KEB Combivert R6-S Instruction Manual
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KEB Combivert R6-S Instruction Manual

Power supply and regenerative unit
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C O M B I V E R T
Instruction Manual
Type R6-S
Translation of the original manual
Document
Part
20311685
ENG
Power Supply and Regenerative Unit
Version
00
Size 15/19

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Summary of Contents for KEB Combivert R6-S

  • Page 1 C O M B I V E R T Instruction Manual Power Supply and Regenerative Unit Type R6-S Size 15/19 Translation of the original manual Document Part Version 20311685...

  • Page 3: Table Of Contents

    Standard device size ......................15 Special device Peak Power ....................16 Overload (OL) function ......................17 Operating conditions ......................18 Accessories ........................19 Options ..........................19 Dimensions and weights ....................20 3.7.1 COMBIVERT R6-S ......................20 3.7.2 Commutation reactor ......................20 3.7.3 Synchronisation unit ......................21 3.7.4 Radio interference filter (sub-mounted) ................22 3.7.5 Ferrite rings ..........................22 Installation .....................
  • Page 4 Special adjustments ......................44 Monitoring and analysis parameters ................41 Special adjustments ......................44 Annex A ......................48 Dimension of power supply and regenerative units ............48 DC link capacities of KEB drive controllers ..............49 Decoupling diodes ......................51 A.3.1 Assignment ..........................51 A.3.2 Dimensions of the decoupling diodes ..................52 Annex B ......................

  • Page 5: Introduction

    Introduction Introduction Preface First we would like to welcome you as a customer of the KEB Automation KG and congrat- ulation to the purchase of this product. You have decided for a product on highest technical niveau. The described hardware and software are developments of the KEB Automation KG. The enclosed documents correspond to the conditions valid at printing.

  • 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 devices.

  • Page 8: Unit Identification

    Introduction Unit identification 1 9 . R 6 . S 3 E - 9 0 0 A Type A: Heat sink (standard) B: Flat rear Design 0: Standard reserved 0: Standard Voltage 9: 3-ph.; 180…550 V; AC Housing Options 0: without 3: Precharging, DC-fuses 1: Precharging Control S: 1B.R6...

  • Page 9: Safety Instructions

    Safety Instructions Safety Instructions General instructions COMBIVERT R6 power supply and 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 exist in the unit after switching off the supply sys- tem.

  • 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. The equipment must not be switched on if it is dam- Protect aged as it may no longer comply with mandatory standards.
  • Page 11 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.
  • Page 12 • The maximum DC current of the R6-S must not be exceeded. • If several drive controllers are connected to the COMBIVERT R6-S the max. permissible DC link capacities of all connected drive controllers must be considered during supply operation (see technical data). The COMBIVERT R6 can be adjusted by such way that the inverter restarts automatically after an error case (e.g. phase failure). System design must take...
  • Page 13 Safety Instructions When using systems with RCD, the instructions or the requirements of RCD (resid- VDE 0100 -T 530 (IEC 60364-5) must be observed. The recommended tripping ual current current of the RCD type "B" is 300 mA. operated cir- cuit-break- GB - 13...

  • Page 14: Emc Instructions

    The person installing / operating the machine / unit is obliged to prove the protective meas- ures demanded by the EMC directive are complied with. The prescribed ratings can usually be complied with when using the radio interference voltage filters specified by KEB, and when observing the following measures and installation guidelines.

  • 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. If the DC infeed current > 85 A DC use two by two of the DC terminals (++ and --) to meet the requirements of the UL standard. The connection cables are parallel connected. Please contact KEB for higher values. IT and delta power system after consultation KEB. GB - 15...

  • Page 16: Special Device Peak Power

    If the DC infeed current > 85 A DC use two by two of the DC terminals (++ and --) to meet the require- ments of the UL standard. The connection cables are parallel connected. After consultation KEB IT and delta power system. continued on the next page GB - 16...

  • Page 17: Overload (Ol) Function

    Technical Data 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 Exceeding of the max. rechargeable DC link capacity can lead to a defect. A load draw from the DC circuit may be done only when the message "ready“ is set. 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.

  • Page 18: 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 (with temperature over 45°C to max. 55°C Temperature...

  • Page 19: Accessories

    15Z1C04-1000 19Z1C04-1000 1) 2) 1) 2) (not for UL) Please contact KEB for further sizes and data to the THD value at regenerative operation in accordance with EN 61000-2-12. DC fuses 690 V / 50 A 690 V / 125 A (also see annex B.1.2)

  • Page 20: Dimensions And Weights

    Dimensions and weights Dimensions and weights 3.7.1 COMBIVERT R6-S Ø F Housing Weight 5.6 kg C1 with operator Table 3: Dimensions and weights for COMBIVERT R6-S in E housing 3.7.2 Commutation reactor Ø Part number Weight 15Z1B05-1001 11.5 kg 15Z1B05-1003 79.4 8.5 kg...

  • Page 21: Synchronisation Unit

    Dimensions and weights 3.7.3 Synchronisation unit A (1 : 1) 49,5 105,5 65,5 45,5 Cable Max. tightening Part number Weight Terminal Connection length torque M6 stud for ring 4.5 Nm / 40 Ib crimp connector inch 00R6940-2407 0.65 kg M4 ring crimp con- L1.1, L2.1, L3.1 240 mm nector (AWG 16)

  • Page 22: Radio Interference Filter (Sub-Mounted)

    Dimensions and weights 3.7.4 Radio interference filter (sub-mounted) ØF Part number Weight 15E4T60-1001 2 kg 19R6T60-1001 6 kg Table 6: Radio interference filter (sub-mounted) 3.7.5 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.

  • Page 23: Installation

    Installation Installation EMC-compatible control cabinet installation Mains fuse Main contactor EMC side mount filter (≥ size 25 R-S or R6-N) EMC back mount filter (≤ size 19 R6-S) If necessary, external voltage limi- 150 mm tation / synchronisation 150 mm Commutation reactor / harmonic filter COMBIVERT R6 If necessary, external DC fuses 150 mm Drive controller 30 mm 150 mm...

  • Page 24: Connection Of The Combivert R6

    DC bus. A table for this can be found in the appendix. The supply source (rectifier module 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 devices supplied by the DC bus have a starting current limiting at the DC voltage input.
  • Page 25 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. Table 7: General description of input terminals at KEB inverter GB - 25...

  • Page 26: Connection Terminals Of The R6 Power Circuit

    L1.2 L2.2 L3.2 Terminals Description of terminals at KEB inverters ++, -- DC voltage output with starting current limiting for loading the connect- ed inverters; 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.
  • Page 27 Connection of the COMBIVERT R6 Housing size E Tightening torque [Nm] permissible cable cross-section Size Name Function Size 15 3-phase supply input of max. 0.5…10 mm² the commutation reactor (AWG 20…8) DC voltage output with Size 19 Size – – starting current limiting 1.5…25 mm²...

  • Page 28: Terminals Commutation Reactor / Harmonic Filter

    Connection of the COMBIVERT R6 4.3.3 Terminals commutation reactor / harmonic filter 15/19Z1B05-1000 (commutation reactor) 15/19Z1C05-1000 (harmonic filter) Tightening torque [Nm] permissible cable cross-section Size L1.1 L1.2 L2.1 L2.2 L3.1 L3.2 Name Function L1.1 Size 15 1.2…2 3-phase mains con- L2.1 2.5…16 mm² nection (AWG 20…6) L3.1 L1.2 Size Size 19 L2.2 Output to COMBIV-...

  • Page 29: Connection Power Unit R6-S

    L1.1 L1.2 L2’ L2.1 L2.2 - - / - L3’ L3.1 L3.2 Table 12: Power supply and regeneration at inverter current ≤ inverter current of one COMBIVERT R6-S 4.4.2 Power supply and regeneration at inverter current ≤ inverter current of one COMBIV- ERT R6-S L1’ L1.1 L1.2 L2’ L2.1 L2.2 L3’ L3.1 L3.2...

  • Page 30: Combivert R6-S

    2) 4) 5) harmonic filter If the inverter current > inverter current of the COMBIVERT R6-S, it must be wired at an external termi- nal (6). The cable cross-section may not be smaller than 10 mm². It must be dimensioned for the DC rated current of the load. Otherwise appropriate fuses in the DC bus (7) are required. The indicated maximum...

  • Page 31: Regeneration With Decoupling Diodes

    10 DC fuses type aR/gR 1) 4) 3) 5) 1a Regenerative contactor Commutation reactor 11 Inverter (type A1, A2, C1, C2) Mains fuses COMBIVERT R6-S 12 Inverter (type A1, A2 -> 4.3.1) Mains fuses type gR Decoupling diodes (see annex) 13 Motor Radio interference filter DC fuses type aR/gR A mains choke with uk=4 % is mandatory required for reduction of circulating currents.
  • Page 32 10 DC fuses type aR/gR 1) 4) 3) 5) 1a Regenerative contactor Commutation reactor 11 Inverter (all types) Mains fuses COMBIVERT R6-S 12 Inverter (type B1, B2) Mains fuses type gR Decoupling diodes (see annex) 13 Motor Radio interference filter DC fuses type aR/gR A mains choke with uk=4 % is mandatory required for reduction of circulating currents.

  • Page 33: Regenerative Operation At Parallel Operation Of Up To Three R6-S With Decoupling Diodes

    If the inverter current > inverter current of the COMBIVERT R6-S, it must be wired at an external termi- nal (12). The mains contactor may only be connected if the precharging in the DC bus of the regenerative unit is completed.
  • Page 34 A load draw from the DC circuit may be done only when the message "ready for operation“ 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...

  • Page 35: Connection Of The Control Board Version S

    Connection of the control board version S Connection of the control board version S 4.5.1 Assignment of the control terminal strip X2A 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Conductor cross-section 0.14…1.5 mm², tightening torque 0.22...0.25 Nm PIN Function Name...

  • Page 36: Assignment Of The Socket X2B

    Connection of the control board version S 4.5.2 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 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 •...

  • Page 38: Operator

    Operator Operator An operator is required as an accessory for local or external operation of the COMBIVERT R6-S. To avoid malfunctions, the COMBIVERT must be set to nOP status (open control re- lease) before plugging/unplugging the operator. When the COMBIVERT is put into operation, it is started with the last saved values or the factory setting. Digital operator (part number 00F5060-1000) Interface operator (part number 00F5060-2000) x x 5-digit LED display x x Operation/error display Normal "LED on“...

  • Page 39: Operation Of The Device

    The correct connection of the COMBIVERT R6-S is now ensured. If the control release (terminal ST) is set, the COMBIVERT R6-S now independently starts the intended 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 activated...

  • Page 40: Parameter Summary

    Parameter summary Parameter summary The CP-Parameters are one of the parameter selection defined by KEB. You need an appli- cation manual in order to get access to the entire parameters. Display Parameter Setting range Resolu- Factory based tion setting CP.00 Password 0…9999 – Ud.01 CP.01 Inverter state – – – ru.00 CP.02 Actual line frequency –...

  • Page 41: Monitoring And Analysis Parameters

    Monitoring and analysis parameters View of the work meter The displayed values of the work meters only provide an estimated value due to measurement and calculation inaccuracies. These displayed values are not suitable for accounting purposes and cannot replace any measuring devices. Monitoring and analysis parameters The following parameters serve for the functional monitoring during operation.
  • Page 42 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" state.
  • Page 43 The error can be reset now. Name Enter based on 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 - 43...

  • Page 44: Special Adjustments

    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 based on CP.14 Total regen –...
  • Page 45 Special adjustments Name Enter based on CP.18 ANOUT 1 gain – An.33 The amplification to the desired output voltage can be 0…±20.00 1.00 adapted with CP.18. Max. possible: ±10 V. Name Enter based on CP.19 Comparison level 0 – LE.00 This parameter determines the switching level for transistor output O1, as well as relay output 2.
  • Page 46 Special adjustments Name Enter based on CP.29 Software version – – In.06 Value range Meaning 0.00…9.99 Display of the inverter software version number (e.g. 1,11). Name Enter based on CP.30 Software date – – In.07 Value range Meaning 0…6553.5 Display of the inverter software date in the format "ddmm.y“. Name Enter based on...
  • Page 47 GB - 47...

  • Page 48: Annex A

    Annex A Annex A Dimension of power supply and regenerative units Dimensioning of the power supply and regenerative unit Bridge over ext. load-shunt with Acquire: only regeneration ? CZK_all > CZK_max contactor (special ZK_all unit) Acquire: Decoupling R6-N (see 4.4.4 to , t1, T, η η η Mmax 4.4.5) Calculate: ILM, ILMmax Acquire:...

  • Page 49: Dc Link Capacities Of Keb Drive Controllers

    Annex A DC link capacities of KEB drive controllers Drive controller COMBIVERT F5 200 V devices 400 V devices Device size Capacity Device 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 Annex A Drive controller COMBIVERT G6 Housing size Device size Capacity / µF Precharging circuit Type A1 Type A1 Type A1 Type A1 1120 1035 1400 Type B1 1985 Drive controller COMBIVERT S6 Housing size Device size Capacity / µF Precharging circuit Type A1 Type A1...

  • Page 51: Decoupling Diodes

    Annex 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

    Annex 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) Table 22: Dimensions of the decoupling diodes GB - 52...

  • Page 53: Annex B

    B.1.2 UL Certification Acceptance according to UL is marked at KEB power supply and regener- ative 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 54 • Use in a Pollution Degree 2 environment“ • Following external DC fuses need to be installed in accordance with wiring diagrams in chapter 4.4 for following units without internal DC fuses: 15R6N1E-xxxx Rated 690 Vac / 700 Vdc 50 A (KEB No.: 009025H-3459): R/C (JFHR2, JFHR8 or CSA Certified) - Type Sitor 3NE8- 15R6S1E-xxxx 717-1, manufactured by Siemens or Type 170M1364-1, manufactured by Bussmann 19R6N1E-xxxx Rated 690 Vac / 700 Vdc 125 A (KEB No.: 009025H-3559):...
  • Page 55 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. KEB Japan Ltd. No. 435 Qianpu Road, Chedun Town, Songjiang District, 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...

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