Freno BU300

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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

QQ

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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13 GEI-100492

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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19 GEI-100492

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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21 GEI-100492

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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23 GEI-100492

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

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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

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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


series1800 48.3

7 7,5 1.119 internal 80qty 2


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



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


BUs in //48000 42


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

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31 GEI-100492

8/2/2019 Freno BU300

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1S9G70

Documents

Freno BU300