Control Techniques Unidrive M700 Assembly instructions

0478-0015-04
1 Safety information
2 Introduction
This braking resistor has been especially designed to be mounted within
the heatsink of the Unidrive M600, M700, M800 size 3. 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 (1220-2752-01)
The following items are supplied in the box:
•1x75ΩBrake resistor assembly
• 2 x Cable crimps
• 1 x Installation sheet
3 Installation
Step 1: Removing the terminal covers
Figure 1-1 Removing the AC and DC terminal covers
• To remove the terminal covers, undo the screw and remove the
covers in direction shown above (Figure 1-1).
• The AC terminal cover (1) must be removed prior to the DC terminal
cover (2).
• When replacing the terminal covers the screw should be tightened to
a maximum torque of 1 N m (0.7 lb ft).
Step 2: Removing the internal EMC filter
Figure 1-2 Removing the internal EMC filter
The internal EMC filter needs to be removed to establish brake resistor
electrical connections. To remove the internal EMC filter:
• Loosen / remove the screw and nut as shown (1) and (2)
• Lift away from securing points and then rotate away from the drive (3).
Ensure the screw and nut are replaced and re-tightened with a
maximum torque of 2 N m (1.47 lb ft).
Step 3: Preparing for installation
Figure 1-3 Removing the brake resistor bung
Remove the brake resistor bung from the hole in the chassis as shown
above. The cap at the closed end of the bung will need to be removed,
see Figure 1-4.
Figure 1-4 Removing the bung cap (end with lug on)
Remove the end of the bung with the lug on by piercing with a pair of
long nose pliers and pulling out in the direction shown above to leave a
hollow bung so that the cable can be routed through.
Unidrive M600, M700, M800
Size 3 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 energized, the AC supply
must be isolated at least ten minutes before work may
continue. Refer to section 3.1 Safety information in the User
Guide.
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 installed, the backplate should be
made from a non-flammable material.
WARNING
WARNING
WARNING

0478-0015-04
Figure 1-5 Inserting the brake resistor cable through the bung
• Feed the brake resistor bung on to the outer insulation of the brake
resistor cable. The wider end of the bung should be inserted first.
The narrow end should then align with the end of insulation.
Step 4: Secure the braking resistor
Figure 1-6 Installing the brake resistor
• Secure the braking resistor using captive M4 (x2) screws as shown
above. The screws should be tightened to a maximum torque of
2 N m (1.5 lb ft).
• Route the brake resistor cable and bung through the hole on the top
left corner of the drive as shown above (Figure 1-6). The bung
should penetrate as far as possible into the hole. Ensure the cables
are routed between the fins of the heatsink, and the cables are not
trapped between the heatsink fins and the resistor.
• Cut 70 mm (2.76 in) length off from one of the cables. Strip about 10
mm (0.39 in) of insulation from both of the cables and terminate the
cables with the crimps provided.
Step 5: Establishing brake resistor electrical connections
Figure 1-7 Electrical connections
• Connect the brake resistor cables to BR and +DC terminals as
shown above. Tighten the screw terminals to a maximum torque of
1.5 N m (1.1 lb ft).
• Replace the internal EMC Filter. When replacing the EMC filter the
screw and nut should be tightened to a maximum torque of 1.5 N m
(1.1 lb ft).
• Replace both terminal covers. When replacing the terminal covers
the screw should be tightened to a maximum torque of 1 N m (0.7 lb
ft).
Resistor specification
Failure to observe the following information may damage
the resistor.
Parameter settings
Fan speed should be set to a maximum (Pr 06.045 to 11). The
drive software contains an overload protection function for a
braking resistor. On size 3 this function is enabled at default to
protect the heatsink mounted braking resistor. Below are the
parameter settings.
For more information on the braking resistor software overload
protection, see the Parameter Reference Guide.
Parameter Value
DC resistance at 25 °C 75 Ω
Peak instantaneous power over 1 ms at nominal
resistance 8 kW
Average power over 60 s 50 W
Ingress Protection (IP) rating IP54
Maximum altitude 2000 m
3
Heatsink mounted
braking resitor
BR
+DC
-DC
Internal
EMC filter
CAUTION
Parameter
Size 3
200V Drive 400V Drive
Braking Resistor Rated
Power Pr 10.030 50 W
Braking Resistor Thermal
Time Constant Pr 10.031 3.3 s
Braking Resistor
Resistance Pr 10.061 75 Ω