Küenle KFU 2 Series User manual

Manual
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 620.1108 E

KFU 2-/4-
KN 620.1108 E 1
General Information about the Documentation
The present documentation refers to the frequency inverters KFU 2- and KFU 4- se-
ries. With their factory settings, both series of devices are suited for a wide range of
applications. The modular hardware and software structure enables customer-specific
adaptation of the frequency inverters. Applications with high functionality and dynam-
ics requirements can be realized easily.
The KFU 2-/4- series can be recognized by its label on the case and the identification
below the top cover.
(Position of ID
depends on size)
For better clarity, the documentation is structured according to the customer-specific
requirements made on the frequency inverter.
Quick Start Guide
The Quick Start Guide describe the basic steps required for mechanical and electrical
installation of the frequency inverter. The guided commissioning supports you in the
selection of necessary parameters and the configuration of the frequency inverter by
the software.
Operating Instructions
The Operating Instructions describe and document all functions of the frequency in-
verter. The parameters required for adapting the frequency inverter to specific appli-
cations as well as the wide range of additional functions are described in detail.
Application Manual
The application manual supplements the documentation for purposeful installation
and commissioning of the frequency inverter. Information on various subjects con-
nected with the use of the frequency inverter are described specific to the application.
Installation Instructions
Complementing the Brief Instructions and the Operating Instructions, the Installation
Instructions provide information on how to install and use the additional/optional com-
ponents.
If you need a copy of the documentation or additional information, contact your na-
tional representative of your supplier.

KFU 2-/4-
KN 620.1108 E 2
The following pictograms and signal words are used in the documentation:
Danger!
Danger refers to an immediate threat. Non-compliance with the precaution described
may result in death, serious injury or material damage.
Warning!
Warning refers to a possible threat. Non-compliance with the warning may result in
death, serious injury or material damage.
Caution!
Caution refers to an indirect threat. Non-compliance may result in personal or mate-
rial damage.
Attention!
Attention refers to a possible operational behavior or an undesired condition that can
occur in accordance with the reference text.
Note
Note marks information that facilitates handling for you and supplements the corre-
sponding part of the documentation.

KFU 2-/4-
3
TABLE OF CONTENTS
1General Safety Instructions and Information on Use................................................................. 9
1.1 General Information................................................................................................................ 9
1.2 Purpose of the Frequency Inverters ................................................................................... 10
1.3 Transport and Storage ......................................................................................................... 10
1.4 Handling and Installation ..................................................................................................... 10
1.5 Electrical Connection ...........................................................................................................11
1.6 Information on Use ............................................................................................................... 11
1.7 Maintenance and Service..................................................................................................... 11
1.8 Safety Instructions on Function „Safe Torque Off“ (STO) ............................................... 12
2Scope of Supply........................................................................................................................... 14
2.1 KFU 2-(up to 3.0 kW) and KFU 4- (up to 4.0 kW)................................................................ 14
2.2 KFU 2-(4.0 to 9.2 kW) and KFU 4- (5.5 to 15.0 kW)............................................................. 15
2.3 KFU 4- (18.5 to 30.0 kW) ....................................................................................................... 16
2.4 KFU 4- (37.0 to 65.0 kW) ....................................................................................................... 17
2.5 KFU 4- (75.0 to 132.0 kW) ..................................................................................................... 18
3Technical Data.............................................................................................................................. 19
3.1 General technical data..........................................................................................................19
3.2 Technical Data – Control Electronic Equipment................................................................ 20
3.3 KFU 2- (0.25 to 1.1 kW, 230 V).............................................................................................. 21
3.4 KFU 2- (1.5 to 3.0 kW, 230 V)................................................................................................ 22
3.5 KFU 2- (4.0 to 9.2 kW, 230 V)................................................................................................ 23
3.6 KFU 4- (0.25 to 1.5 kW, 400 V).............................................................................................. 24
3.7 KFU 4- (1.85 to 4.0 kW, 400 V).............................................................................................. 25
3.8 KFU 4- (5.5 to 15.0 kW, 400 V).............................................................................................. 26
3.9 KFU 4- (18.5 to 30.0 kW, 400 V)............................................................................................ 27
3.10 KFU 4- (37.0 to 65.0 kW, 400 V) ........................................................................................ 28
3.11 KFU 4- (75.0 to 132.0 kW, 400 V) ...................................................................................... 29
3.12 Operation diagrams .......................................................................................................... 30
4Mechanical Installation................................................................................................................ 31
4.1 KFU 2- (up to 3.0 kW) and 401 (up to 4.0 KW).................................................................... 31
4.2 KFU 2- (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) ................................................................. 32
4.3 KFU 4- (18.5 to 30.0 kW) ....................................................................................................... 33
4.4 KFU 4- (37.0 to 65.0 kW) ....................................................................................................... 34
4.5 KFU 4- (75.0 to 132.0 kW) ..................................................................................................... 35
5Electrical Installation ................................................................................................................... 36
5.1 EMC Information ................................................................................................................... 37
5.2 Block diagram ....................................................................................................................... 38
5.3 Optional Components .......................................................................................................... 39

KFU 2-/4-
4
5.4 Connection of Unit................................................................................................................ 40
5.4.1 Dimensioning of conductor cross-section........................................................................ 40
5.4.1.1 Typical cross-sections .............................................................................................. 40
5.4.2 Mains Connection ............................................................................................................ 42
5.4.3 Motor Connection ............................................................................................................ 42
5.4.3.1 Length of motor cables, without filter........................................................................ 42
5.4.3.2 Motor cable length, with output filter dU/dt ............................................................... 42
5.4.3.3 Motor cable length, with sinus filter .......................................................................... 43
5.4.3.4 Group drive............................................................................................................... 43
5.4.3.5 Speed sensor connection......................................................................................... 43
5.4.4 Connection of a Brake Resistor ....................................................................................... 43
5.5 Connection of types .............................................................................................................44
5.5.1 KFU 2- (up to 3.0 kW) and 401 (up to 4.0 kW) ................................................................ 44
5.5.2 KFU 2- (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) ............................................................ 46
5.5.3 KFU 4- (18.5 to 30.0 kW)................................................................................................. 48
5.5.4 KFU 4- (37.0 to 65.0 kW)................................................................................................. 50
5.5.5 KFU 4- (75.0 to 132.0 kW)............................................................................................... 52
5.6 Control Terminals ................................................................................................................. 54
5.6.1 External DC 24 V power supply....................................................................................... 56
5.6.2 Relay Output....................................................................................................................56
5.6.3 Motor Thermo-Contact..................................................................................................... 56
5.6.4 Control terminals – Connection diagrams of configurations............................................ 57
5.7 Configurations overview...................................................................................................... 57
5.7.1 Configuration 110 – Sensorless Control.......................................................................... 58
5.7.2 Configuration 111 – Sensorless Control with Technology Controller .............................. 58
5.7.3 Configuration 410 – Sensorless Field-Oriented Control.................................................. 59
5.7.4 Configuration 411 – Sensorless Field-Oriented Control with Technology Controller ...... 60
5.7.5 Configuration 430 – Sensorless Field-Oriented Control, Speed and Torque Controlled 61
5.7.6 Configuration 210 – Field-Oriented Control, Speed Controlled....................................... 62
5.7.7 Configuration 211 – Field-Oriented Control with Technology Controller ........................ 62
5.7.8 Configuration 230 – Field-Orientated Control, Speed and Torque Controlled ................ 63
5.7.9 Configuration 510 – Field-Oriented Control of Synchronous Machine, Speed Controlled
64
5.7.10 Configuration 530 – Field-Orientated Control of a Synchronous Machine, Speed and
Torque Controlled........................................................................................................................... 65
6Control Unit KP500....................................................................................................................... 66
6.1 Menu Structure...................................................................................................................... 67
6.2 Main Menu.............................................................................................................................. 67
6.3 Actual Value Menu (VAL) ..................................................................................................... 68
6.4 Parameter Menu (PARA) ...................................................................................................... 69
6.5 Copy Menu (CPY).................................................................................................................. 70
6.5.1 Reading the Stored Information....................................................................................... 70
6.5.2 Menu Structure ................................................................................................................ 71
6.5.3 Selecting the Source........................................................................................................ 71
6.5.4 Selecting the Destination ................................................................................................. 72
6.5.5 Copy Operation................................................................................................................ 72
6.5.6 Error Messages................................................................................................................ 73
6.6 Reading Data From Control Unit......................................................................................... 74
6.6.1 Activation ......................................................................................................................... 74
6.6.2 Data transfer .................................................................................................................... 75
6.6.3 Resetting to Normal Operation ........................................................................................ 76
6.7 Control Menu (CTRL)............................................................................................................ 76
6.8 Controlling the Motor via the Control Unit......................................................................... 77

KFU 2-/4-
5
7Commissioning of the Frequency Inverter................................................................................ 80
7.1 Switching on Mains Voltage ................................................................................................ 80
7.2 Setup Using the Control Unit............................................................................................... 80
7.2.1 Configuration.................................................................................................................... 81
7.2.2 Data Set ........................................................................................................................... 82
7.2.3 Motor Type....................................................................................................................... 83
7.2.4 Machine Data................................................................................................................... 83
7.2.5 Plausibility check ............................................................................................................. 84
7.2.6 Parameter identification ................................................................................................... 86
7.2.7 Application data ............................................................................................................... 88
7.2.7.1 Acceleration and deceleration deceleration deceleration......................................... 88
7.2.7.2 Set points at multi-functional input ........................................................................... 89
7.2.8 Quitting commissioning.................................................................................................... 89
7.2.9 Selection of an actual value for display ........................................................................... 90
7.3 Check direction of rotation .................................................................................................. 90
7.4 Speed sensor......................................................................................................................... 91
7.4.1 Speed sensor 1................................................................................................................ 91
7.4.2 Speed sensor 2................................................................................................................ 92
7.5 Set-up via the Communication Interface............................................................................ 93
8Inverter Data ................................................................................................................................. 96
8.1 Serial Number........................................................................................................................ 96
8.2 Optional Modules.................................................................................................................. 96
8.3 Inverter Software Version .................................................................................................... 96
8.4 Set Password......................................................................................................................... 96
8.5 Control Level......................................................................................................................... 97
8.6 User Name ............................................................................................................................. 97
8.7 Configuration......................................................................................................................... 97
8.8 Language............................................................................................................................. 100
8.9 Programming....................................................................................................................... 100
9Machine Data.............................................................................................................................. 101
9.1 Rated Motor Parameters .................................................................................................... 101
9.2 Further motor parameters.................................................................................................. 102
9.2.1 Stator Resistance .......................................................................................................... 102
9.2.2 Leakage Coefficient ....................................................................................................... 102
9.2.3 Magnetizing Current ...................................................................................................... 103
9.2.4 Rated slip correction factor ............................................................................................ 103
9.2.5 Voltage constant ............................................................................................................ 104
9.2.6 Stator inductance........................................................................................................... 104
9.2.7 Peak current................................................................................................................... 104
9.2.8 Change sense of rotation............................................................................................... 105
9.3 Internal values..................................................................................................................... 105
9.4 Speed Sensor 1................................................................................................................... 106
9.4.1 Operation Mode Speed Sensor 1 .................................................................................. 106
9.4.2 Division marks, speed sensor 1..................................................................................... 108
9.4.3 Gear factor speed sensor 1 ........................................................................................... 109
9.5 Sensor evaluation............................................................................................................... 110
10 System Data................................................................................................................................ 111
10.1 Actual System Value....................................................................................................... 111

KFU 2-/4-
6
10.2 Volume Flow and Pressure ............................................................................................ 111
11 Operational Behavior................................................................................................................. 112
11.1 Starting Behavior............................................................................................................. 112
11.1.1 Starting Behavior of Sensorless Control System........................................................... 112
11.1.1.1 Starting Current ...................................................................................................... 114
11.1.1.2 Frequency Limit ...................................................................................................... 114
11.1.1.3 Brake release time.................................................................................................. 114
11.1.2 Flux Formation............................................................................................................... 115
11.2 Stopping Behavior........................................................................................................... 116
11.2.1 Switch-Off Threshold ..................................................................................................... 118
11.2.2 Holding Time.................................................................................................................. 118
11.3 Direct current brake ........................................................................................................ 118
11.4 Auto Start......................................................................................................................... 119
11.5 Search Run....................................................................................................................... 120
11.6 Positioning....................................................................................................................... 121
11.6.1 Reference Positioning.................................................................................................... 122
11.6.2 Axle Positioning ............................................................................................................. 125
12 Error and warning behavior ...................................................................................................... 128
12.1 Overload Ixt...................................................................................................................... 128
12.2 Temperature..................................................................................................................... 128
12.3 Controller status.............................................................................................................. 129
12.4 IDC Compensation Limit................................................................................................. 129
12.5 Frequency Switch-Off Limit............................................................................................ 130
12.6 Motor Temperature.......................................................................................................... 130
12.7 Phase Failure................................................................................................................... 131
12.8 Automatic Error Acknowledgment................................................................................ 132
13 Reference Values ....................................................................................................................... 133
13.1 Frequency Limits............................................................................................................. 133
13.2 Slip Frequency................................................................................................................. 133
13.3 Percentage Value Limits................................................................................................. 133
13.4 Frequency reference channel ........................................................................................ 134
13.4.1 Block diagram ................................................................................................................ 135
13.5 Reference percentage channel...................................................................................... 137
13.5.1 Block diagram ................................................................................................................ 137
13.6 Fixed reference values.................................................................................................... 139
13.6.1 Fixed Frequencies ......................................................................................................... 139
13.6.2 JOG frequency............................................................................................................... 140
13.6.3 Fixed Percentages......................................................................................................... 140
13.7 Frequency ramps............................................................................................................. 141
13.8 Percentage Value Ramps ............................................................................................... 144
13.9 Block Frequencies .......................................................................................................... 144
13.10 Motor Potentiometer ....................................................................................................... 145
13.10.1 Motorpoti (MP) ........................................................................................................... 146
13.10.2 Motorpoti (KP) ............................................................................................................ 146
13.10.3 Controlling the Motor via the Control Unit .................................................................. 147
13.11 PWM-/repetition frequency input................................................................................... 148

KFU 2-/4-
7
14 Control Inputs and Outputs ...................................................................................................... 150
14.1 Multi-Function Input MFI1............................................................................................... 150
14.1.1 Analog input MFI1A ....................................................................................................... 150
14.1.1.1 Characteristic.......................................................................................................... 150
14.1.1.2 Scaling .................................................................................................................... 152
14.1.1.3 Tolerance Band and Hysteresis ............................................................................. 152
14.1.1.4 Filter Time Constant ............................................................................................... 153
14.1.1.5 Error and warning behavior .................................................................................... 154
14.2 Multi-Function Output MFO1.......................................................................................... 155
14.2.1 Analog output MFO1A ................................................................................................... 155
14.2.1.1 Output Characteristic.............................................................................................. 156
14.2.2 Frequency Output MFO1F............................................................................................. 156
14.2.2.1 Scaling .................................................................................................................... 156
14.3 Digital Outputs................................................................................................................. 157
14.3.1 Digital Signal.................................................................................................................. 160
14.3.2 Setting Frequency.......................................................................................................... 161
14.3.3 Reference value reached............................................................................................... 162
14.3.4 Flux Forming finished .................................................................................................... 163
14.3.5 Brake release................................................................................................................. 163
14.3.6 Current Limitation .......................................................................................................... 163
14.3.7 External Fan................................................................................................................... 163
14.3.8 Warning Mask................................................................................................................ 164
14.3.9 Application warning mask .............................................................................................. 166
14.4 Digital inputs.................................................................................................................... 167
14.4.1 Start command............................................................................................................... 172
14.4.2 3-wire control ................................................................................................................. 172
14.4.3 Error Acknowledgment .................................................................................................. 173
14.4.4 Timer.............................................................................................................................. 173
14.4.5 Thermo contact.............................................................................................................. 173
14.4.6 n-/M Control Change-Over ............................................................................................ 173
14.4.7 Data Set Change-Over .................................................................................................. 174
14.4.8 Fixed Value Change-Over ............................................................................................. 175
14.4.9 Motor Potentiometer ...................................................................................................... 175
14.4.10 Handshake Traverse Function ................................................................................... 176
14.4.11 External error ............................................................................................................. 176
14.5 Function Modules............................................................................................................ 177
14.5.1 Timer.............................................................................................................................. 177
14.5.1.1 Timer – Time Constant ........................................................................................... 178
14.5.2 Comparator .................................................................................................................... 180
14.5.3 Function table ................................................................................................................ 181
14.5.4 Multiplexer/Demultiplexer .............................................................................................. 182
15 V/f-Characteristic........................................................................................................................ 184
15.1 Dynamic Voltage Pre-Control......................................................................................... 185
16 Control Functions ...................................................................................................................... 186
16.1 Intelligent current limits.................................................................................................. 186
16.2 Voltage controller............................................................................................................ 187
16.3 Technology Controller.................................................................................................... 192
16.4 Functions of Sensorless Control................................................................................... 201
16.4.1 Slip compensation ......................................................................................................... 201
16.4.2 Current limit value controller .......................................................................................... 201
16.5 Functions of Field-Orientated Control .......................................................................... 202
16.5.1 Current Controller .......................................................................................................... 202
16.5.2 Torque Controller........................................................................................................... 204
16.5.2.1 Limit Value Sources................................................................................................ 204

KFU 2-/4-
8
16.5.3 Speed controller............................................................................................................. 205
16.5.3.1 Limitation of Speed Controller ................................................................................ 207
16.5.3.2 Limit Value Sources................................................................................................ 208
16.5.3.3 Integral time speed synchronization....................................................................... 208
16.5.4 Acceleration Pre-Control................................................................................................ 208
16.5.5 Field Controller............................................................................................................... 209
16.5.5.1 Limitation of field controller..................................................................................... 210
16.5.6 Modulation Controller..................................................................................................... 211
16.5.6.1 Limitation of Modulation Controller......................................................................... 212
17 Special Functions....................................................................................................................... 213
17.1 Pulse Width Modulation.................................................................................................. 213
17.2 Fan .................................................................................................................................... 214
17.3 Bus controller.................................................................................................................. 214
17.4 Brake Chopper and Brake Resistance.......................................................................... 216
17.4.1 Dimensioning of Brake Resistor .................................................................................... 217
17.5 Motor Protection Switch................................................................................................. 218
17.6 V-belt Monitoring............................................................................................................. 220
17.7 Functions of Field-Orientated Control .......................................................................... 220
17.7.1 Motor Chopper............................................................................................................... 220
17.7.2 Temperature Adjustment ............................................................................................... 221
17.7.3 Speed Sensor Monitoring .............................................................................................. 223
17.8 Traverse function ............................................................................................................ 224
18 Actual Values.............................................................................................................................. 226
18.1 Actual Values of the Frequency Inverter ...................................................................... 226
18.1.1 STO Status .................................................................................................................... 228
18.2 Actual Values of the Machine......................................................................................... 229
18.3 Actual value memory ...................................................................................................... 230
18.4 Actual Values of the System.......................................................................................... 231
18.4.1 Actual System Value...................................................................................................... 231
18.4.2 Volume Flow and Pressure............................................................................................ 232
19 Error Protocol............................................................................................................................. 233
19.1 Error List .......................................................................................................................... 233
19.1.1 Error Messages.............................................................................................................. 233
19.2 Error Environment........................................................................................................... 236
20 Operational and Error Diagnosis.............................................................................................. 238
20.1 Status Display.................................................................................................................. 238
20.2 Status of Digital Signals ................................................................................................. 238
20.3 Controller Status ............................................................................................................. 239
20.4 Warning Status and Warning Status Application ........................................................ 240
21 Parameter List ............................................................................................................................ 242
21.1 Actual Value Menu (VAL)................................................................................................ 242
21.2 Parameter Menu (PARA)................................................................................................. 245
22 Functions of the control terminals (table)............................................................................... 253

KFU 2-/4-
9
1 General Safety Instructions and Information on Use
Warning! The specifications and instructions contained in the documentation
must be complied with strictly during installation and commissioning.
Only qualified staff who has read the documentation and, in particular,
the safety instructions carefully is allowed to carry out installation or
commissioning work or to operate the frequency inverters. The term
„Qualified Staff“ refers to anybody who is familiar with the installation,
assembly, commissioning and operation of the frequency inverter and
has the proper qualification for the job.
The present documentation was prepared with great care and it was subjected to
extensive and repeated reviews. For reasons of clarity, it was not possible to include
all details of all types of the product in the documentation. Neither was it possible to
consider all conceivable installation, operation or maintenance situations. If you re-
quire further information or if you meet with specific problems which are not dealt
with in sufficient detail in the documentation, contact your supplier of drive systems.
We would also like to point out that the contents of this documentation do not form
part of any previous or existing agreement, assurance or legal relationship. Neither
are they intended to supplement or replace such agreements, assurances or legal
relationships. The manufacturer's obligations are exclusively specified in the relevant
purchase contract. This contract also contains all and any warranty regulations which
may apply to the relevant scope of supply. These contractual warranty provisions are
neither extended nor limited by the specifications contained in this documentation.
The manufacturer reserves the right to correct or amend the specifications, product
information and omissions in these operating instructions without notice. The manu-
facturer shall not be liable for any damage, injuries or costs which may be caused by
the aforementioned reasons.
1.1 General Information
Warning! The DC-link circuit of the frequency inverter is charged during opera-
tion, i.e. there is always the risk of contact with high voltage. Frequency
inverters are used for driving moving parts and they may become hot at
the surface during operation.
Any unauthorized removal of the necessary covers, improper use,
wrong installation or operation may result in serious injuries or material
damage.
In order to avoid such injuries or damage, only qualified staff may carry
out the transport, installation, setup or maintenance work required. The
standards EN 50178, IEC 60364 (Cenelec HD 384 or DIN VDE 0100),
IEC 60664-1 (Cenelec HD 625 or VDE 0110-1), BGV A2 (VBG 4) as well
as the applicable national regulations must be complied with. The term
„Qualified Staff“ refers to anybody who is familiar with the installation,
assembly, commissioning and operation of the frequency inverter as
well as the possible hazards and has the proper qualification for the job.