Large capacity AC Drives of the VF5 series do not have an integrated brake unitand must be equipped with a separate dynamic brake.Consult Table 'A'for standardsize dynamic brakes.NOTE:Consult Drivecon Corporation if specifications are beyond the standardratings of the specified dynamic brake and resistor bination notedon Table 'A'.All models with integrated dynamic brake or with extemal dynamic brake require a separateDB resistor and thermal overload device.The resistor and thermal overload ratings are pro-vided in Table'A'.Damage to the AC drive or DB unit may occur if these resistors are notsized correctly or a thermal overload device is not used.The thermal overload must be usedto interrupt the main 3 phase power supply to the drive via a 3 pole input contactor.INSTALLATION:1)DBUNITThe standard VFDB unit is designed to be mounted in a control panel of sufficientrating for the ambient environment.Itis furnished as a chassis mount control sotherefore has exposed circuits and terminals.Care mustbe taken when installing,notto physically damage the control.A clear plastic cover is provided with the dynamicbrake module.It is strongly remended to keep this cover on unit to prevent accidental contact with VFDB PC board.Select a location that satisfies the followingconditions:Ambient temperature-0-125 degrees FRelative humidity-less than 90%NO CONDENSATIONVibration-less than.5 GFree air circulationLocation within 3 ft.from AC drive unit.Refer to drawing #VFDB-5 for mounting dimensions and clearances.WARNING:Do not touch ponents on VFDB PC boardsince high voltage is present at the PCB.32)THERMAL RELAY:A suitable thermal relay must be installed in series with the resistor wires for protectionof the resistor from overload.The control contacts of this overload must be interlocked with a 3phase disconnect device in series with the R,S,and T terminals of the AC drive.Suitabledevices are 3 pole contactors or shunt trip circuit breakers.The thermal relay is also furnishedopen for mounting in a control cabi.Care must be taken not to disturb the thermal tripsetting when installing the overload.Aprovision for automatic or manual reset is providedwith all DB thermal overloads.Consult chart on pages 7 and 8 for correct DB thermal overload rating.A clear protective cover is supplied with each DB thermal relay.The cover isinstalled after the overload is wired.The cover is secured by fastening the cover to the powerwires of the overload with 2 tie straps.3)DB RESISTORS:Mount the resistors in a well ventilated location free from vibration.Since the resistorsare a source of heat,they should not be installed near any electrical ponents such as theVF series drive.We suggest specifying enclosed resistors and mounting them outside themain control cabi in which the drive installed in.Or at least above the drive in open envi-ronments.The maximum wire distance from the DB unit to the resistors shall be less than 10ft.Twist wires which run to resistors together to minimize stray induction.High temperatureinsulation must be used at resistor connections.We suggest SRML type of appropriategauge.USE SRML WIREVF series3FT.10FT.DBAC DriveVFDBResistorsMaximum Wire DistanceIMPORTANT:Drivecon furnishes enclosed resistors with perforated or louvered enclosures.Care must betaken not to leave resistors uncovered due to heat generated and the very high potentialvoltage to ground present.Check resistors and wire leads for grounds before turning onpower supply.WARNING:High potential is available at resistors up to 2 minutesafter power is switched off.Insure terminals P and N of drive are atOV before touching resistor element.4DISABLE OPERATIONPROVISIONTwo methods are available.One method must be used.1)A contactor interlock must be provided to disable the VFDB unit from falseoperation when the line voltage rises above nominal levels and causes theVFDB to tumn on.This contactor must be rated for 600V at 1 amp and isinstalled in series with terminal P on VFDB unit.Should extra contacts beavailable wire 2 contacts in series for a double break configuration.The controlof this contactor is sequenced from the run signal of the AC drive,terminals 22and 23.A jumper selectable enable circuit is now provided on all VFDB units.Thisenable circuit provides a method of enabling or disabling the VFDB with asimple 120VAC signal at terminals 1(RE)and 2(REN)of TB1,located on theVFDB's main PCB.A header connection is provided for selection of this enableinput.Heade r number 2(HD2)has 3 pins,a jumper is provided for selectingthe following modes of operation.Jumper between pins 2 and 3(factory default)enabling inputis bypassed.TheVFDB will be enabled continuously(method #1 above must be used to disableVFDB).Jumper between pins 1 and 2 enable circuit active.120V must beapplied to pins 1(RE)and 2(REN)of TB1 in order for VFDB to operate.WARNING:DUE TO HAZARDOUS VOLTAGE AVAILABLE AT VFDB NEVERCHANGE JUMPER LOCATION WHILE POWER IS APPLIED ORCHARGE LIGHT ON VFDB IS ILLUMINATED.5)MASTER SLAVE OPERATIONIn many applications,additional dynamic braking capacity is required.This can beachieved by applying multiple VFDB's in parallel.Each VFDB unit has a Master outputsignal connection and a Slave input signal connection.When multiple VFDB's areused,one VFDB unit is configured as the Master unit.All other VFDB units areconfigured to Slave units.This is done by placing the jumper across pins 1 and 2 ofheader 1 [HD1]on each Slave unit.On the Master VFDB unit,the Master output signal is available at TB1 terminals 5[MO+]and 6[MO-].This signal is applied to the first Slave unit at TB1 terminals 3[SI+]and 4[SI-].These wires should be kept as short as possible,routed away from powerwiring and twisted together to minimize the chance of noise interference.If there is a second Slave VFDB unit,the Master output signalfrom the first Slave unitTB1 terminals 5[MO+]and 6[MO-]are applied to terminals 3[Sl+]and 4[SI-]on thesecond Slave unit.Again,these wires should be kept as short as possible,routedaway from wiring and twisted together to minimize the chance of noise interferenceAny additional VFDB units would be wired in the same way,with the Master output fromthe second Slave unit going to the Slave input on the third VFDB unit.5WARNING:DUE TO HAZARDOUS VOLTAGE AVAILABLE AT PCB NEVER CHANGEJUMPER LOCATION WHILE POWER IS APPLIED OR CHARGE LIGHTIS ILLUMINATED.WIRING:Refer to the correct diagram for your AC drive model since connections vary depending uponcapacity.Size all conductors for rated amperage of VFDB unit shown on first page of thismanual.[All conductors except the wires running from terminal P of AC drive through disablecontactor to terminal P of VFDB require a current capacity at or above the rating of the VFDBunit.The wire running to the disable contactor needs only to be sized at 14AWG].All conduc-tors must be rated for 1000V.Use high temperature insulation near any resistor connections.COMMISSIONING:Prior to connecting power,check all wiring with schematic diagram,also check resistors forearth grounds.Insure cover of resistor is installed before applying power.The VFDB isequipped with a red LED to signify active power dissipation.This LED will illuminate whenpower transistor is on.Normal operation usually provides a blinking LED during brakingcycles.Normalturn-on levels are:380V DC for 200V VFDB720V DC for 400V VFDB740V DC for 480V VFDBThese levels are preset and are not to be adjusted.Once operational,install cover on VFDB by locating holes on side of cover with semi-perfora-tions in side of VFDB.Should persistent overload tripping occur or incorrect operation exist please contact DriveconCorporation at 847-855-9150 for technical assistance.Drivecon820 Lakeside Drive-Gurnee,IL60031Tel:847-855-9150Fax.:847-855-9650800-374-8266E-mail:drive.sales@drivecon.ww.drivecon.6Dynamic Brake Module and Resistor Kit Data Sheet for200/230V VF5120HG series VFD200/230V SERIES VF5120HG DYNAMIC BRAKE SIZING TABLEAVFD MODELDB MODULEDB RESISTORRESISTOR SIZEFULL LOADTHERMALPARTOVERLOAD KITTHERMALHEATERPART#RATINGVF5120HG-3INTEGRATEDDBK1-70-400-*4X4X42.2AFH23VF5120HG-5INTEGRATEDDBK1-46-800-*4.2AFH30VF5120HG-7.5INTEGRATEDDBK1-30-800-*5.2AFH33VF5120HG-10INTEGRATEDDBK1-20-800-*6.2AFH34VF5120HG-15INTEGRATEDDBK1-15-1K-8.0AFH37VF5120HG-25VFDB302DBK1-9-1.6K-*12.6AFH42VF5120HG-30VFDB302DBK1-9-1.6K-12.6AFH42VF5120HG-50VFDB502DBK1-7-2.4K-*16.0AFH45VF5120HG-60VFDB502DBK1-7-2.4K-*16.0AFH45VF5120HG-100VFDB1002DBK2-7-2.4K-*2X16.0A2x FH45Consult factory above 100HPDynamic brake resistor overload kit:DBKX-X-X.Normally closed contact only.Dynamic brake resistor and overload kit:DBKCX-X-X.Form'C'contact.(Optional)Thermal overload of specified amperage rating is supplied for each resistor and providedloose for customer panel mounting.Enclosed units are also available,consult factory.Amagic line disconnect on the input side of the VF5100 is to be opened if thermal overloadtrips.Consult Drivecon on rating of line disconnect.a)Dynamic brakes are sized for the 100%braking torque for a maximum of 10%duty cycle-consult Drivecon for higher torques or higher cycle rates.*-O:OPEN*-P:PERFORATED*-L:LOUVERED820 Lakeside Drive-Gurnee,IL60031DriveconTel.:847-855-9150Fax:847-855-9650800-374-8266E-mail:drive.sales@drivecon.ww.drivecon.Dynamic Brake Module and Resistor Kit Data Sheet for400/480V VF5140HG VF5148HG series VFD400/480V SERIES VF5140HG/VF5148HG DYNAMIC BRAKE SIZING TABLE AVFD MODELDB MODULEDB RESISTORRESISTOR SIZEFULL LOADTHERMALVF5140HGPARTOVERLOAD KITTHERMALHEATERVF5148HGPARTRATINGINTEGRATEDDBK1-300-400-*1.1AFH16-5INTEGRATEDDBK1-160-500-*1.7AFH20-7.5INTEGRATEDDBK1-120-500-*2.0AFH22-10INTEGRATEDDBK1-90-500-*2.5AFH25-15INTEGRATEDDBK1-60-1.2K-*4.6AFH3125INTEGRATEDDBK1-40-1.6K-*6.3AFH35VFDB304/305DBK1-30-2.4K-*9.0AFH3850VFDB304/305DBK1-28-3.2K-*10.7AFH40-75VFDB504/505DBK1-20-3.6K-*13.4AFH43-100VFDB504/505DBK1-16-4.8K-*17.3AFH46-150VFDB1004/1005DBK2-20-3.6K-*10×10×262X13.4A2X FH43Consult factory above 150HPDynamic brake resistor and overload kit DBKX-X-X.Normally closed contact only.Dynamic brake resistor and overload kit DBKCX-X-X.For'C'contact.(Optional)Thermal overload of specified amperage rating is supplied for each resistor and providedloose for customer panel mounting.Enclosed units are also available,consultfactory.Amagic line disconnect on the input side of the VF5100 is to be opened if thermal overloadtrips.Consult Drivecon on ratings of line disconnect.a)Dynamic brakes are sized for the 100%braking torque for a maximum of 10%duty cycle-consult Drivecon for higher torques or higher cycle rates.*-O:OPEN*-P:PERFORATED*-L:LOUVERED820 Lakeside Drive-Gurnee,IL60031DriveconTel.:847-855-9150Fax.:847-855-9650800-374-8266E-mail:drive.sales@drivecon.www.drivecon.89-5-96Dynamic Brake Module and Resistor Kit Data Sheet for200/230V VF61 VF64 series VFD200/230V SERIES VF61/VF64 DYNAMIC BRAKE SIZING TABLE AVFD MODELDB MODULEDB RESISTORFULL LOADTHERMALVF61-PARTSIZETHERMAL O.L.HEATER#VF64-RAT NGPART2R222INTEGRATEDDBK1-70-400-22AF233R722INTEGRATEDDBK1-46-800-*4.2AFH305R522NTEGRATEDDBK1-30-800-52AFH337R522NTEGRATEDDBK1-20-800-62AFH341122NTEGRATEDDBK1-15-1K-°8.0AFH371522VFDB302DBK1-15-1K-8.0AFH372222VFDB302DBK1-916K-5X13X1212.6AFH423022VFDB302DBK1-916K-5X13X1212.6AFH423722VFDB502DBK1-7-24K-16.0AFH454522VFDB502DBK1-7-24K-16.0AFH455522VFDB502DBK1-632K-18.0AFH467522VFDB1002DBK2-7-24K-2X16.0A2 x FH459022VFDB1002DBK2-632K-2X18.0A2 x FH46Corsult factory above 125HPDynamic brake resistor overload kit:DBKX-X-X.Normally closed contact only.Dynamic brake resistor and overload kit:DBKCX-X-X.Form 'C'contact.(Optional)Thermal overload of specified amperage rating is supplied for each resistor and providedloose for customer panel mounting.Enclosed units are also available,consult factory.Amagic line disconnect on the input side of the VF61 is to be opened if thermal overloadtrips.Consult Drivecon on rating of line disconnect.a)Dynamic brakes are sized for the 100%braking torque for a maximum of 10%duty cycle-consult Drivecon for higher torques or higher cycle rates.*-O:OPEN*-P:PERFORATED*-L:LOUVERED820 Lakeside Drive-Gurnee,IL 60031DriveconTel:847-855-9150Fax:847-855-9650800-374-8266E-mail:drive.sales@drivecon.ww.drivecon.9Dynamic Brake Module and Resistor Kit Data Sheet for400/480V VF61 VF64 series VFD400/480V SERIES VF61 VF64 DYNAMIC BRAKE SIZING TABLE AVFD MODELDB MODULEDB RESIS TORRESISTORFULL LOADTHERMALVF61-PARTOVERLOADSIZETHERMAL O.LHEATERVF64-KTRATINGPART#2R244INTEGRATEDDBK1-300400-*1.1AFH163R744INTEGRATEDDBK1-160-500-*5x7x121.7AFH205R544INTEGRATEDDBK1-120-500*2.0AFH227R544INTEGRATEDDBK1-90-500*5x7x122.5AFH251144INTEGRATEDDBK1-601.2K-*5×10×1246AFH311544INTEGRATEDDBK140-1.6K-*6.3AFH352244VFDB3C4/305DBK1-30-2.4K-*9.0AFH383044VFDB3C4/305DBK1-30-2.4K*5x10x189.0AFH383744VFDB3C4/305DBK1-283.2K*5x13x1810.7AFH404544VFDB5C4/505DBK1-283.2K-*107AFH405544VFDB5C4/505DBK1-20-3.6K-*5x10x26134AFH437544VFDB5C4/505DBK1-164.8K-*17.3AFH4611044VFDB1004/1005DBK2-20-3.6K-*10×10x262x12.6A2X FH4216044VFDB1004/1005DBK2-164.8K-*10×13×262×17.3A2X FH4620044VFDB1504/1505DBK3164.8K*15×13x263x17.3A3X FH4625044VFDB20C4/2005DBK4-164.8K*4×17.3A4X FH46Consult factory a bove 300HPThermal overload of specified amperage rating is supplied for each resistor and providedloose for customer panel mounting.Enclosed units are also available,consultfactory.Amagic line disconnect on the input side of the VF61 is to be opened if thermal overloadtrips.Consult Drivecon on rating of line disconnect.a)Dynamic brakes are sized for the 100%braking torque for a maximum of 10%duty cycle-consult Drivecon for higher torques or higher cycle rates.*-O:OPEN*-P:PERFORATED*-L:LOUVERED820 Lakeside Drive-Gurnee,IL60031DriveconTel:847-855-9150Fax.:847-855-9650800-374-8266E-mail:drive.sales@drivecon.10www.drivecon.Table 6-3:Dynamic Brake Wire SizeA)200-230V Inverters(Use 600V rated wire)(AWG)MODELVF5120 HG /VF61-xx22 /VF64-xx22HP51015202530506075100VF DB MODELNANA30230230250250250210021002P1 P214141210884DRIVETERMINALSB1414141412、N14141414121210840,2.41414141414141414141414タ14VFDBTERMINALSP14141414141414141414141414PR N1414141412128gDynamic brake module is integrated in inverter chassis in 200V models up to 15HP.ShouldVFDB unit be required for models below 15HP due to braking capacity,follow wire size givenfor individual drive.B)380-480V Inverters(Use 1000V rated wire)(AWG)MODELVF5140HG/VF5148HG/VF61-xx44/VF64-xx4457520406075100150VFDB MODELNANAANANA30430430450450450410043053053055055055051005P1,P214121088TERMNALS1414121414141412128VFDB141414g1414141414141414TERMNALSP1414141414141414タPR,N141414141212121088882Dynamic brake module is integrated in inverter chassis in 400V models up to 25HP.ShouldVFDB unit be required for models below 25HP due to braking capacity,follow wire size givenfor individual drive.11