Sunteți pe pagina 1din 32
BU-300 UL AC Drive Braking Unit INSTRUCTIONS GE GE Industrial Industrial Systems Systems

BU-300 UL

AC Drive Braking Unit

INSTRUCTIONS

GEGE IndustrialIndustrial SystemsSystems

© 2001 General Electric Company, USA.

All rights reserved.

Supersedes GEI-100350A 6/98

These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met during installation, operation, and maintenance. If further information is desired or if particular problems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to GE Industrial Systems, Salem, Virginia, USA.

This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Industrial Systems.

Table of Contents

Safety Symbol Legend / Légende des Signes de Sécurité

4

Chapter 1 - Description

5

Chapter 2 - Main Features

6

Chapter 3 - Technical Data

7

3.1. Weights and Dimensions

7

3.2. Required Power, Fuses, LED, Terminals and Switches

9

3.2.1. Required Power

9

3.2.2. External Fuses

9

3.2.3. Internal Fuses

10

3.2.4. LEDs

10

3.2.5. Terminal Strips, Power Cables

10

3.2.6. Dip-switch Description

11

3.3. Inverter Selection and Intervention Thresholds

13

3.4. Unit Parallel Connection

14

3.5. Alarm Intervention

16

3.6. Dc Link Discharge Function

17

Chapter 4 - Dimensioning of the Braking Unit and its Corresponding Resistor

18

4.1.

Resistor Simplified Sizing

21

4.2 Simplified Resistor Sizing Based on Stopping Time

23

Chapter 5 - Minimum Value of the Used Resistors

25

Chapter 6 - Standard Braking Resistor

26

Chapter 7 - Block Diagram

30

Safety Symbol Legend / Légende des Signes de Sécurité

WARNING! Commands attention to an operating procedure, practice, condition, or statement which, if not strictly observed, could result in personal injury or death.

Attire l’attention sur les modes d’utilisation et les procédés et conditions d’exploitation qui, en cas d’inobservation, pourraient entraîner des blessures corporelles ou la mort.

CAUTION!

Commands attention to an operating procedure, practice, condition, or statement which, if not strictly observed, could result in damage or destruction of equipment.

The seriousness of the injuries and of the damages which could be caused by the non- observance of such indications, depends on the different conditions. Anyway, the instructions given below should always be fol- lowed with the highest attention.

Attire l’attention sur les modes d’utilization et les procédés et conditions d’exploitation qui, en cas d’inobservation, pourraient entraîner la détérioration ou la destruction des appareils.

La gravité des blessures et des dommages matériels possibles dépendent de différent facteurs. Toutefois, les instructions mentionées ci-dessous devraient être toujours suivies avec la plus grande attention.

NOTE!

Commands attention to an operating procedure, practice, condition, or statement that must be highlighted.

Attire l’attention sur les modes d’utilization et les procédés et conditions d’exploitation qui présentent un intéret particulier.

Chapter 1 - Description

The BU-300 braking unit consists of a static switch (IGBT) controlled by the voltage in the inverter intermediate circuit (DC Link).

When a fixed voltage threshold is exceeded, the static switch is closed connecting a resistor across the DC link dissipating the developed energy. It is possible to obtain faster decelerations and to avoid the tripping of the inverter “overvoltage” protection caused by a sudden increase in the DC Link voltage.

Through a parallel connection of the units via the C and D terminals, and a cascade connection

of the braking command (master/slave function), it is possible to configure 2 parallel braking

units which are simultaneously active.

A protection circuit has been implemented in order to protect the IGBT against possible

short circuits of the braking resistor connections.

Other protections are:

- Heatsink thermal protection.

- Power supply voltage control.

The trip can be reset, after the alarm condition has been cleared, via a button on the unit or via a remote dedicated command.

A command allows a quick discharge of the inverter intermediate circuit.

Such command must be directly interlocked with the contactors supplying energy to the inverters.

Chapter 2 - Main Features

- IP20 protection level

- Max. working rated ambient temperature: 40°C (max. 50°C with a 20% derating)

- Max. duty cycle: 50%

- Circuit power supply derived from the DC Link

- Possibility to parallel-connect up to 3 units (Master unit included) controlled by a “MASTER” unit

- Turn on threshold to be set through the switches

- +24V power supply (green LED)

- BR activity (yellow LED), Braking is active

- AL alarm condition (red LED)

- OK condition (green LED)

- OK relay contact available for the alarm sequences

- Possibility to connect the resistor protection

- Possibility to discharge quickly the DC Link.

Chapter 3 - Technical Data

Model

Max. dissipated power @ Duty cycle

Peak current

 

Current

 

Duty cycle*

Average

rms

6KBU300-20UL

50 W

40

A

20

A

28

A

50%

6KBU300-50UL

180

W

100

A

50

A

70

A

50%

6KBU300-85UL

280

W

170

A

85

A

120

A

50%

T ON

* Duty cycle = T ON + T OFF

Depending of BU and inverter size. Duty cycle max 50%

WARNING!

The electronic circuit of the braking unit is directly connected to the DC Link, whose voltage value can reach 850Vdc.

If the device cover is removed, the live parts can not be touched (IP 20).

3.1. Weights and Dimensions

M6 CABLE LENGTH = 2m PE BR CR C D 210mm (8.27") 72 mm (2.8")
M6
CABLE LENGTH = 2m
PE BR CR
C
D
210mm (8.27")
72 mm (2.8")
144 mm(5.7")
Model
lbs/Kg
6KBU300-20UL
12.1
/ 5.5
6KBU300-50UL
13.2
/ 6
6KBU300-85UL
16.7
/ 7.6
300
mm (12.1")
320
mm (12.6")

Figure 3.1.1: Front view

BU-300 CAUTION! Dc-link twisted wires have a maximum length of 2 meters. The dc-link twisted
BU-300
CAUTION!
Dc-link twisted wires have a maximum
length of 2 meters.
The dc-link twisted wirers must be
disconnected at the inverter C and D
terminals before removing the cover
or performing any maintenance or
inspection operation.
Do not perform voltage test at the
control card terminals with megger
equipment or higt voltage testers.
PRECAUTION!
Les fils torsades du dc-link ont
une longueur maxi de 2 metres.
Les fils torsades du dc-link doivent
être decorennectes des connections C
et D avant d’ôter le couvercle ou
d'effectuer toute operation d'entretien
et de contrôle.
N'effecteur aucun test de tension
aux connections de la carte de
contrôle avec equipment megger
ou des testeurs de haute tension.

Figure 3.1.2: Panel clearances

Figure 3.1.2: Panel clearances 150mm (6") PE BR CR C D PE BR CR C D
150mm (6") PE BR CR C D PE BR CR C D 10mm (0.4") 50mm
150mm (6")
PE BR CR
C
D
PE BR CR
C
D
10mm (0.4")
50mm (2")
150mm (6")
50mm (2“)
10mm (0,4")

3.2. Required Power, Fuses, LED, Terminals and Switches

3.2.1. Required Power

The braking unit power supply is derived directly from the DC Link; the maximum consumption is 15W.

3.2.2. External Fuses

The inverter power supply, which the BU-300 braking unit is connected to, must be protected via F1 external fuses (see figure. 3.4.1 and 3.4.2).

NOTE!

No fuses are needed on the wiring connection between drive and braking unit.

3.2.3.

Internal Fuses

Denomination

Protection for

Fuse

F2

+24V supply (terminals 1 and 2) Master output command (terminals 5 and 6)

0.3A Autoresettable

NOTE!

The F2 fuse resets itself after the short has been removed.

Replacement vendor source: RAYCHEM code: SMD030

3.2.4. LEDs

Denomination

Colour

Function

24 V

green

It shows the presence of the power supply

MASTER

yellow

The braking unit is set as master

BR

yellow

The braking unit is active (braking)

OK

green

OK relay status (closed = OK)

AL

red

It shows the alarm condition

3.2.5. Terminal Strips, Power Cables

The power terminal strip consists of the following terminals:

Terminals

Function

I/Q

Volt. max.

Curr. max.

C

Connection to inverter DC link

I

820Vdc

I peak

D

Connection to inverter DC link

I

820Vdc

I peak

CR

Connection to the braking resistor

Q

775V dc

I peak

BR

Connection to the braking resistor

Q

775V dc

I peak

PE

Ground connection

The two pluggable terminal strips, on the regulation card, consist of:

Terminals

Name

Function

I/Q

Volt. max.

Curr. max.

X2-1

+24V

Input power supply (TIM, RESET)

Q

24V

200mA

X2-2

0V 24V

Reference potential for the +24V power supply

   

 

X2-3

TIM

External alarm connection

I

15

30V

3.2

6.4

mA

X2-4

RESET

Remote reset of the alarm condition

I

15

30V

3.2

6.4

mA

X2-5

MCMD

Command starting the Slave braking procedure

Q

24V ± 5%

30

mA

X2-6

0V 24V

Reference potential for the signal controlling the start of the Slave unit

   

 

X2-7

SIN

Command starting the Slave unit

I

8

30V

16

mA

X2-8

SIN

Command starting the Slave unit

I

8

30V

16

mA

X2-9

SOUT

Cascade connection for the Slave unit

Q

8

30V

16

mA

X2-10

SOUT

Cascade connection for the Slave unit

Q

8

30V

16

mA

X3-75

OK

Contact without the OK relay potential (closed = OK)

Q

250Vca

 

1

A

X3-76

OK

Contact without the OK relay potential (closed = OK)

Q

250Vca

 

1

A

Cable sizes of the power terminals CR,BR

Model

Maximum permissible Cable Cross-Section

flexible [mm]

multi-core [mm]

AWG

6KBU300-20UL

4…16

2,5…25

12…4

6KBU300-50UL

4…16

2,5…25

12…4

6KBU300-85UL

0.75…35

0,75…50

18…0

Cable sizes of the regulation board terminals

Terminals

 

Maximum permissible Cable Cross-Section

 

flexible [mm]

multi-core [mm]

AWG

1

76

0.35

1.5

0.35

1.5

22

16

3.2.6. Dip-switch Description

The following table lists the switches on the regulation card, removing the front cover of the braking unit.

   

Function

Description

Mains Voltage

Braking threshold

[Vac]

Turn ON [Vdc]

Turn OFF [Vdc]

 

230

402

392

380

646

636

Mains

400

678

668

Voltage

415

702

692

440

743

733

460

753

743

480

775

765

S2

MASTER = Selection of braking unit function as Master (standard) SLAVE = Selection of braking unit as Slave

S3

Button Reset of alarm condition

 

S4

Enabling of the function for quick discharge of the DC link Standard = OFF

 

WARNING!

Remove power, and insure DC link is discharged before opening cover and changing settings.

Figure 3.2.6.1: Position of switches, LEDs, fuses and terminals on the BUy-C card Side view
Figure 3.2.6.1: Position of switches, LEDs, fuses and terminals on the BUy-C card
Side view
BU-300
FRONT
Mains
Voltage

3.3. Inverter Selection and Intervention Thresholds

The units are set according to a standard configuration:

- Inverter power supply voltage = 480Vac

- Intervention threshold = 775Vdc

Figure 3.3.1: Switch standard selection Mains Voltage 230V 380V 400V 415V 440V 460V 480V
Figure 3.3.1: Switch standard selection
Mains
Voltage
230V
380V
400V
415V
440V
460V
480V

The braking unit intervention threshold must be set according to the value of the inverter power supply voltage, which the braking unit must be connected to.

NOTE!

It is possible to select just one braking threshold

Mains Voltage

Braking threshold [V BR ]

230

Vac

400

Vdc

380

Vac

640

Vdc

400

Vac

680

Vdc

415

Vac

702

Vdc

440

Vac

745

Vdc

460

Vac

753

Vdc

480

Vac

775

Vdc

The 400Vac mains voltage requires the 680Vdc threshold.

3.4. Unit Parallel Connection

NOTE!

A minimum clearance of 2 inches is required when the braking units are parallel connected (see figure 3.1.2).

A WRONG CONNECTION OF THE POWER SECTION COULD DESTROY THE UNIT AND/OR THE CONNECTED INVERTERS!

The braking unit is supplied with the power cables connecting the inverter to the C and D terminals (cable length: 2 meters).

WARNING!

CAUTION!

These cables must be used for installation. Do not substitute. If required, they can only be shortened.

Figure 3.4.1: Parallel connection of several units (Master and Slave) to AV-300i Drive

L1 L2 L3 N PE F1 K1M L1 ~ FILTER ~ U1 V1 W1 PE1
L1
L2
L3
N
PE
F1
K1M
L1
~
FILTER
~
U1
V1 W1
PE1
AV-300i DRIVE
U2 V2 W2
PE2
C
D
M
3~
C
D 7
C
D
76
76
75
8
75
BU300
BU300
E
9
5
9
SLAVE
7
MASTER
10
6
10
8
CR
BR
CR
1 3
BR
1 3
THERMAL RELAY
BRAKING RESISTORS
BRAKING RESISTORS
ENABLE

When a drive provides the trigger command for external braking units, all the BU-300 must be configured as Slave. The MCMD and 0V24 terminals of the inverter must be connected to the terminals number 7 and 8 (SIN) of the first BU-300, which, on its turn, is connected to the following BU-300 via its terminals number 5 and 6 (SOUT), as shown in the following example.

Figure 3.4.2: Parallel connection of several units (Slave) to the AV-300 Master Drive

L1 L2 L3 N PE F1 K1M L1 ~ FILTER ~ U1 V1 W1 PE1
L1
L2
L3
N
PE
F1
K1M
L1
~
FILTER
~
U1
V1 W1
PE1
AV-300 MASTER DRIVE
U2 V2 W2
PE2
C
D
M
3~
C
D
C
D
9
76
76
75
75
10
BU300
BU300
E
9
7
5
7
SLAVE
SLAVE
10
8
6
8
CR
BR
CR
1 3
BR
1
3
THERMAL RELAY
BRAKING RESISTORS
BRAKING RESISTORS
ENABLE
MCMD *
0V24

* The MCMD terminal is available only on AV-300 Drives equipped with the following cards:

· PSS-AMV32-1 Rev.”a” or higher

(for sizes from 6KAV3003 to 6KAV3011)

· P1-AMV32

Rev.”d” or higher

(for sizes from 6KAV3015 to 6KAV3160)

· PL-AMV32

Rev. “a” or higher

(for sizes from 6KAV3250 to 6KAV3315)

Figure 3.4.2: Auxiliary control circuits

L01 K0 S11 OFF S12 K2 K1M STOP Thermal relay 80 G1 S2 K2T OK
L01
K0
S11
OFF
S12
K2
K1M
STOP
Thermal
relay
80
G1
S2
K2T
OK
ON/START
82
K2
K2
K1M
K0
K2T
L00
Mains contactor
EMERGENGY-OFF
ON/OFF
T = 1s
START/STOP
3.5. Alarm Intervention
EMERGENCY-OFF

On an internal alarm, the braking unit is immediately disabled, the AL red LED lights up and the OK relay contact opens (terminals X3-75/ X3-76).

After the alarm condition has been restored, the braking unit can be reset using one of the following methods:

- via the S3 button

- via a remote command on the X2-1 and X2-4 terminals.

- by cycling power on the braking unit.

3.6. Dc Link Discharge Function

The braking unit can be used to discharge a DC Link with a high capacitive value (for example in systems where the DC Link is parallel connected).

For this use set the S4 switch in position ON and jumper the X2-9 and X2-10 terminals.

With such a setting, the DC Link discharge can reach a value equal or lower than 60V dc by taking an external voltage included between 10 and 30V dc to the X2-7 and X2-8 SIN terminals or using the internal voltage of the X2-1 and X2-2 terminals.

WARNING! In order to avoid damages to the braking resistor, the command execution is critical. This signal must be supplied to the braking unit via a contact interlocked with those contactors which power the inverter.

Chapter 4 - Dimensioning of the Braking Unit and its Corresponding Resistor

Here following are some general information. Chapter 6 lists a series of normalized resistors to be used with the BU-300 braking units in specifically assumed conditions.

Remember that:

P PBR [W]

Power peak while braking

P NBR [W]

Resistor rated power

E BR [J]

Braking energy

V BR

[V] Braking voltage

I PBR [A] Peak braking current

I AVBR [A] I PBU [A]

n 1 ,

t BR , T

J TOT [Kg* m2]

Average braking power

Braking unit peak current

Initial and final speed

Braking time and cycle time

Total moment of inertia (referred to the motor shaft)

n 2 [RPM]

[S]

Therefore:

(referred to the motor shaft) n 2 [RPM] [S] Therefore: Resistor ohmic value: R = V
(referred to the motor shaft) n 2 [RPM] [S] Therefore: Resistor ohmic value: R = V

Resistor ohmic value:

R = V BR BR I PBR f004
R
=
V BR
BR
I PBR
f004

Resistor continuous rated power:

P

NBR

 

P

PBR

*t

BR

E BR

=

=

2T

T

f005

CAUTION!

This formula calculates an average power value which could be different from the instant power in case of very low duty cycles.

The resistors can not usually bear a power peak which is 5 to 10 times higher than their rated value. As a consequence, if the duty cycles are lower than 10%, this value can not be used as a resistor rated power. See also the calculations in chapters 4.1 and 6.

Consult the resistor producer for further details about the overload capacity.

Being n2 = 0 (stop), the formula states that:

E

BR

=

1

2

P

PBR

*t

BR

f006

Braking unit features:

I

PBU

I

PBR

f007

The peak current allowed by the BU-300 must be higher or equal to the real one. The average current is stated through:

I

=

AVBR

E BR

t

BR

*V

BR

I

AVBU

I

AVBR

f008

Dimensioning example

Data:

- Mains voltage

3 x 460 V

- Inverter

6KAV3015

- Motor rated power

(P M )

15 HP

- Motor rated speed

(n n )

3515 rpm

- Moment of inertia of the motor

(J M )

0.033 kgm 2

- Moment of inertia loading the motor shaft

(J L )

0.95 kgm 2

- Friction of the system

(M S )

10% of the rated torque

- Initial braking speed

(n 1 )

3000 rpm

- Final braking speed

(n 2 )

0 rpm

- Braking time

(t BR )

10 sec

- Cycle time

(T)

120 sec

Total moment of inertia:

J TOT = J M + J L = 0.033 + 0.95 = 0.983 kgm 2

e

∆ω = [2Π * (n 1 - n 2 )] / 60 sec/min = 2Π * 3000 / 60 = 314 sec -1

Motor rated torque:

M M = P M / ω n = (15 * 745.7) / ( 2Π * 3515 / 60) = 30.4 Nm

Machine friction:

M S = 0.1 M M = 3.04 Nm

The braking energy is given by:

E BR = (J TOT / 2) * (2Π / 60) 2 * (n 1 2 -n 2 2 ) = (0.983 / 2) * (0.10472) 2 * 3000 2 = 48509 Joules

or Wsec

Taking into account also the system friction, the braking energy to be dissipated by the braking unit is lower.

The required braking torque is:

M b = (J TOT * ∆ω) / t BR = 0.983 * 314 / 10 = 30.9 Nm

The braking torque consists of two sections: the machine friction and the torque to be supplied by the motor electric braking:

M bM = M b - M S = 30.9 - 3.04 = 27.86 Nm

The average power of the braking process is given by:

P AVE = (M bM * ∆ω) / 2 = 27.86 * 314 * 0.5 = 4374 W

The new value of the braking energy is therefore:

New E BR = P AVE * t BR = 4374 * 10 = 43740 Joules or Ws

it is obviously lower than the previous one.

The peak braking power is given by

P PBR = (J TOT * n 1 * ∆ω * 2Π) / (t BR * 60) = 9.7 kW therefore

I PBR = P PBR / V BR = 9700 / 745 = 13A and

R BR V BR / I PBR = 745 / 13 = 57

Being I PBR = 13A, the 6KBU300-20UL unit meets the requirements.

Resistor choice

The resistor rated power must be:

P NBR = (P PBR * t BR ) / 2T = (9700 * 10) / 240 = 404 W

The resistor rated power is low because of the low duty cycle (10 / 20) but the resistor must be in a position to bear the energy applied during the 10-second braking process. This energy corresponds to 43740 Joules. In the table of the standard braking resistors (chapter 6) it is possible to notice how the model BRR 1K0T 49R has a sufficient rated power value and a too low E BR value (21kWsec).

As a consequence the chosen model is BRR 1K3T 31R whose E BR value is 44kWsec.

4.1. Resistor Simplified Sizing

In case all the above mentioned data are not available, it is possible to carry out a simplified and rough calculation of the braking resistance.

The following formulas can be used for the calculation of the different braking values:

be used for the calculation of the different braking values: Having to calculate the resistor value

Having to calculate the resistor value for an inverter (100A braking peak current) which is power supplied at 400Vac, (braking threshold), we have that:

R

BR

=

680

100

= 6.8 Ohm

f012

This formula states just the ohmic value; the following considerations, on the contrary, refer to the resistor power:

The braking resistor is normally used with an intermittent cycle; it is therefore normal to use a resistor power lower than the one obtained through R BR * I PBR 2 .

The following diagram can be used to define the overload factor (similar diagrams can be supplied by the producer of the used resistor).

RESISTANCE POWER

1000 100 10 1 0,1 1 2 3 4 5 6 7 8 9 10
1000
100
10
1
0,1
1
2 3
4
5
6
7
8
9
10
OVERLOAD TIME (seconds - log. Scale)

OVERLOAD FACTOR

Pause time 15 seconds 30 seconds 1 minute 5 minutes 30 minutes
Pause time
15
seconds
30
seconds
1
minute
5
minutes
30
minutes

Using this diagram to calculate the value of the continuous (rated) power of the braking resistor, it is possible to apply the following formula:

continuative power R

BR

=

regenerated power

overload factor

f013

Having to brake a 30-kW motor with a 150% overload, the maximum regenerated power is 45 kW.

Assuming that the braking time is 5 seconds (resistor overload time) and the break time is 1 minute, the diagram supplies an overload factor of 3.9. The resistor rated power is therefore:

45000

3.9

= 11.5 kW

f014

4.2 Simplified Resistor Sizing Based on Stopping Time

1)

2)

3)

4)

Add Motor Inertia + Gearbox Inertia + Reflected Machine Inertia = Total System inertia [ft lb 2 ]

Reflected Machine Inertia =

Machine Inertia

(Gear Ratio) 2

Calculate system energy running at top speed.

[Total System Inertia] [Top rpm 2 ]

4300000

= System Energy [kW sec]

rmp time
rmp
time

Calculate average [kW] needed to absorb to stop, neglecting friction and efficiencies.

(System Energy) kW sec

(Stop time)

sec

= Average Stopping Power [kW]

Calculate the resistor Ohms needed to dissipate the average stopping power [kW].

(DC Bus Volts)

2

(Ave Stopping kW * 1000 * 2) =

For AV-300i as master, at 460 VAC, DC bus volts =

780.

This is the largest ohm value that can be used to stop the drive in time. Smaller Ohm values can be used.

5)

Calculate the resistor ohms needed for the motor to reach current limit anytime during the stop.

Motor HP * .746 = Motor kW

Current Limit kW = Motor kW * 1.5 (150% overload)

6)

(DC Bus Volts)

2

Current Limit kW * 1000 =

Select a resistor value desired in the range between the answers found in steps 4) and

5).

Seleting closer to the value in step 5) may cause your resistor to be higher power rating to support the:

Instantaneous Current =

DC Bus Volts

Current Limit Ohms

selecting closer to the value found in step d) doesnt leave room for field adjustement of faster stop times later.

7)

Use the final resistance value, determined in step f), to check the resistor peak current and BU peak current needed.

DC Link Volts DB Resistance Ohms = Peak Current [Amps]

this determines quantity of braking units needed, and which type of BU based on the peak amps needed.

8)

For an occasional stop, for example, once every 10 minutes, or stop then cool to ambient, then the resistor can be selected on its short time rating, for example a 15 sec rating or 30 sec rating average stopping kW if the resistor rating is in kW.

or:

Average Stopping kW Resistor Ohm
Average Stopping kW
Resistor Ohm

= Short Time Current [Amps]

The resistor power rating must meet both instantaneous and short time ratings.

For overhauling loads, or more frequent stopping cycles, use the previous detailed calculations.

Chapter 5 - Minimum Value of the Used Resistors

Model

 

Mains voltage and resistor minimum value

 

230V

380V

400V

415V

440V

460V

480V

6KBU300-20UL

10

ohm

16 ohm

17

ohm

17

ohm

18.6

ohm

18.6

ohm

19.37 ohm

6KBU300-50UL

4

ohm

6.4

ohm

6.8 ohm

6.8 ohm

7.5

ohm

7.5

ohm

7.75

ohm

6KBU300-85UL

2.4 ohm

3.7

ohm

4

ohm

4

ohm

4.4

ohm

4.4

ohm

4.55

ohm

The ohmic value listed in the table is the resistor absolute minimum value to be connected to the different braking units according to the set braking threshold. In case this value is not available, the following higher ohmic value has to be used. For example, with the 6KBU300- 20UL braking unit, whose intervention threshold is 680V, the stated resistor value is 17, but the following commercial ohmic value to be used is 18Ω.

This indication allows a better use of the braking resistors when several parallel-connected resistors are present; in this case see the ohmic values listed in the table.

CAUTION!

The units are protected against any direct short circuit between the terminals CR and BR

26

Table 6.1: 10% duty typical DB resistors for AV-300i for decel on ramp with motor power capable of 150% of rated motor HP.

Chapter 6 - Standard Braking Resistor

—————— BU-300 UL ——————

AV-300i HP

max.HP

10% DB

BU-300

equivalent

IPC

 

DB pkg

available %

 

DB 10 sec 1 time capability in X times motor inertia

model #

(with OL)

duty KW

type

DB

resistor bank

 

DB ckt

watts

duty with

ave Watts stopping from 1800 rpm in 5 sec

6KAVi43

output

resistor

model #

configuration

this R &

ohms

DB combo

F75

0,75

0,05595

internal

200

6KE$34DBR001

 

200

35,7

45.2

22,119

1

1

0,0746

internal

200

6KE$34DBR001

 

200

26,8

45.2

22,119

2

2

0,1492

internal

200

6KE$34DBR001

 

200

13,4

60.3

16,590

3

3

0,2238

internal

160

6KE$34DBR003

 

400

17,9

45.2

44,239

5

5

0,373

internal

100

qty 2

2 resistors in series

400

10,7

60.3

33,179

6KE$34DBR001

7

7,5

0,5595

internal

80

6KE$34DBR007

 

900

16,1

150.7

29,861

10*

10

0,746

BU-300-20

40

6KE$34DBR015

 

1400

18,8

150.7

46,451

           

allows 100% CL +

       

10*

10

0,746

internal*

80

6KE$34DBR007*

losses~(110%)

900

12,1

150.7

29,861

15

15

1,119

internal

40

6KE$34DBR015

 

1400

12,5

331.5

21,114

20

20

1,492

internal

27

6KE$34DBR025

 

1800

12,1

452.1

19,907

25

25

1,865

internal

22

6KE$34DBR030

 

1800

9,7

828.8

10,859

30

30

2,238

internal

15

6KE$34DBR040

 

3600

16,1

904.2

19,907

40

40

2,984

internal

12

6KE$34DBR050

 

4800

16,1

979.5

24,501

50

50

3,73

internal

10

6KE$34DBR060

 

6000

16,1

1085.0

27,649

60

60

4,476

internal

7,5

6KE$34DBR075

 

7200

16,1

1959.1

18,376

75

75

5,595

BU-300-85

6

qty 2

2

resistors in

9600

17,2

2109.8

22,751

6KE$34DBR050

parallel

100

100

7,46

BU-300-85

5

qty 2

2

resistors in

12000

16,1

6027.9

9,954

6KE$34DBR060

parallel

125

125

9,325

qty 2 , BU-

3,35

qty 2

1 resistor/BU, 2 BUs in //

14400

15,4

6027.9

11,944

300-50

6KE$34DBR075

150

150

11,19

qty 2 , BU-

3,35

qty 2

1 resistor/BU, 2 BUs in //

14400

12,9

9795.3

7,350

300-85

6KE$34DBR075

200

200

14,92

qty 2 , BU-

2,5

qty 2

1 resistor/BU, 2 BUs in //

24000

16,1

16576.7

7,239

300-85

6KE$34DBR060

Table 6.2: 20% duty typical DB resistors for AV-300i for decel on ramp with motor power capable of 150% of rated motor HP.

27

GEI-100492——————

AV-300i HP

max.HP

20% DB

BU-300

equivalent

IPC

 

DB pkg

available % duty with this R & DB combo

ave Watts stopping from 1800 rpm in 5 sec

DB 10 sec 1 time capability in X times motor inertia

model #

(with OL)

duty KW

type

DB

resistor bank

 

DB ckt

watts

6KAVi43

output

resistor

model #

configuration

ohms

F75

0,75

0.1119

internal

200

6KE$34DBR001

 

200

35.7

45.2

22.119

1

1

0.1492

internal

200

6KE$34DBR001

 

200

26.8

45.2

22.119

2

2

0.2984

internal

160

6KE$34DBR003

 

400

26.8

60.3

33.179

3

3

0.4476

internal

160

qty 2

2

resistors in

1600

71.5

45.2

176.955

6KE$34DBR007

series

5

5

0.746

internal

120

qty 2

2

resistors in

1800

48.3

60.3

149.306

6KE$34DBR010

series

7

7,5

1.119

internal

80

qty 2

2

resistors in

2800

50.0

150.7

92.901

6KE$34DBR015

series

10*

10

1.492

BU-300-20

27

6KE$34DBR015

 

1800

24.1

150.7

59.722

10*

10

1.492

internal

80

qty 2

allows 100%

2800

37.5

150.7

92.901

6KE$34DBR015

 

CL+

15

15

2.238

BU-300-50

15

6KE$34DBR040

 

3600

32.2

331.5

54.293

           

2

resistors in

       

20

20

2.984

internal

30

6KE$34DBR040

series

7200

48.3

452.1

79.630

25

25

3.73

internal

15

6KE$34DBR030

 

3600

19.3

828.8

21.717

30

30

4.476

internal

10

6KE$34DBR060

 

6000

26.8

904.2

33.179

40

40

5.968

internal

10

6KE$34DBR060

 

6000

20.1

979.5

30.627

50

50

7.46

internal

7.5

6KE$34DBR075

 

7200

19.3

1085.0

33.179

60

60

8.952

internal

6

6KE$34DBR050

2

resistors in //

9600

21.4

1959.1

24.501

75

75

11.19

BU-300-

5

qty 2

2

resistors in

12000

21.4

2109.8

28.439

85

6KE$34DBR060

parallel

100

100

14.92

BU-300-

5

qty 4

2

resistors in

24000

32.2

6027.9

19.907

85

6KE$34DBR060

series, in parallel

125

125

18.65

qty 3 , BU-

3.75

qty 4

2 // resistor/BU, 2 BUs in //

21600

23.2

6027.9

17.917

300-50

6KE$34DBR040

150

150

22.38

qty 3 , BU-

2.5

qty 3

1 resistor/BU, 3 BUs in //

24000

21.4

9795.3

12.251

300-85

6KE$34DBR075

200

200

29.84

qty 3 , BU-

1.67

qty 6

2// resistor/BU, 3 BUs in //

36000

24.1

16576.7

10.859

300-85

6KE$34DBR060

28

Table 6.2: 50% duty typical DB resistors for AV-300i for decel on ramp with motor power capable of 150% of rated motor HP.

—————— BU-300 UL ——————

                   

DB 10 sec

AV-300i HP

max.HP

50% DB

BU-300

equivalent

IPC

 

DB ckt

DB pkg

available %

ave Watts

1 time

model #

(with OL)

duty KW

type

DB

resistor bank

 

configuration

watts

duty with

stopping

capability

6KAVi43

output

resistor

model #

 

this R &

from 1800

in X times

ohms

DB combo

rpm in 5 sec

motor

inertia

F75

0,75

0.27975

internal

160

6KE$34DBR003

 

400

71.5

45.2

44.23

1

1

0.373

internal

160

6KE$34DBR003

 

400

53.6

45.2

44.23

2

2

0.746

internal

260

qty 2, 6KE$34DBR005

2

resistors in series

800

53.6

60.3

66.35

3

3

1.119

internal

160

qty 2, 6KE$34DBR007

2

resistors in series

1600

71.5

45.2

176.95

5

5

1.865

internal

120

qty 2, 6KE$34DBR010

2

resistors in series

1800

48.3

60.3

149.3

7

7,5

2.7975

internal

80

qty 2, 6KE$34DBR008

2

resistors in series

2800

50.0

150.7

92.9

10

10

3.73

BU-300-50

12

6KE$34DBR050

 

4800

64.3

150.7

159.25

15

15

5.595

BU-300-50

10

6KE$34DBR060

 

6000

53.6

331.5

90.48

20

20

7.46

internal

30

6KE$34DBR040

2

resistors in series

7200

48.3

452.1

79.63

25

25

9.325

BU-300-85

6

qty 2, 6KE$34DBR050

 

2

resistors in //

9600

51.5

828.8

57.91

30

30

11.19

BU-300-85

5

qty 2, 6KE$34DBR060

 

2

resistors in //

12000

53.6

904.2

66.35

         

qty 4, 6KE$34DBR050

 

2

// resistor/BU, 2

       

40

40

14.92

qty 2 BU-300-85

3

 

BUs in //

19200

64.3

979.5

98.0

         

qty 4, 6KE$34DBR050

 

2

// resistor/BU, 2

       

50

50

18.65

qty 2 BU-300-85

3

 

BUs in //

19200

51.5

1085.0

88.47

60

60

22.38

qty 2 BU-300-85

1,875

qty 4, 6KE$34DBR075

 

2

// resistor/BU, 2 BUs in //

24000

53.6

1959.1

61.25

75

75

27.975

qty 2 BU-300-85

2,5

qty 4, 6KE$34DBR050

 

2

// resistor/BU, 2 BUs in //

28800

51.5

2109.8

68.25

100

100

37.3

qty 3, BU-300-85

1,67

qty 6 ,6KE$34DBR060

 

2

// resistor/BU, 3 BUs in //

36000

48.3

6027.9

29.86

125

125

46.625

qty 4 , BU-300-85

1,25

qty 8 ,6KE$34DBR060

 

2

// resistor/BU, 4 BUs in //

48000

51.5

6027.9

39.81

150

150

55.95

qty 4 , BU-300-85

1,25

qty 8 ,6KE$34DBR060

 

2

// resistor/BU, 4 BUs in //

48000

42.9

9795.3

24.5

200

200

74.6

qty 4 , BU-300-85

1,25

qty 8 ,6KE$34DBR060

 

2

// resistor/BU, 4 BUs in //

48000