KEB R6-S Housing R v2 Installation Manual
Below you will find brief information for R6 25R6S3R-xxxx. This unit converts three-phase AC to DC, supplying KEB frequency inverters or DC interconnections. In regenerative mode, it refeeds excess energy into the supply system, replacing braking resistors, reducing heat loss, and improving energy balance. It is environmentally friendly and space-saving.
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CO M B I V E RT
Instruction Manual
Type R6-S
Power Supply and Regenerative Unit
Type 25R6S3R-xxxx
Translation of the original manual
Document Part Version
20311834 ENG 00
Table of Contents
Table of contents
4.4.1 Power supply and regenrative operation at inverter current ≤ inverter current of one
4.5.1 Power supply and regenrative operation at inverter current ≤ inverter current of one
GB - 3
Table of Contents
List of Figures
Radio interference filter 24E6T60-3000 (side-mounted) .........................................23
Radio interference filter 25E4T60-1001 (side-mounted) .........................................24
General description of input terminals at KEB inverter ...........................................29
Description of the input terminals of the COMBIVERT R6 ......................................30
RJ45 socket for phase synchronization and temperature sensor ...........................33
Dimensioning power supply and regenerative units ...............................................50
GB - 4
Introduction
1. Introduction
1.1 Preface
First we would like to welcome you as a customer of the KEB Automation KG and congratulation to the purchase of this product. You have decided for a product on highest technical niveau.
The enclosed documents as well as the indicated hardware and software are developments of the KEB Automation KG. Errors excepted. KEB Automation KG has created these documents and the hardware and software to the best of knowledge, but they assume no liability that the specifications will provide the benefits sought by the user. KEB Automation KG re serves the right to change specifications without prior notice or to inform third parties. This list is not exhaustive.
The used pictograms have following significance:
Danger
Warning
Caution
Notice absolutely observe
Information
Help
Tip
1.2 Product description
This instruction manual describes the power supply and regenerative unit KEB COMBIVERT
R6-S. The COMBIVERT R6-S has the following features.
In power supply operation
• converts a three-phase input voltage into DC voltage.
• supplies single KEB frequency inverter or via DC interconnection.
• can be parallel connected if higher power supply is required.
In regenerative operation
• refeeds excess energy from regenerative operation into the supply system.
• replaces braking resistor and braking transistor.
• reduces the heat loss dissipation compared to the braking resistor
• improves the energy balance
• is environmentally friendly and space-saving.
• is economical.
GB - 5
Introduction
The COMBIVERT R6-S is generally protected against overcurrent, ground fault and temperature. The internal DC fuses protect the DC circuit against short-circuit to the line side. The following accessories are necessary for operation with the COMBIVERT R6-S:
• Mains choke
• HF filter (for observance of EMC standard)
Interface communication
Connection synchronization (net work coverage)
Control
Power unit
K2
X1B L1
X1C L1
X1A L12
X1A L22
X1A L32
A
A
A
X1C L2
X1B L2
K2
Figure 1: Block diagram of the COMBIVERT R6S
+
V
I / O
X1A ++
X1C Fo.1
X1C Fo.2
X1A --
GB - 6
Introduction
1.3 Validity and liability
Application and use of our units in the target products is outside of our control and therefore exclusively in the area of responsibility of the machine manufacturer.
The information contained in the technical documentation, as well as any user-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 responsibility. This also applies to any violation of industrial property rights of a third-party.
Selection of our units in view of their suitability for the intended use must be done generally by the user.
Inspections and tests can only be done by the machine manufacturer within the framework of the application. Inspections and tests must be repeated, even if only parts of hardware, software or the unit adjustment are modified.
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 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 corresponding text, which is valid and equivalent to the intended meaning. The rest of the agreement shall remain unaffected and valid.
1.4 Copyright
The customer may 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 the 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.
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 devices.
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.
GB - 7
Introduction
All control card outputs of the R6 are "one-channel, no diagnostic coverage and therefore not safe“ according to ISO 13849. If required, additional protective measures must be met by the user.
1.5.1 Standard operation
Generally the power supply and regenerative unit is a DC supply. If the DC voltage increases to a value above the peak value of the mains voltage, regeneration of the current into the mains occurs automatically. The regenerative level can be defined with parameter CP.34 or cS.02. The mains voltage is analog measured. Regeneration occurs by square-wave current curve which corresponds in phase position to the current flow period of a B6 bridge circuit.
Regeneration is completed if the regenerative and puls off level (CP.32 or cS.06) is fallen below.
1.5.2 Abnormal operation
When exceeding the permissible limit values for voltage, current or temperature the current flow between DC link and mains is blocked during regeneration. An appropriate error mes sage is also displayed during supply. The device 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 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 - 8
Introduction
1.6 Device identification
2 5 . R 6 . S 3 R - 9 0 0 A
Type
Design reserved
Voltage
Housing
Options
Control
Series
Device size
A: Standard
D. ext. fan power supply
H: Water cooling
0: Standard
0: Standard
9: 3-ph.; 400 V; AC
R
3: Precharging, DC fuses
S: 2B.R6
R6
25
1: modified standard
GB - 9
Safety Instructions
2. Safety Instructions
2.1 General instructions
Electric
Shock
COMBIVERT R6 power supply and regenerative units contain dangerous voltages 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 exist in the unit after switching off the supply sys tem.
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 elec tro-personnel
All work from the transport, to installation and start-up as well as maintenance may only be done by qualified personnel (IEC 364 and/or CENELEC HD 384 and IEC-Report 664 and note national safety regulations). According to this manual qualified 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.
Observe standards
The COMBIVERT R6 must not be started until it is determined that the installation complies with the Machine directive (2006/42/EC) (note EN 60204).
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 influence. Observe the marking on the final packing! After removing the final packing the COMBIVERT must be shut down on a stable base.
GB - 10
Safety Instructions
Protect against 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 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.
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 device can be worked on again, after it has been switched off for 5 minutes.
Safe 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 requirements are met. For devices without safe isolation from the supply circuit, all control lines must be included in further protective measures (e.g. double insulated or shielded, earthed and insulated).
Voltage with respect to ground
The connection of COMBIVERT R6 is allowed to:
Symmetrical mains with a phase voltage (L1, L2, L3) to neutral conductor / earth (N/PE) of max. 305 V.
Fixed
Connection
The COMBIVERT R6 is designed for fixed connection, since discharge currents of > 3.5 mA occur especially when using together with EMI filters. Therefore, the requirements or instructions from EN 60204-1 (VDE 0113) and EN 61800-
5-1 (IEC 0160-5-1) must be observed.
GB - 11
Safety Instructions
Insulation measurement
When doing an insulation or voltage measurement in accordance with in
EN 60204-1 / VDE 0113-1, the power semiconductor of the unit and existing radio interference filters must be disconnected because of the danger of de struction. 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.
Prevent interferences
A trouble-free and safe operation of the COMBIVERT R6 is only guaranteed when the connection instructions below are strictly followed. Incorrect operation or damage may result from incorrect installation:
• Pay attention to 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 connection to mains earth. (avoid earth loops)
• Use exclusively the line commutation throttle specified by KEB.
• The maximum DC current of the R6-S must not be exceeded.
• If several drive controllers are connected to the COMVIBERT R6-S, the max. permissible DC link capacities of all connected drive controllers must be considered (see technical data).
Automatic restart of operation
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 features added where necessary.
GB - 12
Safety Instructions
Conditionally short-circuit proof
The COMBIVERT R6 is conditionally short-circuit proof (VDE 0160). The in tended function is guaranteed after resetting the internal protection devices.
Exception:
• If earth or short circuits often occurs at the output during regenerative operation, this can lead to a defect in the device.
• If earth fault or short circuits occur in during supply operation, semi-conductor protection is only limited.
Cyclic activation and deactivation
With applications requiring the COMBIVERT R6 to be switched on and off cy clically, 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 undefined conditions.
RCD (residual current operated circuit-breaker)
When using systems with RCD, the instructions or the requirements of
VDE 0100 -T 530 (IEC 60364-5) must be observed. The recommended tripping current of the 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 commercial units.
According to the EMC Directive 2014/30/EU, these devices are components for further processing within the meaning of the Directive that are operated by competent machine and system manufacturers and are not independently operable.
The person installing / operating the machine / unit is obliged to prove the protective measures demanded by the EMC directive are complied with. The prescribed ratings can usually be complied with when using the radio interference voltage filters 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 noise, separate supply lines, DC lines, motor lines, control and data lines (low-voltage level < 48 V) 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 met al-to-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 mounting 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 synchronisation between the mains choke and the COMBIVERT R6-S must not exceed a length of 1 m..
• Further information can be found in the internet, see "www.keb.de“.
GB - 14
Technical Data
3. Technical Data
Device size
Housing size
Phases
Permitted mains forms
Rated voltage
Mains voltage range
Mains frequency
DC voltage range
Regenerative operation
Rated apparent output power
Rated active power
Max. power output
Max. active power
Rated regenerative current
Regenerative DC current
Overload current (E.OL) 60 s
5)
[Hz]
[V
[V]
[V]
DC
Sn [kVA]
[kW]
[kVA]
[kW]
*)
1) [A
[A]
2)
[A
DC
[A]
DC
]
]
Max. DC regenerative current 60 s
Power supply operation
Rated input power
Rated active power
Max. input power
Max. active power
Rated supply current
DC supply current
Overload current (E.OL) 60s
Max. DC supply current 60s
Overload disconnection (E.OL)
Overvoltage switch-off (E.OP)
Rated output voltage
Max. permissible DC link capacity 4)
Max. permissible total load current at precharging (I_
LSF)
I 2 t Integral of the limiting load of the semiconductor
Max. permissible mains fuse type gR / aR
Sn [kVA]
[kW]
[kVA]
[kW]
*), 3) [A]
1) [A
DC
]
[A
AC
]
[A 2 s]
[A]
[A
[A]
DC
]
[V
[%]
[V
DC
DC
[mF]
]
]
]
25
R
3
TN, TT
400
305…528
50 / 60 ±2
420…747
153
140
230
210
221 (184)
270
331
405
153
140
230
210
221 (184)
270
331
405
160
840
540
50 (400 V class) 35 (480 V class)
≤4
39000
*)
1)
2)
Permissible mains fuse (no delta power system)
Permissible mains fuse (no delta power system) for UL
Max. permissible DC fuse Bussmann Type aR
Short-circuit factor at the connection point (S kn
Power dissipation at rated operation
Max. heat sink temperature
3)
4)
/S n
) or (S scp
/S n
[W]
[°C]
)
315
Siemens 3NE8731 /
Eaton Bussmann 170M1372 or 170M1422
Ferraz Shawmut HSJ300, rated 300A / 600Vac see options
15 < S kn
“ / S n
< 350
1300
88
The values in brackets must be observed when UL approval is required!
Lay two connection cables parallel at supply and regenerative current > 230 A DC.
The overload current is specified for 1 minute. The overload cycle is 300 seconds. This corresponds to duty class 2
EN 2-60146-1.
The current data are based on a fundamental frequency component of g=0.95. The fundamental frequency 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.
Please contact KEB for higher values.
GB - 15
Technical Data
5) IT and delta power systems after consultation KEB.
Voltage stabilization must be activated at the inverter connected to the DC circuit if a harmonic filter (OSF) is used.
Exceeding of the max. rechargeable DC link capacity can lead to a defect.
A load draw from the DC circuit 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 load must be disconnected in case of overcurrent or overload.
The device must be disconnected from the mains supply if a mains fuse has triggered.
3.1 Overload (OL) function
Release time [s]
150
100
60
270
250
200
105 110 120
Figure 2: Overload (OL) function
130 140 150 160
Load [%]
GB - 16
Technical Data
3.2 Operating conditions
Standard Standard/ class
Instructions
EN 61800-2 Inverter product standard:
Definition according to
Site altitude
EN 61800-5-1
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 consideration)
Ambient conditions during operation
Climate Temperature
Mechanical
Humidity
Vibration
EN 60721-3-3
3K3
3K3
3M4 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) max. acceleration amplitude 7 m/s²
(13…200 Hz)
Contamination
Gas
Solids
Ambient conditions during transport
3C2
3S2
Mechanical
Vibration
EN 60721-3-2
Contamination
Surge
Gas
Solids
Ambient conditions for the storage
Mechanical
Contamination
Vibration
Type of protection
Environment
Overvoltage category
Definition according to
Surge
Gas
Solids
EN 60721-3-1
EN 60529
IEC 664-1
EN 618005-1
EN 61800-3
EMC emitted interference
Conducted interference emisEN 55011 sion
Radiated interferences EN55011
Interference immunity
Static discharges EN 61000-4-2
Burst - control lines + bus EN 61000-4-4
Burst - mains supply EN 61000-4-4
2K3
2K3
2M1
2M1
2C2
2S2
1K4
1K3
1M2
1M2
1C2
1S2
IP20
Class III
C2
C2
8 kV
2 kV
Conducted immunity, induced by high-frequency fields
Electromagnetic fields EN 61000-4-3 10 V/m
(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
(without condensation) max. vibration amplitude 1.5 mm (2…9 Hz) max. acceleration amplitude 5 m/s² (9...200 Hz) max. 40 m/s²; 22 ms
Pollution degree 2
Inverter product standard: with EMC filter and ferrit
EMC with EMC filter and ferrit upto 100 m line length
AD (air discharge) and CD (contact discharge)
4 kV
Surge - mains supply EN 61000-4-5 1 / 2 kV Phase-phase / phase-ground
EN 61000-4-6 10 V 0.15-80 MHz continued on the next page
GB - 17
Technical Data
Standard Standard/ class
Instructions
Voltage variation/ voltage drops EN 61000-2-1
Voltage unsymmetries / frequency changes EN 61000-2-4
3.3 Accessories
Device size
Rated voltage
Commutation reactor
Synchronisation unit
Sync cable
+10 %, -15 %; 90 %
3 %; 2 %
25
400 V
25Z1B04-1000
00R6940-2407
Control cabinet installation; max. distance to the power supply and regenerative unit 1m
00F50C3-4010
Length 1 m for connection of the synchronization unit with R6 regenerative unit
GB - 18
Technical Data
3.4 Options
Device size
HF radio interference filter (EMC)
25
For an ED of max. 82 % -> 24E6T60-3000
For an ED of 100 % -> 25E4T60-1001 in accordance with EN 61800-3
C2 (only with ferrite rings and motor cable lengths < 100m)
C1 (after consultation with KEB)
690V / 400A Mat.No. 009025H-4651 DC fuses
Micro switch for fuse
009025H-4651
Fuse holder for NH00 and NH000 fuses
0090278-0001
0090574-0001
Harmonic filter
(no UL certification)
Harmonic filter
(with UL certification)
25Z1C04-1000 2)
Please contact KEB for data to the THD value at regenerative operation in accordance with EN 61800-2-12.
Compliance with the IEEE519 requirements at a 480V / 60Hz mains is possible with the following harmonic filter:
22Z1C05-1000, 23Z1C05-1000, 24Z1C05-1000,
25Z1C05-1000
Digital operator, interface operator Operators
Bus operators
CAN ® , ProfiBus ® , INTERBUS ® , EtherCAT ® , Ethernet ® , Sercos,
ModBus, PROFINET ® 3) , LCD, Devicenet, HSP5
1) The ON time ED refers to the regenerative unit R6-S
2)
Depending on the load, the following harmonic filters are also possible with the techni cal data given therein:20Z1C04-1000, 21Z1C04-1000, 22Z1C04-1000, 23Z1C04-1000,
24Z1C04-1000
3) ProfiNet from operator firmware V3.4 of 30.01.2015
CANopen® is a registered trademark of the CAN in AUTOMATION - International Users and Manufacturers
Group e.V
INTERBUS® is a registered trademark of Phoenix Contact GmbH & Co. KG.
EtherCAT® is a registered trademark and patented technology licensed by Beckhoff Automation GmbH, Ger many
Industrial Ethernet® is a registered trademark of Siemens AG
PROFBUS® is a registered trademark of Siemens AG
PROFINET® is a registered trademark of Siemens AG
GB - 19
Technical Data
3.4.1 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 inverter. The conductors must passed through the ferrite core for the use as current-compensated choke. PE is passed outside the core. 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 - 20
3.5 Dimensions and weights
3.5.1 Dimensions air cooler built-in version
Dimensions and weights
357
300
11
Weight: 25 kg
Figure 3: COMBIVERT R6 with fan heat sink
GB - 21
Dimensions and weights
3.5.2 Commutation reactor / mains choke
PE
316
10
153
222
200
292 d
Mat.-Number
Inductance
[mH]
25Z1B04-1000 0.133
Type and cross-section of the terminals
I
N
[A]
221
PE d
M12 Stud for ring crimp connector
Ø8 Hole for screw M8
Figure 4: Mains choke
P
V
[W]
265
Frequency
[Hz]
Weight
[kg]
45…65 30
Maximum tightening torque
25 Nm 200 lb inch
GB - 22
3.5.3 Radio interference filter (side-mounted)
Dimensions and weights
200
150
PE L3 L2
Input
L1
PE L3 `
Output
L2 ` L1 `
11
Mat.-Number
U
N
[V]
24E6T60-3000 3x480
I
N
[A]
200
P
V
[W]
100
Type and cross-section of the terminals/-cable
PE
M10 stud for ring crimp connector
Terminals L1,
L2, L3, f
N
[Hz]
50 / 60 ± 2
Weight
[kg]
9.2
Maximum tightening torque
35 Nm / 310 lb inch
L1´,L2´,L3´
35...95 mm² /
AWG 4...AWG 4/0
15 Nm / 133 Ib inch
Figure 5: Radio interference filter 24E6T60-3000 (side-mounted)
GB - 23
Dimensions and weights
PE Stud M10
500
80
110
1000
574
598
630
Mat.-Number
U
[V]
25E4T60-1001 3x480
I
N
[A]
250
P
V
[W]
50
Type and cross-section of the terminals/-cable
PE
Connection cable
M10 stud for ring crimp connector each 3 x 70 mm² (AWG 2/0) f
[Hz]
50/60
Weight
[kg]
16
Maximum tightening torque
37 Nm
Figure 6: Radio interference filter 25E4T60-1001 (side-mounted)
320 lb inch
GB - 24
Dimensions and weights
3.5.4 Synchronisation unit
100
135
153
A
6
M6
9
R2,9
A (1 : 1)
49,5
R4,25
13
105,5
65,5
20 80 45,5
8
81
171
15
Part number Weight Terminal
PE
00R6940-2407 0.65 kg
Figure 7: Synchronisation unit
Connection
M6 stud for ring crimp connector
Cable length
-
240 mm
Max. tightening torque
4.5 Nm /
40 Ib inch
-
GB - 25
Dimensions and weights
3.5.5 Fuse holder with cover
GB - 26
Part number: 0090574-0001
Figure 8: Fuse holder
A
Dimensions:
4,96" 126 mm
B1 1,57" 40 mm
F
G
H
D
E
B2 1,34" 34 mm
C 0,5" 13 mm
0,75" 19 mm
3,15" 80 mm
0,12" 3 mm
1,81 " 46 mm
2,91" 74 mm
I
J
0,26" 6,5 mm
0,6" 15,5 mm
K 0,63" 16 mm
L 1 5,75" 146 mm
L2 6,5" 165 mm
M M8
N 0,98" 25 mm
Installation
4. Installation
4.1 EMC-compatible control cabinet installation
1
2
3
4
5
Mains fuse
Main contactor
EMC side mount filter
(≥ size 25 R-S or R6-N)
EMC back mount filter
(≤ size 19 R6-S)
If necessary, external voltage limitation / synchronisation
Commutation reactor / harmonic filter
6
7
COMBIVERT R6
If necessary, external DC fuses
8 Drive controller
9a DC cables with ferrite
9b Motor cable with ferrite
10a Protective Earth (PE) on the mounting plate control circuit
10b Protective Earth (PE) on the mounting plate power circuit
10c Equipotential bonding with the housing earth
11 Mains connection power circuit
11a Mains connection control circuit
12 Control lines
12
11a
10a
2
1
11
Control circuit
150 mm
3
5
4
150 mm
10b
Power circuit
Large area contact at the mounting plate
Figure 9: EMC-compatible control cabinet installation
150 mm
6
10c
150 mm
7 9a
8
9b
30 mm
Direction of the cooling fins
4.2 Installation instructions
• Stationary 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.
• For EMC reasons, the cables between R6 and commutating reactor/harmonic filter must be limited to < 1m or shielding must be used..
• The inverters must be placed in the immediate vicinity of the R6-S.
GB - 27
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 integrated into the DC bus by way that the supply unit(s) limit the starting current.
The precharging must be completed within ten seconds.10
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 (rectifier module or inverter with AC input) must be suitable for this value.
Terminals Description of terminals at KEB inverters
++, -DC voltage input with starting current limiting; usable as output only if all devices supplied by the DC bus have a starting current limiting at the DC voltage input.
+(PA), -
PA, PB
L1, L2, L3
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 - 28
Connection of the COMBIVERT R6
Type A1: AC/DC inverter Type B1: AC inverter
+PA
Type C1: DC inverter
L1
L2
L3
+
++
-
++
L1
L2
L3
+ or also type D1
+
+PA --
--
L1
L2
L3
+
L1
L2
L3
Type A2: AC/DC inverter
++
+
Type B2: AC inverter
-
+PA
Type C2: DC inverter
++
L1
L2
L3
+
+
--
-
--
This type can be supplied by mains and by DC circuit.
The starting current limitation 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 inverter with starting current limiting. The DC inverter can be combined with all other types in consideration of the maximum DC link capacity.
Figure 10: General description of input terminals at KEB inverter
GB - 29
Connection of the COMBIVERT R6
4.3.2 Connection terminals of the power circuit
All terminal strips meet the requirements on EN 60947-7-1 (IEC 60947-7-1)
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.
Equivalent circuit diagram for R6-S in E housing
++
Equivalent circuit diagram for R6-S in R
X1B L1
X1C L1 housing with internal DC-fuse
I_LSF
++
L1.2
L2.2
L3.2
+
L1.2
L2.2
L3.2
+
X1C L2
X1B L2 --
--
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 11: Description of the input terminals of the COMBIVERT R6
GB - 30
Connection of the COMBIVERT R6
X1C
X1A
+ +
Fo.1 Fo.2
L1 L2
- -
L1.2 L2.2
L3.2
Terminal
X1A
X1C
PE
Name Function
L1.2, L2.2, L3.2 3-phase mains connection to the commutation throttle
DC voltage output with starting current limiting; Connection for
++, --
L1, L2
1) Min. 20 V / 30 mA the inverter, the connection terminals are each internally connected in parallel.
Fo.1, Fo.2
NC contact for safety monitoring (250 Vac /2 A, 24 Vdc / 0.4 A 1) )
Precharging
Connection for shielding /earthing
Type and cross-section of the terminals
Conductor cross-section
[mm²] min
35 max
95
Tightening torque
Nm
15...20
lb inch
175 Screw terminals (6mm internal hexagon)
Screw terminals Fo.1, Fo.2,
L1, L2 (slit)
Stud M10
0.5
Stud for ring crimp connector 10 mm
Figure 12: Connection terminals of the power circuit
16 1.5...1.8
11...20
15...25 133...220
Unused terminals must be tightened with the preset torque!
Mains potential may be at terminals X1A, X1B or X1C (see the following chap ter)!
GB - 31
Connection of the COMBIVERT R6
4.3.3 Connections of the control board
X4B
GB - 32
X2B
X1B
X2C X2A.10...23
X2A.24...29
Terminal Function
X1B
Connection mains contactor
(AC15: 6A 230V AC / DC13: 6A
24V DC) and precharging
Mains voltage potential !
X2B Connection for synchronization line
X2C Activation of the mains contactor self-holding
X4B HSP5 operator interface No direct PC connection
X2A Control terminal strip ly !
Install control and mains cable separate-
Terminal
X1B
X2A
X2C
Conductor cross-section [mm²] min
0.2
0.14
0.14
max
6
1.5
1.5
Tightening torque
Nm
0.7...0.8
0.22...0.25
0.22...0.25
Figure 13: Connection terminals of the control board
Ib inch
7
1.9...2.2
1.9...2.2
Connection of the COMBIVERT R6
Unused terminals must be tightened with the preset torque!
For UL approval the following values should be observed for X1B:
X1B: 230 Vac 2 A
X2A: 23...30 Vdc 0.01...2 A
Precharging must be carried out via the terminal X1C!
4.3.4 Connection of the synchronization unit
RJ45 socket for phase synchronization and temperature sensor
No.
1
X2B
8
X2B.1
X2B.2
Name Function t1 Connection for temperature sent2 sor (option)
X2B.3
U13_syn Synchronization phase 1 / 3
X2B.4
– reserved
X2B.5
U21_syn Synchronization phase 2 / 1
X2B.6
– reserved
X2B.7
U32_syn Synchronization phase 3 / 2
X2B.8
– reserved
Figure 14: RJ45 socket for phase synchronization and temperature sensor
GB - 33
Connection power unit R6-S without UL
4.4 Connection power unit R6-S without UL
4.4.1 Power supply and regenrative operation at inverter current ≤ inverter current of one
COMBIVERT R6-S without UL
L1
L2
L3
24VDC
Control voltage
F1
Sync
S1
13
14
F3 F2 F2 K1
2
1 3
4
5
6
K0
13
14
1
2
3
4
L1
L2
L3
EMC
L1'
L2'
L3'
L1.1
L2.1
L3.1
Z1
L1.2
L2.2
L3.2
K0
23
24
S2
13
14
21
K1
22
T1
L1 L2 K2 K2
X1B
13 14
L1 L2
X1C
L1.2 L2.2 L3.2
X1A
12 17 18 24 26
X2A
ST Uout COM RLA RLB
25R6S3R -xxxx
24 25
X2C X2B
GB - 34
X1C
Fo1 Fo2
X1A
++ -PE
F4
F4
Ferrite
XX
ST
0V
XX
FC
U
V
W
PE
Ferrite
M
S3
13
14
K0 K1
GND
24V GND
1
3
13 14
23 24
2
4
1
3
2
4
5 6
21 22
F1 Mains fuses type aR/gR
F2 10 A fuse gG/gL or automat characteristic K
F3 10 A fuse gG/gL
F4 DC fuses type aR/gR
(optional)
S1/K0 Power on/off
S2/S3 External control release
The cable cross section as well as the DC fuses must be dimensioned to the
DC rated current of the load (see technical data of the inverter).
K1 Line contactor with auxiliary contacts continued on the next page
Connection power unit R6-S without UL
Sync Synchronization unit (max. length of the phase lines 1 m)
Z1 Commutation reactor / harmonic filter t1 Regenerative unit COMBIVERT R6-S
X1A Power circuit terminals
X1B Connection for line contactor and precharging
X1C Connection for DC fuse monitoring
X2A Control terminal strip (X2A.12: control release; X2A.17: voltage output)
X2B Connection for synchronization line
X2C Activation of the self-holding of the load shunt relay
EMC EMC filter
M Motor
FC Drive controller
K0 Switch on relay (400V / 12A AC3)
Ferrite (optional)
Figure 15: Power supply and regenrative operation at inverter current ≤ inverter current of one COMBIVERT R6-S
NOTICE
Destruction of the regenerative unit!
► A load draw may be done only if relay 1 is active.
► In case of failure disconnect the line contactor with S1/K1 from the supply system.
GB - 35
Connection power unit R6-S with UL
4.5 Connection power unit R6-S with UL
4.5.1 Power supply and regenrative operation at inverter current ≤ inverter current of one
COMBIVERT R6-S with UL
L1
L2
L3
24VDC
Control voltage
F1
Sync
S1
13
14
F3 F2 F2
1
K1
2
3
4
5
6
K0
13
K2
14 2
1 3
4
L1
L2
L3
EMC
L1'
L2'
L3'
L1.1
L2.1
L3.1
Z1
L1.2
L2.2
L3.2
K0
23
24
S2
13
14
T1
L1 L2
X1B
K2 K2 L1 L2
X1C
L1.2 L2.2 L3.2
X1A
12 17 18
X2A
24 26 24 25
X2C
ST Uout COM RLA RLB
25R6S3R -xxxx
X2B
GB - 36
X1C
Fo1 Fo2
X1A
++ -PE
F4
F4
S3
13
14
Ferrite
XX
ST
0V
XX
FC
U
V
W
PE
Ferrite
M
K2
21
K1
22
K0 K1
GND
24V GND
13 14
23 24
1
3
2
4
5 6
21 22
1
3
2
4
F1 Mains fuses type aR/gR
F2 10 A fuse gG/gL or automat characteristic K
F3 10 A fuse gG/gL
F4 DC fuses type aR/gR
(optional)
S1/K0 Power on/off
S2/S3 External control release
The conductor cross-section as well as the DC fuses must be dimensioned to the DC rated current of the load (see technical data of the inverter).
K1 Mains contactor with auxiliary contacts continued on the next page
Connection power unit R6-S with UL
K2 Pre-charging contactor (400 V / 12 A AC3)
Sync Synchronization unit (max. length of the phase lines 1 m)
Z1 Commutation reactor / harmonic filter t1 Regenerative unit COMBIVERT R6-S
X1A Power circuit terminals
X1B Connection for mains contactor
X1C Connection for precharging and DC fuse monitoring
X2A Control terminal strip (X2A.12: control release; X2A.17: voltage output)
X2B Connection for synchronization line
X2C Activation of the self-holding of the load shunt relay
EMC EMC filter
M Motor
FC Drive controller
K0 Switch on relay
Ferrite (optional)
Figure 16: Power supply and regenrative operation at inverter current ≤ inverter current of one COMBIVERT R6-S
NOTICE
Destruction of the regenerative unit!
► A load draw may be done only if relay 1 is active.
► In case of failure disconnect the line contactor with S1/K1 from the supply system.
4.5.2 Regenerative power supply in parallel operation with a drive controller
More information and a detailed wiring diagram can be found under the following link: https://www.keb.de/fileadmin/media/Techinfo/dr/tn/01_inverter_servo/ti_wiring_r6s_diode_ fu_0501_0001_deu.pdf
4.5.3 Power supply and regenerative operation at parallel operation with a further regenerative unit
More information and a detailed wiring diagram can be found under the following link: https://www.keb.de/fileadmin/media/Techinfo/dr/tn/01_inverter_servo/ti_wiring_r6s_para_ r6s_0501_0002_deu.pdf
Parallel operation
When connecting in parallel operation, the parameter default set must be changed. See application instructions R6-S under "Special functions for parallel connection“.
GB - 37
Connection of the control board version S
4.6 Connection of the control board version S
4.6.1 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
15 Digital input 4
16 Digital input or output
17 24V output
18 Mass
19 Digital output 1
20 Digital output 2
21 Analog output
COM
ST
I1
I2
I3
I/O
(I4)
Uout
COM
O1
O2
ANOUT
Set selection programmable
Set selection programmable
Ext. error
Reference potential
Control release / reset programmable
Active signal (connection of all R6 in parallel operation in master-slave mode)
Voltage supply for in and
DC > 600 V
Error message outputs
Reference potential
Transistor output (DC >
CP.19)
Transistor output (error mes sage)
Difference to mains frequency
(CP.18) see terminal 17
Reference potential
22 24V output
23 Mass
24 Relay 1 / NO contact
Uout
COM
RLA Ready for operation (no error)
25 Relay 1 / NC contact RLB
26 Relay 1 / switching RLC contact
27 Relay 2 / NO con-
29 Relay 2 / switching contact
FLA DC > 600 V tact
28 Relay 2 / NC contact FLB
FLC
*) max. 1Aac is permissible for 125Vac.
Relay output
Ready signal (Status "Stb" or
"rEGEn")
Relay output (DC > CP.19)
Ri: 4.4 kΩ approx. 24 V / max. 100 mA
Imax: 25 mA
Imax: 25 mA
0…±10 V / max.
5 mA max. 30 V DC
0.01…2 A DC max. 30 V DC
0.01…2 A DC
*)
*)
GB - 38
Connection of the control board version S
4.6.2 Assignment of the socket X2B
RJ45 socket for phase synchronization and temperature sensor
No. Name Function
1 8
1
2 t1 Connection for temperature sent2 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 17: RJ45 socket
The connection is made with a sync cable 1:1 with the socket X2B, X2C or X2D on the commutating choke or synchronisation unit.
4.6.3 Assignment of the terminal block X2C
24 25 26
Conductor cross-section 0.14…1.5 mm², tightening torque 0.22...0.25 Nm
PIN Function
24 Bridge between pin
25 24 and pin 25
Description
Activation of the self-holding of the mains contactor
26 not assigned -
GB - 39
Connection of the control board version S
4.6.4 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
16
18 max. 25 mA DC per digital output
U
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
17
18
19
20
21
22
23
X2A
10
11
12
13
14
15
16
24
25
26
27
28
29
Figure 18: Wiring example R6-S
GB - 40
Operation of the Device
5. Operation of the Device
5.1 Operation with PC and 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 supply voltage. The power unit code is checked first. When 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 unit must be checked.
The COMBIVERT R6-S changes into synchronisation phase if a valid power unit is recognized. The following procedures take place one after another during this synchronisation phase:
• Check for correct synchronisation connection (if a synchronisation signal is missing, error
"E.nEt" is triggered)
• Checking the phase allocation of synchronous signals to the mains phases. If a phase is missing or a phase allocation error occurs, error "E.SYn" is triggered.
The current mains frequency and mains voltage are determined after successful synchronisation. The correct connection of the COMBIVERT R6-S is now ensured. If the control release (terminal ST) is set, the COMBIVERT R6-S now independently starts the intended 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 frequency 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 activated and the unit changes into regenerative operation. The regenerative unit is switched active, if regenerative operation is requested by an additional installed COMBIVERT R6-S in the system (master /slave operation).
GB - 41
Parameter summary
5.3 Parameter summary
The CP-Parameters are one of the parameter selection defined by KEB. You need an appli cation manual in order to get access to the entire parameters.
Display Parameter
CP.00 Password
CP.01 Inverter state
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 output current
CP.09 DC voltage
CP.10 Peak DC voltage
CP.11 Power module temperature
CP.12 OL counter display
CP.13 Active 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 0
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
0.1 A
1 %
1 %
Factory setting
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
±20.00
±30000.00 V
0…10
–
–
–
–
–
–
–
–
1.11
0801.7
0…3
100…120 %
0.1 A
1 V
1 V
1 °C
1 %
0.1 kW
–
–
–
–
–
–
0.1 kWh
0.1 kWh
0.1 kWh
0.1 kVA
1
–
–
–
–
–
–
0.01
1.00
An.33
0.01 V 600.00 V LE.00
3
–
– ru.82
ru.83
ru.84
ru.85
Pn.15
In.21
In.21
ru.15
ru.19
ru.20
ru.38
ru.39
ru.81
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1.11
0801.7
0.0…-1000.0 kW 0.1 kW -0.8 kW
1
1 %
0
103 %
In.21
In.21
In.21
In.21
In.21
In.21
In.06
In.07
cS.06
Pn.19
cS.02
based on
Ud.01
ru.00
ru.03
ru.08
ru.09
ru.10
ru.13
ru.14
GB - 42
Monitoring and analysis parameters
View of the work meter
The displayed values of the work meters only provide an estimated value due to measurement and calculation inaccuracies. These displayed values are not suitable for accounting purposes and cannot replace any measuring devices.
5.4 Monitoring and analysis parameters
The following parameters serve for the functional monitoring during operation.
No.
CP.01
Name
Inverter state
The status display shows the actual working condition of the COMBIVERT.
–
Status messages rEGEn Regeneration active (regenerative operation) r/w Enter based on
– ru.00
bbL noP nEtoF
Stb R6-S regenerative unit in stand-by operation (motor operation)
Error Messages
E.dOH
"ERROR! drive overheat“, temperature monitoring of the commutation reactor has triggered and the waiting time has expired.
E.EF
Count down of the base-block time, R6-S released
"no Operation“ control release not bridged, modulation switched off
Net off; regenerative operation is further possible, if the disconnecting time E.nEt
(Pn.14) > 0 s
E.FnEt
E.LSF
"ERROR! external fault“, error message by an external unit
"ERROR! Line frequency", the line frequency deviates more than 5 %. The max. mains frequency deviation can be adjusted in the application mode with CS.03.
ERROR! Charging circuit, load-shunt defective or wrong or input voltage too low.
This message is displayed for a short time during the power-on phase (no error message follows).
E.nEt
"ERROR! net", one or more phases are missing
E.nOH
no E. overheat pow.mod. overheat pow.mod. temperature not present (E.OH), 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 power module (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
E.Pu
"ERROR! power flicker det.“, mains interruption (phase) during the initialisation phase
"ERROR! power unit“, power unit code is missing, load shunt relay defective continued on the next page
GB - 43
Monitoring and analysis parameters
No.
Name
CP.01
Inverter state
E.Puci
"ERROR! Power unit code inv.“ power unit code is invalid
E.Puch
"ERROR! Power unit code changed“.
r/w Enter based on
– – ru.00
E.PuIn
"ERROR! Mains voltage“, ripple of rectified mains voltage too high
E.SYn
"ERROR! Synchronization“, Phase allocation at commutating reactor not correct
E.UP
"ERROR! Underpotential“, DC link voltage too low
No.
Name
CP.02
Actual line frequency r/w Enter based on
– – 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" state.
Resolution Meaning
0.01 Hz positive values = forward rotating field negative values = reverse 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 based on
–
–
–
–
–
–
Meaning
Display of the actual input current of the respective phase.
ru.08
ru.09
ru.10
No.
Name
CP.06
Act. DC utilization
Resolution
1 % r/w Enter based on
– – ru.13
Meaning
Independent whether power supply or regenerative operation, the display indicates the actual utilization of the COMBIVERT R6-S. 100 % correspond to the rated current of the COMBIVERT R6-S.
GB - 44
No.
Name
CP.07
peak DC utilization
Resolution r/w Enter based on
– – ru.14
Meaning
Parameter CP.07 enables to recognize short-term peak utilization with-
1 % 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 via bus by writing any value you like to the address of
CP.07. Switching off COMBIVERT R6-S also clears the memory.
Monitoring and analysis parameters
No.
Name
CP.08
DC current
Resolution Meaning
0.1 A r/w Enter based on
– –
Display of the calculated DC output current in amperes.
ru.15
No.
Name r/w Enter based on
CP.09
DC voltage
Resolution
1 V
– – 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 based on
– – ru.20
Parameter CP.10 enables to recognize voltage peaks within an operating 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 via 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 r/w Enter based on
– – ru.38
Meaning
Display of the actual power module temperature. On exceeding the
1 °C maximum power module temperature (see "Technical data") the mod ulation 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 % r/w Enter based on
– – ru.39
Meaning
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 - 45
Special adjustments
No.
Name
CP.13
Active power
Resolution
0.1 kW
Meaning r/w Enter based on
– – ru.81
CP.13 displays the actual power of the COMBIVERT R6-S. Motor power is displayed with positive values, generatoric power is displayed with negative values.
No.
Name
CP.14
Total regen
Resolution
1 kW r/w Enter based on
– – ru.82
Meaning
Counter for the regeneratoric electric work to mains.
No.
Name
CP.15
Total motor
Resolution
1 kW r/w Enter based on
– –
Meaning
Counter for the supplied electrical work from mains in kWh.
ru.83
No.
Name
CP.16
Total net
Resolution
1 kW r/w Enter based on
– – 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 based on
– – ru.85
Meaning
Display of the current apparent power at the mains input.
5.5 Special adjustments
The power supply and regenerative unit can be adapted to the application with the following parameters.
No.
CP.18
Name
ANOUT 1 gain r/w yes
Enter
– based on
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
GB - 46
Special adjustments
No.
Name
CP.18
ANOUT 1 gain
0…±20.00
1.00
r/w Enter yes – based on
An.33
The amplification to the desired output voltage can be adapted with CP.18. Max. possible: ±10 V.
No.
CP.19
Comparison level 0 output 2.
Name r/w yes
Enter
– based on
LE.00
This parameter determines the switching level for transistor output O1, as well as relay
Setting range
0…3200.00 V
Setting Meaning
The switching condition is fulfilled and the transistor
600.00 V output is set if the DC voltage level exceeds the adjusted 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
0
1…10 r/w Enter yes – based on
Pn.15
A general fault reset can be activated with this parameter. Attention, the machine manufacturer must observe appropriate protective measures for operating personnel and machine.
Setting Meaning
3
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 the terminal strip can be made.
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
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
– based on
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.
GB - 47
Special adjustments
No.
Name
CP.29
Software version
Value range
0.00…9.99
Meaning r/w Enter based on
– –
Display of the inverter software version number (e.g. 1,11).
In.06
No.
Name
CP.30
Software date
Value range
0…6553.5
Meaning r/w Enter based on
– –
Display of the inverter software date in the format "ddmm.y“.
In.07
No.
Name
CP.32
Puls off level r/w Enter yes – based on cS.06
Value range Standard Meaning
If the adjusted regenerative power is decreased, the COM-
0.0…-1000.0 kW -0.8 kW BIVERT R6-N switches the modulation off after turn-off de lay and changes into standby mode (display: "Stb“).
-
No.
CP.33
Name
Operating mode r/w Enter based on 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
0
Meaning
Master with commutation reactor
3
4
1
2
5
Master with harmonic filter
Slave with commutation reactor
Slave with harmonic filter
Master-Slave with commutation reactor input selection
Master-Slave with harmonic filter input selection
No.
Name
CP.34
Regeneration level
Value range r/w Enter based on yes – cS.02
Meaning
The feedbacklevel determines the starting value to energy regenera-
100…120 % tion. The adjusted value refers to the reference value of the DC voltage in percentage. The status changes from Standby "Stb“ to regeneration
"rEGEn“.
GB - 48
GB - 49
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)
T < 300 s no t1 > 60 s no
Calculate: ILM, ILMmax
Acquire:
PM, PMmax, t1, T, ηM, ηG, ηFI
Calculate:
ILG, ILGmax yes select higher unit or parallel connection of R6-S
(n • IDC, n • IDCmax)
IDCmax > ILGmax no yes yes select higher unit or parallel connection 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 connection of R6-S
IDCmax > ILGmax
(n • IDC, n • IDCmax) no
IDC > ILG yes no yes
IDC > ILG no
Regenerative unit capable yes
Power supply and regenerative unit capable t
PM
PMmax t1 n
Mechanical power
Max. mechanical power
Overload time
Last cycle
η M
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 19: Dimensioning power supply and regenerative units
GB - 50
Appendix A
A.2 DC link capacitors of KEB frequency inverters
19
20
21
15
16
17
18
Unit size
05
07
09
10
12
13
14
Frequency inverter COMBIVERT F5
200 V units
Capacity
780 µF
880 µF (940 µF*)
1080 µF
1080 µF
2220 µF
3280 µF
4100 µF
4100 µF
5040 µF
9900 µF
13200 µF
15600 µF
16500 µF
19800 µF
19
20
21
22
23
15
16
17
18
Unit size
05
07
09
10
12
13
14
400 V units
Capacity
180 µF
180 µF (300 µF*)
300 µF
345 µF
470 µF
580 µF
650 µF
24
25
26
27
28(P)/28(W)
29(P)/(W)
30
31
32-35
36
940 µF
1290 µF
1640 µF
1875 µF
2700 µF
3900 µF
4950 µF
4950 µF
6350 µF
8400 µF
9900 µF
11700 µF
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 respective power circuit manual.
GB - 51
Appendix A
Housing size
A
B
C
D
E
Housing size
2
4
Frequency inverter COMBIVERT G6
Unit size
10
12
7
9
13
Capacity / µF
135
195
235
470
560
14
15
16
16
17
13
14
15
13
18
19
680
750
680
840
1120
1035
1400
1985
Frequency inverter COMBIVERT S6
Unit size
10
12
7
9
13
Capacity / µF
195
1955
235
470
560
Precharging circuit
Type A1
Type A1
Type A1
Type A1
Type B1
Precharging circuit
Type A1
Type A1
When using G6 / S6 inverters ferrites must be used in each case at the input and output.
GB - 52
Appendix A
A.3 Decoupling diodes
Use decoupling diodes when using the R6 as regenerative unit only, to avoid that the connected 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
15
19
25
29
0090147-3500
0090147-4101
0090147-6009
0090147-6009
Type
1600 V / 80 A
1600 V / 120 A
1600 V / 560 A
1600 V / 560 A
Volume
2
2
2
2 x 2
Ta [°C]
45
45
45
45
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]
90
90
90
90
1.50
0.84
0.19
0.09
GB - 53
Appendix A
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)
GB - 54
Figure 20: Dimensions of the decoupling diodes
Appendix B
B. Appendix B
B.1 Certification
B.1.1 CE Marking
CE marked power supply and regenerative units were developed and manufactured to comply with the regulations of the Low-Voltage Directive 2014/3/5EU.
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 (2014/30/EU)(note EN
60204).
The power supply and regenerative units meet the requirements of the Low-Voltage Directive 2014/35/EU. The harmonized standards of the series EN 61800-5-1 in connection with
EN 60439-1 and EN 60146 were 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.
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.
To be conform according to UL for the use on the North American Market the following instructions 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 100kA rms Symmetrical
Amperes, 480 Volts Maximum“ and „When Protected by Fuses as listed below:
Feedback unit Cat. No.
Fuse
25.R6 (400 / 480 V) Type HSJ300 mfr. by Ferraz Shawmut, rated 300A/600Vac, high speed, UL listed NDB6-26
• Use 75°C Copper Conductors Only“
• Use in a Pollution Degree 2 environment
• Writing 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 of all 25.R6 units: 175 Ib-in (20 Nm)
GB - 55
KEB Automation KG
Südtraße 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.
© KEB
Part/Version DEU
Date
20311834
00
2022-07-12
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Key features
Three-phase AC to DC conversion
Regenerative operation for energy refeeding
Reduces heat loss compared to braking resistors
Improves energy efficiency
Compact and space-saving design
Frequently asked questions
It serves for the supply of frequency inverters with DC input and/or regeneration of excess energy into the supply system.
The device must be disconnected from the mains supply.
Excess energy from regenerative operation is refeeded into the supply system. It also replace braking resistor and braking transistor.