KEBCO COMBIVERT F5 User manual

COMBIVERT
Mat.No. Rev.
00F50EB-KR00 2K
GB INSTRUCTION MANUAL Power Unit Housing R
18.5 ...45 kW 230 V
22 ...90 kW 400 V

GB - 3
Table of Contents
1. Preface..............................................................................................................5
1.1 General ................................................................................................................................. 5
1.2 Safety Instructions .............................................................................................................. 5
1.3 Validity and liability ............................................................................................................. 5
1.4 Copyright.............................................................................................................................. 6
1.5 Speciedapplication........................................................................................................... 6
1.6 Product description............................................................................................................. 7
1.7 Part code .............................................................................................................................. 8
1.7 Installation instructions ...................................................................................................... 9
1.7.1 Cooling systems .................................................................................................................... 9
1.7.2 Control cabinet installation................................................................................................... 10
1.8 Safety and application notes .............................................................................................11
2. Technical Data ...............................................................................................12
2.1 Operating conditions......................................................................................................... 12
2.2 Technical data of the 230V class...................................................................................... 13
2.2.1 Technical data of the 400 V class......................................................................................... 14
2.3 DC supply ........................................................................................................................... 15
2.3.1 Calculation of the DC input current...................................................................................... 15
2.3.2 Internal input circuit.............................................................................................................. 15
2.4 Dimensions and Weights .................................................................................................. 16
2.4.1 Dimensions air-cooling mounted version 1.......................................................................... 16
2.4.2 Dimensions air-cooling mounted version 2.......................................................................... 17
2.4.3 Dimensions air-cooling through-mount version ................................................................... 18
2.4.4 Dimensions water cooling mounted version ........................................................................ 19
2.4.5 Dimensions water cooling through-mount version............................................................... 20
2.4.6 Dimensions water cooling through-mount version............................................................... 21
2.5 Terminal strips of the power circuit ................................................................................. 22
2.6 Connection accessories ................................................................................................... 24
2.6.1 Filter and chokes ................................................................................................................. 24
2.7 Connection Power Unit ..................................................................................................... 25
2.7.1 Mains and motor connection................................................................................................ 25
2.7.2 Selection of the motor cable ................................................................................................ 26
2.7.3 Connection of the motor ...................................................................................................... 26
2.7.4 Temperature detection T1, T2.............................................................................................. 27
2.7.4.1 Use of the temperature input in KTY mode ......................................................................... 28
2.7.4.2 Use of the temperature input in PTC mode ......................................................................... 28
2.7.5 Connection of a braking resistor .......................................................................................... 29
2.7.5.1 Braking resistor without temperature monitoring ................................................................. 29
2.7.5.2 Braking resistor with over-heat protection and GTR7 monitoring (water-cooled inverters) . 30
2.7.5.3 Braking resistor with over-heat protection and GTR7 monitoring (air-cooled inverters) ...... 31
Annex A .....................................................................................................................32
A.1 Overload characteristic..................................................................................................... 32

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Table of Contents
A.2 Overload protection in the lower speed range ............................................................... 32
A.3 Calculation of the motor voltage...................................................................................... 33
A.4 Maintenance ....................................................................................................................... 33
A.5 Storage ............................................................................................................................... 33
A.5.1 Cooling circuit ...................................................................................................................... 34
Annex B.....................................................................................................................35
B.1 Certication........................................................................................................................ 35
B.1.1 CE Marking .......................................................................................................................... 35
B.1.2 UL Marking .......................................................................................................................... 35
Annex C.....................................................................................................................38
C.1 Installation of water-cooled units..................................................................................... 38
C.1.1 Heat sink and operating pressure........................................................................................ 38
C.1.2 Materials in the cooling cicuit............................................................................................... 38
C.1.3 Requirements on the coolant............................................................................................... 39
C.1.4 Connection to the cooling system........................................................................................ 40
C.1.5 Coolant temperature and moisture condensation................................................................ 40
C.1.6 Coolantheatingdependingonpowerlossandowratewithwater.................................... 42
C.1.7 Typicallyfallofpressuredependingontherateofow....................................................... 42
Annex D.....................................................................................................................43
D.1 Changing the response threshold of the braking transistor ......................................... 43

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Preface
1. Preface
1.1 General
First we would like to welcome you as a customer of the company KEB Automation KG and
congratulation to the purchase of this product. You have decided for a product on highest
technical level.
The described hard- and software are developments of the KEB Automation KG. Die
beigefügten Unterlagen entsprechen dem bei Drucklegung gültigem Stand. Misprint, mis-
takes and technical changes reserved.
The instruction manual must be made available to the user. Before working with the unit the
user must become familiar with it. This especially applies to the knowledge and observance
of the following safety and warning indications. The pictographs used in this instruction man-
ual have following meaning:
Danger Is used when the life or health of the user is in danger or con-
siderable damage to property can occur.
Warning
Caution
Attention Is used, if a measure is necessary for safe and trouble-free
operation.
observe at
all costs
Information Isused,ifameasuresimpliesthehandlingoroperationof
the unit.
Aid
Tip
1.2 Safety Instructions
Observe safety and
operating instruc-
tions
Precondition for all further steps is the knowledge and obser-
vance of the safety-, EMC- and operating instructions (Part 1
„Before Starting“ 0000NEB-0000“). This instruction is provid-
ed with the unit or by download of www.keb.de.
Non-observance of the safety instructions leads to the loss of any liability claims. The safety
andwarninginstructionsspeciedinthismanualdonotlayclaimoncompleteness.Thislist
is not exhaustive.
1.3 Validity and liability
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 machine manufacturer.
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 responsibil-
ity. 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.

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Preface
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.
Unauthorised opening and tampering may lead to bodily injury and property damage and
may entail the loss of warranty rights. Original spare parts and authorized accessories by the
manufacturer serve as security. The use of other parts excludes liability for the consequences
arising out of.
Thesuspensionofliabilityisespeciallyvalidalsoforoperationinterruptionloss,lossofprot,
datalossorotherdamages.Thisisalsovalid,ifwereferredrsttothepossibilityofsuch
damages.
If single regulations should be or become void, invalid or impracticable, the effectivity of all
other regulations or agreements is not affected.
1.4 Copyright
The customer may use the instruction manual as well as further documents or parts from it for
internal purposes. Copyrights are with KEB and remain valid in its entirety. All rights reserved.
KEB®, COMBIVERT®, KEB COMBICONTROL® and COMBIVIS® are registered trade-
marks of KEB Automation KG.
Other wordmarks or/and logos are trademarks (TM) or registered trademarks (®) of their
respectiveownersandarelistedinthefootnoteontherstoccurrence.Whencreatingour
documents we pay attention with the utmost care to the rights of third parties. Should we
have not marked a trademark or breach a copyright, please inform us in order to have the
possibility of remedy.
1.5 Speciedapplication
The KEB COMBIVERT serves exclusively for stepless open loop / closed-loop speed control
of three-phase a.c. motors.
The operation of other electric consumers is prohibited and can lead to the de-
struction of the unit.
The used semiconductors and components of KEB are developed and dimensioned for the
use in industrial products. If the KEB COMBIVERT is used in machines, which work under
exceptional conditions or if essential functions, life-supporting measures or an extraordinary
safetystepmustbefullled,thenecessaryreliabilityandsecuritymustbeensuredbythe
machine builder. The operation of the KEB COMBIVERT outside the indicated limit values of
the technical data leads to the loss of any liability claims.
Units with safety function are limited to a service life of 20 years. After this time the units must
be replaced.

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Preface
1.6 Product description
This instruction manual describes the power circuits of the following units:
Unit type: Frequency inverter
Series: COMBIVERT F5/F6
Power range: 18.5…45 kW / 200 V
22…90 kW / 400 V
Housing size: R
Features of the power circuits :
• only slight switching losses due to IGBT
• low noise development due to high switching frequency
• extensive safety device for current, voltage and temperature
• voltage and current monitoring in static and dynamic operation
• conditionally short circuit proof and earth-fault proof
• hardware current limit
• integrated cooling fan

GB - 8
Preface
1.7 Part code
18 F5 C 1 R-9 7 0 A
Cooling
0, 5, A, F heat sink (standard)
1, B, G Flat rear
2, C, H Water cooling
3, D, I convection
Encoder interface
0:none
Switching frequency; short time current limit; overcurrent limit
02 kHz; 125 %; 150 % 54 kHz; 150 %; 180 % A8 kHz; 180 %; 216 % F16 kHz; 200 %; 240 %
14 kHz; 125 %; 150 % 68 kHz; 150 %; 180 % B16 kHz; 180 %; 216 % G2 kHz; 400 %; 480 %
28 kHz; 125 %; 150 % 716 kHz; 150 %; 180 % C2 kHz; 200 %; 240 % H4 kHz; 400 %; 480 %
316 kHz; 125 %; 150 % 82 kHz; 180 %; 216 % D4 kHz; 200 %; 240 % I8 kHz; 400 %; 480 %
42 kHz; 150 %; 180 % 94 kHz; 180 %; 216 % E8 kHz; 200 %; 240 % K16 kHz; 400 %; 480 %
Inputidentication
01ph 230 VAC/DC 5 400 V class DC A6ph 400 VAC
13ph 230 VAC/DC 61ph 230 VAC B3ph 600 VAC
21/3ph 230 VAC/DC 73ph 230 VAC C6ph 600 VAC
33ph 400 VAC/DC 8 1/3ph 230 VAC D600 V DC
4230 V class DC 93ph 400 VAC
Housing type A, B, D, E, G, H, R, U, W, P
Accessories (A...D with safety relay)
0, A none
1, 5, B Braking transistor (5 with braking transistor monitoring)
2, C integratedlter
3, 7, D Brakingtransistorandintegratedlter(7withbrakingtransistormonitoring)
Control type
A APPLICATION K like A with safety technology
C COMPACT (controlled frequency inverter)
E SCL P like E with safety technology
G GENERAL (controlled frequency inverter)
H ASCL L like H with safety technology
M
MULTI(regulated,eld-orientedfrequencyinverterforthree-phaseasynchronousmo-
tors)
S SERVO (regulated frequency inverter for synchronous motors)
Series F5/F6
Inverter size
Thetypecodeisnotusedasordercode,butonlyforidentication!

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General
1.7 Installation instructions
1.7.1 Cooling systems
The KEB COMBIVERT F5/F6 is available for different cooling systems:
Heat sink with cooling fan (mounted version)
The standard version is delivered with heat sink and cooling fan.
Special versions
The dissipation of power loss must be guaranteed by the machine builder.
Flat rear
There is no heat sink at this version. The unit must be mounted on an appropriate ground for
heat dissipation.
Water cooling
This version is dimensioned for the connection to an available cooling system. The dissipa-
tion of the power loss must be ensured by the machine builder. In order to avoid moisture
condensation, the minimum inlet temperature may not decrease the ambient temperature.
The max. inlet temperature may not exceed 40°C. No aggressive coolant shall be used.
Measures against contamination and calcination must be done externally. We recommend a
pressure of 4 bar on the cooling system.
Convection (trough-mount version)
In this version the heat sink is placed externally with a cutout in the control cabinet.
CAUTION
!
DO NOT TOUCH!
Hot Surfaces
© 2005 KEB
In case of burn, cool inflicted area
immediately and seek medical attention.
Heat sinks can reach temperatures, which can cause burns when
touching. If in case of structural measures a direct contact cannot
be avoided, a warning notice "hot surface" must be mounted at the
machine.

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General
1.7.2 Control cabinet installation
Mounting distances Dimen-
sion
Distance in mm Distance in
inch
C
A
B
DD
A 150 6
B 100 4
C 30 1.2
D 30 1.2
X 1) 50 2
1) Distance to preceding elements in the cabinet door.
Direction of the
cooling 󰘰ns
Front and side view of the coolant inlet
Coolant outlet
Coolant inlet
See annex C for instructions of water-cooled units.