KEB COMBIVERT F5 Series Instructions For Use Manual Download Page 70

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REVISION HISTORy

11 Revision History

Version

Date

Description

2016-10 Completion Pre-series

2018-01 Changeover to new KEB-ci; general changes

2019-02

Certified version included, WEEE registration added; editorial changes

2020-10 Changing the term from AFE to AIC; editorial changes

Summary of Contents for COMBIVERT F5 Series

Page 1: ...COMBIVERT F5 INSTRUCTIONS FOR USE INSTALLATION ACTIVE INFEED CONTROLLER Translation of the original manual Document 20132138 EN 03...

Page 2: ......

Page 3: ...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 w...

Page 4: ...well as any user specific 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...

Page 5: ...ions 14 1 1 Target group 14 1 2 Transport storage and proper use 14 1 3 Installation 15 1 4 Electrical connection 16 1 4 1 EMC compatible installation 17 1 4 2 Voltage test 17 1 4 3 Insulation measure...

Page 6: ...4 1 Use of the temperature input in KTY mode 41 6 4 2 Use of the temperature input in PTC mode 41 6 5 Input and pre charging circuits 42 6 6 Circuit examples 43 6 6 1 Instructions to the following cir...

Page 7: ...9 1 Dimensioning instructions 58 9 2 Technical data of COMBIVERT drive converters 59 9 3 Technical data of the COMBIVERT F5 AIC devices 61 10 Cooling System 62 10 1 Installation of liquid cooled devic...

Page 8: ...t external power supply 51 Figure 18 Digital outputs 51 Figure 19 Relay outputs 52 Figure 20 Analog outputs 52 Figure 21 Voltage output 52 Figure 22 Operation with digital operator 53 Figure 23 Passwo...

Page 9: ...inet installation 34 Table 15 Description of the input terminals at the drive converter 35 Table 16 Cross sections and tightening torques of the terminals 39 Table 17 Wiring example in PTC mode 42 Tab...

Page 10: ...technology EN 61508 1 7 for the size of error probability 0V Earth potential free common point 1ph 1 phase mains 3ph 3 phase mains AC AC current or voltage AFE From 07 2019 AIC replaces the pre vious...

Page 11: ...with 8 lines SCL Synchronous sensorless closed loop SELV Safety Extra Low Voltage 60V SIL The security integrity level is a measure for quantifying the risk reduction Term used in the safety technolog...

Page 12: ...ements and tests IEC 60664 1 EN60721 3 1 Classification of environmental conditions Part 3 1 Classification of groups of environmental parameters and their severities Section 1 Storage IEC 60721 3 1 G...

Page 13: ...rs IEC 64 1610 CD DIN VDE 0100 729 Low voltage electrical installations Part 7 729 Requirements for special installations or locations Operating or maintenance gangways IEC 60364 7 729 2007 modified G...

Page 14: ...ct 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 followin...

Page 15: ...omponents are bent and or isolation distances are changed The device must not be put into operation in case of mechanical defects Non compliance with the applicable standards Do not allow moisture or...

Page 16: ...operation please pay attention to the following instructions The electrical installation shall be carried out in accordance with the relevant re quirements Cable cross sections and fuses must be dime...

Page 17: ...ation Observance of the limit values required by EMC law is the responsibility of the customer Notes on EMC compatible installation can be found here www keb de fileadmin media Manuals emv 0000neb0000...

Page 18: ...res e g limit switch that are independent of the drive converter Secure motors against automatic restart CAUTION High temperatures at heat sink and coolant Burning of the skin Cover hot surfaces safe...

Page 19: ...ghten if necessary Check system for loose screws and plugs and tighten if necessary Clean drive converter from dirt and dust deposits Pay attention especially to coo ling fins and protective grid of t...

Page 20: ...agreement has been made between the customer and KEB or no deviating mandatory legal regulation exists KEB products marked in this way can be returned Company and keyword to the return point can be t...

Page 21: ...ver optional possible as protection in case of mains power failure Supplies single KEB drive converter or after consulting via DC bus connection Active power factor correction PFC and cos phi control...

Page 22: ...ilder The operation of our products outside the indicated limit values of the technical data leads to the loss of any liability claims Restriction If the KEB COMBIVERT F5 is used in machines which wor...

Page 23: ...ng system Design system 1 Standard F5 Plus E Stainless steel Serial number for special version 0 Standard S Certified according to CEI 0 21 and VDE AR N 4105 Special version Y Special version Housing...

Page 24: ...3 3 3K3 5 40 C extended to 10 45 C With temperature over 45 C to max 55 C a derating of 5 per 1K must be taken into con sideration Coolant inlet tem perature Air 0 40 C 10 45 C Water 5 40 C Relative...

Page 25: ...s Vibration limits EN 60721 3 3 3M4 Vibration amplitude 3 5mm 2 9Hz Acceleration amplitude 10m s 9 200Hz EN 61800 5 1 Vibration amplitude 0 075mm 10 57Hz Acceleration amplitude 10m s 57 150Hz Shock li...

Page 26: ...ces EN 61800 3 C2 Interference immunity Standard Level Notes Static discharges EN 61000 4 2 8kV 4kV AD air discharge CD contact discharge Burst Ports for process measurement control lines and signal i...

Page 27: ...urrent cut off E OC IOC 216 180 180 180 180 216 Overload current E OL 30s IOL 180 150 150 150 150 180 Max permissible DC link capacity Cext mF 50 50 Max AIC charging current 6 5 IAIC A 29 6 57 29 226...

Page 28: ...150 125 125 125 125 Max permissible DC link capacity Cext mF 45 43 40 35 35 Max AIC charging current 6 5 IAIC A 226 226 226 98 98 Max external charging current 6 5 Iext A Max permissible total chargi...

Page 29: ...missible DC link capacity Cext mF 150 6 250 6 150 6 250 6 Max AIC charging current 6 5 IAIC A 98 6 145 6 98 6 146 6 Max external charging current 6 5 Iext A Max permissible total charging current 6 5...

Page 30: ...CL filters are required for the characteristic of sinusoidal currents They filter the switching frequency of the drive converter The basic assembly consists of two inductors and capacitors LCL filter...

Page 31: ...er 22 R 22Z1I04 1000 8 16 115 24H6J4F 1001 22Z1H04 1000 26 U 4 16 250 26Z1K04 1000 26Z1H04 1000 29 P 29Z1I04 1000 4 16 460 29Z1K04 1000 29Z1H04 1000 Table 9 Common mode filter Sine wave EMC filters wi...

Page 32: ...00 4 x 0090249 5659 129 x 60 750 400 33 2 x 29U420W 5W00 6 x 0090249 5659 129 x 60 750 400 34 2 x 29U420W 5W00 4 x 0090249 5689 129 x 75 750 630 38 3 x 29U420W 5W00 6 x 0090249 5689 129 x 75 750 630 T...

Page 33: ...ilter Material number Resistance Rv Power Voltage 0090013 0048 5 8 165W 1100V 4 3 Dimensions and weights The COMBIVERT F5 AIC have identical housings with the COMBIVERT F5 drive con verters Dimensions...

Page 34: ...connection control circuit 11 Control lines Large area contact at the mounting plate Control circuit Power circuit Direction of the cooling fins Table 14 EMC compatible control cabinet installation 5...

Page 35: ...COMBIVERT drive converters The AIC must be suitable for this value Terminal Description DC voltage input with starting current limiting usable as output only if all devices supplied by the DC bus have...

Page 36: ...nection for temperature sensor 2 PE Connection for protective earth 3 Figure 2 Terminal blocks housing E Housing G Name Function Terminal L1 L2 L3 3 phase mains connection 4 U V W AIC mains connection...

Page 37: ...in connection with terminals T1 T2 only at water cooling systems PE Connection for protective earth 10 Figure 5 Terminal blocks housing R Housing U Name Function Terminal L1 L2 L3 U V W K1K2 T1T2 L1 L...

Page 38: ...B Connection for braking resistor PA Connection for DC bus connection X1D T1 T2 Connection for temperature sensor only master 9 K1 K2 Monitoring of the braking transistor GTR7 only water cooled device...

Page 39: ...AWG 1 0 MCM 6 8 75 82 35 90 4 AWG 2 0 MCM 15 20 180 9 0 2 4 24 AWG 10 AWG 0 6 5 3 10 10mm stay bolt for ring crimp connector 25 220 11 50 150 1 0 AWG 300 MCM 25 30 270 12 10 mm stud for ring crimp con...

Page 40: ...ock X1F Connection terminals Voltage supply 24VDC 10 Current consumption per module Housing U Device size 24 26 2 5A Device size 27 4A Housing P Device size 28 30 33 4A Spare fuse s 3 15A Type gG Figu...

Page 41: ...erature range Protec tion of the motor winding is no longer guaranteed NOTICE KTY sensors may not be combined with other devices Otherwise wrong measurements would be the consequence Examples for the...

Page 42: ...starting current limiting at the DC voltage input The maximum charging current must be observed Type D1 AC drive converter PA L1 L2 L3 Rv Ipre IAIC Iext Type D1 can be supplied by mains In consid era...

Page 43: ...onitoring of the LCL filter is done by the F5 AIC The inputs and outputs are pre programmed for the following circuit example NOTICE For a safe function of the AIC system use models with positively dr...

Page 44: ...4 sensor 2 F1 Main fuses S7 Motor temperature switch F2 Pre charging fuses 20A slow U5 COMBIVERT F5 AIC F3 Fuse for filter fan U6 Drive converter K2 Pre charging contactor G1 Motor K3 Main contactor U...

Page 45: ...otor F2 Pre charging fuses 20A slow S5 S6 Temperature detection NC contact and KTY84 sensor 2 F3 Fan fuse S7 Motor temperature switch K2 Pre charging contactor U5 COMBIVERT F5 AIC K3 Main contactor U6...

Page 46: ...s 2 S6 Temperature detection NC contact and KTY84 sensor 3 F3 F4 Fan fuse S7 Motor temperature switch F5 Pre charging fuses 20 A slow U3 U4 Common mode filter F6 F7 F8 F9 DC fuses 2 U7 U8 COMBIVERT F5...

Page 47: ...2 21 22 13 14 13 14 11 11 12 11 12 14 12 K4 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 13 14 13 14 13 14 13 14 1 3 5 2 4 6 Legend K1 Coupling relay control on off S2 Second setpoint customer K2 Pre charging contac...

Page 48: ...d The control release is set by switch S1 if the pre charging contactor K2 drops out and the main contactor has tightened A delay time di 42 starts simultaneously with the control release by input I2...

Page 49: ...mA for setpoint poten tiometer 8 Analog ground COM Ground for analog inputs and out puts 9 10 Progr input 1 I1 2 Setpoint of the control voltage All digital inputs are freely program mable The control...

Page 50: ...FLC Figure 14 Assignment of the terminal block X2A 7 1 2 Connection of the control In order to prevent a malfunction caused by interference voltage supply on the control inputs the following direction...

Page 51: ...nal power supply When the power unit is switched off the control remains in operation by an external voltage supply of the control board To prevent undefined conditions at external power supply genera...

Page 52: ...tputs 7 1 8 Analog outputs Uout 0 10 V DC Imax 10 mA X2A 1 2 3 4 5 6 7 8 9 Figure 20 Analog outputs 7 1 9 Voltage output The voltage output is used to control the digital inputs and for the supply of...

Page 53: ...onverter The connection of a serial standard cable would destroy the PC interface 8 2 Operation with digital operator A digital operator is available as an accessory for local operation of the COMBIVE...

Page 54: ...ction occurs during operation then the actual display is overwritten by the error message The error message in the display is reset by ENTER Error ENTER F R With ENTER only the error message in the di...

Page 55: ...C RS232 485 interface Figure 24 Interface operator 8 3 1 Description of the diagnostic and parameter interface X6B The HSP5 interface X6B enables access to the drive converter for diagnostic or pro gr...

Page 56: ...face X6C 8 3 3 Connection of the RS232 interface A RS232 cable is required to connect the interface operator with a PC Serial cable to connect the operator with a PC 0058025 001D 1 5 6 9 1 5 6 9 8 3 4...

Page 57: ...for remote control of the COMBIVERT F5 Hereby the operator is mounted separate from the drive converter e g into the control cabinet door Operator Material number Suitable cable F5 HSP5 485 connection...

Page 58: ...to protect the precharging resistors Mains input circuit type A No current limitation for external connected DC devices is available at DC terminals marking of type A Current limitation must be ensure...

Page 59: ...2 B 4 9 5 470 10 NTC 62 7 D 0 75 2 6 180 33 NTC 19 9 D 1 5 4 1 300 10 NTC 62 10 D 2 2 5 8 345 10 NTC 62 12 D 4 9 5 470 10 NTC 62 13 D 5 5 12 580 10 NTC 62 14 D 7 5 16 5 650 10 NTC 62 12 E 4 9 5 470 20...

Page 60: ...0 11700 2 5 27 U 160 300 14100 2 5 28 P 200 370 16200 5 8 29 P 250 460 19800 5 8 30 P 315 570 19800 5 8 32 P M S 400 710 39600 2 9 33 P M S 450 800 39600 2 9 34 P M S 500 890 39600 2 9 35 P M S 560 10...

Page 61: ...000 35 000 2 5 250 270 24 125 8250 35 000 30 000 2 5 250 270 26 173 11700 33 000 27 000 2 5 250 270 27 208 14100 30 000 24 000 2 5 250 270 28 256 19800 27 000 20 000 5 8 107 117 1 29 319 19800 27 000...

Page 62: ...zed even in the ducts NOTICE In order to avoid a deformation of the heat sink and the damages there by the indicated max operating pressure may not be exceeded briefly also by pressure peaks Pay atten...

Page 63: ...the cooling Particulary the interactions between cool ing water and components of the cooling system are described pH value Aluminum is particularly corroded by lixiviums and salts The optimal pH valu...

Page 64: ...used by clogged corroded heat sinks or other obvious operating errors leads to the loss of the warranty claims 10 1 4 Coolant temperature The flow temperature may not exceed 40 C The maximum overheat...

Page 65: ...g ducts according to installation instructions for fitting 0000650 G14K he connection to the coolant must be carried out with flexible pressure resistant hoses and secured with clamps Pay attention to...

Page 66: ...3 6 4 0 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 Legend Recommended working range 10 30 in l min Single device Series connection of two modules Master Slave Series connection of three mo...

Page 67: ...e done in a series connection It should be noted that the temperature is analog measured in the slave modules and an error signal is given digitally to the master The water return flow should always b...

Page 68: ...on in the liquid cooler 10 1 5 3 Volume flow in dependence of the heat power dissipation and temperature difference Pv in kW T in K 0 1 2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Legen...

Page 69: ...fore starting the COMBIVERT Other elements in the cooling circuit such as pumps shut off valves ventilation etc must be attached according to the cooling system and the local conditions The total volu...

Page 70: ...n Date Description 00 2016 10 Completion Pre series 01 2018 01 Changeover to new KEB ci general changes 02 2019 02 Certified version included WEEE registration added editorial changes 03 2020 10 Chang...

Page 71: ...E KEB PARTNERS WORLDWIDE www keb co uk contact contact worldwide P R China KEB Power Transmission Technology Shanghai Co Ltd No 435 QianPu Road Chedun Town Songjiang District 201611 Shanghai P R China...

Page 72: ...Automation with Drive www keb de KEB Automation KG Suedstrasse 38 32683 Barntrup Tel 49 5263 401 0 E Mail info keb de...

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