KB Electronics KBAC SERIES Instruction Manual

Installation & Operation Manual

KBAC SERIES

Adjustable Frequency Drives 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 & 60 Hz

3-Phase & PSC2 AC Induction Motors from Subfractional thru 10 HP

AC MOTOR SPEED CONTROL

Hybrid Drive

KBAC SERIES • NEMA 4X / IP65

™

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

AC MOTOR SPEED CONTROL

Hybrid Drive

KBAC SERIES • NEMA 4X / IP 65

™

AC MOTOR SPEED CONTROL

Hybrid Drive

KBAC SERIES • NEMA 4X / IP 65

™

This Manual Covers Models

KBAC-24D, 27D, 29, 29 (1P), 45, 48, 217, 217S, 217F, 217SF, 416, 416S, 416F, 416SF

NOTE: THE DRIVE IS FACTORY SET FOR

See Safety Warning on Page 6.

60 Hz MOTORS. FOR 50 Hz MOTORS, SEE SECTION 6.4 ON PAGE 24.

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 – contact our Sales Department. 3. GFCI Operation: Models KBAC-24D, 27D, 29, 29 (1P), 45, 48 require custom software – contact our Sales Department. The KBAC-217, 416 Series are jumper selectable (J12) for standard (G1) and sensitive (G2) GFCIs. 4. Installation of a CE approved RFI lter is required.

Table of Contents

Section Page

1 Quick-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Important Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing). . . . . . . . . . . . . . . . . . . . 26

9 Reconditioning the Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10 Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

11 AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

12 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

13 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Appendix A – Optional SIAC-PS Signal Isolator with Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Tables Page

1 Jumper Selectable Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 General Performance Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Electrical Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 Drive Operating Condition and Run/Fault Relay Contact Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7 Drive Operating Condition and Status LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figures Page

1 Quick-Start Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 KBAC-24D Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 KBAC-27D, 29, 29 (1P), 45, 48 Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 KBAC-217, 416 Series Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Model KBAC-24D Mechanical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6 Models KBAC-27D, 29, 29 (1P), 45, 48 Mechanical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7 KBAC-217, 416 Series Mechanical Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 Maximum Allowed Motor Torque vs. Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9 Open Ventilated Motor with External Fan Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

10 Models KBAC-24D, 27D, 29 (1P), AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . 20

11 Models KBAC-29, 45, 48 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . 20

12 KBAC-217, 416 Series AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . 20

13 Remote Main Speed Potentiometer Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

14 Remote Start/Stop Switch Connection with Normally Open Stop Contact . . . . . . . . . . . . . . . . . . . . 21

15 Remote Start/Stop Switch Connection with Normally Closed Stop Contact . . . . . . . . . . . . . . . . . . . 21

16 Start/Stop Function Eliminated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

17 Voltage Following Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

18 Enable Circuit Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

19 Run/Fault Relay Output Contacts Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

20 Models KBAC-24D, 27D AC Line Input Voltage Selection (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . 23

21 Removing Jumper J1 on Models KBAC-24D, 27D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

22 Motor Horsepower Selection (Jumper J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

23 Automatic Ride-Through or Manual Restart Selection (Jumper J3) . . . . . . . . . . . . . . . . . . . . . . . . . 24

24 60 Hz and 50 Hz Motor Selection (Jumpers J4 and J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

25 Available Torque vs. Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

26 120 Hz and 100 Hz Drive Output Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

27 Fixed or Adjustable Boost Selection (Jumper J6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

28 Regenerative or DC Injection Braking Selection (Jumper J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

29 “Run” or “Fault” Output Relay Operation Selection (Jumper J8). . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

30 Normally Open or Closed Stop Contact Selection (Jumper J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

31 Constant or Variable Torque Selection (Jumper J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

32 Switching Frequency and GFCI Selection (Jumper J12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

33 Typical Hi-Pot Test Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

34 Minimum Speed Trimpot (MIN) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

36 Acceleration Trimpot (ACCEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

37 Deceleration Trimpot (DEC/I) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

38 DC Injection Brake Trimpot (DEC/I) Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

39 Slip Compensation Trimpot (COMP) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

40 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

41 I2t Trip Time vs. Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

42 Boost Trimpot (BOOST) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

43 Jog Trimpot (JOG) Range Run-Stop-Jog Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

44 Run-Stop-Jog Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Items Included In this Package:

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

Drive Model Nos. and Part Nos.

Model No.

KBAC-24D 9987 9988 KBAC-217 8868 8879 KBAC-27D 9520 9521 KBAC-217S 8863 8855 KBAC-29 9528 9529 KBAC-217F 8861 8853 KBAC-29 (1P) 10001 10002 KBAC-217SF 8869 8880 KBAC-45 9530 9531 KBAC-416 8870 8881 KBAC-48 9540 9541 KBAC-416S 8864 8856

*White FDA approved nish.

Part No.

Gray White* Gray White*

Model No.

KBAC-416F 8874 8883 KBAC-416SF 8871 8882

Part No.

UL Notice

230 VAC Controls

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 ºC.

Suitable for Operation in a Maximum Surrounding Air Temperature of 40 ºC.

460 VAC Controls

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 ºC.

Suitable for Operation in a Maximum Surrounding Air Temperature of 40 ºC.

iii

1 QUICK-START INSTRUCTIONS

see Section 5.2 on page 20.

Models KBAC-416 , 416S, 416F, 416SF see Section 5.1 on pages 19 and 20.

Important – You must read these simplied 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.

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.

See Figure 1. Also see Section 4 - Important Application Information on Page 18.

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

Figure 1 – Quick-Start Connection Diagram*

TB1

L1V WU L3

AC LINEM OTOR

Motor

208/230 Volt, 1-Phase,

50/60 Hz, AC Line Input

3-Phase

AC Induction Motor:

see Section 5.3 on page 21.

(Terminals L1, L2) Models KBAC-24D, 27D, 29, 29 (1P): see Section 5.1 on pages 19 and 20.

Ground (Earth):

208/230 Volt, 3-Phase, 50/60 Hz, AC Line Input (Terminals L1, L2, L3)

Models KBAC-29, 217, 217S, 217F, 217SF see Section 5.1 on pages 19 and 20.

400/460 Volt, 3-Phase, 50/60 Hz, AC Line Input (Terminals L1, L2, L3)

*Layout may vary.

1.1 AC Line Input Connection – Wire the AC Line input to Terminal Block TB1. See Section 5.1 on pages 19 and 20.

Application Note: GFCI Operation: Models KBAC-24D, 27D, 29, 29 (1P), 45, 48 require custom

software – contact our Sales Department. The KBAC-217, 416 Series are jumper selectable (J12) for Standard (G1) or Sensitive (G2) GFCIs.

Note: The rated AC Line voltage of the drive must match the actual AC Line input voltage. On Models

KBAC-24D and 27D, the setting of Jumper J1 must match the AC Line input voltage.

Models 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. See Figure 10 on page 20.

Note: Model 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.

Model 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. See Figure 11 on page 20.

Note: Rated for 2 HP maximum with 1-phase AC Line input and 3 HP maximum with 3-phase AC Line

input. For 3 HP rating with single-phase input, use Model KBAC-29 (1P).

Models 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. See Figure 12 on page 20.

Models KBAC-45, 48, 416, 416S, 416F, 416FS: Designed to accept 3-phase (Terminals L1, L2, L3)

AC Line input only. Rated for 400/460 Volt AC Line input only. See Figure 12 on page 20.

1.2 AC 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 14. Also see Section 11 on page 28.

1.3 Ground Connection – Connect the ground wire (earth) to the ground screw, as shown in Figures 10 -12 on page 20. See Section 5.2 on page 20.

1.4 Motor Connection – Wire the motor to Terminal Block TB1 Terminals U, V, W, as shown in Figures 10 -12 on page 20. (Special reactors may be required for cable lengths over 100 ft. (30 m) – consult our Sales Department.) See Section 5.3 on page 21.

1.5 60 Hz And 50 Hz Motor Operation – The drive is factory set for 60 Hz 3-phase 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 24.

1.6 Start/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 page 21. 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 25.

1.7 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 specic application. See section 6 on pages 23 – 26.

IMPORTANT: In order 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 22 on page 24.

1.8 Trimpot Settings – All trimpots have been factory set for most applications. Some applications require adjustment of the trimpots in order to tailor the drive for a specic requirement. See Section 13 on pages 29 – 32.

1.9 Diagnostic LEDs – After power has been applied, observe the LEDs to verify proper drive operation, as described in Section 12 on pages 28 and 29.

2 SAFETY WARNING

Denition of Safety Warning Symbols

Electrical Hazard Warning Symbol – Failure to observe this warning could result in electrical

shock or electrocution.

Operational Hazard Warning Symbol – Failure to observe this warning could result in serious

injury or death.

This product must be installed and serviced by a qualied technician, electrician, or

Proper installation, which includes electrical connections, fusing or other current protection, and grounding, can reduce the chance of electrical shocks, and/or res, 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 ltering of this product can reduce the emission of radio frequency interference (RFI) which may adversely aect 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)

required. See RFI Filters & Chokes Selection Guide D-321 (Part No. A42027) for selection of lters that meet the Industrial or Residential Standard. Additional shielded cable and/or AC Line cables may be required along with a signal isolator (SIAC-PS).

3 INTRODUCTION

Thank you for purchasing the KBAC Adjustable Frequency Drive. KB Electronics, Inc. is committed to pro-

viding 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 eciency 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 specic

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 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 equipment on or o , 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, DEC/I, 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 (KBAC-217 Series and KBAC-416 Series only).

electrical maintenance person familiar with its operation and the hazards involved.

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 lter is

Optional accessories include: Forward-Stop-Reverse Switch, On/O 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 (Models KBAC-24D, 27D, 29, 29 (1P), 45, 48) – contact our Sales Department.

*UL approved as an electronic overload protector for motors.

3.1 Standard Features

• Industrial Duty Die-Cast Aluminum Case with Hinged Cover – Available in Dark Gray nish or

FDA approved white nish.

• 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. (KBAC-217 Series and KBAC-416 Series only.)

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

• Run/Fault Relay Output Contacts – Can be used to turn equipment on or o, 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.

Note: GFCI Operation: Models KBAC-24D, 27D, 29, 29 (1P), 45, 48 require custom software – contact

our Sales Department. The KBAC-217 Series and KBAC-416 Series are jumper selectable (J12) for Standard (G1) or Sensitive (G2) GFCIs.

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 (I2t) 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 – Protects the drive components against damaging voltage

spikes on the AC Line.

• 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 13.1 on page 29.

• Maximum Speed (MAX) – Sets the maximum speed of the motor. See Section 13.2 on page 29.

• Acceleration (ACCEL) – Sets the amount of time for the motor to accelerate from zero speed to

full speed. See Section 13.3 on page 29.

• Deceleration (DEC/I) – Sets the amount of time for the motor to decelerate from full speed to

zero speed. See Section 13.4 on page 27.

• DC Injection Brake (DEC/I) – When the drive is set for DC Injection Braking (Jumper J7 set to

the “INJ” position), the DEC/I trimpot is used to set the DC Injection Brake voltage and time. See Section 13.5 on pages 29 and 30.

• Slip Compensation (COMP) – Maintains set motor speed under varying loads. See Section 13.6

on page 30.

• Current Limit (CL) – Sets the current limit (overload) which limits the maximum current to the

motor. See Section 13.7 on pages 30 and 31.

• Boost (BOOST) – Sets the amount of Boost which can be used to obtain maximum low speed

performance. See Section 13.8 on pages 31 and 32.

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

Switch Kit (See Table 2 on page 9). See Section 13.9 on page 32.

Table 1 – Jumper Selectable Features

Description

AC Line Input Voltage (115, 230) J1 Motor Horsepower (see Table 4 - Electrical Ratings on page 14) J2 Automatic Ride-Through or Manual Restart (A2, M) J3 Frequency Multiplier (1X, 2X) J4 Motor Frequency (50Hz, 60Hz) J5 Fixed or Adjustable Boost (FIX, ADJ) J6 Regenerative or DC Injection Braking (RG, INJ) J7 “Run” or “Fault” Output Relay Operation (R, F) J8 Normally Open or Closed Stop Contact (NO, NC) J9 Constant or Variable Torque (VT, CT) J10 Factory Use Only J11 — — — Switching Frequency and GFCI (8 kHz, 12 kHz, G1, G2) J12 — —

Notes: 1. Bold indicates factory setting. 2. In Automatic Ride-Through Mode, the drive will automatically restart due to a momentary power loss of less than 2 seconds.

PC Board

Designation KBAC-24D, 27D KBAC-29, 29 (1P), 45, 48

p p p

— —

KBAC-217 Series KBAC-416 Series

Table 2 – Optional Accessories

Description KBAC-24D KBAC-27D KBAC-29 KBAC-29 (1P) 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 liquidtight integrity.

On/O AC Line Switch – Disconnects the AC Line. Mounts on the enclosure 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 with a switch seal to maintain liquidtight integrity.

SIAC-PS Signal Isolator with Power Supply – Provides isolation between a non-isolated signal source 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 and is supplied with a switch seal to maintain liquidtight integrity.

AC Line Filter* – Provides Class A RFI (EMI) suppression. Installs onto the drive’s PC board with quick-connect terminals. “S” Sux: Filter is used when On/O AC Line Switch is installed. “NS” Sux: Filter is used when On/O AC Line Switch is not installed.

Liquidtight Fittings – Provide a liquidtight seal for wiring the drive. Kit includes three 1/2” and one 3/4” liquidtight ttings for case A and case B drives, and one 1/2” and two 3/4” liquidtight ttings for case C drives.

* Complies with CE Council Directive 89/336/EEC Industrial Standard.

9480 9480 9480 9480 9480 9480 8888

9482 9523 9532 9532 9532 9532

9340 9340 9340 9340 9340 9340 8889

9600C* 9600C* 9600C* 9600C* 9600C* 9600C* 8890

9481 9481 9481 9481 9481 9481 8891

“S”

9507 9512 9479 — 9479 9479

Sux

“NS”

9507 9512 9515 — 9515 9515

Sux

9526 9526 9526 9526 9526 9526 8892

KBAC-217 Series KBAC-416 Series

“S” Sux Models (Factory Installed

Only)

9516

*Warning! It is highly recommended that the SIAC-PS Signal Isolator with Power Supply be

installed when using the drive with external control signals. See Appendix A, on Page 33,

for more information.

Figure 2 – KBAC-24D Control Layout

LED Board See Section 12 on page 23.

POWER STATUS

Violet (High)

Orange (Wiper)

White (Low)

Main Speed Potentiometer See Section 5.4 on page 21.

Start/Stop Switch See Section 5.5 on page 21.

Run/Fault Relay Output Contacts See Section 5.9 on page 23.

Used for optional Forward-Stop-Reverse Switch. See Table 2 on page 9.

Used for optional SIAC Signal Isolator. See Table 2 on page 9.

White

Black

Red

TB2

N.C.

COM

N.O.

CON2

FWD

COM

REV

RUN

COM

STOP

MAX ACCEL DECELMIN CLBOOST

MAX MIN ACCEL DEC/I BOOST

JOGP1P2P3

B- B+

(BLK)

(RED)

JOGCOMP

J10

COMP JOG

1HP 3/4 1/2

1/4 1/8

FIX BST ADJ

INJ

RELAY

STOP

J11

MAN

AUTO

1X MULT

60HZ

FREQ 50HZ

CON1

115V

230V J1

L2BL2AL1BL1A

TB1

WVU

MOTOR

L1 L2 AC LINE

All jumpers and trimpots are shown in factory set positions.

A – JOG Terminal. Used with optional Run/Jog Switch Kit. See Table 2 on page 9.

B – Adjustable trimpots. See Section 13 on Pages 29 - 32. C – J3: Automatic Ride -Through or Manual Restart selection.

See S ection 6.3 on page 23. E – J2: Motor Horsepower selection. See S ection 6.2 on pages 23 and 24. D – J4: 1X or up to 2X Rated Motor RPM Operation selection. See S ection 6.4 on page 24. G – J6: Fixed or Adjustable Boost selection. See S ection 6.5 on page 24. F – J5: 60 Hz or 50 Hz Motor Operation selection. See S ection 6.4 on page 24. H – J7: Regenerative or Injection Braking selection.

See S ection 6.6 on page 25.

I – J8: Run or Fault Output Relay Operation selection. See S ection 6.7 on page 25. J – J9: Normally Open or Closed Stop Contact selection. See S ection 6.8 on page 25.

L – J11: Not used. K – J10: Constant or Variable Torque selection.

See S ection 6.9 on page 25. M – CON1: Used to connect optional accessories to the drive. See Table 2 on page 9. N – J1: AC Line Input Voltage selection. (Models KBAC-24D, 27D only.) See S ection 6.1 on page 23. O – L1A/L1B and L2A/L2B: For optional On/O AC Line Switch. See Table 2 on page 9. P – TB1: Motor and AC Line input connections. See S ections 5.1 - 5.3 on pages 19 - 21.

Start/Stop Switch

Orange (Wiper)

Main Speed Potentiometer

E 1/2

All jumpers and trimpots are shown in factory set positions.

C 1

D 3/4

B 1 1/2

A 2

2 B

ADJ

FIXJ6RG

INJJ7R

FJ8NC

1 A

J10

AJ32X

1XJ460Hz

50Hz

J11

CON1

MIN ACCELMAX CLDECEL BOOST JOG COMP

MIN ACCELMAX CLDEC/I BOOST JOG COMP

*On Model KBAC-27D, J11 is Labeled "A" , "B"

Figure 3 – KBAC-27D*, 29, 29 (1P), 45, 48 Control Layout

CON2

LED Board

STATUS

POWER

JOG

P1P2P3

Violet (High)

FWD

*On Model KBAC-27D, J12 is Labeled "2", "1 1/2", "1", "3/4", "1/2"

COM

REV

RUN

COM

STOP

N.C.

N.O.

COM

TB2

Red

Black

White

White (Low)

+ 24 hidden pages