INSTRUCTIONS

GE Industrial Systems

BU-300 UL
AC Drive Braking Unit

 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 purchasers 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 / Lgende des Signes de Scurit ............ 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 / Lgende des Signes de Scurit

WARNING! Commands attention to an operating procedure, practice, condition, or statement which, if not strictly observed, could result in personal injury or death. Attire lattention sur les modes dutilisation et les procds et conditions dexploitation qui, en cas dinobservation, pourraient entraner 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 followed with the highest attention. Attire lattention sur les modes dutilization et les procds et conditions dexploitation qui, en cas dinobservation, pourraient entraner la dtrioration ou la destruction des appareils. La gravit des blessures et des dommages matriels possibles dpendent de diffrent facteurs. Toutefois, les instructions mentiones ci-dessous devraient tre toujours suivies avec la plus grande attention.

NOTE!

Commands attention to an operating procedure, practice, condition, or statement that must be highlighted. Attire lattention sur les modes dutilization et les procds et conditions dexploitation qui prsentent un intret 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.

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Chapter 2 - Main Features

IP20 protection level Max. working rated ambient temperature: 40C (max. 50C 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.

BU-300 UL

Chapter 3 - Technical Data

Max. dissipated power Peak current @ Duty cycle 6KBU300-20UL 50 W 40 A 6KBU300-50UL 180 W 100 A 280 W 170 A 6KBU300-85UL Model Current Average 20 A 50 A 85 A Duty cycle* rms 28 A 70 A 120 A 50% 50% 50%

TON * Duty cycle = TON + TOFF

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

300 mm (12.1")

320 mm (12.6")

72 mm (2.8") 144 mm(5.7")

210mm (8.27")

Model 6KBU300-20UL 6KBU300-50UL 6KBU300-85UL

lbs/Kg 12.1 / 5.5 13.2 / 6 16.7 / 7.6

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Figure 3.1.1: Front view

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 tre decorennectes des connections C et D avant dter le couvercle ou d'effectuer toute operation d'entretien et de contrle. N'effecteur aucun test de tension aux connections de la carte de contrle avec equipment megger ou des testeurs de haute tension.

BU-300 UL

Figure 3.1.2: Panel clearances

150mm (6")

PE BR CR C D

PE BR CR C D

10mm (0.4") 50mm (2) 150mm (6") 10mm (0,4")

50mm (2")

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.
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3.2.3. Internal Fuses

Denomination F2 Protection for +24V supply (terminals 1 and 2) Master output command (terminals 5 and 6) Fuse 0.3A Autoresettable

The F2 fuse resets itself after the short has been removed. NOTE! Replacement vendor source: RAYCHEM code: SMD030

3.2.4. LEDs
Denomination 24 V MASTER BR OK AL Colour green yellow yellow green red Function It shows the presence of the power supply The braking unit is set as master The braking unit is active (braking) OK relay status (closed = OK) It shows the alarm condition

3.2.5. Terminal Strips, Power Cables

The power terminal strip consists of the following terminals:
Terminals C D CR BR PE Function Connection to inverter DC link Connection to inverter DC link Connection to the braking resistor Connection to the braking resistor Ground connection I/Q I I Q Q Volt. max. 820Vdc 820Vdc 775V dc 775V dc Curr. max. I peak I peak I peak I peak

The two pluggable terminal strips, on the regulation card, consist of:
Terminals X2-1 X2-2 X2-3 X2-4 X2-5 X2-6 X2-7 X2-8 X2-9 X2-10 X3-75 X3-76 I/Q Volt. max. Curr. max. Name Function Q 24V 200mA +24V Input power supply (TIM, RESET) 0V 24V Reference potential for the +24V power supply I 15...30V 3.2...6.4 mA TIM External alarm connection I 15...30V 3.2...6.4 mA RESET Remote reset of the alarm condition Q 24V 5% 30 mA MCMD Command starting the Slave braking procedure 0V 24V Reference potential for the signal controlling the start of the Slave unit I 8...30V 16 mA SIN Command starting the Slave unit I 8...30V 16 mA SIN Command starting the Slave unit Q 8...30V 16 mA SOUT Cascade connection for the Slave unit Q 8...30V 16 mA SOUT Cascade connection for the Slave unit 250Vca 1A OK Contact without the OK relay potential (closed = OK) Q 250Vca 1A OK Contact without the OK relay potential (closed = OK) Q

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BU-300 UL

Cable sizes of the power terminals CR,BR

Model 6KBU300-20UL 6KBU300-50UL 6KBU300-85UL Maximum permissible Cable Cross-Section flexible [mm] 416 416 0.7535 multi-core [mm] 2,525 2,525 0,7550 AWG 124 124 180

Cable sizes of the regulation board terminals

Terminals 1 ... 76 Maximum permissible Cable Cross-Section flexible [mm] 0.35 ... 1.5 multi-core [mm] 0.35 ... 1.5 AWG 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.
Description Function Mains Voltage Braking threshold [Vac] Turn ON [Vdc] Turn OFF [Vdc] 230 402 392 380 646 636 400 678 668 415 702 692 440 743 733 460 753 743 480 775 765 MASTER = Selection of braking unit function as Master (standard) SLAVE = Selection of braking unit as Slave Button Reset of alarm condition Enabling of the function for quick discharge of the DC link Standard = OFF

Mains Voltage

S2 S3 S4

WARNING!

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

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Figure 3.2.6.1: Position of switches, LEDs, fuses and terminals on the BUy-C card Side view

BU-300 FRONT

Mains Voltage

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BU-300 UL

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

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 230 Vac 380 Vac 400 Vac 415 Vac 440 Vac 460 Vac 480 Vac Braking threshold [V BR] 400 Vdc 640 Vdc 680 Vdc 702 Vdc 745 Vdc 753 Vdc 775 Vdc

The 400Vac mains voltage requires the 680Vdc threshold.

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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!

WARNING!

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

AV-300i DRIVE C D

U2 V2 W2 PE2

M 3~
E

76 75 9 10

BU300 MASTER
1 3

7 8 5 6

76 75 9 10

D
7 8 3

BU300 SLAVE
1

CR BR

CR BR

BRAKING RESISTORS

BRAKING RESISTORS

THERMAL RELAY

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BU-300 UL

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
ENABLE MCMD *

AV-300 MASTER DRIVE C D

U2 V2 W2 PE2

M 3~
E

76 75 9 10

D
7 8 3

BU300 SLAVE
1

76 75 5 6

9 10 7 8 3

BU300 SLAVE
1

CR BR

CR BR

BRAKING RESISTORS

BRAKING RESISTORS

* The MCMD terminal is available only on AV-300 Drives equipped with the following cards: PSS-AMV32-1 P1-AMV32 PL-AMV32 Rev.a or higher Rev.d or higher Rev. a or higher (for sizes from 6KAV3003 to 6KAV3011) (for sizes from 6KAV3015 to 6KAV3160) (for sizes from 6KAV3250 to 6KAV3315)

0V24
THERMAL RELAY

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Figure 3.4.2: Auxiliary control circuits

L01 K0

EMERGENCY-OFF

S11 OFF

Thermal relay

S12 STOP S2 ON/START G1 OK 80 82

K2

K1M

K2T K2

K0 L00 EMERGENGY-OFF

K2 ON/OFF START/STOP T = 1s

K2T

K1M Mains contactor

3.5. Alarm Intervention

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.

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BU-300 UL

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.

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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: PPBR [W] PNBR [W] EBR [J] VBR [V] IPBR [A] IAVBR [A] IPBU [A] tBR, T [S] Power peak while braking Resistor rated power Braking energy Braking voltage Peak braking current Average braking power Braking unit peak current Braking time and cycle time

n1, n2 [RPM] Initial and final speed JTOT [Kg* m2] Total moment of inertia (referred to the motor shaft) Therefore:

Resistor ohmic value:

RBR =

VBR IPBR

f004

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BU-300 UL

Resistor continuous rated power:

PNBR=

PPBR * tBR 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:

EBR =

1 P *t 2 PBR BRf006

Braking unit features:

IPBU

IPBR

f007

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

IAVBR =

EBR tBR * VBR

IAVBU

IAVBR
f008

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Dimensioning example Data: - Mains voltage - Inverter - Motor rated power - Motor rated speed - Moment of inertia of the motor - Moment of inertia loading the motor shaft - Friction of the system - Initial braking speed - Final braking speed - Braking time - Cycle time Total moment of inertia: JTOT= JM + JL = 0.033 + 0.95 = 0.983 kgm2 e = [2 * (n1 - n2)] / 60 sec/min = 2 * 3000 / 60 = 314 sec-1 Motor rated torque: MM = PM / n = (15 * 745.7) / ( 2 * 3515 / 60) = 30.4 Nm Machine friction: MS = 0.1 MM = 3.04 Nm 3 x 460 V 6KAV3015 (PM) (nn) (JM) (JL) (M S) (n1) (n2) (t BR) (T) 15 HP 3515 rpm 0.033 kgm2 0.95 kgm2 10% of the rated torque 3000 rpm 0 rpm 10 sec 120 sec

The braking energy is given by: EBR = (JTOT / 2) * (2 / 60)2 * (n12 -n22) = (0.983 / 2) * (0.10472)2 * 30002 = 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: Mb = (JTOT * ) / tBR = 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: MbM = Mb - MS = 30.9 - 3.04 = 27.86 Nm The average power of the braking process is given by: PAVE = (MbM * ) / 2 = 27.86 * 314 * 0.5 = 4374 W

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BU-300 UL

The new value of the braking energy is therefore: New EBR = PAVE * tBR = 4374 * 10 = 43740 Joules or Ws it is obviously lower than the previous one. The peak braking power is given by PPBR = (JTOT * n1 * * 2) / (tBR * 60) = 9.7 kW therefore IPBR = PPBR / VBR = 9700 / 745 = 13A RBR VBR / IPBR = 745 / 13 = 57 Being IPBR = 13A, the 6KBU300-20UL unit meets the requirements. Resistor choice The resistor rated power must be: PNBR = (PPBR * tBR) / 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 EBR value (21kWsec). As a consequence the chosen model is BRR 1K3T 31R whose EBRvalue is 44kWsec. and

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:

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

RBR =

680 = 6.8 Ohm 100

f012

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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 RBR * IPBR 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
OVERLOAD TIME (seconds - log. Scale)

100

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

10

0,1

10

OVERLOAD FACTOR

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 RBR =

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 = 11.5 kW 3.9

f014

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BU-300 UL

4.2 Simplified Resistor Sizing Based on Stopping Time

1) Add Motor Inertia + Gearbox Inertia + Reflected Machine Inertia = Total System inertia [ft lb2] Reflected Machine Inertia = Machine Inertia (Gear Ratio)2

2)

Calculate system energy running at top speed.

[Total System Inertia] [Top rpm2] 4300000

= System Energy [kW sec]

3) rmp

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

time (System Energy) kW sec (Stop time) sec

= Average Stopping Power [kW]

4)

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.

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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) (DC Bus Volts)2 Current Limit kW * 1000 =

6)

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: DC Bus Volts Instantaneous Current = 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 = 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.

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BU-300 UL

Chapter 5 - Minimum Value of the Used Resistors

Model 6KBU300-20UL 6KBU300-50UL 6KBU300-85UL 230V 10 ohm 4 ohm 2.4 ohm 380V 16 ohm 6.4 ohm 3.7 ohm Mains voltage and resistor minimum value 400V 17 ohm 6.8 ohm 4 ohm 415V 17 ohm 6.8 ohm 4 ohm 440V 18.6 ohm 7.5 ohm 4.4 ohm 460V 480V 18.6 ohm 19.37 ohm 7.5 ohm 7.75 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 6KBU30020UL braking unit, whose intervention threshold is 680V, the stated resistor value is 17, but the following commercial ohmic value to be used is 18. 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

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26
AV-300i HP model # 6KAVi43... max.HP (with OL) output 10% DB duty KW BU-300 type equivalent DB resistor ohms F75 1 2 3 5 7 10* 10* 15 20 25 30 40 50 60 75 100 125 150 200 0,75 1 2 3 5 7,5 10 10 15 20 25 30 40 50 60 75 100 125 150 200 0,05595 0,0746 0,1492 0,2238 0,373 0,5595 0,746 0,746 1,119 1,492 1,865 2,238 2,984 3,73 4,476 5,595 7,46 9,325 11,19 14,92 internal internal internal internal internal internal BU-300-20 internal* internal internal internal internal internal internal internal BU-300-85 BU-300-85 qty 2 , BU300-50 qty 2 , BU300-85 qty 2 , BU300-85 200 200 200 160 100 80 40 80 40 27 22 15 12 10 7,5 6 5 3,35 3,35 2,5 6KE$34DBR001 6KE$34DBR001 6KE$34DBR001 6KE$34DBR003 qty 2 2 resistors in series 6KE$34DBR001 6KE$34DBR007 6KE$34DBR015 6KE$34DBR007* 6KE$34DBR015 6KE$34DBR025 6KE$34DBR030 6KE$34DBR040 6KE$34DBR050 6KE$34DBR060 6KE$34DBR075 qty 2 6KE$34DBR050 qty 2 6KE$34DBR060 qty 2 6KE$34DBR075 qty 2 6KE$34DBR075 qty 2 6KE$34DBR060 2 resistors in parallel 2 resistors in parallel 1 resistor/BU, 2 BUs in // 1 resistor/BU, 2 BUs in // 1 resistor/BU, 2 BUs in // allows 100% CL + losses~(110%) 200 200 200 400 400 900 1400 900 1400 1800 1800 3600 4800 6000 7200 9600 12000 14400 14400 24000 IPC resistor bank model # DB ckt configuration DB pkg watts available % duty with this R & DB combo 35,7 26,8 13,4 17,9 10,7 16,1 18,8 12,1 12,5 12,1 9,7 16,1 16,1 16,1 16,1 17,2 16,1 15,4 12,9 16,1

DB 10 sec 1 time ave Watts capability stopping in X times from 1800 motor rpm in 5 sec inertia 22,119 45.2 22,119 45.2
60.3 45.2 60.3 150.7 150.7 150.7 331.5 452.1 828.8 904.2 979.5 1085.0 1959.1 2109.8 6027.9 6027.9 9795.3 16576.7 16,590 44,239 33,179 29,861 46,451 29,861 21,114 19,907 10,859 19,907 24,501 27,649 18,376 22,751 9,954 11,944 7,350 7,239

for decel on ramp with motor power capable of 150% of rated motor HP.

Chapter 6 - Standard Braking Resistor

Table 6.1: 10% duty typical DB resistors for AV-300i

BU-300 UL

AV-300i HP max.HP 20% DB model # (with OL) duty KW 6KAVi43... output F75 1 2 3 5 7 10* 10* 15 20 25 30 40 50 60 75 100 125 150 200 0,75 1 2 3 5 7,5 10 10 15 20 25 30 40 50 60 75 100 125 150 200 0.1119 0.1492 0.2984 0.4476 0.746 1.119 1.492 1.492 2.238 2.984 3.73 4.476 5.968 7.46 8.952 11.19 14.92 18.65 22.38 29.84

BU-300 equivalent type DB resistor ohms internal internal internal internal internal internal BU-300-20 internal BU-300-50 internal internal internal internal internal internal BU-30085 BU-30085 qty 3 , BU300-50 qty 3 , BU300-85 qty 3 , BU300-85 200 200 160 160 120 80 27 80 15 30 15 10 10 7.5 6 5 5 3.75 2.5 1.67

IPC resistor bank model # 6KE$34DBR001 6KE$34DBR001 6KE$34DBR003 qty 2 6KE$34DBR007 qty 2 6KE$34DBR010 qty 2 6KE$34DBR015 6KE$34DBR015 qty 2 6KE$34DBR015 6KE$34DBR040 6KE$34DBR040 6KE$34DBR030 6KE$34DBR060 6KE$34DBR060 6KE$34DBR075 6KE$34DBR050 qty 2 6KE$34DBR060 qty 4 6KE$34DBR060 qty 4 6KE$34DBR040 qty 3 6KE$34DBR075 qty 6 6KE$34DBR060

DB ckt configuration

2 resistors in series 2 resistors in series 2 resistors in series allows 100% CL+ 2 resistors in series

DB 10 sec DB pkg available % ave Watts 1 time watts duty with stopping capability this R & from 1800 in X times DB combo rpm in 5 sec motor inertia 200 35.7 45.2 22.119 200 26.8 45.2 22.119 400 26.8 60.3 33.179 1600 1800 2800 1800 2800 3600 7200 3600 6000 6000 7200 9600 12000 24000 21600 24000 36000 71.5 48.3 50.0 24.1 37.5 32.2 48.3 19.3 26.8 20.1 19.3 21.4 21.4 32.2 23.2 21.4 24.1 45.2 60.3 150.7 150.7 150.7 331.5 452.1 828.8 904.2 979.5 1085.0 1959.1 2109.8 6027.9 6027.9 9795.3 16576.7 176.955 149.306 92.901 59.722 92.901 54.293 79.630 21.717 33.179 30.627 33.179 24.501 28.439 19.907 17.917 12.251 10.859

for decel on ramp with motor power capable of 150% of rated motor HP.

Table 6.2: 20% duty typical DB resistors for AV-300i

GEI-100492

2 resistors in // 2 resistors in parallel 2 resistors in series, in parallel 2 // resistor/BU, 2 BUs in // 1 resistor/BU, 3 BUs in // 2// resistor/BU, 3 BUs in //

27

28
DB 10 sec AV-300i HP model # 6KAVi43... max.HP (with OL) output 50% DB duty KW BU-300 type equivalent DB resistor ohms F75 1 0,75 1 2 3 5 7,5 10 15 20 25 30 40 50 60 75 100 125 150 200 0.27975 0.373 0.746 1.119 1.865 2.7975 3.73 5.595 7.46 9.325 11.19 14.92 18.65 22.38 27.975 37.3 46.625 55.95 74.6 internal internal internal internal internal internal BU-300-50 BU-300-50 internal BU-300-85 BU-300-85 qty 2 BU-300-85 qty 2 BU-300-85 qty 2 BU-300-85 qty 2 BU-300-85 qty 3, BU-300-85 qty 4 , BU-300-85 qty 4 , BU-300-85 qty 4 , BU-300-85 160 160 260 160 120 80 12 10 30 6 5 3 3 1,875 2,5 1,67 1,25 1,25 1,25 6KE$34DBR003 6KE$34DBR003 qty 2, 6KE$34DBR005 qty 2, 6KE$34DBR007 qty 2, 6KE$34DBR010 qty 2, 6KE$34DBR008 6KE$34DBR050 6KE$34DBR060 6KE$34DBR040 qty 2, 6KE$34DBR050 qty 2, 6KE$34DBR060 qty 4, 6KE$34DBR050 qty 4, 6KE$34DBR050 qty 4, 6KE$34DBR075 qty 4, 6KE$34DBR050 qty 6 ,6KE$34DBR060 qty 8 ,6KE$34DBR060 qty 8 ,6KE$34DBR060 qty 8 ,6KE$34DBR060 2 resistors in series 2 resistors in // 2 resistors in // 2 // resistor/BU, 2 BUs in // 2 // resistor/BU, 2 BUs in // 2 // resistor/BU, 2 BUs in // 2 // resistor/BU, 2 BUs in // 2 // resistor/BU, 3 BUs in // 2 // resistor/BU, 4 BUs in // 2 // resistor/BU, 4 BUs in // 2 // resistor/BU, 4 BUs in // 2 resistors in series 2 resistors in series 2 resistors in series 2 resistors in series 400 400 800 1600 1800 2800 4800 6000 7200 9600 12000 19200 19200 24000 28800 36000 48000 48000 48000 IPC resistor bank model # DB ckt configuration DB pkg watts available % duty with this R & DB combo 71.5 53.6 53.6 71.5 48.3 50.0 64.3 53.6 48.3 51.5 53.6 64.3 51.5 53.6 51.5 48.3 51.5 42.9 32.2 ave Watts stopping from 1800 rpm in 5 sec 45.2 45.2 60.3 45.2 60.3 150.7 150.7 331.5 452.1 828.8 904.2 979.5 1085.0 1959.1 2109.8 6027.9 6027.9 9795.3 16576.7 1 time capability in X times motor inertia 44.23 44.23 66.35 176.95 149.3 92.9 159.25 90.48 79.63 57.91 66.35 98.0 88.47 61.25 68.25 29.86 39.81 24.5 14.47

for decel on ramp with motor power capable of 150% of rated motor HP.

Table 6.2: 50% duty typical DB resistors for AV-300i

BU-300 UL

2 3 5 7 10 15 20 25 30 40 50 60 75 100 125 150 200

Resistor sizing notes: 1) A power resistor is restricted in maximum amps, usually 5 or 10 times it's continuous rating. This limitation may increase the power rating even though the RMS power may be relatively low. Consult with the particular resistor vendor for the actual maximum restrictions if different than above. Per IPC, resistor banks are rated for 5 times continuous rating for 10 seconds, with a off time of "cool to ambient". "ave watts stopping from 1800 rpm in 5 seconds" can be used to estimate stopping requirements. This number is proportional to the square of the rpm.Time is inversely proportional.

2) 3)

4) DB 10 second, one time capability shows how much load inertia can be stopped in fast stop conditions once then cool to ambient, for the % duty.

GEI-100492

29

+24V
C-BOT
1

400V

X3-6

0V24V

415V

BR

440V C

460V

X3-7

480V

VHT
Vth Von
Gate

C-BU-y

30
BUy-C ESE3036
+24F

AL

X2-1

X3-76
S

Fault
X2-3
FAULT

OK

K1

X3-75
R

Reset
XT1 XT2

Only for: 6KBU300-20UL-50UL Only for: 6KBU300-85UL

CR BR C C

R-Break

X3-4

RESET

S3 +10V 3

RESET

Mains Voltage
SN-BUy ESE3139/1 ESE3139/2

X3-1

+24VF

230V

F2

+24V

380V

Vout
X1-1
RES-SN

X3-8 X3-9
+15V M 0V -15V +24V 0V24 S +15V 0V -15V +24V

D INVERTER

X3-10

XY6
Emitter

X1-2 XV1 XV2 D

2

Chapter 7 - Block Diagram

BU-300 UL
MASTER/SLAVE
SALVE S4=ON S3=MASTER S4 S2 MASTER SLAVE MASTER SMPS-ON OK

+24VF

X3-5

Break
PE

MASTER

S4=OFF

S3=SLAVE

Nr: ESE_3210 Date 12/02/01

 GEI-100492

31

1S9G70

GE Industrial Systems
+ 1 540 387 7000 www.GEindustrial.com General Electric Company 1501 Roanoke Blvd. Salem, VA 24153-6492 USA GEI-100492 010502 SIEI