ABB DSHP 150 Load Module (5735128-A/1)

Overview

In variable frequency drive applications, when a motor decelerates quickly or overhauls, it acts as a generator, feeding energy back into the DC link. Without a means to dissipate this energy, the DC bus voltage would rise, potentially tripping the drive or damaging components. The DSHP 150 load module provides a controlled path for this energy by converting it to heat via rugged power resistors. It is commonly used with ABB ACS800, ACS880, and other industrial drives.

Key Features

• Power Rating: 150 kW continuous braking power (at 40°C ambient).

• Resistance Value: Typically 2.7 Ω or as specified for the drive.

• Thermal Capacity: High thermal mass for short-term overloads (e.g., 150% for 60 s).

• Protection: Integrated thermal switch (normally closed) for overtemperature monitoring.

• Enclosure: IP20 rated, sheet steel housing with ventilation slots.

• Cooling: Natural convection or forced air (depending on installation).

• Connection: Terminal block for power and thermal switch wiring.

Technical Specifications

• Resistance Tolerance: ±10%.

• Operating Voltage: Up to 1000 V DC (compatible with drive DC link).

• Thermal Switch Rating: 250 V AC, 5 A.

• Operating Temperature: -20°C to +50°C (ambient).

• Dimensions: 600 x 400 x 300 mm (approx, depending on variant).

• Weight: Approximately 25 kg.

Functional Description

The DSHP 150 is connected across the DC bus of the drive via a braking chopper (internal or external). When the DC voltage exceeds a threshold, the chopper switches the resistor across the bus, converting excess energy to heat. The module's resistors are made of high-grade alloy wire wound on ceramic cores, embedded in insulating cement within a perforated metal enclosure. The built-in thermal switch opens if the resistor overheats, signaling the drive to inhibit braking or trip, protecting both the load module and the drive.

Applications

• Cranes and hoists (controlled lowering).

• Centrifuges and decanters (fast stopping).

• Test stands and dynamometers.

• Conveyors with frequent starts/stops.

• Elevators and lifts.

Installation Considerations

The load module must be mounted on a non-flammable surface with adequate clearance for airflow (at least 200 mm around). It should be installed in a clean, dry location, away from combustible materials. The cable between the drive and the load module must be rated for the full DC voltage and current; shielded cable is recommended to reduce EMI. The thermal switch should be connected to a digital input on the drive to enable fault monitoring.

Safety and Compliance

• CE marked, RoHS compliant.

• Designed according to IEC 60204-1, UL 508C.

• Surface temperature can exceed 200°C during operation – caution signs required.

Note: This document provides technical information only. For proper sizing and integration, refer to the drive's hardware manual and the DSHP 150 datasheet.