vacon® nx

ac drives

brake resistors
user manual
GENERAL vacon • 1

TABLE OF CONTENTS Document code: DPD01573C

Date edited: 7.12.2016

1. GENERAL ............................................................................................................................................ 2
1.1 The requirements for braking ......................................................................................... 2

1.2 Brake components ......................................................................................................... 2

1.3 Classes of use ................................................................................................................ 2

2. TECHNICAL DATA .............................................................................................................................. 3
2.1 Standard resistors for partial use ................................................................................... 3
2.1.1 380-500V range .............................................................................................................................. 4
2.1.2 208-240V range .............................................................................................................................. 5
2.1.3 525-690V range .............................................................................................................................. 6
2.2 Other resistors ............................................................................................................... 8

2.3 Power rating of standard resistors ............................................................................... 11

2.4 Environment ................................................................................................................ 13

2.5 Thermal protection for the LD resistors ....................................................................... 14

2.5.1 Thermal protection ...................................................................................................................... 15
3. CHOOSING A BRAKE RESISTOR ..................................................................................................... 16
3.1 General ........................................................................................................................ 16

3.2 Sizing principles........................................................................................................... 16

3.2.1 Calculating braking time ............................................................................................................. 17
3.2.2 Calculating the moment of inertia .............................................................................................. 17
3.2.3 Internal resistors ......................................................................................................................... 21
4. CONNECTIONS ................................................................................................................................. 22
4.1 General ........................................................................................................................ 22

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 2 • vacon GENERAL

1. GENERAL
1.1 The requirements for braking
When you want to slow down a running asynchronous motor fed by an AC drive it turns into a
generator, feeding energy back into the AC drive. The energy increases the voltage in the DC-link. The
AC drive compensates for this increase by increasing the output frequency, decreasing the
instantaneous slip and increasing the motor load.
The deceleration is, in this case, dependent on the power losses in the converter and in the motor.
This is usually sufficient in most cases, for pumps, fans, conveyors etc. where the kinetic energy in
the load is small or the braking time is not critical.
When you have to brake the motor faster than the losses allow, you have to use an external brake
resistor for energy dissipation together with an internal, factory-mounted brake chopper. The extra
energy from the load is turned into heat in the brake resistor.
Applications where dynamic braking is usually needed include centrifuges, cranes, some conveyors
and AC drives requiring very fast reversing.

1.2 Brake components

The brake chopper is an extra IGBT mounted into the NX AC drives at the time of manufacturing.
Smaller AC drives (FR4 to FR6 and MF4 to MF6) contain it as standard. If the DC link voltage increases
too much, the brake IGBT turns on and discharges the capacitors through the brake resistor. The
brake chopper in the NX AC drive ranges is rated for continuous AC drive rated power.
The brake resistor is an external, low impedance resistor. In order to achieve the correct power
handling capacity for a specific application, resistors can be connected in series and parallel, keeping
within the limits in Table 7.

Brake resistor

Brake chopper

nxbr1.fh11

Figure 1. The brake components and their basic connection

1.3 Classes of use

a) Partial use (most typical)
The process requires regular or irregular rapid decelerations, stops or reversings.
b) Continuous use
The motor continuously brakes with constant torque.
c) Combination use
The motor continuously brakes with variable torque.
d) DC-link voltage smoothing
The brake resistor smooths overvoltage spikes from the supply.

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1
TECHNICAL DATA vacon • 3

2. TECHNICAL DATA
2.1 Standard resistors for partial use
Brake resistors for partial use for the NX ranges for 208-240V, 380-500V and 525-690V supply
voltages can be chosen from the tables below.
For the NX_5 range we have predefined two ranges of brake resistors, one for heavy duty and one for
light duty. The heavy duty resistor is sized for a 3-second full power braking with a 7-second ramp to
zero. The light duty resistor is rated for a 5-second ramp from full power to zero. See Figure 2.

Predefined power pulses

1,2
1
Relative power

0,8
Heavy duty
0,6
Light duty
0,4
0,2
0
0 1 2 3 4 5 6 7 8 9 10
Time (s)

Figure 2. Heavy and light duty braking definitions.

Relative power handling capability of the

standard brake resistor ranges Peak power

1,20
1,00
0,80
Heavy duty
0,60 Average power =
Light duty
0,40 Continuos power
0,20
0,00
0%
2%
3%
5%
7%
8%
17 %
25 %
33 %
42 %
50 %
67 %
83 %
100 %

ED% ( based on 120 s period)

Figure 3. Peak and average power definitions.

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 4 • vacon TECHNICAL DATA

2.1.1 380-500V range

Light duty
Energy [kJ] Average power
[kW]
5 sec full torque
Type code Resistance 1 pulse/2 min
braking
BRR 0022 LD 5 63 28 0.24
BRR 0031 LD 5 42 42 0.35
BRR 0045 LD 5 21 84 0.71
BRR 0061 LD 5 14 127 1.06
BRR 0105 LD 5 6.5 273 2.28
BRR 0300 LD 5 3.3 547 4.56
BRR 0520 LD 5 1.4 1270 10.6
BRR 0730 LD 5 0.9 1975 16.5
Heavy duty
Energy Average power
[kJ] [kW]
3 sec full torque
Type code Resistance decreasing to zero in 7s 1 pulse / 2min
BRR 0022 HD 5 63 73 0.61
BRR 0031 HD 5 42 110 0.91
BRR 0045 HD 5 21 220 1.83
BRR 0061 HD 5 14 330 2.74
BRR 0105 HD 5 6.5 710 5.9
BRR 0300 HD 5 3.3 1421 11.8
BRR 0520 HD 5 1.4 3300 27.4
BRR 0730 HD 5 0.9 5132 43
Table 1. Brake resistors for the voltage range 380-500V

Choose the resistor for all types of AC drives (NXL, NXS and NXP) according to the table below:

Unit Enclosure Light duty Heavy duty

size resistor resistor
NX_ 0003 5
NX_ 0004 5
NX_ 0005 5
FR4 BRR 0022 LD 5 BRR 0022 HD 5
NX_ 0007 5
NX_ 0009 5
NX_ 0012 5
NX_ 0016 5
FR5 BRR 0022 LD 5 BRR 0022 HD 5
NX_ 0022 5
NX_ 0031 5 FR5 BRR 0031 LD 5 BRR 0031 HD 5
NX_ 0038 5
FR6 BRR 0045 LD 5 BRR 0045 HD 5
NX_ 0045 5
NX_ 0061 5 FR6 BRR 0061 LD 5 BRR 0061 HD 5
NX_ 0072 5
FR7 BRR 0105 LD 5 BRR 0105 HD 5
NX_ 0087 5
NX_ 0105 5 FR7 BRR 0105 LD 5 BRR 0105 HD 5
NX_ 0140 5 FR8 BRR 0300 LD 5 BRR 0300 HD 5

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TECHNICAL DATA vacon • 5

NX_ 0168 5
NX_ 0205 5 FR8 BRR 0300 LD 5 BRR 0300 HD 5
NX_ 0261 5
FR9 BRR 0300 LD 5 BRR 0300 HD 5
NX_ 0300 5
NX_0385 5
NX_0460 5 FR10 BRR 0520 LD 5 BRR 0520 HD 5
NX_0520 5
NX_0590 5
NX_0650 5 FR11 BRR 0730 LD 5 BRR 0730 HD 5
NX_0730 5
NX_0820 5
NX_0920 5 FR12 2 x BRR 0520 LD 5 2 x BRR 0520 HD 5
NX_1030 5
Table 2. Brake resistors used with AC drives

Light duty resistor:IP50 with direct wire connection, BRR0022 LD5 has a thermal protection as option.
Heavy duty resistor:IP20/21, connecting box, thermal protection as standard.

2.1.2 208-240V range

Light duty
Energy [kJ] Average power
[kW]
5 sec full torque
Type code Resistance 1 pulse/2 min
braking
BRR 0025 LD2 30 12.55 0.10
BRR 0031 LD2 20 18.8 0.16
BRR 0061 LD2 10 38 0.31
BRR 0114 LD2 3.3 114 0.95
BRR 0205 LD2 1.4 269 2.24
Heavy duty
Energy Average power
[kJ] [kW]
3 sec full torque
decreasing to zero in
Type code Resistance 7 sec 1 pulse / 2min
BRR 0034 LD6 30 32.6 0.27
BRR 0031 HD2 20 49 0.41
BRR 0061 HD2 10 98 0.81
BRR 0114 HD2 3.3 297 2.47
BRR 0205 HD2 1.4 699 5.81
Table 3. Brake resistors for the voltage range 208-240V

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 6 • vacon TECHNICAL DATA

Choose the resistor for the AC drive (voltage range 208-240V) according to the table below:

Unit Enclosure Light duty Heavy duty

size resistor resistor
NX_ 0003 2
NX_ 0004 2
NX_ 0007 2
FR4 BRR 0025 LD 2 BRR 0034 LD6 *
NX_ 0008 2
NX_ 0011 2
NX_ 0012 2
NX_ 0017 2
FR5 BRR 0025 LD 2 BRR 0034 LD6 *
NX_ 0025 2
NX_ 0031 2 FR5 BRR 0031 LD 2 BRR 0031 HD 2
NX_ 0048 2
FR6 BRR 0061 LD 2 BRR 0061 HD 2
NX_ 0061 2
NX_ 0075 2
NX_ 0088 2 FR7 BRR 0114 LD 2 BRR 0114 HD 2
NX_ 0114 2
NX_0140 2
NX_0170 2 FR8 BRR 0205 LD2 BRR 0205 HD2
NX_0205 2
NX_0261 2
FR9 BRR 0205 LD2 BRR 0205 HD2
NX_0300 2
Table 4. Brake resistors used with AC drives

* = Thermal switch (OT1) optional.

Light duty resistor: IP50 with direct wire connection.
Heavy duty resistor: IP20/21, connecting box, thermal protection as standard.

2.1.3 525-690V range

Light duty
Energy [kJ] Average power
[kW]
5 sec full torque
Type code Resistance 1 pulse/2 min
braking
BRR 0013 LD 6 100 34 0.28
BRR 0034 LD 6 30 113 0.94
BRR 0052 LD 6 18 188 1.6
BRR 0100 LD 6 9 376 3.1
BRR 0208 LD 6 7 484 4.0
BRR 0416 LD 6 2.5 1355 11
BRR 0590 LD 6 1.7 1993 17

Heavy duty
Energy Average power
[kJ] [kW]
3 sec full torque
decreasing to zero in
Type code Resistance 7 sec 1 pulse / 2min
BRR 0013 HD 6 100 88 0.73

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2
TECHNICAL DATA vacon • 7

BRR 0034 HD 6 30 294 2.4

BRR 0052 HD 6 18 489 4.1
BRR 0100 HD 6 9 978 8.1
BRR 0208 HD 6 7 1258 10
BRR 0416 HD 6 2.5 3523 29
BRR 0590 HD 6 1.7 5181 43
Table 5. Brake resistors for the voltage range 525-690V

Choose the resistor for the AC drive (voltage range 208-240V) according to the table below:

Unit Enclosure Light duty Heavy duty

size resistor resistor
NX_ 0003 6
NX_ 0004 6
NX_ 0005 6
FR6 BRR 0013 LD 6 BRR 0013 HD 6
NX_ 0007 6
NX_ 0010 6
NX_ 0013 6
NX_ 0018 6
NX_ 0022 6
FR6 BRR 0034 LD 6 BRR 0034 HD 6
NX_ 0027 6
NX_ 0034 6
NX_ 0041 6
FR7 BRR 0052 LD 6 BRR 0052 HD 6
NX_ 0052 6
NX_ 0062 6
NX_ 0080 6 FR8 BRR 0100 LD 6 BRR 0100 HD 6
NX_ 0100 6
NX_ 0144 6
NX_ 0170 6 FR9 BRR 0208 LD 6 BRR 0208 HD 6
NX_ 0208 6
NX_0261 6
NX_0325 6
FR10 BRR 0416 LD 6 BRR 0416 HD 6
NX_0385 6
NX_0416 6
NX_0460 6
NX_0502 6 FR11 BRR 0590 LD 6 BRR 0590 HD 6
NX_0590 6
NX_0650 6
NX_0750 6 FR12 BRR 0416 LD 6 BRR 0416 HD 6
NX_0820 6
Table 6. Brake resistors used with AC drives

Light duty resistor:IP50 with direct wire connection.

Heavy duty resistor:IP20/21, connecting box, thermal protection as standard.

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 8 • vacon TECHNICAL DATA

2.2 Other resistors

If other types of resistors are used, make sure that the resistance is higher than the minimum
resistance defined. The power handling capacity must be sufficient for the application.

Mains voltage 208-240 V, 50/60 Hz, 3~

Enclosure size Drive type The minimum Brake power*
brake resistance @ 405 VDC [kW]
]
FR4 0003 30 0.55
0004 30 0.75
0007 30 1.1
0008 30 1.5
0011 30 2.2
0012 30 3.0
FR5 0017 30 4.0
0025 30 5.5
0031 20 7.5
FR6 0048 10 11.0
0061 10 15.0
FR7 0075 3.3 22.0
0088 3.3 22.0
0114 3.3 30.0
FR8 0140 1.4 37.0
0170 1.4 45.0
0205 1.4 55.0
FR9 0261 1.4 75.0
0300 1.4 90.0
Table 7. Specification for other types of resistors

* When you use the recommended resistor types.

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2
TECHNICAL DATA vacon • 9

Mains voltage 380-500 V, 50/60 Hz, 3~

Enclosure size Drive type The minimum Brake power*
brake resistance @ 845 VDC [kW]
]
FR4 0003 63 1.5
0004 63 2.2
0005 63 3.0
0007 63 4.0
0009 63 5.5
0012 63 7.5
FR5 0016 63 11.0
0022 63 11.3
0031 42 17.0
FR6 0038 19 22.0
0045 19 30.0
0061 14 37.0
FR7 0072 6.5 45.0
0087 6.5 55.0
0105 6.5 75.0
FR8 0140 3.3 90.0
0168 3.3 110.0
0205 3.3 132.0
FR9 0261 2.5 160.0
0300 2.5 200.0
FR10 0385 1.4 250.0
0460 1.4 315.0
0520 1.4 355.0
FR11 0590 0.9 400.0
0650 0.9 450.0
0730 0.9 500.0
FR12 0820 2 x 1.4 560.0
0920 2 x 1.4 630.0
1030 2 x 1.4 710.0
Table 8. Specification of brake resistors in 380-500 V

* When you use the recommended resistor types.

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2
 10 • vacon TECHNICAL DATA

Mains voltage 525-690 V, 50/60 Hz, 3~

Enclosure size Drive type The minimum Brake power*
brake resistance @ 1166 VDC [kW]
]
FR6 0004 100 3.0
0005 100 4.0
0007 100 5.5
0010 100 7.5
0013 100 11.0
0018 30 15.0
0022 30 18.5
0027 30 22.0
0034 30 30.0
FR7 0041 18 37.5
0052 18 45.0
FR8 0062 9 55.0
0080 9 75.0
0100 9 90.0
FR9 0125 6.7 110.0
0144 6.7 132.0
0170 6.7 160.0
0208 6.7 194.2
FR10 0261 2.5 250.0
0325 2.5 315.0
0385 2.5 355.0
0416 2.5 400.0
FR11 0460 1.7 450.0
0502 1.7 500.0
0590 1.7 560.0
FR12 0650 2 x 2.5 630.0
0750 2 x 2.5 710.0
0820 2 x 2.5 800.0
Table 9.Specification of brake resistors in 525-690 V

* When you use the recommended resistor types.

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2
TECHNICAL DATA vacon • 11

2.3 Power rating of standard resistors

The power handling capacity of the standard resistors as a function of the duty cycle is shown in
Figure 4. The figure shows the relative power handling capacity at various duty cycles, i.e. compared
to continuous 120 s braking.

Relative power handling capability of the

standard brake resistor ranges

1,20
1,00
0,80
Heavy duty
0,60
Light duty
0,40
0,20
0,00
0%
2%
3%
5%
7%
8%
17 %
25 %
33 %
42 %
50 %
67 %
83 %
100 %

ED% ( based on 120 s period)

Figure 4. Relative power rating of standard resistors

Power at different duty cycles based on a 120 sec cycle

60%
100% ED ED 40 % ED 25 % ED 10 % ED 5 % ED
kW
BRR 0025 LD 2 0.10 0.17 0.26 0.42 1.0 2.1
BRR 0031 LD 2 0.16 0.26 0.39 0.63 1.6 3.1
BRR 0061 LD 2 0.31 0.52 0.78 1.3 3.1 6.3
BRR 0114 LD 2 0.95 1.6 2.4 3.8 9.5 19.0
BRR 0205 LD 2 2.2 3.7 5.6 9.0 22 45

BRR 0022 LD 5 0.24 0.39 0.59 0.94 2.4 4.7

BRR 0031 LD 5 0.35 0.59 0.88 1.41 3.5 7.1
BRR 0045 LD 5 0.71 1.2 1.8 2.8 7.1 14.1
BRR 0061 LD 5 1.1 1.8 2.6 4.2 10.6 21
BRR 0105 LD 5 2.3 3.8 5.7 9.1 23 46
BRR 0300 LD 5 4.6 7.6 11.4 18.2 46 91
BRR 0520 LD 5 11 17.6 26 42 106 212
BRR 0730 LD 5 16 27 41 66 165 329

BRR 0013 LD 6 0.28 0.47 0.71 1.13 2.8 5.6

BRR 0034 LD 6 0.94 1.6 2.4 3.8 9.4 18.8
BRR 0052 LD 6 1.6 2.6 3.9 6.3 15.7 31
BRR 0100 LD 6 3.1 5.2 7.8 12.5 31 63
BRR 0208 LD 6 4.0 6.7 10.1 16.1 40 81
BRR 0416 LD 6 11 19 28 45 113 226
BRR 0590 LD 6 17 28 42 66 166 332

BRR 0031 HD 2 0.41 0.68 1.0 1.6 4.1 8.1

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2
 12 • vacon TECHNICAL DATA

BRR 0061 HD 2 0.81 1.4 2.0 3.3 8.1 16.3

BRR 0114 HD 2 2.5 4.1 6.2 9.9 25 49
BRR 0205 HD 2 5.8 9.7 14.5 23 58 116

BRR 0022 HD 5 0.61 1.02 1.52 2.44 6.1 12.2

BRR 0031 HD 5 0.91 1.5 2.3 3.7 9.1 18.3
BRR 0045 HD 5 1.8 3.0 4.6 7.3 18.3 37
BRR 0061 HD 5 2.7 4.6 6.9 11.0 27 55
BRR 0105 HD 5 5.9 9.8 14.8 24 59 118
BRR 0300 HD 5 11.8 19.7 30 47 118 236
BRR 0520 HD 5 27 46 69 110 274 549
BRR 0730 HD 5 43 71 107 171 427 854

BRR 0013 HD 6 0.73 1.2 1.8 2.9 7.3 14.6

BRR 0034 HD 6 2.4 4.1 6.1 9.8 24 49
BRR 0052 HD 6 4.1 6.8 10.2 16.3 41 81
BRR 0100 HD 6 8.1 13.6 20 33 81 163
BRR 0208 HD 6 10 17.4 26 42 105 209
BRR 0416 HD 6 29 49 73 117 293 586
BRR 0590 HD 6 43 72 108 172 431 862
Table 10.

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TECHNICAL DATA vacon • 13

2.4 Environment
Surface temperature of the resistor box <80ºC
Maximum ambient temperature 30ºC
Protection class IP20, IP21, IP50

NOTE! On mounting the resistor package, note the high surface temperature (up to 200 C). The
mounting surface must be non-flammable and there must be sufficient free space around the
resistor (100 mm).

The resistors are designed for natural convection cooling in a free space. Ensure sufficient ventilation
of the area.

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2
 14 • vacon TECHNICAL DATA

2.5 Thermal protection for the LD resistors

There are two different overtemperature sensors in use – one for the resistors with a smooth surface
and the other for the ones with cooling fins. The larger steel plate resistors have a thermal
supervision built in as standard.

OT1 – for brake resistors with cooling fins

Figure 5.Thermal supervision OT1

This is intended to be mounted on the lower (connector) end when the resistor is mounted vertically.
It is screwed onto the fins.

BRR 0114 LD 2 BRR 0031 LD 5 BRR 0034 LD 6

BRR 0205 LD 2 BRR 0045 LD 5 BRR 0052 LD 6
BRR 0061 LD 5 BRR 0100 LD 6
BRR 0105 LD 5 BRR 0206 LD 6
BRR 0031 HD 2 BRR 0300 LD 5
BRR 0061 HD 2 BRR 0013 HD 6
BRR 0114 HD 2 BRR 0022 HD 5 BRR 0034 HD 6
BRR 0205 HD 2 BRR 0031 HD 5
BRR 0045 HD 5
BRR 0061 HD 5
Table 11.Types

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2
TECHNICAL DATA vacon • 15

OT2

This thermal supervision is designed for the resistors with a smooth surface. The thermistor is placed
beneath the clip and the clip clipped onto the resistor surface.

Figure 6. Thermal protection and the holder for it

2.5.1 Thermal protection

The thermal protection in the resistors should be connected to the external Fault input on the AC
drive.

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2
 16 • vacon CHOOSING A BRAKE RESISTOR

3. CHOOSING A BRAKE RESISTOR

3.1 General
When you choose the brake resistor for your AC drive, start from the requirements of the process/AC
drive.
The choice of brake resistor is influenced by

a) the average braking power during one cycle; this defines the power dissipation required of the
brake resistor

b) the maximum power dissipation; this defines the instantaneous power handling capacity of the
brake resistor and

c) the maximum current of the brake IGBT; this defines the minimum resistance for the brake
resistor.

VACON Technical Support will assist you in all matters concerning braking.

3.2 Sizing principles

All rotating parts contain kinetic energy. When the load is braked, the energy difference between the
higher speed and the lower speed must be dissipated somewhere. Some of the energy is used in the
losses of the motor and the AC drive, but the majority must be dissipated in the brake resistor.
The energy of a load at speed n is given by the formula:
1 2
E J
2

where
J is the moment of inertia of the load (in kgm2) and
is the rotating speed of the load (in radians/s)

In engineering units

1
E Jn 2
182,3

where n is the rotating speed (in 1/min)

The difference between the energy at two speeds is thus

1 1
E E1 E2 J (n12 n 22 ) J( 2
1
2
2 )
182,3 2

The average power required is

E
P
t

where t is the braking time.

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3
CHOOSING A BRAKE RESISTOR vacon • 17

If the load has a cycle with a total cycle time tc, the average power of the cycle is

E
P
tc

The chosen resistor must be able to handle this power. If the braking time is longer than 1 minute,
the resistor must be sized for the continuous braking power.

3.2.1 Calculating braking time

The time required to accelerate or brake a load can be calculated as follows:

The basic equation is:

d
T J
dt

where T is the required torque.

The time required to change the speed of a load is

1 2
t J
T

or the torque required to change the speed in time t is

1 2
T J
t

The available torque consists of the torque generated by the motor Tmotor and the braking torque
generated by the load and friction in it Tload.

Ttotal Tmotor Tload

In many cases the frictional torque is sufficient to brake the load, it might even be too high, so the
motor must drive the load even if the speed is slowing down.

This torque required from the motor should be compared to the rated torque of the motor:

P
T 9550
n

If the rated torque is higher, the motor can perform the required acceleration/deceleration.

3.2.2 Calculating the moment of inertia

The moment of inertia as ‘seen’ by the motor consists of the motor inertia plus the load inertia,
changed by the gear ratio as follows:

J tot J motor g 2 J load

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3
 18 • vacon CHOOSING A BRAKE RESISTOR

where g is the gear ratio, Jmotor is the motor inertia and Jload is the load inertia. The ratio g is > 1 if the
load speed is higher than the motor speed and < 1 if the load speed is lower than the motor speed.

In many cases the moment of inertia of the motor is very small compared to the moment of inertia of
the load. Only in cases where the load turns very slowly (i.e. the gear ratio is low) the motor inertia is
significant.

The moment of inertia of typical shapes is shown in Figure 7.

Figure 7.

The moment of inertia of a specific machine is often specified on the rating plate. Otherwise the
manufacturer is responsible to give this information.

Sizing procedure:

1. Maximum speed n1 rpm

2 Minimum speed n2 rpm

3 Moment of inertia = J kgm2

2
J tot J motor g J load
g = gear ratio
4 Energy to be 1 kJ
dissipated
J (n12 n22 )
182,3
E E1 E2
1000

5 Braking time t s

6 Braking power E kW
P
t

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3
CHOOSING A BRAKE RESISTOR vacon • 19

7 Determine duty cycle t

for braking f
t1
t1 = duration of cycle –
assumption 120 s.

8 Determine average Pave fP kW

power for the resistor

9 Calculate the relative Pave %

power required.
Prel
Pres
Pres = peak power of
chosen resistor

10 Verify that the pair of

values in 7 and 9 are
within limits for the
chosen resistor – see
Figure 7

7 Calculate the braking n1 n2 Nm

torque required
T J 0,105
t

8 Verify motor rated PM Nm

torque > required TM 9550
nM
torque

PM in kW

nM in rpm

Figure 8. Speed profile of one drive cycle.

t1 = length of cycle
t2 = deceleration time
t3 = stop time
n1 = minimum speed of motor
n2 = maximum speed of motor

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3
 20 • vacon CHOOSING A BRAKE RESISTOR

The relative power handling capability of the standard resistor ranges is shown in the figure below:

Relative power handling capability of the

standard brake resistor ranges

1,20
1,00
0,80
Heavy duty
0,60
Light duty
0,40
0,20
0,00
0%
2%
3%
5%
7%
8%
17 %
25 %
33 %
42 %
50 %
67 %
83 %
100 %
ED% ( based on 120 s period)

Figure 9.

Verify the following:

a) The chosen brake resistor type can handle the required power. (Note that as the brake IGBT
current is limited by the device, a resistance with a smaller impedance than the minimum specified
for the AC drive cannot be used.)

b) If this is not the case, the resistor has to be sized specifically for the application. In many cases a
suitable combination of series and parallel connection of standard resistances may be the solution, in
others a special resistor must be defined and manufactured.

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CHOOSING A BRAKE RESISTOR vacon • 21

3.2.3 Internal resistors

The enclosure sizes FR4, FR5 and FR6 (380-500 V) can be equipped with an internal brake resistor as
a factory option. The brake resistors are designed for a 2 second full torque braking from nominal
motor speed to zero or a 1 second full power braking every minute.

Type code Resistance Energy Average power

] 2 s full torque braking 1 pulse/min
[kJ] [W]
NX_5 FR4 120 4 45
NX_5 FR5 55 8.9 100
NX_5 FR6 30 16 175
Table 12.

Relative power handling capability of internal

resistors

1,20
1,00
0,80
0,60
0,40
0,20
0,00
0

10

20

30

40

50

60

Time (sec)

Figure 10.

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 22 • vacon CONNECTIONS

4. CONNECTIONS
4.1 General
Make sure that your AC drive is equipped with a brake chopper. This is a factory installed
option!
The brake resistor is connected to the DC+ and R– connectors on the AC drive. The minimum cable
sizes are shown in Table 1 and Table 2. When you size the cables, note that the input fuses of the AC
drive also protect this cable.
Avoid running the brake resistor cable too near other cables. The recommended minimum distance to
e.g. the control cables is 0.5 m.

NOTE! To connect the brake resistor, disconnect the AC drive from the mains. Wait a further 5
minutes before opening the AC drive cover. Perform measurements to ensure that no voltage is
present on the DC and R- connectors.

Read chapter Safety in the User Manual of your VACON ® NX product.

Cable and Cable and

Resistor Resistor
terminal terminal
BRR 0025 LD 2 Integral AWG16
BRR 0031 LD 2 Integral AWG16 BRR 0031 HD 2 6
BRR 0061 LD 2 Integral AWG16 BRR 0061 HD 2 6
BRR 0114 LD 2 Integral AWG10 BRR 0114 HD 2 16
BRR 0205 LD 2 16-50 BRR 0205 HD 2 16-50

BRR 0022 LD 5 Integral AWG16 BRR 0022 HD 5 6

BRR 0031 LD 5 Integral AWG16 BRR 0031 HD 5 6
BRR 0045 LD 5 Integral AWG16 BRR 0045 HD 5 6
BRR 0061 LD 5 Integral AWG14 BRR 0061 HD 5 16
BRR 0105 LD 5 16 BRR 0105 HD 5 M8 / 3X16+16
BRR 0300 LD 5 16-50 BRR 0300 HD 5 M8 / 3X70+35
BRR 0520 LD 5 M8 / 3X95+50 BRR 0520 HD 5 M8 / 3X95+50
BRR 0730 LD 5 M8 / 3X95+50 BRR 0730 HD 5 M8 / 3X95+50

BRR 0013 LD 6 Integral AWG16 BRR 0013 HD 6 6

BRR 0034 LD 6 Integral AWG16 BRR 0034 HD 6 6
BRR 0052 LD 6 Integral AWG14 BRR 0052 HD 6 6
BRR 0100 LD 6 16-50 BRR 0100 HD 6 M8/3X16+16
BRR 0208 LD 6 16-50 BRR 0208 HD 6 M8/3X50+25
BRR 0416 LD 6 M8/ 3X70+35 BRR 0416 HD 6 M8/ 3X70+35
BRR 0590 LD 6 M8/ 3X70+35 BRR 0590 HD 6 M8/ 3X70+35
Table 13.Cable sizing

M8 = M8 bolt on the resistor

Only two conductors of a normal three phase cable are needed. The shield of the cable should be
connected at each end. The third, unused connector should be grounded by connecting it to ground at
one end.

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4
CONNECTIONS vacon • 23

AWG Number Ø [In] Ø [mm] Ø [mm²]

6/0 = 000000 0.580 14.73 170.30
5/0 = 00000 0.517 13.12 135.10
4/0 = 0000 0.460 11.7 107
3/0 = 000 0.410 10.4 85.0
2/0 = 00 0.365 9.26 67.4
1/0 = 0 0.325 8.25 53.5
2 0.258 6.54 33.6
4 0.204 5.19 21.1
6 0.162 4.11 13.3
8 0.128 3.26 8.36
10 0.102 2.59 5.26
12 0.0808 2.05 3.31
14 0.0641 1.63 2.08
16 0.0508 1.29 1.31
18 0.0403 1.02 0.823
20 0.0320 0.812 0.518
Table 14.Cable sizes

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4
 www.danfoss.com

Document ID:

Vacon Ltd
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Runsorintie 7 Rev. C
65380 Vaasa
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