KEBCO COMBIVERT F5 User manual

COMBIVERT F5/F6
INSTRUCTIONS FOR USE | INSTALLATION F5/F6 HOUSING P
Translation of the original manual
Document 20164377 EN 00 | Mat.No. 00F50EB-KP02

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.
www.keb.de/nc/search

4
PREFACE
Laws and guidelines
KEBAutomationKGconrmswiththeECdeclarationofconformitywiththeCEmark
on the unit name plate, that the device 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
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
Glossary ................................................................................................................................................ 11
Standards for drive converters / control cabinets .............................................................................13
Product standards that apply directly to the drive converter ........................................................13
Basic standards to which drive converter standards refer directly............................................... 13
Standards that are used in the environment of the drive converter ............................................. 14
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 .............................................................................................................................................21
1.8 Disposal..........................................................................................................................................21
2 Product Description .................................................... 22
2.1 Specied application.....................................................................................................................22
2.1.1 Residual risks .....................................................................................................................22
2.2 Improper use..................................................................................................................................22
2.3 Product features ............................................................................................................................23
2.4 Part code ........................................................................................................................................24
3 Technical Data ............................................................. 25
3.1 Operating conditions ....................................................................................................................25
3.1.1 Climatic environmental conditions......................................................................................25
3.1.2 Mechanical environmental conditions ................................................................................26
3.1.3 Chemical / mechanical active substances..........................................................................26
3.1.4 Electrical operating conditions............................................................................................27

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TABLE OF CONTENTS
3.1.4.1 Deviceclassication........................................................................................................ 27
3.1.4.2 Electromagnetic compatibility..........................................................................................27
3.2 Block diagram of energy ow in the device................................................................................28
3.3 Technical data 400V class ............................................................................................................29
3.3.1 Single Drive........................................................................................................................ 29
3.3.2 Master / slave system..........................................................................................................31
3.3.3 Master / slave / slave system ...............................................................................................33
3.4 Technical data 690V class ............................................................................................................35
3.4.1 Single Drive........................................................................................................................ 35
3.4.2 Master / slave system..........................................................................................................37
3.4.3 Master / slave / slave system ...............................................................................................39
3.5 Dimensions and weights ..............................................................................................................41
3.5.1 Dimensions air cooler built-in version.................................................................................41
3.5.2 Dimensions air-cooled inverter through-mount version......................................................42
3.5.3 Dimensions liquid cooler through-mount version ...............................................................43
3.5.4 Dimensions liquid cooler installation version......................................................................44
3.5.5 Dimensions liquid cooler built-in version with stainless steel tube .....................................45
4 Mechanical Installation ............................................... 46
4.1 Control cabinet installation ..........................................................................................................46
4.1.1 General instructions ...........................................................................................................46
4.1.2 Mounting distances ............................................................................................................46
4.1.3 Assembly aids ....................................................................................................................47
4.2 Cooling system..............................................................................................................................48
4.2.1 Air cooler ............................................................................................................................49
4.2.2 Liquid cooling .....................................................................................................................50
4.2.3 Connection of the liquid cooling to the cooling system.......................................................50
4.3 Series connection cooling circuit ................................................................................................ 51
4.3.1 General instructions ...........................................................................................................51
4.3.2 Connection diagram series connection cooling circuit ....................................................... 52
4.4 Parallel connection of the coolant circuit ...................................................................................53
4.4.1 General instructions ..........................................................................................................53
4.4.2 Connection scheme parallel connection of the cooling circuit............................................53
5 Operation of liquid-cooled devices ........................... 54
5.1 General information ......................................................................................................................54
5.1.1 Pressure in the liquid cooler............................................................................................... 54
5.1.2 Material of the heat sink .....................................................................................................54
5.1.3 Materials in the cooling cicuit .............................................................................................55
5.1.4 Requirements on the coolant ............................................................................................. 56
5.1.5 Requirements for open and half-open cooling systems .....................................................57
5.1.6 Coolant temperature...........................................................................................................57
5.1.7 Moisture condensation .......................................................................................................57
5.1.8 Supply of temper coolant....................................................................................................58

7
TABLE OF CONTENTS
5.2 Diagrams of the cooling design ...................................................................................................59
5.2.1 Pressure drop aluminium extrusion casting heat sink........................................................ 59
5.2.2 Pressure drop aluminium heat sink with stainless steel tubes ...........................................60
5.2.3 Series connection of liquid coolers.....................................................................................61
5.2.4 Parallel connection of liquid coolers................................................................................... 62
6 Electrical Installation................................................... 63
6.1 General information ......................................................................................................................63
6.1.1 Wiring .................................................................................................................................63
6.1.2 Connection of the shield connection .................................................................................. 64
6.1.3 Connection of the protective earth ..................................................................................... 64
6.2 Connection terminals power unit.................................................................................................65
6.2.1 Permitted cable cross-sections and tightening torques of the terminals ............................65
6.2.2 External fan power supply.................................................................................................. 66
6.3 Mains connection ..........................................................................................................................67
6.3.1 Note about hard mains....................................................................................................... 67
6.3.2 Recommended type of mains cable................................................................................... 67
6.4 Motor connection ..........................................................................................................................68
6.4.1 General instructions ...........................................................................................................68
6.4.2 Selection of the motor cable...............................................................................................68
6.4.3 Recommended type of the motor cable ............................................................................. 69
6.4.4 Connection of the motor..................................................................................................... 69
6.4.5 Calculation of the motor voltage.........................................................................................69
6.4.6 Cable cross-sections.......................................................................................................... 70
6.4.6.1 Cable cross-sections 400 V class....................................................................................70
6.4.6.2 Cable cross-section 690 V class...................................................................................... 70
6.4.7 Motor cable lengths............................................................................................................ 71
6.5 DC connection ...............................................................................................................................72
6.5.1 General instructions ...........................................................................................................72
6.6 Temperature detection T1, T2.......................................................................................................73
6.6.1 Use of the temperature input in KTY mode........................................................................ 74
6.6.2 Use of the temperature input in PTC mode........................................................................74
6.7 Connection of a braking resistor .................................................................................................75
6.7.1 Monitoring braking transistor .............................................................................................76
6.7.2 External braking resistor without temperature monitoring.................................................. 76
6.7.3 External braking resistor with overtemperature protection................................................. 77
6.7.4 Sub-mounted braking resistors without overtemperature protection..................................77
6.8 Temperature switch braking resistor, mains and motor choke ................................................77
6.8.1 General instructions ...........................................................................................................77
6.8.2 Parameterization of the control board ................................................................................77
6.9 Connection of the master / slave wiring.......................................................................................78
6.9.1 Connection master / slave...................................................................................................78
6.9.2 Connection master / slave / slave.........................................................................................80

8
TABLE OF CONTENTS
7 Wiring Diagrams .......................................................... 82
7.1 Unit size 28...30..............................................................................................................................82
7.1.1 Mains and control connection.............................................................................................82
7.2 Unit size 32...35..............................................................................................................................83
7.2.1 Mains and motor connection master / slave system ...........................................................83
7.2.2 Connection braking resistor master / slave system............................................................. 84
7.2.3 DC connection master / slave system ................................................................................. 85
7.2.4 Mains connection master / slave system.............................................................................86
7.3 Unit size 36...39..............................................................................................................................87
7.3.1 Mains and motor connection master / slave / slave system................................................. 87
7.3.2 Connection braking resistor master / slave / slave system...................................................88
7.3.3 DC connection master / slave / slave system....................................................................... 89
7.3.4 Mains connection master / slave / slave system .................................................................. 90
8 Protection of drive converters.................................... 91
8.1 Use of circuit breakers..................................................................................................................91
9 Certication.................................................................. 92
9.1 CE Marking.....................................................................................................................................92
9.2 UL Marking ....................................................................................................................................92
9.3 Further informations and documentation ...................................................................................95
10 Characteristics........................................................... 96
10.1 Overload characteristic...............................................................................................................96
10.2 Overload protection in the lower speed range .........................................................................96
10.3 Power dissipation of the 400V class at rated operation ..........................................................97
10.3.1 Power dissipation of different switching frequencies........................................................97
10.4 Power dissipation of the 690V class at rated operation ..........................................................98
10.4.1 Power dissipation at 2 kHz switching frequency...............................................................98
10.4.2 Power dissipation at 4 kHz switching frequency...............................................................99
11 Accessories.............................................................. 100
11.1 Filter and chokes .......................................................................................................................100
11.2 Assembly aids............................................................................................................................101
11.3 Connections to the coolant ......................................................................................................101
11.4 Connecting cable master / slave system..................................................................................101
11.5 Heat sink fan ..............................................................................................................................101
12 Revision History ...................................................... 102

9
LIST OF FIGURES
List of Figures
Figure1: Blockdiagramofenergyowinthedevice......................................................................28
Figure 2: Dimensions air cooler built-in version ..............................................................................41
Figure 3: Dimensions air-cooled inverter through-mount version ................................................... 42
Figure 4: Dimensions liquid cooler push-through version ...............................................................43
Figure 5: Dimensions liquid cooler built-in version.......................................................................... 44
Figure 6: Dimensions liquid cooler built-in version with stainless steel tube................................... 45
Figure 7: Mounting distances..........................................................................................................46
Figure 8: Assembly aids.................................................................................................................. 47
Figure 9: Ventilation ........................................................................................................................49
Figure 10: Connections to the coolant series connection .................................................................52
Figure 11: Connections to the coolant parallel connection ...............................................................53
Figure12: Pressuredropoftheheatsinkasafunctionofthevolumeow .....................................59
Figure13: Pressuredropoftheheatsinkasafunctionofthevolumeow(stainlesssteelcooler). 60
Figure14: Volumeowandtemperaturedifferenceforseriesconnection .......................................61
Figure15: Volumeowandtemperaturedifferenceforparallelconnection .....................................62
Figure 16: Laying the cables.............................................................................................................64
Figure 17: Connection terminals of the power circuit........................................................................65
Figure 18: External fan power supply................................................................................................66
Figure 19: Cross-section type of mains cable...................................................................................67
Figure 20: Cross-section type of the motor cable .............................................................................69
Figure 21: Connection of a KTY sensor............................................................................................74
Figure 22: Wiring example in PTC mode ..........................................................................................74
Figure 23: Intrinsically safe braking resistor without temperature monitoring ...................................76
Figure 24: Connection master / slave ................................................................................................78
Figure 25: Master / slave connections ...............................................................................................79
Figure 26: Cable clamps master / slave connections......................................................................... 79
Figure 27: Connection master / slave / slave ......................................................................................80
Figure 28: Master / slave / slave connections .....................................................................................81
Figure 29: Cable clamps master / slave / slave connections .............................................................. 81
Figure 30: Mains and control connection ..........................................................................................82
Figure 31: Mains and motor connection master / slave system .........................................................83
Figure 32: Connection braking resistor master / slave system ..........................................................84
Figure 33: DC connection master / slave system............................................................................... 85
Figure 34: Mains connection master / slave system .......................................................................... 86
Figure 35: Mains and motor connection master / slave / slave system ..............................................87
Figure 36: Connection braking resistor master / slave / slave system ................................................88
Figure 37: DC connection master / slave / slave system .................................................................... 89
Figure 38: Mains connection master / slave / slave system ................................................................90
Figure 39: Overload characteristic ....................................................................................................96
Figure 40: Overload protection in the lower speed range .................................................................96
Figure 41: Power dissipation of different switching frequencies 400V class..................................... 97
Figure 42: Power dissipation at 2 kHz switching frequency 690V class............................................ 98
Figure 43: Power dissipation at 4 kHz switching frequency 690V class............................................ 99

10
LIST OF TABLES
List of Tables
Table 1: Part code..........................................................................................................................24
Table 2: Climatic environmental conditions ................................................................................... 25
Table 3: Mechanical environmental 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 400V class - Single Drive...............................................................30
Table 8: Technical data of the 400 V class master / slave...............................................................32
Table 9: Technical data of the 400 V class master / slave / slave ...................................................34
Table 10: Technical data of the 690V class - Single Drive...............................................................36
Table 11: Technical data of the 690 V class master / slave...............................................................38
Table 12: Technical data of the 690 V class master / slave / slave ...................................................40
Table 13: Pressure in the liquid cooler.............................................................................................54
Table 14: Heat sink and operating pressure....................................................................................54
Table 15: Electro-chemical voltage series / standard potentials against hydrogen .........................55
Table 16: Requirements on the coolant...........................................................................................56
Table 17: Requirements for open and half-open cooling systems................................................... 57
Table 18: Supply of temper coolant .................................................................................................58
Table 19: Permissible cable cross-sections and tightening torques of the terminals ......................65
Table 20: Connection of the motor...................................................................................................69
Table 21: Calculation of the motor voltage ......................................................................................69
Table 22: Cable cross-sections 400 V class ....................................................................................70
Table 23: Cable cross-section 690 V class ......................................................................................70
Table 24: Maximum permissible motor cable lengths...................................................................... 71
Table 25: Temperature detection T1, T2..........................................................................................73
Table 26: Function motor temperature display ................................................................................73
Table 27: Parameterization of the control board.............................................................................. 77
Table 28: Protection of drive converters ..........................................................................................91
Table 29: Use of circuit breakers .....................................................................................................91
Table30: Externalltersandchokes...............................................................................................93
Table 31: UL fuses...........................................................................................................................94
Table 32: Cable protection switch.................................................................................................... 94
Table 33: Filter and chokes............................................................................................................100
Table 34: Assembly aids................................................................................................................ 101
Table 35: Connections to the coolant ............................................................................................101
Table 36: Connecting cable master / slave system ........................................................................101
Table 37: Heat sink fan..................................................................................................................101