VFC x610 Series
Brake Chopper

Operating Instructions
R912007234

Edition 01

Bosch Rexroth AG

Brake Chopper

Record of Revision
EditionRelease Date

Notes

DOK-RCON04-VFC*BRAKE**-IT01-EN-P

2016.09First Release

Version Matching Table
FirmwareOperating Instructions

01V02

Edition 01

Copyright© Bosch Rexroth (Xi'an) Electric Drives and Controls Co., Ltd. 2016
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth (Xi'an) Electric Drives
and Controls Co., Ltd. It may not be reproduced or given to third parties without
its consent.
Liability
The specified data is intended for product description purposes only and shallnot be deemed to be a guaranteed characteristic unless expressly stipulated in
the contract. All rights are reserved with respect to the content of this documentation and the availability of the product.
RS-20d7d2d0a025f1d20a347ea501f379a5-1-en-US-10

Brake Chopper

Bosch Rexroth AG
Table of Contents

Table of Contents
Page
1
1.1
1.2
1.3
1.3.1
1.3.2
1.3.3
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6

Safety Instructions for Electric Drives and Controls.............................. 1
Definitions of Terms............................................................................... 1
Explanation of signal words and the Safety alert symbol...................... 2
General Information............................................................................... 4
Using the Safety Instructions and Passing Them on to Others.............. 4
Requirements for Safe Use.................................................................... 4
Hazards by Improper Use....................................................................... 5
Instructions with Regard to Specific Dangers....................................... 7
Protection against Contact with Electrical Parts and Housings............. 7
Protective Extra-Low Voltage as Protection Against Electric Shock ...... 8
Protection against Dangerous Movements............................................. 8
Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting........................................................................... 10
Protection against contact with hot parts........................................... 10
Protection during handling and mounting........................................... 11

2
2.1
2.2

Important Directions for Use...............................................................
Appropriate Use...................................................................................
Inappropriate Use................................................................................

12
12
12

3
3.1
3.1.1
3.1.2
3.2
3.3
3.4
3.5

Delivery and Storage............................................................................
Product Identification..........................................................................
Packing Nameplate..............................................................................
Product Nameplate..............................................................................
Visual Inspection..................................................................................
Scope of Supply...................................................................................
Transport of the Components..............................................................
Storage of the Components.................................................................

13
13
13
14
14
14
15
15

4
4.1
4.2
4.2.1
4.3
4.3.1
4.3.2
4.4

Brake Chopper Overview.....................................................................
Work Principle.....................................................................................
Product Features.................................................................................
Conditions...........................................................................................
Technical Data......................................................................................
Electric Data........................................................................................
Requirement of Cable Length..............................................................
Applicable Model of Frequency Converter...........................................

16
16
17
17
18
18
18
18

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Table of Contents

Brake Chopper

Page
4.5
4.5.1
4.5.2

Brake Chopper and Brake Resistor...................................................... 19
Braking Ratio....................................................................................... 19
Recommended Brake Chopper and Brake Resistor............................. 19

5
5.1
5.2
5.2.1
5.2.2

Brake Chopper Mounting.....................................................................
Installation Conditions.........................................................................
Figures and Dimensions.......................................................................
Figures.................................................................................................
Dimensions..........................................................................................

21
21
22
22
22

6
6.1
6.1.1
6.1.2
6.1.3
6.2
6.2.1
6.2.2
6.3
6.3.1
6.3.2
6.3.3

Brake Chopper Wiring..........................................................................
System Wiring......................................................................................
Electrical Interface...............................................................................
Typical Connection Mode 1..................................................................
Typical Connection Mode 2..................................................................
Cable Specifications............................................................................
Power Cables.......................................................................................
Control Cables.....................................................................................
Terminals.............................................................................................
Power Terminals..................................................................................
Control Terminals................................................................................
Digital Signal Internal Wiring...............................................................

23
23
23
24
24
26
26
28
29
29
30
32

7
7.1

33

7.2
7.3

Electromagnetic Compatibility (EMC).................................................
Cable Connections between Brake Chopper and Frequency Converter.........................................................................................................
Mounting and Wiring in Control Cabinet.............................................
Installing Signal Lines and Signal Cables.............................................

8
8.1
8.1.1
8.1.2
8.1.3
8.2
8.2.1
8.2.2
8.3

Operating Panel and Dust Cover.........................................................
LED Panel............................................................................................
Appearance..........................................................................................
Operating Descriptions........................................................................
Fast Access to Parameters with Button Combinations........................
LCD Panel............................................................................................
LCD Panel Introduction........................................................................
Operating Example..............................................................................
Dust Cover...........................................................................................

36
36
36
37
37
39
39
40
40

II

33
34
35

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Table of Contents

Page
9
9.1
9.1.1
9.1.2
9.1.3
9.2
9.2.1
9.2.2

Parameter and Typical Application......................................................
Parameter Descriptions.......................................................................
Terminology and Abbreviation in Parameter List.................................
Parameter List.....................................................................................
Parameter Setting Description............................................................
Typical Application...............................................................................
Quick Start-up at Default Parameter Setting.......................................
Master / Slave Control Mode...............................................................

41
41
41
41
43
48
48
48

10
10.1
10.2
10.3
10.3.1
10.3.210.3.310.3.410.3.510.3.610.3.7

Diagnosis.............................................................................................
Status Code.........................................................................................
Warning Code......................................................................................
Error Code...........................................................................................
Error 01 (OE-b): Brake Chopper Overvoltage......................................
Error 02 (OC-b): Brake Chopper Overcurrent......................................
Error 03 (SC): Surge Current or Short Circuit.....................................
Error 05 (OH-b): Brake Chopper Overheat..........................................
Error 07 (OH-r): Brake Resistor Overheat............................................
Error 09 (E.Par): Invalid Parameter Setting.........................................
Error 10 (idE-): Brake Chopper Internal Error......................................

49
49
49
50
50
50
50
50
51
51
51

11
11.1
11.2
11.3
11.4
11.4.1
11.4.211.4.3

Maintenance........................................................................................
Safety Instructions...............................................................................
Daily Inspection...................................................................................
Periodic Inspection..............................................................................
Removable Components Maintenance.................................................
Construction Overview........................................................................
Disassembly of Dust Cover..................................................................
Disassembly of Fans............................................................................

52
52
52
53
54
54
55
56

12

Service and Support............................................................................ 57

13
13.1
13.2

Environmental protection and disposal ..............................................
Environmental protection....................................................................
Disposal...............................................................................................

14
14.1

Appendix.............................................................................................. 60
Appendix I: Certification...................................................................... 60

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58
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Table of Contents

Brake Chopper

Page
14.1.1 CE........................................................................................................
14.1.2 EAC......................................................................................................
14.2
Appendix II: Type Coding.....................................................................

IV

60
61
62

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Safety Instructions for Electric Drives and Controls

1 Safety Instructions for Electric Drives and Controls
1.1 Definitions of Terms
Documentation
A documentation comprises the entire documentation used to inform the user ofthe product about the use and safety-relevant features for configuring, integrating, mounting, installing, commissioning, operating, maintaining, repairing anddecommissioning the product. The following terms are also used for this kind of
documentation: Operating Instructions, Instruction Manual, Commissioning
Manual, Application Description, Assembly Instructions, Project Planning Manual, Safety Notes, Product Insert, etc.
Component
A component is a combination of elements with a specified function, which arepart of a piece of equipment, device or system. Components of the electric driveand control system are, for example, supply units, drive controllers, mains
choke, mains filter, motors, cables, etc.
Control System
A control system comprises several interconnected control components placedon the market as a single functional unit.
DeviceA device is a finished product with a defined function, intended for users andplaced on the market as an individual piece of merchandise.
Electrical Equipment
Electrical equipment encompasses all devices used to generate, convert, transmit, distribute or apply electrical energy, such as electric motors, transformers,
switching devices, cables, lines, power-consuming devices, circuit board assemblies, plug-in units, control cabinets, etc.
Electric Drive System
An electric drive system comprises all components from mains supply to motor
shaft; this includes, for example, electric motor(s), motor encoder(s), supply
units and drive controllers, as well as auxiliary and additional components, suchas mains filter, mains choke and the corresponding lines and cables.
Installation
An installation consists of several devices or systems interconnected for a defined purpose and on a defined site which, however, are not intended to beplaced on the market as a single functional unit.
MachineA machine is the entirety of interconnected parts or units at least one of which
is movable. Thus, a machine consists of the appropriate machine drive elements,
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Safety Instructions for Electric Drives and Controls

Brake Chopper

as well as control and power circuits, which have been assembled for a specificapplication. A machine is, for example, intended for processing, treatment,
movement or packaging of a material. The term "machine" also covers a combination of machines which are arranged and controlled in such a way that theyfunction as a unified whole.
Manufacturer
The manufacturer is an individual or legal entity bearing responsibility for the design and manufacture of a product which is placed on the market in the individual's or legal entity's name. The manufacturer can use finished products, finishedparts or finished elements, or contract out work to subcontractors. However,
the manufacturer must always have overall control and possess the required authority to take responsibility for the product.
Product
Examples of a product: Device, component, part, system, software, firmware,
among other things.
Qualified Persons
In terms of this application documentation, qualified persons are those persons
who are familiar with the installation, mounting, commissioning and operation of
the components of the electric drive and control system, as well as with the hazards this implies, and who possess the qualifications their work requires. To
comply with these qualifications, it is necessary, among other things,
1) to be trained, instructed or authorized to switch electric circuits and devices
safely on and off, to ground them and to mark them2) to be trained or instructed to maintain and use adequate safety equipment3) to attend a course of instruction in first aid
User
A user is a person installing, commissioning or using a product which has beenplaced on the market.

1.2 Explanation of signal words and the Safety alert symbol
The Safety Instructions in the available application documentation contain specific signal words (DANGER, WARNING, CAUTION or NOTICE) and, where required, a safety alert symbol (in accordance with ANSI Z535.6-2011).
The signal word is meant to draw the reader's attention to the safety instruction
and identifies the hazard severity.
The safety alert symbol (a triangle with an exclamation point), which precedes
the signal words DANGER, WARNING and CAUTION, is used to alert the reader
to personal injury hazards.

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Safety Instructions for Electric Drives and Controls

DANGERIn case of non-compliance with this safety instruction, death or serious injury
will occur.

WARNING
In case of non-compliance with this safety instruction, death or serious injury
could occur.

CAUTION
In case of non-compliance with this safety instruction, minor or moderate injury
could occur.

NOTICEIn case of non-compliance with this safety instruction, property damage could
occur.

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Safety Instructions for Electric Drives and Controls

Brake Chopper

1.3 General Information
1.3.1 Using the Safety Instructions and Passing Them on to Others
Do not attempt to install and operate the components of the electric drive andcontrol system without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation
prior to working with these components. If you do not have the user documentation for the components, contact your responsible Bosch Rexroth sales partner.
Ask for these documents to be sent immediately to the person or persons responsible for the safe operation of the components.
If the component is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the component in the official
language of the user's country.
Improper use of these components, failure to follow the safety instructions inthis document or tampering with the product, including disabling of safety devices, could result in property damage, injury, electric shock or even death.

1.3.2 Requirements for Safe Use
Read the following instructions before initial commissioning of the componentsof the electric drive and control system in order to eliminate the risk of injury
and/or property damage. You must follow these safety instructions.
●

Bosch Rexroth is not liable for damages resulting from failure to observe thesafety instructions.

●

Read the operating, maintenance and safety instructions in your language before commissioning. If you find that you cannot completely understand the application documentation in the available language, please ask your supplier toclarify.

●

Proper and correct transport, storage, mounting and installation, as well as
care in operation and maintenance, are prerequisites for optimal and safe operation of the component.

●

Only qualified persons may work with components of the electric drive andcontrol system or within its proximity.

●

Only use accessories and spare parts approved by Bosch Rexroth.

●

Follow the safety regulations and requirements of the country in which thecomponents of the electric drive and control system are operated.

●

Only use the components of the electric drive and control system in the manner that is defined as appropriate. See chapter "Appropriate Use".

●

The ambient and operating conditions given in the available application documentation must be observed.

●

Applications for functional safety are only allowed if clearly and explicitly
specified in the application documentation "Integrated Safety Technology". If
this is not the case, they are excluded. Functional safety is a safety concept in

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Safety Instructions for Electric Drives and Controls

which measures of risk reduction for personal safety depend on electrical,
electronic or programmable control systems.
●

The information given in the application documentation with regard to the useof the delivered components contains only examples of applications and suggestions.
The machine and installation manufacturers must
– make sure that the delivered components are suited for their individual application and check the information given in this application documentation
with regard to the use of the components,– make sure that their individual application complies with the applicablesafety regulations and standards and carry out the required measures,
modifications and complements.

●

Commissioning of the delivered components is only allowed once it is surethat the machine or installation in which the components are installed complies with the national regulations, safety specifications and standards of theapplication.

●

Operation is only allowed if the national EMC regulations for the application
are met.

●The instructions for installation in accordance with EMC requirements can befound in the section on EMC in the respective application documentation.
The machine or installation manufacturer is responsible for compliance withthe limit values as prescribed in the national regulations.

●

The technical data, connection and installation conditions of the components
are specified in the respective application documentations and must be followed at all times.

National regulations which the user must take into account●European countries: In accordance with European EN standards●

United States of America (USA):– National Electrical Code (NEC)– National Electrical Manufacturers Association (NEMA), as well as local engineering regulations– Regulations of the National Fire Protection Association (NFPA)●

Canada: Canadian Standards Association (CSA)●

Other countries:– International Organization for Standardization (ISO)– International Electrotechnical Commission (IEC)

1.3.3 Hazards by Improper Use●

High electrical voltage and high working current! Danger to life or serious injury by electric shock!

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Safety Instructions for Electric Drives and Controls

Brake Chopper●High electrical voltage by incorrect connection! Danger to life or injury byelectric shock!

●

Dangerous movements! Danger to life, serious injury or property damage byunintended motor movements!

●

Health hazard for persons with heart pacemakers, metal implants and hearing
aids in proximity to electric drive systems!

●

Risk of burns by hot housing surfaces!

●

Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!

●

Risk of injury by improper handling of pressurized lines!

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Safety Instructions for Electric Drives and Controls

1.4 Instructions with Regard to Specific Dangers
1.4.1 Protection against Contact with Electrical Parts and HousingsThis section concerns components of the electric drive and control
system with voltages of higher than 50 V.
Contact with parts conducting voltages above 50 V can cause personal danger
and electric shock. When operating components of the electric drive and control
system, it is unavoidable that some parts of these components conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or serious
injury!
●Only qualified persons are allowed to operate, maintain and/or repair thecomponents of the electric drive and control system.

●

Follow the general installation and safety regulations when working on power
installations.

●

Before switching on, the equipment grounding conductor must have been permanently connected to all electric components in accordance with the connection diagram.

●

Even for brief measurements or tests, operation is only allowed if the equipment grounding conductor has been permanently connected to the points ofthe components provided for this purpose.

●

Before accessing electrical parts with voltage potentials higher than 50 V, youmust disconnect electric components from the mains or from the power supply unit. Secure the electric component from reconnection.

●

With electric components, observe the following aspects:
Always wait 30 minutes after switching off power to allow live capacitors todischarge before accessing an electric component. Measure the electricalvoltage of live parts before beginning to work to make sure that the equipment is safe to touch.

●

Install the covers and guards provided for this purpose before switching on.

●

Never touch electrical connection points of the components while power isturned on.

●

Do not remove or plug in connectors when the component has been powered.

●

Under specific conditions, electric drive systems can be operated at mains
protected by residual-current-operated circuit-breakers sensitive to universal
current (RCDs/RCMs).

●

Secure built-in devices from penetrating foreign objects and water, as well asfrom direct contact, by providing an external housing, for example a control
cabinet.

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Safety Instructions for Electric Drives and Controls

High housing voltage and high leakage current! Danger to life, risk of injury byelectric shock!
●Before switching on and before commissioning, ground or connect the components of the electric drive and control system to the equipment grounding
conductor at the grounding points.

●

Connect the equipment grounding conductor of the components of the electric drive and control system permanently to the main power supply at all
times. The leakage current is greater than 3.5 mA.

1.4.2 Protective Extra-Low Voltage as Protection Against Electric Shock
Protective extra-low voltage is used to allow connecting devices with basic insulation to extra-low voltage circuits.
On components of an electric drive and control system provided by Bosch
Rexroth, all connections and terminals with voltages between 5 and 50 volts are
PELV ("Protective Extra-Low Voltage") systems. It is allowed to connect devices
equipped with basic insulation (such as programming devices, PCs, notebooks,
display units) to these connections.
Danger to life, risk of injury by electric shock! High electrical voltage by incorrectconnection!
If extra-low voltage circuits of devices containing voltages and circuits of morethan 50 volts (e.g., the mains connection) are connected to Bosch Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV ("Protective Extra-Low Voltage").

1.4.3 Protection against Dangerous Movements
Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:●

Improper or wrong wiring or cable connection●

Operator errors●

Wrong input of parameters before commissioning●

Malfunction of sensors and encoders●

Defective components●

Software or firmware errors

These errors can occur immediately after equipment is switched on or even after
an unspecified time of trouble-free operation.
The monitoring functions in the components of the electric drive and control
system will normally be sufficient to avoid malfunction in the connected drives.
Regarding personal safety, especially the danger of injury and/or property damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case

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Safety Instructions for Electric Drives and Controlsthat faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of injury, serious injury or property
damage!
A risk assessment must be prepared for the installation or machine, with its specific conditions, in which the components of the electric drive and control system are installed.
As a result of the risk assessment, the user must provide for monitoring functions and higher-level measures on the installation side for personal safety. The
safety regulations applicable to the installation or machine must be taken into
consideration. Unintended machine movements or other malfunctions are possible if safety devices are disabled, bypassed or not activated.
To avoid accidents, injury and/or property damage:●

Keep free and clear of the machine’s range of motion and moving machineparts. Prevent personnel from accidentally entering the machine’s range of
motion by using, for example:– Safety fences– Safety guards– Protective coverings– Light barriers●

Make sure the safety fences and protective coverings are strong enough to resist maximum possible kinetic energy.

●

Mount emergency stopping switches in the immediate reach of the operator.
Before commissioning, verify that the emergency stopping equipment works.
Do not operate the machine if the emergency stopping switch is not working.

●

Prevent unintended start-up. Isolate the drive power connection by means of
OFF switches / OFF buttons or use a safe starting lockout.

●

Make sure that the drives are brought to safe standstill before accessing or
entering the danger zone.

●

Disconnect electrical power to the components of the electric drive and control system using the master switch and secure them from reconnection("lock out") for:– Maintenance and repair work
– Cleaning of equipment– Long periods of discontinued equipment use●

Prevent the operation of high-frequency, remote control and radio equipment
near components of the electric drive and control system and their supply
leads. If the use of these devices cannot be avoided, check the machine or installation, at initial commissioning of the electric drive and control system, forpossible malfunctions when operating such high-frequency, remote control

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Safety Instructions for Electric Drives and Controls

Brake Chopperand radio equipment in its possible positions of normal use. It might possibly
be necessary to perform a special electromagnetic compatibility (EMC) test.

1.4.4 Protection Against Magnetic and Electromagnetic Fields During
Operation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
or permanent magnets of electric motors represent a serious danger to persons
with heart pacemakers, metal implants and hearing aids.
Health hazard for persons with heart pacemakers, metal implants and hearing
aids in proximity to electric components!
●

Persons with heart pacemakers and metal implants are not allowed to enter
the following areas:– Areas in which components of the electric drive and control systems aremounted, commissioned and operated.
– Areas in which parts of motors with permanent magnets are stored, repaired or mounted.

●

If it is necessary for somebody with a heart pacemaker to enter such an area,a doctor must be consulted prior to doing so. The noise immunity of implanted heart pacemakers differs so greatly that no general rules can be given.

●Those with metal implants or metal pieces, as well as with hearing aids, must
consult a doctor before they enter the areas described above.

1.4.5 Protection against contact with hot parts
Hot surfaces of components of the electric drive and control system. Risk ofburns!
●Do not touch hot surfaces of, for example, braking resistors, heat sinks, supply units and drive controllers, motors, windings and laminated cores!

●

According to the operating conditions, temperatures of the surfaces can behigher than 60 °C (140 °F) during or after operation.

●

Before touching motors after having switched them off, let them cool down
for a sufficient period of time. Cooling down can require up to 140 minutes!
The time required for cooling down is approximately five times the thermal
time constant specified in the technical data.

●

After switching chokes, supply units and drive controllers off, wait 15 minutes
to allow them to cool down before touching them.

●Wear safety gloves or do not work at hot surfaces.

●

For certain applications, and in accordance with the respective safety regulations, the manufacturer of the machine or installation must take measures toavoid injuries caused by burns in the final application. These measures can

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Safety Instructions for Electric Drives and Controls

be, for example: Warnings at the machine or installation, guards (shieldings or
barriers) or safety instructions in the application documentation.

1.4.6 Protection during handling and mounting
Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!
●Observe the relevant statutory regulations of accident prevention.

●

Use suitable equipment for mounting and transport.

●

Avoid jamming and crushing by appropriate measures.

●

Always use suitable tools. Use special tools if specified.

●

Use lifting equipment and tools in the correct manner.

●

Use suitable protective equipment (hard hat, safety goggles, safety shoes,
safety gloves, for example).

●

Do not stand under hanging loads.

●

Immediately clean up any spilled liquids from the floor due to the risk of falling!

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Important Directions for Use

2 Important Directions for Use
2.1 Appropriate UseBosch Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability.
The products can only be used in the appropriate way. Otherwise, situations resulting in property damage and personal injury may occur.
Bosch Rexroth as manufacturer is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and therights to payment of damages resulting from inappropriate use areforfeited. The user alone carries all responsibility of the risks.
Before using Bosch Rexroth products, make sure that all the pre-requisites forappropriate use of the products are satisfied.
●

Personnel that in any way or form use our products must first read and understand the relevant safety instructions and be familiar with appropriate use.

●

If the products take the form of hardware, they must remain in their originalstate, in other words, no structural changes are permitted.

●

It is not permitted to decompile software products or alter source codes.

●

Do not mount damaged or faulty products or use them in operation.

●

Make sure that the products have been installed in the manner described in
the relevant documentation.

2.2 Inappropriate Use
Using the brake choppers outside of the operating conditions described in thisdocumentation and outside of the indicated technical data and specifications isdefined as "inappropriate use".
Brake choppers shall not be used under following conditions:●

They are subject to operating conditions that do not meet the specified ambient conditions. These include, for example, operation under water, extreme
temperature fluctuations or extremely high temperatures.

●

Furthermore, the brake choppers shall not be used in applications which havenot been expressly authorized by Rexroth. Please carefully follow the specifications outlined in the general Safety Instructions!

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Delivery and Storage

3 Delivery and Storage
3.1 Product Identification
3.1.1 Packing Nameplate
Check if the model information on the packing nameplate is the same as you ordered immediately after receipt. If the model is wrong, please contact Bosch
Rexroth distributor.

1
2
3
4
5
6
7

Product series
Short text / Type code
VolumeNet weightMaterial number
Product version index
Mass weight

8
9
10
11
12
13

Production week: e.g., 14W20 means
week 20 in 2014
Product QR code
Serial number
Manufacturer
QR code (Internal use)
Certification

Fig. 3-1: Packing nameplate

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Delivery and Storage

3.1.2 Product Nameplate
Check if the model information on product nameplate is the same as you ordered immediately after unpacking. If the model is wrong, please contact Bosch
Rexroth distributor.

1
2
3
4
5

Brand logo
Product series
Short text / Type code
Technical data
Production week: e.g., 14W20 means
week 20 in 2014

6
7
8

Certification
Product QR code
Manufacturer

Fig. 3-2: Product nameplate

3.2 Visual Inspection
Check the product for transport damages, e.g. deformation or loose parts, immediately after unpacking. In case of damage, contact the forwarder at once andarrange for a thorough review of the situation.
This is also applicable if the packaging is undamaged.

3.3 Scope of Supply
If any of the following standard supply items is missing, please contact Bosch
Rexroth distributor.
●

Brake chopper●

Operating Instructions

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Delivery and Storage

3.4 Transport of the Components
Symbol

Unit

Value

Temperature range

Description

Ta_tran℃-25…70Relative humidity

–

%

5…95

Absolute humidity

–

1…60

Climate category (IEC 721)
Moisture condensation
Icing

–
–
–

g/m3
–
–
–

2K3
not allowed
not allowed

Tab. 3-1: Transport conditions

3.5 Storage of the Components
CAUTION
Damage to the components caused by long storage periods!
When storing these components for a long period of time, remember to operatethem once a year.
Symbol

Unit

Value

Temperature range

Description

Ta_store℃-20…60Relative humidity

–

%

5…95

Absolute humidity

–

1…29

Climate category (IEC 721)
Moisture condensation
Icing

–
–
–

g/m3
–
–
–

1K3
not allowed
not allowed

Tab. 3-2: Storage conditions

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Brake Chopper Overview

Brake Chopper

4 Brake Chopper Overview
4.1 Work Principle
Brake chopper is used to consume the electrical energy returned from the external motor to frequency converter during braking, and limit the DC-bus voltage of
frequency converter into a rational range to improve the braking performanceand finally stop motor quickly. Before the brake chopper is normally running, thestart voltage for braking should be properly set according to the selected frequency converter and its load condition, while the stop voltage for braking canbe set by parameter H6.03.
When brake chopper is normally running, its control circuit detects the DC-bus
voltage in real time. If the bus voltage reaches the pre-set start voltage which
can be set by parameter H6.01, brake chopper will start braking during which
the electrical energy returned from the motor is consumed by the external braking resistor, and stop braking until the bus voltage reduces to the stop voltage.
The braking duty cycle can be adjusted by parameter H6.02. The higher the duty
cycle is, the better the braking performance will be. Braking duty cycle should
be properly set according to the actual load condition. For example, if the brake
resistor overheats, the duty cycle should be appropriately reduced with thepremise that the braking performance is satisfied.

Fig. 4-1: Work principle

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Brake Chopper Overview

4.2 Product Features
4.2.1 Conditions
Rated ambient temperature
Derating / ambient temperature
Rated storage temperature
Rated altitude
Derating / altitude
Relative humidity
Degrees of protection
Degrees of pollution
Vibration
Mounting mode
Cooling type
Certification-10...40 ℃
1.5 % / 1 °C (40...50 °C)-20...60 ℃≤ 1,000 m
1 % / 100 m (1,000...4,000 m)≤ 90 % RH (No condensation)
IP 20
2 (EN 50178)
10 Hz ≤ f ≤ 57 Hz amplitude: 0.075 mm
57 Hz < f ≤ 150 Hz acceleration: 1 g
Wall mounting
Natural cooling
Enforced air cooling
CE, EAC

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Brake Chopper Overview

Brake Chopper

4.3 Technical Data
4.3.1 Electric Data
Voltage class
Brake chopper model
Output current
Input
Brake
chopper startand outvoltage
put
specifiMaximum hysteresis
cations
Synchronous signal
PowerDC-bus voltage range
supplyHeat sink overheat

3P 380...480 VAC (-15 % / +10 %); 50 / 60 Hz (±5 %)FEAE07.1-VA1-NNNN
FEAE07.1-VA2-NNNN
0.0...80.0 A
0.0...125.0 A
600...785 V
0...100 V
Linkage input, Linkage output, up to 3 brake choppers in parallel
600...810 VDC

Active when the temperature exceeds the setting point.
RELAY junction 0.6 A 125 VAC / 2 A 30 VDC (Ta, Tb are normallyProtecError output
open contact)tion
Overvoltage protection / Overheat protection / Overcurrent proOther protections
tection / Short circuit protection
Digital input terminal 5 digital input terminals
Terminal
Digital output terminal Digital output terminals OUT+, OUT-, one relay output
Maximum current continuous brak- 0.0...10.0 s (ED = 10 %)ing time
Power indication / Error indication / Master-slave indication /Indication functions
Brake indication
Tab. 4-1: Technical specifications

4.3.2 Requirement of Cable Length●

The cable length between brake chopper and frequency converter is less thanor equal to 5 m●

The cable length between brake chopper and brake resistor is less than orequal to 5 m

4.4 Applicable Model of Frequency Converter
Model of brake chopper

Model of frequency converter

FEAE07.1-VA1-NNNN
FEAE07.1-VA2-NNNN

VFC 5610 30...55 kW
VFC 5610 75, 90 kW

Tab. 4-2: Applicable model of frequency converter

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Brake Chopper Overview

4.5 Brake Chopper and Brake Resistor
4.5.1 Braking Ratio
Brake resistors with different power ratings are available to dissipate braking energy when the frequency converter is in generator mode. The following tablelists the details of brake chopper and brake resistor corresponding to eachbrake power in the condition that a certain braking ratio is given.

ED Braking ratio
Tb Braking time

Tc

Engineering cycle time in application

Fig. 4-2: Braking ratio

4.5.2 Recommended Brake Chopper and Brake Resistor
When braking voltage is 750 V, ED = 10 % and braking torque is 100%, the recommended brake chopper and brake resistor are listed as below.
Brake power (KW)

Brake chopper
type code

0.4
0.75
1.5
2.2
3.0
4.0
5.5
7.5
11.0
15.0
18.5
22.0
30
37
45
55

Internal
Internal
Internal
Internal
Internal
Internal
Internal
Internal
Internal
Internal
Internal
Internal

Power of brake resisBrake resistence(Ω)
Number oftor(KW)
Number ofparalleled
brake
RecomRecombrake rechoppers mended Min. value mended Min. value
sistors
value
value

FEAE07.1-VA1NNNN

DOK-RCON04-VFC*BRAKE**-IT01-EN-P

1
1
1
1

750
750
400
250
150
150
75
75
40
40
32
25
20
16
13.6
20

≥8
≥8
≥8
≥8

0.08
0.08
0.26
0.26
0.39
0.39
0.78
0.78
1.56
1.56
4.80
4.80
6.00
9.60
9.60
6.00

≥4
≥5
≥6
≥7

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2

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Brake Chopper Overview

Brake power (KW)

Brake chopper
type code75
90

FEAE07.1-VA2NNNN

Brake ChopperPower of brake resisBrake resistence(Ω)
Number oftor(KW)
Number ofparalleled
brake
RecomRecombrake rechoppers mended Min. value mended Min. value
sistors
value
value
1
13.6
≥5
9.60
≥9
2
1
20
≥5
6.00
≥10
3

Tab. 4-3: Type selection of brake resistor

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●

The recommended resistance of the brake resistor is 100 % braking torque, selected according to necessity. If the actually needed
torque is not 100 %, the resistance of the brake resistor in the table should be adjusted in inverse proportion, i.e. how much thebraking torque increases based on 100 %, the resistance of thebrake resistor should decrease by the same amount, vice versa.

●

When selecting brake resistor Rb, make sure the current Ic whichflows through the resistor is less than the current output ability ofthe brake chopper. The current Ic through the brake resistor canbe calculated by formula Ic = Ud / Rb, in which Ud is the braking
operating voltage of brake chopper.

●

After the adjustment of the resistance of brake resistor, the powerof brake resistor should be also adjusted appropriately. The power can be calculated by formula Pmax = Ud2 / Rb. According to theactual working condition, the braking ratio ED % can be selected
to reduce the power of brake resistor reasonably for intermittent
braking load. The power of brake resistor can be calculated by formula PR = k × Pmax × ED %, in which 'k' is the derating coefficientof brake resistor. The selection of the braking torque should be ingeneral smaller than 150 % of the rated motor torque, or consult
the technical support for more information.

●

When ED>10 %, the master / slave control mode is recommended(see chapter 9.2.2 "Master / Slave Control Mode" on page 48),or consult the technical support.

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Bosch Rexroth AG
Brake Chopper Mounting

5 Brake Chopper Mounting
5.1 Installation Conditions
The brake chopper must be vertically installed.
If one brake chopper is arranged above another, make sure the upper limit of air
temperature (50 ℃) into the inlet is not exceeded. An air guide is recommended
between the brake choppers to prevent the rising hot air being drawn into theupper brake chopper if the upper limit of air temperature is exceeded.

Fig. 5-1: Mounting distance and arrangement

dhor: Distance horizontal = 0 mm
dtop: Minimum top distance = 125 mm
dbot: Minimum bottom distance = 125 mm
1: Air inlet at brake chopper
2: Air inlet at control cabinet
3: Brake chopper
4: Air outlet at brake chopper
5: Heated air conveying direction
6: Air guide in control cabinet
7: Fan in control cabinet
8: Discharge of heated air

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Brake Chopper Mounting

Brake Chopper

5.2 Figures and Dimensions
5.2.1 Figures

Fig. 5-2: Brake chopper dimensions figure

5.2.2 Dimensions
Model

W

H

D

w

h

d

Ø

FEAE07.1VA1-NNNN
FEAE07.1VA2-NNNN

100

215

149

70

205

140

4.5

Screw

Net

size

weight [kg]
2.24

M4
2.34

Tab. 5-1: Brake chopper dimensions (unit: mm)

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Brake Chopper Wiring

6 Brake Chopper Wiring
6.1 System Wiring
6.1.1 Electrical Interface

Fig. 6-1: Electrical interface of brake chopper

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Brake Chopper Wiring

Brake Chopper

6.1.2 Typical Connection Mode 1

Fig. 6-2: Typical connection mode 1

6.1.3 Typical Connection Mode 2

Fig. 6-3: Typical connection mode 2

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Brake Chopper Wiring●

Make sure that terminals (+), (-) of frequency converter are connected to the corresponding terminals P, N of brake chopper respectively. Incorrect connection may damage the brake chopper.

●

Please connect to frequency converter directly or install a terminal block.

●

The master / slave control mode of the brake chopper supports
the following two connections, which currently supports up to
three brake choppers in parallel.
– Two devices: master + slave– Three devices: master + slave + slave

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Brake Chopper Wiring

6.2 Cable Specifications
6.2.1 Power Cables
Brake chopper
model

Fuse (gG)

FEAE07.1-VA1-NNNN
FEAE07.1-VA2-NNNN

100
160

Power cables installationmode
PE cable
B1
B2
E

Torque / Screw[mm2] [mm2] [mm2][mm2][N·m / lb·in] (Mx)

10.0
10.0

10.0
10.0

1.76 / 15.6 (M4)
1.76 / 15.6 (M4)

10.0
10.0

10.0
10.0

Tab. 6-1: Fuse and cable dimensions for international without USA / Canada

Brake chopper
model

Fuse (Class J)

FEAE07.1-VA1-NNNN
FEAE07.1-VA2-NNNN

Power cables

PE cable

Torque / Screw

[AWG]

[AWG]

[N·m / lb·in] (Mx)

8
6

8
6

1.76 / 15.6 (M4)
1.76 / 15.6 (M4)

100
175

Tab. 6-2: Fuse and cable dimensions for USA / Canada

The recommended values of the fuse listed in the tables above arebased on the Max. output current, please select the proper fuse according to the actual application.
Dimensioning variables of the table values
1. Installation types:●

B1 according to IEC 60364-5-52, e.g. stranded wires routed in cableduct●

B2 according to IEC 60364-5-52, e.g. multi-core line routed in cable duct●

E according to EN 60204-1, e.g. multi-core line routed on open cable tray●

According to NFPA 79 (external wiring), UL 508A (internal wiring), NEC,NFPA 70:– 1 cable with 3 conductors, 1 neutral conductor and 1 equipment
grounding conductor– Routed in pipe on the wall
Internal wiring: Routing inside of control cabinet or of devices.
Field wiring: Routing of cross sections of terminal connectors wired by
the user (in the field).

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Brake Chopper Wiring

Brake Chopper

B1 Conductors in installation pipes andin installation channels that can be
openedB2 Cables or lines in installation pipes
and in installation channels that canbe opened

C
E

Cables or lines on walls
Cables or lines on open cable trays

Fig. 6-4: Cable installation types (cf. IEC 60364-5-52; DIN VDE 0298-4; EN 60204-1)

2. Recommendation for design of the fuses:●

International except for USA / Canada: Class gL-gG; 500 V, 690 V; design
NH, D (DIAZED) or D0 (NEOZED).
Characteristics
In the case of error (e.g. ground error at connections L+, L-), fuses ofcharacteristic gL (general-purpose fuse link for cables and lines) andgG (general-purpose fuse link for general installations) protect thelines in system.
To protect the brake chopper, you can use fuses of characteristic gR.

●

USA / Canada: Class J; 600 V

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Brake Chopper Wiring

Brake Chopper

6.2.2 Control Cables
The requirements of control cables are as follows:
Cable
Type
Wire-end ferrule w/plastic collar
Cross-section
Ferrule length
Stripped length
Wire-end ferrule w/o plastic collar
Cross-section
Ferrule length
Stripped length

Unit

Min.

Max.

Shielded cable
mm2
AWG
mm
mm

1

1

17
12
15

17
12
15

mm2
AWG
mm
mm

1

1.5

17
10
10

16
10
10

Tab. 6-3: Cable requirements

Please follow the steps below for wiring of control terminals.
Step 1: Switch off the brake chopper before performing wiring.
Step 2: Deactivate the control signals in the wiring process.
Step 3: Switch on the brake chopper.
Step 4: Set respective parameters.
Step 5: Activate respective control signals.

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Brake Chopper Wiring

6.3 Terminals
6.3.1 Power Terminals

Fig. 6-5: Power terminals

Terminal
P
N
PB
P1

Description
Mains supply input terminals
Output terminals

Tab. 6-4: Power terminals description

Fig. 6-6: Grounding and PE terminals

1: Power circuit terminal
2: Control circuit terminal

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Brake Chopper Wiring

Brake Chopper

6.3.2 Control Terminals
Control terminals figure

Fig. 6-7: Control circuit terminals

CAUTIONThe brake chopper might be damaged!
Please make sure that the power supply of the brake chopper has been switched off before plugging or unplugging the connector.

The terminal block is ONLY for wiring convenience, which CANNOT
be used for fixing the cables. Additional measures need to be taken
by users for cable fixing purpose.

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Brake Chopper Wiring

Control terminals description
Digital signal terminals
TerminalIN+
INOUT+
OUT+

Signal function
Digital inputs
Digital outputs

Reset

Digital input

TG

Digital input

COM

Shared connection

Description

Signal requirement

Control signal input terminals
when brake chopper is set toslave
Control signal output terminals
when brake chopper is set tomasterInputs via opto-electric couplers:
Short circuit with COM. Used for
24 VDC, 8 mA / 12 VDC, 4 mAerror reset
Short circuit with COM. Used foroverheat protection of brake resistor
COM as a reference point, isolation with GND

Relay signal terminals
Terminal
Ta
Tc
Tb

Signal function

Description

Relay changeover contacts
See parameter H6.10
Relay shared contact

Signal requirement
Rated capacity:
250 VAC, 3 A; 30 VDC, 3 A

External power-supply terminals
Terminal
DC_IN
GND

Signal function

Description

External +24 V supply input for
Auxiliary power supply control and panel boards
for control board(NOT used for digital inputs)
Shared connection

DOK-RCON04-VFC*BRAKE**-IT01-EN-P

Isolated from COM

Signal requirement
Rated capacity:
24 V (-10...+15 %)200 mA–

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Brake Chopper Wiring

Brake Chopper

6.3.3 Digital Signal Internal Wiring①②

Use of terminal TG
Use of terminal Reset

Fig. 6-8: Wiring of terminals TG and Reset

Terminals Reset and TG are using the switching signals. Do not needexternal power supply.

Fig. 6-9: Wiring of terminals IN and OUT

Terminals IN+, IN-, OUT+ and OUT- are ONLY used in Master / Slave
control mode.

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Electromagnetic Compatibility (EMC)

7 Electromagnetic Compatibility (EMC)
7.1 Cable Connections between Brake Chopper and Frequency
Converter

Fig. 7-1: Cable connections between brake chopper and frequency converter

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Electromagnetic Compatibility (EMC)

7.2 Mounting and Wiring in Control Cabinet
Influence of the Motor Power Cable
The longer the motor cable, the greater its leakage capacitors. To comply with acertain EMC limit value, the allowed leakage capacitance of he mains filter islimited.
●Run the shortest possible motor power cables.

Routing the Motor Power Cables and Motor Encoder Cables
Route the motor power cables and motor encoder cables along grounded metal
surfaces, both inside the control cabinet and outside of it, in order to minimize
radiation of interference fields. If possible, route the motor power cables andmotor encoder cables in metal-grounded cable ducts.
Route the motor power cables and motor encoder cables●

with a distance of at least dmin. = 100 mm to inference-free lines, as well as tosignal cables and signal lines (alternatively separated by a grounded distanceplate)●

in separate cable ducts, if possible

Routing the Motor Power Cables and Mains Connection Lines
For frequency converters (drive controllers with individual mains connection),route motor power cables and (unfiltered) mains connection lines in parallel fora maximum distance of 300 mm. After that distance, route motor power cables
and power supply cables in opposite directions and preferably in separate cableducts.
Ideally, the outlet of the motor power cables at the control cabinet should be
provided in a distance of at least 200 mm from the (filtered) power supply cable.
The required cable length between frequency converter and brake chopper (orbetween brake chopper and brake resistor) is less than or equal to 5 m.

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Electromagnetic Compatibility (EMC)

7.3 Installing Signal Lines and Signal Cables
Line Routing
The following measures are recommend:●

Route signal and control lines separately from frequency converter power cables , motor power cables and brake chopper power cables with a minimum
distance of dmin. = 100 mm or with a grounded separating sheet. The optimum
way is to route them in separate cable ducts. If possible, lead signal lines into
the control cabinet at one point only.

●

If signal lines are crossing power cables, route them in an angle of 90° in order to avoid interference injection.

●

Ground spare cables, that are not used and have been connected, at least at
both ends so that they do not have any antenna effect.

●

Avoid unnecessary line lengths.

●

Run cables as close as possible to grounded metal surfaces (reference potential). The ideal solution are closed, grounded cable ducts or metal pipes
which, however, is only obligatory for high requirements (sensitive instrument
leads).

●

Avoid suspended lines or lines routed along synthetic carries, because they
are functioning like reception antennas (noise immunity) and like transmitting
antennas (emission of interference). Exceptional cases are flexible cable
tracks over short distances of a maximum of 5 m.

ShieldingConnect the cable shield immediately at the devices in the shortest and most direct possible way and over the largest possible surface area.
Connect the shield of analog signal lines at one end over a large surface area,
normally in the control cabinet at the analog device. Make sure the connection
to ground/housing is short and over a large surface area.
Connect the shield of digital signal lines at both ends over a large surface area
and in short form. In the case of potential differences between beginning andend of the line, run an additional bonding conductor in parallel. This preventscompensating current from flowing via the shield. The guide value for the crosssection is 10 mm2.
You absolutely have to equip separate connections with connectors with grounded metal housing.
In the case of non-shielded lines belongs to the same circuit, twist feeder andreturn cable.

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Operating Panel and Dust CoverBrake Chopper

8 Operating Panel and Dust Cover
8.1 LED Panel
8.1.1 Appearance

Fig. 8-1: LED panel

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Operating Panel and Dust Cover

8.1.2 Operating Descriptions

Fig. 8-2: Operating mode

8.1.3 Fast Access to Parameters with Button Combinations
Brake chopper provides fast access to parameters within a parameter groupwith '<Func> + <▲>' or '<Func> + <▼>' combinations.
●

Press '<Func> + <▲>' once, the blinking bit move one bit to left.

●

Press '<Func> + <▼>' once, the blinking bit move one bit to right.

Example:Change the value of parameter b0.20 from '0' to '1000', perform the following
steps.
●

Step 1: press '<Func> + <▲>' or '<Func> + <▼> to active the fast access function, '0' is displayed.

●

Step 2: press '<Func> + <▲>' for three times, move three bits to the left, '0000'
is displayed and the left-most '0' is blinking.

●

Step 3: press <▲> button to change left-most '0' to '1', then '1000' is displayedand '1' is blinking.

●

Step 4: press <Set> button to save the setting. The screen will return to previous menu and parameter 'b0.10' will be displayed.

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Operating Panel and Dust Cover

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Brake Chopper●

The parameter fast access function is only available to the parameters with a number type setting range, not available to parameters with a optional type setting range.

●

Press <Func> button and do not release it until <▲> or <▼> button
has been pressed.

●

Press <▲> or <▼> button within 2 s if <Func> button is pressed.

●

If <Func> button is pressed and no other buttons be pressed within 2 s, the setting will not take effect.

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Operating Panel and Dust Cover

8.2 LCD Panel
8.2.1 LCD Panel Introduction

Fig. 8-3: LCD panel appearance(1) Rotary encoder
1. Scroll between parameter and group code
2. Set the parameter value(2) Func button: Enter the parameter group screen and go back to previous
screens.
(3) Text area: Used for displaying:
1. Parameter monitoring screen
2. Parameter group / Parameter code
3. Parameter name
4. Parameter value and unit
5. Other screens: Error / Warning display screen, welcome screen, customer
information message screen(4) Error / Warning information: Error / Warning code will be displayed in this
sector. Please refer to chapter 10 "Diagnosis" on page 49.
(5) Permanent monitoring: By default, its display as "Actual output frequency" isset by parameter U2.09. Value and unit of parameter will be displayed.
(6) Panel Locked / Unlocked: Panel can be locked by the following ways:
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Operating Panel and Dust CoverBrake Chopper●

Setting [U2.02] to '1', or●Pressing Func button with Loc button for longer than 3 s.

Panel can be unlocked by the following ways:●

Setting [U2.02] to '0' (only in communication mode), or●

Pressing Func button with Loc button for longer than 3 s.

8.2.2 Operating Example
Please follow the steps below to set parameter [b0.10] to '1: Restore to default
settings' through LCD panel.
1. Press Func button.
2. Rotate Rotary encoder to select parameter group b0.
3. Press Rotary encoder and rotate it to select parameter b0.10.
4. Press Rotary encoder and rotate it to select parameter value '1: Restore todefault settings'.
5. Press Rotary encoder to finish setting.

8.3 Dust CoverFig. 8-4: Dust Cover

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Parameter and Typical Application

9 Parameter and Typical Application
9.1 Parameter Descriptions
9.1.1 Terminology and Abbreviation in Parameter List●

Code: Function / parameter code, written in bx.xx, Hx.xx, Ux.xx, dx.xx●

Name: Parameter name●Default: Factory default●

Min.: Minimum setting step●

Attri.: Parameter attribute– Run: Parameter setting can be modified when brake chopper is in run orstop status.
– Stop: Parameter setting can only be modified when brake chopper is instop status.
– Read: Parameter setting is read-only and cannot be modified.

●[bx.xx], [Hx.xx], [Ux.xx], [dx.xx]: Function / parameter values

9.1.2 Parameter List
Code

Name

Setting range

Default

Min.

Attri.

0

–

Stop

0

–

Stop

0

–

Run

0

–

Stop

750
100%

1
1

Stop
Stop

30

1

Stop

0: Inactive
b0.10 Parameter initialization

1: Restore to default settings
2: Clear error record
0: Inactive

b0.11 Parameter copy
b0.20 User password

H6.00 Brake chopper mode

1: Backup parameters to panel
2: Restore parameters frompanel
0... 65,535
0: Standalone
1: Master
2: Master / slave

3: Slave
H6.01 Brake chopper start voltage 600...785 V
H6.02 Brake chopper duty cycle
1...100 %Brake chopper hysteresis
H6.03
0...100 V
voltage

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Parameter and Typical Application

Code

Name

H6.10 Relay output selection

H6.11 Fan control
H6.50
H6.51
H6.52
H6.53
H6.54
H6.55
d9.00
d9.01
d9.02
d9.05
d9.99

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Brake Chopper

Setting range
0: Brake chopper fault

Default

Min.

Attri.

1: Brake chopper working

0

–

Stop

0

–

Run

–
–
–
–
–

–
–
–
1
0.1

Read
Read
Read
Read
Read

–

1

Read

–
–
–
–
–

1
0.1
1
–
0.01

Read
Read
Read
Read
Read

2: Brake chopper ready
0: Automatic
1: Always on
–
–
–
–
–

Last error type
Second last error type
Third last error typeDC-bus voltage at last error
Braking current at last error
Power module temperature at–last error
DC voltage–
Braking current–
Temperature–
Relay output–
Firmware version–

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Parameter and Typical Application

Brake Chopper

9.1.3 Parameter Setting Description
b0.10: Parameter initialization

●

Code

Name

b0.10

Parameter initialization

Setting range
0...2

Default

Min.

Attri.

0–Stop

0: Inactive
This parameter will be reset to '0: Inactive' automatically after parameter initialization.

●

1: Restore to default settings
All parameters are restored to factory default settings except for:H6.50, H6.51, H6.52, H6.53, H6.54, H6.55 (error records).

●

2: Clear error record
Parameter H6.50, H6.51, H6.52, H6.53, H6.54, H6.55 (error records) will becleared.

b0.11: Parameter copy
This function is used for the same settings of multiple brake choppers via theoperating panel.
With this function, users only need set parameters of one brake chopper, andthen replicate its settings for all the other brake choppers.

●

Code

Name

b0.11

Parameter copy

Setting range
0...2

Default

Min.

Attri.

0–Stop

0: Inactive
This parameter will be reset to '0: Inactive' automatically after parameter replication.

●

1: Backup parameters to panel (from source brake chopper to panel)
All parameter settings are copied from the source brake chopper to the operating panel EXCEPT that of– Read-only parameters– H6.50, H6.51, H6.52, H6.53, H6.54, H6.55 (error records)– b0.10, b0.11, b0.20●

2: Restore parameters from panel (from panel to target brake choppers)
All parameter settings are replicated from the operating panel to the target
brake choppers EXCEPT that of– Read-only parameters– H6.50, H6.51, H6.52, H6.53, H6.54, H6.55 (error records)– b0.10, b0.11, b0.20

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Parameter and Typical Application

b0.20: Password Protection
User password is used to protect parameter settings from unauthorized or unintended changes.
Code

Name

b0.20

User password

Setting range
0...65,535

Default

Min.

Attri.

0–Run

Possible operations with passwords are as below:●

Set user password
The default setting of user password is '0' (inactive). Enter any integer number between 1 and 65,535.

●

Change user password
Enter the existing user password first, and then modify the value with entering another integer number between 1 and 65,535.

●

Clear user password
Enter the existing user password or super user password, then user password
will be cleared.

H6.00...H6.03: Brake chopper mode
Brake chopper can run under standalone mode, or connect with multiple brake
choppers in parallel.
Brake chopper mode is set by inputting function code directly via the panel, not
via the jumper cap or pin.
Code

Name

Setting range

Default

Min.

Attri.

0

–

Stop

750
100 %
30

1
1
1

Stop
Stop
Stop

0: Standalone
H6.00 Brake chopper mode

H6.01 Brake chopper start voltage
H6.02 Brake chopper duty cycle
H6.03 Brake chopper hysteresis voltage

1: Master
2: Master / slave
3: Slave600...785 V
1...100 %0...100 V

To operate this function, take the following steps:
Step 1: Select brake chopper mode
Braking mode is selected according to the actual application situations, and its
default mode is 'Standalone'. When multiple brake choppers run in parallel, thecorresponding master or slave mode can be selected.
H6.00 is set to '0: Standalone': when bus voltage is higher than brake chopper
start voltage [H6.01], brake chopper starts running. Digital input IN+ is not detected and digital output OUT+ is disabled.

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Parameter and Typical Application

H6.00 is set to '1: Master': when bus voltage is higher than braking start voltage[H6.01], brake chopper starts running. Meanwhile, as the master, brake chopper
enables the digital output OUT+ in running status. Digital input IN+ is not detected.
H6.00 is set to '2: Master / slave': when bus voltage is higher than braking start
voltage [H6.01], as the slave controlled by input terminal IN+ (closed-loop effective), this brake chopper starts running. It can also be the master which enables
the digital output OUT+ in running status.
H6.00 is set to '3: Slave': when bus voltage is higher than braking start voltage[H6.01], as the slave controlled by input terminal IN+ (closed-loop effective),
this brake chopper starts running. In this mode, digital output OUT+ is inactive.
Step 2: Set the braking start voltage
Set the braking start voltage according to the actual situations. The default valueof VFC model is set to 750 V.
Brake chopper starts running at the pre-set start voltage, and shuts down with ahysteresis voltage (set by H6.03). For example, if parameter H6.01 is set to 750
V, H6.03 is set to 30 V, brake chopper will start braking at 750 V and shut down
at 720 V.
Step 3: Set brake chopper duty cycle
Set parameter H6.02 'Brake chopper duty cycle' according to the actual situations. Its default value is 100 %.
When the brake resistor overheats, brake chopper duty cycle can be reduced appropriately. Notice that excessive low brake chopper duty cycle would affect thebraking performance.
The diagram of brake chopper duty cycle is shown as below:

Fig. 9-1: Brake chopper duty cycle

In the diagram above, t1 = t2 x [H6.02] / 100 %; t2 = 50 ms
The diagram of the stop voltage point for brake chopper:

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Parameter and Typical Application

Fig. 9-2: Stop voltage point

H6.10: Relay output selection
Please read through the information on 'Wiring diagram' and 'Terminal' before
the selection of 'Relay output'.
Code

Name

Setting range

Default

Min.

Attri.

0–Stop

0: Brake chopper fault
H6.10 Relay output selection

1: Brake chopper working
2: Brake chopper ready●

0: Brake chopper fault
The output is active when an error occurs, inactive when the error is reset.

●

1: Brake chopper working
The output is active when the brake chopper is running.

●

2: Brake chopper ready
After powering on, if no error occurs and not being in braking state, brake
chopper is ready for running and the output is active.

H6.11: Fan control
This function is used to set the running mode of the fan for the heat sink.
ONLY model 'FEAE07.1-VA2-NNNN' is equipped with fan units.
Code
H6.11 Fan control●

Name

Setting range
0: Automatic
1: Always on

Default

Min.

Attri.

0–Run

0: Automatic

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Parameter and Typical Application

The fan for the heat sink is by default switched on / off automatically according to the temperature of the heat sink. In this mode, the noise level of thebrake chopper can be reduced.
●

1: Always on
The fan for the heat sink is switched on and running all the time once thebrake chopper is powered on. In this mode, a better cooling performance ofthe brake chopper can be achieved.

H6.50...H6.55: Error parameters
Error parameters which record and indicate the error information are read-only,
and can not be modified.
Code
H6.50
H6.51
H6.52
H6.53
H6.54
H6.55

Name

Setting range Default

Last error type
Second last error type
Third last error typeDC-bus voltage at last error
Braking current at last error
Power module temperature at last error

–
–
–
–
–
–

–
–
–
–
–
–

Min.

Attri.

–
–
–
1
0.1
1

Read
Read
Read
Read
Read
Read

Setting range of H6.50…H6.52:
0: No error
1: OE-b, brake chopper overvoltage
2: OC-b, brake chopper overcurrent
3: SC, surge current or short circuit
4: OL-b, brake chopper overload
5: OH-b, brake chopper overheat
7: OH-r, brake resistor overheat
9: E.Par, parameter settings invalid
10: idE-, brake chopper internal error
d9.00...d9.99: Monitoring parameters
Code

Name

Min. unit

d9.00
d9.01
d9.02
d9.05
d9.99

DC voltage
Braking current
Temperature
Relay output
Firmware version

1V
0.1 A
1 °C
–
0.01

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Parameter and Typical Application

9.2 Typical Application
9.2.1 Quick Start-up at Default Parameter Setting
By default, brake chopper works in standalone mode. Its default value of start
voltage is 750 V and duty cycle is 100 %.
In standalone mode, when DC-bus voltage reaches to start voltage, brake chopper will start braking with 100 % of duty cycle, which is irrelevant to terminals
IN and OUT of the master / slave control mode.
To meet actual requirements, start voltage and duty cycle of brake chopper canbe adjusted according to actual situations.
Brake chopper is not equipped with jumper cap or contact pin. All
parameters should be set via the panel.

9.2.2 Master / Slave Control Mode
System connection
Please refer to chapter 6.1.3 "Typical Connection Mode 2" on page 24.
Parameter setting
When required braking power is high and singe brake chopper cannot meet requirements, the way to connect multiple brake choppers in parallel (currently
support up to 3 choppers) for master/slave control is selected.
Before the brake chopper is powered on, terminals OUT of the master should beconnected to terminals IN of the slave. For example, when three brake choppers
are connected in parallel, terminals OUT of brake chopper #1 connect to terminals IN of brake chopper #2, and terminals OUT of brake chopper #2 connect toterminals IN of brake chopper #3. Ensure that the connection between master’s
terminals OUT and slave’s terminals IN must be correct. Otherwise the slave will
fail to work although the bus voltage reaches to brake chopper start voltage.
Parameter setting paralleled:
The braking mode of the first-level brake chopper is set as 'Master', the secondlevel set as 'Master / slave', and the third-level set as 'Slave'.
For example, when three brake choppers are connected in parallel, 'H6.00' of
brake chopper #1, #2, and #3 should be set to '1', '2', and '3', respectively.
Be noticed that the braking start voltage of the slave should keep consistency
with that of the master. Otherwise, it may cause the overload or even breakdown of the brake chopper with relatively low braking start voltage.
Parameter setting:Brake chopper #1: H6.00 = 1, H6.01 = 750, H6.02 = 100 %Brake chopper #2: H6.00 = 2, H6.01 = 750, H6.02 = 100 %Brake chopper #3: H6.00 = 3, H6.01 = 750, H6.02 = 100 %48/65

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Diagnosis

10 Diagnosis
10.1 Status CodeCode

Description'-' '--' '---' '----' '-----'

During parameter backup…

10.2 Warning CodeCode

Description

S.Err
PrSE

Parameter change blocked
Parameter setting contradiction

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Diagnosis

Brake Chopper

10.3 Error Code10.3.1 Error 01 (OE-b): Brake Chopper Overvoltage
Possible reason

Solution

Surge voltage from power supply
Check input power supply
Excessive low resistance of brake resisRecalculate and choose brake resistor
tor
Excessive high setting of brake chopper
Adjust start voltage of brake chopper
start voltage
Wrong wiring of brake resistor
Check the wiring of brake resistor
Damage of brake chopper
Contact with service

10.3.2 Error 02 (OC-b): Brake Chopper Overcurrent
Possible reason

Solution

Excessive low resistance of brake resisRecalculate and choose brake resistor
tor
Wrong wiring of brake resistor
Check the wiring of brake resistor
The power of brake chopper is too small Choose brake chopper with proper power

10.3.3 Error 03 (SC): Surge Current or Short Circuit
Possible reason

Solution

Earth surge
Remove the short circuit
The power of brake chopper is too small Choose brake chopper with proper power
Damage of brake chopper
Contact with service

10.3.4 Error 05 (OH-b): Brake Chopper Overheat
Possible reason

Solution● Reduce ambient temperature, improve ventilation andBrake chopper (heat sink) temperature
heat dissipation.
is higher than max. allowable tempera- ● Check fan and its power supply connection
ture 57 °C● Adjust power of brake resistor

Inappropriate setting for duty cycle ofReduce the duty cycle accordingly
brake chopper
Circuit of temperature detection error Contact with service

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Diagnosis

10.3.5 Error 07 (OH-r): Brake Resistor Overheat
Possible reason

Solution

Inappropriate type or bad heat of brake ● Check power of brake resistor
resistor● Provide good heat condition
temperature sensor of brake resistor Check the feedback signal of the resistor's temperature senerrorsorInappropriate threshold setting of temAdjust threshold of temperature sensor of brake resistor
perature sensor of brake resistor
Inappropriate setting for duty cycle ofReduce the duty cycle accordingly
brake chopper

10.3.6 Error 09 (E.Par): Invalid Parameter Setting
Possible reason

Solution

Parameter setting invalid after parameInitialize all parameters
ter copy

10.3.7 Error 10 (idE-): Brake Chopper Internal Error
Possible reason

SolutionInternal error

Contact with service

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MaintenanceBrake Chopper

11 Maintenance11.1 Safety Instructions
WARNING

High electric voltage! Risk of death or severe
bodily injury by electric shock!

●

Only those trained and qualified to work with or on electric equipment are
permitted to operate, maintain and repair this equipment.

●

Do not operate electric equipment at any time, even for brief measurementsor tests, if the equipment grounding conductor is not permanently connectedto the mounting points of the components provided for this purpose.

●

Before working with electric parts with voltage potentials higher than 50 V,
the device must be disconnected from the mains voltage. Ensure that themains voltage is not reconnected.

11.2 Daily Inspection
Please conduct daily inspection as indicated in the table below in order to prolong the life cycle of brake choppers.
Inspection
category

Ambient
conditions

Brake Chopper
Motor

Inspection item

Inspection criteria

Temperature
Relative humidity
Dust, water-10...50 ℃ (no frost or condensation)≤ 90 % (no condensation)
No heavy dust or sign of leakage

and leakage
Gas
Sound
Panel display
Fan
Sound

(visual inspection)
No strange smell
No strange soundNo error code
No blockage or contamination
No strange soundInspection
resultTab. 11-1: Daily inspection list

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MaintenanceBrake Chopper

11.3 Periodic Inspection
In addition to daily inspection, periodic inspection of brake choppers is also
necessary. The inspection cycle should be less than 6 months. For operation details, please see table below:
Inspection

Inspection item

category
Power supply

VoltagePower cable
Signal line

Power cable
Signal line
Crimp terminal

Terminal

and cable / line
Crimp terminal

connection

and terminal block
Visualappearance

Inspection criteria
Specified in nameplate
No color change or damage

No loose connection

No deformation
No color change

Fan
Brake chopper
Cooling systemor deformation
No blockage
or contamination
No blockage(radiator, inlet, outlet) or foreign matters

Accessories

Printed circuit board

No dust or oil contamination

Connection
Cable

No loose connection
No color change or damage

Solution
3P: 380...480 VAC(-15 % / +10 %)Replace cable
Replace signal line
Tighten crimp
and terminal screw

Contact with service
Replace fan
Eliminate blockage
and clean fan
Eliminate blockage
and clear foreign matters
Clean printed
circuit board
Tighten terminal screw
Replace cableTab. 11-2: Periodic inspection list

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Maintenance11.4 Removable Components Maintenance11.4.1 Construction Overview

(1)
(2)
(3)
(4)
(5)
(6)

Dust cover
Keyboard tray
Cover
Control board
Drive board
Module(7) Heat sink(8) Above baffle(9) Below baffle(10) Fan cover(11) Frame(12) Fan

Fig. 11-1: Construction overview

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Maintenance11.4.2 Disassembly of Dust CoverFig. 11-2: Disassembly of dust cover●

Step 1: Press two buckles as circles indicating in the above figure●

Step 2: Hold dust cover and pull it out horizontally from the mounting plate
Remove the dust cover when use the brake chopper for the firsttime, install an operating panel to set the related parameters, thendisassembly the operating panel and reinstall the dust cover.

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MaintenanceBrake Chopper

11.4.3 Disassembly of Fans

Fig. 11-3: Disassembly of fan●

Step 1: Unscrew the two screws on the fan cover●

Step 2: Take off the fan cover●

Step 3: Slowly remove the fan●

Step 4: Disconnect fan power wires

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Service and Support

12 Service and Support
Our worldwide service network provides an optimized and efficient support.
Our experts offer you advice and assistance should you have any queries. You
can contact us 24/7.
Service Germany
Our technology-oriented Competence Center in Lohr, Germany, is responsible
for all your service-related queries for electric drive and controls.
Contact the Service Helpdesk & Hotline under:

Phone:
Fax:
E-mail:Internet:+49 9352 40 5060
+49 9352 18 4941
service.svc@boschrexroth.dewww.boschrexroth.com

Additional information on service, repair (e.g. delivery addresses) and training
can be found on our internet sites.
Service worldwide
Outside Germany, please contact your local service office first. For hotline numbers, refer to the sales office addresses on the internet.
Preparing information
To be able to help you more quickly and efficiently, please have the following information ready:●

Detailed description of malfunction and circumstances resulting in the malfunction●

Type plate name of the affected products, in particular type codes and serial
numbers●Your contact data (phone and fax number as well as your email address)

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Environmental protection and disposal

13 Environmental protection and disposal
13.1 Environmental protection
Production processes
The products are made with energy- and resource-optimized production processes which allow re-using and recycling the resulting waste. We regularly try
to replace pollutant-loaded raw materials and supplies by more environmentfriendly alternatives.
No release of hazardous substances
Our products do not contain any hazardous substances which may be releasedin the case of appropriate use. Normally, our products will not have any negativ
influences on the environment.
Significant components
Basically, our products contain the following components:
Electronic devices∙ steel∙ aluminum∙ copper∙ synthetic materials∙ electronic components and modules

Motors∙ steel∙ aluminum∙ copper∙ brass∙ magnetic materials∙ electronic components and modules

13.2 Disposal
Return of products
Our products can be returned to our premises free of charge for disposal. It is aprecondition, however, that the products are free of oil, grease or other dirt.
Furthermore, the products returned for disposal must not contain any undue foreign material or foreign components.
Send the products ”free domicile” to the following address:
Bosch Rexroth AG
Electric Drives and Controls
Buergermeister-Dr.-Nebel-Strasse 297816 Lohr am Main, Germany
Packaging
The packaging materials consist of cardboard, wood and polystyrene. These materials can be recycled anywhere without any problem.
For ecological reasons, please refrain from returning the empty packages to us.

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Environmental protection and disposal

Batteries and accumulators
Batteries and accumulators can be labeled with this symbol.

The symbol indicating "separate collection" for all batteries and accumulators is the crossed-out wheeled bin.
The end user within the EU is legally obligated to return used batteries. Outside
the validity of the EU Directive 2006/66/EC keep the stipulated directives.
Used batteries can contain hazardous substances, which can harm the environment or the people´s health when they are improper stored or disposed of.
After use, the batteries or accumulators contained in Rexroth products have tobe properly disposed of according to the country-specific collection.
Recycling
Most of the products can be recycled due to their high content of metal. In orderto recycle the metal in the best possible way, the products must be disassembled into individual modules.
Metals contained in electric and electronic modules can also be recycled bymeans of special separation processes.
Products made of plastics can contain flame retardants. These plastic parts arelabeled according to EN ISO 1043. They have to be recycled separately or disposed of according to the valid legal requirements.

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Appendix

14 Appendix
14.1 Appendix I: Certification
14.1.1 CE
Declaration of conformity
For Brake Choppers, there are declarations of conformity which confirm that thedevices comply with the applicable EN Standards and EC Directives. If required,
you may ask our sales representative for the declarations of conformity.
EU directives
Low-Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU

Standard
EN 61800-5-1 (IEC 61800-5-1: 2007)
EN 61800-3 (IEC 61800-3: 2004+A1: 2012)

Tab. 14-1: EU directives and standards

CE label

Fig. 14-1: CE label

High-voltage test
According to standard EN 61800-5-1, VFC x610 (0K40...90K0) components aretested with high voltage.

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Appendix

14.1.2 EAC
Brake Choppers have EAC certification. EAC marking is required for Custom Union, including Russia, Belarus and Kazakhstan.
EAC marking

Fig. 14-2: EAC marking

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Appendix

Brake Chopper

14.2 Appendix II: Type Coding

Fig. 14-3: Brake chopper type coding

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Brake Chopper

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Notes

Bosch Rexroth AG

Bosch Rexroth (Xi’an)
Electric Drives and Controls Co., Ltd.
No. 3999, Shangji Road,
Economic and Technological Development
Zone, 710021 Xi’an, P.R. China
Phone +49 9352 40 5060
Fax +49 9352 18 4941
service.svc@boschrexroth.dewww.boschrexroth.com*R912007234*
R912007234

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