KEBCO COMBIVERT F5 User manual

COMBIVERT F5/F6
INSTRUCTIONS FOR USE | INSTALLATION F5/F6 HOUSING V | 600...1000 KVA
Translation of the original manual
Document 20128815 EN 01

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.........................................................................................................................................8
List of Tables ..........................................................................................................................................9
Glossar ..................................................................................................................................................10
Standards for drive converters / control cabinets .............................................................................12
1 Basic Safety Instructions............................................ 14
1.1 Target group...................................................................................................................................14
1.2 Transport, storage and proper use .............................................................................................. 14
1.3 Installation......................................................................................................................................15
1.4 Electrical connection ....................................................................................................................16
1.4.1 EMC-compatible installation...............................................................................................17
1.4.2 Voltage test.........................................................................................................................17
1.4.3 Insulation measurement..................................................................................................... 17
1.5 Start-up and operation ..................................................................................................................18
1.6 Maintenance...................................................................................................................................19
1.7 Repair .............................................................................................................................................19
1.8 Disposal..........................................................................................................................................20
2 Product Description .................................................... 21
2.1 Product features ............................................................................................................................21
2.1.1 Four quadrant operation.....................................................................................................21
2.2 Specied application.....................................................................................................................22
2.2.1 Residual risks .....................................................................................................................22
2.3 Improper use..................................................................................................................................22
2.4 Part code ........................................................................................................................................23
3 Functional Overview.................................................... 24
3.1 Schematic diagram of the electrical power unit for the Q4 operation...................................... 24
3.2 Interior ventilation .........................................................................................................................25
4 Mechanical Installation ............................................... 26
4.1 Cooling system .............................................................................................................................26
4.2 Connection cooling system..........................................................................................................26
4.2.1 Coolant connections of the drive converter........................................................................ 27

6
TABLE OF CONTENTS
4.2.2 Wiring diagram cooling system ..........................................................................................28
4.3 Dimensions of the housing ..........................................................................................................29
4.4 Fixing points at the housing.........................................................................................................30
4.5 Assembly aids ...............................................................................................................................31
4.6 Assembly in the control cabinet ..................................................................................................33
4.6.1 Assembly of the slide rails and safety devices at the drive converter ................................33
4.6.2 Function of the locking levers.............................................................................................34
4.6.3 Assembly of the side guide rails.........................................................................................35
4.6.4 Positions of the side guide rails in the control cabinet........................................................36
4.6.5 Installation of the drive converter in the control cabinet .....................................................38
4.7 Disassembly from the control cabinet ........................................................................................43
5 Electrical Installation................................................... 44
5.1 General information ......................................................................................................................44
5.2 Laying the cables ..........................................................................................................................44
5.3 Connection of the shield connection ..........................................................................................45
5.4 Connection of the protective earth .............................................................................................. 45
5.5 Terminal power unit.......................................................................................................................46
5.5.1 Permissible cable cross-sections and tightening torques of the terminals......................... 47
5.5.2 Wiring diagram for the Q4 operation ..................................................................................48
5.6 Connection of the control boards................................................................................................49
5.6.1 Wiring diagram for WRA and WRB with F5 control boards ...............................................50
5.6.2 Wiring diagram for WRA with F5 control board and WRB with F6 control board ...............51
5.7 Mains cable types..........................................................................................................................52
5.8 Motor connection ..........................................................................................................................53
5.8.1 General information............................................................................................................53
5.8.2 Connection motor cable .....................................................................................................53
5.8.3 Selection of the motor cable...............................................................................................54
5.8.4 Motor cable types............................................................................................................... 54
5.9 Temperature detection T1A, T2A, T1B and T2B .........................................................................55
5.9.1 Use of the temperature input in KTY mode........................................................................ 56
5.9.2 Use of the temperature input in PTC mode........................................................................56
5.10 Connection braking resistor.......................................................................................................57
5.10.1 External intrinsically safe braking resistor without temperature monitoring......................58
5.10.2 External braking resistor with overheat protection ........................................................... 59
6 Technical Data.............................................................. 60
6.1 Operating conditions ....................................................................................................................60
6.1.1 Climatic conditions .............................................................................................................60
6.1.2 Mechanical ambient conditions ..........................................................................................60
6.1.3 Other operating conditions .................................................................................................60
6.1.4 Electromagnetic compatibility according to EN 61800-3 ....................................................61
6.2 Electrical data 690 V mains voltage .............................................................................................62

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TABLE OF CONTENTS
6.3 Electrical data 4000 V mains voltage ...........................................................................................64
7 Start-Up......................................................................... 65
7.1 Procedure for initial start-up ........................................................................................................65
7.2 Switch-on procedures...................................................................................................................66
7.3 Diagram switch-on procedure......................................................................................................67
A Annex - Diagrams........................................................ 68
A.1 Overload characteristic ................................................................................................................68
A.2 Overload protection in the lower speed range...........................................................................68
A.3 Power dissipation of the drive converter ...................................................................................69
B Annex - Certication ................................................... 70
B.1 CE Marking ....................................................................................................................................70
C Annex - Cooling System............................................. 71
C.1 Installation of liquid-cooled drive converters ............................................................................71
C.1.1 Heat sink and operating pressure......................................................................................71
C.1.2 Materials in the cooling cicuit.............................................................................................71
C.1.3 Requirements on the coolant.............................................................................................72
C.1.4 Special requirements for open and half-open cooling systems: ........................................73
C.1.5 Coolantowtemperature...................................................................................................73
C.1.6 Moisture condensation.......................................................................................................73
C.1.7 Supply of temper coolant................................................................................................... 74
C.1.8 Cooling circuit ....................................................................................................................74
C.1.9 Fall of pressure at the liquid cooling unit ........................................................................... 75
C.1.10 Volumeowdependingontotalpowerdissipationandtemperaturedifference.............. 76
D Annex - Accessories ................................................... 77
D.1 Accessories...................................................................................................................................77
D.1.1 Filter...................................................................................................................................77
D.1.2 Internal fan.........................................................................................................................77
D.1.3 Screw connection ..............................................................................................................77
D.1.4 Industrial sole distributor....................................................................................................77
D.1.5 Extension system...............................................................................................................77
D.1.6 Assembly aids....................................................................................................................77

8
LIST OF FIGURES
List of Figures
Figure 1: Schematic diagram of the electrical power unit ............................................................... 24
Figure 2: Interior ventilation.............................................................................................................25
Figure 3: Coolant connections of the drive converter......................................................................27
Figure 4: Wiring diagram cooling system........................................................................................28
Figure 5: Dimensions of the housing...............................................................................................29
Figure 6: Fixing points at the housing .............................................................................................30
Figure 7: Lifting device....................................................................................................................31
Figure 8: Eyebolts ...........................................................................................................................32
Figure 9: Assembly aids.................................................................................................................. 32
Figure 10: Assembly of the slide rails ...............................................................................................33
Figure 11: Function of the locking levers ..........................................................................................34
Figure 12: Assembly of the side guide rails ......................................................................................35
Figure 13: Positions of the side guide rails in the control cabinet .....................................................36
Figure 14: Distances .........................................................................................................................37
Figure 15: Schematic diagram ..........................................................................................................38
Figure 16: Transport.......................................................................................................................... 39
Figure 17: Connect the drive converter housing V with the control cabinet......................................40
Figure 18: Fix the drive converter housing V in the control cabinet ..................................................41
Figure 19: Drive converter housing V assembled in the control cabinet...........................................42
Figure 20: Laying the cables.............................................................................................................45
Figure 21: Connection terminals of the power circuit........................................................................46
Figure 22: DC-link connection........................................................................................................... 47
Figure 23: Wiring diagram for AFE / drive operation ..........................................................................48
Figure 24: Wiring diagram of the control unit with F5 control boards................................................ 50
Figure 25: Wiring diagram for the control unit with F5/F6 control boards ......................................... 51
Figure 26: Cross-section mains cable types .....................................................................................52
Figure 27: Cross section motor cable ...............................................................................................54
Figure 28: Connection of a KTY sensor............................................................................................56
Figure 29: Wiring example in PTC mode ..........................................................................................56
Figure 30: Intrinsically safe braking resistor without temperature monitoring ...................................58
Figure 31: External braking resistor with overheat protection...........................................................59
Figure 32: Flow diagram switch-on procedure..................................................................................67
Figure 33: Overload characteristic ....................................................................................................68
Figure 34: Overload protection in the lower speed range .................................................................68
Figure 35: Power dissipation of the drive converter..........................................................................69
Figure36: Fallofpressureattheliquidcoolingsystemdependingonthevolumeow ...................75
Figure37: Volumeowdependingontotalpowerdissipationandtemperaturedifference.............. 76

9
LIST OF TABLES
List of Tables
Table 1: Part code..........................................................................................................................23
Table 2: Permissible cable cross-sections and tightening torques ................................................47
Table 3: Temperature detection .....................................................................................................55
Table 4: Functions temerature input ..............................................................................................55
Table 5: Technical Data .................................................................................................................63
Table 6: Electro-chemical voltage series .......................................................................................72
Table 7: Requirements on the coolant...........................................................................................72
Table 8: Special requirements for open and half-open cooling systems: ...................................... 73
Table 9: Supply of temper coolant .................................................................................................74
Table 10: Accessories......................................................................................................................77
Table 11: Internal fan.......................................................................................................................77
Table 12: Screw connection.............................................................................................................77
Table 13: Industrial sole distributor..................................................................................................77
Table 14: Extension system............................................................................................................. 77
Table 15: Assembly aids.................................................................................................................. 77

10
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