Klingenburg KR4 User manual

·KLINGENBURG
·KLINGENBURG
Rotor controllers
Type KR4 and KR7
Rotation controller for regenerative
heat exchangers
ENERGY RECOVERY

·KLINGENBURG 2
3
4
5
6
7
8
9
10
11
13
14
17
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19
Table of Contents
General
What can the controller do?
Functions of the KR4 and KR7 basic controllers
Functions of the KR4 Z and KR7 Z controllers
with additional functions
Technical specifications KR4 / KR7 and KR4 Z / KR7 Z
Motor data
Terminal configurations of the KR4 / KR7 controllers
Terminal configurations of the KR4 Z / KR7 Z controllers
Hooking up KR4 und KR7 basic controllers
Hooking up KR4 Z und KR7 Z controllers
with additional functions
Ordering a controller
Putting in operation KR4 und KR7 basic controllers
Putting in operation KR4 Z und KR7 Z
controllers with additional functions
Summary of features
Safety and Warning Instructions
Page

·KLINGENBURG 3
General
The efficiency of regenerative heat exchangers can be adjusted
by means of the rotor speed.
The rotor speed can be adjusted by means of the KR controller
across the complete control range. For further performance
features see page 4.
The new KR controller is the fourth generation of a series of
controllers for regulating regenerative heat exchangers
developed by our company since 1979. Developments in
modern processing technology and our wish to make the
operating controls as simple as possible provided the impetus
for an extensive development programme.
Only two types are required for all rotor sizes:
KR4 = 400 Watt
rotor diameters smaller than 3760 mm
KR7 = 750 Watt
rotor diameters larger than 3760 mm
The KR controllers represent the latest standards for rotor
technology.
The controller is housed in an extruded aluminium case which
improves heat dissipation and increases mechanical stability.
The case also ensures good electric screening. More space
was provided for the wiring and the new configuration of the
terminals makes it easier to hook up the controller.
And of course all new industry standards have been taken into
account. The radio shielding incorporates the latest technology.
The rotor drive is effected through three-phase alternating
current motors which can be operated up to a rotor diameter of
1919 mm direct from the mains. Furthermore, an acceleration
and deceleration ramp must be utilised for the gears.
So, for the optimum control of the drive, the rotor controller KR
is required.

·KLINGENBURG 4
What can the controller do?
The KR4 and KR7 control units and their central component,
the frequency inverter, permit you to fully adjust the rotor
speed for the entire permissible range.
These control units can be utilised worldwide.
(With supply voltage 230V ~)
When designing these control units, all known regulations were
taken in consideration.
Quality features
·Latest processor technology
·CE conformity
·Casing IP 54
·Short-circuit-proof output
·EN 55011 tested
·EN 61000-3 tested
·EN 61000-4-2 tested
·EN 61000-4-4 (Burst) tested
·EN 61000-4-5 (Surge) tested
·EN 61800-3 tested
·Each single module is tested repeatedly
·exchangable info sheet
Optional features
The following functions can be selected by means of the
extended Z-controller:.
·Summer operation including display of function *)
-Enthalpy comparison
-Temperature comparison
-Temperature switching over
·supply air temperature control *)
·sequence switching register including function display
In this case the controller bears the model number KR4 Z or
KR7 Z. See page 13 for order codes.
*) The corresponding sensors must be installed for the control
features marked with an asterisk.
Performance features
·6 detailed fault display
·Thermal protection including function display
·Starting and running out switching
·Menu controlled programming
·Clear text display via LCD display
·Three push-button operation
·External control signal processing
·Self-cleaning function
·Rotor operation control *)

·KLINGENBURG 5
Functions of the KR4 and KR7 basic controllers
Self-cleaning operation
One result of the constant air flow in regenerative heat
exchangers is a very beneficial self-cleaning effect. As a result,
cleaning is not required in most cases. In case of doubt, please
consult us.
At times when the ventilation unit is running but the rotor
function itself is not required, it is still expedient to activate the
rotor periodically. The cleaning cycle can be set for 20, 40, 60,
80 or 100 minutes. In this manner smaller dirt deposits can be
cleaned away.
Speed display
You can calculate the speed of the rotor from the frequency.
80 Hz corresponds to approximately 10 rpm.
Rotation monitor
As the rotor turns, the rotation is monitored by a magnetic
proximity switch mounted inside the rotor case. A magnet
which is mounted on the circumference of the rotor reports the
rotation movement back to the controller. In case of a rotor
operation fault, e.g. the V-belt comes off, the fault contact
switches over from S1 to S2. The following error message then
appears on the display.
KR4 = 400 Watt forrotordiameterssmallerthan3760mm
KR7 = 750 Watt forrotordiametersbiggerthan3760mm
The electronics function test checks motor current and processor
operation. After starting the motor it checks the functions of the
motor.In addition it verifies for short circuits or earth faults.
In case of a fault the fault contact switches over from S1 to S2.
The error message appears on the display. (see page 16)
Example:
Operation mode: Manual operation
In manual operation mode you can determine by depressing
the selection push-button a fixed rotational speed.
Operation mode: External operation
By evaluation of a external control signal (0 - 20 mA, 4 - 20 mA or
0-10 V) the rotational speed is justified.
Hardware err:EXX
If the rotor stops turning, the reaction time of the controller will
vary between 0.5 and 3 minutes, depending upon the speed of
the rotor beforehand. The controller renews operation once the
error message has been acknowledged by pressing the three
buttons on the controller.
The function of the rotation monitor is not active at frequencies
£10 Hz.
The rotation monitor is a component of the basic controller. If
you require this function, you must order the magnetic
proximity switch and the installation set that comes with it
(KR4 R or KR7 R).
Runcontrol error

·KLINGENBURG 6
Functions of KR4 Z and KR7 Z controllers
with additional functions
1. Setting supply air temperature
The supply air temperature can be set to a value between 10-
40°C. The rotor speed increases and decreases until the
desired temperature is reached or until the rotor reaches its
minimum / maximum speed. A temperature sensor type PT
1000 is required in order to regulate the supply air temperature
(200 mm resp. 2000 mm).
Other temperature ranges require a special order.
2. Sequence switch
The sequencer is a change-over switch which allows you, e.g.,
to operate a downstream heat source in sequence with the
rotor. It ensures that the heating is switched on only if the rotor
is already turning. In this manner, you can be sure that the
heating is only being used as a residual heater. The heating
activation value is set under the menu item "Activation value". It
can be set to a value between 5- 100 % in 5%-steps. In the
center of the display a "#" indicates that the sequence switch
is activated.
3. Summer mode, Cooling mode
As you well know, your rotary heat exchanger is not only the
ideal solution for recuperating heat; it can also be used as a
"cooler". If the exhaust air in summer is cooler than the outer
air, the rotor can be used as a cost-saving cooling unit. By
running the rotor at full speed, it is possible to pre-cool the
outer air. The KR Z automatically tests whether the conditions
merit operating in summer mode. You can choose from
different versions of the summer operating mode:
3.1 Temperature comparison mode
In the temperature comparison mode, the KR Z decides when
to switch the rotor to cooling mode by comparing the
temperature of the outer air with that of the exhaust air. If the
exhaust air is cooler than the outer air, then the rotor can use
the outer air to cool the supply air. Two temperature sensors
are required for the temperature comparison mode.
3.2 Enthalpy comparison mode
In the enthalpy comparison mode, the KR Z decides when to
switch the rotor to cooling mode by comparing the total heat
content of the outer air with that of the exhaust air. If the
enthalpy of the outer air is higher than that of the exhaust air,
then the rotor can use the outer air to cool the incoming air.
Two enthalpy sensors are required for the enthalpy comparison
mode.
3.3 Outer temperature measurement
This method uses an adjustable reference value to decide
when to change over to summer mode. It is also referred to as
the change-over mode. When the outside temperature
surpasses the set value, the rotor switches to cooling mode.
The rotor then runs at maximum speed. The change-over mode
requires a temperature sensor to measure the outside
temperature.
The extended version with independent sensor evaluation bears
the number KR4 Z or KR7 Z.
The “Z” controler is extended by the following functions.
·Supply air temperature control
·sequence switch-heat register
·Summer operation mode

·KLINGENBURG 7
128
40
180
40
207
230
260
265
218
23 21 21 16 16
1616
21
21
23
£ 1419
1420-2379
2380-3759
³3760
90
180
370
750
230/400
230/400
230/400
230/400
0,37
0,60
1,20
2,00
F
F
F
F
IP 54
IP 54
IP 54
IP 54
0,64
1,05
2,07
3,46
(230 V) (400 V)
Technical specifications
KR4/KR7 and KR4 Z/KR7 Z
Motor data
DimensionsType KR4 KR7
Output: 0,4 kW 0,75 kW
Fuse: 6,3 A 10 A
Supply voltage: 220-240 V
Weight: 3200 g 3500 g
Operating temperature: -10°C - + 40°C
When operating temperatures
are below 0 °C, we recommend
that the motors be left off when the
power is first turned on to allow
the controller to warm up.
Supply air temperature: 10°C - 40°C
Other temperature ranges can
be specially ordered.
System of protection: IP 54
Output frequency: 0 - 80 HZ
Frequency resolution: 0,08 Hz
Control signals: 0 - 10 V, 0 - 20 mA, 4 - 20 mA
Fault contact: 230 V, 1 A
Power cord: A shielding power cord must
be used in all cases and if
longer than 15m, additional main
suppression filter should be
installed. Please ask for more
information.
Motor data
Rotor diameter
[mm]
Performance
[W]
Supply voltage
[V]
Max. current consumption [A] Isolation class Type of protection

·KLINGENBURG 8
{
{
0 - 10 Volt
0 - 20 mA
4 - 20 mA
PE
PE
PE
N
L1
S3
S2
S1
{
{
W
V
U
{
+
+
-
-
10
8
7
6
5
4
3
2
1
9
{
{
Terminal configuration of the KR4 / KR7 controller
black
brown
blue
Thermal protection relay - motor
control unit release
(potential free contact)
Rotation monitor
Three-phase motor
(3x230 Volt)
Error message
During operation S1 and S3 closed
By occurring of defects or net failure
S2 and S3 closed
Mains (230 Volt) 50 - 60 Hz
There is a supply voltage
of 24 V on the contacts 5, 7, 9
10 Volt power supply
External control signal 0 - 10 V, 0 - 20 mA
Jumper

·KLINGENBURG
+
-
10
8
7
6
5
4
3
2
1
9
{
9
{ {
0 - 10 Volt
0 - 20 mA
4 - 20 mA
26
24
23
22
21
20
19
18
17
25
-
S
+
-
S
+
-
+
-
S
{
{
{
{
PE
PE
PE
N
L1
S3
S2
S1
{
{
W
V
U
{
{
16
15
14
{
13
12
11
Terminal configuration of the KR4 Z / KR7 Z controller
black
brown
blue
Thermal protecton relay - motor
Rotation monitor
External control signal 0 - 10 V, 0 - 20 mA
Three-phase motor
(3x230 Volt)
Mains (230 Volt)
50 - 60 Hz
There is a supply voltage
of 24 V on the contacts 5, 7, 9
There is a supply voltage
of 10 V on the contacts 17, 20
10 Volt power supply for
sensor (e.g. enthalpy sensor)
Summer mode
Sequence switch
External control signal
0 - 10 V, 0 - 20 mA
Supply air sensor
Exhaust air sensor
Outside air sensor
Jumper
Error message
During operation S1 and
S3 closed. By occurring of
defects or net failure S2
and S3 closed
control unit release
(potential free contact)

·KLINGENBURG
N
L1
S3
S2
S1
3
2
+
-
V
U
W
0 - 20 mA
4 - 20 mA
0 - 10 Volt
3
7
8
3
9
10
10
5
4
6
-
+
S
{
0 - 10 Volt
{
0 - 20 mA
4 - 20 mA
Hooking up KR4 and KR7 basic controllers
1. Power supply
Both the KR4 and KR7 models must be hooked up to a 230 V
power supply.
2. Hooking up the fault contact
In the normal operating conditions, S1 is connected with S3. In
case of a fault or when the device is voltage free, S2 is
connected with S3.
3. Motor connection
In order to avoid interference from the connecting wires to the
motor, it is necessary to install each of these separately in a
shielded cable. The KR4 and KR7 frequency inverter from
Klingenburg operate with an output voltage of 3 x 230 V. This
must be taken into account when wiring the terminal board on
the motor. Using standard motors 230/400 V they have to be
installed in delta connection.
4. External control signal inputs
Control signal connection
The KR can process the following signals:
Hook up the control signal to terminals 2 and 3.
For a control signal of 0 - 20 mA or 4 - 20 mA, the pins must
be jumped as illustrated below.
For a control signal of 0 - 10 V, the pins must be jumped as
illustrated below.
5. Connecting the rotation monitor
The rotation sensor must be hooked up to terminals 4, 5 and 6.
6. Controller release (Enable)
The controller release is driven over terminals 7 and 8 on the
control terminal strip. The contact used to connect the
controller release must be voltage free.
7. Thermal protection relay - motor
The thermal protection relay must be connected using shielded
wire in order to protect the motor from excessive overheating
when running at low speeds. The warranty is voided if the
thermal protection relay for the motor is not connected.
blue
brown
black