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
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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
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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
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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
1)
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
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1

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
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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
1
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
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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
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130BD901.10
200 mm
500 mm
200 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 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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