Regeneration unit select guidance

Definition of resistor

A resistor is a two-terminal electronic component having a resistance (R) that produces a

voltage (V) across its terminals that is proportional to the electric current (I) flowing
through it in accordance with Ohm's law:

V = IR 。
Within rated temperature, voltage and current, resistor is linear. However, when the
voltage or current is beyond rated value, the resistor will be overheated to dismatch Ohm’s
law. Sometimes it will be even burnt. When selecting a resistor, we need to take a closer
look at its specification and features about its rated current, voltage.
Classification of resistors
There are many kinds of resistors with different structures and different way to classify.
There are carbon film resistors, metal film resistors, winding resistors, metal oxide film
resistors, SQP and pellet resistors.
You could check the features of different resistors as attached.

Rule of resistor：

The current through resistors in series stays the same, but the voltage across each resistor
can be different. The sum of the potential differences (voltage) is equal to the total
voltage. To find their total resistance:

Resistors in a parallel configuration each have the same potential difference (voltage).
To find their total equivalent resistance (Req):
 Regeneration unit
Regeneration unit of servo systems takes advantage of its resistance features to
transform and absorb electrical power. Due to its special working conditions, there are
some special requirements about regeneration units.
Now big power level regeneration units are normally classified as RSLG and RXHG.
These two kinds of resistors could be capable of high temperature endurance,
continuously being loaded by big power and big current to meet the demand of servo
systems.

Wire wound resistors are commonly made by winding a metal wire, usually nichrome,
around a ceramic, plastic, or fiberglass core. The ends of the wire are soldered or welded
to two caps or rings, attached to the ends of the core. The assembly is protected with a
layer of paint, molded plastic, or an enamel coating baked at high temperature.。
Wire wound resistor

Aluminum resistor is composed of spring alloy and shaped alumina coat. After high
temperature, special noninflammable heatproof cement is filled and then dried in the
shade, finally processed to be fixed and insulated. Because the whole resistor is filled with
heatproof cement, no external mechanical force or dusty environment will affect. It is big
power level, hard, anti-vibration, well heat dissipated, low resistance/temperature ratio,
linear and easily installed resistor.
Principle of regeneration
Regeneration happens when motor decelerates. At this moment, motor could be
considered as a generator. Regeneration could absorb the energy of a rotating load and
transform this energy into electrical power that is finally reverted back to the servo drive.
The major job of regeneration is to consume the inertia power of load in the movement
and transfer the power to the capacitor to dissipate.

When EDB servo system is undertaking the maximum load inertia at rated speed, EDB
must absorb all the energy generated when the load stops to prevent its system from
being damaged. If the system operates above rated speed or maximum load, external
regeneration is necessary.
Regeneration relies on 3 factors: Torque, deceleration speed and movement cycle.
Sometimes, in some special applications the power of C1 or R1 is not big enough and an
external resistor or capacitor will be necessary.
The aim of regeneration:
EDC servo drive: Capacitor is used for internal regeneration. If external regeneration
is required, we need to connect external regeneration unit to terminal P and N. If in one
system there are a lot of similar servo drives, all the P terminals could be connected
together and all the N terminals could be connected together, which could add the
regeneration power. This is just like connecting all C1 together but it relies on a complete
analysis of system operating cycle.
EDB servo drive: There are internal resistor R1 and capacitor C1. If any external
regeneration is required, we will have to remove the internal R1 and connect a resistor
between terminal B1 and terminal B2.

Regeneration process:
Normally, the power supply to one servo system is 200v.
A normal P-N bus voltage is 283v(200”1.41). When a servo motor begins to
decelerate, the energy feedback to the servo drive begin to increase the P-N voltage. Some
or all the energy is used to charge C1. However, when the voltage surpasses 380vDC,
regeneration transistor TR1 will be activated. Then, the energy will be consumed by
resistor R1. Hence, the transistor will be switched cyclic between 380VDC and 370VDC.
Deceleration with load will need several cycle. When the power couldn’t be
consumed completely, A13, overvoltage alarm could happen and bus voltage is above
420VDC then. Sometimes A16 (regeneration error) could happen, which means TR1 has
been switched on for too long time. (There is a internal register to record TR1’s on/off
time.

Regeneration sequence:
If A13 and A16 happen, we need to change the resistance of R1. We need to consume
more current through the resistor. According to V=I*R, we could increase the current by
using a smaller resistor. Increasing the power of the resistor is not the only solution
because the current through R1 is still the same.
After changing the resistor, we need to recheck. Once we reduce R1, the current
through R1 increases. If the current increase too much, it may exceed the rated power of
the resistor so we will need to increase the power of the resistor.

The calculation of regeneration:

If the regeneration power is beyond the rated power of internal resistor, we need to
add an extra resistor.
As what we see in equations, the energy generated when motor stops, load, capacitor
C1, motor wiring and resistor R1 should be considered.

Energy generated by motor:

En=0.5JM[(2πN/60)2]
Energy consumed by capacitor:
Ec=0.5C（Vk2-Vr2）
Energy consumed by the winding of motor.
Em= 3[JMN(2πIr/60Tr)]2*(Ra/td)
Energy consumed by load
EL=0.5TL(2πNtd/60)
Because the sum of all kinds of energy should be 0, we could calculate the
energy that the resistor needs to consume:
Er=En-Ec-Em-EL
Hence we could calculate the power of regeneration resistor:
Wr=Er/Cycle
Negative load
If one load forces servo motor to rotate, this kind of load is called negative load. In
this situation, continuous regeneration happens to the servo drive. We should avoid the
motor’s output torque to be different from the motor’s actual rotation direction.
Application of negative load:
 Load descends without a counter weight

motor used in conveyor belt

Regeneration resistor selection guidance
Please refer to the form as below to choose a suitable resistor.
Specification of internal resistor Mininum
Suitable Servo Drive allowable
Resistance（Ω） Capacity（W）
resistance（Ω）
EDB-08 50 60 40
EDB-10 50 60 40
EDB-15 50 60 40
EDB series
EDB-20 30 150 20
EDB-30 10 300 10
EDB-50 10 300 10
Pronet-10 50 60 40
Pronet-15 50 60 40
Pronet-20 30 150 20
Pronet-30 10 300 10
Pronet series
Pronet-50 10 300 10
Pronet-75D 11 1500 10
Pronet-1AD 11 1500 10
Pronet-1ED 11 1500 10
Notice: When we add external regeneration resistors, we will need to remove internal
regeneration resistors at first. Before ordering, please add “-x” after the model ( For
example, EDB-08AMA-x), in which regeneration resistor is not included.
 Addendum: normal resistor list
Carbon resistor Metal film Wire wound Metal oxide Cement resistor Sheet resistor Integrated
Name
（RT） register（RJ） resistor（RX） film（RY） （RL） circuit（B-YW）

Apperance