KEBCO Combivert R6 User manual

COMBIVERT
GB Instruction Manual Power Supply and Regenerative Unit
Type R6-S Type 25R6S3R-xxxx
Mat.No. Rev.
00R6SEB-KR01 2B

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 ................................................................................................................8
1.5.2 Abnormal operation ...............................................................................................................8
1.6 Unitidentication ................................................................................................................9
2. Safety Instructions ....................................................................................... 10
2.1 General instructions..........................................................................................................10
2.2 Transport, storage and installation..................................................................................10
2.3 Electrical connection......................................................................................................... 11
2.4 EMC instructions ...............................................................................................................14
2.5 EMC conform installation .................................................................................................14
3. Technical Data .............................................................................................. 15
3.1 Overload (OL) function......................................................................................................16
3.2 Operating conditions.........................................................................................................17
3.3 Accessories........................................................................................................................18
3.4 Options ...............................................................................................................................19
3.4.1 Ferrite rings..........................................................................................................................20
3.5 Dimensions and weights...................................................................................................21
3.5.1 Dimensions air cooling system mounted version.................................................................21
3.5.2 Commutation reactor / mains choke ....................................................................................22
3.5.3 Radiointerferencelter(side-mounted) ..............................................................................23
3.5.4 Synchronization unit ............................................................................................................25
3.5.5 Fuse holder with cover.........................................................................................................26
4. Installation..................................................................................................... 27
4.1 EMC-compatible control cabinet installation..................................................................27
4.2 Installation instructions ....................................................................................................27
4.3 Connection of the COMBIVERT R6 ..................................................................................28
4.3.1 General description of inverter input terminals ....................................................................28
4.3.2 Connection terminals of the power circuit............................................................................30
4.3.3 Connections of the control board.........................................................................................32
4.3.4 Connection of the synchronization unit................................................................................33
4.4 Connection power unit R6-S without UL .........................................................................34
4.4.1 Powersupplyandregenrativeoperationatinvertercurrent≤invertercurrentofone
COMBIVERT R6-S without UL ............................................................................................34
4.5 Connection power unit R6-S with UL...............................................................................36
4.5.1 Powersupplyandregenrativeoperationatinvertercurrent≤invertercurrentofone
COMBIVERT R6-S with UL .................................................................................................36
4.5.2 Power supply and regenerative operation at parallel operation with one frequency
inverter.................................................................................................................................37
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Table of Contents

4.5.3 Power supply and regenerative operation at parallel operation with a further regenera-
tive unit ................................................................................................................................37
4.6 Connection of the control board version S.....................................................................38
4.6.1 Assignment of the control terminal strip X2A.......................................................................38
4.6.2 Assignment of the socket X2B.............................................................................................39
4.6.3 Assignment of the terminal block X2C.................................................................................39
4.6.4 Wiring example ....................................................................................................................40
5. Operation of the Unit.................................................................................... 41
5.1 Operation with PC und system software COMBIVIS ......................................................41
5.2 Switch-on procedure .........................................................................................................41
5.3 Parameter summary ..........................................................................................................42
5.4 Monitoring and analysis parameters ...............................................................................43
5.5 Special adjustments ..........................................................................................................47
A. Appendix A.................................................................................................... 50
A.1 Dimensioning power supply and regenerative units .....................................................50
A.2 DC link capacitors of KEB frequency inverters ..............................................................51
A.3 Decoupling diodes.............................................................................................................53
A.3.1 Assignment ..........................................................................................................................53
A.3.2 Dimensions of the decoupling diodes ..................................................................................54
B. Appendix B.................................................................................................... 55
B.1 Certication........................................................................................................................55
B.1.1 CE Marking ..........................................................................................................................55
B.1.2 ULCertication ....................................................................................................................55
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
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Table of Contents

1. Introduction
1.1 Preface
First we would like to welcome you as a customer of KEB and congratulation to the purchase
of this product. You have decided for a product on highest technical niveau.
The enclosed documents as well as the indicated hard- and software are developments of
the KEB Automation KG. Errors excepted. KEB Automation KG has created these docu-
ments and the hard- and software to the best of knowledge, but they assume no liability that
thespecicationswillprovidethebenetssoughtbytheuser.KEBAutomationKGreserves
therighttochangespecicationswithoutpriornoticeortoinformthirdparties.Thislistisnot
exhaustive.
Theusedpictogramshavefollowingsignicance:
Danger
Warning
Caution
Attention
absolutely observe
Information
Help
Tip
1.2 Product description
This instruction manual describes the power supply and regenerative unit KEB COMBIVERT
R6-S. The COMBIVERT R6-S has the following features.
In power supply operation
• converts a three-phase input voltage into DC voltage.
• supplies single KEB frequency inverter or via DC interconnection.
• can be parallel connected if higher power supply is required.
In regenerative operation
• refeeds excess energy from regenerative operation into the supply system.
• replaces braking resistor and braking transistor.
• reduces the heat loss dissipation compared to the braking resistor
• improves the energy balance
• is environmentally friendly and space-saving
• is economically
GB - 5
Introduction

The COMBIVERT R6-S is generally protected against overcurrent, ground fault and tempera-
ture. The internal DC fuses protect the DC circuit against short-circuit to the line side. The
following accessories are necessary for operation with the COMBIVERT R6-S:
• Mains choke
• HFlter(forobservanceofEMCstandard)
+
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
GB - 6
Introduction

1.3 Validity and liability
Application and use of our units in the target products is outside of our control and
therefore exclusively in the area of responsibility of the machine manufacturer.
Theinformationcontainedinthetechnicaldocumentation,aswellasanyuser-specicadvice
in spoken and written and through tests, are made to best of our knowledge and information
about the application. However, they are considered for information only without responsibil-
ity. 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 insur-
ances and this cause loss of the warranty. Original spare parts and authorized accessories
by the manufacturer serve as security. The use of other parts excludes liability for the conse-
quences arising out of.
Thesuspensionofliabilityisespeciallyvalidalsoforshutdowndamages,lostprot,dataloss
or other consequential damages. This is also valid, if we have been 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 cor-
responding text, which is valid and equivalent to the intended meaning. The rest of the agree-
ment shall remain unaffected and valid.
1.4 Copyright
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® 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
breach a copyright, please inform us in order to have the possibility of remedy.
1.5 Speciedapplication
The COMBIVERT R6-S serves exclusively for the supply of frequency inverters with DC input
and/or regeneration of excess energy into the supply system. The operation of other electrical
consumers is prohibited and can lead to malfunctions or to the destruction of the units.
The used semiconductors and components of KEB are developed and dimensioned for the
use in industrial products. 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build-
er. The operation of our products outside the indicated limit values of the technical data leads
to the loss of any liability claims.
GB - 7
Introduction

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
Generally the power supply and regenerative unit is a DC supply. If the DC voltage increases
to a value above the peak value of the mains voltage, regeneration of the current into the
mainsoccursautomatically.TheregenerativelevelcanbedenedwithparameterCP.34or
cS.02. The mains voltage is analog measured. Regeneration occurs by square-wave current
curvewhichcorrespondsinphasepositiontothecurrentowperiodofaB6bridgecircuit.
Regenerationiscompletediftheregenerativeandpulsofflevel(CP.32orcS.06)isfallen
below.
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mes-
sage 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 mes-
sage E.nEt is displayed.
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.
GB - 8
Introduction

1.6 Unitidentication
2 5 . R 6 . S 3 R - 9 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 9: 3-ph.; 400 V; AC
Housing R
Options 3: Precharging, DC fuses
Control S: 2B.R6
Series R6
Unit size 25
GB - 9
Introduction

2. Safety Instructions
2.1 General instructions
Electric
shock
COMBIVERT R6 power supply und regenerative units contain dangerous volt-
ages which can cause death or serious injury.
COMBIVERT R6 can be adjusted by way that energy is regenerated into the
supply system in case of power failure at regenerative operation. Therefore a
dangerous high tension can be in the unit after switching off the supply system.
Before working with the unit check the isolation from supply by measure-
ments in the unit.
Care should be taken to ensure correct and safe operation to minimise 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staffmeansthosewhoareabletorecogniseandjudgethe
possible dangers based on their technical training and experience and those
withknowledgeoftherelevantstandardsandwhoarefamiliarwiththeeldof
power transmission.
Observe
standards
The COMBIVERT R6 must not be started until it is determined that the installa-
tioncomplieswith2006/42/EC(machinedirective)(noteEN60204).
The COMBIVERT R6 meets the requirements of the Low-Voltage Directive
2006/95/EC.TheharmonizedstandardoftheseriesEN61800-5-1(VDE0160)
is used.
This is a product of limited availability in accordance with IEC 61800-3. This
product may cause radio interference in residential areas. In this case the op-
erator may need to take corresponding measures.
2.2 Transport, storage and installation
The storage of the COMBIVERT must be done in the original packing. It is to be protected
against humidity and excessive cooling and thermal effect. A long-distance transport must be
carriedoutintheoriginalpacking.Itistobesecuredagainstimpactinuence.Observethe
markingonthenalpacking!AfterremovingthenalpackingtheCOMBIVERTmustbeshut
down on a stable base.
GB - 10
Safety Instructions