KEBCO Combivert User manual

09/99
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GB
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© KEB 00.00.EMV-K002
COMBIVERT
C
Bevor Sie beginnen
Getting Started
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Prima di Iniziare
Antes de comenzar
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Antes de começar
Innan start
Før De begynder
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ANTRIEBSTECHNIK
RU

© KEB 00.00.EMV-K002
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NTRIEBSTECHNIK
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1. Introduction
1.1 About this Manual
Before you start with the installation of the frequency inverter/servo, please read
this manual carefully and pay special attention to the notes and suggestions.
This manual contains:
–safetyandwarninginstructions
–installation instructions that conform with EMC
–explanation of the EG directive/CE mark
–sticker to fasten onto the inverter/servo controller
This manual must be made available to every user. Before working with the unit
theusermustbecomefamiliarwithit.Thisespeciallyappliesto the knowledge and
observance of the following safety and warning indications.
The pictograms used here have the following meaning:
Danger
Warning
Caution
Attention
Essential
Measure
Is used when the life or health of the user is in
danger or considerable damage to property can
occur.
Isusedwhen a measure is necesary for safe and
disturbancefreeoperation.
1. Introduction ...................................................................11
1.1 About this Manual ........................................................................... 11
2. Safety and Application Instructions ............................12
2.1 General ............................................................................................. 12
2.2 Use as directed ................................................................................ 12
2.3 Transport, Storage and Installation ................................................ 12
2.4 Electrical Connection ...................................................................... 13
2.5 Operating Instructions..................................................................... 14
3. EMC Fundamentals ......................................................15
3.1 General ............................................................................................. 15
3.2 Installation ....................................................................................... 15
3.3 Installation of an EMC Conform Cabinet........................................ 16
3.4 Explanations .................................................................................... 17
3.5 Connection of the Interference Suppression Filter ....................... 17
3.6 Connection of the Control Lines .................................................... 18
4. CE Marking ....................................................................18
5. Manufacturer´s Declaration..........................................18
6. Fastening the Safety Sticker ........................................91
Table of Contents

12
2. Safety and Application
Instructions
2.1 General
Danger to Life
The directions in this chapter must be absolutely observed for the following
reasons:
–Safety for people and machines
–Function and susceptibility to faults
–Guaranteeand warranties
Inverters/servo drives contain dangerous voltages which can cause death or
serious injury. Care should be taken to ensure correct and safe operation to
minimise risk to personnel and equipment.
Allwork from the transport, to installation and start-up as well as maintenance may
only be done by qualified personnel (IEC 364 and/or CENELEC HD 384 and IEC-
Report664 andnotenational safetyregulations).According tothismanual qualified
staff means:
–those who are able to recognise and judge the possible dangers based on their
technical training and experience
–those with knowledge of the relevant standards and who are familiar with the
field of power transmission (VDE 0100, EN 50178, EN 60204 as well as the
approporiateregulationsforyourarea).
Inverters/servo drives are designed for speed control of asynchronous and
permanentmagnetmotors, repsectively.Use forother purposeisnotrecommended
and may lead to equipment damage.
The inverter/servo drive must not be started until it is determined that the
installation complies with 89/392/EEC (machine directive) as well as the EMC-
directive(89/336/EEC)(note EN60204).
The frequency inverters/servo drives meet the requirements of the Low-Voltage
Directive 73/231/EEC. The harmonized standards of the series EN 50178 in
conenction with EN 60439-1 and EN 60146 were used.
Inverters/servodrives must be protected against physicaldamage during tranport,
installation and use. Components and covers must not be bent or moved as this
may affect insulation distances. The equipment must not be switched on if it is
damaged as it may no longer comply with mandatory standards.
This eqipment contains electrostatic sensitive devices which may be damaged by
carelesshandling.
Makesure that during installation thereisenough minimum clearance and enough
cooling. Climatic conditions must be observed in accordance with EN 50178.
2.2 Use as directed
Observe
Standards
2.3 Transport,Storage
andInstallation
ProtectAgainst
Accidental
Contact
Only Qualified
Electro-Personnel

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2.4 ElectricalConnection
Before any installation and connection work, the system must be switched off and
secured. After clearing the frequency inverter the intermediate circuit capacitors
arestill charged with high voltage for a short period of time. The unit can be worked
on again, after it has been switched off for 5 minutes.
Withfrequency inverters that arenotisolated from the supply circuitall control lines
mustbe included in other protective measures (e.g. double insulation or shielded,
earthedand insulated). Furtherinformation is foundinthe technical documentation
part 3.
Connection of the frequency inverter is only permissible on symmetrical networks
with a maximum line voltage (L1, L2, L3) with respect to earth (N/PE) of 300V. An
isolating transformer must be used for supply networks which exceed this value!
The units may be damaged if this is not observed.
The inverter is only designed for a fixed connection, because when using filters
a leakage current > 3.5mA can occur. Protective conductor cross section must be
at least 10mm2copper or a 2nd conductor must be electrically parallel to the
protectiveconductor onseparateterminals. Ground point-to-pointwith the shortest
connection possible to mains earth (avoid earth loops).
When using IGBT inverters, high voltage peaks may arise in the motor due to the
switchingaction of the inverter output devices. These voltage peaks may damage
the insulation of the motor winding and must be taken into account when using
motor cables longer than 15m with high frequency motors. In this case, the motor
can be protected with a motor choke, dv/dt filter or sine filter.
When doing an insulation measurement in accordance with VDE 0100 / Part 620,
thepowersemiconductor of the unit and existing radio interferience filters must be
disconnected because of the danger of destruction. This is permissible in
compliance with the standard, since all inverters are given a high voltage test in
the end control at KEB in accordance with EN 50178.
When using components without isolated inputs/outputs, it is necessary that
equipotential bonding exists between the components to be connected (e.g.
throughtheequalizer). Disregard can cause destruction of the components by the
equalizingcurrents.
Atrouble-free and safeoperation of thefrequencyinverter is onlyguaranteed when
the connection instructions below are strictly followed. Incorrect operation or
damage may result from incorrect installation.
–Note mains voltage and rated motor voltage.
–Install power cables and control cables separately (> 15cm separation).
–Use shielded/twisted control lines. Connect shield to PE at inverter only.
–Onlyuse suitable circuit elements to control the logic and analog inputs, whose
contacts are rated for extra-low voltages.
–Make sure inverter and motor housing are well grounded. The screen of the
cablebetween theinverter and themotor must bedirectly and securelyattached
to both the inverter PE terminal and the motor ground terminal. Remove paint
finish where necessary.
–Connect the braking module/ braking resistor with shielded/twisted cables
(install shield on one side of the inverter).
–Ground the cabinet or the system earth star point with the shortest connection
to mains earth (avoid earth loops).
Only Fixed
Connection
Insulation
Measurement
VoltagePeaks
NoteCapacitor
DischargeTime
Voltage with
respectto
ground
Prevent
Disturbances
Control
Lines
DifferentEarth-
Potentials

14
RCD
(FI-Protective
Switch)
If personnel protection is required during installation of the system the frequency
inverters must be protected according to EN 50178 (VDE 0160):
–1-phase inverters by RCD type A (pulse-current sensitive FI’s) or type B (all-
current sensitive FI’s)
–3-phase inverters (with B6 bridge-connected rectifier) by RCMA’s with
separation (used privileged) or RCD’s type B (all-current sensitive FI’s)
The tripping current should be 300mA or more, in order to avoid a premature
triggering of the inverter by discharge currents (about 200mA).
Dependent on the load, the length of the motor cable and the use of a radio
interference filter, substantially higher leakage current can occur.
Theconnection instructions fromthemanufacturer and the validlocal reqirements
must be observed.
Dependent on the available mains form (TN, IT, TT) further protective measures
arenecessary inaccordancewith VDEPart410 (Part4;Chapter 41).Forexample,
with TN-mains this protection is made with overcurrent protective devices. With
IT-mains it is insulation monitoring with a pulse-code measuring method. A
protective separation can be used with all mains forms as long as the required
power and cable lengths permit this.
Before starting, all respective enclosures must be secured again, as well as the
terminals and screws must be checked to see that they are securely fixed.
Inverters/servo drives may be set, dependent on type, to restart automatically
following a fault stoppage (e.g. Undervoltage Error), when the fault conditions
clear. System design must take this into account, if appropriate, and additional
monitoring or protective features added where necessary.
The frequency inverters/servo drives are conditionally short-circuit proof (EN
50178). After resetting the internal protection devices, the function as directed is
guaranteed.
Exceptions:
–If an earth-leakage fault or short-circuit often occurs at the output,
this can lead to a defect in the unit.
–If a short-circuit occurs during regenerative operation (2nd or 4th quadrant,
feedback into the intermediate circuit), this can lead to a defect in the unit.
2.5 OperatingInstructions
Automatic
Restart
Conditionally
Short-Circuit
Proof

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3. EMC Fundamentals
3.1 General
Frequencyinverters/servo drives are electrical equipment for use in industrial and
commercial systems. They are used for the stepless speed adjustment of three-
phase/permanentmagnetmotors.InaccordancewiththeEMC-directive89/336/EEC
theseunits do not require a CE-marking. In the sense of the EMC-directiveandthe
EMVG the frequency inverter/servo drive components are not designed for stand
alone operation, while they are only a part of the machine/system to be used by
competent machine or system manufacturers.The proof of compliance with the
required protective measures in the EMC-directives must be furnished by the
erector/owner of the machine/system.
By using interference filters specified by KEB and following the advice given the
quoted limits are realized.
According to production norm EN 61800-3, the KEB COMBIVERT with filter
is designed to be used in class "A" environments.
;Install the cabinet or system correctly.
;In order to prevent noise crosstalk
–Mains/supply lines
–Motor lines from inverters and servo controllers
–Control and data lines (low voltage levels < 48V)
must have a clearance of at least 15 cm when installed.
;Inordertomaintain low-resistance high frequency connections, earthing and
shielding,as well as other metallic connections (e.g. mounting plate, installed
units)must be in metal-to-metal contact with the mounting plate, overaslarge
an area as possible. Use earthing and equipotential lines with a section as
large as possible (min. 10mm2) or use thick earthing strips.
;Onlyuse shielded cable with copper or tin-plated braid, since steel braidisnot
suitable for high frequency ranges. Always install the shield with clamps or
metal cable glands onto the equalizing bars and/or PE-connections. Do not
extend cable screens with single wires, but connect the braid directly to the
appropriatepoint.
;If external interference suppression filters are used, then these must be
installed as close as possible to (<30cm from) the interference source and in
metal-to-metal contact with the mouting plate, over as large an area as
possible.
;Always equip inductive control elements (contactors, relays etc.) with
suppressors such as varistors, RC-elements or damping diodes.
;All connections must be kept as short as possible and as close as possible
to the earth, as free floating lines work as active and passive aerials.
;Keep connection cables straight (do not bundle). Install a non-assigned wire
on both sides of the protective conductor.
;The flow and return circuit must be twisted when the lines are not shielded, in
order to dampen common-mode noise.
;Further informations are found in the instruction manual part 2/3.
1) Mains Fuse
2) Main Protection
3) Line Reactor
4) Interference Suppression Filter
(if not already installed)
5) Inverter with Braking Resistor
6) Motor Choke or Output Filter
7) Motor
1)
2)
3)
4)
5)
6)
7)
M
3~
PE
L1, L2, L3
3.2 Installation

16
1
2
4
3
4
56
6
7
7
8
8
8
9
9
10 11
12 13
14 14
14 14
15
16
17
PowerRange Control Range
1. Cabinet 9. Mounting plate as neutral point
2. Mounting Plate 10. Potential equalization to building PE
3. Interference SuppressionFilter 11. Additional Earthing
4. Mains Supply 12. Mains Choke
5. Line betweeninterferencesuppression 13. Power Supply
filter and mains supply 14. Control
6. Motor Supply 15. Inverter
7. ControlCable 16. Mains Fuse
8. Shield with Clamps 17. MainsContactor
3.3 Installation of an EMC
ConformCabinet

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;Asystem should be broadly separated into power sectionandcontrolsection,
whether comprising a single enclosure or multiple enclosures. It is
recommended that a screen wall is installed between the two sections
because of the radiated noise from the power section. This screen must be
in good metal-to-metal contact with the mouting plate, over as large an area
as possible.
;The inverter together with its filter must be mounted on a common mounting
plate. They must make good metal-to-metal contact with the mounting plate,
over as large an area as possible.
;Theconnection cablebetweeninterference suppressionfilterand theinverter,
must be installed on both sides as a shielded cable normally no longer than
50 cm.
;The mounting plate of the inverter must be seen as the neutral point for the
entire earthing and shield connection in the machine or system. If the motor
or other system parts lead to disturbances, then the HF-connection of these
elements is bad. In this case equipotential bonding must be done.
;Agood connectionofthe shield ontothe motor terminalbox is onlygiven,when
the terminal box is made out of metal, and a metal cable gland is used to
connect the screen. When a plastic box is available, then the shield must be
equipped with a cable lug and be directly connected with the earthing point.
;The leakage currents in the circuit increase when interference suppression
filters are used. Since these lie above the 3,5mA threshold, one of the
following conditions must be met:
–Protective conductor section at least 10 mm²copper
–Monitoring of the protective conductor by a device that independently
switches off under fault conditions.
–Install a second conductor electrically parallel to the protective conductor
via separate terminals.
;If an additional line reactor is used because of the load on the mains, then this
must be installed on the mains side of the interference suppression filter.
3.4 Explanations
3.5 Connectionof the Interference
SuppressionFilter
Thedrawing below showsthe assembly andconnectionof an externalinterference
suppression filter.
filtered cable to the frequency
inverter
Mount the filter directly to
the mounting plate in good
metal-to-metalcontact
Equipotentialbonding
Mains cable
Shielding bus out of copper, extensively
connect with the mounting plate
Additional earthing strip
Mountingplate
Protective conductor connected

18
Leitung vom
Drehgeber analoge
Leitung ungeschirmte Steuersignale
Anschluß-
klemmen Schirmschienen nicht als Zugent-
lastung verwenden
Schirmschiene flächig
mit der entlackten
Montageplatte ver-
binden
Datenleitung
3.6 Connection of the
Control Lines
Notes:
–The shield from the digital signal lines, which is not connected via terminals,
must be clamped to the screen bus, both at the cabinet entrance and near the
inverter, in order to decrease the screen impedance.
–Ifdigitalsignal lines are connected via terminals, the screen must be clamped
to the screen bus before and after the terminals.
–If a screen bus is used near the inverter ( max 20 cm distance ), then the
screen no longer needs to be connected to the inverter.
–If the shield is earthed with a single charger, then the interference derivation
deteriorates by 70%.
–Metal copper pipe clips are suitable as a shield connection.
–When using non-shielded signal lines, they should always be installed as a
twisted pair with a forward and return circuit.
CEmarked frequencyinverterand servo driveswere developed andmanufactured
to comply with the regulations of the Low-Voltage Directive 73/23/EEC.
The applied standards are listed in the technical documentation part 2.
A manufacturer declaration in accordance with 89/392 EEC can be provided by
KEB if needed.
Line from Analog Non-shielded Data line
encoder line control signal
Connect the
screen bus to the
mounting plate
with good metal-
to-metal
contact, over as
large an area
as possible.
Do not use the shield
bus as a cable grip
4. CE-Marking
Connection
terminals
5. Manufacturer´s
Declaration

Karl E. Brinkmann GmbH
Försterweg 36 - 38 • D - 32683 Barntrup
Telefon 00 49 / 52 63 / 4 01 - 0 • Fax 00 49 / 52 63 / 4 01 - 1 16
Internet: www.keb.de • E-mail: [email protected]
KEB Antriebstechnik GmbH & Co. KG
Wildbacher Str. 5 • D- 08289 Schneeberg
Telefon 0049 / 37 72 / 67 - 0 • Telefax 0049 / 37 72 /67 - 2 81
E-mail: [email protected]
KEB Antriebstechnik Austria GmbH
Ritzstraße 8 • A- 4614 Marchtrenk
Tel.: 0043 / 7243 / 53586 - 0 • FAX: 0043 / 7243 / 53586 - 21
E-mail: [email protected]
KEB Antriebstechnik
Herenveld 2 • B- 9500 Geraadsbergen
Tel.: 0032 / 5443 / 878 • FAX: 0032 / 5443 / 7898
E-mail: [email protected]
KEB China
Xianxia Road 299 • CHN - 200051 Shanghai
Tel.: 0086 / 21 / 62350922 • FAX: 0086 / 21 / 62350015
E-mail: [email protected]
Société Française KEB
Z.I. de la Croix St. Nicolas • 14, rue Gustave Eiffel
F- 94510 LA QUEUE EN BRIE
Tél.: 0033 / 1 / 49620101 • FAX: 0033 / 1 / 45767495
E-mail: [email protected]
KEB (UK) Ltd.
6 Chieftain Buisiness Park, Morris Close
Park Farm, Wellingborough, GB - Northants, NN8 6 XF
Tel.: 0044 / 1933 / 402220 • FAX: 0044 / 1933 / 400724
Internet: www.keb-uk.co.uk • E-mail: [email protected]
KEB Italia S.r.l.
Via Newton, 2 • I- 20019 Settimo Milanese (Milano)
Tel.: 0039 / 02 / 33500782 • FAX: 0039 / 02 / 33500790
Internet: www.keb.it • E-mail: [email protected]
KEB - YAMAKYU Ltd.
711 Fukudayama, Fukuda
J- Shinjo-Shi, Yamagata (996-0053)
Tel.: 0081 / 233 / 29 / 2800 • FAX: 0081 / 233 / 29 / 2802
E-mail: [email protected]
KEB Taiwan Co., Ltd.
1F, No.19-5, Shi Chou Rd., Tounan Town
R.O.C. - Yin-Lin Hsian / Taiwan
Tel.: 00886 / 5 / 5964242 • FAX: 00886 / 5 / 5964240
E-mail: [email protected]
KEBCO Inc.
1335 Mendota Heights Road
USA - Mendota Heights, MN 55120
Tel.: 001 / 651 / 4546162 • FAX: 001 / 651 / 4546198
Internet: www.kebco.com • E-mail: [email protected]
© KEB 00.00.EMV-K002 04/2001