KB Genesis KBAC-24D, KBAC-27D, KBAC-48, KBAC-45, KBAC-29 Installation & Operation Manual

Installation & Operation Manual

KBAC SERIES

Variable Speed/ Soft-Start AC Motor Drive

with Electronic Motor Overload Protection for Inverter Duty Motors

1

Washdown and Watertight for Indoor and Outdoor Use

Rated for 208 – 230 and 400/460 Volt 50 & 60 Hz

3-Phase & PSC

2

AC Induction Motors from Subfractional thru 5 HP

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

2,3

See Safety Warning,
on page 5.

NOTE: THE DRIVE IS FACTORY SET FOR
60 Hz MOTORS. FOR 50 Hz MOTORS,
SEE SECTION 6.4, ON PAGE 17.

The information contained in this manual is intended to be accurate. However, the manufacturer retains

the right to make changes in design which may not be included herein.

Notes: 1. UL approved as an electronic overload protector for motors. 2. Special software is available – contact
our Sales Department. 3. Do not use this drive with GFCIs. 4. Installation of a CE approved RFI filter is required.

© 2008 KB Electronics, Inc.

(see back cover)

Adjustable Frequency Drives for 3-Phase AC Motors

NEMA-4X/IP-65

4

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

TABLE OF CONTENTS

Section Page

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

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

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

4 Important Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . . . . . . . . . . . . . . . . . 19

9 Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

10 AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

11 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

12 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Tables Page

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

2 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Drive Operating Condition and Run/Fault Relay Contact Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7 Drive Operating Condition and Status LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figures Page

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

2 Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Model KBAC-24D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Models KBAC-27D, 29, 45, 48 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5 Maximum Allowed Motor Torque vs. Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6 Open Ventilated Motor with External Fan Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7 Models KBAC-24D, 27D AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . 13

8 Models KBAC-29, 45, 48 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . 14

9 Remote Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10 Remote Start/Stop Switch Connection with Normally Open Stop Contact . . . . . . . . . . . . . . . . . . . . . . . . 15

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

12 Start/Stop Function Eliminated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

13 Voltage Following Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

14 Enable Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

15 Run/Fault Relay Output Contacts Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

16 Models KBAC-24D, 27D AC Line Input Voltage Selection (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

17 Removing Jumper J1 on Models KBAC-24D, 27D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

18 Motor Horsepower Selection (Jumper J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

19 Automatic Ride-Through or Manual Restart Selection (Jumper J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

20 60 Hz and 50 Hz Motor Selection (Jumpers J4 and J5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

21 Available Torque vs. Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

22 120 Hz and 100 Hz Drive Output Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

23 Fixed or Adjustable Boost Selection (Jumper J6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

24 Regenerative or DC Injection Braking Selection (Jumper J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

25 “Run” or “Fault” Output Relay Operation Selection (Jumper J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

26 Normally Open or Closed Stop Contact Selection (Jumper J9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

27 Constant or Variable Torque Selection (Jumper J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

28 I

2

t Overload Selection (Jumper J11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

29 Typical Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ii

30 Minimum Speed Trimpot (MIN) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

31 Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

32 Acceleration Trimpot (ACCEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

33 Deceleration Trimpot (DECEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

34 DC Injection Brake Trimpot (DECEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

35 Slip Compensation Trimpot (COMP) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

36 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

37 I

2

t Trip Time vs. Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

38 Boost Trimpot (BOOST) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

39 Run-Stop-Jog Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

40 Jog Trimpot (JOG) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Items Included In this Package:

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

iii

Model No.

Part No.

Black White*

KBAC-24D 9987 9988

KBAC-27D 9520 9521

KBAC-29 9528 9529

KBAC-45 9530 9531

KBAC-48 9540 9541

Drive Model Nos. and Part Nos.

*White FDA approved finish.

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.

UL Notice

4

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

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

1 QUICK-START INSTRUCTIONS

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

pages 13 – 14.

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

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

Models KBAC-24D, 27D: Designed to accept single-phase (Terminals “L1”, “L2”) AC line input only.
Rated for 208/230 Volt AC line input with Jumper J1 set to the “230V” position (factory setting). Rated
for 115 Volt AC line input with Jumper J1 set to the “115V” position. See Figure 7, on page 13.

Note: Model KBAC-27D is rated for 1

1

⁄2 HP maximum with 115 Volt AC line input and 2 HP maximum

with 208/230 Volt AC line input.

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

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

Important – You must read these simplified instructions before proceeding. These instructions are to be
used as a reference only and are not intended to replace the details provided herein. You must read the
Safety Warning on, page 5, before proceeding.

see Section 5.2, on page 14.

Ground (Earth):

(Terminals L1, L2, L3)

see Section 5.1, on pages 13 – 14.

(Models KBAC-29, 45, 48):

50/60 Hz, AC Line Input

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

(Terminals L1, L2)

see Section 5.1, on pages 13 – 14.

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

50/60 Hz, AC Line Input

208/230 Volt, Single Phase,

3-Phase

see Section 5.3, on page 14.

AC Induction Motor:

AC LINEMOTOR

Motor

TB1

L2

L1V WUL3

FIGURE 1 – QUICK-START CONNECTION DIAGRAM*

*Layout of Model KBAC-24D varies slightly.

Models KBAC-45, 48: Designed to accept 3-phase (Terminals “L1”, “L2”, “L3”) AC line input only.
Rated for 400/460 Volt AC line input only. See Figure 8, on page 14.

1.2 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 10. Also see Section 10, on page 21.

1.3 GROUND CONNECTION – Connect the ground wire (earth) to the ground screw, as shown in Figure

7, on page 13, and Figure 8, on page 14. See Section 5.2, on page 14.

1.4 MOTOR CONNECTION – Wire the motor to Terminal Block TB1 Terminals “U”, “V”, “W”, as shown in

Figure 7, on page 13, and Figure 8, on page 14. (Special reactors may be required for cable lengths
over 100 ft. (30 m) – consult our Sales Department.) See Section 5.3, on page 14.

1.5 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 17.

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 pages 14 – 15. This switch must be used
to “start” the drive each time the AC line is applied to the drive or to “restart” the drive. Also see
Section 6.8, on page 18.

1.7 JUMPER SETTINGS – All jumpers have been factory set for most applications, as shown in Figure 2,

on page 9. Some applications require setting of the jumpers in order to tailor the drive for a specific
requirement. See Section 6, on pages 16 – 18.

1.8 TRIMPOT SETTINGS – All trimpots have been factory set for most applications, as shown in Figure

2, on page 9. Some applications require adjustment of the trimpots in order to tailor the drive for a
specific requirement. See Section 12, on pages 22 – 25.

1.9 DIAGNOSTIC LEDs – After power has been applied, observe the LEDs to verify proper drive opera-

tion, as described in Section 11, on pages 21 – 22.

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.

5

This product should be installed and serviced by a qualified technician, electrician, or

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

installation, which includes wiring, fusing or other current protection, and grounding can reduce the

chance of electrical shocks, and/or fires, in this product or products used with this product, such as

electric motors, switches, coils, solenoids, and/or relays. Do not use this drive in an explosion-proof

application. Eye protection must be worn and insulated adjustment tools must be used when working

with drive under power. This product is constructed of materials (plastics, metals, carbon, silicon, etc.)

which may be a potential hazard. Proper shielding, grounding, and filtering of this product can reduce

the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic

equipment. It is the responsibility of the equipment manufacturer and individual installer to supply this

Safety Warning to the ultimate end user of this product. Be sure to follow all instructions carefully. Fire

and/or electrocution can result due to improper use of this product. (SW 1/2006)

6

3 INTRODUCTION

Thank you for purchasing the KBAC Adjustable Frequency Drive. KB Electronics, Inc. is committed to
providing total customer satisfaction by producing quality products that are easy to install and operate. The
KBAC is manufactured with surface mount components incorporating advanced circuitry and technology.

The drives are variable speed controls housed in a rugged NEMA-4X / IP-65 washdown and watertight
die-cast aluminum enclosure. They are designed to operate 208 – 230 and 400/460 Volt 50 & 60 Hz
3-phase AC induction motors from subfractional thru 5 HP. The sine wave coded Pulse Width Modulated
(PWM) output operates at a carrier frequency of 16 kHz which provides high motor efficiency and low noise.
Adjustable Linear Acceleration and Deceleration are provided, making the drive suitable for soft-start
applications.

Due to its user-friendly design, the KBAC AC drive is easy to install and operate. Tailoring to specific applica­tions is accomplished with selectable jumpers and trimpots, which eliminate the computer-like programming
required on other drives. However, for most applications no adjustments are necessary. For more advanced
programming, PC based Drive-Link™ software is available.

Main features include adjustable RMS Current Limit and I

2

t Motor Overload Protection.* In addition, Adjustable
Slip Compensation with Static Auto-Tune and Boost provides high torque and excellent load regulation over a
wide speed range. Power Start™ delivers over 200% motor torque to ensure start-up of high frictional loads.
Electronic Inrush Current Limit (EICL™) eliminates harmful AC line inrush current. A Run/Fault Relay is provid­ed, which can be used to turn on or off equipment or to signal a warning if the drive is put into the Stop Mode
or if a fault has occurred. The drive is suitable for machine or variable torque (HVAC) applications. Also, a
jumper is provided for selection of Regenerative or DC Injection Braking.

Standard front panel features include Diagnostic LEDs for “Power On” and “Drive Status”, a Start/Stop Switch,
and a Main Speed Potentiometer. Other features include a Barrier Terminal Block to facilitate wiring of the AC
line and motor, adjustable trimpots (MIN, MAX, ACCEL, DECEL, COMP, CL, JOG, BOOST), customer selec­table jumpers (Line Voltage (dual voltage models only), Motor Horsepower, Automatic 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, I

2

t Overload Selection).

Optional accessories include: Forward-Stop-Reverse Switch, On/Off AC Line Switch, Run-Stop-Jog Switch,
Signal Isolator, Auto/Manual Switch, Class ”A” AC Line Filter, Multi-Speed Board, Programming Kit, Modbus
Communication Module, and Liquidtight Fittings. A connector is provided for easy installation of accessories.
Custom software: all models can be factory programmed for applications which require special timing, PLC
functions, and GFCI operation – contact our Sales Department.

*UL approved as an electronic overload protector for motors.

3.1 STANDARD FEATURES

• Industrial Duty Die-Cast Aluminum Case with Hinged Cover – Available in black finish or FDA

approved white finish.

• Simple to Operate – Does not require programming. Uses trimpots and jumpers, which are factory

set for most applications.

• Motor HP Selection Jumper – Allows the drive to be used on a wide range of motors without

recalibration.

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

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

warning if the drive is put into the Stop Mode or a fault has occurred.

This product complies with all CE directives pertinent at the time of manufacture. Contact our Sales

Department for Declaration of Conformity. Installation of a CE approved RFI filter is required. See RFI
Filters & Chokes Selection Guide D-321 (Part No. A42027) for selection of filters to meet the Industrial or
Residential Standard. Additional shielded cable and/or AC line cables may be required along with a signal
isolator (SIAC (Part No. 9600)).

• Start/Stop Switch – Provides electronic start and stop functions.

• Barrier Terminal Block – Facilitates wiring of motor, AC line, and Run/Fault Relay Output Contacts.

• Jumper Selection of Drive Output Frequency – Increases the motor speed up to two times the

rated RPM.

• Ride-Through – Provides smooth recovery to the previous set speed during a momentary power

loss (of less than 2 seconds).

• Holding Torque at Zero Speed – Resists motor shaft rotation when the drive is in Stop Mode.

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

3.2 PERFORMANCE FEATURES

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

loads.

• Slip Compensation with Static Auto-Tune and Boost – Provides excellent load regulation over a

wide speed range.

• Speed Range – 60:1

3.3 PROTECTION FEATURES

• Motor Overload (I

2

t) with RMS Current Limit* – Provides motor overload protection which pre-

vents motor burnout and eliminates nuisance trips.*

• Electronic Inrush Current Limit (EICL™) – Eliminates harmful Inrush AC line current during startup.

• Short Circuit – Shuts down the drive if a short circuit occurs at the motor (phase-to-phase).

• Regeneration – Eliminates tripping due to high bus voltage caused by rapid deceleration of high

inertial loads.

• Undervoltage and Overvoltage – Shuts down the drive if the AC line input voltage goes above or

below the operating range.

• MOV Input Transient Suppression.

• Microcontroller Self Monitoring and Auto Reboot.

*UL approved as an electronic overload protector for motors.

3.4 TRIMPOT ADJUSTMENTS

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

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

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

speed. See Section 12.3, on page 22.

• Deceleration (DECEL) – Sets the amount of time for the motor to decelerate from full speed to zero

speed. See Section 12.4, on page 23.

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

“INJ” position), the DECEL trimpot is used to set the DC Injection Brake voltage and time. See
Section 12.5, on page 23.

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

on page 23.

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

See Section 12.7, on page 24.

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

formance. See Section 12.8, on pages 24 – 25.

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

Switch Kit (Part No. 9340). See Section 12.9, on page 25.

7

8

Description

1

PC Board

Designation

KBAC-24D KBAC-27D KBAC-29 KBAC-45 KBAC-48

AC Line Input Voltage (115, 230) J1

3 3

— — —

Motor Horsepower (see Table 4 - Electrical Ratings, on page 10) J2

3 3 3 3 3

Automatic Ride-Through or Manual Restart (A*, M) J3

3 3 3 3 3

Frequency Multiplier (1X, 2X) J4

3 3 3 3 3

Motor Frequency (50Hz, 60Hz) J5

3 3 3 3 3

Fixed or Adjustable Boost (FIX, ADJ) J6

3 3 3 3 3

Regenerative or DC Injection Braking (RG, INJ) J7

3 3 3 3 3

“Run” or “Fault” Output Relay Operation (R, F) J8

3 3 3 3 3

Normally Open or Closed Stop Contact (NO, NC) J9

3 3 3 3 3

Constant or Variable Torque (VT, CT) J10

3 3 3 3 3

I2t Overload Selection (1, 2)

J11

3 3 3 3 3

TABLE 1 – JUMPER SELECTABLE FEATURES

TABLE 2 – OPTIONAL ACCESSORIES

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.

Notes: 1. Complies with CE Council Directive 89/336/EEC Industrial Standard. 2. If a USB communication cable is required, purchase Part No. 19008.

3. Other protocols available – contact our Sales Department.

Description

Model

KBAC-24D

Model

KBAC-27D

Model

KBAC-29

Model

KBAC-45

Model

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.

9480 9480 9480 9480 9480

On/Off AC Line Switch – Disconnects the AC line. Mounts on the enclosure
cover and is supplied with a switch seal to maintain liquidtight integrity.

9482 9523 9532 9532 9532

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.

9340 9340 9340 9340 9340

Signal Isolator – Provides isolation between a non-isolated signal source and the
drive. Mounts on the drive’s PC board with four snap-ins.

9600* 9600* 9600* 9600* 9600*

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.

9481 9481 9481 9481 9481

AC Line Filter1– Provides Class A RFI (EMI) suppression.
Installs onto the drive’s PC board with quick-connect terminals.

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

Suffix “S” 9516 9512 9479 9479 9479

Suffix “NS” 9507 9512 9515 9515 9515

Multi-Speed Board – Provides multi-speed operation using external contacts or a
PLC. Mounts on the drive’s PC board with four snap-ins.

9489 9489 9489 — —

Programming Kit2 – Includes DownLoad Module™ (DLM) handheld programming
device which uploads and downloads drive programs, PC to DLM serial communica-

tion cable, DLM to drive communication cable, and PC Windows® based Drive­Link™ communication software.

9582 9582 9582 9582 9582

Modbus Communication Module – Allows direct communication between drive

and Modbus

3

protocol.

9517 9517 9517 9517 9517

Liquidtight Fittings – Provide a liquidtight seal for wiring the drive. Kit includes
three 1/2” and one 3/4” liquidtight fittings

9526 9526 9526 9526 9526

* Warning! It is highly recommended that the Signal Isolator (Part No. 9600) be installed when using the
drive with external control signals.

Output Contacts:

Run/Fault Relay

Start/Stop Switch:

Main Speed Potentiometer:

Diagnostic LEDs:

J4: 1X or up to 2X

J9: Normally Open or ClosedJ11: I t Overload selection.

CON1: Used to connect

optional accessories to the drive.

Stop Contact selection.

Torque selection.

J10: Constant or Variable

J7: Regenerative or

Output Relay Operation selection.

Injection Braking selection.

J8: "Run" or "Fault"

J6: Fixed or Adjustable Boost selection.

Rated Motor RPM Operation selection.

Motor Operation selection.

J5: 60 Hz or 50 Hz

All jumpers and trimpots are shown in factory set positions.

J1: AC Line Input Voltage selection

J2: Motor Horsepower selection

3

.

(Models KBAC-24D, 27D only).

J3: Automatic Ride-Through

4

or Manual Start selection.

Used with optional Run-Stop-Jog Switch Kit.

Adjustable Trimpots

2

.

JOG Terminal.

See Section 6.6, on page 18.

See Section 6.7, on page 18.

See Section 6.4, on page 17.

See Section 6.4, on page 17.

See Section 6.5, on page 18.

See Section 6.1, on pages 16 – 17.

See Section 6.2, on page 17.

See Section 6.3, on page 17.

See Section 12, on pages 22 – 25.

See Table 2, on page 8.

2

see Section 5.5,

see Section 5.9,

on page 16.

on pages 14 – 15.

Normally Closed

Red

Normally Open

Relay Common

see Section 5.4, on page 14.

Black

White

See Section 6.10, on page 18.

See Table 2, on page 8.

See Section 6.8, on page 18.

See Section 6.9, on page 18.

White (Low) (P1)

Violet (High) (P3)

Orange (Wiper) (P2)

see Section 11, on pages 21 – 22.

STATUS

POWER

STOP

NCNO COM

FWDCOM RUN REV COM

CON2

JOGP1P3 P2

ACCELMINMAX JOGCLDECEL BOOST

TB2

MA

J32XJ4

50Hz

J5

60Hz 1X

J8J9

NCNO F

J11 J10

CT21 VT

CON1

FIXJ6RGR INJ

J7

ADJ

A

J2

ECD

B

COMP

9

FIGURE 2 – CONTROL LAYOUT

1

Notes: 1. Layout of Model KBAC-24D varies slightly. 2. On Model KBAC-24D, the JOG and COMP Trimpots are located vertically, along the right edge of the PC board (below the mounting screw). 3. On Model KBAC-24D, Jumper J2 is

labeled “1”, “3/4”, “1/2”, “1/4”, “1/8” (factory set to the “1” position). On Model KBAC-27D, Jumper J2 is labeled “2”, “1

1

⁄2”, “1”, “3/4”, “1/2” (factory set to the “1

1

⁄2” position). On Models KBAC-29, 45, 48, Jumper J2 is labeled “A”, “B”,

“C”, “D”, “E” (factory set according to Table 4, on page 10. 4. On Model KBAC-24D, Jumper J3 is labeled “AUTO” and “MAN”.

A B C D E

10

Description Specification Factory Setting

115 Volt AC Line Input Voltage Operating Range (Volts AC) 115 (±15%) —

208/230 Volt AC Line Input Voltage Operating Range (Volts AC) 208 (-15%) / 230 (+15%) —

400/460 Volt AC Line Input Voltage Operating Range (Volts AC) 380 (-15%) – 460 (+15%) —

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

Carrier, Switching Frequency (kHz) 16, 8 —

Signal Following Input Voltage Range1(Volts DC)

0 – 5 —

Output Frequency Resolution (Bits, Hz) 10, .06 —

Minimum Speed Trimpot (MIN) Range (% Frequency Setting) 0 – 40 0

Maximum Speed Trimpot (MAX) Range (% Frequency Setting) 70 – 110 100

Acceleration Trimpot (ACCEL) and Deceleration Trimpot (DECEL) Range (Seconds) .3 – 20 1.5

Boost Trimpot (BOOST) Range (Volts/Hz) 0 – 30 5

Slip Compensation Trimpot (COMP) Range at Drive Rating (Volts/Hz) 0 – 3 1.5

Current Limit Trimpot (CL) Range (% Full Load) 40 – 200 160

Jog Trimpot (JOG) Range (% Frequency Setting) 0 – 100 35

Motor Frequency Setting (Hz) (Jumper J5) 50, 60 60

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

2

1, 2 1

Minimum Operating Frequency at Motor (Hz) 1 —

Speed Range (Ratio) 60:1 —

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

3

2.5 —

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

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

4

76 – 141 —

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

4

151 – 282 —

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

4

302 – 567 —

Run/Fault Relay Output Contact Rating (Amps at 30 Volts DC, 125 Volts AC, 250 Volts AC) 1, 0.5, 0.25 —

Operating Temperature Range (°C / °F) 0 – 45 / 32 – 113 —

TABLE 3 – GENERAL PERFORMANCE SPECIFICATIONS

TABLE 4 – ELECTRICAL RATINGS

Notes: 1. Requires an isolated signal. If a non-isolated signal is used, or if using 0 to ±2.5 thru 0 to ±25 Volts DC, or 4 – 20 mA DC signal input,
install the SIAC Signal Isolator (Part No. 9600). 2. Allows the motor to operate up to two times the rated RPM. Constant horsepower will result when
operating the drive in the “X2” mode above the motor rated frequency. 3. Dependent on motor performance. 4. Do not operate the drive outside the
specified AC line input voltage operating range.

Model No.

Part No.

AC Line Input

Fuse or

Circuit

Breaker

Rating

(Amps)

Drive Output

Motor Horsepower

Selection

2

(Jumper J2)

Net Wt.

Volts AC

(50/60 Hz)

Phase

(φ)

Maximum

Current

(Amps AC)

Voltage

Range
(Nominal)
(Volts AC)

Maximum

Continuous

Load Current

(RMS Amps/Phase)

Maximum

Horsepower

(HP (kW))Black

White

1

lbs kg

KBAC-24D 9987 9988

115 1 16 20 0 – 230

3.6 1 (.75) 1 3/4 1/2 1/4 1/8 5.9 2.7

208/230 1 10 15 0 – 230

KBAC-27D 9520 9521

115 1 22 25 0 – 230 5.5 11⁄2 (1.13) —

11⁄2

4

1 3/4 1/2 10.3 4.7

208/230 1 15 20 0 – 230 6.7 2 (1.5)

2

4

KBAC-29 9528 9529 208/230

1 15 20 0 – 230 6.7 2 (1.5) —

2

5

11⁄2 1 3/4 10.3 4.7

3 10.8 15 0 – 230 9.0 3 (2.25)

3

5

KBAC-45

3

9530 9531 400/460 3 5.3 10 0 – 400/460 4.6 3 (2.25) 3 2 11⁄2 1 3/4 10.3 4.7

KBAC-48

3

9540 9541 400/460 3 9.6 10 0 – 400/460 8.3 5 (3.75) 5 3 2 11⁄2 1 10.3 4.7

Notes: 1. White FDA approved finish. 2. Bold indicates factory setting. Jumper J2 on Model KBAC-24D is labeled “1”, “3/4”, “1/2”, “1/4”, “1/8” (facto­ry set to the “1” position). Jumper J2 on Model KBAC-27D is labeled “2”, “1

1

⁄2”, “1”, “3/4”, “1/2” (factory set to the “11⁄2” position). Jumper J2 on
Models KBAC-29, 45, 48 is labeled “A”, “B”, “C”, “D”, “E” (factory set according to the table). 3. Models KBAC-45, 48 are rated 0 – 400 Volts AC for
50 Hz motor operation and 0 – 460 Volts AC for 60 Hz motor operation. 4. Model KBAC-27D is rated 1

1

⁄2 HP maximum with 115 Volt AC line input and
2 HP maximum with 208/230 Volt AC line input. 5. Model KBAC-29 is rated 2 HP maximum with single-phase AC line input and 3 HP maximum with
3-phase AC line input.

0.31

7.97

5.86

Maximum Depth:

149

8.20 9.53

208 242

2.53

64.4

0.25

8.85

225

6.4

4* 1*

2* 3*

5.51

129

5.06

140

2X ∅

11

FIGURE 3 – MODEL KBAC-24D MECHANICAL SPECIFICATIONS (INCHES/mm) FIGURE 4 – MODELS KBAC-27D, 29, 45, 48 MECHANICAL SPECIFICATIONS (INCHES/mm)

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

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

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

Contains 2 mounting holes for standard 1/2” liquidtight fittings and 1 mounting hole for standard 3/4” liquidtight fitting.

0.30

7.37

2X 2X

25.4

2X

77.7

1.00

3.05

7.55

192

7.15

181

7.25

184

2X

6.4

8.50

216

0.25

9.80

249

9.25

235

4X ∅

Maximum Depth:

4* 1*

2* 3*

12

4 IMPORTANT APPLICATION INFORMATION

4.1 MOTOR WITH EXTERNAL FAN COOLING – Most totally enclosed fan-cooled (TEFC) and open ven-

tilated 3-phase AC induction motors will overheat if used beyond a limited speed range at full torque.
Therefore, it is necessary to reduce motor load as speed is decreased.

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

WARNING! Some motors have low speed characteristics which cause overheating and winding
failure under light load or no load conditions. If the motor is operated in this manner for an

extended period of time, it is recommended that the unloaded motor current be checked from
2 – 15 Hz (60 – 450 RPM) to ensure motor current does not exceed the nameplate rating. Do not

use motor if the motor current exceeds the nameplate rating.

It is recommended that the drive be used with Inverter Duty or TENV motors.

Inverter duty and most totally
enclosed non-ventilated (TENV)
motors can provide full rated torque
over an extended speed range
without overheating. See Figure 5.

If external fan cooling is provided,
open ventilated motors can also
achieve an extended speed range at
full rated torque. A box fan or blower
with a minimum of 100 CFM per HP
is recommended. Mount the fan or
blower so the motor is surrounded
by the airflow. See Figure 6.

4.2 ELECTRONIC MOTOR OVERLOAD
PROTECTION – The drive contains

Modified I

2

t Overload Protection.*
Part of this function consists of a
Current Limit (CL) circuit, which limits
the drive current to a factory preset
level of 160% of the rated drive
current. The CL Trimpot is used to
recalibrate the drive current from
60% thru 200%. The Power Start™
circuit provides an overshoot function
that allows most motors to develop
more than 200% of starting torque and breakdown torque.

Standard I

2

t is undesirable because it causes nuisance tripping. It allows a very high motor current to
develop and will turn the drive off after a short period of time. KB’s RMS Current Limit Circuit avoids
this nuisance tripping while providing maximum motor protection.

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

2

t Timer starts. If the
motor continues to be overloaded at the 120% level, the timer will shut down the drive after 30
minutes. If the motor is overloaded to 160% of full load, the drive will trip in 6 seconds.

*UL approved as an overload protector for motors.

FIGURE 5 – MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED

FIGURE 6 – OPEN VENTILATED MOTOR WITH EXTERNAL FAN COOLING

Motors

and TENV

Inverter Duty

Maximum Allowed

Motor Tor que (%)

TEFC and Open Ventilated

Motors

Fan Cooled

10060708050304010020 90

Motor Speed (%)

40

0

20

60

80

100

Open Ventilated Motor

Fan or Blower

(100 CFM Min.

per HP)

Airflow

5.1 AC LINE INPUT CONNECTION – Wire

the AC line input to Terminal Block TB1.

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

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

Models KBAC-24D, 27D: Designed to
accept single-phase (Terminals “L1”, “L2”) AC line input only. Rated for 208/230 Volt AC line input with
Jumper J1 set to the “230V” position (factory setting). Rated for 115 Volt AC line input with Jumper J1
set to the “115V” position. See Figure 7.

5 WIRING INSTRUCTIONS

WARNING! 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. It is highly recommended that the SIAC Signal Isolator (Part No. 9600)
be installed when using signal following.

WARNING! Remote connections of potentiometer, switches, etc., will have wiring that is at line
potential. It is required that the signal isolator be installed for remote connections.

Application Note – To avoid erratic operation, do not bundle the AC line and motor wires with each
other or with wires from signal following, start/stop contacts, or any other signal wires. Also, do not
bundle motor wires from multiple drives in the same conduit. Use shielded cables on all signal wiring
over 12” (30 cm). The shield should be earth grounded on the drive side only. Wire the drive in
accordance with the National Electrical Code requirements and other local codes that may apply.

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

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

The drive is designed with a hinged case so that when the front cover is open, all wiring stays intact.
To open the cover, the four screws must be loosened so they are no longer engaged in the case
bottom. After mounting and wiring, close the cover making sure that the wires do not get caught or
crimped as the cover is closed. Tighten the four screws so that the gasket is slightly compressed.
The recommended tightening torque is 12 in-lbs (14 kg-cm). See Figures 3 and 4, on page 11, for the
tightening sequence. Do not overtighten.

13

Terminal Block Description Model

Maximum Wire Size (Cu) Recommended Tightening Torque

AWG

mm

2

in-lbs kg-cm

TB1 AC Line Input and Motor Wiring

KBAC-24D 12 3.3 7 8

KBAC-27D, 29, 45, 48 12 3.3 12 14

TB2 Run/Fault Relay Output Contacts All 16 1.3 3.5 3

TABLE 5 – TERMINAL BLOCK WIRING INFORMATION

FIGURE 7 – MODELS KBAC- 24D, 27D*

AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS

AC LINEMOTOR

Motor

VUW

AC Line Input

115, 208/230 Volt

Single-Phase Ground (Earth)

L1 L2

TB1

*Model KBAC-27D is rated 11⁄2 HP maximum with 115 Volt AC line input and 2
HP maximum with 208/230 Volt AC line input.

14

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

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

5.2 GROUND CONNECTION – Connect the ground wire (earth) to the Green Ground Screw. The Ground

Screw is located next to Terminal Block TB1. See Figure 7, on page 13, and Figure 8.

5.3 MOTOR CONNECTION – Wire the motor to Terminal Block TB1 Terminals “U”, “V”, “W”. See Figure

7, on page 13, and Figure 8. Motor cable length should not exceed 100 ft (30 m) – special reactors
may be required – consult our Sales Department.

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

5.4 REMOTE MAIN SPEED POTENTIOMETER

CONNECTION – The drive is supplied with a

prewired Main Speed Potentiometer mounted
on the front cover.

To operate the drive from a remote poten­tiometer (5 kΩ), remove the white, orange,
and violet potentiometer leads from Terminals
“P1”, “P2”, and “P3”. The wires may be taped
and left inside the drive. The potentiometer
assembly may be removed if a watertight seal
is used to cover the hole in the front cover.
Wire the Main Speed Potentiometer to
Terminals “P1” (low side), “P2” (wiper), and “P3” (high side). See Figure 9.

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

Application Note – If it is required that the Remote Main Speed Potentiometer be isolated from the

AC line, install the SIAC Signal Isolator (Part No. 9600).

5.5 REMOTE START/STOP SWITCH CONNECTION – The drive is supplied with a prewired Start/Stop

Switch mounted on the front cover to electronically start and stop the drive.

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

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

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

Model KBAC-29 Only

Wire the single-phase AC line input

208/230 Volt

AC Line Input

Single-Phase, 50/60 Hz

Ground (Earth)

L3L2L1

AC LINE

Ground (Earth)3-Phase, 50/60 Hz

208/230, 400/460 Volt

Motor

AC Line Input

WU V

MOTOR

TB1

L1 L3L2

AC LINE

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

FIGURE 9 – REMOTE MAIN SPEED

POTENTIOMETER CONNECTION

Main Speed

Potentiometer

Orange (Wiper)
Violet (High)

White (Low)

P1P2P3

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

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

5.6 AUTOMATIC RESTART – Automatic

restart requires the elimination of the
Start/Stop Switch. Remove the white,
black, and red wires from Terminals
“RUN”, “COM”, and “STOP”. The wires
may be taped and left inside the drive.
The switch assembly may be removed if
a liquidtight seal is used to cover the hole
in the front cover.

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

WARNING! Using a jumper to eliminate the

start/stop function will cause the motor to
run at the Main Speed Potentiometer setting when
the AC line is applied.

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

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

*If a non-isolated signal is used,
install the SIAC Signal Isolator (Part No. 9600). The SIAC accepts voltage (0 to ±2.5 thru 0 to ±25
Volts DC) or current (4 – 20 mA DC) signal inputs. See Table 2, on page 8.

Note: For signal following operation, the Minimum Speed Trimpot (MIN) must be set fully counter­clockwise.

WARNING! The signal input must be isolated from the AC line. Earth grounding signal
wiring will damage the drive and void the warranty. It is highly recommended that the

SIAC Signal Isolator (Part No. 9600) be installed when using signal following.

5.8 ENABLE CIRCUIT CONNECTION – The drive can also be started and stopped with an Enable circuit

(close to run, open to stop). See Figure 14, on page 16.

15

FIGURE 10 – REMOTE START/STOP SWITCH CONNECTION

WITH NORMALLY OPEN STOP CONTACT

(J9 Installed in “NO” Position)

COM

Black

STOP

STOP

Red

START

RUN

White

NO

J9

NC

FIGURE 12 – START/STOP FUNCTION ELIMINATED

(TERMINALS HARDWIRED) (JUMPER INSTALLED)

(J9 INSTALLED IN “NO” POSITION)

COMSTOP RUN

NO

J9

NC

FIGURE 11 – REMOTE START/STOP SWITCH CONNECTION

WITH NORMALLY CLOSED STOP CONTACT

(J9 INSTALLED IN “NC” POSITION)

COM

(Push to Stop)

Normally Closed

Momentary Contact

STOP

STOP

Normally Open

Momentary Contact

(Push to Start)

RUN

START

NO

J9

NC

FIGURE 13 – VOLTAGE FOLLOWING CONNECTIONS (ISOLATED)

0 – 5

Volts DC

P2P3P1

V

-

+

0 – 10

Volts DC

P2P3P1

10k V

10k

-

+

16

The Enable function is established by
wiring a switch or contact in series with
the orange Main Speed Potentiometer
lead which connects to Terminal “P2”.
When the Enable Switch is closed, the
motor will accelerate to the Main
Speed Potentiometer setting. When
the Enable Switch is opened, the
motor will decelerate to stop.

WARNING! If the Enable

Switch is to be mounted
remotely, it is highly recommended
that the SIAC Signal Isolator
(Part No. 9600) be installed.

5.9 Run/Fault Relay Connection – The Run/Fault

Relay Output Contacts are located at TB2 and
can be used to turn on or off equipment or to
signal a warning if the drive is put into the Stop
Mode or a fault has occurred. See Figure 15.

The Run/Fault Relay Contact status for various
drive operating conditions is shown in Table 6.

FIGURE 14 – ENABLE CIRCUIT CONNECTION

Main Speed

Potentiometer

Enable Switch or Relay

Orange (Wiper)
Violet (High)

White (Low)

(Close to Run)

P1P2P3

FIGURE 15 – RUN/FAULT RELAY OUTPUT

CONTACTS CONNECTION

Output Contacts

Run/Fault Relay

Normally Closed

Relay Common

Normally Open

NCNO

TB2

COM

6 SETTING SELECTABLE JUMPERS

The drive has customer selectable
jumpers which must be set before
the drive can be used. For the
location of jumpers, see Figure 2,
on page 9.

Note: Disconnect the AC line
before changing position of
jumpers.

6.1 LINE INPUT VOLTAGE
SELECTION (J1 (MODELS
KBAC-24D, 27D ONLY)) –

Jumper J1 is factory installed
on Terminal “230V” for 208/230 Volt AC line input. For 115 Volt AC line input, the jumper must be
removed and installed on Terminal “115V”. See Figure 16.

Drive

Operating

Condition Description

Run Relay Operation

(Jumper J8 Installed in “R” Position)

(Factory Setting)

Fault Relay Operation

(Jumper J8 Installed in “F” Position)

Normally

Open Contact

Normally

Closed Contact

Normally

Open Contact

Normally

Closed Contact

Power Off Main Power Disconnected Open Closed Open Closed

Run Mode* Normal Drive Operation Closed Open Closed Open

Stop Mode* Selected by Operator Open Closed Closed Open

Fault** Drive Tripped Open Closed Open Closed

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

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

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

208/230 Volt AC Line Input

(Factory Setting)

(J1 Installed on Terminal “230V”)

115 Volt AC Line Input

(J1 Installed on Terminal “115V”)

115VJ1230V

J1

115V 230V

*Layout of Model KBAC-24D varies slightly.

Using pliers, gently rock the female terminal back and forth
while pulling it upward. See Figure 17

6.2 MOTOR HORSEPOWER SELECTION (J2) – Set Jumper J2
to the corresponding position for the motor being used.
See Figure 18.

6.3 AUTOMATIC RIDE-THROUGH OR MANUAL START
SELECTION (J3)* – Jumper J3 is factory set to the “A” posi-

tion for Automatic Ride-Through. If the power is interrupted
for up to 2 seconds, the drive will shut down and then
“ride-through” and automatically return to the set frequency.
If Jumper J3 is set to the “M” position, the drive will have to
be manually restarted for a momentary power loss using the Start/Stop Switch. See Figure 19. Also
see Section 11.2, on page 22, for the Status (ST) LED indication.

*On Model KBAC-24D, Jumper J3 is labeled “AUTO” and “MAN”.

6.4 60 Hz AND 50 Hz MOTOR
OPERATION AND DRIVE
OUTPUT FREQUENCY
SELECTION (J4 AND J5) –

Both jumpers must be set for the
appropriate motor nameplate
frequency rating.

6.4.1 SETTING THE DRIVE

FOR 60 Hz OR 50 Hz
MOTOR OPERATION –

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

6.4.2 SETTING THE DRIVE FOR TWO

TIMES THE RATED MOTOR RPM –

The drive can also be used to oper­ate the motor up to two times the
rated RPM. However, constant
horsepower will result when operat­ing the drive in the “2X” mode
above the motor rated frequen­cy. See Figure 21, on page 18.

For 120 Hz output with 60 Hz
motor, set Jumper J4 to the
“2X” position and be sure
Jumper J5 is set to the “60Hz”
position. For 100 Hz output with
50 Hz motor, set Jumper J4 to
the “2X” position and set
Jumper J5 to the “50Hz” position. See Figure 22, on page 18.

17

FIGURE 17 – REMOVING JUMPER J1

ON MODELS KBAC-24D, 27D

FIGURE 18 – MOTOR HORSEPOWER SELECTION

Terminal
Installed

Removed

Terminal

FIGURE 19 – AUTOMATIC RIDE-THROUGH

OR MANUAL START SELECTION*

Automatic Ride-Through

(Factory Setting)

(J3 Installed in “A” Position)

Manual Start

(J3 Installed in “M” Position)

A

J3

M

A

J3

M

J2

KBAC-24D KBAC-27D

1 2**

3/4 11⁄2**

1/2 1

1/4 3/4

1/8 1/2

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

3*** 3 5

2*** 2 3

11⁄2 11⁄2 2

1 1 11⁄2

3/4 3/4 1

A

B

C

D

E

The factory setting is shown in bold.
*Jumper J2 on Models KBAC-29, 45, 48 is labeled “A”, “B”, “C”, “D”, “E”. **Model
KBAC-27D is rated 1

1

⁄2 HP maximum with 115 Volt AC line input and 2 HP maximum
with 208/230 Volt AC line input. ***Model KBAC-29 is rated 2 HP maximum with
single-phase AC line input and 3 HP maximum with 3-phase AC line input.

FIGURE 20 – 60 Hz & 50 Hz MOTOR SELECTION

60 Hz Motor Operation

(Factory Setting)

(J4 Installed in “1X” Position)

(J5 Installed in “60Hz” Position)

50 Hz Motor Operation

(J4 Installed in “1X” Position)

(J5 Installed in “50Hz” Position)

2X

J4

1X

50Hz

J5

60Hz

2X

J4

1X

50Hz

J5

60Hz

*On Model KBAC-24D, Jumper J3 is labeled “AUTO” and “MAN”.

18

6.5 BOOST MODE SELECTION (J6) –

Jumper J6 is factory set to the “FIX”
position for Fixed Boost. For
Adjustable Boost using the BOOST
Trimpot, set Jumper J6 to the “ADJ”
position. See Figure 23. Also see
Section 12.8, on pages 24 – 25, for
the BOOST Trimpot range.

6.6 BRAKING MODE SELECTION (J7) –

Jumper J7 is factory set to the “RG”
position for Regenerative Braking when
the Start/Stop Switch is set to the
“STOP” position. For DC Injection
Braking, set Jumper J7 to the “INJ”
position. See Figure 24. Also see
Section 12.5, on page 23.

When the Injection Brake Mode is
selected, the DECEL Trimpot is used
to adjust the brake time and intensity.

6.7 RUN/FAULT OUTPUT RELAY
OPERATION SELECTION (J8) –

Jumper J8 is factory set to the “R”
position for “Run” operation of the
Run/Fault Relay. For “Fault” operation
of the Run/Fault Relay, set Jumper J8
to the “F” position. See Figure 25, on
page 19.

For Run/Fault Relay output contacts,
see Section 5.8, on pages 15 – 16.
The Run/Fault Relay contact status for
various drive operating conditions is
shown in Table 6, on page 16.

6.8 STOP CONTACT SELECTION (J9) –

Jumper J9 is factory set to the “NO”
position for a normally open stop
contact. For remote normally closed
stop contact, set Jumper J9 to the
“NC” position. See Figure 26, on
page 19. For wiring information, see
Section 5.5, on pages 14 – 15.

6.9 TORQUE MODE SELECTION (J10) –

Jumper J10 is factory set to the “CT”
position for Constant Torque Mode,
which is desirable for most machine
applications. For Variable Torque
Mode, used for HVAC and fan
applications, set Jumper J10 to the “VT” position. See Figure 27, on page 19.

6.10 I

2

t OVERLOAD SELECTION (J11) – Jumper J11 is factory set to the “1” position for Inverter Duty

Rated Motors. For Non Inverter Duty Rated Motors and HVAC applications, set Jumper J11 to the “2”
position. See Figure 28, on page 19. Also see Section 12.7, on page 24.

FIGURE 22

120 H

Z & 100 HZ DRIVE OUTPUT FREQUENCY SELECTION

120 Hz Output with 60 Hz Motor

(J4 Installed in “2X” Position)

(J5 Installed in “60Hz” Position)

100 Hz Output with 50 Hz Motor

(J4 Installed in “2X” Position)

(J5 Installed in “50Hz” Position)

2X

J4

1X

50Hz

J5

60Hz

2X

J4

1X

50Hz

J5

60Hz

FIGURE 21 – AVAILABLE TORQUE VS. OUTPUT FREQUENCY

50/60

Output Frequency (Hz)

0

20

% Torque

50

100/120

100

FIGURE 23 – FIXED OR ADJUSTABLE BOOST SELECTION

Fixed Boost

(Factory Setting)

(J6 Installed in “FIX” Position)

Adjustable Boost

(J6 Installed in “ADJ” Position)

ADJ

J6

FIX

ADJ

J6

FIX

FIGURE 24 – REGENERATIVE OR DC INJECTION BRAKING SELECTION

Regenerative Braking

(Factory Setting)

(J7 Installed in “RG” Position)

DC Injection Braking

(J7 Installed in “INJ” Position)

INJ

J7

RG

INJ

J7

RG

7 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.
Although the drive is designed for outdoor
and washdown use, 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 Figures 3 and 4, on page 11.

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

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 29, on page 20. 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.

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.

19

FIGURE 25 – “RUN” OR “FAULT”

OUTPUT RELAY OPERATION SELECTION

“Run” Output Relay Operation

(Factory Setting)

(J8 Installed in “R” Position)

“Fault” Output Relay Operation

(J8 Installed in “F” Position)

F

J8

R

F

J8

R

FIGURE 26 – NORMALLY OPEN

OR CLOSED STOP CONTACT SELECTION

Normally Open Stop Contact

(Factory Setting)

(J9 Installed in “NO” Position)

Normally Closed Stop Contact

(J9 Installed in “NC” Position)

NO

J9

NC

NO

J9

NC

FIGURE 27 – CONSTANT OR VARIABLE TORQUE SELECTION

Constant Torque

(Factory Setting)

(J10 Installed in “CT” Position)

Variable Torque

(J10 Installed in “VT” Position)

VT

J10

CT

VT

J10

CT

FIGURE 28 – I2t OVERLOAD SELECTION

Inverter Duty Rated Motor

(Factory Setting)

(J11 Installed in “1” Position)

Non Inverter Duty Rated

Motor Operation

(J11 Installed in “2” Position)

1

J11

2

1

J11

2

20

Chassis

P3

Chassis

Machine Equipment or Frame

Adjustable Frequency Drive

(Main Power Disconnected)

to AC Line Inputs

Connect Hi-Pot

L2

L1

P2

P1

Auxiliary Equipment

L3

Signal Inputs

L2

H. V.

AC Line Input

MAX

ZERO

L1

RESET

RETURN

10mA0mA

VOLTAGETEST

AC KILOVOLTS

LEAKAGE

1

0 3

2

High Voltage Dielectric Withstand Tes ter (Hi-Pot Tester)

Motor Wires

W

V

Frame

Connect All Drive Terminals Together

U

(Main Power Disconnected)

FIGURE 29 – TYPICAL HI-POT TEST SETUP

9 DRIVE OPERATION

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

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

WARNING! Using a jumper to eliminate the start/stop function will cause the motor to run at the
Main Speed Potentiometer setting when the AC line is applied. See Section 9.2.

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

9.2 STARTING THE DRIVE AFTER A FAULT HAS BEEN CLEARED

1, 2

– The drive monitors four faults

(Undervoltage, Overvoltage, Short Circuit (at the motor (phase-to-phase)), and Overload). See Section

11.2 for the Status (ST) LED indication. Also see Section 6.3, on page 17, for Automatic Ride­Through or Manual Restart selection with Jumper J3.

To start the drive after a fault has been cleared, use the Start/Stop Switch

2, 3

.

If the Start/Stop Switch has been eliminated (bypassed), see Section 5.6, on page 15.

4

The drive can
be started (after the fault has been cleared), by disconnecting the AC power until all LEDs are no
longer illuminated and then reconnecting the AC power.

Notes: 1. For an Overload Fault, be sure the fault has been cleared before restarting the drive. Check
the motor current with an AC RMS responding ammeter. Also, the CL setting may be set too low. See
Section 12.7, on page 24. 2. For an Overvoltage Fault, if the drive is set for Automatic Ride-Through,
the drive will automatically restart when the AC line voltage returns to below the specified Overvoltage
Trip Point. 3. If the Forward-Stop-Reverse Switch has been installed, it can be used to restart the
drive. 4. If the Start/Stop Switch has been eliminated (bypassed), the AC line must be used to start
the drive after an Overload Fault has been cleared.

10 AC LINE FUSING

The drive does not contain line fuses. Most electrical codes require that each ungrounded conductor con­tain circuit protection. Do not fuse neutral or ground connections. It is recommended to install a fuse
(Littelfuse 312/314, Buss ABC, or equivalent) or a circuit breaker in series with each ungrounded conduc­tor. Do not fuse motor leads. For the recommended fuse size, see Table 4, on page 10.

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

11 DIAGNOSTIC LEDS

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

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

to the drive.

WARNING! Do not depend on the PWR LED as a guaranteed power off condition.
Be sure the main power switch or circuit breaker is in the “OFF” position before

servicing this drive.

11.2 STATUS LED (ST) – The “ST” LED is a tricolor LED which provides indication of a fault or abnormal

condition. The information provided can be used to diagnose an installation problem such as incorrect
input voltage, overload condition, and drive output miswiring. It also provides a signal which informs

21

22

12 TRIMPOT ADJUSTMENTS

The drive contains trimpots which are factory set for most applications.
See Figure 2, on page 9, for the location of the trimpots and their
approximate factory calibrated positions. Some applications may require
readjustment of the trimpots in order to tailor the drive for a specific
requirement. The trimpots may be readjusted as described below.

WARNING! If possible, do not adjust trimpots with the

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

12.1 MINIMUM SPEED (MIN) – Sets the minimum speed of the

motor. The MIN Trimpot is factory set to 0% of frequency setting.
For a higher minimum speed setting, rotate the MIN Trimpot
clockwise. See Figure 30.

12.2 MAXIMUM SPEED (MAX) – Sets the maximum speed of the

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

12.3 ACCELERATION (ACCEL) – Sets the amount of time for the

motor to accelerate from zero speed to full speed. The ACCEL
Trimpot is factory set to 1.5 seconds. For a longer acceleration
time, rotate the ACCEL Trimpot clockwise. For more rapid
acceleration, rotate the ACCEL Trimpot counterclockwise.
See Figure 32.

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

the user that all drive and microcontroller operating parameters are normal. Table 7, summarizes the
“ST” LED functions.

Drive Operating Condition

Flash Rate1and LED Color

Normal Operation Slow Flash Green

Overload (120% – 160% Full Load)

Steady Red

2

I2t (Drive Timed Out)

Quick Flash Red

2

Short Circuit Slow Flash Red

Undervoltage

Quick Flash Red / Yellow

3

Overvoltage

Slow Flash Red / Yellow

3

Stop Steady Yellow

Stand-By

4

Slow Flash Yellow

TABLE 7 – DRIVE OPERATING CONDITION AND STATUS LED INDICATOR

Notes: 1. Slow Flash = 1 second on and 1 second off. Quick Flash = 0.25 second on and 0.25 second off. 2. When the Overload is
removed, before the I

2

t times out and trips the drive, the “ST” LED will flash green. 3. When the Undervoltage or Overvoltage condition is

corrected, the “ST” LED will flash Red / Yellow / Green. 4. Only if the Forward-Stop-Reverse Switch is installed.

(Shown Factory Set to 0% Frequency Setting)

0

MIN

40

15 35

30

FIGURE 30 – MINIMUM SPEED

TRIMPOT RANGE

(Shown Factory Set to 100% Frequency Setting)

70

MAX

110

75 90

100

80

FIGURE 31 – MAXIMUM SPEED

TRIMPOT RANGE

0.3

(Shown Factory Set to 1.5 Seconds)

ACCEL

20

3

1.5

17

10

FIGURE 32 – ACCELERATION

TRIMPOT RANGE

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

motor to decelerate from full speed to zero speed. The DECEL
Trimpot is factory set to 1.5 seconds. For longer deceleration time,
rotate the DECEL Trimpot clockwise. For more rapid deceleration,
rotate the DECEL Trimpot counterclockwise. See Figure 33.

Application Note – On applications with high inertial loads, the
deceleration may automatically increase in time. This will slow
down the rate of speed of decrease to prevent the bus voltage
from rising to the Overvoltage Trip point. This function is called
Regeneration Protection. It is recommended that for very high

inertial loads that both
the ACCEL and DECEL
Trimpots be set to
greater than 10 seconds.

12.5 DC INJECTION BRAKE

(DECEL) – The drive is

factory set for
Regenerative Braking
(Jumper J7 set to the “RG”
position). When the drive is
set for DC Injection Brake
(Jumper J7 set to the
“INJ” position), the DECEL trimpot is used to set the DC Injection
Brake voltage and time. See Figure 34. Also see Section 6.6,
on page 18.

The DC Injection Brake voltage and time range is 10% of full drive
output voltage for 3 seconds with the trimpot fully clockwise and
25% of full drive output voltage for 1 second with the trimpot fully
counterclockwise. Models KBAC-24D, 27D, 29 are factory set for
49 Volts for 1.2 seconds and Models KBAC-45, 48 are factory set
for 98 Volts for 1.2 seconds.

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

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

to maintain set motor speed under varying loads. The COMP
Trimpot is factory set to 1.5 Volts/Hz, which provides excellent
speed regulation for most motors. To increase the slip compensa­tion, rotate the COMP Trimpot clockwise. To decrease the slip
compensation, rotate the COMP Trimpot counterclockwise.
See Figure 35.

The slip compensation may be adjusted as follows:

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

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

1500/1725 RPM motors).

3. Using a tachometer, record the unloaded speed.

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

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

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

23

0.3

(Shown Factory Set to 1.5 Seconds)

DECEL

20

3

1.5

17

10

FIGURE 33 – DECELERATION

TRIMPOT RANGE

FIGURE 34 – DC INJECTION BRAKE TRIMPOT RANGE

COMP

(Shown Factory Set to 1.5 Volts/Hz)

0

0.8

3

2.3

1.5

FIGURE 35 – SLIP COMPENSATION

TRIMPOT RANGE

CL

(Shown Factory Set to 160% Full Load)

40 200

80 160

120

FIGURE 36 – CURRENT LIMIT

TRIMPOT RANGE

Models KBAC-24D, 27D, 29 Models KBAC-45, 48

(Shown Factory Set to 49 Volts for 1.2 Seconds)

57, 1.0

DECEL

23, 3.0

43, 1.5

49, 1.2

31, 2.5

40, 2.0

(Shown Factory Set to 98 Volts for 1.2 Seconds)

114, 1.0

DECEL

46, 3.0

86, 1.5

98, 1.2

62, 2.5

80, 2.0

24

12.8 BOOST (BOOST) – The drive is factory set for Fixed Boost (Jumper J6 set to the “FIX” position).

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

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

12.7 MOTOR OVERLOAD (I

2

t) WITH RMS CURRENT LIMIT (CL)* – Sets the current limit (overload),

which limits the maximum current to the motor, which prevents motor burnout and eliminates nui­sance trips. The CL Trimpot is factory set to 160% of the drive rated current. To increase the current
limit, rotate the CL Trimpot clockwise. To decrease the current limit, rotate the CL Trimpot counter­clockwise. See Figure 36, on page 23, and Figure 37.

*UL approved as an electronic overload protector for motors.

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

In order to ensure that the motor is properly protected with the I

2

t feature, it is required that

the CL Trimpot be set for 160% of the motor nameplate rated current, as described below.

Note: This adjustment must be made within 6 seconds or the I

2

t Trip will occur.

The current limit may be adjusted as follows:

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

2. Set the CL Trimpot fully counterclockwise.

3. Adjust the speed setting to 30%.

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

Trip Time (Minutes)

CL (Factory Setting)

140110 120 130

0.1

Motor Current (%)

1

160150

10

100

1000

FIGURE 37 – I2t TRIP TIME VS. MOTOR CURRENT

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

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

The boost voltage may be adjusted as follows:

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

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

3. Increase the boost until the ammeter reaches the motor

nameplate rated current (Amps AC).

4. Using the Main Speed Potentiometer, slowly adjust the motor speed over a 1 – 15 Hz (0 – 450

RPM) range. If the motor current exceeds the nameplate rating, decrease the boost setting.

12.9 JOG (JOG) – The Jog feature requires the installation of a Run-Stop-Jog Switch. The switch must be

wired according to Figure 39. The JOG Trimpot range is shown in Figure 40.

The orange Main Speed Potentiometer wire (wiper) which connects to Terminal “P2” on the drive must
be removed and installed on Terminal “RUN” on the switch. The “JOG” Terminal on the drive connects
to “JOG” on the switch. Terminal “P2” on the drive connects to the center (common) terminal on the
switch.

When the switch is in the “JOG” position, the JOG Trimpot is used to set the “jog” speed. When the
switch is in the “RUN” position, the Main Speed Potentiometer is used for speed setting.

The Run-Stop-Jog Switch (Part No. 9340) is available as an optional accessory. See Table 2,
on page 8.

25

BOOST

(Shown Factory Set to 5 Volts/Hz)

5

0

8

30

22

15

FIGURE 38 – BOOST

TRIMPOT RANGE

35

JOG

(Shown Factory Set to 35% Frequency Setting)

0

25

100

75

50

FIGURE 40 – JOG

TRIMPOT RANGE

Run-Stop-Jog Switch

P3 P2

Orange (Wiper)

(JOG)

(P2)

White (Low) (P1)

Potentiometer

Violet (High) (P3)

Main Speed

CL JOG COMPBOOSTACCEL DECEL

JOG

MAX MIN

P1

J2

Jog Trimpot

(SPDT - Center Off)

(Wiper)

E

D

A

C

B

MA

J3

FIGURE 39 – RUN-STOP-JOG SWITCH CONNECTION (SPDT – CENTER OFF)

– NOTES –

26

– NOTES –

27

LIMITED WARRANTY

For a period of 18 months from the date of original purchase, KB Electronics, Inc. will repair or replace
without charge, devices which our examination proves to be defective in material or workmanship. This
warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or
improperly installed and has been used in accordance with the instructions and/or ratings supplied. The
foregoing is in lieu of any other warranty or guarantee, expressed or implied. KB Electronics, Inc. is not
responsible for any expense, including installation and removal, inconvenience, or consequential damage,
including injury to any person, caused by items of our manufacture or sale. Some states do not allow
certain exclusions or limitations found in this warranty and therefore they may not apply to you. In any
event, the total liability of KB Electronics, Inc., under any circumstance, shall not exceed the full purchase
price of this product. (rev 2/2000)

COPYRIGHT © 2008 KB Electronics, Inc.

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

KB ELECTRONICS, INC.

12095 NW 39th Street, Coral Springs, FL 33065-2516 • [phone] • FAX [phone]
Outside Florida Call Toll Free [phone] • [e-mail]
www.kbelectronics.com

(A40206) – Rev. C – 11/2010

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