Download Altivar 66/58/18 Dynamic Braking Resistor Kits User`s Manual

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Bulletin No. VD0C06N908C
July 1998
ALTIVAR 66, 58, 18 Dynamic Braking Resistor Kit
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LOSS OF BRAKING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PART 1: ALTIVAR 66 DYNAMIC BRAKING RESISTOR KIT . . . . . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Current-Time Characteristic for DB Resistor Assemblies . . . . . . . . . . . . . . . . . . . . . . . 8
Pre-Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bus Voltage Measurement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting Instructions for Kits VW3A66711, -712, -714 . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting on Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wall Mounting Separately from Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mounting Instructions for Kits VW3A66715, -716, -717 (QTY 1) . . . . . . . . . . . . . . . . 18
Mounting on Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mounting on ALTIVAR 66 Units ATV66C10N4, C13N4, C15N4, C19N4 . . . . . . . 21
Mounting Separately from Controller and/or Controller Enclosure . . . . . . . . . . . . 22
Mounting Instructions for Kits VW3A66717 (QTY 2) AND -718 (QTY 2) . . . . . . . . . . 23
Mounting on ALTIVAR 66 Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mounting Separately from Drive Controller and/or Enclosure . . . . . . . . . . . . . . . . 24
PART 2: ALTIVAR 58 DYNAMIC BRAKING RESISTOR KIT . . . . . . . . . . . . . . . . . . . . . 35
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Current-Time Characteristic for DB Resistor Assemblies . . . . . . . . . . . . . . . . . . . . . . 36
Pre-Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Bus Voltage Measurement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mounting Instructions for Kits VW3A66711, -712, -713, -714 . . . . . . . . . . . . . . . . . . . 41
Mounting on Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wall-Mounting Separately from Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . 42
PART 3: ALTIVAR 18 DYNAMIC BRAKING RESISTOR KIT . . . . . . . . . . . . . . . . . . . . . 47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Current-Time Characteristic for DB Resistor Assemblies . . . . . . . . . . . . . . . . . . . . . . 48
© 1997 Square D All Rights Reserved
i
Chpt 1Book.book Page ii Sunday, August 10, 2003 5:59 PM
ALTIVAR 66, 58, 18 Dynamic Braking Resistor Kit
Contents
Bulletin No. VD0C06N908C
July 1998
Pre-Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Bus Voltage Measurement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Drive Controllers ATV18•••M2 and ATV18U18N4 to D12N4 . . . . . . . . . . . . . . . . 51
Drive Controllers ATV18D16N4 and ATV18D23N4 . . . . . . . . . . . . . . . . . . . . . . . 52
Mounting Kits VW3A66711, -712, -713, -714 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Mounting on Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wall-Mounting Separately from Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . 55
APPENDIX A: CALCULATING DYNAMIC BRAKING RESISTOR REQUIREMENTS FOR
ALTIVAR 66 CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
APPENDIX B: CALCULATING DYNAMIC BRAKING RESISTOR REQUIREMENTS FOR
ALTIVAR 58 CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
APPENDIX C: CALCULATING DYNAMIC BRAKING RESISTOR REQUIREMENTS FOR
ALTIVAR 18 CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ii
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page iii Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
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Figure 36:
ALTIVAR 66, 58, 18 Dynamic Braking Resistor Kit
Contents
Dynamic Braking Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Terminal Strip Locations: ATV66U41N4 to D79N4 . . . . . . . . . . . . . . . . . . . 13
Terminal Strip Locations: ATV66C10N4 to C19N4 . . . . . . . . . . . . . . . . . . . 14
Terminal Strip Locations: ATV66C23N41 to C31N41 . . . . . . . . . . . . . . . . . 15
Removing Cover and Bottom Pan: VW3A66711, 712, 713, 714 . . . . . . . . 26
Removing Cover and Bottom Pan: VW3A66715, 716, 717, 718 . . . . . . . . 26
Enclosure Mounting Dimensions: VW3A66711, 712, 713, 714 . . . . . . . . . 27
Enclosure Mounting Dimensions: VW3A66715, 716, 717, 718 . . . . . . . . . 28
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Liquid-Tight Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dynamic Braking Resistor Assy Terminals: VW3A66711, 712, 713, 714 . 29
Dynamic Braking Resistor Assy Terminals: VW3A66715, 716, 717, 718 . 30
Wall Mounting Dimensions: VW3A66711 and VW3A66712 . . . . . . . . . . . . 30
Wall Mounting Dimensions: VW3A66713 and VW3A66714 . . . . . . . . . . . . 31
Mounting Dimensions: VW3A66715, 716, 717, 718 . . . . . . . . . . . . . . . . . . 32
Mounting on ALTIVAR 66 Drive Controller: VW3A66716, 717 . . . . . . . . . . 33
Mounting on ALTIVAR 66 Drive Controller: VW3A66717, 718 . . . . . . . . . . 34
Dynamic Braking Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DC Bus Measurement Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removing Cover and Bottom Pan: VW3A66711, 712, 713, 714 . . . . . . . . 43
Enclosure Mounting Dimensions: VW3A66711, 712, 713, 714 . . . . . . . . . 43
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Liquid-Tight Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Dynamic Braking Resistor Assy Terminals: VW3A66711, 712, 713, 714 . 45
Wall Mounting Dimensions: VW3A66711 and VW3A66712 . . . . . . . . . . . . 45
Wall Mounting Dimensions: VW3A66713 and VW3A66714 . . . . . . . . . . . . 46
Dynamic Braking Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Measuring Bus Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ATV18 Power Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removing Cover and Bottom Pan: VW3A66711, 712, 713, 714 . . . . . . . . 56
Enclosure Mounting Dimensions: VW3A66711, 712, 713, 714 . . . . . . . . . 57
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Liquid-Tight Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Dynamic Braking Resistor Assy Terminals: VW3A66711, 712, 713, 714 . 58
Wall Mounting Dimensions: VW3A66711 and VW3A66712 . . . . . . . . . . . . 59
Wall Mounting Dimensions: VW3A66713 and VW3A66714 . . . . . . . . . . . . 59
© 1997 Square D All Rights Reserved
iii
Chpt 1Book.book Page iv Sunday, August 10, 2003 5:59 PM
ALTIVAR 66, 58, 18 Dynamic Braking Resistor Kit
Contents
iv
Bulletin No. VD0C06N908C
July 1998
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 5 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Introduction
INTRODUCTION
This bulletin contains installation instructions for the dynamic braking
resistor kits for ALTIVAR 66 (ATV66), ALTIVAR 58 (ATV58), and
ALTIVAR 18 (ATV18) drive controllers:
• For ALTIVAR 66 controllers, see Part 1, page 6.
• For ALTIVAR 58 controllers, see Part 2, page 35.
• For ALTIVAR 18 controllers, see Part 3, page 47.
WARNING
OVERSPEED HAZARD
•
•
Generation of braking torque throughout the operating speed
range of the drive controller requires that dynamic braking be
present and operating.
Dynamic braking resistor must be selected to generate required
torque.
NO HOLDING TORQUE
• Dynamic braking does not provide holding torque at zero speed.
• Dynamic braking does not function during loss of power or drive
controller fault.
• When required, use separate braking function for holding torque.
LOSS OF BRAKING TORQUE
The dynamic braking resistor contains an internal thermal protection
switch to open the circuit if the resistor is overloaded. THIS CAN
RESULT IN DRIVE CONTROLLER SHUTDOWN AND LOSS OF
BRAKING TORQUE.
• Always verify that the dynamic braking resistor assembly has
sufficient capacity for the application.
• Provide alternative braking means in safety-critical applications.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.
© 1997 Square D All Rights Reserved
5
Chpt 1Book.book Page 6 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Contents of Kit
Bulletin No. VD0C06N908C
July 1998
PART 1: ALTIVAR 66 DYNAMIC BRAKING RESISTOR KIT
Introduction
The dynamic braking resistor kit allows ATV66 drive controllers to
function in quadrants 2 and 4 of the speed/torque curve, dissipating the
excess braking energy in an external resistor.
Contents of Kit
This kit contains:
•
•
•
•
One dynamic braking resistor assembly
Four liquid-tight nylon sleeves
One liquid-tight three-hole bushing
Six danger labels: two French (52012-664-02); two German (52012664-03); two Spanish (52012-664-04)
• Instruction Bulletin VD0C06N908_ (latest revision)
6
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 7 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Technical Specifications
Technical Specifications
Table 1:
Braking Resistor Kit Technical Specifications
For Drives [1]
Ohmic
Value
Continuous
Catalog
Current Rating
Number
[2]
of Assembly
Quantity
of Kits
Used
Rdb
Ir
ATV66U41N4, U54N4,
U72N4
120 ¾
1.0 A
VW3A66711
1
ATV66U90N4, D12N4
56 ¾
1.45 A
VW3A66712
1
ATV66D16N4, D23N4
28 ¾
2.7 A
VW3A66713
1
ATV66D33N4, D46N4
14 ¾
3.8 A
VW3A66714
1
ATV66D54N4
10 ¾
10.0 A
VW3A66715
1
ATV66D64N4, D79N4
5¾
14.0 A
VW3A66716
1
ATV66C10N4, C13N4,
C15N4, C19N4
2.5 ¾
20.0 A
VW3A66717
1
ATV66C23N41
2 ¾ [3]
32.0 A [4]
VW3A66718
2 [5]
ATV66C28N41, C31N41
1.25 ¾ [3]
40.0 A [4]
VW3A66717
2 [5]
[1]
For Class 8839 Enclosed ALTIVAR 66 drive controllers, refer to the product
nameplate for the part number of the drive controller used.
[2]
Current rating of resistor assembly is calculated based on setting of internal overload
protective device in assembly, overload setting based on enclosure overtemperature
protection, and resistor overload versus time characteristics. Resistors are rated for
stopping six times rotor inertia of four-pole motor with drive at current limit. Motor
inertias are based on NEMA MG-1 14.45.
[3]
Ohmic value indicated is equivalent resistance of two resistor kits used in parallel.
The ohmic value of each resistor kit is twice the value indicated.
[4]
The continuous current rating indicated is the equivalent current rating of two resistor
kits in parallel. The continuous current rating of each resistor kit is half the value
indicated.
[5]
Mounting the dynamic braking resistor assemblies on the ATV66C23N41 to C31N41
controllers requires the use of Dynamic Braking Resistor Mounting Plate Kit
VY1A66202.
© 1997 Square D All Rights Reserved
7
Chpt 1Book.book Page 8 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Current-Time Characteristic for DB Resistor Assemblies
Bulletin No. VD0C06N908C
July 1998
Current-Time Characteristic for DB Resistor Assemblies
Figure 1 shows allowable time according to multiples of current setting
with the dynamic braking resistor assembly located in a 40 °C ambient
temperature environment. For an example of calculating resistor size,
refer to Appendix A.
Time (s)
10000
1000
100
1
2
10
1
0.1
0.01
0.001
1
1.5
100
10
Multiples of current setting (lr)
(1) Cold state
(2) Hot state
Figure 1:
8
Dynamic Braking Curves
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 9 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Pre-Installation Considerations
Pre-Installation Considerations
The dynamic braking resistor assembly may be wall-mounted or attached
to prepared spaces on top of Class 8839 enclosed ALTIVAR 66 drive
controllers. The resistor assembly can also be used with certain general
purpose enclosures.
The following points should be considered before installation:
• The dynamic braking resistor generates heat during braking. When
operating at rated nameplate power in a 40 °C ambient temperature,
the resistor enclosure can reach temperatures of 80 °C. The dynamic
braking resistor should not be installed below or directly against heatsensitive materials or equipment. Do not mount against combustible
surfaces or on polymeric enclosures. Refer to local and national codes
for resistor mounting requirements.
• For proper cooling, always orient the resistor assembly as shown in
Figures 13, 14, or 15 on pages 30 - 32. Do not block ventilation
openings of the enclosure. Ensure that ventilation and clearance is
adequate for the rated power. Calculate the rated power of the
assembly from nameplate information using the following formula:
Power Rating = 〈 Nameplate Current Rating〉 2 × Resistance
• If the time-current capability of the resistor is exceeded, protection is
provided to prevent resistor damage or excessive enclosure
temperatures. A thermal overload switch located inside the dynamic
braking resistor assembly will trip and open the resistor circuit to
prevent damage. The thermal overload switch may be reset once the
overload condition has been corrected. The reset pushbutton of the
thermal overload switch is accessed through the small hole in the front
of the resistor enclosure (T). See Figures 5 and 6 on page 26.
• The mounting surface must be capable of safely supporting the weight
of the dynamic braking resistor assembly. Refer to Table 2 for
assembly weights.
Table 2:
Assembly Weight
Dynamic Braking Assembly Part No.
Weight
VW3A66711 and VW3A66712
11 lbs (5 kg)
VW3A66713 and VW3A66714
16 lbs (7.3 kg)
VW3A66715, 716, 717, 718
58 lbs (26.5 kg)
© 1997 Square D All Rights Reserved
9
Chpt 1Book.book Page 10 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Pre-Installation Considerations
Bulletin No. VD0C06N908C
July 1998
• The enclosure of the dynamic braking resistor assembly is rated
Type 1 per UL 50. The insulation system is intended for use in a
Pollution Degree 3 environment (refer to NEMA ICS-1). The
installation environment must be compatible with this rating.
• Self-tapping M5 hardware is supplied with the dynamic braking
resistor assembly and is intended for reuse during some installation
procedures. When threaded into a 0.182 in (4.52 mm) diameter hole,
the M5 hardware requires a minimum sheet metal thickness of 0.075
in (1.9 mm) in mild steel for rated thread strength. Do not thread
fasteners into dissimilar metals or non-metallic materials. Torque the
self-threading M5 fasteners to 32 to 41 lb-in (3.6 to 4.6 N•m).
• When connecting the dynamic braking resistor assembly to the drive
controller, use conductors with a cross-sectional size, insulation
temperature rating, and insulation voltage rating suitable for the
application. For 460 V drive controller applications, follow the
recommendations in Table 3 for minimum conductor requirements.
Table 3:
PA, PB, GND Minimum Conductor Requirements
Drive Controller
Part No.
Individual Conductor Individual Conductor Individual
Conductor Length ð
Length ð
Length ð
100 ft (30.4 m)
50 ft (15.2 m)
10 ft (3.0 m)
ATV66U41N4 to U72N4
600 V, #14 AWG,
60/75 °C Copper
—
600 V, #8 AWG,
60/75 °C Copper
ATV66U90N4 to D12N4
600 V, #14 AWG,
60/75 °C Copper
—
600 V, #8 AWG,
60/75 °C Copper
ATV66D16N4 to D23N4
600 V, #10 AWG,
60/75 °C Copper
—
600 V, #8 AWG,
60/75 °C Copper
ATV66D33N4 to D46N4
600 V, #10 AWG,
60/75 °C Copper
—
600 V, #8 AWG,
60/75 °C Copper
ATV66D54N4 to D79N4
600 V, #8 AWG,
60/75 °C Copper
600 V, #4 AWG,
60/75° C Copper
—
ATV66C10N4 to C19N4
600 V, #8 AWG,
60/75 °C Copper
600 V, #4 AWG,
60/75° C Copper
—
ATV66C23N41 to C31N41
600 V, #4 AWG,
60/75 °C Copper [2]
600 V, #4 AWG,
60/75° C Copper [2]
—
[1]
[2]
10
In addition to the required continuous current rating, the conductor cross-sectional size has been selected to
minimize the possibility of insulation damage should an overcurrent or ground fault occur at the DB resistor
assembly. The coordination of the conductors in the table is based upon the maximum input line fuse
recommended on the specific drive controller nameplate, the use of feeder ground and line conductors
selected per ANSI/NFPA 70 (National Electrical Code), and the optional use of a feeder reactor with saturating
characteristics.
Separate PA, PB, and GND conductors must be installed to the drive controller for each dynamic braking
resistor unit. Do not series the connections.
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 11 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Pre-Installation Considerations
• The bushing supplied with the dynamic braking resistor assembly can
be used as a feed-through for the three conductors from the dynamic
braking resistor assembly while maintaining a Type 12 seal through an
enclosure wall. The bushing supplied with kits VW3A66711 to
VW3A66714 is compatible with conductors with outside diameters of
0.16 ± 0.01 in (4.0 ± 0.25 mm). The bushing supplied with kits
VW3A66715 to VW3A66718 is compatible with conductors with
outside diameters of 0.22 ± 0.01 in (5.6 ± 0.25 mm). Both bushings can
be used with surface thicknesses to 0.10 in (2.5 mm).
• Refer to ANSI/NFPA 70 (National Electrical Code) for information
concerning insulated conductor dimensions. The bushing supplied
with kits VW3A66711 to VW3A66714 is primarily intended for use with
#10 AWG conductors. The bushing supplied with kits VW3A66715 to
VW3A66718 is primarily intended for use with #8 AWG conductors.
• Good wiring practice requires separation of dynamic braking power
wiring from all other drive controller wiring. Control and power wiring
should cross at right angles only. Use metal conduit for all dynamic
braking wiring outside the drive controller enclosure. Do not run control
or other power wiring in same conduit with dynamic braking power
wiring.
© 1997 Square D All Rights Reserved
11
Chpt 1Book.book Page 12 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Installation
Bulletin No. VD0C06N908C
July 1998
Installation
Before installing the dynamic braking resistor assembly, perform the bus
voltage measurement procedure.
Bus Voltage Measurement Procedure
DANGER
HAZARDOUS VOLTAGE
•
•
•
•
Read and understand Bus Voltage Measurement Procedure
before installing dynamic braking resistor. Measurement of DC
bus capacitor voltage must be performed by qualified personnel.
DC bus LED is not an accurate indication of absence of DC bus
voltage.
DO NOT short across capacitors or touch unshielded
components or terminal strip screw connections with voltage
present.
Many parts in this drive controller, including printed wiring boards,
operate at line voltage. DO NOT TOUCH. Use only electrically
insulated tools.
Electrical shock will result in death or serious injury.
The PA and - terminals are located inside the ALTIVAR 66 drive controller.
See Figures 2 - 4 on pages 13 - 15 for terminal locations. To measure bus
capacitor voltage:
1. Disconnect and verify that all power is removed from the drive
controller. If drive controller is housed in a larger enclosure,
disconnect and verify that all power is removed from the enclosure.
2. Wait 1 minute to allow the DC bus to discharge.
3. For Class 8839 enclosed ALTIVAR 66 drive controllers, or for
situations where the drive controller is housed in a user-supplied
enclosure:
— Open the outer enclosure door for access to the drive controller.
— Open the front cover (if present) of the drive controller for access
to terminal strip J2 and the PA and - terminals.
For ALTIVAR 66 drive controllers not housed inside supplementary
enclosures, open the front cover of the drive controller for access to
terminal strip J2 and the PA and - terminals.
4. Set the volt meter to the 1000 VDC scale. Measure the bus capacitor
voltage between the PA and - terminals to verify that the DC voltage
12
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 13 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Installation
is less than 45 V. Do not short across capacitor terminals with
voltage present!
5. If the bus capacitors are not fully discharged, contact your local
representative — do not operate the drive controller.
6. Close all doors to the drive controller and enclosure.
AI2-U
AI2-I
J13
J12
J2
AI2-U
AI2-I
—
PA
PB
ATV66U41N4 to D12N4
Figure 2:
© 1997 Square D All Rights Reserved
—
PB
PA
ATV66D16N4 to D79N4
Terminal Strip Locations: ATV66U41N4 to D79N4
13
Chpt 1Book.book Page 14 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Installation
Bulletin No. VD0C06N908C
July 1998
AI2-U
AI2-I
L1
L2
L3
PA PB
F5
F6
—
Figure 3:
14
PA
PB
Terminal Strip Locations: ATV66C10N4 to C19N4
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 15 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Installation
F1
F2
L1
L3
PB
-
F6
CE
PA
F5
NOTI
PA
F3
L2
PB
4
DANGER
—
Figure 4:
© 1997 Square D All Rights Reserved
Terminal Strip Locations: ATV66C23N41 to C31N41
15
Chpt 1Book.book Page 16 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66711 to 714
Bulletin No. VD0C06N908C
July 1998
Mounting Instructions for Kits VW3A66711, -712, -714
Mounting on Enclosures
1. Remove dynamic braking resistor assembly cover by removing four
screws (A). See Figure 5 on page 26.
2. Remove bottom pan of dynamic braking resistor assembly by
removing four screws (B). See Figure 5 on page 26. Keep screws for
use in step 4.
3. Refer to hole patterns in Figure 7 on page 27. When drilling or
punching holes, avoid dropping metal chips or debris into the
enclosure. Clean interior of enclosure thoroughly using a vacuum
cleaner equipped with an insulated nozzle. Do not use compressed
air to blow debris from the enclosure.
For Class 8839 Enclosed ALTIVAR 66 Drive Controllers:
— Locate the center punch marks on top of the enclosure.
— Drill four 0.182 in (4.52 mm) diameter holes for attachment of the
dynamic braking resistor assembly using the M5 self-tapping
screws.
— Punch a 0.80 in (20.32 mm) diameter hole for the feed-through
bushing.
For User-Supplied Enclosures Housing ALTIVAR 66 Drive
Controllers:
NOTE: It is the installer’s responsibility to determine the suitability of
the enclosure construction for installation of the dynamic braking
resistor assembly. Refer to the section “Pre-Installation
Considerations” on page 9 for construction requirements.
— Lay out a hole pattern on the top of the enclosure as illustrated in
Figure 7 on page 27.
— Drill four 0.182 in (4.52 mm) diameter holes (C) for attachment of
the dynamic braking resistor assembly using the M5 self-tapping
screws.
— Punch a 0.80 in (20.32 mm) diameter hole (D) for the feed-through
bushing.
4. Position the dynamic braking resistor assembly on top of the
enclosure so that the mounting holes align with holes drilled on top of
the drive enclosure. Install nylon sleeves (E) and secure dynamic
braking resistor assembly to top of drive enclosure with the four
screws saved from step 2 (F). See Figure 9 on page 28.
16
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 17 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66711 to 714
5. Install the bushing (G) into the 0.80 in diameter (20.32 mm) hole in the
drive enclosure. See Figure 10 on page 29. When installing the
bushing attachment nut (J), torque the nut to approximately 24 lb-in
(2.8 N•m).
6. Route three conductors (refer to Table 3 on page 10) through the
rubber plug (H) and bushing so that 6 to 8 in (152.4 to 203.2 mm) of
conductor extends into dynamic braking resistor assembly cabinet. If
necessary, lubricate conductors using cable soap that will not
damage conductor insulation. Once conductors are installed, fingertighten cap of the feed-through bushing (I) so that the three wires are
gripped tightly by the bushing. See Figure 10 on page 29.
7. Make connections from terminals PA, PB, and ground on the drive
controller (see Figure 2 on page 13) to terminals PA, PB, and ground
inside the dynamic braking resistor assembly cabinet (see Figure 11
on page 29).
NOTE: In ALTIVAR 66 drive controllers, the drive-side ground is made
to a lug on the drive controller terminal strip. In Class 8839 enclosed
ALTIVAR 66 drive controllers, this connection is made to the ground
bar in the enclosure.
8. Verify that the thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 11 on page 29.
9. Replace dynamic braking resistor cover and secure with four screws
(A). See Figure 5 on page 26.
10. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 5 on page 26 and
Figure 11 on page 29.
Wall Mounting Separately from Drive Enclosure
1. Remove dynamic braking resistor assembly cover by removing four
screws (A). See Figure 5 on page 26.
2. Refer to hole patterns in Figure 13 on page 30 or Figure 14 on page
31. Drill three holes (M) in mounting surface.
3. Open conduit entry (N) on side of dynamic braking resistor assembly.
Conduit entry knockouts are provided for 3/4 in (19.05 mm) and 1/2 in
(12.7 mm) pipe.
4. Mount dynamic braking resistor to mounting surface and secure with
three user-supplied screws. 1/4 in (6.35 mm) diameter screws are
recommended.
© 1997 Square D All Rights Reserved
17
Chpt 1Book.book Page 18 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66715 to 717
Bulletin No. VD0C06N908C
July 1998
5. Make connections (refer to Table 3 on page 10) from terminals PA,
PB, and ground on drive controller (see Figure 2 on page 13) to
terminals PA, PB, and ground inside dynamic braking resistor
assembly cabinet (see Figure 11 on page 29).
NOTE: In ALTIVAR 66 drive controllers, the drive-side ground is made
to a lug on the drive controller terminal strip. In Class 8839 enclosed
ALTIVAR 66 drive controllers, this connection is made to the ground
bar in the enclosure.
6. Verify that thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 11 on page 29.
7. Replace dynamic braking resistor cover and secure with four screws
(A). See Figure 5 on page 26.
8. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 5 on page 26 and
Figure 11 on page 29.
Mounting Instructions for Kits VW3A66715, -716, -717 (QTY 1)
Mounting on Enclosures
Dynamic braking resistor units VW3A66715, -716, and -717, if ordered as
an integral part of a Class 8839 controller, may be supplied unmounted
to limit the overall shipping height of the controller. When this is done, the
top of the drive controller enclosure is factory prepared to accept the
assembly. If the drive controller enclosure has a Type 12 rating, the
preparation maintains the integrity of the enclosure construction. When
the dynamic braking resistor assembly is installed per this procedure, the
Type rating of the enclosure will be maintained. Factory preparation of the
top of the enclosure consists of the following:
• All mounting holes are pre-drilled and equipped with M5 self-tapping
mounting hardware with nylon sleeves.
• The feed-through bushing has been installed.
• The PA, PB, and GND conductors are installed in the feed-through
bushing and connected within the controller. The ends of the
conductors exiting the top of the enclosure have been identified with
markers and insulated with tape for shipment.
18
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 19 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66715 to 717
To mount kits VW3A66715, -716, -717 on enclosures:
1. Remove dynamic braking resistor assembly cover by removing six
screws (A). See Figure 6 on page 26.
2. Remove bottom pan of dynamic braking resistor assembly by
removing four screws (B). See Figure 6 on page 26. Keep screws for
use in step 4.
3. Refer to hole patterns in Figure 8 on page 28. When drilling or
punching holes, avoid dropping metal chips or debris into the
enclosure. Clean interior of enclosure thoroughly using a vacuum
cleaner equipped with an insulated nozzle. Do not use compressed
air to blow debris from the enclosure.
For Class 8839 Enclosed ALTIVAR 66 Drive Enclosures with
Unprepared Tops:
— Locate the center punch marks on top of the enclosure.
— Drill four 0.182 in (4.52 mm) diameter holes for attachment of the
dynamic braking resistor assembly using the M5 self-tapping
screws.
— Punch a 0.80 in (20.32 mm) diameter hole for the feed-through
bushing.
For Class 8839 Enclosed ALTIVAR 66 Drive Controllers with
Prepared Tops:
— Remove the insulating tape from the ends of the PA, PB, and GND
conductors.
— Remove the four M5 screws from the top plate of the enclosure.
— Attach the dynamic braking resistor assembly on top of the
enclosure so that the mounting holes on each side align with the
pre-drilled holes. Secure the assembly to the top of the enclosure
by re-using the hardware removed in the previous step or use the
hardware saved from step 2. See Figure 9 on page 28 (F). If the
hardware removed in step 2 is used, install the nylon sleeves (E)
supplied with the kit.
— Skip to step 7.
© 1997 Square D All Rights Reserved
19
Chpt 1Book.book Page 20 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66715 to 717
Bulletin No. VD0C06N908C
July 1998
For User-Supplied Enclosures Housing ALTIVAR 66 Drive
Controllers:
NOTE: It is the installer’s responsibility to determine the suitability of
the enclosure construction for installation of the dynamic braking
resistor assembly. Refer to the section “Pre-Installation
Considerations” on page 9 for construction requirements.
— Lay out a hole pattern on top of the enclosure as illustrated in
Figure 8 on page 28.
— Drill four 0.182 in (4.52 mm) diameter holes for attachment of the
dynamic braking resistor assembly using the M5 self-tapping
screws.
4.
5.
6.
7.
8.
20
— Punch a 0.80 in (20.32 mm) diameter hole for the feed-through
bushing.
Position dynamic braking resistor assembly on top of the enclosure so
that the mounting holes on each side align with holes drilled on top of
the drive enclosure. Install nylon sleeves (E) and secure dynamic
braking resistor assembly to top of drive enclosure with the four
screws saved from step 2 (F). See Figure 9 on page 28.
Install the bushing (G) into the 0.80 in diameter (20.32 mm) hole in the
drive enclosure. See Figure 10 on page 29. When installing the
bushing attachment nut (J), torque the nut to approximately 24 lb-in
(2.8 N•m).
Route three conductors (refer to Table 3 on page 10) through the
rubber plug (H) and bushing so that 6 to 8 in (152.4 to 203.2 mm) of
conductor extends into dynamic braking resistor assembly cabinet. If
necessary, lubricate conductors using cable soap that will not
damage conductor insulation. Once conductors are installed, fingertighten cap of the feed-through bushing (I) so that the three wires are
gripped tightly by the bushing. See Figure 10 on page 29.
Make connections from terminals PA, PB, and ground on drive
controller (see Figure 2 on page 13 and Figure 3 on page 14) to
terminals PA, PB, and ground inside dynamic braking resistor
assembly cabinet (see Figure 12 on page 30).
NOTE: In ALTIVAR 66 drive controllers, the drive-side ground is made
to a lug on the drive controller terminal strip. In Class 8839 enclosed
ALTIVAR 66 drive controllers, this connection is made to the ground
bar in the enclosure.
Verify that thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 12 on page 30.
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 21 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66715 to 717
9. Replace dynamic braking resistor cover and secure with six screws
(A). See Figure 6 on page 26.
10. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 6 on page 26 and
Figure 12 on page 30.
Mounting on ALTIVAR 66 Units ATV66C10N4, C13N4, C15N4, C19N4
1. Remove dynamic braking resistor assembly cover by removing six
screws (A). See Figure 6 on page 26.
2. Open the 1.25 in (30.63 mm) conduit entry (S) on drive top cover. See
Figure 16 on page 33.
For ALTIVAR 66 Drives Without a Factory-Provided Top Cover Wire
Knockout:
— With drive door closed and secured by fastening screws, remove
the two rear screws (U) and six front screws (T) from the top of the
drive controller (Figure 16 on page 33). Keep screws for later use.
Remove the drive top cover.
— Punch a 0.80 in (20.32 mm) diameter hole in the drive top cover.
See Figure 16 on page 33.
3.
4.
5.
6.
— Replace the drive top cover and secure with only the two back
screws (U).
Remove the six screws (T) from the top of the ALTIVAR 66 drive (if
not already removed). See Figure 16 on page 33. Keep screws for
use in step 5.
Install the bushing (G) into the 0.80 in (20.32 mm) diameter hole in the
bottom pan of the dynamic braking resistor assembly. Assemble the
bushing opposite that shown in Figure 10 on page 29. The nut (J)
should be on the top of the pan. Torque the nut to approximately 24
lb-in (2.8 N•m). Discard the rubber plug (H) and cap (I).
Position dynamic braking resistor assembly on top of the drive so that
the mounting holes align with the six holes on the drive top cover.
Secure braking resistor assembly with the six screws (T) saved from
step 3.
Route three conductors through the bushing on the dynamic braking
resistor assembly mounting pan so that 6 to 8 in (152.4 to 203.2 mm)
of conductor extends into dynamic braking resistor assembly cabinet.
Make connections to the PA, PB, and ground terminals inside the
dynamic braking resistor assembly cabinet. See Figure 12 on page
30.
© 1997 Square D All Rights Reserved
21
Chpt 1Book.book Page 22 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66715 to 717
Bulletin No. VD0C06N908C
July 1998
7. Route the three conductors down the right side of the inside of the
drive controller. Connect the PA, PB, and ground conductors from the
resistor assemblies to their respective PA, PB, and ground terminals
inside the drive controller (see Figure 3 on page 14).
8. Verify that the thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 12 on page 30.
9. Replace dynamic braking resistor cover and secure with six screws
(A). See Figure 6 on page 26.
10. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 6 on page 26 and
Figure 12 on page 30.
Mounting Separately from Controller and/or Controller Enclosure
NOTE: For proper cooling, always orient resistor assembly in an upright
position. Do not mount resistor assembly on a wall without a mounting
bracket that places the resistor assembly in an upright position.
1. Remove dynamic braking resistor assembly cover by removing six
screws (A). See Figure 6 on page 26.
2. Refer to hole patterns in Figure 15 on page 32. Drill six holes (M) in
mounting surface.
3. Open conduit entry (N) on side of dynamic braking resistor assembly.
Conduit entry knockouts are provided for 1.0 in (24.5 mm) and 1.25 in
(30.63 mm) pipe.
4. Mount dynamic braking resistor to mounting surface and secure with
six user-supplied screws. 1/4 in (6.35 mm) diameter screws are
recommended.
5. Make connections (refer to Table 3 on page 10) from terminals PA,
PB, and ground on drive controller (see Figure 2 on page 13 and
Figure 3 on page 14) to terminals PA, PB, and ground inside dynamic
braking resistor assembly cabinet (see Figure 12 on page 30).
6. Verify that thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 12 on page 30.
7. Replace dynamic braking resistor cover and secure with six screws
(A). See Figure 6 on page 26.
8. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 6 on page 26 and
Figure 12 on page 30.
22
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 23 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66717 and 718
Mounting Instructions for Kits VW3A66717 (QTY 2) AND -718 (QTY 2)
NOTE: This procedure is for mounting kits VW3A66717 and VW3A66718
when used in parallel with drives ATV66C23N4, C28N4, or C31N4. In
some steps, you will refer to figures which show only one resistor
assembly. You should perform all steps on both resistor assemblies being
installed.
Mounting on ALTIVAR 66 Drive Controller
NOTE: This procedure requires the use of Dynamic Braking Resistor
Mounting Plate Kit VY1A66202. The mounting plate is available as a
separate kit.
1. Remove dynamic braking resistor assembly covers by removing six
screws (A) from both resistor assemblies. See Figure 6 on page 26.
2. Remove bottom pans of dynamic braking resistor assemblies by
removing four screws (B) from both resistor assemblies. See Figure
6 on page 26. Keep screws for use in step 5.
3. Remove the ten screws (V) and drive top plate (X) from the top of the
ALTIVAR 66 drive. See Figure 17 on page 34. Keep screws for use in
step 4.
4. Position dynamic braking resistor mounting plate VY1A66202 (Y) on
top of the drive so that the mounting holes align with the ten holes on
the drive top cover. See Figure 17 on page 34. Secure the resistor
mounting plate with the ten screws saved from step 3.
5. Position dynamic braking resistor assemblies on top of the mounting
plate so that the mounting holes align with the holes on the mounting
plate. Make sure the resistor assemblies are oriented as shown in
Figure 17 on page 34.
6. Install nylon sleeves (E) and secure dynamic braking resistor
assemblies to top of drive enclosure with the screws saved from
step 2 (F). See Figure 9 on page 28.
7. Route three conductors (refer to Table 3 on page 10) from each
dynamic braking resistor assembly through the respective bushing in
the dynamic braking resistor mounting plate. Make connections to the
PA, PB, and ground terminals of the drive controller (see Figure 4 on
page 15) and also to the inside of the dynamic braking resistor
assembly cabinets (see Figure 12 on page 30).
8. Route the six wires down the left wall of the drive controller. Make
connections with the PA, PB, and ground wires from the resistor
assemblies to their respective PA, PB, and ground terminals inside
the drive controller (see Figure 4 on page 15).
© 1997 Square D All Rights Reserved
23
Chpt 1Book.book Page 24 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66717 and 718
Bulletin No. VD0C06N908C
July 1998
NOTE: In ALTIVAR 66 drive controllers, the drive-side ground is made
to a lug on the drive controller. Two PA and PB terminals have been
supplied in the drive controller for connection of both resistor
assemblies.
9. Verify that thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current ratings, and that thermal
overload start switches (L) are in On position.
See Figure 12 on page 30.
10. Replace both dynamic braking resistor covers and secure each with
six screws (A). See Figure 6 on page 26.
11. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 6 on page 26 and
Figure 12 on page 30.
Mounting Separately from Drive Controller and/or Enclosure
NOTE: For proper cooling, always orient resistor assemblies in an upright
position. Do not mount resistor assemblies on a wall without a mounting
bracket that positions the resistor assemblies in an upright position.
1. Remove dynamic braking resistor assembly covers by removing six
screws (A) from both resistor assemblies. See Figure 6 on page 26.
2. Referring to Figure 15 on page 32, lay out hole patterns for two
resistor assemblies. Drill six holes (M) for each assembly in mounting
surface.
3. Open conduit entries (N) on side of dynamic braking resistor
assemblies. Conduit entry knockouts are provided for 1.0 in (24.5
mm) and 1.25 in (30.63 mm) pipe.
4. Mount dynamic braking resistor assemblies to mounting surface and
secure both with six user-supplied screws each. 1/4 in (6.35 mm)
diameter screws are recommended.
5. Route three conductors (refer to Table 3 on page 10) from each
dynamic braking resistor assembly to the drive controller. Make
connections to the PA, PB, and ground terminals of the drive
controller (see Figure 4 on page 15) and also to inside the dynamic
braking resistor assembly cabinets (see Figure 12 on page 30).
NOTE: In ALTIVAR 66 drive controllers, the drive-side ground is made
to a lug on the drive controller. Two PA and two PB terminals have
been suppled for connection of each of the resistor assemblies.
6. Verify that thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current ratings, and that thermal
overload start switches (L) are in On position (Figure 12 on page 30).
24
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 25 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Mounting Kits VW3A66717 and 718
7. Replace dynamic braking resistor covers and secure each with six
screws (A). See Figure 6 on page 26.
8. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 6 on page 26 and
Figure 12 on page 30.
© 1997 Square D All Rights Reserved
25
Chpt 1Book.book Page 26 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
A
A
A
A
T
DANGER
GEFAHR
B
HAZARDOUS VOLTAGE.
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
B
(4 Places)
HAZARDOUS VOLTAGE.
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
Suggested location of alternate
language hazard label
Figure 5:
Removing Cover and Bottom Pan: VW3A66711, 712, 713,
714
A
A
A
A
A
GEFAHR
HAZARDOUS VOLTAGE.
A
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
B
T
Suggested location of alternate
language hazard label
Figure 6:
26
B
(4 places)
Removing Cover and Bottom Pan: VW3A66715, 716, 717,
718
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 27 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
14.00
(355.6)
in
(mm)
13.50
(342.9)
13.00
(330.2)
C
5.44
(138.17)
3.68
(93.47)
.42
(10.67)
1.00
(25.4)
TOP VIEW
D
Figure 7:
© 1997 Square D All Rights Reserved
.182
(4.52) DIA (4 places)
.750 DIA Conduit Entry
(19.05)
Enclosure Mounting Dimensions: VW3A66711, 712, 713,
714
27
Chpt 1Book.book Page 28 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
19.82
(503.4)
in
(mm)
19.12
(485.6)
18.42
(467.9)
C
.42
(10.67)
9.125
(231.8)
4.0
(101.6)
NOTE: Only one resistor
assembly shown. If mounting
two resistor assemblies,
be sure to lay out two separate
sets of mounting holes.
1.50
(38.10)
TOP VIEW
D
Figure 8:
.182
(4.52) DIA (4 places)
.750 DIA Conduit Entry
(19.05)
Enclosure Mounting Dimensions: VW3A66715, 716, 717,
718
F
E
Figure 9:
28
Mounting
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 29 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
G
H
I
J
Figure 10: Liquid-Tight Bushing
L3
T3
5
6
L2
T2
4
PA
- Ground equipment.
- Before servicing, remove
GEFAHR
3
OFF
PB
all power. Wait 1 minute.
Verify no voltage is
1
T1
present.
2
Failur
in injury .
DANGER
HAZARDOUS VOLTAGE.
L1
round equipment.
efore servicing, remove
l power. Wait 1 minute.
ify no voltage is
ent.
1
ZARDOUS VOLTAGE.
-
Failure to comply will result
L
TO LIMIT RESISTOR
ENCLOSURE SURFACE
TEMP RISE TO 40œC,
THE RESISTOR O.L.
PROTECTION SHOULD
BE SET NO GREATER
THAN THE RESISTOR
NAMEPLATE CURRENT.
in injury or death.
2
Suggested location
of alternate language
hazard labels
NOTE:
PA
52012-575-01
PB
K
Figure 11: Dynamic Braking Resistor Assembly Terminals:
VW3A66711, 712, 713, 714
© 1997 Square D All Rights Reserved
29
Chpt 1Book.book Page 30 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
Resistor Elements
GEFAHR
HAZARDOUS VOLTAGE.
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
Suggested location
of alternate language
hazard labels.
PA
K
L
PB
Figure 12: Dynamic Braking Resistor Assembly Terminals:
VW3A66715, 716, 717, 718
5.68
(144.3)
R
N
6.00
(152.4) 1.33
(33.8)
0.75
(19.0)
6.00
(152.4)
M
in
(mm)
6.50
(165.1)
.27
DIA (3 Places)
(6.9)
12.00
(304.8)
15
(381.0)
Figure 13: Wall Mounting Dimensions: VW3A66711 and
VW3A66712
30
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 31 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
5.68
(144.3)
R
in
(mm)
N
9.00
(228.6)
1.33
(33.8)
0.75
(19.0)
6.00
(152.4)
M
6.50
(165.1)
.27
DIA (3 Places)
(6.9)
12.00
(304.8)
15.00
(381.0)
Figure 14: Wall Mounting Dimensions: VW3A66713 and
VW3A66714
© 1997 Square D All Rights Reserved
31
Chpt 1Book.book Page 32 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
10.38
(263.7)
in
(mm)
20.00
(508)
0.84
(21.43)
N
18.63
(473.2)
20.64
(524.3)
22.29
(566.2)
M
M
4.36
(110.7)
M
M
4.36
(110.7)
M
.27 Dia.
(6.9)
(6 places)
21.55
(547.4)
M
22.29
(566.2)
Figure 15: Mounting Dimensions: VW3A66715, 716, 717, 718
32
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 33 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
U
U
in
(mm)
T
T
T
T
S
T
1.74
(44.20)
T
0.68
(17.3)
Figure 16: Mounting on ALTIVAR 66 Drive Controller: VW3A66716,
717
© 1997 Square D All Rights Reserved
33
Chpt 1Book.book Page 34 Sunday, August 10, 2003 5:59 PM
Part 1: ALTIVAR 66 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
Label Side Of Resistor
Assembly Facing Right
Y
V
V
V
V
V
V
V
V
X
V
V
Front Of Altivar 66
Figure 17: Mounting on ALTIVAR 66 Drive Controller: VW3A66717, 718
34
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 35 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Technical Specifications
PART 2: ALTIVAR 58 DYNAMIC BRAKING RESISTOR KIT
Introduction
The dynamic braking resistor kit allows ALTIVAR 58 drive controllers to
function in quadrants 2 and 4 of the speed/torque curve, dissipating the
excess braking energy in an external resistor.
Contents of Kit
This kit contains:
•
•
•
•
One dynamic braking resistor assembly
Four liquid-tight nylon sleeves
One liquid-tight three-hole bushing
Six danger labels: two French (52012-664-02); two German (52012664-03); two Spanish (52012-664-04)
• Instruction Bulletin VD0C06N908_ (latest revision)
Technical Specifications
Table 4:
Braking Resistor Kit Technical Specifications
Ohmic
Value
Continuous
Current Rating of
Assembly [1]
Average
Power
Rdb
Ir
W
120 ¾
1.0 A
120
VW3A66711
ATV58•U29M2, U41M2,
U90N4, D12N4
56 ¾
1.45 A
118
VW3A66712
ATV58•U54M2, U72M2,
D16N4, D23N4
28 ¾
2.7 A
204
VW3A66713
ATV58•U90M2, D12M2
14 ¾
3.8 A
202
VW3A66714
For Drives
ATV58•U09M2[2],
Catalog
Number
U18M2[2],
U18N4, U29N4, U41N4,
U54N4, U72N4
[1]
Current rating of resistor assembly is calculated based on setting of internal overload protective device in
assembly, overload setting based on enclosure overtemperature protection, and resistor overload versus
time characteristics. Resistors are rated for stopping six times rotor inertia of four-pole motor with drive at
current limit. Motor inertias are based on NEMA MG-1 14.45.
[2]
Requires external braking module (VW3A58701).
© 1997 Square D All Rights Reserved
35
Chpt 1Book.book Page 36 Sunday, August 10, 2003 5:59 PM
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Current-Time Characteristics for DB Resistor Assemblies
Bulletin No. VD0C06N908C
July 1998
Current-Time Characteristic for DB Resistor Assemblies
Figure 18 shows allowable time according to multiples of current setting
with the dynamic braking resistor assembly located in a 40 °C ambient
temperature environment. For an example of calculating resistor size,
refer to Appendix B.
Time (s)
10000
1000
100
1
2
10
1
0.1
0.01
0.001
1
1.5
100
10
Multiples of current setting (lr)
(1) Cold state
(2) Hot state
Figure 18: Dynamic Braking Curves
36
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 37 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Pre-Installation Considerations
Pre-Installation Considerations
The dynamic braking resistor assembly may be wall-mounted. The
resistor assembly can also be used with certain general purpose
enclosures.
The following points should be considered before installation:
• The dynamic braking resistor generates heat during braking. When
operating at rated nameplate power in a 40 °C ambient temperature,
the resistor enclosure can reach temperatures of 80 °C. The dynamic
braking resistor should not be installed below or directly against heatsensitive materials or equipment. Do not mount against combustible
surfaces or on polymeric enclosures. Refer to local and national codes
for resistor mounting requirements.
• For proper cooling, always orient the resistor assembly as shown in
Figures 25 and 26 on pages 45 and 46. Do not block ventilation
openings of the enclosure. Ensure that ventilation and clearance is
adequate for the rated power. Calculate the rated power of the
assembly from nameplate information using the following formula:
Power Rating = ( Nameplate Current Rating ) 2 × Resistance
• If the time-current capability of the resistor is exceeded, protection is
provided to prevent resistor damage or excessive enclosure
temperatures. A thermal overload switch located inside the dynamic
braking resistor assembly will trip and open the resistor circuit to
prevent damage. The thermal overload switch may be reset once the
overload condition has been corrected. The reset pushbutton of the
thermal overload switch is accessed through the small hole in the front
of the resistor enclosure (T). See Figure 20 on page 43.
• The mounting surface must be capable of safely supporting the weight
of the dynamic braking resistor assembly. Refer to Table 5 for
assembly weights.
Table 5:
Assembly Weight
Dynamic Braking Assembly
Part No.
Weight
VW3A66711 and VW3A66712
11 lbs (5 kg)
VW3A66713 and VW3A66714
16 lbs (7.3 kg)
© 1997 Square D All Rights Reserved
37
Chpt 1Book.book Page 38 Sunday, August 10, 2003 5:59 PM
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Pre-Installation Considerations
Bulletin No. VD0C06N908C
July 1998
• The enclosure of the dynamic braking resistor assembly is rated Type
1 (per UL 50). The insulation system is intended for use in a Pollution
Degree 3 environment (refer to NEMA ICS-1). The installation
environment must be compatible with this rating.
• Self-tapping M5 hardware is supplied with the dynamic braking
resistor assembly and is intended for reuse during some installation
procedures. When threaded into a 0.182 in (4.52 mm) diameter hole,
the M5 hardware requires a minimum sheet metal thickness of 0.075
in (1.9 mm) in mild steel for rated thread strength. Do not thread
fasteners into dissimilar metals or non-metallic materials. The selfthreading M5 fasteners should be torqued to 32 to 41 lb-in (3.6 to 4.6
N•m).
• When connecting the dynamic braking resistor assembly to the drive
controller, use conductors with a cross-sectional size, insulation
temperature rating, and insulation voltage rating suitable for the
application. Follow the recommendations in Table 6 for minimum
conductor requirements.
Table 6:
PA, PB, GND Conductor Requirements
PA, PB, GND Minimum Conductor
Requirements [1]
Drive Controller
Part No.
Individual Conductor
Length not Exceeding
10 ft (3.0 m)
Individual Conductor
Length not Exceeding
100 ft (30.4 m)
ATV58•U09M2 to U18M2
600 V, #14 AWG,
60/75 °C Copper
-
ATV58•U29M2 to U72M2
ATV58•U18N4 to D12N4
600 V, #14 AWG,
60/75 °C Copper
600 V, #8 AWG,
60/75 °C Copper
ATV58•U90M2 to D12M2
ATV58•D16N4 to D23N4
600 V, #10 AWG,
60/75 °C Copper
600 V, #8 AWG,
60/75 °C Copper
[1]
38
In addition to the required continuous current rating, the conductor cross-sectional
size has been selected to minimize the possibility of insulation damage should an
overcurrent or ground fault occur at the DB resistor assembly. The coordination of
the conductors in the table is based upon the maximum input line fuse recommended
on the specific drive controller nameplate, the use of feeder ground and line
conductors selected per ANSI/NFPA 70 (National Electrical Code), and the optional
use of a feeder reactor with saturating characteristics.
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 39 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Installation
• The bushing supplied with the dynamic braking resistor assembly can
be used as a feed-through for the three conductors from the dynamic
braking resistor assembly while maintaining a Type 12 seal through an
enclosure wall. It can be used with surface thicknesses up to 0.10 in
(2.5 mm).
• Refer to ANSI/NFPA 70 (National Electrical Code) for information
concerning insulated conductor dimensions. The bushing supplied
with kits VW3A66711 to VW3A66714 is primarily intended for use with
#10 AWG conductors.
• Good wiring practice requires separation of dynamic braking power
wiring from all other drive controller wiring. Control and power wiring
should cross at right angles only. Use metal conduit for all dynamic
braking wiring outside the drive controller enclosure. Do not run control
or other power wiring in same conduit with dynamic braking power
wiring.
Installation
Bus Voltage Measurement Procedure
DANGER
HAZARDOUS VOLTAGE
• Read and understand the Bus Voltage Measurement Procedure
before performing procedure. Measurement of bus capacitor
voltage must be performed by qualified personnel.
• DO NOT short across capacitors or touch unshielded
components or terminal strip screw connections with voltage
present.
• Many parts in this drive controller, including printed wiring boards,
operate at line voltage. DO NOT TOUCH. Use only electrically
insulated tools.
Electrical shock will result in death or serious injury
© 1997 Square D All Rights Reserved
39
Chpt 1Book.book Page 40 Sunday, August 10, 2003 5:59 PM
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Installation
Bulletin No. VD0C06N908C
July 1998
The voltage is measured between the + and - terminals as shown in
Table 7. Refer to Figure 19 for terminal location.
Table 7:
DC Bus Measurement Terminals
Drive Controller
ATV58•
U09M2 and U18M2
U29M2 to U72M2 and
U18N4 to U90N4
U90M2 to D12M2 and
D12N4 to D23N4
+ Terminal
- Terminal
J2-4 (+)
J2-5 (-)
J2-5 (PA)
J18-7
J18-7
L1 L2
+
-
U
V
W
L1 L2 L3 PA PB U
V
ATV58•U09M2 and U18M2
(Single-phase input only)
W
All other drive controllers
J2 Terminal Block
Figure 19: DC Bus Measurement Terminals
To measure the bus capacitor voltage:
1.
2.
3.
4.
Disconnect all power from the drive controller.
Wait three minutes to allow the DC bus to discharge.
Open the cover.
Set the voltmeter to the 1000 VDC scale. Measure the voltage
between the + terminal and the - terminal to verify that the DC voltage
is less than 45 V for each measurement.
5. If the bus capacitors are not fully discharged, contact your local
Square D representative – do not operate the drive controller.
6. Replace all covers.
40
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 41 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Mounting Kits VW3A66711 to 714
Mounting Instructions for Kits VW3A66711, -712, -713, -714
Mounting on Enclosures
1. Remove dynamic braking resistor assembly cover by removing four
screws (A). See Figure 20 on page 43.
2. Remove bottom pan of dynamic braking resistor assembly by
removing four screws (B). See Figure 20 on page 43. Keep screws for
use in step 4.
3. Refer to hole patterns in Figure 21 on page 43. When drilling or
punching holes, avoid dropping metal chips or debris into the
enclosure. Clean interior of enclosure thoroughly using a vacuum
cleaner equipped with an insulated nozzle. Do not use compressed
air to blow debris from the enclosure.
For user-supplied enclosures housing ALTIVAR 58 drive controllers:
NOTE: It is the installer’s responsibility to determine the suitability of
the enclosure construction for installation of the dynamic braking
resistor assembly. Refer to the section “Pre-Installation
Considerations” on page 37 for construction requirements.
— Lay out a hole pattern on the top of the enclosure as illustrated in
Figure 21 on page 43.
— Drill four 0.182 in (4.52 mm) diameter holes (C) for attachment of
the dynamic braking resistor assembly using the M5 self-tapping
screws.
— Punch a 0.80 in (20.32 mm) diameter hole (D) for the feed-through
bushing.
4. Position dynamic braking resistor assembly on top of the enclosure so
that the mounting holes align with holes drilled on top of the drive
enclosure. Install nylon sleeves (E) and secure dynamic braking
resistor assembly to top of drive enclosure with the four screws saved
from step 2 (F). See Figure 22 on page 44.
5. Install the bushing (G) into the 0.80 in diameter (20.32 mm) hole in the
drive enclosure. See Figure 23 on page 44. When installing the
bushing attachment nut (J), torque the nut to approximately 24 lb-in
(2.8 N•m).
6. Route three conductors (refer to Table 6 on page 38) through the
rubber plug (H) and bushing so that 6 to 8 in (152.4 to 203.2 mm) of
conductor extends into dynamic braking resistor assembly cabinet. If
necessary, lubricate conductors using cable soap that will not
damage conductor insulation. Once conductors are installed, fingertighten cap of the feed-through bushing (I) so that the three wires are
gripped tightly by the bushing. See Figure 23 on page 44.
© 1997 Square D All Rights Reserved
41
Chpt 1Book.book Page 42 Sunday, August 10, 2003 5:59 PM
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Mounting Kits VW3A66711 to 714
Bulletin No. VD0C06N908C
July 1998
7. Make connections from terminals PA, PB, and ground on drive
controller (see Figure 19 on page 40) to terminals PA, PB, and ground
inside dynamic braking resistor assembly cabinet (see Figure 24 on
page 45).
8. Verify that the thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 24 on page 45.
9. Replace dynamic braking resistor cover and secure with four screws
(A). See Figure 20 on page 43.
10. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 20 on page 43
and Figure 24 on page 45.
Wall-Mounting Separately from Drive Enclosure
1. Remove dynamic braking resistor assembly cover by removing four
screws (A). See Figure 20 on page 43.
2. Refer to hole patterns in Figure 25 on page 45 or Figure 26 on page
46. Drill three holes (M) in mounting surface.
3. Open conduit entry (N) on side of dynamic braking resistor assembly.
Conduit entry knockouts are provided for 3/4 in (19.05 mm) and 1/2 in
(12.7 mm) pipe.
4. Mount dynamic braking resistor to mounting surface and secure with
three user-supplied screws. One-fourth in (6.35 mm) diameter screws
are recommended.
5. Make connections from terminals PA, PB, and ground on drive
controller (see Figure 19 on page 40) to terminals PA, PB, and ground
inside dynamic braking resistor assembly cabinet (see Figure 19 on
page 40). Refer to Table 6 on page 38.
NOTE: In Altivar 58 drive controllers, the drive-side ground may be
connected to the power terminal strip.
6. Verify that thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 24 on page 45.
7. Replace dynamic braking resistor cover and secure with four screws
(A). See Figure 20 on page 43.
8. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 20 on page 43
and Figure 24 on page 45.
42
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 43 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Figures
A
A
A
A
T
GEFAHR
B
HAZARDOUS VOLTAGE.
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
DANGER
B
(4 Places)
HAZARDOUS VOLTAGE.
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
Suggested location of alternate
language hazard label
Figure 20: Removing Cover and Bottom Pan: VW3A66711, 712, 713,
714
14.00
(355.6)
in
(mm)
13.50
(342.9)
13.00
(330.2)
C
5.44
(138.17)
3.68
(93.47)
.42
(10.67)
.182
(4.52) DIA (4 places)
1.00
(25.4)
TOP VIEW
D
.750 DIA Conduit Entry
(19.05)
Figure 21: Enclosure Mounting Dimensions: VW3A66711, 712, 713,
714
© 1997 Square D All Rights Reserved
43
Chpt 1Book.book Page 44 Sunday, August 10, 2003 5:59 PM
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
F
E
Figure 22: Mounting
G
H
I
J
Figure 23: Liquid-Tight Bushing
44
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 45 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Figures
L3
T3
5
6
L2
T2
4
PA
- Ground equipment.
- Before servicing, remove
GEFAHR
PB
3
OFF
all power. Wait 1 minute.
1
Verify no voltage is
T1
present.
2
Failur
in injury .
DANGER
HAZARDOUS VOLTAGE.
L1
round equipment.
efore servicing, remove
l power. Wait 1 minute.
ify no voltage is
ent.
1
ZARDOUS VOLTAGE.
-
Failure to comply will result
NOTE:
TO LIMIT RESISTOR
ENCLOSURE SURFACE
TEMP RISE TO 40œC,
THE RESISTOR O.L.
PROTECTION SHOULD
BE SET NO GREATER
THAN THE RESISTOR
NAMEPLATE CURRENT.
in injury or death.
52012-575-01
2
Suggested location
of alternate language
hazard labels
PA
L
PB
K
Figure 24: Dynamic Braking Resistor Assembly Terminals:
VW3A66711, 712, 713, 714
5.68
(144.3)
6.00
(152.4) 1.33
(33.8)
0.75
(19.0)
6.00
(152.4)
M
R
in
(mm)
N
6.50
(165.1)
.27
DIA (3 Places)
(6.9)
12.00
(304.8)
15
(381.0)
Figure 25: Wall Mounting Dimensions: VW3A66711 and
VW3A66712
© 1997 Square D All Rights Reserved
45
Chpt 1Book.book Page 46 Sunday, August 10, 2003 5:59 PM
Part 2: ALTIVAR 58 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
5.68
(144.3)
R
in
(mm)
N
9.00
(228.6)
1.33
(33.8)
0.75
(19.0)
6.00
(152.4)
M
6.50
(165.1)
.27
DIA (3 Places)
(6.9)
12.00
(304.8)
15.00
(381.0)
Figure 26: Wall Mounting Dimensions: VW3A66713 and
VW3A66714
46
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 47 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Introduction
PART 3: ALTIVAR 18 DYNAMIC BRAKING RESISTOR KIT
Introduction
The dynamic braking resistor kit allows ALTIVAR 18 drive controllers to
function in quadrants 2 and 4 of the speed/torque curve, dissipating the
excess braking energy in an external resistor.
Contents of Kit
This kit contains:
•
•
•
•
One dynamic braking resistor assembly
Four liquid-tight nylon sleeves
One liquid-tight three-hole bushing
Six danger labels: two French (52012-664-02); two German (52012664-03); two Spanish (52012-664-04)
• Instruction Bulletin VD0C06N908_ (latest revision)
Technical Specifications
Table 8:
Braking Resistor Kit Technical Specifications
Ohmic
Value
Continuous
Current Rating of
Assembly [1]
Average
Power
Rdb
Ir
W
ATV18U09M2, U18M2,
U18N4, U29N4, U41N4,
U54N4
120 ¾
1.0 A
120
VW3A66711
ATV18U29M2, U72N4,
U90N4, D12N4
56 ¾
1.45 A
118
VW3A66712
ATV18U41M2, U54M2,
U72M2, D16N4, D23N4
28 ¾
2.7 A
204
VW3A66713
ATV18U90M2, D12M2
14 ¾
3.8 A
202
VW3A66714
For Drives
[1]
Catalog
Number
Current rating of resistor assembly is calculated based on setting of internal overload protective device in
assembly, overload setting based on enclosure overtemperature protection, and resistor overload versus
time characteristics. Resistors are rated for stopping six times rotor inertia of four-pole motor with drive at
current limit. Motor inertias are based on NEMA MG-1 14.45.
© 1997 Square D All Rights Reserved
47
Chpt 1Book.book Page 48 Sunday, August 10, 2003 5:59 PM
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Current-Time Characteristics for DB Resistor Assemblies
Bulletin No. VD0C06N908C
July 1998
Current-Time Characteristic for DB Resistor Assemblies
Figure 27 shows allowable time according to multiples of current setting
with the dynamic braking resistor assembly located in a 40 °C ambient
temperature environment. For an example of calculating resistor size,
refer to Appendix C.
Time (s)
10000
1000
100
1
2
10
1
0.1
0.01
0.001
1
1.5
100
10
Multiples of current setting (lr)
(1) Cold state
(2) Hot state
Figure 27: Dynamic Braking Curves
48
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 49 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Pre-Installation Considerations
Pre-Installation Considerations
The dynamic braking resistor assembly may be wall-mounted. The
resistor assembly can also be used with certain general purpose
enclosures.
The following points should be considered before installation:
• The dynamic braking resistor generates heat during braking. When
operating at rated nameplate power in a 40 °C ambient temperature,
the resistor enclosure can reach temperatures of 80 °C. The dynamic
braking resistor should not be installed below or directly against heatsensitive materials or equipment. Do not mount against combustible
surfaces or on polymeric enclosures. Refer to local and national codes
for resistor mounting requirements.
• For proper cooling, always orient the resistor assembly as shown in
Figures 35 and 36 on page 59. Do not block ventilation openings of the
enclosure. Ensure that ventilation and clearance is adequate for the
rated power. Calculate the rated power of the assembly from
nameplate information using the following formula:
2
Power Rating = ( Nameplate Current Rating ) × Resistance
• If the time-current capability of the resistor is exceeded, protection is
provided to prevent resistor damage or excessive enclosure
temperatures. A thermal overload switch located inside the dynamic
braking resistor assembly will trip and open the resistor circuit to
prevent damage. The thermal overload switch may be reset once the
overload condition has been corrected. The reset pushbutton of the
thermal overload switch is accessed through the small hole in the front
of the resistor enclosure (T). See Figure 30 on page 56.
• The mounting surface must be capable of safely supporting the weight
of the dynamic braking resistor assembly. Refer to Table 9 for
assembly weights.
Table 9:
Assembly Weight
Dynamic Braking Assembly
Part No.
Weight
VW3A66711 and VW3A66712
11 lbs (5 kg)
VW3A66713 and VW3A66714
16 lbs (7.3 kg)
© 1997 Square D All Rights Reserved
49
Chpt 1Book.book Page 50 Sunday, August 10, 2003 5:59 PM
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Pre-Installation Considerations
Bulletin No. VD0C06N908C
July 1998
• The enclosure of the dynamic braking resistor assembly is rated
Type 1 per UL 50. The insulation system is intended for use in a
Pollution Degree 3 environment (refer to NEMA ICS-1). The
installation environment must be compatible with this rating.
• Self-tapping M5 hardware is supplied with the dynamic braking
resistor assembly and is intended for reuse during some installation
procedures. When threaded into a 0.182 in (4.52 mm) diameter hole,
the M5 hardware requires a minimum sheet metal thickness of 0.075
in (1.9 mm) in mild steel for rated thread strength. Do not thread
fasteners into dissimilar metals or non-metallic materials. The selfthreading M5 fasteners should be torqued to 32 to 41 lb-in (3.6 to 4.6
N•m).
• When connecting the dynamic braking resistor assembly to the drive
controller, use conductors with a cross-sectional size, insulation
temperature rating, and insulation voltage rating suitable for the
application. Follow the recommendations in Table 10 for minimum
conductor requirements.
Table 10:
PA, PB, GND Conductor Requirements
PA, PB, GND Minimum Conductor
Requirements [1]
Drive Controller
Part No.
Individual Conductor
Length not Exceeding
10 ft (3.0 m)
Individual Conductor
Length not Exceeding
100 ft (30.4 m)
ATV18U09M2 toU72M2
ATV18U18N4 to U54N4
600 V, #14 AWG,
60/75 °C Copper
-
ATV18U90M2 to D12M2
ATV18U72N4 to D23N4
600 V, #10 AWG,
60/75 °C Copper
-
ATV18U90M2 to D12M2
ATV18U90N4 to D23N4
-
600 V, #8 AWG,
60/75 °C Copper
[1]
50
In addition to the required continuous current rating, the conductor cross-sectional
size has been selected to minimize the possibility of insulation damage should an
overcurrent or ground fault occur at the DB resistor assembly. The coordination of
the conductors in the table is based upon the maximum input line fuse
recommended on the specific drive controller nameplate, the use of feeder ground
and line conductors selected per ANSI/NFPA 70 (National Electrical Code), and the
optional use of a feeder reactor with saturating characteristics.
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 51 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Installation
• The bushing supplied with the dynamic braking resistor assembly can
be used as a feed-through for the three conductors from the dynamic
braking resistor assembly while maintaining a Type 12 seal through an
enclosure wall. It can be used with surface thicknesses up to 0.10 in
(2.5 mm).
• Refer to ANSI/NFPA 70 (National Electrical Code) for information
concerning insulated conductor dimensions. The bushing supplied
with kits VW3A66711 to VW3A66714 is primarily intended for use with
#10 AWG conductors.
• Good wiring practice requires separation of dynamic braking power
wiring from all other drive controller wiring. Control and power wiring
should cross at right angles only. Use metal conduit for all dynamic
braking wiring outside the drive controller enclosure. Do not run control
or other power wiring in same conduit with dynamic braking power
wiring.
Installation
Bus Voltage Measurement Procedure
DANGER
HAZARDOUS VOLTAGE
• Read and understand the Bus Voltage Measurement Procedure
before performing the procedure.
• DO NOT short across capacitors or touch unshielded
components or terminal strip screw connections with voltage
present.
• Many parts in this drive controller, including printed wiring boards,
operate at line voltage. DO NOT TOUCH. Use only electrically
insulated tools.
Electrical shock will result in death or serious injury.
Drive Controllers ATV18•••M2 and ATV18U18N4 to D12N4
The voltage is measured between the equipment ground and each
terminal on the power terminal strip. The equipment ground is located on
the heat sink for drive controllers ATV18U09M2 and U18M2, and on the
metal conduit entry plate for the other products. The power terminal strip
is located on the power board, as shown in Figure 28 on page 52. A
second measurement is made between the PA terminal, located on the
power terminal strip and the other terminals on the power terminal strip.
© 1997 Square D All Rights Reserved
51
Chpt 1Book.book Page 52 Sunday, August 10, 2003 5:59 PM
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Installation
Bulletin No. VD0C06N908C
July 1998
To measure the bus capacitor voltage:
1.
2.
3.
4.
Disconnect all power from drive controller.
Wait 1 minute to allow the DC bus to discharge.
Remove all covers.
Set the voltmeter to the 1000 VDC scale. Measure the voltage
between the equipment ground terminal and each terminal on the
power terminal strip and verify the DC voltage is less than 45 V for
each measurement.
5. With the voltmeter at the 1000 VDC scale, measure between the PA
terminal and all of the other terminals on the power terminal strip.
Verify the DC voltage is less than 45 V for each measurement.
6. If the bus capacitors are not fully discharged, contact your local
Square D representative – do not operate the drive controller.
7. Replace all covers.
DATA ENT
Equipment
ground terminal
Power
terminals
Figure 28: Measuring Bus Capacitor Voltage
Drive Controllers ATV18D16N4 and ATV18D23N4
For these drive controllers, the voltage is measured between the PA and
PC terminals located on the power board, as shown in Figure 28.
52
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 53 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Installation
To measure the bus capacitor voltage:
1.
2.
3.
4.
Disconnect all power from drive controller.
Wait 1 minute to allow the DC bus to discharge.
Remove all covers.
Set the voltmeter to the 1000 VDC scale. Measure the bus capacitor
voltage between the PA and PC terminals to verify that DC voltage is
less than 45 V. Do not short across capacitor terminals with
voltage present!
5. If the bus capacitors are not fully discharged, contact your local
Square D representative – do not operate the drive controller.
6. Replace all covers.
L1
L2
E PO PA PB
L1
L2 L3
L1
L2
U
ATV18 U09M2 to U41M2
V
W
E
E PO PA PB
U
V
W
L3 G/E PO PA PB
U
V
W G/E
E
ATV18 U54M2, U72M2, and
ATV18 U18N4 to U72N4
ATV18 U90M2, D12M2,
U90N4, and D12N4
PA PB PC
PO L1
L2 L3 G/E U
V
W G/E
ATV18 D16N4 and D23N4
Figure 29: ATV18 Power Terminal Locations
© 1997 Square D All Rights Reserved
53
Chpt 1Book.book Page 54 Sunday, August 10, 2003 5:59 PM
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Mounting Kits VW3A66711 to 714
Bulletin No. VD0C06N908C
July 1998
Mounting Kits VW3A66711, -712, -713, -714
Mounting on Enclosures
1. Remove dynamic braking resistor assembly cover by removing four
screws (A). See Figure 30 on page 56.
2. Remove bottom pan of dynamic braking resistor assembly by
removing four screws (B). See Figure 30 on page 56. Keep screws for
use in step 4.
3. Refer to hole patterns in Figure 31 on page 57. When drilling or
punching holes, avoid dropping metal chips or debris into the
enclosure. Clean interior of enclosure thoroughly using a vacuum
cleaner equipped with an insulated nozzle. Do not use compressed
air to blow debris from the enclosure.
For user-supplied enclosures housing ALTIVAR 18 drive controllers:
NOTE: It is the installer’s responsibility to determine the suitability of
the enclosure construction for installation of the dynamic braking
resistor assembly. Refer to the section “Pre-Installation
Considerations” on page 37 for construction requirements.
— Lay out a hole pattern on the top of the enclosure as illustrated in
Figure 31 on page 57.
— Drill four 0.182 in (4.52 mm) diameter holes (C) for attachment of
the dynamic braking resistor assembly using the M5 self-tapping
screws.
— Punch a 0.80 in (20.32 mm) diameter hole (D) for the feed-through
bushing.
4. Position dynamic braking resistor assembly on top of the enclosure so
that the mounting holes align with holes drilled on top of the drive
enclosure. Install nylon sleeves (E) and secure dynamic braking
resistor assembly to top of drive enclosure with the four screws saved
from step 2 (F). See Figure 32 on page 57.
5. Install the bushing (G) into the 0.80 in diameter (20.32 mm) hole in the
drive enclosure. See Figure 33 on page 58. When installing the
bushing attachment nut (J), torque the nut to approximately 24 lb-in
(2.8 N•m).
6. Route three conductors (refer to Table 10 on page 50) through the
rubber plug (H) and bushing so that 6 to 8 in (152.4 to 203.2 mm) of
conductor extends into dynamic braking resistor assembly cabinet. If
necessary, lubricate conductors using cable soap that will not
damage conductor insulation. Once conductors are installed, finger-
54
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 55 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Mounting Kits VW3A66711 to 714
tighten cap of the feed-through bushing (I) so that the three wires are
gripped tightly by the bushing. See Figure 33 on page 58.
7. Make connections from terminals PA, PB, and ground on drive
controller (see Figure 29 on page 53) to terminals PA, PB, and ground
inside dynamic braking resistor assembly cabinet (see Figure 34 on
page 58).
8. Verify that the thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 34 on page 58.
9. Replace dynamic braking resistor cover and secure with four screws
(A). See Figure 30 on page 56.
10. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 30 on page 56
and Figure 34 on page 58.
Wall-Mounting Separately from Drive Enclosure
1. Remove dynamic braking resistor assembly cover by removing four
screws (A). See Figure 30 on page 56.
2. Refer to hole patterns in Figure 35 on page 59 or Figure 36 on page
59. Drill three holes (M) in mounting surface.
3. Open conduit entry (N) on side of dynamic braking resistor assembly.
Conduit entry knockouts are provided for 3/4 in (19.05 mm) and 1/2 in
(12.7 mm) pipe.
4. Mount dynamic braking resistor to mounting surface and secure with
three user-supplied screws. One-fourth in (6.35 mm) diameter screws
are recommended.
5. Make connections (refer to Table 10 on page 50) from terminals PA,
PB, and ground on drive controller (see Figure 29 on page 53) to
terminals PA, PB, and ground inside dynamic braking resistor
assembly cabinet (see Figure 34 on page 58).
NOTE: In Altivar 18 drive controllers, the drive-side ground may be
connected to the power terminal strip or to an M5 screw terminal. The
screw terminal is located on the heat sink of the ATV18U09M2 and
U18M2 and on the metal cable entry plate of all other units.
6. Verify that thermal overload switch setting (K) matches dynamic
braking resistor assembly nameplate current rating, and that thermal
overload start switch (L) is in On position. See Figure 34 on page 58.
7. Replace dynamic braking resistor cover and secure with four screws
(A). See Figure 30 on page 56.
© 1997 Square D All Rights Reserved
55
Chpt 1Book.book Page 56 Sunday, August 10, 2003 5:59 PM
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
8. Attach French, Spanish, or German danger labels (R) to dynamic
braking resistor assembly enclosure as appropriate. For suggested
location of alternate language labels, refer to Figure 30 on page 56
and Figure 34 on page 58.
A
A
B
A
A
T
GEFAHR
HAZARDOUS VOLTAGE.
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
DANGER
HAZARDOUS VOLTAGE.
- Ground equipment.
- Before servicing, remove
all power. Wait 1 minute.
Verify no voltage is
present.
Failure to comply will result
in injury or death.
B
(4 Places)
Suggested location of alternate
language hazard label
Figure 30: Removing Cover and Bottom Pan: VW3A66711, 712, 713,
714
56
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 57 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Figures
14.00
(355.6)
in
(mm)
13.50
(342.9)
13.00
(330.2)
C
.42
(10.67)
5.44
(138.17)
3.68
(93.47)
.182
(4.52) DIA (4 places)
1.00
(25.4)
TOP VIEW
D
.750 DIA Conduit Entry
(19.05)
Figure 31: Enclosure Mounting Dimensions: VW3A66711, 712, 713,
714
F
E
Figure 32: Mounting
© 1997 Square D All Rights Reserved
57
Chpt 1Book.book Page 58 Sunday, August 10, 2003 5:59 PM
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Figures
Bulletin No. VD0C06N908C
July 1998
G
H
I
J
Figure 33: Liquid-Tight Bushing
L3
T3
5
6
L2
T2
4
PA
- Ground equipment.
- Before servicing, remove
GEFAHR
3
OFF
PB
all power. Wait 1 minute.
Verify no voltage is
1
T1
present.
2
Failur
in injury .
DANGER
HAZARDOUS VOLTAGE.
L1
round equipment.
efore servicing, remove
l power. Wait 1 minute.
ify no voltage is
ent.
1
ZARDOUS VOLTAGE.
-
Failure to comply will result
L
TO LIMIT RESISTOR
ENCLOSURE SURFACE
TEMP RISE TO 40œC,
THE RESISTOR O.L.
PROTECTION SHOULD
BE SET NO GREATER
THAN THE RESISTOR
NAMEPLATE CURRENT.
in injury or death.
2
Suggested location
of alternate language
hazard labels
NOTE:
PA
52012-575-01
PB
K
Figure 34: Dynamic Braking Resistor Assembly Terminals:
VW3A66711, 712, 713, 714
58
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 59 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Part 3: ALTIVAR 18 Dynamic Braking Resistor Kit
Figures
5.68
(144.3)
N
6.00
(152.4) 1.33
(33.8)
0.75
(19.0)
M
6.00
(152.4)
in
(mm)
R
6.50
(165.1)
.27
DIA (3 Places)
(6.9)
12.00
(304.8)
15
(381.0)
Figure 35: Wall Mounting Dimensions: VW3A66711 and
VW3A66712
5.68
(144.3)
R
in
(mm)
N
9.00
(228.6)
1.33
(33.8)
0.75
(19.0)
6.00
(152.4)
M
6.50
(165.1)
.27
DIA (3 Places)
(6.9)
12.00
(304.8)
15.00
(381.0)
Figure 36: Wall Mounting Dimensions: VW3A66713 and
VW3A66714
© 1997 Square D All Rights Reserved
59
Chpt 1Book.book Page 60 Sunday, August 10, 2003 5:59 PM
Appendix A: Calculating ALTIVAR 66 DB Resistor Requirements
Introduction
Bulletin No. VD0C06N908C
July 1998
APPENDIX A: CALCULATING DYNAMIC BRAKING RESISTOR REQUIREMENTS FOR
ALTIVAR 66 CONTROLLERS
Introduction
The standard Dynamic Braking (DB) resistor assemblies listed in this
manual are suitable for a wide variety of drive system stopping service
applications. However, when the driven machinery may present an
overhauling load or large inertia to the drive system, the suitability of the
DB resistor assembly for the application should be checked.
The suitability of a DB resistor assembly is determined by analyzing the
mechanical system of the driven machinery. From the analysis, the
following three key parameters are computed:
• The peak braking power required during stopping or speed changes
(Pi). The value of Pi determines the maximum allowable ohmic value
of the DB resistor.
• The amount of power that must be absorbed (Ps) for a given time (td)
by the DB resistors during stopping or speed changes of the drive. The
value of Pd and Td determine the required time-current characteristic
of the DB resistor.
• The calculation of dynamic braking power requires Vdb.
Vdb = 795 V for 460 V drives
Vdb = 397 V for 230 V drives
• The average power that must be dissipated by the DB resistor during
an entire cycle of the machine (Pa). The value of Pa determines the
required continuous current rating of the DB resistor.
Examples
The following example illustrates the process.
Given:
The application consists of a 5 hp, 1740 rpm motor with a rotor inertia of
0.28 lbf-ft2. The motor is being controlled by an ATV66U72N4 operating
in the constant torque mode. The motor is driving a machine with an
inertia 10 times that of the motor with no interposing speed changer. The
machine resistive (friction) torque is one-tenth of the rated motor torque
at full speed. The requirement is to stop in 5 seconds from rated speed at
a rate of 2 cycles per minute.
60
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 61 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Appendix A: Calculating ALTIVAR 66 DB Resistor Requirements
Examples
Mechanical system parameters:
Rated motor torque:
Tn = (hp x 5250)/Nbase = (5 x 5250)/1740 = 15.1 lbf-ft
Machine cycle time:
tc = (60 seconds)/(two operations per minute) = 30 seconds
Machine speed change during deceleration:
Nd = 1740 rpm - 0 rpm = 1740 rpm
Machine deceleration time:
td = 5 seconds
Mechanical system resistive (friction) torque:
Tr = (15.1 lbf-ft)/10 = 1.51 lbf-ft
Mechanical system overhauling torque:
To = 0.00 lbf-ft
Mechanical system combined inertia:
Jc = 0.28 lbf-ft2 + (10) x 0.28 lbf-ft2 = 3.08 lbf-ft2
Mechanical system inertial torque for a given deceleration rate (as set by
controller decel ramp):
Tj = Jc x (Nd)/(308 x (td)) = 3.08 x 1740/(308 x 5) = 3.48 lbf-ft
Required braking torque from motor:
Tb = Tj + To - Tr = 3.48 + 0.00 - 1.51 = 1.97 lbf-ft
NOTE: The required braking torque must not exceed the motor’s ability
to produce torque. For inertial loads, including those depicted in the
above examples, the required braking torque must not exceed either 1.5
times the motor rated torque for constant torque controllers or 1.1 times
the motor rated torque for variable torque controllers.
For machines that can continuously overhaul the motor, the value of
overhauling torque (To) minus the resistive torque (Tr) must not exceed
the motor continuous torque rating at any speed.
© 1997 Square D All Rights Reserved
61
Chpt 1Book.book Page 62 Sunday, August 10, 2003 5:59 PM
Appendix A: Calculating ALTIVAR 66 DB Resistor Requirements
Examples
Bulletin No. VD0C06N908C
July 1998
DB resistor requirements:
Peak braking power required to develop braking torque (Tb) when
decelerating from a given speed (N):
Pi = Tb x N/(7.04) = (1.97 x 1740)/(7.04) = 487 W
The braking power that must be absorbed for a time (td) during stopping
or speed changing operation:
Pd = 0.5 x Pi = 0.5 x 487 = 243 W for a period of td seconds
The average braking power that must be dissipated during a machine
cycle:
Pa = Pd x td/tc = 243 x 5/30 = 40.5 W
Capability of VW3-A66711 DB resistor assembly for ATV66U72N4
controller:
Peak braking power that can be developed with VW3-A66711 DB resistor
assembly with controller configured for 460 V input line operation:
Pi = (Vdb)2/Rdb = (795 V)2/120W = 5267 W
The braking power that can be absorbed for td (based on DB resistor hot
state current-time characteristic curve shown in Figure 1 on page 8):
Pd = Rdb x ((Multiple of Ir at td) x Ir)2 = 120W x (3.5 x 1)2 = 1470 W
NOTE: Since Rdb limits the peak current that can be drawn from the drive
controller DC bus, the value of [(Multiple of Ir) x Ir] must be limited to no
greater than (÷ pi/Rdb).
The average braking power that can be dissipated continuously:
Pa = Rdb x (Ir)2 = 120W x (1)2 = 120 W
For the example, the VW3-A66711 DB resistor assembly will work as
intended for the application.
62
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 63 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Appendix B: Calculating ALTIVAR 58 DB Resistor Requirements
Introduction
APPENDIX B: CALCULATING DYNAMIC BRAKING RESISTOR REQUIREMENTS FOR
ALTIVAR 58 CONTROLLERS
Introduction
The standard Dynamic Braking (DB) resistor assemblies listed in this
manual are suitable for a wide variety of drive system stopping service
applications. However, when the driven machinery may present an
overhauling load or large inertia to the drive system, the suitability of the
DB resistor assembly for the application should be checked.
The suitability of a DB resistor assembly is determined by analyzing the
mechanical system of the driven machinery. From the analysis, the
following four key parameters are computed:
• The peak braking power required during stopping or speed changes
(Pi). The value of Pi determines the maximum allowable ohmic value
of the DB resistor.
• The amount of power that must be absorbed (Pd) for a given time (td)
by the DB resistors during stopping or speed changes of the drive. The
value of Pd and Td determine the required time-current characteristic
of the DB resistor.
• The calculation of dynamic braking power requires Vdb.
Vdb = 850 V for 460 V drives
Vdb = 375 V for 230 V drives
• The average power that must be dissipated by the DB resistor during
an entire cycle of the machine (Pa). The value of Pa determines the
required continuous current rating of the DB resistor.
Examples
The following example illustrates the process.
Given:
The application consists of a 5 hp, 460 V, 1740 rpm motor with a rotor
inertia of 0.28 lbf-ft2. The motor is being controlled by an ATV58U72N4
operating in the constant torque mode. The motor is driving a machine
with an inertia 10 times that of the motor with no interposing speed
changer. The machine resistive (friction) torque is one-tenth of the rated
motor torque at full speed. The requirement is to stop in 5 seconds from
rated speed at a rate of 2 cycles per minute.
© 1997 Square D All Rights Reserved
63
Chpt 1Book.book Page 64 Sunday, August 10, 2003 5:59 PM
Appendix B: Calculating ALTIVAR 58 DB Resistor Requirements
Examples
Bulletin No. VD0C06N908C
July 1998
Mechanical system parameters:
Rated motor torque:
Tn = (hp x 5250)/Nbase = (5 x 5250)/1740 = 15.1 lbf-ft
Machine cycle time:
tc = (60 seconds)/(two operations per minute) = 30 seconds
Machine speed change during deceleration:
Nd = 1740 rpm - 0 rpm = 1740 rpm
Machine deceleration time:
td = 5 seconds
Mechanical system resistive (friction) torque:
Tr = (15.1 lbf-ft)/10 = 1.51 lbf-ft
Mechanical system overhauling torque:
To = 0.00 lbf-ft
Mechanical system combined inertia:
Jc = 0.28 lbf-ft2 + (10) x 0.28 lbf-ft2 = 3.08 lbf-ft2
Mechanical system inertial torque for a given deceleration rate (as set by
controller decel ramp):
Tj = Jc x (Nd)/(308 x (td)) = 3.08 x 1740/(308 x 5) = 3.48 lbf-ft
Required braking torque from motor:
Tb = Tj + To - Tr = 3.48 + 0.00 - 1.51 = 1.97 lbf-ft
NOTE: The required braking torque must not exceed the motor’s ability
to produce torque. For inertial loads, including those depicted in the
above examples, the required braking torque must not exceed the torque
producing ability of the dynamic braking unit with the recommended
braking resistor (approximately 1.5 times the motor rated torque).
For machines that can continuously overhaul the motor, the value of
overhauling torque (To) minus the resistive torque (Tr) must not exceed
the motor continuous torque rating at any speed.
64
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 65 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Appendix B: Calculating ALTIVAR 58 DB Resistor Requirements
Examples
DB resistor requirements:
Peak braking power required to develop braking torque (Tb) when
decelerating from a given speed (N):
Pi = Tb x N/(7.04) = (1.97 x 1740)/(7.04) = 487 W
The braking power that must be absorbed for a time (td) during stopping
or speed changing operation:
Pd = 0.5 x Pi = 0.5 x 487 = 243 W for a period of td seconds
The average braking power that must be dissipated during a machine
cycle:
Pa = Pd x td/tc = 243 x 5/30 = 40.5 W
Capability of VW3-A66711 DB resistor assembly for ATV58U72N4
controller:
Peak braking power that can be developed with VW3-A66711 DB resistor
assembly with controller configured for 460 V input line operation:
Pi = (Vdb)2/Rdb = (850 V)2/120 Ω = 6020 W
The braking power that can be absorbed for td (based on DB resistor hot
state current-time characteristic curve shown in Figure 18 on page 36):
Pd = Rdb x ((Multiple of Ir at td) x Ir)2 = 120Ω x (3.5 x 1.0)2 = 1470 W
Since Rdb limits the peak current that can be drawn from the drive
controller DC bus, the value of [(Multiple of Ir) x Ir] must be limited to no
greater than (√ pi/Rdb).
The average braking power that can be dissipated continuously:
Pa = Rdb x (Ir)2 = 120Ω x (1)2 = 120 W
For the example, the VW3-A66711 DB resistor assembly will work as
intended for the application.
© 1997 Square D All Rights Reserved
65
Chpt 1Book.book Page 66 Sunday, August 10, 2003 5:59 PM
Appendix C: Calculating ALTIVAR 18 DB Resistor Requirements
Introduction
Bulletin No. VD0C06N908C
July 1998
APPENDIX C: CALCULATING DYNAMIC BRAKING RESISTOR REQUIREMENTS FOR
ALTIVAR 18 CONTROLLERS
Introduction
The standard Dynamic Braking (DB) resistor assemblies listed in this
manual are suitable for a wide variety of drive system stopping service
applications. However, when the driven machinery may present an
overhauling load or large inertia to the drive system, the suitability of the
DB resistor assembly for the application should be checked.
The suitability of a DB resistor assembly is determined by analyzing the
mechanical system of the driven machinery. From the analysis, the
following four key parameters are computed:
• The peak braking power required during stopping or speed changes
(Pi). The value of Pi determines the maximum allowable ohmic value
of the DB resistor.
• The amount of power that must be absorbed (Pd) for a given time (td)
by the DB resistors during stopping or speed changes of the drive. The
value of Pd and Td determine the required time-current characteristic
of the DB resistor.
• The calculation of dynamic braking power requires Vdb.
Vdb = 795 V for 460 V drives
Vdb = 397 V for 230 V drives
• The average power that must be dissipated by the DB resistor during
an entire cycle of the machine (Pa). The value of Pa determines the
required continuous current rating of the DB resistor.
Examples
The following example illustrates the process.
Given:
The application consists of a 5 hp, 460 V, 1740 rpm motor with a rotor
inertia of 0.28 lbf-ft2. The motor is being controlled by an ATV18U72N4
operating in the constant torque mode. The motor is driving a machine
with an inertia 10 times that of the motor with no interposing speed
changer. The machine resistive (friction) torque is one tenth of the rated
motor torque at full speed. The requirement is to stop in 5 seconds from
rated speed at a rate of 2 cycles per minute.
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© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 67 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
Appendix C: Calculating ALTIVAR 18 DB Resistor Requirements
Examples
Mechanical system parameters:
Rated motor torque:
Tn = (hp x 5250)/Nbase = (5 x 5250)/1740 = 15.1 lbf-ft
Machine cycle time:
tc = (60 seconds)/(two operations per minute) = 30 seconds
Machine speed change during deceleration:
Nd = 1740 rpm - 0 rpm = 1740 rpm
Machine deceleration time:
td = 5 seconds
Mechanical system resistive (friction) torque:
Tr = (15.1 lbf-ft)/10 = 1.51 lbf-ft
Mechanical system overhauling torque:
To = 0.00 lbf-ft
Mechanical system combined inertia:
Jc = 0.28 lbf-ft2 + (10) x 0.28 lbf-ft2 = 3.08 lbf-ft2
Mechanical system inertial torque for a given deceleration rate (as set by
controller decel ramp):
Tj = Jc x (Nd)/(308 x (td)) = 3.08 x 1740/(308 x 5) = 3.48 lbf-ft
Required braking torque from motor:
Tb = Tj + To - Tr = 3.48 + 0.00 - 1.51 = 1.97 lbf-ft
NOTE: The required braking torque must not exceed the motor’s ability
to produce torque. For inertial loads, including those depicted in the
above examples, the required braking torque must not exceed 1.5 times
the motor rated torque for constant torque controllers.
For machines that can continuously overhaul the motor, the value of
overhauling torque (To) minus the resistive torque (Tr) must not exceed
the motor continuous torque rating at any speed.
© 1997 Square D All Rights Reserved
67
Chpt 1Book.book Page 68 Sunday, August 10, 2003 5:59 PM
Appendix C: Calculating ALTIVAR 18 DB Resistor Requirements
Examples
Bulletin No. VD0C06N908C
July 1998
DB resistor requirements:
Peak braking power required to develop braking torque (Tb) when
decelerating from a given speed (N):
Pi = Tb x N/(7.04) = (1.97 x 1740)/(7.04) = 487 W
The braking power that must be absorbed for a time (td) during stopping
or speed changing operation:
Pd = 0.5 x Pi = 0.5 x 487 = 243 W for a period of td seconds
The average braking power that must be dissipated during a machine
cycle:
Pa = Pd x td/tc = 243 x 5/30 = 40.5 W
Capability of VW3-A66712 DB resistor assembly for ATV18U72N4
controller:
Peak braking power that can be developed with VW3-A66712 DB resistor
assembly with controller configured for 460 V input line operation:
Pi = (Vdb)2/Rdb = (795 V)2/56Ω = 11,286 W
The braking power that can be absorbed for td (based on DB resistor hot
state current-time characteristic curve shown in Figure 27 on page 48):
Pd = Rdb x ((Multiple of Ir at td) x Ir)2 = 56Ω x (3.5 x 1.45)2 = 1442 W
Since Rdb limits the peak current that can be drawn from the drive
controller DC bus, the value of [(Multiple of Ir) x Ir] must be limited to no
greater than (√ pi/Rdb).
The average braking power that can be dissipated continuously:
Pa = Rdb x (Ir)2 = 56Ω x (1.45)2 = 118 W
For the example, the VW3-A66712 DB resistor assembly will work as
intended for the application.
68
© 1997 Square D All Rights Reserved
Chpt 1Book.book Page 69 Sunday, August 10, 2003 5:59 PM
Bulletin No. VD0C06N908C
July 1998
© 1997 Square D All Rights Reserved
Appendix C: Calculating ALTIVAR 18 DB Resistor Requirements
Examples
69