INSTALLATION AND OPERATING INSTRUCTIONS VARI-DRIVE TM 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 VARI-DRIVE TM DC MOTOR SPEED CONTROL 40 50 60 ON 70 30 20 80 10 90 0 OFF 100 (%) SPEED TM See Page 2 ! See Safety Warning on Page 1 The information contained in this manual is intended to be accurate.
TABLE OF CONTENTS Section Page i. Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 II. Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 terminals L1 and L2. Be sure the model number corresponds to the correct input voltage. MODEL NO.
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.
TABLE 2 – ELECTRICAL RATINGS Model No. Part No. Input Voltage (VAC - 50/60 Hz) Max. AC Load Current (RMS Amps) KBWM-120 9380 115 KBWM-240 9381 Armature Voltage (VDC) Max. DC Load Current (DC Amps) Max. Horsepower HP, (kW) 5.0 0 – 90 3.5 1/3, (0.25) 5.0 0 – 180 3.5 3/4, (0.50) 5.0 0 – 90* 3.5 1/3, (0.25) 208/230 *Note – Step-down Operation: Motor may have reduced brush life. Consult motor manufacturer.
4 6.36 [161.50] 5.28 [134.00] 60 80 90 100 20 10 0 (%) SPEED 70 50 30 40 TM TM 0.09 R [2.30] OFF ON DC MOTOR SPEED CONTROL VARI-DRIVE 1.84 [46.80] 3.69 [93.60] REMOVE SCREWS TO OPEN CASE DO NOT REMOVE THESE (5) SCREWS. 6.81 [173.00] 3.00 [76.20] 2.31 [58.
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.
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 090 Volts DC output), set J2 to the “90V” position. See Figure 3. J2 Set for 180 Volt DC Motors (Factory Setting) J2 Set for 90 Volt DC Motors (Step-Down) 90V 180V MOUNTING The KBWM™ is mounted via the rear cover mounting strap.
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.
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.
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 FACTORY SETTING 2 SEC. RAPID 0.2 SEC. 5 SEC. SLOW C.
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.
ON/OFF SWITCH VIOLET (P3) ORANGE (P2) WHITE (P1) ENCLOSURE COVER MAX ACCEL DECEL L1 MIN I1 F+ B ENCLOSURE BASE P1 P2 P3 T L2 J2 I2 SW6 90V 180V MAIN SPEED POTENTIOMETER BLUE (SW6) WHITE (SW3) WHITE (L1) BLUE (L2) F1 SW3 WHT BLU L2 F2 CL A+ LINE GROUND SCREW L1 ARM IR A- TB1 F- J2 IS INSTALLED ON KBWM-240 ONLY CL LED PLUG-IN HORSEPOWER RESISTOR (CUSTOMER INSTALLED) LINE FUSE (FACTORY INSTALLED) ARMATURE FUSE (CUSTOMER INSTALLED) FIGURE 7 – INTERNAL CONNECTION DIAGR
– NOTES – 12
– 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.
