AK DBU - Dynamic Braking Unit 600/690 VAC · 2014. 4. 14. · Figure P.1 shows the block diagram of the DBU with the Dynamic Brake Resistor. The DBU is shown connected to the positive

AK DBU -Dynamic Braking Unit600/690 VAC

User Manual

Important User InformationSolid 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: Identifies information that is critical for successful application and understanding of the product.

PowerFlex is a registered trademark of Rockwell Automation.

!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.

!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.

Table of Contents

Preface OverviewWho Should Use this Manual?. . . . . . . . . . . . . . . . . . . . . . . . P-1Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2Catalog Number Explanation. . . . . . . . . . . . . . . . . . . . . . . . . P-3Description and Block Diagram. . . . . . . . . . . . . . . . . . . . . . . P-4Line Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-7Permissible Loading of the DBU . . . . . . . . . . . . . . . . . . . . . . P-8

Chapter 1 Installation/WiringMinimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . 1-1Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Protection of Brake Resistors and Conductors . . . . . . . . . . . 1-3Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8CE Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Chapter 2 Start Up / TroubleshootingStart-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2DC Power on LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Appendix A SpecificationsDBU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3Diagnostic Card BUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4Resistor Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4Fuse Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Appendix B CE ConformityGeneral Installation & Wiring Guidelines for CE Conform. . B-1Essential Requirements for CE Compliance . . . . . . . . . . . . . B-2Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Wiring Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Appendix C Design InformationDetermining Dynamic Brake Requirements . . . . . . . . . . . . . C-1Determine Values of Equation Variables . . . . . . . . . . . . . . . . C-4Selecting the Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . C-7Example 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.

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.

The following manuals are recommended for general drive information:

For detailed PowerFlex Inverter information including specifications:

For information on…See page For information on…

See page

Who Should Use this Manual? P-1 Catalog Number Explanation P-3Reference Materials P-1 Description and Block Diagram P-4Manual Conventions P-2 Line Voltage Selection P-7General Precautions P-2 Permissible Loading of the DBU P-8

Who Should Use this Manual?

Reference Materials

Title Publication Available Online at …Wiring and Grounding Guide for PWM AC Drives

DRIVES-IN001A-EN-Pwww.ab.com/manuals/dr

Preventive Maintenance of Industrial Control and Drive System Equipment

DRIVES-SB001A-EN-E

Reactors and Isol. Transformers 1321-TD001D-EN-PGuarding Against Electrostatic Damage

8000-4.5.2www.ab.com/manuals/gi

Safety Guidelines for the Appli- cation, Installation and Mainte- nance of Solid State Control

SGI-1.1

A Global Reference Guide for Reading Schematic Diagrams

0100-2.10 Not available online, contact your local RA Sales Office

Title Publication Available . . .PowerFlex Reference Manual

PFLEX-RM001D-EN-E on the CD supplied with the drive or at www.ab.com/manuals/dr

Common Bus Application Guide

TBD TBD

P-2 Overview

• 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:

Manual Conventions

Word MeaningCan Possible, able to do somethingCannot Not possible, not able to do somethingMay Permitted, allowedMust Unavoidable, you must do thisShall Required and necessaryShould RecommendedShould Not 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

The catalog numbering scheme for the AK Dynamic Braking Unit is shown below.

Catalog Number Explanation

AK DBU F 300 N EProduct Voltage Rating Rating Enclosure Documentation

ProductName Cat.CodeAK Dynamic Braking Unit AK DBU

Version & Voltage Rating

Input VoltageFull On Voltage

Cat. Code

600/690 VAC 950/1090 VDC F

Rating - Output Peak Current Amps Voltage Cat. Code300.0 600/690 VAC 300

Enclosure Type & Conformal CoatingRating Conf. Coating Cat. CodeOpen / IP00 No N

Documents & Shipping CartonDocument(s) Ship. Carton Cat. CodeEnglish U. M. Yes E

P-4 Overview

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.

Description and Block Diagram

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 nega-tive (DC-) terminals of an AC PWM Drive.

Figure P.1 Block diagram of Inverter with Dynamic Braking Unit

DC-

DC+ BR1

PEDBU

DC Power on Brake on

10

11

0

115

M

TransistorControlBUC RC

Snubber

PE

BUB

DC+

DC-

BR2

>°C

>°C

Inverter

F2

to customer's supplied 115 VACpower source

to inverter's main contactorcircuit

to inverter's maincontactor circuit

to customer grounding schemeor earth ground

R

FieldinstalledFuses F1

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

-

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

Figure P.3 Pulse Width (Jumper Setting) in Relation to DC Bus Voltage

The default jumper voltage selection shipped from the factory is 690V AC line voltage.

Line Voltage Selection

600V

Jumper plug on rear side,shown in position for 600V AC line

BUC-Card

690V

100% 95%

0% VDC

Jumper at 600: 913V 950V 690: 1047V 1090V

!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

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

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)

Current-time area: (300 * 5) / 2 = 750 Amp-Min.

Current-time area: (300 * 1) + (112.5 * 4) = 750 Amp-Min.

5 10

IPeak

minutest

300A

0 4

10

IPeak

112.5A

tminutes1

300A

0

Chapter 1

Installation/Wiring

This chapter provides the information needed for the installation and wiring of the Allen-Bradley Dynamic Braking Module.

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.

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.

For information on…Seepage For information on…

Seepage

Minimum Mounting Clearances 1-1 Power Wiring 1-4Grounding Requirements 1-2 Control Wiring 1-8Fuses 1-3 CE Conformity 1-9Protection of Brake Resistors and Conductors 1-3

!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

1-2 Installation/Wiring

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

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.

Grounding Requirements

+DC

PE PE

+DC

- DC - DC

R (L1)S (L2)T (L3)

Drive

Ground Grid, Girder or GroundRod (Building Ground Potential)

DBU

Installation/Wiring 1-3

National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.

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.

Fuses

!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


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.

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.

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.

!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.


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

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

AC-Drive

10 11

DB-ResistorAssembly

DBU

F2

R

DC- DC-

F1

Cable lengthmax.3m

DC+ DC+

Cable lengthmax.30m

BR1

BR2Field

InstalledFuses


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.


Power and Control Terminals

Figure 1.3 Location of Power Connections and Control Terminals for Customer Wiring (Front View Shown)

Table 1.A Power Terminals

Table 1.B Power Terminal Specifications

No. Description NotesBR1 DC Brake (+) Brake Resistor Connection (+)BR2 DC Brake (-) Brake Resistor Connection (-)DC+ DC Bus (+) DC Bus Connection (+)DC- DC Bus (-) DC Bus Connection (+)PE Protective Earth

10/11 Thermostat N.C. contact For control terminals see Figure 1.4

No. DescriptionWire Size Range (1)

(1) Max./Min. sizes the terminals will accept - these are not recommendations.

TorqueMaximum Minimum Maximum Recommend

Power ConnectionsBus Bars with Bolts M10

95 mm2

(4/0 AWG)10 N-m(89 lb.-in)

10 N-m(89 lb.-in)

PE Bolt M10

50 mm2

(6 AWG)50 mm2

(AWG)10 N-m(89 lb.-in)

10 N-m(89 lb.-in)

Thermostat N.C. contact and Fan Supply Terminal

For control terminal specifications see Table 1.C

PE

BR2 DC- DC+ BR1


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

Table 1.C Input Control Terminal Specifications

Drive(s) Run Interlock

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.

Control Wiring

No. Connection

Wire Size Range (1)

(1) Max./Min. sizes the terminals will accept - these are not recommendations.

TorqueMaximum Minimum

0, 115 Fan Supply, 115V AC 4 mm2

(11 AWG)0.5 mm2

(22 AWG)0.8 Nm(7 lb.-in.)10, 11 Thermostat NC Output Contact,

Opens at power stack over temperature

Thermostat N.C. output contact

Fan Supply Input Terminals

11101150

!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.


Figure 1.5 Control Wiring of Drive(s) Main Contactor Interlock

For Mounting and Wiring Instructions concerning CE Conformity refer to Appendix B.

AC-Drive

10 11

Brake ResistorAssembly

DBUTree-PhaseAC Input

>°C >°C

F1

F2

F3 F4

R

10 11

ResistorThermostat

TemperatureSensor

PowerSource

Power off

K1M

K1M

Power on

R (L1)S (L2)T (L3)

K1M

CE Conformity


Chapter 2

Start Up / Troubleshooting

This chapter provides the necessary information for the start up and troubleshooting of the DBU.

For information on . . . See page . . .Start-Up 2-2DC Power ON LED 2-3Troubleshooting 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

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

Start Up / Troubleshooting 2-3

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.

Figure 2.1 DC Power on and Brake on Indicating LEDs

DC Power ON LED

!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!

Brake OnDC Power On

2-4 Start Up / Troubleshooting

Table 2.A Possible Faults and Corrective Actions

Troubleshooting

Fault Cause Corrective ActionHeat sink Over Temperature

Heat sink temperature exceeds maximum rating.

1. Verify the maximum ambient temperature has not been exceeded.

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.DC Output Voltage Loss

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.


Seepage

DBU A-1 Brake Resistor Specifications A-4Dimensions A-3 Fuse Ratings A-4Diagnostic Card BUB A-4

DBU

SpecificationsPower RatingsInput Voltage 600V 690VPeak Braking Power 268 kW 305 kW

Minimum Brake Resistor Value permitted for Peak Braking Power

3.2 ohm 3.7 ohm

Max. Peak Braking Current with 150sec ON time at up to 25% duty cycle

300 Amp

Maximum Mean RMS Braking Current 150 Amp

Heat Dissipation (Average) at 25% duty cycle 170 W

Power consumption of the control circuits 27mA

Maximum DC bus Voltage at terminals DC+,DC-

DC 1150V

Pulse width modulation PWM, switching frequency

0.67 kHz

Capacitance of the built-in snubber 4µFControl Output SpecificationsHeat sink temperature sensor The temperature sensor trips if heat sink

temperature exceeds maximum temperature.

NC contact output rating (max.) 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

Approvals and Standards ComplianceThe DBU is designed to meet the following specifications:NFPA 70 - US National Electrical CodeNEMA 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 DirectivesEMC 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 SpecificationsAltitude: 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 / IP00Ambient Operating Temperature without derating:

0 to 40°C (32 to 104°F)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-condensingShock: 15G peak for 11ms duration (±1.0 ms)Vibration: 0.152 mm (0.006 in.) displacement,

1G peak

Specifications

C

Specifications A-3

Figure A.3 Dimensions and Location of Bus-Bar Customer Connection Points

Front view Side view

Dimensions are in millimeters and (inches)

Weight: 10 kg (22 lb.)

Required cooling air: 158 m3/h

Dimensions

80(3.15)

8 (0.3)

350(13.8)

157(6.18)

PE

215 (8.46)

225 (8.86)

5(0.2)

32 (1.3)

42 36 36 36 25 50 89(3.5)

356(14.0)

2)

310(12.2)

BR2 DC- DC+ BR1

(1.65) (1.42) (1.42) (1.42) (1.0) (2.0)

ø6.5(0.26)

5(0.2)

5(0.2)

Min.100(4.0)

Air Flow

Min.100(4.0)

A-4 Specifications

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

The time constant (t) of the brake resistor: t = L/R, must be <40 µs

L: Effective inductance of the brake resistor and cableR: 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..

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

Notes:(1) Minimum protection device size is the lowest rated device that supplies maximum

protection without nuisance tripping.

Diagnostic Card BUB

Function LED Status Condition

DC Power ON ON when DC bus voltage exceeds 50V

Brake ON ON when braking current flows

Brake Resistor Specifications

Fuse Ratings

AC Line DBU Rating Fuse Fuse HolderVolt kW Amps Amps Volt Type Type Manufacturer600 268 300 300 700-800 FWJ-300 BH-3 Bussmann

A100P300-4TI P266L Ferraz690 305 300 315 1000 G300547 SI DIN 110 630 Ferraz

Appendix B

CE Conformity

This appendix provides the installation and wiring instructions necessary for the CE-conformity of the Dynamic Braking Unit.

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.

• 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


Seepage

General Installation and Wiring Guidelines for CE Conformity

B-1 Mounting Instructions B-3Wiring Instructions B-4

Essential Requirements for CE Compliance B-2 Configuration Examples B-6

General Installation and Wiring Guidelines for CE Conformity

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.

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.

Essential Requirements for CE Compliance

CE Conformity B-3

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.

Mounting Instructions

B-4 CE Conformity

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.

Wiring Instructions

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

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.

Stranded copper wire

Plastic insulation

Inner plastic sheath

Compact screen of galvanized (tinned) copper or steel braid

Outer plastic jacket

B-6 CE Conformity

Figure B.2 Cabinet Mounted Drive and Related Components

Configuration Examples

U,V,W

M

PE

PE

2

1

5

3

4

RDBU

U, V, W(T1,T2,T3)

R, S, T(L1,L2,L3)

DC+, DC-

External line reactor(if used)

Input contactor

Input fuses

Terminals for 4-wireline input cable

Cabinet protective ground bus bar

Cabinet

Panel

Brake resistor

Inverter

RFI Filter(if used)

Cable bracket

Shield

Shielded 4-wire motor cable

Shielded signal conductor cable(feedback, reference)

EMC type armoured cable gland at terminal box

1

2

3

4

5Speed FeedbackDevice

CE Conformity B-7

Figure B.3 Stand Alone Drive and Related Components

U,V,W

M

PE

34

Stand AloneRFI Filter(if used)

1

6

R

DBU

BR1BR2

PE

6 6

DC+DC-

4-wire line input cable

Shielded 4-wire motor cable

Shielded control or signal conductor cable

EMC type armoured cable gland at all enclosure entries and motor

Shielded cable with PE conductor

1

3

4

5

6

U, V, W(T1,T2,T3)

R, S, T(L1,L2,L3)

DC+DC-

ResistorEnclosure

DBU Enclosure

INVERTER

11

Inverter Enclosure

>°C>°C

10to

K1Mcontrolcircuit

K1M

B-8 CE Conformity

Notes:

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.

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 thermo-dynamic 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.

For information on… See pageDetermining Dynamic Brake Requirements C-1Determine Values of Equation Variables C-4Selecting the Resistor C-7Example Calculation C-10

Determining Dynamic Brake Requirements

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) = Motor shaft speed in radians per second (rps)

N = Motor shaft speed in Revolutions Per Minute (RPM)

T(t) = Motor shaft torque in Newton-meters1.0 lb.-ft. = 1.356 N-m

P(t) = Motor shaft power in watts 1.0 HP = 746 watts

ωb = Rated angular rotational speed

ωo = Angular rotational speed less than ωb (can equal 0)

-Pb = Motor shaft peak regenerative power in watts

ω 2πN60

----------=

Rads

---------

Rads

---------

Design Information C-3

Figure C.1 Application Speed, Torque and Power Profiles

0 t1 t2 t3 t4 t1 + t4 t

0 t1 t2 t3 t4 t1 + t4 t

0 t1 t2 t3 t4 t1 + t4 t

ω(t)

T(t)

P(t)

-Pb

ωo

ωb

Speed

Torque

Power


Step 1 Total Inertia

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)

If the gear ratio is 2:1 then

JL = Load inertia (kg-m2 or WK2 in lb.-ft.2)1.0 lb.-ft.2 = 0.042 kg-m2

Calculate Total Inertia:

Record Total Inertia:

Determine Values of Equation Variables

JT =

JT Jm GR2 JL×( )+=

GR Load SpeedMotor Speed-----------------------------=

GR 12-- 0.5= =

JT oooooooooo[ ] oooooooooo oooooooooo×( )+=


Step 2 Peak Braking Power

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


ωo = Angular rotational speed,less than rated speed down to zero

Nb = Maximum application motor speed (RPM)

t3 – t2 = Deceleration time from ωb to ωo (seconds)

Calculate Peak Braking Power:

Record the Peak Braking Power:

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

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.

Pb =

Line Voltage Vd R Pmax600 VAC 950 VDC 3.2 Ohms 268 kW690 VAC 1090 VDC 3.7 Ohms 305 kW

PbJT ωb ωb ωo–( )[ ]

t3 t2–( )----------------------------------------=

Rads

---------2πNb

60------------=

Rads

---------

Pbooooo[ ] oooooo[ ] ooooo ooooo–( )××

ooooooooo ooooooooo–( )------------------------------------------------------------------------------------------------=


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:

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)


ωo = Angular rotational speed,less than rated speed down to zero

The Average Power in watts regenerated over the period t4 is:

Calculate Average Power in watts regenerated over the period t4:

Record Average Power in watts regenerated over the period t4:

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.

Pav =

Pb

2-----

ωb ωo+( )ωb

------------------------×

Rads

---------

Rads

---------

Pav

t3 t2–( )t4

------------------Pb

2-----

ωb ωo+( )ωb

------------------------=

Pavoooooo oooooo–( )

oooooo[ ]----------------------------------------------- oooooo[ ]

2-----------------------× oooooo oooooo+( )

oooooo[ ]-----------------------------------------------×=


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

Step 4 Calculate the Maximum Dynamic Brake Resistance ValueThe maximum allowable Dynamic Brake resistance value (Rdb1) must be calculated.

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)

Selecting the Resistor

!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.

Rdb1

0.95 Vd( )× 2

Pb----------------------------

Pmax R×Pb

---------------------==


Calculate Maximum Dynamic Brake Resistance:

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):

Drive Efficiency = 0.975

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.

Line Voltage Vd Pmax R Pmax x R Rdb1600V AC 950V DC 268,000 W 3.2 Ohms 857375 Ohm690V AC 1090V DC 305,000 W 3.7 Ohms 1128695 Ohm

Rdb1oooooooo·[ ]

ooooooooo[ ]--------------------------------=

Pb

2-----⎝ ⎠⎛ ⎞ t3 t2–( )× watt-seconds=

Watt-second lossesPb

2------x t3 t2–( ) x 1 motor efficiencyxdrive efficiency( )–[ ]=

Total watt-seconds watt-seconds watt-second losses–=


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.

!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.


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.

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.

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

(GR)2 = 0

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.

Example Calculation

Rated Power 250 HP= 746 watts 186500 W=×

Rated Speed ωb 1600= RPM 2π= =160060

----------× 167.5 Rads

-----------------------=

Lower Speed ωo 0= RPM 2π 060-----× 0 Rad

s-------------= = =

JT Jm GR2 JL×( )+=

JT 166= . 44+ 210 lb.-ft.2 210 0.042 8.82 kg-m2=×==


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)

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

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.

Deceleration Time t3 t2–( ) 2 seconds= =

Cycle Period t4 40 seconds= =

Peak Braking Power PbJT ωb ωb ωo–( )[ ]

t3 t2–( )----------------------------------------= =

Pb8.82 167.5 167.5 0–( )[ ]

2----------------------------------------------------- 123700 watts= =

Average Braking Power Pav

t3 t2–( )t4

------------------Pb

2-----

ωb ωo+( )ωb

------------------------= =

Pav240-----⎝ ⎠⎛ ⎞ 123700

2----------------⎝ ⎠⎛ ⎞ 167.5 0+

167.5---------------------⎝ ⎠⎛ ⎞ 4120 watts= =


Step 4 Calculate the Maximum Dynamic Brake Resistance

Rdb1 = (Pmax x R) / Pb

Rdb1 = (268 000 x 3.2) / 123 700 = 6.93 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

Step 6 Select a Resistor

From Table C.B resistor PF6F5R4K39 with 6.5 ohm, 4394 watts and256 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.

Line Voltage Vd Pmax R Pmax x R Rdb1600V AC 950V DC 268 000 W 3.2 Ohms 857 375 Ohm690V AC 1090V DC 305 000 W 3.7 Ohms 1 128 695 Ohm

Total watt-seconds 123700 20000 103700=–=


Table C.B IPC & PowerOhm Braking Resistors for 600/690V AC Drives - 950/1090V DC Full-on

Ohms WattsWatt- Seconds

Catalog No. Manuf.

14.0 1200 24500 T14R1K2 IPC14.0 1200 39800 PR2210-8A P.O.14.0 1200 153900 PRT14R1K2 P.O.14.0 1600 61500 PR2210-8 P.O.14.0 1800 27800 T14R1K8 IPC14.0 1800 153900 PR14R1K80 P.O.14.0 1800 251300 PRT14R1K8 P.O.14.0 2012 61344 222-8A IPC14.0 2400 50200 PR222-8 P.O.14.0 2657 154455 222-8 IPC14.0 3150 251300 PR14R3K15 P.O.14.0 4495 117367 225-8A IPC14.0 4536 157200 PR14R4K53 P.O.14.0 4536 164900 PR225-8A P.O.14.0 6160 216700 PRT14R6K16 P.O.14.0 6160 232000 T14R6K16 IPC14.0 6642 172138 225-8 IPC14.0 6708 172138 220-8A IPC14.0 7406 376000 PR225-8 P.O.14.0 9464 600500 PR220-8 P.O.14.0 10045 523728 220-8 IPC14.0 11400 734000 T14R11K4 IPC14.0 11400 1027000 PRT14R11K4 P.O.14.0 12700 1027000 PRT14R12K7 P.O.14.0 12700 1038000 T14R12K7 IPC13.0 1200 88900 PR13R1K20 P.O.13.0 1600 111200 PF13R1K60 P.O.13.0 2250 233400 PR13R2K25 P.O.13.0 2800 238800 PF13R2K80 P.O.13.0 3328 144900 PR13R3K32 P.O.13.0 5200 193100 PR13R5K20 P.O.13.0 5457 191600 PF13R5K45 P.O.13.0 11000 1048200 PF13R11K0 P.O.12.0 1200 134700 PR12R1K20 P.O.12.0 2250 215400 PR12R2K25 P.O.12.0 2400 215300 PR4405-14A P.O.12.0 3072 133600 PR12R3K07 P.O.12.0 3888 140800 PR5505-16A P.O.12.0 3888 155500 PR4405-14 P.O.12.0 4800 191500 PR4410-14A P.O.12.0 6348 342000 PR12R6K34 P.O.12.0 6348 376000 PR5505-16 P.O.12.0 8112 500400 PR4410-14 P.O.12.0 9641 440372 442-14A IPC12.0 10092 898400 PR442-14A P.O.12.0 10092 1048100 PR5510-16 P.O.12.0 12288 1433800 PR552-16A P.O.12.0 12398 890985 442-14 IPC12.0 13780 890985 552-16A IPC12.0 15552 1955200 PR442-14 P.O.12.0 19200 3595700 PR552-16 P.O.12.0 20673 599876 552-16 IPC

12.0 21531 1924486 445-14A IPC12.0 24300 3941400 PR445-14A P.O.12.0 30000 6169500 PR445-14 P.O.12.0 30000 6450000 PR555-16A P.O.12.0 30776 1040221 555-16A IPC12.0 32136 1040221 440-14A IPC12.0 32297 1040221 445-14 IPC12.0 43200 10984300 PR555-16 P.O.12.0 45934 2387466 550-16A IPC12.0 46170 2247026 555-16 IPC12.0 48204 1314510 440-14 IPC12.0 58800 16476500 PR440-14 P.O.12.0 68911 10015318 550-16 IPC12.0 86700 28607000 PR550-16 P.O.11.0 1200 48300 PR2205-9 P.O.11.0 1600 39400 PR2210-9A P.O.11.0 2000 197400 PR2210-9 P.O.11.0 2400 197400 PR222-9A P.O.11.0 2561 121123 222-9A IPC11.0 3381 100080 222-9 IPC11.0 3564 116600 PR222-9 P.O.11.0 5720 237243 225-9A IPC11.0 5819 321000 PR225-9A P.O.11.0 8454 407344 225-9 IPC11.0 8537 407344 220-9A IPC11.0 9251 898400 PR225-9 P.O.11.0 12784 890985 220-9 IPC11.0 14256 1737900 PR220-9 P.O.10.4 1500 25400 T10F4R1K5 IPC10.4 1500 186700 PRT10F4R1K5 P.O.10.4 1800 186700 PR10F4R1K80 P.O.10.4 2662 115900 PR10F4R2K66 P.O.10.4 2970 81600 PRT10F4R2K97 P.O.10.4 2970 95100 T10F4R2K97 IPC10.4 4160 153300 PR10F4R4K16 P.O.10.4 5360 274400 PRT10F4R5K36 P.O.10.4 5360 329000 T10F4R5K36 IPC10.4 6040 274400 PRT10F4R6K4 P.O.10.4 6040 489000 T10F4R6K4 IPC10.4 8746 855700 PR10F4R8K74 P.O.10.4 8890 770300 PRT10F4R8K89 P.O.10.4 8890 801000 T10F4R8K89 IPC10.4 11000 359000 T10F4R11K0 IPC10.4 11000 1168200 PRT10F4R11K0 P.O.10.4 15500 1742000 T10F4R15K5 IPC10.4 15500 2490600 PRT10F4R15K5 P.O.10.4 16640 2966900 PR10F4R16K6 P.O.10.4 18900 1991000 T10F4R18K9 IPC10.4 18900 3790000 PRT10F4R18K9 P.O.10.4 26000 2002000 T10F4R26K0 IPC10.4 26000 5718700 PR10F4R26K0 P.O.10.4 26000 5885300 PRT10F4R26K0 P.O.


Catalog No. Manuf.


10.4 35600 1230000 T10F4R35K6 IPC10.4 35600 10024700 PRT10F4R35K6 P.O.10.4 43900 1367000 T10F4R43K9 IPC10.4 43900 14328100 PRT10F4R43K9 P.O.10.4 72300 4620000 T10F4R72K3 IPC10.4 72300 18257600 PRT10F4R72K3 P.O.10.1 1200 112100 PF10F1R1K20 P.O.10.0 4000 163500 PR5505-17A P.O.10.0 6760 400300 PR5505-17 P.O.10.0 8410 898400 PR5510-17A P.O.10.0 12960 1737900 PR5510-17 P.O.10.0 16000 2824200 PR552-17A P.O.10.0 17713 479901 552-17A IPC10.0 25000 5328200 PR552-17 P.O.10.0 26569 903350 552-17 IPC10.0 36000 8787400 PR555-17A P.O.10.0 39559 1956117 555-17A IPC10.0 49000 13730400 PR550-17A P.O.10.0 51840 6453800 PR555-17 P.O.10.0 59043 1950414 550-17A IPC10.0 59339 1950414 555-17 IPC9.50 3800 135500 PR4405-15A P.O.9.50 5025 266000 PR4405-15 P.O.9.50 6422 400300 PR4410-15A P.O.9.50 9728 1075300 PR4410-15 P.O.9.50 11926 316618 442-15A IPC9.50 12312 1520700 PR442-15A P.O.9.50 15200 2596900 PR442-15 P.O.9.50 17890 479901 442-15 IPC9.50 23750 5047800 PR445-15A P.O.9.50 26636 3000513 445-15A IPC9.50 34200 8787400 PR445-15 P.O.9.50 38912 4056700 PR440-15A P.O.9.50 39755 2851152 440-15A IPC9.50 39955 1079776 445-15 IPC9.50 49248 6146500 PR440-15 P.O.9.50 59635 1820386 440-15 IPC9.20 1200 102200 PF9F2R1K20 P.O.9.20 1600 75500 PF9F2R1K60 P.O.9.20 2000 161600 PF9F2R2K00 P.O.9.20 2355 98000 PF9F2R2K35 P.O.9.20 2981 116700 PF9F2R2K98 P.O.9.20 3751 135600 PF9F2R3K75 P.O.9.20 4867 282100 PF9F2R4K86 P.O.9.20 6601 341800 PF9F2R6K60 P.O.9.20 7737 748700 PF9F2R7K73 P.O.9.20 9421 1075400 PF9F2R9K42 P.O.9.20 11923 1520800 PF9F2R11K9 P.O.9.20 15001 545200 PF9F2R15K0 P.O.9.20 19467 1064100 PF9F2R19K4 P.O.9.20 24876 1416000 PF9F2R24K8 P.O.9.20 30948 2965500 PF9F2R30K9 P.O.


Catalog No. Manuf.

9.20 37683 4056800 PF9F2R37K6 P.O.9.20 47693 6146600 PF9F2R47K6 P.O.9.20 58880 10387700 PF9F2R58K8 P.O.9.20 69635 6672400 PF9F2R69K6 P.O.9.20 90001 9127700 PF9F2R90K0 P.O.9.20 132480 23372300 PF9F2R132K2 P.O.8.0 4232 240700 PR4405-16A P.O.8.0 5408 300200 PR4405-16 P.O.8.0 8192 896100 PR4410-16A P.O.8.0 10368 1303400 PR4410-16 P.O.8.0 14093 401656 442-16A IPC8.0 16200 2786200 PR442-16A P.O.8.0 16200 2846600 PR442-16 P.O.8.0 21143 693480 442-16 IPC8.0 23427 1211023 552-18A IPC8.0 28800 7322900 PR445-16A P.O.8.0 31474 1564893 445-16A IPC8.0 35138 2494758 552-18 IPC8.0 39200 10984300 PR552-18 P.O.8.0 41472 4917200 PR445-16 P.O.8.0 46977 2966898 440-16A IPC8.0 47219 1560331 445-16 IPC8.0 52321 1559677 555-18A IPC8.0 57800 19071300 PR555-18A P.O.8.0 64800 10510600 PR440-16 P.O.8.0 70477 3325398 440-16 IPC8.0 78475 5345909 555-18 IPC8.0 80000 15704400 PR555-18 P.O.7.30 1200 26200 PR2205-10A P.O.7.30 1600 131000 PR2205-10 P.O.7.30 1868 77700 PR2210-10A P.O.7.30 2920 107400 PR2210-10 P.O.7.30 3826 164245 222-10A IPC7.30 3861 199500 PR222-10A P.O.7.30 5095 267369 222-10 IPC7.30 6139 598900 PR222-10 P.O.7.30 7475 896100 PR225-10A P.O.7.30 8545 566990 225-10A IPC7.30 11680 2259300 PR225-10 P.O.7.30 12738 359925 225-10 IPC7.30 12754 359925 220-10A IPC7.30 14782 2476600 PR220-10A P.O.7.30 18250 3964700 PR220-10 P.O.7.30 19264 656981 220-10 IPC7.0 1200 123900 PF7R1K20 P.O.7.0 1600 77000 PF7R1K60 P.O.7.0 1792 77800 PR7R1K79 P.O.7.0 2800 107500 PF7R2K80 P.O.7.0 4732 269500 PR7R4K73 P.O.7.0 7383 765100 PF7R7K38 P.O.7.0 11251 436200 PF7R11K2 P.O.7.0 14812 802700 PF7R14K8 P.O.


Catalog No. Manuf.


7.0 23548 2330100 PF7R23K5 P.O.7.0 36912 4610000 PF7R36K9 P.O.7.0 55001 5083700 PF7R55K0 P.O.7.0 81648 10141900 PF7R81K6 P.O.7.0 127575 21021300 PF7R127K7 P.O.7.0 157500 34493700 PF7R157K7 P.O.6.50 2106 92600 PF6F5R2K10 P.O.6.50 2600 90400 PF6F5R2K60 P.O.6.50 3438 188100 PF6F5R3K43 P.O.6.50 4394 256400 PF6F5R4K39 P.O.6.50 5466 599000 PF6F5R5K46 P.O.6.50 6656 717000 PF6F5R6K65 P.O.6.50 8424 1086300 PF6F5R8K42 P.O.6.40 4326 256300 PR4405-17A P.O.6.40 6553 716900 PR4405-17 P.O.6.40 8294 1086200 PR4410-17A P.O.6.40 12960 2167000 PR4410-17 P.O.6.40 16000 3568300 PR442-17A P.O.6.40 17529 574859 442-17A IPC6.40 23040 5858300 PR442-17 P.O.6.40 26292 719851 442-17 IPC6.40 33177 4302500 PR445-17A P.O.6.40 39148 1231840 445-17A IPC6.40 58430 4818224 440-17A IPC6.40 58718 4929414 445-17 IPC6.40 64000 13460900 PR445-17 P.O.6.0 7776 1086200 PR5505-19A P.O.6.0 12150 1857400 PR5505-19 P.O.6.0 15000 3171800 PR5510-19A P.O.6.0 21600 5176500 PR5510-19 P.O.6.0 28008 1960167 552-19A IPC6.0 29400 8238200 PR552-19A P.O.6.0 38400 6392400 PR552-19 P.O.6.0 42015 1981674 552-19 IPC6.0 60000 12900000 PR555-19A P.O.6.0 62551 2135190 555-19A IPC5.70 1846 61700 PR2205-11 P.O.5.70 2280 90300 PR2210-11A P.O.5.70 3853 212300 PR2210-11 P.O.5.70 4793 449200 PR222-11A P.O.5.70 4938 260816 222-11A IPC5.70 5836 612000 PR222-11 P.O.5.70 6525 421193 222-11 IPC5.70 11029 905640 225-11A IPC5.70 11542 1857400 PR225-11A P.O.5.70 16314 880744 225-11 IPC5.70 16461 880744 220-11A IPC5.70 20520 5176500 PR225-11 P.O.5.70 24694 1781970 220-11 IPC5.70 27930 8238200 PR220-11 P.O.5.40 1200 97000 PR5F4R1K20 P.O.5.40 1382 59900 PR5F4R1K38 P.O.


Catalog No. Manuf.

5.40 1670 55700 T5F4R1K67 IPC5.40 1670 81800 PRT5F4R1K67 P.O.5.40 1749 61700 PR5F4R1K74 P.O.5.40 1949 61700 PR5F4R1K94 P.O.5.40 2680 182900 PRT5F4R2K68 P.O.5.40 2680 185000 T5F4R2K68 IPC5.40 2856 154800 PR5F4R2K85 P.O.5.40 3650 207900 PR5F4R3K65 P.O.5.40 4541 444300 PR5F4R4K54 P.O.5.40 5080 385200 PRT5F4R5K8 P.O.5.40 5080 401000 T5F4R5K8 IPC5.40 5529 603100 PR5F4R5K52 P.O.5.40 5780 169000 T5F4R5K78 IPC5.40 5780 500700 PRT5F4R5K78 P.O.5.40 6998 902500 PR5F4R6K99 P.O.5.40 7280 328000 T5F4R7K28 IPC5.40 7280 809200 PRT5F4R7K28 P.O.5.40 8640 1540500 PR5F4R8K64 P.O.5.40 12000 699000 T5F4R12K0 IPC5.40 12000 3328300 PRT5F4R12K0 P.O.5.40 13500 2973600 PR5F4R13K5 P.O.5.40 19440 4904100 PR5F4R19K4 P.O.5.40 20300 738000 T5F4R20K3 IPC5.40 20300 5451100 PRT5F4R20K3 P.O.5.40 22000 717000 T5F4R22K0 IPC5.40 22000 5451100 PRT5F4R22K0 P.O.5.40 27993 3607800 PR5F4R27K9 P.O.5.40 34560 6164200 PR5F4R34K5 P.O.5.40 37700 2310000 T5F4R37K7 IPC5.40 37700 9294800 PRT5F4R37K7 P.O.5.40 43740 7276600 PR5F4R43K7 P.O.5.40 48100 712100 PRT5F4R48K1 P.O.5.40 48100 1845000 T5F4R48K1 IPC5.40 51900 712100 PRT5F4R51K9 P.O.5.40 51900 1953000 T5F4R51K9 IPC5.40 54000 11877300 PR5F4R54K0 P.O.5.40 104000 3444000 T5F4R104K0 IPC5.40 104000 29551700 PRT5F4R104K0 P.O.5.0 6480 868900 PR4405-18A P.O.5.0 8000 1412100 PR4405-18 P.O.5.0 12500 2775300 PR4410-18A P.O.5.0 18000 4658800 PR4410-18 P.O.5.0 22848 1603773 442-18A IPC5.0 24500 6865200 PR442-18A P.O.5.0 30978 1651395 552-20A IPC5.0 32000 5593300 PR442-18 P.O.5.0 34269 959801 442-18 IPC5.0 36125 11352000 PR552-20A P.O.5.0 46464 3891643 552-20 IPC5.0 50000 11217400 PR552-20 P.O.5.0 51028 1733701 445-18A IPC5.0 76534 3651418 445-18 IPC


Catalog No. Manuf.


5.0 98000 6865200 PR5510-20 P.O.5.0 98000 25630100 PR445-18 P.O.4.80 2580 185000 T4F8R2K58 IPC4.80 4036 395900 PR4F8R4K03 P.O.4.80 4590 401000 T4F8R4K59 IPC4.80 4590 500700 PRT4F8R4K59 P.O.4.80 5490 169000 T4F8R5K49 IPC4.80 5490 809200 PRT4F8R5K49 P.O.4.80 6220 802200 PR4F8R6K22 P.O.4.80 7680 1369400 PR4F8R7K68 P.O.4.80 8880 260000 T4F8R8K88 IPC4.80 8880 1674500 PRT4F8R8K88 P.O.4.80 10900 359000 T4F8R10K9 IPC4.80 10900 2912200 PRT4F8R10K9 P.O.4.80 19200 586000 T4F8R19K2 IPC4.80 19200 4360900 PRT4F8R19K2 P.O.4.80 23520 6752000 PR4F8R23K5 P.O.4.80 25800 984000 T4F8R25K8 IPC4.80 25800 6330400 PRT4F8R25K8 P.O.4.80 34600 628300 PRT4F8R34K6 P.O.4.80 34600 2310000 T4F8R34K6 IPC4.80 38880 6468100 PR4F8R38K8 P.O.4.80 58200 3696000 T4F8R58K2 IPC4.80 58200 18507200 PRT4F8R58K2 P.O.4.80 61000 3916000 T4F8R61K0 IPC4.80 61000 18507200 PRT4F8R61K0 P.O.4.80 69120 17575000 PR4F8R69K1 P.O.4.80 99300 6159000 T4F8R99K3 IPC4.80 99300 25969700 PRT4F8R99K3 P.O.4.80 132000 8077000 T4F8R132K0 IPC4.80 132000 33527500 PRT4F8R132K0 P.O.4.50 1800 71600 PR2205-12A P.O.4.50 2380 133000 PR2205-12 P.O.4.50 3042 168400 PR2210-12A P.O.4.50 4608 537600 PR2210-12 P.O.4.50 4608 2028300 PR225-12 P.O.4.50 5832 741800 PR222-12A P.O.4.50 6184 152850 222-12A IPC4.50 8266 239950 222-12 IPC4.50 9112 1547800 PR222-12 P.O.4.50 13810 660558 225-12A IPC4.50 16200 4141200 PR225-12A P.O.4.50 20612 1425576 220-12A IPC4.50 20715 1425576 225-12 IPC4.50 22050 6407500 PR220-12A P.O.4.50 28800 4794300 PR220-12 P.O.4.50 30918 1486256 220-12 IPC4.0 8100 1238300 PR4405-19A P.O.4.0 10000 2378800 PR5505-21A P.O.4.0 14400 3623500 PR4405-19 P.O.4.0 19600 5492100 PR5510-21A P.O.4.0 20736 2765900 PR4410-19 P.O.


Catalog No. Manuf.

4.0 25600 4394700 PR442-19A P.O.4.0 32400 5255300 PR5510-21 P.O.4.0 40000 8413000 PR442-19 P.O.4.0 40000 8973900 PR552-21A P.O.4.0 42308 1386961 442-19 IPC4.0 44057 3441020 552-21A IPC4.0 57600 14645800 PR445-19A P.O.4.0 66084 1799627 552-21 IPC3.90 7897 1238300 PR4405-20A P.O.3.90 14040 3623500 PR4405-20 P.O.3.90 24960 4394700 PR4410-20 P.O.3.90 31590 5255300 PR442-20A P.O.3.90 32736 2405659 442-20A IPC3.90 45489 5531800 PR442-20 P.O.3.90 49108 3246136 442-20 IPC3.90 62996 8013142 445-19A IPC3.80 2010 105400 PR2205-13A P.O.3.80 3195 317700 PR2205-13 P.O.3.80 3891 459000 PR2210-13A P.O.3.80 6080 1129600 PR2210-13 P.O.3.80 7227 182571 222-13A IPC3.80 7695 1238300 PR222-13A P.O.3.80 9500 1982300 PR222-13 P.O.3.80 9788 328491 222-13 IPC3.80 16139 430346 225-13A IPC3.80 18620 5176500 PR225-13A P.O.3.80 24089 751149 220-13A IPC3.80 24212 1321116 225-13 IPC3.80 24320 3995200 PR225-13 P.O.3.80 36138 2672955 220-13 IPC3.80 38000 8413000 PR220-13 P.O.3.30 1200 61000 PF3F3R1K20 P.O.3.30 1876 105500 PF3F3R1K87 P.O.3.30 2230 124600 PF3F3R2K23 P.O.3.30 2775 317800 PF3F3R2K77 P.O.3.30 3379 380400 PF3F3R3K37 P.O.3.30 4299 556400 PF3F3R4K29 P.O.3.30 6982 376100 PF3F3R6K98 P.O.3.30 9251 512700 PF3F3R9K25 P.O.3.30 11101 1197900 PF3F3R11K1 P.O.3.30 13516 1530100 PF3F3R13K5 P.O.3.30 21489 3595800 PF3F3R21K4 P.O.3.30 24977 2541900 PF3F3R24K9 P.O.3.30 38491 5071000 PF3F3R38K4 P.O.3.30 47520 8390100 PF3F3R47K5 P.O.3.30 75001 15984900 PF3F3R75K0 P.O.3.30 106920 26362500 PF3F3R106K6 P.O.3.30 150001 41191400 PF3F3R150K0 P.O.3.30 214582 70836500 PF3F3R214K4 P.O.


Catalog No. Manuf.

www.rockwellautomation.com

Corporate HeadquartersRockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: +1 414.212.5200, Fax: +1 414.212.5201

Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing SolutionsAmericas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: +1 414.382.2000, Fax: +1 414.382.4444Europe/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 0640Asia 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 ProductsAmericas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: +1 864.297.4800, Fax: +1 864.281.2433Europe/Middle East/Africa: Rockwell Automation, Herman-Heinrich-Gossen-Strasse 3, D-50858 Köln, Germany, Tel: +49 (0)2234 379410, Fax: +49 (0)2234 3794164Asia 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 2005Copyright 2005 Rockwell International Corporation. All rights reserved.