Detailed instructions for use are in the User's Guide.
Installation & Operation Manual
KBVF SERIES
Chassis / IP-20 AC Drives Variable Speed / Soft-Start AC Motor Drive with Electronic Motor Overload Protection* Rated for 208-230 and 400/460 Volt 50 & 60 Hz 3-Phase & PSC** AC Induction Motors from 2 thru 5 HP Operates from 208/230 Volt and 400/460 Volt 50/60 Hz AC Line Input***
CON3 J2 50/60Hz
J1
X1 X2
CON1
This Manual Covers Models KBVF-27, 29, 45, 48
See Safety Warning, on page 8.
****
Note: The drive is factory set for 60 Hz motors. For 50 Hz motors, see Section 6.1, on page 14.
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.
*UL approved as an electronic overload protector for motors. **Custom software is required for PSC motors. See PSC Motor Addendum (Part No. A42142). ***Do not use this drive with GFCIs. Special software is available  contact our Sales Department. ****Installation of a CE approved RFI filter is required.
A Complete Line of Motor Drives
© 2006 KB Electronics, Inc. (see back cover)
A/M
CL
MAX
MIN
DEC/B
ACC
COMP
TB1 U MOTOR V W L1 AC LINE L2 L3
TABLE OF CONTENTS Page Section 1 Quick-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4 Important Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5 Finger-Safe Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6 Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . . . . . . . . . . . . . . . . . 16 9 Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 10 AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 11 Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 12 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 13 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Tables Page 1 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4 Drive Operating Condition and Run/Fault Relay Contact Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5 Fault Recovery and Resetting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 6 Drive Operating Condition and Status LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Figures Page 1 Models KBVF-27, 29 Quick-Start Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Models KBVF-45, 48 Quick-Start Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 SIVFR Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 Mechanical Specifications and Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 5 Expanded View of Jumpers and Trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6 Maximum Allowed Motor Torque vs. Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 7 Open Ventilated Motor with External Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 8 60 Hz and 50 Hz Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 9 Available Torque vs. Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 10 120 Hz and 100 Hz Drive Output Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11 Automatic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 12 Models KBVF-27, 29 Forward/Reverse Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 13 Typical Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 14 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 15 Models KBVF-27, 29 Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 16 Unidirectional Main Speed Potentiometer and Forward-Stop-Reverse Switch Connections . . . . . . . . . . . . 18 17 Bidirectional Main Speed Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 18 Models KBVF-27, 29 Voltage Following Signal Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 Models KBVF-45, 48 Voltage Following Signal Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 20 Models KBVF-45, 48 Current Following Signal Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 21 Manual Start Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 22 Forward-Stop-Reverse Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 23 Form "C" Contact or Relay Forward-Stop-Reverse Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 24 Open Collector Forward-Stop-Reverse Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 25 Enable Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 26 Run/Fault Relay Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 27 Run/Fault Relay Output Contact Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 28 Models KBVF-27, 29 Minimum Speed Trimpot (MIN) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 ii
TABLE OF CONTENTS (Continued) Page Figures 29 SIVFR Offset Trimpot (OFFSET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 30 Models KBVF-27, 29 Maximum Speed Trimpot (MAX) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 31 Models KBVF-45, 48 Maximum Speed Trimpot (MAX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 32 Acceleration Trimpot (ACC) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 33 Deceleration Trimpot (DEC/B) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 34 Slip Compensation Trimpot (COMP) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 35 Boost Trimpot (DEC/B) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 36 Model KBVF-27 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 37 Model KBVF-29 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 38 Model KBVF-45 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 39 Model KBVF-48 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Items Included in this Package: KBVF Adjustable Frequency Drive, KBVF Series Installation and Operation Manual, Main Speed Potentiometer Kit with Insulator and Mounting Hardware, 3 Main Speed Potentiometer Quick-Connect Terminals, 2-Wire and 3-Wire Connector Kit (Models KBVF-27, 29 Only), Status Indicator Label, Trimpot Adjustment Tool, CE Approved Product Information Card, Warranty Registration Card.
iii
COMP
MIN
DEC/B
Motor Connection: see Section 9.3, on page 18.
MAX
ST
P3
CL
P1
CON3
50/60Hz
J2
X1 X2 J1 CON1 A/M CON2
F-S-R
AC LINE L2
PWR
P2
MOTOR V
Motor
ACC
4 (Shown without Finger-Safe Cover Installed)
FIGURE 1 Â MODELS KBVF-27, 29 QUICK-START CONNECTION DIAGRAM
Adjustable Trimpots: see Section 13, on pages 23 Â 26.
Ground (Earth): see Section 9.2, on page 17.
TB1
U
Main Speed Potentiometer (5 k) (Supplied) (Front View): see Section 9.4, on page 18.
W
Diagnostic LEDs: see Section 12, on pages 22 and 34. High Wiper Low Voltage Following Signal Input in Lieu of Main Speed Potentiometer: see Section 9.5, on page 19.
L1
L3
Single-Phase Connection (Use L1, L2) (Model KBVF-27 Only): see Section 9.1, on page 17. For 60 Hz or 50 Hz Motor Operation: see Section 6.1.1, on page 14. For Two Times the Rated Motor RPM: see Section 6.1.2, on page 15.
3-Phase Connection (Use L1, L2, L3) (Models KBVF-27, 29): see Section 9.1, on page 17.
Communication Port for Accessories and Programming: see Section 3.5, on page 10.
Automatic Start: see Section 6.2, on page 15. Manual Start Switch Connection: see Section 9.6, on page 20.
Forward/Reverse Speed Selection: see Section 6.3, on page 15. Forward-Stop-Reverse Switch Connection: see Section 9.7, on page 20. Enable Switch Connection, see Section 9.8, on pages 20 and 21.
FIGURE 2 Â MODELS KBVF-45, 48 QUICK-START CONNECTION DIAGRAM
(Shown without Finger-Safe Cover Installed)
Ground (Earth): see Section 9.2, on page 17.
TB2
COMP
Run/Fault Relay Output Contacts: see Section 9.9, on page 21.
Motor Connection: see Section 9.3, on page 18.
MAX MIN CL
DEC/B
J1
CON3 J2 50/60Hz
CON1
AC Line 3-Phase Connection: see Section 9.1, on page 17. For 60 Hz or 50 Hz Motor Operation: see Section 6.1.1, on page 14. For Two Times the Rated Motor RPM: see Section 6.1.2, on page 15. Automatic Start: See Section 6.2, on page 15. Manual Start Switch Connection: see Section 9.6, on page 20.
X1 X2
A/M
Communication Port for Accessories and Programming: see Section 3.5, on page 7.
MOTOR V
Motor
ACC
TB1
U
Adjustable Trimpots: see Section 13, on page 23.
W
TB1
Diagnostic LEDs (Located Under Ribbon Cable) see Section 12, on page 22.
L1
AC LINE L2
L3
Main Speed Potentiometer (Supplied), Signal Input, and Direction Switch or Contact Connections: (Isolated Inputs) see Sections 9.4.2, 9.5, and 9.7.2 on pages 18 Â 20.
5
VOLT
NO
TB1
TB2
PWR
OFFSET
MAX
DBM
CON1
FAULT RUN
CUR
NC
NDBM
6
FIGURE 3 Â SIVFR CONTROL LAYOUT
(SIVFR is Built-In on Models KBVF-45, 48 and Optional on Models KBVF-27, 29)
K1 J1 J2 K2
+5V
-5V
OV
FWD
REV
SIG1
COM1
All jumpers are shown in factory set positions. Sets the Run/Fault Relay Output Contacts for normally open or closed operation. Sets the drive for oper ...
