RUA

Dynamic Brake

Installation & Operating Manual

11/00 MN782
 Table of Contents

Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Dynamic Brake Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Sizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hoisting Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Section 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Physical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Section 4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

MN782 Table of Contents i

Section 1
General Information

ii Table of Contents MN782

Section 1
General Information

Overview Whenever a motor is abruptly stopped or forced to slow down faster than if allowed to
coast to a stop, the motor becomes a generator. When connected to a Baldor control, the
motor has the ability to produce braking torque. The braking torque is non–continuous
and is limited by the available peak current, the peak current time rating and the dynamic
braking (DB) capacity built into or connected to the control. Should these ratings and DB
capacity be exceeded during braking, the control may trip off due on an overvoltage.
Table 1-1 defines the voltage trip points.
Table 1-1 Voltage Operating Levels

Parameter Description Control Input Voltage Rating

Nominal Voltage 230VAC 460VAC 575VAC
AC Input Voltage Range 180-264VAC 340-528VAC 495-660VAC
DB ON Voltage 388VDC 776VDC 970VDC
DB OFF Voltage 375VDC 750VDC 938VDC

Limited Warranty

For a period of two (2) years from the date of original purchase, BALDOR will
repair or replace without charge controls and accessories which our
examination proves to be defective in material or workmanship. This
warranty is valid if the unit has not been tampered with by unauthorized
persons, misused, abused, or improperly installed and has been used in
accordance with the instructions and/or ratings supplied. This warranty is in
lieu of any other warranty or guarantee expressed or implied. BALDOR
shall not be held responsible for any expense (including installation and
removal), inconvenience, or consequential damage, including injury to any
person or property caused by items of our manufacture or sale. (Some
states do not allow exclusion or limitation of incidental or consequential
damages, so the above exclusion may not apply.) In any event, BALDOR’S
total liability, under all circumstances, shall not exceed the full purchase
price of the control. Claims for purchase price refunds, repairs, or
replacements must be referred to BALDOR with all pertinent data as to the
defect, the date purchased, the task performed by the control, and the
problem encountered. No liability is assumed for expendable items such as
fuses.

Goods may be returned only with written notification including a BALDOR

Return Authorization Number and any return shipments must be prepaid.

MN782 General Information 1-1

Safety Notice This equipment contains voltages that may be as high as 1000 volts! Electrical shock
can cause serious or fatal injury. Only qualified personnel should attempt the start–up
procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts
that are driven by this equipment. Improper use can cause serious or fatal injury. Only
qualified personnel should attempt the start–up procedure or troubleshoot this equipment.
PRECAUTIONS
WARNING: Be sure to read all precautions statements in the manual for your
control before you install the dynamic brake hardware. Failure to
observe all precautions may result in injury.
WARNING: The outlet air from the RUA Dynamic Brake is very hot. To prevent
severe burns do not place your hands or other body parts above
the brake. Placing you hand or other objects above the brake may
cause severe burns.
WARNING: The Dynamic Brake may generate enough heat to ignite
combustible materials. Keep all combustible materials and
flammable vapors away from the brake.
WARNING: Be sure the system is properly grounded before applying power.
Do not apply AC power before you ensure that all grounding
instructions have been followed. Electrical shock can cause
serious or fatal injury.
Caution: If the DB hardware mounting is in any position other than vertical,
the DB hardware must be derated by 10% of its rated capacity.

Caution: Baldor controls with an “E” or “W” suffix have an internal dynamic
braking transistor and resistor installed. If you are installing a larger
external Dynamic Brake, be sure to disconnect and tape the internal
resistor wires from terminals B+/R1and R2 inside the Baldor
Control. Failure to disconnect the internal resistor may result in
equipment damage.

Caution: Do not obstruct the air inlet at the bottom of the RUA Dynamic
Brake. The dynamic brake must have air flow for cooling. Allow at
least 3 to 6 inches clearance below the brake for proper air flow.

1-2 General Information MN782

Section 2
Dynamic Brake Sizing

Sizing Procedure This sizing procedure (with different formulas) is used to determine the required DB
Hardware capacity for general industrial machinery or hoisting applications.

General Machinery To determine regenerated watts (Wr), use the following formulas:
Determine TDEC:
T DEC + D RPM WK2 (1)
308 t
Where:
TDEC = Deceleration torque in lb-ft.
D RPM = Change in speed.
WK2 = Inertia in lb-ft2.
t= Time in seconds.
Determine Dr:
D r + BT (2)
TCT
Where:
Dr = Duty cycle.
BT= Brake time required to decelerate.
TCT= Total cycle time.
Determine Wr:
W r + T DEC (Sr * S m) Dr (0.0712) (3)
Where:
Wr = Regenerated watts.
TDEC = Deceleration torque in lb-ft.
Sr = Maximum speed regenerating (in RPM).
Sm= Minimum speed regenerating (in RPM).
Dr = Duty cycle.
Determine part number of the RUA Dynamic Brake to order:
Refer to Tables in Section 3 of this manual to select the part number. (4)

Sr
(RPM)

Sm
(RPM)
BT
TCT

MN782 DB Sizing 2-1

Section 1
General Information

Hoisting Applications To determine regenerated watts (Wr), use the following formulas:
Determine Dr:
D r + LT (1)
TCT
Where:
Dr = Duty cycle.
LT= Lowering time.
TCT= Total cycle time.
Determine Wr:

Wr + ǒD X lbs X44FPM X EFFǓ X 1.25

r
(2)

Where:
Wr = Regenerated watts.
Dr = Duty cycle.
FPM= Speed in feet per minute (to lower the load).
EFF= Mechanical efficiency (a decimal number).
1.25= Safety factor.
Note: To provide maximum life and allow for unusual loads,
allow a 1.25 safety factor in the watts value.
Determine part number of the RUA Dynamic Brake to order:
Refer to Tables in Section 3 of this manual to select the part number. (3)

2-2 DB Sizing MN782

Section 3
Installation and Operation

Physical Installation Dynamic Brake (DB) Hardware must be installed on a flat, non-flammable, vertical
surface to obtain effective cooling and operation.
1. Select a clean VERTICAL surface that is free from corrosive gasses, liquids,
vibration, dust and metallic particles.
2. Mount the DB hardware as shown in Figure 3-1.
Figure 3-1 Small RUA Brake Maximum Temperatures
Maximum temperatures

ÉÉ
near wall.
Maximum temperatures
above the enclosure.

ÉÉ
50°C

ÉÉ
35°C

ÉÉ
60°C

ÉÉ
45°C

ÉÉ
75°C
50°C 48″

ÉÉ 100°C 36″

75°C
ÉÉ
ÉÉ
70°C
12″
24″

ÉÉ
ÉÉ
ÉÉ
ÉÉ
Side view of wall

ÉÉ
mounted enclosure.

ÉÉ
ÉÉ
Fan

ÉÉ Air Inlet

Figure 3-1 Large RUA Brake Maximum Temperatures

ÉÉ
Maximum temperatures
near wall.

ÉÉ
Maximum temperatures
above the enclosure.

ÉÉ
100°C

ÉÉ
45°C
110°C

ÉÉ 50°C

ÉÉ 170°C

ÉÉ 70°C 48″

75°C
ÉÉ
ÉÉ
125°C
250°C

24″
36″

ÉÉ
12″

ÉÉ
ÉÉ
ÉÉ
ÉÉ
Side view of wall
mounted enclosure.

ÉÉ
ÉÉ
ÉÉ
Fan

Air Inlet

MN782 Installation & Operation 3-1

 Electrical Installation Connect the DB assembly to the control terminal strip as shown in Figure 3-2. Be sure to
use wire size specified for your control (Table 3-1).
If an internal DB resistor is present, be sure to disconnect and tape the internal resistor
wires from the control terminals. These factory installed wires must be removed and the
wire ends insulated with electrical tape to prevent contact with other components. The
braking capability may also need to be disabled in software. Be sure to select the proper
size kit based on the dissipation rating of the resistor(s) to handle the average watts of
the overhauling or cyclic load.
Note: To disable the brake capability within the control software, set the resistor
ohms value to minimum (1 ohm) and set the watts value to maximum.
Figure 3-2 Interconnection Diagram

Control
Assembly

Chassis must be
Control Terminals grounded to Earth.
R2 B+/R1 B– GND
NC Thermal 200°C Thermal Switch
Normally Closed contact
Earth NC Thermal (mounted on chassis).
B+
S+ Dynamic
Use Baldor cables: Brake
LD5157A05 – 5 Ft. No Connection
LD5157A10 – 10 Ft. Assembly
S–
LD5157A20 – 20 Ft.
LD5157A30 – 30 Ft. B–
LD5157A50 – 50 Ft.

Note: Sense lines S+ and S– must be shielded, twisted pair wire. See recommended Wire Sizes and Terminal
Terminate shields at control end only. Tightening Torques in Table 3-1.

3-2 Installation & Operation MN782

 Table 3-1 Terminal Torques & Wire Size

B+ and B– Terminals S+ and S– Terminals

Braking
Control Shielded Tightening Shielded Tightening
Size Option
Catalogg No. Rating
g HP Ohm IRMS Wire Specification Torque Wire Specification Torque

Watts
VAC AC AC
Max. AWG mm2 Lb-in Nm AWG mm2 Lb-in Nm
Volt Volt
RUA2-F7 S 230 1 60 1.92 746 16 1.31 300 9 1 20 0.51 300 9 1
RUA2-1F5 S 230 2 30 3.85 1492 16 1.31 300 9 1 20 0.51 300 9 1
RUA2-1F8 S 230 2.5 20 4.81 1865 16 1.31 300 9 1 20 0.51 300 9 1
RUA2-2F2 L 230 3 20 5.77 2238 14 2.08 300 9 1 20 0.51 300 9 1
RUA2-3F7 L 230 5 12 9.61 3730 14 2.08 300 9 1 20 0.51 300 9 1
RUA2-5F6 L 230 7.5 7.5 14.43 5600 14 2.08 300 9 1 20 0.51 300 9 1
RUA4-F7 S 460 1 240 0.96 746 16 1.31 600 9 1 20 0.51 600 9 1
RUA4-1F5 S 460 2 120 1.93 1492 16 1.31 600 9 1 20 0.51 600 9 1
RUA4-1F8 S 460 2.5 80 2.41 1865 16 1.31 600 9 1 20 0.51 600 9 1
RUA4-2F2 L 460 3 80 2.89 2238 16 1.31 600 9 1 20 0.51 600 9 1
RUA4-3F7 L 460 5 48 4.81 3730 14 2.08 600 9 1 20 0.51 600 9 1
RUA4-5F6 L 460 7.5 30 7.23 5600 14 2.08 600 9 1 20 0.51 600 9 1
RUA5-F7 S 575 1 375 0.77 746 16 1.31 600 9 1 20 0.51 600 9 1
RUA5-1F5 S 575 2 188 1.54 1492 16 1.31 600 9 1 20 0.51 600 9 1
RUA5-1F8 S 575 2.5 125 1.92 1865 16 1.31 600 9 1 20 0.51 600 9 1
RUA5-2F2 L 575 3 125 2.31 2238 16 1.31 600 9 1 20 0.51 600 9 1
RUA5-3F7 L 575 5 75 3.85 3730 16 1.31 600 9 1 20 0.51 600 9 1
RUA5-5F6 L 575 7.5 48 5.77 5600 16 1.31 600 9 1 20 0.51 600 9 1

S = Small RUA Enclosure, L = Large RUA Enclosure.

MN782 Installation & Operation 3-3

Operation When the Dynamic Brake assembly is connected, any of three LED’s may be visible in
the location shown in Figure 3-3. The purpose of each LED is as follows:

Red Fault Condition exists. To reset a fault condition, turn power off, then on.
Green Power is applied to brake assembly (DC Bus is ON and unit is OK).
Yellow Dynamic Brake Transistor is ON and power is being dissipated.

Figure 3-3 LED location

DANGER
HOT
LED’s

PROPER GROUNDING
REQUIRED
Lack of proper grounding may create
hazards and void the product warranty.
See Installation and Operating Manual

3-4 Installation & Operation MN782

Section 4
Dimensions

Figure 4-1 Mounting Dimension for Small RUA Enclosure

0.281 [7.1mm] Dia. 7.55 [191.8mm]

6.65 [168.9mm]
Mounting Holes

DANGER
HOT

Air Outlet

15.596 [396.15mm]

16.546 [420.28mm]
14.65
[372.1mm]
0.3 [7.62mm]

PROPER GROUNDING
REQUIRED
Lack of proper grounding may create
hazards and void the product warranty.
See Installation and Operating Manual

0.281 [7.1mm] Air Inlet

6.65 [168.9mm]

7.25 [184.2mm]

MN782 Dimensions 4-1

 Figure 4-2 Mounting Dimension for Large RUA Enclosure
11.15 [283.2mm] 0.28 [7.1mm] Dia.
MOUNTING HOLES 7.547 [191.7mm]

DANGER

HOT
Air Outlet

14.65 [372.1mm]

15.6 [396.2mm]

16.55 [420.3mm]
PROPER GROUNDING
REQUIRED
Lack of proper grounding
hazards and void the product
may create
warranty.
See Installation and Oper-
ating Manual
0.3 [7.6mm]

0.281
[7.1mm] Air Inlet
11.15 [283.2mm]

11.75 [298.5mm]

4-2 Dimensions MN782

 BALDOR ELECTRIC COMPANY
P.O. Box 2400
Ft. Smith, AR 72902–2400
(501) 646–4711
Fax (501) 648–5792
 Baldor Electric Company Printed in USA
MN782 11/00 C&J 1500