Lenze ERBS015R800W - User Manual

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Contents i

EDKRBS047R DE/EN/FR/ES/IT 8.0

1 About this documentation 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Validity information 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Target group 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Document history 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conventions used 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Notes used 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety instructions 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General safety instructions 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual hazards 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Product description 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application as directed 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensioning conditions 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Technical data 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General data and operating conditions 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rated data 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical data 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Mechanical installation 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting clearance 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting steps 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Electrical installation 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important notes 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection data 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection plan 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting steps 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Maintenance 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance intervals 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance operations 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Do you have a question about the Lenze ERBS015R800W and is the answer not in the manual?

This document describes the Lenze brake resistor, a component designed for integration into drive and automation systems. It provides essential information for qualified skilled personnel regarding its installation, operation, and maintenance.

Function Description

The Lenze brake resistor is an electrical component primarily used in drive systems to dissipate regenerative energy generated during braking operations. When a motor decelerates, it acts as a generator, feeding energy back into the drive. If this energy is not dissipated, it can lead to an overvoltage condition in the DC bus of the drive, potentially damaging the system. The brake resistor converts this excess electrical energy into heat, which is then safely dissipated into the surrounding environment. This process ensures stable and controlled deceleration of the motor, protecting the drive and connected components from overvoltage.

The brake resistor is designed to operate under specific dimensioning conditions to ensure its effectiveness and longevity. It is crucial that the mean value of regenerative power does not exceed the permanent power (Pd) of the brake resistor. Similarly, the regenerative power during braking time must be less than the heat quantity (QB) of the brake resistor. The braking time itself should be less than 10% of the total cycle time (braking time plus dead time). To prevent overheating, a thermal contact is integrated into the brake resistor. This thermal contact must be connected to the system monitoring in such a way that the mains supply is switched off if the device overheats. This safety mechanism is critical for preventing damage to the brake resistor and ensuring the overall safety of the system.

The operation of the brake resistor is intrinsically linked to the drive system. It is not a standalone machine but rather a component that works in conjunction with power conversion equipment (drives). Its primary role is to manage energy flow during deceleration, making it an indispensable part of many industrial applications where controlled braking is required.

Usage Features

The Lenze brake resistor is designed for mounting in machines and for assembly with other components to form a complete machine. It is electrical equipment intended for installation in control cabinets or similar closed electrical operating areas. It complies with the protective requirements of the "Low voltage" EC Directive and is not classified as a machine under the Machines EC Directive. It is also not a household appliance but rather a specialized component for commercial use.

Installation and Mounting: The brake resistor can be mounted in two primary positions:

Vertically suspended: With connections at the bottom.
Horizontally standing: Using a fixing bracket at the bottom.

Specific free spaces must be maintained around the brake resistor to ensure adequate air circulation for heat dissipation. For standard vertical mounting, a clearance of at least 200 mm is required above the resistor, and 15 mm on the sides. For horizontal mounting, a clearance of at least 200 mm is required above the resistor, and 45 mm on the sides. The mounting location must comply with the device features mentioned in the "General data" section of the manual. It is critical that flammable materials or substances are not placed in the vicinity of the brake resistor, and the heat generated must be dissipated freely to prevent fire hazards and ensure proper operation. The mounting location and material must ensure a permanent mechanical connection.

Electrical Connection: The brake resistor requires careful electrical connection. It has terminals for the brake resistor itself (RB1, RB2), a PE (protective earth) conductor, and thermal contact cables (T1, T2).

Brake Resistor Cables (RB1, RB2): For cables up to 0.5 m, a twisted cable should be used. For longer cables, up to 5 m, a shielded cable is recommended. The cable must be passed through the designated cable gland and connected to the RB1 and RB2 terminals, observing the specified tightening torque. The PE connection must comply with EN 61800-5-1. For shielded cables, the shield must be securely connected to the cable gland with as large a surface as possible.
Thermal Contact Cables (T1, T2): A twisted cable should be used for the thermal contact. This cable is passed through a separate cable gland and connected to the T1 and T2 terminals, again observing the specified tightening torque. The thermal contact is a crucial safety feature; it is an NC (normally closed) contact that opens at 230 °C. It must be integrated into the system monitoring to switch off the mains supply if the brake resistor overheats, for example, via a mains contactor control.

Safety Considerations: Operating the brake resistor without proper heat dissipation can lead to overheating, potentially destroying the resistor and causing the drive to coast to a standstill instead of braking. Therefore, always connect the thermal contact and integrate it into the overall equipment monitoring system. Before any work on the brake resistor, the basic device must be disconnected from the mains, and all power terminals must be checked for safe isolation from the supply. The terminals can carry dangerous voltages for up to three minutes after mains disconnection. During operation, the brake resistor's surface can become very hot (up to 1000 °C in case of improper use, and 250 °C on the surface during rated operation), posing a risk of severe burns or fire if flammable materials are nearby. Protective measures include checking the surface temperature before working on it, ensuring proper mounting location and operating conditions, and protecting the mounting location with suitable fire prevention and contact protection.

Maintenance Features

The Lenze brake resistor is designed to be maintenance-free under normal operating conditions. However, regular visual inspections are recommended, taking into account the ambient conditions. These inspections are crucial to ensure the continued safe and trouble-free operation of the device.

Key aspects to check during visual inspection include:

Operating Conditions: Verify that the environment of the brake resistor still corresponds to the operating conditions specified in the technical data. Any changes in the ambient conditions, such as increased temperature or reduced ventilation, could affect the resistor's performance and lifespan.
Heat Dissipation: Ensure that no dust or dirt has accumulated on or around the brake resistor that could impede its heat dissipation. Blocked ventilation can lead to overheating, even if the thermal contact is functioning. Regular cleaning of any dust or debris is important.
Mechanical and Electrical Connections: Confirm that all mechanical and electrical connections are correct and secure. Loose connections can lead to increased resistance, localized heating, or intermittent operation, potentially causing damage or system failure.

Cleaning the Brake Resistor: If cleaning is necessary, follow these steps to ensure safety:

Disconnect Power: Disconnect the standard device (the drive) from the mains supply.
Wait for Discharge: Wait at least three minutes after disconnecting the power to allow any residual voltage to dissipate.
Check Temperature: Check the temperature of the brake resistor. If it is hot, allow it to cool down completely before proceeding with cleaning.
Verify Isolation: Before touching the resistor, check it for safe isolation from the supply using appropriate testing equipment.
Clean: Clean the brake resistor without using any cleaning agents. A dry cloth or brush is usually sufficient to remove dust and dirt. Avoid using liquids or abrasive cleaners, as these could damage the resistor's components or insulation.

By adhering to these maintenance guidelines, users can ensure the long-term reliability and safety of their Lenze brake resistors, contributing to the overall efficiency and longevity of their drive systems.