INSTALLATION AND OPERATION MANUAL KBMK SERIES Adjustable Frequency Drives for 1/8 HP thru 1 HP 3-Phase AC Motors Rated 208 – 230 VAC, 50/60 Hz NEMA-1 / IP-40 Operate from 115* and 208/230 Volt 50/60 Hz AC Line Variable Speed / Soft-Start with Electronic Motor Overload Protection1 *IMPORTANT This drive is factory set for: 1. 60 Hz Motors. For 50 Hz motors, see Figure 12, on page 16. 2. 208/230 Volt AC Line Input. For 115 Volt AC line input, see Section 7, on page 14. See Safety Warning, on page 5.
TABLE OF CONTENT3S Sections Page 1 Quick-Start Instructions....................................................................................................................................... 4 2 Safety Warning ................................................................................................................................................... 5 3 Introduction .....................................................................................................................................
TABLE OF CONTENTS (CONTINUED) Figures Page 7 Open Ventilated Motor with External Fan Cooling ............................................................................................. 11 8 AC Line Input, Motor, and Ground Connections ................................................................................................ 12 9 Multi-Function Output Relay Contacts...............................................................................................................
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.
1.4 GROUND CONNECTION: Connect the ground wire (earth) to Terminal Block TB1 (Terminal "GND"), as shown in Figure 1, on page 4. 1.5 MOTOR CONNECTION: Connect the motor to Terminal Block TB1 (Terminals "U", "V", "W"), as shown in Figure 1, on page 4. Be sure the motor is properly grounded. Motor cable length should not exceed 100ft (30 m) – special reactors may be required – consult our Sales Department. See Section 6.3, on page 13. 1.
3 INTRODUCTION Thank you for purchasing the KBMK Adjustable Frequency Drive. KB Electronics, Inc. is committed to providing total customer satisfaction by producing quality products that are easy to install and operate. The KBMK Adjustable Frequency Drives are variable speed controls housed in a rugged NEMA-1 / IP-40 enclosure. They are designed to operate 208 – 230 Volt 50 & 60 Hz 3-phase AC induction motors from 1/8 HP thru 1 HP.
3.2 PERFORMANCE FEATURES ▪ Power Start™ – Provides more than 200% starting torque which ensures startup of high frictional loads. ▪ Programmable Flux Vector Compensation with Static Auto-Tune and Boost – Provides excellent load regulation and dynamic response over a wide speed range. ▪ Speed Range – 60:1 3.3 PROTECTION FEATURES ▪ Motor Overload (I2t) with RMS Current Limit: Provides motor overload protection, which prevents motor burnout and eliminates nuisance trips.
TABLE 3 GENERAL PERFORMANCE SAPECIFICATIONS Description Specification 115 Volt AC Line Input Voltage Operating Range (Volts AC) 115 (±15%) 208/230 Volt AC Line Input Voltage Operating Range (Volts AC) 208 (-15%) / 230 (+15%)1 Maximum Load (% Current Overload for 1 Minute) 150 Switching Frequency (kHz)2 8, 10, 12 Output Frequency Resolution (Bits, Hz) 10, .06 Minimum Operating Frequency at Motor (Hz) 0.3 Speed Range (Ratio) 60:1 3 Speed Regulation (30:1 Speed Range, 0 – Full Load) (% Base Speed) 2.
FIGURE 3 COVER LAYOUT I FIGURE 4 DRIVE LAYOUT 9
FIGURE 5 MECHANICAL SPECIFICATIONS 4.95 126 4.30 109 0.30 7.6 4X Ø 0.2 5.08 1.10 27.9 4.15 105 0.39 4X Ø 9.91 2.35 59.7 3.20 81.3 1.00 25.4 5.10 7.00 130 178 1.75 44.5 0.95 24.1 5.10 130 0.95 24.1 1.45 36.8 0.35 9.0 4 IMPORTANT APPLICATION INFORMATION 4.1 MOTOR WITH EXTERNAL FAN COOLING: Most totally enclosed fan-cooled (TEFC) and open ventilated 3-phase AC induction motors will overheat if used beyond a limited speed range at full torque.
FIGURE 6 MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED Inverter Duty and TENV Motors 4.2 FIGURE 7 OPEN VENTILATED MOTOR WITH EXTERNAL FAN COOLING Fan Cooled TEFC and Open Ventilated Motors ELECTRONIC MOTOR OVERLOAD PROTECTION: The drive contains Modified I2t Overload Protection.* Part of this function consists of a Current Limit (CL) circuit, which limits the drive current to a preset level of 160% of the Motor Nameplate Rated Current setting.
Be sure to properly fuse each AC line conductor that is not at ground potential. Do not fuse neutral or grounded conductors. A separate AC line switch or contactor must be connected as a disconnect so that each ungrounded conductor is opened. For fuse or circuit breaker selection, see Table 2, on page 7. Also see Section 6.1, on page 12. The drive is designed with a removable cover. To open the cover, the two front cover screws must be removed.
6.2 GROUND CONNECTION: Connect the ground (earth) wires from the AC line and motor to Terminal Block TB1 (Terminal "GND"). Be sure the motor is also properly grounded. See Figure 8, on page 12. 6.3 MOTOR CONNECTION: Connect the motor to Terminal Block TB1 (Terminals "U", "V", "W"). See Figure 8, on page 12. Be sure the motor is properly grounded. Motor cable length should not exceed 100 ft (30 m) – special reactors may be required – consult our Sales Department. Be sure Function No. 0.
7 AC LINE INPUT VOLTAGE SELECTION (JUMPER J1) Do not connect the AC line input until Jumper J1 is set for the proper input voltage being applied to the drive. Catastrophic failure will occur if a 230 Volt AC line is applied when the drive is set for 115 Volt AC line input. The drive is factory set for 208/230 Volt AC line input (Jumper J1 not installed). For 115 Volt AC line input, install Jumper J1 (supplied). See Figure 10.
FIGURE 11 TYPICAL HI-POT TEST SETUP LEAKAGE 0mA RETURN H. V. 10mA TEST VOLTAGE RESET ZERO 9 MAX DRIVE OPERATION Before operating the drive, read Section 9.2, for instructions on the Digital Keypad Operation. See Figure 2, on page 8, for the keypad layout. The 4-digit display can indicate various functions of the drive: Set Frequency, Motor RPM, Output Current and Voltage, Custom Units, Function Numbers, Function Codes or Values, and Fault Codes. See Section 9.4, on page 20. See Section 9.
TABLE 6 KEYPAD DESCRIPTION Key Description Starts or Stops the drive. Changes motor direction. Up Key: Increases Output Frequency, Set Frequency, Function Number Value, and Code setting. Down Key: Decreases Output Frequency, Set Frequency, Function Number Value, and Code setting. Factory programmed to function as a Jog Key. When the key is pressed, it toggles between Run Mode and Jog Mode (the "JOG/REM" LED will illuminate and the display will show the Jog Frequency Setting (see Function No. 3.13)).
FIGURE 13 FLOW CHART TO PROGRAM MOTOR CURRENT FROM 3.6 AMPS TO 2.5 AMPS *The drive's factory setting of Motor Nameplate Current (Function No. 0.01) is 3.6 Amps. FIGURE 14 FLOW CHART TO PROGRAM SET FREQUENCY FROM 5.00 Hz TO 43.21 Hz (DRIVE IN STOP MODE) * *If Function No. 2.01 is set to "0000", frequency change requires "ENTER". Throughout this sequence you must proceed to the next step within 20 seconds, before the "Press Enter Key" step, or the display will revert to "05.00".
FIGURE 15 FLOW CHART TO PROGRAM ACCEL TIME VALUE FROM 1.5 SECONDS TO 120 SECONDS *The factory setting of Accel Time (Function No. 3.03) is "1.5" seconds. The minimum setting of Accel is 0.1 seconds, therefore, the left digits must be changed first since an Accel setting of 000.0 is not allowed. FIGURE 16 FLOW CHART TO PROGRAM THE DRIVE TO DISPLAY MOTOR RPM *The factory setting of Display Mode (Function No. 4.00) is Frequency ("0000").
FIGURE 17 FLOW CHART TO PROGRAM THE DRIVE TO DISPLAY CUSTOM UNITS "012.0" Notes: 1. The factory setting of Display Mode (Function No. 4.00) is Frequency ("0000"). 2. The factory setting of Custom Units Significant Digits (Function No. 4.01) is "0100". 3. The factory setting of Custom Units Display (Function No. 4.02) is Whole Numbers ("0000"). 4. The Custom Unit setting "012.0" will be displayed at full speed.
9.4 4-DIGIT DISPLAY: The 4-digit display provides readout of drive status, operating parameters, and faults. See Table 7, for the Digital Readout Codes displayed and their descriptions. WARNING! Wait at least 1 minute before opening the cover. Be sure the main power switch or circuit breaker is in the "OFF" position before servicing the drive.
9.5 FAULT RECOVERY: The drive monitors many faults. See Function No. 1.05, on page 21, for restarting the drive after a fault has been cleared. See Section 9.4, on page 20, for the Digital Readout Codes. See Section 11, on page 29, for descriptions of the Diagnostic LEDs. See Appendix A, on pages 30 – 49, for IODA faults. Drive Faults: Undervoltage ("–LU–"), Overvoltage ("–OU–"), Short Circuit at the motor (phase-to-phase) ("–SC–"), and I2t or I•t Fault ("OL–t").
PROGRAMMABLE FUNCTION SUMMARY LIST (Rev. 100.1) Model Software Revision Codes (Rev. 100.1) The Programmable Function List, on Pages 22 – 28, is Applicable to Software Revision Code 14/1.01 (or higher). PROGRAMMABLE FUNCTION GROUPS Function Group No.
FUNCTION GROUP 1 – Run/Stop Mode Function No. Description Factory Range/Code Setting 0000: Keypad 1.00 * Run/Stop-Forward/Reverse Control 0001: External Contacts (1) 0000 0002: Communication (2) 0000: Instant Reverse 0001: Stop Command Must be Given Prior to 1.01 * Forward/Reverse Control Reverse Command 0000 0002: Reverse Command Disabled 0003: Forward Command Disabled 0000: Forward 1.02 * Motor Direction 0000 0001: Reverse 0000: Accelerates to Last Set Frequency 1.
FUNCTION GROUP 2 – Frequency Control Function No. Description Code 0000: 0001: 0002: 0003: 0004: 0005: 0000: Factory Setting Keypad Built-In Potentiometer Analog Signal 1 (1) 0000 2.00 * Frequency Control Analog Signal 2 (1) Communication (2) Up/Down Using MFITs (1) Frequency Change Requires Enter Command 0000 2.01 * Up Key, Down Key Operation Mode 0001: Direct Frequency Change 0002: Keypad Disable 0000: Jog Enabled 0001: Jog Disabled 0002: Jog Disabled; Local/Remote Enabled 0000 2.
FUNCTION GROUP 4 – Digital Display Modes Function Factory No. Description Range/Code Setting 0000: Frequency 4.00 Display Mode 0001: RPM (1) 0000 0002: Custom Units 4.01 Custom Units Significant Digits 0 – 9999 100 0000: Whole Numbers 0001: One Decimal Place 4.02 Custom Units Display 0000 0002: Two Decimal Places 0003: Three Decimal Places 0000: Displays Last Run Setting 4.03 Display in Stop Mode 0001: Displays "StoP" 0000 0002: Displays "0000" 0000: Disabled 4.
FUNCTION GROUP 6 – Drive Status and Reset Function No. Description Code 6.00 * Software Version ── 6.01 * Drive Horsepower ── 6.02 * Fault Log 1 ── 6.03 * Fault Log 2 ── 6.04 * Fault Log 3 ── 1110: 50 Hz Operation 6.05 ** Reset Drive to Factory Setting 1111: 60 Hz Operation *Read only. **Functions which can only be changed while the drive is in the Stop Mode. Factory Setting ── ── ── ── ── 0000 FUNCTION GOUP 7 – Multi-Function Input Terminals (IODA Option Board Required) Function Factory No.
FUNCTION GROUP 8 – Multi-Function Output Relays and Output Signal Operation (IODA Required) Function Factory No. Description Range/Code Setting 0000: Run Multi-Function Output Relay 1 8.00 * 0000 0001: Fault (1) (Terminals 23 – 25) 0002: Target Frequency (Function No. 8.04 ± Function No. 8.05) Multi-Function Output Relay 2 8.01 * 0001 0003: Frequency Threshold Level (Terminals 26 – 28) (> Function No. 8.04 – Function No. 8.05) (2) 0004: Frequency Threshold Level Multi-Function Open Collector Output 1 8.
FUNCTION GROUP 10 – Communication Mode (DIAC Required) Function No. Description Range/Code Assigned Communication Station 10.00 * 1 – 247 Number 10.01 Communications Watchdog Timer 0000: Disabled 0001: Enabled 10.02 Watchdog Timeout (Seconds) 0.50 – 2.00 0 0: Stop 1: Run 1 0: Forward 1: Reverse 2 0: N/A 1: Fault Reset 0: JOG-LCL/REM Command Off 3 1: JOG-LCL/REM Command On 4 0: N/A 1: Preset Frequency 1 10.
11 STATUS LEDs The drive's cover contains 8 LEDs which provide indication of the drive’s status and operating mode (Hz, PGM, LCL/REM, STOP, FWD, REV, OL, JOG/REM). See Table 8, for a description of the LEDs. WARNING! Wait at least 1 minute before opening the cover. Be sure the main power switch or circuit breaker is in the "OFF" position before servicing the drive. Do not depend on the Status LEDs or the 4-Digit Display to no longer be illuminated as a guaranteed power off condition.
APPENDIX A – OPTIONAL IODA INPUT/OUTPUT MULTI-FUNCTION BOARD For detailed operation of the IODA, see the IODA Installation and Operation Instruction Manual (Part No. A40159). The IODA Input/Output Multi-Function Board provides a variety of functions which include preset frequency, up/down frequency control, signal isolation, isolated output voltage for controlling auxiliary devices, output relay contacts, and open collector outputs. The IODA mounts on the drive's PC board with 3 screws (provided).
TABLE 9 IODA STATUS INDICATOR LED Condition Red STATUS LED Normal Operation Not Illuminated 1 Communication Error Flashes 1 Second On and 1 Second Off 2 Current Source Trip Illuminated Notes: 1. When a Communication Error occurs, the drive's 4-Digit Display will show "Err4". 2. When a Current Source Trip occurs, the drive's 4-Digit Display will show "CS-t".
FIGURE 21 IODA TERMINAL BLOCK TB1 LAYOUT Common Terminals "8", "12", "14", "16", "18, "20", "22" are all internally connected and are shown shaded. TABLE 11 IODA FUNCTIONS, FEATURES, AND TERMINAL ASSIGNMENT Terminal Assignment Multi1 Multi-Function Analog Analog Relay Power Function MFIT 2 Input Terminal Codes Outputs2 Inputs2 Outputs3 (Digital Inputs) Supply Outputs2 1–7 8 15 19 23 0000: Preset Frequency Operation1 11 Common Analog Out 1 Analog In 1 Relay 1 N.O.
USING IODA MULTI-FUNCTION INPUT TERMINALS FOR REMOTE OPERATIONS A1. PRESET FREQUENCIES The drive is factory programmed for 7 Preset Frequencies, which can be selected using remote switches or contacts connected to Multi-Function Input Terminals "1" – "3". See Table 13, for drive programming. See Figure 22, for connections. See Table 14, on page 34, for the Multi-Function Input Terminals to select for the preset frequencies.
TABLE 14 PRESET FREQUENCY SELECTION Multi-Function Input Terminals to Select Preset Frequency Terminal 1 Terminal 2 Terminal 3 Hz Function No. 7.00 Function No. 7.01 Function No. 7.02 Set to "0000"* Set to "0001"* Set to "0002"* No. Function No. (Factory Setting) ● 1 7.07 5.00 ● 2 7.08 10.00 ● ● 3 7.09 20.00 ● 4 7.10 25.00 ● ● 5 7.11 30.00 ● ● 6 7.12 35.00 ● ● ● 7 7.13 40.00 *Factory setting. A2.
TABLE 15 UP/DOWN FREQUENCY CONTROL PROGRAMMING Function No. Code/Range 1.00: Run/Stop-Forward/Reverse Control 0001: External Contacts 2.00: Frequency Control 0005: Up/Down Using MFITs 7.04: Multi-Function Input Terminal 5 0010: N.O. Start* 7.05: Multi-Function Input Terminal 6 0003: Up Frequency Command* 7.06: Multi-Function Input Terminal 7 0004: Down Frequency Command. 7.14: Up/Down Frequency Control Mode 0000: Free-Running 0001:Incremental 7.15: Increment of Up/Down Frequency** 0.01 – 30.
FIGURE 24 ACCEL/DECEL "2" CONENCTIONS A4. FORWARD/STOP AND REVERSE/STOP Remote Forward/Stop and Reverse/Stop operation can be performed by connecting switches or contacts to the Multi-Function Input Terminals. See Table 17, for drive programming. See Figure 25, for connections. Connect the Start/Stop Switch or Contact to Multi-Function Input Terminal "5", which is factory set for N.O. Start ("0010").
A5. EXTERNAL FAULT The Multi-Function Input Terminals can be used to "stop" the drive when a fault condition occurs elsewhere in the equipment. The connection to the Multi-Function Input Terminal can be from a normally open or normally closed relay contact or PLC. See Table 18, for drive programming. See Figure 26, for connections. Note: For a normally open contact, program the respective Multi-Function Input Terminal to "0008".
A6. RESET It is advisable to connect a momentary normally open switch or contact to Multi-Function Input Terminal "4". This allows the drive to be restarted after a fault has been cleared. See Table 19, for drive programming. See Figure 27, for connections.
FIGURE 28 2-WIRE START/STOP CONNECTIONS 3-WIRE START/STOP SWITCH OR CONTACT CONNECTION 3-Wire Start/Stop requires momentary switches or contacts. Connect the normally open side of the switch or contact to Multi-Function Input Terminal "5". Connect the normally closed side of the switch or contact to any other Multi-Function Input Terminal "1" – "7". Connect the common of the switches or contacts to Terminal "8". See Table 21, for drive programming. See Figure 29, for connections.
OTHER FUNCTIONS AND FEATURES OF THE IODA A8. SIGNAL FOLLOWING An analog voltage (unidirectional or bidirectional), current, or PWM signal input can be used to control motor speed in lieu of the Keypad. The drive output will linearly follow the signal input. The inputs can be programmed for the desired gain, slope, offset, and response time. Analog Input 1 is used for a DC voltage signal which has a positive or negative slope and is unidirectional or bidirectional.
FIGURE 31 ANALOG INPUT "1" AND "2" SIGNAL GAIN AND OFFSET WITH NEGATIVE SLOPE (HIGH-TO-LOW SIGNAL) (FUNCTION NO. 9.01 OR 9.06 SET TO "0001") ANALOG INPUT "1" See Table 22, for Analog Input 1 electrical ratings. Connect the signal input to Terminal "19" and the common to Terminal "20". Connect the Start (Jumper) to Terminal "5", which is factory set for N.O. Start ("0010") and to any available common terminal ("8", "12", "14", "16", "18" "20", "22"). See Table 23, on page 42, for drive programming.
TABLE 23 ANALOG INPUT "1" SIGNAL VOLTAGE FOLLOWING PROGRAMMING Function No. Code/Range 2.00:Frequency Control 0002: Analog Signal 1 9.00:Analog Input 1 Gain 0 – 500: Set to the Desired Gain 7.04:Multi-Function Input Terminal 5 0010: N.O. Start* 0000: Positive 9.01:Analog Input 1 Slope 0001: Negative 9.02:Analog Input 1 Offset 0 – 100: Set to the Desired Offset 0000: Unidirectional 9.03:Analog Input 1 Type 0001: Bidirectional 9.
TABLE 24 ANALOG INPUT "2" ELECTRICAL RATINGS Parameter Specification Factory setting Voltage Range (Volts DC) 0 – ±2.5 thru 0 – ±25 0–5 MAX2 Scaling Trimpot Range (Volts DC) 0 – 24 5 Current Range (mA DC) 0 – 20* – Input Impedance for Current Mode (Ω) 270 – PWM (kHz, Duty Cycle) 0.15 – 1, 0 – 100 – *If using 4 – 20 mA DC signal input, the offset setting in Function No. 9.07 must be increased from "0%" (factory setting) to "20%". Set Jumper J1 to the "CUR" position.
FIGURE 34 ANALOG OUTPUTS "1" AND "2" GAIN FIGURE 35 ANALOG OUTPUTS "1" AND "2" CONNECTIONS Jumpers J2 and J3 TABLE 27 ANALOG OUTPUTS "1" AND "2" PROGRAMMING Function No. Code/Range 0000: Motor Frequency 0001: Set Frequency 8.06: Analog Output 1 Mode 0002: Motor Voltage 0003: Bus Voltage 0004: Motor Current 8.07: Analog Output 1 Gain 0 – 200: Set to the Desired Gain 0000: Motor Frequency 0001: Set Frequency 8.
ANALOG OUTPUT "1" Connect the auxiliary device signal input to Terminal "15" and the common to Terminal "16". ANALOG OUTPUT "2" Connect the auxiliary device signal input to Terminal "17" and the common to Terminal "18". Voltage Signal Output: Set both Jumpers J2 and J3 to the "VOLT" position (factory setting). Current Signal Output: Set both Jumpers J2 and J3 to the "CUR" position. A10.
FIGURE 36 REMOTE UNIDIRECTIONAL SPEED POTENTIOMETER CONNECTIONS MAX2 Trimpot and Jumper J1 *Use a jumper, between Terminals "5" and "8", if a Start/Stop Switch or Contact is not required. BIDIRECTIONAL OPERATION WITH START/STOP (Use Analog Input "1" Only) Connect the potentiometer to Terminals "9" (+5 Volts), "19" (Analog Input 1), and "10" (-5 Volts). Connect the Start/Stop Switch or Contact to Terminal "5", which is factory set for N.O.
BIDIRECTIONAL OPERATION WITH FORWARD/REVERSE: Connect the potentiometer to Terminals "9" (+5 Volts), "19" (Analog Input 1), and "8" (Common) (Terminals "12", "14", "16", "18", "22" can also be used for Common). Connect the Forward Switch or Contact to a MultiFunction Input Terminal "1" – "7". Connect the Reverse Switch or Contact to a Multi-Function Input Terminal "1" – "7". Connect the Start (Jumper) to Terminal "5", which is factory set for N.O.
TABLE 31 MULTI-FUNCTION OUTPUT RELAY CONTACTS PROGRAMMING Function No. Code 0000: Run 0001: Fault 0002: Target Frequency 0003: Frequency Threshold Level (> 8.04 – 8.05) 8.00: Multi-Function Output Relay 1 0004: Frequency Threshold Level (< 8.04 + 8.05) 0005: I2t or I•t Fault 0006: Load Loss 0007: External Fault 0008: Motor Overload 0000: Run 0001: Fault 0002: Target Frequency 0003: Frequency Threshold Level (> 8.04 – 8.05) 0004: Frequency Threshold Level (< 8.04 + 8.05) 8.
TABLE 32 MULTI-FUNCTION OPEN COLLECTOR OUTPUT PROGRAMMING Function No. Code 0000: Run 0001: Fault 0002: Target Frequency 0003: Frequency Threshold Level (> 8.04 – 8.05) 8.02:Multi-Function Open Collector Output 1 0004: Frequency Threshold Level (< 8.04 + 8.05) 0005: I2t or I•t Fault 0006: Load Loss 0007: External Fault 0008: Motor Overload 0000: Run 0001: Fault 0002: Target Frequency 0003: Frequency Threshold Level (> 8.04 – 8.05) 8.
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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.