Managing
regen energy
Managing regen energy
0
10
100
Energy storages and brake resistors
in wire-wound and PTC technology
Safety, dependability and efficiency are the basis of our company and product policies.
Today and in the future we will be following this path consistently.
When the Michael Koch GmbH was founded, the main focus was on the development of new designs and
technologies for brake resistors up to protection class IP65 and to ensure that these devices are safe and
conform to the applicable standards. Our Bxx and PTC product lines safely dispose of excess energy from
the DC link of drives, while our product line Dynamic Energy Storage DES accumulates and returns this
energy if required. And when power interruptions occur, our Dynamic Energy Supply DEV product line
guarantees that the drive has sufficient energy to complete its task.
Our headquarters are in the Baden village Ubstadt-Weiher,
between the Rhine plain and Kraichgau. From this convenient
location we supply our products to our customers globally.
2
T cycle [S]
Emergency stopp
Content
Quality, environment, workplace safety and fairness - these criteria are important to
us. We are certified in accordance with DIN EN ISO 9001:2008, the European EcoManagement and Audit Scheme EMAS III regulation and we are a corporate member
of Transparency International, the coalition against corruption. These areas are
audited by independent parties on a regular basis.
In addition to tested products and certified processes, we offer a high degree of
flexibility and responsiveness. Our aims are short delivery times and absolute
reliability. We count on long term relationships and are a reliable partner who
trusts in direct customer relationships.
Qualitätsmanagement
ISO 9001:2008
Regelmäßige freiwillige
Überwachung
Dynamic Energy Storage
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DES 2.0
EM 2.0
Brake resistors in wire-wound
and PTC technology
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PTC Serie
BWx150
BWx250
BWx500
BWx600
BWx1000
7
8
10
11
12
13
14
Our modular system for
brake resistors
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18
19
20
21
22
BWx...K...R...
BWx...K...
BAx...
BxP...
BxH...V...
BxH..H....
BWK...
Special solutions and accessories 23
D-138-00051
Dynamic Energy Supply
24
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DEV 2.0
EM 2.0
Communication channels
27
3
Dynamic Energy Storage
DES 2.0
The Dynamic Energy Storage DES offers new opportunities to deal with braking energy. I.e. without power grid. A device, that can be used on
almost all inverters and servo controllers that have a maximum DC link voltage of 850 VDC. For a number of applications, this represents an
opportunity to increase energy efficiency, save on resources while also protecting your nerves and even the electrical grid.
Active buffer module
for DC links
> for single axis and multi axes
systems
> adjusts itself independently right
from the start (Black Box)
> no buttons, display indicators,
other controls
> shorter cycle times result in
increased efficiency
The operation - saving without power quality disturbances
Contrary to a direct extension of the capacity of the inverter´s DC link, the active DES is not
connected to the upstream electrical grid. The DES is only charged when braking. One of the most
important consequences of this feature is: The DES does not result in power quality disturbances. The
energy supply determines the level of its threshold voltage independently. The DES absorbs all the
energy that would cause the voltage in the DC link to rise above this level. Conversely, the DES returns
energy when the voltage level is not reached, i.e. the inverter would be driven by electrical energy
derived from the power grid. This is the decisive point to save energy. If the energy level in the DES
capacitor falls below the dynamically determined charging voltage due to energy being dissipated, the
DES terminates its operation and waits for the next braking event to recharge its capacitor with the
available energy. Charging, discharging, recharging, etc. can take place in a fraction of a second
without power quality disturbances.
Technical specifications DES 2.0
Dimensions and
mounting holes (mm)
Parameter
Value
Available storage capacity, up to
Continuous voltage DC link
Short-term peak voltage DC link
Output power
Installed PTC braking resistor
Dimensions H x W x D
Weight
Protection class
1,600 Ws
850 VDC max.
950 VDC max. (30 s in 6 min.)
18 kW max.
R25 60 Ohm, Pcont 30 W
300 x 100 x 201 mm
approx. 6.9 kg
IP 20
Voltage curve of the DC link
Energy savings with the DES 2.0
300
258
with DES 2.0
without DES 2.0
energy savings
with DES 2.0
without DES 2.0
U[VDC]
P[W]
UBRC
21
UDES
58
100
21
UNETZ
Time
4
Time
1
2
Simple connections I (bottom)
Simple connections II (top)
With only three cables, the DES is extremely
easy to connect. And it works.
1. Polarity protected interface for the connection
of expansion modules
Terminal 1: negative terminal of the DC link
2. Safety relevant LED: flashes while the storage
unit is charged
Terminal 2: brake transistor (brake chopper)
Terminal 3: positive terminal of the DC link
The small built in PTC braking resistor
in DES safely absorbs expected and
unexpected power surges.
Simple to try
Based on its concept, it is easy to test the DES
in an existing system. The DES is simply
connected in parallel to the brake resistor of
the drive system. After a few cycles, the data
collected by the processor of the DES can be
read and analyzed. After the course was
analyzed, an appropriate storage device is
selected. It could not be easier.
Energy fluctuation/cycle time diagram
For an ambient temperature of 40º Celsius
Cycle time in seconds
2,0
1,8
1,6
1,4
1,2
1,0
0,8
0,6
0,4
0,2
0,0
200
400
600
800
1000
1200
1400
1600
Energy consumption in Ws
5
Expansion module
EM 2.0
Under some conditions, the Dynamic Energy Storage DES suffers from an
insufficient storage volume. This is when expansion modules are being used.
They are simply connected with the DES by means of a cable with polarity
protected plugs. Nothing else.
Before connecting the DES, the storage capacitors are to be safely
discharged via the discharge resistor installed in the expansion modules.
The number of connected expansion modules, i.e. the amount of stored
energy is tailored to match the requirements of the application.
Storage expansion
for the DES
Technical specifications
> increasing the stored energy
x-times
> simple connection using a plug
> no configuration or
commissioning required
> discharge resistor on board
Parameter
EM 2.0A20
EM 2.0A2020
Available storage capacity, up to
Built-in PTC discharge resistor
Dimensions H x W x D mm
Weight approx.
Protection class
1,600 Ws
+
300 x 100 x 201
4.1 kg
IP 20
3,200 Ws
+
300 x 100 x 201
6.2 kg
IP 20
1
2
Dimensions and
mounting holes (mm)
1
300
258
3
Simple connections I (bottom)
Simple connections II (top)
Ground terminals
1. Polarity protected interface for the connection
of the DES or additional expansion modules
21
2. Center polarity protected interface:
discharge resistor
58
100
6
21
3. Safety relevant LED: flashes while the
storage unit is charged
Brake resistors in wire-wound
and PTC technology
Wire-wound resistors
Safe brake resistors for electrical drive technology must meet specific
requirements. High pulse loading capacity with controlled surface
temperatures and a coherent safety concept under persistent
overloads are required.
We have achieved optimum results with our wire-wound resistors to manage this
balancing act. In compliance with the relevant standards, sub-components were selected and mounted in
rugged, anodized aluminum housings using specific constructive measures.
Results speak for themselves: Low-inductance resistors that are particularly pulse resistant, with a specific safety
concept to guarantee long life.
PTC resistors
PTC denotes Positive Temperature Coefficient with special characteristics. The characteristics of a PTC resistor cause its
resistance to exponentially increase from a defined temperature until it reaches high resistance. This property is used
to provide advantages in various applications; in our equipment it is used as a brake resistor with the focus on the
intrinsic safety of the components. When an integrated PTC is overloaded, the inverter signals an overvoltage on the
DC link that can be compensated by an additional external resistor. Regarding the design the temperature and voltage
dependencies of the PTC resistor must be taken into account.
Advantages of all series
> compact
> protection class up
to IP 65
> particularly
impulse-resistant
> low inductance
> "intrinsically safe"* under persistent overloads
- no short-circuit
- no fault to frame
- self-extinguishing
* "intrinsic safety" is usually provided by wire-wound resistors when the rated power at 35% duty cycle ED is multiplied by four. It is typical for PTC resistors.
Special requirements
Different requirements in combination with the special properties of the brake resistor do not present a problem.
A broad spectrum of fully adaptive combinations is available in the range from 100 watts to 7.2 kW. Special
geometrical properties to match the hole-pattern of the converter, an enclosure in a particular color or a special
connector do not constitute a problem. All this is available with IP 65 protection class within 24 hours.
60,000 types...
ex-stock!
Inquiry, design, offer and
delivery in one day.
7
Brake resistor
PTC8006xx
Self-protecting PTC element (aluminum housing) with very high
operating voltage limit; protection class IP20.
Rated power (W)
See tables
Resistance (Ohm)
See tables
Dimensions (mm)
Enclosure: See tables
Wiring:
up to 450 mm
Ø AWG 20 or 0.6 mm²
With four mechanical and electrical ranges of 35, 70, 105 and 140
watts continuous power on a heat sink, the PTC brake resistors cover
the power requirements of small frequency inverters and servo controllers.
Similar to the level of wire-based brake resistors, the impulse power ratings are of major importance
for the applications and have a factor of 35 with a 1 percent duty cycle. The elements which may be
installed in the inverter´s enclosure are also known as ballast resistors and have an IP20 protection
class. Several mechanical designs are available in the series. Customer requirements are implemented
as necessary when the order involves sufficient quantities. The resistance values for each type are
dynamic with respect to the temperature at the PTC (see R(T) curve) and the applied voltage.
Technical specifications
(ϑA = 20°C, unless otherwise stated)
Parameter
Symbol
Tolerance (resistance)
Max. perm. operating voltage
UB
Pulse rating
Certifications
Pi
cCSAus
Value
Unit
Conditions
± 35
%
Attention: PTC-typical and
not to be reduced
£ 600 AC
£ 850 DC
£ 20
V
V
kW
Value in approach
Standard CSA-C22.2
Versions
28
B
PTC
H
PTC with connector
4.5
Dimensions and mounting holes (mm)
3.25
450
10
L
Case temperature
Brake resistor PTC8006xx
Resistance-temperature characteristic
Type specific of request
R(Ohm)
PTC with custom specific
connector
PTC with custom specific
connector
8
0
20
40
60
80
100
120
140
160
180
T (°C)
PTC - 35 W
Impulse loading
(ϑA = 20°C, unless otherwise stated)
Parameter
Symbol
Value
Unit
Conditions
Resistances
Rated power
R
P
Ω
Dimensions
L
175, 350, 1750
10
35
67.0 ± 1
89.0 ± 0.4
34.0 ± 0.3
10.5 ± 0.5
11.5 ± 0.5
*
unobstructed convection
on heat sink (70 °C)
alternatively
W
H
W
W
mm
mm
mm
mm
mm
Duty cycle (%)
100
On heat sink
70°C
10
Ambient temperature
20°C
alternatively
1
10
P(W)
100
PTC - 70 W
(ϑA = 20°C, unless otherwise stated)
Duty cycle (%)
100
Parameter
Symbol
Value
Unit
Conditions
Resistances
Rated power
R
P
Ω
Dimensions
L
90, 175, 875
20
70
115.0 ± 0.5
124.0 ± 0.5
34.0 ± 0.3
10.5 ± 0.5
11.5 ± 0.5
*
unobstructed convection
on heat sink (70 °C)
alternatively
On heat sink
70°C
W
H
W
W
mm
mm
mm
mm
mm
10
Ambient temperature
20°C
1
10
alternatively
100
1,000
P(W)
Duty cycle (%)
PTC - 105 W
100
(ϑA = 20°C, unless otherwise stated)
Parameter
Symbol
Value
Unit
Conditions
Resistances
Rated power
R
P
Ω
*
unobstructed convection
on heat sink (70 °C)
Dimensions
L
W
H
60, 120
30
105
139.0 ± 0.4
34.0 ± 0.3
10.5 ± 0.5
On heat sink
70°C
10
W
W
mm
mm
mm
Ambient temperature
20°C
1
10
PTC - 140 W
100
1,000
P(W)
Duty cycle (%)
100
(ϑA = 20°C, unless otherwise stated)
Parameter
Symbol
Value
Unit
Conditions
Resistances
Rated power
R
P
Ω
*
unobstructed convection
on heat sink (70 °C)
Dimensions
L
W
H
44, 88
40
140
167.0 ± 0.4
34.0 ± 0.3
10.5 ± 0.5
W
W
mm
mm
mm
On heat sink
70°C
10
Ambient temperature
20°C
1
10
100
1,000
P(W)
* The resistance values for each type are dynamic with respect to the temperature at the PTC (see R(T) curve) and the applied voltage.
9
Brake resistor
BWx150
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors) in an aluminum case,
IP65 protection class.
Technical specifications
(ϑA = 20°C, unless otherwise specified)
Parameter
Symbol
Value
Unit
Conditions
Tolerance (resistance)
Temperature coefficient
Insulation resistance
±5
20 ... 100
³ 100
%
10-6/K
MΩ
Room temperature
TK
RISO
Umess = 1,000 VDC
75, 300
Inductance
Capacity against enclosure
L
C
£ 30
£ 300
µH
pF
f = 300 kHz, Umess = 50 mV
f = 300 kHz, Umess = 50 mV
Dimensions (mm)
Thermal time constant
Weight
Certifications
Energy absorption
τ
m
cCSAus
Q
approx. 250
230
s
g
Maximum permissible
operating voltage
UB
kJ
kJ
V
V
V
V
V
Standard CSA-C22.2
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
Taking into consideration
the "intrinsic safety"
cCSAus certification
cCSAus certification
f = 50 Hz; t = 1 min
unobstructed convection
Rated power (W)
60 (150 with duty cycle
ED = 35%, ϑA = 20°C)
Resistance (Ohm)
Enclosure: 80 x 52 x 28
Wiring:
length 510±40 mm
Ø AWG16 or 1.5 mm²
Isolation voltage
Uiso
2.2
4.4
£ 700 AC
£ 1,000 DC
£ 600 AC
£ 850 DC
³ 4,000 AC
Max. permissible case temp.
ϑC
£ 250
°C
Storage temperature
ϑS
-25 ... +85
°C
Dimensions and mounting holes (mm)
5
28
Versions
24.5
52
BWD150
BWS150
24.5
510
80
3
Pulse loading capacity
Case temperature
Brake resistor BWx150
Brake resistor BWx150
With duty cycle ED = 100%
Maximum permissible temperature T = 250 °C
Duty cycle (%)
T (°C)
100
250
50
Ambient temperature
70°C
200
BWS150 with custom specific
connector
Ambient temperature
20°C
150
10
100
Ambient temperature
20°C
5
Ambient temperature
70°C
50
0
1
60
100
200
500
1,000
2,000
4,000
P(W)
10
0
25
50
75
P(W)
Brake resistor
BWx250
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors) in an anodized aluminum case,
IP65 protection class.
Technical specifications
(ϑA = 20°C, unless otherwise specified)
Parameter
Symbol
Value
Unit
Conditions
Tolerance (resistance)
Temperature coefficient
Insulation resistance
%
TK
RISO
±5
20 ... 100
³ 100
MΩ
Room temperature
10-6/K
Umess = 1,000 VDC
Inductance
Capacity against enclosure
L
C
£ 30
£ 300
µH
pF
f = 300 kHz, Umess = 50 mV
f = 300 kHz, Umess = 50 mV
Thermal time constant
Weight
Certifications
τ
m
cCSAus
cURus
Q
approx. 550
280
s
g
Energy absorption
Maximum permissible
operating voltage
UB
4
8
£
£
£
£
³
700 AC
1,000 DC
600 AC
850 DC
4,000 AC
Rated power (W)
100 (250 with duty cycle
ED = 35%, ϑA = 20°C)
kJ
kJ
V
V
V
V
V
Standard CSA-C22.2
UL 508
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
Taking into consideration
the "intrinsic safety"
UL certification
UL certification
AC; f = 50 Hz; t = 1 min
unobstructed convection
Isolation voltage
Uiso
Max. permissible case temp.
ϑC
£ 250
°C
Storage temperature
ϑS
-25 ... +85
°C
Dimensions and mounting holes (mm)
Resistance (Ohm)
3, 10, 24, 27, 33, 47, 60, 72, 100,
120, 150, 200, 220, 330, 390, 430,
530, 620, 830
Dimensions (mm)
Enclosure: 110 x 80 x 15
Wiring:
length 510±40 mm
Ø AWG16 or 1.5 mm²
80
15
60
Versions
67
BWD250
10
4.8
6
98
110
510
Pulse loading capacity
Case temperature
Brake resistor BWx250
Brake resistor BWx250
BWG250
With duty cycle ED = 100%
Maximum permissible temperature T = 250 °C
Duty cycle (%)
T (°C)
100
250
50
Ambient temperature
70°C
200
BWS250
Ambient temperature
20°C
150
10
100
Ambient temperature
20°C
5
Ambient temperature
70°C
50
0
1
100
200
500
1,000
2,000
5,000
10,000
P(W)
0
50
100
150
P(W)
BWT250*
*without CSA and UL approval
11
Brake resistor
BWx500
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors) in an anodized aluminum case,
IP65 protection class.
Technical specifications
(ϑA = 20°C, unless otherwise specified)
Rated power (W)
200 (500 with duty cycle
ED = 35%, ϑA = 20°C)
Resistance (Ohm)
10,12, 15, 22, 27, 35, 40, 43, 47,
50, 60, 72, 100, 130,150, 160, 200,
210, 240, 300, 310, 360, 430, 620
Dimensions (mm)
Enclosure: 216 x 80 x 15
Wiring:
length 510±40 mm
Ø AWG16 or 1.5 mm²
Parameter
Symbol
Value
Unit
Conditions
Tolerance (resistance)
Temperature coefficient
Insulation resistance
±5
20 ... 100
³ 100
%
TK
RISO
MΩ
Room temperature
10-6/K
Umess = 1,000 VDC
Inductance
Capacity against enclosure
L
C
£ 30
£ 300
µH
pF
f = 300 kHz, Umess = 50 mV
f = 300 kHz, Umess = 50 mV
Thermal time constant
Weight
Certifications
τ
m
cCSAus
cURus
Q
approx. 550
550
s
g
Energy absorption
kJ
kJ
V
V
V
V
V
Standard CSA-C22.2
UL 508
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
Taking into consideration
the "intrinsic safety"
UL certification
UL certification
AC; f = 50 Hz; t = 1 min
unobstructed convection
Isolation voltage
Uiso
7.5
15
£ 700 AC
£ 1,000 DC
£ 600 AC
£ 850 DC
³ 4,000 AC
Max. permissible case temp.
ϑC
£ 250
°C
Storage temperature
ϑS
-25 ... +85
°C
Maximum permissible
operating voltage
UB
80
15
60
Dimensions and mounting holes (mm)
Versions
67
BWD500
10
4.8
6
204
216
510
BWG500
Pulse loading capacity
Case temperature
Brake resistor BWx500
Brake resistor BWx500
With duty cycle ED = 100%
Maximum permissible temperature T = 250 °C
Duty cycle (%)
T (°C)
100
250
50
Ambient temperature
70°C
200
BWS500
Ambient temperature
20°C
150
10
100
Ambient temperature
20°C
5
Ambient temperature
70°C
BWT500*
*without CSA and UL approval
12
50
0
1
100
200
500
1,000
2,000
5,000
10,000
P(W)
0
100
200
300
P(W)
Brake resistor
BWx600
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors) in an anodized aluminum case,
IP65 protection class.
Technical specifications
(ϑA = 20°C, unless otherwise specified)
Parameter
Symbol
Value
Unit
Conditions
Tolerance (resistance)
Temperature coefficient
Insulation resistance
%
TK
RISO
±5
20 ... 100
³ 100
MΩ
Room temperature
10-6/K
Umess = 1,000 VDC
Inductance
Capacity against enclosure
L
C
£ 30
£ 300
µH
pF
f = 300 kHz, Umess = 50 mV
f = 300 kHz, Umess = 50 mV
Thermal time constant
Weight
Certifications
τ
m
cCSAus
cURus
Q
approx. 600
1,050
s
g
Energy absorption
Maximum permissible
operating voltage
13
26
£
£
£
£
³
UB
700 AC
1,000 DC
600 AC
850 DC
4,000 AC
Rated power (W)
240 (600 with duty cycle
ED = 35%, ϑA = 20°C)
kJ
kJ
V
V
V
V
V
Standard CSA-C22.2
UL 508
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
Taking into consideration
the "intrinsic safety" (4kW)
UL certification
UL certification
AC; f = 50 Hz; t = 1 min
unobstructed convection
Isolation voltage
Uiso
Max. permissible case temp.
ϑC
£ 250
°C
Storage temperature
ϑS
-25 ... +85
°C
Dimensions and mounting holes (mm)
Resistance (Ohm)
5, 10, 14, 18, 20, 22, 27, 33, 47, 72,
80, 100, 150, 200, 220, 240, 300
Dimensions (mm)
Enclosure: 216 x 80 x 30
Wiring:
length 510±40 mm
Ø AWG14 or 2.5 mm²
80
30
60
Versions
BWD600
10
4.8
67
6
204
216
510
Pulse loading capacity
Case temperature
Brake resistor BWx600
Brake resistor BWx600
BWG600
With duty cycle ED = 100%
Maximum permissible temperature T = 250 °C
Duty cycle (%)
T (°C)
100
250
50
Ambient temperature
70°C
200
BWS600
Ambient temperature
20°C
150
10
100
Ambient temperature
20°C
5
Ambient temperature
70°C
50
0
1
100
200
500
1,000
2,000
5,000
10,000
20,000
P(W)
0
100
200
300
P(W)
BWT600*
*without CSA and UL approval
13
Brake resistor
BWx1000
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors) in an anodized aluminum case,
IP65 protection class.
Technical specifications
(ϑA = 20°C, unless otherwise specified)
Parameter
Symbol
Value
Unit
Conditions
Tolerance (resistance)
Temperature coefficient
Insulation resistance
±5
20 ... 100
³ 100
%
TK
RISO
MΩ
Room temperature
10-6/K
Umess = 1,000 VDC
5, 10, 14, 18, 20, 22, 27, 33, 47, 72,
80, 100, 150, 200, 220, 240, 300
Inductance
Capacity against enclosure
L
C
£ 30
£ 300
µH
pF
f = 300 kHz, Umess = 50 mV
f = 300 kHz, Umess = 50 mV
Dimensions (mm)
Thermal time constant
Weight
Energy absorption
τ
m
Q
Maximum permissible
operating voltage
Isolation voltage
UB
Uiso
approx. 850
1,050
13
26
£ 700 AC
£ 1,000 DC
³ 4,000 AC
s
g
kJ
kJ
V
V
V
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
Taking into consideration
the "intrinsic safety"
AC; f = 50 Hz; t = 1 min
Max. permissible case temp.
ϑC
£ 300
°C
unobstructed convection
Storage temperature
ϑS
-25 ... +85
°C
Rated power (W)
400 (1,000 with duty cycle
ED = 35%, ϑA = 20°C)
Resistance (Ohm)
Enclosure: 216 x 80 x 30
Wiring:
length 510±40 mm
Ø AWG14 or 2.5 mm²
4.8
67
10
BWD1000
6
204
216
510
BWG1000
80
30
60
Dimensions and mounting holes (mm)
Versions
Pulse loading capacity
Case temperature
Brake resistor BWx1000
Brake resistor BWx1000
With duty cycle ED = 100%
Maximum permissible temperature T = 300 °C
Duty cycle (%)
T (°C)
100
300
50
250
BWS1000
Ambient temperature
20°C
Ambient temperature
70°C
200
150
10
Ambient temperature
20°C
100
5
Ambient temperature
70°C
50
BWT1000
0
1
100
200
500
1,000
2,000
5,000
10,000
20,000
P(W)
14
0
100
200
300
400
P(W)
Our modular system
for brake resistors
We manufacture resistor combinations by an
extensive set of accessories for high performance applications.
The system is based on individual modules of the series BWD 250 to
1,000 with output powers rated from 100 to 400 Watts, whose technical
specifications are available on pages 11-14.
In addition to its high performance, this modular system combines a compact
design with extreme flexibility. This results in the optimization of the braking
resistor in accordance with the specifications of each individual application.
Optimized application that may be implemented are:
Required power - no "unnecessary over-dimensioning"
Many resistance values – according to the inverters requirements
Mechanical design – depending on the existing installation space
Assembly - horizontal or vertical
Protection class IP 20 or IP 65 - according to installation location and environmental conditions
Individual modules with UL and CSA standard approval
Several braking resistors in a resistor combination, e.g. for moving and hoisting gear
Technical specifications of individual modules
(ϑA = 20°C, unless otherwise specified)
Parameter
Symbol
Value
Unit
Conditions
Tolerance (resistance)
Insulation resistance
RISO
±5
³ 100
%
MΩ
Room temperature
Umess = 1,000 VDC
Inductance
Capacity against enclosure
L
C
£ 30
£ 300
µH
pF
f = 300 kHz, Umess = 50 mV
f = 300 kHz, Umess = 50 mV
Thermal time constant
Energy absorption BWD250
τ
τ
τ
Q
Energy absorption BWD500
Q
Energy absorption BWD600/1000
Q
Maximum permissible
operating voltage
UB
s
s
s
kJ
kJ
kJ
kJ
kJ
kJ
V
V
V
V
V
BWD250/500
BWD600
BWD1000
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
with 1.2 s (1% duty cycle)
with 7.2 s (6% duty cycle)
Taking into consideration
the "intrinsic safety"
UL certification
UL certification
f = 50 Hz; t = 1 min
Isolation voltage
Uiso
approx. 550
approx. 600
approx. 850
4
8
7,5
15
13
26
£ 700 AC
£ 1,000 DC
£ 600 AC
£ 850 DC
³ 4,000 AC
Max. permissible case temp.
ϑC
£ 250
°C
unobstructed convection
ϑC
£ 300
°C
unobstructed conv. (BWD1000)
ϑS
-25 ... +85
°C
Storage temperature
15
Brake resistor combination
BWx...K...R...
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors), consisting of single
resistor modules installed in a base frame.
Rated power (kW)
Technical specifications
Depending on the combination
For technical data, please refer to page 15 or the pages
for the respective individual modules.
Resistance (Ohm)
Depending on the combination
Type-specific sizes available upon request.
7
Dimensions and mounting holes (mm)
9
Dimensions (mm)
Individual upon request
individual
Individual solutions
8
Model with BWD250 and a
single frame
6
10
38
90
Nomenclature
Brake resistor combination BWx...K...R...
Model with BWD250 and a
double frame
BWD500100K02R1302K
Individual design
Design for 1 or 2 resistors each
Frame width in mm
Letter code for product frame
Number of individual resistors (e.g.: 2 piece = 02, 12 piece = 12)
Description for a combination
Three-digit resistance for single resistor
Series designation of individual resistors
Version (D, G, S, T)
Product name braking/ballast resistor
Model with BWD500 and a
double frame
16
Brake resistor combination
BWx...K...
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors), consisting of single
resistor modules installed in combination.
Technical specifications
For technical data, please refer to page 15 or the pages
for the respective individual modules.
Rated power (kW)
0.1 - 7.2
Resistance (Ohm)
1 - 14,940
1
Dimensions and mounting holes (mm)
Mounting bracket for brake resistor combinations BWX ... K. ..
Detailed dimensions for specific versions available upon request.
5
Dimensions (mm)
Upon request
5
176
216
204
216
1
Individual solutions
1
5
70
110
60
80
10
10
Bracket W110
31
18.5
6
20
18.5
6
20
10
31
30
Bracket W080
Brake resistor combination with
BWD250 and bracket W110 in
IP20
40
10
5
25
98
110
5
5
Bracket W216
Nomenclature
Brake resistor combination BWx...K...
Brake resistor combination with
BWD600/1000 and bracket W080
and temperature monitor in IP65
BWD1000200K01ALV
Connections
V:
in IP20
VIP65:
in terminal box
Without: no entry
Type of bracket
L:
long (flat on the base)
K:
narrow (module vertically oriented, upside-down)
M:
narrow (module vertical)
Without: no entry
Radiating panels
With:
A
Without: no entry
Number of individual resistors (e.g.: 2 piece = 02, 12 piece = 12)
Description for a combination
Three-digit resistance for single resistor
Series designation of individual resistors
Version (D, G, S, T)
Product name braking/ballast resistor
Brake resistor combination with
BWD500 and bracket W080 and
temperature monitor in IP20
17
Brake resistor combination
BAx...
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors), consisting of single
resistor modules installed in combination.
Rated power (kW)
Technical specifications
0.2 - 7.2
For technical data, please refer to page 15 or the pages
for the respective individual modules.
Resistance (Ohm)
1 - 17,360
Dimensions (mm)
Dimensions and mounting holes (mm)
Upon request
Mounting plates for brake resistor combinations BAx.
Detailed dimensions for specific versions available upon request.
170
30
235
12.5
145
Mounting plate P250D
Mounting plate P250
85
Mounting plate P250H
Nomenclature
Brake resistor combination BAx...
Brake resistor combination on
double mounting plate in IP65
Brake resistor combination on
double mounting plate including
temperature monitor in IP20
18
250
6
250
237
23.5
37.5
7.5
30
6.5
40
6.5
30
7
7
Brake resistor combination on
half a mounting plate in IP65
250
237
Individual solutions
BAF2.4100D-1000TS
Temperature switch
Series designation of the installed resistors (with 500, no entry)
Number of individual resistors on a single plane
Without: simple, normal plate with mounting and top-hat rail
D: double plate/radiating panel with fasteners for top-hat rail/s
H: half plate without any facilities for a top-hat rail
Z: strain relief option for connections with strain relief
Three-digit resistance of the individual resistor
Total continuous or rated power of the combination in kW
Combination wired to the base plate (BAF via spring-loaded terminals,
BAS via screw-type terminals)
Brake resistor combination
BxP...
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors), consisting of single
resistor modules installed in combination.
Technical specifications
For technical data, please refer to page 15 or the pages
for the respective individual modules.
Rated power (kW)
0.4 - 4.8
Resistance (Ohm)
1 - 7,400
Dimensions and mounting holes (mm)
Mounting plates for brake resistor combinations BxP.
Detailed dimensions for specific versions available upon request.
Dimensions (mm)
212.5
Upon request
212.5
212.5
325
465
Individual solutions
20
20
7
7
Brake resistor combination
with cover to IP20
6.5
6.5
259
259
Mounting plate P259A
Mounting plate P259B
Nomenclature
Brake resistor combination BxP...
Brake resistor combination
with cover to IP65
B2P3.2100-1000H
Individual design
Series designation of the installed resistors (with 500, no entry)
Three-digit resistance of the individual resistor
Total continuous or rated power of the combination in kW
Combination on base plate, wired
Number of individual resistors on a single plane, 1, 2, 3, …
Position of the top-hat rail
P: in parallel with the individual resistors
H: at right angles to the individual resistors
Brake resistor combination, IP20
19
Brake resistor combination
BxH...V...
Rated power (kW)
Technical specifications
0.4 - 1.2
Upon request
Resistance (Ohm)
Dimensions and mounting holes (mm)
1.67 - 2,480
Mounting plates for brake resistor combinations BxH…V ...
Detailed dimensions for specific versions available upon request.
12
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors), consisting of single
resistor modules installed in combination.
Dimensions (mm)
95
Upon request
20
170
530
345
550
305
Detailed views
Detailed view of a terminal box
9
8
5
305
20
215
15
230
345
Cover H305
Mounting plate P550-230
Nomenclature
Brake resistor combination BxH...V...
H305 cover not installed
B3H0.7100-600IP65VS
Individual design
Module installation type
Protection class
Series designation of the installed resistors (with 500, no entry)
Three-digit resistance of the individual resistor
Total continuous or rated power of the combination in kW
Combination on base plate, wired
Number of individual resistors on a single plane, 1, 2, 3, …
Position of the top-hat rail
H: at right angles to the individual resistors
Structure without cover
20
Brake resistor combination
BxH...H...
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors), consisting of single
resistor modules installed in combination.
Technical specifications
Upon request
Rated power (kW)
0.4 - 3.6
Dimensions and mounting holes (mm)
12
Mounting plates for brake resistor
combinations BxH...H... Detailed dimensions for
specific versions available on request.
Resistance (Ohm)
1 - 7,400
Dimensions (mm)
135
Upon request
550
Detailed views
270
530
320
Detailed view of a terminal box
9
8
5
320
15
165
315
330
Cover H320
Mounting plate P550
Nomenclature
Brake resistor combination BxH...H...
H320 cover not installed
B3H3.6100-600IP65HS
Individual design
Module installation type
Protection class
Series designation of the installed resistors (with 500, no entry)
Three-digit resistance of the individual resistor
Total continuous or rated power of the combination in kW
Combination on base plate, wired
Number of individual resistors on a single plane, 1, 2, 3, …
Position of the top-hat rail
H at right angles to the individual resistors
Structure without cover
21
Brake resistor combination
BWK...
Short-circuit proof, "intrinsically safe" resistor for use in
inverters (brake transistors), consisting of single
resistor modules installed in an enclosure.
Rated power (kW)
Technical specifications
0.2 - 2.4
For technical data, please refer to page 15 or the pages
for the respective individual modules.
Resistance (Ohm)
1 - 6,640
Dimensions (mm)
Dimensions and mounting holes (mm)
465 x 310 x 124
420 x 160 x 105
530 x 160 x 105
135
160
34.5
34.5
114.5
313
465
358
420
313
530
Individual solutions
12.5
285
310
12.5
Brake resistor combination in an
enclosure to IP20
Nomenclature
Brake resistor combination BWK...
BWK2.0047-1000H
Individual design
Series designation of the installed resistors (with 500, no entry)
Three-digit resistance of the individual resistor
Total continuous or rated power of the combination in kW
Metal enclosure
Product name braking/ballast resistor
Brake resistor combination in an
enclosure to IP65
22
135
160
12.5
Special solutions
Custom designs
demonstrate our flexibility:
Brake resistor combination
G900S
Starting with the correct
interpretation of the
requested application,
almost no limits apply due
to the many available
mechanical options ...
Consisting of:
frame R900S, hood H904S, cover D904S
and 3 for fan DV6224
Power rating: to 12 kW with 100 % duty cycle
to 360 kW with 1 % duty cycle
Prot. class:
IP 20
RoHS-conform 2002/95/EG
Temperature monitoring
Fan power:
120 W
Brake resistor combination
BWD1.5DV15B
Brake resistor combination
BWD600100K18KDVF
Brake resistor combination
BAS0.5033-600IP65
Power rating: 1.5 kW \ 9 x 150 Ohm \
4 x 100 Ohm \ 2 x 72 Ohm
Prot. class: IP20
RoHS-conform 2002/95/EG
Power rating: 4.32 kW \ 5.6 Ohm
Prot. class: IP20
RoHS-conform 2002/95/EG
Power rating: 0.48 kW \ 16.5 Ohm
Prot. class: IP65
RoHS-conform 2002/95/EG
Radiating plates
Mounting plates
Connectors and connector housings
Standoffs, screws, etc.
Accessories
We provide a full set of accessories such
as brackets, spacers, temperature
switches, base frames, flat connectors,
etc., an almost unlimited variety of
installation and combination options.
Brackets
23
Dynamic Energy Supply
DEV 2.0
Two factors are of particular importance to companies with regard to electric energy: a secure supply and low prices. The phasing out of atomic
energy calls both these factors into question. When the big picture is broken down to a single electric drive or combined drives, power
interruptions currently present a special challenge even to developed countries. The Dynamic Energy Supply for drives and servo controllers
can at least be used to bypass and minimize the effects of short-term power interruptions.
Active supply module
for DC links
> for single axis and multi axes
systems
> no buttons, display indicators,
other controls
> provides support during power
failures or interruptions
> with a digital interface
Short-term UPS for drives
Caring for the power grid and the drives
The Dynamic Energy Supply DEV acts as a
short-term uninterruptible power supply to
drive and servo controllers. The active
capacity expansion for the DC link of the
inverters stores an amount of energy that is
defined according to the technical design.
In case of a power failure, this is used to
maintain the voltage level of the DC link at
a level to bypass the interruption without
disturbance and/or to bring the machine to
a defined stop. The objective in each case is
that the drive and all of the systems powered
by it are either not affected by the power
failure or that they are placed into a defined
state, from where it may be restarted
without effort.
The energy storage is charged when the inverter
is turned on by the charging routine that is
designed for delicate operations to avoid
excessive loads on the charging circuit of the
inverter and to reduce power quality disturbances
as much as possible. The DEV is fully operational
after approx. eight seconds. Then it is ready to
supply power to the DC link at any time when
its voltage drops below 470 VDC.
Digital interface included
The Dynamic Energy Supply DEV is equipped with
a digital interface with a 24 volt input to monitor
its operation. The controller of the machine
evaluates the signal and it initiates any
predetermined procedures.
Technical specifications DEV 2.0
Value
Usable energy
Continuous voltage DC link
Momentary peak voltage DC link
Working voltage (ex-factory)
Output power
Digital interface
Built-in PTC discharge resistor
Dimensions H x W x D
Weight approx.
Protection class
approx. 2,000 Ws
850 VDC max.
950 VDC max. (30 s in 6 min.)
470 VDC (others available)
18 kW max.
24 VDC (to monitor operations)
300 x 100 x 201 mm
6.9 kg
IP 20
300
258
Dimensions and
mounting holes (mm)
Parameter
U[VDC]
Voltage curve of the DC link
without DEV 2.0
with DEV 2.0
21
UZK
58
100
21
Power failure
24
Time
1
2
3
Simple connections I (bottom)
Simple connections II (top)
With only two cables, the DEV is extremely
easy to connect. And it works.
1. Polarity protected interface for the connection
of expansion modules
Terminal 1: negative terminal of the DC link
2. Digital interface to monitor proper operations
Terminal 2: discharge resistor
3. Safety relevant LED: flashes while the storage
unit is charged
Terminal 3: positive terminal of the DC link
The small PTC braking resistor
installed in the DEV is used as
discharge resistor
Applications of the dynamic energy
"insurance" DEV
Tools and parts are protected; valves are closed
in time to prevent damage. Machines are
stopped deliberately; robots are moved to their
home position from where they can start
without further effort.
In brief: The Dynamic Energy Supply DEV
protects against additional expenses that may
result from power failures. It acts like an
insurance policy.
25
Expansion module
EM 2.0
In some circumstances, the storage of the Dynamic Energy Supply DEV does
not have sufficient capacity. This is when expansion modules are being used.
They are simply connected with the DEV by means of the supplied cable with
polarity protected plugs. Nothing else.
Before connecting the unit, the storage is safely discharged via the discharge
resistor installed in the expansion modules. The number of connected
expansion modules, i.e. the amount of stored energy is tailored to match the
requirements of the application.
Storage expansion
for the DEV
Technical specifications
> increasing the stored energy
x-times
> simple connection using a plug
> no configuration or
commissioning required
> discharge resistor on board
Parameter
EM 2.0A20
EM 2.0A2020
Usable storage capacity approx.
Built-in PTC discharge resistor
Dimensions: H x W x D mm
Weight approx.
Protection class
2,000 Ws
+
300 x 100 x 201
4.1 kg
IP 20
4,000 Ws
+
300 x 100 x 201
6.2 kg
IP 20
1
2
Dimensions and
mounting holes (mm)
1
300
258
3
Simple connections I (bottom)
Simple connections II (top)
Ground terminals
1. Polarity protected interface for the connection of
the DEV or additional expansion modules
21
2. Center polarity protected interface:
discharge resistor
58
100
26
21
3. Safety relevant LED: flashes while the
storage unit is charged
Do you have questions about products, technology or applications?
Communication channels
There are many ways to get in contact. Direct personal contact is most easily accomplished by phone and/or e-mail. Here you can obtain all
the support on the interpretation and the application of our products. Numerous sources of information are available on the Internet where
you can gain an overview by yourself. Take advantage of our offer!
Direct contact
Call us, send us an e-mail or a fax. We will
respond immediately.
Tel. +49 7251/962620, mail@brakeenergy.com,
Fax +49 7251/962621
Ulrich Piaszinski
Tel. +49 7251/962612
u.piaszinski@bremsenergie.de
Wolfgang Streckert
Tel. +49 7251/962625
w.streckert@bremsenergie.de
Matthias Goll
Tel. +49 7251/962615
m.goll@bremsenergie.de
Holger Barth
Tel. +49 7251/962634
h.barth@bremsenergie.de
www.brakeenergy.com
Use our website to get an overview of our services by yourself. There you will find all the information about
individual modules, accessories and more than 60,000 data sheets of the available combinations. And if you should
not be able to find a solution for your application, just ask us! We will most certainly find an appropriate response
for your requirements.
www.blog.bremsenergie.de
Would you like to learn more about the DES or the DEV? Or about current developments in our braking resistors?
You might also want to get a different impression of our company. We provide you with the opportunity to learn
more about us. Our blog contains a wide variety of information about our company, our products and all our
activities. Take some time and visit us at www.blog.bremsenergie.de.
www.newsletter.bremsenergie.de
You want to receive all the information about our company free of charge? You wish to be up to date without
having to search? No problem. Our newsletter will always provide you with the latest information, as it were "hot
off the press" and delivered to you digitally. You can register directly at www.newsletter.bremsenergie.de or simply
scan the QR code shown alongside.
Braking energy - App
"Bremsenergie" is the name of the App that is available free of charge in the Apple App Store. This provides the
link between the iPhone and/or iPad and the DES, the Dynamic Energy Storage. The app enables users to calculate
the savings that may be achieved by means of the DES in advance. This assists the user to decide whether the DES
is a solution for his specific application or not. Interested and curious persons can find interpretations regarding
the different technical details about all the relevant aspects of the device.
YouTube
And if you like video clips, then you will find a small collection of videos on our YouTube Channel. Product launches,
celebrations, the Grand Prix of medium-sized enterprises, the final construction phase. Be curious and take a look:
www.youtube.com/user/MichaelKochGmbH.
27
Managing regen energy
Energy storages and braking resistors
in wire-wound and PTC technology
www.
brakeenergy.com
What we offer:
l Tested product quality
– delivered in optimum lot sizes
www.blog.
bremsenergie.de
l Certified processes
– regular third-party certification
l Individual application support
– over 60,000 solutions available thanks to our
modular system
www.newsletter.
bremsenergie.de
l Machine-specific design and construction
– bespoke products for your machines
l Rapid responses
– immediate suitable offers
l Quick delivery times
Appstore
– all components kept in stock
l Reliable partners
– valued long-term business relationships
l Direct customer reliationships
– no distributors
l www.brakeenergy.com
We look forward to hearing from you!
www.brakeenergy.com
KOCH
Michael Koch GmbH, Zum Grenzgraben 28, 76698 Ubstadt-Weiher, Germany
Tel. +49 7251 962620, Fax +49 7251 962621
mail@brakeenergy.com, www.brakeenergy.com
Subject to change without notice. Revised 04-2012.
Qualitätsmanagement
ISO 9001:2008
Regelmäßige freiwillige
Überwachung
D-138-00051