Yaskawa 600 User Manual
YASKAWA
FOR VARISPEED-600 SERIES INVERTER
BRAKING UNIT
BRAKING RESISTOR UNIT
INSTRUCTIONS
MODEL: BRAKING UNIT CDBR-
BRAKING RESISTOR UNIT LKEB-
Upon receipt of the product and prior to initial operation, read these instructions
thoroughly, and retain for future reference.
YA S K A W A
MANUAL NO. TOE-C726-2F
PREFACE
Braking resistor unit and braking unit are used to consume regenerative energy from motor in the braking
resistor unitat deceleration andto improve the transistor inverter braking ability.
Before using the braking resistor unit and braking unit,
a thorough understanding of this manual is recom-
mended. This instruction manual will be of great help
for daily maintenance, inspection and troubleshoot-
ing.
Inverters to which the braking resistorunit and braking
unit can be connected are of the following series:
- VS−616 Series
- VS−676 Series
- VS−866 Series
3
General Precautions
: Some drawings in this manual are shownwith the protectivecover or shields
removed, in order to describe with more clarity. Make sure all covers and
shields are replaced before operating this product.
: Since the drawings in this manual are represented examples, some are sub-
ject to differ from delivered products.
: This manual may be modified when necessary because of improvement of
the product, modification or changes in specifications. Such modifications
are denoted by a revised manual No.
: To order a copy of this manual, if your copy has been damaged or lost, con-
tact your YASKAWA representative.
: YASKAWAis not responsible for any modification of the product made by
the user since that will void your guarantee.
4
NOTES FOR SAFE OPERATION
Read this instruction manual thoroughly before installation, operation,
maintenance or inspection of the braking unit and the braking resistor unit. In this
manual, NOTES FOR SAFE OPERATION are classified as “WARNING” or
“CAUTION.”
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury to personnel.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury to personnel and damage to equipment.
It may also be used to alert against unsafe practices.
Even items described in
situations. In either case, follow these important notes.
: These are steps to be taken to insure proper operation.
NOTE
CAUTION
may result in a vital accident in some
5
RECEIVING
CAUTION
: Do not install or operate any braking unit or braking resistor
unit which is damaged or has missing parts.
Failure to observe this caution may result in personal injury or
equipment damage.
INSTALLATION
CAUTION
: Lift the cabinet bythe base. When moving the unit, never lift
by the front cover.
Otherwise, the main unit may be dropped causing damage to the
unit.
(Ref. page)
15
(Ref. page)
16
: Mount the braking unit and braking resistor unit on nonflam-
mable material (i.e. metal).
Failure to observe this caution can result in a fire.
: When mounting multiple units in an enclosure, install a fan or
other cooling device to keep the intake air temperature below 40EC.
Overheating may cause a fire or damage to the unit.
6
16
16
WIRING
WARNING
: Only commence wiring after verifying that the power supply
is turned OFF.
Failure to observe this warning can result in an electrical shock or a
fire.
(Ref. page)
27
: High voltage exists at all terminals of braking unit and brak-
ing resistor unit.
Failure to observe this warning can result in an electrical shock.
: Wiring should be performed only by qualified personnel.
Failure to observe this warning can result in an electrical shock or a
fire.
: When wiring the emergency stop circuit, check the wiring
thoroughly before operation.
Failure to observe this warning can result in personal injury.
: Make sure to ground the ground terminal .
(Ground resistance
200V class: 100W or less, 400V class: 10W or less)
Failure to observe this warning can result in an electrical shock.
27
27
27
27
7
CAUTION
: Verifythat the ratedvoltage of the braking unit and the brak-
ing resistor unit coincides with the AC power supply voltage.
Failure to observe this caution can result in personal injury or a fire.
(Ref. page)
27
: Do not perform a withstand voltage test of the braking unit
and braking resistor unit.
It may cause semi−conductor elements to be damaged.
: Connect braking resistors, braking resistor units, and brak-
ing units as shown in the I/O wiring examples. Use properly
rated wire in accordance with table 2 on page 31.
Otherwise, a fire can occur.
: Tighten terminal screws to the specified tightening torque.
Failure to observe this caution can result in a fire.
27
27
27
8
OPERATION
WARNING
: Only turnON the input power supply afterreplacing the front
cover. Do not remove the cover while current is flowing.
Failure to observe this warning can result in an electrical shock.
CAUTION
: Never touch the heatsink or discharging resistor since the
temperature is very high.
Failure to observe this caution can result in harmful burns to the
body.
(Ref. page)
41
(Ref. page)
41
: Do not check signals during operation.
The machine or the inverter may be damaged.
: All the constants of the the braking unitand the brakingresis-
tor unit have been preset at the factory. Do not change the
settings unnecessarily.
9
41
41
MAINTENANCE AND INSPECTION
WARNING
: Never touch high−voltage terminals in the the braking unit
and braking resistor unit.
Failure to observe this warning can result in an electrical shock.
(Ref. page)
46
: Replace all protective covers before powering up the brak-
ing unit and the braking resistor unit. To remove the cover,
make sure to shut OFF the molded −case circuit breaker.
Failure to observe this warning can result in an electrical shock.
: Perform maintenance or inspection only after verifying that
the CHARGE LED goes OFF, after the main circuit power
supply is turned OFF.
The capacitors are still charged and can be dangerous.
: Only authorized personnel should be permitted to perform
maintenance, inspections or parts replacement.
[Remove all metal objects (watches, bracelets, etc.) before
operation.]
(Use tools which are insulated against electrical shock.)
Failure to observe this warning can result in an electrical shock.
46
46
46
10
CAUTION
: The control PC board employs CMOS ICs. Do not touch the
CMOS elements.
They are easily damaged by static electricity.
(Ref. page)
46
: Do not connect or disconnect wires or connectors while
power is applied to the circuit.
Failure to observe this caution can result in personal injury.
OTHERS
WARNING
: Never modify the product.
Failure to observe this warning can result in an electrical shock or
personal injury and will invalidate the guarantee.
46
11
WARNING INDICATION
A warning label is displayed on the front cover of the braking unit, as shown below.
Follow these instructions when handling the braking unit and the braking resistor
unit .
Warning
Indication
Example of Braking Unit Model CDBR−4045B
12
Warning Indication
May cause injury or electric shock.
⋅⋅⋅⋅ Please follow the instructions in the manual before
installation or operation.
⋅⋅⋅⋅ Disconnect all power before opening front cover of
unit. Wait 3 minutes until DC Bus capacitors
discharge.
⋅⋅⋅⋅ Use proper grounding techniques.
13
CONTENTS
NOTES FOR SAFE OPERATION 5.........................
1. RECEIVING 15.......................................
2. INSTALLATION 16....................................
2.1 LOCATION 16.......................................
2.2 INSTALLATION 16...................................
2.3 REPLACEMENT OF CONVENTIONAL BRAKING UNITS
WITH NEW UNITS 25................................
3. WIRING 27..........................................
3.1 REMOVING AND REPLACING THE COVERS OF THE
BRAKING UNIT (MODELS CDBR−2015B, −2022B,
−4030B, −4045B) 27..................................
3.2 SECTION NAMES 28.................................
3.3 CIRCUITS AND WIRING SPECIFICATIONS 31..........
3.4 WIRING PRECAUTIONS 32...........................
3.5 INTERCONNECTION 33..............................
4. OPERATION 41......................................
4.1 ADJUSTMENT 41....................................
4.2 POWER SUPPLY VOLTAGE SELECTION CONNECTOR
SETTING 41........................................
4.3 MASTER/SLAVE SELECTION CONNECTOR SETTING 44
4.4 PARALLEL CONNECTION OF BRAKING UNIT 44.......
4.5 OPERATION 45......................................
5. TROUBLESHOOTING 46..............................
6. SPECIFICATIONS 47..................................
6.1 BRAKING UNIT AND BRAKING RESISTOR UNIT
APPLICATION LIST 47...............................
6.2 BRAKING UNIT FOR 575V CLASS APPLICATION LIST 49
6.3 LIST OF APPLICABLE/NOT APPLICABLE
COMBINATIONS WITH CONVENTIONAL
MODELS (VS−616HII/H3, VS−616GII/G3, VS−676) 50....
6.4 BRAKING UNIT SPECIFICATIONS 51..................
6.5 BRAKING RESISTOR UNIT SPECIFICATIONS 52........
14
1. RECEIVING
1. RECEIVING
The braking resistor unit and braking unit have been put through severe tests at the
factory before shipment. After unpacking, however, check and see the following.
If any malfunctions are found, contact your YASKAWA representative.
: Their nameplate data meet your requirements.
: They have sustained no damage while in transit.
: Fastening bolts and screws are not loose.
15
2. INSTALLATION
2.1 LOCATION
If the units are temporarily stored or machine stops for an extended length of time,
the following precautions should be taken. Store the units under the following conditions.
: Free from rainfall and drops of water.
: Clean and dry.
: Free from corrosive gases and liquids.
: Free from dirt and dust.
: Ambient temperature: 14 to 104EF, −10 to 4 0EC.
: Humidity: 90% RH or less (no condensation)
: Free from vibration.
2.2 INSTALLATION
For full use of the braking resistor unit or braking unit functions, install the units
in a location to satisfy the following conditions:
Figs. 1 to 8 show the external dimensions and the spaces from the periphery.
: Provide the spaces shown in Figs. 1 to 8 between the units and the periph-
ery.
: Since the braking resistor unit generates heat, provide sufficient spaces
from devices which are weak against heat.
: Install the units at such locations that all requirements described in Par.
2.1 “LOCATION” are satisfied.
: Install the units in the directions shown in Figs. 1 to 8. There will be n o
problem if they are installed vertically.
16
2. INSTALLATION
1.18 (30)
OR MORE
4−M4 MTG HOLE
1.5 (38)
1.5 (38)
5.04 (128)
5.51 (140)
5.43 (138)
5.91 (150)
1.18 (30)
OR MORE
2.83 (72)
2.73 (66.5)
4.51 (114.5)
5.45 (138.5)
3−LEAD WIRE OUTLET
[0.87 (20) DIA RUBBER BUSH]
Fig. 1 Braking Unit Dimensions in inches (mm) CDBR−2015B, −2022B,−4030B,
−4045B
3.94 (100) OR MORE
3.94 (100) OR MORE
17
0.39 (10)
1.14 (29)
3.94 (100)
4−M6
MTG HOLE
3.94 (100)
OR MORE
2.19 (55.5)
MAIN CIRCUIT
TERMINAL M4
1.97 (50)
3.94 (100)
5.51 (140)
1.18 (30)
OR MORE
2.30
(58.5)
6.57 (167)
11.02 (280)
10.23 (260)
9.25 (235)
1.18 (30)
OR MORE
Fig. 2 Braking Unit Dimensions in inches (mm) CDBR−5037B
3−LEAD WIRE
OUTLET
1.10 (28) DIA
RUBBER BUSH
3.94 (100)
OR MORE
18
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