KEBCO COMBIVERT H6 User manual

COMBIVERT H6
INSTRUCTIONS FOR USE | INSTALLATION RECTIFIER MODULE
Translation of original manual
Document 20105353 EN 03
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3
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.
There are safety informations in the documentation in front of these operations. Security
signs are located on the device or machine. A warning contains signal words which are
explained in the following table:
DANGER Dangerous situation, which will cause death or serious injury in case of
non-observance of this safety instruction.
WARNING Dangerous situation, which may cause death or serious injury in case of
non-observance of this safety instruction.
CAUTION Dangerous situation, which may cause minor injury in case of non-ob-
servance of this safety instruction.
NOTICE Situation, which can cause damage to property in case of non-obser-
vance.
RESTRICTION
Is used when certain conditions must meet the validity of statements or the result is
limited to a certain validity range.
Is used when the result will be better, more economic or trouble-free by following
these procedures.
More symbols
► Thisarrowstartsanactionstep.
• / - Enumerations are marked with dots or indents.
=> Cross reference to another chapter or another page.
Note to further documentation.
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4
PREFACE
Laws and guidelines
KEBAutomationKGconrmswiththeECdeclarationofconformityandtheCEmarkon
the device nameplate that it complies with the essential safety requirements.
The EC declaration of conformity can be downloaded on demand via our website. Fur-
therinformationisprovidedinchapter"Certication".
Warranty and liability
The warranty and liability on design, material or workmanship for the acquired device is
given in the general sales conditions.
Hereyouwillndourgeneralsalesconditions.
www.keb.de/terms-and-conditions
Furtheragreementsorspecicationsrequireawrittenconrmation.
Support
Through multiple applications not every imaginable case has been taken into ac-
count. If you require further information or if problems occur which are not treated de-
tailed in the documentation, you can request the necessary information via the local
KEB Automation KG agency.
The use of our units in the target products is outside of our control and therefore
lies exclusively in the area of responsibility of the customer.
Theinformationcontainedinthetechnicaldocumentation,aswellasanyuser-specic
advice in spoken and written and through tests, are made to best of our knowledge and
information about the intended use. However, they are regarded as being only informal
and changes are expressly reserved, in particular due to technical changes. This also
applies to any violation of industrial property rights of a third-party. Selection of our units
in view of their suitability for the intended use must be done generally by the user.
Tests can only be done within the intended end use of the product (application) by
the customer. They must be repeated, even if only parts of hardware, software or
the unit adjustment are modied.
Copyright
The customer may use the instructions for use as well as further documents or parts
from it for internal purposes. Copyrights are with KEB Automation KG and remain valid
in its entirety.
This KEB product or parts thereof may contain third-party software, including free and/
or open source software. 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.
Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their
respective owners.
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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 ..........................................................................................................................................9
Glossary ................................................................................................................................................10
Standards for drive converters / control cabinets .............................................................................12
Product standards that apply directly to the drive converter ........................................................12
Basic standards to which drive converter standards refer directly...............................................12
Standards that are used in the environment of the drive converter .............................................13
1 Basic Safety Instructions............................................ 14
1.1 Target group...................................................................................................................................14
1.2 Transport, storage and proper use .............................................................................................. 14
1.3 Installation......................................................................................................................................15
1.4 Electrical connection ....................................................................................................................16
1.4.1 EMC-compatible installation...............................................................................................17
1.4.2 Voltage test.........................................................................................................................17
1.4.3 Insulation measurement.....................................................................................................17
1.5 Start-up and operation ..................................................................................................................18
1.6 Maintenance...................................................................................................................................19
1.8 Repair .............................................................................................................................................20
1.7 Disposal..........................................................................................................................................20
2 Product Description .................................................... 21
2.1 Specied application.....................................................................................................................22
2.2 Unintended use..............................................................................................................................22
2.3 Product features ............................................................................................................................23
2.4 Type code .......................................................................................................................................24
3 Technical Data.............................................................. 25
3.1 Operating conditions ....................................................................................................................25
3.1.1 Climatic ambient conditions................................................................................................25
3.1.2 Mechanical ambient conditions ..........................................................................................26
3.1.3 Chemical / mechanical active substances..........................................................................26
3.1.4 Electrical operating conditions............................................................................................27
3.1.4.1 Deviceclassication........................................................................................................27
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TABLE OF CONTENTS
3.1.4.2 Electromagnetic compatibility..........................................................................................27
3.2 Technical data of the H6 power supply units..............................................................................28
3.3 DC link capacity.............................................................................................................................29
3.4 Mechanical installation .................................................................................................................30
3.4.1 Control cabinet installation .................................................................................................30
3.4.2 Installationinstructionsforatrearheatsink .....................................................................31
3.4.3 Dimensions central heat sink .............................................................................................31
3.4.3.1 Air heat sink.....................................................................................................................31
3.4.3.2 Liquid heat sinks..............................................................................................................32
3.4.4 Dimensionsandweightsofthepowersupplyunitswithatrearheatsink........................33
3.4.5 Dimensions and weights of the power supply units with air heat sink................................34
3.4.6 Mains chokes .....................................................................................................................36
3.4.7 EMClter............................................................................................................................37
3.4.7.1 Connection cross sections and tightening torques..........................................................37
4 Installation and Connection........................................ 38
4.1 Construction of the unit................................................................................................................38
4.1.1 Status-LEDs .......................................................................................................................41
4.1.1.1 Status-LED safety module...............................................................................................41
4.1.1.2 Status-LED unit ...............................................................................................................41
4.2 Connection of the power unit.......................................................................................................42
4.2.1 Connection of the DC bus X1D ..........................................................................................42
4.2.2 Connection of the 24V bus X1C.........................................................................................42
4.2.3 Power unit terminal strips X1A, X1B ..................................................................................43
4.2.4 Connection for power supply..............................................................................................44
4.2.5 Connectionofabrakingresistorwithreprotectionmonitoring.........................................45
4.3 Connection of the control.............................................................................................................46
4.3.1 Error chain terminal X2C, X2D...........................................................................................46
4.3.1.1 Error linkage circuit (channel 1).......................................................................................46
4.3.1.2 Error power supply unit (channel 2) ................................................................................46
4.3.1.3 Wiring example error linkage circuit ................................................................................46
4.3.2 EtherCat system bus terminal X4B ....................................................................................47
4.3.3 Diagnosis/Visualisation X4A..............................................................................................47
4.3.3.1 Assignment of the interfaces ...........................................................................................48
4.3.4 Digital inputs and outputs X2A ...........................................................................................48
4.3.4.1 Technical data of the inputs.............................................................................................48
4.3.4.2 Technical data of the outputs...........................................................................................48
4.3.5 Assembly of the wires to PUSH IN terminals .....................................................................49
4.3.5.1 Assignment of the terminal block X2A.............................................................................50
4.3.5.2 Connection of the digital inputs .......................................................................................50
4.3.5.3 Connection of the digital outputs.....................................................................................50
4.3.5.4 Example for the control of digital inputs and digital outputs ............................................51
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TABLE OF CONTENTS
5 Certication.................................................................. 52
5.1 CE Marking.....................................................................................................................................52
5.2 UL Marking .....................................................................................................................................52
5.3 Further information and documentation .....................................................................................54
6 Cooling System............................................................ 55
6.1 Installation of water-cooled units ................................................................................................55
6.1.1 Heat sink and operating pressure ......................................................................................55
6.1.2 Materials in the cooling circuit ............................................................................................55
6.1.3 Requirements on the coolant .............................................................................................56
6.1.4 Connection to the cooling system ......................................................................................57
6.1.5 Coolant temperature and moisture condensation ..............................................................57
6.1.6 Coolantheatingdependingonpowerlossandowratewithwater ..................................59
6.1.7 Typicallyfallofpressuredependingontherateofow......................................................59
7 Revision History .......................................................... 60
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LIST OF FIGURES
List of Figures
Figure 1: Control cabinet installation...............................................................................................30
Figure 2: Main heat sink for COMBIVERT H6.................................................................................32
Figure 3: Housing C and G .............................................................................................................33
Figure 4: Housing S ........................................................................................................................34
Figure 5: Housing W .......................................................................................................................35
Figure 6: Construction of the unit....................................................................................................38
Figure 7: Connections of the front side ...........................................................................................38
Figure 8: View rear side of the unit ................................................................................................39
Figure9: Internalwiringoftherectiermodule(schematicdiagram) .............................................39
Figure 10: View upper side of the unit...............................................................................................40
Figure 11: Status-LEDs.....................................................................................................................41
Figure 12: Connection of the DC bus................................................................................................42
Figure 13: Connection of the 24V bus...............................................................................................42
Figure 14: Connection for power supply ...........................................................................................44
Figure 15: Connection of a braking resistor ......................................................................................45
Figure 16: Error chain terminal X2C, X2D.........................................................................................46
Figure 17: Wiring example error linkage circuit.................................................................................46
Figure 18: Assignment of the interfaces............................................................................................48
Figure 19: Assembly of the control cable..........................................................................................49
Figure 20: Assignment of the terminal block X2A .............................................................................50
Figure 21: Connection of the digital inputs DI1…DI4.......................................................................50
Figure 22: Connection of the digital outputs DO1…DO4 .................................................................50
Figure 23: Example for the control of digital inputs and digital outputs.............................................51
Figure 24: Coolant heating depending on power loss.......................................................................59
Figure25: Typicallyfallofpressuredependingontherateofow ...................................................59
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LIST OF TABLES
List of Tables
Table 1: Type code ........................................................................................................................24
Table 2: Climatic ambient conditions .............................................................................................25
Table 3: Mechanical ambient conditions........................................................................................26
Table 4: Chemical / mechanical active substances .......................................................................26
Table5: Deviceclassication.........................................................................................................27
Table 6: Electromagnetic compatibility ..........................................................................................27
Table7: TechnicaldataoftheH6rectiermodules.......................................................................28
Table 8: DC link capacity ...............................................................................................................29
Table 9: Mains chokes...................................................................................................................36
Table10: EMClter .........................................................................................................................37
Table 11: Connection cross sections and tightening torques ..........................................................37
Table 12: Power unit terminal strips housing C/S............................................................................43
Table 13: Power unit terminal strips housing G/W...........................................................................43
Table 14: EtherCat System bus socket X4B....................................................................................47
Table 15: Diagnosis/Visualisation X4A ...........................................................................................47
Table 16: Technical data of the outputs ...........................................................................................48
Table 17: Wire-end ferrules and stripping length.............................................................................49
Table 18: Requirements on the coolant...........................................................................................56
Table 19: Supply of temper coolant .................................................................................................58
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GLOSSARY
Glossary
Endat Bidirectional encoder interface of the
company Heidenhain
EtherCAT Real-time Ethernet bus system of the
company Beckhoff
Ethernet Real-timebussystem-denespro-
tocols, plugs, types of cables
FE Functional earth
FSoE Functional Safety over Ethernet
FU Drive converter
GND Reference potential, ground
GTR7 Braking transistor
HFlter Highfrequencyltertothemains
Hiperface Bidirectional encoder interface of the
company Sick-Stegmann
HMI Human machine interface (touch
screen)
HSP5 Fast, serial protocol
HTL Incremental signal with an output
voltage (up to 30V) -> TTL
IEC International standard
IP xx Degree of protection (xx for level)
KEB product The KEB product is subject of this
manual.
KTY Silicium temperature sensor (pola-
rized)
Manufacturer The manufacturer is KEB, unless
otherwisespecied(e.g.asma-
nufacturer of machines, engines,
vehicles or adhesives).
MCM American unit for large wire cross
sections
Modulation Means in drive technology that the
power semiconductors are controlled
MTTF Mean service life to failure
NN Sea level
OC Overcurrent
OH Overheat
OL Overload
OSSD Output signal swithching device; - an
output signal that is checked in regu-
lar intervals on its shutdown. (safety
technology)
PDS Power drive system incl. motor and
measuring probe
PE Protective earth
PELV Protective Extra Low Voltage
PFD Term used in the safety technology
(EN 61508-1...7) for the size of error
probability
0V Earth-potential-free common point
1ph 1-phase mains
3ph 3-phase mains
AC AC current or voltage
AFE From 07/2019 AIC replaces the pre-
vious name AFE
AFElter From07/2019AIClterreplacesthe
previousnameAFElter
AIC Active Front End module
AIClter Filter for Active Front End Module
(AIC)
Application The application is the intended use
of the KEB product.
ASCL Asynchronous sensorless closed
loop
Auto motor
ident.
Automaticallymotoridentication;
calibration of resistance and induc-
tance
AWG American wire gauge
B2B Business-to-business
BiSS Open source real-time interface for
sensors and actuators (DIN 5008)
CAN Fieldbus system
CDM Complete drive module including
auxiliary equipment (control cabinet)
COMBIVERT KEB drive converters
COMBIVIS KEB start-up and parameterizing
software
Customer The customer has purchased a KEB
product from KEB and integrates the
KEB product into his product (cus-
tomer product) or resells the KEB
product (dealer)
DC DC current or voltage
DI Demineralized water, also referred to
as deionized (DI) water
DIN German Institut for standardization
DS 402 CiADS402-CANdeviceprolefor
drives
EMC Electromagnetic compatibility
Emergency
stop
Shutdown of a drive in emergency
case (not de-energized)
Emergency
switching off
Switching off the voltage supply in
emergency case
EN European standard
Encoder emu-
lation
Software-generated encoder output
End customer The end customer is the user of the
customer product.
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GLOSSARY
PFH Term used in the safety technology
(EN 61508-1...7) for the size of error
probability per hour
PLC Programmable logic controller
PT100 TemperaturesensorwithR0=100Ω
PT1000 TemperaturesensorwithR0=1000Ω
PTC PTC-resistor for temperature detec-
tion
PWM Pulse width modulation
RJ45 Modular connector with 8 lines
SCL Synchronous sensorless closed loop
SELV Safety Extra Low Voltage (<60V)
SIL The security integrity level is a
measure for quantifying the risk
reduction. Term used in the safety
technology (EN 61508 -1...7)
SS1 Safety function „Safe stop 1“ in ac-
cordance with IEC 61800-5-2
SSI Synchronous serial interface for
encoder
STO Safety function „Safe Torque Off“ in
accordance with IEC 61800-5-2
TTL Incremental signal with an output
voltage up to 5V
USB Universal serial bus
VARAN Real-time Ethernet bus system
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STANDARDS FOR DRIVE CONVERTERS/CONTROL CABINETS
Standards for drive converters / control cabinets
Product standards that apply directly to the drive converter
EN61800-2 Adjustable speed electrical power drive systems - Part 2: General requirements-
Ratingspecicationsforlowvoltageadjustablefrequencya.c.powerdrive
systems (VDE0160-102, IEC61800-2)
EN61800-3 Speed-adjustableelectricaldrives.Part3:EMCrequirementsandspecictest
methods (VDE0160-103, IEC61800-3)
EN61800-5-1 Adjustable speed electrical power drive systems - Part 5-1: Safety requirements
- Electrical, thermal and energy (IEC 61800-5-1); German version EN 61800-5-1
EN61800-5-2 Adjustable speed electrical power drive systems - Part 5-2: Safety Requirements
- Functional (IEC 22G/264/CD)
UL61800-5-1 American version of the EN 61800-5-1 with „National Deviations“
Basic standards to which drive converter standards refer directly
EN55011 Industrial,scienticandmedicalequipment-Radiofrequencydisturbance
characteristics - Limits and methods of measurement (CISPR 11); German
version EN 55011
EN55021 Interference to mobile radiocommunications in the presence of impulse noise -
Methods of judging degradation and measures to improve performance (IEC/
CISPR/D/230/FDIS); German version prEN 55021
EN60529 Degrees of protection provided by enclosures (IP Code) (IEC 60529)
EN60664-1 Insulation coordination for equipment within low-voltage systems Part 1: Princi-
ples, requirements and tests (IEC 60664-1)
EN60721-3-1 Classicationofenvironmentalconditions-Part3-1:Classicationofgroupsof
environmental parameters and their severities - Section 1: Storage (IEC 60721-
3-1); German version EN 60721-3-1
EN60721-3-2 Classicationofenvironmentalconditions-Part3:Classicationofgroupsof
environmental parameters and their severities - Section 2: Transportation and
handling (IEC 104/670/CD)
EN60721-3-3 Classicationofenvironmentalconditions-Part3:Classicationofgroupsof
environmental parameters and their severities; section 3: Stationary use at
weatherprotected locations; Amendment A2 (IEC 60721-3-3); German version
EN 60721-3-3
EN61000-2-1 Electromagnetic compatibility (EMC) - Part 2: Environment - Section 1: Descrip-
tion of the environment - Electromagnetic environment for low-frequency
conducted disturbances and signalling in public power supply systems
EN61000-2-4 Electromagnetic compatibility (EMC) - Part 2-4: Environment; Compatibility
levels in industrial plants for low-frequency conducted disturbances (IEC 61000-
2-4); German version EN 61000-2-4
EN61000-4-2 Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement
techniques - Electrostatic discharge immunity test (IEC 61000-4-2); German
version EN 61000-4-2
EN61000-4-3 Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement
techniques-Radiated,radio-frequency,electromagneticeldimmunitytest(IEC
61000-4-3); German version EN 61000-4-3
EN61000-4-4 Electromagnetic compatibility (EMC) - Part 4-4: Testing and measurement
techniques - Electrical fast transient/burst immunity test (IEC 61000-4-4);
German version EN 61000-4-4
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13
STANDARDS FOR DRIVE CONVERTERS/CONTROL CABINETS
EN61000-4-5 Electromagnetic compatibility (EMC) - Part 4-5: Testing and measurement
techniques - Surge immunity test (IEC 61000-4-5); German version EN 61000-4-5
EN61000-4-6 Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement
techniques - Immunity to conducted disturbances, induced by radio-frequency
elds(IEC61000-4-6);GermanversionEN61000-4-6
EN61000-4-34 Electromagnetic compatibility (EMC) - Part 4-34: Testing and measurement
techniques - Voltage dips, short interruptions and voltage variations immunity
tests for equipment with mains current more than 16 A per phase (IEC 61000-4-
34); German version EN 61000-4-34
EN61508-1...7 Functional safety of electrical/electronic/programmable electronic safety-related
systems – Part 1...7 (VDE0803-1…7, IEC61508-1…7)
EN62061 Safety of machinery - functional safety of electrical, electronic and program-
mable electronic safety-related systems (VDE0113-50, IEC62061)
EN ISO13849-1 Safety of machinery - safety-related parts of control systems - Part 1: General
principles for design (ISO13849-1); German version EN ISO 13849-1
Standards that are used in the environment of the drive converter
DGUV regulation 3 Electrical installations and equipment
DIN 46228-1 Wire-end ferrules; Tube without plastic sleeve
DIN 46228-4 Wire-end ferrules; Tube with plastic sleeve
DINIEC60364-5-54 Low-voltage electrical installations - Part 5-54: Selection and erection of
electrical equipment - Earthing arrangements, protective conductors and protec-
tive bonding conductors (IEC 64/1610/CD)
DIN VDE 0100-729 Low-voltage electrical installations - Part 7-729: Requirements for special
installations or locations - Operating or maintenance gangways (IEC 60364-7-
729:2007,modied);GermanimplementationHD60364-7-729:2009
DNVGL-CG-0339 Environmentaltestspecicationforelectrical,electronicandprogrammable
equipment and systems
EN1037 Safety of machinery - Prevention of unexpected start-up; German version EN 1037
EN 12502-1...5 Protection of metallic materials against corrosion - Part 1...5
EN60204-1 Safety of machinery - electrical equipment of machines Part 1: General require-
ments (VDE0113-1, IEC44/709/CDV)
EN60439-1 Low-voltage switchgear and controlgear assemblies - Part 1: Type-tested and
partially type-tested assemblies (IEC 60439-1); German version EN 60439-1
EN 60947-7-1 Low-voltage switchgear and controlgear - Part 7-1: Ancillary equipment -
Terminal blocks for copper conductors (IEC 60947-7-1:2009); German version
EN 60947-7-1:2009
EN 60947-8 Low-voltage switchgear and controlgear - Part 8: Control units for built-in
thermal protection (PTC) for rotating electrical machines (IEC 60947-8:2003 +
A1:2006 + A2:2011)
EN61373 Railway applications - Rolling stock equipment - Shock and vibration tests (IEC
61373); German version EN 61373
EN61439-1 Low-voltage switchgear and controlgear assemblies - Part 1: General rules (IEC
121B/40/CDV); German version FprEN 61439-1
VGB R 455 P Water treatment and use of materials in cooling systems
ISO 4017 Fasteners - Hexagon head screws - Product grades A and B
ISO 4762 Hexagon socket head cap screws
ISO 7090 Plain washers, chamfered - Normal series - Product grade A
ISO 7092 Plain washers - Small series - Product grade A
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14
BASIC SAFETY INSTRUCTIONS
1 Basic Safety Instructions
The COMBIVERT is designed and constructed in accordance with state-of-the-art tech-
nology and the recognised safety rules and regulations However, the use of such de-
vices may cause functional hazards for life and limb of the user or third parties, or dama-
ges to the system and other material property.
The following safety instructions have been created by the manufacturer for the area of
electric drive technology. They can be supplemented by local, country- or application-
specic safety instructions. This list is not exhaustive. Non-observance of the safety
instructions by the customer, user or other third party leads to the loss of all resulting
claims against the manufacturer.
NOTICE Hazards and risks through ignorance.
►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qualications:
• Knowledge and understanding of the safety instructions.
• Skills for installation and assembly.
• Start-up and operation of the product.
• Understanding of the function in the used machine.
• Detection of hazards and risks of the electrical drive technology.
• Knowledge of DIN IEC 60364-5-54.
• Knowledge of national safety regulations (e.g. DGUV regulation 3).
1.2 Transport, storage and proper use
The transport is carried out by qualified persons in accordance with the environmental
conditions specified in this manual. Drive converter shall be protected against excessive
strains.
Transport of drive converters with an edge length >75 cm
The transport by forklift without suitable tools can cause a deflection of the heat
sink. This leads to premature aging or destruction of internal components.
►Transport of drive converters on suitable pallets.
►Do not stack drive converters or burden them with other heavy objects.
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15
BASIC SAFETY INSTRUCTIONS
ESD
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!
EX
►The COMBIVERT is not intended for the use in potentially explosive
environment.
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.
• To prevent damages to the device:
• 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. Non-
compliance with the applicable standards.
• Do not allow moisture or mist to penetrate the unit.
• Avoiddustpermeatingthedevice.Allowforsufcientheatdissipationifinstalledin
a dust-proof housing.
• Note installation position and minimum distances to surrounding elements. Do not
cover the ventilation openings.
• Mountthedriveinverteraccordingtothespecieddegreeofprotection.
• Make sure that no small parts fall into the COMBIVERT during assembly and wiring
(drilling chips, screws etc.). This also applies to mechanical components, which can
lose small parts during operation.
• Checkthereliabletofthedeviceconnectionsinordertoavoidcontactresistances
and sparking.
• Do not walk-on drive converter.
• The safety instructions are to be kept!
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16
BASIC SAFETY INSTRUCTIONS
1.4 Electrical connection
DANGER Voltage at the terminals and in the device !
Danger to life due to electric shock !
►Never work on the open device or never touch exposed parts.
►For any work on the unit switch off the supply voltage, secure it
against switching on and check absence of voltage by measure-
ment.
►Wait until all drives has been stopped in order that no regenerative
energy can be generated.
►Await capacitor discharge time (5 minutes) if necessary, measure
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 pur-
poses).
►Connect the protective earth conductor always to drive converter
and motor.
►Install all required covers and protective devices for operation.
►The control cabinet shall be kept closed during operation.
►Residual current: This product may cause a dc current in the pro-
tective earth conductor. When a residual current protective device
(RCD) or a residual current monitoring device (RCM) is used for the
protection against direct or indirect contact, only a RCD or RCM type
B is permitted on the power supply side of this product.
►Drive converters with a leakage current >3.5mA AC current (10mA
DC current) are intended for a stationary connection. Protective
earth conductors must be designed in accordance with the local
regulations for equipment with high leakage currents according to
EN 61800-5-1, EN 60204-1 or DIN IEC 60364-5-54 .
If personnel protection is required during installation of the
system, suitable protective devices must be used for drive
converters.
www.keb.de/leadmin/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.
act respecting technical equipment, accident prevention rules etc. They must always be
complied with, also for drive converter bearing a CE marking.
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17
BASIC SAFETY INSTRUCTIONS
For a trouble-free and safe operation, please pay attention to the following instructions:
• The electrical installation shall be carried out in accordance with the relevant re-
quirements.
• Cable cross-sections and fuses must be dimensioned by the user according to the
speciedminimum/maximumvaluesfortheapplication.
• Thewiringmustbemadewithexiblecoppercableforatemperature>75°C.
• Connection of the drive converter is only permissible on symmetrical networks with
a maximum line voltage (L1, L2, L3) with respect to earth (N/PE) of max. 300V. An
isolating transformer must be used for supply networks which exceed this value! In
case of non-compliance the control is not longer considered to be a PELV circuit.
• With existing or newly wired circuits the person installing the units or machines must
ensure that the PELV requirements are met.
• For drive converters that are not isolated from the supply circuit (in accordance with
EN 60721-3-2) all control lines must be included in other protective measures (e.g.
double insulation or shielded, earthed and insulated).
• When using components without isolated inputs/outputs, it is necessary that equi-
potential bonding exists between the components to be connected (e.g. by the equi-
potential line). Disregard can cause destruction of the components by equalizing
currents.
1.4.1 EMC-compatible installation
Observance of the limit values required by EMC law is the responsibility of the customer.
Notes on EMC-compatible installation can be found here.
www.keb.de/leadmin/media/Manuals/emv/0000neb0000.pdf
1.4.2 Voltage test
Testing with AC voltage (in accordance with EN 60204-1 chapter 18.4) may not be exe-
cuted, since there is danger for the power semiconductors in the drive inverter.
Due to the radio interference suppression capacitors, the test generator will
switch off immediately with a current fault.
According to EN 60204-1 it is permissible to disconnect already tested com-
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 EN 60204-1 chapter 18.3) with DC
500V is permissible, if all power unit connections (grid-connected potential) and all con-
trol connections are bridged with PE. The insulation resistance of the respective device
can be found in the technical data.
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18
BASIC SAFETY INSTRUCTIONS
NOTICE Continuous operation (S1) with load > 60 % !
Premature ageing of the electrolytic capacitors !
►Insert mains choke with Uk= 4%.
►From a rated motor power of 55 kW, a mains choke with Uk= 4%
must be used !
1.5 Start-up and operation
The drive converter must not be started until it is determined that the installation com-
plies with the machine directive; Account is to be taken of EN 60204-1.
WARNING Software protection and programming !
Hazards caused by unintentional behavior of the drive!
►Check especially during initial start-up or replacement of the drive
converter if parameterization is compatible to application.
►Securing a unit solely with software-supported functions is not suf-
cient.Itisimperativetoinstallexternalprotectivemeasures(e.g.
limit switch) that are independent of the drive converter.
►Secure motors against automatic restart.
VORSICHT High temperatures at heat sink and coolant!
Burning of the skin!
►Cover hot surfaces safe-to-touch.
►If necessary, attach warning signs on the system.
►Before touching, check the surface and coolant lines.
►Before working let the unit cool down.
• During operation, all covers and doors shall be kept closed.
• 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/leadmin/media/Manuals/knowledge/04_techinfo/00_gene-
ral/ti_format_capacitors_0400_0001_gbr.pdf
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19
BASIC SAFETY INSTRUCTIONS
Short-circuit resistance
The drive converters are conditional short-circuit proof. After resetting the internal pro-
tection devices, the function as directed is guaranteed.
Exceptions:
• If an earth-leakage fault or short-circuit often occurs at the output, this can lead to a
defect in the unit.
• If a short-circuit occurs during regenerative operation (2nd or 4th quadrant, regen-
eration into the DC link), this can lead to a defect in the unit.
Switching at the output
Switching between motor and drive converter is prohibited for single drives during ope-
ration as this may trigger the protection gear of the device. Function ‚speed search‘ must
be activated if switching can not be avoided. Speed search may only be triggered after
closing the motor contactor (e.g. by switching the control release).
Connecting and disconnecting is permissible with multiple motor drives if at least 1 mo-
tor is running during the switch-over process. The drive converter must be dimensioned
to the occurring starting currents.
The ‚speed search‘ function must be activated if the motor is still running during a restart
of the drive converter (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.
1.6 Maintenance
The following maintenance work has to be carried out when required, but at least once
per year by authorized and trained personnel.Check unit for loose screws and plugs and
tighten if necessary.
►Check system for loose screws and plugs and tighten if necessary.
►Clean drive converter from dirt and dust deposits. Pay attention especially to coo-
lingnsandprotectivegridofthefans.
► Examineandcleanextractedairlterandcoolingairlterofthecontrolcabinet.
►Check the function of the fans of the drive converter. The fan must be replaced in
case of audible vibrations or squeak.
►In the case of liquid-cooled drive converters a visual test of the cooling circuit for
leaks and corrosion must be carried out.The cooling circuit must be completely
empty if a unit shall be switched off for a longer period. The cooling circuit must be
blownoutadditionallywithcompressedairattemperaturesbelow0°C.
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20
BASIC SAFETY INSTRUCTIONS
1.8 Repair
In case of malfunction, unusual noises or smells inform a person in charge!
DANGER Unauthorized exchange, repair and modications!
Unpredictable malfunctions!
►The function of the drive converter is dependent on its parameteri-
zation. Never replace without knowledge of the application.
► ModicationorrepairispermittedonlybyKEBAutomationKGau-
thorized personnel.
►Only use original manufacturer parts.
►Infringement will annul the liability for resulting consequences.
In case of failure, please contact the machine manufacturer. Only the machine manu-
facturer knows the parameterisation of the used drive converter and can provide an
appropriate replacement or induce the maintenance.
1.7 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. These devices may not be disposed at the collection centres of
public sector disposal organisations.
If no deviating agreement has been made between the customer and
KEB or no deviating mandatory legal regulation exists, KEB products
marked in this way can be returned. Company and keyword to the return
point can be taken from the list below. Shipping costs are paid by the
customer. Thereupon the devices will be professionally recycled and
disposed.
Theentrynumbersarelistedcountry-specicinthefollowingtable.Thecorresponding
KEB return addresses can be found on our website.
Withdrawal by WEEE-Reg.-No. Keyword
Austria
KEB Automation GmbH ERA: 51976 Stichwort „Rücknahme WEEE“
France
RÉCYLUM - Recycle point ADEME: FR021806 Mots clés „KEB DEEE“
Germany
KEB Automation KG EAR: DE12653519 Stichwort „Rücknahme WEEE“
Italy
COBAT AEE: (IT) 19030000011216 Parola chiave „Ritiro RAEE“
The packaging must be feed to paper and cardboard recycling.
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