Delta VFDB 4132 Series - Manual

2 0 0 8 -0 9 -1 0

5 0 11 6 69 6 0 1 -1 C B U

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

Outpu

t

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

3.4

Ω

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

Prote

cti

on

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

Environmen

t

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

5.0

Ω

BR1K2W6P8 1200W

6.8

Ω

BR1K2W008 1200W

8.0

Ω

BR1K5W040 1500W

40

Ω

BR1K0W050 1000W

50

Ω

BR1K0W075 1000W

75

Ω

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

N o t e 1 : Wh e n t h e A C m ot o r d r iv e i s u s ed w i t h D C r e a ct o r, pl e a se r ef e r t o t h e w i r i n g

d i a gr a m i n t h e A C d r i ve u se r ma n ua l f or w i r i n g t e r mi n a l D C + o f br ak e u n i t.
N o t e 2 :

w i r e t e r m in a l D C - to t h e n eu t r a l p o i nt o f p o w e r s y st e m.

DO NO T

N F B

R / L 1

M C

S / L 2
T / L 3

O . L .

M C

S A

T h er m a l O ve r l oa d

R e l ay or Te m pe r a t u r e s w i t ch

S u r g e A b so r b e r

R / L 1
S / L 2
T / L 3

VFD Se rie s

R / L 1
S / L 2
T / L 3

I M

+ ( P )

- ( N )

E . F

D C M

M ot o r

D C +
D C -

R A

R C

VF DB

Bra k e

Uni t

B 1

B 2

B R

O . L .

T h er m a l
O v e r l oa d

R e l ay

B r a ke

R e s is t o r

Tem p er a t u r e S w it c h

N OT E

„

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

V F D se r i e s

M ax 8 M

M ax 5 M

B R

V F D B

s er i e s

A C Mo t o r D r i ve

B ra ke U n i t

B ra ke R e si s t or

^

Definition for the Brake Usage ED%

1 00 %

T0

T1

Brake Ti me

C y cle Ti me

E D % = T1 /T 0x 1 00 (% )

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.

N OT E

„

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%

C H AR G E A CT

O C

4 8 0 V
4 6 0 V
4 4 0 V

4 1 5 V
4 0 0 V

3 8 0 V

O H

Power lamp Brake lamp Over-curr ent

lamp

Overheat

lamp

I n pu t Vol t a g e S e t t in g

F o r V F D B 41 3 2

F a ct o ry s e tt i n g : 4 4 0V

I np ut v ol ta ge s et ti ng f or VF D B 4 13 2

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

( )

VF D

Se rie s

M1
M2

M

B1

O .L .

DC +

B R

- (N )

DC -

B2

M1
M2

B1

O .L .

DC +

B R

DC -

B2

S1
S2

S

B1

O .L .

DC +

B R

DC -

B2

S1
S2

S

4 8 0 V

4 6 0 V
4 4 0 V

4 1 5 V
4 0 0 V
3 8 0 V

In p ut Vo lt ag e Se tt i ng

M

S

MAST ER /SLAV E
S et ti ng J um per

M1 : SL AVE out put s i gn al +
M2 : SL AVE out put s i gn al -
S1: SL AVE i nput s i gn al +
S2: SL AVE i nput s i gn al -

NO T E: Pl ea se u se s h ie l ded

w i re s w hi l e wi r i ng.

SLAVE o utp ut/i n put t er mi nal Alar m out put t er minals

M2

M1

S2

S1

RA RC

Th e Po s it io n of th e J um pe r

N OT E

„

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

V

o

ltag

e

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

5

Ω

4132

1 BR1K5W005 9

120

5

Ω

110A

150 110 61 21600W

4

Ω

4132

1 BR1K2W008 18

120

4

Ω

135A

175 132 73.5 21600W

4

Ω

4132

1 BR1K2W008 18

100

4

Ω

135A

215 160 89 21600W

3.4

Ω

4132

1 BR1K2W6P8 18

97 3.4

Ω

160A

250 185 103 27000W

2.5

Ω

4132

2 BR1K5W005 18

115 2.5

Ω

220A

460V

300 220 122.5 27000W

2.5

Ω

4132

2 BR1K5W005 18

96 2.5

Ω

220A

a

Examples

N OT E

„

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

VF D 900_43_

VFD9 00_43 _ uses wi th 3 BR set s in pa rall el, w hich 3P CS 1K 5W00 5 brak e r esist ors

ar e co nnect ed in ser ies.

VF D

Ser i es

+ (P)

-( N)

D C+

D C-

BR

BR

BR

BR

BR

BR

BR

BR

BR

BR

BR

BR

M

BR

BR

BR

BR

BR

BR

Bra ke Uni t

Bra ke

Res isto r

Therm al O ver loa d Rel ay

460V 150HP, 175HP, 215HP

O . L .

B 1

B 2

V F DB

4 1 3 2

V F D1 1 0 0 _ 4 3 _
V F D1 3 2 0 _ 4 3 _
V F D1 6 0 0 _ 4 3 _

V F D1 1 0 0 _ 4 3 _ u s e s w it h 6 B R s e t s in p a ra l le l, w h ic h 3 P C S 1 K 2 W 0 0 8 b ra ke r e s is to rs
a re c o n n e c te d in s e rie s.

V F D
S e r ie s

+ (P )

-( N)

D C+

D C-

B R

B R

B R

B R

B R

B R

M

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B R

B ra ke U n it

T h e rm a l O v e r lo a d Re l a y

B ra ke
R e si st o r

V F D1 6 0 0 _ 4 3 _ u se s w it h 6 B R se t s in p a ra ll e l, wh ic h 3 P C S 1 K 2 W 6 P 8 b ra k e re si st o r s
a re c o n n e c te d in s e rie s.

1 K 2 W 0 0 8 b ra k e re s is t o rs

a re c o n n e c te d in s e rie s.

V F D1 3 2 0 _ 4 3 _ u se s w it h 6 B R s e t s in p a r a ll e l, wh ic h 3 P CS

460V 250HP, 300HP

V F D
S e r ie s

+ (P ) -( N)

V FD1 85 0 _4 3 _
V FD2 20 0 _4 3 _

V FD1 85 0 _4 3 _ u se s wit h 2 VF DB4 1 32 b rak e u n its a n d e a ch bra ke u nit us e s with
3 B R se ts i n p a rall el, wh ich 3 P CS 1 K5 W 0 05 b rak e re sis to rs a re co n n ec te d in se rie s.
V FD2 20 0 _4 3 _ u se s wit h 2 VF DB4 1 32 b rak e u n its a n d e a ch bra ke u nit us e s with
3 B R se ts i n p a rall el, wh ich 3 P CS1 K 5W 0 0 5 b ra ke re si sto rs a re c on n e ct ed in s eri es .

O .L .

B 1

B 2

V FDB

41 3 2

DC+ DC-

M

M1 M2

BR

BR

BR

BR

BR

BR

BR

BR

BR

O .L .

B 1

B 2

V FDB

41 3 2

DC+ DC-

BR

BR

BR

BR

BR

BR

BR

BR

BR

S 1 S 2

S

B rak e Un it

Th e rmal O ve rlo ad Rel ay

Th e rmal O ve rlo ad Rel ay

B rak e Un it

B rak e
Re sis to r

B rak e
Re sis to r