CPA BC 2.2 Series Manual
2 Instruction and Operation Manual Misprints and technical changes reserved
About This Instruction Manual
If you look for some definite topic you can use the table of contents at the beginning of these
instruction and operation manual.
In these instructions is a row of symbols which shall provide you with a fast orientation and show
the importants.
This symbol stands for notes and useful informations which shall make the
operation easier for you.
Note, disregard can damage or destruct the chopper
Note, disregard means a danger for the operator.
1. Instruction of Safety
Before you put the chopper into operation, please read this instruction and
operation manual completly.
The operation should only be done by qualified personnel.
The precautions and warnings below must be observed at the operation of the
chopper. The braking chopper instruction and operation manual do not replace
the manual of initial operation of the inverter.
1.1 Instructions and Rules
During installation, general installation regulations such as following should be observed
DIN VDE 0100 General requirements for the installation of power with mains
VDE 0113 General requirements for the installation of electrical equipment for
production and tooling machines
VDE 0160 Requirements for electronic equipment for use in electrical power
installations
VDE 0470 Part 1 International protection
1.2 Safety
Caution Danger !
Disconnect unit from mains and wait until the capacitors have discharged
before making any repairs. After the installation make sure that the unit
and motor is properly grounded in order to avoid electrical hazard.
Misprints and technical changes reserved Instruction and Operation Manual 3
As with any form of electrical equipment, there is always a risk involved in
the handling of electrical machinery. The greatest care must always be
exercised during installation and maintenance. It is recommended that
service is performed by authorized personnel only
Caution !
1. Do not connect or disconnect the chopper when it has power.
2. Please take care of the correct polarity.
3. If you exchange the connections BUSS + and BUSS- the inverter or the
chopper can be destroyed.
4. Ultrafast semiconductor fuses for the protection of the IGBT is not
installed.
Table of contents
1. Instruction of Safety................................................................................................ 2
1.1 Instructions and Rules ............................................................................................. 2
1.2 Safety ...................................................................................................................... 2
2. Function .................................................................................................................. 3
2.1 General data / application conditions ..................................................................... 4
2.2 Technical Data Chopper voltage 1000V................................................................... 4
3. Connections and Indications .................................................................................. 5
3.1 Design...................................................................................................................... 5
3.2 Connectiondiagramm.............................................................................................. 6
4. Example of Connection............................................................................................ 7
5. Dimensions.............................................................................................................. 7
6. Options.................................................................................................................... 8
6.1 Overcurrent relay .................................................................................................... 8
6.2 Ultrafast semiconductor fuses................................................................................. 8
7. Calculation Braking Chopper and Resistor............................................................... 8
8. Connection Diagramm option Master –Slave....................................................... 10
2. Function
If the speed of the motor is reduced the motor behaves like a generator. Since the kinetical
energy is not sent back with the Inverter to mains the intermediate circuit (BUSS) capacitors
store the energy. The voltage of the intermediate circuit increases. If the intermediate circuit
voltage the inverter protects itself by turning off.
To avoid the interuption of braking, a Braking Choppers is used. It is activated if the voltage of
the intermediate circuit is higher than the tolerable intermediate circuit voltage. The braking
resistor is connected with the intermediate circuit and the additional energy is transformed to
4 Instruction and Operation Manual Misprints and technical changes reserved
heat. If big masses have to be decelerated the braking resistor must have enough power related
to the kinetical energy.
The value of the brake resistor has to be equal or higher than Rmin. and depends
on the required output. If the brake resistor is lower than Rmin., the IGBT (Insulated
Gate Bipolar Transistor) can be destroyed. The output is protected against short
circuit but not against permanent overload.
2.1 General data / application conditions
Range
Values
Permissible temperature range
During transport of the unit:
-25°C…+70°C (to VDE 0160)
During storage of the unit:
-25°C…+55°C (to VDE 0160)
During operation of the unit:
5°C…+40°C (without power derating)
40°C…+55°C (with power derating)
Humidity class
Humidity class F without condensation (5% - 85% relative humidity)
Environment:
Base standard:
DIN EN 60068-2-6
Resonance seach
Test specification:
(5 Hz-13,2 Hz)-150 Hz, 2mm peak to peak 0,7g
Installation height h:
H ≤ 1000 m a.m.s.l.
without power derating
1000 m a.m.s.l. < h 4000 m a.m.s.l.
with power derating
Air pressure
86kPa –106kPa to VDE0875 part 11 and prEN55082
Degree of pollution
VDE 0110 Part 2 degree 2
Enclosure:
IP20
2.2 Technical Data Chopper voltage 1000V
Connection voltage
500 - 1200 VDC
BUSS +/-
Power and Brake Resistor at Chopper voltage: 1000V
type
Article-No.
Brake power in kVA at
Permanent
current
[in A]
Peak current
[in A]
Superfast fuse
F2
[in A]
Brake resistor
>Rmin.
Permanent load
Peak load
BC 2.2-90/13
12272-0F
13
90
13
90
100
BC 3.2-90/58
12273-0F
58
90
58
90
100
11,2
BC 3.2-180/72
12273-2F
72
180
72
180
200
5,6
BC 4.2-300/90
12274-1F
95
300
95
300
355
3,4
BC 4.2-460/117
12274-2F
102
400
102
400
500
2,5
BC 4.2-490/110
12274-3F
112
500
112
500
500
2
Dimensions
refer to Chapter 5.
Misprints and technical changes reserved Instruction and Operation Manual 5
3. Connections and Indications
Indications
Overcurrent
red
Overcurrent/Short circuit
Active
clear
Chopper is active
Power
green
Chopper is ready
DC Buss Voltage
red
Buss Voltage
Connections of the terminal blocks
Grounding: Large-area earthing of the cover is
recommended, e.g. mounting on a galvanized
assembly plate.
BUSS-
-connection BUSS-voltage inverter
BUSS+
+connection BUSS-voltage inverter
R1 - R2
a bimetal relay must be connected in series to the
braking resistor. This has to be adjusted to the nominal
current of the brake resistor. (see Chapter 4 Example
of Connection)
Caution !
1. Do not connect or disconnect the chopper under voltage.
2. Please take care of the correct polarity.
3. If you exchange the connections BUSS + and BUSS- the inverter or the
chopper can be destroyed.
4. Ultrafast semiconductor fuses for the protection of the IGBT is not
installed.
3.1 Design
(Mainboard)
Dipswitch S1.7:
without Master/Slave-OptionON
at Master/Slave-Option OFF
Dipswitch S1
ON
OFF
(Optionsboard)
6 Instruction and Operation Manual Misprints and technical changes reserved
3.2 Connectiondiagramm
Misprints and technical changes reserved Instruction and Operation Manual 7
4. Example of Connection
If cables between inverter and chopper resp. chopper and brake resistor are less than 25 cm, they have
to be twisted and if they are longer than 25 cm they have to be shielded
5. Dimensions
Type
B
B1
H
H1
T
S
BC 2.2
100
48,5
170
158
243
6
BC 3.2
130
64,5
210
198
208
6
BC 4.2
131
64,5
298
280
318
9
8 Instruction and Operation Manual Misprints and technical changes reserved
6. Options
oBrake resistors up to 60kW permanent load in enclosure IP 20. Specific possible after previous
Consulation with TAE.
oOvercurrent relays for protection of the brake resistor against thermal overstressing. Overcurrent
relays with higher rated current on request
6.1 Overcurrent relay
Rated current in A:
Part.-No:
Rated current in A:
Part.-No:
0,1 - 0,16
36770-A2
1,6 - 2,4
36770-G2
0,16 - 0,24
36770-B2
2,4 - 4
36770-H2
0,24 - 0,4
36770-C2
4 - 6
36770-I2
0,4 - 0,6
36770-D2
6 - 10
36770-K2
0,6 - 1
36770-E2
10 - 16
36770-L2
1 - 1,6
36770-F2
16 - 24
36770-M2
Bracket for Overcurrent relay: Art.-No. 36770-Z2
6.2 Ultrafast semiconductor fuses
Use with Braking chopper:
Fuse value in A A
Part.-No. Fuse
Art.-No. Fuse Breaker 3pol
12262-0F...
50
34606-00
34529-00
12262-1F...
63
34607-00
34529-00
12263-AF...
100
34609-00
34529-00
12263-0F...
100
34609-00
34529-00
12263-1F...
125
34610-00
34529-00
12263-2F...
200
34621-00
34529-01
12264-0F...
250
34622-00
34529-01
12264-1F...
355
34633-00
34529-02
12264-2F...
500
on request
34529-03
7. Calculation Braking Chopper and Resistor
Basis of calculation:
Constant Brake torque and
linear speed reduction
Example:
Brake torque 100 Nm
Max Speed 2400 min-1
Motor operation time 14 sec.
Brake time 3 sec.
Stop 3 sec.
Chopper voltage 750 V
n[min-1]
P[kW]
M+
[Nm]
M-
[Nm]
tRUN= 14 s
MMAX
PMAX BRAKE
tBRAKE=
3 s tOFF = 3 s
nmax= 2400 min -1
nmittel=1200 min -1
0
0
0
100 Nm
t[s]
t[s]
t[s]
25,1 kW
Misprints and technical changes reserved Instruction and Operation Manual 9
Calculation Peak Load PMAX BRAKE
P=× M
9550 =2400 × 100
9550 =25,1 kW
PMAX BRAKE
in [kW]
peak load brake chopper
nMAX
in [min-1]
max speed
MMAX
in [Nm]
max brake torque
Calculation RMS Brake load PBREAK RMS
PBRAKE RMS
in [kW]
RMS brake load
PMAX BRAKE
in [kW]
peak load brake chopper
tBRAKE
in [seconds]
brake time
tRUN
in [seconds]
motoring operation
tBRAKE
in [seconds]
regen operation
tOFF
in [seconds]
stop
Calculation Brake Resistor
R
in [Ω]
brake resistor
U
in [V]
(turn-on) voltage
PMAX BRAKE
in [W]
peak load brake chopper
Brake Chopper selected from table 2.2 (refer to technical data)
Brake chopper BC2.2-90/13 Part.-No. 12272-0F
Chopper voltage 750V
Permanent Load:
PBRAKE RMS = 5,6 < 13 kW OK
Peak Load:
PMAX BRAKE= 25,1 < 90 kW OK
Brake Resistor:
R= 22,4 > 11,2 ΩOK
10 Instruction and Operation Manual Misprints and technical changes reserved
8. Connection Diagramm option Master – Slave
This manual suits for next models
7
Table of contents
