Kb Electronics KBAC-SERIES User Manual.pdf

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Installation & Operation Manual

KBAC SERIES

Adjustable Frequency Drives for 3-Phase AC Motors

NEMA-4X / IP-65

Variable Speed/Soft-Start AC Motor Drive

with Electronic Motor Overload Protection for Inverter Duty Motors*

Washdown and Watertight for Indodor and Outdoor Use Rated for 208 – 230 and 400/460 Volt 50 & 60 Hz 3-Phase & PSC** AC Induction Motors from 1HP thru 5 HP

Operates from 115, 208/230 Volt and 400/460 Volt 50/60 Hz AC Line**

This Manual Covers Models KBAC-24D, 27D, 29, 45, 48

See Safety Warning,

***

Note: The drive is factory set for

60 Hz motors. For 50 Hz motors,

on page 5.

 

 

 

 

see Section 6.1, on pages 16 – 17.

 

 

 

 

 

 

 

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.

*UL approved as an electronic overload protector for motors. **Do not use this drive with GFCIs. Special software is available – contact our Sales Department. ***Installation of a CE approved RFI filter is required.

A Complete Line of Motor Drives

©2006 KB Electronics, Inc. (see back cover)

 

TABLE OF CONTENTS

 

Section

Page

1

Quick-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 4

2

Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 5

3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 6

4

Important Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 12

5

Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 13

6

Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 16

7

Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 19

8

Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . . . . . . . . . . . . . . .

. . 19

9

Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 21

10

AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 21

11

Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 21

12

Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 22

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 28

Tables

Page

1

Jumper Selectable Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 8

2

Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 8

3

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

. . 10

4

Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 10

5

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

. . 13

6

Drive Operating Condition and Run/Fault Relay Contact Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 16

7

Drive Operating Condition and Status LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 22

Figures

Page

1

Quick-Start Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 4

2

Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 9

3

Model KBAC-24D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 11

4

Models KBAC-27D, 29, 45, 48 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 11

5

Maximum Allowed Motor Torque vs. Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 12

6

Open Ventilated Motor with External Fan Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 12

7

Models KBAC-24D, 27D AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . .

. . 13

8

Models KBAC-29, 45, 48 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . .

. . 14

9

Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 14

10

Remote Start/Stop Switch Connection with Normally Open Stop Contact . . . . . . . . . . . . . . . . . . . . . .

. . 15

11

Remote Start/Stop Switch Connection with Normally Closed Stop Contact . . . . . . . . . . . . . . . . . . . . .

. . 15

12

Start/Stop Function Eliminated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 15

13

Voltage Following Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 15

14

Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 16

15

Run/Fault Relay Output Contacts Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 16

16

Models KBAC-24D, 27D AC Line Input Voltage Selection (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . . .

. . 16

17

Removing Jumper J1 on Models KBAC-24D, 27D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 17

18

Motor Horsepower Selection (Jumper J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 17

19

Automatic Ride-Through or Manual Restart Selection (Jumper J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 17

20

60 Hz and 50 Hz Motor Selection (Jumpers J4 and J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 17

21

Available Torque vs. Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 18

22

120 Hz and 100 Hz Drive Output Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 18

23

Fixed or Adjustable Boost Selection (Jumper J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 18

24

Regenerative or DC Injection Braking Selection (Jumper J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 18

25

“Run” or “Fault” Output Relay Operation Selection (Jumper J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 19

26

Normally Open or Closed Stop Contact Selection (Jumper J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 19

27

Constant or Variable Torque Selection (Jumper J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 19

28

I2t Overload Selection (Jumper J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 19

29

Typical Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 20

ii

 

 

30 Minimum Speed Trimpot (MIN) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 31 Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 32 Acceleration Trimpot (ACCEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 33 Deceleration Trimpot (DECEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 34 DC Injection Brake Trimpot (DECEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 35 Slip Compensation Trimpot (COMP) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 36 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 37 I2t Trip Time vs. Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 38 Boost Trimpot (BOOST) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 39 Jog Trimpot (JOG) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Items Included In this Package:

Adjustable Frequency Drive, Installation and Operation Manual, Trimpot Adjustment Tool, CE Approved Product Information Card, Warranty Registration Card.

iii

1 QUICK-START INSTRUCTIONS

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 Warning on, page 5, before proceeding.

See Figure 1. Also see Section 4 - Important Application Information, on page 12.

WARNING! Disconnect main power before making connections to the drive.

FIGURE 1 – QUICK-START CONNECTION DIAGRAM*

TB1

 

 

 

 

 

U

V

W

L1

L2

L3

 

MOTOR

 

 

AC LINE

 

Motor

 

 

208/230 Volt, Single Phase,

 

 

 

 

 

 

 

50/60 Hz, AC Line Input

 

 

 

 

3-Phase

 

 

(Terminals L1, L2)

 

 

 

 

 

(Models KBAC-24D, 27D, 29):

 

 

 

 

 

 

 

AC Induction Motor:

 

 

 

 

 

 

 

 

 

see Section 5.1, on pages 13 – 14.

 

 

 

 

 

 

 

 

 

 

 

 

see Section 5.3, on page 14.

 

 

 

Ground (Earth):

 

 

 

 

 

 

see Section 5.2, on page 14.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

208/230, 400/460 Volt, 3-Phase,

50/60 Hz, AC Line Input

(Terminals L1, L2, L3)

(Models KBAC-29, 45, 48): see Section 5.1, on pages 13 – 14.

*Layout of Model KBAC-24D varies slightly.

1.1AC LINE INPUT CONNECTION – Wire the AC line input to Terminal Block TB1. See Section 5.1, on pages 13 – 14.

Application Note: Do not wire this drive to a GFCI. If operation with a GFCI is required, contact our Sales Department.

Note: The rated AC line voltage of the drive must match the actual AC line input voltage. On Models KBAC-24D, 27D, the setting of Jumper J1 must match the AC line input voltage.

Models KBAC-24D, 27D: Designed to accept single-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. See Figure 7, on page 13.

Note: Model KBAC-27D is rated for 112 HP maximum with 115 Volt AC line input and 2 HP maximum with 208/230 Volt AC line input.

Model KBAC-29: Designed to accept single-phase (Terminals “L1”, “L2”) or 3-phase (Terminals “L1”, “L2”, “L3”) AC line input. Rated for 208/230 Volt AC line input only. See Figure 8, on page 14.

Note: Rated for 2 HP maximum with single-phase AC line input and 3 HP maximum with 3-phase AC line input.

4

Models KBAC-45, 48: Designed to accept 3-phase (Terminals “L1”, “L2”, “L3”) AC line input only.

Rated for 400/460 Volt AC line input only. See Figure 8, on page 14.

1.2AC LINE 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 4, on page 10. Also see Section 10, on page 21.

1.3GROUND CONNECTION – Connect the ground wire (earth) to the ground screw, as shown in Figure 7, on page 13, and Figure 8, on page 14. See Section 5.2, on page 14.

1.4MOTOR CONNECTION – Wire the motor to Terminal Block TB1 Terminals “U”, “V”, “W”, as shown in Figure 7, on page 13, and Figure 8, on page 14. (Special reactors may be required for cable lengths over 100 ft. (30 m) – consult our Sales Department.) See Section 5.3, on page 14.

1.560 Hz and 50 Hz MOTOR OPERATION – The drive is factory set for 60 Hz motor operation (Jumper J5 set to the “60Hz” position). For 50 Hz motor operation, set Jumper J5 to the “50Hz” position. See Section 6.4, on page 17.

1.6START/STOP SWITCH – The drive is supplied with a prewired Start/Stop Switch to electronically “start” and “stop” the drive, as described in Section 5.5, on pages 14 – 15. 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 6.8, on page 18.

1.7JUMPER SETTINGS – All jumpers have been factory set for most applications, as shown in Figure 2, on page 9. Some applications require setting of the jumpers in order to tailor the drive for a specific requirement. See Section 6, on pages 16 – 18.

1.8TRIMPOT SETTINGS – All trimpots have been factory set for most applications, as shown in Figure 2, on page 9. Some applications require adjustment of the trimpots in order to tailor the drive for a specific requirement. See Section 12, on pages 22 – 25.

1.9DIAGNOSTIC LEDs – After power has been applied, observe the LEDs to verify proper drive operation, as described in Section 11, on pages 21 – 22.

2SAFETY 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 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, 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. Be sure to follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product. (SW 1/2006)

5

This product complies with all CE directives pertinent at the time of manufacture. Contact our Sales Department 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 to meet the Industrial or Residential Standard. Additional shielded cable and/or AC line cables may be required along with a signal isolator (SIAC (Part No. 9488)).

3INTRODUCTION

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 / IP-65 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 1 HP thru 5 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. For more advanced programming, PC based Drive-Link™ software is available.

Main features include adjustable RMS Current Limit and I2t Motor Overload Protection.* 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 on or off equipment or 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 RideThrough / 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, I2t Overload Selection).

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, Programming Kit, Modbus Communication Module, 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 – contact our Sales Department.

*UL approved as an electronic overload protector for motors.

3.1STANDARD FEATURES

Industrial Duty Die-Cast Aluminum Case with Hinged Cover – Available in black 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 – Allows the drive to be used on a wide range of motors without recalibration.

Diagnostic LEDs – Power on (POWER) and drive status (STATUS).

Run/Fault Relay Output Contacts – Can be used to turn on or off equipment or to signal a

6

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.

Note: GFCI Operation – This drive can operate with GFCIs (optional software required) – contact our Sales Department.

3.2 PERFORMANCE 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

3.3 PROTECTION FEATURES

• Motor Overload (I2 t) with RMS Current Limit* – Provides motor overload protection which prevents motor burnout and eliminates nuisance trips.*

• 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.

• Microcontroller Self Monitoring and Auto Reboot.

*UL approved as an electronic overload protector for motors.

3.4 TRIMPOT ADJUSTMENTS

• Minimum Speed (MIN) – Sets the minimum speed of the motor. See Section 12.1, on page 22.

• Maximum Speed (MAX) – Sets the maximum speed of the motor. See Section 12.2, on page 22.

• Acceleration (ACCEL) – Sets the amount of time for the motor to accelerate from zero speed to full speed. See Section 12.3, on page 22.

• Deceleration (DECEL) – Sets the amount of time for the motor to decelerate from full speed to zero speed. See Section 12.4, on page 23.

• DC Injection Brake (DECEL) – When the drive is set for DC Injection Braking (Jumper J7 set to the “INJ” position), the DECEL trimpot is used to set the DC Injection Brake voltage and time. See Section 12.5, on page 23.

• Slip Compensation (COMP) – Maintains set motor speed under varying loads. See Section 12.6, on page 23.

• Current Limit (CL) – Sets the current limit (overload) which limits the maximum current to the motor. See Section 12.7, on page 24.

• Boost (BOOST) – Sets the amount of Boost which can be used to obtain maximum low speed performance. See Section 12.8, on pages 24 – 25.

• Jog (JOG) – Sets the “jog” speed of the motor. Must be used with the optional Run-Stop-Jog

Switch Kit (Part No. 9488). See Section 12.9, on page 25.

7

TABLE 1 – JUMPER SELECTABLE FEATURES

 

PC Board

 

 

 

 

 

Description (bold indicates factory setting)

Designation

KBAC-24D

KBAC-27D

KBAC-29

KBAC-45

KBAC-48

AC Line Input Voltage (115, 230)

J1

3

3

 

 

 

 

 

 

 

Motor Horsepower (see Table 4 - Electrical Ratings)

J2

3

3

3

3

3

 

 

 

 

 

 

 

Automatic Ride-Through or Manual Restart (A*, M)

J3

3

3

3

3

3

 

 

 

 

 

 

 

Frequency Multiplier (1X, 2X)

J4

3

3

3

3

3

 

 

 

 

 

 

 

Motor Frequency (50Hz, 60Hz)

J5

3

3

3

3

3

 

 

 

 

 

 

 

Fixed or Adjustable Boost (FIX, ADJ)

J6

3

3

3

3

3

 

 

 

 

 

 

 

Regenerative or DC Injection Braking (RG, INJ)

J7

3

3

3

3

3

 

 

 

 

 

 

 

“Run” or “Fault” Output Relay Operation (R, F)

J8

3

3

3

3

3

 

 

 

 

 

 

 

Normally Open or Closed Stop Contact (NO, NC)

J9

3

3

3

3

3

 

 

 

 

 

 

 

Constant or Variable Torque (VT, CT)

J10

3

3

3

3

3

 

 

 

 

 

 

 

I2t Overload Selection (1, 2)

J11

3

3

3

3

3

* In Automatic Ride-Through Mode, the drive will automatically restart due to a momentary power loss of less than 2 seconds.

TABLE 2 – OPTIONAL ACCESSORIES

 

 

Model

Model

Model

Model

Model

Description

 

KBAC-24D

KBAC-27D

KBAC-29

KBAC-45

KBAC-48

Forward-Stop-Reverse Switch – Provides motor reversing and stop functions.

 

 

 

 

 

Mounts on the enclosure cover and is supplied with a switch seal to maintain

9480

9480

9480

9480

9480

liquidtight integrity.

 

 

 

 

 

 

 

 

 

 

 

 

On/Off AC Line Switch – Disconnects the AC line. Mounts on the enclosure

9482

9523

9532

9532

9532

cover and is supplied with a switch seal to maintain liquidtight integrity.

 

 

 

 

 

 

 

 

 

 

 

 

 

Run-Stop-Jog Switch – Selects speed setting from either the Main Speed

 

 

 

 

 

Potentiometer or the JOG Trimpot. Mounts on the enclosure cover and is supplied

9524

9524

9524

9524

9524

with a switch seal to maintain liquidtight integrity.

 

 

 

 

 

 

 

 

 

 

 

 

Signal Isolator – Provides isolation between a non-isolated signal voltage source

9488*

9488*

9488*

9488*

9488*

and the drive. Mounts on the drive’s PC board with four snap-ins.

 

 

 

 

 

 

 

 

 

 

 

 

 

Auto/Manual Switch – When used with the Signal Isolator, it selects remote

 

 

 

 

 

process signal or the Main Speed Potentiometer. Mounts on the enclosure cover

9481

9481

9481

9481

9481

and is supplied with a switch seal to maintain liquidtight integrity.

 

 

 

 

 

 

 

 

 

 

 

 

 

AC Line Filter1 – Provides Class A RFI (EMI) suppression.

Suffix “S”

9516

9512

9479

9479

9479

Installs onto the drive’s PC board with quick-connect terminals.

 

 

 

 

 

 

Suffix “S”: Filter is used when On/Off AC Line Switch is installed.

Suffix “NS”

9507

9513

9515

9515

9515

Suffix “NS”: Filter is used when On/Off AC Line Switch is not installed.

 

 

 

 

 

 

 

Multi-Speed Board – Provides multi-speed operation using external contacts or a

9489

9489

9489

9489

9489

PLC. Mounts on the drive’s PC board with four snap-ins.

 

 

 

 

 

 

 

 

 

 

 

 

 

Programming Kit 2 – Includes DownLoad Module™ (DLM) handheld programming

 

 

 

 

 

device which uploads and downloads drive programs, PC to DLM serial communica-

9582

9582

9582

9582

9582

tion cable, DLM to drive communication cable, and PC Windows® based Drive-

 

 

 

 

 

Link™ communication software.

 

 

 

 

 

 

 

 

 

 

 

 

Modbus Communication Module – Allows direct communication between drive

9517

9517

9517

9517

9517

and Modbus3 protocol.

 

 

 

 

 

 

 

Liquidtight Fittings – Provide a liquidtight seal for wiring the drive. Kit includes two

9526

9526

9526

9526

9526

1/2” and one 3/4” liquidtight fittings

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Notes: 1. Complies with CE Council Directive 39/336/EEC Industrial Standard. 2. If a USB communication cable is required, purchase Part No. 19008. 3. Other protocols available – contact our Sales Department.

*Warning! It is highly recommended that the Signal Isolator (Part No. 9488) be installed when using the

drive with external control signals.

8

FIGURE 2 – CONTROL LAYOUT 1

Diagnostic LEDs: see Section 11, on page 21.

POWER

STATUS

Violet (High) (P3)

Orange (Wiper) (P2)

White (Low) (P1)

Main Speed Potentiometer:

see Section 5.4, on page 14.

White

Black

Red

Normally Closed

Relay Common

Normally Open

Start/Stop Switch: see Section 5.5, on pages 14 – 15.

Run/Fault Relay

Output Contacts:

see Section 5.8,

on pages 16.

CON3 CON2

ON COM NC TOPS OMC R UN REV COM WDF

TB2

All jumpers and trimpots are shown in factory set positions.

P3

P2

P1

JOG

MAX

MIN

ACCEL DECEL

 

BOOST

CL

JOG

COMP

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M

 

 

B

 

 

 

 

 

 

 

J3

J2

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

 

D

 

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

J4

1X

 

 

 

 

 

 

 

 

 

 

2X

 

IXF

 

 

 

 

 

 

 

 

 

J6

 

 

 

 

 

 

 

 

J5

60Hz

 

ADJ

 

 

 

 

 

 

 

 

50Hz

J7

INJ RG

 

 

 

 

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

 

 

 

J8

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

J9

NC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ON

 

 

 

 

 

 

 

 

CON1

 

J10

CT

 

 

 

 

 

 

 

 

 

 

 

VT

 

 

 

 

 

 

 

 

 

 

J11

2

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J11: I2 t Overload selection.

 

 

J9: Normally Open or Closed

 

 

See Section 6.10, on page 18.

 

 

Stop Contact selection.

CON1: Used to connect

 

 

See Section 6.8, on page 18.

 

 

J10: Constant or Variable

optional accessories to the drive.

 

 

 

 

See Table 2, on page 8.

 

Torque selection.

 

 

 

See Section 6.9, on page 18.

JOG Terminal.

Used with optional Run-Stop-Jog Switch Kit.

See Table 2, on page 8.

Adjustable Trimpots.

See Section 12, on pages 22 – 25.

J1: AC Line Input Voltage selection (Models KBAC-24D, 27D only).

See Section 6.1, on pages 16 – 17.

J2: Motor Horsepower selection.2

See Section 6.2, on page 17.

J3: Automatic Ride-Through or Manual Restart selection.

See Section 6.3, on page 17.

J4: 1X or up to 2X

Rated Motor RPM Operation selection.

See Section 6.4, on pages 17.

J5: 60 Hz or 50 Hz

Motor Operation selection.

See Section 6.4, on page 17.

J6: Fixed or Adjustable Boost selection.

See Section 6.5, on page 18.

J7: Regenerative or

Injection Braking selection.

See Section 6.6, on page 18.

J8: "Run" or "Fault"

Output Relay Operation selection.

See Section 6.7, on page 18.

Notes: 1. Layout of Model KBAC-24D varies slightly. 2. Jumper J2 on Model KBAC-24D is labeled “1”, “3/4”, “1/2”, “1/4”, “1/8” (factory set to the “1” position). Jumper J2 on Model KBAC-27D is labeled “2”, “112”, “1”, “3/4”, “1/2” (factory set to the “112” position). Jumper J2 on Models KBAC-29, 45, 48 is labeled “A”, “B”, “C”, “D”, “E” (factory set according to Table 4, on page 10.

9

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

 

 

 

Carrier, Switching Frequency (kHz)

16, 8

 

 

 

Signal Following Input Voltage Range1 (Volts DC)

0 – 5

Output Frequency Resolution (Bits, Hz)

10, .06

 

 

 

 

 

Minimum Speed Trimpot (MIN) Range (% Frequency Setting)

0

40

0

 

 

 

 

 

Maximum Speed Trimpot (MAX) Range (% Frequency Setting)

70

110

100

 

 

 

Acceleration Trimpot (ACCEL) and Deceleration Trimpot (DECEL) Range (Seconds)

.3 – 20

1.5

 

 

 

 

 

Boost Trimpot (BOOST) Range (Volts/Hz)

0

30

5

 

 

 

Slip Compensation Trimpot (COMP) Range at Drive Rating (Volts/Hz)

0 – 3

1.5

 

 

 

 

 

Current Limit Trimpot (CL) Range (% Full Load)

40

200

160

 

 

 

Jog Trimpot (JOG) Range (% Frequency Setting)

0 – 100

35

 

 

 

Motor Frequency Setting (Hz) (Jumper J5)

50, 60

60

 

 

 

 

Output Frequency Multiplier (1X, 2X) (Jumper J4)2

 

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)3

 

2.5

Overload Protector Trip Time for Stalled Motor (Seconds)

 

6

 

 

 

 

 

Undervoltage/Overvoltage Trip Points for 115 Volt AC Line Input (± 5%) (Volts AC)4

76

141

Undervoltage/Overvoltage Trip Points for 208/230 Volt AC Line Input (± 5%) (Volts AC)4

151 – 282

Undervoltage/Overvoltage Trip Points for 400/460 Volt AC Line Input (± 5%) (Volts AC)4

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 – 45 / 32 – 113

 

 

 

 

 

Notes: 1. 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 SIAC Signal Isolator (Part No. 9467). 2. 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. 3. Dependent on motor performance. 4. Do not operate the drive outside the specified AC line input voltage operating range.

TABLE 4 – ELECTRICAL RATINGS

 

 

 

AC Line Input

Fuse or

 

Drive Output

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part No.

 

 

 

Circuit

Voltage

Maximum

 

Motor Horsepower

Net Wt.

 

 

 

Maximum

Breaker

Range

Continuous

Maximum

 

 

 

 

Selection2

 

 

 

 

 

Phase

 

 

 

 

 

 

White1

Volts AC

Current

Rating

(Nominal)

Load Current

Horsepower

 

 

 

 

Model

Black

(50/60 Hz)

(φ)

(AmpsAC)

(Amps)

(Volts AC)

(RMS Amps/Phase)

(HP (kW))

 

(Jumper J2)

 

lbs

kg

KBAC-24D

9987

9988

115

1

16

20

0 – 230

3.6

1 (.75)

1

3/4

1/2

1/4

1/8

5.9

2.7

 

 

 

 

 

208/230

1

10

15

0 – 230

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

KBAC-27D

9520

9521

115

1

22

25

0 – 230

5.5

112 (1.13)

112 4

1

3/4

1/2

10.3

4.7

 

 

 

 

 

 

 

 

208/230

1

15

20

0 – 230

6.7

2 (1.5)

2 4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

B

C

D

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

KBAC-29

9528

9529

208/230

1

15

20

0 – 230

6.7

2 (1.5)

25

112

1

3/4

10.3

4.7

 

 

 

 

 

 

 

3

10.8

15

0 – 230

9.0

3 (2.25)

3 5

 

 

 

 

 

 

 

 

 

 

KBAC-453

9530

9531

400/600

3

5.3

10

0 – 400/460

4.6

3 (2.25)

3

2

112

1

3/4

10.3

4.7

KBAC-48 3

9540

9541

400/600

3

9.6

10

0 – 400/460

8.3

5 (3.75)

5

3

2

112

1

10.3

4.7

Notes: 1. White FDA approved finish. 2. Bold indicates factory setting. Jumper J2 on Model KBAC-24D is labeled “1”, “3/4”, “1/2”, “1/4”, “1/8” (factory set to the “1” position). Jumper J2 on Model KBAC-27D is labeled “2”, “112”, “1”, “3/4”, “1/2” (factory set to the “112” position). Jumper J2 on Models KBAC-29, 45, 48 is labeled “A”, “B”, “C”, “D”, “E” (factory set according to the table). 3. Models KBAC-45, 48 are rated 0 – 400 Volts AC for 50 Hz motor operation and 0 – 460 Volts AC for 60 Hz motor operation. 4. Model KBAC-27D is rated 112 HP maximum with 115 Volt AC line input and 2 HP maximum with 208/230 Volt AC line input. 5. Model KBAC-29 is rated 2 HP maximum with single-phase AC line input and 3 HP maximum with 3-phase AC line input.

10

FIGURE 3 – MODEL KBAC-24D MECHANICAL SPECIFICATIONS (INCHES/mm)

 

 

 

5.51

 

 

 

 

140

 

 

 

 

5.06

Maximum Depth:

 

 

 

129

0.31

 

 

5.86

2X

0.25

2.53

7.97

 

6.4

64.4

149

 

4*

 

 

1*

8.85

8.20

9.53

225

208

242

2*

3*

Contains 2 mounting holes for standard 1/2” liquidtight fittings

* Tighten these screws, in the sequence shown, to 12 in-lbs (14 kg-cm).

FIGURE 4 – MODELS KBAC-27D, 29, 45, 48 MECHANICAL SPECIFICATIONS (INCHES/mm)

 

 

 

2X

3.05

 

 

 

 

 

 

 

 

77.7

 

 

 

 

4X

0.25

 

2X

1.00

2X

0.30

 

 

6.4

 

25.4

7.37

 

 

4*

 

 

 

 

1*

 

 

 

 

 

 

 

 

 

8.50

 

 

 

 

 

 

 

 

216

 

 

 

 

 

 

 

 

2X

9.25

 

 

 

 

 

 

 

235

 

 

 

 

 

 

 

 

 

9.80

 

 

 

 

 

 

 

 

249

2*

 

 

 

 

3*

 

 

 

 

 

 

7.15

 

 

Maximum Depth:

7.25

 

 

7.55

181

 

 

184

 

 

 

 

 

 

 

 

 

 

192

 

 

 

 

 

 

11

Contains 2 mounting holes for standard 1/2” liquidtight fittings and 1 mounting hole for standard 3/4” liquidtight fitting. * Tighten these screws, in the sequence shown, to 12 in-lbs (14 kg-cm).

(100 CFM Min.)
and breakdown torque.
FIGURE 6 – OPEN VENTILATED MOTOR WITH EXTERNAL FAN COOLING
Airflow
Open Ventilated Motor
Fan or Blower

4IMPORTANT APPLICATION INFORMATION

4.1MOTOR 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 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 motor if the motor current exceeds the nameplate rating.

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 5.

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 6.

FIGURE 5 – MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED

 

 

100

 

 

 

 

 

 

 

 

 

 

 

 

80

Inverter Duty

 

 

 

 

 

 

 

 

 

 

and TENV

 

 

 

 

 

 

 

 

 

Maximum Allowed

Motor Torque (%)

 

Motors

 

 

 

 

 

Fan Cooled

 

 

 

60

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TEFC and Open Ventilated

 

 

 

 

 

 

 

 

 

Motors

 

 

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20

 

 

 

 

 

 

 

 

 

 

 

 

0

10

20

30

40

50

60

70

80

90

100

 

 

0

 

 

 

 

 

 

Motor Speed (%)

 

 

 

 

4.2 ELECTRONIC MOTOR OVERLOAD PROTECTION – The drive contains Modified I2t Overload Protection.*

Part of this function consists of a Current Limit (CL) circuit, which limits the drive current to a factory 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

Standard I2t 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. KB’s RMS Current Limit Circuit avoids this nuisance tripping while providing maximum motor protection.

If the motor is overloaded to 120% of full load (75% of the CL setting), the I2t 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.

*UL approved as an overload protector for motors.

12

5 WIRING INSTRUCTIONS

WARNING! Read Safety Warning, on page 4, before using the drive. Disconnect main power before making connections to the drive. To avoid electric shock, be sure to properly ground 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 wiring over 12” (30 cm). The shield should be earth grounded on the drive side only. Wire the drive in accordance with the National Electrical Code requirements and other local codes that may apply.

Be sure to properly fuse each AC line conductor that is not at ground potential. Do not fuse neutral or grounded conductors. A separate AC line switch or contactor must be wired as a disconnect so that each ungrounded conductor is opened. For fuse or circuit breaker selection, see Table 5. Also see Section 10, on page 21.

To maintain the watertight integrity of the drive, be sure to use suitable watertight connectors and wiring which are appropriate for the application. Model KBAC-24D contains two mounting holes for standard 1/2” liquidtight fittings (not supplied) (one watertight plug is provided, if only one knockout is used). Models KBAC-27D, 29, 45, 48 contain two mounting holes for standard 1/2” liquidtight fittings (not supplied) and one mounting hole for standard 3/4” liquidtight fitting (not supplied) (two watertight plugs are provided, if only one knockout is used).

The drive is designed with a hinged case so that when the front cover is open, all wiring stays intact. To open the cover, the four screws must be loosened so they are no longer engaged in the case bottom. After mounting and wiring, close the cover making sure that the wires do not get caught or crimped as the cover is closed. Tighten the four screws so that the gasket is slightly compressed. Do not overtighten.

TABLE 5 – TERMINAL BLOCK WIRING INFORMATION

 

 

 

Maximum Wire Size (Cu)

Recommended Tightening Torque

 

 

 

 

 

 

 

Terminal Block

Description

Model

AWG

mm2

in-lbs

kg-cm

TB1

AC Line Input and Motor Wiring

KBAC-24D

12

3.3

7

8

 

 

 

 

 

KBAC-27D, 29, 45, 48

12

3.3

12

14

 

 

 

 

 

 

 

 

 

TB2

Run/Fault Relay Output Contacts

All

16

1.3

3.5

3

 

 

 

 

 

 

 

5.1AC LINE INPUT CONNECTION –

Wire the AC line input to Terminal Block TB1.

GFCI Operation – Do not connect this drive to an AC power source controlled by a Ground Fault Circuit Interrupter. Special software is available for GFCI operation – contact our Sales Department.

Note: The rated AC line voltage of the drive must match the actual AC line input voltage. On Models KBAC24D, 27D, the setting of Jumper J1 must match the AC line input voltage.

FIGURE 7 – MODELS KBAC24D, 27D*

AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS

TB1

 

 

 

 

MOTOR

 

 

 

AC LINE

U

V

W

L1

L2

115, 208/230 Volt

Motor Single-Phase Ground (Earth)

AC Line Input

*Model KBAC-27D is rated 112 HP maximum with 115 Volt AC line input and 2 HP maximum with 208/230 Volt AC line input.

Models KBAC-24D, 27D: Designed to accept single-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. See Figure 7.

13

FIGURE 8 – MODELS KBAC-29*, 45, 48 AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS

 

 

 

 

 

 

 

Model KBAC-29 Only

 

 

 

 

 

 

 

Wire the single-phase AC line input

 

 

 

 

 

 

to Terminals "L1", "L2", as shown below.

TB1

 

 

 

 

 

 

 

 

U

V

W

L1

L2

L3

L1

L2

L3

MOTOR

AC LINE

 

AC LINE

 

Motor

208/230, 400/460 Volt

Ground (Earth)

208/230 Volt

Ground (Earth)

3-Phase, 50/60 Hz

Single-Phase, 50/60 Hz

 

AC Line Input

 

AC Line Input

 

*Model KBAC-29 is rated 2 HP maximum with single-phase AC line input and 3 HP maximum with 3-phase AC line input.

Model KBAC-29: Designed to accept single-phase (Terminals “L1”, “L2”) or 3-phase (Terminals “L1”, “L2”, “L3”) AC line input. Rated for 208/230 Volt AC line input only. See Figure 8.

Models KBAC-45, 48: Designed to accept 3-phase (Terminals “L1”, “L2”, “L3”) AC line input only. Rated for 400/460 Volt AC line input only. See Figure 8.

5.2GROUND CONNECTION – Connect the ground wire (earth) to the Green Ground Screw. The Ground Screw is located next to Terminal Block TB1. See Figure 7, on page 13, and Figure 8.

5.3MOTOR CONNECTION – Wire the motor to Terminal Block TB1 Terminals “U”, “V”, “W”. See Figure 7, on page 13, and Figure 8. Motor cable length should not exceed 100 ft (30 m) – special reactors may be required – consult our Sales Department.

Be sure Jumper J2 is set to the corresponding motor horsepower rating, as described in Section 6.2, on page 17.

5.4 REMOTE MAIN SPEED POTENTIOMETER

FIGURE 9 – REMOTE MAIN SPEED

CONNECTION – The drive is supplied with a

POTENTIOMETER CONNECTION

prewired Main Speed Potentiometer mounted

 

on the front cover.

White (Low)

To operate the drive from a remote poten-

Orange (Wiper)

Violet (High)

tiometer (5 kΩ), remove the white, orange,

 

and violet potentiometer leads from Terminals

Main Speed

“P1”, “P2”, and “P3”. The wires may be taped

Potentiometer

 

and left inside the drive. The potentiometer

 

assembly may be removed if a watertight seal

P3 P2 P1

is used to cover the hole in the front cover.

 

Wire the Main Speed Potentiometer to

 

Terminals “P1” (low side), “P2” (wiper), and “P3” (high side). See Figure 9.

WARNING! Do not earth ground any Main Speed Potentiometer terminals.

Application Note – If it is required that the Remote Main Speed Potentiometer be isolated from the AC line, install the SIAC Signal Isolator (Part No. 9488).

5.5REMOTE START/STOP SWITCH CONNECTION – The drive is supplied with a prewired Start/Stop Switch mounted on the front cover to electronically start and stop the drive.

To operate the drive from a remote Start/Stop Switch (type (ON)-OFF-ON, SPDT), remove the white, black, and red wires from Terminals “RUN”, “COM”, and “STOP”. The wires may be taped and left

14

inside the drive. The switch assembly may be removed if a watertight seal is used to cover the hole in the front cover. After applying power to the drive, momentarily set the Start/Stop switch to the “START” position.

For Start/Stop Switch with normally open stop contact, set Jumper J9 to the “NO” position (factory setting). For Start/Stop Switch with normally closed stop contact, set Jumper J9 to the “NC” position. See Figures 10 and 11. Also see Section 6.8, on page 18.

FIGURE 10 – REMOTE START/STOP SWITCH CONNECTION

WITH NORMALLY OPEN STOP CONTACT

(J9 Installed in “NO” Position)

START

White

RUN

 

 

 

 

 

NC

 

Black

COM

J9

 

 

 

Red

STOP

 

NO

 

 

 

 

STOP

 

 

 

 

Note: To eliminate the start/stop function, hardwire Terminals ”RUN” and “COM” with the jumper that is provided. Set Jumper J9 to the “NO” position. See Figure 12.

WARNING! Using a jumper to eliminate the start/stop func-

tion will cause the motor to run at the Main Speed Potentiometer setting when the AC line is applied.

FIGURE 11 – REMOTE START/STOP SWITCH CONNECTION

WITH NORMALLY CLOSED STOP CONTACT

(J9 INSTALLED IN “NC” POSITION)

 

START

 

 

Normally Open

RUN

 

NC

Momentary Contact

 

(Push to Start)

COM

J9

 

Normally Closed

NO

STOP

 

 

Momentary Contact

 

 

(Push to Stop)

STOP

 

 

5.6VOLTAGE FOLLOWING CONNECTION – An isolated* 0 – 5 Volt DC analog signal input can also

be used to control motor speed in lieu of the Main Speed Potentiometer. The drive output will linearly follow the analog signal input. Wire the signal input positive lead (+) to Terminal “P2” and the negative lead (-) to Terminal “P1”. With external circuitry, a 0 – 10 Volt DC analog signal can also be used. See Figure 13.

*If a non-isolated signal is used, install the SIAC Signal Isolator (Part No 9488). The SIAC accepts voltage

(0 to ±2.5 thru 0 to ±25 volts DC) or current

(4 – 20 mA DC) signal inputs. See Table 2, on page 8.

FIGURE 12 – START/STOP FUNCTION ELIMINATED (TERMINALS HARDWIRED) (JUMPER INSTALLED)

(J9 INSTALLED IN “NO” POSITION)

RUN

 

NC

COM

J9

STOP

 

NO

Note: For signal following operation, the Minimum

Speed Trimpot (MIN) must FIGURE 13 – VOLTAGE FOLLOWING CONNECTIONS (ISOLATED) be set fully counterclockwise.

WARNING! The signal

 

 

+

0 – 5

 

10k

10k

+

0 – 10

input must be isolat-

 

 

V

Volts DC

 

 

V

Volts DC

 

 

-

 

 

 

-

ed from the AC line. Earth

 

 

 

 

 

 

 

 

 

grounding signal wiring will

 

 

 

 

 

 

 

 

 

damage the drive and void

 

 

 

 

 

 

 

 

 

the warranty. It is highly

P3

P2

P1

 

P3

P2

P1

 

 

recommended that the

 

 

 

 

 

 

 

 

 

 

 

 

SIAC Signal Isolator

 

 

 

 

 

 

 

 

 

(Part No. 9488) be installed when using signal following.

 

 

 

 

 

5.7ENABLE CIRCUIT CONNECTION – The drive can also be started and stopped with an Enable circuit (close to run, open to stop). See Figure 14, on page 16.

15

*Layout of Model KBAC-24D varies slightly.

The Enable function is established by

FIGURE 14 – ENABLE CIRCUIT CONNECTION

wiring a switch or contact in series with

 

 

the orange Main Speed Potentiometer

 

Enable Switch or Relay

lead which connects to Terminal “P2”.

White (Low)

(Close to Run)

When the Enable Switch is closed, the

Orange (Wiper)

 

Violet (High)

 

motor will accelerate to the Main

 

 

 

Speed Potentiometer setting. When

Main Speed

 

the Enable Switch is opened, the

Potentiometer

 

motor will decelerate to stop.

 

 

WARNING! If the Enable

P3

P2

P1

 

 

 

Switch is to be mounted

 

 

 

remotely, it is highly recommended

 

 

 

that the SIAC Signal Isolator

FIGURE 15 – RUN/FAULT RELAY OUTPUT

(Part No. 9488) be installed.

CONTACTS CONNECTION

 

 

5.8 RUN/FAULT RELAY CONNECTION – The

Normally Closed

 

NC

Run/Fault Relay Output Contacts are located at

Relay Common

 

 

 

TB2 and can be used to turn on or off equip-

 

COM

Normally Open

 

ment or to signal a warning if the drive is put into

 

NO

 

 

the Stop Mode or a fault has occurred. See

TB2

 

 

Figure 15.

 

 

 

 

 

 

Run/Fault Relay

 

 

The Run/Fault Relay Contact status for various

Output Contacts

 

 

drive operating conditions is shown in Table 6.

 

 

 

TABLE 6 – DRIVE OPERATING CONDITION AND RUN/FAULT RELAY CONTACT STATUS

 

 

Run Relay Operation

 

 

 

 

(Jumper J8 Installed in “R” Position)

Fault Relay Operation

Drive

 

(Factory Setting)

(Jumper J8 Installed in “F” Position)

 

 

 

 

 

Operating

 

Normally

Normally

Normally

Normally

Condition

Description

Open Contact

Closed Contact

Open Contact

Closed Contact

 

 

 

 

 

 

Power Off

Main Power Disconnected

Open

Closed

Open

Closed

 

 

 

 

 

 

Run Mode*

Normal Drive Operation

Closed

Open

Closed

Open

 

 

 

 

 

 

Stop Mode*

Selected by Operator

Open

Closed

Closed

Open

 

 

 

 

 

 

Fault**

Drive Tripped

Open

Closed

Open

Closed

 

 

 

 

 

 

*Run Mode or Stop Mode is selected using the Start/Stop Switch. **Overload, I2t, Short Circuit, Undervoltage, Overvoltage.

6 SETTING SELECTABLE JUMPERS

FIGURE 16 – MODELS KBAC-24D*, 27D AC LINE INPUT VOLTAGE SELECTION

The drive has customer selectable

208/230 Volt AC Line Input

 

jumpers which must be set before

 

(J1 Installed on Terminal “230V”)

115 Volt AC Line Input

the drive can be used. For the

(Factory Setting)

(J1 Installed on Terminal “115V”)

location of jumpers, see Figure 2,

 

 

 

on page 9.

 

 

 

Note: Disconnect the AC line

 

J1

 

before changing position of

115V

23

 

jumpers.

 

 

 

6.1LINE INPUT VOLTAGE SELECTION (J1 (MODELS

KBAC-24D, 27D ONLY)) –

Jumper J1 is factory installed

on Terminal “230V” for 208/230 Volt AC line input. For 115 Volt AC line input, the jumper must be removed and installed on Terminal “115V”. See Figure 16.

16

The factory setting is shown in bold.
*Jumper J2 on Models KBAC-29, 45, 48 is labeled “A”, “B”, “C”, “D”, “E”. **Model KBAC-27D is rated 112 HP maximum with 115 Volt AC line input and 2 HP maximum with 208/230 Volt AC line input. ***Model KBAC-29 is rated 2 HP maximum with sin- gle-phase AC line input and 3 HP maximum with 3-phase AC line input.

Using pliers, gently rock the female terminal back and forth

FIGURE 17 – REMOVING JUMPER J1

while pulling it upward. See Figure 17

ON MODELS KBAC-24D, 27D

6.2 MOTOR HORSEPOWER SELECTION (J2) – Set Jumper J2

Terminal

to the corresponding position for the motor being used.

Removed

See Figure 18.

Terminal

 

6.3 AUTOMATIC RIDE-THROUGH OR MANUAL RESTART

Installed

 

SELECTION (J3) – Jumper J3 is factory set to the “A” position

 

for Automatic Ride-Through. If the power is interrupted for up

 

to 2 seconds, the drive will shut down and then “ride-through”

 

and automatically return to the set frequency. If Jumper J3 is

 

set to the “M” position, the drive will have to be manually

 

restarted for a momentary power loss using the Start/Stop

 

Switch. See Figure 19. Also see Section 11.2, on page 22, for

 

the Status (ST) LED indication.

 

6.4 60 HZ AND 50 HZ MOTOR

OPERATION AND DRIVE

 

OUTPUT FREQUENCY

 

SELECTION (J4 AND J5) – Both

 

jumpers must be set for the

 

appropriate motor

J2

nameplate frequency rating.

 

6.4.1 SETTING THE DRIVE FOR 60 HZ OR 50 HZ MOTOR OPERATION –

The drive is factory set to operate 60 Hz motors. Jumper J4 is factory set to the “1X” position and Jumper J5 is factory set to

the “60Hz” position. For 50 Hz motors, set Jumper J5 to the “50Hz” position, and be sure Jumper J4 is set to the “1X” position. See Figure 20.

6.4.2 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 “2X” mode above the motor rated frequency. See Figure 21, on page 18.

For 120 Hz output with 60 Hz motor, set Jumper J4 to the “2X” position and be sure Jumper J5 is set to the “60Hz” position. For 100 Hz output with 50 Hz motor, set Jumper J4 to

the “2X” position and set Jumper J5 to

FIGURE 18 – MOTOR HORSEPOWER SELECTION

KBAC-24D KBAC-27D

1 2**

3/4 112**

1/2 1

1/4

3/4

1/8

1/2

KBAC-29* KBAC-45* KBAC-48*

A

3***

3

5

 

 

 

 

B

2***

2

3

 

 

 

 

C

112

112

2

 

 

 

 

D

1

1

112

 

 

 

 

E

3/4

3/4

1

 

 

 

 

FIGURE 19 – AUTOMATIC RIDE-THROUGH

OR MANUAL RESTART SELECTION

Automatic Ride-Through

 

 

 

 

(Factory Setting)

Manual Restart

(J3 Installed in “A” Position)

(J3 Installed in “M” Position)

J3

 

 

M

J3

 

 

M

 

 

 

 

 

 

A

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE 20 – 60 Hz AND 50 Hz MOTOR SELECTION

 

60 Hz Motor Operation

 

 

 

 

 

 

 

 

 

 

 

(Factory Setting)

 

50 Hz Motor Operation

(J4 Installed in “1X” Position)

(J4 Installed in “1X” Position)

(J5 Installed in “60Hz” Position)

(J5 Installed in “50Hz” Position)

J4

 

 

1X

 

J5

 

 

60Hz

J4

 

 

1X

 

J5

 

 

60Hz

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2X

 

 

 

 

50Hz

 

 

 

2X

 

 

 

 

50Hz

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the “50Hz” position. See Figure 22, on page 18.

17

6.5 BOOST MODE SELECTION (J6) –

FIGURE 21 – AVAILABLE TORQUE VS. OUTPUT FREQUENCY

Jumper J6 is factory set to the “FIX”

 

 

 

 

 

position for Fixed Boost. For

 

100

 

 

 

Adjustable Boost using the BOOST

 

 

 

 

 

 

 

 

 

Trimpot, set Jumper J6 to the “ADJ”

 

 

 

 

 

position. See Figure 23. Also see

 

 

 

 

 

Section 12.6, on page 23, for the

 

 

 

 

 

BOOST Trimpot range.

Torque

 

 

 

 

6.6 BRAKING MODE SELECTION (J7) –

50

 

 

 

 

 

 

 

%

 

 

 

 

Jumper J7 is factory set to the “RG”

 

 

 

 

 

 

 

 

 

position for Regenerative Braking when

 

 

 

 

 

the Start/Stop Switch is set to the

 

 

 

 

 

“STOP” position. For DC Injection

 

 

 

 

 

Braking, set Jumper J7 to the “INJ”

 

0

 

 

 

position. See Figure 24. Also see

 

0

2

50/60

100/120

Section 12.5, on page 23.

 

 

 

Output Frequency (Hz)

 

When the Injection Brake Mode is

 

 

 

 

 

selected, the DECEL Trimpot is used

 

 

 

 

 

to adjust the brake time and intensity.

 

 

 

FIGURE 22 – 120 HZ & 100 HZ

 

 

 

 

DRIVE OUTPUT FREQUENCY SELECTION

 

6.7RUN/FAULT OUTPUT RELAY

OPERATION SELECTION (J8) –

120 Hz Output with 60 Hz Motor

100 Hz Output with 50 Hz Motor

Jumper J8 is factory set to the “R”

(J4 Installed in “2X” Position)

(J4 Installed in “2X” Position)

position for “Run” operation of the

(J5 Installed in “60Hz” Position)

(J5 Installed in “50HZ” Position)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Run/Fault Relay. For “Fault” operation

 

 

 

1X

 

 

 

 

60Hz

 

 

 

1X

 

 

 

 

60Hz

of the Run/Fault Relay, set Jumper J8

J4

 

 

 

J5

 

 

J4

 

 

 

J5

 

 

to the “F”

 

 

 

2X

 

 

 

 

50Hz

 

 

 

2X

 

 

 

 

50Hz

position. See Figure 25, on page 19.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

For Run/Fault Relay output contacts,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

see Section 5.8, on page, 16. The

FIGURE 23 – FIXED OR ADJUSTABLE BOOST SELECTION

Run/Fault Relay contact status for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fixed Boost

 

 

 

 

 

 

 

 

 

 

various drive operating conditions is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Factory Setting)

 

 

Adjustable Boost

shown in Table 6, on page 16.

 

(J6 Installed in “FIX” Position)

(J6 Installed in “ADJ” Position)

6.8 STOP CONTACT SELECTION (J9) –

 

 

 

 

J6

 

 

FIX

 

 

 

J6

 

 

FIX

 

 

 

 

 

 

 

 

 

 

 

Jumper J9 is factory set to the “NO”

 

 

 

 

 

 

ADJ

 

 

 

 

 

ADJ

position for a normally open stop

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

contact. For remote normally closed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

stop contact, set Jumper J9 to the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“NC” position. See Figure 26, on

FIGURE 24 – REGENERATIVE OR DC INJECTION BRAKING

page 19. Also see Section 5.5, on

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Regenerative Braking

 

 

 

 

 

 

 

 

 

 

pages 14 – 15.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Factory Setting)

 

 

DC Injection Braking

 

 

 

 

 

 

 

 

(J7 Installed in “RG” Position)

(J7 Installed in “INJ” Position)

6.9TORQUE MODE SELECTION (J10) –

Jumper J10 is factory set to the “CT” RG RG

position for Constant Torque Mode, J7 J7 which is desirable for most machine INJ INJ

applications. For Variable Torque Mode, used for HVAC and fan

applications, set Jumper J10 to the “VT” position. See Figure 27, on page 19.

6.10I2T OVERLOAD SELECTION (J11) – Jumper J11 is factory set to the “1” position for Inverter Duty Rated Motors. For Non Inverter Duty Rated Motors and HVAC applications, set Jumper J11 to the “2” position. See Figure 28, on page 19. Also see Section 12.7, on page 24.

18

7

MOUNTING INSTRUCTIONS

 

 

 

FIGURE 25 – “RUN” OR “FAULT”

 

 

It is recommended that the drive be mounted

 

OUTPUT RELAY OPERATION SELECTION

 

 

vertically on a flat surface with adequate

 

 

 

 

 

 

 

 

 

 

 

“Run” Output Relay Operation

 

 

 

 

 

 

ventilation. Leave enough room below the

 

 

 

 

 

 

(Factory Setting)

“Fault” Output Relay Operation

 

drive to allow for AC line, motor connections,

(J8 Installed in “R” Position)

(J8 Installed in “F” Position)

 

and any other wiring that is required.

 

 

 

 

R

 

 

 

 

R

 

Although the drive is designed for outdoor

J8

 

 

 

J8

 

 

 

 

 

 

 

 

 

 

 

 

 

and washdown use, care should be taken to

 

 

 

 

F

 

 

 

 

F

 

avoid extreme hazardous locations where

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

physical damage can occur. When mounting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the drive in an enclosure, the enclosure

 

 

 

 

 

 

 

 

 

 

 

should be large enough to allow for proper

 

 

 

 

FIGURE 26 – NORMALLY OPEN

 

 

heat dissipation so that the ambient temper-

 

 

 

 

 

 

 

OR CLOSED STOP CONTACT SELECTION

 

ature does not exceed 45 °C (113 °F) at full

 

 

 

 

 

 

 

 

 

 

 

 

 

rating. See Figures 3 and 4, on page 11.

Normally Open Stop Contact

 

 

 

 

 

 

 

 

 

 

(Factory Setting)

Normally Closed Stop Contact

 

 

 

 

WARNING! Do not use this drive in

(J9 Installed in “NO” Position)

(J9 Installed in “NC” Position)

 

 

 

 

an explosion-proof application.

J9

 

 

 

NC

J9

 

 

 

NC

 

 

 

 

 

 

 

 

 

 

 

8

RECOMMENDED HIGH VOLTAGE

 

 

 

NO

 

 

 

NO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DIELECTRIC WITHSTAND TESTING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(HI-POT TESTING)

 

 

 

 

 

 

 

 

 

 

 

Testing agencies such as UL, CSA, VDE,

 

 

 

 

 

 

 

 

 

 

 

etc., usually require that equipment undergo

FIGURE 27 – CONSTANT OR VARIABLE TORQUE SELECTION

 

a hi-pot test. In order to prevent catastrophic

 

 

 

 

 

 

 

 

 

 

 

Constant Torque

 

 

 

 

 

 

damage to the drive which has been installed

 

 

 

 

 

 

(Factory Setting)

Variable Torque

 

in the equipment, the following procedure

(J10 Installed in “CT” Position)

(J10 Installed in “VT” Position)

 

is recommended. A typical hi-pot test setup

 

 

 

 

CT

 

 

 

 

CT

 

is shown in Figure 29, on page 20. All drives

J10

 

 

 

J10

 

 

 

 

 

 

 

 

 

 

 

 

 

have been factory hi-pot tested in accor-

 

 

 

 

VT

 

 

 

 

VT

 

dance with UL requirements.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING! All equipment AC line

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

inputs must be disconnected

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

from the AC power.

 

FIGURE 28 – I2t OVERLOAD SELECTION

 

 

8.1 Connect all equipment AC power input

Inverter Duty Rated Motor

Non Inverter Duty Rated

 

 

 

 

lines together and connect them to the

(Factory Setting)

Motor Operation

 

 

 

 

H.V. lead of the hi-pot tester. Connect

(J11 Installed in “1” Position)

(J11 Installed in “2” Position)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the RETURN lead of the hi-pot tester

 

 

 

 

2

 

 

 

 

2

 

 

 

 

to the frame on which the drive and

J11

 

 

 

 

J11

 

 

 

 

 

 

 

 

other auxiliary equipment are mounted.

 

 

 

 

1

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8.2The hi-pot tester must have an

automatic ramp-up to the test voltage and an automatic ramp-down to zero voltage.

Note: If the hi-pot tester does not have automatic ramping, then the hi-pot output must be manually increased to the test voltage and then manually reduced to zero. This procedure must be followed for each machine to be tested. A suggested hi-pot tester is Slaughter Model 2550.

CAUTION! Instantly applying the hi-pot voltage will cause irreversible damage to the drive, which will void the warranty.

19

20

FIGURE 29 – TYPICAL HI-POT TEST SETUP

High Voltage Dielectric Withstand Tester (Hi-Pot Tester)

12

LEAKAGE

0

3

AC KILOVOLTS

0mA

10mA

 

 

 

 

RETURN

TEST

VOLTAGE

 

 

 

H. V.

RESET

 

 

 

 

 

ZERO

MAX

 

 

Connect All Drive Terminals Together

 

 

 

 

 

 

 

 

 

Adjustable Frequency Drive

(Main Power Disconnected)

AC Line Input

 

 

 

 

 

 

 

 

L1

U

 

 

 

 

L2

V

Motor Wires

 

 

 

 

 

 

 

L3

W

Frame

 

 

 

 

 

 

 

Auxiliary Equipment

Signal Inputs

 

 

 

 

 

Connect Hi-Pot

 

L1

P1

 

 

to AC Line Inputs

 

 

 

 

 

 

 

 

(Main Power Disconnected)

 

L2

P2

 

 

 

 

 

 

 

 

Chassis

P3

 

Chassis

Machine Equipment or Frame

 

 

 

 

9DRIVE OPERATION

9.1START-UP PROCEDURE – After the drive has been properly setup (jumpers and trimpots set to the desired positions) and wiring completed, the start-up procedure can begin. If the AC power has been properly brought to the drive, the power (PWR) LED will illuminate green. The status (ST) LED will indicate drive status, as described in Section 11.2, on page 22.

To start the drive, momentarily set the Start/Stop Switch to the “START” position. The motor will begin to accelerate to the set speed.

WARNING! Using a jumper to eliminate the start/stop function will cause the motor to run at the Main Speed Potentiometer setting when the AC line is applied.

Note: If the motor rotates in the incorrect direction, it will be necessary to disconnect the AC line, reverse any two motor leads, and repeat the start-up procedure.

9.2FAULT RECOVERY – The drive monitors four faults (Undervoltage, Overvoltage, Short Circuit at the motor (phase-to-phase), I2t).

See Section 9.3, for restarting the drive after an I2t fault has cleared. Also see Section 11.2, on page 22, for the Status (ST) LED indication.

9.3RESTARTING THE DRIVE AFTER AN I2T FAULT – The drive can be restarted after an I2t Fault has cleared by any of the following methods.

Note: Be sure the fault (overload) has been cleared before restarting the drive. Check the motor current with an AC RMS responding ammeter. Also, the CL setting may be set too low. See Section 12.7, on page 24.

1.Set the Start/Stop Switch to the “START” position.

2.Disconnect and reconnect the AC power (approximately 15 seconds). The “ST” LED must change from quick flashing red to flashing red/yellow.

3.Set the Main Speed Potentiometer to zero (fully counterclockwise).

Note: In order to be able to restart the drive by setting the Main Speed Potentiometer to zero, it is necessary to have the MIN Trimpot set to zero (fully counterclockwise).

Note: If the Forward-Stop-Reverse Switch has been installed, it can be used to restart the drive.

10AC LINE FUSING

The drive does not contain line fuses. Most electrical codes require that each ungrounded conductor contain circuit protection. Do not fuse neutral or ground connections. It is recommended to install a fuse (Littelfuse 326, Buss ABC, or equivalent) or a circuit breaker in series with each ungrounded conductor. Do not fuse motor leads. For the recommended fuse size, see Table 4, on page 10.

Wire the drive in accordance with the National Electrical Code requirements and other local codes that may apply to the application.

11DIAGNOSTIC LEDS

The drive contains two diagnostic LEDs mounted on the enclosure cover to display the drive’s operational status.

11.1POWER ON LED (PWR) – The “PWR” LED will illuminate green when the AC line is applied to the drive.

WARNING! Do not depend on the PWR LED as a guaranteed power off condition.

Be sure the main power switch or circuit breaker is in the “OFF” position before

servicing this drive.

21

11.2STATUS LED (ST) – The “ST” LED is a tricolor LED which provides indication of a fault or abnormal condition. The information provided can be used to diagnose an installation problem such as incorrect input voltage, overload condition, and drive output miswiring. It also provides a signal which informs the user that all drive and microcontroller operating parameters are normal. Table 7, summarizes the “ST” LED functions.

TABLE 7 – DRIVE OPERATING CONDITION AND STATUS LED INDICATOR

Drive Operating Condition

Flash Rate1 and LED Color

Normal Operation

Slow Flash Green

 

 

Overload (120% – 160% Full Load)

Steady Red 2

I2t (Drive Timed Out)

Quick Flash Red 2

Short Circuit

Slow Flash Red

 

 

Undervoltage

Quick Flash Red / Yellow3

Overvoltage

Slow Flash Red / Yellow3

Stop

Steady Yellow

 

 

Notes: 1. Slow Flash = 1 second on and 1 second off. Quick Flash = 0.25 second on and 0.25 second off. 2. When the Overload is removed, before the I2t times out and trips the drive, the “ST” LED will flash green. 3. When the Undervoltage or Overvoltage condition is corrected, the “ST” LED will flash Red / Yellow / Green.

12TRIMPOT ADJUSTMENTS

The drive contains trimpots which are factory set for most applications. See Figure 2, on page 9, 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 described below.

WARNING! If possible, do not adjust trimpots with the main power applied. If adjustments are made with the main power applied, an insulated adjustment tool must be used and safety glasses must be worn. High voltage exists in this drive. Fire and/or electrocution can result if caution is not exercised. Safety Warning, on page 5, must be read and understood before proceeding.

12.1MINIMUM SPEED (MIN) – Sets the minimum speed of the motor. The MIN Trimpot is factory set to 0% of frequency setting. For a higher minimum speed setting, rotate the MIN Trimpot clockwise. See Figure 30.

12.2MAXIMUM SPEED (MAX) – Sets the maximum speed of the motor. The MAX Trimpot is factory set to 100% of frequency setting. For a lower maximum speed setting, rotate the MAX Trimpot counterclockwise. For a higher maximum speed setting, rotate the MAX Trimpot clockwise. See Figure 31.

12.3ACCELERATION (ACCEL) – Sets the amount of time for the motor to accelerate from zero speed to full speed. The ACCEL Trimpot is factory set to 1.5 seconds. For a longer acceleration time, rotate the ACCEL Trimpot clockwise. For more rapid acceleration, rotate the ACCEL Trimpot counterclockwise. See Figure 32.

FIGURE 30 – MINIMUM SPEED

TRIMPOT RANGE

 

30

15

35

0

40

MIN

(Shown Factory Set to 0% Frequency Setting)

FIGURE 31 – MAXIMUM SPEED

TRIMPOT RANGE

 

80

75

90

 

100

70

110

MAX

(Shown Factory Set to 100% Frequency Setting)

FIGURE 32 – ACCELERATION

TRIMPOT RANGE

 

10

3

17

1.5

 

0.3

20

ACCEL

(Shown Factory Set to 1.5 Seconds)

Note: Rapid acceleration settings may cause the current limit circuit to activate, which will extend the acceleration time.

22

12.5

12.4 DECELERATION (DECEL) – Sets the amount of time for the

 

FIGURE 33 – DECELERATION

motor to decelerate from full speed to zero speed. The DECEL

 

 

 

TRIMPOT RANGE

Trimpot is factory set to 1.5 seconds. For longer deceleration time,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

rotate the DECEL Trimpot clockwise. For more rapid deceleration,

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

17

rotate the DECEL Trimpot counterclockwise. See Figure 33.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Application Note – On applications with high inertial loads, the

 

1.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.3

 

 

 

 

 

 

 

 

 

 

 

20

deceleration may automatically increase in time. This will slow

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DECEL

down the rate of speed of decrease to prevent the bus voltage

 

 

 

 

 

 

 

 

 

(Shown Factory Set to 1.5 Seconds)

from rising to the Overvoltage Trip point. This function is called

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Regeneration Protection. It is recommended that for very high

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

inertial loads that both

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the ACCEL and DECEL

 

FIGURE 34 – DC INJECTION BRAKE TRIMPOT RANGE

Trimpots be set to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Models KBAC-24D, 27D, 29

 

 

Models KBAC-45, 48

greater than 10 seconds.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

40, 2.0

 

 

 

 

 

 

80, 2.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DC INJECTION BRAKE

43, 1.5

 

 

 

 

 

 

 

 

 

31, 2.5

 

86, 1.5

 

 

 

 

 

 

 

 

 

 

62, 2.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(DECEL) – The drive is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

49, 1.2

 

 

 

 

 

 

 

 

 

 

 

98, 1.2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

factory set for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

57, 1.0

 

 

 

 

 

 

 

 

 

23, 3.0

 

114, 1.0

 

 

 

 

 

 

 

 

 

 

46, 3.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Regenerative Braking

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DECEL

 

 

 

 

 

 

 

DECEL

(Jumper J7 set to the “RG”

 

 

 

 

 

 

 

 

 

 

 

(Shown Factory Set to 49 Volts for 1.2 Seconds)

 

(Shown Factory Set to 98 Volts for 1.2 Seconds)

position). When the drive is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

set for DC Injection Brake

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Jumper J7 set to the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“INJ” position), the DECEL trimpot is used to set the DC Injection

 

FIGURE 35 – SLIP COMPENSATION

Brake voltage and time. See Figure 34. Also see Section 6.6,

 

 

 

TRIMPOT RANGE

on page 18.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The DC Injection Brake voltage and time range is 10% of full drive

 

0.8

 

 

 

 

 

 

 

 

 

 

 

2.3

 

 

 

 

 

 

 

 

 

 

 

 

output voltage for 3 seconds with the trimpot fully clockwise and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

25% of full drive output voltage for 1 second with the trimpot fully

 

0

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

counterclockwise. Models KBAC-24D, 27D, 29 are factory set for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COMP

49 Volts for 1.2 seconds and Models KBAC-45, 48 are factory set

 

 

 

 

 

 

 

 

 

(Shown Factory Set to 1.5 Volts/Hz)

for 98 Volts for 1.2 seconds.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Adjust the trimpot so that the load stops within the required time.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12.6 SLIP COMPENSATION (COMP) – Sets the amount of Volts/Hz

 

FIGURE 36 – CURRENT LIMIT

to maintain set motor speed under varying loads. The COMP

 

 

 

TRIMPOT RANGE

Trimpot is factory set to 1.5 Volts/Hz, which provides excellent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

120

 

 

 

 

 

 

 

speed regulation for most motors. To increase the slip compensa-

 

 

 

 

 

 

 

 

 

 

 

80

 

 

 

 

 

 

 

 

 

 

 

 

 

 

tion, rotate the COMP Trimpot clockwise. To decrease the slip

 

 

 

 

 

 

 

 

 

 

 

 

160

compensation, rotate the COMP Trimpot counterclockwise.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

See Figure 35.

 

 

 

 

 

 

 

 

 

 

 

 

 

40

 

 

 

 

 

 

200

The slip compensation may be adjusted as follows:

 

 

 

 

 

 

 

 

CL

 

(Shown Factory Set to 160% Full Load)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.Wire an AC RMS ammeter in series with one motor phase.

2.Run the motor and set the unloaded speed to approximately 50% (900 RPM on 4-pole 1500/1725 RPM motors).

3.Using a tachometer, record the unloaded speed.

4.Load the motor to the nameplate rated current (AC Amps).

5.Adjust the COMP Trimpot until the loaded RPM is equal to the unloaded RPM.

6.The motor is now compensated to provide constant speed under varying loads.

23

12.7MOTOR OVERLOAD (I2T) WITH RMS CURRENT LIMIT (CL)* – Sets the current limit (overload), which limits the maximum current to the motor, which prevents motor burnout and eliminates nuisance trips. The CL Trimpot is factory set to 160% of the drive rated current. To increase the current limit, rotate the CL Trimpot clockwise. To decrease the current limit, rotate the CL Trimpot counterclockwise. See Figure 36, on page 23, and Figure 37.

*UL approved as an electronic overload protector for motors.

CAUTION! Adjusting the current limit above 160% of the motor nameplate rating can cause overheating of the motor. Consult the motor manufacturer. Do not leave the motor in a locked rotor condition for more than a few seconds since motor damage may occur.

In order to ensure that the motor is properly protected with the I2t feature, it is required that the CL Trimpot be set for 160% of the motor nameplate rated current, as described below.

Note: This adjustment must be made within 6 seconds or the I2t Trip will occur.

The current limit may be adjusted as follows:

1.Connect an AC RMS ammeter in series with one motor phase.

2.Set the CL Trimpot fully counterclockwise.

3.Adjust the speed setting to 30%.

4.Lock the motor shaft and adjust the CL Trimpot to 160% of the motor nameplate rated current.

FIGURE 37 – I2t TRIP TIME VS. MOTOR CURRENT

Trip Time (Minutes)

1000

100

10

CL (Factory Setting)

1

0.1

110

120

130

140

150

160

Motor Current (%)

12.8BOOST (BOOST) – The drive is factory set for Fixed Boost (Jumper J6 set to the “FIX” position). When the drive is set for Adjustable Boost (Jumper J6 set to the “ADJ” position), the BOOST Trimpot can be used to adjust the amount of boost voltage to the motor. See Figure 38, on page 25. Also see Section 6.5, on page 18.

Application Note – The Boost function operates over a frequency range of 0 – 15 Hz. If the frequency range required is above 15 Hz, Boost adjustment is not necessary.

24

WARNING! To avoid motor winding overheating and failure, do not overboost the motor.

Note: An unloaded motor with excessive boost will draw more current than a partially loaded motor.

The boost voltage may be adjusted as follows:

1.Wire an AC RMS ammeter in series with one motor phase.

2.Run the motor unloaded at approximately 4 Hz (or 120 RPM).

3.Increase the boost until the ammeter reaches the motor nameplate rated current (Amps AC).

4.Using the Main Speed Potentiometer, slowly adjust the motor speed over a 1 – 15 Hz (0 – 450 RPM) range. If the motor current exceeds the nameplate rating, decrease the boost setting.

12.9JOG (JOG) – The Jog feature must be used with the optional Run-Stop-Jog Switch. A “jog” speed can be obtained by wiring a contact from Terminal “JOG” to Terminal “COM”. When the JOG contact is closed, the Main Speed Potentiometer is disabled and the JOG Trimpot is used for the speed setting. When the JOG contact is opened, the drive must be restarted (using the Start/Stop Switch to “start” the drive). See Figure 39.

FIGURE 38 – BOOST

TRIMPOT RANGE

 

15

8

22

5

 

0

30

BOOST

(Shown Factory Set to 5 Volts/Hz)

FIGURE 39 – JOG

TRIMPOT RANGE

35

50

 

25

75

0

100

JOG

(Shown Factory Set to 35% Frequency Setting)

A Run-Stop-Jog Switch (Part No. 9524) is available as an optional accessory. See Table 2, on page 8.

25

– NOTES –

26

– NOTES –

27

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)

COPYRIGHT © 2006 KB Electronics, Inc.

All rights reserved. In accordance with the United States Copyright Act of 1976, no part of this publication may be reproduced in any form or by any means without permission in writing from KB Electronics, Inc. (8/2002)

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 • info@kbelectronics.com www.kbelectronics.com

(A40206) – Rev. A – 3/2006

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