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 4 Unit Data ............... 27 4.1 Overload characteristic ......................... 30 4.2 Accessories ........................... 30 4.2.1 AIC, LCL and EMC filters ....................30 4.2.2 Common mode filter ......................31 4.2.3 DC fuses ..........................32 4.2.3.1 Alternative DC-fusing ....................... 32 4.2.4 Additional precharging resistor at master-slave operation ..........33 4.3 Dimensions and weights ......................
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TAbLE OF CONTENTS 8 Operation of the Control ..........53 8.1 Operation without operator ......................53 8.2 Operation with digital operator ....................53 8.2.1 Keyboard operation ......................54 8.2.1.1 Parameter numbers and / values ..................54 8.2.1.2 Resetting of error messages ................... 54 8.2.1.3 Password input ........................
Description of the RS232/485 interface X6C ..............56 Table 19: Technical data of COMBIVERT drive converters ............. 60 Table 20: Technical data of KEB COMBIVERT F5 AIC devices ............61 Table 21: Heat sink and operating pressure ..................62 Table 22: Electrochemical series / standard potentials against hydrogen ........
(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!
• When using components without isolated inputs/outputs, it is necessary that equipo- tential bonding exists between the components to be connected (e.g. by the equipo- tential line). Disregard can cause destruction of the components by the equalizing currents. • Use only the KEB specified AFE-/LCL filter.
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...
Use only approved accessories for this device. • Never touch terminals, busbars or cable ends. 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...
SAFETy INSTRUCTIONS 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- tective devices the intended function is guaranteed. Exceptions: • Repeatedly occurring ground faults or short-cicuits at the input can lead to the de- vective of the unit.
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.
Replaces braking resistor and braking transistor; thus reduces the heat emission; however optional possible as protection in case of mains power failure. • Supplies single KEB drive converter or after consulting via DC-bus connection. • Active power factor correction (PFC) and cos phi control possible.
Active Infeed Controller is done in cooperation with KEB. The used semiconductors and components of KEB are developed and dimensioned for the use in industrial products. If the KEB COMBIVERT F5 is used in machines, which work under exceptional conditions 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 Part code xx xx x x x - x x x x Cooling A Air cooling D External fan power supply (P housing) H Water-cooling system Design system 1 Standard F5 „Plus“ E Stainless steel Serial number for special version 0 Standard S Certified according to CEI 0-21 and VDE AR N 4105 Special version...
3 Technical Data Unless otherwise indicated, all electrical data in the following chapter refer to a 3-phase AC voltage supply. 3.1 Operating conditions 3.1.1 Climatic environmental conditions Storage Standard Class Notes Ambient temperature -25…55 °C EN 60721-3-1 Relative humidity EN 60721-3-1 5…95 % (without condensation) Storage height –...
3.1.2 Mechanical environmental conditions Storage Standard Class Notes Vibration amplitude 1.5 mm (2…9 Hz) Vibration limits EN 60721-3-1 Acceleration amplitude 5 m/s² (9…200 Hz) Shock limit values EN 60721-3-1 40 m/s²; 22 ms Transport Standard Class Notes Vibration amplitude 3.5 mm (2…9 Hz) Vibration limits Acceleration amplitude 10 m/s²...
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.
UNIT DATA 4 Unit Data Information on the dimensioning => „Dimensioning“. Device size Housing size Cooling mode (L=air; W=water) Input data Mains phases Permitted mains forms TN system Rated input voltage Input voltage range 340…480 ± 0% Mains frequency / Hz 50 / 60 ±...
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UNIT DATA Device size Housing size Cooling mode (L=air; W=water) Number of modules for master/slave – – – – – – Input data Mains phases Permitted mains forms TN system Rated input voltage Input voltage range 340…480 ± 0% Mains frequency / Hz 50 / 60 ±...
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UNIT DATA Device size Housing size Cooling mode (L=air; W=water) Number of modules for master/slave Input data Mains phases Permitted mains forms TN system Rated input voltage Input voltage range 340…480 ± 0% Mains frequency / Hz 50 / 60 ± 2 Rated input power / kVA 1005...
14Z1B04-1000 16.5 0LZ1I05-1001 18Z1B04-1000 8...16 0PZ1I05-1001 22Z1B04-1000 0SZ1I05-1001 24Z1B04-1000 0XZ1I05-1001 27Z1B04-1000 4...16 0YZ1I05-1001 29Z1B04-1000 Table 10: Sinus EMC filters and mains chokes Further information can be found under the following link: Installation sinus EMC filter. www.keb.de/fileadmin/media/Manuals/dr/ma_dr_z1-inst-sinus-emv-fil- ter_20146892_de.pdf Programming manual COMBIVERT F5-AIC. www.keb.de/fileadmin/media/Manuals/f5afe/prog/F5_AFE_pro- gramm_20104270_deu.pdf...
UNIT DATA 4.2.3 DC fuses Assembly kit Fuse body in U in I in Size Fuse (holders and fuses) V DC 14U42EG-3W00 2 x 0090249-5419 Ø27 x 60.3 16U42GH-3W00 2 x 0090249-5459 Ø27 x 60.3 18U420H-3W00 2 x 0090249-5519 Ø27 x 60.3 19U42HR-3W00 2 x 0090249-5529 Ø27 x 60.3...
Dimensions, weights and terminal descriptions can be found in the following instruction manuals: Size Housing Instruction manual Housing E Housing G Housing H 20, 22 Housing R 24, 26, 27 Housing U 28, 29, 30, 33, 34, 38 Housing P Table 13: Dimensions and weights The instruction manuals can be found in the specified links or under www.keb.de/de/service/downloads.
INSTALLATION 5 Installation 5.1 EMC-compatible control cabinet installation Mains fuse Pre-charging fuse Pre-charging contactor Main contactor (before LCL filter) EMC filter AIC/LCL filter (if necessary integrat- ed in 4) COMBIVERT F5-AIC If necessary external load-shunt External DC fuses 150 mm Drive converter Motor cable Power unit equipotential bonding 150 mm with the housing earth Protective Earth (PE) on the mount- ing plate power circuit...
PA, PB Connection for braking resistor; optionally, only if a braking transistor is installed. In this case additional terminals are available for the monitoring of the braking transistor. If necessary, please contact KEB! L1, L2, L3 Mains input 3-phase U, V, W...
CONNECTION OF THE COMbIVERT F5-AIC 6.2 Terminal blocks of the devices The assignment of the numbering under "Terminal" for cross sections and tightening torques => „Cross-sections and tightening torques of the terminals“. The + contact of the temperature evaluation must be connected to terminal T1 to terminal block X1A! For more information =>...
CONNECTION OF THE COMbIVERT F5-AIC Housing R Name Function Terminal L1, L2, L3 3-phase mains connection U, V, W AIC mains connection 7 / 8 +PA, PB Connection for braking resistor K1K2 T1 T2 +PA, – Connection for DC-bus connection T1, T2 Connection for temperature sensor Monitoring of the braking transistor...
CONNECTION OF THE COMbIVERT F5-AIC Housing P Terminal width max. 42,5mm Terminal Name Function Terminal block L1, L2, L3 3-phase mains connection U, V, W AIC mains connection +PA, PB Connection for braking resistor +PA, – Connection for DC-bus connection T1, T2 Connection for temperature sensor (only master) K1, K2...
CONNECTION OF THE COMbIVERT F5-AIC 6.3 External fan supply for housing P and U Housing U Housing P Legend Terminal block Connection terminals +, - Voltage supply +24 V DC ± 10 % Device size 24...26 2.5 A Housing U Current consumption per module Device size 27 Housing P...
CONNECTION OF THE COMbIVERT F5-AIC 6.4 Temperature detection T1, T2 NOTICE • Do not lay KTY or PTC cable of the motor or AIC/LCL filter (also shielded) together with the control cable ! • KTY or PTC cable only permissible with double shielding within the motor cable ! 6.4.1 Use of the temperature input in KTy mode Connection of a KTy sensor...
„Dimensioning“ NOTICE Leakage capacitors against earth in the DC link Drive converters with leakage capacitors in the DC link against earth are not allowed for F5-AIC operation and can be destroyed. Only re- leased units by KEB may be connected.
CONNECTION OF THE COMbIVERT F5-AIC 6.6 Circuit examples 6.6.1 Instructions to the following circuit example In the following circuit example the drive converter is connected via the F5-AIC with a LCL filter to the supply system. The temperature monitoring of the LCL filter is done by the F5-AIC. The inputs and outputs are pre-programmed for the following circuit example. NOTICE For a safe function of the AIC system use models with positively driv- en auxiliary contacts for power contactors K2 and K3 (pre-charging and...
CONNECTION OF THE COMbIVERT F5-AIC 6.6.2 Circuit example for the power unit with AIC/LCL filter °C °C 1) U T1 T2 KTY+ KTY- F-T1 F-T2 T1 T2 W PE L2 L3 PE Legend Q1 Main switch S5 / S6 Temperature detection NC contact and KTY84 sensor F1 Main fuses Motor temperature switch...
CONNECTION OF THE COMbIVERT F5-AIC 6.6.3 Circuit example for the power unit with AIC/LCL filter and common mode filter °C °C 1) U T1 T2 KTY+ KTY- F-T1 F-T2 T1 T2 W PE L1 L2 L3 PE Legend Q1 Main switch Common mode filter F1 Main fuses Motor...
CONNECTION OF THE COMbIVERT F5-AIC 6.6.4 Circuit example for the master-slave operation with AIC/LCL filter and common mode filter °C °C 1) U T1 T2 KTY+ KTY- 1) U T1 T2 KTY+ KTY- Master Slave W PE T1 T2 Legend Main switch Motor Temperature detection NC contact and KTY84...
CONNECTION OF THE COMbIVERT F5-AIC 6.6.5 Circuit example for the control circuit Uout 24Vdc Legend Coupling relay (control on/off) Second setpoint (customer) Pre-charging contactor Error reset K3 / K4 Main contactor External release for drive converter Coupling relay (max. 50 mA) for main COMBIVERT F5-AIC contactor External control release...
CONNECTION OF THE COMbIVERT F5-AIC 6.6.6 Functional description The pre-charging contactor (K2) is switched by applying a 24 V DC voltage to the cou- pling relay (K1). If the DC link voltage reaches an adjustable value (480 V DC at factory setting LE.04) output O1 is set and the coupling relay switches (K5).
CONNECTION OF THE CONTROL 7 Connection of the Control 7.1 Control board for F5 AIC devices 7.1.1 Assignment of the terminal block X2A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 PIN Function Name...
CONNECTION OF THE CONTROL 7.1.4 Analog inputs Connect not connected setpoint inputs to the analog ground to avoid setpoint changes ! Analog setpoint setting external Analog setpoint setting internal Ri = 55 k 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 R = 3...10 k 0...±10 V DC...
CONNECTION OF THE CONTROL 7.1.7 Relay outputs In case of inductive load on the relay outputs a protective circuit must be provided (e.g. free-wheeling diode)! 24 25 26 27 28 29 max. 30 V DC / 1 A Figure 19: Relay outputs 7.1.8 Analog outputs X2A 1 2 3 4 5 6 7 8 9...
COMBIVERT without operator. The cable is connected between HSP5 interface X4A and serial RS232 PC interface (COM1 or COM2). Operation occurs via the program COMBIVIS 5. The KEB-USB converter or the Port-Expander is required for COMBIVIS 6. RS232-HSP5 converter 00F50C0-0010...
OPERATION OF THE CONTROL 8.2.1 Keyboard operation 8.2.1.1 Parameter numbers and / values When COMBIVERT F5 is switched on, the display shows the value of customer param- eter CP.1. The function key (FUNC) changes between the parameter FUNC. value and parameter number. SPEED STOP STOP...
0010). Access to the drive converter parameters in the application mode is possible via the PC software KEB COMBIVIS 5. The KEB-USB converter or the Port-Expander is required for COMBIVIS 6.The operator parameters can be read out and adjusted or parameterized by download.
OPERATION OF THE CONTROL Required accessories: Adapter RJ45/DSub-9 Converter HSP5/RS232 00F50C0-0020 00F50C0-0010 C0F50C0-0020 8.3.2 Description of the RS232/485 interface X6C RS485 Signal Meaning reserved Transmission signal RS232 Receive signal RS232 5 4 3 2 1 A‘ RxD-A Receive signal A RS485 B‘...
The last three digits of the material number determine the cable length in dm. 8.3.6 Further operators Additionally to the described operators, the COMBIVERT can be equipped with other operators for special applications (PROFIBUS, INTERBUS, SERCOS, CAN). Further information => www.keb.de.
DIMENSIONING 9 Dimensioning 9.1 Dimensioning instructions The dimensioning of the COMBIVERT F5 AIC occurs to the maximum permissible rated input current. The power specifications refer to 400 V rated input voltage. The DC current is dependent on the adjusted DC voltage and is not measured sepa- rately. Precharging Depending on the mains input circuit of the AIC unit either the „max. external charging current“...
OMBIVERT F5 drive converter precharging by AIC at an ambient temperature T = 45°C and U = 440V. Corresponding higher charging currents are expected at higher N_max mains voltages. In this case please contact KEB! Load-shunt Max. charging Housing Size...
Internal capacity Cint Cextmax Maximum, connectable capacity Load-shunt Table 20: Technical data of KEB COMBIVERT F5 AIC devices Option precharging resistor => „Additional precharging resistor at master-slave operation“. NOTICE A restart for AIC with NTC is allowed only after 5 minutes.
COOLING SySTEM 10 Cooling System 10.1 Installation of liquid-cooled devices In continuous operation liquid-cooled drive converters are operated with lower tempera- ture than air-cooled inverters. This has positive effects on lifetime-relevant components such as fan and DC link capacitors and power modules (IGBT). Also the temperature de- pendent switching losses are positively effected. The use of liquid-cooled COMBIVERT drive converters is offered in the drive technology, because there are process-caused coolants available with some applications. 10.1.1 Heat sink and operating pressure Max.
COOLING SySTEM Electrochemical series / standard potentials against hydrogen Standard Standard Material Generated Ion Material Generated Ion potential potential Lithium -3.04 V Cobald -0.28 V Potassium -2.93 V Nickel -0.25 V Calcium -2.87 V -0.14 V Sodium -2.71 V Lead -0.13 V Magnesium Iron...
COOLING SySTEM Special requirements for open and half-open cooling systems: Impurities Mechanical impurities in half-open cooling systems can be counteracted when appropriate water filters are used. Salt concentration The salt content can increase through evaporation at half- open systems. Thus the water is more corrosive. Adding of fresh water and removing of process water works against.
COOLING SySTEM Coolant inlet temperature [°C] is depending on ambient temperature and air humidity Air humidity in % Surrounding temperature in °C Coolant inlet temperature in °C Table 24: Coolant inlet temperature [°C] is depending on ambient temperature and air humidity 10.1.5 Connection to the cooling system •...
COOLING SySTEM 10.1.5.1 Pressure drop of the heat sink depending on the flow rate The pump capacity required for the COMBIVERT F5 is derived from the following spec- ifications, which are represented in the diagram chapter „Connection scheme for a cool- ing circuit (series connection)". l/min Legend Recommended working range 10...30 in l/min ① Single device ② Series connection of two modules (Master/Slave) ③...
COOLING SySTEM 10.1.5.2 Connection scheme for a cooling circuit (series connection) Coolant connection for a master / slave system F5/F6 F5/F6 Master Slave Coolant outlet Coolant inlet Coolant connection for a master / slave / slave system F5/F6 F5/F6 F5/F6 Slave 1 Master Slave 2...
COOLING SySTEM NOTICE The maximum temperature difference between pre-run and return flow is specified in the technical data and should not be exceeded. If the vol- ume flow (above 30 l/min per module) is selected too large, increases the risk of erosion in the liquid cooler. 10.1.5.3 Volume flow in dependence of the heat power dissipation and temperature difference ΔT in K Pv in kW Legend ② Master / Slave / Slave 9...12 ΔT in K 15 l/min ③ Master / Slave 6...10 ΔT in K 20 l/min ④ Master 3...6 ΔT in K 25 l/min ① ⑤ 10 l/min 30 l/min Figure 29: Volume flow in dependence of the heat power dissipation and temperature difference...
COOLING SySTEM 10.1.5.4 Connection scheme for a cooling circuit (parallel connection) This connection scheme is only an installation proposal and does not replace professional planning and execution! ① ② ② ③ 1/2“ 1/2“ Slave ① ② ② ③ ➃ ➄ 3/4“...
REVISION HISTORy 11 Revision History Version Date Description 2016-10 Completion Pre-series 2018-01 Changeover to new KEB-ci; general changes 2019-02 Certified version included, WEEE registration added; editorial changes 2020-10 Changing the term from AFE to AIC; editorial changes...