PDF Braking Resistor Calculation en

FAQ about Drives Technology
Calculating the braking resistors for MM4 and

G120
MICROMASTER 440
SINAMICS G120
Calculating the braking resistors for MM4 and G120
Item-ID: 7800906
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Version 1.1 issue June 2008 2/10

Item-ID: 7800906
Table of Contents
Table of Contents ......................................................................................................... 3
1 Overview.......................................................................................................... 4
1.1 Examples to select braking resistors for MM4 and SINAMICS G120 ............... 4
Table for 230V units ..................................................................................... 5
Table for 400V units ..................................................................................... 6
Table for 575V units ..................................................................................... 7
1.2 Examples .......................................................................................................... 8
1.2.1 Example 1:........................................................................................................ 8
1.2.2 Example 2:........................................................................................................ 8
1.2.3 Example 3:........................................................................................................ 9
Note:............................................................................................................. 9
2 Appendix ....................................................................................................... 10
2.1 Internet links ................................................................................................... 10
2.2 History............................................................................................................. 10
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Item-ID: 7800906
1 Overview
The selection of the braking resistors for MM4 will be described in the
application 22101908. MICROMASTER 4 – engineering braking chopper
operation for MICROMASTER 440
More technical details are found in FAQ ID: 8400450. MM440: Braking
resistors (MLFBs and dimensions)
Information about braking resistors in use with inverter SINAMICS G120 is

found in the catalogue “SINAMICS G110/SINAMICS G120 Inverter chassis
units SINAMICS G120D Distributed frequency inverter” in chapter “DC link
components”. SINAMICS G110/SINAMICS G120 Inverter Chassis Units
SINAMICS G120D Distributed Frequency Inverters catalogue
More detail information about operate with braking resistors and settings of
duty cycle contains the chapter “Dynamic braking” of the function manual.
Function manual
Braking resistors are not available for the SINAMICS G120 / G120D with
PM250 / PM250D 1. The Power Module is capably of energy recovery
(regenerative feedback into the line supply). This means that the energy is
fed back into the line supply and does not have to be dissipated in the form
of heat in a braking resistor.
1.1 Examples to select braking resistors for MM4 and SINAMICS

G120
The tables provided on the following pages can be used when selecting
and specifying resistors when they are purchased from other
manufacturers.
1
PM250D: PM = Power Module; 250 = capable of energy recovery; D = distributed technology

Item-ID: 7800906
Table for 230V units
Supply Inverter frame Inverter power Calculated power rating 1 Resistance Braking current at Recommended Voltage DC-voltage
voltage size range (kW) +/- 10% voltage trip level cable size 4 rating wrt rating (V)
6
(Ohms) 2 (A) 3 (mm²/AWG) Earth

(Vrms) 5
Contin. (W) Instantan. (12s
duration) (W)
230V
A 0.12-0.75 44 889 180 2.3 1.0/17 265 450
B 1.1 118 2353 68 6.2 1.0/17 265 450
B 1.5 / 2.2 118 2353 68 6.2 1.0/17 265 450
C 3 205 4103 39 10.8 1.0/17 265 450
C 4 / 5.5 296 5926 27 15.6 1.5/15 265 450
D 7.5 – 15 800 16000 10 42.0 10/7 265 450
E 18.5 / 22 1176 23529 6.8 61.8 16/5 265 450
F 2424 48485 3.3 127.3 70/-2 265 450
1
The actually required rated power normally lies between these two values and depends on the operating cycle that can be expected. In case of doubt,
select a larger (higher rating) resistor than required as the associated costs are relatively low.
2
Normal and minimum resistance value that should be specified.
3
Braking current in the braking controller (braking chopper) and resistor
4
Ensure that the connecting cable is suitable for the operating voltage as well as the high temperatures of the braking resistor. Shielded cables should
be used. The maximum cable size and the cable connection type depend on the manufacturer of the brake resistor.
5
Minimum ground insulation
6
Maximum rated voltage of the resistor
Item-ID: 7800906

voltage size range (kW) +/-10% voltage trip level cable size 4 rating wrt rating (V)
6
(Ohms) 2 (A) 3 (mm²/AWG) Earth

(Vrms) 5
Contin. (W) Instantan.
(12s
duration) (W)
400V
A 0.37 – 1.5 86 1724 390 2.2 1.0/17 530 900
B 2.2 – 3 210 4203 160 5.3 1.0/17 530 900
B 4 210 4203 160 5.3 1.0/17 530 900
C 5.5 600 12007 56 15.0 1.5/15 530 900
C 7.5 / 11 600 12007 56 15.0 1.5/15 530 900
D 15 – 22 1245 24904 27 31.1 6.0/9 530 900
E 30 / 37 2241 44827 15 56.0 15/5 530 900
F 45 - 75 4100 82000 8.2 102.4 35/2 530 900
1
2
3
4
5
6
Item-ID: 7800906
voltage size range (kW) +/-10% voltage trip level cable size4 rating wrt rating
(Ohms)2 (A)3 2
(mm /AWG) Earth (V)
6
(Vrms)5
Contin. (W) Instantan.
(12s
duration) (W)
575V
C 0.75 - 2.2 442 8841 120 8.8 1.0/17 660 1100
C 4 / 5.5 442 8841 120 8.8 1.0/17 660 1100
C 7.5 / 11 647 12938 82 12.8 1.5/15 660 1100
D 15 - 22 1360 27203 39 26.9 4/11 660 1100
E 30 / 37 1965 39293 27 38.9 10/7 660 1100
F 45 - 75 4420 88408 12 87.5 35/2 660 1100
1
2
3
4
5
6
Item-ID: 7800906
Please use columns 6, 7and 8 to select the cable for the braking resistor.
All of this information should be provided to the supplier so that the correct
resistor can be selected.
1.2 Examples
1.2.1 Example 1:
A 7.5 kW 400V drive operates a lifting system that lifts for 15 seconds and
then lowers for 15 seconds.
Resistor duty cycle: 50%

Resistor specification: 56 Ohms, 6000W continuous, 12000W
instantaneous (15 seconds on, 15 seconds off), operating at up to 900V
DC, 600V wrt Earth. Ambient temperature XX centigrade, protection level
IPYY.
1.2.2 Example 2:
A downhill conveyer is required to provide continuous braking on an

18.5kW 400V inverter.
Resistor duty cycle: 100%
Losses will be high on a conveyor system, so assume 18.5kW maximum
power.
Resistor specification: 27 Ohms, 18.5kW continuous rating operation at up
to 900V DC, 600V wrt Earth. Ambient temperature XX centigrade,
protection level IPYY.

Item-ID: 7800906
1.2.3 Example 3:
A pallet handling machine using a 5.5kW 230V inverter must ramp down
and stop once a minute, with a ramp down time of 5 seconds.
Resistor duty cycle: 5 seconds in 60; say 10%
Resistor specification: 27 Ohms, 6000W instantaneous rating, 300W
continuous (5 seconds every minute) operating at up to 450V DC, 265V wrt
Earth. Ambient temperature XX centigrade, protection level IPYY.
Note:
The resistor specifications for this example can be taken from FAQ
8400450 MM440: Braking resistors (MLFBs and dimensions) or the
„SINAMICS G110/SINAMICS G120 Inverter Chassis Units SINAMICS
G120D Distributed Frequency Inverters catalog“ in Chapter "DC link
components".

Item-ID: 7800906
2 Appendix
2.1 Internet links
This list is by no means complete and only provides a selection of

appropriate sources.
Topic Title
\1\ FAQ MM440: Braking resistor (MLFBs and dimensions)
\2\ Catalog SINAMICS G110/G120 Inverter Chassis Units
SINAMICS G120D Distributed Frequency Inverters
\3\ Application MICROMASTER4 – Engineering braking chopper
operation for MICROMASTER 440
\4\ Instruction Braking resistors for MICROMASTER 440
Sheet
\5\
2.2 History
Table 2-1 History
Version Date Changes
V1.0 May 2003 First issue
V1.1 June 2008 Text revised, Tables revised

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FAQ about Drives Technology

Calculating the braking resistors for MM4 and

Warranty, liability and support

Copyright© 2008 Siemens A&D. It is not permissible to transfer or

Version 1.1 issue June 2008 2/10

Version 1.1 issue June 2008 3/10

Information about braking resistors in use with inverter SINAMICS G120 is

1.1 Examples to select braking resistors for MM4 and SINAMICS

Version 1.1 issue June 2008 4/10

Calculating the braking resistors for MM4 and G120

Table for 230V units

(Ohms) 2 (A) 3 (mm²/AWG) Earth

Calculating the braking resistors for MM4 and G120

Table for 400V units

(Ohms) 2 (A) 3 (mm²/AWG) Earth

Calculating the braking resistors for MM4 and G120

Table for 575V units

Resistor duty cycle: 50%

A downhill conveyer is required to provide continuous braking on an

Version 1.1 issue June 2008 8/10

Version 1.1 issue June 2008 9/10

2.1 Internet links

This list is by no means complete and only provides a selection of

Version 1.1 issue June 2008 10/10

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