KEBCO COMBIVERT G6 Bedienungsanleitung

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

GB - 4

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

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 %

GB - 10

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)

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