WEG DBW03 Series User manual

Motors | Automation | Energy | Transmission & Distribution | Coatings
Dynamic Braking Module
Módulo de Freno Dinámico
Módulo de Frenagem Reostática
DBW03
User’s Manual
Manual del Usuario
Manual do Usuário

User's Manual
Manual del Usuario
Manual do Usuário
Series/Serie/Série: DBW03
English / Español / Português
Document/Documento: 10001560747 / 01
Models/Modelos: 380 A / 380...480 V
250 A / 500...690 V
Date/Fecha/Data: 09/2012

English
English
4 | DBW03
Summary of Revisions / Sumario de las Revisiones / Sumário das Revisões
Revision Description Chapter
1First edition -
Revisión Descripción Capítulo
1Primera edición -
Revisão Descrição Capítulo
1Primeira edição -

Summary
English
English
1 SAFETY INSTRUCTIONS.................................................................... 6
1.1 SAFETY WARNINGS IN THE MANUAL ....................................................6
1.2 SAFETY WARNINGS IN THE PRODUCT .................................................6
1.3 PRELIMINARY RECOMMENDATIONS ....................................................7
2 GENERAL INFORMATION .................................................................. 9
2.1 ABOUT THE MANUAL ...............................................................................9
2.2 TERMS AND DEFINITIONS USED IN THE MANUAL .............................9
2.3 ABOUT THE DBW03................................................................................ 10
2.4 DBW03 IDENTIFICATION LABEL........................................................... 13
2.5 HOW TO SPECIFY THE DBW03 MODEL (SMART CODE)................... 14
2.6 RECEIVING AND STORAGE................................................................... 15
3 INSTALLATION AND CONNECTION................................................ 16
3.1 ENVIRONMENTAL CONDITIONS........................................................... 16
3.2 MECHANICAL INSTALLATION............................................................... 17
3.3 ELECTRICAL INSTALLATION................................................................. 18
3.3.1 Power Terminals, Grounding Points and Fuses......................... 19
3.3.2 Dimensioning of the Braking Resistor ....................................... 21
3.3.3 Installation of the Braking Resistor............................................ 21
3.3.4 Control Connections ....................................................................22
3.3.5 Master / Slave Connection........................................................... 27
4 FIRST POWER-UP AND START-UP.................................................29
4.1 START-UP PREPARATION......................................................................29
4.1.1 Cautions during Power-Up/Start-up ...........................................29
4.2 START-UP.................................................................................................29
5 FAULTS ...............................................................................................30
5.1 OPERATION OF FAULTS .........................................................................30
5.2 INFORMATION NECESSARY FOR CONTACTING TECHNICAL
SUPPORT .......................................................................................................30
5.3 PREVENTIVE MAINTENANCE................................................................ 31
5.3.1 Cleaning Instructions....................................................................32
6 OPTIONAL KITS AND ACCESSORIES ............................................33
6.1 OPTIONAL KITS.......................................................................................33
6.2 ACCESSORIES.........................................................................................33
7 TECHNICAL SPECIFICATIONS ........................................................ 34
7.1 POWER DATA............................................................................................34
7.2 ELECTRONICS/GENERAL DATA............................................................34
7.2.1 Codes and Standards....................................................................34
7.3 MECHANICAL DATA ................................................................................35
7.3.1 Weight..............................................................................................35
7.3.2 Dimensions.....................................................................................35

6 | DBW03
Safety Instructions
English
English
1 SAFETY INSTRUCTIONS
This manual contains information necessary for the correct use of the dynamic
braking module.
Only trained and qualified personnel should attempt to install, start-up, and
troubleshoot this type of equipment.
1.1 SAFETY WARNINGS IN THE MANUAL
The following safety warnings are used in the manual:
DANGER!
The procedures recommended in this warning have the purpose of
protecting the user against death, serious injuries and considerable
material damage.
ATTENTION!
The procedures recommended in this warning have the purpose of
avoiding material damage.
NOTE!
The text intents to supply important information for the correct
understanding and good operation of the product.
1.2 SAFETY WARNINGS IN THE PRODUCT
The following symbols are attached to the product, serving as safety notices:
High voltages are present.
Components sensitive to electrostatic discharge.
Do not touch them.
Mandatory connection to the protective earth (PE).
Connection of the shield to the ground.
Hot surface.

DBW03 | 7
Safety Instructions
English
English
1.3 PRELIMINARY RECOMMENDATIONS
DANGER!
Only qualified personnel familiar with the DBW03 and associated
equipment should plan or implement the installation, start-up and
subsequent maintenance of this equipment.
These personnel must follow all the safety instructions included in this
manual and/or defined by local regulations.
Failure to comply with these instructions may result in life threatening
and/or equipment damage.
NOTES!
For the purposes of this manual, qualified personnel are those trained
to be able to:
1. Install, ground, power-up and operate the DBW03 according to this
manual and the effective legal safety procedures.
2. Use protective equipment according to the established standards.
3. Provide first aid.
DANGER!
Always disconnect the main power supply before touching any electrical
device associated with the dynamic braking module.
Several components may remain charged with high voltage and/
or in movement (fans), even after the AC power supply has been
disconnected or turned off.
Wait at least 10 minutes to guarantee the fully discharge of capacitors.
Always connect the equipment frame to the ground protection (PE).
ATTENTION!
Electronic boards have components sensitive to electrostatic
discharges. Do not touch directly on components or connectors.
If necessary, touch the grounded metallic frame before or use an
adequate grounded wrist strap.

8 | DBW03
Safety Instructions
English
English
Do not perform any high pot tests with the dynamic braking module.
If it is necessary, consult WEG.
NOTE!
Read this entire manual before installing or operating this braking
module.

DBW03 | 9
General Information
English
English
English
2 GENERAL INFORMATION
2.1 ABOUT THE MANUAL
This manual contains information regarding the proper installation and operation,
start-up, the main characteristics and shows how to troubleshoot the most common
problems of the DBW03 braking module.
The DBW03 is an accessory that enables the braking of motors driven by inverters,
with reduced time, providing faster dynamics when necessary.
2.2 TERMS AND DEFINITIONS USED IN THE MANUAL
DC Link: Inverter intermediate circuit. DC voltage obtained from the rectification of
the AC input voltage or from an external power supply. It supplies the output inverter
bridge, formed by IGBTs.
Inverter: circuit that transforms the direct voltage of the DC link into alternate voltage AC.
IGBT: Insulated Gate Bipolar Transistor - basic component of the output inverters.
They work as electronic switches in the modes: saturated (closed switch) and cut
off (open switch).
Braking IGBT: works as a switch to turn on the braking resistors. It is controlled by
the DC link level.
PE: Protective Earth.
PWM: Pulse Width Modulation; modulation by pulse width; pulsed voltage generated
by the output inverter which feeds the motor.
Switching Frequency: it is the inverter bridge IGBTs commutation frequency,
specified normally in kHz.
Heatsink: it is a metal part designed for dissipating the heat generated by the power
semiconductors.
Amp, A: amperes.
°C: Celsius degree.
°F: Fahrenheit degree.
AC: Alternating Current.
DC: Direct Current.
CFM: “Cubic Feet per Minute”; it is a flow measurement unit.
cm: centimeter.

10 | DBW03
General Information
English
hp: “Horse Power” = 746 Watts (power measurement unit, normally used to indicate
the mechanical power of electric motors).
Hz: hertz.
l/s: liters per second.
kg: kilogram = 1000 gram.
kHz: kilohertz = 1000 hertz.
m: meter.
miliampere = 0.001 ampere.
min: minute.
ms: millisecond.
Nm: Newton meter; torque measurement unit.
rms: “Root mean square”; effective value.
rpm: revolutions per minute; speed measurement unit.
s: second.
V: volts.
Ω: ohms.
2.3 ABOUT THE DBW03
The DBW03 dynamic braking module is used in applications with high-inertia loads,
requiring short braking times. It is also used in lifting applications that require speed
control of the load. In these cases, the power flows from the line to the motor while
it is motorizing, see figure 2.1.
Frequency inverter
M J
+UD
-UD
Figure 2.1: Motorization step

DBW03 | 11
General Information
English
In the next step, it is necessary to reduce the motor speed. The motor becomes a
generator and the power is returned to the DC link.
In order to avoid overvoltage, the energy is dissipated in a resistor by using the dynamic
braking module, as shown in figure 2.2.
Frequency inverter
DBW03
M J
+UD
+UD
BR
-UD
-UD
External
braking
resistor
+UD
Figure 2.2: Braking step
The DBW03 dynamic braking module has the following characteristics:
Supply of the electronics obtained directly from the DC link.
Digital control.
Self-contained operating mode.
Slave operating mode.
Disabling via external control.
Braking resistor temperature monitoring via thermostat.
Ground fault monitoring.
Module status signaling via LEDs.
Relay outputs for fault indication.

12 | DBW03
General Information
English
External
braking
resistor
Heatsink fans
+UD
+UD
-UD
BR
LEDs
Braking
IGBT
Ground
fault
sensor
Capacitor
bank
Fiber optic
emitter
(synchronism
output N3)
Input for DIT
thermostat
Digital
input DI1
Digital outputs
RL1 and RL2
Fiber optic
receiver
(synchronism
input N2)
PSB1
Power supply
board
CDB1
Control card with
CPU 32 bits "RISC"
GDB5 / CRG9
Gate-driver and gate
resistor boards
POWER
CONTROL
220 V
Ext.
Figure 2.3: General scheme of the module

DBW03 | 13
General Information
English
Figure 2.4: Main components of the DBW03 braking module
2.4 DBW03 IDENTIFICATION LABEL
The identification label of the DBW03 is located on the side of the module.
DBW03 Model WEG part number
Manufacturing date
(12 corresponds to
week and I to year)
Serial number
Rated data
Figure 2.5: Example of identification label of the DBW03

14 | DBW03
General Information
English
Figure 2.6: Location of the identification label
2.5 HOW TO SPECIFY THE DBW03 MODEL (SMART CODE)
To specify the model of the DBW03, fill out the respective fields for rated supply
voltage and rated output current in the intelligent code with the desired voltage and
current values, as example in table 2.1.
Tab le 2.1: Smart code
Braking Module Model
Example DBW03 0380 D3848 S Z
Field
description
WEG braking
module series
03
Rated current -Inverter rated voltage Optional kit Character that
identifies the
code end
Available
options
0380 = 380 A (1)
0250 = 250 A (2)
3848=380...480 V (3)
5069=500...690 V (4)
S = standard
product
(1) Available only for voltage of 380...480 V.
(2) Available only for voltage of 500...690 V.
(3) Available only for current of 380 A.
(4) Available only for current of 250 A.
Example: DBW030380D3848SZ corresponds to a braking module DBW03 of 380 A,
for an inverter with input voltage (power supply) from 380 V to 480 V.

DBW03 | 15
General Information
English
2.6 RECEIVING AND STORAGE
The DBW03 is packaged and shipped in a cardboard box.
There is an identification label affixed to the outside of the package, identical to the
one affixed to the DBW03.
Verify whether:
The DBW03 nameplate corresponds to the purchased model;
Any damage occurred during transportation.
Report any damage immediately to the carrier that delivered your DBW03.
If the DBW03 is not installed soon, store it in a clean and dry location (temperature
between -25 °C and 60 °C (-13 °F and 140 °F)), with a cover to prevent dust
accumulation inside it.

16 | DBW03
Installation and Connection
English
3 INSTALLATION AND CONNECTION
This chapter describes the DBW03 electrical and mechanical installation procedures.
The guidelines and suggestions must be followed aiming personnel and equipment
safety, as well as the proper operation of the dynamic braking module.
3.1 ENVIRONMENTAL CONDITIONS
Avoid installing the inverter in an area with:
Direct exposure to sunlight, rain, high humidity, or sea-air.
Inflammable or corrosive gases or liquids.
Excessive vibration.
Dust, metallic particles, and oil mist.
Environment conditions for the operation of the inverter:
Temperature: -10 ºC to 45 ºC (14 °F to 113 °F) – nominal conditions (measured
surrounding the dynamic braking module).
From 45 ºC to 55 ºC (113 °F to 131 °F) - current derating of 2 % each °C (or 1.11 %
each °F) above 45 ºC (113 °F).
Air relative humidity: 5 % to 90 % non-condensing.
Altitude: up to 1000 m (3.300 ft) - nominal conditions.
From 1000 m to 4000 m (3.300 ft to 13.200 ft) - 1 % of current derating for each
100 m (or 0.3 % each 100 ft) above 1000 m (3.300 ft) altitude.
From 2000 m to 4000 m (6.600 ft to 13.200 ft) above sea level - maximum voltage
reduction (480 V for 380...480 V models) of 1.1 % for each 100 m (330 ft) above
2000 m (6.600 ft).
Pollution degree: 2 (according to EN50178 and UL508C), with non-conductive
pollution. Condensation must not originate conduction through the accumulated
residues.

DBW03 | 17
Installation and Connection
English
3.2 MECHANICAL INSTALLATION
Mount the module in the upright position on a flat surface.
Observe the clearances shown in figure 3.1 to allow the circulation of cooling air.
External dimensions and position of fixation points are presented in Section
7.3 - Mechanical Data.
First put the screws on the surface where the module will be installed, install the
module and then tighten the screws. Four M6 screws are used (recommended torque:
8.5 N.m) for fixing the module.
Do not install heat sensitive components just above the module.


100 mm (3.93 in)
130 mm (5.11 in)
40 mm (1.57 in) 40 mm (1.57 in)
50 mm (1.96 in)
Figu re 3.1: Ventilation clearances

18 | DBW03
Installation and Connection
English
The DBW03 has a mechanical accessory for the mounting of connecting cables "+UD"
and "-UD," illustrated in figure 3.2. For further details, contact WEG.
Accessory
to assemble
cables
∅11.2 mm (0.44 in)
Figure 3.2: Accessory for the mounting cables of connections "+UD" and "-UD"
3.3 ELECTRICAL INSTALLATION
DANGER!
The following information is merely a guide for proper installation.
Comply with applicable local regulations for electrical installations.
DANGER!
Make sure the AC power supply is disconnected before starting the
installation.

DBW03 | 19
Installation and Connection
English
3.3.1 Power Terminals, Grounding Points and Fuses
The connections of +UD and –UD (see figure 3.3) are performed by means of two
bolts M10 x 25 mm (0.98 in) (recommended torque: 30 N.m).
-UD +UD
Figure 3.3: Input connections +UD and –UD
In figure 3.4 are presented the connections of the grounding and braking resistor. The
braking resistor is connected by means of bolts M10 x 25 mm (0.98 in) (recommended
torque: 30 N.m). For the grounding, bolts M8 x 20 mm (0.78 in) are used (recommended
torque: 10 N.m).

20 | DBW03
Installation and Connection
English
Braking
resistor
BR
+UD
Figure 3.4: Connections of the grounding and braking resistor
Use cables with the gauge indicated in table 3.1 to connect the DBW03 braking module.
Tab le 3.1: Connecting cables of the DBW03
Line
(V)
Current
(A)
Minimum Section
of the Resistor
Cables
[mm2(AWG)]
Minimum Section
of the Cables for
+UD and –UD
[mm2(AWG)]
Minimum Section
of the Grounding
Cable
[mm2(AWG)]
380-480 380 240 (2 x 4/0) 240 (2 x 4/0) 120 (4/0)
500-690 250 120 (4/0) 120 (4/0) 70 (2/0)
It is recommended to use fuses when the braking module is connected to a DC
link with more than one inverter. Two fuses must be installed, one for the +UD and
another for the –UD. The current of each fuse must be 630 Arms with i2t maximum
of 1,440,000 A2s.
They must have an interruption capacity for direct voltage of 800 Vdc for the line
380...480 V, 1000 Vdc for the line 500...600 V and 1200 Vdc for the line 660...690 Vdc.

DBW03 | 21
Installation and Connection
English
3.3.2 Dimensioning of the Braking Resistor
For the proper dimensioning of the braking resistor, consider the application data,
such as:
Desired deceleration time.
Load inertia.
Braking cycle.
In any case, the effective current and maximum braking current values presented in
table 7.1 must be observed.
The maximum braking current defines the minimum ohm value allowed for the braking
resistor. The DC link voltage level for actuation of the rheostatic braking is defined by
the setting of the DIP Switch S2 (rheostatic braking actuation voltage); see table 3.4.
The braking resistor power is defined according to the deceleration time, load inertia
and resistive torque.
For most applications, it may be used a resistor with the ohm value indicated in table
7.1 and power of 20 % of the rated power value of the driven motor.
Use resistors of STRIP or WIRE type in ceramic support, with proper insulation voltage
and that stand high instant powers in relation to the rated power.
For critical applications with very short braking times, high inertia loads (ex: centrifuges)
or with very short and frequent duty cycles, contact WEG, to define the most suitable
resistor.
Note:
The effective braking current presented is just an orientative value, because it depends
on the braking cyclic ratio in the application. In order to obtain the effective braking
current, use the formula below, where tbr is given in minutes and corresponds to the
sum of the braking actuation periods during the severest cycle of five minutes.
Ieffective = Imax x tbr
5
√
3.3.3 Installation of the Braking Resistor
Connect the braking resistor between the power terminals +UD and BR, see figure 3.5.
Separate these power cables from the signal and control wiring. Dimension the cables
according to the application, observing the maximum and effective currents.
If the braking resistor is mounted within the inverter cabinet, take its energy into
account when dimensioning the ventilation of the cabinet.
In order to avoid the destruction of the resistor or risk of fire, include a thermal relay in
series with the resistor and/or a thermostat in contact with its housing, connected in
such a way to disconnect the input power supply of the inverter, as shown in figure 3.5.