KEB COMBIVERT G6 series Instructions For Use Manual Download

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COMBIVERT

INSTRUCTIONS FOR USE |

INSTALLATION G6 HOUSING A

Translation of the original manual

Document 20086425 EN 05

Summary of Contents for COMBIVERT G6 series

Page 1: ...COMBIVERT G6 INSTRUCTIONS FOR USE INSTALLATION G6 HOUSING A Translation of the original manual Document 20086425 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 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 condi...

Page 4: ...s 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 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 suitabi...

Page 5: ...erter 13 1 Basic 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 Insulation measurement 17 1 5 Start up and operation 18 1 6 Maintenance 19 1 7 Repair 20 1 8 Disposal 20 2 Product Description 21 2 1 Specified application 21 2 1 1 Residual risks 21 2 2...

Page 6: ...8 4 2 3 1 Terminal block X1B DC connection 38 4 2 4 Connection of the motor 38 4 2 4 1 Selection of the motor cable 38 4 2 4 2 Cable feed disturbances depending on the motor line length at AC supply 39 4 2 4 3 Motor line length at operation with DC voltage 39 4 2 4 4 Motor cable length for parallel operation of motors 39 4 2 4 5 Motor cable cross section 39 4 2 4 6 Interconnection of the motor 39 ...

Page 7: ...tents 5 Certification 44 5 1 CE Marking 44 5 2 Functional safety 44 5 3 UL Marking 44 5 4 Further informations and documentation 47 6 Accessories 48 6 1 Mounting kit shield connection braket 48 7 Revision History 49 ...

Page 8: ...tion of the mains supply 230V 1 phase 37 Figure 10 Connection of the mains supply 400V 3 phase 37 Figure 11 Connection at DC voltage supply 38 Figure 12 Terminal block X1B DC connection 38 Figure 13 Terminal block X1B motor connection 40 Figure 14 Wiring of the motor 40 Figure 15 Terminal block X1B connection of a braking resistor 41 Figure 16 Wiring of an intrinsically safe braking resistor 41 Fi...

Page 9: ...conditions 26 Table 4 Chemical mechanical active substances 26 Table 5 Device classification 27 Table 6 Electromagnetic compatibility 27 Table 7 Technical data 230V class 28 Table 8 Technical data 400V class 29 Table 9 Calculation of the motor voltage 43 Table 10 Mounting kit shield connection braket for G6 housing A 48 ...

Page 10: ...y 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 name AFE AFE filter From 07 2019 AIC filter replaces the previous name AFE filter AIC Active Infeed Converter AIC filter Filter for Active Infeed Converter Application The application is the intende...

Page 11: ...r 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 technology EN 61508 1 7 SS1 Safety function Safe stop 1 in ac cordance with IEC 61800 5 2 SSI Synchronous serial interface for encoder STO Safety function Safe Torque Off in accordance with IEC 61800 5 2 TTL...

Page 12: ...rements 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 German version EN 60721 3 1 EN60721 3 2 Classification of environmental conditions Part 3 Classification of groups of environmental parameters and their severities Section 2 Transportation and handlin...

Page 13: ...ors 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 German implementation HD 60364 7 729 2009 DNVGL CG 0339 Environmental test specification for electrical electronic and programmable equipment and systems EN1037 Safety of machinery Prevention of unexp...

Page 14: ...act 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 qualifications 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 De...

Page 15: ...components 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 mist to penetrate the unit Avoid dust permeating the device Allow for sufficient heat dissipation if installed in a dust proof housing Note installation position and minimum distances to surrounding ...

Page 16: ...current 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 RCD or RCM type B is permitted on the power supply side of this product Drive converters with a leakage current 3 5mA AC current 10mA DC current are intended for a stationary connection Protective e...

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 destruction of the components by equalizing currents 1 4 1 EMC compatible installation Observance of the limit values required by EMC law is the responsibility of the customer Notes on EMC compatible installat...

Page 18: ...ware 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 CAUTION High temperatures at heat sink and coolant Burning of the skin Cover hot surfaces safe to touch If necessary attach warning signs on the system Before touching check the surface and coolant ...

Page 19: ...f 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 drive converter maintain an off time of at least 5 min after the last switch on If you require shorter cycle times please contact KEB Automation KG 1 6 Maintenance The following maintenance work has to...

Page 20: ...called 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 disposal organisations If no deviating 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 a...

Page 21: ...s or machines Technical data and information for connection conditions shall be taken from the type plate and from the instruction manual and must be strictly observed The used semiconductors and components of the KEB Automation KG are developed and dimensioned for the use in industrial products Restriction If the product is used in machines which work under exceptional conditions or if essen tial...

Page 22: ...rehensive operating concept Wide operating temperature range Low switching losses by IGBT power unit Low noise development due to high switching frequencies Different heat sink concepts Air cooler as built in version Flat rear version Temperature controlled fans replaceable Depending on the operating mode the torque limits and s curves are adjustable to protect the gearbox General protection funct...

Page 23: ...hing frequency Short time current limit Overcurrent cut off 4 5 4kHz 150 180 9 4kHz 180 216 A 8kHz 180 216 Voltage Connection type 4 0 1ph 230V AC DC 3 3ph 400V AC DC 5 3ph 400V DC A Z Customer special version firmware hardware download Housing A B C E Equipment 0 Without filter without braking transistor without safety function STO 1 Without filter with braking transistor without safety function ...

Page 24: ...rCAT is registered trademark and patented technology licensed by Beckhoff Automation GmbH Germany 2 CANopen is registered trademark of CAN in AUTOMATION Interna tional Users and Manufacturers Group e V 3 IO LINK is registered trademark of PROFIBUS user organisation e V 4 Not valid for customer special versions 5 SCL Sensorless Closed Loop 6 ASCL Asynchronous Sensorless Closed Loop ...

Page 25: ...Notes Surrounding temperature EN 60721 3 3 3K3 5 40 C extended to 10 45 C Coolant inlet temperature Air 5 40 C 10 45 C Liquid 5 40 C Relative humidity EN 60721 3 3 3K3 5 85 without condensation Version and degree of protection EN 60529 IP20 Protection against foreign material ø12 5mm No protection against water Non conductive pollution occasional conden sation when PDS is out of service Site altit...

Page 26: ...dard Class Notes 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 limit values EN 60721 3 3 3M4 100m s 11 ms Table 3 Mechanical ambient conditions Not tested 3 1 3 Chemical mechanical active substances Storage Standard Class Notes Contamination Gases EN...

Page 27: ...erences 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 interfaces EN 61000 4 4 2kV Burst Power ports EN 61000 4 4 4kV Surge Power ports EN 61000 4 5 1kV 2kV Phase phase Phase ground Immunity to conducted distur bances induced by radio fre quency fields...

Page 28: ...s frequency fN Hz 50 60 2 Rated input voltage DC UN_dc V 325 UL 340 Input voltage range at DC supply Uin_dc V 275 373 0 DC switch off level Error Underpotential UUP_dc V 216 Switching level DC braking resistor UB_dc V 380 DC switch off level Error Overpotential UOP_dc V 400 Output voltage 5 Uout V 3 x 0 Uin Output voltage at DC devices 5 Uout_dc V 3 x 0 Uin_dc 2 Output frequency depending on the o...

Page 29: ...ltage range Uin V 340 528 0 Mains frequency fN Hz 50 60 2 Rated input voltage DC UN_dc V 565 UL 680 Input voltage range at DC supply Uin_dc V 480 746 0 DC switch off level Error Underpotential UUP_dc V 240 Switching level DC braking resistor UB_dc V 780 DC switch off level Error Overpotential UOP_dc V 840 Output voltage 6 Uout V 3 x 0 Uin Output voltage at DC devices 6 Uout_dc V 3 x 0 Uin_dc 2 Out...

Page 30: ... power system means that the nodal point power Snet of the mains is very high 200 compared to the output rated power of the drive converter Sout k Snet 200 e g k 2MVA supply transformer 303 Choke required Sout 6 6kVA 12G6 3 3 1 Overload and derating 80 100 120 140 160 180 200 220 fd 6 Hz f0 0 Hz fout Hz IN IHSR IN IOC IHSR 09G6 8 kHz 10G6 8 kHz 07G6 8 kHz 09 10G6 4 kHz IHSR Legend IN Rated current...

Page 31: ... integrator starts When falling below the integrator counts backwards If the integrator achieves the overload characteristic that corresponds to the drive converter ERROR overload is triggered After a cooling period the message no ERROR overload is displayed The error can be reset now The drive converter must remain switched on during the cooling period 31 Technical data G6 400V class ...

Page 32: ...32 Dimensions and weights 3 4 Dimensions and weights 175 204 5 185 M4 5 90 200 Housing A Weight 1 3kg Dimensions All dimensions in mm Figure 3 Dimensions and weights for G6 housing A ...

Page 33: ...rol cab inet door Figure 4 Mounting distances 3 4 1 1 Ventilation in the control cabinet If construction conditioned the control cabinet cannot be without indoor ventilation ap propriate filters must avoid suction of foreign objects Installation of the drive converter For reliable operation the drive converter must be mounted without clearance on a smooth closed bare metal mounting plate Direction...

Page 34: ...32 485 interface with DIN66019 II 4 X2B Safety function STO optional 5 X2A Control terminal strip 32pole 6 X1A Mains input 7 LED1 Drive converter state there is no operator 8 Operator with display and keyboard 9 Nameplate 10 PE Protective earth at connection to protective earth each terminal may be assigned only once The shielding e g from the motor cable is laid on the mounting plate in the contr...

Page 35: ...ircuit drive converter type NOTICE Unit switches off Cyclic switching on and off of the unit leads to temporary high resistance of the resistor PTC in the input The unit displays Error load shunt fault in this state When switching the control release during this fault the unit will switch off A restart without limitation is possible after cooling Waiting time Technical data G6 400V class 4 2 1 1 W...

Page 36: ...G without wire end ferrule mm with wire end ferrule 0 5 0 6A 5 6lb inch 24 14 0 2 2 5 multi wire L1 L2 L3 Mains connec tion 3 phase AWG without wire end ferrule mm with wire end ferrule 0 5 0 6A 5 6lb inch 24 14 0 2 2 5 multi wire PE Connection for protective earth Screw M4 for ring crimp connector 1 3 Nm 11lbinch Figure 8 Line terminal strip X1A ...

Page 37: ... Line contactor 4 Mains choke 07 or 09Z1B02 1000 5 KEB COMBIVERT G6 Figure 9 Connection of the mains supply 230V 1 phase 4 2 2 2 AC supply 400V 3 phase L1 L2 L3 PE L1 L2 L3 U V W T1 T2 Legend 1 Mains voltage 3 phase 400V Mains form TN TT IT Personal protection RCMA with separator or RCD type B Insulation monitor 2 Mains fuses Type gG or MCCB 3 Line contactor 4 Mains choke 07 09 or 10Z1B04 1000 5 K...

Page 38: ...B Name Function Cross section Tightening torque DC connection AWG without wire end ferrule mm with wire end ferrule 0 5 0 6A 5 6lb inch 24 14 0 25 2 5 multi wire PE Connection for protective earth Screw M4 for ring crimp connector 1 3 Nm 11lbinch Figure 12 Terminal block X1B DC connection 4 2 4 Connection of the motor 4 2 4 1 Selection of the motor cable The correct cabling as well as the motor ca...

Page 39: ... line length at operation with DC voltage The maximum motor line length at DC operation is basically dependent on the capacity of the motor cable The internal filter is not active at DC operation External measures must be taken here if necessary The following data apply for operation under nominal rating conditions Size Motor cable standard Motor cable low capacitance 07 25m 50m 09 10 4 2 4 4 Moto...

Page 40: ...t wire end ferrule mm with wire end ferrule 0 5 0 6A 5 6lb inch 24 14 0 25 2 5 multi wire Figure 13 Terminal block X1B motor connection 4 2 4 8 Wiring of the motor L1 L2 L3 U V W U V W T1 T2 1 KEB COMBIVERT 2 Apply motor cable shielding on both sides over a large surface on the function earth 3 Three phase motor 4 Temperature monitoring optional Connection of a temperature detection 5 Connection v...

Page 41: ...1B connection of a braking resistor Terminal R can alternatively be labeled with PB 4 2 5 2 Wiring of an intrinsically safe braking resistor X1B R U V W Figure 16 Wiring of an intrinsically safe braking resistor NOTICE Only intrinsically safe braking resistors are permissible for this oper ation since these resistors interrupt themselves at fault such as safety fuse without fire risk Technical dat...

Page 42: ...stance undefined 1 65 4kΩ tripping resistance 4kΩ T1 T2 open Figure 17 Temperature detection terminals T1 T2 The behaviour of the drive converter in case of error warning is defined with parameter CP37 Pn12 At factory setting the switching condition 9 dOH warning is set when terminals T1 T2 are open 4 2 6 2 Terminal block X1C temperature detection X1C Name Function Cross section Tightening torque ...

Page 43: ... 4 2 7 Final test information Final test information of the machines systems which are provided with drive converters according to EN 60204 1 of 2007 4 3 Calculation of the motor voltage The motor voltage for dimensioning of the drive is depending on the used components The mains voltage reduces according to the following table Components Example Mains choke Uk 4 Closed loop drive converter with m...

Page 44: ... Internal Overload Protection Operates prior to reaching the 200 of the Motor Full Load Current For 480V rated models Suitable For Use On A Circuit Capable Of Delivering Not More Than 5000 rms Sym metrical Amperes 480 Volts Maximum see instruction manual for Branch Circuit Protection details and Suitable For Use On A Circuit Capable Of Delivering Not More Than 18000 rms Symmetrical Amperes 480 Vol...

Page 45: ...ries I Fuses Cat No Housing Input Voltage V Class CC J or RK5 UL248 Fuse rating 600V A 07G6 A 240 1ph 15 09G6 A 240 1ph 20 07G6 A 480 3ph 6 09G6 A 480 3ph 10 10G6 A 480 3ph 10 The voltage rating of the external fuses shall be at least equal to the input voltage of the drives WARNING The opening of the branch circuit protective device may be an indication that a fault current has been interrupted T...

Page 46: ...n Allen Bradley 480Y 277V 15A III Listed NKJH NKJH7 CSA Certified Type E Self Protected Manual Motor Control lers Type and manufacturer and electrical ratings as specified below Cat No Housing Self Protected Manual Motor Controller Type Manufac turer Self Protected Manual Motor Controller ratings Dial setting A 07G6 A PKZM0 1 6 3 E Eaton 480Y 277V 3 0 Hp 6 09G6 A PKZM0 1 10 E Eaton 480Y 277V 7 5 H...

Page 47: ...etc Instruction and 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 create downloads for parameterizing the drive converter Approvals and approbations Declaration of conformity CE TÜV certificate FS certification Others COMBIVIS the software for comfortab...

Page 48: ...mounting kit is available for large surface of the shieldings of the connecting cables Material number Name B0G6T88 0001 Mounting kit shield connection braket Table 10 Mounting kit shield connection braket for G6 housing A 56 Figure 20 G6 housing A with optional mounting kit ...

Page 49: ...12 07 Terminal description supplement 1F 2013 09 Completely revised 230V class included 1G 2014 04 Type code extended to VARAN Technical data have been adapted Voltages for DC operation UL certification adapted Version Date Description 00 2014 04 Changed to document number Revision 1G is identical to version 00 01 2018 03 Insertion of dimensions Conversion to new KEB corporate identity optics 02 2...

Page 50: ...50 NOTES ...

Page 51: ...net www keb jp MORE 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 Tel 86 21 37746688 Fax 86 21 37746600 E Mail info keb cn Internet www keb cn Poland KEB Automation KG Tel 48 60407727 E Mail roman trinczek keb de Internet www keb de Republic of Ko...

Page 52: ...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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