COMBIVERT USA F5-B Indexing INDUSTRIAL MOTION CONTROL, LLC Installation Guide & Operation Manual
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Contents Table of Contents 1. Safety and Operating Instructions ...........................................5 2. Product Description ..................................................................6 2.1 Application .................................................................................... ..6 2.2 Part Number Identification ............................................................ ..6 2.3 Technical Data .............................................................................. ..7 2.3.
Contents 3.5.1 Terminal Strip Connections ............................................................. ..26 3.5.2 Connection of the control signals .................................................... ..26 3.5.3 Digital Inputs .................................................................................... ..27 3.5.4 Analog Inputs ................................................................................... ..27 3.5.5 Analog Output .................................................................
Important, please read 1. Safety and Operating Instructions Safety and operating instructions for AC motor controls (in conformity with the low-voltage directive 73/23/EEC) 1. General 4. Installation AC motor controls, depending on their degree of protection, may have exposed live, un-insulated, and possibly also moving or rotating parts, as well as hot surfaces. The installation and cooling of the unit shall be in accordance with the specifications contained with in this document.
Product Description 2. Product Description 2.1 Application The KEB COMBIVERT F5 series motor control is designed exclusively for the control and regulation of induction motors. The operation of other electric devices and loads is prohibited and can lead to the destruction of the unit. The F5 series motor control is a component which is intended for the installation in electric systems or machines. 2.2 Part Number Identification 07.F5.
Product Description 2.3 Technical Data 2.3.1 Technical Data 230V Class Inverter Size Recommended Motor Power Housing size 5 [hp] 1/2 A 7 1 A 9 2 B 10 3 B 12 5 D Input Ratings Supply voltage [V] Supply voltage frequency [Hz] Input phases Rated input current [A] Recommended maximum input fuse [A] Recommended wire gauge1) [awg] Output Ratings Rated output power [kVA] Rated motor power [kW] Rated output current [A] Peak current (30 seconds) [A] Over current fault (E.
Product Description 2.3.2 Technical Data 460V Class Inverter Size Recommended Motor Power Housing size 5 [hp] 1/2 A 7 9 10 12 13 14 1 2 3 5 7.5 10 A A B B D D Input Ratings Supply voltage [V] Supply voltage frequency [Hz] Input phases Rated input current [A] Recommended maximum input fuse [A] 1) Recommended wire gauge [awg] 305...500 ±0 (460 V Nominal 50 / 60 +/- 2 3 3 3 3 3 1.4 2.5 4.8 6.7 10.6 15 15 15 15 20 14 14 14 14 12 voltage) 3 15.4 20 12 3 19.
Product Description 2.4 Dimensions and terminals 2.4.1 A Housing A X1 tor era Op ver ith o W ith C W A X4 A X2 L PE a W ++ L3 /L2 1N B 158 mm 6.2 in 144 mm 5.7 in - o eK Di ntlad g e eträ e b in F z s ei na E hut s al aß sig sc t al tzm Ìäs is chu zul S icht n X1 PE U V W T PB PA 1T2 mm 175 6.9 in mm 185 7.3 in m 5m 0.2 in mm 76 .
Product Description 2.4.2 B Housing X2A wi th X4 wi th Co Op er ve A r BA ato r L RA C SI NE GE C O E T R 3 2 1 159,5 mm / 6,28 inch 173,5 mm / 6,83 inch 4 IV ar W 5 B t No PC for 6 M de on eit e K ez m Di ntlad gt 5 le e eträ eh b in F tz s E hu al sc t als tzm is chu zul S icht n 1 1 7 1 8 2 9 2 0 2 1 23 2 1 9 1 0 1 1 1 2 1 3 1 4 16 5 7 8 X1 A L1 L2 L3 + - PB U V W T1 T2 53 116 00 014 1B-2A 5.G m m 10 10.
Product Description 2.4.3 D Housing X2A -B F5 X4A -G t No r PC fo F5 ar W 180.5 mm 7.11 inch * 194.5mm 7.66 inch de on eit e K ez m Di tlad gt 5 le en trä eh be in F tz s E hu al sc t als tzm is chu zul S cht ni X1A L1 L2 L3 + - PB U V W 0402 0 9508 C-122 5.S0 90 5m m mm 0 3.5 .2 inc h 4 in ch 07.F 24 m 5m 5 9.6 m 4 9.
Installation and Connection 3. Installation and Connection Enclosure type: IP20/ Open Type Operation temperature: -10...45 °C / 14...113°F Storage temperature: -25...70 °C / -13...158°F max. heat sink temperature: 90 °C / 194°F Climatic category: 3K3 in accordance with EN 50178 Relative humidity: max. 95 % without condensation Power derating for high altitude: 1% for every 100m/330ft above 1000m/3300ft Maximum altitude for operation: 2000m / 6,600ft Installation requirements: 150 6” 3.
Installation and Connection 3.2 Good EMC Installation Techniques 1) Mount the COMBIVERT F5 on a conductive (zinc or nickel plated not painted) subpanel. This sub plate serves as the central grounding point for the machine. 2) Always connect the shield of motor and control cables with maximum surface area, use a metal cable clamp to contact cable shield on all sides. Using a single strand of the shield or the drain wire from the shield as the only connection can reduce the shield’s effectiveness by 70%.
Installation and Connection 3.3 Connection of Power Circuit 3.3.1 Wiring instructions RISK OF ELECTRIC SHOCK! Always disconnect supply voltage before servicing the COMBIVERT F5. Wait 5 minutes before attempting to change the connections as the DC Bus capacitors may still be charged. Absolutely pay attention to the nameplate voltage of the KEB COMBIVERT and the connected line voltage. A 230V-unit will be immediately destroyed on a 460V-power supply. Never exchange the line and motor cables.
Installation and Connection 3.3.2 Terminal X1.A & Line Connection A Housing: -E L3 L1 2 L 7 A Housing: L3 L2 L1 GND L3 N L1 PE X1.A -++ L3 L2/N L1 PE ++ X1.A -++ L3 L2/N L1 PE Line connection 230 V 3-phase & 460 V 3-phase -- Line connection 230 V 1-phase /L2 A Housing: L2 L1 GND ++ Steps to wire the connectors •Remove the connector from the inverter housing by grasping it firmly and pulling straight out •The maximum wire gauge is 14 awg or 1.5mm •Strip the insulation back 0.
Installation and Connection B & D Housings: L1 N/L 2 B & D Housings: L1 L3 ++ -- PB U V L2 L3 ++ -- PB W U V T1 T2 Terminal strip X1A / 230 V - class Provides connections for: • 230 V AC / 1-phase (L1/L2) • 230 V AC / 3-phase (L1, L2, L3) • DC-Supply 250...
Installation and Connection A, B, and D Housings: A,B, and D Housings: DC-connection 230 V-class 250...370 V DC + - For branch circuit protection use fuses rated for DC voltage. (Bussmann type FWP) X1A PE L1 N/L2 L3 ++ -PB U V W T1 T2 *X1A terminal layout varies depending on housing DC-connection 460 V-class 420...
Installation and Connection 3.3.3 Motor Connection A Housing: PE U V Terminal X1B provides connections for: • ++, PB Braking resistor • U, V, W Motor • T1, T2 Temperature sensor/Switch NOTE: The T1/T2 terminals aren’t present on the 230 VAC A-housing inverters. W PA PB T T1 2 A Housing: The maximum motor cable length listed in the tables in section 2.3 is based on several factors: use of shielded motor cables, ground current limitations, increased EMI noise levels, voltage peaks at the motor terminals.
Installation and Connection 3.3.4 Motor Overload Protection The COMBIVERT F5 motor control by default provides motor overload protection at 130% of the unit’s rated output current. See tables in section 2.3 for rated output current. Two additional motor overload protection systems are available.
Installation and Connection 3.3.6 IMC Motors Hp 1/8 1/6 1/4 Operating Voltage 230V/460V 230V/460V 230V/460V 1/3 230V/460V 1/2 230V/460V 3/4 230V/460V 1 230V/460V 1.5 230V/460V 2 230V/460V 3 230V/460V 4 230V/460V 5 230V/460V 7.
Installation and Connection 3.3.8 CAM Gear Box Limit Switch Keyway Type II Extra CAM LOBE A standard Roller Gear unit with the CAM & Limit Switch mounted on the correct keyway position directly opposite of the output shaft, 90 degrees(clockwise or counter clockwise) from the CAM Lobe. The CAM & Limit Switch may also be mounted on the reducer. *If the unit has a “Type II” motion, a special Limit Switch CAM is needed with one extra Lobe, 180 degrees from the first Lobe.
Installation and Connection 3.4 Breaking Resistor 3.4.1 Explanation The COMBIVERT F5 inverter can be equipped with an external braking resistor for limited 4 quadrant operation. The energy the motor regens into the inverter during deceleration is dissipated through the internal braking transistor to the braking resistor. The braking resistor heats up during braking.
Installation and Connection 3.4.3 Connection Braking resistor connection with high temperature drive fault • The resistor has a PTC type sensor and is connected to the T1, T2 ter minal on the COMBIVERT F5. If a motor temperature sensor and braking resistor sensor is used they should be placed in series.
Installation and Connection 3.4.4 Selection Different braking resistors are available from KEB. They are selected according to their application requirements. The selection formulas and technical data of the resistors are listed on the following pages. In most cases the suggested braking resistor is sufficant. This can be verified using the procedure below. *Braking resistors aren’t required on 1/3 to 1 HP applications 1. Establish desired braking time. 2.
Installation and Connection Formulas 1. Braking time without braking resistor 2. Braking torque (required) (JM + JL) • (n1 - n2) tBmin = 307 • (K • TN + TL) Valid range: n1 > nN (field weakening) - TL (307 • tB) Conditions: TB - 1.5 • TN f < 1.4 x rated frequency of motor 3. Peak braking power 4. Braking time with braking resistor (JM + JL) • (n1 - n2) T B • n1 tBmin = PB = 307 • K• TN+ TL+ 7.04 Conditions: (JM + JL) • (n1 - n2) TB = ( PB < PR Valid range: (PR • 7.
Installation and Connection 3.5 Control Circuit: F5-BASIC X2A 1 5 7 8 10 11 14 15 16 20 22 24 25 26 27 28 29 3.5.1 Terminal Strip Connections PIN 1 Function Description + Analog input 1 Voltage input for speed control, resolution:11 Bit, 0...±10 VDC, scan time: 2 ms 5 Analog Output Outputs 10 VDC when motor speed is 0 rpm 7 +10V Output Analog supply voltage for speed ref. +10 VDC ±5%, max.
Installation and Connection 3.5.3 Digital Inputs Use of internal voltage supply X2A 1 20 22 10 11 14 15 16 GND Use of external voltage supply X2A 1 10 11 14 15 16 Rin = 2.1 kΩ 22 GND + 20...30 VDC Regulated 3.5.4 Analog Inputs Internal analog speed ref. setting X2A 1 5 7 8 External analog speed ref. setting 22 GND X2A 1 5 7 8 R = 3...10 kW + optional: 3.5.5 Analog Output X2A 1 5 7 8 22 + 22 GND 0...±10 VDC Ri = 30 kW 0(4)...20 mADC Ri = 250 W GND +10 VDC / 5 mA 3.5.
Installation and Connection 3.5.7 Suggested wiring 1 REF ZERO SPEED OUTPUT 5 +10 VDC 7 COM 8 QUICK STOP 10 STOP INDEX 11 MOMENTARY PULSE STARTS INDEX 16 DRIVE ENABLE OPEN = FORWARD CLOSED = REVERSE 24 VDC 20 0V 22 25 RLB 28 FLB 27 FLA FLC 29 28 DRIVE FAULT RELAY 26 RLC OPEN = NO OPERATION CLOSED = DRIVE READY *Cycle INPUT 16 for Error Reset 24 RLA STOP SIGNAL - SUPPLIED WITH A MECHANICAL SWITCH (NO) 15 FOR/REV *See Diagram 3.5.
Installation and Connection As a momentary signal is sent to INPUT 14 the drive indexes until it 3.5.8 Operation Explanation receives a signal on INPUT 11. On reception of signal on INPUT 11 the drive either decelerates and stops or the stop point is delayed for a positioning stop. This depends on the value entered in CP.27. In the index mode, the start pulse takes priority over the stop pulse.
Installation and Connection Examples of Correct and Incorrect Signaling Indexing Mode 6ms minimum pulse Incorrect Signaling ST (pin 16) Quick Stop (pin 10) Start (pin 14) Stop (pin 11) Motor (RPM) ST: Must be high Quick Stop: Must be high Start pulse: Motor accelerates and runs at speed Stop signal: Motor decelerates and stops at a repeatable distance from the stop sensor * Incorrect singaling 1. Start pulse overrides the stop signal 2.
REF COM +10V REF COM 3.5.9 Optional Speed Control Wiring +10V Installation and Connection 7 1 8 7 1 8 CP10 CP10 Single preset speed +10V REF COM +10V REF COM Potentiometer 3K to 10K Ohm 7 1 8 7 1 8 CP10 CP10 = max frequency CP9 CP9 + - CP9 = low frequency PLC Dual preset speeds There are two differences between the F4si and F5Bi drives. First the numbering of the pins has changed, these are shown below.
Operation of the Drive 4. Operation of the inverter As an accessory for displaying and editing "CP" parameter values, a "digital operator" is necessary. To remotely mount the digital operator, a operator remote cable is required. To prevent malfunctions, the inverter must be brought into nOP status (remove signal from control release terminal 16) before connecting / disconnecting the operator. When starting the inverter without an operator, it is started with the last stored values. 4.
Operation of the Drive 4.1.1 Keypad When switching on the KEB COMBIVERT F5, the value of parameter CP.1 appears in the operator display. (see "Drive Mode" to switch the keypad function) The function key (FUNC) changes between the parameter value and parameter number. ) and With UP ( DOWN ( ), the value of the parameter number is increased or decreased. Generally; when a value is changed, parameter values are immediately accepted and stored nonvolatile.
Operation of the Drive 4.2 Parameter Summary Display Parameter Setting Range Resolution Factory Setting CP.0 Password Input 0 ... 9999 1 Read Only CP.1 Actual Frequency Display - .0125 Read Only CP.2 Inverter State - - Read Only CP.3 Actual Utilization - 1% Read Only CP.4 Peak Utilization - 1% Read Only CP.5 Rated Frequency 0.0000 ... 400.0000 Hz .0125 Hz 60.0000 Hz CP.6 B o o st 0.0 ... 25.5 % 0.1 % 5.0 % CP.7 Acceleration Time 0.00 ... 300.00 s 0.01 s .15 s .
Operation of the Drive From the factory, the frequency inverter is supplied without password protection, this means that all parameters can be adjusted. After programming, the unit can be protected against unauthorized access thus preventing the values from being changed. 4.3 Password Input FUNC. SPEED Locking the CPParameters (Read only) START ENTER F/R FUNC. SPEED FUNC. SPEED Releasing the CP-Parameters START ENTER F/R FUNC. SPEED 4.
Operation of the Drive "Forward Acceleration" drive accelerates with direction of rotation forward . "Forward Deceleration" drive decelerates with direction of rotation forward. "Reverse Acceleration" drive accelerates with direction of rotation reverse. "Reverse Deceleration" drive decelerates with direction of rotation reverse. "Forward Constant" drive runs with a constant speed and direction of rotation forward. "Reverse Constant" drive runs with constant speed and direction of rotation reverse.
Adjustment of the Drive Boost In the lower speed range losses in the motor become greater. This parameter can be used to boost the voltage in order to overcome these losses. With proper adjustment, the torque output of the motor will remain constant even at the lowest speeds. U V A Adjustment range: Resolution: Factory setting: 0.0...25.5 % 0.1 % 5.0 % 0 CP.6 f f CP.5 Adjustment: 1) Determine the load level (CP.3) with no-load operation at the rated frequency.
Adjustment of the Drive f 100 Hz Adjustment range: Resolution: Factory setting: -1; 0.00...300.00 s 0.01 s .12 s t CP. 8 By depressing DOWN arrow key, one increment passed the 0.0, the display will show "=Acc". This means the same value stored in CP.7 (Decel=Accel time)! Example: actual deceleration time = 5s; the drive should decelerate from 60 Hz to 10 Hz. delta f = 60 Hz - 10 Hz = 50 Hz CP.
Adjustment of the Drive Max. ramp current This function acts as an adjustable current limit during acceleration or deceleration. It can be used to prevent the load current from exceeding the inverter's peak current rating, thereby preventing shut down with an E.OC fault. When the load level reaches the adjusted value, the acceleration or deceleration is stopped until the load drops below the adjusted value. Note: if this parameter is adjusted too low, the motor may not be able to accelerate to full speed.
Adjustment of the Drive Speed search condition When starting the frequency inverter into a spinning motor, an E.OC fault can be triggered because of the difference between the actual motor speed and the inverter set speed. By activating speed search, the inverter searches for the actual motor speed, adjusts its output frequency to match. It will then accelerate with the adjusted ramp time to the given set value. During speed search CP.2 displays "SSF".
Adjustment of the Drive If the supply voltage drops to190 V and CP.17=230 V, the inverter will still provide rated voltage to the motor up until 190V. The output voltage can not be increased further beyond the input therefore the motor will operate in field weakening. To calculate at which frequency this will occur use the following formula: f = (60Hz/ 230 V)*190 V= 50 Hz CP.17 = 230V Vsupply = 190V * Both scenarios above, it is assumed no boost (CP.6=0%).
Adjustment of the Drive DC-braking Time If the braking time depends on the actual frequency (CP.20 = 2...7), it is f calculated as follows: 100 Hz tBrake = CP.21 x f real ––––––––– 100 Hz factual t Otherwise the braking time corresponds to CP.21. Adjustment range: Resolution: Factory setting: Relay output 2 tBrake CP.21 0.00...100.00 s 0.01 s 0.10 s CP.22 determines the function of Relay Output 2. Relay output 2 (terminal X2A.27...X2A.29) The switching level of CP.22 is CP.
Adjustment of the Drive 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Actual load utilization (CP.3) > 100% Active current > switching level Actual DC voltage >switching level Actual frequency (CP.1) > switching level Set frequency > switching level Ref. point run complete {F5G only} Actual torque > level {F5G only} Absolute speed on AN1 > switching level Absolute speed on AN2 > switching level {F5G only} Absolute.
Adjustment of the Drive Factory setting CP.22: 27 Note: Enter-Parameter Relay output 2 Switching level This parameter determines the switching point for relay output 2. Since the operator display can only view 5 characters, the last digits are not displayed for the higher values. Note; all conditions chosen with CP.22 don't require use of CP.23. Adjustment range: -30000.00...30000.00 Resolution: 0.01 Factory setting: 0.
Adjustment of the Drive Setting -2; S_int -1; Off 0.00...327.67 Factory Setting Function Positioning Off Positioning Off Positioning On; positioning delay by adjusted value 0.00; Positioning On; No delay Program Revision This parameter identifies the revision number of the programing in Identifier the drive. This will allow for easy identification of errors or upgrades to the software. Please don't change this parameter. Adjustment range: Resolution: Factory setting: Customer Identification Number 0 ...
Drive Mode 4.6 The "Drive Mode" The Drive Mode is a operating mode of KEB COMBIVERT that permits the manual starting of the drive through the keypad display unit. After applying a signal to the control release terminal 16, the set value (speed ref.) and rotation setting are effected exclusively over the keypad. In order to activate the Drive Mode the corresponding password (500) must be entered in CP.0. The display switches over as follows. 4.6.
Error Diagnosis 5. Error Diagnosis KEB COMBIVERT Error messages are always represented with an "E.xx" and the appropriate error code in the display. Errors cause the immediate turn off of the output to the motor. Restart is possible, only after reset. Malfunctions are represented with an "A.xx" and the appropriate code. Responses to malfunctions can vary depending on the programmed condition. In the following table the error codes and their causes are described. Display Description Value Meaning E.
Error Diagnosis E.dOH ERROR drive overheat E.nEd no ERROR detected E.ndOH no ERROR drive overheat E. PU ERROR power unit 9 Error: Overtemperature signal from motor temperature sensor. Error can only be reset at E.ndOH, when sensor resistance decreases.
Error Diagnosis E.PUCO E. power unit common. 22 Error: Parameter value could not be written to the power circuit. Acknowledgment from PC <> OK E.OH2 ERROR motor protection 30 Error: Electronic motor protective relay has tripped. E. EF 31 Error: External error is triggered when a digital input is being programmed as an external error input. 32 Error: Encoder cable and/or connection wiring ERROR external fault E.ENC ERROR encoder E.nOH no E. over heat pow. mod.
Error Diagnosis A. EF ABN.STOP external fault A.ndOH no A. drive overheat 90 Warning: external error. This will be shown on Quick Stop condition. 91 Warning: no more overtemperature of motor TEMPERATURE SENSOR. Motor SENSOR is low-resistance again. A.nOHI no A.STOP overheat int. 92 Warning: no more overtemperature in the interior A.buS ABN.STOP bus 93 Warning: Watchdog for communication between operator/ control card has responded A.PRF ABN.STOP prot. rot. for.
6. Quick Reference Display Parameter Setting Range Resolution CP.0 Password Input 0 ... 9999 1 Read Only CP.1 Actual Frequency Display - .0125 Read Only CP.2 Inverter State - - Read Only CP.3 Actual Utilization - 1% Read Only CP.4 Peak Utilization - 1% Read Only CP.5 Rated Frequency 0.0000 ... 400.0000 Hz .0125 Hz CP.6 B o o st 0.0 ... 25.5 % 0.1 % CP.7 Acceleration Time 0.00 ... 300.00 s 0.01 s CP.8 Deceleration Time -0.01; 0.00 ... 300.00 s 0.01 s CP.
Quick Reference From the factory, the frequency inverter is supplied without password protection, this means that all parameters can be adjusted. After programming, the unit can be protected against unauthorized access thus preventing the values from being changed. Password Input FUNC. Locking the CP Parameters (Read only) SPEED START ENTER F/R FUNC. SPEED FUNC. SPEED Releasing the CP-Parameters START ENTER F/R FUNC.
Suggested Systems 7.
Accessories 8. Accessories PC to Inverter Programming PART NUMBER F5 Serial Operator 92C84982320000 (Display, Keypad, COMBIVIS Port) COMBIVIS Serial Cable 92A78348030000 *COMBIVIS software can be downloaded at www.kebamerica.
Notes 55
00.MC.0U0-K000 © KEB Additional copies of manuals are available at www.camcoindex.
