Brake Chopper

BC 2.1 - BC 4.1
Instruction and Operation Manual

Caution:
There is always a risk involved in the handling of electrical machinery!
Therefore mounting and maintenance should only be done by authorized personnel.

TAE Antriebstechnik GmbH • Am Kappengraben 20 • D-61273 Wehrheim

Stand 24.02.2014 V-7 EBC2-1.PMD The German text applies in cases of doubt
Chopper BC 2.1 - BC 4.1
About This Instruction Manual
If you look for some definite topic you can use the table of contents at the beginning of these instruction
and operation manual.

In these instructions is a row of symbols which shall provide you with a fast orientation and show the
importants.

This symbol stands for notes and useful informations which shall make the operation
easier for you.

Note, disregard can damage or destruct the chopper.

Note, disregard means a danger for the operator.

1. Instruction of Safety
Before you put the chopper into operation, please read this instruction and operation
manual completly. The operation should only be done by qualified personnel. The
precautions and warnings below must be observed at the operation of the chopper. The
braking chopper instruction and operation manual do not replace the manual of initial
operation of the inverter.

1.1 Instructions and Rules

During installation, general installation regulations such as following should be observed.
DIN VDE 0100 General requirements for the installation of power with mains
VDE 0113 General requirements for the installation of electrical equipment for production and
tooling machines
VDE 0160 Requirements for electronic equipment for use in electrical power installations.
VDE 0470 part 1 International protection

2 Instruction and Operation Manual

 Chopper BC 2.1 - BC 4.1
1.2 Safety
Caution Danger !
Disconnect unit from mains and wait untill the capacitors have discharged before making
any repairs. After the installation make sure that the unit and motor is properly grounded in
order to avoid electrical hazzards.

As with any form of electrical equipment, there is always a risk involved in the handling of
electrical machinery. The greatest care must always be exercised during installation and
maintenance. It is recommended that service is performed by authorized personnel only.

Caution !
1. Do not connect or disconnect the chopper when it has power.
2. Please take care of the correct polarity.
3. If you exchange the connections BUSS + and BUSS- the inverter or the chopper can be
destroyed.
4. An ultra rapid fuse for the protection of the IGBT is not installed.

Table of content
1. Instruction of Safety ............................................................................................... 2
1.1 Instructions and Rules ........................................................................................................ 2
1.2 Safety ................................................................................................................................. 3

2. Function .................................................................................................................. 4
3. Mounting and Location ........................................................................................... 4
4. Technical Data ......................................................................................................... 5
4.1 Chopper voltage 375V ........................................................................................................ 5
4.2 Chopper voltage 750V ........................................................................................................ 5

5. Load Curve .............................................................................................................. 6

6. Connections and Indications ................................................................................. 7
7. Example of Connection .......................................................................................... 7
8. Dimensions ............................................................................................................. 8
9. Spare Parts ............................................................................................................. 8
10. Options .................................................................................................................... 9
10.1 Overcurrent relay ................................................................................................................ 9
10.2 Ultrafast semiconductor fuses ............................................................................................. 9

11. Calculation Braking Chopper and Resistor .......................................................... 9

12. Connection diagram option, ready for operation and chopper active ................ 11
13. Connection diagram option Master - Slave .......................................................... 12

Instruction and Operation Manual 3

Chopper BC 2.1 - BC 4.1
2. Function
If the speed of the motor is reduced the motor behaves like a generator. Since the kintical energy is not
sent back with the Inverter to mains the intermediate circuit (BUSS) capacitors store the energy. The
voltage of the intermediate circuit increases. If the intermediate circuit voltage the inverter protects itself
by turning off.
To avoid the interuption of braking, a Braking Choppers is used. It is activated if the voltage of the inter-
mediate circuit is higher than the tolerable intermediate circuit voltage. The braking resistor is connected
with the intermediate circuit and the additional energy is transformed to heat.
If big masses have to be decelerated the braking resistor must have enough power related to the kinetical
energy.

3. Mounting and Location

BC 2.1 BC 3.1
2
2
3

1
1 4 3
4

BC 4.1
2 5 Position
type
1 2 3 4 5
3 BC 2.1-16/5,5
BC 2.1-24/6
-
BC 2.1-33/11
BC 2.1-51/13
BC 3.1-32/13 -
BC 3.1-32/22
1x
BC 3.1-47/25 1x IGBT 2MBI
Jumper Fan
BC 3.1-65/27 BR2 & Fuse F1
BC 3.1-67/26 Potentio- PC- (only -
BC 3.1-67/45 meter P1 Board Electronic
Chopper not IGBT) 1x
BC 3.1-97/52
1 4 voltage Fan
BC 3.1-135/56
BC 4.1-90/33
BC 4.1-120/36 2x IGBT 2MBI
(Hauptplatine - Mainboard)
BC 4.1-180/67 1x IGBT 2MBI
BC 4.1-185/41 2x
BC 4.1-250/75 2x IGBT 2MBI Fan
BC 4.1-375/82

Connection Voltage
BR2 200 - 440V 450 - 800V
Chopper Voltage 375V 750V
at potentiometer
P1 at factory adjustment 340V 680V
Steckbrücke BR2 - Jumper

4 Instruction and Operation Manual

 Chopper BC 2.1 - BC 4.1
4. Technical Data
4.1 Chopper voltage 375V
Connection voltage 200 - 440 VDC BUSS +/-
Factory adjustment Jumper BR2 right:375V, BR2 left: 340V
Chopper voltage
Control range potentiometer P1: 240 to 440, cw:10V/turn lower
Permanent Superfast
Brake power in kVA at Peak current Brake resistor
current fuse F2
Type Article-No.
Permanent
Peak load in A in A in A >Rmin.
load
BC 2.1-16/5,5 12262-0F01 5,5 16 15 45 50 8Ω
BC 2.1-24/6 12262-1F01 6 24 17 68 63 5,3Ω
BC 3.1-32/13 12263-AF01 13 32 35 90 100 4Ω
BC 3.1-32/22 12263-0F01 22 32 60 90 100 4Ω
BC 3.1-47/25 12263-1F01 25 47 70 130 125 2,8Ω
BC 3.1-65/27 12263-2F01 27 65 75 180 200 2Ω
BC 4.1-90/33 12264-0F01 33 90 90 240 250 1,6Ω
BC 4.1-120/36 12264-1F01 36 120 100 330 355 1,1Ω
BC 4.1-185/41 12264-2F01 41 185 110 500 500 0,75Ω
Ambient temperature 0-40°C
Dimensions refer to Chapter 8.

4.2 Chopper voltage 750V

Connection voltage 450 - 800 VDC BUSS +/-
Factory adjustment Jumper BR2 right:750V, BR2 left: 680V
Chopper voltage
Control range potentiometer P1: 540 to 800, cw:25V/turn lower
Permanent Superfast
Brake power in kVA at Peak current Brake resistor
current fuse F2
Type Article-No.
Permanent
Peak load in A in A in A >Rmin.
load
BC 2.1-33/11 12262-0F00 11 33 15 45 50 16Ω
BC 2.1-51/13 12262-1F00 13 51 17 68 63 11Ω
BC 3.1-67/26 12263-AF00 26 67 35 90 100 8,5Ω
BC 3.1-67/45 12263-0F00 45 67 60 90 100 8,5Ω
BC 3.1-97/52 12263-1F00 52 97 70 130 125 5,5Ω
BC 3.1-135/56 12263-2F00 56 135 75 180 200 4,2Ω
BC 4.1-180/67 12264-0F00 67 180 90 240 250 3,2Ω
BC 4.1-250/75 12264-1F00 75 250 100 330 355 2,3Ω
BC 4.1-375/82 12264-2F00 82 375 110 500 500 1,5Ω
Ambient temperature 0-40°C
Dimensions refer to Chapter 8.

The value of the brake resistor has to be equal or higher than Rmin. and depends on the
required output. If the brake resistor is lower than Rmin., the IGBT (Insulated Gate Bipolar
Transistor) can be destroyed. The output is protected against short circuit but not against
permanent overload.

Instruction and Operation Manual 5

Chopper BC 2.1 - BC 4.1
5. Load Curve
at 40°C ambient temperature

Peak Current
in A

70

60
BC 2.1
50 BC
2.1-
BC 2 51/1
.1-33 3&
BC
40 /11 &
BC 2
2.1-
24/6
.1-16
/5,5
30

20

Max. brakeing
5 10 30 60 120 ∞ in seconds

Min. break
200 150 120 100 60 0 in seconds

Peak current
in A

500

400 BC
4.1
-3
BC 3.1 & BC 4.1
75/
82
&B
C4
.1-1
300 85/
41
BC 4
.1-25
0/75
& BC
4.1-1
200 20/36

BC 4.1
BC 3.1 -180/67
-135/5 & BC 4.
1-90/3
150 6&B
C 3.1-6 3
5/2 7
BC 3.1-97
/52 & BC
3.1-47/2
5
100
BC 3.1-67/45 & BC 3.1-32
/22
BC 3.1-67/26 &
BC 3.1-32/13
50
25
Max. brakeing
in minutes
1 2 3 4 5 ∞
Min. break
5 4 3 2 1 0 in minutes

6 Instruction and Operation Manual

 Chopper BC 2.1 - BC 4.1
6. Connections and Indications
Indications:
Overcurrent red Overcurrent/Short circuit
BC... Active clear Chopper is active
CHOPPER Power green Chopper is ready

OVERCURRENT
ACTIVE
POWER Connections of the terminal blocks:
Connection for earth ( )
DANGER
Earth the cover large surfaced , e.g. mounting on a
HIGH VOLTAGE !
galvanized assembly plate.
BUSS- -connection BUSS-voltage inverter
BUSS+

BUSS+ +connection BUSS-voltage inverter

BUSS

R1
R2

R1 - R2 a thermo protection has to be connected in row to the brake

resistor. This thermo protection has to be adjusted to the
nominal current of the brake resistor.
(see Chapter 7 Example of Connection)

Caution !
1. Do not connect or disconnect the chopper when it has power.
2. Please take care of the correct polarity.
3. If you exchange the connections BUSS + and BUSS- the inverter or the chopper can
be destroyed.
4. An ultra rapid fuse for the protection of the IGBT is not installed.

7. Example of Connection

BC...
CHOPPER
Brake resistor

OVERCURRENT
ACTIVE
POWER

Inverter
DANGER
HIGH VOLTAGE !
BUSS+
BUSS -

R1
R2

BUSS voltage

L1 L2 L3 + R R
F2
Ultrafast Fuses
(refer to Chapter 10 Options)
Overload Relay
(refer to Chapter 10 Options)

Line
Inverter

If cables between inverter and chopper resp. chopper and brake resistor are less than 25 cm, they have to be twisted
and if they are longer than 25 cm they have to be shielded.

Instruction and Operation Manual 7

Chopper BC 2.1 - BC 4.1
8. Dimensions
B
S

BC...
CHOPPER

OVERCURRENT
ACTIVE
POWER
H1
H

DANGER
HIGH VOLTAGE !
BUSS+
BUSS

R
R

B1 T

Device size B B1 H H1 T S
BC 2.1 82,5 40,5 150 138 220 6
BC 3.1 130 64,5 205 193 208 6
BC 4.1 131 64,5 298 280 300 9

9. Spare Parts
Device type BC 2.1 BC 3.1 BC 4.1

Art.-No. Description 12262-0F.. 12262-1F.. 12263-AF.. 12263-0F.. 12263-1F.. 12263-2F.. 12264-0F.. 12264-1F.. 12264-2F..

34292-42 IGBT 2MBI 50N-120 50A

34292-47 IGBT 2MBI 75N-120 75A

34292-52 IGBT 2MBI 100N-120 100A

34292-55 IGBT 2MBI 150N-120 150A

34292-62 IGBT 2MBI 200N-120 200A

34292-67 IGBT 2MBI 300N-120 300A

34472-00 F1 Fuse for electronic 30x5 medium blow 3,15A

68053-00 Fan 24V

78303-0F PC-Board

8 Instruction and Operation Manual

 Chopper BC 2.1 - BC 4.1
10. Options
H Brake resistors up to 60kW permanent load enclosure IP 20 and different types according to customer
wishes. Please consult TAE Antriebstechnik.
H Overcurrent relays for protection of the brake resistor against thermal overstressing.
Overcurrent relays with higher rated current of enquiry.
10.1 Overcurrent relay
Rated current in A: Art.-No: Rated current in A: Art.-No:
0,1 - 0,16 36770-A0 1,6 - 2,4 36770-G0
0,16 - 0,24 36770-B0 2,4 - 4 36770-H0
0,24 - 0,4 36770-C0 4 -6 36770-I0
0,4 - 0,6 36770-D0 6 - 10 36770-K0
0,6 - 1 36770-E0 10 - 16 36770-L0
1 - 1,6 36770-F0 16 - 24 36770-M0

10.2 Ultrafast semiconductor fuses

Use with Braking chopper: Fuse value in A Art.-No. Fuse Art.-No. Fuse Breaker 3pol

12262-0F... 50 34606-00 34529-00

12262-1F... 63 34607-00 34529-00
12263-AF... 100 34609-00 34529-00
12263-0F... 100 34609-00 34529-00
12263-1F... 125 34610-00 34529-00
12263-2F... 200 34621-00 34529-01
12264-0F... 250 34622-00 34529-01
12264-1F... 355 34633-00 34529-02
12264-2F... 500 on request 34529-03

11. Calculation Braking Chopper and Resistor

Basis of calculation:
Constant Brake torque and linear speed reduction.
-1
n[min ] -1
nmax= 2400 min
-1
nmittel=1200 min

0 t[s]
tRUN= 14 s tBREAK=
3s tOFF= 3 s

M+
[Nm]

0 t[s]

MMAX
100 Nm
M-
[Nm]
Example:
P[kW]
Brake torque 100 Nm
Max Speed 2400 min-1
t[s]
Motor operation time 14 sec.
0
Brake time 3 sec.
Stop 3 sec.
25,1 kW PMAX BREAK Chopper voltage 750 V

Instruction and Operation Manual 9

Chopper BC 2.1 - BC 4.1
Calculation Peak Load PMAX BREAK

nMAX × MMAX 2400 x 100

PMAX BREAK = = = 25,1 kW
9550 9550

PMAX BREAK in kW peak load brake chopper

nMAX in min-1 max speed
MMAX in Nm max brake torque

Calculation RMS Brake load PBREAK RMS

t BREAK 3
PBREAK RMS = PMAX BREAK × = 25,1× = 5,6 kW
3 × (t RUN + t BREAK + t OFF ) 3 × (14 + 3 + 3)

PBREAK RMS in kW RMS brake load

PMAX BREAK in kW peak load brake chopper
tBREAK in seconds brake time
tRUN in seconds motoring operation
tBREAK in seconds regen operation
tOFF in seconds stop

Calculation Brake Resistor

U2 750 2
R= = = 22,4 Ω
PMAX BREAK 25100

R in W brake resistor
U in V (turn-on) voltage
PMAX BREAK in W peak load brake chopper

Brake Chopper selected from table 4.2 (refer to technical data)

Brake chopper BC2.1-33/11 Art.-No. 12262-0F00
Chopper voltage 750V

Permanent Load:
PBREAK RMS = 5,6 < 11 kW OK

Peak Load:
PMAX BREAK = 25,1 < 33 kW OK

Brake Resistor:
R = 22,4 > 16 W OK

10 Instruction and Operation Manual

 Chopper BC 2.1 - BC 4.1
12. Connection diagram option, ready for operation and chopper active

C2/A2 Stör- und Betriebsbereitmeldung

C1/A1 Chopper Aktiv, verzögert Aus
C2/A2 message "error" and "ready for operation"
C1/A1 Chopper active, delayed OFF

message "error" and "ready for operation"

max 30mA Stör- und Betriebsbereitmeldung
C2 A2 C1 A1

Chopper active, delayed OFF

max 30mA Chopper Aktiv, verzögert Aus
Jumper - closed

(+24V)
+24V
Logic Output C1 - A1
DIP-Switch S1 Chopper ON - -C2 A2 C1 A1- -
DIP OUT - ON OUT - OFF
OFF

0 0
S1.1 ON
ON

1 1
4 3 2 1
S1.2 ON
S1.3 ON
S1.4 ON

Steckbrücke - Jumper

Instruction and Operation Manual 11

Chopper BC 2.1 - BC 4.1
13. Connection diagram option Master - Slave

Achtung !!! Anschlüsse O,G,I,C führen 400VDC nach Erde!

Caution !!! Connection O,G,I,C lead 400VDC to ground!

Anschluss Variante 1: Master - Slave (in Reihe) - Connection version 1: Master - Slave (in series)

--O G I C-- --O G I C-- --O G I C--

--O G I C-- BC... BC... BC...

CHOPPER CHOPPER CHOPPER

MS - Master
OVERCURRENT OVERCURRENT OVERCURRENT
ACTIVE ACTIVE ACTIVE
POWER POWER POWER

DANGER DANGER DANGER

HIGH VOLTAGE ! HIGH VOLTAGE ! HIGH VOLTAGE !

--O G I C--
BUSS+

BUSS+

BUSS+
BUSS

BUSS

BUSS
R1
R2

R1
R2

R1
R2
SL - Slave

Master Slave 1 Slave 2

O Output
G Ground R R R R R R
Bremswiderstand

Bremswiderstand

Bremswiderstand
I Input
Brake resistor

Brake resistor

Brake resistor
C Com

Anschluss Variante 2: Master - Slave (Parallel) - Connection version 2: Master - Slave (parallel)
(max 5 Slaves Parallel)

--O G I C-- --O G I C-- --O G I C--

--O G I C-- BC... BC... BC...

CHOPPER CHOPPER CHOPPER

MS - Master
OVERCURRENT OVERCURRENT OVERCURRENT
ACTIVE ACTIVE ACTIVE
POWER POWER POWER

DANGER DANGER DANGER

HIGH VOLTAGE ! HIGH VOLTAGE ! HIGH VOLTAGE !

--O G I C--
BUSS+

BUSS+

BUSS+
BUSS

BUSS

BUSS
R1
R2

R1
R2

R1
R2

SL - Slave

Master Slave 1 Slave 2

O Output
R R R R R R
G Ground
Bremswiderstand

Bremswiderstand

Bremswiderstand

I Input
Brake resistor

Brake resistor

Brake resistor

C Com

12 Instruction and Operation Manual