Cause : Braking resistor overload comes when the braking resistor connected to the drive is experiencing an excessive current flow, surpassing its rated capacity.

• The braking energy is too large.
• The braking resistor is not suited for the application.

In motor control systems, braking resistors are used to dissipate excess energy generated during deceleration or braking operations. When the motor is decelerating rapidly, especially in applications where quick stops are required or when regenerative braking is used, the excess energy needs to be dissipated to prevent damage to the drive or motor. The braking resistor helps absorb this excess energy by converting it into heat.

However, if the braking resistor is subjected to a current higher than its capacity for an extended period, it can lead to overheating and potential damage. This situation is commonly referred to as "braking resistor overload."

Several factors can contribute to braking resistor overload:

1. Oversized motor or drive: If the motor or drive is oversized for the application, it may generate more braking energy than the braking resistor can handle.

2. High deceleration rates: Rapid deceleration or frequent braking operations can result in higher energy dissipation, leading to overload.

3. Incorrect resistor sizing: If the braking resistor is undersized for the application, it may not be able to handle the amount of energy generated during braking, resulting in overload.

4. Faulty braking circuit: Malfunctions in the braking circuit, such as short circuits or damaged components, can cause excessive current flow to the braking resistor.