Küenle KFU 210 Series Instruction manual

Quick Start
Manual
for Set-up
Frequency Inverter
Series KFU 210- / 410-
0,25 to 9,2 kW – 230 V – KFU 210-
0,25 to 400 kW – 400 V – KFU 410-
>400 kW to 1,6 MW On Request
KN 621.1710 EN

KFU 210- / 410-
1
TABLE OF CONTENTS
1General Information ................................................................................... 3
1.1Safety Instructions ...................................................................................................... 3
1.2Designated use ........................................................................................................... 5
1.3Transport and strorage ............................................................................................... 5
1.4After unpacking ........................................................................................................... 5
1.5Place of installation ..................................................................................................... 6
1.6Operation conditions ................................................................................................... 6
2Frequency inverter – type .......................................................................... 7
2.1Identifications on the data plate .................................................................................. 7
3Mechanical Installation .............................................................................. 9
3.1.1KFU 210 sizes 1 and 2 (up to 3,0 kW) – KFU 410 sizes 1 and 2 (up to 4,0 kW) ........................... 9
3.1.2KFU 210 sizes 3 and 4 (4,0 - 9,2 kW) – KFU 410 sizes 3 and 4 (5,5 – 15 kW) ........................... 10
3.1.3KFU 410 size 5 (18,5 – 30 kW) ..................................................................................................... 10
3.1.4KFU 410 size 6 (37 - 65 kW) ........................................................................................................ 11
3.1.5Dimensions without optional components .................................................................................... 11
3.1.6KFU 410 size 7 (75 - 132 kW) ...................................................................................................... 12
3.1.7Dimensions without optional components size 7 .......................................................................... 12
3.1.8KFU 410 / KFU 510 / KFU 610 size 8 (160 – 400 kW) ................................................................. 13
3.1.9Dimensions without optional components size 8 .......................................................................... 13
4Electrical installation ................................................................................ 14
4.1EMC information and connection .............................................................................. 15
4.1.1KFU 210 (up to 3,0 kW) and 410 (up to 4,0 kW) .......................................................................... 17
4.1.2KFU 210 (4,0 to 9,2 kW) and 410 (5,5 and 15,0 kW) ................................................................... 18
4.1.3KFU 410 (18,5 to 30 kW) .............................................................................................................. 19
4.1.4KFU 410 (37 to 65 kW) ................................................................................................................. 20
4.1.5KFU 410 (75 to 132 kW) ............................................................................................................... 21
4.1.6KFU 410 / KFU 510 / KFU 610 (160 to 400 kW) .......................................................................... 22
4.2Control terminals ....................................................................................................... 24
4.2.1Control terminals X210A and X210B ............................................................................................ 25
4.2.2External 24 V power supply X210A.1 & X210A.2 ......................................................................... 26
4.2.3Control terminal X10 ..................................................................................................................... 27
4.3X13 connection in KFU510 and KFU610 .................................................................. 27
5Commissioning......................................................................................... 29
5.1Guided commissioning .............................................................................................. 29
6Parameter .................................................................................................. 33
6.1Description of parameters ......................................................................................... 33
6.1.1Adjustable parameters .................................................................................................................. 33
6.1.2Actual value parameters ............................................................................................................... 35
6.2Parameter setting options ......................................................................................... 35

KFU 210- / 410-
2
7Control unit messages ............................................................................. 39
7.1Warning and error messages during operation ......................................................... 39
7.2Status messages during commissioning (SS…) ....................................................... 41
7.3Warning and error messages during commissioning (SA…/SF…) ........................... 42
8Technical Data .......................................................................................... 44
8.1Size 1 - KFU 210 (0,25 to 1,1 kW, 230 V) ................................................................. 44
8.2Size 2 KFU 210 (0,25 to 1,1 kW, 230 V) .................................................................. 45
8.3Size 3 and 4 KFU 210 (4,0 to 9,2 kW, 230 V) ........................................................... 46
8.4Size 1 KFU 410 (1,85 to 4,0 kW, 400 V) ................................................................... 47
8.5Size 2 KFU 410 (1,85 to 4,0 kW, 400 V) ................................................................... 48
8.6Size 3 and 4 KFU 410 (5,5 to 15,0 kW, 400 V) ......................................................... 49
8.7Size 5 KFU 410 (18,5 to 30,0 kW, 400 V) ................................................................. 50
8.8Size 6 KFU 410 (37 to 65kW, 400 V) ........................................................................ 51
8.9Size 7 KFU 410 (75 to 132 kW, 400 V) ..................................................................... 52
8.10Size 8 KFU 410 (160 to 400 kW, 400 V) ................................................................... 53
8.11Size 8 KFU 510 (160 to 400 kW, 525 V) .................................................................. 54
8.12Size 8 KFU 610 (160 to 400 kW, 690 V) .................................................................. 55

KFU 210- / 410-
3
1 General Information
This documentation describes the first steps for easy commissioning of frequency inverters series KFU 210- /
410-.
This series can be recognized by its label on the case and the identification below the top cover.
Position of the
mark depends
on the inverter
size
1.1 Safety Instructions
WARNING
 Note and follow all safety and usage instructions in this manual.
 This manual must be read before installation and commissioning of the frequency inverter.
 Non-compliance with the safety and usage instructions may result in death, serious injuries
and significant material damage.
 Only qualified technical personnel who is familiar with the installation, commissioning and use
of frequency inverters may work on the frequency inverter.
 The electrical installation must be carried out by qualified electricians according to the general
and regional safety and installation directives.
 Persons not familiar with the operation of the frequency inverter and children must not have
access to the device.
 When working at the frequency inverter, comply with the relevant accident prevention
regulations, the applicable standards BGV A2 (VBG 4), VDE 0100, standards governing work
on systems with dangerous voltages (e.g. EN 50178) and other national directives.
 Prior to commissioning and start of operation as intended, all covers must be fixed, all
standard equipment components of the frequency inverter must be installed, and the terminals
must be checked.
 No connection work shall be carried out while power supply is on.
 Do not touch any terminals as long as the DC-link capacitors are charged.
Sizes 1 through 7 (up to 132 kW): The DC-link may have dangerous voltage levels even up to
3 minutes after shutdown.
Size 8 (as from 160 kW): The DC-link may have dangerous voltage levels even up to 10
minutes after shutdown.

KFU 210- / 410-
4
WARNING!
 Do not touch the heat sink of the frequency inverter during operation. Danger of burns due to
high surface temperatures.
 Do not remove any covers of the frequency inverter during operation.
 Please note that Küenle Antriebssysteme will not accept any responsibility for compatibility
with third-party products (e.g. motors, cables, filters, etc.). If you use the device in combination
with third-party products, you do so at your own risk.
 The earth leakage current of the frequency inverter may exceed AC 3.5 mA or DC 10 mA.
 Please note (according to EN61800-5-1): This product may cause direct current in the
protective earth conductor. Where residual current devices (RCD) or residual current monitors
(RCM) are used as a protection against direct or indirect contact, only RCDs / RCMs of Type
B are permissible on the power supply side of this product.
 Do not touch electronic components or contacts.
 Defective components must not be put into operation.
 Any repair work may only be carried out by the manufacturer or persons approved/licensed by
the manufacturer.
 Any repair work must be carried out by qualified electricians.
 Except for modifications described in this document, the frequency inverter must not be
changed in any way.
 Do not connect inappropriate voltage sources.
 Keep the instructions accessible to the user.
NOTE
The frequency inverter may be connected to power supply every 60 s.
This must be considered when operating a mains contactor in jog operation mode. For commissioning
or after an emergency stop, a non-recurrent, direct restart is permissible.
NOTE
For more information about the range of functions of the frequency inverter and about operation,
maintenance and storage, refer to the co-applicable Operating Instructions.

KFU 210- / 410-
5
1.2 Designated use
The product is a frequency inverter. It is designed for
 installation in machines and electrical equipment
 industrial environments
The frequency inverters are electrical drive components intended for stationary installation in electrical cabinets of
industrial plants or machines. They may only be used for driving asynchronous three-phase squirrel cage motors
or permanently excited three-phase synchronous motors which are designed for operation with frequency
inverters. Where built-in motor temperature sensors are evaluated via the frequency inverter, a double/reinforced
insulation of the temperature sensor against the motor winding must be provided according to DIN EN 61800-5-1.
Commissioning and start of operation is not allowed until it has been verified that the machine meets the
requirements of the EC Machinery Directive 2006/42/EC and DIN EN 60204-1.
The frequency inverters meet the requirements of the low voltage directive 2006/95/EEC and DIN EN 61800-5-1.
CE-labeling is based on these standards. Responsibility for compliance with the EMC Directive 2004/108/EC lies
with the operator.
Frequency inverters are only available at specialized dealers and are exclusively intended for commercial use as
per EN 61000-3-2.
No capacitive loads may be connected to the frequency inverter.
1.3 Transport and strorage
 Ambient temperature: -25 ... 55 °C
 Relative humidity: 5 ... 95%, no water condensation
 Store product in its original package in dust-free room.
 Avoid high temperatures.
 After one year of storage, connect the device to mains voltage for 60 minutes.
1.4 After unpacking
 Check if the delivered devices corresponds to the order.
 Check the device for transport damage and completeness.
 Any defects/damage must be reported to the supplier immediately.

KFU 210- / 410-
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1.5 Place of installation
 In rooms without weather exposure.
 Avoid direct insolation.
 Avoid dust.
 Not in the neighborhood of strong electromagnetic fields.
 Not in the neighborhood of inflammable material.
 Provide for sufficient cooling. Install a fan if the frequency inverter is installed in a closed electrical
cabinet.
 Altitude of installation: ≤ 4000 m, above 1000 m with reduced power (reduced output current).
 Ingress protection rating of frequency inverter: IP20.
 The frequency inverter produces noise. For this reason it should be installed in areas where people
normally don't stay.
 Noise emission in operation is < 85 dB(A) in the case of sizes 1 through 7.
 Noise emission in operation is approx. 86 dB(A) in the case of size 8. Ear protectors must be used when
staying near the frequency inverter
 Use of the device in explosive atmospheres is not permitted.
1.6 Operation conditions
 Size 1…7:
Ambient temperature: 0…55°C, as from 40°C, power reduction of 2.5% / K should be considered.
 Size 8
Ambient temperature: -25…55°C, as from 45°C, power reduction of 2.5% / K should be considered.
 Relative humidity: 5 ... 85%, no water condensation
 Ambient pressure: 70 ... 106 kPa to be checked
 The frequency inverter may be operated in TN, TT and IT grid types.
 Operation in a corner-grounded TN grid shall not be permissible.
 Environment specification: Pollution degree 2 and overvoltage category III (IEC 60664-1 /DIN VDE 0110-
1).
 The frequency inverter may be connected to power supply every 60 s. If the unit is switched on more
frequently, it may be damaged. This must be considered when operating a mains contactor in jog
operation mode.
 Max. permissible expected short circuit current at mains connection:
 up to 132 kW device power (Size 7): 5 kA;
 160…250 kW device power (size 8): 18 kA
 as from 315 kW device power (size 8): 30 kA

KFU 210- / 410-
7
2 Frequency inverter – type
 Identify the type of frequency inverter.
 Check if frequency inverter rated voltage matches the local mains voltage.
2.1 Identifications on the data plate
 Type identifier, e.g. KFU 410-075/37/1.5 xxxx
410: Rated voltage 400 V (or 210: = rated voltage 230 V)
075: Rated current = identifier
37: Recommended power
1,5: …-x Rated torque
xxxx: Special design, where applicable
 Marking for UL508c (where applicable)
 Part number
 Serial number
 Warning symbols
Warning! Components sensitive to electrostatic energy.
Warning! High leakage current.
Warning! Dangerous voltage. Danger of electric shock.
Warning! Hot surface,
Identifier Size
Recommended power
KFU 210:
AC 1x230V / 3x230V
-32 4 15,0 kW
-40
5
18,5 kW
-45 22,0 kW
-1,6
1
0,25 kW -60 30,0 kW
-2,5 0,37 kW -75
6
37,0 kW
-3,0 0,55 kW -90 45,0 kW
-4,0 0,75 kW -110 55,0 kW
-5,4 1,1 kW -125 65,0 kW
-7,0
2
1,5 kW -150
7
75,0 kW
-9,5 2,2 kW -180 90,0 kW
-12,5 3,0 kW1) -210 110,0 kW
-18,0 3 4,0 kW -250 132,0 kW
-22,0 5,5 kW2) -305
8
160,0 kW
-32,0 4 7,5 kW2) -380 200,0 kW
-35,0 9,2 kW2) -475 250,0 kW
-595 315,0 kW

KFU 210- / 410-
8
Identifier Size Recommended power
KFU 410: AC 3x400V
-645 355,0 kW
-735 400,0 kW
-1,0
1
0,25 kW
-1,6 0,37 kW
Identifier Size
Recommended power
KFU 510: AC 3x525V
KFU 610: AC 3x690V
-1,8 0,55 kW
-2,4 0,75 kW
-3,2 1,1 kW
8
160,0 kW
-3,8 1,5 kW 200,0 kW
-4,2
2
1,85 kW 250,0 kW
-5,8 2,2 kW 315,0 kW
-7,8 3,0 kW 355,0 kW
-9,0 4,0 kW 400,0 kW
-14,0
3
5,5 kW
-18,0 7,5 kW 1) Maximum output current = 9.5 A with single-phase
and two-phase connection
2) Three-phase connection permissible only.
-22 9,2 kW
-25 4 11,0 kW

KFU 210- / 410-
9
3 Mechanical Installation
WARNING!
 During installation, comply with the following installation and safety instructions as well as the
installation and safety instructions of the co-applicable documents.
 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.
 Make sure that no foreign particles (e.g. dust, chips, wires, screws, tools) can get inside the
frequency inverter.
 Install the frequency inverter on a non-flammable surface.
 The frequency inverter may only be installed in vertical position.
 Screw the frequency inverter on a metal surface (unpainted).
 The frequency inverter must be grounded.
 For equipotential bonding, connect the frequency inverter, electrical cabinet, motor case, filter,
etc. to a common grounding point via short cables.
3.1.1 KFU 210 sizes 1 and 2 (up to 3,0 kW) – KFU 410 sizes 1 and 2 (up to 4,0 kW)
Screw fixing brackets to heat sink and mounting plate.

KFU 210- / 410-
10
3.1.2 KFU 210 sizes 3 and 4 (4,0 - 9,2 kW) – KFU 410 sizes 3 and 4 (5,5 – 15 kW)
Top fixing bracket
(screws M4x20)
Bottom fixing bracket
(screws M4x60)
Screw fixing brackets to heat sink and mounting plate.
3.1.3 KFU 410 size 5 (18,5 – 30 kW)
Top screw fixture
M4x20
Bottom screw
fixture M4x70
Screw fixing brackets to heat sink of frequency inverter
and mounting plate.

KFU 210- / 410-
11
3.1.4 KFU 410 size 6 (37 - 65 kW)
Top screw fixture M5x20 Bottom screw fixture
M5x20
Screw fixing brackets to heat sink of frequency inverter
and mounting plate.
3.1.5 Dimensions without optional components
Dimensions in mm
A
ssenmbl
y
dimensions in mm
k
W
a b c a1 a2 b1c1
KFU 210
0,25…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 410
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 210- / 410-
12
3.1.6 KFU 410 size 7 (75 - 132 kW)
The diameter of the fixing holes is 9
mm.
Screw the rear wall of the frequency
inverter heat sink to the mounting
plate.
3.1.7 Dimensions without optional components size 7
Dimensions in mm
A
ssembl
y
dimensions in mm
KFU410 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 210- / 410-
13
3.1.8 KFU 410 / KFU 510 / KFU 610 size 8 (160 – 400 kW)
The diameter of the fixing holes is 8.5
mm.
Screw the rear wall of the frequency
inverter heat sink to the mounting
plate.
3.1.9 Dimensions without optional components size 8
Dimensions in mm
A
ssembl
y
dimensions in mm
Type kW a b c a1 b1 b2 c1
KFU410
KFU510
KFU610
160,0…400,0 1067 439 375 1017 330 110 345
NOTE
Before unpacking the frequency inverter, transfer it as close as possible to
the designated place of installation.
 First, remove the protective packaging.
 Screw 2 crane eyebolts into the threads provided for that purpose.
 Use the crane eyebolts and a crane for lifting, handling and
installation. The crane must be of a design that it can carry the
weight of the frequency inverter.

KFU 210- / 410-
14
4 Electrical installation
DANGER !
 The five safety rules must be complied with.
 Disconnect the frequency inverter from mains voltage (AC and DC) and protect it against
being energized unintentionally.
 Verify safe isolation from power supply.
 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.
 Sizes 1 through 7 (up to 132 kW): The DC-link may have dangerous voltage levels even up to
3 minutes after shutdown.
 Size 8 (as from 160 kW): The DC-link may have dangerous voltage levels even up to 10
minutes after shutdown.
 Switch off power supply before connecting or disconnecting the mains cables to/from terminal
X1, and the motor cables and braking resistor to X2.
NOTE
 The cables connected to the frequency inverters may not be subjected to high-voltage
insulation tests.
 Use copper cables designed for an ambient temperature of at least 30 °C.
 In the case of UL/CSA installations: Only use 75°C copper cables.
 The earth leakage current of the frequency inverter may exceed AC 3.5 mA or DC 10 mA.
NOTE
Please note (according to EN61800-5-1):
 This product may cause direct current in the protective earth conductor. Where residual
current de-vices (RCD) or residual current monitors (RCM) are used as a protection against
direct or indirect contact, only RCDs / RCMs of Type B are permissible on the power supply
side of this product.

KFU 210- / 410-
15
4.1 EMC information and connection
The frequency inverter is designed according to the requirements and limit values of product norm EN 61800-3
with an interference immunity factor (EMI) for operation in industrial applications. Electromagnetic interference is
to be avoided by expert installation and observation of the specific product information.
Measures
Install the frequency inverters and commutating chokes on a metal mounting panel. Ideally, the mounting panel
should be galvanized, not painted.
Provide proper equipotential bonding within the system or plant. Plant components such as electrical cabinets,
control panels, machine frames must be connected by means of PE cables, i.e. sufficient area and with good
conductivity.
The shield of the control cables is to be connected to ground potential properly, i.e. with good conductivity, on
both sides (shield clamp). Mount shield clamps for cable shields close to the unit.
Connect the frequency inverter, the commutating choke, external filters and other components to an earthing
point via short cables.
Excessive cable length and loosely suspended cabling must be avoided.
Contactors, relays and solenoids in the electrical cabinet are to be provided with suitable interference suppression
components.
1. Fuse
2. Circuit breaker
3. Line choke (optional or mandatory)
4. Input filter (optional)
5. Cable shield (recommended)
6. Brake resistor (optional)
7. Output filter (optional)

KFU 210- / 410-
16
A
Mains connection
The mains supply cable may be as long as
required. To be separated from control, data and
motor cable.
B
DC-link connection
The frequency inverter is to be connected to the
same mains potential or a common direct voltage
source. Cables with a length >300 mm must be
shield-ed, the cable shield must be connected to
the mounting plate on both sides. Use twisted
cables where possible.
C
Control connection
Control and signal cables must be kept physically
separate from the power cables. Analog signal
lines are to be connected to the shield potential on
one side. Install sensor cables separate from motor
cables.
The low voltage circuits (e.g. terminal X210A,
X210B) are isolated from the main circuit (e.g. U,
V, W) by way of safety isolation and safety
impedance.
D
Motor and brake resistor
The shield of the motor cable is to be connected to
ground potential properly on both sides. On the
motor side use a metal compression gland. On the
frequency inverter side an appropriate shield clamp
is to be used. The signal cable used for monitoring
the motor temperature must be kept separate from
the motor cable. Connect the shield of this line on
both sides. If a braking resistor is used, the
connection cable must also be shielded, and the
shield is to be connected to earth potential on both
sides.
E
Relay
The relay enables using high-energy signals.
As from size 8, with AC 3x525 V or AC 3x690 V mains operation, terminal X13 must be connected
additionally. Note the connection information for size 8.
Line choke
Line chokes reduce mains harmonics and reactive power. In addition, a longer service life of the frequency
inverter is possible. When using a line choke, note that line chokes may reduce the maximum output voltage of
the frequency inverter. The line choke must be installed between the mains connection and the input filter.
Input filter
Input filters reduce grid-bound, high-frequency radio interference voltage. Install input filter on the mains side up-
stream of the frequency inverter.

KFU 210- / 410-
17
Caution!
The frequency inverters meet the requirements of the low-voltage directive 2006/95/EC and the
requirements of the EMC directive 2004/108/EC. The EMC product standard EN 61800-3 relates to
the drive system. The documentation provides information on how the applicable standards can be
complied if the frequency inverter is a component of the drive system. The declaration of conformity is
to be issued by the supplier of the drive system.
4.1.1 KFU 210 (up to 3,0 kW) and 410 (up to 4,0 kW)
Mains connection, X1
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 connection
For connection of the ground conductor of the mains and motor cable, use the provided terminal connection
options X1 and X2. Other connection options for connecting the mains and motor cable are not permissible.
For connection of a braking resistor, use terminals Rb1 and Rb2.
Delta circuit
S
tar circui
t

KFU 210- / 410-
18
4.1.2 KFU 210 (4,0 to 9,2 kW) and 410 (5,5 and 15,0 kW)
Mains connection
Motor connection
For connection of the ground conductor of the mains and motor cable, use the provided terminal connection
options X1 and X2. Other connection options for connecting the mains and motor cable are not permissible.
For connection of a braking resistor, use terminals Rb1 and Rb2.
KFU 210-18,0
Delta circuit
S
tar circui
t

KFU 210- / 410-
19
4.1.3 KFU 410 (18,5 to 30 kW)
Mains connection
Motor connection
For connection of the ground conductor of the mains and motor cable, use the provided terminal connection
options X1 and X2. Other connection options for connecting the mains and motor cable are not permissible.
For connection of a braking resistor, use terminals Rb1 and Rb2.
Delta circuit
Star circuit