KB Electronics KBWK-23D Operation Manual

INSTALLATION AND OPERATION MANUAL

KBWK-23D

ADJUSTABLE FREQUENCY DRIVE FOR 3-PHASE AC MOTORS

NEMA 1 / IP 20 ENCLOSURE

MULTI-FUNCTION KEYPAD WITH 4-DIGIT LED DISPLAY

• Simplified Group Programming • 8 LED Status Indicators

Subfractional thru 1/2 HP 3-Phase AC and 1-Phase PSC* Induction Motors

Operates from 115 and 208/230 Volt 50/60 Hz AC Line Input

*Operation with

PSC motors requires

factory programming.

SEE

SAFETY WARNING

ON PAGE 4

This Manual Covers Model KBWK-23D (Part No. 8860)

AC Line Input Voltage Setting: The drive is factory set for 208/230 Volt

AC Line input. For 115 Volt AC Line input, see Section 10 on page 18. Motor Frequency Setting: The drive is factory set for 60 Hz Motors. For 50 Hz Motors, see Section 6.1 on page 12.

Rated for 208 – 230 Volt 50 and 60 Hz

Variable Speed / Soft Start

with Electronic Motor Overload Protection

STOP

IMPORTANT

RUN

FWD REV

RESET

JOG

READ

ENTER

RoHS

KBWK SERIES

(see back cover)

The QR Code link

to this manual is also

located on the inside of

the drive cover.

TABLE OF CONTENTS

Section Page

1 SAFETY WARNING, CE INFORMATION, AND UL NOTICE...............................4

2 QUICK-START INSTRUCTIONS ..........................................................................5

3 FAMILIARIZING YOURSELF WITH THE DRIVE .................................................6

4 ELECTRICAL RATINGS AND SPECIFICATIONS...............................................9

5 INTRODUCTION .................................................................................................10

5.1 Standard Features ..................................................................................11

5.2 Performance Features............................................................................11

5.3 Selectable Jumper (J3) ..........................................................................11

5.4 Protection Features ................................................................................12

5.5 Customization for OEMs........................................................................12

6 IMPORTANT PROGRAMMING INFORMATION ................................................ 12

6.1 50 Hz Motors ...........................................................................................12

6.2 Motor Current Setting ............................................................................12

6.3 Reset Drive..............................................................................................12

7 IMPORTANT APPLICATION INFORMATION ....................................................13

7.1 Motor with External Fan Cooling ..........................................................13

7.2 Electronic Motor Overload Protection..................................................14

8 MOUNTING .........................................................................................................14

9 REMOVING AND INSTALLING THE COVER ....................................................16

9.1 Removing the Cover...............................................................................16

9.2 Installing the Cover ................................................................................16

10 SETTING AC LINE INPUT VOLTAGE SELECTION JUMPER J3 .....................18

11 RECONDITIONING THE BUS CAPACITORS ....................................................18

12 ELECTRICAL CONNECTIONS...........................................................................18

12.1 AC Line Input and Ground .....................................................................20

12.2 Motor and Ground ..................................................................................20

12.3 AC Line Input Fusing .............................................................................20

13 HIGH VOLTAGE DIELECTRIC WITHSTAND TEST (HI-POT TEST) ................20

14 DRIVE OPERATION............................................................................................22

14.1 Start-Up Procedure.................................................................................22

14.2 Keypad Description ................................................................................22

14.3 Flow Charts for Important Programming Functions ...........................23

15 4-DIGIT DISPLAY READOUT CODES ............................................................... 29

16 PROGRAMMABLE FUNCTIONS LIST...............................................................31

Appendix A: Keypad/Potentiometer Set Frequency Select (Shortcut) .................36

Appendix B: Changing Operating Sense of the FWD/REV Key (Shortcut) ..........37

Appendix C: Reset and Memory Functions .............................................................38

LIMITED WARRANTY.................................................................................. Back Cover

TABLE OF CONTENTS (CONTINUED)

Table Page

1 Descriptions of 4-Digit Display, LEDs, Keys, and Potentiometer ...................7

2 Electrical Ratings.................................................................................................9

3 General Performance Specifications .................................................................9

4 Terminal Block TB1 Wire and Tightening Torque Specifications .................19

5 DC Hi-Pot Tester Setup Information.................................................................21

6 Digital Readout Codes.......................................................................................29

Figure Page

1 Front Panel Layout ..............................................................................................6

2 Drive Layout .........................................................................................................8

3 Maximum Allowed Motor Torque vs. Speed....................................................13

4 Open Ventilated Motor with External Cooling .................................................13

5 Mechanical Specifications ................................................................................15

6 Cover Positioned On Top of Case....................................................................17

7 AC Line Input Voltage Selection Jumper J3.................................................... 18

8 AC Line Input, Motor, and Ground Connections ............................................19

9 Typical Hi-Pot Test Setup..................................................................................21

10 Flow Chart to Program Motor Nameplate Current ..........................................23

11 Flow Chart to Program Set Frequency ............................................................24

12 Flow Chart to Program Rated Motor Frequency.............................................24

13 Flow Chart to Program Accel Time ..................................................................25

14 Flow Chart to Program Display for Custom Units ..........................................26

15 Flow Chart to Program Display ........................................................................27

16 Flow Chart to Add Parameters to Basic Display............................................. 27

17 Flow Chart to Program Passcode Enable and Set A Passcode ....................28

18 Function No. Description ..................................................................................31

ITEMS INCLUDED IN THIS PACKAGE

Description Part No.

KBWK Drive 8860 Installation and Operation Manual A40197 Hardware Bag: Jumper J3 (to Set the Drive for 115 Volt AC Line Input), Extra 6-32 X 1-1/4" Cover Screw, and two Universal Bushings. Mounting Template A42326 Warranty Registration Card A40101

F36875

1 SAFETY WARNING, CE INFORMATION, AND UL NOTICE

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.

CE INFORMATION

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. Additional shielded cable and/or AC Line cables may be required.

Note: In order for this drive to meet CE requirements, a separate CE approved filter must be installed.

UL NOTICE

115 Volt Drives:

Suitable for use on a circuit capable of delivering not more than 5 kA RMS symmetrical Amperes. 115 Volts maximum. Use copper conductors rated 75 °C. Suitable for operation in a maximum surrounding air temperature of 40 °C.

230 Volt Drives: Suitable for use on a circuit capable of delivering not more than 5 kA RMS symmetrical Amperes. 230 Volts maximum. Use copper conductors rated 75 °C. Suitable for operation in a maximum surrounding air temperature of 40 °C.

2 QUICK-START INSTRUCTIONS

2.1 REMOVE THE COVER

Remove the cover to setup and wire the drive. See Section 9.1 on page 16.

2.2 MOUNT THE DRIVE

See Section 8 on pages 14 and 15.

2.3 AC LINE INPUT SELECTION

The drive is factory set for 208/230 Volt AC Line input (Jumper J3 not installed). Install the supplied jumper to set the drive for 115 Volt AC Line input. See Section 10 on page 18. Note: The drive will operate 230 Volts AC motors with 115 Volt AC line

input.

2.4 AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS

At Terminal Block TB1, wire the AC Line input to "L1 and "L2"; the ground wire(s) to "GND"; and the motor to "U", "V", and "W". See Section 12 on pages 18 – 20.

2.5 INSTALL THE COVER

After the drive has been setup, mounted, and wired, install the cover. See Section 9.2 on page 16.

2.6 GFCI OPERATION

Allows the drive to operate with Ground Fault Circuit Interruption circuit breakers and outlets. Use Function 0.04 to program for GFCI operation. (May increase audible motor noise.)

2.7 SELECTING SET FREQUENCY ADJUSTMENT METHOD (SHORTCUT)

The Keypad/Potentiometer shortcut allows the selection of the source for adjusting the Set Frequency without requiring reprogramming the drive. The Keypad is factory programmed as the default for adjusting the Set Frequency. To use the Built-In Potentiometer to adjust Set Frequency, press both Up and Down Keys simultaneously for 4 seconds. To switch back to using the Keypad to adjust Set Frequency, press both Up and Down Keys simultaneously for 4 seconds. See Appendix A on page 36.

2.8 CHANGING OPERATING SENSE OF THE FWD/REV KEY (SHORTCUT)

For applications that require changing motor direction, the sense of the FWD/REV Key can be changed, without requiring reprogramming the drive or reversing any two motor leads. Put the drive in the Stop Mode and press and hold the FWD/REV Key for 5 seconds. The forward direction will now be "reverse" and the reverse direction will now be "forward". See Appendix B on page 37.

2.9 MOTOR FREQUENCY SELECTION

The drive is factory set to operate 60 Hz motors (Function 0.00 set to "0000"). For 50 Hz motors, set Function 0.00 to "0001". See Flow Chart (Figure 12) on page 24.

3 FAMILIARIZING YOURSELF WITH THE DRIVE

The drive has a 4-Digit LED Display, 8 Status LEDs, a Multi-Function Keypad, a builtin potentiometer, and a factory installed On/Off AC Line Switch. See Figure 1, below, and Table 1 on page 7. Remove the cover to access Jumper J3 terminals (AC Line Input Voltage Selection) and Terminal Block TB1 (AC Line input, Motor, and Ground connections). See Figure 2 on page 8.

 Mounting: Section 8 on pages 14 and 15.  Removing and Installing the Cover: Section 9 on pages 16 and 17.  AC Line Input Voltage Selection Jumper J3: Section 10 on page 18.  Electrical Connections: Section 12 on pages 18 – 20.  Drive Operation: Section 14 on pages 22 – 28.

FIGURE 1

FRONT PANEL LAYOUT (SEE TABLE 1 ON PAGE 7 FOR DESCRIPTIONS)

RUN

STOP

RESET

FWD REV

KBWK SERIES

JOG

READ

ENTER

DESCRIPTIONS OF 4-DIGIT DISPLAY, LEDs, KEYS, AND POTENTIOMETER

TABLE 1

No. Feature Description

RUN

STOP

FWD REV

RESET

JOG

4-Digit Display: Provides readout of drive status, functions, and faults.

JOG LED: Indicates that the drive is in Jog Mode.

OL LED: Indicates that the drive is in Overload.

FWD LED: Indicates that the drive is set for Forward Direction.

REV LED: Indicates that the drive is set for Reverse Direction.

RUN LED: Indicates that the drive is in the Run Mode.

STOP LED: Indicates that the drive is in Stop Mode.

PGM LED: Indicates that the drive is in Program Mode.

Hz LED: Indicates that the display is set to show Drive Output

Frequency (in Hz).

RUN / STOP Key: Starts and stops the drive.

FWD/REV Key: Changes motor direction.

Up Key:* Increases Output Frequency, Set Frequency, Function Number Value, and Code setting. Also used as shortcut key.*

Down Key:* Decreases Output Frequency, Set Frequency, Function Number Value, and Code setting. Also used as shortcut key.*

Left Shift / Reset Key: Moves the changeable digit or Resets the

drive after a fault has cleared.

JOG Key: Provides a fixed speed.

PROGRAM / DISPLAY Key: Puts the drive into Program Mode or

Display Mode. If pressed while Set Frequency is displayed, the

previously entered Function Number will be shown. If 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.

READ

ENTER

READ / ENTER Key: Reads or Enters a Function Value or Code Setting.

Potentiometer:* Sets the Drive Output Frequency in lieu of the

Keypad. To change the Keypad for Potentiometer Operation, set Function 2.00 to "0001".

*Adjustment of Set Frequency can be switched between the built-in potentiometer and the keypad by pressing both Up and Down Keys simultaneously for 4 seconds. See Appendix A on page 36.

DRIVE LAYOUT (SEE DESCRIPTIONS BELOW)

FIGURE 2

(SHOWN WITH COVER REMOVED)

TB1

1. Drive mounting hole. 2. Cover mounting hole. 3. TB1 for AC Line Input, Motor, and Ground connections. See Sections 12.1 and 12.2 on page 20. 4. J3 for AC Line Input voltage selection (factory set for 208/230 Volt AC Line Input). See Section 10 on page

18. 5. CON2 for Keypad interface connector. 6. To factory installed On/Off AC Line Switch. 7. Cover mounting Hole. 8. Drive mounting slot.

4 ELECTRICAL RATINGS AND SPECIFICATIONS

TABLE 2

ELECTRICAL RATINGS

Maximum

Horsepower

(HP (kW))

0.5 (0.37)

AC Line Input Output Net Wt.

Volts AC

(50/60 Hz)

115 1 8.8 15 2.2

208/230 1 6.0 10 2.4

Phase

(Ø)

Maximum

Current

(Amps AC)

Fuse or

Circuit

Breaker

Rating

(Amps)

Maximum

Continuous

Load Current

(RMS Amps)

Maximum

Voltage

(Volts AC)

230 1.72 0.78

lbs kg

TABLE 3

GENERAL PERFORMANCE SPECIFICATIONS

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)

Maximum Load (% Current Overload for 2 Minutes) 150 —

Switching Frequency (Function 3.17) (kHz) 8, 10, 12 8

Output Frequency Resolution (Hz) 0.06 —

Minimum Operating Frequency at Motor (Hz) 1 —

Acceleration Time (Function 3.03) (Seconds) 0.1 – 180.0 1.5

Deceleration Time (Function 3.04) (Seconds) 0.3 – 180.0 1.5

Speed Range (Ratio) 60:1 —

Speed Regulation (30:1 Speed Range, 0 – Full Load) (% Base Speed)

Overload Protector Trip Time for Stalled Motor (Seconds) 6 —

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

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

Operating Temperature Range (°C / °F)

Operating Humidity Range (% Relative, Non-Condensing) 0 – 95 —

Storage Temperature (°C / °F)

208 (-15%) /

230 (+15%)

2.5 —

76 – 141 —

151 – 282 —

0 – 40 /

32 – 104

-25 – +85 /

-13 – +185

Factory

Setting

208/230

—

Notes: 1. Dependent on motor performance. 2. Do not operate the drive outside the specified AC line input voltage operating range.

5 INTRODUCTION

Thank you for purchasing the KBWK Digital AC Drive. KB Electronics, Inc. is

committed to providing total customer satisfaction by providing quality products that

are easy to install and operate.

The KBWK drive is housed in NEMA 1 / IP 20 enclosure. It is designed to operate

subfractional through 1/2 HP 208 – 230 Volt 50 and 60 Hz 3-phase AC and PSC

induction motors.

Flux Vector Control provides high torque, low noise, and excellent

load regulation over a wide speed range. Adjustable linear acceleration and

deceleration make the drive suitable for soft-start applications.

Due to its user-friendly design and simple to use and understand instruction manual,

the KBWK 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 Display provides readout of drive operation, programming functions, and

displays Output Frequency, Motor RPM, Output Current, Output Voltage, Bus Voltage,

Function Codes and Values, Fault Codes, and Custom Units. The 8 LEDs provide

indication of the drive's operational status. The on-board memory can store a user-

defined custom program.

Main Features: Adjustable RMS Current Limit and I2t Motor Overload Protection.2

Flux Vector Control with Static Auto-Tune 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 and programmable Injection Braking provides

rapid motor stop. Electronic Inrush Current Limit (EICL™) eliminates harmful AC Line

inrush current, allowing the drive to be AC Line switched. The drive is suitable for

machine or variable torque (HVAC) applications. A terminal block is provided to

facilitate AC line input, motor, and ground connections. A selectable jumper (supplied)

allows the drive to be set for 115 or 208/230 Volt AC Line input. The drive includes a

built-in potentiometer and an illuminated On/Off AC Line Switch. The drive also

contains a programmable passcode feature, which can be used to prevent tampering

or unauthorized changes to programmed functions and settings. Adjustment of Set

Frequency can be switched, without requiring programming, between the built-in

potentiometer and the keypad using shortcut keys.

Notes: 1. PSC motor operation requires OEM software – contact our Sales Department. 2. UL approved as an electronic overload protector for motors.

5.1 STANDARD FEATURES

 Simplified Programming: Programmable functions are organized into easy-to-

understand intuitive groups. Factory programming available.

 Current and Torque Limit: Current and torque limiting in motoring and braking

quadrants. Automatic extending of Accel and Decel eliminates tripping caused by

rapid acceleration and deceleration of high inertial loads. Spin Start operation

catches a spinning load and allows a smooth return to the set motor speed.

 4-Digit Display and 8 LEDs: Provide readout of programming functions and

indication of the drive's operational status.

 Easy-to-Use Multi-Function Keypad: Facilitates programming the drive.

 Dual Voltage AC Line Input Operation: The drive operates from 115 and 208/230

Volt 50/60 Hz AC Line input. See Section 10 on page 18.

 Built-In Potentiometer: Adjusts set motor speed in lieu of the keypad.

 Factory Installed On/Off AC Line Switch: The switch illuminates when power is

applied to the drive and the switch is in the on position.  GFCI OPERATION: Tripless operation with GFCI software allows the equipment to

operate with Ground Fault Circuit Interruption circuit breakers or outlets. (May increase audible motor noise.) See Function 0.04.

 Passcode: Programamble passcode feature can be used to prevent tampering or

unauthorized changes to programmed functions and settings.

 Custom Programming for OEM Applications: Provides out-of-the-box operation.

5.2 PERFORMACE FEATURES

 High Performance Sensorless Flux Vector Control with Static Auto Tuning:

Provides excellent speed regulation with high torque loads throughout the entire

speed range. Auto energy savings at light loads. Smooth motor torque.

 Library of Advanced Algorithms: Custom programming and PLC functions for

OEM applications.

 Power Start™: Provides more than 200% starting torque, which ensures startup of

high frictional loads.

 Speed Range: Full torque control over a 60:1 speed range.

5.3 SELECTABLE JUMPER (J3)

 J3 (115V): The drive is factory set for 230 Volt AC Line input (J3 not installed). For

115 Volt AC Line input, install Jumper J3 (supplied). See Section 10 on page 18.

5.4 PROTECTION FEATURES  Motor Overload (I

t) with RMS Current Limit: Provides motor overload protection

which prevents motor burnout and eliminates nuisance trips. UL approved as an

electronic overload protector for motors. See Section 6.2 below.

 Electronic Inrush Current Limit (EICL™): Eliminates harmful inrush AC Line

current during startup and allows rapid start with AC Line.

 Short Circuit: Shuts down the drive if a short circuit occurs at the motor (phase-to-

phase).

 Regeneration: Eliminates nuisance 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: Protects the drive components against

damaging voltage spikes on the AC line.

 Microcontroller Self Monitoring and Auto-Reboot.

5.5 CUSTOMIZATION FOR OEMs

 Custom Software: The drive is preset and ready to use "out-of-the-box". Custom

front panels are also available. The drive can be factory programmed for

applications that require special switching, timing, PLC functions, and GFCI

operation. Contact our Sales Department.

6 IMPORTANT PROGRAMMING INFORMATION

6.1 50 Hz MOTORS

This drive is factory programmed to operate 60 Hz motors. For 50 Hz motors, set

Function 0.00 to "0001" (50 Hz). See Flow Chart (Figure 12) on page 24.

6.2 MOTOR CURRENT SETTING

The motor current is factory set to the maximum drive rating, as shown in Table 2 on

page 9. In order for the Motor Overload Protection to operate properly, the drive must

be reprogrammed to the actual Motor Nameplate Current (see Function 0.01). Do not

exceed the drive's maximum current rating. See Flow Chart (Figure 10) on page 23.

6.3 RESET DRIVE

For Factory Settings, set Function 5.06 to "1111". For OEM Custom Program, set Function 5.06 to "1010". For User Custom Program set Function 5.06 to "1100". See Appendix C on pages 38 and 39.

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