VACON NX Brake Resistors User Manual
Contents
1. ud CH WN 80 90 pueui6i Pe ud y C E uer d NS CN odd ol IL Pann VL 2 001 ME 1401 294402 HJLTASDASGH ce aduna Ouduvy C IXeIN 0002 TIES YN H SH C9 dI dOLNDAS 3 00 z J ES QI G y 20u04 Duc CIX9IN 0102 TES IN W SW G9 d dlllNDIS n 320000 02000 wn flo o SEI aan c ean ca ES PAPA ER S E x lt HUESEN x e e o Ve 90000 00000 aig a j co Ecg ESO Vd JS IN EN 0241 JOLUOZIUO Nc Lo Nc i DU se O ail i E ch fo a adj 5 550 4011391044 4015 59 3 o Jj aya uonisod siy UT 3 UMOR XOQ UO JIAUUOJ l ULM 1021149 m ONT INDIA 26 9 VACON VACON 27 TECHNICAL DATA NOISIA3H V sus C8CLOXXXA 1490 ON ONIMVAQ caH 9020 dadd E im GL 31vos AHAOAd2. GE E v SU L ag ROS CNYTNI 180 LDOXA 483087 YSYYA I8 GO Un KU des L0221e 102 p BSE x94 Ge xog Od NOISIASS ON ONIAVAG WON aJADaddy Tele 102 lt 0 866 ne ahuluosuny LJ LU 133H8 3114 LON 1900 d NAVI A NICA TECHNICAL DATA 400 1a 097 Aygo 6 009 09 oo 620 069 9 4 Ton 9 aH 00 dag Mcv rez LHA 099 eo 9v ooz oov oos 960 009 9 a4 z saHteoo dag veg lez 1a 007 Ago se ovs ooe oor 890 os 9 Jj eSuva4 e9 sah zz00 eya HOL L8z LHA 096 eo or ooz oov oos 960 oez 9 94 OL zah 900 39 aoz tez 1go9zn vz oov oo oc svo oz 9 S94 oz zaHteooysal BY GT CF CF MM A zlULU AZIS WHO 3dAL NOOVA y m uu 17 WW T UU 7 3MOd 39VLTOA 318VO 3NVYW3 EI TANINON ANI LO O CN oo CN oo CN oo O CN O 00 LO mM gt O LL e CN CN NT C CN O 00 LO C9 DV
3. Min 500 Mounting holes 09 24 hour support 358 0 201 212 575 e Email vacon dvacon com 32 VACON TECHNICAL DATA BRR 0730 LD5 0 9 Fri1 M8 3X95 50 37 500V 19 2 kW BRR 0590 LD 6 Fr11 50 mm2 M8 3X70 35 690V 19 0 kW Connection Terminals for cable M8 Torque moment 4 5 Nm B Terminals for cable M8 Torque moment 4 5 Nm Cable gland SH40 Clamping range 29 40 5 mm Connection Earth PE Screen braiding Cable gland The connection cable to the brake resistor is to be screened armoured Always connect the screen armouring in both ends Note for proper performance the resistor sheets have to be vertical Mounting SE TEE EE EE OE 253397835 IEEE Min 150 Min 500 f je W e Le 380 500 480 530 Mounting holes 09 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 33 Vacon code mm BRR 0520 HD 5 BRR 0416 HD 6 Connection Cable gland SH40 Clamping range 29 40 5 mm Terminals for cable M 8 Torque moment 4 5 Nm Connection Earth PE Screen braiding Cable gland The connection cable to the brake resistor is to be screened armoured Always connect the screen armouring in both ends ns wai 48 t Li H ver Teo RAE WEE H v Cd H VCOXRTTS e SREL mae a H ae STEE ERD cavas NL anne 5 ut t
4. Note for proper performance the resistor sheets Mounting have to be vertical Si nts n SES 2 E EH PE CNT HIS Si Csi REE Be k Me pt How SERIES RRA RANA EN p mrak alim TE EE EE EE Hm SSH und 33 ui a Sou EARS n SMS IE HEN EAS HEES Ee or Zen SET MW SE eme H ges zu oy N lo GC in Ts Min 450 Min 500 300 L 380 500 cc 480 530 Mounting holes 09 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 9 31 Vacon code Ohm Danotherm code FRAME Connection oie Vac Pn kW Weight kg BRR 0300 HD5 BRC 17 AT20 3R25 E726 Fr8 Fr9 M8 3x70 35 500 V 12 84 kW 2 BRR 0520 LD5 1 4 BRC 17 AT20 1R4 E725 M8 3x95 50 37 500 V BRR 0208 HD6 7 BRC 17 AT20 7R E724 M8 3x50 25 28 690 V BRR 0416 LD6 2 5 BRC 17 AT20 2R5 E726 M8 3x70 35 32 690 V Connection Terminals for cable M8 Torque moment 4 5 Nm D Terminals for cable M8 Torque moment 4 5 Nm a Cable gland M25 Clamping range 18 23 5 mm Connection Earth PE 2 Screen braiding l EJ Cable gland e The connection cable to the brake resistor is to be screened armoured Always connect the screen armouring in both ends Mounting c ebbe JE ih eR ERE 88 EE ii 33 M ER 4 2e e lep 2 3 33 35 p amac NOAA OA i ooo S SCH
5. 069 xJegoseenso zt ole oos y HOLHOSOrPASO srs ose sor ego oez 919Mv ey Ozoseznso 990 ope soz zo Ot y SH MO O S9L Ago 600 op sor Wo oez DN ww 11 JUBIOM l E OSdl Sept uonoejoJd Vi S UOZIJOH JO umop Sa qeo UJIM BOIS A ONILNNOM KLEER soy en ste AT E SLOMV gt lt JV lt 99mY V 91OMV 9 91OMWV Loos 913 S d 914 d Gld 9L MY 18122 ae sd MA lU 3ZIS WHO 3dAL NOOVA Y3MOd 39W110A dlavo 3WVsHd Y J3NINON SANIT 9 001 9 Sd1 2200 dag OL oz oe G dd 2200 del 9 d1 100 dd9d G q1 1900 HU c q1 1 00 444 011600 ddgd Le L1 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 23 im IM 1908101 x T S Dn ponit raisto DIU logs 13 P x m z5 U m AA Horfroatol IF10 CO IEC deyn In L R p E NE BRR 1025 HD 2 Ag GH EE MA AA BEA be VACON OYJ 24 hour support 358 0 201 212 575 e Email vaconldvacon com TECHNICAL DATA 24 VACON LE ES CL os OXXXA7HHOOEr CI PIIO ddd INOISIAZM ON ONIMVHQ J3NVN ISPULBA d H8L HO SZZ WA gao 9 s 929 sz SL 069 vLOMV 44 el 901 2500 dag gt daA0dddV SEL 008 HO 92S AH999 Y 921 92S 90 L 006 VLOMV 914 vL G
6. Partial use most typical The process requires regular or irregular rapid decelerations stops or reversings b Continuous use The motor continuously brakes with constant torque c Combination use The motor continuously brakes with variable torque d DC link voltage smoothing The brake resistor smooths overvoltage spikes from the supply Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 9 3 2 TECHNICAL DATA 2 1 Standard resistors for partial use Brake resistors for partial use for the NX ranges for 208 240V 380 500V and 525 690V supply voltages can be chosen from the tables below For the NX_5 range we have predefined two ranges of brake resistors one for heavy duty and one for light duty The heavy duty resistor is sized for a 3 second full power braking with a 7 second ramp to zero The light duty resistor is rated for a 9 second ramp from full power to zero See Figure 2 Predefined power pulses 2 Heavy duty lt Light duty o oa Ew G OC Figure 2 Heavy and light duty braking definitions Relative power handling capability of the standard brake resistor ranges 1 20 1 00 Ge Heavy duty 0 60 ed Average power 0 40 d Continuos power 0 20 0 00 sre a a a a a a a a a as a ON O ot ot D o ot o Q O D ED based on 120 s period Figure
7. 00 LO mM gt O LL e CN CN NT C CN O 00 LO C9 DV TECHNICAL DATA VACON 29 Connection Terminals for cable M8 Torque moment 4 5 Nm u Terminals for cable M8 Torque moment 4 5 Nm Cable gland SH21 Clamping range 18 23 5 mm Connection Earth PE Screen braiding Cable gland The connection cable to the brake resistor is to be screened armoured Always connect the screen armouring in both ends Note for proper performance the resistor sheets Mounting have to be vertical d wu aH SA abbat SERIE B nes theo SA min QV RS Sonate rm DEE Le BE Ver o TRE inm Hi GE Kam 8i D amp iih HU k LGE ZE ag LI Min 150 ame a k A A E D Y L 380 o c Ge 480 a sua Mounting holes 24 hour support 358 0 201 212 575 e Email vacon dvacon com 30 VACON TECHNICAL DATA ee om ae comeston RP wr vv ST BRR 0100 HD 6 9 0 Frt0 16mm2 M8 3X16 16 23 690V oul 20 Connection Terminals for cable M8 Torque moment 4 5 Nm DN Terminals for cable M8 Torque moment 4 5 Nm Cable gland M25 Clamping range 18 23 5 mm Connection Earth PE EC Screen braiding Cable gland The connection cable to the brake resistor is to be screened armoured Always connect the screen armouring in both ends
8. Hi 111 EZ e Nin 150 E p e Mounting holes 09 24 hour support 358 0 201 212 575 e Email vacon dvacon com 34 VACON Vacon code BRR 0730 HD 5 TECHNICAL DATA mm K Connection Cable gland SH40 Clamping range 29 0 40 5 mm Terminals for cable M 8 Torque moment 4 5 Nm C Connection Earth PE Screen braiding Cable gland 4 Core 2 3 4 The connection cable to the brake resistor is to be screened armoured Always connect the screen armouring in both ends Note for proper performance the resistor sheets have to be vertical Mounting Min 150 I Min 500 A d p T py Eh RETIRE EE 5M EDO RESA INSSE a i d Nu H SHEET EE SEI Gute ue ipe EE EE EI Home Sall d BEER El Bem dun men epus d oC dee el iE a 2 goog iii TIME IA GI ESI Medis ub SE EE EE Bien pnr SE RRASS RRSARSRERE RAIN FRERE LEES ES ET enn ud EE SE HP de et Red Ee SE K ccn HE 2 R de 20 HOTTHT n NEC 1320 Mounting holes 9 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 VACON DRIVEN BY DRIVES Find your nearest Vacon office on the Internet at WWW Vacon com Manual authoring Document ID documentation dvacon com Runsorintie 7 65380 Vaasa D P D 0 1 5 7 3 B Finland Rev B Subject to change without prior notice
9. O 2015 Vacon Plc
10. motor load The deceleration is in this case dependent on the power losses in the converter and in the motor This is usually sufficient in most cases for pumps fans conveyors etc where the kinetic energy In the load is small or the braking time is not critical When you have to brake the motor faster than the losses allow you have to use an external brake resistor for energy dissipation together with an internal factory mounted brake chopper The extra energy from the load is turned into heat in the brake resistor Applications where dynamic braking is usually needed include centrifuges cranes some conveyors and drives requiring very fast reversing 1 2 Brake components The brake chopper is an extra IGBT mounted into the NX frequency converters at the time of manufacturing Smaller drives FR4 to FR6 and MF4 to MF6 contain it as standard If the DC link voltage increases too much the brake IGBT turns on and discharges the capacitors through the brake resistor The brake chopper in the NX frequency converter ranges Is rated for continuous drive rated power The brake resistor is an external low impedance resistor In order to achieve the correct power handling capacity for a specific application resistors can be connected in series and parallel keeping within the limits in Table 7 Brake resistor o D T ES M Figure f The brake components and their basic connection Brake chopper 1 3 Classes of use a
11. 3 Peak and average power definitions 24 hour support 358 0 201 212 575 e Email vacon dvacon com 4 0 VACON TECHNICAL DATA 2 1 1 380 500V range Light duty Energy kJ Average power kW l 5 sec full torque BRR 0730 LD 0 9 1975 165 Heavy duty Energy Average power kJ kW 3 sec full torque Type code Resistance decreasing to zero in 7s 1 pulse 2min BRR0730HD5 09 5832 8 S lable f Brake resistors for the voltage range 380 500V Choose the resistor for all types of frequency converters NXL NXS and NXP according to the table below Light duty Unit Frame resistor Heavy duty resistor NX 0003 5 NX 0004 5 NX 0005 5 NX 0007 5 NX 0009 5 NX 0012 5 NX_ 0016 5 BRR 0022 LD 5 BRR 0022 HD 5 NX 0022 5 NX 0031 5 NX 0038 5 NX 0045 5 NX 0061 5 NX 0072 5 NX 0087 5 NX 0105 5 NX 0140 5 BRR 0022 LD 5 BRR 0031 LD 5 BRR 0045 LD 5 BRR 0061 LD 5 BRR 0105 LD 5 BRR 0105 LD 5 BRR 0300 LD 5 BRR 0022 HD 5 BRR 0031 HD 5 BRR 0045 HD 5 BRR 0061 HD 5 BRR 0105 HD 5 BRR 0105 HD 5 BRR 0300 HD 5 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 9 5 NX 0168 5 NX 0205 5 BRR 0300 LD 5 BRR 0300 HD 5 NX_ 0261 5 NX_ 0300 5 NX_0385 5 NX_0460 5 BRR 0520 LD 5 BRR 0520 HD 5 BRR 0300 LD 5 BRR 0300 HD 5 NX 0520 5 NX 05905 NX 06505 BRR 0730 LD 5 BRR 0730 HD 5 NX 07305 NX 08205 NX 09205 2x BRR 0520 LD 5 2 x BRR 0520 HD 5 NX 10305 Table 2 Brake resist
12. 96 oo sez oo 9 44 s9 saison gg eye 187 IHO099HI80 A Sci oo 099 oo sz occ oF 44 ee zaHbilouua tul lel HOSYSH 189 N w 4 vo srs sie oez 0991 614 813 vi 2 d1 8020 dag jeysouay DY LI L1 1 dAMOd OVA zu AWVds INHO AdAL NOOVA IH9I3JM TANINON 4OVLIOA 3 18VO 3NIT WN 8 0 90 Buiueju n anbso jeune ww 9 Duddune M AOOE Zh vc SMV n A008 MU y Z 0 041 UONDBUUOD M S YM Z GO XINSOHd edAL ZL LL POHEN UOHDDUUOJ UDJIMS oway qru 06 WNOL BurueuBn anbio euer u 8 2 vue e Buiddujs M A009 9 O L SMV AN So nJJo J esf zulul 9 G Z A064 zWW OS 9 Z o3l L93M ojsug ed zada Lgs POMEN S EUIUJJ9 JOJSISOY Ozdl jeyuozuoH JO Lad S SSED UOIn99 oJd 10 SISAJ eu uonisod siuj ul UMOP XOq UOHDAUUOD UUM JE9IHOA ONILNNOW ww 0 Ge eBues Buidue 9 W SW UOIJIBUUOJ uoj s OULU JOJ pueb ejqe2 ww GL WeIQ pleIg WNUWIIUIJAJ ww gz 61 abuey Buidwejo W 9S SW e qe9 10 SIS J JOY UONOB UUOD U8891IS UJIM pugo 81429 JIVIS a IVL4G 00 00 0000 di LI O E O O gt KS O O gt LU e LO N LO N wre N wre O N CO LO M U O o o 5 T U O ic I M N
13. ECHNICAL DATA 2 2 Other resistors Should other types of resistors be used make sure that the resistance Is higher than the minimum resistance defined The power handling capacity must be sufficient for the application The minimum resistances calculated at the trip level NX_5 911VDC NX 2 437VDC and NX 6 1200VDC can be found in the following tables 380 500V range 208 240V range Brake chopper Brake chopper Frame om 80 C Frame om 80 C Rain LO NX 0003 5 x NX_0003 2 NX 00225 E oe NX 00252 i u NX_0031 5 17 42 NX 0031 2 20 NX 0038 5 xx NX 0048 2 NX 0045 5 gt d mes NX 00612 i NX 0075 2 m NX 00615 65 14 x NX 01142 NX_0072 5 NX 01402 NX_0105 5 D Ss mm NX 03002 ka NX 0140 5 U NX_0300 5 eg E E BE U NX_0820 5 eg NX_1030 5 2 x 570 2x 1 4 575 690V range Brake chopper Frame om d80 C NX_0004 6 NX_0013 6 NX_0018 6 NX_0034 6 NX 0041 6 NX 00526 NX 0061 6 NX 0100 6 NX 0125 6 NX 0208 6 NX 0261 6 NX 0416 6 NX 0460 6 NX 0590 6 NX 0650 6 NX 0820 6 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 9 9 2 3 Power rating of standard resistors The power handling capacity of the standard resistors as a function of the duty cycle is shown in Figure A The figure shows the relative power handling capacity at various duty cycles i e compared to continuous 120 s braking Relative power handlin
14. J x0 105 x 8 Verify motor rated P torque gt required Ty Zu T torgue M Py in kW ny In rpm Figure 6 Speed profile of one drive cycle t length of cycle t deceleration time tz stop time ni minimum speed of motor Nz maximum speed of motor The relative power handling capability of the standard resistor ranges is shown in the figure below 24 hour support 358 0 201 212 575 e Email vacon dvacon com 18 0 VACON TECHNICAL DATA Relative power handling capability of the standard brake resistor ranges 1 20 7 1 00 0 80 Heavy dut 0 60 a Light duty 0 40 0 20 0 00 0 2 3 5 8 17 25 33 42 50 67 83 100 ED based on 120 s period Figure 7 Verify the following a The chosen resistor type can handle the required power NOTE As the brake IGBT current is limited by the device a resistance with a smaller impedance than the minimum specified for the drive cannot be used b If this is not the case the resistor has to be sized specifically for the application In many cases a sultable combination of series and parallel connection of standard resistances may be the solution in others a special resistor must be defined and manufactured Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 19 3 2 3 Internal resistors Frame sizes FRA FR5 and FR6 380 500V drives can b
15. L DATA 28 VACON L8cLAXXXH L1490 NOISIA3H ON ONIMVAQ CV ous SQH Sv00 ddd PS im GL amos ONVINIA VSVVA L8 S9 AJINOYAAV Wd NMVYQ AO NOOVA LOZZLZ LOZ 0 89 Xe4 GZ Xog Od LZLZ LOZ 0 8SE SL Z onuuosuny Hoe lez IHd099H182 A i 008 08 ube lez 1Hao09sHI8o A et 007 0 ae UT C fT WN 8 0 90 Buluaxy6n anblo jeuiuue ww g Duddue M AOOE CL ve 9MV IN A008 MU y Z 0 941 uonoeuuo Mee UJIM Z GD XINJOHd S0AL ULI PONJEW UuOnoeuuo YIHMS oway WN 8 1 5 1 GuiuauGiy enbuo jeuiuue L wwz Duddune aM A009 9 02 SMV IN A008 zt O S 0 941 Z 019 XIN3OHd ed zadu Lgs PoMeW S euiulJ9 JOJSISDY 0Zdl JejuozuoH ez 09 9 7d 9dHre00das cc oo 9 4 kz S OH stoo dag 099 09S 1 OVA zuu 3ZiS WHO AdALNODVA avo1 39vVLI0A leva aves y TANIWON 2ND ww 0 Ge ebuey Buiduue 2 W SW UONOBUUOD UDJIMS oway 104 puejB ajgeo ww G 7 WeIg preJg WUNLUIUIA ww 9 9L 6 93Buey Buidue 5 IN OS SIN 9 29 10 SISO1 JOY UOHDAUUOJ UIAJIS UJIM pue o 81429 L 11V9S a IVLAG JO LZd S SE UOI 29 0Jd JOJSISAI 092 eu uonisod Sy ul umop Xoq uonoeuuo2 UUM JEJI9A ONILNNOW di 00 o 0ODO LO O CN oo CN oo CN oo O CN O
16. VACON NX AC DRIVES BRAKE RESISTORS USER MANUAL VACON DRIVEN BY DRIVES TECHNICAL DATA VACON 1 INDEX Document code DPD01573B Date edited 24 4 2015 1 A ce U e 2 1 1 Keguitement tor DEaKIBO EE 2 1 2 Brake e al enn 2 1 3 35555 Eeer 2 2 TECHNICAE DATA ieee Re ae eee ee eee ee ne eee eee ee ee eee ee 3 2 1 histeieren UE 3 ZN ES 0 SO P 4 PR Oo we EE D Ako ENEE 6 2 2 OtherTesiStorS erns se icceead antes mecansuseate a nceseecece gnatemoset ia aso ne SE a aE S Ra 8 2 3 Power rating or standard KCSISUORS E 9 2 4 ENVIFONME EE 11 2 9 Thermal protection for the LD resistors ss 12 A la oo iil Eege Mer 13 3 CHOICE XOF BISAKE RESISTOR cuasi ndo 14 3 1 Ent 14 3 2 SIZING PNC AA 14 3 24 Galcula tig braking UI Est a nent 15 3 2 2 Calculating themoment Or ING UA seek eo ee bab bobus tabu bot b dis Mee av Me odo Bakalu 15 A ea ens entre P cep ene ee ee 19 4 CONNECTIONS bai ote ba 20 4 1 General aan 20 24 hour support 358 0 201 212 575 e Email vacon dvacon com 2 9 VACON TECHNICAL DATA 1 GENERAL 1 1 Requirement for braking When you want to slow down a running asynchronous motor fed by a frequency converter it turns into a generator feeding energy back into the frequency converter The energy increases the voltage in the DC link The frequency converter compensates for this increase by increasing the output frequency decreasing the instantaneous slip and increasing the
17. dy NMYad GNYINI4 VSVVA 18 99 ZO0ZZ1Z LOZ 0 89 XE4 GZ Xog Od LZLZ LOZ 0 89 SL 7 onuuosuny AO NOOVA HZ 282 HO 099180 N CHE Z8Z HO 092 A180 N 62 VUL 28c IHO 092 A LHO A 6 je1souueu 64 ypa M WN 80 90 Duueuufn enbo jeuiuuo L ww g Buiddujs SIM A00 Zl v6 OMY IN A008 MU 0 941 UONIBUUOD M S UJIM Z GD XIN3OHd 9d L CL LL POMEW UOHDAUUOJ YOUMS OUJJ9U aru 06 WNOL DuuieuDn enbuo jeuuue L ul g 2 wuez Buddus SIM A009 9 0 1 OMV IN Sso naJe J esf ulul 9 GZ NOSZ WU OS 9 z 29 193M 01SU3 ad cas Lgs POHEN S BUlUJJ9 JOJSISDY ozdl Ie UOZINOH JO LZdl S SSEI9 UOIno9joJd 1OJSISAJ eu uonisod emt ul uMop xoq uonooeuuoo UUM EBOIUSA ONILNNOW zy ERN eu 7 L A1V9S V 11130 00G oez uonoeuu oso 64 9G18020u8 0991 614 814 GZ G Q100 0 usa 0991 614 7814 VL z GH sozo dual H v LU AWYad WHO 3dAL NOOVA Aava y ww 0 G g ebuey Dudugr W SW 09 YOUMS oway 104 puej6 ajgeo ww GL WeIg plelg uunuuluijN ww 92 6 3Buey Guiduelo W OS SW e qe9 JOJSISA1 104 UOHDAUUOJ UIAJIS UJIM PUEIO 21429 O E O O gt KS O O gt LU e LO N LO N wre N wre O N CO LO M U O o o 5 T U O ic I M N TECHNICA
18. e equipped with an internal brake resistor as a factory option The resistors are designed for a 2s full torque braking from nominal motor speed to zero or a 1 second full power braking every minute Type code Resistance Energy Average power O Ze full torgue braking 1 pulse min kJ NX 5 FR5 NX 5 FR6 able 8 Relative power handling capability of internal resistors o PH AN A Time sec Figure 6 24 hour support 358 0 201 212 575 e Email vacon dvacon com 20 VACON TECHNICAL DATA 4 CONNECTIONS 4 1 General Make sure that your frequency converter is equipped with a brake chopper This is a factory installed option The brake resistor is connected to the DC and R connectors on the frequency converter The minimum cable sizes are shown in Table 1 and Table 2 When you size the cables note that the input fuses f the converter also protect this cable Avoid running the brake resistor cable too near other cables The recommended minimum distance to e g the control cables is 0 5 meters Note Disconnect the frequency converter from the mains when connecting the brake resistor Wait a further 5 minutes before opening the frequency converter cover Perform measurements to ensure that no voltage is present on the DC and R connectors Read Chapter 1 SAFETY in Vacon NX User s Manual Cable sizino Cable and Cable and BRR0025LD2 IntegralAWG16 BRR0025HD2 6 BRR0031LD2 I
19. g capability of the standard brake resistor ranges 1 20 1 00 0 80 Heavy dut Li u 0 40 g y 0 20 0 00 XX af aft O9 oa oa at oa O CN O O N or IO O WN O NO O T WN O st LO O O ED based on 120 s period Figure 4 Relative power rating of standard resistors BEDS UE Power at different duty cycles based on a 120 sec cycle nu Z 100 ED 60 ED 40 ED 25 ED 1096 ED 5 ED ewe KK OK O O W BRR 0205 LD2 22 37 56 90 22 45 O o el BRR 0022LD5 0 24 039 059 094 24 47 BRR 0105 LD5 23 38 57 91 23 46 BRR 0300LD5 46 76 1L4 182 46 91 BRR 0730 LD 5 16 27 41 Lee 165 329 O M BRR 0034 LD 6 0 94 16 24 38 94 188 63 BRR 0208 LD 6 40 oi 101 161 40 81 BRR 0590 LD 6 17 28 42 66 ep 332 LO 24 hour support 358 0 201 212 575 e Email vacon dvacon com 10 9 VACON TECHNICAL DATA BRR0114HD2 25 Al 62 99 25 ag A E BRR 0045 HD 5 18 30 46 7 3 183 37 BRR 0061 HD 5 27 46 69 11 0 27 Jas BRR 0105 HD 5 59 98 148 24 ag 118 BRR 0520 HD5 27 46 69 110 X274 549 O EE uu Lou ia m BRRO052HD6 41 68 102 163 a 81 BRRO416 HD6 29 Lag 73 117 293 586 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 11 2 4 Environment Surface temperature of the resis
20. motor inertia plus the load inertia changed by the gear ratio as follows M 2 J m 8 where gis the gear ratio Jo Is the motor inertia and J 4 is the load inertia The ratio gis gt 1 if the load speed is higher than the motor speed and 1 If the load speed is lower than the motor speed 24 hour support 358 0 201 212 575 e Email vacon dvacon com 16 0 VACON TECHNICAL DATA In many cases the moment of inertia of the motor is very small compared to the moment of Inertia of the load Only in cases where the load turns very slowly i e the gear ratio is low the motor inertia is significant The moment of inertia of typical shapes is shown in Figure 5 I 2m D d ys J rvan F Frin Figure 3 The moment of inertia of a specific machine is often specified on the rating plate Otherwise the manufacturer is responsible to give this information Sizing procedure 3 Moment of inertia 2 SES lu T 8 J road g gear ratio 4 Energy to be dissipated 6 Braking power 7 Determine duty cycle for braking t duration of cycle assumption 120 s Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 0 17 8 Determine average power for the resistor 9 Calculate the relative power required Pres peak power of chosen resistor 10 Verify that the pair of values In 7 and 9 are within limits for the chosen resistor see Figure 5 7 Calculate the braking torque required T
21. ntegralAWG16 BRR 0031 HD2 6 BRR0061LD2 IntegralAWG16 BRR0061HD2 6 o jb _BRR 0022 LD 5 IntegralAWG16 BRR0022HD5 6 _BRR 0031 LD 5 IntegralAWG16 BRR 0031 HD5 6 9 _BRR 0045 LD 5 Integral AWG16 BRRO045HD5 6 M8 3X95 50 RA _BRR 0013 LD 6 IntegralAWG16 BRROOIBHD6 6 Integral AWG16 BRRO034HD6 6 BRR0052LD6 IntegralAWG14 BRR 0052 HD6 6 M8 M8 bolt on the resistor Only two conductors of a normal three phase cable are needed The shield of the cable should be connected at each end The third unused connector should also be grounded by connecting it to ground at one end Tel 358 0 201 2121 e Fax 358 0 201 2121 205 VACON 21 TECHNICAL DATA Cable sizes 170 30 M N le m r c o N 00 re olo o olo olo olo olo olo INI olo A ju 135 10 107 11 7 0 410 10 4 0 460 4 0 0000 3 0 000 85 0 O E O O gt KS O O gt LU e LO N LO N vr N vr O N CO LO M U O o o 5 T U O ic I M N TECHNICAL DATA 22 0 VACON OXXXAS8O0 Fr NOISIA3H ON DNIMVAG ev L33HS 3 114 19600 ddd AWYN ALON S rod GL sqvos ANYINIH VSVVA L8ES9 ZOZZ21Z LOZ 0 8S xe4 GZ xog Od 43A0HddY IZIZ LOZ 0 89 191 2 anunosuny japuey d AO NOOVA H 9 008 9 SEE AGD ZL 9e E 7 00 O SOVAgO sr 98
22. ors used with drives Light duty resistor P50 with direct wire connection BRR0022 LDS has a thermal protection as option Heavy duty resistor P20 21 connecting box thermal protection as standard 2 1 2 208 240V range Light duty Energy kJ Average power kW 5 sec full torque 269 2 24 kJ kW I sec full torque decreasing to zero In Type code Resistance sec pulse 2min 0 27 BRR 0031 HD2 20 oa 0 41 BRR0061HD2 10 98 0 81 297 2 47 BRR 0205 HD2 1 4 699 5 87 O Table 3 Brake resistors for the voltage range 208 240V Heavy duty 24 hour support 358 0 201 212 575 e Email vacon dvacon com 6 9 VACON TECHNICAL DATA Choose the resistor for the frequency converter voltage range 208 240V according to the table below Light duty resistor Heavy duty resistor NX 0003 2 NX 0004 2 NX 0007 2 NX 0008 2 NX 0011 2 NX 0012 2 NX 0017 2 NX 0025 2 BRR 0025 LD 2 BRR 0025 HD 2 NX 0031 2 BRR 0031 LD 2 BRR 0031 HD 2 NX 0048 2 BRR 1LD2 BRR 1HD 2 NX 0061 2 aa NX_ 00752 NX 0088 2 BRR 0114 LD 2 BRR 0114 HD 2 NX_ 01142 NX_0140 2 NX_0170 2 BRR 0205 LD2 BRR 0205 HD2 NX 0205 2 NX 0261 2 NX 0300 2 able 4 Brake resistors used with drives BRR 0025 LD 2 BRR 0025 HD 2 BRR 0205 LD2 BRR 0205 HD2 Light duty resistor P50 with direct wire connection Heavy duty resistor P20 21 connecting box thermal protection as standard 2 1 3 525 690V range Light duty Energy kJ Ave
23. qI 1900 9439 ULZ 008 HO 9zb Ayao es oze ozr to oos 9LOMV 4 iz salrsroo ug 1N Her ezv O S07 AGO sv 98e sov seo 009 o1omv ou zr sa eoo dag cue HO 92y Aygo ee oze aer seo oez OLOMV 4 ce Zd bilo dag MY A MUI AZIS WHO AdALNODVA Y3MOd 39VLIOA d18vO INV X4 Y 3NIINON JNN ONY INIJ VSVVA 18859 LOZZLZ LOZ 0 8GE Xe4 Sz Xxog Od IZIZ LOZ 0 8s RL Z anunosuny AO NOOVA E pom D AW q 62000 d OSdl 6 SSE 9 UOI N9 Ol a N O u JEJUOZIIOH M JO UMOP Sa gEe3 UM EDDA NN ONLLNNOW T v 079 e Nam Oz 90303 PO P i S x o oo I LC C CN E CN NC CN vo O CN O 00 LO C9 O LL e CN oo CN oo O CN O 00 LO eo D ER VACON 25 TECHNICAL DATA 1821 L DXXXH LHOOEV NOISIA3H ON ONIMVAQ F gt im GL 31vos G19020 444 SINVN ZOZZLZ LOZ 0 8S Xe4 sc xog Od qaAOsddv LZLZ LOZ 0 8S 191 7 enuuosuns ONVINI VSVVA 18 99 AO NOOVA 086 187 LHO 092 H189 N Lat 096 099 oo ze 069 osos els 6 9070010 38 yv 187 LHO 099 H 18D A szi 098 099 099 gc oo oF 94 vi S0H1900 dag S49 182 HO 099 H 189 N L t 098 0
24. r for it 2 5 1 Thermal protection The thermal protection in the resistors should be connected to the external Fault input on the drive 24 hour support 358 0 201 212 575 e Email vacon dvacon com 14 VACON TECHNICAL DATA 3 CHOICE OF BRAKE RESISTOR 3 1 General When you choose the brake resistor for your drive start from the requirements of the process drive The choice of brake resistor is influenced by a the average braking power during one cycle this defines the power dissipation required of the brake resistor b the maximum power dissipation this defines the instantaneous power handling capacity of the brake resistor and c the maximum current of the brake IGBT this defines the minimum resistance for the brake resistor Vacon Technical Support will assist you In all matters concerning braking 3 2 Sizing principles All rotating parts contain kinetic energy When the load is braked the energy difference between the higher speed and the lower speed must be dissipated somewhere Some of the energy Is used in the losses of the motor and the frequency converter but the majority must be dissipated in the brake resistor The energy of a load at speed n is given by the formula HS 2 where Jis the moment of inertia of the load in kgm and w is the rotating speed of the load in radians s In engineering units a 182 3 where is the rotating speed in 1 min The difference between the energy at
25. rage power kW 5 sec full torque BRRO100LD6 9 36 84 O LL E SL OLO D LC Heavy duty kJ kW 3 sec full torque decreasing to zero in Type code Resistance 7sec pulse 2min BRR 0013 HD 6 88 BRR 0034 HD 6 BRR 0052 HD 6 Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 97 BRR0100HD6 9 98 _____ 801 BRRO208HD6 7 1258 BRR 0416HD6 25 3523 BRR 0590 HD 6 17 Log Table 5 Brake resistors for the voltage range 525 690V Choose the resistor for the frequency converter voltage range 208 240V according to the table below Light duty resistor Heavy duty resistor NX_ 0003 6 NX_ 0004 6 NX_ 0005 6 NX_ 0007 6 NX_ 0010 6 NX_ 0013 6 NX 0018 6 NX_ 0022 6 BRR 0034 LD 6 BRR 0034 HD 6 NX 0027 6 NX 0034 6 NX 0041 6 NX 0052 6 NX 0062 6 NX_ 0080 6 BRR 0100 LD 6 BRR 0100 HD 6 NX 0100 6 NX 0144 6 NX 0170 6 BRR 0208 LD 6 BRR 0208 HD 6 NX_ 0208 6 NX 0261 6 NX 0325 6 NX 0385 6 NX 04166 NX 0460 6 NX 0502 6 BRR 0590 LD 6 BRR 0590 HD 6 NX 0590 6 NX 0650 6 NX 0750 6 BRR 0416 LD 6 BRR 0416 HD 6 NX 0820 6 Table 6 Brake resistors used with drives BRR 0013 LD 6 BRR 0013 HD 6 BRR 0052 LD 6 BRR 0052 HD 6 BRR 0416 LD 6 BRR 0416 HD 6 Light duty resistor P50 with direct wire connection Heavy duty resistor P20 21 connecting box thermal protection as standard 24 hour support 358 0 201 212 575 e Email vacon dvacon com 8 0 VACON T
26. tor box Maximum ambient temperature 309C IP20 IP21 IP50 NOTE On mounting the resistor package note the high surface temperature up to 200 C The mounting surface must be non flammable and there must be sufficient free space around the resistor 100 mm The resistors are designed for natural convection cooling in a free space ensure sufficient ventilation of the area 24 hour support 358 0 201 212 575 e Email vacon dvacon com 12 VACON TECHNICAL DATA 2 5 Thermal protection for the LD resistors There are two different overtemperature sensors in use one for the resistors with a smooth surface and the other for the ones with cooling fins The larger steel plate resistors have a thermal supervision built in as standard OT1 for brake resistors with cooling fins Thermal supervision OT1 This is intended to be mounted on the lower connector end when the resistor is mounted vertically It is screwed onto the fins Types BRRO0O61LD5 X BRROIO0LDO BRR 0031 HD 2 BRR0300LD5 U BRR 0061 HD 2 BRRO013HD6 BRR 0205 HD 2 BRR 0031 HD5 BRR0045HD5 TI O o0 LI BRROOG1HD5 TI Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 13 OT2 This thermal supervision is designed for the resistors with a smooth surface The thermistor is placed beneath the clip and the clip clipped onto the resistor surface Thermal protection and the holde
27. two speeds is thus l 2 l AE E E ETS m Hay 05 The average power required is LAE P where fis the braking time Tel 358 0 201 2121 e Fax 358 0 201 2121 205 TECHNICAL DATA VACON 9 15 If the load has a cycle with a total cycle time the average power of the cycle is LAE C P The chosen resistor must be able to handle this power If the braking time is Longer than 1 minute the resistor must be sized for the continuous braking power 3 2 1 Calculating braking time The time required to accelerate or brake a load can be calculated as follows The basic equation is T 29 dt where is the required torque The time required to change the speed of a load is 0 0 At J or the torque required to change the speed in time fis fag t The available torque consists of the torque generated by the motor oto and the braking torque generated by the load and friction in it T T T zu Toad total motor In many cases the frictional torque is sufficient to brake the load it might even be too high so the motor must drive the load even if the speed is slowing down This torque required from the motor should be compared to the rated torque of the motor P T 9550 n If the rated torque is higher the motor can perform the required acceleration deceleration 3 2 2 Calculating the moment of inertia The moment of inertia as seen by the motor consists of the
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