KEB COMBIVERT F5-A,-E,-H 4.0. APPLICATION MANUAL (2008)

Preparatory Measures

Start-up

The following chapter is intended for everybody who has no experience with the KEB frequency inverters. It

shall allow a correct entering into this field. But because of the complex application possibilities we must restrict

ourselves to explaining the start-up of standard applications.

6.1

Preparatory measures

6.1.1

After unpacking the goods

After unpacking the goods and checking them for complete delivery following measures are to be carried out:

 Visual control for transport damage

Should any external damages to the KEB COMBIVERT be visible get in tough with your forwarding agent

and return the unit with a corresponding report to KEB.

 Check the voltage class:

Absolute check before assembly whether the supply voltage of the KEB COMBIVERT matches the applica-

tion.

6.1.2

Installation and connection

The EMC-conform installation of the inverter is described in the Instruction Manual Part 1. Installation and con-

nection instructions are found in the instruction manual part 2.

 The mounting surface of the inverter must be bright.

 If necessary, use contact lacquer as protection against corrosion.

 Connect the earthing strip to central point in the control cabinet

Picture 6.1.3 Installation and connection

Page6.1 - 3

Preparatory Measures

6.1.3

Checklist prior to start-up

Before switching on the inverter go through the following checklist.

 Is the inverter firmly bolted in the control cabinet?

 Is there enough space to ensure sufficient air circulation?

 Are mains and motor cables as well as the control cables installed separately from each other?

 Are the inverters connected to the correct supply voltage?

 Are all mass and earthing cables attached and well contacted?

 Ensure that mains and motor cables are not interchanged as that will lead to the destruction of

the inverter!

 Is the motor connected in phase?

 Check tacho, initiator and encoder for firm attachment and correct connection!

 Check, whether all power and control cables are firmly in place!

 Remove any tools from the control cabinet!

 Attach all covers and protective caps to ensure that all live parts are secured against direct

contact.

 When using measuring instruments or computers an isolating transformer should be used, if not,

make sure that the equipotential bonding between the supply lines is guaranteed!

 Open the control release of the inverter to avoid the unintended starting of the machine.

Page6.1 - 4

Start-up

6.2

Initial start-up

After all preparatory measures have been carried out and checked the KEB COMBIVERT F5 can be switched

on.

The control release ST (X2A.16) must be deactivated when switching on the first time, since the frequency

inverter is not custom-specific parameterized.

The following descriptions suppose that the frequency inverter is on the password level "application mode"

(ud.01 = application mode). The selection of the password level is described in the manual chapter 4. The start-

up should be executed with COMBIVIS in order to have a short start-up time.

Operating lists are available on the KEB homepage (www.keb.de). This lists contain the necessary parameters

for start-up.

Attention: The start-up instruction manual can only give a short overview of the parameter adjustments which

are mandatory necessary to start-up the motor.

Thus it represents a check list and not a complete parameter description.

The appropriate chapters of the application manual must be read carefully for exact information about the pa-

rameters, additionally points to consider and application-specific adjustments!

The wiring of the motor must be checked before start-up:

in-phase connection (inverter terminals U, V, W must be connected at the motor terminal board with the

appropriate contacts)

If the wiring is correct the following direction of rotation occurs at setting "clockwise rotation":

large surface of shield connection, well grounding (see „EMC conform wiring“ in the manual „… before

start-up“)

6.2.1

Start-up of an asynchronous motor

The following chapters describe the start-up of an asynchronous motor in the 4 available modes:

•

V/F characteristics open loop operation (F5A-M)

•

speed-controlled operation with encoder feedback without motor model (F5A-M)

•

speed-controlled operation with encoder feedback with motor model (F5A-M) (recommended operating

mode when using a speed feedback)

•

speed-controlled operation without encoder feedback (ASCL / F5H-M)

Page6.2 - 3

Start-up

6.2.1.1V/F characteristic operation

Open control release

Deactivate terminal X2A.16

→ Inverter state ru.00 = „noP“/„0:no control release“

Selection of the speed range

The required speed range (e.g.: 0..+/- 4000 rpm) is selected in

Attention: Changing the controller type

control type ud.02.

releases loading of the default para-

meters!

→ ud.02 control type = 4…7

The speed range should be selected

at least 10% higher than the highest

All data for the adjustment of the controller type (e.g. resolution

setpoint speed in the application.

of the speed, etc.) see chapter 5.1

Loading the default parameters

Loading the default parameters (KEB factory setting) by

Attention: Pre-adjustments (e.g. func-

tion of the digital inputs) disappear

→ Fr.01 copy parameter set = - 4

Selection of the controller configuration

Adjust V/F characteristic operation

→ CS.00 speed control config. = 0: off

(default V/F characteristic operation)

Motor data are not necessary for standard V/F characteristic

operation.

The following parameters must be examined if SMM (sensor-

less motor management for speed stabilization during load)

should not be used:

Frequency when the highest voltage is output:

→ uF.00 rated frequency

Voltage [in%], which is output at 0Hz:

→ uF.01 boost

If these adjustments for the motor are made correctly continue

to proceed at point 9.

Page6.2 - 4

Start-up

Input of the motor data

Values dr.00 to dr.05 must be taken from the motor name

plate.

The value for dr.06 can be identified automatically (see point

6).

→ dr.00 DASM rated current

→ dr.01 DASM rated speed

→ dr.02 DASM rated voltage

→ dr.04 DASM rated cos (phi)

→ dr.05 DASM rated frequency

→ dr.06 DASM stator resistance

Calibration of the stator resistance

The stator resistance dr.06 can be determined automatically

by the KEB COMBIVERT.

Inverter must be in status „70: standstill (modulation off)“. Start

measurement with the input of

→ dr.06 = 250000: on

Open control release (X2A.16) after the measurement is finis-

hed

Calculation of motor-dependent data

Activation of SMM, as well as the adaption of the U/f characte-

ristic is made by the input of:

→ Fr10 load mot. dependent parameter = 3

Adjust speed controller

The speed controller must be adapted to the application via

cS.06 and cS.09.

Enter application specific data

e.g. limit values (speed limits, torque limits etc.)

Proper data for the adaption of the in-

acceleration- / deceleration ramps,

verter to the respective application can

function of the digital in- / outputs,

be find in the corresponding chapters

Type of speed setpoint setting etc.

10.

Test run

Test run, in order to check whether the drive runs stable in all

speed ranges and under all load conditions and if a sufficient

safety distance to the power limits is available etc.

Page6.2 - 5

Start-up

6.2.1.2Vector controlled operation with encoder feedback without motor model

With this start-up description it is provided that an incremental encoder to encoder interface 1 (Sub-D15 socket

X3A) is used for speed feedback.

Read chapter 7.11 "Speed measurement" for necessary adjustments of your speed encoder when using ano-

ther encoder type.

Also it must be secured that the motor phases and the incremental encoder are correct wired (in phase, large

surface of shield connection, well earth connection). The motor temperature sensor must be connected.

A controlled start-up (V/F characteristic) of the drive can be executed for examination in case of insecurity about

the phase allocation (motor and incremental encoder).

Open control release

Deactivate terminal X2A.16

→ inverter state ru.00 = „noP“/„0: no control release“

Selection of the speed range

The required speed range (e.g.: 0..+/- 4000 rpm) is selected

Attention: Changing the controller type

in control type ud.02.

releases loading of the default parame-

ters!

→ ud.02 control type = 4…7

All data for the adjustment of the con-

troller type (e.g. resolution of the speed,

The speed range should be selected at least 10% higher than

etc.) see chapter 5.1

the highest setpoint speed in the application.

Loading the default parameters

Loading the default parameters (KEB factory setting) by

Attention: Pre-adjustments (e.g. func-

tion of the digital inputs) disappear

→ Fr.01 copy parameter set = - 4

Selection of the controller configuration

Adjust speed-controlled operation

→ CS.00 speed control config. = 4

(control mode = speed control)

Select source of the speed feedback

The motor speed feedback must be connected to Sub-D so-

cket X3A.

→ cS.01 act. source = 0:channel 1

Enter increments per revolution of the speed feedback

Page6.2 - 6

Start-up

Enter the number of increments per revolution according to

Note: Further adjustments are neces-

the name plate of the encoder

sary when using another encoder type.

Read chapter

7.11 speed measure-

→ Ec.01 encoder 1 (inc/r)

ment

Input of the motor data

Values dr.00 to dr.05 must be taken from the motor name

Note:

plate.

The equivalent circuit data dr.06..dr.10

are without meaning

→ dr.00

→ dr.01

→ dr.02

→ dr.03

→ dr.04

→ dr.05

Activate maximum voltage controller

The maximum voltage controller must be activated for the

Attention: Further adjustments must be

field-weakening range if the motor reaches the voltage limita-

done in connection with the maximum

tion (modulation grade ru.42 = 100%).

voltage controller.

→ dS.04 = 24

Parameterization of the controller,

Activation of the active current limitation in the field-weake-

ning range

Calculation of motor-dependent data

Adaption of the adjustments to the motor

Note:

Since the equivalent circuit data are

→ Fr10 load mot. dependent parameter = 2: actual DC link

unknown at this control type, the cur-

voltage

rent controllers cannot be optimally ad-

apted to the motor, as per control with

motor model.

Page6.2 - 7

Start-up

10. Enter application specific data

Application specifc data are e.g.

Proper data for the adaption of the in-

verter to the respective application can

•Limit values (speed limits, etc.)

be find in the corresponding chapters.

→ oP parameter (chapter 7.4.5 setpoint limits)

•Acceleration- / deceleration ramps

→ oP parameter (chapter 7.4.7 ramp generator)

•Function of the digital in- / outputs

→ di parameter (chapter 7.3 digital in- and outputs)

•Type of speed setpoint setting

→ oP parameter (chapter 7.4.2, 7.4.3, 7.4.6)

11. Adjust speed controller

The speed controller parameters must be adapted to the ap-

plication

The maximum voltage controller must be parameterized if the

field weakening range is used.

12. Test run

Activate control release (terminal X2A.16) and make a test

run, whether the drive runs stable in all speed ranges and

under all load conditions

If error messages occur during the start-up phase, read chapter 8.1 "Error causes and displays"

Page6.2 - 8

Start-up

6.2.1.3Vector controlled operation with encoder feedback with motor model

Attention: With this start-up description it is provided that an incremental encoder to encoder interface 1 (Sub-

D15 socket X3A) is used for speed feedback.

Also it must be secured that the motor phases and the incremental encoder are correct wired (in phase, large

surface of shield connection, well grounding).

The motor temperature sensor must be connected.

A controlled start-up (V/F characteristic) of the drive can be executed for examination in case of insecurity about

the phase allocation (motor and incremental encoder).

Open control release

Deactivate terminal X2A.16

→ Inverter state ru.00 = „noP“/„0: no control release“

Selection of the speed range

The required speed range (e.g.: 0..+/- 4000 rpm) is selected

Attention: Changing the controller type

in control type ud.02.

releases loading of the default parame-

ters!

→ ud.02 control type = 4…7

All data for the adjustment of the con-

troller type (e.g. resolution of the speed,

The speed range should be selected at least 10% higher

etc.) see chapter 5.1

than the highest setpoint speed in the application.

Loading the default parameters

Loading the default parameters (KEB factory setting) by

Attention: Preadjustments

(e.g. func-

tion of the digital inputs) disappear.

→ Fr.01 copy parameter set = - 4

Selection of the controller configuration

Adjust speed-controlled operation

→ cS.00 speed control config. = 4

(control mode = speed control)

Select source of the speed feedback

The motor speed feedback must be connected to Sub-D so-

cket X3A.

→ cS.01 actual source = 0: channel 1

Enter increments per revolution of the speed feedback

Enter the number of increments per revolution according to

Note: Further adjustments are neces-

the name plate of the encoder

sary when using another encoder type.

Read chapter 7.11 speed measure-

→ Ec.01 encoder 1 (inc/r)

ment

Page6.2 - 9

Start-up

Input of the motor data

Values dr.00 to dr.05 must be taken from the motor name

Attention: The interconnection of the

plate.

motor must be considered at accep-

The values for dr.06 upto dr.08 can be taken from the motor

tance of the values of the motor data

data sheet (if available) or they can be identified automatical-

sheet. The data sheet contains mostly

ly (see point 10).

phase values. The phase-phase values

The DASM head-inductance (dr.10) should always be iden-

must be entered in parameters dr.06...

tified, because it is dependent on the selected magnetizing

dr.10.

current.

The default values can remain in dr.06

→ dr.00 DASM rated current

to dr.10 up to the identification if no

→ dr.01 DASM rated speed

equivalent circuit data are known.

→ dr.02 DASM rated voltage

→ dr.03 DASM rated power

→ dr.04 DASM rated cos (phi)

→ dr.05 DASM rated frequency

→ dr.06 DASM stator resistance

→ dr.07 DASM sigma-inductance

→ dr.08 DASM rotor resistance

→ dr.10 DASM head-inductance

Parameterize flux/rotor adaptation mode

The operation with motor model is activated in parameter

Attention: Further adjustments must be

ds.04 flux/rotor adaptation mode.

done in connection with the maximum

voltage controller.

→ dS.04 = 249

Parameterization of the controller 7.9.1

Activation of the active current limitati-

Further necessary adjustments for the operation with motor

on in the field-weakening range 7.9.2

model are additionally made by this parameter:

Further information about the flux con-

• Maximum voltage controller, maximum voltage 100%

troller and flux build-up see chapter

(without overmodulation)

7.6.2.3.3.1

• Flux controller and magnetization build-up active before

start-up

Calculation of motor-dependent data

The motor-dependent data (e.g. dr.18 field weak. speed)

must be calculated here, even if the motor data dr.06 to dr.10

are unknown.

→ Fr.10 load mot. dependent para. =

2:act. DC link vol-

tage

Page6.2 - 10

Start-up

10.

Identification of the equivalent circuit data

The equivalent circuit data dr.06..dr.10 can be automatically

Attention:

determined by the KEB COMBIVERT.

Depending on the used motor the iden-

The following must be considered:

tification takes some minutes. Noises

• The motor must be in no-load operation for identification

in the motor can occur caused by high

of the main inductance. As standard the motor rotates with

frequency test signals. The sequence

dr.17: "speed for max torque“.The speed limits (oP-parame-

of the identification can be tracked in

ter/chapter 7.4.5) must be programmed accordingly if this is

parameter dr.62 "state motor ident.".

not permissible.

Since the drive is not optimally parame-

• The direction of rotation is clockwise, the acceleration time

terized, a flat acceleration ramp (dr.49)

is preset by dr.49: „Lh.ident. acc/dec time“

should be selected for the identification

• The speeed controller must be parameterized for acce-

to avoid overload of the motor.

leration (dynamics not necessary => select small value for

Note:

cS.09: KI speed)

If the measurement is interrupted with

• The brake control mode must be activated

an error, ru.00 = 60 (error! drive data /

(corresponding to KEB factory setting)

E.Cdd) is displayed.

After successful measurement ru.00 = 127 "drive data calcu-

Read chapter 7.6 for further data of the

lated/Cddr" is displayed.

identification.

The identification is started with:

→ dr.48 = 8: complete AutoIdentification !with rotation!

Close control release (X2A.16) for starting the identification

and open it after the measurement.

11.

Adjustment of specific data

→ dS.02 Current decoupling = 1:on

→ uF.15 Hardw. curr. lim. mode = 0: off

→ uF.18 Deadtime comp. mode = 3: automatically

12.

Enter application specific data

Application specifc data are e.g.

Proper data for the adaption of the in-

• Limit values (speec limits, torque limits etc.)

verter to the respective application can

be find in the corresponding chapters.

→ oP parameter (chapter 7.4.5 setpoint limits)

→ CS parameter (chapter 7.8 torque display and limitation)

• Acceleration / deceleration ramps

→ oP parameter (chapter 7.4.7 ramp generator)

• Function of the digital in- / outputs

→ di parameter (chapter 7.3 digital in- and outputs)

• Type of speed setpoint setting

→ oP parameter (chapter 7.4.2, 7.4.3, 7.4.6) etc.

Page6.2 - 11

Start-up

13. Adjust speed controller

The speed controller parameters can be calculated by the

inverter for applications with constant inertia and rigidly cou-

pled load (see chapter 7.7.1).

The speed controller must be manually adapted, if this ad-

justment is not workable for the application or if the result is

nonsatisfying.

The maximum voltage controller must be parameterized, if

the field weakening range is used.

Note:

Current and flux controller are automatically adjusted during

identification.

14. Test run

Check whether the drive operates stable in all speed ranges

and under all load conditions.

If error messages occur during the start-up phase, read chapter 8.1 "Error causes and displays"

6.2.1.4Start-up F5H-M (ASCL/ vector controlled without encoder feedback with motor model)

Attention: The motor temperature sensor must be connected.

Open control release

Deactivate terminal X2A.16

→ Inverter state ru.00 = „noP“/„0: no control release“

Selection of the speed range

The required speed range (e.g.: 0..+/- 4000 rpm) is selected

Attention: Changing the controller type

in control type ud.02.

releases loading of the default para-

meters!

→ ud.02 control type = 4…7

All data for the adjustment of the

controller type (e.g. resolution of the

The speed range should be selected at least 10% higher

speed, etc.) see chapter 5.1

than the highest setpoint speed in the application.

Page6.2 - 12

Start-up

Loading the default parameters

If the control type ud.02 was not changed, loading of the de-

Attention: Preadjustments (e.g. func-

fault parameters (KEB factory setting) can be released by

tion of the digital inputs) disappear

→ Fr.01 copy parameter set = - 4

Selection of the controller configuration

Adjust speed-controlled operation

→ CS.00 speed control config. = 4

(control mode = speed control)

Select source of the speed feedback

Motor speed feedback not available.

→ cS.01 actual source = 2: calculated actual value

Input of the motor data

Values dr.00 to dr.05 must be taken from the motor name

Attention: The interconnection of the

plate.

motor must be considered at accep-

The values for dr.06 upto dr.08 can be taken from the motor

tance of the values of the motor data

data sheet (if available) or they can be identified automati-

sheet. The data sheet contains mostly

cally (see point 10).

phase values. The phase-phase va-

The DASM head-inductance (dr.10) should always be iden-

lues must be entered in parameters

tified, because it is dependent on the selected magnetizing

dr.06...dr.10.

current.

The default values can remain in dr.06

to dr.10 up to the identification if no

→ dr.00 DASM rated current

equivalent circuit data are known.

→ dr.01 DASM rated speed

→ dr.02 DASM rated voltage

→ dr.03 DASM rated power

→ dr.04 DASM rated cos (phi)

→ dr.05 DASM rated frequency

→ dr.06 DASM stator resistance

→ dr.07 DASM sigma-inductance

→ dr.08 DASM rotor resistance

→ dr.10 DASM head-inductance

Page6.2 - 13

Start-up

Parameterize flux/rotor adaptation mode

The operation with motor model is activated in parameter

Attention: Further adjustments must be

ds.04 flux/rotor adaptation mode.

done in connection with the maximum

voltage controller. Parameterization of

→ dS.04 = 249

the controller,

Activation of the active current limitati-

Further necessary adjustments for the operation with motor

on in the field-weakening range 7.9.2.

model are additionally made by this parameter:

Further information about the flux con-

• Maximum voltage controller, maximum voltage 100%

troller and flux build-up see chapter

(without overmodulation)

7.6.2.3.3.1

• Flux controller and magnetization build-up active before

start-up

Calculation of motor-dependent data

The motor-dependent data (e.g. dr.18 field weak. speed)

must be calculated here, even if the motor data dr.06 to

dr.10 are unknown.

→ Fr.10 load mot. dependent para. =

2:act. DC link vol-

tage

Identification of the equivalent circuit data

The equivalent circuit data dr.06..dr.10 can be automatically

Attention:

determined by the KEB COMBIVERT.

Depending on the used motor the iden-

The following must be considered:

tification takes some minutes. Noises

• The motor must be in no-load operation for identification

in the motor can occur caused by high

of the main inductance. As standard the motor rotates with

frequency test signals. The sequence

dr.17: "speed for max torque“.The speed limits (oP-parame-

of the identification can be tracked in

ter/chapter 7.4.5) must be programmed accordingly if this is

parameter dr.62 "state motor ident.".

not permissible.

Since the drive is not optimally para-

meterized, a flat acceleration ramp

• The direction of rotation is clockwise, the acceleration time

(dr.49) should be selected for the iden-

is preset by dr.49: „Lh.ident. acc/dec time“

tification to avoid overload of the mo-

tor.

• The speeed controller must be parameterized for acce-

Note:

leration (dynamics not necessary => select small value for

If the measurement is interrupted with

cS.09: KI speed)

an error, ru.00 = 60 (error! drive data /

E.Cdd) is displayed.

• The brake control mode must be activated

Read chapter 7.6 for further data of the

(corresponding to KEB factory setting)

identification

After successful measurement ru.00 = 127 "drive data cal-

culated/Cddr" is displayed.

The identification is started with

→ dr.48 = 8:complete AutoIdentification !with rotation!

Close control release (X2A.16) for starting the identification

and open it after the measurement.

Page6.2 - 14

Start-up

10.

Adjustment of specific data

→ dS.02 Current decoupling = 1: on

→ uF.15 Hardw. curr. lim. mode = 0: off

→ uF.18 Deadtime comp. mode = 3: automatically

11.

Enter application specific data

Application specifc data are e.g.

Proper data for the adaption of the in-

• Limit values (speec limits, torque limits etc.)

verter to the respective application can

be find in the corresponding chapters

→ oP parameter (chapter 7.4.5 setpoint limits)

→ cS parameter (chapter 7.8 torque display and limita-

tion)

•Acceleration- / deceleration ramps

→ oP parameter (chapter 7.4.7 ramp generator)

• Function of the digital in- / outputs

→ di parameter (chapter 7.3 digital in- and outputs)

• Type of speed setpoint setting

→ oP parameter (chapter 7.4.2, 7.4.3, 7.4.6) etc.

12.

Adjust speed controller

The speed controller parameters can be calculated by the

Note:

inverter for applications with constant inertia and rigidly cou-

Current and flux controller are automa-

pled load (see chapter 7.11)

tically adjusted during identification.

The speed controller must be manually adapted if this ad-

justment is not workable for the application or if the result is

nonsatisfying.

The maximum voltage controller must be parameterized if

the field weakening range is used.

13.

Test run

Check whether the drive operates stable in all speed ranges

and under all load conditions.

In some cases operation with ASCL at low speed is critical. If

the behaviour of the drive (e.g. when reversing or stopping)

is not optimal, additional measures must be executed (de-

scribed in chapter 7.6.2.3.5.1 "operation at low speed").

If error messages occur during the start-up phase, read chapter 8.1 "Error causes and displays"

Page6.2 - 15

KEB COMBIVERT F5-A,-E,-H 4.0. APPLICATION MANUAL (2008) - page 3