Control Techniques Unidrive Size 2 Assembly instructions

0471-0028-04
Safety information
Introduction
This braking resistor has been especially designed to be mounted within the heatsink of the Unidrive SP size 2. The design of the resistor is such that
no thermal protection circuit is required, as the device will fail safely under fault conditions. The in built software overload protection is set up at default
to protect the braking resistor.
Contents of the box (1220-2758-01)
The following items should be supplied in the box:
1x 37.5ΩBrake resistor assembly 1x Through hole grommet 1x Wire clip 1x Installation sheet
Fitting instructions
Unidrive SP Size 2 Braking
Resistor Installation Sheet
Stored charge
The drive contains capacitors that remain charged to a potentially lethal voltage after the AC supply has been disconnected. If the drive
has been energised, the AC supply must be isolated at least ten minutes before work may continue.
Refer to section 3.1 Safety information in the Unidrive SP User Guide.
If the drive has been used at high load levels for a period of time, the heatsink and heatsink mounted braking resistor can reach
temperatures in excess of 70°C (158°F). Human contact with the heatsink and heatsink braking resistor should be restricted.
To avoid the risk of fire when the drive is surface mounted with the braking resistor fitted, the back plate should be a non-flammable
material.
Figure 1-1 Removing the DC terminal cover and break-outs
• To remove the DC terminal cover, undo the screw
and lift off as shown in the diagram opposite.
• When replacing the terminal covers the screws
should be tightened to a maximum torque of 1 N m
(0.7 lb ft).
• The two break-outs that line up with the BR and
DC2 terminal connections must be removed, as
shown in the diagram opposite.
• Grasp the 48V/DC terminal cover break-outs with
pliers and twist to remove.
• Remove any flash / sharp edges once the break-
outs are removed.
Figure 1-2 Removing the baffle plate
• Lift the hinged fan baffle by pushing plastic tabs in
the direction shown (1). Push tab in the direction
shown (2), and lift the baffle as shown (3).
• Remove the metal heatsink baffle plate by
removing the two screws. These two screws are no
longer required.
Figure 1-3 Modifying the fan baffle
• Remove 5mm (0.197in) from the length of the clip
on the plastic fan baffle.
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WARNING
WARNING
WARNING
Pozi Pz2
Flat 5mm
Remove these
two break-outs
2
3
1
1
Remove 5mm
(0.197in) from
the length
of this clip

0471-0028-04
Figure 1-7 Unidrive SP size 2 DC connections
Figure 1-4 Fitting of the heatsink mounted braking resistor
• Fit clip to heatsink in the position shown in diagram
opposite. Route the long cables of the resistor
assembly between the fins of the heatsink as
shown in the diagram opposite.
• Fit the heatsink baffle plate in place with the cables
routed underneath. Ensure the cables are not
trapped between a heatsink fin and the baffle plate.
• Fit the braking resistors to the heatsink. The
resistors are fitted with captive screws.
• The screws should be tightened to a maximum
torque of 2.0 N m (1.5 lb ft).
• Close the hinged fan baffle.
• Fit cables to heatsink clip.
Figure 1-5 Connecting the brake resistor on a surface mounted drive
• Fit the DC terminal cover grommets supplied in the
accessory box with the drive, to the cables.
• Terminate the cables with suitable crimps and
connect to the BR and DC2 terminals.
• Replace the terminal cover.
Figure 1-6 Connecting the brake resistor on a through-panel mounted drive
• See section 3.10 in the Unidrive SP User Guide for
through-panel mounting cut-out details.
• Pass the cables through the hole in the panel and
fit the hole grommet.
• Fit the mounting bracket.
• Fit the DC terminal cover grommets supplied in the
accessory box with the drive, to the cables. To
ensure a good seal, the grommets are a tight fit.
Lubrication may be required to help fit the
grommets to the cables.
• Terminate the cables with suitable crimps and
connect to the BR and DC2 terminals.
• Replace the terminal cover.
Failure to observe the following information may damage the resistor.
Parameter Settings
The Unidrive SP software contains an overload protection function for a braking
resistor. On Unidrive SP size 2 this function is enabled at default to protect the
heatsink mounted resistor. Below are the parameter settings.
For more information on the braking resistor software overload protection, see the
Unidrive SP Advanced User Guide.
If the resistor is to be used at more than half of its average power rating then the
drive's cooling fan must be set to full speed by setting Pr 6.45 to On (1).
Resistor Specification
* To keep the temperature of the resistor below 70°C (158°F) in a 30°C (86°F) ambient, the
average power rating is 100W. The above parameter settings ensure this is the case.
Approvals
The resistor is UL recognised under UL file number E234469.
Route the cables
between these
two heatsink fins
2
BRDC1 DC2 48V -DC +DC
Internal
EMC filter
DC1 = -
DC2 = +
CAUTION
Parameter 200V Drive 400V Drive
Full power braking time Pr 10.30 0.09 0.02
Full power braking period Pr 10.31 2.0
Parameter Value
DC resistance at 25°C37.5Ω
Peak instantaneous power over 1ms at nominal resistance 16kW
Average power over 60s 100W *
Ingress Protection (IP) rating IP54
Maximum altitude 2000m