KBBW SERIES INSTALLATION AND OPERATION INSTRUCTIONS

KBBW SERIES INSTALLATION AND OPERATION INSTRUCTIONS
KBBW SERIES
INSTALLATION AND OPERATION INSTRUCTIONS
These Installation and Operation Instructions Cover Models KBBW-12 (Part No. 9140) and KBBW-22 (Part No. 9141)
SAFETY WARNING ON PAGE 4 MUST BE READ AND UNDERSTOOD BEFORE PROCEEDING!
1
INTRODUCTION
DESCRIPTION
STANDARD FEATURES
Thank you for purchasing the KBBW Series Pulse Width Modulated ● Plug-In Horsepower Resistor® (PHR): Automatically calibrates
(PWM) DC/DC Low Voltage Motor speed control. KB Electronics, Inc. the IR Compensation and Current Limit settings when used on
is committed to providing total customer satisfaction by providing various horsepower motors. Supplied separately by your distributor.
quality products that are easy to install and operate.
● Short Circuit protection: Prevents drive failure if a short circuit
occurs at the motor.
The KBBW Series of Pulse Width Modulated (PWM) DC/DC motor ● Undervoltage protection: Shuts down the drive if the input voltage
speed controls provide excellent dynamic response to load variations. goes below the lower limit of the operating range. The drive will
The efficient PWM waveform produces an almost pure DC current to resume operation when the input voltage returns.
the motor (form factor <1.05), low audible motor noise, and provides ● Quick-Connect Terminals: Battery Input, Motor, and Inhibit.
long brush life. Pulse-by-pulse current limit provides short circuit ● Inhibit Circuit: Can be used to stop and start the drive
protection and prevents control damage due to shorted motors. electronically with a switch or contact.
Armature feedback provides excellent load regulation.
● Signal Inputs: 5 kΩ potentiometer (supplied), 0 – 5 Volt DC analog
signal, or PWM microprocessor output signal.*
The Plug-In Horsepower Resistor® (PHR) (supplied separately)
eliminates the need for recalibrating the IR Compensation and Current
TRIMPOT ADJUSTMENTS
Limit settings when the control is used on various horsepower motors. ● Minimum Speed (MIN): Sets the minimum speed of the motor.
Quick-connect terminals are standard for all connections to the drive. ● Maximum Speed (MAX): Sets the maximum speed of the motor.
Adjustable trimpots allow the drive to be tailored to specific ● Acceleration (ACCEL): Sets the amount of time for the motor to
applications. The Inhibit Circuit can be used to stop and start the drive accelerate from zero speed to full speed.
● Deceleration (DECEL): Sets the amount of time for the motor to
electronically with a switch or contact.
decelerate from full speed to zero speed.
The 5 kΩ potentiometer (supplied), a 0 – 5 Volt DC analog signal, or a ● Current Limit (CL): Sets the current limit (overload) which limits the
PWM microprocessor output signal can be used to control motor maximum current to the motor.
● IR Compensation (IR): Sets the amount of compensating voltage
speed.*
required to keep the motor speed constant under varying loads.
The optional Auxiliary Heat Sink Kit (Part No. 9142) increases the
OPTIONAL ACCESSORY
drive's current rating from 14 Amps DC to 20 Amps DC.
● Auxiliary Heat Sink Kit (Part No. 9142): Increases the drive's
current rating from 14 Amps DC to 20 Amps DC.
*When connecting multiple drives, an isolated signal or isolation diode must be used.
FIGURE 1
CONTROL LAYOUT
(Shown with Plug-In Horsepower Resistor© Installed)*
TABLE 1
GENERAL PERFORMANCE SPECIFICATIONS
Specification
10 – 15
20 – 30
Factory
Setting
──
──
Model KBBW-12 Output Voltage Range (Volts DC)
0 – 12*
──
Model KBBW-22 Output Voltage Range (Volts DC)
0 – 24*
──
Speed Range (Ratio)
50:1
──
Operating Frequency (kHz)
>16
──
Form Factor (RMS/Average Amps)
<1.05
──
Input Regulation (% Base Speed)
0.5
──
Load Regulation (% Base Speed)
1**
──
Description
Model KBBW-12 Input Voltage Range (Volts DC)
Model KBBW-22 Input Voltage Range (Volts DC)
A+
A−
L1 / B+
L2 / B−
Minimum Speed Trimpot (MIN) Range (% Base Speed)
Maximum Speed Trimpot (MAX) Range (% Base Speed)
*A Plug-In Horsepower Resistor© must be installed for the drive to
operate. See Table 3 on page 2.
0 – 30
0
60 – 100
100
Acceleration Trimpot (ACCEL) Range (Seconds)
0.1 – 10
2.5
Deceleration Trimpot (DECEL) Range (Seconds)
0.1 – 10
2.5
Current Limit Trimpot (CL) Range (% Range Setting)
0 – 200
150
IR Compensation Trimpot (IR) Range (% Rating)
0 – 30
──
Analog Input Voltage (Voltage Following) (Volts DC)
0–5
──
5k
──
0 – 40 / 32 – 104
──
Main Speed Potentiometer (1/4 Watt) (Ω)
Operating Temperature Range (°C / °F)
Operating Humidity Range (% Relative, Non-Condensing)
0 – 95
──
Storage Temperature (°C / °F)
-25 – +85 / -13 – +185
──
*The maximum output voltage is nominally 0.5 Volts DC less than the input voltage.
**Based on a motor having linear IR Compensation characteristics.
KBBW Series Installation and Operation Instructions
(A40361) – Rev. A00 – 12/18/2014
Page 1 of 4
Model No.
KBBW-12
KBBW-22
Part No.
9140
9141
TABLE 2
ELECTRICAL RATINGS*
Rating Without Auxiliary Heat Sink
Maximum
Maximum
Continuous
Input Voltage
Load Current
Horsepower
(Volts DC)
(Amps DC)
(HP (kW))
12
14
1/6 (0.12)
24
14
1/3 (0.25)
Rating With Auxiliary Heat Sink
Maximum
Maximum
Continuous
Load Current
Horsepower
(Amps DC)
(HP (kW))
20
1/4 (0.18)
20
1/2 (0.37)
*Suggested Fuse or Circuit Breaker Rating: 20 Amps for 14 Amps load current and 25 Amps for 20 Amps load current.
2
PLUG-IN HORSEPOWER RESISTOR® (PHR)
The PHR is supplied by your distributor and must be installed for the drive to operate. It is used to automatically calibrate the IR Compensation
and Current Limit based on motor horsepower. It eliminates the need to recalibrate the drive in most applications. Select the appropriate PHR
in accordance with Table 3. Be sure it is inserted completely into the mating sockets and installed as shown in Figure 1 on page 1.
TABLE 3
PLUG-IN HORSEPOWER RESISTOR® CHART*
Motor Horsepower
(HP (kW))
Plug-In Horsepower Resistor®
KB Part No.
Ω
(Individual)
0.006
9850
0.01
9843
0.015
9842
0.025
9841
Motor Current
(Amps DC)
20
14
10
6
Model
KBBW-12
1/4 (0.18)
1/6 (0.12)
1/8 (0.09)
1/14 (0.05)
Model
KBBW-22
1/2 (0.37)
1/3 (0.25)
1/4 (0.18)
1/7 (0.11)
*For a motor current that is not listed on the chart, use the next lower value Plug-In Horsepower Resistor®. Supplied separately by your distributor.
3
MOUNTING INSTRUCTIONS
The drive should be mounted on a flat surface and located in an area where it will not be exposed to contaminants such as water, metal chips,
solvents, or excessive vibration. 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 2.
FIGURE 2
MECHANICAL SPECIFICATIONS (INCH / mm)
6.265
159
5.625
143
4.30
109
3.80
96.5
0.50
12.7
0.75
19.1
A+
A−
A+
A−
L1 / B+
L2 / B−
0.18
4.6
8 Places
0.20
4X
5.08
L1 / B+
L2 / B−
2.50
63.5
1.75 2.50 3.65
44.5 63.5 92.5
0.65
16.5
4.00
102
1.00
25.4
0.95 1.25 1.65
24.1 31.8 41.9
3.025
76.8
KBBW Series Installation and Operation Instructions
(A40361) – Rev. A00 – 12/18/2014
Page 2 of 4
4
ELECTRICAL CONNECTIONS
See Figure 3 for the general connections to the drive.
FIGURE 3
GENERAL CONNECTION DIAGRAM
WARNING! Disconnect the main power
before making connections to the drive. Read
Safety Warning on page 4.
4.1 DC Input: Connect the positive (+) lead to
Terminal L1/B+ and the negative (-) lead to Terminal
L2/B-. Be sure the DC input corresponds to the drive
voltage rating, as shown in Table 2 on page 2.
Caution! Connecting the battery incorrectly will
permanently damage the drive.
A+
A−
L1 / B+
L2 / B−
4.2 DC Input Fusing: The drive does not contain a
DC input fuse. It is suggested that a fuse be installed
in series with the positive (+) DC input going to
Terminal L1/B+. For a 14 Amp load current, install a
20 Amp fuse or circuit breaker. For a 20 Amp load
current install a 25 Amp fuse or circuit breaker.
4.3 Motor Armature: Connect the positive (+) lead
to Terminal A+ and the negative (-) lead to Terminal
A-. Be sure the motor voltage corresponds to the
drive output voltage rating, as shown in Table 2 on
page 2.
Note: If the motor rotates in the incorrect direction, it
will be necessary to disconnect the DC input power
and reverse the armature leads.
4.4 Inhibit Switch or Contact: The drive can be electronically stopped and started with an Inhibit switch or contact connected to Terminals
I1 and I2. When the switch or contact is closed, the motor will coast to stop. When the switch or contact is opened, the motor will run at the
Main Speed Potentiometer or signal input setting.
Warning! Inhibit is never to be used as a safety disconnect since it is not fail-safe. Use only the DC input for this purpose.
4.5 Signal Input: The drive can be operated with a 5 kΩ Main Speed Potentiometer (supplied), a 0 – 5 Volt DC analog signal, or an isolated
PWM microprocessor signal. See Figures 4 – 6.
Note: When connecting multiple drives, an isolated signal or isolation diode must be used.
4.5.1 Main Speed Potentiometer:
Connect the potentiometer low side to
Terminal P1, the wiper to Terminal P2,
and the high side to Terminal P3. See
Figure 4.
4.5.2 Voltage Following Signal Input:
Connect the signal input negative (-) lead
to Terminal P1 and the positive (+) lead to
Terminal P2 and the. See Figure 5.
4.5.3 Microprocessor Signal Input:
Connect the isolated PWM signal negative
(-) lead to Terminal P1, the signal lead to
Terminal P2, and the positive (+) lead to
Terminal P3. The output frequency must
be 200 Hz or higher. See Figure 6.
FIGURE 4
MAIN SPEED POTENTIOMETER
FIGURE 5
VOLTAGE FOLLOWING SIGNAL INPUT
FIGURE 6
MICROPROCESSOR SIGNAL INPUT
5
ADJUSTABLE TRIMPOTS
The drive contains trimpots which have been factory set for most applications. Some applications may require readjustment of the trimpots in
order to tailor the drive for a specific requirement. See Figures 7 – 12 for the trimpot ranges and Sections 5.1 – 5.6 on page 4 for descriptions.
WARNING! If possible, do not adjust trimpots with the main power applied. If adjustments are made with the main power
applied, an isolated adjustment tool must be used and safety glasses must be worn. The Safety Warning on page 4 must be read
and understood before proceeding.
FIGURE 7
CL TRIMPOT
RANGE
(% RANGE SETTING)
FIGURE 8
IR TRIMPOT
RANGE
(% RATING)
FIGURE 9
MAX TRIMPOT
RANGE
(% BASE SPEED)
KBBW Series Installation and Operation Instructions
FIGURE 10
MIN TRIMPOT
RANGE
(% BASE SPEED)
FIGURE 11
ACCEL TRIMPOT
RANGE
(SECONDS)
FIGURE 12
DECEL TRIMPOT
RANGE
(SECONDS)
(A40361) – Rev. A00 – 12/18/2014
Page 3 of 4
5.1 Current Limit Trimpot (CL): Be sure the appropriate Plug-In Horsepower Resistor® is installed, in accordance with Table 3 on page 2.
The CL Trimpot sets the current limit (overload), which limits the maximum current (torque) to the motor. The CL also limits the DC input
inrush current to a safe level during startup. The CL Trimpot is factory set to 1.5 times the full load rating of the drive. To increase the current
limit, rotate the CL Trimpot clockwise. To decrease the current limit, rotate the CL Trimpot counterclockwise. See Figure 7 on page 3. Do not
exceed 2 times motor current rating (maximum clockwise position).
To Recalibrate the CL Trimpot:
1 Disconnect the DC input power and wire a DC ammeter in series with either motor armature lead.
2 Set the Main Speed Potentiometer to approximately 30 – 50% clockwise position.
3 Set the CL Trimpot fully counterclockwise.
4 Lock the motor shaft (be sure the CL Trimpot is set fully counterclockwise).
5 Apply power and rotate the CL Trimpot clockwise until the desired current reading is observed on the DC ammeter. Factory Current Limit
setting is 1.5 times the full load rating of the motor.
Caution! Do not leave motor shaft locked for more than 2 – 3 seconds or motor damage may result.
5.2 IR Compensation Trimpot (IR): Be sure the appropriate Plug-In Horsepower Resistor® is installed, in accordance with Table 3 on
page 2. The IR Trimpot sets the amount of compensating voltage required to keep the motor speed constant under changing loads. If the load
does not vary substantially, the IR Trimpot may be set to a minimum level (approximately 1/4 of full clockwise rotation). To increase the
amount of compensating voltage, rotate the IR Trimpot clockwise. To decrease the amount of compensating voltage, rotate the IR Trimpot
counterclockwise. See Figure 8 on page 3.
Note: Excessive IR Compensation will cause the motor to become unstable, which causes cogging.
To Recalibrate the IR Trimpot:
1 Set the IR Trimpot to approximately 25% rotation.
2 Run the motor unloaded at approximately 1/3 speed and record the RPMs.
3 Run the motor with the maximum load and adjust the IR Trimpot so that the motor speed equals the unloaded speed recorded in step 2.
4 Remove the load and recheck the RPMs.
5 If the unloaded RPM has changed, repeat steps 2 – 4 for more exact regulation.
The control is now compensated to provide minimal speed change due to changing loads.
5.3 Maximum Speed Trimpot (MAX): The MAX Trimpot sets the maximum speed of the motor when the Main Speed Potentiometer is set
fully clockwise. The MAX Trimpot is factory set to 100% of base motor speed. To increase the maximum speed, rotate the MAX Trimpot
clockwise. To decrease the maximum speed, rotate the MAX Trimpot counterclockwise. See Figure 9 on page 3.
Caution! Do not set the maximum speed above the rated motor RPM since unstable motor operation may occur.
5.4 Minimum Speed Trimpot (MIN): The MIN Trimpot sets the minimum speed of the motor when the Main Speed Potentiometer is set
fully counterclockwise. The MIN Trimpot is factory set to 0% of base motor speed. To increase the minimum speed, rotate the MIN Trimpot
clockwise. To decrease the minimum speed, rotate the MIN Trimpot counterclockwise. See Figure 10 on page 3.
5.5 Acceleration Trimpot (ACCEL): The ACCEL Trimpot is provided to allow for a smooth start over an adjustable time period each time
the DC input is applied or the Main Speed Potentiometer is adjusted to a higher speed. The ACCEL Trimpot is factory set to 2.5 seconds,
which is the amount of time it will take for the motor to accelerate from zero speed to full speed. To increase the acceleration time, rotate the
ACCEL Trimpot clockwise. To decrease the acceleration time, rotate the ACCEL Trimpot counterclockwise. See Figure 11 on page 3.
5.6 Deceleration Trimpot (DECEL): The DECEL Trimpot controls the amount of ramp-down time when the Main Speed Potentiometer is
adjusted to a lower speed. The DECEL Trimpot is factory set to 2.5 seconds, which is the amount of time it will take for the motor to decelerate
from full speed to zero speed. To increase the deceleration time, rotate the DECEL Trimpot clockwise. To decrease the acceleration time,
rotate the DECEL Trimpot counterclockwise. See Figure 12 on page 3.
Note: The deceleration time cannot be made less than the natural coast time of the motor and actual load.
6
OPERATION
After the drive has been set up properly and wiring has been completed, the start-up procedure can begin. Before starting, be sure that the
Main Speed Potentiometer is in the minimum position (fully counterclockwise). Be sure the appropriate Plug-In Horsepower Resistor® is
installed, in accordance with Table 3 on page 2. To start the drive, rotate the potentiometer clockwise. The motor should begin to rotate.
Note: If the motor rotates in the incorrect direction, it will be necessary to disconnect the DC input power and reverse the armature leads.
SAFETY WARNING! – PLEASE READ CAREFULLY!
This product must 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 electrical connections, fusing or other current protection, and grounding, can reduce the chance of
electrical shocks, and/or fires, in this product or products used with this product, such as electric motors, switches, coils, solenoids, and/or relays. Do
not use this drive in an explosion-proof application. Eye protection must be worn and insulated adjustment tools must be used when working with drive
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. 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 the drive. However, these circuits are never to be used as safety
disconnects since they are not fail-safe. Use only the DC input for this purpose. Be sure to read and follow all instructions carefully. Fire can result due
to improper use of this product.
KBBW Series Installation and Operation Instructions
(A40361) – Rev. A00 – 12/18/2014
Page 4 of 4
KB Electronics, Inc.
12095 NW 39th Street, Coral Springs, FL 33065-2516 ● (954) 346-4900 ● Fax (954) 346-3377
Outside Florida Call Toll Free (800) 221-6570 ● [email protected]
COPYRIGHT © 2014 KB Electronics, Inc.
www.kbelectronics.com
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