Detailed instructions for use are in the User's Guide.
Installation & Operation Manual
KBVF SERIES
Chassis / IP-20 AC Drives
Variable Speed / Soft-Start with Electronic Motor Overload Protection*
Rated for 208-230 Volt 50 & 60 Hz 3-Phase & PSC** AC Induction Motors from Subfractional thru 11/2 HP Operates from 115 and 208/230 Volt 50/60 Hz AC Line Input***
230V 115V
BÂ
B+
50/60Hz
J1
P1
P2
ST PWR
P3
CON1
CON2 A/M
See Safety Warning, on pages 8 and 9. This manual covers Models
KBVF-21D, 22D, 13, 23, 23D, 14, 24, 24D, 26D
****
Note: The drive is factory set for 60 Hz motors. For 50 Hz motors, see Section 6.2, on page 25.
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 required -- Contact our Sales Department. ****Requires CE approved RFI /Filter. See RFI Filters & Chokes Selection Guide D-321 (Part No. A42027) for selection of filters to meet the Industrial or Residential Standard.
A Complete Line of Motor Drives
© 2006 KB Electronics, Inc. (see back cover)
F-S-R
X1 X2
CON3 J2
CL
MAX
MIN
DEC/B
J1
ACC
COMP
U
MOTOR
V W
AC LINE
L1 L2
TABLE OF CONTENTS Section Page 1 Quick-Start Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Â 8 2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Â 9 3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Â 20 4 Important Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Â 22 5 Finger-Safe Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Â 23 6 Setting Selectable Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Â 27 7 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Â 28 8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . . . . . . 28 Â 30 9 Wiring Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Â 35 10 AC Line Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 11 Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Â 37 12 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Â 38 13 Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Â 43 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Table Page 1 Electrical Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3 Fault Recovery and Resetting the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4 Drive Operating Condition and Status LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure Page 1 Quick-Start Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2A Models KBVF-21D, 22D, 13, 23, 23D Mechanical Specifications and Control Layout. . . . . . . . . . 16 2B Models KBVF-21D, 22D, 13, 23, 23D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 17 ii
TABLE OF CONTENTS (Continued) Figure Page 3A Models KBVF-14, 24, 24D, 26D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3B Models KBVF-14, 24, 24D, 26D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4 Expanded View of Jumpers and Trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5 Maximum Allowed Motor Torque vs. Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6 Open Ventilated Motor with External Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7 Models KBVF-21D, 22D, 23D, 24D AC Line Input Voltage Selection . . . . . . . . . . . . . . . . . . . . . . 24 8 Model KBVF-26D AC Line Input Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 9 Removing Jumper J1 on Model KBVF-26D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 10 60 Hz and 50 Hz Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 11 Available Torque vs. Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 12 120 Hz and 100 Hz Drive Output Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 13 Automatic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 14 Forward/Reverse Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 15 Typical Hi-Pot Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 16 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 17 Main Speed Potentiometer Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 18 Voltage Following Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 19 Manual Start Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 20 Forward-Stop-Reverse Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 21 Enable Switch connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 22 Minimum Speed Trimpot (MIN) Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 23 Maximum Speed Trimpot (MAX) Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 24 Acceleration Trimpot (ACC) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 25 Deceleration Trimpot (DEC/B) Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 26 Slip Compensation Trimpot (COMP) Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 iii
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 Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 31 Models KBVF-14, 24, 24D Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 32 Model KBVF-26D Current Limit Trimpot (CL) Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Items Included in this Package: KBVF Adjustable Frequency Drive, KBVF Series Installation and Operation Manual, Main Speed Potentiometer Kit with Insulator and Mounting Hardware, Main Speed Potentiometer Terminals (3 Orange), Motor and AC Line Terminals (5 Blue), 2-Wire and 3-Wire Connector Kit, Status Indicator Label, Trimpot Adjustment Tool, CE Approved Product Information Card, Warranty Registration Card.
iv
FIGURE 1 Â QUICK-START CONNECTION DIAGRAM
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. Adjustable Trimpots: see Section 13, on pages 38 Â 43.
230V 115V ACC COMP
Chassis
U
MOTOR
Motor Motor Connection: see Section 9.3, on page 31.
CL
MAX
MIN
DEC/B
J1
P3
Single-Phase, 50/60 Hz AC Line Input: see Section 9.1, on page 30.
B+
P2
50/60Hz
J1
P1
CON1
CON2
A/M
F-S-R
X1 X2
CON3 J2
Communication Port for Accessories and Programming: see Section 3.5, on page 13. For 60 Hz or 50 Hz Motor Operation: see Section 6.2.1, on page 25. For Two Times the Rated Motor RPM: see Section 6.2.2, on pages 25 and 26. Automatic Start: see Section 6.3, on page 26. Manual Start Switch Connection: see Section 9.6, on page 33.
V W
AC LINE
B-
Main Speed Potentiometer (5 K) (Supplied) (Front View): see Section 9.4, on pages 31 and 32.
L1 L2
High
ST PWR
Wiper Low Diagnostic LEDs: see Section 12, on pages 37 and 38. Voltage Following Signal Input in Lieu of Main Speed Potentiometer: see Section 9.5, on pages 32 and 33. Forward/Reverse Speed Selection: see Section 6.4, on page 27. Forward-Stop-Reverse Switch Connection: see Section 9.7, on page 34. Enable Switch Connection, see Section 9.8, on pages 34 and 35.
5
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 pages 20  22. WARNING! Disconnect main power when making connections to the drive. 1.1 AC Line Connection  Wire the single-phase AC line input to Terminals "L1" and "L2", as shown in Figure 16, on page 31. See Section 9.1, on pages 30 and 31. Application Note: Do not wire this drive to a GFCI. If operation with a GFCI is required, contact our Sales Department. Models KBVF-13, 14  Rated for 115 Volt AC line input only. Models KBVF-23, 24  Rated for 208/230 Volt AC line input only. Models KBVF-21D, 22D, 23D, 24D, 26D*  Rated for 208/230 Volt AC line input with Jumper J1 (on upper PC board) set to the "230V" position (factory setting). Rated for 115 Volt AC line input with Jumper J1 (on upper PC board) set to the "115V" position ). *On Model KBVF-26D, Jumper J1 is labeled "115VAC" and "230VAC". 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.
6
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. Motor Connection  Wire the motor to quick-connect Terminals "U", "V", "W", as shown in Figure 16, on page 31. (Special reactors may be required for cable lengths over 100 ft. (30 m)  consult our Sales Department.) See Section 9.3, on page 31. Note: The drive is programmed to operate 3-phase AC induction motors. For PSC motors, optional software is required  contact our Sales Department.
1.4
1.5
60 Hz and 50 Hz Motor Operation (Jumpers J1 and J2 On the Lower PC Board)  The drive is factory set for 60 Hz motor operation (Jumper J1 set to the "60Hz" position and Jumper J2 set to the "X1" position). For 50 Hz motor operation, set Jumper J1 to the "50Hz" position and be sure Jumper J2 is set to the "X1" position. See Section 6.2.1, on page 26. Trimpot Settings  All trimpots have been factory set for most applications, as shown in Figure 4, on page 20. Some applications require adjustment of the trimpots in order to tailor the drive for a specific requirement. See Section 13, on pages 38  43. Main Speed Potentiometer Connection  For unidirectional speed operation, wire the 5 k potentiometer (supplied) to Terminals "P1" (low), "P2" (wiper), "P3" (high). See Section 9.4, on pages 31 and 32. Vo ...
