Lenze ERBG023D05K6 User manual

EDKRBG018R
.@RI
Ä.@RIä
ERB
l
ERBGxxxxxxxx
Brake resistor
Mounting Instructions
L−force Drives

,Please read these instructions and the documentation of the standard
device before you start working!
Observe the safety instructions given therein!

Contents i
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EDKRBG018R DE/EN/FR/ES/IT 7.0
1 About this documentation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Validity information 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Target group 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Document history 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Conventions used 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Notes used 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety instructions 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Residual hazards 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Product description 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Overview 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Identification 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Application as directed 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Dimensioning conditions 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Technical data 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General data and operating conditions 43. . . . . . . . . . . . . . . . . . . . . . . .
4.2 Rated data 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Mechanical data 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Mechanical installation 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Mounting steps 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Electrical installation 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Important notes 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Connection data 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Connection plan 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Mounting steps 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Maintenance intervals 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Maintenance operations 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this documentation
Validity information
1
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30 EDKRBG018R DE/EN/FR/ES/IT 7.0
0Fig. 0Tab. 0
1 About this documentation
1.1 Validity information
These instructions are valid for
ƒBrake resistors ERBGxxxxxxxx
1.2 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
1.3 Document history
Material number Version Description
.@RI 7.0 01/2011 TD29 Revision

About this documentation
Conventions used
1
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EDKRBG018R DE/EN/FR/ES/IT 7.0
1.4 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

About this documentation
Notes used
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32 EDKRBG018R DE/EN/FR/ES/IT 7.0
1.5 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

About this documentation
Notes used
1
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EDKRBG018R DE/EN/FR/ES/IT 7.0
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.

Safety instructions
General safety instructions
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34 EDKRBG018R DE/EN/FR/ES/IT 7.0
2 Safety instructions
2.1 General safety instructions
}Danger!
Disregarding the following basic safety measures may lead to
severe personal injury and damage to material assets!
ƒLenze 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.
ƒAll 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.
ƒOnly 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
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EDKRBG018R DE/EN/FR/ES/IT 7.0
2.2 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.

Safety instructions
Residual hazards
2
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36 EDKRBG018R DE/EN/FR/ES/IT 7.0
(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).

Safety instructions
Residual hazards
2
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EDKRBG018R DE/EN/FR/ES/IT 7.0
OWarnings!
Conditions of Acceptability:
ƒThe product covered by this report is intended for use with Power
Conversion Equipment and the like.
ƒThe devices were tested for horizontal mounting positions. If
other mounting positions are necessary in the end use
applications, a temperature test shall be performed to ensure the
maximum allowed temperature rise.
ƒThese devices are intended for factory wiring only. The cable lug
connector shall be mounted direct on the surface of the copper
busbar to provide appropriate connection.
ƒTemperature tests have been conducted for continuous duty as
indicated in the rating table with closed bottom surface. The
heat capability and the maximum temperature rise for higher
current ratings at shorter duty cycles shall be determined in the
end use.
ƒThe device were evaluated related to spacings according UL508.
The appropriate spacings has to be determined in the end use
application. The maximum Voltage rating each element could be
max. 1000 V Ac. Therefore the spacing related to UL508 have to
be 601−1000 V 14 mm through air and 25.4 mm over surface.
ƒThe temperature rating of the connection cable shall be at least
105 °C to ensure proper connection.
ƒThe required wire bending space and the spacings at the
terminals after connection shall be determined in the end use
application.

Product description
Overview
3
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38 EDKRBG018R DE/EN/FR/ES/IT 7.0
3 Product description
3.1 Overview
ERBG001
Scope of supply
Pos. Description
Brake resistor
Mounting Instructions
Brake resistor elements
Pos. Description
0Nameplate
1Cable gland for brake resistor cable
2Cable gland for thermal contact cable

Product description
Identification
3
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EDKRBG018R DE/EN/FR/ES/IT 7.0
3.2 Identification
Lenze
Type

ERBG002

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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40 EDKRBG018R DE/EN/FR/ES/IT 7.0
3.3 Application as directed
Brake resistors
ƒmust only be actuated under the operating conditions specified in these
operating instructions.
ƒare 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.
ƒare electrical equipment for mounting in control cabinets or similar closed
electrical operating areas.
ƒcomply with the protective requirements of the "Low voltage" EC
Directive.
ƒare not machines as defined by the Machines EC Directive.
ƒare not household appliances, but are only designed as components for
subsequent commercial use.
Drive systems with brake resistors
ƒThe 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
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EDKRBG018R DE/EN/FR/ES/IT 7.0
3.4 Dimensioning conditions
If brake resistors are used, observe the following:
ƒMean value of regenerative power < permanent power Pdof the brake
resistor.
ƒRegenerative power during braking time < heat quantity QBof the brake
resistor.
ƒBraking time < 10 % of cycle time (braking time + dead time).
ƒAlways 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

Product description
Dimensioning conditions
3
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42 EDKRBG018R DE/EN/FR/ES/IT 7.0
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
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EDKRBG018R DE/EN/FR/ES/IT 7.0
4 Technical data
4.1 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. E221095) for USA and Canada
Protection of persons and equipment
Enclosure EN 60529 IP20
NEMA 250 Protection against
contact to type 1
Thermal contact
Design NC contact, 100 °C
Switching capacity 250 V AC / 2.5 A
110 V AC / 1.6 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: 1 %/°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 0.7 g

Technical data
General data and operating conditions
4
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44 EDKRBG018R DE/EN/FR/ES/IT 7.0
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 Horizontally standing
Variant Vertically suspended with connections at the bottom.
Free spaces
Standard Top > 200 mm
To the sides > 100 mm
Variant Top > 200 mm
To the sides > 100 mm
Bottom > 300 mm

Technical data
Rated data
4
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EDKRBG018R DE/EN/FR/ES/IT 7.0
4.2 Rated data
Electrical data
RBPdQBUmax
[W] [W] [kWs] [VDC]
ERBG023D05K6 2.3 5600 840
1000
ERBG028D04K1 2.8 4100 615
ERBG035D03K3 3.5 3300 495
ERBG043D03K0 4.3 3000 450
ERBG005R02K6 5.0 2600 390
ERBG075D01K9 7.5 1900 285
ERBG012R01K9 12.0
ERBG012R05K2 5200 780
ERBG015R03K3
15.0
3300 495
ERBG015R06K2 6200 930
ERBG015R10K0 10000 1500
ERBG018R04K3 18.0 4300 645
RBResistance
PdPermanent power
QBHeat quantity
Umax Max. operating voltage
Temperatures
Tnom TTK Tmax
[°C]
Inside 390 530 690
At the housing 200 240 300
On the clearance
edge *) 120 160 200
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
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46 EDKRBG018R DE/EN/FR/ES/IT 7.0
4.3 Mechanical data
ERBG003
a b c d e g1
[mm] [kg]
ERBG023D05K6
486 302 380
400 426
6.3
15.9
ERBG028D04K1 12.8
ERBG035D03K3
300 326
12.6
ERBG043D03K0 11.8
ERBG005R02K6 11.0
ERBG075D01K9 210 236 9.5
ERBG012R01K9
ERBG012R05K2 400 426 15.1
ERBG015R03K3 300 326 12.6
ERBG015R06K2 500 526 17.0
ERBG015R10K0 710 736 22.0
ERBG018R04K3 400 426 13.5