Danfoss VLT Brake Resistor MCE 101 Guide

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT®Brake Resistor MCE 101

VLT®Frequency Converters • FC 51 • FC 102 • FC 202 • FC 301

FC 302 • FC 360 • FCD 302 • VLT®2800

www.danfoss.com/drives

Contents

1 Introduction 4

1.1 How to Read this Design Guide 4

1.2 Conformity 4

1.3 Safety Precautions 4

1.4 Disposal 4

2 Product Overview 5

2.1 Description of the Brake System 5

2.2 Horizontal or Vertical Load 5

2.3 Aluminium-housed Brake Resistors 6

2.3.1 Aluminium-housed Flat-pack Brake Resistors 6

2.3.2 Aluminium-housed Compact Brake Resistor 6

2.4 Steel Grid Brake Resistors 6

3 Installation 7

3.1 Mechanical Installation 7

3.1.1 Aluminium-housed Compact Brake Resistors and Flat-pack Brake Resistors 7

3.1.2 Steel Grid Brake Resistors 10

3.1.3 Accessories 11

3.2 Electrical Installation 12

3.2.1 EMC Precautions 12

3.2.2 Cable Connection 12

3.2.3 Brake Cable 13

3.3 Protective Functions 13

3.3.1 Overtemperature Protection 13

3.3.2 Brake Resistor and Brake IGBT 14

4 System Integration 15

4.1 Brake Resistor Calculation 15

4.1.1 Brake Set-up 15

4.1.2 Calculation of Brake Resistor Resistance 15

4.1.3 Calculation of Braking Power 16

4.1.4 Calculation of the Brake Resistor Peak Power 17

4.1.5 Calculation of the Brake Resistor Average Power 17

4.1.6 Braking of Inertia 17

5 Programming 18

5.1 Parameters for VLT®Micro Drive FC 51 18

5.2 Parameters for VLT®HVAC Drive FC 102 and VLT®AQUA Drive FC 202 18

Contents Design Guide

5.3 Parameters for VLT®AutomationDrive FC 301/FC 302 and ®Decentral Drive FCD

302 21

5.4 Parameters for VLT®AutomationDrive FC 360 24

5.5 Parameters for VLT®2800 25

6 Application Examples 27

6.1 Conveyor Belt 27

6.2 Centrifuge 29

6.3 Continuous Braking 29

7 Special Conditions 30

7.1 Alternative Braking Methods 30

7.1.1 DC Injection Braking 30

7.1.2 AC-braking 30

7.1.3 Mechanical Holding Brake 30

7.1.4 DC Braking 31

8 Selection Guide 32

8.1 Selection Flow Chart 32

8.2 Selection Tables for Recommended Brake Resistors 33

8.2.1 Abbreviations used in the Brake Resistor Tables 33

8.2.2 VLT®Micro Drive FC 51 33

8.2.3 VLT®HVAC Drive FC 102 35

8.2.4 VLT®AQUA Drive FC 202 41

8.2.5 VLT®AutomationDrive FC 301 48

8.2.6 VLT®AutomationDrive FC 302 51

8.2.7 VLT®AutomationDrive FC 360 57

8.2.8 VLT®Decentral Drive FCD 302 59

8.2.9 VLT®2800 60

8.3 Selection Tables for Alternative Brake Resistors 62

8.3.1 Abbreviations used in the Brake Resistor Tables 62

8.3.2 VLT®HVAC Drive FC 102, T2 62

8.3.3 VLT®HVAC Drive FC 102, T4 62

8.3.4 VLT®AQUA Drive FC 202, T2 63

8.3.5 VLT®AQUA Drive FC 202, T4 63

8.3.6 VLT®AutomationDrive FC 301, T2 64

8.3.7 VLT®AutomationDrive FC 302, T2 64

8.3.8 VLT®AutomationDrive FC 301, T4 65

8.3.9 VLT®AutomationDrive FC 302, T5 65

9 Specifications 66

Contents Design Guide

9.1 Ambient Conditions 66

9.2 General Electrical Specifications 66

9.3 Electrical Data: MCE 101 Product Types 9xx 67

9.4 Mechanical Data: MCE 101 Product Types 9xx 74

9.5 Electrical Data: Product Types BWD and BWG 81

9.6 Mechanical Data: Product Types BWD and BWG 82

9.7 Mechanical Drawings 83

9.7.1 Figure 1 - 914CBT-HxxxDHT 83

9.7.2 Figure 2 - 914CBT-HxxxCHT 87

9.7.3 Figure 3 - 914CBT-HxxxBHT 90

9.7.4 Figure 4 - 914CBR-VxxxDT 93

9.7.5 Figure 5 - 914CBR-VxxxCT 96

9.7.6 Figure 6 - 914CBR-VxxxBT 98

9.7.7 Figure 7 - 914CCHxxxCT 101

9.7.8 Figure 8 - 917CM13 103

9.7.9 Figure 9 - 917CM15 105

9.7.10 Figure 10 - 917CM17 107

9.7.11 Figure 11 - 917CM25 109

9.7.12 Figure 12 - 917CM27 111

9.7.13 Figure 13 - 917CM37 113

9.7.14 Figure 14 - 917CMD27 115

9.7.15 Figure 15 - 917CMD37 117

9.7.16 Figure 16 - 929CBT-VxxxGHT 119

9.7.17 Figure 17 - 929CBT-VxxxBGHT 122

9.7.18 Figure 18 - 930CBT-VxxxGHT 125

9.7.19 Figure 19 - 930CBT- VxxxBGHT 128

9.7.20 Figure 20 - BWD250xxx 131

9.7.21 Figure 21 - BWD500xxx 132

9.7.22 Figure 22 - BWD600xxx 133

9.7.23 Figure 23 - BWG250xxx 135

9.7.24 Figure 24 - BWG500xxx 136

9.8 Mechanical Drawings: Accessories 137

9.8.1 Mounting Brackets: L Profile 137

9.8.2 Mounting Brackets: Footprint 139

Index 142

Contents Design Guide

1 Introduction

1.1 How to Read this Design Guide

Danfoss VLT®Brake Resistors MCE 101 are optimised for:

•VLT®Micro Drive FC 51

•VLT®HVAC Drive FC 102

•VLT®AQUA Drive FC 202

•VLT®AutomationDrive FC 300

•VLT®AutomationDrive FC 360

•VLT®Decentral Drive FCD 302

•VLT®2800

General versions for horizontal and vertical applications are

available.

The Design Guide provides the information required to

select and plan installation of the right brake resistor for

an application:

•Selection of the correct brake resistor

•Pre-installation considerations

•Programming.

As an alternative to using a brake resistor, other braking

methods can be applied depending on the braking profile

of the application, see chapter 7 Special Conditions.

Additional technical literature is also available online at

www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-

tations/Technical+Documentation.

1.2 Conformity

Table 1.1 Approval

1) See Table 9.2 and Table 9.4 for UL conformity.

What is CE Conformity and Labelling

The purpose of CE labelling is to avoid technical trade

obstacles within EFTA and the EU. The EU has introduced

the CE label as a simple way of showing whether a

product complies with the relevant EU directives. The CE

label says nothing about the specifications or quality of

the product. Brake resistors are regulated by the following

EU directive:

The low-voltage directive (2006/95/EC)

Brake resistors must be CE labelled in accordance with the

low-voltage directive of December 12, 2006. The directive

applies to all electrical equipment and appliances used in

the 50-1000 V AC and the 75-1500 V DC voltage ranges.

Danfoss CE-labels in accordance with the directive and

issues a declaration of conformity upon request.

1.3 Safety Precautions

WARNING

When in use, the brake resistor surface temperature

rises. DO NOT touch the brake resistor during operation.

WARNING

Never work on a brake resistor in operation.

NOTICE

Never attempt to repair a defective brake resistor.

1.4 Disposal

Equipment containing electrical components

may not be disposed of together with

domestic waste.

It must be separately collected with electrical

and electronic waste according to local and

currently valid legislation.

Introduction Design Guide

2 Product Overview

2.1 Description of the Brake System

When the speed reference of a frequency converter is

reduced, the motor acts as a generator and the frequency

converter brakes. When a motor acts as a generator, it

supplies energy to the frequency converter which is

collected in the DC link. The function of the brake resistor

is to provide a load on the DC link during braking, thereby

ensuring that the braking power is absorbed by the brake

resistor.

If a brake resistor is not used, the DC-link voltage of the

frequency converter continues to increase, until discon-

necting for protection. The advantage of using a brake

resistor is that it enables braking of a heavy load quickly,

e.g. on a conveyor belt.

The brake resistors in this series are all external

components. Therefore, the brake resistor does not form

an integral part of the frequency converter.

The external brake resistor provides the following

advantages:

•The resistor time cycle can be selected as

required.

•The heat developed during braking can be

conveyed beyond the panel cabinet to allow the

energy to be used.

•The electronic components do not overheat, even

when the brake resistor is overloaded.

The brake resistor series is suitable for Danfoss frequency

converters

•VLT®Micro Drive FC 51

•VLT®HVAC Drive FC 102

•VLT®AQUA Drive FC 202

•VLT®AutomationDrive FC 300

•VLT®AutomationDrive FC 360

•VLT®Decentral Drive FCD 302

•VLT®2800

2.2 Horizontal or Vertical Load

2.2.1 How to Select

The Danfoss brake resistor range consists of 2 groups:

•Brake resistors for horizontal loads (conveyors,

trolleys, gantry cranes, etc.), see Illustration 2.1;

•Brake resistors for vertical loads (cranes, hoists,

elevators), see Illustration 2.2.

150/160%

175UA067.10

Illustration 2.1 Horizontal Loads

100%

150/160%

175UA068.10

Illustration 2.2 Vertical Loads

The brake resistor range is intended to cover the general

braking requirements for horizontal and vertical brake

applications.

To select the best brake resistor for an application, refer to

chapter 8.1 Selection Flow Chart. The flow chart links to

further information, either selection tables or calculations

of inertia or duty cycle.

To cater for both the horizontal and vertical ranges, 3

types of brake resistors are available:

•Aluminium-housed flat-pack brake resistors

•Aluminium-housed compact brake resistors

•Steel grid brake resistors

Product Overview Design Guide

2.3 Aluminium-housed Brake Resistors

2.3.1 Aluminium-housed Flat-pack Brake

Resistors

The flat-pack brake resistor is an anodized aluminium-

housed resistor suitable for wall mounting or on a

footprint or an L-profile bracket. The L-profile bracket is

used for rear mounting. The brake resistor is designed for

high pulse loads of up to 40 times the nominal load and is

therefore suitable for both vertical and horizontal

applications. The enclosure protection is IP54 or IP65.

130BD245.12

Illustration 2.3 Flat-pack IP54

2.3.2 Aluminium-housed Compact Brake

Resistor

The compact brake resistor is housed in aluminium profiles

with pre-mounted brackets for wall mounting. It is

designed for high pulse loads of up to 60 times the

nominal load and is therefore used for both horizontal and

vertical loads. The enclosure protection class is either IP21,

IP54 or IP65. The brake resistor IP classes IP21 and IP65 are

equipped with a connection box containing cable glands

and cable connection to the resistor and the temperature

switch. IP54 versions have fixed unscreened cables.

130BD646.10

Illustration 2.4 CBR-V-CT IP54

130BD228.10

Illustration 2.5 CBR-V-DT IP21

130BD217.10

Illustration 2.6 CBR-V-BT IP65

2.4 Steel Grid Brake Resistors

The steel grid brake resistor is steel grid housed and

consists of multiple elements. This brake resistor is suitable

for pulse loads between 10 and 20 times the nominal load,

suitable for frequent braking applications such as cranes,

hoists and elevators. It is supplied in an IP20 enclosure

with cable glands and has a built-in temperature switch.

130BD586.10

Illustration 2.7 Steel Grid House IP20

Product Overview Design Guide

3 Installation

3.1 Mechanical Installation

The brake resistors are cooled by natural convection, and

the specified minimum clearances must be observed to

ensure efficient ventilation. The ventilation must be

efficient enough to dispatch the regenerative power in the

brake resistor.

NOTICE

When installing the brake resistor, ensure all precautions

are in place to avoid the risk of overloading. Overloading

can lead to a fire hazard due to the heat generated in

the brake resistor.

The brake resistor is very hot during or after braking.

The brake resistor must be located in a secure

environment to avoid fire risk.

•Mount the brake resistor free of any combustible

materials at a well ventilated location.

•The MCE 101 brake resistors product type 9xx

contain a built-in temperature switch (for

overtemperature protection purposes. See

chapter 3.3 Protective Functions).

3.1.1 Aluminium-housed Compact Brake

Resistors and Flat-pack Brake

Resistors

The aluminium-housed compact and flat-pack brake

resistors are designed for vertical mounting for optimum

cooling performance. However, horizontal mounting is

possible for both flat-pack and compact brake resistors.

Derating with 20% is required when mounting the

compact brake resistors horizontally. No derating for flat-

packs are required. The enclosure protection of the IP21

types is reduced to IP20 when mounted horizontally.

NOTICE

All resistors are cooled by natural convection. To ensure

sufficient airflow and cooling, follow minimum clearance

in Illustration 3.1 to Illustration 3.8.

Vertical Mounting, IP54

For minimum clearances for vertical mounting for all

aluminium-housed compact and flat-pack brake resistors,

see Illustration 3.1 and Illustration 3.2.

130BD900.10

200 mm

Illustration 3.1 Vertical Mounting, IP54

Versions with Fixed Cables

Installation Design Guide

130BD901.10

200 mm

500 mm

200 mm

Illustration 3.2 Vertical Mounting, IP54

Versions with Fixed Cables

Horizontal mounting, IP54

For minimum clearances for horizontal mounting for all

aluminium-housed compact and flat-pack brake resistors,

see Illustration 3.3 (top view).

200 mm

200 mm200 mm

130BD902.10

Illustration 3.3 Horizontal mounting, IP54

Versions with Fixed Cables

For minimum clearances for horizontal mounting for all

aluminium-housed compact and flat-pack brake resistors,

IP54 versions (versions with fixed cables), see Illustration 3.4

(side view).

130BD903.10

500 mm

Illustration 3.4 Horizontal mounting, IP54

Versions with Fixed Cables

Vertical mounting, IP21 and IP65

For minimum clearances for vertical mounting for all

aluminium-housed compact brake resistors, see

Illustration 3.5 and Illustration 3.6.

130BD904.10

200 mm

Illustration 3.5 Vertical Mounting, IP21 and IP65

Versions with Connection Box

Installation Design Guide

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