Yaskawa Dynamic Brake Module Instruction manual

YASKAWA

FOR VARISPEED-600 SERIES INVERTER

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. TOE-C726-2F

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:

-

VS − 616 Series

-

VS − 676 Series

-

VS − 866 Series

3

General Precautions

: Some drawings in this manual areshown 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.

:

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

:

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.

:

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

: 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

RECEIVING

CAUTION

:

Do not install or operate any braking unit or braking resistor unit which is damaged or has missing parts.

Failure to observe this caution may result in personal injury or equipment damage.

(Ref. page)

15

INSTALLATION

CAUTION

:

Lift the cabinet by the base. When moving the unit, never lift by the front cover.

Otherwise, the main unit may be dropped causing damage to the unit.

(Ref. page)

16

16

:

Mount the braking unit and braking resistor unit on nonflammable material (i.e. metal).

Failure to observe this caution can result in a fire.

:

Whenmountingmultipleunitsinanenclosure,installafanor other cooling device to keep the intake air temperature below 40

E

C.

Overheating may cause a fire or damage to the unit.

16

6

WIRING

WARNING

:

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

:

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

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

:

Wiring should be performed only by qualified personnel.

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

:

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

27

: Make sure to ground the ground terminal .

(Ground resistance

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

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

7

CAUTION

:

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

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

It may cause semi − conductor elements to be damaged.

:

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

:

Tighten terminal screws to the specified tightening torque.

Failure to observe this caution can result in a fire.

27

8

OPERATION

WARNING

:

Only turn ONthe 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

:

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

:

Do not check signals during operation.

The machine or the inverter may be damaged.

:

Alltheconstantsofthethebrakingunitandthebrakingresistor unit have been preset at the factory. Do not change the settings unnecessarily.

41

41

9

MAINTENANCE AND INSPECTION

WARNING

:

Never touch high − voltage terminals in the the braking unit and braking resistor unit.

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

:

Replace all protective covers before powering up the braking unit and the braking resistor unit. To remove the cover, make sure to shut OFF the molded − case circuit breaker.

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

:

Perform maintenance or inspection only after verifying that the CHARGE LED goes OFF, after the main circuit power supply is turned OFF.

The capacitors are still charged and can be dangerous.

:

Only authorized personnel should be permitted to perform maintenance, inspections or parts replacement.

[Remove all metal objects (watches, bracelets, etc.) before operation.]

(Use tools which are insulated against electrical shock.)

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

(Ref. page)

46

46

46

46

10

CAUTION

:

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

CMOS elements.

They are easily damaged by static electricity.

:

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.

(Ref. page)

46

46

OTHERS

WARNING

:

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 .

Warning

Indication

Example of Braking Unit Model CDBR − 4045B

12

Warning Indication

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.

13

CONTENTS

NOTES FOR SAFE OPERATION

1.

RECEIVING

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

15

2.

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

REPLACEMENT OF CONVENTIONAL BRAKING UNITS

WITH NEW UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

16

16

25

3.

WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

REMOVING AND REPLACING THE COVERS OF THE

BRAKING UNIT (MODELS CDBR − 2015B, − 2022B,

− 4030B, − 4045B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

SECTION NAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

CIRCUITS AND WIRING SPECIFICATIONS . . . . . . . . . .

3.4

WIRING PRECAUTIONS

3.5

INTERCONNECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

27

28

31

32

33

4.

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

4.1

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

41

4.2

POWER SUPPLY VOLTAGE SELECTION CONNECTOR

SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

4.3

MASTER/SLAVE SELECTION CONNECTOR SETTING 44

4.4

PARALLEL CONNECTION OF BRAKING UNIT 44

4.5

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

5.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

6.

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

6.1

BRAKING UNIT AND BRAKING RESISTOR UNIT

APPLICATION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

6.2

BRAKING UNIT FOR 575V CLASS APPLICATION LIST 49

6.3

LIST OF APPLICABLE/NOT APPLICABLE

COMBINATIONS WITH CONVENTIONAL

6.4

MODELS (VS − 616HII/H3, VS − 616GII/G3, VS

BRAKING UNIT SPECIFICATIONS

− 676) . . . .

. . . . . . . . . . . . . . . . . .

6.5

BRAKING RESISTOR UNIT SPECIFICATIONS . . . . . . . .

50

51

52

14

1. RECEIVING

1. RECEIVING

The braking resistor unit and braking unit have been put through severe tests at the factory before shipment. After unpacking, however, check and see the following.

If any malfunctions are found, contact your YASKAWA representative.

: Their nameplate data meet your requirements.

:

They have sustained no damage while in transit.

: Fastening bolts and screws are not loose.

15

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 under the following conditions.

:

Free from rainfall and drops of water.

:

Clean and dry.

: Free from corrosive gases and liquids.

:

Free from dirt and dust.

: Ambient temperature: 14 to 104 E F, − 10 to 40 E C.

: Humidity: 90% RH or less (no condensation)

: Free from vibration.

2.2 INSTALLATION

For full use of the braking resistor unit or braking unit functions, install the units in a location to satisfy the following conditions:

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

:

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

:

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

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

2.1 “LOCATION” are satisfied.

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

16

4 − M4 MTG HOLE

2.

INSTALLATION

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

Braking Resistor

Unit Model

(LKEB −

P

)

20P7

21P5

22P2

23P7

25P5

27P5

40P7

41P5

42P2

43P7

45P5

47P5

Dimensions in inches (mm)

A B C D E

4.13 (105) 10.83 (275) 1.97 (50) 10.24 (260) M5

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6

4.13 (105) 10.83 (275) 1.97 (50) 10.24 (260) M5

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5

5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6

9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6

Fig. 7 Braking Resistor Unit Dimensions in inches (mm) [for 0.5 to 10HP (0.4 to

7.5kW)]

23

Braking Resistor

Unit Model

(LKEB −

P

)

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

(2 0 )

ATTACHMENT

0.28(7)

4 − M6 MTG HOLE

3.94 (100)

0.79

(2 0 )

3.94 (100)

5.51 (140) 0.28(7)

0.39 (

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

N

P

P

0

B

©

¨

¨

©

0

0

26

3. WIRING

3.

WIRING

3.1

REMOVING AND REPLACING THE COVERS OF THE

BRAKING UNIT (MODELS CDBR

−

2015B,

−

2022B,

−

4030B,

−

4045B)

(1) Removing and Replacing the Terminal Cover

For removing, grasp the terminal cover at (1) on both sides and then lift in the direction of (2). For replacing, reverse the method.

Terminal

Cover

(2) Removing and Replacing the Indicating Cover

Remove the terminal cover first. Push down on the lever in the direction of

(1) and lift the cover in the direction of (2). For replacing, reverse the method.

Indicating Cover

(2)

Lever

(1)

27

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.

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

3.3 CIRCUITS AND WIRING SPECIFICATIONS

Table 2 Circuits and Wiring Specifications

Name Circuit

Terminals

Wire

Size

AWG

(mm 2 )

Max.

Torque lb ⋅ in

(N ⋅ m)

Braking Unit

( (Models CDBR

− 2015B 2022B

− 4030B, − 4045B,

− 5037B)

Main

Control

¨ ¨

© ©

0

0

1 2 3

4 5 6

12

(3.5

18

−

−

−

(0.75

10

5.5)

14

− 2)

(1.50)

Braking Unit

(Model CDBR

− 2045B, − 4090B,

− 5110B)

Braking Unit

( (Model

CDBR − 2110B,

− 4220B, − 5300B)

Main

Control

Main

¨ ¨

© ©

1 2 3

4 5 6

¨

©

¨

©

0

0

0

0

1 2 3

4 5 6

(5.5

(0.75

− 2)

(8

10 − 8

18 −

− 8) 600V

14

4 (22)

8

−

− 6

14) *1

18 − 14

(0.75

− 2)

(High

Voltage) *3 vinyl sheathed wire or equivalent

M5

M4

M6

21.7

(2.45)

15.6

(1.76)

43.4

(4.90)

Braking Resistor

Unit

(Model LKEB j )

−

Control

Main

Control

B

1

P

2

12

(3.5

18

−

−

−

(0.75

10

5.5)

14

− 2)

M4

M4

(M5)

M4

*2

15.6

(1.76)

15.6 (1.76)

(21.7(2.45))

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

:

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.

: Braking unit grounding terminal must be provided with class 3 ground

(ground resistance: 100 Ω or less.)

: 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

∼ ∼

∼ ∼

Fault Contact

35

Level Detection

∼ ∼

∼ ∼

Fault Contact

36

3. WIRING

Level Detection

∼ ∼

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

∼ ∼

Fault Contact

37

Level Detection ∼ ∼

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

∼ ∼

Fault Contact

38

3. WIRING

Level Detection

∼ ∼

∼ ∼

Fault Contact

39

Level Detection

∼ ∼

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

∼ ∼

Fault Contact

40

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:

: 200V class: 220V

:

400V class: 440V

:

575V class: 575V

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

41

BRAKING UNIT MODEL:CDBR − 20 1 5B

200V CLASS FOR 1 5kW

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

208V

220V

230V

4 00V class

380V

400V

415V

440V

460V

Fig. 2 1 Braking Unit Power Supply Voltage Selection

(Models CDBR − 20 1 5B, − 2022B, − 4030B, − 4045B, Terminal Cover and

Indicating Cover Removed)

42

4.

OPERATION

200V class

200V

208V

220V

230V

575V class

500V

400V class

380V

400V

415V

440V

460V

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 −

Voltage) bar

760V (TYP)

730V (TYP)

690V (TYP)

660V (TYP)

630V (TYP)

575V

Class*

Power

Supply

Voltage

575V

−

−

500V

−

Braking Start

Voltage

(PN Bus −

Voltage) bar

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.)

:

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.

: 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.

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

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

1, 2 of the braking units.

: 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

2

Braking

B

¨ 0 © 0

Resistor

Unit

© ¨

MASTER

Braking Resistor

Overheat Contact

(Thermal Relay Trip Contact)

1 2

B

Braking

Resistor

Unit

P

¨ 0 © 0

MASTER

©

Braking Resistor

Overheat Contact

(Thermal Relay Trip Contact)

1

P

2

B

Braking

Resistor

Unit

¨ ¨ 0 © 0

MASTER

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.

45

5. TROUBLESHOOTING

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

No.

Fault Status Corrective Action

1

Braking resistor unit overload relay (or thermal p t ) t i h decelerating.

t

Inverter trips at overvoltage (OV).

Cause

:

Without braking unit

Inverter built − in main circuit discharging transistor short circuited

:

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)

Insufficient braking resistor unit capacity

Braking unit fault

Replace the inverter.

Replace the unit.

Set it again.

Examine the braking conditions again.

Check and repair.

Replace the unit.

3

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

Insufficient braking resistor unit capacity

Examine the braking conditions again.

4

Braking unit trips by heat sink overheat.

Excessive start/stop switching frequency

Excessive load inertia

Improper combination of braking

Examine the operating conditions again.

unit and braking resistor unit

Reset.

Ambient temperature 104 E F (40 E C) Reduce it.

46

6. SPECIFICATIONS

6. SPECIFICATIONS

6.1

BRAKING UNIT AND BRAKING RESISTOR UNIT

APPLICATION LIST

200 to 230V

Inverter

Max Applicable

Motor Capacity

HP(kW)

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)

Braking Unit

Model

(CDBR

− P )

—

—

—

—

—

—

—

2015B

2015B

2022B

2022B

2015B

2015B

2022B

2022B

2110B

2110B

2110B

Unit

Q’ty

2

1

2

2

1

1

1

2

1

1

—

—

—

1

—

—

—

—

Braking Resistor Unit

Model

(LKEB

− P )

2015

2018

2022

2015

2015

2022

2022

2022

2022

2022

20P7

20P7

21P5

22P2

23P7

25P5

27P5

2011

Resistor Spec.

(per unit)

70W 200

70W 200

260W 100

260W 70

390W 40

520W 30

780W 20

3000W 10

4800W 8

3000W 10

3000W 10

Ω

Ω

Ω

Ω

Ω

Ω

2400W 13.6

Ω

4800W 6.8

4800W 6.8

4800W 6.8

4800W 6.8

4800W 6.8

4800W 6.8

Ω

Ω

Ω

Ω

Ω

Ω

Ω

Ω

Ω

Ω

Ω

Unit

Q’ty

2

3

2

2

4

5

1

2

1

1

1

1

1

1

1

1

1

1

Approx.

Braking

Torque

(10%ED)

%

125

125

125

125

100

120

100

110

120

100

220

125

125

120

125

115

125

125

47

380 to 460V

Inverter

Max Applicable

Motor Capacity

HP(kW)

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)

Braking Unit

Model

(CDBR

−

P

)

—

—

—

—

4030B

4030B

4030B

4045B

—

—

—

—

—

4045B

4030B

4045B

4030B

4220B

4220B

4220B

4220B

Unit

Q’ty

1

1

1

1

—

—

—

—

—

—

—

—

—

2

3

1

2

2

4

1

1

Braking Resistor Unit

Model

(LKEB

−

P

)

40P7

40P7

41P5

42P2

43P7

45P5

47P5

4011

4015

4018

4022

4030

4037

4045

4030

4045

4030

4045

4037

4045

4045

Resistor Spec.

(per unit)

Unit

Q’ty

70W 750 Ω

70W 750 Ω

260W 400 Ω

260W 250 Ω

1

1

1

1

390W 150 Ω

520W 100 Ω

780W 75 Ω

1040W 50 Ω

1560W 40 Ω

1

1

1

1

1

4800W 32 Ω

4800W 27.2

Ω

6000W 20 Ω

1

1

1

9600W 1 6 Ω

9600W 13.6

Ω

6000W 20 Ω

9600W 13.6

Ω

1

1

2

2

6000W 20 Ω

9600W 13.6

Ω

9600W 16 Ω

9600W 13.6

Ω

3

4

5

6

9600W 13.6

Ω 12

Approx.

Braking

Torque

(10%ED)

%

135

130

135

125

125

125

125

125

230

130

125

135

135

125

135

145

100

140

110

110

110

48

6. SPECIFICATIONS

6.2

BRAKING UNIT FOR 575V CLASS APPLICATION LIST

Inverter

Max Applicable

Motor Capacity

HP(kW)

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)

Braking Unit

Model

(CDBR −

P

)

Unit Q’ty

—

—

—

—

—

—

5037B

5037B

5037B

5037B

5037B

5110B

5110B

5110B

5300B

2

2

1

1

1

—

—

—

1

—

—

—

1

1

1

Braking Resistor Unit

Resistor Spec.

560W 150 Ω

560W 150 Ω

750W 100 Ω

1100W 75 Ω

1500W 50 Ω

2300W 40 Ω

2800W 38 Ω

3900W 33 Ω

4900W 27 Ω

5900W 22

12000W 11

15000W 9

21000W 6.8

Ω

7200W 18 Ω

9800W 13.6

Ω

Ω

Ω

Ω

Approx.

Braking

Torque

(10%ED)

110

110

110

110

105

125

140

140

125

%

180

125

140

110

110

100

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 etc.

Model

LKEB etc.

Model

LKEB etc.

−

−

−

2015

4.8K

2015

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)

Max. Discharge

Current(A)

Output charac-

(peak value) *

Rated Discharge

Current (A) teristics Braking Start

Voltage

Max. Hysteresis

Error

Power

Supply

VDC

Protective

Functions

Fin Overheat

Power Charge

Indication

Envionmental

Conditions

Location

Altitude

Ambient

Temperature

Storage

Transportation

Temperature

Humidity

Vibration

Protective Configuration

Heat Loss (W)

201

5B

20

(15)

40

200V to 300V

2022

B

30

2045

B

60

(22)

60

(45)

100

2110

B

150

(110)

250

4030

B

40

(30)

40

380V to 460V

4045

B

60

4090

B

120

(45) (90)

60 100

4220

B

300

(220)

250

500V to 575V

5037

B

57

5110

B

150

(37)

40

(110)

5300

B

400

(300)

15 20 30 80 15 18

¦ 6V

30

630/660/690/730/760V

Approx. 16V

80 15 30 80

330/345/365/380V

Approx. 8V

¦ 3V 825V/ 950V ¦ 8V

243 (1.35

¢

400V peak

200 ¢ 0.9) to 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

E

F ( − 10 to +40

E

C) (not frozen)

Approx.

20V

607

(1.35

¢ 500 ¢ 0.9) to

1000V

32 38

− 4 to 140

E

F ( − 20 to +60

E

C)

90%RH (non − condensing)

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

Wall − mounted enclosed type

31 64 54 59 35 71 22

100

53

250

116

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

51

Model

(LKEB

− P )

41P5

42P2

43P7

45P5

47P5

4011

4015

4018

4022

4030

4037

4045

20P7

21P5

22P2

23P7

25P5

27P5

2011

2015

2018

2022

40P7

6.5 BRAKING RESISTOR UNIT SPECIFICATIONS

Specifications

200 to

70W 200 Ω

260W 100 Ω

260W 70 Ω

390W 40 Ω

520W 30 Ω

780W 20 Ω

2400W 13.6

Ω

3000W 10 Ω

4800W 8 Ω

4800W 6.8

Ω

70W 750 Ω

260W 400 Ω

260W 250 Ω

390W 150 Ω

520W 100 Ω

780W 75 Ω

1040W 50 Ω

380 to

460 1560W 40 Ω

4800W 32 Ω

4800W 27.2

Ω

6000W 20 Ω

9600W 16 Ω

9600W 13.6

Ω

Allowable

Average

Dissipated

Power

(W)

440

600

740

880

1200

1500

1800

60

89

150

220

300

440

600

740

880

30

30

60

89

150

220

300

Allowable

Average

Current

(Effective Value)

(A)

0.39

0.60

1.0

1.5

2.0

3.0

3.9

4.8

5.7

7.7

9.7

11.5

0.39

0.77

1.1

1.9

2.7

3.9

5.7

7.7

9.6

11.4

0.20

Allowable

Ambient

Temperature

+14 to 122 E F

( ( 10 to +50 E 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)

200 to

230V

380 to

460V

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)

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)

1 (0.75)

2 (1.5)

Resistor Spec.

(per unit)

70W 200 Ω

260W 100 Ω

260W 70 Ω

390W 40 Ω

520W 30 Ω

780W 20 Ω

2400W 13.6

Ω

3000W 10 Ω

4800W 8 Ω

4800W 6.8

Ω

70W 750 Ω

260W 400 Ω

260W 250 Ω

390W 150 Ω

520W 100 Ω

780W 75 Ω

1040W 50 Ω

1560W 40 Ω

4800W 32 Ω

4800W 27.2

Ω

6000W 20 Ω

9600W 16 Ω

9600W 13.6

Ω

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 72600 − K2110

LKEB − 2015 72600 − K2150

LKEB − 2018 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 72600 − K4110

LKEB − 4015 72600 − K4150

LKEB − 4018 72600 − K4180

LKEB − 4022 72600 − K4220

LKEB − 4030 72600 − K4300

LKEB − 4037 72600 − K4370

LKEB − 4045 72600 − K4450

54

英文 No.4-4(A4) メカトロ製品用 TOE

FOR VARISPEED-600 SERIES INVERTER

BRAKING UNIT

BRAKING RESISTOR UNIT

INSTRUCTIONS

IRUMA BUSINESS CENTER

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

Phone 81-42-962-5696 Fax 81-42-962-6138

YASKAWA ELECTRIC AMERICA, INC.

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

Phone 1-847-887-7000 Fax 1-847-887-7370

MOTOMAN INC. HEADQUARTERS

805 Liberty Lane West Carrollton, OH 45449, U.S.A.

Phone 1-937-847-6200 Fax 1-937-847-6277

YASKAWA ELETRICO DO BRASIL COMERCIO LTD.A.

Avenida Fagundes Filho, 620 Bairro Saude-Sao Paulo-SP, Brazil CEP: 04304-000

Phone 55-11-5071-2552 Fax 55-11-5581-8795

YASKAWA ELECTRIC EUROPE GmbH

Am Kronberger Hang 2, 65824 Schwalbach, Germany

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

Motoman Robotics Europe AB

Box 504 S38525 Torsas, Sweden

Phone 46-486-48800 Fax 46-486-41410

Motoman Robotec GmbH

Kammerfeldstra β e 1, 85391 Allershausen, Germany

Phone 49-8166-90-100 Fax 49-8166-90-103

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

Kfpa Bldg #1201, 35-4 Youido-dong, Yeongdungpo-Ku, Seoul 150-010, Korea

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

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.

151 Lorong Chuan, #04-01, New Tech Park Singapore 556741, Singapore

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

YASKAWA ELECTRIC (SHANGHAI) CO., LTD.

4F No.18 Aona Road, Waigaoqiao Free Trade Zone, Pudong New Area, Shanghai 200131, China

Phone 86-21-5866-3470 Fax 86-21-5866-3869

YATEC ENGINEERING CORPORATION

4F., No.49 Wu Kong 6 Rd, Wu-Ku Industrial Park, Taipei, Taiwan

Phone 886-2-2298-3676 Fax 886-2-2298-3677

YASKAWA ELECTRIC (HK) COMPANY LIMITED

Rm. 2909-10, Hong Kong Plaza, 186-191 Connaught Road West, Hong Kong

Phone 852-2803-2385 Fax 852-2547-5773

BEIJING OFFICE

Room No. 301 Office Building of Beijing International Club, 21

Jianguomenwai Avenue, Beijing 100020, China

Phone 86-10-6532-1850 Fax 86-10-6532-1851

TAIPEI OFFICE

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

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

SHANGHAI YASKAWA-TONGJI M & E CO., LTD.

27 Hui He Road Shanghai China 200437

Phone 86-21-6553-6060 Fax 86-21-5588-1190

BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO., LTD.

30 Xue Yuan Road, Haidian, Beijing P.R. China Post Code: 100083

Phone 86-10-6233-2782 Fax 86-10-6232-1536

SHOUGANG MOTOMAN ROBOT CO., LTD.

7, Yongchang-North Street, Beijing Economic Technological Investment & Development Area,

Beijing 100076, P.R. China

Phone 86-10-6788-0551 Fax 86-10-6788-2878

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.

MANUAL NO. TOE-C726-2F

○ Printed in Japan August 2002 91-3

24

02-5 ①