tronic KFU- Table of contents Important information ................5 Notes on the documentation ..................5 1.1.1 Other applicable documents ................5 1.1.2 Storing the documentation .................. 5 1.1.3 Symbols....................... 5 Qualified staff......................6 CE-marking ........................ 6 Safety instructions ...................... 6 1.4.1 General informations ...................
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tronic KFU- Installing the wall-mounted drive control ..............25 4.4.1 Suitable installation location for wall mounting ..........25 4.4.2 Mechanical Installation ..................26 4.4.3 Power connection....................28 4.4.4 Brake copper ..................... 28 4.4.5 Control connections ..................28 Commissioning ................... 29 Safety instructions during commissioning..............
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tronic KFU- Optional accessories ................67 Adapter plates ......................67 8.1.1 Motor-adapter plates ..................67 8.1.2 Motor adapter plates (specific) ................69 8.1.3 Wall adapter plates (standard) ................69 MMI manual control unit..................71 PC communication cable ..................71 Guidelines, Norms and Standards ............72 EMV limit classes ......................
tronic KFU- 1 Important information This chapter contains important information on the safe handling of the product and on the op- erating manual. 1.1 Notes on the documentation The following notes are a directory for the overall documentation. We assume no liability for any damage resulting from the non-observance of this manual. Provide this manual to the operator of the system so that it will be available when required.
tronic KFU- 1.2 Qualified staff In the context of this operating manual and the notes relating to the product itself, qualified staff refers to electronic specialists that are familiar with the installation, assembly, start-up and operation of the drive control and with the dangers involved, and whose specialist training and knowledge of relevant standards and regulations provide them with the necessary abilities.
tronic KFU- ATTENTION! The drive control can only be operated safely if the required environmental conditions listed in the “Suitable environmental conditions” chapter are fulfilled. ATTENTION! This operating manual must be accessible near the device and available to all users. ATTENTION! Please read these safety instructions and warnings before installation and start-up;...
tronic KFU- 1.4.3 Commissioning WARNING! Danger of injury through electric shock. Non-observance of warnings can result in serious injury or damage. Only hard-wired network connections are permitted. The device must be grounded (DIN EN 61140; VDE 0140-1). Frequency converters of the INVEOR series can contain contact currents (leakage currents) >...
tronic KFU- ATTENTION! Risk of damaging the drive control. If the notes are not observed, the drive control could be damaged and destroyed during subse- quent start-up. Observe the following instructions during operation: o The motor parameters, especially the l T settings, have to be configured properly to provide proper motor overload protection.
tronic KFU- 1.5 Proper Use If the device is installed in a machine, converters may not be started up (i.e. intended operation may not begin) until it has been determined that the machine complies with the regulations in EC Directive 2006/42/EC (machine directive); DIN EN 60204-1; VDE 0113-1:2007-06 must be observed.
tronic KFU- 2 General description The inverter KFU-tronic is a device for the speed control of three-phase asynchronous motors. The drive control can be integrated in the motor (with the standard adapter plate) or close to the motor (with the wall installation adapter plate). The permitted ambient temperatures specified under Technical data refer to operation at nomi- nal load.
tronic KFU- 3 Technical data 3.1 Overview of installation sizes The drive controls are available in the following performance classes and under the specified in- stallation size names. Installation size Recommended 0,55 / 0,75 / 11,0 / 15,0 / 2,2 /3,0 / 4,0 5,5 / 7,5 motor power (kW) 1,1 / 1,5...
tronic KFU- 3.2 General data Installations size Rated motor power 0,55 0,75 [kW] / 4-pole motor Ambient temperature -25 (non condensing) to +50 (without derating) * [°C] Mains voltage [V] 3~ 200 -10% … 480 +10% Mains frequency [Hz] 47 to 63 Network configura- TN/TT tions...
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tronic KFU- Installations size Rated motor power 18,5 [kW] / 4-pole motor Ambient temperature -25 (non condensing) to +50 (without derating) * [°C] Mains voltage [V] 3~ 200 -10% … 480 +10% Mains frequency [Hz] 47 to 63 Network configurations TN/TT Mains current [A] 10,8...
tronic KFU- 3.3 Specification of interfaces Designation Function Digital inputs 1–4 - Switching level low < 5 V / high > 15 V - Imax (at 24 V) = 3 mA - Rin = 8.6 kOhm Analogue inputs 1, 2 - In +/- 10 V or 0–20 mA - In 2–10 V or 4–20 mA - Resolution 10 Bit...
tronic KFU- 4 Installation 4.1 Safety instructions during installation WARNING! Installation may be performed only be appropriately qualified employees who are trained in the set-up, installation, start-up and operation of the product. Work performed on the drive control by unqualified staff and non-observance of warnings can result in serious in- jury or damage.
tronic KFU- 4.2.2 Suitable installation location for the motor integrated drive control Stellen Sie sicher, dass der Motor mit motorintegriertem Antriebsregler nur in den im nach- folgenden Bild gezeigten Ausrichtungen montiert und betrieben wird. 4.2.3 Basic connection versions Star or triangle connection for drive controls integrated in the motor ATTENTION! Risk of damaging the drive control.
tronic KFU- Unused open cable ends in the motor terminal box must be insulated. If a PTC or Klixxon is used, the electric jumper fitted on the connection terminal for the PTC in the delivery state has to be removed. The cross-section of the supply line has to be designed according to the transfer category and the maximum permitted current.
tronic KFU- 4.2.6 Preventing electromagnetic interferences Screened lines should be used for control circuits where possible. The screening should be ap- plied to the line end with special care without laying the leads across longer stretches without screening. Screening for analogue target values should only be applied on one side of the drive control. In principle, control lines should always be laid as far away from power-conducting lines;...
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tronic KFU- The standard adapter plate is an adapter plate whose underpart has not been refinished. There are no boreholes. Individual tailored adapter plates for selected motors are available from your KFU-tronic. sup- plier Adjust the adapter plate (1) by creating the appropriate boreholes (2) for attachment to the motor.
tronic KFU- 4.3.2 Power connection Unscrew the four bolts from the housing cover of the drive control and remove the cover. Guide the power cord through the cable connection and connect the phases to contacts L1, L2, L3 and the ground cable to the PE contact of the connection terminal. The cable provides strain relief, and the PE connection line has to be connected in a leading fashion (considerably longer).
tronic KFU- 4.3.4 Control connections ATTENTION! Danger of external signals being coupled in. Use only screened control lines.
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tronic KFU- Terminal configurations X5 Terminal no. Designation Configuration 24 V In ext. power supply GND (ground) Mass 24 V Out int. power supply GND (ground) Mass 24 V Out int. power supply Dig. In 1 Target value release (parameter 1,131) Dig.
tronic KFU- Terminal configuration X7 (relay 2) Terminal no. Designation Configuration Centre contact relay 2 Closing contact relay 2 Opening contact relay 2 In the factory setting,“no function” is allocated to relay 2 (parameter 4.210). 4.3.5 Terminal connection diagram The drive control is operational after the 400 V power supply has been switched on. Alterna- tively, the drive control can be started up by connecting an external 24 V power supply.
tronic KFU- 4.4 Installing the wall-mounted drive control 4.4.1 Suitable installation location for wall mounting Ensure that the installation location for a INVEOR wall mounting meets the following con- ditions: o The drive control has to be mounted on an even and fixed surface. o The drive control may only be mounted on non-flammable bases.
tronic KFU- 4.4.2 Mechanical Installation Wiring on the motor connection box Open the motor connection box. ATTENTION! Depending on the required motor voltage, the star or triangle connection must be made in the motor connection box! Use a suitable EMC screw connection to attach the screened cable to the motor connec- tion box and ensure that the screening contact is in order (large surface).
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tronic KFU- DANGER! The drive control may not be installed without an adapter plate! Find a position that meets the required ambient conditions as described in the "Installation requirements" section. To achieve optimum self-convection of the drive control, ensure that the (EMC) screw connection is facing upwards when installing.
tronic KFU- Attaching the drive control Position the drive control (1) on the adapter plate (2) so that the collar of the adapter dips into the opening on the floor of the cooling element. Fasten the control unit to the adapter plate with the help of the screws (3) provided (torque: 4.0 Nm).
tronic KFU- 5 Commissioning 5.1 Safety instructions during commissioning. ATTENTION! Danger of damage If the notes are not observed, the drive control could be damaged and destroyed during subse- quent start-up. Commissioning may only be performed by qualified staff. Safety precautions and warnings must always be observed WARNING! Danger of injury...
tronic KFU- 5.4 Start-up steps Parameterising is possible prior to installation. Parameterisation can be performed before the drive control is installed in the engine. The drive control has a 24 V low-voltage input for this purpose, which can supply the electric system without requiring mains power.
tronic KFU- 6 Parameter This chapter contains the following: o An introduction to the parameters o An overview of the most important start-up and operation parameters 6.1 Safety instructions for dealing with parametern WARNING! Danger of injury due to restarting motors. Non-observance can result in serious injury or damage.
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tronic KFU- PID inverse: The PID feedback can be inverted using the 3.061 parameter. The feedback is imported in- versely, i.e. 0 V…10 V correspond internally to 100%…0%. Please note that the reference must also be defined inversely. An example A sensor with an analogue output signal of (0 V…10 V) is to operate as the source of the feed- back channel (at AIx).
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tronic KFU- Stand-by function in PID process control: This function can provide energy savings in applications such as booster stations where PID process control is used to control to a specific process value and the pump has to run on a “minimum frequency”...
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tronic KFU- Preset speed: In this operating mode, preset speed references are transferred to the motor control. There are 7 preset speeds (2,051 to 2,057) that are BCD coded and attached fixedly to digital inputs 1 to 3. These seven preset speeds can be released in three groups via the “preset speed mode” (2,050) parameter: 0 = preset speed 1, 1 = preset speed 1 to 3, 2 = preset speed 1 to 7.
tronic KFU- 6.2.2 Structure of the parameter tables Parameter numbers Unit Description in the parameter manual Field for entering an own value on page ... Parameter name Explanation of the parameter Transfer status There are further parameters that switch drive control off and relate to these parameters on for transfer set hardware release again...
tronic KFU- 6.3 Application parameters 6.3.1 Basic parameters 1.020 Low speed Unit: Hz Relationship to own value (to min: Parameter manual: Transfer status: parameter: be entered!) max.: 400 p. xy def.: 0 1,150 The low speed is the frequency provided by the drive control as soon as it 3,070 released and no additional target value is pending.
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tronic KFU- 1.051 Acceleration 1 Unit: s Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 1000 p. xy def.: 5 1,021 Acceleration 1 is the time that the inverter takes to speed up from 0 Hz to 1,054 the high speed.
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tronic KFU- 1.054 Ramp section Unit: integer Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 6 p. xy def.: 0 1,050 to 1,053 Selection of used ramp pair 0 = deceleration 1 (1.050) / acceleration 1 (1.051) 1 = deceleration 2 (1.052) / acceleration 2 (1.053) 2 = digital input 1 (false = ramp pair 1 / True = ramp pair 2) 3 = digital input 2 (false = ramp pair 1 / true = ramp pair 2)
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tronic KFU- 1.131 Enable software Unit: integer Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 11 p. xy def.: 0 1,132 WARNING 1,150 The motor may start immediately, depending on the change made. 2,050 Selection of the source for the control release.
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tronic KFU- 1.150 Rotational direction Unit: integer Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 7 p. xy def.: 0 1,131 Selecting the rotational direction specification 0 = dependent on target value (depending on the plus or minus sign of the target value: positive: forward;...
tronic KFU- 1.182 Quantity of automatic reset Unit: Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 500 p. xy def.: 5 1,180 Next to the automatic reset (1,181), it is possible to limit the number of 1,181 maximum automatic resets here.
tronic KFU- 6.3.3 Motorized potentiometer This mode must be selected in the parameter 1.130. This function can be used as a source of target values for the frequency setting mode as well as for the PID process controller. 2.150 MOP digital Input unit: integer Relationship to min:...
tronic KFU- 2.154 MOP reference memory Unit: integer Relationship to min: Own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 1 p. xy def.: 0 Defines whether the target value of the motor potentiometer is retained even after power outage. 0 = deactivated 6.3.4 PID process controller This mode has to be selected in parameter 1,100,...
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tronic KFU- 3.060 PID feedback Unit: integer Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 2 p. xy def.: 0 1,100 Selection of the input source from which the feedback for the PID process 1,130 controller is imported: 3,061...
tronic KFU- 3.070 PID stand-by time Unit: s Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 10000 S. xy def.: 0 1,020 If the drive control operates the set time with the low speed (parameter 1,020), the motor is stopped (0 Hz), see also Chapter 5.2.1, “PID process control”...
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tronic KFU- 4.023/4.053 Alx dead time Unit: % Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 100 p. xy def.: 0 4.024/4.054 Alx filter time Unit: s Relationship to min: 0.02 own value (to Parameter manual: Transfer status: parameter:...
tronic KFU- 4.035/4.065 Alx physical maximum Unit: Relationship to min:-10,000 own value (to Parameter manual: Transfer status: parameter: be entered!) max.:+10,000 p. xy def.: 100 4,033/4,063 Selection of the upper limit of a physical value to be displayed. 6.3.6 Digital inputs 4.110 to 4.113 DIx inverted Unit: integer...
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tronic KFU- 4.101 AO1 minimum output Unit: Relationship to min:-10,000,000 own value (to Parameter manual: Transfer status: parameter: be entered!) max.:+1,000,000 p. xy def.: 0 4,100 Describes which area is to be resolved to the 0-10 V output voltage or the 4.102 AO1 maximum output Unit:...
tronic KFU- 6.3.8 Digital outputs For digital outputs 1 and 2 (DOx display DO1/DO2) 4.150/4.170 DOx function Unit: integer Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 50 p. xy def.: 0 4,151/4,171 Selection of the process value to which the output should switch. 4,152/4,172 0 = not allocated / KFU-TRONIC Soft-PLC 1= intermediate circuit voltage...
tronic KFU- 4.152/4.172 DOx off Unit: Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.:1,000,000 p. xy def.: 0 6.3.9 Relay For relays 1 and 2 (Rel.x – display Rel. 1/Rel. 2) 4.190/4.210 Rel.x function Unit: integer Relationship to min:...
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tronic KFU- 4.191/4.211 Rel.x on Unit: Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.:1000000 p. xy def.: 0 4.192/4.212 Rel.x off Unit: Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.:1000000 p.
tronic KFU- 6.3.10 External fault 5.010/5.011 External fault 1/2 Unit: integer Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 4 p. xy def.: 0 4,110 to 4,113 Selection of the source from which an external error can be reported. 0 = not allocated / KFU-TRONIC Soft-PLC 1 = digital input 1 2 = digital input 2...
tronic KFU- 6.3.11 Motor current limit This function limits the motor current to a parameterised maximum value after a parameterised current-time surface has been reached. This motor current limit is monitored at application level and thereby limits with relatively low dynamics.
tronic KFU- 6.3.12 Stall detection 5.080 Stall detection Unit: integer Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 1 5,081 p. xy def.: 0 This parameter can be used to activate stall detection. 0 = disable 5.081 Blocking time Unit: s...
tronic KFU- 6.4 Performance parameters 6.4.1 Motor data 33.001 Type of motor Unit: Integer Relationship to own value (to min: Parameter manual: Transfer status: parameter: be entered!) max.: 2 S. xy def.: 1 34,010 Selecting the type of motor 1 = asynchronous motor 2 = synchronous motor The parameters are shown depending on the type of motor selected.
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tronic KFU- 33.035 Motor frequency Unit: Hz Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 100 p. xy def.: 0 This is where the nominal motor frequency f is set. 33.050 Stator resistance Unit: Ohm Relationship to min: own value (to...
tronic KFU- 33.201 Nominal flow Unit: mVs Relationship to min: Own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 5000 p. xy def.: 0 For synchronous motors only. The nominal flow can be optimised here if the automatically determined 6.4.2 I²T 33.010 T fact.
tronic KFU- 6.4.3 Switching frequency The internal switching frequency (clocking frequency) can be changed in order to control the power element. A high setting reduces noise in the motor but increases EMV emission and losses in the drive control. 34.030 Switching frequency Unit: Hz Relationship to...
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tronic KFU- 34.012 Encoder line count Unit: integer Relationship to min: Own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 10000 34,010 p. xy def.: 1024 34,011 Selection of the line count of the sensor used. 34.013 Encoder offset Unit: °...
tronic KFU- 34.110 Slip trimmer Unit: Relationship to min: own value (to Parameter manual: Transfer status: parameter: be entered!) max.: 1.3 p. xy def.: 1 33,034 Only for asynchronous motors. This parameter can be used to optimise or deactivate slippage compensa- tion.
tronic KFU- 6.4.6 Synchronous motor controller data Field weakening 34.225 Unit: integer Relationship to min: own value Parameter manual: Transfer status: parameter: (to be en- max.: 1 tered!) p. xy Def.: 0 For synchronous motors only. 0 = inactive, the motor cannot be run in the field weakening. 1 = active, the motor can be placed in the field weakening until the con- 34.226 Starting current...
tronic KFU- 7 Error detection and troubleshooting This chapter contains the following: o A list of the LED flash codes for error recognition o A description of error recognition using PC tools o A list of errors and system errors o Notes on error detection with the MMI WARNING! Danger injury and danger of electric shock.
tronic KFU- 7.2 List of errors and system errors When an error occurs, the converter is switched off; you can find the corresponding error num- bers in the flash code table or the PC tool. Error messages can only be confirmed once the error has been remedied. Error messages can be confirmed as follows: o digital input (programmable) o via the MMI (manual operating unit)
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tronic KFU- Error name Description of fault Possible cause/remedy Excess frequency con- Inner temperature too high Insufficient cooling, low verter temperature appli- motor speed and high cation torque, clocking frequency too high Bus time-out No answer from bus sharing unit Check bus wiring or MMI/PC Confirmation error...
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tronic KFU- Error name Description of fault Possible cause/remedy Ground leak Ground leak during a motor Insulation error phase Motor connection dis- No motor current in spite of con- No motor connected rupted trol through frequency converter Motor parameters Plausibility check for motor pa- Parameter set not OK rameters failed Drive control parameters...
tronic KFU- 8 Optional accessories This chapter contains brief descriptions of the following optional accessories o Adapter plates o Manual control unit MMI including connection cable RJ11 on plug M12 o Brake resistors 8.1 Adapter plates 8.1.1 Motor-adapter plates A standard motor adapter plate (with an integrated terminal board) is available for each KFU- tronic installation size.
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tronic KFU- Hole pattern for BG B standard adapter plate - 2,2 to 4 kW: Hole pattern for BG C standard adapter plate - 5,5 to 7,5 kW...
tronic KFU- When using raised-cylindrical head screws (cf. DIN 912 / DIN 6912) or flat head screws (cf. DIN EN ISO 7380), the hole pattern must be drilled in compliance with the applicable drawing on the KFU-tronic mounting frame. The drill-hole centres should be on the respective centre lines of the slots illustrated on the diagram.
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tronic KFU- Hole pattern for Size B standard wall adapter plate Hole pattern for size C standard wall adapter plate...
tronic KFU- 8.2 MMI manual control unit including a 3 m RJ11 connection cable on an M12 plug The MMI manual control unit is connected to the integrated M12 interface of the KFU-tronic. This operating unit allows the user to write (program) and/or to visualize all the parameters of the KFU-tronic.
tronic KFU- 9 Guidelines, Norms and Standards This chapter contains information about electromagnetic compatibility (EMC), and guidelines, norms and standards. 9.1 EMV limit classes Please note that EMV limit classes are only reached if the standard switching frequency (clock- ing frequency) of 8 kHz is complied with. Depending on the installation material used and/or extreme ambient conditions, it might be necessary to use additional sheath wave filters (ferrite rings).
tronic KFU- 9.3 Standards and guidelines Required Markings For installation on industrial machines in accordance with the Standard for Industrial Machinery NFPA79 only Maximum Ambient Temperature: Electronic Adapter Ambient INV MA 4 1.5 ADP MA WDM 35°C INV MB 4 2.2 ADP MB WDM 45°C INV MB 4 3.0...
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