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
Pag. 2 / 34
REVISION L IS T
manufacturing of the first sample.

MANUAL
EFU10000
4.0kVA INVERTER UNIT
Pag. 3 / 34
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
Pag. 4 / 34
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

MANUAL
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.

MANUAL
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.

MANUAL
EFU10000
4.0kVA INVERTER UNIT
Pag. 7 / 34
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.

MANUAL
EFU10000
4.0kVA INVERTER UNIT
Pag. 8 / 34
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.

MANUAL
EFU10000
4.0kVA INVERTER UNIT
Pag. 9 / 34
AIR
FLOW
Figure 5: Mounting position of the inverter and air flow

NN
OUTPUT
NL
MANUAL
EFU10000
4.0kVA INVERTER UNIT
Pag. 12 / 34
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.