RS PRO 209-6384 Manual

Issued March 2023
8461
Instruction Leaflet
DC Injection-brake modules
Size 0.25...2.2 kW
1.1...5.5 kW
RS stock no. 209-6384
209-6407
Figure 1 Recommended connection for use with induction motors with DOL starting
General
RS DC Injection-Brake Modules provide a method of rapidly
stopping production and machine tool processes smoothly.
Designed to replace mechanical brakes these modules will brake
three-phase induction motors from 0.25 up to 5.5 kW in 2 module
sizes. These compact DIN-rail mounted modules have the
advantages of separate braking torque and braking time-out
adjustment; fast initiation of function, no maintenance
requirements and simple connection.
Adjustment procedure
1. Set potentiometer A (Braking time-out) and potentiometer B
(Braking torque), both fully counter clockwise.
2. Increase potentiometer B in a clockwise direction until the required
braking performance is obtained by starting and stopping the
motor.
3. Adjust potentiometer A until Braking Relay (MB) opens just after
the motor has stopped (braking complete).
Note The above should be carried out for the maximum operational
load that the motor is likely to experience with the motor at
operating temperature.
CE.DRW

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Adjustment ranges
Designation, Meaning
Scaling
Explanation
B - Braking torque
Rated braking
torque
A - Braking time-out
Electrical braking
time
▪Suggestion for initial setting (initial factory setting)
The above values are approximate values only
Control input
Signal
Terminals
Remarks
L2-4
BB - Command "Brake"
Inhibited
Enable
Caution, supply
voltage
Control output
Signal
Terminals
Remarks
0-1
1-2
MB - Control output
"Braking"
open
closed
closed
open
Braking
End of braking,
no supply
Isolated relay contact with rating AC 250 V, 2 A; 250 VA
Technical specifications
Electrical
RS Stock no. 209-6384
RS Stock no. 209-6407
Rated Voltage
2AC 400 V +10-15 %
Rated Frequency
50/60 Hz ±2 %
Rated Motor Power
2.2 kW
5.5 kW
Min. Motor Power
0.25 kW
1.1 kW
Max. braking current
11 A
30 A
Output voltage
DC 0...150 V
DC 0...150 V
Max braking duty* at max. braking current
- side-by-side
- intermediate spacing 10 mm
10 %
15 %
3 %
5 %
EN 60947-4-2: - Utilization category
- Form designation
11 A: AC-53a: 1-10: 10-36
1 (any starting method
with controlled braking)
30 A: AC-53a: 1-10: 3-11
1 (any starting method
with controlled braking)
Overvoltage category to EN 60664-1/
III / AC 230 V only for use with TT/TN supplies with earthed neutral
Rated insulation voltage to PE
Terminals
1.0...2.5 mm2multistrand with end ferrules
D style semiconductor protection fuse type gR,
20 A
35 A
recommended RS Stock No.
(for prospective short-circuit current up to 50 kA)
422-551
421-520
* Braking duty refers to the percentageof operating timetheRS DC Injection-Brake Module is performing braking.
Environment
Permissible
temperatures:
Operation: 0... +40 °C
Storage: -25... +55 °C
Transport -25... +70 °C
Climatic conditions:
Class 3K3 to EN 60721-3-3 (5...85 % relative humidity). The cooling air must have little
dust and be non-corrosive and non-flammable.
Pollution:
Degree 2 to EN 60664-1:
Dry non conducting dust or particles, infrequent light condensationwhen switched off
permissible
Altitude:
max. 2000 m NN above sea level, 1000 m: 1,5 % / 100 m power derating
Safety
Relevant standards:
EN 60947-4-2, EN 50178
Protective class:
I to EN 61140 i.e. basic insulation with PE connection (protective earth). The user is
responsible for the PE connection.
IP Protection:
IP20 to EN 60529 Finger protection
Signal and control terminals:
The control circuit is protected by basic insulation from the supply voltage. Any
components connected to the control circuit (e.g. external push buttons) must be
protected against direct contact by additional insulation.
Installation
Weight (approx.)
400 g
450 g
Dimensions: Height
Width
Depth
75 mm
45 mm
120 mm
75 mm
45 mm
120 mm
General
Technical data subject to change without notice

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Planning the installation
Intended use:
RS DC Injection-Brake Modules are equipment to be mounted in a
suitable enclosure (e.g. equipment cabinet) as part of a machine or
electrical system.
The technical data as well as information concerning the supply
conditions are to be taken from rating plate and from this data sheet
and must be strictly observed.
Required braking current:
The motor powers referred to in the Technical data are for normal
applications with a loadinertia up to around 4 x that of the motor and with
braking times of several seconds.
Voltage supply system:
To meet the requirements of the LOW-VOLTAGE DIRECTIVE RS DC
Injection-Brake Modules may only be used with earthed neutral TT/TN
supply systems
Short-circuit protection of controller:
Fast semiconductor fuses are required for protection of the RS DC
Injection-Brake Modules against short circuits on the output terminals
of the controller (see Technical Data).
Wiring protection:
Short-circuit and overload protection of the wiring corresponding to
the size of cable used (e.g. as in
EN 60439-1, EN 60204-1 for machines) must be provided for. A circuit
breaker, motor starter, or additional fuses are required.
Thermal considerations:
RS DC Injection-Brake Modules are designed for continuous operation
with motors up to the indicated maximum braking currents / duty cycles
indicated in the Technical Data (check spacing).
Important !
Braking duty =
Braking time
Cycle time
EN 60947-4-2:
EN 60947-4-2 is a standard for DC Injection-Brake Modules when used
with squirrel-cage induction motors. Information on the following data
must be provided:
- Utilization category: 30 A: AC-53a: 1-10: 3-11;
with 11 A: Rated braking current IB
AC-53a: Braking operation (without bridging relay)
1-10: Max. braking current 1 x IBfor 10 s
10-36: 10 % braking duty, 36 braking cycles
per hour at maximum braking load
- Form designation: 1 i.e. any starting method with
controlled braking
Combination with soft-start modules:
All RS DC Injection-Brake Modules can be combined with RS Snatch-
Free Soft-Start Modules RS (Stock number 209-6356 and 209-6362) or
RS Soft-Start Modules (Stock No. 212-8683 and 212-8699). Suitable
connection suggestions are shown on page 6.
Insulation tests:
The use of test equipment with a high voltage (e.g. Megger) can damage
the module. Remove all connections to the injection brake modules
before using such equipment.
Interference suppression:
When opening contactor or relay coils, or electric brakes, high energy
R.F. interference can occur. In extreme conditions this can result in a
malfunction of the RS DC Injection-Brake Modules. For this reason, the
coils should be fitted with suitable interference suppressors:
- DC coils: Suppressor diodes
- AC coils: RC-suppressors
Obtaining maximum immunity:
Control inputs and outputs should be wired as short as possible and
away from supply, motor or control cables which could carry significant
interference. A direct connection to equipment external to the metal
enclosure should not be made.
Safety:
RS DC Injection-Brake Modules are very reliable due to the relatively
small number of electronic components used. However, it is not
permissible that the safety of persons, machines or other equipment
depends on the correct function or adjustment of the controller.
Additionalmeans ofprovidingthe requiredsafetymust be provided for.
(e.g. fail-safe brakes, overspeed grabs etc.).
Warnings and safety information
In operation RS DC Injection-Brake Modules, depending on their
degree of protection, may have live, uninsulated and hot surfaces.
In case of improper use, incorrect installation or maloperation, there
is a danger of serious personal injury and damage to property.
These RS DC Injection-Brake Modules can affect the movement of
dangerous machinery or moving constructions. The following safety
precautions must be taken before commissioning:
⚫Provide adequate means of preventing persons from coming
within the dangerous areas of machinery or moving constructions
⚫Verify that all measures to comply with the EMC DIRECTIVE are
complied with.
⚫Verify if all requirements of the LOW-VOLTAGE DIRECTIVE are
adhered to.
⚫Verify that all requirements of the MACHINERY DIRECTIVE are
adhered to and that safety-relevant equipment (e.g. EMERGENCY
STOP) is functioning correctly.
The successful and safe operation of this equipment is dependent on
proper transport, storage, planning and as installing well as
commissioning. Hazardous voltages are present in this electrical
equipment during operation.
Equipment showing transport or other damage, or with insulating
distances altered must not be used.
Never operate with the cover removed. Non-observance of the
warning or safety instructions can result in severe personal injury or
property damage.
Only qualified trained persons may work in an enclosure on or near these
controllers. For the purpose of this documentation a "qualified trained
person" is one who is familiar with the technical data, recommendations
for planning and installing, commissioning instruction and recommended
connections contained herein and the hazards involved. In addition, this
person has the following qualifications:
- Is trained in the requirements to comply with the
EMC DIRECTIVE
- Is trained in the requirements to comply with the
LOW-VOLTAGE DIRECTIVE
- Is trained in the requirement of the
MACHINERY DIRECTIVE (e.g. EN 60204-1)
- Is trained and authorized to energize, de-energize, clear, ground
and tag circuits and equipment in accordance with established
safety practices
- Is trained in the appropriate wiring and installation regulations
including local regulations where applicable.
- Is trained in the proper care and use of protective equipment in
accordance with established safety practices
- Is trained in rendering first aid
Suitable standards (IEC 364 or CENELEC 384 or DIN
VDE 0100 and IEC-Report 664 or DIN 0110) are to be used to establish
if a person is suitably qualified.

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EC directives and regulations
'CE' marking
The 'CE' marking of the RS DC Injection-Brake Modules is at the date at
which this Product Manual is issued valid for the EU DIRECTIVES
- 2014/30/EU EMC DIRECTIVE
- 2014/35/EU LOW-VOLTAGE DIRECTIVE
Manufacturers of apparatus and machines sold as functional units are
fully responsible for issuing a Declaration of Conformity and applying
the 'CE' mark.
EMC directive
RS DC Injection-Brake Modules are components with a function which
is determined by the construction and layout of the complete
installation. It is the responsibility of user to ensure that the EMC
DIRECTIVE is adhered to. The following standards are particularly
relevant:
Product Standard for EN 60947-4-2
AC semiconductor motor starters
(also valid for braking equipment):
RF Interference: EN 55011
Immunity: EN 61000-4-2/-3/-4/-5
Declaration of Conformity:
A Declaration of Conformity declaring conformance of these RS DC
Injection-Brake Modules with the EMC DIRECTIVE based on the Product
Standard EN60947-4-2 which references the above standards for RF
Interference and Immunity is available on request. Particular reference
should be made to the instructions for planning the installation
concerning interference suppression and immunity.
During continuous operation Interference Limit B for use in residential,
commercial and light industry supplied directly from public electricity
supply (including public buildings, banks, hospitals etc.) is adhered to.
Other important information:
The user should be conversant with the following issues:
- EMC 'CE' Responsibility, and in particular the CEMEP
recommendations for application of the EMC DIRECTIVE to
electronic power drive equipment
- Limit values of permissible EMC interference when used in:
- Residential areas (Class B)
- Industrial areas with own transformer station (Class A)
- Responsibility of manufacturers of apparatus and
machines sold as complete functional units
Low-voltage directive
It is the responsibility of the user to ensure that the complete
installation adheres to the LOW-VOLTAGE DIRECTIVE. The following
standards should be considered as is appropriate:
- Product Standard for EN 60947-4-2
AC semiconductor motor starters
(also valid for braking equipment):
- Installation with power EN 50178
electronic equipment:
- Installation regulations EN 60439-1
in electrical enclosures:
- Electrical equipment EN 60204-1
of machines:
Declaration of Conformity:
A Declaration of Conformity declaring conformance of these injection
brake modules with the LOW-VOLTAGE DIRECTIVE based on the product
standard EN 60947-4-2 and EN 50178 is available on request. Particular
reference should be made to the Technical Data and to the instructions
for planning the installation.
Machinery directive
RS DC Injection-Brake Modules are components to be incorporated into
machinery and may not be operated alone. Pay particular reference to
the following standard:
- Electrical equipment of machines EN 60204-1
Disposal
During transport, our products are protected by packaging
as far as necessary. The packaging consists entirely of environmentally
compatible material that should be taken for central disposal as
valuable secondary raw materials.
Contact the relevant Local Authority department to find out about
disposal, including disposal of old appliances.
Table for fault finding
Fault
Possible cause
Cure
1.
Not enough braking
torque
•Adjustments not suitable
- Increase breaking torque by turning potentiometer B cw
- Check braking time-out. Increase time by
turning potentiometer A ccw if necessary.
•Motor not suitable for d.c. injection
braking
- Change motor, the next frame size may help
2.
Frequent failures of
brake module with
damaged power
semiconductors
•Short circuit due to connection fault
- Verify correct function of interlocks for motor and
braking contactors. Compare with recommended
connections. Caution with software interlocks.
3.
Controller suspected to
be faulty (e.g. following a
short circuit)
•Power semiconductors damaged.
Check the terminals do not have a
short circuit using a -meter.
- Return controller to supplier
4.
Everything tried without
success
- Send circuit diagram of application and
potentiometer settings by fax to your supplier

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Figure 2 Alternative connection for use with induction motors with DOL starting
Figure 3 Alternative connections without a braking contactor (only suitable for fractional-horsepower motors)
Figure 4 Recommended connection combined with star-delta starting

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Figure 5 Recommended connection
as combined soft-start and injection brake using RS Soft-Start Modules 212-8683 and 212-8699
Figure 6 Alternative connection with PLC-control as combined soft-start and injection brake using
RS Soft-Start Modules 212-8683 and 212-8699
The information provided in RS instruction leaflet is believed to be accurate and reliable, however RS Components assumes no responsibility for unaccuracies or omissions, or for the use
of this information, and all use of such information shall be entirely at the user's own risk.
No responsibility is assumed by RS Components for any infringements of patents or other rights of third parties which may result from its use.
Specifications shown in RS Components instruction leaflets are subject to change without notice.
RS Components Ltd., Birchington Road, Corby, NN179RS, United Kingdom
RS Components GmbH, Mainzer Landstraße 180, 60327 Frankfurt/Main, Germany