CDBR-B - Products On American Crane & Equipment Corp.
Contents
1. CDBR B Dynamic Braking Unit Instruct Manual ion MATERIAL HANDLING MAGNETEK W April 2009 Part Number 146 10001 R1 Copyright 2009 Electromotive Systems 2009 MAGNETEK All rights reserved This notice applies to all copyrighted materials included with this product including but not limited to this manual and software embodied within the product This manual is intended for the sole use of the persons to whom it was provided and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of MAGNETEK JN WARNING Do not touch any circuitry components while the main AC power is on In addition you must wait until the red CHARGE LED is out before performing any service on that unit It may take as long as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level Do not check signals during operation Make sure the unit is set for the appropriate voltage Make sure to ground the ground terminal Failure to observe these warnings can result in electrical shock A warning label is displayed on the front cover of the braking unit Follow these instructions when handling the braking unit CDBR B Installation Instructions Preface A Dynamic Braking Unit and Resistor are used to dissipate regenerative energy from the2. 370 200 CDBR 4090B 8 66 14 76 7 87 220 375 200 CDBR 4220B 9 84 14 76 7 87 250 375 200 CDBR 5037B 5 5 11 02 6 29 CDBR B Installation Instructions April 2009 1 8 Circuits and Wiring Specifications Table 4 Circuits and Wiring Specifications Wire Size Terminal Max Torque Model Number Circuit Terminals AWG Wire Type Screw Ib in CDBR 2022B Main C Qo 12 10 600V vinyl M4 133 4045B 5037B OQ Oo sheathed Control 1 2 3 18 14 WHE OF 4 5 6 equivalent CDBR 2045B Main D Qo 10 8 600V vinyl M5 21 7 4090B Q Qo sheathed Control 1 2 3 18 14 WPC OL M4 15 6 4 5 6 equivalent A CDBR 4220B Main X 0 4 600 V vinyl M6 43 4 O Qo 8 6 sheathed Control 1 2 3 18 14 JOIE OF M4 15 6 4 5 6 equivalent Braking Unit Specification Table 5 Braking Unit Specifications 200V to 300V 380V to 460V 500V to 575V Braking Unit Model CDBR 2022 B 2045 B 2110 B 4045 B 4090 B 4220 B 5037 B Max Discharge Current 60 100 250 60 100 250 40 A k value Output peak value Character Rated Discharge Current 20 30 80 18 30 80 15 istics A Braking Start Voltage 330 345 365 380V 3V 630 660 690 730 760V 6 V 825 950 V 8V Max Hysteresis Error Approx 8V Approx 16V Approx 20V Power VDC 243 1 35x200x0 9 to 400V Peak 460 1 35x380x0 9 to 800V Peak 607 1 35x500x Supply 0 9 to 1000v Protective Fin Overheat Thermostat Functions Power Cha
3. a jJ fA S L D MASTER SLAVE JM SELECTION CONNECTOR fA ij kJ u ofofolo o olo o o o o o o ojo ololol o o oj ojo G ur SbBAW MM no no UL OO Woo d S ooUO0G OnO lt lt lt lt lt lt lt lt lt lt lt WER SUPPLY _ SELECTION CONNECTOR o OPERATIONAL INDICATOR Lights When Braking fi A Er A TU Figure 4 CDBR 2045B 2110B 4090B 4220B 5037B Indicating Cover Removed CDBR B Installation Instructions April 2009 1 6 CDBR B Braking Unit Dimensions 4 M4 Mtg Hole o cr ri DL Q Ag sd W1 Le D ss Le W I Figure 5 CDBR B Drawing Table 2 CDBR B Dimensions Dimensions in inches mm Model Number Overall WI H1 d 5 04 128 5 43 138 16 4 5 04 128 5 43 138 16 4 4 56 2 07 4 82 2 19 CDBR 2022B 5 51 140 5 91 150 5 45 138 5 CDBR 4045B 5 51 140 5 91 150 5 45 138 5 CDBR B Installation Instructions April 2009 1 7 Z d 4 places W1 MIEL HEIN D Figure 6 CDBR B Drawing Table 3 CDBR B Dimensions Dimensions in inches mm Model Number Overall CDBR 2045B 7 09 14 57 7 87 180 370 200 CDBR 2110B 7 09 14 57 7 87 180
4. ean and dry Free from excessive vibration CDBR B Installation Instructions April 2009 1 2 Installation Mounting Wiring 1 Disconnect all electrical power to the drive 2 Remove drive front cover 3 Verify that voltage has been disconnected by using a voltmeter to check for voltage at the incoming power terminals 4 The braking unit and braking resistor emit heat during operation Select a mounting location away from other heat emitting devices or devices that are heat sensitive To guarantee proper air flow for cooling the braking unit should not be mounted any closer to external devices than 1 18 in 30mm on either side and 3 94 in 100mm of the top and bottom Select mounting locations so that the wiring distances between the drive and the braking unit is less than 16 4 feet 5m and the distance between the braking unit and the braking resistor is less than 32 8 feet 10m 5 Make connections between the drive braking unit s and braking resistor s according to Figure 1 single units or Figure 2 multiple units Grounding 6 The enclosure of the braking resistor should be grounded If the braking unit cannot be mounted in a grounded enclosure ground it by using a lead from the mounting screw of the unit 7 Grounding resistance of the braking unit should be 100 ohms or less 8 Use a grounding lead conforming to your National Electric code Adjustments 9 a It may be necessary to change the appropriate i
5. ge to terminals and Slowly increase the voltage to approximately 50V at which time the Charge LED on 1PCB should illuminate With a DC Voltmeter monitor terminals O and O and continue to increase the DC voltage to 780 VDC at which time you should see the DC Voltmeter turn on to read the 780 VDC applied voltage and the Brake LED on 1PCB should illuminate At this same time you should also read 15 VDC across terminals 5 and 6 which indicates that the output to active a slave CDBR has turned on Remove power from terminals and Place the jumper on 4CN on1PCB to the Slave position Apply power 325 VDC for 200V models and 650 VDC for 400V models to terminals and Using a separate DC power supply apply 7 VDC to terminals 1 and 2 on 1PCB This 7 VDC signal should cause the main transistor ITRM to turn on and you should read the applied DC Bus Voltage across terminals O and O and the Brake LED on 1PCB should illuminate With power still applied to terminals and monitor terminals 3 and 4 on 1PCB with an Ohmmeter This meter should read Infinite Ohms Place a jumper across the terminal switch pins 1 and 2 on 3CN which should cause the Fault Relay to change state and 0 Ohms should read on the Ohmmeter Remove the terminals and and return the 4CN jumper on 1PCB back to the Master position CDBR B Installation Instructions April 2009 1 11 This page intentional
6. her components that generate heat or do not tolerate heat Free from drops of water and corrosive gases Free of dirt and dust Free of physical shock and vibration Operational Verification 11 During dynamic braking operations make sure that the required deceleration characteristic 1s obtained The operation indicator BRAKE lamp in the braking unit lights 12 Reinstall and secure front covers on the drive and braking units s Table 1 Minimum Resistance Values for Braking Resistors Minimum Resistance O Supply Turn On Voltage Voltage CDBR CDBR CDBR CDBR CDBR CDBR CDBR 2022B 2045 B 2110B 4045B 4090B 4220B 5037B 200VAC 330VDC 5 5 3 3 1 4 _ _ _ 208VAC 345VDC 5 8 3 5 1 4 _ _ _ _ 220VAC 365VDC 6 1 3 7 1 5 _ _ _ _ 230VAC 380VDC 6 4 3 8 1 6 _ _ _ _ 380VAC 630VDC _ _ _ 10 5 6 3 2 6 _ 400VAC 660VDC _ _ _ 11 0 6 6 2 7 _ 415VAC 690VDC _ _ _ 11 5 6 9 2 8 _ 440VAC 730VDC _ _ _ 12 2 7 3 3 0 460VAC 760VDC _ _ _ 12 8 7 6 3 2 _ 500VAC 825VDC _ _ _ _ _ _ 20 7 575VAC 950VDC _ 23 8 For use with CDBM 4220 Only G VG ee Series2 or rs Series3 Inverter p Braking Resistor 85 Figure 1 Single Unit Wiring Diagram CDBR B Installation Instructions April 2009 1 4 LINN e LINN 1 LINN ONDIVA4 DNDIV2Ig NISN 28 1 5 f Braking Unit NOI NOILI3130 NOL193130 13437 1 713431 ANS 131371 E CDBR B Insta
7. ination of braking unit and resistor Ambient Temperature gt 104 F 40 C Braking Module Test Procedure JN WARNING Reduce load Verify proper braking unit resistor Install air conditioner Do NOT touch any circuit components while AC main power is on or immediately after main AC power is disconnected from the unit You must wait until the red CHARGE lamp is extinguished It may take as long as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level Failure to adhere to this warning could result in serious injury 1 Remove the cover and check IPCB for physical damage 2 Using a Digital Multimeter set the Diode Check function perform static checks on the main transistor module ITRM For CDBR 2045B 2110B 4090B 4220B check the following Place the positive lead on terminal and the negative lead on terminal O This will check the collector to emitter junction for a short circuit A reading of between 0 200V and 0 250V indicates a good reading Place the positive lead on terminal O and the negative lead on terminal O This will check the diode connected to the collector for a short circuit A reading of between 0 200V and 0 375V indicates a good reading For CDBR 2015B 2022B 4030B 4045B check the following Place the positive lead on terminal and the negative on terminal O This will check the collector to emitter junction for a short circuit A
8. llation Instructions April 2009 Ion Oo ways 7s 5l o T s u31SVu M3ISVR L a 831SvA4 OLSIS 34 WU1S1833 ON Ayya ON SE 1IN9819 3150 OL 119819 91007 OL 1InJa 91907 Di HILIAS UWMIHL HILIMS TeNH3Hl H311AS WHWASHL sea 30 sea Jd CDBR B Parallel connect Figure 2 CDBR B Parallel Connection Notes Braking units have a MASTER SLAVE selection jumper See Figure 2 Select MASTER for Braking Unit 1 and SLAVE for all subsequent braking units Connect thermal protectors on the parallel CDBR Bs in parallel to the drive s multi function input Use twisted pair wire 20 or 22 AWG with ferrules for connections between terminals 5 6 and 1 2 of the CDBR Bs lp m i ey BRAKING UNIT RES NO o o o o ojo ojo WARNING FH olololo o ojojo Jue TU TO ro o 1 UD Qnoco nr og o0o S Sus POWER SUPPLY _ 1 lt lt lt lt PESSE SELECTION CONNECTOR CALIBRATION RESISTOR 1 h tAD USTED PRIOR TD SHIPMENT ae MASTER SLAVE OPERATION INDICATOR SELECTION CONNECTOR LIGHTS WHEN eo BRAKING LE ele erelelelel ee TOT JE H1I21IS5I67T 3141 CONTROL CIRCUIT T DO TERMINALS 1 TD 6 qo T XE J Tx T LEAD WIRE OUTLET 4 PLACES RUBBER BUSH CHARGE INDICATUR ER 56 o0 CHARGE INDICATD TERMINALS P A
9. ly left blank
10. motor Whenever an excited motor is operated in the negative slip region or is subjected to an overhauling load the motor will behave as an induction generator In this mode energy will actually flow from the motor back into the drive This will cause the DC bus voltage to rise When the DC bus voltage reaches a certain level the Dynamic Braking Unit will activate The Dynamic Braking Unit will shunt the regenerative energy away from the DC bus capacitors and will dissipate it as heat in the DB resistors Since the regenerative energy is dissipated in the resistors the overvoltage OV trip is prevented thus the motor remains excited and continues to produce braking torque The following Electromotive Systems products can be used with these units MPULSE G IMPULSE G IMPULSE VG MPULSE G Series 2 MPULSE VGr Series 2 MPULSE G Series 3 MPULSE VGr Series 3 I I I I Receiving All equipment is tested against defect at the factory After unpacking verify that there is no damage evident Report any damage or shortage to the commercial carrier who transported the equipment Contact you Electromotive Systems sales representative for assistance Storage If the Dynamic Braking unit is not installed immediately it must be stored under the following conditions Ambient temperature 10 to 40 C Protected from rain and moisture Free from corrosive gases or liquids Free from dust or metal particles Cl
11. nput voltage selection This determines the voltage that the dynamic braking unit will turn on See Figure 3 or 4 and set the jumper to the nominal three phase supply voltage Table 1 indicates the DC voltage level that the braking unit will turn on for different jumper settings Failure to set the jumper at the nominal voltage can cause premature failure of the braking unit b Iftwo or more braking modules are applied ensure that unit 1 is set as the MASTER while the other unit s are set for SLAVE See Figure 1 or 2 depending on number of braking modules If only one braking unit is applied verify that the jumper is set to MASTER 10 The installation of the braking unit may require programming of the drive a For an IMPULSE G Program Sn 05 to xx1x which disables stall prevention during deceleration b For an IMPULSE G Program Sn 07 to xx1x which disables stall prevention during deceleration c For an IMPULSE G Series 2 Program L3 04 to 0 which disables stall prevention during deceleration d For an IMPULSE VG Series 2 Program L3 04 to 0 which disables stall prevention during deceleration CDBR B Installation Instructions April 2009 1 3 Installation Be sure the CDBR B is mounted in a location that conforms to the following conditions Provide at least 3 94 in 100mm above and below the CDBR B Provide at least 1 18 in 30mm on either side of the CDBR B Provide sufficient space between ot
12. reading of OL indicates a good reading CDBR B Installation Instructions April 2009 1 10 3 Place the positive lead on terminal O and the negative lead on terminal O This will check the diode connected to the collector for a short circuit A reading of approximately 0 5V indicates a good reading Remove connector 3CN on 1PCB and place the ohmmeter leads on terminals 1 and 2 of the connector The meter should read infinite Ohms Normally Open Thermal Relay ITHG Replace connector 3CN Place the 4CN jumper on 1PCB to the Master position 200V Models Verify that the Power Supply Voltage Selection Jumper is set to 230V With a variable DC power supply which is capable of producing 400 VDC output apply the DC voltage to terminals and Slowly increase the voltage to approximately 50V at which time the Charge LED on 1PCB should illuminate With a DC Voltmeter monitor terminals O and O and continue to increase the DC voltage to 380 VDC at which time you should see the DC Voltmeter turn on to read the 380 VDC applied voltage and the Brake LED on 1PCB should illuminate At this same time you should also read 15 VDC across terminals 5 and 6 which indicates that the output to activate a slave CDBR has turned on 400V Models Verify that the Power Supply Voltage Selection Jumper is set to 460V With a variable DC power supply which is capable of producing 800 VDC output apply the DC volta
13. rge Indication Charge lamp stays ON until bus voltage drops below 50V Location Indoor protected from corrosive gases and dust Enyi Ambient Temperature 14 to 104 F 10 to 40 C not frozen nviron mental Storage Temperature 4 to 140 F 20 to 60 C Conditions Humidity 90 RH non condensing Vibration 1G at 10 to less than 20Hz up to 0 2G at 20 to 50Hz Protective Configuration Wall mounted enclosed type Heat Loss W 38 62 129 59 94 135 70 Loading time rate can be used below 10 ED max 10 min CDBR B Installation Instructions April 2009 1 9 Troubleshooting To troubleshoot the dynamic braking circuit braking unit and braking resistor unit refer to the chart below Fault Status Drive trips at overvoltage OV Possible Cause Insufficient braking unit capacity Insufficient resistor capacity Improper wiring Deceleration time too short Braking unit fault Corrective Action Verify CDBR B capacity Verify resistor capacity Verify wiring is correct Lengthen deceleration time Replace the braking unit Braking Unit Thermal Overload trips when not decelerating Improper braking unit power supply voltage selection setting Incoming line voltage too high Discharge transistor shorted Verify jumper setting Correct line voltage Replace the braking unit Braking Unit trips by heatsink overheat Excessive load inertia Improper comb
Download Pdf Manuals
Related Search