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 described hard- and software are developments of the KEB Automation KG. The en closed documents correspond to the conditions valid at printing. Misprint, mistakes and tech nical changes reserved.

The manual must be made accessible for each user. 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 used pictograms have following significance:

Danger

Warning

Caution

Is used, if life or health of the user is in danger or if substan tial damage to property can occur.

Attention

Essential discharge time

Information

Help

Tip

Is used, if a measure is necessary for the safe and troublefree operation.

Is used, if a measure simplifies the handling or operation of the unit.

Non-observance of the safety instructions leads to the loss of any liability claims. This list is not exhaustive.

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 single KEB frequency inverter or via DC interconnection.

• can be parallel connected 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.

GB - 5

Introduction

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

• HF filter (for observance of EMC standard)

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-specific 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 modified.

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 profit, 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 first 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.

GB - 6

Introduction

1.5 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 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 fulfilled, 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.

All output functions of the R6 are "one-channel according to ISO 13849, no diagnostic cover age and therefore not safe." If required, additional protective measures must be met by the user.

1.5.1 Standard operation

If the DC link voltage increases to a value above the peak value of the mains voltage (nega tive power), regeneration of the current into the mains occurs automatically. The regenera tive level is defined with parameter CP.34 or cS.02. The mains voltage is analog measured.

Regeneration is carried out in square-wave, whereby the current flow period is corresponding to the times 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 flow 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 defined time in case of return of power supply.

GB - 7

Introduction

1.6 Unit identification

1 9 . R 6 . S 3 E - 9 0 0 A

Type

Design reserved

Voltage

Housing

Options

Control

Series

Unit size

A: Heat sink (standard)

0: default

9: 3-ph.; 180…550 V; AC

0: without

1: precharging

S: 1B.R6

15 (13), 19 (16)

B: Flat Rear

3: Precharging, DC-fuses

GB - 8

Safety Instructions

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 measurements in the unit.

Care should be taken to ensure correct and safe operation to minimise risk to personnel and equipment.

Only qualified electropersonnel

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 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 field of power transmission.

Standards discharge time

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 influence. Observe the marking on the final packing! After removing the final packing the COMBIVERT must be shut down on a stable base.

GB - 9

Safety Instructions

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 electrostatic sensitive devices which can be destroyed by inappropriate handling. For that reason the contact of electronic devices and contacts is to be avoided. The equipment must not be switched on if it is dam aged 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.

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 that 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

The connection of COMBIVERT R6 is allowed to: symmetrical mains with a voltage phase (L1, L2, L3) with respect to neutral conductor/ ground (N/PE) of maximum 305 V.

Stationary connection

The COMBIVERT R6 is designed for fixed connection, since discharge cur rents of > 3.5 mA occur especially when using together with EMC filters. There fore, the requirements or instructions from EN 60204-1 (VDE 0113) and EN

61800-5-1 (IEC 0160-5-1) must be observed.

GB - 10

Safety Instructions

Insulation measurement

When doing an insulation or voltage measurement in accordance with EN 60204-

1 / VDE 0113-1, the power semiconductor of the unit and existing radio interfer ence filters must be disconnected because of the danger of destruction. This is permissible in compliance with the standard, since all inverters are given a high voltage test in the end control at KEB. In the case of special requirements please contact KEB.

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). Disregard can cause destruction of the components by the equalizing currents.

GB - 11

Safety Instructions

Prevent disturbances

A trouble-free and safe operation of the COMBIVERT R6 is only guaranteed when the connection instructions below are strictly followed. Incorrect opera tion 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) !

• Ground the cabinet or the system earth star point with the shortest connec tion to mains earth. (avoid earth loops)

• Use exclusively the line commutation throttle specified by KEB.

• The average value of the supplied DC current may not exceed the maxi mum DC current.

• If several frequency inverters are connected to the COMVIBERT R6-S the max. permissible DC link capacities of all connected frequency inverters must be considered during supply operation (see technical data).

Automatic restart

The COMBIVERT R6 can be adjusted by such way that the inverter restarts automatically after an error case (e.g. phase failure). System design must take this into account, if appropriate, and additional monitoring or protective fea tures added where necessary.

Not shortcircuit proof

(supply)

The COMBIVERT R6 is not short-circuit proof at the power supply input ! A con ditional protection at the supply input is possible if the I 2 t-protection is adapted with a gR fuse. Short-circuit protection at the DC output is ensured by internal or external aR or gR fuses.

GB - 12

Safety Instructions

Conditionally shortcircuit proof

(regeneration)

The COMBIVERT R6 is conditionally short-circuit proof (EN 61800-5-1 /

VDE 0160). The intended function is guaranteed after resetting the internal protection devices.

Exception:

• If earth- or short-circuits often occurs at the output, this can lead to a defect in the unit.

Cyclic activation and deactivation

With applications requiring the COMBIVERT R6 to be switched on and off cycli cally, maintain an off-time of at least 5 min. If you require shorter cycle times please contact KEB.Switching off during the initialization phase can cause un defined conditions.

RCD (residual current operated circuitbreaker)

When using systems with RCD, the instructions or the requirements of VDE

0100 -T 530 (IEC 60364-5) must be observed. The recommended tripping cur rent of RCD type "B" is 300 mA.

GB - 13

EMC instructions

2.4 EMC instructions

COMBIVERT R6-S represent electrical equipment designed for use in industrial and com mercial units.

In accordance with the EMC directive 2014/30/EU, these devices are with the meaning of the directive components to be further processed by the respective machine and unit manufac turer and are not operable independently.

The person installing / operating the machine / unit is obliged to proove the protective meas ures demanded by the EMC directive are complied with. The prescribed ratings can usually be complied with when using the radio interference voltage filters specified by KEB and when observing the following measures and installation guidelines.

2.5 EMC conform installation

The COMBIVERT R6 is designed to be used in the second environment as defined in EN

61800-3 (unit with its own supply transformer). Take additional filter measures when using it in the first environment (residential and commercial area connected to public low-voltage mains)!

• Install the control cabinet or system in an appropriate and correctly way (see chapter „EMC conform control cabinet installation“).

• To avoid coupled-in noises, separate supply lines, DC lines, motor lines, control and data lines (low-voltage level < 48V) and leave a space of at least 15 cm between them when installing.

• In order to maintain low-resistance high frequency connections, earthing and shielding, as well as other metallic connections (e.g. mounting plate, installed units) must be in metalto-metal contact with the mounting plate, over as large an area as possible. Make ground connections with a surface as large as possible (earthing strips).

• Only use shielded cable with copper or tin-plated braid, since steel braid is not suitable for high frequency ranges. The screen must always be installed on the compensating rail and fastened with clips or guided through the wall of the housing. Do not elongate the screen end (pigtails) with individual conductors!

• If external interference suppression filters are used, then these must be installed as close as possible to (< 30 cm from) the interference source and in metal-to-metal contact with the mouting plate, over as large an area as possible.

• Always equip inductive control elements (contactors, relays etc.) with suppressors such as varistors, RC-elements or damping diodes.

• All connections must be kept as short as possible and as close as possible to the earth, as free floating lines work as active and passive aerials.

• Keep connection cables straight (do not bundle). Install a non-assigned wire at one sides to the protective earth conductor.

• The flow and return circuit must be twisted when the lines are not shielded, in order to dampen common-mode noise.

• The cable for phase synchronization between mains choke and COMBIVERT R6-S may not exceed a cable length of 1 m.

• Further information can be found in the internet, see „www.keb.de“.

GB - 14

Technical Data

3. Technical Data

3.1 Standard unit size

Unit size

Housing size

Phases permitted mains forms

Rated voltage

Input voltage UL

Mains voltage range

Mains frequency

DC voltage range

Regenerative operation

Output rated power

Rated active power

Max. power output

Max. active power

Regenerative rated current

Regenerative DC current

Over load current (E.OL) 60 s

Max. regenerative DC current 60 s

Power supply operation

Input rated power

Rated active power

Max. input power

Max. active power

Rated supply current

DC supply current

Over load current (E.OL) 60 s

Max. DC supply current 60 s

Overload disconnection (E.OL)

Overvoltage switch-off (E.OP)

Output rated voltage

Max. permissible DC link capacity

I 2 t Integral of the limiting load of the semiconduc -

[V]

[Hz]

Sn *) [kVA]

*) [kW]

*) [kVA]

*) [kW]

[A]

Sn *) [kVA]

*) [kW]

*) [kVA]

[kW]

[A]

]

[%]

]

[µF]

]

4) *)

[A 2 s] tor

Max. permissible mains fuse type gR / aR [A]

Mains fuse type RK5 rated current/min. voltage *)

Permissible aR fuse Siemens Sitor / Bussmann (no delta power system)

Mains fuse type RK1 "fast acting" or "J fast acting" *)

Short-circuit factor at the connection point (S kn

Power loss at nominal operating

Max. heat sink temperature

" / Sn) or (S scp

/ S n

[W]

[°C]

)

15 (13)

160

5000

1200

(10,5)

(10)

(15,5)

(14,5)

TN TT 5)

400 (230)

(21500)

900

540 (310)

19 (16)

240/400/480

180…550 ±0 %

50 / 60 ±2

250…780 (UL: 340…680)

25,5 (15)

(10,5)

(10)

(15,5)

50 A / 480 V (50 A / 250 V)

67,5 (39)

97,5

120

(26)

(23)

(34,5)

48,5 (28)

44,5 (25,5)

72,5 (42)

5000

105

130

160

4500

100

(38)

(21500)

90 A / 480V (90A / 250V)

3NC2240 / FWP-40A22FA 3NC2240 / FWP-40A22FA

50A / 480V (50A / 250V) 90A / 480V (90A / 250V)

200

20 < S kn

" / S n

< 350

470

Bracket values obtain for operation at 230 V power supply.

The overload current is specified for 1 minute. The overload cycle is 300 seconds. This corresponds to duty class 2

EN 60146-1-1.

B6 converters the phase angle cosφ1 can be set to one, so the value of the fundamental frequency components is equal to the value of the power factor.

If the DC infeed current > 85 A DC use two by two of the DC terminals (++ and --) to meet the requirements of the

UL standard. The connection cables are parallel connected.

Please contact KEB for higher values.

IT and delta power system after consultation KEB.

GB - 15

Technical Data

3.2

GB - 16

Special unit Peak Power

Inverter size

Housing size

Phases

Approaved mains phases

Rated voltage

Input voltage UL

Mains voltage range

Mains frequency

DC voltage range

Regenerative operation

Output rated power

Rated active power

Max. power output

Max. active power

Regenerative rated current

Regenerative DC current

Overload current (E.OL) 10 s

Max. regenerative DC current 10 s

Power supply operation

Input rated power

Rated active power

Max. input power 10 s

Max. active power 10 s

Rated supply current

DC supply current

Overload current (E.OL) 10 s

Max. DC supply current 10 s

Sn *)

[Hz]

[V]

[kVA]

[ kW ]

[kVA]

[ kW ]

[A]

]

[A]

]

[kVA]

*) [ kW ]

[kVA]

[ kW ]

[A]

]

Overload disconnection (E.OL)

Overvoltage switch-off (E.OP)

Rated output voltage

Max. permissible DC link capacity *)

I 2 t Integral of the limiting load of the semiconductor

Max. permissible mains fuse type gR / aR

Permissible aR fuse Siemens Sitor / Bussmann (no delta power system)

[A]

]

[%]

]

[µF]

[A 2 s]

[A]

Line fuse for UL type RK1 "fast acting" or "J fast acting"

Short-circuit factor at the connection point (S

Power dissipation at nominal operating

Max. heat sink temperature kn

" / S n

) or (S scp

/ S n

)

[W]

[°C]

Special unit Peak Power 19 (16)

TN, TT 3)

400 (230)

240/400/480

180…550 ±0 %

50 / 60 ±2

250…780 (UL: 340…680)

48.5

44.5

117

144

126

156

200

900

(26)

(23)

(46,6)

(42)

(28)

(25.5)

(50)

(46)

540 (310)

10000 (42000)

3058

100

3NC2240 / FWP-40A22FA

90A / 480V (90A / 250V)

20 < S kn

" / S n

< 350

430

Bracket values obtain for operation at 230 V power supply. The unit is automatically adjusted by the soft ware when switching on.

The current data are based on a fundamental frequency component of g=0.95. The fundamental fre quency component or the effective value of the input current is dependent on load and line supply conditions. At uncontrolled B6 converters the phase angle cosφ1 can be set to one, so the value of the fundamental frequency components is equal to the value of the power factor.

If the DC supply current > 85 A DC use two by two of the DC terminals (++ and --) to meet the require ments of the UL standard.

The connection cables are parallel connected.

After consultation KEB IT and delta power system (see also safety instructions, voltage with respect to ground)

Technical Data

Voltage stabilization must be activated at the inverter if a harmonic filter is used.

The units are not short circuit proof without corresponding dimensioned fuses

Exceeding of the max. rechargeable DC link capacity can lead to a defect.

A load removal in the DC link circle may be done only after the message „ready“.

If the control release is set when switching off the mains, this can lead to an overcurrent error and the lifetime of the module can be reduced.

The unit must be disconnected from the supply system or the load must be switched off in case of overcurrent or overload.

3.3 Overload (OL) function

Standard:

Release time [s]

270

250

200

150

100

140 150 160

Load [%]

105 110 120 130

Figure 1: Overload (OL) function

Modified standard (increased overload):

Release time [s}

300

270

250

200

150

100

105 110 120 130 140 150

1. Depending on the line supply impedance

Figure 2: Overload (OL) function

160 180

①

200

Load [%]

GB - 17

Technical Data

3.4 Operating conditions

Standard Standard/ class

Instructions

Definition according to

Site altitude

EN 61800-2

EN 61800-5-1

Inverter product standard: rated specifications

Inverter product standard: general safety max. 2000 m above sea level

(with site altitudes over 1000 m a derating of

1 % per 100 m must be taken into considera tion)

Ambient conditions during operation

Climate Temperature EN 60721-3-3

Humidity

3K3

Track

3K3

EN 50155

Germ. Lloyd Part 7-3 extended to -10…45 °C

(with temperature over 45°C to max. 55°C a derating of 5 % per 1 K must be taken into consideration)

5…85 % (without condensation) max. amplitude of a vibration 1 mm

(5…13 Hz)

Mechanical Vibration

EN 60721-3-3 3M4

3C2

3S2 max. acceleration amplitude 7 m/s²

(13…200 Hz)

Contamination

Ambient conditions during transport

Gas

Solids

Mechanical

Vibration

EN 60721-3-2

Contamination

Surge

Gas

Solids

Ambient conditions for the storage

2K3

2M1

2C2

2S2

(without condensation) max. vibration amplitude 3.5 mm (2…9 Hz) max. acceleration amplitude 15 m/s² (9…200 Hz) max. 100 m/s²; 11 ms

Mechanical

Contamination

Vibration

Surge

EN 60721-3-1

Gas

Solids

EN 60529

IEC 664-1

EN 61800-3

1K4

1K3

1M1

1C2

1S2

IP20

(without condensation) max. amplitude of a vibration 1 mm

(5…13 Hz) max. acceleration amplitude 7 m/s² (13…200 Hz) max. 100 m/s²; 11 ms

Type of protection

Environment

Definition according to

EMC emitted interference

Cable-based interferences

Pollution degree 2

Inverter product standard: EMC

Radiated interferences

Interference immunity

Electro-static discharge

–

EN 61000-4-2

8 kV with emc filter, ferrite rings and motor cable length < 100m with emc filter and ferrite rings

AD (air discharge) and CD (contact dis charge)

Burst - control lines + bus EN 61000-4-4

Burst - mains supply EN 61000-4-4

2 kV

4 kV

Surge - mains supply EN 61000-4-5 1 / 2 kV Phase-phase / phase-ground further on next side

GB - 18

Technical Data

Immunity to conducted disturbances, induced by radio-frequency fields voltage drop

Voltage unsymmetries/ frequency changes

Standard

EN 61000-4-6

Standard/ class

10 V

Electromagnetic fields EN 61000-4-3 10 V/m

Voltage variation/

EN 61000-2-1

EN 61000-2-4

0.15...80 MHz

3 %; 2 %

Instructions

+10 %, -15 %; 90 %

3.5 Accessories

Unit size

Rated voltage

Commutation choke with synchronization without synchronization max. short-term overload (regenerative mode) max. short-term overload (supply mode)

Synchronization unit

15 (13) 19 (16)

Patch cable (length: 1 m)

* Acceptance according cUR

** Peak Power commutation reactor with acceptance according cUR

400 V

15Z1B05-1001

15Z1B05-1010*

15Z1B05-1003

15Z1B05-1013*

19Z1B05-1000

19Z1B05-1011**

19Z1B05-1003

19Z1B05-1013*

150 %

150 % / 180%

00R6940-2408

Control cabinet installation; max. distance to the commuta tion choke or harmonic filter 1 m

00F50C3-4010

3.6 Options

Unit size

Mains filter

Ferrite rings

Harmonic filter

(not for UL)

DC fuses

(also see annex B.1.2)

Fuse holder for NH00 and NH000 fuses

Operators

Bus operators with synchronization without synchronization

15 (13)

15E4T60-1001

19 (16)

19R6T60-1001

Limit class in accordance with EN 61800-3

C2 (only with ferrite rings)

C1 on consultation with KEB see chapter 3.5.4

15Z1C04-1002

15Z1C04-1000

19Z1C04-1002

19Z1C04-1000

Please contact KEB for further sizes and data to the THD value at regenerative operation in accordance with EN 61000-2-12.

690 V / 50 A

(Part number 009025H-3459)

690 V / 125 A

(Part number 009025H-3559)

0090574-0001

Digital operator, interface operator

CAN, ProfiBus, InterBus, EtherCAT, Ehternet, Sercos, ModBus,

PROFINET, LCD-Operator, DeviceNet, HSP5

GB - 19

Dimensions and weights

3.7 Dimensions and weights

3.7.1 COMBIVERT R6-S

A C C1

H B

Ø F

Housing

130

290

208

C1 with operator

Figure 3: Dimensions and weights for COMBIVERT R6-S in E housing

275

3.7.2 Commutation choke

Weight

5.6 kg

GB - 20

Part number

15Z1B05-1001

15Z1B05-1003

19Z1B05-1000

100

115

258

178

290

19Z1B05-1003 115 233

Figure 4: Commutation reactor

178

243

Ø F

4.8

79.4

166

225

Weight

11.5 kg

8.5 kg

13.8 kg

11.3 kg

3.7.3 Radio interference filter (sub-mounted)

A C

Dimensions and weights

H B

Part number

15E4T60-1001

352

132

19R6T60-1001 65 422 198

Figure 5: Radio interference filter (sub-mounted)

ØF

100

150

335

397

Weight

2 kg

6 kg

3.7.4 Ferrite rings

Ferrite rings are used for the reduction of the cable-based and radiated interferences. For a high damping, the ferrite rings are attached as close as possible to the interference source, i.e. at the DC and at the motor output terminals of the frequency inverter. The conductors must passed through the ferrite core for the use as current-compensated choke. PE must be passed outside. Further information can be taken from the provided documentation. Which ferrite ring shall be used is dependent on the used cable cross-section.

Part number

0090396-2621

0090390-5241

0090395-3820

0090395-5222

0090395-5520

Nominal size in mm

R 42/26/18

R 56/32/18

R 63/38/25

R 87/54/30

R 102/66/15

Inside diameter in mm

24.9

29.5

36.0

54.5

64.5

GB - 21

Installation

4. Installation

4.1 EMC-compatible control cabinet installation

Mains fuse

Main contactor

HF-side-mounted filter (≥ size 25

R-S or R6-N)

HF-sub-mounted filter (≤ size 19

R6-S) if necessary external synchroniza tion

Commutation reactor / harmonic filter

COMBIVERT R6 if necessary external DC fuses

Frequency inverter

Motor lines

Protective Earth (PE) on the mounting plate power circuit

10b Protective Earth (PE) on the mounting plate control circuit

10c Equipotential bonding with the housing earth

11 Mains connection power circuit

11 A Mains connection control circuit

11a

10a

150 mm

10b

12 Control lines

Large area contact at the mounting plate

Control circuit Power circuit

Figure 6: EMC-compatible control cabinet installation

10c

150 mm

9a 9b

30 mm

Direction of the cooling fins

4.2 Installation instructions

• Stationarily install and earth COMBIVERT.

• The device must not be permeated by mist or water.

• Allow for sufficient heat dissipation if installed in a dust-proof housing.

• Install the COMBIVERT in an appropriate housing in accordance with the local regulations when operating it in explosion-endangered spaces.

• Protect COMBIVERT against conductive and aggressive gases and liquids.

• The lines of the R6-S commutation reactor must be limiting to 50 cm.

• The frequency inverters must be placed in the immediate vicinity of the R6-S.

GB - 22

Connection of the COMBIVERT R6

4.3 Connection of the COMBIVERT R6

4.3.1 General description of inverter input terminals

Starting current limiting

When connecting inverters to a DC bus pay attention to the internal wiring of the

DC voltage inputs !

Inverters that directly output the DC link bus to the DC terminals must be inte grated into the DC bus by way that the supply unit(s) limit the starting current.

The precharging must be completed within two seconds.

Terminals

++, – –

Maximum DC link capacity

The maximum DC link capacity can be calculated by adding the DC link capacities of all inverters in the DC bus. A table for this can be found in the appendix.

The supply source (supply unit or inverter with AC input) must be suitable for this value.

+(PA), -

PA, PB

L1, L2, L3

Description of terminals at KEB inverters

DC voltage input with starting current limiting; usable as output only if all units supplied by the DC bus have a starting current limiting at the DC voltage input.

DC voltage output with starting current limiting; usable as input only if the starting current is limited by the supply source.

Connection for braking resistor; optionally only if a braking transistor is installed

Mains input 3-phase

GB - 23

Connection of the COMBIVERT R6

Type A1: AC/DC inverter Type B1: AC inverter

+PA

Type C1: DC inverter

+PA

Type A2: AC/DC inverter

Type B2: AC inverter

+PA

Type C2: DC inverter

This type can be supplied by mains and by DC circuit.

The starting current limita tion is designed after the input terminals. When used as output parallel connected inverters must have an own starting current limiting at the

DC voltage input. Observe the max. load current.

This type can be supplied by mains. In consideration of the DC link capacity the

DC voltage terminals can be used as output. When used as input ensure that the starting current is externally limited.

This type is only a DC in verter with starting current limiting. The DC inverter can be combined with all other types in consideration of the maximum DC link capacity.

Figure 7: General description of input terminals at KEB inverter

GB - 24

Connection of the COMBIVERT R6

4.3.2 Connection terminals of the R6 power circuit

Input voltage

The COMBIVERT R6 in E-housing is suitable for rated voltages of 230 V and

400 V.

View of power supply and regenerative units

The terminals of a power supply and regenerative unit can be input or output dependent on the actual operating status (power supply or regeneration). For the standardization of the view the line side is always regarded as input and the DC voltage side is always regarded as output.

R6-S in E-housing

L1.2

L2.2

L3.2

Terminals

++, – –

Description of terminals at KEB inverters

DC voltage output with starting current limiting for loading the connected inverters; usable as input for regenerative operation. If inverters with mains supply of type A1 or A2 (see 4.3.1) are available in the DC bus, these may be switched to mains only after loading the DC bus. Note the maximum

DC link capacity or decoupling diodes !

L1.2, L2.2, L3.2 Mains input 3-phase coming from the commutation reactor

Figure 8: Description of the input terminals of the COMBIVERT R6

GB - 25

Connection of the COMBIVERT R6

- - - -

Housing Size E

++ ++ L12 L22 L32

Name

L12

L22

L32

– –

Tightening torque [Nm] permissible line cross section

Function

3-phase supply input of the commutation reactor

DC voltage output with starting current limiting

Size 15

0.5…10 mm²

(AWG 20…8)

Size

15 max.

2.3

Size 19

1.5…25 mm²

(AWG 16…4)

Size

2…4

Figure 9: Terminals / earth handle

PE,

Connection for shield ing/grounding occurs via provided copper bar by clamping yoke or ring thimble. It must be mount ed with four screws at the heat sink. The strain relief and the shielding must be done by the customer.

– 3

GB - 26

Connection of the COMBIVERT R6

4.3.3 Terminals commutation reactor / harmonic filter

15/19Z1B05-1000 (commutation reactor)

15/19Z1C05-1000 (harmonic filter)

L1.1 L1.2 L2.1 L2.2 L3.1 L3.2

X2D

8 1

X2C

8 1

X2B

Name

L1.1

L2.1

L3.1

L1.2

L2.2

L3.2

Tightening torque [Nm] permissible line cross section Size

Function

3-phase mains con nection

Size 15

2.5…16 mm²

(AWG 20…6)

1,2…2

Output to COMBI-

VERT R6-S

Size 19

2.5…35 mm²

(AWG 12…2)

Size

2,5…5

X2B,-C,-D see below

Connection for shielding/earthing

Figure 10: Commutation reactor / harmonic filter

–

X2B, X2C, X2D RJ45 socket for phase synchronization and temperature sen sor

No. Name Function

1 8

1 t1

2 t2

Connection for temperature sensor

(optional)

3 U13_syn Synchronization phase 1 / 3

4 – reserved

5 U21_syn Synchronization phase 2 / 1

6 – reserved

7 U32_syn Synchronization phase 3 / 2

8 – reserved

Figure 11: RJ45-socket

GB - 27

Connection Power Unit R6-S

4.4 Connection Power Unit R6-S

4.4.1 Power supply and regenerative operation at inverter current ≤ current of one COMBI -

VERT R6-S

1 2 3 4 5 6 10

L1’

L2’

L3’

L1.1

L2.1

L3.1

X2B

L1.2

L2.2

L3.2

X2B

L12

L22

L32

- -

++/+PA

- - / -

Figure 12: Power supply and regenerative operation at inverter current ≤ current of one

COMBIVERT R6-S

4.4.2 Power supply and regenerative operation at inverter currents ≤ current of one COM -

BIVERT R6-S

1 2 3 4 5 6 7

L1’

L2’

L3’

L1.1

L2.1

L3.1

X2B

L1.2

L2.2

L3.2

X2B

L12

L22

L32

- -

- -/

++/

+PA

U V W PE

- -/

++/

+PA

U V W PE

10 10

1 Mains fuse type gR

2 Mains contactor

3 Radio interference filter

4 Commutation reactor / harmonic filter

5 COMBIVERT R6-S

DC fuses type aR/gR

1) 2)

8 Frequency inverter with I N(8) ≥ I N(9)

(FI type A1…C2 possible)

9 Frequency inverter

(FI type A1…C2 possible)

10 Motor

1) The cable cross-section may not be smaller than 10 mm². It must be dimensioned for the DC rated cur rent of the load. Otherwise appropriate fuses in the DC bus (6) are required. The indicated maximum protection for the connected frequency inverters must be observed !

2) If R6 units without internal DC- fusing are used, fuses in accordance with annex B.1.2 must be used to be conform according to UL. The specified fuses there refer to a maximum fusing of the R6 units.

Smaller fuses according to the connected inverter can be done with fuses of the same type.

Figure 13: Power supply and regenerative operation at inverter currents ≤ current of one COMBIVERT R6-S

GB - 28

Connection Power Unit R6-S

4.4.3 Power supply and regenerative operation at inverter currents ≥ current of one COM -

BIVERT R6-S

(Parallel operation of up to three units with an error at current sharing of the R6-S units of

≤ 10 %)

1 2 3

L1’

L2’

L3’

L1.1

L2.1

L3.1

L1’

L2’

L3’

L1.1

L2.1

L3.1

X2B

X2C

L1.2

L2.2

L3.2

X2B

L12

L22

L32

L1.2

L2.2

L3.2

X2B

L12

L22

L32

- -

6 8

A ≥ 25mm²

+PA

- -

+PA

- -

Mains contactor

Mains fuses type gR 4)

Radio interference filter

5a COMBIVERT R6-S Master 5) 8 DC fuses type aR/gR 5)

5b COMBIVERT R6-S Slave 5) 9 Frequency inverter with I N(9) < I N(5)

(FI type A1…C2 possible)

6 External terminal 1) 10 Frequency inverter with I

N(10)

(FI type A1…C2 possible)

> I N(5)

4 Commutation choke / harmonic filter 3)

7 DC fuses type aR/gR 2) 4) 5) 11 Motor

1) If the inverter current > current of the COMBIVERT R6-S it must be wired at an external terminal (6).

2) The cable cross-section may not be smaller than 10 mm². It must be dimensioned for the DC rated cur rent of the load. Otherwise appropriate fuses in the DC bus (7) are required. The indicated maximum protection for the connected frequency inverters must be observed !

3) In case of parallel connection of R6-S the total power can be smaller up to 10 % caused by production tolerances of the commutation choke. The impedance voltages uk of the commutation chokes must be the same in case of parallel connection of R6-S with different sizes.

4) Mains- and DC fuses must be monitored.

5) If R6 units without internal DC- fusing are used, fuses in accordance with annex B.1.2 must be used to be conform according to UL. The specified fuses there refer to a maximum fusing of the R6 units.

Smaller fuses according to the connected inverter can be done with fuses of the same type.

When connecting the units absolutely pay attention to correct phasing !

A load draw from the DC circuit may be done only if the ready signal is active.

Figure 14: Power supply and regenerative operation at inverter currents ≥ current of one COMBIVERT R6-S

Parallel operation

When connecting in parallel operation, the parameter defaults record must be changed. See application instructions R6-S under „Special Functions for the par allel connection“.

GB - 29

Connection Power Unit R6-S

4.4.4 Regenerative operation with decoupling diodes

Regenerative inverter currents ≤ current of one R6-S

(with mains-operated inverter of type A1 or A2)

1 5 2

L1’

L2’

L3’

L1’

L2’

L3’

L1.1

L2.1

L3.1

6 X2B

L1.2

L2.2

L3.2

X2B

L12

L22

L32 PE

- -

-++

U V W PE

- ++

U V W PE

13 13

1 Mains contactor 6)

5 Mains choke 1) 4)

Regenerative contactor 2) 6 Commutation reactor 4)

2 Mains fuses

3 Mains fuses type gR

7 COMBIVERT R6-S 5)

DC fuses type aR/gR 3) 5)

Inverter (type A1, A2, C1, C2)

12 Inverter (type A1, A2 -> 4.3.1)

8 Decoupling diodes (see annex) 13 Motor

4 Radio interference filter 9 DC fuses type aR/gR 5)

1) A mains choke with uk=4 % is mandatory required for reduction of circulating currents.

3) The cable cross-section may not be smaller than 10 mm². It must be dimensioned for the DC rated cur rent of the load. Otherwise appropriate fuses in the DC bus (10) are required. The indicated maximum protection for the connected frequency inverters must be observed !

4) Parallel connection of the frequency inverter and R6-S causes a circulating current in regenerative op eration. It is depending on the inductance of the mains choke/ commutation reactor. The total regenera tive power is 75...90 % of the R6-S regenerative power.

5) If R6 units without internal DC-fusing are used, fuses in accordance with annex B.1.2 must be used to be conform according to UL. The specified fuses there refer to a maximum fusing of the R6 units.

Smaller fuses according to the connected inverter can be done with fuses of the same type.

6) The mains contactor may only be connected if the precharging in the DC bus of the regenerative unit is completed. Note the permissible DC link capacity of the charging circuit of the inverter !

Figure 15: Regenerative inverter currents ≤ current of one R6-S (inverter type A1 or A2)

GB - 30

Connection Power Unit R6-S

Regenerative inverter currents ≤ current of one R6-S

(with mains-operated inverter of type B1 or B2)

L1’

L2’

L3’

L1’

L2’

L3’

L1.1

L2.1

L3.1

6 X2B

L1.2

L2.2

L3.2

X2B

L12

L22

L32 PE

- -

9 xx xx

U V W PE

+PA

U V W PE

13 13

1 Mains contactor 2)

5 Mains choke 1) 4)

Regenerative contactor 2) 6 Commutation reactor 4)

2 Mains fuses

3 Mains fuses type gR

7 COMBIVERT R6-S 5)

DC fuses type aR/gR

Inverter (all types)

12 Inverter (types B1, B2)

8 Decoupling diodes (see annex) 13 Motor

3) 5)

4 Radio interference filter 9 DC fuses type aR/gR 5)

1) A mains choke with uk=4 % is mandatory required for reduction of circulating currents.

2) Here alternatively the regenerative- or mains contactor can be switched first. The respective other contactor may be connected only if the precharging in the R6-S or DC bus of the frequency inverters is completed. If the precharging of R6-S and frequency inverter is in the same DC branch (R6-S in E housing and inverter type B2), a regenerative contactor is eventually not necessary (depending on the charging resistors and the DC link capacity). Note the permissible DC link capacity of the charging circuit of the inverter !

5) If R6 units without internal DC-fusing are used, fuses in accordance with annex B.1.2 must be used to be conform according to UL. The specified fuses there refer to a maximum fusing of the R6 units.

Smaller fuses according to the connected inverter can be done with fuses of the same type.

Figure 16: Regenerative inverter currents ≤ current of one R6-S (inverter type B1 or B2)

4.4.5 Regenerative operation at parallel operation of up to three R6-S with decoupling di-

GB - 31

Connection Power Unit R6-S

GB - 32 odes

(Parallel operation with an error at current sharing of the R6-S units of ≤10 %)

L1’

L2’

L3’

L1.1

L2.1

L3.1

L1’

L2’

L3’

L1.1

L2.1

L3.1

X2B

X2C

L1.2

L2.2

L3.2

X2B

L12

L22

L32 PE

- -

L1.2

L2.2

L3.2

X2B

L12

L22

L32 PE

- -

13 12

6 PE

+PA

- -

U V W PE

L1’

L2’

L3’

6 PE

+PA

- -

U V W PE

1 Mains fuses

2 Mains contactor 4)

2a Regenerative contactor

Mains fuses type gR

Radio interference filter

5 Commutation reactor 5) 6)

6 Mains choke 1) 5)

7 COMBIVERT R6-S

8 Inverter (type A1/A2 or B1/B2) same type and size

9 Motor

10 DC fuses type aR/gR 2)

11 DC fuses type aR/gR

12 External terminal 3)

13 Decoupling diodes (see annex)

1) A mains choke with uk=4 % is mandatory required for reduction of circulating currents.

2) The cable cross-section may not be smaller than 10 mm². It must be dimensioned for the DC rated cur rent of the load. Otherwise there are fuses in the DC link circle (10) necessary The indicated maximum protection for the connected frequency inverters must be observed !

3) If the inverter current > current of the COMBIVERT R6-S it must be wired at an external terminal (12).

4) The mains contactor may only be connected if the precharging in the DC bus of the regenerative unit is completed. Note the permissible DC link capacity of the charging circuit of the inverter !

5) Parallel connection of the frequency inverter and R6-S causes a circulating current in regenerative op eration. It is depending on the inductance of the mains choke. The total regenerative power is 75...90 % of the R6-S regenerative power.

further on next side

Connection Power Unit R6-S

6) In case of parallel connection of R6-S the total power can be smaller up to 10 % caused by production tolerances of the commutation reactor. The impedance voltages uk of the commutation reactors must be the same in case of parallel connection of R6-S with different sizes.

When connecting the units absolutely pay attention to correct phasing !

Figure 17: Regenerative operation at parallel operation of up to three R6-S with decoupling diodes

Parallel operation

When connecting in parallel operation, the parameter defaults record must be changed. See application instructions R6-S under „Special Functions for the par allel connection“.

Wiring of the control release of the connected inverters

X2A

A load draw in the DC circuit may be done only when the message „ready“ is set. This can be guaranteed by a series connection of the relay R1 of the R6-S units with the control release of the connected inverters.

G1, G2 Regenerative unit COMBIVERT R6-S

X2A Control terminal strip

24 Relay 1 / NO contact

25 Relay 1 / NC contact

26 Relay 1 / switching contact

Ready for operation relay

G3, G4 Frequency inverter KEB COMBIVERT

X2A Control terminal strip

16 Control release

20 24 V output

S3, S4 Control release for one KEB COMBIVERT

This terminal assignment refers only to one KEB COMBIVERT

Figure 18: Wiring of the control release of the connected inverters

GB - 33

Connection of the control board version S

4.5 Connection of the control board version S

4.5.1 Assignment of the control terminal strip X2A

X2A

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Conductor cross-section 0.14…1.5 mm², tightening torque 0.22...0.25 Nm

PIN Function

10 24V input

Name Default

Uin

Description

External supply of the control board

Specifications

21.6...26.4 V DC

/ 1 A

11 Mass

12 Digital input 1

13 Digital input 2

14 Digital input 3

COM

Set selection

Reference potential

Control release / reset programmable programmable

Ri: 4.4 kΩ

15 Digital input 4 I3

16 Digital input or output I/O

(I4)

17 24 V output Uout

Ext. error programmable

Active signal (connection of all R6 at parallel operation in master-slave mode)

Voltage supply for in- and approx. 24 V /

18 Mass

19 Digital output 1

20 Digital output 2

COM

O2 outputs

Reference potential

DC >600 V Transistor output (DC >

CP.19)

Error mes sage

Transistor output (error mes sage)

max. 100 mA

Imax: 25 mA

21 Analog output

22 24 V output

23 Mass

AN-

OUT

Uout

COM

24 Relay 1 / NO contact RLA Ready for

25 Relay 1 / NC contact RLB operation

(no error)

Difference to mains frequency

(CP.18) see terminal 17

Reference potential

Relay output

Ready signal (status "Stb" or

"rEGEn")

0…±10 V / max.

5 mA max. 30 V DC

0.01…2 A DC

26 Relay 1 / switching contact

RLC

27 Relay 2 / NO contact FLA DC > 600 V

28 Relay 2 / NC contact FLB

29 Relay 2 / switching contact

FLC

Relay output (DC > CP.19) max. 30 V DC

0.01…2 A DC

*) The relay outputs must be operated with max. 48 V DC protective separation voltage to guaran tee the CE standard. After consultation KEB a current of max. 2A DC is permissible for 120 V AC

(depending on the switching capacity etc.).

GB - 34

Connection of the control board version S

4.5.2 Assignment of the socket X2B

RJ45 socket for phase synchronization and temperature sensor

No. Name Function

1 8

T1 Connection for temperature sen -

T2 sor (option)

3 U13_syn Synchronization phase 1 / 3

4 – reserved

5 U21_syn Synchronization phase 2 / 1

6 – reserved

7 U32_syn Synchronization phase 3 / 2

8 – reserved

Figure 19: RJ45 socket

The connection is made with a sync cable 1:1 with the socket X2B, X2C or X2D at the com mutation reactor or synchronisation unit.

4.5.3 Assignment of the terminal block X2C

24 25 26

PIN Function

24 Bridge between pin

Conductor cross-section 0.14…1.5 mm², tightening torque 0.22...0.25 Nm

Description

Activation of the self-holding of the line contactor

24 and pin 25

26 not assigned -

GB - 35

Connection of the control board version S

4.5.4 Wiring example

In order to prevent a malfunction caused by interference voltage supply on the control inputs, the following directions should be observed:

EMC

• Use shielded/drilled cables

• Lay shield on one side of the inverter onto earth potential

• Lay control and power cable separately (about 10...20 cm apart); lay crossings in a right angle

Active signal for further R6-S units at parallel operation

18 max. 25 mA DC per digital output

Analog output

0…±10 V DC / 5 mA

Supply voltage of the inverter inputs max. 30 V DC

0.01…2 A

Control release inverter max. 30 V DC

0.01…2 A

X2A

Figure 20: Wiring example R6-S

GB - 36

Operator

4.6 Operator

An operator is necessary as accessories for local or external operation of the COMBIVERT

R6-S. To prevent malfunctions, the COMBIVERT must be brought into nOP status before connecting/ disconnecting the operator (open control release). When starting the COMBI -

VERT, it is started with the last stored values or factory setting.

Digital operator (part number 00F5060-1000)

Interface operator (part number 00F5060-2000) x x 5-digit LED Display x x Operating-/Error display

Normal "LED on"

Error "LED blinks"

- x Interface control

Bus operation "LED on" x x Double function keyboard

- x X6B HSP5 programming and diagnostic interface

- x X6C RS232/RS485 X6B

ENTER

F/R

START

STOP

FUNC.

SPEED

X6C

C O M B I V E R T

X6D

Only use the operator interface for the serial data transfer to RS232/485. The di rect connection, PC to the COMBIVERT is only permissible with a HSP5-special cable (part number 00F50C0-0001) otherwise it would lead to the destruction of the PC-interface !

X6C

5 4 3 2 1

9 8 7 6

RS 232 cable

Part number

0058025-001D

Length 3 m

PIN RS485 Signal Meaning

reserved

TxD Transmission signal RS232

RxD Receive signal RS232

A‘ RxD-A Receive signal A RS485

B‘ RxD-B Receive signal B RS485

VP Voltage supply +5 V (Imax=50 mA)

7 C/C‘ DGND Data reference potential

A TxD-A Transmission signal A RS485

B TxD-B Transmission signal B RS485

9-pole Sub-D socket to the PC

9-pole Sub-D connector

Housing (PE) to the operator

GB - 37

Operation of the Unit

5. Operation of the Unit

5.1 Operation with PC und system software COMBIVIS

Instructions for the installation and operation of the system software COMBIVIS can be taken from the appropriate software instruction.

5.2 Switch-on procedure

The COMBIVERT R6-S is initialized after connection of the power supply. The power circuit identification is checked first. If an invalid power unit is recognized, error „E.Puci” (Power unit code invalid) is released and displayed in the operator. This error cannot be reset, the power circuit must be checked.

The COMBIVERT R6-S changes into synchronisation phase if a valid power circuit is rec ognized. The following procedures happens one after another during this synchronisation phase:

• Inspection of correct synchronisation connection (error "E.nEt" is released, if the synchro nous signal is missing)

• Inspection of the phase allocation of synchronous signals to the mains phases. Error

"E.SYn" is released if a phase is missing or in case of phase allocation failure.

The actual line frequency and the mains voltage is determined after successful synchronisa tion. The correct connection of the COMBIVERT R6-S is now ensured. If the control release

(terminal ST) is set, the COMBIVERT R6-S starts independently with the normal operation.

Depending whether regenerative requirement is available, the COMBIVERT R6-S is in status

„rEGEn” or „Stb”.

Status „Stb“

COMBIVERT R6-S detects a typical voltage level in the DC link circuit of the connected fre quency inverter (motor operation) and keeps the modulation signals of the regenerative unit deactivated.

Status „rEGEn”

If the DC voltage in the DC link (CP.09 or ru.19) exceeds the value of the regeneration level (CP.34 or cS.02) referring to the reference value ru.18, the modulation signals are ac tivated and the unit changes into regenerative operation. Furthermore the regenerative unit is switched active, if regenerative operation is requested by an additional installed COMBI -

VERT R6-S in the system (master /slave operation).

GB - 38

Parameter summary

5.3 Parameter summary

The CP parameters are one of the parameter selection defined by KEB. You need an applica tion manual in order to get access to the entire parameters.

Display Parameter Origin

CP.00

password input

CP.01

status display

CP.02

actual line frequency

CP.03 AC current L1

CP.04 AC current L2

CP.05 AC current L3

CP.06 act.DC utilization

CP.07 peak DC utilization peak value

CP.08 DC current

CP.09 DC voltage

CP.10 peak DC voltage

CP.11

power module temperature

CP.12

OL counter display

CP.13

actual power

CP.14 total regen

CP.15 total motor

CP.16 total net

CP.17 actual net

CP.18 ANOUT 1 / gain

CP.19

comparison level

CP.20

general fault reset

CP.21

last error

CP.22

last error -1

CP.23

last error -2

CP.24

last error -3

CP.25

last error -4

CP.26

last error -5

CP.27

last error -6

CP.28

last error -7

CP.29

software version

CP.30

software date

CP.32

puls off level

CP.33 operating mode

CP.34 regeneration level

Setting range Resolution

0…9999 1

–

0.1 Hz

–

0.1 A

–

0.1 A

1 %

Factory setting

–

±20.00

±30000.00 V

0…10

–

1.11

–

0801.7

–

0.0…-1000.0 kW 0.1 kW

0…3

100…120 %

1 %

0.1 A

1 V

1 °C

1 %

0.1 kW

0.1 kWh

–

0.1 kVA

0.01

–

1.00

ru.85

An.33

0.01 V 600.00 V LE.00

1 3 Pn.15

–

In.21

ru.15

ru.19

ru.20

ru.38

ru.39

ru.81

ru.82

ru.83

ru.84

–

1.11

0801.7

103 %

In.21

In.06

In.07

-0.8 kW cS.06

Pn.19

cS.02

ud.01

ru.00

ru.03

ru.08

ru.09

ru.10

ru.13

ru.14

GB - 39

Monitoring and analysis parameters

Approach of the working meters

The displayed values of the working meters offer only an estimate value because of measurement and calculation inaccuracies. These displayed values are un suitable for tariff applications and cannot replace any measuring devices.

5.4 Monitoring and analysis parameters

The following parameters serve for the functional monitoring during operation.

No.

Name

CP.01

status display r/w Enter

– –

The status display shows the actual working conditions of the COMBIVERT.

Origin ru.00

Status Messages rEGEn Regeneration active (regenerative operation) bbL noP

Count down of the base-block time, R6-S released

„no Operation“ control release not bridged, modulation switched off nEtoF

Stb

Mains power failure; regenerative operation is further possible, if the disconnect ing time E.nEt (Pn.14) > 0 s

R6-S regenerative unit in stand-by operation (motoric operation)

Error Messages

E.dOH

„ERROR ! overheat choke“, temperature monitoring of the commutation choke has triggered and the coolong-off period is up.

E. EF „ERROR ! external fault“, error message by an external unit

E.FnEt

„ERROR ! mains frequency", the mains frequency deviates more than 5 %. The max. mains frequency deviation can be adjusted in the application mode with

CS.03.

E.LSF

ERROR! load-shunt defective or wrong respectively input voltage too low. This message is displayed for a short time during the power-on phase (no error mes sage follows).

E.nEt

„ERROR net", one or more phases are missing

E.nOH

no ERROR overheat pow.mod. (E.OH) not any longer present, error can be reset.

E.nOL

No Over Load, cooling time after E.OL is up , error can be reset.

E. OC „ERROR overcurrent, output current too high or ground fault

E. OH „ERROR overheat pow.mod.“, overheating at heat sink (see „Technical data“)

E.OHI

„ERROR overheat internal“, temperature in the interior > 70°C

E. OL „ERROR overload, overload monitoring of the regenerative unit has responded

E. OP „ERROR overpotential, DC link voltage too high

E.PFd

„ERROR initialisation“, power failure (phase) during the initialisation phase

E. Pu „ERROR power unit“, power unit code is missing, load shunt relay defective

E.Puci

„ERROR pow.unit code inv.“ power unit code is invalid

E.Puch

„ERROR power unit changed“.

continued on the next page

GB - 40

Monitoring and analysis parameters

No.

Name

CP.01

status display

E.PUIN

„ERROR net“, ripple of the rectified mains voltage too high

E.SYn

„ERROR synchronisation, phase allocation at commutation throttle not correct

E. UP „ERROR underpotential, DC link voltage too low r/w Enter Origin

– – ru.00

No.

Name

CP.02

actual line frequency r/w Enter Origin

– – ru.03

After switching on, the actual mains frequency is determined during the initialization phase.

Slowly changes of the line frequency during the operation are recognized and displayed in CP.02. CP.02 displays the actual regenerative frequency, if the COMBIVERT R6-S is in

"netof" status.

Resolution

0.01 Hz

Meaning positive values = clockwise rotating field negative values = counterclockwise rotating field

No.

Name

CP.03

AC current L1

CP.04

AC current L2

CP.05

AC current L3

Resolution

0.1 A r/w Enter Origin

–

Meaning

Display of the actual input current of the respective phase.

ru.08

ru.09

ru.10

No.

Name

CP.06

actual DC utilization

Resolution

1 %

Meaning r/w

–

Enter

–

Origin ru.13

Independent whether power supply or regenerative operation, the dis play indicates the actual utilization of the COMBIVERT R6-S. 100 % correspond to the rated current of the COMBIVERT R6-S.

No.

Name

CP.07

peak DC utilization

Resolution

1 %

Meaning r/w

–

Enter

–

Origin ru.14

Parameter CP.07 enables to recognize short-term peak utilization with in an operating cycle. For that the highest value of CP.06 is stored in

CP.07. The peak value memory can be cleared by pressing the UP and

DOWN key or over bus by writing any value you like to the address of

CP.07. Switching off COMBIVERT R6-S also clears the memory.

GB - 41

Monitoring and analysis parameters

No.

Name

CP.08

DC current

Resolution Meaning

0.1 A r/w Enter Origin

–

Display of the calculated DC output current in ampere.

– ru.15

No.

Name

CP.09

DC voltage

Resolution

1 V r/w

–

Enter

–

Origin ru.19

Meaning

Display of actual DC link voltage in volt. The value is measured at the

DC output terminals of the COMBIVERT R6-S.

No.

Name

CP.10

peak DC voltage

Value range

0…1000 V

Meaning r/w

–

Enter

–

Origin ru.20

Parameter CP.10 enables to recognize voltage peaks within an operat ing cycle. For that the highest value of CP.09 is stored in CP.10. The peak value memory can be cleared by pressing the UP and DOWN key or over bus by writing any value you like to the address of CP.10.

Switching off COMBIVERT R6-S also clears the memory.

No.

Name

CP.11

power module temperature

Resolution Meaning

1 °C r/w

–

Enter

–

Origin ru.38

Display of the actual power module temperature. On exceeding the maximum power module temperature (see "technical data") the modu lation is switched off and error E.OH is displayed. Message E.nOH is displayed after the cooling period. The error can be reset now.

No.

Name

CP.12

OL counter display

Resolution

1 %

Meaning r/w

–

Enter

–

Origin ru.39

The permanent load of the COMBIVERT R6-S can be evaluated with this parameter, in order to avoid an E.OL error (in-time load reduction).

Error E.OL is released, if the overload counter reaches 100 %.

GB - 42

Monitoring and analysis parameters

No.

Name r/w Enter Origin

CP.13

active power

Resolution Meaning

0.1 kW

– – ru.81

CP.13 displays the actual power of the COMBIVERT R6-S. Motor pow er is displayed with positive values, generatoric power is displayed with negative values.

No.

Name

CP.14

total regen

Resolution

1 kW r/w Enter Origin

– – ru.82

Meaning

Counter for the regeneratoric electric work to the mains.

No.

Name

CP.15

total motor

Resolution

1 kW r/w Enter Origin

– – ru.83

Meaning

Counter for the supplied electrical work from the mains in kWh.

No.

Name

CP.16

total net

Resolution

1 kW r/w Enter Origin

– – ru.84

Meaning

Display of the difference between supplied and regeneratoric work.

The result is displayed by right sign.

No.

Name

CP.17

actual net

Resolution

0.01 kVA r/w Enter Origin

– – ru.85

Meaning

Display of the current apparent power at the mains input.

GB - 43

Special adjustments

5.5 Special adjustments

The power supply and regenerative unit can be adapted to the application with the following parameters.

No.

Name

CP.18

ANOUT 1 gain

0…±20.00

1.00

r/w Enter yes –

Origin

An.33

The analog output displays the difference between actual supply frequency and set supply frequency. At factory setting of CP.18 this corresponds to 1 V per 0.1 Hz difference. The dis play occurs with right sign. The reference value of 50 or 60 Hz is determined during power on.

Setting range Setting Meaning

The amplification to the desired output voltage can be adapted with CP.18. Max. possible: ±10 V.

No.

Name

CP.19

comparison level 0

0…3200.00 V 600.00 V r/w Enter yes –

Origin

LE.00

This parameter determines the switching level for transistor output O1, as well as relay output 2.

Setting range Setting Meaning

The switching condition is fulfilled and the transistor output is set if the DC voltage level exceeds the ad justed value in CP.19. Relay output 2 is set, if the load shunt relay is additionally tightened.

No.

Name

CP.20

general fault reset

Setting range r/w Enter yes –

Origin

Pn.15

A general fault reset can be activated with this parameter. Atten tion, the machine manufacturer must observe appropriate protective measures for operators staff and machine.

Setting Meaning

1…10

No general fault reset.

Maximum errors, which are reset within one hour. If the number of errors per hour exceeds the adjusted value in CP.20, only a manual reset via terminal strip can be made.

GB - 44

Special adjustments

No.

CP.21

CP.22

CP.23

CP.24

CP.25

CP.26

CP.27

Name last error last error -1 last error -2 last error -3 last error -4 last error -5 last error -6

CP.28

last error -7 r/w Enter

–

Origin

In.24 set 0

In.24 set 1

In.24 set 2

In.24 set 3

In.24 set 4

In.24 set 5

In.24 set 6

In.24 set 7

Parameters CP.21…CP.28 display the last eight errors. With exception error "underpotential

E.UP" is not stored. The oldest error is displayed in CP.28. A new error is stored in CP.21.

All other errors are shifted to the next parameter. The oldest error (CP.28) is not applicable.

The meaning of the error messages is described in parameter CP.01.

No.

Name

CP.29

software version

Value range Meaning

0.00…9.99

r/w

–

Enter

–

Display of the inverter software version number (e.g. 1,11).

Origin

In.06

No.

Name r/w Enter

CP.30

software date

Value range Meaning

0…6553.5

– –

Display of the inverter software date in the format „ddmm.y“.

Origin

In.07

No.

Name

CP.32

puls off level r/w Enter yes –

Origin cS.06

Value range

0.0…-1000.0 kW default Meaning

-0.8 kW

If the adjusted regenerative power is decreased, the COM -

BIVERT R6-S switches the modulation off after turn-off de lay and changes into standby mode (display: „Stb“).

No.

Name

CP.33

operating mode r/w yes

Enter yes

Origin

Pn.19

This parameter determines the master or slave of regenerative units at parallel connection.

Further it is adjusted whether a harmonic filter or a commutation choke is series-connected.

Single units must be adjusted to master.

Value range

Meaning

Master with commutation choke

Master with harmonic filter

Slave with commutation choke

Slave with harmonic filter

GB - 45

Special adjustments

No.

Name r/w Enter Origin

CP.33

operating mode yes yes Pn.19

This parameter determines the master or slave of regenerative units at parallel connection.

Further it is adjusted whether a harmonic filter or a commutation choke is series-connected.

Single units must be adjusted to master.

Value range

Meaning

Master-Slave with commutation reactor input selection

Master-Slave with harmonic filter input selection

No.

Name

CP.34

regeneration level

Value range Meaning

100…120 % r/w yes

Enter

–

Origin cS.02

The regeneration level determines the starting value to energy regen eration. The adjusted value refers to the reference value of the DC voltage in percentage. The status changes from Standby „Stb“ to re generation „rEGEn“.

GB - 46

Appendix A

A. Appendix A

A.1 Dimensioning power supply and regenerative units

Dimensioning of the power supply and regenerative unit

Only regeneration ?

no Acquire:

C ZK_all

CZK_all > CZK_max no

Acquire:

P M , P Mmax , t1, T, η M, η G, η FI yes bridgeover ext. load-shunt with contactor (special unit) yes

Decoupling R6-S (see 4.4.3 to

4.4.5)

Calculate: ILM, ILMmax

Acquire:

PM, PMmax, t1, T, ηM, ηG, ηFI

Calculate:

ILG, ILGmax yes

T < 300 s no t1 > 60 s no select higher unit or paral lel connection of R6-S

(n • IDC, n • IDCmax)

IDCmax > ILGmax no yes yes select higher unit or parallel con nection of R6-S

IDCmax > ILMmax

(n • IDC, n • IDCmax) no yes

T < 300 s no yes t1 > 60 s no yes

IDC > ILM yes no

Calculate: ILG, ILGmax select higher unit or parallel con nection of R6-S

IDCmax > ILGmax

(n • IDC, n • IDCmax) no

IDC > ILG no yes yes

IDC > ILG no

Regenerative unit capable yes

Power supply and regenerative unit capable t

PMmax t1 n

Mechanical power

Overload time

Last cycle

η M

Max. mechanical power ηG

ηFU

ILM

Motor efficiency

Gearbox efficiency

Inverter efficiency

IDC DC output current R6-S

IDCmax max. DC output current

ILG

R6-S

DC load regenerative current

DC load motoric current ILGmax Max. DC load regenerative

Number R6-S ILMmax

Max. DC load motoric current current

CZK_all DC link capacity of all fre-

CZK_ max quency inverters max. connecting capacity

R6-S

Figure 21: Dimensioning power supply and regenerative units

GB - 47

Appendix A

A.2 DC link capacitors of KEB frequency inverters

Unit size

200 V units

Frequency inverter COMBIVERT F5

400 V units

Capacity

780 µF

Unit size

880 µF (940 µF*)

1080 µF

2220 µF

3280 µF

4100 µF

5040 µF

9900 µF

13200 µF

15600 µF

16500 µF

19800 µF

Capacity

180 µF

180 µF (300 µF*)

300 µF

345 µF

470 µF

580 µF

650 µF

940 µF

1290 µF

1640 µF

1875 µF

2700 µF

3900 µF

4950 µF

6350 µF

8400 µF

9900 µF

11700 µF

28(P)/28(W)

29(P)/(W)

32-35

14100 µF

16200 / 19800 µF

19800 / 23400 µF

28200 µF

32900 µF

39600 µF

59400 µF

* Special unit

The precharge circuit must be taken for COMBIVERT F5 inverters from the re spective power circuit manual.

GB - 48

Appendix A

Housing size

Frequency inverter COMBIVERT G6

Unit size

Capacity / µF

135

195

235

470

560

680

750

680

840

1120

1035

1400

1985

Frequency inverter COMBIVERT S6

Unit size Capacity / µF

195

1955

235

470

560

Precharging circuit

Type A1

Type B1

Precharging circuit

Type A1

When using G6 / S6 inverters ferrites must be used in each case at the input and output.

GB - 49

Appendix A

A.3 Decoupling diodes

Use decoupling diodes when using the R6 as regenerative unit only, to avoid that the con nected inverters cannot be supplied via the regenerative unit. Appropriate decoupling diodes are defined for the different sizes.

A.3.1 Assignment

R6-S Material number

0090147-3500

0090147-4101

0090147-6009

Type

1600 V / 80 A

1600 V / 120 A

1600 V / 560 A

Volume

2 x 2

Ta [°C]

Legend

Ta: maximum ambient temperature

Th: maximum heat sink temperature

Rha: required thermal resistance of the heat sink at rated operation

(thermal value of the thermal compound ≥ 0.5 W/(m*K))

Th [°C] Rha [K/W]

1.50

0.84

0.19

0.09

GB - 50

A.3.2 Dimensions of the decoupling diodes

Material number connection

0090147-3500 1 (anode)

2 (cathode) or

3 (anode)

1 (cathode)

Dimensions

0090147-4101 1 (anode)

2 (cathode) or

3 (anode)

1 (cathode)

0090147-6009 3 (anode)

2 (cathode)

Appendix A

Figure 22: Dimensions of the decoupling diodes

GB - 51

Appendix B

B. Appendix B

B.1 Certification

B.1.1 CE Marking

CE marked power supply-/regenerative units were developed and manufactured to comply with the regulations of the Low-Voltage Directive 2006/95/EC.

The described units must not be started until it is determined that the installation complies with the Machine directive (2006/42/EC) as well as the EMC-directive (2004/108/EC)(note

EN 60204).

The power supply-/regenerative units meet the requirements of the Low-Voltage Directive 2006/95/EC. The harmonized standards of the series EN 61800-5-1 in connection with

EN 60439-1 and EN 60146 were used.

B.1.2 UL Certification

Acceptance according to UL is marked at KEB power supply and regenerative units with the adjacent logo on the type plate.

GB - 52

To be conform according to UL for the use on the North American Market the following in structions must be observed (original text of the UL file in English):

• Maximum Surrounding Air Temperature 45°C“

• Suitable For Use On A Circuit Capable Of Delivering Not More Than 10000rms Symmetri cal Amperes, 240 or 480 Volts Maximum“ and „When Protected by Fuses as listed below:

Feedback unit Cat. No.

Fuse

15R6 (240V) 1) RK1 fast acting or J fast acting, rated 50A, min. 250V

19R6 (240V)

2) Special purpose, type 3NC2240, rated 40A/690Vac, mfr. by

Siemens or type FWP-40A22FA, manufactured by Bussmann

1) RK1 fast acting or J fast acting, rated 90A, min. 250V

15R6 (400/480V)

2) Special purpose, type 3NC2200, rated 100A/690Vac, mfr. by

Siemens or type FWP-100A22FA, manufactured by Bussmann

1) RK1 fast acting or J fast acting, rated 50A, min. 480V

2) Special purpose, type 3NC2240, rated 40A/690Vac, mfr. by

Siemens or type FWP-40A22FA, manufactured by Bussmann

1) RK1 fast acting or J fast acting, rated 90A, min. 480V 19R6 (400/480V)

2) Special purpose, type 3NC2200, rated 100A/690Vac, mfr. by

Siemens or type FWP-100A22FA, manufactured by Bussmann

• Use 75°C Copper Conductors Only“

• Use in a Pollution Degree 2 environment“

• Following external DC fuses need to be installed in accordance with wiring diagrams in chapter 4.4 for following units without internal DC fuses:

Appendix B

15R6S1E-xxxx

Rated 690 Vac / 700 Vdc 50 A (KEB No.: 009025H-3459):

R/C (JFHR2) - Type Sitor 3NE8-717-1, manufactured by Sie mens or Type 170M1364-1, manufactured by Bussmann

Rated 690 Vac / 700 Vdc 125 A (KEB No.: 009025H-3559):

R/C (JFHR2) - Type Sitor 3NE8-722-1, manufactured by Sie mens or Type 170M1368-1, manufactured by Bussmann

• For Feedback units 15.R6.S1E-xxxx and 19.R6.S1E-xxxx

In case of Semiconductor Fuses as specified in item 4 and 12 above, the marking shall also state that the Feedback unit and overcurrent protection device must be integrated within the same overall assembly (effective date: May 9, 2013)

• Only for 15R6S1E-xxxx and 15R6S3E-xxxx:

“Use max Wire Size: 8 AWG, strip wire insulation at 10 mm.”

• Wiring terminals are marked to show a range of values or a nominal value of tightening torque in pound-inches to be applied to the clamping screws as shown below:

Mains Terminals AWG 8: 20.5 lb-in (2,3 Nm)

Mains Terminals AWG 4: 18.0 lb-in (2.0 Nm)

GB - 53

KEB Automation KG

Südstraße 38 • 32683 Barntrup fon: +49 5263 401-0 • fax: +49 5263 401-116 net: www.keb.de

• mail: [email protected]

KEB worldwide…

KEB Automation GmbH

Ritzstraße 8 • 4614 Marchtrenk fon: +43 7243 53586-0 • fax: +43 7243 53586-21 net: www.keb.at

• mail: [email protected]

KEB Automation KG

Herenveld 2 • 9500 Geraadsbergen fon: +32 5443 7860 • fax: +32 5443 7898 mail: [email protected]

KEB Power Transmission Technology (Shanghai) Co.,Ltd.

No. 435 Qianpu Road, Chedun Town, Songjiang District,

Shanghai 201611, P.R. China fon: +86 21 37746688 • fax: +86 21 37746600 net: www.keb.de

• mail: [email protected]

KEB Automation GmbH

Organizační složka

Suchovrbenske nam. 2724/4 • 370 06 České Budějovice fon: +420 387 699 111 • fax: +420 387 699 119 mail: [email protected]

KEB Antriebstechnik GmbH

Wildbacher Str. 5 • 08289 Schneeberg fon: +49 3772 67-0 • fax: +49 3772 67-281 mail: [email protected]

KEB Espa ñ a

C/ Mitjer, Nave 8 - Pol. Ind. LA MASIA

08798 Sant Cugat Sesgarrigues (Barcelona) fon: +34 93 897 0268 • fax: +34 93 899 2035 mail: [email protected]

Société Française KEB

Z.I. de la Croix St. Nicolas • 14, rue Gustave Eiffel

94510 LA QUEUE EN BRIE fon: +33 1 49620101 • fax: +33 1 45767495 net: www.keb.fr

• mail: [email protected]

KEB (UK) Ltd.

Morris Close, Park Farm Industrial Estate

Wellingborough, NN8 6 XF fon: +44 1933 402220 • fax: +44 1933 400724 net: www.keb.co.uk

• mail: [email protected]

KEB Italia S.r.l.

Via Newton, 2 • 20019 Settimo Milanese (Milano) fon: +39 02 3353531 • fax: +39 02 33500790 net: www.keb.de

• mail: [email protected]

KEB Japan Ltd.

15–16, 2–Chome, Takanawa Minato-ku

Tokyo 108-0074 fon: +81 33 445-8515 • fax: +81 33 445-8215 mail: [email protected]

KEB Korea Seoul

Room 1709, 415 Missy 2000

725 Su Seo Dong, Gang Nam Gu

135-757 Seoul/South Korea fon: +82 2 6253 6771 • fax: +82 2 6253 6770 mail: [email protected]

KEB RUS Ltd.

Lesnaya Str. House 30, Dzerzhinsky (MO)

140091 Moscow region fon: +7 495 632 0217 • fax: +7 495 632 0217 net: www.keb.ru

• mail: [email protected]

KEB America, Inc.

5100 Valley Industrial Blvd. South

Shakopee, MN 55379 fon: +1 952 224-1400 • fax: +1 952 224-1499 net: www.kebamerica.com

• mail: [email protected]

More and latest addresses at http://www.keb.de

Mat.No. 00R6SDB-KE00

Rev. 1P

Date 07/2018

Table of Contents

1.1 Preface

1.2 Product description

1.3 Validity and liability

1.4 Copyright

1.5 Specified application

1.6 Unit identification

2.1 General instructions

2.2 Transport, storage and installation

2.3 Electrical connection

2.4 EMC instructions

2.5 EMC conform installation

3.1 Standard unit size

3.3 Overload (OL) function

3.4 Operating conditions

3.5 Accessories

3.6 Options

3.7 Dimensions and weights

4.1 EMC-compatible control cabinet installation

4.2 Installation instructions

4.3 Connection of the COMBIVERT R6

4.4 Connection Power Unit R6-S

4.5 Connection of the control board version S

4.6 Operator

5.1 Operation with PC und system software COMBIVIS

5.2 Switch-on procedure

5.3 Parameter summary

5.4 Monitoring and analysis parameters

5.5 Special adjustments

A.1 Dimensioning power supply and regenerative units

A.2 DC link capacitors of KEB frequency inverters

A.3 Decoupling diodes

B.1 Certification

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