Danfoss VLT 2800, VLT 5000, VLT 5000 FLUX Installation guide

Contents
VLT®2800/5000/5000 FLUX/FCD 300
Introduction
Description of the brake system ............................................................................. 2
....................................................................................................... 2
Examples ............................................................................................................ 3
Example 2 - Centrifuge ........................................................................................... 5
Calculation of the brake resistor ............................................................ 6
Brake setup ........................................................................................................... 6
Calculation of brake resistor values ......................................................................... 6
Calculation of braking power .................................................................................. 7
Calculation of the brake resistor peak power .......................................................... 7
Calculation of the brake resistor average power ..................................................... 8
Braking ................................................................................................................. 9
Braking of inertia .................................................................................................... 9
Continuous braking ................................................................................................ 9
D.C. injection braking ............................................................................................. 9
AC-braking VLT 2800 and FCD 300 ....................................................................... 9
Optimum braking ................................................................................................... 9
Brake cable ............................................................................................................ 10
Protective functions during installation .................................................................... 10
Description of VLT 5000 brake ............................................................................... 11
Programming .................................................................................................... 12
VLT 5000 Process parameters ............................................................................... 12
VLT 5000 FLUX parameters .................................................................................... 12
VLT 2800 parameters ............................................................................................. 13
FCD 300 parameters .............................................................................................. 13
Brake resistor overview .............................................................................. 14
Brake resistor for VLT 5001-5500 10% duty-cycle data and codenumber .............. 14
Brake resistor for VLT 5001-5102 40% duty-cycle data and codenumber .............. 16
Brake resistor for VLT 2803-2882 duty-cycle 40% data and codenumber .............. 17
Brake resistor for VLT FCD 303-335 duty-cycle 40% data and codenumber .......... 17
Brake resistor for VLT 5001-5500 10% duty-cycle cablegland, weight and drawing
no. ......................................................................................................................... 19
Brake resistor for VLT 5001-5102 40% duty-cycle cablegland, weight and drawing
no. ......................................................................................................................... 20
Brake resistor for VLT 2803-2882 40% duty-cycle cablegland, weig
no. ......................................................................................................................... 21
Brake resistor for VLT FCD 303-335 40% duty-cycle cablegland, weight and drawing
no. ......................................................................................................................... 21
ht and drawing
Drawings 1 - 19 ................................................................................................ 22
MI.90.F1.02 - VLT is a registered Danfoss trademark
1
Danfoss offers a range of brake resistors for frequency converters, types 2800, 5000, 5000 FLUX and FCD 300.
Description of the brake system
When the speed reference of a frequency converter is reduced, the motor acts as a generator and brakes. When a motor acts as a generator, it supplies energy to the frequency converter which is collected in the intermediate circuit. The function of the brake resistor is to provide a load on the intermediate circuit during braking, thereby ensuring that the braking power is absorbed by the brake resistor.
If a brake resistor was not used, the intermediate circuit voltage of the frequency converter would continue to increase, until it cuts out for protection. The advantage of using a brake resistor is it enables braking of a heavy load quickly, e.g. on a conveyor belt.
Danfoss has chosen a solution in which the brake resistor does not form an integral part of the frequency converter. This offers the user the following advantages:
- The resistor time cycle can be selected as required
- The heat developed during braking can be conveyed beyond the panel cabinet to allow theenergytobeused
- There is no overheating of the electronic components, even if the brake resistor is overloaded
VLT®2800/5000/5000 FLUX/FCD 300
Knowledge of the system
If the right brake resistor is to be selected, it is necessary to know how often and by how much the motors are to brake.
In the following, some examples are given of calculations of the required braking for a conveyor belt and a centrifuge, respectively.
2
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Example 1 - Conveyor belt
Fig. 1 shows the relation between the braking power and the acceleration/braking of a conveyor belt. As can be seen, the motor power during braking is negative, since the torque on the motor shaft is negative. The braking power, i.e. the power to be dissipated to the brake resistor, corresponds almost to the negative motor power, taking the losses in the motor and the frequency converter into account. The example also shows that the motor power is time-dependent.
Kinetic energy (E) in conveyor belt + motor:
m = mass with linear movement [kg] v = speed of mass with linear movement [m/s]
2
j = inertia of motor and gear box (kgm
]
VLT®2800/5000/5000 FLUX/FCD 300
This formula may also be expressed as follows:
However, not all of the energy is to be dissipated to the brake resistor. The friction of the conveyor belt andthepowerlossofthemotoralsocontributetothe braking function. Consequently, the formula for energy dissipation (E
) to the brake resistor is as follows:
b
Mf= Friction torque [Nm]
= Motor efficiency
M
When:
Examples
is inserted, the result is as follows:
MI.90.F1.02 - VLT is a registered Danfoss trademark
3
Fig. 1
The relation between braking power and acceleration/braking of a conveyor belt.
VLT®2800/5000/5000 FLUX/FCD 300
4
MI.90.F1.02 - VLT is a registered Danfoss trademark
Example 2 - Centrifuge
Another typical application in which braking can be required on centrifuges. The weight of the centrifuge content is m.
VLT®2800/5000/5000 FLUX/FCD 300
jC= centrifuge inertia =
2
2
+r
½xmx(r
j
= Gear motor inertia [kgm2]
M
= Gear motor efficiency
η
M
n
= max. motor speed [rpm]
1
= max. centrifuge speed [rpm]
n
2
1
)[kgm2]
2
Examples
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5
Brake setup
Fig. 2 shows a brake set-up using a frequency converter.
The following sections use expressions and abbreviations with respect to a brake set-up that can be seen from fig. 2.
Fig. 2
VLT®2800/5000/5000 FLUX/FCD 300
Calculation of brake resistor values
To keep the VLT frequency converter from cutting out for protection when the motor brakes, the resistor values are to be selected on the basis of the peak braking power and the intermediate circuit voltage:
As can be seen, the brake resistor depends on the intermediate circuit voltage (Udc).
Udc is the voltage, where the brake is activated. For values see further on in this instruction.
Another option is to use the brake resistor recommended by Danfoss (Rrec). This guarantees that the frequency converter is able to brake at the highest braking torque (Mbr), i.e. 160% / 150% / 100%. See the tables further on in this instruction.
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MI.90.F1.02 - VLT is a registered Danfoss trademark
NB!:
Remember to check whether your brake resistor is able to handle the intermediate voltage (Udc for your specific drive can be found in the table
below) if you do not use Danfoss brake resistors.
VLT®2800/5000/5000 FLUX/FCD 300
ηηηη
VLT type Udc
is typically 0,9, while ηηηη
motor
is typically 0,98. R
vlt
can be expressed as follows:
rec
Max. Braking torque
5001-5027 Process and FLUX / 200-240 Volt 397 Volt 160 %
5032-5052 Process and FLUX / 200-240 Volt 390 Volt 150 %
5001-5062, 5072 and 5102 Process and FlLUX / 380-500 Volt
822 Volt 160 %
5075, 5100 and 5125-5500 Process / 380-500 Volt 795 Volt 150 %
5075, 5100 and 5125-5500 FLUX / 380-500 Volt 795 Volt 100 %
5001-5250 Process / 550-600 Volt 958 Volt 160 %
2803-2840 / 200-240 Volt 385 Volt 160 %
R
=
rec
2805-2882 and FCD 303-335 / 380-480 Volt 770 Volt 160%
NB!:
Choose a brake resistor which is max. 10% below the value recommended by Danfoss.
If a bigger brake resistor is selected, 160% / 150% / 100% braking torque cannot be obtained, and there is a risk that the frequency converter will cut out for protection.
Ifbrakingisonlye.g. at80%torque,itispossibleto install a bigger brake resistor, the size of which can be calculated using the formula R
Calculation of braking power
When calculating the braking power, it is to be ensured that the brake resistor is able to handle the average power as well as the peak power. The average power is
, no. 1.
rec
determined by the process period time, i.e. the length of the braking time in relation to the process period time. The peak power is determined by the braking torque, which means that as braking progresses, the brake resistor must be able to dissipate the energy input.
Fig. 3 shows the relation between the average power and the peak power.
Fig. 3
brake resistor
Calculation of the
MI.90.F1.02 - VLT is a registered Danfoss trademark
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VLT®2800/5000/5000 FLUX/FCD 300
Calculation of the brake resistor peak power
P
peak, mec
is the peak power by which the motor brakes
on the motor shaft. It is calculated as follows:
P
is the name used for the braking power dissipated
peak
to the brake resistor when the motor brakes.
is lower than P
P
peak
peak,mec
since the power is reduced by the efficiencies of the motor and the VLT frequency converter.
The peak power is calculated as follows:
If the brake resistor recommended by Danfoss is selected (R
) on the basis of the tables further
rec
on in this instruction, the brake resistor will be certain to provide a braking torque of 160% / 150% / 100% on the motor shaft.
Calculation of the brake resistor average power
The average power is determined by the process period time, i.e. the length of the braking time in relation to the process period time.
Danfoss offers brake resistors with a duty-cycle of max. 10% and 40%, respectively (some drives are only available with a duty-cycle of max. 10%). If a 10% duty-cycle is applied, the brake resistors are able to absorb Ppeak for 10% of the period time. The remaining 90% of the period time will be used on deflecting excess heat.
The average power with 10% duty-cycle can be calculated as follows:
The average power with 40% duty-cycle can be calculated as follows:
The calculations apply to intermittent braking using a period time of 120/300 seconds (to define whether it is 120 or 300 seconds. Please see the tables further on).
NB!:
Longer time than the specified intermittent braking period time may result in overheating of the resistor.
If the amount of kinetic energy (Eb) transferred to the resistor in each braking sequence (see examples 1 and 2) is known, the average power of the resistor can be calculated as follows:
Tp= period time in seconds (see drawing on page 3).
If the amount of kinetic energy transferred to the resistor in each braking sequence is not known, the average power can be calculated on the basis of the process period time and the braking time.
The duty-cycle for the braking sequence is calculated as follows:
Tp= process period time in seconds. T
= braking time in seconds.
b
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VLT®2800/5000/5000 FLUX/FCD 300
Braking of inertia
In the case of braking of high inertia values on the motor shaft, the brake resistor values can be based on the inertia,
ω, t. See fig. 4.
Fig. 4
t is determined by the ramp-down time
in parameter 208.
NB!:
The ramp-down time goes from the rated motor frequency in parameter 104 to 0 Hz.
P
can be calculated as:
peak
Since the electrical resistance of the rotor cage is very low, even small induced voltages can create a high rotor current. This current will produce a strong braking effect on the bars and hence on the rotor. As the speed falls, the frequency of the induced voltage falls and with it the inductive impedance. The ohmic resistance of the rotor gradually becomes dominant and so increases the braking effect as the speed comes down. The braking torque generated falls away steeply just before standstill and finally ceases when there is no further movement. Direct current injection braking is therefore not suitable for actually holding a load at rest.
AC-braking VLT 2800 and FCD 300
WhenthemotoractsasabraketheDC-linkvoltagewill increase because energy is fed back to the DC-link. The principle in AC-brake is to increase the magnetisation during the braking and thereby increase the thermal losses of the motor. Using par. 144 in VLT 2800 and FCD 300 it is possible to adjust the size of the generator torque that can be applied to the motor without the intermediate circuit voltage exceeding the warning level.
The braking torque depends on the speed. With the AC-brake function enabled and parameter 144 = 1,3 (factory setting) it is possible to brake with about 50 % of rated torque below 2/3 of rated speed and with about 25 % at rated speed. The function is not working at low speed (below 1/3 of nominal motor speed). It is only possible to run for about 30 seconds with parameter 144 greater than 1.2.
jistheinertiaofthemotorshaft. Calculate the value on the brake resistor as described under the preceding paragraphs.
Continuous braking
For continuous braking, select a brake resistor in which the constant braking power does not exceed the average power P
of the brake resistor.
avg
NB!:
Please contact your Danfoss distributor for further information.
D.C. injection braking
If the three-phase winding of the stator is fed with direct current, a stationary magnetic field
will be set up in the stator bore causing a voltage to be induced in the bars of the cage rotor as long as the rotor is in motion.
NB!:
If the value in parameter 144 is increased, the motor current will simultaneously increase significantly when generator loa
ds are applied. The parameter should therefore only be changed if it is guaranteed during measurement that the motor current in all operating situa
tions will never exceed the maximum permitted current in the motor. Please note: The current can not be read out from the display.
Optimum braking
Dynamic braking is useful from max. speed down to a certain frequency. Below this frequency DC braking is to be applied as required. The most efficient way of doing this is to use a combination of dynamic and DC braking. See fig. 5. The parameters can be found further on in this instruction.
Braking
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9
VLT®2800/5000/5000 FLUX/FCD 300
Fig. 5
NB!:
When changing from dynamic to DC braking, there will be a short period (2-6 milliseconds) with very low braking torque.
How to calculate optimum DC-brake cut in frequency:
Slip S=
NB!:
The brake resistor is to be fitted on a non-flammable material.
For protection of the installation, a thermal relay should be fitted that cuts off the frequency converter if the brake current becomes too high.
Calculate the brake current setting of the thermal relay as follows:
Itherm relay =
Rbris the current brake resistor value calculated in the section on "Calculation of brake resistor values". Fig. 6 shows an installation with a thermal relay.
The brake current setting of thermal relay for Danfoss brake resistors can be found in tables further on in this instruction.
Synchronous speed [1/min]
f = frequency p=no. ofpolepairs
= speed of the rotor
n
n
DC-brake cut in frequency =
Hz
Brake cable
Max. length [m]: 20 m
The connection cable to the brake resistor is t screened/armoured. Connect the screen/armouring to the conductive back plate at the VLT frequency converter and to the brake resistor metal c by means of cable clamps.
NB!:
If Danfoss brake resistors are not used, make sure that the brake resistors used are induction-free.
obe
abinet
Protective functions during installation
When installing a brake resistor
, every measure should be taken to avoid the risk of overloading, since a fire hazard may arise owing to the heat generated in the heat resistor
.
10
MI.90.F1.02 - VLT is a registered Danfoss trademark
Fig. 6
VLT®2800/5000/5000 FLUX/FCD 300
Some of the Danfoss Brakeresistors contain a thermal switch (see tables further on in this instruction). This switch is NC (normally closed) and can be used e.g. coasting stop reverse between terminal 12 and 27. The drive will then coast, if the thermal switch is opened.
NB!:
The thermal switch is not a protective device. For protection, use a thermal switch as shown in fig. 6.
Description of VLT 5000 brake
Danfoss VLT 5000 Series enables activation of an integral brake monitor to guarantee that the braking power does not exceed a given limit.
The power is calculated on the basis of the resistor ohm value (parameter 401), the intermediate circuit voltage and the resistor running time. For further information, see page 10.
NB!:
The brake power monitoring system is not a protective device. For protection, use a thermal switch as shown in fig. 6.
Via the digital/relay outputs, it is possible to get a status message concerning the brake, e.g. indicating brake faults. Furthermore, VLT 5000 Series features an integral function to check whether the brake resistor has been connected/is intact at the time of power-up.
Additionally, the brake is protected against short-circuiting by the brake resistor. The brake circuit is not earthing proof.
Braking
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11
VLT®2800/5000/5000 FLUX/FCD 300
VLT 5000 Process parameters
The following is a list of parameters for the VLT 5000 Process Series which are important or relevant for thedynamicbrakeandtheDCbrake.
Parameter Suggestion of settings
125 DC braking current Depends on the desired braking torque 126 DC braking time Set the desired DC braking time 127 DC brake cut-in frequency Set the desired DC brake cut-in frequency 222 Torque limit for generating operation 160 % 319 Output (terminal 42) Brake no warning,
Brake ready no fault or
Brake fault 321 Output (terminal 45) Same as 319 323 Output (relay 01) Same as 319 326 Output (relay 4) Same as 319 400 Brake function/overvoltage control Resistor brake 401 Brake resistor, ohm Depends on the unit, see the tables further on in this
instruction 402 Brake power limit, kW Depends on the unit, see the tables further on in this
instruction 403 Power monitoring Warning or trip 404 Brake check Warning or trip
VLT 5000 FLUX parameters
The following is a list of parameters for the VLT 5000 FLUX Series which are important or relevant for the dynamic brake and the DC brake.
Parameter Suggestion of settings
125 DC braking current Depends on the desired braking torque 126 DC braking time Set the desired DC braking time 127 DC brake cut-in frequency Set the desired DC brake cut-in frequency 222 Torque limit for generating operation 160 % 323 Output (relay 01) Brake no warning,
Brake ready no fault or
Brake fault 326 Output (relay 4) Same as 323 341 Output (terminal 46) Same as 323 355 Output (terminal 26) Same as 323 400 Brake function/overvoltage control Resistor brake 401 Brake resistor, ohm Depends on the unit, see the tables further on in this
instruction 402 Brake power limit, kW Depends on the unit, see the tables further on in this
instruction 403 Power monitoring Warning or trip 404 Brake check Warning or trip
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MI.90.F1.02 - VLT is a registered Danfoss trademark
The sizes VLT 5125 and 5150 are equipped with a better dynamic brake performance compared to the same sizes in VLT 5000 Process.
Itispossibletobrake4minout10mininatotal cycle (Duty type S% 40% EN 60034-1)
VLT 2800 parameters
The following is a list of parameters for the VLT 2800 Series which are important or relevant for the dynamic brake and the DC brake.
VLT®2800/5000/5000 FLUX/FCD 300
VLT 5125 FLUX and VLT 5150 FLUX
Parameter Suggestion of settings
126 DC braking time Set the desired DC braking time 127 DC brake engaging frequency Set the desired DC brake engaging frequency 132 DC brake voltage Depends on the desired braking torque 400 Brake function Resistor or AC brake 456 Brake voltage reduce 0 should only be used if there are problems with
overvoltage in the intermediate circuit
FCD 300 parameters
The following is a list of parameters for the VLT FCD 300 Series which are important or relevant for thedynamicbrakeandtheDCbrake.
Parameter Suggestion of settings
126 DC braking time Set the desired DC braking time 127 DC brake engaging frequency Set the desired DC brake engaging frequency 132 DC brake voltage Depends on the desired braking torque 400 Brake function Resistor or AC brake 456 Brake voltage reduce 0 should only be used if there are problems with
overvoltage in the intermediate circuit
MI.90.F1.02 - VLT is a registered Danfoss trademark
Programming
13
Brake resistor for VLT 5001-5500 10% duty-cycle
data and codenumber
VLT®2800/5000/5000 FLUX/FCD 300
VLT type
P=Process
F=FLUX
5001 P, F (200V) 120 0,75 130 145 0,065 0,7 1820 1,5****** 5002 P, F (200V) 120 1,1 81 90 0,095 1,0 1821 1,5****** 5003 P, F (200V) 120 1,5 58 65 0,25 2,0 1822 1,5****** 5004 P, F (200V) 120 2,2 45 50 0,285 2,4 1823 1,5****** 5005 P, F (200V) 120 3,0 31 35 0,43 2,5 1824 1,5****** 5006 P, F (200V) 120 4,0 22 25 0,8 5,7 1825 1,5****** 5008 P, F (200V) 120 5,5 18 20 1,0 7,1 1826 1,5****** 5011 P, F (200V) 120 7,5 13 15 2,0 11 1827 1,5****** 5016 P, F (200V) 120 11,0 9,0 10 2,8 17 1828 2,5****** 5022 P, F (200V) 120 15,0 6,3 7,0 4,0 24 1829 4****** 5027 P, F (200V) 120 18,5 5,2 6,0 4,8 28 1830 4****** 5032 P, F (200V) 300 22,0 4,2 4,7 6,0 36 1954 10****** 5042 P, F (200V) 300 30,0 3,0 3,3 8,0 49 1955 10****** 5052 P, F (200V) 300 37,0 2,4 2,7 10,0 61 1956 16******
5001 P, F (500V) 120 0,75 557 620 0,065 0,3 1840 1,5****** 5002 P, F (500V) 120 1,1 382 425 0,095 0,5 1841 1,5****** 5003 P, F (500V) 120 1,5 279 310 0,25 0,9 1842 1,5****** 5004 P, F (500V) 120 2,2 189 210 0,285 1,2 1843 1,5****** 5005 P, F (500V) 120 3,0 135 150 0,43 1,7 1844 1,5****** 5006 P, F (500V) 120 4,0 99 110 0,6 2,3 1845 1,5****** 5008 P, F (500V) 120 5,5 72 80 0,85 3,3 1846 1,5****** 5011 P, F (500V) 120 7,5 58,5 65 1,0 3,9 1847 1,5****** 5016 P, F (500V) 120 11,0 36 40 2,0 7,1 1848 1,5****** 5022 P, F (500V) 120 15,0 27 30 2,8 9,7 1849 1,5****** 5027 P, F (500V) 120 18,5 22 25 3,5 12 1850 1,5****** 5032 P, F (500V) 120 22,0 18 20 4,0 14 1851 1,5****** 5042 P, F (500V) 120 30,0 13 15 4,8 18 1852 2,5****** 5052 P, F (500V) 120 37,0 10,8 12 5,5 21 1853 2,5****** 5060 P, F (500V)**** 300 45,0 7,0 7,8 12 39 N.A. 10****** 5062 P, F (500V) 120 45,0 9,8 9,8 15 39 2008 10****** 5072 P, F (500V) 120 55,0 7,3 7,3 13 42 0069 10****** 5075 P (500V)* 300 55,0 5,1 5,7 14 50 1958 10****** 5075 F (500V) * 600******* 55,0 5,1 5,7 21 61 0076 16****** 5100 P (500V)** 300 75,0 4,2 4,7 18 62 1959 16****** 5100 F (500V)** 600******* 75,0 4,2 4,7 29 79 0077 25****** 5102 P, F (500V) 120 75,0 5,7 6,33 15 49 0067 10****** 5125 P (500V) 300 90,0 3,4 3,8 22 76 1960 25****** 5125 F (500V) 600******* 90,0 3,4 3,8 36 97 0078 35****** 5150 P (500V) 300 110 2,9 3,2 27 92 1961 35****** 5150 F (500V) 600******* 110 2,9 3,2 42 115 0079 50****** 5200 P, F (500V) 300 132 2,3 2,6 32 111 1962 50****** 5250 P, F (500V) 300 160 1,9 2,1 39 136 1963 70******
Intermittent
braking period
time
[seconds]
P
motor
[kW]
R
[ ]
min
R
[ ]
rec
Pb,max
[kW]
Therm.
relay
[Amp]
Code
number
175Uxxxx
Cable cross
section
[mm
2
]
14
MI.90.F1.02 - VLT is a registered Danfoss trademark
VLT®2800/5000/5000 FLUX/FCD 300
VLT type
P=Process
F=FLUX
5300 P, F (500V) 300 200 3,14 3,3 56 130 2 x 1061*** 50****** 5350 P, F (500V) 300 250 2,47 2,6 72 166 2 x 1062*** 70****** 5450 P, F (500V) 300 315 2,19 2,3 90 198 2 x 1063*** 95****** 5500 P, F (500V) 300 355 2,00 2,1 100 218 2 x 1064*** 120******
5001 P (600V) 120 0,75 797 797 R.d. ***** N.A. 5002 P (600V) 120 1,1 534 534 R.d. ***** N.A. 5003 P (600V) 120 1,5 398 398 R.d. ***** N.A. 5004 P (600V) 120 2,2 267 267 R.d. ***** N.A. 5005 P (600V) 120 3,0 199 199 R.d. ***** N.A. 5006 P (600V) 120 4,0 149 149 R.d. ***** N.A. 5008 P (600V) 120 5,5 107 107 R.d. ***** N.A. 5011 P (600V) 120 7,5 80 80 R.d. ***** N.A. 5016 P (600V) 120 11,0 53,4 53,4 R.d. ***** N.A. 5022 P (600V) 120 15,0 39,8 39,8 R.d. ***** N.A. 5027 P (600V) 120 18,5 32,0 32,0 R.d. ***** N.A. 5032 P (600V) 120 22,0 26,7 26,7 R.d. ***** N.A. 5042 P (600V) 120 30,0 19,9 19,9 R.d. ***** N.A. 5052 P (600V) 120 37,0 16,0 16,0 R.d. ***** N.A. 5062 P (600V) 120 45,0 13,3 13,3 R.d. ***** N.A. 5075 P (600V) 300 55,0 11,0 11,0 R.d. ***** N.A. 5100 P (600V) 300 75,0 8,2 8,2 R.d. ***** N.A. 5125 P (600V) 300 90,0 6,8 6,8 R.d. ***** N.A. 5150 P (600V) 300 110 5,6 5,6 R.d. ***** N.A. 5200 P (600V) 300 132 4,3 4,3 R.d. ***** N.A. 5250 P (600V) 300 160 3,3 3,3 R.d. ***** N.A.
Intermittent
braking period
time
[seconds]
P
motor
[kW]
R
[ ]
min
R
[ ]
rec
Pb,max
[kW]
Therm.
relay
[Amp]
Code
number
175Uxxxx
Cable cross
section
[mm
2
]
overview
Brake resistor
*to be replaced by VLT 5072 **to be replaced by VLT 5102 ***Order 2 pcs. ****Replaced by VLT 5062
*****Itherm relay = ******Always observe national and local regulations ******* Please observe drawing at VLT 5000 FLUX parameters
P
motor
R
min
R
rec
P
b, max
: Rated motor size for VLT type : Minimum permissible brake resistor : Recommended brake resistor (Danfoss)
: Brake resistor rated power as stated by supplier Therm. relay : Brake current setting of thermal relay Code number : Order numbers for Danfoss brake resistors Cable cross section : Recommended m
inimum value based upon PVC insulated cober cable, 30
degree Celsius ambient temperature with normal heat dissipation R.d. : Resistor dependent
MI.90.F1.02 - VLT is a registered Danfoss trademark
15
Brake resistor for VLT 5001-5102 40% duty-cycle
data and codenumber
VLT®2800/5000/5000 FLUX/FCD 300
VLT type P=Process F=FLUX
5001 P, F (200V) 120 0,75 130 145 0,26 1,3 1920 1,5** 5002 P, F (200V) 120 1,1 81 90 0,43 2,2 1921 1,5** 5003 P, F (200V) 120 1,5 58 65 0,8 3,5 1922 1,5** 5004 P, F (200V) 120 2,2 45 50 1,0 4,5 1923 1,5** 5005 P, F (200V) 120 3,0 31 35 1,35 6,2 1924 1,5** 5006 P, F (200V) 120 4,0 22 25 3,0 11,0 1925 1,5** 5008 P, F (200V) 120 5,5 18 20 3,5 13,0 1926 1,5** 5011 P, F (200V) 120 7,5 13 15 5,0 18,0 1927 2,5** 5016 P, F (200V) 120 11,0 9 10 9,0 30,0 1928 10** 5022 P, F (200V) 120 15,0 6,5 7 10,0 38,0 1929 16** 5027 P, F (200V) 120 18,5 5,2 6 12,7 46,0 1930 16**
5001 P, F (500V) 120 0,75 557 620 0,26 0,6 1940 1,5** 5002 P, F (500V) 120 1,1 382 425 0,43 1,0 1941 1,5** 5003 P, F (500V) 120 1,5 279 310 0,8 1,6 1942 1,5** 5004 P, F (500V) 120 2,2 189 210 1,35 2,5 1943 1,5** 5005 P, F (500V) 120 3,0 135 150 2,0 3,7 1944 1,5** 5006 P, F (500V) 120 4,0 99 110 2,4 4,7 1945 1,5** 5008 P, F (500V) 120 5,5 72 80 3,0 6,1 1946 1,5** 5011 P, F (500V) 120 7,5 59 65 4,5 8,3 1947 1,5** 5016 P, F (500V) 120 11,0 36 40 5,0 11 1948 1,5** 5022 P, F (500V) 120 15,0 27 30 9,3 18 1949 2,5** 5027 P, F (500V) 120 18,5 22 25 12,7 23 1950 4** 5032 P, F (500V) 120 22,0 18 20 13,0 25 1951 4** 5042 P, F (500V) 120 30,0 14 15 15,6 32 1952 10** 5052 P, F (500V) 120 37,0 10 12 19,0 40 1953 16** 5062 P, F (500V) 120 45,0 9,8 9,8 38,0 62 2007 16** 5072 P, F (500V) 120 55,0 7,3 7,3 38,0 72 0068 25** 5102 P, F (500V) 120 75,0 5,7 6,0 45,0 87 0066 25** 5125 F (500V) 600*** 90,0 3,4 3,8 75 140 2 x 0072 2x70** 5150 F (500V) 600*** 110 2,9 3,2 90 168 2 x 0073 2x70**
Intermittent braking period time [seconds]
P
motor
[kW]
R
[ ]
min
R
[ ]
rec
P
b, max
[kW]
Therm.re-
lay
[Amp]
Code
number
175Uxxxx
Cable cross
section
2
[mm
]
5001 P (600V) 120 0,75 797 797 R.d. * N.A. 5002 P (600V) 120 1,1 534 534 R.d. * N.A. 5003 P (600V) 120 1,5 398 398 R.d. * N.A. 5004 P (600V) 120 2,2 267 267 R.d. * N.A. 5005 P (600V) 120 3,0 199 199 R.d. * N.A. 5006 P (600V) 120 4,0 149 149 R.d. * N.A. 5008 P (600V) 120 5,5 107 107 R.d. * N.A. 5011 P (600V) 120 7,5 80 80 R.d. * N.A. 5016 P (600V) 120 11,0 53,4 53,4 R.d. * N.A. 5022 P (600V) 120 15,0 39,8 39,8 R.d. * N.A. 5027 P (600V) 120 18,5 32,0 32,0 R.d. * N.A.
16
MI.90.F1.02 - VLT is a registered Danfoss trademark
VLT®2800/5000/5000 FLUX/FCD 300
VLT type P=Process F=FLUX
5032 P (600V) 120 22,0 26,7 26,7 R.d. * N.A. 5042 P (600V) 120 30,0 19,9 19,9 R.d. * N.A. 5052 P (600V) 120 37,0 16,0 16,0 R.d. * N.A. 5062 P (600V) 120 45,0 13,3 13,3 R.d. * N.A.
*Itherm relay = **Always observe national and local regulations *** Please observe drawing at VLT 5000 Flux parameters
P
motor
R
min
R
rec
P
b, max
Intermittent braking period time [seconds]
: Rated motor size for VLT type : Minimum permissible brake resistor : Recommended brake resistor (Danfoss) : Brake resistor rated power as stated by supplier
P
motor
[kW]
R
[ ]
min
R
[ ]
rec
P
b, max
[kW]
Therm.re-
lay
[Amp]
number
175Uxxxx
Therm. relay : Brake current setting of thermal relay Code number : Order numbers for Danfoss brake resistors Cable cross section : Recommended m
inimum value based upon PVC insulated cober cable, 30
degree Celsius ambient temperature with normal heat dissipation
R.d. : Resistor dependent
Code
Cable cross
section
2
[mm
]
overview
Brake resistor
Brake resistor for VLT 2803-2882 duty-cycle
40% data and codenumber
VLT type Intermit-
tent brak-
ing period
time
[seconds]
2803 (200V) 120 0,37 297 330 0,16 0,7 1900* 1,5** 2805 (200V) 120 0,55 198 220 0,25 1,1 1901* 1,5** 2807 (200V) 120 0,75 135 150 0,32 1,5 1902* 1,5** 2811 (200V) 120 1,1 99 110 0,45 2,0 1975* 1,5** 2815 (200V) 120 1,5 74 82 0,85 3,2 1903* 1,5** 2822 (200V) 120 2,2 50 56 1,00 4,2 1904* 1,5** 2840 (200V) 120 3,7 22 25 3,00 11,0 1925 1,5**
2805 (400V) 120 0,55 747 830 0,45 0,7 1976* 1,5** 2807 (400V) 120 0,75 558 620 0,32 0,7 1910* 1,5** 2811 (400V) 120 1,1 387 430 0,85 1,4 1911* 1,5** 2815 (400V) 120 1,5 297 330 0,85 1,6 1912* 1,5** 2822 (400V) 120 2,2 198 220 1,00 2,1 1913* 1,5** 2830 (400V) 120 3,0 135 150 1,35 3,0 1914* 1,5** 2840 (400V) 120 4,0 99 110 1,60 3,8 1979* 1,5** 2855 (400V) 120 5,5 80 80 2,00 5,0 1977* 1,5** 2875 (400V) 120 7,5 56 56 3,00 6,8 1978* 1,5** 2880 (400V) 120 11 40 40 5,00 11,2 1997* 1,5** 2881 (400V) 120 15 30 30 10,0 18,3 1998 2,5** 2882 (400V) 120 18,5 25 25 13,0 22,8 1999 4**
P
motor
[kW]
R
min
[ ]
R
[ ]
rec
P
b, max
[kW]
Therm.re-
lay
[Amp]
Code
number
175Uxxxx
Cable cross
section
2
[mm
]
*With KLIXON switch **Always observe national and local regulations
MI.90.F1.02 - VLT is a registered Danfoss trademark
17
Brake resistor for VLT FCD 303-335 duty-cycle
40% data and codenumber
VLT®2800/5000/5000 FLUX/FCD 300
VLT type Intermit-
tent brak-
ing period
time
[seconds]
303 (400 V) 120 0,37 520 830 0,45 0,7 1976 1,5* 305 (400 V) 120 0,55 405 830 0,45 0,7 1976 1,5* 307 (400 V) 120 0,75 331 620 0,32 0,7 1910 1,5* 311 (400 V) 120 1,1 243 430 0,85 1,4 1911 1,5* 315 (400 V) 120 1,5 197 330 0,85 1,6 1912 1,5* 322 (400 V) 120 2,2 140 220 1,00 2,1 1913 1,5* 330 (400 V) 120 3,0 104 150 1,35 3,0 1914 1,5* 335 (400 V) 120 3,3 104 150 1,35 3,0 1914 1,5*
*Always observe national and local regulations
P
motor
R
min
R
rec
P
b, max
P
motor
[kW]
R
min
[ ]
R
[ ]
rec
P
b, max
[kW]
: Rated motor size for VLT type : Minimum permissible brake resistor : Recommended brake resistor (Danfoss) : Brake resistor rated power as stated by supplier
Therm.re-
lay
[Amp]
Code
number
175Uxxxx
Therm. relay : Brake current setting of thermal relay Code number : Order numbers for Danfoss brake resistors Cable cross section : Recommended m
inimum value based upon PVC insulated cober cable, 30
degree Celsius ambient temperature with normal heat dissipation
Cable cross
section
2
[mm
]
18
MI.90.F1.02 - VLT is a registered Danfoss trademark
Brake resistor for VLT 5001-5500 10% duty-cycle
cablegland, weight and drawing no.
VLT®2800/5000/5000 FLUX/FCD 300
VLT type
P=Process
F=FLUX
5001 P, F (200V) PG 9 1,1 1820 1 5002 P, F (200V) PG 9 1,1 1821 1 5003 P, F (200V) PG 9 2,1 1822 3 5004 P, F (200V) PG 9 2,1 1823 3 5005 P, F (200V) PG 9 2,2 1824 4 5006 P, F (200V) PG 9 3,0 1825 6 5008 P, F (200V) PG 9 3,5 1826 7 5011 P, F (200V) PG 16 5,8 1827 9 5016 P, F (200V) PG 21 13,5 1828 12 5022 P, F (200V) PG 21 15,0 1829 12 5027 P, F (200V) PG 21 16,5 1830 12 5032 P, F (200V) PG 21 19,0 1954 12 5042 P, F (200V) PG 21 20,0 1955 13 5052 P, F (200V) PG 21 32,0 1956 14
5001 P, F (500V) PG 9 1,1 1840 1 5002 P, F (500V) PG 9 1,2 1841 2 5003 P, F (500V) PG 9 2,1 1842 3 5004 P, F (500V) PG 9 2,1 1843 3 5005 P, F (500V) PG 9 2,2 1844 4 5006 P, F (500V) PG 9 2,4 1845 5 5008 P, F (500V) PG 9 3,0 1846 6 5011 P, F (500V) PG 9 3,5 1847 7 5016 P, F (500V) PG 16 5,8 1848 9 5022 P, F (500V) PG 16 13,5 1849 12 5027 P, F (500V) PG 16 15,0 1850 12 5032 P, F (500V) PG 16 15,0 1851 12 5042 P, F (500V) PG 21 16,5 1852 12 5052 P, F (500V) PG 21 19,0 1853 12 5062 P, F (500V) PG 21 36,0 2008 15 5072 P, F (500V) PG 21 40,0 0069 15 5075 P (500V) PG 21 49,0 1958 15 5075 F (500V) PG 29 65,0 0076 17 5100 P (500V) PG 21 52,0 1959 15 5100 F (500V) PG 36 67,0 0077 17 5102 P, F (500V) PG 21 40,0 0067 15 5125 P (500V) PG 29 56,0 1960 16 5125 F (500V) PG 36 90,0 0078 18 5150 P (500V) PG 29 66,0 1961 17 5150 F (500V) PG 36 94,0 0079 18 5200 P, F (500V) PG 36 72,0 1962 17 5250 P, F (500V) PG 36 125,0 1963 18 5300 P, F (500V) PG 36 70/pcs 2 x 1061 2x17 5350 P, F (500V) PG 36 90/pcs 2 x 1062 2x18 5450 P, F (500V) PG 36 90/pcs 2 x 1063 2x18 5500 P, F (500V) PG 42 125/pcs 2 x 1064 2x19
Cablegland Weight
[kg]
Code
number
175Uxxxx
Drawing
No.
overview
Brake resistor
MI.90.F1.02 - VLT is a registered Danfoss trademark
19
Brake resistor for VLT 5001-5102 40% duty-cycle
cablegland, weight and drawing no.
VLT®2800/5000/5000 FLUX/FCD 300
VLT type
P=Process
F=FLUX
5001 P, F (200V) PG 9 2,1 1920 3 5002 P, F (200V) PG 9 2,2 1921 4 5003 P, F (200V) PG 9 3,0 1922 6 5004 P, F (200V) PG 9 3,5 1923 7 5005 P, F (200V) PG 16 4,6 1924 8 5006 P, F (200V) PG 16 13,5 1925 12 5008 P, F (200V) PG 16 15,0 1926 12 5011 P, F (200V) PG 21 16,5 1927 12 5016 P, F (200V) PG 21 25,0 1928 14 5022 P, F (200V) PG 21 25,0 1929 14 5027 P, F (200V) PG 21 32,0 1930 15
5001 P, F (500V) PG 9 2,1 1940 3 5002 P, F (500V) PG 9 2,2 1941 4 5003 P, F (500V) PG 9 3,0 1942 6 5004 P, F (500V) PG 16 4,6 1943 8 5005 P, F (500V) PG 16 5,8 1944 9 5006 P, F (500V) PG 16 7,2 1945 10 5008 P, F (500V) PG 16 7,6 1946 11 5011 P, F (500V) PG 16 16,5 1947 12 5016 P, F (500V) PG 16 17,0 1948 12 5022 P, F (500V) PG 21 25,0 1949 14 5027 P, F (500V) PG 21 32,0 1950 14 5032 P, F (500V) PG 21 34,0 1951 15 5042 P, F (500V) PG 21 35,0 1952 15 5052 P, F (500V) PG 29 47,0 1953 16 5062 P, F (500V) PG 36 95,0 2007 18 5072 P, F (500V) PG 36 125 0068 18 5102 P, F (500V) PG 36 150 0066 18 5125 F (500V) PG 36 90/pcs 2 x 0072 2x18 5150 F (500V) PG 36 95/pcs 2 x 0073 2x18
Cablegland Weight
[kg]
Code
number
175Uxxxx
Drawing
No.
20
MI.90.F1.02 - VLT is a registered Danfoss trademark
Brake resistor for VLT 2803-2882 40% duty-cycle
cablegland, weight and drawing no.
VLT®2800/5000/5000 FLUX/FCD 300
VLT type Cablegland Weight
[kg]
2803 (200 V) PG 7 (Thermo) / PG 9 (power) 1,2 1900 2 2805 (200 V) PG 7 (Thermo) / PG 9 (power) 2,1 1901 3 2807 (200 V) PG 7 (Thermo) / PG 9 (power) 2,1 1902 3 2811 (200 V) PG 7 (Thermo) / PG 9 (power) 2,2 1975 4 2815 (200 V) PG 7 (Thermo) / PG 9 (power) 2,4 1903 5 2822 (200 V) PG 7 (Thermo) / PG 9 (power) 3,5 1904 7 2840 (200 V) PG 16 13,5 1925 12
2805 (400 V) PG 7 (Thermo) / PG 9 (power) 2,2 1976 4 2807 (400 V) PG 7 (Thermo) / PG 9 (power) 2,2 1910 4 2811 (400 V) PG 7 (Thermo) / PG 9 (power) 2,4 1911 5 2815 (400 V) PG 7 (Thermo) / PG 9 (power) 3,0 1912 6 2822 (400 V) PG 7 (Thermo) / PG 9 (power) 3,5 1913 7 2830 (400 V) PG 7 (Thermo) / PG 16 (power) 4,6 1914 8 2840 (400 V) PG 7 (Thermo) / PG 16 (power) 4,6 1979 8 2855 (400 V) PG 7 (Thermo) / PG 16 (power) 5,8 1977 9 2875 (400 V) PG 7 (Thermo) / PG 16 (power) 7,6 1978 11 2880 (400 V) PG 21 17 1997 12 2881 (400 V) PG 21 25 1998 14 2882 (400 V) PG 21 34 1999 15
Code
number
175Uxxxx
Drawing
No.
overview
Brake resistor
Brake resistor for VLT FCD 303-335 40% duty-cycle
cablegland, weight and drawing no.
VLT type Cablegland Weight
303 (400 V) PG 7 (Thermo) / PG 9 (power) 2,2 1976 4 305 (400 V) PG 7 (Thermo) / PG 9 (power) 2,2 1976 4 307 (400 V) PG 7 (Thermo) / PG 9 (power) 2,2 1910 4 311 (400 V) PG 7 (Thermo) / PG 9 (power) 2,4 1911 5 315 (400 V) PG 7 (Thermo) / PG 9 (power) 3,0 1912 6 322 (400 V) PG 7 (Thermo) / PG 9 (power) 3,5 1913 7 330 (400 V) PG 7 (Thermo) / PG 16 (power) 4,6 1914 8 335 (400 V) PG 7 (Thermo) / PG 16 (power) 4,6 1914 8
[kg]
Code
number
175Uxxxx
Drawing
No.
MI.90.F1.02 - VLT is a registered Danfoss trademark
21
Drawing no. 1
Drawing no. 2
VLT®2800/5000/5000 FLUX/FCD 300
Drawing no. 3
22
MI.90.F1.02 - VLT is a registered Danfoss trademark
Drawing no. 4
Drawing no. 5
VLT®2800/5000/5000 FLUX/FCD 300
- 19
Drawing no. 6
Drawings 1
MI.90.F1.02 - VLT is a registered Danfoss trademark
23
Drawing no. 7
Drawing no. 8
VLT®2800/5000/5000 FLUX/FCD 300
Drawing no. 9
24
MI.90.F1.02 - VLT is a registered Danfoss trademark
Drawing no. 10
VLT®2800/5000/5000 FLUX/FCD 300
Drawing no. 11
Drawing no. 12
- 19
Drawings 1
MI.90.F1.02 - VLT is a registered Danfoss trademark
25
Drawing no. 13
Drawing no. 14
VLT®2800/5000/5000 FLUX/FCD 300
Drawing no. 15
Drawing no. 16
26
MI.90.F1.02 - VLT is a registered Danfoss trademark
Drawing no. 17
Drawing no. 18
VLT®2800/5000/5000 FLUX/FCD 300
- 19
Drawings 1
MI.90.F1.02 - VLT is a registered Danfoss trademark
27
Drawing no. 19
VLT®2800/5000/5000 FLUX/FCD 300
28
MI.90.F1.02 - VLT is a registered Danfoss trademark
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