Siemens COMBIMASTER User manual

COMBIMASTER &

MICROMASTER Integrated

Operating Instructions -

BRAKE OPTIONS

Bedienungsanleitung -

BREMS-OPTIONEN

CONTENTS

Section 1 Safety and CE Compliance............. 1-2

Section 2 E-M Brake Option ............................ 3

Section 3 E-M Brake Option Installation ........ 3-6

Section 4 E-M Brake Option Commissioning 6

Section 5 R Brake Option ................................ 6-7

Section 6 R Brake Option Installation ............ 8-9

Section 7 DC Link Threshold Selection ......... 9

1 SAFETY AND CE COMPLIANCE

WARNING

Before installing and putting this equipment into operation, read the warnings

and cautions carefully. Also read and comply with the warning labels attached

to the equipment. Ensure that warning labels are kept in a legible condition

and replace any missing or damaged labels.

This equipment contains dangerous voltages. Loss of life, severe personal

injury or property damage can result if the procedures contained in these

instructions are not followed.

The surface of the braking unit becomes hot during operation.

WARNING

Only suitably qualified personnel

should install, operate or maintain

this equipment, and, only after

becoming familiar with all the

safety notices and installation,

operation and maintenance

procedures which are contained

in the COMBIMASTER /

MICROMASTER Integrated (MMI)

Operating Instructions.

CAUTION

Do not allow children or the

general public to access or

approach this equipment.

Use this equipment only for the

manufacturer’s specified purpose.

Do not carry out modifications or fit

spare parts not sold or

recommended by the

manufacturer; this could cause fire,

electric shock or other injuries.

CAUTION

Do not paint over the black case

finish as this will affect the unit’s

thermal performance.

High voltage insulation test

equipment must not be used on

cables connected to this

equipment.

CMOS components used in this

equipment are particularly sensitive

to static electricity. Avoid touching

these components, or their printed

circuit boards, with bare hands or

metal objects.

The brake options 6SE9996-0XA10 (E-M)

and 6SE9996-0XA11 (R) are designed to

work with the Case Size B inverter range.

Brake option 6SE9996-0XA07 (E-M) is

designed for Case Size A.

The parameters used to set up the brake

options are as summarised in the

COMBIMASTER and MICROMASTER

Integrated (MMI) Reference Manual.

EUROPEAN LOW VOLTAGE & EMC DIRECTIVES

The COMBIMASTER and MICROMASTER Integrated

Brake Options product ranges comply with the

requirements of the Low Voltage Directive73/23/EEC as

amended by Directive 93/68/EEC.

The units are certified for compliance with the following standards:

EN 60146-1-1 Semiconductor converters - EN 60204-1 Safety of machinery -

General requirements and Electrical equipment

line com mutated converters of machines

EUROPEAN MACHINERY DIRECTIVE

The COMBIMASTER and MICROMASTER Integrated Brake Options product ranges do not fall under the

scope of the Machinery Directive. However, the products have been fully evaluated for compliance with

the essential Health & Safety requirements of the directive when used in a typical machine application. A

declaration of incorporation is available on request.

ISO 9001

Siemens plc operates a Quality Management System,

which fully complies with the requirements of ISO 9001.

2 E-M BRAKE OPTION

The 6SE9996-0XA10 (Case Size B) &

6SE9996-0XA07 (Case Size A)

Electromechanical (E-M) Brake options

allow the COMBIMASTER or MMI to

directly control a mechanical motor brake.

The E-M Brake Option fits in place of the

existing inverter cover. Full IP65 protection

is maintained.

The unit provides an output to drive the coil

of an electromechanical brake. It can be

configured for either fast or slow activation

of the brake (~10ms difference).

The unit is set up using the parameters

P062, P063 and P064, which control the

brake release and the stopping time.

Brake Coil Voltage:

6SE9996-0XA10 = 45% Vmains

e.g. 180Vdc for 400V mains

6SE9996-0XA07 = 45% or 90% Vmains

The 180V dc brake coil

voltage for 400V mains is

not suitable for the standard

Siemens electromechanical

brake option G26.

3 E-M BRAKE OPTION INSTALLATION

Case Size A E-M Brake Option Parts

x1 Long Wire Link

x3 Short Wire Link

x2 Long Socket

x2 Socket

x1 Control PCB Insulation

x1 PG9 Cable Gland

The E-M Brake Option fits in place of the

existing inverter cover. It does not require

a separate mains input. It picks up two of

the mains input phases to the inverter.

Case Size B E-M Brake Option Parts

x6 Socket

x1 Gate Drive Insulation with Label

x1 PG9 Cable Gland

E-M Brake Option Installation Process:

•Discard the E-M brake option PG9

blanking gland.

•Connect the motor E-M brake coil using

0.5mm2, 2-core double insulated cable,

strip length = 5mm. The diameter of the

outer insulation must be in the range

4.5–6.0mm.

•Pass the cable through the PG9 gland

provided (part A6/B3) and secure the

gland to form a tight fit around the cable

insulation. Keep the cable as short as

possible to minimise electromagnetic

radiation and/or pickup.

3 E-M BRAKE OPTION INSTALLATION (Continued)

•Set the E-M Brake Option as shown

in Fig. 1 for fast or slow activation.

•For CS A E-M Brake Option, set also

for 45% or 90% to suit the brake coil.

Fast Brake Activation Case Size A E-M Brake Option Slow Brake Activation

90% Case Size A E-M Brake Option 45%

Case Size B E-M Brake Option - Fast Brake Activation

Case Size B E-M Brake Option - Slow Brake Activation

Fig. 1 E-M Brake Option Connection Diagram

3 E-M BRAKE OPTION INSTALLATION (Continued)

The unit is now ready to be fitted to the inverter.

WARNING

Under no circumstances attempt to fit or remove the braking unit while the

inverter is still powered.

Case Size A E-M Brake Option

•Ensure that the inverter is isolated from

the mains supply. Remove and discard

the inverter case cover.

•Locate stud holes ST500 (L2) and ST501

(L1), at the fan cowl end of the inverter

on the control PCB. Insert the two long

sockets (part A3) into these stud holes

and secure onto the studs below. Use a

6mm flat-blade screwdriver and torque-

down the long sockets to 0.8Nm.

•Locate studs ST502 and ST503 (E-M

brake relay control) on the control PCB.

Fit the other two metal sockets provided

(part A4), to these studs and secure and

torque-down as in the previous step.

•Fit the control PCB insulation (part A5)

supplied with the option. This part fits

loosely – align the holes in the insulation

with studs ST502, ST503 and ST501.

CAUTION

Ensure that the control PCB

insulation is in place before fitting

the brake option inverter cover.

•Fit and screw down the brake option

inverter cover and check that the four

corners of the cover are making contact

with the inverter case. This ensures that

the brake option is correctly earthed.

Case Size B E-M Brake Option

•Ensure that the inverter is isolated from

the mains supply. Remove and discard

the inverter case cover.

•Remove and discard the internal black

plastic insulation cover, but retain the two

securing screws.

•Locate studs ST100 (L1) and ST102

(L3), on the now exposed gate drive

PCB. Replace the two nuts, which each

secure a flying lead to its stud, with two

of the metal sockets (part B1) provided.

Secure the flying leads via the sockets

using a 6mm flat-blade screwdriver and

torque-down to 0.8Nm.

•Locate studs ST500 and ST501 (E-M

brake relay control). Fit two more metal

sockets (part B1) to these studs and

secure and torque-down as in the

previous step.

•Locate studs ST103 (DC+) and ST104

(DC-). Fit the last two metal sockets

(part B1) to these studs and secure and

torque-down as in the previous step.

Note that these studs are not electrically

part of the E-M brake option, but provide

for greater ease in fitting of the option.

•Fit the gate drive PCB insulation (part

B2) supplied with the option. Secure

with the retained securing screws and

torque-down to 2Nm.

CAUTION

Ensure that gate drive PCB

insulation is in place before fitting

the brake option inverter cover.

•Ensure the cover gasket is correctly

positioned and fit and screw down the

brake option inverter cover. Check the

four corners of the cover are making

contact with the inverter case to ensure

that the brake option is correctly earthed.

3 E-M BRAKE OPTION INSTALLATION (Continued)

Fig. 2 External Brake Parameters

Brake Option Parameters:

P063 - External brake release delay.

When the inverter is set to RUN, it will

run at the minimum frequency for the

time set by the parameter, before

activating the E-M brake control relay

and releasing the brake (see Fig. 2).

Default value is 1.0s.

P064 - External brake stopping time.

This defines the period for which the

inverter continues to run at the minimum

frequency after ramping down and while

the E-M brake is applied.

Default value is 1.0s.

P063 and P064 settings should

be slightly longer than the actual

time taken for the E-M brake to

apply and release respectively.

P063 & P064 settings should be

kept as short as possible,

especially with a high minimum

frequency, as an overcurrent

warning or trip may result when

the inverter attempts to move a

locked motor shaft.

4 E-M BRAKE OPTION COMMISSIONING

The E-M brake option RL500 relay

operates the E-M brake, controlled by the

inverter software. The OPM2 Clear Text

Display option is required for inverter set-

up.

Apply mains power to the inverter and

access parameter P062 using the OPM2.

Using Fig. 2 as a guide, set P062 to P064

to enable and set-up the E-M brake

(disabled by default).

5 R BRAKE OPTION

The Case Size B COMBIMASTER and

MMI Resistor (R) Brake Option 6SE9996-

0XA11, integrates the E-M brake control,

together with a pulsed resistor braking unit.

Although 6SE9996-0XA11

incorporates E-M brake and R

brake options, the unit should

not be used as both E-M and

R brake simultaneously.

The R Brake option is not available for

Case Size A inverters.

The R Brake Option fits in place of the

existing inverter cover. Full IP65 protection

is maintained.

The E-M brake control is identical to that

previously described.

The pulsed R Brake Option gives the

COMBIMASTER and MMI increased

immunity to over-voltage trips. It can also

be used to provide up to 7kW (peak) of

braking power for stopping the system

more quickly than would otherwise be

possible.

~10ms

E-M Brake Option Output

[DC Average volts]

Inverter Frequency

[Hz.]

Time

[s]

RUN

Command

STOP

Command

Minimum

Frequency

Set Point

P002 P003

P064

P063

45% Vmains

90% Vmains

Note: Idealised Waveform

FAST

SLOW

BRAKE ONBRAKE ON

BRAKE OFF

5 R BRAKE OPTION (Continued)

Technical Overview

The pulsed R brake electronics operate

completely independently of the inverter

electronics, monitoring the DC link voltage.

During braking, the motor will regenerate,

causing the DC link voltage to rise.

When a set threshold is reached, the

pulsed R brake electronics will switch the

resistor onto the DC link. This will cause

the regenerated energy to be dissipated as

heat in the resistor, thus preventing an

over-voltage trip.

Whilst the resistor is switched onto the DC

link, the resistor temperature will rise.

When the threshold temperature (Tmax), is

reached, the electronics will limit the power

in the integrated resistor to approximately

5% of the peak power. If the temperature

continues to rise, the resistor will be

disabled completely, until the temperature

has fallen.

In the event of a fault the

resistor may become

permanently connected

and overheat.

The resistor temperature is

monitored by an internal

circuit, which will indicate

resistor overheating by

means of a fault relay

(RL100).

The fault relay (RL100) is

provided to connect to an

external contactor, wired

to isolate the inverter, if

the relay detects an over-

heat condition.

Fig. 3 R Brake Option Duty Cycle

Maximum duty cycle is 5%.

The actual duty cycle depends on the

braking energy required.

P1 – 7kW

P2 – 350W (5%)

T1 and T2 are variables up to the following

maximums:

If heatsink <90 deg C

T1 = 10s max (so, T2 = 190s).

If heatsink >90 deg C

T1 = 3s max (so, T2 = 57s).

If heatsink >105 deg C

Inverter Trips.

T2T1

Tmax

6 R BRAKE OPTION INSTALLATION

Case Size B R Brake Option Parts

x6 Socket

x1 Gate Drive Insulation with Label

x1 PG9 Cable Gland

WARNING

CMOS components used in this

equipment are particularly

sensitive to static electricity.

Avoid touching these components,

or their printed circuit boards, with

bare hands or metal objects.

The R Brake Option fits in place of the

existing inverter cover. Prior to connection,

ensure that the mains contactor is

adequately suppressed using transient

suppressors.

R Brake Option Installation Process:

•Refer to Fig. 4.

•Connect the mains supply to the inverter

via a three phase contactor. Wire the

live supply to the contactor coil through

relay RL100, which is open when the

braking unit is not powered.

•Use a double insulated 2-core cable to

connect to the relay contacts CN101 (1)

and CN101 (2). The diameter of the

outer insulation must be in the range 4.5

to 6.0mm.

•Pass the cable through the PG9 gland

provided (part B3) and secure the gland

to form a tight fit around the cable.

•Connect a momentary action switch

across CN101 (2) and CN 101 (1) to

check the operation of the inverter. The

resistive brake option is powered from

the inverter and once powered, RL100

permanently powers the inverter.

Fig. 4 R Brake Option Connection Diagram

CONTACTOR COIL LIVE SUPPLY

6 R BRAKE OPTION INSTALLATION (Continued)

The unit is now ready to be fitted to the inverter.

WARNING

Under no circumstances attempt to fit or remove the braking unit while the

inverter is still powered.

•Ensure that the inverter is isolated from

the mains supply. Remove and discard

the inverter case cover.

•Remove and discard the internal black

plastic insulation cover, but retain the two

securing screws.

•Locate studs ST100 (L1) and ST102

(L3), on the now exposed gate drive

PCB. Replace the two nuts, which each

secure a flying lead to its stud, with two

of the metal sockets (part B1) provided.

Secure the flying leads via the sockets

using a 6mm flat-blade screwdriver and

torque-down to 0.8Nm.

Note that these studs are not electrically

part of the R brake option, but provide for

greater ease in fitting of the option.

•Locate studs ST500 and ST501 (E-M

brake relay control). Fit two more metal

sockets (part B1) to these studs and

secure and torque-down as in the

previous step.

Note that these studs are not electrically

part of the R brake option, but provide for

greater ease in fitting of the option.

•Locate studs ST103 (DC+) and ST104

(DC-). Fit the last two metal sockets

(part B1) to these studs and secure and

torque-down as in the previous step.

•Fit the gate drive PCB insulation (part

B2) supplied with the option. Secure

with the retained securing screws and

torque-down to 2Nm.

CAUTION

Ensure that gate drive PCB

insulation is in place before fitting

the brake option inverter cover.

•Ensure the cover gasket is correctly

positioned.

•Making sure the arrows on the labels

fitted to the outside of the R brake option

are pointing towards the motor shaft,

gently align the 4mm nickel plated plugs

on the brake option circuit board with the

newly fitted sockets in the inverter and

push down. The brake option will only fit

one way round. Do not use excessive

force. The unit may be damaged if

plugs/sockets are not properly aligned.

•Check the four corners of the cover are

making contact with the inverter case to

ensure that the brake option is correctly

earthed.

•The R Brake Option does not require any

inverter parameter changes, and once

installed, is ready for use.

7 DC LINK THRESHOLD SELECTION

WARNING

Selecting a 750V threshold for

supply voltages greater than

500VAC will damage the

braking resistor.

The DC link threshold defines the point at

which braking pulses are generated and

depends on the mains voltage.

Supply Voltages < 500VAC

X201 = open and X301 = closed

(threshold = 750VDC).

Supply Voltages > 500VAC

X201 = closed and X301 = open

(threshold = 800VDC).

Locate X201 & X301 in Fig. 4.

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