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 RoHS Provision for Forward-Stop-Reverse Switch (supplied). (See Sec.
SAFETY WARNING Definition of Safety Warning Symbols Electrical Hazard Warning Symbol: Failure to observe this warning could result in electrical shock or electrocution. Operational Hazard Warning Symbol: Failure to observe this warning could result in serious injury or death. This product must be installed and serviced by a qualified technician, electrician, or electrical maintenance person familiar with its operation and the hazards involved.
QUICK-START INSTRUCTIONS 1. REMOVE THE COVER: The cover must be removed to setup and wire the drive. See Section 5.1, on pages 16 and 17. 2. AC LINE INPUT SELECTION: The drive is factory set for 208/230 Volt AC Line input (Jumper J3 not installed). Install the supplied jumper to set the drive for 115 Volt AC Line input. See Section 7.1, on page 19. 3. MOTOR FREQUENCY SELECTION: Jumpers J1 and J2 are both factory set for 60 Hz motors. For other motors, see Section 7.2, on pages 19 – 21. 4.
TABLE OF CONTENTS Section Page 1 FAMILIARIZING YOURSELF WITH THE DRIVE .................................................7 2 ELECTRICAL RATINGS AND SPECIFICATIONS ...............................................9 3 INTRODUCTION .................................................................................................10 4 3.1 Standard Features ..................................................................................11 3.2 Performance Features.........................................
TABLE OF CONTENTS (CONTINUED) Section 10 11 12 13 14 Page ELECTRICAL CONNECTIONS...........................................................................24 10.1 AC Line Input and Ground .....................................................................25 10.2 Motor and Ground ..................................................................................25 10.3 AC Line Input Fusing .............................................................................
TABLE OF CONTENTS (CONTINUED) Figure Page 1 Cover Layout ........................................................................................................7 2 Drive Layout .........................................................................................................8 3 Maximum Allowed Motor Torque vs. Speed....................................................14 4 Open Ventilated Motor with External Fan Cooling .........................................
1 FAMILIARIZING YOURSELF WITH THE DRIVE The drive has a factory installed On/Off AC Line Switch and a Main Speed Potentiometer. It also has provision for a Forward-Stop-Reverse Switch (supplied). See Figure 1. Remove the cover to access the drive's jumpers, connectors, adjustable trimpots, and the terminal block to wire 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.
FIGURE 2 DRIVE LAYOUT (SHOWN WITH COVER REMOVED) 8
2 ELECTRICAL RATINGS AND SPECIFICATIONS TABLE 1 ELECTRICAL RATINGS AC Line Input Maximum Model No. Horsepower (HP (kW)) (Part No.) KBWA-23D 1/2 (0.37) (9946) KBWA-22D 1/4 (0.18) (9926) KBWA-21D 1/10 (0.07) (9925) KBWA-2P6D Subfractional (9923) KBWA-2P3D Subfractional (9922) Drive Output Fuse or Circuit Maximum Maximum Breaker Continuous Maximum Rating Load Current Voltage Volts AC Phase Current (50/60 Hz) (Ф) (Amps AC) (Amps) (RMS Amps) (Volts AC) 115 1 8.8 15 2.2 230 208 / 230 1 6.0 10 2.4 115 1 5.
3 INTRODUCTION Thank you for purchasing the KBWA Series Hybrid Drive. KB Electronics, Inc. is committed to providing total customer satisfaction by providing quality products that are easy to install and operate. The KBWA Series are Digital Drives with Analog Interface. Model KBWA-23D is housed in a NEMA 1 / IP20 vented enclosure. Models KBWA-22D, 21D, 2P6D, 2P3D are housed in a NEMA 1 / IP50 non vented enclosure.
3.1 STANDARD FEATURES Model KBWA-23D: Housed in a NEMA 1 / IP20 vented enclosure. Models KBWA-22D, 21D, 2P6D, 2P3D: Housed in a NEMA 1 / IP50 non vented enclosure. Dual Voltage AC Line Input Operation: The drive operates from 115 and 208/230 Volt 50/60 Hz AC Line input. See Section 7.1, on page 19. Simple to Operate: Does not require programming. Uses trimpots and jumpers, which are factory set for most applications.
3.3 PROTECTION FEATURES 2 Motor Overload (I t) with RMS Current Limit: Provides motor overload protection which prevents motor burnout and eliminates nuisance trips. UL approved as an oveload protector for motors. See Section 12.6, on page 31. Electronic Inrush Current Limit (EICL™): Eliminates harmful inrush AC line current during startup. Short Circuit: Prevents drive failure if a short circuit occurs at the motor (phase-tophase).
3.6 CUSTOMIZATION FOR OEMs Custom Software: The drives are preset and ready to use "out-of-the-box". Custom front panels are also available. The drive can be factory programmed for applications that require special switching, timing, PLC functions, and GFCI operation. Contact our Sales Department. 4 IMPORTANT APPLICATION INFORMATION 4.1 50 Hz MOTORS The drive is factory set for 60 Hz motors (Jumper J1 set to the "60 Hz" position). For 50 Hz motors, set Jumper J1 to the "50 Hz" position.
4.3 MOTOR WITH EXTERNAL FAN COOLING Most totally enclosed fan-cooled (TEFC) and open ventilated 3-phase AC induction motors will overheat if used beyond a limited speed range at full torque. Therefore, it is necessary to reduce motor load as speed is decreased. Note: Some fan-cooled motors can be used over a wider speed range. Consult the motor manufacturer for details. WARNING! Some motors have low speed characteristics which cause overheating and winding failure under light load or no load conditions.
If external fan cooling is provided, open ventilated motors can also achieve an extended speed range at full rated torque. A box fan or blower with a minimum of 100 CFM per HP is recommended. Mount the fan or blower so the motor is surrounded by the airflow. See Figure 4. FIGURE 4 OPEN VENTILATED MOTOR WITH EXTERNAL FAN COOLING 4.4 ELECTRONIC MOTOR OVERLOAD PROTECTION 2 The drive contains Modified I t Overload Protection (UL approved as an oveload protector for motors).
5 REMOVING AND INSTALLING THE COVER The cover must be removed to set up the drive. See Section 5.1, below, for instructions on removing the cover. See Section 5.2, on page 17, for instructions on installing the cover. Model KBWA-23D is housed in a NEMA 1 / IP20 vented enclosure. Models KBWA-22D, 21D, 2P6D, 2P3D are housed in a NEMA 1 / IP50 non vented enclosure. Note: To install the supplied Forward-Stop-Reverse Switch, remove the cover, as described in Section 5.
FIGURE 5 COVER POSITIONED ON TOP OF CASE (All Wires Omitted for Clarity) 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.
6 INSTALLING THE SUPPLIED FORWARD-STOP-REVERSE SWITCH The Forward-Stop-Reverse Switch is used to change motor direction. The switch assembly easily installs onto the cover. Follow steps 1 – 10, below, and see Figure 6. WARNING! Disconnect the main power before installing the Forward-Stop-Reverse Switch. Installing the Forward-Stop-Reverse Switch 1. Remove the cover, as described in Section 5.1, on pages 16 and 17. 2. Remove the hole plug from the cover. 3. Remove the jumper from CON2 (F-S-R). 4.
7 SETTING SELECTABLE JUMPERS The drive has selectable jumpers which must be set before the drive can be used. For the location of jumpers, see Figure 2, on page 8. 7.1 AC LINE INPUT VOLTAGE SELECTION (JUMPER J3) The drive is factory set for 208/230 Volt AC Line input (Jumper J3 not installed). For 115 Volt AC line input, install Jumper J3 (supplied) onto the two PC board quickconnect terminals. See Figure 7. Note: 230 Volts AC will be applied to the motor with 115 Volt AC line input.
FIGURE 8 60 Hz AND 50 Hz MOTOR SELECTION 60 Hz Motor Operation (Factory Setting) 50 Hz Motor Operation (J1 Installed in "60 Hz" Position) (J1 Installed in "50 Hz" Position) (J2 Installed in "X1" 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.
For 120 Hz output with 60 Hz motor, be sure Jumper J1 is set to the "60 Hz" position and set Jumper J2 to the "X2" position. For 100 Hz output with 50 Hz motor, set Jumper J1 to the "50 Hz" position and set Jumper J2 to the "X2" position. See Figure 10.
7.3.2 MANUAL START MODE The Manual Start Mode is used to manually start the drive or restart the drive (reset) if a fault has occurred. Remove the jumper that FIGURE 12 MANUAL START (Jumper Removed from CON1) is installed on CON1. See Figure 12. Important Note: To operate the drive in the Manual Start Mode, the supplied Forward-Stop-Reverse Switch must be installed. See Section 6, on page 18.
8 MOUNTING Use the supplied mounting template to facilitate locating the holes to mount the drive. It is recommended that the drive be mounted vertically on a flat surface with adequate ventilation. Leave enough room below the drive to allow for AC Line, motor connections, and any other connections that are required. Care should be taken to avoid extreme hazardous locations where physical damage can occur.
9 RECONDITIONING THE BUS CAPACITORS This drive contains bus capacitors which must be reconditioned if the drive has been in storage for over one year. To recondition the capacitors, apply the AC Line for a minimum of one hour, with the Main Speed Potentiometer set to zero, or set the Forward-Stop-Reverse Switch, if installed, to the Stop position.
TABLE 4 TERMINAL BLOCK TB1 WIRE AND TIGHTENING TORQUE SPECIFICATIONS Copper Wire Size Range (Solid or Stranded*) Stripping Length Tightening Torque Range 2 AWG mm in mm in-lbs kg-cm 0.25 6 30 – 14 0.05 – 2.08 4.4 – 5.3 5.1 – 6.1 *If using stranded wire, be sure that all strands are contained in the terminal block housing. 10.1 AC LINE INPUT AND GROUND Connect the single-phase AC line input to TB1 Terminals "L1" and "L2". Connect the Ground (earth) to TB1 Terminal "GND". See Figure 15, on page 26.
FIGURE 15 AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS Drive Wired for Drive Wired 208/230 Volt AC Line Input for 115 Volt AC Line Input (J3 Not Installed) (Factory Setting) (J3 (Supplied) Installed) 10.3 AC LINE INPUT FUSING The drive 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.
11 HIGH VOLTAGE DIELECTRIC WITHSTAND TEST (HI-POT TEST) DESCRIPTION Testing agencies such as UL, CSA, etc., usually require that equipment undergo an AC Hi-Pot Test. In order to prevent catastrophic damage to the drive, which has been installed in the equipment, the following procedure is recommended. A typical Hi-Pot Test Setup is shown in Figure 16, on page 28. All drives have been factory hi-pot tested in accordance with UL requirements. DC Hi-Pot Test Voltage = ((Line Voltage X 2) + 1000) X 1.
FIGURE 16 TYPICAL HI-POT TEST SETUP 12 TRIMPOT ADJUSTMENTS The drive contains trimpots which are factory set for most applications. See Figure 2, on page 8, for the location of the trimpots and their approximate factory calibrated positions. Some applications may require readjustment 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.
12.1 MINIMUM SPEED TRIMPOT (MIN) Sets the minimum speed of the motor. The MIN Trimpot is factory FIGURE 17 MINIMUM SPEED TRIMPOT (MIN) RANGE set to 0% of frequency setting. For a higher minimum speed setting, rotate the MIN Trimpot clockwise. See Figure 17. 12.2 MAXIMUM SPEED TRIMPOT (MAX) Sets the maximum speed of the motor. The MAX Trimpot is factory FIGURE 18 MAXIMUM SPEED TRIMPOT (MAX) RANGE set to 100% of frequency setting. For a higher maximum speed setting, rotate the MAX Trimpot clockwise.
12.4 DECELERATION TRIMPOT (DEC) Sets the amount of time for the motor to decelerate from full speed to zero speed. The DEC Trimpot is factory set to 1.5 seconds. FIGURE 20 DECELERATION TRIMPOT (DEC) RANGE For longer deceleration time, rotate the DEC Trimpot clockwise. For more rapid deceleration, rotate the DEC Trimpot counterclockwise. See Figure 20. Application Note: On applications with high inertial loads, the deceleration may automatically increase in time.
12.6 CURRENT LIMIT TRIMPOT (CL) 2 Motor Overload (I t) with RMS Current Limit (CL) sets the current limit (overload), which limits the maximum current to the motor, prevents motor burnout, and eliminates nuisance trips. In order to ensure that the motor is properly protected with 2 the I t feature, it is required that the CL Trimpot be set for 160% of the motor nameplate rating. The CL Trimpot is factory set to 160% of the drive’s Maximum Continuous Load Current rating.
13 DRIVE OPERATION 13.1 START-UP PROCEDURE After the drive has been properly setup (jumpers and trimpots set to the desired positions) and wiring completed, the startup procedure can begin. WARNING! The motor will run at the Main Speed Potentiometer setting when the AC Line is applied to the drive and the On/Off AC Line Switch is set to the on position. To start the drive, set the On/Off AC Line Switch to the "On" ("I") position.
TABLE 6 FAULT RECOVERY AND RESETTING THE DRIVE* (In Automatic Start Mode (Jumper Installed Onto CON1 (Factory Setting)) Fault Drive Recovery Drive will automatically start after the bus voltage returns to the Undervoltage operational level or when the drive is first turned on (power up). Drive will automatically start after the bus voltage returns to the Overvoltage operational level. Short Circuit After two faults, the drive must be restarted using the AC line.
14.1 ILLUMINATED ON/OFF AC LINE SWITCH The On/Off AC Line Switch will illuminate when the AC line is applied to the drive and the switch is in the ON ("I") position. 14.2 POWER ON LED (PWR) The "PWR" LED, located on the drive's PC board, will illuminate green when the AC line is applied to the drive and the On/Off AC Line Switch is set to the on ("I") position. 14.3 STATUS LED (ST) The "ST" LED, located on the drive's PC board, is a tricolor LED which provides indication of a fault or abnormal condition.
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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.
