Installation and MaintenanceInstructions

S10 & Smooth-BRAKEDC Injection Brake Modules

This is

Crompton ControlsCrompton Controls

LT011 Issue 1Tel: +44 (0)1924 368251

DC Injection Brake Module Installation and Maintenance Document

S10 and Smooth-BRAKE

WarrantyAll goods are guaranteed for one year from the date of purchase. This does not affect thestatutory rights of the user.

Safety warningImportant Safety Information

All electrical equipment for operating on low voltages contain devices which are capable ofcausing serious or fatal injuries. Any person involved in installation or maintenance of this equipment should be fullycompetent to conduct the work. Such persons should be familiar with the Health and Safety at Work Act, Electricity atWork Regulations and have a working knowledge of the IEE Wiring Regulations.

If in doubt please contact,Crompton Controls Ltd Tel: +44 (0)1924 368 251

General Description of the equipmentCrompton Controls DC injection Braking starters are suitable for controlled stopping of induction motors.When the machine starter is de energised the brake timer senses the break in supply andapplies a DC voltage to the motor windings to provide a controlled braking force for atimed duration.NOTE:DC injection braking is a PUWER 98 approved method of stopping AC electricmotors and requires the mains supply to be present to operate correctly.

Induction motorsInduction motors can be braked to standstill, by injecting a DC current into the winding,this creates a stationary field and any shaft rotation will produce a braking torque.Braking from full speed an induction motor behaves as a twice speed generator, the generated currents help to stop the motor and full load braking torque requires a DC current of approx 2 to 2.5 times motor full load current. The DC is produced using athyristor with controlled half rectification and a diode is connected across the motor torectify the generated current, without the diode the motor would not brake. The externallyapplied dc current will rise as the machine brakes to a halt. Motor noise is normal whenusing phase angle control due to the nature of the unsmoothed dc waveform.The DC current produces magnetic flux in the motor air gap, current can increase butthere is a saturation effect that means flux and braking torque will increase with currentup to saturation after which high currents will not produce much extra braking.Most braking systems provide a voltage to apply to the windings, at standstill the currentwill be determined by ohms law, current=voltage/winding resistance.

Part Numbers Rated operational voltagesBR011 S10/400 400 volt 50Hz 25 Amp brake moduleBR016 S10/240 240 volt 50Hz 25 Amp brake moduleBR021 S10/110 110 volt 50Hz 25 Amp brake moduleBR025 Smooth-Brake 400 volt 50Hz 60 Amp brake assemblyBR026 Smooth-Brake 400 volt 50Hz 90 Amp brake assembly

BR024 Smooth-Brake Control Module

2

Electrical SpecificationConforming to Standards BS/EN60947

DC CURRENT: S10 25A nominal current flows through L1, L2, M1 & M2Smooth-BRAKE 60 Amp or 90 Amp high current connections directly

to thyristor diode module.FREQUENCY: The unit is for rated 50 Hz.DWELL TIME: From operating main contactor to closing DC contactor:

S10 0.5 secondsSmooth-BRAKE 1 second

TIME RANGE: S10 braking time range is 0.1 to 12.7 seconds (270° rotation linear potentiometer)

Smooth-BRAKE 0.2 to 50 seconds (270° rotation linear potentiometer)

DC VOLTAGE: The voltage range is up to approx. 160 volts, with the minimum voltage dependent on thyristor latching current.

DUTY CYCLE: S10 Limited by software to 10%. For every second of braking 10 is added to a register. For every second not braking 1 is subtracted. Restart is inhibited if the register is above a value of 250.Note: if the unit will not start it will be waiting for this register to countdown below 250. The maximum delay is approx. 2 minutes.Smooth-BRAKE No software limitation of duty cycle. Heat sink rated for 10 off equally spaced 35 second stops per hour, maximum at statedcurrent.

DIMENSIONS: S10 81H x 45W x 121D (mm) - DIN Rail mountingSmooth-BRAKE 100H x 160W x 125D (mm)

TERMINALS: S10 2 times 2.5mm2 maxSmooth-BRAKE main terminals M5 screw

control terminals 2 times 2.5mm2 maxWEIGHT: S10 200g

Smooth-BRAKE 1.0kgHUMIDITY: 85% non condensingAMBIENT TEMP: Operating -10 to +40C Storage -20 to +70CPROTECTION: IP code IP20RELAYS: RL1 Internal 8A rated contacts, 440Vac max breaking voltage.

RL2 The relay terminals 17 18 28 are volt free and can be wired in a controlcircuit at lower voltage.The relay contacts can be protected with a 4 Amp Control fuse.

BRAKE FUSE: Semiconductor fuseS1030A (10mm x 38mm) FL078 740 A2sec Ferraz 660gRB10-30 A070gRB30T13 ref M330015 or equivalent.Diode 40EPS12 800 A2 sec Thyristor 40TPS12 1250 A2 sec

Smooth-BRAKE60 Amp SKNH56 or IRKN56 8000 A2 sec FE100 semiconductor fuse 1800A2sec NSD 32 3000 A2sec approx 60A 100 sec trip pointNSD 40 6000 A2sec approx 100A 100 sec trip point90 Amp SKNH91 or IRKN91 15000 A2 sec FE120 semiconductor fuse 1900A2secESD 50 8700 A2sec approx 120A 100 sec trip pointESD 63 13300 A2sec approx 150A 100 sec trip point

3

4

S10 Module Terminals Identification and marking

L1 Common phase connectionL2 Phase connection - connected to M2M1 Motor connectionM2 Motor connection - connected directly to L2B2 Voltage sense input17 Relay input - common to RL1 and RL218 RL1 Relay output - motor contactor via stop start circuit28 RL2 Relay output connects to brake contactor

The B2 terminal to signal the unit to brake requires the full operating voltage of the module applied.L1 is common internally so a normally open auxiliary contact on the main contactor isused to provide a signal on B2 from L2.

81

121

45

L1 L2 M1 M2

2818

17B2

Part NumbersBR011 400vBR016 240vBR021 110v

5

Smooth-BRAKE Module Terminals Identification and markingOutline and Mounting Dimensions

Terminal Description

L1 Common phase connection to thyristor terminal 2L2 Phase connection to thyristor terminal 3M1 Motor connection to thyristor terminal 1M2 Motor connection also to thyristor terminal 3M3 Motor connection - generated voltageB2 Voltage sense input relative to L117 Relay input common to RL1 and RL218 RL1 Relay output - motor contactor via stop start circuit28 RL2 Relay output connects to brake contactor G Gate to connect to external thyristor

NOTE: A Voltage Dependant Resistor – VDR is fitted across the M1 M2 motor terminalsto protect the diode.Terminal covers not shown - MUST be fitted.PCB fuse rating - 500V, 1A, quick blow, 6.3mm x 32mm ceramic tube, eg SIBA ref: 70-065-63 1 Amp or equivalent.

L1 L2

M2M1 M3

Time

Torque

L1 L2 M1 M2 M3

28 18 17 B2 G

1 2 3

1 3

4

1

3

2

2

L2

L1

M1

G

C

Relay inputStart contactor CBrake contactor BC

Volt FreeContacts

G

160mm

100mm

125mm(Depth)

Part NumbersBR025 400v 60ABR026 400v 90A

6

Description of operation

Both S10 and Smooth-BRAKE units are powered at operational voltage on L1 and L2. L1is connected internally to the PCB OV common. A secure connection to the incoming supplymust be made at all termination and switching points. The voltage sensing input to B2 ismeasured relative to L1.. At power on there is a short initial delay and RL1, one of thetwo internal relays, is energized giving an output on terminal 18, provided terminal 17has a supply. This output is wired to the main start contactor which can be energized tostart the motor; an auxiliary terminal on this contactor is used to connect a voltage to theB2 sensing input. When voltage is applied to B2 nothing happens, until on removal of thisvoltage when the timing sequence starts:-

1 25mS dwell, then re-check no voltage on B2 – to prevent the startup voltage drop causing dc injection

2 RL1 opens removing the feed to 18 preventing the main contactor from operating3 500mS dwell period to allow the contactor arcs and motor EMF to decay – the setting

potentiometers are also read at this time. 4 RL2 is then energized to bring in the external brake contactor, connecting terminals

M1 and M2 directly to the motor.5 This enables DC to be injected for the time and voltage as set on the potentiometers.

(Smooth brake without M3 connected).The DC is increased progressively to the set value to avoid mechanical shock.

6 RL2 is then de-energized after turning off the DC7 Dwell period to allow the DC to decay8 RL1 is then re-energized to allow the motor to be started again.

NOTE:DC injection braking is a PUWER 98 approved method of stopping AC electricmotors and requires the mains supply to be present to operate correctly.

S10 and Smooth-BRAKE (without M3 connection)Basic setting procedure

A Braking Time Setting (0-100% S10 0.1- 12.7 sec Smooth Brake 0.2 to 50 sec)1. From minimum, turn the Braking Time Pot slightly clockwise.2. Start the motor.3. Stop the motor and check the time the brake contactor energises for.4. Repeat steps 1 – 3 until the required time is reached (10 seconds or less).

B Braking Torque Setting (0-100% - approx 160v dc)1. From minimum, turn the Braking Torque Pot slightly clockwise.2. Start the motor.3. Stop the motor and measure the time taken to stop.4. If the motor continues to rotate after the Braking Time (contactor) has lapsed repeat

steps 1 – 3 until there is sufficient braking to stop the motor within the required time.

7

Description of operation

Smooth-BRAKE with M3 connectedControlled Stopping with feedback from motor

The M3 terminal provides voltage feedback from the motor during braking. The basic setting is as page 6 but the braking torque setting will become the main adjustment andswitch the unit off a few seconds after coming to rest. The time setting needs to be longenough to allow this to happen. Removal of the wire from the M3 terminal will remove thevoltage signal and braking will be to the torque and time settings only.

Operation with voltage feedback i.e. M3 connected

A three stage stop utilizing the voltage generated by the motor during braking as a speedsignal. The amount of voltage varies with the speed and amount of DC injection. Withhigh levels of DC and the motor spinning fast there is a strong signal.

Stage 1 The unit brakes at full until this signal reduces to approx 18%.Stage 2 Then the braking strength is reduced.

There is an increase in voltage as standstill is approached to trigger the switch to stage 3.After this the voltage is too low to provide an accurate signal.

Stage 3 A low level of DC for a time is then used to bring the shaft to rest.

NOTE: The Time potentiometer provides an overriding switch off point adjustment from0.2 to 50 sec.Stages 2 and 3 have inbuilt timeouts dependent on the length of time in stage 1.Stage 2 timeout equals two times the stage one time plus 2 sec.Stage 3 timeout equals one times the stage one time plus 3.5 sec.

100%

20%

0%

Speed

ReducingVoltage &Braking

100%

50%

25%

100%

50%

Stage 1

Stage 2

Stage 3

Time set on pot

TimeoutStage 2

Stage 3

Voltage from motor

100%

20%

0%

Speed

ReducingVoltage &Braking

100%

50%

25%

100%

50%

Stage 1

Stage 2

Stage 3

Time set on pot

TimeoutStage 2

Stage 3

Voltage from motor

Braking Strength

Typical Direct on Line DC brake retro fit

8

Supply

Brake Module

MotorM3~

UVW

246

135

CF1

4AgG

C1

18 M3 M2 M1

Stop

380-415/3ph/50~

L1L2L3

Start

246

COL

Example Direct on Line Starter

BrakeSupply

B2 17 28

L1

L2

L1

L2

6

4

2

5

3

1

18 M3 M2 M1

A2 A114 1396 95

C2OL

Remove existingcontrol supply

L1

L2

ControlSupply

S1

S2

BF2

B2 17 28

34 33

C4

21 22

C3

A2 A1BC1

21 22

BC2

BF1

n/c contact fromstandard D.O.L. starterto interlock braking

n/o contact fromstandard D.O.L. starterto signal braking

DC Brake retro fit unit

BC

NOTE: M3 connection only applies to Smooth-BRAKE modules.See page 3 for BF1 and BF2 Brake Fuse rating.The Brake Contactor, ‘BC’ should be sized to cover the relative braking current.

9

Direct on Line starter with S10 Brake Module3 phase

Remote Connections

Remove link between95 ON OL & 14 ON C.

95 ON OL 14 ON C 13 ON C

Start Stop

2.5mm sq2.5mm sq

M3~ Motor

2

4

6

2

4

6

1

3

5

M2 M1 S10 - 400Brake Module

17 18 B2 28

L1L1L2

L2

M2 M1

17 18 B2 28

CF1

4AgGC3

33 34 21 22 A2 A1

C4

All control cableto be 1.0mm sq

Start

StopReset C2 BC2

OL

BC1

C121 22 A2 A114 1396 95

6

4

2

5

3

1

OLC

BC

L1L2L3

Supply

380-415/3ph/50~

UVW

RL1 RL2

10

Direct on Line starter with S10 Brake Module1 phase

NOTE: On braking there is a diode in the brake circuit connected directly across the motor.Single phase induction motors have capacitors, permanent capacitors can be dc injectedand the diode needs to be rated for the discharge currents of the motor capacitors thiscurrent can also produce a torque pulse on the shaft.The capacitance in circuit prolongs the decay of electrical energy in the motor so a longerdwell time is required from pressing the stop button to connecting the brake.Capacitors can be short time rated and if so it is better to remove them from circuit during braking.To remove the capacitors during braking use a normally closed auxiliarycontact on the brake contactor.Aux contacts normally carry a 10 Amp rating and this may not be sufficient for the startwinding current for some single phase motors. The normally closed contact allows thecapacitor energy to discharge through the motor wining as normal otherwise a bleedresistor would be needed.

Remote Connections

Remove link between95 & 14

95 ON OL 14 ON C 13 ON C

Start Stop

2.5mm sq2.5mm sq

M3~ Motor

2

4

6

2

4

6

1

3

5

M2 M1 S10 - 240Brake Module

17 18 B2 28

L1L1L2

L2

M2 M1

17 18 B2 28

CF1

4AgGC3

33 34 21 22 A2 A1

C4

All control cableto be 1.0mm sq

Start

StopReset C2 BC2

OL

BC1

C121 22 A2 A114 1396 95

6

4

2

5

3

1

OLC

BC

L

N

Supply U1U2

RL1 RL2

11

Separate control supply version

S2S1

Separate supply

2.5mm sq

M3~ Motor

UVW

2

4

6

2

4

6

OL

BC

2.5mm sq

6

4

2

5

3

1

1

3

5

2.5mm sq

L1L2L3

Supply

380-415/3ph/50~

M2 M1

L2L2

M2 M1

C333 34

17 18

17 18

B2 28

B2 28

Start

StopReset C2

OL

14 1396 95

All control cableto be 1.0mm sq

BC1

C1

A2 A1

A2 A1

S10 - 400Brake Module

L1L1

CF1

4AgG

C

Remote Connections

Remove link between95 ON OL & 14 ON C.

95 ON OL 14 ON C 13 ON C

Start Stop

RL1 RL2

12

Star Delta starter with S10 Brake Module

1

3

5

1

3

5ST1 3 5

2

4

6

4

5

6

2

4

6

1

3

5

2 4 6

C

SupplyL1

L2

L3

2.5mm sq

1

3

5

2

4

6

10

BC

11

8

9

7

OL

RN

V2

W2

U2

U1

V1

W1

M3~

6 2 4

Motor

17 18 B2 28

L1 L1L2 L2

M2 M1

M2 M1

S10 - 400Brake Module

2.5mm sq

2.5mm sq

17 18 B2 28

14 15

13 14

16 1917 18 21 22

20 21

28 21 22

YD2 RN2

YD3 ST2

C2

All control cableto be 1.0mm sq

Stop/Lock Start

CF1

4gG

OL BC2 C313 12

96 95 22 21 33 34 21 22 A2 A122

A2 A1

A2 A1

A2 A1

A2 A1

C4BC1

C1

30secYD1

ST1

RN1

BF1

30ArG

BF2

30ArG

RL1 RL2

13

Star Delta Starter with Smooth-BRAKE Assembly

1.5mm sq

6mm sq 2.5mm sq (x2)

6mm sq

6mm sq

1.5mm sq

Black

Black

6mm sq

6mm sq

M3~

Feed MotorUVW

246

2OL

L1L2L3

Supply

135

456

MF12C

123

135

246

246

789

Main Motor

1C

1RN 1ST

135

Smooth-BRAKE Unit

Smooth-BRAKE ModuleB2 17 18 28

B2 17 18 28

1OL

135

246

1BC

1 3 5

2 4 6

U1V1W1

V2W2U2

M3~

CF1 2A

CF2 2A

CF3 2A

CF4 2A

14 15

16 19

10 6

33 34

20

24 25 26 29

21 22

A2 A1

A2 A1

A2 A1

A2 A1

13 14

A4 A1

A2 A1

43 44

21 22

21 22

21 22

13 14

13 14

13 14

53 54

CF5 2A

G L1

M2 M1

3(M2) 1(M1)

L2 M1

M2 M3

L22(L1)

L2L123

14SKNH56/91

M3 1BC3

1R3

1C3

1BC1

1BC3

1C1

1YD1

1ST11BC4 1RN21YD2

1C41BC2

1C2R

R

O

O

T

T

TOR

17 1827

T5 T6

T7

Main MotorStart

30

31

Filter

0-1min

0

13

W1

U1

V1

C10G16

415V

110V

96 95 96 9523 22 21

TOR

40 41

31 32 9 5

36 37

39

FeederStop

FeederStart

T10T11

T12 T13

1RN3 1R2

2C2

1RN4

1YD3 1ST21RN1

1R1

2C1

32

31 3233 33A

3428

35

38

42

OffRun Track

T4 T3 1OL2OL

RL1 RL2

14

Fault finding

Check power to L1 L2 supply to module - volt meter check 1.Supply to terminal 17 control fuses and wiring - volt meter check 2.Relay closed internally linking 17 to 18 module fault if doesn’t close- volt meter check 3.

Check voltage signal to B2 – fed from auxiliary contact block on themain contactor - volt meter check 4.Application of voltage causes no change however removal of voltagetriggers the braking.Check voltage on 28 to ensure internal relay operating - volt metercheck 5.

Wiring from M1 M2 to motor – Isolate supply test with meter on resistance across M1 M2 when operating the BC brake contactor byhand should be able to measure the winding resistance - resistancecheck 6.Motor connections for star delta.DC injection fuse.Faulty contactor.Wiring fault.Module fault.

If semiconductor fuses are not fitted and high currents result fromearth faults.If voltage setting is too large for the motor impedance.If Interlocks incorrectly wired and AC and DC contactors operate atthe same time.

Initially check for loose connections and physical damage

Not Starting

Brake contactor not operating

Brake Contactor operating but not braking

Module tracks can be damaged

Time

Torque

L1 L2 M1 M2

28 18 17 B2

V~0hms

V~

V~

V~

V~

1 6

R

5

3

2

4

15

Interlocks

The two internal relays controlling the starting (RL1) and braking (RL2) provide in initialdegree of interlocking. The normally closed on the first relay feeds the common on thesecond so the outputs 18 and 28 cannot be on at the same time. Electrical interlocks arealso used on the main and DC contactors. However if the interlocking is bypassed forsome reason then the AC and DC contactors energised together put a direct short circuitacross two phases and supply fuse size will determine the amount of damage.

If several brake modules are used with a common control circuit it is important to maintain interlocks across all the units. Use volt free relay contacts in the common circuitfrom relays connected to terminal 18 on each module.

General Notes

• Star Delta run up times of approx 15 sec or more could result in the overload tripping.• Star Delta connections are important easy to have the motor start and run but not dc

inject if the 6 leads are not correctly marked or wired.• Inertia can result in the need to increase the amount of dc current. E.g. Disc sanders,

band saws, and high-speed routers.• Mechanical damage can occur with very high levels of dc injection.• The motor resistance will change with temp up to 30% from cold to hot, reducing

braking as the motor warms.• Bad connections can cause severe damage to contactors –old machines have old

motors, wiring and starters. Sawdust and woodchips inside contacts is a prime cause ofbad connections.

• More than one motor can be dc injected using the same thyristor/diode power assembly if all can be stopped together.

• Multi motor machines (tennoners) can have individual start buttons but one common stop which will dc inject all motors running or stationary.

• Aux block on the main contactor has to be moved to allow the starter to be wired. If not put back in place this may result in no braking i.e. the brake contactor doesn’t operate.

• Check connections to the motor if the brake contactor is operating but the motor is notbraking.This can be quickly done by measuring the winding resistance across the diode M1 to M2 while operating the brake contactor by hand to make the circuit.

All information contained in this publication is, as faras possible, correct at the time of going to print.However, due to our policy of continued improvement,we reserve the right to alter specifications and priceswithout prior notice.© 2008 Crompton Controls Ltd.

All rights reserved.

Printed in England j4design.co.uk Part No: LT011 EP/2K/09/08

Crompton Controls LtdMonckton Road,Wakefield,West Yorkshire WF2 7AL UKTel: +44 (0)1924 368251Fax: +44 (0)1924 367274E-mail: sales@cromptoncontrols.co.ukwww.cromptoncontrols.co.uk

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