KEBCO COMBIVERT T6APD User manual

COMBIVERT T6APD
INSTRUCTIONS FOR USE
INSTALLATION MODULAR DRIVE CONVERTER SYSTEM
Translation of the original manual
Document 20108384 EN 05

3
PREFACE
Preface
The hardware and software described in this document are products of KEB. The infor-
mation contained in this document is valid at the time of publishing. KEB reserves the
right to update this document in response to misprints, mistakes or technical changes.
Signal words and symbols
Certain procedures within this document can cause safety hazards during the installati-
on or operation of the device. Refer to the safety warnings in this document when per-
forming these procedures. Safety signs are also located on the device where applicable.
A safety warning is marked by one of the following warning signs:
DANGER Dangerous situation, which will cause death or serious injury iif this safe-
ty warning is ignored.
WARNING Dangerous situation, which may cause death or serious injury if this
safety warning is ignored.
CAUTION Dangerous situation, which may cause minor injury if this safety warning
is ignored.
NOTICE Situation, which can cause damage to property if this safety warning is
ignored.
RESTRICTION
Used when the following statements depend on certain conditions or are only valid for
certain ranges of values.
Used for informational messages or recommended 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/service/downloads

4
PREFACE
Laws and guidelines
KEBAutomationKGconrmswiththeECdeclarationofconformityandtheCEmarkon
the device nameplate that it complies with the essential safety requirements.
The EC declaration of conformity can be downloaded on demand via our website.
Warranty and liability
The warranty and liability on design, material or workmanship for the acquired device is
given in the general sales conditions.
Hereyouwillndourgeneralsalesconditions.
www.keb.de/terms-and-conditions
Furtheragreementsorspecicationsrequireawrittenconrmation.
Support
Although multiple applications are referenced, not every case has been taking into ac-
count. If you require further information or if problems occur which are not referenced in
the documentation, you can request the necessary information via the local KEB agency.
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 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 intended use. However, they are regarded as being only informal
and changes are expressly reserved, in particular due to technical changes. 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.
Tests can only be done within the intended end use of the product (application) by
the customer. They must be repeated, even if only parts of hardware, software or
the unit adjustment are modied.
Copyright
The customer may use the instructions for use as well as further documents or parts
from it for internal purposes. Copyrights are with KEB and remain valid in its entirety.
This KEB product or parts thereof may contain third-party software, including free and/
or open source software. If applicable, the license terms of this software are contained
in the instructions for use. The instructions for use are already available to you, can be
downloaded free of charge from the KEB website or can be requested from the respec-
tive KEB contact person.
Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their
respective owners.

5
TABLE OF CONTENTS
Table of Contents
Preface ....................................................................................................................................................3
Signal words and symbols .............................................................................................................3
More symbols.................................................................................................................................3
Laws and guidelines.......................................................................................................................4
Warranty and liability......................................................................................................................4
Support ........................................................................................................................................4
Copyright........................................................................................................................................4
Table of Contents ...................................................................................................................................5
List of Figures.........................................................................................................................................8
List of Tables ..........................................................................................................................................9
Glossary ................................................................................................................................................10
List of standards ..................................................................................................................................12
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 Requirements to the entire system..............................................................................................18
1.6 Start-up and operation ..................................................................................................................19
1.7 Maintenance...................................................................................................................................21
1.8 Repair .............................................................................................................................................21
1.9 Disposal..........................................................................................................................................22
2 Product Description .................................................... 23
2.1 T6APD - Principle construction .....................................................................................................25
2.1.1 System architecture............................................................................................................26
2.2 Specied application.....................................................................................................................29
2.2.1 Residual risks.....................................................................................................................29
2.3 Unintended use..............................................................................................................................30
2.4 Overview of the COMBIVERT T6APD ..........................................................................................30
2.5 Nameplate ......................................................................................................................................31
2.6 Congurable options ....................................................................................................................32
2.7 Type code .......................................................................................................................................33

6
TABLE OF CONTENTS
3 Technical Data.............................................................. 34
3.1 Operating conditions ....................................................................................................................34
3.1.1 Evironmental conditions .....................................................................................................34
3.1.2 Mechanical environmental conditions ................................................................................34
3.1.3 Electrical operating conditions............................................................................................35
3.1.3.1 Deviceclassication........................................................................................................35
3.1.3.2 Electromagnetic compatibility..........................................................................................36
3.2 System and module data ..............................................................................................................37
3.2.1 System weight....................................................................................................................37
3.2.2 Electrical system data ........................................................................................................37
3.2.2.1 Operation at the AIC (Active Infeed Controller)...............................................................38
3.2.3 Electrical data High Voltage Interlock Loop (HVIL) ............................................................39
3.2.4 Low Voltage LV-DC input....................................................................................................39
3.2.5 Inverter modules A, B, C ....................................................................................................40
3.2.5.1 Overload characteristic (OL) ...........................................................................................41
3.2.5.2 Frequency-dependent maximum current (OL2) ..............................................................42
3.2.6 Switching frequency and temperature................................................................................44
3.2.7 Cooling and coolant connection .........................................................................................44
3.2.7.1 Pressure drops................................................................................................................46
3.2.7.2 Materials in the cooling circuit .........................................................................................47
3.2.8 Requirements for the coolant .............................................................................................48
3.3 Mechanical data.............................................................................................................................49
3.3.1 Dimensions system length A ..............................................................................................49
3.3.2 Dimensions system length B..............................................................................................50
3.3.3 Dimensions system length C..............................................................................................51
3.3.4 Dimensions system length D..............................................................................................52
3.3.5 Dimensions system length E..............................................................................................53
3.3.6 Dimensions system length F ..............................................................................................54
3.3.7 Connection to the coolant for all housing sizes..................................................................55
4 Installation and Connection........................................ 56
4.1 Mounting ........................................................................................................................................56
4.1.1 Durchsteckmontage ...........................................................................................................57
4.2 Permissible installation position .................................................................................................58
4.2.1 Externalmagneticelds .....................................................................................................59
4.3 Connection of the power unit.......................................................................................................60
4.3.1 High voltage DC supply......................................................................................................60
4.3.1.1 High Voltage Interlock Loop (HVIL) - Exemplary connection ..........................................61
4.3.1.2 Protective earth ...............................................................................................................61
4.3.1.3 HV-DC supply X3A ..........................................................................................................62
4.3.1.4 Coupling for HV-DC supply .............................................................................................63
4.3.2 Motor connection................................................................................................................64

7
TABLE OF CONTENTS
4.3.2.1 Inverter module A and B - socket X1B.............................................................................65
4.3.2.2 Motor connector for inverter module A and B..................................................................66
4.3.2.3 Inverter module C - socket X1B ......................................................................................67
4.3.2.4 Motor connector for inverter module C............................................................................68
4.3.2.5 Motor cable length...........................................................................................................69
4.3.2.6 Interconnection of the motor............................................................................................69
4.3.3 Temperature detection........................................................................................................69
4.3.3.1 Connection of a KTY sensor ...........................................................................................70
4.3.3.2 Connection of a PT1000 sensor......................................................................................70
4.3.3.3 Connection of the temperature input in operating mode PTC.........................................71
4.4 Connection of the control.............................................................................................................72
4.4.1 Assignment of the connector X1A ......................................................................................72
4.4.1.1 Terminal 15 „Enable“ .......................................................................................................74
4.4.1.2 SpecicationoftheCANbus...........................................................................................74
4.4.1.3 Connection example 1 - Connection of the CAN client at T6APD .............................................. 75
4.4.1.4 Connection example 2 - Assignment of both CAN interfaces with T6APD at the end
of the respective bus.....................................................................................................76
4.4.2 Connection plug for X1A.....................................................................................................77
4.4.3 Bus interface X2A...............................................................................................................78
4.4.3.1 Assignment of the Ethernet interface X2A.......................................................................79
5 Certication.................................................................. 80
5.1 ECE R10..........................................................................................................................................80
5.2 Manufacturer´s declaration ..........................................................................................................81
6 Revision History .......................................................... 84

8
LIST OF FIGURES
List of Figures
Figure 1: T6APD - Principle construction .........................................................................................25
Figure 2: T6APD - Complete overview .............................................................................................30
Figure 3: Nameplate........................................................................................................................31
Figure4: AICwith7.2%Ukchokeltering .....................................................................................38
Figure5: AICwithsine-waveEMClter..........................................................................................38
Figure6: Switch-o󰀨timetdependingontheoverloadI/IN(OL)withtheexampleofmoduleA.....41
Figure 7: Typical overload characteristic in the lower output frequencies (OL2) Example module A42
Figure 8: Typical pressure drops.....................................................................................................46
Figure 9: Dimensions system length A............................................................................................49
Figure 10: Dimensions system length B............................................................................................50
Figure 11: Dimensions system length C ...........................................................................................51
Figure 12: Dimensions system length D ...........................................................................................52
Figure 13: Dimensions system length E............................................................................................53
Figure 14: Dimensions system length F............................................................................................54
Figure 15: Connection to the coolant ................................................................................................55
Figure 16: Mounting holes.................................................................................................................56
Figure 17: Push-through mounting....................................................................................................57
Figure 18: Permissible installation position.......................................................................................58
Figure19: Externalmagneticelds...................................................................................................59
Figure 20: Connection at DC voltage supply.....................................................................................60
Figure 21: Example of a HVIL wiring.................................................................................................61
Figure 22: Protective earth................................................................................................................61
Figure 23: HV-DC supply X3A (front view on the device)..................................................................62
Figure 24: Coupling for HV-DC supply (counterpart for X3A) ...........................................................63
Figure 25: Wiring between motor and T6APD..........................................................................................................64
Figure 26: Socket inverter module A and B (front view socket).........................................................65
Figure 27: Coupling motor connector for inverter module A and B ...................................................66
Figure 28: Socket inverter module C (front view socket) ..................................................................67
Figure 29: Coupling motor connector for inverter module C .............................................................68
Figure 30: Connection of a KTY sensor............................................................................................70
Figure 31: Connection of a PT1000 sensor ......................................................................................70
Figure 32: Connecting examples temperature input .........................................................................71
Figure 33: Assignment of the terminal block X1A .............................................................................73
Figure 34: Connection of the input terminal 15 „Enable“ ..................................................................74
Figure 35: Connection example 1 of the CAN clients at T6APD.......................................................75
Figure 36: Connection example 2 Assignment of both CAN interfaces with T6APD ........................76
Figure 37: Coupling for control connector X1A .................................................................................77
Figure 38: Bus interface X2A ............................................................................................................78
Figure 39: Bus interface X2A ............................................................................................................78
Figure 40: Declaration of conformity .................................................................................................83

9
LIST OF TABLES
List of Tables
Table 1: System architecture .........................................................................................................28
Table2: Congurableoptions........................................................................................................32
Table 3: Type code ........................................................................................................................33
Table 4: Evironmental conditions...................................................................................................34
Table 5: Mechanical environmental conditions..............................................................................34
Table6: Deviceclassication.........................................................................................................35
Table 7: Electromagnetic compatibility ..........................................................................................36
Table 8: Electrical system data......................................................................................................37
Table 9: System data.....................................................................................................................38
Table 10: Electrical data High Voltage Interlock Loop (HVIL)..........................................................39
Table 11: Electrical data low voltage DC input ................................................................................39
Table 12: Power input of the modules .............................................................................................40
Table 13: Electrical data of the inverter modules.............................................................................40
Table 14: Frequency-dependent maximum current for module A....................................................43
Table 15: Frequency-dependent maximum current for module B....................................................43
Table 16: Frequency-dependent maximum current for module C ...................................................43
Table 17: Switching frequency and temperature .............................................................................44
Table 18: Technical data coolant .....................................................................................................45
Table 19: Electrochemical series / standard potentials against hydrogen.......................................47
Table 20: General requirements for the coolant: .............................................................................48
Table 21: Plug-in connector coding .................................................................................................63
Table 22: Possible applications of temperature detection ...............................................................69
Table23: Specicationofthetemperatureinput .............................................................................70
Table24: Specicationofthetemperatureinput .............................................................................70
Table25: Specicationofthetemperatureinput .............................................................................71
Table26: Specicationsoftheinput„Enable“ .................................................................................74
Table27: SpecicationsoftheCANbus .........................................................................................74
Table 28: PIN description RJ45 Ethernet.........................................................................................79
Table29: CerticationaccordingtoECERegulationNo.10includingAmendment05Supple-
ment 01............................................................................................................................80

10
GLOSSARY
Glossary
AC AC current or voltage
AFE From 07/2019 AIC replaces the pre-
vious name AFE
AFElter From07/2019AIClterreplacesthe
previousnameAFElter
AIC Active Infeed Converter
Ancillary com-
ponents
All ancillary drives of a vehicle, which
e󰀨ectnotor,atleast,notimmediate-
ly its movement
APD Auxiliaries Power Drives; drive inver-
ter modules
Application The application is the intended use
of the KEB product
ASCL Asynchronous sensorless closed
loop
Attachments For agricultural machinery e.g. ferti-
lizer spreader, tedders or tools: saw,
shredders, etc.
Auto motor
ident.
Automaticallymotoridentication;
calibration of resistance and induc-
tance
AWG American wire gauge
B2B Business-to-business
BAM Broadcast Announced Message
CAN open CAN-based communication protocol
from automation technology
CAN SAE
J1939
SAE J1939 describes the CAN com-
munication in commercial vehicles
COMBIVERT KEB drive converters
COMBIVIS KEB start-up and parameterizing
software
Customer The customer has purchased a KEB
product from KEB and integrates the
KEB product into his product (cus-
tomer product) or resells the KEB
product (dealer)
CV Commercial vehicle
DC DC current or voltage
DCU Drive Control Unit; drive converter
controlboard(drivermware:u/f,
SCL, ASCL)
DIN German Institut for standardization
DM1 J1939 Diagnostic Message Type
Drive inverter
system
Component consisting of several
inverter modules
DS 402 CiADS402-CANdeviceprolefor
drives
ECE regulati-
ons
ECE regulations describe a catalog
of internationally agreed uniform
technical regulations for vehicles,
parts and equipment of motor vehic-
les.
EMC Electromagnetic compatibility
Emergency
stop
Shutdown of a drive in emergency
case (not de-energized)
Emergency
switchingo󰀨
Switchingo󰀨thevoltagesupplyin
emergency case
EN European standard
End customer The end customer is the user of the
customer product
Ethernet Real-timebussystem-denespro-
tocols, plugs, types of cables
EVCU Electronic vehicle control unit
FE Functional earth
Filter DCEMVltersinstalledinallinverter
modules
FU Drive converter
GND Reference potential, ground
HMI Human machine interface (touch
screen)
HV_DC High voltage DC supply (on-board
power supply)
HVAC Heating - Ventilation - Air conditio-
ning
HVIL Hazardous Voltage Interlock Loop
- Protection against unintentional
disconnection of high-voltage plug
connections
Hybrid vehicle Vehiclewith2di󰀨erentdrivesour-
ces, e.g. Diesel engine with electric
motor (power via battery, supercaps
etc) or diesel engine with hydraulic
and hydraulic accumulator
Implement Agricultural for the application of an
attachment
Inverter module AC inverter from a drive inverter
system
IP xx Degree of protection (xx for level)
ISOBUS ISOBUSdenesCANapplicationsat
agricultural machinery
IT mains General information for ungrounded
power system. Therefore, insulation
monitoring must be applied as pro-
tective measure
KEB product The KEB product is subject of this
manual
KL15 EN Enable – switched plus from the
ignition starter switch