BU-300 UL

AC Drive Braking Unit

GE Industrial SystemsGE Industrial Systems

INSTRUCTIONS

© 2001 General Electric Company, USA.

All rights reserved.

Supersedes GEI-100350A 6/98

These instructions do not purport to cover all detailsor variations in equipment, nor to provide everypossible contingency to be met during installation,operation, and maintenance. If further information isdesired or if particular problems arise that are notcovered sufficiently for the purchaser’s purpose, thematter should be referred to GE Industrial Systems,Salem, Virginia, USA.

This document contains proprietary information ofGeneral Electric Company, USA and is furnished toits customer solely to assist that customer in theinstallation, testing, operation, and/or maintenance ofthe equipment described. This document shall not bereproduced in whole or in part nor shall its contents bedisclosed to any third party without the writtenapproval of GE Industrial Systems.

Table of ContentsSafety Symbol Legend / Légende des Signes de Sécurité ............ 4

Chapter 1 - Description ................................................................... 5

Chapter 2 - Main Features .............................................................. 6

Chapter 3 - Technical Data ............................................................. 73.1. Weights and Dimensions ............................................................................ 73.2. Required Power, Fuses, LED, Terminals and Switches ................................. 9

3.2.1. Required Power .................................................................................... 93.2.2. External Fuses ...................................................................................... 93.2.3. Internal Fuses ..................................................................................... 103.2.4. LEDs ................................................................................................... 103.2.5. Terminal Strips, Power Cables ............................................................ 103.2.6. Dip-switch Description ....................................................................... 11

3.3. Inverter Selection and Intervention Thresholds ......................................... 133.4. Unit Parallel Connection ............................................................................ 143.5. Alarm Intervention .................................................................................... 163.6. Dc Link Discharge Function ....................................................................... 17

Chapter 4 - Dimensioning of the Braking Unit and itsCorresponding Resistor ............................................................ 184.1. Resistor Simplified Sizing ......................................................................... 214.2 Simplified Resistor Sizing Based on Stopping Time .................................... 23

Chapter 5 - Minimum Value of the Used Resistors ...................... 25

Chapter 6 - Standard Braking Resistor ......................................... 26

Chapter 7 - Block Diagram ............................................................ 30

Safety Symbol Legend / Légende des Signes de Sécurité

WARNING! Commands attention to an operating procedure, practice, condition, orstatement which, if not strictly observed, could result in personal injury ordeath.

Attire l’attention sur les modes d’utilisation et les procédés et conditionsd’exploitation qui, en cas d’inobservation, pourraient entraîner des blessurescorporelles ou la mort.

CAUTION! Commands attention to an operating procedure, practice, condition, orstatement which, if not strictly observed, could result in damage ordestruction of equipment.

The seriousness of the injuries and of the damages which could be causedby the non- observance of such indications, depends on the differentconditions. Anyway, the instructions given below should always be fol-lowed with the highest attention.

Attire l’attention sur les modes d’utilization et les procédés et conditionsd’exploitation qui, en cas d’inobservation, pourraient entraîner ladétérioration ou la destruction des appareils.

La gravité des blessures et des dommages matériels possibles dépendent dedifférent facteurs. Toutefois, les instructions mentionées ci-dessous devraientêtre toujours suivies avec la plus grande attention.

NOTE! Commands attention to an operating procedure, practice, condition, orstatement that must be highlighted.

Attire l’attention sur les modes d’utilization et les procédés et conditionsd’exploitation qui présentent un intéret particulier.

5—————— GEI-100492——————

Chapter 1 - Description

The BU-300 braking unit consists of a static switch (IGBT) controlled by the voltage in theinverter intermediate circuit (DC Link).

When a fixed voltage threshold is exceeded, the static switch is closed connecting a resistoracross the DC link dissipating the developed energy. It is possible to obtain faster decelerationsand to avoid the tripping of the inverter “overvoltage” protection caused by a suddenincrease in the DC Link voltage.

Through a parallel connection of the units via the C and D terminals, and a cascade connectionof the braking command (master/slave function), it is possible to configure 2 parallel brakingunits which are simultaneously active.

A protection circuit has been implemented in order to protect the IGBT against possibleshort circuits of the braking resistor connections.

Other protections are:

- Heatsink thermal protection.

- Power supply voltage control.

The trip can be reset, after the alarm condition has been cleared, via a button on the unit orvia a remote dedicated command.

A command allows a quick discharge of the inverter intermediate circuit.

Such command must be directly interlocked with the contactors supplying energy tothe inverters.

—————— BU-300 UL ——————6

Chapter 2 - Main Features

- IP20 protection level- Max. working rated ambient temperature: 40°C (max. 50°C with a 20% derating)- Max. duty cycle: 50%- Circuit power supply derived from the DC Link- Possibility to parallel-connect up to 3 units (Master unit included) controlled by a

“MASTER” unit- Turn on threshold to be set through the switches- +24V power supply (green LED)- BR activity (yellow LED), Braking is active- AL alarm condition (red LED)- OK condition (green LED)- OK relay contact available for the alarm sequences- Possibility to connect the resistor protection- Possibility to discharge quickly the DC Link.

7—————— GEI-100492——————

Depending of BU and inverter size. Duty cycle max ≅ 50%

WARNING! The electronic circuit of the braking unit is directly connected to the DCLink, whose voltage value can reach 850Vdc.

If the device cover is removed, the live parts can not be touched (IP 20).

3.1. Weights and Dimensions

M6

CRBRPE C D

30

0m

m(1

2.1

")

32

0m

m(1

2.6

")

72 mm (2.8")

144 mm(5.7")

210mm (8.27")

Chapter 3 - Technical Data

CABLE LENGTH = 2m

Model

6KBU300-20UL6KBU300-50UL6KBU300-85UL

Max. dissipated power @ Duty cycle

50 W180 W280 W

Peak current

40 A100 A170 A

Average20 A50 A85 A

rms28 A70 A120 A

Current Duty cycle*

50%50%50%

Model6KBU300-20UL6KBU300-50UL6KBU300-85UL

lbs/Kg12.1 / 5.513.2 / 616.7 / 7.6

* Duty cycle = TON

+ TOFF

TON

—————— BU-300 UL ——————8

Figure 3.1.1: Front view

CAUTION!

PRECAUTION!

Dc-link twisted wires have a maximumlength of 2 meters.

The dc-link twisted wirers must bedisconnected at the inverter C and Dterminals before removing the coveror performing any maintenance orinspection operation.

Do not perform voltage test at thecontrol card terminals with meggerequipment or higt voltage testers.

Les fils torsades du dc-link ontune longueur maxi de 2 metres.

Les fils torsades du dc-link doiventêtre decorennectes des connections Cet D avant d’ôter le couvercle oud'effectuer toute operation d'entretienet de contrôle.

N'effecteur aucun test de tensionaux connections de la carte decontrôle avec equipment meggerou des testeurs de haute tension.

BU-300

9—————— GEI-100492——————

Figure 3.1.2: Panel clearances

PE BR CR C D PE BR CR C D

10mm (0.4")

50mm (2“) 10mm (0,4") "150mm (6 )

"150mm (6 )

50mm (2")

3.2. Required Power, Fuses, LED, Terminals and Switches3.2.1. Required Power

The braking unit power supply is derived directly from the DC Link; the maximumconsumption is 15W.

3.2.2. External Fuses

The inverter power supply, which the BU-300 braking unit is connected to, must beprotected via F1 external fuses (see figure. 3.4.1 and 3.4.2).

NOTE! No fuses are needed on the wiring connection between drive and brakingunit.

—————— BU-300 UL ——————10

3.2.3. Internal Fuses

NOTE! The F2 fuse resets itself after the short has been removed.

Replacement vendor source: RAYCHEM code: SMD030

3.2.4. LEDs

Denomination24 V

MASTERBROKAL

Colourgreenyellowyellowgreenred

FunctionIt shows the presence of the power supply

The braking unit is set as masterThe braking unit is active (braking)

OK relay status (closed = OK)It shows the alarm condition

DenominationF2

Protection for+24V supply (terminals 1 and 2)

Master output command (terminals 5 and 6)

Fuse0.3A Autoresettable

3.2.5. Terminal Strips, Power Cables

The power terminal strip consists of the following terminals:

TerminalsCD

CRBRPE

FunctionConnection to inverter DC linkConnection to inverter DC link

Connection to the braking resistorConnection to the braking resistor

Ground connection

I/QIIQQ–

Volt. max.820Vdc820Vdc775V dc775V dc

–

Curr. max.I peakI peakI peakI peak

–

TerminalsX2-1X2-2X2-3X2-4X2-5X2-6

X2-7X2-8X2-9X2-10X3-75X3-76

Name+24V0V 24V

TIMRESETMCMD0V 24V

SINSIN

SOUTSOUT

OKOK

FunctionInput power supply (TIM, RESET)

Reference potential for the +24V power supplyExternal alarm connection

Remote reset of the alarm conditionCommand starting the Slave braking procedure

Reference potential for the signal controlling the startof the Slave unit

Command starting the Slave unitCommand starting the Slave unit

Cascade connection for the Slave unitCascade connection for the Slave unit

Contact without the OK relay potential (closed = OK)Contact without the OK relay potential (closed = OK)

Volt. max.24V–

15...30V15...30V

24V ± 5%–

8...30V8...30V8...30V8...30V250Vca250Vca

Curr. max.200mA

–3.2...6.4 mA3.2...6.4 mA

30 mA–

16 mA16 mA16 mA16 mA

1 A1 A

I/QQ

IIQ

IIQQQQ

The two pluggable terminal strips, on the regulation card, consist of:

11—————— GEI-100492——————

3.2.6. Dip-switch Description

The following table lists the switches on the regulation card, removing the front cover of thebraking unit.

Cable sizes of the regulation board terminals

WARNING! Remove power, and insure DC link is discharged before opening cover andchanging settings.

Model

6KBU300-20UL6KBU300-50UL6KBU300-85UL

Maximum permissible Cable Cross-Section

flexible [mm]4…164…16

0.75…35

multi-core [mm]2,5…252,5…250,75…50

AWG12…412…418…0

Terminals

1 ... 76

Maximum permissible Cable Cross-Section

flexible [mm]0.35 ... 1.5

multi-core [mm]0.35 ... 1.5

AWG22 ... 16

Cable sizes of the power terminals CR,BR

Description

Mains Voltage

S2

S3S4

Mains Voltage[Vac]230380400415440460480

Function

Turn ON [Vdc]402646678702743753775

Turn OFF [Vdc]392636668692733743765

MASTER = Selection of braking unit function as Master (standard)SLAVE = Selection of braking unit as SlaveButton Reset of alarm conditionEnabling of the function for quick discharge of the DC linkStandard = OFF

Braking threshold

—————— BU-300 UL ——————12

Figure 3.2.6.1: Position of switches, LEDs, fuses and terminals on the BUy-C card

Side view

MainsVoltage

BU-300FRONT

13—————— GEI-100492——————

3.3. Inverter Selection and Intervention ThresholdsThe units are set according to a standard configuration:

- Inverter power supply voltage = 480Vac

- Intervention threshold = 775Vdc

Figure 3.3.1: Switch standard selection

MainsVoltage

230V380V400V

440V415V

460V480V

The braking unit intervention threshold must be set according to the value of the inverterpower supply voltage, which the braking unit must be connected to.

NOTE! It is possible to select just one braking threshold

Mains Voltage

230 Vac380 Vac400 Vac415 Vac440 Vac460 Vac480 Vac

Braking threshold[VBR]

400 Vdc640 Vdc680 Vdc702 Vdc745 Vdc753 Vdc775 Vdc

The 400Vac mains voltage requires the 680Vdc threshold.

—————— BU-300 UL ——————14

3.4. Unit Parallel Connection

NOTE! A minimum clearance of 2 inches is required when the braking units areparallel connected (see figure 3.1.2).

WARNING! A WRONG CONNECTION OF THE POWER SECTION COULDDESTROY THE UNIT AND/OR THE CONNECTED INVERTERS!

The braking unit is supplied with the power cables connecting the inverter to the C and Dterminals (cable length: 2 meters).

CAUTION! These cables must be used for installation. Do not substitute. If required,they can only be shortened.

Figure 3.4.1: Parallel connection of several units (Master and Slave) to AV-300i Drive

L1

L2

L3

N

PE

F1

K1M

FILTER

L1

U1 V1 W1

U2 V2 W2

M

3~

E

PE1

PE2 C

C

CR CR

C

D

D

BR BR

D

EN

AB

LE

BU300

MASTER

BU300

SLAVE9 95 7

7

75 75

76 76

10 106 8

8

1 13 3

BRAKING RESISTORS BRAKING RESISTORS

~~

AV-300i DRIVE

THERMAL RELAY

15—————— GEI-100492——————

When a drive provides the trigger command for external braking units, all the BU-300 mustbe configured as Slave. The MCMD and 0V24 terminals of the inverter must be connectedto the terminals number 7 and 8 (SIN) of the first BU-300, which, on its turn, is connectedto the following BU-300 via its terminals number 5 and 6 (SOUT), as shown in thefollowing example.

Figure 3.4.2: Parallel connection of several units (Slave) to the AV-300 Master Drive

L1

L2

L3

N

PE

FILTER

THERMAL RELAY

F1

K1M

L1

U1 V1 W1

U2 V2 W2

M

3~

E

PE1

PE2 C

C

CR CR

C

D

D

BR BR

D

EN

AB

LE

MC

MD

*

0V

24

BU300

SLAVE

BU300

SLAVE9 57 7

9

75 75

76 76

10 68 8

10

1 13 3

BRAKING RESISTORS BRAKING RESISTORS

~~

AV-300 MASTER DRIVE

* The MCMD terminal is available only on AV-300 Drives equipped with the followingcards:

· PSS-AMV32-1 Rev.”a” or higher (for sizes from 6KAV3003 to 6KAV3011)

· P1-AMV32 Rev.”d” or higher (for sizes from 6KAV3015 to 6KAV3160)

· PL-AMV32 Rev. “a” or higher (for sizes from 6KAV3250 to 6KAV3315)

—————— BU-300 UL ——————16

Figure 3.4.2: Auxiliary control circuits

L01

L00

EM

ER

GE

NC

Y-O

FF

K0

S11OFF

S12STOP

K2T

K2

K2 K1M

K1M

G1OK

K2T

S2ON/START

K0 K2

80

82

Thermalrelay

Mains contactorT = 1sON/OFFSTART/STOP

EMERGENGY-OFF

3.5. Alarm InterventionOn an internal alarm, the braking unit is immediately disabled, the AL red LED lights up andthe OK relay contact opens (terminals X3-75/ X3-76).

After the alarm condition has been restored, the braking unit can be reset using one of thefollowing methods:

- via the S3 button

- via a remote command on the X2-1 and X2-4 terminals.

- by cycling power on the braking unit.

17—————— GEI-100492——————

3.6. Dc Link Discharge FunctionThe braking unit can be used to discharge a DC Link with a high capacitive value (forexample in systems where the DC Link is parallel connected).

For this use set the S4 switch in position ON and jumper the X2-9 and X2-10 terminals.

With such a setting, the DC Link discharge can reach a value equal or lower than 60V dc bytaking an external voltage included between 10 and 30V dc to the X2-7 and X2-8 SINterminals or using the internal voltage of the X2-1 and X2-2 terminals.

WARNING! In order to avoid damages to the braking resistor, the commandexecution is critical. This signal must be supplied to the braking unitvia a contact interlocked with those contactors which power theinverter.

—————— BU-300 UL ——————18

Chapter 4 - Dimensioning of the Braking Unit and itsCorresponding Resistor

Here following are some general information. Chapter 6 lists a series of normalized resistorsto be used with the BU-300 braking units in specifically assumed conditions.

Remember that:

PPBR

[W] Power peak while braking

PNBR

[W] Resistor rated power

EBR

[J] Braking energy

VBR

[V] Braking voltage

IPBR

[A] Peak braking current

IAVBR

[A] Average braking power

IPBU

[A] Braking unit peak current

n1, n

2 [RPM] Initial and final speed

tBR

, T [S] Braking time and cycle time

JTOT

[Kg* m2] Total moment of inertia (referred to the motor shaft)

Therefore:

Resistor ohmic value:

f004

R =BR VBR

IPBR

19—————— GEI-100492——————

Resistor continuous rated power:

P =NBR =P * tPBR BR EBR

2T Tf005

CAUTION! This formula calculates an average power value which could be differentfrom the instant power in case of very low duty cycles.

The resistors can not usually bear a power peak which is 5 to 10 timeshigher than their rated value. As a consequence, if the duty cycles are lowerthan 10%, this value can not be used as a resistor rated power. See also thecalculations in chapters 4.1 and 6.

Consult the resistor producer for further details about the overload capacity.

Being n2 = 0 (stop), the formula states that:

E =BR P * tPBR BR

12

f006

Braking unit features:I IPBU PBR

f007

The peak current allowed by the BU-300 must be higher or equal to the real one. Theaverage current is stated through:

I =AVBR

EBR

t * VBR BR

I IAVBU AVBRf008

—————— BU-300 UL ——————20

Dimensioning example

Data:

- Mains voltage 3 x 460 V

- Inverter 6KAV3015

- Motor rated power (PM

) 15 HP

- Motor rated speed (nn) 3515 rpm

- Moment of inertia of the motor (JM

) 0.033 kgm2

- Moment of inertia loading the motor shaft (JL) 0.95 kgm2

- Friction of the system (MS) 10% of the rated torque

- Initial braking speed (n1) 3000 rpm

- Final braking speed (n2) 0 rpm

- Braking time (tBR

) 10 sec

- Cycle time (T) 120 sec

Total moment of inertia:

JTOT

= JM

+ JL = 0.033 + 0.95 = 0.983 kgm2 e

∆ω = [2Π * (n1 - n

2)] / 60 sec/min = 2Π * 3000 / 60 = 314 sec-1

Motor rated torque:

MM

= PM

/ ωn = (15 * 745.7) / ( 2Π * 3515 / 60) = 30.4 Nm

Machine friction: MS = 0.1 M

M = 3.04 Nm

The braking energy is given by:

EBR

= (JTOT

/ 2) * (2Π / 60)2 * (n12 -n

22) = (0.983 / 2) * (0.10472)2 * 30002 = 48509 Joules

or Wsec

Taking into account also the system friction, the braking energy to be dissipated by thebraking unit is lower.

The required braking torque is:

Mb = (J

TOT * ∆ω) / t

BR = 0.983 * 314 / 10 = 30.9 Nm

The braking torque consists of two sections: the machine friction and the torque to besupplied by the motor electric braking:

MbM

= Mb - M

S = 30.9 - 3.04 = 27.86 Nm

The average power of the braking process is given by:

PAVE

= (MbM

* ∆ω) / 2 = 27.86 * 314 * 0.5 = 4374 W

21—————— GEI-100492——————

The new value of the braking energy is therefore:

New EBR

= PAVE

* tBR

= 4374 * 10 = 43740 Joules or Ws

it is obviously lower than the previous one.

The peak braking power is given by

PPBR

= (JTOT

* n1 * ∆ω * 2Π) / (t

BR * 60) = 9.7 kW therefore

IPBR

= PPBR

/ VBR

= 9700 / 745 = 13A and

RBR

≤ VBR

/ IPBR

= 745 / 13 = 57 Ω

Being IPBR

= 13A, the 6KBU300-20UL unit meets the requirements.

Resistor choice

The resistor rated power must be:

PNBR

= (PPBR

* tBR

) / 2T = (9700 * 10) / 240 = 404 W

The resistor rated power is low because of the low duty cycle (10 / 20) but the resistor mustbe in a position to bear the energy applied during the 10-second braking process. Thisenergy corresponds to 43740 Joules. In the table of the standard braking resistors (chapter6) it is possible to notice how the model BRR 1K0T 49R has a sufficient rated power valueand a too low E

BR value (21kWsec).

As a consequence the chosen model is BRR 1K3T 31R whose EBR

value is 44kWsec.

4.1. Resistor Simplified SizingIn case all the above mentioned data are not available, it is possible to carry out a simplifiedand rough calculation of the braking resistance.

The following formulas can be used for the calculation of the different braking values:

Having to calculate the resistor value for an inverter (100A braking peak current) which ispower supplied at 400Vac, (braking threshold), we have that:

R =BR = 6.8 Ohm680

100f012

—————— BU-300 UL ——————22

This formula states just the ohmic value; the following considerations, on the contrary, referto the resistor power:

The braking resistor is normally used with an intermittent cycle; it is therefore normal touse a resistor power lower than the one obtained through R

BR * I

PBR 2.

The following diagram can be used to define the overload factor (similar diagrams can besupplied by the producer of the used resistor).

1000

100

10

1

0,11 3 4 5 6 7 8 9 10

RESISTANCE POWER

2

OVERLOAD FACTOR

OV

ER

LO

AD

TIM

E(s

eco

nd

s-

log.

Sca

le)

Pause time

15 seconds

30 seconds

1 minute

5 minutes

30 minutes

Using this diagram to calculate the value of the continuous (rated) power of the brakingresistor, it is possible to apply the following formula:

continuative power R =BR

regenerated power

overload factorf013

Having to brake a 30-kW motor with a 150% overload, the maximum regenerated power is45 kW.

Assuming that the braking time is 5 seconds (resistor overload time) and the break time is1 minute, the diagram supplies an overload factor of 3.9. The resistor rated power istherefore:

= 11.5 kW45000

3.9f014

23—————— GEI-100492——————

rmp

time

Machine Inertia

(Gear Ratio)2Reflected Machine Inertia =

= System Energy [kW ⋅⋅⋅⋅⋅ sec][Total System Inertia] [Top rpm2]

4300000

(System Energy) kW ⋅⋅⋅⋅⋅ sec

(Stop time) sec= Average Stopping Power [kW]

4.2 Simplified Resistor Sizing Based on Stopping Time

1) Add Motor Inertia + Gearbox Inertia + Reflected Machine Inertia = Total Systeminertia [ft lb2]

2) Calculate system energy running at top speed.

3) Calculate average [kW] needed to absorb to stop, neglectingfriction and efficiencies.

4) Calculate the resistor Ohms needed to dissipate the average stopping power [kW].

(DC Bus Volts)2

(Ave Stopping kW * 1000 * 2)= ΩΩΩΩΩ

For AV-300i as master, at460 VAC, DC bus volts =780.

This is the largest ohm value that can be used to stop the drive in time. Smaller Ohmvalues can be used.

—————— BU-300 UL ——————24

(DC Bus Volts)2

Current Limit kW * 1000= ΩΩΩΩΩ

DC Bus Volts

Current Limit OhmsInstantaneous Current =

DC Link Volts

DB Resistance Ohms= Peak Current [Amps]

Average Stopping kW

Resistor Ohm= Short Time Current [Amps]

5) Calculate the resistor ohms needed for the motor to reach current limit anytime duringthe stop.

Motor HP * .746 = Motor kW

Current Limit kW = Motor kW * 1.5 (150% overload)

6) Select a resistor value desired in the range between the answers found in steps 4) and5).

Seleting closer to the value in step 5) may cause your resistor to be higher power ratingto support the:

selecting closer to the value found in step d) doesnt leave room for field adjustementof faster stop times later.

7) Use the final resistance value, determined in step f), to check the resistor peak currentand BU peak current needed.

this determines quantity of braking units needed, and which type of BU based on thepeak amps needed.

8) For an occasional stop, for example, once every 10 minutes, or stop then cool toambient, then the resistor can be selected on its short time rating, for example a 15 secrating or 30 sec rating average stopping kW if the resistor rating is in kW.

or:

The resistor power rating must meet both instantaneous and short time ratings.

For overhauling loads, or more frequent stopping cycles, use the previous detailedcalculations.

25—————— GEI-100492——————

Model

6KBU300-20UL6KBU300-50UL6KBU300-85UL

Mains voltage and resistor minimum value

230V10 ohm4 ohm

2.4 ohm

380V16 ohm6.4 ohm3.7 ohm

400V17 ohm6.8 ohm4 ohm

415V17 ohm6.8 ohm4 ohm

440V18.6 ohm7.5 ohm4.4 ohm

460V18.6 ohm7.5 ohm4.4 ohm

480V19.37 ohm7.75 ohm4.55 ohm

Chapter 5 - Minimum Value of the Used Resistors

The ohmic value listed in the table is the resistor absolute minimum value to be connectedto the different braking units according to the set braking threshold. In case this value is notavailable, the following higher ohmic value has to be used. For example, with the 6KBU300-20UL braking unit, whose intervention threshold is 680V, the stated resistor value is 17Ω,but the following commercial ohmic value to be used is 18Ω.This indication allows a better use of the braking resistors when several parallel-connectedresistors are present; in this case see the ohmic values listed in the table.

CAUTION! The units are protected against any direct short circuit between theterminals CR and BR

——

——

——

BU-300 U

L ——

——

——

26

DB 10 secAV-300i HP max.HP 10% DB BU-300 equivalent IPC DB pkg available % 1 time

model # (with OL) duty KW type DB resistor bank watts duty with ave Watts capability6KAVi43... output resistor model # this R & stopping in X times

ohms DB combo from 1800 motor

rpm in 5 sec inertiaF75 0,75 0,05595 internal 200 6KE$34DBR001 200 35,7 45.2 22,119

1 1 0,0746 internal 200 6KE$34DBR001 200 26,8 45.2 22,119

2 2 0,1492 internal 200 6KE$34DBR001 200 13,4 60.3 16,590

3 3 0,2238 internal 160 6KE$34DBR003 400 17,9 45.2 44,239

5 5 0,373 internal 100qty 2

6KE$34DBR0012 resistors in series 400 10,7 60.3 33,179

7 7,5 0,5595 internal 80 6KE$34DBR007 900 16,1 150.7 29,861

10* 10 0,746 BU-300-20 40 6KE$34DBR015 1400 18,8 150.7 46,451

10* 10 0,746 internal* 80 6KE$34DBR007*allows 100% CL +

losses~(110%)900 12,1 150.7 29,861

15 15 1,119 internal 40 6KE$34DBR015 1400 12,5 331.5 21,114

20 20 1,492 internal 27 6KE$34DBR025 1800 12,1 452.1 19,907

25 25 1,865 internal 22 6KE$34DBR030 1800 9,7 828.8 10,859

30 30 2,238 internal 15 6KE$34DBR040 3600 16,1 904.2 19,907

40 40 2,984 internal 12 6KE$34DBR050 4800 16,1 979.5 24,501

50 50 3,73 internal 10 6KE$34DBR060 6000 16,1 1085.0 27,649

60 60 4,476 internal 7,5 6KE$34DBR075 7200 16,1 1959.1 18,376

75 75 5,595 BU-300-85 6qty 2

6KE$34DBR050

2 resistors in

parallel9600 17,2 2109.8 22,751

100 100 7,46 BU-300-85 5qty 2

6KE$34DBR060

2 resistors in

parallel12000 16,1 6027.9 9,954

125 125 9,325qty 2 , BU-

300-503,35

qty 2

6KE$34DBR075

1 resistor/BU, 2

BUs in //14400 15,4 6027.9 11,944

150 150 11,19qty 2 , BU-

300-853,35

qty 2

6KE$34DBR075

1 resistor/BU, 2

BUs in //14400 12,9 9795.3 7,350

200 200 14,92qty 2 , BU-

300-852,5

qty 2

6KE$34DBR060

1 resistor/BU, 2

BUs in //24000 16,1 16576.7 7,239

DB ckt

configuration Chapter 6 - Standard Braking ResistorTable 6.1: 10%

duty typical DB resistors for AV-300i

for decel on ramp w

ith motor pow

er capable of 150% of rated m

otor HP.

27—

——

——

— G

EI-100492——

——

——

DB 10 sec

AV-300i HP max.HP 20% DB BU-300 equivalent IPC DB pkg available % ave Watts 1 time

model # (with OL) duty KW type DB resistor bank watts duty with stopping capability

6KAVi43... output resistor model # this R & from 1800 in X times

ohms DB combo rpm in 5 sec motor

inertia

F75 0,75 0.1119 internal 200 6KE$34DBR001 200 35.7 45.2 22.1191 1 0.1492 internal 200 6KE$34DBR001 200 26.8 45.2 22.1192 2 0.2984 internal 160 6KE$34DBR003 400 26.8 60.3 33.179

3 3 0.4476 internal 160qty 2

6KE$34DBR0072 resistors in

series1600 71.5 45.2 176.955

5 5 0.746 internal 120qty 2

6KE$34DBR0102 resistors in

series1800 48.3 60.3 149.306

7 7,5 1.119 internal 80qty 2

6KE$34DBR0152 resistors in

series2800 50.0 150.7 92.901

10* 10 1.492 BU-300-20 27 6KE$34DBR015 1800 24.1 150.7 59.722

10* 10 1.492 internal 80qty 2

6KE$34DBR015allows 100%

CL+2800 37.5 150.7 92.901

15 15 2.238 BU-300-50 15 6KE$34DBR040 3600 32.2 331.5 54.293

20 20 2.984 internal 30 6KE$34DBR0402 resistors in

series7200 48.3 452.1 79.630

25 25 3.73 internal 15 6KE$34DBR030 3600 19.3 828.8 21.71730 30 4.476 internal 10 6KE$34DBR060 6000 26.8 904.2 33.17940 40 5.968 internal 10 6KE$34DBR060 6000 20.1 979.5 30.62750 50 7.46 internal 7.5 6KE$34DBR075 7200 19.3 1085.0 33.17960 60 8.952 internal 6 6KE$34DBR050 2 resistors in // 9600 21.4 1959.1 24.501

75 75 11.19BU-300-

855

qty 26KE$34DBR060

2 resistors inparallel

12000 21.4 2109.8 28.439

100 100 14.92BU-300-

855

qty 46KE$34DBR060

2 resistors inseries, in parallel

24000 32.2 6027.9 19.907

125 125 18.65qty 3 , BU-

300-503.75

qty 46KE$34DBR040

2 // resistor/BU,2 BUs in //

21600 23.2 6027.9 17.917

150 150 22.38qty 3 , BU-

300-852.5

qty 36KE$34DBR075

1 resistor/BU, 3BUs in //

24000 21.4 9795.3 12.251

200 200 29.84qty 3 , BU-

300-851.67

qty 66KE$34DBR060

2// resistor/BU, 3BUs in //

36000 24.1 16576.7 10.859

DB ckt

configuration

Table 6.2: 20% duty typical DB resistors for AV-300i

for decel on ramp w

ith motor pow

er capable of 150% of rated m

otor HP.

——

——

——

BU-300 U

L ——

——

——

28

DB 10 sec

AV-300i HP max.HP 50% DB BU-300 equivalent IPC DB pkg available % ave Watts 1 time

model # (with OL) duty KW type DB resistor bank watts duty with stopping capability

6KAVi43... output resistor model # this R & from 1800 in X times

ohms DB combo rpm in 5 sec motor

inertia

F75 0,75 0.27975 internal 160 6KE$34DBR003 400 71.5 45.2 44.23

1 1 0.373 internal 160 6KE$34DBR003 400 53.6 45.2 44.23

2 2 0.746 internal 260 qty 2, 6KE$34DBR005 2 resistors in series 800 53.6 60.3 66.35

3 3 1.119 internal 160 qty 2, 6KE$34DBR007 2 resistors in series 1600 71.5 45.2 176.95

5 5 1.865 internal 120 qty 2, 6KE$34DBR010 2 resistors in series 1800 48.3 60.3 149.3

7 7,5 2.7975 internal 80 qty 2, 6KE$34DBR008 2 resistors in series 2800 50.0 150.7 92.9

10 10 3.73 BU-300-50 12 6KE$34DBR050 4800 64.3 150.7 159.25

15 15 5.595 BU-300-50 10 6KE$34DBR060 6000 53.6 331.5 90.48

20 20 7.46 internal 30 6KE$34DBR040 2 resistors in series 7200 48.3 452.1 79.63

25 25 9.325 BU-300-85 6 qty 2, 6KE$34DBR050 2 resistors in // 9600 51.5 828.8 57.91

30 30 11.19 BU-300-85 5 qty 2, 6KE$34DBR060 2 resistors in // 12000 53.6 904.2 66.35

40 40 14.92 qty 2 BU-300-85 3 qty 4, 6KE$34DBR0502 // resistor/BU, 2

BUs in //19200 64.3 979.5 98.0

50 50 18.65 qty 2 BU-300-85 3 qty 4, 6KE$34DBR0502 // resistor/BU, 2

BUs in //19200 51.5 1085.0 88.47

60 60 22.38 qty 2 BU-300-85 1,875 qty 4, 6KE$34DBR0752 // resistor/BU, 2

BUs in //24000 53.6 1959.1 61.25

75 75 27.975 qty 2 BU-300-85 2,5 qty 4, 6KE$34DBR0502 // resistor/BU, 2

BUs in //28800 51.5 2109.8 68.25

100 100 37.3 qty 3, BU-300-85 1,67 qty 6 ,6KE$34DBR0602 // resistor/BU, 3

BUs in //36000 48.3 6027.9 29.86

125 125 46.625 qty 4 , BU-300-85 1,25 qty 8 ,6KE$34DBR0602 // resistor/BU, 4

BUs in //48000 51.5 6027.9 39.81

150 150 55.95 qty 4 , BU-300-85 1,25 qty 8 ,6KE$34DBR0602 // resistor/BU, 4

BUs in //48000 42.9 9795.3 24.5

200 200 74.6 qty 4 , BU-300-85 1,25 qty 8 ,6KE$34DBR0602 // resistor/BU, 4

BUs in //48000 32.2 16576.7 14.47

DB ckt

configuration

Table 6.2: 50% duty typical DB resistors for AV-300i

for decel on ramp w

ith motor pow

er capable of 150% of rated m

otor HP.

29—————— GEI-100492——————

Resistor sizing notes:

1) A power resistor is restricted in maximum amps, usually 5 or 10 times it's continuousrating. This limitation may increase the power rating even though the RMS powermay be relatively low. Consult with the particular resistor vendor for the actualmaximum restrictions if different than above.

2) Per IPC, resistor banks are rated for 5 times continuous rating for 10 seconds, with aoff time of "cool to ambient".

3) "ave watts stopping from 1800 rpm in 5 seconds" can be used to estimate stoppingrequirements. This number is proportional to the square of the rpm.Time is inverselyproportional.

4) DB 10 second, one time capability shows how much load inertia can be stopped in faststop conditions once then cool to ambient, for the % duty.

—————— BU-300 UL ——————30

On

ly f

or:

6K

BU

300-

20U

L-50

UL

Onl

y fo

r: 6

KB

U30

0-85

UL

C-B

OT

C-BU-y

Gate

Em

itte

r

FA

ULT

Vth

VH

T

Re

set

XY

6

Vo

nV

ou

t

Bre

ak

Fau

lt

Nr:

ESE

_3

21

0D

ate

12

/02

/01

Main

sV

oltag

e

X3

-75

X3

-76

X3

-4

X3

-1

X3

-6

X3

-7

X3

-8

X3

-9

X3

-10

X3

-5

RE

SE

T

RE

SE

T

+2

4V

F+

24

V

+2

4V

0V

24

V

OK

K1

S3

F2

BR

+2

4V

F

AL

+1

0V

23

0V

38

0V

40

0V

41

5V

44

0V

46

0V

48

0V

+1

5V

+1

5V

0V

0V

-15

V-1

5V

+2

4V

0V2

4

MA

ST

ER

S4

=O

FF

S3

=S

LA

VE

SA

LV

E

S4

=O

N

S3

=M

AS

TE

RS

4S

2

MA

ST

ER

MA

ST

ER

SLA

VE

SM

PS

-ON

OK

M S

BU

y-C

ES

E3

03

6

S R

+2

4F

X2

-1

X2

-3

XT

1

XT

2

C X1

-1

X1

-2

XV

1X

V2

+2

4V

D

2

1

3S

N-B

Uy

ES

E3

13

9/1

ES

E3

13

9/2

RE

S-S

N

D PE

CBR

CR

R-B

reak IN

VE

RT

ER

C D

MA

ST

ER

/SLA

VE

Chapter 7 - Block Diagram

31—————— GEI-100492——————

1S9G70

GE Industrial Systems

+ 1 540 387 7000

www.GEindustrial.com

General Electric Company

1501 Roanoke Blvd.

Salem, VA 24153-6492 USA

GEI-100492

010502

SIEI