Delta Electronics VFDB 4132 Series Network Card User Manual


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2008-09-10
5011669601-1CBU
VFDB 4132 Series Brake Modules
Instruction Sheet
X
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.
Y 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
Output
Rating
Braking Start-up Voltage (DC)
618/642/667/690/725/750±6V
Input
Rating
DC Voltage 480-750VDC
Min. Equivalent Resistor for Each Brake Unit
3.4Ω
Heat Sink Overheat Temperature Temperature exceeds +95
o
C (203
o
F)
Alarm Output for Overheat
Relay contact 3A250VAC/30VDC
(RA, RC)
Power Charge Display
ON until the bus (P-N) voltage is
below 50VDC
Protection
Over-current Protection Level 320A
Installation Location
Indoor (no corrosive gases, metallic
dust)
Operating Temperature -10
o
C~+50
o
C (14
o
F to 122
o
F)
Storage Temperature -20
o
C ~+60
o
C (-4
o
F to 140
o
F)
Humidity Less than 90% Non-condensing
Environment
Vibration
9.8m/s
2
(1G) under 20Hz / 2m/s
2
(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
Z Dimensions
3.1 Brake resistor
3.2 Brake unit
VFDB4132
CHARGE ACT OC OH
[ Internal Components and Terminals
4.1 Internal Components
4.2 Wire Gauge for Terminals
Circuit Terminals
Wire Gauge AWG
(mm
2
)
Screw Torque
Power Input
Circuit
DC+, DC-
4~6AWG
(13.3~21.2mm
2
)
M8
30 kgf-cm
(26 in-lbf)
Brake
Resistor
B1, B2
4~6AWG
(13.3~21.2mm
2
)
M8
30 kgf-cm
(26 in-lbf)
Output M1, M2
SLAVE
Circuit
Input S1, S2
18~20AWG
(0.8~0.5mm
2
)
(With shielded wires)
M2
4 kgf-cm
(3 in-lbf)
Fault
Circuit
RA, RC
18~20AWG
(0.8~0.5mm
2
)
M2
4 kgf-cm
(3 in-lbf)
\ Basic Wiring Diagram
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: wire terminal DC- to the neutral point of power system.
DO NOT
NFB
R/L1
MC
S/L2
T/L3
O.L.
MC
SA
Thermal Overload
Relay or Temperature switch
Surge Absorber
R/L1
S/L2
T/L3
VFD Series
R/L1
S/L2
T/L3
IM
+(P)
-(N)
E.F
DCM
Motor
DC+
DC-
RA
RC
V
FDB
Brake
Unit
B1
B2
BR
O.L.
Thermal
Overload
Relay
Brake
Resistor
Temperature Switch
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
Max 5M
BR
VFDB
series
AC Motor Drive
Brake Unit
Brake Resistor
^ Definition for the Brake Usage ED%
100%
T0
T1
Brake Time
Cycle Time
ED% = T1/T0x100(%)
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)
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
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 DELTA’s 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
Brake Start-up voltage
DC Bus (DC+, DC-) Voltage
380VAC (460V Mode) 618VDC
400VAC (460V Mode) 642VDC
415VAC (460V Mode) 667VDC
440VAC (460V Mode) 690VDC
460VAC (460V Mode) 725VDC
480VAC (460V Mode) 750VDC
NOTE: Input Power With Tolerance
±
10%
CHARGE
ACT
OC
480V
460V
440V
415V
400V
380V
OH
Power lamp
Brake lamp
Over-current
lamp
Overheat
lamp
Input Voltage Setting
For VFDB4132
Factory setting: 440V
Input voltage setting for VFDB 4132
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.
+P( )
VFD
Series
M1
M2
M
B1
O.L.
DC+
BR
-(N) DC -
B2
M1
M2
B1
O.L.
DC+
BR
DC -
B2
S1
S2
S
B1
O.L.
DC+
BR
DC -
B2
S1
S2
S
480V
460V
440V
415V
400V
380V
Input Voltage Setting
M
S
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.
SLAVE output/input terminal
Alarm output terminals
M2
M1
S2
S1
RA RC
The Position of the Jumper
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.
` Brake Resistors/Units for Delta VFD
AC Motor Drives Series
Applicable
Motor
Voltage
HP kW
Full-load
Torque
kg-M
Resistor Value
Spec. for Each
AC Motor
Drive
Brake Unit
Part No.
and
Quantity
Brake Resistors
Part No. and
Quantity
Brake
Torque
10%ED
Min.
Equivalent
Resistor Value
for Each AC
Motor Drive
Typical
Thermal
Overload
Relay
Value
120 90 52.5 13500W 5Ω 4132 1 BR1K5W005 9 120 5Ω 110A
150 110 61 21600W 4Ω 4132 1 BR1K2W008 18 120 4Ω 135A
175 132 73.5 21600W 4Ω 4132 1 BR1K2W008 18 100 4Ω 135A
215 160 89 21600W 3.4Ω 4132 1 BR1K2W6P8 18 97 3.4Ω 160A
250 185 103 27000W 2.5Ω 4132 2 BR1K5W005 18 115 2.5Ω 220A
460V
300 220 122.5 27000W 2.5Ω 4132 2 BR1K5W005 18 96 2.5Ω 220A
a 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
O.L.
B1
B2
VFDB
4132
VFD900_43_
VFD900_43_ uses with 3 BR sets in parallel, which 3PCS 1K5W005 brake resistors
are connected in series.
VFD
Series
+(P)
-(N)
DC+
DC-
BR
BR
BR
BR
BR
BR
BR
BR
BR
BR
BR
BR
M
BR
BR
BR
BR
BR
BR
Brake Unit
Brake
Resistor
Thermal Overload Rela
y
460V 150HP, 175HP, 215HP
O.L.
B1
B2
VFDB
4132
VFD1100_43_
VFD1320_43_
VFD1600_43_
VFD1100_43_ uses with 6 BR sets in parallel, which 3PCS 1K2W008 brake resistors
are connected in series.
VFD
Series
+(P)
-(N)
DC+
DC-
BRBR
BRBR
BRBR
M
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
BRBR
Brake Unit
Thermal Overload Relay
Brake
Resistor
VFD1600_43_uses with 6 BR sets in parallel, which 3PCS 1K2W6P8 brake resistors
are connected in series.
1K2W008 brake resistors
are connected in series.
VFD1320_43_ uses with 6 BR sets in parallel, which 3PCS
460V 250HP, 300HP
VFD
Series
+(P) -(N)
VFD1850_43_
VFD2200_43_
VFD1850_43_ uses with 2 VFDB4132 brake units and each brake unit uses with
3 BR sets in parallel, which 3PCS 1K5W005 brake resistors are connected in series.
VFD2200_43_ uses with 2 VFDB4132 brake units and each brake unit uses with
3 BR sets in parallel, which 3PCS1K5W005 brake resistors are connected in series.
O.L.
B1
B2
VFDB
4132
DC+ DC-
M
M1 M2
BR
BR
BR
BR
BR
BR
BR
BR
BR
O.L.
B1
B2
VFDB
4132
DC+ DC-
BR
BR
BR
BR
BR
BR
BR
BR
BR
S1 S2
S
Brake Unit
Thermal Overload Relay
Thermal Overload Relay
Brake Unit
Brake
Resistor
Brak e
Resistor