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COMBIVERT F5/F6 INSTRUCTIONS FOR USE | INSTALLATION SYSTEM V | 600…1000 KVA Translation of the original manual Document 20136714 EN 01 | Mat.No. 00F6NEM-0V00...
PrEFAcE Preface The described hard- and software are developments of the KEB Automation KG. The enclosed documents correspond to conditions valid at printing. Misprint, mistakes and technical changes reserved. Signal words and symbols Certain operations can cause hazards during the installation, operation or thereafter.
The customer may use the instruction manual as well as further documents or parts from it for internal purposes. Copyrights are with KEB Automation KG and remain valid in its entirety. Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their...
TAbLE OF cONTENTS Table of contents Preface ..............................3 Signal words and symbols ......................3 More symbols ..........................3 Laws and guidelines ........................4 Warranty ............................4 Support ............................4 Copyright ............................4 Table of contents ........................... 5 List of Figures ............................9 List of Tables ............................10 Glossar ..............................
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TAbLE OF cONTENTS 3.6.4 Overcurrent and short-circuit protection ................36 3.7 c6 HMI program functionalities ....................37 3.7.1 Self-test at power-on-reset ....................37 3.7.2 Monitoring cooling circuit ....................37 3.7.3 Monitoring mains ........................ 37 3.7.4 Data logger ........................38 3.7.5 Visualisation ........................38 4 Overview cabinet system ..........
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TAbLE OF cONTENTS 6.5.3 Instructions for installation ....................57 6.6 Selection installation of the motor cable ..................58 6.6.1 General information ......................58 6.6.2 Selection of the motor cable ....................59 6.6.3 Connection of the motor cable ................... 60 6.7 connection motor temperature monitoring ................61 6.7.1 General information ......................
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TAbLE OF cONTENTS c Annex - cooling System ..........83 c.1 General information ........................83 C.1.1 Materials in the cooling cicuit ..................... 83 C.1.2 Requirements on the coolant ..................... 84 C.1.3 Cooling circuit ........................84 C.1.4 Special requirements for open and half-open cooling systems ......... 85 C.1.5 Coolant flow temperature ....................
LIST OF FIGUrES List of Figures Figure 1: Functional overview ......................27 Figure 2: Overview of the electrical power unit ................28 Figure 3: Overview of the electrical power unit with braking option ..........29 Figure 4: Structure of the higher-level control ................. 30 Figure 5: Structure of the liquid distribution..................
International standard Synchronous sensorless closed Inverter A loop Inverter B Synchronous serial interface for COMBIVERT KEB drive converters encoder COMBIVIS KEB start-up and parameterizing PT1000 Temperature sensor with software R0=1000Ω MTTF mean service life to failure PT100 Temperature sensor with R0=100Ω...
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GLOSSAr Term used in the safety technolo- gy (EN 61508-1...7) for the size of error probability Term used in the safety technolo- gy (EN 61508-1...7) for the size of error probability per hour Universal serial bus Inverter B...
STANDArDS FOr DrIVE cONVErTErS / cONTrOL cAbINETS Standards for drive converters / control cabinets DGUV regulation 3 Electrical systems and equipment DIN 46228-1 Wire-end ferrules; Tube without plastic sleeve DIN 46228-4 Wire-end ferrules; Tube with plastic sleeve DIN IEC 60364-5-54 Low-voltage electrical installations - Part 5-54: Selection and erection of electrical equipment - Earthing arrangements, protective conductors and protec- tive bonding conductors...
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STANDArDS FOr DrIVE cONVErTErS / cONTrOL cAbINETS EN 61439-1 Low-voltage switchgear and controlgear assemblies - Part 1: General rules (IEC 121B/40/CDV:2016); German version FprEN 61439-1:2016 EN 61508-1...7 Functional safety of electrical/electronic/programmable electronic safety-related systems – Part 1...7 (VDE 0803-1…7, IEC 61508-1…7) EN 61800-2 Adjustable speed electrical power drive systems - Part 2: General requirements - Rating specifications for low voltage adjustable frequency a.c. power drive...
Hazards and risks through ignorance. ► Read the instruction manual ! ► Observe the safety and warning instructions ! ► If anything is unclear, please contact KEB Automation KG ! 1.1 Target group This instruction manual is determined exclusively for electrical personnel. Electrical per- sonnel for the purpose of this instruction manual must have the following qualifications: •...
bASIc SAFETY INSTrUcTIONS Drive converters contain electrostatic sensitive components. ► Avoid contact. ► Wear ESD-protective clothing. Do not store drive converters • in the environment of aggressive and/or conductive liquids or gases. • with direct sunlight. • outside the specified environmental conditions. 1.3 Installation DANGEr Do not operate in an explosive environment! ►...
bASIc SAFETY INSTrUcTIONS 1.4 Electrical connection DANGEr Voltage at the terminals and in the device ! Danger to life due to electric shock ! ► Never work on the open device or never touch exposed parts. ► For any work on the unit switch off the supply voltage and secure it against switching on.
Accordng to EN 60204-1 it is permissible to disconnect already tested com- ponents. Drive converters of the KEB Automation KG are delivered ex works voltage tested to 100% according to product standard. 1.4.3 Insulation measurement An insulation measurement (in accordance with EN 60204-1 chapter 18.3) with DC...
bASIc SAFETY INSTrUcTIONS 1.5 Start-up and operation The drive converter must not be started until it is determined that the installation com- plies with the machine directive; Account is to be taken of 60204-1. WArNING Software protection and programming ! Hazards caused by unintentional behavior of the drive! ►...
For applications that require cyclic switching on and off of the drive converter, main- tain an off-time of at least 5 min. If you require shorter cycle times please contact KEB Automation KG. Short-circuit proof The drive converters are conditional short-circuit proof. After resetting the internal pro- tection devices, the function as directed is guaranteed.
Drive converters with safety function are limited to a service life of 20 years. Then the devices must be replaced. Drive converters of the KEB Automation KG are professional, electronic devices exclu- sively for further industrial processing (so-called B2B devices). Thus the marking does not occur with the symbol of the crossed-out wheeled bin, but by the word mark and the date of manufacture.
All conventional three-phase machines with and without encoder system can be operated. The sensor- less KEB technologies SCL and ASCL are additionally available for highest require- ments even without encoder feedback.
The technical data as well as the data of the connection conditions must be taken from the type plate and the instruction manual and must be complied with. The semiconductors and components used at KEB Automation KG have been devel- oped and designed for the use in industrial products.
FUNcTIONAL OVErVIEW 3 Functional overview This chapter provides an overview of the arrangement of all components in the cabinet system. It contains the following areas: • Electrical power unit • Braking option • Superior control • Liquid distribution • Cabinet air conditioning •...
FUNcTIONAL OVErVIEW 3.1 representation of the electrical power unit with higher-level control External back-up fuse or circuit breaker to protect the power supply control cabinet A Circuit breaker > > > DEIF Current sensors GPU3 HF filter C6 IPC HMI 15,6" Wide AFE filter control cabinet b Drive converter...
FUNcTIONAL OVErVIEW 3.2 representation of the electrical power unit with braking option External back-up fuse or circuit breaker to protect the power supply control cabinet A Circuit breaker > > > Current sensors HF filter AFE filter control cabinet b control cabinet b Drive converter Connection second braking option...
FUNcTIONAL OVErVIEW 3.3 Structure of the higher-level control The structure includes the following features: Diagnostic interface Accessible via HSP5 or RS485 (for setting mode, remote access via router, mainte- nance, usable). control operation via the PLc control Requests of different parameters for monitoring/control of the cabinet system, as well as control of the drive converter.
FUNcTIONAL OVErVIEW 3.4 Structure of the liquid distribution • The cabinet system and all essential heat sources are liquid-cooled and thus they have only a low heat dissipation to their direct environment. • A tempered water-glycol mixture should be used as coolant. •...
FUNcTIONAL OVErVIEW 3.5 Structure of the cabinet air conditioning • The cabinet system is designed for protection class IP54. • An LW heat exchanger is used for the removal of the ambient heat generated in the cabinet system. • The power dissipation caused by heat output in the cabinet system is refeed into the cooling circuit via the LW heat exchanger.
FUNcTIONAL OVErVIEW 3.6 General specifications 3.6.1 Machine safety The functional safety and stop categories "Safe Torque Off (STO)" are integrated into the cabinet system. These allow an optimum adaptation of the drive to the required safety category for the machine. The function "Safe torque off" switches off the control voltage for the power semiconductors and prevents by way that the drive converter gen- erates the AC voltage required to turn the motor.
FUNcTIONAL OVErVIEW 3.6.2 Switching frequency A circuit breaker is integrated in the cabinet system for switching off the mains voltage. With frequent start / stop commands, switching off should be done via the EtherCat bus or the potential-free customer interface. A "Safe Torque Off"...
FUNcTIONAL OVErVIEW 3.6.3 Emergency stop function • The emergency stop button is integrated in the cabinet door. • Pressing the emergency stop button interrupts the safety chain. • Precharging and circuit breaker are switched off. • The voltage supply of the drive converter is interrupted. •...
FUNcTIONAL OVErVIEW 3.6.4 Overcurrent and short-circuit protection The cabinet system has integrated the following protective devices. Drive converter • Two integrated inverters with electronic current measuring system. • The possibility to monitor the input and the output current. • OC-tripping current up to 150% depending on the operating mode. •...
FUNcTIONAL OVErVIEW 3.7 c6 HMI program functionalities 3.7.1 Self-test at power-on-reset • Error state of both inverter units • Last error (e.g. prior off by error) • Main switch state • Supply monitoring state • Fuse monitoring state • Fieldbus interface 3.7.2 Monitoring cooling circuit •...
Contains the drive converter, the liquid distributors and connec- tions for the AC motor. Optional control cabinet c: Contains the sinusoidal output filter and an area for the optional assembly of braking resistors. Braking resistors should be designed in consultation with KEB for the respec- tive application. Figure 8: Overview cabinet system...
DIL 1000. The additional control cabinet is equipped with a mechanical main switch, NH fuses, as well as the mains connections. basic system with Dc-busbar It is possible to install a DC-busbar with DC fuses above the cabinet system in order to connect additional components. This should be designed and configured together with KEB.
OVErVIEW cAbINET SYSTEM 4.2 Cabinet system without sine-wave filter at the output Legend control cabinet A control cabinet b Control electronics Drive converter LW heat exchanger Liquid distributors Circuit breaker mains connection Motor connection terminals AFE filter Figure 9: Basic system without SF filter...
OVErVIEW cAbINET SYSTEM 4.3 Cabinet system with sine-wave filter at the output Legend A control cabinet A control cabinet b c control cabinet c Control electronics Drive converter 8 Optional for braking resistors LW heat exchanger Liquid distributors 9 SF filter Circuit breaker mains connection Motor connection terminals AFE filter...
OVErVIEW cAbINET SYSTEM 4.3.1 Dimensions Used cabinet type Rittal TS8. Figure 12: Dimension drawing with SF filter Side view identical with „Figure 10: Dimension drawing without SF filter“.
MEcHANIcAL INSTALLATION 5 Mechanical Installation 5.1 General information This chapter contains information about transport, assembly and the permissible ambi- ent conditions. For further data please refer to chapter „Technical Data“. Transport and store the cabinet system in its packaging before installation. Remove the tightening straps and loose the fastening screws on the pallet only after reaching the final position.
Type Ver.No. Input AC 3 PH 50/60Hz manufactured by 400...690V xxxA Output AC 3 PH 0...400Hz 0...Uin xxxA UL: KEB Automation KG xxxkVA Südstraße 38 D-32683 Barntrup Made in Germany Figure 14: Type plate Delivery with transport damage. ► Stop unpacking the goods.
MEcHANIcAL INSTALLATION 5.4 Installation of the cabinet system The cabinet system is delivered with lifting eye. These are used to accommodate corresponding lifting devices. The lifting eyes can be removed after the transport. After removing the lifting eyes, the original fixing screws must be screwed again in order to ensure the degree of protection IP54. WArNING Risk of tipping without fixed screw! ►...
MEcHANIcAL INSTALLATION 5.5 Installation location requirements Alignment in balance. ► Check the ground with a water level. 90° ► Align the cabinet system at a 90° angle to the ground. • The installation location must be free from dirt and moisture. •...
MEcHANIcAL INSTALLATION 5.6 Attach the cabinet system 5.6.1 Fixing at ground level • There are four borings M10 intended in the socle for the mounting on the ground. • The dimensions for the fixing points can be found in the following chapter„5.6.2 Hole distances“. • Each cabinet section must be fixed to the ground with at least one fixing point on the front and back side. • If this is not possible because of accessibility, the fixing points of the adjacent cabi- net sections must be increased accordingly. •...
MEcHANIcAL INSTALLATION 5.6.2 Hole distances 15 x 10 92,5 Front side Figure 18: Hole distances 5.6.3 Distances to the wall • The cabinet system is suitable for vertical installation in electrical operating rooms, as well as in the area of production facilities •...
MEcHANIcAL INSTALLATION 5.6.4 Mounting on the wall • The cabinet system has a pull-out system for disassembling the drive converter. • If it is necessary to remove the drive converter, make sure that the cabinet system is securely anchored to the wall. •...
MEcHANIcAL INSTALLATION 5.7 Installation of the coolant connection 5.7.1 General information • The connection to the cooling system can occur as closed or open cooling circuit. • The connection to a closed cooling circuit is recommended since the risk of contam- ination of the cooling liquid is extremely low.
KEB assumes no liability for installations which do not comply with laws, local and / or other reg- ulations. If the recommendations provided by KEB are not observed, problems can occur when using the drive converter, which are not covered by the warranty.
ELEcTrIcAL INSTALLATION 6.3 Shield connection • Cable shields must not be used for current flow. • A cable shield may not simultaneously assume the function of an N or PE conductor. • Attach the cable shields always in a large surface. • Do not create lengthening of the cable shield by unshielded wire connections to the grounding point.
ELEcTrIcAL INSTALLATION 6.5.2 connection to circuit breaker • The circuit breaker NZM4 is equipped with a tunnel terminal per phase. • The circuit breaker has four connections in two levels. • Connect the mains cable to terminals L1 / L2 / L3 of the circuit breaker and the PE conductor to the earthing bar.
ELEcTrIcAL INSTALLATION 6.5.3 Instructions for installation We recommend the use of Lappkabel Ölflex Classic 100. ► Remove the upper insulation of the connection cables over a length of 43 cm, this facilitates the entry into the cabinet. ► Cut the rubber sleeve of the cable entry at 46 mm - 52 mm to ensure a clean seal. ►...
ELEcTrIcAL INSTALLATION 6.6 Selection installation of the motor cable 6.6.1 General information • The motor cables must be designed to the maximum continuous current. • They are valid for 0...100 Hz (up to 300 Hz the cable losses increase by approx. 25% due to the skin effect).
ELEcTrIcAL INSTALLATION 6.6.2 Selection of the motor cable The correct selection and installation of the motor cable is very important for high motor power: • Lower load of the motor bearings through bearing currents. • Better EMC characteristics. • Lower symmetrical operating capacities. •...
ELEcTrIcAL INSTALLATION 6.6.3 connection of the motor cable • The motor cables are connected to copper bars placed horizontally shifted in the depth. • To fix the motor cables to the copper bars, ring cable lugs should be pressed on the single conductor.
ELEcTrIcAL INSTALLATION 6.7 connection motor temperature monitoring 6.7.1 General information The motor must be protected against overheating in accordance with the regulations. The output current is switched off if an overload of the motor occurs. The drive converter has a thermal protection function which protects the motor and switches off the current, if required.
Parameter In.17 displays the function of the used temperature input in the first digit of the hex value. The KEB COMBIVERT is delivered as standard with a switchable PTC / KTY evaluation. The required function is set with Pn.72 (dr33 at F6) and operates...
ELEcTrIcAL INSTALLATION ATTENTION KTY or PTc cables and sensors ► Do not lay KTY or PTC cable from the motor (also screened) together with control cables! ► KTY or PTC cable within the motor cable only permitted with double shielding! ►...
• Braking resistors can optionally be used for protection against mains power failure. The braking resistors should be designed in consultation with KEB for the respective application. In regenerative operation, braking resistors convert the energy cAUTION generated by the motor into heat.
ELEcTrIcAL INSTALLATION 6.9 connection „Safe torque off (STO)“ If the cabinet system is ordered with "Safe torque off", the STO function can be wired to the terminal block -X2B. Figure 31: Connection „Safe torque off (STO)“ -X2B Figure 32: Wiring „Safe torque off (STO)“ Information on the F6 control boards can be found here.
TEcHNIcAL DATA 7 Technical Data 7.1 Operating conditions Definition according to EN 61800 Speed-changeable electric drives EN 61800-2 Part 2: Basic specifications for AC drive converters EN 61800-3 Part 3: EMC requirements, including special test procedures EN 61800-5-1 Part 5-1: Safety requirements 7.1.1 climatic conditions Operation extended to -5…45 °C (use frost protection for water Temperature cabinet system EN 60721-3-3 cooling systems and temperatures below zero)
TEcHNIcAL DATA 7.1.4 Electromagnetic compatibility according to EN 61800-3 EMc emitted interference Cable-based interferences – 1) 2) according to EN55011 Radiated interferences – Interference immunity Static discharges EN 61000-4-2 8 kV AD (air discharge) and CD (contact dis- charge) Burst - control lines + bus EN 61000-4-4 2 kV Burst - mains supply...
TEcHNIcAL DATA 7.2 Electrical data 690 V mains voltage Power Drive System Mains input Input rated voltage V AC 600 / 690 Input voltage range V AC 360…760 ±0 % Mains frequency 48-63 Phases permitted mains forms TN, TT max. system unbalance max.
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The tubes must be designed for min. 1 bar, depending on the dimension of the pipelines. The technical data are for 2/4-pole standard motors. With other pole numbers the inverter must be dimensioned onto the motor rated current. Contact KEB for special or medium frequency motors.
STArT-UP 8 Start-up 8.1 Liquid distribution 8.1.1 General To ensure an unrestricted function of the cooling system, it is necessary to flush the complete cooling system before the start-up of the cabinet system in order to remove air inclusions. ATTENTION When flushing do not use the flow rate of 130 l/min required to operate the cabinet system.
STArT-UP The table shows the volume flows in the entire system. Size 37 Total in l/min LW heat exchanger Table 10: Volume flows in the entire system 8.1.3 Structure liquid distribution Legend Main shut-off valve return ① ② Main shut-off valve pre-run flow Converter A WRB Converter B Sine-wave filter LW heat exchanger Shut-off valves AFE filter...
STArT-UP 8.1.4 Position stopcock closed half open open Figure 35: Position stopcock 8.1.5 Shutoff valves at the liquid distributor An Allen key of size 5 is required to open and close the respective cooling circuits. Figure 36: Shutoff valves at the liquid distributor...
STArT-UP 8.2 Power unit 8.2.1 Key switch S1 Position 0 In this position of the key switch, the commissioning of the cabinet system is be in the responsibility of the higher-level control . • The cabinet system can be activated manually on the HMI, if the drive has been parameterized accordingly before (see chapter =>...
STArT-UP 8.2.2 Arrangement of the control boards Figure 38: Arrangement of the control boards ① ② Legend ① ② Diagnostic interface WRA Diagnostic interface WRB Figure 39: Control boards...
STArT-UP 8.2.3 Procedure for initial start-up ► By switching on the main switch Q1, the components installed in the cabinet system are supplied with voltage. • The 24 V DC voltage of the cabinet system supplies the control boards externally with voltage.
F5 control board. Several possibilities are available here. One variant is shown as an example in the instruction manual of the drive converter. The realization of a different release should be done in consultation with KEB. Instructions for the drive converter can be found here.
ANNEx - GrAPHS A.3 Power dissipation of the cabinet system The diagram below shows the power dissipation of the cabinet system to the output current. ① 55,0 52,5 50,0 ② 47,5 45,0 42,5 40,0 37,5 35,0 32,5 30,0 27,5 25,0 22,5 20,0 17,5...
ANNEx - cErTIFIcATION b Annex - Certification b.1 cE Marking CE marked frequency inverters and servo drives were developed and manufactured to comply with the regulations of the Low-Voltage Directive and EMC directive.The harmo- nized standards of the series EN 61800-5-1 EN 61800-3 were used.
ANNEx - cOOLING SYSTEM c Annex - cooling System c.1 General information Since a liquid cooling is used for the cabinet system, the used components can be oper- ated significantly cooler in continuous operation than in air-cooled cabinet systems. This has positive effects on the lifetime of components such as fans, DC link capacitors and power modules (IGBT).
ANNEx - cOOLING SYSTEM Other materials must be tested before use. The specific case of application must be checked by the customer in conjunction of the complete cooling circuit and must be classified according to the used materials. With hoses and seals take care that halo- gen-free materials are used.A liability for occuring damages by wrongly used materials and from this resulting corrosion cannot be taken over! c.1.2 requirements on the coolant The requirements on the coolant are depending on the ambient conditions, as well as from the used cooling system.
ANNEx - cOOLING SYSTEM c.1.4 Special requirements for open and half-open cooling systems Problem Solution Impurities Mechanical impurities in half-open cooling systems can be counteracted when ap- propriate water filters are used. Salt concentration The salt content can increase through evaporation at half-open systems. Thus the water is more corrosive.
ANNEx - cOOLING SYSTEM c.1.7 Supply of temper coolant This is possible by using heatings in the cooling circuit for the control of the coolant tem- perature. The following dew point table is available for this. Coolant inlet temperature [°C] is depending on ambient temperature [°C] and air humid- ity [%]: Air humidity [%] Surrounding...
ANNEx - cOOLING SYSTEM c.1.8 Pressure drop of the cabinet system • The curve characteristic described below is valid for 25°C flow temperature and Antifreeze N 52 %. • If higher flow temperatures are reached, the pressure drop in the system drops. • The same is in the case with other cooling media (e.g., water) or another glycol mixture.
ANNEx - cOOLING SYSTEM c.1.9 Volume flow depending on total power dissipation and temperature difference ① ② ③ ④ ⑤ ⑥ Total power dissipation Pv in kW Legend ① ② ––––– ––––– 90 l/min 100 l/min ③ ④ ––––– ––––– 110 l/min 120 l/min ⑤...
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Tel: +55 16 31161294 E-Mail: roberto.arias@keb.de Room 1709, 415 Missy 2000 725 Su Seo Dong Gangnam Gu 135- 757 Seoul Republic of Korea Tel: +82 2 6253 6771 Fax: +82 2 6253 6770 E-Mail: vb.korea@keb.de Société Française KEB SASU France Z.I.
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