES 2001 KB Electronics Inc Hi Pot Tested 1500 VAC Note A PLug In Horsepower Resistor must be installed for this product to opera...

Page 2: ... 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 Electrical Ratings 10 2 General Performance Specifications 11 3 Plug In Horsepower Resistor Selection 12 4 Recommended AC Line Fuse ...

Page 3: ...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 ...

Page 4: ... 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 ...

Page 5: ...fect sensitive electronic equipment If further information is required on this product con tact 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 ...

Page 6: ...ermanent 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...

Page 7: ...it 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 protecti...

Page 8: ...n Horsepower Resistor Supplied Separately KBWS 180V 90V A A L1 L2 CL PWR ON J1 P3 P2 P1 CON1 IR CL DEC MIN ACC MAX FIGURE 1 CONTROL LAYOUT Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings ...

Page 9: ...9 KBWS 180V 90V A A L1 L2 CL PWR ON J1 P3 P2 P1 CON1 IR CL DEC MIN ACC MAX 2 98 75 8 1 23 31 4 0 48 12 3 4 30 109 2 3 62 92 1 3 80 96 5 FIGURE 2A MECHANICAL SPECIFICATIONS Inches mm ...

Page 10: ...ts AC Motor Voltage Volts DC Maximum AC Line Current Amps AC Maximum Load Current Amps DC KBWS 12 KBWS 15 KBWS 22D KBWS 25D 3 4 0 5 9490 9491 9492 9493 115 115 115 208 230 208 230 115 208 230 208 230 0 90 130 0 90 130 0 90 130 0 180 220 0 90 130 0 90 130 0 90 130 0 180 220 4 0 3 4 0 5 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 ...

Page 11: ... for 2 Minutes Switching Frequency at Motor kHz Signal Following Input Voltage Range Volts DC Maximum Speed Trimpot MAX Range Base Speed Minimum Speed Trimpot MIN Range Base Speed Acceleration Trimpot ACC Range Seconds Deceleration Trimpot DEC Range Seconds Current Limit Trimpot CL Range Full Load IR Compensation Trimpot IR Range at 90 130 Volts DC Output Volts DC IR Compensation Trimpot IR Range ...

Page 12: ...ial Do not fuse neutral or grounded conductors See Section VIII on page 18 A separate AC line switch or contactor must be wired as a disconnect so that each ungrounded con ductor is opened See Application Note Section VII on page 18 0 18 SCR Rated Motor Horsepower Ranges HP PWM Rated Motor Horsepower Ranges HP Motor Current Amps DC 9836 3 3 5 0 Plug In Horsepower Resistor 90 Volt DC 180 Volt DC 13...

Page 13: ...than is desired disconnect power and reverse the motor leads C Main Speed Potentiometer Connection The control is supplied with a Main Speed Potentiometer Connect the Main Speed Potentiometer high side to P3 terminal wiper to P2 terminal and low side to P1 terminal as shown in Figure 5 Rotating the Main Speed Potentiometer clockwise will increase motor speed Rotating the Main Speed Potentiometer c...

Page 14: ... the control will accelerate to the Main Speed Potentiometer setting F Enable Circuit Connection The control can also be started and stopped with an Enable Circuit close to start See Figure 8 The Enable function is established by wiring a switch in series with the high side of the Main Speed Potentiometer lead which connects to the P3 terminal When the Enable switch is closed the control will acce...

Page 15: ...TRUCTIONS It is recommended that the control be mounted on a flat surface with adequate ven tilation If the control is mounted in a closed unventilated location a minimum of a 12 x 12 x 12 enclosure should be used to allow for proper heat dissipation The maximum allowable ambient temperature at full rating is 45 ºC 113 ºF Care should be taken to avoid extreme hazardous locations where physical dam...

Page 16: ...and other auxiliary equipment are mounted B The hi pot tester must have an automatic ramp up to the test voltage and an automatic ramp down to zero voltage Note If the hi pot tester does not have automatic ramping then the hi pot out put must be manually increased to the test voltage and then manually reduced to zero This procedure must be followed for each machine tested A suggest ed hi pot teste...

Page 17: ...DIELECTRIC WITHSTAND TESTER MOTOR SPEED CONTROL HI POT TESTER SIGNAL INPUTS TERMINALS L1 L2 FRAME CHASSIS CHASSIS MOTOR MOTOR WIRES AC LINE INPUTS RESET TEST TO BOTH CONNECT HI POT AC LINE INPUT LEAKAGE 0mA 10mA MAX ZERO VOLTAGE AUXILIARY EQUIPMENT MACHINE OR EQUIPMENT FRAME L1 L2 P1 P2 P3 FIGURE 10 HI POT TEST SETUP ...

Page 18: ... conductor contain circuit protec tion It is recommended to install a fuse Littelfuse 326 BUSS ABC or equivalent or a circuit breaker in series with each unground ed conductor An AC Line Fuse Kit P N 9851 is available Check all electrical codes that apply to the application See Table 4 IX TRIMPOT ADJUSTMENTS The KBWS contains trimpots which are factory set for most applications Figure 1 on page 8 ...

Page 19: ...X trimpot clockwise For a lower maximum speed setting rotate the MAX trimpot counterclockwise See Figure 11 To Calibrate the MAX Trimpot 1 Adjust the MAX trimpot to the desired position and set the Main Speed Potentiometer for full output voltage 2 Monitor the armature voltage and readjust the MAX trimpot to the desired voltage B Minimum Speed MIN Sets the minimum speed of the motor The MIN trimpo...

Page 20: ...s factory set to 1 second To increase he deceleration time rotate the DEC trimpot clock wise To decrease the deceleration time rotate the DEC trimpot counterclockwise See Figure 14 E Current Limit CL Sets the current limit over load which limits the maximum current to the motor The CL trimpot is factory set to 150 of the nominal motor current established by the Plug In Horsepower Resistor See Tabl...

Page 21: ... current limit CL setting is reached WARNING Do not leave the motor shaft locked for more that 2 3 seconds or motor damage may result F IR Compensation IR Sets the amount of compensating voltage required to keep the motor speed constant under changing loads The IR trimpot is factory set for 10 Volts at 180 220 Volts DC output and 5 Volts at 90 130 Volts DC output For higher compensating voltage ro...

Page 22: ...r ational status A Power On PWR ON The PWR ON LED will illuminate green when the AC line is applied to the control B Overload CL The CL LED will illuminate red when the control goes into cur rent limit indicating that the current limit set point has been reached established by the CL trimpot setting and the selection of the Plug In Horsepower Resistor If the CL LED remains illuminated during norma...

Page 23: ...roper Plug In Horsepower Resistor is not installed See Table 3 on page 12 XI OPTIONAL ACCESSORIES Complete instructions and connection diagrams are supplied with all accessories to facilitate installation A DIN Rail Mounting Kit P N 9995 Allows mounting of the control to a DIN rail B Product Safety Module PSM P N 8611 Protects the machine operator from injury due to a runaway or uncontrolled accel...

Page 24: ...e 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 exclu sions or limitations found in this warranty and therefore they may not apply to you In any event the total liability of KB Electronics Inc under any circumstance shall not exceed the full purchase...

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