DBU Technical & Installation

ALSPA GDB400HV

ALSPA MV3000e Technical Data & Installation Instructions for 400A 415V to 690V ac Dynamic Brake Units Publication No. T1687EN Rev. 0006 (07/06)

SAFETY INSTRUCTIONS

Care has been taken with the design of this product to ensure that it is safe. However, in common with all products of this type, misuse can result in injury or death. Therefore, it is very important that the instructions in this manual and on the product are observed during transportation, commissioning, operation, maintenance and disposal. This technical manual should be regarded as part of the product. It should be stored with the product and passed on to any subsequent owner or user. Local safety laws and regulations must always be observed. Persons working on the product must be suitably skilled and should have been trained in that work for these products. The product is a component designed for incorporation in installations, apparatus and machines. The product must not be used as a single item safety system. In applications where maloperation of the product could cause danger, additional means must be used to prevent danger to persons. Product approvals and certifications will be invalidated if the product is transported, used or stored outside its ratings or if the instructions in this manual are not observed. Third party approvals to safety standards UL 508C and CSA C22.2 No 14 are marked on the product. In the European Union:

• Products within the scope of the Low Voltage Directive, 73/23/EEC as amended are CE marked. • The product complies with the essential protection requirements of the EMC directive 89/336/EEC

as amended, when installed and used as described in this manual. The requirements of the EMC Directive should be established before any installation, apparatus or machine which incorporates the product is taken into service.

• A machine should not be taken into service until the machine has been declared in conformity with the provisions of the Machinery (Safety) Directive, 98/37/EEC.

Publication No. T1687EN Rev. 0006 (08/06)

© - Converteam UK Ltd - 2006. Converteam, the logo Converteam and their frameworks are trademarks and service trademark applications of Converteam. The other names mentioned, registered or not, are the property of their respective companies.

CHANGES FROM PREVIOUS EDITION Previous Edition: Rev. 0005 (08/01): Resistor protection added. TP7 connections clarified. This edition: Rev. 0006 (07/06) Company name change

GDB400HV DB Units Contents

Issue (07/06) ALSPA GDB400HV 400 A 690 V Dynamic Braking Units Page i

CONTENTS Section Page 1. Introduction............................................................................................................................................. 1-1 1.1 About this Manual ..................................................................................................................................... 1-1 1.2 General Description.................................................................................................................................. 1-1 1.3 Range of DB Units described in this Manual ........................................................................................... 1-1 1.4 Customer Support and Training............................................................................................................... 1-1 1.5 Associated Publications............................................................................................................................ 1-2 2. Specification............................................................................................................................................ 2-1 2.1 Electrical.................................................................................................................................................... 2-1 2.2 Mechanical/Environmental ....................................................................................................................... 2-2 2.3 Protection.................................................................................................................................................. 2-3 2.4 Safety Standards ...................................................................................................................................... 2-4 3. Hardware Description ............................................................................................................................ 3-1 3.1 Introduction ............................................................................................................................................... 3-1 3.2 20X4285.................................................................................................................................................... 3-1 3.3 20X4245.................................................................................................................................................... 3-1 3.4 Intelligent Power Module .......................................................................................................................... 3-1 3.5 Operating Information............................................................................................................................... 3-2 3.5.1 Enable/Reset............................................................................................................................... 3-2 3.5.2 Resistor Overtemperature Input ................................................................................................. 3-2 3.5.3 Healthy Output............................................................................................................................. 3-2 4. System Design........................................................................................................................................ 4-1 4.1 General ..................................................................................................................................................... 4-1 4.2 DB Units .................................................................................................................................................... 4-1 4.2.1 Unit Types and Associated Resistor Data.................................................................................. 4-1 4.3 Resistor Selection..................................................................................................................................... 4-1 4.4 Calculation for Resistors........................................................................................................................... 4-2 4.4.1 Calculation Based on Power....................................................................................................... 4-2 4.4.2 Calculation Based on Inertia ....................................................................................................... 4-3 4.4.3 Example....................................................................................................................................... 4-4 4.4.4 Braking Times against Load Inertia ............................................................................................ 4-4 4.5 Illustration of Ratings ................................................................................................................................ 4-4 4.5.1 DB Units for ALSPA MV3000e Drives........................................................................................ 4-7 4.6 Power Connections .................................................................................................................................. 4-9 4.7 Control Connections ............................................................................................................................... 4-10 4.8 Paralleling DB Units................................................................................................................................ 4-10 4.9 External Resistor Protection................................................................................................................... 4-12 5. Installation ............................................................................................................................................... 5-1 5.1 General Information.................................................................................................................................. 5-1 5.1.1 Receipt of Equipment on site...................................................................................................... 5-1 5.1.2 Identification of Unit..................................................................................................................... 5-1 5.1.3 Storage ........................................................................................................................................ 5-1 5.1.4 Handling....................................................................................................................................... 5-1 5.1.5 Environment ................................................................................................................................ 5-2 5.2 Installation Details..................................................................................................................................... 5-2 5.2.1 Special Tools and Equipment ..................................................................................................... 5-2 5.2.2 Acoustic Noise at Resistor .......................................................................................................... 5-2

Contents GDB400HV DB Units

Page ii ALSPA GDB400HV 400 A 690 V Dynamic Braking Units Issue (07/06)

5.2.3 Electromagnetic Compatibility (EMC) .........................................................................................5-2 5.2.4 Cooling and Ventilation................................................................................................................5-2 5.2.5 Access..........................................................................................................................................5-2 5.2.6 Installing the Dynamic Braking Unit.............................................................................................5-2 5.2.7 Electrical Connections .................................................................................................................5-3 6. Commissioning .......................................................................................................................................6-1 6.1 Mechanical Checks...................................................................................................................................6-1 6.2 Input Power Connections..........................................................................................................................6-1 6.3 ALSPA MV3000e Drive Parameters ........................................................................................................6-2 6.4 ALSPA GD2000/GD2000E/GD3000/GD3000E Drive Parameters.........................................................6-3 6.5 Diagnostics ................................................................................................................................................6-4 7. Maintenance.............................................................................................................................................7-1 7.1 Preventive Maintenance ...........................................................................................................................7-1 7.1.1 Special Tools & Equipment .........................................................................................................7-1 7.1.2 Maintenance Schedules ..............................................................................................................7-1 7.2 Component Replacement .........................................................................................................................7-1 7.3 Fault-Finding..............................................................................................................................................7-1 7.3.1 Fault Indication.............................................................................................................................7-1 7.3.2 Trip Resetting...............................................................................................................................7-2 7.4 Ordering Information .................................................................................................................................7-2 8. Disposal....................................................................................................................................................8-1 LIST OF FIGURES

Figure 2-1 Dimensions for 400 A Dynamic Braking Unit......................................................................2-5 Figure 3-1 Schematic Diagram of a Dynamic Braking Unit..................................................................3-1 Figure 4-1 DB Resistor Power Dissipation...........................................................................................4-3 Figure 4-2 Braking times from 1500 rpm for GDB400-4601 & GDB400-4602 types ...........................4-6 Figure 4-3 Braking times from 1500 rpm for GDB400-4603 & GDB400-4604 types ...........................4-6 Figure 4-4 Power Connections.............................................................................................................4-9 Figure 4-5 Protective Earth (ground) symbol to IEC 60417 (Symbol 5019).........................................4-9 Figure 4-6 Control Connections .........................................................................................................4-10 Figure 4-7 Parallel Operation of DB Units – Fusing Arrangement .....................................................4-11 Figure 4-8 DB resistor protection by removing the supply from the drive ..........................................4-12 Figure 4-9 DB resistor protection by disconnection ...........................................................................4-13 LIST OF TABLES

Table 2-1 DC Link Cut-in Voltage for Braking - relationship between DB Unit and Compatible Equipment ...........................................................................................................................2-1

Table 2-2 Vibration Immunity - Operational ........................................................................................2-3 Table 4-1 Electrical Specification for DB Units used with MV3000 Drives .........................................4-8

GDB400HV DB Units 1. Introduction

Issue (07/06) ALSPA GDB400HV 400 A 690 V Dynamic Braking Units Page 1-1

1. Introduction

1.1 About this Manual

This Dynamic Braking Manual provides a competent user trained in electrical installation practice with sufficient information to safely install, commission, maintain and dispose of an ALSPA GDB400HV Dynamic Braking (DB) Unit. The manual should be read in conjunction with the appropriate technical manuals for the compatible host drive equipment listed at Table 2-1. The technical manuals for the compatible equipment are listed at 1.5.

This manual should be regarded as part of the ALSPA GDB400HV Dynamic Braking (DB) Unit. It should be retained for the life of the product and passed on to any subsequent owner or user.

1.2 General Description

The Dynamic Braking Unit (DB Unit) is used in conjunction with an externally mounted resistor, to dissipate kinetic energy stored in a motor and its load. This is regenerated into the AC drive (MV3000e/GD2000E/GD3000E) during deceleration or when the load is overhauling. The unit contains circuitry to monitor the DC link voltage, and a switching transistor (IGBT) that is used to switch the resistor into circuit when the voltage exceeds a pre-set level.

The unit generates its own internal electronics supplies from the connected DC link. A separate Enable/Reset control input allows the unit to be externally prevented from turning the DB resistor on, and also to reset any trips.

A volt free Healthy/Tripped signal (the unit must be enabled and not tripped to be Healthy) is available for fault feedback.

1.3 Range of DB Units described in this Manual

Table 2-1 lists the range of GDB400HV 400 A Dynamic Braking Units and their compatibility with other drive equipment supplied by Converteam.

1.4 Customer Support and Training

Converteam provides comprehensive telephone technical support, application planning, service customer training.

Contact Converteam at the appropriate address shown on the back of this manual.

1. Introduction GDB400HV DB Units

Page 1-2 ALSPA GDB400HV 400 A 690 V Dynamic Braking Units Issue (07/06)

1.5 Associated Publications

The following publications are associated with this manual for the GDB400HV DB Units and should be referred to as appropriate for the application of the DB Unit:

• T1676 ALSPA MV3000e Getting Started Manual for AC-fed Drives • T1679 ALSPA MV3000e Software Technical Manual • T1689 ALSPA MV DELTA Technical Manual • T1693 ALSPA MV DELTA Liquid Cooled Drive System Technical Manual • T1623 ALSPA GD2000 Technical Manual • T1635 ALSPA GD2000E Technical Manual • T1619 ALSPA GD3000 Technical Manual • T1660 ALSPA GD3000E Technical Manual • T1641 ALSPA GD DELTA Technical Data and Assembly Instructions • T1681 ALSPA Liquid Cooled DELTA System Technical Manual

GDB400HV DB Units 2. Specification


2. Specification

2.1 Electrical

Maximum Braking Current : 400 A

Maximum Braking Duty : 25% (Up to 30 seconds in 120 seconds)

DC Link Cut-in Voltage for Braking : Selectable by jumper TP7 (see 4.7 and Table 2-1)

Table 2-1 DC Link Cut-in Voltage for Braking - relationship between DB Unit and Compatible Equipment

DB Unit Type

Number

DC Link* Cut-in

Voltage

TP7 Link Position

s on 20X4245

Compatible Equipment Maximum Host AC Supply Voltage

Drive Overvoltag

e Trip Voltage V

d.c.

Minimum Dissipation Resistance

ohm

GDB400-4601

1125 830

GD3000E DELTA SYSTEMS

690 V ± 10% 525 V ± 10%

1165 875

2.91 2.18

GDB400-4602

760 660

GD2/3000E BDM AND GD DELTA SYSTEMS

480 V ± 10% 415 V ± 10%

795 795

1.98 1.98

GDB400-4603

848 734

MV3000e MICROCUBICLE AND MV DELTA SYSTEMS

525 V ± 10% 440 V ± 10%

882 784

2.20 1.96

GDB400-4604

1121 1052

MV3000e MICROCUBICLE AND MV DELTA SYSTEMS

690 V ± 10% 600 V ± 10%

1172 1172

2.93 2.93

* DC link Cut-in Voltage selected by TP7 – see Section 4.7

Maximum DC Link Voltage : 1165 V ±8 V Overvoltage Trip, 1200 V withstand Enable Input : Unit is enabled by connecting TB1 pins 1 & 2 together. Trip Reset : Unit may be reset at any time (fault removed) by

momentary (0.5 second) interruption of the enable connection.

Resistor Overtemperature : Unit may be disabled by an external, normally closed

thermostat wired in series with the enable connection. Closed is unit enabled, open is unit disabled.

Note that the thermostat must be galvanically isolated

from the resistor itself. Healthy/Tripped Output : Volt-free normally open contact. Energised when healthy, de-energised on removal of DC

link, or on overtemperature, overvoltage or overcurrent trip

Maximum Voltage : 120 V a.c. Maximum Current : 3 A (resistive load). Max IGBT switching frequency : 2 kHz

2. Specification GDB400HV DB Units


2.2 Mechanical/Environmental

Mechanical Protection : IP20 (NEMA 1). Protected against the ingress of solid foreign objects greater than 12.7 mm (0.5 in) diameter, not protected against water. Unit must be mounted within a cubicle or enclosure which ensures a pollution degree 2 environment according to UL840 and CSA 22.2 No.0.2.

Temperature

Operating : 0°C to 50°C.

Storage : -25°C to +55°C.

Transport : -25°C to +70°C. Humidity : 5% to 95% Relative Humidity (non-condensing). Cooling : Unit contains internal cooling fans.

Free air space of 100 mm (minimum) must be allowed above and below the unit for correct airflow.

Cooling air : The unit must be mounted in clean dust free air which is

free from corrosive vapours.

Overvoltage Category : The ALSPA GDB400HV complies with the insulation co-ordination requirements of IEC 664-1 (1992) and UL840 (1993) when installed in an overvoltage category III environment (Maximum rated impulse Voltage 6000 V).

External means must be applied to control the

overvoltage within this limit unless the characteristics of the supply already do so. Any devices fitted for this purpose must meet the requirements of UL1449 (1996) Standard for Transient Voltage Surge Suppressors.

Acoustic Noise : Less than 75 dB(A) at 1 metre (any angle).

Altitude : Normal operation up to 1000 m (3,300 ft) above sea level. Derate duty cycle by 10% per 1000 m (3,300 ft) up to a

maximum of 2000 m (6,600 ft). Physical Dimensions : see Figure 2-1 for full details

Width 370 mm (14.6 in); 402 mm (15.8 in) including removable handles;

Depth 270 mm (11 in) – additional 330 mm (13 in) clearance is required for front panel opening;

Height 410 mm (16.1 in) – additional 100 mm (3.94 in) clearance is required above and below the unit for ventilation and approximately 50 mm (1.97 in) at the bottom of the unit for cable access;

Weight : 23.5 kg (52 lb) Terminations Power : M8 steel studs for cables. Control : Screw terminals for cable up to 2.5 mm².

Vibration Immunity (Operational) : see Table 2-2.



Table 2-2 Vibration Immunity - Operational

Frequency IEC 721-3-3 Class 3M1

EN 50178 Composite

2 Hz to 9 Hz 0.3 mm amplitude 0.3 mm amplitude

9 Hz to 28.13 Hz 1 m/s2 0.032 mm from 10 Hz 1 m/s2

28.13 Hz to 57 Hz 1 m/s2 0.032 mm amplitude 0.032 mm amplitude

57 Hz to 150 Hz 1 m/s2 5 m/s2 5 m/s2

150 Hz to 200 Hz 1 m/s2 1 m/s2

Vibration : Class 2M1 of IEC 721-3-2: (Storage & Transport, 2 to 9 Hz 3.5 mm amplitude packed for Transport) 9 to 200 Hz 10 m/s² 200 to 500 Hz 15 m/s² Drop (Transport, : Class 2M1 of IEC 7-3-2 packed for Transport) 0.25 m

2.3 Protection

Overcurrent Protection : Internal protection against overcurrent - including short circuits between resistor terminals.

Note that short circuits or earth faults on or between DC+,

DC- or RES+ may lead to cable/busbar damage. If the Dynamic Braking unit is connected to a drive with a

rating of 300 A or less then the required protection will be provided by the a.c. input fuses of the drive. Otherwise, additional fuses rated for the appropriate d.c. voltage and duty current must be fitted in the DC+ and DC- connections close to the source of supply.

Resistor Protection : This unit does not provide resistor overtemperature

protection. This may be achieved by connecting a resistor-mounted thermostat in series with the enable input (see Section 4.9).

Note that this thermostat must be galvanically isolated

from the resistor which is at DC link potential. Note that to fully protect the installation in the event of

short-circuit failure of the internal IGBT, the installer must make separate provision for the supply to be removed from the system, and for drives which may regenerate to be disabled, before the resistor reaches a dangerous temperature.

Overvoltage Protection : Internal protection against overvoltage. Unit switches off

output and trips. If the DC input continues to rise above 1200 V DC, unit will be permanently damaged.

Undervoltage Protection : Unit will disable and send trip signal in the event of DC

link undervoltage.

Over-temperature : Internal protection against heatsink overtemperature. Protection Switches off resistor current and signals a trip.



Fault Indication : Volt-free normally open contact. Energised when healthy

and enabled. De-energised on trip or removal of enable input.

An internally fitted Light Emitting Diode (D1) also

indicates when the unit is healthy and enabled. Fault Reset : Unit may be reset at any time (fault removed) by

momentary interruption (0.5 second) of the enable input

2.4 Safety Standards

Designed to comply with the requirements of the following: (a) EN 50178 Electronic Equipment for use in power installations; (b) ANSI/UL 508C Power Conversion Equipment, as marked on unit;

(c) CAN/CSA C22.2-14 Industrial Equipment, Industrial Products.



Figure 2-1 Dimensions for 400 A Dynamic Braking Unit



(This page is intentionally left blank)

GDB400HV DB Units 3. Hardware Description


3. Hardware Description

3.1 Introduction

INTELLIGENT POWER MODULE (IPM)

DC+ and RES+ Power Terminal

RES- Power Terminal

DC- Power Terminal

14-way

20X4285 High Voltage Switch Mode Power Supply

TB1

PL2

Enable Input

20X4245 Dynamic Brake Control Board

TP7

Healthy Output

PL212

TB2

40-way

PL1

DC Capacitors

DC Supply

DC Link

Figure 3-1 Schematic Diagram of a Dynamic Braking Unit

3.2 20X4285

This PCB contains the high voltage SMPS and the isolated DC link voltage measurement. The overvoltage detector is on this PCB.

3.3 20X4245

This PCB contains the switching comparator and the overcurrent and overtemperature protection circuits.

The switching comparator threshold is selectable for either of two voltages using jumper TP7 (see Table 2-1).

3.4 Intelligent Power Module

The IPM contains the IGBT switching element, the signal to power isolation and the current and temperature feedback circuits.

3. Hardware Description GDB400HV DB Units


3.5 Operating Information

Operation of the ALSPA DB Dynamic Braking Unit is entirely automatic. It is enabled when the DC link rises above the threshold of the internal switch mode power supply and the enable input is active. When the d.c. input exceeds the cut-in level of the unit the output transistor switches the external resistor across the DC link.

The cut-in level is selectable, for different voltage systems, by use of jumper TP7 on the 20X4245 printed circuit board. The selection position for each voltage is shown at Figure 4-6. For example, on the GDB400-4603 DB Unit with the jumper on TP7 in the right hand position, the unit will cut in at 848 V d.c. On the same unit with the jumper on TP7 in the left hand position, the unit will cut in at 734 V d.c.

3.5.1 Enable/Reset

The unit is enabled by connecting TB1 pins 1 and 2 together on the 20X4245 printed circuit board. Alternatively 24 V with respect to ground (see Figure 4-4) may be applied to TB1 pin 2.

In the event of a trip, after the fault has been removed, the unit may be reset at any time by briefly (1 second or longer) removing the enable input.

3.5.2 Resistor Overtemperature Input

An external normally closed thermostat in thermal contact with the resistor and connected in series with the enable input will disable the unit to protect the external braking resistor. This is not a latched trip.

Closed = Healthy. Open = Overtemperature (disabled).

The thermostat must be isolated from the DC link voltage.

3.5.3 Healthy Output

A volt free normally open contact is provided for unit healthy/tripped status (see Figure 4-4). The unit must be enabled and healthy for this output to be healthy.

GDB400HV DB Units 4. System Design


4. System Design

4.1 General

A Dynamic Braking (DB) unit is required when the required deceleration rate is faster than the normal "free wheel" rate, and the input rectifying device is incapable of returning energy to the main supply. This is normally the case with an input rectifier. The machine returns energy to the DC link which then rises in voltage. This rise is detected by the DB Unit which switches on a resistor across the link thus dissipating energy.

4.2 DB Units

4.2.1 Unit Types and Associated Resistor Data

Four ALSPA GD400HV DB Units exist each of which has two selectable voltages. Table 2-1 at Section 2 lists the DB Unit types and the associated resistor values.

The DB Unit is rated for a 25% duty cycle with a maximum "on" time of 30 seconds in 2 minutes. This means that for maximum rating of the unit, the average current would not exceed I/4. The peak current must not be maintained for a period of greater than 30 seconds.

Resistor suppliers normally quote resistance value and watts capability for various times. DB resistors tend to increase in value with temperature and often have surface temperatures in excess of 300°C. Suppliers can fit temperature-sensing devices to the resistors but please note the specification section on resistor protection.

It is important to estimate the change in resistor value, arising from increases in temperature and tolerance, so that the maximum value with all these factors considered does not exceed the maximum resistor value required to achieve the desired braking power.

These resistors are not supplied by Converteam but can be obtained from specialist resistor manufacturers/suppliers.

4.3 Resistor Selection

When selecting a DB Unit, and its associated resistor, the following points should be considered:

(a) The energy regenerated into an a.c. drive from the motor(s) and its load is limited to a rate based on the drive's capability. The drive overload current limit applies when motoring or regenerating.

(b) The minimum resistor value, in ohms, is usually determined by the DB Unit current capability and the maximum voltage at which it operates (see Table 2-1).

(c) If the motor and load were loss free, the acceleration, and deceleration times would be identical for the same applied accelerating / decelerating torque (or full load current). In practice, losses aid deceleration.

(d) In some applications with high frictional loads no DB may be necessary for the desired deceleration. In the particular case of fan loads the initial losses caused by air friction are significant, so less braking energy will be dissipated. The analysis at 4.4 assumes no losses.

(e) The power dissipated in the DB resistor depends on the time taken to decelerate and the frequency of decelerations. The following notes should aid the selection of this resistor.

4. System Design GDB400HV DB Units


(f) For the minimum system (motor and load) deceleration time, the DB Unit should be rated 1.22 times (or higher) than the overload current limit of the drive. The 1.22 multiplier is an approximate conversion from the drive's AC output current into the DC input current into the DB. This is required as the AC Drive is rated in AC current and the DB Unit in DC current. The overload rating of the drive is normally 1.1 times full load current, but different between ALSPA MV3000e and GD2000E/GD3000E Drives – refer to the separate drive manuals for the actual figures.

4.4 Calculation for Resistors

Standard resistor values may be used with the DB Unit. However, when it is required to use a braking resistor with a non-standard value, the following procedure should be used. Two methods are given, one based on a known power and the other upon a known inertia.

4.4.1 Calculation Based on Power

If the power being returned to the drive is known (e.g. overhauling load), the resistor may be calculated as follows:

Resistance, Ω=p

DB

PV

R2

where DBV = DB operating voltage (see Table 2-1)

pP = Peak power during braking.

The calculated resistance value is the maximum resistance that can be used to achieve the desired braking effort. As most dynamic braking resistors increase in resistance as they heat up, this change can be significant and must be allowed for when specifying the resistor. Although a resistance lower than the calculated value could be used (providing that it is greater than the minimum value given at Table 2-1) it will stress the system components more than is necessary to achieve the application requirement. The higher instantaneous current requirement may also increase the cost of the resistor and its cabling.

The resistor should have a peak power capability equal to the power during braking and be able to withstand this power for the braking time t1.

It should also have an average power capability given by:

Long term average power = Average power during braking 3

1

tt

×

where 1t = braking time

and 3t = total on/off cycle time. This is illustrated at Figure 4-1.



Total Start/Stop cycle time (t3)

Repeat

AverageRegenerativePower

Peak Regenerative Power

time

pow

er

t1 t2

Figure 4-1 DB Resistor Power Dissipation

4.4.2 Calculation Based on Inertia If the regenerative power is not known, but the inertia of the load is known, the resistance and power rating may be calculated as follows:

Resistance, Ω−

=)(

2.91

122

12

NNJNtVR DB

where DBV = DB operating voltage (see Table 2-1)

J = system inertia (kgm2)

1t = braking time (seconds)

2N = initial speed (r/min)

1N = final speed (r/min)

Note: J = ))/(1( 2ratioboxgearJJ loadmotor ×+ .

If there is no gear box, ratioboxgear = 1. Inertia of the motor and load to be determined from the respective suppliers.

Peak power (at start of braking) = pP = J N N N

t( )

.2 1 2

1912−

The resistor should have a peak power capability equal to the power during braking and be able to withstand this power for the braking time t1.

It should also have an average power capability given by:



Long term average power = energytotal cycle time

= 3

21

22

4.182)(

tNNJ −

where t3 = total stop-start cycle time in seconds.

4.4.3 Example

Suppose we have an inertia of 0.9 kgm2, a top speed of 3000 rpm and we require to brake to zero speed in 2 seconds repeated every 100 seconds. Assume DB switching voltage is 732 V.

R =)(

2.91

122

12

NNJNtV DB

−=

)03000(30009.027322.91 2

−××××

= 12.07 Ω

Peak power = J N N N

t( )

.2 1 2

1912−

= 22.91

3000)03000(9.0×

×−×

= 44408 Watts or 44.4 kW

Long term average power = 3

21

22

4.182)(

tNNJ −

= 1004.182

)03000(9.0 2

×−×

= 444 Watts

Current in resistor = R

VDB = 07.12

732 = 60.6 A

4.4.4 Braking Times against Load Inertia

To further aid selection of DB Units the graphs at and Figure 4-3 show braking times against load inertia to zero speed from 1500 rpm for the range of 400 A DB Units available from Converteam. These graphs are based on use of the nearest standard resistor values.

4.5 Illustration of Ratings

The ability of the DB Units to absorb the energy from inertial loads during deceleration to zero speed is now illustrated. For speed reductions from one speed to another (not zero) refer to 4.4.

Figure 4-2 and Figure 4-3 show the time taken to brake a given inertia from a typical speed of 1500 rpm to zero speed, for the DB Units detailed at Table 2-1. The units will operate at 400 V, 480 V and 690 V nominal supply volts. The graphs are based on use of the nearest standard resistor values.

It is assumed that the braking torque during deceleration is constant.



• If the initial speed is not 1500 rpm, the braking time to zero can be found by using the graph to find the braking time grapht for 1500 rpm and scaling by the following formula:

where 1t = actual braking time

2N = initial speed

• Inertia is shown in kg m2.

1 kg m2 = 23.73 lb ft2.

2

22

1 1500N

tt graph ×=



Figure 4-2 Braking times from 1500 rpm for GDB400-4601 & GDB400-4602 types

Figure 4-3 Braking times from 1500 rpm for GDB400-4603 & GDB400-4604 types

0

5

10

15

20

25

30

0 100 200 300 400 500 600

Total Inertia (kgm2)

Bra

king

tim

e fr

om 1

500

r/min

(sec

onds

)

GDB400-4601(525 V)

GDB400-4601(690 V)

GDB400-4602(415 V)

GDB400-4602(480 V)

0

5

10

15

20

25

30

0 100 200 300 400 500 600

Total Inertia (kgm2)

Bra

king

tim

e fr

om 1

500

r/min

(sec

onds

)

GDB400-4603(440 V)

GDB400-4603(525 V)

GDB400-4604(600 V)

GDB400-4604(690 V)



4.5.1 DB Units for ALSPA MV3000e Drives

Table 4-1 lists the maximum power each ALSPA MV3000e Drives can generate, along with the DB Unit and resistor required to dissipate this power.

4.5.1.1 Application Notes for use with Table 4-1

Consider the following notes when using Table 4-1:

(a) The minimum braking resistance is the greater of two possible minimum resistances. The first is the minimum DB resistor value such that the DB Unit will not exceed its rated current at the switching threshold. The second is the minimum DB resistor value such that the DB Unit cannot create excessive DC link voltage ripple.

(b) The maximum braking resistance is the biggest resistance that can achieve the required drive kW rating, at the selected DB threshold voltage, when drive operation at 1.1 or 1.5 overload is considered.

(c) *: the chosen braking resistor must not be less than the minimum resistor value including its tolerance and temperature variation. If the rated braking power given at Table 4-1 is required the chosen resistor should not exceed the maximum resistance value including its tolerance and temperature variation.

(d) If the application does not require the full nominal power of the DB Unit, a braking resistor may be used which has a higher ohmic value (see 4.4 for notes on the calculation of braking power).

(e) =: this maximum resistor value is based on the use of two DB Units and braking resistors and is only applicable for the 30 seconds ON time duty cycle.



Table 4-1 Electrical Specification for DB Units used with MV3000e Drives

DB Unit Braking Resistor *

MV Model MV Frame Size

DB Type Number

Maximum DB

Operating Voltage (V)

Peak Power (kW) during

30 s ON time

Resistance (ohm)

Minimum Maximum

MV3058A4A1 3 GDB400-4603 734 33 4.4 16.33 MV3071A4A1 3 GDB400-4603 734 45 2.93 11.97 MV3086A4A1 4 GDB400-4603 734 55.5 3 9.70 MV3105A4A1 4 GDB400-4603 734 67.5 2 7.98 MV3140A4A1 4 GDB400-4603 734 82.5 1.98 6.53 MV3168A4A1 6 GDB400-4603 734 112.5 1.98 4.79 MV3204A4A1 6 GDB400-4603 734 135 1.98 3.99 MV3244A4A1 6 GDB400-4603 734 165 1.98 3.26 MV3292A4A1 6 GDB400-4603 734 198 1.98 2.72 MV3364A4A1 6 GDB400-4603 734 240 1.98 2.24 MV3449A4A1 7 GDB400-4603 734 300 1.98 3.58 = MV3503A4A1 7 GDB400-4603 734 375 1.98 2.88 = MV3566A4A1 7 GDB400-4603 734 375 1.98 2.88 = MV3052A5A1 3 GDB400-4603 848 33.6 5.94 21.39 MV3065A5A1 3 GDB400-4603 848 44.8 5.94 16.04 MV3077A5A1 4 GDB400-4603 848 56.0 4.05 12.83 MV3096A5A1 4 GDB400-4603 848 67.2 2.7 10.69 MV3124A5A1 4 GDB400-4603 848 84.0 2.7 8.55 MV3156A5A1 6 GDB400-4603 848 112.0 2.22 6.42 MV3180A5A1 6 GDB400-4603 848 140.0 2.22 5.13 MV3240A5A1 6 GDB400-4603 848 168.0 2.22 4.28 MV3302A5A1 6 GDB400-4603 848 224.1 2.22 3.21 MV3361A5A1 7 GDB400-4603 848 280.1 2.22 2.57 MV3414A5A1 7 GDB400-4603 848 336.1 2.22 4.28 = MV3477A5A1 7 GDB400-4603 848 392.1 2.22 3.66 = MV3071J5A1 3 GDB400-4603 734 45 3.96 11.97 MV3140J5A1 4 GDB400-4603 734 82.5 2.7 6.53 MV3364J5A1 6 GDB400-4603 734 240 2.22 2.24 MV3566J5A1 7 GDB400-4603 734 375 2.22 2.86 = MV3062A6A1 4 GDB400-4604 1052 56.0 5.04 19.75 MV3077A6A1 4 GDB400-4604 1052 67.2 5.04 16.46 MV3099A6A1 4 GDB400-4604 1052 84.0 4.44 13.17 MV3125A6A1 6 GDB400-4604 1052 112.0 3.36 9.87 MV3144A6A1 6 GDB400-4604 1052 140.0 2.96 7.90 MV3192A6A1 6 GDB400-4604 1052 168.0 2.96 6.58 MV3242A6A1 6 GDB400-4604 1052 224.1 2.96 4.94 MV3289A6A1 7 GDB400-4604 1052 280.1 2.96 3.95 MV3336A6A1 7 GDB400-4604 1052 336.1 2.96 3.29 MV3382A6A1 7 GDB400-4604 1052 392.1 2.96 5.64 = MV3099J6A1 4 GDB400-4604 1052 84.0 4.44 13.17 MV3242J6A1 6 GDB400-4604 1052 224.1 2.96 4.94 MV3382J6A1 7 GDB400-4604 1052 392.1 2.99 5.64 =



4.6 Power Connections

The power terminals must be connected as shown at Figure 4-4. Incorrect connection will result in permanent damage to the unit.

RES+

DissipationResistor

RES-

DC+DC-

From DC+ and DC- Terminals ofDELTA Module(s) or host drive

ALSPA GDB400HVDynamic Braking Unit

TB124V EN

21

Earth / Safety Ground

TB221

Healthy

Enable Input

To DriveInterlock Circuit

Fit DC FusesORConnectGDB400HVusing Cable ofsuitable ratingfor protectionby systemincoming fuses

These wires to bekept as close together

as possible to minimisenoise generation

24 VInterlock

MV3000 GD2000E GD3000E

TB3/10TB3/9

TB6/20TB6/13

TB3/7TB3/6

Figure 4-4 Power Connections

The terminal labelled, as shown at Figure 4-5, must be securely attached to earth (Safety Ground).

Figure 4-5 Protective Earth (ground) symbol to IEC 60417 (Symbol 5019)



The DC+ & DC- terminals should be connected directly to the DC+ & DC- terminals of the DELTA module(s) or host drive. They must be kept as close together as possible to minimise noise generation.

The RES+ & RES- terminals are connected to the dissipation resistor. They must be kept as close together as possible to minimise noise generation.

For the DB Unit input/output and earth (ground) cables to be protected by the connected drive's input fuses (see 2.3), these cables MUST be sized on the full rating of the drive. Otherwise these cables must be protected by d.c. fuses (see 2.3).

The cables for DC+ and DC- must not be more than 1 metre in length, and terminated at the GDB400HV using copper ring terminals with a torque setting of 15 Nm (130 lbf in).

4.7 Control Connections

The control connections and indications are on the 20X4245 control PCB illustrated at Figure 4-6.

Refer to Section 2.1 for the most appropriate TP7 settings.

4.8 Paralleling DB Units

In some applications it is necessary to use parallel operation of the DB Units to achieve the required resistance. Figure 4-7 shows a parallel arrangement in simplified form. In these applications it is most important to adhere to the following guidance:

(a) all DB Units must be of the same type;

(b) all DB Units must have the same voltage selection at the TP7 switch;

(c) each DB resistor must have the same value and this should be the maximum value that can be used to achieve the required braking power;

20X4245 Control PCB

D1 - HEALTHYTB2 - Healthy

1 2

TB1 - EnableIn

ter n

al 2

4 V

Logi

c S

uppl

yE

nabl

e I n

put

D7 - BRAKING

TP7-VOLTAGE SELECT

1 2

Contact Closedwhen Enabledand Healthy

Figure 4-6 Control Connections

Higher voltage

Lower voltage



(d) all resistors should be of the same type;

(e) fuse protection should be provided as shown in the typical circuit at Figure 4-7.

For ALSPA MV3000e applications Table 4-1 identifies those drives which would require a parallel arrangement of DB Units to dissipate the maximum power the drive would regenerate.

Enable Input

To Drive InterlockCircuit

Enable Input

ALSPA GDB400HVDB Unit

ALSPA GDB400HVDB Unit

Healthy Healthy

TB2 TB2TB1 TB1

DC- DC-DC+ DC+RES+ RES+

RES-RES-

Figure 4-7 Parallel Operation of DB Units – Fusing Arrangement



4.9 External Resistor Protection

Note: All braking resistors must be fitted with an over-temperature thermostat. The thermostat must be isolated from the DC link voltage, but for safety reasons the thermostat output should never be connected directly to the drive. It should always be connected indirectly, typically as shown in this section.

In the unlikely event of failure of the DB unit, it is possible for the braking resistor to be switched continuously across the DC link. Converteam therefore recommend that protection circuits should be included, such as those shown in Figures 4-8 or 4-9.

M

Drive System

LineContactor

FusedMainsInput

R

S

T

DB Resistor

U

V

W

RES+

Digital Input

3

ExternalSupply T1

Aux.

IsolationBarriers

DB Unit

DC+

DC-RES-

DC+

DC-

DC link

Figure 4-8 DB resistor protection by removing the supply from the drive

In Figure 4-8 protection is provided by thermostat T1. If the resistor temperature exceeds its maximum rated value, T1 operates to open the line contactor and remove the mains supply. An auxiliary contact is used to trip the drive via a digital input. In the case of MV3000e this input should be linked to control flag CF111 (parameter P23.09). The line contactor and thermostat T1 are fed by an external supply; the contacts of thermostats fitted to braking resistor assemblies should be rated up to 240 V rms at 10 A and are isolated from the resistor. The auxiliary contact of the contactor must be rated for double or re-enforced insulation to prevent dangerous voltages being transmitted to the drive control terminals. The contact must also be suitable for handling currents as low as 1.6 mA at 24 V d.c.

As shown in Figures 4-8 and 4-9, braking resistors must be fitted with isolation barriers to fully isolate the thermostat from the resistor. Ensure that the resistor temperature sensing device is isolated from the resistor using double or re-enforced insulation.

An alternative method of protection is shown in Figure 4-9. The external supply energises the DC rated contactor, which completes the circuit to the braking resistor. If the resistor overheats, the thermostat opens and the contactor breaks the resistor supply. The drive continues to operate but regenerative braking is no longer available and the drive will trip on overvolts if a rapid deceleration is performed.



Drive System

DC ratedContactor

FusedMainsInput

R

S

T

DB Resistor

U

V

W

ExternalSupply

M3

DigitalInput

IsolationBarriers

DB Unit

RES-

RES+

DC+

DC+

DC-

DC-

DC link

Figure 4-9 DB resistor protection by disconnection

For the method shown in Figure 4-9, if it is required to warn the drive when the DB resistor has been disconnected, one possible solution would be to use a contactor having a volts-free auxiliary contact and connect this to activate a drive digital input to flag a warning. Alternatively a lower rated thermostat could be used to warn of imminent disconnection. In either case, the contact connected to the digital input must be rated for double or re-inforced insulation to prevent dangerous voltages being transmitted to the drive control terminals. Control wiring must be segregated from power wiring as described in Section 5.2.7.4 and in the relevant drive user manual.




GDB400HV DB Units 5. Installation


5. Installation

WARNINGS • Wait at least 5 minutes after isolating supplies and check that voltage between

DC+ and DC- has reduced to a safe level before working on this equipment.

• This equipment may be connected to more than one live circuit. Disconnect all supplies before working on the equipment.

• Replace all shrouds and close all doors before energising the equipment.

• Items marked with weights greater than 20 kg should only be moved with lifting apparatus.

• Air used to cool the product is unfiltered. Air ejected from the product may contain foreign particles. Air outlets should deflect the air away from the eyes.

CAUTION

Ensure that all conductors connected to this equipment are mechanically restrained.

5.1 General Information

5.1.1 Receipt of Equipment on site

When the equipment arrives on site, unpack it carefully and inspect it for any sign of damage. Check the complete consignment against the delivery note for any loss in transit. If any damage or loss has occurred, contact the supplier immediately giving the following details:

- A list of damaged or missing items.

- A description of the damage.

- The order number and item number of the affected part.

- The delivery advice note number and date.

5.1.2 Identification of Unit

Details of the unit type, serial number, modification status and basic electrical information are given on the identification label fixed to the right hand side of the unit.

5.1.3 Storage

If equipment delivered to site is not to be installed immediately:

- Re-pack it in its original packaging material. If this is not possible it should be enclosed in polythene sheet to protect it from ingress of dust.

- Store it in a clean dry atmosphere, preferably at room temperature (The storage temperature limits are -25°C to +55°C).

5.1.4 Handling

Only lift a DB Unit with Lifting equipment by attachment at the M12 eyebolts.

5. Installation GDB400HV DB Units


5.1.5 Environment

To ensure trouble free operation with minimum maintenance, the installation site must fulfil the following requirements:

The atmosphere must be clean and dust free, in particular it must be free from corrosive vapours and conductive dusts.

The ambient temperature must be in the range 0°C to 50°C, with no rapid changes of temperature.

The Relative Humidity must be in the range 5% to 95% (non-condensing).

Measures must be taken to prevent the ingress of metallic swarf generated by process or maintenance activities.

5.2 Installation Details

5.2.1 Special Tools and Equipment

A torque wrench is required to correctly tighten the power connections. Lifting equipment is also required.

5.2.2 Acoustic Noise at Resistor

Acoustic noise is generated at the resistor as a consequence of the switching of the dynamic braking unit. The noise output and frequency depend on the duty cycle and the construction of the dissipation resistor.

5.2.3 Electromagnetic Compatibility (EMC)

Care should be taken that no radio frequency transmissions (e.g. from portable telephones) take place in the vicinity of the unit when the cubicle or enclosure door is open and the unit is powered up.

If there is a requirement to meet radiated noise emission limits, the dissipation resistor should be mounted in a (suitably ventilated) metal enclosure. Power cables between the two enclosures (i.e. resistor and GDB400HV unit) should be overall screened (shielded), with the screens bonded to both enclosures.

Further EMC guidelines are given in the appropriate ALSPA Drive User Manual.

5.2.4 Cooling and Ventilation

The DB Unit is cooled by two internal fans. It is essential that adequate clearance be maintained at all times to allow free flow of cooling air through the heatsink at the top and bottom of the unit. Minimum clearances for ventilation are shown at Figure 2-1.

5.2.5 Access

The GDB400HV Dynamic Braking unit must not be operated with the front panel or shrouds opened or removed.

5.2.6 Installing the Dynamic Braking Unit

The Dynamic Braking unit must be mounted inside a cubicle or enclosure.

- Mark out the fixing centres to the dimensions as shown at Figure 2-1.

- Drill 4 holes for the 6 mm fixing screws.

GDB400HV DB Units 5. Installation


- Insert the two top screws and partially tighten leaving 6 to 8 mm of the screw standing clear of the wall.

- Lift the dynamic braking unit, position the top two keyhole slots on the braking unit over the protruding screw heads and hang the unit on the two fixing screws.

- Insert the two lower 6 mm fixing screws and tighten. Tighten the top two 6 mm fixing screws.

5.2.7 Electrical Connections

WARNING The DC+, DC-, RES+ and RES- terminals on the power terminals carry dangerous d.c. voltage (1200 V).

Refer to the appropriate drive manual (see 1.5) for the location of electrical connections on the drive to which the DB Unit will be connected.

5.2.7.1 Earth Connections

The Dynamic Braking unit must be connected to earth (ground) with a cable which is the same size as the power cables, unless local safety regulations dictate that a larger size is used.

The safety earth (ground) cable must be connected to the terminal (plated steel M8 stud) on the unit using an insulated copper ring terminal and a torque setting of 15 Nm (130 lbf in).

5.2.7.2 DC Link Connections

Connect the input power connections to the DC+ and DC- terminals (plated steel M8 stud terminals). Ensure that the polarity of these connections is correct, as permanent damage to the unit (and associated motor controller) will occur if incorrectly connected.

The cables must be terminated at the GDB400HV using copper ring terminals and a torque setting of 15 Nm (130 lbf in).

5.2.7.3 Connecting the Dissipation Resistor

The resistor should be connected between RES+ and RES- (plated steel M8 stud terminals). The polarity of the connection to the resistor is not important, current will flow from RES+ to RES-.

The wire used must be suitable to withstand the conducted heat from the resistor.

The cables must be terminated at the GDB400HV using copper ring terminals, and a torque setting of 15 Nm (130 lbf in).

5.2.7.4 Segregation

Control connections are generally low voltage and low current signals. This makes them inherently susceptible to interference from magnetic noise generated by power cabling. Therefore, in any application, the control wiring should not be run directly alongside power wiring.

Ideally, separate trunking should be used to run control wires, though if this is not possible a separation of at least 300 mm should be maintained between the control wires and any power cables.

5. Installation GDB400HV DB Units


5.2.7.5 Interlock ‘Healthy Signal’

It is recommended that the user connects the interlocking circuit for the ‘Healthy Signal’ – refer to Figure 4-4 for an example of connection into a drive circuit.

GDB400HV DB Units 6. Commissioning


6. Commissioning

WARNINGS • Wait at least 5 minutes after isolating supplies and check that voltage between

DC+ and DC- has reduced to a safe level before working on this equipment.

• Replace all shrouds and close all doors before energising the equipment.

• This equipment may be connected to more than one live circuit. Disconnect all supplies before working on the equipment.

• Do not use mobile phones or walkie talkies within 2 metres (6 feet) of the equipment.

• Surfaces on braking resistors can reach high temperatures.

• The combined audible noise emitted by fans in an installation can be greater than 70 dB(A), dependent on the air flow path. Measure the audible noise level in the installation.

When the audible noise level exceeds 70 dB(A), appropriate warning notices should be displayed.

CAUTIONS • High voltage insulation tests can damage this equipment. Cables/external

components to be insulation tested must be disconnected from this equipment.

• Ensure that all conductors connected to this product are mechanically restrained.

6.1 Mechanical Checks

Check that:

- The unit has been installed in accordance with the instructions given at Section 5.

- The unit is set for the appropriate DC braking voltage (refer to Table 2-1 and Section 4.7)

- There is adequate clearance around the unit for ventilation, and that the ventilation grills are not covered or blocked.

6.2 Input Power Connections CAUTIONS

• Connecting the input DC supply with incorrect polarity will result in permanent damage to the unit or connected drive.

• Connecting the Dynamic Braking unit into a drive system employing an AC supply or DC link system of higher voltage than that for which the unit has been configured by adjustment of jumper link TP7 will result in serious damage to the associated motor controller and the dissipation resistor.

(a) Ensure the drive is commissioned before connecting the dynamic braking unit.

Check that the input supply voltage to the unit is within the range specified in the technical specification (see Section 2).

6. Commissioning GDB400HV DB Units


(b) Connect the dynamic braking unit and its dissipation resistor.

- Ensure that the cabling to the unit is adequate for the duty.

- Ensure that the unit is correctly earthed.

- Ensure that the connected dissipation resistor is within the range detailed in the technical specification (see Section 2).

(c) Apply power to the drive.

- Check that current does not flow in the output cables.

(d) Enable the unit.

- Check that the dynamic braking unit is enabled and healthy by either checking for a healthy signal from TB2, or that the green healthy led (D1) on the control board is on.

- Check that current does not flow in the output cables.

(f) If fitted to an ALSPA MV3000e Drive:

- Refer to 6.3 before running the drive.

(e) If fitted to an ALSPA GD2000/GD2000E or GD3000/3000E Drive:

- Refer to 6.4 before running the drive.

(h) Run the drive.

- Check that on motor deceleration, the unit switches on / off when the requested deceleration rate is significantly greater than the normal free-wheel deceleration rate of the motor.

After commissioning the drive system, check that the duty cycle of the dynamic braking unit is within the limits detailed in the technical specification at Section 2.

6.3 ALSPA MV3000e Drive Parameters

ALSPA MV3000e Drive parameters must be configured to allow correct operation of the DB Unit with a drive. Access to menus and parameters is described in the ALSPA MV3000e Getting Started Manual T1676, and the drive is set up using a Keypad, or using a suitable PC and appropriate software such as ALSPA Drive Coach.

The values to be entered for these parameters allow the drive to safely operate with the dynamic brake and associated braking resistor.

Note: Set P1.31 to 2 to open the extended menus.

Parameter 23.20 – Non-MV DB Fitted

This parameter defines whether an external DB Unit is fitted to the ALSPA MV3000e Drive. The value 1 or 0 can be entered into this parameter.

Set P23.20 to 1 (i.e. an external DB Unit is connected to the drive).

GDB400HV DB Units 6. Commissioning


Parameter 23.05 – Motor Regeneration Power Limit

This defines the maximum power that the drive will regenerate from the load. It is entered in kW and is used in the case when the Dynamic Braking Unit connected to the drive has a peak power dissipation less than the drive’s peak regeneration power.

Allowed values for P23.05 are in the range:

-0.1 kW to 3000.0 kW

-0.1 means NO LIMIT; the energy is to be absorbed by the DB Unit.

6.4 ALSPA GD2000/GD2000E/GD3000/GD3000E Drive Parameters

ALSPA GD2000/GD2000E/GD3000/GD3000E Drive parameters must be configured to allow correct operation of the DB Unit with a drive. Access to menus and parameters is described in the product manuals (see 1.5 for details). A drive is set up using any of the following methods:

(a) pushbutton controls and LED display on the product front panel;

(b) an enhanced programming unit;

(c) a suitable PC and appropriate software such as ALSPA Drive Coach (a PLC may also be used).

The values to be entered for these parameters allow the drive to safely operate with the dynamic brake and associated braking resistor.

If fitted to an ALSPA GD2000 or GD2000E:

- Ensure that Parameter 122 on the drive is set to 1.

1 = Dynamic braking unit fitted.

If fitted to an ALSPA GD3000 or GD3000E:

- Ensure that the Regeneration Power Limit parameter P4.12 is set to the peak rating of the dissipation resistor.

- Allowed values for P4.12 are in the range:

-0.1 = No Limit

0.0 to 3000.0 kW

6. Commissioning GDB400HV DB Units


6.5 Diagnostics

If any problems occur during commissioning check for the following:

(a) If the DB Unit indicates that it is unhealthy (TB2: 1 and 2 open circuit) check for:

- ENABLE made i.e. TB1: pins 1 and 2 shorted together;

OR

- 24 V applied between TB1 pin 2 and the DB Unit ground;

(b) If the FAN is not running or Power Supply Unit (PSU) LED is OFF check:

- that the DC+ or DC- voltage is 440 V d.c.

GDB400HV DB Units 7. Maintenance


7. Maintenance

WARNINGS

• Wait at least 5 minutes after isolating supplies and check that voltage between DC+ and DC- has reduced to a safe level before working on this equipment.

• Do not use mobile phones or walkie talkies within 2 metres (6 feet) of the equipment.

7.1 Preventive Maintenance

The ALSPA GDB400HV Dynamic Braking Unit has minimum maintenance requirements. The simple maintenance routines which follow should ensure that the unit performs reliably for many years.

7.1.1 Special Tools & Equipment

No special tools are required for the maintenance of the 400 A Dynamic Braking Unit.

7.1.2 Maintenance Schedules

7.1.2.1 Monthly Check

The following checks should be carried out at monthly intervals:

Ensure all ventilation apertures are unobstructed and heatsink tines are not clogged (e.g. by dust/fluff).

Examine the input and output power terminations for signs of overheating.

7.1.2.2 Six Monthly Check

Perform monthly checks as detailed above.

Check all terminations are secure.

Remove any accumulated dust from the equipment, using a suction type cleaner with a non-conducting nozzle.

7.2 Component Replacement

There are no user-maintainable components within the unit. If it is suspected to be faulty, please contact your local authorised Converteam dealer.

7.3 Fault-Finding

7.3.1 Fault Indication

When a fault condition arises this is indicated by the healthy LED (D1) being extinguished on the control board and the healthy relay switching open. This condition is also caused by opening of the Enable/Reset input (if any).

7. Maintenance GDB400HV DB Units


7.3.2 Trip Resetting

As long as the fault has cleared the unit may be reset by momentarily opening, then closing an Enable/Reset input.

7.4 Ordering Information

If a new DB Unit is required refer to the Ordering Codes (e.g. GDB400-4601) included at Table 2-1. Contact your nearest Converteam Sales Office at the telephone number/address shown at the end of this manual.

GDB400HV DB Units 8. Disposal


8. Disposal This equipment or any part of the equipment should be disposed of in accordance with the laws of the country of use. Modern high technology materials have been used in the manufacture of the equipment to ensure optimum performance. Care has been taken with the selection of these materials to minimise risks to health and safety. However, some materials require special consideration during disposal. In common with all products of this type, the high voltage electrolytic capacitors contain an electrolyte which must be disposed of as hazardous waste. The electrolytes are solutions of organic and /or boric acid. The major solvents in the capacitors are butyrolactone and ethylene glycol. The electrolyte is non-carcinogenic, but may cause irritation to the skin if contact is prolonged.

8. Disposal GDB400HV DB Units



Converteam France 9, rue Ampère 91345 Massy Cedex Sales Tel: +33 (0) 8 25 02 11 02 Support Tel (International): +33 (0) 3 84 55 33 33 Support Tel. (National): 08 25 02 11 02 Germany Culemeyerstraße 1 D-12277 Berlin Sales Tel: +49 (0) 30 74 96 27 27 Support Tel (International): +49 (0) 69 66 99 831 Support Tel (National): 01 80 3 23 45 72 UK Boughton Road, Rugby Warwickshire, CV21 1BU Sales Tel: +44 (0) 1788 563625 Support Tel: +44 (0) 1788 547490 USA 610 Epsilon Drive Pittsburgh, PA 15238 Sales Tel: +1 412 967 0765 Support Tel: +1 800 800 5290

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MV3000e A.C. DRIVESPrice List 2006

Converteam Ltd

West Avenue, Kidsgrove

Stoke-on-Trent, ST7 1TW (UK)

Tel: +44(0)1782 781000

Fax: +44(0)1782 781001

a Converteam Group company www.converteam.com

Documents

DBU Technical & Installation