Drive System Application

Transcription

1 Drive Sysem Applicaion Engineering braking chopper operaion Applicaion descripion for SINAMICS G120 and MICROMASTER 440

2 Warrany, liabiliy and suppor Noe The Applicaion Examples are no binding and do no claim o be complee regarding he circuis shown, equipping and any evenualiy. The Applicaion Examples do no represen cusomer-specific soluions. They are only inended o pro-vide suppor for ypical applicaions. You are responsible in ensuring ha he de-scribed producs are correcly used. These Applicaion Examples do no relieve you of he responsibiliy in safely and professionally using, insalling, operaing and servicing equipmen. When using hese Applicaion Examples, you recognize ha Siemens canno be made liable for any damage/claims beyond he liabiliy clause described. We reserve he righ o make changes o hese Applicaion Examples a any ime wihou prior noice. If here are any deviaions beween he recommendaions provided in hese Applicaion Examples and oher Siemens publicaions - e.g. Caalogs - hen he conens of he oher documens have prioriy. Warrany, liabiliy and suppor We do no accep any liabiliy for he informaion conained in his documen. Any claims agains us - based on whaever legal reason - resuling from he use of he examples, informaion, programs, engineering and performance daa ec., described in his Applicaion Examples shall be excluded. Such an exclusion shall no apply in he case of mandaory liabiliy, e.g. under he German roduc Liabiliy Ac ( rodukhafungsgesez ), in case of inen, gross negligence, or injury of life, body or healh, guaranee for he qualiy of a produc, fraudulen concealmen of a deficiency or breach of a condiion which goes o he roo of he conrac ( wesenliche Verragspflichen ). However, claims arising from a breach of a condiion which goes o he roo of he conrac shall be limied o he foreseeable damage which is inrinsic o he conrac, unless caused by inen or gross negligence or based on mandaory liabiliy for injury of life, body or healh The above provisions does no imply a change in he burden of proof o your derimen. Copyrigh 2008 Siemens A&D. I is no permissible o ransfer or copy hese Applicaion Examples or excerps of hem wihou firs having prior auhorizaion from Siemens A&D in wriing. If you have any recommendaions relaing o his documen hen please send hem o us a he following address: mailo:sdsuppor.aud@siemens.com Version 1.2 Issue March /27

3 reposiion reposiion Aim of he applicaion For applicaions where loads mus be quickly moved or lowered, or where higher momens of ineria mus be braked, hen power is regeneraed for a specific lengh of ime. The moor hen operaes as generaor and supplies power back ino he DC link hrough he inverer in he drive converer. This causes he DC link volage o increase. In order o avoid ha he DC link volage increases o an excessive level and an associaed faul rip, he MM440 and G120 wih M240 drive unis include funcions ha mainain he DC link volage wihin a permissible range. One of hese funcions is he braking chopper ha is inegraed as sandard in sizes A-F ( kw). When he moor regeneraes, his braking chopper dissipaes he braking energy in a braking resisor. Informaion on he mode of operaion of he braking chopper and how o engineer regeneraive braking operaion is provided in he following descripion. Exclusion This applicaion does no include a descripion of The individual drive inverer The STARTER Tool The puing ino operaion of primary conrols I is assumed ha he reader has basic knowledge abou hese subjecs. Reference o he Auomaion and Drives Service & Suppor This aricle is from he Inerne Applicaion oral of he Auomaion and Drives Service & Suppor. You can go direcly o he download page of his documen using his link. hp://suppor.auomaion.siemens.com/ww/view/en/ Version 1.2 Issue March /27

4 Table of Conens Table of Conens Table of Conens Mode of operaion of he braking chopper in he MM440 and G120 wih M Response hreshold of he braking chopper Load duy cycles and he load capabiliy of he braking chopper Engineering braking operaion Maximum braking power Average braking power Informaion on columns 1 8 of Table 1 and 2: Example o calculae and check he maximum and average braking power Checking he maximum braking power Checking he average braking power Flow diagram Braking resisors Connecing he braking resisor Thermal proecion for he braking resisor Operaion ogeher wih oher ypes of braking DC link volage conroller Summary of he frequency converer parameers ha are imporan for regeneraive operaion References Reference daa Hisory Version 1.2 Issue March /27

5 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 1 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 The braking chopper in he MM440 and SINAMICS G120 wih M 240 essenially comprises an IGBT ransisor. If braking operaion is acivaed by he drive converer parameer 1237, hen he braking chopper is auomaically swiched-in a a specific DC link volage when he moor is regeneraing. Above his chopper swich-in hreshold VDCChopper, he DC link is conneced o an exernal braking resisor via he clocked braking ransisor (refer o Fig. 1). While he braking ransisor is conducing, a 2 VDCChopper power of Brakingresisor max is dissipaed in he braking RBrakingresisor resisor. The braking chopper is pulsed wih a frequency of 2 khz. This corresponds o a period of 500µs (refer o Fig. 2). ~ MM440 ~ Braking resisor B+ / DC+ Chopper conrol B- ~ Fig. 1: rinciple design of he MM440 and G120 drive converer wih braking chopper (a he G120 wih M240 he clamps for he braking resisor are called DC/R1 and R2). Version 1.2 Issue March /27

6 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 f V DC V DC, ac V DC, chopper Chopper, ON Chopper acive Chopper 1 f Chopper Hz Fig. 2: Clocking he braking chopper for regeneraive operaion wih he seleced load duy cycle. When he moor is regeneraing and he DC link volage VDC increases, hen he braking chopper auomaically swiches iself on he chopper swich-on hreshold VDCChopper. If he regeneraive power presenly fed back from he moor ino he drive converer DC link is less han he power dissipaed in he braking resisor a he chopper swich-on hreshold, hen he DC link volage again falls below he chopper swich-on hreshold and he braking chopper swiches iself off afer 2ms. When he DC link volage increases again, he braking chopper again swiches-on and he procedure is repeaed (refer o Fig. 3). Version 1.2 Issue March /27

7 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 f V DC V DC, chopper V DC, ac Chopper acive 2ms Fig. 3: Braking chopper operaion for low regeneraive power If he braking power presenly regeneraed by he moor is greaer han he braking power dissipaed in he braking resisor a he chopper hreshold, hen in spie of he fac ha he braking resisor is swiched-in, he DC link volage coninues o increase up o a poin, where he DC link volage corresponds o he regeneraive braking power. A his value, he DC link volage sabilizes wih a braking power ha is sill available and he braking chopper is permanenly swiched-on (refer o Fig.4). This coninuous operaion is only briefly inerruped for approx. 10µs afer 500µs (braking chopper is clocked wih 2 khz). The procedure is hen appropriaely repeaed. However, he brief inerrupion of coninuous operaion for 10µs can be negleced and has no been aken ino accoun in hese diagrams. This coninuous operaion can be used for a maximum duraion ON. This ime depends on he magniude of he load duy cycle seleced in 1237 (refer o Fig. 6). Version 1.2 Issue March /27

8 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 f V DC, ac V DC V DC, chopper Chopper acive e.g. 5s Fig. 4: Braking chopper operaion for higher regeneraive power e.g. due o higher load momens of ineria Afer he maximum duraion ON has expired for he coninuous operaion he drive converer goes ino he load duy cycle se using This is o hermally proec he conneced braking resisor. The load duy cycle is hen formed as a resul of he raio beween he swich-on ime chopperon and he chopper cycle ime chopper ( 500µs). For a load duy cycle se in 1237 of e.g. 5%, he swich-on ime chopperon is herefore 25µs (refer o Fig. 5). Version 1.2 Issue March /27

9 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 f V DC, ac V DC V DC, chopper 25µs Chopper acive 12s Fig. 5: Example for coninuous operaion wih a subsequen load duy cycle of 5% The maximal value for he DC link volage in braking operaion is he drive converer over volage shudown hreshold VDC max which is lised in Table 1 and 2 for he paricular drive converer. The maximum possible braking power o be dissipaed can be calculaed form his: brakingres isor max VDC max R min 2 However, his value is a peak value ha in pracice canno be fully uilized because of he proximiy o he over volage shudown (rip) hreshold. For safe braking operaion wih a sufficien safey margin o he over volage shudown hreshold, hen 5% mus be subraced from his maximum braking power. brakingresisor max 500µs There is sill a ransiion area available above he chopper swich-on hreshold VDCchopper. In his range, he braking chopper lineally increases he on-o-off raio during he chopper cycle ime chopper ( 500µs) linearly o a value of 100% depending on he ampliude of he DC link volage. The DC link volage range Δ VDC for his ransiion is, for drive unis wih line supply volages of 1/3-ph V AC equal o 9.8V DC 3-ph V AC equal o 17.0V DC 3-ph V AC equal o 21.3V DC Version 1.2 Issue March /27

10 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 However, his ransiion range above he chopper swich-on hreshold VDCChopper is negleced for reasons of simplificaion. 1.1 Response hreshold of he braking chopper The swich-on hreshold for he braking chopper VDCChopper is auomaically deermined in he MM440 and G120 wih M240 drive converer each ime he power is conneced (a each power-up). An appropriae reference value is saved in parameer r1242. The swich-on hreshold for he braking chopper VDCChopper is in his case 98% of he reference value deermined in parameer r1242 ( VDCChopper 0.98 r1242 ). The auomaic deerminaion of he DC link volage reference value r1242 can also be deseleced using parameer The swich-on hreshold for he braking chopper VDCChopper hen depends on parameer 0210 (line supply volage): VDCChopper The magniude of he value for he swich-on hreshold of he braking chopper VDCChopper does no deermine he maximum possible braking power of he drive converer. The reason for his is ha for an appropriaely high braking power of he moor, he DC link volage can sill coninue o increase while he braking chopper is operaional. 1.2 Load duy cycles and he load capabiliy of he braking chopper In order o proec he conneced braking resisor, a load duy cycle for braking operaion mus be enered a he MM440 and G120 wih M240 frequency converer using parameer For he braking resisors assigned o he MM440 frequency converer in Caalog DA51.2 and for G120 wih M240 frequency converer in Caalog DA11.1, a permissible load duy cycle is specified as 5%. The braking chopper inegraed in he MM440 and G120 frequency converer can have a coninuous load of he 2 VDC max maximum braking power Brakingres isor max Rmin (refer o able 1 and 2). However, in his case i is imporan ha he frequency converer can handle his level of power wih is inverer (overload capabiliy of he frequency converer) and he conneced braking resisor is designed for his power raing. If he maximum frequency converer power (overload capabiliy, 200% for 3s) is less han he maximum braking power of he inegraed braking chopper Brakingresisor max, hen his power is he maximum braking power ha can be achieved. Version 1.2 Issue March /27

11 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 When selecing a specific load duy cycle for braking operaion in parameer 1237 (e.g. 5% when using he MM440 or G120 braking resisors), hen for a appropriaely high braking power, he braking chopper can brake for he maximal duraion ON wih he maximum braking power Brakingresisor max. Afer his ime expires, he seleced load duy cycle (e.g. 5%) us forcibly seleced by he swich-on o swich-off raio during he chopper cycle ime chopper ( 500µs) (refer o Fig. 5). If he acual braking power is hen higher han ha corresponding o he seleced load duy cycle, hen he DC link over volage shudown poin (rip poin) wih a faul message. In his case, a higher load duy cycle should be se in parameer 1237 using a suiable braking resisor. For a single braking operaion, he drive can brake wih he maximum braking power Brakingresisor max for he maximum duraion ON followed by he coninuous power Brakingresisoraverage. For cyclic operaions, afer braking wih he maximum braking power Brakingresisor max for he maximum duraion ON, here mus be a no-load ime OFF before he maximum braking power Brakingresisor max can be used again (refer o Fig. 6). Depending on he seing of he load duy cycle in parameer 1237, differen values for he maximum duraion ON wih maximum braking power Brakingresisor max, no-load inerval ime OFF and he load duy cycle duraion cyclechopper are obained. The appropriae values are shown in Fig. 6 ha mus be used as basis when engineering braking operaion. resisor max 1237 ON OFF cycle chopper resisor aver. 5 % % resisor average ON OFF cycle Chopper 20 % % % Infinie 0 Infinie 1.00 Fig. 6: Swich-on and no-load inerval ime ( ON and OFF ) as well as he load duy cycle duraion cyclechopper as a funcion of parameer 1237;, ON OFF and cyclechopper in (s). Version 1.2 Issue March /27

12 Mode of operaion of he braking chopper in he MM440 and G120 wih M240 The above menioned braking profile only defines he maximum load capabiliy of he braking chopper as a funcion of he load duy cycle se in parameer 1237 o proec he conneced braking resisor. However, in pracice and depending on he applicaion, he iming/sequence of he braking operaion can differ. A check as o wheher his applicaion-specific braking profile can be achieved wih he frequency converer is described in he following ex. Version 1.2 Issue March /27

13 Engineering braking operaion 2 Engineering braking operaion When engineering he drive for braking operaion, o sar, he maximum and average braking power for he applicaion mus be deermined. In his case, for example, he SIZER program from version 2.1 onwards can be used. However, i should be noed ha he SIZER program uses a load duy cycle duraion of 90s as basis when calculaing he average braking power for he applicaion. If he load duy cycle duraion, which is obained from he seleced load duy cycle wih parameer 1237, is greaer han 90s, hen he average braking power can be aken from he SIZER program. For a seleced load duy cycle of 5% ( cyclechopp er 240s ) and 10% ( cyclechopp er s ) his is guaraneed. For a load duy cycle ha is seleced o be 20% in parameer 1237, he load duy cycle duraion cyclechopper is less han 90s and his means ha he value from he SIZER program canno be used o check he average braking power (refer o Fig. 6). 2.1 Maximum braking power In his case a check mus be made as o wheher he maximum braking power occurring in he applicaion appl max can be dissipaed in he braking resisor. In his case, he following condiion mus be fulfilled: Brakingappl max Brakingresisor max Brakingappl max : Maximum peak braking power ha occurs for he applicaion Brakingresisor max : Maximum possible peak braking power of he braking chopper wih he seleced braking resisor (refer o Table 1 and 2) The maximum possible peak braking power of he braking chopper Brakingresisor max depends on he resisor value of he conneced braking resisor. I is calculaed as follows: Brakingresisor max VDC max R 2 Brakingresisor Version 1.2 Issue March /27

14 Engineering braking operaion As has already been menioned, his value is a peak value ha canno be fully uilized in pracice because of he proximiy o he over volage shudown hreshold. For safe braking operaion wih a sufficien safey margin o he over volage shudown hreshold, 5% mus be subraced from his maximum braking power. Brakingresisor max A minimum resisor value R min mus be mainained in order o proec he chopper ransisor (refer o Table 1 and 2). The peak braking power of he braking chopper Brakingresisor max ha can be achieved wih his minimum resisor value is herefore a maximum value. A prerequisie when uilizing he maximum peak braking power of he braking chopper is ha he maximum frequency converer oupu curren (overload curren) is no reached when he moor is regeneraing. The overload capabiliy of he MM440 and G120 wih M240 frequency converer in sizes A-F is as follows: For MM x frequency converer raed oupu curren for 3s every 300s 1.5 x frequency converer raed oupu curren for 60s every 300s For G120 wih M x frequency converer raed oupu curren for 3s every 300s 1.5 x frequency converer raed oupu curren for 57s every 300s The maximum moor curren occurring for he paricular applicaion can e.g. be calculaed using he SIZER program. 2.2 Average braking power The average braking power is predominanly checked o hermally proec he conneced braking resisor. The braking resisors assigned o he MM440 frequency converer in Caalog DA52.1 and for G120 wih M240 in Caalog DA11.1 have an average braking power of approx. 5% of he maximum braking power (refer o Table 1 and 2). If his average braking power of he MM440/G120 braking resisor is oo low for he applicaion, hen when 4x MM440/G120 braking resisors are used, he available coninuous braking power can be increased o 20% of he maximum braking power. To realize his, he braking resisors are conneced as shown in Fig. 7. Version 1.2 Issue March /27

15 Engineering braking operaion R R R R R B+ B- B+ B- Chopper conrol Chopper conrol (5 %) (20 %) Fig. 7: Increasing he coninuous braking power using 4x MM440/G120 braking resisors (a he G120 wih M240 he clamps for he braking resisor are called DC/R1 and R2) As an alernaive, oher barking resisors can be used e.g. from he MASTERDRIVES produc range. When he braking resisors are appropriaely dimensioned, he average braking power can be increased up o 100% of he maximum braking power. However in his case he prerequisie up o 100% of he frequency converer raed oupu curren is no exceeded. The load duy cycles, shown in Fig. 6, can be seleced using parameer For a load duy cycle of e.g. 5%, his means ha he average permissible braking power is approx. 5% of he Brakingresisoraverage maximum braking power. In operaion, he frequency converer moniors he braking resisor load and limis his o he seleced value, when he load duy cycle is se and herefore he average permissible braking power in 1237, hen his also modifies he load duy cycle duraion cyclechopper of he braking chopper (refer o Fig. 6). If he load duy cycle of he applicaion cycleappl is less han he load duy cycle duraion cyclechopper of he braking Brakingapplaverage chopper, hen he average braking power of he applicaion can be direcly compared o he average permissible braking power : Brakingresisoraverage cycleappl cyclechopper Brakingapplaverage Brakingresisoraverage For a longer load duy cycle duraion of he applicaion cycleappl ( cycleappl > cyclechopp er ), a ime slice wih a duraion of cyclechopper mus be seleced from he applicaion load duy cycle where he average value of he braking power is he highes. This value for Brakingapplaverage Brakingapplaverage is hen used o make he check. Version 1.2 Issue March /27

16 Engineering braking chopper operaion Engineering braking operaion MM440 braking resisor Order No. 6SE6400- Frequency converer frame size Frequency converer inpu volage (V) Frequency converer power raing CT (kw) Coninuous braking power (W) Maximum braking power (W) MM440 braking resisance value / R min (Ω) Maximum DC link volage V DC max (V) 4BC05-0AA0 A BC11-2BA0 B BC12-5CA0 C BC13-0CA0 C BC18-0DA0 D BC21-2EA0 E BC22-5FA0 F BD11-0AA0 A BD12-0BA0 B BD16-5CA0 C BD21-2DA0 D BD22-2EA0 E BD24-0FA0 F BE14-5CA0 C BE16-5CA0 C BE21-3DA0 D BE21-9EA0 E BE24-2FA0 F Table 1: Technical daa for braking chopper operaion using he MM440 and G120 wih M240 for Sizes A-F (power raings from 0.12 o 75kW) Version 1.2 Issue March /27

17 Engineering braking chopper operaion Engineering braking operaion For frame size B here is a special braking resisor for SINAMICS G120 wih he following daa: MM440 braking resisor Order No. 6SL3201- Frequency converer frame size Frequency converer inpu volage (V) Frequency converer power raing CT (kw) Coninuous braking power (W) Maximum braking power (W) MM440 braking resisance value / R min (Ω) Maximum DC link volage V DC max (V) 0BE12-0AA0 B Table 2: Technical daa for braking chopper operaing using he G120 special for frame size B. Version 1.2 Issue March /27

18 Engineering braking operaion 2.3 Informaion on columns 1 8 of Table 1 and 2: Column: 1) Order number of he assigned MM440/G120 braking resisor 2) Applicable frame size of he frequency converer 3) Frequency converer inpu volage 4) ower range of he frequency converer for he paricular frame size 5) Coninuous braking power Brakingresisoraverage of he assigned MM440/G120 braking resisor wih a load cycle duraion of 240s. 6) Maximum achievable peak braking power Brakingresisor max of he inegraed braking chopper. However, his peak value is only reached if he DC link volage, during braking increases up o he shudown hreshold (rip hreshold) of he frequency converer due o a high braking power ha has o be dissipaed. In pracice, he value specified in column 6 canno be fully uilized because of he proximiy o he over volage shudown hreshold. In order o achieve safe braking operaion wih sufficien safey margin o he over volage shudown hreshold, hen 5% mus sill be subraced from he maximum braking power. The maximum Brakingresisor max peak braking power of he inegraed braking chopper is limied by he max. frequency converer power (overload capabiliy, 200% for 3s and 150% for 60s for MM440, overload capabiliy for G120, 200% for 3s and 150% for 57s). The inegraed braking chopper can also be coninually loaded wih he specified peak braking power. However, his value is limied from he maximum possible coninuous power of he frequency converer. Furher, a suiable braking resisor mus be used. 7) Value of he resisance of he assigned MM440/G120 braking resisor. This is also he minimum resisance value of an exernal resisor ha can be conneced. 8) Maximum DC link volage ha can be reached unil he frequency converer is shudown due o an over volage condiion. 2.4 Example o calculae and check he maximum and average braking power A grinding disk drive is o be braked from a speed of 2900 RM down o sandsill (refer o Fig. 8); in his case he effec of fricion is negleced. The oher applicaion daa include: Frequency converer raed power: conv 5. 5kW Version 1.2 Issue March /27

19 Engineering braking operaion Max. braking power of he braking chopper in he freq. converer: 12. kw Brakingresisor max 6 Moor raed power: moorn 5. 5kW Moor efficiency: η Moor raed speed: moor n moorn 2925RM Moor momen of ineria: J moor 0.015kgm 2 Momen of ineria of he grinding wheel (referred o he moor): 2 J grind 0.4kgm Max. moor speed for he applicaion: Grinding disk braking ime: Brakeappl 5s n max 2900RM Load duy cycle duraion of he applicaion: n moor M brake appl 5s cycleappl 15s brake brake appl max 15s brake appl average Fig. 8: Characerisic of he braking orque and he braking power for he applicaion example Version 1.2 Issue March /27

20 Engineering braking operaion Checking he maximum braking power Braking orque: M Brakeappl ( J moor + J grind ) nmax 9.55 brakeappl 2 2 (0.015kgm + 0.4kgm 2900RM M Brakeappl 25. 2Nm s M Brakeappl nmax Maximum braking power: Brakeappl max η moor Nm 2900RM Brakeappl max kW 9.55 This means ha he condiion Brakeappl max ( 6.6kW ) Brakingres isor max (12.6kW ) is fulfilled Checking he average braking power Average braking power in he applicaion load duy cycle 15s: 1 Brakeappl applaverage appl max 2 cycleappl 1 5s applaverage 6.6kW 1. 1kW 2 15s A suiable braking resisor mus now be seleced wih he average braking power of Brakeappla verage 1. 1kW and he load duy cycle duraion of he applicaion cycleappl 15s. The braking resisor assigned in Caalog DA51.2 and Caalog DA11.1 wih an average permissible braking power Brakingres isoraverage 0. 65kW is oo small for his applicaion. For he applicaion example, 4x MM440/G120 braking resisors can be used ha mus be conneced-up as shown in Fig. 7. The permissible average braking power Brakingresisoraverage is hen kW 2. 6kW and is herefore sufficien. The load duy cycle a he frequency converer mus be se o 3 (20%) in he MM440/G120 parameer 1237; he load duy cycle duraion of he braking chopper cyclechopper hus obained is wih 71.2s (refer o Fig. 6) greaer han he load duy cycle duraion of he applicaion cycleappl 15s. The condiions: cycleappl ( 15s) cyclechopp er (71.2s) and Version 1.2 Issue March /27

21 Engineering braking operaion Brakeapplaverage are herefore fulfilled. ( 1.1kW ) (2.6kW ) Brakingresisoraverage As an alernaive, anoher individual braking resisor can be used ha can dissipae he average braking power. A suiable braking resisor from he MASTERDRIVES produc range is he resisor wih Order No. 6SE7018-0ES87-2DC0. This has a permissible average braking power of 1.24kW, a resisor value of 80Ω and a cycle ime of 90s. A subsequen calculaion is required due o he higher resisor value wih respec o he MM440/G120 braking resisor (56Ω). The maximum peak braking power ha can be dissipaed in he 80Ω resisor is given by: VDC max R V 80Ω 2 2 Brakingresisor max Brakingresisor kw This value is higher han he max. braking power of he applicaion (6.6kW) and is herefore adequae. In order o be able o dissipae he average braking power of he applicaion Brakeappla verage 1. 1kW, a load duy cycle duraion of 20% should be se in parameer The frequency converer load duy cycle monioring limis he average braking power o 20% of Brakingresisor max (20% of 8.82kW) 1.76kW; however his is no reached in his paricular applicaion. The cycle ime (90s) of he braking resisor is greaer han he load duy cycle duraion of he braking chopper cyclechopper (71.2s). This means ha i is no overloaded for his paricular load duy cycle. Informaion: For his applicaion, i is no possible o connec 2x MM440/G120 braking resisors in series as he oal (summed) resisor of 2 56Ω 112Ω would resul in a maximum peak braking power of 6.3kW ha is oo small. The maximum braking power Brakingresisor max from Table 1 and 2 is no achieved for he applicaion example so ha sufficien safey margin o he over volage shudown hreshold is guaraneed. 2.5 Flow diagram The following flow diagram (Fig. 9) clearly shows he procedure on how he braking powers are checked. Version 1.2 Issue March /27

22 Engineering braking operaion Sar The maximum occurring braking power for he applicaion Brake appl max is calculaed The average braking power for he applicaion Brake appl average is calculaed The peak braking power of he braking chopper braking resisor max is deermined form Table 1 and 2 The permissible average braking power of he braking resisor Braking resisor average is deermined; for he MM440/G120 braking resisor. Values from able 1 und 2 Brake appl max < Braking resisor max Use he higher values Brakingresisor max and Brakingresisoraverage of he higher raing frequency converer Brake appl average < Braking resisor average Is i possible o use a larger MM440/G120 frequency converer wih a higher maximum braking power? Is i possible o ener modified applicaion daa, e.g. a longer ramp-down ime? I is no possible o use he MM440/G120 for he seleced applicaion The seleced MM440/G120 frequency converer and braking resisor can be used End The seleced braking resisor canno be used. Remedy: Use 4x MM440/G120 braking resisors load duy cycle 20% Use anoher suiable braking resisor (e.g. from he MASTERDRIVES produc range) load duy cycle up o 100% In so doing he following values should be mainained: R Braking resisor > R min Brake appl max < Braking resisor max Brake appl average < Braking resisor average End End Fig. 9: Flow diagram o check he braking powers Version 1.2 Issue March /27

23 Engineering braking operaion 2.6 Braking resisors The MM440/G120 braking resisors, assigned in Caalog DA51.2 and Caalog DA11.1 are predominanly used as he braking resisors (refer o Table 1 and 2). The average braking power of he braking resisors is approx. 5% of he maximum braking power Brakingresisoraverage Brakingresisor max (5% load duy cycle). In order o increase Brakingresisoraverage, 4x braking resisors according o Fig. 7 can be used. In his case, 400% of he average braking power can be reached; he load duy cycle (parameer 1237) can be se o 20%. However, he maximum braking power Brakingresisor max does no change as he resuling value of he resisance a R min remains he same. As an alernaive, oher braking resisors wih a higher average braking power Brakingresisoraverage (e.g. from he MASTERDRIVES produc range) can be used. In his case he following condiions mus be mainained: Required volage srengh of he braking resisors: 1/3-ph. 200V 240V AC devices: 450V DC 3-ph. 380V 480V AC devices : 900V DC 3-ph. 500V 600V AC devices : 1100V DC RBrakingres R (values for R min refer o Table 1 and 2) isor min Brakeappl max Brakingres isor max The maximum peak braking power ha can be achieved wih he braking resisor: Brakingresisor max VDC max R 2 Brakingresisor (minus 5% due o he safey margin o he over volage shudown limi) Brakeapplaverage Brakingresisoraverage (he load duy cycle of he resisor mus in his case be greaer han he load duy cycle duraion of he braking chopper ) cyclechopper Version 1.2 Issue March /27

24 Engineering braking operaion The following applies: R Brakingresisor : Resisance of he exernal braking resisor R min : Lowes possible value of resisance - corresponds o he resisance of he assigned MM440/G120 braking resisor Brakeapplaverage : Average braking power of he applicaion Brakingresisoraverage : Coninuous power of he braking resisor Brakeappl max : eak braking power of he applicaion Brakingresisor max : eak braking power of he braking resisor VDC max : Maximum DC link volage (refer o Table 1 and 2) The Inerne addresses of poenial braking resisor manufacures are lised in he following. The informaion provided by he suppliers when using braking resisors mus be carefully observed. REO, D Solingen hp:// GINO, D Bonn hp:// Koch, D Ubsad hp:// Connecing he braking resisor The braking resisor is conneced a erminals B+/DC+ and B- of he frequency converer MM440 (a he SINAMICS G120 wih M240 he clamps are called DC/R1 and R2). In order o avoid EMC noise emission, he connecing cable mus be shielded and he shield mus be conneced a boh ends. The EMC Design Guidelines mus be carefully observed, including he spaial separaion of power and signal cables. Addiional informaion and insrucions for an EMC-correc design are included in he EMC Design Guidelines for MICROMASTER. The maximum disance beween he MM440 frequency converer and braking resisor (Sizes A-F) is 25m (shielded). For he SINAMICS G120 wih M240 he maximum disance beween frequency converer and braking resisor is 15m. Formaier: Ialienisch (Ialien) Feldfunkion geänder Formaier: Ialienisch (Ialien) Formaier: Ialienisch (Ialien) Version 1.2 Issue March /27

25 Engineering braking operaion Thermal proecion for he braking resisor The conneced MM440/G120 braking resisor is hermally moniored using he load duy cycle monioring of he frequency converer. To realize his, parameer 1237 should be se o 1 (5% load duy cycle) or for 4x conneced MM440/G120 braking resisors as shown in Fig. 7 he value 3 (20% load duy cycle). When hird-pary braking resisors are used, under cerain circumsance, he permissible average braking power of he resisor doesn precisely correspond o he load duy cycle seleced in By evaluaing a hermo swich, provided in he braking resisor, his can however be hermally proeced. 2.7 Operaion ogeher wih oher ypes of braking Regeneraive braking using braking resisors is he mos effecive and mos accurae braking echnique for he MM440 and G120 wih M240 drive unis. When he resisor braking is acivaed using parameer 1237, i is no permissible ha compound braking (1236) is used. The compound braking swiches iself in, dependen on he magniude of he DC link volage, a he same swich-on hreshold as for he braking chopper. If boh braking ypes were o be simulaneously used, hen his would cause he frequency converer o malfuncion. When required, DC braking (parameer ) can be swiched-in if, for example, a holding orque should be provided when he moor is a a sandsill. 2.8 DC link volage conroller If he braking chopper of he frequency converer is acivaed, han he VDC max conroller of he frequency converer (parameer 1240) mus be deacivaed as boh funcions muually influence one anoher and can cause he frequency converer o malfuncion. The VDC min conroller of he frequency converer can however be acivaed (kineic buffering, ha can also be se using parameer 1240). Version 1.2 Issue March /27

26 Engineering braking operaion 2.9 Summary of he frequency converer parameers ha are imporan for regeneraive operaion MM440 and G120 parameers Commen 1121 Ramp-down ime: Longer ramp-down imes resul in a lower maximum braking power. The maximum braking power occurs a he beginning of he ramp down Ramp-down iniial rounding ime: An ramp-down iniial rounding-ime reduces he maximum braking power DC braking: This can, for example, be acivaed o lock he moor afer regeneraive braking down o zero speed (resisor braking) Compound braking: This may no be simulaneously acivaed wih he resisor braking due o he same response hresholds Resisor braking: This is acivaed by seing a value greaer han "0". This eners he load duy cycle for he braking chopper V DC conroller: When resisor braking is acivaed, his may no be se o he value 1 or 3. r1242 Swich-on signal level V DC max conroller: The braking chopper swichesin a V DC chopper 0.98 r1242. The value for r1242 is newly sensed each ime ha he frequency converer is conneced o he line supply Auomaically sensing he V DC max swich-in level: This funcion is deacivaed for he seing "0". Seing hen wih 210 (line supply volage). Version 1.2 Issue March /27

27 References 3 References 3.1 Reference daa This lis is in no way complee and only reflecs a selecion of suiable references. Table 3-1 Subjec area Tile /1/ Caalog D11.1 SINAMICS G110/G120 Inverer chassis unis SINAMICS G120D Disribued frequency inverers /2/ Caalog DA51.2 Frequency inverers MICROMASTER 420/430/440 /3/ Manuals SINAMICS G120 /4/ Manuals MICROMASTER 4 /5/ Manuals MICROMASTER 4: EMC Design Guideline /6/ Up dae [Inrane] 3.2 Hisory Release for sale, exended power raings for SINAMICS M240 Framesize F 110 kw and 132 kw Table 3-2 Hisory Version Daum Change V1.0 March 2004 Firs ediion V1.1 June 2006 V1.2 March 2008 Tex revised, inser G120 / M240 daa Version 1.2 Issue March /27