KEB COMBIVERT G6 Quick Start Manual

USING THE QUICK GUIDE
• Serves for safe handling with the KEB drive converter.
• Provides information on handling, assembly and installation.
• Remains for later use at the drive converter.
• Does not replace the electronically provided instructions for use.
This instruction manual is determined exclusively for electrical personnel. Electrical personnel
for the purpose of this instruction manual must have the following qualifications:
• Knowledge and understanding of the safety instructions.
• Skills for installation and assembly.
• Understanding of the function in the used machine.
• Detection of hazards and risks of the electrical drive technology.
• Knowledge of IEC 60364-5-54.
• Knowledge of national safety regulations.
SAFETY INSTRUCTIONS
DANGER Interventions by unauthorized personne!
Danger to life by electric shock and malfunction!
► Modification or repair is only permitted by KEB authorized personnel.
NOTICE Getting more documentation
Hazards and risks through ignorance.
► Open the KEB homepage at www.keb.de.
► By entering the material number in the search field, you will get the cor-
responding parts of the instructions for use.
► Read the instructions for use carefully !
► Observe the safety and warning instructions !
► If you have any questions, please contactservice@keb.de !
TRANSPORT
The transport must be carried out by instructed persons, observing the following instructions.
CAUTION Maximum design edges and high weight!
Contusions and bruises!
► Never stand under suspended loads.
► Wear safety shoes.
► Secure drive converter accordingly when using lifting gear.
NOTICE Behaviour in case of transport damage
► When receiving goods, check the device for transport damage such as
deformations or loose parts.
► In case of damage, contact the carrier immediately.
► Do not operate the device in case of transport damage!
STORAGE
Do not store drive converters
• in the environment of aggressive and/or conductive liquids or gases.
• at places with direct sunlight.
• outside the specified environmental conditions.
UNPACKING AND CHECKING
• Make sure that no components are bent and/or isolation distances are changed.
• The device must not be put into operation in case of mechanical defects. There is no
compliance with applicable safety standards any more.
The electrolytic capacitors of the DC link must be reformed if the drive con-
verter was stored or out of operation for more than one year.
See www.keb.de/nc/search with search term „electrolytic capacitors".
INSTALLATION
Drive converters contain electrostatic sensitive components.
► Avoid contact.
ESD
► Wear ESD-protective clothing.
• Do not allow moisture or mist to penetrate the unit. Mount the drive converter according
to the required degree of protection.
• Make sure that no small parts fall into the device during assembly and wiring (drilling
chips, screws etc.). This also applies to mechanical components, which can lose small
parts during operation.
• The device is intended for the use in a pollution degree 2 environment.
• Maximum surrounding temperature 45°C
• Maximum pressure for liquid-cooled drive converters 10 bar (145 psi) at +5...+40°C.
• UL / CSA: For push-through versions, the part of thends to "NEMA Type 1".
• UL / CSA: Use only 75°C copper cables for UL-compliant connections for all power con-
nections!
• CSA: For installations according to the Canadian National Standard C22.2 No. 274-13
overvoltage category III.
MEASURMENTS
Dimen-
Mounting position Minimum distances
sion
A
B
A
C
C D
D D
X
1)
1) Distance to front operating
elements in the cabinet door.
Direction of airflow
B
INSTALLATION / ELECTRICAL CONNECTION
DANGER Voltage at the terminals and in the device !
Danger to life by electric shock !
► Never work under voltage on the open device or touch exposed parts.
► For any work on the unit switch off the supply voltage and secure it
against switching on.
► Wait until the drive has stopped in order that no regenerative energy can
be generated.
► Wait until the DC link capacitors are discharged (5 minutes). Verify by
measuring the DC voltage at the terminals.
► If personal protection is required, install suitable protective devices for
drive converters.
► Never bridge upstream protective devices (also not for test purposes).
► Connect the protective earth conductor properly to drive converter and motor.
► Leakage current higher than 3,5 mA: The minimum cross-section of the
protective earth conductor must comply with local safety regulations for
protective earth conductors for equipment with high leakage current.
► Install all required covers and protective devices for operation.
► Residual current: This product can cause a DC current in the protective
earth conductor. When a residual current device (RCD) or a residual cur-
rent monitor (RCM) is used for the protection of direct or indirect contact,
only a RCD or RCM of Type B is permitted for this product on the power
supply side.
For a trouble-free and safe operation, please pay attention to the following instructions:
► Check for reliable fit of the device connections in order to minimize contact resistance
and avoid sparking.
► Connection of the drive converter is only permissible on symmetrical networks with a max-
imum line voltage (L1, L2, L3) with respect to earth (N/PE) of maximum 300 V. USA UL:
480 / 277 V. An isolating transformer must be used for supply networks which exceed this val-
ue. In case of non-compliance the control is not longer considered as "safe separate circuit".
► Within systems or machines the person installing electrical wiring must ensure that on
existing or new wired safe ELV circuits the EN requirement for safe insulation is still met!
► For drive converters that are not isolated from the supply circuit (in accordance with EN
61800-5-1) all control lines must be included in other protective measures (e.g. double
insulation or shielded, earthed and insulated).
► Installations with additional safety or protective measures in accordance with their re-
quirements have to be checked. When using drive converters, to be in accordance with
the given applications notes or recommendation when using these.
PROTECTION
NOTICE Important:
UL / CSA Branch Circuit Protection
Input voltage Max. fuse size
COMBIVERT
Motor protection switch
IEC UL
Unit size IEC UL
„gG" „J,CC, RK5"
1)
Eaton PKZM0 (1) 16-E
07G6 A 15 A
AC 1ph AC 1ph 480Y/277V, 2.0 Hp
20 A
230 V 200-230 V
Eaton PKZM0 (1) 20-E
09G6 A 20 A
480Y/277V, 3.0 Hp
Eaton PKZM0 (1) 6.3-E
07G6 A 6 A
480Y/277V, 3.0 Hp
16 A
09G6 A Eaton PKZM0 (1) 10-E
10 A
480Y/277V, 7.5 HP
10G6 A
Eaton PKZM0(1) 16-E
12G6 B 20 A 15 A
480Y/277V, 10.0 Hp
13G6 B
20 A
AC 3ph AC 3ph Eaton PKZM0(1) 25-E
13G6 C 25 A
480Y/277V, 15.0 Hp
400 V 480 V
14G6 C 25 A
Eaton PKZM0(1) 32-E
15G6 C 35 A 40 A
480Y/277V, 20.0 Hp
16G6 E 50 A 50 A
17G6 E 63 A 60 A
18G6 E 70 A
80 A
19G6 E 90 A
1)
Information on the manufacturers of UL approved fuses are available in the in-
structions for use of the corresponding housing size.
WIRING
Dimension in Mains connection 1-phase (L1, N) Mains connection 3-phase (L1, L2, L3)
mm
150
T1 T2 U
100
L1
L1 L1 V
L2
30
N N
W
L3
0
PE
PE
50
1: Mains voltage 3: Mains contactor
2: Mains fuse 4: Mains choke (option)
DC connection Connection brake resistor
➄
T1 T2
+U ++
U
➅
V
-U
- -
W
PE
1: U 480...746V ±0% 2: DC fuse 3: COMBIVERT
dc
External starting current limiting
5: 6: Alternative +/- at housing E
(only at housing E)
Max. switch-on time 50 % /
7: Only intrinsically safe braking resistors 8:
playing time 120 s
Motor connection with temperature
Brake connection
monitoring
T1 T2
L1 U
U
HB+
L2 V V
HB -
L3 W W
Temperature
1: COMBIVERT 2: Motor 3-phase 3:
measurement
24V supply control unit Connection of control unit
The connection of the control depends on
➀
➁ the programming of the machine manu-
facturer. See the documentation for the
- machine.
+
10
Overcurrent protection required!
X2A
2
U = 24V - 15%...+20%
dc
I = 400mA
max
1: COMBIVERT 2: 24V supply
No. from Table 2 Terminal strip(s)
X1A X1B
L1, L2, L3, N U, V, W +, -, ++, - -, R (PB)
Housing
G6 A 3 3
G6 B 4 4
G6 C 5 5
G6 E 6 6
Table 1: Assignment of terminals to terminal numbers
Permissible cross-section
stranded wire
No. from
Mounting type
Table 1
mm² with wire
end ferrule
1 Plug component 0,25...1,5
1)
2 Connector 0,25...1
3 Plug component 0,25...2,5
4 Plug component 0,25...6
5 Screw clamp 2,5...10
6 Screw clamp 1,5...16
M4 Screw for
7 ―
cable lug
―
―
8 M6 Bolt for cable lug
―
Table 2: Assignment of terminal number to cross-section and tightening torque
―
―
• Cable cross-sections and fuses must be dimensioned according to the design of the
machine manufacturer. Specified minimum / maximum values may not be fallen below /
exceeded.
Malfunctions caused by loose cable connections and to short wireend ferrules !
1)
► Use wire-end ferrules according to table 3 "Wire-end ferrules and stripping
► Strip cable according to table 3 "Wire-end ferrules and stripping
Cross-section Wire-end ferrule
0,50 mm
2
with plastic collars
0,75 mm 2
1,00 mm 2
T1 T2
without plastic collars
L1
U 1,50 mm 2
L2 V
L3
W
0,14...1,5 mm 2
without wire-end ferrule
single- or finewire
Table 3: Wire-end ferrules and stripping length
5: COMBIVERT
START-UP AND OPERATION
WARNING Function of the drive converter determines the machine manufacturer!
➃
Hazards caused by unintentional behavior of the drive!
X1B
► The documentation of the machine manufacturer is required for the
R
R
- - start-up and operation of the product.
➅
PA
++ ► Check especially during initial start-up or replacement of the drive
U
converter if parameterization is compatible to application.
➆
V ► The drive converter must not be started until it is determined that the
➇
W installation complies with the machine directive;
EN 60204-1
4: Braking resistor
FS
For devices with FS logo on the name plate, the corresponding KEB
safety manual must be observed !
During the UL evaluation, only electrical safety and risk of fire aspects
Only motor inverters
were investigated. Functional safety aspects were not evaluated.
➀ ➃
See www.keb.de/nc/search with search term „safety manual".
=205V
4 U
WARNING Triggering of overcurrent protection devices
dc
5 I =0,5A
max
Risk of fire or electric shock!
► Triggering of an overcurrent protection device will be a hint for an
overload or short circuit. Triggering a RCD may be caused by a leak-
age current.
4: Brake
► In order to reduce the risk of fire or electric shock, live parts and other
components of the controller should be checked and replaced in case
of damage.
► If the contacts of an overload relay are burned, the complete relay
must be replaced.
MAINTENANCE
DANGER Unauthorized exchange, repair and modifications!
Unpredictable malfunctions!
► The function of the drive converter is dependent on its parameteriza-
tion. Never replace without knowledge of the application.
► Modification or repair is permitted only by KEB Automation KG au-
thorized personnel.
► Only use original manufacturer parts.
X1C PE
The following maintenance work has to be carried out when required, but at least once a year
all PINs
by authorized and trained personnel.
3 7
► Clean drive converter from dirt and dust deposits. Pay attention especially to cooling fins
1
4 7
and protective grid of the fans.
► Check the function of the fans of the drive converter. The fans must be replaced in case
5 2 7
of audible vibrations or squeak.
6 1 8
► Make a visual test of the cooling circuit for leaks and corrosion at liquid-cooled drive
converters.
► In case of malfunction, unusual noises or smells inform a person in charge!
Tightening torque ► In case of failure, please contact the machine manufacturer. Only the machine manufac-
turer knows the parameterisation of the used drive converter and can provide an appro-
AWG without
Nm lb inch priate replacement or induce the maintenance.
wire end ferrule
30...14 0,22...0,25 2
DISPOSAL
24...16 ― ―
24...14 0,5...0,6 5...6 ► Devices with safety function are limited to a service life of 20 years. Then the devices must
be replaced.
24...10 0,5...0,8 7
► Drive converters of the KEB Automation KG are professional, electronic devices exclu-
20...8 1,2...1,5 12
sively for further industrial processing (so-called B2B devices). Thus the marking does
16...4 2,4...4 26
not occur with the symbol of the crossed-out wheeled bin, but by the word mark and the
date of manufacture.
― 1,3 11
► Unlike devices mainly used in private households, these devices may not be disposed
― at the collection centres of public sector disposal organisations. They must be disposed
4,5 40
after the end of use in accordance with national applicable law to environmentally correct
disposal of electrical and electronic equipment.
length".
length".
Metal sleeve length Stripping length
10 mm 12 mm
12 mm 14 mm
(DIN 46228-4)
12 mm 15 mm
10 mm 10 mm
(DIN 46228-1)
― 10...15 mm
must be observed.