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KEB COMBIVERT H6 Series Instructions For Use Manual Download Page 49

4.2  Structure of the charging module

Front view

Remove the front cover

Front without cover

• Pull with both hands low in the 

cover.

• Tilt cover forward to approx. 

45 degrees, until the plates 

solve above from the mount-

ing.

• Remove the cover forward.

Remove the cover from the DC 

bus

• Compress lug of the cover, 

remove forward.

Figure 17:  Front view of the device

 DANGER

Hazardous voltage under the cover of the DC bus

 

►

Secure isolation from supply of the DC bus at the power supply and 

regenerative unit!

The terminal blocks meet the requirements of 

EN 60947-7-1

.

49

 INSTALLATION  AND  CONNECTION

Summary of Contents for COMBIVERT H6 Series

Page 1: ...COMBIVERT H6 INSTRUCTIONSFORUSE INSTALLATION ACTIVE INFEED CONTROLLER AIC AND CHARGING MODULE Translation of original manual Document 20105449 EN 05...

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: ...sic Safety Instructions 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...

Page 6: ...e wave EMC filter with DC regeneration 41 4 Installation and Connection 42 4 1 Construction of the device 42 4 1 1 Status LED displays AIC module 48 4 1 1 1 Status LED 1 AIC module 48 4 1 1 2 Status L...

Page 7: ...module 64 4 5 1 Module type 0 terminal block X2B 64 4 5 2 Control release 64 5 Certification 65 5 1 CE Marking 65 5 2 UL Marking 65 5 3 Further informations and documentation 66 6 Cooling System 67 6...

Page 8: ...erminal block X1B 52 Figure 24 Connection for protective earth and function earth 52 Figure 25 Status LED displays charging module 52 Figure 26 View upper side of the device 53 Figure 27 Connection of...

Page 9: ...H6 modules 30 Table 10 Mounting instructions for control cabinet installation 32 Table 11 Sine wave EMC filter with DC regeneration 41 Table 12 Status LED 1 AIC module 48 Table 13 Status LED 2 safety...

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: ...mation 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 qualifica...

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: ...urrent in the pro tective earth conductor When a residual current protective device RCD or a residual current monitoring device RCM is used for the protection against direct or indirect contact only a...

Page 17: ...using components without isolated inputs outputs it is necessary that equi potential bonding exists between the components to be connected e g by the equi potential line Disregard can cause destructio...

Page 18: ...are supported functions is not suf ficient It is imperative to install external protective measures e g limit switch that are independent of the drive converter Secure motors against automatic restart...

Page 19: ...the motor is still running during a restart of the drive converter mains on e g due to large rotating masses Switching an the input For applications that require cyclic switching off and on of the dr...

Page 20: ...alled B2B devices Manufacturers of B2B devices are obliged to take back and recycle devices manufac tured after 14 08 2018 These devices may not be disposed at the collection centres of public sector...

Page 21: ...regeneration The AIC can regenerate excess energy in sinusoidal form from the DC bus connection into the mains Precharging is required when using an AIC 24V power supply module Provides the 24V DC pow...

Page 22: ...k under exceptional condi tions or if essential functions life supporting measures or an extraordinary safety step must be fulfilled the necessary reliability and security must be ensured by the machi...

Page 23: ...ion of displays or service tools Inputs and outputs 4 digital inputs 4 digital outputs Separate supply Internal supply of the control unit and driver power unit are safe separated Internal fuses The d...

Page 24: ...data 2 Special overload behaviour A Z Customer special version firmware and download Housing Flat rear heat sink B 50mm E 200mm C 100mm G 300mm Air heat sink P 50mm U 200mm S 100mm W 300mm Control ty...

Page 25: ...lass Notes Surrounding temperature EN 60721 3 3 3K3 5 40 C extended to 10 45 C Coolant inlet tem perature Air 5 40 C 10 45 C Water 5 40 C Relative humidity EN 60721 3 3 3K3 5 85 without condensation V...

Page 26: ...n 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 limit values...

Page 27: ...le length Radiated interferences 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 measureme...

Page 28: ...e connection point Skn Sn 15 Skn Sn 350 Power dissipation heat sink 4 PDext W 181 698 1090 1850 2315 1979 Power dissipation interior 4 PDint W 53 95 131 175 218 189 Max heat sink temperature THS C 80...

Page 29: ...precharging current IO_dc A 5 Braking transistor GTR7 Max brake power switching cycle 40 P_max kW 46 2 Max braking current IB_max_dc A 146 176 Min braking resistor RB_min 6 10 5 10 Connection cross s...

Page 30: ...0 12 double axis module 195 195 390 13 280 14 390 15 560 16 705 18 1020 19 1360 20 1650 21 1950 22 2350 23 3100 24 3900 25 4700 Active Infeed Controller AIC Device size Capacity in F 14 390 19 1650 21...

Page 31: ...e and the displacement between the units must be kept to a minimum CAUTION Hot Surface Heat sinks can reach temperatures which can cause burns when touch ing If in case of structural measures a direct...

Page 32: ...t sink ATTENTION Overheating of the device Never operate flat rear devices without main cooler Select suitable cooling surfaces e g water heat sink ribbed heat sink machine base Screw the flat rear of...

Page 33: ...ilable if no usable cooling surface exists at customer side Heat sink Cabinet outcut Size L1 in mm L2 in mm L3 in mm 04H6TFW 0400 452 435 406 06H6TFW 0600 652 635 606 08H6TFW 0800 852 835 806 10H6TFW...

Page 34: ...nsions and weights of modules with flat rear heat sink 198 50 407 60 5 395 7 200 300 150 50 50 Housing Module width in mm Weight in kg B charging module 50 3 8 C 100 5 8 E 200 12 5 G 300 18 Figure 3 D...

Page 35: ...chanical installation 3 4 5 Dimensions and weights of modules with air heat sink 49 7 6 5 7 395 407 11 109 289 Housing Module width in mm Weight in kg P charging module 50 5 5 Figure 4 Dimensions hous...

Page 36: ...36 Mechanical installation 395 7 407 99 7 50 6 5 109 289 Housing Module width in mm Weight in kg S 100 9 Figure 5 Dimensions housing S...

Page 37: ...37 Mechanical installation 150 199 7 395 407 7 109 289 Housing Module width in mm Weight in kg U 200 17 Figure 6 Dimensions housing U...

Page 38: ...38 Mechanical installation 150 250 299 7 7 394 5 407 109 289 Housing Module width in mm Weight in kg W 300 28 Figure 7 Dimensions housing W...

Page 39: ...00 36 25 275 21 5 1 19H6J4F 1000 60 42 395 16 50mm AWG 6 0 4Nm 34 2 21H6J4F 1000 54 37 4 360 32 2 21H6J4F 1001 90 62 535 42 5 2 IN Rated current S Apparent power PD Power dissipation Figure 8 AIC filt...

Page 40: ...590 16 50mm AWG 6 0 4Nm M8 40 2 24H6J4G 1000 180 8 125 1100 M10 Stud 25Nm 220lbinch M10 68 3 26H6J4G 1000 1 150 8 104 695 26H6J4G A000 150 8 104 695 M10 Stud 25Nm 220lbinch M10 60 3 26Z1K04 1000 2 25...

Page 41: ...24 0SZ1I05 1001 24Z1B04 1000 24E6T60 3000 180 270 4 23 0XZ1I05 1001 27Z1B04 1000 22E6T60 3000 145 290 26 0XZ1I05 1001 27Z1B04 1000 24E6T60 3000 200 378 26 0XZ1I05 1001 27Z1B04 1000 26U5A0U 3000 250 37...

Page 42: ...to approx 45 degrees until the plates solve above from the mounting Remove the cover forward Remove the cover from the DC bus Compress lug of the cover remove forward Figure 10 Front view of the devic...

Page 43: ...4V bus X1C 1 X1C 3 24V bus 0V X1C 2 X1C 4 0V DC bus X1D 1 X1D 3 DC bus displayed with protection against contact for exterior devices DC bus X1D 2 X1D 4 Snap in for front cover Output to the filter X1...

Page 44: ...24 10 0 7Nm 6 2lbinch V W X1B BR Connection for 24V DC brake 0 25 1 5 mm AWG 28 16 0 25Nm 2 2 lbinch BR T1 Connection for PTC KTY filter temperature monitoring T2 PE Connection for shielding earthing...

Page 45: ...g torque X1A U Connection to the filter Connect inphase 35 95mm AWG 4 0 15Nm 132lb inch V W PE Connection for shielding earthing M8 stud for ring crimp connector 12Nm 110lbinch Figure 13 View of the b...

Page 46: ...nection to the filter Connect inphase M10 stud for ring crimp connector max width 30mm 12Nm 110lbinch V W PE Connection for shielding earthing M8 stud for ring crimp connector 12Nm 110lbinch Figure 14...

Page 47: ...link and error output of the axis modules X2D Error chain 2 1 X4A reserved 1 6 reserved TxD RS232 2 7 DGND reference potential RxD RS232 3 8 TxD A RS485 RxD A RS485 4 9 TxD B RS485 RxD B RS485 5 X4C E...

Page 48: ...oltage supply of the device yellow Device initialised green Device ready for operation red Device in error routine Table 12 Status LED 1 AIC module 4 1 1 2 Status LED 2 safety module The LED indicate...

Page 49: ...e above from the mount ing Remove the cover forward Remove the cover from the DC bus Compress lug of the cover remove forward Figure 17 Front view of the device DANGER Hazardous voltage under the cove...

Page 50: ...length 10mm C1 FT2 Temperature monitoring of the AIC filter FT1 RT2 Temperature monitoring of the braking resistor RT1 Figure 19 Terminal block X1E X1F Name Function Connection data C out Control for...

Page 51: ...esistor Figure 21 View rear side of the device X1A Name Function Conductor cross section Tightening torque L1 L2 L3 Mains connection for pre charging 0 2 6mm AWG 24 10 0 7Nm 6 2lbinch PE Connection fo...

Page 52: ...th M8 4 5Nm 40lbinch Figure 24 Connection for protective earth and function earth 4 2 1 Status LED displays charging module Status LED 1 without function Status LED 2 Charging module Figure 25 Status...

Page 53: ...put Dig output 4 8 7 0V Dig output 3 6 5 0V Dig output 2 4 3 0V Dig output 1 2 1 0V X2C Error chain 2 1 Charging status of the DC link and error output of the axis modules X2D Error chain 2 1 X4A rese...

Page 54: ...devices upper rail DC lower rail DC Place plastic cap as protection against accidental contact at the end of the system Torx oval head screw M4x10 required tool Torx screw driver TX20 Tightening torq...

Page 55: ...erature switch 5 AIC filter with fan and temperature monitoring switch off 6 Mains contactor K1 with protective circuit 7 Charging module 8 AIC module 9 Axis module 10 Superior control optional 11 Mot...

Page 56: ...ature switch 5 AIC filter with fan and temperature monitoring switch off 6 Mains contactor K1 with protective circuit 7 Charging module 8 AIC module 9 Axis module 10 24V power supply module with super...

Page 57: ...e input of the charg ing unit Thermal contact NC contact minimum switching current 2mA R T1 R T2 Figure 31 Wiring example temperature monitoring NOTICE If no braking resistor is required a bridge must...

Page 58: ...s modules U 9V X2D Figure 32 Error chain terminal X2C X2D 4 4 1 1 Error chain channel 1 The first error channel is an error chain If there is an error in a module the other mod ules can be notified of...

Page 59: ...ellow Speed 1 8 X4B EtherCAT IN 6 RX 7 off 10MBit 8 on 100Mbit Table 15 EtherCat System bus socket X4B Does not apply to the charging module 4 4 3 Diagnosis Visualisation X4A The integrated RS232 485...

Page 60: ...wheeling diode max 300mJ Table 17 Technical data of the outputs 4 4 3 3 Assignment of the interfaces 5 4 3 2 1 9 8 7 6 5 4 3 2 1 9 8 7 6 reserved do not assign 1 6 reserved do not assign TxD RS232 2 7...

Page 61: ...15 mm Table 18 Wire end ferrules and stripping length Front view 18 a b a Pusher b Wire hole Figure 35 Assembly of the control cable Press pusher by hand Insert connecting wires into the respective ho...

Page 62: ...eable 2 1 0V Figure 36 Assignment of the terminal block X2A AIC module 4 4 5 2 Assignment of the terminal block X2A charging module Digital inputs and outputs Function Default setting Term 1 2 3 4 5 6...

Page 63: ...utputs DO1 4 0V IL_max Figure 39 Connection of the digital outputs DO1 DO4 4 4 5 5 Example for the control of digital inputs and digital outputs DO1 DI1 DO2 DI2 DO3 DI3 DO4 DI4 Operation with hardware...

Page 64: ...le cross sections see section Assembly of the wires to PUSH IN termi nals Figure 41 Safety module type 0 terminal block X2B top view The digital inputs are specified in accordance with IEC61131 2 type...

Page 65: ...ed standards of the series EN 61800 5 1 for drive converters were used The COMBIVERT is a product of limited availability in accordance with EN 61800 3 This product may cause radio interference in res...

Page 66: ...d information for construction and development Input fuses in accordance with UL Programming manual for control and power unit Motor configurator to select the appropriate drive converter and to creat...

Page 67: ...g pressure was executed Pay attention to the guidelines 97 23 EC of pressure units 6 1 2 Materials in the cooling circuit For the screw connections and also for the metallic articles in the cooling ci...

Page 68: ...minum is particularly corroded by lixiviums and salts The optimal pH value for aluminum should be in the range of 7 5 8 0 Abrasive substances Abrasive substances as used in abrasive quartz sand cloggi...

Page 69: ...e with the manual The connection to the coolant must be carried out with flexible pressure resistant hoses and secured with clamps Pay attention to flux direction and check tightness The cooling flow...

Page 70: ...0 1 4 6 8 9 15 18 7 3 1 4 7 9 11 13 15 20 12 4 1 5 9 12 14 16 18 20 25 8 0 5 10 13 16 19 21 23 25 30 6 3 10 14 18 21 24 26 28 30 35 2 8 14 18 22 25 28 31 33 35 40 1 11 18 22 27 31 33 36 38 40 45 4 15...

Page 71: ...in 20 l min 10 l min 5 l min Figure 43 Coolant heating depending on power loss 6 1 7 Typically fall of pressure depending on the rate of flow bar 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 1 1 1 2 1...

Page 72: ...start up Step by step start up H6 AIC 7 1 Default setting The COMBIVERT H6 AIC is an universally applicable power supply regenerative unit that requires an individual adjustment of the basic settings...

Page 73: ...ofcommunication between PC and AFE arealso possible de15 0 set co08 2 Deviceis reset to factory settings Requirement Hardwarecircuit electrically checked Application meets the mains connection require...

Page 74: ...ing frequency is included Internet available copy LCLFilter data dr15 dr17 dr49 dr53 dr65 dr66 Reset deletes all data Also operating hours etc See programming manual LCL filter 10 11 12 13 14 15 16 17...

Page 75: ...ntrol voltageis for example at 400V AC min 680V DC yes no dr12 rated current ofMCB de28 100 Commissioning under test environment de28 de29 dr12 is the mains supply rated device power yes no current se...

Page 76: ...yes is lineinductance network resistance known set control word dr99 0 set co00 3 38 39 40 42 43 44 45 data saved precharging on check and set cu21 1 DC voltage see programming guide DC Bus PID Set p...

Page 77: ...4 45 46 data saved ST precharging on control word co00 3 commissioning at costumer site no yes on site commissioning 47 48 50 49 Final commissioning on site after delivery to the customer commissionin...

Page 78: ...on off no yes Identification successfully completed 1 2 3 4 5 6 7 8 9 10 11 modulation on or toggleI2 Modulation off precharging off set control word co00 0 Start identification see programming manual...

Page 79: ...top to bottom The direction of the arrow gives the sequence of the individual steps The order is important Some settings are based on other settings which need to be set in advance 1 With software V1...

Page 80: ...re series 01 2016 08 Heatsink concepts wrong terminal 02 2017 09 New CI general revision linkage with InCopy components 03 2018 05 Editorial changes 04 2019 06 Product description adapted updates have...

Page 81: ...et www keb jp MORE KEB PARTNERS WORLDWIDE www keb de de contact contact worldwide P R China KEB Power Transmission Technology Shanghai Co Ltd No 435 QianPu Road Chedun Town Songjiang District 201611 S...

Page 82: ...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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