Regeneration

Overview

Regeneration, or "shunting", dissipates energy from the DC bus during deceleration of the motor load. During deceleration, the motor acts as a generator that pumps energy back into the system. If this energy is not dissipated, then the bus energy level can exceed acceptable levels (VBUS.OVFTHRESH ). If the system exceeds the maximum bus voltage, then the drive generates an over voltage fault (F501n501 ) and shuts down. A regeneration resistor, or regen resistor, is an external device that dissipates excess energy and allows the drive to function normally during deceleration.

Follow these steps to determine the regen needs for your system and to configure the drive for regen:

  1. Calculate motor peak and continuous regenerative energy and use this value to size the regen resistor.
  2. Select a compatible regen resistor.
  3. Configure regen parameter values in WorkBench.

From the Regen view, the following drive regen settings can be viewed and configured.

Button or Dialog Box Description Parameter

Regen Resistor Type

Sets the regen resistor type to either -1-External Regen or 0-Internal Regen (if available).

REGEN.TYPE

External Regen Resistance

Sets the external, user-defined regen resistor resistance (only visible for external regen).

REGEN.REXT

External Regen Heat Up Time

Sets the external regen resistor thermal protection time constant (only visible for external regen).

REGEN.TEXT

External Regen Power

Sets the regen resistor's power fault level for an external regen resistor (only visible for external regen).

REGEN.WATTEXT

Regen Power

Reads the regen power (only visible for external regen).

REGEN.POWER

Regen Resistor Options

Select "-1 External Regen" from the Regen. Resistor Type box (REGEN.TYPE ) to view the Select Resistor drop-down box.

The Select resistor drop-down contains pre-sized resistors for your drive. Select the model regen resistor that you are using and the drive will populate the remainder of the fields. If you are using a nonstandard resistor, then choose <User defined> and fill in the appropriate values for your resistor.


  • If you use a nonstandard resistor, contact Kollmorgen technical support to confirm that the nonstandard resistor will work correctly with your system.

Regen diagnostic

The AKD detects the following error conditions if the external regen resistor is configured:

  • Short circuit detected by hardware. This creates fault F519 .
  • Open circuit detected by REGEN.TEST command. This creates fault F634.
  • Wrong configuration detected by REGEN.TEST command. This creates fault F634.

Calculating Motor Peak Energy and Regen Resistor Size

In order to determine whether or not your system requires a regen resistor, you must calculate the peak kinetic energy that the motor generates during deceleration and the continuous regeneration energy created by the motor. If this energy exceeds the drive capacity, then you need a regen resistor. In many cases, peak or continuous regenerated energy does not exceed the drive capacity and no regen resistor is needed.

The calculation for peak kinetic energy requires values for several factors that affect the generation of energy in a motion system:

  • Load inertia
  • Motor inertia
  • Motor speed from which deceleration occurs
  • Time required to decelerate

Regen resistor sizing information for your particular application can be calculated using the Motioneering® Application Engine. You can download this program here:

https://www.kollmorgen.com/en-us/service-and-support/technical/motioneering-online/

After you install and set up this program, highlight your application (1) and then click on the Power Supply Sizing icon (2).

The application then displays the regen sizing tool; see the application help for further sizing assistance.

Selecting a Compatible Regen Resistor

After you calculate the appropriate resistor size, compare the results with the capabilities of the drive and, if necessary, select an external regeneration resistor which matches these capabilities from the chart below. The resistors shown below are included in the WorkBench setup. If you do not find a match for your application, please contact the Kollmorgen customer support team for further assistance.

NA Part Number

EU Part Number

Resistor Type

AKD-x00306

AKD-x00606

AKD-x01206

AKD-x02406

AKD-x00307

AKD-x00607

AKD-x01207

AKD-x02407

BAFP-100-33

DE-201437

External Resistor, 100 W, 33 ohms

x

x

    x x x  

BAFP-200-33

DE-201438

External Resistor, 200 W, 33 ohms

x

x

    x x x  

BAR-250-33

DE-106254

External Resistor, 250 W, 33 ohms

x

x

   

x

x

x

 

BAR-500-33

DE-106255

External Resistor, 500 W, 33 ohms

x

x

   

x

x

x

 

BAR-1500-33

DE-106258

External Resistor, 1500 W, 33 ohms

x

x

   

x

x

x

 

BAS-3000-33

DE-201407

External Resistor, 3000 W, 33 ohms

x

x

   

x

x

x

 

BAR-600-23

DE-200613

External Resistor, 600 W, 23 ohms

             

x

BAR-1000-23

DE-200614

External Resistor, 1000 W, 23 ohms

             

x

BAS-2000-23

DE-200615

External Resistor, 2000 W, 23 ohms

             

x

BAS-3000-23

DE-200616

External Resistor, 3000 W, 23 ohms

             

x

BAS-4000-23

DE-200617

External Resistor, 4000 W, 23 ohms

             

x

BAR-500-15

DE-201439

External Resistor, 500 W, 15 ohms

   

x

x        

BAR-1000-15

DE-201440

External Resistor, 1000 W, 15 ohms

   

x

x        

BAS-2000-15

DE-103871

External Resistor, 2000 W, 15 ohms

   

x

x        

BAS-3000-15

DE-103872

External Resistor, 3000 W, 15 ohms

   

x

x        

BAS-6000-15

DE-103873

External Resistor, 6000 W, 15 ohms

   

x

x        

Configuring Regen Parameter Values

If you use an external regen resistor, then you must configure three regen parameter values. These values are automatically inserted in WorkBench if the resistor is pre-sized. The chart below summarizes these three additional values:

  • External Regen Resistance (REGEN.REXT, ohms)
  • External Regen Heat Up Time (REGEN.TEXT, seconds)
  • External Regen Power (REGEN.WATTEXT, watts)

These parameters allow the regen resistor to function properly and dissipate power appropriately for your system.

NA Part Number

EU Part Number

Resistor Type

(all resistors UL recognized)

Resistance

ohms

(REGEN.REXT)

Heat Up Time

s

(REGEN.TEXT)

Power Rating

W

(REGEN.WATTEXT)

BAFP-100-33 DE-201437 External Resistor, 100 W, 33 ohms

33

16.5

100

BAFP-200-33 DE-201438 External Resistor, 200 W, 33 ohms

33

27.5

200

BAR-250-33 DE-106254 External Resistor, 250 W, 33 ohms

33

22.0

250

BAR-500-33 DE-106255 External Resistor, 500 W, 33 ohms

33

33.0

500

BAR-1500-33 DE-106258 External Resistor, 1500 W, 33 ohms

33

25.7

1,500

BAS-3000-33 DE-201407 External Resistor, 3000 W, 33 ohms

33

77.0

3,000

BAR-600-23 DE-200613 External Resistor, 600 W, 23 ohms

23

27.5

600

BAR-1000-23 DE-200614 External Resistor, 1000 W, 23 ohms

23

27.5

1,000

BAS-2000-23 DE-200615 External Resistor, 2000 W, 23 ohms

23

77.0

2,000

BAS-3000-23 DE-200616 External Resistor, 3000 W, 23 ohms

23

84.3

3,000

BAS-4000-23 DE-200617 External Resistor, 4000 W, 23 ohms

23

77.0

4,000

BAR-500-15 DE-201439 External Resistor, 500 W, 15 ohms

15

33.0

500

BAR-1000-15 DE-201440 External Resistor, 1000 W, 15 ohms

15

27.5

1,000

BAS-2000-15 DE-103871 External Resistor, 2000 W, 15 ohms

15

77.0

2,000

BAS-3000-15 DE-103872 External Resistor, 3000 W, 15 ohms

15

84.3

3,000

BAS-6000-15 DE-103873 External Resistor, 6000 W, 15 ohms

15

91.7

6,000

Related Parameters

REGEN Parameters

VBUS.OVWTHRESH

VBUS.VALUE