KEB COMBIVERT R6-S Instruction Manual
Power supply and regenerative unit
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Summary of Contents for KEB COMBIVERT R6-S
- Page 1 C O M B I V E R T GB INSTRUCTION MANUAL Power Supply and Regenerative Unit Type R6-S Size 29 Mat.No. Rev. 00R6SEB-KP00...
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Page 3: Table Of Contents
Connections of the control board ..................27 4.3.5 Connection of the synchronization unit ................27 Connection Power Unit R6-S ....................28 4.4.1 Power supply and regenerative operation at inverter current ≤ current of one COMBIVERT R6-S ......................28 4.4.2 Power supply and regenerative operation at inverter currents ≤ current of one COMBIVERT R6-S ......................29 4.4.3 Power supply and regenerative operation at parallel operation of up to three R6-S ...30 4.4.4... - Page 4 Parameter summary ......................40 Monitoring and analysis parameters ................41 Special adjustments ......................45 Appendix A ....................48 Dimensioning power supply and regenerative units .............48 DC link capacitors of KEB frequency inverters ..............49 Decoupling diodes ......................51 A.3.1 Assignment ..........................51 A.3.2 Dimensions of the decoupling diodes ..................52 Appendix B ....................
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Page 5: Introduction
Introduction Introduction Preface The described hard- and software are developments of the KEB Automation KG. The en- closed documents correspond to the conditions valid at printing. Misprint, mistakes and tech- nical changes reserved. The manual must be made accessible for each user. Before working with the unit the user must become familiar with it. -
Page 6: 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 7: Specified Application
Introduction 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. The operation of other electrical consumers is prohibited and can lead to malfunctions or to the destruction of the units. -
Page 8: Unit Identification
Introduction Unit identification 2 9 R 6 S 1 P - 9 1 0 D Type D: External fan power supply Design 0: default reserved 0: default 1: modified standard Voltage 9: 3-ph.; 400 V; AC Housing Options 1: Precharging intern Control S: 2B.R6 Series Unit size... -
Page 9: Safety Instructions
Safety Instructions Safety Instructions General instructions COMBIVERT R6 power supply und regenerative units contain dangerous volt- ages which can cause death or serious injury. COMBIVERT R6 can be adjusted by way that energy is regenerated into the supply system in case of power failure at regenerative operation. Therefore a dangerous high tension can be in the unit after switching off the supply system. -
Page 10: 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 11 Insulation is permissible in compliance with the standard, since all inverters are given a measure- high voltage test in the end control at KEB. In the case of special requirements ment 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.
- Page 12 • Ground the cabinet or the system earth star point with the shortest connec- tion to mains earth. (avoid earth loops) • Use exclusively the line commutation throttle specified by KEB. • The average value of the supplied DC current may not exceed the maxi- mum DC current. • If several frequency inverters are connected to the COMVIBERT R6-S the max.
- Page 13 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.Switching off during the initialization phase can cause un- vation and defined conditions.
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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
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. IT and delta power system after consultation KEB (see also safety instructions, voltage with respect to ground). Voltage stabilization must be activated at the inverter if a harmonic filter is used. The units are not short circuit proof without corresponding dimensioned fuses... -
Page 16: Overload (Ol) Function
Technical Data Exceeding of the max. rechargeable DC link capacity can lead to a defect. A load removal in the DC link circle may be done only after the message „ready“. If the control release is set when switching off the mains, this can lead to an overcurrent error and the lifetime of the module can be reduced. The unit must be disconnected from the supply system or the load must be switched off in case of overcurrent or overload. - Page 17 Technical Data Standard Standard/ Instructions class extended to -10…45 °C (with temperature over 45°C to max. 55°C Temperature Climate a derating of 5 % per 1 K must be taken into consideration) Humidity 5…85 % (without condensation) EN 60721-3-3 max. amplitude of a vibration 1 mm (5…13 Hz) Mechanical Vibration max.
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Page 18: Accessories
1000 V/500 A Mat.no. 009025H-3679 or DC fuses 750 V/500 A Mat.no. 0090249-5679 (two parallel for each) 29Z1C04-1000 The overload current reduces at certain mains conditions ! Harmonic filter Please contact KEB for data to the THD value at regenera- tive operation in accordance with EN 61000-2-12. Operators Digital operator, interface operator CAN, ProfiBus, InterBus, Ethercat, Ehternet, Sercos, Mod- Bus operators Bus, PROFINET, Devicenet, HSP5 5.4.1... -
Page 19: Dimensions And Weights
Dimensions and weights Dimensions and weights 5.5.1 Dimensions air cooling system mounted version M10 / 4x Figure 22: Fan heat sink Weight per module A-heat sink airflow, B-inside ventilation 97.5 kg GB - 71... -
Page 20: Commutation Reactor/Mains Choke
Dimensions and weights 5.5.2 Commutation reactor/mains choke Inductance Irated Frequency Weight Mat.-Number [mH] [Hz] [kg] 29Z1B04-1000 0.061 45…65 Technical data of the connection terminals Maximum tightening torque Stay bolt for ring thimble 25 Nm 200 lb inch Ø8 Hole for screw M12 for max. two ring thimbles each with 240 mm² Figure 23: Commutation reactor / mains choke GB - 72... -
Page 21: Radio Interference Filter (Side-Mounted)
Dimensions and weights 5.5.3 Radio interference filter (side-mounted) 6xø12 Interference Height A Weight rated rated Mat.-Number level/ [kg] [mm] Line length 15E4T60-1001 3x400/480 C2 / 30 m Technical data of the connection terminals Maximum tightening torque M12 M10 stay bolt for ring thimble 48 Nm 400 lb inch Ø8... -
Page 22: Installation
Installation Installation EMC-compatible control cabinet installation Mains fuse Main contactor HF-side-mounted filter (≥ size 25 R-S or R6-N) HF-sub-mounted filter (≤ size 19 R6-S) if necessary external synchroniza- tion Commutation reactor / harmonic 150 mm filter 150 mm COMBIVERT R6 if necessary external DC fuses Frequency inverter Motor lines 150 mm Protective Earth (PE) on the 30 mm mounting plate power circuit... -
Page 23: Connection Of The Combivert R6
The supply source (supply unit or inverter with AC input) must be suitable for this value. Terminals Description of terminals at KEB inverters ++, – – DC voltage input with starting current limiting; usable as output only if all units supplied by the DC bus have a starting current limiting at the DC volt- age input. - Page 24 DC link capacity. inverters must have an own starting current is externally starting current limiting at the limited. DC voltage input. Observe the max. load current. Figure 27: General description of input terminals at KEB inverter GB - 76...
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Page 25: Connection Terminals Of The Power Circuit
L2.2 L2.2 L3.2 L3.2 Terminals Description of terminals at KEB inverters ++, – – DC voltage output with starting current limiting for loading the connected inverter; usable as input for regenerative operation. If inverters with mains supply of type A1 or A2 (see 4.3.1) are available in the DC bus, these may be switched to mains only after loading the 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... -
Page 26: External Fan Power Supply
Connection of the COMBIVERT R6 L1.2 L2.2 L3.2 All terminals must be provided with cover caps against electric shock. Name Function L1.2, L2.2, L2.3 3-phase mains connection to the commutation reactor ++, – – DC voltage output with starting current limiting; Connection for inverter Connection for shielding /earthing Technical data of the connection terminals... -
Page 27: Connections Of The Control Board
Connection of the COMBIVERT R6 6.3.4 Connections of the control board X2A.10...23 X2A.24...29 Mains contactor (AC15: 6A 230V AC / DC13: Supply voltage potential ! 6A 24V DC) and connection 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 ! Figure 31: Connection terminals of the control board 6.3.5 Connection of the synchronization unit RJ45 socket for phase synchroni-... -
Page 28: Connection Power Unit R6-S
F2 10 A fuse gG/gL or automat characteristic K F3 10 A fuse gG/gL F4 DC fuses type aR/ The cable cross section as well as the DC fuses (see chapter 2.1) must be di- mensioned 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) G2 Frequency inverter all types (see 4.3.1) -
Page 29: Power Supply And Regenerative Operation At Inverter Currents ≤ Current Of One
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 dimen- aR/gR 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) G2 Frequency inverter all types (see 4.3.1) -
Page 30: Power Supply And Regenerative Operation At Parallel Operation Of Up To Three R6-S
Connection Power Unit R6-S 6.4.3 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 31 10 A fuse gG/gL DC fuses type aR (see technical data) F1, F2 DC fuses type aR/gR The cable cross section as well as the DC fuses (see chapter 2.1) must be dimensioned 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 all types (see 4.3.1)
- Page 32 A load draw in the DC circuit may be done only when the message „ready“ is set. This can be guaranteed by a series connection of the relay R1 of the R6-S units with the control release of the connected inverters. G1, G2 Regenerative unit COMBIVERT R6-S Control terminal strip Relay 1 / NO contact...
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Page 33: Regenerative Operation At Parallel Operation Of Up To Three R6-S With Decoupling Diodes
Connection Power Unit R6-S 6.4.4 Regenerative operation at parallel operation of up to three R6-S with decoupling di- odes (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’ L1.1 L1.2 L1.2 L2’... - Page 34 10 A fuse gG/gL must be monitored (see technical data) DC fuses type aR must be monitored (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 dimensioned 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) Frequency inverter all types (see 4.3.1) Frequency inverter type B1/B2 (see 4.3.1)
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Page 35: 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 - 87... -
Page 36: Assignment Of The Socket X2B
Connection of the control board version S 6.5.2 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 37: Wiring Example
Connection of the control board version S 6.5.4 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 38: Operator
Operator Operator An operator is necessary as accessories for local or external operation of the COMBIVERT R6-S. To prevent malfunctions, the COMBIVERT must be brought into nOP status before connecting/ disconnecting the operator (open control release). When starting the COMBI- VERT, it is started with the last stored values or factory setting. -
Page 39: 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 40: 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 41: 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 42: 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 43: 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 - 95... -
Page 44: 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 45: 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 46: 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 47: 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 48: 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 nection of R6-S (n • IDC, n • IDCmax) -
Page 49: 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 50 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 51: 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 52: 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 40: Dimensions of the decoupling diodes GB - 104... - Page 53 Appendix B 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/EC) as well as the EMC-directive (2004/108/EC)(note EN 60204).
- Page 54 Notizen / Notes...
- Page 55 Notizen / Notes...
- Page 56 Herenveld 2 • 9500 Geraadsbergen KEB Italia S.r.l. fon: +32 5443 7860 • fax: +32 5443 7898 Via Newton, 2 • 20019 Settimo Milanese (Milano) mail: vb.belgien@keb.de fon: +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 Tokyo 108-0074 net: www.keb.de • mail: info@keb.cn...