Delta Electronics instruction sheet BUE Series Brake Modules, Instruction Sheet, X Preface

2007-11-07

3.2 Brake unit

NOTE NOTE

5011642602-BU02

BUE Series Brake Modules

Instruction Sheet

XPreface

Congratulations on your purchase of DELTA’s brake module. BUE brake units are applied to absorb the motor regenerative energy when 3-phase induction motor stops by deceleration. With BUE brake unit, the regenerative energy is dissipated in the brake resistors. To prevent mechanical or human injury, please read this instruction sheet thoroughly before wiring.

BUE brake units are suitable for VFD-E/VFD-EL Series. BUE brake units need to be used in conjunction with BR series brake resistors to provide the optimum brake characteristics.

BUE brake units (20015 and 40015) 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.

YSpecifications

		115/230V Series			460V Series
		BUE-20015	BUE-20037	BUE-40015		BUE-40037
Max. Motor Capacity (KW)		1.5	3.7		1.5	3.7
Output Rating	Max. Peak Discharge	3.6	16		1.8	8
	Current (A) 10%ED
	Brake Start-up	328/345/362/380/400±3V		656/690/725/760/800±6V
	Voltage (DC)
Input Rating	DC Voltage	200~400VDC			400~800VDC
	Heat Sink Overheat	Temperature over +100°C

3.3 DIN Rail Installation

[Outline and Wire Gauge

4.1Outline

Power Input Terminal

Power lamp

Brake lamp

Fault lamp

2 40 23 0 22 02 10 2 0019 0

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 avoid damaging the brake resistor.

Please refer to “7 Brake Resistor/Units for the AC Drives” for the specification of the thermal overload relay.

]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-E/VFD-EL Series), connected to the brake unit (BUE), must be confirmed for correct polarity lest the drive and the brake unit be damaged when power on.

When the brake unit performs brake, 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-E/VFD-EL		20015
series		BUE-20037	BR
0.2~1.5kW		40015
			Max. 1M
	Max. 2M	40037
115V/230/460V			Brake Resistor
AC Motor Drive		Brake Unit

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 +(P), -(N).

Please install the brake resistor with forced air-cooling or the

“-“ means no Delta product. Please use the brake unit according to the Equivalent Resistor Value.

The cycle time of brake usage ED% in the above table is 10 seconds.

For the detail applicable models, refer to the following list:

A.BUE20015 is used for VFD002E11A/11P/11C/21A/21P/21C/23A/23P/23C, VFD004E11A/11P/11C/21A/21P/21C/23A/23P/23C, VFD007E21A/21P/21C/23A/23P/23C, VD015E23A/23P/23C, VFD002EL11A/21A/23A, VFD004EL11A/21A/23A, VFD007EL11A/21A/23A, VFD015EL21A/23A

B.BUE20037 is used for VFD022EL21A/23A, VFD037EL23A

C.BUE40015 is used for VFD004E43A/43P/43C, VFD007E43A/43P/43C, VFD015E43A/43C, VFD004EL43A, VFD007EL43A, VFD015EL43A

D.BUE40037 is used for VFD022EL43A, VFD037EL43A

_Definition for the Brake Usage ED%

100%

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

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

The power source of the brake unit is the DC power from the + (P) and - (N) terminals of the AC motor drive. Therefore, it is an important step to set the voltage by the input voltage of the AC motor drive before operation. This setting will affect the voltage level of the brake unit.

Protection	Power Charge	Blackout until bus (+~-) voltage below 50VDC
	Display
	Installation Location	Indoor (no corrosive gases, metallic dust)
Environment	Operating	-10℃~+50℃
	Temperature
	Storage Temperature	-20℃~+60℃
	Humidity	90%R.H., Non-condensing
	Vibration	9.8m/s2 (1G) under 20Hz
		2m/s2 (0.2G) at 20~50Hz

MASTER/SLAVE Switch

Dip Switch

for Input Voltage Setting

ON OFF

Slave output/input Terminals

M1：SLAVE output signal +

M2：SLAVE output signal -

S1：SLAVE input signal +

S2：SLAVE input signal -

Brake Resistor Terminal

equivalent when frequent deceleration brake is performed (over 10%ED).

To avoid personal injury, do not connect/disconnect wires or regulate the setting of the brake 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

We suggest to use ring terminals for main circuit wiring. Make sure the terminals are fastened before power on.

^ Brake Resistors/Units for Delta VFD

Table 1: The voltage selection and operation level of the PN DC voltage

115V/230V	Brake Start-up	460V Model	Brake Start-up voltage
Model	voltage
		AC Power	DC Bus (+(P), -(N))
AC Power	DC Bus (+(P), -(N))
		Voltage	Voltage
Voltage	Voltage
190Vac	330Vdc	380Vac	660Vdc
200Vac	345Vdc	400Vac	690Vdc
210Vac	360Vdc	420Vac	725Vdc
220Vac	380Vdc	440Vac	760Vdc

Mechanical Configuration Wall-mounted enclosed type IP20

Z Dimensions and Installations

4.2 Wire Gauge for Terminals

Circuit	Terminal	Wire Gauge	Terminal
	Symbol	AWG/mm2

AC Motor Drives Series

230Vac 400Vdc 460Vac 800Vdc

NOTE: Input Power With Tolerance ±10%

3.1 Brake resistor

Power Input	+(P), -(N)	20~22AWG/0.5~0.3mm2	M4 Screw
Circuit		20~22AWG/0.5~0.3mm2
Brake Resistor	B1, B2		M4 Screw
	M1, M2	24AWG/0.2mm2
SLAVE Circuit		M1, M2, S1, S2 with shielded	M2 Screw
	S1, S2
		wires
\ Basic Wiring Diagram

NFB

	Applicable		Full-load	Equivalent					Brake	Min.	Typical
	Motor									Equivalent
Voltage				brake	Brake Unit		Brake Resistor				Thermal
			output						Torque	Resistor
				resistor for	Model and		Model and				Overload
			torque						10%	Value for
	HP	kW		each AC	Quantity		Quantity				Relay
			KG-M						ED%	Each AC
				drive							Value
										Drive
	1/4	0.2	0.110	200W 250Ω	BUE20015	1	BR200W250	1	320	200Ω	2A
Series	1/2	0.4	0.216	200W 250Ω	BUE20015	1	BR200W250	1	170	100Ω	3A
	1	0.75	0.427	200W 150Ω	BUE20015	1	BR200W150	1	140	80Ω	4A

24 02 30220 21 02 0019 0

ON OFF

240230220210200190

For BUE-20015 Series/ BUE-20037 Series Factory setting: 190V

ON OFF

480460440420400380

For BUE-40015 Series/

R/L1

S/L2

T/L3

MC

R/L1 U/T1

S/L2 V/T2

T/L3 W/T3

IM

MOTOR

Thermal Overload

115/230V	2	1.5	0.849	300W100Ω BUE20015 1	BR300W100 1		107	80Ω	4A
	3	2.2	1.262	600W 50Ω BUE20037 1	BR300W100 2		150	25Ω	12A
	5	3.7	2.080	900W 30Ω BUE20037 1	-	-	150	25Ω	12A

BUE-40037 Series

Factory setting: 380V

ON OFF

TYPE L1 L2 H D W MAX.

O.L.

MC Thermal

SA

VFD-E/VFD-EL

Series

+/B1(P)

B1

+(P) BUE

Relay

O.L.

1/2 0.4 0.216 300W 400Ω BUE40015 1 BR300W400 1 400 400Ω 2A

NOTE

						WEIGHT(g)
BR080W200	140	125	20	5.3	60	160
BR080W750	140	125	20	5.3	60	160
BR300W400	215	200	30	5.3	60	750

Overload

Relay Surge

Absorber

-(N)

-(N) Brake

Unit

B2

BR

Brake Resistor

1 0.75 0.427 300W 400Ω BUE40015 1 BR300W400 1 200 200Ω 3A

Before setting the voltage, make sure the power has been turned off.

Please set power voltage as the possible highest voltage for

Note1: When the AC drive uses with DC reactor, please refer to the wiring diagram in the VFD-E/EL user manual for wiring terminal +(P) of brake unit.

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

460V	2	1.5	0.849	400W 300Ω BUE40015 1	BR200W150 1		140	160Ω	4A
	3	2.2	1.262	300W 400Ω BUE40037 1	BR300W400 2		150	100Ω	6A
	5	3.7	2.080	900W 120Ω BUE40037 1	-	-	150	100Ω	6A

unstable power system. Take 380VAC power system for example. If the voltage may be up to 410VAC, 415VAC should be selected.

For VFD-E/VFD-EL Series, please set parameter Pr06.00=0 (Over Voltage Stall Prevention) to disable over-voltage stall prevention, to ensure stable deceleration characteristic.