Shangchin Electronics Corp. TOPGIN GENERAL-PURPOSE

INVERTER WITH FLUXVECTOR CONTROL

TG 300 220V 0.75 ~ 75KWTG 600 440V 2.2 ~ 300KW

BRAKING UNIT

THIS INSTRUCTION MANUAL WILL BE OF GREAT HELP FOR DAILY MAINTENANCE, INSPECTION AND TROBLE-SHOOTING.

265, SEC. 3, CHANG MEI ROAD, HO MEI ZHENCHANG-HUA HSIEN, TAIWAN, R.O.C.TEL : 886-4-7564838 FAX : 886-4-7565521E-MAIL: topgin@topgin.com.twhttp:// www.topgin.com.tw

INSTRUCTION MANUAL

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Before using the braking unit, a thorough understanding of this manual recommended for daily maintenance, troubleshooting and inspection.

CONTENTS

1 RECEIVING -------------------------------------------------------- 2

2 STORAGE---------------------------------------------------------- 2

3 INSTALLATION--------------------------------------------------- 3

4 WIRING------------------------------------------------------------- 44.1 PART NAMES ------------------------------------------------ 44.2 CIRICUITS AND WIRING ----------------------------------44.3 WIRING PRECAUTIONS ---------------------------------- 54.4 WIRING DIAGRAM ----------------------------------------- 6

5 OPERATION ------------------------------------------------------- 75.1 ADJUSTMENT ------------------------------------------------ 75.2 INPUT VOLTAGE SETTING ------------------------------ 75.3 MASTER / SLAVE SETTING ------------------------------ 75.4 PARALLEL USAGE OF BRAKING UNITS ----------- 85.5 OPERATION --------------------------------------------------- 8

6 TROUBLE-SHOOTING ----------------------------------------- 9

7 BRAKING UNIT APPLICATION LIST --------------------- 10

8 SEPARATELY-INSTALLED TYPE BRAKING RESISTOR ---------11

9 SPECIFICATIONS -------------------------------------------------12

10 MODEL DESCRIPTION ---------------------------------------- 12

1 -

1 RECEIVING

The braking unit has been put through demanding tests at the factory beforeshipment. If any problems (see below) are found after unpacking, please contact TOPGIN'S representatives. ( 1 ) The nameplate does not meet your demands (Please refer to page 12);( 2 ) Transit damage

Besides, please tighten the loose screws.

2 STORAGE

The braking unit must be stored at places where the following conditions are met :( 1 ) Protected from rain;( 2 ) Free from airborne dust and metallic particles;( 3 ) Free from corrosive gases or liquids;( 4 ) Keep clean and dry;( 5 ) Ambient temperature : -10 ~ +40;( 6 ) Free from vibration.

CAUTION

1No withstand voltage tests to the braking units2No unnecessary adjustments to the calibration resistor (RVI)3Ground the grounding terminal " E " 4Be sure to close the cover when the braking unit is applied internally to high voltage. Once the cover is open, please turn off the inverter main circuit power supply and check the "CHARGE" LED has been extinguished. 5Make sure the power has been turned off before changing the INPUT VOLTAGE SELECTOR (CP1) or MASTER / SLAVE SELECTOR (CP2)

2 -

3 INSTALLATION

Location of the braking unit is important to achieve proper performance. Please install the braking unit to comply with the requirements below. Fig. 1shows the size of braking unit and mounting space needed.

1Provide the mounting space shown in Fig. 1.2Devices sensitive to heat should be kept away from the braking resistor generating heat. 3The braking unit must be installed at places meeting the requirements in Par. 2 STORAGE.4Install the braking unit in the direction shown in Fig. 1 to avoid ventilation problems.

Fig. 1 Braking Unit Dimensions in mm

3 -

4 WIRING4.1 PART NAMES

Fig. 2

4.2 CIRCUITS AND WIRING

TABLE 1

Circuit Terminal Wire Size AWG (m) Wire Type Screw

Main Circuit N P Po DB 12 - 10 ( 3.5 - 5.5 )600V Vinyl

Sheathed leador equivalentControl Circuit 1 2 3

4 5 6 18 - 14 ( 0.75 - 2 )M 4

4 -

MASTER /SLAVE

CHARGELED

INPUTVOLTAGESELECTOR

CALIBRATIONRESISTOR

BRAKE LED

GROUNDING TERMINAL

4.3 WIRING PRECAUTIONS

4.3.1 RUBBER BUSHLead in the wire through the rubber bush on the bottom of the braking unitto get better insulation.

4.3.2 SEPARATION FROM SIGNAL LINESSeparating the braking unit and braking resistor from signal lines can reduce the noise interference to signal lines.

4.3.3 WIRING DISTANCEConnect the braking resistor, braking unit and inverter to comply with the requirement shown in Fig. 3.

TG600L200 TGL 400

BR

Max 10M Max 5M

INVERTER BRAKING UNIT BRAKING RESISTOR UNIT

Fig. 3 Wiring Distance

4.3.4 GROUNDING 1Mount the braking resistor on a grounded metallic plate or pull out the lead wire from the mounting screw to ground. 2Ground the grounding terminal of braking unit with class 3 ground (ground resistance is 100 or less.3Select the grounding wire to comply with the "INTERNAL CONNECTION SPECIFICATIONS".

5 -

4.4 WIRING DIAGRAM

Fig. 4 shows the interconnection between the braking unit, braking resistorand TG600.

Fig. 4 Wiring Diagram

6 -

N

BrakingResistorUnit

BrakingUnit

AC 250V below 1ADC30V below 1A

49

5OPERATION5.1 ADJUSTMENT

Except for the cases described in Sec. 5.2 INPUT VOLTAGE SETTING and Sec. 5.3MASTER / SLAVE SETTING, no adjustment is necessary for the braking unit.

5.2 INPUT VOLTAGE SETTINGPlease set the CP1 (INPUT VOLTAGE SELECTOR, see Fig. 5) according to the power supply voltage for inverter. The relationship between the input voltageand braking start voltage is shown in Table 2. The factory setting of CP1 is:220V for 220V class and 440V for 440V class.

220V Class 440V Class

230V 460V 220V 440V 208V 415V 200V 400V

380V

Fig. 5 Input Voltage Selector CP1

TABLE 2Input Voltage 220V Class 230V 220V 208V 200V --------

* Braking Start Voltage 380V(TYP) 365V(TYP) 5V(TY 330V(TYP) --------

Input Voltage 440V Class 460V 440V 415V 400V 380V* Braking Start Voltage 760V(TYP) 730V(TYP) 0V(TY 660V(TYP) 630V(TYP)

*Allowable voltage fluctuation is 10%

5.3 MASTER / SLAVE SETTING The factory setting for CP2 (MASTER / SLAVE SELECTOR) is on MASTER side. Only when more than one braking unit is used and the braking start voltage must coinside , CP2 has to be set on SLAVE side. Refer to Sec. 5.4 PARALLEL USAGE OF BRAKING UNITS for details.

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MASTER /SLAVE

CHARGELED

INPUTVOLTAGESELECTOR

CALIBRATIONRESISTOR

BRAKE LED

GROUNDING TERMINAL

5.4 PARALLEL USAGE OF BRAKING UNITS

For parallel using more than one braking unit, please check the following conditions (see Fig. 6)

1Check the CP2 (MASTER / SLAVE SELECTOR) on each braking unit pcb (see Fig. 2). Only the CP2 of braking unit 1 is set on MASTER side and others are set on SLAVE side for braking units 2 and 3.2Refer to Fig. 4 for proper wiring.3Set the CP1 (INPUT VOLTAGE SELECTOR) according to the power supply voltage.4Use twisted-pair leads for connection between 5 6 and 1 2 of the braking units.5Maximal quantity of parallel-connected braking units is 10. Refer to Par. 7. APPLICATION LIST OF BRAKING UNITS for details (see page 10)

Fig. 6 Example of Parallel Connection of Three Braking Units.

5.5 OPERATION

Check the required decelerating performance can be achieved.

DANGER

High voltage is applied to the braking unit. DO NOToperate the braking unit with cover opened.

8 -

6 TROUBLE - SHOOTING

No. Failure Mode Causes Action to be taken

The overload relay or Without braking unit : Replace the inverterthermal protector The built-in main circuit braking (option) for braking transistor of inverter is short-resistor trips when circuited. motor doesn't decelerate. With braking unit : Replace the braking unit

1 The main circuit braking transistor of braking unit is short-circuited.

The INPUT VOLTAGE SELECTOR Set CP1 again (CP1) of braking unit is set improperly. (Actual power supply voltage > setting value)

The inverter trips and Braking resistor capacity is insufficient Check the braking conditionsdisplays OV (Over

2 Voltage)Improper wiring Check wiring

Braking unit faults Replace the braking unit

The overload relay or Braking resistor capacity is insufficient Check the braking conditions3 thermal protector

(option) for braking resistor trips sometimes

Excessive START/STOP switching Check the working The braking unit trips frequency conditionsby the overheated heat Excessive load inertia 4 sink Improper combination of braking unit and Select again

braking resistor

Ambient temperature is higher than 104(40) Reduce temperature

9 -

7BRAKING UNIT APPLICATION LISTINVERTER INVERTER - MOUNTED TYPE SEPARATELY - INSTALLED TYPE

VOL-TAGE

MAX.Applicable

Motor(HP)

Resistor BrakingTorque

(3%ED)%

Braking Unit ResistorMax.

Connectabletable Q'TY

Min.Resistance

BrakingTorque

(10%ED)%Resistance

(150W)CODE

No. Q'TYMODEL

No. Q'TYCODE

No.Resistance(per unit)

Q'TY

220VClass

0.5 200 TG24 1 220 TG1 70W 200 1 4 48 2201 200 TG25 1 125 TG1 70W 200 1 4 48 1252 100 TG26 1 125 TG2 260W 100 1 5 16 1253 70 TG27 1 120 TG3 260W 70 1 4 16 1205 62 TG28 1 100 TG4 390W 40 1 2 16 1257.5 TG5 520W 30 1 3 9.6 11510 TG6 780W 20 1 2 9.6 12515 TGL-400 1 TG7 2400W 13.6 1 1 9.6 12520 TGL-400 1 TG8 3000W 10 1 1 9.6 12525 TGL-600 1 TG9 4800W 8 1 1 6.4 12530 TGL-600 1 TG10 4800W 6.8 1 1 6.4 12540 TGL-400 2 TG8 3000W 10 2 1 9.6 12550 TGL-400 2 TG8 3000W 10 2 1 9.6 10060 TGL-600 2 TG9 4800W 6.8 2 1 6.4 12075 TGL-600 2 TG9 4800W 6.8 2 1 6.4 100100 TGL-600 3 TG10 4800W 6.8 3 1 1.6 110

440VClass

0.5 750 TG29 1 230 TG11 75W 750 1 7 64 2301 750 TG30 1 130 TG11 75W 750 1 7 64 1302 400 TG31 1 125 TG12 260W 400 1 6 64 1253 300 TG32 1 115 TG13 260W 250 1 3 32 1355 TG14 390W 150 1 4 32 1357.5 TG15 520W 100 1 3 32 13510 TG16 780W 75 1 2 32 13015 TG17 1040W 50 1 2 20 13520 TG18 1560W 40 1 2 20 12525 TGH-400 1 TG19 4800W 32 1 1 19.2 12530 TGH-400 1 TG20 4800W 27.2 1 1 19.2 12540 TGH-400 1 TG21 6000W 20 1 1 19.2 12550 TGH-600 1 TG22 9600W 16 1 1 12.8 12560 TGH-600 1 TG23 9600W 13.6 1 1 12.8 12575 TGH-400 2 TG21 6000W 20 2 1 19.2 135100 TGH-600 2 TG23 9600W 13.6 2 1 12.8 145150 TGH-400 3 TG21 6000W 20 3 1 3.2 100200 TGH-600 4 TG23 9600W 13.6 4 1 3.2 140250 TGH-400 4 TG23 9600W 13.6 4 1 3.2 120300 TGH-600 5 TG23 9600W 13.6 5 1 3.2 125400 TGH-600 6 TG23 9600W 13.6 6 1 3.2 110

10

8 SEPARATELY - INSTALLED TYPE BRAKING RESISTOR

ApplicableVoltage

Codeno.

Size(mm) Resistor Spec.(per unit)

Resistorno. (per

unit)

Wiringdiagram

Applicable HPA B Screw

220VClass

TG1 120 180 M5*2 70W 200 1 1TG2 120 260 M5*4 260W 100 2 1 2TG3 120 260 M5*4 260W 70 2 1 3TG4 120 320 M5*4 390W 40 2 1 5TG5 155 340 M9*4 520W 30 2 1 7.5TG6 155 415 M9*4 780W 20 2 1 10TG7 340 425 M9*8 2400W 13.6 4 2 15TG8 380 425 M9*8 3000W 10 4 2 20TG9 380 485 M9*8 4800W 8 4 2 25TG10 380 485 M9*8 4800W 6.8 4 2 30

440VClass

TG11 80 140 M5*4 70W 750 2 1 1TG12 120 260 M5*4 260W 400 2 1 2TG13 120 260 M5*4 260W 250 2 1 3TG14 120 320 M5*4 390W 150 2 1 5TG15 150 340 M9*4 520W 100 2 1 7.5TG16 150 415 M9*4 780W 75 2 1 10TG17 150 425 M9*4 1040W 50 2 1 15TG18 170 425 M9*4 1560W 40 2 1 20TG19 380 485 M9*8 4800W 32 4 3 25TG20 380 485 M9*8 4800W 27.2 4 3 30TG21 440 640 M9*8 6000W 20 4 2 40TG22 440 790 M9*8 9600W 16 4 2 50TG23 440 790 M9*8 9600W 13.6 4 2 60

11

B

Amm

260

200mm(Min.)

200mm(Min.)

2P

R2

R1

R4

R3

B

1

R2R1

P B

Wiring Diagram

MOUNTING SPACE

NoteA and B are the approximate lengthfor the resistor unit

P

3

B

R3R2R1

P

B

R4

9 SPECIFICATIONS

Braking Unit Model No. TGL-400 TGL-600 TGH-400 TGH-600

Max. Applicable Motor Output HP 20 30 40 60Max. Braking Current (A) 40 60 40 60( Peak Value ) *

Rated Braking Current (A) 15 20 15 18Braking Start Voltage 330/345/365/380V 3V 630/660/690/730/760V 6V

Max. Hysteresis Error about 8V about 16V

DC Power Supply 243~400 VDC 460~800 VDCCooling Fin Overheat Protection Protected by thermoswitchPower Charge Indication Charge lamp stays ON until main circuit DC voltage >= 50

Location Indoor ( Protected from corrosive gases and dust )Ambient Temperature +14 to 104 (-10 to 40 ) ( not frozen )Storage Temperature -4 to 140 ( -20 to 60 )Humidity 90% RH or less ( non-condensing )

VibrationUp to 9.8 m/S2 (1G) at less than 20 HzUp to 2 m/S2 (0.2G) at 20 to 50Hz

Protective Configuration Enclosed wall-mounted type

* The loading time rate at max. braking current must be less than 10%ED (max. 10 sec.)

10 DEFINITION OF ED%

100% ED% = ( T1/T0 ) * 100 (%)

T1

T0

12 -

Out

put C

hara

cter

istic

sEn

viro

nmen

tal

Con

ditio

ns

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