electrical automation

Installation & Operating Manual

Dynamic Braking Unit

Installation & Operating Manual

5/07 MN763DB

Any trademarks used in this manual are the property of their respective owners.

Contents I

Table of Contents

Dynamic Braking Unit Installation & Operating Manual1.1 Getting Assistance from Baldor .......................................................................... 11.2 Safety Notice ...................................................................................................... 11.3 Introduction to Dynamic Braking Unit ................................................................. 31.4 Nomenclature ..................................................................................................... 51.5 Specifications ..................................................................................................... 51.6 Installation .......................................................................................................... 61.7 Terminal Configuration ....................................................................................... 81.8 Terminal Wiring .................................................................................................. 81.9 Basic Wiring........................................................................................................ 91.10 Master / Slave Operation .................................................................................. 101.11 Combination of DB Units Corresponding to Drive Capacity ............................. 121.12 Display LED and Fault Reset ........................................................................... 151.13 Dimensions ....................................................................................................... 16

II Dynamic Braking Unit Installation & Operating Manual

1

DYNAMIC BRAKING UNITInstallation & Operating Manual

1.1 Getting Assistance from Baldor

For technical assistance, call your local Baldor District Sales Office. Before calling, please review the troubleshooting section of this manual and check the Baldor Drives website at http://vsdrives.baldor.com for additional information. When you call technical support, you will be asked for the drive model number or catalog number and this instruction manual number.

1.2 Safety Notice

This equipment contains voltages that my be as high as 1000 volts! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the startup procedure or troubleshoot this equipment.

Precautions: Classifications of cautionary statements

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WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

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CAUTION: Indicates a potentially hazardous situation which, if not avoided, could result in damage to property.

Precautions

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WARNING: This manual is intended as a guide for proper installation. Baldor Electric Company cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise, for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment exists if codes are ignored during installation.

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WARNING: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

2 Dynamic Braking Unit

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WARNING: Do not touch any circuit board, power device or electrical connection before you first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

!!

WARNING: Be sure that you are completely familiar with the safe operation of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

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WARNING: Do not use motor overload relays with an automatic reset feature. These are dangerous since the process may injure someone if a sudden or unexpected automatic restart occurs. If manual reset relays are not available, disable the automatic restart feature using external control wiring.

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WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury.

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WARNING: Do not remove cover for at least ten (10) minutes after AC power is disconnected to allow capacitors to discharge. Dangerous voltages are present inside the equipment. Electrical shock can cause serious or fatal injury.

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WARNING: Motor circuit may have high voltage present whenever AC power is applied, even when motor is not rotating. Electrical shock can cause serious or fatal injury.

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WARNING: Dynamic brake resistors may generate enough heat to ignite combustible materials. Keep all combustible materials and flammable vapors away from brake resistors.

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WARNING: Make sure the input power is off before wiring. Failure to observe this prediction could result in bodily injury.

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WARNING: You must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation can result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

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WARNING: This unit is connected to a drive that contains high voltage capacitors that take time to discharge after removal of main supply. Before working on the unit, ensure isolation of main supply from line inputs. Wait ten (10) minutes for capacitors to discharge to safe voltage levels. Failure to observe this precaution could result in severe bodily injury or loss of life.

3

1.3 Introduction to Dynamic Braking Unit

This section describes the safety instructions that must be followed when installing, operating, and servicing the Dynamic Braking Unit (DBU). Read this manual completely before installing. The unit contains high voltage that can cause electric shock resulting in personal injury or loss of life.

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WARNING: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait ten (10) minutes for the DC Bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

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WARNING: Be sure to remove the drive power input while performing maintenance. Failure to observe this precaution could result in severe bodily injury or loss of life.

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WARNING: Be sure to perform maintenance only after checking that the bus has discharged to less than 30 VDC. The bus capacitors may retain a charge after power is turned off. Failure to observe this precaution could result in severe bodily injury or loss of life.

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CAUTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

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CAUTION: Apply the rated torque to terminal screws. Loose screws can cause short circuit and malfunction. Tightening the screws too much can damage the terminals and cause short circuit and malfunction.

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CAUTION: Do not leave wire fragments inside the unit. Wire fragments can cause faults, breakdowns and malfunctions.

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WARNING: Do not remove the cover of the unit while power is applied or the unit is in operation; otherwise electric shock could occur.

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WARNING: Do not run the Dynamic Braking Unit (DBU) with the front cover removed. Failure to comply could result in electric shock due to high voltage terminals or charged capacitor exposure.

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WARNING: Do not remove the cover except for periodic inspections or wiring, even if the input power is is not applied; otherwise, you may contact live parts causing an electric shock.

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WARNING: Wiring and periodic inspections should be performed at least 10 minutes after disconnecting the input power and after checking the DC link voltage is discharged with a meter (below DC 30V); otherwise, you may get an electric shock.


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WARNING: Operate the switches with dry hands; otherwise, you may get an electric shock.

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WARNING: Do not use wire or cable with damaged insulation; otherwise, you may get an electric shock.

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WARNING: Do not subject wires and cables to scratches, excessive stress, heavy loads or pinching; otherwise, you may get an electric shock.

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CAUTION: Install the DB unit on a non-flammable surface. Do not place flammable material nearby; otherwise; fire could occur.

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CAUTION: Disconnect the input power if the inverter or DB unit gets damaged; otherwise, the result could be a secondary accident and fire.

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CAUTION: Do not connect the braking resistor directly to the DC terminal (P/B1, N) of the DB unit; otherwise, fire could occur.

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CAUTION: Do not touch DB unit, Inverter and the resistor right after the power is disconnected. The resistor may still be hot.

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CAUTION: Do not allow lint, paper, wood chips, dust, metallic chips or other foreign matter into the DB unit; otherwise, fire or accident could occur.

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CAUTION: Do not apply power to a damaged inverter or to DB unit with missing parts even if the installation is complete; otherwise, electric shock or fire could occur.

5

1.4 Nomenclature

1.5 Specifications

1.5.1 200V Class

VS1PF - T 4 20

20 10 ~ 20HP30 25 ~ 30HP50 40 ~ 50HP75 60 ~ 75HP100 100HP

2 200 ~ 230V4 400 ~ 460V

T

Dynamic Braking

Transistor Unit

VS1PF Family

HP Range

Drive Input Voltage

Product Type

Product Family

VS1PF-T220 VS1PF-T230 VS1PF-T250 VS1PF-T275

Max. DC Input Voltage DC 400V Applicable Drive

Capacity [HP] 10 ~ 20 25 ~ 30 40 ~ 50 60 ~ 75

Wattage 3.2 [KW] 4.8 [KW] 6.4 [KW] 9.6 [KW] Braking Resistor Minimum

Resistance 8.5 [Ω] 5.7 [Ω] 4.2 [Ω] 2.8 [Ω]

Spec.

Model


1.5.2 400V Class

1.5.3 General Specifications

1.6 Installation

1.6.1 Environmental Conditions

1.6.1.1 Do not mount the unit in direct sunlight. Isolate the unit from excessive vibration.

1.6.1.2 Protect from moisture, dust, metallic particles, corrosive gases and liquid. Install the units on a smooth non-flammable surface.

1.6.1.3 When installing multiple units in a panel, panel layout and cooling requirements must be analysed for proper heat dissapation.

See the following examples to aid in panel and cooling design.

VS1PF-T420 VS1PF-T430 VS1PF-T450 VS1PF-T475 VS1PF-T4100

Max. DC Input Voltage DC 800V Applicable Drive

Capacity [HP] 10 - 20 25 -30 40 - 50 60 - 75 100

Wattage 3.2 [KW] 4.8 [KW] 6.4 [KW] 9.6 [KW] 12.8 [KW] Braking Resistor Minimum

Resistance 33.9 [Ω] 22.8 [Ω] 16.9 [Ω] 11.4 [Ω] 8.4 [Ω]

Spec. Model

Average Braking Torque 100% Maximum Duty Cycle 10% Parallel Connection Connectable up to 3 units in parallel Maximum On Time 6 seconds Output Signal Heat Sink Overheat, Fuse Open, OC

Trip Protection Heat Sink Overheat Protection, Over-

Current Protection, Output Short Circuit Protection

Ambient Temperature -10°C ~ 40°C

Humidity Less Than 90 % RH Max. (Non-Condensing)

Maximum Altitude 1,000m above sea level

Cooling Method Natural Convection

Environmental Conditions

Location No Corrosive Gas, Combustible Gas, Oil mist or Dust

7

Fan location in a panel

1.6.2 Mounting

The units must be mounted vertically with sufficient clearance (horizontally and vertically) to adjacent equipment.

Installing units in a panel

DB Unit or DB Resistor



Correct Incorrect



Cooling fan



Air flow

Correct Incorrect

DBU

over 2”

over 4”

Over 4”

over 2”


1.7 Terminal Configuration

1.7.1 Power Terminals

1.7.2 Control Terminals

1.8 Terminal Wiring

VS1PF drives are supplied with two different power terminal configurations based upon the HP rating and whether or not the drive has a built-in DC reactor. Make sure the connections are made according to the proper configuration.

Terminal Description

P DC (+) input. Connect to “P2” or “P” terminal of the drive

N DC (-) input. Connect to “N” terminal of the drive

G Ground Terminal

B1 Connect to braking resistor

B2 Connect to braking resistor

Terminal Function

IN+ Slave turn on signal input (when “Slave Mode” selected)

IN- Slave turn on signal input (when “Slave Mode” selected)

OUT+ Slave turn on signal output (when “Master Mode” selected)

OUT- Slave turn on signal output (when “Master Mode” selected)

30A

Fault signal output

30A : Normal open contact

30B : Normal close contact

30C : Common terminal

9

1.8.1 Wiring Drive, DB unit and DB resistor

1.8.2 Wiring Drive, DB unit, DB resistor and DC reactor

1.9 Basic Wiring

1.9.1 Single Unit Operation

• Mount DB unit within 15’ of the drive and the DB resistor within 15’ of the DB unit. Make connections with twisted pair wire.

• Be sure to connect the “G” terminal of both the drive and DB unit to ground.

DB Unit

DB Resistor

Drive

Common bus bar

DB Unit

DB Resistor

Drive

MCCB Drive

R

S

T

V

U

W

M Motor

P2

N

G

P1

AC Input

Power

N

P

G 30C

30B

B1 B2 B2 B1 15’ max.

TH1

TH2

DB Unit DB Resistor

Twisted pair

Twisted pair

15’ max.

30A


• Wire Size: Use copper conductors only

1.10 Master / Slave Operation

When the application requires the parallel operation of two braking units, one unit must be set up as a “Master” and the other as a “Slave”. Note that when the application is for a single braking unit, it must be set up as a “Master”, which is the factory default.

1.10.1 Master Setup

Set the Switch JP1 per the figure below.

1.10.2 Slave Setup

Set the Switch JP1 per the figure below.

1.10.3 Connection between Master and Slave

• Set one DB unit to “Master” and the other to “Slave”.

• Connect “OUT+” terminal of Master to “IN+” terminal of Slave and “OUT-” terminal of Master to “IN-” terminal of Slave.

1.10.4 Connecting 3 DB Units

• Set one DB unit to “Master” and other two units to “Slave”.

Wire Size AWG [mm2]VS1PF-T220 10 [5.5]VS1PF-T230 8 [8.0]VS1PF-T250 6 [14.0]VS1PF-T275 6 [14.0]VS1PF-T420 10 [5.5]VS1PF-T430 10 [5.5]VS1PF-T450 10 [5.5]VS1PF-T475 8 [8.0]VS1PF-T4100 6 [14.0]

DB Unit

230V

460V

11

• Connect “OUT+” terminal of Master to “IN+” terminal of both Slaves and “OUT-” terminal of Master to “IN-” terminal of both Slaves.

OUT-

OUT+

IN -

IN+

OUT-

OUT+

IN -

IN+ J13

MASTER SLAVE

3.2 feet (1m) max. (Twist)

OUT-

OUT+

IN -

IN+ J13

SLAVE

3.28 feet (1m) max. (Twist)


1.10.5 Master/Slave Operation

1.11 Combination of DB Units Corresponding to Drive Capacity

1.11.1 Combination of Braking Units

• 200V Class

• 400V Class

MCCB

R

S

T

V

U

W

IM Motor

P2

G

P1

AC Input

Power

P

B1 B2 B2 B1 16.4 feet (5M) max.

TH1

TH2

MASTER DB DB Resistor

N

P

G

B1 B2 B2 B1

TH1

TH2

SLAVE DB Unit DB Resistor

IN+

IN-

OUT

OUT

6.56 feet (2M) max.

16.4 feet (5M) max.

Applicable Drive [HP] 10 - 20 25 - 30 40 - 50 60 -75

Braking Unit VS1PF-T220 VS1PFT-T230 VS1PF-T250 VS1PF-T275

Braking Resistor 3.2KW 8.5Ω 4.8KW 5.7Ω 6.4KW 4.2Ω 9.6KW 2.8Ω

Applicable Motor [KW]

15 20 25 30 40 50 60 75

Applicable Drive [HP] 15 20 25 30 40 50

Braking Unit VS1PF-T420 VS1PF-T430 VS1PF-T450

Braking Resistor 3.2KW 33.9Ω 4.8KW 22.8Ω 6.4KW 16.9Ω


15 20 25 30 40 50

13

Applicable Drive [HP] 60 75 100 125 - 200 300

Braking Unit VS1PF-T475 VS1PF-T4100

VS1PF-T4100Qty.2

VS1PF-T4100 Qty. 3

Braking Resistor 9.6KW 11.4Ω 12.8KW 8.4Ω

12.8KW 8.4ΩQty. 2

12.8KW 8.4ΩQty. 3


60 75 100 125 - 200 300


1.11.2 Application Example: Combination of 200V Class Units

1.11.3 Application Example: Combination of 400V Class Units

15

1.12 Display LED and Fault Reset

The DB Unit has five LEDs on the front cover. The green LEDs display braking operation. The red LEDs display main power input and fault status of the unit.

Display Function

POWER (RED)

This LED is on when the input power of the unit is present.

RUN (GREEN)

This LED is on when the unit is braking.

OHT (RED)

This LED is on and the unit disabled when the heat sink of the unit is over heated

OCT (RED)

This LED is on when excessive current flows through the IGBT and the unit disables the output to protect the unit.

FOT (RED) The LED is on when the internal protective fuse is open.


1.13 Dimensions

Dynamic Braking Unit

R U

ST P

(P2)VW N

IM

WIRING

B1

B2

PN

G

Baldor District Offices

UNITED STATES ARIZONA PHOENIX 4211 S 43RD PLACE PHOENIX, AZ 85040 PHONE: 602-470-0407 FAX: 602-470-0464

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