Dynamic Braking Unit

Installation & Operating Manual

5/07

Installation & Operating Manual

MN763DB

Any trademarks used in this manual are the property of their respective owners.

Table of Contents
Dynamic Braking Unit Installation & Operating Manual
1.1 Getting Assistance from Baldor .......................................................................... 1
1.2 Safety Notice ...................................................................................................... 1
1.3 Introduction to Dynamic Braking Unit ................................................................. 3
1.4 Nomenclature ..................................................................................................... 5
1.5 Specifications ..................................................................................................... 5
1.6 Installation .......................................................................................................... 6
1.7 Terminal Configuration ....................................................................................... 8
1.8 Terminal Wiring .................................................................................................. 8
1.9 Basic Wiring........................................................................................................ 9
1.10 Master / Slave Operation .................................................................................. 10
1.11 Combination of DB Units Corresponding to Drive Capacity ............................. 12
1.12 Display LED and Fault Reset ........................................................................... 15
1.13 Dimensions ....................................................................................................... 16

Contents

II

Dynamic Braking Unit Installation & Operating Manual

DYNAMIC BRAKING UNIT

Installation & Operating Manual
1.1

Getting Assistance from Baldor

For technical assistance, call your local Baldor District Sales Office. Before calling,
please review the troubleshooting section of this manual and check the Baldor Drives
website at http://vsdrives.baldor.com for additional information. When you call
technical support, you will be asked for the drive model number or catalog number
and this instruction manual number.

1.2

Safety Notice
This equipment contains voltages that my be as high as 1000 volts! Electrical shock
can cause serious or fatal injury. Only qualified personnel should attempt the start-up
procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts
that are driven by this equipment. Improper use can cause serious or fatal injury. Only
qualified personnel should attempt the startup procedure or troubleshoot this
equipment.
Precautions: Classifications of cautionary statements

WARNING: Indicates a potentially hazardous situation which, if not

avoided, could result in injury or death.

!! CAUTION: Indicates a potentially hazardous situation which, if not

avoided, could result in damage to property.
!
Precautions
!

!
!

WARNING: This manual is intended as a guide for proper installation.

Baldor Electric Company cannot assume responsibility for the compliance
or the noncompliance to any code, national, local or otherwise, for the
proper installation of this drive or associated equipment. A hazard of
personal injury and/or equipment exists if codes are ignored during
installation.
WARNING: Only qualified electrical personnel familiar with the
construction and operation of this equipment and the hazards involved
should install, adjust, operate, or service this equipment. Read and
understand this manual and other applicable manuals in their entirety
before proceeding. Failure to observe this precaution could result in severe
bodily injury or loss of life.

!
!

!
!

!
!

!
!

WARNING: Be sure that you are completely familiar with the safe
operation of this equipment. This equipment may be connected to other
machines that have rotating parts or parts that are controlled by this
equipment. Improper use can cause serious or fatal injury. Only qualified
personnel should attempt the start-up procedure or troubleshoot this
equipment.
WARNING: Do not use motor overload relays with an automatic reset
feature. These are dangerous since the process may injure someone if a
sudden or unexpected automatic restart occurs. If manual reset relays are
not available, disable the automatic restart feature using external control
wiring.
WARNING: Be sure the system is properly grounded before applying
power. Do not apply AC power before you ensure that all grounding
instructions have been followed. Electrical shock can cause serious or fatal
injury.
WARNING: Do not remove cover for at least ten (10) minutes after AC
power is disconnected to allow capacitors to discharge. Dangerous
voltages are present inside the equipment. Electrical shock can cause
serious or fatal injury.

WARNING: Motor circuit may have high voltage present whenever AC

power is applied, even when motor is not rotating. Electrical shock can
cause serious or fatal injury.

WARNING: Dynamic brake resistors may generate enough heat to ignite

combustible materials. Keep all combustible materials and flammable
vapors away from brake resistors.

WARNING: Make sure the input power is off before wiring. Failure to
observe this prediction could result in bodily injury.

!
!
!
!

!
!

WARNING: Do not touch any circuit board, power device or electrical

connection before you first ensure that power has been disconnected and
there is no high voltage present from this equipment or other equipment to
which it is connected. Electrical shock can cause serious or fatal injury.
Only qualified personnel should attempt the start-up procedure or
troubleshoot this equipment.

WARNING: You must provide an external, hardwired emergency stop

circuit outside of the drive circuitry. This circuit must disable the system in
case of improper operation. Uncontrolled machine operation can result if
this procedure is not followed. Failure to observe this precaution could result
in bodily injury.
WARNING: This unit is connected to a drive that contains high voltage
capacitors that take time to discharge after removal of main supply. Before
working on the unit, ensure isolation of main supply from line inputs. Wait
ten (10) minutes for capacitors to discharge to safe voltage levels. Failure
to observe this precaution could result in severe bodily injury or loss of life.

Dynamic Braking Unit

WARNING: DC Bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input power, wait ten
(10) minutes for the DC Bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this precaution
could result in severe bodily injury or loss of life.

WARNING: Be sure to remove the drive power input while performing

maintenance. Failure to observe this precaution could result in severe
bodily injury or loss of life.

!
!

!
!

CAUTION: The user is responsible for conforming with all applicable

local, national, and international codes. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.

CAUTION: Apply the rated torque to terminal screws. Loose screws can
cause short circuit and malfunction. Tightening the screws too much can
damage the terminals and cause short circuit and malfunction.

CAUTION: Do not leave wire fragments inside the unit. Wire fragments
can cause faults, breakdowns and malfunctions.

!
!
!
1.3

WARNING: Be sure to perform maintenance only after checking that the

bus has discharged to less than 30 VDC. The bus capacitors may retain a
charge after power is turned off. Failure to observe this precaution could
result in severe bodily injury or loss of life.

Introduction to Dynamic Braking Unit

This section describes the safety instructions that must be followed when installing,
operating, and servicing the Dynamic Braking Unit (DBU). Read this manual
completely before installing. The unit contains high voltage that can cause electric
shock resulting in personal injury or loss of life.

!
!
!
!

!
!

!
3

WARNING: Do not remove the cover of the unit while power is applied
or the unit is in operation; otherwise electric shock could occur.
WARNING: Do not run the Dynamic Braking Unit (DBU) with the front
cover removed. Failure to comply could result in electric shock due to high
voltage terminals or charged capacitor exposure.
WARNING: Do not remove the cover except for periodic inspections or
wiring, even if the input power is is not applied; otherwise, you may contact
live parts causing an electric shock.
WARNING: Wiring and periodic inspections should be performed at least
10 minutes after disconnecting the input power and after checking the DC
link voltage is discharged with a meter (below DC 30V); otherwise, you may
get an electric shock.

!
!
!
!
!

WARNING: Do not use wire or cable with damaged insulation; otherwise,

you may get an electric shock.
WARNING: Do not subject wires and cables to scratches, excessive
stress, heavy loads or pinching; otherwise, you may get an electric shock.

CAUTION: Install the DB unit on a non-flammable surface. Do not place

flammable material nearby; otherwise; fire could occur.

CAUTION: Disconnect the input power if the inverter or DB unit gets

damaged; otherwise, the result could be a secondary accident and fire.

CAUTION: Do not connect the braking resistor directly to the DC terminal

(P/B1, N) of the DB unit; otherwise, fire could occur.

CAUTION: Do not touch DB unit, Inverter and the resistor right after the
power is disconnected. The resistor may still be hot.

CAUTION: Do not allow lint, paper, wood chips, dust, metallic chips or
other foreign matter into the DB unit; otherwise, fire or accident could occur.

CAUTION: Do not apply power to a damaged inverter or to DB unit with

missing parts even if the installation is complete; otherwise, electric shock
or fire could occur.

!
!
!
!
!
!

WARNING: Operate the switches with dry hands; otherwise, you may get
an electric shock.

Dynamic Braking Unit

1.4

Nomenclature

VS1PF - T 4 20

HP Range
20
10 ~ 20HP
30
25 ~ 30HP
50
40 ~ 50HP
75
60 ~ 75HP
100
100HP
Drive Input Voltage
2
200 ~ 230V
4
400 ~ 460V
Product Type
Dynamic
Braking
T
Transistor
Unit
Product Family
VS1PF Family

1.5

Specifications

1.5.1 200V Class

Model
Spec.
Max. DC Input Voltage
Applicable Drive
Capacity [HP]
Wattage
Braking
Minimum
Resistor
Resistance

VS1PF-T220

VS1PF-T230

VS1PF-T250

VS1PF-T275

DC 400V
10 ~ 20

25 ~ 30

40 ~ 50

60 ~ 75

3.2 [KW]

4.8 [KW]

6.4 [KW]

9.6 [KW]

8.5 []

5.7 []

4.2 []

2.8 []

1.5.2 400V Class

Model
VS1PF-T420

Spec.
Max. DC Input Voltage
Applicable Drive
Capacity [HP]
Wattage
Braking
Minimum
Resistor
Resistance

VS1PF-T430

VS1PF-T450

VS1PF-T475

VS1PF-T4100

DC 800V
10 - 20

25 -30

40 - 50

60 - 75

100

3.2 [KW]

4.8 [KW]

6.4 [KW]

9.6 [KW]

12.8 [KW]

33.9 []

22.8 []

16.9 []

11.4 []

8.4 []

1.5.3 General Specifications

Average Braking Torque
Maximum Duty Cycle
Parallel Connection
Maximum On Time
Output Signal
Protection

Ambient
Temperature
Humidity
Environmental Maximum
Conditions
Altitude
Cooling
Method
Location

1.6

100%
10%
Connectable up to 3 units in parallel
6 seconds
Heat Sink Overheat, Fuse Open, OC
Trip
Heat Sink Overheat Protection, OverCurrent Protection, Output Short
Circuit Protection
-10C ~ 40C
Less Than 90 % RH Max. (NonCondensing)
1,000m above sea level
Natural Convection
No Corrosive Gas, Combustible Gas,
Oil mist or Dust

Installation

1.6.1 Environmental Conditions

1.6.1.1 Do not mount the unit in direct sunlight. Isolate the unit from excessive
vibration.
1.6.1.2 Protect from moisture, dust, metallic particles, corrosive gases and liquid.
Install the units on a smooth non-flammable surface.
1.6.1.3 When installing multiple units in a panel, panel layout and cooling requirements
must be analysed for proper heat dissapation.
See the following examples to aid in panel and cooling design.
6

Dynamic Braking Unit

DB Unit or
DB Resistor
DB Unit or
DB Resistor

DB Unit or
DB Resistor

Correct

Incorrect

Installing units in a panel

Cooling
fan

DB Unit or
DB Resistor
DB Unit or
DB Resistor

DB Unit or
DB Resistor
DB Unit or
DB Resistor

Air flow

Correct

Incorrect

Fan location in a panel

1.6.2 Mounting
The units must be mounted vertically with sufficient clearance (horizontally and
vertically) to adjacent equipment.

over 4

DBU
over 2

over 2

Over 4

1.7

Terminal Configuration

1.7.1 Power Terminals

Terminal
P

%

%

Description
DC (+) input. Connect to P2 or P terminal of the drive

DC (-) input. Connect to N terminal of the drive

Ground Terminal

B1

Connect to braking resistor

B2

Connect to braking resistor

1.7.2 Control Terminals

,1

,1

287 287

Terminal

%

&

$

Function

IN+

Slave turn on signal input (when Slave Mode selected)

IN-

Slave turn on signal input (when Slave Mode selected)

OUT+

Slave turn on signal output (when Master Mode selected)

OUT-

Slave turn on signal output (when Master Mode selected)

Fault signal output

30A

30A : Normal open contact

30B : Normal close contact
30C : Common terminal

1.8

Terminal Wiring
VS1PF drives are supplied with two different power terminal configurations based
upon the HP rating and whether or not the drive has a built-in DC reactor. Make sure
the connections are made according to the proper configuration.

Dynamic Braking Unit

1.8.1 Wiring Drive, DB unit and DB resistor

DB Unit

3

1

* % %

Common bus bar

Drive

3
%

%

3

1
DB Resistor

1.8.2 Wiring Drive, DB unit, DB resistor and DC reactor

DB Unit

3 1 * % %
Drive

'&5HDFWRU

3
3
1

% %
DB Resistor

1.9

Basic Wiring

1.9.1 Single Unit Operation

MCCB
AC
Input
Power

Drive
R

Twisted pair
M

Motor

W
Twisted pair
P1

B1

P2

B2

N

B2

B1

30A

30B

30C

15 max.
G

15 max.

DB Unit

TH1
TH2
DB Resistor

Mount DB unit within 15 of the drive and the DB resistor within 15 of the DB unit.
Make connections with twisted pair wire.

Be sure to connect the G terminal of both the drive and DB unit to ground.

 Wire Size: Use copper conductors only

230V

460V

DB Unit
VS1PF-T220
VS1PF-T230
VS1PF-T250
VS1PF-T275
VS1PF-T420
VS1PF-T430
VS1PF-T450
VS1PF-T475
VS1PF-T4100

Wire Size AWG [mm2]

10 [5.5]
8 [8.0]
6 [14.0]
6 [14.0]
10 [5.5]
10 [5.5]
10 [5.5]
8 [8.0]
6 [14.0]

1.10 Master / Slave Operation

When the application requires the parallel operation of two braking units, one unit
must be set up as a Master and the other as a Slave. Note that when the
application is for a single braking unit, it must be set up as a Master, which is the
factory default.

1.10.1 Master Setup

Set the Switch JP1 per the figure below.
6/$9(

0$67(5

1.10.2 Slave Setup

Set the Switch JP1 per the figure below.
6/$9(

0$67(5

1.10.3 Connection between Master and Slave

Set one DB unit to Master and the other to Slave.
Connect OUT+ terminal of Master to IN+ terminal of Slave and OUT- terminal of
Master to IN- terminal of Slave.

1.10.4 Connecting 3 DB Units

Set one DB unit to Master and other two units to Slave.

10

Dynamic Braking Unit

 Connect OUT+ terminal of Master to IN+ terminal of both Slaves and OUT-
terminal of Master to IN- terminal of both Slaves.
3.2 feet (1m)
max. (Twist)

MASTER

-

OUT-

OUT-

OUT+

OUT+

IN -

IN -

IN+

IN+

3.28 feet (1m)

max. (Twist)

SLAVE 
J13

OUTOUT+
IN IN+

11

SLAVE
J13

1.10.5 Master/Slave Operation

'ULYH

MCCB
R

AC
Input
Power

IM

Motor

P1

B1

P2

B2

1 

OUT

1
*

16.4 feet
(5M)
max.

B2

B1
TH1

OUT

TH2

MASTER DB

DB Resistor
6.56 feet (2M) max.
16.4 feet (5M) max.

B1

B2

IN+

IN-

B2

B1
TH1
TH2

G
DB Resistor

SLAVE DB Unit

1.11 Combination of DB Units Corresponding to Drive

Capacity
1.11.1 Combination of Braking Units
200V Class
Applicable
Drive [HP]

10 - 20

25 - 30

Braking Unit

VS1PF-T220

VS1PFT-T230

VS1PF-T250

VS1PF-T275

Braking
Resistor

3.2KW 8.5

4.8KW 5.7

6.4KW 4.2

9.6KW 2.8

15

25

40

60

Applicable
Motor [KW]

20

30

40 - 50

60 -75

50

75

400V Class
Applicable
Drive [HP]

20

25

30

40

50

Braking Unit

VS1PF-T420

VS1PF-T430

Braking
Resistor

3.2KW 33.9

4.8KW 22.8

6.4KW 16.9

15

25

40

Applicable
Motor [KW]

12

15

20

30

VS1PF-T450

50

Dynamic Braking Unit

Applicable
Drive [HP]

75

100

125 - 200

300

Braking
Unit

VS1PF-T475

VS1PF-T4100

VS1PF-T4100
Qty.2

VS1PF-T4100
Qty. 3

Braking
Resistor

9.6KW 11.4

12.8KW 8.4

12.8KW 8.4
Qty. 2

12.8KW 8.4
Qty. 3

100

125 - 200

300

Applicable
Motor [KW]

13

60

60

75

1.11.2 Application Example: Combination of 200V Class Units

1.11.3 Application Example: Combination of 400V Class Units

14

Dynamic Braking Unit

1.12 Display LED and Fault Reset

The DB Unit has five LEDs on the front cover. The green LEDs display braking
operation. The red LEDs display main power input and fault status of the unit.
Display
POWER
(RED)

This LED is on when the input power of the unit is present.

RUN
(GREEN)

This LED is on when the unit is braking.

OHT
(RED)

This LED is on and the unit disabled when the heat sink of the
unit is over heated

OCT
(RED)

This LED is on when excessive current flows through the IGBT

and the unit disables the output to protect the unit.

FOT (RED)

15

Function

The LED is on when the internal protective fuse is open.

1.13 Dimensions

Dynamic Braking Unit

WIRING
R

S
T (P2)
P N

V
W

IM
B2
B1
G
N
P

16

Dynamic Braking Unit

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FAX: 81-45-412-4507
KOREA
ROOM 208-37
INCHEON INDUSTRIAL GOODS
CIRCULATING CENTER
SONGHYEON 3-DONG, DONG-GU
INCHEON. KOREA, 401-705
PHONE: (82) 32 588 3253
FAX: (82) 32 588 3254
MXICO
KM. 2.0 BLVD. AL AEROPUERTO
LEN 37545, GUANAJUATO,
MXICO
PHONE: 52 477 761 2030
FAX: 52 477 761 2010
MIDDLE EAST & NORTH AFRICA
VSE INTERNATIONAL CORP.
3233 NORTH ARLINGTON HEIGHTS
SUITE 100W
ARLINGTON HEIGHTS, IL 60004
PHONE: 847 590 5547
FAX: 847 590 5587
SINGAPORE
51 KAKI BUKIT ROAD
2 KB WAREHOUSE COMPLEX
SINGAPORE 417863
PHONE: (65) 6744 2572
FAX: (65) 6747 1708
SWITZERLAND
POSTFACH 73
SCHUTZENSTRASSE 59
CH-8245 FEUERTHALEN
SWITZERLAND
PHONE: +41 52 647 4700
FAX: +41 52 659 2394
TAIWAN
1F, NO 126 WENSHAN 3RD STREET,
NANTUN DISTRICT,
TAICHUNG CITY 408
TAIWAN R.O.C
PHONE: (886) 4 238 04235
FAX: (886) 4 238 04463
UNITED KINGDOM
6 BRISTOL DISTRIBUTION PARK
HAWKLEY DRIVE
BRISTOL BS32 0BF U.K.
PHONE: +44 1454 850000
FAX: +44 1454 859001

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