KW-Generator EFU 1000 User manual

MANUAL
EFU10000
4.0kVA INVERTER UNIT
Pag. 1 / 34
INVERTER EFU 1000
MANUAL
KW-Generator GmbH & Co.KG
Bänglesäcker 24
73527 Schwäbisch-Gmünd / Lindach
Tel: [phone] – 0
Fax: [phone] – 29
www.kw-generator.com
[e-mail]

Rev. Nr. Date Modification Description Required By
0 05.03.2014 First emission of the specification 1
0A 29.03.2014
Detailed new messaging signals and specified that first
prototype shall not comply to standards of paragraph 11.9.
2 / 1
0 B 29.05.2014
Added output under voltage not severe condition. Modified
Operative and Diagnostic Signals table.
1
1 07.07.2014
Several modifications due to customer visit and
2 / 1
2 19.10.2014
Prepared complete version of the manual. Added several figures
and notes.
1
MANUAL
EFU10000
4.0kVA INVERTER UNIT
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REVISION L IS T
manufacturing of the first sample.

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EFU10000
4.0kVA INVERTER UNIT
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1. CONTENTS
REVISION L IS T ................................................................................................................................ 2
1. C O N TE N T S ................................................................................................................................ 3
2. SAFETY INSTRUCTIONS ..................................................................................................... 5
2.1 G ENERAL NOTES ............................................................................................................... 5
2.2 U SER ’ S INFORMATION ....................................................................................................... 5
2.3 E XPLANATION OF THE SYMBOLS ON THIS MANUAL . .......................................................... 6
2.4 S PECIAL NOTES ................................................................................................................. 6
2.5 P ARALLELING ................................................................................................................... 8
3. LABELS LO CA T I O NS ............................................................................................................. 9
3.1 S AFETY L ABELS ................................................................................................................ 9
4. COMPONENT IDENTIFICATION ...................................................................................... 12
4.1 I NVERTER ........................................................................................................................ 12
4.2 I NVERTER G ROUNDING ................................................................................................... 12
4.3 M OTOR I NPUT C ONNECTIONS ......................................................................................... 13
4.4 230VAC OU T PU T ......................................................................................................... 13
4.5 S IGNALS C ONNECTOR ..................................................................................................... 13
4.6 R ELAY C ONNECTOR ........................................................................................................ 14
4.7 B RAKE R ESISTOR C ONNECTORS ..................................................................................... 14
4.8 CON4 & C ON5 .............................................................................................................. 14
5. PRE-OPERATION CHECK .................................................................................................. 15
5.1 M OUNTING I NSTRUCTIONS .............................................................................................. 15
6. STARTING THE SYS TEM .................................................................................................... 16
7. INVERTER US E ...................................................................................................................... 18
7.1 G ENERATION S TARTING .................................................................................................. 18
7.2 B RAKING ......................................................................................................................... 19
7.3 B EHAVIOUR OF LED S ..................................................................................................... 19
7.4 M OUNTING AND CONNECTING THE INVERTER ................................................................. 20
7.5 S WITCHING OFF THE INVERTER ....................................................................................... 20
8. MAINTENANCE ..................................................................................................................... 21
9. TRANSPORTING AND STORAGE ..................................................................................... 22
10. TROUBLESHOOTING .......................................................................................................... 23
11. S PE CI F ICA T I O NS .................................................................................................................. 24

MANUAL
EFU10000
4.0kVA INVERTER UNIT
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11.1. G ENERAL .............................................................................................................................. 24
11.2. I NVERTER I NPUT F EATURES (G ENERATOR S IDE ) .................................................................. 24
11.3. 230V
AC
O UPUT .................................................................................................................... 24
11.4. C ONNECTORS AND / OR W IRING ............................................................................................. 25
11.5. 230V
AC
O UTPUT P ROTECTIONS ............................................................................................ 26
11.6. I NPUT P ROTECTIONS ............................................................................................................. 27
11.7. B RAKE R ESISTOR C OMMAND P ROTECTION .......................................................................... 27
11.8. DC BUS P ROTECTINS .......................................................................................................... 27
11.9. O PERATIVE & D IAGNOSTIC S IGNALS ................................................................................... 28
11.10. M ESSAGING S IGNALS ........................................................................................................... 29
11.11. D IAGRAMS AND I NTERFACES ................................................................................................ 30
11.12. A PPLICABLE S TANDARDS ..................................................................................................... 32
12. GUARANTEE .......................................................................................................................... 33
13. DRAWINGS ............................................................................................................................. 34

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EFU10000
4.0kVA INVERTER UNIT
Pag. 5 / 34
2. SAFETY INSTRUCTIONS
This manual provides the necessary information for operating correctly the inverter EFU10000
(hereinafter referred as “inverter”) when correctly connected to the KW Generator electric motors
(hereinafter referred as “Motor”). Read and understand this manual before operating the equipment.
Failure to do so could result in personal injuries or equipment damage!
More precisely this shall avoid:
danger arising from the operation
danger to the operator
losses of time and increases of equipment reliability and durability
This manual should be considered as a permanent part of the equipment and should remain always
with it!
Customer Service
For further information please contact the manufacturer of the equipment:
KW-Generator GmbH & Co.KG
Bänglesäcker 20
73527 Schwäbisch-Gmünd / Lindach
Tel: [phone] – 0
Fax: [phone] – 29
www.kw-generator.com
[e-mail]
2.1 G
ENERAL NOTES
All information in this publication is based on the latest product information available at the
time of approval for printing.
KWG reserves the right to make changes at any time without notice and without
incurring any obligation.
Illustrations may vary.
No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the product and should remain
with it if it is resold.
2.2 U SER ’ S INFORMATION
Before starting the equipment:
please read this description and note carefully the safety instructions.

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EFU10000
4.0kVA INVERTER UNIT
Pag. 6 / 34
2.3 E XPLANATION OF THE SYMBOLS ON THIS MANUAL .
This manual contains important safety and operational instructions that must be accurately
understood and followed during the installation and maintenance of the equipment. To reduce the
risk of electrical shock hazards, and to make sure the equipment is safely installed, special safety
symbols are used in this manual to highlight potential safety risks and important safety information.
The symbols are:
WARNING
N OTE
2.4 S PECIAL NOTES
The paragraphs highlighted by this symbol contain processes and
instructions that must be absolutely understood and followed to avoid
potential danger to people.
Indicates a possibility of personal injury or equipment damage if
instructions are not followed.
Attention! High voltage!
Important instructions to be observed to prevent risk for the operator!
The paragraph highlighted by this symbol contains processes and
instructions that must be rigorously understood and followed to avoid
potential damage to the equipment and negative results. Moreover it
gives helpful information.
Equipment grounding conductor (Main grounding protective earth,
PE)
WARNING
N OTE
KWG’s inverter is designed to give safe and dependable service if
operated according to instructions.
Read and understand this Manual before operating it. Failure to do so could
result in personal injury or equipment damage.
If a problem should arise, or if you have any questions about the system,
consult KWG authorized technicians.

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EFU10000
4.0kVA INVERTER UNIT
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WARNING
N OTE
KWG inverter, in order to work correctly, needs that the temperature does
not exceed:
o 70°C on the inverter heat sink (see Figure 11),
Normally these temperature is not reached if ambient conditions are in
according with specification of Chapter 11.
To ensure safe operation
Always make a pre-operation inspection of the system before and during its
mounting on the engine and the box.
The inverter must be cooled down by air ventilation blowing on the heat
sink fins as per Figure 5.
Vibration on the inverter, for all frequencies and situations, must be limited
as per paragraph 11.12.3.
After you started the motor for the first time check all functions of the
system.
Do not operate the inverter directly in rain or snow and do not let it in
water.
If the inverter falls in water, do not try to dry it and operate it, but send it
back to KWG for safety controls.
Connection and maintenance must be done by qualified operators.
It’s not allowed to open or remove the inverter encapsulation resin, nor to
modify or replace any of its part. Any guarantee on modified and externally
damaged parts will decay. In these conditions KWG can’t give any
guarantee on the product and responsibilityfor any type of accidents.
Know how to stop the motor quickly in every case of problems. Never
permit anyone to operate the generator without proper instructions
Keep children and pets away from the generator when it is in operation.
Keep away from rotating parts while the generator is running.
Don’t clean the inverter with corrosive substances.
Do not use on avionic applications.
When working, the system is a potential source of electrical shocks; do not
operate it with wet hands.

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EFU10000
4.0kVA INVERTER UNIT
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2.5 P ARALLELING
WARNING
The inverter is not designed for operating in parallel with other
inverters.
The inverter is not designed for connection to the public grid
Connections for standby power to a building’s electrical system must be
made by a qualified electrician and must comply with all applicable laws
and electrical codes. Improper connections can allow electrical current from
the inverter to back feed into the utility lines. Such back feed may
electrocute utility company workers or others who contact the lines during a
power outage, and when utility power is restored, the inverter may explode,
burn or cause fires in the building’s electrical system.

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EFU10000
4.0kVA INVERTER UNIT
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AIR
FLOW
Figure 5: Mounting position of the inverter and air flow

NN
OUTPUT
NL
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EFU10000
4.0kVA INVERTER UNIT
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4. COMPONENT IDENTIFICATION
4.1 I NVERTER
The inverter converts the motor output into a standard 230VAC 50Hz outputs, normally
independent by motor oscillations and loading.
The location of its input and output connections is shown in Figure 7.
CON7 CON6
CON4
C O N5
TO BRAKE
RESISTOR
L1 L2 L 3
IN P U T
Figure 7: Inverter input and output connections
While in the following paragraphs a detail of each single connection is reported.
4.2 I NVERTER G ROUNDING
The inverter grounding must be made on its heat sink.

Figure 8: Inverter input and output connections
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4.0kVA INVERTER UNIT
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4.3 M OTOR I NPUT C ONNECTIONS
Three M6 studs L1, L2 and L3, are available for connecting the inverter to the motor.
NOTE For connecting the inverter to the motor use wires according with the
following:
o copper section 2.5 mm
2
,
o insulation voltage 1000V
AC
and minimum temperature range -25°C +155°C.
4.4 230VACOUTPUT
Two M6 studs L (Live) and N (Neutral), are available for the 230V
AC
output.
NOTE For connecting the inverter to the AC loads use wires according with the
following:
o copper section 4 mm
2
,
o insulation voltage 1000V
AC
and minimum temperature range -25°C +155°C.
4.5 S IGNALS C ONNECTOR
A 10 ways connector (named CON7) makes available all the signals described in paragraph 11.9
and 11.10. Its lay-out is shown on Figure 9, while the signals reference is listed on Table 1.
NOTE For connecting CON7 use only counterpart Hirose DF1B-10S-2.5R with
proper terminals.
10 1
Figure 9: CON7 connector lay-out
POSITION
ON CON7 DESCRIPTION
VOLTAGE
VALUE
1
RED LE D
0/12V
DC
2
GREEN LE D
0/12V
DC
3
YELLOW LED
0/12V
DC
4
OVERTEMPERATURE LED
0/12V
DC
5
INVERTER STATUS LED
0/12V
DC
6
DANGEROUS OUTPUT VOLTAGE LED
0/12V
DC
7
INPUT START COMMAND
0/12V
DC
8
INPUT – NOT CONFIGURATE
N.D.
9
INPUT – NOT CONFIGURATE
N.D.
10
INSULATED GROUND
0V
DC
Table 1: Signals on CON7 connector

POSITION
ON CON6 DESCRIPTION
VOLTAGE
VALUE
1
RL2 NORMALLY CLOSED
N.A.
2
RL2 COMMON
N.A.
3
RL2 NORMALLY OPEN
N.A.
4
G E N ERIC
0/12V
DC
5
12V
DC
OUTPUT
12V
DC
6
12V
DC
OUTPUT
0V
DC
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EFU10000
4.0kVA INVERTER UNIT
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4.6 R ELAY C ONNECTOR
A 6 ways auxiliary connector (named CON6) is available.
It provides the contacts of an integrated relay, named RL2
1
, a generic signal output, together with a
12V
DC
– 400mA insulated power supply.
Its lay-out is shown on Figure 10, while the signals reference is listed on Table 2.
NOTE For connecting CON7 use only counterpart Hirose DF1B-10S-2.5R with
proper terminals.
1 2 3
4 5 6
Figure 10: CON6 connector lay-out
CONTACT
CONTACT
CONTACT
OUTPUT (SIGNA L )
INSU L A TE D
INSULATED G RO UND
Table 2: Signals on CON7 connector
4.7 B RAKE R ESISTOR C ONNECTORS
The customer shall connects to the two proper M6 studs an external brake resistor with a nominal
value of 40 ±10%.
4.8 CON4 & CON5
Connectors reserved to KWG for programming and diagnostic.
1
Relay RL2 nominal specification: 6A - 250V
AC
– Maximum power 250VA (AC 15).

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EFU10000
4.0kVA INVERTER UNIT
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5. PRE-OPERATION CHECK
5.1 M OUNTING I NSTRUCTIONS
NOTE
NOTE
Use only the specific cable to connect the inverter to the motor.
Use only the counterpart plugs and sockets for the connection of the
inverter.
The cooling system must always work properly. Avoid obstructions.
The inverter is provided with temperature sensors. Maximum allowable
temperature must not be exceeded (see Chapter 6 and paragrah 11.1.2).
Avo i d vibrations and mechanical stresses on the inverter higher than 5g.
A short circuit of one of the three inverter input wires toward ground could
result into an inverter fail.
The cooling system must work properly starting from low speed revolutions.
The inverter is provided with temperature sensors. Maximum allowable
temperature must not be exceeded (see Chapter 6 and paragrah 11.1.2).
A shock absorbing mounting system (for example with silent-block) is
requested in order to reduce mechanical stress on the inverters and keep
maximum vibrations according to paragraph 11.12.3
The system operates correctly with revolution speed ranging from 1400 to
3600rpm. Speed revolutions lower than 1400rpm can not guarantee
adequate operational performances.

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EFU10000
4.0kVA INVERTER UNIT
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NOTE When working with the maximum output power it must be less than 70°C at
point A of Figure 11 (point A is given as per its Cartesian coordinates
referred to the origin point O (0;0)).
Higher temperatures than the above mentioned reduce drastically the output
performances and damage the inverter.
On new applications control the temperatures with a thermocouple.
A (130.5;133)
O (0,0)
Figure 11: Temperature measurement point

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4.0kVA INVERTER UNIT
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7. INVERTER USE
The inverter provides a 230VAC – 50Hz output. The nominal power is 4kW at an engine revolution
speed between 1700 rpm and 3000 rpm.
NOTE
WARNING
The AC output wave distortion (clipping) could increase at lower speed
revolutions.
To prevent electrical shocks from insulation damaged or faulty appliances,
t h e inverter should be grounded. Connect a braid of heavy copper wire
between the inverter’s heat sink and the external ground source.
Read carefully this manual before using the inverter.
For continuous operation, do not exceed the rated power (see Chapter 11).
In either case, the total wattage of all appliances connected must be
considered.
Do not exceed the specified current and power limits.
A suitable suppressor should be installed as close as possible to the output
terminals to prevent failures caused by coupling of external over voltages on
the output lines.
Substantial overloading that continuously trips the inverter may damage it.
Marginal overloading that temporary happens, may shorten the service life
of the inverter.
Be sure that all appliances are in good working before connecting them to
the generator. If an appliance begins to operate abnormally, becomes
sluggish, or stops suddenly, turn off the generator engine switch
immediately. Then disconnect the appliance and examine it for signs of
malfunction.
Do not connect the inverter to a household circuit. This could cause the
damage to the inverter or to electrical appliances in the house.
Do not modify or use the generator for other purposes than it is intended for.
7.1 G ENERATION S TARTING
When inverter is power supplied it starts to operate and performs a pre-test procedure lasting about
3 seconds.
If no problem is encountered inverter is ready to start generating.
When a start command is available, start switch must be close (ON position). It is also possible that
pin 7 of connector CON7 stays always grounded, by means of a jumper with pin 10.
The behavior of signalization LEDs is described on paragraph 11.9.

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4.0kVA INVERTER UNIT
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7.2 B RAKING
A braking system is used in order to prevent the DC voltage rising to an impermissible value. When
used, it activates a braking resistor (external to inverter) that is connected in parallel to the inverter
BUS capacitors. The over voltage energy is converted to heat via the braking resistor.
WARNING
Braking resistors may be subject to unexpected overloads due to faults.
Resistors MUST be protected using thermal cutouts. These devices
must not interrupt the circuit in which the resistor is inserted but their
auxiliary contact must cut off the power supply to the power section of
the inverter. If the resistor requires a protection contact, this must be
used together with that of the thermal cutout.
7.3 B EHAVIOUR OF LED S
On connector CON7 three LEDs can be externally connected for monitoring the inverter working
conditions. A detailed description of the LEDs behavior is reported on Table 3, while on paragraph
10 “TROUBLESHOOTING” the related user’s operating actions are suggested.
POS.
RED LED GREEN LED YELLOW LED CONDITION
1
Fast flashing Fast flashing Fast flashing Pre-Test & Start-Up
2
Slow flashing Slow flashing Slow flashing Inverter ready for generating
3
OFF ON OFF Inverter normally operating
4
Slow flashing ON ON Overload Condition
5
ON OFF ON Overload Protection
6
Slow flashing- ON Slow flashing Overtemperature Condition
7
ON OFF Slow flashing Overtemperature Protection
8
OFF Slow flashing OFF Output Undervoltage (see paragraph
11.5.7)
9
ON Slow flashing ON Output Undervoltage (not Severe)
Protection
10
ON Slow flashing OFF Output Undervoltage (Severe)
Protection
11
Slow flashing ON Fast flashing BUS Overvoltage Condition (I
st
level)
12
ON OFF Fast flashing BUS Overvoltage Protection
13
ON OFF OFF Inverter Failure
14
ON Fast flashing Fast flashing Brake Resistor Protection
15
ON ON ON Generator behavior or external AC
voltage connected to the inverter output
Table 3: LEDs b e h a v i our

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4.0kVA INVERTER UNIT
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7.4 M OUNTING AND CONNECTINGTHE INVERTER
NOTE
WARNING
Use correct silent blocks to avoid direct transmission of any vibrations to
the inverter (see paragraph 11.12.3 for the limits).
Before to start the engine it is preferable that all the appliances stay
switched off.
Start the engine and make sure the AC output indicator comes on.
When an extension cable is required, be sure to use a tough rubber sheathed
flexible and fireproof cable. Limit length of extension cables depends on the
voltage drop along the cable. This drop must be lower than 2.5% value of
the nominal output voltage.
Keep the generator away from other electrical cables or wires such as
commercial power supply lines.
Most appliance motors require more than their rated wattage for start-up.
Use a threaded hole of the heat sink for connecting the external ground
source to the inverter.
KEEP OUT OF REACH OF CHILDREN.
7.5 S WITCHING OFF THE INVERTER
In order to provide sufficient time to the inverter for the saving of the internal parameter and
diagnostic codes, it is important to previosly detach all the loads before switching off the inverter
power supply.

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EFU10000
4.0kVA INVERTER UNIT
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8. MAINTENANCE
The purpose of the maintenance schedule is to keep the system in the best operating conditions.
The inverter needs a few operations of maintenance if correctly used.
WARNING
NOTE
Shut off the engine before performing any maintenance.
Do not touch the box and the wires of the electronic inverter within 10
minutes after the engine has come to a complete stop. High voltage is still
present inside the Inverter.
When a problem happens and it is different from those specified on Chapter
10 TROUBLESHOOTING, contact an authorized inverter dealer.
The heat sink and the fan of the inverter may become dirty as a consequence
of the generator use, and so the inverter can loose part of its heat transfer
capability. Every 6 months or sooner it is necessary to visual inspect the
generator set slots and the dust filters, cleaning them with low pressure
compressed and dry air, if necessary.
Every 3 months control cables and connectors.

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4.0kVA INVERTER UNIT
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9. TRANSPORTING AND STORAGE
See Chapter 11 for minimum and maximum storage temperatures.
Use the original card boxes and respect the positioning specifications (UP
and DOWN directions) when moving the parts.
Do not put any weight above the card boxes.
Be sure that the card boxes do not come in contact with water, high
humidity and direct sun.
The boxes cannot be thrown or shocked.

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4.0kVA INVERTER UNIT
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10. TROUBLESHOOTING
The following instructions must be followed when appliance does not operate with engine
running.
POS. R E D LE D GREEN LED Y ELLO W LE D CONDITION INSTRUCTION
4
Slow flashing ON ON Overload Condition Decrease the load
5
ON OFF ON
Overload Protection Switch OFF inverter
power supply
Control the load
Decrease the load
6
Slow flashing- ON Slow flashing
Overtemperature
Condition
Decrease the load
Control the cooling
system
7
ON OFF
Slow flashing
Overtemperature
Protection
Switch OFF inverter
power supply
Wait for temperature
decreasing
8
OFF Slow flashing OFF Output Undervoltage
(see paragraph 11.5.7)
Control the load
Decrease thr load
9
ON
Slow flashing
ON
Output Undervoltage
(not Severe) Protection
Switch OFF inverter
power supply
Control the load
Decrease the load
10
ON
Slow flashing
OFF
Output Undervoltage
(Severe) Protection
Switch OFF inverter
power supply
Control the load
Decrease the load
11
Slow flashing ON Fast flashing BUS Overvoltage
Condition (I
st
level)
Control the load
Decrease the load
12
ON OFF Fast flashing
BUS Overvoltage
Protection
Switch OFF inverter
power supply
Wait for bus capacitors
to be completely
discharge
13
ON OFF OFF Inverter Failure
Control the load
Control the generator
14
ON Fast flashing Fast flashing
Brake Resistor
Protection
Switch OFF inverter
power supply
Wait for bus capacitors
to be completely
discharge
15
ON ON ON Generator Behavior
Switch OFF inverter
power supply
Control for an app
lied
external voltage source
Control generato
r
connection and/o
r
behaviour
WARNING
When, after following the proper instruction, the problem persists, send
back the unit to KWG