Table of Contents
Advertisement
Quick Links
INSTALLATION AND OPERATION MANUAL
for 1/8 HP thru 1 HP 3-Phase AC Motors Rated 208 – 230 VAC, 50/60 Hz
Operate from 115* and 208/230 Volt 50/60 Hz AC Line
Variable Speed / Soft-Start with Electronic Motor Overload Protection
This Manual Covers Models KBMK-24D and KBMK-24DF
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.
Notes: 1. UL approved as an electronic overload protector for motors. 2. Model KBMK-24DF contains a built-in
AC line Class A RFI (EMI) filter which meets CE Council Directive 89/336/EEC Industrial Requirement. For Class
B Residential Requirement, install the KBRF-300 RFI (EMI) Filter (Part No. 9484).
KBMK SERIES
Adjustable Frequency Drives
NEMA-1 / IP-40
I
Automation and Control
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.
LISTED
IND. CONT.
EQ. – 70ZA
COPYRIGHT © 2008 KB Electronics, Inc.
*IMPORTANT
2
2
(see back cover)
1
RoHS
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Genesis KBMK Series
Summary of Contents for Genesis KBMK Series
- Page 1 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 Protection...
-
Page 2: Table Of Contents
TABLE OF CONTENT3S Sections Page Quick-Start Instructions............................4 Safety Warning ..............................5 Introduction ................................. 6 Important Application Information........................10 Mounting Instructions ............................11 Electrical Connections Instructions........................11 AC Line Input Voltage Selection (Jumper J1)....................14 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing)............14 Drive Operation.............................. - Page 3 TABLE OF CONTENTS (CONTINUED) Figures Page Open Ventilated Motor with External Fan Cooling ..................... 11 AC Line Input, Motor, and Ground Connections ....................12 Multi-Function Output Relay Contacts....................... 13 10 AC Line Input Voltage Selection (Jumper J1)....................14 11 Typical Hi-Pot Test Setup..........................15 12 Flow Chart to Program the Drive for 50 Hz Motors....................
-
Page 4: Quick-Start Instructions
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. -
Page 5: Safety Warning
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) –... -
Page 6: Introduction
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. -
Page 7: Optional Accessories
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. ▪... -
Page 8: General Performance Specifications
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%) Maximum Load (% Current Overload for 1 Minute) Switching Frequency (kHz) 8, 10, 12 Output Frequency Resolution (Bits, Hz) -
Page 9: Cover Layout
FIGURE 3 COVER LAYOUT FIGURE 4 DRIVE LAYOUT... -
Page 10: Important Application Information
FIGURE 5 MECHANICAL SPECIFICATIONS 4.95 4.30 0.30 1.10 27.9 4X Ø 5.08 4.15 3.20 0.39 4X Ø 81.3 9.91 2.35 59.7 1.00 25.4 5.10 7.00 1.75 0.95 0.95 1.45 44.5 24.1 24.1 36.8 5.10 0.35 IMPORTANT APPLICATION INFORMATION 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. -
Page 11: Mounting Instructions
FIGURE 7 FIGURE 6 OPEN VENTILATED MOTOR MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED WITH EXTERNAL FAN COOLING Inverter Duty and TENV Motors Fan Cooled TEFC and Open Ventilated Motors ELECTRONIC MOTOR OVERLOAD PROTECTION: The drive contains Modified I t 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. -
Page 12: Drive Terminal Blocks Wire And Tightening Torque Specifications
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. -
Page 13: Multi-Function Output Relay "Run" And "Fault" Operating Modes
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. MOTOR CONNECTION: Connect the motor to Terminal Block TB1 (Terminals "U", "V", "W"). Figure 8, on page 12. -
Page 14: Ac Line Input Voltage Selection (Jumper J1)
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. -
Page 15: Drive Operation
FIGURE 11 TYPICAL HI-POT TEST SETUP LEAKAGE 10mA RETURN VOLTAGE TEST H. V. RESET ZERO 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. -
Page 16: Keypad Description
TABLE 6 KEYPAD DESCRIPTION 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"... -
Page 17: Flow Chart To Program Motor Current From 3.6 Amps To 2.5 Amps
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. -
Page 18: Flow Chart To Program Accel Time From 1.5 Seconds To 120 Seconds
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. -
Page 19: Flow Chart To Program The Drive To Display Custom Units "012.0
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. -
Page 20: Digital Readout Codes
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"... -
Page 21: Programmable Function Summary List
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. -
Page 22: Function No. Description
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. Description Motor and Drive Parameters Run/Stop Mode Frequency Control Drive Operating Parameters... - Page 23 FUNCTION GROUP 1 – Run/Stop Mode Function Factory Description Range/Code Setting 0000: Keypad 1.00 * Run/Stop-Forward/Reverse Control 0001: External Contacts 0000 0002: Communication 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...
- Page 24 FUNCTION GROUP 2 – Frequency Control Function Factory Description Code Setting 0000: Keypad 0001: Built-In Potentiometer 0002: Analog Signal 1 2.00 * Frequency Control 0000 0003: Analog Signal 2 0004: Communication 0005: Up/Down Using MFITs 0000: Frequency Change Requires Enter Command 2.01 * Up Key, Down Key Operation Mode 0000...
- Page 25 FUNCTION GROUP 4 – Digital Display Modes Function Factory Description Range/Code Setting 0000: Frequency 4.00 Display Mode 0001: RPM 0000 0002: Custom Units 4.01 Custom Units Significant Digits 0 – 9999 0000: Whole Numbers 0001: One Decimal Place 4.02 Custom Units Display 0000 0002: Two Decimal Places 0003: Three Decimal Places...
- Page 26 FUNCTION GROUP 6 – Drive Status and Reset Function Factory Description Code Setting 6.00 * Software Version ── ── 6.01 * Drive Horsepower ── ── 6.02 * Fault Log 1 ── ── 6.03 * Fault Log 2 ── ── 6.04 * Fault Log 3 ──...
- Page 27 FUNCTION GROUP 8 – Multi-Function Output Relays and Output Signal Operation (IODA Required) Function Factory Description Range/Code Setting 0000: Run Multi-Function Output Relay 1 8.00 * 0001: Fault 0000 (Terminals 23 – 25) 0002: Target Frequency (Function No. 8.04 ± Function No. 8.05) Multi-Function Output Relay 2 8.01 * 0001...
- Page 28 FUNCTION GROUP 10 – Communication Mode (DIAC Required) Function Factory Description Range/Code Setting Assigned Communication Station 10.00 * 1 – 247 Number 10.01 Communications Watchdog Timer 0000: Disabled 0001: Enabled 0000 10.02 Watchdog Timeout (Seconds) 0.50 – 2.00 0.50 0: Stop 1: Run 0: Forward 1: Reverse...
-
Page 29: Status Leds
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"... -
Page 30: Appendix A - Optional Ioda Input/Output Multi-Function Board
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. -
Page 31: Ioda Status Indicator Led
TABLE 9 IODA STATUS INDICATOR LED Condition Red STATUS LED Normal Operation Not Illuminated Communication Error Flashes 1 Second On and 1 Second Off Current Source Trip Illuminated Notes: 1. When a Communication Error occurs, the drive's 4-Digit Display will show "Err4". 2. -
Page 32: Ioda Functions, Features, And Terminal Assignment
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 Multi- Multi-Function MFIT Power Function Analog Analog Relay Input Terminal Codes... -
Page 33: Preset Frequency Selection With 2-Wire Start/Stop Programming
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. -
Page 34: Preset Frequency Selection
TABLE 14 PRESET FREQUENCY SELECTION Multi-Function Input Terminals to Select Preset Frequency Terminal 1 Terminal 2 Terminal 3 Function No. 7.00 Function No. 7.01 Function No. 7.02 Set to "0002"* No. Function No. (Factory Setting) Set to "0000"* Set to "0001"* ●... -
Page 35: Up/Down Frequency Control Programming
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. -
Page 36: Forward/Stop-Reverse/Stop Programming
FIGURE 24 ACCEL/DECEL "2" CONENCTIONS 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"). -
Page 37: External Fault Programming
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". -
Page 38: Reset Programming
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. CAUTION! If a maintained Reset Switch or Contact is used and kept in the closed position while the drive is in the Run Mode (Start hard wired or the Start/Stop switch is in the "Start"... -
Page 39: 21 3-Wire Start/Stop Programming
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"... -
Page 40: Analog Input 1 Signal Gain And Offset With Positive Slope
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. -
Page 41: Analog Input 1 Electrical Ratings
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. -
Page 42: Analog Input 1 Signal Voltage Following 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... -
Page 43: Analog Input 2 Electrical Ratings
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 Current Range (mA DC) 0 – 20* –... -
Page 44: Analog Outputs 1 And 2 Programming
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... -
Page 45: Remote Unidirectional Speed Potentiometer Programming
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"... -
Page 46: Remote Bidirectional Speed Potentiometer Programming
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. -
Page 47: Remote Speed Potentiometer With Forward/Reverse Programming
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 Multi- Function Input Terminal "1"... -
Page 48: Multi-Function Output Relay Contacts Programming
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: I t or I•t Fault 0006: Load Loss 0007: External Fault... -
Page 49: Multi-Function Open Collector Outputs Programming
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: I t or I•t Fault 0006: Load Loss 0007: External Fault... - Page 50 – NOTES –...
- Page 51 – NOTES –...
- Page 52 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.
- Page 53 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.
Need help?
Do you have a question about the KBMK Series and is the answer not in the manual?
Questions and answers