Solcon Solbrake User manual

Solbrake (SMB)
Electronic Motor Brake (DC Injection)
8 - 390A, 220 - 690V
I
In ns st tr ru uc ct ti io on n M Ma an nu ua al l
Ver.11.0/11. 2002
1

2
Table of Contents
Page Subject
3 Brake selection
4 Installation Notes
5 Mode of operation
6-7 Wiring and operation
8 Potentiometer settings and Start up
procedure
9 Fuse Selection Table
10 Dimensions
11 Technical Specification
* Read this manual carefully before operating the equipment and follow its instructions
* Installation, operation and maintenance should be in strict accordance with this manual, national
codes and good practice. Installation or operation not performed in strict accordance with these
instructions will void manufacturer's warranty.
* Disconnect all power inputs before servicing the Solbrake / SMB and/or the motor.
* After installation, check and verify that no parts (bolts, washers, etc) have fallen into the power
Section (IP00).
ATTENTION
1. This product was designed and tested for compliance with IEC947-4-2 for class A equipment.
2. The Solbrake / SMB brakes are designed to meet UL requirements
3. Use of the product in domestic environments may cause radio interference, in which case the user
may be required to employ additional mitigation methods.
4. Utilization category is AC-53a or AC53b. Form1.
5. For further information see Technical Specification
WARNING
* Internal components and P.C.B's are at mains potential when the Solbrake / SMB is connected
to mains.
This voltage is extremely dangerous and may cause death or severe injury if contacted.
* When the Solbrake / SMB is connected to mains, even if operation signal is disconnected full
voltage may appear on Solbrake / SMB's output.
* Unit must be grounded to ensure correct operation, safety and to prevent damage.
* Check that Power Factor capacitors are not connected to the output side of the Solbrake / SMB.

Brake Selection
General
The Solbrake / SMB - Solid State Motor Brake provides
fast, smooth, frictionless braking of three-phase
squirrel-cage motors by injecting controlled DC current to
the motor windings, after Mains contactor opened. This
induces a stationary magnetic field, which exerts a braking
torque on the rotor.
Stopping time can be similar to the time it takes to reach
full speed on a Direct-On-Line starting.
Adjustable Braking Torque and Braking Time enable
perfect matching of the brake to the driven load.
Automatic sensing System turns the brake off
automatically when the motor comes to a full stop. This
minimizes the motor heating.
Brakes ratings and Frame sizes
Max Motor
FLA (Amp)
Brake Type
FLC
Frame
Size
Case
material
10 Solbrake 10 SB0
PC/ABS
17 Solbrake 17
31 Solbrake 31
58 Solbrake 58
SB1
Aluminum
105 Solbrake 105
170 Solbrake 170
210 Solbrake 210
SB2
310 Solbrake 310
390 Solbrake 390
SB3
Metal
Dimensions (mm)
Size Width Height Depth
SB0 45 75 105
SB1 65 190 114
SB2 154 280 160
SB3 224 384 222
Select the brake according to the following criteria:
M
otor Current & starting conditions
• Motor's Full Load Ampere (FLA) - as indicated
on its nameplate (even if the motor is not fully
loaded).
• The Solbrake (SMB) is designed for a duty cycle
f 10% or less; e.g. 10 sec. operation, 90 sec. rest.o
Duty Cycle - the ratio between operating time
and
total cycle time (rest time + Braking time).
Braking time
Duty Cycle = ------------------------------- x 100 (%)
Rest time + Braking time
Note:
If a higher duty cycle is required select a higher Solbrake
(SMB) type to allow enough brake time current.
Centrifuge
RPM
Stopping Time t
SMB
Wood Saw
Mains Voltage (line to line)
Thyristor's PIV rating, internal circuitry and insulation
determines six voltage levels: Each brake is factory set
for one of the following levels according to the Ordering
Information.
Voltage Tolerance
220- 240 V +10 -15 %
380 - 415 V +10 -15 %
440 V +10 -15 %
460 - 500 V +10 -15 %
575 - 600 V +10 -15 %
690 V (210A-390A) +10 -15 %
Each brake is factory set for one of the above levels and
suitable for 50 or for 60 Hz (±5%).
Options (see Ordering Information)
For extended braking time - consult factory and provide the
following information:
• Ambient temperature.
• Actual stopping current.
• Actual stopping time.
• Time interval between starts
• Load characteristics
3

Installation Notes
4
Prior to Installation
Check that Motor's Full Load Ampere (FLA) is lower than
or equal to Solbrake / SMB Full Load Current (FLC) and
verify that Mains voltage and frequency are as indicated on
the Solbrake / SMB label.
Mounting
* The Solbrake / SMB must be mounted vertically, allow
space above and below the unit for sufficient airflow.
* It is recommended to mount the SMB directly on the rear
metal plate for better heat dissipation.
* Do not mount the Solbrake / SMB near heat sources.
* Protect the Solbrake / SMB from dust and corrosive
atmosphere.
Temp. Range and Heat Dissipation
The Solbrake / SMB is rated to operate over a temperature
range of -10°C (14°F) to +50°C (122°F).
Relative non-condensed humidity inside the enclosure
should not exceed 93%.
The average heat dissipation of the Solbrake / SMB
depends on the Braking Torque setting and on the duty
cycle.
Heating inside the enclosure can be reduced through the
use of additional ventilation.
Note: The heat generated in the motor during braking is
similar to the heat generated during starting. Therefore,
high setting of the Braking Torque and/or a high duty cycle
may require an external cooling fan for the motor. It is
recommended to use temperature sensor in the motor
which will allow restarting only after the motor
temperature has reduced to an allowed level.
Short Circuit Protection
The Solbrake / SMB must be protected against short circuit
by fast-acting fuses. Recommended I2 t values in page 9.
Transient Protection
Line transient voltages can cause malfunctioning of the
brake and damage to the SCRs.
When high transients are expected, an external protection
should be used, (consult factory).
Wiring
Connections to L1, L2, U, V and W should be done with
power cables. Connections to terminals 1-6 are for control
only.
Do not connect two Solbrake / SMB brakes in parallel as
they are not synchronized and will be damaged.
Mechanical and electrical interlock between Mains
contactor C1and braking contactor C2must be installed to
prevent both contactors from being closed simultaneously.
Solbrake / SMB Wiring
The Solbrake / SMB (10-17) are meant for installation on a
Din-Rail. See options list for other Din-Rail ratings.
U V W L
1L
2123456
Power Factor Capacitors
Power factor correction capacitors must not be installed on
the load side of the Solbrake / SMB. When required,
capacitors should be installed on the Solbrake / SMB's line
side.
N
otes:
1. The Solbrake / SMB uses Mains power to produce
the braking torque. Therefore, a power failure or
disconnection will disable the DC braking and the
motor will coast to a stop without braking.
2. When required to stop a motor during a power
outage, an electro-mechanical brake must be used.
3. The Solbrake / SMB cannot be used for continuous
holding of loads, after motor had stopped. An
electro-mechanical brake should be used for holding
at stop position.
Warning
Wrong connections of Solbrake line and load sides
will cause damage to the brake and motor.

Mode of Operation
Stop signal opens motor contactor
C1that in turn initiates the closing
of brake contacts C2.
The Thyristor is switched on and
fire (to inject DC current to the
motor) after time delay, to induce
the braking current.
The torque, which is a function
of the DC current, can be
controlled
by the firing angle of the
Thyristor.
Note: there is a time delay
between opening of one
contactor and closing the other
one to reduce the EMF. The time
delay correlate to the size of the
motor.
Braking Time
Braking time depends on the inertia, friction of the load,
speed, and braking current. The required braking time is
best established by practical experience.
The Solbrake / SMB offers two operating modes,
Automatic and Manual. Selection between the modes is
one by an internal dip switch.d
Dip sw. Operation Mode
On Manual
O
ff Automatic
It is recommended to use the Automatic mode (factory
default setting) to reduce the braking time and minimize
motor heating.
Automatic operation
DC injection duration is
automatically controlled
by the Solbrake / SMB.
Injection ceases when
Motor has come to a
complete stop.
Manual operation
DC injection duration is
according to the Braking
Time setting on the front
panel.
Notes:
1. Motor heating during braking is similar to heating
during Direct On Line starting. Therefore, always
adjust for the shortest DC injection time duration.
2. In general, for improved braking process to be in effect,
it is recommended to apply some minimal inertia on the
motor shaft.
The Solbrake / SMB incorporates the following built-in
time delays:
t1
DC Injection
Brake Contactor
Motor Contactor
1 - 2 Open
t2t
3t4t 5
1 - 2 Closed
Power ON
Motor
Running
Braking
Process
Start Sto
p
M
Where:
t1- Time delay between opening of motor's contactor C1
and closing of brake contactor C2, allowing motor's
back EMF to diminish (see table below).
t2- Time delay of 0.05 sec between closing of brake
contactor C2and initiation of DC current, to ensure
that brake contactor does not switch DC current,
enabling the use of regular AC contactor.
t3- In Auto Mode – Enabling of DC current injection.
In Manual Mode - time of DC current injection.
Range: 1-10 sec.
t4- Time delay between end of DC current injection and
opening of brake contactor C2to ensure that the
contactor does not switch DC current, enabling the
use of regular AC contactor (see table below).
t5- Time delay of 0.2 sec. between opening of brake
contactor C2and enabling motor's restart.
Approximate Time Delays (sec).
Sec.
10 1
DC Injection
Motor Stopped
Braking contactor Closed
Restart Enable
Solbrake
/ SMB
8
17 58 105 210 390
t1
0.2
0.3 0.6 1.1 1.7 2.5
t4
0.2
0.2 0.3 0.8 1.2 1.9
Sec.
10 1
DC Injection
Motor Stopped
Braking contactor
Restart Enable
Torque at standstill
When required to maintain the DC braking current after the
motor has come to a complete stop, set Auto/Man Dip
Switch to On (Manual operation). Set Braking Time to a
longer time than it takes the motor to come to a complete
stop.
Note - DC Injection after motor has come to a complete
stop may cause excessive heating of both the motor and the
brake.
5

Wiring & Operation
Solbrake / SMB with Direct on Line Starter
Motor contactor C1(with one N.O + two N.C contacts).
* Contact C1-3 - Holding N.O contact of contactor C1
* Contact C1-1 - auxiliary N.C contact of contactor C1,
initiates the braking process.
* Contact C1-2 - auxiliary N.C contact of motor contactor
acts as an interlock preventing operation of brake
contactor as long as motor contactor is closed.
Brake contactor C2 (with one N.C contacts).
* Contact C2-1 - auxiliary N.C contact of contactor C2,
acts as an interlock preventing operation of motor
contactor as long as brake contactor is closed.
Note:
There is electro mechanical interlock between C1and C2.
Solbrake / SMB contacts
* Ca contact (Solbrake / SMB terminals 3-4 ), contact
closes when Mains voltage is connected to Solbrake /
SMB terminals and terminal 1-2 are open.
* Cb contact (Solbrake / SMB terminals 5-6), closes upon
stop signal and contact terminals 1-2 closes after time
delay t1.
Notes
* Motor contactor C1cannot be operated when Mains
voltage is not connected to terminals L1and L2 (internal
contact Ca in Solbrake / SMB, controlling motor
contactor, closes after Mains voltage is connected and
terminal 1-2 are open.
* When operating in Manual mode, DC injection will stop
after time delay t3as set on the Braking Time
potentiometer.
Operation
Upon start signal, as Ca is closed, motor contactor C1
closes, motor will operate and contact C1-1 opens.
Upon stop signal, motor contactor C1opens, contact C1-1
closes and initiates the braking process.
Contact Ca opens, preventing motor contactor operation,
and after time delay t1 contact Cbcloses, closing the brake
contactor C2.
The yellow LED on Solbrake / SMB's front panel will light
up indicating that brake contactor is closed.
After time delay of approx. 0.05 sec. DC current will be
injected to motors' winding.
The yellow LED on Solbrake / SMB's front panel will light
up indicating that braking current is now injected to the
motor.
The DC injection will automatically cease when motor
comes to a complete stop (when Automatic mode is
selected) and the yellow LED turns off.
Contact Ca closes after time delay t5, permitting motor
restarting.
6
M
L
1L 2
U V W
C
1C 2
O/L
12
C
1-1
SMB
Power
3456
C
aC b
C
2-1 C 1-2
C
1
Start
Stop
O/L
C
1C
2
SMB
Control

Wiring & Operation
Emergency Brake
A dedicated Emergency Stop button, with
wo contacts initiates braking.t
When Stop contact is opened, contactor C1opens,
he Solbrake / SMB is not initiated.t
When Emergency Button is pressed, the Emergency
Contact is opened and the N.O. contact of the
Emergency Stop closes and initiates the braking
rocess.p
When Emergency Stop contact is opened, C1
contactor opens and the Solbrake / SMB is operated,
initiating the braking process.
M
L
1L 2
UVW
C
1C 2
O/L
12
Emergency
SMB
Power
3456
C
aC b
C
2-1 C 1-2
C
1
Start
Stop
O/L
C
1C
2
SMB
Control
M
L
1L 2
UVW
C
2
O/L
12
SMB
Power
3456
C
aC b
C
2-1 C r-2
Stop
O/L
C
fC
2
SMB
Control
Start
Forward
C
f-2
C
r-1
C
f-1
C
r-3
C
f-4
C
r
Start
Reverse
C
f-3
C
r-4
C
f
C
r
Reversing
C2- SMB Contactor.
Cf - Forward Contactor
Cr - Reversing Contactor
Interlocked Contactors.
Braking process is initiated
when Contactors Cf or Cr open.
Star-Delta
Cb- SMB Contactor.
Cs - Star Contactor
Cd - Delta Contactor
Cl - Line Contactor
T - Timer Relay
Braking process is initiated
when Contactors Cd or Cl will
open. Hence, a mechanical
interlock between Cb and Cd+Cl
L1 L2
UV W
O/L
12
Solbrake
SMB
Power
Cd
Cl
ClCd
UVW
M
W2 U2 V2
Cs
L1 L2 L3
3456
Ca Cb
Cb
Cd
Stop
O/L Reset
Cs Cb
Solbrake
SMB
Control
Cl
Cl
CT
T
Cs
Cd
Cs
Cl
ClCs
Start
Cb
O/L
is recommended.
7

Potentiometer Setting Start-Up Procedure
Braking torque
Determines the value of DC current the Solbrake / SMB
injects to the motor. The Solbrake / SMB can produce a
braking current of up to four times motor's nominal current.
A too high setting may cause a fast stop and high
mechanical shock. A too low setting may result in
rolonged time until motor stops.p
Braking Time
* For Automatic Time-out - The setting on the front
panel determines the period of time during which the
braking contactor is closed. DC current ceases
automatically when the motor stops (Factory
default internal Dip Switch setting) .
* For Manual Time-out - The setting on the front panel
determines the period of time during which
DC current is injected to motor windings, regardless of
when the motor stops (can be modified with the
internal
Dip Switch).
LED Display
The Green LED indicates that power supply is connected
to the Solbrake / SMB (L1, L2).
The Yellow LED indicates that contactor C2is closed.
Motor restart is disabled when this LED is lit.
The yellow LED indicates that DC current is being injected
in the motor windings.
During start-up the dip switch should be in the Off position
for Automatic Time-Out.
Braking Torque
2 10 Sec.
110
Braking Time (Sec.)
On
Braking
DC Injection On
1
. Set Braking Torque to 5
2. Set Braking Time to 10
3
. Start motor and wait until it reaches full speed.
4. Stop motor and check the braking procedure.
a)If braking has ceased and motor is still turning,
increase braking Torque setting and try again.
b)If motor has stopped and the Yellow LED remains
on, decrease Braking Time setting until the Yellow
LED turns off shortly after the yellow LED has
turned off.
Note: Set Braking Time potentiometer t3to a slightly
longer time than the time required for motor to come to a
complete stop, even if the brake operates in an Automatic
mode. This is required for two reasons:
1. Ensuring that even if the automatic time-out circuit
did not sense that motor had stopped, the DC
injection will cease shortly after motor stopped
preventing excessive heating.
2. During time delay t3, braking contactor remains
closed even if the Automatic Time-Out circuit has
stopped the DC current.
Measuring the Braking Current
Approximate measurement of the braking current can be
made with a true RMS ammeter.
Trouble Shooting
1. Disconnect Mains voltage and check that contacts 3-4
and 5-6 are open.
2. Connect power to L1and L2. The green LED (On)
should light up.
Dip Sw. S1.2 = Not in use
Off = Automatic
1 2 On = Manual
Dip Sw. S1.1=Auto/Man.
Solbrake, Main PCB
3. Check that contact between terminals 3-4 is closed.
4
. Check that contact between terminals 5-6 is open.
5. Start the motor. Motor contactor should close. If it
doesn't, check connection to contactor.
6. Press Stop button; motor contactor should open and
brake contactor should close after a short time delay.
Simultaneously the Braking Time and DC injection
LEDs should be lit. If LEDs do not light up, check that
auxiliary contact of Mains contactor connected between
control terminals 1-2 is closed.
8

Fuse Selection Table (400V)
FUSE SELECTION (recommended values for mains supply of 400V)
SMB fuse value
Title numbers in
Amp's
Max.
Thyristor I2t
allowed
2
ALSTOM
Ultra Fast Acting fuse
JEAN MULLER
Semicon fuse
links
FERRAZ / SHAUMAT
Carbone Lorraine
Protistor series
FERRAZ Specific
Reference /Publication
Solbrake / SMB 8 400 GSGB30 500V - 40A 6,9 gRB17.63 G220967 / A600070
Solbrake / SMB 17 5000 GSGB55 500V - 50A 6,9 gRB17.63 G220967 / A600070
Solbrake / SMB 31
Solbrake / SMB 58 18000 GSGB170 500V - 250A 6,6 URC 000 BS 88 180 C330144 / H600399
Solbrake / SMB 105 100000 GSGB350 500V - 350A 6,6 URD 2x000 BS 88 355 V330160 / H600399
Solbrake / SMB 210 600000 GSGB580 500V - 710A 6,6 URD 31 D 11 0630 Q300026 / D600188
Solbrake / SMB 310
Solbrake / SMB 390 800000 GSGB800 500V - 1000A 6,6 URD 32 D 11 0800 W300192 / D600188
Notes: 1. The above table is for maximum stop current of 400 % of FLC, maximum time of 30 sec and rated voltage of 400 V (see note 3 for exception).
2. Rating may change with different external conditions such as ambient temperature, forced cooling etc. Refer to fuse manufacturer catalogs to confirm correct values.
3. Ferraz ratings are simulated for 4xIn, 4 times per hour with a 10 sec. stop time for each stop.
9

Technical Specification
Solbrake 17A
105
90 105
75
6 5 4 3 2 1 L
2
L
1
W V U
Solbrake 31-58A
10

Technical Specification
Solbrake 105-210A
77
12
2017 12
12
M6
WL1 L2 U V
280 263
160
Solbrake 310-390A
V
63.4
LW V
222
224
W L
384
18
18
LUU L
11

Technical Specification
12
Environment
Supply voltage Two phase, line to line. 220-600VAC
(690VAC for 210A – 390A)
+10% -15%
Frequency 50 / 60 Hz
Load Three-Phase, Three-Wire, Squirrel
Cage Induction Motor
Duty cycle 10% max. 10 sec. operation, 90 sec. rest
Degree of protection IP 20 up to 58A (IP00 up to 390A)
Altitude 1000 m above sea level
Adjustments
Braking current 1-10 for 0 - 4 times FLC
Braking time 2-10 sec. Optionally 1-30 sec.
Protection
Automatic stopped motor sensor Switches off the DC injection automatically when motor has come to a
complete stop.
Indications
ON - Green Illuminates when power is connected
to SMB on L1 and L2.
C2 closed – Yellow Illuminates when contactor C2 is
closed.
Indication lights (LEDs)
DC Injection ON - Yellow Illuminates when DC current is being
injected to the motor windings.
Temperatures
Operating -10° to 50°C
Storage -20° to 70°C
Relative humidity 93 % - non condensed
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