3.2 Brake unit
2008-09-10
] Wiring Warnings
-(N)
DC -
DC -
DC -
DC+
+(P)
DC+
DC+
„
„
„
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.
M1
M2
S1
S2
M1
M2
S1
S2
VFD
Series
M
5011669601-1CBU
S
S
CHARGE ACT
OC
OH
„
„
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.
B1 B2
BR
B1 B2
BR
B1 B2
BR
VFDB 4132 Series Brake Modules
VFDB4132
O.L.
O.L.
O.L.
The Position of the Jumper
Instruction Sheet
M
MASTER/SLAVE
Setting Jumper
S
„
„
„
„
„
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.
Input Voltage Setting
X Preface
480V
460V
440V
415V
400V
380V
M1: SLAVE output signal +
M2: SLAVE output signal -
S1: SLAVE input signal +
S2: SLAVE input signal -
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
NOTE: Please use shielded
wires while wiring.
[ Internal Components and Terminals
4.1 Internal Components
M1
S1
M2
RA RC
S2
SLAVE output/input terminal
Alarm output terminals
Wiring distance
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.
VFDB
series
VFD series
BR
Max 5M
Brake Resistor
Max 8M
AC Motor Drive
Brake Unit
^ Definition for the Brake Usage ED%
100%
Y Specifications
` Brake Resistors/Units for Delta VFD
VFDB 4132 Brake Units
Specification
Max. Motor Capacity (kW)
460V Series
132
AC Motor Drives Series
T1
ED% = T1/T0x100(%)
Brake Time
4.2 Wire Gauge for Terminals
Min.
Typical
Thermal
Overload
Relay
T0
Applicable
Motor
Resistor Value Brake Unit
Spec. for Each Part No.
AC Motor
Drive
Max. Discharge Current (A) 10%ED
240
Cycle Time
Wire Gauge AWG
Full-load
Torque
kg-M
Brake Resistors Brake
Equivalent
Resistor Value
for Each AC
Motor Drive
Circuit
Terminals
DC+, DC-
Screw
M8
Torque
(mm2)
4~6AWG
Torque
Part No. and
Continuous Discharge Current (A)
Braking Start-up Voltage (DC)
75
and
Quantity
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.
Quantity
10%ED
Power Input
Circuit
Brake
30 kgf-cm
(26 in-lbf)
30 kgf-cm
(26 in-lbf)
HP kW
Value
(13.3~21.2mm2)
4~6AWG
618/642/667/690/725/750±6V
120 90
150 110
175 132
215 160
250 185
52.5
61
13500W 5Ω 4132
21600W 4Ω 4132
21600W 4Ω 4132
21600W 3.4Ω 4132
27000W 2.5Ω 4132
1
1
1
1
2
2
BR1K5W005
9
120
5Ω
4Ω
110A
135A
135A
160A
220A
220A
Input
Rating
B1, B2
M8
Resistor
(13.3~21.2mm2)
18~20AWG
DC Voltage
480-750VDC
BR1K2W008 18 120
BR1K2W008 18 100
73.5
89
4Ω
Output M1, M2
Input S1, S2
3.4Ω
Min. Equivalent Resistor for Each Brake Unit
Heat Sink Overheat Temperature
SLAVE
Circuit
4 kgf-cm
(3 in-lbf)
(0.8~0.5mm2)
(With shielded wires)
18~20AWG
BR1K2W6P8 18
BR1K5W005 18 115
BR1K5W005 18 96
97
3.4Ω
2.5Ω
2.5Ω
M2
M2
Temperature exceeds +95 oC (203oF)
Relay contact 3A250VAC/30VDC
(RA, RC)
ON until the bus (P-N) voltage is
below 50VDC
_ 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.
103
Fault
Circuit
4 kgf-cm
(3 in-lbf)
300 220 122.5 27000W 2.5Ω 4132
Alarm Output for Overheat
RA, RC
(0.8~0.5mm2)
Power Charge Display
Over-current Protection Level
Installation Location
a Examples
\ Basic Wiring Diagram
320A
Indoor (no corrosive gases, metallic
dust)
NOTE
NFB
MC
Motor
IM
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.
Operating Temperature
Storage Temperature
Humidity
-10oC~+50oC (14oF to 122oF)
-20oC ~+60oC (-4oF to 140oF)
Less than 90% Non-condensing
9.8m/s2 (1G) under 20Hz / 2m/s2
(0.2G) at 20~50Hz
R/L1
S/L2
T/L3
R/L1
S/L2
T/L3
R/L1
S/L2
T/L3
„
„
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.
Thermal
Overload
Relay
460V 120HP
O.L.
VFD Series
Thermal Overload Relay
B1
Vibration
MC
+(P)
DC+
B1
O.L.
BR
+(P)
-(N)
DC+
DC-
DC- VFDB
-(N)
E.F
Mechanical Configuration
Wall-mounted enclosed type IP10
O.L.
SA
BR
BR
BR
BR
BR
BR
BR
BR
BR
VFD
Series
VFDB
4132
Brake Unit
Brake
Unit
RA
RC
Surge Absorber
Brake
Resistor
DCM
B2
Brake
Resistor
Thermal Overload
Relay or Temperature switch
Brake Resistors
Table 1: The Selection of AC Power Voltage and Voltage Setting
M
VFD900_43_
Model no.
Specification
1500W 5.0Ω
1200W 6.8Ω
1200W 8.0Ω
1500W 40Ω
1000W 50Ω
1000W 75Ω
Temperature Switch
Brake Start-up voltage
AC Power Voltage
B2
BR1K5W005
BR1K2W6P8
BR1K2W008
BR1K5W040
BR1K0W050
BR1K0W075
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 DC- to the neutral point of power system.
DC Bus (DC+, DC-) Voltage
VFD900_43_ uses with 3 BR sets in parallel, which 3PCS 1K5W005 brake resistors
are connected in series.
380VAC (460V Mode)
400VAC (460V Mode)
415VAC (460V Mode)
440VAC (460V Mode)
460VAC (460V Mode)
480VAC (460V Mode)
618VDC
642VDC
667VDC
690VDC
725VDC
750VDC
460V 150HP, 175HP, 215HP
NOTE
Therm al Over load Relay
B1
„
„
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.
+(P)
-( N)
DC+
DC-
BR
BR
BR
BR
BR BR BR
O.L.
VFD
Ser ies
VFDB
4132
Bra ke Unit
BR
BR
BR BR BR
Bra ke
Resistor
NOTE: Input Power With Tolerance ±10%
VFD1100_ 43_
VFD13 20_43_
VFD16 00_43_
Z Dimensions
3.1 Brake resistor
M
BR
BR
BR
BR BR BR
Input voltage setting for VFDB 4132
B2
CHARGE
Power lamp
OC
OH
ACT
VFD1100_ 43_ uses with 6 BR sets in p arallel, which 3PCS 1K2W 008 bra ke r esisto rs
are con necte d in serie s.
„
„
Please refer to the specification of the thermal overload relay.
Brake lamp
Over-current Overheat
lamp lamp
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.
VFD13 20_43_ use s with 6 BR sets in par allel, wh ich 3PCS 1 K2W00 8 brake resistors
are con necte d in serie s.
Input Voltage Setting
480V
VFD16 00_43_ use s with 6 BR sets in pa rallel, wh ich 3PCS 1K2W6 P8 brake re sistors
are con necte d in serie s.
460V
For VFDB4132
Factory setting: 440V 440V
460V 250HP, 300HP
415V
400V
380V
Thermal Overload Relay
Thermal Overload Relay
DC+ DC-
DC+ DC-
„
„
+ (P) -(N)
B1
B1
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.
BR BR BR
BR BR BR
BR BR BR
BR BR BR
BR BR BR
BR BR BR
VFDB
4132
VFDB
4132
O.L.
O.L.
Brake
Resistor
VFD
Series
Brak e Unit
Brake Unit
M
VFD1850_43_
VFD2200_43_
B2
S1 S2
B2
M1 M2
S
Brak e
Resistor
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.
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.
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.
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