KB Electronics KBDA-24D, KBDA-27D, KBDA-29, KBDA-48, KBDA-45 Installation And Operation Manual
K4 SERIES (KBDA)
TABLE OF CONTENTS
Section Page
1 Quick-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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
2 General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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
Figure Page
1 Quick-Start Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Keypad Layout with Main Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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
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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, Warranty Registration Card, and Mounting Template.
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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.
460 VAC Controls
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.
UL Notice
If this drive has been in storage for over one year it is necessary to recondition the power supply bus
capacitors. To recondition the bus capacitors, apply the AC Line, with the drive in the Stop Mode, for a
minimum of one hour. Not following this procedure will cause the bus capacitors to fail.
RECONDITIONING THE BUS CAPACITORS
4
IMPORTANT APPLICATION INFORMATION
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 – The motor current for all drive models is factory set to the maximum drive rating, 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 Volt 50/60 Hz AC line input (factory setting of motor current and AC line input voltage).
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
1
⁄2 HP (1.13 kW)). Be sure to reprogram Motor Current
(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 Volt 50/60 Hz single-phase AC 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).
FIGURE 1 – QUICK-START CONNECTION DIAGRAM
1
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 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 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
See Figure 1. Also see Section 4 - Important Application Information, on page 16.
WARNING! HIGH VOLTAGE – Disconnect main power before making connections
to the drive.
Notes: 1. Layout of Models KBDA-24D, 27D
vary slightly. 2. 50/60 Hz AC line input.
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 Circuit-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 Volt AC line input with Jumper J1 set to the “230V” position (factory setting) and rated for
115 Volt AC line input with Jumper J1 set to the “115V” position. See Figure 10, on page 18.
Note: 230 Volts AC will be applied to the motor with 115 Volt AC line input.
Model KBDA-27D – Terminals “L1”, “L2” – Designed for single-phase AC line input only. Rated for
208/230 Volt AC line input with Jumper J1 set to the “230V” position (factory setting) and
rated for 115 Volt AC line input with Jumper J1 set to the “115V” position. Rated for 1
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 Volts AC will be applied to the motor with 115 Volt AC line input.
Model KBDA-29 – Terminals “L1”, “L2”, “L3” – Designed for single-phase or 3-phase AC line input.
Rated for 208/230 Volt AC line input only. 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 Volt 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 recommended 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
Screws are 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 sure 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 Figure 16, on
page 23. For other motor frequencies, set Function No. 0.00 to “0002”.
1.6 JUMPER J1 SETTING (Models KBDA-24D, 27D Only) – Jumper J1 has been factory set for 230
Volt AC line input (installed in the “230V” position). For 115 Volt 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
6
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 should be installed and serviced by a qualied 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 res, 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 ltering 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)).
3 INTRODUCTION
Thank you for purchasing the KBDA Adjustable Frequency Drive. KB Electronics, Inc. is committed to
providing total customer satisfaction by producing quality products that are easy to install and operate.
The 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 Multi-Function 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.
Main Features – Adjustable RMS Current Limit and I2t Motor Overload Protection.* Flux Vector
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/Off AC Line Switch, Class “A” AC Line Filter, IODA Input/Output MultiFunction Board, Programming Kit, DIAC Modbus Communication Module, and Liquidtight Fittings. See
Table 1, on page 9.
3.1 STANDARD FEATURES
• Industrial Duty Die-Cast Aluminum Enclosure with Hinged Cover – Available in dark gray
finish or FDA approved white finish.
• Multi-Function Keypad – The keys are used to operate the drive, change operating parameters, reprogram functions, and change the display output (Run/Stop, Forward/Reverse, Up,
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 Frequency, Motor RPM, Output Current, Output Voltage, Bus Voltage,
Function No. Codes and Values, Fault Codes, and Custom Units.
7
8
• 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 turn on or off equipment or to signal
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 Current Selection – Programmable motor current allows the drive to be used on a wide
range of motor horsepower.
• Compatible with GFCIs. See Function No. 0.04, on page 32.
3.2 PERFORMANCE FEATURES
• 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 regulation and dynamic response 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.
• 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.
• Microcontroller Self Monitoring and Auto-Reboot.
*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)).
9
Description
Accessory Part No.
Model
KBDA-24D
Model
KBDA-27D
Model
KBDA-29
Model
KBDA-45
Model
KBDA-48
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.
9482 9523 9532 9532 9532
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.
Suffix
“S”
9507 9512 9479 9479 9479
Suffix
“NS”
9507 9512 9515 9515 9515
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.
9668 9668 9668 9668 9668
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.
9582 9582 9582 9582 9582
DIAC Modbus Communication Module – Allows direct communication
between drive and Modbus2protocol.
9517 9517 9517 9517 9517
Liquidtight Fittings – Provide a liquidtight seal for wiring the drive. Kit
includes three 1/2” and one 3/4” liquidtight fittings.
9526 9526 9526 9526 9526
TABLE 1 – OPTIONAL ACCESSORIES
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS
Notes: 1. Complies with CE Council Directive 89/336/EEC Industrial Standard. 2. Other protocols available – contact our Sales Department.
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.
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)
0 – 5 —
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)
2
2.5 —
Overload Protector Trip Time for Stalled Motor (Seconds) 6 —
Undervoltage/Overvoltage Trip Points for 115 Volt AC Line Input (± 5%) (Volts AC)
3
76 / 141 —
Undervoltage/Overvoltage Trip Points for 208/230 Volt AC Line Input (± 5%) (Volts AC)
3
151 / 282 —
Undervoltage/Overvoltage Trip Points for 400/460 Volt AC Line Input (± 5%) (Volts AC)
3
302 / 567 —
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 —
10
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 voltage selection jumper. 5. Model KBDA-27D is
rated 1
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
(1.5 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 Amps or higher (3 HP (2.25 kW)). 8. Models KBDA-45, 48 are rated
0 – 400 Volts AC for 50 Hz motor operation and 0 – 460 Volts AC for 60 Hz motor operation.
Notes: 1. The JOG-LCL/REM Key is factory programmed to function as a Jog Key. When the JOG-LCL/REM Key is pressed, the “JOG/REM”
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), the “LCL/REM” LED will illuminate.
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 show Output Frequency. 4. If the PROGRAM/DISPLAY Key is pressed while Set Frequency is displayed, the previously entered Function Number will be shown. If the PROGRAM/DISPLAY Key is pressed while Function Number is displayed, the Set
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”.
TABLE 3 – ELECTRICAL RATINGS
Model
Part No.
(Gray / White
1
)
AC Line Input
Fuse or
Circuit
Breaker
Rating
(Amps AC)
Output
Net Wt.
Volts AC
2
(50/60 Hz)
Phase
(
φ)
Maximum
Current
(Amps AC)
Voltage
Range
(Volts AC)
Maximum
Continuous
Load Current
3
(RMS Amps/Phase)
Maximum
Horsepower
(HP (kW))
lbs kg
KBDA-24D
4
9536/9537
115 1 14 20
0 – 230 3.6 1 (.75) 5.9 2.7
208/230 1 8.1 15
KBDA-27D
4,5
9543/9544
115 1 22 25 0 – 230 5.5 11⁄2 (1.13)
10.3 4.7
208/230 1 16.7 20 0 – 230
6.7
3
2 (1.5)
KBDA-29
6,7
9545/9546 208/ 230
1 20.5 20 0 – 230 6.7 2 (1.5)
10.3 4.7
3 11.7 15 0 – 230
9
3
3 (2.25)
KBDA-45
7,8
9659/9660 400 / 460 3 7.2 10 0 – 400/460 5.5 3 (2.25) 10.3 4.7
KBDA-48
7,8
9661/9662 400/460 3 11 15 0 – 400/460 8.3 5 (3.75) 10.3 4.7
FIGURE 2 – KEYPAD LAYOUT WITH MAIN SPEED POTENTIOMETER
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 Operation.
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 Operation.
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
TB1
WU V L2L1
L1A L2BL2AL1B
TB2
NO COM
NC
CON1
MOTOR AC LINE
115V
J1
230V
11
FIGURE 3 – MODEL KBDA-24D DRIVE LAYOUT
12
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
AC LINE
L2A L3AL1A
L3BL2BL1B
L1W L2 L3U V
TB1
MOTOR
TB2
NCCOMNO
CON1
13
FIGURE 5 – MODELS KBDA-29, 45, 48 DRIVE LAYOUT
14
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*
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).
FIGURE 6 – MODEL KBDA-24D MECHANICAL SPECIFICATIONS (Inches/mm)
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*
15
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).
FIGURE 7 – MODELS KBDA-27D, 29, 45, 48 MECHANICAL SPECIFICATIONS (Inches/mm)
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. If the
motor current exceeds the
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.
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 8.
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 9.
4.2 ELECTRONIC MOTOR OVERLOAD PROTECTION – The drive contains Modified I2t Overload
Protection.* Part of this function consists of a Current Limit (CL) circuit, which limits the drive current to a preset level of 160% of the Motor Nameplate Rated Current setting. The factory setting
for motor nameplate current is the drive rated current, which must be set to the actual
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 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.
16
FIGURE 8 – MAXIMUM ALLOWED MOTOR TORQUE VS. SPEED
FIGURE 9 – OPEN VENTILATED MOTOR WITH EXTERNAL FAN COOLING
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
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
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 connections 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.
Be sure the drive is securely mounted.
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. To avoid electric shock,
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 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 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 ttings and wires
that are appropriate for the application. Model KBDA-24D contains mounting holes for standard 1/2”
liquidtight ttings (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 ttings (not
supplied) and one mounting hole for standard 3/4” liquidtight tting (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.
17
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