Ma - DR - f5 V Pu Inst 20128815 - en

COMBIVERT F5/F6
INSTRUCTIONS FOR USE | INSTALLATION F5/F6 HOUSING V | 600...1000 KVA
Translation of the original manual

Document 20128815 EN 02
Preface
Preface
The described hard- and software are developments of the KEB Automation KG. The
enclosed documents correspond to conditions valid at printing. Misprint, mistakes and
technical changes reserved.
Signal words and symbols

Certain operations can cause hazards during the installation, operation or thereafter.
There are safety informations in the documentation in front of these operations. Security
signs are located on the device or machine. A warning contains signal words which are
explained in the following table:
DANGER Dangerous situation, which will cause death or serious injury in 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 conditions must meet the validity of statements or the result is
limited to a certain validity range.
Is used when the result will be better, more economic or trouble-free by following
these procedures.
More symbols
► This arrow starts an action step.
• / - Enumerations are marked with dots or indents.
=> Cross reference to another chapter or another page.
Note to further documentation.

www.keb.de/nc/search
3
Preface
Laws and guidelines

KEB Automation KG confirms with the EC declaration of conformity with the CE mark
on the unit name plate, that the device complies with the essential safety requirements.
The EC declaration of conformity can be downloaded on demand via our website. Fur-
ther information is provided in chapter "Certification".
Warranty
The warranty on design, material or workmanship for the acquired device is given in the
current terms and conditions.
Here you will find our current terms and conditions.

www.keb.de/terms-and-conditions
Further agreements or specifications require a written confirmation.
Support
Through multiple applications not every imaginable case has been taken into ac-
count. If you require further information or if problems occur which are not treated de-
tailed in the documentation, you can request the necessary information via the local
KEB Automation KG agency.
The use of our units in the target products is beyond of our control and therefore
exclusively the responsibility of the machine manufacturer, system integrator or
customer.
The information contained in the technical documentation, as well as any user-specific
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 responsibility. 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 gener-
ally 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 modified.
Copyright
The customer may use the instruction manual as well as further documents or parts from
it for internal purposes. Copyrights are with KEB Automation KG and remain valid in its
entirety.
Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their
respective owners and are listed in the footnote on the first occurrence.
4
Table of Contents
Table of Contents
Preface..................................................................................................................................................... 3
Signal words and symbols.............................................................................................................. 3
More symbols..................................................................................................................................3
Laws and guidelines........................................................................................................................ 4
Warranty ........................................................................................................................................4
Support ........................................................................................................................................4
Copyright.........................................................................................................................................4
Table of Contents.................................................................................................................................... 5
List of Figures.......................................................................................................................................... 8
List of Tables........................................................................................................................................... 9
Glossary................................................................................................................................................. 10
Standards for drive converters / control cabinets.............................................................................. 12
Product standards that apply directly to the drive converter......................................................... 12
Basic standards to which drive converter standards refer directly................................................ 12
Standards that are used in the environment of the drive converter.............................................. 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.............................................................................................................................................. 19
1.8 Disposal........................................................................................................................................... 20
2 Product Description..................................................... 21
2.1 Product features............................................................................................................................. 21
2.1.1 Four quadrant operation...................................................................................................... 21
2.2 Specified application...................................................................................................................... 21
2.2.1 Residual risks...................................................................................................................... 22
2.3 Improper use................................................................................................................................... 22
2.4 Part code......................................................................................................................................... 23
3 Functional Overview.................................................... 24
3.1 Schematic diagram of the electrical power unit for the Q4 operation....................................... 24
3.2 Interior ventilation.......................................................................................................................... 25
4 Mechanical Installation................................................ 26
5
Table of Contents
4.1 Cooling system .............................................................................................................................. 26

4.2 Connection cooling system........................................................................................................... 26
4.2.1 Coolant connections of the drive converter......................................................................... 27
4.2.2 Wiring diagram cooling system........................................................................................... 28
4.3 Dimensions of the housing........................................................................................................... 29
4.4 Fixing points at the housing.......................................................................................................... 30
4.5 Assembly aids................................................................................................................................ 31
4.6 Assembly in the control cabinet................................................................................................... 33
4.6.1 Assembly of the slide rails and safety devices at the drive converter................................. 33
4.6.2 Function of the locking levers.............................................................................................. 34
4.6.3 Assembly of the side guide rails.......................................................................................... 35
4.6.4 Positions of the side guide rails in the control cabinet........................................................ 36
4.6.5 Installation of the drive converter in the control cabinet...................................................... 38
4.7 Disassembly from the control cabinet......................................................................................... 42
5 Electrical Installation.................................................... 43
5.1 General information....................................................................................................................... 43
5.2 Laying the cables........................................................................................................................... 43
5.3 Connection of the shield connection........................................................................................... 44
5.4 Connection of the protective earth............................................................................................... 44
5.5 Terminal power unit........................................................................................................................ 45
5.5.1 Permissible cable cross-sections and tightening torques of the terminals.......................... 46
5.5.2 Wiring diagram for the Q4 operation................................................................................... 47
5.6 Connection of the control boards................................................................................................. 48
5.6.1 Wiring diagram for WRA and WRB with F5 control boards ................................................ 49
5.6.2 Wiring diagram for WRA with F5 control board and WRB with F6 control board................ 50
5.7 Mains connection........................................................................................................................... 51
5.7.1 Required mains cable type.................................................................................................. 51
5.8 Motor connection........................................................................................................................... 52
5.8.1 General information............................................................................................................. 52
5.8.2 Connection motor cable...................................................................................................... 52
5.8.3 Selection of the motor cable................................................................................................ 53
5.8.4 Required motor cable type.................................................................................................. 53
5.9 Temperature detection T1A, T2A, T1B and T2B.......................................................................... 54
5.9.1 Use of the temperature input in KTY mode......................................................................... 55
5.9.2 Use of the temperature input in PTC mode......................................................................... 55
5.10 Connection braking resistor........................................................................................................ 56
5.10.1 External intrinsically safe braking resistor without temperature monitoring....................... 57
5.10.2 External braking resistor with overheat protection............................................................ 58
6 Technical Data............................................................... 59
6.1 Operating conditions..................................................................................................................... 59
6.1.1 Climatic ambient conditions................................................................................................. 59
6
Table of Contents
6.1.2 Mechanical ambient conditions........................................................................................... 60

6.1.3 Chemically / mechanically active substances................................................................ 60
6.1.4 Electrical operating conditions............................................................................................. 61
6.1.4.1 Device classification......................................................................................................... 61
6.1.4.2 Electromagnetic compatibility........................................................................................... 61
6.1.5 Cable cross-sections........................................................................................................... 62
6.1.6 Motor cable lengths............................................................................................................. 62
6.2 Electrical data 690 V mains voltage.............................................................................................. 63
7 Start-Up.......................................................................... 65
7.1 Procedure for initial start-up......................................................................................................... 65
7.2 Switch-on procedures.................................................................................................................... 66
7.3 Diagram switch-on procedure....................................................................................................... 67
A Annex - Diagrams......................................................... 68
A.1 Overload characteristic................................................................................................................. 68
A.2 Overload protection in the lower speed range............................................................................ 68
A.3 Power dissipation of the drive converter........................................................................................
B Annex - Certification.................................................... 70
B.1 CE Marking..................................................................................................................................... 70
C Annex - Cooling System.............................................. 71

C.1 General information....................................................................................................................... 71
C.1.1 Heat sink and operating pressure....................................................................................... 71
C.1.2 Materials in the cooling cicuit.............................................................................................. 71
C.1.3 Requirements on the coolant.............................................................................................. 72
C.1.4 Special requirements for open and half-open cooling systems:......................................... 73
C.1.5 Coolant flow temperature.................................................................................................... 73
C.1.6 Moisture condensation........................................................................................................ 73
C.1.7 Supply of temper coolant.................................................................................................... 74
C.1.8 Cooling circuit.....................................................................................................................74
C.1.9 Fall of pressure at the liquid cooling unit............................................................................ 75
C.1.10 Volume flow depending on total power dissipation and temperature difference............... 76
D Annex - Accessories.................................................... 77
D.1 Accessories.................................................................................................................................... 77
D.1.1 Filter....................................................................................................................................77
D.1.2 Internal fan.......................................................................................................................... 77
D.1.3 Screw connection............................................................................................................... 77
D.1.4 Industrial sole distributor..................................................................................................... 77
D.1.5 Extension system................................................................................................................ 77
D.1.6 Assembly aids..................................................................................................................... 77
7
List of Figures
List of Figures
Figure 1: Schematic diagram of the electrical power unit................................................................ 24
Figure 2: Interior ventilation.............................................................................................................25
Figure 3: Coolant connections of the drive converter...................................................................... 27
Figure 4: Wiring diagram cooling system......................................................................................... 28
Figure 5: Dimensions of the housing............................................................................................... 29
Figure 6: Fixing points at the housing.............................................................................................. 30
Figure 7: Lifting device.....................................................................................................................31
Figure 8: Eyebolts............................................................................................................................32
Figure 9: Assembly aids...................................................................................................................32
Figure 10: Assembly of the slide rails................................................................................................ 33
Figure 11: Function of the locking levers........................................................................................... 34
Figure 12: Assembly of the side guide rails....................................................................................... 35
Figure 13: Positions of the side guide rails in the control cabinet...................................................... 36
Figure 14: Distances..........................................................................................................................37
Figure 15: Schematic diagram...........................................................................................................38
Figure 16: Transport...........................................................................................................................39
Figure 17: Connect the drive converter housing V with the control cabinet....................................... 40
Figure 18: Fix the drive converter housing V in the control cabinet................................................... 41
Figure 19: Drive converter housing V assembled in the control cabinet............................................ 42
Figure 20: Laying the cables..............................................................................................................44
Figure 21: Connection terminals of the power circuit......................................................................... 45
Figure 22: DC-link connection............................................................................................................ 46
Figure 23: Wiring diagram for AFE / drive operation........................................................................... 47
Figure 24: Wiring diagram of the control unit with F5 control boards................................................. 49
Figure 25: Wiring diagram for the control unit with F5/F6 control boards.......................................... 50
Figure 26: Cross-section mains cable type........................................................................................ 51
Figure 27: Cross section motor cable type........................................................................................ 53
Figure 28: Connection of a KTY sensor............................................................................................. 55
Figure 29: Wiring example in PTC mode........................................................................................... 55
Figure 30: Intrinsically safe braking resistor without temperature monitoring.................................... 57
Figure 31: External braking resistor with overheat protection............................................................ 58
Figure 32: Flow diagram switch-on procedure................................................................................... 67
Figure 33: Overload characteristic..................................................................................................... 68
Figure 34: Overload protection in the lower speed range.................................................................. 68
Figure 35: Power dissipation of the drive converter........................................................................... 69
Figure 36: Fall of pressure at the liquid cooling system depending on the volume flow.................... 75
Figure 37: Volume flow depending on total power dissipation and temperature difference............... 76
8
List of Tables
List of Tables
Table 1: Part code..........................................................................................................................23
Table 2: Permissible cable cross-sections and tightening torques................................................. 46
Table 3: Temperature detection...................................................................................................... 54
Table 4: Functions temperature input............................................................................................. 54
Table 5: Climatic ambient conditions.............................................................................................. 59
Table 6: Mechanical ambient conditions......................................................................................... 60
Table 7: Chemically / mechanically active substances................................................................... 60
Table 8: Device classification......................................................................................................... 61
Table 9: Electromagnetic compatibility........................................................................................... 61
Table 10: Cable cross-sections........................................................................................................ 62
Table 11: Cable lengths motor connection....................................................................................... 62
Table 12: Technical Data..................................................................................................................64
Table 13: Electro-chemical voltage series........................................................................................ 72
Table 14: Requirements on the coolant............................................................................................ 72
Table 15: Special requirements for open and half-open cooling systems:....................................... 73
Table 16: Supply of temper coolant.................................................................................................. 74
Table 17: Accessories......................................................................................................................77
Table 18: Internal fan........................................................................................................................77
Table 19: Screw connection.............................................................................................................77
Table 20: Industrial sole distributor................................................................................................... 77
Table 21: Extension system..............................................................................................................77
Table 22: Assembly aids...................................................................................................................77
9
Glossary
Glossary
0V Earth-potential-free common point MCM American unit for large wire cross
1ph 1-phase mains sections
3ph 3-phase mains Modulation Means in drive technology that the
AC AC current or voltage power semiconductors are controlled
AFE Active Front End MTTF Mean service life to failure
AFE filter Filter for the AFE device NN Sea level
ASCL Asynchronous sensorless closed OC Overcurrent
loop OH Overheat
AW heat ex- Air-water heat exchanger OL Overload
changer PA Potential equalization
AWG American wire gauge PDS Power drive system incl. motor and
B2B Business-to-business measuring probe
CAN Fieldbus system PE Protective earth
CDM Complete drive module including PELV Protective Extra Low Voltage
auxiliary equipment (control cabinet) PFC Power factor correction
COMBIVERT KEB drive converters PFD Term used in the safety technology
COMBIVIS KEB start-up and parameterizing (EN 61508-1...7) for the size of error
software probability
DC DC current or voltage PFH Term used in the safety technology
DEIF Producer of control boards (EN 61508-1...7) for the size of error
DI Demineralized water, also referred to probability per hour
as deionized (DI) water PLC Programmable logic controller
DIN German Institut for standardization Port Part of a network address to the
EMC Electromagnetic compatibility assignment of TCP and UDP con-
Emergency Shutdown of a drive in emergency nections
stop case (not de-energized) PT100 Temperature sensor with R0=100Ω
Emergency Switching off the voltage supply in PT1000 Temperature sensor with R0=1000Ω
switching off emergency case PTC PTC-resistor for temperature detec-
EN European standard tion
EtherCAT Real-time Ethernet bus system of the PWM Pulse width modulation
company Beckhoff RJ45 Modular connector with 8 lines
Ethernet Real-time bus system - defines pro- SCL Synchronous sensorless closed loop
tocols, plugs, types of cables SELV Safety Extra Low Voltage (< 60 V)
FE Functional earth SF filter Sine-wave filter
FU Drive converter SS1 Safety function „Safe stop 1“ in ac-
GND Reference potential, ground cordance with IEC 61800-5-2
GTR7 Braking transistor SSI Synchronous serial interface for
HF filter High frequency filter to the mains encoder
HMI Human machine interface (touch STO Safety function „Safe Torque Off“ in
screen) accordance with IEC 61800-5-2
HSP5 Fast, serial protocol TTL Incremental signal with an output
HTL Incremental signal with an output voltage up to 5 V
voltage (up to 30V) -> TTL UCE Monitoring the saturation voltage of
I²t-monitoring Software function for thermal monito- the power switch
ring of the motor winding USB Universal serial bus
IEC International standard VARAN Real-time Ethernet bus system
IP xx Degree of protection (xx for level) WRA Inverter A
KTY Silicium temperature sensor (pola- WRB Inverter B
rized)
10
Glossary
11
Standards for drive converters / control cabinets

Product standards that apply directly to the drive converter
EN 61800-2 Adjustable speed electrical power drive systems - Part 2: General requirements -
Rating specifications for low voltage adjustable frequency a.c. power drive
systems (VDE 0160-102, IEC 61800-2)
EN 61800-3 Speed-adjustable electrical drives. Part 3: EMC requirements and specific test
methods (VDE 0160-103, IEC 61800-3)
EN 61800-5-1 Adjustable speed electrical power drive systems - Part 5-1: Safety requirements
- Electrical, thermal and energy (IEC 61800-5-1); German version EN 61800-5-1
EN 61800-5-2 Adjustable speed electrical power drive systems - Part 5-2: Safety Requirements
- Functional (IEC 22G/264/CD)
UL 61800-5-1 American version of the EN 61800-5-1 with „National Deviations“
Basic standards to which drive converter standards refer directly

EN 55011 Industrial, scientific and medical equipment - Radio frequency disturbance
characteristics - Limits and methods of measurement (CISPR 11); German
version EN 55011
EN 55021 Interference to mobile radiocommunications in the presence of impulse noise -
Methods of judging degradation and measures to improve performance (IEC/
CISPR/D/230/FDIS); German version prEN 55021
EN 60529 Degrees of protection provided by enclosures (IP Code) (IEC 60529)
EN 60664-1 Insulation coordination for equipment within low-voltage systems Part 1: Princi-
ples, requirements and tests (IEC 60664-1)
EN 60721-3-1 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
EN 60721-3-2 Classification of environmental conditions - Part 3: Classification of groups of
environmental parameters and their severities - Section 2: Transportation and
handling (IEC 104/670/CD)
EN 60721-3-3 Classification of environmental conditions - Part 3: Classification of groups of
environmental parameters and their severities; section 3: Stationary use at
weatherprotected locations; Amendment A2 (IEC 60721-3-3); German version
EN 60721-3-3
EN 61000-2-1 Electromagnetic compatibility (EMC) - Part 2: Environment - Section 1: Descrip-
tion of the environment - Electromagnetic environment for low-frequency
conducted disturbances and signalling in public power supply systems
EN 61000-2-4 Electromagnetic compatibility (EMC) - Part 2-4: Environment; Compatibility
levels in industrial plants for low-frequency conducted disturbances (IEC 61000-
2-4); German version EN 61000-2-4
EN 61000-4-2 Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement
techniques - Electrostatic discharge immunity test (IEC 61000-4-2); German
version EN 61000-4-2
techniques - Radiated, radio-frequency, electromagnetic field immunity test (IEC
61000-4-3); German version EN 61000-4-3
12

techniques - Electrical fast transient/burst immunity test (IEC 61000-4-4);
German version EN 61000-4-4
techniques - Surge immunity test (IEC 61000-4-5); German version EN 61000-4-5
techniques - Immunity to conducted disturbances, induced by radio-frequency
fields (IEC 61000-4-6); German version EN 61000-4-6
techniques - Voltage dips, short interruptions and voltage variations immunity
tests for equipment with mains current more than 16 A per phase (IEC 61000-4-
34); German version EN 61000-4-34
EN 61508-1...7 Functional safety of electrical/electronic/programmable electronic safety-related
systems – Part 1...7 (VDE 0803-1…7, IEC 61508-1…7)
EN 62061 Safety of machinery - functional safety of electrical, electronic and program-
mable electronic safety-related systems (VDE 0113-50, IEC 62061)
EN ISO 13849-1 Safety of machinery - safety-related parts of control systems - Part 1: General
principles for design (ISO 13849-1); German version EN ISO 13849-1
Standards that are used in the environment of the drive converter

DGUV regulation 3 Electrical installations and equipment
DIN 46228-1 Wire-end ferrules; Tube without plastic sleeve
DIN 46228-4 Wire-end ferrules; Tube with plastic sleeve
DIN IEC 60364-5-54 Low-voltage electrical installations - Part 5-54: Selection and erection of
electrical equipment - Earthing arrangements, protective conductors and protec-
tive bonding conductors (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
EN 1037 Safety of machinery - Prevention of unexpected start-up; German version EN 1037
EN 12502-1...5 Protection of metallic materials against corrosion - Part 1...5
EN 60204-1 Safety of machinery - electrical equipment of machines Part 1: General require-
ments (VDE 0113-1, IEC 44/709/CDV)
EN 60439-1 Low-voltage switchgear and controlgear assemblies - Part 1: Type-tested and
partially type-tested assemblies (IEC 60439-1); German version EN 60439-1
EN 61373 Railway applications - Rolling stock equipment - Shock and vibration tests (IEC
61373); German version EN 61373
EN 61439-1 Low-voltage switchgear and controlgear assemblies - Part 1: General rules (IEC
121B/40/CDV); German version FprEN 61439-1
VGB R 455 P Water treatment and use of materials in cooling systems
13
Basic Safety Instructions
1 Basic Safety Instructions

The COMBIVERT is designed and constructed in accordance with state-of-the-art tech-
nology and the recognised safety rules and regulations. However, the use of such devic-
es may cause functional hazards for life and limb of the user or third parties, or damages
to the system and other material property.
The following safety instructions have been created by the manufacturer for the area of
electric drive technology. They can be supplemented by local, country- or application-
specific safety instructions. This list is not exhaustive. Non-observance will lead to the
loss of any liability claims.
NOTICE Hazards and risks through ignorance.
►► Read the instruction manual !
►► Observe the safety and warning instructions !
►► If anything is unclear, please contact 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.
• Detection of hazards and risks of the electrical drive technology.
• Knowledge of DIN IEC 60364-5-54.
• Knowledge of national safety regulations (e.g. DGUV regulation 3).
1.2 Transport, storage and proper use

The transport is carried out by qualified persons in accordance with the environmental
conditions specified in this manual. Drive converter shall be protected against excessive
strains.
Transport of drive converters with an edge length >75 cm

The transport by forklift without suitable tools can cause a deflection of the heat
sink. This leads to premature aging or destruction of internal components.
►► Transport of drive converters on suitable pallets.
►► Do not stack drive converters or burden them with other heavy objects.
14
Drive converters contain electrostatic sensitive components.

►► Avoid contact.
ESD ►► Wear ESD-protective clothing.
Do not store drive converters

• in the environment of aggressive and/or conductive liquids or gases.
• with direct sunlight.
• outside the specified environmental conditions.
1.3 Installation
DANGER Do not operate in an explosive environment!
►► The COMBIVERT is not intended for the use in potentially explosive

environment.
EX
CAUTION Design-related edges and high weight!
Contusions and bruises!

►► Never stand under suspended loads.
►► Wear safety shoes.
►► Secure drive converter accordingly when using lifting gear.
To prevent damages to the device:

• Make sure that no 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 elements. Do not
cover the ventilation openings.
• Mount the drive inverter according to the specified degree of protection.
• Make sure that no small parts fall into the COMBIVERT during assembly and wiring
(drilling chips, screws etc.). This also applies to mechanical components, which can
lose small parts during operation.
• Check the reliable fit of the device connections in order to avoid contact resistances
and sparking.
• Do not walk-on drive converter.
• The safety instructions are to be kept!
15
1.4 Electrical connection
DANGER Voltage at the terminals and in the device !
Danger to life due to electric shock !

►► Never work on the open device or never touch exposed parts.
►► For any work on the unit switch off the supply voltage and secure it
against switching on.
►► Wait until the drive has stopped in order, that perhaps regenerative
energy can be generated.
►► Await capacitor discharge time (5 minutes) if necessary, measure

DC voltage at the terminals.
►► If personal protection is required, install suitable protective devices

for drive converters.
►► Never bridge upstream protective devices (also not for test pur-
poses).
►► Connect the protective earth conductor to drive converter and motor

everytime.
►► Install all required covers and protective devices for operation.
►► The control cabinet shall be kept closed during operation.
For a trouble-free and safe 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 dimensioned by the user accordly to the
specified minimum / maximum values for the opperation.
• Drive converters are only intended for permanent connection. Cross-sections of pro-
tective earth conductors should be interpreted in accordance with DIN IEC 60364-
5-54.
• Connection of the drive converter is only permissible on symmetrical networks with
a maximum line voltage (L1, L2, L3) with respect to earth (N/PE) of max. 300 V. An
isolating transformer must be used for supply networks which exceed this value. In
case of non-compliance the control is not longer considered as "PELV circuit".
• With existing or newly wired circuits the person installing the units or machines must
ensure the EN requirements are met.
• For drive converters that are not isolated from the supply circuit (in accordance with
EN 61800-5-1) all control lines must be included in other protective measures (e.g.
double insulation or shielded, earthed and insulated).
• When 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.
16
If personnel protection is required during installation of the

system, suitable protective devices must be used for drive
converters.
https://www.keb.de/fileadmin/media/Manuals/knowledge/04_techinfo/00_
general/ti_rcd_0400_0002_gbr.pdf
Installations which include drive converter shall be equipped with additional control and
protective devices in accordance with the relevant applicable safety requirements, e.g.
act respecting technical equipment, accident prevention rules etc. They must always be
complied with, also for drive converter bearing a CE marking.
1.4.1 EMC-compatible installation
Observance of the limit values required by EMC law is the responsibility of the manufac-
turer of the installation or machine.
Notes on EMC-compatible installation can be found here.

https://www.keb.de/fileadmin/media/Manuals/emv/0000neb0000.pdf
1.4.2 Voltage test
Testing with AC voltage (in accordance with EN 60204-1 Chapter 18.4) may not be ex-
ecuted, since there is danger for the power semiconductors in the drive converter.
Because of the noise suppression capacitors the test generator will immedi-
ately trigger with current error.
Accordng to EN 60204-1 it is permissible to disconnect already tested com-

ponents. Drive converters of the KEB Automation KG are delivered ex works
voltage tested to 100% according to product standard.
1.4.3 Insulation measurement
An insulation measurement (in accordance with EN 60204-1 chapter 18.3) with DC

500 V is permissible, if all power unit connections (grid-connected potential) and all con-
trol connections are bridged with PE. At any unit it can be expected with an insulating
resistance > 5 MΩ !
17
1.5 Start-up and operation

The drive converter must not be started until it is determined that the installation com-
plies with the machine directive; Account is to be taken of EN 60204-1.
WARNING Software protection and programming !
Hazards caused by unintentional behavior of the drive!

►► Check especially during initial start-up or replacement of the drive
converter if parameterization is compatible to application.
►► Securing a unit solely with software-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 cooling water lines.
►► Before working let the unit cool down.
• During operation, all covers and doors shall be kept closed.

• Use only approved accessories for this device.
• Never touch terminals, busbars or cable ends.
Observe the following instructions if the drive converter for

more than one year was not in operation before start-up.
https://www.keb.de/fileadmin/media/Manuals/knowledge/04_techinfo/00_
general/ti_format_capacitors_0400_0001_gbr.pdf
Switching at the output

Switching between motor and drive converter is prohibited for single drives during op-
eration as this may trigger the protection gear of the device. Function “speed search”
must be activated if switching can not be avoided. Control release may only be triggered
after closing the motor contactor (e.g. by switching the control release).
Connecting and disconnecting is permissible with multiple motor drives if at least 1 mo-
tor is running during the switch-over process. The drive converter must be dimensioned
to the occurring starting currents.
The “speed search” function must be activated if the motor is still running during a restart
of the drive converter (mains on) (e.g. due to large rotating masses).
18
Switching on the input

For applications that require cyclic switching on and off 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.
Short-circuit proof
The drive converters are conditional short-circuit proof. After resetting the internal pro-
tection devices, the function as directed is guaranteed.
Exceptions:
• If an earth-leakage fault or short-circuit often occurs at the output, this can lead to a
defect in the unit.
• If a short-circuit occurs during regenerative operation (2nd or 4th quadrant, regen-
eration into the DC link), this can lead to a defect in the unit.
1.6 Maintenance
The following maintenance work has to be carried out when required, but at least once
per year by authorized and trained personnel.
►► Check unit for loose screws and plugs and tighten if necessary.
►► Clean drive converter from dirt and dust deposits. Pay attention especially to cool-
ing fins and protective grid of the fans.
►► Examine and clean extracted air filter and cooling air filter of the control cabinet.
►► Check the function of the fans of the drive converter. The fan must be replaced in
case of audible vibrations or squeak.
►► Make a visual leak test of the cooling circuit for water-cooled inverters.
1.7 Repair
In case of malfunction, unusual noises or smells inform a person in charge!
DANGER Unauthorized exchange, repair and modifications!
Unpredictable malfunctions!
►► The function of the drive converter is dependent on its parameteriza-
tion. Never replace without knowledge of the application.
►► Modification or repair is permitted only by KEB Automation KG au-

thorized personnel.
►► Only use original manufacturer parts.
►► Infringement will annul the liability for resulting consequences.
In case of failure, please contact the machine manufacturer. Only the machine manu-
facturer knows the parameterisation of the used drive converter and can provide an
appropriate replacement or induce the maintenance.
19
1.8 Disposal
Drive converters with safety function are limited to a service life of 20 years. Then the
devices must be replaced.
Drive converters of the KEB Automation KG are professional, electronic devices exclu-
sively for further industrial processing (so-called B2B devices). Thus the marking does
not occur with the symbol of the crossed-out wheeled bin, but by the word mark and the
date of manufacture.
Unlike devices mainly used in private households, these devices may not be disposed
at the collection centres of public sector disposal organisations. They must be disposed
after the end of use in accordance with national applicable law to environmentally cor-
rect disposal of electrical and electronic equipment.
20
Product Description
2 Product Description
The COMBIVERT F5 / F6 is a four quadrant drive converter. It consists of two inverters,
which are connected internally via a DC link. The V housing has AC pre-charging which
makes it possible to pre-charge another unit of the same size. The drive converter is
designed for 400V / 690V mains.
2.1 Product features
2.1.1 Four quadrant operation
If drive converter A operates as AFE (Active Front End), it reaches a sinusoidal current
consumption at the mains side. The operation is permitted only on symmetrical three-
wire systems in connection with special AFE filters. The inverter A requires a corre-
sponding AFE software.At inverter B of the operation of different motors is possible. In
case of regenerative operation of the motors, the electrical power is regenerative feed-
back directly into the mains via inverter A. An additional feedback unit is not required.
This offers the following advantages:
• Inverter A operates as a step-up controller to stabilize the DC bus voltage.

• Lower mains reactions, harmonics and commutation notches.
• No synchronization unit required.
• Simple precharge of the DC link via the parallel AC input.
• Feeds back excess energy from the regenerative operation into the supply mains.
• Replaces brake resistor and brake transistor;reduces the heat output.
• Brake transistor as an option to protection in case of power failure.
• Feeds KEB drive converters individually or after consultation via DC network.
• Active power factor correction (PFC) and cos phi control possible.
• Internal protection against overcurrent and overtemperature.
• At AFE operation, the DC link voltage can be varied depending on the selected
mains voltage.
• Voltage drops to the engine which can be caused by the use of sine-wave filters,
motor chokes or filters can be compensated accordingly.
KEB offers specifically for this type of operation a complete cabinet system which can be
fitted with additional components by customer requirements.

https://www.keb.de/fileadmin/media/Manuals/dr/ma_dr_f5-sv-pu-
inst-20136714_en.pdf
2.2 Specified application

The COMBIVERT serves exclusively for the control and regulation of three-phase mo-
tors. The COMBIVERT is intended for the installation in electric systems or machines.
21
Product Description
The technical data as well as information concerning the supply conditions shall be
taken from the type plate and from the instruction manual and shall 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 functions, life-supporting measures or an extraordinary safety step must be fulfilled,
the necessary reliability and security must be ensured by the machine builder.
2.2.1 Residual risks
In spite of the intended use, the drive converter may assume unpredictable operating
conditions in the event of a fault, wrong parameterisation, wrong connection or unau-
thorized intervention and repairs. This can be:
• Wrong direction of rotation
• High motor speed
• Motor is running into limitation
• Motor can also be under voltage also at standstill
• Automatic restart
2.3 Improper use

The operation of other electric consumers is prohibited and can lead to the destruction of
the unit. The operation of our products outside the indicated limit values of the technical
data leads to the loss of any liability claims.
22
Product Description
2.4 Part code

xx xx x x x-x x x x
Liquid cooling system with stainless steel piping

Heat sink models 2:
(standard)
F5 control board without STO, SCL closed-loop,

E: encoder resolver input / incremental encoder out-
put TTL
F5 control board without STO, AFE closed-loop,
Control type WRB and F:
encoder incremental in-/output
encoder interface
F6 control board with STO, multi software, multi
M:
encoder interface, fieldbus EtherCAT1
N:
encoder interface, fieldbus Varan
Switching frequency, WRA 4 kHz 125 % / WRB 2/4 kHz 125 % / 150 %

A:
overload characteristic (standard)
A: 3ph 400 V AC
Voltage / B: 3ph 690 V AC
connection type C: 400 V DC
D: 690 V DC
Housing V
0: without braking transistor

1: with braking transistor WRB (RB)
Variants
2: with braking transistor WRA (RA)
3: with braking transistor WRA / WRB (RA / RB)
F5 control board without STO, SCL closed-loop,

E: encoder resolver input / incremental encoder out-
put TTL
F5 control board without STO, AFE closed-loop,
Control type WRA and F:
encoder incremental input / output
encoder interface
M:
encoder interface, fieldbus EtherCAT1
N:
encoder interface, fieldbus Varan
F5: COMBIVERT F5
Series
F6: COMBIVERT F6
33: 600 kVA
Inverter size
37: 980 kVA
Table 1: Part code
1
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation
GmbH, Germany
23
Functional Overview
3 Functional Overview
3.1 Schematic diagram of the electrical power unit for the Q4 operation
L1
L2
L3
Fuses
Mains fuses
Pre-charging circuit
HF filter EMV
AFE filters
L3´
Drive converter
L2´
WRA
Drive converter A L1´ Connection second
RA Braking option
DC link - +
Connection + /- - + DC link
Connection + /-
WRB
Drive converter B
RB
Braking resistor
SF filter optional
optional
U V W
M
3~
PE
Figure 1: Schematic diagram of the electrical power unit
24
Functional Overview
3.2 Interior ventilation

The drive converter is designed by way that interior ventilation is not necessary at rated
operation. The interior is cooled by thermal convection.
The following conditions must be fulfilled:
• No other heat sources should be installed below the drive inverter (e.g. AFE filter,
motor chokes).
• The drive converter operates in rated operation (max. 45 °C ambient conditions in
the control cabinet, max. switching frequency 4 kHz).
• The coolant distributor should be installed below the drive converter (see cabinet
instruction manual).
If the drive converter should be operated under different ambient conditions, it is possi-
ble to install an external fan (120 mm x 120 mm) at the rear panel of the device.
Please note the following:

• The correct direction of the air flow (see => Figure 2).
• The supply must be externally from the control cabinet.
Dependent on the available voltage supply in the control cabinet, use a fan on the
basis of 24 V DC voltage or 230 V AC voltage.
A suitable fan is listed in the chapter Annex Accessories.

This fan can be supplied via KEB (see „D.1.5 Extension system“).
Figure 2: Interior ventilation
25
Mechanical Installation
4 Mechanical Installation
4.1 Cooling system

The KEB COMBIVERT in V housing is available exclusively for liquid cooling systems.
The dissipation of the power loss must be ensured by the machine builder.
ATTENTION Operation only with flow switch and flow monitor permissible.
►► When connecting the cooling circuit, absolutely follow the notes

from annex C.
►► Already brief interruptions of the cooling circuit can destroy the

device.
CAUTION High temperatures at heat sink and coolant!
Burning of the skin!

►► Cover hot surfaces safe-to-touch.
►► Before working let the unit cool down.
►► Before touching, check the surface and cooling water lines.
►► If necessary, attach warning signs on the system.
4.2 Connection cooling system

• The connection to the cooling system can occur as closed or open cooling circuit.
• The connection to a closed cycle cooling circuit is recommended, because the dan-
ger of contamination of the coolant is very small.
• Preferably also a monitoring of the pH value of the coolant should be installed.
• Pay attention to a corresponding cable cross-section at required equipotential bond-
ing in order to avoid electro-chemical procedures.
• 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.
• Recommnendation: Connection to the cooling circuit by using elastic, pres-
sure-resistant hoses in conjunction with the supplied functional nuts.
ATTENTION Volume flow meter and temperature monitoring
• The use of volume flow meters and temperature monitoring is

mandatory.
• The coolant flow must always be started before starting the KEB
COMBIVERT.
• Observe appropriate wiring of input I3.
26
4.2.1 Coolant connections of the drive converter
Legend
A WRA B WRB
Coolant outlet Coolant outlet
Coolant inlet Coolant inlet
Figure 3: Coolant connections of the drive converter
Screw connections for the coolant connection can be found under „D.1.3
Screw connection“. These are supplied by KEB as standard.
27
4.2.2 Wiring diagram cooling system
This connection diagram serves only as an installation proposal and restores

no professional planning and design!
① ② Housing V ② ③
¾“ ¾“
WRA
① ② ② ③
➃ ¾“ ¾“ ➄
11/4“
WRB 11/4“
① ② ② ③
5/8“ 5/8“
AFE
Legend
WRA Drive converter A
WRB Drive converter B
① Throttle valve adjustable 10 - 40 l/min
② Ball valve/shut-off valve
③ Volume flow meter
④ Forward
⑤ Reverse
AFE filter; the values for falling pressure, volume flow and flow temperature can be taken from
AFE
the technical data sheet of the AFE filter.
Figure 4: Wiring diagram cooling system
ATTENTION ►► Liquid cooling systems and other components in the cooling circuit
must be operated parallelly.
►► Pay attention to flux direction and check tightness !

• The min. volume flow depends on the total power loss.
• Max. temperature difference (ΔT) between inlet and return flow 7 K.
• A volume flow over 40 l/min increases the risk of erosion in the
liquid cooler.
• A discontinuous operation is not permitted, this leads to immediate
destruction of the dunit.
• For further details on the AFE filter, please refer to the technical
data sheet of the filter.
28
4.3 Dimensions of the housing
424 71
25
917
870
F
KEB Automation KG
32683 Barntrup
Made in Germany
475
487
Figure 5: Dimensions of the housing
29
4.4 Fixing points at the housing
325 400
175 350
4xØ9
350
825
F
KEB Automation KG
32677 Barntrup
Made in Germany
350
132
57
4xØ9
325
425
Front side Rear side

Figure 6: Fixing points at the housing
Alternative fixing points on the rear side.Note that in this mounting option, the
access to the rear wall of the control cabinet must be guaranteed.
30
4.5 Assembly aids

Two different tools, which can be ordered separately are available for the assembly of
the unit in a control cabinet. There is a lifting device as assembly kit, as well as a eye
bolt set size M12 DIN 580.
Figure 7: Lifting device
31
Figure 8: Eyebolts
Assembly aids
Assembly kit ring bolts M12 DIN 580
Item number 00F5ZTB-0004
Mounting kit hoisting device
Item number 00F5ZTB-0013
Figure 9: Assembly aids
32
4.6 Assembly in the control cabinet

This section describes the assembly of a drive converter housing V into a Rittal TS8
control cabinet (600 mm width).
4.6.1 Assembly of the slide rails and safety devices at the drive converter
The figure shows the assembly of the slide rail and safety device for the right side. Re-
peat the procedure on the left side.
F
KE
B Au
32 to
Ma 683 matio
de Barn n
in KG
Ge trup
rm
an
y
3
3
4 1
2 4
5, 6
5, 6
Figure 10: Assembly of the slide rails
Pos. Designation KEB Part number Torque

1 2x slide rails D0V6T09-0009
2 2x locking lever D0V6T09-0049
3 4x sheet metal bearing D0V6T09-0059
4 8x M5x 10mm oval-head screws ISO 7045 9905071-510K 4 Nm
5 4x M12x20mm socket screws ISO 4762 9905044-Z009 30 Nm
6 4x lock washer S12,00 zinc plated 9918009-0019
For more information see Accessories „D.1.5 Extension system“.
33
4.6.2 Function of the locking levers
The locking levers for securing the drive converter in the control cabinet can be opened
or closed by moving the long front end.
Locking lever open Locking lever closed

Figure 11: Function of the locking levers
34
4.6.3 Assembly of the side guide rails
The figure shows the assembly of the side guide rails. The guide rails are mounted later
in the control cabinet. They are the breakpoints for the drive converter in the control
cabinet.
4
4
5
7
3
5
6
4
6
5
1
4
Figure 12: Assembly of the side guide rails
Pos. Designation KEB Part number Rittal Part number

1 1x angular rail left D0V6T09-000L -
2 1x angular rail right D0V6T09-000R -
3 2x slide rail D0V6T09-0069 -
4 10x 4x M8x20mm socket screws ISO 4762 -
5 6x Rittal cage nut M8 - TS 4165.000
6 4x Rittal speed nuts M8 - TS 4165.000
7 2x Rittal TS System-Chassis 23 x 73 mm - TS 8612.560
For more information see Accessories „D.1.5 Extension system“.
35
4.6.4 Positions of the side guide rails in the control cabinet
Decisive for the installation is the minimum dimension of 132 mm given above. This
must not be lower, since otherwise the distances of the +/- rails of the DC link to the
control cabinet housing are not met. Based on this dimension, all other dimensions are
defined for the assembly of the guide rails and fixing rails. The specifications of Rittal
have to be complied with for the assembly of the rails in the control cabinet TS8.
min. 132
X
Y Y
752
Z Z
X-X X
Cross section through the control cabinet Front view

Figure 13: Positions of the side guide rails in the control cabinet
36
66,5 50 325 50
75 175 75 116,5
Y-Y Z-Z
View from above View from above
Upper fixing points of the drive converter Lower fixing points of the drive converter
66,5 125
32,5
75
41,5 225 250
A (1 : 2)
Cross section through the control cabinet

Cutout A
Figure 14: Distances
37
4.6.5 Installation of the drive converter in the control cabinet
Schematic diagram
The control cabinet shown in the following drawings is merely a section of the
total system for better illustration. It is not a single control cabinet.
Figure 15: Schematic diagram
38
ATTENTION Observe weight during transport
►► The drive converter has a weight of 150 kg.
►► The transport must be done only with approved lifting devices.
It is recommended to assembly the drive converter into the control cabinet with
a forklift or crane.
F
KEB
Auto
3268
Mad 3 mati
e inBarn on KG
trup
Germ
any
Figure 16: Transport
39
WARNING Risk of tipping without fixed screw connection !
►► Provide sufficient stability for the control cabinet.
►► Firmly fix to the ground or integrate into a cabinet system.
►► Avoid top-heaviness of the control cabinet.
Procedures:
1. Place the drive converter with open locking levers to the control cabinet.
2. Place the drive converter on the guide rails.
F
KEB
Autom
32683
Made ation
Barnt
in KG
Germrup
any
F
KEB
Autom
32683
Made ation
Barnt
in KG
Germrup
any
Figure 17: Connect the drive converter housing V with the control cabinet
40
Procedures:
3. Push the drive converter slowly past the front vertical frame rails to the stopper of
the opened locking levers into the control cabinet.
4. Close the locking levers by pressing them down.
5. Remove the lifting device.
6. Push the drive converter to the end point.
7. Fix the rear wall of the drive converter at 8 points (each 4 at the top and bottom) with
M8 x 20 mm screws on the rear horizontal mounting rails.
The specifications of company Rittal must be observed when screwing.
F
KEB
Autom
32683
Made ation
Barnt
in KG
Germrup
any
F
KEB
Autom
32683
Made ation
Barnt
in KG
Germrup
any
Figure 18: Fix the drive converter housing V in the control cabinet
41
The figure shows the drive converter housing V assembled in the control cabinet.
F
KEB
Aut
326 om
Mad 83 atio
e inBarntru
n KG
Ger p
man
y
Figure 19: Drive converter housing V assembled in the control cabinet
4.7 Disassembly from the control cabinet

Carry out the disassembly from the control cabinet in reverse order to the assembly.
Screws which have been attached during the assembly, must be loosened at disas-
sembly.
42
Electrical Installation
5 Electrical Installation
5.1 General information

This chapter contains the information which must be observed when selecting the ca-
bles, the protective measures, as well as the cable routing in the control cabinet.
ATTENTION The applicable laws and local regulations must always be observed
when planning and executing the installation. KEB assumes no liability
for installations when laws, local and / or other regulations have not
been complied. If the recommendations provided by KEB have been
ignored, there can be problems when using the drive converter which
are not covered by the warranty.
The indicated conductor cross sections in chapter „Technical Data“ are recommenda-
tions for the dimensioning and serve as standard values for multicore copper power
cables. They are valid for a maximum ambient temperature of 40°C and open laying
cables. This must be taken into account accordingly in case of deviating ambient condi-
tions and local regulations.
5.2 Laying the cables

• Lay cables being susceptible to interference or sources of interference at the high-
est possible distance from each other (min. 200 mm).
• If the distance is not complied with, additional shielding measures shall be provided.
• Cables must be placed as close as possible to grounded housing parts, mounting
plates or cabinet frames. This reduces noise emissions and noise injection.
• Crossings of cables with signals of different classes must be avoided.
• If another cable laying is not possible, cross the cables in a right angle, especially if
it concerns to sensitive and interfering signals.
• Cores of signal and data cables which are not used must be grounded at both ends.
• Avoid long cables and interference sources in order to prevent additional coupling
points in the cabinet system.
• Not used cables must be grounded on one side in the control cabinet.
• Make ground connections with the largest possible cross-section to further control
cabinets, system components and decentralized devices.
• Avoid larger cable loops.
43
0
20
>230 V AC
≤24 V DC
>230 V AC
≤24 V DC
Figure 20: Laying the cables
5.3 Connection of the shield connection

• Cable shields must not be used for power supply.
• A cable shield must not simultaneously assume the function of a N- or PE conductor.
• Always ground the cable shields by means of large surface.
• Do not make extensions of the cable shield by unshielded wire connections to the
grounding point. This reduces the shielding effect by up to 90 %.
• Connect the cable shield directly after the entry of the cable in the control cabinet to
an earthing bar.
5.4 Connection of the protective earth

• The drive converter or the control cabinet wherein the drive converter is installed
must be connected to the protective earth at destination.
• Use a protective earth conductor which corresponds at least to the half cross-sec-
tion of the cables for the supply of the power terminals.
• An earthing stud is available at the drive converter for the connection of the motor
protective earth.
• The resistance of the protective earth should be 0.1 Ω or less.
• The minimum cross section of the protective earth conductor must comply with the
local safety regulations concerning protective earth conductor for high leakage cur-
rent equipment in accordance with EN 61800-5-1.
WARNING Indirect touch

The device meets the requirements for the protection against indirect
contact only with properly connected protective earth conductor.
44
5.5 Terminal power unit
②
L3‘ L2‘ L1‘
①
③
T2b T1b T2A T1A

⑦
⑤
No. Terminals Function

① L1‘, L2‘, L3‘ Mains input for precharging
② UA, VA, WA Phase connection WRA
③ UB, VB, WB Phase connection WRB
④ RA, RB Connection braking resistor
T1A, T2A Connection filter temperature monitoring
⑤ T1B, T2B Connection motor temperature monitoring
⑥ Connection shielding / earthing
⑦ – Control WRB
⑧ – Control WRA
continued on the next page
Figure 21: Connection terminals of the power circuit
Information about the F5 control boards can be found

here.
https://www.keb.de/fileadmin/media/Manuals/f5/control/f5g/00f5gebk320.pdf

here.
https://www.keb.de/fileadmin/media/Manuals/dr/00f6nesk000.pdf
45
No. Terminals Function

⑨ + DC-link connection +
⑩ - DC-link connection -
Figure 22: DC-link connection
5.5.1 Permissible cable cross-sections and tightening torques of the terminals
Permissible cross-section flexible Maximum tightening torque

mm² AWG/MCM
Nm lb inch
No. min max min max
1, 5 0,2 6 24 AWG 10 AWG 1 6
6, 9,
M10 stay bolt for ring thimble 23 203
10
M12 through hole for max. 2 ring terminals, each with 240mm2 35 310
2, 3,
4 Terminal of Druseidt part number 02223 Dimensions 60 x 60 mm
see manufacturer's instructions
for connecting current and lamella bars.
Table 2: Permissible cable cross-sections and tightening torques
46
5.5.2 Wiring diagram for the Q4 operation
-Q1
Legend
L3
F1 Mains fuses
L2
F2 Pre-charging fuses
L1 G1 Motor
PE K2 Pre-charging contactor
-W1
K3 Main contactor
Q1 Main switch / circuit breaker
S1 Filter temperature switch
S2 Motor temperature switch
L1 L2
U
L3 U1 Varistors
-U1
L1‘ L2‘ L3‘ U2 HF filter
L1.1 L2.1 L3.1
U3 AFE filters
-U2
L1.2 L2.2 L3.2 U4 COMBIVERT housing V
W1 Short-circuit proof line
U1.1 V1.1 W1.1 PE
-U3
-S1
U1.2 V1.2 W1.2
-U4
L1‘
UA VA WA PE T1A T2A WRB
L2‘
L3‘
WRA T1B T2B UB VB WB PE
-S2
Figure 23: Wiring diagram for AFE / drive operation
47
5.6 Connection of the control boards

In the following circuit examples, the WRA of the drive converter is connected to the
mains supply via an AFE filter. The temperature monitoring of the AFE filter occurs
by the WRA. The inputs and outputs are pre-programmed for the subsequent circuit
example.

https://www.keb.de/fileadmin/media/Manuals/dr/ma_dr_f5-afe-pu-
phb-20136715_en.pdf
CAUTION Contactor lock required!

K2 and K3 never switch simultaneously (destruction of the device).
For safe operation of the drive converter in the Q4 mode
►► use the power contactors K2 and K3 (pre-charging and main con-

tactor) with positively driven auxiliary contacts.
This ensures in case of failure a secure locking of defective contactors.
ATTENTION Check before starting up!
►► Pre-charging contactor K2 and mains contactor K3 interlock against

each other.
►► Parameterization of I3 in the drive converter control (pre-parameter-

ized).
►► Protect motor against voltage peaks.
►► Start the coolant flow (warranty by the volume flow meter).
48
5.6.1 Wiring diagram for WRA and WRB with F5 control boards
-U4
L X2A
11 10 (I1) WRA
-K2
12
13
11 (I2)
12 (I3)
Control
-K3
14
-S6 16 (ST)
17 (RST)
board
-S2 -S3 -S4
18 (O1)
20 (Uout 24V)
-K1
13 + 21 (Uin)
22 (0V)
14
27 (FLA)
11 -S1
-K4 29 (FLC)
12 14 A1 X2A
24V DC -K1
A2 -K4
A1 10 (I1) WRB
-K3
11
12
-K2
21 A2 11 (I2)
12 (I3)
Control
22
- -S5 -S7
16 (ST)
17 (RST) board
18 (O1)
A1 A1 20 (Uout 24V)
-K2 -K3 21 (Uin)
A2 A2 22 (0V)
27 (FLA)
29 (FLC)
N
Legend
K1 Coupling relay switching on / off S1 Switch on U4
K2 Pre-charging contactor S2 External release WRA (AFE)
K3 Main contactor S3 Second setpoint
K4 Coupling relay for the main contactor S4 Error reset
U4 WRA (Active Front End) S5 External release WRB (FU)
U4 WRB (motor inverter) S6 Volume flow meter WRA
S7 Volume flow meter WRB
Figure 24: Wiring diagram of the control unit with F5 control boards
49
5.6.2 Wiring diagram for WRA with F5 control board and WRB with F6 control board
-U4
L X2A
11 10 (I1) WRA
-K2
12
11 (I2) Control board
13 12 (I3)
-K3
-S6 16 (ST) F5
14 17 (RST)
-S2 -S3 -S4
13 18 (O1)
-K1
20 (Uout 24V)
14
+ 21 (Uin)
22 (0V)
11 14 27 (FLA)
-S1
29 (FLC)
-K4
12 A1
X2B
24V DC -K1
A2 -K4
A1
1 (STO1+) WRB
11 21 A2 3 (STO1-) Control board
-K3 -K2 5 (STO2+)
12 22
7 (STO2-) F6
- 9 (STO Out)
-S7 X2A
A1 A1 2 (0V)
-K2 -K3
A2 A2 13 (I3)
25(24V in)
26 (0V)
N
Legend
K1 Coupling relay switching on / off S1 Switch on U4
K2 Pre-charging contactor S2 External release WRA (AFE)
K3 Main contactor S3 Second setpoint
K4 Coupling relay for the main contactor S4 Error reset
U4 WRA (Active Front End) S6 Volume flow meter WRA
U4 WRB (motor inverter) S7 Volume flow meter WRB
Figure 25: Wiring diagram for the control unit with F5/F6 control boards
50
5.7 Mains connection
5.7.1 Required mains cable type
At high motor ratings, symmetrical shielded motor

cables are required.
PE
• Cable type: 2XSLCYK-J.
• The protective earth conductor is tripartited and
U V •
uniformly placed between the phase lines.
Compliance with the requirements according to EN
12502-1...5.
PE PE
W
Figure 26: Cross-section mains cable type
51
5.8 Motor connection
5.8.1 General information
• The motor cables must be designed to the maximum continuous current.

• They are valid for 0...100 Hz (up to 300 Hz the cable losses increase by approx.
25% due to the skin effect).
• The IGBT modules cause high-frequency interferences which cause a stronger der-
ivation into the earth potential with increasing motor cable length.
• The consequence is an increase of the cable-based interferences on the line side.
• If the motor cables are too long, the damping of the mains filter is no longer sufficient
and the permitted interference limits are exceeded.
• At the output of the drive converter, pulses with approx. 1.35-fold of the mains volt-
age and very short rise times are generated independently of the output frequency.
• This is the case for all drive converters with modern IGBT drive converter technol-
ogy.
• The voltage of the pulses can be almost double at the motor terminals, depending
on the motor cable properties.
• This can lead to additional load on the motor and motor cable insulation.
• Modern speed-controlled drives with its rapidly rising voltage pulses and high switch-
ing frequencies can cause current pulses which run through the motor bearings and
lead to a gradual damage of the bearing raceways.
ATTENTION Protect motor against voltage peaks !
►► The connecting-up instructions of the motor manufacturer are al-

ways generally valid !
►► Inverter switch at the output with high voltage rise speed see „Tech-
nical Data“. 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 du/dt filter as well as a sine-wave filter can be
used to protect the motor.
5.8.2 Connection motor cable
ATTENTION
By default, all 690 V motors are connect in star connection.
52
5.8.3 Selection of the motor cable
Correct selection and wiring of the motor cable is very important for high motor ratings:
• Smaller load of the motor bearings by bearing currents.

• Improved EMC characteristics.
• Lower symmetrical operating capacities.
• Less losses by transient currents.
• Because of the large currents shielded motor cables can be connected parallel be-
tween the drive converter and motor.
• All three phases must passing through each line.
• The required cross-section is described in chapter „Technical Data“.
• To keep an asymmetry as small as possible, all motor cables should have the same
length.
• The shielding must be placed always with large surface on both sides (mounting
plate and motor housing).
5.8.4 Required motor cable type
At high motor ratings, symmetrical shielded motor

cables are required.
PE
• Cable type: 2XSLCYK-J.
• The protective earth conductor is tripartited and
U V •
uniformly placed between the phase lines.
Compliance with the requirements according to EN
12502-1...5.
PE PE
W
Figure 27: Cross section motor cable type
53
5.9 Temperature detection T1A, T2A, T1B and T2B

Parameter In.17 shows in the first digit of the hex value the function of the used temper-
ature input.The KEB COMBIVERT F5/F6 is delivered as standard with switchable PTC/
KTY evaluation. The desired function is adjusted with Pn.72 (dr33 at F6) and operates
in accordance with the following table:
In.17 Function of T1x, Pn.72 Resistance Display ru.46 Error/Warn-

(Hex) T2x (dr33) (F6 => ru28) ing 1)
< 215 Ω Detection error 253 yes
498 Ω 1 °C no 2)
KTY84 0 1 kΩ 100 °C yes 2)
1.722 kΩ 200 °C yes 2)
> 1811 Ω Detection error 254 yes
5xh < 750 Ω T1x-T2x closed no
0.75…1.65 kΩ
PTC undefined –
(reset resistance)
(in accordance with 1
1.65…4 kΩ
DIN EN 60947-8) undefined –
(tripping resistance)
> 4 kΩ T1x-T2x open yes
6xh PT100 – upon request
Table 3: Temperature detection
1) The column is valid at factory setting. The function must be parameterized accordingly with parame-
ters Pn.12, Pn.13, Pn.62 and Pn.72 for F5 operating mode GENERAL.
2) Disconnection is depending on the adjusted temperature in Pn.62 (F6 => pn11/14).
The behaviour of the drive converter in case of error/warning is defined with

parameters Pn.12 (CP.28), Pn.13 (F6 => pn12/13).
Dependent on the application the temperature input can be used for the following func-
tions:
Function Mode (F5 => Pn.72; F6 => dr33)

Motor temperature display and monitoring KTY84
Motor temperature monitoring PTC
Temperature control for liquid-cooled motors 1)
KTY84
General fault sensing PTC
Table 4: Functions temperature input
1) If the temperature input is used for other functions, the motor temperature control can be done indirectly
via the coolant circuit of the drive converter.
54
ATTENTION KTY or PTC cable and sensors
►► Do not lay the KTY or PTC cable of the motor (also shielded) to-
gether with the control cable!
►► KTY or PTC cable inside the motor cable is only permissible with
double shielding!
►► KTY sensors may not be combined in connection with other sens-

ings. Otherwise this causes wrong measurements.
5.9.1 Use of the temperature input in KTY mode
Connection of a KTY sensor
T1
+
-
KTY84
T2
Figure 28: Connection of a KTY sensor
5.9.2 Use of the temperature input in PTC mode
If the temperature input is operated in PTC mode, all possibilities are available for the
user within the specified resistance range. This can be:
Wiring example in PTC mode
T1
Thermal contact (NC contact)

T2
T1
Temperature sensor (PTC)
T2
T1
Mixed sensor chain
T2
Figure 29: Wiring example in PTC mode
The function can be switched off with Pn.12 = “7“ (CP.28) if no evaluation of the input is
desired (standard in operating mode GENERAL). Alternatively a bridge can be installed
between T1A, T2A and T1B, T2B.
55
5.10 Connection braking resistor
Braking resistors dissipate the produced energy of the motor into

CAUTION heat during generatoric operation.
Burns and fire hazard due to the high surface temperatures.
►► Pay attention to appropriate protection against contact and fire.
►► In the case of a defective braking transistor always switch off the

mains voltage (fire hazard).
►► If constructional related a direct contact can not be avoided, install

warning label "hot surfaces".
DANGER Regenerative operation
Danger to life due to electric shock !

The drive converter remains in operation in spite of switched off power
supply in regenerative operation.
►► An error must be released by external wiring which switches the
modulation off in the drive converter. This can occur e.g. at termi-
nals T1 / T2 or via digital input.
►► The drive converter must be parameterized accordingly in each

case.
Technical data and design for intrinsically safe braking re-

sistors.
https://www.keb.de/fileadmin/media/Manuals/dr/ma_dr_safe-braking-re-
sistors-20106652_en.pdf
Technical data and design for non-intrinsically safe braking

resistors.
https://www.keb.de/fileadmin/media/Manuals/dr/ma_dr_braking-resis-
tors-20116737_en.pdf
56
5.10.1 External intrinsically safe braking resistor without temperature monitoring
RA/RB
-R1 F5/F6 -U4
Legend
U4 COMBIVERT F5 / F6 R1 Braking resistor
Figure 30: Intrinsically safe braking resistor without temperature monitoring
ATTENTION Only "intrinsically safe" braking resistors are permissible for the opera-
tion without temperature monitoring.
57
5.10.2 External braking resistor with overheat protection
This circuit provides an indirect protection with defective braking transistor.
• In case of failure the brake resistor overheats and opens the OH terminals.
• These open the hold circuit of the input contactor and switches off input voltage.
The regenerative operation is secured as follows.
• The opening of the auxiliary contacts of K3 triggers an error in the drive converter.
• The input I2 must be programmed and inverted to "external error".
• Automatic restarting after cooling of the braking resistor is prevented by the self-hold-
ing circuit of K3.
PTC / KTY evaluation
If the PTC / KTY evaluation at terminals T1A, T2A / T1B, T2B are not used,
these can be used instead of the programmable input.The temperature input
must be operated in PTC mode.
+ 24V DC
14
-K3
13
-R1
I2
OH1
RA/RB
F5/F6 -U4
OH2 + 0V
S1
K1
-
Legend
K1 Coupling relay switching on / off U4 COMBIVERT F5 / F6
S1 Switch on U4 R1 Braking resistor with temperature switch
K3 Line contactor with auxiliary contacts „Wiring diagram for WRA and WRB with F5 control boards“
Figure 31: External braking resistor with overheat protection
58
Technical Data
6 Technical Data
6.1 Operating conditions
6.1.1 Climatic ambient conditions
Storage Standard Class Notes

Ambient temperature EN 60721-3-1 1K4 -25…55 °C
Relative humidity EN 60721-3-1 1K3 5…95 % (without condensation)
Storage height – – max. 3000 m above sea level
Transport Standard Class Notes
Ambient temperature EN 60721-3-2 2K3 -25…70 °C
Relative humidity EN 60721-3-2 2K3 95 % at 40 °C (without condensation)
Operation Standard Class Notes
5…40 °C (extended to -10…45 °C)
Ambient temperature EN 60721-3-3 3K3 (with temperature over 45 °C to max. 55 °C
a derating of 5 % per 1 K must be taken into
consideration)
Coolant inlet
Water – – 5…40 °C
temperature
Relative humidity EN 60721-3-3 3K3 5…85 % (without condensation)
No protection against foreign bodies.
Type of protection EN 60529 IP00
No protection against water.
max. 2000 m above sea level
• With site altitudes over 1000 m a derating
of 1 % per 100 m must be taken into con-
sideration.
Site altitude – –
• With site altitudes over 2000 m, the control
board to mains has only basic insulation.
Additional measures must be taken for the
wiring of the control.
Table 5: Climatic ambient conditions
59
Technical Data
6.1.2 Mechanical ambient conditions

Vibration amplitude 0.3 mm (2…9 Hz)
Vibration limits EN 60721-3-1 1M1
Acceleration amplitude 1 m/s² (9…200 Hz)
Shock limit values EN 613731 1M1 40 m/s²; 22 ms
Vibration limits EN 60721-3-2 2M1 Acceleration amplitude 10 m/s² (9…200 Hz)
Shock limit values EN 60721-3-1 2M1 100 m/s²; 11 ms
EN 60721-3-3 3M4
Vibration limits EN 61800-5-1 –
Railway applications
EN 61373 1A
Assembled on the vehicle body.
Shock limit values EN 60721-3-3 3M4 100 m/s²; 11 ms
Pressure in the water cooler – – Max. operating pressure: 10 bar
Table 6: Mechanical ambient conditions
6.1.3 Chemically / mechanically active substances

Gases 1C2 –
Contamination EN 60721-3-1
Solids 1S2 –
Gases 2C2 –
Solids 2S2 –
Gases 3C2 –
Solids 3S2 –
Table 7: Chemically / mechanically active substances
60
Technical Data
6.1.4 Electrical operating conditions
6.1.4.1 Device classification
Requirement Standard Class Notes

EN 61800-5-1 –
Overvoltage category III
EN 60664-1 –
Non-conductive pollution, occasional conden-
Pollution degree EN 60664-1 2
sation when PDS is out of service
Table 8: Device classification
6.1.4.2 Electromagnetic compatibility
The specified values apply only to devices with external filter.
EMC emitted interference Standard Class Notes

Cable-based interferences EN 61800-3 C2 –
Radiated interferences EN 61800-3 C2 –
Interference immunity Standard Level Notes
8 kV AD (air discharge)
Static discharges EN 61000-4-2
4 kV CD (contact discharge)
Burst - connections for pro-
cess-oriented measurement
EN 61000-4-4 2 kV –
and control functions and
signal interfaces
Burst - power interfaces EN 61000-4-4 4 kV –
1 kV Phase-phase
Surge - power interfaces EN 61000-4-4
2 kV Phase-ground
Cable-fed disturbances, in-
EN 61000-4-6 10 V 0.15...80 MHz
duced by high frequency fields
10 V/m 80 MHz...1 GHz
Electromagnetic fields EN 61000-4-3 3 V/m 1.4...2 GHz
1 V/m 2...2.7 GHz
Voltage variation / EN 61000-2-1 -15 %...+10 %
–
voltage drop EN 61000-4-34 90 %
Frequency changes EN 61000-2-4 – ≤ 2 %
Voltage deviations EN 61000-2-4 – ±10 %
Voltage unsymmetries EN 61000-2-4 – ≤ 3 %
Table 9: Electromagnetic compatibility
61
Technical Data
6.1.5 Cable cross-sections
ATTENTION If the minimum cross-section of the motor connection is distributed to

several lines, the permissible cable length is reduced. See 6.1.6 Motor
cable lengths.
The recommended minimum cross sections for mains and motor connection at rated
power are shown in the following table:
Cable cross-sections
Inverter size 33 37
Mains connection mm 2
2 x 120 2x240
2 x 120
Motor connection mm2 2 x 240
1 x 240
Table 10: Cable cross-sections
6.1.6 Motor cable lengths
• The maximum cable lengths are specified for the recommended cable types.
• The permissible cable lengths depend on the number of cables per phase.
• Longer cables may only be used after consultation with KEB.
• The specified cable lengths represent the actual distance between the drive con-
verter and the motor.
• Factors such as parallel laying, current carrying capacity and laying factor are con-
sidered.
When motor cables are parallel connected, the line capacitance is doubled. This
leads to higher leakage currents between the drive converter and motor. The
leakage currents should always be kept as low as possible.
The resulting motor cable length at parallel operation of motors, or for parallel laying by
multi-core connection results from the following formula:
Resulting motor cable length = ∑single cable length x √number of motor cables
Maximum permissible cable lengths motor connection

Cable lengths
Cross section m
Inverter size
mm2 without SF filter at the with SF filter at the output
output
1 x 240 100 500
33
2 x 120 35 175
37 2 x 240 35 175
Table 11: Cable lengths motor connection
62
Technical Data
6.2 Electrical data 690 V mains voltage

Inverter size 33 37
Drive converter A (AFE)
Input rated voltage UN V AC 600 / 690
Input voltage range Uin V AC 360…760 ±0 %
Mains frequency F Hz 48 - 63
Phases 3
Permitted mains forms 1) TN, TT, IT
Max. supply imbalance % 8
Max. permissible mains short-circuit Icc kA 50
current
Input rated power Sin kVA 600 980
Max. input power Pn kW 450 710
Supply / regenerative rated current Iin A AC 500 820
Max. short time current (E.OL) 30 s IOL % 125 125
OC-tripping current (E.OC) IOC % 150 150
Rated switching frequency fS kHz 4 4
Voltage rise (10-90%) du/dt kV/μs 5
Line protection for customer-supplied mains supply line
Fuse In A AC 630 -
Circuit breaker In A AC optional 2)
Drive converter B (Drive)
Output rated power Sout kVA 600 980
Max. output power Pout kW 450 710
Output rated current Iout A AC 500 820
Max. short time current (E.OL) 30 s 3) IOL % 125 125
OC-tripping current IOC % 150 150
Standstill current at 4 kHz 4) Idc A DC 343 563
Output voltage 5) Uout V AC 0…Uin
Rated switching frequency fSN kHz 4 4
Max. switching frequency 6) fSmax kHz 4 4
Output frequency 7) fout Hz 0…max. 599
Min. frequency at continuous full load fmin Hz 3
Voltage rise (10-90%) du/dt kV/μs 5
Overload characteristic see A.1 Overload characteristic
Cable cross-section
Min. mains cable cross-section mm²
see 6.1.5 Cable cross-sections
Motor cable cross-section 8) mm²
Max. motor line length shielded m see 6.1.6 Motor cable lengths
63
Technical Data
Inverter size 33 37
DC link data
DC link capacity Cint µF 7800
Max. external DC link capacity Cext µF 7800
DC under voltage level V DC 360
DC overvoltage level V DC 1200
DC control voltage level V DC 1100
Min. braking resistor 9) Ω 1,0
Switch-off level braking resistor 9) V DC 1140
Overcurrent cut-off braking current A DC 1500
Other data
Max. precharging current Ipre A AC 65 65
Permissible precharging fuse (F2) 10) A AC 35 35
Power loss (in the coolant) 11) Pv kW 18 28
Total power dissipation 12) Pv kW 20 30
ΔT forward/reverse ΔT °C 3…8
Flow temperature (typically) 13) T °C 35 30
Max. flow temperature 13) T °C 45 40
Max. heat sink temperature (OH) T °C 79 79
Coolant content per liquid cooling system L 5,3
Volume flow Q l/min see C.1.10
Fall of pressure Δpv bar see C.1.9
Max. operating pressure P bar 6
Weight m kg 150
Table 12: Technical Data
1) Usage on IT mains depends on the application. A release is possible after consultation with KEB.
2) Use circuit breaker, which disconnects the system all poles in error case.
3) With the regulated operating modes MULTI and SERVO 5 % are to be subtracted as control reserve.
4) Max. current before the OL2 function triggers (in operating mode MULTI and SERVO).
5) The voltage (3ph) at the motor is dependent on the series-connected units and on the control method.
6) Higher switching frequencies on request.
7) The output frequency is to be limited in such way that 1/10 of the switching frequency is not exceed-
ed. Units with higher max. output frequency are subject to export restrictions and are only available on
request.
8) Recommended minimum cross section of the motor line for rated power and a cable length of upto
100 m (CU).
9) This data is only valid for units with internal brake transistor (see "unit identification").
10) The starting current is decreased below 50 % of the initial value in max.1 s.
Pre-charging contactor: We recommend e.g., DIL M25 or better DIL M(C) 25 (for capacitive load 14 kW
690 V AC3)
Rated current: 25 A @ AC3 @ 400 V (AC3 = max. 6 x starting current)
Imaxin = 25 A * 6 = 150 A (at DIL M C 25 even 350 A; see data sheet)
That are 50 % current reserve to ensure an appropriate lifetime/ number of switch-on procedures.
11) Depending on the selected flow temperature and the volume flow (±2 kW).
12) The details of the total power loss refer to both converters at rated operation.
13) Other flow temperatures see C.1.5 Coolant flow temperature.
The technical data are for 2/4-pole standard motors. With other pole numbers
the drive converter must be dimensioned onto the motor rated current. Con-
tact KEB for special or medium frequency motors.
64
Start-Up
7 Start-Up
7.1 Procedure for initial start-up
ATTENTION The coolant flow must always be started before starting the KEB
COMBIVERT.
• The control boards can be put into operation via an external 24 V DC supply.
• This enables the pre-parameterization of the control boards without charging the DC
link of the drive converter.
• The communication with the converters can be established via the diagnostic inter-
faces of the control boards.
• This requires a PC and the corresponding software to parameterize the converters.
• The structure of the communication is described in the application manuals of the
control boards.
• The WRA (AFE) is factory pre-parameterized via download. No further settings need
to be made.
• Adjustments must only be made if the cabinet system is not operated at 690 V AC
voltage. Information can be found in the programming manual AFE housing V.

here.
https://www.keb.de/fileadmin/media/Manuals/f5/control/f5g/00f5gebk320.pdf

here.
https://www.keb.de/fileadmin/media/Manuals/dr/00f6nesk000.pdf

phb-20136715_en.pdf
65
Start-Up
7.2 Switch-on procedures

Switch-on procedure WRA (AFE)
►► S1 switches the pre-charging contactor K2 via the coupling relay.
• DC link voltage reaches the pre-set value in parameter LE.04.
• Output O1 is set and switches the interface relay K4.
• K4 disconnects the pre-charging contactor K2 and switches the main contactor K3.
• Further charging of the DC link occurs via K3, WRA or AFE filter.
By internal programming (OA, IA) the modulation is suppressed as long as

• the adjustable threshold value (LE.04) is reached.
• the waiting time (di.48) has expired.
The control release is set if

►► S2 has been set.
• the pre-charging contactor K2 has dropped.
• the main contactor K3 has closed.
• by input I2 the delay time (di.42) has expired.
Following the modulation will be released.
After that phase position and rotating field (left / right) of the mains voltage will be de-
tected.
• The DC link voltage will be regulated to the setpoint (oP.03).
• If the setpoint (oP.03) is reached, the relay output 2 (FLC) switches.
Switch-on procedure WRB (FU)

►► The F5 control board sets the control release by switch (S5).
►► With the F6 control board the control release occurs via terminal X2B.1 (STO +).
66
Start-Up
7.3 Diagram switch-on procedure

The following diagram illustrates graphically the switch-on procedure.
K1
K2
O1 (K4)
K3
5s (di.48)
OA->IA (AFE)
S2
Modulation (AFE)
R2 (AFE)
S5
5s (di.42)
1s
oP.03
Uin x √2
LE.00/04
Udc
Figure 32: Flow diagram switch-on procedure

phb-20136715_en.pdf
67
Annex - Diagrams
A Annex - Diagrams
A.1 Overload characteristic
Time t in s
330
300
270
240
210
180
150
120
90
60
30
0
0 105 110 115 120 125 130 135 140 145 150
Load in %
Figure 33: Overload characteristic
On exceeding a load of 105 % the overload integrator starts. When falling below the
integrator counts backwards. If the integrator achieves the overload characteristic that
corresponds to the drive converter, the error E.OL is triggered.
A.2 Overload protection in the lower speed range
►► The characteristic line applies only to the operating modes MULTI and SERVO.
►► Not for the operating mode AFE.
Load in %
OC-tripping current
Short time current limit E.OL2 E.OL
Start of overload integrator

at 105%
Stand still current

(see technical data) f in
Hz
Min. frequency at continuous full load
(see „Technical Data“)
Figure 34: Overload protection in the lower speed range
A PT1-element (τ = 280 ms) starts if the permissible current is exceeded. After its se-
quence of operation the error E.OL2 is triggered.
68
Annex - Diagrams
A.3 Power dissipation of the drive converter

The diagram below shows the power dissipations of the drive converter to the output
current.
①
②
38
36
34
32
30
28
Power dissipation in kW
26
24
22
20
18
16
14
12
10
2
100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000
Output current in A
Legend
① ––––– Total power dissipation 690 V mains voltage, 4 kHz switching frequency WRA / WRB
② ––––– Heat loss power 50 Hz motor output frequency, 25 °C flow temperature
Figure 35: Power dissipation of the drive converter
69
Annex - Certification
B Annex - Certification
B.1 CE Marking
CE marked drive converters and servo drives were developed and manufactured to
comply with the regulations of the Low-Voltage Directive and EMC directive.The harmo-
nized standards of the series VGB R 455 P and EN 61800-3 were used.
This is a product of limited availability in accordance with EN 61800-3. This product may
cause radio interferences in residential areas; In this case the operator may need to take
corresponding measures.
The drive converter or servo drive must not be started until it is determined that the
installation complies with the Machine directive as well as the EMC directive (note
EN 60204-1).
70
Annex - Cooling System
C Annex - Cooling System
C.1 General information

ln continuous operation liquid-cooled drive converters are operated with lower temper-
ature than air-cooled converters. This has positive effects on lifetime-relevant compo-
nents such as fan and DC link circuit capacitors and power modules (IGBT). Also the
temperature dependent switching losses are positively effected. The use of liquid-cooled
KEB COMBIVERT drive converters is offered in the drive technology, because there are
process-caused coolants available with some applications.
C.1.1 Heat sink and operating pressure
Design system Material Max. operating pres- Connection

sure
Cooling plate with Stainless steel Functional nut
6 bar
pressed-in tubes 1.4404 „D.1.3 Screw connection“
ATTENTION Observe maximum operating pressure.
►► To avoid deformation of the heatsink and related consequential

damages, the specified maximum operating pressure must not be
exceeded. Even not by momentary pressure peaks.
►► Pay attention to the guidelines 97/23/EG of pressure units.
C.1.2 Materials in the cooling cicuit
For all metallic elements in the cooling circuit which are in contact with the coolant
(electrolyte), a material must be selected which forms a small voltage difference to the
heat sink (see electro-chemical series). Thus, the formation of contact corrosion and/or
pitting corrosion is avoided.
Electro-chemical voltage series / standard potentials against hydrogen

Material generated Ion Standard poten- Material generated Ion Standard poten-
tial tial
Lithium Li+ -3.04 V Nickel Ni2+ -0.25 V
Potassium K +
-2.93 V Tin Sn 2+
-0.14 V
Calcium Ca2+ -2.87 V Lead Pb3+ -0.13 V
Sodium Na +
-2.71 V Iron Fe 3+
-0.037 V
Magnesium Mg 2+
-2.38 V Hydrogen 2H +
0.00 V
Titan Ti2+
-1.75 V stainless steel div. 0.2…0.4 V
Aluminium Al 3+
-1.67 V Copper Cu 2+
0.34 V
Manganese Mn 2+
-1.05 V Carbon C 2+
0.74 V
Zinc Zn2+ -0.76 V Silver Ag+ 0.80 V
Chrome Cr 3+
-0.71 V Platinum Pt 2+
1.20 V
71
Electro-chemical voltage series / standard potentials against hydrogen

Material generated Ion Standard poten- Material generated Ion Standard poten-
tial tial
Iron Fe2+ -0.44 V Gold Au3+ 1.42 V
Cadmium Cd 2+
-0.40 V Gold Au +
1.69 V
Cobald Co 2+
-0.28 V
Table 13: Electro-chemical voltage series
We recommend the use of stainless steel or nickel plated screw connection.
Other materials must be examined in each case before employment. The specific case
of application must be checked by the customer in tuning of the complete cooling circuit
and must be classified according to the used materials. With hoses and seals take care
that halogen-free materials are used.
A liability for occuring damages by wrongly used materials and from this resulting corro-
sion cannot be taken over!
C.1.3 Requirements on the coolant
The requirements on the coolant are depending on the ambient conditions, as well as
from the used cooling system.
Requirements Application
Suspended solids The size and the proportion of suspended solids in the cooling water should not ex-
ceed the following values: < 100 μm < 10 mg per liter.
pH-value The optimal pH-value should be in the range of 7.5…8.0.
Abrasive substances Abrasive substances as used in abrasive (quartz sand), clogging the cooling circuit
and should be avoided.
Hard water The cooling water may not cause scale deposits or loose excretions. The total hard-
ness should be between 7...20° dH, the carbon hardness at 3...10° dH.
Soft water Soft water (<7° dH) corrodes the material.
Frost protection An appropriate antifreeze must be used for applications when the heat sink or the
coolant is exposed temperatures below zero. Use only products of one manufacturer
for a better compatibility with other additives. We recommend the antifreeze Anti-
frogenN of the company Clariant with a maximum volume percent of 52 %.
Corrosion protection Additives can be used as corrosion protection. In connection with frost protection the
antifreeze must have a concentration of 20…25 % Vol, in order to avoid a change of
the additives.
Table 14: Requirements on the coolant
72
C.1.4 Special requirements for open and half-open cooling systems:
Problem Solution
Impurities Mechanical impurities in half-open cooling systems can be counteracted when ap-
propriate water filters are used.
Salt concentration The salt content can increase through evaporation at half-open systems. Thus the
water is more corrosive. Adding of fresh water and removing of process water
works against.
Algae and Algae and myxobacteria can arise caused by increased water temperature and
myxobacteria contact with atmospheric oxygen. The algae and myxobacteria clog the filters and
obstruct the water-flow. Biocide containing additives can avoid this. Especially at
longer OFF periods of the cooling circuit preventive maintenance is necessary.
Organic materials The contamination with organic materials must be kept as small as possible, be-
cause separate slime can be caused by this.
Table 15: Special requirements for open and half-open cooling systems:
ATTENTION Damages at the unit
►► Damages at the unit which are caused by clogged, corroded liquid

heat sinks or other obvious operating errors, leads to the loss of the
warranty claims.
C.1.5 Coolant flow temperature
The coolant flow temperature is depending on the unit size and is specified in the
technical data.
Flow temperature
The flow temperature should be selected depending on the volume flow by
way that the heat sink temperature at rated operation is always 10 K below
the overtemperature level. This avoids sporadic shutdown.
C.1.6 Moisture condensation
Due to high air humidity and high temperatures it can lead to moisture condensation.
Moisture condensation is dangerous for the drive converter, because the drive converter
can be destroyed by any occuring short-circuits.
ATTENTION Moisture condensation
►► The user must ensure that any moisture condensation is avoided!
73
C.1.7 Supply of temper coolant
This is possible by using heatings in the cooling circuit for the control of the coolant tem-
perature. The following dew point table is available for this:
Coolant inlet temperature in °C is depending on ambient temperature in °C and air hu-

midity in %:
Air humidity in % 10 20 30 40 50 60 70 80 90 100
Surrounding
temperature in °C
-25 -45 -40 -36 -34 -32 -30 -29 -27 -26 -25
-20 -42 -36 -32 -29 -27 -25 -24 -22 -21 -20
-15 -37 -31 -27 -24 -22 -20 -18 -16 -15 -15
-10 -34 -26 -22 -19 -17 -15 -13 -11 -11 -10
-5 -29 -22 -18 -15 -13 -11 -8 -7 -6 -5
0 -26 -19 -14 -11 -8 -6 -4 -3 -2 0
5 -23 -15 -11 -7 -5 -2 0 2 3 5
10 -19 -11 -7 -3 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 22 27 32 36 38 41 43 45
50 8 19 28 32 36 40 43 45 48 50
Coolant inlet temperature in °C
Table 16: Supply of temper coolant
C.1.8 Cooling circuit
The cooling circuit must be completely empty if a unit shall be switched off for a longer
period. The cooling circuit must be blown out additionally with compressed air at tem-
peratures below 0 °C.
74
C.1.9 Fall of pressure at the liquid cooling unit
• The curve characteristic described below is valid for 25 °C flow temperature and
Antifrogen N 52 %.
• If higher flow temperatures are reached, the pressure drop in the system decreases.
• This also applies for coolants such as water or other glycol mixture.
• We recommend a glycol mixture of Clariant in a ratio of 52 % or 33 %.
ATTENTION Parallel operation
►► The COMBIVERT F5/F6 consists of two liquid cooling systems

which are parallel operated.
►► The following diagram refers to a single liquid cooling system.
Pressure drop in bar

3,00
2,70
2,40
2,10
1,80
1,50
1,20
0,90
0,60
0,30
0,00
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
Volume flow in l/min
Legend
––––– Pressure drop at 25 °C and 52 % glycol mixture
Recommended operating range
Figure 36: Fall of pressure at the liquid cooling system depending on the volume flow
75
C.1.10 Volume flow depending on total power dissipation and temperature difference
15
①
14
13
12
②
Temperature difference ΔT in K
11
10 ③
9
④
8
7
⑤
0
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Total power dissipation Pv in kW

Legend
① ––––– 40 l/min total ④ ––––– 70 l/min total
20 l/min per liquid cooling system 35 l/min per liquid cooling system
② ––––– 50 l/min total ⑤ ––––– 80 l/min total
25 l/min per liquid cooling system 40 l/min per liquid cooling system
③ ––––– 60 l/min total
Recommended operating range
30 l/min per liquid cooling system
Figure 37: Volume flow depending on total power dissipation and temperature difference
76
Annex - Accessories
D Annex - Accessories
D.1 Accessories
D.1.1 Filter
Voltage class Inverter size Varistor SF filter HF filter LCL filter

690 V 33 upon request 33Z1K16-0000 35E5T60-8001 33Z1K06-1001
690 V 37 upon request 37Z1K16-0000 39E5T60-8001 37Z1K06-1001
Table 17: Accessories
D.1.2 Internal fan
Internal fan Number Description Data

0090990-9035 1 120 x 120 mm ext. 24 V DC max. 190 mA
Table 18: Internal fan
D.1.3 Screw connection
Assembly set screw Product Number

connection
00V6DD0-0000 Functional nut for 18mm pipe metric M26 x 1.5 4
Table 19: Screw connection
D.1.4 Industrial sole distributor
Industrial sole Product Number

distributor
Industrial sole distributor for the distribution of the cool-
00F6KMV-0001 1
ant flow
Table 20: Industrial sole distributor
D.1.5 Extension system
Assembly kit extension Product Number

system
D0V6T99-0009 Extension system 1
Table 21: Extension system
D.1.6 Assembly aids
Assembly aids Product Number

00F5ZTB-0004 Assembly kit ring bolts M12 DIN 580 1
00F5ZTB-0013 Mounting kit hoisting device 1
Table 22: Assembly aids
77
NOTES
78
Austria | KEB Antriebstechnik Austria GmbH Japan | KEB Japan Ltd.
Ritzstraße 8 4614 Marchtrenk Austria 15 - 16, 2 - Chome, Takanawa Minato-ku
Tel: +43 7243 53586-0 Fax: +43 7243 53586-21 Tokyo 108 - 0074 Japan
E-Mail: [email protected] Internet: www.keb.at Tel: +81 33 445-8515 Fax: +81 33 445-8215
E-Mail: [email protected] Internet: www.keb.jp
Belgium | KEB Automation KG
Herenveld 2 9500 Geraardsbergen Belgium P.R. China | KEB Power Transmission Technology (Shanghai) Co. Ltd.
Tel: +32 544 37860 Fax: +32 544 37898 No. 435 QianPu Road Chedun Town Songjiang District
E-Mail: [email protected] Internet: www.keb.de 201611 Shanghai P.R. China
Tel: +86 21 37746688 Fax: +86 21 37746600
Brazil | KEB South America - Regional Manager E-Mail: [email protected] Internet: www.keb.cn
Rua Dr. Omar Pacheco Souza Riberio, 70
CEP 13569-430 Portal do Sol, São Carlos Brazil Republic of Korea | KEB Automation KG
Tel: +55 16 31161294 E-Mail: [email protected] Room 1709, 415 Missy 2000 725 Su Seo Dong
Gangnam Gu 135- 757 Seoul Republic of Korea
France | Société Française KEB SASU Tel: +82 2 6253 6771 Fax: +82 2 6253 6770 E-Mail: [email protected]
Z.I. de la Croix St. Nicolas 14, rue Gustave Eiffel
94510 La Queue en Brie France Russian Federation | KEB RUS Ltd.
Tel: +33 149620101 Fax: +33 145767495 Lesnaya str, house 30 Dzerzhinsky MO
E-Mail: [email protected] Internet: www.keb.fr 140091 Moscow region Russian Federation
Tel: +7 495 6320217 Fax: +7 495 6320217
Germany | Headquarters E-Mail: [email protected] Internet: www.keb.ru
KEB Automation KG
Südstraße 38 32683 Barntrup Germany Spain | KEB Automation KG
Telefon +49 5263 401-0 Telefax +49 5263 401-116 c / Mitjer, Nave 8 - Pol. Ind. LA MASIA
Internet: www.keb.de E-Mail: [email protected] 08798 Sant Cugat Sesgarrigues (Barcelona) Spain
Tel: +34 93 8970268 Fax: +34 93 8992035 E-Mail: [email protected]
Germany | Geared Motors
KEB Antriebstechnik GmbH United Kingdom | KEB (UK) Ltd.
Wildbacher Straße 5 08289 Schneeberg Germany 5 Morris Close Park Farm Indusrial Estate
Telefon +49 3772 67-0 Telefax +49 3772 67-281 Wellingborough, Northants, NN8 6 XF United Kingdom
Internet: www.keb-drive.de E-Mail: [email protected] Tel: +44 1933 402220 Fax: +44 1933 400724
E-Mail: [email protected] Internet: www.keb.co.uk
Italia | KEB Italia S.r.l. Unipersonale
Via Newton, 2 20019 Settimo Milanese (Milano) Italia United States | KEB America, Inc
Tel: +39 02 3353531 Fax: +39 02 33500790 5100 Valley Industrial Blvd. South
E-Mail: [email protected] Internet: www.keb.it Shakopee, MN 55379 United States
Tel: +1 952 2241400 Fax: +1 952 2241499
E-Mail: [email protected] Internet: www.kebamerica.com

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COMBIVERT F5/F6

INSTRUCTIONS FOR USE | INSTALLATION F5/F6 HOUSING V | 600...1000 KVA

Translation of the original manual

Signal words and symbols

NOTICE Situation, which can cause damage to property in case of non-obser-

Note to further documentation.

Laws and guidelines

Here you will find our current terms and conditions.

Further agreements or specifications require a written confirmation.

1 Basic Safety Instructions............................................. 14

4.1 Cooling system .............................................................................................................................. 26

6.1.2 Mechanical ambient conditions........................................................................................... 60

C Annex - Cooling System.............................................. 71

Standards for drive converters / control cabinets

Basic standards to which drive converter standards refer directly

EN 61000-4-4 Electromagnetic compatibility (EMC) - Part 4-4: Testing and measurement

Standards that are used in the environment of the drive converter

1 Basic Safety Instructions

NOTICE Hazards and risks through ignorance.

►► Read the instruction manual !

►► Observe the safety and warning instructions !

►► If anything is unclear, please contact KEB Automation KG !

1.1 Target group

1.2 Transport, storage and proper use

Transport of drive converters with an edge length >75 cm

Drive converters contain electrostatic sensitive components.

ESD ►► Wear ESD-protective clothing.

Do not store drive converters

DANGER Do not operate in an explosive environment!

►► The COMBIVERT is not intended for the use in potentially explosive

CAUTION Design-related edges and high weight!

Contusions and bruises!

►► Wear safety shoes.

►► Secure drive converter accordingly when using lifting gear.

To prevent damages to the device:

1.4 Electrical connection

DANGER Voltage at the terminals and in the device !

Danger to life due to electric shock !

►► Await capacitor discharge time (5 minutes) if necessary, measure

►► If personal protection is required, install suitable protective devices

►► Connect the protective earth conductor to drive converter and motor

►► Install all required covers and protective devices for operation.

►► The control cabinet shall be kept closed during operation.

If personnel protection is required during installation of the

1.4.1 EMC-compatible installation

Notes on EMC-compatible installation can be found here.

1.4.2 Voltage test

Accordng to EN 60204-1 it is permissible to disconnect already tested com-

1.4.3 Insulation measurement

An insulation measurement (in accordance with EN 60204-1 chapter 18.3) with DC

1.5 Start-up and operation

WARNING Software protection and programming !

Hazards caused by unintentional behavior of the drive!

►► Securing a unit solely with software-supported functions is not suf-

►► Secure motors against automatic restart.

CAUTION High temperatures at heat sink and coolant!

Burning of the skin!

►► If necessary, attach warning signs on the system.

►► Before touching, check the surface and cooling water lines.