2008-09-10

3.2 Brake unit

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 AC Motor Drive Max 8M VFDB series Brake Unit BR Max 5M Brake Resistor

+(P)

-(N)

DC+ DC M1 M2 M

DC+ DC S1 S2 M1 M2 S

DC+ DC S1 S2 S B1 O.L. B2
BR

5011669601-1CBU

VFD Series

VFDB 4132 Series Brake Modules Instruction Sheet

Preface
Thank you for choosing DELTAs 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.

CHARGE ACT

OC

OH

B1 O.L.

B2
BR

B1 O.L.

B2
BR

VFDB4132

The Position of the Jumper

M S Input Voltage Setting
480V 460V 440V 415V 400V 380V

MASTER/SLAVE Setting Jumper M1: SLAVE output signal + M2: SLAVE output signal S1: SLAVE input signal + S2: SLAVE input signal NOTE: Please use shielded wires while wiring.

Internal Components and Terminals

4.1 Internal Components

M1 M2 S1 S2 SLAVE output/input terminal

RA RC Alarm output terminals

NOTE
Please make sure that power is OFF before setting the jumper. The steps for jumper setting: Step 1. Remove the top cover. 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 screws for each side). Step 4. After removing the power line of the fan, pull out the heat sink slowly until the jumper can be seen. Then the jumper can be set.

Definition for the Brake Usage ED%

100%

Specifications
VFDB 4132 Brake Units Specification Max. Motor Capacity (kW) Max. Discharge Current (A) 10%ED Output Rating Continuous Discharge Current (A) Braking Start-up Voltage (DC) 460V Series 132 240 75 618/642/667/690/725/750 6V

4.2 Wire Gauge for Terminals

Wire Gauge AWG (mm2) 4~6AWG Power Input DC+, DCCircuit (13.3~21.2mm2) Brake 4~6AWG B1, B2 Resistor (13.3~21.2mm2) Output M1, M2 18~20AWG SLAVE (0.8~0.5mm2) Circuit Input S1, S2 (With shielded wires) Fault 18~20AWG RA, RC Circuit (0.8~0.5mm2) Circuit Terminals Screw M8 M8 M2 M2 Torque 30 kgf-cm (26 in-lbf) 30 kgf-cm (26 in-lbf) 4 kgf-cm (3 in-lbf) 4 kgf-cm (3 in-lbf)

Brake Time

T1 T0

ED% = T1/T0x100(%)

Brake Resistors/Units for Delta VFD AC Motor Drives Series

Min. Typical Applicable Resistor Value Brake Unit Full-load Brake Resistors Brake Thermal Equivalent Motor Spec. for Each Part No. Torque Torque Resistor Value Overload Part No. and AC Motor and Relay kg-M Quantity 10%ED for Each AC HP kW Drive Quantity Value Motor Drive 120 90 52.5 13500W 5 4132 1 BR1K5W005 9 120 5 110A 150 110 61 21600W 4 4132 1 BR1K2W008 18 120 4 135A 175 132 73.5 21600W 4 4132 1 BR1K2W008 18 100 4 135A 215 160 89 21600W 3.4 4132 1 BR1K2W6P8 18 97 3.4 160A 250 185 103 27000W 2.5 4132 2 BR1K5W005 18 115 2.5 220A 300 220 122.5 27000W 2.5 4132 2 BR1K5W005 18 96 2.5 220A Voltage 460V

Cycle Time

Input DC Voltage 480-750VDC Rating 3.4 Min. Equivalent Resistor for Each Brake Unit Heat Sink Overheat Temperature Temperature exceeds +95 oC (203oF) 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) Operating Temperature -10oC~+50oC (14oF to 122oF) Storage Temperature -20oC ~+60oC (-4oF to 140oF) Humidity Less than 90% Non-condensing 9.8m/s2 (1G) under 20Hz / 2m/s2 Vibration (0.2G) at 20~50Hz Mechanical Configuration Wall-mounted enclosed type IP10 Protection Environment Brake Resistors Model no. BR1K5W005 BR1K2W6P8 BR1K2W008 BR1K5W040 BR1K0W050 BR1K0W075 Specification 1500W 5.0 1200W 6.8 1200W 8.0 1500W 40 1000W 50 1000W 75

The definition of the brake usage ED(%) is to assure having enough time for the brake unit and brake resistor to dissipate the heat generated by brake. When the brake resistor heats up, the resistance would increase with temperature, and brake torque would decrease accordingly.

The Voltage Settings

1. Voltage setting: the power source of the brake unit is DC voltage from +(P), -(N)

Basic Wiring Diagram

NFB R/L1 S/L2 T/L3 O.L. MC SA Surge Absorber Thermal O verload Relay or Tem perature switch MC R/L1 S/L2 T/L3 R/L1 S/L2 T/L3 Motor IM Thermal Overload Relay O.L. BR Brake Resistor Temperature Sw itch

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.

Examples
NOTE
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
Thermal O verloa d Rel ay B1 +(P) DC+ VFDB DC- 4132 Bra ke Uni t
M

NOTE
Before changing the setting of 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 set. For DELTAs AC motor drive (VFD Series), please set parameter (Over Voltage Stall Prevention) as close to disable over-voltage stall prevention, to ensure stable deceleration characteristic. Table 1: The Selection of AC Power Voltage and Voltage Setting AC Power Voltage 380VAC (460V Mode) 400VAC (460V Mode) 415VAC (460V Mode) 440VAC (460V Mode) 460VAC (460V Mode) 480VAC (460V Mode) Brake Start-up voltage DC Bus (DC+, DC-) Voltage 618VDC 642VDC 667VDC 690VDC 725VDC 750VDC NOTE: Input Power With Tolerance
CHARGE ACT OC OH

VFD Series +(P) -(N) E.F DCM

DC+ B1 DC- VFDB RA Brake Unit RC B2

VFD Series

O.L.

BR

-( N)

BR BR BR

BR BR BR

VFD900_43_

BR Bra ke Resisto r BR B2

Note 1: When the AC motor drive is used with DC reactor, please refer to the wiring diagram in the AC drive user manual for wiring terminal DC+ of brake unit. Note 2: DO NOT wire terminal D C- to the neutral point of power system.

VFD9 00_43 _ uses wi th 3 BR sets in pa rall el, which 3P CS 1K 5W00 5 brake r esistors ar e co nnected in ser ies.

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.

460V 150HP, 175HP, 215HP

T herm al Ov er load Rel ay + (P) VFD S er ies -( N) D C+ B1 O. L. BR BR BR BR BR BR Bra ke BR BR BR BR BR BR R esi stor BR BR BR BR BR BR VF DB D C4132 B ra ke U nit M B2

Dimensions
3.1 Brake resistor

10%

Input voltage setting for VFDB 4132

V F D1100_ 43_ V F D13 20_43_ V F D16 00_43_

Input Voltage Setting

Power lamp Brake lamp Over-current Overheat lamp lamp

480V 460V For VFDB 4132 Factory setting: 440V 440V 415V 400V 380V

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. VF D13 20_43_ use s w it h 6 BR s ets in par all el, wh ic h 3PCS 1 K2W00 8 brak e res is tors are c on nec te d in s erie s. V F 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 are c on nec te d in s erie s.

460V 250HP, 300HP

Thermal O verload Rel ay DC+ DCThermal O verload Rel ay DC+ DC- B1 BR BR BR BR BR BR VFDB VFDB O.L . O.L . Brak e 4132 4132 BR BR BR Resis tor BR BR BR Brak e Unit Brak e Unit M BR BR BR BR BR BR B2 B2 S Brak e M1 M2 S1 S2 Resis tor B1

2. MASTER (M) /SLAVE (S) setting: the factory setting is M. The S setting is

+ (P) -( N) VF D Ser ies VFD1850_43_ VFD2200_43_

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.

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 .