YASKAWA Dynamic Brake Module Installation guide

CDBR-

LKEB-

BRAKING UNIT CDBR-

BRAKING RESISTOR UNIT LKEB-

Braking unit,

Braking resistor unit

YASKAWA AC Drive Option

Installation Manual

To properly use the product, read this manual thoroughly and retain

for easy reference, inspection, and maintenance. Ensure the end user

receives this manual.

MANUAL NO. TOBP C720600 00F

3

PREFACE

Braking resistor unit and braking unit are used to con-sume regenerative

energy from motor in the braking resistor unit at deceleration and to

improve the transis-tor inverter braking ability.

Before using the braking resistor unit and braking unit, a thorough under-

standing of this manual is recom-mended. This instruction manual will be

of great help for daily maintenance, inspection and troubleshoot-ing.

Inverters to which the braking resistor unit and braking unit can be con-

nected are of the following series:

• YASKAWA AC Drive 1000 Series

• Varispeed Series

Wiring sequence should shut off power to the drive when a braking

resistor Overload Relay Trip Contact (Thermal Protector Contact)

output is triggered.

NOTENOTE

4

General Precautions

SSome 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.

SSince the drawings in this manual are represented examples, some are subject

to differ from delivered products.

SThis 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.

STo order a copy of this manual, if your copy has been damaged or lost, contact

your YASKAWA representative.

SYASKAWA is not responsible for any modification of the product made by the

user since that will void your guarantee.

5

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.”

Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury to personnel.

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 acci-

dent in some situations. In either case, follow these important notes.

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

WARNING

CAUTION

NOTENOTE

7

WIRING

(Ref. page)

• Only commence wiring after verifying that the power sup-

ply is turned OFF.

Failure to observe this warning can result in an electrical shock

or a fire.

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.

27

• Wiring should be performed only by qualified personnel.

Failure to observe this warning can result in an electrical shock

or a fire.

27

• Wiring sequence should shut off power to the drive when

a braking resistor Overload Relay Trip Contact (Thermal

Protector Contact) output is triggered.

Failure to observe this warning can result in a fire.

27

• When wiring the emergency stop circuit, check the wiring

thoroughly before operation.

Failure to observe this warning can result in personal injury.

27

• 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

• 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 symmet-rical

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.

WARNING

8

CAUTION

(Ref. page)

SVerify 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.

27

SDo not perform a withstand voltage test of the braking unit and

braking resistor unit.

It may cause semi−conductor elements to be damaged.

27

SConnect 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

STighten terminal screws to the specified tightening torque.

Failure to observe this caution can result in a fire.

27

SBe 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

9

OPERATION

WARNING

(Ref. page)

SOnly 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.

41

CAUTION

(Ref. page)

SNever 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.

41

SDo not check signals during operation.

The machine or the inverter may be damaged.

41

SAll the constants ofthe the braking unit andthe braking resistor

unit have been preset at the factory. Do not change the

settings unnecessarily.

41

11

CAUTION

(Ref. page)

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

CMOS elements.

They are easily damaged by static electricity.

46

SDo 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

SNever modify the product.

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

personal injury and will invalidate the guarantee.

12

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

Warning

Indication

$4#-+0)70+6

㧹㧻㧰㧱㧸㧦㧯㧰㧮㧾㧙㧠㧜㧠㧡㧮

ޓޓޓޓޓޓ㧠㧜㧜㨂ޓ㧯㧸㧭㧿㧿ޓ㧲㧻㧾ޓ㧠㧡㨗㨃

ߌ߇ޔᗵ㔚ߩ߅ߘࠇ߇޽ࠅ߹ߔޕ

࡮ᝪ߃ઃߌޔㆇォߩ೨ߦߪᔅߕขᛒ⺑᣿ᦠࠍ⺒ࠎߢޔ

ޓ

ߘߩᜰ␜

ߦᓥߞߡߊߛߐ޿ޕ

ᗵ㔚ߩ߅ߘࠇ߇޽ࠅ߹ߔޕ

࡮ㅢ㔚ਛ෸߮㔚Ḯㆤᢿᓟ㧡ಽએౝߪޔ⴫㕙ࠞࡃ࡯ࠍ㐿ߌ

ޓ

ߥ޿ߢ

ߊߛߐ޿ޕ

࡮⏕ታߦធ࿾ࠍⴕߞߡߊߛߐ޿ޕ

㧹㨍㨥ޓ㨏㨍㨡㨟㨑ޓ㨕㨚㨖㨡㨞㨥ޓ㨛㨞㨑㨘㨑㨏㨠㨞㨕㨏ޓ㨟㨔㨛㨏㨗㧚

࡮

㧼㨘㨑㨍㨟㨑ޓ㨒㨛㨘㨘㨛㨣ޓ㨠㨔㨑ޓ㨕㨚㨟㨠㨞㨡㨏㨠㨕㨛㨚㨟ޓ㨕㨚ޓ㨠㨔㨑

ޓ

㨙㨍㨚㨡㨍㨘ޓ㨎㨑㨒㨛㨞㨑ޓ㨕㨚㨟㨠㨍㨘㨘㨍㨠㨕㨛㨚ޓ㨛㨞ޓ㨛㨜㨑㨞㨍㨠㨕㨛㨚㧚

࡮

㧰㨕㨟㨏㨛㨚㨚㨑㨏㨠ޓ㨍㨘㨘ޓ㨜㨛㨣㨑㨞ޓ㨎㨑㨒㨛㨞㨑ޓ㨛㨜㨑㨚㨕㨚㨓

ޓ

㨒㨞㨛㨚㨠ޓ㨏㨛㨢㨑㨞ޓ㨛㨒ޓ㨡㨚㨕㨠㧚

㨃㨍㨕㨠ޓ㧡ޓ㨙㨕㨚㨡㨠㨑㨟ޓ㨡㨚㨠㨕㨘ޓ㧰㧯ޓ㧮㨡㨟ޓ㨏㨍㨜㨍㨏㨕㨠㨛㨞㨟

㨐㨕㨟㨏㨔㨍㨞㨓㨑㧚

࡮

㨁㨟㨑ޓ㨜㨞㨛㨜㨑㨞ޓ㨓㨞㨛㨡㨚㨐㨕㨚㨓ޓ㨠㨑㨏㨔㨚㨕㨝㨡㨑㨟㧚

㧺㧼㧶㨀㧠㧞㧡㧜㧞㧙㧝㧙㧜

ෂ㒾ޓ㨃㧭㧾㧺㧵㧺㧳

Ἣἴߩ߅ߘࠇ߇޽ࠅ߹ߔޕ

࡮೙േᛶ᛫ེߩࠨ࡯ࡑ࡞࡝࡟࡯࠻࡝࠶ࡊធὐߢ㔚Ḯ஥ࠍ

ޓㆤᢿߔࠆࠪ࡯ࠤࡦࠬࠍ⚵ࠎߢߊߛߐ޿ޕ

㧾㨕㨟㨗ޓ㨛㨒ޓ㨒㨕㨞㨑㧚



㨁㨟㨑ޓ㨟㨑㨝㨡㨑㨚㨏㨑㨞ޓ㨠㨛ޓ㨎㨞㨑㨍㨗ޓ㨜㨛㨣㨑㨞ޓ㨟㨡㨜㨜㨘㨥ޓ㨟㨕㨐㨑

ޓ

㨛㨚ޓ㨛㨢㨑㨞㨘㨛㨍㨐ޓ㨞㨑㨘㨍㨥ޓ㨠㨞㨕㨜ޓ㨏㨛㨚㨠㨍㨏㨠ޓ㨛㨒ޓ

ޓ

㨎㨞㨍㨗㨕㨚㨓ޓ㨞㨑㨟㨕㨟㨠㨛㨞㧚

ㅢ㔚೨ߦᧄࠞࡃ࡯ࠍߪߕߒߡޔ

ࠦࡀࠢ࠲ߩ⸳ቯࠍ߅ߎߥߞߡਅߐ޿ޕ

㧔ขᛒ⺑᣿ᦠෳᾖߩߎߣޕ㧕

UGVVJGEQPPGEVQTU

DGHQTGVWTPKPIVJG

RQYGTQP

5GG+PUVTWEVKQPU

4GOQXGVJKUEQXGTCPF

.KIJVU

YJGP

DTCMKPI

13

Warning Indication

ߌ߇ޔᗵ㔚ߩ߅ߘࠇ߇޽ࠅ߹ߔޕ

࡮ᝪ߃ઃߌޔㆇォߩ೨ߦߪᔅߕขᛒ⺑᣿ᦠࠍ⺒ࠎߢޔ

ޓ

ߘߩᜰ␜

ߦᓥߞߡߊߛߐ޿ޕ

ᗵ㔚ߩ߅ߘࠇ߇޽ࠅ߹ߔޕ

ㅢ㔚ਛ෸߮㔚Ḯㆤᢿᓟ㧡ಽએౝߪޔ⴫㕙ࠞࡃ࡯ࠍ

ޓ

㐿ߌߥ޿ߢ

ߊߛߐ޿ޕ

⏕ታߦធ࿾ࠍⴕߞߡߊߛߐ޿ޕ

㧹㨍㨥ޓ㨏㨍㨡㨟㨑ޓ㨕㨚㨖㨡㨞㨥ޓ㨛㨞㨑㨘㨑㨏㨠㨞㨕㨏ޓ㨟㨔㨛㨏㨗㧚



㧼㨘㨑㨍㨟㨑ޓ㨒㨛㨘㨘㨛㨣ޓ㨠㨔㨑ޓ㨕㨚㨟㨠㨞㨡㨏㨠㨕㨛㨚㨟ޓ㨕㨚ޓ㨠㨔㨑

ޓ

㨙㨍㨚㨡㨍㨘ޓ㨎㨑㨒㨛㨞㨑ޓ㨕㨚㨟㨠㨍㨘㨘㨍㨠㨕㨛㨚ޓ㨛㨞ޓ㨛㨜㨑㨞㨍㨠㨕㨛㨚㧚



㧰㨕㨟㨏㨛㨚㨚㨑㨏㨠ޓ㨍㨘㨘ޓ㨜㨛㨣㨑㨞ޓ㨎㨑㨒㨛㨞㨑ޓ㨛㨜㨑㨚㨕㨚㨓

ޓ

㨒㨞㨛㨚㨠ޓ㨏㨛㨢㨑㨞ޓ㨛㨒ޓ㨡㨚㨕㨠㧚

㨃㨍㨕㨠ޓ㧡ޓ㨙㨕㨚㨡㨠㨑㨟ޓ㨡㨚㨠㨕㨘ޓ㧰㧯ޓ㧮㨡㨟ޓ㨏㨍㨜㨍㨏㨕㨠㨛㨞㨟

㨐㨕㨟㨏㨔㨍㨞㨓㨑㧚



㨁㨟㨑ޓ㨜㨞㨛㨜㨑㨞ޓ㨓㨞㨛㨡㨚㨐㨕㨚㨓ޓ㨠㨑㨏㨔㨚㨕㨝㨡㨑㨟㧚

㧺㧼㧶㨀㧠㧞㧡㧜㧞㧙㧝㧙㧜

ෂ㒾ޓ㨃㧭㧾㧺㧵㧺㧳

Ἣἴߩ߅ߘࠇ߇޽ࠅ߹ߔޕ

೙േᛶ᛫ེߩࠨ࡯ࡑ࡞࡝࡟࡯࠻࡝࠶ࡊធὐߢ㔚Ḯ஥ࠍ

ޓㆤᢿߔࠆࠪ࡯ࠤࡦࠬࠍ⚵ࠎߢߊߛߐ޿ޕ

㧾㨕㨟㨗ޓ㨛㨒ޓ㨒㨕㨞㨑㧚



㨁㨟㨑ޓ㨟㨑㨝㨡㨑㨚㨏㨑㨞ޓ㨠㨛ޓ㨎㨞㨑㨍㨗ޓ㨜㨛㨣㨑㨞ޓ㨟㨡㨜㨜㨘㨥ޓ㨟㨕㨐㨑

ޓ

㨛㨚ޓ㨛㨢㨑㨞㨘㨛㨍㨐ޓ㨞㨑㨘㨍㨥ޓ㨠㨞㨕㨜ޓ㨏㨛㨚㨠㨍㨏㨠ޓ㨛㨒

ޓ

㨎㨞㨍㨗㨕㨚㨓ޓ㨞㨑㨟㨕㨟㨠㨛㨞㧚

14

CONTENTS

NOTES FOR OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

1 RECEIVING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

1.1 NAMEPLATE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

2 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

2.1 LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

2.2 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

2.3 REPLACEMENT OF CONVENTIONAL BRAKING UNITS

WITH NEW UNITS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

3 WIRING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27

3.1 REMOVING AND REPLACING THE COVERS OF

THE BRAKING UNIT (MODELS CDBR-2015B, -2015C,

-2022B, -2022C, -4030B, -4045B) - - - - - - - - - - - - - - - - - - - 27

3.2 SECTION NAMES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

3.3 CIRCUITS AND WIRING SPECIFICATIONS - - - - - - - - - - - 31

3.4 WIRING PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - 32

3.5 INTERCONNECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - 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 MODELS (VS-616HII/H3,

VS-616GII/G3, VS-676) - - - - - - - - - - - - - - - - - - - - - - - - - - 50

6.4 BRAKING UNIT SPECIFICATIONS - - - - - - - - - - - - - - - - - - 51

6.5 BRAKING RESISTOR UNIT SPECIFICATIONS - - - - - - - - - 52

6.6 MODELS AND CODE NOS. OF BRAKING UNIT AND

BRAKING RESISTOR UNIT - - - - - - - - - - - - - - - - - - - - - - - 53

1 RECEIVING

15

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 follow-

ing. 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.

1.1 NAMEPLATE

(1) NAMEPLATE INFORMATION (BRAKING UNIT)

(2) NAMEPLATE INFORMATION (BRAKING RESISTER UNIT)

• Do not install and attempt to use a braking resistor or braking resis-

tor unit If there are any damaged or missing components.

Failure to comply can result in personal injury.

For long term storage, the unit should be kept in a clean area

indoors.

CAUTION

NOTENOTE

Braking Unit

Model Number

Design

Revision

Order

Braking Resistor

Unit Model Number

16

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.

• 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°F, 10 to 40°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

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.

• 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.

2 INSTALLATION

17

• Install the units in the directions shown in Figs. 1 to 8. There will be

no problem if they are installed vertically.

Fig. 1 Braking Unit Dimensions in inches (mm) CDBR-2015B, -2015C,

-2022B,-2022C,-4030B, -4045B

4−M4 MTG HOLE

1.5 (38) 1.5 (38)

1.18 (30)

OR MORE

3−LEAD WIRE OUTLET

[0.87 (20) DIA RUBBER BUSH]

5.04 (128)

5.51 (140)

2.83 (72) 2.73 (66.5)

4.51 (114.5)

5.45 (138.5)

1.18 (30)

OR MORE

5.43 (138)

5.91 (150)

3.94 (100) OR MORE

18

6.57 (167)

3.94 (100)

OR MORE

5.51 (140)

3.94 (100)

1.97 (50)

1.18 (30)

OR MORE

(58.5)

2.19 (55.5)

11.02 (280)

10.23 (260)

9.25 (235)

0.39 (10)

1.14 (29)

3.94 (100)

MAIN CIRCUIT

TERMINAL M4

3−LEAD WIRE

OUTLET

1.10 (28) DIA

RUBBER BUSH

4−M6

MTG HOLE

2.30

1.18 (30)

OR MORE

3.94 (100)

OR MORE

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

2 INSTALLATION

19

Fig. 3 Braking Unit Dimensions in inches (mm) CDBR-2045B

5.51 (140)

(59)

7.09 (180)

4.37 (111)

6.14 (156)

7.87 (200)

3.86 (98)

3.94 (100)

2.95 (75)

12.48 (317)

13.78 (350)

14.57 (370)

1.44 (36.5)

0.47 (12)

5.51 (140)

MAIN CIRCUIT

TERMINAL M5

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER

BUSH

4−M6

MTG HOLE

3.94 (100)

OR MORE

WIRE OUTLET 1.10 (28)

DIA RUBBER BUSH

3.94 (100)

OR MORE

2.32 1.97 (50)

1.18 (30)

OR MORE

1.18 (30)

OR MORE

20

MAIN CIRCUIT

TERMINAL M6

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER

BUSH

4−M6

MTG HOLE

3.94 (100)

OR MORE

WIRE OUTLET 1.10 (28)

DIA RUBBER BUSH

3.94 (100)

OR MORE

12.48 (317)

13.78 (350)

14.57 (370)

1.44 (36.5)

0.47 (12)

3.94 (100)

2.87 (73)

5.51 (140)

(59)

7.09 (180)

2.32 1.97 (50)

1.18 (30)

OR MORE

1.18 (30)

OR MORE

4.37 (111)

6.14 (156)

7.87 (200)

4.09

(104)

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

21

MAIN CIRCUIT

TERMINAL M5

4−M6

MTG HOLE

1.44 (36.5)

0.35 (9)

7.09 (180)

12.48 (317)

13.98 (355)

14.57 (370)

5.45 (138.5)

2.95 (75)

8.66 (220)

(68.5) 7.09 (180)

2.70 1.97 (50)

1.18 (30)

OR MORE

1.18 (30)

OR MORE

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER

BUSH

WIRE OUTLET 1.10 (28)

DIA RUBBER BUSH

3.94 (100)

OR MORE

4.37 (111)

6.14 (156)

7.87 (200)

3.94 (100)

OR MORE

3.86 (98)

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

2.INSTALLATION

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YASKAWA Dynamic Brake Module Installation guide

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YASKAWA Dynamic Brake Module Installation guide

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