Lenze ERBS015R800W User manual

Contents i
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1 About this documentation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Validity information 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target group 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Document history 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions used 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes used 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General safety instructions 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Residual hazards 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Product description 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application as directed 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensioning conditions 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Technical data 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General data and operating conditions 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rated data 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical data 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Mechanical installation 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting clearance 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting steps 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Electrical installation 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important notes 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection data 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection plan 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting steps 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance intervals 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance operations 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 About this documentation
Validity information
EDKRBS047R DE/EN/FR/ES/IT 8.0
30 l
0Fig. 0Tab. 0
1 About this documentation
Validity information
These instructions are valid for brake resistors
ƒ ERBS015R800W
ƒ ERBS015R01K2
ƒ ERBS015R02K4
ƒ ERBS018R800W
ƒ ERBS018R01K2
ƒ ERBS018R01K4
ƒ ERBS018R01K9
ƒ ERBS018R02K8
ƒ ERBS027R600W
ƒ ERBS027R01K2
ƒ ERBS027R01K4
ƒ ERBS047R400W
ƒ ERBS047R800W
Target group
This documentation is directed at qualified skilled personnel according to IEC 60364.
Qualified skilled personnel are persons who have the required qualifications to carry out all
activities involved in installing, mounting, commissioning, and operating the product.
ITip!
Information and auxiliary devices around the Lenze products can be found in
the download area at
http://www.Lenze.com
Document history
Material number Version Description
.@R_ 8.0 02/2011 TD29 Revision

About this documentation
Conventions used
1
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Conventions used
Type of information Identification Examples/notes
Spelling of numbers
Decimal separator Point In general, the decimal point is used.
For instance: 1234.56
Warnings
UL warnings JAre only given in English.
UR warnings O
Text
Program name » « PC software
For example: »Engineer«, »Global
Drive Control« (GDC)
Icons
Page reference ^Reference to another page with
additional information
For instance: ^16 = see page 16

1 About this documentation
Notes used
EDKRBS047R DE/EN/FR/ES/IT 8.0
32 l
Notes used
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Structure of safety instructions:
}Danger!
(characterises the type and severity of danger)
Note
(describes the danger and gives information about how to prevent dangerous
situations)
Pictograph and signal word Meaning
{Danger!
Danger of personal injury through dangerous electrical
voltage.
Reference to an imminent danger that may result in
death or serious personal injury if the corresponding
measures are not taken.
}Danger!
Danger of personal injury through a general source of
danger.
Reference to an imminent danger that may result in
death or serious personal injury if the corresponding
measures are not taken.
(Stop!
Danger of property damage.
Reference to a possible danger that may result in
property damage if the corresponding measures are not
taken.

About this documentation
Notes used
1
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Application notes
Pictograph and signal word Meaning
)Note! Important note to ensure troublefree operation
ITip! Useful tip for simple handling
,Reference to another documentation
Special safety instructions and application notes for UL and UR
Pictograph and signal word Meaning
JWarnings!
Safety or application note for the operation of a
UL−approved device in UL−approved systems.
Possibly the drive system is not operated in compliance
with UL if the corresponding measures are not taken.
OWarnings!
Safety or application note for the operation of a
UR−approved device in UL−approved systems.
Possibly the drive system is not operated in compliance
with UL if the corresponding measures are not taken.

2 Safety instructions
General safety instructions
EDKRBS047R DE/EN/FR/ES/IT 8.0
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2 Safety instructions
General safety instructions
}Danger!
Disregarding the following basic safety measures may lead to severe personal
injury and damage to material assets!
ƒ Lenze drive and automation components ...
... must only be used for the intended purpose.
... must never be operated if damaged.
... must never be subjected to technical modifications.
... must never be operated unless completely assembled.
... must never be operated without the covers/guards.
... can − depending on their degree of protection − have live, movable or rotating parts
during or after operation. Surfaces can be hot.
ƒ All specifications of the corresponding enclosed documentation must be observed.
This is vital for a safe and trouble−free operation and for achieving the specified product
features.
The procedural notes and circuit details provided in this document are proposals which
the user must check for suitability for his application. The manufacturer does not accept
any liability for the suitability of the specified procedures and circuit proposals.
ƒ Only qualified skilled personnel are permitted to work with or on Lenze drive and
automation components.
According to IEC 60364 or CENELEC HD 384, these are persons ...
... who are familiar with the installation, assembly, commissioning and operation of the
product,
... possess the appropriate qualifications for their work,
... and are acquainted with and can apply all the accident prevent regulations, directives
and laws applicable at the place of use.

Safety instructions
Residual hazards
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Residual hazards
{Danger!
Dangerous electrical voltage
The terminals of the brake resistor may carry dangerous voltages during
operation of the basic device and up to three minutes after mains
disconnection.
Possible consequences:
ƒDeath or severe injuries when touching the terminals.
Protective measures:
ƒBefore working on the brake resistor disconnect the basic device from the
mains.
ƒCheck all power terminals for safe isolation from supply.
ƒSelect the mounting location so that the operating conditions mentioned
in the technical data are always ensured.
}Danger!
Hot surface during operation
During operation, the brake resistor becomes very hot. (For temperatures, see
Technical data.)
Possible consequences:
ƒSevere burns when touching the brake resistor.
ƒFire or smouldering fire if flammable materials or substances are placed
near the brake resistor or may get to it.
Protective measures:
ƒBefore working on the brake resistor, check its surface temperature.
ƒSelect the mounting location so that the operating conditions mentioned
in the technical data are always ensured.
ƒProtect the mounting location by suitable fire prevention and protection
against contact.

2 Safety instructions
Residual hazards
EDKRBS047R DE/EN/FR/ES/IT 8.0
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OWarnings!
Conditions of Acceptability:
ƒThe products covered by this report are intended for use with Power
Conversion Equipment (drives) only.
ƒThe Temperature Switch must be connected to the drive, so that the drive
switches off in case when the maximum operating temperature is
exceeded.
ƒTemperature tests and abnormal operation tests have only been
conducted for single resistive elements and for continuous duty as
indicated under RATINGS. For any grouping of the resistor elements an
additional temperature test must be conducted, depending on the
evaluation of the mechanical construction and the expected temperature
rise.
ƒFor any duty cycle operation in the end−use application it must be
guaranteed that the maximum Wattage rating will not be exceeded. This
may be evaluated by calculation. If there will be any concern regarding to
this, additional temperature tests have to be conducted under end−use
conditions.

Product description
Overview
3
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3 Product description
Overview
ERBS101
Scope of supply
Pos. Description
Brake resistor
Mounting Instructions
Brake resistor elements
Pos. Description
0Nameplate
1Terminal box
2Cable gland for thermal contact cable
3Cable gland for brake resistor cable
4Warning note
5Fixing bracket

3 Product description
Identification
EDKRBS047R DE/EN/FR/ES/IT 8.0
38 l
Identification
ERBS104

Type code ERBx xxxx xxxx
Product series
Resistance RB[W]
e.g. 470R = 470 W
075D = 7.5 W
Permanent power Pd[W]
e.g. 120W = 120 W
01k2 = 1.2 kW

Product description
Application as directed
3
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Application as directed
Brake resistors
ƒ must only be actuated under the operating conditions specified in these operating
instructions.
ƒ are components
– for mounting in a machine.
– for assembly with other components to a machine.
Commissioning of the brake resistor is prohibited until it has been determined that the
machine into which the brake resistor is to be mounted complies with the regulations
of the EC Machinery Directive.
ƒ are electrical equipment for mounting in control cabinets or similar closed electrical
operating areas.
ƒ comply with the protective requirements of the "Low voltage" EC Directive.
ƒ are not machines as defined by the Machines EC Directive.
ƒ are not household appliances, but are only designed as components for subsequent
commercial use.
Drive systems with brake resistors
ƒ The responsibility for compliance with the EC Directives in the machine application is
that of the re−user.
Any other use shall be deemed inappropriate!

3 Product description
Dimensioning conditions
EDKRBS047R DE/EN/FR/ES/IT 8.0
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Dimensioning conditions
If brake resistors are used, observe the following:
ƒ Mean value of regenerative power < permanent power Pdof the brake resistor.
ƒ Regenerative power during braking time < heat quantity QBof the brake resistor.
ƒ Braking time < 10 % of cycle time (braking time + dead time).
ƒ Always connect the thermal contact and integrate it in a way into the system
monitoring that the mains supply will be switched off when the standard device is
overheated.
At all times, the following must apply: In the time interval tcyc,RB (brake resistor cycle) the
cumulative braking times tbrk must always be £of the maximum total braking time
tbrk,max.
Calculation
Brake resistor cycle tcyc,RB:
tcyc,RB +QB
Pd
with
QBHeat quantity in Ws
PdPermanent power in W
Max. total braking time tbrk,max within the time interval tcyc,RB:
tbrk,max +QB@RB
Umax
2with
QBHeat quantity in Ws
RBResistance in W
Umax Max. operating voltage in V
Examples of the evaluation of the condition
The brake resistor cycle tcyc,RB = 150 s and the max. total braking time tbrk,max = 10 s are
given. The braking times tbrk and the process cycle tcyc,Prc are exemplary.

Product description
Dimensioning conditions
3
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1010 5050 100100 200200150150
tbrk [s]
t [s]
0.5 0.5
1 1 0.5 0.5 10.5 0.5 10.5 0.5 10.5 0.5
tcyc,RB = 150 s
tt
brk brk,max
= 7 s £
S
tt
brk brk,max
= 6.5 s £
S
Stt
brk brk,max
= 6.5 s £
1010 5050 100100 200200150150
tbrk [s]
t [s]
11111
tcyc,Prs
1 1
tcyc,Prs
1 1
tcyc,Prs
1 1
tcyc,Prs
111
tcyc,Prs
1
tt
brk brk,max
= 10 s £
tt
brk brk,max
= 11 s ³
S
S
ü
ü
ü
ü
û
û
tt
brk brk,max
= 10 s £
Sü
ü
In the above example, the dimensioning condition is observed at all times. In the example
below, the dimensioning condition is once not observed, which means that the brake
resistor selected is not suitable for the process specified. Use a brake resistor with a greater
power (shorter brake resistor cycle tcyc,RB).

4 Technical data
General data and operating conditions
EDKRBS047R DE/EN/FR/ES/IT 8.0
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4 Technical data
General data and operating conditions
Conformity and approval
Conformity
CE 2006/95/EC Low−Voltage Directive
Approval
UR UL508 Industrial Control Equipment, Underwriter
Laboratories (File−No. E232497) for USA and Canada
Protection of persons and equipment
Enclosure EN 60529 IP65
NEMA 250 Protection against contact to type 4
Thermal contact
Design NC contact, 230 °C
Switching capacity 250 V AC / 5 A
Environmental conditions
Climate
Storage IEC/EN 60721−3−1 1K3 (−25 ... +60 °C)
Transport IEC/EN 60721−3−2 2K3 (−25 ... +70 °C)
Operation IEC/EN 60721−3−3 3K3 (−10 ... +55 °C)
Current derating from +45 ... +55 °C: 2.5 %/°C
Site altitude 0 ... 4000 m amsl
1000 ... 4000 m amsl: Current derating 5 %/1000 m
Vibration resistance
(9.81 m/s2= 1 g)
EN 50178,
IEC 61800−5−1,
Germanischer
Loyd, general
conditions
Acceleration resistant up to 1 g

Technical data
General data and operating conditions
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Mounting conditions
Mounting location lThe mounting location must comply with the
device features mentioned in the chapter "General
data".
lFlammable materials or substances may not be
placed in the vicinity of the brake resistor.
lThe heat generated by the brake resistor must be
dissipated freely.
Mounting position
Standard Vertically suspended with connections at the bottom
Variant Horizontally standing with fixing bracket at the
bottom
Free spaces
Standard ^ 48
Variant ^ 49

4 Technical data
Rated data
EDKRBS047R DE/EN/FR/ES/IT 8.0
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Rated data
Electrical data
RBPdQBUmax
[W][W] [kWs] [VDC]
ERBS015R800W
15
800 120
800
ERBS015R01K2 1200 180
ERBS015R02K4 2400 420
ERBS018R800W
18
800 120
ERBS018R01K2 1200 180
ERBS018R01K4 1400 210
ERBS018R01K9 1900 285
ERBS018R02K8 2800 420
ERBS027R600W
27
600 90
ERBS027R01K2 1200 180
ERBS027R01K4 1400 210
ERBS047R400W 47 400 60
ERBS047R800W 800 120
RBResistance
PdPermanent power
QBHeat quantity
Umax Max. operating voltage

Technical data
Rated data
4
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Temperatures
Tnom TTK Tmax
[°C]
On the surface 250 400 1000
On the clearance
edge *) 120 200 300
Tnom Maximum temperature for rated data
TTK Temperature at which the thermal contact is activated
Tmax Maximum temperature in the case of improper use
*) Measured for air as the ambient medium (small coefficient of thermal conductivity); if
materials which heat up are located at the clearance edge (greater coefficient of
thermal conductivity), the temperature continues to rise.

4 Technical data
Mechanical data
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46 l
Mechanical data
Design 1
ERBS102
a b c1 c3 c4 c5 d3 e e1 g1
[mm] [kg]
ERBS015R800W 710
105 155.5 48
531
45 90 114 110 6.2
4.0
ERBS015R01K2 1020 841 5.6
ERBS018R800W 710 531 4.0
ERBS018R01K2 1020 841 5.6
ERBS018R01K4 1110 931 6.3
ERBS027R600W 550 371 3.1
ERBS027R01K2 1020 841 5.6
ERBS027R01K4 1110 931 6.3
ERBS047R400W 400 221 2.3
ERBS047R800W 710 531 4.0

Technical data
Mechanical data
4
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Design 2
ERBS107
a b c1 c3 c4 c5 d3 e e1 g1
[mm] [mm] [kg]
ERBS015R02K4 1020
105 155.5 48
841
45 180 204 200 6.2
10.0
ERBS018R01K9 825 646 8.7
ERBS018R02K8 1110 931 12.0

5 Mechanical installation
Mounting clearance
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5 Mechanical installation
Mounting clearance
Free spaces for standard mounting
ERBS106
x Wiring clearance
y Cable bending radius
All dimensions in millimetres