Delta Electronics VFDB 4132 Series Instruction Sheet

2008-09-10
5011669601-1CBU
VFDB 4132 Series Brake Modules
Instruction Sheet
Preface
Thank you for choosing DELTA's brake module. VFDB brake units are applied to
absorb the motor regeneration energy when the three-phase induction motor stops by
deceleration. With VFDB brake unit, the regeneration energy will be dissipated in
dedicated brake resistors. To prevent mechanical or human injury, please refer to this
instruction sheet before wiring. VFDB brake units are suitable for DELTA AC Motor
Drives VFD Series 230V/460V/575V. VFDB brake units need to be used in conjunction
with BR series brake resistors to provide the optimum brake characteristics. VFDB
brake units (4132) are approved by Underwriters Laboratories, Inc. (UL) and Canadian
Underwriters Laboratories (cUL). The content of this instruction sheet may be revised
without prior notice. Please consult our distributors or download the most updated
version at http://www.delta.com.tw/industrialautomation.
Specifications
VFDB 4132 Brake Units
Specification 460V Series
Max. Motor Capacity (kW) 132
Max. Discharge Current (A) 10%ED 240
Continuous Discharge Current (A) 75
Braking Start-up Voltage (DC) 618/642/667/690/725/750±6V
Input
DC Voltage 480-750VDC
Rating
3.4Ω
Min. Equivalent Resistor for Each Brake Unit
Heat Sink Overheat Temperature Temperature exceeds +95
Relay contact 3A250VAC/30VDC
Alarm Output for Overheat
(RA, RC)
ON until the bus (P-N) voltage is
Power Charge Display
below 50VDC
Over-current Protection Level 320A
Indoor (no corrosive gases, metallic
Installation Location
dust)
o o o
Operating Temperature -10 C~+50 C (14 F to 122
o o o
Storage Temperature -20 C ~+60 C (-4 F to 140
Humidity Less than 90% Non-condensing
2
9.8m/s (1G) under 20Hz / 2m/s
Vibration
(0.2G) at 20~50Hz
Mechanical Configuration Wall-mounted enclosed type IP10
Brake Resistors
Model no. Specification
BR1K5W005 1500W 5.0Ω
BR1K2W6P8 1200W 6.8Ω
BR1K2W008 1200W 8.0Ω
BR1K5W040 1500W 40Ω
BR1K0W050 1000W 50Ω
BR1K0W075 1000W 75Ω
Dimensions
3.1 Brake resistor
3.2 Brake unit
CHARGE ACT OC OH
VFDB4132
Internal Components and Terminals
4.1 Internal Components
4.2 Wire Gauge for Terminals
Wire Gauge AWG
Circuit Terminals
2
(mm )
Power Input 4~6AWG
DC+, DC-
2
Circuit (13.3~21.2mm )
Brake 4~6AWG
B1, B2
2
Resistor (13.3~21.2mm )
Output M1, M2 18~20AWG
SLAVE
2
(0.8~0.5mm )
o o Circuit
C (203 F) Input S1, S2
(With shielded wires)
Fault 18~20AWG
RA, RC
2
Circuit (0.8~0.5mm )
Basic Wiring Diagram
NFB
MC
R/L1
o R/L1 R/L1
F)
S/L2
o S/L2 S/L2
F)
T/L3
T/L3 T/L3
2
O.L. VFD Series
MC
+(P) DC+
-(N) DC-
SA
E.F RA
Surge Absorber
DCM RC
Thermal O verload
Relay or Tem perature switch
Note 1: When the AC m otor drive is used with DC reactor, please refer to the wiring
diagram in the AC drive user manual for wiring terminal DC+ of br ake unit.
Note 2: DO NOT wire terminal D C- to the neutral point of power system.
NOTE
For safety consideration, install an overload relay between the brake unit and the
brake resistor. In conjunction with the magnetic contactor (MC) prior to the drive,
it can perform complete protection against abnormality.
The purpose of installing the thermal overload relay is to protect the brake resistor
from damage due to frequent brake, or due to brake unit keeping operating
resulted from unusual high input voltage. Under such circumstance, just turn off
the power to prevent damaging the brake resistor.
Please refer to the specification of the thermal overload relay.
The alarm output terminals (RA, RC) of the brake unit will be activated when the
temperature of the heat sink exceeds 95°C. It means that the temperature of the
installation environment may exceed 50°C, or the brake %ED may exceed
10%ED. With this kind of alarm, please install a fan to force air-cooling or reduce
the environment temperature. If the condition not due to the temperature, the
control circuit or the temperature sensor may have been damaged. At this time,
please send the brake unit back to the manufacturer or agency for repair.
The AC Motor Drive and brake unit will be electrified at the same time while
turning on the NFB (No-fuse breaker). For the operation/stop method of the motor,
please refer to the user manual of the AC Motor Drives VFD Series. The brake
unit will detect the inner DC voltage of the AC motor drive when it stops the motor
by deceleration. The extra regeneration will be dissipated away rapidly by the
brake resistor in the form of heat. It can ensure the stable deceleration
characteristic.
Besides, using thermal overload relay to be the protection system and brake
resistor, temperature switch can be installed on brake resistor side as the
protection. The temperature switch must comply with the brake resistor
specification or contact your dealer.
Wiring Warnings
Do not proceed with wiring while power is applied to the circuit.
The wiring gauge and distance must comply with the local regulations.
The +(P), -(N) terminals of the AC motor drive (VFD Series), connected to the
brake unit (VFDB), must be confirmed for correct polarity lest the drive and the
brake unit be damaged when power on.
When the brake unit performs braking, the wires connected to DC+, DC-, B1 and
B2 would generate a powerful electromagnetic field for a moment due to high
current passing through. These wires should be wired separately from other low
voltage control circuits lest they make interference or mis-operation.
Inflammable solids, gases or liquids must be avoided at the location where the
brake resistor is installed. The brake resistor had better be installed in individual
metallic box with forced air-cooling.
Connect the ground terminal to the Earth Ground. The ground lead must be at
least the same gauge wire as leads DC+, DC-.
Please install the brake resistor with forced air-cooling or the equivalent when
frequent deceleration braking is performed (over 10%ED).
Do NOT change any wirings and settings and touch any terminals and
components while power is applied to avoid electric shock.
It is recommended to use the ring terminals for main circuit wiring. Make sure the
terminals are fastened before power on.
Wiring distance
VFD series
Max 8M
AC Motor Drive
Definition for the Brake Usage ED%
100%
Brake Time
Cycle Time
Screw Torque
The definition of the brake usage ED(%) is to assure having enough time for the brake
30 kgf-cm
M8 unit and brake resistor to dissipate the heat generated by brake. When the brake
(26 in-lbf)
resistor heats up, the resistance would increase with temperature, and brake torque
30 kgf-cm
M8
(26 in-lbf) would decrease accordingly.
4 kgf-cm The Voltage Settings
M2
(3 in-lbf)
4 kgf-cm
Voltage setting: the power source of the brake unit is DC voltage from +(P), -(N)
1.
M2
(3 in-lbf)
terminals of the AC motor drive. It is very important to set the voltage of the brake
unit based on the actual input power of the AC motor drive before operation. The
setting has a great influence on the potential of the operation voltage for the brake
unit. Please refer to the table below.
NOTE
Motor
Before changing the setting of the power voltage, make sure the power has been
IM
Therm al
turned off. Please set power voltage as the possible highest voltage for unstable
Overload
power system. Take 380VAC power system for example. If the voltage may be up
Relay
to 410VAC, 415VAC should be set.
B1 For DELTA's AC motor drive (VFD Series), please set parameter (Over Voltage
O.L.
VFDB
Stall Prevention) as "close" to disable over-voltage stall prevention, to ensure
BR
Brake
stable deceleration characteristic.
Unit
Brake
B2
Resistor
Table 1: The Selection of AC Power Voltage and Voltage Setting
Tem perature Sw itch
AC Power Voltage
380VAC (460V Mode)
400VAC (460V Mode)
415VAC (460V Mode)
440VAC (460V Mode)
460VAC (460V Mode)
480VAC (460V Mode)
Input voltage setting for VFDB 4132
Input Voltage Setting
For VFDB 4132
Factory setting: 440V
2. MASTER (M) /SLAVE (S) setting: the factory setting is "M". The "S" setting is
applied to two or more brake units in parallel, making these brake units be
enabled/disabled synchronously. Then the power dissipation of each unit will be
equivalent so that they can perform the brake function completely.
In the following diagram, it shows jumper setting for the application of three brake
units. After wiring, the jumper in the first brake unit should be set to "M" and others
must be set to "S" to complete the system setting.
Input Voltage Setting
480V
460V
440V
415V
400V
380V
Please make sure that power is OFF before setting the jumper.
VFDB
BR
series The steps for jumper setting:
Max 5M Step 1. Remove the top cover.
Brake Unit
Brake Resistor
Step 2. Remove the screws on the side case (3 screws for each side).
Step 3. Remove the screws that connected bottom case to the side case (2
Step 4. After removing the power line of the fan, pull out the heat sink slowly until
Brake Resistors/Units for Delta VFD
AC Motor Drives Series
T1
ED% = T1/T0x100(%)
T0 Applicable
Motor
HP kW
120 90
150 110
175 132
215 160
250 185
300 220
Examples
Before wiring, please notice equivalent resistors value shown in the column
"Equivalent resistors specification for each brake unit" in the above table to
prevent damage.
460V 120HP
VFD
Series
VFD900_43_
Brake Start-up voltage
DC Bus (DC+, DC-) Voltage
VFD9 00_43 _ uses wi th 3 BR sets in pa rall el, which 3P CS 1K 5W00 5 brake r esistors
618VDC
ar e co nnected in ser ies.
642VDC
460V 150HP, 175HP, 215HP
667VDC
690VDC
725VDC
VF D
Ser ies
750VDC
NOTE: Input Power With Tolerance ± 10%
VF D1100_ 43_
VF D13 20_43_
VF D16 00_43_
CHARGE ACT OC OH
VF D1100_ 43_ us es w it h 6 BR s ets in p aral lel, w hic h 3PC S 1K2W 008 bra ke r es is to rs
are c on nec te d in s erie s.
Power lamp Brake lamp Over-current Overheat
VF D13 20_43_ use s w ith 6 BR s ets in par all el, wh ic h 3PCS
lamp lamp
are c on nec te d in s erie s.
VF D16 00_43_ use s w it h 6 BR sets in pa rall el, wh ic h 3PC S 1K2W6 P8 brak e re si stor s
480V
are c on nec te d in s erie s.
460V
440V
460V 250HP, 300HP
415V
400V
380V
+ (P) -( N)
VF D
Ser ies
VFD1850_43_
VFD2200_43_
VFD1850_43_ uses with 2 VF DB4132 brak e units and each brake unit us es with
3 BR sets i n parall el, which 3PCS 1K5W005 brak e resis tors are connec ted in series.
VFD2200_43_ uses with 2 VF DB4132 brak e units and each brake unit us es with
3 BR sets i n parall el, which 3PCS1K5W005 brake resi stors are c onnect ed in s eri es .
+ P ( ) -(N) DC+ DC - DC+ DC - DC+ DC -
M1 S1 M1 S1
M2 S2 M2 S2
VFD
M
Series
S S
B1 B2 B1 B2 B1 B2
BR BR BR
O.L. O.L. O.L.
The Position of the Jumper
M
MASTER/SLAVE
Setting Jumper
S
M1: SLAVE output signal +
M2: SLAVE output signal -
S1: SLAVE input signal +
S2: SLAVE input signal -
NOTE: Please use shielded
wires while wiring.
M1 S1
M2 S2 RA RC
SLAVE output/input terminal
Alarm output terminals
NOTE
screws for each side).
the jumper can be seen. Then the jumper can be set.
Min.
Resistor Value Brake Unit
Full-load Brake Resistors Brake
Equivalent
Spec. for Each Part No.
Torque Torque
Part No. and Resistor Value
AC Motor and
kg-M Quantity 10%ED for Each AC
Drive Quantity
Motor Drive
52.5 13500W 5Ω 4132 1 BR1K5W005 9 120 5Ω
61 21600W 4Ω 4132 1 BR1K2W008 18 120 4Ω
73.5 21600W 4Ω 4132 1 BR1K2W008 18 100 4Ω
89 21600W 3.4Ω 4132 1 BR1K2W6P8 18 97 3.4Ω
103 27000W 2.5Ω 4132 2 BR1K5W005 18 115 2.5Ω
122.5 27000W 2.5Ω 4132 2 BR1K5W005 18 96 2.5Ω
NOTE
Thermal O ver loa d Rel ay
B1
+(P)
DC+
O.L.
BR BR BR BR BR BR
VFDB
-( N)
DC-
4132
BR BR BR BR BR BR
Bra ke Uni t
Bra ke
M Resisto r
BR BR BR BR BR BR
B2
T herm al Ov er load Rel ay
B1
+ (P) D C+
BR BR BR BR BR BR
BR BR BR BR BR BR
O.L.
VF DB
-( N) D C-
4132
BR BR
BR BR BR BR BR BR BR BR BR BR
Bra ke
Bra ke U nit
R esi stor
M
BR BR BR BR
BR BR BR BR BR BR BR BR
B2
1 K2W00 8 brak e res is tors
Thermal O verload Rel ay
Thermal O verload Rel ay
DC+ DC- DC+ DC-
B1 B1
BR BR BR BR BR BR
VFDB VFDB
O.L . O.L .
Brak e
4132 4132
BR BR BR Brak e Unit BR BR BR
Brak e Unit Resis tor
M
BR BR BR
BR BR BR
B2 B2
S
Brak e
M1 M2 S1 S2
Resis tor
Typical
Thermal
Overload
Relay
Value
110A
135A
135A
160A
220A
220A