INVERTER EFU 1000 - KW Generator · MANUAL EFU10000 / 34 4.0kVA INVERTER UNIT Pag. 1 INVERTER EFU...

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]

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

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


REVISION L IST

manufacturing of the first sample.

MANUAL

EFU10000


1. CONTENTS

REVISION L IST ................................................................................................................................ 2

1. CONTENTS................................................................................................................................ 3

2. SAFETY INSTRUCTIONS ..................................................................................................... 5

2.1 GENERAL NOTES ............................................................................................................... 5

2.2 USER’S INFORMATION ....................................................................................................... 5

2.3 EXPLANATION OF THE SYMBOLS ON THIS MANUAL. .......................................................... 6

2.4 SPECIAL NOTES ................................................................................................................. 6

2.5 PARALLELING ................................................................................................................... 8

3. LABELS LOCATIONS ............................................................................................................. 9

3.1 SAFETY LABELS ................................................................................................................ 9

4. COMPONENT IDENTIFICATION ...................................................................................... 12

4.1 INVERTER ........................................................................................................................ 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 SWITCHING OFF THE INVERTER ....................................................................................... 20

8. MAINTENANCE ..................................................................................................................... 21

9. TRANSPORTING AND STORAGE ..................................................................................... 22

10. TROUBLESHOOTING .......................................................................................................... 23

11. SPECIFICA TIONS.................................................................................................................. 24

MANUAL

EFU10000


11.1. GENERAL.............................................................................................................................. 24

11.2. INVERTER INPUT FEATURES (GENERATOR SIDE) .................................................................. 24

11.3. 230VAC OUPUT .................................................................................................................... 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 & D IAGNOSTIC SIGNALS ................................................................................... 28

11.10. MESSAGING SIGNALS ........................................................................................................... 29

11.11. DIAGRAMS AND INTERFACES................................................................................................ 30

11.12. APPLICABLE STANDARDS ..................................................................................................... 32

12. GUARANTEE .......................................................................................................................... 33

13. DRAWINGS ............................................................................................................................. 34

MANUAL

EFU10000


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: +49 (0) 7171 104 17 – 0 Fax: +49 (0) 7171 104 17 – 29 www.kw-generator.com [email protected]

2.1 GENERAL 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 USER’S INFORMATION

Before starting the equipment: please read this description and note carefully the safety instructions.

MANUAL

EFU10000


2.3 EXPLANATION 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

NOTE

2.4 SPECIAL 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

NOTE

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


WARNING

NOTE

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 responsibility for 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


2.5 PARALLELING

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


AIR FLOW

Figure 5: Mounting position of the inverter and air flow

N N

OUTPUT

N L

MANUAL

EFU10000


4. COMPONENT IDENTIFICATION

4.1 INVERTER 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

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.

Figure 8: Inverter input and output connections

MANUAL

EFU10000


4.3 MOTOR INPUT CONNECTIONS

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 mm2, o insulation voltage 1000VAC and minimum temperature range -25°C +155°C.

4.4 230VAC OUTPUT Two M6 studs L (Live) and N (Neutral), are available for the 230VAC output.

NOTE For connecting the inverter to the AC loads use wires according with the following: o copper 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: CON7 connector lay-out

POSITION ON CON7

DESCRIPTION VOLTAGE VALUE

1 RED LED 0/12VDC

2 GREEN LED 0/12VDC

3 YELLOW LED 0/12VDC

4 OVERTEMPERATURE LED 0/12VDC

5 INVERTER STATUS LED 0/12VDC

6 DANGEROUS OUTPUT VOLTAGE LED 0/12VDC

7 INPUT START COMMAND 0/12VDC

8 INPUT – NOT CONFIGURATE N.D. 9 INPUT – NOT CONFIGURATE N.D. 10 INSULATED GROUND 0VDC

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 GENERIC 0/12VDC

5 12VDC OUTPUT 12VDC

6 12VDC OUTPUT 0VDC

MANUAL

EFU10000


4.6 RELAY CONNECTOR

A 6 ways auxiliary connector (named CON6) is available. It provides the contacts of an integrated relay, named RL21, a generic signal output, together with a 12VDC – 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 (SIGNAL)

INSULATED

INSULATED GROUND

Table 2: Signals on CON7 connector

4.7 BRAKE RESISTOR CONNECTORS

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 - 250VAC – Maximum power 250VA (AC 15).

MANUAL

EFU10000


5. PRE-OPERATION CHECK

5.1 MOUNTING INSTRUCTIONS

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). Avoid 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.

MANUAL

EFU10000


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

MANUAL

EFU10000


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,

the 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 GENERATION STARTING

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.

MANUAL

EFU10000


7.2 BRAKING

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 BEHAVIOUR OF LEDS

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 (Ist 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 behaviour

MANUAL

EFU10000


7.4 MOUNTING AND CONNECTING THE 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 SWITCHING 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.

MANUAL

EFU10000


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.

MANUAL

EFU10000


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.

MANUAL

EFU10000


10. TROUBLESHOOTING

The following instructions must be followed when appliance does not operate with engine running.

POS. RED LED GREEN LED YELLO W LED 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


10

ON

Slow flashing

OFF

Output Undervoltage (Severe) Protection


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 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 applied

external voltage source Control generator

connection and/or behaviour

WARNING When, after following the proper instruction, the problem persists, send back the unit to KWG

MANUAL

EFU10000


11. SPECIFICATIONS

11.1. GENERAL 11.1.1 Air Cooling Air Flow

Rating

To be Defined Forced ventilation by means of external fan

11.1.2 Operating Ambient Temperature

TOP

-20°C ≤ TOP ≤ +40°C

Class G2. For range -25°C ≤ TOP ≤ +60°C Operating Class may be reduced to G1

11.1.3 Storage Temperature TST -25°C ≤ TST ≤ +60°C

11.1.4 Maximum Altitude HAMB MAX 2000 m

11.1.5 Environment Conditions

To be Defined

11.1.6 Sealing Protection IP 00 According to IEC 60529 11.1.7 Acoustic Noise < 55 dB

11.1.8 Weight ~ 12.5 Kg

11.1.9 Dimensions See Figure 16 11.1.10 Block Diagram N.A.

11.2. INVERTER INPUT FEATURES (GENERATOR SIDE) 11.2.1 Nominal Input

Voltage

V IN_NOM

400VAC ±10% Sinus 3 phase.

Frequency: 46÷120Hz 11.2.2 Minimum Input

Voltage

V IN_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 Arms

11.3.3 Maximum Output Current

IOUT_MAX

32 Arms Maximum Current before Current Limiter Circuit intervention

11.3.4 Nominal Output Frequency FNOM 50Hz ISO 8528-5 Class G2 (see 11.3.9)

11.3.5 Nominal Output Power POUT_NOM 4.0kVA

@ -20°C ≤ TOP ≤ +40°C

11.3.6 Load Power factor Pf 0.6÷1 Inductive load 11.3.7 Efficiency

η Typically higher than 92%

@ POUT = 2.0kW – Pf=1

11.3.8 Total Harmonic Distortion

THD

≤ 5% @ Nominal Output Power - Nominal Input Voltage and Frequency

11.3.9 Output Type ISO 8528-5 Class G2

@ Nominal Input Voltage and Frequency, -20°C ≤ TOP ≤ +40°C

MANUAL

EFU10000


11.4. CONNECTORS AND/OR WIRING DESCRIPTION NAME QTY - TYPE - MANUFACTURER COUNTERPART

11.4.1 Input

L1 – L2 – L3 Nr.3 Würth PowerOne Bolt P/N 91042

M6 Ring Terminals

11.4.2 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 DF1B-10S-2.5R

11.5. 230VAC OUTPUT PROTECTIONS 11.5.1 Overload

IOVERLOAD

18 ± 0.5 ARMS

When protection takes place the inverter switches off automatically. Before restarting the inverter it is preferable to detach all appliances. The protection curve, shown in Figure 12, informs about the transitory time before protection intervention.

11.5.2 Output Current Limiter

IMAX

32 ARMS ± 5%

Output current is reduced if exceeding the indicated threshold. Output voltage remains sinusoidal till peak current limiter threshold is reached.

11.5.3 Short Circuit on Output Inverter switches off automatically. Before restarting the inverter it is preferable to detach all appliances.

11.5.4 Peak Current Limiter Threshold

50 A ± 10%

Inverter clips the output current in order to keep the absolute peak value inside a safety region.

11.5.5 Maximum Output Current Derating

-0.8 ARMS/°C

When temperature overcomes the fixed threshold of 55±5°C on the heat sink temperature test point, the inverter reduce the 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-by condition) due to low BUS voltage. Auto-restart function when normal operative conditions turn back.

11.5.8 Output Undervoltage due to Severe Overload

100 VRMS ± 5%

Unit trips immediately when peak current limiter is working. Before restarting the inverter it is preferable to detach all appliances.

11.5.9 Output Undervoltage due to not Severe Overload

180 VRMS ± 5%

Unit trips after 6 sec. Before restarting the inverter it is preferable to detach all appliances.

11.5.10 Pre Test at Starting Before starting the inverter, controls if measurable input conditions are inside tolerance (see 11.2).

MANUAL

EFU10000


207VRMS

2 Output voltage till 207VRMS shall be sinusoidal, without clipping, a part from situations when current limiter is working.

MANUAL

EFU10000


11.6. INPUT PROTECTIONS 11.6.1 Inrush Current Limiter A resistor shall limit Inrush Current

during start-up. When the Bus Voltage stays over 330VDC for at least 3 seconds, the resistor is bypassed by means of a relay.

11.7. BRAKE RESISTOR COMMAND PROTECTION 11.7.1 Brake Resistor

Overcurrent Protection Limit

IBR PROT

24 ADC ± 5%

When current through brake resistor overcomes IBR PROT, the brake resistor is disconnected and RL2 is activated. In any case heavy overloads, i.e. brake resistor 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 its control are integrated on the PCB.

11.8.2 BUS Overvoltage Protection – 2nd Level

760VDC ± 5%

When BUS Voltage reaches the threshold of 760VDC±5%, inverter output is switched off automatically and RL2 becomes activated. Engine must be switched off and the full discharge of the BUS must be waited before turning on the system again.

MANUAL

EFU10000


11.9. OPERATIVE & D IAGNOSTIC SIGNALS

LED STATUS

LED SIGNALS

RED LED GREEN

LED YELLOW

LED

COMMENTS

11.9.1 Pre-Test & Start-Up

Fast flashing

Fast flashing

Fast flashing Duration 3 seconds before starting of sinus generation.

11.9.2 Ready to Start

Slow flashing

Slow flashing

Slow flashing Inverter ready for generating the sinus voltage.

11.9.3 Normal Operation3 OFF ON OFF Normal operating of the inverter.

11.9.4 Overload Condition

Slow flashing

ON

ON Avoid to operate in these conditions (check the loads).

11.9.5 Overload Protection

ON

OFF

ON

No output voltage. Generator must be switched OFF and ON.

11.9.6 Overtemperature Condition

Slow flashing-

ON

Slow flashing Automatic current derating activation.

11.9.7 Overtemperature Protection

ON

OFF

Slow flashing

No output voltage. Generator must be switched OFF and waited for its cooling down (see 11.5.5).

11.9.8 Output Undervoltage (see paragraph 11.5.7)

OFF

Slow flashing

OFF

No output voltage. When voltage comes back to tolerance values, an automatic restart will happen.

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.

11.9.11 BUS Overvoltage Condition (Ist level) Slow flashing ON Fast flashing Avoid to operate in these situations

11.9.12 BUS Overvoltage

Protection

ON

OFF

Fast flashing

No output voltage. Generator must be switched OFF and user must wait for full discharge of BUS capacitors (all LEDs must be OFF).

11.9.13 Inverter Failure

ON

OFF

OFF Loads and generator must be checked4.

11.9.14 Brake Resistor Protection

ON

Fast flashing

Fast flashing

No output voltage. Generator must be switched OFF and user must wait for full discharge of BUS capacitors (all LEDs must be OFF).

11.9.15 Generator Behavior

ON

ON

ON

Input frequency signal lost on input line voltage L1 – L3. AC voltage applied to the inverter output.

3 When switching on, the inverter can find a voltage already present on its output terminals and consider this still as a normal operating situation if this voltage stays into the specification. In such case the inverter will try to put itself in parallel with this source. 4 In case of repetitive failures contact KWG.

MANUAL

EFU10000


NOTE When Start Command is available, it is possible to avoid the switching off and on of the generator, resetting the following protections by commutating OFF and ON the start command switch: - Overload, - Over temperature, - Output under voltage (not severe), - Output under voltage (severe).

In case of more than a fault condition at the same time, the priority of

signalization will be as per the following:

1. BUS Overvoltage 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 11.10.1 Inverter Temperature5

OUTPUT

1 Inverter temperature overcomes 55±5°C

0 Inverter working in nominal range (no limiting) 11.10.2 Inverter Status5

OUTPUT

1 Inverter switched OFF or limiting

0 Inverter output voltage higher than 48VRMS 11.10.3 Dangerous Voltage5

OUTPUT

1 Inverter output voltage lower than 48VRMS

CLOSE Inverter starts to generate 11.10.4 Start Command6

INPUT

OPEN Inverter stops to generate

5 See Figure 14 for signal interface. 6 See Figure 15 for signal interface.

MANUAL

EFU10000


11.11. DIAGRAMS AND INTERFACES

Figure 12: Overload protection trip delay Vs. output current diagram

Figure 13: Overload protection trip delay Vs. load

MANUAL

EFU10000


Figure 14: Interface from inverter to LED and messaging signals (OPEN COLLE CTOR)

Figure 15: Start command interface

MANUAL

EFU10000


11.12. APPLICABLE STANDARDS7

11.12.1. MARKING ACCORDING TO 11.12.1.1 Safety EN 60950 - Protection Class I 11.12.1.2 Emission for Residential,

Commercial and Light- Industrial Enviroments

EN 61000-6-3

11.12.1.3 Conducted Emission for Industrial Enviroments EN 61000-6-4

11.12.1.4 Immunity for Industrial Enviroments EN 61000-6-2

11.12.1.5 Construction Machinery - Electromagnetic Compatibility of Machines with Internal Power Supply

EN 13309

11.12.2. SEALING PROTECTION LEVEL 8

11.12.2.1 Sealing protection level IP

IP 00

11.12.3. VIBRATIONS 9

11.12.3.1. Along 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 prototypes. This compliance will be quoted separately after validation of the first prototypes when power supplied by customer’s motor and concerning the main electrical characteristics detailed in paragraph 11. 8 The reaching of a sealing protection level IP 67 depends completely on the enclosure made by the customer. 9 Vibrations test to be performed and fixed by customer or quoted separately by KWG.

MANUAL

EFU10000


12. GUARANTEE

KWG gives a period of guarantee of 12 months for the inverter.

The starting date for the guarantee is that marked on the delivery documents.

NOTE

NOTE

NOTE

NOTE

NOTE

When a faulty inverter happens it must be sent back to KWG, free of charge, together with some digital pictures of the part taken before the 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 will not be liable neither for failures nor for unwanted output

tripping i f the maximum operating temperatures are exceeded (inverter temperature on measurement point).

MANUAL

EFU10000


13. DRAWINGS

INVERTER EFU 1000 - KW Generator · MANUAL EFU10000 / 34 4.0kVA INVERTER UNIT Pag. 1 INVERTER EFU...

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