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Installation

4-4

8250BA0903

4.2 Electrical installation

4.2.1

Operator’s safety

Danger!

After switching off the mains voltage, all power terminals (+U

G

,

-U

G

and RB1, RB2) of the brake unit remain live for up to

3 minutes.
Therefore please wait for 3 minutes after having switched off the
mains voltage before you start to work.

- For single drives, the brake unit carries a hazardous

voltage up to three minutes after mains disconnection.

- In a drive network, all controllers must be inhibited and

disconnected from the mains.

Danger!

During braking operation (e.g. test stand, high inertia loads etc.)
the voltage is still present after mains switching (OFF).
It is therefore necessary to set all controllers to controller inhibit.

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Summary of Contents for 8250 Series

Page 1: ...EDB8250EN PM8 Operating Instructions Brake unit 8250 series UG UG RB1 RB2 PE T1 T2 Ä PM8ä Show Hide Bookmarks ...

Page 2: ... E 0x 8251 8253 In connection with the unit series as from the nameplate data 820X E 0x 0x 8201 8204 821X E 0x 0x 8211 8218 Type Design E Enclosure IP20 IB Module Hardware level and index Software level and index Variant Explanation revised Edition of 10 1996 01 1997 09 2003 Show Hide Bookmarks ...

Page 3: ...LED Display of the operating state D green flashing when voltage is applied to terminals UG UG D yellow flashing when brake unit is in braking operation Display of faults see chapter 6 page 6 1 UG UG RB1 RB2 PE 1 2 3 T1 T2 3 Connections D Voltage link UG UG only 8251 8252 brake module D Thermostat T1 T2 only 8253 brake chopper D Brake resistor RB1 RB2 Show Hide Bookmarks ...

Page 4: ... have the qualifications necessary for their occupation 2 Application as directed Drive controllers are components which are designed for installation in electrical systems or machinery When installing in machines commissioning of the drive controllers i e the starting of operation as directed is prohibited until it is proven that the machine corresponds to the regulations of the EC Directive 89 3...

Page 5: ...nt of filters and laying of cables are included in the documentation of the drive controllers These notes must also be observed in all cases for drive controllers with the CE mark The compliance with the required limit values demanded by the EMC legislation is in the responsibility of the manufacturer of the system or machine 6 Operation Systems where drive controllers are installed must be equipp...

Page 6: ...ng conditions 3 2 3 3 Rated data 3 3 3 3 1 Brake units 3 3 3 3 2 Assignment table for brake resistors 3 3 3 3 3 Overcurrent relay and cable cross sections 3 4 3 4 Dimensions 3 4 4 Installation 4 1 4 1 Mechanical installation 4 1 4 1 1 Important notes 4 1 4 1 2 Standard assembly with fixing rail 4 2 4 1 3 DIN rail assembly 4 3 4 2 Electrical installation 4 4 4 2 1 Operator s safety 4 4 4 2 2 Protec...

Page 7: ...i 8250BA0903 5 Commissioning 5 1 6 Troubleshooting and fault elimination 6 1 7 Waste disposal 7 1 8 Supplement 8 1 8 1 Accessories 8 1 8 1 1 Brake resistors 8 1 8 2 Glossary 8 3 8 3 Index 8 4 Show Hide Bookmarks ...

Page 8: ...must always be in a complete and perfectly readable state 1 1 1 Terminology used Brake unit The 8251 brakemodule the 8252 brakemodule or the 8253 brake chopper with brake resistor are called brake unit in the following text Controller In the following text the term controller is used for 82XX frequency inverter Drive system For drive systems with 825X brake units and other Lenze drive components t...

Page 9: ... scope of supply matches the accompanying papers Lenze does not accept any liability for deficiencies claimed subsequently Claim visible transport damage immediately to the forwarder visible deficiencies incompleteness immediately to your Lenze representative 1 3 825X brake units 1 3 1 Labelling Lenze 825X brake units are clearly identified by the indications on the nameplate CE mark Conformity wi...

Page 10: ...n into control cabinets or similar closed operating rooms They meet the protection requirements of the EC Low Voltage Directive They are not machinery in the sense of the EC Machinery Directive They are not household appliances but are intended exclusively as components for further commercial use Drive systems with 825X brake units They correspond to the EC Electromagnetic Compatibility Directive ...

Page 11: ...does not take responsibility for the suitability of the process and circuit proposals The indications given in these Operating Instructions describe the features of the product without warranting them Lenze does not accept any liability for damage and operating interference caused by Disregarding these Operating instructions Unauthorized changes of the brake units Operating mistakes Improper worki...

Page 12: ... the personnel have the Operating Instructions available for all corresponding operations to prohibit non qualified personnel from working with and on the drive system Qualified personnel Qualified personnel are persons who are because of their education experience instructions and knowledge about corresponding standards and regulations rules for the prevention of accidents and operating condition...

Page 13: ...hese Operating Instructions are for guidance only and must be adapted to your own specific application Brake units must be designed so that they comply with their function and do not cause any hazards for persons under the conditions of correct installation and faultless operation as instructed This is also effective for the interaction with the complete plant Take additional measures to limit con...

Page 14: ... electrical voltage Death or very severe injuries Warning Warns of potential very hazardous situations Possible consequences if disregarded D th i j i Warning of a general danger q g Death or very severe injuries general danger Caution Warns of potential hazardous situations Possible consequences if disregarded Possible consequences if disregarded Light or minor injuries Warning of material damage...

Page 15: ...ion of persons After mains voltage disconnection the power terminals UG UG remain live for 3 minutes Brake units may have surface temperatures of up to 130 C for up to 30 minutes after mains disconnection Touching the brake unit may cause burns Show Hide Bookmarks ...

Page 16: ...h 8211 8213 frequency inverters 8253 brake chopper with external brake resistor for high load continuous braking for operation with 821X frequency inverter Conversion of the mechanical braking energy into thermal energy Controller does not set pulse inhibit during braking i e the braking operation still remains controlled Very short braking times are possible Enclosure IP10 for installation in a c...

Page 17: ... transport 25 C 70 C during storage 25 C 70 C during operation 0 C 40 C Permissible installation height h h 1000 m a m s l without power derating 1000 m a m s l h 4000 m a m s l with power derating Degree of pollution VDE 0110 part 2 pollution degree 2 Insulation strength Overvoltage category III according to VDE 0110 Packing to DIN 4180 Type of protection IP10 NEMA 1 Protection against contact Ap...

Page 18: ...50 C 2 K 1000 m a m s l h 4000 m a m s l 5 1000 m Weight 1 3 kg 1 3 kg 1 1 kg 1 max 10 s with switch on cycle 3 2 max 60 s with switch on cycle 50 3 3 2 Assignment table for brake resistors The assignment depends on the motor power and is effectiveup to the indicated limit value Motor power Recommended Lenze brake resistor oto po e Order no Resistor Peak braking power Thermal capacity kW Ω kW kWs ...

Page 19: ...ia overcurrent relay The cable cross sections used must meet the valid regulations We recommend Type Input UG UG Overcurrent relay Cable cross section A mm2 8251 not required 1 5 8252 not required 1 5 8253 max 12 2 5 depending on the brake resistor 3 4 Dimensions The dimensions of the brake units depend on the mechanical installation see chapter 4 1 Show Hide Bookmarks ...

Page 20: ...e g separate air duct installation of filters regular cleaning etc Do not exceed the permissible range of the operating ambient temperature see chapter 3 2 If the brake units are permanently subjected to vibration or shaking Check whether shock absorbers are necessary Danger Operation with 8253 brake chopper and external brake resistor In the event of failures brake resistors can become very hot t...

Page 21: ...trip at the bottom assembled on attached fixing rail see chapter 4 1 2 or DIN rail see chapter 4 1 3 4 1 2 Standard assembly with fixing rail UG UG RB1 RB2 PE T1 T2 a e b f d g k Fig 4 1 Dimensions for fixing rail assembly Type a b c d e f g k 8251 8252 8253 56 210 28 190 170 130 6 5 30 All dimensions in mm Show Hide Bookmarks ...

Page 22: ...y 1 1 UG UG RB1 RB2 PE T1 T2 a e b c1 c2 c3 f Fig 4 2 Dimensions for DIN rail assembly 1 Assembly with one DIN rail in the middle or with 2 DIN rails top bottom possible Type a b c1 c2 c3 e f 8251 8252 8253 56 190 16 98 149 173 133 Show Hide Bookmarks ...

Page 23: ...switched off the mains voltage before you start to work For single drives the brake unit carries a hazardous voltage up to three minutes after mains disconnection In a drive network all controllers must be inhibited and disconnected from the mains Danger During braking operation e g test stand high inertia loads etc the voltage is still present after mains switching OFF It is therefore necessary t...

Page 24: ...used The cables used must comply with the approvals required at the site eg UL The prescribed minimum cross sections of PE conductors must be maintained in all cases The cross section of the PE conductor must be at least as large as the cross section of the power connections VDE 0160 The screening quality of a cable is determined by a good screen connection a low screen resistance Use only screens...

Page 25: ...m If the brake unit is directly connected with the controller and the cable length does not exceed 0 5 m the cables can be used as unscreened single cores For a radio interference suppression limit value class A or B to DIN 55011 observe the following The cables must be screened For cable lengths up to 1 m it is sufficient to connect the screen at the middle For cable lengths 1 m the screen must a...

Page 26: ... L2 U V W M 3 PE K10 F1 8201 8204 UG UG 8251 28 E1 20 PE Z1 X1 Z2 K10 RFR RB T1 T2 L1 N UG UG K10 OFF ON Z3 PE PE PE Fig 4 3 Connection of 8251 brake module to 820X controller Z1 Brake module Z2 Controller Z3 Mains choke K10 Mains contactor F1 Mains fuse recommended Show Hide Bookmarks ...

Page 27: ... M 3 PE K10 F1 F3 8211 8213 UG UG 8252 28 E1 20 PE Z1 X1 Z2 K10 RFR RB T1 T2 L1 L2 L3 UG UG Z3 PE PE PE K10 OFF ON K10 Fig 4 4 Connection of 8252 brake module to 821X controller Z1 Brake module Z2 Controller Z3 Mains choke K10 Mains contactor F1 F3 Mains fuses recommended Show Hide Bookmarks ...

Page 28: ... X1 Z2 K10 RFR L1 L2 L3 UG UG UG UG Z3 PE PE PE K10 OFF ON RB2 RB1 RB Z4 K10 RB K10 F1 F3 Fig 4 5 Connection of 8253 brake chopper to 821X controller Z1 Brake chopper Z2 Controller Z3 Mains choke Z4 Brake resistor K10 Mains contactor F1 F3 Mains fuses recommended JRB Thermal overcurrent release Brake resistor Show Hide Bookmarks ...

Page 29: ... off in the event of a failure Use the thermostats of the brake resistors to separate the controller from the mains if the temperature monitoring is activated and set controller inhibit in all connected controllers For connection of the thermostat see the corresponding signal flow diagrams chapter 4 3 2 4 3 4 Show Hide Bookmarks ...

Page 30: ...luminated when the brake unit is supplied with voltage and is ready for operation yellow LED illuminated when brake unit is in braking operation Note The deceleration time of the drive will be prolonged if the feedback power is higher than the peak brake power of the assigned brake resistor In this case the controller sets pulse inhibit and indicates overvoltage Prolong the Tif time via the decele...

Page 31: ...Commissioning 5 2 8250BA0903 Show Hide Bookmarks ...

Page 32: ...minals UG UG of the controller Controller sets pulse inhibit during braking and indicates overvoltage Yellow LED is not illuminated The brake unit is not connected to the terminals UG UG of the controller Connect the brake unit to the terminals UG UG of the controller Yellow LED is illuminated Brake resistor is not connected Connect brake resistor Brake resistance too high Use lower value brake re...

Page 33: ...Troubleshooting and fault elimination 6 2 8250BA0903 Show Hide Bookmarks ...

Page 34: ...ake unit consists of different materials The following table indicates which materials must be recycled and which require separate disposal Material recycle dispose Metal x Plastic x Printed board assemblies x Operating Instructions x Show Hide Bookmarks ...

Page 35: ...Waste disposal 7 2 8250BA0903 Show Hide Bookmarks ...

Page 36: ...e k Fig 8 1 Brake modules with integrated temperature monitoring Resistance Order no Rated power a b c d e g k Ω W mm mm mm mm mm mm mm 470 ERBM470R100W 100 70 240 50 225 60 5 7 5 370 ERBM370R150W 150 80 240 70 225 95 5 7 5 200 ERBM240R200W 200 80 340 70 325 70 5 7 5 Show Hide Bookmarks ...

Page 37: ...istance Order no a b c d e f g h Ω mm mm mm mm mm mm mm mm 180 ERBD180R300W 440 89 354 64 115 326 6 5 13 100 ERBD100R600W 640 89 530 64 115 426 6 5 13 82 ERBD082R600W 640 89 554 64 115 526 6 5 13 68 ERBD068R800W 540 177 454 150 115 426 6 5 13 47 ERBD047R01K2 640 177 554 150 115 526 6 5 13 Show Hide Bookmarks ...

Page 38: ...rake power Maximum power which can be converted into heat by a resistor PTC PTC thermistor PTC positive temperature coefficient RB Brake resistor Residual hazards Hazards which cannot be eliminated by design Use Appropriate Appropriate use of the machine according to the manufacturer s information or to common use according to its design and function Inappropriate Any other use which is not instru...

Page 39: ... 8 3 I Installation 4 1 electrical 4 4 mechanical 4 1 L Legal regulations 1 4 Liability 1 4 List of special terms See Glossary M Material 7 1 O Operating conditions 3 2 Operator 2 1 P Personnel qualified 2 1 R Rated data 3 3 Recycling 7 1 S Safety information general 2 2 Layout 2 3 Scope of delivery 1 2 Supplement 8 1 T Technical data 3 1 Dimensions 3 4 Features 3 1 General data operating conditio...

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