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Küenle KFU 2 Series - User Manual

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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

Table of Contents

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Summary

General Information about the Documentation

Quick Start Guide

Basic steps for mechanical and electrical installation of the frequency inverter.

Operating Instructions

Detailed description of all functions, parameters, and additional functions.

Application Manual

Supplements documentation for installation and commissioning, application-specific topics.

Installation Instructions

Information on installing and using additional or optional components.

General Safety Instructions and Information on Use

General Information

Safety precautions during operation, risk of high voltage, hot surfaces, and improper handling.

Purpose of the Frequency Inverters

Intended use, compliance with directives, CE marking, and UL label.

Transport and Storage

Guidelines for proper transportation and storage conditions to maintain device integrity.

Handling and Installation

Precautions for careful handling, avoiding mechanical stress, and electrostatic discharge.

Electrical Connection

Safety instructions before connection, discharging capacitors, and complying with standards.

Information on Use

Guidelines on power supply connection, restart behavior, and pre-commissioning checks.

Maintenance and Service

Warnings against unauthorized interventions and specifying authorized repair personnel.

Safety Instructions on Function Safe Torque Off“ (STO)

Details on the STO function, its limitations, and safety requirements for its use.

Scope of Supply

KFU 2-(up to 3.0 kW) and KFU 4- (up to 4.0 kW)

Details the components included in the delivery for specific models.

KFU 2-(4.0 to 9.2 kW) and KFU 4- (5.5 to 15.0 kW)

Lists the delivery scope for intermediate power range models.

KFU 4- (18.5 to 30.0 kW)

Specifies the scope of delivery for higher power KFU 4 models.

KFU 4- (37.0 to 65.0 kW)

Details the delivery contents for the next power range of KFU 4 inverters.

KFU 4- (75.0 to 132.0 kW)

Outlines the scope of supply for the highest power KFU 4 models.

Technical Data

General technical data

CE conformity, EMC directive, UL approval, ambient temperature, environmental class, and degree of protection.

Technical Data - Control Electronic Equipment

Specifications for control terminals X210A, X210B, and relay output X10.

KFU 2- (0.25 to 1.1 kW, 230 V)

Technical specifications including output current, mains voltage, fuses, and dimensions.

KFU 2- (1.5 to 3.0 kW, 230 V)

Technical data for higher power KFU 2 models operating at 230 V.

KFU 2- (4.0 to 9.2 kW, 230 V)

Technical specifications for the upper power range of KFU 2 inverters at 230 V.

KFU 4- (0.25 to 1.5 kW, 400 V)

Technical data for the lower power range of KFU 4 inverters at 400 V.

KFU 4- (1.85 to 4.0 kW, 400 V)

Technical specifications for KFU 4 inverters in the mid-power range at 400 V.

KFU 4- (5.5 to 15.0 kW, 400 V)

Technical data for higher power KFU 4 inverters at 400 V.

KFU 4- (18.5 to 30.0 kW, 400 V)

Technical specifications for the upper power range of KFU 4 inverters at 400 V.

KFU 4- (37.0 to 65.0 kW, 400 V)

Technical data for the highest power KFU 4 inverters at 400 V.

KFU 4- (75.0 to 132.0 kW, 400 V)

Technical specifications for the very highest power KFU 4 inverters at 400 V.

Operation diagrams

Graphical representation of derating based on installation height, coolant temperature, and mains voltage.

Mechanical Installation

KFU 2- (up to 3.0 kW) and 401 (up to 4.0 KW)

Details mounting instructions and dimensions for KFU 2 and 401 inverters up to 3.0 kW.

KFU 2- (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW)

Mounting instructions and dimensions for KFU 2/401 inverters from 4.0 kW to 15.0 kW.

KFU 4- (18.5 to 30.0 kW)

Installation guidelines and dimensions for KFU 4 inverters in the 18.5 to 30.0 kW range.

KFU 4- (37.0 to 65.0 kW)

Mechanical installation details and dimensions for KFU 4 inverters, 37.0 to 65.0 kW.

KFU 4- (75.0 to 132.0 kW)

Installation and dimensioning specifications for the highest power KFU 4 inverters.

Electrical Installation

EMC Information

Measures for electromagnetic interference avoidance, equipotential bonding, and cable shielding.

Block diagram

Visual representation of mains connection, DC link, control, and motor connections.

Optional Components

Information on available hardware modules like control units and communication modules.

Connection of Unit

Guidelines for selecting conductor cross-sections based on current load and voltage drop.

Mains Connection

Instructions for selecting mains fuses, cable cross-sections, and adhering to standards.

Motor Connection

Recommendations for using shielded cables, connecting motors, and managing cable lengths.

Connection of types

Details mains and motor connection for KFU 2/401 up to 3.0 kW.

Control Terminals

Information on configuring control and software functionality for reliable operation.

External DC 24 V power supply

Requirements for an external DC 24 V power supply used for control terminals.

Relay Output

Details the connection and function of the freely programmable relay output.

Motor Thermo-Contact

Configuration of digital input for motor thermal switch evaluation.

Control terminals - Connection diagrams of configurations

Illustrates terminal logic and function assignments for standard configurations.

Configurations overview

Table summarizing possible combinations of functions and control methods available.

Configuration 110 - Sensorless Control

Functions for variable-speed control of 3-phase machines in standard applications using V/f characteristic.

Configuration 111 - Sensorless Control with Technology Controller

Extends sensorless control with functions for flow, pressure, level, or speed control.

Configuration 410 - Sensorless Field-Oriented Control

Enables sensorless, field-oriented control of 3-phase machines for high drive dynamics.

Configuration 411 - Sensorless Field-Oriented Control with Technology Controller

Combines field-oriented control with a Technology Controller for advanced process control.

Configuration 430 - Sensorless Field-Oriented Control, Speed and Torque Controlled

Adds torque-dependent control to field-oriented control for precise operation.

Configuration 210 - Field-Oriented Control, Speed Controlled

Provides speed-controlled, field-oriented control with speed sensor feedback for high performance.

Configuration 211 - Field-Oriented Control with Technology Controller

Integrates Technology Controller with field-oriented control for process automation.

Configuration 230 - Field-Oriented Control, Speed and Torque Controlled

Offers torque-dependent field-oriented control for precise speed and torque management.

Configuration 510 - Field-Oriented Control of Synchronous Machine, Speed Controlled

Field-oriented control for synchronous machines with resolver feedback for precise speed performance.

Configuration 530 - Field-Oriented Control of a Synchronous Machine, Speed and Torque Controlled

Combines field-oriented control with torque-dependent control for synchronous machines.

Control Unit KP500

Keys

Description of the functions of the control unit keys for navigation and operation.

Menu Structure

Overview of the control unit's menu navigation structure and key functions.

Main Menu

Explanation of how to access and navigate through the four main menu branches.

Actual Value Menu (VAL)

How to display and monitor various actual values of the frequency inverter.

Parameter Menu (PARA)

Instructions for navigating, selecting, and editing parameters for configuration.

Copy Menu (CPY)

Functionality for copying parameter values between the control unit and frequency inverter.

Reading the Stored Information

Process of reading stored data from the control unit and handling initialization or errors.

Menu Structure

Details the three main functions within the copy menu: Format, All, and Active.

Selecting the Source

How to select the data source (frequency inverter or control unit files) for copy operations.

Selecting the Destination

Procedure for selecting the target location (data sets or files) for the copy operation.

Copy Operation

Steps involved in transferring parameter settings and handling potential errors during the copy process.

Error Messages

Table listing error codes, meanings, and remedies for the copy function.

Reading Data From Control Unit

How to activate parameter transmission from the control unit to the frequency inverter.

Activation

Steps for activating parameter transmission via keyboard or communication module.

Data transfer

Procedure for transmitting files from the control unit to the frequency inverter.

Resetting to Normal Operation

How to reset the control unit to normal operation mode after parameter transmission.

Control Menu (CTRL)

Information on controlling the drive via the control unit, including necessary connections.

Controlling the Motor via the Control Unit

How to control motor speed and functions using the control unit and its keys.

Commissioning of the Frequency Inverter

Switching on Mains Voltage

Checks to perform before switching on mains voltage and the inverter's self-test procedure.

Setup Using the Control Unit

Guided commissioning process to set parameters relevant to the application.

Configuration

Explains parameter Configuration 30's role in defining control inputs, outputs, and software functions.

Data Set

How the data set change-over function allows selection of parameter storage sets.

Motor Type

How parameter Motor type 369 affects control functions and parameter verification.

Machine Data

Entry of motor data from the nameplate for accurate machine model calculation and plausibility checks.

Plausibility check

Verification process for machine data and handling of warning/error messages.

Parameter Identification

Process for measuring and identifying further machine data for precise control.

Application data

Importance of checking further parameters for specific applications after guided commissioning.

Acceleration and deceleration deceleration deceleration

Defines how output frequency changes after reference value changes, start, stop, or brake commands.

Set points at multi-functional input

Parameterizing the multi-functional input MFI1 for reference value signals.

Quitting commissioning

Procedure for terminating the guided commissioning process and inverter initialization.

Selection of an actual value for display

How to select and display specific actual values on the control unit after commissioning.

Check direction of rotation

Procedure for checking motor rotation direction and troubleshooting incorrect rotation.

Speed sensor

Adapting inverters to applications requiring incremental speed sensors.

Speed sensor 1

Connecting and configuring speed sensor 1, including operation modes and division marks.

Speed sensor 2

Details on connecting and configuring speed sensor 2, which requires an expansion module.

Set-up via the Communication Interface

Performing parameter setting and commissioning via communication interfaces.

Inverter Data

Serial Number

Information on identifying the device type and fabrication data.

Optional Modules

Details on modular hardware extensions and their designations.

Inverter Software Version

Information on the firmware version, software key, and copyright.

Set Password

How to set a password for protection against unauthorized access to parameters.

Control Level

Defines the scope of functions available for parameterization.

User Name

Entering plant or machine designation via optional control software.

Configuration

Explains Configuration 30's role in assigning functions to control inputs/outputs and software features.

Language

Setting the display language for parameter descriptions.

Programming

Acknowledging fault messages and resetting to factory settings using parameters.

Machine Data

Rated Motor Parameters

Setting motor parameters based on the rating plate for accurate machine model calculation.

Further motor parameters

Data not on rating plate, required for precise calculation in field-oriented control.

Stator Resistance

Measurement and optimization of stator resistance for asynchronous and synchronous motors.

Leakage Coefficient

Defines leakage inductivity ratio for optimizing field-oriented control systems.

Magnetizing Current

Measure of motor flux, used for optimizing sensorless field-oriented control.

Rated slip correction factor

Factor accounting for rotor time constant variations due to temperature and current.

Voltage constant

Improves control behavior for synchronous machines with high dynamic requirements.

Stator inductance

Value between two motor phases, used for high dynamic control of synchronous machines.

Peak current

Sets limits for Isq value to protect synchronous motors, taken from motor data sheet.

Change sense of rotation

Reversing the motor's rotating direction via parameter or input signals.

Internal values

Parameters used for internal calculation of motor data, requiring no setup.

Speed Sensor 1

Connecting and configuring speed sensor 1, including operation modes and division marks.

Operation Mode Speed Sensor 1

Selecting appropriate modes for speed sensor 1 based on sensor type and evaluation method.

Division marks, speed sensor 1

Adjusting the number of speed sensor increments for application-specific speed range.

Gear factor speed sensor 1

Setting parameters to define mechanical transmission ratio between sensor and motor shaft.

Sensor evaluation

Explanation of sensor evaluation accuracy levels and types (single, double, quadruple).

System Data

Actual System Value

Using parameter 389 to monitor drive via actual value 242.

Volume Flow and Pressure

Parameterizing factors for monitoring drive using actual values for volume flow and pressure.

Operational Behavior

Starting Behavior

Parameterizing machine start behavior based on control functions and methods.

Starting Behavior of Sensorless Control System

Setting starting behavior modes for sensorless control, including magnetization and current impression.

Starting Current

Parameter for impressing starting current, ensuring sufficient torque for high start torque applications.

Frequency Limit

Setting a limit for output frequency, above which control method transitions occur.

Brake release time

Time delay for releasing the motor holding brake before starting the drive.

Flux Formation

Regulation of flux and torque forming current components for field-oriented control upon startup.

Stopping Behavior

Defining machine stopping behavior using parameter Operation mode 630 and logic signals.

Switch-Off Threshold

Defining the frequency from which drive standstill is recognized for switch-off.

Holding Time

Time duration for maintaining current supply to the motor when stopped, considered in certain stopping behaviors.

Direct current brake

Activating direct current braking for stopping behaviors and search run functions.

Auto Start

Function allowing drive start upon mains voltage application, with controller enabling and start command.

Search Run

Synchronizing the drive to a rotating motor without overcurrent faults.

Positioning

Defining positioning operations using reference or axle positioning modes.

Reference positioning

Positioning based on a digital reference signal and positioning distance.

Axle Positioning

Positioning based on a speed sensor feedback and reference orientation.

Error and warning behavior

Overload Ixt

Setting warning limits for short-term and long-term overload based on switching frequency.

Temperature

Parameterizing warning limits for heat sink and inside temperatures to prevent fault switch-off.

Controller status

Indicating controller interventions and their impact on operating behavior.

IDC Compensation Limit

Compensating DC components in output current by setting a maximum output voltage limit.

Frequency Switch-Off Limit

Setting a maximum output frequency to prevent inverter switch-off with fault message.

Motor Temperature

Monitoring motor temperature and configuring behavior for warnings or delayed switch-off.

Phase Failure

Monitoring for phase failures and configuring inverter/motor shutdown behavior.

Automatic Error Acknowledgment

Enabling automatic acknowledgment of specific faults and defining limits for this.

Reference Values

Frequency Limits

Defining the output frequency and speed setting range using minimum and maximum frequency parameters.

Slip Frequency

Limiting torque in machine model calculation using slip frequency parameter.

Percentage Value Limits

Setting percentage ranges for reference values used in scaling and frequency calculation.

Frequency reference channel

Connecting various signal sources for defining the reference frequency.

Block diagram

Describes software switches for frequency reference value channel based on selected source.

Reference percentage channel

Combining signal sources for definition of reference figures and facilitating application integration.

Block diagram

Describes software switches for the reference percentage value channel based on selected source.

Fixed reference values

Parameterizing fixed frequencies or percentages for configuration and function.

Fixed Frequencies

Defining reference values selected via fixed frequency change-over modes.

JOG frequency

Function for manual setup and positioning, setting output signal frequency via FUN key.

Fixed Percentages

Defining percentage reference values selected via fixed percentage change-over modes.

Frequency ramps

Determining how quickly the frequency value changes based on reference value changes or commands.

Percentage Value Ramps

Scaling reference value change (in percent) for input functions, using acceleration/deceleration ramps.

Block Frequencies

Fading out reference frequencies to avoid resonance points and stationary operating points.

Control Inputs and Outputs

Multi-Function Input MFI1

Configuring MFI1 as voltage, current, or digital input for various software functions.

Analog input MFI1 A

Default configuration for analog reference value using voltage signal, with option for current signal.

Characteristic

Mapping analog input signals to reference frequency or percentage values via parameterization.

Scaling

Mapping analog input signals to drive setting ranges using frequency or percentage limits.

Tolerance Band and Hysteresis

Adapting analog input characteristic with sign change for reference value and tolerance band.

Filter Time Constant

Setting time constant for averaging analog reference value input using a low-pass filter.

Error and warning behavior

Selecting operation modes for monitoring analog input signals and defining warning/shutdown behavior.

Multi-Function Output MFO1

Configuring MFO1 as digital, analog, or repetition frequency output.

Analog output MFO1 A

Configuring MFO1A for pulse width modulated signal with adjustable voltage range.

Output Characteristic

Adjusting voltage range of output signal based on actual values and voltage parameters.

Frequency Output MFO1 F

Using MFO1 as frequency output, assigning speed or frequency via parameter.

Scaling

Corresponds repetition frequency mode to incremental sensor mapping, parameterizing division marks.

Digital Outputs

Linking digital outputs and relay output to various functions based on configuration.

Digital Signal

Selecting signals for digital outputs and linking them with inverter functions.

Setting Frequency

Activating digital output when actual stator frequency exceeds a set frequency value.

Reference value reached

Generating a signal when actual frequency or percentage value reaches the reference.

Flux Forming finished

Output becomes active when flux formation is ended, influenced by starting behavior.

Brake release

Activating a brake unit via digital output based on starting/stopping behavior and control commands.

Current Limitation

Linking digital outputs to intelligent current limits and reducing power based on selected operation mode.

External Fan

Controlling an external fan via digital output based on controller release or temperature.

Warning Mask

Configuring logic signals for monitoring functions to combine warnings and enable control.

Application warning mask

Setting logic signals for monitoring functions and enabling warnings based on limit switches or errors.

Digital inputs

Assigning control signals to software functions, differing by configuration and operation mode.

Start command

Linking start parameters to digital inputs or internal logic signals for drive acceleration.

3-wire control

Controlling the drive using digital pulses for start, stop, and direction via specific signals.

Error Acknowledgment

Adapting monitoring functions via error/warning behavior and acknowledging faults.

Timer

Selecting time functions for time-control of digital signals using operation modes and time constants.

Thermo contact

Monitoring motor temperature by linking digital input to operation mode for temperature measurement.

n-;M Control Change-Over

Functions for speed or torque-dependent control, monitoring transition between control systems.

Data Set Change-Over

Storing parameter values in four data sets and enabling change-over via logic signals.

Fixed Value Change-Over

Specifying reference figures via fixed frequencies or percentages and enabling change-over via logic signals.

Motor Potentiometer

Controlling motor speed via digital control signals or control unit keys.

Motorpoti (MP)

Parameterizing motor potentiometer function via reference frequency or percentage sources.

Motorpoti (KP)

Availability of Motorpoti (KP) function in reference frequency channel, controlled via KP500 keys.

Controlling the Motor via the Control Unit

How to control motor speed and functions using the control unit and its keys.

PWM-;repetition frequency input

Using PWM or repetition frequency signals for reference value specification, evaluated via digital inputs.

V;f-Characteristic

Dynamic Voltage Pre-Control

Accelerates control behavior of current/voltage controllers by adjusting output voltage.

Control Functions

Intelligent current limits

Setting current limits to avoid inadmissible load and prevent fault switch-off, optimizing overload reserve.

Voltage controller

Monitoring DC link voltage and controlling it to a set limit, including power failure regulation.

Technology Controller

PID controller behavior for process control like pressure, volume flow, or speed.

Functions of Sensorless Control

Additional functions supplementing V/f characteristic for sensorless control.

Slip compensation

Compensating load-dependent speed difference without feedback, correcting stator frequency and speed.

Current limit value controller

Ensuring drive system is not overloaded by reducing load during acceleration.

Functions of Field-Orientated Control

Control functions based on cascade control and complex machine model calculation.

Current Controller

Inner control loop of field-oriented control, impressing motor current via flux and torque components.

Torque Controller

Demands speed limitation in operating points without load moment by increasing speed to reference torque limits.

Limitation of Speed Controller

Limiting output signal of speed controller (torque-forming current component Isq) via various parameters.

Limit Value Sources

Limiting output values by fixed value or linking to analog input via parameters.

Integral time speed synchronization

Setting integrating portion of speed control for speed accuracy in synchronization modes.

Acceleration Pre-Control

Activating acceleration pre-control in speed-controlled configurations to reduce drive system reaction time.

Field Controller

Controlling flux-forming current component via field controller, optimizing parameters for machine model.

Limitation of field controller

Limiting field controller output signal and integrating part via parameters.

Modulation Controller

Adapting output value to machine behavior in speed and field weakening areas, reducing flux.

Limitation of Modulation Controller

Limiting controller output and integrating part to prevent control loop oscillations.

Special Functions

Pulse Width Modulation

Reducing motor noise by changing switching frequency and adjusting output signal.

Fan

Setting switch-on temperature for heat sink fan and controlling external fan.

Bus controller

Connecting digital controller inputs for drive control and enabling output stage.

Brake Chopper and Brake Resistance

Connecting external brake resistor and setting trigger threshold for brake chopper activation.

Dimensioning of Brake Resistor

Values needed for dimensioning brake resistors, including peak braking power and operation time.

Motor Protection Switch

Protecting motors against overload and short-circuits, with options for warning or immediate disconnection.

V-belt Monitoring

Continuous monitoring of load behavior and connection between machine and load via V-belt system.

Motor Chopper

Function for adapted implementation of generator energy into heat for dynamic speed changes.

Temperature Adjustment

Measuring motor temperature and adjusting parameters for precise machine model calculation.

Speed Sensor Monitoring

Monitoring speed sensor signals for faulty behavior and affecting fault switch-off.

Traverse function

Superimposing a triangle-shaped frequency signal for traverse function with acceleration/deceleration times.

Actual Values

Actual Values of the Frequency Inverter

Displaying actual value parameters like DC link voltage, modulation, and frequency.

STO Status

Extended diagnosis of digital inputs STOA and STOB for safety function STO.

Actual Values of the Machine

Reading control variables and actual values of the machine or system for diagnosis.

Actual value memory

Storing various actual values for operating behavior assessment and maintenance.

Actual Values of the System

Calculating actual system figures based on parameterized system data and electrical variables.

Actual System Value

Monitoring the drive via actual value 242, calculated from actual frequency and system value factor.

Volume Flow and Pressure

Parameterizing factors for monitoring drive using actual values for volume flow and pressure.

Error Protocol

Error List

Storing last 16 fault messages chronologically and showing the total number of errors.

Error Messages

Detailed explanation of error codes, meanings, and remedies for various fault conditions.

Error Environment

Documents operational behavior during last four faults for troubleshooting.

Operational and Error Diagnosis

Status Display

Using green and red LEDs and control unit messages (RUN, WARN, FAULT) to display operational status.

Status of Digital Signals

Checking digital input/output signals and their assignment to software functions during commissioning.

Controller Status

Establishing active control functions and displaying controller codes based on sums of individual codes.

Warning Status and Warning Status Application

Displaying current warnings via status messages and linking them to application-specific configurations.

Parameter List

Actual Value Menu (VAL)

Listing actual values of the machine, frequency inverter, and system with units and display ranges.

Parameter Menu (PARA)

Comprehensive list of all parameters, structured by menu branches and numerical order.

Küenle KFU 2 Series Specifications

General IconGeneral
BrandKüenle
ModelKFU 2 Series
CategoryDC Drives
LanguageEnglish

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