AK DBU Dynamic Braking
Unit
600/690 VAC
User Manual
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls” (Publication SGI-1.1 available from
your local Rockwell Automation Sales Office or online at http://
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because
of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
!
Important:
!
WARNING: Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment, which may
lead to personal injury or death, property damage, or economic loss.
Identifies information that is critical for successful application and
understanding of the product.
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Shock Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that dangerous voltage may be
present.
Burn Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that surfaces may be at dangerous
temperatures.
PowerFlex is a registered trademark of Rockwell Automation.
Table of Contents
Preface
Overview
Who Should Use this Manual?. . . . . . . . . . . . . . . . . . . . . . . .
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalog Number Explanation. . . . . . . . . . . . . . . . . . . . . . . . .
Description and Block Diagram. . . . . . . . . . . . . . . . . . . . . . .
Line Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permissible Loading of the DBU . . . . . . . . . . . . . . . . . . . . . .
Chapter 1
Installation/Wiring
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . .
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection of Brake Resistors and Conductors . . . . . . . . . . .
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2
P-1
P-1
P-2
P-2
P-3
P-4
P-7
P-8
1-1
1-2
1-3
1-3
1-4
1-8
1-9
Start Up / Troubleshooting
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
DC Power on LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Appendix A
Specifications
DBU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Diagnostic Card BUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Resistor Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Fuse Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Appendix B
CE Conformity
General Installation & Wiring Guidelines for CE Conform. . B-1
Essential Requirements for CE Compliance . . . . . . . . . . . . . B-2
Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Wiring Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Appendix C
Design Information
Determining Dynamic Brake Requirements . . . . . . . . . . . . . C-1
Determine Values of Equation Variables . . . . . . . . . . . . . . . . C-4
Selecting the Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
2
Table of Contents
Preface
Overview
The purpose of this manual is to provide the necessary information for
the installation, start-up and trouble shooting of the AK Dynamic
Braking Unit.
For information on…
Who Should Use this Manual?
Reference Materials
Manual Conventions
General Precautions
See
page
P-1
P-1
P-2
P-2
For information on…
Catalog Number Explanation
Description and Block Diagram
Line Voltage Selection
Permissible Loading of the DBU
See
page
P-3
P-4
P-7
P-8
Who Should Use this Manual?
This manual is intended for personnel qualified in the installation,
programming, and operation of adjustable Frequency Drives and their
use in common DC bus systems.
Reference Materials
The following manuals are recommended for general drive information:
Title
Wiring and Grounding Guide for
PWM AC Drives
Preventive Maintenance of
Industrial Control and Drive
System Equipment
Reactors and Isol. Transformers
Guarding Against Electrostatic
Damage
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control
A Global Reference Guide for
Reading Schematic Diagrams
Publication
Available Online at …
DRIVES-IN001A-EN-P
www.ab.com/manuals/dr
DRIVES-SB001A-EN-E
1321-TD001D-EN-P
8000-4.5.2
www.ab.com/manuals/gi
SGI-1.1
0100-2.10
Not available online, contact
your local RA Sales Office
For detailed PowerFlex Inverter information including specifications:
Title
PowerFlex
Reference Manual
Common Bus Application
Guide
Publication
Available . . .
PFLEX-RM001D-EN-E on the CD supplied with the drive
or at www.ab.com/manuals/dr
TBD
TBD
P-2
Overview
Manual Conventions
•
In this manual we refer to the AK Dynamic Braking Unit as DBU
and to the Adjustable Frequency AC Drive (AFD) as; drive, inverter
or PowerFlex Drive.
•
The following words are used in the manual to describe an action:
Word
Can
Cannot
May
Must
Shall
Should
Should Not
Meaning
Possible, able to do something
Not possible, not able to do something
Permitted, allowed
Unavoidable, you must do this
Required and necessary
Recommended
Not Recommended
General Precautions
!
ATTENTION: This DBU contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
!
ATTENTION: An incorrectly applied or installed DBU can result in
component damage or a reduction in product life. Wiring or application
errors, such as, incorrect or inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the system.
!
ATTENTION: Only qualified personnel familiar with AFD’s and
associated machinery should plan or implement the installation,
start-up and subsequent maintenance of the system. Failure to comply
may result in personal injury and/or equipment damage.
!
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the DC bus terminals (which are connected to the DC bus
capacitors of the Inverter) has discharged before performing any work
on the DBU. Measure the DC bus voltage at the +DC and -DC terminal
of the Output Power Terminals. The voltage must be zero.
ATTENTION: Second source of power for cooling blower is present.
To avoid an electric shock hazard or moving blades, verify the
AC-power supply has been removed prior to performing any
maintenance or repairs.
Overview
P-3
Catalog Number Explanation
The catalog numbering scheme for the AK Dynamic Braking Unit is
shown below.
AK DBU
F
300
N
E
Product
Voltage Rating
Rating
Enclosure
Documentation
Product
Name
Cat.Code
AK Dynamic Braking Unit AK DBU
Version & Voltage Rating
Full On
Cat.
Input Voltage
Voltage
Code
600/690 VAC 950/1090 VDC
F
Rating - Output Peak Current
Amps
Voltage
Cat. Code
300.0
600/690 VAC
300
Enclosure Type & Conformal Coating
Rating
Conf. Coating Cat. Code
Open / IP00
No
N
Documents & Shipping Carton
Document(s) Ship. Carton Cat. Code
English U. M.
Yes
E
P-4
Overview
Description and Block Diagram
The DBU includes the following main components:
The Chopper Transistor is an Isolated Gate Bipolar Transistor
(IGBT). The Chopper Transistor is either ON or OFF. When in the
ON state the Dynamic Brake Resistor connects to the inverter’s DC
bus and dissipates regenerated energy from the load. When in the
OFF state, the Dynamic Brake Resistor is electrically isolated from
the inverter’s DC bus and no energy regeneration occurs. Several
transistor ratings are used in the available DBUs. The most important
rating is the collector current rating of the Chopper Transistor that
contributes in determining the minimum ohmic value used for the
Dynamic Brake Resistor.
Chopper Transistor Voltage Control BUC (PWM type) regulates
the voltage of the DC Bus during regeneration. The average DC bus
voltage is 950V DC for 600V AC input and 1090V DC for 690V AC
input.
DBU Overtemperature Sensor located in the heat-sink for thermal
protection of the DBU.
Power Resistor (customer supplied) or resistor assembly with
Overtemperature Sensor for thermal protection. If the resistor
overheats, this contact disables the connected drive(s).
RC-snubber circuit
Cooling Fan that must be connected to a customer supplied 115V AC
Power Supply. The fan must run if the inverter is energized.
Diagnostic card BUB
The breaking unit includes the BUB diagnostic card with the two
indicating LEDs DC Power on and Brake on.
Overview
P-5
Figure P.1 shows the block diagram of the DBU with the Dynamic Brake
Resistor. The DBU is shown connected to the positive (DC+) and negative (DC-) terminals of an AC PWM Drive.
Figure P.1 Block diagram of Inverter with Dynamic Braking Unit
to customer grounding scheme
or earth ground
PE
Field
installed
Fuses
F1
DC+
DBU
PE
DC+
BR1
R
Inverter
BR2
>°C
Transistor
Control
BUC
DC-
F2
RC
Snubber
to inverter's main
contactor circuit
DC115
BUB
M
0
DC Power on
Brake on
11
>°C
10
to customer's
supplied
115 VAC
power source
to inverter's
main contactor
circuit
P-6
Overview
Theory of Operation
When the rotor of an induction motor is turning slower than the
synchronous speed set by the drive’s output power, the motor is
transforming electrical energy obtained from the drive into mechanical
energy available at the drive shaft of the motor. This process is referred
to as motoring. When the rotor is turning faster than the synchronous
speed set by the drive’s output power, the motor is transforming
mechanical energy available at the drive shaft of the motor into electrical
energy that can be transferred back into the utility grid. This process is
referred to as regeneration.
Most AC PWM drives convert AC power from the fixed frequency utility
grid into DC power by means of a diode rectifier bridge or controlled
SCR bridge before it is inverted into variable frequency AC power.
Diode and SCR bridges can only handle power in the motoring direction.
Therefore, if the motor is regenerating, the bridge cannot conduct the
necessary negative DC current. Depending on parameter setting, the
drive regulator will either increase the DC bus voltage and cause a Bus
Overvoltage trip at the drive, or extend the set deceleration rate or
increase the output frequency.
When a drive is dissipating regenerative electrical energy on an
occasional or periodic basis, a DBU connected to the DC bus of a drive
and feeding a power resistor can be specified. When a drive is
consistently operating in the regenerative mode, a regenerative unit or
RGU should be used to transform the DC regenerated energy to the fixed
frequency utility energy.
Parameter Setting on the Inverter
ATTENTION: When the braking unit is connected to a drive, the drive
Bus Regulation should be turned off. In addition the Regen Power Limit
should be set to the motor power limit or the braking unit power limit,
whichever is greater.
For example on a PowerFlex 700
• Parameters 161/162 [Bus Reg. Mode A/B] must be set to 0 (Disabled)
• Parameter 163 [DB Resistor Type] must be set to 2 (None)
• Parameter 153 [Regen Power Lim] must be set to the motor power
limit or braking unit power limit, whichever is greater.
Overview
P-7
-
Line Voltage Selection
After removing the cover plate of the DBU, a red jumper plug located on
the BUC card allows for the line voltage selection of 690V / 600V.
The selection of this jumper plug defines the DC bus voltage at which
the DBU switches the brake resistor to the DC bus.
Figure P.2 Jumper plug location on the BUC card
BUC-Card
600V
690V
Jumper plug on rear side,
shown in position for 600V AC line
Figure P.3 Pulse Width (Jumper Setting) in Relation to DC Bus Voltage
100%
95%
0%
VDC
Jumper at 600: 913V
690: 1047V
950V
1090V
The default jumper voltage selection shipped from the factory is
690V AC line voltage.
!
ATTENTION: Without the jumper plug in place, the default line
voltage selection of the DBU is set to 600V AC. When operating on a
690V AC line the brake resistor will be constantly switched on. This
can cause an overtemperature trip on the DBU and/or the brake resistor.
Verify the jumper plug is present and has been properly selected for the
application.
P-8
Overview
Permissible Loading of the DBU
To prevent thermal overload of the Braking Unit, it must operate within
the following limits:
In a time range of 10 minutes the permissible loading must be limited
to the maximum peak current of the DBU (300A) up to a maximum of
2.5 minutes.
This maximum current-time area of 750 Amp.-minutes can be of any
shape, as long as 300A is not exceeded.
The peak current (IPeak) in the following two examples is 300 Amp
(maximum current with Rmin = 3.2 ohm at 600 VAC line) and the
current-time area also meets the 750 Amp.-minutes requirement.
Figure P.4 Examples for Permissible Loading of the DBU
1) Linear deceleration to zero speed of
a drive with high inertia connected
(e.g. centrifuge)
2) Drive with active load
(e.g. crane)
IPeak
IPeak
300A
300A
112.5A
0
t
minutes
5
10
Current-time area:
(300 * 5) / 2 = 750 Amp-Min.
0
4
t
minutes
1
10
Current-time area:
(300 * 1) + (112.5 * 4) = 750 Amp-Min.
Chapter
1
Installation/Wiring
This chapter provides the information needed for the installation and
wiring of the Allen-Bradley Dynamic Braking Module.
For information on…
Minimum Mounting Clearances
Grounding Requirements
Fuses
Protection of Brake Resistors and Conductors
See
page
1-1
1-2
1-3
1-3
For information on…
Power Wiring
Control Wiring
CE Conformity
See
page
1-4
1-8
1-9
Most start-up difficulties are the result of incorrect wiring. Every
precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.
!
ATTENTION: The following information is merely a guide for proper
installation. The Rockwell Automation Company cannot assume
responsibility for the compliance or the noncompliance to any code,
national, local or otherwise for the proper installation of this device or
associated equipment. A hazard of personal injury and/or equipment
damage exists if codes are ignored during installation.
Minimum Mounting Clearances
For free air circulation through the cooling fins of the power section, the
braking unit must be mounted in the vertical position only. In order to
prevent overheating due to heat build-up, minimum clearances for air
circulation of 100 mm (25 in) above and below the unit must be
observed.
The rate of cooling air for the forced ventilated DBU is 158 m3/h,
with a bottom to top of the unit air flow.
See Appendix A, Figure A.3 for detailed dimension information.
1-2
Installation/Wiring
Grounding Requirements
The Safety Ground terminal (PE) must be connected to the building
grounding scheme. Ground impedance must conform to the
requirements of national and local industrial safety regulations and/or
electrical codes. The integrity of all ground connections should be
periodically checked.
For installations within a cabinet, a single safety ground point or ground
bus bar connected directly to building steel should be used. All circuits
should be grounded independently and directly to this point/bar.
Figure 1.1 Typical Grounding
R (L1)
S (L2)
T (L3)
Drive
PE
DBU
+DC
+DC
- DC
- DC
PE
Ground Grid, Girder or Ground
Rod (Building Ground Potential)
Safety Ground Terminal - PE
The DBU safety ground (PE) must be connected to the customer
grounding scheme or earth ground. This is the safety ground for the
DBU that is required by code. This point must be connected to adjacent
building steel (girder, joist, a floor ground rod, bus bar or building
ground grid) see Figure 1.1. Grounding points must comply with
national and local industrial safety regulations and/or electrical codes.
For additional information refer to publication DRIVES-IN001A-EN-P.
Installation/Wiring
1-3
Fuses
National and local industrial safety regulations and/or electrical codes
may determine additional requirements for these installations.
!
ATTENTION: The DBU does not provide DC Bus branch short
circuit protection. Specifications for the recommended fuse to provide
protection against short circuits are provided in Appendix A.
Protection of Brake Resistors and Conductors
In case of a failed DBU (IGBT short circuit or a constantly ON
command), the rectified AC line voltage is passed to the brake resistor.
Since the IGBT in the DBU is not switching and therefore its
temperature is not increasing, this fault will not be detected by the
temperature sensor located on the heat sink of the DBU.
To prevent possible damages due to the overloading of the brake
resistors, leads and input rectifier, the installation of a thermal switch on
the brake resistor heat sink is recommended:
The contact of the thermal switch on the brake resistor should be wired
in series with the thermal switch on the DBU to the drives main
contactor control circuit. Refer to Figure 1.5.
1-4
Installation/Wiring
Power Wiring
!
ATTENTION: National Codes and standards (NEC, VDE, BSI etc.)
and local codes outline provisions for safely installing electrical
equipment. Installation must comply with specifications regarding wire
types, conductor sizes, and disconnect devices. Failure to do so may
result in personal injury and/or equipment damage.
Recommendations for the selection and wiring of power cables
•
Cable must have copper conductors only
•
Cable with 1,000V rating or greater is required
•
Shielded cable is preferred
•
For unshielded cable allow a spacing of 0.3 meters (1 foot) for every
10 meters (32.8 feet) of length. Long parallel runs must be avoided.
•
Do not use cable with an insulation thickness less than or equal to
15 mils (0.4 mm/0.015 in.).
•
See “Use of Unshielded Cable”
Use of Unshielded Cable
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of
15 mils and should not have large variations in insulation concentricity.
EMC Compliance
Refer to Appendix B for details.
Cable Trays and Conduit
If cable trays or large conduits are to be used, refer to guidelines
presented in the PowerFlex 700 Reference Manual.
!
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” motor leads.
Connect DBU, fuses and brake resistors according to the block diagram
in Figure P.1. Refer also to General Installation and Wiring Guidelines
for CE Conformity on page B-1.
Installation/Wiring
1-5
Connection leads between Inverter and DBU
During switching of the braking unit’s IGBT the inductance of the leads
between the DC bus capacitors of the inverter and the DBU generates
short time (milliseconds) bus over voltage peaks.
These bus over voltages, which are dampened by the RC snubber circuits
in the DBU, must not exceed 200 volts.
Drives Connected to a Single Motor
For drives connected to a single motor this can be accomplished by the
following measures (see Figure 1.2):
•
The conductors must be bound together and run separatedly from
other conductors or multi-core cables (EMC shielded). This is to
reduce the cable inductance.
•
Limiting the total cable length between the drive and the DBU to a
maximum of 3 m (120 in)
Connection example
Figure 1.2 Connection to single motor drive
AC-Drive
DBU
Cable length
max.3m
Cable length
max.30m
DB-Resistor
Assembly
F1
DC+
DC+
BR1
R
F2
DC-
DC-
BR2
Field
Installed
Fuses
10
11
Multiple Drives Coupled through a Common DC Bus
For a DBU that is connected to several drives which are coupled through
a common DC bus, the bus over voltages must also not exceed 200 V.
The inductance of the DC bus connection leads to the engaged DC bus
capacitors must be kept low by adhering to the following measures:
•
Use short leads with low inductance.
•
Locate the DBU as close as possible to the largest DC bus capacitors.
•
Wires should be twisted
1-6
Installation/Wiring
Connection leads between the DBU and the Brake Resistor (R)
The cable length between the DBU and the Brake Resistor must not
exceed 30 meters, but the limiting factor for this connection is the time
constant of the brake resistor (Ratio of Inductance to Resistance).
See Brake Resistor Specifications on page A-4
The inductance of the cables or leads can be reduced by bundling single
leads or using multi core (EMC shielded) cable.
To connect the brake resistors, heat-resistant cables and cable sockets
must be used (min. 90°C). Brake resistor cable selection should be based
on the maximum mean rms braking current of the DBU. See page A-1.
For Max./Min. cable cross sections (mm2 and AWG) and tightening
torque see Table 1.B.
Cooling Fan Supply Voltage
A 115 VAC (50/60 Hz, 0.2A) customer supplied power supply is
required for the DBU cooling fans. The 115V AC Power source should
be connected between terminals (0) and (115) located on the fan unit.
See Figure 1.3 and Figure 1.4.
Installation/Wiring
1-7
Power and Control Terminals
Figure 1.3 Location of Power Connections and Control Terminals
for Customer Wiring (Front View Shown)
PE
BR2
DC-
Table 1.A Power Terminals
No.
Description
BR1 DC Brake (+)
BR2 DC Brake (-)
DC+ DC Bus (+)
DC- DC Bus (-)
PE
Protective Earth
DC+ BR1
Notes
Brake Resistor Connection (+)
Brake Resistor Connection (-)
DC Bus Connection (+)
DC Bus Connection (+)
10/11 Thermostat N.C. contact For control terminals see Figure 1.4
Table 1.B Power Terminal Specifications
Wire Size Range (1)
Maximum Minimum
No. Description
Power Connections
95 mm2
Bus Bars with Bolts M10
(4/0 AWG)
50 mm2
PE
50 mm2
Bolt M10
(6 AWG) (AWG)
Thermostat N.C. contact and
Fan Supply Terminal
(1)
Torque
Maximum Recommend
10 N-m
10 N-m
(89 lb.-in) (89 lb.-in)
10 N-m
(89 lb.-in)
10 N-m
(89 lb.-in)
For control terminal specifications see Table 1.C
Max./Min. sizes the terminals will accept - these are not recommendations.
1-8
Installation/Wiring
Control Wiring
Recommendations for the selection and wiring of the control cables:
•
•
•
Cable must have copper conductors only.
Cable with 600V rating or greater is required.
Control cables outside the cabinet should be separated from power
cables by at least 0.3 meters (1 foot).
Figure 1.4 Input Control Terminals
11
10
115
0
Thermostat N.C. output contact
Fan Supply Input Terminals
Table 1.C Input Control Terminal Specifications
Wire Size Range (1)
Connection
Maximum Minimum Torque
0, 115 Fan Supply, 115V AC
4 mm2
0.5 mm2 0.8 Nm
(11 AWG) (22 AWG) (7 lb.-in.)
No.
10, 11 Thermostat NC Output Contact,
Opens at power stack over temperature
(1) Max./Min. sizes the terminals will accept - these are not recommendations.
Drive(s) Run Interlock
!
ATTENTION: The DBU and the drive(s) do not offer protection for
externally mounted brake resistors. Risk of fire exists if the brake
resistors are not protected. Resistor packages must be self-protected
from overtemperature or a circuit equivalent to the one shown in Figure
1.5 must be supplied.
In order to protect the DBU from an overtemperature condition, the
normally closed contact (DBU Overtemperature - terminals 10 and 11)
must be connected in series with a resistor thermostat to an AC-line
input contactor to ensure the drives are stopped if an overtemperature
condition occurs either in the DBU or the Brake Resistor.
See Appendix A for contact ratings.
Installation/Wiring
1-9
Figure 1.5 Control Wiring of Drive(s) Main Contactor Interlock
AC-Drive
Tree-Phase
AC Input
DBU
F1
Brake Resistor
Assembly
K1M
R
R (L1)
S (L2)
T (L3)
F2
Temperature
Sensor
F3 >°C
10
11
11
Power off
Power
Source
Resistor
Thermostat
F4 >°C
Power on
K1M
K1M
CE Conformity
For Mounting and Wiring Instructions concerning CE Conformity refer
to Appendix B.
1-10
Installation/Wiring
Chapter
2
Start Up / Troubleshooting
This chapter provides the necessary information for the start up and
troubleshooting of the DBU.
For information on . . .
Start-Up
DC Power ON LED
Troubleshooting
!
See page . . .
2-2
2-3
2-4
ATTENTION: Power must be applied to the connected drive(s) to
perform the following start-up procedure. Some of the voltages present
are at dangerous level. To avoid electric shock hazard or damage to
equipment, only qualified service personnel should perform the
following procedure. Thoroughly read and understand the start up and
troubleshooting procedures before beginning. If an event does not occur
while performing these procedures, Do Not Continue. Remove Power
including user supplied control voltages. User supplied voltages may
exist even when main AC power is not applied to the drive(s). Correct
the malfunction before continuing.
!
ATTENTION: Second source of power for cooling blower is present.
To avoid an electric shock hazard or moving blades, verify the
AC-power supply has been removed prior to performing any
maintenance or repairs.
!
ATTENTION: Disabling the drive does not stop the AC line from
being rectified. Full potential will still be present on the DC bus. A
failure of the IGBT will result in brake resistor failure. The AC line
must be disconnected from the drive.
2-2
Start Up / Troubleshooting
Start-Up
Before Applying Power to the Drive(s)
❏ 1. Verify all inputs are connected to the correct terminals and are
properly torqued.
❏ 2. Verify the AC line power at the drive(s) disconnecting device is
within the rated value of the drive(s).
❏ 3. Verify the control power voltage is correct (115V AC for the fan).
❏ 4. Verify the DBU Overtemperature N.C. contact output is correctly
wired. This normally closed contact output is used to stop the
drive(s) when an overtemperature condition exists. Verify this
interlocking circuit has been wired correctly according to customer’s
application. See Figure 1.5 on page 1-9.
Applying Power to the Drive(s)
❏ 1. Apply AC power to the drive(s) and control voltage (115V AC) to the
fan of the DBU.
The red DC Power ON LED on the DBU should be on if power is
applied to terminals R, S, T (L1, L2, L3) of the connected drive(s).
See Figure 2.1.
❏ 2. If the red DC Power ON LED is not on at this point, refer to the Table
2.A for troubleshooting guidelines.
Start Up / Troubleshooting
2-3
DC Power ON LED
The red DC Power ON LED is visible through the front panel and will
illuminate when power is applied to the drive and the DC bus voltage has
exceeded 50V.
!
ATTENTION: The LEDs on the DBU are only operational when the
unit is energized. Servicing energized equipment can be hazardous.
Severe injury or death can result from electrical shock, burn, or
unintended actuation of the controlled equipment. Follow Safety related
practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE
WORKPLACES. DO NOT work alone on energized equipment!
Figure 2.1 DC Power on and Brake on Indicating LEDs
DC Power On
Brake On
2-4
Start Up / Troubleshooting
Troubleshooting
Table 2.A Possible Faults and Corrective Actions
Fault
Heat sink Over
Temperature
DC Output
Voltage Loss
Cause
Corrective Action
Heat sink temperature 1. Verify the maximum ambient temperature
exceeds maximum
has not been exceeded.
rating.
2. Check fan for correct operation.
Replace fan if necessary with fan kit
No. SK-D9-FAN1
3. Check for excess load on the DBU.
Refer to Appendix C for calculations.
Verify the braking duty cycle does not
exceed the drive(s) design specification.
4. Check for proper clearance around the
DBU.
5. Contact your local RA sales office.
Loss of DC Bus Power 1. Check 3-Phase AC Incoming Power on the
drive(s) for undervoltage or phase loss.
2. Check Fuses on DC bus input leads.
3. Check Inverter.
4. Contact your local RA sales office
Appendix A
Specifications
This appendix provides electrical, environmental, functional and
physical specifications for the DBU and the diagnostic card BUB.
For information on…
DBU
Dimensions
Diagnostic Card BUB
See
page
A-1
A-3
A-4
For information on…
Brake Resistor Specifications
Fuse Ratings
See
page
A-4
A-4
DBU
Specifications
Power Ratings
Input Voltage
Peak Braking Power
600V
268 kW
690V
305 kW
Minimum Brake Resistor Value permitted
for Peak Braking Power
Max. Peak Braking Current with 150sec ON
time at up to 25% duty cycle
Maximum Mean RMS Braking Current
3.2 ohm
3.7 ohm
Heat Dissipation (Average) at 25% duty cycle
170 W
Power consumption of the control circuits
27mA
Maximum DC bus Voltage
at terminals DC+,DCPulse width modulation PWM,
switching frequency
Capacitance of the built-in snubber
Control Output Specifications
Heat sink temperature sensor
NC contact output rating (max.)
300 Amp
150 Amp
DC 1150V
0.67 kHz
4µF
The temperature sensor trips if heat sink
temperature exceeds maximum
temperature.
Resistive Rating: 15A at 125V AC,
10A at 250V AC,
7A at 24V DC
Inductive Rating: 10A at 125V AC,
6A at 250V AC
A-2
Specifications
Specifications
Approvals and Standards Compliance
The DBU is designed to meet the following specifications:
NFPA 70
- US National Electrical Code
NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection,
Installation and Operation of Adjustable Speed Drive Systems.
IEC 146
- International Electrical Code.
UL and cUL Listed to UL508C
and CAN/CSA-C2.2 No. 14-M91
(600V AC only)
Marked for all applicable European
Directives
C
EMC Directive (89/336/EEC)
Emissions: EN 61800-3 Adjustable
Speed electrical power drive
systems Part 3
Immunity: EN 61800-3 Second
Environment, Category C3
Low Voltage Directive (73/23/EEC)
EN 50178 Electronic Equipment for use
in Power Installations
Environmental Specifications
Altitude:
1000 m (3300 ft.) max. without derating.
Above 1000 m the derating for the
nominal current is 1% per 100 m
(330 ft.).
Degree of protection
Open / IP00
Ambient Operating Temperature
0 to 40°C (32 to 104°F)
without derating:
For temperatures higher than 40°C up to
max 55°C (131°F), the max. peak
braking current must be derated by 1.5%
per °C (0.8% per °F)
Storage Temperature:
–25 to 55°C (–25 to 131°F)
Transportation Temperature:
–25 to 70°C (–25 to 158°F)
(70°C max 24 hours)
Relative Humidity:
5 to 95% non-condensing
Shock:
15G peak for 11ms duration (±1.0 ms)
Vibration:
0.152 mm (0.006 in.) displacement,
1G peak
Specifications
A-3
Dimensions
Figure A.3 Dimensions and Location of Bus-Bar Customer Connection Points
Min.
100
(4.0)
42
36
36
36
25
(1.65) (1.42) (1.42) (1.42) (1.0)
89
(3.5)
50
(2.0)
32
(1.3)
5
(0.2)
ø6.5
(0.26)
PE
BR2
DC-
DC+ BR1
2)
350
(13.8) 310
(12.2)
356
(14.0)
Air Flow
8
(0.3)
80
(3.15)
5
Min. (0.2)
100
(4.0)
215
(8.46)
5
(0.2)
225
(8.86)
Front view
Dimensions are in millimeters and (inches)
Weight: 10 kg (22 lb.)
Required cooling air: 158 m3/h
157
(6.18)
Side view
A-4
Specifications
Diagnostic Card BUB
The DBU contains the BUB diagnostic card which includes the two red
indication LEDs Power ON and Brake ON.
Table A.1 Function/State of Indication LEDs
Function
LED Status
Condition
DC Power ON
ON
when DC bus voltage exceeds 50V
Brake ON
ON
when braking current flows
Brake Resistor Specifications
The time constant (t) of the brake resistor: t = L/R, must be <40 µs
L: Effective inductance of the brake resistor and cable
R: Resistance of the resistor (R)
Due to the many different types of brake resistor constructions their
inductance varies widely. Specifically wire wound resistors on ceramic
core can have high inductance. For example a brake resistor with 3.1
ohm resistance shall not have more than 110µH inductance if the cable
inductance for 30m (90ft) is assumed to be 10µH..
Fuse Ratings
Table A.2 provides the recommended fuse ratings for the DBU.
The recommended fuses meet the UL and IEC requirements and are
based on 40°C (104°F) and the U.S. National Electrical Code. Other
country, state or local codes may require different ratings.
If the available fuse ampere ratings do not match those recommended,
the next higher fuse rating should be chosen.
• IEC – BS88 (British Standard) Parts 1 & 2,
EN60269-1, Parts 1 & 2, type aR or equivalent should be used.
• UL – Recognised; A100P (Ferraz) or FWJ (Bussmann) must be used.
Table A.2 Recommended Short Circuit Protection Fusing
AC Line
Volt
DBU Rating Fuse
kW
Amps Amps
Volt
600
268
300
300
700-800
690
305
300
315
1000
Type
FWJ-300
A100P300-4TI
G300547
Fuse Holder
Type
Manufacturer
BH-3
P266L
SI DIN 110 630
Bussmann
Ferraz
Ferraz
Notes:
(1) Minimum protection device size is the lowest rated device that supplies maximum
protection without nuisance tripping.
Appendix B
CE Conformity
This appendix provides the installation and wiring instructions necessary
for the CE-conformity of the Dynamic Braking Unit.
For information on…
General Installation and Wiring Guidelines
for CE Conformity
See
page
B-1
Essential Requirements for CE Compliance B-2
For information on…
Mounting Instructions
Wiring Instructions
Configuration Examples
See
page
B-3
B-4
B-6
Conformity with the Low Voltage (LV) Directive and Electromagnetic
Compatibility (EMC) Directive has been demonstrated using
harmonized European Norm (EN) standards published in the Official
Journal of the European Communities. The DBUs comply with the EN
standards listed below when installed according to the instructions
provided in the User Manual.
CE Declarations of Conformity are available online at:
http://www.ab.com/certification/ce/docs.
Low Voltage Directive (73/23/EEC)
•
EN50178 Electronic equipment for use in power installations
EMC Directive (89/336/EEC)
•
EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
General Installation and Wiring Guidelines for CE Conformity
•
The cable length between the DBU and inverter should be kept less
than 3m (10ft) in order to reduce electromagnetic emission as well as
capacitive currents. The inverter should be located in the same
cabinet or next to the cabinet with the DBU. If the connection leads
between DBU and inverter(s) leave the cabinet, shielded cables must
be used and cable length must be minimized.
•
Cabinets should be designed for radiated EMC attenuation.
Recommended cabinets include Rittal TS8 series.
•
Brake resistor assemblies should be mounted outside of the control
cabinet in a separate metal cabinet or screened enclosure designed to
dissipate the thermal energy.
•
The DBU meets CE EMC emission limits for the industrial
B-2
CE Conformity
environment, it is not intended to be used on a low-voltage public
network which supplies domestic premises. If used in a residential or
domestic environment it will cause radio interference. The user is
required to take all the necessary measures to prevent interference in
addition to the essential requirements for CE compliance listed
below.
•
Conformity of the drive with CE EMC requirements does not
guarantee that the entire machine installation will comply with CE
EMC requirements. Many factors can influence total machine and
installation compliance.
Essential Requirements for CE Compliance
Conditions 1 to 6 listed below must be satisfied in order for the DBU to
meet the requirements of EN61800-3.
1. The DBU and brake resistors must be installed in a cabinet or
enclosure which provides good attenuation of radiated radio
frequency emissions from the DBU and brake resistor.
Such enclosures incorporate the following construction features:
•
•
•
•
•
•
enclosure of steel construction surrounds the DBU and the brake
resistor on all sides, top and bottom
conductive, corrosion-resistant (not painted) mounting surfaces
inside
high frequency, low impedance electrical bonding between all
sides and earth
continuous metal-to-metal contact between adjacent sides, top
and bottom
continuous conductive gasketing at mating surfaces of opening
doors or removable covers
conductive screening over all enclosure openings, including
ventilation openings, such that no single opening is larger than
6mm in diameter (0.24 in).
2. Use of CE compliant inverter(s).
3. Review important precautions/attentions statements throughout this
document before installing the DBU.
4. Grounding as described on page B.4.
5. All Power wiring (except line input) and control wiring outside the
cabinet must be braided, shielded cable with a coverage of 75% or
better, or metal conduit, or conductors with equivalent attenuation.
6. The shield of all cables outside the cabinet must be connected to the
cabinets earthed bus bar or to the cabinet enclosure using EMC style
cable glands.
For additional requirements refer to the Drive(s) User Manual.
CE Conformity
B-3
Mounting Instructions
Cabinet Mounted Drives (see Figure B.2)
If the drive related components are mounted in a cabinet, the following
rules must be observed:
•
If located in a common cabinet, all drive related components must be
screwed directly to a blank (non painted) panel with good
conductivity and the largest possible contact area.
•
The support panel for the DBU and an inverter with filters must be a
conducting steel sheet with a common ground bus bar located at the
bottom of the support panel. This ground bus bar, must be solidly
connected to the panel to ensure good conductivity.
•
All cable screens for cables entering the cabinet must be solidly
connected to the cabinet’s ground bus bar or to the ground stud of the
inverter with a large connection area and good conductivity to ensure
that the grounding represents a low impedance for HF signals.
•
Either galvanized cable brackets or EMC cable glands are required.
Standalone Drives and Related Components (see Figure B.3)
•
If the drive and related components (inverter, RFI-Filter, DBU and
brake resistor) are mounted in separate enclosures, these must be of
conductive metallic material in which the diameter of ventilation
holes should not exceed 6 mm (0.24 in).
•
The spacing between brake resistor assembly and the enclosure wall
shall be 100 mm (4 in) minimum.
B-4
CE Conformity
Wiring Instructions
General
•
Earth conductors must be either 16 mm2 or 50% of the cross section
of the phase conductor whichever is larger.
•
The connections between the inverter and the DBU should not
exceed 3 m (10 ft.).
•
Signal leads inside the cabinet must be separated from power leads.
•
Input power wires on the line side of the drive or EMC filter for the
drive should be widely separated from other wiring inside the cabinet
or should be shielded.
Shielded Cables entering the Cabinet
(see Figure B.1 and Figure B.2)
•
The shield or screen must be tinned copper braid or tinned steel
braid.
•
If shielded cable is not available (limited by the obtainable cross
sections) the individual conductors and protective conductors must
be run in steel conduits or enclosed metal cable ducts also connected
to earth at both ends.
•
Signal and control leads (e.g. reference, feedback, relays) must be
shielded cable. The individual conductors must be stranded, but
twisted pairs are not required. The shield must be grounded at both
ends.
•
The motor cable shall be 4-wire shielded cable (3 phases and earth
conductor green/yellow) or run in a separate steel conduit.
CE Conformity
B-5
Power Connections between Enclosures
(see Figure B.1 and Figure B.3)
•
The power cables between the enclosures housing of the inverter, the
DBU and the brake resistor shall be 3-wire shielded cable (+, -, and
earth conductor green/yellow) or run in a separate steel conduit.
•
Between each enclosure and the protective earth (PE) of the line
input, an uninterrupted connection (green/yellow conductors) must
be provided to ensure correct grounding of the equipment.
•
The braid of shielded cables must be connected to the enclosures by
the use of suitable EMC type cable glands.
Figure B.1 Specification for shielded cable
Stranded copper wire
Plastic insulation
Inner plastic sheath
Compact screen of galvanized
(tinned) copper or steel braid
Outer plastic jacket
Cable Glands
•
Use suitable EMC-tested cable glands only.
•
The conductivity of the shield to earth connection is ensured by
laying the braid over a plastic cone which will press it to the inner
side of the gland when mounted.
•
It is important that the connection area is 360 degree around the
cone.
•
The cable glands provide pull-relief through the cable jacket.
B-6
CE Conformity
Configuration Examples
Figure B.2 Cabinet Mounted Drive and Related Components
Cabinet
DBU
Panel
R
Brake resistor
Inverter
DC+, DC-
RFI Filter
(if used)
U, V, W
(T1,T2,T3)
R, S, T
(L1,L2,L3)
External
line reactor
(if used)
Input contactor
Input fuses
PE
Terminals for 4-wire
line input cable
Cabinet protective
ground bus bar
1
2
PE
3
1 Cable bracket
4
2 Shield
5
3 Shielded 4-wire motor cable
4 Shielded signal conductor cable
(feedback, reference)
U,V,W
M
5 EMC type armoured cable gland
Speed
Feedback
Device
at terminal box
CE Conformity
B-7
Figure B.3 Stand Alone Drive and Related Components
1
K1M
Inverter Enclosure
Stand Alone
RFI Filter
(if used)
DBU Enclosure
Resistor
Enclosure
INVERTER
DBU
DC+
DC-
>°C
R, S, T
(L1,L2,L3)
DC+
DC- 10
to
K1M
control
circuit
U, V, W
(T1,T2,T3)
6
6
3
>°C
BR1 PE
11 BR2
R
6
4
1 4-wire line input cable
3 Shielded 4-wire motor cable
PE
U,V,W
M
4 Shielded control or signal
conductor cable
5 EMC type armoured cable gland
at all enclosure entries and motor
6 Shielded cable with PE conductor
B-8
Notes:
CE Conformity
Appendix C
Design Information
This appendix provides the design information which is necessary for
calculating and selecting an external brake resistor for connecting to the
Dynamic Braking Unit.
For information on…
Determining Dynamic Brake Requirements
Determine Values of Equation Variables
Selecting the Resistor
Example Calculation
See page
C-1
C-4
C-7
C-10
Determining Dynamic Brake Requirements
How to Determine Dynamic Brake Requirements
When a drive is consistently operating in the regenerative mode of
operation, serious consideration should be given to equipment that will
transform the electrical energy back to the fixed frequency utility grid.
As a general rule, Dynamic Braking is used when the need to dissipate
regenerative energy occurs on an occasional or periodic basis. In general,
the motor power rating, speed, torque, and details regarding the
regenerative mode of operation will be needed in order to estimate what
Dynamic Brake Resistor value is needed.
The Peak Regenerative Power and Average Regenerative Power
required for the application must be calculated in order to determine the
brake resistor value, and to verify the suitability of the DBU.
The power rating of the Dynamic Brake Resistor is estimated by
applying what is known about the drive’s motoring and regenerating
modes of operation. The Average Power Dissipation must be estimated
and the power rating of the Dynamic Brake Resistor chosen to be greater
than that average. If the Dynamic Brake Resistor has a large thermodynamic heat capacity, then the resistor element will be able to absorb a
large amount of energy without the temperature of the resistor element
exceeding the operational temperature rating. Thermal time constants in
the order of 50 seconds and higher satisfy the criteria of large heat
capacities for these applications. If a resistor has a small heat capacity
(defined as thermal time constants less than 5 seconds) the temperature
of the resistor element could exceed its maximum.
C-2
Design Information
The Peak Regenerative Power can be calculated as:
•
Horsepower (English units)
•
Watts (The International System of Units, SI)
•
Per Unit System (pu) which is relative to a value
The final number must be in watts of power to estimate the resistance
value of the Dynamic Brake Resistor. The following calculations are
demonstrated in SI units.
Gather the following information
•
Power rating from motor nameplate in watts, kilowatts, or
horsepower
•
Speed rating from motor nameplate in rpm or rps (radians per sec.)
•
Required decel time (per Figure C.1, t3 – t2). This time is a process
requirement and must be within the capabilities of the drive
programming.
•
Motor inertia and load inertia in kg-m2 or WK2 in lb.-ft.2
•
Gear ratio (GR) if a gear is present between the motor and load
•
Motor shaft speed, torque, and power profile of the drive application
Figure C.1 shows typical application profiles for speed, torque and
power. The examples are for cyclical application that is periodic over t4
seconds. The following variables are defined for Figure C.1:
ω(t)
N
2πN
= Motor shaft speed in radians per second (rps) ω = ---------60
= Motor shaft speed in Revolutions Per Minute (RPM)
T(t)
= Motor shaft torque in Newton-meters
1.0 lb.-ft. = 1.356 N-m
P(t)
= Motor shaft power in watts 1.0 HP = 746 watts
Rad
= Rated angular rotational speed --------s
Rad
= Angular rotational speed less than ωb (can equal 0) --------s
= Motor shaft peak regenerative power in watts
ωb
ωo
-Pb
Design Information
C-3
Figure C.1 Application Speed, Torque and Power Profiles
Speed
ω(t)
ωb
ωo
0
t1
t2
t3
t4
t1 + t4
t
t1
t2
t3
t4
t1 + t4
t
t1
t2
t3
t4
t1 + t4
t
Torque
T(t)
0
Power
P(t)
0
-Pb
C-4
Design Information
Determine Values of Equation Variables
Step 1
Total Inertia
2
J T = J m + ( GR × J L )
JT
= Total inertia reflected to the motor shaft
(kg-m2 or WK2 in lb.-ft.2)
Jm
= Motor inertia (kg-m2 or WK2 in lb.-ft.2)
GR
= Gear ratio for any gear between motor and load
(dimensionless)
Load Speed
GR = ----------------------------Motor Speed
JL
1
If the gear ratio is 2:1 then GR = -- = 0.5
2
= Load inertia (kg-m2 or WK2 in lb.-ft.2)
1.0 lb.-ft.2 = 0.042 kg-m2
Calculate Total Inertia:
J T = [ oooooooooo ] + ( oooooooooo × oooooooooo )
Record Total Inertia:
JT
=
Design Information
Step 2
C-5
Peak Braking Power
JT [ ωb ( ω b – ωo ) ]
Pb = ---------------------------------------( t3 – t2 )
Pb
= Peak braking power (watts). 1.0 HP = 746 watts
Pb1
= Pb x (motor efficiency x drive efficiency)
JT
= Total inertia reflected to the motor shaft (kg-m2)
ηM, ηD = Motor and drive efficiency
ωb
ωo
Nb
2πN
Rad
= Rated angular rotational speed --------- = -----------b60
s
= Angular rotational speed,
Rad
less than rated speed down to zero --------s
= Maximum application motor speed (RPM)
t3 – t2 = Deceleration time from ωb to ωo (seconds)
Calculate Peak Braking Power:
[ ooooo ] × [ oooooo ] × ( ooooo – ooooo -)
Pb = ----------------------------------------------------------------------------------------------( ooooooooo – ooooooooo )
Record the Peak Braking Power:
Pb
=
Calculate Pb1:
Pb1 = Pb x (motor efficiency x drive efficiency)
Compare the Pb1 to the Maximum Peak Braking Power of the DBU
(Pmax). If Pb1 is greater than Pmax, the decel time must be increased, or
the inertia or the speed must be decreased, so that the drive does not
enter current limit.
Table C.A DC bus Voltage and Minimum Brake Resistance
Line Voltage
Vd
R
Pmax
600 VAC
950 VDC
3.2 Ohms
268 kW
690 VAC
1090 VDC
3.7 Ohms
305 kW
For the purposes of this document, it is assumed that the motor used in
the application is capable of producing the required regenerative torque
and power.
C-6
Design Information
Step 3
Minimum Power Requirements for the Dynamic Brake
Resistors
It is assumed that the application exhibits a periodic function of
acceleration and deceleration. If (t3 – t2) equals the time in seconds
necessary for deceleration from rated speed to ωo speed, and t4 is the
time in seconds before the process repeats itself, then the average duty
cycle is (t3 – t2)/t4. The power as a function of time is a linearly
decreasing function from a value equal to the peak regenerative power to
some lesser value after (t3 – t2) seconds have elapsed. The average power
regenerated over the interval of (t3 – t2) seconds is:
Pb ( ωb + ωo )
----- × -----------------------ωb
2
Pav
= Average dynamic brake resister dissipation (watts)
t3 – t2 = Deceleration time from ωb to ωo (seconds)
t4
= Total cycle time or period of process (seconds)
t4 cannot exceed 900 + (t3 – t2). See Note below.
Pb
= Peak braking power (watts)
ωb
Rad
= Rated angular rotational speed --------s
= Angular rotational speed,
Rad
less than rated speed down to zero --------s
ωo
The Average Power in watts regenerated over the period t4 is:
( t3 – t2 ) Pb ( ωb + ω o )
Pav = ------------------ ----- -----------------------t4
2
ωb
Calculate Average Power in watts regenerated over the period t4:
( oooooo – oooooo )
[ oooooo ]
( oooooo + oooooo )
P av = ----------------------------------------------- × ----------------------- × ----------------------------------------------[ oooooo ]
2
[ oooooo ]
Record Average Power in watts regenerated over the period t4:
Pav
=
Note: Since a resistor will typically cool in 15 minutes (900 seconds),
it will not be possible to take advantage of a higher duty cycle.
Design Information
C-7
Selecting the Resistor
In order to select the appropriate Dynamic Brake Resistor for your
application, the following data must be calculated.
Peak Regenerative Power
(Expressed in watts)
This is used to determine the maximum resistance value of the Dynamic
Brake Resistor. If this value is greater than the maximum imposed by the
peak regenerative power of the drive, the drive can trip off due to
transient DC bus overvoltage problems.
Power Rating of the Dynamic Brake Resistor
The average power dissipation of the regenerative mode must be
estimated and the power rating of the Dynamic Brake Resistor chosen to
be greater than the average regenerative power dissipation of the drive.
(See Step 3 on page C-6).
Protecting External Resistor Packages
!
ATTENTION: The DBU and most drives do not offer protection for
externally mounted brake resistors. Risk of fire exists if external
braking resistors are not protected. External resistor packages must be
self-protected from overtemperature or circuit equivalent to the one
shown in Figure 1.5 must be supplied.
Step 4
Calculate the Maximum Dynamic Brake Resistance Value
The maximum allowable Dynamic Brake resistance value (Rdb1) must be
calculated.
0.95 × ( V d ) 2 P max × R
R db1 = ---------------------------- = -------------------Pb
Pb
Rdb1 = Maximum allowable value for the dynamic brake resistor
(ohms)
Vd
= DC bus voltage used for calculating maximum power.
(950V DC for 600V AC, or 1090V DC for 690V AC)
Pb
= Peak breaking power calculated in Step 2 (watts)
C-8
Design Information
Calculate Maximum Dynamic Brake Resistance:
·
[ oooooooo ]
R db1 = -------------------------------[ ooooooooo ]
Line Voltage
Vd
600V AC
950V DC
690V AC
1090V DC
Pmax
268,000 W
305,000 W
R
3.2 Ohms
3.7 Ohms
Pmax x R
857375
1128695
Rdb1
Ohm
Ohm
Vd = DC Bus Regulation Voltage
R = Minimum Brake Resistance Value
Record the Maximum Dynamic Brake Resistance Rdb1in above table.
The choice of the Dynamic Brake resistance value should be less than
the value calculated in this step. If the value is greater, the drive can trip
on DC bus overvoltage.
Step 5
Calculate Required Joule Rating
(joules = Watt-Seconds):
⎛P
----b-⎞ × ( t 3 – t 2 ) = watt-seconds
⎝ 2⎠
Pb
Watt-second losses = ------x
( t – t ) x [ 1 – ( motor efficiencyxdrive efficiency ) ]
2 3 2
Drive Efficiency = 0.975
Total watt-seconds = watt-seconds – watt-second losses
Step 6
Select a Resistor
Select a resistor bank from the following tables or from your resistor
supplier that has all of the following:
•
a resistance value that is less than the value (Rdb1 in Ohms)
calculated in Step 4, but as close as possible below this value.
•
a resistance value that is greater than the minimum resistance for the
DBU listed in Table C.A,
•
a power value that is greater than the value calculated in Step 3
(Pav in watts),
•
a watt-second value greater than the value calculated in Step 5.
Design Information
!
C-9
ATTENTION: Damage of the IGBT will result if the resistance value
of the resistor bank is less than the minimum resistance value for the
DBU as indicated in the product’s nameplate data and in Table C.A.
Verify the resistance value of the selected resistor bank is greater than
the minimum resistance for the DBU.
If no resistor appears in the following tables that is greater than the
minimum allowable resistance (R) and is less than the calculated
maximum resistance (Rdb):
•
Adjust the deceleration time of the application to fit an available
resistor package.
or
•
Use the calculated data to purchase resistors locally.
C-10
Design Information
Example Calculation
A 250 HP, 600 Volt motor and drive are accelerating and decelerating as
depicted in Figure C.1.
•
Cycle period (t4) is 40 seconds
•
Rated speed is 1600 RPM
•
Deceleration time from rated speed to 0 speed is 2.0 seconds
•
Motor load can be considered purely as an inertia and all power
expended or absorbed by the motor is absorbed by the motor and
load inertia.
•
Load inertia is 44.0 lb-ft2 directly coupled to the motor
•
Motor inertia is 166 lb-ft2
•
A PowerFlex 700H, 250 HP, 600V Normal Duty rating is chosen.
•
Drive efficiency is 0.975 and motor efficiency is 0.86.
Proceed with the following calculation to verify the AKDBU300 is
suitable for the application, and select the Dynamic Brake Resistor.
Rated Power = 250 HP × 746 watts = 186500 W
This information was given and must be known before the calculation
process begins. This can be given in HP, but must be converted to watts
before it can be used in the equations.
1600
167.5 Rad
Rated Speed = ω b = 1600 RPM = 2π × ---------- = ----------------------60
s
0
0 Rad
Lower Speed = ω o = 0 RPM = 2π × ----- = ------------60
s
This information was given and must be known before the calculation
process begins. This can be given in RPM, but must be converted to
radians per second before it can be used in the equations.
Step 1
Total Inertia
2
J T = Jm + ( GR × JL )
(GR)2 = 0
JT = 166 . + 44 = 210 lb.-ft. 2 = 210 × 0.042 = 8.82 kg-m 2
This value can be in lb.-ft.2 or Wk2, but must be converted into kg-m2
before it can be used in the equations.
Design Information
C-11
Deceleration Time = ( t3 – t 2 ) = 2 seconds
Cycle Period = t 4 = 40 seconds
DC Bus Regulation Voltage = Vd = 950 Volts
This was known because the drive is rated at 600 Volts rms.
All of the preceding data and calculations were made from knowledge of
the application under consideration. The total inertia was given and did
not need further calculations as outlined in Step 1.
Step 2 Calculate the Peak Braking Power (Pb) and (Pb1) then
compare (Pb1) to the Peak Braking Power of the DBU (Pmax)
JT [ ωb ( ωb – ωo ) ]
Peak Braking Power = Pb = ---------------------------------------( t3 – t2 )
8.82 [ 167.5 ( 167.5 – 0 ) ]
P b = ----------------------------------------------------- = 123700 watts
2
Pb1 = Pb x (motor effic. x drive effic.)
Pb1 = 123 700 x (0.975 x 0.86) = 103 722 watts < Pmax
Note that this is 56% of rated power and is less than the maximum drive
limit of 150% current limit. This calculation determines the power that
must be dissipated by the Dynamic Brake Resistor.
The DBU is suitable for this application because Pb1 is less than Pmax.
Step 3
Calculate the Average Braking Power
( t3 – t2 ) Pb ( ωb + ω o )
Average Braking Power = P av = ------------------ ----- -----------------------ωb
t4
2
2 123700 167.5 + 0
Pav = ⎛⎝ -----⎞⎠ ⎛⎝ ----------------⎞⎠ ⎛⎝ ---------------------⎞⎠ = 4120 watts
167.5
40
2
Verify the power rating of the Dynamic Brake Resistor, or if applicable
the sum of the power ratings of the Dynamic Brake Resistors chosen in
Step 6 is greater than the value calculated in Step 3.
C-12
Design Information
Step 4
Calculate the Maximum Dynamic Brake Resistance
Rdb1 = (Pmax x R) / Pb
Rdb1 = (268 000 x 3.2) / 123 700 = 6.93 Ohm
Line Voltage
Vd
Pmax
600V AC
950V DC 268 000 W
690V AC
1090V DC 305 000 W
R
3.2 Ohms
3.7 Ohms
Pmax x R
857 375
1 128 695
Rdb1
Ohm
Ohm
Vd = DC Bus Regulation Voltage
R = Minimum Brake Resistance Value
Record the Maximum Dynamic Brake Resistance Rdb1in above table.
The choice of the Dynamic Brake resistance value should be less than
the value calculated in this step. If the value is greater, the drive can trip
on DC bus overvoltage.
Step 5
Calculate Required Joule Rating (joules = watt-seconds)
(Pb /2) x (t3 - t2) = (123 700/2) x 2 = 123 700 watt-seconds
Drive Efficiency = 0.975, Motor Efficiency = 0.86
Watt-second losses = [Pb /2 x (t3 - t2)] x [1 – Motor Effic. x Drive Effic.)]
Watt-second losses = 123 700 x [1 – 0.86 x 0.975] = 20 000
Calculate total watt-seconds
Total watt-seconds = 123700 – 20000 = 103700
Step 6
Select a Resistor
From Table C.B resistor PF6F5R4K39 with 6.5 ohm, 4394 watts and
256 400 watt-seconds should be selected based on the following data:
•
Maximum Dynamic Brake Resistance Value (Rdb1) of 6.9 ohms.
The selected resistor must be less than (Rdb1) but as close as possible
below 6.9 ohms.
•
Minimum Brake Resistance (R) of 3.2 ohms.
See Table C.A. The selected resistor must be greater than (R).
•
Average Braking Power (Pav). The power rating of the selected
resistor must be greater than 4120 W or 4.12 kW.
•
Watt-seconds. The watt-seconds for the selected resistor must be
greater than 103 700 Watt-seconds or 103.7 kW-seconds.
Design Information
C-13
Table C.B IPC & PowerOhm Braking Resistors
for 600/690V AC Drives - 950/1090V DC Full-on
Ohms Watts
WattCatalog No.
Seconds
Manuf.
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
13.0
13.0
13.0
13.0
13.0
13.0
13.0
13.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
24500
39800
153900
61500
27800
153900
251300
61344
50200
154455
251300
117367
157200
164900
216700
232000
172138
172138
376000
600500
523728
734000
1027000
1027000
1038000
88900
111200
233400
238800
144900
193100
191600
1048200
134700
215400
215300
133600
140800
155500
191500
342000
376000
500400
440372
898400
1048100
1433800
890985
890985
1955200
3595700
599876
1200
1200
1200
1600
1800
1800
1800
2012
2400
2657
3150
4495
4536
4536
6160
6160
6642
6708
7406
9464
10045
11400
11400
12700
12700
1200
1600
2250
2800
3328
5200
5457
11000
1200
2250
2400
3072
3888
3888
4800
6348
6348
8112
9641
10092
10092
12288
12398
13780
15552
19200
20673
T14R1K2
PR2210-8A
PRT14R1K2
PR2210-8
T14R1K8
PR14R1K80
PRT14R1K8
222-8A
PR222-8
222-8
PR14R3K15
225-8A
PR14R4K53
PR225-8A
PRT14R6K16
T14R6K16
225-8
220-8A
PR225-8
PR220-8
220-8
T14R11K4
PRT14R11K4
PRT14R12K7
T14R12K7
PR13R1K20
PF13R1K60
PR13R2K25
PF13R2K80
PR13R3K32
PR13R5K20
PF13R5K45
PF13R11K0
PR12R1K20
PR12R2K25
PR4405-14A
PR12R3K07
PR5505-16A
PR4405-14
PR4410-14A
PR12R6K34
PR5505-16
PR4410-14
442-14A
PR442-14A
PR5510-16
PR552-16A
442-14
552-16A
PR442-14
PR552-16
552-16
IPC
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
IPC
IPC
IPC
P.O.
P.O.
IPC
IPC
P.O.
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
P.O.
IPC
IPC
P.O.
P.O.
IPC
Ohms Watts
WattCatalog No.
Seconds
Manuf.
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
11.0
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
10.4
1924486
3941400
6169500
6450000
1040221
1040221
1040221
10984300
2387466
2247026
1314510
16476500
10015318
28607000
48300
39400
197400
197400
121123
100080
116600
237243
321000
407344
407344
898400
890985
1737900
25400
186700
186700
115900
81600
95100
153300
274400
329000
274400
489000
855700
770300
801000
359000
1168200
1742000
2490600
2966900
1991000
3790000
2002000
5718700
5885300
21531
24300
30000
30000
30776
32136
32297
43200
45934
46170
48204
58800
68911
86700
1200
1600
2000
2400
2561
3381
3564
5720
5819
8454
8537
9251
12784
14256
1500
1500
1800
2662
2970
2970
4160
5360
5360
6040
6040
8746
8890
8890
11000
11000
15500
15500
16640
18900
18900
26000
26000
26000
445-14A
PR445-14A
PR445-14
PR555-16A
555-16A
440-14A
445-14
PR555-16
550-16A
555-16
440-14
PR440-14
550-16
PR550-16
PR2205-9
PR2210-9A
PR2210-9
PR222-9A
222-9A
222-9
PR222-9
225-9A
PR225-9A
225-9
220-9A
PR225-9
220-9
PR220-9
T10F4R1K5
PRT10F4R1K5
PR10F4R1K80
PR10F4R2K66
PRT10F4R2K97
T10F4R2K97
PR10F4R4K16
PRT10F4R5K36
T10F4R5K36
PRT10F4R6K4
T10F4R6K4
PR10F4R8K74
PRT10F4R8K89
T10F4R8K89
T10F4R11K0
PRT10F4R11K0
T10F4R15K5
PRT10F4R15K5
PR10F4R16K6
T10F4R18K9
PRT10F4R18K9
T10F4R26K0
PR10F4R26K0
PRT10F4R26K0
IPC
P.O.
P.O.
P.O.
IPC
IPC
IPC
P.O.
IPC
IPC
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
IPC
P.O.
IPC
P.O.
IPC
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
IPC
IPC
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
C-14
Design Information
Ohms Watts
WattCatalog No.
Seconds
Manuf.
10.4
10.4
10.4
10.4
10.4
10.4
10.1
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.50
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
9.20
1230000
10024700
1367000
14328100
4620000
18257600
112100
163500
400300
898400
1737900
2824200
479901
5328200
903350
8787400
1956117
13730400
6453800
1950414
1950414
135500
266000
400300
1075300
316618
1520700
2596900
479901
5047800
3000513
8787400
4056700
2851152
1079776
6146500
1820386
102200
75500
161600
98000
116700
135600
282100
341800
748700
1075400
1520800
545200
1064100
1416000
2965500
35600
35600
43900
43900
72300
72300
1200
4000
6760
8410
12960
16000
17713
25000
26569
36000
39559
49000
51840
59043
59339
3800
5025
6422
9728
11926
12312
15200
17890
23750
26636
34200
38912
39755
39955
49248
59635
1200
1600
2000
2355
2981
3751
4867
6601
7737
9421
11923
15001
19467
24876
30948
T10F4R35K6
PRT10F4R35K6
T10F4R43K9
PRT10F4R43K9
T10F4R72K3
PRT10F4R72K3
PF10F1R1K20
PR5505-17A
PR5505-17
PR5510-17A
PR5510-17
PR552-17A
552-17A
PR552-17
552-17
PR555-17A
555-17A
PR550-17A
PR555-17
550-17A
555-17
PR4405-15A
PR4405-15
PR4410-15A
PR4410-15
442-15A
PR442-15A
PR442-15
442-15
PR445-15A
445-15A
PR445-15
PR440-15A
440-15A
445-15
PR440-15
440-15
PF9F2R1K20
PF9F2R1K60
PF9F2R2K00
PF9F2R2K35
PF9F2R2K98
PF9F2R3K75
PF9F2R4K86
PF9F2R6K60
PF9F2R7K73
PF9F2R9K42
PF9F2R11K9
PF9F2R15K0
PF9F2R19K4
PF9F2R24K8
PF9F2R30K9
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
IPC
IPC
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
IPC
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
Ohms Watts
WattCatalog No.
Seconds
Manuf.
9.20
9.20
9.20
9.20
9.20
9.20
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.30
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
4056800
6146600
10387700
6672400
9127700
23372300
240700
300200
896100
1303400
401656
2786200
2846600
693480
1211023
7322900
1564893
2494758
10984300
4917200
2966898
1560331
1559677
19071300
10510600
3325398
5345909
15704400
26200
131000
77700
107400
164245
199500
267369
598900
896100
566990
2259300
359925
359925
2476600
3964700
656981
123900
77000
77800
107500
269500
765100
436200
802700
37683
47693
58880
69635
90001
132480
4232
5408
8192
10368
14093
16200
16200
21143
23427
28800
31474
35138
39200
41472
46977
47219
52321
57800
64800
70477
78475
80000
1200
1600
1868
2920
3826
3861
5095
6139
7475
8545
11680
12738
12754
14782
18250
19264
1200
1600
1792
2800
4732
7383
11251
14812
PF9F2R37K6
PF9F2R47K6
PF9F2R58K8
PF9F2R69K6
PF9F2R90K0
PF9F2R132K2
PR4405-16A
PR4405-16
PR4410-16A
PR4410-16
442-16A
PR442-16A
PR442-16
442-16
552-18A
PR445-16A
445-16A
552-18
PR552-18
PR445-16
440-16A
445-16
555-18A
PR555-18A
PR440-16
440-16
555-18
PR555-18
PR2205-10A
PR2205-10
PR2210-10A
PR2210-10
222-10A
PR222-10A
222-10
PR222-10
PR225-10A
225-10A
PR225-10
225-10
220-10A
PR220-10A
PR220-10
220-10
PF7R1K20
PF7R1K60
PR7R1K79
PF7R2K80
PR7R4K73
PF7R7K38
PF7R11K2
PF7R14K8
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
IPC
IPC
P.O.
IPC
IPC
P.O.
P.O.
IPC
IPC
IPC
P.O.
P.O.
IPC
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
IPC
P.O.
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
Design Information
Ohms Watts
WattCatalog No.
Seconds
Manuf.
7.0
7.0
7.0
7.0
7.0
7.0
6.50
6.50
6.50
6.50
6.50
6.50
6.50
6.40
6.40
6.40
6.40
6.40
6.40
6.40
6.40
6.40
6.40
6.40
6.40
6.40
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.70
5.40
5.40
2330100
4610000
5083700
10141900
21021300
34493700
92600
90400
188100
256400
599000
717000
1086300
256300
716900
1086200
2167000
3568300
574859
5858300
719851
4302500
1231840
4818224
4929414
13460900
1086200
1857400
3171800
5176500
1960167
8238200
6392400
1981674
12900000
2135190
61700
90300
212300
449200
260816
612000
421193
905640
1857400
880744
880744
5176500
1781970
8238200
97000
59900
23548
36912
55001
81648
127575
157500
2106
2600
3438
4394
5466
6656
8424
4326
6553
8294
12960
16000
17529
23040
26292
33177
39148
58430
58718
64000
7776
12150
15000
21600
28008
29400
38400
42015
60000
62551
1846
2280
3853
4793
4938
5836
6525
11029
11542
16314
16461
20520
24694
27930
1200
1382
PF7R23K5
PF7R36K9
PF7R55K0
PF7R81K6
PF7R127K7
PF7R157K7
PF6F5R2K10
PF6F5R2K60
PF6F5R3K43
PF6F5R4K39
PF6F5R5K46
PF6F5R6K65
PF6F5R8K42
PR4405-17A
PR4405-17
PR4410-17A
PR4410-17
PR442-17A
442-17A
PR442-17
442-17
PR445-17A
445-17A
440-17A
445-17
PR445-17
PR5505-19A
PR5505-19
PR5510-19A
PR5510-19
552-19A
PR552-19A
PR552-19
552-19
PR555-19A
555-19A
PR2205-11
PR2210-11A
PR2210-11
PR222-11A
222-11A
PR222-11
222-11
225-11A
PR225-11A
225-11
220-11A
PR225-11
220-11
PR220-11
PR5F4R1K20
PR5F4R1K38
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
IPC
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
IPC
IPC
P.O.
IPC
IPC
P.O.
IPC
P.O.
P.O.
P.O.
Ohms Watts
WattCatalog No.
Seconds
Manuf.
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.40
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
55700
81800
61700
61700
182900
185000
154800
207900
444300
385200
401000
603100
169000
500700
902500
328000
809200
1540500
699000
3328300
2973600
4904100
738000
5451100
717000
5451100
3607800
6164200
2310000
9294800
7276600
712100
1845000
712100
1953000
11877300
3444000
29551700
868900
1412100
2775300
4658800
1603773
6865200
1651395
5593300
959801
11352000
3891643
11217400
1733701
3651418
1670
1670
1749
1949
2680
2680
2856
3650
4541
5080
5080
5529
5780
5780
6998
7280
7280
8640
12000
12000
13500
19440
20300
20300
22000
22000
27993
34560
37700
37700
43740
48100
48100
51900
51900
54000
104000
104000
6480
8000
12500
18000
22848
24500
30978
32000
34269
36125
46464
50000
51028
76534
T5F4R1K67
PRT5F4R1K67
PR5F4R1K74
PR5F4R1K94
PRT5F4R2K68
T5F4R2K68
PR5F4R2K85
PR5F4R3K65
PR5F4R4K54
PRT5F4R5K8
T5F4R5K8
PR5F4R5K52
T5F4R5K78
PRT5F4R5K78
PR5F4R6K99
T5F4R7K28
PRT5F4R7K28
PR5F4R8K64
T5F4R12K0
PRT5F4R12K0
PR5F4R13K5
PR5F4R19K4
T5F4R20K3
PRT5F4R20K3
T5F4R22K0
PRT5F4R22K0
PR5F4R27K9
PR5F4R34K5
T5F4R37K7
PRT5F4R37K7
PR5F4R43K7
PRT5F4R48K1
T5F4R48K1
PRT5F4R51K9
T5F4R51K9
PR5F4R54K0
T5F4R104K0
PRT5F4R104K0
PR4405-18A
PR4405-18
PR4410-18A
PR4410-18
442-18A
PR442-18A
552-20A
PR442-18
442-18
PR552-20A
552-20
PR552-20
445-18A
445-18
C-15
IPC
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
IPC
P.O.
P.O.
IPC
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
IPC
IPC
Design Information
Ohms Watts
WattCatalog No.
Seconds
Manuf.
5.0
5.0
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.80
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.50
4.0
4.0
4.0
4.0
4.0
6865200
25630100
185000
395900
401000
500700
169000
809200
802200
1369400
260000
1674500
359000
2912200
586000
4360900
6752000
984000
6330400
628300
2310000
6468100
3696000
18507200
3916000
18507200
17575000
6159000
25969700
8077000
33527500
71600
133000
168400
537600
2028300
741800
152850
239950
1547800
660558
4141200
1425576
1425576
6407500
4794300
1486256
1238300
2378800
3623500
5492100
2765900
98000
98000
2580
4036
4590
4590
5490
5490
6220
7680
8880
8880
10900
10900
19200
19200
23520
25800
25800
34600
34600
38880
58200
58200
61000
61000
69120
99300
99300
132000
132000
1800
2380
3042
4608
4608
5832
6184
8266
9112
13810
16200
20612
20715
22050
28800
30918
8100
10000
14400
19600
20736
PR5510-20
PR445-18
T4F8R2K58
PR4F8R4K03
T4F8R4K59
PRT4F8R4K59
T4F8R5K49
PRT4F8R5K49
PR4F8R6K22
PR4F8R7K68
T4F8R8K88
PRT4F8R8K88
T4F8R10K9
PRT4F8R10K9
T4F8R19K2
PRT4F8R19K2
PR4F8R23K5
T4F8R25K8
PRT4F8R25K8
PRT4F8R34K6
T4F8R34K6
PR4F8R38K8
T4F8R58K2
PRT4F8R58K2
T4F8R61K0
PRT4F8R61K0
PR4F8R69K1
T4F8R99K3
PRT4F8R99K3
T4F8R132K0
PRT4F8R132K0
PR2205-12A
PR2205-12
PR2210-12A
PR2210-12
PR225-12
PR222-12A
222-12A
222-12
PR222-12
225-12A
PR225-12A
220-12A
225-12
PR220-12A
PR220-12
220-12
PR4405-19A
PR5505-21A
PR4405-19
PR5510-21A
PR4410-19
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
P.O.
IPC
P.O.
P.O.
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
IPC
IPC
P.O.
IPC
P.O.
IPC
IPC
P.O.
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
Ohms Watts
WattCatalog No.
Seconds
Manuf.
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
3.90
3.90
3.90
3.90
3.90
3.90
3.90
3.90
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.80
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
3.30
4394700
5255300
8413000
8973900
1386961
3441020
14645800
1799627
1238300
3623500
4394700
5255300
2405659
5531800
3246136
8013142
105400
317700
459000
1129600
182571
1238300
1982300
328491
430346
5176500
751149
1321116
3995200
2672955
8413000
61000
105500
124600
317800
380400
556400
376100
512700
1197900
1530100
3595800
2541900
5071000
8390100
15984900
26362500
41191400
70836500
25600
32400
40000
40000
42308
44057
57600
66084
7897
14040
24960
31590
32736
45489
49108
62996
2010
3195
3891
6080
7227
7695
9500
9788
16139
18620
24089
24212
24320
36138
38000
1200
1876
2230
2775
3379
4299
6982
9251
11101
13516
21489
24977
38491
47520
75001
106920
150001
214582
PR442-19A
PR5510-21
PR442-19
PR552-21A
442-19
552-21A
PR445-19A
552-21
PR4405-20A
PR4405-20
PR4410-20
PR442-20A
442-20A
PR442-20
442-20
445-19A
PR2205-13A
PR2205-13
PR2210-13A
PR2210-13
222-13A
PR222-13A
PR222-13
222-13
225-13A
PR225-13A
220-13A
225-13
PR225-13
220-13
PR220-13
PF3F3R1K20
PF3F3R1K87
PF3F3R2K23
PF3F3R2K77
PF3F3R3K37
PF3F3R4K29
PF3F3R6K98
PF3F3R9K25
PF3F3R11K1
PF3F3R13K5
PF3F3R21K4
PF3F3R24K9
PF3F3R38K4
PF3F3R47K5
PF3F3R75K0
PF3F3R106K6
PF3F3R150K0
PF3F3R214K4
C-16
P.O.
P.O.
P.O.
P.O.
IPC
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
IPC
IPC
P.O.
P.O.
P.O.
P.O.
IPC
P.O.
P.O.
IPC
IPC
P.O.
IPC
IPC
P.O.
IPC
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
P.O.
www.rockwellautomation.com
Corporate Headquarters
Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: +1 414.212.5200, Fax: +1 414.212.5201
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Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: +1 414.382.2000, Fax: +1 414.382.4444
Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, B-1170 Brussels, Belgium, Tel: +32 2 663 0600, Fax: +32 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: +852 2887 4788, Fax: +852 2508 1846
Headquarters for Dodge and Reliance Electric Products
Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: +1 864.297.4800, Fax: +1 864.281.2433
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Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: +65 6356 9077, Fax: +65 6356 9011
Publication AKDBU-UM001A-EN-P – January 2005
Copyright 2005 Rockwell International Corporation. All rights reserved.