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CO M B I V E RT

INSTRUCTION MANUAL

Power Supply and Regenerative

Unit

Type R6-N

Size 15/19

Original manual
Document

Part

Version

20116581

ENG

Summary of Contents for Combivert R6

Page 1: ...COMBI VERT INSTRUCTION MANUAL Power Supply and Regenerative Unit Type R6 N Size 15 19 Original manual Document Part Version 20116581 ENG 02 ...

Page 2: ......

Page 3: ...nsions and weights 22 3 7 1 COMBIVERT R6 N 22 3 7 2 Commutation reactor 22 3 7 3 Radio interference filter 23 3 7 4 Fuse holder with cover 25 3 7 5 Ferrite rings 25 4 Installation 26 4 1 EMC compatible control cabinet installation 26 4 2 Installation instructions 26 4 3 Connection of the COMBIVERT R6 N 27 4 3 1 General description of inverter input terminals 27 4 3 2 Connection terminals of the R6...

Page 4: ...on of the Unit 41 5 1 Operation with PC and system software COMBIVIS 41 5 2 Switch on procedure 41 5 3 Parameter summary 42 5 4 Password input 43 5 5 Monitoring and analysis parameters 43 5 6 Special adjustments 46 A Annex A 50 A 1 Dimension of power supply and regenerative units 50 A 2 DC link capacities of KEB frequency inverters 51 A 3 Decoupling diodes 53 A 3 1 Assignment 53 A 3 2 Dimensions o...

Page 5: ...f the COMBIVERT R6 N 29 Figure 13 Terminals earth handle 30 Figure 14 Terminals for commutation reactor harmonic filter 30 Figure 15 Power supply and regenerative operation at inverter current current of one COMBIVERT R6 N 31 Figure 16 Power supply and regenerative operation at inverter currents inverter current 32 Figure 17 Power supply and regenerative operation at inverter current inverter curr...

Page 6: ...sed when noise sensitive or unrequested operation may be the consequence of non observance of the measure Info Is used when a better or simpler result can be the consequence of the measure For a special case the instructions can be supplemented by additional pictograms and text 1 2 Documentation Attention Documentation via www keb de Prior to performing any work on the unit it is absolutely necess...

Page 7: ... for the intended use must be done generally by the user Tests can only be done within the application by the machine manufacturer They must be repeated even if only parts of hardware software or the unit adjustment are mod ified Danger by tamper from unauthorized personnel Unauthorised opening and tampering may lead to death bodily injury prop erty damage and malfunctions Modification or repair i...

Page 8: ...cts If the KEB COMBIVERT F5 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 builder The operation of our products outside the indicated limit values of the technical data leads to the loss of any liability claims All ...

Page 9: ...T R6 N The COMBIVERT R6 N 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 while maintaining a base load 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 energ...

Page 10: ...Flat rear D ext fan power supply E Special fan Design 0 Standard reserved 0 Standard 1 modified standard increased overload Voltage 9 3 ph 180 550V AC Housing E Options 0 without 3 Precharging DC fuses 1 Precharging Control N 1N R6 Series R6 Inverter size 15 13 19 16 ...

Page 11: ... 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 Attention Observe stan...

Page 12: ...e is enough minimum clearance and enough cooling Climatic conditions must be observed in accordance with the instruction manual Warning 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 Danger Observe capacitor di...

Page 13: ...rents of 3 5 mA occur especially when using together with EMI filters Therefore the requirements or instruc tions from EN 60204 1 VDE 0113 and EN 61800 5 1 IEC 0160 5 1 must be observed Caution Insulation measurement When doing an insulation or voltage measurement in accordance with in EN60204 1 VDE0113 1 the power semiconductor of the unit and existing radio interference filters must be disconnec...

Page 14: ...ceed the maximum DC current If several frequency inverters are connected to the COMBIVERT R6 N the max permis sible DC link capacities of all connected frequency inverters must be considered during supply operation see technical data Warning Automatic restart The COMBIVERT R6 can be adjusted by such way that the inverter restarts automatically after an error case e g broken phase line System desig...

Page 15: ...u require shorter cycle times please contact KEB Switching off during the initialization phase can cause undefined conditions Attention RCD residual current operated circuit breaker When using systems with RCD the instructions or the requirements of VDE0100 T530 IEC 60364 5 must be observed The recommended tripping current of the RCD type B is 300mA 15 Safety Instructions ...

Page 16: ...ween 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 pla...

Page 17: ...r A2 s 1200 4500 Max permissible mains fuse type gR aR A 40 100 Permissible aR fuse Siemens Sitor Bussmann no delta power system 3NC2240 FWP 40A22FA 3NC2240 FWP 40A22FA Line fuse for UL type RK1 fast acting or J fast acting 50A 480V 50A 250V 90A 480V 90A 250V Short circuit factor at the connection point Skn Sn or Sscp Sn 20 Skn Sn 350 Power loss at nominal operating W 200 470 Max heat sink tempera...

Page 18: ... I2 t Integral of the limiting load of the semiconductor A2 s 3058 Max permissible mains fuse type gR aR A 100 Permissible aR fuse Siemens Sitor Bussmann no delta power system 3NC2240 FWP 40A22FA Line fuse for UL type RK1 fast acting or J fast acting 90A 480V 90A 250V Short circuit factor at the connection point Skn Sn or Sscp Sn 20 Skn Sn 350 Power dissipation at nominal operating W 430 Max heat ...

Page 19: ...rol 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 overcur rent or overload 3 3 Overload OL function Standard 105 110 120 130 140 150 160 100 150 200 250 270 60 Release time s Load Figure 1 Overload OL function Modified st...

Page 20: ...nt conditions during transport Climate Tempera ture EN60721 3 2 2K3 Humidity 2K3 without condensation Mechanical Vibration 2M1 max vibration amplitude 3 5mm 2 9Hz max acceleration amplitude 15m s 9 200Hz Surge 2M1 max 100m s 11ms Contamination Gas 2C2 Solids 2S2 Ambient conditions for the storage Climate Tempera ture EN60721 3 1 1K4 Humidity 1K3 without condensation Mechanical Vibration 1M1 max am...

Page 21: ... accordance with EN61800 3 C2 only with ferrite rings C1 on consultation with KEB Harmonic filter no UL certification 15Z1C04 1000 max overload 125 regenerative 150 motoric 19Z1C04 1000 max overload 140 regenerative 150 motoric 3 Please contact KEB for further sizes and data to the THD value at regenerative operation in accordance with EN61000 2 12 Harmonic filter with UL cer tification 17Z1C05 10...

Page 22: ... 14 7 275 5 6 kg C1 with operator Figure 3 Dimensions and weights for the COMBIVERT R6 N 3 7 2 Commutation reactor ØF B G C A H1 H2 Part number A B C F G H1 H2 Weight 15Z1B04 1000 72 5 180 178 4 8 55 113 166 4 4kg 19Z1B04 1000 135 220 219 7 91 136 201 12 0kg 20Z1B04 1000 150 220 219 7 91 136 201 12 0kg Figure 4 Commutation reactor ...

Page 23: ...art number A B C D E F G H Weight 14E6T60 3000 252 55 92 237 25 7 5 5 5 15 1 25kg Figure 5 Radio interference filter 14E6T60 3000 C A H D F G E B Part number A B C D E F G H Weight 16E6T60 3000 252 65 106 237 30 7 5 5 5 15 1 8kg Figure 6 Radio interference filter 14E6T60 3000 ...

Page 24: ... C D E F G H Weight 18E6T60 3000 240 130 142 220 100 8 9 88 3 9kg Figure 7 Radio interference filter 14E6T60 3000 C H A F D G E B Part number A B C D E F G H Weight 20E6T60 3000 240 160 142 220 130 8 9 88 5 0kg Figure 8 Radio interference filter 14E6T60 3000 ...

Page 25: ...urbances For a high damping they are placed as close as possible to the interference source that means at the DC and motor output terminals of the inverter The conductor are passed through the ferrite core for the use as current compensated reactor PE is passed outside the core Further information is specified in the provided documentation The ferrite ring to be used arises from the used cable cro...

Page 26: ...rth PE on the mounting plate control circuit 11 Mains connection power circuit 11 A Mains connection control circuit 12 Control lines Large area contact at the mount ing plate Figure 10 EMC compatible control cabinet installation 4 2 Installation instructions Warning General installation instructions Stationary install and earth COMBIVERT The device must not be permeated by mist or water Allow for...

Page 27: ...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 Terminals Description of terminals at KEB inverters DC voltage input with starting current limiting usable as output only if all units supplied by the DC b...

Page 28: ...put parallel connected inverters must have an own starting current limiting at the DC voltage input The maximum charging current is taken into account This type can be supplied by mains The DC terminals can be used as output with regard to the maximum DC link capacity When used as input ensure that the starting current is externally limited This type is only a DC in verter with starting current li...

Page 29: ...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 re garded as output R6 N 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 su...

Page 30: ...rain relief shield ing The strain relief and the shielding must be done by the customer e g with two clips 3 Figure 13 Terminals earth handle 4 3 3 Terminals commutation reactor harmonic filter 15 19Z1B04 1000 commutation reactor 15 19Z1C04 1000 harmonic filter Name Tightening torque Nm PE PE L1 1 L 2 1 L3 1 L1 2 L2 2 L3 2 permissible line cross section Size 15 1 2 2 Function Size 15 2 5 16 mm AWG...

Page 31: ...C2 possi ble 2 Line contactor with protec tive wiring 6 DC fuses type aR gR 1 2 3 Radio interference filter E6 7 DC fuses type aR gR 2 10 Ferrite optional 4 Commutation reactor harmonic filter 8 Frequency inverter with IN 8 IN 9 FI type A1 C2 possible 11 Motor 1 The cable cross section may not be smaller than 10mm It must be dimensioned for the DC rated cur rent of the load Otherwise appropriate f...

Page 32: ...ter with IN 9 IN 5 FI type A1 C2 possible 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 10mm It must be dimensioned for the DC rated current of the load Otherwise appropriate fuses in the DC bus 7 are required The indicated maximum protection for the connected frequency inverter must be observed ...

Page 33: ...14 Motor 1 The cable cross section may not be smaller than 10mm 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 inverter must be observed 2 The contactor may only be connected if the precharging in the regenerative unit is completed Note the permissible DC link capaci...

Page 34: ...Mains fuse type gR 8 Decoupling diodes see annex 13 Ferrite optional 4 Radio interference filter E6 9 DC fuses type aR gR 3 14 Motor 1 The cable cross section may not be smaller than 10mm 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 inverter must be observed 2 The ...

Page 35: ...ating field required A load draw from the DC circuit may be done only if the ready signal is active In case of failure the line contactor must disconnect the units from the supply system Figure 19 Regenerative inverter currents inverter current type B1 B2 ...

Page 36: ...quency inverter typ A1 A2 or B1 B2 same type and size 12 DC fuses type aR gR 5 3 Main fuses type gR 5 9 Ferrite optional 13 External terminal block 2 4 Radio interference filter E6 14 Decoupling diodes see annex 5 Mains choke xxZ1B04 1000 harmonic filter xxZ1C04 1000 6 8 1 The cable cross section may not be smaller than 10mm It must be dimensioned for the DC rated current of the load Otherwise the...

Page 37: ...Parallel connection requires a base load per R6 N greater than 10 Figure 20 Regenerative operation at parallel operation Connection of the control release of the connected inverters STO 0V 25 24 26 S4 G2 X2A 25 24 26 S3 G1 X2A STO 24V 24V 0V G3 G4 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 relay R1 of the R6 N units...

Page 38: ...for in and outputs approx 24V max 100mA 18 Mass COM Reference potential 19 Digital output 1 O1 DC 600V Transistor output DC CP 19 Imax 25mA 20 Digital output 2 O2 Error message Transistor output error mes sage Imax 25mA 21 Analog output ANOUT Difference to mains frequen cy CP 18 0 10V max 5mA 22 24V output Uout see terminal 17 23 Mass COM Reference potential 24 Relay1 NO contact RLA Ready for oper...

Page 39: ...ration of regenerative units No Name 1 8 1 IGBT off High 2 IGBT off Low 3 SLAVE active High 4 IGBT on High 5 IGBT on Low 6 SLAVE active Low 7 nc 8 nc Attention at parallel connection At parallel connection the regenerative units are connected with the KEB catch cable see Chapter Accessories via the socket X2D ...

Page 40: ...ed cables Lay shield on one side of the inverter onto earth potential Lay control and power cable separately about 10 20cm apart lay crossings in a right angle max 25mA DC per digital output Analog output 0 10VDC 5mA max 30VDC 0 01 2A max 30VDC 0 01 2A Power supply of the inverter inputs Control release inverter U X2A 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Figure 21 Wiring exa...

Page 41: ...ation error E SYn is triggered if a phase allocation error occurs reverse rotation The actual mains frequency is determined and the correct connection of the COMBIVERT R6 N is secured after successful synchronisation If the control release terminal ST is set the COMBIVERT R6 N starts independently with the specified operation Depending whether regenerative requirement is available the COMBIVERT R6...

Page 42: ...1V ru 20 CP 11 power module temperature 1 C ru 38 CP 12 OL counter display 1 ru 39 CP 13 actual power 0 1kW ru 81 CP 14 total regen 0 1kWh ru 82 CP 15 total motor 0 1kWh ru 83 CP 16 total net 0 1kWh ru 84 CP 17 actual net 0 1kVA ru 85 CP 18 ANOUT1 gain 20 00 0 01 1 00 An 33 CP 19 comparison level 0 30000 00V 0 01V 600 00V LE 00 CP 20 general fault reset 0 10 1 3 Pn 15 CP 21 last error In 21 CP 22 ...

Page 43: ...rror Messages E EF 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 Frlr Error Fault reset level reached is triggered when the adjusted value in parameter Pn 15 is reached within one hour The error can be reset E LSF Error Charging circuit loa...

Page 44: ...lization 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 N is in netof state Resolution Meaning 0 01Hz positive values forward rotating field negative values reverse rotating field not permissible error E SYn No Name r w Enter based on CP 03 AC current L1 ru 08 CP 04 AC curren...

Page 45: ...lay of actual DC link voltage in volt The value is measured at the DC output terminals of the COMBIVERT R6 N No Name r w Enter based on CP 10 peak DC voltage ru 20 Value range Meaning 0 1000V Parameter CP 10 enables to recognize voltage peaks within an oper ating 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...

Page 46: ...egative values No Name r w Enter based on CP 14 total regen ru 82 Resolution Meaning 1kW Counter for the regeneratoric electric work to mains No Name r w Enter based on CP 15 total motor ru 83 Resolution Meaning 1kW Counter for the supplied electrical work from mains in kWh No Name r w Enter based on CP 16 total net ru 84 Resolution Meaning 1kW Display of the difference between supplied and regene...

Page 47: ...ng level for transistor output O1 as well as relay output 2 Setting range Setting Meaning 0 3200 00V 600 00V 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 r w Enter based on CP 20 general fault reset yes Pn 15 A general fault reset can...

Page 48: ...on number e g 1 11 No Name r w Enter based on CP 30 software date In 07 Value range Meaning 0 6553 5 Display of the inverter software date in the format ddmm y No Name r w Enter based on CP 31 power unit code Sy 03 The COMBIVERT R6 N detects the connected supply system 230V 400V at the first switching on Depending on the supply system the COMBIVERT R6 S adjusts internally certain parameter values ...

Page 49: ...ter with commutation reactor 1 Master with harmonic filter 2 Slave with commutation reactor 3 Slave with harmonic filter 4 Master Slave with commutation reactor input selection 5 Master Slave with harmonic filter input selection No Name r w Enter based on CP 34 regeneration level yes cS 02 Value range Meaning 100 120 The regeneration level determines the starting value to energy regen eration The ...

Page 50: ...t1 60s T 300s IDC ILM yes no yes no yes no yes no Calculate ILG ILGmax IDCmax ILGmax IDC ILG yes no yes no select higher unit or parallel con nection of R6 N n IDC n IDC max Power supply regenerative unit capable Bridge over ext load shunt with contactor special unit no yes no PM Mechanical power ηM Motor efficiency IDC DC output current R6 N PM max Max mechanical power ηG Gearbox efficiency IDCma...

Page 51: ...1080µF 09 300µF 10 1080µF 10 345µF 12 2220µF 12 470µF 13 3280µF 13 580µF 14 4100µF 14 650µF 15 4100µF 15 940µF 16 5040µF 16 1290µF 17 9900µF 17 1640µF 18 13200µF 18 1875µF 19 15600µF 19 2700µF 20 16500µF 20 3900µF 21 19800µF 21 4950µF 22 4950µF 23 6350µF 24 8400µF 25 9900µF 26 11700µF 27 14100µF 28 P 28 W 16200 19800µF 29 P W 19800 23400µF 30 28200µF 31 32900µF 32 35 39600µF 36 59400µF Special uni...

Page 52: ...Type A1 13 560 C 13 680 Type A1 14 15 750 D 13 680 Type A1 14 15 840 16 1120 E 16 1035 Type B1 17 1400 18 19 1985 Frequency inverter S6 Housing Unit size Capacity µF Precharging circuit 2 7 195 Type A1 9 195 10 235 4 12 470 Type A1 13 560 Attention Ferrites at the input and output are required in any case when using G6 S6 ...

Page 53: ...a K W 15 0090147 3500 1600V 80A 2 45 90 1 50 19 0090147 4101 1600V 120A 2 45 90 0 84 25 0090147 6009 1600V 560A 2 45 90 0 19 29 0090147 6009 1600V 560A 2 x 2 45 90 0 09 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 5W m K A 3 2 Dimensions of the decoupling diodes Mat...

Page 54: ...54 Annex A Material number Connection Dimensions 0090147 4101 1 anode 2 cathode or 3 anode 1 cathode 0090147 6009 3 anode 2 cathode Figure 23 Dimensions of the decoupling diodes ...

Page 55: ...orm 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 Sym metrical Amperes 240 or 480 Volts Maximum and When Protected by Fuses as listed below Feedback unit Cat No Fuse 15R6 240V 1 RK1 fast a...

Page 56: ...n For Feedback units 15R6N1E xxxx and 19R6N1E 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 15R6N1E xxxx and 19R6N1E xxxx Use max Wire Size 8 AWG strip wire insulation at 10 mm Use max Wire Size 4 AWG ...

Page 57: ...57 Notes ...

Page 58: ...58 Notes ...

Page 59: ...59 Notes ...

Page 60: ...0101 fax 33 1 45767495 net www keb fr mail info keb fr 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 info keb co uk 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 kebitalia keb it KEB Japan Ltd 15 16 2 Chome Takanawa Minato ku Tokyo 108 00...

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