User's Manual

NOTE
 Before regulating 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 regulated.
 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. For VFDB-5055, the jumper
can only be put on the position as shown in the
following figure. Do NOT remove the jumper
to other place.
2007-07-19
5011628404-BM04
VFDB Series
Braking Modules Instruction Sheet
X Preface
Thank you for choosing DELTA’s braking module. VFDB braking units are applied to absorb the motor regeneration energy when the
three-phase induction motor stops by deceleration. With VFDB braking unit, the regeneration energy will be dissipated in dedicated
braking resistors. To prevent mechanical or human injury, please refer to this instruction sheet before wiring. VFDB braking units are
suitable for DELTA AC Motor Drives VFD Series 230V/460V/575V. VFDB braking units need to be used in conjunction with BR series
braking resistors to provide the optimum braking characteristics. VFDB braking units (2015, 2022, 4030, 4045 and 5055) 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 Braking Units Braking Resistors
Specification 230V Series 460V Series 575V Series Model no. Specification
Model VFDB- 2015 2022 4030 4045 5055 BR1K5W005
1500W 5.0Ω
Max. Motor Capacity (KW) 15 22 30 45 55 BR1K2W6P8
1200W 6.8Ω
Max. Discharge Current
(A) 10%ED
40 60 40 60 60
BR1K2W008
1200W 8.0Ω
Continuous Discharge
Current (A)
15 20 15 18 20
BR1K5W040
1500W 40Ω
Output Rating
Braking Start-up Voltage
(DC)
330/345/360/380/400/
415±3V
660/690/720/760/800/
830±6V
950±8V
BR1K0W050
1000W 50Ω
Input
Rating
DC Voltage
200—400VDC 400—800VDC
607-1000VDC BR1K0W075
1000W 75Ω
Min. Equivalent Resistor for Each
Braking Unit
10Ω 6.8Ω 20Ω 13.6Ω 15.8Ω
Heat Sink Overheat
Temperature over +95℃ (203
o
F)
Alarm Output Relay contact 5A120VAC/28VDC (RA, RB, RC)
Protection
Power Charge Display Blackout until bus (+~-) voltage is below 50VDC
Installation Location Indoor (no corrosive gases, metallic dust)
Operating Temperature
-10℃~+50℃ (14
o
F to 122
o
F)
Storage Temperature
-20℃~+60℃ (-4
o
F to 140
o
F)
Humidity 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 IP50
Z Dimensions
- Braking Resistors
Z Dimensions - VFDB Braking Units [ Individual Parts and
Function Explanation
80.0 [3.15]
121.0 [4.76]
189.5 [7.46]
200.0 [7.87]
130.0 [5.12]
R3.3 [R0.13]
ACT.
YELLOW
CHARGE
GREEN
ERR.
RED
Power Input Circuit
+(P) -(N) ，
Braking Resistor
B1 B2 ，
SLAVE Circuit
Fault Circuit
Jumper for input
voltage setting
Terminal Wire Gauge
Circuit Terminal Mark Wire Gauge AWG (mm
2
) Screw Torque
Power Input Circuit +(P), -(N) 10~12AWG (3.5~5.5mm
2
) M4 18 kgf-cm (15.6 in-lbf)
Braking Resistor B1, B2 10~12AWG (3.5~5.5mm
2
) M4 18 kgf-cm (15.6 in-lbf)
Output M1, M2
SLAVE Circuit
Input S1, S2
20~18AWG (0.25~0.75mm
2
)
(with shielded wires)
M2 4 kgf-cm (3 in-lbf)
Fault Circuit RA, RB, RC 20~18AWG (0.25~0.75mm
2
) M2 4 kgf-cm (3 in-lbf)
\ Basic Wiring Diagram
Operation Explanation: 1. For safety consideration, install an overload relay between the braking unit and the braking resistor. In
conjunction with the magnetic contactor (MC) prior to the drive, it can perform complete protection against abnormality.
2. The purpose of installing the thermal overload relay is to protect the braking resistor from damage due to frequent braking, or due to
braking unit keeping operating resulted from unusual high input voltage. Under such circumstance, just turn off the power to prevent
damaging the braking resistor.
3. Please refer to the specification of the thermal overload relay.
4. The alarm output terminals (RC, RA, RB) of the braking unit will be activated when the temperature of the heat sink exceeds 95
o
C. It
means that the temperature of the installation environment may exceed 50
o
C, or the braking %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 braking unit back to the
manufacturer or agency for repair.
R/L1
S/L2
T/L3
NFB
MC
VFD
Series
VFDB
MOTOR
O.L.
U/T1
V/T2
W/T3
+P
-N
()
()
B1
B2
RA
RC
E.F
DCM
SA
R/L1
S/L2
T/L3
MC
IM
BR
O.L.
Thermal
Overload
Relay or
temperature
switch
Surge
Absorber
Thermal Overload
Relay
Braking
Resistor
Braking
Unit
+P
-N
()
()
Note1: When using the AC drive with DC reactor, please refer to wiring diagram in the AC drive
user manual for the wiring of terminal +(P) of Brak ing unit.
Note2: wire terminal -(N) to the neutral point of power system.
Do NOT
Temperature
Switch
5. The AC Motor Drive and braking
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 braking 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
braking resistor in the form of heat. It
can ensure the stable deceleration
characteristic.
6. Besides using thermal overload relay to be the protection system and braking resistor, temperature switch can be installed on braking
resistor side as the protection. The temperature switch must comply with the braking resistor specification or contact your dealer.
] Wiring Notice
 Do not proceed with wiring while power is applied to the circuit.
 The wiring gauge and distance must comply with the electrical code.
 The +(P), -(N) terminals of the AC motor drive (VFD Series), connected to the braking unit (VFDB), must be confirmed
for correct polarity lest the drive and the braking unit be damaged when power on.
 When the braking unit performs braking, the wires connected to +(P), -(N), 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.
 Wiring distance
VFD series
15~55kW
230/460/
575V
Max 10M
Max 5M
BR
VFDB
2015
2022
4030
4045
5055
AC Motor Drive
Braking Unit
Braking Resistor
 To prevent personal injury, do not connect/disconnect wires or
regulate the setting of the braking unit while power on. Do not touch
the terminals of related wiring and any component on PCB lest users
be damaged by extreme dangerous DC high voltage.
 Inflammable solids, gases or liquids must be avoided at the
location where the braking resistor is installed. The braking
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 +(P), -(N).
 Please install the braking resistor with forced air-cooling or
the equivalent when frequent deceleration braking is
performed (over 10%ED).
 The ring terminals are suggested to be used for main circuit
wiring. Make sure the terminals are fastened before power on.
^ Definition for Braking Usage ED%
100%
T0
T1
Braking Time
Cycle Time
ED% = T1/T0x100(%)
Explanation: The definition of the barking usage ED(%) is for assurance of
enough time for the braking unit and braking resistor to dissipate away heat
generated by braking. When the braking resistor heats up, the resistance would
increase with temperature, and braking torque would decrease accordingly.
_ The Voltage Settings
1. Regulation of power voltage: the power source of the braking unit is DC voltage from +(P), -(N) terminals of the AC motor drive. It is
very important to set the power voltage of the braking unit based on the input power of the AC motor drive before operation. The setting
has a great influence on the potential of the operation voltage for the braking unit. Please refer to the table below.
Table 1: The Selection of Power Voltage and Operation Potential of PN DC Voltage
230V Model
AC Power
Voltage
Braking Start-up voltage
DC Bus (+(P), -(N)) Voltage
460V Model
AC Power
Voltage
Braking Start-up voltage
DC Bus (+(P), -(N)) Voltage
575V Model
AC Power
Voltage
Braking Start-up voltage
DC Bus (+(P), -(N)) Voltage
190Vac 330Vdc 380Vac 660Vdc 575Vac 950Vdc
200Vac 345Vdc 400Vac 690Vdc - -
210Vac 360Vdc 415Vac 720Vdc - -
220Vac 380Vdc 440Vac 760Vdc - -
230Vac 400Vdc 460Vac 800Vdc - -
240Vac 415Vdc 480Vac 830Vdc - -
NOTE: Input Power With Tolerance ±10%
Input voltage setting for VFDB-2015/2022/4030/4045 Input voltage setting for VFDB-5055
For VFDB-4030/4045
Factory setting: 460V
For VFDB-2015/2022
Factory setting: 230V
480V
460V
440V
415V
400V
380V
240V
230V
220V
210V
200V
190V
Input Voltage Setting
CHARGE
Power lamp
ACT
Braking lamp
ERR
Fault lamp
For VFDB-5055 Series
Factory setting: 575V
------
575V
------
------
------
------
Input Voltage Setting
CHARGE
Power lamp
ACT
Braking lamp
ERR
Fault lamp
2. MASTER/SLAVE setting: The MASTER/SLAVE jumper is set “MASTER” as factory setting. The “SLAVE” setting is applied to two
or more braking units in parallel, making these braking units be enabled/disabled synchronously. Then the power dissipation of each unit
will be equivalent so that they can perform the braking function completely.
The position of the jumper
The SLAVE braking application of three braking units is
shown as the above diagram. After wiring, the jumper of
first unit shall be set as “MASTER” and that of others must
be set as “SLAVE” to complete the system installation.
+P -N() ()
VFD
Series
M1
M2
MASTER
B1 B2
O.L.
M1
M2
B1 B2
O.L.
S1
S2
B1 B2
O.L.
S1
S2
SLAVE
SLAVE
BR
BR BR
+P -N() () +P -N() () +P -N() ()
------
575V
------
------
------
------
240V
230V
220V
210V
200V
190V
MASTER/SLAVE
Setting Jumper
M1:
M2:
S1:
S2:
SLAVE output signal +
SLAVE output signal -
SLAVE input signal +
SLAVE input signal -
NOTE: Please use shielded wires
whil e wiring.
Slave
output/input
Te r min al
Alarm output terminals
M2 M1 S2 S1 RC RB RA
MASTER
SLAVE
CHARGE
Power lamp
ACT
Braking lamp
ERR
Fault lamp
480V
460V
440V
415V
400V
380V
` All Braking Resistors & Braking Units Use in the AC Drives
Applicable
Motor
Voltage HP kW
Full- load
Torque
kg-M
Resistor Value
Spec for Each
AC Motor Drive
Braking Unit
Model VFDB
No. of Units
Used
Braking Resistors
Model and No. of Units
Used
Braking
Torque
10%ED
Min.
Equivalent
Resistor Value
for Each AC
Motor Drive
Typical
Thermal
Overload
Relay Value
20 15 8.248 3000W 10Ω 2015 1 BR1K5W005 2 125 10Ω 30
25 18.5 10.281 4800W 8Ω 2022 1 BR1K2W008 4 125 8Ω 35
30 22 12.338 4800W 6.8Ω 2022 1 BR1K2W6P8 4 125 6.8Ω 40
40 30 16.497 6000W 5Ω 2015 2 BR1K5W005 4 125 5Ω 30
230V
50 37 20.6 9600W 4Ω 2015 2 BR1K2W008 8 125 4Ω 30
20 15 8.248 1500W 40Ω 4030 1 BR1K5W040 1 125 40Ω 15
25 18.5 10.281 4800W 32Ω 4030 1 BR1K2W008 4 125 32Ω 15
30 22 12.338 4800W 27.2Ω 4030 1 BR1K2W6P8 4 125 27.2Ω 20
40 30 16.497 6000W 20Ω 4030 1 BR1K5W005 4 125 20Ω 30
50 37 20.6 9600W 16Ω 4045 1 BR1K2W008 8 125 16Ω 40
60 45 24.745 9600W 13.6Ω 4045 1 BR1K2W6P8 8 125 13.6Ω 50
75 55 31.11 12000W 10Ω 4030 2 BR1K5W005 8 125 10Ω 30
460V
100 75 42.7 19200W 6.8Ω 4045 2 BR1K2W6P8 16 125 6.8Ω 50
20 15 8.248 3000W 60Ω 5055 1 BR1K0W020 3 125 60Ω 15
25 18.5 10.281 4000W 50Ω 5055 1 BR1K0W050 4 125 50Ω 15
30 22 12.338 6000W 40Ω 5055 1 BR1K2W008 5 125 40Ω 20
40 30 16.497 6000W 34Ω 5055 1 BR1K2W6P8 5 125 34Ω 25
50 37 20.6 7500W 25Ω 5055 1 BR1K5W005 5 125 25Ω 30
60 45 24.745 12000W 20Ω 5055 1 BR1K2W008 10 125 20Ω 35
75 55 31.11 12000W 17Ω 5055 1 BR1K2W6P8 10 125 17Ω 45
575V
100 75 42.7 15000W 12.5Ω 5055 2 BR1K5W005 10 125 12.5Ω 45
a Wiring Examples of Braking Resistors
NOTE: Before wiring, please notice equivalent resistors value shown in the column “Equivalent resistors specification for each braking
unit” in the above table to prevent damage.
230V 20HP
VFD
Series
O.L.
B1
B2
Braking
Unit
VFDB
2015
Thermal Overload
Relay
VFD150_23_
VFD150_23_ uses with 2PCS BR1K5W005 braking resistors in series
+P
-N
()
()
Braking
Resistor
+P
-N
()
()
MASTER
230V 25HP/30HP
+P
-N
()
()
O.L.
Braking
Resistor
B1
B2
Braking
Unit
VFDB
2022
Thermal Overload
Relay
VFD185_23_
VFD220_23_
1. VFD185_23_ uses with two BR sets in parallel, which 2PCS BR1K2W008 braking resistors
in series for each BR set .
2. VFD220_23_ uses with two BR sets in parallel, which 2PCS BR1K2W6P8 braking resistors
in serie s fo r each BR s et .
VFD
Series
+P
-N
()
()
+P
-N
()
()
MASTER
230V 40HP
O.L.
B1
B2
Braking
Unit
VFDB
2015
VFD300_23_
VFD300_23_ use with two VFDB2015 braking units, and each braking unit uses with
2PCS BR1K5W005 braking resistors in series.
SLAVE
S1 S2
O.L.
Braking
Resistor
B1
B2
Braking
Unit
VFDB
2015
Thermal Overload Relay
M1 M2
MASTER
VFD
Series
+P -N() ()
Thermal Overload Relay
Braking
Resistor
+P -N() ()
+P -N() ()
230V 50HP
O.L.
B1
B2
Braking
Unit
VFDB
2015
VFD370_23_
SLAVE
S1 S2
O.L.
Braking
Resistor
B1
B2
Braking
Uni t
VFDB
2015
Thermal Overload Relay
M1 M2
MASTER
VFD
Series
+P -N() ()
Thermal Overload Relay
Braking
Resistor
+P -N() ()
+P -N() ()
VFD370_23_ uses with two VFDB2015 braking units, and each braking unit uses with two
BR sets in parallel, which 2PCS BR1K2W008 braking resistors in series.
460V 20HP
O.L.
Braking
Resistor
B1
B2
Braking
Unit
VFDB
4030
Thermal Overload
Relay
VFD150_43_
VFD150_43_ uses with BR1K5W040 1PCS braking resistor
+P
-N
()
()
VFD
Series
+P
-N
()
()
MASTER
460V 25HP/30HP/40HP
O.L.
Braking
Unit
B1
B2
Braking
Unit
VFDB
4030
Thermal Overload
Relay
VFD185_43_
VFD220_43_
VFD300_43_
1. VFD185_43_ uses with BR1K2W008 braking resistors in series
2. VFD220_43_ uses BR1K2W6P8
3. VFD300_43_ uses BR1K5W005
4PCS
with 4PCS braking resistors in series
with 4PCS braking resistors in series
VFD
Series
+P
-N
()
()
+P
-N
()
()
MASTER
460V 50HP/60HP
O.L.
Braking
Resistor
B1
B2
Braking
Uni t
VFDB
4045
Thermal Overload
Relay
VFD370_43_
VFD450_43_
1. VFD370_43_ uses with two BR sets in parallel, which 4PCS BR1K2W008
braking resistors in series for each BR set.
VFD450_43_ uses with two BR sets in parallel, which 4PCS BR1K2W6P8
braking resistors in series for each BR set.
2.
VFD
Series
+P
-N
()
()
+P
-N
()
()
MASTER
460V 75HP
O.L.
B1
B2
Braking
Unit
VFDB
4030
VFD550_43_
VFD550_43_ uses with two VFDB4030 braking units, and each braking unit uses with
4PCS BR1K5W005 braking resistors in series.
SLAVE
S1 S2
O.L.
Braking Resistor
B1
B2
Braking
Unit
VFDB
4030
Thermal Overload Relay
M1 M2
MASTER
VFD
Series
+P -N() ()
Thermal Overload Relay
Braking Resistor
+P -N() ()
+P -N() ()
460V 100HP
O.L.
B1
B2
Braking
Unit
VFDB
4045
VFD750_43_
SLAVE
S1 S2
O.L.
Braking
Resistor
B1
B2
Braking
Unit
VFDB
4045
Thermal Overload Relay
M1 M2
MASTER
VFD
Series
+P -N() ()
Thermal Overload Relay
Braking
Resistor
+P -N() ()
+P -N() ()
VFD750_43_ uses with two VFDB4045 braking units, and each braking unit uses with two
BR sets in parallel, which 4PCS BR1K2W6P8 braking resistors in series.
575V 20HP
VFD150_53_ uses with 3PCS BR1K0W020 braking resistors in series
O.L.
Braking
Resistor
B1
B2
Braking Unit
VFDB
5055
Thermal Overload
Relay
VFD150_53_
VFDSeries
+(P)
-(N)
+(P)
-(N)
MASTER
575V 25HP
O.L.
Braking
resistor
B1
B2
Braking
Unit
VFDB
5055
Thermal Overload
Relay
VFD185_53_
VFD185_53_ uses with 5 BR1K0W050 braking resistors in seriesPCS
VFD
Series
+P
-N
()
()
+P
-N
()
()
MASTER
575V 30HP/40HP/50HP
1. VFD220_53_ uses with 5PCS BR1K2W008 braking resistors in series
2. VFD300_53_
3.
uses with 5PCS BR1K2W6P8 braking resistors in series
VFD370_53_ uses with 5PCS BR1K5W005 braking resistors in series
O.L.
Braking
Resistor
B1
B2
Braking Unit
VFDB
5055
Thermal Overload
Relay
VFD220_53_
VFD300_53_
VFD370_53_
VFDSeries
+(P)
-(N)
+(P)
-(N)
MASTER
575V 60HP/75HP
1. VFD450_53_ uses with two BR sets in parallel, which 5PCS BR1K2W008 braking resistors
in series for each BR set
2. VFD550_53_ uses with two BR sets in parallel, which 5PCS BR1K2W6P8 braking resistors
in series for each BR set
O.L.
Braking
Resistor
B1
B2
Braking Unit
VFDB
5055
Thermal Overload
Relay
VFD450_53_
VFD550_53_
VFDSeries
+(P)
-(N)
+(P)
-(N)
MASTER
575V 100HP
VFD750_53_
B1
B2
VFDB
5055
M1 M2
MASTER
VFD750_53_uses with two VFDB5055 braking units, and each braking unit uses with
5PCS BR1K5W005 braking resistors in series.
VFD
Series
+(P) -(N) +(P) -(N)
O.L.
Thermal Overload
Relay
Thermal Overload
Relay
Braking
Resistor
Braking Unit
Braking
Resistor
B1
B2
VFDB
5055
SLAVE
S1 S2
+(P) -(N)
O.L.
Braking Unit