Lenze Global Drive ERB Series User manual

Mounting Instructions
EDKRBM002
.El1
Ä.El1ä
ERB 20 ... 35 W
l
ERBM470R020W, ERBM100R035W
Brake resistor
Global Drive

,Lesen Sie zuerst diese Anleitung und die
Dokumentation zum Grundgerät, bevor Sie mit
den Arbeiten beginnen!
Beachten Sie die enthaltenen Sicherheitshinweise.
,Please read these instructions and the
documentation of the standard device before you
start working!
Observe the safety instructions given therein!
,Lire le présent fascicule et la documentation
relative à l’appareil de base avant toute
manipulation de l’équipement !
Respecter les consignes de sécurité fournies.

Contents i
EDKRBM002 DE/EN/FR 4.0 23
l
1 About this documentation 24. . . . . . . . . . . . . . . . . . . . .
Validity information 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Target group 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Document history 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions used 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes used 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 26. . . . . . . . . . . . . . . . . . . . . . . . . . .
General safety instructions 26. . . . . . . . . . . . . . . . . . . .
Residual hazards 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Product description 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application as directed 30. . . . . . . . . . . . . . . . . . . . . . . .
Dimensioning conditions 31. . . . . . . . . . . . . . . . . . . . . .
4 Technical data 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General data and operating conditions 33. . . . . . . . .
Rated data 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical data 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Mechanical installation 36. . . . . . . . . . . . . . . . . . . . . . .
Mounting steps 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Electrical installation 37. . . . . . . . . . . . . . . . . . . . . . . . .
Important notes 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection data 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection plan 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting steps 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance intervals 40. . . . . . . . . . . . . . . . . . . . . . . .
Maintenance operations 40. . . . . . . . . . . . . . . . . . . . . .

1 About this documentation
Validity information
EDKRBM002 DE/EN/FR 4.0
24 l
0Fig. 0Tab. 0
1 About this documentation
Validity information
These instructions are valid for
ƒ Brake resistors ERBM470R020W
ƒ Brake resistors ERBM100R035W
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
.El1 4.0 02/2011 TD29 Revision
Conventions used
Type of information Identifica−
tion
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

About this documentation
Notes used
1
EDKRBM002 DE/EN/FR 4.0 25
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.
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
EDKRBM002 DE/EN/FR 4.0
26 l
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
2
EDKRBM002 DE/EN/FR 4.0 27
l
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
EDKRBM002 DE/EN/FR 4.0
28 l
(Stop!
Possible overheating of the brake resistor during
operation
Inadequate heat dissipation during operation can
cause the brake resistor to overheat.
Possible consequences:
ƒThe brake resistor is destroyed.
ƒThe drive is not braked but coasts to a standstill.
Protective measures:
ƒAlways connect the thermal contact of the brake
resistor.
ƒIntegrate the thermal contact into the overall
equipment monitoring apparatus in such a way
that the supply of power to the standard device is
switched off if the brake resistor overheats (e.g.
switch−off by means of mains contactor control).

Product description
Overview
3
EDKRBM002 DE/EN/FR 4.0 29
l
3 Product description
Overview
ERBMF001
Scope of supply
Pos. Description
Brake resistor
Mounting Instructions
Brake resistor elements
Pos. Description
0Nameplate
1Thermal contact
2Terminals RB1, RB2, T1, T2
3PE connection
Identification
L

0
ERBMXXX011

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

3 Product description
Application as directed
EDKRBM002 DE/EN/FR 4.0
30 l
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!

Product description
Dimensioning conditions
3
EDKRBM002 DE/EN/FR 4.0 31
l
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 QB
of 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

3 Product description
Dimensioning conditions
EDKRBM002 DE/EN/FR 4.0
32 l
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.
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 £
S
ü
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).

Technical data
General data and operating conditions
4
EDKRBM002 DE/EN/FR 4.0 33
l
4 Technical data
General data and operating conditions
Conformity and approval
Conformity
CE 2006/95/EC Low−Voltage Directive
Protection of persons and equipment
Enclosure EN 60529 IP20
NEMA 250 Protection
against contact
to type 1
Thermal contact
Design NC contact, 130 °C
Switching
capacity
250 V AC / 0.5 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,
Germanisch
er Loyd,
general
conditions
Acceleration resistant up to 1 g
Mounting conditions
Mounting
location
lIn the control cabinet
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
Vertically suspended with connecting
cables at the bottom.
Free space
at the top > 100 mm
at the bottom > 100 mm
to the sides > 25 mm

4 Technical data
Rated data
EDKRBM002 DE/EN/FR 4.0
34 l
Rated data
Electrical data
RBPdQBUmax
[W][W] [kWs] [VDC]
ERBM470R020W 470 20 3.0 800
ERBM100R035W 100 35 4.5
RBResistance
PdPermanent power
QBHeat quantity
Umax Max. operating voltage
Temperatures
Tnom TTK Tmax
[°C]
On the surface 150 250 500
On the clearance
edge *) 90 100 120
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.

Technical data
Mechanical data
4
EDKRBM002 DE/EN/FR 4.0 35
l
Mechanical data
ERBMF003
a b e d2 d3
[mm]
ERBM470R020W 40 160 36 7.5 145
ERBM100R035W 240 225
g1 h1 h2 k1 k2 o1
[mm] [kg]
ERBM470R020W 625 25 100 100 25 0.25
ERBM100R035W 0.52

5 Mechanical installation
Mounting steps
EDKRBM002 DE/EN/FR 4.0
36 l
5 Mechanical installation
Mounting steps
How to mount the brake resistor:
1. Select a suitable mounting location.
– The mounting location must always ensure the
operating conditions mentioned in the technical data; if
required, additional measures must be taken.
– Ensure unimpeded air circulation for heat dissipation.
2. Screw down the brake resistor at the mounting location.
– The mounting location and the mounting material must
ensure the permanent mechanical connection.

Electrical installation
Important notes
6
EDKRBM002 DE/EN/FR 4.0 37
l
6 Electrical installation
Important notes
(Stop!
Possible overheating of the brake resistor during
operation
Inadequate heat dissipation during operation can
cause the brake resistor to overheat.
Possible consequences:
ƒThe brake resistor is destroyed.
ƒThe drive is not braked but coasts to a standstill.
Protective measures:
ƒAlways connect the thermal contact of the brake
resistor.
ƒIntegrate the thermal contact into the overall
equipment monitoring apparatus in such a way
that the supply of power to the standard device is
switched off if the brake resistor overheats (e.g.
switch−off by means of mains contactor control).
Connection data
Connection Connection
type
Connection
size
Tightening
torque
RB1, RB2
(Brake resistor) Screw
terminals
0.33 ... 4 mm2
22 ... 12 AWG
0.5 Nm
4.4 lb−in
T1, T2
(Thermal contact)
PE (protective
conductor) Flat connector 6.3 x 0.8 −

6 Electrical installation
Connection plan
EDKRBM002 DE/EN/FR 4.0
38 l
Connection plan
Version 1 (short cables)
R
B
RB1 RB2
< 0.5 m
PE
T1 T2
ERBG008
Twisted cables
Version 2 (long cables)
R
B
RB1 RB2
<5m
PE
PES
PES
T1 T2
ERBG007
HF−shield termination by extensive PE connection
Twisted cables

Electrical installation
Mounting steps
6
EDKRBM002 DE/EN/FR 4.0 39
l
Mounting steps
ERBMF006
How to connect the brake resistor:
1. Disconnect the basic device from the mains and check all
power terminals for safe isolation from supply.
2. Installing the brake resistor cable:
– Use twisted cables for a cable length up to 0.5 m
(connection plan version 1).
– Use shielded cables for a cable length up to 5 m
(connection plan version 2).
– Connect cores to the terminals RB1, RB2 and PE,
tightening torque must be observed. Connect PE
according to EN 61800−5−1.
– Apply cores and shield to the basic device; the
documentation of the basic device must be observed.
3. Installing the thermal contact cable:
– Use the twisted cable.
– Connect cores to the terminal T1 and T2; tightening
torque must be observed.
– When integrating the thermal contact into the system
monitoring ensure that the mains supply will be
switched off when the brake resistor is overheated.

7 Maintenance
Maintenance intervals
EDKRBM002 DE/EN/FR 4.0
40 l
7 Maintenance
Maintenance intervals
The brake resistor is maintenance−free. Nevertheless, a visual
inspection must be executed in short and regular intervals
considering the ambient conditions.
Ensure that:
ƒ the environment of the brake resistor still corresponds to
the operating conditions included in the technical data.
ƒ no dust or dirt impedes the heat dissipation of the brake
resistor.
ƒ the mechanical and electrical connections are correct.
Maintenance operations
Cleaning the brake resistor
1. Disconnect the standard device from the mains and wait at
least three minutes.
2. Check temperature of the brake resistor and allow it to cool,
if required.
3. Check the brake resistor for safe isolation from supply.
4. Clean brake resistor without using cleaning agents.