ABB HIES308461R0012 2.5 Ω Water-Cooled Braking Resistor

Description

Key Features & Functions

• Superior Heat Dissipation: Utilizes a forced water-cooling system with internal copper channels to achieve cooling efficiency 5 to 10 times greater than traditional air-cooled resistors . This enables continuous, high-power operation without overheating.

• High Overload Capacity: Engineered to handle significant short-term overloads, with a capability of up to 300% of its rated power for 10 seconds, making it ideal for absorbing peak braking energies .

• Low Inductance Design: Features a very low inductance (typically <1 µH), which makes it suitable for use in high-frequency switching applications and ensures rapid current response during braking events .

• Precision Resistance for Compatibility: Provides a precise resistance value of 2.5 Ω (±5% accuracy), ensuring perfect compatibility with the control algorithms and braking choppers of ABB ACS-series drives for optimal dynamic performance .

• Rugged, Modular Construction: Housed in a corrosion-resistant aluminum alloy or stainless steel enclosure with IP20 to IP54 protection ratings, offering resilience against shock, vibration, humidity, and dust in industrial settings . The modular design allows for easy installation and connection to standard industrial cooling systems via flanged hose connections (DN15-DN25) .

Technical Specifications

• Part Number: HIES308461R0012 .

• Product Type: Water-Cooled Braking / Dynamic Braking Resistor .

• Resistance Value: 2.5 Ω (±5% tolerance) .

• Rated Power: 1500 W to 8461 W (actual power capability is highly dependent on the flow rate and inlet temperature of the cooling water) .

• Cooling Method: Forced Water Cooling (requires an external water or coolant circulation system) .

  • Cooling Water Temperature: 5°C to 35°C (requires anti-freeze protection in cold environments) .

  • Recommended Flow Rate: ≥ 3 L/min .

• Electrical Specifications:

  • Overload Capability: 300% for 10 seconds .

  • Inductance: < 1 µH (low inductance design) .

  • Insulation Voltage: ≥ 2 kV AC / 1 min .

• Physical Characteristics:

  • Housing Material: Aluminum Alloy / Stainless Steel .

  • Weight: Approximately 4.2 kg (weight can vary by manufacturer data) .

  • Connections: Heavy-duty M6/M8 copper bolt terminals for power; Ø10 mm or DN15-DN25 flanged connectors for cooling water .

• Environmental Ratings:

  • Operating Temperature: -25°C to +120°C (resistor body) .

  • Protection Rating: IP20 (for cabinet installation) up to IP54 (dust and water spray protected) .

Application Scenarios

• High-Power Industrial Drives: Essential for braking and energy absorption in large conveyors, crushers, mills, extruders, and test benches driven by ABB ACS880 or ACS1000 drives where high inertia loads must be stopped quickly and safely .

• Metal Processing (Rolling Mills): Used in steel and aluminum rolling mills to absorb the massive regenerative energy produced when a rolling stand decelerates or when material tension is controlled, ensuring precise speed and tension regulation .

• Marine and Harbor Applications: Deployed in marine propulsion systems, winches, and harbor cranes to handle rapid load reversals and provide controlled braking for heavy lifting and positioning operations .

• Mining and Material Handling: Installed on downhill conveyors or mine hoists where the load itself can drive the motor. The resistor dissipates the excess energy to maintain a controlled, safe speed and prevent mechanical runaway .

• Renewable Energy Systems: Applied in wind turbine pitch control and braking systems, as well as in large solar inverters, to safely dump excess power during grid faults or emergency stops .

• High-Power Test Equipment: Serves as a reliable load for testing large generators, motors, and power supplies, providing a stable and controllable method for energy absorption during validation and commissioning phases .