Delta Electronics VFDB Series dimensions 230V 25HP/30HP, 230V 50HP, 460V 100HP 575V 20HP

NFB

5. The AC Motor Drive and braking

R/L1

S/L2

T/L3

MC

R/L1	U/T1
S/L2	V/T2	IM
T/L3	W/T3	MOTOR

Thermal Overload

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

`All Braking Resistors & Braking Units Use in the AC Drives

O.L.

MC Thermal

Overload SA

Relay or Surge temperature Absorber switch

VFD	+(P)	+(P)	B1
Series	-(N)	-(N) VFDB
	E.F	RA	Braking
			Unit
	DCM	RC	B2

Relay

O.L.

Braking

BR Resistor

Temperature

Switch

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

Voltage

Applicable

Full- load

Resistor Value

Braking Unit

Min.

Typical

Motor

Braking Resistors

Braking

Equivalent

Model VFDB

Thermal

Torque

Spec for Each

No. of Units

Model and No. of Units

Torque

Resistor Value

Overload

HP

kW

kg-M

AC Motor Drive

for Each AC

Used

Used

10%ED

Motor Drive

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

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 Braking unit.

Note2: Do NOT wire terminal -(N) to the neutral point of power system.

can ensure the stable deceleration

characteristic.

230V	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
	50	37		20.6		9600W 4Ω	2015		2		BR1K2W008	8		125		4Ω	30

2007-07-19

5011628404-BM04

VFDB Series Braking Modules Instruction Sheet

XPreface

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.

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.

	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
460V	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
	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

YSpecifications					VFDB Braking Units
			Specification	230V Series		460V Series		575V Series
			Model VFDB-	2015	2022	4030	4045	5055
	Max. Motor Capacity (KW)			15	22	30	45	55
	Rating		Max. Discharge Current	40	60	40	60	60
			(A) 10%ED
	Output		Continuous Discharge	15	20	15	18	20
			Current (A)
			Braking Start-up Voltage	330/345/360/380/400/		660/690/720/760/800/		950±8V
			(DC)	415±3V		830±6V
	Input Rating		DC Voltage	200—400VDC		400—800VDC		607-1000VDC
	Min. Equivalent Resistor for Each			10Ω	6.8Ω	20Ω	13.6Ω	15.8Ω
			Braking Unit
	Protection		Heat Sink Overheat	Temperature over +95℃ (203oF)
			Alarm Output	Relay contact 5A120VAC/28VDC (RA, RB, RC)
			Power Charge Display	Blackout until bus (+~-) voltage is below 50VDC
			Installation Location	Indoor (no corrosive gases, metallic dust)
	Environment		Operating Temperature	-10℃~+50℃(14oF to 122oF)
			Humidity	90% Non-condensing
			Storage Temperature	-20℃~+60℃	(-4oF to 140oF)
			Vibration	9.8m/s2 (1G) under 20Hz
				2m/s2 (0.2G) at 20~50Hz
		Mechanical Configuration		Wall-mounted enclosed type IP50

Braking 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

ZDimensions

-Braking Resistors

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.

	30	22	12.338	6000W 40Ω	5055	1	BR1K2W008	5	125	40Ω	20
575V	40	30	16.497	6000W 34Ω	5055	1	BR1K2W6P8	5	125	34Ω	25

Wiring distance

VFD series		VFDB
		2015
15~55kW		2022
		4030	Max 5M	BR
230/460/	Max 10M	4045
575V		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.

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
100	75	42.7	15000W 12.5Ω	5055	2	BR1K5W005	10	125	12.5Ω	45

aWiring 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.

^Definition for Braking Usage ED%

100%

Braking Time T1	ED% = T1/T0x100(%)
Cycle Time	T0

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.

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.

230V 20HP

230V 25HP/30HP

Thermal Overload

Thermal Overload

B1

Relay

B1

Relay

+(P)

+(P)

VFD

+(P)

+(P)

O.L.

VFD

VFDB

O.L.

VFDB

-(N)

-(N)

Series

-(N)

-(N)

2015

Series

2022

Braking

Braking

Braking

Resistor

VFD185_23_

Unit

VFD150_23_

Unit

Braking

VFD220_23_

Resistor

MASTER

MASTER

B2

B2

1. VFD185_23_ uses with two BR sets in parallel, which 2PCS BR1K2W008 braking resistors

VFD150_23_ uses with 2PCS BR1K5W005 braking resistors in series

in series for each BR set.

2. VFD220_23_ uses with two BR sets in parallel, which 2PCS BR1K2W6P8 braking resistors

in series for each BR set.

230V 40HP

230V 50HP

Thermal Overload Relay

Thermal Overload Relay

Thermal Overload Relay

Thermal Overload Relay

+(P) -(N)

+(P) -(N) B1

+(P) -(N)

B1

+(P) -(N)

+(P) -(N)

B1

+(P) -(N)

B1

VFDB

VFDB

VFD

O.L.

O.L.

VFDB

O.L.

VFDB

O.L.

2015

2015

VFD

Series

Braking

Braking

2015

2015

Series

Braking

Braking

Unit

Unit

VFD300_23_

Unit

Unit

SLAVE

VFD370_23_

MASTER B2

B2

SLAVE

Braking

Braking

MASTER

B2

B2

M1 M2

S1 S2

Braking

Braking

ZDimensions - VFDB Braking Units			[Individual Parts and
			Function Explanation
121.0 [4.76]		130.0 [5.12]	Jumper for input
80.0 [3.15]	R3.3 [R0.13]
			voltage setting
			SLAVE Circuit
			Fault Circuit
	189.5 [7.46]	200.0 [7.87]

	Braking Resistor
Power Input Circuit
	B1，B2
+(P)，-(N)

Terminal Wire Gauge

Circuit	Terminal Mark		Wire Gauge AWG (mm )	Screw	Torque
Power Input Circuit	+(P), -(N)		10~12AWG (3.5~5.5mm2)	M4	18 kgf-cm (15.6 in-lbf)
Braking Resistor	B1, B2		10~12AWG (3.5~5.5mm2)	M4	18 kgf-cm (15.6 in-lbf)
	Output	M1, M2	2
SLAVE Circuit			20~18AWG (0.25~0.75mm )	M2	4 kgf-cm (3 in-lbf)
			(with shielded wires)
	Input	S1, S2
Fault Circuit	RA, RB, RC		20~18AWG (0.25~0.75mm2)	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 95oC. It means that the temperature of the installation environment may exceed 50oC, 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.

_The Voltage Settings

Resistor	Resistor	M1 M2	S1 S2
		Resistor	Resistor
VFD300_23_ use with two VFDB2015 braking units, and each braking unit uses with

2PCS BR1K5W005 braking resistors in series. 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

460V 25HP/30HP/40HP

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	Braking Start-up voltage	460V Model	Braking Start-up voltage	575V Model	Braking Start-up voltage
AC Power		AC Power		AC Power
	DC Bus (+(P), -(N)) Voltage		DC Bus (+(P), -(N)) Voltage		DC Bus (+(P), -(N)) Voltage
Voltage		Voltage		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

							Thermal Overload
							Relay
	+(P)	+(P)	VFDB		B1
VFD						O.L.
			4030
	-(N)	-(N)
Series			Braking
VFD150_43_				Unit
								Braking
			MASTER
								Resistor
					B2

VFD150_43_ uses with 1PCS BR1K5W040 braking resistor

460V 50HP/60HP

Thermal Overload

Relay

	+(P)	+(P)			B1
VFD			VFDB			O.L.
	-(N)	-(N) 4045
Series
			Braking
VFD370_43_				Unit		Braking
						Resistor
VFD450_43_
			MASTER		B2

1.VFD370_43_ uses with two BR sets in parallel, which 4PCS BR1K2W008 braking resistors in series for each BR set.

2.VFD450_43_ uses with two BR sets in parallel, which 4PCS BR1K2W6P8 braking resistors in series for each BR set.

					Thermal Overload
				B1	Relay
VFD	+(P)	+(P)	VFDB		O.L.
	-(N)	-(N)	4030
Series			Braking
VFD185_43_			Unit		Braking
					Unit
VFD220_43_			MASTER
VFD300_43_				B2

1.VFD185_43_ uses with 4PCS BR1K2W008 braking resistors in series

2.VFD220_43_ uses with 4PCS BR1K2W6P8 braking resistors in series

3.VFD300_43_ uses with 4PCS BR1K5W005 braking resistors in series

460V 75HP

		Thermal Overload Relay		Thermal Overload Relay
+(P) -(N)	+(P) -(N) B1		+(P) -(N) B1
VFD	VFDB		O.L.	VFDB	O.L.
	4030			4030
Series	Braking			Braking
VFD550_43_	Unit			Unit
	MASTER			SLAVE
		B2		B2
	M1 M2		Braking Resistor	S1 S2
				Braking Resistor

VFD550_43_ uses with two VFDB4030 braking units, and each braking unit uses with 4PCS BR1K5W005 braking resistors in series.

CHARGE

ACT

ERR

460V 100HP

575V 20HP

CHARGE

ACT

ERR

Thermal Overload

Thermal Overload Relay

Power lamp Braking lamp Fault lamp

Power lamp

Braking lamp

Fault lamp

Thermal Overload Relay

B1

Relay

Input Voltage Setting

Input Voltage Setting

------

+(P) -(N)

+(P) -(N)

B1

+(P) -(N) B1

+(P)

+(P)

Braking

480V

240V

VFDB

O.L.

VFDB

O.L.

O.L.

460V

230V

575V

VFD

VFDSeries

Resistor

4045

4045

-(N)

VFDB

440V

220V

------

Series

Braking

Braking

-(N)

5055

415V

210V

------

VFD750_43_

Unit

Unit

Braking Unit

400V

200V

SLAVE

380V

190V

------

MASTER

B2

B2

VFD150_53_

------

Braking

Braking

MASTER

For VFDB-4030/4045

For VFDB-2015/2022

M1 M2

S1 S2

Resistor

Factory setting: 460V

Factory setting: 230V

For VFDB-5055 Series

Resistor

B2

Factory setting: 575V

VFD750_43_ uses with two VFDB4045 braking units, and each braking unit uses with two

VFD150_53_ uses with 3PCS BR1K0W020 braking resistors in series

2. MASTER/SLAVE setting: The MASTER/SLAVE jumper is set “MASTER” as factory setting. The “SLAVE” setting is applied to two

BR sets in parallel, which 4PCS BR1K2W6P8 braking resistors in series.

or more braking units in parallel, making these braking units be enabled/disabled synchronously. Then the power dissipation of each unit

575V 25HP

Thermal Overload

575V 30HP/40HP/50HP

Thermal Overload

will be equivalent so that they can perform the braking function completely.

B1

Relay

Braking

B1

Relay

Braking

The position of the jumper

+(P)

+(P)

VFDB

O.L.

resistor

+(P)

+(P)

O.L.

Resistor

The SLAVE braking application of three braking units is

VFD

VFDSeries

-(N) VFDB

-(N)

-(N)

5055

-(N)

shown as the above diagram. After wiring, the jumper of

Slave

CHARGE

ACT

ERR

Series

Braking

VFD220_53_

5055

Braking Unit

first unit shall be set as “MASTER” and that of others must

output/input

Unit

VFD300_53_

Power lamp

Braking lamp Fault lamp

VFD370_53_

Terminal

VFD185_53_

MASTER

be set as “SLAVE” to complete the system installation.

MASTER

B2

M2

------

480V

240V

B2

1. VFD220_53_ uses with 5PCS BR1K2W008 braking resistors in series

2. VFD300_53_ uses with 5PCS BR1K2W6P8 braking resistors in series

M1

575V

460V

230V

VFD185_53_ uses with 5PCS BR1K0W050 braking resistors in series

3. VFD370_53_ uses with 5PCS BR1K5W005 braking resistors in series

------

440V

220V

575V 60HP/75HP

575V 100HP

S2

------

415V

210V

+(P)

-(N)

+(P)

-(N)

+(P)

-(N)

+(P)

-(N)

SLAVE

------

400V

200V

Thermal Overload

Thermal Overload

Thermal Overload

Relay

Relay

S1

------

380V

190V

B1

Braking

Relay

M1

S1

M1

S1

+(P)

+(P)

O.L.

Resistor

+(P) -(N)

+(P) -(N) B1

+(P) -(N)

VFD

M2

S2

M2

S2

VFDSeries

B1

M1: SLAVE output signal +

VFDB

-(N)

-(N)

VFDB

O.L.

VFDB

O.L.

Series

SLAVE

SLAVE

RC

MASTER

M2: SLAVE output signal -

5055

VFD

5055

5055

VFD450_53_

Braking Unit

MASTER

MASTER/SLAVE

S1: SLAVE input signal +

Series

Braking Unit

Braking Unit

VFD550_53_

VFD750_53_

SLAVE

RB

Setting Jumper

S2: SLAVE input signal -

MASTER

B2

B1

B2

B1

B2

B1

B2

B2

MASTER B2

1. VFD450_53_ uses with two BR sets in parallel, which 5PCS BR1K2W008 braking resistors

M1 M2

Braking

S1 S2

Braking

O.L.

BR

O.L.

BR

O.L.

BR

RA

NOTE: Please use shielded wires

in series for each BR set

Resistor

Resistor

while wiring.

2. VFD550_53_ uses with two BR sets in parallel, which 5PCS BR1K2W6P8 braking resistors

VFD750_53_uses with two VFDB5055 braking units, and each braking unit uses with

Alarm output terminals

in series for each BR set

5PCS BR1K5W005 braking resistors in series.