Küenle KFU 2 Series Programming manual

Quick Start
Instructions
Frequency Inverter
Series KFU 2- / 4-
0,55 to 3,0 kW – 230 V – KFU 2-
0,55 to 132 kW – 400 V – KFU 4-
KN 621.1401
e

KFU 2-/4-
1
This documentation describes the first steps for an easy commissioning of the frequency inverters KFU 2-/4-…
The labels on the housing and behind the upper cover helps to identify the devices of the KFU series.
Warning!
The safety instructions and information on use contained in this documentation and in the
operating instructions manual on the attached CD must be complied with strictly during
installation and commissioning of the frequency inverter.
According to the application and optional components refer to additional manuals on CD.
Non-compliance with the precaution described will result in death, serious injury or material
damage.
The present documentation is applicative for qualified staff who is familiar with the installation,
assembly, commissioning and operation of the frequency inverter and has the proper
qualification for the job.
Persons who are not familiar with the operation of the frequency inverter and children may not
have access to the device.
Commissioning and start of operation is not allowed until it has been verified that the machine
meets the requirements of the EC Machinery Directive 98/37/EEC and EN 60204.
When working at the frequency inverter, comply with the applicable standards BGV A2 (VBG 4),
VDE 0100, standards for equipment of heavy current installations such as EN 50178 and other
national directives.
Before commissioning and the start of the operation fix all covers and check the terminals.
Check the additional monitoring and protective devices according to EN 60204 and applicable
the safety directives (e.g. Working Machines Act, Accident Prevention Directives etc.). No
connection work may be performed, while the system is in operation.

KFU 2-/4-
2

KFU 2-/4-
3
TABLE OF CONTENTS
1Safety instructions for “Safe torque off” function (STO)............................................... 5
1Mechanical Installation.................................................................................................. 7
2Electrical Installation................................................................................................... 11
2.1................................................................................................................................................EMC Information
........................................................................................................................................................... 11
2.2...........................................................................................KFU 2- (up to 3.0 kW) and 401 (up to 4.0 kW)
........................................................................................................................................................... 11
2.3.......................................................................................KFU 2- (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW)
........................................................................................................................................................... 12
2.4.................................................................................................................................KFU 4- (18.5 to 30.0 kW)
........................................................................................................................................................... 12
2.5.................................................................................................................................KFU 4- (37.0 to 65.0 kW)
........................................................................................................................................................... 13
2.6........................................................................................................................KFU 4- (75.0 kW to 132.0 kW)
........................................................................................................................................................... 14
2.7..............................................................................................................................................Control Terminals
........................................................................................................................................................... 15
2.7.1External 24 VDC voltage supply................................................................................................. 16
3Commissioning via the control unit KP500.................................................................. 17
3.1...............................................................................................................................................Functions of keys
........................................................................................................................................................... 17
1.1.....................................................................................................................................Guided Commissioning
........................................................................................................................................................... 18
4Parameter settings....................................................................................................... 21
5Actual values................................................................................................................23
6Control Unit messages ................................................................................................. 25
6.1...........................................................................................Warning and error messages during operation
........................................................................................................................................................... 26
6.2...................................................................Warning and error messages during Guided commissioning
........................................................................................................................................................... 27

KFU 2-/4-
4

KFU 2-/4-
5
1Safety instructions for “Safe torque off” function (STO)
The function “Safe torque off” (STO) is a function-safeguard which protects persons and avoids material damage
in professional engineering and installation conditions as well as intended use. The function does not switch the
machine to a de-energized state.
Install an emergency-stop device according to EN 60204 to de-energize the machine, for example for
maintenance work.
For personal safety and to prevent material damage comply with the following instructions.
Warning!
Improper installation of the safety technique can cause an uncontrolled starting of the drive. This
can result in death, serious injury or material damage.
Only qualified staff may install and commission the safety functions.
The STO (Safe torque off) function does not allow emergency switch-off according to standard
EN 60204. Emergency switch-off can be realized by a mains contactor installation.
Emergency switch-off according to EN 60204 must be functioning in all operation modes of the
frequency inverter. The reset of emergency switch-off may not cause an uncontrolled starting of
the drive.
The drive restarts if the function STO is not requested any more. According to EN 60204 the drive
may only start after an acknowledgement.
Without a mechanical brake the drive might not stop immediately; but coast down. Risk of injury or
material damage has to be prevented by providing additional safety devices.
If risk of injury is possible after the motor power supply is switched off by the STO function the
access to the danger area must be locked. The access to the danger area must be locked until the
drive is come to a standstill.
Check the safety function in periodic maintenance according to your risk assessment. We
recommend an inspection latest after one year.
The STO function is one-fail-safe. No single fault or component failure can cause a disabled drive
to produce motor shaft torque. Only in extremely unlike combinations of component faults the
motor shaft could move jerky with sudden acceleration (maximum 180°/number of pole pairs, for
example jerky movement of 90° for 4-pole motor, 180°/2) and produce torque. It must be
checked, if this behaviour can cause a dangerous machine movement.
If the safety function STO is applied comply with the special safety-, installation- and operating
instructions.
Warning! Dangerous voltage!
The safety function „Safe torque off“ is practical only for mechanical work on driven machines, but not
for work on live-line voltage-carrying components.
Before working (maintenance) on live-line voltage-carrying components electrical isolation from
mains supply is necessary by a main switch.
When the 24VDC power supply is switched off the mains voltage is still alive at the DC link circuit.
Although the motor is de-energized, in standstill or coasts down the motor terminals live with high
voltage.
The motor is not electrically isolated from the DC link circuit of the frequency inverter if the „Safe
torque off“-function is activated and the motor is de-energized. High voltage may live at the motor
terminals.
Do not touch voltage-carrying contacts.
Note:
According to the EU Machinery Directive 98/37/EG the machine must be subjected to a risk
assessment, carried out by the manufacturer. In this assessment the effect of the safety features in
the control system will be taken into account when looking at the overall risk of each possible
hazardous event. Standard EN 1050 – Principles for risk assessment – describes the information,
which is necessary for risk assessment.

KFU 2-/4-
6

KFU 2-/4-
7
1Mechanical Installation
Warning!
During installation the following installation and safety instructions as well as the instructions in the
additional manuals on CD must be complied with.
During assembly, make sure that no foreign particles (e.g. filings, dust, wires, screws, tools) can
get inside the frequency inverter.
Mount the devices with sufficient clearance to other components so that the cooling air can
circulate freely. Avoid soiling by grease and air pollution by dust, aggressive gases, etc.
KFU 2- (up to 3.0 kW) and KFU 4- (up to 4.0 KW)
b
b1
a1
aa2
c
c1
x
x
b1
x 100 mm
Insert the long side of the fixing plate in
the heat sink.
Screw the fixing plate to the mounting
plate.
KFU 2- (4.0 to 9.2 kW) and KFU 4- (5.5 to 15.0 kW)
b
b1
a
a1 a2
c
x
x
c1
x 100 mm
top M4x20
bottom M4x60
Screw the fixing brackets to the heat sink
of the frequency inverter and the assembly
panel.

KFU 2-/4-
8
KFU 4- (18.5 to 30.0 kW)
c
c1
a
a1 a2
x
b
b1
x
x 100 mm
top M4x20 bottom M4x70
Screw the fixing brackets to the heat sink
of the frequency inverter and the assembly
panel.
KFU 4- (37.0 to 65.0 kW)
a
a1
a2
x
b
b1
x
c
c1
x 100 mm
top M5x20 bottom M5x20
Screw the fixing brackets to the heat sink
of the frequency inverter and the assembly
panel.
Dimensions without optional components:
Dimensions in mm Installation dimensions in mm
kW a b c a1 a2 b1 c1
KFU 2-
0.55...1.1 190 60 178 210...230 260 30 133
1.5...3.0 250 60 178 270...290 315 30 133
4.0…5.5 250 100 200 270...290 315 12 133
7.5…9.2 250 125 200 270...290 315 17.5 133
KFU 4-
0.55...1.5 190 60 178 210...230 260 30 133
1.85...4.0 250 60 178 270...290 315 30 133
5.5...9.2 250 100 200 270...290 315 12 133
11.0...15.0 250 125 200 270...290 315 17.5 133
18.5...30.0 250 200 260 270…290 315 20 160
37.0…65.0 400 275 260 425…445 470 20 160

KFU 2-/4-
9
KFU 4- (75.0 to 132.0 kW)
a
b
c
c1
c2
c3
b1
b2
b3
a1
x
x
x300 mm
x300 mm
The diameter of the mounting holes is 9 mm.
Screw the heat sink back panel of the frequency inverter to the assembly panel.
Dimensions without optional components:
Dimensions in mm Installation dimensions in mm
ACTIVE
Cube 401
kW a b c a1 b1 b2 b3 c1 c2 c3
75.0…132.0 510 412 351 480 392 382 342 338 305 110

KFU 2-/4-
10

KFU 2-/4-
11
2Electrical Installation
Danger!
When the frequency inverter is disconnected from power supply, the mains, DC-link voltage and
motor terminals may still be live for some time. Wait for some minutes until the DC link
capacitors have discharged before starting to work at the unit.
The unit may only be connected with the power supply switched off.
Make sure that the frequency inverter is discharged.
2.1 EMC Information
The frequency inverters are designed for operation in industrial applications. Electromagnetic interference can be
avoided by the following precautions:
Install the frequency inverters and commutating chokes on a metal mounting panel. Ideally, the mounting
panel should be galvanized.
Provide proper equipotential bonding within the system or the plant. Plant components such as control
cabinets, control panels, machine frames, etc. must be connected by means of PE cables.
Connect the frequency inverter, the commutating choke, external filters and other components to an earthing
point via short cables.
Keep the cables as short as possible and avoid sagging cables for installation.
Contactors, relays and solenoids in the electrical cabinet are to be provided with suitable interference
suppression components.
The mains connection cable must be installed separate from the control, data and motor cables.
Connect the shield of the motor cable to ground potential properly on both sides by using shield clamps.
Connect the shield of the control cables to ground potential properly on both sides.
2.2 KFU 2- (up to 3.0 kW) and 401 (up to 4.0 kW)
Mains power connection, X1
X1
1ph / 230V AC
+
-
L1
L2 L3L1
NPE
3ph / 230V AC
3ph / 400V AC
+
-
L1
L2 L3L1
L2 L3 PE
2ph / 230V AC
+
-
L1 L2 PE
L2 L3
L1
550 W … 1.1 kW
2ph / 230V AC1ph / 230V AC
1.5 kW … 3.0 kW
L1 N PE
+
-
L1 L2 L3L1
3ph / 230V AC
3ph / 400V AC
PE
1.5 kW … 3.0 kW 1.5 kW … 4.0 kW
+
-
L1 L2 L3L1
L1 L2 PE L1
+
-
L1 L2 L3L1
L2 L3
1
With a mains current above 10 A, the mains power connection 230 V 1ph/N/PE and the mains power
connection 230 V 2ph/N/PE are to be done on two terminals.
Motor power connection, X2
X2
VW
U
Delta connection
VW
U
Star connection
V W
U
Rb2
Rb1
M
3~
Use the terminals Rb1 and Rb2 to connect a brake resistor.

KFU 2-/4-
12
2.3 KFU 2- (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW)
Mains power connection, X1
X1
+
-
L1
L2 L3L1
L2 L3 PE
3ph / 230V AC
3ph / 400V AC
X1
A
C
T
201
-
18
(
4.
0
kW
)
:
+
-
L1
L2 L3L1
NPE
1ph / 230V AC
X1
KFU 2--18 (4.0 kW): 1- und 3-phase connection is possible
Motor power connection, X2
X2
VW
U
Delta connection
VW
U
Star connection
X2
VW
U
Rb2
Rb1
M
3~
Use the terminals Rb1 and Rb2 to connect a brake resistor.
2.4 KFU 4- (18.5 to 30.0 kW)
Mains power connection, X1
X1
+
-
L1
L2 L3L1
L2 L3 PE
3ph / 400V AC
X
1
2.5 Nm
22.1 lb-in
Motor power connection, X2
X2
VW
U
Delta connection
VW
U
Star connection
X
2
VW
U
Rb2
Rb1
M
3~
2.5 Nm
22.1 lb-in
Use the terminals Rb1 and Rb2 to connect a brake resistor.

KFU 2-/4-
13
2.5 KFU 4- (37.0 to 65.0 kW)
Mains power connection, X1
X1
+
-
L1
L2 L3L1
L2 L3 PE
3ph / 400V AC
X1
8 Nm
70.8 lb-in
Motor power connection, X2
X2
VW
U
Delta connection
VW
U
Star connection
X
2
VW
U
Rb2
Rb1
M
3~
8 Nm
70.8 lb-in
Use the terminals Rb1 and Rb2 to connect a brake resistor.

KFU 2-/4-
14
2.6 KFU 4- (75.0 kW to 132.0 kW)
VW
L1 L2 L3
Rb2 ZK+
ZK-
Motor power connection
W
U
M
3~
WU
Delta connection
WU
Star connection
Connection of a brake resistor with temperature switch
b
T1
ZK+ Rb2
T
2
Rb2
ZK+
Terminal Rb2 for a brake resistor is optional.
Mains power connection
L2 L3L1
L2 L3 PE
3ph / 400V AC
10 Nm
88.5 lb-in
Threaded bolt M8x20

KFU 2-/4-
15
2.7 Control Terminals
Caution!
Switch off power supply before connecting or disconnecting the control inputs and outputs.
S7IND
S1OUTD
MFO1A
+10 V/4 mA
MFI1A
GND 10 V
1
2
3
4
5
6
7
X
2
1
0
A
+20 V
STOA
STOB
GND 20 V
S1IND
S2IND
S3IND
S4IND
S5IND
S6IND
X210B
1
2
3
4
5
6
7
V
+
-
+
-
24 V
ext.
X10
1
2
3
S3OUT
Control terminal X210A Control terminal X210B
X210A.1 20VDC voltage output (Imax=180mA) or
input for external supply voltage
24VDC ±10%
X210B.1 Digital input
1)
X210A.2 Ground 20V/ Ground 24V (ext.) X210B.2 Digital input STOB
(2nd secure disable line)
safety-related
X210A.3 Digital input STOA
(1st secure disable line)
safety-related X210B.3 Digital output
1)
X210A.4 Digital inputs
1) X210B.4 Multi-function output 1) (voltage
proportional to actual frequency, factory
setting)
X210A.5 X210B.5 Supply voltage +10 V for reference value
potentiometer, (Imax=4mA)
X210A.6 X210B.6 Multi-function input
1) (speed reference
value 0 … +10V, factory setting)
X210A.7 X210B.7 Ground 10V
Relay output X10
S3OUT Feedback signal
1) The control terminals are freely programmable.
Activation „Safe torque off“: Contacts at X210A.3 and X210B.2 opened.
Release of frequency inverter: Contacts at X210A.3 and X210B.2 closed.
Note:
The listed assignment of functions to control terminals is the factory setting in the configurations 110 and 410
(setting of parameter Configuration 30 to the value 110 or 410). The functions can be assigned to the control
terminals freely programmable. Further configurations are listed in the operating instructions manual.

KFU 2-/4-
16
Technical Data of the control terminals
Digital inputs (X210A.3 … X210B.2): Low signal: DC 0 V … 3 V, High signal: DC 12 V … 30 V,
input resistance: 2,3 kΩ, response time: 2 ms (STOA and STOB: 10 ms), PLC-compatible
Digital output (X210B.3): Low signal: DC 0 V… 3 V, High signal: DC 12 V … 30 V,
maximum output current: 50 mA, PLC-compatible
Multi-function output (X210B.4):
Analog signal: DC 19 V… 28 V, maximum output current: 50 mA, pulse width modulated (fPWM= 116 Hz),
Digital signal: Low signal: DC 0 V… 3 V, High signal: DC 12 V … 30 V, maximum output current: 50 mA,
PLC-compatible,
Frequency signal: output voltage: DC 0 V … 24 V, maximum output current: 40 mA,
Maximum output frequency: 150 kHz
Multi-function input (X210B.6):
Analog signal: input voltage: DC 0 V … 10 V (Ri=70 kΩ), input current: DC 0 mA … 20 mA (Ri=500 Ω),
Digital signal: Low signal: DC 0 V… 3 V, High signal: DC 12 V … 30 V, response time: 4 ms, PLC-compatible
Conductor cross section:
Suitable conductor cross sections for the control terminals are:
With wire end ferrule: 0.25…1.0 mm²
Without wire end ferrule: 0.14…1.5 mm²
2.7.1 External 24 VDC voltage supply
The bidirectional control terminals X210A.1/X210A.2 can be used as voltage output or voltage input. If an
external 24 VDC voltage supply is connected to the terminals X210A.1/X210A.2 the parameterisation and
communication is possible and input and outputs are active, even if the mains voltage is switched off.
The specification of technical requirements of the external voltage supply can be found in the operating
instructions manual.
Requirements of the external voltage supply
Input voltage range 24 VDC ±10%
Input rated current Max. 1.1 A
Inrush current peak Typical: < 25 A
External fuse protection Via commercial available circuit breakers for rated current, charakteristic: slow-
acting
Safety Extra safety low voltage (SELV) according to EN 61800-5-1

KFU 2-/4-
17
3Commissioning via the control unit KP500
The optional control unit KP500 enables the parameterization, parameter display and control of the frequency
inverter. It must be connected to the front of the frequency inverter.
Note:
Further methods of commissioning (e.g. via optional communication modules) are described in the operating
instructions manual on the attached CD.
3.1 Functions of keys
Keys
RUN Start drive (alternative to control signal S2IND or S3IND). Opening the CTRL menu.
Opening the motor potentiometer function.
STOP Stop drive (alternative to control signal S2IND or S3IND). Opening the CTRL menu.
Acknowledging faults
▲▼Adjusting the output frequency in the Motor potentiometer function Pot.
Navigating in the menu structure and selecting parameters.
Increasing/decreasing of parameter values.
ENT
Reversal of the direction of rotation independent of the control signal on the terminals Clockwise
S2IND or Anticlockwise S3IND.
Opening parameters or switching to another menu within the menu structure.
Confirmation of the selected function or the parameter setting.
ESC Aborting parameter settings or switching back to the previous menu within the menu structure.
Cancelling the function or resetting the parameter value.
FUN
Switching over the key function. Access to special functions.
Changing from Internal reference value int or Motor potentiometer function Pot to the adjusted JOG-
frequency; the drive starts. Releasing the FUN key stops the drive.

KFU 2-/4-
18
1.1 Guided Commissioning
Warning!
The frequency inverter may be connected to power supply every 60 s. More frequent switch-on
operations may damage the device. Consider this for a jog operation of a mains contactor.
Disable the frequency inverter; open contacts at control inputs STOA (digital input S1IND/terminal X210A.3)
and STOB (digital input S7IND/terminal X210B.2).
Switch on mains power.
The frequency inverter carries out a self-test.
Attention!
Before starting the Guided commissioning the machine should not have been in operation because part of the
machine data depends on the operating temperature.
ENT
ENT
When the unit is in "as-delivered" condition, the guided commissioning procedure is started
automatically. After successful commissioning, the guided commissioning can be carried out
again later via the sub-menu CTRL.
Use the ENT key to switch to the CTRL sub-menu.
In the CTRL sub-menu, select the menu item "SEtUP" and confirm by pressing the ENT key.
Use the ENT key to select parameter Configuration 30.
Use the arrow keys to enter the number 110 or 410.
110: sensorless control, V/f characteristic
410: sensorless field-oriented control
If the setup was changed, the message "SEtUP" is displayed again.
Confirm this message by pressing the ENT key in order to continue the commissioning procedure.
After initialization, confirm the selected configuration by pressing the ENT key.
For parameter Motor type 369 select the connected machine.
Caution!
If the motor type is not entered correctly the drive may be damaged.
Operation mode Function
0 - Unknown The motor is not a standard type.
1 - Asynchronous Three-phase asynchronous motor, squirrel cage
2 - Synchronous Three-phase synchronous motor
3 - Reluctance Three-phase reluctance motor
10 - Transformer Transformer with three primary windings
Enter the machine data which is indicated on the type plate of the machine into the following parameters.
No. Description No. Description
370 Rated Voltage 374 Rated Cosinus Phi
371 Rated Current 375 Rated Frequency
372 Rated Speed 376 Rated Mech. Power
Use the arrow keys to select the required parameter and edit the parameter value.
Use the ENT key to confirm the selected parameter and the parameter values entered.

KFU 2-/4-
19
Attention!
The rated data of the motor must be entered according to the specifications on the rating plate for the motor
connection type used (star or delta connection). If the data entered deviate from the rating plate, the parameters
will not be identified correctly. Take the higher rated current in case of switching from star to delta connection of
the connected asynchronous motor into account.
After the machine data have been entered, the calculation or examination of the parameters is
started automatically. The display changes over to "CALC" for a short time. If the verification of
the machine data is successful, the guided commissioning procedure continues with the
identification of the parameters (measuring additional machine data).
The warning and error messages displayed during the verification process have to be observed.
To ignore the warning messages, press the ENT key. The guided commissioning is continued. However, it is
recommended that the data be checked and corrected if necessary.
To correct the entered parameter values after the warning or error message, press the ESC key. Use the
arrow keys to switch to the parameter value which is to be corrected.
While the drive is at a standstill additional machine data is measured.
The measured values are entered in the parameters automatically.
Confirm the display "PAidE" by pressing the ENT key.
After completion of the parameter identification, observe warning and error messages.
No signals are present at digital inputs S1IND (STOA) and S7IND (STOB). If signals were already
applied at the beginning of the guided commissioning, the "StO" message is not displayed.
Note:
The parameter identification feature of the frequency inverter requires the presence of signals at digital inputs
S1IND (STOA) and S7IND (STOB) for release of the power unit.
Confirm the final "rEAdY" message by pressing the ENT key.
Canceling the operation with the ESC key or withdrawing the release signal S1IND (STOA) or
S7IND (STOB) results in an incomplete take-over of the values.
Note:
In the case of higher requirements as regards the accuracy of the speed/torque control, you should carry out the
guided commissioning procedure once again under operating conditions because part of the machine data
depends on the operating temperature.
During this procedure, confirm the rated values for the machine data already entered.
Confirm the "End" display by pressing the ENT key.
The guided commissioning of the frequency inverter is terminated via a reset and the initiali-
zation of the frequency inverter. The relay output X10 signals a fault.
After successful initialization of the frequency inverter, the factory-set parameter Actual
Frequency 241 is displayed.
The drive is accelerated to the adjusted Minimum Frequency 418 (default value 3.50 Hz) by:
signals at digital inputs S1IND (STOA) and S7IND (STOB) and
start clockwise operation with positive signal edge at S2IND or
start anti-clockwise operation with positive signal edge at S3IND