KEBCO Combivert R6 User manual

COMBIVERT
GB INSTRUCTION MANUAL Power Supply
and Regenerative Unit
Type R6-S Size 25
Mat.No. Rev.
00R6SEB-KR00 1J

GB This instruction manual describes the power supply and regenerative unit KEB
COMBIVERT R6-S. Before working with the unit the user must become familiar
with it. This especially applies to the knowledge and observance of the following
safety and warning indications. The pictographs used in this instruction manual
have following meaning:
Danger Attention Information
Warning Essential Mea-
sure
Help
Caution Tip

GB - 3
1. Introduction.................................................4
1.1 Preface ............................................................ 4
1.2 Product description ....................................... 4
1.3 Validity and liability........................................ 5
1.4 Copyright ........................................................ 5
1.5 Speciedapplication ..................................... 5
1.5.1 Standard operation........................................... 5
1.5.2 Abnormal operation.......................................... 5
1.6 Unitidentication........................................... 6
2. Safety Instructions .....................................7
2.1 General instructions ...................................... 7
2.2 Transport, storage and installation .............. 7
2.3 Electrical connection ..................................... 8
2.4 EMC Instructions...........................................11
2.5 EMC conform installation.............................11
3. Technical Data ..........................................12
3.1 Overload (OL) function ................................ 13
3.2 Operating conditions ................................... 13
3.3 Accessories .................................................. 14
3.4 Options.......................................................... 14
3.4.1 Ferrite rings .................................................... 15
3.5 Dimensions and weights ............................. 16
3.5.1 Dimensions air-cooled inverter mounting
version............................................................ 16
3.5.2 Commutation reactor/mains choke ................ 17
3.5.3 Side-mountedEMIlter.................................. 18
3.5.4 Synchronization unit....................................... 18
4. Installation.................................................19
4.1 EMC-compatible control cabinet
installation .................................................... 19
4.2 Installation instructions............................... 19
4.3 Connection of the COMBIVERT R6 ............ 20
4.3.1 General description of inverter input
terminals......................................................... 20
4.3.2 Connection terminals of the power circuit ...... 20
4.3.3 Connections of the control board ................... 21
4.3.4 Connection of the synchronization unit .......... 22
4.4 Connection Power Unit R6 .......................... 23
4.4.1 Power supply and regenrative operation at
invertercurrent≤currentofoneCOMBIVERT
R6-S ......................................................................23
4.4.2 Power supply and regenrative operation at inverter
currents≤currentofoneCOMBIVERTR6-S.........24
4.4.3 Power supply and regenerative operation at
parallel operation of up to three R6-S ............ 25
4.4.4 Regenerative operation at parallel operation
of up to three R6-S with decoupling diodes ... 28
4.5 Connection of the control board version S 30
4.5.1 Assignment of the control terminal strip X2A . 30
4.5.2 Assignment of socket X2B ............................. 30
4.5.3 Wiring example .............................................. 31
4.6 Operator ........................................................ 32
Table of Contents
5. Operation of the Unit................................33
5.1 Keyboard....................................................... 33
5.2 Operation with PC und system software
COMBIVIS ..................................................... 33
5.3 Switch-on procedure ................................... 33
5.4 Parameter summary..................................... 35
5.5 Password input ............................................ 36
5.6 Monitoring and analysis parameters.......... 36
5.7 Special adjustments .................................... 40
Appendix A......................................................43
A.1 Dimensioning power supply and
regenerative units ........................................ 43
A.2 DC link capacitors of KEB frequency
inverters ........................................................ 44
A.3 Decoupling diodes ....................................... 44
A.3.1 Assignment .................................................... 44
A.3.2 Dimensions .................................................... 45
Appendix B......................................................46
B.1 Certication .................................................. 46
B.1.1 CE Marking .................................................... 46

GB - 4
Preface
1. Introduction
1.1 Preface
First we would like to welcome you as a customer of the company Karl E. Brinkmann GmbH
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speciedhard-andsoftwarearedevelopmentsofthe
Karl E. Brinkmann GmbH. Errors excepted. The Karl E. Brinkmann GmbH has created these
documents, this hard- and software with best the knowledge. We doesn´t accept the guarantee
thattheusergetstheprotwiththisspecications.TheKarlE.BrinkmannGmbHreservesthe
righttochangespecicationswithoutpriornoticeortoinstructthirdpersons.Thislistisnot
exhaustive.
Theusedpictogramshavefollowingsignicance:
Danger
Warning
Caution
Attention
Essential
Discharge Time
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.
The supply unit
• converts a three-phase input voltage into DC voltage.
• supplies KEB frequency inverter individually or via DC interconnection.
• can be switched parallel, if higher power supply is required.
• increases the stability of the DC link voltage in the DC interconnection.
The regenerative unit
• feeds back the excess energy from generatoric operation into the supply system.
• reduces the energy demand.
• reduces the heat emission.
• is environmentally friendly and space-saving.
• replaces braking resistor and braking transistor.
• is cost-saving.
The COMBIVERT R6-S is generally protected against overcurrent, ground fault and tempera-
ture. Appropriate dimensioned DC fuses protects the DC link circuit against short-circuit. The
following accessories are necessary for operation with the COMBIVERT R6-S:
• Mains choke for inverter input
• EMIlter(forobservanceofEMCstandard)

GB - 5
Preface
1.3 Validity and liability
Application and use of our units in the target products is outside of our control and the-
refore 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 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, soft-
ware or the unit adjustment are modi󰘰ed.
Unauthorized opening and improper tampering can lead to bodily injuries or liability insurances
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 consequences
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 corre-
sponding text, which is valid and equivalent to the intended meaning. The rest of the agree-
ment shall remain una󰘯ected 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 e󰘯ective also to
the full extent.
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.
1.5.1 Standard operation
IftheDClinkvoltageincreasestoavalueabovethepeakvalueofthemainsvoltage(negative
power),feedbackofthecurrentintothemainsoccursautomatically.Themainsvoltageisana-
logmeasured.Thefeedbackoccursinasquare-waveformat,wherebythecurrentowperiod
correspondstothetimesofaB6bridgecircuit.RegenerationisnishediftheDClinkvoltage
decreasesthesupplypeakvoltage(positivepower).
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. This can be done by opening the control re-
lease of the frequency inverter.
At factory setting the modulation is switched off in case of a net phase and/or a synchronisation
line failure and 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denedtimeincaseofreturnofpowersupply.

GB - 6
Preface
1.6 Unitidentication
2 5 . R 6 . s 1 R - 9 0 0 A
Type A: Heatsink(standard)
Design 0: default
reserved 0: default 1: modieddefault
Voltage 9: 3-ph.; 400 V; AC
housing R
Options 1: internal precharging
Control S: 2B.R6
Series R6
Unit size 25

GB - 7
Safety Instructions
2. Safety Instructions
2.1 General instructions
Electric Shock
COMBIVERT R6 power supply und regenerative units contain dangerous voltages which
can cause death or serious injury.
COMBIVERT R6 can be adjusted by way that energy is refeed into the supply system in
case of power failure at generatoric operation. Therefore a dangerous high tension can exist
in the unit after switching off the supply system.
Before working with the unit check the isolation from supply by measurements in the
unit.
Care should be taken to ensure correct and safe operation to minimise risk to personnel and
equipment.
OnlyQualied
Electro-Perso-
nnel
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 Stan-
dards
The COMBIVERT R6 must not be started until it is determined that the installation com-
plieswith2006/42/EC(machinedirective)aswellastheEMCdirective(2004/108/EC)(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 operator 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 set down on a stable base.
Protect Against
Accidental
Contact
The COMBIVERT R6 must be protected against invalid loading. Components and covers
must not be bent or moved as this may affect insulation distances. The units contain elec-
trostatically endangered components which can be destroyed by inappropriate handling. For
that reason the contact of electronic components and contacts is to be avoided. The equip-
ment must not be switched on if it is damaged as it may no longer comply with mandatory
standards.
Make sure that during installation there is enough minimum clearance and enough cooling.
Climatic conditions must be observed in accordance with the instruction manual.
Hot Surface
Heat sinks can reach temperatures, which can cause burns when touching. If in case of
structural measures a direct contact cannot be avoided, a warning notice "hot surface" must
be mounted at the machine.

GB - 8
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 clearing the DC link capacitors are still charged with high voltage for a short period of
time. The unit can be worked on again, 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. With frequency inverters that are not isolated from the
supplycircuitallcontrollinesmustbeincludedin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 maxi-
mumlinevoltage(L1,L2,L3)withrespecttoearth(N/PE)of305V.Anisolatingtransformer
mustbeusedforsupplynetworkswhichexceedthisvalue!Theunitsmaybedamagedif
this is not observed.
Earthed Exter-
nal
Conductor
The COMBIVERT R6 can be connected to power systems with earthed external conductors
(e.g.deltapowersystems)ifthefollowingexceptionsapply:
• the control system is no longer regarded as “securely isolated circuit”, further protection
measures are therefore required
• •withthistypeofpowersystem,themax.voltagephase/earthmustnotexceed528V
absolute
• external DC fuses at the DC connections are necessary for the 400 V class. Use the
COMBIVERT R6-S without internal DC fuses.
Stationary
Connection
TheCOMBIVERTR6isdesignedforxedconnectiononlyasdischargecurrentsof>3.5
mAmayoccurespeciallywhenusingEMIlters.InaccordancewithEN61800-5-1the
following cross sections of the protective earth conductor must be used:
Cross-section
of the phase
conductors
Minimum cross-section of the protective earth conductor
<10 mm²
10 mm² CU or
additional connection terminal for a second protective earth conductor
with the same cross-section as the phase conductor
10…16 mm² Protective earth conductor with cross-section as phase conductor
16…35 mm² Protective earth conductor with a cross-section of 16 mm²
>35mm² Protective earth conductor with a cross-section of 50% of the phase
conductor.
Insulation Mea-
surement
Whenperformingan"InsulationTest"or"VoltageTest"onthecompleteelectricalsystem(as
requiredinEN60204-1/VDE0113-1)theinverterandEMI-lterhavetobedisconnected
(becauseofdangerofdestruction).Thisisincompliancewiththegivenstandardbecause
KEB inverter are 100 % voltage tested at manufacturing output routine test. In case of spe-
cial requirements contact KEB for further information.
Different Earth
Potentials
When using components without isolated inputs / outputs, it is necessary that equipotential
bondingexistsbetweenthecomponentstobeconnected(e.g.throughtheequalizer).Disre-
gard can cause destruction of the components by the equalizing currents.

GB - 9
Safety Instructions
Prevent
Disturbances
A trouble-free and safe operation of the COMBIVERT R6 is only guaranteed when the con-
nection instructions below are strictly followed. Incorrect operation or damage may result
from incorrect installation.
• Pay attention to mains voltage.
• Installpowercablesandcontrolcablesseparately(>15cmseparation).
• Use shielded / twisted control lines. Lay shield at one side to COMBIVERT R6-S to
PE!
• Only use suitable circuit elements to control the logic and analog inputs, whose contacts
are rated for extra-low voltages.
• Housing of the COMBIVERT R6 must be well earthed. Screens of larger power cable
must be directly and securely attached to both the inverter PE terminal and the motor
groundterminal.Removepaintnishwherenecessary.
• Ground the cabinet or the system earth star point with the shortest connection to mains
earth(avoidearthloops)
• Useexclusivelythecommutationreactorspecied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 COMVIBERT R6-S the max. permis-
sible DC link capacities of all connected frequency inverters must be considered during
supplyoperation(seetechnicaldata).
Automatic Re-
start
The COMBIVERT R6 can be adjusted by such way that the inverter restarts automatically
afteranerrorcase(e.g.brokenphaseline).Systemdesignmusttakethisintoaccount,if
appropriate, and additional monitoring or protective features added where necessary.
Not Short-Cir-
cuit Proof
(Supply)
The COMBIVERT R6 is not short-circuit proof at the power supply input
!IftheI2t-protection
is adapted with a gR fuse, a conditional protection at supply input is possible. The short-
circuit protection at DC output is ensured by internal or external aR respectively gR fuses.
Conditionally
Short-Circuit
Proof
(Feedback)
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:
• If an earth-leakage fault or short-circuit often occurs at the output, this can lead to a
defect in the unit.
Cyclic Activati-
on And Deacti-
vation
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.

GB - 10
Safety Instructions
RCD (Residual
Current Ope-
rated Circuit-
Breaker)
If personnel protection of the system is required, the COMBIVERT R6-S must be protected
according to EN 61800-5-1:
• 3-phaseinverters(withB6bridge-connectedrectier)byRCMA’swithseparation(used
privileged)orRCD’stypeB(all-currentsensitiveFI’s)
The tripping current should be 300mA or more, in order to avoid a premature triggering by
dischargecurrents(about200mA.Dependentontheload, the length of themotorcable
and the use of a radio interference lter, substantially higher leakage current can occur.
The connection instructions from the manufacturer and the valid local reqirements must be
observed.
Dependentontheavailablemainsform(TN,IT,TT)furtherprotectivemeasuresareneces-
saryinaccordancewithVDEPart4104(Part4;Chapter41).
For example, with TN-mains this protection is made with overcurrent 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 inver-
ter!
Circuit diagram of low voltage distribution (principle of the protective elements)
Mains
to further
sub-divisions
Outlet 1
Outlet 2
Outlet 3
Level1
Level2
type
A
type
A
RCD
type A
sel. T RCMA/
RCD
type B
Isolator
according to
EN 60947-2
To further consumers that do not pre-
vent the tripping of the FI.
To the consumers not
compatible with FI.