KEBCO COMBIVERT G6 User manual

COMBIVERT
Original Manual
Mat.No. Rev.
00G6NEL-0C00 1E
GB Installation Manual Housing C
Power Unit Power 5.5…11 kW

GB - 3
Table of Contents
1. Preface..............................................................................................................5
1.1 General ................................................................................................................................. 5
1.2 Validity and liability ............................................................................................................. 5
1.3 Copyright.............................................................................................................................. 6
1.4 Speciedapplication........................................................................................................... 6
1.5 Product description............................................................................................................. 6
1.6 Part Code.............................................................................................................................. 7
1.7 Safety and operating instructions...................................................................................... 8
2. Technical Data .................................................................................................9
2.1 Operating conditions........................................................................................................... 9
2.2 Technical data G6 400V class........................................................................................... 10
2.3 Mechanical installation ..................................................................................................... 12
2.3.2 Dimensions and weights...................................................................................................... 12
2.3.3 Control cabinet installation................................................................................................... 13
3. Installation and Connection .........................................................................14
3.1 Overview of the COMBIVERT G6...................................................................................... 14
3.2 Connection of the power unit ........................................................................................... 15
3.2.1 Connection of the voltage supply......................................................................................... 15
3.2.1.1 Wiring instructions ............................................................................................................... 15
3.2.1.2 AC supply 400V / 3-phase ................................................................................................... 16
3.2.1.3 Line terminal strip X1A......................................................................................................... 16
3.2.1.4 Supply cable ........................................................................................................................ 16
3.2.1.5 Connection at DC voltage supply ........................................................................................ 17
3.2.1.6 Terminal strip X1B DC connection ....................................................................................... 17
3.2.2 Connection of the motor ...................................................................................................... 17
3.2.2.1 Selection of the motor cable ................................................................................................ 17
3.2.2.2 Motor line length at operation with DC voltage .................................................................... 17
3.2.2.3 Cable-fed disturbances depending on the motor line length at AC supply .......................... 18
3.2.2.4 Motor cable cross-section.................................................................................................... 18
3.2.2.5 Interconnection of the motor ................................................................................................ 18
3.2.2.6 Terminal strip X1B motor connection ................................................................................... 18
3.2.2.7 Wiring of the motor .............................................................................................................. 19
3.2.3 Connection of a braking resistor .......................................................................................... 19
3.2.3.1 Terminal strip X1B connection braking resistor.................................................................... 19
3.2.3.2 Wiring of an intrinsically safe braking resistor...................................................................... 19
3.2.3.3 Using a non-intrinsically safe braking resistor ..................................................................... 19
3.2.4 Connection of a Temperature Detection .............................................................................. 20
3.2.4.1 Temperature detection terminals T1, T2 .............................................................................. 20
3.2.4.2 Terminal strip X1C temperature detection ........................................................................... 20
3.2.4.3 Use of the temperature input in PTC mode ......................................................................... 21
3.2.5 Final test informations of the machines/systems which are provided with frequency
inverters according to EN 60204 Part 1 of 2007 .................................................................. 21
3.2.5.1 Voltage test (in accordance with EN60204-1 chapter 18.4)................................................. 21
3.2.5.2 Isolation resistance measurement (in accordance with EN60204-1 chapter 18.3).............. 21

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Table of Contents
Annex A .....................................................................................................................22
A.1 Calculation of the motor voltage...................................................................................... 22
A.2 Maintenance ....................................................................................................................... 22
A.3 Shut down .......................................................................................................................... 23
A.3.1 Storage ................................................................................................................................ 23
Annex B.....................................................................................................................24
B.1 Certication........................................................................................................................ 24
B.1.1 CE-Marking.......................................................................................................................... 24
B.1.2 UL Marking........................................................................................................................... 24
B.2 Further informations and documentation ....................................................................... 26

GB - 5
Preface
1. Preface
1.1 General
First we would like to welcome you as a customer of KEB and congratulation to the purchase
of this product. You have decided for a product on highest technical niveau.
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 tech-
nical changes reserved.
The instruction manual must be made available to the user. Prior to performing any work on
the unit the user must familiarize himself with the unit. This especially applies to the know-
ledge and observance of the following safety and warning indications. The used pictograms
have following signicance:
Danger Is used when the life or health of the user is in danger or con-
siderable damage to property can occur.
Warning
Caution
Attention Is used when a measure is necesary for safe and disturbance
free operation.
observe at
all costs
Information Is used, if a measure simplies the handling or operation of
the unit.
Aide
Tip
Non-observance of the safety instructions leads to the loss of any liability claims. This list is
not exhaustive.
1.2 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 responsibili-
ty. 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 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.

GB - 6
Preface
If single regulations should be or become void, invalid or impracticable, the effectivity of all
other regulations or agreements is not affected.
1.3 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.
1.4 Speciedapplication
The COMBIVERT G6 serves exclusively for the control and regulation of three-phase motors.
The operation of other electric consumers is prohibited and can lead to the destruction of the
unit. Frequency inverter are components which are intended for the installation in electric
systems or machines.
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 ma-
chine builder. The operation of our products outside the indicated limit values of the technical
data leads to the loss of any liability claims.
1.5 Product description
The product family COMBIVERT G6 has been developed for the universal use at open-loop
three-phase drives. The units are equipped with an integrated EMC lter. This manual descri-
bes only the power circuits.
This accompanying instruction manual contains only information for the installa-
tion and connection of the power circuit KEB COMBIVERT G6.
Further parts of the installation manual are required depending on the ordered
type:
• Connection and adjustments of the control
• Safety function STO
• Safe digital output for f=0Hz
A manual with general safety requirements and EMC conform installation is
available under www.keb.de.

GB - 7
Preface
1.6 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
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
E IO-link
F EtherCAT
GPronet
G6 unit type
Inverter size

GB - 8
Safety Instructions
1. General
In operation, drive converters, depending on their degree
of protection, may have live, uninsulated, and possibly
also moving or rotating parts, as well as hot surfaces.
In case of inadmissible removal of the required covers,
of improper use, wrong installation or maloperation, there
is the danger of serious personal injury and damage to
property.
For further information, see documentation.
All operations serving transport, installation and commis-
sioning as well as maintenance are to be carried out by
skilled technical personnel (Observe IEC 364 or CENELEC
HD 384 or DIN VDE 0100 and IEC 664 or DIN/VDE 0110
and national accident prevention rules!).
For the purposes of these basic safety instructions, „skilled
technical personnel“ means persons who are familiar with
the installation, mounting, commissioning and operation
of the product and have the qualications needed for the
performance of their functions.
2. Intended use
Drive converters are components designed for inclusion in
electrical installations or machinery.
In case of installation in machinery, commissioning of the
drive converter (i.e. the starting of normal operation) is
prohibited until the machinery has been proved to conform
to the provisions of the directive 2006/42/EC (Machine-
ry Safety Directive - MSD). Account is to be taken of EN
60204.
The drive converters meet the requirements of the Low-
Voltage Directive 2006/95/EC. They are subject to the har-
monized standards of the series EN 61800-5-1.
The technical data as well as information concerning the
supply conditions shall be taken from the rating plate and
from the documentation and shall be strictly observed.
3. Transport, storage
The instructions for transport, storage and proper use shall
be complied with.
The climatic conditions shall be in conformity with EN
61800-5-1 .
4. Installation
The installation and cooling of the appliances shall be in
accordance with the specications in the pertinent docu-
mentation.
The drive converters shall be protected against excessive
strains. In particular, no components must be bent or iso-
lating distances altered in the course of transportation or
handling. No contact shall be made with electronic compo-
nents and contacts.
1.7 Safety and operating instructions
Safety and operating instructions for drive converters
(in conformity with the Low-Voltage Directive 2006/95/EC)
Drive converters contain electrostatic sensitive compo-
nents which are liable to damage through improper use.
Electric components must not be mechanically damaged
or destroyed (potential health risks).
5. Electrical connection
When working on live drive converters, the applicable nati-
onal accident prevention rules (e.g. VBG 4) must be com-
plied with.
The electrical installation shall be carried out in accordance
with the relevant requirements (e.g. cross-sectional areas
of conductors, fusing, PE connection). For further informa-
tion, see documentation.
Instructions for the installation in accordance with EMC
requirements, like screening, earthing, location of lters
and wiring, are contained in the drive converter documen-
tation. They must always be complied with, also for drive
converters bearing a CE marking. Observance of the limit
values required by EMC law is the responsibility of the ma-
nufacturer of the installation or machine.
6. Operation
Installations which include drive converters shall be equip-
ped with additional control and protective devices in ac-
cordance with the relevant applicable safety requirements,
e.g. act respecting technical equipment, accident preven-
tion rules etc.. Changes to the drive converters by means
of the operating software are admissible.
After disconnection of the drive converter from the voltage
supply, live appliance parts and power terminals must not
be touched immediately because of possibly energized
capacitors. In this respect, the corresponding signs and
markings on the drive converter must be respected.
During operation, all covers and doors shall be kept
closed.
7. Service and maintenance
The manufacturer’s documentation shall be followed.
KEEP SAFETY INSTRUCTIONS IN A SAFE PLACE!

GB - 9
Technical Data
2. Technical Data
2.1 Operating conditions
Standard Standard/
class
Instructions
Denition acc.
EN 61800-2 Inverter-product standard: Ratedspecications
EN 61800-5-1 Inverter-product standard: General safety
EN 61800-5-2 Inverter-product standard: Functional safety
Site altitude
max. 2000 m above sea level
With site altitudes over 1000 m a derating of 1% per
100 m must be taken into consideration.
Ambient conditions during operation
Climate Temperature EN 60721-3-3 3K3
extended to -10…45 °C
With temperature over 45°C to max. 55°C a derating of
5 % per 1 K must be taken into consideration.
Humidity 3K3 5…85 % (without condensation)
Mechanical Vibration
Track EN50155 max. amplitude of a vibration 1 mm (5…13Hz)
max. acceleration amplitude 7 m/s² (13…100Hz)
1 m/s² (100…200 Hz)
Germ. Lloyd Part 7-3
Contamination Gas EN 60721-3-3 3C2
Solids 3S2
Ambient conditions during transport
Climate Temperature
EN 60721-3-2
2K3
Humidity 2K3 (without condensation)
Mechanical Vibration 2M1 15 m/s² (200…500 Hz)
Surge 2M1 50 g/30 ms; drop from 0.25 m height
Contamination Gas 2C2
Solids 2S2
Ambient conditions for the storage
Climate Temperature
EN 60721-3-1
1K4
Humidity 1K3 (without condensation)
Contamination Gas 1C2
Solids 1S2
Type of protection EN 60529 IP20
Environment IEC 664-1 Pollution degree 2
Denition acc. EN 61800-3 Inverter-product standard: EMC
EMC emitted interference
Cable-based interferences – C1/C2 see chapter 3.2.2.3
Radiated interferences – C2
Interference immunity
Static discharges EN 61000-4-2 8 kV
4 kV
AD (air discharge)
CD (contact discharge)
Burst - Ports for process measu-
rement control lines and signal
interfaces
EN 61000-4-4 1 kV tested with 2 kV
Burst - Power ports EN 61000-4-4 2 kV tested with 4 kV
Surge - Power ports EN 61000-4-5 1 kV
2 kV
Phase-phase
Phase-ground
Immunity to conducted disturban-
ces, induced by radio-frequency
elds
EN 61000-4-6 10 V 0.15-80 MHz
Electromagnetic elds EN 61000-4-3 10 V/m
Voltage variation /
voltage drop EN 61000-2-1 +10 %, -15 % 90 %
Voltage unsymmetries /
Frequency changes EN 61000-2-4 3 % 2 %

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Technical Data
2.2 Technical data G6 400V class
Inverter size 13 14 15
Housing size C
Phases 3
Output rated power SA[kVA] 8.3 11 17
Max. rated motor power Pmot [kW] 5.5 7.5 11
Output rated current IN[A] 12 16.5 24
Max. short time current IHSR 1) [%] 180 180 150
Over current IOC 1) [%] 216 216 180
Maximum current 0Hz/corner frequency fd at fS=4 kHz If0/Ifd 1) [%] 100/180 100/180 100/180
Maximum current 0Hz/corner frequency fd at fS=8 kHz If0/Ifd 1) [%] 100/180 70/160 70/150
Maximum current 0Hz/corner frequency fd at fS=16 kHz If0/Ifd 1) [%] 60/150 – –
rated frequency fd [Hz] 6
Input rated current Iin [A] 17 23 31
Max. permissible main fuse type gG [A] 25 25 35
Rated switching frequency fSN 2) [kHz] 8 4 4
Max. switching frequency fSmax 2) [kHz] 16 8 8
Power loss at nominal operating PD3) [W] 210 220 285
Power loss at DC supply PDdc [W] 180 180 230
Power loss standby (nOP) PDnop [W] 10 10 11
Power loss control (separated supply) PDsep [W] 2
Max. heat sink temperature THS [°C] 82
Temperature for derating the switching frequency Tdr 4) [°C] 75
temperature for uprating the switching frequency Tur 4) [°C] 70
Min. braking resistor RBmin [Ω] 39
Max. braking current IBmax [A] 21.5
Input rated voltage UN5) [V] 400 (UL: 480)
Input voltage range Uin [V] 305…528 ±0
Input voltage range at DC supply Uindc [V] 420…746 ±0
Mains frequency FN[Hz] 50 / 60 ±2
Output voltage UA6) [V] 3 x 0…Umains
Output frequency FA2) [Hz] 0…400 (fs=4 kHz)
0…800 (fs=8 kHz)
minimum waiting period between two switch-on procedures [min] 5
1) The values refer percentage to the output rated current IN
2) The output frequency is to be limited in such way that 1/10 of the switching frequency is not exceeded.
3) Rated operation corresponds to UN=400 V; fSN; fA=50 Hz (typically value)
4) On reaching the temperature Tdr the switching frequency is step down. The switching frequency is increased again on cooling down to temperature
Tur.
5) At rated voltages > 460 V multiply the rated current with factor 0.86
6) The voltage at the motor is dependent on the series-connected units and on the control method (example see chapter A.1 in the annex)
The technical data are for 2/4-pole standard motors. With other pole numbers the inverter must be
dimensioned onto the motor rated current. Contact KEB for special or medium frequency motors.
The service life of the frequency inverter with intermediate voltage circuit depends on the current load
of the electrolytic capacitors in the intermediate circuit. The use of mains chokes can increase the
service life of the condensators to a considerable extent, especially when connecting to „hard“ power
systems or when under permanent drive load (continuous duty). For continuous duty (S1) drives with
a medium duty of >60%, KEB provided the use of mains chokes with a terminal voltage (Uk) of 4%.
The term "hard" power system means that the nodal point power (SNet) of the mains is very high (>>
200) compared to the output rated power of the inverter (SA).
k = SNet 2 MVA (supply transformer) –––– >> 200 e.g. k = ––––––––––––––––––––– = 303 ––> Choke required
SA6.6 kVA (12.F5)