Installation & Operation Manual KBAC SERIES Adjustable Frequency Drives for 3-Phase AC Motors NEMA 4X / IP 65 Variable Speed/Soft-Start AC Motor Drive with Electronic Motor Overload Protection1 Washdown and Watertight for Indoor and Outdoor Use Rated for 208 – 230 and 400/460 Volt 50 & 60 Hz 3-Phase & PSC2 AC Induction Motors from Subfractional thru 5HP Operates from 115, 208/230 Volt and 400/460 Volt 50/60 Hz AC Line2,3 AC MOTOR SPEED CONTROL AC MOTOR SPEED CONTROL Hybrid Drive™ Hybrid Drive™ KBAC S
Table of Contents Section Page 1 Quick-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Regenerative or DC Injection Braking Selection (Jumper J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “Run” or “Fault” Output Relay Operation Selection (Jumper J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . Normally Open or Closed Stop Contact Selection (Jumper J9) . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 QUICK-START INSTRUCTIONS Important – You must read these simplified instructions before proceeding. These instructions are to be used as a reference only and are not intended to replace the details provided herein. You must read the Safety Warning on page 5 before proceeding. Reconditioning the Bus Capacitors – If this drive has been in storage for over one year, it is necessary to recondition the power supply bus capacitors.
Note: Rated for 2 HP maximum with single-phase AC line input and 3 HP maximum with 3-phase AC line input. For 3 HP rating with single-phase input, use Model KBAC-29 (1P). Models KBAC-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 15. 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.
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 that 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.
Table 1 – Jumper Selectable Features PC Board Designation KBAC-24D KBAC-27D KBAC-29 KBAC-29 (1P) KBAC-45 KBAC-48 AC Line Input Voltage (115, 230) J1 p p — — — — Motor Horsepower (see Table 4 - Electrical Ratings on page 10) J2 p p p p p p Automatic Ride-Through or Manual Restart (A2, M) J3 p p p p p p Frequency Multiplier (1X, 2X) Motor Frequency (50Hz, 60Hz) Fixed or Adjustable Boost (FIX, ADJ) Regenerative or DC Injection Braking (RG, INJ) “Run” or “Fault” Output Relay Opera
STATUS Run/Fault Relay Output Contacts. See Section 5.9 on Page 17. Normally Open Relay Common P3 P2 Used for optional Forward-Stop-Reverse Switch. CON2 TB2 P1 MAX MIN J11: I2t Overload selection. See Section 6.10 on Page 20. CON1: Used to connect optional accessories to the drive. See Table 2 on Page 8. JOG ACCEL DECEL BOOST All jumpers and trimpots are shown in factory set positions. Figure 2 – Control Layout1 A B C D E JOG J9: Normally Open or Closed Stop Contact selection.
Table 3 – General Performance Specifications Description 115 Volt AC Line Input Voltage Operating Range (Volts AC) 208/230 Volt AC Line Input Voltage Operating Range (Volts AC) 400/460 Volt AC Line Input Voltage Operating Range (Volts AC) Maximum Load (% Current Overload for 2 Minutes) Carrier, Switching Frequency (kHz) Signal Following Input Voltage Range1 (Volts DC) Output Frequency Resolution (Bits, Hz) Minimum Speed Trimpot (MIN) Range (% Frequency Setting) Maximum Speed Trimpot (MAX) Range (% Frequency
Figure 3 – Model KBAC-24D Mechanical Specifications (Inches/mm) 5.51 140 0.31 7.97 2X Ø 0.25 6.4 5.06 129 2.53 64.4 4* 1* AC MOTOR SPEED CONTROL Hybrid Drive™ 8.85 225 8.20 208 9.53 242 KBAC SERIES • NEMA 4X / IP 65 2* 1.35 34.3 3* 2.70 68.6 1.35 34.3 3X 0.875 22.2 5.97 152 2.76 70.1 * Tighten these screws, in the sequence shown, to 12 in-lbs (14 kg-cm).
Figure 4 – Models KBAC-27D, 29, 29 (1P), 45, 48 Mechanical Specifications (Inches/mm) 4X Ø 3.15 2X 80.0 1.00 2X 25.4 0.25 6.4 4* 2X 0.29 7.37 1* AC MOTOR SPEED CONTROL Hybrid Drive™ 8.67 220 9.24 235 9.82 249 KBAC SERIES • NEMA 4X / IP 65 2* 3* 7.30 185 7.69 195 1.60 40.6 3.20 81.3 1.60 40.6 1.09 22.2 0.875 2X 22.2 2.97 75.4 3.07 77.9 * Tighten these screws, in the sequence shown, to 12 in-lbs (14 kg-cm). 12 7.
IMPORTANT APPLICATION INFORMATION 4.1 Motor With External Fan Cooling – Most totally enclosed fan-cooled (TEFC) and open ventilated 3-phase AC induction motors will overheat if used beyond a limited speed range at full torque. Therefore, it is necessary to reduce motor load as speed is decreased. Note: Some fan-cooled motors can be used over a wider speed range. Consult the motor manufacturer for details.
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! HIGH VOLTAGE – REMOTE CONNECTIONS OF POTENTIOMETER, SWITCHES, ETC., WILL HAVE WIRING THAT IS AT LINE POTENTIAL.
Figure 8 – Models KBAC-29*, 45, 48 AC Line Input, Motor, and Ground Connections Model KBAC-29 Only Wire the single-phase AC line input to Terminals "L1", "L2", as shown below. TB1 U V MOTOR Motor W L1 L2 AC LINE L3 208/230, 400/460 Volt 3-Phase, 50/60 Hz AC Line Input L1 L2 AC LINE L3 208/230 Volt Single-Phase, 50/60 Hz AC Line Input Ground (Earth) Ground (Earth) *Note: 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 11 – Remote Start/Stop Switch Connection with Normally Closed Stop Contact (J9 Installed in “NC” Position) START NC NO J9 COM STOP HIGH VOLTAGE! See Warning on Page 14. NC STOP COM 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.
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.
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. Figure 16 – Models KBAC-24D*, 27D AC Line Input Voltage Selection 208/230 Volt AC Line Input (Factory Setting) (J1 Installed on Terminal “230V”) WARNING! HIGH VOLTAGE Disconnect the AC line before changing position of jumpers. 6.
Figure 19 – Automatic Ride-Through or Manual Start Selection* Automatic Ride-Through (Factory Setting) (J3 Installed in “A” Position) J3 M M Manual Start (J3 Installed in “M” Position) A A J3 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 20.
Inverter Duty Rated Motor (Factory Setting) (J11 Installed in “1” Position) INJ NC NO Non Inverter Duty Rated Motor Operation (J11 Installed in “2” Position) 1 1 J11 2 2 J11 VT J10 CT VT J10 6.
RESET H. V.
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 21. All drives have been factory hi-pot tested in accordance with UL requirements.
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. 12 DIAGNOSTIC LEDs The drive contains two diagnostic LEDs mounted on the enclosure cover to display the drive’s operational status. 12.
Figure 33 – Deceleration Trimpot Range Figure 34 – DC Injection Brake Trimpot Range Models KBAC-24D, 27D, 29 10 3 1.5 0.3 Models KBAC-45, 48 80, 2.0 40, 2.0 17 20 DECEL (Shown Factory Set to 1.5 Seconds) 43, 1.5 49, 1.2 57, 1.0 31, 2.5 23, 3.0 DECEL (Shown Factory Set to 49 Volts for 1.2 Seconds) 13.1 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.
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. 13.
Figure 38 – Boost Trimpot Range 13.8 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. Also see Section 6.5 on page 19. 15 8 5 0 Application Note – The Boost function operates over a frequency range of 0 – 15 Hz.
APPENDIX A – OPTIONAL SIAC SIGNAL ISOLATOR (PART NO. 9600) See SIAC Installation Instructions (Part No. A40149) for details and connections. Description The SIAC provides an isolated interface between non-isolated signal sources and the drive. It is used with the KBAC Series drives to isolate, amplify, and condition DC voltage and current signals from any source (tach-generators, transducers, PLCs, and potentiometers).
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 upon our examination prove 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.
