Converteam ALSPA MV3DB Series User manual

Dynamic Braking
ALSPA MV3000e
Dynamic Braking Units MV3DB Series
Publication No. T1684EN Rev. 0005 (07/06)

SAFETY INSTRUCTIONS
Care has been taken with the design of this product to ensure that it is safe. However, in common with all
products of this type, misuse can result in injury or death. Therefore, it is very important that the instructions
in this manual and on the product are observed during transportation, commissioning, operation,
maintenance and disposal.
This technical manual should be regarded as part of the product. It should be stored with the product and
passed on to any subsequent owner or user.
Local safety laws and regulations must always be observed.
Persons working on the product must be suitably skilled and should have been trained in that work for
these products.
The product is a component designed for incorporation in installations, apparatus and machines.
The product must not be used as a single item safety system. In applications where maloperation of the
product could cause danger, additional means must be used to prevent danger to persons.
Product approvals and certifications will be invalidated if the product is transported, used or stored outside
its ratings or if the instructions in this manual are not observed.
Third party approvals to safety standards UL 508C and CSA C22.2 No 14 are marked on the product.
In the European Union:
•Products within the scope of the Low Voltage Directive, 73/23/EEC as amended are CE marked.
•The product complies with the essential protection requirements of the EMC directive 89/336/EEC
as amended, when installed and used as described in this manual. The requirements of the EMC
Directive should be established before any installation, apparatus or machine which incorporates
the product is taken into service.
•A machine should not be taken into service until the machine has been declared in conformity
with the provisions of the Machinery (Safety) Directive, 98/37/EEC.
CHANGES FROM PREVIOUS EDITION
Publication No. T1684EN Rev.0005 (07/06)
©2006 CONVERTEAM UK LIMITED
Revision 0004 Warning texts revised.
References to other manuals revised.
Revision 0005 Company Name change

MV3DB Series DB Units Documentation Structure
(07/06) ALSPA MV3000e Dynamic Braking Units Page i
PLANNING
&
DB UNIT SELECTION
SECTION 4
COMPREHENSIVE
INSTRUCTIONS FOR
INSTALLATION IN
BASIC DRIVE
MODULES
INSTALLATION
COMMISSIONING
SECTION 5
COMMISSIONING
PROCEDURE
+
DETAILED
DESCRIPTION OF
ASSOCIATED DRIVE
PARAMETERS
MAINTENANCE
AND
DIAGNOSTICS
SECTIONS 6 & 7
SIMPLE MAINTENANCE
+
DETAILED
DIAGNOSTIC
INFORMATION
SPARES
&
DISPOSAL
THIS MANUAL
(T1684EN) DB UNIT
STAGES OF USE
SELECTION OF
BRAKING RESISTOR
SECTION 3
DETAILED
INSTRUCTIONS FOR
SELECTION OF
BRAKING RESISTOR
SECTIONS 1 - 3
SPECIFICATIONS AND
OTHER DATA
SECTIONS 8 & 9
USER-REPLACEABLE
SPARES
+
SAFE DISPOSAL
INSTRUCTIONS

Overview MV3DB Series DB Units
ALSPA MV3000e Dynamic Braking Units (07/06)
Page ii
OVERVIEW
Section Page
1. Introduction ...................................................................................................................... 1-1
Introduces the Dynamic Braking Manual and the ALSPA MV3000e Dynamic
Braking Units (DB Units). A table shows the complete range of DB Units available
for MV3000e drives.
2. Specifications................................................................................................................... 2-1
Provides electrical and mechanical specifications for all MV3000e DB Units, also
weights and miscellaneous data common to all the units, such as derating
information.
3. System Design...................................................................................................................3-1
Contains a functional description of MV3000e DB Units and application specific
information to assist with system design, including the selection and protection of
braking resistors, with examples and suggested circuits. Topics covered include the
layout of braking components with regard to EMC requirements and wiring
segregation.
4. Installation ........................................................................................................................ 4-1
Explains how to properly install a DB Unit into a drive and how to install proprietary
Converteam braking resistors.
5. Commissioning ................................................................................................................ 5-1
Explains how to commission a DB Unit and how to configure a drive to operate with
a DB Unit and braking resistor.
6. Preventive Maintenance .................................................................................................. 6-1
Simple maintenance procedures for keeping the DB Unit serviceable.
7. Diagnostics....................................................................................................................... 7-1
What to do if the drive indicates that the DB Unit or the braking resistor has caused
a Warning or Trip to occur. Provides diagnostic hints to help find possible faults.
Refers to the Getting Started manual for information to display Warning and Trip
codes, to view a history of any previous incidents which may help with diagnosis
and to reset drive trips.
8. Spare Parts ........................................................................................................................8-1
Lists any spare parts required for user repair.
9. Disposal ............................................................................................................................ 9-1
Provides disposal instructions for the DB Unit.

MV3DB Series DB Units Contents
(07/06) ALSPA MV3000e Dynamic Braking Units Page iii
TABLE OF CONTENTS
Section Page
1. Introduction .................................................................................................................................1-1
1.1 About this Manual .........................................................................................................................1-1
1.2 About the ALSPA MV3000e Dynamic Braking Unit......................................................................1-1
1.3 Range of DB Units covered by this Manual..................................................................................1-2
1.4 Range of Standard Braking Resistors supplied by Converteam ..................................................1-2
1.5 Identity Codes...............................................................................................................................1-2
1.6 Use of Metric Units........................................................................................................................1-2
1.7 Customer Support and Training....................................................................................................1-3
1.8 Associated Publications................................................................................................................1-3
2. Specifications..............................................................................................................................2-1
2.1 Electrical Specification of DB Units and Standard Braking Resistors...........................................2-1
2.2 Duty Cycle.....................................................................................................................................2-2
2.3 Data Common to all DB Units.......................................................................................................2-2
2.4 Safety Standards...........................................................................................................................2-3
2.5 Illustration of Ratings.....................................................................................................................2-4
3. System Design ............................................................................................................................3-1
3.1 Introduction ...................................................................................................................................3-1
3.2 Functional Description...................................................................................................................3-1
3.3 Standard Braking Resistor Selection............................................................................................3-1
3.4 Alternative Braking Resistor Selection..........................................................................................3-2
3.5 Calculation for Alternative Resistors.............................................................................................3-2
3.5.1 Calculation Based on Power....................................................................................................3-2
3.5.2 Calculation Based on Inertia....................................................................................................3-3
3.6 Equivalence of Duty Cycles ..........................................................................................................3-4
3.6.1 For braking times longer than 18 seconds:..............................................................................3-4
3.6.2 For braking times less than 18 seconds: .................................................................................3-5
3.7 Braking Resistor Cable Selection .................................................................................................3-5
3.8 Resistor Protection........................................................................................................................3-6
3.8.1 Internal Protection....................................................................................................................3-6
3.8.2 External Protection...................................................................................................................3-7
3.9 Cabinet layout and EMC...............................................................................................................3-8
4. Installation ...................................................................................................................................4-1
4.1 Introduction ...................................................................................................................................4-1
4.2 Receipt of Equipment....................................................................................................................4-1
4.2.1 Inspection.................................................................................................................................4-1
4.2.2 Storage.....................................................................................................................................4-1
4.2.3 Handling...................................................................................................................................4-1
4.3 Installing the DB Unit.....................................................................................................................4-2
4.3.1 Cable Lugs and Recommended Torque Settings....................................................................4-2
4.3.2 Access to Drive Components...................................................................................................4-3
4.3.3 Installation to Frame Size 3 Drives..........................................................................................4-4
4.3.4 Installation to Frame Size 4 Drives........................................................................................4-10
4.3.5 Installation to Frame Size 6 Drives........................................................................................4-14
4.3.6 Installation to Frame Size 7 Drives........................................................................................4-18
4.4 Installing the Braking Resistor ....................................................................................................4-22
5. Commissioning ...........................................................................................................................5-1
5.1 Installation Assumptions ...............................................................................................................5-1
5.2 Commissioning Procedure............................................................................................................5-1
5.2.1 Mechanical Checks..................................................................................................................5-1
5.2.2 Power Connections..................................................................................................................5-1
5.2.3 Procedure.................................................................................................................................5-1
5.3 Drive Parameters..........................................................................................................................5-2
5.4 Dynamic Brake Status Flags.........................................................................................................5-4

Contents MV3DB Series DB Units
ALSPA MV3000e Dynamic Braking Units (07/06)
Page iv
6. Preventive Maintenance .............................................................................................................6-1
6.1 Tools and Equipment Required.....................................................................................................6-1
6.2 Maintenance Schedules................................................................................................................6-1
6.2.1 Access to Equipment ...............................................................................................................6-1
6.2.2 Monthly Servicing.....................................................................................................................6-1
6.2.3 Annual Servicing ......................................................................................................................6-1
7. Diagnostics..................................................................................................................................7-1
7.1 Fault monitoring.............................................................................................................................7-1
7.2 Warnings .......................................................................................................................................7-1
7.3 Trips...............................................................................................................................................7-1
8. Spare Parts...................................................................................................................................8-1
9. Disposal........................................................................................................................................9-1
Index
Support

MV3DB Series DB Units 1. Introduction
(07/06) ALSPA MV3000e Dynamic Braking Units Page 1-1
1. Introduction
1.1 About this Manual
This Dynamic Braking Manual provides a competent user trained in electrical installation
practice with sufficient information to safely install, commission, maintain and dispose of an
ALSPA MV3000e Dynamic Braking (DB) Unit. The manual should be read in conjunction with
the relevant ALSPA MV3000e Getting Started Manual.
This manual should be regarded as part of the ALSPA MV3000e DB Unit. It should be retained
for the life of the product and should be passed on to any subsequent owner or user.
To use a ALSPA MV3000e DELTA system configured with a DB Unit, refer to T1689, the
Technical Manual for MV3000e DELTA.
1.2 About the ALSPA MV3000e Dynamic Braking Unit
The DB Units described in this manual are intended only to be used when installed within the
associated ALSPA MV3000e MicroCubicle™- style drive and must not be used in any other
manner.
The DB Unit is used in conjunction with an externally mounted braking resistor, to dissipate
kinetic energy stored in a motor and its load. This is regenerated into the ALSPA MV3000e
drive during deceleration or when the load is overhauling. The drive monitors the DC link
voltage and uses the DB Unit to switch the braking resistor into circuit when the voltage
exceeds a pre-set level.
All DB Units are mounted within the MicroCubicle™, and are powered and controlled by the
drive. Braking functions may be configured using parameters which are described in Section 5
(Commissioning).
A typical DB Unit is illustrated in Figure 1-1.
Figure 1-1 A typical DB Unit

1. Introduction MV3DB Series DB Units
ALSPA MV3000e Dynamic Braking Units (07/06)
Page 1-2
1.3 Range of DB Units covered by this Manual
Table 1-1 shows the full range of DB Units available for MV3000e drives. There is one DB Unit
for each frame size at each available supply voltage rating. Electrical data, dimensions and
weights are provided in Section 2.
Table 1-1 – Range of DB Units available
Drive Supply Voltage
Drive
Frame
Size 380 V – 440 V 460 V – 525 V 575 V – 690 V
3 MV3DB045S5 MV3DB045S5 N/A
4 MV3DB092S5 MV3DB092S5 MV3DB061S6
6 MV3DB247S5 MV3DB247S5 MV3DB185S6
7 MV3DB391S5 MV3DB391S5 MV3DB246S6
1.4 Range of Standard Braking Resistors supplied by Converteam
Converteam produces a range of standard braking resistors designed to allow each internal
DB Unit to produce the maximum possible braking effort. Section 2.1 shows the braking
resistor model number associated with each DB Unit. The maximum permitted sizes of resistor
connecting cables are given in Section 3.7.
Instruction Sheet T1947 provides detailed installation instructions for these resistors.
1.5 Identity Codes
The code used to identify DB Units is explained in Figure 1-2 below. The figure shows the
code for a standard duty DB Unit rated at 92 Amps and with a maximum supply voltage of 525
V.
MV3DB092S5
A
LSP
A
MV3000
Series
Current
Ra ti n g (Am p s)
Dynamic
Brake Duty
Ra ti n g Voltage
Grade
Figure 1-2 DB Unit identity code
1.6 Use of Metric Units
The ALSPA MV3DB range of DB Units has been designed to IEC standards using SI units. In
this manual approximate values for inches, lb and hp are also included for convenience.

MV3DB Series DB Units 1. Introduction
(07/06) ALSPA MV3000e Dynamic Braking Units Page 1-3
1.7 Customer Support and Training
Converteam provides comprehensive telephone technical support, application planning,
service and customer training.
Contact Converteam at the address and telephone numbers shown at the end of this manual.
1.8 Associated Publications
Various ALSPA MV3000e Getting Started Manuals for Converteam
MicroCubicle™ Drives
These manuals provide competent users trained in electrical installation practice
with sufficient information to safely install, commission, operate, maintain and
dispose of simple MicroCubicle™ drive installations.
T1679 ALSPA MV3000e Software Technical Manual
This manual contains detailed technical information to enable a competent user
trained in drives to safely configure the ALSPA MV3000e drives for specific
applications. It includes full descriptions of the menu structure and parameters, also
the serial communications systems.
T1947 ALSPA MV3DBR Series Braking Resistors
This Instruction Sheet provides detailed instructions for installing braking resistors
produced by Converteam.

1. Introduction MV3DB Series DB Units
ALSPA MV3000e Dynamic Braking Units (07/06)
Page 1-4
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