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Powerohm Resistors BM Series Instruction Manual

Braking modules
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Powerohm Instruction Manual
For BM "BG" Series
Braking Modules
IMPORTANT: These instructions should be read thoroughly before installation. All warnings and
precautions should be observed for both personal safety and for proper equipment performance
and longevity. Failure to follow these instructions could result in equipment failure and/or serious
injury to personnel. Braking modules contain lethal voltages when connected to the inverter. It is
very important to remove power to the inverter before installing or servicing this unit. Always
allow adequate time (approximately 5 minutes) after removing power before touching any
components. The LED's must be completely out before servicing the unit.

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Summary of Contents for Powerohm Resistors BM Series

  • Page 1 Powerohm Instruction Manual For BM “BG” Series Braking Modules IMPORTANT: These instructions should be read thoroughly before installation. All warnings and precautions should be observed for both personal safety and for proper equipment performance and longevity. Failure to follow these instructions could result in equipment failure and/or serious injury to personnel.
  • Page 2 Table of Contents • Page 2: Table of Contents for installation manual HCPMAN0001_R3 (2018-03-05) • Page 3: Table of Contents (cont.) • Page 4: Product Overview • Page 5: Inspection & Environmental Conditions • Page 6: Electrical Ratings for 450 & 600 amp Models •...
  • Page 3 • Page 33: Communications Channel Assignments • Page 34: Communications Module Location • Page 35: Communications Module ProfiBus Addressing • Page 36: Communications Module ProfiBus Cables • Page 37: Brake Module Start Up • Page 38: Brake Module Start Up •...
  • Page 4 Product Overview AC variable frequency drives are commonly used with general purpose AC induction motors to form reliable variable speed drive systems. Problems with these drive systems can occur when an application requires a deceleration rate faster than what can be managed by the drive alone, or when motor speeds exceed the synchronous speed set by the output frequency of the drive (which is called an overhauling load condition).
  • Page 5 Inspection upon Receipt Upon receipt of your PowerOhm Braking Module, be sure to carefully unpack the module and inspect the unit carefully for any shipping damage. The module contains electronics that can be damaged by static electricity, so handle in accordance with industry standards. Check for loose, broken or otherwise damaged parts due to shipping.
  • Page 6 Electrical Ratings The PowerOhm Type BG Braking Module is available in line voltages ranging from 208 to 720 volts. Peak currents up to the maximum are allowed at intermittent duty cycles (reference the below tables for details). Options are designated in the part number after the dash at the end. -24v = 24vdc control power. -AEN = Acromag Ethernet communications module.
  • Page 7 TABLE 1c: General Specifications for 900 amp Type BG Braking Modules Minimum Nominal PowerOhm Ohms Turn ON AC Line Cont Peak Watt Part No. @ listed Voltage Voltage Current Current Loss Turn ON HCPBM208900-( 24,AEN,APB HCPBM240900-( 24,AEN,APB HCPBM380900-( 24,AEN,APB HCPBM415900-( 24,AEN,APB 1350 2257...
  • Page 8 Equipment Installation The PowerOhm Type BG Braking Module should be installed on a low vibration surface that is non-flammable. Attention: Installation and removal of this equipment should be done by qualified personnel only. Equipment must be installed in accordance with all applicable national and local electrical codes and regulations.
  • Page 9 Mounting Orientation The PowerOhm BG Series Braking Module must be installed in a vertical position in order to meet published current ratings. (see Figure 1). FIGURE 1: Mounting Orientation for BM Braking Modules a brand of ICD, Inc.
  • Page 10 Dimensions and Weight FIGURE 2a: Braking Module Dimensions for 450 & 600 amp Models Weight: The weight of the 450 amp unit is 30lbs and the 600 amp is 34 lbs. a brand of ICD, Inc.
  • Page 11 FIGURE 2b: Braking Module Dimensions for 900 & 1200 amp Models Weight: The weight of the 900 amp unit is 55lbs and the 1200amp is 60lbs. a brand of ICD, Inc.
  • Page 12 Wiring Recomendations It is recommended that the AC drive manual, braking resistor instructions and any other pertinent documentation be thoroughly reviewed before proceeding. NEVER bundle power wires and control wires together. Control and power wiring should be separated to avoid electrical noise and interference problems.
  • Page 13 Wire Sizing The National Electric Code (NEC) and local regulations govern the installation and wiring of electrical equipment such as variable frequency drives, braking resistors and braking modules. DC power wiring, AC power wiring, control wiring and conduit must be installed in accordance with all applicable codes and regulations. Reference Table 2 for suggested minimum wire sizes only.
  • Page 14 Power Connections POWER CONNECTIONS • The PowerOhm Type BG Braking Module features a total of five power connections. • Field wiring to studs must be made by a UL listed clamp or closed terminal connector • sized for the wire gauge involved •...
  • Page 15 TABLE 3b: Descriptions of Power Connections for 900 & 1200 amp Terminal Connection Socket Torque Terminal Description Designation Type Size (lb-ft) DC - DC Bus Connection (Negative) Two ½” studs ¾” ¾” DC Bus Connection (Positive) Two ½” studs Ground Connection 3/8”...
  • Page 16 Control Power Connections TABLE 4a: Standard 115vac Control Power TB3 Terminal Electrical Max Wire Maximum Terminal Description (TB3) Number Ratings Size Torque (lb-in) 115vac (Non Polarized) 115vac / 1a 14awg 115vac (Non Polarized) *18AWG is sufficient for control wiring While it is safe to earth ground the external control supply neutral, the placement of this ground could inadvertently add to system noise in the control loop.
  • Page 17 TABLE 4b: Special 24vdc Control Power (- 24 option) Electrical Max Wire Maximum Terminal Terminal Description (TB3) Ratings Size Torque (lb-in) Number 1 (+) 24vdc Input Power Pos 24vdc / 3a 14awg 2 (-) 24vdc Input Power Neg *18AWG is sufficient for control wiring While it is safe to earth ground the external control supply, the placement of this ground could inadvertently add to system noise in the control loop.
  • Page 18 Control Input Connections TABLE 5: TB2 Input Control Command Descriptions Maximum TB2 Terminal Electrical Max Wire Terminal Description (TB2) Torque (lb- Number Ratings Size 1 (+) Enable 2 (-) Common 3 (+) Master or Slave Select 4 (-) Common 5 (+) IOC/ IOV, IUV Reset 6 (-) Common...
  • Page 19 Control Input Connections FIG 4: TB2 Input Command Details I/O INPUT COMMAND DESCRIPTIONS (TB2) 1. ENABLE a. Short TB2, 1 & 2 to enable brake module b. Allows the brake module to output pulses to IGBT switch c. Front panel “Control Enabled” LED ON indicates the presence of an enable contact closure 2.
  • Page 20 3. RESET a. Short TB2, 5 & 6 to reset b. For best noise immunity keep closed, and then momentarily cycle to reset c. Clears any temporary faults d. Will not clear IGBT short or over-temp faults if they still exist 4.
  • Page 21 Status Output Connections TABLE 6: TB1 Isolated Output Status Terminal Descriptions TB1 Terminal Electrical Max Wire DC Pol Terminal Description (TB1) Torque Number Ratings Size (lb-in) Control Enabled Power Section Ready Master Slave Status Instant Over Current (IOC) 150ma 250v 14awg* AC or DC IOV/ IUV...
  • Page 22 FIG 5: TB1 Output Status Signal Details a brand of ICD, Inc.
  • Page 23 I/O OUTPUT SIGNAL DESCRIPTIONS (TB1) 1. CONTROL ENABLED a. Indicates the Enable signal is present b. TB1-1&2 are closed when Enabled c. Front panel “Control Enabled” LD8 ON indicates the presence of an enable contact closure 2. PWR SEC READY a.
  • Page 24 6. OT a. If an OT occurs the front panel “Fault” LD7 will turn ON i. *there is no control board LED for OT. b. TB1-11&12 are normally closed, and open on OT. Non-latching. c. TB1-3&4 are normally closed, and open with this fault d.
  • Page 25 Master Slave Connections TABLE 7: Fiber Optic Specifications Maximum Lenght Component Specification CABLE 1mm core diameter 60 ft CONNECTOR SMA Type Connector While it is usually not necessary to use fiber optic cables in single slave systems (one Master, one Slave), it is recommended for best noise immunity and to prevent ground loops in the control power.
  • Page 26 Module Setup JUMPER SETTINGS The PowerOhm Type BG Braking Module has eight jumper settings located in the top right corner of the main control board, accessible by removing the center front cover that contains the LED indicators. The jumper allows for a wide range of drive input voltages as listed in Table 12.
  • Page 27 System Integration Figure 6: Drive DC BUS Power Connections Always connect DIRECTLY to the capacitor bank of the drive. Connecting to the Rectifier or upstream of any pre-charge or inductance can cause IOV faults and possible damage to the brake module. Check drive topology drawings from drive manual itself to confirm that available DC connections are directly from the capacitor bank.
  • Page 28 Figure 7: Typical Power Connections for a Single Braking Module Wiring Notes: In order to minimize interference between power and signal cabling, all DC power wiring between the drive, braking module and braking resistor, should be run separate from all control wiring. If control and power wires must cross paths, cross at 90 deg angles and keep at least 2 inches away from each other.
  • Page 29 Figure 8: Typical Power Connections for Two Braking Modules Wiring Notes: In order to minimize interference between power and signal cabling, all DC power wiring between the drive, braking module and braking resistor, should be run separate from all control wiring. If control and power wires must cross paths, cross at 90 deg angles and keep at least 2 inches away from each other.
  • Page 30 Figure 9: Typical Power Connections for Multiple Slave Modules (2 or more) Wiring Notes: In order to minimize interference between power and signal cabling, all DC power wiring between the drive, braking module and braking resistor, should be run separate from all control wiring. If control and power wires must cross paths, cross at 90 deg angles and keep at least 2 inches away from each other.
  • Page 31 Figure 10: Typical Control Connections for Two Braking Modules Master - Slave Settings: In all master slave systems ONLY one module is set to be the Master, and the remaining modules are set as Slaves. Wiring Notes: In order to minimize interference between power and signal cabling all control wiring must be twisted or shielded and run separate from all power wiring.
  • Page 32 Figure 12: Typical Control Connections for Three or more Braking Modules Master - Slave Settings: In all master slave systems ONLY one module is set to be the Master, and the remaining modules are set as Slaves. Wiring Notes: In order to minimize interference between power and signal cabling all control wiring must be twisted or shielded and run separate from all power wiring.
  • Page 33 Communication Channel Assignments for Acromag Communications The Acromag Ethernet and ProfiBus modules are hard wired internally to make the I/O channels compatible with existing protocol. Channel assignments are shown below in tables 9 & 10. TABLE 9: Input Signal Descriptions I/O Channel Description CH 8...
  • Page 34 FIGURE 14: Communication Module Location Communication Module Access: It may be easier to remove the bottom cover in order to make connection to the Acromag module. WARNING: It is important to check the DC Bus Voltage before servicing a braking module or any connected peripheral equipment.
  • Page 35 Communication Module Description for Acromag ProfiBus Figure 15: Acromag ProfiBus Module addressing • Set Slave address on Acromag dip switches on top of module before mounting module HEX ADDRESS TOP EDGE VIEW SET SWITCHES TO A VALID SLAVE AD DRESS FROM 0 TO 125 (00H TO 7DH ) 1.
  • Page 36 • Using PROFIBUS cable and connect to front PROFIBUS serial communications connector DB9 CONNECTIO NS Shield No Connection Data A Request To Send Acromag Gr ound 46 45 43 42 32 31 SLA VE No Connection ADD RES S (HEX ) Data B DIGITAL IN or OUT No Connection...
  • Page 37 Brake Module Start Up PRELIMINARY: • Ensure the DC bus connections are proper polarity. • Ensure DC bus connections are directly on drive capacitor bank, with no pre-charge or filtering circuits between. If not already known, check drive manual for topology drawing showing DC bus structure. •...
  • Page 38 BRAKING CYCLE: Start the drive and run the motor unloaded. Stop the drive quickly and monitor the green BRAKE LED. The LED will flash on, the heavier the braking, the more it flashes. Load motor, then start and stop drive and again monitor braking LED. Note DC bus level during the peak of the braking cycle. If the unloaded nominal DC bus is within 10% of the peak DC Bus during braking, consider increasing the braking voltage threshold or using a drive contact to disable the brake while drive is idle.
  • Page 39 Acromag Ethernet Module Start Up LED Indicators: 1. Run (Green) - Constant ON if power is on and unit is OK. Flashing ON/OFF indicates unit is in “wink” ID mode. 2. Bus (Yellow) – Blinking slowly indicated module is in default communication mode. Blinking rapidly indicates a watchdog timeout error has occurred.
  • Page 40 TABLE 11: Acromag Ethernet Module Troubleshooting SYMPTOM POSSIBLE CAUSE POSSIBLE FIX Green RUN LED Internal 3.3v power has failed Return Module for repair does not light. Continuous Read Module Status register to verify “wink” status. flashing green Module in “wink” mode Write 5555H to wink mode.
  • Page 41 Acromag PROFIBUS Module Start Up LED Indicators: 1. Run (Green) - Constant ON if power is on and unit is OK. Flashing ON/OFF indicates unit is performing diagnostics (first few seconds after power-up), or has failed diagnostics (after a few seconds). 2.
  • Page 42 TABLE 11: Acromag ProfiBus Module Troubleshooting SYMPTOM POSSIBLE CAUSE POSSIBLE FIX Initialization Problem. LED ON if Check Station Address. Is GSD file correct. module in data exchange state. Check for wiring error. Yellow BUS LED Both the internal EEPROM and Module awaiting Set Slave Address command does not light.
  • Page 43 Maintenance CAUTION: NEVER perform any maintenance while power is present. ALWAYS be sure to double check for safe voltage levels by measuring the DC bus input as well as any external power, control or status signals before working on equipment. Monthly: Check that the Green power LED is ON, The Amber DC Bus LED is ON, The Control Enabled LED is on, and the Red Fault LED is OFF.
  • Page 44 Troubleshooting LEDs BRAKE MODULE FRONT PANEL LED INDICATORS CONTROL POWER: An illuminated green LED indicates that control power is present. DC BUS: An illuminated amber LED indicates that DC bus voltage is present BRAKE ACTIVE: An illuminated red LED indicates that the module is braking. CONTROL ENABLE: An illuminated green LED indicates that the control has been enabled.
  • Page 45 Troubleshooting Before removing equipment covers or making any changes in jumper positions or adjustments, power down equipment and wait for DC bus to drop to safe levels. Always use an insulated screwdriver or insulated pliers when making jumper changes or adjustments Follow these steps and make note of indications before calling for help.
  • Page 46 • Check actual system AC line voltage for high harmonic content (high peak to RMS ratio) or for excessive noise spikes as this may cause an unusually high DC bus level on an unloaded drive • Remove the enable signal. This should force the brake module to turn off. •...
  • Page 47 • Monitor Braking LED on all modules. If master braking LED turns on but any slave does not, and wiring is correct, replace slave module(s). • Master braking LED never turns on follow steps for “Red braking LED never turns on” IOC FAULTS OCCUR •...
  • Page 48 HCPMAN0001_R3 (2018-03-05) a brand of ICD, Inc.

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