Peter electronic BR Series Training manual

electronic
Quality is our Drive.
Assembly and Commissioning Instructions
Braking Devices
BR 230/400 - 10...400

BR 230/400-10...400 1
as per 04/10 11600.10001
Table of Contents Page
1. Safety notes 3
2. Conformity 3
3. General description 4
4. Usage to the intended purpose 4
5. EC Declaration of Conformity 5
6. Block diagram 6
7. Functional description (see connection diagram) 7
7.1 LED indicators 7
8. Control inputs and outputs 8
8.1 Control inputs 8
8.2 Control outputs 8
9. Potentiometers 9
10. Technical data 10
10.1 Ambient conditions 10
11. Commissioning 11
11.1 Mounting instructions 11
11.2 Connection 11
11.3 Commissioning 12
12. Dimensioning rules 13
12.1 Dimensioning of braking contactors 13
12.2 Dimensioning of pre-fuses 13
12.3 Permissible braking frequency of BR ...-10 and BR...-20 15
12.4 Permissible braking frequency of BR ...-40...400 15
13. Dimensions 16
14. Typical connections 18
14.1 Connection diagramm 18

2 BR 230/400-10...400
Notes and symbols used in these instructions
Note: Notes explain the advantages of certain adjustments or settings and help
you to make use of the device in the best possible way.
Warning notices: Read them carefully and follow them strictly!
Warning notices are indicated in order to protect you against danger or to
help you to prevent the device from being damaged.
Caution: Danger to life through electric shock!
When you see this sign, always make sure that the device is de-energized
and secured against unintentional energizing.
These commissioning instructions were prepared with great care. Nevertheless, PETER
electronic GmbH & Co. KG does not assume liability for damage resulting from mistakes
possibly contained in this manual. Technical changes that serve to improve the product are
subject to change without notice.

BR 230/400-10...400 3
1. Safety notes
The described devices are electrical equipment for use in industrial electrical power
installations. An impermissible removal of the covers during operation can cause
serious damage to your health, since these devices contain live parts with high
voltages.
Adjustment work may only be performed by trained staff observing the safety regulations.
Assembly and mounting work may only be carried out with the equipment deenergized.
Make sure that all drive components are properly earthed.
Please read these commissioning instructions carefully before putting the device into operation.
Besides, the user must ensure that the devices and associated components are fitted and
connected in accordance with the appliable local, legal and technical regulations. The VDE-
regulations VDE 0100, VDE 0110 (EN 60664), VDE 0160 (EN 50178) , VDE 0113 (EN 60204,
EN 61310),VDE 0660 (EN 50274) plus the appropriate regulations of the TÜV (Technical Control
Association) and the trade associations apply in Germany.
The user must ensure that the drive turns into a safe operating state following a device failure, in
the event of maloperation, or if the control unit has failed etc..
Caution: Even if the motor is at rest, it is not physically separated from the mains.
2. Declaration of conformity
In industrial linguistic usage the electronic brakes of the type BR... are called "devices", however,
in the sense of the "device-safety-law", the "EMC-law" or the "EC-guideline for machinery" they
are not devices or machines ready for use or connection but they are components. It is only
possible to define their final function, when these components are integrated into the design and
construction of the user.
To be able to use the devices to their intended purpose, it requires power supply networks
according to DIN EN 50160 (IEC38).
The user takes the responsibility that the user’s design and construction comply with the appli-
cable legal provision.
The commissioning is strictly forbidden as long as the conformity of the final product with the
guidelines 2006/42/EC (Machinery directive) and 2006/95/EC (Low voltage directive) is not
proved.

4 BR 230/400-10...400
3. General description
The electronic braking devices of the BR...-type enable a non-wearing braking of three-phase
asynchronous motors and A.C. motors. The braking devices are used for drives that due to safety
or functional reasons have to be reliably slowed down.
Special features
• non-wearing and maintenance-free
• retrofitting in existing systems possible
• also available for special voltages
• for all asynchronous motors
4. Usage to the intended purpose
The devices of the BR-series are electrical equipment that is used in industrial electrical power
installations. They are designed for the application in machines, in order to slow down rotating
masses on drives with three-phase motors. With due regard to the installation guidelines they
meet the following requirements:
Typical applications
• sawing machines
• centrifuges
• wood working machines
• textile machinery
• conveying machines

BR 230/400-10...400 5
5. EC Declaration of conformity
EC Declaration of Conformity
Name / Address: Peter Electronic GmbH & Co.KG
Bruckäcker9
92348 Berg
Germany
hereby declares that the following product (device, component, unit) in the version as supplied
Product designation: Braking Device
Serien / type designation: BR ... - 10...600
Article group: 216...
Year of manufacture: 1997
complies with the provisions of the following EC-directives:
2004/108/EG concerning
Electromagnetic compatibility
and
2006/95/EG concerning
Electrical equipment designed for use within
certain voltage limits
The following harmonized standards have been applied:
EN 60947-1: Low-voltage switchgear and
2008 controlgear
General rules
EN 60947-4-2: Low-voltage switchgear and
2007 controlgear
Contactors and motor-starters -
AC semiconductor motor
controllers and starters
This EC Decleration of Conformity is no longer valid, if the products is modified or changed
without our agreement.
This declaration is issued under the sole responsibility of the signatory.
Berg, 05.08.2009 Dr. Thomas Stiller, Managing Director
(place, date)
(signatory and function of the signatory)
(signature)
The manufacturer / company placing the product on the market
(authorized representatives of the manufacturer / companies placing the product on the market
that are established within the Community)

6 BR 230/400-10...400
6. Block diagram
X6
main contactor
interlock
Devices from 40A on
braking contactor external
U V
Braking
contactor
control
L1 L2/N
Pulse
stage
X5
Interlock
braking signal
X3X4
Timing
control
Starting
logic

BR 230/400-10...400 7
7. Functional description (see connection diagram)
After switching on the operating voltage on L1 and L2 the main contactor interlock (terminal
X5,X6) closes. The motor can be started.
A starting logic makes sure that braking is not yet initiated when the plant is switched on with the
master switch while the motor is still switched off.
The fully automatic run of the braking interval starts with the switch-off of the motor contactor
which at the same time closes the contact (terminal X3,X4). During braking the main contactor is
interlocked via the contact (terminal X5,X6). After a delay time in which the remanent voltage of
the motor decays to a value that is harmless for the power semiconductors (0.25sec. for small-
size braking devices, up to 1.5sec. for the 400A-version), the braking contactor pulls in. After-
wards an adjustable d.c. voltage is applied to the motor winding. The resulting magnetic field has
a braking effect on the still rotating rotor. The d.c. voltage is generated by a thyristor generalized
phase control. Special circuits protect the power semiconductors against overvoltage. With the
potentiometer "I" the braking torque can be adjusted in wide ranges. Experience shows that a
braking current amounting to double rated motor current has a good braking effect. When
commissioning the device, the braking current, for safety reasons, has to be checked with a
moving-iron instrument. Multimeters and clamp-on probes give wrong measurements and must
not be used for this purpose. Value-adjustments higher than the rated device current are not
allowed. If, due to heavy rotating masses to be slowed down, the braking time at rated device
current is still too long, the next larger braking device has to be used.
With the potentiometer "t" the braking time can be adjusted from 2 to 14sec.. At the end of the
adjusted braking time the braking voltage is switched off and the braking contactor drops out with
delay. Thereupon the contact (terminal X5,X6) recloses, so that the motor can be started anew.
Warning note :
When putting the device into operation for the first time, the braking current
should be checked with a true r.m.s. measuring instrument. Clamp-on
probes or digital multimeters may only be used if they can measure the true
r.m.s..
Note: If the braking time at rated device current is too short, due to the fact that the
centrifugal masses to be slowed down are too large, a device featuring a
higher rated current has to be used.
7.1 LED indicators
LED – green mains voltage is applied, braking device is ready
LED – red braking current flows

8 BR 230/400-10...400
8. Control inputs and outputs
8.1 Control inputs
Caution: Danger to life through electric shock!
The terminals X3, X4 carry mains potential. If a switch or contactor contact is
connected to these terminals, it must have a test voltage of 2.5kV.
8.2 Control outputs
1) devices from 40A up, braking contactor external
Control
terminals
Designation Description
X3, X4 Starting contact Connection of a break contact of the motor contactor
Control
terminals
Designation Description
X1, X21) Contact for
braking contactor
The contact closes during braking.
Loop the normally opened contact into the branch of
the braking contactor.
X5, X6 Interlock The interlock prevents the motor from being switched on
during braking.
Loop the normally closed contact into the branch of the
motor contactor.

BR 230/400-10...400 9
9. Potentiometers
With the potentiometers on the front panel of the BR-devices the following paramteters can be
adjusted.
Warning note :
The devices BR 230-10 to BR 400-200 feature overcurrent cut-off. If the
rated device current ist exceeded, the braking current will be switched off.
If the braking current is adjusted to a too high value, the braking current will
be cut off after approx. 0.5s.
In the event, adjust the braking current „I“ downwards so that the required braking time is reached
again.
If, with the maximum braking time, the motor does not come to a reset, a braking device of the
next higher performance category or a device with an extended braking time (special device) has
to be used.
„I“ Adjusting the braking current
Adjust the braking current as small as possible, in order to avoid unnecessary heating
ot the power semiconductors and the motor. This is especially important in the case of
frequent operation. We recommend to limit the maximum braking current to double
rated motor current.
The required braking torque is to be adjusted with the potentiometer „I“. It is important
that the braking current does not exceed the rated device current that is indicated on
the nameplate of the device.
„t“ Adjusting the braking time
The time, in which the braking current flows, is to be adjusted with the potentiometer „t“.
It should be so long that, as soon as the motor has come to rest, the braking current is
switched off.
When the motor has reached operating temperature, check the settings and, if
necessary, readjust them.

10 BR 230/400-10...400
10. Technical data
10.1 Ambient conditions
Type designation
BR ....
230-10
400-10
230-20
400-20
230-40
400-40
230-60
400-60
230-100
400-100
230-200
400-200
230-400
400-400
Nominal voltage
according to DIN EN
50160 (IEC 38)
BR230 ... 220/240V ±10% 50/60Hz other voltages
BR400 ... 380/415V ±10% 50/60Hz upon request
Power draw of the
electronics
6 VA
Recommended for
rated motor currents
up to
5A 10A 20A 30A 50A 100A 200A
Rated device current 10A 20A 40A 60A 100A 200A 400A
c.d.f. at max. braking
current
20% 20% 15% 15% 15% 15% 15%
I²t-value of power sem-
iconductors (A²s)
40 680 8000 8000 8000 80000 320000
Braking voltage 0 ... 130VDC at 220/240V
0 ... 220VDC at 380/415V
Braking time 2 ... 14s
(other times upon request)
Contact rating relay contact for motor contactor = 6A/250VAC; 6A/30VDC
-contact for braking contactor
= 6A/250VAC; 6A/30VDC
Delay time for reduc-
tion of residual e.m.f.
250ms 250ms 600ms 600ms 1500ms 1500ms 1500ms
max. Cross-sectional
area / connect. cable
2,5mm² 2,5mm² 16mm² 16mm² 35mm² 35mm² Screw
M8
Weight 0,5kg 0,55kg 2,4kg 2,4kg 2,55kg 3,55kg 7,6kg
Storage temperature -25 ... 75°C
Operating temperature 0 ... 45°C
Protection class IP 20
Environment Overvoltage category III, pollution degree 2

BR 230/400-10...400 11
11. Commissioning
The device is to be put into operation in 3 steps::
1. Mounting
2. Connection and
3. Parameter setting
11.1 Mounting instructions
Caution: Danger to life through electric shock!
The following conditions are to be complied with in order to ensure a safe
and reliable operation of the BR ...:
1. The device series BR ... is to be used under overvoltage conditions of the
category III.
2. Make sure that pollution degree 2 or better, in accordance with IEC664, is
complied with.
3. The device is to be installed into a housing (min. degree of protection: IP54).
4. The device must be operated without being exposed to contamination by
water, oil, carbon deposits, dust, etc..
Warning:
Make sure that a minimum distance to adjoining devices is kept. Above and
underneath the housing a minimum distance of 50mm is to be kept.
11.2 Connection
The braking device has to be connected according to the attached connection diagram. For other
connections refer to the factory.
Note: Further connection proposals for special circuit arrangements are available
via our hompage at www.peter-electronic.com.
Note: Prior to putting the motor brake into operation, the wiring has to be checked.
To ensure a reliable operation it is important to keep to the interlocking conditions:
1. In order to initiate braking, a potential-free break-contact of the main contactor is
necessary, i.e., when the motor contactor is dropped out the terminals X3,X4 of the braking
device are connected.
2. The interlocking contact of the braking unit (terminal X5,X6) has to be looped into the
control circuit of the motor contactor, so that the motor contactor cannot pull in during
braking.

12 BR 230/400-10...400
3. When using braking devices with separate braking contactors (devices with rated currents
from 40A up), braking contactor and motor contactor have to be interlocked against each
other. (Electrical interlock with break contact)
11.3 Commissioning
Sequence of commissioning:
1. Disconnect plant from supply mains.
2. Connect current measuring instrument to the supply line from the braking device to the
motor. The adjustment of the braking current (r.m.s. value) requires a moving-iron
instrument. Do not use clamp-on probes or moving-coil instruments. The true r.m.s. value
is to be measured by using a current probe.
3. Turn potentiometer "t" to right stop (maximum).
4. Turn potentiometer "I" to left stop (minimum).
5. Switch on the plant.
6. Initiate braking by switching the motor contactor ON/OFF.
Note: When putting the device into operation for the first time, the braking current
should be checked with a true r.m.s. measuring instrument. Clamp-on
probes or digital multimeters may only be used if they can measure the true
r.m.s..
Adjusting the braking current
Adjust the braking current as small as possible, in order to avoid unnecessary heating of the
power semiconductors and the motor. This is especially important in the case of frequent
operation. We recommend to limit the maximum braking current to double rated motor current.
The required braking torque is to be adjusted with the potentiometer "I". It is important that the
braking current does not exceed the rated device current that is indicated on the nameplate of the
device.
If the braking current is adjusted to a too high value, the braking devices will be switched off
immediately.
Warning note:
The devices do not have a current control or overcurrent cut-off function.
If the potentiometer “I“ is turned up to an accordingly high level, the braking
current may be higher than the rated device current and can thus destroy the
braking device.
If, due to non-compliance with the above adjustment instructions, the current has been set to a
too high value, it may happen that in the case of devices up to 20A the braking current will be
switched off after approx. 0.5s.
In the event, adjust the braking current “I“ downwards so that the required braking time is reached
again.

BR 230/400-10...400 13
Adjusting the braking time
The time, in which the braking current flows, is to be adjusted with the potentiometer "t". It should
be so long that, as soon as the motor has come to rest, the braking current is switched off.
When the motor has reached operating temperature, check the settings and, if necessary,
readjust them.
12. Dimensioning rules
Note! All data sheets and commissioning instructions are avaialble on our
homepage at www.peter-electronic.com.
12.1 Dimensioning of braking contactors
The braking contactor is switched on or off via a control contact of the braking device (no-load
switching).
When selecting the braking contactor, it must be ensured that the contacts are able to carry the
maximally occuring braking current (nominal/rated device current). Therefore, the value „conven-
tional thermal current“ (Ith) is decisive when selecting the braking contactor.
If this value is not indicated, the rated operational current for AC1-operation may be used instead.
Tip: By connecting contacts in parallel it is often possible to use a lower-priced
contactor of a smaller design.
12.2 Dimensioning of pre-fuses
Basically, two types of fuse protection are available for the user:
1. Fusing according to allocation type „1“, DIN EN 60947-4-2.
After a short circuit, the braking device is allowed to be inoperative.
2. Fusing according to allocation type „2“, DIN EN 60947-4-2.
After a short circuit, the braking device must be suitable for further use. However, there is
the danger that the contacts of the braking relay (braking contactor) weld. Therefore, if
possible, these contacts are to be checked prior to reconnecting the device to the supply. If
this check cannot be carried out by the user, the device has to be returned to the producer
in order to have it checked.
The following dimensioning information refers to the below operating conditions:
• Use of standard asynchronous motors
• Braking time not exceeding 20s, for braking devices up to 36A.
• Braking time not exceeding 40s, for braking devices from 40A up.
• Braking current not exceeding 2.5x INOM of the motor.
• Cyclic duration factor (c.d.f.) not exceeding the value indicated in the data sheet.

14 BR 230/400-10...400
Fusing according to allocation type „1“:
As pre-fuses, we recommend to use line protection fuses (utilization category gL) or automatic
circuit-breakers with tripping characteristic B, C, D or K.
Taking into account the maximum braking currents that occur (normally the nominal/rated device
current), we recommend fuses according to table 2, column 3.
Note: Wiring cross-sectional area according to DIN VDE 0100-430,
DIN EN 57100-430.
Fusing according to allocation type „2“:
The power semiconductors are to be protected by fuses of the utilization category gR (semicon-
ductor fuses, high-speed fuses). However, since these fuses do not ensure line protection, it is
necessary to use additionally line protection fuses (utilization category gL).
As for the dimensioning of the line protection fuse (gL), please refer to table 2, column 3.
To protect the semiconductors it is necessary to select gR-fuses featuring cutoff-I²t-values of the
ranges indicated in table 2, column 4. In this connection, the current value of the selected fuse
should not be smaller than the braking current to be expected (nominal/rated device current).
Note 1: On the basis of the recommended I²t-value, braking current, and possibly the
c.d.f., the fuse supplier is able to select a suitable type. Due to the great
variety of producers, sizes and types, PETER electronic does not
recommend any particular fuses.
Note 2: If the value of the fuse or cutoff-I²t-value is selected too small, it may happen
that the semiconductor fuse reacts during braking..
Table 2
Column 1 Column 2 Column 3 Column 4
max. Braking
current / Rated
device current
Device type Fuse value
allocation type „1“
Recommended range for
cutoff-I²t-value of semiconductor
protection fuses allocation type „2“
10A BR …-10 10A 30... 38 A²s
20A BR …-20 16A 300… 650 A²s
40A BR …-40 32A / 35A 1.400… 3.500 A²s
60A BR …-60 40A 3.000 … 4.650 A²s
100A BR …-100 63A 6.000 … 7.600 A²s
200A BR …-200 125A 50.000 …76.000 A²s
400A BR …-400 250A 200.000 … 305.000 A²s

BR 230/400-10...400 15
12.3 Permissible braking frequency of BR ...-10 and BR...-20
The braking frequency depends on the adjusted braking current.
The braking devices of the BR 230/400-10-20A type allow the following braking frequencies:
Warning!
When setting up a machine or during commissioning, it is possible to carry
out 10 braking operations in succession, i.e., with rated device current and at
a braking time of 14s. After such operating conditions, however, the device
needs a recovery time of 20 minutes.
12.4 Permissible braking frequency of BR ...-40...400
The braking frequency depends on the adjusted braking current.
The braking devices of the BR 230/400-40...400A type are designed for a cyclic duration factor
c.d.f.) of 15% and allow the following braking frequencies:
Attention!
If braking times exceeding 40s are required, it is absolutely necessary to
reduce the permissible max. braking current according to the following table.
Non-observance can damage the braking device and motor!
Braking current Braking time Braking frequency
rated device current 5s
14s
1 braking per 25s
1 braking per 70s
75% rated device current 5s
14s
1 braking per 20s
1 braking per 55s
50% rated device current 5s
14s
1 braking per 13s
1 braking per 35s
Braking current Braking time Braking frequency
rated device current 5s
14s
1 braking per 33s
1 braking per 100s
75% rated device current 5s
14s
1 braking per 27s
1 braking per 80s
50% rated device current 5s
14s
1 braking per 17s
1 braking per 50s

16 BR 230/400-10...400
table 3
Reduction of the permissible max. braking current in the case of braking times exceeding
40 seconds for braking devices of the BR type up to 40A
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400
Braking time in seconds
Permissible max. braking current in % of the rated device current

BR 230/400-10...400 17
13. Dimensions
All dimensions in mm!
100 120
73
BR 230-10 ... 20
BR 400-10 ... 20
185 (225 with BR 230/400-200 ... 400)
200 (240 with BR 230/400-200 ... 400)
146 (286 with BR 230/400-400)
175 (315 with BR 230/400-400)
Depth: 172mm
BR 230-40 ... 400
BR 400-40 ... 400
for M4

18 BR 230/400-10...400
14. Typical connections
14.1 Connection diagramm
moving-iron
instrument
The limit values for emitted interference according to the applicable device standards do not rule out
the possibility that receivers and susceptible electronic devices within a radius of 10m are subjected
to interference.
If such interference, that is definitely attributable to the operation of the braking devices "BR",
occurs, the emitted interference can be reduced by taking appropriate measures.
Such measures are, e.g.:
to connect reactors (3mH) or a suitable mains filter in series before the soft starter, or to connect
X-capacitors (0,15µ F) in parallel to the supply voltage terminals.
F1 F2
Attention:
If, in spite of a long braking time, the braking
current is instantly switched off,
the braking current is adjusted to a too high value.
3
~
EMC
W
M
V
U
F4
K1
UV
A
power
terminals
L2/NL1
BR 230-40 ... 400
BR 400-40 ... 400
N
L1
L3
L2
BR 230-10 ... 20
BR 400-10 ... 20
L1
N
L3
L2
WU
V
M
3
~
F1
F4
K1
F2
F3
braking
contactor
A2
motor
contactor
K1
A1
K2
OFF
K2
X5
control
unit
X6
X2
X3
X1
X4
K1
K1ON
K2 K1
F4
A2
A1
F4
OFF
A
moving-iron
instrument
motor contactor
K1
K1
A1
A2
ON
Typ BR 230
K1
UV
L2/NL1 X3
X4
X5
X6
F3
Typ BR 230

BR 230/400-10...400 19