Magnetek Cdbr-d User Manual

CDBR-D

Dynamic Braking Unit

Instruction Manual

Part Number: 146-10068

© Copyright 2012 Magnetek

May 2012

Table of Contents

CDBR-D Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Mounting/Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Wiring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Operational Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

CDBR-D Parallel Connection Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

CDBR-D Braking Unit Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Braking Unit Enable Input Setting (S1, S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

CDBR Braking Start Voltage Switch (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Retrofit Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Circuits and Wiring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Braking Unit Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Braking Module Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

CDBR-D Installation Instructions - May 2012
2

©2012 Magnetek

All rights reserved. This notice applies to all copyrighted materials included with this product,
including, but not limited to, this manual and software embodied within the product. This manual is
intended for the sole use of the persons to whom it was provided, and any unauthorized distribution
of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in
whole or in part by any means whatsoever without the expressed written permission of Magnetek.

PRODUCT SAFETY INFORMATION

Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products
and adjustable frequency drives, and industrial braking systems for material handling applications.
This manual has been prepared by Magnetek to provide information and recommendations for the
installation, use, operation and service of Magnetek’s material handling products and systems
(Magnetek Products). Anyone who uses, operates, maintains, services, installs or owns Magnetek
Products should know, understand and follow the instructions and safety recommendations in this
manual for Magnetek Products.

The recommendations in this manual do not take precedence over any of the following requirements
relating to cranes, hoists lifting devices or other material handling equipment which use or include
Magnetek Products:

• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
Magnetek Products are used,

• Plant safety rules and procedures of the employers and the owners of the facilities where the
Magnetek Products are being used,

• Regulations issued by the Occupational Health and Safety Administration (OSHA),

• Applicable local, state or federal codes, ordinances, standards and requirements, or

• Safety standards and practices for the industries in which Magnetek Products are used.

This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners,
users, and operators of the Magnetek Products to know, understand, and follow all of these
requirements. It is the responsibility of the employer to make its employees aware of all of the above
listed requirements and to make certain that all operators are properly trained. No one should use

Magnetek Products prior to becoming familiar with and being trained in these requirements
and the instructions and safety recommendations for this manual.

PRODUCT WARRANTY INFORMATION

Magnetek, hereafter referred to as Company, assumes no responsibility for improper installation of
an option by untrained personnel. An option should only be installed and configured by a trained
technician who has read and understands the contents of this manual. Improper installation can
lead to unexpected, undesireable, or unsafe operation or performance of the controls. This may
result in damage to equipment or personal injury. Company shall not be liable for economic loss,
property damage, or other consequential damages or physical injury sustained by the purchaser or
by any third party as a result of such installations. Company neither assumes nor authorizes any
other person to assume for Company any other liability in connection with the sale or use of this
product.

For information on Magnetek’s product warranties by product type, please visit
www.magnetekmh.com.

CDBR-D Installation Instructions - May 2012

3

A warning label is displayed on the front cover of the braking unit. Follow these instructions when

WARNING

• Do not touch any circuitry components while the main AC power is on. In addition,
you must wait until the red “CHARGE” LED is out before performing any service on
that unit. It may take as long as 10 minutes for the charge on the main DC bus
capacitors to drop to a safe level.

• Do not check signals during operation.

• Make sure the unit is set for the appropriate voltage.

• Make sure to ground the ground terminal.

• Failure to observe these warnings can result in electrical shock.

handling the braking unit.

CDBR-D Installation Instructions - May 2012
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CDBR-D Installation Instructions

Preface

A Dynamic Braking Unit and Resistor are used to dissipate regenerative energy from the motor.
Whenever an excited motor is operated in the negative slip region or is subjected to an overhauling
load, the motor will behave as an induction generator. In this mode, energy will actually flow from the
motor back into the drive.

This will cause the DC bus voltage to rise. When the DC bus voltage reaches a certain level, the
Dynamic Braking Unit will activate. The Dynamic Braking Unit will shunt the regenerative energy
away from the DC bus capacitors and will dissipate it as heat in the DB resistors. Since the
regenerative energy is dissipated in the resistors, the overvoltage (OV) trip is prevented; thus the
motor remains excited and continues to produce braking torque.

The following Magnetek products can be used with these units:

• IMPULSE®•G

• IMPULSE®•G+

• IMPULSE®•VG+

• IMPULSE®•G+ Series 2

• IMPULSE®•VG+ Series 2

• IMPULSE®•G+ Series 3

• IMPULSE®•VG+ Series 3

• IMPULSE®•G+ Series 4

• IMPULSE®•VG+ Series 4

• MagnePulse™ Digtial Magnet Control (DMC)

Receiving

All equipment is tested against defect at the factory. After unpacking, verify that there is no damage
evident. Report any damage or shortage to the commercial carrier who transported the equipment.
Contact your Magnetek sales representative for assistance.

Storage

If the Dynamic Braking unit is not installed immediately, it must be stored under the following
conditions:

• Ambient temperature: -10 to +60°C (+14 to +140°F)

• Protected from rain and moisture

• Free from corrosive gases or liquids

• Free from dust or metal particles

• Clean and dry

• Free from excessive vibration

CDBR-D Installation Instructions - May 2012

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Model Number

CDBR-D Installation Instructions - May 2012
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Installation

Mounting/Wiring

1. Disconnect all electrical power to the drive.

2. Remove drive front cover.

3. Verify that voltage has been disconnected by using a voltmeter to check for voltage at the
incoming power terminals.

4. The braking unit and braking resistor emit heat during operation. Select a mounting location
away from other heat emitting devices or devices that are heat sensitive. To guarantee proper
air-flow for cooling, the braking unit should not be mounted any closer to external devices than

1.18 in. (30 mm) on either side and 4.72 in. (120 mm) of the top and bottom. Select mounting
locations so that the wiring distances between the drive and the braking unit is less than 16.4
feet (5 m), and the distance between the braking unit and the braking resistor is less than 32.8
feet (10 m).

5. Make connections between the drive, braking unit(s), and braking resistor(s) according to Figure
9 (single units) or Figure 10 (multiple units).

Grounding

6. The enclosure of the braking resistor should be grounded. If the braking unit cannot be mounted
in a grounded enclosure, ground it by using a lead from the mounting screw of the unit.

7. Grounding resistance of the braking unit should be 100 ohms or less.

8. Use a grounding lead conforming to your National Electric code.

Adjustments

9. Configuration

a) It may be necessary to change the appropriate input voltage selection. This determines

the voltage that the dynamic braking unit will turn on. See Figure 14 and turn S3 to the
nominal three phase supply voltage. Tables 1 and 4 indicate the DC voltage level that the
braking unit will turn on for different settings. Failure to set the switch at the nominal
voltage can cause premature failure of the braking unit.

b) If two or more braking modules are applied, ensure that unit #1 is set as the MASTER

while the other unit(s) are set for SLAVE (see Figure 10). If only one braking unit is
applied, verify that the switch is set to MASTER.

10. The installation of the braking unit may require programming of the drive.

a) For an IMPULSE®•G: Program Sn-05 to xx1

deceleration.

b) For an IMPULSE®•G+: Program Sn-07 to xx1

deceleration.

c) For an IMPULSE®•G+ and VG+ Series 2: Program L3-04 to 0

prevention during deceleration.

d) For an IMPULSE®•G+ and VG+Series 4: Program L08-55 to 0

fault.

x, which disables stall prevention during

x, which disables stall prevention during

, which disables stall

, which disables the RF

CDBR-D Installation Instructions - May 2012

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Installation

Be sure the CDBR-D is mounted in a location that conforms to the following conditions:

• Provide at least 4.72 in. (120 mm) above and below the CDBR-D.

• Provide at least 1.18 in (30 mm) on either side of the CDBR-D.

• Provide sufficient space between other components that generate heat or do not tolerate
heat.

• Free from drops of water and corrosive gases.

• Free of dirt and dust.

• Free of physical shock and vibration.

Figure 1: Correct Installation Orientation (Braking Unit)

Figure 2: Space Between CDBR braking units (Side-by-Side Mounting)

CDBR-D Installation Instructions - May 2012
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Wiring Procedure

WARNING

Fire Hazard. Tighten terminal screws to the specified tightening torque. Loose electrical

connections could result in death or serious injury by fire due to overheating. Tightening
screws beyond the specified tightening torque may cause erroneous operation, damage
the terminal block, or cause a fire. Failure to observe these warnings can result in
electrical shock.

1. Loosen the front cover screw.

Figure 3: Loosen the Screw Securing the Front Cover

2. Push in on the hooks located on the sides of the front cover and gently pull forward.

Figure 4: Push the Tabs Inward and Pull Forward on the Front Cover

CDBR-D Installation Instructions - May 2012

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3. Connect ground wiring to the ground terminals.

4. Connect main circuit wires to the main circuit terminals B1, B2, (+) and (-).

5. Connect control circuit wiring to the control circuit terminals.

6. Ensure all main circuit and control circuit wires exit through the openings in the bottom of the
CDBR Braking Unit enclosure.

Figure 5: Wiring the Terminals

7. Reattach the front cover. After wiring to the CDBR Braking Unit and drive is complete, double­check all connections before reattaching the cover.

8. Insert the tab on the upper portion of the front cover to the corresponding opening, then connect
the cover into place from the front of the unit.

Figure 6: Reattach the Front Cover

CDBR-D Installation Instructions - May 2012
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9. Reinstall and secure the front cover on the drive.

Figure 7: Tighten the Front Cover Screw

CDBR-D Installation Instructions - May 2012

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Operational Verification

During dynamic braking operations, make sure that the required deceleration characteristic is
obtained. The MASTER/SLAVE LED flashes to indicate operation of the unit.

Table 1: Minimum Resistance Values for Braking Resistors

Supply

Vol tag e

200 VAC 331 VDC 5.5 – –

208 VAC 343 VDC 5.7 – –

220 VAC 368 VDC 6.1 – –

230 VAC 380 VDC 6.3 – –

380 VAC 630 VDC – 10.5 –

400 VAC 659 VDC – 11.0 –

415 VAC 688 VDC – 11.5 –

440 VAC 731 VDC – 12.2 –

460 VAC 760 VDC – 12.7 –

500 VAC 825 VDC – – 20.7

575 VAC 950 VDC – – 23.8

Turn O n

Vol tag e

CDBR-2022D CDBR-4045D CDBR-5037D

Minimum Resistance ()

LED Color Lit Off Flashing

MASTER Green

SLAVE Green

DISABLE Red Fault has occurred Normal operation --

CHARGE Red

NOTE: During CDBR activation, flashing of the LED is based on the bus voltage level. When the

bus voltage goes above the activation level, the LED turns off and the bus is then
discharged. When the bus voltage falls below the activation level, the LED will turn back
on.

CDBR-D Installation Instructions - May 2012
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Figure 8: CDBR Braking Unit LED Display

CDBR is functioning

as Master

CDBR is functioning

as Slave

CDBR is powered

on

CDBR is functioning

as Slave

CDBR is functioning

as Master

-- --

CDBR is activating

CDBR is activating

<1> If drive does NOT have a +3 terminal, use B1.

Figure 9: Single Unit Wiring Diagram

Protection Features

Short Circuit Relay

The Short Circuit Relay (EC/EA/EB) <2> protects the drive from failure when a braking resistor short
circuits. The latching circuit shown in Figure 9 above <3> is designed to power down the drive and
CDBR in the event of a short. Assuming no CDBR short circuit, pushing the momentary ON switch
will latch in the main line contactor and enable the drive. When a short occurs, EB will open and the
main line contactor coil will de-energize causing the drive to shut down.

Fault Relay

The Fault Relay (MC/MA/MB) <4> will change state in the event of any CDBR fault including a short
circuit. If connected to a drive input, program H1-xx to include this feature.

Enable Input

The Enable contact SB <5> can be connected to a drive output to have the CDBR shut off in the
event of a specific fault, or connected through a Klixon to have the unit shut off as a result of high
temperatures in the braking resistors.

CDBR-D Installation Instructions - May 2012

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<1> Connect directly to the drive or install a terminal block.

<2> Connect the CDBR transistor short-circuit detection output to disconnect power to the drive when any master or slave CDBR EA-EB-EC
fault is output.

Figure 10: CDBR-D Parallel Connection of Braking Unit

CDBR-D Installation Instructions - May 2012
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CDBR-D Parallel Connection Notes

• Braking units have a MASTER/SLAVE selection switch. Select “MASTER” for Braking Unit
1 and “SLAVE” for all subsequent braking units (see Figure 11 for location).

• Connect thermal protectors on the parallel CDBR-Ds in parallel to the drive’s multi-function
input.

• Use twisted pair wire, 20 or 22 AWG with ferrules, for connections between terminals OUT1,
IN1 and OUT2, IN2 of the CDBR-Ds.

Figure 11: CDBR 2022D, 4045D, and 5037D (Terminal Cover and Indicating Cover

Removed)

CDBR-D Installation Instructions - May 2012

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CDBR-D Braking Unit Dimensions

Figure 12: CDBR-D Drawing

Table 2: CDBR-D Dimensions

Model

Number

CDBR-2022D

CDBR-5037D

W H D W1H1H2D1 t d

4.72

(120)

5.91

(150)

Dimensions in inches (mm)

6.18

(157)

4.13

(105)

5.35

(136)

0.28
(7)

1.89

(48.6)

0.24
(6)

M4 4.4 (2)CDBR-4045D

Braking Unit Enable Input Setting (S1, S4)

The braking unit will turn on only if SB-SC Enable Input is applied. Use the Sinking/Sourcing Switch
(S1) to select sinking or sourcing mode for terminals SB-SC. When selecting the sourcing mode, an
external 24 VDC power supply is required.

Use switch S4, A or B setting for selecting N.O./N.C input type for SB-SC Enable Input terminals.

The default settings are sinking mode S1 = SINK, and normally open S4 = A.

Wt. in lbs.

(kg)

Figure 13: Setting Sink/Source Switch (S1) and N.O./N.C. Switch (S4)

CDBR-D Installation Instructions - May 2012
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Table 3: CDBR Enable/Disable Status

S1- SINK/SOURCE

SINK A Open Enabled

SINK A Close Disabled

SINK B Open Disabled

SINK B Close Enabled

SOURCE A 0 V Input Enabled

SOURCE A 24 V Input Disabled

SOURCE B 0 V Input Disabled

SOURCE B 24 V Input Enabled

S4-SB/SC

Terminals N.O./N.C.

SB-SC-Enable CDBR Status

CDBR-D Installation Instructions - May 2012

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CDBR Braking Start Voltage Switch (S3)

Set the braking start level voltage level switch S3 to match the power supply of the main circuit. The
default S3 setting is 9. Refer to Table 4 for details on S3 switch position and braking start voltage.

NOTE: 1. The setting does not typically require adjustment.

2. Consider the amount of voltage fluctuation in the DC bus when changing S3 setting
values. If the starting voltage is incorrectly set to a low value, applying power to the drive
may active the CDBR and overheat the braking resistor.

3. Be sure to firmly click the switch into the proper position in accordance with the
incoming power supply. A switch that is stuck in between positions may cause the CDBR
to operate incorrectly.

Figure 14: CDBR Voltage Activation Level, Switch (S3)

Table 4: Switch S3 Settings and Voltage Activation Levels

230 V Class 460 V Class 575 V Class

No.

Input

Voltage

(VAC)

0 160 270 (TYP) 380 630 (TYP) 500 825 (TYP)

1 170 282 (TYP) 390 644 (TYP) 505 839 (TYP)

2 175 294 (TYP) 400 659 (TYP) 515 835 (TYP)

3 185 307 (TYP) 405 673 (TYP) 525 867 (TYP)

4 190 319 (TYP) 415 688 (TYP) 530 881 (TYP)

5 200 331 (TYP) 425 702 (TYP) 540 894 (TYP)

6 208 343 (TYP) 430 717 (TYP) 550 894 (TYP)

7 215 356 (TYP) 440 731 (TYP) 555 922 (TYP)

8 220 368 (TYP) 450 746 (TYP) 565 936 (TYP)

9 <1> 230 380 (TYP) 460 760 (TYP) 575 950 (TYP)

<1> Default Setting

Braking

Activation

Voltage

(VDC)

Input

Voltage

(VAC)

Braking

Activation

Voltage

(VDC)

Input

Voltage

(VAC)

Braking

Activation

Voltage

(VDC)

CDBR-D Installation Instructions - May 2012
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Retrofit Attachment

Use the Retrofit Attachment when replacing an older model CDBR Braking Unit (CDBR-B). Contact
your local Magnetek representative for ordering.

Figure 15: Retrofit Attachement (CDBR-BD-A) for CDBR-2022D and CDBR-4045D

Figure 16: Retrofit Attachment (CDBR-BD-B) for CDBR-5037D

CDBR-D Installation Instructions - May 2012

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Table 5: Retrofit Attachment Dimensions

Attachment

Braking Unit

CDBR-

2022D

4045D

5037D 16 CDBR-BD-B

Figure Model No.

15 CDBR-BD-A

Dimensions in inches (mm)

WHDW1H1

5.51

(140)

4.72

(120)

5.91

(150)

11. 02
(280)

6.77

(172)

6.57

(167)

5.04

(128)

3.94

(100)

5.43

(138)

10.24
(260)

Table 6: Main Circuit Terminal Cross-Reference Chart for New and Previous

Version Model CDBR Braking Units

CDBR-XD CDBR-XB, CDBR-XC CDBR-X

B1

B2

N

P

P

0

0

0

B

CDBR-D Installation Instructions - May 2012
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Circuits and Wiring Specifications

Table 7: Circuits and Wiring Specifications

Model
Number

CDBR-2022D,
4045D, 5037D

Term inal
Block

TB3

TB4

Wire

Circuit Terminals

Size

Wire Type

AWG

Main

Control 18–14 M3.5 7.1 to 8.9

B1
B2

10–8

600 V vinyl
sheathed
wire or
equivalent

Terminal
Screw

M5 23.9 to 26.6

Table 8: CDBR Braking Unit Main Circuit Terminals

Terminal No. Terminal Name Specifications

B1

B2

Main Circuit
Negative Terminal

Main Circuit Positive
Terminal

Main Circuit B1
Terminal

Main Circuit B2
Terminal

Connects to the negative (-) terminal on the drive

Connects to the +3 terminal on the drive

Connects to the B1 terminal on the EDB braking
resistor unit, or connects to braking resistor terminal
of non-Magnetek resistor unit.

Connects to the B2 terminal on the EDB braking
resistor unit, or connects to braking resistor terminal
of non-Magnetek resistor unit.

Max. Torque
lb. in.

-- Grounding terminal

For 230 V class: 100 Ω or less
For 460 V class and 575 V class: 10 Ω or less

CDBR-D Installation Instructions - May 2012

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Table 9: CDBR Braking Unit Control Circuit Terminals

Term inal
Block

TB1

TB2

<1> Digital Input-SB, SC. Powered by internal 24 VDC LVLC source. If external power supply used, it shall be UL Listed Class 2 power
source only or equivalent.

Term inal
No.

IN1 Slave Input

IN2 Slave Input Common

OUT1 Master Output

OUT2

SC <1> Enable Input Common

SB <1> Enable Input

MA

MB

MC

EA

EB

EC

Terminal Name Specifications

Master Output
Common

Fault Contact Output
(N.O.)

Fault Contact Output
(N.C.)

Fault Contact Output
Common

CDBR transistor Short
Detection Output
(N.O.)

CDBR transistor Short
Detection Output
(N.C.)

CDBR transistor Short
Detection Output
Common

Input the signal when using CDBR braking units in
parallel

Output the signal when using CDBR braking units in
parallel

Enable/Disable contact input to disable the CDBR
and activate MA-MB-MC fault contact output.

Output the signal when a fault occurs or when SB­SC is closed (default) (example: CDBR braking unit
overheating, EDB braking resistor unit short-circuit
detection, external fault)
Relay output
250 VAC, max. 1 A
30 VDC, max. 1 A
min. 5 VDC, 10 mA

Output the signal when EDB braking resistor unit
shortcircuit or CDBR braking unit fault is detected.
Wiring sequence should shut off power to the drive
when the signal is output.
Relay output
250 VAC, max. 1 A
30 VDC, max. 1 A
min. 5 VDC, 10 mA

CDBR-D Installation Instructions - May 2012
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Braking Unit Specification

Table 10: Braking Unit Specifications

Braking Unit Model CDBR-

Applicable Motor Output Capacity

Output

Input DC Voltage (V) 243 to 400 460 to 800 607 to 1000

Protection

Function

Environment

<1> Allows for 10 separate steps to be set

<2> Not available for 575 V class models.

(kW)

Peak Discharge

Current (A) (10% ED,

10 s)

Continuous Rated

Discharge Current (A)

Braking Voltage

Activation Level (VDC)

Max. Hysteresis (V) Approx. 8 Approx. 16 Approx. 20

Heatsink Overheat Thermistor

Charge LED Charge lamp stays ON until bus voltage drops below 50 V.

Overcurrent Protection Faults the CDBR in the event of IGBT overcurrent.

Area of use Indoors (free from corrosive gasses and dust)

Altitude

Ambient Temperature -10 to +60 °C (IP00, IP20)

Storage Temperature -20 to +70 °C

Humidity 95 RH% or less (no condensation)

Vibration/Shock

Standards UL508C, CE <2>, RoHS

Protection Design IP00 enclosure, IP20 enclosure

Watt Loss (W) 273624

230 V Class 460 V Class 575 V Class

2022D 4045D 5037D

22 45 37

60 60 40

20 18 15

270 to 380 <1>

(Default setting: 380)

Up to 1000 meters without derating; up to 3000 m with drive output and

current derating. Contact Magnetek or your nearest sales representative

630 to 760 <1>

(Default setting: 760)

for details.

10 to 20 Hz: 9.8 m/s2
20 to 55 Hz: 5.9 m/s2

825 to 950 <1>

(Default setting: 950)

CDBR-D Installation Instructions - May 2012

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Troubleshooting

To troubleshoot the dynamic braking circuit (braking unit and braking resistor unit), refer to the chart
below:

Fault Status Possible Cause Corrective Action

Drive trips at overvoltage (OV) • Insufficient braking unit capacity

Braking Unit Thermal Overload trips
when not decelerating

The thermal relay (or the thermal
protector) on the braking resistor unit
trips occasionally.

Fault output contacts MA-MB-MC
changes states. Overvoltage (ov)
may occur on drive:

- CDBR heatsink over temperature

- CDBR transistor overcurrent

The fault contact on the CDBR
braking unit closed momentarily
when input power was applied.

The CDBR braking unit is not
operating.

Braking Unit trips by heatsink
overheat

• Verify CDBR-D capacity

• Insufficient resistor capacity

• Improper wiring

• Deceleration time too short

• Braking unit fault

• Improper braking unit power
supply voltage selection setting

• Incoming (line) voltage too high

• Discharge transistor shorted

• The braking resistor unit is too
small.

•

• The CDBR braking unit is
damaged.

• Incorrect CDBR switch position.

• Incoming main supply voltage
increases momentarily.

• The application is experiencing
excessive starting and stopping,
or the load inertia is too large for
the CDBR unit.

• The CDBR braking unit and EDB
braking resistor unit are not
appropriately matched.

• Resistor is wired incorrectly.

• Ambient temperature exceeded
50°C. CDBR heatsink is too hot.

• The CDBR braking unit is
damaged.

• No braking resistor (EDB braking
resistor unit) is installed.

• A master unit is incorrectly set to
be a slave device and there is no
master unit.

• Incorrect braking activation switch
position.

• The braking unit is damaged. • Replace the CDBR braking unit.

• Excessive load inertia

• Improper combination of braking

unit and resistor

• Ambient Temperature >122°F
(50°C)

• Verify resistor capacity

• Verify wiring is correct

• Lengthen deceleration time

• Replace the braking unit

• Verify S3 setting

• Correct line voltage

• Replace the braking unit

• Re-evaluate the braking
conditions required for the
application.

• Replace the CDBR braking unit.

• Correct the switch settings.

• Investigate the cause of high input
voltage.

• Re-evaluate the braking
requirements.

• Use the correct combination of
CDBR braking unit and EDB
braking resistor unit.

• Check for proper resistance.

• Reduce the ambient temperature.

• Replace the CDBR braking unit.

• Install a braking resistor (EDB
braking resistor unit).

• Check the CDBR braking unit
Master/Slave switch S2 and make
sure it is properly set. The master
LED (green) should be
illuminated on the master CDBR
unit.

• Check brake activation level
switch S3 for proper setting.

• Observe the Master and Slave
LEDs (only if slave units are
used). The LEDs should blink
when the CDBR is activating.

• Reduce load

• Verify proper braking unit/resistor

• Install air conditioner

CDBR-D Installation Instructions - May 2012
24

Braking Module Test Procedure

WARNING

Do NOT touch any circuit components while AC main power is on or immediately after main AC
power is disconnected from the unit. You must wait until the red “CHARGE” lamp is
extinguished. It may take as long as 10 minutes for the charge on the main DC bus capacitors to
drop to a safe level. Failure to adhere to this warning could result in serious injury.

1. Check for physical damage.

2. Using a Digital Multimeter, set the Diode Check function and perform static checks on the main
transistor module.

Check the following:

• Place the positive lead on terminal and the negative lead on terminal B2. This will check

the collector to emitter junction for a short circuit. A reading of “OL” indicates a good reading.

• Place the positive lead on terminal B2 and the negative lead on terminal B1. This will check

the diode connected to the collector for a short circuit. A reading of approximately 0.5 V
indicates a good reading.

3. Switch S2 to “Master” position.

4. 230 V Models

With a variable DC power supply, which is capable of producing 400 VDC output, apply the DC

voltage to terminals and . Slowly increase the voltage to approximately 50 V, at which
time the Charge LED should illuminate. With a DC Voltmeter, monitor terminals B2 and B1, and
continue to increase the DC voltage to 380 VDC. The voltmeter should read the 380 VDC
applied voltage, and the Master LED should flash. At this same time, the voltmeter should also
read 15 VDC across terminals OUT1 and OUT2, which indicates that the output to activate a
slave CDBR has turned on.

460 V Models

With a variable DC power supply, which is capable of producing 800 VDC output, apply the DC

voltage to terminals and . Slowly increase the voltage to approximately 50 V, at which
time the Charge LED should illuminate. With a DC Voltmeter, monitor terminals B1 and B2, and
continue to increase the DC voltage to 780 VDC. The voltmeter should read the 780 VDC
applied voltage, and the Master LED on should flash. At this same time the voltmeter should
also read 15 VDC across terminals OUT1 and OUT2, which indicates that the output to activate
a slave CDBR, has turned on.

575 V Models

With a variable DC power supply, which is capable of producing 1000 VDC output, apply the DC

voltage to terminals and . Slowly increase the voltage to approximately 50 V, at which
time the Charge LED should illuminate. With a DC Voltmeter, monitor terminals B1 and B2, and
continue to increase the DC voltage to 950 VDC. The voltmeter should read the 950 VDC
applied voltage, and the Master LED on should flash. At this same time the voltmeter should
also read 15 VDC across terminals OUT1 and OUT2, which indicates that the output to activate
a slave CDBR, has turned on.

CDBR-D Installation Instructions - May 2012

25

5. Remove power from terminals and .

6. Turn S2 to Slave position.

7. Apply power (325 VDC for 230 V models, 650 VDC for 460 V models, and 812 VDC for 575 V

models) to terminals and . Using a separate DC power supply, apply 15 VDC to
terminals IN1 and IN2. The 15 VDC signal should cause the main transistor to turn on and a
voltmeter should read the applied DC Bus Voltage across terminals B1 and B2, and the Slave
LED should flash.

8. With power still applied to terminals and , monitor terminals MC and MA with an

Ohmmeter. This meter should read Infinite Ohms. Place a jumper across the terminal switch
(pins 1 and 2 on CN35), which should cause the Fault Relay to change state, and 0 Ohms
should read on the Ohmmeter. Remove the jumper and replace the wires.

9. With power still applied to terminals and , monitor terminals EC and EA with an

Ohmmeter. The meter should read Infinite Ohms. Move the ohmmeter leads to terminals EC and
EB which should read 0 ohms

10. Remove power from terminals and . Return S2 back to “Master” position.

CDBR-D Installation Instructions - May 2012
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