Bodine PACESETTER 2999 User guide

Part No. 07401117.B
www.bodine-electric.com
Instructions for Installation and Operation
Model 2999 Speed and Direction Control
NEMA-4X/IP-65
SPECIFICATIONS
Input Voltage..........................................................................................115; 208/230 VAC +/-10%, 50/60 Hz,
Single Phase
Input Current..........................................................................................8.1 Amps AC
Output Voltage.......................................................................................0 – 208/230 VAC, Three Phase
Output Current, per Phase...................................................................3.6 Amps RMS
Maximum Motor HP (kW)....................................................................1 HP (0.74 kW)

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Table of Contents
Section Page
1 Quick-Start Instructions ................................................................4
2 Safety Warning........................................................................5
3 Introduction...........................................................................6
4 Important Application Information ......................................................12
5 Wiring Instructions ...................................................................13
6 Setting Selectable Jumpers............................................................17
7 Mounting Instructions.................................................................19
8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) ...................21
9 Reconditioning the Bus Capacitors .....................................................21
10 Drive Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11 AC Line Fusing .......................................................................22
12 Diagnostic LEDs ......................................................................22
13 Trimpot Adjustments ..................................................................23
Limited Warranty .........................................................................27
Tables................................................................................ Page
1 Jumper Selectable Features ............................................................8
2 General Performance Specifications ....................................................10
3 Electrical Ratings .....................................................................10
4 Terminal Block Wiring Information ......................................................13
5 Drive Operating Condition and Run/Fault Relay Contact Status .............................16
6 Drive Operating Condition and Status LED Indicator.......................................22
Figures............................................................................... Page
1 Quick-Start Connection Diagram .........................................................4
2 Control Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Mechanical Specifications .............................................................11
4 Maximum Allowed Motor Torque vs. Speed...............................................12
5 Open Ventilated Motor with External Fan Cooling ..........................................12
6 AC Line Input, Motor, and Ground Connections ............................................13
7 Remote Main Speed Potentiometer Connection ...........................................14
8 Remote Start/Stop Switch Connection with Normally Open Stop Contact .....................14
9 Remote Start/Stop Switch Connection with Normally Closed Stop Contact....................14
10 Start/Stop Function Eliminated ..........................................................15
11 Voltage Following Connections..........................................................15
12 Enable Circuit Connection ..............................................................15
13 Run/Fault Relay Output Contacts Connection..............................................16
14 AC Line Input Voltage Selection (Jumper J1) ..............................................17
15 Removing Jumper J1...................................................................17
16 Motor Horsepower Selection (Jumper J2) ................................................17
17 Automatic Ride-Through or Manual Restart Selection (Jumper J3) ..........................18
18 60 Hz and 50 Hz Motor Selection (Jumpers J4 and J5) ......................................18
19 Available Torque vs. Output Frequency ...................................................18
20 120 Hz and 100 Hz Drive Output Frequency Selection .......................................18
21 Fixed or Adjustable Boost Selection (Jumper J6) ..........................................18
22 Regenerative or DC Injection Braking Selection (Jumper J7) ................................19
23 “Run” or “Fault” Output Relay Operation Selection (Jumper J8) .............................19
24 Normally Open or Closed Stop Contact Selection (Jumper J9)...............................19

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25 Constant or Variable Torque Selection (Jumper J10 and J12)................................19
26 I2t Overload Selection (Jumper J11)......................................................19
27 Operation with GFCI Circuit Breakers and Outlets (Jumper J12) .............................19
28 Typical Hi-Pot Test Setup ...............................................................20
29 Minimum Speed Trimpot (MIN) Range....................................................23
30 Maximum Speed Trimpot (MAX) Range...................................................23
31 Acceleration Trimpot (ACCEL) Range.....................................................23
32 Deceleration Trimpot (DECEL) Range.....................................................23
33 DC Injection Brake Trimpot (DECEL) Range................................................23
34 Slip Compensation Trimpot (COMP) Range................................................24
35 Current Limit Trimpot (CL) Range.........................................................24
36 I2t Trip Time vs. Motor Current ...........................................................25
37 Boost Trimpot (BOOST) Range...........................................................25
38 Jog Trimpot (JOG) Range Run-Stop-Jog Switch Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
39 Run-Stop-Jog Switch Connection .......................................................26
230 VAC Controls
Suitable For Use on a Circuit Capable of Delivering Not More Than 5 kA RMS Symmetrical
Amperes, 230 Volts Maximum.
Use Copper Conductors Rated 75 ºC.
Suitable for Operation in a Maximum Surrounding Air Temperature of 40 ºC.
UL Notice
© 2019 Bodine Electric Company.
All rights Reserved. All data subject to change without notice. Printed in U.S.A.

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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 page 5 before proceeding.
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 capaci-
tors, apply the AC Line with the drive in the Stop Mode for a minimum of one hour. Not follow-
ing this procedure will cause the bus capacitors to fail.
See Figure 1. Also see Section 4 - Important Application Information on Page 12.
WARNING! Disconnect main power before making connections to the drive.
1.1 AC Line Input Connection – Wire the AC line input to Terminal Block TB1. See Section 5.1 on
pages 13.
Application Note: Do not wire this drive to a GFCI. If operation with a GFCI is required,
contact our Customer Service Team.
Note: The rated AC line voltage of the drive must match the actual AC line input voltage. The
setting of Jumper J1 must match the AC line input voltage.
The drive is designed to accept single-phase (Terminals “L1”, “L2”) AC line input only. Rated
for 208/230 Volt AC line input with Jumper J1 set to the “230V” position (factory setting).
Rated for 115 Volt AC line input with Jumper J1 set to the “115V” position. See Figure 6 on
page 13.
1.2 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 4 on page 10. Also see Section 11 on page 22.
1.3 Ground Connection – Connect the ground wire (earth) to the ground screw, as shown in
Figure 6 on page 13. See Section 5.2 on page 14.
see Section 5.2 on page 14.
Ground (Earth):
(Terminals L1, L2)
see Section 5.1 on pages 13.
50/60 Hz, AC Line Input
115/208-230VAC, Single Phase,
3-Phase
see Section 5.3 on page 14.
AC Induction Motor:
AC LINEM OTOR
Motor
TB1
L2
L1V WU
Figure 1 – Quick-Start Connection Diagram*

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1.4 Motor Connection – Wire the motor to Terminal Block TB1 Terminals “U”, “V”, “W”, as
shown in Figure 6 on page 13. (Special reactors may be required for cable lengths over 100
ft. (30 m) – consult our Sales Department.) See Section 5.3 on page 14.
1.5 60 Hz And 50 Hz Motor Operation – The drive is factory set for 60 Hz 3-phase motor opera-
tion (Jumper J5 set to the “60Hz” position). For 50 Hz motor operation, set Jumper J5 to the
“50Hz” position. See Section 6.4 on page 17.
1.6 Start/Stop Switch – The drive is supplied with a pre-wired Start/Stop Switch to electroni-
cally “start” and “stop” the drive, as described in Section 5.5 on page 14. This switch must
be used to “start” the drive each time the AC line is applied to the drive or to “restart” the
drive. Also see Section 6.8 on page 18.
1.7 Jumper Settings – All jumpers have been factory set for most applications, as shown in
Figure 2 on page 9. However, some jumpers may need to be set in order to tailor the drive
for a specific application. See Section 6 on pages 17 – 19.
IMPORTANT: In order to ensure that the motor is properly protected with the I2t Overload
Protection feature, it is required that Jumper J2 is set to the corresponding position for the
motor horsepower being used, as shown in Figure 16 on page 17.
1.8 Trimpot Settings – All trimpots have been factory set for most applications, as shown in
Figure 2 on page 9. Some applications require adjustment of the trimpots in order to tailor
the drive for a specific requirement. See Section 13 on pages 23 – 26.
1.9 Diagnostic LEDs – After power has been applied, observe the LEDs to verify proper drive
operation, as described in Section 12 on page 22.
2 SAFETY WARNING
Definition of Safety Warning Symbols
Electrical Hazard Warning Symbol – Failure to observe this warning could result in electrical
shock or electrocution.
Operational Hazard Warning Symbol – Failure to observe this warning could result in serious
injury or death.
This product must 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, 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. Do not use this drive in an explosion-proof application. Eye
protection must be worn and insulated adjustment tools must be used when working with
a drive 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. It is the responsibility of the equipment
manufacturer and individual installer to supply this Safety Warning to the ultimate end user
of this product. (SW 8/2012)
The control does not provide motor over temperature protection. The user is responsible
for providing this protection in the equipment where this control is used (Remarque: La
détection de la surchauffe du moteur n’est pas assurée par cette control).

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Contact our Customer Service Team if you have questions about CE.
3 INTRODUCTION
Thank you for purchasing the Bodine Adjustable Frequency Drive. Bodine Electric Company is
committed to providing total customer satisfaction by producing quality products that are easy
to install and operate. The drive is manufactured with surface mount components incorporating
advanced circuitry and technology.
The drive is a variable speed control housed in a rugged NEMA-4X / IP-65 washdown and
watertight die-cast aluminum enclosure. The drive is designed to operate 208-230V, 50 & 60 Hz
3-phase AC induction gearmotors and motors up to 1HP. 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.
Due to its user-friendly design, the Bodine AC drive is easy to install and operate. Tailoring to
specific applications is accomplished with selectable jumpers and trimpots, which eliminate the
computer-like programming required on other drives. However, for most applications no adjustments
are necessary. For more advanced programming, PC based Drive-Link™ software is available.
Main features include adjustable RMS Current Limit and I2t Motor Overload Protection.* In
addition, Adjustable Slip Compensation with Static Auto-Tune and Boost provides high torque
and excellent load regulation over a wide speed range. Power Start™ delivers over 200% motor
torque to ensure start-up of high frictional loads. Electronic Inrush Current Limit (EICL™) eliminates
harmful AC line inrush current. A Run/Fault Relay is provided, which can be used to turn equipment
on or off , to signal a warning if the drive is put into the Stop Mode, or if a fault has occurred. The
drive is suitable for machine or variable torque (HVAC) applications. Also, a jumper is provided for
selection of Regenerative or DC Injection Braking.
Standard front panel features include Diagnostic LEDs for “Power On” and “Drive Status”, a
Start/Stop Switch, and a Main Speed Potentiometer. Other features include a Barrier Terminal
Block to facilitate wiring of the AC line and motor, adjustable trimpots (MIN, MAX, ACCEL, DECEL,
COMP, CL, JOG, BOOST), customer selectable jumpers (Line Voltage - dual voltage models
only), Motor Horsepower, Automatic Ride-Through / Manual Start, Motor Frequency, Frequency
Multiplier, Fixed/Adjustable Boost, Regenerative / Injection Braking, “Run” or “Fault” Output Relay
Operation, NO/NC Stop Contact, Constant/Variable Torque and I2t Overload Selection).
*UL approved as an electronic overload protector for motors.

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3.1 Standard Features
• Industrial Duty Die-Cast Aluminum Case with Hinged Cover – Dark Gray finish.
• Simple to Operate – Does not require programming. Uses trimpots and jumpers, which
are factory set for most applications.
• Motor HP Selection Jumper – Allows the drive to be used on a wide range of motors
without recalibration.
• Diagnostic LEDs – Power on (POWER) and drive status (STATUS).
• Run/Fault Relay Output Contacts – Can be used to turn equipment on or off, to signal a
warning if the drive is put into the Stop Mode, or a fault has occurred.
• Start/Stop Switch – Provides electronic start and stop functions.
• Barrier Terminal Block – Facilitates wiring of motor, AC line, and Run/Fault Relay Output
Contacts.
• Jumper Selection of Drive Output Frequency – Increases the motor speed up to two times
the rated RPM.
• Ride-Through – Provides smooth recovery to the previous set speed during a momentary
power loss (of less than 2 seconds).
• Holding Torque at Zero Speed – Resists motor shaft rotation when the drive is in Stop Mode.
• GFCI (Ground Fault Circuit Interrupter) Compatibility – Allows operation with GFCI circuit
breakers and outlets. See Section 6.11 on page 19, and Figure 2 on page 9 for jumper location.
3.2 Performance Features
• Power Start™ – Provides more than 200% starting torque which ensures startup of high
frictional loads.
• Slip Compensation with Static Auto-Tune and Boost – Provides excellent load regulation
over a wide speed range.
• Speed Range – 60:1
3.3 PROTECTION FEATURES
• Motor Overload (I2t) with RMS Current Limit* – Provides motor overload protection which
prevents motor burnout and eliminates nuisance trips.*
• Electronic Inrush Current Limit (EICL™) – Eliminates harmful Inrush AC line current during
startup.
• S gh inertial loads.
• Undervoltage and Overvoltage – Shuts down the drive if the AC line input voltage goes
above or below the operating range.
• MOV Input Transient Suppression – Protects the drive components against damaging
voltage spikes on the AC line.
• Microcontroller Self Monitoring and Auto Reboot.
*UL approved as an electronic overload protector for motors.

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3.4 TRIMPOT ADJUSTMENTS
• Minimum Speed (MIN) – Sets the minimum speed of the motor. See Section 13.1 on page 23.
• Maximum Speed (MAX) – Sets the maximum speed of the motor. See Section 13.2 on
page 23.
• Acceleration (ACCEL) – Sets the amount of time for the motor to accelerate from zero
speed to full speed. See Section 13.3 on page 23.
• Deceleration (DECEL) – Sets the amount of time for the motor to decelerate from full
speed to zero speed. See Section 13.4 on page 23.
• DC Injection Brake (DECEL) – When the drive is set for DC Injection Braking (Jumper J7
set to the “INJ” position), the DECEL trimpot is used to set the DC Injection Brake voltage
and time. See Section 13.5 on page 24.
• Slip Compensation (COMP) – Maintains set motor speed under varying loads. See
Section 13.6 on pages 24.
• Current Limit (CL) – Sets the current limit (overload) which limits the maximum current to
the motor. See Section 13.7 on page 24.
• Boost (BOOST) – Sets the amount of Boost which can be used to obtain maximum low
speed performance. See Section 13.8 on page 25.
• Jog (JOG) – Sets the “jog” speed of the motor. Must be used with the optional Run-Stop-
Jog Switch Kit (Part No. 9340). See Section 13.9 on page 26.
Table 1 – Jumper Selectable Features
Description1
PC Board
Designation
AC Line Input Voltage (115, 230) J1
Motor Horsepower (see Table 4 - Electrical Ratings on page 10) J2
Automatic Ride-Through or Manual Restart (A2, M) J3
Frequency Multiplier (1X, 2X) J4
Motor Frequency (50Hz, 60Hz) J5
Fixed or Adjustable Boost (FIX, ADJ) J6
Regenerative or DC Injection Braking (RG, INJ) J7
“Run” or “Fault” Output Relay Operation (R, F) J8
Normally Open or Closed Stop Contact (NO, NC) J9
Constant or Variable Torque (VT, CT) J10
I2t Overload Selection (1, 2) J11
GFCI Operation (Ground Fault Circuit Interrupter) (GF1, GF2) J12
Notes: 1. Bold indicates factory setting. 2. In Automatic Ride-Through Mode, the drive will automatically
restart due to a momentary power loss of less than 2 seconds.
*Warning! The model 2999 Speed Control does not support remote operation.

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Output Contacts.
Run/Fault Relay
Start/Stop Switch.
Main Speed Potentiometer.
Diagnostic LEDs.
J4: 1X or up to 2X
J9: Normally Open or Closed Stop Contact selection. See Section 6.8 on Page 18. J11: I2t Overload selection. See Section 6.10 on Page 19.
CON1: Used to connect optional accessories to the drive. J12 (8K, 12K, GF1, GF2)
Used to select the drive’s switching frequency(8 kHz or 12 kHz).
See Section 6.9 on page 19.
Used to set the drive for use with a GFCI(Standard GFCI [GF1]
or Sensitive GFCI [GF2]). See Section 6.11 on Page 19.
J10: (CT,VT) Sets the drive for ConstantTorque or
Variable Torque applications. See Section 6.9 on Page 19.
J7: Regenerative or Injection Braking selection. See Section 6.6 on Page 18. J8: "Run" or "Fault" Output Relay Operation selection. See Section 6.7 on Page 18. J6: Fixed or Adjustable Boost selection.
Rated Motor RPM Operation selection. Motor Operation selection. J5: 60 Hz or 50 Hz
All jumpers and trimpots are shown in factory set positions.
J1: AC Line InputVoltage selection
J2: Motor Horsepower selection
3
.
J3: Automatic Ride-Through
4
or Manual Start selection.
Used with optional Run-Stop-Jog Switch Kit. Adjustable Trimpots
2
.
JOG Terminal.
See Section 6.4 on Page 17. See Section 6.4 on Page 17. See Section 6.5 on Page 18.
See Section 6.1 on Page 17.
See Section 6.2 on Page 17.
See Section 6.3 on Page 17.
See Section 13 on Pages 23 – 26.
See Section 5.5
See Section 5.9
on Page 16.
on Page 14.
Normally Closed
Red
Normally Open
Relay Common
See Section 5.4 on Page 14.
Black
White
Used for optional Forward-Stop-Reverse Switch.
White (Low) (P1)
Violet (High) (P3)
Orange (Wiper) (P2)
See Section 12 on Page 22.
STATUS POWER
STOP
NCNO COM FWDCOM RUN REV COM
CON2
P1P3 P2
TB2
CON1
JOG COMP
ACCELMINMAXJOG CLDECEL BOOST
J3J4
50Hz
J5
60Hz
GF2 GF1 12K 8K
MAN AUTO FREQ 2X 1X MULT
J12CON2
1
J2
1/8 1/2 1/4 3/4
J11
21
J8J9
NCNO F
J10
CTVT FIX
J6
RGR INJ
J7
ADJ
Figure 2 – Control Layout1
Notes: 1. The JOG and COMP Trimpots are located vertically, along the right edge of the PC board (below the mounting screw). 2. Jumper J2 is factory set to the “1” position. Jumper J3 is labeled “AUTO” and “MAN”.

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Table 2 – General Performance Specifications
Description Specification Factory
Setting
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 2 Minutes) 150 —
Carrier, Switching Frequency (kHz)116, 8 —
Signal Following Input Voltage Range2(Volts DC) 0 – 5 —
Output Frequency Resolution (Bits, Hz) 10, .06 —
Minimum Speed Trimpot (MIN) Range (% Frequency Setting) 0 – 40 0
Maximum Speed Trimpot (MAX) Range (% Frequency Setting) 70 – 110 100
Acceleration Trimpot (ACCEL) and Deceleration
Trimpot (DECEL) Range (Seconds) .3 – 20 1.5
Boost Trimpot (BOOST) Range (Volts/Hz) 0 – 30 5
Slip Compensation Trimpot (COMP) Range
at Drive Rating (Volts/Hz) 0 – 3 1.5
Current Limit Trimpot (CL) Range (% Full Load) 40 – 200 160
Jog Trimpot (JOG) Range (% Frequency Setting) 0 – 100 35
Motor Frequency Setting (Hz) (Jumper J5) 50, 60 60
Output Frequency Multiplier (1X, 2X) (Jumper J4)31, 2 1
Minimum Operating Frequency at Motor (Hz) 1 —
Speed Range (Ratio) 60:1 —
Speed Regulation (30:1 Speed Range,
0 – Full Load) (% Base Speed)42.5 —
Overload Protector Trip Time for Stalled Motor (Seconds) 6 —
Undervoltage/Overvoltage Trip Points for
115 Volt AC Line Input (± 5%) (Volts AC)576 – 141 —
Undervoltage/Overvoltage Trip Points for 208/230 Volt AC Line Input
(± 5%) (Volts AC)5151 – 282 —
Run/Fault Relay Output Contact Rating (Amps at 30 Volts DC,
125 Volts AC, 250 Volts AC) 1, 0.5, 0.25 —
Operating Temperature Range (°C / °F)60 – 40 / 32 – 104 —
Operating Humidity Range (% Relative, Non-Condensing) 0 – 95 —
Storage Temperature Range (°C / °F) -2.5 – +85 /
-13 – +185 —
Notes: 1. Not user-selectable. 2. Requires an isolated signal. 3. Allows the motor to operate up to two
times the rated RPM. Constant horsepower will result when operating the drive in the “X2” mode above
the motor rated frequency. 4. Dependent on motor performance. 5. Do not operate the drive outside the
specified AC line input voltage operating range. 6. See Table 3 below.
Table 3 – Electrical Ratings
Model
No.
Max.
HP AC Line
Voltage
(50/60 Hz)
Phase
(Ø)
Max.
AC Line
Current
(Amps
AC)
Fuse or
Circuit
Breaker
Rating
(Amps)
Voltage
Range
(Volts AC)
Max. Load
Current
(Amps/
Phase)
Motor
Horsepower
Selection1
(Jumper J2)
Net Wt.
HP kW lbs kg
2999 1 .75 115 116 20 0 - 208/230 3.6 13/4 1/2 1/4 1/8 5.9 2.7
208/230 10 15
Notes: 1. Bold indicates factory setting. Jumper J2 is labeled “1”, “3/4”, “1/2”, “1/4”, “1/8”
(factory set to the “1” position).

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2X Ø 2.53
0.25
0.31
8.85
2* 3*
4* 1*
225
7.97 6.4 64.4
5.51
129
5.06
140
8.20
208
9.53
242
2.70
68.6
1.35
34.3
1.35
34.3
2.76
70.1
5.97
152
0.875
22.2
3X
AC MOTOR SPEED CONTROL
KBAC SERIES • NEMA 4X / IP 65
Hybrid Drive
™
Figure 3 – Mechanical Specifications (in./mm)
* Tighten these screws, in the sequence shown, to 12 lb-in. (14 kg-cm).

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4 IMPORTANT APPLICATION INFORMATION
4.1 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. 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 the motor
manufacturer for details.
WARNING! Some motors have low speed characteristics which cause 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
current be checked from 2 – 15 Hz (60 – 450 RPM) to ensure motor current does not exceed
the nameplate rating. Do not use motor if the motor current exceeds the nameplate rating.
It is recommended that the drive be used with Inverter Duty or TENV motors.
Inverter duty and most totally
enclosed non-ventilated
(TENV) motors can provide
full rated torque over an
extended speed range
without overheating. See
Figure 4.
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 per HP is recommended.
Mount the fan or blower so
the motor is surrounded by the airflow.
See Figure 5.
4.2 Electronic Motor Overload
Protection – The drive con-
tains Modified I2t 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.
Standard I2t is undesirable because it causes nuisance tripping. It allows a very high motor
current to develop and will turn the drive off after a short period of time. KB’s RMS Current
Limit Circuit avoids this nuisance tripping while providing maximum motor protection.
If the motor is overloaded to 120% of full load (75% of the CL setting), the I2t Timer starts.
If the motor continues to be overloaded at the 120% level, the timer will shut down the
drive after 30 minutes. If the motor is overloaded to 160% of full load, the drive will trip in 6
seconds.
*UL approved as an overload protector for motors.
and TENV Motors
Inverter Duty
Maximum Allowed
Motor Torque (%)
TEFC and Open Ventilated
Motors
Fan Cooled
100
60 70 805030 40100 20 90
Motor Speed (%)
40
0
20
60
80
100
Figure 4 – Maximum Allowed
Motor Torque vs. Speed
Open Ventilated Motor Fan or Blower
(100 CFM Min.
per HP)
Airow
Figure 5 – Open Ventilated Motor
with External Fan Cooling

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5 WIRING INSTRUCTIONS
WARNING! Read Safety Warning, on page 5, before using the drive. Disconnect main
power before making connections to the drive. To avoid electric shock, be sure to
properly ground the drive. The model 2999 Speed Control does not support remote operation.
WARNING! HIGH VOLTAGE – REMOTE CONNECTIONS OF POTENTIOMETER, SWITCHES,
ETC., WILL HAVE WIRING THAT IS AT LINE POTENTIAL. IT IS REQUIRED THAT THE SIGNAL
ISOLATOR BE INSTALLED.
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.
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 wired as a
disconnect so that each ungrounded conductor is opened. For fuse or circuit breaker selection,
see Table 4. Also see Section 11 on page 22.
To maintain the watertight integrity of the drive, be sure to use suitable watertight connectors and
wiring which are appropriate for the application. The drive contains three holes for standard 1/2”
liquidtight fittings (not supplied). One watertight plug is provided, if only one knockout is used.
The drive is designed with a hinged case so that when the front cover is open, all wiring stays
intact. To open the cover, the four screws must be loosened so they are no longer engaged in the
case bottom. After mounting and wiring, close the cover making sure that the wires do not get
caught or crimped as the cover is closed. Tighten the four screws so that the gasket is slightly
compressed. The recommended tightening torque is 12 lb-in. (14 kg-cm). See Figure 3 on page 11
for the tightening sequence. Do not overtighten.
Table 4 – Terminal Block Wiring Information
Terminal
Block Description
Maximum Wire Size (Cu) Recommended Tightening
Torque
AWG mm2lb-in. kg-cm
TB1 AC Line Input and Motor Wiring 12 3.3 7 8
TB2 Run/Fault Relay Output Contacts 16 1.3 3.5 4
5.1 AC Line Input Connection – Wire the
AC line input to Terminal Block TB1.
GFCI Operation – Do not connect
this drive to an AC power source
controlled by a Ground Fault
Circuit Interrupter.
Note: The rated AC line voltage of
the drive must match the actual AC
line input voltage. The setting of
Jumper J1 must match the AC line
input voltage.
The drive is designed to accept
single-phase AC line input only
(Terminals “L1”, “L2”). Rated for
208/230 Volt AC line input with Jumper J1 set to the “230V” position (factory setting). Rated
for 115 Volt AC line input with Jumper J1 set to the “115V” position. See Figure 6.
AC LINE
MOTOR
Motor
VU W
AC Line Input
115, 208/230 Volt
Single-Phase
Ground (Earth)
L1 L2
TB1
Figure 6 – AC Line Input, Motor,
and Ground Connections

14 www.bodine-electric.com
5.2 Ground Connection – Connect the
Ground Wire (Earth) to the Green
Ground Screw. The Ground Screw
is located next to Terminal Block
TB1. See Figure 6 on page 13.
5.3 Motor Connection – Wire the motor
to Terminal Block TB1 Terminals
“U”, “V”, “W”. See Figure 6 on
page 13. Motor cable length should
not exceed 100 ft (30 m) – special
reactors may be required – consult
our Customer Service Team.
Be sure Jumper J2 is set to
the corresponding motor
horsepower rating, as described
in Section 6.2 on page 17.
5.4 Remote Main Speed
Potentiometer Connection –
The drive is supplied with
a pre-wired Main Speed
Potentiometer mounted on the
front cover.
To operate the drive from a
remote potentiometer (5 kΩ),
remove the white, orange,
and violet potentiometer leads
from Terminals “P1”, “P2”,
and “P3”. The wires may be
taped and left inside the drive.
The potentiometer assembly may be removed if a watertight seal is used to cover the hole
in the front cover. Wire the Main Speed Potentiometer to Terminals “P1” (low side), “P2”
(wiper), and “P3” (high side). See Figure 7 on page 14.
WARNING! Do not earth ground any Main Speed Potentiometer terminals.
Application Note – The model 2999 Speed Control does not support remote operation.
Requires isolation card.
5.5 Remote Start/Stop Switch
Connection – The drive is
supplied with a pre-wired
Start/Stop Switch mounted
on the front cover to
electronically start and stop
the drive.
To operate the drive
from a remote Start/Stop
Switch (type ON-OFF-ON,
SPDT), remove the white,
black, and red wires from
Terminals “RUN”, “COM”,
and “STOP”. The wires may
be taped and left inside the
drive. The switch assembly may be removed if a liquidtight seal is used to cover the hole in
the front cover. After applying power to the drive, momentarily set the Start/Stop Switch to
the “START” position.
Figure 7 – Remote Main Speed
Potentiometer Connection
Main Speed
Potentiometer
Orange (Wiper)
Violet (High)
White (Low)
P1P2P3
HIGH VOLTAGE! See Warning on Page 13.
Figure 8 – Remote Start/Stop Switch
Connection with Normally Open Stop Contact
(J9 Installed in “NO” Position)
COM
Black
STOP
STOP
Red
START
RUN
White
NO
J9
NC
HIGH VOLTAGE! See Warning on Page 13.
HIGH VOLTAGE! See Warning on Page 13.
NO
J9
NC
COM
(Push to Stop)
Normally Closed
Momentary Contact
STOP
STOP
Normally Open
Momentary Contact
(Push to Start)
RUN
START
Figure 9 – Remote Start/Stop Switch Connection
with Normally Closed Stop Contact
(J9 Installed in “NC” Position)

www.bodine-electric.com 15
For Start/Stop Switch with normally closed
stop contact, set Jumper J9 to the “NC”
position. See Figure 8 on page 14 and
Figure 9. Also see Section 6.8 on page 18.
5.6 Automatic Restart – Automatic restart
requires the elimination of the Start/Stop
Switch. Remove the white, black, and red
wires from Terminals “RUN”, “COM”, and
“STOP”. The wires may be taped and left
inside the drive. The switch assembly may
be removed if a liquidtight seal is used to
cover the hole in the front cover.
To eliminate the Start/Stop function,
hardwire Terminals ”RUN” and “COM”
with the jumper that is provided. Be sure
Jumper J9 is set to the “NO” position. See
Figure 10.
WARNING!
Using a jumper to
eliminate the Start/
Stop function will
cause the motor to
run at the Main Speed
Potentiometer setting
when the AC line is
applied.
5.7 Voltage Following
Connection – An
isolated 0 – 5 Volt DC
analog signal input can
also be used to control motor speed in lieu of the Main Speed Potentiometer. The drive
output will linearly follow the analog signal input. Wire the signal input positive lead (+) to
Terminal “P2” and the negative lead (-) to Terminal “P1”. With external circuitry, a 0 – 10
Volt DC analog signal can also be used. See Figure 11.
Note: For signal following operation, the Minimum Speed Trimpot (MIN) must be set fully
counterclockwise.
WARNING! The signal input
must be isolated from the AC
line. Earth grounding signal
wiring will damage the drive
and void the warranty.
5.8 Enable Circuit Connection –
The drive can also be started
and stopped with an Enable
circuit (close to run, open to
stop). See Figure 12.
NO
J9
NC
COMSTOP RUN
HIGH VOLTAGE! See Warning on Page 13.
0 – 5
Volts DC
P2P3 P1
V
-
+
0 – 10
Volts DC
P2P3 P1
10k V
10k
-
+
Figure 10 – Start/Stop Function
Eliminated(Terminals Hardwired)
(Jumper Installed)
(J9 Installed in “NO” Position)
Figure 11 – Voltage Following Connections (Isolated)
HIGH VOLTAGE! See Warning on Page 13.
HIGH VOLTAGE! See Warning on Page 13.
Main Speed
Potentiometer
Enable Switch or Relay
Orange (Wiper)
Violet (High)
White (Low) (Close to Run)
P1P2P3
Figure 12 – Enable Circuit Connection

16 www.bodine-electric.com
The Enable function is established by
wiring a switch or contact in series with
the orange Main Speed Potentiometer lead
which connects to Terminal “P2”. When
the Enable Switch is closed, the motor will
accelerate to the Main Speed Potentiometer
setting. When the Enable Switch is opened,
the motor will decelerate to stop.
5.9 Run/Fault Relay Connection – The Run/Fault
Relay Output Contacts are located at TB2
and can be used to turn equipment on or
off, to signal a warning if the drive is put into
the Stop Mode, or a fault has occurred. See
Figure 13.
The Run/Fault Relay Contact status for
various drive operating conditions is shown
in Table 5.
Table 5 – Drive Operating Condition and Run/Fault Relay Contact Status
Drive
Operating
Condition Description
Run Relay Operation
(Jumper J8 Installed in “R”
Position) (Factory Setting)
Fault Relay Operation
(Jumper J8 Installed in
“F” Position)
Normally
Open Contact
Normally
Closed Contact
Normally
Open
Contact
Normally
Closed
Contact
Power Off Main Power
Disconnected Open Closed Open Closed
Run
Mode*
Normal Drive
Operation Closed Open Closed Open
Stop
Mode*
Selected by
Operator Open Closed Closed Open
Fault** Drive Tripped Open Closed Open Closed
*Run Mode or Stop Mode is selected using the Start/Stop Switch. **Overload, I2t, Short Circuit,
Undervoltage and Overvoltage.
HIGH VOLTAGE! See Warning on Page 13.
Output Contacts
Run/Fault Relay
Normally Closed
Relay Common
Normally Open
NCNO
TB2
COM
Figure 13 – Run/Fault Relay Output
Contacts Connection

www.bodine-electric.com 17
6 SETTING SELECTABLE JUMPERS
The drive has customer selectable jumpers which must be set before the drive can be used. For
the location of jumpers, see Figure 2 on page 9.
WARNING! HIGH VOLTAGE Disconnect the AC line before changing position of jumpers.
6.1 Line Input Voltage Selec-
tion (J1) Jumper J1 is fac-
tory installed on Terminal
“230V” for 208/230 Volt AC
line input. For 115 Volt AC
line input, the jumper must
be removed and installed
on Terminal “115V”. See
Figure 14.
Using pliers, gently rock
the female terminal back
and forth while pulling it
upward. See Figure 15.
6.2 Motor Horsepower Selection (J2) – Set Jumper J2
to the corresponding position for the motor being
used. See Figure 16.
6.3 Automatic Ride-Through or Manual Start Selec-
tion (J3)* Jumper J3 is factory set to the “A” posi-
tion for Automatic Ride-Through. If the power is
interrupted for up to 2 seconds, the drive will shut
down and then “ride-through” and automatically
return to the set frequency.
If Jumper J3 is set to the “M” position, the drive
will have to be manually restarted for a momen-
tary power loss using the Start/Stop Switch. See
Figure 17 on page 18. Also see Section 12.2, on page
23, for the Status (ST) LED indication.
*Jumper J3 is labeled “AUTO” and “MAN”.
6.4 60 Hz and 50 Hz Motor Operation and Drive Output
Frequency Selection (J4 and J5) – Both jumpers
must be set for the appropriate motor nameplate
frequency rating.
6.4.1 Setting the Drive for 60 Hz or 50 Hz Motor
Operation – The drive is factory set to oper-
ate 60 Hz motors. Jumper J4 is factory set to
the “1X” position and Jumper J5 is factory
set to the “60Hz” position. For 50 Hz motors,
set Jumper J5 to the “50Hz” position, and be sure Jumper J4 is set to the “1X” posi-
tion. See Figure 18 on page 18.
6.4.2 Setting the Drive for Two Times the Rated Motor RPM – The drive can also be used
to operate the motor up to two times the rated RPM. However, constant horse-
power will result when operating the drive in the “2X” mode above the motor rated
frequency. See Figure 19.
For 120 Hz output with 60 Hz motor, set Jumper J4 to the “2X” position and be sure
Jumper J5 is set to the “60Hz” position. For 100 Hz output with 50 Hz motor, set Jumper
J4 to the “2X” position and set Jumper J5 to the “50Hz” position. See Figure 20.
115V
J1
230V
J1
115V 230V
208/230 Volt AC Line Input
(Factory Setting)
(J1 Installed on Terminal“230V”)
115 Volt AC Line Input
(J1 Installed on Terminal“115V”)
Figure 14 – Line Input Voltage Selection
Terminal
Installed
Removed
Terminal
Figure 15 –
Removing Jumper J1
The factory setting is shown in bold.
Figure 16 – Motor
Horsepower Selection
J2
1
3/4
1/2
1/4
1/8

18 www.bodine-electric.com
6.5 Boost Mode Selection (J6) –
Jumper J6 is factory set to the
“FIX” position for Fixed Boost.
For Adjustable Boost using the
BOOST Trimpot, set Jumper
J6 to the “ADJ” position. See
Figure 21. Also see Section
13.8 on page 25 for the BOOST
Trimpot range.
6.6 Braking Mode Selection (J7) –
Jumper J7 is factory set to the
“RG” position for Regenerative
Braking when the Start/Stop
Switch is set to the “STOP”
position. For DC Injection
Braking, set Jumper J7 to the
“INJ” position. See Figure 22
on page 19. Also see Section
13.5 on page 24.
When the Injection Brake
Mode is selected, the DECEL
Trimpot is used to adjust the
brake time and intensity.
6.7 Run/Fault Output Relay
Operation Selection (J8) –
Jumper J8 is factory set to
the “R” position for “Run”
operation of the Run/Fault
Relay. For “Fault” operation of
the Run/Fault Relay, set Jumper
J8 to the “F” position. See
Figure 23 on page 19.
For Run/Fault Relay output
contacts, see Section 5.8 on
page 15. The Run/Fault Relay
contact status for various drive
operating conditions is shown
in Table 5 on page 16.
6.8 Stop Contact Selection (J9) –
Jumper J9 is factory set to the
“NO” position for a normally
open stop contact. For remote
normally closed stop contact,
set Jumper J9 to the “NC”
position. See Figure 24 on page
19. For wiring information, see
Section 5.5 on page 14.
Automatic Ride-Through
(Factory Setting)
(J3 Installed in “A”Position)
Manual Start
(J3 Installed in “M”Position)
A
J3
M
A
J3
M
Figure 17 – Automatic Ride-Through
or Manual Start Selection*
60 Hz Motor Operation
(Factory Setting)
(J4 Installed in “1X”Position)
(J5 Installed in “60Hz” Position)
50 Hz Motor Operation
(J4 Installed in “1X”Position)
(J5 Installed in “50Hz” Position)
50Hz
J5
60Hz
2X
J4
1X
50Hz
J5
60Hz
2X
J4
1X
Figure 18 – 60 Hz & 50 Hz Motor Selection
50/60
Output Frequency (Hz)
020
% Torque
50
100/120
100
Figure 19 – Available Torque vs.
Output Frequency
120 Hz Output with 60 Hz Motor
(J4 Installed in “2X”Position)
(J5 Installed in “60Hz” Position)
100 Hz Output with 50 Hz Motor
(J4 Installed in “2X”Position)
(J5 Installed in “50Hz” Position)
50Hz
J5
60Hz
2X
J4
1X
50Hz
J5
60Hz
2X
J4
1X
Figure 20 – 120 Hz & 100 Hz Drive Output
Frequency Selection
Fixed Boost
(Factory Setting)
(J6 Installed in “FIX”Position)
Adjustable Boost
(J6 Installed in “ADJ” Position)
ADJ
J6
FIX
ADJ
J6
FIX
Figure 21 –
Fixed or Adjustable Boost Selection

www.bodine-electric.com 19
6.9 Torque Mode Selection (J10 and J12) – Jumper J10 is factory set to the “CT” position for
Constant Torque Mode, which is desirable for most machine applications and Jumper J12 is
set to “8K” (8 kHz switching frequency). For Variable Torque Mode, used for HVAC and fan
applications, set Jumper J10 to the “VT” position and set Jumper J12 to the “12K” position
(12 kHz switching frequency reduces audible motor noise). See Figure 25.
6.10 I2t Overload Selection (J11) – Jumper J11 is factory set to the “1” position for Inverter Duty
Rated Motors. For Non Inverter Duty Rated Motors and HVAC applications, set Jumper J11
to the “2” position. See Figure 26. Also see Section 13.7 on page 24.
6.11 Operation with GFCI Circuit Breakers and Outlets (J12) Jumper J12 allows the drive to
operate with Ground Fault Circuit Interrupter (GFCI) circuit breakers and outlets. (May
increase audible motor noise.) For standard GFCIs, set Jumper J12 to the “GF1” position.
For sensitive GFCIs, set Jumper J12 to the “GF2” position. See Figure 27.
7 MOUNTING INSTRUCTIONS
It is recommended that the drive be mounted vertically on a flat surface with adequate ventilation.
Leave enough room below the drive to allow for AC line, motor connections, and any other
wiring that is required. Although the drive is designed for outdoor and washdown use, care
should be taken to avoid extreme hazardous locations where physical damage can occur. When
mounting the drive in an enclosure, the enclosure should be large enough to allow for proper
heat dissipation so that the ambient temperature does not exceed 40 °C (104 °F) at full rating. See
Figure 3 on page 11.
WARNING! Do not use this drive in an explosion-proof application.
Regenerative Braking
(Factory Setting)
(J7 Installed in “RG”Position)
DC Injection Braking
(J7 Installed in “INJ”Position)
INJ
J7
RG
INJ
J7
RGINJ
J7
RG
Figure 22 – Regenerative
or DC Injection Braking Selection
Regenerative Braking
(Factory Setting)
(J7 Installed in “RG”Position)
DC Injection Braking
(J7 Installed in “INJ”Position)
F
J8
R
F
J8
R
Figure 23 – “Run” or “Fault”
Output Relay Operation Selection
Figure 24 – Normally Open
or Closed Stop Contact Selection
Normally Open Stop Contact
(Factory Setting)
(J9 Installed in “NO” Position)
Normally Closed Stop Contact
(J9 Installed in “NC” Position)
NO
J9
NC
NO
J9
NC
Constant Torque
(Factory Setting)
(J10 Installed in“CT”Position;
J12 Installed in“8K”Position)
Variable Torque
(J10 Installed in“VT”Position
J12 Installed in 12K Position)
VT
J10
CT
8K
12K
J12
8K
12K
J12
J10
CTVT
Figure 25 –
Constant or Variable Torque Selection
Inverter Duty Rated Motor
(Factory Setting)
(J11 Installed in “1”Position)
Non Inverter Duty Rated
Motor Operation
(J11 Installed in “2”Position)
1
J11
2
J11
21
Standard GFCI
(Factory Setting)
J12 Installed in“GF1”Position)
Sensitive GFCI
J12 Installed in“GF2”Position)
GF1
GF2
J12
GF1
GF2
J12
Figure 26 –
I2t Overload Selection
Figure 27 –
Operation with GFCI Circuit Breakers

20 www.bodine-electric.com
Chassis
P3
Chassis
Machine Equipment or Frame
Adjustable Frequency Drive
(Main Power Disconnected)
to AC Line Inputs
Connect Hi-Pot
L2 L1
P2 P1
Auxiliary Equipment
L2 Signal Inputs
H. V.
AC Line Input
MAX
ZERO
L1
RESET
RETURN
10mA0mA
VOLTAGETEST
AC KILOVOLTS
LEAKAGE
1
03
2
High Voltage Dielectric Withstand Tester (Hi-Pot Tester)
Motor Wires
W
V
Frame
Connect All Drive Terminals Together
U
(Main Power Disconnected)
Figure 28 – Typical Hi-Pot Test Setup