YASKAWA CDBR 2015B, 2022B, 2045B, 2110B, 4030B, 4045B, 4090B, 5037B, 5110B, 5300B, LKEB 20P7, 21P5, 22P2, 23P7, 25P5, 27P5, 2011, 2015, 2018, 2022, 40P7, 41P5, 42P2, 43P7, 45P5, 47P5, 4011, 4015, 4018, 4022, 4030, 4037, 4045 Instructions

YASKAWA

YASKAWA AC Drive-Option

BRAKING UNIT,

BRAKING RESISTOR UNIT

INSTRUCTIONS

MODEL: BRAKING UNIT CDBR-

BRAKING RESISTOR UNIT LKEB-

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

YASKAWA

MANUAL NO. TOBP C720600 00C

PREFACE

Braking resistor unit and braking unit are used to consume regenerative energy from motor in the braking resistor unit at deceleration and to improve the transistor inverter braking ability.

Before using the braking resistor unit and braking unit, a thorough understanding of this manual is recommended. This instruction manual will be of great help for daily maintenance, inspection and troubleshooting.

Inverters to which the braking resistor unit and braking unit can be connected are of the following series:

D

YASKAWA AC Drive 1000 Series

D

Varispeed Series

3

General Precautions

S

Some drawings in this manual are shown with the protective cover or shields removed, in order to describe with more clarity. Make sure all covers and shields are replaced before operating this product.

S

Since the drawings in this manual are represented examples, some are subject to differ from delivered products.

S

This manual may be modified when necessary because of improvement of the product, modification or changes in specifications. Such modifications are denoted by a revised manual No.

S

To order a copy of this manual, if your copy has been damaged or lost, contact your YASKAWA representative.

S

YASKAWA is not responsible for any modification of the product made by the user since that will void your guarantee.

4

NOTES FOR SAFE OPERATION

Read this instruction manual thoroughly before installation, operation, maintenance or inspection of the braking unit and the braking resistor unit. In this manual, NOTES FOR SAFE OPERATION are classified as “WARNING” or

“CAUTION.”

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury to personnel and damage to equipment.

It may also be used to alert against unsafe practices.

Even items described in

CAUTION

may result in a vital accident in some situations. In either case, follow these important notes.

NOTE

: These are steps to be taken to insure proper operation.

5

WIRING

WARNING

S

Only commence wiring after verifying that the power supply is turned OFF.

Failure to observe this warning can result in an electrical shock or a fire.

(Ref. page)

27

S

High voltage exists at all terminals of braking unit and braking resistor unit.

Failure to observe this warning can result in an electrical shock.

S

Wiring should be performed only by qualified personnel.

Failure to observe this warning can result in an electrical shock or a fire.

S

When wiring the emergency stop circuit, check the wiring thoroughly before operation.

Failure to observe this warning can result in personal injury.

27

27

27

S

Make sure to ground the ground terminal .

(Ground resistance

200V class: 100Ω or less, 400V class: 10Ω or less)

Failure to observe this warning can result in an electrical shock.

27

S

Short Circuit Current Rating (SCCR)

Install adequate branch short circuit protection according to applicable codes.

Failure to comply could result in damage to the drive.

The device is suitable for circuits capable of delivering 31,000 RMS symmetrical Amperes, 240 Vac maximum (200V Class), 480 Vac maximum (400V

Class) and 575Vac (600V Class) or the SCCR rating of the drive it is connected to, which ever is greater.

7

CAUTION

S

Verify that the rated voltage of the braking unit and the braking resistor unit coincides with the AC power supply voltage.

Failure to observe this caution can result in personal injury or a fire.

(Ref. page)

27

S

Do not perform a withstand voltage test of the braking unit and braking resistor unit.

It may cause semi−conductor elements to be damaged.

S

Connect braking resistors, braking resistor units, and braking units as shown in the I/O wiring examples. Use properly rated wire in accordance with table 2 on page 31.

Otherwise, a fire can occur.

27

27

27

S

Tighten terminal screws to the specified tightening torque.

Failure to observe this caution can result in a fire.

S

Be sure to connect braking resistors or braking resistor units to the braking units.

If neither braking resistor nor braking resistor unit is connected to a braking unit, the fault contact may instantaneously turn ON when the power is turned ON, resulting in malfunction of the inverter.

27

8

OPERATION

WARNING

S

Only turn ON the input power supply after replacing the front cover. Do not remove the cover while current is flowing.

Failure to observe this warning can result in an electrical shock.

(Ref. page)

41

CAUTION

S

Never touch the heatsink or discharging resistor since the temperature is very high.

Failure to observe this caution can result in harmful burns to the body.

(Ref. page)

41

41

S

Do not check signals during operation.

The machine or the inverter may be damaged.

S

Alltheconstantsofthethebrakingunit andthe brakingresistor unit have been preset at the factory. Do not change the settings unnecessarily.

41

9

CAUTION

S

The control PC board employs CMOS ICs. Do not touch the

CMOS elements.

They are easily damaged by static electricity.

(Ref. page)

46

S

Do not connect or disconnect wires or connectors while power is applied to the circuit.

Failure to observe this caution can result in personal injury.

46

OTHERS

WARNING

S

Never modify the product.

Failure to observe this warning can result in an electrical shock or personal injury and will invalidate the guarantee.

11

WARNING INDICATION

A warning label is displayed on the front cover of the braking unit, as shown below.

Follow these instructions when handling the braking unit and the braking resistor unit .

Example of Braking Unit Model CDBR−4045B

12

13

2. INSTALLATION

2.1 LOCATION

If the units are temporarily stored or machine stops for an extended length of time, the following precautions should be taken. Store the units at pollution level 2 or less

(UL standard) and under the following conditions.

S

Free from rainfall and drops of water.

S

Clean and dry.

S

Free from corrosive gases and liquids.

S

Free from dirt and dust.

S

Ambient temperature: 14 to 104_F, −10 to 40_C.

S

Humidity: 90% RH or less (no condensation)

S

Free from vibration.

2.2 INSTALLATION

For full use of the braking resistor unit or braking unit functions, install the units at pollution level 2 or less (UL standard) and in a location to satisfy the following conditions:

Figs. 1 to 8 show the external dimensions and the spaces from the periphery.

S

Provide the spaces shown in Figs. 1 to 8 between the units and the periphery.

S

Since the braking resistor unit generates heat, provide sufficient spaces from devices which are weak against heat.

S

Install the units at such locations that all requirements described in Par.

2.1 “LOCATION” are satisfied.

16

2. INSTALLATION

S

Install the units in the directions shown in Figs. 1 to 8. There will be no problem if they are installed vertically.

4−M4 MTG HOLE

2.83 (72) 2.73 (66.5)

1.18 (30)

OR MORE

1.5 (38)

1.5 (38)

5.04 (128)

5.51 (140)

3−LEAD WIRE OUTLET

[0.87 (20) DIA RUBBER BUSH]

1.18 (30)

OR MORE

Fig. 1

4.51 (114.5)

5.45 (138.5)

Braking Unit Dimensions in inches (mm) CDBR−2015B, −2022B, −4030B,

−4045B

17

3.94 (100)

4−M6

MTG HOLE

MAIN CIRCUIT

TERMINAL M4

2.30

(58.5)

3−LEAD WIRE

OUTLET

1.10 (28) DIA

RUBBER BUSH

1.18 (30)

OR MORE

1.97 (50)

3.94 (100)

5.51 (140)

1.18 (30)

OR MORE

6.57 (167)

Fig. 2 Braking Unit Dimensions in inches (mm) CDBR−5037B

18

2. INSTALLATION

5.51 (140)

4−M6

MTG HOLE

Fig. 3

MAIN CIRCUIT

TERMINAL M5

3.86 (98)

WIRE OUTLET 1.10 (28)

DIA RUBBER BUSH

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER

BUSH

3.94 (100)

2.32 1.97 (50)

(59)

5.51 (140)

7.09 (180)

1.18 (30)

OR MORE

1.18 (30)

OR MORE

4.37 (111)

6.14 (156)

7.87 (200)

Braking Unit Dimensions in inches (mm) CDBR−2045B

19

5.51 (140)

4−M6

MTG HOLE

MAIN CIRCUIT

TERMINAL M6

4.09

(104)

3.94 (100)

2.32 1.97 (50)

(59)

5.51 (140)

7.09 (180)

1.18 (30)

OR MORE

1.18 (30)

OR MORE

4.37 (111)

6.14 (156)

7.87 (200)

Fig. 4 Braking Unit Dimensions in inches (mm) CDBR−2110B

WIRE OUTLET 1.10 (28)

DIA RUBBER BUSH

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER

BUSH

20

2. INSTALLATION

7.09 (180)

4−M6

MTG HOLE

MAIN CIRCUIT

TERMINAL M5

3.86 (98)

WIRE OUTLET 1.10 (28)

DIA RUBBER BUSH

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER

BUSH

5.45 (138.5)

2.70

1.97 (50)

(68.5) 7.09 (180)

8.66 (220)

1.18 (30)

OR MORE

1.18 (30)

OR MORE

4.37 (111)

6.14 (156)

7.87 (200)

Fig. 5 Braking Unit Dimensions in inches (mm) CDBR−4090B, −5110B

21

8.27 (210)

4−M6

MTG HOLE

Fig. 6

MAIN CIRCUIT

TERMINAL M6

4.09

(104)

WIRE OUTLET 1.10 (28)

DIA RUBBER BUSH

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER

BUSH

6.16 (156.5)

4.67 (118.5)

1.97 (50)

8.27 (210)

9.84 (250)

1.18 (30)

OR MORE

1.18 (30)

OR MORE

4.37 (111)

6.14 (156)

7.87 (200)

Braking Unit Dimensions in inches (mm) CDBR−4220B, −5300B

22

2. INSTALLATION b a b

Braking Resistor

Unit Model

(LKEB−j)

20P7

21P5

22P2

23P7

25P5

27P5

40P7

41P5

42P2

43P7

45P5

47P5

Fig. 7

A

Dimensions in inches (mm)

B C D

4.13 (105) 10.83 (275) 1.97 (50) 10.24 (260)

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335)

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335)

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335)

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335)

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335)

4.13 (105) 10.83 (275) 1.97 (50) 10.24 (260)

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335)

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335)

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335)

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335)

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335)

E

M5

M5

M5

M5

M6

M6

M5

M5

M5

M5

M6

M6

Braking Resistor Unit Dimensions in inches (mm) [for 0.5 to 10HP (0.4 to

7.5kW)]

23

Braking Resistor

Unit Model

(LKEB−j)

2011

2015

2018

2022

4011

4015

4018

4022

4030

4037

4045

Dimensions in inches (mm)

A B C D E

10.48 (266) 21.38 (543) 9.69 (246) 13.39 (340) M8

14.02 (356) 21.38 (543) 13.23 (336) 13.39 (340) M8

17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8

17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8

13.78 (350) 16.22 (412) 12.99 (330) 12.80 (325) M6

13.78 (350) 16.22 (412) 12.99 (330) 12.80 (325) M6

17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8

17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8

14.02 (356) 37.64 (956) 13.23 (336) 29.13 (740) M8

17.56 (446) 37.64 (956) 16.77 (426) 29.13 (740) M8

17.56 (446) 37.64 (956) 16.77 (426) 29.13 (740) M8

Fig. 8 Braking Resistor Unit Dimensions in inches (mm) [for 15 to 60HP (11 to

45kW)]

24

2. INSTALLATION

2.3 REPLACEMENT OF CONVENTIONAL BRAKING

UNITS WITH NEW UNITS

To replace conventional braking units (models CDBR−2015, −2022, −4030, −4045) with new units (CDBR−2015B, −2022B, −4030B, −4045B), an exclusive−use attachment is required. Contact your YASKAWA representative.

0.79

(20)

ATTACHMENT

0.28(7)

4−M6 MTG HOLE

3.94 (100)

0.79

(20)

3.94 (100)

5.51 (140)

0.28(7)

0.39 (10

5.45 (138.5)

Code No.: DACT32732−AD

0.39 (10)

Fig. 9 Mounting Dimensions of Attachment in inches (mm)

25

The main circuit terminal symbols are different between conventional models and new models. Refer to the following table.

Table 1 Main Circuit Terminal Symbols

Conventional Models New Models

P

0

B

N

P

©

¨

¨

©

0

0

26

3.2 SECTION NAMES

Figs. 10, 11 and 12 show appearance and each section name of braking unit and braking resistor unit respectively.

Thermal overload relay protects the braking resistor unit for models LKEB−20P7 to −27P5, and thermal protector protects the braking resistor unit for models

LKEB−2011 to −2022 and −4018 to −4045.

WARNING

BRAKING UNIT

MODEL:CDBR−2015B

200V CLASS FOR 15kW

May cause injury or electric shock.

Please follow the instructions in the manual before installation or operation.

Disconnect all power before opening front cover of unit. Wait 3 minutes until DC Bus capacitors discharge.

Use proper grounding techniques.

Power Supply Selection

Connector

Master/Slave

Selection Connector

Calibration Resistor

(Adjusted Prior to

Shipment)

Operation Indicator

(Lights when Discharging.)

Charge Indicator

(Charge Lamp)

© ¨ ¨

0

©

0

1 2 5 6

Control Circuit

Terminals 1 to 6

Lead Wire Outlet

(3 Places: Rubber Bush)

Control Circuit Terminals

© ¨ ¨

0

©

0

Fig. 10 Braking Resistor Unit Model CDBR−2015B (Terminal Cover and

Indicationg Cover Removed)

28

3. WIRING

Thermal Overload Relay

(Automatically Reset)

Lead Wire Outlet

(Rubber Bush)

Fig. 11

Control Circuit Terminals

B, P, 1, 2

Braking Resistor Unit Model LKEB−20P7 (Front Cover Removed)

29

Resistor

Thermal

Overload

Protector

Lead Wire Outlet

(Rubber Bush)

Control Circuit Terminals

B, P, 1, 2

Fig. 12 Braking Resistor Unit Model LKEB−2022 (Front Cover Removed)

30

3. WIRING

3.3 CIRCUITS AND WIRING SPECIFICATIONS

Table 2

Name

Circuits and Wiring Specifications

Circuit

Terminals

Wire

Size

AWG

(mm

2

)

Max.

Torque lb⋅in

(N⋅m)

(

Braking Unit

( (Models CDBR

2015B 2022B

−4030B, −4045B,

−5037B)

Braking Unit

(Model CDBR

−2045B, −4090B,

−5110B)

Braking Unit

(Model

CDBR−2110B,

−4220B, −5300B)

Braking Resistor

Unit

(Model LKEB− j

)

Main

Control

Main

Control

Main

Control

Main

¨

©

¨

©

1 2 3

4 5 6

B

¨

©

¨

©

P

0

0

1 2 3

4 5 6

¨ ¨

0

© ©

0

1 2 3

4 5 6

0

0

12−10

(3.5−5.5)

18−14

(0.75−2)

10−8

(5.5−8) 600V

18−14

(0.75−2)

(High

Voltage)

*3

4 (22)

8−6

(8−14)

*1

18−14

(0.75−2) vinyl sheathed wire or equivalent

12−10

(3.5−5.5)

18−14

(0.75−2)

M5

M4

M6

M4

M4

(M5)

*2

(1.50)

21.7

(2.45)

15.6

(1.76)

43.4

(4.90)

15.6

(1.76)

15.6 (1.76)

(21.7(2.45))

Control

1 2 M4 15.6 (1.76)

*1 For wire size of 8−6 (8−14), use UL1283 heat−resistant vinyl−insulated wire or equivalent.

*2 M4 for Models LKEB−20P7 to −27P5 or −40P7 to −4015.

M5 for Models LKEB−2011 to −2022 or −4018 to −4045.

*3 Models−5037B, −5100B, and −5300B can reach an operating voltage of 1040 VDC.

Please select wire which is suitable for the operating voltage.

31

3.4 WIRING PRECAUTIONS

(1) Wiring Leading−in Method

Lead in the wire through the knockout hole on the unit bottom. Since the knockout hole is provided with a rubber bush, cut the rubber bush central crosswise with a blade and lead the wire through.

(2) Separation from Signal Lines

Since strong noise component is superimposed on the braking resistor unit and braking unit wiring, separate the units from signal lines which are weak against noise.

(3) Wiring Distance

Wiring distance between the braking resistor unit and braking unit or braking unit and inverter must be provided as shown in Fig. 13. Make sure to bundle the wires between the units.

Braking Resistor

Unit

Braking Unit

Inverter

32.8ft

(10m) or less

Fig. 13 Wiring Distance

16.4ft

(5m) or less

32

3. WIRING

(4) Grounding Method

S

Mount the braking resistor unit on a grounded metallic plate. When it cannot be mounted on a grounded metallic plate, pull out the lead wire from the mounting screw section to ground.

S

Braking unit grounding terminal must be provided with the ground resistance of 100Ω or less in 200V class ,or 10Ω or less in 400V class.

S

Use the sizes specified in “INTERNAL CONNECTION SPECIFI-

CATIONS” for grounding cables.

3.5 INTERCONNECTION

Figs. 14 to 20 show the interconnecting diagrams of the braking unit or braking resistor unit and VS−616G5.

Refer to Par. 3.3, “Wiring Precautions” for proper wiring in actual wiring design and work.

Be sure to connect braking resistors or braking resistor units to the braking units.

Connect only braking resistors or Braking Resistor Units (LKEB−XXXX) to Braking Units.

NOTE

If using another braking resistor instead of YASKAWA braking resistor unit, be sure to protect by thermal overload relay.

33

or 380

34

Fault Contact

3. WIRING

Level Detection

35

Fault Contact

Level Detection

36

Fault Contact

3. WIRING

Level Detection

37

Voltage Selection 460/440/415/ 400/380V

Fault Contact

Level Detection

38

) Voltage Selection

460/440/415/ 400/380V

Fault Contact

3. WIRING

Level Detection

39

Fault Contact

Level Detection

40

Voltage Selection 460/440/415/ 400/380V

Fault Contact

4. OPERATION

4. OPERATION

4.1 ADJUSTMENT

The braking resistor unit and braking unit do not have to be adjusted.

Especially, do not readjust the braking unit except in the case described in Par. 4.2,

“Power Supply Voltage Selection Connector Setting.”

4.2 POWER SUPPLY VOLTAGE SELECTION CON-

NECTOR SETTING

It may be necessary to select power supply voltage selection connector for braking unit according to main circuit power supply type. Table 3 shows the relationship between the power supply voltage selection connector and braking start voltage.

The following is the setting prior to shipment:

S

200V class : 220V

S

400V class : 440V

S

575V class : 575V

For removing the terminal cover and the indicating cover, refer to Par. 3.1.

41

WARNING

BRAKING UNIT MODEL:CDBR( 2015B

200V CLASS FOR 15kW

May cause injury or electric shock.

Please follow the instructions in the manual before installation or operation.

Disconnect all power before opening front cover of unit. Wait 3 minutes until DC Bus capacitors discharge.

Use proper grounding techniques.

© ¨ ¨

0

©

0

1 2

5 6

200V class

200V

20

8V

2

20V

2

30V

400V class

380V

400V

4 15V

4

40V

4

60V

Fig. 21 Braking Unit Power Supply Voltage Selection

(Models CDBR−2015B, −2022B, −4030B, −4045B, Terminal Cover and

Indicating Cover Removed)

42

4. OPERATION

200V class

200V

20 8V

2 20V

2 30V

575V class

500V

400V class

380V

400V

4

15V

4 40V

4 60V

575V

Fig. 22 Braking Unit Power Supply Voltage Selection

(Models CDBR−2045B, −2110B, −4090B, −5037B, −5110B, −5300B,

Indicating Cover Removed)

Table 3

200V

Class*

Power

Supply

Voltage

230V

220V

208V

200V

−

Power Supply Voltage Selection Connector and Braking Start Voltage

Braking Start

Voltage

(PN Bus−bar

Voltage)

380V (TYP)

365V (TYP)

345V (TYP)

330V (TYP)

−

400V

Class*

Power

Supply

Voltage

460V

440V

415V

400V

380V

*Allowable voltage fluctuation is ±10%

Braking Start

Voltage

(PN Bus−bar

Voltage)

760V (TYP)

730V (TYP)

690V (TYP)

660V (TYP)

630V (TYP)

575V

Class*

Power

Supply

Voltage

575V

−

−

500V

−

Braking Start

Voltage

(PN Bus−bar

Voltage)

950V (TYP)

−

−

825V (TYP)

−

43

4.3 MASTER/SLAVE SELECTION CONNECTOR SETTING

Selection Connector Setting MASTER side is selected prior to shipment. Use the units without changing the setting.

SLAVE side is selected when more than one braking unit is combined to use and braking start levels must coincide. Refer to Par. 4.4, “Parallel Connection of Braking Unit” for details.

4.4 PARALLEL CONNECTION OF BRAKING UNIT

For using more than one parallel−connected braking unit, connect and select the connectors as follows. (See Fig. 23.)

S

Braking units have a MASTER/SLAVE selection connector. (See Fig.

10.) Select MASTER side only for braking unit 1 and select SLAVE side for braking units 2 and 3.

S

Connect thermal protector on the braking resistor unit and thermoswitch on the braking unit in parallel. Refer to Figs. 15 and 18 for proper wiring.

S

Use properly rated wire in accordance with table 2 on page 31.

S

Use twisted−pair wires of 1mm or less for connection between 5, 6 and

1, 2 of the braking units.

S

Parallel connection of braking unit is possible up to a maximum of 10 units.

44

4. OPERATION

¨

3

Inverter

Unit

©

1

2

©

¨

Braking Resistor

Overheat Contact

(Thermal Relay Trip Contact)

1

P

¨

0

2

Braking

B

Resistor

Unit

©

0

© ¨

MASTER

Braking Resistor

Overheat Contact

(Thermal Relay Trip Contact)

1

P

¨

0

MASTER

2

B

Braking

Resistor

Unit

©

0

©

¨

Braking Resistor

Overheat Contact

(Thermal Relay Trip Contact)

1 2

B

Braking

Resistor

Unit

P

¨

0

MASTER

©

0

Level Detection

SLAVE

+15

5 1

6

P

2

SLAVE

Braking Unit 2

5 1

6

P

2

SLAVE

Braking Unit 3

5

6

Braking Unit 1

3 4

Cooling Fin

Overheat Contact

(Thermoswitch Contact)

3 4

Cooling Fin

Overheat Contact

(Thermoswitch Contact)

3 4

Cooling Fin

Overheat Contact

(Thermoswitch Contact)

Fig. 23 Example of Parallel Connection of Three Braking Units

4.5 OPERATION

Check that required deceleration characteristics can be obtained. While the braking unit is operating, BRAKE lamp lights for easy check of operation.

NOTE

High voltage is applied to the braking unit. At normal operation, do not operate the unit without cover.

4 5

5. TROUBLESHOOTING

Only authorized personnel should be permitted to perform maintenance and inspections or replace parts.

No.

Fault Status Cause Corrective Action

S

Without braking unit

1

3

Braking resistor unit overload relay (or thermal p

) i h decelerating.

4

Braking unit trips by heat sink overheat.

Inverter built−in main circuit discharging transistor short circuited

S

With braking unit

Braking unit main circuit discharging transistor short circuited

Improper braking unit power supply voltage selection connector setting

(Power supply voltage > power supply voltage selection position)

Inverter trips at overvoltage (OV).

Insufficient braking resistor unit capacity

Improper wiring

Braking unit fault

Braking resistor unit overload relay (or thermal protector) sometimes trips.

Insufficient braking resistor unit capacity

Replace the inverter.

Replace the unit.

Set it again.

Examine the braking conditions again.

Check and repair.

Replace the unit.

Examine the braking conditions again.

Excessive start/stop switching frequency

Examine the operating conditions again.

Excessive load inertia

Improper combination of braking unit and braking resistor unit

Reset.

Ambient temperature 104_F (40_C) Reduce it.

5

The fault contact of a braking unit instantaneously turned ON when the power was turned ON.

Neither a braking resistor nor a braking resistor unit is connected to the braking unit.

Connect a braking resistor or braking resistor unit to the braking unit.

46

6. SPECIFICATIONS

6. SPECIFICATIONS

6.1 BRAKING UNIT AND BRAKING RESISTOR UNIT

APPLICATION LIST

The applicable braking unit and braking resistor unit models differ depending on the inverter model. Refer to the catalog of the relevant inverter.

Example: 200−V Class Inverter Model CIMR−G5 j

Inverter

Max Applicable

Motor Capacity

HP(kW)

Braking Unit

Model

(CDBR

− j)

Unit

Q’ty

Braking Resistor Unit

Model

(LKEB

− j)

Resistor Spec.

(per unit)

Unit

Q’ty

Approx.

Braking

Torque

(10%ED)

0.5 (0.4)

1 (0.75)

2 (1.5)

3 (2.2)

5 (3.7)

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

30 (22)

40 (30)

50 (37)

60 (45)

75 (55)

100 (75)

120 (90)

150 (110)

−

−

−

−

−

−

−

2015B

2015B

2022B

2022B

2015B

2015B

2022B

2022B

2110B

2110B

2110B

−

−

−

−

−

−

−

1

1

1

1

2

2

2

2

1

1

1

20P7

20P7

21P5

22P2

23P7

25P5

27P5

2011

2015

2018

2022

2015

2015

2022

2022

2022

2022

2022

70W 200Ω

70W 200Ω

260W 100Ω

260W 70Ω

390W 40Ω

520W 30Ω

780W 20Ω

2400W 13.6Ω

3000W 10Ω

4800W 8Ω

4800W 6.8Ω

3000W 10Ω

3000W 10Ω

4800W 6.8Ω

4800W 6.8Ω

4800W 6.8Ω

4800W 6.8Ω

4800W 6.8Ω

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

3

4

5

Note:

The above table lists the applicable braking unit and braking resistor unit models for the 200−V class inverter model CIMR−G5j. For other inverter models, refer to the catalog of the relevant inverter.

120

100

110

120

100

125

125

125

125

100

%

220

125

125

120

125

115

125

125

47

Example: 400−V Class Inverter Model CIMR−G5 j

Inverter

Max Applicable

Motor Capacity

HP(kW)

Braking Unit

Model

(CDBR

− j)

Unit

Q’ty

Braking Resistor Unit

Model

(LKEB

− j)

Resistor Spec.

(per unit)

Unit

Q’ty

Approx.

Braking

Torque

(10%ED)

%

0.5 (0.4)

1 (0.75)

2 (1.5)

3 (2.2)

5 (3.7)

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

30 (22)

40 (30)

50 (37)

60 (45)

75 (55)

100 (75)

150 (110)

200 (160)

300 (220)

400 (300)

800 (600)

−

−

−

−

−

−

−

−

−

4030B

4030B

4030B

4045B

4045B

4030B

4045B

4030B

4220B

4220B

4220B

4220B

−

−

−

−

−

−

−

−

−

1

1

1

1

1

2

2

3

1

1

2

4

40P7

40P7

41P5

42P2

43P7

45P5

47P5

4011

4015

4018

4022

4030

4037

4045

4030

4045

4030

4045

4037

4045

4045

70W 750Ω

70W 750Ω

260W 400Ω

260W 250Ω

390W 150

Ω

1

520W 100Ω

780W 75Ω

1040W 50Ω

1560W 40Ω

1

1

1

1

4800W 32

Ω

4800W 27.2Ω

1

1

6000W 20Ω

9600W 16Ω

9600W 13.6Ω

6000W 20Ω

9600W 13.6Ω

6000W 20Ω

9600W 13.6Ω

9600W 16Ω

1

1

1

2

2

3

4

5

9600W 13.6Ω 6

9600W 13.6Ω 12

1

1

1

1

125

125

125

125

135

135

130

135

125

125

135

230

130

125

135

145

100

140

110

110

110

Note:

The above table lists the applicable braking unit and braking resistor unit models for the 400−V class inverter model CIMR−G5j. For other inverter models, refer to the catalog of the relevant inverter.

48

6. SPECIFICATIONS

6.2 BRAKING UNIT FOR 575V CLASS APPLICATION LIST

Example: 575−V Class Inverter Model CIMR−G5 j

Inverter

Max Applicable

Motor Capacity

HP(kW)

Braking Unit

Model

(CDBR− j)

Unit Q’ty

Braking Resistor Unit

Resistor Spec.

Approx.

Braking

Torque

(10%ED)

5 (3.7)

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

30 (22)

40 (30)

50 (37)

60 (45)

75 (55)

100 (75)

120 (90)

150 (110)

200 (160)

−

−

−

−

−

−

5037B

5037B

5037B

5037B

5037B

5110B

5110B

5110B

5300B

−

−

−

−

−

−

1

1

1

2

2

1

1

1

1

560W 150Ω

560W 150Ω

750W 100Ω

1100W 75Ω

1500W 50Ω

2300W 40Ω

2800W 38Ω

3900W 33Ω

4900W 27Ω

5900W 22Ω

7200W 18Ω

9800W 13.6Ω

12000W 11Ω

15000W 9Ω

21000W 6.8Ω

%

180

125

140

125

140

140

125

110

110

110

110

105

110

110

100

Note:

The above table lists the applicable braking unit and braking resistor unit models for the 575−V class inverter model CIMR−G5j. For other inverter models, refer to the catalog of the relevant inverter.

49

Conventional

Model

VS−616HII/H3

VS−616GII/G3

VS−676

VS−616HII/H3

VS−616GII/G3

VS−676

VS−616HII/H3

VS−616GII/G3

VS−676

VS−616HII/H3

VS−616GII/G3

VS−676

6.3 LIST OF APPLICABLE/NOT APPLICABLE COMBINA-

TIONS WITH CONVENTIONAL MODELS (VS−616HII/

H3, VS−616GII/G3, VS−676)

Braking

Unit

−

Model

CDBR−15H etc.

Models

CDBR

−2015,

−2015B etc.

Models

CDBR

−2015,

−2015B etc.

Braking Resistor Unit

Applicable/

Not Applicable

Model

LKEB−20P7 etc.

Model

LKEB−2015 etc.

Model

LKEB−4.8K

etc.

Model

LKEB−2015 etc.

Applicable

Applicable

Not applicable

Applicable

Remarks

See connection examples of Fig 14.

Use sequencer to break power supply side on thermal protector of the braking resistor unit side.

No thermal protective function of braking resistor unit.

See connection examples of Figs. 15 to 18.

50

6. SPECIFICATIONS

6.4 BRAKING UNIT SPECIFICATIONS

Braking Unit Model

CDBR−

Applicable Motor Output

HP (kW)

Output characteristics

Max. Discharge

Current(A)

(peak value) *

Rated Discharge

Current (A)

Braking Start

Voltage

Max. Hysteresis

Error

Power

Supply

Protective

Functions

VDC

Fin Overheat

Power Charge

Indication

Envionmental

Conditions

Location

Altitude

Ambient

Temperature

Storage

Transportation

Temperature

Humidity

Vibration

Protective Configuration

Heat Loss (W)

2015

B

20

(15)

200V to 300V

2022

B

30

2045

B

60

(22) (45)

40 60 100

2110

B

150

(110)

250

4030

B

40

(30)

380V to 460V

4045

B

60

4090

B

120

(45) (90)

40 60 100

4220

B

300

(220)

250

57

500V to 575V

5037

B

5110

B

150

5300

B

400

(37)

40

(110)

100

(300)

250

15 20 30

330/345/365/380V ±3V

80 15 18 30 80

630/660/690/730/760V ±6V

243 (1.35×200×0.9) to 400V peak

Approx. 8V Approx. 16V

460 (1.35×380×0.9) to 800V peak

Thermostat

Charge lamp stays ON until bus voltage drops below 50V.

Indoor (protected from corrosive gases and dust)

1000m max.

+14 to 104_F (−10 to +40_C) (not frozen)

15 30 80

825V/ 950V ±8V

Approx.

20V

607 (1.35×500×0.9) to 1000V

32 38

−4 to 140_F (−20 to +60_C)

90%RH (non−condensing)

1G at 10 to less than 20Hz, up to 0.2G at 20 to 50 Hz

31 64

Wall−mounted enclosed type

54 59 35 71 22 53 116

* Loading time rate can be used below 10% ED (max. 10 sec.)

51

Model

(LKEB

− j)

42P2

43P7

45P5

47P5

4011

4015

4018

4022

4030

4037

4045

20P7

21P5

22P2

23P7

25P5

27P5

2011

2015

2018

2022

40P7

41P5

6.5 BRAKING RESISTOR UNIT SPECIFICATIONS

200 to

380 to

Specifications

70W 200Ω

260W 100Ω

260W 70Ω

390W 40Ω

520W 30Ω

780W 20Ω

2400W 13.6Ω

3000W 10Ω

4800W 8Ω

4800W 6.8Ω

70W 750Ω

260W 400Ω

260W 250Ω

390W 150Ω

520W 100Ω

780W 75Ω

1040W 50Ω

1560W 40Ω

4800W 32Ω

4800W 27.2Ω

6000W 20Ω

9600W 16Ω

9600W 13.6Ω

Allowable

Average

Dissipated

Power

(W)

600

740

880

1200

1500

1800

89

150

220

300

440

600

740

880

30

60

30

60

89

150

220

300

440

Allowable

Average

Current

(Effective Value)

(A)

3.9

4.8

5.7

7.7

9.7

11.5

0.60

1.0

1.5

2.0

3.0

7.7

9.6

11.4

0.20

0.39

0.39

0.77

1.1

1.9

2.7

3.9

5.7

Allowable

Ambient

Temperature

+14 to 122_F

( 10 to +50_C)

52

6. SPECIFICATIONS

6.6 MODELS AND CODE NOS. OF BRAKING UNIT AND

BRAKING RESISTOR UNIT

(1) Braking Unit

Inverter

Voltage HP (kW)

200 to

230V

380 to

460V

500 to

575V

20 (15) CDBR−2015B 72600−R2150B

30 (22) CDBR−2022B 72600−R2220B

60 (45) CDBR−2045B 72600−R2450B

150 (110) CDBR−2110B 72600−R21100B

40 (30) CDBR−4030B 72600−R4300B

60 (45) CDBR−4045B 72600−R4450B

120 (90) CDBR−4090B 72600−R4900B

300 (220) CDBR−4220B 72600−R42200B

50 (37) CDBR−5037B 72600−R5370B

150 (110) CDBR−5110B 72600−R51100B

400 (300) CDBR−5300B 72600−R53000B

53

(2) Braking Resistor Unit

Inverter

Voltage HP(kW)

1 (0.75)

200 to

230V

2 (1.5)

3 (2.2)

5 (3.7)

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

30 (22)

1 (0.75)

380 to

460V

2 (1.5)

3 (2.2)

5 (3.7)

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

30 (22)

40 (30)

50 (37)

60 (45)

Resistor Spec.

(per unit)

70W 200Ω

260W 100Ω

260W 70Ω

390W 40Ω

520W 30Ω

780W 20Ω

2400W 13.6Ω

3000W 10Ω

4800W 8Ω

4800W 6.8Ω

70W 750Ω

260W 400Ω

260W 250Ω

390W 150Ω

520W 100Ω

780W 75Ω

1040W 50Ω

1560W 40Ω

4800W 32Ω

4800W 27.2Ω

6000W 20Ω

9600W 16Ω

9600W 13.6Ω

LKEB−20P7 72600−K2P70

LKEB−21P5 72600−K2010

LKEB−22P2 72600−K2020

LKEB−23P7 72600−K2030

LKEB−25P5 72600−K2050

LKEB−27P5 72600−K2070

LKEB−2011

LKEB−2015

LKEB−2018

72600−K2110

72600−K2150

72600−K2180

LKEB−2022 72600−K2220

LKEB−40P7 72600−K4P70

LKEB−41P5 72600−K4010

LKEB−42P2 72600−K4020

LKEB−43P7 72600−K4030

LKEB−45P5 72600−K4050

LKEB−47P5 72600−K4070

LKEB−4011

LKEB−4015

LKEB−4018

LKEB−4022

LKEB−4030

LKEB−4037

LKEB−4045

72600−K4110

72600−K4150

72600−K4180

72600−K4220

72600−K4300

72600−K4370

72600−K4450

54

英文 No.10-4（B6） インバータ製品用

YASKAWA AC Drive-Option

BRAKING UNIT,

BRAKING RESISTOR UNIT

INSTRUCTIONS

IRUMA BUSINESS CENTER (SOLUTION CENTER)

480, Kamifujisawa, Iruma, Saitama, 358-8555, Japan

Phone: 81-4-2962-5696 Fax: 81-4-2962-6138

YASKAWA ELECTRIC CORPORATION

New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo, 105-6891, Japan

Phone: 81-3-5402-4511 Fax: 81-3-5402-4580 http://www.yaskawa.co.jp

YASKAWA ELECTRIC AMERICA, INC.

2121 Norman Drive South, Waukegan, IL 60085, U.S.A.

Phone: (800) YASKAWA (800-927-5292) or 1-847-887-7000 Fax: 1-847-887-7310 http://www.yaskawa.com

YASKAWA ELÉTRICO DO BRASIL COMÉRCIO LTDA.

Avenda Fagundes Filho, 620 Bairro Saude, São Paulo, SP04304-000, Brasil

Phone: 55-11-3585-1100 Fax: 55-11-5581-8795 http://www.yaskawa.com.br

YASKAWA ELECTRIC EUROPE GmbH

Hauptstraβe 185, 65760 Eschborn, Germany

Phone: 49-6196-569-300 Fax: 49-6196-569-398

YASKAWA ELECTRIC UK LTD.

1 Hunt Hill Orchardton Woods, Cumbernauld, G68 9LF, United Kingdom

Phone: 44-1236-735000 Fax: 44-1236-458182

YASKAWA ELECTRIC KOREA CORPORATION

7F, Doore Bldg. 24, Yeoido-dong, Youngdungpo-Ku, Seoul, 150-877, Korea

Phone: 82-2-784-7844 Fax: 82-2-784-8495

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.

151 Lorong Chuan, #04-02A, New Tech Park, 556741, Singapore

Phone: 65-6282-3003 Fax: 65-6289-3003

YASKAWA ELECTRIC (SHANGHAI) CO., LTD.

No. 18 Xizang Zhong Road, Room 1702-1707, Harbour Ring Plaza, Shanghai, 200001, China

Phone: 86-21-5385-2200 Fax: 86-21-5385-3299

YASKAWA ELECTRIC (SHANGHAI) CO., LTD. BEIJING OFFICE

Room 1011A, Tower W3 Oriental Plaza, No. 1 East Chang An Ave.,

Dong Cheng District, Beijing, 100738, China

Phone: 86-10-8518-4086 Fax: 86-10-8518-4082

YASKAWA ELECTRIC TAIWAN CORPORATION

9F, 16, Nanking E. Rd., Sec. 3, Taipei, Taiwan

Phone: 886-2-2502-5003 Fax: 886-2-2505-1280

YASKAWA ELECTRIC CORPORATION

YASKAWA

In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture thereof, the export will fall under the relevant regulations as stipulated in the Foreign

Exchange and Foreign Trade Regulations. Therefore, be sure to follow all procedures and submit all relevant documentation according to any and all rules, regulations and laws that may apply.

Specifications are subject to change without notice for ongoing product modifications and improvements.

©

2005-2010 YASKAWA ELECTRIC CORPORATION. All rights reserved.

MANUAL NO. TOBP C720600 00C

Published in Japan April 2010 05-3

10-3-3

8 -0