KB Electronics KBDF SERIES Operation Manual

INSTALLATION AND OPERATION MANUAL

KBDF SERIES

DIGITAL AC DRIVE

IP-20 Enclosure

Rated for 208 – 230 and 400/460 Volt 50 & 60 Hz

1/8 HP thru 5 HP 3-Phase AC Induction Motors

Operates from 115, 208/230, and 400/460 Volt 50/60 Hz AC Line

SEE

SAFETY

WARNING

ON PAGE 9

NOTE

This drive is factory

set for 60 Hz Motors.

For 50 Hz Motors, see

Section 2.1, page 7.

KBDF-13, 23, 23F, 23D, 23P, 14, 24, 24F, 24D, 24P, 16, 27, 27F, 27D, 27P, 29, 42, 43, 45, 48

However, the manufacturer retains the right to make changes in design, which may not be included herein.

The information contained in this manual is intended to be accurate.

RUN

STOP

FWD REV

This Manual Covers Models

KBDF SERIES

RoHS

KB Electronics, Inc.

(see back cover)

TABLE OF CONTENTS

Section Page

1 FAMILIARIZING YOURSELF WITH THE DRIVE ...................................................................6

2 IMPORTANT PROGRAMMING INFORMATION.................................................................... 7

2.1 50 Hz Motors.................................................................................................................7

2.2 Motor Current Setting.................................................................................................. 7

3 IMPORTANT APPLICATION INFORMATION .......................................................................8

3.1 Motor with External Fan Cooling................................................................................ 8

3.2 Electronic Motor Overload Protection .......................................................................8

4 SAFETY WARNING................................................................................................................9

5 INTRODUCTION ................................................................................................................... 10

5.1 Standard Features .....................................................................................................11

5.2 Performance Features ...............................................................................................12

5.3 Protection Features ................................................................................................... 12

6 DRIVE LAYOUT .................................................................................................................... 16

7 MOUNTING ........................................................................................................................... 18

8 ELECTRICAL CONNECTIONS ............................................................................................20

8.1 AC Line Input and Ground ........................................................................................22

8.2 AC Line Input Fusing................................................................................................. 24

8.3 Motor and Ground...................................................................................................... 24

8.4 Remote Operation......................................................................................................25

8.4.1 Start/Stop and Forward/Reverse ....................................................................27

8.4.1.1 Automatic Start ....................................................................................27

8.4.1.2 2-Wire Start/Stop .................................................................................28

8.4.1.3 3-Wire Start/Stop .................................................................................28

8.4.1.4 Forward/Stop and Reverse/Stop .........................................................29

8.4.2 Frequency Control ...........................................................................................30

8.4.2.1 Analog Input ........................................................................................30

8.4.2.1.1 Voltage Following .............................................................. 31

8.4.2.1.2 Current Following...............................................................32

8.4.2.2 Remote Main Speed Potentiometer ....................................................32

8.4.2.3 Up/Down Frequency Control ............................................................... 34

8.4.2.4 Preset Frequency Control.................................................................... 37

8.4.2.5 Modbus Communication...................................................................... 38

8.4.3 Multi-Function Input Terminals* ..................................................................... 39

*For NPN and PNP Transistor Circuits, see Appendix E, on page 70.

8.4.3.1 Reset ................................................................................................... 39

8.4.3.2 External Fault ......................................................................................39

8.4.3.3 Accel/Decel #2..................................................................................... 40

8.4.4 Multi-Function Output Relay .......................................................................... 41

8.4.5 Analog Output ................................................................................................. 42

9 HIGH VOLTAGE DIELECTRIC WITHSTAND TESTING (HI-POT TEST)............................ 43

10 DRIVE OPERATION ............................................................................................................. 44

10.1 Start-Up Procedure.................................................................................................... 44

10.2 Local/Remote Operation ........................................................................................... 44

10.3 Keypad Description ...................................................................................................44

10.4 Flow Charts for Important Programming Functions .............................................. 45

11 4-DIGIT DISPLAY READOUT CODES.................................................................................52

12 PROGRAMMABLE FUNCTION LIST................................................................................... 54

APPENDIX A: Optional IODF Input/Output Multi-Function Expansion Module APPENDIX B: Optional DIDF RS-232 and RS-485 Modbus RTU Communication Module..67

APPENDIX C: Optional Memory Module ..................................................................................68

APPENDIX D: Optional Dynamic Brake Module (Case "B" Drives Only)..............................69

APPENDIX E: Multi-Function Input Terminals with NPN and PNP Transistor Circuits....... 70

LIMITED WARRANTY.................................................................................................. Back Cover

...................64

TABLE OF CONTENTS (CONTINUED)

Table Page

1 Options....................................................................................................................................13

2 General Performance Specifications....................................................................................... 14

3 Electrical Ratings ....................................................................................................................15

4 Descriptions of 4-Digit Display, LEDs, Keys, and Potentiometer ............................................ 17

5 Drive Terminal Block Wire and Tightening Torque Specifications ..........................................22

6 Drive Multi-Function Input Terminal, Function, and Factory Code Assignment ......................25

7 Drive Input and Output Connections .......................................................................................26

8 Preset Frequency Selection ....................................................................................................37

9 Drive Multi-Function Output Relay "Run" and "Fault" Operating Modes................................. 41

10 Digital Readout Codes ...................................................................................................... 52, 53

11 IODF Multi-Function Output Relay "Run" and "Fault" Operating Modes................................. 64

12 IODF Input and Output Connections.......................................................................................65

13 IODF Terminal Block Wire and Tightening Torque Specifications..........................................65

14 IODF Multi-Function Input Terminal, Function, and Factory Code Assignment...................... 66

Figure Page

1 Description of 4-Digit Display, LEDs, Keys, and Main Speed Potentiometer............................ 6

2 Maximum Allowed Motor Torque vs. Speed ............................................................................. 8

3 Drive Layout ............................................................................................................................16

4 Case "A" Drives Mechanical Specifications ............................................................................18

5 Case "B" Drives Mechanical Specifications ............................................................................19

6 General Connection Diagram..................................................................................................21

7 Models KBDF-13, 14, 16 AC Line Input and Ground Connections .........................................22

8 Models KBDF-23D, 24D, 27D AC Line Input and Ground Connections .................................23

9 Models KBDF-23, 23F, 24, 24F, 27, 27F AC Line Input and Ground Connections ................ 23

10 Models KBDF-23P, 24P AC Line Input and Ground Connections .......................................... 23

11 Models KBDF-27P, 29 AC Line Input and Ground Connections............................................. 23

12 Models KBDF-42, 43, 45, 48 AC Line Input and Ground Connections ...................................24

13 Motor and Ground Connections ..............................................................................................24

14 Automatic Start Connections and Drive Programming............................................................27

15 2-Wire Start/Stop Connections and Drive Programming.........................................................28

16 3-Wire Start/Stop Connections and Drive Programming.........................................................28

17 Forward/Stop and Reverse/Stop Connections and Drive Programming................................. 29

18 Analog Input Signal Gain and Offset with Positive Slope (Low-to-High Signal)...................... 30

19 Analog Input Signal Gain and Offset with Negative Slope (High-to-Low Signal) .................... 30

20 Analog Input Jumper J2 Settings ............................................................................................ 31

21 Voltage Following Connections, Jumper J2 Settings, and Drive Programming......................31

22 Current Following Connections, Jumper J2 Settings, and Drive Programming ...................... 32

23 Unidirectional Remote Main Speed Potentiometer with Start/Stop

Connections, Jumper J2 Settings, and Drive Programming ................................................... 33

24 Bidirectional Remote Main Speed Potentiometer with Start/Stop

Connections, Jumper J2 Settings, and Drive Programming ................................................... 33

25 Unidirectional Remote Main Speed Potentiometer with Forward/Reverse

Connections, Jumper J2 Settings, and Drive Programming ................................................... 34

26 Unidirectional Up/Down Frequency Control with 2-Wire Start/Stop

Connections, Jumper J2 Settings, and Drive Programming ...................................................35

27 Bidirectional Up/Down Frequency Control Connections and Drive Programming .................. 36

28 Unidirectional Preset Frequency Selection with 2-Wire Start/Stop

Connections and Drive Programming .....................................................................................38

29 Unidirectional Preset Frequency Selection with 3-Wire Start/Stop

Connections and Drive Programming .....................................................................................38

30 Reset Connections and Drive Programming........................................................................... 39

31 External Fault Connections and Drive Programming ..............................................................40

TABLE OF CONTENTS (CONTINUED)

Figure Page

32 Accel/Decel #2 Connections and Drive Programming ............................................................ 41

33 Multi-Function Output Relay Connections...............................................................................41

34 Analog Output Connections and Drive Programming ............................................................. 42

35 Analog Output Gain .................................................................................................................42

36 Typical Hi-Pot Test Setup .......................................................................................................43

37 Flow Chart to Program Motor Current from 6.7 Amps to 5.5 Amps ........................................ 45

38 Flow Chart to Change Set Frequency from 5.00 Hz TO 43.21 Hz..........................................46

39 Flow Chart to Program Accel Time from 1.5 Seconds to 120 Seconds..................................47

40 Flow Chart to Program the Drive to Display Motor RPM......................................................... 48

41 Flow Chart to Program the Drive to Display Custom Units "012.0"......................................... 49

42 Flow Chart Showing Motor Current, Motor Voltage, and Bus Voltage

Added to Basic Display ...........................................................................................................50

43 Flow Chart to Program the Drive for Remote Operation Only................................................. 50

44 Flow Chart to Program the Drive for 50 Hz Motors .................................................................51

45 Function No. Description......................................................................................................... 54

46 IODF Layout ............................................................................................................................ 66

47 DIDF Layout ............................................................................................................................67

48 Memory Module ...................................................................................................................... 68

49 Dynamic Brake Module Connection (Case "B" Drives Only) ..................................................69

50 Sinking Mode Using NPN Transistors with Internal Power Supply

Connections and Jumper J1 Setting .......................................................................................70

51 Sinking Mode Using NPN Transistors with External Power Supply

Connections and Jumper J1 Setting .......................................................................................70

52 Sourcing Mode Using PNP Transistors with Internal Power Supply

Connections and Jumper J1 Setting .......................................................................................70

53 Sourcing Mode Using PNP Transistors with External Power Supply

Connections and Jumper J1 Setting .......................................................................................70

ITEMS INCLUDED IN THIS PACKAGE

KBDF Drive, Installation and Operation Manual, Mounting Template, and Warranty Registration Card.

UL NOTICE

115 Volt Drives

Suitable for use on a circuit capable of delivering not more than

5 kA RMS symmetrical Amperes.

115 Volts maximum.

Use copper conductors rated 75 °C.

Suitable for operation in a maximum surrounding air temperature of 40 °C.

230 Volt Drives

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 °C.

Suitable for operation in a maximum surrounding air temperature of 40 °C.

460 Volt Drives

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 °C.

Suitable for operation in a maximum surrounding air temperature of 40 °C.

1 FAMILIARIZING YOURSELF WITH THE DRIVE

To get acquainted with the operation and programming, the drive does not need to be installed

into the application or have a motor connected. In addition, drives rated for 3-phase AC Line

input, can be operated with only 1-phase.

To better understand the programmable features of the drive, review the Programmable

Function List in Section 12, on pages 54 – 63.

To familiarize yourself with the input/output features of the drive, review the Remote Operations

section, on pages 25 – 43.

To facilitate the programming procedures of the drive, review the flow charts in Section 10.4, on

pages 45 – 51.

DESCRIPTION OF

4-DIGIT DISPLAY, LEDs, KEYS, AND MAIN SPEED POTENTIOMETER

FIGURE 1

RUN

STOP

FWD REV

2 IMPORTANT PROGRAMMING INFORMATION

2.1 50 Hz MOTORS

This drive has been factory programmed to operate 60 Hz motors. For 50 Hz motor operation,

set Function 0.00 to "0001" (50 Hz Motors). See Flow Chart (Figure 44), on page 51.

2.2 MOTOR CURRENT SETTING

The motor current is factory set to the maximum drive rating, as shown in Table 3, on page 15.

In order for the Motor Overload Protection to operate properly, the drive must be reprogrammed

to the actual Motor Nameplate Current (see Function 0.01). Do not exceed the drive's maximum

current rating. See Flow Chart (Figure 37), on page 45.

Model KBDF-27D:

 With 208/230 Volt 50/60 Hz AC Line input, the maximum current rating is 6.7 Amps

(2 HP (1.5 kW)). This is the factory setting of motor current.

 With 115 Volt 50/60 Hz AC Line input, the maximum current rating is 5.5 Amps

(1½ HP (1.13 kW)).

Model KBDF-29:

 With 208/230 Volt 50/60 Hz 3-phase AC Line input, the maximum current rating is 9.0 Amps

(3 HP (2.25 kW)).

 With 208/230 Volt 50/60 Hz 1-phase AC Line input, the maximum current rating is 6.7 Amps

(2 HP (1.5 kW)).

3 IMPORTANT APPLICATION INFORMATION

3.1 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

FIGURE 2

MAXIMUM ALLOWED

MOTOR TORQUE VS. SPEED

range at full torque. Therefore, it is

necessary to reduce motor load as speed is

decreased. See Figure 2.

Note: Some fan-cooled motors can be used

over a wider speed range. Consult the motor

manufacturer for details.

Inverter duty and most Totally Enclosed Non-Ventilated (TENV) motors can provide full rated

torque over an extended speed range without overheating.

It is recommended that the drive be used with Inverter Duty or TENV motors.

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 3.14). Do not use motor if the motor current exceeds the nameplate rating.

3.2 ELECTRONIC MOTOR OVERLOAD PROTECTION

The drive contains Modified I

t Overload Protection (UL approved as an overload protector for

motors). 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 Programming Information (Section 2.2), on page 7). See

Table 3, on page 15. See Function 0.01, on page 55.

Standard I

t 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 the Motor Nameplate Rated Current, the I

t 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.

4 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 fires,

in this product or products used with this product, such as electric motors, switches,

coils, solenoids, and 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 8/2012)

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 RFI Filters & Chokes Selection Guide D-321 (Part No. A42027) for the

selection of filters to meet the Industrial or Residential Standard. Additional shielded cable

and/or AC Line cables may be required.

5 INTRODUCTION

Thank you for purchasing the KBDF Digital AC Drive. KB Electronics, Inc. is committed to

providing total customer satisfaction by providing quality products that are easy to install and

operate.

The KBDF Series of Digital AC Drives are housed in IP-20 enclosures. They are designed to

operate 1/8 thru 5 HP 208 – 230 and 400/460 Volt 50 & 60 Hz 3-phase AC and 1-phase PSC

induction motors.

Flux Vector Control provides high torque, low noise, and excellent load

regulation over a wide speed range. Adjustable Linear Acceleration and Deceleration make the

drive suitable for soft-start applications.

Due to its user-friendly design and simple to use and understand instruction manual, the KBDF

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 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.

The 8 LEDs provide indication of the drive’s status and operating mode. When used with

process control, the Local/Remote Key can be used to switch from process control to manual

control if a process fault occurs.

The on-board memory can store up to 4 programs and the optional Memory Module can store

an additional 4 programs for cloning and archiving.

Main features include adjustable RMS Current Limit and I

t Motor Overload Protection.2 Power

Start™ delivers over 200% motor torque to ensure startup of high frictional loads and

programmable Injection Braking provides rapid motor stop. Electronic Inrush Current Limit

(EICL™) eliminates harmful AC Line inrush current, allowing the drive to be AC Line switched. A

Multi-Function 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. The drive also contains AC

Line Phase Loss Protection.

The drive is suitable for machine or variable torque (HVAC)

applications.

For Remote Operation, a removable cover allows access to Multi-Function Input Terminals,

Analog Inputs/Outputs, and Multi-Function Output Relay Contacts. The Potentiometer can be

used to adjust motor speed in lieu of the built-in keypad.

Optional accessories include IODF Input/Output Multi-Function Expansion Module, DIDF

RS-232 and RS-485 Modbus RTU Communication Module, Plug-In Memory Module and PC

Windows® based programming software.

Notes: 1. PSC motor operation requires OEM software – contact our SalesDepartment. 2. UL

approved as an electronic overload protector for motors. 3. Models KBDF-23P, 24P, 27P, 29,

42, 43, 45, 48 contain AC line Phase Loss Protection.

5.1 STANDARD FEATURES

● Simplified Programming: Programmable parameters are organized into easy-to-understand

intuitive groups. Factory programming available.

● Local/Remote Operation: When used with process control, the Local/Remote Key can be

used to switch from process control to manual control if a process fault occurs.

● Built-In EMC Filter

: Complies with CE Council Directive 89/336/EEC Class A Industrial

Standard. Reduces the footprint and cost compared to an external filter. See Note 1.

● Memory Module

: The optional Memory Module can store up to 4 programs for cloning and

archiving. The drive can also store up to 4 programs.

● Contactor Style Feed-Throughs: Provides top entry AC power connections and bottom entry

motor connections. Space saving design easily replaces contactors and provides simplified

panel wiring and installation.

● Current and Torque Limit: Current and torque limiting in motoring and braking quadrants.

Automatic extending of Accel and Decel eliminates tripping caused by rapid acceleration and

deceleration of high inertial loads. Spin Start operation catches a spinning load and allows a

smooth return to the set motor speed.

● 4-Digit Display, 8 status LEDs, and Easy-to-Use Multi-Function Keypad: Provides readout

of drive operating parameters and programming functions, indication of drive status and

operating modes.

● Inputs/Outputs: 7 Multi-Function Inputs with sink or source mode control logic, 2 Analog

Inputs, 2 Multi-Function Output Relays, 1 Analog Output, and External Power Supply Input. All

control inputs are isolated from the AC Line. 7 Preset Frequencies. Remote Start/Stop, and

Forward/Reverse Control. NPN or PNP Inputs can be used for sinking or sourcing. Some

features require the optional IODF Input/Output Multi-Function Expansion Module.

● Built-In Potentiometer: Adjusts set motor speed in lieu of the keypad.

● Custom Programming for OEM Applications: Provides out-of-the-box operation.

Notes: 1. Models KBDF-23F, 24F, 27F contain a built-in Class A RFI (EMI) AC Line Filter.

2. Optional Accessory.

5.2 PERFORMANCE FEATURES

● High Performance Sensorless Flux Vector Control with Static Auto Tuning: Provides

excellent speed regulation with high torque loads throughout the entire speed range. Auto

energy savings at light loads. Smooth motor torque.

● Library of Advanced Algorithms: Custom programming and PLC functions for OEM

applications.

● Power Start™: Provides more than 200% starting torque, which ensures startup of high

frictional loads.

● Speed Range: Full torque control over a 50:1 speed range.

● Built-In PID with Sleep/Wake and Inverse Functions: Control loop for constant process

control of flow, pressure, level, and temperature. Requires optional IODF Input/Output Multi-

Function Expansion Module.

● Serial Communication: Setup and control via RJ45 Modbus RTU port provides a low-cost

networking solution. DIDF required.

● GFCI Operation: Tripless operation with GFCIs. (May cause increased audible motor noise.)

5.3 PROTECTION FEATURES

● Motor Overload (I

t) with RMS Current Limit: Provides motor overload protection which

prevents motor burnout and eliminates nuisance trips. UL approved as an electronic overload

protector for motors.

● Electronic Inrush Current Limit (EICL™): Eliminates harmful inrush AC Line current during

startup and allows rapid start with AC Line.

● Short Circuit: Shuts down the drive if a short circuit occurs at the motor (phase-to-phase).

● AC Line Phase Loss Protection: Shuts down the drive if one of the AC Line input phases is

disconnected. Models KBDF-23P, 24P, 27P, 29, 42, 43, 45, 48 only.

● 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.

TABLE 1

OPTIONS

Option Part No. Description

IODF Input/Output Multi-

Function Expansion Module

9646

DIDF RS-232 and RS-485

Modbus RTU

Communication Module

9647

Memory Module 9634

Dynamic Brake Module XXXX

Drive-Link™ Programming

Kit

XXXX

Provides additional input/output and Multi-Function

Relay. Increases the functionality of the standard

input/output of the drive.

Allows direct communication between the drive and

Modbus RTU protocol. Uses RS-232 and RS-485

Modbus RTU Communication Module. (Required for

Drive-Link™.)

The optional plug-in memory module can store up to 4

programs for cloning and archiving. This is in addition

to the (4) on-board programs.

Provides dynamic braking of the motor. Externally

mounted. Case "B" drives only.

PC Windows® based programming software. Includes

DIDF Modbus Communication Module

Custom Programming for

OEMs

Our Engineering staff will evaluate your application and

provide a pre-programmed drive ready to use out-of-

──

the-box. The design can incorporate PLC functions,

torque control, multi-speed, and PID operation.

Contact our Sales Department.

GENERAL PERFORMANCE SPECIFICATIONS

TABLE 2

Factory

Description Specification

115 Volt AC Line Input Operating Range (Volts AC, 50/60 Hz)

208/230 Volt AC Line Input Operating Range (Volts AC, 50/60 Hz)

400/460 Volt AC Line Input Operating Range (Volts AC, 50/60 Hz)

Maximum Load (% of Current Overload for 2 Minutes)

Switching Frequency (kHz)

Voltage Following Signal Input Range (Volts DC)

Current Following Signal Input Range (mA DC)

PWM Following Signal Input Range (kHz / % Duty Cycle)

Analog Output (Volts DC)

Output Frequency Resolution (Hz)

Minimum Operating Frequency at Motor (Hz)

Acceleration Time (Seconds)

Deceleration Time (Seconds)

Speed Range (Ratio)

Speed Regulation (30:1 Speed Range, 0 – Full Load) (% Base Speed)

115 (± 15%) ──

208 (-15%) / 230 (+15%) ──

380 (-15%) – 460 (+15%) ──

150 ──

8, 10, 12, 14, 16 8

0 – ±5, 0 ±10 0 – 5

4 – 20, 0 – 20 ──

0.15 – 1 / 0 - 100 ──

0 – 5 ──

0.06 ──

0.3 ──

0.1 – 180.0 1.5

0.3 – 180.0 1.5

50:1 ──

2.5 ──

Setting

Overload Protector Trip Time for Stalled Motor (Seconds) 6 ──

115 Volt AC Line Input Undervoltage/Overvoltage Trip Points (± 5%) (Volts AC)

208/230 Volt AC Line Input Undervoltage/Overvoltage Trip Points (± 5%) (Volts AC)

400/460 Volt AC Line Input Undervoltage/Overvoltage Trip Points (± 5%) (Volts AC)

Multi-Function Relay Output Contact Rating (Amps at 30 Volts DC, 125 Volts AC, 250 Volts AC)

Operating Temperature Range (°C / °F)

Operating Humidity Range (% Relative, Non-Condensing)

Storage Temperature (°C / °F)

76 – 141 ──

151 – 282 ──

302 / 567 ──

1, 0.5, 0.25 ──

0 – 40 / 32 – 104 ──

0 – 95 ──

-25 – +85 / -13 – +185 ──

Notes: 1. Dependent on motor performance. 2. Do not operate the drive outside the specified

AC Line input voltage operating range.

TABLE 3

ELECTRICAL RATINGS

AC Line Input Output Net Wt.

Model No.

Part

No.

Maximum

Horsepower

(HP (kW))

Volts AC

(50/60 Hz)

Maximum

Current

(Amps AC)

Phase (Ф)

KBDF-13 9623 0.5 (0.37) 115 1 9.6 15 230 2.4

KBDF-23 9688 0.5 (0.37) 208/230 1 6 10 230 2.4

KBDF-23F1 9691 0.5 (0.37) 208/230 1 7 10 230 2.4

KBDF-23D 9673 0.5 (0.37)

115 1 9.6 15

208/230 1 6 10

KBDF-23P2 9694 0.5 (0.37) 208/230 3 3.1 10 230 2.4

KBDF-14 9624 1 (0.75) 115 1 16 20 230 4.0

KBDF-24 9689 1 (0.75) 208/230 1 10 15 230 4.0

Fuse or

Circuit

Breaker

Rating

(Amps AC)

Maximum

Voltage

(Volts AC)

Maximum

Continuous

Load Current

(RMS Amps/Phase) lbs kg

230 2.4 2.25 1.05

Case Size

KBDF-24F1 9692 1 (0.75) 208/230 1 10 15 230 4.0

KBDF-24D 9674 1 (0.75)

115 1 16 20

208/230 1 10 15

230 4.0 2.75 1.25

KBDF-24P2 9695 1 (0.75) 208/230 3 5.2 10 230 4.0

KBDF-164 9625 1.5 (1.13) 115 1 22 25 230 5.5

KBDF-274 9690 2 (1.5) 208/230 1 17 20 230 6.7

KBDF-27F

KBDF-27D4 9675

KBDF-27P

KBDF-29

KBDF-42

KBDF-45

KBDF-48

1,4

9693 2 (1.5) 208/230 1 17 20 230 6.7

1.5 (1.13) 115 1 22 25 230 5.5

2 (1.5) 208/230 1 17 20 230 6.7

2,4

9696 2 (1.5) 208/230

2,4

9641

2,4

9642 1 (0.75) 400/460 3 2.6 5 400/460 2.0 4.50 2.05

2 (1.5) 208/230 1 17 20 230 6.7

3 (2.25) 208/230 3 11.7 15 230 9.0

1 17 20 230

3 8.7 15 230

6.7

KBDF-432 2 (1.5) 400/460 3 3.8 5 400/460 3.3 4.50 2.05

2,4

9643 3 (2.25) 400/460 3 5.3 10 400/460 4.6 4.50 2.05

2,4

9644 5 (3.75) 400/460 3 11 15 400/460 8.3 4.50 2.05

2.85 1.30

4.65 2.10

Notes: 1. Models KBDF-23F, 24F, 27F contain a built-in Class A RFI (EMI) AC Line Filter.

2. Models KBDF-23P, 24P, 27P, 29, 42, 43, 45, 48 contain AC Line Phase Loss Protection.

3. See Figures 4 and 5, on pages 18 and 19, for the mechanical specifications. 4. Models

KBDF-16, 27, 27D, 27F, 27P, 29, 42, 45, 48 contain a built-in cooling fan.

6 DRIVE LAYOUT

See Figure 3 for the Drive Layout. See Table 4, on page 17, for description of the Keypad,

4-Digit Display, LEDs, and Potentiometer.

The drive contains 8 LEDs to provide indication of the drive’s status and operating mode (REM,

LCL, FWD, REV, STOP, OL, PGM, Hz). The Keypad is used for Local Operation of the drive.

For Remote Operation see Function Group 2, on page 57. To operate the drive using the

Potentiometer, set Function 2.00 to "0001".

WARNING! Do not depend on the LEDs or the 4-Digit Display to no longer be

illuminated as a guaranteed power off condition. Be sure that the main power switch or

circuit breaker is in the "OFF" position before servicing the drive.

FIGURE 3

DRIVE LAYOUT

(SHOWN WITH FRONT COVER REMOVED)

(SEE DESCRIPTIONS, ON PAGE 17)

RUN

STOP

FWD

REV

MEMORY

MODULE

DESCRIPTIONS OF 4-DIGIT DISPLAY, LEDs, KEYS, AND POTENTIOMETER

TABLE 4

No. Feature Description

4-Digit Display: Provides readout of drive status, operating parameters, and faults.

REM LED: Indicates that the drive is set for Remote Operation.

RUN

STOP

FWD

REV

LCL LED: Indicates that the drive is set for Local (Keypad) Operation.

FWD LED: Indicates that the drive is set for Forward Direction.

REV LED: Indicates that the drive is set for Reverse Direction.

STOP LED: Indicates that the drive is in Stop Mode.

OL LED: Indicates that the drive is in Overload.

PGM LED: Indicates that the drive is in Program Mode.

Hz LED: Indicates that the display is set to show Drive Output Frequency

(in Hz).

RUN / STOP Key: Starts and Stops the drive.

FWD/REV Key: Changes motor direction.

Up Key: Increases Output Frequency, Set Frequency, Function Number

Value, and Code setting.

Down Key: Decreases Output Frequency, Set Frequency, Function Number Value, and Code setting.

Left Shift / Reset Key: Moves the changeable digit or Resets the drive after a fault has cleared.

LOCAL / REMOTE Key: Used to toggle between Local (Keypad) Operation or Remote Operation. When in Local (Keypad) Operation, the LCL LED will remain illuminated. When in Remote Signal Operation, the REM LED will flash 1 second on and 1 second off.

PROGRAM / DISPLAY Key: Puts the drive into Program Mode or Display Mode. If pressed while Set Frequency is displayed, the previously entered Function Number will be shown. If pressed while Function Number is displayed, the Set Frequency will be shown. When more than one display function is enabled, the key is used to toggle between displays.

READ / ENTER Key: Reads or Enters a Function Value or Code Setting.

Potentiometer: Sets the Drive Output Frequency in lieu of the Keypad. To

change the Keypad for Potentiometer Operation, set Function 2.00 to code "0001".

7 MOUNTING INSTRUCTIONS

It is recommended that the drive be mounted vertically on a flat surface with adequate

ventilation. Leave enough room above and below the drive to allow for AC Line, motor

connections, and any other connections that are required. 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 proper heat dissipation so that the

ambient temperature does not exceed 40 °C (104 °F) at full rating. See Figure 4, below, and

Figure 5, on page 19.

WARNING! DO NOT USE THIS DRIVE IN AN EXPLOSIVE ENVIRONMENT. AN

EXPLOSION CAN CAUSE SERIOUS OR FATAL INJURY. THIS DRIVE IS NOT EXPLOSION

PROOF.

FIGURE 4

CASE "A" DRIVES MECHANICAL SPECIFICATIONS (INCHES / mm)

0.225

4X Ø

5.72

RUN

STOP

FWD REV

KBDF SERIES

2.80

71.1

3.40

86.4

6.785 172

7.25 184

5.10 130

CASE "B" DRIVES MECHANICAL SPECIFICATIONS (INCHES / mm)

FIGURE 5

0.225

4X Ø

5.72

RUN

STOP

FWD REV

7.357 7.825 187

199

KBDF SERIES

3.80

96.5

4.40 112

6.25 159

8 ELECTRICAL CONNECTIONS

The drive is designed with contactor-type feed-throughs to facilitate wring of the AC Line input,

Motor, and Ground connections, as shown in Figures 7 – 13, on pages 22 – 24. See Table 5, on

page 22.

The removable cover allows access to the terminal blocks and jumpers for wiring and setting up

the drive for Remote Operation in lieu of the Keypad (Local Operation).

Note: Wire the control in accordance with the National Electrical Code requirements and other

local codes that may apply to the application.

WARNING! HIGH VOLTAGE! Read Safety Warnings, on page 9, before using the

drive. Disconnect the main power before making connections to the drive. To avoid

electric shock, be sure to properly ground the drive.

Application Notes:

1. To avoid erratic operation, do not bundle AC Line input and motor wires with each other. 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.

2. 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 used as a

disconnect so that each ungrounded conductor is opened. For fuse or circuit breaker selection,

see Table 3, on page 15. Also see Section 8.2, on page 24.

3. If operation with a Ground-Fault Circuit-Interrupter (GFCI) is required, see Function 0.04, on

page 55.

GENERAL CONNECTION DIAGRAM

FIGURE 6

Notes: 1. Multi-Function Input Terminals (MFIT 1 – 5 on TB1 of the drive) are factory set for

N.O. Contacts or NPN Transistors (J1 set to the "N.O. / NPN" position), which use the internal

power supply. For NPN Transistors, which use an external power supply (5 – 24 Volts DC), set

Jumper J1 to the "EXT" position. For PNP Transistor circuits, which use the internal power

supply or an external power supply (5 – 24 Volts DC), set Jumper J1 to the "PNP" position.

2. Multi-Function Output Relay Contact Ratings: 1 Amp at 30 Volts DC, 0.5 Amp at 125 Volts

AC, and 0.25 Amp at 250 Volts AC. 3. Multi-Function Input Terminals (MFIT 6 – 7 on TB1 of the

IODF) only accept N.O. Contacts or NPN Transistors (which use the internal power supply).

DRIVE TERMINAL BLOCK WIRE AND TIGHTENING TORQUE SPECIFICATIONS

TABLE 5

Maximum Wire Size

(Cu)

Description Location Model

Multi-Function Input

Terminals and Signals In/Out

TB1 on Drive and IODF

(Under Cover)

(2)

(1)

AWG mm2Lbs-in kg-cm

All 16 1.31 2.7 3.1

Recommended

Tightening

Torque

Multi-Function

Output Relay

AC Line Input and Ground Top of Drive

Motor and Ground Bottom of Drive

Motor, Ground, and Dynamic

Brake Module

(3)

TB2 on Drive

and TB3 on IODF

(Under Cover)

Bottom of Drive

(2)

Case

16 1.31 2.6 2.9

All

14 2.08 7 8.1

"A"

12 3.31 12 14

"B"

14 2.08 7 8.1

"A"

12 3.31 12 14

"B"

Notes: 1. Case "A" Drives: Models KBDF-13, 23, 23F, 23D, 23P, 14, 24, 24F, 24D, 24P, 16, 27,

27F, 27D, 27P. Case "B" Drives: Models KBDF-29, 42, 43, 45, 48. 2. The IODF is an optional

accessory for all models. 3. The Dynamic Brake Module is an externally mounted optional

accessory for Case "B" drives only.

8.1 AC LINE INPUT AND GROUND

Connect the AC Line input and ground (earth) to the drive as shown in Figures 7 – 13, on pages

22 – 24. Connect the Ground (earth) to the drive chassis Terminal "GND".

Note: The rated AC Line voltage of the drive must match the actual AC Line input voltage. See

Electrical Ratings, Table 3, on page 15.

Models KBDF-13, 14, 16:

Designed for 115 Volt

1-phase AC Line input. Connect the AC Line input

hot lead to Terminal "L1" and the neutral lead to

MODELS KBDF-13, 14, 16

FIGURE 7

AC LINE AND GROUND CONNECTIONS

Terminal "N". See Figure 7.

Note: 230 Volts AC will be applied to the motor

with 115 Volt AC Line input.

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