Delta Electronics Braking Modules VFDB Series Instruction Sheet

2007-07-19
5011628404-BM 04
VFDB Series
Braking Modules Instruction Sheet
Preface
Thank you for choosing DELTA's braking module. VFDB braking units are applied to absorb the motor regeneration energy when the
three-phase induction motor stops by deceleration. With VFDB braking unit, the regeneration energy will be dissipated in dedicated
braking resistors. To prevent mechanical or human injury, please refer to this instruction sheet before wiring. VFDB braking units are
suitable for DELTA AC Motor Drives VFD Series 230V/460V/575V. VFDB braking units need to be used in conjunction with BR series
braking resistors to provide the optimum braking characteristics. VFDB braking units (2015, 2022, 4030, 4045 and 5055) 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 Braking Units
Specification 230V Series 460V Series 575V Series
Model VFDB- 2015 2022 4030 4045 5055
Max. Motor Capacity (KW) 15 22 30 45 55
Max. Discharge Current
40 60 40 60 60
(A) 10%ED
Continuous Discharge
15 20 15 18 20
Current (A)
Braking Start-up Voltage 330/345/360/380/400/ 660/690/720/760/800/
950±8V
(DC) 415±3V 830±6V
DC Voltage 200—400VDC 400—800VDC 607-1000VDC
Min. Equivalent Resistor for Each
10Ω 6.8Ω 20Ω 13.6Ω 15.8Ω
Braking Unit
o
Heat Sink Overheat Temperature over +95℃ (203 F)
Alarm Output Relay contact 5A120VAC/28VDC (RA, RB, RC)
Power Charge Display Blackout until bus (+~-) voltage is below 50VDC
Installation Location Indoor (no corrosive gases, metallic dust)
-10℃~+50℃ (14 o F to 122 o F)
Operating Temperature
Storage Temperature -20℃~+60℃ (-4 o F to 140 o F)
Humidity 90% Non-condensing
2
9.8m/s (1G) under 20Hz
Vibration
2
2m/s (0.2G) at 20~50Hz
Mechanical Configuration Wall-mounted enclosed type IP50
Dimensions - Individual Parts and
VFDB Braking Units
Function Explanation
121.0 [4.76] 130.0 [5.12]
Jumper for input
R3.3 [R0.13]
80.0 [3.15]
voltage setting
SLAVE Circuit
CHARGE ACT. ERR.
G REEN YELLOW RED
Fault Circuit
Terminal Wire Gauge
2
Circuit Terminal Mark Wire Gauge AWG (mm ) Screw
2
Power Input Circuit +(P), -(N) 10~12AWG (3.5~5.5mm ) M4
Braking Resistor B1, B2 10~12AWG (3.5~5.5mm 2 ) M4
Output M1, M2
2
20~18AWG (0.25~0.75mm )
SLAVE Circuit M2
(with shielded wires)
Input S1, S2
2
Fault Circuit RA, RB, RC 20~18AWG (0.25~0.75mm ) M2
Basic Wiring Diagram
Operation Explanation: 1. For safety consideration, install an overload relay between the braking unit and the braking resistor. In
conjunction with the magnetic contactor (MC) prior to the drive, it can perform complete protection against abnormality.
2. The purpose of installing the thermal overload relay is to protect the braking resistor from damage due to frequent braking, or due to
braking unit keeping operating resulted from unusual high input voltage. Under such circumstance, just turn off the power to prevent
damaging the braking resistor.
3. Please refer to the specification of the thermal overload relay.
4. The alarm output terminals (RC, RA, RB) of the braking unit will be activated when the temperature of the heat sink exceeds 95
o
means that the temperature of the installation environment may exceed 50 C, or the braking %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 braking unit back to the
manufacturer or agency for repair.
NFB
MC
R/L1
S/L2
T/L3
O.L.
MC
Thermal
Overload SA
Relay or
Surge
temperature Absorber
switch
Note1: When using the AC drive with DC reactor, please refer to wiring diagram in the AC drive
user manual for the wiring of terminal +(P) of Braking unit.
Note2: Do NOT wire terminal -(N) to the neutral point of power system.
6. Besides using thermal overload relay to be the protection system and braking resistor, temperature switch can be installed on braking
resistor side as the protection. The temperature switch must comply with the braking resistor specification or contact your dealer.
Wiring Notice
Do not proceed with wiring while power is applied to the circuit.
The wiring gauge and distance must comply with the electrical code.
The +(P), -(N) terminals of the AC motor drive (VFD Series), connected to the braking unit (VFDB), must be confirmed
for correct polarity lest the drive and the braking unit be damaged when power on.
When the braking unit performs braking, the wires connected to +(P), -(N), 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
Braking Resistors
other low voltage control circuits lest they make interference or mis-operation.
Wiring distance
Model no. Specification
VFD series
BR1K5W005 1500W 5.0Ω
15~55kW
1200W 6.8Ω
BR1K2W6P8
230/460/
Max 10M
575V
1200W 8.0Ω
BR1K2W008
AC Motor Drive
1500W 40Ω
BR1K5W040
To prevent personal injury, do not connect/disconnect wires or
regulate the setting of the braking unit while power on. Do not touch
BR1K0W050 1000W 50Ω
the terminals of related wiring and any component on PCB lest users
be damaged by extreme dangerous DC high voltage.
BR1K0W075 1000W 75Ω
Definition for Braking Usage ED%
Dimensions
-
Braking Resistors
100%
Braking Time
Cycle Time
Explanation: The definition of the barking usage ED(%) is for assurance of
enough time for the braking unit and braking resistor to dissipate away heat
generated by braking. When the braking resistor heats up, the resistance would
increase with temperature, and braking torque would decrease accordingly.
The Voltage Settings
1. Regulation of power voltage: the power source of the braking unit is DC voltage from +(P), -(N) terminals of the AC motor drive. It is
very important to set the power voltage of the braking unit based on the input power of the AC motor drive before operation. The setting
has a great influence on the potential of the operation voltage for the braking unit. Please refer to the table below.
Table 1: The Selection of Power Voltage and Operation Potential of PN DC Voltage
230V Model
Braking Start-up voltage
AC Power
DC Bus (+(P), -(N)) Voltage
Voltage
190Vac
200Vac
210Vac
220Vac
230Vac
240Vac
Input voltage setting for VFDB-2015/2022/4030/4045
Braking Resistor
Power Input Circuit
B1 B2
，
+(P) -(N) ，
Input Voltage Setting
Torque
For VFDB-4030/4045
18 kgf-cm (15.6 in-lbf)
Factory setting: 460V
18 kgf-cm (15.6 in-lbf)
2. MASTER/SLAVE setting: The MASTER/SLAVE jumper is set "MASTER" as factory setting. The "SLAVE" setting is applied to two
or more braking units in parallel, making these braking units be enabled/disabled synchronously. Then the power dissipation of each unit
4 kgf-cm (3 in-lbf)
will be equivalent so that they can perform the braking function completely.
4 kgf-cm (3 in-lbf) The SLAVE braking application of three braking units is
shown as the above diagram. After wiring, the jumper of
first unit shall be set as "MASTER" and that of others must
be set as "SLAVE" to complete the system installation.
+ P ( ) - N ( ) + P ( )
VFD
Series
MASTER
o C. It
B1
O.L.
5. The AC Motor Drive and braking
unit will be electrified at the same time
R/L1
U/T1
while turning on the NFB (No-fuse
S/L2 IM
V/T2
breaker). For the operation/stop
T/L3
W/T3 MOTOR method of the motor, please refer to the
Thermal Overload
user manual of the AC Motor Drives
Relay
VFD
+ P ( ) B1 VFD Series. The braking unit will
+ P ( )
Series O.L.
detect the inner DC voltage of the AC
- N ( ) - N ( )
Braking
VFDB
Resistor motor drive when it stops the motor by
Braking BR
E.F RA
Unit deceleration. The extra regeneration
DCM RC B2
Temperature will be dissipated away rapidly by the
Switch
braking resistor in the form of heat. It
can ensure the stable deceleration
characteristic.
Inflammable solids, gases or liquids must be avoided at the
location where the braking resistor is installed. The braking
VFDB
resistor had better be installed in individual metallic box with
2015
forced air-cooling.
2022
4030 BR Connect the ground terminal to the Earth Ground. The ground
Max 5M
4045
lead must be at least the same gauge wire as leads +(P), -(N).
5055
Please install the braking resistor with forced air-cooling or
Braking Unit Braking Resistor
the equivalent when frequent deceleration braking is
performed (over 10%ED).
The ring terminals are suggested to be used for main circuit
wiring. Make sure the terminals are fastened before power on.
NOTE
Before regulating the power voltage, make
sure the power has been turned off. Please set
power voltage as the possible highest voltage
for unstable power system. Take 380VAC
power system for example. If the voltage may
be up to 410Vac, 415VAC should be regulated.
T1
ED% = T1/T0x100(%)
For DELTA's AC motor drive VFD Series,
T0
please set parameter (Over Voltage Stall
Prevention) as "close" to disable over-voltage
stall prevention, to ensure stable deceleration
characteristic. For VFDB-5055, the jumper
can only be put on the position as shown in the
following figure. Do NOT remove the jumper
to other place.
460V Model 575V Model
Braking Start-up voltage Braking Start-up voltage
AC Power AC Power
DC Bus (+(P), -(N)) Voltage DC Bus (+(P), -(N)) Voltage
Voltage Voltage
330Vdc 380Vac 660Vdc 575Vac 950Vdc
345Vdc 400Vac 690Vdc -
360Vdc 415Vac 720Vdc -
380Vdc 440Vac 760Vdc -
400Vdc 460Vac 800Vdc -
415Vdc 480Vac 830Vdc -
NOTE: Input Power With Tolerance ±10%
Input voltage setting for VFDB-5055
CHARGE ACT
CHARGE ACT ERR
Power lamp Braking lamp
Power lamp Braking lamp Fault lamp
Input Voltage Setting
------
480V 240V
575V
460V 230V
440V 220V ------
415V 210V
------
400V 200V
------
380V 190V
------
For VFDB-2015/2022
Factory setting: 230V For VFDB-5055 Series
Factory setting: 575V
The position of the jumper
CHARGE ACT
Slave
output/input
Power lamp Braking lamp
Terminal
------ 480V
575V 460V
------ 440V
------ 415V
------ 400V
SLAVE
- N ( ) + P ( ) - N ( ) + P ( ) - N ( )
------ 380V
M1 S1 M1 S1
M2 S2 M2 S2
M1: SLAVE output signal +
SLAVE SLAVE MASTER
M2: SLAVE output signal -
MASTER/SLAVE
S1: SLAVE input signal +
Setting Jumper
S2: SLAVE input signal -
B2 B1 B2 B1 B2
NOTE: Please use shielded wires
BR BR BR
O.L. O.L.
while wiring.
Alarm output terminals
All Braking Resistors & Braking Units Use in the AC Drives
Applicable
Full- load
Resistor Value
Motor
Torque Spec for Each
kg-M AC Motor Drive
HP kW
20 15 8.248 3000W 10Ω
25 18.5 10.281 4800W 8Ω
30 22 12.338 4800W 6.8Ω
40 30 16.497 6000W 5Ω
50 37 20.6 9600W 4Ω
20 15 8.248 1500W 40Ω
25 18.5 10.281 4800W 32Ω
30 22 12.338 4800W 27.2Ω
40 30 16.497 6000W 20Ω
50 37 20.6 9600W 16Ω
60 45 24.745 9600W 13.6Ω
75 55 31.11 12000W 10Ω
100 75 42.7 19200W 6.8Ω
20 15 8.248 3000W 60Ω
25 18.5 10.281 4000W 50Ω
30 22 12.338 6000W 40Ω
40 30 16.497 6000W 34Ω
50 37 20.6 7500W 25Ω
60 45 24.745 12000W 20Ω
75 55 31.11 12000W 17Ω
100 75 42.7 15000W 12.5Ω
Wiring Examples of Braking Resistors
NOTE: Before wiring, please notice equivalent resistors value shown in the column "Equivalent resistors specification for each braking
unit" in the above table to prevent damage.
230V 20HP
Thermal Overload
Relay
B1
+ P ( ) + P ( )
O.L.
VFD
VFDB
- N ( )
Series - N ( ) 2015
Braking
Unit Braking
VFD150_23_
Resistor
MASTER
B2
VFD150_23_ uses with 2PCS BR1K5W005 braking resistors in series
230V 40HP
Thermal Overload Relay
Thermal Overload Relay
+ P - N ( ) ( ) + P - N ( ) ( ) B1 + P - N ( ) ( ) B1
VFDB VFDB
O.L.
VFD
2015 2015
Series Braking
Braking
Unit
Unit
VFD300_23_
SLAVE
MASTER
B2 B2
M1 M2 Braking S1 S2
Resistor
VFD300_23_ use with two VFDB2015 braking units, and each braking unit uses with
2PCS BR1K5W005 braking resistors in series.
460V 20HP
Thermal Overload
Relay
B1
+ P ( ) + P ( )
VFDB
O.L.
VFD
4030
- N ( ) - N ( )
Series
Braking
Unit
VFD150_43_
MASTER
B2
VFD150_43_ uses with 1PCS BR1K5W040 braking resistor
460V 50HP/60HP
- Thermal Overload
Relay
B1
-
+ P ( ) + P ( )
VFDB O.L.
- VFD
4045
- N ( ) - N ( )
Series
Braking
-
Unit
Braking
VFD370_43_
Resistor
-
VFD450_43_
MASTER
B2
1. VFD370_43_ uses with two BR sets in parallel, which 4PCS BR1K2W008
braking resistors in series for each BR set.
2. VFD450_43_ uses with two BR sets in parallel, which 4PCS BR1K2W6P8
braking resistors in series for each BR set.
460V 100HP
ERR
Thermal Overload Relay
Thermal Overload Relay
Fault lamp
+ P - N ( ) ( ) + P - N ( ) ( ) B1 + P - N ( ) ( ) B1
VFDB VFDB
O.L. O.L.
VFD 4045 4045
Series Braking
Braking
Unit
Unit
VFD750_43_
SLAVE
MASTER B2 B2
Braking
M1 M2 S1 S2
Resistor
VFD750_43_ uses with two VFDB4045 braking units, and each braking unit uses with two
BR sets in parallel, which 4PCS BR1K2W6P8 braking resistors in series.
575V 25HP
Thermal Overload
Relay
B1
+ P ( ) + P ( )
VFDB
O.L.
VFD
5055
- N ( ) - N ( )
ERR Series
Braking
Unit
Fault lamp
VFD185_53_
MASTER
240V B2
230V
VFD185_53_ uses with 5 PCS BR1K0W050 braking resistors in series
220V
575V 60HP/75HP
210V
Thermal Overload
200V
Relay
190V B1
Braking
+(P) +(P)
Resistor
O.L.
VFDSeries
VFDB
-(N) -(N)
5055
Braking Unit
VFD450_53_
VFD550_53_
MASTER
B2
1. VFD450_53_ uses with two BR sets in parallel, which 5PCS BR1K2W008 braking resistors
in series for each BR set
2. VFD550_53_ uses with two BR sets in parallel, which 5PCS BR1K2W6P8 braking resistors
in series for each BR set
Min.
Braking Unit Typical
Equivalent
Braking Resistors Braking
Model VFDB Thermal
Resistor Value
Model and No. of Units Torque
No. of Units Overload
for Each AC
Used 10%ED
Used Relay Value
Motor Drive
2015 1 BR1K5W005 2 125 10Ω 30
2022 1 BR1K2W008 4 125 8Ω 35
2022 1 BR1K2W6P8 4 125 6.8Ω 40
2015 2 BR1K5W005 4 125 5Ω 30
2015 2 BR1K2W008 8 125 4Ω 30
4030 1 BR1K5W040 1 125 40Ω 15
4030 1 BR1K2W008 4 125 32Ω 15
4030 1 BR1K2W6P8 4 125 27.2Ω 20
4030 1 BR1K5W005 4 125 20Ω 30
4045 1 BR1K2W008 8 125 16Ω 40
4045 1 BR1K2W6P8 8 125 13.6Ω 50
4030 2 BR1K5W005 8 125 10Ω 30
4045 2 BR1K2W6P8 16 125 6.8Ω 50
5055 1 BR1K0W020 3 125 60Ω 15
5055 1 BR1K0W050 4 125 50Ω 15
5055 1 BR1K2W008 5 125 40Ω 20
5055 1 BR1K2W6P8 5 125 34Ω 25
5055 1 BR1K5W005 5 125 25Ω 30
5055 1 BR1K2W008 10 125 20Ω 35
5055 1 BR1K2W6P8 10 125 17Ω 45
5055 2 BR1K5W005 10 125 12.5Ω 45
230V 25HP/30HP
Thermal Overload
Relay
B1
+ P ( ) + P + P ( ) ( )
O.L.
VFD VFDB
- N ( )
Series - N - N ( ) ( ) 2022
Braking
Braking
Resistor
Unit
VFD185_23_
VFD220_23_
MASTER
B2
1. VFD185_23_ uses with two BR sets in parallel, which 2PCS BR1K2W008 braking resistors
in series for each BR set.
2. VFD220_23_ uses with two BR sets in parallel, which 2PCS BR1K2W6P8 braking resistors
in series for each BR set.
230V 50HP
Thermal Overload Relay
Thermal Overload Relay
+ P - N ( ) ( ) + P - N ( ) ( ) B1 + P - N ( ) ( ) B1
O.L. VFDB VFDB
O.L. O.L.
VFD
2015 2015
Series Braking Braking
Unit
Unit
VFD370_23_
SLAVE
MASTER B2 B2
Braking
Braking
M1 M2 S1 S2 Braking
Resistor
Resistor
Resistor
VFD370_23_ uses with two VFDB2015 braking units, and each braking unit uses with two
BR sets in parallel, which 2PCS BR1K2W008 braking resistors in series.
460V 25HP/30HP/40HP
Thermal Overload
Relay
B1
+ P ( ) + P ( )
VFDB
O.L.
VFD
4030
- N ( ) - N ( )
Series Braking
Unit
Braking
VFD185_43_
Unit
VFD220_43_
MASTER
Braking
VFD300_43_
Resistor B2
1. VFD185_43_ uses with 4PCS BR1K2W008 braking resistors in series
2. VFD220_43_ uses with 4PCS BR1K2W6P8 braking resistors in series
3. VFD300_43_ uses with 4PCS BR1K5W005 braking resistors in series
460V 75HP
Thermal Overload Relay
Thermal Overload Relay
+ P - N ( ) ( ) + P - N ( ) ( ) B1 + P - N ( ) ( ) B1
VFDB VFDB
O.L. O.L.
VFD 4030 4030
Braking
Series
Braking
Unit
Unit
VFD550_43_
SLAVE
MASTER
B2 B2
M1 M2 S1 S2
Braking Resistor
Braking Resistor
VFD550_43_ uses with two VFDB4030 braking units, and each braking unit uses with
4PCS BR1K5W005 braking resistors in series.
575V 20HP
Thermal Overload
Relay
B1
+(P) +(P) Braking
O.L.
VFDSeries Resistor
-(N) -(N) VFDB
5055
Braking Unit
VFD150_53_
Braking
MASTER
Resistor B2
VFD150_53_ uses with 3PCS BR1K0W020 braking resistors in series
575V 30HP/40HP/50HP
Thermal Overload
Relay
Braking B1 Braking
resistor Resistor
+(P) +(P)
O.L.
VFDSeries
-(N) -(N) VFDB
5055
VFD220_53_
Braking Unit
VFD300_53_
VFD370_53_
MASTER
B2
1. VFD220_53_ uses with 5PCS BR1K2W008 braking resistors in series
2. VFD300_53_ uses with 5PCS BR1K2W6P8 braking resistors in series
3. VFD370_53_ uses with 5PCS BR1K5W005 braking resistors in series
575V 100HP
Thermal Overload
Thermal Overload
Relay
Relay
+(P) -(N)
+(P) -(N) +(P) -(N) B1
B1
VFDB VFDB O.L.
O.L.
VFD 5055 5055
Series Braking Unit
Braking Unit
VFD750_53_
SLAVE
B2
MASTER
B2
M1 M2 Braking S1 S2 Braking
Resistor Resistor
VFD750_53_uses with two VFDB5055 braking units, and each braking unit uses with
5PCS BR1K5W005 braking resistors in series.