Lenze 6034 User Manual

EDB6032_G/GB
00376698

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Antriebstechnik
Operating Instructions

Brake chopper
6032/6033/6034

These operating instructions are valid for the devices with the nameplate data:

6032_G.2E
6033_G.2E
6034_G.1A

Type
Built-in device IP00
Hardware version +

index

Corrected edition of: 09.01.1995
Date of print: 16.01.1995

How to use these Operating Instructions...

To locate information on specific topics, simply refer to the table of
contents at the beginning of these Operating Instructions.

These Operating Instructions use a series of different symbols to
provide quick reference and to highlight important items.

This symbol refers to items of information intended to facilitate
operation.

Notes which should be observed to avoid possible damage to or
destruction of equipment.

Notes which should be observed to avoid health risks to the
operating personnel.

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1

Safety information

The equipment described is intended for use in industrial drive
systems.

This equipment can endanger life through rotating machinery and
high voltages, therefore it is essential that guards for both electrical
and mechanical parts are not removed.

The following points should be observed for the safety of the
personnel:

• Only qualified personnel familiar with the equipment are

permitted to install, operate and maintain the devices

• System documentation must be available and observed at all

times.

• All non-qualified personnel must be kept at a safe distance

from the equipment.

• The system must be installed in accordance with local

regulations.

A qualified person is someone who is familiar with all safety notes
and established safety practices, with the installation, operation and
maintenance of this equipment and the hazards involved. For more
detailed definitions see IEC 364.

These safety notes do not represent a complete list of the steps
necessary to ensure safe operation of the equipment. For further
information, please contact your nearest Lenze representative.

The information given in these Operating Instructions only apply to
the hardware and software versions that are indicated on the cover
page. If the version of your equipment is not listed these Operating
Instructions must not be used. Lenze cannot be held responsible for
any malfunction resulting from the above.

The specifications, processes and circuitry described in these
Operating Instructions are for guidance only and must be adapted
to your own specific applications. Lenze does not guarantee the
suitability of the processes and circuitry described in these
Operating Instructions for individual applications.

The specifications in these Operating Instructions describe the
features of the products without guarantee.

Lenze personnel have carefully checked these Operating
Instructions and the equipment described, but cannot be held
responsible for its accuracy.

2

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Content

1. Features 4

1.1. Scope of delivery 4

2. Technical data 4

3. Dimensions and installation 5

3.1. Installation of brake choppers 5

3.2. Dimensions 5

4. Selection of the brake resistors 6

4.1. Selection tables for brake resistors 7

4.2. Dimensions of brake resistors 8

4.2.1. Resistor with integrated temperature monitoring (50 to 200W) 8

4.2.2. Screened wire-wound resistors equipped with integrated temperature monitoring
(300 and 600W) 8

4.3. Brake chopper connection 9

4.3.1. Brake chopper 6032G with frequency inverters 8201-8204 9

4.3.2. Brake choppers 6033G and 6034G with frequency inverters 8211-8216 10

5. Operation 11

5.1. Parallel connection of brake choppers 11

6. Accessories 11

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3

1. Features

The brake choppers 6032, 6033 und 6034 are additional
components for frequency inverters with DC bus.

In generator mode, e.g. during deceleration of the drive, the
machine feeds back energy into the DC bus of the controller. If, as
a result, the DC bus voltage exceeds the maximum permissible
value, pulse inhibit will be set and "Overvoltage" will be displayed.
As soon as the voltage falls below this maximum permissible value,
the controller will be enabled again.

• Enclosure IP00 for cabinet assembly

• Assembly on DIN rails, alternatively assembly on module

resistors

• Dissipation of brake energy in form of heat

• Very short brake times possible

• If not defined, the controller will not set pulse inhibit during

braking

1.1. Scope of delivery

• Brake chopper

• Snap-on assembly kit for DIN rails

• Operating Instructions

2. Technical data

Brake chopper 6032_G 6033_G 6034_G

Order no. 33.6032_G 33.6033_G 33.6034_G
Article no. 340 917 340 918 366 190
Supply voltage
Switching threshold
Permanent brake power
Peak brake power
Max. brake enery
Smallest brake resis tor
Temperature range 0 - 45°C
Storage temperature -20°C to +70°C
Humidity Humidity class G to DIN 40040

The following brake chopper types are available:

• 6032G:

For frequency inverters with single-phase mains connection
(V

230V∼) e.g. 8201-8204.

rated

• 6033G:

For frequency inverters with three-phase mains connection
(V

400V∼) e.g. B. 8211-8216.

rated

• 6034G:

For frequency inverters with three-phase mains connection
(V

460V∼ for application in e.g. USA) e.g. 8211-8215.

rated

270-380VDC

375VDC

1.5kW

3.0kW

60kWs

47Ω

470-660VDC

650VDC

2.6kW

5.1kW

100kWs

82Ω

max. 85%, no condensati on

520-730VDC

725VDC

2.6kW

5.1kW

100kWs

100Ω

4

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3. Dimensions and installation

3.1. Installation of brake choppers

The housing must be assembled vertically, terminals at the bottom.
To ensure the unimpeded cooling air circulation, a free space of
100 mm at the top and the bottom is required. The ambient
temperature may not exceed +45°C.

3.2. Dimensions

Dimension of the brake chopper:

Brake Chopper

ON

g

bd

630

ae

Brake chopper
Type a

mm

6032_G
6033_G 45 109 95 127 4.5
6034_G

b
mm

d
mm

e
mm

g
mm

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5

4. Selection of the brake resistors

The resistance is calculated as follows:

Resistance [ ] =

The value may not fall below the minimum resistance of the brake
chopper. Otherwise, the unit might be destroyed.

After having calculated the resistance, determine the rated
power of the brake resistor for cyclic braking operation.

For most applications, the brake time remains under 15s. In cyclic
braking operations, the relative ON period does not exceed max.
10%.

Rated power [W] =

For single or cyclic braking operations the heat capacity of the
brake resistor is calculated as follows:

Heat capacity kWs = ON period s peak brake power W⋅required

To avoid a thermal overload of the resistor, the heat capacity of the
brake resistor must be considered (if necessary please contact the
manufacturer).

Ω

(Threshold)2 [V]

required peak power [W]

ON period [s]
Cycle time [s]

2

required peak brake power [W]⋅

Brake resistors may reach surface temperatures of up to 350°C.
Therefore the resistors mentioned above are equipped with
temperature monitoring. When using other brake resistors, an
appropriate overcurrent/overtemperature protection, e.g. thermal
overcurrent sensors, must be provided.

The thermostats of the brake resistors should be used to
disconnect the inverter from the mains in case of overheating (see
pages 9 and 10).

6

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4.1. Selection tables for brake resistors

Selection table for frequency inverters with a mains voltage of 190...260V (6032G):

Rated motor
power/kW

0.37 470 50 ERBM470R050W 360115

0.75 200 100 ERBM200R100W 360114

1.5 100 150 ERBM100R150W 360113

2.2 82 200 ERBM082R200W 360112

Brake resistor

Resistance/Ω Continuous power/W Order no. Article no.

Selection table for frequency inverters with a mains voltage of 330...450V (6033G):

Rated motor
power/kW

0.75 470 100 ERBM470R050W 361839

1.5 370 150 ERBM370R150W 357872

2.2 240 200 ERBM240R200W 357874

3.0 180 300 ERBD180R300W 357875

4.0 100 600 ERBD100R600W 357876

5.5 82 600 ERBD082R600W 365902

Brake resistor

Resistance/Ω Continuous power/W Order no. Article no..

Selection table for frequency inverters with a mains voltage of 370...510V (6034G):

Rated motor
power/kW

0.75 470 100 ERBM470R050W 361839

1.5 370 150 ERBM370R150W 357872

2.2 240 200 ERBM240R200W 357874

3.0 180 300 ERBD180R300W 357875

4.0 100 600 ERBD100R600W 357876

Brake resistor

Resistance/Ω Continuous power/W Order no. Article no..

All brake resistors are equipped with integrated temperature
protection which must be used as safety protection (see pages 9
and 10).

When using other brake resistors, appropriate
overcurrent/overtemperature protection, e.g. thermal overcurrent
sensors etc. must be provided.

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7

4.2. Dimensions of brake resistors

4.2.1. Resistor with integrated temperature monitoring
(50 to 200W)

e

c

a

P/W R/Ω Order no. a

50 470 ERBM470R050W 60 240 50 225 60 5 7.5
100 470 ERBM470R100W 70 240 50 225 60 5 7.5
100 200 ERBM200R100W 80 160 70 145 95 5 7.5
150 370 ERBM370R150W 80 240 70 225 95 5 7.5
150 100 ERBM100R150W 80 240 70 225 95 5 7.5
200 240 ERBM240R200W 80 340 70 325 70 5 7.5
200 82 ERBM082R200W 80 340 70 325 70 5 7.5

k

b

mm

mm

c
mm

d

bg

d
mm

e
mm

g
mmkmm

4.2.2. Screened wire-wound resistors equipped with integrated
temperature monitoring (300 and 600W)

e

d

b

g

f

c

a

P/W R/Ω Order no. a

mm

300 180 ERBD180R300W 479 89 430 64 115 326 13
600 100 ERBM100R600W 579 89 530 64 115 426 13
600 82 ERBM082R600W 579 89 530 64 115 426 13

8

b
mm

c
mm

d
mm

e
mm

f
mm

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k
mm

4.3. Brake chopper connection

4.3.1. Brake chopper 6032G with frequency inverters 8201-8204

L1

N
PE

K1

Off

On

ϑ

RB

K1

The cross section of the PE
connection must be at least as
large as the cross section of the
power connection.

Cable protection

Mains contactor

K1

Brake
resistor
RB

RB1

RB2

+UG -UG

6032G

Brake chopper

Motor choke /
motor voltage
filter

+UG

-UG

Filter

L1

N

8201E to 8204E

U

V

W

Mains choke

Operation of 8204E only wi th
assigned mains choke

Mains filter

PE and screen connections
at inverter

Caution! All power terminals remain
live up to 3 minutes after mains
disconnection

Screened cabl es and mains filter
are required for radio interference
suppression to EN 55011.
Level A or B

Terminal bus in control cabinet

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PE

M

3~

For group drives a motor protection
relay is necessary.
PTC thermistors or thermostats
are recommended for temperature
monitoring

∆

Motor interconnection:

at 230/400V

9

4.3.2. Brake choppers 6033G and 6034G with frequency inverters
8211-8216

L1
L2

L3

N

PE

K1

Off

On

ϑ

K1

RB

K1

K1

K1

The cross section of the PE has to be
at least as large as the cross section
of the power connection

Cable protection fuse

Mains cont actor

Mains choke
Operation of 8214E and 8218E only

with assigned mains choke

Brake
resistor
RB

RB1 RB2

+UG

6033G
6034G

Brake chopper

Motor choke /
motor voltage
filter

-UG

+UG

-UG

Filter

L1

L2

L3

8211E to 8218E

W

UV

Mains filter

PE and screen connection at
inverter

Caution! All power terminals remain
live up to 3 minutes after mains
disconnection

Screened cables and mains filters
are required for radio interference
suppression to EN 55011.

Terminal bus in control cabinet

10

PE

M

3~

For group drives a motor protection
relay is necessary.
PTC thermistors or thermostats are
recommended for temperature
monitoring

Motor interconnection:

Y at 230/400V

∆

at 400/690V

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5. Operation

• It is absolutely necessary to check the connection of the

terminals +U
destruction of the brake chopper and the frequency inverter.

• In case of mains overvoltage the brake chopper may be

activated. When using resistors without overload protection the
resistor may be destroyed. Therefore, only resistors equipped
with integrated or external temperature monitoring must be
fitted.

• All brake resistors recommended by Lenze are equipped with

an integrated temperature monitoring.

• Due to the application of the brake chopper, the inverter exactly

follows the programmed deceleration time. However, if the
feedback power exceeds the peak power of the assigned brake
resistor, the inverter will be inhibited and will display
"Overvoltage". This results in an uncontrolled prolongation of
the deceleration time. To overcome this problem, you must
either prolong the Tif time or, if possible, select a lower-value
brake resistor.

• LED ON (yellow) indicates the release of the brake chopper.

and -U

G

Incorrect connection may cause

G.

5.1. Parallel connection of brake choppers

With high brake powers it may be necessary to reduce the brake
resistance to the minimum permissible value (see table page 7). If
this is not enough, two brake choppers can be connected to double
the peak power. In this case, please note the following:

• Each brake chopper must be separately connected to +U

-U

of the frequency inverter.

G

• Each brake chopper must be connected to a separate brake

resistor (terminals RB1 and RB2).

• The thermostats of the brake resistors (break contacts) must be

connected in series.

• The lowest resistance must not be smaller than the one

indicated in the Technical Data of the specific brake chopper.

G

and

6. Accessories

The brake chopper can also be assembled on module resistors by
means of an assembly kit. This kit can be ordered under the order
no. ER00370969.

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11

12

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