KBVF - KB Electronics, Inc.
Contents
1. The Right Control for Your Application 4 12095 NW 39 Street Coral Springs FL 33065 2516 KB Electronics Inc Telephone 954 346 4900 Fax 954 346 3377 KBVF Installation and Operation Manual Supplemental Information for Dual Voltage Models KBVF 22D Part No 9572 and KBVF 26D Part No 9496G This document is supplied with Models KBVF 22D Part No 9572 and KBVF 26D Part No 9496G IMPORTANT The following information and instructions are to be used as a supplement to the KBVF Installation and Operation Manual Part No A40288 until the new manual is available with the addition of Models KBVF 22D Part No 9572 and KBVF 26D Part No 9496G The KBVF Series has been changed to a second generation version 2G The General Performance Specifications have not changed This 2G version has an additional Frequency Multiplier Jumper a single Input Line Voltage Selection Jumper and an additional connector for accessories The KBVF manual must be read and understood before attempting to operate this control For further assistance contact our Sales Department at 954 346 4900 or Toll Free at 800 221 6570 outside Florida Also see KBVF 2G Version Supplemental Connection Diagrams and Jumper Settings Part No A40090G Table 1 Electrical Ratings AC Line Input Motor Output Maximum Maximum Maximum Volts AC Current Voltage Range Continuous Load Current Horsepower Model Part No 50 60 Hz Amps AC V2. Figure 4 Model KBVF 22D CL Trimpot Range Figure 5 Model KBVF 26D CL Trimpot Range 2 4 Factory Setting _ 8 8 Factory Setting 4 Optional Accessories CONS is used for optional accessory modules The planned accessory modules are Updated Input Signal Isolator Modbus Communication External Dynamic Brake Multi Speed Board Digital Programmer Readout and Drive Link PC Programming See Figure 1 on page 1 of this Supplemental Information for the location of CONS u l lfr A42128 Rev E00 10 18 2004 Z2747E00 Page 2 of 2 INSTALLATION AND OPERATING INSTRUCTIONS KBVF Adjustable Frequency Drive Variable Speed Soft Start AC Motor Control with I t Electronic Overload Protection for 3 Phase Induction Motors through 1 HP rey I I See Safety Warning on Page 3 This Manual Covers the Following Model Numbers KBVF 13 23 23D 14 24 and 24D 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 CE PENTA X POWER s See Page 4 i A COMPLETE LINE OF MOTOR DRIVES TABLE OF CONTENTS Section Page Figures Continued Page i Simplified Setup and 2 Motor with External Cooling 8 Operating Instructions 1 2 3 Control Layout 00 9 ii SafetyWarning 3 4A KBV
3. completely remove jumper J1 on lower PC board Note In 50 Hz mode DECEL trimpot becomes adjustable boost For 120 Hz over speed operation place jumper J1 in the 120 Hz position g 2 50 60 Hz AND 60 Hz 50 Hz 28 83 f FACTORY SETTING NO JUMPER INSTALLED 88 4 TRIMPOT SETTINGS The KBVF has been factory set for most applications For readjustment procedures see sec X p 24 5 POTENTIOMETER CONNECTIONS Connect the 5K ohm potentiometer to terminals P1 P2 and P3 as shown in fig 10A p 19 6 SIGNAL FOLLOWING For signal following an isolated Notch on trimpot knob indicates position 0 5VDC must be used Connect signal POS to P2 and signal NEG to P1 Note For signal following the MIN trimpot must be set to zero CCW Warning Do not earth ground any input signal wiring 7 FUSING Install a fuse or circuit breaker in the AC line Fuse each conductor not at ground potential See sec VI p 21 for recommended fuse size AN SAFETY WARNING PLEASE READ CAREFULLY 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 wiring mounting in proper enclosure fusing or other overcurrent protection and grounding can reduce the chance of electric shocks fires or explosion in this product or products used with this product such as electric motors switches c
4. 12 3 1 10 FIG 4B KBVF HP MECHANICAL SPECIFICATIONS INCHES mm RO 100 R25 TYP SPL 0 250 B 3 80 Si 6 4 96 4 30 109 NOTE MAXIMUM HEIGHT MAY BE INCREASED T 2 659 67 5 FIG 5A KBVF 1 HP MECHANICAL SPECIFICATIONS INCHES mm 4 30 109 0 485 12 3 IE o QN 12 14 FIG 5B KBVF 1 HP MECHANICAL SPECIFICATIONS INCHES mm M kk mm amp i I T CONTROL HEIGHT KAVF 24 CONTROL HEIGHT KBVF 14 240 JUMPER SETTINGS A Dual Voltage Controls Models KBVF 23D and KBVF 24D have the capability of operating standard 208 230VAC 50 60 Hz 3 phase motors from either a 115VAC or 230VAC 50 60 Hz AC line The jumpers are factory set for 230VAC 50 60 Hz Use jumpers J1 and J2 on the top PC board to change the voltage input FIG 6A J1 amp J2 SET TO 230 VOLTS FIG 6B J1 amp J2 SET TO 115 VOLTS a gt D gt aS A N N amp Warning Do not change jumper position with AC line connected Be 4 sure proper input voltage is applied to control corresponding to jumper setting Connecting 230VAC to a 115VAC control input will permanently damage control 115VAC and 230VAC labels are provided Use the appropriate label to identify th
5. Inrush Current Limit EICL which eliminates harmful AC line inrush current and a built in dV dT filter which reduces harmful voltage spikes to the motor Also two LED indicator lamps provide the user with diagnostic information The drive is housed in a versatile U frame chassis which facilitates mounting and wiring TABLE 1 GENERAL PERFORMANCE SPECIFICATIONS All Models Recommended AC Line Input Operating Range of nominal 115 230 VAC Maximum Input Voltage Range 115 VAC Models VAC Maximum Input Voltage Range 230 VAC Models VAC Maximum Load Current Overload for 2 Minutes Switching Frequency at Motor kHz Signal Following Input Voltage VDC Signal Following Input Resolution bits Minimum Speed Trimpot Range of frequency setting Output Frequency Setting Hz Maximum Speed Trimpot Range of frequency setting Speed Range ratio Isolated Input Signal must be used Factory Setting 10 97 135 195 270 0 5 0 40 50 60 120 70 110 50 1 General Performance Specifications Continued Acceleration Trimpot Range secs Deceleration Trimpot Range secs Boost Trimpot Range 50 Hz only Slip Compensation Trimpot Range Volts Hz Amp Current Limit Trimpot Range HP amps AC Current Limit Trimpot Range 1 HP amps AC Speed Regulation 0 Full Load 30 to 1 Speed Range Base Speed Operating Temperature Range C Overload Protector Tr
6. Use a normal or slow blow fuse according to the table below TABLE 4 FUSE SELECTION CHART Mosel AG ine Voltage Wax AG Line Curent AG Line Fuse rps heres ws 0 6 ev ao o o S o oo a a a a KBVF 24D 80 00 5 OPERATION M 4 Warning Read Safety Warning on page 3 before attempting to operate Severe injury or death may result After all wiring and setup is completed and rechecked the control can be powered up The main speed potentiometer should initially be set at the minimum position CCW and gradually rotated clockwise to increase motor speed Check status LED s to verify proper operation See sec VIII p 22 21 TABLE 5 KBVF STATUS INDICATORS Normal Control Operation Slow Flash CL current limit Steady Re seno aara er VIII LED STATUS INDICATORS The KBVF adjustable frequency drive contains two LED status indicators The first LED is a tricolor lamp ST that indicates a fault or abnormal condition The information provided can be used to diagnose an installation problem such as incorrect input voltage overload condition and control circuit miswiring It also provides a normal signal that informs the user that all control and micro processor operating parameters are proper The second LED is a Power On indicator PWR that senses the presence of the bus voltage and the operation of the main control logic power supply The status functions are summarized in
7. input The control is factory set to operate from a 208 230 Volt AC line input Jumper J1 in the 230V position To operate the control from a 115 Volt AC line input set Jumper J1 to the 115V position See Figure 2 on page 2 A WARNING Do not change jumper position with the AC line connected Be sure proper input voltage is applied to the control corresponding to jumper setting Connecting a 230 Volt AC line with Jumper J1 set to the 115V position will permanently damage the control 115VAC and 230VAC labels are provided Use the appropriate label to identify the correct input voltage after setting Jumper J1 see A42128 Rev E00 10 18 2004 Z2747E00 Page 1 of 2 The Right Control for Your Application 4 12095 NW 39 Street Coral Springs FL 33065 2516 KB Electronics Inc Telephone 954 346 4900 Fax 954 346 3377 KBVF Installation and Operation Manual Supplemental Information for Dual Voltage Models KBVF 22D Part No 9572 and KBVF 26D Part No 9496G Figure 2 AC Line Input Voltage Selection Jumper J1 230 Volt AC Line Input Factory Setting 115 Volt AC line Input 1 2 Motor Frequency Selection Jumpers J1 and J2 on the Lower PC Board The control is factory set to operate 60 Hz motors Jumper J1 factory set to the 60Hz position and Jumper J2 factory set to the X1 position See Figure 3 below To operate 50 Hz motors set Jumper J1 to
8. installed Important These controls are designed for 208 230 VAC motors be sure motor is wired correctly 18 20 Signal Following The control may IMPORTANT Do not bundle low voltage signal wiring main speed potentiometer signal following manual start or forward stop reverse enable with any main power wiring from AC line or motor For all signal wiring over 18 shielded cable is recommended Do not ground earth shield Speed Potentiometer Connect FIG 10A Main Speed speed potentiometer as shown The Potentiometer Connection high side is wired to P3 and the wiper is wired to P2 Wire the low side to P1 MAJN SPEED POTENTIOMETER do not ground earth low side of potentiometer or catastrophic control failure will result be operated with a 0 5VDC isolated signal in lieu of the main speed potentiometer Connect pos signal to P2 and neg to P1 Do not ground neg signal wire FIG 10B SIGNAL FOLLOWING FIG 10C SIGNAL FOLLOWING 0 5VDC Isolated 0 10VDC Isolated tee 18K a 5VRC c 1nVvoc ISOLATED ISQLATEN Note For proper operation MIN trimpot must be turned to zero CCW If 0 10VDC operation is required a resistor network can be added as per fig 10C If an isolated signal is not available a separate signal isolator must be used KBSI 240D or equivalent Do not ground earth signal wiring 19 Manual Start Mode To operate in the manua
9. table 5 22 Controller Status Controller Status LED Color Recovered Fault in Auto Mode in Manual Start Mode Manual Mode Run Run Run Run Green Shutdown Red Yellow Green Shutdown Red Yellow Green Slow flash 1 sec on 1 sec off Quick flash 25 sec on 25 sec off 1 2 3 4 Trip Control will stop and not restart when fault is cleared See instructions for restart procedure sec V E p 20 5 If a fault occurs in the manual start mode such as undervoltage or loss of AC power the drive will trip The status ST LED will begin to quick flash Red Yellow The drive cannot be restarted if the undervoltage condition persists When the voltage returns to normal the ST LED will begin to flash Red Yellow Green This signifies that there was an undervoltage or loss of voltage condition that has been corrected The control can now be restarted with the manual start contact When control recovers from CL or Stop the Status LED returns to the normal flashing green Shutdown Control will stop but will resume operation after fault is cleared 23 IX TRIMPOT ADJUSTMENTS These controls contain trimpots which have been factory adjusted for most applications Paragraph 4 on page 2 illustrates the location of the trimpots and their approximate adjustment positions Some applications may require readjustment of the trimpots in order to tailor the control to
10. vs Speed 8 i Mi N SIMPLIFIED SETUP AND OPERATING INSTRUCTIONS IMPORTANT You must read these simplified operating instructions before you proceed These instructions are to be used as a reference only and are not intended to replace the detailed instructions provided herein You must read the Safety Warning before proceeding Be sure to read Important Application Information on page 7 ae 1 AC POWER r Use 115VAC rated controls on 115VAC and 230VAC 9 AQ rated controls on 230VAC For dual input voltage o controls be sure the AC line jumpers J1 and J2 earth on upper PC board are both set for the correct AC line voltage 115 or 230VAC Connect the AC power to terminals L1 and L2 Be sure the AC power is disconnected when making connections to control Do not bundle AC power and motor wires with any other wires to control When the power is turned on the PWR LED will light and the ST LED will flash Connect ground earth to green ground screw located on the control chassis 2 MOTOR LEADS Connect the three motor leads to terminals U V and W Be sure motor is wired for proper voltage 208 230VAC only Motor cable length should not exceed 100 feet special reactors may be required consult factory AC LINE 50 60 Hz 3 MOTOR FREQUENCY SELECTION Control is factory set for 60 Hz and 50 60 Hz motors For 50 Hz motors
11. 8 Inverter duty and FIG 1 MAXIMUM ALLOWED MOTOR TORQUE vs SPEED most totally enclosed nonventilated TENV motors can provide full rated aa peer Fan caaled motor torque over an Duty and TEFC gnd open extended speed TENV motars range without overheating see fig 1 vent matars 40 50 ab 70 a eG 100 Matar Spaen ai Therefore it is e recommended that this control be used with inverter duty and totally enclosed nonventilated TENV motors FIG 2 MOTOR WITH EXTERNAL COOLING If external fan cooling is provided open ventilated motors can also achieve an extended speed range at full rated torque A box fan or blower with a minimum of 100 CFM is recommended Mount the fan a few inches from the motor so it is surrounded by the air flow FIG 3 CONTROL LAYOUT Illustrates factory setting of jumpers and approximate setting of trimpots rm AAD C N g m al 9 FIG 4A KBVF HP MECHANICAL SPECIFICATIONS INCHES mm 4 30 109 i Je O At Je l 7 SJ Ue FE OE OR 3 87 l O 94 2 z Q P Ox E 2 985 Typ 9 75 8 ii KBVF es NW sine re ms al aaf eS pa maf Bs an T 1 235 i 2 l m oe i Bgg T zU il 0 435 Typ
12. 945A or equivalent is required Additional shielded motor cable and or AC line cables may be required along with a signal isolator SIVF KB P N 9474 or equivalent I GENERAL INFORMATION The KBVF Adjustable Frequency Drive is designed to provide variable speed control of standard three phase AC induction motors Adjustable linear acceleration and deceleration are provided making the drive suitable for soft start applications The output voltage is sinewave coded PWM operating at 16 kHz which provides high motor torque high efficiency and low noise The KBVF is a full featured drive and due to its user friendly design it is easy to install and operate Simple trimpot adjustments eliminate the computer like programming required on other drives However for most applications no adjustments are necessary The KBVF main features include Adjustable RMS Current Limit and t Motor Overload Protection Adjustable Slip Compensation provides excellent load regulation over a wide speed range Power Start delivers over 200 motor torque to insure startup of high frictional loads Several models through 1 HP are available to control a standard 208 230VAC 50 60 and 50 60Hz motor from either a 115 or 230VAC 50 60Hz AC line The KBVF is easily tailored to specific requirements via selectable jumpers such as Frequency Range 0 60 0 50 0 120Hz Manual Auto Restart and Forward Stop Reverse operation Other standard features include Electronic
13. F HP l General Information 4 Mechanical Specifications 10 Il Important Application Information 7 4B KBVF HP Ill Jumper Settings 14 Mechanical Specifications 11 IV Mounting 2 eee eee 17 5A KBVF 1HP V Wiring 2 00 000 002 eee 17 Mechanical Specifications 12 MIs ARUSING cece a penaa a ty aean a 21 5B KBVF 1HP VII Operation nananana nana 21 Mechanical Specifications 13 VIII LED Status Indicator 22 6A J1 and J2 Set for 230 Volts 14 IX Trimpot Adjustments 24 6B J1 and J2 Set for 115 Volts 14 X Limited Warranty 30 7 Jumper J1 Output Frequency Setting 15 TABLES 8 Available Torque vs Output Frequency 15 1 General Performance Specifications 5 6 9 Motor and AC Line Connections 18 2 Electrical Ratings 7 10A Main Speed Potentiometer Connection 19 3 Terminal Wiring Information 17 10B Signal Following O 5VDC 19 4 Fuse Selection Chart 21 10C Signal Following 0 10VDC 19 5 KBVF Status Indicators 22 23 11A Auto Manual Selection 20 6 CL Setpoint vs Trip Time 27 11B Manual Start Switch Connection 20 FIGURES 12 Forward Stop Reverse Enable 20 1 Maximum Allowed 13A G Trimpot Adjustments 24 28 Motor Torque
14. Rotate main potentiometer to maximum speed position full clockwise 2 Adjust MAX trimpot to desired setting of motor speed the motor to reach full speed from an initial zero start The trimpot is factory set to approximately 1 5 seconds Adjust the ACC trimpot as required for the application See fig 13C Note When the control is set for 50 Hz operation the ACC trimpot will automatically change to adjustable acceleration and deceleration NOTE Rapid acceleration may cause the current limit circuit to activate This will automatically extend the acceleration time Deceleration DEC The DEC trimpot sets the time it will take the motor to reach zero speed from an initial full speed setting The trimpot is factory set to approximately 1 5 seconds Adjust the trimpot as required for application Note When the control is set for 50 Hz operation the DEC trimpot will automatically change to Adjustable Boost See sec IX G p 28 25 Application Note On applications with high inertial Fig 13D DEC loads the deceleration may automatically increase in time SECONDS This will slow down the rate of speed decrease to prevent 85Hz ONLY the D C bus voltage from rising to the overvoltage trip 10 0 point This function is called regeneration protection It is recommended that for very high inertial loads that both the ACC and DEC trimpots be set toa minimum of 10 seconds The CL trimpot is used to set the maximum moto
15. ately 4 Hz or 120 RPM Note An unloaded motor with excessive boost will draw more current than a partially loaded motor 3 Turn up boost until the ammeter reaches the nameplate motor rating 4 Using the main speed potentiometer slowly adjust motor speed over a 0 15 Hz 0 450 RPM range If motor current exceeds nameplate rating lower boost setting WARNING TO AVOID MOTOR WINDING OVERHEATING AND FAILURE DO NOT OVER BOOST MOTOR 29 X LIMITED WARRANTY For a period of 18 months from date of original purchase KB 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 and we are not responsible for any expense including installation and removal inconvenience or consequential damage including injury to any person caused by items of our manufacture or sale Some states do not allow certain exclusions or limitations found in this warranty so that they may not apply to you In any event KB s total liability under all circumstances shall not exceed the full purchase price of this unit rev 4 88 Note DO NOT REPAIR This control must be returned to a certified fa
16. ctory repair center KB Electronics Inc 12095 NW 39th Street Coral Springs FL 33065 954 346 4900 Fax 954 346 3377 4 Outside Florida Call TOLL FREE e 800 221 6570 E mail info kbelectronics com www kbelectronics com A40288 Rev D 6 99
17. e correct input voltage after setting jumpers W ce B Motor Frequency The controls are factory set to operate 60 Hz and 50 60 Hz motors For 50 Hz motors completely remove jumper J1 on lower PC board Note When the control is set for 50 Hz operation the DECEL trimpot will automatically change to adjustable boost See sec IX G p 28 FIG 7 JUMPER J1 OUTPUT FREQUENCY SETTING Bale 50 80 Hz AND 60 Hz i 50 Hz 2a f FACTORY SETTING gt 2 NO JUMPER INSTALLED The control can also operate 60 Hz and 50 60 Hz motors not 50 Hz motors in an over speed mode Note In this mode motor will produce full rated torque up to 60 Hz Above 60 Hz torque will linearly reduce to 50 at 120 Hz FIG 8 AVAILABLE TORQUE vs OUTPUT FREQUENCY C Auto Manual Operation i Auto Operation The control is factory set to start automatically each time the AC line is connected It will also automatically start when recovering from faults due to overvoltage undervoltage and short circuit If an l t fault occurs due to a prolonged overload the control must be manually restarted aa GUTPUT FREQUENCY Note The control can be restarted due to an lt fault by one of the following methods 1 Disconnect and reconnect the AC power ST LED must change from flashing green to Red Yellow flash approximately 15 seconds 2 Turning the main speed pot to zero MIN speed trimpot must be set to zero s
18. exact requirements See table 1 pages 5 and 6 for range and factory setting of trimpots Readjust trimpots as follows A N WARNING Do not adjust trimpots with main power on if possible If adjustments are made with power on insulated adjustment tools must be used and safety glasses must be worn High voltage exists in this control Electrocution and or fire can result if caution is not exercised Safety Warning on page 3 must be read and understood before proceeding Failure to follow the Safety Warning instructions may result in electric shock fire or explosion A Minimum Speed MIN The MIN trimpot is used to set the FIG 13A MIN minimum output frequency of the drive which sets the minimum motor speed The minimum speed is factory set to zero Readjust the MIN trimpot as follows 1 Rotate main speed potentiometer to the minimum speed position full counterclockwise 2 Increase setting of MIN trimpot so that motor runs at desired minimum speed Note For signal following operation the MIN trimpot is not operational and must be set to its minimum position full counterclockwise 24 26 Acceleration ACC The ACC trimpot sets the time it takes Current Limit with I t Shutdown CL B Maximum Speed MAX The MAX trimpot is used to set the FIG 13B MAX maximum output frequency of the drive The maximum speed is factory set to full rated motor speed Readjust the MAX trimpot as follows 1
19. ip Time Stalled Motor Secs Bus Overvoltage Trip Point VDC Equivalent AC Line Volts 230 VAC Line Bus Undervoltage Trip Point VDC Equivalent AC Line Volts 230 VAC Line Factory Setting 1 5 4 5 2 5 7 5 400 283 260 184 TABLE 2 ELECTRICAL RATINGS y Maximum Maximum Nominal Maximum 7 KB Part Input Voltage Gatsut loro soon Continuous AC Line Model No VAC 50 60 Hz p p Output Load Input No A Voltage Rating Single Phase VAC HP KW Current RMS Current Amps Phase Amps AC KBVF 23D 9959 115 230 0 230 1 2 37 11 0 7 0 KBVF 24D 9979 115 230 0 230 1 75 16 0 10 0 Il IMPORTANT APPLICATION INFORMATION Most fan cooled TEFC and open ventilated 3 phase motors will overheat if used with an inverter beyond a limited speed range at full rated torque Therefore it is necessary to reduce motor load as speed is decreased Note Some fan cooled motors can be used over a wider speed range Consult motor manufacturer for details A N WARNING There may be some motors whose characteristics may cause FaN overheating and winding failure under light load or no load conditions If the motor is operated in this manner for an extended period of time it is recommended that the unloaded motor amperage be checked from 2 15 Hz 60 450 RPM to ensure motor current does not exceed the nameplate rating Do not use the motor if the motor current exceeds the nameplate rating Continued on page
20. l FIG 11A AUTO MANUAL start mode the A M jumper must be SELECTION removed and the 2 wire connector supplied must be installed Cantral Sat Far The connector must be wired to a f Automatic Start momentary reset switch or contact Jumet Oparatian See fig 11B In the Manual mode the Installed Factory Setting control will trip due to all faults overvoltage undervoltage short circuit and Pt and FIG 11B MANUAL START remain tripped even when the fault SWITCH CONNECTION condition is corrected See LED diagnostics sec VIII p 22 The control s must be reset manually by closing the z Manual A M contacts Also the control must Start Made be restarted each time the AC line Jumper Reniqved MOMENTARY is interrupted Forward Stop Reverse Enable The KBVF may be controlled in several ways using the Forward Stop Reverse Enable FIG 12 FORWARD STOP REVERSE ENABLE circuit Remove Forward Step Raversa Enable Switch the F S R jumper Switch Cannaction Cennectian and install the 3 wire connector F o REVERSE s CLOSE supplied a STOP 7 TO ENABLE The control can ik FORWARD u now be made to instantly reverse or start stop electronically Enable See fig 12 for Start Stop Enable and Forward Stop Reverse connections VI FUSING It is recommended that a fuse or circuit breaker be used on each AC line connection not at ground potential Do not fuse neutral or ground connections
21. ll insulating disc between potentiometer and inside of front panel Warning Do not use Start Stop or Enable circuits as an emergency A N stop or severe injury may result Warning Do not wire control with power on Electrocution or death A N may result V WIRING Use the quick connect terminals provided for AC line motor and speed pot wiring TABLE 3 TERMINAL WIRING INFORMATION Terminal Connection Type Supply Wire Gauge Designation Designation of Connector Minimum Maximum A AC Line Wire the correct input AC line voltage 115 230VAC 50 60 Hz to terminals L1 and L2 depending on model number and jumper selection for dual voltage models Be sure to connect proper AC LINE f input voltage to MOTOR 50 60 Hz control GN earth catastrophic control failure can result due to improper voltage Itis recommended that a fuse be installed on each ungrounded conductor Do not fuse neutral conductors Follow NEC or other electrical codes that apply See sec VI page 21 for recommended fuse size Be sure to ground chassis using green ground screw Do not ground earth any signal connections See fig 9 B Motor Connect motor wires to terminals U V and W It is recommended that the cable length be limited to 100 feet between control and motor See fig 9 Note If cable length is greater than 100 feet special reactors may have to be
22. oils solenoids and or relays Eye protection must be worn and insulated adjustment tools must be used when working with control under power This product is constructed of materials plastics metals carbon silicon etc which may be a potential hazard Proper shielding grounding and filtering of this product can reduce the emission of radio frequency interference RFI which may adversely affect sensitive electronic equipment If information is required on this product contact our factory It is the responsibility of the equipment manufacturer and individual installer to supply this safety warning to the ultimate user of this product SW effective 11 92 This control contains electronic Start Stop and Enable circuits that can be used to start and stop the control However these circuits are never to be used as safety disconnects since they are not fail safe Use only the AC line for this purpose The input circuits of this control potentiometer start stop enable are not isolated from AC line Be sure to follow all instructions carefully Fire and or electrocution can result due to improper use of this product After disconnecting AC power high voltage exists on this control until both LED s are extinguished This product complies with all CE directives pertinent at the time of manufacture 4 Contact factory for detailed installation instructions and Declaration of Conformity Installation of a CE approved RFI filter KBRF 200A KB P N 9
23. olts AC RMS Amps Phase HP kW z 1 115 6 0 i KBVF 22D 9572 208 230 38 0 230 1 5 Va 18 j 2 115 22 0 p g 1 1 KBVF 26D 9496G 208 230 140 0 230 5 5 1 2 1 13 1 5 Notes 1 Model KBVF 22D CL Trimpot Range Amps AC 0 9 2 8 Factory Setting 2 4 2 Model KBVF 26D CL Trimpot Range Amps AC 3 5 10 5 Factory Setting 8 8 Model KBVF 26D is rated 2 HP 1 5 kW for most premium efficiency motors Figure 1 Model KBVF 26D Mechanical Specifications Inches mm and Control Layout 1 Setting Selectable Jumpers This control has selectable jumpers which may have to be set before the control can be used See Figure 1 above for the location of jumpers WARNING Disconnect the AC line before changing position of jumpers See Section Ill on pages 14 16 of the manual 1 1 AC Line Input Voltage Selection Jumper J1 on Upper PC Board This control can operate standard 208 230 Volt AC 50 60 Hz 3 induction motors from either 115 or 208 230 Volt 50 60 Hz 1 AC line
24. peed in order to reset with main speed pot 3 Use Enable contact See section V F on page 20 Note If the control trips in l t the motor may be overloaded Check motor current with an AC ammeter Use RMS responding meter Also the CL setting may be set too low see sec IX E p 26 ii Manual Operation To operate in the manual mode the A M jumper must be removed and the 2 wire connector supplied must be installed See sec V E p 20 for complete details D Forward Reverse The controls are factory set for Forward operation If after wiring the control it is determined the motor direction is incorrect simply change the F S R jumper position from F S to the S R position Ww WARNING Be sure to disconnect power and wait for the PWR LED A to extinguish See sec V F p 20 for complete details on using the F S R function Note Two motor leads can be interchanged to change rotation 16 IV MOUNTING Mount the control on a flat surface free of moisture metal chips and other contamination including corrosive atmosphere that may be harmful For maximum cooling efficiency mount the control with fins or sides in a vertical position If controls are to be mounted in an enclosure allow at least 6 x 8 x 12 for HP and 8 x 8 x 16 for 1 HP Also mount control as close as possible to the bottom of the enclosure When mounting the 5K remote speed potentiometer be sure to insta
25. r current that occurs in a stalled condition The CL trimpot is factory set to approximately 160 of full control rating 3 8 amps HP 20 6 8 amps 1 HP The CL trimpot can t be readjusted as required See fig 13E The current limit also contains an Ft trip function The control will trip according to a predetermined current versus time function The trip curve is directly related to the CL setpoint and can be changed with the CL trimpot Table 6 p 27 relates the CL setpoint to trip time The current limit with Pt shutdown is designed to provide motor overload protection Readjust the CL trimpot so that it is set to 160 of full rated motor current as follows 28 Boost When the control is set for 50 Hz motors the Decel 1 Connect an AC ammeter in series with one motor phase 2 Lock motor shaft and quickly adjust desired locked rotor motor current using CL trimpot Note This adjustment must be made within 6 seconds or I t trip will occur Example A HP motor has a full load current of 1 8 amps Set the CL trimpot to 1 8 x 160 2 9 amps I t trip will now protect the motor against overloads TABLE 6 CL SETPOINT vs TRIP TIME Percent of Trip Time Control Rating CL Setpoint Minutes 100 1 6 sec 160 Slip Compensation COMP The COMP trimpot is used to maintain set motor speed under varying loads The factory COMP trimpot setting of 1 5 volts Hz amp provides excellent speed regulation for mo
26. st motors The COMP trimpot can be adjusted for specific applications as required 1 Wire an AC ammeter in series with one motor phase 27 FIG 13F COMP 2 Run motor and set unloaded speed to approximately 50 speed 900 RPM on 4 pole 1500 1725 RPM motors Using a tachometer record unloaded speed 3 Load motor to rated motor nameplate current AC amps 4 Adjust COMP trimpot so that loaded RPM is equal to unloaded RPM 5 Motor is now compensated to provide constant speed under varying loads trimpot becomes Adjustable Boost Most 60 Hz motors conforming to NEMA standards can operate from a preset volts per hertz curve 50 Hz motors generally differ widely in their characteristics Therefore it is necessary to have Adjustable Boost to obtain maximum motor performance Since the boost trimpot was the DEC trimpot in the 60 Hz mode it will take on the prior setting of the DEC trimpot In the boost mode the trimpot scale is shown in fig 13G In order for the 50 Hz motor to run properly the boost must be adjusted If the application does not require full torque below 10 Hz the boost trimpot can be conservatively set at 8 9 o clock position If more precise speed regulation is required due to varying load the boost can be set as follows 1 Place an AC analog RMS ammeter in series with one motor lead Generally digital or clamp on meters do not yield accurate readings 2 Run the motor unloaded at approxim
27. the 50Hz position Be sure that Jumper J2 is set to the X1 position To operate 120 Hz motors be sure that Jumper J1 is set to the 60Hz position and set Jumper J2 to the X2 position To operate 100 Hz motors set Jumper J1 to the 50Hz position and set Jumper J2 to the X2 position Figure 3 Motor Frequency Selection Jumpers J1 and J2 60 Hz Motor Operation Factory Setting __50 Hz Motor Operation 120Hz Motor Operation 100 Hz Motor Operation N N rio L az I S y fo Qiao To Fy D N ajy N N N gt lt w gt lt i gt lt Si gt lt S H x H B SF gt lt ox o gt lt 2 AC Line Fusing Install a fuse or circuit breaker in the AC line Fuse each conductor that is not at ground potential See Table 2 below See Section VI on page 21 of the manual Table 2 Fuse Selection Chart AC Line Voltage Maximum AC Line Current AC Line Fuse Model Part No Volts AC Amps AC Amps 115 6 0 8 KBVF 22D 9572 230 38 5 115 22 0 30 KBVF 26D 9496G 230 140 20 3 CL Trimpot Adjustment Figure 4 below shows the CL Trimpot range for Model KBVF 22D Figure 5 below shows the CL Trimpot range for Model KBVF 26D See Figure 1 on page 1 of this Supplemental Information for the location of trimpots For other trimpot settings see Section IX on pages 24 29 of the manual
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