KEB COMBIVERT R6 Instruction Manual
Power supply and regenerative unit
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Summary of Contents for KEB COMBIVERT R6
- Page 1 C O M B I V E R T GB Instruction Manual Power Supply and Regenerative Unit Type R6-S Type 25R6S3R-xxxx Mat.No. Rev. 00R6SEB-KR01...
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Page 3: Table Of Contents
3.5.5 Fuse holder with cover ......................26 Installation ..................... 27 EMC-compatible control cabinet installation ..............27 Installation instructions ....................27 Connection of the COMBIVERT R6 ..................28 4.3.1 General description of inverter input terminals ..............28 4.3.2 Connection terminals of the power circuit ................30 4.3.3 Connections of the control board ..................32... - Page 4 EMC-compatible control cabinet installation ............27 Figure 10: General description of input terminals at KEB inverter ...........29 Figure 11: Description of the input terminals of the COMBIVERT R6 ........30 Figure 12: Connection terminals of the power circuit ...............31 Figure 13: Connection terminals of the control board ..............32 Figure 14: RJ45 socket for phase synchronization and temperature sensor ......33...
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Page 5: Introduction
Introduction Preface First we would like to welcome you as a customer of KEB and congratulation to the purchase of this product. You have decided for a product on highest technical niveau. The enclosed documents as well as the indicated hard- and software are developments of the KEB Automation KG. -
Page 6: Figure 1: Block Diagram Of The Combivert R6S
Introduction The COMBIVERT R6-S is generally protected against overcurrent, ground fault and tempera- ture. The internal DC fuses protect the DC circuit against short-circuit to the line side. The following accessories are necessary for operation with the COMBIVERT R6-S: •... -
Page 7: Validity And Liability
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. All rights reserved. KEB®, COMBIVERT®, KEB COMBICONTROL® and COMBIVIS®... -
Page 8: Standard Operation
At factory setting the modulation is switched off in case of a net phase failure and error mes- sage E.nEt is displayed. Special adjustments from KEB are necessary if the modulation and/or the standard operation should start again within a defined time in case of return of power supply. GB - 8... -
Page 9: Unit Identification
Introduction Unit identification 2 5 . R 6 . S 3 R - 9 0 0 A Type A: Standard D. ext. fan power supply H: Water cooling Design 0: Standard reserved 0: Standard 1: modified standard Voltage 9: 3-ph.; 400 V; AC Housing Options 3: Precharging, DC fuses... -
Page 10: Safety Instructions
The COMBIVERT R6 must not be started until it is determined that the installa- tion complies with 2006/42/EC (machine directive) (note EN60204). The COMBIVERT R6 meets the requirements of the Low-Voltage Directive 2006/95/EC. The harmonized standard of the series EN 61800-5-1 (VDE 0160) is used. -
Page 11: Electrical Connection
Safety Instructions The COMBIVERT R6 must be protected against invalid loading. Components and covers must not be bent or moved as this may affect insulation distances. The units contain electrostatic sensitive devices which can be destroyed by inappropriate handling. For that reason the contact of electronic devices and contacts is to be avoided. - Page 12 Insulation struction. This is permissible in compliance with the standard, since all inverters measure- are given a high voltage test in the end control at KEB. In the case of special ment requirements please contact KEB. When using components without isolated inputs/outputs, it is necessary that equipotential bonding exists between the components to be connected (e.g. by...
- Page 13 If earth fault or short circuits occur in power supply operation, semi-conduc- tor protection is only limited. With applications requiring the COMBIVERT R6 to be switched on and off cycli- cally, maintain an off-time of at least 5 min. If you require shorter cycle times Cyclic acti- please contact KEB.
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Page 14: Emc Instructions
EMC instructions EMC instructions COMBIVERT R6-S represent electrical equipment designed for use in industrial and com- mercial units. In accordance with the EMC directive 2014/30/EU, these devices are with the meaning of the directive components to be further processed by the respective machine and unit manufac- turer and are not operable independently. -
Page 15: Technical Data
The current data are based on a fundamental frequency component of g=0.95. The fundamental frequency com- ponent or the effective value of the input current is dependent on load and line supply conditions. 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. Please contact KEB for higher values. GB - 15... -
Page 16: Overload (Ol) Function
Technical Data Connection to IT and delta power systems after consultation KEB. Voltage stabilization must be activated at the inverter if a harmonic filter is used If a harmonic filter is used, volt- age stabilization must be activated for the inverter which is connected to the DC circuit. Exceeding of the max. rechargeable DC link capacity can lead to a defect. -
Page 17: Operating Conditions
Technical Data 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 considera- tion) Ambient conditions during operation extended to -10…45 °C... -
Page 18: Accessories
Technical Data Accessories Unit size Rated voltage 400 V Commutation choke 25Z1B04-1000 00R6940-2407 Synchronization unit Control cabinet installation; max. distance to the power supply and regenerative unit 1m 00F50C3-4010 Length 1 m Sync cable for connection of the synchronization unit with R6 regenerative unit GB - 18... -
Page 19: Options
Fuse holder for NH00 0090574-0001 and NH000 fuses 25Z1C04-1000 Harmonic filter Please contact KEB for data to the THD value at regenerative (no UL certification) operation in accordance with EN 61800-2-12. Compliance with the IEEE519 requirements at a 480V / 60Hz Harmonic filter mains is possible with the following harmonic filter:... -
Page 20: 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 21: Dimensions And Weights
Dimensions and weights Dimensions and weights 3.5.1 Dimensions air cooling system mounted version Weight: 25 kg Figure 3: COMBIVERT R6 with fan heat sink GB - 21... -
Page 22: Commutation Reactor / Mains Choke
Dimensions and weights 3.5.2 Commutation reactor / mains choke Inductance Frequency Weight Mat.-Number [mH] [Hz] [kg] 25Z1B04-1000 0,133 45…65 Type and cross-section of the terminals Maximum tightening torque Stay bolt for ring thimble 25 Nm 200 lb inch Ø8 Hole for screw M8 Figure 4: Mains choke GB - 22... -
Page 23: Radio Interference Filter (Side-Mounted)
Dimensions and weights 3.5.3 Radio interference filter (side-mounted) Input Input Output L3 ` L2 ` L1 ` Weight Mat.-Number [Hz] [kg] 24E6T60-3000 3x480 50 / 60 ± 2 Type and cross-section of the terminals/- Maximum tightening torque cable M10 stay bolt for ring thim- 35 Nm / 310 lb inch Terminals L1, 35...95 mm²... -
Page 24: Figure 6: Radio Interference Filter 25E4T60-1001 (Side-Mounted)
Dimensions and weights PE Stud M10 1000 Weight Mat.-Number [Hz] [kg] 25E4T60-1001 3x480 50/60 Type and cross-section of the terminals/- Maximum tightening torque cable M10 stay bolt for ring thim- 37 Nm 320 lb inch Connection each 3 x 70 mm² (AWG 2/0) cable Figure 6: Radio interference filter 25E4T60-1001 (side-mounted) GB - 24... -
Page 25: Synchronization Unit
Dimensions and weights 3.5.4 Synchronization unit A (1 : 1) 49,5 105,5 65,5 45,5 Line Max. tightening Part number Weight Terminal connection length torque M6 stay bolt for 4.5 Nm / 40 Ib ring thimble inch 00R6940-2407 0.65 kg M4 ring cable lug L1.1, L2.1, L3.1 240 mm (AWG 16) -
Page 26: Fuse Holder With Cover
Dimensions and weights 3.5.5 Fuse holder with cover Dimensions: 4,96" 126 mm 1,57" 40 mm 1,34" 34 mm 0,5" 13 mm 0,75" 19 mm 3,15" 80 mm 0,12" 3 mm 1,81 " 46 mm 2,91" 74 mm 0,26" 6,5 mm 0,6"... -
Page 27: Installation
(≥ size 25 R-S or R6-N) EMC sub-mounted filter (≤ size 19 R6-S) If necessary, external voltage limi- tation / synchronisation Commutation choke / harmonic filter 150 mm COMBIVERT R6 150 mm if necessary external DC fuses Frequency inverter DC lines with ferrite Motor line with ferrite 150 mm Protective Earth (PE) on the... -
Page 28: Connection Of The Combivert R6
Connection of the COMBIVERT R6 Connection of the COMBIVERT R6 4.3.1 General description of inverter input terminals Starting current limiting When connecting inverters to a DC bus pay attention to the internal wiring of the DC voltage inputs ! Inverters that directly output the DC link bus to the DC terminals must be inte- grated into the DC bus by way that the supply unit(s) limit the starting current. -
Page 29: Figure 10: General Description Of Input Terminals At Keb Inverter
DC link capacity. inverters must have an own starting current is externally starting current limiting at limited. the DC voltage input. Ob- serve the max. load current. Figure 10: General description of input terminals at KEB inverter GB - 29... -
Page 30: Connection Terminals Of The Power Circuit
DC bus. Note the maximum DC link capacity or decoupling diodes ! L1.2, L2.2, L3.2 Mains input 3-phase coming from the commutation reactor Figure 11: Description of the input terminals of the COMBIVERT R6 GB - 30... -
Page 31: Figure 12: Connection Terminals Of The Power Circuit
Connection of the COMBIVERT R6 Fo.1 Fo.2 L1.2 L2.2 L3.2 Termi- Name Function L1.2, L2.2, L3.2 3-phase mains connection to the commutation throttle DC voltage output with starting current limiting; Connection for ++, – – the inverter, the connection terminals are each internally con- nected in parallel. -
Page 32: Connections Of The Control Board
Connection of the COMBIVERT R6 4.3.3 Connections of the control board X2A.10...23 X2A.24...29 Terminal Function Connection line contactor and Mains voltage potential ! precharging 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 ! Conductor cross-section [mm²]... -
Page 33: Connection Of The Synchronization Unit
Connection of the COMBIVERT R6 For UL approval the following values should be observed for X1B: Uin = 23...30 V or 230 Vac Iin = 0.01...2 A or 2 A. Precharging must be carried out via the terminal X1C! 4.3.4 Connection of the synchronization unit RJ45 socket for phase synchroni-... -
Page 34: Connection Power Unit R6-S Without Ul
Connection power unit R6-S without UL Connection power unit R6-S without UL 4.4.1 Power supply and regenrative operation at inverter current ≤ inverter current of one COMBIVERT R6-S without UL 24VDC Control voltage Sync L1.1 L1.2 L2.1 L2.2 L3.1 L3.2 17 18 24 25 L1.2 L2.2 L3.2 24 26 K2 K2 L1 L2... -
Page 35: Figure 15: Power Supply And Regenerative Operation At Inverter Current ≤ Current Of One Combivert R6-S
Connection power unit R6-S without UL Sync Synchronization unit (max. length of the phase lines 1 m) Commutation choke / harmonic filter Regenerative unit COMBIVERT R6-S Power circuit terminals Connection for line contactor and precharging Connection for DC fuse monitoring 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... -
Page 36: Connection Power Unit R6-S With Ul
Connection power unit R6-S with UL Connection power unit R6-S with UL 4.5.1 Power supply and regenrative operation at inverter current ≤ inverter current of one COMBIVERT R6-S with UL 24VDC Control voltage Sync L1.1 L1.2 L2.1 L2.2 L3.1 L3.2 L1.2 L2.2 L3.2 17 18 24 25 24 26 K2 K2 L1 L2... -
Page 37: Power Supply And Regenerative Operation At Parallel Operation With One Frequency Inverter
Connection power unit R6-S with UL Pre-charging contactor (400 V / 12 A AC3) Sync Synchronization unit (max. length of the phase lines 1 m) Commutation choke / harmonic filter Regenerative unit COMBIVERT R6-S Power circuit terminals Connection for line contactor Connection for precharging and DC fuse monitoring 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... -
Page 38: Connection Of The Control Board Version S
Relay 2 / NC contact max. 30 V DC *) Relay output (DC > CP.19) 0.01…2 A DC Relay 2 / switching contact *) The relay outputs must be operated with max. 48 V DC protective separation voltage to guaran- tee the CE standard. After consultation KEB a current of max. 2A DC is permissible for 120 V AC (depending on the switching capacity etc.). GB - 38... -
Page 39: Assignment Of The Socket X2B
Connection of the control board version S 4.6.2 Assignment of the socket X2B RJ45 socket for phase synchronization No. Name Function and temperature sensor Connection for temperature sen- sor (option) 3 U13_syn Synchronization phase 1 / 3 – reserved 5 U21_syn Synchronization phase 2 / 1 –... -
Page 40: Wiring Example
Connection of the control board version S 4.6.4 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 •... -
Page 41: Operation Of The Unit
(terminal ST) is set, the COMBIVERT R6-S starts independently with the normal 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” If the DC voltage in the DC link (CP.09 or ru.19) exceeds the value of the regeneration level (CP.34 or cS.02) referring to the reference value ru.18, the modulation signals are ac-... -
Page 42: Parameter Summary
Parameter summary 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. Display Parameter Setting range Resolu- Factory Origin tion setting CP.00 password input 0…9999 – ud.01 CP.01 status display – – – ru.00 CP.02 actual line frequency –... -
Page 43: Monitoring And Analysis Parameters
Monitoring and analysis parameters Approach of the working meters The displayed values of the working meters offer only an estimate value because of measurement and calculation inaccuracies. These displayed values are un- suitable for tariff applications and cannot replace any measuring devices. Monitoring and analysis parameters The following parameters serve for the functional monitoring during operation. -
Page 44: Cp.01 Status Display
After switching on, the actual mains 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 45: Peak Value
The error can be reset now. Name Enter Origin CP.12 OL counter display – – ru.39 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 - 45... -
Page 46: Cp.14 Total Regen
Origin CP.13 active power – – ru.81 Resolution Meaning CP.13 displays the actual power of the COMBIVERT R6-S. Motor pow- 0.1 kW er is displayed with positive values, generatoric power is displayed with negative values. Name Enter Origin CP.14 total regen –... -
Page 47: Special Adjustments
Special adjustments Special adjustments The power supply and regenerative unit can be adapted to the application with the following parameters. Name Enter Origin CP.18 ANOUT 1 gain – An.33 The analog output displays the difference between actual supply frequency and set supply frequency. -
Page 48: Last Error
Special adjustments Name Enter Origin CP.21 last error – – In.24 set 0 CP.22 last error -1 – – In.24 set 1 CP.23 last error -2 – – In.24 set 2 CP.24 last error -3 – – In.24 set 3 CP.25 last error -4 –... -
Page 49: Cp.34 Regeneration Level 100
Special adjustments Name Enter Origin CP.33 operating mode Pn.19 This parameter determines the master or slave of regenerative units at parallel connection. Further it is adjusted whether a harmonic filter or a commutation choke is series-connected. Single units must be adjusted to master. Value range Meaning Master-Slave with commutation reactor input selection Master-Slave with harmonic filter input selection Name Enter Origin... -
Page 50: Dimensioning Power Supply And Regenerative Units
Appendix A Appendix A Dimensioning power supply and regenerative units Dimensioning of the power supply and regenerative unit bridgeover ext. Only load-shunt with Acquire: CZK_all > CZK_max regeneration ? contactor (special ZK_all unit) Acquire: Decoupling R6-S (see 4.4.3 to , t1, T, η η η Mmax 4.4.5) Calculate: ILM, ILMmax Acquire: select higher unit or parallel con- PM, PMmax, t1, T, ηM, ηG, ηFI... -
Page 51: Dc Link Capacitors Of Keb Frequency Inverters
Appendix A DC link capacitors of KEB frequency inverters Frequency inverter COMBIVERT F5 200 V units 400 V units Unit size Capacity Unit size 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... - Page 52 Appendix A Frequency inverter COMBIVERT G6 Housing size Unit size Capacity / µF Precharging circuit Type A1 Type A1 Type A1 Type A1 1120 1035 1400 Type B1 1985 Frequency inverter COMBIVERT S6 Housing size Unit size Capacity / µF Precharging circuit 1955 Type A1...
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Page 53: Decoupling Diodes
Appendix A Decoupling diodes Use decoupling diodes when using the R6 as regenerative unit only, to avoid that the con- nected inverters cannot be supplied via the regenerative unit. Appropriate decoupling diodes are defined for the different sizes. A.3.1 Assignment R6-S Material number Type Volume Ta [°C] Th [°C] Rha [K/W]... -
Page 54: Dimensions Of The Decoupling Diodes
Appendix A A.3.2 Dimensions of the decoupling diodes 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) Figure 20: Dimensions of the decoupling diodes GB - 54... -
Page 55: Certification
B.1.2 UL Certification Acceptance according to UL is marked at KEB power supply and regen- erative units with the adjacent logo on the type plate. To be conform according to UL for the use on the North American Market the following in- structions must be observed (original text of the UL file in English): •... - Page 56 +39 02 3353531 • fax: +39 02 33500790 net: www.keb.de • mail: kebitalia@keb.it KEB Power Transmission Technology (Shanghai) Co.,Ltd. No. 435 Qianpu Road, Chedun Town, Songjiang District, KEB Japan Ltd. Shanghai 201611, P.R. China 15–16, 2–Chome, Takanawa Minato-ku fon: +86 21 37746688 • fax: +86 21 37746600...
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