KW-Generator EFU 1000 Manual Download

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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: +49 (0) 7171 104 17 – 0
Fax: +49 (0) 7171 104 17 – 29

www.kw-generator.com

[email protected]

Summary of Contents for EFU 1000

Page 1: ... 4 0kVA INVERTER UNIT Pag 1 34 INVERTER EFU 1000 MANUAL KW Generator GmbH Co KG Bänglesäcker 24 73527 Schwäbisch Gmünd Lindach Tel 49 0 7171 104 17 0 Fax 49 0 7171 104 17 29 www kw generator com info kw generator com ...

Page 2: ...ly to standards of paragraph 11 9 2 1 0B 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 LIST manufacturing of the first sample ...

Page 3: ...NVERTER 12 4 2 INVERTER GROUNDING 12 4 3 MOTOR INPUT CONNECTIONS 13 4 4 230VAC OUTPUT 13 4 5 SIGNALS CONNECTOR 13 4 6 RELAY CONNECTOR 14 4 7 BRAKE RESISTOR CONNECTORS 14 4 8 CON4 CON5 14 5 PRE OPERATION CHECK 15 5 1 MOUNTING INSTRUCTIONS 15 6 STARTING THE SYSTEM 16 7 INVERTER USE 18 7 1 GENERATION STARTING 18 7 2 BRAKING 19 7 3 BEHAVIOUR OF LEDS 19 7 4 MOUNTING AND CONNECTING THE INVERTER 20 7 5 S...

Page 4: ...PUT 24 11 4 CONNECTORS AND OR WIRING 25 11 5 230VAC OUTPUT PROTECTIONS 26 11 6 INPUT PROTECTIONS 27 11 7 BRAKE RESISTOR COMMAND PROTECTION 27 11 8 DC BUS PROTECTINS 27 11 9 OPERATIVE DIAGNOSTIC SIGNALS 28 11 10 MESSAGING SIGNALS 29 11 11 DIAGRAMS AND INTERFACES 30 11 12 APPLICABLE STANDARDS 32 12 GUARANTEE 33 13 DRAWINGS 34 ...

Page 5: ...hould 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 49 0 7171 104 17 0 Fax 49 0 7171 104 17 29 www kw generator com info kw generator com 2 1 GENERAL NOTES All information in this publication is based on the latest product information available at the time of...

Page 6: ...void 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 negati...

Page 7: ...ly 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 th...

Page 8: ...g 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 bur...

Page 9: ...MANUAL EFU10000 4 0kVA INVERTER UNIT Pag 9 34 AIR FLOW Figure 5 Mounting position of the inverter and air flow ...

Page 10: ...ormally independent by motor oscillations and loading The location of its input and output connections is shown in Figure 7 CON7 CON6 CON4 CON5 TO BRAKE RESISTOR L1 L2 L3 INPUT Figure 7 Inverter input and output connections While in the following paragraphs a detail of each single connection is reported 4 2 INVERTER GROUNDING The inverter grounding must be made on its heat sink ...

Page 11: ...opper section 4 mm2 o insulation voltage 1000VAC and minimum temperature range 25 C 155 C 4 5 SIGNALS CONNECTOR 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 CO...

Page 12: ...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 SIGNAL INSULATED INSULATED GROUND Table 2 Signals on CON7 connector 4 7 BRAKE RESISTOR CONNECTORS The customer shall connects to the two pr...

Page 13: ...nverter 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 bloc...

Page 14: ... 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 ...

Page 15: ...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 disconne...

Page 16: ...tions 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...

Page 17: ...imit 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 ...

Page 18: ...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 i...

Page 19: ...um 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 ...

Page 20: ...tage 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 Ist level Control the load Decrease the load 12 ON OFF Fast flashing BUS Overvoltage Protection Switch OFF inverter...

Page 21: ... Voltage VIN_MIN 220VAC 10 0 Sinus 3 phase Crest Factor 1 41 Inverter Output Voltage 207VAC Inverter Output Load Conditions IOUT_NOM 11 2 3 Nominal Input Current IIN_NOM 7 5Arms 1400 RPM 4 0kVA 11 2 4 Maximum Input Current IIN_MAX 14 7Arms 1400 RPM 7 0kVA 11 3 230VAC OUPUT 11 3 1 Nominal Output Voltage VOUT_NOM 230 Vrms ISO 8528 5 Class G2 see 11 3 9 11 3 2 Nominal Output Current IOUT_NOM 17 4 Arm...

Page 22: ...2 230VAC Output L N Nr 2 Würth PowerOne Bolt P N 91042 M6 Ring Terminals 11 4 3 Brake Resistor J8 J9 Nr 2 Würth PowerOne Bolt P N 91042 M6 Ring Terminals 11 4 4 Programming CON4 NOT AVAILABLE FOR KWG USE ONLY 11 4 5 Diagnostic CON5 NOT AVAILABLE FOR KWG USE ONLY 11 4 6 Relay Connector CON6 HIROSE DF5A 6DP 5DSA 05 HIROSE DF1B 10S 2 5R 11 4 7 Signal Connector CON7 HIROSE DF1BD 10P 2 5 DSA HIROSE DF1...

Page 23: ... Maximum Output Current value IMAX 11 5 6 Over Temperature 70 5 C When temperature overcomes the fixed threshold of 70 5 C on the heat sink temperature test point the inverter switches off automatically Before restarting the inverter it is preferable to detach all appliances 11 5 7 Output Undervoltage due to Insufficient Input Voltage 2 5 0 After 5 sec unit trips without overload conditions stand ...

Page 24: ...tor less than 10 shall be avoided 11 8 DC BUS PROTECTINS 11 8 1 BUS Overvoltage Protection 1st Level 680VDC 5 When BUS Voltage reaches the threshold of 680VDC 5 a Brake Resistor is connected in parallel to the BUS itself by means of an IGBT The protection will be automatically disabled when BUS Voltage will reach a value of 600VDC 5 Hysteresis The resistor shall be on customer side while IGBT and ...

Page 25: ... 11 9 9 Output Undervoltage not Severe Protection ON Slow flashing ON No output voltage Generator must be switched OFF and ON 11 9 10 Output Undervoltage Severe Protection ON Slow flashing OFF No output voltage Generator must be switched OFF and ON 11 9 11BUS Overvoltage Condition Ist level Slow flashing ON Fast flashing Avoid to operate in these situations 11 9 12BUS Overvoltage Protection ON OFF...

Page 26: ...rvoltage 2 Overload condition 3 Over temperature 11 10 MESSAGING SIGNALS DESCRIPTION TYPE SEEN FROM INVERTER STATUS CONDITION 0 Inverter temperature stays below 55 5 C 11 10 1Inverter Temperature5 OUTPUT 1 Inverter temperature overcomes 55 5 C 0 Inverter working in nominal range no limiting 11 10 2Inverter Status5 OUTPUT 1 Inverter switched OFF or limiting 0 Inverter output voltage higher than 48V...

Page 27: ...MANUAL EFU10000 4 0kVA INVERTER UNIT Pag 30 34 11 11 DIAGRAMS AND INTERFACES Figure 12 Overload protection trip delay Vs output current diagram Figure 13 Overload protection trip delay Vs load ...

Page 28: ...MANUAL EFU10000 4 0kVA INVERTER UNIT Pag 31 34 Figure 14 Interface from inverter to LED and messaging signals OPEN COLLECTOR Figure 15 Start command interface ...

Page 29: ... X and Y axis 3 5g Sinus between 10 80Hz 11 12 3 2 Along Z axis vertical 4g Sinus between 10 80Hz 11 12 3 3 Shock along X axis front direction 5 g 11 12 3 4 Shock along X axis back direction 5 g 11 12 3 5 Shock along Y axis 5 g 11 12 3 6 Shock along Z axis top direction 5 g 11 12 3 7 Shock along Z axis bottom direction 5 g 7 The applicable standards compliance is out of the offer for the first pro...

Page 30: ...shipment showing the complete equipment status When a faulty part happens KWG reserves the rights to control the complete application generator at its facilities in Montebelluna Treviso Italy KWG will not be liable neither for incorrect connections between the Generator or any of the output cables and the inverter nor for any failure of the inverter due to a damage of any of the above cables KWG w...

Page 31: ...MANUAL EFU10000 4 0kVA INVERTER UNIT Pag 34 34 13 DRAWINGS ...

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