Installation & Operation Manual KBVF SERIES Chassis / IP-20 AC Drives Variable Speed / Soft-Start with Electronic Motor Overload Protection1 Rated for 208-230 Volt 50 & 60 Hz 3-Phase & PSC 2 AC Induction Motors from Subfractional thru 11⁄2 HP Operates from 115 and 208/230 Volt 50/60 Hz AC Line Input 3 See Safety Warning, on pages 8 and 9. This Manual Covers Models 4 KBVF-21D, 22D, 13, 23, 23D, 23P, 14, 24, 24D, 24P, 26D Note: The drive is factory set for 60 Hz motors. For 50 Hz motors, see Section 6.
TABLE OF CONTENTS Section Page 1 Quick-Start Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4 Important Application Information . .
TABLE OF CONTENTS (Continued) Figure Page 3A Models KBVF-14, 24, 24D, 24P, 26D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 18 3B Models KBVF-14, 24, 24D, 24P, 26D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 19 4 Expanded View of Jumpers and Trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5 Maximum Allowed Motor Torque vs. Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) Figure Page 27 Boost Trimpot (DEC/B) Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 28 Model KBVF-21D Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 29 Model KBVF-22D Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 30 Models KBVF-13, 23, 23D, 23P Current Limit Trimpot (CL) Range . . . . . . . . . .
FIGURE 1 – QUICK-START CONNECTION DIAGRAM (Model KBVF-22D Shown) Ground (Earth): see Section 9.2, on page 31. AC Line Input Voltage Selection (Dual Voltage Models Only): see Section 6.1, on page 24. Chassis ACC DEC/B J1 B- Main Speed Potentiometer (5 KΩ) (Supplied) (Front View): see Section 9.4, on page 31. MIN W CL L1 AC LINE MAX Motor Connection: see Section 9.3, on page 31. V Motor 230V 115V MOTOR COMP U Adjustable Trimpots: see Section 13, on page 38 .
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, pages 8 and 9, before proceeding. See Figure 1 on page 5. Also see Section 4 – Important Application Information, on page 20. WARNING! Disconnect main power before making connections to the drive. 1.
1.2 Ground Connection – Connect the ground wire (earth) to the ground screw, as shown in Figure 16, on page 31. See Section 9.2, on page 31. Note: Model KBVF-21D, due to its double insulated design, does not contain a ground screw. 1.3 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 1, on page 14. Also see Section 10, on page 35. 1.
1.8 Voltage Following – An isolated* 0 – 5 Volt DC analog signal input can be used to control motor speed in lieu of the Main Speed Potentiometer. The drive output will linearly follow the analog signal input. Connect the signal input positive lead (+) to Terminal “P2” and the negative lead (–) to Terminal “P1”. See Section 9.5, on page 32. *If a non-isolated signal is used, install the SIVFR — Signal Isolator (Part No. 9597). The SIVFR accepts voltage (0 to ±2.
This product should be installed and serviced by a qualified technician, electrician, or electrical maintenance person familiar with its operation and the hazards involved. Proper installation, which includes electrical connections, mounting and adequate enclosure, 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.
The KBVF Adjustable Frequency Drives provide variable speed control for standard 3-phase and Permanent Split Capacitor (PSC)1 AC induction motors from subfractional thru 11⁄2 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.
Notes: 1. Optional software is required for PSC motors — contact our Sales Department. 2. UL approved as an electronic overload protector for motors. 3. Models KBVF-21D, 22D contain ICL in lieu of EICL™. 4. In 50 Hz Mode, the DEC/B Trimpot automatically becomes Adjustable Boost. 3.1 Standard Features • Simple to Operate – Does not require programming. Uses trimpots and jumpers, which are factory set for most applications. • Diagnostic LEDs – Power on (PWR) and drive status (ST). See Section 12, on page 37.
• Electronic Inrush Current Limit (EICL™) – Eliminates harmful inrush AC line current during startup. Models KBVF-21D, 22D contain ICL in lieu of EICL™. • Short Circuit – Prevents drive failure if a short circuit occurs at the motor (phase-to-phase). • Motor Filter – Reduces harmful voltage spikes to the motor.* • Regeneration – Eliminates nuisance tripping due to bus overvoltage caused by rapid deceleration of high inertial loads.
• Current Limit (CL) – Sets the current limit (overload) which limits the maximum current (torque) to the motor. See Section 13.7, on page 42. 3.5 Optional Accessories • SIVFR — Signal Isolator and Run/Fault Relay (Part No. 9597) – Provides isolation between a non-isolated signal voltage (0 to ±2.5 thru 0 to ±25 Volts DC) or current source (4 – 20 mA DC) and the drive. Can be used in single-ended or bidirectional mode.
TABLE 1 – ELECTRICAL RATINGS AC Line Input Model Part No. KBVF-21D 9581 KBVF-22D 9572 KBVF-13 KBVF-23 9957 9958 KBVF-23D 9959 KBVF-23P KBVF-14 KBVF-24 9676 9977 9978 KBVF-24D 9979 KBVF-24P 9677 KBVF-26D* 9496 Drive Output Volts AC (50/60 Hz) Phase (φ) Maximum Current (Amps AC) Fuse or Circuit Breaker Rating (Amps) Voltage Range (Nominal) (Volts AC) Maximum Net Wt.
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS Description 115 Volt AC Line Input Voltage Operating Range (Volts AC, 50/60 Hz) 208/230 Volt AC Line Input Voltage Operating Range (Volts AC, 50/60 Hz) 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 Setting) Acceleration Trimpot (ACC) and D
FIGURE 2A – MODELS KBVF-21D, 22D, 13, 23, 23D, 23P MECHANICAL SPECIFICATIONS (Inches/mm) (Model KBVF-22D Shown) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) 3.90 99.0 0.25 6.4 (2 Places) 3.00 76.2 1.25 31.8 0.5 12.7 0.2 (10 Places) 5.1 Finger-Safe Cover Retaining Clips* 4.30 109 *Model KBVF-21D contains internal retaining clips. 3.80 96.
FIGURE 2B – MODELS KBVF-21D, 22D, 13, 23, 23D, 23P MECHANICAL SPECIFICATIONS (Inches/mm) – (Model KBVF-22D Shown) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) Finger-Safe Cover Retaining Clips* 0.2 5.1 (2 Places) See Chart 3.80 96.5 0.95 24.1 Maximum Height Model KBVF-21D Models KBVF-22D, 13, 23, 23D, 23P 2.00 50.8 2.75 69.9 *Model KBVF-21D contains internal retaining clips.
FIGURE 3A – MODELS KBVF-14, 24, 24D, 24P, 26D MECHANICAL SPECIFICATIONS (INCHES/MM) (Model KBVF-26D Shown) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) 3.90 99.0 0.4 10.2 (2 Places) 0.08 2.0 (2 Places) FINGER-SAFE COVER RETAINING CLIPS 1.32 33.5 3.07 77.9 3.82 97.0 DO NOT USE THESE FOUR RETAINING CLIPS See Chart A on page 19 0.2 5.
FIGURE 3B – MODELS KBVF-14, 24, 24D, 26D MECHANICAL SPECIFICATIONS (INCHES/MM) (Model KBVF-26D Shown) (See Figure 4, On Page 20, for Expanded View of Jumpers and Trimpots) Chart A - Maximum Length Models KBVF-14, 24, 24D, 24P Model KBVF-26D 4.30 5.70 109 145 Chart B - Maximum Height Models KBVF-14, 24, 24D, 24P Model KBVF-26D 5.00 4.50 127 114 4.70 119 See Chart B 4.
FIGURE 4 – EXPANDED VIEW OF JUMPERS AND TRIMPOTS 50/60Hz X1 X2 J1 230V 115V ST PWR CON3 J2 J1 CON1 A/M P1 P2 P3 CON2 F-S-R Jumpers and Trimpots (Shown in Factory Setting) (Located on Lower PC Board) 4 CL MAX MIN DEC/B ACC COMP Line Voltage Selection Jumper J1 (Located on Upper PC Board) (Models KBVF-21D, 22D, 23D, 24D, 26D Only) IMPORTANT APPLICATION INFORMATION 4.
Inverter duty and most totally enclosed nonventilated (TENV) motors can provide full rated torque over an extended speed range without overheating. See Figure 5. FIGURE 5 – MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED 100 80 Maximum Allowed Motor Torque (%) It is recommended that the drive be used with Inverter Duty or TENV motors.
4.2 Electronic Motor Overload Protection – The drive contains Modified I2 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.
5.1 Removing the Finger-Safe Cover – The Finger-Safe Cover may have to be removed before wiring the drive or setting selectable jumpers. All trimpots can be readjusted with the FingerSafe Cover installed. Notice the orientation of the Finger-Safe Cover before removing it. Note: The Finger-Safe Cover (except that of the KBVF-21D) is designed with a removable panel (on the trimpots side) which must be removed for installation of optional accessories SIVFR Signal Isolator and Run/Fault Relay (Part No.
6.1 FIGURE 7 – MODELS KBVF-21D, 22D, 23D, 24D AC LINE INPUT VOLTAGE SELECTION AC Line Input Voltage Selection (Jumper J1 (Models KBVF-21D, 22D, 23D, 24D, 26D Only)) – Jumper J1 is factory set to the “230V” position for 208/230 Volt AC line input. For 115 Volt AC line input, set Jumper J1 to the “115V” position. Jumper J1 is located on the upper PC board. See Figures 7 and 8.
6.2 60Hz and 50 Hz Motor Operation and Drive Output Frequency Selection (Jumpers J1 and J2) – Both jumpers must be set for the appropriate motor nameplate frequency rating. Jumpers J1 and J2 are located on the lower PC board. FIGURE 9 – REMOVING JUMPER J1 ON MODEL KBVF-26D Terminal Removed Terminal Installed 6.2.1 Setting the Drive for 60 Hz or 50 Hz Motor Operation – The drive is factory set to operate 60 Hz motors.
6.3 26 Automatic Start (CON1) – The drive is factory set for Automatic Start (jumper installed onto CON1), as shown in Figure 13, on page 27. CON1 is located on the lower PC board. The drive will automatically start when power is applied and a run command is given. The drive will automatically restart after a recovered fault due to undervoltage, overvoltage, or short circuit. FIGURE 11 – AVAILABLE TORQUE vs.
For an I2 t Trip, due to a prolonged overload, the drive must be manually restarted. See Section 11.2, on page 35. Also see Section 12.2, on page 38. FIGURE 13 – AUTOMATIC START (Jumper Installed) CON1 A/M For Manual Start, a momentary contact must be installed onto CON1, as described in Section 9.6, on pages 33 and 34. 6.4 Forward/Reverse Speed Selection (CON2) – The drive is factory set for Forward Speed Operation (jumper installed in the “F” position of CON2). CON2 is located on the lower PC board.
Application Note – The enclosure should be large enough to allow for proper heat dissipation so that the ambient temperature does not exceed 45 °C (113 °F). Leave enough room to allow for AC line, motor connection, and other wiring that is required. See Figures 2A, 2B, 3A and 3B, on pages 16 –19. When mounting the Main Speed Potentiometer, be sure to install the insulating disc between the potentiometer and the panel.
FIGURE 15 – TYPICAL HI-POT SETUP High Voltage Dielectric Withstand Tester (Hi-Pot Tester) 2 1 LEAKAGE 0 3 AC KILOVOLTS 0mA 10mA RETURN TEST H. V.
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.
FIGURE 16 – AC LINE INPUT, MOTOR, & GROUND CONNECTIONS Models KBVF-21D, 22D, 13, 23, 23D, 14, 24, 24D, 26D Models KBVF-23P, 24P MOTOR U AC LINE V W L1 MOTOR L2 Chassis L3 U AC LINE V W L1 L2 Chassis Ground (Earth) Motor 208/230 Volt* 3-Phase, 50/60 Hz AC Line Input Ground (Earth)** Motor 115, 208/230 Volt* Single-Phase, 50/60 Hz AC Line Input *Models KBVF-13, 14: 115 Volt AC line input only. Models KBVF-23, 23P, 24, 24P: 208/230 Volt AC line input only.
FIGURE 17 – MAIN SPEED POTENTIOMETER CONNECTION WARNING! Do not earth ground any Main Speed Potentiometer terminals. Note: When mounting the Main Speed Potentiometer, be sure to install the insulating disc (supplied) between the potentiometer and the panel. 9.5 Voltage Following Connection – An isolated* 0 – 5 Volt DC analog signal input can be used to control motor speed in lieu of the Main Speed Potentiometer. The drive output will linearly follow the analog signal input.
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 recommended that the SIVFR — Signal Isolator and Run/Fault Relay (Part No. 9597) be installed when using signal following. 9.6 Manual Start Switch Connection (CON1) – The Manual Start Mode is used to manually start the drive or restart the drive (reset) if a fault has occurred.
9.7 Forward-Stop-Reverse FIGURE 20 – FORWARD-STOP-REVERSE SWITCH CONNECTION Switch Connection (CON2) – Connector Installed for To operate the drive using a Jumper Removed Forward-Stop-Reverse Switch Forward-Stop-Reverse Switch, remove the factory installed CON2 jumper on CON2 and install Forward-Stop-Reverse CON2 Switch the 3-wire connector (supRed Reverse F-S-R plied). CON2 is located on the Black Stop lower PC board. The connecWhite Forward tor must be wired to a “maintained” switch or contact.
9.8 Enable Switch Connection (CON2) – The drive can be started and stopped with an Enable Switch (close to run, open to stop). Remove the factory installed jumper on CON2 and install the 3-wire connector (supplied). CON2 is located on the lower PC board. The connector must be wired to a “maintained” switch or contact. See Figure 21, on page 34. For Forward Enable Operation, wire the switch to the white and black wires. For Reverse Enable Operation, wire the switch to the red and black wires.
TABLE 3 – FAULT RECOVERY AND RESETTING THE DRIVE* Fault Automatic Start Mode (Factory Setting) Undervoltage Drive will automatically start after the bus voltage returns to the operational level or when the drive is first turned on (power up). Overvoltage Drive will automatically start after the bus voltage returns to the operational level. Short Circuit Drive will automatically start after the short circuit is removed. I2 t Drive must be manually restarted.
12 DIAGNOSTIC LEDS The drive contains two diagnostic LEDs to display the drive’s operational status. See Figure 4, on page 20, for the location of the “PWR” and “ST” LEDs. TABLE 4 – DRIVE OPERATING CONDITION & STATUS LED INDICATOR LED ST (Status) PWR (Power) Drive Status Color and Flash Sequence Flash Rate Color and Sequence4 After Recovered Fault Normal Operation (Run) Green 1 Sec.
12.1 Power On (PWR) – The “PWR” LED will illuminate green when the AC line is applied to the drive. 12.2 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 the user that all drive and microcontroller operating parameters are normal.
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. See Figure 22. 13.2 Maximum Speed (MAX) – Sets the maximum speed of the motor. The MAX Trimpot is factory set to 100% of frequency setting. For a higher maximum speed setting, rotate the MAX Trimpot clockwise. For a lower maximum speed setting, rotate the MAX Trimpot counterclockwise. See Figure 23. 13.
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 ACC and DEC/B Trimpots should be set to greater than 10 seconds. For rapid stopping, install the optional DBVF — Dynamic Brake Module (Part No. 9598).
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. 13.6 Boost (DEC/B) – When the drive is set for 50 Hz Motor Operation (Jumper J1 installed in the “50Hz” position), the DEC/B Trimpot automatically becomes the adjustable BOOST Trimpot. Most 60 Hz motors conforming to NEMA standards can operate from a preset Volts/Hz curve. 50 Hz motors, however, generally differ widely in their characteristics.
3. Increase the boost until the ammeter reaches the nameplate rated current (Amps AC). 4. Using the Main Speed Potentiometer, slowly adjust the motor speed over a 0 – 15 Hz (0 – 450 RPM) range. If the motor current exceeds the nameplate rating, decrease the boost setting. 13.7 Motor Overload (I2 t) with RMS Current Limit (CL)* – Sets the current limit (overload), which limits the maximum current to the motor, prevents motor burnout, and eliminates nuisance trips.
FIGURE 28 – MODEL KBVF-21D CURRENT LIMIT TRIMPOT (CL) RANGE FIGURE 29 – MODEL KBVF-22D CURRENT LIMIT TRIMPOT (CL) RANGE 1.9 1.3 .95 1.6 1.5 2.4 .65 1.8 1 2.8 Amps AC (Shown Factory Set Amps AC (Shown Factory Set FIGURE 30 – MODELS KBVF-13, 23, 23D, 23P CURRENT LIMIT TRIMPOT (CL) RANGE FIGURE 31 – MODELS KBVF-14, 24, 24D, 24P CURRENT LIMIT TRIMPOT (CL) RANGE 3 5 2.3 3.8 3.8 6.4 1.5 4.5 2.5 7.
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.
