KB Electronics IODA User Manual

INSTALLATION AND OPERATION MANUAL

IODA INPUT/OUTPUT MULTI-FUNCTION BOARD

(Part No. 9668)

Use with Models KBDA-24D, 27D, 29, 45, 48

RoHS

See Safety Warning, on page 4.

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.

(see back cover)

TABLE OF CONTENTS

Section Page

1 Safety Warning................................................................................................................. 4

2 Introduction ......................................................................................................................5

3 Installation Instructions .....................................................................................................7

4 Electrical Connections....................................................................................................13

5 Operation .......................................................................................................................38

6 Programmable Function Summary List...........................................................................40

7 Diagnostic LEDs............................................................................................................. 43

Limited Warranty..................................................................................................................44

Table Page

1 Terminal Block TB1 Wire and Tightening Torque Specifications.....................................14

2 Functions, Features, and Terminal Assignment..............................................................14

3 Multi-Function Input Terminal, Function No., and Code Assignment.............................. 15

4 Preset Frequency Selection............................................................................................15

5 Unidirectional Preset Frequency Selection with 2-Wire Start/Stop Programming............17

6 Unidirectional Preset Frequency Selection with 3-Wire Start/Stop Programming............18

7 Bidirectional Preset Frequency Selection Programming................................................. 19

8 Unidirectional Up/Down Frequency Control Programming..............................................21

9 Bidirectional Up/Down Frequency Control Programming................................................22

10 Accel/Decel "2" Programming.........................................................................................23

11 Forward/Stop-Reverse/Stop Programming..................................................................... 24

12 External Fault Programming...........................................................................................25

13 Reset Programming........................................................................................................26

14 Analog Input "1" Electrical Ratings................................................................................. 28

15 Analog Input "1" Signal Voltage Following Programming................................................29

16 Analog Input "2" Electrical Ratings................................................................................. 30

17 Analog Input "2" Signal Current Following Programming................................................ 30

18 Analog Outputs "1" and "2" Electrical Ratings.................................................................31

19 Analog Outputs "1" and "2" Programming.......................................................................32

20 Remote Unidirectional Main Speed Potentiometer Program ming................................... 34

21 Remote Bidirectional Main Speed Potentiometer Programming ..................................... 34

22 Remote Main speed Potentiometer Operation with Forward/Reverse Programming......35

23 Multi-Function Output Relay Contacts Programming......................................................37

24 Multi-Function Open Collector Output Programming......................................................38

25 Multi-Function Open Collector Outputs Electrical Ratings...............................................38

26 Digital Readout Codes....................................................................................................40

27 Status Indicator LED.......................................................................................................43

TABLE OF CONTENTS (CONTINUED)

Figure Page

1 IODA Layout.....................................................................................................................6

2 KBDA Layout.................................................................................................................... 7

3 Exploded View of KBDA and IODA Assembly.................................................................. 8

4 Preparing the Drive for Installation of the IODA................................................................9

5 Installing the IODA PC Board onto the Mounting Base.....................................................9

6 Installing the IODA into the Drive.................................................................................... 10

7 Installing the Ribbon Cable into the IODA CON1............................................................10

8 IODA Installed into Model KBDA-24D.............................................................................11

9 IODA Installed into Models KBDA-27D, 29, 45, 48......................................................... 12

10 Terminal Block TB1 Layout.............................................................................................13

11 Unidirectional Preset Frequency Selection with 2-Wire Start/Stop Connections.............17

12 Unidirectional Preset Frequency Selection with 3-Wire Start/Stop Connections.............17

13 Bidirectional Preset Frequency Selection Connections...................................................18

14 Unidirectional Up/Down Frequency Control with 2-Wire Start/Stop Connections............ 20

15 Bidirectional Up/Down Frequency Control Connections................................................. 22

16 Accel/Decel "2" Connections.......................................................................................... 23

17 Forward/Stop-Reverse/Stop Connections....................................................................... 24

18 External Fault Connections.............................................................................................25

19 Reset Connections......................................................................................................... 26

20 Analog Input "1" and "2" Signal Gain and Offset with Positive Slope..............................27

21 Analog Input "1" and "2" Signal Gain and Offset with Negative Slope.............................28

22 Analog Input "1" Signal Voltage Following Connections................................................. 29

23 Analog Input "2" Signal Current Following Connections..................................................30

24 Analog Outputs "1" and "2" Gain ....................................................................................31

25 Analog Outputs "1" and "2" Connection.......................................................................... 32

26 Remote Unidirectional Main Speed Potentiometer Connections..................................... 33

27 Remote Bidirectional Main Speed Potentiometer Connections....................................... 34

28 Remote Main Speed Potentiometer with Forward/Reverse Connections........................35

29 Multi-Function Output Relay Contacts Connections........................................................36

30 Multi-Function Open Collector Output Connections........................................................38

31 Typical Application for Open Collector Output ................................................................39

● IODA Input/Output Multi-Function Board.

● Small Mounting Base (for Model KBDA-24D only).

● Large Mounting Base (for Models KBDA-27D, 29, 45, 48).

● One 6-32 X ½" and one 6-32 X 1" Socket Head Cap Screw (for Small Mounting Base).

● Two 6-32 X 1½ " Socket Head Cap Screws (for Large Mounting Base).

● 7/64" Allen key.

● IODA Input/Output Multi-Function Board Installation and Operation Manual.

● 4" Heat Shrink Tubing (used to enclose IODA wires when using the optional AC line filter).

● CE Approved Product Information Card.

● Warranty Registration Card.

ITEMS INCLUDED IN THIS PACKAGE

1 SAFETY WARNING

Definition of Safety Warning Symbols

Electrical Hazard Warning Symb o l:

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 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 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 1/2006)

The IODA 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 AC line for this purpose.

Be sure to read this manual in its entirety and follow all instructions carefully before proceeding with the installation and operation. Fire and/or electrocution can result due to improper use of this product.

2 INTRODUCTION

Thank you for purchasing the IODA Input/Output Multi-Function Board.

KB Electronics, Inc. is committed to providing total customer satisfaction by producing quality products that are easy to install and operate.

The IODA Input/Output Multi-Function Board provides a variety of functions which

include preset frequency, up/down frequency control, signal isolation, isolated output voltage for controlling auxiliary devices, output relay contacts, and open collector outputs. The IODA mounts on the drive's PC board with 2 snap-ins (located on the bottom of the mounting base) and 2 screws (provided). All of the IODA inputs and outputs are isolated from the AC line.

The IODA has a green power on LED (PWR) and a red status LED (STATUS), which

are used to provide operational information of the IODA. See Table 27, on page 43, for a description of the status LED. See Figure 1, on page 6, for the IODA layout. See Figure 10, on page 13, for Terminal Block TB1 Layout. See Table 1, on page 14, for Terminal Block TB1 Wire and Tightening Torque Specifications. See Table 2, on page 14, for the Functions, Features, and Terminal Assignment. See Sections 4.1 – 4.6, on pages 15 – 26, describing the use of the IODA Multi-Function Input Terminals for remote operations. See Sections 4.7 – 4.11, on pages 26 – 39, for other functions and features of the IODA.

STANDARD FEATURES

▪ Signal Input Isolation: Provides isolation between signal sources and the drive. ▪ Potentiometer Operation: A 5 kΩ potentiometer can be used to in lieu of the

Keypad or the Built-In Potentiometer. The Main Speed Potentiometer can be connected for forward, reverse, or bidirectional motor speed control.

▪ Multi-Function Input Terminals: Used for a variety of functions, which include

Preset Frequency; Up/Down Frequency Command; Forward/Stop and Reverse/Stop Command; External Fault; Reset; 2-Wire and 3-Wire Start/Stop.

▪ Multi-Function Output Relays: Two Multi-Function Output Relays are provided,

which can be programmed for Run, Fault, Target Frequency, Frequency Threshold

Level, I

▪ Multi-Function Open Collector Outputs: Two Multi-Function Output Relays are

▪ Isolated Signal Output: Two isolated analog signal outputs are provided, which can

t or I•t Fault, Load Loss, External Fault, and Motor Overload.

provided, which can be programmed for Run, Fault, Target Frequency, Frequency Threshold Level, I

t or I•t Fault, Load Loss, External Fault, and Motor Overload.

be used to monitor Motor Frequency, set Frequency, Motor Voltage Bus Voltage, and Motor Current. Analog Output 1 provides a 0 – 5 Volt DC signal output. Analog Output 2 can be programmed for 0 – 5 Volt DC, 4 – 20 mA DC, or for 0 – 20 mA DC.

▪ Selectable Jumpers: For voltage or current signal selection. ▪ Multi-Turn Trimpots: For fine adjustment and attenuation of signal inputs. ▪ LEDs: The green power on LED (PWR) indicates that power is applied to the IODA

from the drive. The red status LED (STATUS) provides indication of the IODA operation.

▪ Barrier Terminal: All connections to the IODA are made via the barrier terminal

block. All terminal block connections of the IODA are isolated from the AC line.

▪ Easy Installation: Uses a snap-in base and two screws (provided) for mounting and

a ribbon cable for wiring to the drive.

FIGURE 1

IODA LAYOUT

*The IODA kit contains 2 mounting bases. Use the small base for Model KBDA-24D and the large base for Models KBDA-27D, 29, 45, 48.

FIGURE 2

KBDA LAYOUT

*Model KBDA-24D shown. Layout of Models KBDA-27D, 29, 45, 48 varies slightly.

3 INSTALLATION INSTRUCTIONS

The IODA is designed to be installed onto the KBDA PC board with a mounting base

and screws provided. The ribbon cable in the KBDA contains a connector which is to be plugged into the mating connector on the IODA. See Figures 8 and 9, on pages 11 and 12, showing the IODA installed onto the KBDA PC board.

See Figure 3, on page 8, for the exploded view of the KBDA and IODA assembly.

WARNING! HIGH VOLTAGE – Read Safety Warning, on page 4, before using the drive. Disconnect main power before making connections to the IODA or the drive. To avoid electric shock, be sure to properly ground the drive.

EXPLODED VIEW OF KBDA AND IODA ASSEMBLY (KBDA-24D SHOWN)

FIGURE 3

3.1 PREPARING THE DRIVE FOR INSTALLATION OF THE IODA Use the Allen Key (supplied) to remove the two socket head cap screws located

at the top corners of the KBDA PC board. See Figure 4.

PREPARING THE DRIVE FOR INSTALLATION OF THE IODA*

FIGURE 4

*Model KBDA-24D shown. Layout of Models KBDA-27D, 29, 45, 48 varies slightly.

3.3 INSTALLING THE IODA ONTO THE MOUNTING BASE Use the small mounting base for Model KBDA-24D and the large mounting base

for Models KBDA-27D, 29, 45, 48. Align the IODA PC board holes with the two snap-ins of the mounting base and press firmly into place until the IODA PC board is secured onto the mounting base. See Figure 5.

Note: To prevent damage to components press only on the PC board, not on any

components.

INSTALLING THE IODA PC BOARD ONTO THE MOUNTING BASE

FIGURE 5

3.4 INSTALLING THE IODA INTO THE DRIVE

Place the IODA in the area where it is to be installed. Be sure the ribbon cable is

routed underneath the mounting base. Align the two snap-ins of the mounting base with the two holes on the KBDA PC board and press firmly until the mounting base is secured onto the KBDA PC board. See Figure 6.

Use the 6-32 X ½" and 6-32 X 1" screws for the small Mounting Base (see Figure

8, on page 11). Use the two 6-32 X 1½" screws for the large Mounting Base (see Figure 9, on page 12). Use the Allen Key (supplied) to tighten the screws. Do not over tighten.

Note: To facilitate the connection of the ribbon cable onto the IODA, it is

recommended that the fold of the ribbon cable be positioned in the area where the IODA and mounting base will be located, as shown in Figure 6.

FIGURE 6

INSTALLING THE IODA INTO THE DRIVE

*Model KBDA-24D shown. Layout of Models KBDA-27D, 29, 45, 48 varies slightly.

3.5 INSTALLING THE RIBBON CABLE Install the Ribbon Cable Connector,

located in the middle of the Ribbon Cable, into the Mating Connector

INSTALLING THE RIBBON CABLE

FIGURE 7

INTO THE IODA CON1

CON1 on the IODA PC board. Align the Connector Key with the Key Slot and push down until fully engaged. See Figure 7.

3.6 IODA INSTALLED INTO THE DRIVE After completing the installation, the IODA mounted in Model KBDA -24D will

resemble Figure 8 and the IODA mounted in Models KBDA-27D, 29, 45, 48 will resemble Figure 9, on page 12.

IODA INSTALLED INTO MODEL KBDA-24D

FIGURE 8

IODA INSTALLED INTO MODELS KBDA-27D*, 29, 45, 48

FIGURE 9

*Layout of Model KBDA-27D varies slightly.

4 ELECTRICAL CONNECTIONS

See Sections 4.1 – 4.11, on pages 15 – 38, for the electrical connections to the IODA. See Figure 10, below, for Terminal Block TB1 Layout. Common Terminals "8", "12",

"14", "16", "18", "20", and "22" (shown shaded) are all internally connected and can be used with the Multi-Function Input Terminals "1" – "7", Signal Inputs 1 and 2, and Signal Outputs 1 and 2.

See Table 1, on page 14, for Terminal Block TB1 Wire and Tightening Torque

Specifications. See Table 2, on page 14, for Terminal Block TB1 Functions, Features and Terminal Assignments.

WARNING! HIGH VOLTAGE – Read Safety Warning, on page 4, before

using the drive. Disconnect main power before making connections to the IODA or the drive. To avoid electric shock, be sure to properly ground the drive.

Do not depend on the LEDs or the 4-Digit Display, to no longer be illumi nated as

a guaranteed power off condition. Be sure the main power switch or circuit breaker is in the "OFF" position before servicing the drive.

Application Note: To avoid erratic operation, do not bundle the AC line and

motor wires with each other or with wires from signal following, start/stop contacts, or any other signal wires. Also, do not bundle motor wires from multiple drives in the same conduit. Use shielded cables on all signal wires over 12" (30 cm). The shield should be earth grounded on the drive side only. Connect the drive in accordance with the National Electrical Code requirements and other local codes that may apply.

Local/Remote Operation: When using the IODA with signal following or remote

start/stop, it is desirable to program the drive for Local/Remote Operation. In this mode, the drive frequency setting can be toggled between a process signal and the keypad using the JOG-LCL/REM Key. The following functions can be switched between "remote" and "local" (Keypad) operation: Start/Stop, Forward/Reverse, Analog Signal Inputs 1 and 2, and Up/Down Frequency Control.

Set Jog-Local/Remote (Function No. 2.02) to Jog Disabled; Local/Remote Enabled ("0002") to change the JOG-LCL/REM Key from Jog Operation to Local/Remote Operation.

Note: To stop the drive using the Keypad, when in Remote Operation, first press the JOG-LCL/REM Key and then the Stop Key.

FIGURE 10

TERMINAL BLOCK TB1 LAYOUT

Common Terminals "8", "12", "14", "16", "18", "20", and "22" are all internally connected and are shown shaded.

TABLE 1

TERMINAL BLOCK TB1 WIRE AND TIGHTENING TORQUE SPECIFICATIONS

Maximum Wire Size (Cu) Recommended Tightening Torque

AWG mm2 lbs-in kg-cm

16 1.3 6 7

TABLE 2

FUNCTIONS, FEATURES, AND TERMINAL ASSIGNMENT

Terminal Assignment

Multi-Function Input Terminals1

(Digital Inputs)

Supply

1 – 7

0000: Preset Frequency Operation1

0001: Preset Frequency Operation1

0002: Preset Frequency Operation1

0003: Up Frequency Command

(See Function No. 7.14) 0004: Down Frequency Command

(See Function No. 7.14) 0005: Accel/Decel 2

(See Function No. 7.16)

0006: Forward/Stop Command

0007: Reverse/Stop Command

0008: External Fault

(N.O. Contact)

0009: Reset

0010: N.O. Start

(2-Wire or 3-Wire Start/Stop)

0011: N.C. Stop

Multi-Function Input Terminal Codes (Function Group 7)

(3-Wire Start/Stop) 0012: External Fault

(N.C. Contact)

Common

+5 Volts

-5 Volts

Notes: 1. Multi-Function Input Terminals "1" – "7" can be programmed for: 7 Preset Frequencies*, Up/Down Frequency Command, Accel/Decel 2, Forward/Stop, Reverse/Stop, External Fault, Reset, and 2-Wire/3-Wire Start/Stop. 2. Common Terminals "8", "12", "14", "16", "18", "20", "22" are all internally wired together and can be used with any of the MultiFunction Input Terminals "1" – "7". 3. RY1 Common (Terminal "24") is the contact common only for Relay 1. RY2 Common (Terminal "27") is the contact common only for Relay 2.

*The 7 Preset Frequencies are obtained using a combination of Terminals

Power

Function

Outputs

Open

Collector 1

Common

Open

Collector 2

Common

Analog

Outputs

Analog

Output 1

Common

Analog

Output 2

Common

Analog

Inputs

Analog Input 1

Common

Analog Input 2

Common

Multi-

Relay

Outputs

Common

RY1 N.O.

RY1

RY1 N.C.

RY2 N.O.

RY2

RY2 N.C.

1, 2, 1+2, 3, 1+3, 2+3, 1+2+3.

+ 30 hidden pages