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).
TABLE OF CONTENTS Section Page i. Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 II. Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 III.
Figures 1. Pages Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2A. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2B. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3. Plug-In Horsepower Resistor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4. Power Connections . . . . . . . .
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.
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.
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.
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.
FIGURE 1 – CONTROL LAYOUT (Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings) 180V 90V KBWS P2 A- P3 A+ J1 P1 L1 CON1 L2 CL PWR ON Plug-In Horsepower Resistor® (Supplied Separately) MAX 8 MIN ACC DEC CL IR
FIGURE 2A – MECHANICAL SPECIFICATIONS (Inches / [mm]) 4.30 [109.2] 0.48 [12.3] 180V 90V KBWS P2 A- P3 P1 2.98 [75.8] L1 CON1 L2 CL PWR ON 3.62 [92.1] 1.23 [31.4] A+ J1 MAX MIN ACC DEC CL IR 3.80 [96.
FIGURE 2B – MECHANICAL SPECIFICATIONS (Inches / [mm]) Ø0.19 [Ø4.83] 8 PLACES 0.95 [24.1] KBWS-12: 2.19 [55.5] KBWS-15: 1.99 [50.5] KBWS-22D: 2.19 [55.5] 1.25 [31.8] KBWS-25D: 3.17 [80.5] 3.80 96.5 TABLE 1 – ELECTRICAL RATING Maximum Horsepower Rating HP, (kW) Part No. SCR Rated Motors PWM Rated Motors KBWS-12 9490 115 0 - 90, 130 4.0 2.5 1/4, (0.18) 1/3, (0.25) KBWS-15 9491 115 0 - 90, 130 8.0 5.0 1/2, (0.37) 3/4, (0.5) 115 0 - 90, 130 4.0 2.5 1/4, (0.18) 1/3, (0.
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS Parameter AC Line Voltage Regulation (% Base Speed) Armature Voltage Range at 115 Volt AC Line Input (Volts DC) Armature Voltage Range at 208/230 Volt AC Line Input (Volts DC) Specification Factory Setting 0.
! Note: Disconnect main power when installing or changing the Plug-In Horsepower Resistor®. TABLE 3 – PLUG-IN HORSEPOWER RESISTOR® SELECTION Motor Current (Amps DC) SCR Rated Motor Horsepower Ranges (HP) PWM Rated Motor Horsepower Ranges (HP) 90 Volt DC 180 Volt DC 130 Volt DC 200 Volt DC 3.3 – 5.0 1/3 – 1/2 3/4 – 1 1/2 – 3/4 2.5 1/4 1/2 1/3 1.3 – 2.0 1/8 – 1/6 1/4 – 1/3 0.7 – 1.0 1/15 – 1/10 0.4 – 0.6 0.1 – 0.3 Plug-In Horsepower Resistor® CL Setting (Amps DC) Ω Part No.
MOTOR + A+ A. AC Line Connection – Wire the AC line to L1 and L2 terminals, as shown in Figure 4. FIGURE 4 – POWER CONNECTIONS A- Warning! Do not wire switches or relays in series with the armature. Armature switching can cause catastrophic failure of motor and/or control. ! L2 L1 – B. Permanent Magnet (PM) Motor Connection – Wire the motor armature leads to A+ and A- terminals, as shown in Figure 4. On dual voltage models, be sure that Jumper J1 is set to the correAC LINE sponding motor voltage.
FIGURE 7 – INHIBIT CONNECTION INHIBIT SWITCH OR RELAY (OPEN TO RUN) FIGURE 8 – ENABLE CIRCUIT CONNECTION MAIN SPEED POTENTIOMETER (FRONT VIEW) ENABLE SWITCH OR RELAY (CLOSE TO START) HIGH (VILOET) WIPER (ORANGE) P2 LOW (WHITE) P3 P1 14 P1 F. Enable Circuit Connection – The control can also be started and stopped with an Enable Circuit (close to start). See Figure 8.
Potentiometer setting. When the Enable Switch is opened, the control will coast to the minimum speed setting. ! Warning! Do not use Enable as a safety disconnect. Use only the AC line for this purpose. IV. SETTING SELECTABLE JUMPER (ON DUAL VOLTAGE MODELS) All dual voltage KBWS models contain a selectable jumper which must be set before the control can be used. See Figure 1, on page 8, for the location of Jumper J1.
VI. RECOMMENDED HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING (Hi-Pot Testing) Note: This control has been Hi-Pot tested at 1500 Volts AC. Testing agencies such as UL, CSA, VDE, etc., usually require that equipment undergo a hi-pot test. In order to prevent catastrophic damage to the speed control, which has been installed in the equipment, it is recommended that the following procedure be followed. Figure 10, on page 17 shows a typical hi-pot test setup.
FIGURE 10 – HI-POT TEST SETUP HIGH VOLTAGE DIELECTRIC WITHSTAND TESTER (HI-POT TESTER) 1 LEAKAGE 2 0 3 AC KILOVOLTS 0mA 10mA RETURN TEST H. V.
VII. OPERATION. (You must read the Safety Warning on page 5 before proceeding). After the KBWS has been properly setup, the startup procedure can begin. If AC power has been properly brought to the control, the PWR ON LED will illuminate green. Before starting, be sure that the Main Speed Potentiometer is set to the zero speed position. The motor should begin to run as the Main Speed Potentiometer is rotated clockwise.
Warning! If possible, do not adjust trimpots with main power applied. If adjustments are made with main power applied, an insulated adjustment tool must be used and safety glasses must be worn. High voltage exists in this control. Fire and/or electrocution can result if caution is not exercised. Safety Warning, on page 5, must be read and understood before proceeding. ! A. Maximum Speed (MAX) – Sets the maximum speed of the motor. The MAX trimpot is factory set for 100% of base motor speed.
To Calibrate the MIN Trimpot: 1. Adjust the MIN trimpot to the desired position and set the Main Speed Potentiometer fully counterclockwise. 2. Monitor the armature voltage and readjust the MIN trimpot to the desired voltage. C. Acceleration (ACC) – Sets the amount of time it takes for the control voltage to reach full output. The ACC trimpot is factory set to 1 second. To increase the acceleration time, rotate the ACC trimpot clockwise.
CAUTION! Adjusting the CL above 150% of motor rating can cause overheating and demagnetization of some PM motors. Consult the motor manufacturer. Do not leave the motor in a locked condition for more than a few seconds since armature damage may occur. To Calibrate the CL Trimpot: 1. Disconnect the AC power. Wire in a DC ammeter in series with either motor armature lead. Lock motor shaft. Be sure that the correct Plug-In Horsepower Resistor® is installed. 2. Set the CL trimpot fully counterclockwise. 3.
Note: If the IR compensation is set too high, unstable (oscillatory) operation will result. To Calibrate the IR Trimpot: 1. Run the motor at approximately 30 - 50% of rated speed at no load and measure the actual speed. 2. Load the motor to the rated current. Adjust the IR trimpot so that the loaded speed is the same as the unloaded speed measured in the previous step. X. DIAGNOSTIC LEDs The KBWS is designed with PC board mounted LEDs to display the control’s operational status. A.
Note: In some applications, especially those requiring the motor to cycle on and off or from one speed to another or from stop to high speed, the CL LED may blink, indicating a transient overload. This may be a normal condition for the application. 4. Proper 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.
XII. LIMITED WARRANTY For a period of 18 months from the date of original purchase, KB Electronics, Inc. will repair or replace, without charge, devices which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied.