Power Electronics B150 Series Operator's manual

BrakingDocumentation
B150 Dynamic Braking Unit
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B150 Dynamic Braking Unit
Braking Documentation
Edition: March 2012
SD70DF01BI Rev. B

B150 –Dynamic Braking Unit
POWER ELECTRONICS
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POWER ELECTRONICS
B150 –Dynamic Braking Unit
SAFETY SYMBOLS
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SAFETY SYMBOLS
Always follow safety instructions to prevent accidents and potential hazards
from occurring.
Edition March2012
This publication could present technical imprecision or misprints. The
information here included will be periodically modified and updated, and all
those modifications will be incorporated in later editions.
To consult the most updated information of this product you might access
through www.power-electronics.com where the latest version of this manual
can be downloaded.
Revisions
Date Revision Description
08 / 10 / 2008 A First edition
This symbol means improper operation may results in
serious personal injury or death.
Identifies shock hazards under certain conditions.
Particular attention should be given because dangerous
voltage may be present. Maintenance operation should be
done by qualified personnel.

B150 –Dynamic Braking Unit
POWER ELECTRONICS
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SAFETY SYMBOLS

POWER ELECTRONICS
B150 –Dynamic Braking Unit
INDEX
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INDEX
SAFETY INSTRUCTIONS................................................................................7
1. INTRODUCTION.......................................................................................13
1.1. Description of the B150 Braking Unit...........................................13
2. TECHNICAL CHARACTERISTICS..........................................................15
2.1. Electrical Data..............................................................................15
3. INSTALLATION AND CONNECTION......................................................16
3.1. Installation of B150 Unit...............................................................16
3.2. Power and Control Connections for B150 Unit............................18
3.3. Operating Mode Setting...............................................................27
3.4. Local Settings and Indications.....................................................33
3.5. Safety Connection for the „No Fault‟ Relay..................................34
3.6. Mounting of the Dynamic Braking Resistor..................................34
3.7. Resistor Thermal Protection ........................................................35
4. RECOMMENDATIONS FOR APPLICATIONS........................................36
4.1. Selection of the Dynamic Braking Resistor..................................37
5. PARAMETER SETTING FOR SD700 SERIES........................................39
5.1. Group 17 –G17: Brake................................................................39
6. TROUBLESHOOTING AND MAINTENANCE.........................................40
6.1. Troubleshooting ...........................................................................40
6.2. Maintenance.................................................................................41
7. ANNEX A. OPTIONAL BOARD FOR BRAKING UNIT SLAVE MODE..41

B150 –Dynamic Braking Unit
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INDEX

POWER ELECTRONICS
B150 –Dynamic Braking Unit
SAFETY INSTRUCTIONS
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SAFETY INSTRUCTIONS
IMPORTANT!
Safety instructions showed in this manual are useful to teach user
how to use the product in a correct and safety way with the
purpose of preventing possible personal injuries or property
damages.
Safety messages included here are classified as it follows:
ALARM
Make sure of taking corresponding protection for ESD Electrostatic
Discharge in case of manipulation of the PCB.
Otherwise, the unit could result damaged due to this effect.
Implement the connections of the braking unit after checking the
equipment is not powered.
Otherwise, there is risk of connection error and the unit may get damaged.
Make sure of connecting correctly the braking unit to the drive.
Otherwise, there is risk of connection error and the unit may get damaged.
Do not remove the cover while the drive is powered or the braking unit is
in operation.
Otherwise, electric shock could occur.
Do not run the braking unit with the front cover removed.
Otherwise, you may get an electric shock due to the high voltage terminals or
exposure of charged capacitors.
Do not remove the cover except for periodic inspections or wiring, even if
the input power is not applied.
Otherwise, you may access the charged circuits and get an electric shock.

B150 –Dynamic Braking Unit
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SAFETY INSTRUCTIONS
Wiring and periodic inspections should be performed at least 10 minutes
after disconnecting the input power of the equipment which is going to be
connected with this braking unit and after checking the DC Link voltage is
discharged with a meter (below 30VDC).
Otherwise, you may get an electric shock.
Operate the switches with dry hands.
Otherwise, you may get an electric shock.
Do not use cables with damaged insulation.
Otherwise, you may get an electric shock.
Do not subject the cables to the abrasions, excessive stress, heavy loads
or pinching.
Otherwise, you may get an electric shock.
CAUTION
Install the braking unit on a non-flammable surface. Do not place
flammable material nearby.
Otherwise, fire could occur.
Disconnect the input power if the drive or the braking unit gets damaged.
Otherwise, it could result in a secondary accident or fire.
After the input power is applied or removed, the drive will remain hot for a
couple of minutes.
Touching hot parts may result in skin burns.
Do not apply power to a damaged drive or braking unit, or to a drive or
braking unit with parts missing even if the installation is complete.
Otherwise, fire or accident could occur.
Do not allow lint, paper, wood chips, dust, metallic chips or other foreign
matter into the braking unit.
Otherwise, fire or accident could occur.

POWER ELECTRONICS
B150 –Dynamic Braking Unit
SAFETY INSTRUCTIONS
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WARNINGS
RECEPTION
Material of Power Electronics is carefully tested and perfectly packed
before leaving the factory.
In the even of transport damage, please ensure that you notify the
transport agency and POWER ELECTRONICS: 902 40 20 70
(International [phone]) or your nearest agent, within 24hrs
from receipt of the goods.
UNPACKING
Make sure received merchandise corresponds with delivery note,
models and serial numbers.
Each equipment is supplied with a technical manual.
RECYCLING
Packing of the equipments should be recycled. For this, it is
necessary to separate different materials included (plastic, paper,
cardboard, wood, ...) and deposit them on proper banks.
Waste products of electric and electronic devices should be
selectively collected for their correct environmental management.
SAFETY
Before operating the equipment, read this manual thoroughly to gain
and understanding of the unit. If any doubt exists then please contact
POWER ELECTRONICS, (902 40 20 70 / [phone]) or your
nearest agent.
Wear safety glasses when operating the braking unit close to the drive
with power applied and the front cover is removed.
Handle the braking unit with care according to its weight.
Do not place heavy objects on the braking unit.
Install the braking unit according to the instructions within this manual.

B150 –Dynamic Braking Unit
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SAFETY INSTRUCTIONS
Ensure that the mounting orientation is correct.
Do not drop the braking unit or subject it to impact.
The B150 braking unit consists of electronic cards sensitive to static
electricity. Use procedures to avoid it.
The B150 unit operates with High DC Voltage (VDC) Circuits. Be
careful with the application and the protection of the B150 and the
braking resistors.
Heat generated by the braking resistors connected to the B150 unit
operating at full power or in fault status, can reach a power value
above 220kW. The design of the system must include thermal Fault
Safety protection to prevent the risk of fire under any condition.
The B150 braking unit operates with VDC. The voltage value can be
735VDC whenever main voltage is present. Make sure that the B150
braking unit and any drive and load connected to it, are completely
discharged before removing the gland plate, the cover or before
trying to access in order to make any maintenance action.
The B150 dynamic braking unit provides with a functional braking. It is
not a safety brake and for this reason, it must not be used as it. When
the application requires it, it must be used a safety mechanical brake
separately.
The installer is must follow the manufacturer recommendations and
the local and national safety and electrical regulations. It is
responsible of the safety and correct installation of the system.
The access plate of the B150 unit and its cover must be correctly
installed to meet the specified protection degree IP20.

POWER ELECTRONICS
B150 –Dynamic Braking Unit
SAFETY INSTRUCTIONS
11
CONNECTIONS PRECAUTIONS WITH SD700 DRIVE
The power connection between the SD700 (HVDC+ and HVDC -) and
the dynamic brake should be done with unipolar twisted pair with a
turn ratio of 200mm. The cable length should be less than 2 m
otherwise the cable inductance could damage the Dynamic brake due
to overvoltage pulses.
The power connection between the B150 and the resistors should be
done with unipolar twisted pair with a turn ratio of 200mm. The cable
length should be less than 10 m otherwise the cable inductance could
damage the Dynamic brake due to overvoltage pulses.
To ensure correct operation of the drive it is recommended to use a
SCREENED CABLE for the control wiring.
For EMERGENCY STOP, make sure supply circuitry is open.
It is not recommended to use a 3-wire cable for long distances. Due to
increased leakage capacitance between conductors, over-current
protective feature may not operate correctly.
Do not use power factor correction capacitors, surge suppressors, or
RFI filters on the output side of the drive. Doing so may damage these
components.
Always check whether the DC Link LED is OFF before wiring
terminals. The capacitors may hold high-voltage even after the input
power is disconnected. Use caution to prevent the possibility of
personal injury.
In case of using fuse protection, select suitable fast action DC fuses.
TRIAL RUN
Follow the steps described in this manual.
Always apply voltage and current signals to each terminal that are
within levels indicated within this manual. Otherwise, damage to the
braking unit may result.
Read the Getting Started Manual of the SD700 drive for additional
information.

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SAFETY INSTRUCTIONS
OPERATION PRECAUTIONS WITH SD700 DRIVE
When the Auto Restart function is enabled, keep clear of driven
equipment, as the motor will restart suddenly after a fault is reset.
The “STOP / RESET” key on the keypad is active only if the
appropriate function setting has been made. For this reason, install a
separate EMERGENCY STOP push button that can be operated at
the equipment.
If a fault reset is made with the reference signal still present then a
restart will occur. Verify that it is permissible for this to happen,
otherwise an accident may occur.
Do not modify or alter anything within the drive.
Before programming or operating the SD700 Series, initialise all
parameters back to factory default values.
EARTH CONNECTION
The drive is a high frequency switching device and leakage current
may flow. Ground the drive to avoid electrical shock. Use caution to
prevent the possibility of personal injury.
Connect only to the dedicated ground terminal of the drive. Do not use
the case or the chassis screw for grounding.
When installing, grounding wire should be connected first and
removed last.
The earth cable must have a minimal cross sectional area that meets
local country electrical regulations.
Motor ground must be connected to the drive ground terminal and not
to the installation‟s ground.
Installation ground must be connected to the drive ground terminal.
Eventually the resistor and dynamic brake may suffer a ground fault.
Connect the dedicated terminal to the ground to prevent any
damaged.

POWER ELECTRONICS
B150 –Dynamic Braking Unit
INTRODUCTION
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1. INTRODUCTION
1.1. Description of the B150 Braking Unit
The use of the dynamic braking provides the drives of SD700 Series
with the capacity of covering the regeneration probably generated
during deceleration with high-inertia loads (like a large fan or
centrifuge, ...) or a regenerative load (like the descent of an elevation
crane, ...). The dynamic braking unit turns this regenerative energy into
heat through the dynamic braking resistors, so keeping the motor
control.
Figure 1.1 Description of the B150 Braking Unit
1. Leds for status indication.
Unit reset.
2. Power and Control
Connections.
2
1

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INTRODUCTION
The B150 is the main power switching element of such a dynamic
braking system.
The B150 braking unit can be controlled in Master mode by built-in
voltage sensing circuit. At the same time, the equipment provides with
an output for multiple B150 slaves in order to provide an extra-braking
capacity.
B150 have a safety relay „no fault‟, that connected to one SD700 digital
input and configured as a fault, allows knowing and controlling the fault
status of the brake.
The B150 series is composed by three models that depends on the
rated voltage of the drive. Units B150.2 (230VAC) and B150 (400VAC-
500VAC) can switch up to 300A at 735VDC into a resistive load with a
maximum peak power of 220kW. Unit B150.6 (690VAC) can switch up
to 200A at 1155VDC into a resistive load with a maximum peak power
of 230kW.
It is necessary to select and purchase dynamic braking resistors
adjustable to each application.

POWER ELECTRONICS
B150 –Dynamic Braking Unit
TECHNICAL CHARATERISTICS
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2. TECHNICAL CHARACTERISTICS
2.1. Electrical Data
DYNAMIC BRAKE B150
B150.2
B150
B150.6
ELECTRICAL
SPECIFICATIONS
Using voltage for brake
(jumpers)
230VAC,
400VAC,
500VAC,
690VAC
Maximum switch current
300A
(R=2.4 @ 735VDC)
200A (R=5.75
@ 1155VDC)
Continuous current rating
150A (R=4.9 at
735VDC)
100A (R=11.5
@ 1155VDC)
Minimum resistor rating
2.4
5.75
PROTECTION
IGBT desaturation trip
Trip when switching into to short-circuited
resistor
IGBT heat sink over
temperature
Trip when IGBT heat sink over 90ºC
Over temperature of the
resistors
Available digital input for external trip
connection (thermal sensor of the external
resistor)
BRAKING
VOLTAGE
CONTROL
Mode selection
Master (internal sensing circuit)
Slave (by external drive)
Potentiometer for fine setting
Vin
(VAC)
VBus
max.
(VDC)
Activating Voltage
for Brake (VDC)
0%
+5%
-5%
230
360
400
420
380
400
625
730
765
695
500
780
780
820
740
690
1080
1100
1155
1045
OUTPUTS
Safety relay ‘No Fault’
Changeover relay NO-NC. Activated at normal
conditions, deactivated at fault conditions or no
power.
AMBIENT
CONDITIONS
Protection degree
IP20
Operating temperature
0ºC to +50ºC
Storage temperature
-25ºC to +80ºC
Relative humidity
80% at 31ºC up to 50% at 50ºC
Altitude
1000m
Altitude derating (>1000m)
-1% per 100m, up to 3000m max.
Note: The cable input plate and the cover of the equipment must be correctly installed to guarantee the
specified protection degree for the equipment.

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INSTALLATION AND CONNECTION
3. INSTALLATION AND CONNECTION
3.1. Installation of B150 Unit
The B150 has compact dimensions that make easy the installation and
connection.
CAUTION
The variable speed drives on where B150 dynamic braking units are
connected operate with high voltage.
Make sure the power supply has been disconnected and let at least 10
minutes elapse in order to guarantee the DC bus has been discharged,
before installing B150 Braking Unit. Otherwise, you may get an electric
shock.
Figure 3.1 Dimensions for B150 Braking Unit

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B150 –Dynamic Braking Unit
INSTALLATION AND CONNECTION
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It is recommended to install the B150 braking unit in a suitable
environment in order to the offered performances go on for more time.
The ambient temperature should not be below 0ºC and above 50ºC.
The relative humidity should be lower than 80% at 31ºC (decreasing
linearly down to 50% when temperature is 50ºC). There must be not
condensation. Do not install the equipment in direct sunlight, for better
operation.
The mounting and installation must be in vertical orientation saving the
minimum distances indicated in figure 3.2 and with the back panel
fixed to the wall to ensure proper cooling.
The installation should be done leaving a free-space of 150mm
vertically and 50mm horizontally from adjacent equipments in order to
avoid the ambient temperature exceeds 50ºC. Make sure the air flow
from the fan is not obstructed.
Do not install multiple straight B150 units above other cooling units to
avoid the accumulation of hot air in the installation area.
Avoid cooling the B150 unit with the heated air coming from the
resistors. Otherwise the B150 could suffer overheating problems.
If the B150 unit is installed in a cabinet, make sure the available
cooling is enough in order to internal air does not get hot and does not
exceed the specified temperature.

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INSTALLATION AND CONNECTION
Figure 3.2 Minimum recommended distances for the installation
3.2. Power and Control Connections for B150 Unit
Some applications require a mechanical brake as safety measure in
case of dynamic braking failure. The output of the „No Fault‟ relay, can
be used to operate the mechanical brake through a correct wiring.