Lenze 9350, EMB9351-E, EMB9352-E, EMB9351-C, EMB9352-C Operating Instructions Manual

RGB ELEKTRONIKA AGACIAK CIACIEK

SPÓŁKA JAWNA

Jana Dlugosza 2-6 Street

51-162 Wrocław

Poland

[e-mail]

[phone]

www.rgbautomatyka.pl

www.rgbelektronika.pl

DATASHEET

www.rgbautomatyka.pl

www.rgbelektronika.pl

OTHER SYMBOLS:

4/7132/04020

4713204020, 47132 04020, 47132/04020, 4 713204020, 4 7132 04020, 4 7132/04020, 4/713204020, 4/7132
04020, 4/7132/04020

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EDBMB935X

.;p]

Ä.;p]ä

Operating Instructions

9350

L

EMB9351−E, EMB9352−E, EMB9351−C, EMB9352−C

Braking unit

l

, Please read these instructions before you start working!

Follow the enclosed safety instructions.

RB2

RB1

(T1) (T2)

+UG

0

-UG

1

E1 E2

A1 A2

12

ON

3

OFF

2

3

4

9350br_001

0Fig. 0Tab. 0

Scope of supply

Pos. Description

0 9350 braking unit

Accessory kit with shield sheets and fixing material

Operating Instructions

Elements of the braking unit

Pos. Description

1 Terminals

2 LED

3 Switches

4 Synchronisation

interface

+UG, −UG DC−bus voltage
T1, T2 Temperature switches (only 9351 brake module)
RB1, RB2 Brake resistor (only 9352 brake chopper)
Green Voltage is applied to terminals +UG, −UG
Yello

w

S1, S2 Setting the switching thresholds of the braking unit
S3 Setting of the configuration as master or slave for parallel operation
E1, E2 Inputs
A1, A2 Outputs

Braking unit is in braking operation

4

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EDBMB935X EN 8.0

This documentation applies to ...

ƒ Braking units EMB935x−E. 1x (9351 − 9352)
ƒ Braking units EMB935x−C. 1x V003 cold plate (9351 − 9352)

EMB 935x − x. 1x

Product range

9350 braking unit

9351 = brake module

9352 = brake chopper

Design

C = cold plate

E = built−in unit

Hardware version

Application range

The use of the braking units is permissible with devices of the 8200, 9300 and 82Vector pro­duct series (15 − 90 kW).

EDBMB935X EN 8.0

l

5

Document history

Material number Version Description

.;p] 8.0 08/2008 TD34 Extension by chapter 5.5

.7tG 7.0 11/2007 TD34 Complete revision

!R;ó 6.0 06/2004 – Revision of chapter 4

!NLc 5.0 06/2002 – Change of name

!NùW 4.0 02/2002 – Revision of the chapters 3.3.3 and 4.1.3

!HEx 3.0 04/2000 – Revision of chapter 4.3.2

!HEx 2.0 01/1997 – Revision of chapter 4

!H0m 1.0 08/1996 – First edition, monolingual

0Fig. 0Tab. 0

I Tip!

Current documentation and software updates concerning Lenze products can
be found on the Internet in the "Services & Downloads" area under

http://www.Lenze.com

© 2008 Lenze Drive Systems GmbH, Hans−Lenze−Straße 1, D−31855 Aerzen
No part of this documentation may be reproduced or made accessible to third parties without written consent by
Lenze Drive Systems GmbH.
All information given in this documentation has been selected carefully and complies with the hardware and
software described. Nevertheless, discrepancies cannot be ruled out. We do not take any responsibility or liability
for any damage that may occur. Necessary corrections will be included in subsequent editions.

6

l

EDBMB935X EN 8.0

Contents i

1 Preface and general information 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 About these Operating Instructions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1 Terminology used 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Legal regulations 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety instructions 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General safety and application notes for Lenze controllers 12 . . . . . . . . .

2.2 General safety and application notes for Lenze braking units 16 . . . . . . .

2.3 Residual hazards 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Definition of notes used 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Technical data 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Features 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 General data and operating conditions 20 . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Rated data 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Braking units 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Assignment table for brake resistors 22 . . . . . . . . . . . . . . . . . .

3.3.3 Fuses and cable cross−sections 22 . . . . . . . . . . . . . . . . . . . . . . .

4 Mechanical installation 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Important notes 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Mounting with fixing rails (standard installation) 24 . . . . . . . . . . . . . . . .

4.3 Mounting with thermal separation (push−through technique) 25 . . . . . .

4.4 Mounting in cold−plate design 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Fields of application 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Requirements with regard to the cooler 27 . . . . . . . . . . . . . . .

4.4.3 Thermal behaviour of the complete system 28 . . . . . . . . . . . .

4.4.4 Mounting 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Electrical installation 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Important notes 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Protection of persons 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Device protection 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Cable specification 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EDBMB935X EN 8.0

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7

Contentsi

5.3 Connection 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Power connections 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 Permissible cable lengths 32 . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 Fusing 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.4 Temperature monitoring 34 . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.5 9351 brake module to controllers 822X and E82Vector (15 − 90

kW) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.6 9352 brake chopper to controllers 822X and E82Vector (15 − 90

kW) 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.7 9351 brake module to 93XX controllers 37 . . . . . . . . . . . . . . .

5.3.8 9352 brake chopper to 93XX controllers 38 . . . . . . . . . . . . . . .

5.3.9 Setting the switching threshold 39 . . . . . . . . . . . . . . . . . . . . .

5.4 Parallel connection 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Braking units with brake resistor 40 . . . . . . . . . . . . . . . . . . . . .

5.4.2 Braking units with a common brake resistor 44 . . . . . . . . . . . .

5.5 Use of brake resistors smaller 27R 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Commissioning 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Troubleshooting and fault elimination 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Appendix 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Important notes 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Accessories 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Rating for Lenze brake resistors 48 . . . . . . . . . . . . . . . . . . . . . .

8.2 Glossary 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Index 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

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EDBMB935X EN 8.0

Preface and general information

About these Operating Instructions

1 Preface and general information

1.1 About these Operating Instructions

ƒ The present Operating Instructions will help you to work safely on and

with the 935X braking units. They contain safety instructions that must
be followed.

ƒ All persons working on or with the 935X braking units must have the

Operating Instructions available and observe the information and notes
relevant for them.

ƒ The Operating Instructions must always be in a complete and perfectly

readable state.

1.1.1 Terminology used

Braking unit

1

Terminology used

For 9351 brake module or 9352 brake chopper with brake resistor, the term

braking unit is used in the following text.

Controller

For 93XX servo inverter or 82XX frequency inverter, the term controller is used
in the following text.

Drive system

For drive systems with 935X braking units and other Lenze drive components,
the term drive system is used in the following text.

EDBMB935X EN 8.0

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9

1

1.2 Legal regulations

Preface and general information

Legal regulations

Labelling

Lenze 935X braking units are clearly labelled by the content of the nameplate.

Manufacturer

Lenze Drive Systems GmbH, Hans−Lenze−Straße 1, D−31855 Aerzen, Germany

CE conformity

Compliant with "Low voltage" EC Directive

Application as directed

935Xbraking units

ƒ are additional units for the Lenze controllers:

– 822X frequency inverters (8221 to 8227)
– 824X frequency inverters (8241 to 8246)
– 82Vector frequency inverters (15 − 90 kW)
– 93XX servo inverters (9321 to 9333)
– Operation with the 820X or 821X frequency inverters is possible.

ƒ must only be operated under the ambient conditions prescribed in these

Operating Instructions.

ƒ Are components

– for installation within a machine.
– for assembly with other components into a machine.

ƒ are electrical equipment for installation within control cabinets or similar

closed electrical operating areas.

ƒ meet the protection requirements of the "Low voltage" EC Directive.
ƒ Are not machines in the context of the EC machinery directive.
ƒ Are not household appliances but are intended solely for utilisation as

components for industrial use.

Drive systems with a 935X braking unit

ƒ The user is responsible for the compliance of the machinery application

with the EC directives.

Any other use shall be deemed improper!

10

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EDBMB935X EN 8.0

Preface and general information

Legal regulations

Liability

The information, data and notes in these instructions met the state of the art at
the time of printing. Claims on modifications referring to braking units that
have already been supplied cannot be derived from the information,
illustrations and descriptions.

The information on processes and circuits given in these instructions are
suggestions. The suitability of these suggestions to the related application must
be checked. Lenze does not accept any responsibility for the suitability of the
processes and circuit suggestions given.

The information in these instructions describe the features of the products
without providing any warranty.

No liability is accepted for damage and failures caused by:

ƒ Disregarding of these instructions
ƒ Unauthorised alterations on the braking units
ƒ Operating errors
ƒ Improper working on and with the braking units

1

Warranty

See terms of sales and delivery of Lenze Drive Systems GmbH.
Warranty claims must be made to Lenze immediately after having detected the

defect or fault.
The warranty is void in all cases where liability claims cannot be made.

EDBMB935X EN 8.0

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11

2

Safety instructions

General safety and application notes for Lenze controllers

2 Safety instructions

2.1 General safety and application notes for Lenze controllers

(in accordance with Low−Voltage Directive 2006/95/EC)

For your personal safety

Depending on their degree of protection, some parts of the Lenze controllers
(frequency inverters, servo inverters, DC speed controllers) and their accessory
components can be live, moving and rotating during operation. Surfaces can be
hot.

Non−authorised removal of the required cover, inappropriate use, incorrect
installation or operation, creates the risk of severe injury to persons or damage
to material assets.

For more information, please see the documentation.
High amounts of energy are produced in the controller. Therefore it is required

to wear personal protective equipment (body protection, headgear, eye
protection, ear protection, hand guard).

All operations concerning transport, installation, and commissioning as well as
maintenance must be carried out by qualified, skilled personnel (IEC 364 or
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).

According to this basic safety information, qualified, skilled personnel are
persons who are familiar with the assembly, installation, commissioning, and
operation of the product and who have the qualifications necessary for their
occupation.

12

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EDBMB935X EN 8.0

Safety instructions

General safety and application notes for Lenze controllers

Application as directed

Controllers are components which are designed for installation in electrical
systems or machines. They are not to be used as domestic appliances, but only
for industrial purposes according to EN 61000−3−2.

When controllers are installed into machines, commissioning (i.e. starting of the
operation as directed) is prohibited until it is proven that the machine complies
with the regulations of the EC Directive 98/37/EC (Machinery Directive);
EN 60204 must be observed.

Commissioning (i.e. starting of the operation as directed) is only allowed when
there is compliance with the EMC Directive (2004/108/EC).

The controllers meet the requirements of the Low−Voltage Directive
2006/95/EC. The harmonised standard EN 61800−5−1 applies to the controllers.

The technical data and supply conditions can be obtained from the nameplate
and the documentation. They must be strictly observed.

Warning: Controllers are products which can be installed in drive systems of
category C2 according to EN 61800−3. These products can cause radio
interferences in residential areas. In this case, special measures can be
necessary.

2

Transport, storage

Please observe the notes on transport, storage, and appropriate handling.
Observe the climatic conditions according to the technical data.

Installation

The controllers must be installed and cooled according to the instructions given
in the corresponding documentation.

Ensure proper handling and avoid excessive mechanical stress. Do not bend any
components and do not change any insulation distances during transport or
handling. Do not touch any electronic components and contacts.

Controllers contain electrostatic sensitive devices which can easily be damaged
by inappropriate handling.

Do not damage or destroy any electrical components since this might endanger
your health!

EDBMB935X EN 8.0

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13

2

Safety instructions

General safety and application notes for Lenze controllers

Electrical connection

When working on live controllers, observe the applicable national regulations
for the prevention of accidents (e.g. VBG 4).

The electrical installation must be carried out according to the appropriate
regulations (e.g. cable cross−sections, fuses, PE connection). Additional
information can be obtained from the documentation.

This documentation contains information on installation in compliance with
EMC (shielding, earthing, filters, and cables). These notes must also be observed
for CE−marked controllers. The manufacturer of the system is responsible for
compliance with the limit values demanded by EMC legislation. The controllers
must be installed in housings (e.g. control cabinets) to meet the limit values for
radio interferences valid at the site of installation. The housings must enable an
EMC−compliant installation. Observe in particular that e.g. the control cabinet
doors have a circumferential metal connection to the housing. Reduce housing
openings and cutouts to a minimum.

Lenze controllers can cause a direct current in the protective conductor. If a
residual current device (RCD) is used as a protective means in case of direct or
indirect contact, only a residual current device (RCD) of type B may be used on
the current supply side of the controller. Otherwise, another protective measure
such as separation from the environment through double or reinforced
insulation or disconnection from the mains by means of a transformer must be
applied.

Operation

If necessary, systems including controllers must be equipped with additional
monitoring and protection devices according to the valid safety regulations (e.g.
law on technical equipment, regulations for the prevention of accidents). The
controllers can be adapted to your application. Please observe the
corresponding information given in the documentation.

After the controller has been disconnected from the supply voltage, all live
components and power connections must not be touched immediately because
capacitors can still be charged. Please observe the corresponding stickers on the
controller.

All protection covers and doors must be shut during operation.
Notes for UL−approved systems with integrated controllers: UL warnings are

notes that only apply to UL systems. The documentation contains special UL
notes.

Safety functions

Special controller variants support safety functions (e.g. "safe torque off",
formerly "safe standstill") according to the requirements of Appendix I No. 1.2.7
of the EC Directive "Machinery" 98/37/EC, EN 954−1 Category 3 and EN 1037.
Strictly observe the notes on the safety functions given in the documentation
for the respective variants.

14

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EDBMB935X EN 8.0

Safety instructions

General safety and application notes for Lenze controllers

Maintenance and servicing

The controllers do not require any maintenance if the prescribed operating
conditions are observed.

If the ambient air is polluted, the cooling surfaces of the controller may become
dirty or the air vents may be obstructed. Therefore, clean the cooling surfaces
and air vents periodically under these operating conditions. Do not use sharp or
pointed tools for this purpose!

Disposal

Recycle metal and plastic materials. Ensure professional disposal of assembled
PCBs.

The product−specific safety and application notes given in these instructions
must be observed!

2

EDBMB935X EN 8.0

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2

Safety instructions

General safety and application notes for Lenze braking units

2.2 General safety and application notes for Lenze braking units

ƒ These safety notes do not claim to be complete. If any questions or

problems occur, please contact the responsible Lenze representative.

ƒ The braking unit meets the state of the art at the time of delivery and is

generally safe to operate.

ƒ The information in these Operating Instructions refer to the specified

versions of the braking units.

ƒ The braking unit is hazardous to persons, to the braking unit itself, and to

other properties of the operator if

– non−qualified personnel work on and with the braking unit.
– the braking unit is used improperly.

ƒ The procedural notes and circuit details represented within these

Operating Instructions are recommendations, the transferability of which
to the corresponding application has to be checked.

ƒ The braking units must be planned in such a way that if they are

installedcorrectlyand used for their designed purpose in fault−free
operation, they fulfil their function and do not put any persons at risk.
This also applies to the interaction of the braking units with the system as
a whole.

ƒ Take additional measures in order to narrow down consequences due to

faults, which can cause danger to persons or damage to material assets:

– Further independent equipment taking over the function of the braking

unit

– Electrical or non−electrical protective devices (locking or mechanical

locks) for the drive system

– Measures concerning the system as a whole

ƒ Do not operate the braking unit unless it is in perfect condition.
ƒ Changes or modifications of the braking unit are strictly prohibited. In any

case, consultation with Lenze is required.

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EDBMB935X EN 8.0

Safety instructions

Residual hazards

2

2.3 Residual hazards

Protection of persons

ƒ Before carrying out operations on the braking unit, check whether all

power terminals are in a deenergised state:

– After power−off the power terminals +U

carry dangerous voltage for at least 3 minutes.

ƒ S1, S2 and S3 have a mains potential!

– Wait for at least 3 minutes before changing over the switches.

, −UG and RB1 and RB2 still

G

EDBMB935X EN 8.0

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17

2

Safety instructions

Definition of notes used

2.4 Definition of notes used

The following pictographs and signal words are used in this documentation to
indicate dangers and important information:

Safety instructions

Structure of safety instructions:

} Danger!

(characterises the type and severity of danger)

Note

(describes the danger and gives information about how to prevent
dangerous situations)

Pictograph and signal word Meaning

{ Danger!

} Danger!

( Stop!

Danger of personal injury through dangerous electrical
voltage.

Reference to an imminent danger that may result in death
or serious personal injury if the corresponding measures
are not taken.

Danger of personal injury through a general source of
danger.

Reference to an imminent danger that may result in death
or serious personal injury if the corresponding measures
are not taken.

Danger of property damage.

Reference to a possible danger that may result in property
damage if the corresponding measures are not taken.

18

Application notes

Pictograph and signal word Meaning

) Note!
I Tip!
,

Important note to ensure troublefree operation

Useful tip for simple handling

Reference to another documentation

l

EDBMB935X EN 8.0

3 Technical data

3.1 Features

ƒ Two designs with identical dimensions

– 9351 brake module with internal brake resistor for frequent braking

with low power or unfrequent braking with medium power

– 9352 brake chopper with external brake resistor for higher peak braking

power and continuous braking power

ƒ Conversion of the mechanical braking energy into heat energy

– During braking operation, the controller does not set pulse inhibit

unintentionally, i.e. braking operation remains controlled

ƒ Very short braking times can be reached
ƒ Enclosure IP20 for installation within the control cabinet
ƒ DIN rail mounting
ƒ Separable heatsink

– Cooling outside of the control cabinet can be realised

ƒ Switching threshold for the mains voltages 230 V, 400...460 V and 480 V

can be set via internal switches

ƒ Parallel operation of several braking units possible

– Synchronisation via built−in interface

ƒ Status display via LEDs
ƒ Braking units are not short−circuit−proof

Technical data

Features

3

EDBMB935X EN 8.0

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19

3

Technical data

General data and operating conditions

3.2 General data and operating conditions

General data

Conformity and approval

Conformity

CE

Approval

UL UL 508C Power Conversion Equipment

Protection of persons and equipment

Enclosure EN 60529

Insulation resistance EN 61800−5−1

2006/95/EC Low−Voltage Directive

for USA and Canada
1D74, file No. E132659

IP10

IP20 with mounted terminal covers

IP41 on the heatsink side for thermally separated
mounting (push−through technique).

NEMA 250 Protection against contact according to type 1

Site altitude < 2000 m: Overvoltage category III

Site altitude > 2000 m: Overvoltage category II

Operating conditions

Ambient conditions

Climatic

Storage

Transport IEC/EN 60721−3−2 2K3 (−25 ... +60 °C)

Operation IEC/EN 60721−3−3

Pollution EN 61800−5−1 Degree of pollution 2

Site altitude h

Mechanical

Vibration resistance EN 50178

IEC/EN 60721−3−1 1K3 (−25 ... +70 °C)

3K3 (0 ... +40 °C) without power reduction

3K3 (+40 ... +50 °C) with power reduction by

h £< 1000 m amsl without power reduction

1000 m amsl < h <
4000 m amsl

Acceleration resistant up to 0.7 g
EN 61800−5−1
Germanischer
Lloyd, general
conditions

2.5%/ °C

with power reduction by
5 %/ 1000 m

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EDBMB935X EN 8.0

Technical data

Rated data

Braking units

3

3.3 Rated data

3.3.1 Braking units

Type of braking unit EMB9351 EMB9352

Supply voltage U

Switching threshold UZ

Peak current for 1.33 s On; 1.67 s Off IDC [A] 16 32

Max.continuous current IDC [A] 14 (arithm. mean value)

Peak braking power P
for U

Z

Continuous braking power

for U

P

Bd

(related to the arithm.
mean value)

Smallest brake resistance
R

Bmin

Maximum energy W

Mass [kg] 2.6 2.2

Z

1)

Adjustable (see chapter 5.3.9)

2)

Operation of 2 parallel braking units (master/slave) at 18 W possible. Observe the power
of the resistor (see chapter 5.4.2).
Further information on the selection of the brake resistors or regarding the use of brake
resistors < 27R (see chapter 5.5).

N

1)

Bmax

B

DC 375 V

DC 725 V

DC 765 V

DC 375 V

DC 725 V

DC 765 V

DC 375 V

DC 725 V

DC 765 V

UDC [V] 270 V − 0 % ... 775 V + 0 %

UDC [V] 375, 725, 765

20 (r.m.s. value)

PDC [kW] 3 12

PDC [kW] 11 23

PDC [kW] 12 25

PDC [kW] 0.1 5

PDC [kW] 0.1 10

PDC [kW] 0.1 11

R [W] 47 internal 12 ± 10%

R [W] 47 internal 27 ± 10%

R [W] 47 internal 27 ± 10%

W [kWs] 50 (4s On; 500s Off) (external resistor)

2)

2)

EDBMB935X EN 8.0

l

21

3

Technical data

Rated data
Assignment table for brake resistors

3.3.2 Assignment table for brake resistors

The assignment is carried out on the basis of the motor power and applies up to
the limit value specified.

Motor
power

[kW] [W] [kW] [kW] [kWs]

< 2.6 ERBD180R300W 180 3.0 0.3 45

< 5.2 ERBD082R600W 82 6.0 0.6 90

< 7.4 ERBD068R800W 68 8.0 0.8 120

< 11 ERBD047R01K2 47 12 1.2 180

< 13.2 ERBD033R02K0 33 17 2.0 300

< 20.3 ERBD022R03K0 22 26 3.0 450

< 30 ERBD018R03K0 18 32.5 3.0 450

1)

Recommended Lenze brake resistor for Uz = 765 V or Uz = 725 V

Type

1)

R Peak braking

The resistors are designed for a cycle of:

ƒ max. 15 s of braking with peak braking power
ƒ at least 150 s recovery time after braking

Rated power Thermal capacity

power

3.3.3 Fuses and cable cross−sections

Type

VDE UL mm

9351 20 A 20 A K5 2.5 12

9352 50 A 40 A K5 6

1)

Use terminal pinsif a flexible cable is used

Fuses Cable cross−section

2

1)

AWG

10

22

l

EDBMB935X EN 8.0

4 Mechanical installation

4.1 Important notes

ƒ Only use the braking units as built−in units!
ƒ Observe mounting clearances!

– Observe clearance of 100 mm at the top and at the bottom.

ƒ Make sure that the cooling air can access and the exhaust air can escape

unimpededly.

ƒ If the cooling air is polluted (dust, lints, greases, aggressive gases), which

may affect the function of the braking units:

– Take adequate countermeasures, e. g. separate air guide, installation of

filter, regular cleaning, etc.

ƒ Do not exceed the permissible range of the ambient operating

temperature (see chapter ).

ƒ If the braking units are permanently exposed to vibrations or shocks:

– Check the use of vibration dampers.

Mechanical installation

Important notes

4

} Danger!

ƒ In case of fault, brake resistors can reach very high temperatures;

the brake resistor may even burn down, e. g. in the case of
– mains overvoltage,
– application−specific overload,
– internal error.

ƒ Therefore mount the brake resistors so that no damage can be

caused by the possible, very high temperatures.

Possible mounting positions

ƒ Vertically on the rear panel of the control cabinet, power connections

facing upwards

– Fixed with enclosed fixing rails (see chapter 4.2)
– Thermally separated with an external heatsink ("Push−through

technique") (see chapter 4.3)

– Thermally separated with an external convection cooler ("Cold plate"

technology) (see chapter 4.4)

EDBMB935X EN 8.0

l

23

4

Mechanical installation

Mounting with fixing rails (standard installation)

4.2 Mounting with fixing rails (standard installation)

c

l

b

b1

d

k

g

a

Fig. 1 Dimensions

Type

9351 / 9352 52 384 350 26 365 186 6.5 30

a b b1 c d e g k

[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]

e

e

9350br_002

24

l

EDBMB935X EN 8.0

Mechanical installation

Mounting with thermal separation (push−through technique)

4

4.3 Mounting with thermal separation (push−through technique)

You can mount the heatsink of the braking units outside of the control cabinet
to reduce the heat generation within the control cabinet. You require a
mounting frame with a seal (see accessories).

ƒ Distribution of the power loss:

– Approx. 65% via separate cooler
– Approx. 35% in the interior of the braking unit

ƒ The class of protection of the separated cooler is IP41.
ƒ Furthermore the rated data of the braking unit apply.

Mounting preparation

1. Insert the halves of the mounting frame into the location groove on the
braking unit, which is provided for this purpose.

2. Push the frame halves together until the ends lock into place.

3. Slip the seal over the heatsink of the braking unit and insert it into the
location hole provided.

EDBMB935X EN 8.0

l

25

4

Mechanical installation

Mounting with thermal separation (push−through technique)

l

d1

d

d1

Fig. 2 Dimensions

Type

9351 / 9352

a b b1 c c1 d d1 e f g

[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]

86.5

b

b1

g

c

c1

f

e

a

9350br_003

386

350

34

69.5

367

162.5

186

92

6.5

Mounting cutout Z

Type

9351 / 9352

26

Height Width

[mm] [mm]

350 ± 3

56 ± 3

l

EDBMB935X EN 8.0

Mechanical installation

Mounting in cold−plate design

Fields of application

4

4.4 Mounting in cold−plate design

4.4.1 Fields of application

This variant is especially used in the following applications.

ƒ Use of cooling units without blower:

– Heavy pollution of the cooling air, for instance, impedes the operation

of blowers, as it would affect both the function and the service life of
the fans.

ƒ High degree of protection in the case of thermal separation:

– If thermal separation has to be used due to the power balance within

the control cabinet, and if the enclosure of the cooling unit has to be
greater than IP41.

ƒ Use of the controllers directly within the machine with a reduced overall

depth:

– Constructional elements of the machine take over the cooler function

ƒ Collective coolers (water coolers, forced−air coolers, etc.) for all controllers

are provided for in the system concept.

4.4.2 Requirements with regard to the cooler

The dissipation of the power loss by the braking unit can be effected via coolers
operating with different cooling media (air, water, oil, etc.).

In addition to the characteristics specified by the user, the following is
important for a safe operation:

ƒ Good thermal connection to the cooler

– The contact surface between the external cooler and the cooling plate

of the braking unit at least has to be as large as the cooling plate.

– Surface planarity of the contact surface approx. 0.05 mm.
– Connect cooler and cooling plate with all screwed connections

specified.

ƒ Observe thermal resistance R

medium) according to table. The values apply to

thmin heatsink

(transition of cooler − cooling

– The operation of the braking unit under rated operating conditions (see

chapter 3.3)

– A maximum temperature of the cooling plate of 75 _C, measuring

point: narrow side of the cooling plate level with a point half way up
the controller.

EDBMB935X EN 8.0

l

27

4

Mechanical installation

Mounting in cold−plate design
Thermal behaviour of the complete system

Braking unit

Power to be dissipated P

9351−V003 100 0.3

9352−V003 63 0.3

vAR

4.4.3 Thermal behaviour of the complete system

The thermal conditions within a system are affected by some basic conditions.
The following items have to be taken into consideration when a control cabinet
or system is designed:

Ambient temperature of the controllers

For the ambient temperature of the braking unit, furthermore the rated data
and the corresponding derating factors at increased temperature apply.

Heat generation in the interior of control cabinets

In addition to the device losses that are dissipated via the heatsink, further
losses have to be taken into consideration for the design:

ƒ Losses within the braking unit

– These losses are caused by the electronic supply, fans, DC−bus

capacitors, etc.

ƒ Losses of the components on the mains and motor side
ƒ Radiation of heat from the external cooling unit into the interior

– This portion of the heat energy for instance depends on the type of

cooling unit and the mounting mode.

Cooling path

[W] R

thmin heatsink

[K/W]

Heat distribution on the collective cooler / within the control cabinet

If you mount several components (controllers, braking units, etc.) onto a
common cooler, it has to be ensured that the temperature on the cooling plate
of each individual component does not exceed 75 _C.

Measures:

ƒ Observe minimum clearances around the convection cooler.
ƒ Do not mount the components on top of each other.
ƒ In order to avoid heat concentrations within the control cabinet, use

internal fans, if required.

28

l

EDBMB935X EN 8.0

4.4.4 Mounting

Before screwing the cooler and the cooling plate of the braking unit together,
apply the heat conducting paste supplied, in order to keep the heat transfer
resistance as low as possible.

ƒ Clean the contact surface using spirit.
ƒ Apply the heat conducting paste in a thin layer using a spattle or a paint

brush.

– The heat conducting paste in the accessory kit is sufficient to cover a

surface of approx. 1000 cm

ƒ Mount controller to the heatsink with 4 M5 fixing screws.

– Screw−tightening torque: 3.4 Nm.

l

Mechanical installation

Mounting in cold−plate design

Mounting

2

.

4

b1

g

c
a

Fig. 3 Dimensions

Type

9351−V003
9352−V003

d

b

e

9350br_004

a b b1 c d e g

[mm] [mm] [mm] [mm] [mm] [mm] [mm]

52 381 350 34 367 104 6.5

EDBMB935X EN 8.0

l

29

5

Electrical installation

Important notes
Protection of persons

5 Electrical installation

5.1 Important notes

( Stop!

The drive controller contains electrostatically sensitive components.
The personnel must be free of electrostatic charge when carrying

out assembly and service operations.

5.1.1 Protection of persons

{ Danger!

Before carrying out operations on the controller, check whether all
power terminals are in a deenergised state:

ƒ After power−off the power terminals +U

carry dangerous voltages for 3 minutes.

ƒ S1, S2 and S3 have a mains potential!

Replacing defective fuses

Replace defective fuses only in the deenergised state with the type specified.

5.1.2 Device protection

In the case of condensation, only connect the controllers to the mains voltage
if the humidity has evaporated again.

– Wait for at least 3 minutes before changing over the switches.

ƒ During braking operation the DC−bus voltage is still applied after

power−off:
– In order to avoid that energy is fed into the DC bus further on,

controller inhibit has to be set for all controllers in the
interconnection.

– Observe that the drive system coasts down after controller

inhibit has been set.

, −UG and RB1, RB2 still

G

30

l

EDBMB935X EN 8.0

5.2 Cable specification

ƒ The cables used have to comply with the requirements on the location

(e. g. EN 60204−1).

ƒ The corresponding minimum cross−sections of the cables have to be

observed.

ƒ Only use shielded cables with a braid of tinned or nickel−plated copper.

Shields of steel braid are unsuitable.

– The overlap rate of the braid has to be at least 70 % with an overlap

angle of 90 °.

Electrical installation

Cable specification

5

EDBMB935X EN 8.0

l

31

5

Electrical installation

Connection
Power connections

5.3 Connection

Preparation

ƒ Remove cover of the power connections.
ƒ Remove cover of the control connections.

5.3.1 Power connections

ƒ The data regarding cable cross−sections and fuses are recommendations

and refer to the use:

– In control cabinets and machines
– Installation in the cable duct
– Maximum ambient temperature +40 °C

ƒ The cables between the braking unit and the controller may not exceed a

length of 2 m.

– For cable lengths £ 0.5 m you can use unshielded single cores.

ƒ If an interference suppression of the drive system (limit class A or B in

accordance with DIN 55011) is required, the cables have to be shielded

– Always apply the shield on both sides.

ƒ It is the user’s responsibility to take further standards (e. g.: VDE 0113,

VDE 0289, etc.) into consideration.

5.3.2 Permissible cable lengths

To operate the 9350 braking units in a trouble−free manner, observe the
following installation instructions:

Cable

Controller − 935X (low−inductance
cables, i. e. conduct in a bunched
manner)

935X − external brake resistor (internal brake resistor) 8

Synchronisation cable between 935X
(only for parallel operation)

9351 brake module 9352 brake chopper

[m] [m]

2

2 2

2

32

l

EDBMB935X EN 8.0

Electrical installation

5

Connection

Permissible cable lengths

L

13

L

12

+UG

A1

L

0

-UG

2

L

11

2 2 2

£

011

L+L 2m

Z1

E A E A E A

L2m

£

012

L+L 2m

Z2

L2m

£

21

£

2x

£

01x

L+L 2m

Zx

£

31

L8m

2

2 2

£

32

L8m

£

3x

L8m

Fig. 4 Example circuit for parallel operation

A1 Controller
Z1 Brake chopper 1 = master
Z2 ... Zx Brake chopper 2 ... x = slave 2 ... slave x
RB1, RB2, RBx External brake resistors
L0 Cable length of controller  collection point
L1x Cable length of collection point  braking unit
L2x Cable length of synchronisation cable for parallel operation
L3x Cable length of brake chopper  brake resistor

EDBMB935X EN 8.0

l

RB1

RB2

RBx

9350br_005

33

5

Electrical installation

Connection
Fusing

5.3.3 Fusing

ƒ Fuses in UL−conform systems have to be UL−approved.
ƒ The rated voltages of the fuses have to be dimensioned according to the

DC−bus voltage.

ƒ The use of DC−bus fuses is a recommendation.

– If DC−bus fuses are used, they have to comply with the specifications in

ƒ It is the user’s responsibility to take further standards (e. g.: VDE 0113,

VDE 0289, etc.) into consideration.

Connection

ƒ Connect cables for the power supply module (934X), controller (93XX) and

further braking units (935X) in the DC−bus connection to the screw
terminals +UG, −UG on the top at the braking unit and the controller.

ƒ Observe the screw−tightening torques:

Terminals

+UG, −UG 0.5 ... 0.6 4.4 ... 5.3

PE 1.7 15

chapter 3.3.3.

Tightening torques

[NM] [lb−in]

For shielded cables:

ƒ Apply the shield correctly (required parts in the accessory kit):

– Screw shield sheet onto the fixing bracket.
– Clamp the shield with clips. Do not use as strain relief!
– The PE connection is effected via the fixing bracket.

5.3.4 Temperature monitoring

( Stop!

ƒ Always connect the temperature monitoring.

– The temperature monitoring is required for the safe

disconnection in the case of fault.

Loop the temperature switches of the external brake resistors or the 9351 brake
module in the monitoring circuit, so that the following reactions are triggered
if the temperature monitoring responds:

ƒ All controllers which are connected to the braking units are disconnected

from the mains.

ƒ Controller inhibit is set for those controllers.

34

l

EDBMB935X EN 8.0

Electrical installation

Connection

9351 brake module to controllers 822X and E82Vector (15 − 90 kW)

5

5.3.5 9351 brake module to controllers 822X and E82Vector (15 − 90 kW)

L1

L2

L3

N

PE

F1...F3

K1

Z3

"

"

OFF

K1

ON

"

"

L3

L1

L2

PE

Z2

+UG

F4

-UG

F5

-UG

+UG

RB

PE

T1

K1

T2

9351

PE

U

V

W

28

20

E1

...

Z1

"

"

M

3~

PE

Fig. 5 Connection of the 9351 brake module to controllers 822X and E82Vector (15 − 90 kW)

Z1 Brake module
Z2 Controller
Z3 Mains choke
K1 Mains contactor
F1 ... F3 Mains fuses
F4, F5 DC−bus fuses (recommendation)

Mains voltage [V

Switching threshold [V] 375 725 765

Switch position S1 OFF ON ON

Switch position S2 OFF OFF ON

] 230 400 ... 460 480

eff

K1

RFR

"

"

9350br_006

Default setting

EDBMB935X EN 8.0

l

35

5

Electrical installation

Connection
9352 brake chopper to controllers 822X and E82Vector (15 − 90 kW)

5.3.6 9352 brake chopper to controllers 822X and E82Vector (15 − 90 kW)

L1

L2

L3

N

PE

K1

OFF

ON

JRB

K1

"

"

Z4

RB1

RB2

PE

+UG

F1...F3

-UG

"

K1

Z3

"

"

"

F4 F5

L3

L1

L2

PE

+UG

-UG

9352

Z1

"

"

PE

PE

Z2

U

V

W

M
3~

K1

RFR

28

A1

"

"

9350br_007

Fig. 6 Connection of the 9352 brake chopper to controllers 822X and E82Vector (15 − 90 kW)

Z1 Brake chopper
Z2 Controller
Z3 Mains choke
Z4 Brake resistor
K1 Mains contactor
F1 ... F3 Mains fuses
F4, F5 DC−bus fuses (recommendation)

Default setting

Mains voltage [V

] 230 400 ... 460 480

eff

Switching threshold [V] 375 725 765

Switch position S1 OFF ON ON

Switch position S2 OFF OFF ON

36

l

EDBMB935X EN 8.0

Electrical installation

Connection

9351 brake module to 93XX controllers

5

5.3.7 9351 brake module to 93XX controllers

L1

L2

L3

N

PE

F1...F3

K1

Z3

"

"

"

L3

L1

L2

PE

+UG

F4

F5

-UG

9321 - 9333

Z2

PE

U

V

W

28

E1

A1

A2

...

"

-UG

+UG

PE

RB

T1

9351

Z1

K1

T2

OFF

ON

K1

"

"

PE

3~

M

K1

RFR

"

"

Fig. 7 Connection of the 9351 brake module to 93XXcontrollers

Z1 Brake module
Z2 Controller
Z3 Mains choke
K1 Mains contactor
F1 ... F3 Mains fuses
F4, F5 DC−bus fuses (recommendation)

Default setting

Mains voltage [V

] 230 400 ... 460 480

eff

Switching threshold [V] 375 725 765

Switch position S1 OFF ON ON

Switch position S2 OFF OFF ON

9350br_008

EDBMB935X EN 8.0

l

37

5

Electrical installation

Connection
9352 brake chopper to 93XX controllers

5.3.8 9352 brake chopper to 93XX controllers

L1

L2

L3

N

PE

K1

OFF

ON

JRB

K1

"

"

Z4

RB1

RB2

PE

+UG

F1...F3

-UG

"

K1

Z3

"

L1

"

"

F4 F5

L3

L2

PE

+UG

-UG

9352

Z1

9321 - 9333

U

PE

"

"

3~

PE

Z2

V

W

28

A1

"

"

M

K1

RFR

Fig. 8 Connection of the 9352 brake chopper to 93XXcontrollers

Z1 Brake chopper
Z2 Controller
Z3 Mains choke
Z4 Brake resistor
K1 Mains contactor
F1 ... F3 Mains fuses
F4, F5 DC−bus fuses (recommendation)

Default setting

Mains voltage [V

] 230 400 ... 460 480

eff

Switching threshold [V] 375 725 765

Switch position S1 OFF ON ON

Switch position S2 OFF OFF ON

9350br_009

38

l

EDBMB935X EN 8.0

Electrical installation

Connection

Setting the switching threshold

5

5.3.9 Setting the switching threshold

{ Danger!

ƒ S1, S2 and S3 have a mains potential!

– Wait for at least 3 minutes before changing over the switches.

Important notes

The switching threshold of the braking unit is the voltage value in the DC bus,
at which the brake resistor is connected.

ƒ The switching threshold depends on the mains voltage.

– With the switches S1 and S2 you can adapt the switching threshold to

the corresponding mains voltage of the controller.

ƒ For all braking units connected in parallel in the DC−bus connection the

same switching threshold has to be set.

Setting

1. Switch the controller to a deenergised state and wait for 3 minutes until
the capacitors of the voltage DC−bus are discharged.

2. Remove terminal cover of the control terminals (at the bottom) from the
braking unit.

3. Set switches S1 and S2 according to the following table:

Default setting

Mains voltage [V

Switching threshold [V] 375 725 765

Switch position S1 OFF ON ON

Switch position S2 OFF OFF ON

] 230 400 ... 460 480

eff

4. Press terminal cover onto the braking unit again until it snaps into place.

EDBMB935X EN 8.0

l

39

5

Electrical installation

Parallel connection
Braking units with brake resistor

5.4 Parallel connection

{ Danger!

ƒ S1, S2 and S3 have a mains potential!

– Wait for at least 3 minutes before changing over the switches.

5.4.1 Braking units with brake resistor

You can connect the 935X braking units in parallel in any combination if an
individual braking unit cannot completely convert the arising braking power.

Important notes

ƒ Connect each braking unit in parallel to the terminals +U

controllers.

– For total lengths £ 0.5 m a shielding is not required.

ƒ Connect a brake resistor to each 9352 brake chopper at the terminals RB1

and RB2.

ƒ Connect the contacts (NC contacts) of the brake resistor temperature

monitorings in series.

ƒ Make sure that the minimum resistance specified in the technical data of

the braking units is observed − also in the case of parallel connection of
brake resistors (see chapter 3.3).

ƒ Wire brake resistors connected in parallel so that a simultaneous

connection and disconnection is ensured. Otherwise the braking power is

and −UG of the

G

not divided equally to the brake resistors connected.

40

l

EDBMB935X EN 8.0

( Stop!

Correct synchronisation of braking units connected in parallel:

ƒ Set switching thresholds of all braking units to the same value

(see chapter 5.3.9).

ƒ Connect synchronisation interfaces correctly

– Output: A1, A2 / input E1, E2
– For total lengths £ 0.5 m you do not have to use shields.

ƒ Configuring braking units with switch S3 as master and slave:

– Configure the first braking unit in the interconnection as

– Configure each further braking unit within the interconnection

master (S3 = OFF).

as slave (S3 = ON).

Electrical installation

Parallel connection

Braking units with brake resistor

5

EDBMB935X EN 8.0

l

41

5

Electrical installation

Parallel connection
Braking units with brake resistor

"

K1

Z3

F1...F3

"

Z1x

"

Z12

"

Z11

"

"

"

"

"

"

"

"

"

"

F11

F10

F8 F9

F7

F6F4

F5

-UG

+UG

PE

L3

L2

L1

-UG

+UG

PE

RB2

RB1

-UG

+UG

PE

RB2

RB1

-UG

+UG

PE

RB2

RB1

Z6

9321 - 9333

Zx

9352

Slave X

Z2

9352

Slave 1

Z1

9352

Master

"

"

"

"

K1

RFR

M

3~

PE

A1

28

W
V
U

PE

E2 A1 A2
E1

"

"

E2 A1 A2
E1

"

"

E2 A1 A2
E1

OFF

L3

L1

N

L2

PE

Fig. 9 Parallel connection of 9352 brake choppers

42

K1

ON

JRB1

JRBx

K1

JRB2

l

9350br_010

EDBMB935X EN 8.0

Z1 Brake chopper 1 = master (S3 = OFF)
Z2 Brake chopper 2 = slave (S3 = ON)
Zx Brake chopper x = slave (S3 = ON)
Z3 Mains choke
Z6 Controller
Z11, Z12, Z1x External brake resistors
K1 Mains contactor
F1 ... F3 Mains fuses
F4 ... F11 DC−bus fuses (recommendation)

{ Danger!

The outputs of the synchronisation interfaces have mains potential.

ƒ Only use suitable, insulated cables for wiring.

Electrical installation

Parallel connection

Braking units with brake resistor

5

EDBMB935X EN 8.0

l

43

5

Electrical installation

Parallel connection
Braking units with a common brake resistor

5.4.2 Braking units with a common brake resistor

+UG

-UG

PE

Z3

F1-F2

"

"

JRB

1

0

2

1m, 4mm

£

2

1m, 4mm

£

RB1 RB1 RB2 RB2

"

"

"

"

PE

"

"

X1

"

"

2

1m, 4mm

£

2

1m, 4mm

£

F3-F4

0

+UG

-UG

9352

Maste

r

E1

E2 A1 A2

Fig. 10 Parallel operation of 2 brake choppers on one brake resistor

Z1 Brake chopper 1 = master
Z2 Brake chopper 2 = slave
Z3 Brake resistor
F1 ... F4 DC−bus fuses 25 A
X1 Terminal strip
JRB Thermal contact has to be integrated into the temperature monitoring

0 Length difference of the 4 cables: £ 0.05 m
1 Cable length of braking unit − brake resistor: £ 8 m

PE

RB1

Z1

RB2

RB1

RB2

9352

Slave

E1

E2 A1 A2

£

2m

£

2m

"

"

PE

+UG

Z2

-UG

9350br_013

44

l

EDBMB935X EN 8.0

Electrical installation

Use of brake resistors smaller 27R

Braking units with a common brake resistor

5

5.5 Use of brake resistors smaller 27R

( Stop!

Failure of the brake chopper if the braking times are exceeded:

ƒ Observe the power of the brake resistor.
ƒ Integrate the temperature monitoring of the brake resistor into

the emergency stop chain.

When using the external brake resistors with the EMB 9352 brake chopper, the
maximum braking times are to be observed.

+ t

They result from t

on

The diagram applies to applications with U

I [A]

45

40

35

30

25

20

= 3 s.

off

Imax_18R

Imax_22R

Imax_24R

Imax_27R

Imax_33R

mains

Imax_39R

³ 400 V.

Imax_47R

I_d

15

10

5

0

0

Fig. 11 Braking current of the EMB 9352brake chopper

0.5 1.5 2.51.0 2.0 3.0

I_d Continuous current
t

on

Running time

Example for the determination of the braking times with RB = 33 W:
t

= 1.83 s; t

on

= 1.17 s.

off

5.0

t [s]

on

9350br_014

EDBMB935X EN 8.0

l

45

6

Commissioning

Important notes

6 Commissioning

6.1 Important notes

( Stop!

Before initial switch−on, check

ƒ whether the terminals +U

– If +U

connected can be destroyed.

ƒ the switching thresholds of the braking unit(s) are set to the same

values for the entire drive system via switches S1 and S2
– Setting the switching thresholds: see chapter 5.3.9.

ƒ the braking units are configured correctly via S3 if braking units

are connected in parallel.
– The 1. braking unit as master (S3 = OFF).
– All further braking units as slaves (S3 = ON).

Operating status display

The two LEDs on the braking unit display the operating status:

LED display Operating status

Green Yellow

Off Off Braking unit without voltage, not ready for operation.

On Off Braking unit is supplied with voltage and is ready for operation.

On On Braking unit in braking operation, energy is converted within the brake

and −UG are inverted, braking units and all components

G

resistor.
If the braking power is small, the braking times are short, or, during operation
with a switching threshold of 375 V, the luminosity of the yellow LED is very
low.

and −UG are connected correctly.

G

Operating notes

) Note!

The total braking time of a drive is increased if the power that is
regenerated is greater than the peak braking power of the brake
resistor assigned.

In this case the controller sets pulse inhibit and reports
"overvoltage". Remedy to ensure continuous deceleration with a
steady braking torque:

ƒ Increase deceleration time T
ƒ If permissible, use a low−resistance brake resistor.

46

or the QSP ramp at the controller, or

if

l

EDBMB935X EN 8.0

Troubleshooting and fault elimination 7

7 Troubleshooting and fault elimination

Error Cause Remedy

Green LED is not lit No voltage at terminals +UG, −U

Controller sets pulse inhibit in
braking operation and reports
overvoltage

l Yellow LED is not lit Braking unit not connected to the

terminals +U
controller

Switching threshold set
incorrectly (switch S1, S2)

l Yellow LED is lit Brake resistor not connected Connect brake resistor

Brake resistor dimensioned with
a too high impedance

Irregular heating of the brake
resistors during parallel operation
of several braking units

Yellow LED is lit continuously, the
brake resistor is overheating

Brake resistor is overheating

Braking units that are connected
in parallel are not connected to
terminals +U
controller(s)

Brake resistor not connected Connect brake resistor
Synchronisation not connected Connect synchronisation (see

Switching thresholds of the
braking units which are
connected in parallel are not set
equally (switch S1, S2)

Braking units not configured
correctly as master/slave

Switching threshold(s) of the
braking unit(s) set incorrectly
(switch S1, S2)

Resistor is
dimensionedincorrectly

Switching threshold of the
braking unit set incorrectly
(switch S1, S2)

, −UG of the

G

, −UG of the

G

l Switch on mains

G

l Connect braking unit to the terminals

, −UG of the controller

+U

G

Connect braking unit to the terminals

, −UG of the controller

+U

G

Adapt switching thresholds of braking
unit and controller to the mains voltage
(see chapter 5.3.9)

Use low−resistance brake resistor (if
permissible), possibly connect several
braking units in parallel

Connect braking units to terminals +UG,

of the controller(s)

−U

G

chapter 5.4)

Adapt switching thresholds of braking
unit and controller to the mains voltage
(see chapter 5.3.9)

Correct configuration (see chapter 5.4)

Adapt switching thresholds of braking
unit and controller to the mains voltage
(see chapter 5.3.9)

l Select appropriate resistor for the

drive.

l For use of 9351:

– Possibly use 9352.

Adapt switching thresholds of braking
unit and controller to the mains voltage
(see chapter 5.3.9)

EDBMB935X EN 8.0

l

47

8

Appendix

Accessories
Rating for Lenze brake resistors

8 Appendix

8.1 Accessories

8.1.1 Rating for Lenze brake resistors

e

g

c

a

Fig. 12 Resistor modules with integrated temperature monitoring (50 to 200 W)

Resistance Rated power Order No. a b c d e g k

[W] [W] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
470 50 ERBM470R050W 60 240 50 225 60 5 7.5
470 100 ERBM470R100W 70 240 50 225 60 5 7.5
200 100 ERBM200R100W 80 160 70 145 95 5 7.5
370 150 ERBM370R150W 80 240 70 225 95 5 7.5
100 150 ERBM100R150W 80 240 70 225 95 5 7.5
240 200 ERBM240R200W 80 340 70 325 70 5 7.5

82 200 ERBM082R200W 80 340 70 325 70 5 7.5

k

d
b

9350br_011

48

l

EDBMB935X EN 8.0

Appendix

8

Accessories

Rating for Lenze brake resistors

a

f

d

e

b

g

c

9350br_012

Fig. 13 Grid−protected wire−wound resistors with integrated temperature monitoring

Resistance Rated power Order No. a b c d e f g

[W] [W] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
180 300 ERBD180R300W 440 89 354 64 115 326 6.5
100

82 ERBD082R600W
68 800 ERBD068R800W 540 177 454 150 115 426 13
47 1200 ERBD047R01K2 640 177 554 150 115 526 13
33 2000 ERBD033R02K0 640 265 554 240 115 526 13
22
18 ERBD018R03K0

600

3000

ERBD100R600W

ERBD022R03K0

640 89 554 64 115 526 6.5

740 177 654 150 229 626 13

EDBMB935X EN 8.0

l

49

8

Appendix

Glossary

8.2 Glossary

Term Meaning

Controller General designation for servo drives (93XX), frequency inverters (82XX,

IMP Pulse inhibit

Pictograph Pictorial marking or symbol with clear information

PTC PTC thermistor (PTC: positive temperature coefficient)

RB Brake resistor

Residual hazard Dangers that cannot be avoided by specific designs

Peak braking power Maximum power which a resistor can convert into heat for a short time

Use l Intended:

86XX) and DC drives (48XX, 49XX)

– Appropriate use of the machine according to the manufacturer’s

information oraccording to common use because of its design and
function.

l Improper:

– Any other use which is not intended.

50

l

EDBMB935X EN 8.0

8.3 Index

9351 brake module, 9

9352 brake chopper, 9

A

Ambient conditions

− climatic, 20

− mechanical, 20

Application, as directed, 10

Application as directed, 10

Appendix

Definition of notes used, 18

Definitions of terms, 9

Display

− LED, 46

− operating status, 46

Disposal, 15

E

Electrical installation, 30

8

Index

Application range, 5

B

Brake resistor, 48

Brake resistors, assignment table, 22

Braking unit, 9

− parallel connection, 40

Braking units, 21

C

Cable cross−sections, 22

Cable lengths, permissible, 32

CE conformity, 10

Cold plate, variant, 27

Commissioning, 46

Conformity, 10

Connection, 32

Controller, 9

− application as directed, 10

− labelling, 10

F

Features, 19

Fuses, 22

Fusing, 22 , 34

G

Gases, aggressive, 23

General data, 20

I

Installation, mounting, 29

Installation, electrical, 30

Installation, mechanical, 23

L

Labelling, controller, 10

LED, 46

Legal regulations, 10

Liability, 11

D

Default setting, switch S1/S2, 39

EDBMB935X EN 8.0

l

51

8

Appendix

Index

M

Manufacturer, 10

Master/slave, 40

Mechanical installation, 23

Mounting, 29

− cold−plate design, 27

− standard installation (with fixing rails), 24

− thermally separated (push−through
technique), 25

Mounting clearance, 23

N

Notes, definition, 18

O

Operating conditions, 20

− ambient conditions
climatic, 20
mechanical, 20

Operating notes, 46

Operating status, display, 46

R

Rating, Brake resistors, 48

Residual hazards, 17

S

Safety instructions, 12

− Definition, 18

− Structure, 18

Scope of supply, 4

Site altitude, 20

Switch, S3, 40

− master/slave, 41

Switch S1/S2, 39

Switching threshold, 39

Synchronisation interface, 40

T

Technical data, 19

Temperature monitoring, 34

Terminology used, 9

P

Parallel connection, braking unit, 40

Permissible cable lengths, 32

Pollution, 20

Protection of persons, 17

Push−through technique, 25

52

Troubleshooting and fault elimination, 47

V

Variant, cold plate, 27

W

Warranty, 11

l

EDBMB935X EN 8.0

J

Lenze Drive Systems GmbH
Hans−Lenze−Straße 1
D−31855 Aerzen
Germany

(
( Service

Ê Service

E−Mail [e-mail]
Internet www.Lenze.com

+49(0)515482−0

0080002446877 (24 h helpline)

+49(0)515482−1112

EDBMB935X

EN 8.0

© 08/2008

TD34

10987654321