KB Electronics KBMK SERIES Operation Manual

INSTALLATION AND OPERATION MANUAL

KBMK SERIES

Adjustable Frequency Drives

for 1/8 HP thru 1 HP 3-Phase AC Motors Rated 208 – 230 VAC, 50/60 Hz

NEMA-1 / IP-40

Operate from 115* and 208/230 Volt 50/60 Hz AC Line

Variable Speed / Soft-Start with Electronic Motor Overload Protection

This Manual Covers Models KBMK-24D and KBMK-24DF2

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. Model KBMK-24DF contains a built-in AC line Class A RFI (EMI) filter which meets CE Council Directive 89/336/EEC Industrial Requirement. For Class B Residential Requirement, install the KBRF-300 RFI (EMI) Filter (Part No. 9484).

This drive is factory set for:

1. 60 Hz Motors. For 50 Hz motors, see Figure 12, on page 16.

2. 208/230 Volt AC Line Input.

For 115 Volt AC line input, see Section 7, on page 14.

*IMPORTANT

See Safety Warning, on page 5.

LISTED IND. CONT. EQ. – 70ZA

RoHS

Automation and Control

(see back cover)

Sections Page

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

2 Safety Warning ...................................................................................................................................................5

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

4 Important Application Information...................................................................................................................... 10

5 Mounting Instructions........................................................................................................................................ 11

6 Electrical Connections Instructions....................................................................................................................11

7 AC Line Input Voltage Selection (Jumper J1).................................................................................................... 14

8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing)...................................................... 14

9 Drive Operation................................................................................................................................................. 15

10 Programmable Function Summary List ............................................................................................................. 21

11 Status LEDs...................................................................................................................................................... 29

Appendix A – Optional IODA Input/Output Multi-function Board ..............................................................................30

Limited Warranty ........................................................................................................................................Back Cover

TABLE OF CONTENT3S

Tables Page

1 Optional Accessories ..........................................................................................................................................7

2 Electrical Ratings ................................................................................................................................................ 7

3 General Performance Specifications................................................................................................................... 8

4 Drive Terminal Blocks Wire and Tightening Torque Specifications.................................................................... 12

5 Multi-Function Output Relay "Run" and "Fault" Operating Modes .....................................................................13

6 Keypad Description........................................................................................................................................... 16

7 Digital Readout Codes ...................................................................................................................................... 20

8 LED Descriptions ..............................................................................................................................................29

9 IODA Status Indicator LED................................................................................................................................ 31

10 IODA Terminal Block TB1 Wire and Tightening Torque Specifications..............................................................31

11 IODA Functions, Features, and Terminal Assignment....................................................................................... 32

12 Multi-Function Input Terminal, Function No., and Code Assignment................................................................. 32

13 Preset Frequency Selection with 2-Wire Start/Stop Programming.....................................................................33

14 Preset Frequency Selection .............................................................................................................................. 34

15 Up/Down Frequency Control Programming....................................................................................................... 35

16 Accel/Decel 2 Programming.............................................................................................................................. 35

17 Forward/Stop-Reverse/Stop Programming........................................................................................................36

18 External Fault Programming..............................................................................................................................37

19 Reset Programming .......................................................................................................................................... 38

20 2-Wire Start/Stop Programming ........................................................................................................................ 38

21 3-Wire Start/Stop Programming ........................................................................................................................ 39

22 Analog Input 1 Electrical Ratings.......................................................................................................................41

23 Analog Input 1 Signal Voltage Following Programming..................................................................................... 42

24 Analog Input 2 Electrical Ratings.......................................................................................................................43

25 Analog Input 2 Signal Current Following Programming..................................................................................... 43

26 Analog Outputs 1 and 2 Electrical Ratings ........................................................................................................ 43

27 Analog Outputs 1 and 2 Programming .............................................................................................................. 44

28 Remote Unidirectional Speed Potentiometer Programming ..............................................................................45

29 Remote Bidirectional Speed Potentiometer Programming................................................................................. 46

30 Remote Speed Potentiometer with Forward/Reverse Programming .................................................................47

31 Multi-Function Output Relay Contacts Programming......................................................................................... 48

32 Multi-Function Open Collector Outputs Programming ....................................................................................... 49

33 Multi-Function Open Collector Outputs Electrical Ratings ................................................................................. 49

Figures Page

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

2 Keypad Layout with Built-In Speed Potentiometer............................................................................................... 8

3 Cover Layout....................................................................................................................................................... 9

4 Drive Layout........................................................................................................................................................ 9

5 Mechanical Specifications................................................................................................................................. 10

6 Maximum Allowed Motor Torque vs. Speed...................................................................................................... 11

Figures Page

7 Open Ventilated Motor with External Fan Cooling............................................................................................. 11

8 AC Line Input, Motor, and Ground Connections................................................................................................ 12

9 Multi-Function Output Relay Contacts............................................................................................................... 13

10 AC Line Input Voltage Selection (Jumper J1).................................................................................................... 14

11 Typical Hi-Pot Test Setup..................................................................................................................................15

12 Flow Chart to Program the Drive for 50 Hz Motors............................................................................................ 16

13 Flow Chart to Program Motor Current from 3.6 Amps to 2.5 Amps ................................................................... 17

14 Flow Chart to Change Set Frequency from 5.00 Hz to 43.21 Hz....................................................................... 17

15 Flow Chart to Program Accel Time from 1.5 Seconds to 120 Seconds .............................................................18

16 Flow Chart to Program the Drive to Display Motor RPM....................................................................................18

17 Flow Chart to Program the Drive to Display Custom Units "012.0".................................................................... 19

18 Flow Chart Showing Motor Current, Motor Voltage, and Bus Voltage Added to the Basic Display.................... 19

19 Function No. Description................................................................................................................................... 21

20 IODA Layout .....................................................................................................................................................31

21 IODA Terminal Block TB1 Layout......................................................................................................................32

22 Preset Frequency Selection with 2-Wire Start/Stop Connections...................................................................... 33

23 Up/Down Frequency Control with 2-Wire Start/Stop Connections..................................................................... 35

24 Accel/Decel 2 Connections ............................................................................................................................... 36

25 Forward/Stop-Reverse/Stop Connections......................................................................................................... 36

26 External Fault Connections ............................................................................................................................... 37

27 Reset Connections............................................................................................................................................ 38

28 2-Wire Start/Stop Connections.......................................................................................................................... 39

29 3-Wire Start/Stop Connections.......................................................................................................................... 39

30 Analog Input 1 Signal Gain and Offset with Positive Slope................................................................................40

31 Analog Input 1 Signal Gain and Offset with Negative Slope.............................................................................. 41

32 Analog Input 1 Signal Voltage Following Connections ......................................................................................42

33 Analog Input 2 Signal Current Following Connections.......................................................................................43

34 Analog Outputs 1 and 2 Gain............................................................................................................................ 44

35 Analog Outputs 1 and 2 Connections................................................................................................................ 44

36 Remote Unidirectional Speed Potentiometer Connections................................................................................ 46

37 Remote Bidirectional Speed Potentiometer Connections .................................................................................. 46

38 Remote Speed Potentiometer with Forward/Reverse Connections................................................................... 47

39 Multi-Function Output Relays Contact Connections.......................................................................................... 48

40 Multi-Function Open Collectors Output Connections......................................................................................... 49

41 Typical Application for Open Collectors Output................................................................................................. 49

TABLE OF CONTENTS (CONTINUED)

Items Included In this Package: KBMK Adjustable Frequency Drive, Installation and Operation Manual, Hardware Bag (containing Trimpot Adjustment Tool, AC Line Input Voltage Selection Jumper, and an extra Feed-Through Bushing), CE Approved Product Information Card, and Warranty Registration Card.

UL NOTICE

230VAC Drives

Suitable for use on a circuit capable of delivering not more than 5 kA RMS symmetrical amperes,

230 Volts maximum.

Use copper conductors rated 75 °C.

Suitable for operation in a maximum surrounding air temperature of 40 °C.

1. 50 Hz Motors: This drive has been factory programmed to operate 60 Hz motors. For 50 Hz motor operation, set Function No. 0.00 to 50 Hz "0001". See Figure 12, on page 16.

2. Motor Current Setting: The motor current is factory set to 3.6 Amps (1 HP (0.75 kW)), as shown in Table 2, on page 7. In order for the motor overload protection to operate properly, the drive must be reprogrammed to the actual motor nameplate current. Use Function No. 0.01 to enter the motor nameplate current. See Figure 13, on page 17.

IMPORTANT APPLICATION INFORMATION

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.

Note: This drive contains bus capacitors, which must be reconditioned if the drive has been in storage for over 1 year. To recondition the bus capacitors, apply the AC line, with the drive in the Stop Mode, for a minimum of 30 minutes.

See Figure 1. Also see Section 4 - Important Application Information, on page 10.

WARNING! HIGH VOLTAGE – Disconnect main power before making connections to the drive. Do not depend on the green Power On LED (ON), located on the drive's PC board, as shown in Figure 4, on page 9, or the Status LEDs and the 4-Digit Display, located on the front cover, to no longer be illuminated as a guaranteed power off condition.

Note: It is recommended that both Feed-Through Bushings be used to connect the drive. If signal wiring (for the Multi-Function Output Relay contacts or for a Remote Speed Potentiometer) is required, it is recommended that the extra Feed-Through Bushing (supplied) be used to replace the center Hole Plug. Standard ½" fittings (not supplied) can also be used in lieu of the Feed-Through Bushings.

QUICK-START CONNECTION DIAGRAM

FIGURE 1

1.1 MOUNTING INSTRUCTIONS: See Section 5, on page 11.

1.2 AC LINE INPUT CONNECTION: Connect the AC line input to Terminal Block TB1 (Terminals "L1", "L2"),

as shown in Figure 1, above. Also see Section 6.1, on page 12.

Application Note: If operation with a Ground-Fault Circuit-Interrupter (GFCI) is required, see Function No.

0.04, on page 22.

Note: The drive is factory set for 208/230 Volt AC line input (Jumper J1 not installed). For 115 Volt AC line input, install Jumper J1 (supplied). See Section 7, on page 14.

1.3 AC LINE FUSING: It is recommended that a fuse(s) or circuit breaker(s) be installed in the AC line. Fuse

each conductor that is not at ground potential. For the recommended fuse size, see Table 2, on page 7. Also see Section 6.1, on page 12.

1.4 GROUND CONNECTION: Connect the ground wire (earth) to Terminal Block TB1 (Terminal "GND"), as

shown in Figure 1, on page 4.

1.5 MOTOR CONNECTION: Connect the motor to Terminal Block TB1 (Terminals "U", "V", "W"), as shown in

Figure 1, on page 4. Be sure the motor is properly grounded. Motor cable length should not exceed 100ft (30 m) – special reactors may be required – consult our Sales Department. See Section 6.3, on page 13.

1.6 60 Hz AND 50 Hz MOTR OPERATION: The drive is factory set for 60 Hz motors (Function No. 0.00 set to

"0000"). For 50 Hz motors, set Function No. 0.00 to "0001", as shown in Figure 12, on page 16. For other motor frequencies, set Function No. 0.00 to "0002".

1.7 JUMPER J1 SETTING: The drive is factory set for 208/230 Volt AC line input (Jumper J1 not installed).

For 115 Volt AC line input, install Jumper J1 (supplied). See Section 7, on page 14.

1.8 MOTOR OVERLOAD PROTECTION: Function No. 0.01 must be set to the motor nameplate current for

proper operation of the I

t Motor Overload Protection. See Figure 13, on page 17.

2 SAFETY 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 electrical connections, fusing or other current protection, and grounding, can reduce the chance of electrical shocks, and/or fires, in this product or products used with this product, such as electric motors, switches, coils, solenoids, and/or relays. Do not use this drive in an explosion-proof application. Eye protection must be worn and insulated adjustment tools must be used when working with drive under power. This product is constructed of materials (plastics, metals, carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding, and filtering of this product can reduce the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic equipment. It is the responsibility of the equipment manufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product. (SW 1/2006)

The drive contains electronic Start/Stop circuits, which can be used to start and stop the drive. However, these circuits are never to be used as safety disconnects since they are not fail-safe. Use only the AC line for this purpose.

Be sure to read and follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product.

This product complies with all CE directives pertinent at the time of manufacture. Contact 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 the 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 (IODA Input/Output Multi-Function Board (Part No. 9668)).

3 INTRODUCTION

Thank you for purchasing the KBMK 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 KBMK Adjustable Frequency Drives are variable speed controls housed in a rugged NEMA-1 / IP-40 enclosure. They are designed to operate 208 – 230 Volt 50 & 60 Hz 3-phase AC induction motors from 1/8 HP thru 1 HP. The sine wave coded Pulse Width Modulated (PWM) output provides high motor efficiency and low noise. Adjustable Linear Acceleration and Deceleration make the drive suitable for soft-start applications. Model KBMK-24DF contains a built-in AC line Class A RFI (EMI) filter which meets the CE Council Directive 89/336/EEC Industrial Requirement.

Due to its user-friendly design, the KBMK is easy to install and operate. Setting the drive to specific applications is accomplished using the Multi-Function Keypad, which provides easy operation and programming of the drive. To facilitate programming, all similar functions are presented in common groups.

The 4-Digit LED Display provides readout of drive operating parameters and programming functions and displays Output Frequency, Motor RPM, Output Current, Output Voltage, Bus Voltage, Function Codes and Values, Fault Codes, and Custom Units. In addition to operating the drive, the Multi-Function Keypad is used to change drive operating parameters, reprogram functions, and change the display output. The LEDs provide indication of the drive’s status and operating mode (Hz, PGM, LCL/REM, STOP, FWD, REV, OL, JOG/REM).

The optional IODA Input/Output Multi-Function Board provides a variety of functions, which include preset frequency, up/down frequency control, signal isolation, isolated output voltage for controlling auxiliary devices, open collector outputs, and output relay contacts. See Appendix A, on pages 30 – 49. See Function Groups 0 – 10, on pages 22 – 28.

Main Features: Adjustable RMS Current Limit and I

t Motor Overload Protection.* Flux Vector 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 startup of high frictional loads. Programmable Injection Braking provides rapid motor stop. Electronic Inrush Current Limit (EICL™) eliminates harmful AC line inrush current, which allows the drive to be line switched. A Multi-Function Output Relay is provided, which can be used to turn on or off equipment or to signal a warning if the drive is put into various modes of operation. The drive is suitable for machine or variable torque (HVAC) applications.

Standard Front Panel Features: 4-Digit LED Display, Multi-Function Keypad, Status Indicator LEDs, and a Built-In Speed Potentiometer.

Optional Accessories: Optional accessories include an On/Off AC Line Switch and IODA Input/Output MultiFunction Board. See Table 1, on page 7.

*UL approved as an electronic overload protector for motors.

3.1 STANDARD FEATURES

▪ Multi-Function Keypad: The keys are used to operate the drive, change operating parameters,

reprogram functions, and change the display output (Run/Stop, Forward/Reverse, Up, Down, Shift/Reset, Jog-Local/Remote, Program/Display, Read/Enter).

▪ 4-Digit LED Display: Provides readout of drive operating parameters and programming functions.

Displays Output Frequency, Motor RPM, Output Current, Output Voltage, Bus Voltage, Function Codes and Values, Fault Codes, and Custom Units.

▪ LED Status Indicators: The LEDs provide indication of the drive’s status and operating mode (Hz,

PGM, LCL/REM, STOP, FWD, REV, OL, JOG/REM).

▪ Multi-Function Output Relay Contacts: Can be used to turn on or off equipment or to signal a

warning if the drive is put into various modes of operation. (The optional IODA Input/Output MultiFunction Board contains 9 digital and analog inputs, 4 digital and analog outputs, and 2 additional relay outputs.)

▪ Motor Current Selection: Programmable motor current allows the drive to be used on a wide range

of motor horsepower.

▪ Compatible with most GFCIs. See Function No. 0.04, on page 22.

3.2 PERFORMANCE FEATURES

▪ Power Start™ – Provides more than 200% starting torque which ensures startup of high frictional

loads.

▪ Programmable Flux Vector Compensation with Static Auto-Tune and Boost – Provides excellent

load regulation and dynamic response over a wide speed range.

▪ Speed Range – 60:1

3.3 PROTECTION FEATURES

▪ Motor Overload (I

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).

▪ Decel Extend: Eliminates tripping due to bus overvoltage caused by rapid deceleration of high inertial

loads.

▪ Undervoltage and Overvoltage: Shuts down the drive if the AC line input voltage goes below or

above the operating range.

▪ MOV Input Transient Suppression.

▪ Microcontroller Self Monitoring and Auto-Reboot.

t) with RMS Current Limit: Provides motor overload protection, which prevents

*UL approved as an electronic overload protector for motors (UL File E188974).

3.4 PROTECTION FEATURES

▪ AC LINE INPUT VOLTAGE SELECTION: (115/230 Volts AC) (J1)

TABLE 1

OPTIONAL ACCESSORIES

Description Part No.

On/Off AC Line Switch: Panel mounted. Used to turn the power on and off to the drive. 9683

IODA Input/Output Multi-Function Board: Provides a variety of functions, which include preset

frequency, Up/Down Frequency, signal isolation, isolated output voltage for auxiliary devices, open collector outputs, and output relay contacts. Mounts on the drive's PC board with three screws

9668

(provided). All of the IODA inputs and outputs are isolated from the AC line.

TABLE 2

ELECTRICAL RATINGS

Net

Weight

Lbs. kg

Model

No.

KBMK-24D 9680

KBMK-24DF2 9681

Part

AC Line Input Output

Maximum

Volts AC

(50/60 Hz)

Phase

(Ф)

Current

(Amps AC)

115 1 16 20

208/230

1 10 15

115 1 16 20

208/230

1 10 15

Fuse or

Circuit

Breaker

Rating

(Amps)

Voltage

Range

(Volts AC)

0 – 230 3.6 1 (.75) 2.26 1.03

0 – 230 3.6 1 (.75) 2.33 1.06

Maximum

Continuous

Load Current

(RMS Amps/Phase)

Maximum

Horsepow

(HP (kW))

Notes: 1. The drive is factory set for 208/230 Volt AC line input (J1 not installed). For 115 volt AC line input, install Jumper J1 (supplied). See Figure 10, on page 14. 2. Model KBMK-24DF contains a built-in AC line Class A RFI (EMI) filter which meets the CE Council Directive 89/336/EEC Industrial Requirement.

TABLE 3

GENERAL PERFORMANCE SAPECIFICATIONS

Description Specification

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%)1 Maximum Load (% Current Overload for 1 Minute) 150 Switching Frequency (kHz)2 8, 10, 12 Output Frequency Resolution (Bits, Hz) 10, .06 Minimum Operating Frequency at Motor (Hz) 0.3 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 Multi-Function Output Relay Contact Rating (Amps at 30 Volts DC, 125 Volts AC, 250 Volts AC) 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)

1, 0.5, 0.25

151 / 282 Operating Temperature Range (°C / °F) 0 – 45 / 32 – 113 Operating Humidity Range (% Relative, Non-condensing) 0 – 95 Storage Temperature (°C / °F) -25 – +85 / -13 – +185

Notes: 1. The drive is factory set for 208/230 Volt AC line input (J1 not installed). For 115 volt AC line input, install Jumper J1 (supplied). See Figure 10, on page 14. 2. Set by Function No. 3.15. 3. Dependent on motor performance. 4. Do not operate the drive outside the specified AC line input voltage operating range.

FIGURE 2

KEYPAD LAYOUT WITH BUILT-IN SPEED POTENTIOMETER

Notes: 1. The JOG-LCL/REM Key is factory programmed to function as a Jog Key. When the JOG-LCL/REM Key is pressed, the "JOG/REM" LED will illuminate and the display will show the Jog Frequency Setting (see Function No. 3.13, on page 24). 2. If the JOG-LCL/REM Key is reprogrammed for Local (Keypad) and Remote Signal Operation (see Function No. 2.02, on page 24), the "LCL/REM" LED will illuminate. Pressing the JOG-LCL/REM Key will toggle between Local (Keypad) and Remote Signal Operation. When Remote Signal Operation is selected, the "JOG/REM" LED will flash. The optional IODA (Part No. 9668) is required for remote signal operation. 3. The "Hz" LED will illuminate when the display is set to show Output Frequency. 4. If the PROGRAM/DISPLAY Key is pressed while Set Frequency is displayed, the previously entered Function Number will be shown. If the PROGRAM/DISPLAY Key is pressed while Function Number is displayed, the Set Frequency will be shown. When more than one display function is enabled, the PROGRAM/DISPLAY Key is used to toggle between displays, as shown in Figure 18, on page 19. 5. To change the Keypad for Potentiometer Operation, set Function No. 2.00 to "0001".

FIGURE 3

COVER LAYOUT

FIGURE 4

DRIVE LAYOUT

4.30 109

0.35

FIGURE 5

MECHANICAL SPECIFICATIONS

4.95 126

0.2

4X Ø

5.08

0.39

4X Ø

9.91

9.0

1.10

27.9

5.10 130

0.30

7.6

7.00 178

1.75

44.5

0.95

24.1

5.10 130

0.95

24.1

1.45

36.8

1.00

25.4

2.35

59.7

3.20

81.3

4.15 105

4 IMPORTANT APPLICATION INFORMATION

4.1 MOTOR WITH EXTERNAL FAN COOLING: Most totally enclosed fan-cooled (TEFC) and open ventilated 3-phase AC induction motors will overheat if used beyond a limited speed range at full torque. Therefore, it is necessary to reduce motor load as speed is decreased.

Note: Some fan-cooled motors can be used over a wider speed range. Consult the motor manufacturer for details.

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. If the motor current exceeds the nameplate rating, the Boost value may have to be decreased (see Function No. 3.11). 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 6, on page 11.

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 7, on page 11.

MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED

FIGURE 6

Inverter Duty

and TENV

Motors

Fan Cooled

TEFC and Open Ventilated

Motors

OPEN VENTILATED MOTOR

WITH EXTERNAL FAN COOLING

FIGURE 7

4.2 ELECTRONIC MOTOR OVERLOAD PROTECTION: The drive contains Modified I

t Overload Protection.* Part of this function consists of a Current Limit (CL) circuit, which limits the drive current to a preset level of 160% of the Motor Nameplate Rated Current setting. The factory setting for motor nameplate current is the drive rated current, which must be set to the actual motor nameplate current (see Important Application Information (Item 2), on page 3). See Table 2, on page 7. Also see Function No. 0.01, on page 22.

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 the Motor Nameplate Rated Current 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.

5 MOUNTING INSTRUCTIONS

It is recommended that the drive be mounted vertically on a flat surface with adequate ventilation. Leave enough room below the drive to allow for AC line, motor connections, and any other wiring that is required. Care should be taken to 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 heat dissipation so that the ambient temperature does not exceed 45°C (113 °F) at full rating. See Figure 5, on page 10.

WARNING! Do not use this drive in an explosion-proof application.

Be sure the drive is securely mounted.

6 ELECTRICAL CONNECTIONS

See Table 4, for terminal block wire and tightening torque specifications.

WARNING! HIGH VOLTAGE – Read Safety Warning, on page 5, 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. Connect 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 connected as a disconnect so that each ungrounded conductor is opened. For fuse or circuit breaker selection, see Table 2, on page

7. Also see Section 6.1, on page 12.

The drive is designed with a removable cover. To open the cover, the two front cover screws must be removed. After mounting the drive and making all connections, install and tighten the four front cover screws to 5 in-lbs (6 kg-cm). Do not over tighten.

DRIVE TERMINAL BLOCKS WIRE AND TIGHTENING TORQUE SPECIFICATIONS

Terminal Block Description

TB1 AC Line Input and Motor Wiring 12 3.3 7 8

TB2

6.1 AC LINE INPUT CONNECTION (See Warning, on page 11): Connect the AC line input to Terminal

Multi-Function Output Relay

Block TB1 (Terminals "L1", "L2"), as shown in Figure 8. See Table 2, on page 7.

Application Note: If operation with a Ground-Fault Circuit-Interrupter (GFCI) is required, see Function No. 0.04, on page 22.

Note: The drive is factory set for 208/230 Volt AC line input (Jumper J1 not installed). For 115 Volt AC line input, install Jumper J1 (supplied). See Section 7, on page 14.

AC Line Fusing:

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 (Square D QOU or equivalent) in series with each ungrounded conductor. Do not fuse motor leads. For the recommended fuse size, see Table 2, on page 7.

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

Contacts

The drive does not contain line fuses. Most electrical codes require that each

AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS

TABLE 4

Maximum Wire Size (Cu)

AWG mm

16 1.3 3.5 4

FIGURE 8

in-lbs kg-cm

Recommended

Tightening Torque

6.2 GROUND CONNECTION: Connect the ground (earth) wires from the AC line and motor to Terminal

Block TB1 (Terminal "GND"). Be sure the motor is also properly grounded. See Figure 8, on page 12.

6.3 MOTOR CONNECTION: Connect the motor to Terminal Block TB1 (Terminals "U", "V", "W"). See

Figure 8, on page 12. Be sure the motor is properly grounded. Motor cable length should not exceed 100 ft (30 m) – special reactors may be required – consult our Sales Department. Be sure Function No.

0.01 is set to the corresponding Motor Nameplate Current.

Note: If the motor does not rotate in the desired direction, either: 1. Reverse any two motor leads (with AC line disconnected and motor stopped). or 2. Use the FWD/REV Key. or 3. Use Function No. 1.02 to reprogram the forward and reverse direction.

6.4 MULTI-FUNCTION OUTPUT RELAY CONNECTIONS: The Multi-Function Output Relay Contacts are

located at TB2, as shown in Figure 9. The Multi-Function Output Relay is factory programmed to function as a "Run" relay (Function No. 5.00 set to "0000"). When the drive is put into the Run Mode, the relay contacts will change state (the Normally Open (N.O.) contact will close and the Normally Closed (N.C.) contact will open). See Table 5.

When the Multi-Function Output Relay is programmed to function as a "Fault" relay (Function No. 5.00 set to "0001") and a fault occurs while the drive is in the Run Mode, the relay contacts will change state. The Normally Open (N.O.) contact (closed in the Run Mode) will open and the Normally Closed (N.C.) contact (open in the Run Mode) will close. See Table 5.

The Multi-Function Output Relay can also be programmed for the following functions, as shown in the Programmable Function Summary List (Section 10, Function Group 5, on page 21): Target Frequency, Frequency Threshold, I

Relay Contact Ratings: 1 Amp at 30 Volts DC, 0.5 Amps at 125 Volts AC, and 0.25 Amps at 250 Volts AC.

FIGURE 9

MULTI-FUNCTION

OUTPUT RELAY

CONTACTS

6.5 REMOTE OPERATIONS WHICH REQUIRE THE OPTIONAL IODA (PART NO. 9668): See Appendix

A, on pages 30 – 49. Multi-Function Input Terminals (Preset Frequency Operation, Up/Down Frequency Command, Accel/Decel 2, Forward/Stop-Reverse/Stop Command, External Fault, Reset, 2-Wire and 3-Wire Start/Stop), Signal Following, Analog Signal Output (for controlling auxiliary devices), Remote Speed Potentiometer (5 kΩ), Multi-Function Output Relays, and Multi-function Open Collector Outputs.

t or I•t Fault Mode, and Load Loss.

MULTI-FUNCTION OUTPUT RELAY "RUN" & "FAULT" OPERATING MODES

Drive

Operating Condition

Power Off Open Closed Open Closed

Power On (Stop Mode) Open Closed Closed Open

Run Mode Closed Open Closed Open

All Faults Open Closed Open Closed

TABLE 5

Function No. 5.00 Set to

"0000"

"Run" Relay Mode "Fault" Relay Mode

N.O. Contact N.C. Contact N.O. Contact N.C. Contact

Function No. 5.00 Set to

"0001"

7 AC LINE INPUT VOLTAGE SELECTION (JUMPER J1)

Do not connect the AC line input until Jumper J1 is set for the proper input voltage being applied to the drive. Catastrophic failure will occur if a 230 Volt AC line is applied when the drive is set for 115 Volt AC line input.

The drive is factory set for 208/230 Volt AC line input (Jumper J1 not installed). For 115 Volt AC line input, install Jumper J1 (supplied). See Figure 10.

AC LINE INPUT VOLTAGE SELECTION

FIGURE 10

208/230 Volt AC Line Input

(J1 not Installed (Factory Setting))

115 Volt AC Line Input

(J1 Installed)

Notes: 1. The drive is factory set for 208/230 Volt AC line input (Jumper J1 not installed). For 11 Volt AC line input, install Jumper J1 (supplied). 2. Jumper J1 is supplied in the hardware bag.

8 RECOMMENDED HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING (HI-POT TESTING)

Testing agencies such as UL, CSA, VDE, etc., usually require that equipment undergo a hi-pot test. In order to prevent catastrophic damage to the drive which has been installed in the equipment, the following procedure is recommended. A typical hi-pot test setup is shown in Figure 11, on page 15. All drives have been factory hi-

pot tested in accordance with UL requirements.

WARNING! All equipment AC line inputs must be disconnected from the AC power.

CAUTION! Model KBMK-24DF: To prevent catastrophic damage to the drive, perform a DC Hi-Pot test only.

8.1 Connect all equipment AC power input lines together and connect them to the H.V. lead of the hi-pot

tester. Connect the RETURN lead of the hi-pot tester to the frame on which the drive and other auxiliary equipment are mounted.

8.2 The 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.

LEAKAGE

0mA 10mA

FIGURE 11

TYPICAL HI-POT TEST SETUP

RETURN

H. V.

TEST

RESET

ZERO

VOLTAGE

MAX

9 DRIVE OPERATION

Before operating the drive, read Section 9.2, for instructions on the Digital Keypad Operation. See Figure 2, on page 8, for the keypad layout.

The 4-digit display can indicate various functions of the drive: Set Frequency, Motor RPM, Output Current and Voltage, Custom Units, Function Numbers, Function Codes or Values, and Fault Codes. See Section 9.4, on page 20.

See Section 9.3, on pages 16 – 19, for information on programming the drive. If an error message appears while programming the drive, see Section 9.5, on page 21.

9.1 START-UP PROCEDURE: After the drive has been properly setup and all connections completed, the

start-up procedure can begin. If the AC power has been properly brought to the drive, the LEDs on the front cover will indicate the drive's status, as described in Section 11, on page 29. See Section 9.4, on page 20, for the Digital Readout Codes.

To start the drive, press the RUN Key. The motor will begin to accelerate to the Set Frequency. The factory set frequency is 05.00 Hz.

9.2 KEYPAD DESCRIPTION: The Keypad has eight (8) keys, which are used to program drive functions, as

described in Table 6. The eight (8) LEDs provide indication of the drive’s operational status, as described in Section 11, on page 24. A Built-In Speed Potentiometer is also provided to set the Drive Frequency (Function No. 2.00 set to "0001"). See Figure 2, on page 8.

Note: To avoid damage, never operate the keypad with a screwdriver or other sharp-ended tool.

TABLE 6

Key Description

Starts or Stops the drive.

Changes motor direction.

Up Key: Increases Output Frequency, Set Frequency, Function Number Value, and Code setting.

Down Key: Decreases Output Frequency, Set Frequency, Function Number Value, and Code setting.

Factory programmed to function as a Jog Key. When the key is pressed, it toggles between Run Mode and Jog Mode (the "JOG/REM" LED will illuminate and the display will show the Jog Frequency Setting (see Function No. 3.13)). If the key is reprogrammed for Local/Remote Operation (see Function No. 2.02), the key is used to toggle between Local (Keypad) or Remote Signal Operation (the "LCL/REM" LED will illuminate).* *Optional IODA or Modbus is required for Local/Remote Operation. Used to enter Program Mode and Display Mode. If the key is pressed while Set Frequency is displayed, the previously entered Function Number will be shown. If the key is pressed while Function Number is displayed, the Set Frequency will be shown. When more than one display function is enabled, the key is used to toggle between displays. See Figure 18, on page 19.

Left Shift / Reset Key: Moves the changeable digit or Resets the drive to clear a fault.

Reads or Enters a Function Number's Value or Code setting. The key is also used to read or enter the frequency setting.

9.3 FLOW CHARTS FOR IMPORTANT PROGRAMMING FUNCTIONS: See Figures 12 – 18, on pages

16 – 19, for flow charts to program important functions. The flow charts also serve as a guide to understand the programming procedure.

Note: See Table 7, on page 20, for a description of the Digital Readout Codes.

FLOW CHART TO PROGRAM THE DRIVE FOR 50 Hz MOTORS

KEYPAD DESCRIPTION

FIGURE 12

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