KEBCO combivert R6-S User manual

COMBIVERT
US Instruction Manual Power Supply and Regenerative Unit
Type R6-S Type 25R6S3R-R00A
Mat.No. Rev.
00R6SUB-KR01 1A

Table of Contents
1. Introduction..................................................................................................... 5
1.1 Preface..................................................................................................................................5
1.2 Product description.............................................................................................................5
1.3 Validity and liability .............................................................................................................7
1.4 Copyright..............................................................................................................................7
1.5 Speciedapplication...........................................................................................................7
1.5.1 Standard operation ................................................................................................................7
1.5.2 Abnormal operation ...............................................................................................................8
1.6 Unitidentication ................................................................................................................8
2. Safety Instructions ......................................................................................... 9
2.1 General instructions............................................................................................................9
2.2 Transport, storage and installation....................................................................................9
2.3 Electrical connection.........................................................................................................10
3. Technical Data .............................................................................................. 14
3.1 Overload (OL) function......................................................................................................15
3.2 Operating conditions.........................................................................................................16
3.3 Accessories........................................................................................................................17
3.4 Options ...............................................................................................................................18
3.4.1 Ferrite rings..........................................................................................................................19
3.5 Dimensions and weights...................................................................................................20
3.5.1 Dimensions air cooling system mounted version.................................................................20
3.5.2 Commutation reactor / mains choke ....................................................................................21
3.5.3 Radiointerferencelter(side-mounted) ..............................................................................22
3.5.4 Synchronization unit ............................................................................................................24
3.5.5 Fuse holder with cover.........................................................................................................25
4. Installation..................................................................................................... 26
4.1 EMC-compatible control cabinet installation..................................................................26
4.2 Installation instructions ....................................................................................................26
4.3 Connection of the COMBIVERT R6 ..................................................................................27
4.3.1 General description of inverter input terminals ....................................................................27
4.3.2 Connection terminals of the power circuit............................................................................28
4.4 Connection power unit R6-S with UL...............................................................................30
4.4.1 Powersupplyandregenerativeoperationatinvertercurrent≤invertercurrentofone
COMBIVERTR6-SwithUL .................................................................................................30
4.4.2 Power supply and regenerative operation at parallel operation with one frequency
inverter.................................................................................................................................31
4.4.3 Power supply and regenerative operation at parallel operation with a second regene-
rative unit .............................................................................................................................31
4.4.4 BriefDescriptionofthePre-ChargingSequence.................................................................32
4.5 Connection of the control board version S.....................................................................33
4.5.1 Assignment of the control terminal strip X2A.......................................................................33
4.5.2 Assignment of the socket X2B.............................................................................................34
4.5.3 Assignment of the terminal block X2C.................................................................................34
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Table of Contents

4.5.4 Wiring example ....................................................................................................................35
5. Operation of the Unit.................................................................................... 36
5.1 Operation with PC and system software COMBIVIS 6 ...................................................36
5.2 Switch-on procedure .........................................................................................................36
5.3 Parameter summary ..........................................................................................................37
5.4 Monitoring and analysis parameters ...............................................................................38
5.5 Special adjustments ..........................................................................................................42
A. Appendix A.................................................................................................... 45
A.1 Certication........................................................................................................................45
A.1.1 CE Marking ..........................................................................................................................45
A.1.2 ULCertication ....................................................................................................................45
List of Figures
Figure 1: Block diagram of the COMBIVERT R6S ...................................................................6
Figure2: Overload(OL)function............................................................................................16
Figure 3: COMBIVERT R6 with fan heat sink ........................................................................21
Figure 4: Mains choke............................................................................................................22
Figure5: Radiointerferencelter24E6T60-3000(side-mounted).........................................23
Figure6: Radiointerferencelter25E4T60-1001(side-mounted).........................................24
Figure 7: Synchronization unit................................................................................................25
Figure 8: Fuse holder .............................................................................................................26
Figure9: 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
Figure 15: Powersupplyandregenerativeoperationatinvertercurrent≤currentofoneCOMBIVERTR6-S 35
Figure 16: Powersupplyandregenerativeoperationatinvertercurrent≤currentofoneCOMBIVERTR6-S 37
Figure 17: RJ45 socket ............................................................................................................39
Figure18: WiringexampleR6-S..............................................................................................40
Figure 19: Dimensioning power supply and regenerative units ...............................................50
Figure 20: Dimensions of the decoupling diodes .....................................................................54
US-4

1. Introduction
1.1 Preface
First we would like to welcome you as a customer of KEB and congratulate you on the purchase of this product.
You have decided on a product of the highest technical innovation.
The enclosed documents as well as the specied hardware and software are developments of KEB. KEB has
created these documents, hardware, and software and they are to the best of KEB’s knowledge error free. KEB
reserves the right to change specications without prior notice. This statement is not exclusive.
The icons used throughout this document have the following signicance:
Danger
Warning
Caution
Pay Attention
Important Warning
Information
Help
Tip
1.2 Product description
This instruction manual describes the power supply and recovery unit KEB COMBIVERT R6-S. The COMBIVERT
R6-S has the following technical features.
As a supply unit
• converts a three-phase input voltage into DC voltage.
• supplies a single KEB frequency inverter or multiple units via DC interconnection.
• can be connected in parallel, if higher supply power is required.
• increases the stability of the DC Bus voltage in shared DC Bus applications.
As a regeneration unit
• returns the excess energy from generating operation (i.e. overhauling load) to the utility supply system.
• reduces the net energy demand.
• reduces the heat dissipation.
• is environmentally friendly.
• replaces braking resistor and braking transistor.
• is cost saving and space saving.
The COMBIVERTR6-S is generally protected against over current, ground fault and high temperature.Appropriately
dimensioned DC fuses protect the DC Bus circuit against short-circuit. The following accessories are necessary
for operation with the COMBIVERT R6-S:
• Commutation choke
• HF lter (for observance of European EMC standard)
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Introduction

+
X1A ++
X1A --
X1C L1
X1A L12
X1B L2
X1C L2
X1B L1
V
X1C Fo.1
X1C Fo.2
A
A
A
K2
K2
X1A L22
X1A L32
Power unit
Connection syn-
chronization (net-
work coverage)
Control communication
Connection I / O
Interface communi-
cation
Figure 1: Block diagram of the COMBIVERT R6S
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Introduction

1.3 Validity and liability
Application and use of our units in the target products is outside of our control and therefore is exclu-
sively the responsibility of the machine manufacturer.
The information contained in the technical documentation, as well as any user-specic advice in spoken and
written communication are made to best of our knowledge and information about the application. However, they
are considered for information only without responsibility. This also applies to any violation of industrial property
rights of a third-party.
Selection of our units in view of their suitability for the intended use must be done generally by the user.
Inspections and tests can only be done by the machine manufacturer within the framework of the application.
Inspections and tests must be repeated, even if only parts of hardware, software, or the unit adjustment are
modied.
Unauthorized opening and improper tampering can lead to bodily injuries or liability issues and this causes loss
of the warranty. Only use original spare parts and authorized accessories by the manufacturer. The use of other
parts excludes liability for the consequences arising out of such use.
The suspension of liability is valid also for shutdown damages, lost prot, data loss, or other consequential dam-
ages. This is also valid if we have referred to the possibility of such damages.
Should any part of this agreement be invalid for any reason, it is to be replaced with a corresponding text, which
is valid and equivalent to the intended meaning. The rest of the agreement shall remain unaffected and valid.
1.4 Copyright
The customer may 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® are registered trademarks of KEB Automation KG.
Other wordmarks or/and logos are trademarks (TM) or registered trademarks (®) of their respective owners and
are listed in the footnote on the rst occurrence. When creating our documents we pay attention with the utmost
care to the rights of third parties. Should we have not marked a trademark or breached a copyright, please in-
form us in order to rectify the issue.
1.5 Specied application
The COMBIVERT R6-S serves exclusively for the supply of frequency inverters with DC input and/or regenera-
tion of excess energy into the supply system. The operation of other electrical loads is prohibited and can lead
to malfunctions or destruction of the unit.
The used semiconductors and components of KEB are developed and dimensioned for use in industrial prod-
ucts. If the product is used in machines, which work under exceptional conditions or if essential functions, life-
supporting measures or an extraordinary safety step must be fullled, the necessary reliability and security must
be ensured by the machine manufacturer. The operation of our products outside the indicated limit values of the
technical data leads to the loss of any liability claims.
All control card outputs of the R6 are „one-channel, no diagnostic coverage and therefore not safe“ according to
ISO 13849. If required, additional protective measures must be met by the user.
1.5.1 Standard operation
If the DC Bus voltage increases to a value above the peak value of the line voltage (negative power), regeneration
of the current to the line occurs automatically. The line voltage is measured by the R6 unit. Regeneration
occurs in a square-wave format, whereby the current ow period corresponds to the line frequency and the
normal conduction times of a standard 6 pulse bridge rectier circuit. Regeneration stops if the DC bus voltage
decreases below the line supply peak voltage (positive power).
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Introduction

1.5.2 Abnormal operation
When exceeding the permissible limit values for voltage, current or temperature the current ow between DC
link and mains is blocked during regeneration. An appropriate error message is also displayed during supply.
The unit must be disconnected from the supply system or the load must be switched off in case of overcurrent
or overload. This can be done by opening the control release of the frequency inverter.
At factory setting the modulation is switched off in case of a net phase failure and error message E.nEt is dis-
played.
Special adjustments from KEB are necessary if the modulation and/or the standard operation should start again
within a dened time in case of return of power supply.
1.6 Unit identication
2 5 . R 6 . S 3 R - R 0 0 A
Type A: Standard
D. ext. fan power supply
H: Water cooling
Design 0: Standard
reserved 0: Standard 1: modied standard
Voltage R: 3-ph.; 480 V; AC
Housing R
Options 3: Precharging, DC fuses
Control S: 2B.R6
Series R6
Unit size 25
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Introduction

2. Safety Instructions
2.1 General instructions
CAUTION
- Risk of
Electrical
Shock
The COMBIVERT R6 power supply and recovery unit contains dangerous voltages which can
cause death or serious injury.
The COMBIVERT R6 can be adjusted such that energy is returned to the line supply system
even in case of power failure during generator operation. Therefore dangerous high voltage
can exist in the unit even after disconnection from the line supply system.
Before working with the unit always verify the voltage has dropped to a safe value by
measuring both the DC bus voltage and the AC line voltage at the R6 unit.
Care should be taken to ensure correct and safe operation and to minimize risk to personnel
and equipment.
Only quali-
ed electro-
personnel
All work from the transport, to installation and start-up as well as maintenance may only be
done by qualied personnel (IEC 364 and/or CENELEC HD 384 and IEC-Report 664 and note
national safety regulations). According to this manual, qualied personnel means those who
are able to recognize and judge the possible dangers based on their technical training and
experience as well as those with knowledge of the relevant standards and who are familiar
with the eld of power transmission or conversion.
Observe
standards
The COMBIVERT R6 must not be started until it is determined that the installation complies with
89/392/EEC (machine directive) as well as the EMC-directive (89/336/EEC)(note EN60204),
the US - NEC, and the OSHA machine safety code.
The COMBIVERT R6 meets the requirements of the Low-Voltage Directive 73/231/EEC. The
harmonized standard of the series EN 61800-5-1 (VDE 0160) is used.
This is a product of limited interference susceptibility in accordance with IEC 61800-3. This
product may cause radio interference in residential areas. In this case the installer/operator
may need to take corresponding measures.
2.2 Transport, storage and installation
The storage and transport of the COMBIVERT must be done in the original packing. It is to be protected against
humidity and excessive cooling and thermal effects. Long-distance transportation must be carried out in the
original packing. It is to be secured against physical impact and shock during transport. Verify the packaging for
signs of mishandling before removal from the packaging. Contact the shipper in case of damage. After removing
the nal packing, the COMBIVERT R6 must be mounted on a stable mounting base.
Protect
Against
Accidental
Contact
The COMBIVERT R6 must be protected against abnormal operation. Components and
covers must not be bent or moved as this may affect insulation distances. The units contain
electrostatically endangered components which can be destroyed by inappropriate handling.
For that reason the contact of electronic components and circuit boards is to be avoided.
The equipment must not be switched on if it is damaged as it may no longer comply with
mandatory standards.
Make sure during installation there is at least the minimum clearance and enough cooling.
Climate conditions must be observed in accordance with this instruction manual.
Hot surface
Heatsinks can reach high temperatures, which can cause burns when touched. A warning
notice “hot surface” must be mounted on the machine control panel if direct physical contact
with the heatsink can not be avoided.
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2. Safety Instructions

2.3 Electrical connection
Note Capacitor
Discharge Time
Before any installation and connection work, the system must be switched off and secured.
After switch off, the intermediate circuit capacitors are still charged with high voltage for a
short period of time. The unit can be worked on after it has been switched off for 5 minutes.
Secure
Isolation
The terminals of the control terminal strip are securely isolated in accordance with EN
61800-5-1. With existing or newly wired circuits the person installing the units or machines
must ensure the EN requirements are met. When used together with frequency inverters
that are not isolated from the supply circuit, all control lines must be secured by other
protective measures (e.g. double insulation or shielded, earthed and insulated).
Voltage With
Respect to
Ground
Connection of the COMBIVERT R6 is only permissible on symmetrical networks with a
maximum line voltage (L1, L2, L3) with respect to ground (N/GND) of 305V. An isolating
transformer must be used for networks which exceed this value! The unit may be damaged
if this is not observed.
Grounded Delta
Supply
Connection of the R6 series inverters to voltage systems congured as a corner grounded
delta, center tap grounded delta, open delta, or ungrounded delta may defeat the internal
noise suppression of the inverter. Increased high frequency disturbance in the controller
and on the line may be experienced. A balanced, neutral grounded wye connection
is required. The three phase voltage imbalance must be less than 2% phase-to-phase.
Greater imbalance can lead to damage of the inverter's power circuit.
It is acceptable to use a transformer with a WYE connection on the secondary.
Example of a center grounded wye transformer:
x1x2
x3
x0
Stationary
connection
The COMBIVERT R6 is designed for xed connection only as high frequency ground
leakage currents of > 3.5 mA may occur especially when using EMI lters. It is therefore
necessary to use a ground conductor with a section of at least a #4 AWG (16mm2) copper
conductor or a second ground conductor in compliance with EN 61800-5-1. Ground point-
to-point with the shortest connection possible to the main ground point in the system (avoid
ground loops).
Insulation
Measurement
When doing a high voltage insulation measurement in accordance with VDE 0100 / Part
620, the power semiconductor of the unit and existing radio interference lters must be
disconnected because of the danger of destruction. This is permissible in compliance with
the standard, since all units are given a high voltage test during the quality testing at KEB
in accordance with EN 50178.
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2. Safety Instructions