KEBCO COMBIVERT G6 User guide

COMBIVERT
Original Manual
Mat.No. Rev.
00G6NEF-0000 1H
GB Safety Manual Safety function
COMBIVERT G6 STO

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 .............................................................................................................................. 7
2. Safety Function STO .......................................................................................9
2.1 Emergency stop according EN 60204 .............................................................................. 10
2.2 ClassicationofSTOaccordingIEC61508 ......................................................................11
2.3 ClassicationofSTOaccordingENISO13849 ................................................................11
3. Installation......................................................................................................12
4. Description of the Terminals ........................................................................13
4.1 Assembly of the wires.......................................................................................................... 13
4.2 Inputs .................................................................................................................................. 14
4.2.1 SpecicationoftheSTOinputs ........................................................................................... 14
5. Functional Description..................................................................................15
5.1 Switching off ...................................................................................................................... 15
5.2 Switching on ...................................................................................................................... 15
5.3 Error .................................................................................................................................... 15
6. Wiring Examples............................................................................................16
6.1 Direct switching off with emergency stop switch .......................................................... 16
6.2 Direct switching off with emergency stop switch and monitoring of the wiring......... 17
6.3 Direct switching off by safety module with test pulses ................................................. 18
6.4 Wiring SS1.......................................................................................................................... 19
7. Certication....................................................................................................21
7.1 Annex to the declaration of conformity........................................................................... 21
8. Revisionhistory.............................................................................................23

GB - 4
Table of Contents

GB - 5
Preface
1. Preface
1.1 General
First we would like to welcome you as a customer of the company Karl E. Brinkmann GmbH
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 Karl E. Brinkmann GmbH. The
enclosed documents correspond to conditions valid at printing. Misprint, mistakes and techni-
cal 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usedpictogramshavefollowingsigni-
cance:
Danger Is used, if life or health of the user are endangered or sub-
stantial 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.
Aide
Tip
1.2 Safety instructions
Observe safety and
operating instruc-
tions
Precondition for all further steps is the knowledge and ob-
servance of the safety and operating instructions (instruction
manual part 1). This is provided accompanied by the device
or by the download site of www.keb.de.
Non-observance of the safety and operating instructions leads to the loss of any liability
claims. The warnings and safety instructions in this manual work only supplementary. 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.

GB - 6
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.
Through multitude applications not each possible case of installation, operation or mainte-
nance can be considered. If you require further information or if special problems occur which
are not treated detailed in the documentation, you can request the necessary information via
the local KEB agency.
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.
KEB®, COMBIVERT®, COMBICONTROL®and COMBIVIS®are registered trademarks of Karl
E. Brinkmann GmbH.
Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their re-
spective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 par-
ties. 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 used semiconductors and components of KEB are developed and dimensioned for the
use in industrial products. If the KEB COMBIVERT F5 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 our products outside the indicated limit values of the techni-
cal data leads to the loss of any liability claims. The safety function is limited to a service life
of 20 years. After this time the unit must be replaced.

GB - 7
Preface
1.6 Product description
The safety manual completes the installation manuals COMBIVERT G6 with the safety func-
tion STO. It contains safety-related supplements and regulations for the operation of COM-
BIVERT G6 in safety applications. The basic standards as well as application and country-
specicstandardsmustbeobservedfurthermore.Thestandardsreferredinthismanualmust
be observed supplementary. The safety function STO according to IEC 61800-5-2 contains:
• Safe torque off (Safe Torque Off - STO)
The safety function meet the requirements in accordance with performance level e (ISO13849-
1) and SIL 3 (IEC 61508 and IEC 62061). In case of proper project design, installation and
operation the safety function protects people against mechanical damages. COMBIVERT G6
inverters with integrated STO function correspond to the following numbers code:
Product code
xx G6 x x x - xxxx
A, B, C, D, H, I, K, L
Validity of
certicates
The certication of controllers with safety tech-
nology since 05.2013 is only valid if the material
numbercorrespondswiththespeciednumerical
code and the FS logo is printed on the type plate.
1.7 Part code
xx G6 x x x - x x x x
Cooling (not valid at customer/special version)
0Air-cooling(housingC,D,E);air-cooling/atrear(housingA,B)
1 Flat rear
Control/keyboard/display (not valid at customer/special version)
0Open-loop without keyboard/display A like 0 on ASCL hardware
1 Open-loop with keyboard/display B like 1 on ASCL hardware
2 SCL without keyboard/display
3 SCL with keyboard/display
4 ASCL without keyboard/display
5 ASCL with keyboard/display
Switching frequency; short time current limit; overcurrent cut-off
(not valid at customer/special version)
02 kHz 125 % 150 % 14 kHz 125 % 150 %
28 kHz 125 % 150 % 316 kHz 125 % 150 %
42 kHz 150 % 180 % 54 kHz 150 % 180 %
68 kHz 150 % 180 % 716 kHz 150 % 180 %
82 kHz 180 % 216 % 94 kHz 180 % 216 %
A8 kHz 180 % 216 % B2 kHz 180 % 216 %
Voltage, connection
further on next side

GB - 8
Preface
xx G6 x x x - x x x x
0 1-phase 230 V AC/DC 3 3-phase 400 V AC/DC
1 3-phase 230 V AC/DC 5 400 V DC
2 1/3-phase 230 V AC/DC 6 1-phase 230 V AC
A-Z Customer-/specialversion(rmwareanddownload)
Housing type A, B, C, D, E
Variants
0
withoutlter,withoutbrakingtransis-
tor,
without safety function STO
Alike 0 with
STO Hlike A with f=0Hz
1withoutlter,withbrakingtransistor,
without safety function STO Blike 1 with STO Ilike B with f=0Hz
2internal lter; without braking tran-
sistor, without safety function STO Clike 2 with STO Klike C with f=0Hz
3internallter,withbrakingtransistor,
without safety function STO Dlike 3 with STO Llike D with f=0Hz
Control type
C Analog/digital (standard)
D CAN®1
E IO-Link®2
F EtherCAT®3
G PROFINET®4
G6 unit type
Inverter size
1CANopen®is registered trademark of CAN in AUTOMATION - International Users and Manufacturers Group
e.V.
2IO-LINK®is registered trademark of PROFIBUS user organisation e.V.
3EtherCAT®is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Ger-
many
4PROFINET®is registered trademark of Siemens AG

GB - 9
Safety Function STO
2. Safety Function STO
Electric
Shock
COMBIVERT G6 contain dangerous voltages which can cause
death or serious injury.
The COMBIVERT G6 can be adjusted by way that in regenera-
tive operation energy is regenerated into the DC link also during
mains power failure. Therefore a dangerous high tension can
exist in the unit after switching off the supply system.
Before working with the unit check the isolation from sup-
ply by measurements in the unit.
Care should be taken to ensure correct and safe operation to
minimise risk to personnel and equipment.
Only
Qualied
Staff
Uncontrolled start is possible by improper installation of the safe-
ty technology. This may cause death, serious bodily injuries or
substantial damage to property.
Therefore the safety function may only be installed and put into
operationbyqualiedpersonnelwhicharetrainedinsafetytech-
nology.
Observe
Standards
The COMBIVERT G6 must not be started until it is determined
that the installation complies with 2006/42/EC (machine direc-
tive) as well as the EMC directive (2004/108/EC)(note EN60204).
The COMBIVERT G6 meets the requirements of the Low-Volt-
age Directive 2006/95/EC. The harmonized standard of the se-
ries EN 61800-5-1 (VDE 0160) is used.
This is a product of limited availability in accordance with IEC
61800-3. This product may cause radio interference in residen-
tial areas. In this case the operator may need to take correspond-
ing measures.
With electronic protection devices the safety function is integrated in the drive control in order
to minimize or eliminate danger by malfunctions in machines. The integrated safety function
replace the complex installation of external safety components. The safety function can be
requested or released by an error.
Regular
checks
In order to ensure permanent security, the function must be
checked in regular intervals according to the results of the risk
analysis.
Installation work or troubleshooting can be necessary in hazard areas, whereby protective
devices such as line- or motor contactors shall not be activated. The safety function STO can
be used there. Depending on the application the use of line or motor contactors can be void
by using STO.
In case of error or request, the power semiconductor of the drive module are switched off and
the drive is not supplied, which causes a rotation or torque (in case of a linear drive move-
ment or force). The unit can be safe switched off and/or remain if an error occurs.

GB - 10
Safety Function STO
Electric
Shock Continue mains voltage with active STO function.
Compared to the disconnection by line contactors or motor contactors the integrated safety
function enables a simple integration of drives to functional groups of a system. Thereby safe
torque off can be limited to certain systems. A further advantage is that the recharge and dis-
charge time of the inverter DC link must not be considered. Thus the unit is faster again ready
for operation after an interruption.
Regular electromechanical equipment are liable to abrasion. Loss of these equipment occurs
by using the STO function and the maintenance costs are reduced.
Characteristic data for „Safe torque off“
•Power supply for the rotation direction of the motor is interrupted (free-wheeling motor)
•Used when monitoring of standstill is not necessary
•Unintentional starting of the motor is prevented
•No galvanic isolation of the motor from the inverter DC link
What is realized by the STO function related to EN60204 ?
Emergency stop can be realized by the STO function, since the mains voltage may remain
effective.
Emergency stop can be realized only in connection with a line contactor, which disconnects
the mains voltage !
2.1 Emergency stop according EN 60204
By using suitable safety switchgear units, stop category 0 and 1 according to EN 60204 can
be reached by the STO function in the system. Note chapter 6 for safety switchgear units.
Stop category 0 „uncontrolled stop“, i.e. stop by immediate removal of power to the
actuators.
Stop category 1
„controlled stop“, i.e. power to the actuators is retained to apply
braking until the stop is achieved. The energy is switched off at
standstill.
Emergency stop to EN 60204 must be functional in all operating modes of the drive module.
The reset of emergency stop may not lead to an uncontrolled start of the drive.
Restart only
afterconr-
mation
The drive restarts if function STO is no longer released. In order
to comply with EN 60204, it must be ensured by external meas-
uresthatthedriverestartsonlyafterconrmation.
Without mechanical brake the drive leads to coast; motor is free-wheeling. Additional protec-
tive devices must be installed (e.g.locking systems) if damage to persons or property can
occur.
Ensure coast
of the motor
If danger to persons occur after switching off the motor control
by STO, the entrance to hazard areas must remain closed until
the drive stops.

GB - 11
Safety Function STO
Jerks in error
case
In case of double malfunction it can lead to unwanted jerk, the
rotation angle is depending on the number of poles of the se-
lected drive and the gear ratio.
Calculation of the jerk:
Rotation angle of the jerk WR[°] = 180° –––––––––––––––––––––––––––––––––
Pole-pairnumberp•gearreductionratiog
The probability of the jerk is < 1.84 *10-15 1/h.
This behaviour can occur by a short circuit of the IGBTs. The error should be regarded as
critical, if the drive remains in STO status.
2.2 ClassicationofSTOaccordingIEC61508
PFH 8.1 *10^-11 1/h
PFD 7.1 * 10^-6 on demand
Proof-Test-Interval 20 years
ForSILclassicationinconnectionwiththeapplicationsconsiderthefailureratesoftheex-
ternalswitchdevicesfornalevaluation.
2.3 ClassicationofSTOaccordingENISO13849
Control category 3
MTTFD>2500 years
DC medium
Fortheclassicationwithinaperformancelevelinconnectionwiththeapplicationsconsider
thefailureratesoftheexternalswitchdevicesfornalevaluation.

GB - 12
Installation
3. Installation
Before be-
ginning
Before installation, read and note the EMC and safety instructions
and installation manuals of the COMBIVERT G6.
Additional instructions:
• The unit must be isolated from mains by main switch when working on parts under volt-
age.
• Mechanical brakes must be installed additionally if external forces have effect to the drive
axis, e.g. vertical axes (hanging loads) or rotary axes with asymmetrical weight distribu-
tion.
• For the protection against pollution (pollution degree 2) the installation of the units must
be provided in environment with increased protection (e. g. control cabinet IP 54).
• Make sure that no small parts fall into the COMBIVERT during assembly and wiring. This
also applies to mechanical components, which can lose small parts during operation.
• Check the safety functions and error responses and generate an acceptance report after
installation.
• The start-up can be prevented with interruption of the STO signals. STO may not be
released in case of danger according to EN 60204-1. Also note the instructions to the
external safety switch devices.
• Dimension the safety application by way that the corresponding input current of the safety
functions is available for the inputs (see section 4.1).
Selection of
suitablevolt-
age sources
Use for the connection only suitable voltage sources with safe
isolation (SELV / PELV) in accordance with VDE 0100 with nom-
inalvoltageof24Vdc±10%.Payattentiononasufcientover-
voltage category of the voltage supply.

GB - 13
Description of the Terminals
4. Description of the Terminals
X2B PIN Name I/O
1 STO1+ Input STO channel 1
2 STO1-
3 STO2+ Input STO channel 2
4 STO2-
The individual channels are designed potential-free, so 24V and 0 V can
be connected. The inputs are designed by way that safety switchgear
units with test pulse (OSSD signals) can be connected. The signals are
notevaluated,theyareonlyltered.TheOSSDtestintervalislimitedto
10ms.Theltertimefortheentirevoltagerangeis1ms.
Assembly of connecting wires with wire-end ferrules according to DIN46228/4
Cross-section / AWG Metal sleeve length Stripping length
0.2…0.75 mm2/ 24…19 6 mm 8 mm
Assemblyofconnectingwireswithoutwire-endferrules(rigidyandexible
Cross-section / AWG Stripping length
0.2…1.5 mm2/ 24…16 10 mm
4.1 Assembly of the wires
Required tools:
Screw driver SD 0.4 x 2.5 (DIN 5264)
1. Strip cable
Use wire-end ferrules as round, square or hexagon
pressing.
2. Plug screw driver mid into the square slot.
3. Plug cable into the round slot, that no wires can be seen
from the outside.
4. Removescrewdriverandcheckifcablesarexed.
A safe clamping can not be guaranteed when using shorter wire-end ferrules.

GB - 14
Description of the Terminals
KEB generally recommends the use of wire-end ferrules in industrial environ-
ments.
4.2 Inputs
4.2.1 SpecicationoftheSTOinputs
STO
Inputs
Status 0 Status 1
UL [V] IL [mA] UH [V] IH [mA]
max. 5 15 30 15
min. -3 notdened 15 5

GB - 15
Functional Descriptions
5. Functional Description
ThecontrolboardwiththesafetyfunctionSTOfulllsthefollowingfunctionsaccordingtoIEC
61800-5-2:
• „Safe torque off“ (Safe Torque Off – STO)
The safety-oriented switching off of the modulation is reached by a two channel disconnec-
tion of the control of the IGBT.
The 1st channel switches off the pulse pattern of the control CPU.
The 2nd switches off the supply of the gate control of the IGBT´s in the driver
The switching off of the pulse pattern and the voltage supply of the drivers are monitored.
If for example an input side connected emergency stop unit is activated (STO1 & STO2 = 0V)
it is tested by the diagnosis, if both channels have switched off the pulse generation.
In case of inactivated emergency stop unit (STO1 & STO2 = 24V) an on-off-on test is carried
out before the modulation release to ensure that a switching off is possible.
Testevery24
hours
In order to ensure safe operation, the safety function must car-
ried out every 24 hours that the on-off-on test is executed.
5.1 Switching off
After STO input voltage disconnection the control of the IGBTs is stopped within 12ms. Re-
peated switching on is prevented for the duration of 11 ms after switching off.
5.2 Switching on
24 V on both STO inputs and a direction of rotation must be set at the control (no LS at pa-
rameter ru00) thus the on-off-on test can be executed. The frequency output is delayed by
the test about maximum 120 ms.
5.3 Error
If an error occurs during operation, the inverter turns into a „safe condition“ within 25 ms. ru00
displayes “28: Error! Safety function”.
The „Error! Safety function“ can
•notberesetbyadigitalinput
•onlyberesetbyapower-onresetofthefrequencyinverter.

GB - 16
Wiring Examples
6. Wiring Examples
6.1 Direct switching off with emergency stop switch
U V W PE
M
X1A
X4A
1 - STO1+
2 - STO1-
3 - STO2+
4 - STO2-
X2B
+ -
24Vdc
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
X2A
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
①
②
③
①Power Unit X1A Power terminal block
②Control Circuit X2A Control terminal block
③Safety component X2B STO terminal block
X4A Diagnostic interface
At operation of an emergency stop unit, when both contacts are connected to-
gether against a positive supply signal, make sure that there are no crossfaults.
The wiring must be suitable arranged.

GB - 17
Wiring Examples
6.2 Direct switching off with emergency stop switch and monitoring of the wiring
U V W PE
M
X1A
X4A
1 - STO1+
2 - STO1-
3 - STO2+
4 - STO2-
+ -
24Vdc
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
X2A
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
X2B
①
②
③
①Power Unit X1A Power terminal block
②Control Circuit X2A Control terminal block
③Safety component X2B STO terminal block
X4A Diagnostic interface
The displayed circuit shows wiring errors in the area of the emergency stop unit and supply
line. A possible short circuit on the primary side of the emergency stop switchgear (mass and
24 Vdc) and a short circuit on the secondary side of the unit or within the wiring leads either
directly or with closed contacts to a short circuit of the supply, whereby a series-connected
24V fuse triggers.
Besides the two displayed applications with an emergency stop switchgear, other sensors
(like door switches etc.) can be used similarly.

GB - 18
Wiring Examples
6.3 Direct switching off by safety module with test pulses
U V W PE
M
X1A
X4A
1 - STO1+
2 - STO1-
3 - STO2+
4 - STO2-t
OPEN
CLOSED
S1 S2
Acknowledgment/
Quittung
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
X2A
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
X2B
①
②
③
④
①Power Unit X1A Power terminal block
②Control Circuit X2A Control terminal block
③Safety component X2B STO terminal block
④Safety module X4A Diagnostic interface
With operation of the emergency stop unit, e.g. by protection door, the release paths of the
safety module are disconnected. This leads to the loss of the STO signals (X2B.1 and 3) and
thus to energy disconnection of the drive. The safety module makes a consistency check of
all signal paths via test signals (OSSD).

GB - 19
Wiring Examples
6.4 Wiring SS1
At tripping SS1 (Safe Stop 1) the drive is only disconnected from supply when it has reached
a standstill [IEC 61800-5-2]. The stop mode is not directly requested, but the maximum time
until reaching the standstill is estimated. This period is loaded in a safe time relay, which dis-
connectsthedrivenallyfromsupply.
U V W PE
M
X1A
X4A
1 - STO1+
2 - STO1-
3 - STO2+
4 - STO2-
S1 S2
X2A.12
(I3)
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
X2A
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
OPEN
CLOSED
Acknowledgment/
Quittung
X2B
①
②
③
④④
①Power Unit X1A Power terminal block
②Control Circuit X2A Control terminal block
③Safety component X2B STO terminal block
④Safety module X4A Diagnostic interface
By activation of the emergency stop unit the drive is stopped with a deceleration ramp via
input X2A.12 (I3).
Simultaneously the expiration of the safe time occurs in the safety module. After expiration of
the safe period the control signals STO1 and STO2 (X2B.1 and 3) are removed and thus the
energy supply of the drive is disconnected.
The following adjustments must be done in COMBIVERT G6 for the function „drive stop“:

GB - 20
Wiring Examples
Parameter Adjustment
Pn03 „Reaction to error prg. input“ 1: Quick stopping; modulation off; no auto-
matic restart
Pn04 „Source error prog. input“ 16: I3 (here in the example)
Function: If the selected input becomes active, the drive decelerates with the quick stopping
function and changes then into status 31 „error! External input“.