Magnetek Dynamic Braking Resistors

Transcription

1 Magnetek Dynamic Braking Resistors Motor Control Instruction Manual N49 W13650 Campbell Drive Menomonee Falls, WI Phone: Fax: SERVICE: MAG-SERV ( ) DBR Installation Manual December 2009 Part Number: R4 Copyright 2009 Magnetek Material Handling

2 PRODUCT MANUAL SAFETY INFORMATION Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and adjustable frequency drives, and industrial braking systems for material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek s material handling products and systems (Magnetek Products). Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should know, understand and follow the instructions and safety recommendations in this manual for Magnetek Products. The recommendations in this manual do not take precedence over any of the following requirements relating to cranes, hoists lifting devices or other material handling equipment which use or include Magnetek Products: Instructions, manuals, and safety warnings of the manufacturers of the equipment where the radio system is used, Plant safety rules and procedures of the employers and the owners of facilities where the Magnetek Products are being used, Regulations issued by the Occupational Health and Safety Administration (OSHA), Applicable local, state or federal codes, ordinances, standards and requirements, or Safety standards and practices for the industries in which Magnetek Products are used. This manual does not include or address the specific instructions and safety warnings of these manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users and operators of the Magnetek Products to know, understand and follow all of these requirements. It is the responsibility of the employer to make its employees aware of all of the above listed requirements and to make certain that all operators are properly trained. No one should use Magnetek Products prior to becoming familiar with and being trained in these requirements and the instructions and safety recommendations in this manual. 2

3 2009 MAGNETEK MATERIAL HANDLING All rights reserved. This notice applies to all copyrighted materials included with this product, including, but not limited to, this manual and software embodied within the product. This manual is intended for the sole use of the persons to whom it was provided, and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of MAGNETEK. WARNING, CAUTION, and NOTE Statements WARNING, CAUTION, and NOTE statements are used throughout this manual to emphasize important and critical information. You must read these statements to help ensure safety and to prevent product damage. The statements are defined below. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTE: A note statement is used to notify people of installation, operation, programming, or maintenance information that are important, but not hazard-related. 3

4 WARNING This manual instructs you how to use Magnetek Material Handling s Dynamic Braking Resistors. If you disregard the instructions, information, and/or warranty in the manual, you could be assuming responsibility for damages, costs, or injury incurred by such disregard. Do not touch any circuit components on the circuit board while the main AC or DC power is on. 4

5 Table of Contents Introduction 7 Installation Instructions 8-11 CMAA Ratings Volt Traverse Motions 13 Class C, D, E, F 230 Volt Hoist Motions 14 Class C, D, E, F 460 Volt Traverse Motions Class C, D, E, F 460 Volt Hoist Motions 17 Class C, D, E, F 575 Volt Traverse Motions 18 Class C, D, E, F 575 Volt Hoist Motions 19 Class C, D, E, F 230 Volt Traverse Motions Weatherproof, Louvered Class C, D, E, F 230 Volt Hoist Motions 22 Weatherproof, Louvered Class C, D, E, F 460 Volt Traverse Motions Weatherproof, Louvered Class C, D, E, F 460 Volt Hoist Motions 25 Weatherproof, Louvered Class C, D, E, F 575 Volt Traverse Motions 26 Weatherproof, Louvered Class C, D, E, F 575 Volt Hoist Motions 27 Weatherproof, Louvered Class C, D, E, F 5

6 Type S Enclosures 28 Type W Enclosures 29 Type A Enclosures 30 Panel Mount Resistors 31 DC Dynamic Braking Resistors 32 Type D Enclosures 33 Type G Enclosures 34 6

7 Introduction Welcome to the Magnetek Dynamic Braking Resistors instruction manual. Magnetek Dynamic Braking Resistors consist of grid, smooth wound, wire wound or edge wound type resistor coils mounted in ventilated enclosures. These resistors can be used in any type of AC or DC power circuit/application. They are designed for many types of applications: continuous duty applications where high resistance and low current are required, continuous duty applications where low resistance and high current are required, and low current applications. Units are most commonly used for variable frequency drives, motor control, neutral grounding applications, load testing, and load banks. Magnetek offers a large selection of standard size coils to meet most requirements; for specialized applications or requirements, please consult the factory. 7

8 WARNING 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. Construction: Magnetek s Dynamic Braking Resistors consist of grid, smooth wound, wire wound or edge wound type resistor coils mounted in ventilated enclosures. All current carrying components used to manufacture our resistor coils, including the elements, terminals and terminal hardware, are stainless steel for maximum corrosion resistance. Standard enclosures will be mill galvanized with terminals factory wired to a terminal block. Braking resistors are available with a variety of options such as special enclosure finishes, outdoor ratings and thermal sensing switches. Inspection: Upon receipt of your Dynamic Braking Resistor, be sure to inspect the unit carefully for any shipping damage. After unpacking, check the unit for loose, broken, bent or otherwise damaged parts due to shipping. Report any shipping damage immediately to the freight carrier. Be sure to verify that the part number and ratings listed on the nameplate conform to the order specification. The ohm rating listed on the nameplate is critical (too low of an ohm value may cause damage to the drive). INSTALLATION CAUTION The National Electric Code (NEC) and local regulations govern the installation and wiring of electrical equipment such as braking resistors. DC power wiring, AC power wiring, control wiring and conduit must be installed in accordance with these codes. 8

9 Enclosure Types: Magnetek offers four enclosure types designed with respect to element coil style and intended mounting location. Enclosure Type A D G S W Description High density edge wound or wire wound resistor enclosure Grid resistor enclosure Weatherproof, louvered grid resistor enclosure Edge wound, smooth wound or wire wound resistor enclosure Weatherproof, louvered resistor enclosure for edge wound, smooth wound or wire wound resistors Mounting: Magnetek braking assemblies cool by natural convection, causing hot air to rise vertically from the enclosure. Braking resistors should be mounted in a well-ventilated location free of any combustible materials or equipment affected by heat. Units should be installed with at least 24 inches of free space above the enclosure top and 6 inches of free space surrounding the enclosure sides. If necessary, units can be mounted on spacers or channels to limit heat from conducting from the resistor enclosure to its mounting surface. Type S braking resistor enclosures can be mounted vertically or horizontally. If the unit is mounted vertically, it is important that the resistor coils remain in a horizontal position. Also, if a thermal switch is included with the unit, the switch should be positioned near the top of the enclosure. See Figure 1 for vertical mounting details. Air Flow Correct Vertical Mounting (Front View) Figure 1: Resistor Mounting Orientation Incorrect Vertical Mounting CAUTION Type A, D, G, and W enclosures must be installed with the mounting holes on a horizontal surface. 9

10 Installation: 1. Remove the ventilated cover. a. Type D, G, S, and W enclosures require a 5/16 wrench to remove the cover. b. Type A enclosures require a 7/16 wrench to remove the cover. 2. Fasten the unit securely in place. Mounting holes can be found on the inside of the braking resistor enclosure. The enclosure styles are listed in the tables on the following pages, and the mounting dimensions for each enclosure style are listed on pages 28 through 30, 33, and 34. a. Type S and W enclosures have 7/16 diameter mounting holes designed for 3/8 hardware. b. Type A, D, and G enclosures have 5/8 diameter mounting holes designed for ½ hardware. 3. Remove the proper knockout after determining a suitable entry point. It is preferable to route conduit near the bottom of the resistor enclosure. a. Type D, G, S, and W enclosures have convenient conduit knockouts for easy connection. b. Type A enclosures require field punching for conduit entry. 4. After attaching conduit, pull wiring into the enclosure for connection to resistor. Refer to CDBR-B Dynamic Braking Unit, Regenerative Power Module, or IMPULSE /OmniPulse drive manuals for correct wire sizes. Be sure to properly ground the resistor enclosure to prevent electrical shock. a. If connecting directly to the terminals on the resistor elements, it is necessary to use high temperature silicon or Teflon wire rated 200ºC. b. Try to route wiring along the bottom of the enclosure and avoid running the wiring near the resistor elements. c. If your braking resistor contains an optional factory wired terminal block, then you may connect to the unit with standard 90ºC rated wire. 5. If an optional thermal switch is included with the unit, then connect control wiring directly to the #8 terminals. a. Type A enclosures with the thermal switch option are pre-wired to a terminal block with #10 terminals, located in the bottom of the resistor enclosure. b. Thermal sensing switches are available with either normally closed or normally open contacts. 6. After installing and wiring to your Dynamic Braking Resistor, return the ventilated cover to its proper position. Securely tighten cover hardware (do not exceed 20 inch-pounds of torque). 10

11 Maintenance: Periodically check the unit for loose connections and an accumulation of dust or dirt on the inside and outside of the resistor enclosure. 1) Remove all power before servicing the unit to avoid electrical shock. 2) Allow at ten minutes after input power has been removed for the bus voltage to discharge. Electric shock can cause serious injury or death. 3) Be sure to allow the unit to cool before servicing (contact may result in burn injury). Resistor elements should not glow red under normal operating conditions. If the resistor elements glow red you may need a higher rated braking resistor. Ratings: Magnetek Dynamic Braking Resistor duty cycles are based on Magnetek s interpretation of CMAA 70-2 Crane Classification specification. Consult Magnetek for application assistance where actual duty cycles exceed the below definitions for any class of service, or for applications involving special environmental conditions such as high ambient temperatures. WARNING The total lowering time at full speed should not exceed 60 seconds. Consult Magnetek for application assistance with extended lowering time. CMAA Class C Resistors for CMAA Class C service are based upon ten cycles per hour with an average 50% load. A typical cycle is defined as follows: Motion Duration Load Raise 30 sec 50 % Traverse 60 sec 50 % Lower 30 sec 50 % Raise 30 sec 10 % Traverse 30 sec 10 % Deceleration time for traverse motions is assumed to be 5 seconds, with a maximum 120% retarding torque. 11

12 CMAA Class D Resistors for CMAA Class D service are based upon twenty cycles per hour with an average 65% load. A typical cycle is defined as follows: Motion Duration Load Raise 30 sec 65 % Traverse 60 sec 65 % Lower 30 sec 65 % Raise 30 sec 10 % Traverse 30 sec 10 % Deceleration time for traverse motions is assumed to be 3 seconds, with a maximum 150% retarding torque. CMAA Class E Resistors for CMAA Class E service are based upon twenty-five cycles per hour with an average 100% load. A typical cycle is defined as follows: Motion Duration Load Raise 24 sec 100 % Traverse 24 sec 100 % Lower 24 sec 100 % Raise 24 sec 10 % Traverse 24 sec 10 % Deceleration time for traverse motions is assumed to be 3 seconds, with a maximum 160% retarding torque. CMAA Class F Resistors for CMAA Class F service are based upon continuous service loads approaching rated capacity. A typical cycle is defined as follows: Motion Load Raise 100 % Traverse 100 % Lower 100 % Raise 50 % Traverse 50 % Deceleration time for traverse motions is assumed to be 2 seconds, with a maximum 175% retarding torque. Technical Support: If you have any questions about your braking resistor, contact Magnetek for assistance at (800)

13 230 Volt Traverse Motions CMAA Class C CMAA Class D CMAA Class E CMAA Class F 2022 CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT* 2x S DT S ET S FT S CT* 2x S DT S ET S FT S DT S ET S FT S DT S ET* 2x S FT* 2x S DT S ET* 2x S FT* 2x S DT S ET* 2x S FT* 2x A DT S DT S DT S DT S DT S DT* 2x S DT* 2x S DT* 2x S *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 13

14 230 Volt Hoist Motions CMAA Class C CMAA Class D CMAA Class E CMAA Class F 2003 CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH A CH S DH S EH A FH A CH S DH A EH A FH A CH A DH* 2x S EH* 2x S FH* 2x A CH* 2x S DH* 2x A EH* 2x A FH* 2x A CH* 2x S DH* 2x A EH* 2x A FH* 2x A3 294 *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 14

15 460 Volt Traverse Motions CMAA Class C CMAA Class D CMAA Class E CMAA Class F 4011 CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DTP S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT* 2x S DT S ET S FT S CT* 2x S DT S ET S FT A CT* 2x S DT S ET A FT A CT* 2x S DT S ET A FT* 2x S CT* 3x S DT S ET* 2x S FT* 2x A CT* 3x S DT S ET* 2x A FT* 2x A CT* 3x S DT S ET* 2x A FT* 3x S DT S ET* 3x A FT* 3x A DT S ET* 3x A FT* 4x A DT* 2x S ET* 4x A FT* 4x A DT* 2x S ET* 4x A FT* 4x A

16 460 Volt Traverse Motions CMAA Class C CMAA Class D CMAA Class E CMAA Class F DT* 2x S DT* 3x S DT* 3x S DT* 4x S DT* 4x S *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 16

17 460 Volt Hoist Motions CMAA Class C CMAA Class D CMAA Class E CMAA Class F 4001 CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH A CH S DH S EH A FH A CH S DH S EH A FH A CH S DH A EH A FH A CH A DH A EH A FH A CH A DH A EH A FH A CH A DH A EH A FH* 2x A CH* 2x A DH* 2x A EH* 2x A FH* 2x A CH* 2x A DH* 2x A EH* 2x A FH* 2x A CH* 2x A DH* 2x A EH* 2x A FH* 3x A CH* 2x A DH* 3x A EH* 3x A FH* 3x A CH* 3x A DH* 3x A EH* 3x A FH* 4x A CH* 3x A DH* 4x A EH* 4x A FH* 4x A CH* 3x A DH* 4x A EH* 4x A FH* 4x A *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 17

18 575 Volt Traverse Motions CMAA Class C CMAA Class D CMAA Class E CMAA Class F 5003 CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET S FT S CT S DT S ET* 2x S FT* 2x S CT S DT* 2x S ET* 2x S FT* 2x S CT* 2x S DT* 2x S ET* 2x S FT* 2x S CT* 2x S DT* 2x S ET* 3x S FT* 3x S CT* 2x S DT* 3x S ET* 3x S FT* 3x S CT* 3x S DT* 3x S ET* 3x S FT* 4x S CT* 3x S DT* 4x S ET* 4x S FT* 5x S CT* 4x S DT* 5x S ET* 5x S FT* 6x S CT* 5x S DT* 6x S ET* 6x S FT* 7x S CT* 6x S DT* 7x S ET* 8x S FT* 9x S *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 18

19 575 Volt Hoist Motions CMAA Class C CMAA Class D CMAA Class E CMAA Class F 5003 CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH S FH S CH S DH S EH* 2x S FH* 2x S CH S DH* 2x S EH* 2x S FH* 2x S CH* 2x S DH* 2x S EH* 2x S FH* 2x S CH* 2x S DH* 2x S EH* 3x S FH* 3x S CH* 2x S DH* 3x S EH* 3x S FH* 3x S CH* 3x S DH* 3x S EH* 3x S FH* 4x S CH* 3x S DH* 4x S EH* 4x S FH* 5x S CH* 4x S DH* 5x S EH* 5x S FH* 6x S CH* 5x S DH* 6x S EH* 6x S FH* 7x S CH* 6x S DH* 7x S EH* 7x S FH* 9x S *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 19

20 230 Volt Traverse Motions - Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F 2001 CT W DTP W ET W FT W CT W DTP W ET W FT W CT W DTP W ET W FT W CT W DTP W ET W FT W CT W DTP W ET W FT W CT W DTP W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET* 2x W FT* 2x W CT* 2x W DT W ET* 2x W FT* 2x W CT* 2x W DT W ET* 2x W FT* 2x A DT W DT W DT W DT W

21 230 Volt Traverse Motions - Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F * DT 2x W * DT 2x W * DT 2X W *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 21

22 230 Volt Hoist Motions Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F 2001 CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH A CH W DH W EH A FH A CH W DH A EH A FH A CH A DH* 2x W EH* 2x W FH* 2x A CH* 2x W DH* 2x A EH* 2x A FH* 2x A CH* 2x W DH* 2x A EH* 2X A FH* 2x A4 183 *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 22

23 460 Volt Traverse Motions - Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F 4001 CT W DTP W ET W FT W CT W DTP W ET W FT W CT W DTP W ET W FT W CT W DTP W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT W CT W W ET W FT A CT W W ET A FT A CT W W ET A FT* 2x W CT W W ET* 2x W FT* 2x A CT* 2x W W ET* 2x A FT* 2x A CT* 2x W W ET* 2x A FT* 3x W CT* 2x W W ET* 3x A FT* 3x A CT* 2x W W ET* 3x A FT* 4x A CT* 3x W W ET* 4x A FT* 4x A CT* 3x W * 2x W ET* 4x A FT* 4x A

24 460 Volt Traverse Motions - Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F 4605 CT* 3x W * 2x W * 2x W * 3x W * 3x W * 4x W * 4x W *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 24

25 460 Volt Hoist Motions Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F 4001 CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH A CH W DH W EH A FH A CH W DH W EH A FH A CH W DH A EH A FH A CH A DH A EH A FH A CH A DH A EH A FH A CH A DH A EH A FH* 2x A CH* 2x A DH* 2x A EH* 2x A FH* 2x A CH* 2x A DH* 2x A EH* 2x A FH* 2x A CH* 2x A DH* 2x A EH* 2x A FH* 3x A CH* 2x A DH* 3x A EH* 3x A FH* 3x A CH* 3x A DH* 3x A EH* 3x A FH* 4x A CH* 3x A DH* 4x A EH* 4x A FH* 4x A CH* 3x A DH* 4x A EH* 4x A FH* 4x A *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 25

26 575 Volt Traverse Motions Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F 5003 CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET W FT W CT W DT W ET* 2x W FT* 2x W CT W DT* 2x W ET* 2x W FT* 2x W CT* 2x W DT* 2x W ET* 2x W FT* 2x W CT* 2x W DT* 2x W ET* 3x W FT* 3x W CT* 2x W DT* 3x W ET* 3xW FT* 3x W CT* 3x W DT* 3x W ET* 3x W FT* 4x W CT* 3x W DT* 4x W ET* 4x W FT* 5x W CT* 4x W DT* 5x W ET* 5x W FT* 6x W CT* 5x W DT* 6x W ET* 6x W FT* 7x W CT* 6x W DT* 7x W ET* 8x W FT* 9x W *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 26

27 575 Volt Hoist Motions Weatherproof Louvered CMAA Class C CMAA Class D CMAA Class E CMAA Class F 5003 CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH W FH W CH W DH W EH* 2x W FH* 2x W CH W DH* 2x W EH* 2x W FH* 2x W CH* 2x W DH* 2x W EH* 2x W FH* 2x W CH* 2x W DH* 2x W EH* 3x W FH* 3x W CH* 2x W DH* 3x W EH* 3x W FH* 3x W CH* 3x W DH* 3x W EH* 3x W FH* 4x W CH* 3x W DH* 4x W EH* 4x W FH* 5x W CH* 4x W DH* 5x W EH* 5x W FH* 6x W CH* 5x W DH* 6x W EH* 6x W FH* 7x W CH* 6x W DH* 7x W EH* 8x W FH* 9x W *NOTE: These parts consist of multiple quantities of the enclosure style. The approximate weight already takes into account any multiple quantities. 27

28 Type S Enclosures These heavy gauge screened enclosures feature a solid bottom and a built-in compartment separated from the resistor assembly. The resistors are factory wired to a terminal block mounted in this compartment using high temperature Teflon or silicone wire. During installation, standard 90 C rated wire is routed into the compartment through the removable ½ inch conduit knockouts and connected to the factory wired terminal block. The terminal compartment wall is pre-punched for an optional thermal switch for sensing a resistor temperature overload. Our standard unit includes a screened cover which is CNC punched to obtain maximum cooling and professional aesthetics. Mounting holes are located inside the enclosure and can be easily accessed by removing the cover. Resistor coils are interconnected using stainless steel bus bars and all stainless steel hardware, producing a corrosion resistant current path to withstand nearly any harsh industrial environment. The standard enclosure finish is galvanized, but an optional powder coated, yellow zinc, aluminum or stainless steel finish is available upon request. Enclosure S1 S2 S3 S4 S5 S6 S8 S9 S10 S12 S15 S18 S24 S30 Type S Enclosure Dimensions Dimensions in Inches A B C D E / /2 4-1/ /2 7-1/ /2 10-1/ /2 13-1/ /2 7-1/ /2 10-1/2 26-1/ / /2 13-1/2 26-1/ /2 26-1/ / /2 7-1/ /2 10-1/ /2 13-1/2 Figure 2: Type S Enclosure Dimensions 28

29 Type W Enclosures These heavy gauge louvered enclosures feature a solid bottom and a built-in compartment separated from the resistor assembly. The resistors are factory wired to a terminal block mounted in this compartment using high temperature Teflon or silicone wire. During installation, standard 90 C rated wire is routed into the compartment through the removable ½ inch conduit knockouts and connected to the factory wired terminal block. The terminal compartment wall is pre-punched for an optional thermal switch for sensing a resistor temperature overload. Mounting holes are located inside the enclosure and can be easily accessed by removing the cover. Resistor coils are interconnected using stainless steel bus bars and all stainless steel hardware, producing a corrosion resistant current path to withstand nearly any harsh industrial environment. The standard enclosure finish is galvanized, but an optional powder coated, yellow zinc, aluminum or stainless steel finish is available upon request. Enclosure W1 W2 W3 W4 W5 W6 W8 W9 W10 W12 W15 W18 W24 W30 Type W Enclosure Dimensions Dimensions in Inches A B C D E 12-3/8 4-7/ /2 12-3/8 6-7/ /2 4-1/2 12-3/8 9-7/ /2 7-1/2 12-3/8 12-7/ /2 10-1/2 12-3/8 15-7/ /2 13-1/2 19-3/8 9-7/ /2 7-1/2 19-3/8 12-7/ /2 10-1/2 26-1/2 9-7/ /2 19-3/8 15-7/ /2 13-1/2 26-1/2 12-7/ /2 26-1/2 15-7/ / / /2 7-1/ / /2 10-1/ / /2 13-1/2 Figure 3: Type W Enclosure Dimensions 29

30 Type A Enclosures The Type A enclosure is designed for applications requiring a large number of edge wound or wire wound resistor coils. In addition to the large capacity, these units are available with several options to simplify installation. We offer optional terminal connections up to 400 amps continuous located on a terminal plate in the bottom of the enclosure. These factory wired connections allow standard 90 C rated wire to be used if routed along the enclosure bottom. If installing without the optional terminal connections, always use 150 C rated silicone or Teflon wire when attaching directly to resistors. These rigid enclosures include a screened top and removable front and back screened covers. The enclosure sides and bottom are solid and furnished with two lifting eyes. Mounting holes are located inside the enclosure and can be easily accessed by removing the front or back cover. Resistor coils are interconnected using all stainless steel bus bars and hardware, producing a corrosion resistant current path to withstand nearly any harsh industrial environment. The standard finish is galvanized, but an optional powder coated, hot dipped galvanized, aluminum or stainless steel finish is available upon request. Enclosure A1 A2 A3 A4 A5 A6 A7 A8 A9 Type A Enclosure Dimensions Dimensions in Inches A B C D E Figure 4: Type A Enclosure Dimensions 30

31 Panel Mount Resistors Figure 5: Panel Mount Resistor Dimensions 31

32 DC Dynamic Braking Resistors Magnetek s grid resistors are primarily used for DC dynamic braking applications. Their stainless steel elements and rugged construction make these resistors ideal for high vibration and mill duty applications. DC Dynamic Braking Resistors Enclosure s Part # Enclosure Size Part # Enclosure Size EDB D D1 EDB D D1 EDB D D1 EDB D D1 EDB D D1 EDB D D1 EDB D D1 EDB D D1 EDB D D1 EDB D D1 EDB D D2 EDB D D1 EDB D D2 EDB D D2 EDB D D2 EDB D D2 EDB D D3 EDB D D2 EDB D D4 EDB D D3 EDB D D4 EDB D D4 EDB D D6 EDB D D * D7 EDB D D * D8 EDB D D6 Weatherproof Louvered DC Dynamic Braking Resistors Enclosure s Part # Enclosure Size Part # Enclosure Size EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G1 EDB D- G2 EDB D- G1 EDB D- G2 EDB D- G2 EDB D- G2 EDB D- G2 EDB D- G3 EDB D- G2 EDB D- G4 EDB D- G3 EDB D- G4 EDB D- G4 EDB D- G6 EDB D- G * G7 EDB D- G * G8 EDB D- G6 *NOTE: Parts , , , and include a N.C. series thermostat internal to the enclosure. 32

33 Type D Enclosures The Type D DC Dynamic Braking Resistor enclosure includes a screened top and removable front and back screened covers. The enclosure sides and bottom are solid. The metal has a mill galvanized finish standard and other finishes are available upon request. Type D DC Dynamic Braking Resistor Enclosure Dimensions Enclosure Size Dimensions in Inches H D1 16 D2 24 D3 32 D4 40 D5 56 D6 72 D7 34 D8 58 Figure 6: Type D Enclosure Dimensions 33

34 Type G Enclosures The Type G DC Dynamic Braking Resistor enclosure includes a weatherproof, louvered top, front and back with removable front and back covers. The enclosure sides and bottom are solid. The metal has a mill galvanized finish standard and other finishes are available upon request. Type G DC Dynamic Braking Resistor Enclosure Dimensions Enclosure Size Dimensions in Inches H G G G G G G G G Figure 7: Type G Enclosure Dimensions 34