FAQ about Drives Technology

Calculating the braking resistors for MM4 and G120

MICROMASTER 440 SINAMICS G120

Calculating the braking resistors for MM4 and G120

Item-ID: 7800906

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Copyright 2008 Siemens A&D. It is not permissible to transfer or copy these examples or excerpts of them without first having prior authorization from Siemens A&D in writing. For suggestions about this document please use the following e-mail address: mailto:sdsupport.aud@siemens.com

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Calculating the braking resistors for MM4 and G120

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Table of Contents
Table of Contents ......................................................................................................... 3 1 1.1 Overview.......................................................................................................... 4 Examples to select braking resistors for MM4 and SINAMICS G120 ............... 4 Table for 230V units ..................................................................................... 5 Table for 400V units ..................................................................................... 6 Table for 575V units ..................................................................................... 7 Examples .......................................................................................................... 8 Example 1:........................................................................................................ 8 Example 2:........................................................................................................ 8 Example 3:........................................................................................................ 9 Note:............................................................................................................. 9 Appendix ....................................................................................................... 10 Internet links ................................................................................................... 10 History............................................................................................................. 10

1.2 1.2.1 1.2.2 1.2.3 2 2.1 2.2

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This entry is from the Internet offer of Siemens AG, Automation and Drives, Service & Support. Clicking the link below directly displays the download page of this document. http://support.automation.siemens.com/WW/view/en/7800906

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Calculating the braking resistors for MM4 and G120

Item-ID: 7800906

Overview
The selection of the braking resistors for MM4 will be described in the application 22101908. MICROMASTER 4 engineering braking chopper operation for MICROMASTER 440 More technical details are found in FAQ ID: 8400450. MM440: Braking resistors (MLFBs and dimensions) Information about braking resistors in use with inverter SINAMICS G120 is found in the catalogue SINAMICS G110/SINAMICS G120 Inverter chassis units SINAMICS G120D Distributed frequency inverter in chapter DC link components. SINAMICS G110/SINAMICS G120 Inverter Chassis Units SINAMICS G120D Distributed Frequency Inverters catalogue More detail information about operate with braking resistors and settings of duty cycle contains the chapter Dynamic braking of the function manual. Function manual

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Braking resistors are not available for the SINAMICS G120 / G120D with PM250 / PM250D 1. The Power Module is capably of energy recovery (regenerative feedback into the line supply). This means that the energy is fed back into the line supply and does not have to be dissipated in the form of heat in a braking resistor.

1.1

Examples to select braking resistors for MM4 and SINAMICS G120

The tables provided on the following pages can be used when selecting and specifying resistors when they are purchased from other manufacturers.

PM250D: PM = Power Module; 250 = capable of energy recovery; D = distributed technology

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Calculating the braking resistors for MM4 and G120

Item-ID: 7800906 Table for 230V units

Supply voltage Inverter frame size Inverter power range (kW) Calculated power rating 1 Resistance +/- 10% (Ohms) 2 Braking current at voltage trip level (A) 3 Recommended cable size 4 (mm/AWG) Voltage rating wrt Earth (Vrms) 5 DC-voltage 6 rating (V)

Contin. (W)

Instantan. (12s duration) (W)

230V A B B C C D E F 0.12-0.75 1.1 1.5 / 2.2 3 4 / 5.5 7.5 15 18.5 / 22 44 118 118 205 296 800 1176 2424 889 2353 2353 4103 5926 16000 23529 48485 180 68 68 39 27 10 6.8 3.3 2.3 6.2 6.2 10.8 15.6 42.0 61.8 127.3 1.0/17 1.0/17 1.0/17 1.0/17 1.5/15 10/7 16/5 70/-2 265 265 265 265 265 265 265 265 450 450 450 450 450 450 450 450

The actually required rated power normally lies between these two values and depends on the operating cycle that can be expected. In case of doubt, select a larger (higher rating) resistor than required as the associated costs are relatively low. 2 Normal and minimum resistance value that should be specified. 3 Braking current in the braking controller (braking chopper) and resistor 4 Ensure that the connecting cable is suitable for the operating voltage as well as the high temperatures of the braking resistor. Shielded cables should be used. The maximum cable size and the cable connection type depend on the manufacturer of the brake resistor. 5 Minimum ground insulation 6 Maximum rated voltage of the resistor Version 1.1 issue June 2008 5/10

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Calculating the braking resistors for MM4 and G120

Item-ID: 7800906 Table for 400V units

Supply voltage Inverter frame size Inverter power range (kW) Calculated power rating 1 Resistance +/-10% (Ohms) 2 Braking current at voltage trip level (A) 3 Recommended cable size 4 (mm/AWG) Voltage rating wrt Earth (Vrms) 5 DC-voltage 6 rating (V)

Contin. (W)

Instantan. (12s duration) (W)

400V A B B C C D E F 0.37 1.5 2.2 3 4 5.5 7.5 / 11 15 22 30 / 37 45 - 75 86 210 210 600 600 1245 2241 4100 1724 4203 4203 12007 12007 24904 44827 82000 390 160 160 56 56 27 15 8.2 2.2 5.3 5.3 15.0 15.0 31.1 56.0 102.4 1.0/17 1.0/17 1.0/17 1.5/15 1.5/15 6.0/9 15/5 35/2 530 530 530 530 530 530 530 530 900 900 900 900 900 900 900 900

The actually required rated power normally lies between these two values and depends on the operating cycle that can be expected. In case of doubt, select a larger (higher rating) resistor than required as the associated costs are relatively low. 2 Normal and minimum resistance value that should be specified. 3 Braking current in the braking controller (braking chopper) and resistor 4 Ensure that the connecting cable is suitable for the operating voltage as well as the high temperatures of the braking resistor. Shielded cables should be used. The maximum cable size and the cable connection type depend on the manufacturer of the brake resistor. 5 Minimum ground insulation 6 Maximum rated voltage of the resistor Version 1.1 issue June 2008 6/10

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Calculating the braking resistors for MM4 and G120

Item-ID: 7800906 Table for 575V units

Supply voltage

Inverter frame size

Inverter power range (kW)

Calculated power rating 1

Resistance +/-10% (Ohms)2

Braking current at voltage trip level (A)3

Recommended cable size4 2 (mm /AWG)

Voltage rating wrt Earth (Vrms)5

DC-voltage rating 6 (V)

Contin. (W)

Instantan. (12s duration) (W)

575V C C C D E F 0.75 - 2.2 4 / 5.5 7.5 / 11 15 - 22 30 / 37 45 - 75 442 442 647 1360 1965 4420 8841 8841 12938 27203 39293 88408 120 120 82 39 27 12 8.8 8.8 12.8 26.9 38.9 87.5 1.0/17 1.0/17 1.5/15 4/11 10/7 35/2 660 660 660 660 660 660 1100 1100 1100 1100 1100 1100

The actually required rated power normally lies between these two values and depends on the operating cycle that can be expected. In case of doubt, select a larger (higher rating) resistor than required as the associated costs are relatively low. 2 Normal and minimum resistance value that should be specified. 3 Braking current in the braking controller (braking chopper) and resistor 4 Ensure that the connecting cable is suitable for the operating voltage as well as the high temperatures of the braking resistor. Shielded cables should be used. The maximum cable size and the cable connection type depend on the manufacturer of the brake resistor. 5 Minimum ground insulation 6 Maximum rated voltage of the resistor Version 1.1 issue June 2008 7/10

Calculating the braking resistors for MM4 and G120

Item-ID: 7800906 Please use columns 6, 7and 8 to select the cable for the braking resistor. All of this information should be provided to the supplier so that the correct resistor can be selected.

1.2

Examples

1.2.1

Example 1:

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A 7.5 kW 400V drive operates a lifting system that lifts for 15 seconds and then lowers for 15 seconds. Resistor duty cycle: 50% Resistor specification: 56 Ohms, 6000W continuous, 12000W instantaneous (15 seconds on, 15 seconds off), operating at up to 900V DC, 600V wrt Earth. Ambient temperature XX centigrade, protection level IPYY.

1.2.2

Example 2:

A downhill conveyer is required to provide continuous braking on an 18.5kW 400V inverter. Resistor duty cycle: 100% Losses will be high on a conveyor system, so assume 18.5kW maximum power. Resistor specification: 27 Ohms, 18.5kW continuous rating operation at up to 900V DC, 600V wrt Earth. Ambient temperature XX centigrade, protection level IPYY.

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Calculating the braking resistors for MM4 and G120

Item-ID: 7800906 1.2.3 Example 3:

A pallet handling machine using a 5.5kW 230V inverter must ramp down and stop once a minute, with a ramp down time of 5 seconds. Resistor duty cycle: 5 seconds in 60; say 10% Resistor specification: 27 Ohms, 6000W instantaneous rating, 300W continuous (5 seconds every minute) operating at up to 450V DC, 265V wrt Earth. Ambient temperature XX centigrade, protection level IPYY.

Note: The resistor specifications for this example can be taken from FAQ 8400450 MM440: Braking resistors (MLFBs and dimensions) or the SINAMICS G110/SINAMICS G120 Inverter Chassis Units SINAMICS G120D Distributed Frequency Inverters catalog in Chapter "DC link components".

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Calculating the braking resistors for MM4 and G120

Item-ID: 7800906

Appendix

2.1

Internet links
This list is by no means complete and only provides a selection of appropriate sources.

Topic \1\ \2\ \3\

Copyright Siemens AG 2008 All rights reserved PDF_Braking_resistor_calculation_en_V1.1.doc

Title MM440: Braking resistor (MLFBs and dimensions) SINAMICS G110/G120 Inverter Chassis Units SINAMICS G120D Distributed Frequency Inverters MICROMASTER4 Engineering braking chopper operation for MICROMASTER 440 Braking resistors for MICROMASTER 440

FAQ Catalog Application Instruction Sheet

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2.2

History
Table 2-1 History

Version V1.0 V1.1

Date May 2003 June 2008 First issue

Changes Text revised, Tables revised

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