KEB Combivert R6 Instruction Manual
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KEB Combivert R6 Instruction Manual

KEB Combivert R6 Instruction Manual

Power supply and regenerative unit
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C O M B I V E R T
Power Supply
GB INSTRUCTION MANUAL
and Regenerative Unit
Type R6-S
Size 25
Mat.No.
Rev.
00R6SEB-KR00
1J

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Summary of Contents for KEB Combivert R6

  • Page 1 C O M B I V E R T Power Supply GB INSTRUCTION MANUAL and Regenerative Unit Type R6-S Size 25 Mat.No. Rev. 00R6SEB-KR00...
  • Page 2 This instruction manual describes the power supply and regenerative unit KEB COMBIVERT R6-S. Before working with the unit the user must become familiar with it. This especially applies to the knowledge and observance of the following safety and warning indications. The pictographs used in this instruction manual...

  • Page 3: Table Of Contents

    4. Installation ..........19 EMC-compatible control cabinet installation ............ 19 Installation instructions ....... 19 Connection of the COMBIVERT R6 .... 20 4.3.1 General description of inverter input terminals ............20 4.3.2 Connection terminals of the power circuit ..20 4.3.3 Connections of the control board ....21 4.3.4 Connection of the synchronization unit ..

  • Page 4: Introduction

    • replaces braking resistor and braking transistor. • is cost-saving. The COMBIVERT R6-S is generally protected against overcurrent, ground fault and tempera- ture. Appropriate dimensioned DC fuses protects the DC link circuit against short-circuit. The following accessories are necessary for operation with the COMBIVERT R6-S: • Mains choke for inverter input...

  • Page 5: Validity And Liability

    Copyright The customer may be use the instruction manual as well as further enclosed documents or parts from it for internal purposes. KEB has the copyrights and they remain effective also to the full extent. 1.5 Specified application The COMBIVERT R6-S serves exclusively for the supply of frequency inverters with DC input and/or regeneration of excess energy into the supply system.

  • Page 6: Unit Identification

    Preface 1.6 Unit identification 2 5 . R 6 . s 1 R - 9 0 0 A Type A: Heat sink (standard) Design 0: default reserved 0: default 1: modified default Voltage 9: 3-ph.; 400 V; AC housing Options 1: internal precharging Control S: 2B.R6 Series Unit size...

  • Page 7: Safety Instructions

    COMBIVERT R6 power supply und regenerative units contain dangerous voltages which can cause death or serious injury. COMBIVERT R6 can be adjusted by way that energy is refeed into the supply system in case of power failure at generatoric operation. Therefore a dangerous high tension can exist in the unit after switching off the supply system.

  • Page 8: Electrical Connection

    (because of danger of destruction). This is in compliance with the given standard because Insulation Mea- KEB inverter are 100 % voltage tested at manufacturing output routine test. In case of spe- surement cial requirements contact KEB for further information. When using components without isolated inputs / outputs, it is necessary that equipotential bonding exists between the components to be connected (e.g. through the equalizer). Disre-...
  • Page 9 Safety Instructions A trouble-free and safe operation of the COMBIVERT R6 is only guaranteed when the con- nection instructions below are strictly followed. Incorrect operation or damage may result from incorrect installation. • Pay attention to mains voltage. • Install power cables and control cables separately (>15 cm separation).
  • Page 10 Safety Instructions If personnel protection of the system is required, the COMBIVERT R6-S must be protected according to EN 61800-5-1: • 3-phase inverters (with B6 bridge-connected rectifier) by RCMA’s with separation (used privileged) or RCD’s type B (all-current sensitive FI’s) The tripping current should be 300mA or more, in order to avoid a premature triggering by discharge currents (about 200mA. Dependent on the load, the length of the motor cable and the use of a radio interference filter, substantially higher leakage current can occur.

  • Page 11: Emc Instructions

    All connections must be kept as short as possible and as close as possible to the earth, as free floating lines work as active and passive aerials. • Keep connection cables straight (do not bundle). Install a non-assigned wire at one sides to the protective earth conductor. • The flow and return circuit must be twisted when the lines are not shielded, in order to dampen common-mode noise. • The cable for phase synchronisation between mains choke and COMBIVERT R6-S may not exceed a line length of 1 m. • Further informations are found in the internet, see „www.keb.de“. GB - 11...

  • Page 12: Technical Data

    At uncontrolled B6 converters the phase angle cosφ1 can be set to one, so the value of the fundamental frequency components is equal to the value of the power factor. 4) Please contact KEB for higher values. Voltage stabilization must be activated at the inverter if a harmonic filter is used.

  • Page 13: Overload (Ol) Function

    Technical Data Overload (OL) function Release time [s] Load [%] Operating conditions Standard Standard/ Instructions class EN 61800-2 Inverter product standard: rated specifications Definition according to EN 61800-5-1 Inverter product standard: general safety max. 2000 m above sea level (with site altitudes over 1000 m a derating of Site altitude 1 % per 100 m must be taken into considerati- Ambient conditions during operation extended to -10…45 °C (with temperature over 45°C to max. 55°C a...

  • Page 14: Accessories

    Limit class C2 (only with ferrite rings) Limit class C1 (on consultation with KEB) DC fuses 1000 V/500 A Mat.no. 009025H-3679 25Z1C04-1000 The overload current reduces at certain mains conditions ! Please contact Harmonic filter KEB for data to the THD value at regenerative operation in accordance with EN 61800-2-12. Operators Digital operator, Interface operator Bus operators CAN, ProfiBus, InterBus, EtherCAT, EhterNet, Sercos, ModBus, Device- Net, HSP5 GB - 14...

  • Page 15: Ferrite Rings

    Technical Data 3.4.1 Ferrite rings Ferrite rings are used for the reduction of the cable-based and radiated interferences. For a high damping, the ferrite rings are attached as close as possible to the interference source, i.e. at the DC and at the motor output terminals of the frequency inverter. The conductors must passed through the ferrite core for the use as current-compensated choke.

  • Page 16: Dimensions And Weights

    Technical Data - Dimensions and Weights Dimensions and weights 3.5.1 Dimensions air-cooled inverter mounting version Design Weight Air-cooled heat sink 25 kg GB - 16...

  • Page 17: Commutation Reactor/Mains Choke

    Technical Data - Dimensions and Weights 3.5.2 Commutation reactor/mains choke Inductance Irated Frequency Weight Mat.-number [Hz] [kg] 25Z1B04-1000 0,133 45…65 Technical data of the connection terminals Max. tightening torque Stay bolt for ring thimble 25 Nm 200 lb inch Ø8 Drilling for screw M8 GB - 17...

  • Page 18: Side-Mounted Emi Filter

    Technical Data - Dimensions and Weights 3.5.3 Side-mounted EMI filter PE-Bolzen M10 1000 Interference sup- Weight rated rated Mat.-number pression level/ rated Line length [Hz] [kg] 25E4T60-1001 3x480 C2 / 30 m 50/60 Technical data of the connection terminals/cable Max. tightening torque M10 Stay bolt for ring thimble 37 Nm 320 lb inch Connection cable each with 3 x 70 mm² (AWG 2/0)

  • Page 19: Installation

    Installation Installation EMC-compatible control cabinet installation Main fuse Main contactor Harmonic filter (or 6) COMBIVERT R6 Side-mounted EMI filter (≥ size 25) Sub-mounted EMI filter (≤ size 19) 150 mm Commutation reactor (or 3) 150 mm Frequency inverter if necessary external DC fuses Motor lines 10 A Protective Earth (PE) on the mounting plate power circuit Protective Earth (PE) on the mounting plate control circuit 30 mm...

  • Page 20: Connection Of The Combivert R6

    The maximum DC link capacity can be calculated by adding the DC link capacities of all inverters in the DC bus. A table for this can be found in the appendix. The supply source (supply unit or inverter with AC input) must be suitable for this value. Picture 4.3.1 General description of input terminals at KEB inverters Terminals Description of terminals at KEB inverters ++, – –...
  • Page 21 The terminals of a power supply and regenerative unit can be input or output dependent on the actual operating status (power supply or regeneration). For the standardization of the view the line side is always regarded as input and the DC voltage side is always regarded as output. Picture 4.3.2 Description of the input terminals of the COMBIVERT R6 R6-S in E-housing R6-S in R and P-housing L1.2...

  • Page 22: Connections Of The Control Board

    Connection Terminals 4.3.3 Connections of the control board Connection terminals of the control board X2A.10...23 X2A.24...29 Connection precharging Supply voltage potential ! Connection for synchronization line Activation of the line contactor self-holding HSP5 operator interface No direct PC connection Control terminal strip Install control and mains cable separately ! 4.3.4 Connection of the synchronization unit RJ45 socket for phase synchroniza- Name...

  • Page 23: Connection Power Unit R6

    F1 Mains fuse type gR F2 10 A fuse gG/gL or automat characteristic K F3 10 A fuse gG/gL F4 DC fuses type aR/gR The cable cross section as well as the DC fuses (see chapter 2.1) must be dimen- sioned to the DC rated current of the load (see technical data of the inverter). G1 Regenerative unit COMBIVERT R6-S Power circuit terminals Connection for precharging and switching-on of line contactor K1 Control terminal strip (X2A.12: control release; X2A.17: voltage output) Connection for synchronization line Activation of the self-holding of the load shunt relay (K2 internal)

  • Page 24: Power Supply And Regenrative Operation At Inverter Currents ≤ Current Of One Combivert R6-S

    F2 10 A fuse gG/gL or automat characteristic K F3 10 A fuse gG/gL F4 DC fuses type The cable cross section as well as the DC fuses (see chapter 2.1) must be dimensioned to the aR/gR DC rated current of the load (see technical data of the inverter). G1 Regenerative unit COMBIVERT R6-S Power circuit terminals Connection for precharging and switching-on of line contactor K1 Control terminal strip (X2A.12: Control release; X2A.17: voltage output) Connection for synchronization line Activation of the self-holding of the load shunt relay (K2 internal) G2 Frequency inverter with DC voltage input...

  • Page 25: Power Supply And Regenerative Operation At Parallel Operation Of Up To Three R6-S

    Connect the Power Unit 4.4.3 Power supply and regenerative operation at parallel operation of up to three R6-S (Parallel operation with an error at current sharing of the R6-S units of ≤10 %) 14/K2 13/K2 L1’ L1.1 L1.2 L1.2 L2’ L2.1 L2.2 L2.2 L3’ L3.1 L3.2 L3.2 14/K2 13/K2 L1’ L1.1 L1.2 L1.2 L2’ L2.1 L2.2 L2.2...
  • Page 26 10 A fuse gG/gL DC fuses type aR (see technical data) F6, F7 DC fuses type aR/gR The cable cross section as well as the DC fuses (see chapter 2.1) must be dimensi- oned to the DC rated current of the load (see technical data of the inverter). G1, G2 Regenerative unit COMBIVERT R6-S Power circuit terminals Connection for precharging and switching-on of line contactor K1, K3 Control terminal strip (X2A.12: Control release; X2A.17: voltage output) Connection for synchronization line Activation of the self-holding of the load shunt relay (K2 internal) G3, G4 Frequency inverter with DC voltage input...
  • Page 27 Connect the Power Unit G1, G2 Regenerative unit COMBIVERT R6-S Control terminal strip Relay 1 / NO contact Relay 1 / NC contact Ready for operation relay Relay 1 / switching contact G3, G4 Frequency inverter COMBIVERT F5 Control terminal strip...

  • Page 28: Regenerative Operation At Parallel Operation Of Up To Three R6-S With Decoupling Diodes

    Connect the Power Unit 4.4.4 Regenerative operation at parallel operation of up to three R6-S with decoupling diodes (Parallel operation with an error at current sharing of the R6-S units of ≤10 %) 14/K2 13/K2 L1.1 L1’ L1.2 L1.2 L2’ L2.1 L2.2 L2.2 L3’ L3.1 L3.2 L3.2 14/K2 13/K2 L1L2 L3 L1.1 L1’ L1.2 L1.2 L2’...
  • Page 29 10 A fuse gG/gL DC fuses type aR (see technical data) F6, F7 DC fuses type aR/gR The cable cross section as well as the DC fuses (see chapter 2.1) must be dimensi- oned to the DC rated current of the load (see technical data of the inverter). G1, G2 Regenerative unit COMBIVERT R6-S Power circuit terminals Connection for precharging and switching-on of line contactor K1, K3 Control terminal strip (X2A.12: control release; X2A.17: voltage output) Connection for synchronization line Activation of the self-holding of the load shunt relay (K2 internal) G3, G4 Frequency inverter with DC voltage input...

  • Page 30: Connection Of The Control Board Version S

    Relay 2 / switching contact The relay outputs must be operated with max. 48 V DC protective separation voltage to guarantee the CE standard. After consultation KEB a current of max. 1 A DC is permissible for 120 V AC.

  • Page 31: Wiring Example

    Connection of the Control Board 4.5.3 Wiring example In order to prevent a malfunction caused by interference voltage supply on the control inputs, the following directions should be observed: • Use shielded/drilled cables • Lay shield on one side of the inverter onto earth potential • Lay control and power cable separately (about 10...20 cm apart); Lay crossings in a right angle (in case it cannot be prevented) Active signal for further R6-S units at parallel operation max.

  • Page 32: Operator

    Installation and Connection Operator As an accessory to the local or external (option: cable 00.F5.0C0-1xxx) operation of the COMBIVERT R6-S, an operator is necessary. To prevent malfunctions, the COMBIVERT must be brought into nOP status before con- necting/ disconnecting the operator (open control release). When starting the COMBIVERT, it is started with the last stored values or factory setting. Digital operator (part number 00.F5.060-1000) Interface operator (part number 00.F5.060-2000) x x 5-digit LED Display x x Operating-/Error display Normal "LED on" Error "LED blinks" x Interface control Transmit "LED on"...

  • Page 33: Operation Of The Unit

    The COMBIVERT R6-S is initialized after connection of the power supply. The power circuit identification is checked first. If an invalid power circuit is recognized, error „E.Puci” (Power unit code invalid) is released and displayed in the operator. This error cannot be reset, the power circuit must be checked. If a valid power circuit is recognized, COMBIVERT R6-S changes into status "SYn". The fol- lowing procedures take place one after another during this synchronisation phase: • Inspection of correct synchronisation connection (error "E.nEt" is released, if the synchro- nous signal is missing) • Inspection of the phase allocation of synchronous signals to the mains phases.
  • Page 34 The actual mains frequency is determined and the correct connection of the COMBIVERT R6-S is secured after successful synchronisation. If the control release (terminal ST) is set, the COMBIVERT R6-S starts independently with the specified operation. Depending whether regenerative requirement is available, the COMBIVERT R6-S is in status „rEGEn” or „Stb”. Status „Stb“ COMBIVERT R6-S detects a typical voltage level in the DC link circuit of the connected fre- quency inverter (motor operation) and keeps the modulation signals of the regenerative unit deactivated. Status „rEGEn” The modulation signals are activated and the unit changes into regenerative operation on ex- ceeding the DC voltage in the DC link (CP.09) more than 103 % of the input voltage. Further...

  • Page 35: Parameter Summary

    Operation of the Unit Parameter summary The CP parameters are one of the parameter selection defined by KEB. You need an applica- tion manual in order to get access to the entire parameters. Dis- Parameter Setting range Resolu- Factory Origin...

  • Page 36: Password Input

    CP.00 Password input Ex works the COMBIVERT R6-S is supplied without password protection, i.e. all changeable parameters can be adjusted. After parameterizing the inverter can be secured against unaut- horized access. The adjusted mode is stored. Barring the CP-Parameter...
  • Page 37 After switching on the actual line frequency is determined during the initialization phase. Slowly changes of the line frequency during the operation are recognized and displayed in CP.02. CP.02 displays the actual regenerative frequency, if the COMBIVERT R6-S is in "netof" status.
  • Page 38 OL counter display Resolution Meaning The permanent load of the COMBIVERT R6-S can be evaluated with this parameter, in order to avoid an E.OL error (in-time load reduction). Error E.OL is released, if the overload counter reaches 100 %. GB - 39...
  • Page 39 Origin – – ru.81 CP.13 Actual power Resolution Meaning CP.13 displays the actual power of the COMBIVERT R6-S. Motor power 0.1 kW is displayed with positive values, generatoric power is displayed with ne- gative values. Name Enter Origin – –...

  • Page 40: Special Adjustments

    Operation of the Unit Special adjustments The power supply and regenerative unit can be adapted to the application with the following parameters. Name Enter Origin – An.33 CP.18 Analog output 1 / gain The analog output displays the difference between actual supply frequency and set supply frequency.
  • Page 41 SY.3 CP.31 Power unit identification The COMBIVERT R6-S detects the connected supply system (230 V/400 V) at the first swit- ching on. Depending on the supply system the COMBIVERT R6-S adjusts internally certain parameter values. If the COMBIVERT R6-S connected to another supply system, these stored parameter va- lues are not correct any longer.
  • Page 42 Operation of the Unit Name Enter Origin Pn.19 CP.33 Operating mode This parameter determines the master or slave of regenerative units at parallel connection. Further it is adjusted whether a harmonic filter or a commutation reactor is series-connected. Single units must be adjusted to master. Value range Meaning Master with commutation reactor...

  • Page 43: Dimensioning Power Supply And Regenerative Units

    Appendix Appendix A Dimensioning power supply and regenerative units Dimensioning of the power supply and regenerative unit Only Acquire: Bridgeover ext. load-shunt ZK_all > ZK_max regeneration ? with contactor (special ZK_all unit) Acquire: Decoupling R6-S (see 4.4.3 to 4.4.5) , t1, T, η η η Mmax Calculate: LMmax Acquire: , t1, T, η η η...

  • Page 44: Dc Link Capacitors Of Keb Frequency Inverters

    Appendix DC link capacitors of KEB frequency inverters 200 V units 400 V units Size Capacity Size (housing) Capacity 780 µF 180 µF 880 µF (940 µF*) 180 µF (300 µF*) 1080 µF 300 µF 1080 µF 345 µF 2220 µF 470 µF 3280 µF 580 µF 4100 µF...

  • Page 45: Dimensions

    Appendix A.3.2 Dimensions Material number Connection Dimensions 0090147-3500 1 (Anode) 2 (Cathode) 3 (Anode) 1 (Cathode) 0090147-4101 1 (Anode) 2 (Cathode) 3 (Anode) 1 (Cathode) 0090147-6009 3 (Anode) 2 (Cathode) GB - 46...

  • Page 46: Certification

    Appendix Appendix B B.1 Certification B.1.1 CE Marking CE marked power supply-/regenerative units were developed and manufactured to comply with the regulations of the Low-Voltage Directive 2006/95/EC. The described units must not be started until it is determined that the installation complies with the Machine directive (2006/42/EG) as well as the EMC-directive (2004/108/EC)(note EN 60204).
  • Page 47 Notizen D - 47...
  • Page 48 KEB Italia S.r.l. fon: +32 5443 7860 • fax: +32 5443 7898 Via Newton, 2 • I-20019 Settimo Milanese (Milano) mail: vb.belgien@keb.de fon: +39 02 33535311 • fax: +39 02 33500790 net: www.keb.it • mail: kebitalia@keb.it KEB Power Transmission Technology (Shanghai) Co.,Ltd. No. 435 QianPu Road, Songjiang East Industrial Zone, KEB Japan Ltd. CHN-201611 Shanghai, P.R. China 15–16, 2–Chome, Takanawa Minato-ku fon: +86 21 37746688 • fax: +86 21 37746600 J–Tokyo 108-0074 net: www.keb.cn • mail: info@keb.cn fon: +81 33 445-8515 • fax: +81 33 445-8215...

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