KEB COMBIVERT F5 Instruction Manual
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Summary of Contents for KEB COMBIVERT F5
- Page 1 COMBIVERT GB INSTRUCTION MANUAL COMBIVERT F5/F6 Power Unit Housing W 200…400 kW 250...500 kVA Mat.No. Rev. 00F50EB-KW00...
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Page 3: Table Of Contents
Table of Contents Table of Contents Preface ......................6 Information on special measures ..................6 Documentation ........................6 Validity and liability ......................7 Copyright ..........................7 1.5 Specified application ......................8 Product description ......................8 1.7 Unit identification ........................9 Installation instructions ....................10 1.8.1 Cooling systems ........................10 1.8.2 Control cabinet installation ....................11 Safety and application notes ....................12 Technical Data .................... - Page 4 Table of Contents Annex A ......................38 Overload characteristic .....................38 Overload protection in the lower speed range ...............38 Calculation of the motor voltage ..................39 Maintenance ........................39 Storage ..........................39 A.5.1 Cooling circuit ........................40 Annex B ......................41 B.1 Certification ........................41 B.1.1 CE Marking ..........................41 B.1.2 UL Marking ..........................41...
- Page 5 Table of Contents List of figures Figure 1: Control cabinet installation ..................11 Figure 2: Heat sink with cooling fan (wall mounted version) ..........15 Figure 3: Heat sink with cooling fan (through-mount version) ..........16 Figure 4: Water-cooled inverter - wall mounted version ............17 Figure 5: Water-cooled heat sink (second version)- mounted version ........18 Figure 6:...
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Page 6: Preface
Preface Preface The described hard- and software are developments of the KEB Automation KG. The en- closed documents correspond to conditions valid at printing. Misprint, mistakes and technical changes reserved. Information on special measures The used pictograms have following significance: Is used, when death or serious bodily injury may be the consequence Danger of non-observance of the measure. -
Page 7: Validity And Liability
KEB Automation KG. Copyright The customer may use the instruction manual as well as further documents or parts from it for internal purposes. Copyrights are with KEB and remain valid in its entirety. -
Page 8: Specified Application
Specified application The semiconductors and components used by KEB are developed and designed for 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. -
Page 9: Unit Identification
Preface Unit identification 28 . F5. A 0 W - 9 0 0 A Cooling 0 Heat sink with cooling fan Heat sink with cooling fan (var- nished) at special/customer unit C Water cooling (varnished) consecutive numbering D Through-mount version H Water cooling (second version) Encoder interface at special/customer unit 0 none... -
Page 10: Installation Instructions
Installation instructions Installation instructions 1.8.1 Cooling systems The KEB COMBIVERT F5/F6 is available for different cooling systems: Heat sink with cooling fan (mounted version) The standard version is delivered with heat sink and cooling fan. Special versions The dissipation of power loss must be guaranteed by the machine builder. -
Page 11: Control Cabinet Installation
Installation instructions 1.8.2 Control cabinet installation Mounting distances Dimen- Distance in mm Distance in sion inch 1) Distance to preceding elements in the cabinet door. Direction of the Front and side view of the coolant inlet cooling fins Coolant outlet Coolant inlet Figure 1: Control cabinet installation... -
Page 12: Safety And Application Notes
Safety and application notes Safety and application notes Safety and application notes for drive converter (in accordance with: Low-Voltage Directive 2006/95/EC) 4. Installation 1. General The installation and cooling of the appliances shall be in In operation, drive converter depending on their degree of accordance with the specifications in the pertinent docu- protection, may have live, uninsulated and possibly also mentation. -
Page 13: Technical Data
Technical Data Technical Data Operating conditions Standard Standard/ Instructions class EN 61800-2 Inverter product standard: rated specifications Definition acc. Inverter product standard: general safety EN 61800-5-1 max. 2000 m above sea level Site altitude With site altitudes over 1000 m a derating of 1 % per 100 m must be taken into consideration. -
Page 14: Technical Data Of The 400 V Class
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. Site altitude maximal 2000 m. With site altitudes over 1000 m a derating of 1 % Info per 100 m must be taken into consideration. -
Page 15: Dimensions And Weights
Dimensions and weights Dimensions and weights 2.3.1 Heat sink with cooling fan (wall mounted version) Housing type Weight Standard with sub construction 155,5 Ø13 approx. 160 kg* Standard with sub construction (heightened) 362,5 Ø13 Figure 2: Heat sink with cooling fan (wall mounted version) * The weight varies depending on the size, cooling and build version. -
Page 16: Heat Sink With Cooling Fan (Through-Mount Version)
Dimensions and weights 2.3.2 Heat sink with cooling fan (through-mount version) Ø25 Housing type Weight Through-mount version 2 fans (standard) 155,5 Ø 9 approx. 160 kg* Through-mount version 4 fans (heightened) 362,5 Ø 9 Figure 3: Heat sink with cooling fan (through-mount version) * The weight varies depending on the size, cooling and build version. -
Page 17: Water-Cooled Inverter - Wall Mounted Version
Dimensions and weights 2.3.3 Water-cooled inverter - wall mounted version 287,5 287,5 Housing type Weight Water-cooled heat sink 1/2“ approx. 160 kg* Water-cooled heat sink with braking resistor 1/2“ Figure 4: Water-cooled inverter - wall mounted version * The weight varies depending on the size, cooling and build version. -
Page 18: Water-Cooled Heat Sink (Second Version)- Mounted Version
Dimensions and weights 2.3.4 Water-cooled heat sink (second version)- mounted version 332,5 287,5 287,5 Housing type Weight Water-cooled heat sink with stainless steel tube ca. 160 kg* *) 4 x stainless steel tube 12 mm outside diameter. Connection with commercial cutting ring fit- tings. Interconnection in series starting from the left side. Figure 5: Water-cooled heat sink (second version)- mounted version * The weight varies depending on the size, cooling and build version. -
Page 19: Water-Cooled Inverter - Through-Mount Version
Dimensions and weights 2.3.5 Water-cooled inverter - through-mount version 12,5 214,5 Housing type Weight Water-cooled heat sink 155,5 Ø 9 1/2“ approx. Water-cooled heat sink with braking resistor 155,5 Ø 9 1/2“ 160 kg* Water-cooled heat sink (heightened) 332,5 Ø 9 1/2“... -
Page 20: Terminal Strips Of The Power Circuit
All terminal strips following the requirements of the EN 60947-7-1 Info (IEC 60947-7-1) 2.4.1 Mains input The KEB COMBIVERT is dependent on the input rectifier suitable for 3-phase mains supply (B6-rectifier-circuit) or 6-phase (B12-rectifier-circuit). This can be recognized at the input ter- minals (see picture „Mains input“ und „Mains input 3-phase“). The B12 rectifier circuit is connected to two 3-phase mains supply phase-shifted by 60 de- grees. This effects a reduction of the net reactions at high power. In spite of the electric advantages and increased lifetime, this network configuration is not often realized because of high transformer costs. The DC link of the COMBIVERT with B12 rectifier circuit is dimen-... -
Page 21: Figure 8: Mains Input 3-Phase (B6-Rectifier)
Terminal strips of the power circuit Name Function L1, L1 3-phase mains connection; L2, L2 the respective terminals are L3, L3 internal parallel connected Stay bolt 16 mm for ring thimble; Tightening torque 25 Nm (220 lb inch) The supply cables must be parallel passed and connected with the respec- tive cross section (see technical data). -
Page 22: Motor Output
Terminal strips of the power circuit 2.4.2 Motor output Name Function Motor terminal strip DC link and braking resistor Temperature and GTR monitor- Connection for shielding Connection for external fan pow- er supply under the front cover (only size 31 and 32 air-cooled) Figure 12: View motor output side Name Function... -
Page 23: Other Terminals
Terminal strips of the power circuit 2.4.3 Other terminals Name Function +, + Plus DC link Input/output (no precharg- ing) Use supply input terminals at DC units ! –, – Minus DC link Connection for braking resistor (only at internal braking resistor; see unit identifica- tion) Figure 14:... -
Page 24: Figure 16: Connection For Shielding And Protective Earth Conductor X1E
Terminal strips of the power circuit Name Function Connection for shielding Connection for protective earth conductor Figure 16: Connection for shielding and protective earth conductor X1E Permissible cable cross-sections and tightening torques of the terminals Max. tightening torque lb inch 10 mm stay bolt for ring thimble 16 mm stay bolt for ring thimble Terminals... -
Page 25: Accessories
Accessories Accessories 2.5.1 Filter and chokes The following table describes the possible modes of connection, which results from COMBIV- ERT and phases. Mode of connection Inverter phases Phases Connection picture 3~ –> 3~ 3-phase (B6 rectifier) 3-phase 6~ –> 3~ 6-phase (B12 rectifier) 3-phase 6~ –>... -
Page 26: Connection Power Unit
Mains fuse Mains contactor Mains choke (connection of the temperature detection optional) HF filter KEB COMBIVERT F5/F6 with 3-phase mains input Motor (see „Connection of the motor“) Motor protection temperature sensor (see „temperature detection T1, T2“) Attention Overload of mains chokes The temperature detection of both mains chokes must be integrated in the opening circuit in order to avoid overload of the chokes in error case. -
Page 27: Figure 19: 6-Phase Combivert At 3-Phase Mains
Mains supply 3-phase Mains contactor HF filter Mains fuse Mains choke KEB COMBIVERT F5/F6 with 6-phase mains input Motor (see „Connection of the motor“) Motor protection temperature sensor (see „temperature detection T1, T2“) Attention Overload of mains chokes The temperature detection of both mains chokes must be integrated in the opening circuit in... -
Page 28: Figure 20: 6-Phase Combivert At 3-Phase Mains
Mains supply 3-phase Mains fuse Mains contactor Mains choke HF filter KEB COMBIVERT F5/F6 with 6-phase mains input Motor (see „Connection of the motor“) Motor protection temperature sensor (see „temperature detection T1, T2“) Attention Overload of mains chokes The temperature detection of both mains chokes must be integrated in the opening circuit in... -
Page 29: Figure 21: 6-Phase Combivert At 6-Phase Mains
Mains supply 6-phase (neutral point Yn earthing) Mains fuse Mains contactor Mains choke HF filter KEB COMBIVERT F5/F6 with 6-phase mains input Motor (see „Connection of the motor“) Motor protection temperature sensor (see „temperature detection T1, T2“) Attention Overload of mains chokes The temperature detection of both mains chokes must be integrated in the opening circuit in order to avoid overload of the chokes in error case. -
Page 30: Figure 22: Combivert At Dc Mains
COMBIVERT at DC mains Legend DC supply DC fuses Main contactor KEB COMBIVERT F5/F6 with DC input Motor (see „Connection of the motor“) Motor protection temperature sensor (see „temperature detection T1, T2“) Attention Overload of mains chokes The temperature detection of both mains chokes must be integrated in the opening circuit in... -
Page 31: Selection Of The Motor Cable
Connection Power Unit 2.6.2 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 • lower symmetrical operating capacities •... -
Page 32: Figure 24: Motor Connection In Star Connection
Connection Power Unit Figure 24: Motor connection in star connection Figure 25: Motor connection in delta connection... -
Page 33: Temperature Detection T1, T2
Parameter In.17 displays in high byte the installed temperature input of the inverter. As a standard the KEB COMBIVERT F5/F6 is delivered with switchable KTY84/PTC evaluation. The desired function is adjusted with Pn.72 and operates in accordance with the following table: In.17 Function of T1, T2... -
Page 34: 2.6.4.1 Use Of The Temperature Input In Kty Mode
2.6.4.1 Use of the temperature input in KTY mode KTY sensors are poled semiconductors and must be operated in forward direction! Connect anode to T1 ! Non-observance leads incorrect measurement in the up- per temperature range. Protection of the motor winding KTY84 is no longer guaranteed. -
Page 35: Connection Of A Braking Resistor
2.6.5 Connection of a braking resistor Attention Contact and fire protection Braking resistors dissipate the produced energy of the motor into heat during generatoric operation. Thus braking resistors can cause very high surface temperatures. During assem- bly pay attention to appropriate protection against contact and fire. Info Regenerative unit The use of a regenerative unit is reasonable for applications which produce a lot of regener- ative energy. -
Page 36: Braking Resistor With Over-Heat Protection And Gtr7 Monitoring (Water-Cooled)
2.6.5.2 Braking resistor with over-heat protection and GTR7 monitoring (water-cooled) This circuit offers a direct protection with defective GTR7 (braking transistor). At defective braking transistor an integrated relay opens the terminals K1/K2 and error „E.Pu“ is released. Terminals K1/K2 are integrated that into the holding circuit of the input contactor, so the input voltage is switched off in error case. -
Page 37: Braking Resistor With Over-Heat Protection And Gtr7 Monitoring (Air-Cooled)
2.6.5.3 Braking resistor with over-heat protection and GTR7 monitoring (air-cooled) This circuit offers a direct protection with defective GTR7 (braking transistor). The braking re- sistor overheats and opens the OH terminals with defective GTR7. The OH terminals open the holding circuit of that the input contactor, so that the input voltage is switched off in error case. An error in inverter is released by opening the auxiliary contacts of K3. -
Page 38: Annex A
Annex A Annex A Overload characteristic Time [s] Characteris- Time [s] Characteristic 2 tic 1 Load [%] Load [%] 105 110 115 120 125 130 135 140 145 150 160 170 180 190 200 210 220 105 110 115 120 125 130 135 140 145 150 The characteristic declines device-dependently in this range (see unit identification). -
Page 39: Calculation Of The Motor Voltage
Maintenance Storage The DC link of the KEB COMBIVERT is equipped with electrolytic capacitors. If the electrolyt- ic aluminium capacitors are stored de-energized, the internal oxide layer is removed slowly. Due to the leakage current the oxide layer is unrenewed. If the capacitor starts running with rated voltage there is a high leakage current which can destroy the capacitor. -
Page 40: Cooling Circuit
• Input voltages as before, however double the times per year. Eventually change capac- itors. Table 9: Storage After expiration of this start-up the KEB COMBIVERT can be operated on nominal rating con- ditions or delivered to a new storage. A.5.1 Cooling circuit The cooling circuit must be completely empty if a unit shall be switched off for a longer period. -
Page 41: Annex B
B.1.2 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 the use on the North American and Canadian Market the following instructions must be observed (original text of the UL): •... - Page 42 Annex B Short Circuit rating and Branch Circuit Protection: All 480V Models: „Suitable For Use On A Circuit Capable Of Delivering Not More Than 100 kA rms Symmetrical Amperes, 480 Volts Maximum when Protected by Class RK5 Fuses, rated ___ Amperes as specified in table I”: or when Protected by A Circuit Breaker Having an Interrupting rating Not Less than 100 kA rms Symmetrical Amperes, 480V maximum, rated ___ Amperes as specified in table I”:...
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Page 43: Annex C
This has positive effects on lifetime-relevant components such as fan and DC link circuit capacitors and power modules (IGBT). Also the temperature dependent switching losses are positively effected. The use of water-cooled KEB COMBIVERT frequen- cy inverters is offered in the drive technology, because there are process-caused coolants available with some applications. -
Page 44: Requirements On The Coolant
Annex C Electro-chemical voltage series / standard potentials against hydrogen Material generated Ion Standard po- Material generated Ion Standard po- tential tential Magnesium Iron -0.037 V -2.38 V Titan -1.75 V Hydrogen 0.00 V Aluminium -1.67 V Copper 0.34 V Manganese -1.05 V Carbon... -
Page 45: Connection To The Cooling System
• 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 con- nection to a closed cycle cooling circuit is recommended, because the danger of contamina- tion of coolant is very small. -
Page 46: Table 13: Supply Of Temper Coolant
Annex C In order to avoid a moisture condensation the following possibilities can be done. The appli- cation of both methods is recommended. Supply of temper coolant This is possible by using heatings in the cooling circuit for the control of the coolant temper- ature. -
Page 47: Coolant Heating Depending On Power Loss And Flow Rate With Water
Annex C C.1.6 Coolant heating depending on power loss 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 Pv [kW] Figure 33: Coolant heating C.1.7 Typically fall of pressure depending on the rate of flow l/min Figure 34: Fall of pressure... -
Page 48: Annex D
Annex D Annex D Changing the response threshold of the braking transistor To avoid a premature switching of the brake transistor at an input rated voltage of 480 Vac, the response threshold must be controlled or adjusted according to the following graphic. FUNC. - Page 49 Notes...
- Page 50 CEP 13569-430 Portal do Sol, São Carlos Brazil Gangnam Gu 135- 757 Seoul Republic of Korea Tel: +55 16 31161294 E-Mail: roberto.arias@keb.de Tel: +82 2 6253 6771 Fax: +82 2 6253 6770 E-Mail: vb.korea@keb.de KEB Automation GmbH KEB RUS Ltd.