Automation Direct DURA PULSE GS-2DBU User Manual
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Automation Direct DURA PULSE GS-2DBU User Manual

Dynamic braking
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Dynamic Braking User Manual
GS-DB_UMW

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Summary of Contents for Automation Direct DURA PULSE GS-2DBU

  • Page 1 Dynamic Braking User Manual GS-DB_UMW...
  • Page 2 BLANK PAGE...

  • Page 3: Trademarks

    ~ WARNING ~ Thank you for purchasing automation equipment from Automationdirect.com©, doing business as AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or uses this equipment should read this publication (and any other relevant publications) before installing or operating the equipment.
  • Page 4 ~ AVERTISSEMENT ~ Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.com©, en faisant des affaires comme AutomationDirect. Nous tenons à ce que votre nouvel équipement d’automatisation fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications pertinentes) avant de l’installer ou de l’utiliser.
  • Page 5 ~ WARNINGS ~ dura arning lWays read this manual thoroughly before using the pulse ynamic rake dura ac m nit With the pulse otor rive : ac arning input poWer must be disconnected before performing any maintenance not connect or disconnect Wires or connectors While poWer is applied to the circuit aintenance must only be performed by a qualified technician arning here are highly sensitive...
  • Page 6 BLANK PAGE DURA W–4 Drives Dynamic Braking User Manual – 2nd Ed., Rev.C – 06/14/2019 pulse...
  • Page 7 DURA ynamic raking pUlse anUal evision istory Please include the Manual Number and the Manual Issue, both shown below, when communicating with Technical Support regarding this publication. Manual Number: GS-DB_UMW Issue: Second Edition, Revision C Issue Date: 06/14/2019 ublication istory Issue Date Description of Changes...
  • Page 8 User Manual Revision History BLANK PAGE H–2 DURA Drives Dynamic Braking User Manual – 2nd Ed., Rev.C – 06/14/2019 pulse...

  • Page 9: Table Of Contents

    GS DURA AC D ABle pUlse riveS ABle ABle ynAmiC rAkinG AnUAl onTenTS onTenTS onTenTS ABle of onTenTS anUal ontents � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � W–1 arnings and radeMarks dUra...
  • Page 10 Table of Contents 3: B � � � � � � � � � � � � � � � � � 3–1 Hapter raking oMponent onfigUration and iring Operational Electrical Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3–2 Overload Relay �...
  • Page 11 hapter hapter hapter raking verview and OmpOnent peCifiCatiOnS aBle of ontents Manual Overview � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1–2 Overview of this Publication �...

  • Page 12: Verview And C Omponent S Pecifications

    Chapter 1: Overview and Component Specifications Manual Overview Overview of this Publication The dUra Dynamic Braking User Manual describes the installation, wiring, pUlse configuration, and operation of the dynamic braking unit and braking resistors as used with GS3 and GS4 series dUra AC Drives.

  • Page 13: Special Symbols

    Chapter 1: Overview and Component Specifications Special Symbols When you see the “notepad” icon in the left-hand margin, the paragraph to its immediate right will be a special note. “ ” hen you see the exclamation mark icon in the left hand margin the paragraph to its immediate right Will be a Warning...

  • Page 14: Braking Duty Cycle

    Chapter 1: Overview and Component Specifications Braking Duty Cycle Application of a dUra dynamic braking unit should take into account how often the pUlse motor will stop or decelerate during normal operation. The Duty Cycle is the percentage of time the brake is actually used during deceleration in comparison to the time elapsed between each start or acceleration of the motor.

  • Page 15: Overload Relay

    Chapter 1: Overview and Component Specifications Overload Relay Overload Relay Purpose For safety purposes, install an external overload relay between the dynamic brake unit and the braking resistor. The thermal overload relay protects the braking resistor from damage due to frequent braking, or due to the braking unit operating excessively due to unusually high input voltage.

  • Page 16: Dynamic Braking Component Selection For Durapulse Ac Drives

    Chapter 1: Overview and Component Specifications Dynamic Braking Component Selection for DURApulse AC Drives The following table provides the selection information for the DURA dynamic braking pUlse units designed for use with GS3 and GS4 series AC drives. Braking Component Selection for GS3 DURApulse Drives GS3 AC D rive rAkinG...

  • Page 17: Braking Component Selection For Gs4 Durapulse Drives

    Chapter 1: Overview and Component Specifications Braking Component Selection for GS4 DURApulse Drives GS4 AC D rive rAkinG omponent eleCtion 125% Braking Torque @ 10% Duty Cycle*** Max Braking Torque Motor Braking Braking Total Power Unit Resistor Drive Brake Resis- Total Model Brake...

  • Page 18: Dynamic Braking Unit Specifications

    Chapter 1: Overview and Component Specifications Dynamic Braking Unit Specifications The following table provides the specifications and applications for the dUra dynamic pUlse braking units designed for use with GS3 and GS4 series AC drives. ynAmiC rAkinG peCifiCAtionS Braking Unit Part Number 1DBU 2DBU 3DBU...

  • Page 19: Dynamic Braking Resistors Specifications

    Chapter 1: Overview and Component Specifications Dynamic Braking Resistors Specifications rAkinG eSiStor peCifiCAtionS Dimension Drawing # Part Number Power (W) Resistance (Ω) Type (See chapter 2) GS-20P5-BR GS-21P0-BR GS-22P0-BR open GS-23P0-BR GS-25P0-BR GS-27P5-BR GS-2010-BR-ENC 1000 GS-2015-BR-ENC 2400 13.6 GS-2020-BR-ENC 3000 GS-2025-BR-ENC 4800 enclosed...
  • Page 20 Chapter 1: Overview and Component Specifications BLANK PAGE 1–10 DURA Drives Dynamic Braking User Manual – 2nd Ed., Rev.C – 06/14/2019 pUlse...
  • Page 21 hapter hapter hapter raking omponent nstallation and imensions able of onTenTs Installation                                             2–2 General Installation Guidelines                                     2–2 Minimum Clearances and Air Flow                                   2–2 Braking Unit Dimensions                                    2–4...

  • Page 22: Installation

    Chapter 2: Component Installation and Dimensions Installation General Installation Guidelines Improper installation of the dynamic brake unit will greatly reduce its life. Be sure to observe the following precautions when selecting a mounting location. arning ailure to observe these precautions may damage the unit and void the Warranty •...
  • Page 23 Chapter 2: Component Installation and Dimensions Minimum Clearances for Braking Resistors Mounting Individual Resistors Vertical Ceiling Mounting Horizontal Mounting 500mm [20in] Top View Side View Wall Ceiling 150mm [6in] 150mm [6in] 150mm 150mm 500mm [6in] [6in] [20in] Braking Resistor 150mm 150mm [6in] [6in]...

  • Page 24: Braking Unit Dimensions

    Chapter 2: Component Installation and Dimensions Braking Unit Dimensions A) DBU ≤ 100hp (GS-1DBU, GS-2DBU, GS-3DBU, GS-4DBU) ( Dimensions = mm [in] ) B) DBU > 100hp (GS-5DBU, GS-6DBU, GS-7DBU) ( Dimensions = mm [in] ) 2–4 DURA Drives Dynamic Braking User Manual – 2nd Ed., Rev.C – 06/14/2019 pUlse...
  • Page 25 Chapter 2: Component Installation and Dimensions Braking Resistor Dimensions raking esister imension rawing nDex Resistor Resistor Resistor Resistor GS-20P5-BR GS-41P0-BR GS-BR-080W200 10 GS-BR-1K0W4P3 11 GS-21P0-BR GS-42P0-BR GS-BR-080W750 10 GS-BR-1K0W5P1 11 GS-22P0-BR GS-43P0-BR GS-BR-200W091 10 GS-BR-1K0W016 11 GS-23P0-BR GS-45P0-BR GS-BR-200W360 10 GS-BR-1K0W020 11 GS-25P0-BR GS-47P5-BR...

  • Page 26: Braking Resistor Dimensions

    Chapter 2: Component Installation and Dimensions Braking Resistor Dimensions (continued) #2) GS-27P5-BR, GS-47P5-BR ( Dimensions = mm [in] ) GS-27P5-BR GS-47P5-BR 335 [13.19] 320 [12.60] 30 [1.18] 5.3 [0.21] 60 [2.36] #3) GS-4010-BR ( Dimensions = mm [in] ) GS-4010-BR 400 [15.75] 385 [15.16] 50 [1.97] 5.3 [0.21]...
  • Page 27 Chapter 2: Component Installation and Dimensions Braking Resistor Dimensions (continued) #5) GS-2015-BR-ENC, GS-2020-BR-ENC, GS-2040-BR-ENC ( Dimensions = in [mm] ) FRONT VIEW LEFT SIDE VIEW (4) 1/2 INCH CONDUIT K.O. THERMOSTAT (N.C.) 5 [127.0] 5 [127.0] 10 [254.0] 19 [482.6] TOP VIEW (4) 7/16 [11.11] DIA.
  • Page 28 Chapter 2: Component Installation and Dimensions Braking Resistor Dimensions (continued) #7) GS-4020-BR-ENC ( Dimensions = in [mm] ) LEFT SIDE VIEW FRONT VIEW (4) 1/2 INCH CONDUIT K.O. THERMOSTAT (N.C.) 5 [127.0] 5 [127.0] 12 [304.8] 13 [330.2] TOP VIEW (4) 11.11 [7/16] DIA. [330.2] 10.5 [266.7]...
  • Page 29 Chapter 2: Component Installation and Dimensions Braking Resistor Dimensions (continued) #9) GS-4050-BR-ENC, GS-4060-BR-ENC, GS-4100-BR-ENC ( Dimensions = in [mm] ) FRONT VIEW LEFT SIDE VIEW (4) 1/2 INCH CONDUIT K.O. THERMOSTAT (N.C.) 5 [127.0] 5 [127.0] 16 [406.4] 26.5 [673.1] TOP VIEW (4) 7/16 [11.11] DIA.
  • Page 30 Chapter 2: Component Installation and Dimensions Braking Resistor Dimensions (continued) #11) GS-BR-1K0W4P3, GS-BR-1K0W5P1, GS-BR-1K0W016, GS-BR-1K0W020, GS-BR-1K0W075, GS-BR-1K2W3P9, GS-BR-1K2W015, GS-BR-1K5W3P3, GS-BR-1K5W012, GS-BR-1K5W013, GS-BR-1K5W043  ( Dimensions = mm [in] ) 2–10 DURA Drives Dynamic Braking User Manual – 2nd Ed., Rev.C – 06/14/2019 pUlse...
  • Page 31 hapter hapter hapter raking omponent onfiguration and iring able of onTenTs Operational Electrical Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3–2 Overload Relay �...

  • Page 32: Operational Electrical Information

    Chapter 3: Component Configuration and Wiring Operational Electrical Information The DURa AC Drive and Dynamic Braking Unit will both be energized at the same time pUlse when power is applied to the drive. (Please refer to the applicable DURa AC Drive User pUlse Manual (GS3_UMW or GS4_UMW) to determine the start and stop operation of the motor.) The Dynamic Braking Unit will monitor the internal DC bus voltage of the AC drive.

  • Page 33: Dynamic Braking Unit Setup

    Chapter 3: Component Configuration and Wiring Dynamic Braking Unit Setup DBU Jumper and Wiring Terminal Locations DBU ≤ 100hp (GS-1DBU, GS-2DBU, GS-3DBU, GS-4DBU) CHARGE Slave output/input Power lamp Braking lamp Fault lamp Terminal 480V 240V 460V 230V 440V 220V 415V 210V 400V 200V...

  • Page 34: Dbu Voltage Jumper Settings

    Chapter 3: Component Configuration and Wiring DBU Voltage Jumper Settings The power source for the DURa dynamic braking unit is DC bus voltage from the +(P) pUlse and -(N) terminals of the GS drive. It is important to set the voltage selection jumper of the DURa dynamic braking unit accurately based on the input power of the GS drive before pUlse...

  • Page 35: Dbu Master/Slave Jumper Settings

    Chapter 3: Component Configuration and Wiring DBU Master/Slave Jumper Settings The MASTER/SLAVE jumper on the DURa dynamic braking unit has a factory default pUlse setting as a MASTER. If the application of the DURa AC drive requires the use of more pUlse than one DBU, then the power terminals of the multiple units are wired in parallel and the first unit is set to MASTER while all remaining units are set to SLAVE.

  • Page 36: Dynamic Braking Wiring

    Chapter 3: Component Configuration and Wiring Dynamic Braking Wiring Wiring Warnings and Notes o not proceed With any Wiring While poWer is applied to the circuit or While the drive or led( charge are on o prevent personal injury do not connect disconnect Wires or regulate the setting of the braking unit While poWer on o not touch the terminals of related Wiring and any...

  • Page 37: Maximum Wiring Distances

    Chapter 3: Component Configuration and Wiring Maximum Wiring Distances ire sizes and Wiring distances must comply With applicable electrical codes • From DURa AC Drive (GSx-xxxx) to Braking Resistor (GS-BR-xxxxxxx): 5m [16ft] pUlse • From DURa AC Drive (GSx-xxxx) to DURa Dynamic Braking Unit (GS-xDBU): 10m [33ft] pUlse pUlse...
  • Page 38 Chapter 3: Component Configuration and Wiring DBU Wiring Terminal Specifications raking iring erminal Pecifications Braking Unit Models: GS-1DBU, GS-2DBU, GS-3DBU, GS-4DBU Circuit Terminal Mark Wire Size Screw Torque 10–12 AWG 15.6 in·lb Power Input Circuit +(P), -(N) [3.5–5.5 mm [18 kg·cm] 10–12 AWG 15.6 in·lb Braking Resistor...

  • Page 39: Basic Braking Wiring Diagram

    Chapter 3: Component Configuration and Wiring Basic Braking Wiring Diagram Non Fused Breaker AC MOTOR Thermal Overload Relay* – OR – Motor grounding GS-xxxx-BR-ENC terminal Braking Resistor O.L.* Thermostat – OR – DURA PULSE Grounding N.C. Contact Braking Resistor +(P) AC Drive +(P) / DC+ resistance...

  • Page 40: Specific Braking Wiring Diagrams

    Chapter 3: Component Configuration and Wiring Specific Braking Wiring Diagrams Wiring Diagram Index for GS3 Drives gs3 ac D riVe raking iring iagram nDex 230VAC Drive and Motor Voltage 460VAC Drive and Motor Voltage Motor Braking Braking Motor Braking Braking Power Unit Resistor...
  • Page 41 Chapter 3: Component Configuration and Wiring Wiring Diagram Index for GS4 Drives gs4 ac D riVe raking iring iagram nDex 230VAC Drive and Motor Voltage 460VAC Drive and Motor Voltage Motor Braking Braking Motor Braking Braking Power Unit Resistor Power Unit Resistor Drive...
  • Page 42 Chapter 3: Component Configuration and Wiring Wiring Diagram A: [Drive + 1 Resistor] For GS3 230VAC Drives For GS3 460VAC Drives Braking Unit Braking Resistor Braking Unit Braking Resistor AC Drive AC Drive Part # Part # Part # Part # Part # Part # GS3-21P0...
  • Page 43 Chapter 3: Component Configuration and Wiring Wiring Diagram C: [Drive + (2 Series + 2 Parallel) Resistors] For GS4 460VAC Drives Braking Unit Braking Resistor AC Drive Part # Part # Part # GS4-4040 0 4 GS-BR-1K0W016 C Thermal Overload Relay AC Drive O.L.
  • Page 44 Chapter 3: Component Configuration and Wiring Wiring Diagram E: [Drive + 1 DBU + (2 Series + 2 Parallel) Resistors] For GS4 460VAC Drives Braking Unit Braking Resistor AC Drive Part # Part # Part # GS4-4050 1 GS-4DBU 4 GS-BR-1K2W015 GS4-4060 1 GS-4DBU 4 GS-BR-1K5W013 Thermal Overload Relay...
  • Page 45 Chapter 3: Component Configuration and Wiring H: [Drive + 2 DBUs + 4 Parallel Resistors/DBU] For GS4 460VAC Drives Braking Unit Braking Resistor AC Drive Part # Part # Part # GS4-4075 2 GS-3DBU 8 GS-BR-1K0W5P1 H Thermal Overload Relay Thermal Overload Relay + P - N ( ) ( )
  • Page 46 Chapter 3: Component Configuration and Wiring Wiring Diagram K: [Drive + 4 DBUs + 2 Series Resistors/DBU] For GS4 230VAC Drives Braking Unit Braking Resistor AC Drive Part # Part # Part # GS4-2100 4 GS-2DBU 8 GS-BR-1K2W3P9 K Thermal Overload Thermal Overload Thermal Overload Thermal Overload...
  • Page 47 Chapter 3: Component Configuration and Wiring Wiring Diagram N: [Drive + 1 DBU + (2 Series + 7 Parallel) Resistors/DBU] For GS4 460VAC Drives Braking Unit Braking Resistor AC Drive Part # Part # Part # GS4-4250 1 GS-7DBU 14 GS-BR-1K5W012 N Thermal Overload Relay AC Drive...
  • Page 48 Chapter 3: Component Configuration and Wiring BLANK PAGE 3–18 DURA Drives Dynamic Braking User Manual – 2nd Ed., Rev.C – 06/14/2019 pUlse...
  • Page 49 BLANK PAGE 2nd Ed., Rev.C – 06/14/2019 – DURA Drives Dynamic Braking User Manual pUlse...
  • Page 50 DURApulse Drives Dynamic Braking User Manual – 2nd Ed., Rev.C – 06/14/2019...

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