Converteam ALSPA MV3DB Series Page 58 Manual Download

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8. Spare Parts

MV3DB Series DB Units

ALSPA MV3000e Dynamic Braking Units

(07/06)

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Summary of Contents for ALSPA MV3DB Series

Page 1: ...Dynamic Braking ALSPA MV3000e Dynamic Braking Units MV3DB Series Publication No T1684EN Rev 0005 07 06 ...

Page 2: ...al 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...

Page 3: ...ON 5 COMMISSIONING PROCEDURE DETAILED DESCRIPTION OF ASSOCIATED DRIVE PARAMETERS MAINTENANCE AND DIAGNOSTICS SECTIONS 6 7 SIMPLE MAINTENANCE DETAILED DIAGNOSTIC INFORMATION SPARES DISPOSAL THIS MANUAL T1684EN DB UNIT STAGES OF USE SELECTION OF BRAKING RESISTOR SECTION 3 DETAILED INSTRUCTIONS FOR SELECTION OF BRAKING RESISTOR SECTIONS 1 3 SPECIFICATIONS AND OTHER DATA SECTIONS 8 9 USER REPLACEABLE ...

Page 4: ...ut of braking components with regard to EMC requirements and wiring segregation 4 Installation 4 1 Explains how to properly install a DB Unit into a drive and how to install proprietary Converteam braking resistors 5 Commissioning 5 1 Explains how to commission a DB Unit and how to configure a drive to operate with a DB Unit and braking resistor 6 Preventive Maintenance 6 1 Simple maintenance proc...

Page 5: ...3 5 1 Calculation Based on Power 3 2 3 5 2 Calculation Based on Inertia 3 3 3 6 Equivalence of Duty Cycles 3 4 3 6 1 For braking times longer than 18 seconds 3 4 3 6 2 For braking times less than 18 seconds 3 5 3 7 Braking Resistor Cable Selection 3 5 3 8 Resistor Protection 3 6 3 8 1 Internal Protection 3 6 3 8 2 External Protection 3 7 3 9 Cabinet layout and EMC 3 8 4 Installation 4 1 4 1 Introd...

Page 6: ...ive Maintenance 6 1 6 1 Tools and Equipment Required 6 1 6 2 Maintenance Schedules 6 1 6 2 1 Access to Equipment 6 1 6 2 2 Monthly Servicing 6 1 6 2 3 Annual Servicing 6 1 7 Diagnostics 7 1 7 1 Fault monitoring 7 1 7 2 Warnings 7 1 7 3 Trips 7 1 8 Spare Parts 8 1 9 Disposal 9 1 Index Support ...

Page 7: ...anual for MV3000e DELTA 1 2 About the ALSPA MV3000e Dynamic Braking Unit The DB Units described in this manual are intended only to be used when installed within the associated ALSPA MV3000e MicroCubicle style drive and must not be used in any other manner The DB Unit is used in conjunction with an externally mounted braking resistor to dissipate kinetic energy stored in a motor and its load This ...

Page 8: ...f standard braking resistors designed to allow each internal DB Unit to produce the maximum possible braking effort Section 2 1 shows the braking resistor model number associated with each DB Unit The maximum permitted sizes of resistor connecting cables are given in Section 3 7 Instruction Sheet T1947 provides detailed installation instructions for these resistors 1 5 Identity Codes The code used...

Page 9: ...petent users trained in electrical installation practice with sufficient information to safely install commission operate maintain and dispose of simple MicroCubicle drive installations T1679 ALSPA MV3000e Software Technical Manual This manual contains detailed technical information to enable a competent user trained in drives to safely configure the ALSPA MV3000e drives for specific applications ...

Page 10: ...1 Introduction MV3DB Series DB Units ALSPA MV3000e Dynamic Braking Units 07 06 Page 1 4 This page intentionally left blank ...

Page 11: ...70 11 0 20 3 MV3DBR061S6 11 0 MV3DB247S5 6 400 247 153 30 1 6 3 1 MV3DBR247S4 2 6 6 480 231 171 70 1 8 3 9 MV3DBR231S5 3 3 MV3DB185S6 6 690 185 171 70 3 7 6 7 MV3DBR185S6 5 1 MV3DB391S5 7 400 391 241 9 1 6 1 9 MV3DBR391S4 1 6 7 480 308 228 9 1 8 2 9 MV3DBR308S5 1 8 MV3DB246S6 7 690 246 228 9 3 7 5 0 MV3DBR246S6 3 7 The chosen resistor must not be less than the minimum resistor value given in Table...

Page 12: ...y 3000 m 25 o C to 55 o C 13 o F to 130 o F 5 to 95 non condensing Transport Altitude maximum Temperature range Relative humidity Vibration drop Overland 3000 m Withstands air transport pressurised to 3000 m maximum 25 o C to 70 o C 13 o F to 158 o F 95 non condensing IEC 60721 3 2 Class 2M1 Operating Altitude maximum Temperature range Relative humidity Vibration Cooling air Ingress protection Res...

Page 13: ...ing an unsuitable resistor Configurable I 2 T protection for braking resistor DB Unit Fitted Status Flag 54 DB Resistor OK Status Flag 55 DB Resistor I 2 T Remaining Drive parameter 23 07 DB Resistor Overtemperature Warning Warning Code 104 DB Resistor Overtemperature Trip Trip Code 67 DB Unit Trip Trip Code 151 Status Signals DB Unit Overtemperature Trip Code 152 Table 2 5 Weights unboxed Frame S...

Page 14: ... volts using the standard Converteam braking resistors shown in Table 2 1 It is assumed that the braking torque during deceleration is constant If the initial speed is not 1500 r min the braking time to zero can be found by using the graph to find the braking time graph t for 1500 r min and scaling by the following formula where 1 t actual braking time 2 N initial speed Inertia is shown in kg m2 1...

Page 15: ...0 r min at 690 V supply voltage 0 2 4 6 8 10 12 14 16 18 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 Total Inertia kgm2 Braking time from 1500 r min seconds MV3DB061S6 MV3DB185S6 MV3DB246S6 0 2 4 6 8 10 12 14 16 18 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 Total Inertia kgm2 Braking time from 1500 r min seconds MV3DB045S5 MV3DB092S5 MV3DB247S5 MV3DB391S5 ...

Page 16: ...2 Specifications MV3DB Series DB Units ALSPA MV3000e Dynamic Braking Units 07 06 Page 2 6 This page intentionally left blank ...

Page 17: ... controlled by the same microprocessor that controls the inverter allowing the MV3000e to produce the maximum possible dynamic motor performance Additionally the internal interface between the DB Unit and the microprocessor provides automatic DB Unit detection full fault diagnostics and allows simple software set up for advanced features such as braking resistor protection 3 3 Standard Braking Res...

Page 18: ... resistor as shown in Table 2 1 the following procedure should be used Two methods are given one based on a known power and the other upon a known inertia 3 5 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 P V R 2 where DB V DB operating voltage see Table 2 2 p P Peak power during braki...

Page 19: ...ce Ω 2 91 1 2 2 1 2 N N JN t V R DB where DB V DB operating voltage see Table 2 2 in Section 2 Specifications J system inertia kgm2 1 t braking time seconds 2 N initial speed r min 1 N final speed r min Note J 1 2 ratio box gear J J load motor If there is no gear box ratio box gear 1 Inertia of the motor and load to be determined from the respective suppliers Peak power at start of braking p P J N...

Page 20: ...0 3000 9 0 2 732 2 91 2 12 07 Ω Peak power J N N N t 2 1 2 1 912 2 2 91 3000 0 3000 9 0 44408 Watts or 44 4 kW Long term average power 3 2 1 2 2 4 182 t N N J 100 4 182 0 3000 9 0 2 444 Watts Current in resistor R VDB 07 12 732 60 6 A Hence MV3DB092S5 in frame size 4 will achieve this duty 3 6 Equivalence of Duty Cycles Ratings in Table 2 1 are given for a braking time of 18 seconds 3 6 1 For brak...

Page 21: ...ulations Cables rated less than the peak current rating of the DB Unit in Table 2 1 should not be used unless they are protected against overload by means external to the drive The maximum sizes of cable which can be connected to the optional dynamic braking resistors are shown in Table 3 1 Temperature Limitations 1 Cables connected to the resistor terminals inside the resistor casing must be capa...

Page 22: ...hould be screened e g NYCWY according to VDE 0276 603 or steel wire armoured or fully enclosed in metallic trunking The screen or metallic trunking must be continuous throughout its length and be connected directly to or glanded to both the cabinet and the resistor casing 3 8 Resistor Protection 3 8 1 Internal Protection The drive monitors the power being dissipated by the braking resistor to avoi...

Page 23: ...ly An auxiliary contact is used to trip the drive via a digital input and control flag CF111 parameter P23 09 The line contactor and thermostat T1 are fed by an external supply the contacts of thermostats fitted to Converteam braking resistor assemblies are 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 inforce...

Page 24: ...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 shown in Section 3 9 and in Section 3 of the drive Getting Started Manual 3 9 Cabine...

Page 25: ...input output wiring must be separated by 300 mm 12 in Braking resistor in metal box Thermostat wiring 300 mm 12 in minimum 300 mm 12 in minimum 300 mm 12 in minimum External Supply Cabinet Boundary Mains Supply Cable outside cabinet to be screened and to be glanded at both ends Isolator 2 Cable inside cabinet must comply with segregation rules To reduce induced noise the two wires connecting the b...

Page 26: ...3 System Design MV3DB Series DB Units ALSPA MV3000e Dynamic Braking Units 07 06 Page 3 10 This page intentionally left blank ...

Page 27: ...mmediately Re pack it in its original packaging material If this is not possible it should be enclosed in polythene sheet to protect it from the ingress of dust Store it in a clean dry atmosphere preferably at room temperature ensuring that the storage environment meets the requirements of Section 2 If the DB Unit is unpacked in a warm environment condensation may occur Should condensation be seen...

Page 28: ...upplies 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 All items exposing high voltage must be placed in a suitable enclosure with restricted access Air used to cool the product is unfiltered Air ejected from the product may co...

Page 29: ...4 1 1 Ensure that the drive is upright as shown 2 Open the left plastic door the Control door under the Keypad harbour 1 by carefully pulling the bottom of the door and or the depression at the top 3 Open the right door the Power door by releasing the two screws 2 securing it to the drive chassis Figure 4 1 Access to drive interior 2 2 1 ...

Page 30: ... on the control board by releasing the M5 captive screw 1 5 Remove two M5 screws 2 3 and spring washers securing the DB blanking plate 5 to the drive chassis 6 Remove the M5 screw 9 and spring washer securing the control board to the drive chassis 7 Slide the control board forward by approximately 50 mm 2 inches and disconnect the Keypad ribbon cable from connector PL2 on the board 8 Withdraw the ...

Page 31: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 5 Figure 4 2 Frame size 3 preparation 1 3 4 5 6 7 2 8 9 ...

Page 32: ...c tab on the DB Unit Figure 4 5 1 with the slot in the rectifier moulding follow the dashed line Ensure that the back of the DB Unit is as far to the right as possible Push the DB Unit home and check that the back is not loose i e that the locating pegs at the rear of the DB Unit have located in the slots Figure 4 4 1 in the drive chassis 3 Secure the DB unit to the rectifier terminal assembly usi...

Page 33: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 7 Figure 4 4 Locating the DB Unit Figure 4 5 Frame size 3 installation detail 2 1 1 ...

Page 34: ...release M5 screw Figure 4 2 3 to ease entry of the board Figure 4 6 Keypad and DB Unit cable connection detail 6 Close the plastic shroud over TB1 on the control board and secure using the retained M5 screw 7 Fit busbar links between the RECT and DC studs and between the RECT and DC studs Connect braking resistor cable crimp to the DC stud Secure using M6 nuts spring washers and flat washers Torqu...

Page 35: ...se the power door and secure using two M5 captive screws Note If it is difficult to secure the lower M5 captive screw temporarily release the lower M5 screw retaining the control board see Figure 4 2 9 13 Close the Control door 14 External cables must be secured as close as possible to the drive ...

Page 36: ...ining the two links and remove the links 3 Open the hinged plastic shroud on the control board by releasing the M5 captive screw 1 4 Release the DB Blanking plate as follows i Remove the M5 screw and washer 2 securing the DB blanking plate to the control board ii Remove the two M4 taptite screws 6 on the right hand side of the DB blanking plate iii Remove the M4 taptite screw 3 to the left hand si...

Page 37: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 11 Figure 4 7 Frame size 4 preparation 5 4 7 8 1 6 6 2 9 8 3 Do not remove Blanking plate shown partially withdrawn ...

Page 38: ... 3 in the drive chassis 4 Slide the control board forward by approximately 100 mm 4 in Connect the DB Unit ribbon cable to connector PL8 9 on the control board Slide the control board back into place and re fit its bottom M5 screw 5 Secure the DB Unit to the chassis using two M4 x 12 mm taptite screws 13 one M4 x 6 mm taptite screw 8 and to the control board by one M5 screw 7 6 Fit the non insulat...

Page 39: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 13 Figure 4 8 Frame size 4 installation 3 2 5 4 1 7 9 10 11 12 13 14 15 16 13 14 6 8 ...

Page 40: ...ecuring the blanking plate to the top of the drive casing 2 Remove eight M5 taptite screws 5 securing the fan access plate 6 to the chassis and remove the plate Do not remove the fan securing screw 3 Slide the blanking plate 7 out of the drive and store 4 Remove two M10 nuts spring washers and flat washers 10 securing the link 9 to the DC and RECT studs Remove the link 5 Remove the M10 hex head sc...

Page 41: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 15 Figure 4 9 Fitting to frame size 6 preparation 2 3 5 6 7 9 10 8 1 4 ...

Page 42: ...ibbon to PL8 1 on the control board 4 Re fit the control board into the drive using the procedure in step 2 i to iv in reverse order 5 Secure the DB Unit to the DC busbar using an M10 hex head bolt spring and flat washers 16 supplied in the DB Unit kit Torque as shown above 6 Secure the DB Unit to the DC stud 17 using an M10 nut spring and flat washers 18 Torque as shown above 7 Re fit the fan acc...

Page 43: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 17 Figure 4 10 Frame size 6 installing the DB Unit 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 6 3 1 2 A B 10 ...

Page 44: ...keypad harbour and swing it open 2 Remove seven M5 cross head screws securing the fan access plate 4 to the chassis also remove the M8 bolt and spring washer 6 securing the plate to the transistor transistor unit chassis Do not remove earthing screw 7 or fan securing screw Carefully manoeuvre the top of the access plate past the fan cable 5 and fan terminal blocks then lift the plate clear of the ...

Page 45: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 19 Figure 4 11 Fitting to frame size 7 preparation 8 9 1 1 3 4 5 2 7 6 ...

Page 46: ...onnector to PL8 6 on the control board This is shown in greater detail in Figure 4 6 5 Referring to Figure 4 11 re fit the fan access panel 4 by placing the bottom behind the DC busbar 2 and easing the top past the fan cable and the fan terminal blocks Secure the panel to the drive chassis with seven M5 screws and secure to the transistor transistor chassis with an M8 bolt and spring washer 7 6 At...

Page 47: ...MV3DB Series DB Units 4 Installation 07 06 ALSPA MV3000e Dynamic Braking Units Page 4 21 Figure 4 12 Frame size 7 installing the DB Unit 1 2 4 5 3 6 7 8 9 10 ...

Page 48: ...osure must be earthed grounded Where the drive is installed in a cabinet the braking resistor assembly must always be mounted outside the cabinet typically fixed to the top of the cabinet The resistor assembly must be protected from dripping liquids by use of a protective canopy available from Converteam Specifications and installation instructions for the ALSPA MV3DBR series braking resistors are...

Page 49: ... braking resistor is adequate for the duty see Section 3 7 The connected braking resistor is within the range detailed in Section 2 1 Specifications 5 2 3 Procedure Apply power to the drive but do not enable the output i e do not run the motor Check that current does not flow in the DB Unit output cables WARNING Wait at least 5 minutes after isolating supplies and check that voltage between DC and...

Page 50: ...th a drive Access to menus and parameters is described in the relevant ALSPA MV3000e Getting Started Manual 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 the dynamic brake and associated braking resistor Parameter 23 00 DB Resistor Value Enter the resistanc...

Page 51: ...y still trip on overvoltage P23 05 should be used to limit the regenerative capability of the drive to match that of the DB Unit This parameter is a repeat of P4 12 in the Start Stop menu Permitted values 0 1 kW to 3000 0 kW 0 1 means NO LIMIT the energy is to be absorbed by the dynamic brake Parameter 23 06 Action on DB Resistor Overload This parameter defines the action to be taken by the drive ...

Page 52: ...he default value of P23 06 will cause a DB Resistor Trip P23 09 can be used to connect one of the digital inputs to CF111 The value 1 001 selects Digital Input 1 1 002 selects Digital Input 2 etc Note that preceding the value with a sign inverts the sense of the signal and will allow a normally closed thermostat or auxiliary contact to be used An example is shown below using Digital Input 6 The de...

Page 53: ...e power door RH door Vacuum cleaner having soft e g rubber nozzle 6 2 Maintenance Schedules Note It is suggested that these schedules be integrated with those for the drive unit 6 2 1 Access to Equipment 1 Switch off the drive and isolate it from the electrical supply Comply with the Warning at the top of this page 2 Gain access to the drive interior by opening the doors as shown in Section 4 3 2 ...

Page 54: ...6 Preventive Maintenance MV3DB Series DB Units ALSPA MV3000e Dynamic Braking Units 07 06 Page 6 2 This page intentionally left blank ...

Page 55: ...04 DB resistor There is 25 power dissipation capability remaining If this warning occurs often 1 Use a higher rated braking resistor 2 Power data may be incorrect Review calculations in Section 3 7 3 Trips The drive flashes the TRIPPED indicator if a serious fault has caused it to trip Trips are latched and the drive cannot be used until the fault is cleared and the drive is reset as described in ...

Page 56: ...her an overcurrent or heatsink overtemperature 1 Ohmic value of braking resistor too low 2 Resistor has shorted turns 3 Wiring fault from DB Unit to resistor 4 Excessive use of dynamic brake 5 Possible obstruction of airflow through drive 152 DB overtemperature Heatsink overtemperature 1 Excessive use of dynamic brake 2 Possible obstruction of airflow through drive 3 Ambient temperature too high ...

Page 57: ...MV3DB Series DB Units 8 Spare Parts 07 06 ALSPA MV3000e Dynamic Braking Units Page 8 1 8 Spare Parts The DB Unit contains no user replaceable parts ...

Page 58: ...8 Spare Parts MV3DB Series DB Units ALSPA MV3000e Dynamic Braking Units 07 06 Page 8 2 This page intentionally left blank ...

Page 59: ... Series DB Units 9 Disposal 07 06 ALSPA MV3000e Dynamic Braking Units Index 9 1 9 Disposal This equipment or any part of the equipment should be disposed of in accordance with the laws of the country of use ...

Page 60: ...Index MV3DB Series DB Units ALSPA MV3000e Dynamic Braking Units 07 06 Index 9 2 This page intentionally left blank ...

Page 61: ...ndling 4 1 I Identity codes 1 2 Illustration of ratings 2 4 Inspection 4 1 Installation 4 1 Access to drive components 4 3 DB resistor 4 22 to frame size 3 drives 4 4 to frame size 4 drives 4 10 to frame size 6 drives 4 14 to frame size 7 drives 4 18 Introduction 1 1 M Maintenance 6 1 Annual servicing 6 1 Monthly servicing 6 1 Tools and equipment required 6 1 Metric Units 1 3 Motor regenerative po...

Page 62: ...Index MV3DB Series DB Units ALSPA MV3000e Dynamic Braking Units 07 06 Index 2 This page intentionally left blank ...

Page 63: ...31 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 Converteam UK Ltd 2006 Publication No T1684EN The logo Converteam and their frameworks are trademarks and service trademark applications ofConverteam Other names me...

Page 64: ...MV3000e A C DRIVES Price 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 ...

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