KB Electronics KBDA-42 User Manual
MODELS KBDA-24P & KBDA-42 SUPPLEMENT
IMPORTANT: The KBDA Series manual must be read and understood before attempting
to operate the drive. For further assistance, contact our sales Department at
954-346-4900 or Toll Free at 800-221-6570 (outside Florida).
DESCRIPTION: Models KBDA-24P and KBDA-42 have been added to the KBDA Series
of drives. These models are designed to accept 3-phase AC line input only. Table 3A
shows the Electrical Ratings. Figure 11A shows the AC Line input, Motor, and Ground
connections to Terminal Block TB1. The General Performance Specifications have not
changed (see the manual for specifications). Both models contain AC Line Phase Loss
Detection.
WARNING! HIGH VOLTAGE!
DISCONNECT MAIN POWER BEFORE MAKING CONNECTIONS TO THE DRIVE
ELECTRICAL RATINGS
AC Line Input Output
Model
KBDA-24P 9766 / 9767 208/230 3 4.7 10 0 – 208/230 3.6 1 (0.75)
KBDA-422 9763 / 9764 400/460 3 2.6 5 0 – 400/460 2.0 1 (0.75)
Part No.
(Gray / White1)
Volts AC
(50/60 Hz)
Phase
(Ф)
Maximum
(Amps AC)
Notes: 1. White FDA approved finish. 2. Model KBDA-42 is rated 0 – 400 Volts AC for 50
Hz motor operation and 0 – 460 Volts AC for 60 Hz motor operation.
AC LINE INPUT, MOTOR, AND GROUND CONNECTIONS
TABLE 3A
Fuse or
Circuit
Breaker
Current
Rating
(Amps)
FIGURE 11A
Voltage
Range
(Volts AC)
Maximum
Continuous
Load Current
(RMS Amps/Phase)
Maximum
Horsepower
(HP (kW))
KB Electronics, Inc.
12095 NW 39th Street, Coral Springs, FL 33065-2516 ● (954) 346-4900 ● FAX (954) 346-3377
Outside Florida Call Toll Free (800) 221-6570 ● info@kbelectronics.com
www.kbelectronics.com (A42040) – Rev. A00 – 6/9/2009
Installation & Operation Manual
KBDA SERIES
ADJUSTABLE FREQUENCY DRIVES FOR 3-PHASE AC MOTORS
NEMA-4X / IP-65
Washdown and Watertight for Indoor and Outdoor Use
MULTI-FUNCTION KEYPAD WITH 4-DIGIT LED DISPLAY
• Simplified Group Programming • 8 LED Status Indicators
Rated for 208 – 230 and 400/460 Volt 50* & 60 Hz
3-Phase AC Induction Motors from Subfractional thru 5 HP
Operates from 115, 208/230, and 400/460 Volt 50/60 Hz AC Line
1
This Manual Covers Models KBDA-24D, 27D, 29, 45, 48
See Safety Warning,
on page 6.
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. Models KBDA-24D, 27D contain an AC line input voltage selection jumper. 2. All models are UL Listed for
USA and Canada. 3. Requires CE approved RFI filter. See AC Line Filters, in Table 1, on page 9.
*NOTE: THE DRIVE IS FACTORY SET FOR
32
60 Hz MOTORS. FOR 50 Hz MOTORS,
SEE FIGURE 16, ON PAGE 23.
© 2009 KB Electronics, Inc.
(see back cover)
TABLE OF CONTENTS
Section Page
1 Quick-Start
2 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Important Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 AC Line Input Voltage Selection (Jumper J1 (Models KBDA-24D, 27D Only)) . . . . . . . . . . . . . . . . . . . . 20
8 Recommended High Voltage Dielectric Withstand Testing (Hi-Pot Testing) . . . . . . . . . . . . . . . . . . . . . . 20
9 Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 Programmable Function Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix A – Optional IODA Input/Output Multi-Function Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table Page
1 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General
2
3 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Drive Terminal Block Wire and Tightening Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Multi-Function Output Relay “Run” and “Fault” Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 Digital Readout Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 Model Software Revision Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 LED Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10 IODA Status Indicator LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11 IODA Terminal Block TB1 Wire and Tightening Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12 IODA Functions and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
13 Preset Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
14 Analog Input 1 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15 Analog Input 2 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
16 Analog Outputs 1 and 2 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
17 Multi-Function Open Collector Outputs Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Instructions
Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure Page
1 Quick-Start Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2
3 Model KBDA-24D Drive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Model KBDA-27D Drive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Models KBDA-29, 45, 48 Drive Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Model KBDA-24D Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Models KBDA-27D, 29, 45, 48 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Maximum Allowed Motor Torque vs. Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 Open Ventilated Motor with External Fan Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10 Models KBDA-24D, 27D AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . . 18
11 Models KBDA-29, 45, 48 AC Line Input, Motor, and Ground Connections . . . . . . . . . . . . . . . . . . . . . . 19
12 Multi-Function Output Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
13 Model KBDA-24D AC Line Input Voltage Selection (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
14 Model KBDA-27D AC Line Input Voltage Selection (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
15 Typical Hi-Pot Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16 Flow Chart to Program the Drive for 50 Hz Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
17 Flow Chart to Program Motor Current from 6.7 Amps to 5.5 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
18 Flow Chart to Change Set Frequency from 5.00 Hz to 43.21 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
19 Flow Chart to Program Accel Time from 1.5 Seconds to 120 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . 26
ii
Layout with Main Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Keypad
20 Flow Chart to Program the Drive to Display Motor RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
21 Flow Chart to Program the Drive to Display Custom Units “012.0” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
22 Flow Chart Showing Motor Current, Motor Voltage, and Bus Voltage added to the Basic Display . . . . 29
23 Function No. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
24 IODA Layout (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
25 IODA Terminal Block TB1 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
26 Preset Frequency Selection Switch or Contact Connections and Function Settings . . . . . . . . . . . . . . . 45
27 Up/Down Frequency Control Switch or Contact Connections and Function Settings . . . . . . . . . . . . . . 46
28 Accel/Decel 2 Switch or Contact Connection and Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
29 Forward/Stop-Reverse/Stop Switch or Contact Connections and Function Settings . . . . . . . . . . . . . . 47
30 External Fault Auxiliary Equipment Switch or Contact Connection and Function Setting . . . . . . . . . . . 47
31 Reset Switch or Contact Connection and Function Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
32 2-Wire Start/Stop Switch or Contact Connection and Function Settings . . . . . . . . . . . . . . . . . . . . . . . . 48
33 3-Wire Start/Stop Switch or Contact Connection and Function Settings . . . . . . . . . . . . . . . . . . . . . . . .49
34 Analog Input 1 Signal Voltage Following Connection and Function Settings . . . . . . . . . . . . . . . . . . . . . 49
35 Analog Input 2 Signal Current Following Connection and Function Settings . . . . . . . . . . . . . . . . . . . . . 50
36 Analog Outputs 1 and 2 Connections and Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
37 Bidirectional Motor Operation Main Speed Potentiometer Connection and Function Setting . . . . . . . . 52
38 Multi-Function Output Relay Contacts Connections and Function Settings . . . . . . . . . . . . . . . . . . . . . . 53
39 Multi-Function Open Collector Connections and Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Items Included In this Package:
KBDA Adjustable Frequency Drive, KBDA Series Installation and Operation Manual, CE Approved Product
Information Card, W
arranty Registration Car
d, and Mounting Template.
UL Notice
AC Controls
230 V
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.
AC Controls
460 V
Suitable For Use On A Circuit Capable Of Delivering Not More Than 5 kA RMS Symmetrical Amperes,
460 Volts Maximum.
Use Copper Conductors Rated 75 ºC.
Suitable for Operation in a Maximum Surrounding Air Temperature of 40 ºC.
iii
IMPORTANT APPLICATION INFORMATION
see Section 6.1, on page 18.
(Models KBDA-29, 45, 48):
(Terminals "L1", "L2", "L3")
208/230, 400/460 Volt, 3-Phase
2
see Section 6.1, on page 18.
(Models KBDA-24D, 27D, 29):
(Terminals "L1", "L2")
208/230 Volt, Single Phase
2
AC Induction Motor:
see Section 6.3, on page 19.
3-Phase
Motor
W L1U V
MOTOR
TB1
see Section 6.2, on page 19.
Ground (Earth):
see Section 6.2, on page 19.
Ground (Earth):
L3L2
AC LINE
1. 50 Hz Motors – This drive has been factory programmed to operate 60 Hz motors. For 50 Hz motor
operation, set Function No. 0.00 to “0001”. See Figure 16, on page 23.
2. Motor Current Setting – T
ing, as shown in Table 3, on page 10. In order for the motor overload protection to operate properly, the
drive must be reprogrammed to the actual motor nameplate current. Use Function No. 0.01 to enter the
motor nameplate current. See Figure 17, on page 24.
a. Model KBDA-27D – Has a maximum current rating of 6.7 Amps (2 HP (1.5 kW)) when used with a
208 – 230 V
When used with 115 Volt 50/60 Hz AC line input (Jumper J1 installed in the “115V” position), the
maximum rating of the drive is 5.5 Amps (1
(Function No. 0.01) to the actual motor nameplate current rating (not to exceed 5.5 Amps).
b. Model KBDA-29 – Has a maximum rating of 9.0 Amps (3 HP (2.25 kW)) when used with a 208 – 230
Volt 50/60 Hz 3-phase AC line input. When used with a 208 – 230 V
line input, the maximum rating of the drive is 6.7 Amps (2 HP (1.5 kW)). Be sure to reprogram Motor
Current (Function No. 0.01) to the actual motor nameplate current rating (not to exceed 6.7 Amps).
1 QUICK-START INSTRUCTIONS
Important: You must read these simplified instructions before proceeding. These instructions are to
be used as a refer
read the Safety Warning on, page 6, before proceeding.
Note: This drive contains bus capacitors, which must be reconditioned if the drive has been in storage for over 1 year. To recondition the bus capacitors, apply the AC line, with the drive in the Stop
Mode, for a minimum of 30 minutes.
See Figure 1. Also see Section 4 - Important Application Information, on page 16.
olt 50/60 Hz AC line input (factory setting of motor curr
WARNING! HIGH VOLTAGE – Disconnect main power before making connections
to the drive.
he motor current for all drive models is factory set to the maximum drive rat-
ent and AC line input voltage).
1
⁄2 HP (1.13 kW)). Be sure to reprogram Motor Current
olt 50/60 Hz single-phase AC
ence only and are not intended to replace the details provided herein. You must
FIGURE 1 – QUICK-START CONNECTION DIAGRAM
1
Notes: 1. Layout of Models KBDA-24D, 27D
vary slightly. 2. 50/60 Hz AC line input.
4
1.1 AC LINE INPUT CONNECTION – Connect the AC line input to Terminal Block TB1. See Section
6.1, on page 18.
Application Note – If operation with a Ground-Fault Cir
cuit-Interrupter (GFCI) is required,
see Function No. 0.04, on page 32.
Note: The rated AC line voltage of the drive must match the actual AC line input voltage. On
Models KBDA-24D, 27D, the setting of Jumper J1 must match the AC line input voltage.
Model KBDA-24D – Terminals “L1”, “L2” – Designed for single-phase AC line input only. Rated
for 208/230 V
for 115 V
Note: 230 V
Model KBDA-27D – T
for 208/230 Volt AC line input with Jumper J1 set to the “230V” position (factory setting) and
rated for 115 V
olt AC line input with Jumper J1 set to the “230V” position (factory setting) and rated
olt AC line input with Jumper J1 set to the “115V” position. See Figure 10, on page 18.
olts AC will be applied to the motor with 115 Volt AC line input.
erminals “L1”, “L2” – Designed for single-phase AC line input only. Rated
1
olt AC line input with Jumper J1 set to the “115V” position. Rated for 1
⁄2 HP
maximum with 115 Volt AC line input and 2 HP maximum with 208/230 Volt AC line input.
See Figure 10, on page 18.
Note: 230 V
Model KBDA-29 – T
input. Rated for 208/230 Volt AC line input only
olts AC will be applied to the motor with 115 Volt AC line input.
erminals “L1”, “L2”, “L3” – Designed for single-phase or 3-phase AC line
. Rated for 2 HP maximum with single-phase AC
line input (Terminals “L1”, “L2”) and 3 HP maximum with 3-phase AC line input (Terminals “L1”,
“L2”, “L3”). See Figure 11, on page 19.
Models KBDA-45, 48 – Terminals “L1”, “L2”, “L3” – Designed for 3-phase AC line input only.
Rated for 400/460 V
olt AC line input only
. See Figure 11, on page 19.
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 r
ecommended fuse size, see Table 3,
on page 10. Also see Section 6.1, on page 18.
1.3 GROUND CONNECTION – Connect the ground wire (earth) to the Ground Screw, as shown in
Figures 10 and 11, on pages 18 and 19. Be sure the motor is also properly grounded. Two Ground
ews ar
Scr
e provided.
1.4 MOTOR CONNECTION – Connect the motor to Terminal Block TB1 Terminals “U”, “V”, “W”, as
shown in Figures 10 and 11, on pages 18 and 19. Be sur
e the motor is properly grounded. Motor
cable length should not exceed 100 ft. (30 m) – special reactors may be required – consult our
Sales Department. See Section 6.3, on page 19.
1.5 60 Hz and 50 Hz MOTOR OPERATION – The drive is factory set for 60 Hz motors (Function No.
0.00 set to “0000”). For 50 Hz motors, set Function No. 0.00 to “0001”, as shown in Figur
page 23. For other motor fr
equencies, set Function No. 0.00 to “0002”.
e 16, on
1.6 JUMPER J1 SETTING (Models KBDA-24D, 27D Only) – Jumper J1 has been factory set for 230
olt AC line input (installed in the “230V” position). For 115 V
V
olt AC line input, set Jumper J1 to
the “115V” position. See Section 7, on page 20.
1.7 MOTOR OVERLOAD PROTECTION – Function No. 0.01 must be set to the motor nameplate
current for proper operation of the I2t Motor Overload Protection. See Figure 17, on page 24.
5
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 Hazar
injury or death.
This product should be installed and serviced by a qualified technician, electrician, or
electrical maintenance person familiar with its operation and the hazar
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 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
1/2006)
The drive contains electronic Start/Stop circuits, which can be used to start and stop the drive.
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.
Be sure to read and follow all instructions carefully. Fire and/or electrocution can result due to
improper use of this product.
This product complies with all CE directives pertinent at the time of manufacture. Contact our
Sales Department for Declaration of Conformity. Installation of a CE approved RFI filter is
required. See Table 1, on page 9. For some applications, additional shielded cables, filters, and chokes
may be required along with a signal isolator (IODA Input/Output Multi-Function Board (Part No. 9668)).
d Warning Symbol – Failure to observe this warning could result in serious
ds involved. Pr
oper
6
3 INTRODUCTION
Thank you for purchasing the KBDA Adjustable Fr
providing total customer satisfaction by producing quality products that are easy to install and operate.
The KBDA Adjustable Frequency Drives are variable speed controls housed in a rugged NEMA-4X /
IP-65 washdown and watertight die-cast aluminum enclosure. They are designed to operate 208 – 230
and 400/460 Volt 50 & 60 Hz 3-phase AC induction motors from subfractional thru 5 HP. The sine wave
coded Pulse Width Modulated (PWM) output provides high motor efficiency and low noise. Adjustable
Linear Acceleration and Deceleration make the drive suitable for soft-start applications.
Due to its user-friendly design, the KBDA is easy to install and operate. Setting the drive to specific
applications is accomplished using the Multi-Function Keypad, which provides easy operation and
programming of the drive. To facilitate programming, all similar functions are presented in common
groups. For more advanced programming, PC based Drive-Link™ software is available.
The 4-Digit LED Display provides readout of drive operating parameters and programming functions
and displays Output Frequency, Motor RPM, Output Current, Output Voltage, Bus Voltage, Function
Codes and Values, Fault Codes, and Custom Units. In addition to operating the drive, the MultiFunction Keypad is used to change drive operating parameters, reprogram functions, and change the
display output. The LEDs provide indication of the drive’s status and operating mode (Hz, PGM,
LCL/REM, STOP, FWD, REV, OL, JOG/REM).
The optional 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, open collector outputs, and output relay contacts. See Appendix A, on pages 42 – 54. See
Function Groups 7 – 9, on pages 36 – 38.
equency Drive. KB Electronics, Inc. is committed to
Main Features – Adjustable RMS Current Limit and I2t Motor Overload Pr
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 startup of high frictional
loads. Programmable Injection Braking provides rapid motor stop. Electronic Inrush Current Limit
(EICL™) eliminates harmful AC line inrush current, which allows the drive to be line switched. A MultiFunction Output Relay is provided, which can be used to turn on or off equipment or to signal a warning if the drive is put into various modes of operation. Models KBDA-29**, 45, 48 also contain AC Line
Phase Loss Detection. The drive is suitable for machine or variable torque (HVAC) applications.
*UL approved as an electronic overload protector for motors.
**When used on 3-phase AC line input set for 7.0 Amps or higher (3 HP (2.25 kW)).
Standard Front Panel Features – 4-Digit LED Display, Multi-Function Keypad, Status Indicator LEDs,
and a Main Speed Potentiometer
Optional Accessories – On/Of
Function Board, Pr
Table 1, on page 9.
3.1 STANDARD FEATURES
• Industrial Duty Die-Cast Aluminum Enclosur
finish or FDA appr
• Multi-Function Keypad – The keys are used to operate the drive, change operating parameters, r
Down, Shift/Reset, Jog-Local/Remote, Program/Display, Read/Enter).
• 4-Digit LED Display – Provides readout of drive operating parameters and programming functions. Displays Output Fr
Function No. Codes and Values, Fault Codes, and Custom Units.
ogramming Kit, DIAC Modbus Communication Module, and Liquidtight Fittings. See
ogram functions, and change the display output (Run/Stop, Forward/Reverse, Up,
epr
.
f AC Line Switch, Class “A” AC Line Filter, IODA Input/Output Multi-
e with Hinged Cover – Available in dark gray
oved white finish.
, Motor RPM, Output Current, Output Voltage, Bus Voltage,
equency
otection.* Flux V
ector
7
• LED Status Indicators – The LEDs provide indication of the drive’s status and operating mode
(Hz, PGM, LCL/REM, STOP, FWD, REV, OL, JOG/REM).
• Multi-Function Output Relay Contacts – Can be used to tur
a warning if the drive is put into various modes of operation. (The optional IODA Input/Output
Multi-Function Board contains 9 digital and analog inputs, 4 digital and analog outputs, and 2
additional relay outputs.)
• Motor Curr
range of motor horsepower.
• Compatible with GFCIs. See Function No. 0.04, on page 32.
PERFORMANCE FEATURES
3.2
•
Power Start™ – Provides more than 200% starting torque which ensures startup of high fric-
tional loads.
• Programmable Flux Vector Compensation with Static Auto-Tune and Boost – Provides
excellent load r
• Speed Range – 60:1
ent Selection – P
egulation and dynamic r
rogrammable motor current allows the drive to be used on a wide
esponse over a wide speed range.
n on or of
f equipment or to signal
PROTECTION FEA
3.3
• Motor Overload (I2t) with RMS Current Limit – Provides motor overload protection, which
prevents motor bur
• Electronic Inrush Current Limit (EICL™) – Eliminates harmful inrush AC line current during
startup.
• Short Circuit – Shuts down the drive if a short circuit occurs at the motor (phase-to-phase).
• AC Line Phase Loss Detection (Models KBDA-29**, 45, 48 only.)
• Decel Extend – Eliminates tripping due to bus overvoltage caused by rapid deceleration of
high inertial loads.
• Undervoltage and Overvoltage – Shuts down the drive if the AC line input voltage goes below
or above the operating range.
• MOV Input Transient Suppression.
ocontroller Self Monitoring and Auto-Reboot.
Micr
•
*UL approved as an electronic overload protector for motors.
**When used on 3-phase AC line input set for 7.0 Amps or higher (3 HP (2.25 kW)).
TURES
nout and eliminates nuisance trips.*
8
TABLE 1 – OPTIONAL ACCESSORIES
Accessory Part No.
Model
Model
Model
Description
On/Off AC Line Switch – Disconnects the AC line. Mounts on the enclosure
cover and is supplied with a switch seal to maintain liquidtight integrity.
AC Line Filter1– Provides Class A Industrial Standard RFI (EMI)
suppression. Installs onto the drive’s PC board with quick-connect
terminals.
Suffix “S” – Filter must be used with built-in On/Off AC Line Switch.
Suffix “NS” – Filter must be used without On/Off AC Line Switch.
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, open collector outputs,
and output relay contacts. Mounts on the drive’s PC board with two snap-ins
(located on the bottom of the mounting base) and two screws (provided). All of
the IODA inputs and outputs are isolated from the AC line.
See Appendix A, on page 42.
Programming Kit – Includes DownLoad Module™ (DLM) handheld programming device, which uploads and downloads drive programs, PC to DLM
serial and USB communication cables, DLM to inverter communication cable,
and PC Windows® based Drive-Link™ communication software.
DIAC Modbus Communication Module – Allows direct communication
between drive and Modbus2protocol.
Liquidtight Fittings – Provide a liquidtight seal for wiring the drive. Kit
includes three 1/2” and one 3/4” liquidtight fittings.
Notes: 1. Complies with CE Council Directive 89/336/EEC Industrial Standard. 2. Other protocols available – contact our Sales Department.
KBDA-24D
KBDA-27D
9482 9523 9532 9532 9532
Suffix
9507 9512 9479 9479 9479
“S”
Suffix
9507 9512 9515 9515 9515
“NS”
9668 9668 9668 9668 9668
9582 9582 9582 9582 9582
9517 9517 9517 9517 9517
9526 9526 9526 9526 9526
KBDA-29
Model
KBDA-45
Model
KBDA-48
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%) —
400/460 Volt AC Line Input Voltage Operating Range (Volts AC) 380 (-15%) – 460 (+15%) —
Maximum Load (% of Current Overload for 2 Minutes) 150 —
Switching Frequency (kHz) 8, 10, 12 8
Signal Following Input Voltage Range1(Volts DC)
Output Frequency Resolution (Bits, Hz) 10, .06 —
Minimum Operating Frequency at Motor (Hz) 0.3 —
Acceleration Time (Seconds) 0.1 – 180.0 1.5
Deceleration Time (Seconds) 0.3 – 180.0 1.5
Speed Range (Ratio) 60:1 —
Speed Regulation (30:1 Speed Range, 0 – Full Load) (% Base Speed)
Overload Protector Trip Time for Stalled Motor (Seconds) 6 —
Undervoltage/Overvoltage Trip Points for 115 Volt AC Line Input (± 5%) (Volts AC)
Undervoltage/Overvoltage Trip Points for 208/230 Volt AC Line Input (± 5%) (Volts AC)
Undervoltage/Overvoltage Trip Points for 400/460 Volt AC Line Input (± 5%) (Volts AC)
Run/Fault Output Relay Contact Rating (Amps at 30 Volts DC, 125 Volts AC, 250 Volts AC) 1, 0.5, 0.25 —
Operating Temperature Range (°C / °F) 0 – 45 / 32 – 113 —
Notes: 1. IODA option board required. 2. Dependent on motor performance. 3. Do not operate the drive outside the specified AC line input voltage
operating range.
2
3
3
3
0 – 5 —
2.5 —
76 / 141 —
151 / 282 —
302 / 567 —
9
TABLE 3 – ELECTRICAL RATINGS
Down Key: Decreases Output Frequency,
Set Frequency, Function Number Value,
and Code setting.
Starts or Stops the drive.
Changes motor direction.
Up Key: Increases Output Frequency,
Set Frequency, Function Number Value,
and Code setting.
Drive is in Jog Operation
or Remote Signal Opera tion.
1, 2
Drive is in Overload.
Drive is set for Forward Direction.
Drive is set for Reverse Direction.
Displays or enters a Function Value
or Code Setting.
Used to enter the Program Mode
4
and Display Mode.
Sets the drive to Jog Mode or
changes between Local (Keypad)
or Remote Signal Opera tion.
1, 2
Left Shift / Reset Key: Moves
the changeable digit or Resets
the drive after a fault has cleared.
Drive Frequency displayed.
3
Drive is in Program Mode.
Drive is in Stop Mode.
Indicates JOG-LCL/REM Key
is set for Local/Remote Signal
Operation.
2
4-Digit Display
Potentiometer: Sets Drive Output Frequency.
5
AC Line Input
Maximum
Part No.
Model
KBDA-24D
KBDA-27D
KBDA-29
KBDA-45
KBDA-48
Notes: 1. White FDA approved finish. 2. Bold indicates factory setting of AC line input voltage for Models KBDA-24D, 27D. 3. Factory setting
of motor current (Function No. 0.01). 4. Models KBDA-24D, 27D contain an AC line input volta
rated 1
(1.5 kW) with single-phase AC line input and 3 HP (2.25 kW) with 3-phase AC line input. 7. Also contain AC Line Phase Loss Detection
(Model KBDA-29: when used on 3-phase AC line input set for 7.0
– 400 Volts AC for 50 Hz motor operation and 0 – 460 Volts AC for 60 Hz motor operation.
0
(Gray /White
4
4,5
6,7
7,8
7,8
1
⁄2 HP (1.13 kW) with 115 Volt AC line input and 2 HP (1.5 kW) with 208/230 Volt AC line input. 6. Model KBDA-29 is rated 2 HP
1
9536/ 9537
9543/ 9544
9545 /9546 208/ 230
9659/ 9660 400/ 460 3 5.3 10 0 – 400/460 4.6 3 (2.25) 10.3 4.7
9661 /9662 400/ 460 3 9.6 15 0 – 400/460 8.3 5 (3.75) 10.3 4.7
2
Volts AC
)
(50/60 Hz)
Phase
φ)
(
(Amps AC)
115 1 16 20
208/230 1 10 15
115 1 22 25 0 – 230 5.5 11⁄2 (1.13)
208/230 1 15 20 0 – 230
1 15 20 0 – 230 6.7 2 (1.5)
3 10.8 15 0 – 230
Fuse or
Circuit
Breaker
Current
Rating
(Amps AC)
Amps or higher (3 HP (2.25 kW)). 8. Models KBDA-45, 48 are rated
Voltage
Range
(Volts AC)
0 – 230 3.6 1 (.75) 5.9 2.7
Output
Maximum
Continuous
Load Current
(RMS Amps/Phase)
6.7
9.0
ge selection jumper. 5. Model KBDA-27D is
Maximum
3
Horsepower
(HP (kW))
3
3
2 (1.5)
3 (2.25)
Net Wt.
lbs kg
10.3 4.7
10.3 4.7
FIGURE 2 – KEYPAD LAYOUT WITH MAIN SPEED POTENTIOMETER
Notes: 1. The JOG-LCL/REM Key is factory programmed to function as a Jog Key.When the JOG-LCL/REM Key is pressed,
LED will illuminate and the display will show the Jog Frequency Setting (see Function No. 3.13, on page 34). 2. If the JOG-LCL/REM Key is
reprogrammed for Local (Keypad) and Remote Signal Operation (see Function No. 2.02, on page 34),
Pressing the JOG-LCL/REM Key will toggle between Local (Keypad) and Remote Signal Operation. When Remote Signal Operation is selected, the “JOG/REM” LED will flash. The optional IODA (Part No. 9668) is required for remote signal operation. 3. The “Hz” LED will illuminate
when the display is set to sho
ously entered Function Number will be shown.
Frequency will be shown. When more than one display function is enabled, the PROGRAM/DISPLAY Key is used to toggle between displays,
as shown in Figure 22, on page 29. 5. To change the Keypad for Potentiometer Operation, set Function No. 2.00 to “0001”.
requency. 4. If the PROGRAM/DISPLAY Key is pressed while Set Frequency is displayed, the previ-
w Output F
If the PROGRAM/DISPLAY Key is pressed while Function Number is displayed, the Set
the “LCL/REM” LED will illuminate.
10
the
“JOG/REM”
TB1
WU V L2L1
L1A L2BL2AL1B
TB2
NO COM
NC
CON1
MOTOR AC LINE
115V
J1
230V
FIGURE 3 – MODEL KBDA-24D DRIVE LAYOUT
11
J1
115V 230V
MOTOR
W L2 L3U V
TB1
AC LINE
TB2
NO COM
NC
CON1
L2A L1A
L2B L1B
FIGURE 4 – MODEL KBDA-27D DRIVE LAYOUT
12
AC LINE
L2A L3AL1A
L3BL2BL1B
L1W L2 L3U V
TB1
MOTOR
TB2
NCCOMNO
CON1
FIGURE 5 – MODELS KBDA-29, 45, 48 DRIVE LAYOUT
13
5.86
149
Max. Depth:
208
8.20
9.53
242
8.85
225
0.31
7.97
5.51
140
5.06
129
2X
ø
7.0
2.530.275
64.4
3*2*
4*4* 1*1*
FIGURE 6 – MODEL KBDA-24D MECHANICAL SPECIFICATIONS (Inches/mm)
Model KBDA-24D contains mounting holes for standard 1/2” liquidtight fittings. The recommended mounting screw size is 1/4” (M6).
*Tighten the four enclosure cover screws, in the sequence shown, to 12 in-lbs (14 kg-cm).
14
0.275
4X
ø
7.0
0.30
7.37
2X
25.4
1.00
2X
7.25
Max. Depth:
184
8.50
216
9.25
235
9.80
249
3*
181
7.55
192
7.15
2*
4* 1*
FIGURE 7 – MODELS KBDA-27D, 29, 45, 48 MECHANICAL SPECIFICATIONS (Inches/mm)
Models KBDA-27D, 29, 45, 48 contain two mounting holes for standard 1/2” liquidtight fittings and one mounting hole for
standard 3/4” liquidtight fitting. The recommended mounting screw size is 1/4” (M6).
*Tighten the four enclosure cover screws, in the sequence shown, to 12 in-lbs (14 kg-cm).
15
4 IMPORTANT APPLICATION INFORMATION
10060 70 805030 40100 20 90
Motor Speed (%)
and TENV Motors
Inverter Duty
40
Maximum Allowed
Motor Torque (%)
0
20
60
80
100
TEFC and Open Ventilated
Motors
Fan Cooled
Open Ventilated Motor
Fan or Blower
(100 CFM per HP Min.)
Airflow
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
que. Ther
tor
efore, 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.
ARNING! Some
W
motors have low
FIGURE 8 – MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED
speed characteristics,
which cause overheating
and winding failur
e under
light load or no load conditions. If the motor is
operated in this manner
for an extended period of
time, it is r
ecommended
that the unloaded motor
current be checked from
2 – 15 Hz (60 – 450 RPM)
to ensure motor current
does not exceed the
nameplate rating. If the
motor current exceeds the
FIGURE 9 – OPEN VENTILATED MOTOR WITH EXTERNAL FAN COOLING
nameplate rating, the
Boost value may have to
be decreased (see
Function No. 3.11). Do
not use motor if the
motor current exceeds
the nameplate rating.
ecommended
It is r
that the drive be
used with Inverter Duty
or TENV motors.
Inverter duty and most totally enclosed non-ventilated (TENV) motors can pr
over an extended speed range without overheating. See Figur
nal fan cooling is provided, open ventilated motors can also achieve an extended speed
If exter
e 8.
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 9.
4.2 ELECTRONIC MOTOR OVERLOAD PROTECTION – The drive contains Modified I2t Overload
Protection.* Part of this function consists of a Curr
ent Limit (CL) circuit, which limits the drive cur-
rent to a preset level of 160% of the Motor Nameplate Rated Current setting. The factory setting
for motor nameplate curr
motor nameplate current (see Important Application Information (Item 2), on page 4). See
Table 3, on page 10. Also see Function No. 0.01, on page 32.
Standard I2t is undesirable because it causes nuisance tripping. It allows a very high motor cur-
ent to develop and will tur
r
Circuit avoids this nuisance tripping while providing maximum motor protection.
ent is the drive rated curr
n the drive off after a short period of time. KB’s RMS Current Limit
ent, which must be set to the actual
16
ovide full rated torque
If the motor is overloaded to 120% of the Motor Nameplate Rated Current 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.
5 MOUNTING INSTRUCTIONS
ecommended that the drive be mounted vertically on a flat surface with adequate ventilation.
It is r
eave enough room below the drive to allow for AC line, motor connections, and any other connections
L
that are 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 45°C (113 °F) at full rating. The recommended mounting screw size is
1/4 inch (M6). See Figures 6 and 7, on pages 14 and 15.
WARNING! Do not use this drive in an explosion-proof application.
6 ELECTRICAL CONNECTIONS
WARNING! HIGH VOLTAGE – Read Safety Warning, on page 6, before using the drive.
Disconnect main power before making connections to the drive. T
be sure to properly ground the drive.
Application Note: To avoid erratic operation, do not bundle the AC line and motor wires with each
other or with wir
bundle motor wires from multiple drives in the same conduit. Use shielded cables on all signal wires
over 12” (30 cm). The shield should be earth grounded on the drive side only. Connect 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 installed as a disconnect
so that each ungrounded conductor is opened. For fuse or circuit breaker selection, see Table 3, on
page 10. Also see Section 6.1, on page 18.
To maintain the watertight integrity of the drive, be sure to use suitable liquidtight fittings and wires
that are appropriate for the application. Model KBDA-24D contains mounting holes for standard 1/2”
liquidtight fittings (not supplied) (two liquidtight plugs are provided, if only one knockout is used).
Models KBDA-27D, 29, 45, 48 contain two mounting holes for standard 1/2” liquidtight fittings (not
supplied) and one mounting hole for standard 3/4” liquidtight fitting (not supplied) (two liquidtight
plugs are provided, if only one knockout is used). The Liquidtight Fittings Kit (Part No. 9526) is available for all models (see Table 1, on page 9).
The drive is designed with a hinged case so that, when the front cover is open, all wires stay intact.
To open the cover, the four screws must be loosened so they are no longer engaged in the case bottom. After mounting the drive and all electrical connections are complete, 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 in-lbs (14 kg-cm).
See Figures 6 and 7, on pages 14 and 15, for the tightening sequence. Do not overtighten.
e the drive is secur
Be sur
es fr
om signal following, start/stop contacts, or any other signal wires. Also, do not
ely mounted.
o avoid electric shock,
17
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