YASKAWA YASKAWA AC Drive-Option INSTRUCTIONS MANUAL NO. TOBP C720600 00C Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. BRAKING UNIT, BRAKING RESISTOR UNIT MODEL: BRAKING UNIT CDBR- BRAKING RESISTOR UNIT LKEB- YASKAWA
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YASKAWA
YASKAWA AC Drive-Option
INSTRUCTIONS
MANUAL NO. TOBP C720600 00C
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.
BRAKING UNIT, BRAKING RESISTOR UNIT
MODEL: BRAKING UNIT CDBR- BRAKING RESISTOR UNIT LKEB-
YASKAWA
3
PREFACE
Braking resistor unit and braking unit are used to con-sume regenerative energy from motor in the brakingresistor unit at deceleration and to improve the transis-tor inverter braking ability.
Before using the braking resistor unit and braking unit,a thorough understanding of this manual is recom-mended. This instruction manual will be of great helpfor daily maintenance, inspection and troubleshoot-ing.
Inverters to which the braking resistor unit and brakingunit can be connected are of the following series:
D YASKAWA AC Drive 1000 Series
D Varispeed Series
4
General Precautions
S Some drawings in this manual are shown with the protective cover or shieldsremoved, in order to describe with more clarity. Make sure all covers andshields are replaced before operating this product.
S Since the drawings in this manual are represented examples, some are subjectto differ from delivered products.
S This manual may bemodified when necessary because of improvement of theproduct, modification or changes in specifications. Such modifications aredenoted by a revised manual No.
S To order a copy of this manual, if your copy has been damaged or lost, contactyour YASKAWA representative.
S YASKAWAis not responsible for anymodification of the productmadeby theuser since that will void your guarantee.
NOTE
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 thismanual, NOTES FOR SAFE OPERATION are classified as “WARNING” or“CAUTION.”
WARNINGIndicates a potentially hazardous situation which, if not avoided, could result indeath or serious injury to personnel.
CAUTIONIndicates a potentially hazardous situation which, if not avoided, may result in mi-nor 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 somesituations. In either case, follow these important notes.
: These are steps to be taken to insure proper operation.
7
WIRING
WARNING(Ref. page)
S Only commencewiring after verifying that the power supply isturned OFF.Failure to observe this warning can result in an electrical shock or afire.
27
S High voltage exists at all terminals of braking unit and brakingresistor unit.Failure to observe this warning can result in an electrical shock.
27
S Wiring should be performed only by qualified personnel.Failure to observe this warning can result in an electrical shock or afire.
27
S When wiring the emergency stop circuit, check the wiringthoroughly before operation.Failure to observe this warning can result in personal injury.
27
S Make sure to ground the ground terminal .(Ground resistance200V 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 symmet-rical Amperes, 240 Vac maximum (200V Class), 480 Vac maximum (400VClass) and 575Vac (600VClass) or the SCCR rating of the drive it is connectedto, which ever is greater.
8
CAUTION(Ref. page)
S Verify that the rated voltageof thebrakingunit and thebrakingresistor unit coincides with the AC power supply voltage.Failure to observe this caution can result in personal injury or a fire.
27
S Donot performawithstand voltage test of the braking unit andbraking resistor unit.It may cause semi−conductor elements to be damaged.
27
S Connect braking resistors, braking resistor units, and brakingunits as shown in the I/Owiring examples. Use properly ratedwire in accordance with table 2 on page 31.Otherwise, a fire can occur.
27
S Tighten terminal screws to the specified tightening torque.Failure to observe this caution can result in a fire.
27
S Be sure to connect braking resistors or braking resistor unitsto the braking units.If neither braking resistor nor braking resistor unit is connected to abraking unit, the fault contact may instantaneously turn ON whenthe power is turned ON, resulting in malfunction of the inverter.
27
9
OPERATION
WARNING(Ref. page)
S Only turn ON the input power supply after replacing the frontcover. Do not remove the cover while current is flowing.Failure to observe this warning can result in an electrical shock.
41
CAUTION(Ref. page)
S Never touch the heatsink or discharging resistor since thetemperature is very high.Failure to observe this caution can result in harmful burns to thebody.
41
S Do not check signals during operation.The machine or the inverter may be damaged.
41
S All theconstantsof thethebrakingunitandthebrakingresistorunit have been preset at the factory. Do not change thesettings unnecessarily.
41
11
CAUTION(Ref. page)
S The control PC board employs CMOS ICs. Do not touch theCMOS elements.They are easily damaged by static electricity.
46
S Donot connectordisconnectwiresorconnectorswhilepoweris applied to the circuit.Failure to observe this caution can result in personal injury.
46
OTHERS
WARNINGS Never modify the product.Failure to observe this warning can result in an electrical shock orpersonal injury and will invalidate the guarantee.
12
WARNING INDICATION
Awarning 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 resistorunit .
ExampleofBrakingUnitModelCDBR−4045B
13
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.
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 unitsat pollution level 2 or less (UL standard) and in a location to satisfy the followingconditions:
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 periph-ery.
S Since the braking resistor unit generates heat, provide sufficient spacesfrom devices which are weak against heat.
S Install the units at such locations that all requirements described in Par.2.1 “LOCATION” are satisfied.
17
S Install the units in the directions shown in Figs. 1 to 8. There will be noproblem if they are installed vertically.
4−M4 MTG HOLE
1.5 (38)
1.18 (30)OR MORE
3−LEAD WIRE OUTLET[0.87 (20) DIA RUBBER BUSH]
5.04 (128)5.51 (140)
1.5 (38)
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)ORMORE
3.94(100)ORMORE
Fig. 1 BrakingUnitDimensions in inches (mm) CDBR−2015B,−2022B,−4030B,−4045B
2. INSTALLATION
18
6.57 (167)
3.94
(100)
ORMORE
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 CIRCUITTERMINAL M4
3−LEAD WIREOUTLET1.10 (28) DIARUBBER BUSH
4−M6MTG HOLE
2.30
1.18 (30)OR MORE
3.94
(100)
ORMORE
Fig. 2 Braking Unit Dimensions in inches (mm) CDBR−5037B
19
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 CIRCUITTERMINAL M5
2−LEAD WIRE OUTLET1.38 (35) DIA RUBBERBUSH
4−M6MTG HOLE
3.94 (100)
OR MORE
WIRE OUTLET 1.10 (28)DIA RUBBER BUSH
3.94
(100)
ORMORE2.32 1.97 (50)
1.18 (30)OR MORE
1.18 (30)OR MORE
Fig. 3 Braking Unit Dimensions in inches (mm) CDBR−2045B
2. INSTALLATION
20
MAIN CIRCUITTERMINAL M6
2−LEAD WIRE OUTLET1.38 (35) DIA RUBBERBUSH
4−M6MTG HOLE
3.94
(100)
ORMORE
WIRE OUTLET 1.10 (28)DIA RUBBER BUSH
3.94
(100)
ORMORE
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)
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 CIRCUITTERMINAL M5
4−M6MTG 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 OUTLET1.38 (35) DIA RUBBERBUSH
WIRE OUTLET 1.10 (28)DIA RUBBER BUSH
3.94
(100)
ORMORE4.37 (111)
6.14 (156)
7.87 (200)
3.94
(100)
ORMORE
3.86 (98)
Fig. 5 Braking Unit Dimensions in inches (mm) CDBR−4090B, −5110B
2. INSTALLATION
22
MAIN CIRCUITTERMINAL M6
4−M6MTG HOLE
1.44
(36.5)
0.35
(9)
8.27 (210)
12.48(317)
13.98(355)
14.57(370)
2.76
(70)
6.16 (156.5)
8.27 (210)
4.67 (118.5) 1.97 (50)
1.18 (30)OR MORE
9.84 (250)
1.18 (30)OR MORE
2−LEAD WIRE OUTLET1.38 (35) DIA RUBBERBUSH
WIRE OUTLET 1.10 (28)DIA RUBBER BUSH
3.94
(100)
ORMORE4.37 (111)
6.14 (156)7.87 (200)
3.94
(100)
ORMORE
4.09(104)
Fig. 6 Braking Unit Dimensions in inches (mm) CDBR−4220B, −5300B
23
ab b
Braking ResistorUnit Model
Dimensions in inches (mm)Unit Model(LKEB−j) A B C D E
Fig. 8 Braking Resistor Unit Dimensions in inches (mm) [for 15 to 60HP (11 to45kW)]
25
2.3 REPLACEMENT OF CONVENTIONAL BRAKINGUNITS WITH NEW UNITS
To replace conventional braking units (modelsCDBR−2015,−2022,−4030,−4045)with new units (CDBR−2015B, −2022B, −4030B, −4045B), an exclusive−use at-tachment is required. Contact your YASKAWA representative.
0.39(10)0.28(7)
3.94 (100)
11.02(280)
5.51 (140)
10.24(260)
ATTACHMENT
5.45 (138.5) 0.39 (10)
0.98(25)
5.91(150)
4.13(105)
4−M6 MTG HOLE
Code No.: DACT32732−AD
3.94 (100)0.79(20)
0.28(7)
0.79(20)
Fig. 9 Mounting Dimensions of Attachment in inches (mm)
2. INSTALLATION
26
The main circuit terminal symbols are different between conventional models andnew models. Refer to the following table.
Figs. 10, 11 and 12 show appearance and each section name of braking unit andbraking resistor unit respectively.
Thermal overload relay protects the braking resistor unit for models LKEB−20P7to −27P5, and thermal protector protects the braking resistor unit for modelsLKEB−2011 to −2022 and −4018 to −4045.
*1 For wire size of 8−6 (8−14), use UL1283 heat−resistant vinyl−insulated wire orequivalent.
*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.
3.WIRING
32
3.4 WIRING PRECAUTIONS
(1) Wiring Leading−in Method
Lead in the wire through the knockout hole on the unit bottom. Since theknockout hole is provided with a rubber bush, cut the rubber bush centralcrosswise with a blade and lead the wire through.
(2) Separation from Signal Lines
Since strong noise component is superimposed on the braking resistor unitand braking unit wiring, separate the units from signal lines which are weakagainst noise.
(3) Wiring Distance
Wiring distance between the braking resistor unit and braking unit or brakingunit and inverter must be provided as shown in Fig. 13. Make sure to bundlethe wires between the units.
Braking ResistorUnit
Braking Unit Inverter
32.8ft(10m)or less
16.4ft(5m)or less
Fig. 13 Wiring Distance
3.WIRING
33
(4) Grounding Method
S Mount the braking resistor unit on a groundedmetallic plate.When it can-not be mounted on a grounded metallic plate, pull out the lead wire fromthe mounting screw section to ground.
S Braking unit grounding terminal must be provided with the ground resist-ance 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 re-sistor unit and VS−616G5.
Refer to Par. 3.3, “WiringPrecautions” for properwiring in actualwiring design andwork.
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 Brak-ing Units.
If using another braking resistor instead ofYASKAWAbraking resis-tor unit, be sure to protect by thermal overload relay.
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 brakingunit according to main circuit power supply type. Table 3 shows the relationshipbetween 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.
4.OPERATION
42
200V
208V220V230V
400V415V440V460V
380V
200V class
400V class
1 2 5 6
May cause injury or electric
WARNING
Please follow the instructions inthe manual before installation or
operation.
shock.
Disconnect all power before openingfront cover of unit. Wait 3 minutes
Selection Connector Setting MASTER side is selected prior to shipment. Use theunits without changing the setting.
SLAVE side is selected when more than one braking unit is combined to use andbraking start levels must coincide. Refer to Par. 4.4, “Parallel Connection of Brak-ing Unit” for details.
4.4 PARALLEL CONNECTION OF BRAKING UNIT
For using more than one parallel−connected braking unit, connect and select theconnectors 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 sidefor braking units 2 and 3.
S Connect thermal protector on the braking resistor unit and thermoswitchon 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 and1, 2 of the braking units.
S Parallel connection of braking unit is possible up to a maximum of 10units.
Note: The above table lists the applicable braking unit and braking resistor unitmodels for the 200−Vclassinverter model CIMR−G5j. For other inverter models, refer to the catalog of the relevant inverter.
48
Example: 400−V Class Inverter Model CIMR−G5j
Inverter Braking Unit Braking Resistor Unit Approx.Braking
Note: The above table lists the applicable braking unit and braking resistor unitmodels for the 400−Vclassinverter model CIMR−G5j. For other inverter models, refer to the catalog of the relevant inverter.
6.SPECIFICATIONS
49
6.2 BRAKING UNIT FOR 575V CLASS APPLICATION LIST
Example: 575−V Class Inverter Model CIMR−G5j
Inverter Braking Unit Braking Resistor Unit Approx.Braking
Note: The above table lists the applicable braking unit and braking resistor unitmodels for the 575−Vclassinverter model CIMR−G5j. For other inverter models, refer to the catalog of the relevant inverter.
50
6.3 LIST OF APPLICABLE/NOT APPLICABLE COMBINA-TIONS WITH CONVENTIONAL MODELS (VS−616HII/H3, VS−616GII/G3, VS−676)
ConventionalModel
BrakingUnit
Braking Re-sistor Unit
Applicable/Not Appli-cable
Remarks
VS−616HII/H3VS−616GII/G3VS−676
−ModelLKEB−20P7etc.
Applicable See connection exam-ples of Fig 14.
VS−616HII/H3VS−616GII/G3VS−676
ModelCDBR−15Hetc.
ModelLKEB−2015etc.
Applicable
Use sequencer to breakpower supply side onthermal protector ofthe braking resistorunit side.
VS−616HII/H3VS−616GII/G3VS−676
ModelsCDBR−2015,−2015B etc.
ModelLKEB−4.8Ketc.
Not applica-ble
No thermal protectivefunction of braking re-sistor unit.
VS−616HII/H3VS−616GII/G3VS−676
ModelsCDBR−2015,−2015B etc.
ModelLKEB−2015etc.
Applicable See connection exam-ples of Figs. 15 to 18.
51
6.4 BRAKING UNIT SPECIFICATIONS
Braking Unit Model 200V to 300V 380V to 460V 500V to 575VBraking Unit ModelCDBR− 2015
IRUMA BUSINESS CENTER (SOLUTION CENTER)480, Kamifujisawa, Iruma, Saitama, 358-8555, JapanPhone: 81-4-2962-5696 Fax: 81-4-2962-6138
YASKAWA ELECTRIC CORPORATIONNew Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo, 105-6891, JapanPhone: 81-3-5402-4511 Fax: 81-3-5402-4580http://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: 1-847-887-7310http://www.yaskawa.com
YASKAWA ELÉTRICO DO BRASIL COMÉRCIO LTDA.Avenda Fagundes Filho, 620 Bairro Saude, São Paulo, SP04304-000, BrasilPhone: 55-11-3585-1100 Fax: 55-11-5581-8795http://www.yaskawa.com.br
YASKAWA ELECTRIC EUROPE GmbHHauptstraβe 185, 65760 Eschborn, GermanyPhone: 49-6196-569-300 Fax: 49-6196-569-398
YASKAWA ELECTRIC UK LTD.1 Hunt Hill Orchardton Woods, Cumbernauld, G68 9LF, United KingdomPhone: 44-1236-735000 Fax: 44-1236-458182
YASKAWA ELECTRIC KOREA CORPORATION7F, Doore Bldg. 24, Yeoido-dong, Youngdungpo-Ku, Seoul, 150-877, KoreaPhone: 82-2-784-7844 Fax: 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.151 Lorong Chuan, #04-02A, New Tech Park, 556741, SingaporePhone: 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, ChinaPhone: 86-21-5385-2200 Fax: 86-21-5385-3299
YASKAWA ELECTRIC (SHANGHAI) CO., LTD. BEIJING OFFICERoom 1011A, Tower W3 Oriental Plaza, No. 1 East Chang An Ave., Dong Cheng District, Beijing, 100738, ChinaPhone: 86-10-8518-4086 Fax: 86-10-8518-4082
YASKAWA ELECTRIC TAIWAN CORPORATION9F, 16, Nanking E. Rd., Sec. 3, Taipei, TaiwanPhone: 886-2-2502-5003 Fax: 886-2-2505-1280
英文 No.10-4(B6) インバータ製品用
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.