KEBCO COMBIVERT F5 User manual

COMBIVERT F5/F6
INSTRUCTIONS FOR USE | INSTALLATION SYSTEM V | 600…1000 KVA
Translation of the original manual
Document 20136714 EN 01 | Mat.No. 00F6NEM-0V00

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.
ATTENTION 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.
www.keb.de/nc/search

4
PREFACE
Laws and guidelines
KEBAutomationKGconrmswiththeCEmarkandtheECdeclarationofconformity,
that our device complies with the essential safety requirements.
The CE mark is located on the name plate. The EC declaration of conformity can be
downloaded on demand via our website. Further information is provided in chapter "Cer-
tication".
Warranty
The warranty on design, material or workmanship for the acquired device is given in the
current terms and conditions.
Hereyouwillndourcurrenttermsand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 beyond of our control and therefore
exclusively the responsibility of the machine manufacturer, system integrator or
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 application. However, they are considered for information only
without responsibility. 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 gener-
ally by the user.
Tests can only be done within the application by the machine manufacturer. They
must be repeated, even if only parts of hardware, software or the unit adjustment
are modied.
Copyright
The customer may use the instruction manual as well as further documents or parts from
it for internal purposes. Copyrights are with KEB Automation KG and remain valid in its
entirety.
Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their
respectiveownersandarelistedinthefootnoteontherstoccurrence.

5
TABLE OF CONTENTS
Table of Contents
Preface ....................................................................................................................................................3
Signal words and symbols .............................................................................................................3
More symbols.................................................................................................................................3
Laws and guidelines.......................................................................................................................4
Warranty .......................................................................................................................................4
Support .......................................................................................................................................4
Copyright........................................................................................................................................4
Table of Contents ................................................................................................................................... 5
List of Figures.........................................................................................................................................9
List of Tables ........................................................................................................................................10
Glossar .................................................................................................................................................. 11
Used standards ....................................................................................................................................13
1 Basic Safety Instructions............................................ 15
1.1 Target group...................................................................................................................................15
1.2 Transport, storage and proper use .............................................................................................. 15
1.3 Installation......................................................................................................................................16
1.4 Electrical connection ....................................................................................................................17
1.4.1 EMC-compatible installation...............................................................................................18
1.4.2 Voltage test.........................................................................................................................18
1.4.3 Insulation measurement..................................................................................................... 18
1.5 Start-up and operation ..................................................................................................................19
1.6 Maintenance...................................................................................................................................20
1.7 Repair .............................................................................................................................................20
1.8 Disposal..........................................................................................................................................21
2 Product Description .................................................... 23
2.1 Intended use ..................................................................................................................................23
2.1.1 Residual risks .....................................................................................................................24
2.2 Improper use..................................................................................................................................24
2.3 Type code cabinet system ............................................................................................................25
3 Functional overview .................................................... 27
3.1 Representation of the electrical power unit with higher-level control ..................................... 28
3.2 Representation of the electrical power unit with braking option.............................................. 29
3.3 Structure of the higher-level control ...........................................................................................30
3.4 Structure of the liquid distribution ..............................................................................................31
3.5 Structure of the cabinet air conditioning ....................................................................................32
3.6 General specications ..................................................................................................................33
3.6.1 Machine safety ...................................................................................................................33
3.6.2 Switching frequency ...........................................................................................................34
3.6.3 Emergency stop function....................................................................................................35

6
TABLE OF CONTENTS
3.6.4 Overcurrent and short-circuit protection............................................................................. 36
3.7 C6 HMI program functionalities ...................................................................................................37
3.7.1 Self-test at power-on-reset ................................................................................................. 37
3.7.2 Monitoring cooling circuit....................................................................................................37
3.7.3 Monitoring mains ................................................................................................................37
3.7.4 Data logger ........................................................................................................................38
3.7.5 Visualisation .......................................................................................................................38
4 Overview cabinet system............................................ 39
4.1 System variations..........................................................................................................................40
4.1.1 Basic system ......................................................................................................................40
4.1.2 Basicsystemwithadditionalsinusoidaloutputlter...........................................................40
4.1.3 Accessories and options.....................................................................................................40
4.2 Cabinet system without sine-wave lter at the output ..............................................................41
4.2.1 Dimensions.........................................................................................................................42
4.3 Cabinet system with sine-wave lter at the output.................................................................... 43
4.3.1 Dimensions.........................................................................................................................44
5 Mechanical Installation ............................................... 45
5.1 General information ......................................................................................................................45
5.2 Transport of the cabinet system .................................................................................................. 45
5.3 Check the scope of delivery ......................................................................................................... 46
5.4 Installation of the cabinet system................................................................................................47
5.5 Installation location requirements ............................................................................................... 48
5.5.1 Information about the service life .......................................................................................48
5.6 Attach the cabinet system ............................................................................................................49
5.6.1 Fixing at ground level .........................................................................................................49
5.6.2 Hole distances....................................................................................................................50
5.6.3 Distances to the wall ..........................................................................................................50
5.6.4 Mounting on the wall ..........................................................................................................51
5.7 Installation of the coolant connection.........................................................................................52
5.7.1 General information............................................................................................................52
5.7.2 Coolant connection.............................................................................................................52
6 Electrical Installation................................................... 53
6.1 General information ......................................................................................................................53
6.2 Installation of the cables...............................................................................................................53
6.2.1 Cable installation ................................................................................................................53
6.3 Shield connection..........................................................................................................................54
6.4 Connection protective earth.........................................................................................................54
6.5 Mains connection ..........................................................................................................................55
6.5.1 Connection of the mains cable........................................................................................... 55
6.5.2 Connection to circuit breaker..............................................................................................56

7
TABLE OF CONTENTS
6.5.3 Instructions for installation..................................................................................................57
6.6 Selection installation of the motor cable ....................................................................................58
6.6.1 General information............................................................................................................58
6.6.2 Selection of the motor cable...............................................................................................59
6.6.3 Connection of the motor cable ...........................................................................................60
6.7 Connection motor temperature monitoring ................................................................................61
6.7.1 General information............................................................................................................61
6.7.2 Temperature detection T1B, T2B........................................................................................62
6.7.3 Using the temperature input in the KTY mode ...................................................................63
6.7.4 Using the temperature input in the PTC mode................................................................... 63
6.8 Connection braking resistor.........................................................................................................64
6.9 Connection „Safe torque off (STO)“ ............................................................................................65
7 Technical Data.............................................................. 67
7.1 Operating conditions ....................................................................................................................67
7.1.1 Climatic conditions .............................................................................................................67
7.1.2 Mechanical environmental conditions ................................................................................67
7.1.3 Other operating conditions .................................................................................................67
7.1.4 Electromagnetic compatibility according to EN 61800-3.................................................... 68
7.1.5 Technical data circuit breaker NZM4 .................................................................................. 68
7.2 Electrical data 690 V mains voltage .............................................................................................69
8 Start-up......................................................................... 71
8.1 Liquid distribution .........................................................................................................................71
8.1.1 General...............................................................................................................................71
8.1.2 Flushing the single cooling circuits.....................................................................................71
8.1.3 Structure liquid distribution ................................................................................................. 72
8.1.4 Position stopcock ...............................................................................................................73
8.1.5 Shutoff valves at the liquid distributor.................................................................................73
8.2 Power unit ......................................................................................................................................74
8.2.1 Key switch S1.....................................................................................................................74
8.2.2 Arrangement of the control boards..................................................................................... 75
8.2.3 Procedure for initial start-up ...............................................................................................76
8.2.4 Switch-on procedures.........................................................................................................77
8.2.5 Switch-on procedure diagram ............................................................................................78
A Annex - Graphs............................................................ 79
A.1 Overload characteristic ................................................................................................................79
A.2 Overload protection in the lower speed range...........................................................................79
A.3 Power dissipation of the cabinet system ...................................................................................80
B Annex - Certication ................................................... 81
B.1 CE Marking ....................................................................................................................................81

8
TABLE OF CONTENTS
C Annex - Cooling System............................................. 83
C.1 General information......................................................................................................................83
C.1.1 Materials in the cooling cicuit.............................................................................................83
C.1.2 Requirements on the coolant.............................................................................................84
C.1.3 Cooling circuit ....................................................................................................................84
C.1.4 Special requirements for open and half-open cooling systems .........................................85
C.1.5 Coolantowtemperature...................................................................................................85
C.1.6 Moisture condensation.......................................................................................................85
C.1.7 Supply of temper coolant................................................................................................... 86
C.1.8 Pressure drop of the cabinet system .................................................................................87
C.1.9 Volumeowdependingontotalpowerdissipationandtemperaturedifference................88

9
LIST OF FIGURES
List of Figures
Figure 1: Functional overview .........................................................................................................27
Figure 2: Overview of the electrical power unit ...............................................................................28
Figure 3: Overview of the electrical power unit with braking option ................................................29
Figure 4: Structure of the higher-level control.................................................................................30
Figure 5: Structure of the liquid distribution.....................................................................................31
Figure 6: Structure of the cabinet air conditioning...........................................................................32
Figure 7: Emergency stop button....................................................................................................35
Figure 8: Overview cabinet system.................................................................................................39
Figure9: BasicsystemwithoutSFlter..........................................................................................41
Figure10: DimensiondrawingwithoutSFlter.................................................................................42
Figure11: BasicsystemwithSFlter...............................................................................................43
Figure12: DimensiondrawingwithSFlter......................................................................................44
Figure 13: Transport..........................................................................................................................45
Figure 14: Type plate ........................................................................................................................46
Figure 15: Crane transport................................................................................................................47
Figure 16: Align the control cabinet system ......................................................................................48
Figure 17: Attach the cabinet system................................................................................................ 49
Figure 18: Hole distances .................................................................................................................50
Figure 19: Distance to the wal...........................................................................................................50
Figure 20: Wall mounting ..................................................................................................................51
Figure 21: Coolant connection ..........................................................................................................52
Figure 22: Installation of the cables ..................................................................................................54
Figure 23: Connection mains input ................................................................................................... 55
Figure 24: Connection circuit breaker ...............................................................................................56
Figure 25: Cross-section mains cable types .....................................................................................57
Figure 26: Cross-section motor cable ...............................................................................................59
Figure 27: Connection motor cable...................................................................................................60
Figure 28: Connection motor temperature monitoring ...................................................................... 61
Figure 29: Connection of a KTY sensor............................................................................................63
Figure 30: Wiring examples in the PTC mode .................................................................................. 63
Figure 31: Connection „Safe torque off (STO)“ .................................................................................65
Figure 32: Wiring „Safe torque off (STO)“ .........................................................................................65
Figure 33: Circuit breaker NZM4....................................................................................................... 68
Figure 34: Structure liquid distribution...............................................................................................72
Figure 35: Position stopcock.............................................................................................................73
Figure 36: Shutoff valves at the liquid distributor ..............................................................................73
Figure 37: Key switch S1 ..................................................................................................................74
Figure 38: Arrangement of the control boards .................................................................................. 75
Figure 39: Control boards .................................................................................................................75
Figure 40: Flow chart switch-on procedure.......................................................................................78
Figure 41: Overload characteristic ....................................................................................................79
Figure 42: Overload protection in the lower speed range .................................................................79
Figure 43: Power dissipation of the cabinet system.......................................................................... 80
Figure 44: Pressure drop of the cabinet system ............................................................................... 87
Figure45: Volumeowdependingontotalpowerdissipationandtemperaturedifference.............. 88

10
LIST OF TABLES
List of Tables
Table 1: Type code ........................................................................................................................25
Table 2: Switching frequency......................................................................................................... 34
Table 3: Temperature detection .....................................................................................................62
Table 4: Functions temperature input ............................................................................................62
Table 5: Operating conditions........................................................................................................67
Table 6: Electromagnetic compatibility .......................................................................................... 68
Table 7: Technical data circuit breaker NZM4................................................................................68
Table 8: Technical Data .................................................................................................................69
Table 9: Flushing the single cooling circuits .................................................................................. 71
Table10: Volumeowsintheentiresystem....................................................................................72
Table 11: Electro-chemical voltage series .......................................................................................83
Table 12: Requirements on the coolant...........................................................................................84
Table 13: Special requirements for open and half-open cooling systems ....................................... 85
Table 14: Supply of temper coolant .................................................................................................86

11
GLOSSAR
Glossar
0V Earth-potential-free common point
1ph 1-phase mains
3ph 3-phase mains
AC AC current or voltage
AFE Active Front End
LW heat ex-
changer
Air/water heat exchanger
MCM American unit for large wire cross
sections
AWG American wire gauge
ASCL Asynchronous sensorless closed
loop
GTR7 Braking transistor
CDM Complete drive module including
auxiliary equipment (control cabi-
net)
DC DC current or voltage
IP xx Degree of protection (xx for level)
FU Drive converter
EMC Electromagnetic compatibility
EN European standard
HSP5 Fast, serial protocol
CAN Fieldbus system
AFElter Filter for the AFE device
FE Functional earth
DIN German Institut for standardization
HFlter Highfrequencyltertothemains
HMI Human maschine interface (touch
screen)
Modulation In drive technology it means that
the power semiconductors are
controlled
HTL Incremental signal with an output
voltage (up to 30V) -> TTL
TTL Incremental signal with an output
voltage up to 5 V
IEC International standard
WRA Inverter A
WRB Inverter B
COMBIVERT KEB drive converters
COMBIVIS KEB start-up and parameterizing
software
MTTF mean service life to failure
RJ45 Modular connector with 8 lines
UCE Monitoring the saturation voltage
of the circuit breaker
OC Overcurrent
OH Overheat
OL Overload
Port Part of a network address to the
assignment of TCP and UDP
connections
PDS Power drive system incl. motor
and measuring probe
PFC Power factor correction
DEIF Producer of control boards
PLC Programmable logic controller
PE Protective earth
PELV Protective Extra Low Voltage
PTC PTC-resistor for temperature
detection
PWM Pulse width modulation
VARAN Real-time Ethernet bus system
EtherCAT Real-time Ethernet bus system of
the company Beckhoff
GND Reference potential, ground
SELV Safety Extra Low Voltage (< 60 V)
SS1 Safety function „Safe stop 1“ in
accordance with IEC 61800-5-2
STO Safety function „Safe Torque Off“
in accordance with IEC 61800-5-2
NN Sea level
Emergency
stop
Shutdown of a drive in emergency
case (not de-energized)
KTY Silicium temperature sensor (po-
larized)
SFlter Sine-wavelter
I²t-monitoring Software function for thermal mo-
nitoring of the motor winding
Emergency
switching off
Switching off the voltage supply in
emergency case
SCL Synchronous sensorless closed
loop
SSI Synchronous serial interface for
encoder
PT1000 Temperature sensor with
R0=1000Ω
PT100 Temperature sensor with
R0=100Ω

12
GLOSSAR
PFD Term used in the safety technolo-
gy (EN 61508-1...7) for the size of
error probability
PFH Term used in the safety technolo-
gy (EN 61508-1...7) for the size of
error probability per hour
USB Universal serial bus
WRB Inverter B

13
STANDARDS FOR DRIVE CONVERTERS/CONTROL CABINETS
Standards for drive converters / control cabinets
DGUV regulation 3 Electrical systems and equipment
DIN 46228-1 Wire-end ferrules; Tube without plastic sleeve
DIN 46228-4 Wire-end ferrules; Tube with plastic sleeve
DIN IEC 60364-5-54 Low-voltage electrical installations - Part 5-54: Selection and erection of
electrical equipment - Earthing arrangements, protective conductors and protec-
tive bonding conductors
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
EN 1037 Safety of machinery - Prevention of unexpected start-up; German version EN
1037:1995+A1:2008
EN55011 Industrial,scienticandmedicalequipment-Radiofrequencydisturbance
characteristics - Limits and methods of measurement
EN 55021 Interference to mobile radiocommunications in the presence of impulse noise -
Methods of judging degradation and measures to improve performance
EN 60204-1 Safety of machinery - electrical equipment of machines Part 1: General require-
ments (VDE 0113-1, IEC 44/709/CDV)
EN 60439-1 Low-voltage switchgear and controlgear assemblies - Part 1: Type-tested and
partially type-tested assemblies
EN 60529 Degrees of protection provided by enclosures (IP Code) (IEC 60529)
EN 60664-1 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
EN60721-3-2 Classicationofenvironmentalconditions-Part3:Classicationofgroupsof
environmental parameters and their severities; section 2: Transport
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
EN 61000-2-1 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
EN 61000-2-4 Electromagnetic compatibility (EMC) - part 2-4: Environment; Compatibility
levels in industrial plants for low-frequency conducted disturbances
EN 61000-4-2 Electromagnetic compatibility (EMC) - part 4-2: Testing and measurement
techniques - Electrostatic discharge immunity test
EN 61000-4-3 Electromagnetic compatibility (EMC) - part 4-3: Testing and measurement
techniques-Radiated,radio-frequency,electromagneticeldimmunitytest
EN 61000-4-4 Electromagnetic compatibility (EMC) - part 4-4: Testing and measurement
techniques - Electrical fast transient/burst immunity test
EN 61000-4-5 Electromagnetic compatibility (EMC) - part 4-5: Testing and measurement
techniques - Surge immunity test
EN 61000-4-6 Electromagnetic compatibility (EMC) - part 4-6: Testing and measurement
techniques-Immunitytoconducteddisturbances,inducedbyradio-frequencyelds
EN 61000-4-34 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
EN 61373 Railway applications - Rolling stock equipment - Shock and vibration tests

14
STANDARDS FOR DRIVE CONVERTERS/CONTROL CABINETS
EN 61439-1 Low-voltage switchgear and controlgear assemblies - Part 1: General rules (IEC
121B/40/CDV:2016); German version FprEN 61439-1:2016
EN 61508-1...7 Functional safety of electrical/electronic/programmable electronic safety-related
systems – Part 1...7 (VDE 0803-1…7, IEC 61508-1…7)
EN 61800-2 Adjustable speed electrical power drive systems - Part 2: General requirements-
Ratingspecications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specictest
methods (VDE 0160-103, IEC 61800-3)
EN 61800-5-1 Electrical power drive systems with adjustable speed. Part 5-1: Requirements
on the safety - electrical, thermal and energy requirements (VDE 0160-105-1)
EN 61800-5-2 Electrical power drive systems with adjustable speed. Part 5-2: Requirements
on the safety – functional safety (VDE 0160-105-2, UL61800-5-2)
EN 62061 Safety of machinery - functional safety of electrical, electronic and program-
mable electronic safety-related systems (VDE 0113-50, IEC62061)
EN ISO 13849-1 Safety of machinery - safety-related parts of control systems - Part 1: General
principles for design (ISO 13849-1)
UL61800-5-1 American version of the EN 61800-5-1 with „National Deviations“

15
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 devic-
es may cause functional hazards for life and limb of the user or third parties, or damages
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willleadtothe
loss of any liability claims.
Attention Hazards and risks through ignorance.
►Read the instruction manual !
►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qualiedpersonsinaccordancewiththeenvironmental
conditionsspecied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.

16
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specied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 Design-related 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!

17
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 and secure it
against switching on.
►Wait until the drive has 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 to drive converter and motor.
►Install all required covers and protective devices for operation.
►The control cabinet shall be kept closed during operation.
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 according to the design of
themachinemanufacturer.Speciedminimum/maximumvaluesmaynotbefallen
below /exceeded.
• Drive converters are only intended for permanent connection. Cross-sections of pro-
tective earth conductors should be interpreted in accordance with EN 61800-5-1.
• 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. 300 V. An
isolating transformer must be used for supply networks which exceed this value.
In case of non-compliance the control is not longer considered as "safe separate
circuit".
• With existing or newly wired circuits the person installing the units or machines must
ensure the EN requirements are met.
• For drive converters that are not isolated from the supply circuit (in accordance with
EN 61800-5-1) 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.

18
BASIC SAFETY INSTRUCTIONS
If personnel protection is required during installation of the
system, suitable protective devices must be used for drive
converters.
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.
1.4.1 EMC-compatible installation
Observance of the limit values required by EMC law is the responsibility of the manufac-
turer of the installation or machine.
Notes on EMC-compatible installation can be found here.
0000neb0000.pdf
1.4.2 Voltage test
Testing with AC voltage (in accordance with EN 60204-1 Chapter 18.4) may not be ex-
ecuted, since there is danger for the power semiconductors in the drive converter.
Because of the noise suppression capacitors the test generator will immediately trigger
with current error.
Accordng 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
500 V is permissible, if all power unit connections (grid-connected potential) and all con-
trol connections are bridged with PE. At any unit it can be expected with an insulating
resistance>5MΩ!

19
BASIC SAFETY INSTRUCTIONS
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.
CAUTION High temperatures at heat sink and coolant!
Burning of the skin!
►Cover hot surfaces safe-to-touch.
►Before working let the unit cool down.
►Before touching, check the surface and cooling water lines.
►If necessary, attach warning signs on the system.
• During operation, all covers and doors shall be kept closed.
• Use only approved accessories for this device.
• Never touch terminals, busbars or cable ends.
Observe the following instructions if the drive converter for
more than one year was not in operation before start-up.
ti_format_capacitors_0400_0001_gbr.pdf
Switching at the output
Switching between motor and drive converter is prohibited for single drives during op-
eration as this may trigger the protection gear of the device. Function speed search must
be activated if switching can not be avoided. Control release 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).

20
BASIC SAFETY INSTRUCTIONS
Switching an the input
For applications that require cyclic switching on and off of the drive converter, main-
tain an off-time of at least 5 min. If you require shorter cycle times please contact
KEB Automation KG.
Short-circuit proof
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.
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.
►Clean drive converter from dirt and dust deposits. Pay attention especially to cool-
ing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.
►Make a visual leak test of the cooling circuit for water-cooled inverters.
1.7 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 parameteriza-
tion. 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.