Crompton 3DPM1CHS-10 User Manual

This is

Crompton Controls

Crompton Controls

Installation and Maintenance
Instructions

S10 & Smooth-BRAKE
DC Injection Brake Modules

LT011 Issue 1

Tel: [phone]

DC Injection Brake Module

Installation and Maintenance Document

S10 and Smooth-BRAKE

Warranty

All goods are guaranteed for one year from the date of purchase. This does not affect the
statutory rights of the user.

Safety warning

Important Safety Information

All electrical equipment for operating on low voltages contain devices which are capable of
causing serious or fatal injuries.
Any person involved in installation or maintenance of this equipment should be ful ly
competent to conduct the work.
Such persons should be familiar with the Health and Safety at Work Act, Electricity at
Work Regulations and have a working knowledge of the IEE Wiring Regulations.

If in doubt please contact,

Crompton Controls Ltd Tel: [phone]

General Description of the equipment

Crompton Controls DC injection Braking starters are suitable for controlled
stopping of induction motors.
When the machine starter is de energised the brake timer senses the break in supply and
applies a DC voltage to the motor windings to provide a controlled braking force for a
timed duration.

NOTE:
DC injection braking is a PUWER
motors and requires the mains supply to be present to operate correctly.

98 approved method of stopping AC electric

Induction motors

Induction motors can be braked to standstill, by injecting a DC current into the winding,
this creates a stationary field and any shaft rotation will produce a braking torque.
Braking from full speed an induction motor behaves as a twice speed generator, the
generated currents help to stop the motor and full load braking torque requires a DC
current of approx 2 to 2.5 times motor full load current. The DC is produced using a
thyristor with controlled half rectification and a diode is connected across the motor to
rectify the generated current, without the diode the motor would not brake. The externally
applied dc current will rise as the machine brakes to a halt. Motor noise is normal when
using phase angle control due to the nature of the unsmoothed dc waveform.
The DC current produces magnetic flux in the motor air gap, current can increase but
there is a saturation effect that means flux and braking torque will increase with current
up to saturation after which high currents will not produce much extra braking.
Most braking systems provide a voltage to apply to the windings, at standstill the current
will be determined by ohms law, current=voltage/winding resistance.

Part Numbers Rated operational voltages

BR011 S10/400 400 volt 50Hz 25 Amp brake module
BR016 S10/240 240 volt 50Hz 25 Amp brake module
BR021 S10/110 110 volt 50Hz 25 Amp brake module
BR025 Smooth-Brake 400 volt 50Hz 60 Amp brake assembly
BR026 Smooth-Brake 400 volt 50Hz 90 Amp brake assembly

BR024 Smooth-Brake Control Module

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Electrical Specification

Conforming to Standards BS/EN60947

DC CURRENT: S10 25A nominal current flows through L1, L2, M1 & M2

Smooth-BRAKE 60 Amp or 90 Amp high current connections directly

to thyristor diode module.

FREQUENCY: The unit is for rated 50 Hz.
DWELL TIME: From operating main contactor to closing DC contactor:

S10 0.5 seconds
Smooth-BRAKE 1 second

TIME RANGE: S10 braking time range is 0.1 to 12.7 seconds

(270° rotation linear potentiometer)

Smooth-BRAKE 0.2 to 50 seconds

(270° rotation linear potentiometer)

DC VOLTAGE: The voltage range is up to approx. 160 volts, with the minimum

oltage dependent on thyristor latching current.

v

DUTY CYCLE: S10 Limited by software to 10%. For every second of braking 10 is

added to a register. For every second not braking 1 is subtracted.
Restart is inhibited if the register is above a value of 250.

Note: if the unit will not start it will be waiting for this register to count

down below 250. The maximum dela

y is approx. 2 minutes.
Smooth-BRAKE No software limitation of duty cycle. Heat sink rated
for 10 off equally spaced 35 second stops per hour maximum at stated
current.

DIMENSIONS: S10 81H x 45W x 121D (mm) - DIN Rail mounting

TERMINALS: S10 2 times 2.5mm

Smooth-BRAKE 100H x 160W x 125D (mm)

2

max

Smooth-BRAKE main terminals M5 screw

control terminals 2 times 2.5mm2max

WEIGHT: S10 200g

Smooth-BRAKE 1.0kg

HUMIDITY: 85% non condensing
AMBIENT TEMP: Operating -10 to +40C Storage -20 to +70C
PROTECTION: IP code IP20
RELAYS: RL1 Internal 8A rated contacts, 440Vac max breaking voltage.

RL2 The relay terminals 17 18 28 are volt free and can be wired in a control

circuit at lower voltage.
The rela

y contacts can be protected with a 4 Amp Control fuse.

BRAKE FUSE: Semiconductor fuse

S10

30A (10mm x 38mm) FL078 740 A

2

sec
Ferraz 660gRB10-30 A070gRB30T13 ref M330015 or equivalent.
Diode 40EPS12 800 A2sec
Thyristor 40TPS12 1250 A

2

sec

Smooth-BRAKE
60 Amp SKNH56 or IRKN56 8000 A2sec

FE100 semiconductor fuse 1800A

2

sec
NSD 32 3000 A2sec approx 60A 100 sec trip point
NSD 40 6000 A2sec approx 100A 100 sec trip point

90 Amp SKNH91 or IRKN91 15000 A2sec

FE120 semiconductor fuse 1900A

2

sec
ESD 50 8700 A2sec approx 120A 100 sec trip point
ESD 63 13300 A2sec approx 150A 100 sec trip point

3

S10 Module Terminals Identification and marking

Part Numbers

BR011 400v
BR016 240v
BR021 110v

L1 Common phase connection

L2 Phase connection - connected to M2
M1 Motor connection

M2 Motor connection - connected directly to L2
B2 Voltage sense input
17 Relay input - common to RL1 and RL2
18 RL1 Rela
28 RL2 Relay output connects to brake contactor

The B2 terminal to signal the unit to brake requires the full operating voltage of the
module applied.

L1 is common internally so a normally open auxiliary contact on the main contactor is

used to pro

y output - motor contactor via stop start circuit

vide a signal on B2 from L2.

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Smooth-BRAKE Module Terminals Identification and marking

Outline and Mounting Dimensions

Part Numbers

BR025 400v 60A
BR026 400v 90A

Terminal Description

L1 Common phase connection to thyristor terminal 2
L2 Phase connection to thyristor terminal 3
M1 Motor connection to thyristor terminal 1
M2 Motor connection also to thyristor terminal 3
M3 Motor connection - generated voltage
B2 Voltage sense input relative to L1
17 Relay input common to RL1 and RL2
18 RL1 Relay output - motor contactor via stop start circuit
28 RL2 Relay output connects to brake contactor
G Gate to connect to external thyristor

NOTE: A V

oltage Dependant Resistor – VDR is fitted across the M1 M2 motor terminals
to protect the diode.
Terminal covers not shown - MUST be fitted.
PCB fuse rating - 500V, 1A, quick blow, 6.3mm x 32mm ceramic tube, eg SIBA
ref: 70-065-63 1 Amp or equivalent.

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