Brake Resistor Design Guide Contents

1 Contents1 How to Read this Design Guide3 How to Read this Design Guide3 Abbreviations42 Safety and Conformity5 Safety Precautions5CE Conformity and Labelling53 Introduction7 Description of the Brake System74 How to Choose a Brake Resistor9 Flat Packs9 Wire Wound95 Brake Resistor Overview11 Wire Wound11 Abbreviations for the Tables11 VLT AutomationDrive 10%11 VLT AutomationDrive 40%16 VLT HVAC Drive 10%21 VLT HVAC Drive 40%24 VLT AQUA Drive 10% Duty Cycle27 VLT AQUA Drive 40% Duty Cycle29 VLT 2800 40% Duty Cycle32 VLT FCD300 40% Duty Cycle32 Flat Packs33 Abbreviations for the Tables33 VLT AutomationDrive33 VLT HVAC Drive35 VLT AQUA Drive366 Application Examples37 Examples37 Example 1 - Conveyor Belt37 Example 2 - Centrifuge38 Continuous Braking397 Calculation of the Brake Resistor41 Brake Setup41 Calculation of Brake Resistor Values41 Calculation of Braking Power43 Brake Resistor Design - VLT is a registered Danfoss trademark1 Calculation of the Brake Resistor Peak Power43 Calculation of the Brake Resistor Average Power44 Braking of Inertia458 Installation47 Brake Cable47 Protective Functions During Installation47 Cable Connection499 Programming51 VLT FC 301/302 AutomationDrive Parameters51 VLT 2800 Parameters52 FCD 300 Parameters5210 Brake Resistor Dimension Data53 Brake Resistor for VLT FC-Series 10% Duty-Cycle, Cablegland, Weight and Draw-ing Resistor for VLT FC-Series 40% Duty-Cycle, Cablegland.

2 Weight and Draw-ing Resistor for VLT 2803-2882 40% Duty-cycle, Cablegland, Weight and Draw-ing Resistor for VLT FCD 303-335 40% Duty-cycle, Cablegland, Weight andDrawing Alternative Braking Methods57DC Injection Braking57AC-braking57 Mechanical Holding Brake57 Optimum Braking5812 Drawings 1-1959 Index68 ContentsBrake Resistor Design - VLT is a registered Danfoss trademark1 How to Read this Design How to Read this Design GuideThis Design Guide will introduce all aspects of Brake Resistors for your VLT FC Series Drive; From choosing the right Brake Resistor for the applicationto instructions about how to install it and how to programme the Frequency Drives technical literature is also available online at +Documenta-tion.

3 SymbolsSymbols used in this manual:NB!Indicates something to be noted by the a general a high-voltage warning. Indicates default setting Brake Resistor Design Guide1 How to Read this Design - VLT is a registered Danfoss trademark3 Abbreviations Alternating currentACAmerican wire gaugeAWGA mpere/AMPAA utomatic Motor AdaptationAMAC urrent limitILIMD egrees Celsius CDirect currentDCDrive DependentD-TYPEE lectro Magnetic CompatibilityEMCE lectronic Thermal RelayETRD riveFCGramgHertzHzKilohertzkHzLocal Control PanelLCPM etermMillihenry InductancemHMilliamperemAMillisecondmsMi nuteminMotion Control ToolMCTN anofaradnFNewton MetersNmNominal motor currentIM,NNominal motor frequencyfM,NNominal motor powerPM,NNominal motor voltageUM.

4 Extra Low VoltagePELVP rinted Circuit BoardPCBR ated Inverter Output CurrentIINVR evolutions Per MinuteRPMR egenerative terminalsRegenSecondsSynchronous Motor SpeednsTorque limitTLIMV oltsVThe maximum output currentIVLT,MAXThe rated output current supplied by the frequency converterIVLT,N1 How to Read this Design GuideBrake Resistor Design - VLT is a registered Danfoss trademark1 2 Safety and Safety PrecautionsEquipment containing electrical components may not be disposed of together with domestic must be separately collected with electrical and electronic waste according to local and currently valid 101/102 Design Guide CE Conformity and LabellingWhat is CE Conformity and Labelling?The purpose of CE labelling is to avoid technical trade obstacles within EFTA and the EU.

5 The EU has introduced the CE label as a simple way of showingwhether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Frequencyconverters are regulated by three EU directives:The low-voltage directive (73/23/EEC)Frequency converters must be CE labelled in accordance with the low-voltage directive of January 1, 1997. The directive applies to all electrical equipmentand appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues adeclaration of conformity upon Resistor Design Guide2 Safety and - VLT is a registered Danfoss trademark5 2 WarningsWhen in use the Brake Resistor surface temperature rises.

6 DO NOT touch the Brake Resistor during work on a Brake Resistor in !Never attempt to repair a defective Brake Safety and ConformityBrake Resistor Design - VLT is a registered Danfoss trademark2 Description of the Brake SystemWhen the speed reference of a frequency converter is reduced, the motor acts as a generator and brakes. When a motor acts as a generator, it suppliesenergy to the frequency converter which is collected in the intermediate circuit. The function of the Brake Resistor is to provide a load on the intermediatecircuit during braking, thereby ensuring that the braking power is absorbed by the Brake a Brake Resistor was not used, the intermediate circuit voltage of the frequency converter would continue to increase, until it cuts out for advantage of using a Brake Resistor is it enables braking of a heavy load quickly, on a conveyor has chosen a solution in which the Brake Resistor does not form an integral part of the frequency offers the user the following advantages.

7 -The Resistor time cycle can be selected as required-The heat developed during braking can be conveyed beyond the panel cabinet to allow the energy to be used-There is no overheating of the electronic components, even if the Brake Resistor is overloadedDanfoss offers a range of Brake resistors for frequency converters, VLT FC-Series, 2800 and FCD Design Guide describes how to choose the right Brake Resistor for an application. Alternative to using a Brake Resistor there are other braking methodswhich can be applied depending on the braking profile of the application. The alternative braking methods can be found in the chapter Alternative Resistor Design Guide3 - VLT is a registered Danfoss trademark7 34 How to Choose a Brake ResistorBrake Resistor Design - VLT is a registered Danfoss trademark4 4 How to Choose a Brake ResistorThe Danfoss Brake Resistor programme consists of two types of resistors, flat packs and wire wound - see pictures : Wire WoundIllustration : Flat Pack Flat PacksThe flat pack Brake resistors (see Illustration ) for the VLT FC series is a safe and compact solution for the customer.

8 At a constant load and freeconvection the Resistor is self protecting as a fuse. This means short circuit proof, no fault to frame, no melting of casing and self extinguishing. Thecasing is made of anodized aluminum and is IP65 the compact flat pack Resistor , it is possible to mount the Resistor on the rear of a VLT FC-series frequency flat pack Resistor portfolio covers the lower power range from - kW (both T2, T4 and T5) - and intended for horizontal applications (conveyors). Wire WoundThe Danfoss wire wound Resistor (see Illustration ) consist of fully welded wire wound ceramic resistors. The base material is a very high temperature(up to 700 C) resistant ceramic, called Corderite. This ensures a Resistor which is suitable for pulse loads between 10 - 20 times or more compared tothe nominal load, which is used in frequent braking applications such as cranes, hoists and simplify the selection of the wire wound Brake Resistor Danfoss has chosen to offer two sizes for each drive across the power range, from kW to355 kW (T5).

9 The overall sizes are based on the duty cycle (10% and 40%) which is the proportion between the process time and the braking time. Thus if a 10%duty cycle Resistor is applied it is able to absorb/ Brake away the peak power for 10% of the period. The remaining 90% of the period will be used todeflect excess heat. Depending on the size the periods for the wire wound resistors are 120, 300 and 600 following chapter lists the 10% and 40% Brake resistors available for the VLT FC-Series the optimum Brake Resistor must be selected it is necessary to know how often and how much the motor is to Brake . How to calculate this and applicationexamples can be found in chapter 6 and enclosures comply with rule of thumb the 10% resistors are used for horizontal loads ( conveyors, gantry cranes) and the 40% for vertical loads ( cranes, hoists andelevators).

10 However to help choose the right sized Brake Resistor for an application the flow chart (illustration ) provides guidance. Answer the questions in thediamond shaped boxes and you are guided to either tables for selection of Brake resistors or chapters about how to calculate inertia or duty Resistor Design Guide4 How to Choose a Brake - VLT is a registered Danfoss trademark9 4 Illustration : Brake Resistor Selection Flow Chart*) 40% (same as **)**) See 10% tables in chapter Brake Resistor Overview.**) See the chapter Calculation of the Brake Resistor .**) Please provide the following info: Nominal power 100% Max. power during Brake cycle Braking time / Duty cycle Supply voltage (max. DC) Resistance ( -value) With or without thermswitch IP enclosure rating4 How to Choose a Brake ResistorBrake Resistor Design - VLT is a registered Danfoss trademark4 5 Brake Resistor Wire Abbreviations for the Tables*) Resulting max.