User manual

Braking Unit for Frequency Inverter

Serie 3CV 380 – 480V 18,5 bis 55kW

Tel. (09189) 4147-0, Fax (09189) 4147-47

PETER electronic GmbH & Co. KG, Bruckäcker 9, D-92348 Berg eMail: [email protected]
Internet: www.peter-electronic.com
PREFACE

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

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

The Braking unit can be connected as FUS … /3CV.

Bei der Zusammenstellung von Texten und Abbildungen wurde mit größter Sorgfalt vorgegegangen.
Trotzdem können Fehler nicht vollständig ausgeschlossen werden. Herausgeber und Autor können für
fehlerhafte Angaben und deren Folgen weder eine juristische Verantwortung noch irgendeine Haftung
übernehmen. Für Verbesserungsvorschläge und Hinweise auf Fehler sind wir dankbar.

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Stand 08/06 1F000.10002

CONTENTS

NOTES FOR SAFE OPERATION

1. RECEIVING 6

2. ENVIRONMENTAL PRECATION 6

3. MODEL-IDENTIFICATION 7

4. SPECIFICATION 7

5. SECTION NAME 8
5.1 Circuitry terminal description 8
5.2 Jump function description 9

6. DIMENSION 9

7. WIRE PRECATIONS
7.1 Circuits and wire specification 10
7.2 Wire distance 10

8. INTERCONNECTION 11
8.1 One braking unit installation 11
8.2 Parallel connection of braking units 11
8.3 Braking unit and braking resistor unit application list 12

9. TROUBLESHOOTING 13

2
NOTES FOR SAFE OPERATION

The following conventions are used to indicate precaution in this manual.

Failure to heed precaution provided in this manual can result in serious or possibly even
fatal injury or damage to the products or to related equipment and system.

CAUTION：Indicated precaution that, if not heeded, could result in relatively

serious or minor injury , damage to the product, or faulty operation.

DANGER：Indicated precaution that, if not heeded, could possibly result in loss

of life or serious injury.

───────────RECEIVING──────────

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

─────────────INSTALLATION───────────

Lift 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.

Mount the braking unit and resistor on nonflammable material. Failure to

observe this caution can result in a fire.

When mounting braking unit (Individually or multiple) in an enclosure, install a

fan or other cooling device to keep the intake air temperature below 40 . Over hearting
may cause a fire or damage to the unit.

─────────────WIRING────────────

Connect the Inverter’s DC bus terminal N、P to Braking unit’s main circuit

terminal N(-)、P(+) properly. Otherwise, the Inverter or Braking unit will be damaged.

3
Always turn OFF the input power supply and wait until the CHARGE indicator
light goes out before wiring terminal. Otherwise, an electric shocks or fire can occur.

Do not touch the Braking unit and Braking resistor while power is applied to the
circuit. Failure to observe this warning can result in personal injury.

Wiring should be performed only by qualified personnel. Failure to observe this

warning can result in an electrical shock or a fire.

Make sure to earth the ground terminal , Grounding resistance 200V

class 100Ω or less, 400V class 10Ω or less.

When wiring the emergency stop circuit, check the wiring thoroughly before
operation.Failure to observe this warning can result in personal injury.

Never touch the fins (heat-sink) of the Braking unit or discharge resistor. These
can become very hot. Failure to observe this warning can result in personal injury.

Install the discharge resistor on nonflammable material, provide sufficient

spaces from other devices, the 1 meter distance are recommend, Failure to observe this
caution can result in a fire.

Verify that the rated voltage setting jumper of the braking unit coincides with the
Inverter input supply voltage. Failure to observe this caution can result in personal injury
or a fire.

Tighten terminal screws to the specified tightening torque. Failure to observe

this caution can result in a fire.

Do not perform a withstand voltage test of the braking unit and braking resistor
unit. It may cause braking unit inside element to be damaged.

─────────────OPERATION────────────

Do not remove the cover while the power is ON, current is flowing. Failure to
observe this warning can result in an electrical shock.

Do not check signals during operation. The Braking unit or the Inverter may be
damaged.

4
Never touch the discharge resistor. These can become very hot. Failure to
observe this warning can result in personal injury.

Never modify the product, Failure to observe this warning can result an
electrical shock or personal injury and will invalidate the guarantee.

────MAINTENANCE AND INSPECTION──────

Perform maintenance or inspection only after verifying that the CHARGE LED
goes OFF, after the main power supply is turn OFF. The capacitors are still charged and
can be dangerous.

Never touch high-voltage terminals in the braking unit and braking resistor.
Failure to observe this warning can result in an electrical shock.

Only authorized personnel should be permitted to perform maintenance,

inspection or parts replacement. Failure to observe this warning can result in an
electrical shock.

5
1. RECEIVING
The braking unit has been put though several tests at the factory before shipment. After
unpacking, however, check and see the following.
Their model and capacity of the braking unit meet your requirement.
Is there any damage while transportation. If so, do not apply the power.
If any of above is found, contact nearest distributor or sales representatives.

2. ENVIRONMENTAL PRECATION
The environment will directly affect the proper operation and the life of the braking unit,
so install the braking unit in an environment complies with the following conditions:
Ambient temperature: -10°C - +40°C; (take the dustproof cover off : -10°C - +50°C)
Avoid exposure to rain or moisture. Avoid direct sunlight.
Avoid smoke and salinity. Avoid erosive liquid and gas.
Avoid dust, bats, and small metal pieces. Keep away from radiative and
flammable materials.
When mounting multiple braking units are placed in the same control panel, add
extra heat dissipators to keep the temperature below 40°C.

Place the front side of the braking unit onward and top upward to help heat dissipation.
Install the inverter according to the following figures: (take the dustproof cover off to help
heat dissipation if installed in a box or the environment allows to do so)

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3. MODEL-IDENTIFICATION
Model name TBU - 4 30
Series Applicable Inverter voltage Applicable motor rated capacity
4: 380 - 480V 30: 30Hp

4. SPECIFICATION

Applicable Inverter voltage 380V - 480V

Braking unit model TBU-430
Applicable Motor Output 18,5kW – 55kW
Characteristics

Rated Discharge Current (A) 15

Output

Max Discharge Current (A) 40

618/651/716/748/781VDC
Braking Start Voltage (VDC)
→±6V

Inverter Input Voltage 380 - 480VAC

Supply
Power

Inverter DC BUS Voltage 460 - 800VDC

Overheat Thermostat (with contact output)

Function
Prot.

Power Charge Indication Charge lamp stays ON until bus voltage drops below 50VDC

Location Indoor (Protected from corrosive gases and dust)

Ambient Temperature - 10°C - + 40°C
Storage Temperature - 20°C - + 70°C
Environment Conditions

Humidity 0 - 95%RH (non-condensing)

Vibration 1g less than 20Hz；up to 0.3g at 20 - 50Hz
Enclosure IP20
Safety level CE/UL/cUL
Installation Screw mounted
Parallel connection of braking unit is possible to use in the
Parallel connection
inverter with bigger horsepower
Dimension (W*H*D) 149mm * 184mm * 146mm
● Loading time rate can be used below 10%ED (max. 10s)

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5. SECTION NAME

5.1 Circuitry terminal description

Purpose Terminal Description

Symbol
P(+) DC-Bus power input terminals
N(-) (P(+) positive terminal, N(-) negative terminal)
Main
circuit BR+ Braking resistor output terminals. (Resistor
power BR- specification please refer to braking resistor list)
input
Grounding terminal

SL+ Parallel connect Slave input positive terminal

SL- Parallel connect Slave input negative terminal
Control MA+ Parallel connect Master input positive terminal
circuit MA- Parallel connect Master input negative terminal
OH+ Braking unit over-heat protection relay output
OH- terminal (1A/125VAC, 2A/ 30VDC)

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5.2 Jump function description

Description
JP1 Braking unit power supply voltage selection; selected the
properly voltage level to make the braking start level corrected.
Master / Slave station selection
Master station: MASTER-COM, (Factory default)
JP2
Slave station: SLAVE-COM (Only multiple braking units
needed)

6. DIMENSION

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7. WIRE PRECATION
7.1 Circuits and wire specification

Braking Wire sizes Terminal

Purpose Terminal Symbol Wire type
unit AWG (mm²) Screws

N(-)，P(+)

Main 12-10
BR+，BR- M4
circuit (3.5-5.5 mm²) Power cables, e.g.,
TBU-430 600V, vinyl power
cables

Control SL+ ,SL-, MA+, 18-14

M3
circuit MA-, OH+, OH- (0.75-2 mm²)

7.2 Wire distance

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

Make sure to ground the grounding terminal , use the properly wire and
tighten M4 terminal screws to the specified tightening torque.

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8. INTERCONNECTION

Braking units have a master/slave selection connector, the master side selected prior to
shipment, for using more than one parallel connected braking unit, selected slave side
for braking units second unit and above.

8.1 One braking unit installation

(One Inverter connected to one braking unit)

N N (-) SL +
P P (+) SL -
MA +
MA -
Master
Inverter
480
460
440
BR + 400 OH +
BR - 380 OH -

8.2 Parallel connection of braking units

(One Inverter connected to multiple braking units)

Braking unit 1 Braking unit 2 Braking unit 3

N N (-) SL + SL + N (-) SL + N (-)
P P (+) SL - SL - P (+) SL - P (+)
MA + MA + MA +
Slave Slave
MA - MA - MA -
Master

Inverter 480 480 480

460 460 460
440 440 440
BR + 400 OH + BR + 400 OH + BR + 400 OH +
* * *
BR - 380 OH - BR - 380 OH - BR - 380 OH -

* Thermostat with relay:

1A/125VAC
2A/30VDC

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For using multiple braking units need to parallel connected the barking units’ main circuit
terminal and selector the jumper 2(JP2) as follows:
1) Braking unit 1 as the Master station, check the JP2 selection is in MASTER-COM.
2) Braking unit 2 & 3 as the Slave station. Make sure the JP2 selection is in
SLAVE-COM

3) Connect braking unit 1 terminal MA+，MA- to braking unit 2 terminal SL+，SL-,

Braking unit 2 terminal MA+，MA- to braking unit３terminal SL+，SL-.

4) Braking unit terminal BR+，BR- connect to braking resistor.

5) Make sure all the braking unit JP1 (voltage selection) selected corrected,
then the parallel connection braking units start level will coincide.

8.3 Braking unit and braking resistor unit application list

INVERTER Braking Unit Braking Resistor

Approx.
Braking Min
Braking Torque
Voltage kW Braking Unit Q’ty MODEL NO. Resistor Q’ty Ohm
(10%ED)
Specification Value

18,5 TBU-430 1 1200W/30Ω 4 19.2Ω 119％(10％ED)

22 TBU-430 1 1200W/30Ω 4 19.2Ω 117％(10％ED)

380V – 30 TBU-430 1 1500W/20Ω 4 19.2Ω 119％(10％ED)

480V 37 TBU-430 2 1200W/30Ω 8 19.2Ω 119％(10％ED)

45 TBU-430 2 1200W/30Ω 8 19.2Ω 117％(10％ED)

55 TBU-430 2 1500W/20Ω 8 19.2Ω 126％(10％ED)

Select the braking resistor by this list. Failure to observe this warning can
damage to the unit.

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9. TROUBLESHOOTING

Fault Status Cause Corrective Action

Without braking unit: Repair the Inverter’s braking
Inverter built-in braking discharge circuit.
transistor is in short circuited. Replace the Inverter
Braking unit or
With braking unit: Repair the braking unit’s
resistor acted when
Braking unit discharge transistor is braking circuit.
the Inverter during
in short circuited. Replace the Braking unit
the acceleration or
Improper selection the input Set the correct JP2 position.
constant speed.
voltage level J2, (Power supply
Make the resistor
voltage > braking unit’s power
over load
supply voltage selection).
Input power voltage high than the Improved the input power
voltage specification. voltage.
Examine the braking capacity.
Increase inverter’s
Insufficient braking capacity
Inverter trips at deceleration time
over voltage (OV)
Improper wiring Check the wire
Braking unit malfunction Replace the Braking unit
Inverter Start/Stop frequently Examine the operating
Load inertia too heavy condition
Braking unit trips by
Improper combination of braking
heat sink over heat Selective by specification
unit and transistor
Ambient temperature above 40°C Check the location conditions

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