Lenze 8250 Series User manual

EDB8250EN
!PM8
Operating Instructions
Brake unit
8250 series
-UG +UG RB1 RB2 PE
(T1) (T2)
Ä!PM8ä
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These Operating Instructions are valid for brake units with the following nameplate
data:
825X E. 0x (8251 - 8253)
In connection with the unit series as from the nameplate data:
820X E. 0x. 0x. (8201 - 8204)
821X E. 0x. 0x. (8211 - 8218)
Type
Design:
E = Enclosure IP20
IB = Module
Hardware level and index
Software level and index
Variant
Explanation
revised
Edition of: 10/1996 01/1997 09/2003
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-UG +UG RB1 RB2 PE
1
2
3
(T1) (T2)
Pos. Name/
Meaning
Note
-UG +UG RB1 RB2 PE
1
2
3
(T1) (T2)
1Brake unit D8251/8252 brake module
D8253 brake chopper
-UG +UG RB1 RB2 PE
1
2
3
(T1) (T2)
2LED Display of the operating state
Dgreen:
flashing, when voltage is
applied to terminals +UG,-U
G
Dyellow:
- flashing, when brake unit is
in braking operation
- Display of faults:
see chapter 6, page 6-1
-UG +UG RB1 RB2 PE
1
2
3
(T1) (T2)
3Connections DVoltage link:
+UG,-U
G
only 8251/8252 brake module:
DThermostat: T1, T2
only 8253 brake chopper:
DBrake resistor: RB1, RB2
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Safety and application notes
for controllers
(according to: Low-Voltage Directive 73/23/EEC)
1. General
During operation, drive controllers may have, according to their type of protection, live,
bare, in some cases also movable or rotating parts as well as hot surfaces.
Unauthorized removal of the required cover, inappropriate use, incorrect installation or
operation, creates the risk of severe personal injury or damage to material assets.
Further information can be obtained from the documentation.
All operations concerning transport, installation, and commissioning as well as
maintenance must be carried out by qualified, skilled personnel (IEC 364 and CENELEC
HD 384 or DIN VDE 0100 and IEC report 664 or DIN VDE 0110 and national regulations
for the prevention of accidents must be observed).
Qualified skilled personnel according to this basic safety information are persons who are
familiar with the erection, assembly, commissioning, and operation of the product and
who have the qualifications necessary for their occupation.
2. Application as directed
Drive controllers are components which are designed for installation in electrical systems
or machinery.
When installing in machines, commissioning of the drive controllers (i.e. the starting of
operation as directed) is prohibited until it is proven that the machine corresponds to the
regulations of the EC Directive 89/392/EWG (Machinery Directive); EN 60204 must be
observed.
Commissioning (i.e. starting of operation as directed) is only allowed when there is
compliance with the EMC Directive (89/336/EWG).
The drive controllers meet the requirements of the Low-Voltage Directive 73/23/EWG. The
harmonized standards of the prEN 50178/ DIN VDE 0160 series together with EN
60439-1/DIN VDE 0660 part 500 and EN 60146/DIN VDE 0558 are applicable to drive
controllers.
The technical data and information on the connection conditions must be obtained from
the nameplate and the documentation and must be observed in all cases.
3. Transport, storage
Notes on transport, storage and appropriate handling must be observed.
Climatic conditions must be observed according to prEN 50178.
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4. Erection
The devices must erected and cooled according to the regulations of the corresponding
documentation.
The drive controllers must be protected from inappropriate loads. Particularly during
transport and handling, components must not be bent and/or isolating distances must not
be changed. Touching of electronic components and contacts must be avoided.
Drive controllers contain electrostatically sensitive components which can easily be
damaged by inappropriate handling.Electrical components must not be damaged or
destroyed mechanically (health risks are possible!).
5. Electrical connection
When working on live drive controllers the valid national regulations for the prevention of
accidents (e.g. VBG 4) must be observed.
The electrical installation must be carried out according to the appropriate regulations
(e.g. cable cross-sections, fuses, PE connection). More detailed information is included
in the documentation.
Notes concerning the installation in compliance with EMC - such as screening, grounding,
arrangement of filters and laying of cables - are included in the documentation of the drive
controllers.These notes must also be observed in all cases for drive controllers with the
CE mark. The compliance with the required limit values demanded by the EMC legislation
is in the responsibility of the manufacturer of the system or machine.
6. Operation
Systems where drive controllers are installed must be equipped, if necessary, with
additional monitoring and protective devices according to the valid safety regulations, e.g.
law on technical tools, regulations for the prevention of accidents, etc. Modifications of
the drive controllers by the operating software are allowed.
After disconnecting the drive controllers from the supply voltage, live parts of the
controller and power connections must not be touched immediately, because of possibly
charged capacitors. For this, observe the corresponding labels on the drive controllers.
During operation, all covers and doors must be closed.
7. Maintenance and servicing
The manufacturer’s documentation must be observed.
This safety information must be preserved!
The product-specific safety and application notes in these operating instructions must
also be observed!
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Contents
8250BA0903 i
1 Preface and general information 1-1.................
1.1 About these Operating Instructions ... 1-1.....................
1.1.1 Terminology used 1-1............................
1.1.2 What is new? 1-1...............................
1.2 Scope of delivery 1-2...................................
1.3 825X brake units 1-2...................................
1.3.1 Labelling 1-2..................................
1.3.2 Application as directed 1-3........................
1.3.3 Legal regulations 1-4............................
2 Safety information 2-1............................
2.1 Personnel responsible for safety 2-1.........................
2.2 General safety information 2-2.............................
2.3 Layout of the safety information 2-3.........................
2.4 Residual hazards 2-4...................................
3 Technical data 3-1...............................
3.1 Features 3-1.........................................
3.2 General data /operating conditions 3-2.......................
3.3 Rated data 3-3........................................
3.3.1 Brake units 3-3.................................
3.3.2 Assignment table for brake resistors 3-3...............
3.3.3 Overcurrent relay and cable cross-sections 3-4..........
3.4 Dimensions 3-4.......................................
4 Installation 4-1..................................
4.1 Mechanical installation 4-1...............................
4.1.1 Important notes 4-1.............................
4.1.2 Standard assembly with fixing rail 4-2................
4.1.3 DIN-rail assembly 4-3............................
4.2 Electrical installation 4-4.................................
4.2.1 Operator’s safety 4-4.............................
4.2.2 Protection of the brake unit 4-5.....................
4.2.3 Specification of cables used 4-5....................
4.3 Connection 4-6........................................
4.3.1 Power connection 4-6............................
4.3.2 8251 brake module on 820X controller 4-7.............
4.3.3 8252 brake module on 821X controller 4-8.............
4.3.4 8253 brake chopper on 821X controller 4-9............
4.3.5 Connect temperature monitoring 4-10.................
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Contents
ii 8250BA0903
5 Commissioning 5-1..............................
6 Troubleshooting and fault elimination 6-1............
7 Waste disposal 7-1..............................
8 Supplement 8-1.................................
8.1 Accessories 8-1.......................................
8.1.1 Brake resistors 8-1.............................
8.2 Glossary 8-3.........................................
8.3 Index 8-4............................................
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Preface and general information
8250BA0903 1-1
1 Preface and general information
1.1 About these Operating Instructions ...
•The present Operating Instructions are used for operations
concerning safety measures on and with the 825X brake
units. They contain safety information which must be
observed.
•All persons who work on and with 825X brake units must
have the Operating Instructions available and observe all
relevant notes and instructions.
•The Operating Instructions must always be in a complete
and perfectly readable state.
1.1.1 Terminology used
Brake unit
The ”8251 brake module”, the ”8252 brake module” or the ” 8253
brake chopper with brake resistor” are called ”brake unit” in the
following text.
Controller
In the following text, the term ”controller” is used for ”82XX
frequency inverter”.
Drive system
For drive systems with 825X brake units and other Lenze drive
components, the term ”drive system” is used in the following
text.
1.1.2 What is new?
Material No. Edition Important Contents
393658
12/1996 1st edition
3
9
3
6
5
8
01/1997 revised •Technical data
•Chapter 4.3
474423 09/2003 replaces
393658
•Change of company name
•Chapter 8
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Preface and general information
1-2 8250BA0903
1.2 Scope of delivery
•The scope of delivery includes:
- 1 8251 brake module, 1 8252 brake module or 1 8253
brake chopper
-1push-onterminalstrip
- 1 accessory kit with fixing material
- 1 book of Operating Instructions
•After reception of the delivery, check immediately whether
the scope of supply matches the accompanying papers.
Lenze does not accept any liability for deficiencies claimed
subsequently. Claim
- visible transport damage immediately to the forwarder.
- visible deficiencies/incompleteness immediately to your
Lenze representative.
1.3 825X brake units
1.3.1 Labelling
•Lenze 825X brake units are clearly identified by the
indications on the nameplate.
•CE mark
- Conformity with the EC Low-Voltage Directive
•Manufacturer:
- Lenze Drive Systems GmbH
Postfach 10 13 52
D-31763 Hameln
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Preface and general information
8250BA0903 1-3
1.3.2 Application as directed
8251 brake modules
•Additional units for Lenze controllers:
- 820X frequency inverters (8201 to 8204)
8252 brake modules and 8253 brake choppers
•Additional units for Lenze controllers:
- 821X frequency inverters (8211 to 8218)
825X brake units
•Operate the brake units only under the conditions
prescribed in these Operating Instructions.
•They are components
- for installation in a machine
- for assembly with other components to form a machine.
•They are electrical equipment for installation into control
cabinets or similar closed operating rooms.
•They meet the protection requirements of the EC Low-
Voltage Directive.
•They are not machinery in the sense of the EC Machinery
Directive.
•They are not household appliances but are intended
exclusively as components for further commercial use.
Drive systems with 825X brake units
•They correspond to the EC Electromagnetic Compatibility
Directive if they are installed according to the guidelines of
CE-typical drive systems.
•They can be operated
- on public and non-public mains.
- in industrial as well as residential and commercial
premises.
•The compliance with the EC Directives in machine
application is in the responsibility of the user.
Any other use shall be deemed inappropriate!
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Preface and general information
1-4 8250BA0903
1.3.3 Legal regulations
Liability
•The information, data, and notes in these Operating
Instructions met the state of the art at the time of printing.
Claims referring to drive systems which have already been
supplied cannot be derived from the information,
illustrations, and descriptions.
•The specifications, processes, and circuitry described in
these Operating Instructions are for guidance only and
must be adapted to your own specific application. Lenze
does not take responsibility for the suitability of the
process and circuit proposals.
•The indications given in these Operating Instructions
describe the features of the product without warranting
them.
•Lenze does not accept any liability for damage and
operating interference caused by:
- Disregarding these Operating instructions
- Unauthorized changes of the brake units
- Operating mistakes
- Improper working on and with the brake units
Warranty
•Terms of warranty: see terms of sale and delivery of Lenze
Drive Systems GmbH.
•Warranty claims must be made to Lenze immediately after
detecting the deficiency or fault.
•The warranty is void in all cases where liability claims
cannot be made.
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Safety information
8250BA0903 2-1
2 Safety information
2.1 Personnel responsible for safety
Operator
•An operator is any natural or legal person who uses the
drive system or on behalf of whom the drive system is
used.
•Theoperatororhissafetyofficerareobliged
- to check whether all relevant regulations, notes, and
laws are observed.
- to ensure that only qualified personnel work with and on
the drive system.
- to ensure that the personnel have the Operating
Instructions available for all corresponding operations
- to prohibit non-qualified personnel from working with
and on the drive system.
Qualified personnel
Qualified personnel are persons who are - because of their
education, experience, instructions, and knowledge about
corresponding standards and regulations, rules for the
prevention of accidents, and operating conditions - authorized
by the person responsible for the safety of the plant to perform
the required actions and who are able to recognize and avoid
potential hazards.
(see IEC 364, definition of qualified personnel)
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Safety information
2-2 8250BA0903
2.2 General safety information
•This safety information is not claimed to be complete. In
case of questions and problems please contact your
Lenze representative.
•At the time of delivery the brake unit meets the state of the
art and ensures basically safe operation.
•The indications given in these Operating Instructions refer
to the stated versions of the brake unit.
•The brake unit is hazardous for persons, the brake unit
itself and other property of the operator, if
- non-qualified personnel work with and on the brake unit.
- the brake unit is not used as directed.
•The specifications, processes, and circuitry described in
these Operating Instructions are for guidance only and
must be adapted to your own specific application.
•Brake units must be designed so that they comply with
their function and do not cause any hazards for persons
under the conditions of correct installation and faultless
operation as instructed. This is also effective for the
interaction with the complete plant.
•Take additional measures to limit consequences of
malfunctionswhichmaycausehazardsforpersonsor
material assets:
- Further independent equipment which can take over the
function of the brake unit
- Electrical or non-electrical protection (latching or
mechanical blocking)
- Measures covering the complete system
•Operate the drive system only in a perfect condition.
•Changes or retrofittings to the brake unit are prohibited in
principle. In any case, Lenze must be contacted.
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Safety information
8250BA0903 2-3
2.3 Layout of the safety information
•All safety information in these Operating Instructions has a
uniform layout:
Danger
Note
- The icon designates the type of danger.
- The signal word designates the severity of danger.
- The note describes the danger and suggests how to
avoid the danger.
Warning of danger for persons
Icons used Signal words
Warning of
hazardous
e
l
e
c
t
r
i
c
a
l
v
o
l
t
a
g
e
Danger! Warns of impending danger.
Consequences if disregarded:
D
e
a
t
h
o
r
v
e
r
y
s
e
v
e
r
e
i
n
j
u
r
i
e
s
elect
r
ical voltage Death or very severe injuries.
Warning! Warns of potential, very hazardous situations.
Possible consequences if disregarded:
D
t
h
i
j
i
Warning of a
general danger
q
g
Death or very severe injuries.
g
e
n
e
r
a
l
d
a
n
g
e
r
Caution! Warns of potential, hazardous situations.
P
o
s
s
i
b
l
e
c
o
n
s
e
q
u
e
n
c
e
s
i
f
d
i
s
r
e
g
a
r
d
e
d
:
P
oss
i
b
l
e consequences
i
f
d
i
s
r
ega
r
d
e
d
:
Light or minor injuries.
Warning of material damage
Icons used Signal words
Stop! Warns of possible material damage.
Possible consequences if disregarded:
Damage to the drive system or its environment.
Other notes
Icons used Signal words
Note! Designates a general, useful tip.
If you observe it, handling of the drive system is made
easier.
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Safety information
2-4 8250BA0903
2.4 Residual hazards
Protection of persons
After mains voltage disconnection the power terminals
+UG,-U
Gremain live for 3 minutes.
Brake units may have surface temperatures of up to 130°Cfor
up to 30 minutes after mains disconnection.
Touching the brake unit may cause burns.
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Technical Data
8250BA0903 3-1
3 Technical data
3.1 Features
•Three types:
- 8251 brake module with internal brake resistor for
frequent braking operations with low load or infrequent
braking with medium load for operation with 820X
frequency inverter
- 8252 brake module with internal brake resistor for
frequent braking operations with low load or infrequent
braking with medium load for operation with 8211- 8213
frequency inverters
- 8253 brake chopper with external brake resistor for
high-load continuous braking for operation with 821X
frequency inverter
•Conversion of the mechanical braking energy into thermal
energy
- Controller does not set pulse inhibit during braking, i.e.
the braking operation still remains controlled
•Very short braking times are possible
•Enclosure IP10 for installation in a control cabinet
•DIN-rail assembly possible (additional accessories
required)
•Fixed thresholds for the mains voltages 230 V (8251) and
400¼460 V (8252/8253)
•Current-state display via LED
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Technical Data
3-2 8250BA0903
3.2 General data /operating conditions
Field Values
Vibration resistance Germanischer Lloyd, general conditions (in preparation)
Permissible moisture Humidity class F without condensation (medium relative
humidity 85 %)
Permissible temperature ranges during transport : -25 °C¼+70 °C
during storage: -25 °C¼+70 °C
during operation: 0 °C¼+40 °C
Permissible 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
Degree of pollution VDE 0110 part 2 pollution degree 2
Insulation strength Overvoltage category III according to VDE 0110
Packing to DIN 4180
Type of protection IP10
NEMA 1: Protection against contact
Approvals CE: Low-Voltage Directive
EMC Directive in preparation
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Technical Data
8250BA0903 3-3
3.3 Rated data
3.3.1 Brake units
Type EMB8251-E EMB8252-E EMB8253-E
Order
no.
EMB8251-E EMB8252-E EMB8253-E
Supply voltage VN270 ¼400 V DC 270 ¼750 V DC 270 ¼750 V DC
Threshold VZ375 V DC 725 V DC 725 V DC
Peak current 5.4 A DC 2.7 A DC 15 A DC
Max. continuous current 0.2 A DC 0.1 A DC 7.5 A DC
Peak braking power at VZ2kW
1) 2kW 1) 11.2 kW2)
Continuous braking power at VZ70 W 70 W 5.6 kW
Min. brake resistance (internal resistor) (internal resistor) 47 Ω±10%
Max. energy (min. 5 min break) 20 kWs 20 kWs (external resistor)
Power derating 40 °C<T<50°C: 2%/K
1000 m a.m.s.l. < h < 4000 m a.m.s.l.: 5%/1000 m
Weight 1.3 kg 1.3 kg 1.1 kg
1) max. 10 s with switch-on cycle 3 %
2) max. 60 s with switch-on cycle 50 %
3.3.2 Assignment table for brake resistors
The assignment depends on the motor power and is effective up
to the indicated limit value.
Motor power Recommended Lenze brake resistor
o
t
o
p
o
e
Order no. Resistor Peak braking power Thermal capacity
kW ΩkW kWs
<0.75 ERBM470R100W 470 1.0 15
<1.5 ERBM370R150W 370 1.5 22,5
<2.2 ERBM240R200W 240 2.0 30
<3.0 ERBD180R300W 180 3.0 45
<4.0 ERBD100R600W 100 5.5 90
<5.5 ERBD082R600W 82 6.5 90
<7.5 ERBD068R800W 68 8.0 120
< 11.0 ERBD047R01K2 47 11.5 180
The resistors are designed for a cycle of:
•max. 15 s braking at peak braking power
•min. 150 s release time after braking
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Technical Data
3-4 8250BA0903
3.3.3 Overcurrent relay and cable cross-sections
With a cable cross section of the feeding inverter of > 2.5 mm2,
the cable can be protected via overcurrent relay.
The cable cross-sections used must meet the valid regulations.
We recommend:
Type Input +UG, -UG
Overcurrent relay Cable cross-section
[A] [mm2]
8251 not required 1.5
8252 not required 1.5
8253 max 12 * 2.5
* depending on the brake resistor
3.4 Dimensions
The dimensions of the brake units depend on the mechanical
installation (see chapter 4.1)
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Installation
8250BA0903 4-1
4 Installation
4.1 Mechanical installation
4.1.1 Important notes
•Use the brake units only as built-in devices!
•Observefreespace!
- Allow a free space of 100 mm at the top and at the
bottom.
•Ensure unimpeded ventilation of cooling air and outlet of
exhaust air.
•If the cooling air contains pollutants (dust, fluff, grease,
aggressive gases ), which may impair the function of the
brake units:
- Take suitable preventive measures , e.g. separate air
duct, installation of filters, regular cleaning, etc.
•Do not exceed the permissible range of the operating
ambient temperature (see chapter 3.2).
•If the brake units are permanently subjected to vibration or
shaking:
- Check whether shock absorbers are necessary.
Danger!
Operation with 8253 brake chopper and external brake resistor:
•In the event of failures, brake resistors can become very
hot, they can even burn. E.g. when the following occurs:
- mains overvoltage,
- application-specific overload,
- internal fault.
•Brake resistors must therefore be installed such that the
very high temperatures possible cannot cause any
damage.
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