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Regen Resistor Sizing and Configuration 

Xenus Regeneration Guide 

2

Copley Controls Corp. 

1.1: Regen Resistor Theory 

When a load is accelerated electrical energy is converted into mechanical energy. During 
deceleration the conversion is reversed. This is called regeneration. Some of this regenerated 
energy is lost to friction in the mechanical system. More of this energy is converted to heat due to 
I

2

R losses in the motor windings, cabling and drive electronics. The remainder of the energy is 

added to the electrical energy already stored in the internal capacitor bank of the amplifier. The 
result of this energy being added is an increase in the voltage on the capacitor bank. 
If too much energy is added to the capacitor bank, the voltage will rise to a point where the 
amplifier's over voltage protection will shut down the amplifier. To prevent this, a regen circuit 
shunts some of the energy into an external resistor, known as a regen resistor, when the voltage 
rises too high. 
Xenus provides an internal transistor that is used in combination with an external resistor. Copley 
Controls supplies compatible external resistors. When using a resistor acquired from another 
source, be sure it meets the specifications described in  

Regen Resistor Sizing and Configuration

 (p. 9)

.

The amplifier protects the regen circuit against short circuit, and uses I

2

T peak current/time 

algorithms to protect both the external resistor and internal transistor. 

1.2: Regen Specifications  

This section describes the regen resistor specifications.  

1.2.1: Amplifier Regen Circuit Output Specifications 

Model XSL-230-18 

XSL-230-36 

XSL-230-40 

Continuous Power 

2 kW  

4 kW 

Peak Power 

5 kW 

10 kW 

Minimum Resistance 

30 

15 

Minimum Resistor Wattage  

25 W 

50 W 

Turn On Voltage 

+390 Vdc  

Turn Off Voltage 

+380 Vdc 

DC Bus Capacitance 

1760 

µ

F nominal 

Regen Energy Absorption Capacity 

Input Voltage 120 Vac 

208 Vac 
240 Vac 

 
108 joules 
57 joules 
32 joules 

1.2.2: Copley Standard Regen Resistor Specifications 

Model 

Resistance 

Continuous Power 

Peak Power 

For Use With 

XSL-RA-01 

30 ohms 

167 W 

5 kW 

XSL-230-18 

XSL-RA-02 

15 ohms 

200 W 

10 kW 

XSL-230-36 
XSL-230-40 

Содержание Xenus XSL-230-18

Страница 1: ...Xenus Regeneration Guide P N 95 00306 000 Version 1 1 November 2004...

Страница 2: ...Xenus Regeneration Guide This page for notes...

Страница 3: ...Regen Circuit Output Specifications 2 1 2 2 Copley Standard Regen Resistor Specifications 2 1 2 3 Regen Dimensions 3 1 3 Regen Circuit Wiring 4 1 3 1 Electrical Codes and Warnings 4 1 3 2 Connector Lo...

Страница 4: ...Table of Contents Xenus Regeneration Guide ii Copley Controls Corp This page for notes...

Страница 5: ...omes your comments on this guide See http www copleycontrols com for contact information Copyrights No part of this document may be reproduced in any form or by any means electronic or mechanical incl...

Страница 6: ...equipment damage injury or death Risk of electric shock DANGER High voltage circuits on J1 J2 and J3 are connected to mains power Failure to heed this warning can cause equipment damage injury or dea...

Страница 7: ...RESISTORS FOR XENUS This chapter provides an overview of regeneration and using regen resistors with Xenus The contents of this chapter include Title Page 1 1 Regen Resistor Theory 2 1 2 Regen Specif...

Страница 8: ...voltage rises too high Xenus provides an internal transistor that is used in combination with an external resistor Copley Controls supplies compatible external resistors When using a resistor acquire...

Страница 9: ...esistor Sizing and Configuration Copley Controls Corp 3 1 2 3 Regen Dimensions The following diagram describes the mounting dimensions in inches of both of the Copley supplied resistors 244 TYP 50 TYP...

Страница 10: ...dous voltages DANGER Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death Risk of electric shock DANGER High voltage circuits on J1 J2...

Страница 11: ...figuration Copley Controls Corp 5 1 3 2 Connector Locations Connector locations are shown below The regen connector is J3 CNTRL J4 J3 J2 J1 STATUS RS232 CAN ADDR J5 S1 J6 J7 J8 FDBCK 24V BRAKE RTN REG...

Страница 12: ...in connector kit XSL CK or XSL CA Pin Description Pin Signal Function 1 Regen DC Bus to one side of regen resistor 2 N C No connection 3 Regen Collector of regen transistor to one side of regen resist...

Страница 13: ...2 Select a resistor option Option Description None No external regen resistor is used XSL RA 01 XSL RA 02 Standard regen resistors supplied by Copley Controls Custom Resistor User supplied resistor Se...

Страница 14: ...Regen Resistor Sizing and Configuration Xenus Regeneration Guide 8 Copley Controls Corp This page for notes...

Страница 15: ...hapter describes the formulas used to determine if a regen resistor is required and what the optimal resistor characteristics would be for a given application The contents of this chapter include Titl...

Страница 16: ...onstant of the motor 5 Resistance line to line of the motor windings A 1 1 2 For rotary motor applications gather this additional information 1 Load inertia seen by the motor 2 Inertia of the motor A...

Страница 17: ...ond A 1 4 Determine the Amount of Energy Dissipated by the Motor Calculate the amount of energy dissipated by the motor due to current flow though the motor winding resistance using the following form...

Страница 18: ...ust be dissipated in the regen resistor in joules Ereturned Energy delivered back to the amplifier from the motor in joules Eamp Energy that the amplifier will absorb in joules A 1 8 Calculate Pulse P...

Страница 19: ...LM fuses or equivalent should be selected The peak and continuous currents as well as the peak current time must be taken into consideration for proper fuse selection The duration of the peak current...

Страница 20: ...ntered in the following steps must be correct Damage to the external regen resistor may result from incorrect values entered Damage to the amplifier may result if an incorrect resistance value is ente...

Страница 21: ...ck Next for Step 3 A 2 2 5 Enter a Peak Power within the range described Click Next for Step 4 A 2 2 6 Click Next for Step 5 A 2 2 7 Review the configuration A 2 2 8 Click Finish to save the configura...

Страница 22: ...Xenus Regeneration Guide P N 95 00306 000 Version 1 1 November 2004 2003 2004 Copley Controls Corporation 20 Dan Road Canton MA 02021 USA All rights reserved...

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