KEB COMBIVERT S6 Series, Instructions For Use Manual

Page 1: ...COMBIVERT S6 INSTRUCTIONS FOR USE INSTALLATION S6 HOUSING 4 Translation of the original manual Document 20106280 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 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: ...er 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 8 Repair 20 1 7 Disposal 20 2 Product Description 21 2 1 Specified application 21 2 1 1 Residual risks 21 2 2 Un...

Page 6: ...ure 36 3 3 6 Protection of the drive converter 36 3 3 7 DC link braking transistor function 37 3 3 8 Power dissipation 38 3 3 9 Fan 39 3 3 9 1 Switching behaviour of the fan 39 3 3 9 2 Switching points of the fan 39 4 Installation and Connection 40 4 1 Overview of the COMBIVERT S6 40 4 2 Connection of the power unit 42 4 2 1 Connection of the voltage supply 42 4 2 1 1 Line terminal strip X1A 42 4 ...

Page 7: ...e brake control 50 4 3 2 Specification and connection of the temperature detection 51 4 3 3 Operation without temperature detection 51 4 3 4 Connection of a KTY sensor 52 4 3 5 Connection of PTC temperature switch or PT1000 53 4 4 Brake control and temperature detection 54 4 4 1 Specification and connection of the brake relay control 54 4 4 2 Specification and connection of the temperature detecti...

Page 8: ...Figure 12 Connection for protective earth 43 Figure 13 Connection of the mains supply 44 Figure 14 Connection at DC voltage supply 45 Figure 15 Terminal strip X1B DC connection 45 Figure 16 Terminal strip X1B motor connection 47 Figure 17 Wiring of the motor 48 Figure 18 Terminal block X1B Connection of a braking resistor 48 Figure 19 Wiring of an intrinsically safe braking resistor 49 Figure 20 A...

Page 9: ...Frequency dependent maximum current for unit size 13 35 Table 17 Frequency dependent maximum current for unit size 14 35 Table 18 Switching frequency and temperature 36 Table 19 Protection of the drive converter 36 Table 20 DC link braking transistor function of the 400V units 37 Table 21 Power dissipation 38 Table 22 Fan 39 Table 23 Maximum motor cable length at AC supply 46 Table 24 Motor cable ...

Page 10: ...ety technology EN 61508 1 7 for the size of error probability per hour 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 ...

Page 11: ...d 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 Incremental signal with an output voltage up t...

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: ...omation 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 Detection of ...

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: ...rted 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 lines Befo...

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: ...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 KEB COMBIVERT F5 is used in machines which work under exceptional condi tions or if essential functions life supporti...

Page 22: ...ntegrated safety functionality Basic function STO in the compact version Additional high level safety in the application version Real time Ethernet interfaces CAN RS232 485 for diagnosis or display Book format for space saving control cabinet construction Direct mains connection for 230V and 400V mains alternatively also DC input 260 750V Low leakage current mains filter 5 mA integrated optional w...

Page 23: ...ace Ethernet Fieldbus Inter face Safe relay Terminal DFMC Version power unit 1 AC 480V 3 phase with HF filter 2 AC 480V 3 phase without HF filter 2 3 AC 230V 1 phase with HF filter 4 AC 230V 1 phase without HF filter 2 Housing 2 4 Safety module 1 Type 1 for Strg A STO SBC or STO for Strg K 3 Type 3 for Strg A STO SBC SLS etc 5 Type 5 STO SLS etc FSOE Control type A APPLICATION K COMPACT P PRO Seri...

Page 24: ...on Standard Class Descriptions Surrounding temperature EN 60721 3 3 3K3 5 40 C extended to 10 45 C Coolant inlet temperature 5 40 C 10 45 C Relative humidity EN 60721 3 3 3K3 5 85 without condensation Version and degree of protec tion 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 Si...

Page 25: ...ass Descriptions Vibration limits EN 60721 3 3 3M4 Vibration amplitude 3 0mm 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 Descriptions Contamination G...

Page 26: ...ed emissions EN 61800 3 C2 Immunity Standard Level Descriptions 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 27: ...Required material Tightening torque Screw assembly ISO 7045 M6 8 8 3 2Nm 29lbinch Table 7 Mounting instructions for control cabinet installation 3 2 Dimensions and weights 3 2 1 Built in version 16 89 44 5 275 275 308 14 21 170 227 220 Ø 5 8 Ø 5 8 Housing 4 Dimensions All dimensions in mm Weight 3 2kg Figure 1 Dimensions built in version housing 4 27 Dimensionsand weights ...

Page 28: ...etal mounting plate Mounting distances Dimen sion Distance in mm Distance in inch C A B D D A 150 6 B 100 4 C 30 1 2 D 0 0 X 1 50 2 1 Distance to preceding elements in the cabinet door Figure 2 Mounting distances If construction conditioned the control cabinet cannot be without indoor ventilation ap propriate filters must avoid suction of foreign objects Direction of the air flow Front and side vi...

Page 29: ...ated switching frequency fSN kHz 8 4 Rated input current IIN A 13 17 21 Rated input voltage UN V 400 Input voltage range Uin V 184 550 Input voltage range DC Uin_dc V 260 750 Mains phases 3 Mains frequency fN Hz 50 60 Maximum current 0Hz 50Hz at fS 8kHz Imax_out 189 300 109 216 183 300 Insulation resistance U_dc 500V Riso MΩ 16 67 Table 8 Overview unit data 1 The output frequency is to be limited ...

Page 30: ...output frequency is to be limited in such a way that it does not exceed 1 10 of the switching frequency Units with higher max output frequency are subject to export restrictions and are only available on request DC switching level DC switch off level Error Underpotential UUP_dc V 240 DC switching level braking resistor 1 UB_dc V 780 DC switch off level Error Overpotential UOP_dc V 840 Table 12 DC ...

Page 31: ... diagrams Turn off time depending on the overload at unit size 12 and 13 and Turn off time depending on the overload at unit size 14 Restrictions The thermal design of the heat sink is based on the rated current and the maximum surrounding temperature At high surrounding temperatures and or high heat sink temperatures for example by preceding utilization nearby 100 the drive con verter can change ...

Page 32: ...400 500 Motor current drive converter rated currrent in Release time in s Detail view in the range from 200 to 300 0 5 10 200 210 220 230 240 250 260 270 280 290 300 Motor current drive converter rated currrent in Legend 1 Thermal overload limit 2 Limitation by current controller limit adjustable via software Figure 4 Turn off time depending on the overload OL at unit size 12 and 13 32 Unit data ...

Page 33: ...500 Motor current drive converter rated currrent in Release time in s Detail view in the range from 155 to 210 0 5 10 155 160 165 170 175 180 185 190 200 205 210 Motor current drive converter rated currrent in Legend 1 Thermal overload limit 2 Limitation by current controller limit adjustable via software Figure 5 Turn off time depending on the overload OL at unit size 14 33 Unit data ...

Page 34: ...ary Overload characteristic in the lower speed range OL2 0 50 100 150 200 250 300 350 0 3 1 6 2 12 5 25 50 Output frequency in Hz OL2 current to rated current in The characteristic curves represent the real maximum current values using the example of unit size 12 Legend Overcurrent IOC Switching frequency 4kHz Switching frequency 8kHz Switching frequency 16kHz Not available for modulation The erro...

Page 35: ...requency dependent maximum current fS Basic Time Period 71 4µs Parameter is22 1 Ilim 7kHz 208 265 300 300 300 300 14kHz 125 167 196 225 246 254 Frequency dependent maximum current fS Basic Time Period 83 3µs Parameter is22 2 Ilim 6kHz 233 296 300 300 300 300 12kHz 133 183 217 250 275 283 Frequency dependent maximum current fS Basic Time Period 100µs Parameter is22 3 Ilim 5kHz 258 300 300 300 300 3...

Page 36: ...rature reaches a critical threshold Tdr the switching frequency can be reduced automatically step by step in order to prevent that the drive converter switches off due to overheating of the heat sink If the heat sink temperature falls be low Tur the switching frequency is increased to the setpoint again At temperature Tem the switching frequency is immediately reduced to rated switching frequency ...

Page 37: ... for braking transistor GTR7 2 Table 20 DC link braking transistor function of the 400V units 1 The DC switching level for the braking transistor is adjustable The default value is the value spec ified in the table 2 No protective function Wiring of an intrinsically safe braking resistor NOTICE Destruction of the drive converter if the value has fallen below the minimum brake resistance value The ...

Page 38: ...sconnected from the mains supply within 5 minutes 3 3 8 Power dissipation Unit size 12 13 14 Power dissipation at nominal operating 1 PD W 155 185 250 Power dissipation at DC supply 1 PD_dc W 140 165 220 Table 21 Power dissipation 1 Rated operation corresponds to UN 400V fSN fout 50Hz typically value 38 Unit data ...

Page 39: ...fan is adjustable The switching point for the switch off temper ature cannot be changed and is always 5 C below the switch on temperature 0 20 40 60 80 100 0 20 40 60 50 70 90 80 100 30 10 Temperature C Fan speed Legend Temperature curve Setting range for the switch on temperature Switch on point Switch off point Figure 8 Switching behaviour of the fan 3 3 9 2 Switching points of the fan The switc...

Page 40: ...X2A 1 Control terminal strip X2B 1 Safety functions 24Vdc supply X3A 1 Encoder interface channel A X3B 1 Encoder interface channel B X4A 1 Diagnosis interface X4B 1 Fieldbus interface in X4C 1 Fieldbus interface out PE Protection functional earth S1 S2 1 Rotary coding switch FS ST 1 Safety status VCC 1 Voltage supply NET ST 1 Fieldbus state DEV ST 1 Drive converter state OPT 1 optional 1 Is descri...

Page 41: ...u a inst 20109645_en pdf Instructions for use COMBIVERT S6 control board COMPACT www keb de fileadmin media Manuals dr ma_dr_s6 cu k inst 20087885_en pdf Instructions for use COMBIVERT S6 control board PRO www keb de fileadmin media Manuals dr ma_dr_s6 cu p inst 20156056_en pdf 41 Overview of the COMBIVERT S6 ...

Page 42: ...h on procedures 5minutes 5 min on 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 Destruction of the drive converter Never exchange connections main...

Page 43: ...tion Tightening torque PE Connection for protective earth Screw M4 for crimp connector 1 3 Nm 11lbinch Figure 12 Connection for protective earth 4 2 2 2 Functional earthing A functional earthing may also be necessary if for EMC requirements additional poten tial equalization between devices or parts of the system must be available The use of the functional earth FE is not required if the frequency...

Page 44: ...o observance the limit values according EN 61800 3 for units with out internal filter KEB COMBIVERT S6 Figure 13 Connection of the mains supply The service life of drive converters with voltage DC link depends on the DC voltage sur rounding temperature and the current load of the electrolytic capacitors in the DC link The use of mains chokes can increase the service life of the capacitors to a con...

Page 45: ...ign 4 2 4 DC connection 4 2 4 1 Connection at DC voltage supply U V W PE TA1 TA2 U U Legend DC voltage 260 750V Fuses Type aR Pay attention to the permissible voltage range KEB COMBIVERT S6 Figure 14 Connection at DC voltage supply 4 2 4 2 Terminal strip X1B DC connection X1B Name Function R U V W DC connection Type Push In spring connection Screwdriver blade 08x4 5 Stripping length 12mm Wire cros...

Page 46: ...ce The following data apply for operation under nom inal rating conditions Size Max motor cable length shielded max leakage cur rent at fN 100Hz in accordance with EN 61800 3 Category C2 Motor cable low capacitance 12 100m 5mA 13 14 Table 23 Maximum motor cable length at AC supply The line length can be extend significant by using motor chokes or filters KEB recommends the use of motor chokes or f...

Page 47: ...ons such as bundling and temperature 4 2 5 6 Interconnection of the motor NOTICE Protect motor against voltage peaks Drive converters switch at the output with du dt 5kV µs Voltage peaks that endanger the insulation system at the motor can occur especially in case of long motor cables 15 m A motor choke a dv dt filter or sine wave filter can be used for protection of the motor The connecting up in...

Page 48: ...ction cable of the temperature detection inside the motor cable is only permissible with additional shielding double shielding The input of the temperature detection has basic isolation 4 2 6 Connection of a braking resistor CAUTION Not fall below the minimum braking resistor value Falling below the minimum braking resistor value destroys the braking transistor of the drive converter 4 2 6 1 Termi...

Page 49: ... fault such as safety fuse without fire risk The delivered intrinsically safe braking resistors by KEB are described in the following link Technical data and design for intrinsically safe braking re sistors www keb de fileadmin media Manuals dr ma_dr_safe braking resis tors 20106652_en pdf 4 2 6 3 Using a non intrinsically safe braking resistor Technical data and design for non intrinsically safe ...

Page 50: ...nput Figure 20 Assignment of the terminal block X1C 4 3 1 Specification and connection of the brake control Name BR X1C 1 BR X1C 2 Function Output to supply a brake Output voltage Minimum P24V_IN 2 4V Maximum P24V_IN Maximum output current 2A Others Short circuit proof internal free wheeling path internal filter switching Table 25 Specification of the brake control 2 1 Imax 2A Udc 24V X1C Figure 2...

Page 51: ...permissible with double shielding A switchable KTY84 PTC evaluation is implemented in the KEB COMBIVERT The de sired operating mode can be adjusted by software dr33 Operating mode dr33 Resistance Temperature state if the resistance is too low Short circuit 0 KTY84 130 498Ω 0 C 1kΩ 100 C 1 722kΩ 200 C 1 PTC in ac cordance with DINEN60947 8 standard 750Ω TA1 TA2 closed 0 75 1 5kΩ reset resistance un...

Page 52: ...perate KTY sensors in forward direction Non observance leads incorrect measurement in the upper temperature range KTY sensors may not be combined with other detections Name TA1 X1C 5 TA2 X1C 6 Function Temperature sensor input Stetting dr33 0 KTY84 130 dr33 3 KTY83 110 Table 27 Connection of a KTY sensor TA1 TA2 KTY84 Legend 1 Connection via shield plate if not available place on the mounting plat...

Page 53: ...etting dr33 1 PTC or temperature switch dr33 4 PT1000 Table 28 Connection of PTC temperature switch or PT1000 Thermal contact NC contact TA1 TA2 Temperature sensor PTC or PT1000 TA1 TA2 Mixed sensor chain TA1 TA2 Legend 1 Connection via shield plate if not available place on the mounting plate Figure 23 Connection examples of different temperature sensors ...

Page 54: ...nal brake feedback without additional wiring or external via two digital brake inputs Power reduction through pulse width modulated control Rapid demagnetization with a counter voltage of 27 5 V maximum every 5 s Current monitoring The control parameterization and reading of the feedback inputs of the brake is carried out via the integrated safety module Corresponding wiring and parameterization s...

Page 55: ...sired operating mode can be adjusted by software dr33 Operating mode dr33 Resistance Temperature state at too short resistance short circuit 0 KTY84 130 498Ω 0 C 1kΩ 100 C 1 722kΩ 200 C 1 PTC in accordance with DINEN60947 8 standard 0 75 1 5kΩ reset resistance undefined 1 65 4kΩ tripping resistance undefined 2 by encoder digital by the encoder channel 3 KTY83 110 820Ω 0 C 1670Ω 100 C 2535Ω 175 C 4...

Page 56: ...s may not be combined with other detections Name TA1 X1C 9 TA2 X1C 10 Function Temperature sensor input Stetting dr33 0 KTY84 130 dr33 3 KTY83 110 Table 31 Connection of a KTY sensor X1C 9 TA1 X1C 10 TA2 KTY84 Figure 25 Connection of a KTY sensor 4 4 2 3 Connection of PTC temperature switch or PT1000 Name TA1 X1C 9 TA2 X1C 10 Function Temperature sensor input Stetting dr33 1 PTC or temperature swi...

Page 57: ...ermal contact NC contact TA1 TA2 Temperature sensor PTC or PT1000 TA1 TA2 Mixed sensor chain TA1 TA2 Legend 1 Connection via shield plate if not available place on the mounting plate Figure 26 Connection examples of different temperature sensors ...

Page 58: ...its are designed and manufactured in accordance with the Machine Directive The harmonized standard of the series EN 61800 5 2 is used 5 3 Annex to the declaration of conformity Annex to the EC declaration of conformity for systems with functional safety Product designation Drive converter series xxS6 A K xx xxxx Dimension 07 14 Voltage class 400Vac Hereby we declare that the safety component speci...

Page 59: ...afety of electrical electronic programmable electron ic safety related systems VDE 0803 1 7 EN60204 1 Safety of machinery Electrical equipment of machines Part1 General requirements VDE0113 1 EN62061 Safety of machinery Functional safety of electrical electronic and programmable electronic control systems VDE 0113 50 EN13849 1 Safety of machinery Safety related parts of control systems Table 33 Ap...

Page 60: ...nstruction manual S6 Housing Size 4 3 phase Models 14S6 Suitable For Use On A Circuit Capable Of Delivering Not More Than 5000 rms Sym metrical Amperes xxx Volts Maximum when protected by CC or J Class Fuses S6 Housing Size 4 3 phase Models 12S6 13S6 and 14S6 Suitable For Use On A Circuit Capable Of Delivering Not More Than 30000 rms Symmetrical Amperes xxx Volts Maximum when protected by CC Class...

Page 61: ...N RELAIS DE SURCHARGE LE RELAIS TOUT ENTIER DOIT ÊTRE REMPLACÉ Branch Circuit Protection for series S6 housing size 4 I Class CC or J fuses not more than 5000 rms Symmetrical Amperes SCCR 5kA Class CC fuses not more than 30000 rms Symmetrical Amperes SCCR 30kA Cat No Housing Input Voltage Vac maximum Fuse size A 12S6 04 200 230V 3ph 480 3ph 15 13S6 04 200 230V 3ph 480 3ph 20 14S6 04 200 230V 3ph 4...

Page 62: ...bus modules 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 f...

Page 63: ...015 11 Release version 01 2017 07 Change to new CI optics revision of device data Change of the overview Adjustment of the backup data 02 2018 08 Inserting the unit size 14 03 2019 12 Adjustments of the type code editorial changes 63 Revision History ...

Page 64: ...64 NOTES ...

Page 65: ...b jp Internet 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 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 Repu...

Page 66: ...Automation with Drive www keb de KEB Automation KG Suedstrasse 38 32683 Barntrup Tel 49 5263 401 0 E Mail info keb de ...