Installation & Operation Manual ™ KBMA Adjustable Frequency Drives for 1/8 HP thru 1HP 3-Phase AC Motors rated 208 – 230 VAC, 50* & 60 Hz NEMA-1 / IP-40 Operates from 115* and 208/230 Volt 50/60 Hz AC Line Variable Speed / Soft-Start with Electronic Motor Overload Protection 1 *IMPORTANT This drive is factory set for: 1. 60 Hz Motors, for 50 Hz motors, see Section 7.4, on page 17 and 18. 2. 208/230 Volt AC line input, for 115 VAC operation, see Section 7.1, on page 16. See Safety Warning, on page 5.
TABLE OF CONTENTS Section Page 1 Quick-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 19 Acceleration Trimpot (ACCEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 20 Deceleration Trimpot (DECEL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 21 Slip Compensation Trimpot (COMP) Range . . . .
1 QUICK-START INSTRUCTIONS Important – You must read these simplified instructions before proceeding. These instructions are to be used as a reference only and are not intended to replace the details provided herein. You must read the Safety Warning, on page 5, before proceeding. Note: This drive contains bus capacitors which must be reconditioned if the drive has been in storage for over 1 year.
1.6 JUMPER SETTINGS – All jumpers have been factory set for most applications, as shown in Figure 4, on page 12. Some applications require setting of the jumpers in order to set the drive for a specific application. Jumper J2 must be set to match the horsepower of the motor being used. See Section 7, on pages 16 – 18. 1.7 60 Hz and 50 Hz MOTOR OPERATION – The drive is factory set for 60 Hz motor operation (Jumper J5 set to the “60Hz” position).
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. 3 INTRODUCTION Thank you for purchasing the KBMA Adjustable Frequency Drive.
• Motor Horsepower Selection Jumper – Allows the drive to be used on a wide range of motor horsepower (1/8, 1/4, 1/2, 3/4, 1 HP) without recalibration or programming. • Diagnostic LEDs – PC board mounted LEDs for Power On (ON), Drive Status (ST), and Overload (OL). • 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.
3.5 TRIMPOT ADJUSTMENTS (See Section 11, on pages 21 – 23.) • Minimum Speed (MIN) • Maximum Speed (MAX) • Acceleration (ACCEL) • Deceleration (DECEL) • Slip Compensation (COMP) • Current Limit (CL) TABLE 1 – OPTIONAL ACCESSORIES Description 8 Part No. Forward-Stop-Reverse Switch: Provides motor reversing, stop, and manual start functions. 9519 KBRF-300: Panel mount. AC line Class B RFI (EMI) filter which meets the CE Council Directive 89/336/EEC Residential Requirement.
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS Description 115 Volt AC Line Input Voltage Operating Range (Volts AC) 1 208/230 Volt AC Line Input Voltage Operating Range (Volts AC) 1 Specification Factory Setting 115 (±15%) — 208 (-15%) / 230 (+15%) 2 — 150 — Maximum Load (% Current Overload for 1 Minute) Horsepower Selection (HP) (J2) 1/8, 1/4, 1/2, 3/4, 1 1 16, 8 — Output Frequency Resolution (Bits, Hz) 10, .
4.30 109 0.35 9.0 0.2 5.08 0.39 9.91 4x ø 4x ø 4.95 126 5.10 130 1.10 27.9 7.00 178 0.30 7.6 0.95 24.1 0.95 24.1 1.45 36.8 1.00 25.4 2.35 59.7 3.20 81.3 A mounting template is included to facilitate mounting of the drive. Recommended tightening torque for the two front cover screws: 5 in-lbs (6 kg-cm). Side view is shown dimensioned with the cover installed. 5.10 130 Back view is shown dimensioned without the cover installed. 1.75 44.
FIGURE 3 – COVER LAYOUT Provision for Optional Forward-Stop-Reverse Switch Pilot Light On/Off AC Line Switch Main Speed Potentiometer Front Cover Screws
Blue Black White TB1 Black Panel Mounted On/Off AC Line Switch (Back View) Blue White Panel Mounted Pilot Lamp White Orange Violet Panel Mounted Main Speed Potentiometer (Front View) A J1 U 115VAC B J1-B V MOTOR W CON1 GND L1A L2A L1 L2 AC LINE L1B L2B J6 J5 J2 J4 J3 TB2 FLT RUN C L M A X M I N A C C D E C C O M P P 1 P 2 P 3 F S R * The optional Forward-Stop-Reverse Switch is required for Manual Start. TB2: Run/Fault Relay Output Contacts.
IMPORTANT APPLICATION INFORMATION 4.1 MOTOR WITH EXTERNAL FAN COOLING – Most totally enclosed fancooled (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. FIGURE 5 – MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED 100 Inverter Duty and TENV Motors 80 Maximum Allowed Motor Torque (%) 4 Note: Some fan-cooled motors can be used over a wider speed range.
5 MOUNTING INSTRUCTIONS The drive is designed with a NEMA-1 / IP-40 enclosure for indoor use. It is recommended that the drive be mounted vertically on a flat surface with adequate ventilation. Leave enough room below the drive to allow for AC line, motor connections, and any other wiring that is required. Care should be taken to avoid extreme hazardous locations where physical damage can occur.
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. 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.
TABLE 5 – DRIVE OPERATING CONDITIONS & RUN/FAULT RELAY CONTACT STATUS Run Relay Operation (J5 Installed in “RUN” Position) (Factory Setting) Drive Operating Condition Description Normally Open Contact Normally Closed Contact Fault Relay Operation (J5 Installed in “FLT” Position) Normally Open Contact Normally Closed Contact Power Off Main Power Disconnected Open Closed Open Closed Run Mode 1 Normal Drive Operation Closed Open Closed Open Stop Mode 2 Selected by Operator Open Closed Cl
If an I2 t or Short Circuit Fault occurs, the drive must be restarted by setting the On/Off AC Line Switch to the “OFF” position for a minimum of 5 seconds. 7.3.2 Manual Start and Reset* – In Manual Start Mode, the drive must be manually restarted, after a fault has cleared, using the optional Forward-Stop-Reverse Switch.
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 14. FIGURE 14 – 120 Hz AND 100 Hz DRIVE OUTPUT FREQUENCY SELECTION 120 Hz Output with 60 Hz Motor (J4 Installed in “2X” Position) (J5 Installed in “60Hz” Position) J4 7.
AC Line Input RESET TEST 10mA 0 1 ZERO Connect Hi-Pot to AC Line Inputs (Main Power Disconnected) H. V. RETURN 0mA LEAKAGE VOLTAGE AC KILOVOLTS 3 Chassis L1 L2 Auxiliary Equipment MAX 2 High Voltage Dielectric Withstand Tester Frame TB1 Motor Wires Connect TB1 Terminals "U", "V", "W", "L1", "L2" Together (Except Terminal "GND") (Main Power Disconnected) FIGURE 16 – TYPICAL HI-POT TEST SETUP U V MOTOR W GND TB2 N.C. COM N.O.
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. Note: This drive contains bus capacitors which must be reconditioned if the drive has been in storage for over 1 year. To recondition the bus capacitors, apply the AC line, with the main speed potentiometer set to zero, for a minimum of 30 minutes.
10.1 PILOT LIGHT – Located on the front cover. The Pilot Light will illuminate orange when the AC line is applied to the drive and the On/Off AC Line Switch is set to the “ON” position. 10.2 POWER ON LED (ON) – Located on the PC board. The “ON” LED will illuminate green when the AC line is applied to the drive and the On/Off AC Line Switch is set to the “ON” position. 10.3 STATUS LED (ST) – Located on the PC board. The “ST” LED is a green LED, which provides indication of a fault or abnormal condition.
Note: Rapid acceleration settings may cause the current limit circuit to activate, which will extend the acceleration time. 90 100 110 MAX 11.3 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 19.
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 22. 160 200 80 40 Trip Time vs. Motor Overload. Also see Section CL Figure 23 shows the 4.2, on page 13. I2 t FIGURE 22 – CURRENT LIMIT TRIMPOT RANGE 120 *UL approved as an electronic overload protector for motors.
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.
RECONDITIONING THE BUS CAPACITORS If this drive has been in storage for over one year it is necessary to recondition the power supply bus capacitors. To recondition the bus capacitors, apply the AC Line, with the drive in the Stop Mode, for a minimum of one hour. Not following this procedure will cause the bus capacitors to fail. (A40194) – Rev.