KEBCO COMBIVERT F5 User manual

COMBIVERT
Mat.No. Rev.
00F50EB-KW00 2F
GB INSTRUCTION MANUAL COMBIVERT F5/F6 Power Unit
Housing W 200…400 kW
250...500 kVA

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Table of Contents
Table of Contents
1. Preface............................................................................................................. 6
1.1 Information on special measures.......................................................................................6
1.2 Documentation.....................................................................................................................6
1.3 Validity and liability .............................................................................................................7
1.4 Copyright..............................................................................................................................7
1.5 Speciedapplication...........................................................................................................8
1.6 Product description.............................................................................................................8
1.7 Unitidentication ................................................................................................................9
1.8 Installation instructions ....................................................................................................10
1.8.1 Cooling systems ..................................................................................................................10
1.8.2 Control cabinet installation................................................................................................... 11
1.9 Safety and application notes ............................................................................................12
2. Technical Data .............................................................................................. 13
2.1 Operating conditions.........................................................................................................13
2.2 Technical data of the 400 V class .....................................................................................14
2.3 Dimensions and weights...................................................................................................15
2.3.1 Heat sink with cooling fan (wall mounted version)...............................................................15
2.3.2 Heat sink with cooling fan (through-mount version).............................................................16
2.3.3 Water-cooled inverter - wall mounted version .....................................................................17
2.3.4 Water-cooled heat sink (second version)- mounted version................................................18
2.3.5 Water-cooled inverter - through-mount version ...................................................................19
2.4 Terminal strips of the power circuit .................................................................................20
2.4.1 Mains input ..........................................................................................................................20
2.4.2 Motor output.........................................................................................................................22
2.4.3 Other terminals ....................................................................................................................23
2.5 Accessories........................................................................................................................25
2.5.1 Filter and chokes .................................................................................................................25
2.6 Connection Power Unit .....................................................................................................26
2.6.1 Mains and motor connection................................................................................................26
2.6.2 Selection of the motor cable ................................................................................................31
2.6.3 Connection of the motor ......................................................................................................31
2.6.4 Temperature detection T1, T2..............................................................................................33
2.6.4.1 Use of the temperature input in KTY mode .........................................................................34
2.6.4.2 Use of the temperature input in PTC mode .........................................................................34
2.6.5 Connection of a braking resistor ..........................................................................................35
2.6.5.1 Braking resistor without temperature monitoring .................................................................35
2.6.5.2 Braking resistor with over-heat protection and GTR7 monitoring (water-cooled) ................36
2.6.5.3 Braking resistor with over-heat protection and GTR7 monitoring (air-cooled).....................37

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Table of Contents
A. Annex A ......................................................................................................... 38
A.1 Overload characteristic.....................................................................................................38
A.2 Overload protection in the lower speed range ...............................................................38
A.3 Calculation of the motor voltage......................................................................................39
A.4 Maintenance .......................................................................................................................39
A.5 Storage ...............................................................................................................................39
A.5.1 Cooling circuit ......................................................................................................................40
B. Annex B ......................................................................................................... 41
B.1 Certication........................................................................................................................41
B.1.1 CE Marking ..........................................................................................................................41
B.1.2 UL Marking ..........................................................................................................................41
C. Annex C ......................................................................................................... 43
C.1 Installation of water-cooled units.....................................................................................43
C.1.1 Heat sink and operating pressure........................................................................................43
C.1.2 Materials in the cooling cicuit...............................................................................................43
C.1.3 Requirements on the coolant...............................................................................................44
C.1.4 Connection to the cooling system........................................................................................45
C.1.5 Coolant temperature and moisture condensation................................................................45
C.1.6 Coolantheatingdependingonpowerlossandowratewithwater....................................47
C.1.7 Typicallyfallofpressuredependingontherateofow .......................................................47
D. Annex D ......................................................................................................... 48
D.1 Changing the response threshold of the braking transistor .........................................48
List of tables
Table1: Unitidentication.......................................................................................................9
Table 2: Operating conditions ...............................................................................................13
Table 3: Technical data of the 400 V class............................................................................14
Table 4: Connection accessories..........................................................................................25
Table 5: Connection of the motor..........................................................................................31
Table 6: Temperature detection T1, T2 .................................................................................33
Table 7: Calculation of the motor voltage .............................................................................39
Table 8: Maintenance ...........................................................................................................39
Table 9: Storage ...................................................................................................................40
Table 10: Heat sink and operating pressure ...........................................................................43
Table 11: Materials in the cooling cicuit ..................................................................................44
Table 12: Requirements on the coolant ..................................................................................44
Table 13: Supply of temper coolant ........................................................................................46

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Table of Contents
Listofgures
Figure 1: Control cabinet installation...................................................................................... 11
Figure 2: Heat sink with cooling fan (wall mounted version) ..................................................15
Figure 3: Heat sink with cooling fan (through-mount version)................................................16
Figure 4: Water-cooled inverter - wall mounted version.........................................................17
Figure 5: Water-cooled heat sink (second version)- mounted version...................................18
Figure 6: Water-cooled inverter - through-mount version.......................................................19
Figure 7: View mains input ....................................................................................................20
Figure8: Mainsinput3-phase(B6-rectier)...........................................................................21
Figure9: Mainsinput3-phase(B6-rectier)...........................................................................21
Figure 10: Mains input DC without precharging .......................................................................21
Figure 11: Protective earth conductor connection....................................................................21
Figure 12: View motor output side ...........................................................................................22
Figure 13: Motor terminal strip X1B .........................................................................................22
Figure 14: Terminal strip for DC link and braking resistor X1C ................................................23
Figure 15: Terminal strip for temperature detection and braking transistor monitoring X1D ....23
Figure 16: Connection for shielding and protective earth conductor X1E ................................24
Figure 17: Terminal strip for external fan power supply X1F....................................................24
Figure 18: 3-phase COMBIVERT at 3-phase mains ................................................................26
Figure 19: 6-phase COMBIVERT at 3-phase mains ................................................................27
Figure 20: 6-phase COMBIVERT at 3-phase mains ................................................................28
Figure 21: 6-phase COMBIVERT at 6-phase mains ................................................................29
Figure 22: COMBIVERT at DC mains ......................................................................................30
Figure 23: Cross section of a shielded motor cable with tripartited protective earth conductor31
Figure 24: Motor connection in star connection .......................................................................32
Figure 25: Motor connection in delta connection .....................................................................32
Figure 26: Connection of a KTY sensor ...................................................................................34
Figure 27: Wiring example in PTC mode .................................................................................34
Figure 28: Intrinsically safe braking resistor without temperature monitoring ..........................35
Figure 29: Braking resistor with over-heat protection and GTR7 monitoring ..........................36
Figure 30: Braking resistor with over-heat protection without GTR7 monitoring......................37
Figure 31: Overload characteristic ...........................................................................................38
Figure 32: Overload protection in the lower speed range ........................................................38
Figure 33: Coolant heating.......................................................................................................47
Figure 34: Fall of pressure .......................................................................................................47
Figure 35: Changing the response threshold of the braking transistor ....................................48

6
Preface
1. Preface
The described hard- and software are developments of the KEB Automation KG. The en-
closed documents correspond to conditions valid at printing. Misprint, mistakes and technical
changes reserved.
1.1 Information on special measures
Theusedpictogramshavefollowingsignicance:
Danger Is used, when death or serious bodily injury may be the consequence
of non-observance of the measure.
Warning Is used, when bodily injury and/or substantial property damage may
be the consequence of non-observance of the measure.
Caution Is used, when property damage may be the consequence of non-ob-
servance of the measure.
Attention Is used, when noise sensitive or unrequested operation may be the
consequence of non-observance of the measure.
Info Is used, when a better or simpler result can be the consequence of the
measure.
For a special case the instructions can be supplemented by additional pictograms and text.
1.2 Documentation
Attention Documentation via www.keb.de
Prior to performing any work on the unit, it is absolutely necessary to down-
load and read the documentation, especially the safety precautions and in-
structions for use. Follow these steps to get the documentation:
Step 1 Read the material number (Mat.No.) from nameplate
Step 2
Input the material number at "www.keb.de => Service => Downloads" and
click "search".
Downloads
Search for specific material numbers
Please enter a comlete (11-digit) material number.
Search for:
search
15G6DCD3510
continued on the next page

7
Preface
Step 3
The entire documentation associated with the device will be displayed, in-
cluding the instruction manuals in German and English. If available, other
translations are also indicated. Make sure that the user understands the pro-
vided language.
Should you be unable to read or understand the documentation, do not
take any further steps. Please inform our support network for further
assistance.
Non-observance of the safety instructions leads to the loss of any liability claims. The safety
andwarninginstructionsspeciedinthismanualdonotlayclaimoncompleteness.Thislist
is not exhaustive.
1.3 Validity and liability
The use of our units in the target products is beyond of our control and therefore exclu-
sively 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 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.
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 mod-
ied.
Danger by tamper from unauthorized personnel
Unauthorised opening and tampering may lead to death, bodily injury, prop-
ertydamageandmalfunctions.Modicationorrepairispermittedonlyby
KEB authorized personnel. Infringement will annul the liability for resulting
consequences.
Thesuspensionofliabilityisespeciallyvalidalsoforoperationinterruptionloss,lossofprot,
data loss or other damages. The disclaimer will void the warranty. 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 arise which
are not treated in detail in the documentation, you can request the required information from
the local agency of the company KEB Automation KG.
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.

8
Preface
KEB®, COMBIVERT®, COMBICONTROL®and COMBIVIS®are registered trademarks of KEB
Automation KG.
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
parties. 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 semiconductors and components used by KEB are developed and designed for 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 technical data leads to
the loss of any liability claims.
Units with safety function are limited to a service life of 20 years. After this time the unit must
be replaced.
1.6 Product description
This instruction manual describes the power circuits of the following units:
Unit type: Frequency inverter
Series: COMBIVERT F5/F6
Power range: 200…400 kW
Housing size: W
Version: Heat sink with cooling fan (standard)
Heat sink with cooling fan (through-mount version)
Water cooling (mounted version) Water cooling (through-mount version)
Features of the power circuits :
• only slight switching losses due to IGBT
• low noise development due to high switching frequency
• extensive safety device for current, voltage and temperature
• voltage and current monitoring in static and dynamic operation
• conditionally short circuit proof and earth-fault proof
• hardware current limit
• integrated cooling fan

9
Preface
1.7 Unitidentication
28 . F5. A 0 W - 9 0 0 A
Cooling
0 Heat sink with cooling fan
at special/customer unit
consecutive numbering
AHeat sink with cooling fan (var-
nished)
C Water cooling (varnished)
D Through-mount version
H Water cooling (second version)
Encoder interface
0 none at special/customer unit
consecutive numbering
Switching frequency; short time current limit; overcurrent limit
02 kHz; 125 %; 150 % at special/customer unit
specialmodicationor
customer ID
14 kHz; 125 %; 150 %
Inputidentication
5400 V DC N400 V DC (US unit)
93ph 400 VAC VSpecial-/customer unit 400 V DC
L 400 VAC or AC/DC (US unit) Y Special-/customer unit 400 VAC or
AC/DC
Housing type W
Accessories (A, B and D with safety relay)
0 none A such as 0, but with safety relay
1 Braking transistor B such as 1, but with safety relay
3Braking transistor and integrat-
edlter D such as 3, but with safety relay
Control type
A APPLICATION
E MULTI - SCL
G GENERAL (controlled frequency inverter)
HMULTI - ASCL
MMULTI(regulated,eld-orientedfrequencyinverterforthree-phase
asynchronous motors)
Series F5/F6
Inverter size
Table 1: Unit identication

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Installation instructions
1.8 Installation instructions
1.8.1 Cooling systems
The KEB COMBIVERT F5/F6 is available for different cooling systems:
Heat sink with cooling fan (mounted version)
The standard version is delivered with heat sink and cooling fan.
Special versions
The dissipation of power loss must be guaranteed by the machine builder.
Flat rear
There is no heat sink at this version. The unit must be mounted on an appropriate ground for
heat dissipation.
Water cooling
This version is dimensioned for the connection to an available cooling system. The dissipa-
tion of the power loss must be ensured by the machine builder. In order to avoid moisture
condensation, the minimum inlet temperature may not decrease the ambient temperature.
The max. inlet temperature may not exceed 40°C. No aggressive coolant shall be used.
Measures against contamination and calcination must be done externally. We recommend a
pressure of 4 bar on the cooling system.
Convection (through-mount version)
In this version the heat sink is placed externally with a cutout in the control cabinet.
Warning Hot surface
Heat sinks can reach temperatures, which can cause burns when touching. If
in case of structural measures a direct contact cannot be avoided, a warning
notice "hot surface" must be mounted at the machine.