Post on 05-Apr-2018
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BU-300 UL
AC Drive Braking Unit
GE Industrial SystemsE Industrial Systems
INSTRUCTIONS
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2001 General Electric Company, USA.All rights reserved.
Supersedes GEI-100350A 6/98
These instructions do not purport to cover all details
or variations in equipment, nor to provide every
possible contingency to be met during installation,
operation, and maintenance. If further information is
desired or if particular problems arise that are not
covered sufficiently for the purchasers purpose, the
matter should be referred to GE Industrial Systems,
Salem, Virginia, USA.
This document contains proprietary information of
General Electric Company, USA and is furnished to
its customer solely to assist that customer in theinstallation, testing, operation, and/or maintenance of
the equipment described. This document shall not be
reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written
approval of GE Industrial Systems.
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Table of Contents
Safety Symbol Legend / Lgende des Signes de Scurit ............ 4Chapter 1 - Description ................................................................... 5
Chapter 2 - Main Features ..............................................................6
Chapter 3 - Technical Data .............................................................7
3.1. Weights and Dimensions ............................................................................ 7
3.2. Required Power, Fuses, LED, Terminals and Switches ................................. 9
3.2.1. Required Power .................................................................................... 9
3.2.2. External Fuses ...................................................................................... 93.2.3. Internal Fuses ..................................................................................... 10
3.2.4. LEDs ................................................................................................... 10
3.2.5. Terminal Strips, Power Cables ............................................................ 10
3.2.6. Dip-switch Description ....................................................................... 11
3.3. Inverter Selection and Intervention Thresholds ......................................... 13
3.4. Unit Parallel Connection ............................................................................ 14
3.5. Alarm Intervention .................................................................................... 16
3.6. Dc Link Discharge Function....................................................................... 17Chapter 4 - Dimensioning of the Braking Unit and its
Corresponding Resistor ............................................................18
4.1. Resistor Simplified Sizing ......................................................................... 21
4.2 Simplified Resistor Sizing Based on Stopping Time .................................... 23
Chapter 5 - Minimum Value of the Used Resistors ......................25
Chapter 6 - Standard Braking Resistor .........................................26
Chapter 7 - Block Diagram............................................................30
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Safety Symbol Legend / Lgende des Signes de Scurit
WARNING! Commands attention to an operating procedure, practice, condition, or
statement which, if not strictly observed, could result in personal injury ordeath.
Attire lattention sur les modes dutilisation et les procds et conditions
dexploitation qui, en cas dinobservation, pourraient entraner des blessures
corporelles ou la mort.
CAUTION! Commands attention to an operating procedure, practice, condition, or
statement which, if not strictly observed, could result in damage or
destruction of equipment.
The seriousness of the injuries and of the damages which could be caused
by the non- observance of such indications, depends on the different
conditions. Anyway, the instructions given below should always be fol-
lowed with the highest attention.
Attire lattention sur les modes dutilization et les procds et conditions
dexploitation qui, en cas dinobservation, pourraient entraner la
dtrioration ou la destruction des appareils.
La gravit des blessures et des dommages matriels possibles dpendent de
diffrent facteurs. Toutefois, les instructions mentiones ci-dessous devraient
tre toujours suivies avec la plus grande attention.
NOTE! Commands attention to an operating procedure, practice, condition, or
statement that must be highlighted.
Attire lattention sur les modes dutilization et les procds et conditions
dexploitation qui prsentent un intret particulier.
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5 GEI-100492
Chapter 1 - Description
The BU-300 braking unit consists of a static switch (IGBT) controlled by the voltage in the
inverter intermediate circuit (DC Link).
When a fixed voltage threshold is exceeded, the static switch is closed connecting a resistor
across the DC link dissipating the developed energy. It is possible to obtain faster decelerations
and to avoid the tripping of the inverter overvoltage protection caused by a sudden
increase in the DC Link voltage.
Through a parallel connection of the units via the C and D terminals, and a cascade connection
of the braking command (master/slave function), it is possible to configure 2 parallel braking
units which are simultaneously active.
A protection circuit has been implemented in order to protect the IGBT against possible
short circuits of the braking resistor connections.
Other protections are:- Heatsink thermal protection.
- Power supply voltage control.
The trip can be reset, after the alarm condition has been cleared, via a button on the unit or
via a remote dedicated command.
A command allows a quick discharge of the inverter intermediate circuit.
Such command must be directly interlocked with the contactors supplying energy to
the inverters.
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BU-300 UL 6
Chapter 2 - Main Features
- IP20 protection level
- Max. working rated ambient temperature: 40C (max. 50C with a 20% derating)
- Max. duty cycle: 50%
- Circuit power supply derived from the DC Link
- Possibility to parallel-connect up to 3 units (Master unit included) controlled by a
MASTER unit
- Turn on threshold to be set through the switches
- +24V power supply (green LED)
- BR activity (yellow LED), Braking is active
- AL alarm condition (red LED)
- OK condition (green LED)
- OK relay contact available for the alarm sequences
- Possibility to connect the resistor protection- Possibility to discharge quickly the DC Link.
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7 GEI-100492
Depending of BU and inverter size. Duty cycle max 50%
WARNING! The electronic circuit of the braking unit is directly connected to the DC
Link, whose voltage value can reach 850Vdc.
If the device cover is removed, the live parts can not be touched (IP 20).
3.1. Weights and Dimensions
M6
CRBRPE C D
300mm
(12
.1")
320mm
(12
.6")
72 mm (2.8")
144 mm(5.7")
210mm (8.27")
Chapter 3 - Technical Data
CABLE LENGTH = 2m
Model
6KBU300-20UL
6KBU300-50UL
6KBU300-85UL
Max. dissipated power
@ Duty cycle
50 W
180 W
280 W
Peak current
40 A
100 A
170 A
Average
20 A
50 A
85 A
rms
28 A
70 A
120 A
Current Duty cycle*
50%
50%
50%
Model
6KBU300-20UL
6KBU300-50UL6KBU300-85UL
lbs/Kg
12.1 / 5.5
13.2 / 616.7 / 7.6
* Duty cycle =T
ON+ T
OFF
TON
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BU-300 UL 8
Figure 3.1.1: Front view
CAUTION!
PRECAUTION!
Dc-link twisted wires have a maximumlength of 2 meters.
The dc-link twisted wirers must bedisconnected at the inverter C and Dterminals before removing the coveror performing any maintenance orinspection operation.
Do not perform voltage test at thecontrol card terminals with meggerequipment or higt voltage testers.
Les fils torsades du dc-link ontune longueur maxi de 2 metres.
Les fils torsades du dc-link doivent
tre decorennectes des connections Cet D avant dter le couvercle oud'effectuer toute operation d'entretienet de contrle.
N'effecteur aucun test de tensionaux connections de la carte decontrle avec equipment meggerou des testeurs de haute tension.
BU-300
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9 GEI-100492
Figure 3.1.2: Panel clearances
PE BR CR C D PE BR CR C D
10mm (0.4") 50mm (2) 10mm (0,4") "150mm (6 )
"150mm (6 )
50mm (2")
3.2. Required Power, Fuses, LED, Terminals and Switches
3.2.1. Required Power
The braking unit power supply is derived directly from the DC Link; the maximumconsumption is 15W.
3.2.2. External Fuses
The inverter power supply, which the BU-300 braking unit is connected to, must be
protected via F1 external fuses (see figure. 3.4.1 and 3.4.2).
NOTE!No fuses are needed on the wiring connection between drive and braking
unit.
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BU-300 UL 10
3.2.3. Internal Fuses
NOTE! The F2 fuse resets itself after the short has been removed.
Replacement vendor source: RAYCHEM code: SMD030
3.2.4. LEDs
Denomination
24 V
MASTER
BROK
AL
Colour
green
yellow
yellowgreen
red
Function
It shows the presence of the power supply
The braking unit is set as master
The braking unit is active (braking)OK relay status (closed = OK)
It shows the alarm condition
Denomination
F2
Protection for
+ 24V supply (terminals 1 and 2)
Master output command (terminals 5 and 6)
Fuse
0.3AAutoresettable
3.2.5. Terminal Strips, Power Cables
The power terminal strip consists of the following terminals:
Terminals
C
DCR
BR
PE
Function
Connection to inverter DC link
Connection to inverter DC linkConnection to the braking resistor
Connection to the braking resistor
Ground connection
I/Q
I
IQ
Q
Volt. max.
820Vdc
820Vdc775V dc
775V dc
Curr. max.
I peak
I peakI peak
I peak
Terminals
X2-1
X2-2
X2-3
X2-4
X2-5
X2-6
X2-7
X2-8
X2-9
X2-10
X3-75X3-76
Name
+ 24V
0V 24V
TIM
RESET
MCMD
0V 24V
SIN
SIN
SOUT
SOUT
OKOK
Function
Input power supply (TIM, RESET)
Reference potential for the + 24V power supply
External alarm connection
Remote reset of the alarm condition
Command starting the Slave braking procedure
Reference potential for the signal controlling the start
of the Slave unit
Command starting the Slave unit
Command starting the Slave unit
Cascade connection for the Slave unit
Cascade connection for the Slave unit
Contact without the OK relay potential (closed = OK)Contact without the OK relay potential (closed = OK)
Volt. max.
24V
15...30V15...30V
24V 5%
8...30V
8...30V
8...30V
8...30V
250Vca250Vca
Curr. max.
200mA
3.2...6.4 mA3.2...6.4 mA
30 mA
16 mA
16 mA
16 mA
16 mA
1 A1 A
I/Q
Q
II
Q
I
I
Q
Q
The two pluggable terminal strips, on the regulation card, consist of:
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11 GEI-100492
3.2.6. Dip-switch Description
The following table lists the switches on the regulation card, removing the front cover of the
braking unit.
Cable sizes of the regulation board terminals
WARNING! Remove power, and insure DC link is discharged before opening cover and
changing settings.
Model
6KBU300-20UL
6KBU300-50UL
6KBU300-85UL
Maximum permissible Cable Cross-Section
flexible [mm]
416
416
0.7535
multi-core [mm]
2,525
2,525
0,7550
AWG
124
124
180
Terminals
1 ... 76
Maximum permissible Cable Cross-Section
flexible [mm]
0.35 ... 1.5
multi-core [mm]
0.35 ... 1.5
AWG
22 ... 16
Cable sizes of the power terminals CR,BR
Description
Mains
Voltage
S2
S3
S4
Mains Voltage
[Vac]
230
380
400
415440
460
480
Function
Turn ON [Vdc]
402
646
678
702743
753
775
Turn OFF [Vdc]
392
636
668
692733
743
765
MASTER = Selection of braking unit function as Master (standard)
SLAVE = Selection of braking unit as Slave
Button Reset of alarm condition
Enabling of the function for quick discharge of the DC link
Standard = OFF
Braking threshold
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BU-300 UL 12
Figure 3.2.6.1: Position of switches, LEDs, fuses and terminals on the BUy-C card
Side view
Mains
Voltage
BU-300
FRONT
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3.3. Inverter Selection and Intervention Thresholds
The units are set according to a standard configuration:
- Inverter power supply voltage = 480Vac
- Intervention threshold = 775Vdc
Figure 3.3.1: Switch standard selection
Mains
Voltage
230V380V400V
440V
415V
460V480V
The braking unit intervention threshold must be set according to the value of the inverter
power supply voltage, which the braking unit must be connected to.
NOTE! It is possible to select just one braking threshold
Mains Voltage
230 Vac
380 Vac
400 Vac
415 Vac
440 Vac
460 Vac
480 Vac
Braking threshold[V
BR]
400 Vdc
640 Vdc
680 Vdc
702 Vdc
745 Vdc
753 Vdc
775 Vdc
The 400Vac mains voltage requires the 680Vdc threshold.
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BU-300 UL 14
3.4. Unit Parallel Connection
NOTE! A minimum clearance of 2 inches is required when the braking units are
parallel connected (see figure 3.1.2).
WARNING! A WRONG CONNECTION OF THE POWER SECTION COULD
DESTROY THE UNIT AND/OR THE CONNECTED INVERTERS!
The braking unit is supplied with the power cables connecting the inverter to the C and D
terminals (cable length: 2 meters).
CAUTION! These cables must be used for installation. Do not substitute. If required,
they can only be shortened.
Figure 3.4.1: Parallel connection of several units (Master and Slave) to AV-300i Drive
L1
L2
L3
N
PE
F1
K1M
FILTER
L1
U1 V1 W1
U2 V2 W2
M
3~
E
PE1
PE2 C
C
CR CR
C
D
D
BR BR
D
ENABLE
BU300
MASTER
BU300
SLAVE9 95 7
7
75 75
76 76
10 106 8
8
1 13 3
BRAKING RESISTORS BRAKING RESISTORS
~~
AV-300i DRIVE
THERMAL RELAY
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15 GEI-100492
When a drive provides the trigger command for external braking units, all the BU-300 must
be configured as Slave. The MCMD and 0V24 terminals of the inverter must be connected
to the terminals number 7 and 8 (SIN) of the first BU-300, which, on its turn, is connected
to the following BU-300 via its terminals number 5 and 6 (SOUT), as shown in the
following example.
Figure 3.4.2: Parallel connection of several units (Slave) to the AV-300 Master Drive
L1
L2
L3
N
PE
FILTER
THERMAL RELAY
F1
K1M
L1
U1 V1 W1
U2 V2 W2
M
3~
E
PE1
PE2 C
C
CR CR
C
D
D
BR BR
D
ENABLE
MCMD
*
0V24
BU300
SLAVE
BU300
SLAVE9 57 7
9
75 75
76 76
10 68 8
10
1 13 3
BRAKING RESISTORS BRAKING RESISTORS
~~
AV-300 MASTER DRIVE
* The MCMD terminal is available only on AV-300 Drives equipped with the following
cards:
PSS-AMV32-1 Rev.a or higher (for sizes from 6KAV3003 to 6KAV3011)
P1-AMV32 Rev.d or higher (for sizes from 6KAV3015 to 6KAV3160)
PL-AMV32 Rev. a or higher (for sizes from 6KAV3250 to 6KAV3315)
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BU-300 UL 16
Figure 3.4.2: Auxiliary control circuits
L01
L00
EMERGENCY
-OFF
K0
S11OFF
S12STOP
K2T
K2
K2 K1M
K1M
G1OK
K2T
S2ON/START
K0 K2
80
82
Thermal
relay
Mains contactorT = 1sON/OFFSTART/STOP
EMERGENGY-OFF
3.5. Alarm Intervention
On an internal alarm, the braking unit is immediately disabled, the AL red LED lights up and
the OK relay contact opens (terminals X3-75/ X3-76).
After the alarm condition has been restored, the braking unit can be reset using one of the
following methods:
- via the S3 button- via a remote command on the X2-1 and X2-4 terminals.
- by cycling power on the braking unit.
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3.6. Dc Link Discharge Function
The braking unit can be used to discharge a DC Link with a high capacitive value (for
example in systems where the DC Link is parallel connected).
For this use set the S4 switch in position ON and jumper the X2-9 and X2-10 terminals.
With such a setting, the DC Link discharge can reach a value equal or lower than 60V dc by
taking an external voltage included between 10 and 30V dc to the X2-7 and X2-8 SIN
terminals or using the internal voltage of the X2-1 and X2-2 terminals.
WARNING! In order to avoid damages to the braking resistor, the command
execution is critical. This signal must be supplied to the braking unit
via a contact interlocked with those contactors which power the
inverter.
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BU-300 UL 18
Chapter 4 - Dimensioning of the Braking Unit and its
Corresponding Resistor
Here following are some general information. Chapter 6 lists a series of normalized resistors
to be used with the BU-300 braking units in specifically assumed conditions.
Remember that:
PPBR
[W] Power peak while braking
PNBR
[W] Resistor rated power
EBR
[J] Braking energy
VBR
[V] Braking voltage
IPBR
[A] Peak braking current
IAVBR
[A] Average braking power
IPBU
[A] Braking unit peak current
n1, n
2[RPM] Initial and final speed
tBR
, T [S] Braking time and cycle time
JTOT
[Kg* m2] Total moment of inertia (referred to the motor shaft)
Therefore:
Resistor ohmic value:
f004
R =BR
VBRI
PBR
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Resistor continuous rated power:
P =NBR =P * tPBR BR EBR
2T Tf005
CAUTION! This formula calculates an average power value which could be different
from the instant power in case of very low duty cycles.
The resistors can not usually bear a power peak which is 5 to 10 times
higher than their rated value. As a consequence, if the duty cycles are lower
than 10%, this value can not be used as a resistor rated power. See also the
calculations in chapters 4.1 and 6.
Consult the resistor producer for further details about the overload capacity.
Being n2 = 0 (stop), the formula states that:
E =BR
P * tPBR BR
1
2f006
Braking unit features:I IPBU PBR
f007
The peak current allowed by the BU-300 must be higher or equal to the real one. The
average current is stated through:
I =AVBREBR
t * VBR BRI I AVBU AVBR
f008
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BU-300 UL 20
Dimensioning example
Data:
- Mains voltage 3 x 460 V
- Inverter 6KAV3015
- Motor rated power (PM) 15 HP
- Motor rated speed (nn) 3515 rpm
- Moment of inertia of the motor (JM
) 0.033 kgm2
- Moment of inertia loading the motor shaft (JL) 0.95 kgm2
- Friction of the system (MS) 10% of the rated torque
- Initial braking speed (n1) 3000 rpm
- Final braking speed (n2) 0 rpm
- Braking time (tBR) 10 sec- Cycle time (T) 120 sec
Total moment of inertia:
JTOT
= JM
+ JL
= 0.033 + 0.95 = 0.983 kgm2 e
= [2 * (n1
- n2)] / 60 sec/min = 2 * 3000 / 60 = 314 sec-1
Motor rated torque:
MM
= PM
/n
= (15 * 745.7) / ( 2 * 3515 / 60) = 30.4 Nm
Machine friction: MS
= 0.1 MM
= 3.04 Nm
The braking energy is given by:
EBR
= (JTOT
/ 2) * (2 / 60)2 * (n1
2 -n2
2) = (0.983 / 2) * (0.10472)2 * 30002 = 48509 Joules
or Wsec
Taking into account also the system friction, the braking energy to be dissipated by the
braking unit is lower.
The required braking torque is:
Mb
= (JTOT
* ) / tBR
= 0.983 * 314 / 10 = 30.9 Nm
The braking torque consists of two sections: the machine friction and the torque to be
supplied by the motor electric braking:
MbM
= Mb
- MS
= 30.9 - 3.04 = 27.86 Nm
The average power of the braking process is given by:
PAVE = (MbM * ) / 2 = 27.86 * 314 * 0.5 = 4374 W
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The new value of the braking energy is therefore:
New EBR
= PAVE
* tBR
= 4374 * 10 = 43740 Joules or Ws
it is obviously lower than the previous one.
The peak braking power is given by
PPBR = (JTOT * n1 * * 2) / (tBR * 60) = 9.7 kW therefore
IPBR
= PPBR
/ VBR
= 9700 / 745 = 13A and
RBR
VBR
/ IPBR
= 745 / 13 = 57
Being IPBR
= 13A, the 6KBU300-20UL unit meets the requirements.
Resistor choice
The resistor rated power must be:P
NBR= (P
PBR* t
BR) / 2T = (9700 * 10) / 240 = 404 W
The resistor rated power is low because of the low duty cycle (10 / 20) but the resistor must
be in a position to bear the energy applied during the 10-second braking process. This
energy corresponds to 43740 Joules. In the table of the standard braking resistors (chapter
6) it is possible to notice how the model BRR 1K0T 49R has a sufficient rated power value
and a too low EBR
value (21kWsec).
As a consequence the chosen model is BRR 1K3T 31R whose EBR
value is 44kWsec.
4.1. Resistor Simplified Sizing
In case all the above mentioned data are not available, it is possible to carry out a simplified
and rough calculation of the braking resistance.
The following formulas can be used for the calculation of the different braking values:
Having to calculate the resistor value for an inverter (100A braking peak current) which is
power supplied at 400Vac, (braking threshold), we have that:
R =BR = 6.8 Ohm680
100
f012
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BU-300 UL 22
This formula states just the ohmic value; the following considerations, on the contrary, refer
to the resistor power:
The braking resistor is normally used with an intermittent cycle; it is therefore normal to
use a resistor power lower than the one obtained through RBR
* IPBR
2.
The following diagram can be used to define the overload factor (similar diagrams can be
supplied by the producer of the used resistor).
1000
100
10
1
0,1
1 3 4 5 6 7 8 9 10
RESISTANCEPOWER
2
OVERLOAD FACTOR
OVERLOADTIME
(secon
ds
-lo
g.S
cale
)
Pause time
15 seconds
30 seconds
1 minute
5 minutes
30 minutes
Using this diagram to calculate the value of the continuous (rated) power of the braking
resistor, it is possible to apply the following formula:
continuative power R =BRregenerated power
overload factorf013
Having to brake a 30-kW motor with a 150% overload, the maximum regenerated power is45 kW.
Assuming that the braking time is 5 seconds (resistor overload time) and the break time is
1 minute, the diagram supplies an overload factor of 3.9. The resistor rated power is
therefore:
= 11.5 kW45000
3.9f014
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rmp
time
Machine Inertia(Gear Ratio)2
Reflected Machine Inertia =
= System Energy [kW sec][Total System Inertia] [Top rpm2]
4300000
(System Energy) kW sec
(Stop time) sec= Average Stopping Power [kW]
4.2 Simplified Resistor Sizing Based on Stopping Time
1) Add Motor Inertia + Gearbox Inertia + Reflected Machine Inertia = Total System
inertia [ft lb2]
2) Calculate system energy running at top speed.
3) Calculate average [kW] needed to absorb to stop, neglecting
friction and efficiencies.
4) Calculate the resistor Ohms needed to dissipate the average stopping power [kW].
(DC Bus Volts)2
(Ave Stopping kW * 1000 * 2)=
For AV-300i as master, at
460 VAC, DC bus volts =
780.
This is the largest ohm value that can be used to stop the drive in time. Smaller Ohm
values can be used.
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BU-300 UL 24
(DC Bus Volts)2
Current Limit kW * 1000=
DC Bus Volts
Current Limit OhmsInstantaneous Current =
DC Link Volts
DB Resistance Ohms= Peak Current [Amps]
Average Stopping kW
Resistor Ohm= Short Time Current [Amps]
5) Calculate the resistor ohms needed for the motor to reach current limit anytime during
the stop.
Motor HP * .746 = Motor kW
Current Limit kW = Motor kW * 1.5 (150% overload)
6) Select a resistor value desired in the range between the answers found in steps 4) and
5).
Seleting closer to the value in step 5) may cause your resistor to be higher power rating
to support the:
selecting closer to the value found in step d) doesnt leave room for field adjustement
of faster stop times later.
7) Use the final resistance value, determined in step f), to check the resistor peak current
and BU peak current needed.
this determines quantity of braking units needed, and which type of BU based on the
peak amps needed.
8) For an occasional stop, for example, once every 10 minutes, or stop then cool to
ambient, then the resistor can be selected on its short time rating, for example a 15 sec
rating or 30 sec rating average stopping kW if the resistor rating is in kW.
or:
The resistor power rating must meet both instantaneous and short time ratings.
For overhauling loads, or more frequent stopping cycles, use the previous detailedcalculations.
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Model
6KBU300-20UL6KBU300-50UL
6KBU300-85UL
Mains voltage and resistor minimum value
230V
10 ohm4 ohm
2.4 ohm
380V
16 ohm6.4 ohm
3.7 ohm
400V
17 ohm6.8 ohm
4 ohm
415V
17 ohm6.8 ohm
4 ohm
440V
18.6 ohm7.5 ohm
4.4 ohm
460V
18.6 ohm7.5 ohm
4.4 ohm
480V
19.37 ohm7.75 ohm
4.55 ohm
Chapter 5 - Minimum Value of the Used Resistors
The ohmic value listed in the table is the resistor absolute minimum value to be connected
to the different braking units according to the set braking threshold. In case this value is not
available, the following higher ohmic value has to be used. For example, with the 6KBU300-
20UL braking unit, whose intervention threshold is 680V, the stated resistor value is 17,
but the following commercial ohmic value to be used is 18.
This indication allows a better use of the braking resistors when several parallel-connected
resistors are present; in this case see the ohmic values listed in the table.
CAUTION! The units are protected against any direct short circuit between the
terminals CR and BR
8/2/2019 Freno BU300
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BU-300UL
26
AV-300i HP max.HP 10% DB BU-300 equivalent IPC DB pkg available %
model # (with OL) duty KW type DB resistor bank watts duty with av6KAVi43... output resistor model # this R & s
ohms DB combo fr
rpmF75 0,75 0,05595 internal 200 6KE$34DBR001 200 35,7
1 1 0,0746 internal 200 6KE$34DBR001 200 26,8
2 2 0,1492 internal 200 6KE$34DBR001 200 13,4
3 3 0,2238 internal 160 6KE$34DBR003 400 17,9
5 5 0,373 internal 100qty 2
6KE$34DBR0012 resistors in series 400 10,7
7 7,5 0,5595 internal 80 6KE$34DBR007 900 16,1
10* 10 0,746 BU-300-20 40 6KE$34DBR015 1400 18,8
10* 10 0,746 internal* 80 6KE$34DBR007*allows 100% CL +
losses~(110%)900 12,1
15 15 1,119 internal 40 6KE$34DBR015 1400 12,520 20 1,492 internal 27 6KE$34DBR025 1800 12,1
25 25 1,865 internal 22 6KE$34DBR030 1800 9,7
30 30 2,238 internal 15 6KE$34DBR040 3600 16,1
40 40 2,984 internal 12 6KE$34DBR050 4800 16,1
50 50 3,73 internal 10 6KE$34DBR060 6000 16,1
60 60 4,476 internal 7,5 6KE$34DBR075 7200 16,1
75 75 5,595 BU-300-85 6qty 2
6KE$34DBR050
2 resistors in
parallel9600 17,2
100 100 7,46 BU-300-85 5qty 2
6KE$34DBR060
2 resistors in
parallel12000 16,1
125 125 9,325qty 2 , BU-
300-50
3,35qty 2
6KE$34DBR075
1 resistor/BU, 2
BUs in //
14400 15,4
150 150 11,19qty 2 , BU-
300-853,35
qty 2
6KE$34DBR075
1 resistor/BU, 2
BUs in //14400 12,9
200 200 14,92qty 2 , BU-
300-852,5
qty 2
6KE$34DBR060
1 resistor/BU, 2
BUs in //24000 16,1
DB ckt
configuration
8/2/2019 Freno BU300
27/32
27
GEI-100492
AV-300i HP max.HP 20% DB BU-300 equivalent IPC DB pkg available
model # (with OL) duty KW type DB resistor bank watts duty wit
6KAVi43... output resistor model # this R &
ohms DB com
F75 0,75 0.1119 internal 200 6KE$34DBR001 200 35.7
1 1 0.1492 internal 200 6KE$34DBR001 200 26.82 2 0.2984 internal 160 6KE$34DBR003 400 26.8
3 3 0.4476 internal 160qty 2
6KE$34DBR0072 resistors in
series1600 71.5
5 5 0.746 internal 120qty 2
6KE$34DBR0102 resistors in
series1800 48.3
7 7,5 1.119 internal 80qty 2
6KE$34DBR0152 resistors in
series2800 50.0
10* 10 1.492 BU-300-20 27 6KE$34DBR015 1800 24.1
10* 10 1.492 internal 80
qty 2
6KE$34DBR015
allows 100%
CL+ 2800 37.515 15 2.238 BU-300-50 15 6KE$34DBR040 3600 32.2
20 20 2.984 internal 30 6KE$34DBR0402 resistors in
series7200 48.3
25 25 3.73 internal 15 6KE$34DBR030 3600 19.330 30 4.476 internal 10 6KE$34DBR060 6000 26.8
40 40 5.968 internal 10 6KE$34DBR060 6000 20.150 50 7.46 internal 7.5 6KE$34DBR075 7200 19.3
60 60 8.952 internal 6 6KE$34DBR050 2 resistors in // 9600 21.4
75 75 11.19BU-300-
855
qty 2
6KE$34DBR060
2 resistors in
parallel12000 21.4
100 100 14.92 BU-300-85 5 qty 46KE$34DBR060 2 resistors inseries, in parallel 24000 32.2
125 125 18.65qty 3 , BU-
300-503.75
qty 46KE$34DBR040
2 // resistor/BU,2 BUs in //
21600 23.2
150 150 22.38qty 3 , BU-
300-852.5
qty 36KE$34DBR075
1 resistor/BU, 3BUs in //
24000 21.4
200 200 29.84qty 3 , BU-
300-851.67
qty 66KE$34DBR060
2// resistor/BU, 3BUs in //
36000 24.1
DB ckt
configuration
8/2/2019 Freno BU300
28/32
BU-300UL
28
AV-300i HP max.HP 50% DB BU-300 equivalent IPC DB pkg availa
model # (with OL) duty KW type DB resistor bank watts duty
6KAVi43... output resistor model # this
ohms DB co
F75 0,75 0.27975 internal 160 6KE$34DBR003 400 71
1 1 0.373 internal 160 6KE$34DBR003 400 53
2 2 0.746 internal 260 qty 2, 6KE$34DBR005 2 resistors in series 800 53
3 3 1.119 internal 160 qty 2, 6KE$34DBR007 2 resistors in series 1600 71
5 5 1.865 internal 120 qty 2, 6KE$34DBR010 2 resistors in series 1800 48
7 7,5 2.7975 internal 80 qty 2, 6KE$34DBR008 2 resistors in series 2800 50
10 10 3.73 BU-300-50 12 6KE$34DBR050 4800 64
15 15 5.595 BU-300-50 10 6KE$34DBR060 6000 53
20 20 7.46 internal 30 6KE$34DBR040 2 resistors in series 7200 48
25 25 9.325 BU-300-85 6 qty 2, 6KE$34DBR050 2 resistors in // 9600 51
30 30 11.19 BU-300-85 5 qty 2, 6KE$34DBR060 2 resistors in // 12000 53
40 40 14.92 qty 2 BU-300-85 3 qty 4, 6KE$34DBR0502 // resistor/BU, 2
BUs in //19200 64
50 50 18.65 qty 2 BU-300-85 3 qty 4, 6KE$34DBR0502 // resistor/BU, 2
BUs in //19200 51
60 60 22.38 qty 2 BU-300-85 1,875 qty 4, 6KE$34DBR0752 // resistor/BU, 2
BUs in //24000 53
75 75 27.975 qty 2 BU-300-85 2,5 qty 4, 6KE$34DBR0502 // resistor/BU, 2
BUs in //28800 51
100 100 37.3 qty 3, BU-300-85 1,67 qty 6 ,6KE$34DBR0602 // resistor/BU, 3
BUs in //36000 48
125 125 46.625 qty 4 , BU-300-85 1,25 qty 8 ,6KE$34DBR0602 // resistor/BU, 4
BUs in //48000 51
150 150 55.95 qty 4 , BU-300-85 1,25 qty 8 ,6KE$34DBR0602 // resistor/BU, 4
BUs in //48000 42
200 200 74.6 qty 4 , BU-300-85 1,25 qty 8 ,6KE$34DBR0602 // resistor/BU, 4
BUs in //48000 32
DB ckt
configuration
8/2/2019 Freno BU300
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29 GEI-100492
Resistor sizing notes:
1) A power resistor is restricted in maximum amps, usually 5 or 10 times it's continuous
rating. This limitation may increase the power rating even though the RMS power
may be relatively low. Consult with the particular resistor vendor for the actual
maximum restrictions if different than above.
2) Per IPC, resistor banks are rated for 5 times continuous rating for 10 seconds, with a
off time of "cool to ambient".
3) "ave watts stopping from 1800 rpm in 5 seconds" can be used to estimate stopping
requirements. This number is proportional to the square of the rpm.Time is inversely
proportional.
4) DB 10 second, one time capability shows how much load inertia can be stopped in fast
stop conditions once then cool to ambient, for the % duty.
8/2/2019 Freno BU300
30/32
BU-300 UL 30
Only
for:6KBU300-20UL-50UL
Only
for:6KBU300-85UL
C-B
OT
C-BU-y
Gate
Em
itter
FAULT
Vth
VH
T
Reset
XY6
Von
Vout
Break
Fault
Nr:
ESE
_3210
Date
12/02/01
Ma
ins
Vo
ltage
X3
-7
5
X3-7
6
X3-4
X3-
1
X3-6
X3-7
X3-8
X3-9
X3
-10X3-5
RESET
RESET
+24VF
+24V
+24V
0V24V
OK
K1
S3
F2
BR
+24VF
AL
+10V
230V
380V
400V
415V
440V
460V
480V
+15V
+15V
0V
0V
-15V
-15V
+24V
0V24
MASTER
S4
=OFF
S3
=SLAVE
SALVE
S4
=ON
S3
=MASTER
S4
S2
MASTER
MAST
ER
SLAVE
SMPS
-ON
OK
M S
BUy-C
ESE3036
S R
+24F
X2
-1
X2
-3
XT1
XT2
C X1
-1
X1
-2
XV1
XV2
+24V
D
2
1
3
SN
-BUy
ESE3139/1
ESE3139/2
RES
-SN
D PECBRCR
R-B
rea
kINVERTER
C D
MASTER/SLAVE
Chapter 7 - Block Diagram
8/2/2019 Freno BU300
31/32
31 GEI-100492
8/2/2019 Freno BU300
32/32
1S9G70