KEBCO COMBITRON 91 User manual

COMBITRON
INSTRUCTION MANUAL | Type 91 Rectifier
Original Manual
COMBITRON Type 91
Document 20267590 USA 00
Material No. 00910EB-K000 Rev 1E

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©
2021 KEB America, Inc.

Preface
©
2021 KEB America, Inc.
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1 Preface
The hardware described in this document are products of KEB America, Inc. The
information contained in this document is valid at the time of publishing. KEB reserves
the right to update this document in response to misprints, mistakes or technical
changes.
1.1 Warning Signs and Key Symbols
Certain procedures within this document can cause safety hazards during the installation or
operation of the device. Refer to the safety warnings in this document when performing these
procedures. Safety signs are also located on the device where applicable. A safety warning is
marked by one of the following warning signs:
DANGER
Dangerous situation which will cause death or serious injury if this
safety warning is ignored.
WARNING
Hazardous situation which may cause death or serious injury if
this safety warning is ignored.
CAUTION
Hazardous situation which may cause minor or moderate injury if
this safety warning is ignored.
NOTICE
Situation which may cause property damage if this safety warning
is ignored.
RESTRICTION Used when the following statements depend on certain conditions or
are only valid for certain ranges of values.
i
Used for informational messages or recommended procedures.
1.2 More Symbols
1. Numbered list items begin action steps.
•Enumerations are marked with boxes.
→Thin arrows indicate cross references to another chapter or another page.
Further documentation can be found at
https://www.kebamerica.com
Document search on www.kebamerica.com/em-
documents/

Preface
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©
2021 KEB America, Inc.
1.3 Laws and Requirements
KEB Automation KG has certified the product against the US, Canadian and European
standards. Additionally KEB Automation KG provides the EC declaration of conformity
that the product complies with the essential safety requirements.
The UL, CSA and CE marks are located on the name plate when applicable. The EC
declaration of conformity can be downloaded on demand via our website.
→Further information is provided in Appendix A: Certification.
1.4 Warranty
KEB America Inc provides a limited warranty on all products. This warranty can be found
in the terms and conditions at our website.
KEB America, Inc. Terms and Conditions
Terms and Conditions
Further agreements or specifications require written confirmation from KEB America, Inc.
1.5 Support and Liability
It is not possible to cover every potential application of our device in a single manual. If
you require further information or if problems occur which are not covered in this
document, you can request the necessary information via KEB America, Inc. or the local
KEB Automation KG agency.
The use of our products in the target application is beyond our control and
therefore exclusively the responsibility of the machine manufacturer, system
integrator or customer.
The information contained in this document, as well as any user-specific advice in spoken
or written form or generated through testing, is provided to best of our knowledge and is
considered for informational purposes only. KEB America, Inc. bears no responsibility or
liability for the accuracy of the information listed above, nor for any violation of industrial
property rights committed by a third-party in relation to this information.
Selection of the most suitable product for any given application is the
responsibility of the machine manufacturer, system integrator or customer.
Evaluation of the product can only be performed by the machine manufacturer in
combination with the application. Any tests performed must be repeated every time any
part of the hardware or software is modified, or any time the unit adjustment is changed.
1.6 Copyright
The customer may use the information contained within this document for internal
purposes only. Copyright of this document is held by KEB America, Inc. and remains
valid in its entirety.
Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their
respective owners and are listed in a footnote at the first occurrence.

Copyright
©
2021 KEB America, Inc.
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Table of Contents
1Preface ...................................................................................................3
1.1 Warning Signs and Key Symbols ................................................................... 3
1.2 More Symbols................................................................................................... 3
1.3 Laws and Requirements.................................................................................. 4
1.4 Warranty............................................................................................................ 4
1.5 Support and Liability ....................................................................................... 4
1.6 Copyright .......................................................................................................... 4
Table of Contents ....................................................................................................... 5
1.7 Standards for COMBITRON 91........................................................................ 7
2Safety Instructions................................................................................8
2.1 Target Audience ............................................................................................... 8
2.2 Specified Application....................................................................................... 9
2.3 General Safety Guidelines............................................................................... 9
2.4 Electrical Safety Guidelines ............................................................................ 9
3Product Description............................................................................10
3.1 Scope of this Manual ..................................................................................... 10
3.2 Rectifier Components .................................................................................... 10
3.3 Model Numbers .............................................................................................. 10
3.4 Technical Data................................................................................................ 11
3.4.1 Rated IEC Operating Values................................................................................................. 11
3.4.2 Rated UL Operating Values.................................................................................................. 11
3.4.3 Reduction of Output Current in Accordance with UL ....................................................... 12
3.4.4 Dimensions............................................................................................................................ 12
4Installation ...........................................................................................13
4.1 AC vs DC Switching....................................................................................... 13
4.1.1 AC Side Switching ................................................................................................................ 13
4.1.2 DC Side Switching ................................................................................................................ 13
4.1.3 AC vs DC Switching Summary ............................................................................................ 14
4.2 Connection Diagrams .................................................................................... 14

Table of Contents
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4.3 Maximum Switching Cycles – DC Side Switching....................................... 19
5Appendix..............................................................................................20
5.1 Appendix A: Certification .............................................................................. 20
6Revision History..................................................................................21
7Notes:...................................................................................................22

Preface
©
2021 KEB America, Inc.
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1.7 Standards for COMBITRON 91
•IEC 364
•CENELEC HD 384
•DIN VDE 0100
•DIN VDE 0160 (EN 50178)
•DIN VDE 0113 (EN 60204)
•UL 508
•NFPA 70
•NFPA 79

Safety Instructions
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©
2021 KEB America, Inc.
2 Safety Instructions
The COMBITRON is designed and constructed with state-of-the-art technology in
accordance with recognized safety rules and regulations. Improper use of this device
may cause hazards to life and limb of the user or third-parties, or damage to the
application and other material property.
The following safety instructions have been created by KEB America, Inc. for the
COMBITRON. These instructions can be supplemented by local, country- or application-
specific safety instructions where relevant.
Violation of the safety instructions in this manual will result in the loss of any liability
claims.
NOTICE
Stay Safe! Stay Informed!
Read the instruction manual prior to operating the device!
Follow all safety and warning instructions!
If you are unsure of any part of these instructions, please contact
KEB prior to operating the device!
2.1 Target Audience
This manual is intended exclusively for the use of qualified electrical/mechanical
technicians. Qualified technicians for the purpose of this document must meet the
following:
•Must have fully read and understood the safety instructions contained in this
manual.
•Must be familiar with the installation and assembly of electrical products.
•Must be familiar with the installation and operation of the product as specified in
this manual.
→See the Installation chapter for details.
•Must fully understand the specified application of the product.
→See the Specified Application section for details.
•Must be familiar with the hazards and risks of electromechanical brake
technology.
•Must be familiar with appropriate electrical and safety codes:
oUS: NFPA 70 National Electric Code (NEC)
oCanada: Canadian Electric Code, C22 Part 1 (CEC)
•Must be familiar with national safety regulations (e.g. OSHA Title 29 CFR):
→See the Standards for COMBITRON 91 section for details.

Safety Instructions
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2021 KEB America, Inc.
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2.2 Specified Application
The operational reliability of the COMBITRON is only guaranteed when the device is
used for the specified application. In this context, specified application means the
purpose for which the COMBITRON was ordered and configured.
Any use of the COMBITRON outside of this specified application is considered at the
user’s own risk. Such unintended uses may pose unforeseeable risks or hazards. KEB
America, Inc. retains no liability for any damage or injury resulting from the use of a
COMBITRON outside of the specified application.
2.3 General Safety Guidelines
Carefully observe the following safety guidelines before installation or operation of the
device.
•Only trained personnel should operate the COMBITRON.
•Immediately remove the COMBITRON from operation in case of a malfunction.
•Malfunctions should be corrected by trained personnel before returning the
COMBITRON to operation.
•Never use the COMBITRON in potentially explosive environments.
•The COMBITRON may not be modified or altered in any way not intended by
KEB America, Inc.
2.4 Electrical Safety Guidelines
DANGER
Rick of electrical shock!
Turn off the power supply and secure it against switching on prior
to any work on the device.
Wait until the system has come to a complete stop prior to any
work on the device.
Never bridge branch circuit protection devices.
•Observe all relevant safety standards during the electrical installation.
→See the Standards for COMBITRON 91 section for details specific to the
product.
•Use only wire gauges and fuses rated for the power requirements of the device.
•Ensure new or existing circuits meet NEC or applicable local requirements.
•All “Safe” isolated circuits must include other protective measures, e.g. double
insulation or grounded shielding when run together with high voltage circuits in
accordance with UL61800-5-1 / IEC61800-5-1.
•When using components with isolated inputs/outputs, equipotential bonding must
be used between the connected components. Failure to provide adequate
equipotential bonding may result in the destruction of the components by
equalizing currents.

Product Description
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©
2021 KEB America, Inc.
3 Product Description
3.1 Scope of this Manual
The KEB COMBITRON 91 is a rectification unit designed exclusively for supplying energy
to electromechanical clutches and brakes. The unit employs a rectifier to convert
incoming AC into DC. The units utilize rectifiers configured as either full-wave or half-
wave circuits in order to match the supply voltage to the coil voltage. The units feature a
compact design which is small enough to fit inside most motor terminal boxes. The
rectifiers are rated for a wide temperature range to support use inside the motor terminal
box. The COMBITRON can be switched either on the AC (line) side or the DC (load) side
while internal MOVs offer protection for the switching contacts.
3.2 Rectifier Components
3.3 Model Numbers
COMBITRON model numbers take the following format:

Product Description
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2021 KEB America, Inc.
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3.4 Technical Data
3.4.1 Rated IEC Operating Values
To find the rating for a specific COMBITRON rectifier, look up the model number on the
following table with the format [first row]-[second row]-[third row].
Example: 0291010-CEMV = 0291 010 CEMV
COMBITRON Model Number Units
0291 0491 0591 0691
010 020 010 020 010 010
CEMV CE07 CE07 CE07 CEA7 CE07 CEA7 CE09 CE09
Maximum Input Voltage VAC 275 500 600 720
Maximum Interrupting Voltage VAC 450 900 1000 1600
Input Current A
Mains Frequency Hz 50/60 ±2
Rated Output Voltage VDC 0.45·Uin
0.9
·
Uin
0.45·Uin 0.9·Uin 0.45·Uin
Rated Output Current A 1.2 2.0 1.2 2.0 1.2
DC Contact Switching - Yes Yes External External
Type of Protection - IP20
Climatic Category 3K3 Extended to -10 to 45°C (up to max 85°C with derating)
Terminal Tightening Torque Nm 0.4 0.5 0.4 0.5
Permissable Cable Cross-section mm2 1.2 to 2 0.8 to 2 1.2 to 2 0.8 to 2
Dimensions (See 3.4.4) Figure 2 1 1 2 1 2
3.4.2 Rated UL Operating Values
To find the rating for a specific COMBITRON rectifier, look up the model number on the
following table with the format [first row]-[second row]-[third row].
Example: 0291010-CEMV = 0291 010 CE07
COMBITRON Model Number Units
0291
0491
0591
0691
010 020 010 020 010 010
CE07
CE07
CE07
CEA7
CE07
CEA7
CE09
CE09
Input Voltage VAC 240 240 240 480
Input Current A 0.6 1.2 0.6 1.2 0.6 0.6
Output Voltage VDC 108 216 108 216 108 216
Output Current A 1.2
DC Contact Switching - Yes Yes External External
Type of Protection - IP20
Climatic Category 3K3 Extended to -10 to 45°C (up to max 85°C with derating)
Terminal Tightening Torque Lb.in 3.5 4.5 3.5 3.5
Permissable Cable Cross-section AWG 16 to 18 14 to 18 14 to 18 14 to 18
For surrounding air temperatures ≤ 60°C Use 60/75°C wires
For surrounding air temperatures ≥ 60°C Use at least 90°C Wires
Dimensions (See 3.4.4) Figure 1 1 2 1 2
These devices shall be protected by external Class CC fuses rated maximum 5A for each ungrounded conductor.

Product Description
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©
2021 KEB America, Inc.
3.4.3 Reduction of Output Current in Accordance with UL
Site altitude above sea level ≤
1000m
100% Nominal Current
>
1000m
-1% Nominal Current per 100m (max. 2000m)
Maximum surrounding air temperature 45°C 1.2A output current (nominal current)
60°C 0.9A output current
75°C 0.6A output current
85°C 0.5A output current
3.4.4 Dimensions
Figure 1 – Small Housing
Figure 2 – Large Housing
Isolation Sheet 0091999-9035 Isolation Sheet 04591999-6038
A clearance distance of min. 9.5mm to the terminal must be observed when
assembling on conductive, grounded surface. The included isolation sheet must be
sub-mounted if the minimum clearance distance above is not given.
AC Voltage Input
DC Voltage Output
Switching Input for DC Side. When terminals are not included, the switch contact must
be wired externally.
See wiring diagram.
All dimensions in mm

Installation
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2021 KEB America, Inc.
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4 Installation
Before installing the COMBITRON rectifier, it is important to determine whether to install
the on/off switch for the brake or clutch on the AC or DC side of the rectifier.
4.1 AC vs DC Switching
There are two methods of switching brakes and clutches. These are referred to as AC
side or DC side and indicate on which side of the rectifier the switch is located. Each
method has advantages and disadvantages which may impact the performance of the
brake or clutch in the actual application. The following sections provide more detail on the
two methods of switching. It is up to the end user to determine which method of switching
best suits their application.
4.1.1 AC Side Switching
AC side switching places the switching mechanism on the AC (line) side of the rectifier.
The high voltage AC is switched on and off by a relay or contactor. This switch is
normally placed on all non-grounded conductors after the branch circuit fuse(s). If the
rectifier has a switch contact, a wire jumper is installed into the terminals. Since the
switch is on the AC side, the rectifier provides a path for the inductive current from the
brake or clutch to dissipate. As a result there is very little arcing on the relay contacts
when they open and the load can be considered a resistive load. This means relatively
small control relays can be used to switch the brake or clutch on and off.
The rating of the switching contacts shall be at least equal to the rated AC voltage which
is applied and the current rating shall be 5 amps, AC1 contact rating.
The disadvantage however is that because the rectifier allows the inductive current to
dissipate slowly, the switching time of the brake or clutch is delayed. As an example, with
a COMBISTOP spring applied brake, this delay time is the time between the switching
event and the onset of brake torque. In larger brakes with high inductance, this delay time
can exceed 1 second.
4.1.2 DC Side Switching
DC side switching places the switching mechanism on the DC (load) side of the rectifier.
The high voltage DC is switched on and off using a DC rated contactor. The contactor is
either wired to the switch contacts on the rectifier, or is wired in series with the brake. The
contactor must be rated for switching the rated DC voltage and current, but in addition
must be capable of breaking the circuit without failure resulting from the high voltage
created by the inductance in the brake coil.
The varistors which are internal to the rectifier will clamp the voltage across the switch
contact, however the instantaneous peak value of the voltage may exceed 1000V.
Therefore it is important to take this into consideration when selecting the switching
contactor. Generally for DC side switching the minimum contact ratings are 300VDC 9A,
AC3 rating.
The advantage to DC side switching is the speed of the brake reaction. The delay time
associated with brake engagement can be reduced by over a factor of ten compared to
AC side switching. This results in faster control of the mechanical system which may
provide better safety.

Installation
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4.1.3 AC vs DC Switching Summary
The following table shows a summary of pros and cons of AC vs DC side switching for
ease of reference. Select the type of switching that best fits the application.
Category
AC
DC
Brake* release time
+
+
Brake* engage time - +
Small switching contactor
+
-
Minimal arcing across switch contact (reduced wear and tear)
+
-
Higher safety for hoists and lifts - +
*refers to a KEB COMBISTOP spring applied brake
4.2 Connection Diagrams
The voltage rating of the clutch or brake coil and the available supply voltage will
determine what type of rectifier is required. In general the DC output voltage from a full-
wave rectifier is 0.9 times the AC input, whereas the DC output voltage from a half-wave
rectifier is 0.45 times the AC input. The correct rectifier must be selected based on the
rated voltages of the supply and load. The following diagrams provide examples of the
most common scenarios, however not all possibilities are covered. Please consult KEB
for further assistance if the configuration needed is not found below.
AC Side – Relay Switching – Phase to Neutral
Figure 4.2.1
Switching: AC Side Rectifier: Full-wave Model Number: 0291020-CE07
Line Voltage: 120VAC Input Voltage: 120VAC Coil Voltage: 105VDC
Fbrk = Class CC fuse max. 5A Relay Contact: 120VAC 5A

Installation
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AC Side – Motor Contactor Switching – Phase to Neutral
Figure 4.2.2
Switching: AC Side Rectifier: Full-wave Model Number: 0291020-CE07
Line Voltage: 208/120VAC
Input Voltage: 120VAC
Coil Voltage: 105VDC
Rectifier: Full-wave Model Number: 0491020-CE07
Line Voltage: 400/230VAC Input Voltage: 230VAC Coil Voltage: 205VDC
F
brk
= Class CC fuse max. 5A
Motor contactor sized for motor, min 5A
AC Side – Motor Contactor Switching – Phase to Phase
Figure 4.2.3
Switching: AC Side
Rectifier: Full-wave
Model Number: 0491020-CE07
Line Voltage: 208VAC
Input Voltage: 208VAC
Coil Voltage: 180VDC
Line Voltage: 230VAC Input Voltage: 230VAC Coil Voltage: 205VDC
F
brk
= Class CC fuse max. 5A
Motor Contactor sized for motor, min 5A

Installation
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2021 KEB America, Inc.
AC Side – Independent Contactor Switching – Phase to Phase
Figure 4.2.4
Switching: AC Side
Rectifier: Full-wave
Model Number: 0491020-CE07
Line Voltage: 208VAC
Input Voltage: 208VAC
Coil Voltage: 180VDC
Line Voltage: 230VAC Input Voltage: 230VAC Coil Voltage: 205VDC
F
brk
= Class CC fuse max. 5A
Independent Contactor rated 300VAC, min 5A AC1
AC Side – Motor Contactor Switching – Phase to Phase
Figure 4.2.5
Switching: AC Side
Rectifier: Half-wave
Model Number: 0691020-CE07
Line Voltage: 400VAC Input Voltage: 400VAC Coil Voltage: 180VDC
Line Voltage: 480VAC Input Voltage: 480VAC Coil Voltage: 205VDC
Fbrk = Class CC fuse max. 5A Motor Contactor sized for motor, min 5A

Installation
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2021 KEB America, Inc.
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DC Side – Independent Contactor Switching – Phase to Phase
Figure 4.2.6
Switching: DC Side
Rectifier: Half-wave
Model Number: 0491010-CE07
Line Voltage: 208VAC
Input Voltage: 208VAC
Coil Voltage: 95VDC
Line Voltage: 230VAC Input Voltage: 230VAC Coil Voltage: 105VDC
Rectifier: Full-wave
Model Number: 0491020-CE07
Line Voltage: 208VAC
Input Voltage: 208VAC
Coil Voltage: 180VDC
Line Voltage: 230VAC Input Voltage: 230VAC Coil Voltage: 205VDC
F
brk
= Class CC fuse max. 5A
K
brk_dc
= min 300VDC 9A AC3
Optional redundant contactor for safety Kbrk_ac = min 300VAC 5A AC1

Installation
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2021 KEB America, Inc.
DC Side – Independent Contactor Switching with external MOV – Phase to Phase
Figure 4.2.7
Switching: DC Side
Rectifier: Half-wave
Model Number: 0691010-001U
Line Voltage: 400VAC Input Voltage: 400VAC Coil Voltage: 180VDC
Line Voltage: 480VAC Input Voltage: 480VAC Coil Voltage: 205VDC
Fbrk = Class CC fuse max. 5A Kbrk_dc = min 600VDC 9A AC3 MOV: 625Vrms / 1000Vpk /
500J
Installed at the brake
Optional redundant contactor for safety
K
brk_ac
= min 600VAC 5A AC1

Installation
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2021 KEB America, Inc.
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DC Side – Independent Contactor Switching – Phase to Phase – Long Distance Connection
Figure 4.2.8
Switching: DC Side
Rectifier: Half-wave
Model Number: 0491010-CE07
Line Voltage: 208VAC
Input Voltage: 208VAC
Coil Voltage: 95VDC
Line Voltage: 230VAC Input Voltage: 230VAC Coil Voltage: 105VDC
F
brk
= Class CC fuse max. 5A
K
brk_dc
= min 300VDC 9A AC3
MOV: 0038611-001U
625Vrms / 1000Vpk / 500J
Installed at the brake
Optional redundant contactor for safety Kbrk_ac = min 300VAC 5A AC1
When DC side switching and the conductor length is greater than 20m it is possible a
higher than normal voltage can appear at the rectifier. In this scenario an additional MOV
is required to clamp the voltage at the brake.
4.3 Maximum Switching Cycles – DC Side Switching
The maximum cycle rate is defined by the energy storage of the magnetic coil in the
brake. When the brake is de-energized via the DC side switching, some of the energy is
absorbed by the varistors in the rectifier. High cycle rates together with large brake coils
can result in an overload of the rectifier.
In these cases, the following MOVs may be used externally, connected in parallel to the
brake as shown in figure 4.2.8. The voltage rating of the MOV is dependent on the supply
voltage of the rectifier. The following combinations are recommended.
Supply Voltage KEB Material Number Varistor Voltage
120V, 208V, 230V, 240V 0090045-2753 275VACrms
400V, 480V 0090045-6255 625VACrms

Appendix
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5 Appendix
5.1 Appendix A: Certification
CE Conformity
The COMBITRON 91 meets the requirements of the Low-Voltage Directive
2014/35/EU. Rectifier 0291010-CEMV can exclusively be used on requirements
in accordance with the EMC directive 2014/30/EU (or consultation with KEB).
UL Recognition
These devices have been investigated by UL according to United States
Standard UL508 (Industrial Control Equipment), and to the Canadian Standard
CSA C22.2 No. 14 (Industrial Control Equipment).