Powerohm Resistors BM Series User manual

IMPORTANT: These instructions should be read thoroughly before installation. All warnings and
precautions should be observed for both personal safety and for proper equipment performance
and longevity. Failure to follow these instructions could result in equipment failure and/or serious
injury to personnel. Braking modules contain lethal voltages when connected to the inverter. It is
very important to remove power to the inverter before installing or servicing this unit. Always
allow adequate time (approximately 5 minutes) after removing power before touching any
components. The LED’s must be completely out before servicing the unit.
Powerohm Instruction Manual
For BM “BG” Series
Braking Modules

2 a brand of ICD, Inc.
• Page 2: Table of Contents for installation manual HCPMAN0001_R3 (2018-03-05)
• Page 3: Table of Contents (cont.)
• Page 4: Product Overview
• Page 5: Inspection & Environmental Conditions
• Page 6: Electrical Ratings for 450 & 600 amp Models
• Page 7: Electrical Ratings for 900 & 1200 amp Models
• Page 8: Equipment Installation
• Page 9: Mounting Orientation
• Page 10: Dimensions and Weight for 450 & 600 amp Models
• Page 11: Dimensions and Weight for 900 & 1200 amp Models
• Page 12: Wiring Recommendations
• Page 13: Wire Sizing
• Page 14: Power Connections for 450 & 600 amp models
• Page 15: Power Connections for 900 & 1200 amp models
• Page 16: TB3 115vac Enable & Control Connection Specs
• Page 17: TB3 24vdc Enable & Control Connection Specs
• Page 18: TB2 I/O Input Command Connections Specs
• Page 19: TB2 I/O Input Commands Basic Schematic
• Page 20: TB2 I/O Input Commands Detailed Descriptions
• Page 21: TB1 I/O Output Status Signal Connection Specs
• Page 22: TB1 I/O Output Status Basic Schematic
• Page 23: TB1 I/O Output Status Detailed Descriptions
• Page 24: TB1 I/O Output Status Detailed Descriptions
• Page 25: Master / Slave Fiber Optic Connections
• Page 26: Module Set Up
• Page 27: System Integration - Drive DC Bus Connections
• Page 28: System Integration – Power Connections for single Module
• Page 29: System Integration – Power Connections for 2 Modules
• Page 30: System Integration – Power Connections for 3 or more Modules
• Page 31: System Integration – Control Connections for 2 Module
• Page 32: System Integration – Control Connections for 3 or more Modules
Table of Contents

3 a brand of ICD, Inc.
• Page 33: Communications Channel Assignments
• Page 34: Communications Module Location
• Page 35: Communications Module ProfiBus Addressing
• Page 36: Communications Module ProfiBus Cables
• Page 37: Brake Module Start Up
• Page 38: Brake Module Start Up
• Page 39: Communications Ethernet Module Start Up
• Page 40: Communications Ethernet Module Troubleshooting
• Page 41: Communications ProfiBus Module Start Up
• Page 42: Communications ProfiBus Module Troubleshooting
• Page 43: Maintenance
• Page 44: Brake Module Troubleshooting LEDs
• Page 45: Brake Module Troubleshooting
• Page 46: Brake Module Troubleshooting
• Page 47: Brake Module Troubleshooting
• Page 48: Back Page

4 a brand of ICD, Inc.
AC variable frequency drives are commonly used with general purpose AC induction motors to
form reliable variable speed drive systems. Problems with these drive systems can occur when an
application requires a deceleration rate faster than what can be managed by the drive alone, or
when motor speeds exceed the synchronous speed set by the output frequency of the drive (which
is called an overhauling load condition). Both of these conditions create regenerated power which
flows from the motor back into the drive, causing its DC Bus to rise. To manage the regenerated
power and avoid shutting the drive down due to an over-voltage trip, this power must be dissipated
by an external braking resistor.
PowerOhm Type BG Braking Modules can be used in conjunction with any AC drive to monitor
the DC bus of the drive and activate external braking resistor as needed not only to avoid over-
voltage trips, but to greatly improve the performance of the drive system. The use of Braking
Modules and resistors increase the braking torque capability of a variable frequency drive,
allowing faster and more controlled deceleration times.
To accommodate system horsepower requirements beyond the capability of a single Module,
the Modules are all Master/Slave programmable. This allows an arrangement of multiple Modules
to effectively function as a single higher rated module.
The products covered in this manual are intended to be used with Listed inverter drives. The
input of the DBU is only to be connected across the DC bus of an inverter drive. Conductors for
connection of the DBU shall be according to the NFPA 70 (national Electric Code) and the drives
installation instructions.
Product Overview

5 a brand of ICD, Inc.
Upon receipt of your PowerOhm Braking Module, be sure to carefully unpack the module and inspect the unit
carefully for any shipping damage. The module contains electronics that can be damaged by static electricity, so
handle in accordance with industry standards. Check for loose, broken or otherwise damaged parts due to
shipping. Report any shipping damage immediately to the freight carrier. Be sure to verify that the part number and
ratings listed on the nameplate match the order specification and the capabilities of the drive system. The ratings
listed on the nameplate are critical – installing and energizing the incorrect part number could damage the
braking module and/or the drive!
The PowerOhm Type BG Braking Module should be installed in an environment protected from moisture and
excessive dust. Dust buildup can reduce the electrical insulation characteristics of the unit and moisture can cause
arching or shorting. Air must be free of combustible gases and corrosive vapors.
Chassis classification: Open Type
Ambient Temperature Range: -10ºC to 40ºC
Maximum Altitude: 3300 feet (1000m)
Maximum Vibration: 10 to 20Hz, 32ft/sec/sec; 20 to 50Hz, 6.5 ft/sec/sec
Inspection upon Receipt
Environmental Conditions

6 a brand of ICD, Inc.
The PowerOhm Type BG Braking Module is available in line voltages ranging from 208 to 720 volts. Peak
currents up to the maximum are allowed at intermittent duty cycles (reference the below tables for details).
Options are designated in the part number after the dash at the end. -24v = 24vdc control power.
-AEN = Acromag Ethernet communications module. -APB = Acromag PROFIBUS communications module.
TABLE 1a: General Specifications for 450 amp Type BG Braking Modules
PowerOhm
Part No.
Nominal
AC Line
Voltage
Minimum
Ohms
@ listed
Turn ON
Turn ON
Voltage
RMS
Cont
Current
Max
Peak
Current
Max
Watt
Loss
HCPBM208450-(24,AEN,APB)
208
.56
336
450
600
1155
HCPBM240450-(24,AEN,APB)
240
.65
390
HCPBM380450-(24,AEN,APB)
380
1.02
612
HCPBM415450-(24,AEN,APB)
415
1.12
670
HCPBM480450-(24,AEN,APB)
480
1.29
775
HCPBM600450-(24,AEN,APB)
600
1.62
970
HCPBM690450-(24,AEN,APB)
690
1.82
1090
HCPBM720450-(24,AEN,APB)
720
1.87
1120
TABLE 1b: General Specifications for 600 amp Type BG Braking Modules
PowerOhm
Part No.
Nominal
AC Line
Voltage
Minimum
Ohms
@ listed
Turn ON
Turn ON
Voltage
RMS
Cont
Current
Max
Peak
Current
Max
Watt
Loss
HCPBM208600-(24,AEN,APB)
208
.37
336
600
900
1522
HCPBM240600-(24,AEN,APB)
240
.43
390
HCPBM380600-(24,AEN,APB)
380
.68
612
HCPBM415600-(24,AEN,APB)
415
.74
670
HCPBM480600-(24,AEN,APB)
480
.86
775
HCPBM600600-(24,AEN,APB)
600
1.08
970
HCPBM690600-(24,AEN,APB)
690
1.21
1090
HCPBM720600-(24,AEN,APB)
720
1.24
1120
Electrical Ratings

7 a brand of ICD, Inc.
TABLE 1c: General Specifications for 900 amp Type BG Braking Modules
PowerOhm
Part No.
Nominal
AC Line
Voltage
Minimum
Ohms
@ listed
Turn ON
Turn ON
Voltage
RMS
Cont
Current
Max
Peak
Current
Max
Watt
Loss
HCPBM208900-(24,AEN,APB)
208
.25
336
900
1350
2257
HCPBM240900-(24,AEN,APB)
240
.29
390
HCPBM380900-(24,AEN,APB)
380
.45
612
HCPBM415900-(24,AEN,APB)
415
.5
670
HCPBM480900-(24,AEN,APB)
480
.57
775
HCPBM600900-(24,AEN,APB)
600
.72
970
HCPBM690900-(24,AEN,APB)
690
.81
1090
HCPBM720900-(24,AEN,APB)
720
.83
1120
TABLE 1d: General Specifications for 1200 amp Type BG Braking Modules
PowerOhm
Part No.
Nominal
AC Line
Voltage
Minimum
Ohms
@ listed
Turn ON
Turn ON
Voltage
RMS
Cont
Current
Max
Peak
Current
Max
Watt
Loss
HCPBM2081200-(24,AEN,APB)
208
.19
336
1200
1800
2992
HCPBM2401200-(24,AEN,APB)
240
.22
390
HCPBM3801200-(24,AEN,APB)
380
.34
612
HCPBM4151200-(24,AEN,APB)
415
.37
670
HCPBM4801200-(24,AEN,APB)
480
.43
775
HCPBM6001200-(24,AEN,APB)
600
.54
970
HCPBM6901200-(24,AEN,APB)
690
.61
1090
HCPBM7201200-(24,AEN,APB)
720
.62
1120

8 a brand of ICD, Inc.
The PowerOhm Type BG Braking Module should be installed on a low vibration surface that is non-flammable.
Attention: Installation and removal of this equipment should be done by qualified
personnel only. Equipment must be installed in accordance with all applicable
national and local electrical codes and regulations.
MOUNTING REQUIREMENTS
To allow proper cooling, it is very important to install the fan cooled PowerOhm braking modules in a location
with an ambient temperature not exceeding 40 degrees Celsius or below 0 degrees Celsius.Modules should
be installed in an environment with sufficient circulation of clean, dry air. The module should be installed in an
area allowing a minimum of 6 inches of free space above and below the frame, and 2” on both sides to allow
proper airflow and cooling.
POWER EARTH GROUNDING
A good earth ground is essential in today’s PWM drive installations. The PowerOhm brake module should have
a dedicated Power Earth ground wire that runs directly to the drive PE ground to mitigate drive system noise.
Each drive and cabinet should be properly earth grounded, with all safety grounds connected directly to PE
ground. Excessive common mode noise may need to be shunted to PE ground.
CONTROL EARTH GROUNDING
In order to minimize the effects of drive system noise it is recommended that the control power supply and I/O
INPUTS not be tied to earth ground. If they must be tied to earth for other system components, use a clean
earth ground.
Equipment Installation

9 a brand of ICD, Inc.
The PowerOhm BG Series Braking Module must be installed in a vertical position in order to meet published
current ratings. (see Figure 1).
FIGURE 1: Mounting Orientation for BM Braking Modules
Mounting Orientation

10 a brand of ICD, Inc.
FIGURE 2a: Braking Module Dimensions for 450 & 600 amp Models
Weight: The weight of the 450 amp unit is 30lbs and the 600 amp is 34 lbs.
Dimensions and Weight