KEBCO combivert R6-S User manual

05/2017
00.R6.SUB-K000 rev.2D
COMBIVERT
US INSTRUCTION MANUAL Power Supply and Regeneration Unit
Type R6-S Size 15/19
Version 1.4

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1. Introduction......................................................................................................................4
1.1 Preface............................................................................................................................................... 4
1.2 Product description.......................................................................................................................... 4
1.3 Specified application........................................................................................................................ 5
1.3.1 Standard operation ............................................................................................................................. 5
1.3.2 Abnormal operation............................................................................................................................. 5
1.4 Unit identification.............................................................................................................................. 5
2. Safety Instructions..........................................................................................................6
2.1 General instructions......................................................................................................................... 6
2.2 Transport, storage and installation................................................................................................. 6
2.3 Electrical connection........................................................................................................................ 7
2.4 EMC instructions ............................................................................................................................ 10
2.5 EMC conforming installation.........................................................................................................10
3. Technical Data ...............................................................................................................12
3.1 Power data....................................................................................................................................... 12
3.2 Operating Environment Specifications ....................................................................................... 13
3.3 Accessories..................................................................................................................................... 14
3.4 Options ............................................................................................................................................ 14
3.5 Dimensions and weights................................................................................................................14
3.5.1 COMBIVERT R6-S ........................................................................................................................... 14
3.5.2 Commutation Choke ......................................................................................................................... 15
3.5.3 HF sub-mount filter ........................................................................................................................... 15
3.5.4 Synchronization Cable ..................................................................................................................... 15
3.5.5 Ferrite Rings ..................................................................................................................................... 15
4. Installation......................................................................................................................16
4.1 EMC-compatible control cabinet installation............................................................................... 16
4.2 Installation instructions ................................................................................................................. 16
4.3 Connection of the COMBIVERT R6...............................................................................................17
4.3.1 Connection terminals of the power circuit......................................................................................... 17
4.3.2 Connection terminals of the commutation choke.............................................................................. 17
4.3.3 Connections of the synchronization module .........................................................................................
4.4 Connection power circuit R6-S with internal fuses..................................................................... 18
4.4.1 Points for General Consideration........................................................................................................... 18
4.4.2.1 Wiring Scheme 'A' with Single Regen Unit.......................................................................................... 18
4.4.2.2 Wiring Scheme 'A' with Single Regen Unit and Harmonic Filter ......................................................... 18
4.4.3 Wiring Scheme 'A' with Parallel Regen Units ........................................................................................ 19
4.4.4 Wiring Scheme 'B' with Single Regen Unit ....................................................................................... 20
4.4.5 Wiring Scheme 'B' with Parallel Regen Units ..............................................................................................21
4.4.6 Sizing for Wiring Scheme A..........................................................................................................................22
4.4.7 Sizing F5 DC Bus Capacitances.................................................................................................................23
4.5 Control connections....................................................................................................................... 24
4.5.1 Assignment of the control terminal strip X2A.................................................................................... 24
4.5.2 Assignment of socket X2B ............................................................................................................... 24
4.5.3 Wiring example ................................................................................................................................. 25
4.6 Operator........................................................................................................................................... 26
5. Operation of the Unit.....................................................................................................27
5.1 Keyboard ......................................................................................................................................... 27
5.2 Operation with PC and programming software COMBIVIS......................................................... 27
5.3 Turn-on and operation procedure................................................................................................. 28
5.4 Parameter summary ....................................................................................................................... 29
5.5 Parameter description.................................................................................................................... 30
6. Diagnosis and Troubleshooting...................................................................................34
Table of Contents

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Table of Contents
6.1 Status Display: Status and Error Messages................................................................................ 34
6.1.1 Status Messages .............................................................................................................................. 34
6.1.2 Error Messages................................................................................................................................. 34
6.2 Troubleshooting.............................................................................................................................. 35
6.2.1 Troubleshooting Error Messages...................................................................................................... 35
6.2.2 Troubleshooting Operational Problems ............................................................................................ 38
A.1 Certification..................................................................................................................................... 40
A.1.1 CE Marking........................................................................................................................................ 40
A.1.2 UL Marking ........................................................................................................................................ 40
A.1.3 CSA Marking ..................................................................................................................................... 40

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Preface
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 specified 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 specifications without prior notice. This statement is not exclusive.
The icons used throughout this document have following significance:
Danger
Caution
Discharge Time
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 filter (for observance of European EMC standard)

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Preface
1.3 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 line supply system. The operation of other electrical loads is prohibited and can lead to
malfunctions or destruction of the unit.
1.3.1 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 flow period corresponds to the line frequency and the normal
conduction times of a standard 6 pulse bridge rectifier circuit. Regeneration stops if the DC bus voltage decreases
below the line supply peak voltage (positive power).
1.3.2 Abnormal operation
When exceeding the permissible limit values for voltage, current, or temperature the current flow between DC link
and the line is blocked during regeneration. An appropriate error message is also displayed. When acting as a
supply, the unit must be disconnected from the supply system in case of over current, as current flow can not be
limited by the unit itself when in this mode of operation.
With factory settings, the modulation is switched off in case of a line phase loss and/or a synchronization line
failure. The error message E.nEt is displayed.
Special adjustments from KEB are necessary if the modulation and/or the standard operation should start again
within a defined time in case of return of power supply.
1.4 Unit identification
19.R6.S 3 E-R 0 0 A
Type A: Heat sink (standard) B: Flat Heatsink
Design 0: default
reserved 0: default
K: Kit (High speed Class J fuses, choke, fuse holder)
Voltage R: 3-ph.; 180…550 V; AC
Housing E
Options 0: without pre-charging 3: Pre-charging, DC-fuses
1: pre-charging
Control S: 1B.R6 (Block Commutation) 1N.R6 (NCM)
Series R6
Unit size 15,19

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Safety Instructions
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 Qualified
Electrical
Personnel
All work from the transport, to installation and start-up as well as maintenance may only be
done by qualified personnel (IEC 364 and/or CENELEC HD 384 and IEC-Report 664 and
note national safety regulations). According to this manual, qualified 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 field 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 final 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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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 317V. 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 configured 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
Only Fixed
Connection
The COMBIVERT R6 is designed for fixed connection only as high frequency ground leakage
currents of > 3.5 mA may occur especially when using EMI filters. 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 filters 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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Safety Instructions
Different
Ground
Potentials
When using components without isolated inputs / outputs, it is necessary that equal potential
bonding exist between the components to be connected (e.g. through the equalizer).
Disregard can cause destruction of the components by the equalizing currents.
Fuse Sizing
with Isolation
Transformer
When the R6 unit is supplied through an isolation transformer, the maximum allowable fuse
size is dictated by the size of the transformer as defined in the National Electric Code (NFPA-
70 or CSA 22.1). As per Article 450-3(B) of NFPA-70 (similar statements can be found in CSA
22.1), the max fuse size is defined in table 450.3(B) with a rating not greater than 125% of
the rated secondary current. In the case of multiple secondaries, it is the rated value of the
winding which the unit is supplied from. In this case it is to be assumed that the end customer
will fuse the transformer primary side with fuses exceeding 125% of transformer rated input
current. The value of this secondary fuse may be less than the max fuse value listed in the
technical data section 3.1 of this manual. The fusing of the transformer supercedes the fuse
rating of the unit because the value required for the transformer is lower than the max value
with which the unit was tested.
Prevent
Disturbances
Trouble-free and safe operation of the COMBIVERT R6 is only guaranteed when the
connection instructions below are strictly followed. Incorrect operation or damage may result
from incorrect installation.
• Pay attention to the line supply voltage.
• Supply connection must be a symmetrical, center-grounded wye.
• Install power cables and control cables separately (>6.0 inches (15 cm) separation).
• Use shielded / twisted control lines. Connect the shield at one end to the COMBIVERT
R6-S GND terminal!
• Only use suitable circuit elements to control the logic and analog inputs, whose contacts
are rated for extra-low voltages.
• The heatsink of the COMBIVERT R6 must be well grounded. Shields of large power
cables must be directly and securely attached to both the inverter GND terminal and the
motor ground terminal. Remove paint finish where necessary.
• Ground the cabinet or the system with the shortest connection to the main ground point
(avoid ground loops)
• Use exclusively the commutation choke or harmonic filter specified by KEB.
• The average value of the supplied DC current may not exceed the maximum DC
current.
• If several frequency inverters are connected to the COMBIVERT R6, the maximum
permissible DC bus capacities of all connected frequency inverters must be considered
during supply operation (see technical data).
• A ferrite ring must be installed over both + and - DC bus connections to the
COMBIVERT R6 unit to limit common mode noise on the DC bus.
Automatic
Restart
The COMBIVERT R6 can be adjusted in such a way that the unit will restart automatically
after an error (e.g. single phase brown out or loss). System design must take this into
account. If appropriate, additional monitoring or protective features should be added where
necessary.
Not Short-
Circuit Proof
(Supply)
The COMBIVERT R6 is not short-circuit proof as a power supply input ! If the I2t - protection is
adapted with a class gR fuse, a conditional protection at supply input is possible. If necessary
the short-circuit protection at DC output is ensured by internal class aR fuse.

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Safety Instructions
Conditionally
Short-Circuit
Proof
(Regen)
The COMBIVERT R6 is conditionally short-circuit proof (EN 61800-5-1 / VDE 0160). After
resetting the internal protection devices, the function as directed is guaranteed.
Exception:
• A ground fault or short-circuit frequently occurring at the output, can lead to damage to
the unit.
Cyclic Turn On
and Turn Off
With applications requiring the COMBIVERT R6 to be switched on and off cyclically, maintain
an off-time of at least 5 min. If you require shorter cycle times please contact KEB.
GFI (Ground
Fault Interrupt
Circuit-Breaker)
If personnel protection of the system against ground fault is required, the COMBIVERT R6-S
must be protected according to EN 61800-5-1:
• 3-phase inverters (with B6 bridge-connected rectifier) by RCMA’s with separation (use
privileged) or RCD’s type B (all-current sensitive GFI’s)
The tripping current should be 300mA or more, in order to avoid a premature triggering by
leakage currents (about 200mA. Dependent on the load, the length of the motor cable and
the use of a radio interference filter, substantially higher leakage current can occur). The
connection instructions from the manufacturer and the valid local requirements must be
observed.
Dependent on the available supply type (TN, IT, TT) further protective measures are
necessary in accordance with VDE Part 410 4( Part 4; Chapter 41).
For example, with TN-mains this protection is made with over current protective devices,
with IT-mains it is insulation monitoring with a pulse-code measuring method. A protective
separation can be used with all mains forms as long as the required power and cable lengths
permit this.
The person setting up the unit must present proof of compatibility before installing the
converter!

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EMC instructions
2.4 EMC instructions
The COMBIVERT R6-S represents electrical equipment designed for use in industrial and commercial installations.
In accordance with the EMC directive 89/336/EEC, it is not mandatory to mark these devices as they represent
components to be further handled by the respective machine and system manufacturer and are not operable
independently according to the EMC directive. The person installing / operating the machine / system is obliged
to prove the protective measures demanded by the EMC directive are complied with. The prescribed ratings
can usually be complied with when using the radio interference voltage filters as specified by KEB, and when
observing the following measures and installation guidelines.
2.5 EMC conforming installation
The COMBIVERT R6 is designed to be used in a second environment as defined in EN 61800-3 (unit with its own
supply transformer). Take additional measures when using it in the first environment (residential and commercial
area connected to public low-voltage line)!
• Install the control cabinet or system in an appropriate and correct manner (see chapter "control cabinet
installation")
• To avoid coupled noise, separate during installation high voltage supply lines, motor lines, control and data
lines (low-voltage level < 48V) and leave a space of at least 6.0 inches, 15 cm between them.
• In order to maintain low-resistance high frequency connections, grounding and shielding, as well as other
metallic connections (e.g. mounting plate, installed units), must be made with bare metal to metal contact with
the mounting plate, over as large a surface area as possible. Use ground conductors with a section as large
as possible, minimum #4 AWG (16mm2) or use thick ground straps.
• Only use shielded cable with copper or tin-plated braid, since steel braid is not suitable for high frequency
ranges. The shield must always be connected to the ground bare on the unit or fastened with clamps to the
bare metal of the sub mounting plate. Do not connect the shield using the drain wires alone, this reduces the
effectiveness of the shield by 70%!
• If external interference suppression filters are used, then these must be installed as close as possible <12
inches (30 cm) to the interference source and must be in metal to metal contact with the sub mounting plate,
over as large a surface area as possible.
• Always equip inductive control elements, (contactors, relays etc.), with suppressors such as varistors, RC-
elements or diodes.
All connections must be kept as short as possible and as close as possible to the ground plane. Free floating
cables act as active and passive antenna.
• Keep connection cables straight (do not loop). Tie all spare unassigned wires at one end to the ground.
• The twisted pair cables should be used when the conductors are not shielded in order to dampen common-
mode noise.
• The cable for phase synchronization between the commutation choke and COMBIVERT R6-S may not exceed
a line length of 39 inches (1 m) .
• Further information can be found on the internet, see "www.kebamerica.com".