VFDB 4132 Brake Units

2008-09-10

5011669601-1CBU

VFDB 4132 Series Brake Modules

Instruction Sheet

XPreface

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.

YSpecifications

	Specification	460V Series
Max. Motor Capacity (kW)		132
Output Rating	Max. Discharge Current (A) 10%ED	240
	Continuous Discharge Current (A)	75
	Braking Start-up Voltage (DC)	618/642/667/690/725/750±6V
	Braking Start-up Voltage (DC)	618/642/667/690/725/750±6V
Input	DC Voltage	480-750VDC
Rating	DC Voltage
Rating
Min. Equivalent Resistor for Each Brake Unit		3.4Ω
Protection	Heat Sink Overheat Temperature	Temperature exceeds +95 oC (203oF)
	Alarm Output for Overheat	Relay contact 3A250VAC/30VDC
	Alarm Output for Overheat	(RA, RC)
		(RA, RC)
	Power Charge Display	ON until the bus (P-N) voltage is
	Power Charge Display	below 50VDC
		below 50VDC
	Over-current Protection Level	320A
		Indoor (no corrosive gases, metallic

3.2 Brake unit

CHARGE ACT OC OH

VFDB4132

[Internal Components and Terminals

4.1Internal Components

4.2 Wire Gauge for Terminals

Circuit	Terminals		Wire Gauge AWG	Screw	Torque
			(mm2)

Power Input	DC+, DC-		4~6AWG	M8	30 kgf-cm
Circuit			(13.3~21.2mm2)		(26 in-lbf)
Brake	B1, B2		4~6AWG	M8	30 kgf-cm
Resistor			(13.3~21.2mm2)		(26 in-lbf)
SLAVE	Output	M1, M2	18~20AWG		4 kgf-cm
			(0.8~0.5mm2)	M2

Circuit	Input	S1, S2	(With shielded wires)		(3 in-lbf)
Fault	RA, RC		18~20AWG	M2	4 kgf-cm
Circuit			(0.8~0.5mm2)		(3 in-lbf)

\Basic Wiring Diagram

]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

VFD series	VFDB	BR
	series

AC Motor Drive Max 8M	Brake Unit	Max 5M
		Brake Resistor

^Definition for the Brake Usage ED%

100%


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

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.

+(P) -(N)	DC+ DC -	DC+ DC -		DC+ DC -
	M1	S1	M1	S1
VFD	M2	S2	M2	S2
VFD	M
Series	M
Series			S	S
			S	S

O.L.

The Position of the Jumper

M		MASTER/SLAVE
	S	Setting Jumper
	S

Input Voltage Setting

480V			M1: SLAVE output signal +
460V			M2: SLAVE output signal -
440V
			S1: SLAVE input signal +
415V
			S2: SLAVE input signal -
400V
			NOTE: Please use shielded
380V
M1 M2	S1 S2	RA RC	wires while wiring.

SLAVE output/input terminal		Alarm output terminals

NOTE

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

Voltage

Applicable

Full-load

Resistor Value

Brake Unit

Brake Resistors

Brake

Min.

Typical

Motor

Equivalent

Thermal

Torque

Spec. for Each

Part No.

Part No. and

Torque

Resistor Value

Overload

kg-M

AC Motor

and

Quantity

10%ED

for Each AC

Relay

Drive

Quantity

Motor Drive

Value

120

52.5

13500W 5Ω

4132

BR1K5W005

120

5Ω

110A

150

110

21600W 4Ω

4132

BR1K2W008

120

4Ω

135A

460V

175

132

73.5

21600W 4Ω

4132

BR1K2W008

100

4Ω

135A

215

160

21600W 3.4Ω

4132

BR1K2W6P8

3.4Ω

160A

250

185

103

27000W 2.5Ω

4132

BR1K5W005

115

2.5Ω

220A

300

220

122.5

27000W 2.5Ω

4132

BR1K5W005

2.5Ω

220A

aExamples

NOTE

Environment	Installation Location		dust)
			dust)
	Operating Temperature		-10oC~+50oC (14oF to 122oF)
	Storage Temperature		-20oC ~+60oC (-4oF to 140oF)
	Humidity		Less than 90% Non-condensing
	Vibration		9.8m/s2 (1G) under 20Hz / 2m/s2
	Vibration		(0.2G) at 20~50Hz
			(0.2G) at 20~50Hz
Mechanical Configuration			Wall-mounted enclosed type IP10

		Brake Resistors
	Model no.		Specification

NFB MC

R/L1

S/L2 T/L3

O.L.

SA Surge Absorber

Thermal Overload

Relay or Temperature switch

R/L1 R/L1 S/L2 S/L2 T/L3 T/L3

VFD Series

+(P) -(N) E.F

DCM

Motor

DC+ B1

DC- VFDB

RA Brake

Unit

RC B2

Thermal

Overload

Relay

$\Basic Wiring Diagram$ O.L.

Brake

Resistor

Temperature Switch

NOTE

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

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

Thermal Overload Relay

+(P)

DC+

O.L.

VFD

-(N)

DC-

VFDB

Series

4132

Brake Unit

Brake

VFD900_43_

Resistor

BR1K5W005	1500W 5.0Ω
BR1K2W6P8	1200W 6.8Ω
BR1K2W008	1200W 8.0Ω
BR1K5W040	1500W 40Ω
BR1K0W050	1000W 50Ω
BR1K0W075	1000W 75Ω

ZDimensions

3.1Brake resistor

Note 1: When the AC motor drive is used with DC reactor, please refer to the wiring diagram in the AC drive user manual for wiring terminal DC+ of brake unit.

Note 2: DO NOT wire terminal DC- to the neutral point of power system.

NOTE

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.

AC Power Voltage	Brake Start-up voltage
AC Power Voltage	DC Bus (DC+, DC-) 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%
Input voltage setting for VFDB 4132
	CHARGE ACT	OC	OH
	Power lamp Brake lampOver-current Overheat
Input Voltage Setting		lamp	lamp
Input Voltage Setting
	480V
For VFDB4132	460V
Factory setting: 440V	440V
	415V
	400V
	380V

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.

VFD900_43 _ uses with 3 BR sets in parallel, which 3PCS 1K5W005 brake resistors are connected in series.

460V 150HP, 175HP, 215HP

Therm al Over load Rel ay

+ (P)

D C+

VFD

VF DB

O.L.

Ser ies -( N)

D C-

4132

Bra ke

Bra ke U nit

VF D1100_ 43_

R esi stor

VF D13 20_43_

VF D16 00_43_

VFD1100_ 43_ uses w ith 6 BR sets in p aral lel, w hich 3PC S 1K2W 008 bra ke r esisto rs are con necte d in serie s.

VF D13 20_43_ use s w ith 6 BR sets in par all el, wh ich 3PCS 1 K2W00 8 brake resistors are con necte d in serie s.

VFD16 00_43_ use s w ith 6 BR sets in pa rall el, wh ich 3PC S 1K2W6 P8 brake re si stor s are con necte d in serie s.

460V 250HP, 300HP

Thermal Overload Rel ay

+ (P) -( N)

DC+ DC- B1

VFDB

VF D

O.L .

Brake

4132

Ser ies

Brake Unit

Resistor

VFD1850_43_

VFD2200_43_

Brake

M1 M2

Resistor

S1 S2

VFD1850_43_ uses with 2 VF DB4132 brake units and each brake unit uses with

3 BR sets i n parall el, which 3PCS 1K5W005 brake resistors are connected in series. VFD2200_43_ uses with 2 VFDB4132 brake units and each brake unit uses with

3 BR sets i n parall el, which 3PCS1K5W005 brake resi stors are connected in seri es .

Delta Electronics VFDB 4132 Series specifications VFDB 4132 Brake Units, Brake Resistors

Models: VFDB 4132 Series

VFDB 4132 Series Brake Modules

XPreface

YSpecifications