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.
If applicable, the license terms of this software are contained in the instructions for use. The instructions for use are already available to you, can be downloaded free of charge from the KEB website or can be requested from the respec- tive KEB contact person.
TAbLE Of cONTENTS Table of contents Preface ..............................3 Signal words and symbols ......................3 More symbols ..........................3 Laws and guidelines ........................4 Warranty and liability ........................4 Support ............................4 Copyright ............................4 Table of contents ........................... 5 List of figures ............................8 List of Tables ............................
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TAbLE Of cONTENTS 3.1.4.2 Electromagnetic compatibility ..................27 3.2 Technical data of the axis modules ..................... 28 3.3 Dc link capacities .......................... 31 3.4 Mechanical installation ......................... 32 3.4.1 Control cabinet installation ....................32 3.4.1.1 Mounting instructions for control cabinet installation ............33 3.4.2 Installation instructions for flat rear heat sink ..............
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TAbLE Of cONTENTS 4.3.4.1 Technical data of the inputs ..................... 59 4.3.4.2 Technical data of the outputs ................... 59 4.3.4.3 Assignment of the interfaces ................... 59 4.3.5 Assembly of the wires to PUSH IN terminals ..............60 4.3.5.1 Assignment of the terminal block X2A ................61 4.3.5.2 Connection of the digital inputs ..................
LIST Of fIGURES List of figures Figure 1: Overload characteristic (E.OL, E.OL2) ................28 Figure 2: Control cabinet installation ....................32 Figure 3: Main heat sink for COMBIVERT H6 ................. 34 Figure 4: Dimensions and weights of the axis modules ..............35 Figure 5: Dimensions and weights housing P .................
LIST Of TAbLES List of Tables Table 1: Part code..........................24 Table 2: Climatic ambient conditions ..................... 25 Table 3: Mechanical ambient conditions ..................26 Table 4: Chemical / mechanical active substances ............... 26 Table 5: Device classification......................27 Table 6: Electromagnetic compatibility ..................27 Table 7: Overview of the device data housing B, P ...............
(DIN 5008) IP xx Degree of protection (xx for level) Fieldbus system KEB product The KEB product is subject of this Cyclic duration factor manual Complete drive module including Silicium temperature sensor (pola- auxiliary equipment (control cabinet)
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GLOSSARy Term used in the safety technology (EN 61508-1...7) for the size of error probability per hour Programmable logic controller PT100 Temperature sensor with R0=100Ω PT1000 Temperature sensor with R0=1000Ω PTC-resistor for temperature detec- tion Pulse width modulation RJ45 Modular connector with 8 lines Synchronous sensorless closed loop SELV Safety Extra Low Voltage (<...
STANDARDS fOR DRIvE cONvERTERS / cONTROL cAbINETS Standards for drive converters / control cabinets Product standards that apply directly to the drive converter EN 61800-2 Adjustable speed electrical power drive systems - Part 2: General requirements - Rating specifications for low voltage adjustable frequency a.c. power drive systems (VDE 0160-102, IEC 61800-2) EN 61800-3 Speed-adjustable electrical drives. Part 3: EMC requirements and specific test methods (VDE 0160-103, IEC 61800-3)
STANDARDS fOR DRIvE cONvERTERS / cONTROL cAbINETS EN 61000-4-5 Electromagnetic compatibility (EMC) - Part 4-5: Testing and measurement techniques - Surge immunity test (IEC 61000-4-5); German version EN 61000-4-5 EN 61000-4-6 Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques - Immunity to conducted disturbances, induced by radio-frequency fields (IEC 61000-4-6); German version EN 61000-4-6 EN 61000-4-34...
► Read the instructions for use ! ► 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!
If personnel protection is required during installation of the system, suitable protective devices must be used for drive converters. www.keb.de/fileadmin/media/Manuals/knowledge/04_techinfo/00_gene- ral/ti_rcd_0400_0002_gbr.pdf Installations which include drive converter shall be equipped with additional control and protective devices in accordance with the relevant applicable safety requirements, e.g.
According to it is permissible to disconnect already tested com- EN 60204-1 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 chapter 18.3) with DC...
If a drive converter with electrolytic capacitors in a DC link (see technical data) has not been in operation for more than one year, observe the following instructions. www.keb.de/fileadmin/media/Manuals/knowledge/04_techinfo/00_gene- ral/ti_format_capacitors_0400_0001_gbr.pdf NOTICE continuous operation (S1) with load > 60 % ! Premature ageing of the electrolytic capacitors ! ►...
(mains on) (e.g. due to large rotating masses). Switching an the input For applications that require cyclic switching off and on of the drive converter, maintain an off-time of at least 5 min after the last switch on. If you require shorter cycle times please contact KEB Automation KG. Short-circuit resistance The drive converters are conditional short-circuit proof. After resetting the internal pro- tection devices, the function as directed is guaranteed.
1.8 Disposal Electronic devices of the KEB Automation KG are exclusively professional devices for further industrial processing (so-called B2B devices). Manufacturers of B2B devices are obliged to take back and recycle devices manufac- tured after 14.08.2018.
PRODUcT DEScRIPTION 2 Product Description The product family COMBIVERT H6 is optimized for the use in multi-axis drives. The structure is modular and thus it can be optimally adapted to the respective requirements. A system consists of the following components: Name function Rectifier module...
The used semiconductors and components of the KEB Automation KG are developed and dimensioned for the use in industrial products. RESTRICTION If the KEB COMBIVERT F5 is used in machines, which work under exceptional condi- tions or if essential functions, life-supporting measures or an extraordinary safety step must be fulfilled, the necessary reliability and security must be ensured by the machine builder.
PRODUcT DEScRIPTION 2.3 Product features Diese Gebrauchsanleitung beschreibt folgender Geräte: Unit type: Axis module Series: COMBIVERT H6 Power range: 0,75...110 kW / 400 V Housing: B, P, C, S, E, U, G, W The COMBIVERT H6 is characterized by the following features: Übertragung von Soll- und Istwerten zwischen •...
P: 50 mm U: 200 mm S: 100 mm W: 300 mm KEB standard with control release and brake con- trol type 0 Control type B: KEB standard with safety module type 1 C: KEB standard with safety module type 2...
OPERATING cONDITIONS 3 Technical Data 3.1 Operating conditions 3.1.1 climatic ambient conditions Storage Standard class Notes Ambient temperature EN 60721-3-1 -25…55 °C Relative humidity 5…95 % (without condensation) EN 60721-3-1 Storage height – – Max. 3000 m above sea level Transport Standard class Notes...
OPERATING cONDITIONS 3.1.4 Electrical operating conditions 3.1.4.1 Device classification Requirement Standard class Notes – EN 61800-5-1 Overvoltage category – EN 60664-1 Non-conductive pollution, occasional conden- Pollution degree EN 60664-1 sation when PDS is out of service. Table 5: Device classification 3.1.4.2 Electromagnetic compatibility The indicated values are only valid for devices with external filter.
TEcHNIcAL DATA Of THE AXIS MODULES 3.2 Technical data of the axis modules Module mode Single axis Double axis Device size Housing Rated output power / kVA 2.18 2 x 4 2 x 6.2 Max. rated motor power / kW 0.75 2 x 0.75 2 x 2.2 2 x 4...
TEcHNIcAL DATA Of THE AXIS MODULES Module mode Single axis Device size Housing Rated output power / kVA Max. rated motor power / kW Rated output current 16.5 Short time current limit at 0 Hz (for 60s) Short time current limit (for 60s) 43.2 1) 2) _max...
TEcHNIcAL DATA Of THE AXIS MODULES Module mode Single axis Device size Housing Rated output power / kVA Max. rated motor power / kW Rated output current Short time current limit at 0 Hz (for 60s) Short time current limit (for 60s) 1) 2) _max Min.
Dc LINK cAPAcITIES 3.3 Dc link capacities H6 Axis modules Device size Housing capacity (uf) B / P Single axis module B / P B / P B / P Double axis module B / P B / P Single axis module 1020 1360 E / U...
MEcHANIcAL INSTALLATION 3.4 Mechanical installation 3.4.1 control cabinet installation Mounting distances Dimension Distance in mm Distance in inch 1) Minimum distance for cooling 2) Distance to preceding elements in the cabinet door. ATTENTION Horizontal installation in the control cabinet must be done with special care and the displacement between the units must be kept to a minimum.
► The machine builder is responsible for the cooling of the units. Heat-conducting paste Information about the correct application of the heat-conducting paste are available at under the search term www.keb.co.uk "Heat-conducting paste“. Select correct flow temperature for liquid coolers ► The flow temperature must be choose in such a way, that no mois-...
MEcHANIcAL INSTALLATION 3.4.3 Dimensions central heat sink 3.4.3.1 Air heat sink Central heat sink for air-cooling upon request. 3.4.2.1 Liquid heat sinks Following liquid heat sinks are available, if no usable cooling surface exists at customer side: Heat sink cabinet outcut Size L1 in mm L2 in mm...
MEcHANIcAL INSTALLATION 3.4.4 Dimensions and weights of modules with flat rear heat sink Housing Module width in mm Weight in kg 12.5 Figure 4: Dimensions and weights of the axis modules...
MEcHANIcAL INSTALLATION 3.4.5 Dimensions of modules with air-cooled heat sink 49,7 Housing Module width in mm Weight in kg Figure 5: Dimensions and weights housing P...
INSTALLATION AND cONNEcTION 4 Installation and connection 4.1 construction of the device front view Remove the front cover front without cover • Pull with both hands low in the cover. • Tilt cover forward to ap- prox. 45 degrees, until the plates solve above from the mounting.
INSTALLATION AND cONNEcTION Description Terminal connections of the front side Terminal Description +24V bus X1C.1 X1C.3 +24V bus X1C.2 X1C.4 DC bus (displayed DC bus + X1D.1 X1D.3 with protection against contact for exterior devices) DC bus - X1D.2 X1D.4 Motor temperature and brake control (for X3AB...
INSTALLATION AND cONNEcTION view rear side of the unit Housing b / P Single axis module Double axis module X1BB X1BA Motor terminal block Motor terminal block Motor output A Connection for three-phase motor ! Connect in phase for correct direction of rotation. Motor output B Option terminal block Option terminal block motor A...
INSTALLATION AND cONNEcTION view rear side of the device Housing c/S Housing E / U U V W Device size 13...15 Device size 16...19 Housing G/W Connection for earthing Motor terminal block Connection for three-phase motor ! Connect in phase for correct direction of rotation.
INSTALLATION AND cONNEcTION 4.1.1.1 Status LED safety module Status No voltage supply of the safety module green Safety module ready for operation Safety module in error routine Table 12: Status LED safety module 4.1.1.2 Status LED axis module Status No voltage supply of the unit yellow Unit initialised green...
cONNEcTION Of THE POWER UNIT 4.2 connection of the power unit 4.2.1 connection of the Dc bus X1D The tinned copper bars connect the DC bus of the different H6 devices. Precharging, power supply and regeneration (if required) is provided by the power supply module. The electrical connection is made with metal bridges, which must be mounted (as illus- trated in the photo).
cONNEcTION Of THE POWER UNIT 4.2.3 connection of the motor 4.2.3.1 Motor terminal X1A Housing b / P Name function cross-section Tightening torque Single axis module 0.2...6 mm² 0.7 Nm U, V, W Motor connection AWG 24-10 6.2 lb inch Housing b / P Name function...
cONNEcTION Of THE POWER UNIT Housing c/S Name function cross-section Tightening torque Device size 13...15 0.2...6 mm² 0.7 Nm U, V, W Motor connection AWG 24-10 6.2 lb inch Connection for shielding/ M6 stud for ring crimp 5 Nm earthing connector 44 lb inch Device size 16...19...
cONNEcTION Of THE POWER UNIT 4.2.3.2 Selection of the motor cable Correct selection and wiring of the motor cable is very important for high motor ratings: • Lower abrasion of the motor bearings by leakage currents • Improved EMC characteristics •...
cONNEcTION Of THE POWER UNIT Legend 24 V DC supply of the H6 rectifier module or an external voltage +24V X1C.1 source X1C.2 DC link bus of the H6 power supply-/regenerative unit X1D.1 Motor terminal X1A X1D.2 Three-phase motor Further connection possibilities: U V W PE • Encoder feedback (=> „Encoder interfaces“) •...
KTY or PTC cable inside the motor cable only permissible with double shielding ! • The input is base insulated. The KEB COMBIVERT H6 is delivered with switchable KTY84/PTC evaluation. The desired function is set with dr33 and works in the following table: Error/ dr33...
cONNEcTION Of THE POWER UNIT 4.2.3.7 Use of the temperature input in PTC mode If the temperature input is operated in the PTC mode, the user can provide all possibili- ties within the resistance range specified in chapter „Motor temperature detection“. This can be: Thermal contact (Nc contact) Temperature sensor (PTc) Mixed sensor chain Table 15: Wiring example in PTC mode...
cONNEcTION Of THE POWER UNIT 4.2.4 Encoder interfaces X3AA X3AB Figure 27: Encoder interfaces of housings B/P * The shield of the encoder cables must be applied to these clamps at housing B/P. Figure 28: Encoder interfaces of housings C/S, E/U and G/W...
cONNEcTION Of THE POWER UNIT 4.2.4.1 Encoder interface X3AA (channel 1) The integrated encoder interface X3AA is designed for different encoders. The encoder interface is defined by parameter Ec16. The following table contains the possible encod- ers and the appropriate signal assignment of the plug connector. Encoder Inc-TTL Resolver Hiperface SinCos Endat Sin/Cos- Endat BISS +1 Vss digital Cos+ Cos+ Cos+ Cos+ Cos- Cos- Cos- Cos-...
cONNEcTION Of THE POWER UNIT 4.2.4.2 Encoder interface X3AA (channel 1) for HTL signals The integrated encoder interface X3AA is designed for HTL signals. The encoder inter- face is defined by parameter Ec16. The following table contains the possible encoders and the appropriate signal assignment of the plug connector. Encoder Ink-HTL Resolver A_HTL+ A_HTL- B_HTL+...
cONNEcTION Of THE POWER UNIT The following limitations are valid when operating with two encoders: • The supply voltages 5V and 8V are generated with one programmable voltage source. Only encoders with 5V or 8V supply are possible (e.g. BiSS and HIPER- FACE are not possible).
cONNEcTION Of THE cONTROL 4.3 connection of the control 4.3.1 Error chain terminal X2c, X2D channel Description connecting cable error chain Name The terminal strips X2C and X2D are in- ternally parallel connected. Thus, each terminal strip can be used as input or out- put.
cONNEcTION Of THE cONTROL 4.3.2 Ethercat system bus terminal X4b The EtherCAT system bus serves for the communication of the master with the axis modules and the power supply and regenerative unit. „CanOpen over EtherCAT “ is used as protocol. Upto eight axes can be operated isochron with a cycle time of <250 µs. Description of the LEDs RJ45 socket Assignment...
cONNEcTION Of THE cONTROL 4.3.4 Digital inputs and outputs X2A Additionally to the central inputs and outputs of the control unit each axis module is equipped with own inputs and outputs. Terminal block X2A includes four digital inputs and four digital outputs with the appropriate mass terminals. 4.3.4.1 Technical data of the inputs The digital inputs are specified in accordance with IEC61131-2 type 3.
cONNEcTION Of THE cONTROL 4.3.5 Assembly of the wires to PUSH IN terminals NOTICE Malfunctions caused by loose cable connections! ► Observe metal sleeve length and stripping length Metal sleeve Stripping cross-section Wire-end ferrule length length 0.50 mm 10 mm 12 mm with plastic collars 0.75 mm...
cONNEcTION Of THE cONTROL 4.3.5.1 Assignment of the terminal block X2A Digital inputs and outputs function Term. Term. function Digital input DI 4 Digital input DI 3 Digital input DI 2 Digital input DI 1 Digital output DO 4 Digital output DO 3 Digital output DO 2 Digital output DO 1 Figure 35:...
Safely-Limited Increment; a limited increment is monitored with this safety function. Safe Speed Monitor; The safety function provides a safe output signal below a specified value of a maximum drive speed. Table 21: Safety module terminal block X2B general information Safety manual safety module type 1 www.keb.de/fileadmin/media/Manuals/dr/ma_dr_safety-typ-1- shb-20109577_en.pdf Safety manual safety module type 2 www.keb.de/fileadmin/media/Manuals/h6/safety/h6_safety_ type2_20093648_gbr.pdf...
SAfETy MODULE TERMINAL bLOcK X2b 4.4.2 Module type 0 terminal block X2b Module type 0 is used for switching the control release and brake control release if no safety requirements are made. Name Description Brake release Mass 24V output (I = 100 mA) Control release Assembly and cable cross-sections see „Assembly of the connecting...
Water-cooled drive converters are operated in continuous operation with lower tempera- ture than air-cooled inverters. This has positive effects on lifetime-relevant components such as fan and DC link circuit capacitors and power modules (IGBT). Also the temper- ature dependent switching losses are positively effected. The use of water-cooled KEB COMBIVERT drive converters is offered in the drive technology, because there are pro- cess-caused coolants available with some applications. The following instructions must be observed absolutely when this units are used.
cOOLING SySTEM Material Generated Ion Standard poten- Material Generated Ion Standard poten- tial tial Magnesium -2,38V Iron -0.037 V Titan -1.75 V Hydrogen 0.00 V Aluminium -1.67 V Copper 0.34 V Manganese -1.05 V Carbon 0.74 V Zinc -0.76 V Silver 0.80 V Chrome...
Pay attention to flux direction and check tightness ! • The cooling flow must always be started before starting the KEB COMBIVERT. The connection to the cooling system can occur as closed or open cooling circuit. The connection to a closed cycle cooling circuit is recommended, because the danger of contamination of coolant is very small.
• Temperature control Further information can be found on the following link: Info sheet Coolant Management www.keb.de/fileadmin/media/Techinfo/dr/an/ti_dr_an-cooling-00004_ en.pdf 5.1.6 Emptying the cooling circuit If a system shall be switched off for a longer period, the cooling circuit must be drained completely.
cOOLING SySTEM 5.1.7 Coolant heating depending on power dissipation and flow rate with water ΔT / K 5 l/min 10 l/min 20 l/min 30 l/min 40 l/min 50 l/min 100 l/min / kW Figure 42: Coolant heating depending on power dissipation 5.1.8 Typically fall of pressure depending on the rate of flow l/min Figure 43:...
6.2 UL Marking Acceptance according to UL is marked at KEB inverters with the adjacent logo on the type plate. To be conform according to UL for use on the North American and Canadian Market the...
24H6 60°C or 75°C 25H6 • These drive modules are only for use in combination with other supply and drive modules that are part of the Combivert H6 series. • Maximum heatsink temperature for all H6 drive modules shall be maintained at 80°C via a liquid cooled system. • Connection of an External Temperature Sensor was not evaluated.
REvISION HISTORy 7 Revision History Revision Date Description 2010-07 Manual for the axis modules in german/english completed 2011-07 Link and Speed LED at the EtherCAT bus exchanged 2012-04 Technical data added / changed; Chapter 3.2.1 and 3.2.2 revised; Pin assignment of the encoder interfaces changed;...
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