KB Electronics KBAC-217F, KBAC-48, KBAC-217SF, KBAC-416, KBAC-27D Installation And Operation Manual
...
INSTALLATION AND OPERATION MANUAL
–
KBAC SERIES
Adjustable Frequency Drive for 3-Phase AC Motors
NEMA 4X / IP65
Variable Speed / Soft-Start AC Motor Drive
With Electronic Motor Overload Protection
Washdown and Watertight for Indoor and Outdoor Use
Rated for 208 – 230 and 400/460 Volt 50 Hz and 60 Hz
3-Phase and PSC
Operates from 115, 208/230, and 400/460 Volt 50/60 Hz AC Line Input3
2
AC Induction Motors from Subfractional thru 10 HP
1
NOTE: The drive is factory set for
60 Hz motors. For 50 Hz motors,
see Section 10.4 on page 19.
KBAC-24D, 27D, 29, 29 (1P), 45, 48, 217, 217S, 217F, 217SF, 416, 416S, 416F, 416SF
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.
Notes: 1. UL approved as an electronic overload protector for motors. 2. Special software is available for PSC
motors – contact Technical Support. 3. Third Generation (3G) drives are jumper selectable (J12) for standard and sensitive
GFCIs. 4. Installation of a CE approved RFI (EMI) filter is required. 5. Third Generation (3G) drives KBAC-24D, 27D, 29,
29 (1P), 45, 48 are marked "(3G)" on the product label.
Copyright © 2017 KB Electronics, Inc.
(See Back Cover)
See Safety Warnings on page 5.
This Manual Covers 2G and 3G Models
All KBAC-217, 416 Series drives are Third Generation (3G).
3,5
LISTED
IND. CONT.
EQ.
70ZA
4
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TABLE OF CONTENTS
Section Page
1 Quick-Start Instructions .................................................................................................................................................................................... 4
1.1 Mounting Instructions .............................................................................................................................................................................. 4
1.2 AC Line Input Fusing .............................................................................................................................................................................. 4
1.3 AC Line Input Connection ....................................................................................................................................................................... 4
1.4 Motor Connection .................................................................................................................................................................................... 4
1.5 Ground Connection ................................................................................................................................................................................. 4
1.6 60 Hz and 50 Hz Motor Operation .......................................................................................................................................................... 4
1.7 Start/Stop Switch .................................................................................................................................................................................... 4
1.8 Jumper Settings ...................................................................................................................................................................................... 4
1.9 Trimpot Adjustments ............................................................................................................................................................................... 4
1.10 Diagnostic LEDs ..................................................................................................................................................................................... 4
2 Safety Warnings ............................................................................................................................................................................................... 5
3 Important Application Information ..................................................................................................................................................................... 5
3.1 Motor with External Fan Cooling ............................................................................................................................................................. 5
3.2 Electronic Motor Overload Protection ..................................................................................................................................................... 5
4 Introduction ....................................................................................................................................................................................................... 6
4.1 Standard Features .................................................................................................................................................................................. 6
4.2 Performance Features ............................................................................................................................................................................ 6
4.3 Protection Features................................................................................................................................................................................. 6
5 Mounting ......................................................................................................................................................................................................... 12
6 AC Line Input Fusing ...................................................................................................................................................................................... 15
7 Electrical Connections .................................................................................................................................................................................... 15
7.1 AC Line Input Connection ..................................................................................................................................................................... 15
7.2 Motor Connection .................................................................................................................................................................................. 16
7.3 Ground Connection ............................................................................................................................................................................... 16
7.4 Remote Main Speed Potentiometer Connection .................................................................................................................................. 16
7.5 Remote Start/Stop Switch Connections ................................................................................................................................................ 17
7.6 Automatic Restart ................................................................................................................................................................................. 17
7.7 Voltage Following Connections............................................................................................................................................................. 17
7.8 Enable Circuit Connection .................................................................................................................................................................... 17
7.9 Run/Fault Relay Connection ................................................................................................................................................................. 18
8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) .................................................................................................. 18
9 Reconditioning the Bus Capacitors ................................................................................................................................................................ 18
10 Setting Selectable Jumpers ............................................................................................................................................................................ 19
10.1 AC Line Input Voltage Selection (KBAC-24D, 27D Only) (J1) .............................................................................................................. 19
10.2 Motor Horsepower Selection (J2) ......................................................................................................................................................... 19
10.3 Automatic Ride-Through or Manual Start Selection (J3) ...................................................................................................................... 19
10.4 Motor Frequency Selection (J4 and J5) ................................................................................................................................................ 19
10.4.1 Setting the Drive for 50 Hz or 60 Hz Motor Operation (J4 and J5) .......................................................................................... 19
10.4.2 Setting the Drive for Two Times the Rated Motor RPM (J4 and J5) ........................................................................................ 19
10.5 Boost Mode Selection (J6) .................................................................................................................................................................... 20
10.6 Braking Mode Selection (J7) ................................................................................................................................................................. 20
10.7 Run/Fault Output Relay Operation Selection (J8) ................................................................................................................................ 20
10.8 Stop Contact Type Selection (J9) ......................................................................................................................................................... 20
10.9 Torque Mode Selection (J10) ............................................................................................................................................................... 20
10.10 Jumper J11 (Factory Use Only) ............................................................................................................................................................ 20
10.11 Switching Frequency and GFCI Selection (Third Generation (3G) Drives Only) (J12) ......................................................................... 20
11 Drive Operation .............................................................................................................................................................................................. 20
11.1 Start-Up Procedure ............................................................................................................................................................................... 20
11.2 Restarting the Drive After a Fault Has Cleared .................................................................................................................................... 21
12 Trimpot Adjustments ..........................................................................................................
12.1 Minimum Speed Trimpot (MIN) ............................................................................................................................................................. 21
12.2 Maximum Speed Trimpot (MAX)........................................................................................................................................................... 21
12.3 Acceleration Trimpot (ACCEL).............................................................................................................................................................. 21
12.4 Deceleration Trimpot (DECEL) ............................................................................................................................................................. 21
12.5 DC Injection Brake Trimpot (DECEL) ................................................................................................................................................... 21
12.6 Slip Compensation Trimpot (COMP) .................................................................................................................................................... 22
12.7 Motor Overload (I
12.8 Boost Trimpot (BOOST) ........................................................................................................................................................................ 22
12.9 Jog Trimpot (JOG) ................................................................................................................................................................................ 22
13 Diagnostic LEDs ............................................................................................................................................................................................. 23
13.1 Power On LED (PWR) .......................................................................................................................................................................... 23
13.3 Status LED (ST) .................................................................................................................................................................................... 23
14 Optional Accessories ...................................................................................................................................................................................... 23
Limited Warranty .................................................................................................................................................................................. Back Cover
2
t) with RMS Current Limit Trimpot (CL) ................................................................................................................... 22
............................................................................. 21
Table Page
1 Drive Model No., Part No., and Case Reference Size ...................................................................................................................................... 3
2 Electrical Ratings .............................................................................................................................................................................................. 7
3 General Performance Specifications ................................................................................................................................................................ 7
4 Terminal Block Wire Size and Tightening Torque Specifications ................................................................................................................... 15
5 Drive Operating Condition and Run/Fault Relay Contact Status .................................................................................................................... 18
6 Drive Operating Condition and Status LED Indicator ..................................................................................................................................... 23
7 Optional Accessories ...................................................................................................................................................................................... 23
2
KBAC SERIES INSTALLATION AND OPERATION MANUAL
TABLE OF CONTENTS (CONTINUED)
Figure Page
1 General Connection Diagram ........................................................................................................................................................................... 4
2 Maximum Allowed Motor Torque vs. Speed ..................................................................................................................................................... 5
3 Open Ventilated Motor with External Fan Cooling ............................................................................................................................................ 5
4 KBAC-24D Drive Layout ................................................................................................................................................................................... 8
5 KBAC-27D Drive Layout ................................................................................................................................................................................... 9
6 KBAC-29, 29 (1P), 45, 48 Drive Layout .......................................................................................................................................................... 10
7 KBAC-217, 217S, 217F, 217SF, 416, 416S, 416F, 416SF Drive Layout ....................................................................................................... 11
8 KBAC-24D Mechanical Specifications ............................................................................................................................................................ 12
9 KBAC-27D, 29, 29 (1P), 45, 48 Mechanical Specifications ............................................................................................................................ 13
10 KBAC-217, 217S, 217F, 217SF, 416, 416S, 416F, 416SF Mechanical Specifications .................................................................................. 14
11 KBAC-24D, 27D, 29 (1P) AC Line Input, Motor, and Ground Connections.................................................................................................... 15
12 KBAC-29, 45, 48 AC Line Input, Motor, and Ground Connections................................................................................................................. 16
13 KBAC-217, 217S, 217F, 217SF, 416, 416S, 416F, 416SF AC Line Input, Motor, and Ground Connections ................................................ 16
14 Remote Main Speed Potentiometer Connection ............................................................................................................................................ 16
15 Remote Start/Stop Switch Connection with Normally Open Stop Contact ..................................................................................................... 17
16 Remote Start/Stop Switch Connection with Normally Closed Stop Contact ................................................................................................... 17
17 Start/Stop Function Eliminated ....................................................................................................................................................................... 17
18 Voltage Following Connections ...................................................................................................................................................................... 17
19 Enable Circuit Connection .............................................................................................................................................................................. 17
20 Run/Fault Relay Output Contacts Connection ................................................................................................................................................ 18
21 Typical Hi-Pot Test Setup ............................................................................................................................................................................... 18
22 AC Line Input Voltage Selection (KBAC-24D, 27D Only) (J1) ........................................................................................................................ 19
23 Motor Horsepower Selection (J2) ................................................................................................................................................................... 19
24 Automatic Ride-Through or Manual Start Selection (J3) ................................................................................................................................ 19
25 Available Torque vs. Output Frequency ......................................................................................................................................................... 19
26 Motor Frequency Selection (J4 and J5) .......................................................................................................................................................... 19
27 Boost Mode Selection (J6) ............................................................................................................................................................................. 20
28 Braking Mode Selection (J7) .......................................................................................................................................................................... 20
29 Run/Fault Output Relay Operation Selection (J8) .......................................................................................................................................... 20
30 Stop Contact Type Selection (J9) ................................................................................................................................................................... 20
31 Torque Mode Selection (J10) ......................................................................................................................................................................... 20
32 Switching Frequency and GFCI Selection (Third Generation (3G) Drives Only) (J12) .................................................................................. 20
33 Minimum Speed Trimpot (MIN) Range ........................................................................................................................................................... 21
34 Maximum Speed Trimpot (MAX) Range ......................................................................................................................................................... 21
35 Acceleration Trimpot (ACCEL) Range ............................................................................................................................................................ 21
36 Deceleration Trimpot (DECEL) Range ........................................................................................................................................................... 21
37 DC Injection Brake Trimpot (DECEL) Range ................................................................................................................................................. 21
38 Slip Compensation Trimpot (COMP) Range .................................................................................................................................................. 22
39 Current Limit Trimpot (CL) Range .................................................................................................................................................................. 22
2
t Trip Time vs. Motor Current ....................................................................................................................................................................... 22
40 I
41 Boost Trimpot (BOOST) Range ...................................................................................................................................................................... 22
42 Jog Trimpot (JOG) Range .............................................................................................................................................................................. 22
43 Run-Stop-Jog Switch Connection ................................................................................................................................................................... 22
TABLE 1
DRIVE MODEL NO., PART NO., AND CASE REFERENCE SIZE
Model No.
Gray Case
(2G and 3G
Part No.
2
)
(2G and 3G
White Case
1
2
Case
Reference
) Gray Case White Case1
Size Model No.
3
Part No.
Case
Reference
Size
KBAC-24D 9987 9988 A KBAC-217 8868 8879 C
KBAC-27D 9520 9521 B KBAC-217S 8863 8855 C
KBAC-29 9528 9529 B KBAC-217F 8861 8853 C
KBAC-29 (1P) 10001 10002 B KBAC-217SF 8869 8880 C
KBAC-45 9530 9531 B KBAC-416 8870 8881 C
KBAC-48 9540 9541 B KBAC-416S 8864 8856 C
KBAC-416F 8874 8883 C
KBAC-416SF 8871 8882 C
Notes: 1. White FDA approved finish. 2. Third Generation (3G) drives KBAC-24D, 27D, 29, 29 (1P), 45, 48 are marked "(3G)" on the product
label. Third Generation (3G) drives are jumper selectable (J12) for standard and sensitive GFCIs. 3. All KBAC-217, 416 Series drives are
Third Generation (3G).
UL NOTICE
230 Volt Drives: Suitable for use on a circuit capable of delivering not more than 5 kA RMS symmetrical Amperes. 230 Volts maximum.
Use copper conductors rated 75 °C. Suitable for operation in a maximum surrounding air temperature of 40 °C.
460 Volt Drives: Suitable for use on a circuit capable of delivering not more than 5 kA RMS symmetrical Amperes. 460 Volts maximum.
Use copper conductors rated 75 °C. Suitable for operation in a maximum surrounding air temperature of 40 °C.
KBAC SERIES INSTALLATION AND OPERATION MANUAL
3
1 – QUICK-START INSTRUCTIONS
Also see Section 4 – Important Application Information on page 5.
Important: You must read these simplified instructions before proceeding. These instructions are to be used as a reference only and are not
intended to replace the details provided herein. You must read the Safety Warnings on page 5 before proceeding.
Reconditioning the Bus Capacitors: If this drive has been in storage for over one year, it is necessary to recondition the power supply bus
capacitors. To recondition the bus capacitors, apply the AC Line, with the drive in the Stop Mode, for a minimum of one hour. Not following
this procedure will cause the bus capacitors to fail.
WARNING! High Voltage! Disconnect the main power before making connections to the control. Do not depend on the POWER or
STATUS LEDs, located on the front cover, to no longer be illuminated as a guaranteed power off condition.
1.1 – MOUNTING INSTRUCTIONS
See Section 5 on page 12.
GENERAL CONNECTION DIAGRAM
FIGURE 1
1.2 – AC LINE INPUT FUSING
It is recommended that a fuse(s) or circuit breaker be
installed in the AC Line. Fuse each conductor that is not at
ground potential. For the recommended fuse size, see
Table 2 on page 7. Also see Section 6 on page 15.
1.3 – AC LINE INPUT CONNECTION
Connect the AC Line input to Terminal Block TB1, as
shown in Figure 1. Also see Section 7.1 on pages 15 and
16.
GFCI Operation: Third Generation (3G) drives are jumper
selectable (J12) for standard and sensitive GFCIs.
CAUTION! The rated AC Line voltage of the drive
must match the actual AC Line input voltage.
On KBAC-24D, 27D the setting of Jumper J1 must match
the actual AC Line input voltage.
KBAC-24D, 27D, 29 (1P): Designed to accept 1-phase
(Terminals L1, L2) AC Line input only. Rated for 208/230
Volt AC Line input with Jumper J1 set to the "230V" position (factory setting). Rated for 115 Volt AC Line input with Jumper J1 set to the
"115V" position. KBAC-27D is rated for 1½ HP maximum with 115 Volt AC Line input and 2 HP maximum with 208/230 Volt AC Line input.
KBAC-29: Designed to accept 1-phase (Terminals L1, L2) or 3-phase (Terminals L1, L2, L3) AC Line input. Rated for 208/230 Volt AC Line
input only. Rated for 2 HP maximum with 1-phase AC Line input and 3 HP maximum with 3-phase AC Line input.
KBAC-217, 217S, 217F, 217SF: Designed to accept 3-phase (Terminals L1, L2, L3) AC Line input only. Rated for 208/230 Volt AC Line input
only.
KBAC-45, 48, 416, 416S, 416F, 416SF: Designed to accept 3-phase (Terminals L1, L2, L3) AC Line input only. Rated for 400/460 Volt AC
Line input only.
1.4 – MOTOR CONNECTION
Connect the motor to Terminal Block TB1 Terminals U, V, W, as shown in Figure 1 above. See Section 7.2 on page 16. Motor cable length
should not exceed 100 ft. (30 m) – special reactors may be required – contact Technical Support.
1.5 – GROUND CONNECTION
Connect the ground wire (earth) to the ground screw, as shown in Figure 1 above. See Section 7.3 on page 16. Be sure the motor is also
properly grounded.
1.6 – 60 Hz AND 50 Hz MOTOR OPERATION
The drive is factory set for 60 Hz motor operation (Jumper J4 set to the "1X" position and Jumper J5 set to the "60Hz" position). For 50 Hz
motor operation, be sure Jumper J4 is set to the "1X" position and set Jumper J5 to the "50Hz" position. See Section 10.4 on page 19.
1.7 – START/STOP SWITCH
A prewired Start/Stop Switch is supplied to electronically "start" and "stop" the drive, as described in Section 7.5 on page 17. This switch must
be used to "start" the drive each time the AC Line is applied to the drive or to "restart" the drive. Also see Section 10.8 on page 20.
1.8 – JUMPER SETTINGS
All jumpers have been factory set for most applications. However, some jumpers may need to be set in order to tailor the drive for a specific
application. See Section 10 on pages 19 and 20.
IMPORTANT: To ensure that the motor is properly protected with the I2t Overload Protection feature, it is required that Jumper J2 is set to the
corresponding position for the motor horsepower being used, as shown in Figure 23 on page 19.
1.9 – TRIMPOT ADJUSTMENTS
All trimpots have been factory set for most applications. Some applications require adjustment of the trimpots to tailor the drive for a specific
requirement. See Section 12 on page 21 and 22.
1.10 – DIAGNOSTIC LEDs
After power has been applied, observe the LEDs to verify proper drive operation, as described in Section 13 on page 23.
4
KBAC SERIES INSTALLATION AND OPERATION MANUAL
2 – SAFETY WARNINGS
r
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.
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 control contains electronic Start/Stop circuits, which 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. Disconnect the input power for this purpose. Be sure to read and follow all
instructions carefully. Fire and/or electrocution can result due to improper use of this product.
This product complies with all CE directives pertinent at the time of manufacture. Contact Technical support for Declaration of
Conformity. Installation of a CE approved RFI filter is required. See RFI Filters & Chokes Selection Guide D-321 (Part No. A42027) for
selection of filters that meet the Industrial or Residential Standard. Additional shielded cable and/or AC Line cables may be required along
with a signal isolato
.
3 – IMPORTANT APPLICATION INFORMATION
3.1 – 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.
CAUTION! 1. Some motors have low speed characteristics which cause overheating and winding failure under light load or no-load
conditions. If the motor is operated in this manner for an extended period of time, it is recommended that the unloaded motor current be
checked from 2 – 15 Hz (60 – 450 RPM) to ensure motor current does not exceed the nameplate rating. Do not use the motor if the motor
current exceeds the nameplate rating. 2. It is recommended that the drive be used with Inverter Duty or TENV motors. Inverter duty and most
totally enclosed non-ventilated (TENV) motors can provide full rated torque over an extended speed range without overheating. See Figure 2.
3. 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 3.
MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED
FIGURE 2
OPEN VENTILATED MOTOR WITH EXTERNAL FAN COOLING
FIGURE 3
Inverter Duty
and TENV
Motors
TEFC and Open Ventilated
3.2 – Electronic Motor Overload Protection
The drive contains Modified I
2
t Overload Protection (UL approved as an overload protector for motors). Part of this function consists of a
Current Limit (CL) circuit, which limits the drive current to a preset level of 160% of the rated drive current. The CL Trimpot is used to
recalibrate the drive current from 60% thru 200%. The Power Start™ circuit provides an overshoot function that allows most motors to develop
more than 200% of starting torque and breakdown torque.
Standard I
2
t is undesirable because it causes nuisance tripping. It allows a very high motor current to develop and will turn the drive off after a
short period of time. The RMS Current Limit Circuit, which includes I
this nuisance tripping while providing maximum motor protection.
If the motor is overloaded to 120% of full load (75% of the CL setting), the I•t Timer starts. If the motor continues to be overloaded at the 120%
level, the timer will shut down the drive after 30 minutes. If the motor is overloaded to 160% of full load, the drive will trip in 6 seconds.
KBAC SERIES INSTALLATION AND OPERATION MANUAL
Fan Cooled
Motors
2
t plus an I•t timing circuit (as described in the paragraph below), avoids
5
4 – INTRODUCTION
Thank you for purchasing the KBAC Adjustable Frequency Drive. KB Electronics, Inc. is committed to providing total customer satisfaction by
producing quality products that are easy to install and operate. The KBAC is manufactured with surface mount components incorporating
advanced circuitry and technology.
The drives are variable speed controls housed in a rugged NEMA 4X / IP65 washdown and watertight die-cast aluminum enclosure. They are
designed to operate 208 – 230 and 400/460 Volt 50 & 60 Hz 3-phase AC induction motors from subfractional thru 10 HP. The sine wave
coded Pulse Width Modulated (PWM) output operates at a carrier frequency of 16 kHz which provides high motor efficiency and low noise.
Adjustable Linear Acceleration and Deceleration are provided, making the drive suitable for
soft-start applications.
Due to its user-friendly design, the KBAC AC drive is easy to install and operate. Tailoring to specific applications is accomplished with
selectable jumpers and trimpots, which eliminate the computer-like programming required on other drives. However, for most applications no
adjustments are necessary.
Main features include adjustable RMS Current Limit and I
2
t Motor Overload Protection (UL approved as an electronic overload protector for
motors). In addition, Adjustable Slip Compensation with Static Auto-Tune and Boost provides high torque and excellent load regulation over a
wide speed range. Power Start™ delivers over 200% motor torque to ensure start-up of high frictional loads. Electronic Inrush Current Limit
(EICL™) eliminates harmful AC Line inrush current. A Run/Fault Relay is provided, which can be used to turn equipment on or off, to signal a
warning if the drive is put into the Stop Mode, or if a fault has occurred. The drive is suitable for machine or variable torque (HVAC)
applications. Also, a jumper is provided for selection of Regenerative or DC Injection Braking.
Standard front panel features include Diagnostic LEDs for "Power On" and "Drive Status", a Start/Stop Switch, and a Main Speed
Potentiometer. Other features include a Barrier Terminal Block to facilitate wiring of the AC Line and motor, adjustable trimpots (MIN, MAX,
ACCEL, DECEL, COMP, CL, JOG, BOOST), customer selectable jumpers (Line Voltage (dual voltage models only)), Motor Horsepower,
Automatic Ride-Through / Manual Start, Motor Frequency, Frequency Multiplier, Fixed/Adjustable Boost, Regenerative / Injection Braking,
"Run" or "Fault" Output Relay Operation, NO/NC Stop Contact, Constant/Variable Torque, Switching Frequency, and GFCI operation
(Third Generation (3G) drives only).
Optional accessories include: Forward-Stop-Reverse Switch, On/Off AC Line Switch, Run-Stop-Jog Switch, Signal Isolator, Auto/Manual
Switch, Class A AC Line Filter, Multi-Speed Board, and Liquidtight Fittings. A connector is provided for easy installation of accessories.
Custom software: all models can be factory programmed for applications which require special timing, PLC functions, and GFCI operation.
4.1 – STANDARD FEATURES
Industrial Duty Die-Cast Aluminum Case with Hinged Cover: Available in dark gray finish or FDA approved white finish.
Simple to Operate: Does not require programming. Uses trimpots and jumpers, which are factory set for most applications.
Motor HP Selection Jumper (J2): Allows the drive to be used on a wide range of motors without recalibration.
Switching Frequency and GFCI Selection Jumper (J12): Allows the drive to be operated at 8 kHz or 12 kHz and on Standard (G1) or
Sensitive (G2) GFCIs. (Third Generation (3G) drives only.)
Diagnostic LEDs: Power on (POWER) and drive status (STATUS).
Run/Fault Relay Output Contacts: Can be used to turn equipment on or off, to signal a warning if the drive is put into the Stop Mode, or a
fault has occurred.
Start/Stop Switch: Provides electronic start and stop functions.
Barrier Terminal Block: Facilitates wiring of motor, AC Line, and Run/Fault Relay Output Contacts.
Jumper Selection of Drive Output Frequency: Increases the motor speed up to two times the rated RPM.
Ride-Through: Provides smooth recovery to the previous set speed during a momentary power loss (of less than 2 seconds).
Holding Torque at Zero Speed: Resists motor shaft rotation when the drive is in Stop Mode.
Adjustable Trimpots: Maximum Speed (MAX), Minimum Speed (MIN), Acceleration (ACCEL), Deceleration (DECEL), DC Injection Brake
(DECEL), Boost (BOOST), Current Limit (CL), Jog (JOG), Slip Compensation (COMP).
Selectable Jumpers: AC Line Input Voltage (J1 – KBAC-24D, 27D only), Motor Horsepower (J2), Automatic Ride-Through or Manual Start
(J3), Frequency Multiplier (J4), Motor Frequency (J5), Fixed or Adjustable Boost (J6), Regeneration or DC Injection Braking (J7), "Run" or
"Fault" Output Relay Operation (J8), Normally Open or Closed Stop Contact (J9), Constant or Variable Torque (J10), Switching Frequency
and GFCI (J12 – Third Generation (3G) drives only).
4.2 – PEERFORMANCE FEATURES
Power Start™: Provides more than 200% starting torque which ensures startup of high frictional loads.
Slip Compensation with Static Auto-Tune and Boost: Provides excellent load regulation over a wide speed range.
Speed Range: 60:1.
4.3 – PROTECTION FEATURES
Motor Overload (I
trips. UL approved as an electronic overload protector for motors.
Electronic Inrush Current Limit (EICL™): Eliminates harmful Inrush AC Line current during startup.
Short Circuit: Shuts down the drive if a short circuit occurs at the motor (phase-to-phase).
Regeneration: Eliminates tripping due to high bus voltage caused by rapid deceleration of high inertial loads.
Undervoltage and Overvoltage: Shuts down the drive if the AC Line input voltage goes above or below the operating range.
MOV Input Transient Suppression: Protects the drive components against damaging voltage spikes on the AC Line.
2
t) with RMS Current Limit: Provides motor overload protection which prevents motor burnout and eliminates nuisance
Microcontroller Self-Monitoring and Auto Reboot.
6
KBAC SERIES INSTALLATION AND OPERATION MANUAL
TABLE 2
A
–
–
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
ELECTRICAL RATINGS
Part No.
Model No.
Gray White1
KBAC-24D 9987 9988
KBAC-27D 9520 9521
Volts AC
(50/60 Hz)
c Line Input
Fuse or
Circuit
Maximum
Phase
(Ф)
Current
(Amps AC)
115 1 14.4 20
208/230 1 8.1 15
Breaker
Rating
(Amps)
(Volts AC)
0 – 208/230 3.6 1 (0.75) 1 3/4 1/2 1/4 1/8 5.9 2.7
115 1 22 25 0
Voltage
Range
208/230 5.5 1½ (1.13) ─
Output
Maximum
Continuous
Load Current
(Amps/Phase)
Maximum
Horsepower
(HP (kW))
208/230 1 16.7 20 0 –208/230 6.7 2 (1.5) 2
Horsepower
Selection
(Jumper J2)
3
1 3/4 1/2 10.3 4.7
1½
2
Net
Weight
lbs kg
A B C D E
KBAC-29 9528 9529 208/230
1 16.7 20 0
3 11.7 15 0 –208/230 9.0 3 (2.25) 34
KBAC-29 (1P) 10001 10002 208/230 1 20.5 25 0 –208/230 9.0
KBAC-45 9530 9531 400/460 3 7.2 10 0 –400/460
KBAC-48 9540 9541 400/460 3 11 15 0 –400/460
208/230 6.7 2 (1.5) ─
6
6
5
5.5 3 (2.25) 3 2 1½ 1 3/4
8.3 5 (3.75) 5 3 2 1½ 1
3 (2.25) 3 2 1½ 1 3/4
4
1½ 1 3/4
2
10.3 4.7
A B C ─ ─
KBAC-217 8868 8879
KBAC-217S 8863 8855
KBAC-217F 8861 8853
KBAC-217SF 8869 8880
KBAC-416 8870 8881
KBAC-416S 8864 8856
KBAC-416F 8874 8883
208/230 3 22.1 25 0 – 208/230 17 5 5 3 2
6
400/460 3 20.8 25 0 – 400/460
16 10 10 7.5 3
─ ─ 22 10
KBAC-416SF 8871 8882
Notes: 1. White FDA approved finish. 2. Bold indicates factory setting. KBAC-24D: J2 is labeled "1", "3/4", "1/2", "1/4", "1/8" (factory set to the
"1" position). KBAC-27D: J2 is labeled "2", "1½", "1", "3/4", "1/2" (factory set to the "1½" position). KBAC-29, (29 (1P), 45, 48: J2 is labeled
"A", "B", "C", "D", "E" (factory set according to the table). KBAC-217, 416 Series: J2 is labeled "A", "B", "C" (factory set to the "A" position).
3. KBAC-27D: Rated 1½ HP maximum with 115 Volt AC Line input and 2 HP maximum with 208/230 Volt AC Line input. 4. KBAC-29: Rated
2 HP maximum with 1-phase AC Line input and 3 HP maximum with 3-phase AC Line input. 5. KBAC-29 (1P): Rated 9 Amps at 35 °C / 95 °F
and derated to 8.3 Amps at 40 °C / 104 °F. For ambient temperatures above 40 °C / 104 °F, the drive is derated 2.5% per °C.
6. KBAC-45, 48, 416 Series: Rated 0 – 400 Volts AC for 50 Hz motor operation and 0 – 460 Volts AC for 60 Hz motor operation.
TABLE 3
GENERAL PERFORMANCE SPECIFICATIONS
Description Specification Factory Setting
115 Volt AC Line Input Voltage Operating Range (Volts AC) 115 (±15%)
208/230 Volt AC Line Input Voltage Operating Range (Volts AC) 208 (-15%) / 230 (+15%)
400/460 Volt AC Line Input Voltage Operating Range (Volts AC) 380 (-15%) – 460 (+15%)
Maximum Load (% Current Overload for 2 Minutes) 150
Switching Frequency (kHz) (Jumper J12) (3G Drives Only)
1
8, 12 8
Signal Following Input Voltage Range2 (Volts DC) 0 – 5
Output Frequency Resolution (Bits, Hz) 10, 0.06
Maximum Speed Trimpot (MAX) Range (% Frequency Setting) 70 – 110 100
Minimum Speed Trimpot (MIN) Range (% Frequency Setting) 0 – 40 0
Acceleration Trimpot (ACCEL) Range (Seconds) 0.3 – 20 1.5
Deceleration Trimpot (DECEL) Range (Seconds) 0.3 – 20 1.5
DC Injection Brake (DECEL) (Seconds) 0.3 – 6.0 1.7
Boost Trimpot (BOOST) Range (Volts) 0 – 30 5
Current Limit Trimpot (CL) Range (% Full Load) 40 – 200 160
Jog Trimpot (JOG) Range (% Frequency Setting) 0 – 100 35
Slip Compensation Trimpot (COMP) Range at Drive Rating (Volts/Hz) 0 – 3 1.5
Motor Frequency Setting (Hz) (Jumper J5) 50, 60 60
Output Frequency Multiplier (1X, 2X) (Jumper J4)3 1, 2 1
Minimum Operating Frequency at Motor (Hz) 1
Speed Range (Ratio) 60:1
Speed Regulation (30:1 Speed Range, 0 – Full Load) (% Base Speed)
Overload Protector Trip Time for Stalled Motor (Seconds) 6
Undervoltage/Overvoltage Trip Points for 115 Volt AC Line Input (± 5%) (Volts AC)
Undervoltage/Overvoltage Trip Points for 208/230 Volt AC Line Input (± 5%) (Volts AC)
Undervoltage/Overvoltage Trip Points for 400/460 Volt AC Line Input (± 5%) (Volts AC)
4
5
5
5
2.5
76 – 141
151 – 282
302 – 567
Run/Fault Relay Output Contact Rating (Amps at 30 Volts DC, 125 Volts AC, 250 Volts AC) 1, 0.5, 0.25
Operating Temperature Range (°C / °F) 0 – 40 / 32 – 104
Operating Humidity Range (% Relative, Non-Condensing) 0 – 95
Storage Temperature (°C / °F) -2.5 – +85 / -13 – +185
Notes: 1. Third Generation (3G) drives are marked "(3G)" on the product label. 2. Requires an isolated signal. If a non-isolated signal is used,
or if using 0 to ±2.5 thru 0 to ±25 Volts DC, or 4 – 20 mA DC signal input, install the Signal Isolator. 3. Allows the motor to operate up to two
times the rated RPM. Constant horsepower will result when operating the drive in the "X2" mode above the motor rated frequency.
4. Dependent on motor performance. 5. Do not operate the drive outside the specified AC Line input voltage operating range. 6. See Table 2
above.
KBAC SERIES INSTALLATION AND OPERATION MANUAL
7
KBAC-24D DRIVE LAYOUT (SEE LEGEND BELOW FOR NUMBERED ITEMS)
FIGURE 4
1
2
3
4
5
6
7
8
10
11
12
13
14
15
J1
16
17
WVU L1 L2
MOTOR
LEGEND:
1. Jog Terminal: Used with optional Run-Stop-Jog Switch Kit. See Section 14 on page 23.
2. Adjustable Trimpots: Maximum Speed (MAX), Minimum Speed (MIN), Acceleration (ACCEL), Deceleration (DECEL), DC Injection Brake
(DECEL), Boost (BOOST), Current Limit (CL), Jog (JOG), Slip Compensation (COMP). See Section 12 on pages 21 and 22.
3. Jumper J3: Automatic Ride-Through or Manual Start selection. See Section 10.3 on page 19.
4. Jumper J4: Frequency Multiplier selection. See Section 10.4 on page 19.
5. Jumper J2: Motor Horsepower selection. See Section 10.2 on page 19.
6. Jumper J5: Motor Frequency selection. See Section 10.4 on page 19.
7. Jumper J12: Switching Frequency and GFCI selection. Third Generation (3G) drives only. See Section 10.11 on page 20.
8. Jumper J6: Adjustable Boost selection. See Section 10.5 on page 20.
9. Jumper J7: Regeneration or DC Injection Braking. See Section 10.6 on page 20.
10. Jumper J8: "Run" or "Fault" Output Relay Operation selection. See Section 10.7 on page 20.
11. Jumper J9: Normally Open or Closed Stop Contact selection. See Section 10.8 on page 20.
12. Jumper J10: Constant or Variable Torque selection. See Section 10.9 on page 20.
13. Jumper J11: Factory use only.
14. Connector CON1: Used to connect optional accessories to the drive.
15. Jumper J1: AC Line Input Voltage selection. See Section 10.1 on page 19.
16. Terminals L1A/L1B and L2A/L2B: Used for optional On/Off AC Line Switch Kit and RFI Filter Kit. See Section 14 on page 23.
17. Terminal Block TB1: AC Line input and Motor connections. See Sections 7.1 and 7.2 on page 15 and 16.
AC LINE
8
KBAC SERIES INSTALLATION AND OPERATION MANUAL
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