KEBCO COMBILINE Z1I05-1001 Series User manual

COMBILINE Z1I05
INSTRUCTIONS FOR USE | INSTALLATION SINUS EMC FILTER
Translation of the original manual
Document 20146892 EN 02

3
PREFACE
Preface
The described hard- and software are developments of the KEB Automation KG. The
enclosed documents correspond to conditions valid at printing. Misprint, mistakes and
technical changes reserved.
Signal words and symbols
Certain operations can cause hazards during the installation, operation or thereafter.
There are safety informations in the documentation in front of these operations. Security
signs are located on the device or machine. A warning contains signal words which are
explained in the following table:
DANGER Dangerous situation, which will cause death or serious injury in case of
non-observance of this safety instruction.
WARNING Dangerous situation, which may cause death or serious injury in case of
non-observance of this safety instruction.
CAUTION Dangerous situation, which may cause minor injury in case of non-ob-
servance of this safety instruction.
NOTICE Situation, which can cause damage to property in case of non-obser-
vance.
RESTRICTION
Is used when certain conditions must meet the validity of statements or the result is
limited to a certain validity range.
Is used when the result will be better, more economic or trouble-free by following
these 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. Fur-
therinformationisprovidedinchapter"Certication".
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
Through multiple applications not every imaginable case has been taken into ac-
count. If you require further information or if problems occur which are not treated de-
tailed in the documentation, you can request the necessary information via the local
KEB Automation KG 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 Automation KG 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.........................................................................................................................................7
List of Tables ..........................................................................................................................................8
Standards for EMC components...........................................................................................................9
Product standards:.........................................................................................................................9
Basic standards:.............................................................................................................................9
General standards:.........................................................................................................................9
1 Basic Safety Instructions............................................ 10
1.1 Target group...................................................................................................................................10
1.2 Transport, storage and proper use .............................................................................................. 10
1.3 Installation...................................................................................................................................... 11
1.4 Electrical connection ....................................................................................................................12
1.5 Start-up and operation ..................................................................................................................12
1.6 Repair .............................................................................................................................................13
1.7 Disposal..........................................................................................................................................13
2 Product Description .................................................... 14
2.1 Intended use ..................................................................................................................................14
2.2 Improper use..................................................................................................................................14
2.3 Product features ............................................................................................................................14
3 Technical Data.............................................................. 15
3.1 Operating conditions ....................................................................................................................15
3.1.1 IP protection classes ..........................................................................................................15
3.1.2 Climatic conditions .............................................................................................................15
3.1.3 Mechanical ambient conditions ..........................................................................................16
3.1.4 Chemical/mechanical active substances............................................................................16
3.1.5 Electrical operating conditions............................................................................................16
3.1.5.1 Equipmentclassication..................................................................................................16
3.2 Electrical data ................................................................................................................................17
3.2.1 Electrical equivalent circuit diagram...................................................................................17
4 Installation and Connection........................................ 18
4.1 Schematic diagram........................................................................................................................18

6
TABLE OF CONTENTS
4.1.1 Motor operation ..................................................................................................................19
4.1.2 AIC operation ...................................................................................................................20
4.1.2.1 Usingthesine-wavelterinconjunctionwithAIC(ActiveInfeedController) ..................21
4.2 Connection temperature measurement and fan.........................................................................21
4.2.1 Rated data of the integrated fans.......................................................................................22
4.2.2 Overtemperature shutdown................................................................................................22
4.3 Connection power terminals ........................................................................................................23
4.3.1 Filter type 0D......................................................................................................................23
4.3.2 Filter type 0H and 0L..........................................................................................................24
4.3.3 Filter type 0P and 0S..........................................................................................................25
4.3.4 Filter type 0X and 0Y..........................................................................................................26
4.3.4.1 Alternative connection option ..........................................................................................27
4.4 Transport ........................................................................................................................................ 28
4.5 Mechanical construction ..............................................................................................................29
4.5.1 Dimensionsltertype0D ...................................................................................................29
4.5.2 Dimensionsltertype0Hand0L .......................................................................................30
4.5.3 Dimensionsltertype0Pand0S .......................................................................................31
4.5.4 Dimensionsltertype0Xand0Y .......................................................................................32
4.6 Control cabinet installation ..........................................................................................................33
4.6.1 Installationdistancesofthesine-waveEMClters ............................................................33
4.6.1.1 Mounting instructions for control cabinet installation.......................................................33
4.6.2 EMC conform installation in the control cabinet .................................................................34
4.7 Fan replacement ............................................................................................................................35
5 Mode of Action............................................................. 36
5.1 Sine EMC lter in motor operation .............................................................................................. 36
5.1.1 ModeofactionsineEMClter ...........................................................................................36
5.1.2 Measurement of the emitted interference with unshielded motor lines ..............................38
5.2 Active Infeed Controller operation...............................................................................................39
5.2.1 Comparison of mains harmonics........................................................................................39
5.2.2 Modeofactionsine-waveEMClterinAIC .......................................................................40
6 Certications................................................................ 41
6.1 CE-Marking.....................................................................................................................................41
7 Revision History .......................................................... 42

7
LIST OF FIGURES
List of Figures
Figure1: ElectricalequivalentcircuitdiagramofthesineEMClters ............................................17
Figure 2: Schematic diagram ..........................................................................................................18
Figure 3: Motor operation................................................................................................................19
Figure 4: Complete circuitry with additional elements.....................................................................20
Figure5: Connectionprincipleltertype0D ...................................................................................21
Figure6: Connectionprincipleltertypes0H...0Y..........................................................................21
Figure 7: Filter type 0D....................................................................................................................23
Figure 8: Filter type 0H and 0L........................................................................................................24
Figure 9: Filter type 0P and 0S .......................................................................................................25
Figure 10: Filter type 0X and 0Y .......................................................................................................26
Figure 11: Alternative connection option...........................................................................................27
Figure 12: Transport..........................................................................................................................28
Figure13: Dimensionsltertype0D.................................................................................................29
Figure14: Dimensionsltertype0Hand0L.....................................................................................30
Figure15: Dimensionsltertype0Pand0S.....................................................................................31
Figure16: Dimensionsltertype0Xand0Y.....................................................................................32
Figure17: Installationdistancesofthesine-waveEMClters..........................................................33
Figure 18: EMC conform installation in the control cabinet...............................................................34
Figure 19: Fan replacement..............................................................................................................35
Figure 20: Voltage/current at the drive converter output ..................................................................36
Figure21: Voltage/currentwithsine-waveEMClter ......................................................................36
Figure 22: Voltage U against PE and phase current at the drive converter......................................37
Figure23: VoltageUagainstPEwithsine-waveEMClter..............................................................37
Figure 24: Measurement of the emitted interference with unshielded motor lines............................38
Figure 25: Comparison of mains harmonics in % with the same motor power .................................39
Figure26: DriveconverterwithB6rectierand4%ukchoke ..........................................................39
Figure 27: Active Infeed Controller....................................................................................................39
Figure28: AICwithchokelteringPhagainstPE.............................................................................40
Figure29: AICwithsine-waveEMClterPhagainstPE..................................................................40
Figure30: AICchokelteringUKagainstPE ...................................................................................40
Figure31: AICwithsine-waveEMClterUKagainstPE .................................................................40

8
LIST OF TABLES
List of Tables
Table 1: IP protection classes........................................................................................................15
Table 2: Climatic conditions...........................................................................................................15
Table 3: Mechanical ambient conditions........................................................................................16
Table 4: Chemical/mechanical active substances .........................................................................16
Table5: Equipmentclassication ..................................................................................................16
Table 6: Electrical data ..................................................................................................................17
Table7: InstallationofacompleteAIClter...................................................................................21
Table 8: Voltage supply of the integrated fans...............................................................................22
Table 9: Rated data NC contact.....................................................................................................22
Table10: Lengthoftheconnectioncablesltertype0D.................................................................29
Table11: Lengthoftheconnectioncablesltertype0Hand0L.....................................................30
Table12: Lengthoftheconnectioncablesltertype0Pand0S.....................................................31
Table13: Lengthoftheconnectioncablesltertype0Xand0Y.....................................................32
Table 14: Mounting instructions for control cabinet installation .......................................................33
Table 15: Part numbers of the fans..................................................................................................35

9
STANDARDS FOR EMC COMPONENTS
Standards for EMC components
Product standards:
EN61558-1 Safety of transformers, reactors, power supply units and combinations thereof -
Part 1: General requirements and tests (IEC 96/449/CD:2015)
EN 61558-2-20 Safety of transformers, reactors, power supply units and combinations thereof
- Part 2-20: Particular requirements and tests for small reactors (IEC 61558-2-
20:2010); German version EN 61558-2-20:2011
EN61800-5-1 Adjustable speed electrical power drive systems - Part 5-1: Safety requirements
- Electrical, thermal and energy (IEC 61800-5-1); German version EN 61800-5-1
UL61800-5-1 American version of the EN61800-5-1 with „National Deviations“
Basic standards:
EN60529 Degrees of protection provided by enclosures (IP Code) (IEC 60529)
EN60664-1 Insulation coordination for equipment within low-voltage systems Part 1: Princi-
ples, requirements and tests (IEC 60664-1)
EN60721-3-1 Classicationofenvironmentalconditions-Part3-1:Classicationofgroupsof
environmental parameters and their severities - Section 1: Storage (IEC 60721-
3-1); German version EN 60721-3-1
EN60721-3-2 Classicationofenvironmentalconditions-Part3:Classicationofgroupsof
environmental parameters and their severities - Section 2: Transportation and
handling (IEC 104/670/CD)
EN60721-3-3 Classicationofenvironmentalconditions-Part3:Classicationofgroupsof
environmental parameters and their severities; section 3: Stationary use at
weatherprotected locations; Amendment A2 (IEC 60721-3-3); German version
EN 60721-3-3
General standards:
DGUV regulation 3 Electrical installations and equipment
DNVGL-CG-0339 Environmentaltestspecicationforelectrical,electronicandprogrammable
equipment and systems
DINIEC60364-5-54 Low-voltage electrical installations - Part 5-54: Selection and erection of
electrical equipment - Earthing arrangements, protective conductors and protec-
tive bonding conductors (IEC 64/1610/CD)
EN60204-1 Safety of machinery - electrical equipment of machines Part 1: General require-
ments (VDE0113-1, IEC 44/709/CDV)
EN61373 Railway applications - Rolling stock equipment - Shock and vibration tests (IEC
61373); German version EN 61373
ISO 4762 Hexagon socket head cap screws

10
BASIC SAFETY INSTRUCTIONS
1.2 Transport, storage and proper use
Thetransport iscarried outby qualiedpersons inaccordancewith theenvironmen-
talconditionsspeciedinthismanual.Thefiltersshallbeprotectedagainstexcessive
strains.
ESD
The lters contain electrostatic sensitive components.
►Avoid contact.
►Wear ESD-protective clothing.
Donotstorethelters
• in the environment of aggressive and/or conductive liquids or gases.
• with direct sunlight.
• outsidethespeciedenvironmentalconditions.
1 Basic Safety Instructions
The COMBIVERT is designed and constructed in accordance with state-of-the-art tech-
nology and the recognised safety rules and regulations However, the use of such de-
vices may cause functional hazards for life and limb of the user or third parties, or dama-
ges to the system and other material property.
The following safety instructions have been created by the manufacturer for the area of
electric drive technology. They can be supplemented by local, country- or application-
specic safety instructions. This list is not exhaustive. Non-observance of the safety
instructions by the customer, user or other third party leads to the loss of all resulting
claims against the manufacturer.
NOTICE Hazards and risks through ignorance.
►Read the instructions for use !
►Observe the safety and warning instructions !
►If anything is unclear, please contact KEB Automation KG !
1.1 Target group
This instruction manual is determined exclusively for electrical personnel. Electrical per-
sonnelforthepurposeofthisinstructionmanualmusthavethefollowingqualications:
• Knowledge and understanding of the safety instructions.
• Skills for installation and assembly.
• Start-up and operation of the product.
• Understanding of the function in the used machine.
• Detection of hazards and risks of the electrical drive technology.
• Knowledge of DIN IEC 60364-5-54.
• Knowledge of national safety regulations.