How to use a braking resistor? What factors should we consider when choosing?

Brake resistor is a type of ripple resistor, mainly used in mechanical systems where frequency converters control motors to quickly stop, helping the motors convert the regenerated electrical energy generated by rapid stopping into thermal energy. To help you fully understand, this article will summarize the relevant knowledge of braking resistors. If you are interested in the upcoming content of this article, please continue reading.

Method of selecting braking resistor

1. There are two types of commonly used braking resistors in general engineering: ripple resistors and aluminum shell resistors: ripple resistors use vertical surface ripples to promote heat removal, reduce parasitic inductance, and efficiently maintain resistors with high flame retardant inorganic coatings. The wires do not age and extend their service life; The aluminum shell resistor is easy to install, the radiator is easy to install, and the appearance is beautiful. The high heat dissipation aluminum alloy shell is fully packaged, with strong seismic resistance, aging resistance, and long-term stability; Simple and stable installation, beautiful appearance, widely used in extreme industrial environments.

When the braking unit is working, the braking resistor will generate a large amount of heat, so ventilation, heat removal, and life safety must be considered during the installation process. The minimum ventilation space for the installation of the braking unit is approximately 100mm, with an upper and lower 30mm. Do not place brake resistors around flammable and explosive products. Don't put it in a place that people can come into contact with. Braking resistors can generate high heat, seriously affecting the operation of other equipment. Be sure to consider the installation process in advance. The insulation partition should firmly fix the braking resistor. When installing a braking resistor inside the cabinet, the braking resistor should be installed on the top of the frequency converter cabinet.

3. Cables with specified insulation level and cross-section that meet the standards. Flexible cables have good flexibility, and the cross-section of the wires must comply with the regulations for braking resistors in order to release current. Please select a hot wire to connect the braking resistor. The distance between the braking unit and the frequency converter should be as close as possible, and the larger distance should not exceed 1m. The cables on the DC side should be twisted to reduce radiation and inductance, and there is no limit to the distance between the braking unit and the braking resistor. Short lines will reduce the occurrence of cable faults.

Specification for the use of braking resistors

The utilization rate of braking resistor clarifies the efficiency of braking resistor usage, preventing overheating damage to the braking resistor and affecting the braking effect of the braking unit. The smaller the utilization rate of the braking resistor, the lower the heating level of the resistor, the lower the energy consumed by the resistor, and the worse the braking effect. At the same time, the capacity of the braking unit cannot be fully utilized. In theory, when the utilization rate of braking resistance is 100%, the capacity of the braking unit is fully applied and the braking effect is most obvious. However, this requires a greater cost of braking resistor power, and users should fully consider it. Under the premise of determining the braking resistance value and power, selecting a lower resistance utilization rate will achieve better results for slow deceleration of large inertia loads. For loads that require quick shutdown, a larger braking resistor utilization rate should be selected.

Wiring method of braking resistor

1. The correct selection of braking resistor (refer to the issue of selecting the braking resistor value of the servo controller). If the resistor is too selected, it will lead to slow absorption of braking energy, high bus voltage, poor braking effect, and the servo controller will report overvoltage. 2、 Braking resistor wiring representation:

2. Remove the short circuit between P ⊕ and D, and connect the braking resistor to P ⊕ and C (there is no short circuit between P and D in S1R6 and S2R8 models. If braking is required, please connect the external braking resistor to both sides of P ⊕ and C)

Basic parameters of braking resistor

1. The external braking resistor should be set to H0225 as 1 (natural air cooling) or 2 (forced air cooling);

2. Set the H0226 braking resistor power to be consistent with the actual resistor power;

3. Set the H0227 braking resistance value to be consistent with the actual resistance value;

4. Set the H0224 heat dissipation coefficient according to the specific situation on site. (The heat dissipation coefficient of H02-24 resistor during natural cooling generally does not exceed 30, and the heat dissipation coefficient of H02-24 resistor during forced air cooling generally does not exceed 50).

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