Rockwell Automation RELIANCE ELECTRIC INVERTRON DBU-50 User manual

INVERTRON DBU
Dynamic Braking Unit
Instruction Manual
Manual P/N. 899.05.26 User Manual: 49‘1328e (06)
Publication INVDBU-UM006F-EN-P
UL
CR

.

TABLE OF CONTENTS
49'1328 e DBU I
1. DESCRIPTION 1-1...1-2
Operation.......................................................................................................................1-1
Line voltage selection .................................................................................................... 1-2
Parameter setting on the inverter................................................................................... 1-2
Permissible loading of the electronics ............................................................................ 1-2
2. SPECIFICATIONS 2-1...2-4
Electrical specification of the Braking Unit ..................................................................... 2-1
Ambient conditions......................................................................................................... 2-1
Mechanical specification, dimensions ............................................................................ 2-2
Optional Diagnostic Card BUD....................................................................................... 2-3
3. MOUNTING AND CONNECTION 3-1...3-3
Mounting of the braking Unit .......................................................................................... 3-1
Short circuit protection fuses.......................................................................................... 3-1
Protection of braking resistors and conductors .............................................................. 3-1
Connection..................................................................................................................... 3-1
4. DESIGN INFORMATION 4-1...4-2
Calculation of braking power.......................................................................................... 4-1
Calculation of braking resistors ...................................................................................... 4-1
Example.........................................................................................................................4-2
Appendix A CE-Conformity A-1...A-4
EMC Directive ................................................................................................................A-1
Mounting instruction.......................................................................................................A-1
Wiring instruction ...........................................................................................................A-2
Cabinet mounted units ...................................................................................................A-2
Installation of standalone drives.....................................................................................A-4
Further documentation:
Instruction manual for GV3000/SE AC General Purpose and Vector Drive
Publication GV3000-UMxxxx-EN

GENERAL NOTES
II DBU 49'1328 e
Safety Instructions
DANGER, WARNING, and CAUTION point out potential trouble areas.
A DANGER alerts a person that high voltage is present which could result in severe bodily injury or
loss of life.
A WARNING alerts a person to potential bodily injury if procedures are not followed.
A CAUTION alerts a person that, if procedures are not followed, damage to, or destruction of
equipment could result.
DANGER:Before installing and/or operating this device, this manual must be understood by the
qualified electrical maintenance person who is familiar with this type of equipment and
the hazards involved. Failure to observe this precaution could result in bodily injury.
Machinery Directive
CAUTION:This device is a component intended for implementation in machines or systems for the
capital goods industry.
The start-up of this device in the European market is not permitted until it has been
confirmed that the machine into which the device is built is in conformance with the
regulations of the Council Directive Machinery 98/37/EWG.
Electromagnetic Compatibility (EMC-Directive)
CAUTION :The operating of this device in the European market is only permitted if the Council
Directive Electromagnetic Compatibility 89/336/EWG has been observed.
It is the responsibility of the manufacturer of the machine or system to observe the
immunity and emission limits, requested by the Council Directive EMC in the European
market. Guidelines for the installation according EMC-regulations - for shielding,
grounding, component arrangement as well as wiring instructions - are summarized in
Appendix A ‘CE-Conformance’ of this instruction manual.

DESCRIPTION
49'1328 e DBU 1 - 1
Operation
Frequency converters (Inverters) with DC bus and input diode rectifier bridge are suitable for the
operation of three phase AC-motors in two drive quadrants, motoring in both directions of rotation.
Braking with more than 10% of the rated inverter current is only possible with a braking unit.
Without a braking unit, an excessively rapid deceleration causes an increase in the DC bus voltage.
The regulator responds by
•shut-down due to DC bus overvoltage tripping (e.g. on GV3000: Fault HU)
•extending the set deceleration rate or increasing the output frequency depending on parameter
setting.
By the use of a Dynamic Braking Unit (DBU) and braking resistor the energy in the DC bus circuit can
be converted to heat.
The braking unit DBU is available in four sizes and two variants (Part No. in brackets):
DBU Size without Diagnostic card BUD with BUD built-in
37 kW DBU-50 (837.02.01) DBU-50-DIS (837.02.02)
75 kW DBU-100 (837.02.11) DBU-100-DIS (837.02.12)
150 kW DBU-200 (837.02.21) DBU-200-DIS (837.02.22)
300 kW - DBU-400 (837.02.41) *
* The Diagnostic card BUD is always built in on DBU-400 as a standard
NOTE: Until sept.1997 the units DBU-50 (837.02.00), DBU-100 (837.02.10) and DBU-200 (837.02.20)
with hysteresis type regulator BUA (813.25.00) have been delivered.
The new PWM type regulator BUC (813.01.00) is fully compatible to the BUA regulator.
45
47
48
47
PE
47
45
DBU
+
T
1)
Udc > 50V I > 0
3) Set DBU-DIS 839.25.41
24 V 0 - 20 mA
20 mA
24 V
29
101
T
0
115
M2)
BUC
813.01.00
BUS 813.03.00
2)
-+
X1 1 2 3 4 5 6
PE
Diagnostic Card BUD
1) If the resistor overheats, this contact operates a disconnect that removes AC power from the drive.
2) Fan on DBU-400 only 3) Diagnostic card BUD is built in on DBU-xx-DIS and DBU-400
Figure 1-1: Principle of operation of Inverter with braking unit

DESCRIPTION
1 - 2 DBU 49'1328 e
Line Voltage Selection
After removing the cover plate of the DBU the blue jumper plug with positions 460V / 415V is accessible
at the upper edge of the regulator card (middle on BUC, right on BUA).
This jumper plug defines the DC bus voltage at which the DBU switches the DB resistor to the DC bus.
When delivered from stock the DBU is adjusted for safety reasons to 460 V line voltage.
NOTE: If the blue jumper plug is missing, the DBU is set to 415V.
For the Inverters INVERTRON VTI / VCI / VGI type 415 V the blue jumper plug must be changed
from position 460 to 415.
Reason: On these inverters the max. permissible DC bus voltage is DC 720 V.
This fault trip level is fixed and assigned to the power semiconductors. It requests a DBU
turn-on voltage of 680 V, corresponding to 415 Vac line voltage selection.
For the GV3000 Inverters on line voltages up to 415 V the blue jumper plug must be set to position 415.
For the GV3000 Inverters on line voltages above 415 V and all the other inverters VTI / VCI / VGI type
460 V, GMI, GP2000 and SP500 the jumper must stay in position 460.
Parameter Setting on the Inverter
WARNING!
If an inverter drive is equipped with braking unit, the deceleration ramp extension or regenerative
torque limitation must be switched off depending on DC bus voltage. Please refer to the inverter
instruction manual.
Permissible Loading of the Braking Unit
To prevent thermal overload of the Braking Unit, assure that the unit works within the following limits:
In a time range of 10 minutes the permissible loading must be limited to the following current-time area
of any shape Imax x 2.5 minutes, with the following exception:
On DBU-400 current loading Imax (400 A) is permitted for 110 seconds every 10 minutes.
Examples:
1) Linear deceleration to zero speed of a drive with
high inertia connected (e.g. centrifuge)
2) Drive with active load (e.g. crane)
5 min.
10 min.
Pmax
5 min.
10 min.
Pmax
Pmax
2
Figure 1-2a Figure 1-2b

SPECIFICATIONS
49'1328 e DBU 2 - 1
Electrical Specification
Table 2-1: Power Ratings
DBU-50 DBU-100 DBU-200 DBU-400
Maximum braking current Imax 50 A 100 A 200 A 400 A*
Minimum braking resistor permitted
for max. braking power:
with 415V jumper 12.8 ohms 6.4 ohms 3.2 ohms 1.6 ohms
with 460V jumper 14.4 ohms 7.2 ohms 3.6 ohms 1.8 ohms
Continuous braking power at 460 V 9 kW 18 kW 36 kW 72 kW
Short-time braking power
with 415V jumper
with 460V jumper
34 kW
37.5 kW
68 kW
75 kW
135 kW
150 kW
270 kW*
300 kW*
Power loss (average) 250 W
*On DBU-400 current loading Imax (400 A) is permitted for 110 seconds every 10 minutes.
- Maximum DC bus voltage at terminals 45-47:........................................................................ DC 800 V
- Turn-on and Turn-off voltage of the DBU: ON OFF
a) with BUA: 415V jumper DC 680 V DC 650 V
460V jumper (default) DC 750 V DC 720 V
b) with BUC: Pulse width modulation PWM with 1 kHz switching frequency
Pulse width
720 750
100%
95%
0%
650 680
BUC
BUA
BUC
BUA
VDC
jumper 415V jumper 460V
Figure 1-3: DC bus voltage depending on pulse width (on BUC) respectively duty ratio (on BUA)
- Power consumption of the control circuits.................................................................................. 27 mA
Fan connection voltage and current consumption
only on DBU-400, terminals 0, 115. ................................................................... 115 V, 50/60 Hz, 0.2 A
Ambient Conditions
- Operation temperature .................................................................................................... 0 - 40 degr C
For temperatures higher than 40 degr C up to max 55 degr C,
the nominal continuous current Inom must be derated by ......................................1.5% per degr C
- Storage ........................................................................................................... -25 degr C....+55 degr C
- Transportation..................................................... -25 degr C....+70 degr C (+70 during max. 24 hours)
- Degree of protection....................................... .............................................................................. IP20

SPECIFICATIONS
2 - 2 DBU 49'1328 e
Mechanical Specification, Dimensions
121.5
ø6.5
220
7206
206
103
103
206
7
Weight: 3.1 kg
Figure 2-1: Dimensions and fixing holes for the Braking Units DBU-50 and DBU-100
80
8
350
157
PE 48 45 47 47
215
225
5
5
32
42 36 36 36 25 50
6.5
589
356
PE 47 47 45 48
1)
2)
3)
4)
310
0/115/
29/101
29 101
Type Weight: Power connections Control connections PE Fan
DBU-200 9 kg Terminal block below 1) Terminal block below 1) below without
DBU-400 10 kg Bus bars above 2) Terminals at fan carrier 3) above with 4)
Figure 2-2: Dimensions and fixing holes for the Braking Units DBU-200 and DBU-400

SPECIFICATIONS
49'1328 e DBU 2 - 3
Optional diagnostic card BUD
The diagnostic card BUD, (part No. 813.02.00) is incorporated on units DBU-xx-DIS and all DBU-400.
On units DBU-xx (with PWM-regulator BUC) the diagnostic card option set DBU-DIS (Part No. 839.25.41)
can be built in on site or used as a replacement part.
On DBU-400 units the BUD card is always built-in as a standard.
The BUD works independent from the DBU regulator based on separate DC bus voltage feedback
values and the voltage across the DB resistor. It replaced the DBU indication card BUB (set 839.25.00)
and contains besides the DC bus voltage and braking current indications two additional diagnostic
functions (available at terminals).
Udc > 50V I > 0
Set DBU-DIS
with Diagnostic Card BUD
24 V 0 - 20 mA
20 mA
24 V
-+
X1 1 2 3 4 5 6
DBU
Figure 2-3: Block diagram of the diagnostic card BUD (Set DBU-DIS)
Indications
•DC bus voltage: left LED lights when UDC > 50 V
•braking current : right LED lights when IB> 0
Switched output S1-2 (UDC > 50V)
Wearless transistor switch between terminals 1 (-) and 2 (+)
•S
1-2 is closed, when UDC > 50 V and IB= 0
•S
1-2 is open, when UDC > 50V and IB> 0, or when UDC < 50 V.
As shown in figure 2-4, switch S1-2 is closed after charging of the DC bus, at motor stand still or in
motoring operation mode.
motoring regenerative
operation operation
UDC
0
S1-2
Figure 2-4: Status of switch S1-2 depending on DC bus voltage
This switched output is a monitoring device for the DC bus and the function of the DBU, working
independent from the frequency converter and the DBU-regulator.
Loading of the transistor switch:........................................................................................ 24 V / 20 mA

SPECIFICATIONS
2 - 4 DBU 49'1328 e
Analog output A5-6
Signal A5-6 at terminals 5 and 6 is depending on the power P dissipated in the DB resistor.
The analog signal is generated through a filter circuit from the modulated voltage across the DB-
resistor. The indication range 0% to 100% pulse width (on BUC) respectively duty ratio (on BUA)
corresponds with 0 - 20 mA.
The scaling of the analog signal is depending on:
•jumpers 460V / 415V in relation with UDC and pulse width according to Figure 1-3,
•DB resistor selection, taking into account the minimum values according to Table 2-1,
•pulse width (on BUC) respectively duty ratio (on BUA) ED in %.
Calculation: P = ED x UDC
2/ R x 100 with 415V jumper: UDC = 650 V + (1.6 x analog signal [mA] )
with 460V jumper: UDC = 720 V + (1.6 x analog signal [mA] )
Example: jumper 460V, DB resistor 10 ohms
4 mA = 20% ED at 726V: 52.7 x 0.2 = 10.6 kW
19 mA = 95% ED at 750V: 55.4 x 0.95 = 53.4 kW (95%, 750 V are maximum values)
The analog output at terminals 5 and 6 must be supplied through an external DC current source at
terminals 4 (0 Volts) and 3 (24 V).