EDB8250EN
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!PM8
Ä!PM8ä
Operating Instructions
(T1) (T2)
-UG +UG RB1 RB2 PE
Brake unit
8250 series
These Operating Instructions are valid for brake units with the following nameplate
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data:
825X E. 0x (8251 - 8253)
In connection with the unit series as from the nameplate data:
820X E. 0x. 0x. (8201 - 8204)
821X E. 0x. 0x. (8211 - 8218)
Type
Design:
E = Enclosure IP20
IB = Module
Hardware level and index
Software level and index
Variant
Explanation
Edition of: 10/1996 01/1997 09/2003
revised
1
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1
1
1
Pos. Name/
Meaning
Note
(T1) (T2)
(T1) (T2)
(T1) (T2)
(T1) (T2)
-UG +UG RB1 RB2 PE
-UG +UG RB1 RB2 PE
-UG +UG RB1 RB2 PE
-UG +UG RB1 RB2 PE
1 Brake unit D 8251/8252 brake module
D 8253 brake chopper
2
2
2
2
2 LED Display of the operating state
D green:
flashing, when voltage is
applied to terminals +U
G
,-U
G
D yellow:
- flashing, when brake unit is
in braking operation
- Display of faults:
see chapter 6, page 6-1
3 Connections D Voltage link:
3
3
3
3
,-U
+U
G
G
only 8251/8252 brake module:
D Thermostat: T1, T2
only 8253 brake chopper:
D Brake resistor: RB1, RB2
Safety and application notes
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for controllers
(according to: Low-Voltage Directive 73/23/EEC)
1. General
During operation, drive controllers may have, according to their type of protection, live,
bare, in some cases also movable or rotating parts as well as hot surfaces.
Unauthorized removal of the required cover, inappropriate use, incorrect installation or
operation, creates the risk of severe personal injury or damage to material assets.
Further information can be obtained from the documentation.
All operations concerning transport, installation, and commissioning as well as
maintenance must be carried out by qualified, skilled personnel (IEC 364 and CENELEC
HD 384 or DIN VDE 0100 and IEC report 664 or DIN VDE 0110 and national regulations
for the prevention of accidents must be observed).
Qualified skilled personnel according to this basic safety information are persons who are
familiar with the erection, assembly, commissioning, and operation of the product and
who have the qualifications necessary for their occupation.
2. Application as directed
Drive controllers are components which are designed for installation in electrical systems
or machinery.
When installing in machines, commissioning of the drive controllers (i.e. the starting of
operation as directed) is prohibited until it is proven that the machine corresponds to the
regulations of the EC Directive 89/392/EWG (Machinery Directive); EN 60204 must be
observed.
Commissioning (i.e. starting of operation as directed) is only allowed when there is
compliance with the EMC Directive (89/336/EWG).
The drive controllers meet the requirements of theLow-Voltage Directive 73/23/EWG. The
harmonized standards of the prEN 50178/ DIN VDE 0160 series together with EN
60439-1/DIN VDE 0660 part 500 and EN 60146/DIN VDE 0558 are applicable to drive
controllers.
The technical data and information on the connection conditions must be obtained from
the nameplate and the documentation and must be observed in all cases.
3. Transport, storage
Notes on transport, storage and appropriate handling must be observed.
Climatic conditions must be observed according to prEN 50178.
4. Erection
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The devices must erected and cooled according to the regulations of the corresponding
documentation.
The drive controllers must be protected from inappropriate loads. Particularly during
transport and handling, components must not be bent and/or isolating distances must not
be changed. Touching of electronic components and contacts must be avoided.
Drive controllers contain electrostatically sensitive components which can easily be
damaged by inappropriate handling.Electrical components must not be damaged or
destroyed mechanically (health risks are possible!).
5. Electrical connection
When working on live drive controllers the valid national regulations for the prevention of
accidents (e.g. VBG 4) must be observed.
The electrical installation must be carried out according to the appropriate regulations
(e.g. cable cross-sections, fuses, PE connection). More detailed information is included
in the documentation.
Notes concerning the installation in compliancewith EMC - su ch as screening, grounding,
arrangement of filters and laying of cables - are included in the documentation of thedrive
controllers.These notes must also be observed in all cases for drive controllers with the
CE mark. The compliance with the required limit values demanded by the EMC legislation
is in the responsibility of the manufacturer of the system or machine.
6. Operation
Systems where drive controllers are installed must be equipped, if necessary, with
additional monitoring and protective devices according to the valid safety regulations, e.g.
law on technical tools, regulations for the prevention of accidents, etc. Modifications of
the drive controllers by the operating software are allowed.
After disconnecting the drive controllers from the supply voltage, live parts of the
controller and power connections must not be touched immediately, because of possibly
charged capacitors. For this, observe the corresponding labels on the drive controllers.
During operation, all covers and doors must be closed.
7. Maintenance and servicing
The manufacturer’s documentation must be observed.
This safety information must be preserved!
The product-specific safety and application notes in these operating instructions must
also be observed!
Contents
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1 Preface and general information 1-1.................
1.1 About these Operating Instructions ... 1-1.....................
1.1.1 Terminology used 1-1............................
1.1.2 What is new? 1-1...............................
1.2 Scope of delivery 1-2...................................
1.3 825X brake units 1-2...................................
1.3.1 Labelling 1-2..................................
1.3.2 Application as directed 1-3........................
1.3.3 Legal regulations 1-4............................
2 Safety information 2-1............................
2.1 Personnel responsible for safety 2-1.........................
2.2 General safety information 2-2.............................
2.3 Layout of the safety information 2-3.........................
2.4 Residual hazards 2-4...................................
3 Technical data 3-1...............................
3.1 Features 3-1.........................................
3.2 General data /operating conditions 3-2.......................
3.3 Rated data 3-3........................................
3.3.1 Brake units 3-3.................................
3.3.2 Assignment table for brake resistors 3-3...............
3.3.3 Overcurrent relay and cable cross-sections 3-4..........
3.4 Dimensions 3-4.......................................
4 Installation 4-1..................................
4.1 Mechanical installation 4-1...............................
4.1.1 Important notes 4-1.............................
4.1.2 Standard assembly with fixing rail 4-2................
4.1.3 DIN-rail assembly 4-3............................
4.2 Electrical installation 4-4.................................
4.2.1 Operator’s safety 4-4.............................
4.2.2 Protection of the brake unit 4-5.....................
4.2.3 Specification of cables used 4-5....................
4.3 Connection 4-6........................................
4.3.1 Power connection 4-6............................
4.3.2 8251 brake module on 820X controller 4-7.............
4.3.3 8252 brake module on 821X controller 4-8.............
4.3.4 8253 brake chopper on 821X controller 4-9............
4.3.5 Connect temperature monitoring 4-10.................
8250BA0903 i
Contents
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5 Commissioning 5-1..............................
6 Troubleshooting and fault elimination 6-1............
7 Waste disposal 7-1..............................
8 Supplement 8-1.................................
8.1 Accessories 8-1.......................................
8.1.1 Brake resistors 8-1.............................
8.2 Glossary 8-3.........................................
8.3 Index 8-4............................................
ii 8250BA0903
Preface and general information
39365
8
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1 Preface and general information
1.1 About these Operating Instructions ...
• The present Operating Instructions are used for operations
concerning safety measures on and with the 825X brake
units. They contain safety information which must be
observed.
• All persons who work on and with 825X brake units must
have the Operating Instructions available and observe all
relevant notes and instructions.
• The Operating Instructions must always be in a complete
and perfect ly read able stat e.
1.1.1 Terminology used
Brake unit
The”8251 brakemodule”, the ” 8252 brakemodule” or the”8253
brake chopper with brake resistor” arecalled ”brake unit” in the
following text.
Controller
In the following text, the term ”controller” is used for ” 82XX
frequency inverter”.
Drive system
For drive systems with 825X brake units and other Lenze drive
components, the term ” drive system” is used in the following
text.
1.1.2 What is new?
Material No. Edition Important Contents
12/1996 1st edition
393658
01/1997 revised • Technical data
474423 09/2003 replaces
393658
• Chapte r 4.3
• Change of company name
• Chapter 8
8250BA0903 1-1
Preface and general information
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1.2 Scope of delivery
• The scope of delivery includes:
- 1 8251 brake module, 1 8252 brake module or 1 8253
brake chopper
-1push-onterminalstrip
- 1 accessory kit with fixing material
- 1 book of Operating Instructions
• After rec eption of t he delivery, check immediately whet her
the scope of supply matches the accompanying papers.
Lenze does not accept any liability for deficiencies claimed
subsequently. Claim
- visible transport damage immediately to t he forwarder.
- visible deficiencies/incompleteness immediately to your
Lenze representative.
1.3 825X brake units
1.3.1 Labelling
• Lenze 825X brake units are clearly identified by the
indications on the nameplate.
• CE mark
- Conformity with the EC Low-Voltage Directive
• Manufacturer:
- Lenze Drive Systems GmbH
Postfach 10 13 52
D-31763 Hameln
1-2 8250BA0903
Preface and general information
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1.3.2 Application as directed
8251 brake modules
• Additional units for Lenze controllers:
- 820X frequency inverters (8201 to 8204)
8252 brake modules and 8253 brake choppers
• Additional units for Lenze controllers:
- 821X frequency inverters (8211 to 8218)
825X brake units
• Operate the brake units only under the conditions
prescribed in t hese Operating Instruct ions.
• They are components
- for installation in a machine
- for assembly with other components to form a machine.
• They are electrical equipment for installation into control
cabinets or similar closed operating rooms.
• They meet the protection requirements of the EC LowVoltage Directive.
• They are not machinery in the sense of t he EC Machinery
Directive.
• They are not household ap pliances but are intended
exclusively as components for further commercial use.
Drive systems with 825X brake units
• They correspond to the EC Electromagnetic Compatibility
Directive if they are installed according to the guidelines of
CE-typical drive systems.
• They can b e o perated
- on public and non-public mains.
- in industrial as well as residential and c ommercial
premises.
• The compliance with the EC Directives in machine
application is in the responsibility of the user.
Any other use shall be deemed inappropriate!
8250BA0903 1-3
Preface and general information
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1.3.3 Legal regulations
Liability
• The informat ion, data, and not es in these Op erat ing
Instructions met the state of the art at the time of printing.
Claims referring to drive systems which have already been
supplied cannot be derived from the information,
illustrations, and descriptions.
• The specifications, processes, and circuitry described in
these Operating Instruc tions are for guidanc e only and
must be adapted to your own specific ap plicat ion. Lenze
does not take responsibility for the suitability of the
process and circuit proposals.
• The indications given in these Operating Instructions
describe the features of the product without warranting
them.
• Lenze does not accept any liability for damage and
operating interference caused by:
- Disregarding these Operating instructions
- Unauthorized changes of the brake units
- Operating mistakes
- Improper working on and with the brake units
1-4 8250BA0903
Warranty
• Terms of w arranty: see t erms of sale and delivery of Lenze
Drive Systems GmbH.
• Warranty claims must be made to Lenze immed iat ely aft er
detecting the deficiency or fault.
• The warranty is void in all cases where liability claims
cannot be made.
Safety information
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2 Safety information
2.1 Personnel responsible for safety
Operator
• An operator is any nat ural or legal person w ho uses the
drive system or on behalf of whom the drive system is
used.
• Theoperatororhissafetyofficerareobliged
- to check whether all relevant regulations, notes, and
laws are observed .
- to ensure that only qualified personnel work with and on
the drive system.
- to ensure that the personnel have the Operating
Inst ructions available for all corresponding operations
- to prohibit non-qualified personnel from working with
and on the drive system.
Qualified personnel
Qualified personnel are persons who are - because of their
educat ion, experience, inst ructions, and knowledge about
corresponding st andard s and regulations, rules for the
prevention of accidents, and operating conditions - authorized
by the person responsible for the safety of the plant to perform
the required actions and who are able to rec ognize and avoid
potential hazards.
(see IEC 364, definition of qualified personnel)
8250BA0903 2-1
Safety information
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2.2 General safety information
• This safety information is not claimed t o be complete. In
case of questions and problems please contact your
Lenze representative.
• At the time of delivery t he brake unit meets the state of t he
art and ensures basically safe operation.
• The indications given in these Operating Instructions refer
to the stated versions of the brake unit.
• The brake unit is hazardous for persons, the brake unit
itself and other property of the operator, if
- non-qualified personnel work with and on the brake unit.
- the brake unit is not used as direct ed.
• The specifications, processes, and circuitry described in
these Operating Instruc tions are for guidanc e only and
must be adapted to your own specific ap plicat ion.
• Brake units must be d esigned so that they comply w ith
their function and do not cause any hazards for persons
under the conditions of correct installation and faultless
operation as instructed. This is also effective for t he
interaction with the complete plant.
• Take additional measures to limit c onsequences of
malfunctionswhichmaycausehazardsforpersonsor
material assets:
- Further indep end ent equipment which can take over t he
function of the brake unit
- Electrical or non-electrical protection (latching or
mechanical bloc king)
- Measures covering the complete system
• Operate the drive system only in a perfect condition.
• Changes or ret rofittings to the b rake unit are p rohib it ed in
principle. In any case, Lenze must be contact ed.
2-2 8250BA0903
Safety information
q
g
generaldanger
P
ibl
ifd
isr
r
ded
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2.3 Layout of the safety information
• All safety information in these Operating Instructions has a
uniform layout:
Danger
Note
- The icon designat es the t ype of danger.
- The signal word designates t he severity of danger.
- The note describes the danger and suggests how to
avoid the danger.
Warning of danger for persons
Icons used Signal words
Warning of
hazardous
electrical voltage
Danger! Warns of impending danger.
Consequences if disregarded:
Death or very severe injuries.
Warning! Warns of potential, very hazardous situations.
Warning of a
general danger
Caution! Warns of potential, hazardous situations.
Warning of material damage
Icons used Signal words
Stop! Warns of possible material damage.
Other notes
Icons used Signal words
Note! Designates a general, useful tip.
Possible consequences if disregarded:
Death or very severe injuries.
oss
e consequences
Light or minor injuries.
Possible consequences if disregarded:
Damage to the drive system or its environment.
If you observe it, handling of the drive system is made
easier.
ega
:
8250BA0903 2-3
Safety information
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2.4 Residual hazards
Protection of persons
After mains voltage disconnection the power terminals
,-UGremain live for 3 minutes.
+U
G
Brake units may have surface temperatures of up to 130°Cfor
up to 30 minutes after mains disconnection.
Touching the brake unit may cause burns.
2-4 8250BA0903
3 Technical data
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3.1 Features
• Three types:
- 8251 brake module with internal brake resistor for
frequent braking operations with low load or infrequent
braking with medium load for operation with 820X
frequency inverter
- 8252 brake module with internal brake resistor for
frequent braking operations with low load or infrequent
braking with medium load for operation with 8211- 8213
frequency inverters
- 8253 brake chopper with external brake resistor for
high-load continuous braking for operation with 821X
frequency inverter
• Conversion of the mechanical braking energy into t hermal
energy
- Controller does not set pulse inhibit during braking, i.e.
the braking operation still remains controlled
• Very short braking times are possible
• Enclosure IP10 for installation in a control cabinet
• DIN-rail assembly possible (additional accessories
required)
• Fixed thresholds for the mains voltages 230 V (8251) and
400¼460 V (8252/ 8253)
• Current-state display via LED
Technical Data
8250BA0903 3-1
Technical Data
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3.2 General data /operating conditions
Field Values
Vibration resistance Germanischer Lloyd, general conditions (in preparation)
Permissible moisture Humidity class F without condensation (medium relative
Permissible temperature ranges during transport : -25 °C ¼ +70 °C
Permissible installation height h h £ 1000 m a.m.s.l
Degree of pollution VDE 0110 part 2 pollution degree 2
Insulation strength Overvoltage category III according to VDE 0110
Packing to DIN 4180
Type of protection IP10
Approvals CE: Low-Voltage Directive
humidity 85
during storage: -25
during operation: 0
without power derating
1000 m a.m.s.l
with power derating
NEMA 1: Protection against contact
%)
°C ¼ +70 °C
°C ¼+40 °C
< h £ 4000 m a.m.s.l
EMC Directive in prepara tion
3-2 8250BA0903
Technical Data
otopo
e
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3.3 Rated data
3.3.1 Brake units
Type EMB8251-E EMB8252-E EMB8253-E
Order
no.
Supply voltage V
Threshold V
Peak current 5.4 A DC 2.7 A DC 15 A DC
Max. continuous current 0.2 A DC 0.1 A DC 7.5 A DC
Peak braking power at V
Continuous braking power at V
Min. brake resistance (internal resistor) (internal resistor) 47 Ω ± 10%
Max. energy (min. 5 min break) 20 kWs 20 kWs (external resistor)
Power derating 40 °C<T<50°C: 2%/K
Weight 1.3 kg 1.3 kg 1.1 kg
N
Z
Z
Z
1)
max. 10 s with switch-on cycle 3 %
2)
max. 60 s with switch-on cycle 50 %
EMB8251-E EMB8252-E EMB8253-E
270 ¼ 400 V DC 270 ¼ 750 V DC 270 ¼ 750 V DC
375 V DC 725 V DC 725 V DC
1)
2kW
70 W 70 W 5.6 kW
1000 m a.m.s.l. < h < 4000 m a.m.s.l.: 5%/1000 m
2kW
1)
11.2 kW
2)
3.3.2 Assignment table for brake resistors
Theassignment depends on the motor power and is effective up
to the indicated limit value.
Motor power Recommended Lenze brake resistor
Order no. Resistor Peak braking power Thermal capacity
kW Ω kW kWs
<0.75 ERBM470R100W 470 1.0 15
<1.5 ERBM370R150W 370 1.5 22,5
<2.2 ERBM240R200W 240 2.0 30
<3.0 ERBD180R300W 180 3.0 45
<4.0 ERBD100R600W 100 5.5 90
<5.5 ERBD082R600W 82 6.5 90
<7.5 ERBD068R800W 68 8.0 120
< 11.0 ERBD047R01K2 47 11.5 180
The resistors are designed for a cyc le of:
• max. 15 s braking at peak b raking pow er
• min. 150 s release time after braking
8250BA0903 3-3
Technical Data
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3.3.3 Overcurrent relay and cable cross-sections
With a cab le cross sect ion of the feeding inverter of > 2.5 mm
the cable can be protected via overcurrent relay.
The cable cross-sections used must meet the valid regulations.
We recommend:
Type Input +UG, -UG
Overcurrent relay Cable cross-section
[A] [mm2]
8251 not required 1.5
8252 not required 1.5
8253 max 12 * 2.5
* depending on the brake resistor
3.4 Dimensions
The dimensions of the brake units depend on the mechanical
installation (see chapter 4.1)
2,
3-4 8250BA0903
4 Installation
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4.1 Mechanical installation
4.1.1 Important notes
• Use the brake units only as built-in devices!
• Observefreespace!
- Allow a free space of 100 mm at the top and at the
bottom.
• Ensure unimpeded ventilation of cooling air and outlet of
exhaust air.
• If the cooling air contains pollutants (dust, fluff, grease,
aggressive gases ), which may impair the function of the
brake units:
- Take suitable preventive measures , e.g. separate air
duct, installation of filters, regular cleaning, etc.
• Do not exceed t he permissible range of the operating
ambient temperature (see chapter 3.2).
• If the brake units are permanently subjected to vibration or
shaking:
- Check whether shock absorbers are necessary.
Installation
Danger!
Operation with 8253 brake chopper and external brake resistor:
• In the event of failures, brake resistors can become very
hot, they can even burn. E.g. when the following occurs:
- mains overvoltage,
- application-specific overload,
- internal fault.
• Brake resistors must therefore be installed suc h t hat t he
very high temperatures possible cannot cause any
damage.
8250BA0903 4-1
Installation
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Possible mounting positions
• In vertical position at the b ackside of t he control cabinet.
- terminal strip at the bottom
- assemb led on attached fixing rail (see chapt er 4.1.2) or
DIN rail (see chapter 4.1.3)
4.1.2 Standard assembly with fixing rail
k
g
d
b
4-2 8250BA0903
(T1) (T2)
-UG +UG RB1 RB2 PE
a
Fig. 4-1 Dimensions for fixing-rail assembly
Type a b c d e f g k
8251
8252
8253
56 210 28 190 170 130 6.5 30
All dimensions in mm
f
e
4.1.3 DIN-rail assembly
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1)
c3
c2
1)
Installation
b
Type
8251
8252
8253
c1
(T1) (T2)
-UG +UG RB1 RB2 PE
a
f
e
Fig. 4-2 Dimensions for DIN-rail assembly
1)
Assembly with one DIN rail (in the middle) or with 2 DIN rails (top/bottom) possible.
a b c
1
c
2
c
3
e f
56 190 16 98 149 173 133
8250BA0903 4-3
Installation
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4.2 Electrical installation
4.2.1 Operator’s safety
Danger!
After switching off the mains voltage, all power terminals (+UG,
and RB1, RB2) of the brake unit remain live for up t o
-U
G
3 minutes.
Therefore please wait for 3 minut es after having switc hed off the
mains voltage before you start to work.
- For single drives, the brake unit carries a hazardous
voltage up to three minutes after mains disconnection.
- In a drive network, all controllers must be inhibited and
disconnected from the mains.
Danger!
During braking operation (e.g. test stand, high inertia loads etc.)
the voltage is still present after mains switching (OFF).
It is therefore necessary to set all controllers to controller inhibit.
4-4 8250BA0903
4.2.2 Protection of the brake unit
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Stop!
The brake units contain electrostatically sensitive components.
• Prior to assembly and service operations, the personnel
must be free of elec trostatic charge:
- They can discharge themselves by touching the PE
fixing screw or another grounded metal part in the
control cabinet.
• In the event of condensation connect the brake unit to
mains voltage only after the visible humidity has
evaporat ed.
4.2.3 Specification of cables used
• The cables used must c omply with t he approvals required
atthesite(eg.UL).
• The prescribed minimum cross-sections of PE conductors
must be maintained in all cases. The cross- sect ion of t he
PE conductor must b e at least as large as the
cross-section of the power connections (VDE 0160).
• The screening quality of a cable is d etermined by
- a good screen connection
- a low screen resistance
Use only screens with tin-plated or nickel-plated copper
braid!
Screens of steel braid are not suitab le.
- the degree of coverage of the screen braid:
at least 70% to 80% with a coverage angle of 90°
Installation
Note!
The screens are only required t o comply with existing st andards
(e.g. VDE 0160, EN 50178).
8250BA0903 4-5
Installation
eas
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4.3 Connection
4.3.1 Power connection
• All indications about cable cross-sections are
recommendations and refer t o the applic ation:
- in control cabinets and machines
-incableducts
- at a max. amb ient temperature +40 °C
• The compliance with other standards (e.g.: VDE 0113, VDE
0289, etc.) remains the responsibility of the user.
• The cables betw een brake unit and c ontroller must not be
longer than max. 2 m.
• If the brake unit is directly connected with the controller
and the cable length does not exceed £ 0.5 m, the cables
can be used as unscreened single cores.
• For a radio interference suppression (limit-value class A or
B) to DIN 55011 observe the following:
- The cables must be screened.
- For cable lengths up to 1 m it is sufficient to connect the
screen at t he mid dle.
- For cable lengths > 1 m, the screen must always be
connected on both sides.
4-6 8250BA0903
Connection
• The cables betw een controller and brake unit must be
DC-bus connected to the terminals +UG, -UG.
• Observe st ud torques:
Ter min als
0.5 ... 0.6 Nm
4.4 ... 5.3 lbfin
Installation
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4.3.2 8251 brake module on 820X controller
L1
L2
L3
N
PE
F1
K10
OFF
Z3
L1
N
8201 - 8204
+UG -UG
PE
Z2
-UG
+UG
RB
K10
T1
T2
PE
8251
PE
U
PE
W
V
...
28
E1
20
X1
K10
RFR
M
3~
PE
Fig. 4-3 Connection of 8251 brake module to 820X controller
Z1: Brake module
Z2: Controller
Z3: Mains choke
K10: Mains contactor
F1: Mains fuse (recom mend ed)
Z1
ON
K10
8250BA0903 4-7
Installation
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4.3.3 8252 brake module on 821X controller
L1
L2
L3
N
PE
F1...F3
K10
OFF
Z3
L1
L2
8211 - 8213
L3
+UG -UG
PE
Z2
-UG
+UG
RB
K10
T1
T2
PE
8252
PE
U
PE
W
V
...
20
28
E1
X1
K10
RFR
M
3~
PE
Fig. 4-4 Connection of 8252 brake module to 821X controller
Z1: Brake module
Z2: Controller
Z3: Mains choke
K10: Mains contactor
F1 ... F3: Main s f uses (rec ommended)
Z1
ON
K10
4-8 8250BA0903
Installation
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4.3.4 8253 brake chopper on 821X controller
L1
L2
L3
N
PE
F1...F3
K10
Z3
X1
L1
L2
8211 - 8218
PE
W
U
V
M
3~
PE
OFF
K10
ON
RB
K10
-UG
+UG
PE
PE
K10
RFR
+UG -UG
PE
Z2
...
20
28
E1
L3
Z4
RB2
RB1
8253
RB
Z1
Fig. 4-5 Connection of 8253 brake chopper to 821X controller
Z1: Brake chopper
Z2: Controller
Z3: Mains choke
Z4: Brake resistor
K10: Mains contactor
F1 ... F3: Main s f uses (rec ommended)
J
RB
Thermal overcurrent release
Brake resist or
8250BA0903 4-9
Installation
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4.3.5 Connect temperature monitoring
Danger!
Thetemperaturemonitoring isrequiredto ensuresafeswitch-off
in the event of a failure.
Use the t hermost ats of t he b rake resistors to
• separate the controller from the mains if the temperature
monitoring is activated
and
• set controller inhibit in all connected controllers.
For connection of the thermostat: see the corresponding
signal- flow diagrams (chapter 4.3.2 ¼ 4.3.4).
4-10 8250BA0903
5 Commissioning
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Stop!
If the connections +UGand -UGare reserved, the brake units and
all connected c omponents can be destroyed.
It is therefore absolutely necessary to check the correc t
connection of the terminals before switching on the unit.
The two LEDs at the brake unit indicate the operating state:
• green LED:
illuminated, when the brake unit is supplied with voltage
and is read y for operation
• yellow LED:
illuminated, when brake unit is in braking operation
Note!
The deceleration time of the drive will be prolonged if the
feedbac k power is higher than the peak brake pow er of the
assigned brake resistor. In this case, t he cont roller sets p ulse
inhibit and indicates „ overvoltage“ .
Prolong the T
ramp-function generator or the QSPramp at the controller oruse
a low er- value brake resist or, if permitted.
-time via the deceleration ramp at the
if
Commissioning
8250BA0903 5-1
Commissioning
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5-2 8250BA0903
Troubleshooting and fault elimination
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6 Troubleshooting and fault elimination
Fault Cause Remedy
Green LED is not illuminated No voltage at terminals +UG,-U
Controller sets pulse inhibit during
braking and indicates overvoltage
• Yellow LED is not illuminated The brake unit is not connected to
• Yellow LED is illuminated Brake resistor is not connected Connect brake resistor
the terminals +U
controller
Brake resistance too high Use lower-value brake resistor
,-UGof the
G
• Switch on the mains
G
• Connect the brake unit to the
terminals +U
controller
Connect the brake unit to the
terminals +U
,-UGof the
G
,-UGof the controller
G
8250BA0903 6-1
Troubleshooting and fault elimination
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6-2 8250BA0903
Waste disposal
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7 Waste disposal
The brake unit consists of different materials.
The following table indicates which materials must be recycled
and which require separate disposal.
Material recycle dispose
Metal x Plastic x Printed-board assemblies - x
Operating Instructions x -
8250BA0903 7-1
Waste disposal
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7-2 8250BA0903
8 Supplement
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8.1 Accessories
8.1.1 Brake resistors
e
Appendix
c
a
Fig. 8-1 Brake modules wit h integrated temperature monitoring
Resistance Order no. Rated
Ω W mm mm mm mm mm mm mm
470 ERBM470R100W 100 70 240 50 225 60 5 7.5
370 ERBM370R150W 150 80 240 70 225 95 5 7.5
200 ERBM240R200W 200 80 340 70 325 70 5 7.5
k
power
d
bg
a b c d e g k
8250BA0903 8-1
Appendix
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a
f
d
h
e
g
c
Fig. 8- 2 Grid p rotect ed w ire resisto rs
Brake resistor Dimensions
Resistance Order no. a b c d e f g h
Ω mm mm mm mm mm mm mm mm
180 ERBD180R300W 440 89 354 64 115 326 6.5 13
100 ERBD100R600W 640 89 530 64 115 426 6.5 13
82 ERBD082R600W 640 89 554 64 115 526 6.5 13
68 ERBD068R800W 540 177 454 150 115 426 6.5 13
47 ERBD047R01K2 640 177 554 150 115 526 6.5 13
b
8-2 8250BA0903
Appendix
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8.2 Glossary
Ter m Meaning
Controller General name for servo drives (93XX), frequency inverters (82XX, 86XX) and
Icon Sign or symbol with an unambiguous message.
IMP Pulse inhibit
Peak brake power Maximum power which can be converted into heat by a resistor
PTC PTC thermistor (PTC: positive temperature coefficient)
RB Brake resistor
Residual hazards Hazards which cannot be eliminated by design
Use Appropriate:
DC drives (48XX, 49XX)
Appropriate use of the machine according to the manufacturer’s information
or to common use according to its design and function.
Inappropriate:
Any other use which is not instructed.
8250BA0903 8-3
Appendix
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8.3 Index
A
Accessories, 8-1
B
Brake resistors, 8-1
Brake unit, 1-1, 1-2
C
Cable specification, 4-5
Commissioning, 5-1
Connection, 4-6
Controller, 1-1
Application as directed, 1-3
Labelling, 1-2
D
Definitions, 1-1
Dimensions, 3-4
F
Fault elimination, 6-1
G
Gases, aggressive, 4-1
Glossary, 8-3
I
Installation, 4-1
electrical, 4-4
mechanical, 4-1
L
Legal regulations, 1-4
Liability, 1-4
List of special terms. See Glossary
M
Material, 7-1
O
Operating conditions, 3-2
Operator, 2-1
P
Personnel, qualified, 2-1
R
Rated data, 3-3
Recycling, 7-1
S
Safety information
general, 2-2
Layout, 2-3
Scope of delivery, 1-2
Supplement, 8-1
T
Technical data, 3-1
Dimensions, 3-4
Features, 3-1
General data/operating conditions,
3-2
Rated data, 3-3, 3-4
Troubleshooting, 6-1
W
Warranty, 1-4
Waste disposal, 7-1
8-4 8250BA0903
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