Category Archives: Variable Frequency Drive (VFD)

How a line reactor works

A line reactor (also known as a choke or AC reactor) is used in electrical drive systems to reduce current peaks and minimize power quality issues.
In installations where a
variable frequency drive (VFD)
is used, the current can fluctuate significantly due to the switching of power electronics.

A line reactor smooths these current variations.
As a result, the load on both the variable frequency drive and the electrical grid is reduced.
Within modern industrial automation, a line reactor is therefore an essential component of reliable
drive technology and stable motor control.

How does a line reactor work?

A line reactor is essentially an inductive coil that resists rapid changes in current.
When the current suddenly increases or decreases, the coil generates a counteracting inductive voltage that slows down this change.

Thanks to this property, current peaks are reduced and the waveform becomes smoother.
This helps to limit harmonic distortion in the electrical grid while also protecting the drive electronics.

For more background information on variable frequency drives and drive systems, see the
Fluxcon variable frequency drives wiki.

Why use a line reactor?

When variable frequency drives are connected directly to the power grid, harmonic currents can occur.
These harmonics can lead to additional heat in cables, transformers and other electrical components.

A line reactor helps reduce these effects by improving the current waveform and limiting peak currents.
This extends the lifespan of electrical components and ensures stable system operation.

Applications of line reactors

Line reactors are commonly used in installations where variable frequency drives or other power electronic drives are applied.
Typical applications include:

• Pumps and fans
• Conveyor systems
• Compressors
• Industrial production lines
• Installations with multiple variable frequency drives

In these applications, the line reactor ensures a more stable current and better protection of both the variable frequency drive and the electrical grid.

Selection of a line reactor

When selecting a line reactor, factors such as the rated current of the drive, the supply voltage and the required impedance must be considered.
In addition, the application plays a role, for example whether the reactor is used for harmonic reduction or for protecting the variable frequency drive.

For questions about using line reactors in combination with variable frequency drives, you can also consult our
frequently asked questions about variable frequency drives.

Fluxcon variable frequency drive product range

Fluxcon’s product portfolio consists of electronic components for controlling electric motors.
The range includes product groups such as variable frequency drives, soft starters, braking resistors, brake choppers, line reactors and mains filters.

Customers choose Fluxcon based on practical, no-nonsense engineering.
We offer an excellent price-performance ratio and fast delivery.
Fluxcon engineering delivers solutions based on practical expertise.

Simple solutions are often the best solutions.
Fluxcon strives for transparency in its approach and works closely with customers to find the most suitable solution for each process or application.

In addition, our products are brand-independent.
For example, a braking resistor can also be used with variable frequency drives from other manufacturers.

How a Mains Filter Works

A mains filter is used in electrical installations to reduce disturbances on the power grid.
Electronic power control systems such as a
variable frequency drive
can generate high-frequency interference that flows back into the grid via the supply cable.

These disturbances are also referred to as electromagnetic interference (EMI).
A mains filter suppresses these disturbances before they reach the power grid.
This ensures compliance with EMC standards and prevents interference with other equipment.

How does a mains filter work?

A mains filter consists of a combination of inductors and capacitors that block or divert unwanted high-frequency signals.
The inductors limit rapid changes in current, while the capacitors divert high-frequency signals to ground.

In this way, disturbances generated by power electronics are effectively filtered before they can spread through the power grid.
Mains filters therefore play an important role in reliable drive technology and stable industrial automation.

More background information about variable frequency drives and drive systems can be found in the
Fluxcon VFD wiki.

Why is a mains filter necessary?

Variable frequency drives and other power electronic systems switch very rapidly to control the speed of electric motors.
This switching generates harmonics and high-frequency disturbances on the power grid.

If these disturbances are not filtered, they can cause problems such as:

• Malfunctions in measurement equipment
• Interference with communication and control systems
• Disturbances in other electrical devices
• Non-compliance with EMC standards

By applying a mains filter, these disturbances are significantly reduced, ensuring reliable system operation.

Applications of mains filters

Mains filters are widely used in installations where variable frequency drives and other power electronic systems are applied.
Typical applications include:

• Pumps and fans
• Conveyor systems
• Compressors
• Lifting equipment
• Industrial production lines

In these applications, mains filters help limit electromagnetic interference and ensure compliance with EMC standards.

Selection of a mains filter

When selecting a mains filter, factors such as drive power, rated current and supply voltage must be considered.
In addition, the required level of interference suppression depends on the EMC requirements of the installation.

For questions about the use of mains filters in combination with variable frequency drives, please also visit our
frequently asked questions about VFDs.

Fluxcon Frequency Converter Product Range

The Fluxcon product range consists of electronic components for controlling electric motors. Our portfolio includes product groups such as frequency converters (VFDs), soft starters, braking resistors, brake choppers, reactors and mains filters.

Fluxcon is chosen by customers for its practical approach. We offer an excellent price-performance ratio and fast delivery. Fluxcon engineering provides solutions based on practical expertise.

Simple solutions are often the best. Fluxcon aims to be transparent about chosen solutions and works closely with customers to achieve the best result for each process or application.

Our products are brand-independent. For example, a braking resistor can also be used with third-party frequency converters.

How a Soft Starter Works

A soft starter is used to start and stop electric motors in a controlled manner.
When an electric motor is started directly (DOL), a high inrush current can occur, often several times higher than the motor’s rated current.
This can lead to mechanical stress on the installation and voltage dips in the power supply.

A soft starter prevents these issues by gradually increasing the voltage supplied to the motor.
This limits the starting current and ensures a smooth, controlled start.
Within modern industrial automation, a soft starter is therefore an essential component of reliable
drive technology and efficient motor control.

How Does a Soft Starter Work?

A soft starter controls the voltage supplied to the motor using power electronics, typically thyristors (SCRs).
During startup, the voltage is increased step by step until the motor reaches its nominal speed.

This gradual voltage ramp-up allows the motor current to increase smoothly, reducing mechanical stress on the drive system.
As a result, shocks in the system are minimized and the lifespan of mechanical components such as bearings, gears and couplings is extended.

More technical background on drive systems and motor control can be found in the
Fluxcon variable frequency drives wiki.

Soft Starter With or Without Bypass

Soft starters are available with or without an integrated bypass.
Fluxcon supplies both versions, depending on the application and system requirements.

A bypass is a contactor that bridges the soft starter once the motor reaches full speed.
During startup, the motor is controlled via the thyristors.
After reaching nominal speed, the bypass switches on and the motor is connected directly to the mains.

The advantage is that the soft starter’s power electronics are no longer loaded.
This reduces energy losses and heat generation, improving efficiency and extending component lifetime.

Soft starters without a bypass remain continuously connected through the power electronics.
This can be desirable in applications where controlled stopping or additional functions are required.

Applications of Soft Starters

Soft starters are used in installations where controlled motor starting is important.
Typical applications include:

• Pumps
• Fans
• Compressors
• Conveyors
• Mixers and agitators

In these applications, a soft starter prevents high inrush currents and mechanical shock loads.

Soft Starter or Variable Frequency Drive?

A soft starter is used when only controlled starting and stopping of the motor is required.
If speed control during operation is needed, a
variable frequency drive (VFD) is typically used.

A VFD not only limits starting current but also allows full speed control of the motor.
This makes VFDs ideal for applications requiring energy savings, process control or variable speed operation.

Selection of a Soft Starter

When selecting a soft starter, factors such as motor power, rated current and load type must be considered.
Additional aspects include start frequency, ambient temperature and application requirements.

The choice between a soft starter with or without bypass is also important.
For continuous operation and higher power ratings, a bypass is often preferred due to higher efficiency and lower heat generation.

For questions about selecting soft starters or variable frequency drives, please visit our
frequently asked questions about VFDs.

Fluxcon Product Range – Drive Technology Components

The Fluxcon product portfolio consists of electronic components for controlling electric motors.
The range includes product groups such as variable frequency drives (VFDs), soft starters, braking resistors, brake choppers, line reactors and EMI filters.

Customers choose Fluxcon based on practical engineering and reliability.
We offer an excellent price-performance ratio and fast delivery.
Fluxcon engineering provides straightforward, effective solutions.

Simple solutions are often the best.
Fluxcon values transparency and works closely with customers to find the optimal solution for each process or application.

All products are brand-independent.
For example, braking resistors can also be used with VFDs from other manufacturers.

How a Brake Chopper (Braking Unit) Works

A brake chopper or braking unit is used in drive systems with a variable frequency drive (VFD) to safely dissipate excess energy.
When an electric motor decelerates or needs to hold a load, energy can be fed back into the drive.
This energy increases the voltage in the DC bus of the variable frequency drive (VFD).

The brake chopper continuously monitors the DC bus voltage.
When this voltage exceeds a predefined threshold, the brake chopper automatically switches a braking resistor into the circuit.
This converts the excess electrical energy into heat and prevents the VFD from tripping or shutting down.

Brake Chopper and Regenerative Operation

When an electric motor is mechanically decelerated or when a load moves downward, the motor can operate as a generator.
This is known as regenerative operation.
In this situation, the motor feeds electrical energy back into the drive.

Without a brake chopper, this energy would increase the DC bus voltage until the
VFD
generates a fault or shuts down to protect its electronics.

By using a brake chopper in combination with a braking resistor, this energy is safely dissipated.
The brake chopper activates the resistor when the DC bus voltage becomes too high and switches it off once the voltage returns to a safe level.

More technical background on VFDs and braking systems can be found in the
Fluxcon variable frequency drives wiki.

Applications of Brake Choppers

Brake choppers are used in applications where energy must be dissipated during motor deceleration or load braking.
Typical applications include:

• Hoisting systems and cranes
• Winches and lifting mechanisms
• Fast machine positioning
• Conveyors with high inertia
• Fans with large rotational mass

In these applications, the brake chopper ensures safe and controlled deceleration without overloading the VFD.

Selection of a Brake Chopper

When selecting a brake chopper or braking unit, several parameters are important.
First, the chopper must be compatible with the DC bus voltage of the VFD and the drive power.

In addition, the brake chopper must be correctly matched with a suitable braking resistor.
The resistance value must fall within the allowable ohmic range of the VFD and have sufficient thermal capacity to dissipate the generated energy.

For questions about selecting brake choppers or braking resistors, please visit our
frequently asked questions about VFDs.

Aluminium Braking Resistors IP67

• easy installation
• waterproof
• brand-independent

Braking Resistor Selection

When selecting a braking resistor, the correct resistance value is essential.
Each variable frequency drive specifies an allowable resistance range.
If the resistance is too low, the current can become too high and damage the drive.
If the resistance is too high, the drive may not be able to dissipate sufficient electrical power.

The thermal capacity is also critical.
Depending on your application, varying amounts of excess energy must be converted into heat, as well as the duration of energy dissipation.
For advice, please contact Fluxcon specialists.

Brake Chopper

Up to 15 kW, brake choppers are integrated in the compact VFD series.
These built-in brake choppers can handle up to 50% of the drive’s nominal current to the braking resistor.
An external brake chopper can handle up to 150% of the nominal current.

Above 15 kW, brake choppers are typically not integrated in the drive.
In these cases, an external brake chopper is required when regenerative energy is present.

The brake chopper monitors the DC bus voltage and activates the braking resistor when the voltage becomes too high.

Brake Choppers

• optional on drive
• up to 150% nominal current
• brand-independent

Fluxcon Product Range – Drive Technology Components

The Fluxcon product portfolio consists of electronic components for controlling electric motors.
The range includes variable frequency drives (VFDs), soft starters, braking resistors, brake choppers, line reactors and EMI filters.

Customers choose Fluxcon based on practical engineering and reliability.
We offer an excellent price-performance ratio and fast delivery.
Fluxcon engineering provides straightforward, effective solutions.

Simple solutions are often the best.
Fluxcon values transparency and works closely with customers to find the optimal solution for each process or application.

All products are brand-independent.
For example, braking resistors can also be used with VFDs from other manufacturers.

Variable Frequency Drive (VFD) for Fans

Fans are widely used in industrial installations for ventilation, cooling and air handling in production environments.
The required airflow often varies depending on occupancy, climate conditions or production demands.
To ensure efficient and reliable operation of ventilation systems, precise control of fan speed is essential.

A variable frequency drive (VFD) enables dynamic control of fans, allowing airflow to be adjusted exactly to actual demand.
Within modern industrial automation, VFDs are a key component of reliable
drive technology and efficient motor control.

Constant Airflow and Pressure Control

With a VFD, the fan speed can be automatically adjusted based on airflow or pressure.
By using an integrated PID controller, stable control behavior is achieved, maintaining constant pressure and airflow in the ventilation system.

This type of VFD integration allows ventilation systems to be easily connected to
machine control systems and industrial process control.
More technical background on VFD operation can be found in the
Fluxcon variable frequency drives wiki.

Improved Performance

By adjusting fan speed, fans operate more efficiently and produce less noise.
In addition, resonance issues can be avoided by defining so-called skip frequencies.
This increases system reliability and ensures stable performance in industrial ventilation and process installations.

Energy Savings with VFDs

A major advantage of using a VFD for fans is energy savings.
Since maximum capacity is only required occasionally, fan speed can often be significantly reduced.

A speed reduction of approximately 10% can already result in energy savings of more than 25%.
Would you like a calculation example or more information about energy consumption?
Then visit our VFD FAQ.

IE3 Efficiency Directive

Since January 1, 2015, the IE3 efficiency directive for electric motors has been in force.
All motors from 0.75 kW up to and including 7.5 kW must meet IE2 efficiency requirements,
and all motors above 7.5 kW must comply with IE3 efficiency or IE2 in combination with a
variable frequency drive (VFD).

Reduced Maintenance Costs with VFDs for Fans

Lower pressure and airflow mean the fan operates under reduced load.
This results in less wear, lower maintenance costs and a longer service life.

Suitable VFDs for Fans

The compact VFD series includes a built-in PID controller.
Based on an analog signal from a pressure sensor, the fan can automatically maintain the desired pressure and/or airflow.

Variable Frequency Drive (VFD) for Winches

Winches are widely used in industrial applications for moving and positioning loads.
Depending on the application, winches vary significantly in size, power and construction.
Reliable drive technology and precise motor control are therefore essential to ensure safe and controlled load handling.

The most common winch applications include:

• Lifting loads
• Pulling structures or cables
• Controlled unwinding of cables or lines
• Maintaining constant cable tension
• Precise load positioning

VFDs for Winch Systems

Each application places specific demands on the drive system and therefore on the
variable frequency drive (VFD).
A key characteristic of winch systems is that full control of the load must always be maintained, even at low speeds or under varying load conditions.

For this reason, winch applications typically use VFDs with
vector control.
This control method provides precise torque and speed regulation, enabling safe movement and accurate positioning of loads.

Within modern industrial automation, proper
VFD integration allows winches to be connected to
machine control, safety systems and process control.
More technical background on VFDs can be found in the
Fluxcon variable frequency drives wiki.

Do you have questions about selecting or applying VFDs in winch systems?
Please also visit our VFD FAQ.

Vector Control Without Encoder Feedback

For relatively simple tasks such as lifting or pulling loads at predefined speeds, vector control without feedback is sufficient.
It provides a reliable and efficient drive solution with a relatively simple system design.

Vector Control With Encoder Feedback

For more advanced winch applications, it is necessary to provide the
VFD with accurate feedback about motor behavior.
This enables advanced functions such as constant tension control or four-quadrant operation,
ensuring full control of the load even at 0 Hz (standstill).

Fluxcon Application Expertise

Fluxcon has extensive experience in winch applications.
Typical applications include heave compensation, constant tension control and precise load positioning in environments such as theaters.
We also have expertise in lifting systems for people and goods.

Variable Frequency Drive (VFD) for Conveyors

Conveyors are used in industrial installations to transport products reliably from one point to another.
The capacity and speed of a conveyor often need to be adjusted to match the production process, for example in sorting, packaging or processing applications.

With a variable frequency drive (VFD), the conveyor speed can be easily adjusted to the current process requirements.
Within modern industrial automation, this control is a key element of efficient
drive technology and reliable motor control in conveyor systems.

Optimized Process Control with VFDs

By varying the speed of the drive motor, the capacity of the conveyor can be precisely matched to the production process.
This prevents bottlenecks, ensures a consistent product flow and increases overall system efficiency.

Proper VFD integration allows conveyors to be connected to
machine control, sorting systems and automated production lines.
More technical background on VFD operation can be found in the
Fluxcon variable frequency drives wiki.

Energy Savings with VFDs on Conveyors

An empty or partially loaded conveyor consumes significantly less energy than a fully loaded one.
Depending on the type of conveyor, energy consumption of an empty belt can be approximately 20% to 60% compared to a fully loaded belt.

By using a VFD, the conveyor speed can be optimized to ensure the system operates as efficiently as possible while reducing energy consumption.
For a calculation example, please visit our
VFD FAQ.

VFD Control for Conveyors: Buffering and Process Optimization

A buffer conveyor is ideal when products need to be temporarily stored before continuing in the process.
This buffering can be easily achieved using a properly configured
variable frequency drive on the conveyor.

By running the conveyor at a lower speed during low capacity, additional storage space is created,
allowing a significant amount of product to be buffered on the conveyor.

Integration with Other Processes

Within the Fluxcon VFD range, there are extensive possibilities to synchronize multiple drives.
For example, a primary process can be controlled while the conveyor speed automatically adjusts based on a pulse signal.
This results in an optimized, automated and energy-efficient process.

Fluxcon VFD Solutions

Fluxcon technical specialists work closely with you to analyze complete process flows,
ensuring maximum optimization and energy savings.

As a high-tech company with multiple locations in the Netherlands, Fluxcon operates globally.
We offer a wide range of energy-efficient drive and control solutions, including
variable frequency drives, soft starters and control panels.

Our products are certified by international organizations and used in more than 100 countries.
Fluxcon VFDs stand out due to advanced functionality, ease of use and expert technical support from experienced drive specialists.

Variable Frequency Drive (VFD) for Pumps

Pumps are used in industrial installations to transport liquids, for example in process plants, cooling systems and water treatment.
A pump is typically selected for a specific flow rate at a certain head.
In traditional systems, flow is often controlled using valves or throttling devices.

With a variable frequency drive (VFD), the pump speed can be controlled directly.
This allows the flow rate to be precisely adjusted to process demand without energy losses caused by throttling.
Within modern industrial automation, this control is a key element of efficient
drive technology and reliable motor control.

Optimized Process Control with VFDs

By varying the motor frequency, pump flow can be easily adjusted to match real-time system demand.
This ensures stable pressure and flow, enabling efficient pump operation.

Proper VFD integration allows pumps to be connected to
machine control, process automation and pressure control systems.
More technical background on VFD operation can be found in the
Fluxcon variable frequency drives wiki.

Energy Savings with VFDs on Pumps

A key advantage of using VFDs in pump applications is energy savings.
By reducing pump speed when full capacity is not required, energy consumption can be significantly reduced.

Depending on the application, energy savings of approximately 20% to 40% can be achieved.
Since pumps often operate continuously, this can result in substantial cost savings.

Fluxcon also supplies VFDs suitable for modern
permanent magnet synchronous motors.
These motors offer very high efficiency and exceed current energy efficiency standards.

Would you like a calculation example for pump energy savings?
Then visit our VFD FAQ.

IE3 Efficiency Directive

Since January 1, 2015, the IE3 efficiency directive for electric motors has been in force.
All motors from 0.75 kW up to and including 7.5 kW must meet IE2 efficiency requirements,
and motors above 7.5 kW must comply with IE3 efficiency or IE2 in combination with a
variable frequency drive (VFD).

Reduced Wear with VFD-Controlled Pumps

Lower operating speeds extend maintenance intervals.
Without throttling valves, the pump operates more efficiently with reduced mechanical stress.
This results in lower loads on bearings and reduced pressure on seals, leading to less wear and longer service life.

Thanks to the soft start function, pressure spikes (water hammer) are eliminated, preventing system damage.

Improved Performance with VFDs on Pumps

Using a VFD prevents current peaks and maintains a high power factor (cos φ) in the electrical system.

The integrated PID functionality in the Fluxcon series allows constant pressure or flow control.
This enables variable flow rates based on process demand, ensuring optimal pump performance with minimal energy consumption.

Fluxcon VFD Solutions

Fluxcon technical specialists work with you to analyze your processes and identify opportunities for optimization and energy savings.
With the wide Fluxcon product range, you will always find the optimal solution.

Fluxcon is a high-tech company with multiple locations in the Netherlands and operates worldwide.
We offer a broad range of energy-efficient drive and control solutions, including
variable frequency drives, soft starters and control panels.

Fluxcon products are certified by international organizations and used in more than 100 countries.
Fluxcon VFDs stand out due to advanced functionality, ease of use and expert technical support from experienced drive specialists.

Variable Frequency Drive (VFD) for Compressors

Compressors are used in industrial installations to supply compressed air for a wide range of applications, such as pneumatic drives, production processes and automation systems.
Traditionally, a compressor is connected to a storage tank. When the maximum system pressure is reached, the compressor switches off, and switches back on when the pressure drops.

Because the difference between minimum and maximum pressure is relatively large, the system operates with fewer switching cycles.
However, a disadvantage is that the average system pressure is often higher than required for the process.
Higher pressure results in increased energy consumption and additional wear on the compressor system.

With a variable frequency drive (VFD), the compressor speed can be precisely controlled.
Within modern industrial automation, this control is a key component of efficient
drive technology and reliable motor control.

Constant Pressure Control with VFDs

By using a VFD, the compressor can automatically increase or decrease speed based on the actual system pressure and the desired setpoint.
An integrated PID controller ensures stable and accurate pressure control within the compressed air system.

This type of VFD integration enables seamless interaction with
machine control and industrial process control systems.
More technical background on VFDs can be found in the
Fluxcon variable frequency drives wiki.

An additional advantage is that the storage tank can often be smaller,
as the compressor continuously adjusts to actual air demand.

Energy Savings with VFDs on Compressors

Using a VFD allows the average system pressure to be reduced while maintaining a stable compressed air supply.
For example, reducing system pressure from 7 bar to 6 bar can already result in energy savings of approximately 7%.

In addition, leakage losses in the compressed air system are reduced,
which can increase total energy savings to around 10%.

For a calculation example or more information about energy savings with VFDs,
please visit our VFD FAQ.

IE3 Efficiency Directive

Since January 1, 2015, the IE3 efficiency directive for electric motors has been in force.
All motors from 0.75 kW up to and including 7.5 kW must meet IE2 efficiency requirements,
and motors above 7.5 kW must comply with IE3 efficiency or IE2 in combination with a
variable frequency drive (VFD).

Reduced Maintenance Costs with VFD-Controlled Compressors

Because the average system pressure is lower, the compressor operates under reduced load.
This results in less wear, lower maintenance costs and a longer service life.

Suitable VFDs for Compressors

The Fluxcon compact VFD series includes an integrated PID controller.
Based on an analog signal from a pressure sensor, the compressor can automatically maintain a stable desired pressure.

How a Braking Resistor Works

The operation of a braking resistor in a drive system with a variable frequency drive (VFD) is relatively simple.
When a DC voltage is applied to a braking resistor, current flows according to Ohm’s law (I = U / R).
The electrical energy is then converted into heat according to the power formula (P = I² × R).

The braking resistor must safely dissipate this heat to the surrounding environment.
In the short term, the resistor can absorb heat due to its thermal capacity.
This depends on the material properties, mass of the resistor and the temperature rise (ΔT).

If the temperature rises too high, damage may occur.
For this reason, braking resistors are typically designed with a large cooling surface to dissipate heat through natural air cooling.
In some applications, forced air cooling or water cooling is used.

Braking Resistors in Regenerative Operation

Braking resistors are used when an electric motor feeds energy back into the drive system during operation.
This occurs, for example, when a motor decelerates a load or controls a lowering load.

When a motor is controlled by a
variable frequency drive (VFD),
electrical energy can be generated during so-called regenerative operation.
This energy increases the voltage in the DC bus of the VFD.

If the DC bus voltage rises too high, the VFD may trip or shut down to protect the electronics.
By using a brake chopper (often integrated in the VFD) in combination with a braking resistor,
the excess energy is safely dissipated.

More technical background on VFDs and braking systems can be found in the
Fluxcon VFD wiki.

When is a Braking Resistor Required?

In many industrial applications, a braking resistor is required to safely dissipate excess energy.
This is common in situations such as:

• Hoisting systems where loads are lowered
• Fast deceleration or precise positioning of loads
• Applications with high inertia, such as large fans
• Situations where motors temporarily oppose each other

When a heavy load must be decelerated or an external force must be controlled,
regenerative energy is generated that must be dissipated by the drive system.

Selection of a Braking Resistor

When selecting a braking resistor, the correct resistance value (Ohms) is critical.
Each VFD has an allowable resistance range.

A resistance that is too low can lead to excessive current and damage to the VFD.
A resistance that is too high may result in insufficient energy dissipation.

In addition, the thermal power rating of the braking resistor is important.
Depending on the application, different amounts of energy must be converted into heat over short or extended periods.

For questions about selecting braking resistors or their application with VFDs,
please visit our VFD FAQ.

Aluminum Braking Resistors IP67

• easy installation
• waterproof
• brand-independent

Braking Resistor Selection

When selecting a braking resistor, the correct resistance value is essential.
Each VFD specifies an acceptable resistance range.

If the resistance is too low, current may become too high and damage the drive.
If the resistance is too high, the drive may not be able to dissipate sufficient electrical power.

The thermal rating is also critical.
Depending on the application, more or less energy must be dissipated as heat,
and for different durations.

For advice, please contact Fluxcon specialists.

Brake Chopper

Up to 15 kW, brake choppers are integrated in the
compact VFD series.
These integrated brake choppers can handle up to 50% of the nominal current to the braking resistor.

An external brake chopper can handle up to 150% of the nominal current.

Above 15 kW, VFDs are typically not equipped with a built-in brake chopper.
In these cases, an external brake chopper is required when regenerative energy is present.

The brake chopper monitors the DC bus voltage and activates when the voltage exceeds a threshold,
diverting energy to the braking resistor.

Brake Choppers

• optional on VFD
• up to 150% nominal current
• brand-independent

Fluxcon Drive Product Range

Fluxcon offers a range of electronic components for controlling electric motors,
including variable frequency drives, soft starters, braking resistors, brake choppers, line reactors and EMC filters.

Customers choose Fluxcon for its practical approach, excellent price-performance ratio and fast delivery.
Fluxcon engineering provides solutions based on real-world experience.

Simple solutions are often the best.
Fluxcon values transparency and works closely with customers to find the optimal solution for each application.

All products are brand-independent.
For example, braking resistors can also be used with third-party VFD brands.