Keba BG3 User manual

Operation manual
Compact multi-axis system KeDrive D3
KeDrive D3-DP
Supply unit
BG3 and BG4

2
Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
Overview, KeDrive D3-DP supply unit BG3 and BG4
Supply unit D3-DP 3xx/x BG3 Supply unit D3-DP 3xx/x BG4
D3-DP301/x-45.xx 45 kW
D3-DP301/x-90.xx 90 kW
D3-DP301/x-A2.xx 120 kW
Operation Manual KeDrive D3-DP Supply Unit BG3 and BG4
Compact multi-axis system KeDrive D3
ID no.: 1804.201B.0-00
Date: 08/2021
Applicable as from rmware version: Vx.x
The German version is the original of this documentation.
Compact multi-axis system KeDrive D3
Consisting of the KeDrive D3-DP supply unit, the DC-powered
KeDrive D3-DA axis controllers and a matching controller KeDrive D3-DU, the
Compact multi-axis system KeDrive D3 offers a high degree of solutions expertise and
exibility in the range from 2 A to 210 A rated current.
With the aid of the KeDrive D3-DE expansion module, the KeDrive D3-DA axis
controllers BG1 and BG2 can be combined with the KeDrive D3-DA axis controllers BG3
and BG4 without problems.
The addition to the KeDrive D3-DP supply modules BG3 and BG4 of the KeDrive D3-DC
capacitance module makes possible usage in even more dynamic applications.
The external switched-mode power supply (D3-DP 301/x-004x) is also available upon
request for the 24 V control supply.
Reduction of the wiring and shortening of the installation times are just as easy to
achieve as resource-saving, cost-conscious operation.
Subject to technical change without notice
The content of our documentation was compiled with the greatest care and attention,
and based on the latest information available to us.
We should nevertheless point out that this document cannot always be updated
simultaneously with the ongoing technical development of our products.
Information and specications may be subject to change at any time. Please obtain
information about the latest version in our Docu portal.

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Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
3.2 Mounting clearances ..........................................................................................17
3.3 Cooling the devices ............................................................................................18
3.4 Installation of the devices for wall mounting........................................................18
3.4.1 Dimensions, wall mounting model (housing with heat sink) ................19
3.5 Installation of devices for liquid cooling...............................................................20
3.5.1 Dimensions, liquid cooling model .......................................................21
3.6 Cooling circuit connection .................................................................................22
4 Electrical installation .............................................................. 23
4.1 Before you start .................................................................................................23
4.2 Effective EMC installation ..................................................................................23
4.3 Overview of the connections ..............................................................................25
4.3.1 PE connection according to DIN EN 61800-5-1 ..................................26
4.3.2 Connection principle ...........................................................................27
4.4 Electrical isolation concept.................................................................................27
4.5 AC mains connection (power supply) ................................................................29
4.5.1 Layout, X01A ......................................................................................29
4.5.2 Residual current device ......................................................................31
4.5.3 Mains fuses ........................................................................................32
4.6 Operation on TT, TN and IT system ...................................................................32
4.6.1 Operation of the KeDrive D3-DP supply unit on
TN and TT system ............................................................................32
4.6.2 Operation of the KeDrive D3-DP supply unit on IT system ................32
4.7 24 V control supply ............................................................................................33
4.7.1 Control supply with switched-mode power supply (in preparation) .....33
4.7.2 Control supply via external 24 V power supply unit ............................33
4.8 Busbars for the supply voltages .........................................................................36
4.8.1 DC link supply ....................................................................................36
4.8.2 Overview of busbars in the group........................................................37
Table of contents
1 General .................................................................................... 5
1.1 Target group .......................................................................................................5
1.2 Prerequisites.......................................................................................................5
1.3 Pictograms .........................................................................................................5
1.4 Disclaimer...........................................................................................................5
1.5 Reference documents ........................................................................................6
1.6 Order code .........................................................................................................6
1.7 Rating plate .......................................................................................................7
1.8 Brief description ................................................................................................8
1.9 Scope of supply .................................................................................................8
1.10 Disposal .............................................................................................................8
1.11 S up po r t .............................................................................................................9
2 Safety .....................................................................................11
2.1 O v e r v i e w ............................................................................................................11
2.2 Measures for your safety ....................................................................................11
2.3 General safety instructions and warnings ...........................................................12
2.4 Intended use.......................................................................................................12
2.4.1 Repair..................................................................................................12
2.5 Misuse................................................................................................................13
2.6 Responsibility .....................................................................................................13
2.7 Relevant laws, standards and directives applied ...............................................13
2.8 Declaration of conformity ...................................................................................14
3 Mechanical installation ........................................................... 15
3.1 Notes for installation ...........................................................................................15
3.1.1 Order and arrangement.......................................................................15

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Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
A.6 Certication ........................................................................................................58
A.6.1 CE certication ...................................................................................58
A.6.2 UL certication (in preparation)............................................................58
A.7 Accessories .......................................................................................................58
A.8 Mains lters .......................................................................................................58
A.9 Mains chokes ....................................................................................................59
A.10 Braking resistors.................................................................................................59
4.9 Connection for braking resistor ..........................................................................38
4.9.1 Layout, terminal X30A ........................................................................38
4.9.2 Specication, terminal X30A................................................................39
4.10 Control connections (front panel)........................................................................40
4.10.1 Specication, rt-Ethernet coupler and cross-communication .............42
4.10.2 Specication, relay contact "REL Output" X23A .................................42
4.10.3 Specication, connection of temperature sensors X27A ....................42
4.10.4 Specication, connection "State" X20A ..............................................43
4.11 Commissioning ..................................................................................................43
4.11.1 Connection example, supply unit .......................................................44
5 Diagnostics ........................................................................... 45
5.1 Status indication LED ........................................................................................45
6 Design variants ...................................................................... 47
6.1 KeDrive D3-DP supply unit slave .......................................................................47
6.1.1 Purpose of the variant ........................................................................47
6.1.2 Dimensions ........................................................................................48
6.1.3 ZK +/– connection X30B .....................................................................48
6.1.4 AC mains connection D3-DP 301/x-xx02 slave ..................................48
6.1.5 Connection .........................................................................................49
A Appendix ............................................................................... 53
A.1 Technical data, supply unit BG3 .........................................................................53
A.1.1 Technical data, brake chopper BG3 ...................................................54
A.2 Technical data, supply unit BG4 ........................................................................54
A.2.1 Technical data, brake chopper BG4 ...................................................55
A.3 Ambient conditions.............................................................................................56
A.5 Power reduction at Tunom ≥ 40 °C .......................................................................57

5
General
Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
General
1 General
The product DVD from KEBA Industrial Automation Germany GmbH contains the
complete documentation for the related product series. The documentation for a product
series includes the operation manual (hardware description), device help (software
description) as well as further user manuals (e.g. eld bus description) and specications.
The documents are available in PDF format.
1.1 Target group
Dear user,
The documentation forms part of the device and contains important information about
operation and service. It is aimed at all persons who undertake mounting, installation,
commissioning and servicing work on the product.
1.2 Prerequisites
Prerequisites for usage of the devices from KEBA:
yThe documentation on the devices is to be stored so it is legible, accessible at
all times and for the entire life of the product.
yRead and ensure you understand the documentation on your device.
yQualication: to prevent injury or damage, personnel may only work on the
device if they have electrical engineering qualications.
yKnowledge required:
− National health and safety regulations (e.g. DGUV V3 in Germany)
− Mounting, installation, commissioning and operation of the device
Work in other areas, for example transport, storage and disposal is only allowed to be
undertaken by trained personnel.
1.3 Pictograms
To help the user, in this document we use the following pictograms:
NOTE
Useful information for the user.
Reference to other documents.
You will nd the "safety instructions and warnings" used in this operation manual in
chapter 2 Safety.
1.4 Disclaimer
Following the documentation on the devices from KEBA is a prerequisite:
yFor safe operation.
yTo achieve stated performance features and product characteristics.
KEBA does not accept any liability for injuries, damage or nancial losses that result from
the failure to follow the documentation.

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General
Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
General
1.5 Reference documents
Note:
You will nd all reference documents for this device on our web site in the
DOCU portal:
www.keba.com
1.6 Order code
The article designation provides information about the related variant of the supply unit
supplied. You will nd the signicance of the individual characters of the order code in
the column on the left.
D3- DP 3 0 0 / A - 4 5 0 0 - 0 0 0 0 - 0 0 0 0
Module type Supply
module
Product line
Type of supply 0: Passive
Supply 0: 3 x 230 - 480 VAC
1: 3 x 400 - 480 VAC
Cooling
A: Heat sink
B: Cooling plate
C: Liquid cooling
Power
45: 45 kW
90: 90 kW
A2: 120 kW**
Control supply
24 VDC
0: None
4: 24 VDC/ 20 A on board
5: 24 VDC/ 20 A on board with power failure regulation
Braking
resistor
0: External
1: Integrated
2: Supply module as slave variant (no braking resistor)
Options 0: Not including protective varnish
1: Including protective varnish
Version 0:
1: UL
Models
Field bus 0: rt-Ethernet coupler and cross-communication
Reserved
* Upon request, ** Power for liquid-cooled variant: 140 kW

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General
Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
General
Position of rating plate
T
T1
Figure 1.2 Position of rating plate (T) Figure 1.3 Position of rating plate (T1)
A second rating plate (T1) with only the most important information is on the top of
the busbar cover. In this way the rating plate data can also be seen if the devices are
installed in a row.
1.7 Rating plate
On the rating plate for the device you will nd the serial number, from which you can
identify the date of manufacture based on the following key.
Mac Adr.:
SW:
FS SW1:
SN:
SN:
FS SW2:
Multiple rated equipment. See instruction manual
In:
Out:
Year:
T1
T
KEBA Industrial Automation Germany GmbH
Gewerbestr. 5-9, 35633 Lahnau, www.keba.com
D3-DP 301/A-4500-0000-0000
JJWWSXXXX
400 V AC - 480 V AC
20XX
100 A AC - 85 A AC
565V DC - 678V DC
80 A DC - 67A DC
JJWWSXXXX
MACADR
D3-DP 301/A-4500-0000-0000
A
Serial no. key:
- JJ (YY) = Prod. year
- WW = Calendar week (CW)
- S = Production site
- XXXX = Sequential no. per CW
A: Revision state
Figure 1.1 Hardware rating plate KeDrive D3-DP supply unit (example)

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General
Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
General
1.8 Brief description
Note:
Only the KeDrive D3-DP supply unit BG3 and BG4 is described in this opera-
tion manual.
You will nd information about the controller (KeDrive D3-DU), axis controller
(KeDrive D3-DA), capacitance module (KeDrive D3-DC) and expansion module
(KeDrive D3-DE) in the related operation manuals.
The table below shows the type, device and short designations. All three designations
can be used in the operation manual in different contexts with the same meaning.
Type designation Device designation Short designation
KeDrive D3-DA Axis controller D3-DA
KeDrive D3-DP Supply unit D3-DP
KeDrive D3-DL Charging module D3-DL
KeDrive D3-DC Capacitance module D3-DC
KeDrive D3-DE Expansion module D3-DE
- Single model D3-DE Single
- Dual model D3-DE Dual
- Dual End model D3-DE Dual End
- Size (BG) 1 and size (BG) 2 BG1+2
- Size (BG) 3 and size (BG) 4 BG3+4
* In preparation
1.9 Scope of supply
The scope of supply includes:
yKeDrive D3-DP supply unit
yPre-assembled busbar elements for 24 V control supply -USt
yBusbar elements for DC link connection (in the separate bag of accessories)
yProduct DVD with booklet
1.10 Disposal
Follow the current national regulations!
Depending on their characteristics, dispose of individual parts as:
yElectrical waste
yPlastic waste
yMetal scrap
Or engage a certied disposal organisation with scrapping.

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General
Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
General
1.11 Support
Address: KEBA Industrial Automation Germany GmbH
Gewerbestrasse 5-9
35633 Lahnau
If you have any questions about the project planning for your machine or the
commissioning of your device, our Helpline will provide you with quick, specic
assistance.
The Helpline is available by e-mail or telephone:
Service hours: Mo. - Fr.: 8a.m. - 5p.m. (CET)
E-mail: [email protected]
Telephone: +496441966-180
Internet: www.keba.com
Note:
You will nd detailed information about our services on our web site
www.keba.com  Service

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General
Operation Manual Supply Unit KeDrive D3-DP BG3 and BG4
ID no.: 1804.201B.0-00 Date: 08/2021
General