KB Electronics KBWM-120 & KBWM-240 Owner Manual

INSTALLATION AND OPERATING INSTRUCTIONS

TM

V

ARI

-D

RIVE

NEMA 1 / IP20 SCR Variable Speed DC Motor Controls

Model KBWM-120 rated 1/100 - 1/3 HP (90 Volts DC) @ 115 Volts AC, 50/60 Hz

Model KBWM-240 rated 1/50 - 3/4 HP (180 Volts DC) @ 208/230 Volts AC, 50/60 Hz

V D

TM

DC MOTOR

SPEED CONTROL

50

40

30

20

10

0

(%) SPEED

60

70

80

90

100

TM

ON

OFF

See Page 2

!

See Safety Warning on Page 1

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.

TM

A COMPLETE LINE OF MOTOR DRIVES

© 2001 KB Electronics, Inc.

ii

TABLE OF CONTENTS

Section Page

i.

Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ii.

Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

I.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

II.

Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

III.

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

IV.

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

V.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

VI. Trimpot Adjustments and Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

VII. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Tables

1.

General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.

Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.

Plug-in Horsepower Resistor® Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.

Armature Fuse Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.

Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6.

Field Connection (Shunt Wound Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figures

1.

Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.

Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.

Motor Voltage Selection (J2) (Model KBWM-240 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.

AC Line and Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5A. Full Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5B. Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6A. Accel Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6B. Decel Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7.

Internal Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

i.

KBWM-120, 240 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 before proceeding.

A. Power Connection – Wire AC line to ter-

minals L1 and L2. Be sure the model number corresponds to the correct input voltage.

MODEL NO. & VOLTAGE RATING

Model Number

AC Line Voltage

VAC 50/60 Hz

Armature

Voltage (VDC)

B. Permanent Magnet (PM) Motor

Connection (Two-Wire Type) – Wire

the motor armature leads to terminals

KBWM-120

KBWM-240

115

208/230

A(+) and A(-). Be sure the motor voltage corresponds to the control voltage rating and model number.

0 – 90

0 – 90*, 180

*See “G” below.

Note: Although control is specifically designed for PM motors it can also be used for shunt wound motors. (See Section IV D, page. 7.)

C. Ground – Be sure to earth ground the control by attaching a ground wire to the green stud

located between the Bx knockouts.

D. Plug-in Horsepower Resistor®** – The correct Plug-in Horsepower Resistor® must be

installed for optimum performance. (See Section II A, p. 5.)

E. Armature Fuse** – The correct value armature fuse must be installed for maximum pro-

tection. (See Section II C, p. 5.)

F. Trimpot Settings – All trimpots have been set according to Figure 1, page 3 and Section VI, page 8.

G. Jumper J2 is provided on Model KBWM-240 only and is factory set to “180V” position.

For step-down operation (208/230 Volts AC line input and 0-90 Volts DC output), set J2 to the “90V” position. See Figure 3, on page 6.

**

This control will not operate without installing the proper size Plug-in Horsepower Resistor® and armature fuse

– supplied separately.

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. 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 9/2000).

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.

1

This product complies with all CE directives pertinent at the time of manufacture. Contact factory for detailed installation and Declaration of Conformity. Installation of a CE approved

RFI filter (KBRF-200A [P/N 9945C] or equivalent) is required. Additional shielded motor cable and/or

AC line cables may be required along with a signal isolator (KBSI-240D [P/N 9431] or equivalent).

I.

INTRODUCTION

The KBWM™ Vari-Drive™ adjustable speed SCR control for DC motors offers proven reliability in a rugged all-metal NEMA-1 / IP20 enclosure. The Vari-Drives™ are equipped with the

ultimate KBMM™ speed control module. They are specifically designed for fractional horsepower permanent magnet (PM) DC motors. Two models are offered. The KBWM-120 is designed for 115 VAC input and is rated 1/100-1/3 HP at 90 VDC. The KBWM-240 is designed for 208/230 VAC input and is rated 1/50 – 3/4 HP @ 180 VDC. Note: Model

KBWM-240 can also be used on 90 Volt DC motors. See Section IID, on page 6.

KB’s exclusive Plug-in Horsepower Resistor®* automatically presets the drive’s IR Comp. for maximum performance and CL circuits for safe operation on various motors. Although factory calibrated, internal trimpots for MIN, MAX, IR, CL, ACCEL and DECEL can be used to fine-tune the KBWM™ for specific applications. Connections to the control are via a barrier terminal block. By changing the orientation of the front cover, the wiring can be brought in either from the bottom or the top of the control.

Motor failure due to demagnetization is eliminated by the patented ultra-fast Direct-Fed™ current limit circuit. The controls contain AC line and armature* fusing, which provide protection against catastrophic failure. Auto-Inhibit®, a KB exclusive, allows the drive to be turned on and off rapidly using the AC line without damage to the control and/or motor. The internal CL LED is a diagnostic indicator that lights when the motor is overloaded.

A conveniently located front panel lighted rocker switch controls AC line input power to the drive.

*Plug-in Horsepower Resistor® and armature fuse supplied separately.

TABLE 1 – GENERAL PERFORMANCE SPECIFICATIONS

Parameter

Speed Range Ratio

Armature Feedback Load Regulation (0 - Full Load, 50:1 Speed Range) (% Base Speed)

Line Voltage Regulation at Full Load, ± 10% Line Variation (% Base Speed)

Control Linearity (% Speed vs. Dial Rotation)

CL/Torque Range (% Full Load)

ACCEL Time Range (0 – Full Speed) (Secs.)

DECEL Time Range (Full – 0 Speed) (Secs.)

MIN Speed Trimpot Range (% Full Speed)

MAX Speed Trimpot Range (% Full Speed)

IR Comp. Trimpot Range (at Specified Full Load) (Volts)

Maximum Allowable Ambient Temperature at Full Rating (ºC / ºF)

Specification

50:1

1**

1/2**

2

0 – 200

0.2 – 10

0.2 – 10

0 – 30**

50 – 110**

0 – 24

50/122

**Performance is for SCR rated PM motors only. Lower performance can be expected with other motor types. Factory setting is for 3% load regulation. To obtain superior regulation, see Section VI F on page 10.

2

Model No.

Part No.

KBWM-120

KBWM-240

9380

9381

Input Voltage

(VAC - 50/60 Hz)

115

TABLE 2 – ELECTRICAL RATINGS

Max. AC

Load Current

(RMS Amps)

5.0

Armature

Voltage (VDC)

0 – 90

208/230

5.0

5.0

0 – 180

0 – 90*

Max. DC

Load Current

(DC Amps)

3.5

Max. Horsepower

HP, (kW)

1/3, (0.25)

3.5

3.5

3/4, (0.50)

1/3, (0.25)

*Note – Step-down Operation: Motor may have reduced brush life. Consult motor manufacturer.

FIGURE 1 – CONTROL LAYOUT

(Illustrates Approximate Factory Setting of Trimpots and Jumper)

L1

F1

ARM

F2

LINE

F-

ARMATURE FUSE

(CUSTOMER INSTALLED)

SEE TABLE 4, PAGE 5

LINE FUSE

(FACTORY INSTALLED)

PLUG-IN

HORSEPOWER RESISTOR

(CUSTOMER INSTALLED)

SEE TABLE 3, PAGE 5

DECEL

L2

F+

B

J2

T

ACCEL

CL LED

TB1

MAX

P2

P3

P1

I1

MIN

SW6

I2

L1

L2 A+

CL IR

A-

J2 IS INSTALLED

ON KBWM-240 ONLY

PLUG-IN HORSEPOWER RESISTOR

A Plug-in Horsepower Resistor® must be installed to match the drive to the motor horsepower and armature current. See

Table 4, page 5 for the correct value. Plug-in Horsepower

Resistors® are stocked by your distributor.

CAUTION: Be sure Plug-In

Horsepower

Resistor® is inserted completely into mating sockets.

3

4

FIGURE 2 – MECHANICAL SPECIFICATIONS (Inches / [mm])

TOP VIEW BOTTOM VIEW

II.

CONTROL SETUP

Remove the four (4) 6x32 screws (two on top and two on the bottom) from the enclosure. Slide open the control by separating the front and rear covers. See Figure 2, page 4.

A. Plug-in Horsepower Resistor® – (Must be obtained from your distributor as a separate

part.) The Plug-in Horsepower Resistor® is designed to match the control and motor without having to recalibrate the IR Comp. and CL for most applications. (Note: For recalibration of IR Comp. and CL see Section VI E, F on pages 9 and 10.) Using the Plug-in

Horsepower Resistor® chart, choose the closest value based on motor horsepower and/or armature current. (See Table 3.)

90 VDC

TABLE 3 – PLUG-IN HORSEPOWER RESISTOR® CHART

180 VDC

Motor Horsepower Range

1/100

1/50

1/30, 1/25

1/20

1/15, 1/12

1/10, 1/8, 1/6

1/4

1/3

1/50

1/25

1/15

1/10

1/6

1/4

1/2

3/4

Approx.

Motor Current

(DC Amps)

0.1

0.2

0.35

0.5

0.8

1.3

2.5

3.3

Plug-in Horsepower

Resistor® Value

(Ohms)

1.0

0.51

0.35

0.25

0.18

0.1

0.05

0.035

Individual

Plug-in Horsepower®

Resistor Part No.

9833

9834

9835

9836

9837

9838

9839

9840

Notes:

1.

Motor horsepower and armature current must be specified in order to select correct Plug-in Horsepower Resistor®.

2.

For motor horsepower not indicated, use the lower ohm value Plug-in Horsepower Resistor®.

B. AC Line Fuse – The KBWM™ contains a 5-

Amp AC line fuse used to protect the control against catastrophic failure. If fuse blows, the control may be miswired, the motor is shorted or grounded, or the speed control module is defective. Replace with Littelfuse 326, Buss

ABC or equivalent. Note: Bypassing or eliminating the fuse will void warranty.

TABLE 4 – ARMATURE FUSE

SELECTION CHART

90 VDC 180 VDC

Motor Horsepower

Range

1/100 1/50

Approx.

Motor

Current

(DC Amps)

0.1

Fuse

Rating

(AC Amps)

1/5

1/50 1/25 0.2

3/10

CAUTION: Most electrical codes require that

each ungrounded conductor contain fusing.

Separate branch fusing or circuit breakers may be required on 208/230 VAC line.

1/30

1/20

1/15

1/10

1/15

1/10

1/8

1/5

0.3

0.5

0.7

1.0

1/2

3/4

1

1 1 ⁄

2

1/8 1/4 1.3

2

C. Armature Fuse — The KBWM™ has provi-

sion for installing an armature fuse that helps protect the motor and control from damage

1/6

1/4

1/3

1/2

1.7

2.5

3

4

1/3 3/4 3.3

5 due to overload. Armature fuses are 3 AG type and are available from your distributor.

Note: An armature fuse must be installed or

Note: Specific applications may require a different fuse value than indicated. This is based on several factors such as ambient temperature.

control will not operate. Fuse value is calculated based on 1.7 times the DC current rating of the motor. See Table 4.

5

6

D. Jumper J2 is provided on Model KBWM-240 only and is factory set to “180V” position. For stepdown operation (208/230 Volts AC line input and 0-

90 Volts DC output), set J2 to the “90V” position.

See Figure 3.

FIGURE 3 – MOTOR VOLTAGE SELECTION

(MODEL KBWM-240 ONLY)

J2 Set for

180 Volt DC Motors

(Factory Setting)

J2 Set for

90 Volt DC Motors

(Step-Down)

III.

MOUNTING

The KBWM™ is mounted via the rear cover mounting strap. Before attempting to wire the control, locate the mounting holes using the rear cover as a template or use the dimensions as shown in the outline drawing. (See Figure 2, page 4.) Be sure the control is mounted on a flat surface in a location where it will not be exposed to contaminants such as water, metal chips, solvents or excessive vibration and/or temperature extremes. Note: Allow adequate clearance around control to permit motor and

AC power cables to enter through the Bx knockouts on bottom of enclosure.

When mounting in an airtight enclosure, the air space should be large enough to provide adequate heat dissipation. It is recommended that an enclosure with minimum dimensions of 12”H x 12”W x 6”D (300mm x 300mm x 150mm) be used. The maximum allowable ambient temperature at full rating is 50 ºC (122 ºF). Consult the Sales Department if more information is required.

Note: The KBWM™ can be oriented so that the AC power and motor wiring can be brought in from the top of the control. Mount the rear cover so that the Bx knockouts are located on the top by rotating the rear cover 180º. The front cover is then installed right side up using the four (4) 6x32 screws previously removed from the top and bottom of the enclosure.

After wiring the front cover, install the mating rear cover with the four (4) 6x32 screws previously removed from the top and bottom of enclosures.

IV.

WIRING

Be sure the AC power is “off” before wiring control. Read Safety Warning on page 1 before attempting to use this control.

Terminal Block

Designation

TB1

TABLE 5 – TERMINAL BLOCK WIRING INFORMATION

Connection

Designation

L1, L2, A+, A-

Supply Wire Gauge

Minimum

22

Maximum

14

Maximum Tightening Torque

(in-lbs)

3.5

!

WARNING!

To avoid erratic operation, do not bundle AC line and motor wires with potentiometer, voltage following, enable, inhibit or other signal wiring. Use shielded cables on all signal wiring over 12” (30 cm) – The shield should be earth grounded on the control side only. Wire the control in accordance with the National Electrical Code requirements and other codes that may apply to your area.

A. AC Line – Wire the AC power to terminals L1 and

L2. Be sure that the control model corresponds to the correct AC line input voltage. Model

KBWM–120 is for 115 VAC 50/60 Hz and model

KBWM–240 is for 208/230 VAC 50/60 Hz. See

Figure 4.

FIGURE 4 – AC LINE & ARMATURE

CONNECTION

TB1

SW6

L1

L2 A+

+

M

AC LINE

-

MOTOR

A-

Caution: If control is wired to a transformer, it is advisable to switch the secondary to disconnect power. If the primary is switched, additional snubber capacitors may have to be added across terminals L1 and L2 to prevent power bridge damage.

Separate branch fusing or circuit breaker may be required on 208/230 VAC applications. (See

Section IV E, on page 8.)

B. Motor Armature – Wire the motor armature wires to terminals A+ and A-. Be sure the motor voltage corresponds to the control voltage rating. See Figure 4, on page 6. Note: If motor runs in opposite direction to what is required, turn power off and reverse armature leads.

!

WARNING!

Do not wire a switch or relay in series with the armature leads.

Armature switching can cause catastrophic failure of motor and/or control. If reversing or dynamic braking is required, consult the Sales Department.

C. Ground (earth) – Be sure to ground motor and control to green ground stud located between the Bx knockouts. See Figure 7, on page 11.

D. Field (Shunt motors only) – Do not use F+ and F- terminals for any other motor type. The

KBWM™ control is primarily designed for permanent magnet (PM) motors. However, a shunt motor can also be controlled by wiring the shunt field directly to the 1/4” quick-disconnect terminals located on the main speed control module. See Figures 5A and 5B for the F+ and Fterminal locations. Attach motor field using insulated 1/4” Q-D female terminals. For

Standard PM (2-wire) motors, the Field is not used.

CAUTION: Shunt-wound motors may be damaged if field remains connected without motor rotating for an extended period of time.

TABLE 6 – FIELD CONNECTION (Shunt Wound Motors Only)

AC Line Voltage VAC Motor Voltage Field Voltage (Volts DC) Field Connection

115

115

208/230

208/230

208/230

0 – 90

0 – 90

0 – 180

0 – 180

0 – 90

100

50

200

100

100

F+, F-

F+, L1

F+, F-

F+, L1

F+, L1

FIGURE 5A – FULL VOLTAGE FIELD FIGURE 5B – HALF VOLTAGE FIELD

T

L2

F+

B

J2

F1

ARM

F2

LINE

F-

TB1

I1

SW6

I2

MIN

L1

L2

AC LINE

A+

A-

-

M

+

MOTOR

-

FIELD*

+

F1

ARM

F2

LINE

F-

T

L2

F+

B

J2

TB1

I1

MIN

SW6

I2

L1 L2

AC LINE

A+ A-

-

M

+

MOTOR

-

+

FIELD*

*Shunt motors only

7

8

E. Fusing – As indicated in Section IIB, the KBWM™ contains a single AC line fuse on

208/230 VAC applications. In the USA and other countries where the 208/230 volt is derived from two (2) “hot” leads, both AC lines should be connected to a separate dual circuit breaker. Do not fuse neutral or grounded connections.

F. AC Line Switch – The KBWM™ contains a double pole AC line switch which opens both

legs of the AC line.

V.

OPERATION

After wiring is complete, recheck connections to be sure they are correct. Also be sure correct armature fuse and Plug-in Horsepower Resistor® are installed. Turn main power on.

Internal lamp in power switch should be lighted indicating control is receiving AC line voltage.

Gradually increase main speed dial setting. Motor should rotate in proportion to dial setting.

Note: if motor runs in opposite direction to what is required, turn power off and reverse armature leads.

!

WARNING! If control is operated with cover off, be sure to wear safety glasses

and use insulated tools if any adjustments are to be made.

CL LED – A red light-emitting diode (LED) can be found on the speed control PC board. It

lights when the current limit circuit activates, indicating an overload condition. This is normal when the motor accelerates to full speed or when a transient peak load condition exists.

However, if the LED lights continuously, a severe overload condition may exist. A DC ammeter should be installed in series with either armature lead to observe motor current during actual operation. (See Safety Warning on page 1.) If the actual DC current exceeds the motor rating, a higher horsepower motor should be used. If actual current is equal to or less than the rated motor current, the CL adjustment may be incorrect, or the Plug-in Horsepower

Resistor® value may be too high. Refer to the CL trimpot adjustment procedure and the

Plug-in Horsepower Resistor® chart on page 5.

VI. TRIMPOT ADJUSTMENTS AND CONTROL FUNCTIONS

!

WARNING! If adjustments are made under power, insulated adjustment tools must

be used and eye protection must be worn.

The KBWM™ has been factory adjusted to provide 0 - full speed using the speed control knob. Minimum (MIN) and Maximum (MAX) speed trimpots are provided to change the speed settings. The acceleration (ACCEL) trimpot is provided to allow for a smooth start over an adjustable time period each time the AC power is applied or the Main Speed

Potentiometer is rotated. The DECEL trimpot controls the amount of ramp-down time when the Main Speed Potentiometer is adjusted to a lower speed. The Current Limit (CL, or torque output) adjustment is factory set to approximately 1.5 times the motor rating. The IR

Compensation (IR) is factory adjusted to provide excellent motor regulation under normal operation.

Note: For the IR Comp. and CL trimpot settings to be correct, the proper Plug-in Horsepower

Resistor® must be installed. (See Table 3 on page 5.) Do not attempt to change the settings of the trimpots unless absolutely necessary since they are factory adjusted to near optimum settings.

The following procedure, presented in order of adjustment sequence, should be used when readjusting all trimpot functions:

A. Acceleration Start – The ACCEL is

factory set at approximately 2 seconds.

To readjust to different times, set the knob to the desired position as shown in Figure 6A.

B. Deceleration – The DECEL is factory

set to provide a ramp-down time of 2 seconds. To change the ramp-down time, adjust the DECEL trimpot as indicated in Figure 6B.

FIGURE 6A – ACCEL TRIMPOT ADJUSTMENT

RAPID

0.2 SEC.

FACTORY SETTING 2 SEC.

5 SEC.

C. Minimum Speed Adjustment – If a

higher than zero minimum speed is needed, readjust the minimum speed by turning the speed control knob to zero setting (full CCW position). Then adjust the MIN speed trimpot to the desired setting.

SLOW

10 SEC.

ACCEL

8 SEC.

FIGURE 6B – DECEL TRIMPOT ADJUSTMENT

Note: The minimum speed adjustment will affect the maximum speed setting.

Therefore, it is necessary to readjust the maximum speed after the minimum speed.

D. Maximum Speed Adjustment – Turn

Speed Control Knob to full speed (full

CW position). Adjust MAX speed trimpot to new desired setting.

RAPID

0.2 SEC.

FACTORY SETTING 2 SEC.

5 SEC.

Note: Do not attempt to adjust the maximum speed above the rated motor RPM since unstable motor operation may occur. For moderate changes in the maximum speed, there will only be a slight effect on the minimum speed setting.

SLOW

10 SEC.

DECEL

8 SEC.

E. Current Limit (CL/Torque Adjustment) – CL circuitry is provided to protect the motor

and control against overloads. The CL also limits the inrush current to a safe level during startup. The CL is factory set to approximately 1.5 times the full load rating of the motor.

(CL trimpot is nominally set to approximately 65% of full CW rotation.) Note: Proper size

Plug-in Horsepower Resistor® must be installed.

To set the CL to factory specifications adjust as follows:

1. Set speed control knob at approximately 30 - 50% CW rotation. Set CL trimpot to full

CCW position.

2. Connect a DC ammeter in series with the armature lead.

3. Lock shaft of motor (be sure CL pot is in full CCW position). Apply power and rotate CL pot CW until DC ammeter reads 1.5 times motor rating. (Do not exceed 2 times motor rating.) Do not leave motor in locked rotor position for more than a few seconds or damage may occur. Note: The CL LED will illuminate when the control is in current limit.

9

10

Note: If only an AC ammeter is available, it can be installed in series with AC input line. Follow above instructions; however, set AC amperage at 0.75 motor rating.

F. IR Compensation Adjustment – IR compensation is provided to improve load regulation.

If the load presented to the motor does not vary substantially, the IR adjustment may be set at a minimum level (approximately 1/4 of full setting). The control is factory adjusted to approximately 3% regulation. If superior performance is needed (less than 1% speed change of base speed from 0 - full load), then the IR Comp. should be adjusted as follows:

Note: Excessive IR Comp. will cause control to become unstable, which causes motor cogging.

1. Set IR Comp. trimpot at approximately 25% of CW rotation. Run motor unloaded at approximately 1/3 speed and record RPM.

2. Run motor with maximum load and adjust IR Comp. trimpot so that the motor speed under load equals the unloaded speed per step 1.

3. Remove load and recheck unloaded RPM. If unloaded RPM has shifted, repeat procedure for more exact regulation.

The control is now compensated to provide minimal speed change under large variations of applied load.

FIGURE 7 – INTERNAL CONNECTION DIAGRAM

SW3

WHT

90V 180V

BLU

11

12

– NOTES –

– NOTES –

13

VII. 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. The foregoing is in lieu of any other warranty or guarantee, expressed 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., under any circumstance, shall not exceed the full purchase price of this product. (rev 2/2000)

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 • E-mail – [email protected]

www.kbelectronics.com

(A40275) – Rev. C – 6/2001