YASKAWA

FOR VARISPEED-600 SERIES INVERTER

BRAKING UNIT
BRAKING RESISTOR UNIT
INSTRUCTIONS
MODEL: BRAKING UNIT CDBR-
BRAKING RESISTOR UNIT LKEB-

Upon receipt of the product and prior to initial operation, read these instructions
thoroughly, and retain for future reference.

YASKAWA MANUAL NO. TOBP C720600 00A

 PREFACE

Braking resistor unit and braking unit are used to con-

sume regenerative energy from motor in the braking
resistor unit at deceleration and to improve the transis-
tor inverter braking ability.

Before using the braking resistor unit and braking unit,

a thorough understanding of this manual is recom-
mended. This instruction manual will be of great help
for daily maintenance, inspection and troubleshoot-
ing.

Inverters to which the braking resistor unit and braking

unit can be connected are of the following series:

D VS−616 Series

D VS−676 Series

D VS−866 Series

3
 General Precautions

S Some drawings in this manual are shown with the protective cover or shields
removed, in order to describe with more clarity. Make sure all covers and
shields are replaced before operating this product.

S Since the drawings in this manual are represented examples, some are subject
to differ from delivered products.

S This manual may be modified when necessary because of improvement of the

product, modification or changes in specifications. Such modifications are
denoted by a revised manual No.

S To order a copy of this manual, if your copy has been damaged or lost, contact
your YASKAWA representative.

S YASKAWA is not responsible for any modification of the product made by the
user since that will void your guarantee.

4
NOTES FOR SAFE OPERATION

Read this instruction manual thoroughly before installation, operation,

maintenance or inspection of the braking unit and the braking resistor unit. In this
manual, NOTES FOR SAFE OPERATION are classified as “WARNING” or
“CAUTION.”

WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury to personnel.

CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in mi-
nor or moderate injury to personnel and damage to equipment.
It may also be used to alert against unsafe practices.

Even items described in

CAUTION may result in a vital accident in some
situations. In either case, follow these important notes.

NOTE : These are steps to be taken to insure proper operation.

5
WIRING

WARNING
(Ref. page)

S Only commence wiring after verifying that the power supply is 27

turned OFF.
Failure to observe this warning can result in an electrical shock or a
fire.

S High voltage exists at all terminals of braking unit and braking 27

resistor unit.
Failure to observe this warning can result in an electrical shock.

S Wiring should be performed only by qualified personnel. 27

Failure to observe this warning can result in an electrical shock or a
fire.

S When wiring the emergency stop circuit, check the wiring 27

thoroughly before operation.
Failure to observe this warning can result in personal injury.

S Make sure to ground the ground terminal . 27

(Ground resistance
200V class: 100W or less, 400V class: 10W or less)
Failure to observe this warning can result in an electrical shock.

7
 CAUTION
(Ref. page)

S Verify that the rated voltage of the braking unit and the braking 27
resistor unit coincides with the AC power supply voltage.
Failure to observe this caution can result in personal injury or a fire.

S Do not perform a withstand voltage test of the braking unit and 27

braking resistor unit.
It may cause semi−conductor elements to be damaged.

S Connect braking resistors, braking resistor units, and braking 27

units as shown in the I/O wiring examples. Use properly rated
wire in accordance with table 2 on page 31.
Otherwise, a fire can occur.

S Tighten terminal screws to the specified tightening torque. 27

Failure to observe this caution can result in a fire.

8
OPERATION

WARNING
(Ref. page)

S Only turn ON the input power supply after replacing the front 41
cover. Do not remove the cover while current is flowing.
Failure to observe this warning can result in an electrical shock.

CAUTION
(Ref. page)

S Never touch the heatsink or discharging resistor since the 41

temperature is very high.
Failure to observe this caution can result in harmful burns to the
body.

S Do not check signals during operation. 41

The machine or the inverter may be damaged.

S All the constants of the the braking unit and the braking resistor 41
unit have been preset at the factory. Do not change the
settings unnecessarily.

9
 CAUTION
(Ref. page)

S The control PC board employs CMOS ICs. Do not touch the 46

CMOS elements.
They are easily damaged by static electricity.

S Do not connect or disconnect wires or connectors while power 46

is applied to the circuit.
Failure to observe this caution can result in personal injury.

OTHERS

WARNING
S Never modify the product.
Failure to observe this warning can result in an electrical shock or
personal injury and will invalidate the guarantee.

11
WARNING INDICATION

A warning label is displayed on the front cover of the braking unit, as shown below.
Follow these instructions when handling the braking unit and the braking resistor
unit .

Example of Braking Unit Model CDBR−4045B

12
13
2. INSTALLATION

2.1 LOCATION
If the units are temporarily stored or machine stops for an extended length of time,
the following precautions should be taken. Store the units at pollution level 2 or less
(UL standard) and under the following conditions.
S Free from rainfall and drops of water.

S Clean and dry.

S Free from corrosive gases and liquids.

S Free from dirt and dust.

S Ambient temperature: 14 to 104_F, −10 to 40_C.

S Humidity: 90% RH or less (no condensation)

S Free from vibration.

2.2 INSTALLATION
For full use of the braking resistor unit or braking unit functions, install the units
at pollution level 2 or less (UL standard) and in a location to satisfy the following
conditions:
Figs. 1 to 8 show the external dimensions and the spaces from the periphery.
S Provide the spaces shown in Figs. 1 to 8 between the units and the periph-
ery.

S Since the braking resistor unit generates heat, provide sufficient spaces
from devices which are weak against heat.

S Install the units at such locations that all requirements described in Par.
2.1 “LOCATION” are satisfied.

16
 2. INSTALLATION

S Install the units in the directions shown in Figs. 1 to 8. There will be no

problem if they are installed vertically.

3.94 (100) OR MORE

4−M4 MTG HOLE 2.83 (72) 2.73 (66.5)

5.43 (138)
5.91 (150)

3.94 (100) OR MORE

1.5 (38) 1.5 (38)
4.51 (114.5)
1.18 (30) 5.04 (128) 1.18 (30)
OR MORE 5.51 (140) OR MORE 5.45 (138.5)

3−LEAD WIRE OUTLET

[0.87 (20) DIA RUBBER BUSH]

Fig. 1 Braking Unit Dimensions in inches (mm) CDBR−2015B, −2022B, −4030B,

−4045B

17
 1.14 (29)
0.39 (10)

4−M6

OR MORE
3.94 (100)
3.94 (100) MTG HOLE
10.23 (260)
11.02 (280)

9.25 (235)

MAIN CIRCUIT
TERMINAL M4
2.30
3−LEAD WIRE
(58.5)
OUTLET
2.19 (55.5)

1.10 (28) DIA

RUBBER BUSH

1.97 (50)

OR MORE
3.94 (100)
3.94 (100)
5.51 (140) 6.57 (167)
1.18 (30) 1.18 (30)
OR MORE OR MORE

Fig. 2 Braking Unit Dimensions in inches (mm) CDBR−5037B

18
 2. INSTALLATION

1.44 (36.5)
0.47 (12)

4−M6

OR MORE
5.51 (140)

3.94 (100)
MTG HOLE
14.57 (370)
13.78 (350)
12.48 (317)

MAIN CIRCUIT
TERMINAL M5 WIRE OUTLET 1.10 (28)
3.86 (98) DIA RUBBER BUSH

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER
2.95 (75)

BUSH

3.94 (100)

4.37 (111)

OR MORE
2.32 1.97 (50)

3.94 (100)
(59) 6.14 (156)
5.51 (140)
7.09 (180) 7.87 (200)
1.18 (30) 1.18 (30)
OR MORE OR MORE

Fig. 3 Braking Unit Dimensions in inches (mm) CDBR−2045B

19
 1.44 (36.5)
0.47 (12)

4−M6
5.51 (140)

OR MORE
3.94 (100)
MTG HOLE
14.57 (370)
13.78 (350)
12.48 (317)

MAIN CIRCUIT
TERMINAL M6 WIRE OUTLET 1.10 (28)
4.09 DIA RUBBER BUSH
(104)
2−LEAD WIRE OUTLET
1.38 (35) DIA RUBBER
BUSH
2.87 (73)

3.94 (100)

OR MORE
3.94 (100)
2.32 1.97 (50) 4.37 (111)
(59) 5.51 (140)
6.14 (156)
7.09 (180) 7.87 (200)

1.18 (30) 1.18 (30)

OR MORE OR MORE

Fig. 4 Braking Unit Dimensions in inches (mm) CDBR−2110B

20
 2. INSTALLATION

1.44 (36.5) 4−M6

0.35 (9)

7.09 (180)

OR MORE
3.94 (100)
MTG HOLE
14.57 (370)
13.98 (355)
12.48 (317)

MAIN CIRCUIT
TERMINAL M5 WIRE OUTLET 1.10 (28)
3.86 (98) DIA RUBBER BUSH

2−LEAD WIRE OUTLET

1.38 (35) DIA RUBBER
2.95 (75)

BUSH

5.45 (138.5)

OR MORE
4.37 (111)

3.94 (100)
2.70 1.97 (50)
(68.5) 7.09 (180) 6.14 (156)
8.66 (220) 7.87 (200)
1.18 (30) 1.18 (30)
OR MORE OR MORE

Fig. 5 Braking Unit Dimensions in inches (mm) CDBR−4090B, −5110B

21
 1.44 (36.5)

4−M6
0.35 (9)

8.27 (210)

OR MORE
3.94 (100)
MTG HOLE
14.57 (370)
13.98 (355)
12.48 (317)

MAIN CIRCUIT
WIRE OUTLET 1.10 (28)
TERMINAL M6 4.09 DIA RUBBER BUSH
(104)
2−LEAD WIRE OUTLET
1.38 (35) DIA RUBBER
BUSH
2.76 (70)

6.16 (156.5)

OR MORE
4.37 (111)

3.94 (100)
4.67 (118.5) 1.97 (50)
8.27 (210) 6.14 (156)
9.84 (250) 7.87 (200)
1.18 (30) 1.18 (30)
OR MORE OR MORE

Fig. 6 Braking Unit Dimensions in inches (mm) CDBR−4220B, −5300B

22
 2. INSTALLATION

b a b

Braking Resistor Dimensions in inches (mm)

Unit Model
(LKEB−j) A B C D E
20P7 4.13 (105) 10.83 (275) 1.97 (50) 10.24 (260) M5
21P5 5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5
22P2 5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5
23P7 5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5
25P5 9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6
27P5 9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6
40P7 4.13 (105) 10.83 (275) 1.97 (50) 10.24 (260) M5
41P5 5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5
42P2 5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5
43P7 5.12 (130) 13.78 (350) 2.95 (75) 13.19 (335) M5
45P5 9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6
47P5 9.84 (250) 13.78 (350) 7.87 (200) 13.19 (335) M6

Fig. 7 Braking Resistor Unit Dimensions in inches (mm) [for 0.5 to 10HP (0.4 to
7.5kW)]

23
 Braking Resistor Dimensions in inches (mm)
Unit Model
(LKEB−j) A B C D E
2011 10.48 (266) 21.38 (543) 9.69 (246) 13.39 (340) M8
2015 14.02 (356) 21.38 (543) 13.23 (336) 13.39 (340) M8
2018 17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8
2022 17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8
4011 13.78 (350) 16.22 (412) 12.99 (330) 12.80 (325) M6
4015 13.78 (350) 16.22 (412) 12.99 (330) 12.80 (325) M6
4018 17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8
4022 17.56 (446) 21.38 (543) 16.77 (426) 13.39 (340) M8
4030 14.02 (356) 37.64 (956) 13.23 (336) 29.13 (740) M8
4037 17.56 (446) 37.64 (956) 16.77 (426) 29.13 (740) M8
4045 17.56 (446) 37.64 (956) 16.77 (426) 29.13 (740) M8

Fig. 8 Braking Resistor Unit Dimensions in inches (mm) [for 15 to 60HP (11 to
45kW)]

24
 2. INSTALLATION

2.3 REPLACEMENT OF CONVENTIONAL BRAKING

UNITS WITH NEW UNITS

To replace conventional braking units (models CDBR−2015, −2022, −4030, −4045)

with new units (CDBR−2015B, −2022B, −4030B, −4045B), an exclusive−use at-
tachment is required. Contact your YASKAWA representative.

ATTACHMENT 4−M6 MTG HOLE

0.28(7)
4.13 (105)

0.79 3.94 (100) 0.79

(20) (20)
10.24 (260)
11.02 (280)
5.91 (150)
0.98
(25)

3.94 (100)
0.39
(10)

0.28(7)
5.51 (140)
5.45 (138.5) 0.39 (10)

Code No.: DACT32732−AD

Fig. 9 Mounting Dimensions of Attachment in inches (mm)

25
The main circuit terminal symbols are different between conventional models and
new models. Refer to the following table.

Table 1 Main Circuit Terminal Symbols

Conventional Models New Models

N ©

P ¨

P0 ¨0

B ©0

26
3.2 SECTION NAMES

Figs. 10, 11 and 12 show appearance and each section name of braking unit and
braking resistor unit respectively.
Thermal overload relay protects the braking resistor unit for models LKEB−20P7
to −27P5, and thermal protector protects the braking resistor unit for models
LKEB−2011 to −2022 and −4018 to −4045.

MODEL:CDBR−2015B
BRAKING UNIT 200V CLASS FOR 15kW Power Supply Selection
Connector
WARNING

Master/Slave
Selection Connector
May cause injury or electric
shock.
Please follow the instructions in Calibration Resistor
the manual before installation or
operation.
Disconnect all power before opening
(Adjusted Prior to
front cover of unit. Wait 3 minutes
until DC Bus capacitors discharge. Shipment)
Use proper grounding techniques.

Operation Indicator
(Lights when Dis-
charging.)

© ¨ ¨0 ©0 1 2 5 6 Control Circuit
Terminals 1 to 6

Charge Indicator Lead Wire Outlet

(Charge Lamp) (3 Places: Rubber Bush)

Control Circuit Terminals © ¨ ¨0 ©0

Fig. 10 Braking Resistor Unit Model CDBR−2015B (Terminal Cover and

Indicationg Cover Removed)

28
 3. WIRING

Thermal Overload Relay

(Automatically Reset)

Lead Wire Outlet Control Circuit Terminals

(Rubber Bush) B, P, 1, 2

Fig. 11 Braking Resistor Unit Model LKEB−20P7 (Front Cover Removed)

29
 Resistor

Thermal
Overload
Protector

Lead Wire Outlet Control Circuit Terminals

(Rubber Bush) B, P, 1, 2

Fig. 12 Braking Resistor Unit Model LKEB−2022 (Front Cover Removed)

30
 3. WIRING

3.3 CIRCUITS AND WIRING SPECIFICATIONS

Table 2 Circuits and Wiring Specifications
Wire Max.
Termi- Size Terminal Torque
Name Circuit Wire Type
nals AWG Screw lb⋅in
(mm2) (N⋅m)
Braking Unit ¨ ¨0 12−10
Main
((Models CDBR © ©0 (3.5−5.5) 13.3
−2015B,
2015B −2022B,
2022B M4
Con- 1 2 3 18−14 (1.50)
−4030B, −4045B,
−5037B) trol 4 5 6 (0.75−2)
Braking Unit ¨ ¨0 10−8 21.7
Main M5
(Model CDBR © ©0 (5.5−8) 600V (2.45)
−2045B, −4090B, Con- 1 2 3 18−14 (High
(Hi h
*3
15.6
M4
−5110B) trol 4 5 6 (0.75−2) Voltage) (1.76)
vinyl
4 (22) sheathed 43.4
Braking Unit Main
¨ ¨0
8−6 M6
© © 0 *1
wire or (4.90)
((Model (8−14) equivalent
CDBR 2110B
CDBR−2110B, Con- 1 2 3 18−14 15.6
−4220B, −5300B) M4
trol 4 5 6 (0.75−2) (1.76)
Braking Resistor 12−10 M4 15.6 (1.76)
Unit Main B P
(3.5−5.5) (M5) *2 (21.7(2.45))
(Model LKEB− Con- 18−14
1 2 M4 15.6 (1.76)
j) trol (0.75−2)
*1 For wire size of 8−6 (8−14), use UL1283 heat−resistant vinyl−insulated wire or
equivalent.
*2 M4 for Models LKEB−20P7 to −27P5 or −40P7 to −4015.
M5 for Models LKEB−2011 to −2022 or −4018 to −4045.
*3 Models−5037B, −5100B, and −5300B can reach an operating voltage of 1040 VDC.
Please select wire which is suitable for the operating voltage.

31
3.4 WIRING PRECAUTIONS

(1) Wiring Leading−in Method

Lead in the wire through the knockout hole on the unit bottom. Since the
knockout hole is provided with a rubber bush, cut the rubber bush central
crosswise with a blade and lead the wire through.

(2) Separation from Signal Lines

Since strong noise component is superimposed on the braking resistor unit

and braking unit wiring, separate the units from signal lines which are weak
against noise.

(3) Wiring Distance

Wiring distance between the braking resistor unit and braking unit or braking
unit and inverter must be provided as shown in Fig. 13. Make sure to bundle
the wires between the units.

Braking Resistor Braking Unit Inverter

Unit

32.8ft 16.4ft
(10m) (5m)
or less or less

Fig. 13 Wiring Distance

32
 3. WIRING

(4) Grounding Method

S Mount the braking resistor unit on a grounded metallic plate. When it can-
not be mounted on a grounded metallic plate, pull out the lead wire from
the mounting screw section to ground.

S Braking unit grounding terminal must be provided with class 3 ground

(ground resistance: 100Ω or less.)

S Use the sizes specified in “INTERNAL CONNECTION SPECIFI-

CATIONS” for grounding cables.

3.5 INTERCONNECTION

Figs. 14 to 20 show the interconnecting diagrams of the braking unit or braking re-
sistor unit and VS−616G5.
Refer to Par. 3.3, “Wiring Precautions” for proper wiring in actual wiring design and
work.
Be sure to connect braking resistors or braking resistor units to the braking units.
Connect only braking resistors or Braking Resistor Units (LKEB−XXXX) to Brak-
ing Units.

NOTE If using another braking resistor instead of YASKAWA braking resis-

tor unit, be sure to protect by thermal overload relay.

33
 Use sequencer to break Overload Relay Trip Contact
power supply side on over-
load relay trip contact of
braking resistor unit. 1 2
DC Reactor
(Option)] Braking Resistor Unit #

P B
Short−circuit
Bar
MCCB ¨1 ¨ 2 © B1 B2
3−Phase MC
Power Supply R Motor
L1 (R) U (T1)
200 to 230 V
50/60 Hz S L2 (S) V (T2) IM
or
380 to 460 V T L3 (T) W (T3)
50/60 Hz [ 400/200 V VS−616G5

THRX OFF ON MC

34
MC
SA Ground (200V Class : 100Ω or less
Overload Relay Trip Contact 400V Class : 10Ω or less)
of Braking Resistor Unit
THRX
1 2
≈
SA
≈
MC TRX : Where : is “E” or “V”.

SA [ The transformer is not necessary for 200V class.

TRX ] When installing a DC reactor (option), remove the common bar between ¨1 and ¨2 terminals
(provided as standard) and connect a DC reactor with the terminals.
20 18
Fault # When using the braking resistor unit, set constant L3−04 to “0” (stall prevention selection during
Contact decel is disabled). If it is not changed, the inverter may not stop within set decel time.

Fig. 14 For Models CIMR−G5:20P4 to −G5:27P5 (200 V Class 0.55 to 7.5 kW),
Models CIMR−G5:40P4 to −G5:4015 (400 V Class 0.4 to 15 kW)
 ¨ ¨0 P
Use sequencer to break
power supply side on over-
load relay trip contact of Braking Resistor Unit ]
braking resistor unit. Braking Unit ©0 B
Level
Detection 1 2
DC Reactor
©
(Option)[
Overload Relay Trip Contact
3 4
Short−circuit
Bar
¨1 ¨2 ¨3 ©
MCCB MC
3−Phase L1 (R) Motor
R U (T1)
Power Supply
200 to 230 V S L2 (S) V (T2) IM
50/60 Hz
T L3 (T) W (T3)

35
VS−616G5
THRX OFF ON MC
MC
SA
Overload Relay Trip Contact
Ground (200V Class : 100Ω or less
of Braking Resistor Unit
THRX 400V Class : 10Ω or less)
≈
1 2
≈
SA
MC TRX : Where : is “E” or “V”.
[ When installing a DC reactor (option), remove the common bar between ¨1 and ¨2 terminals
SA (provided as standard) and connect a DC reactor with the terminals.
TRX ] When using the braking resistor unit, set constant L3−04 to “0” (stall prevention selection during
decel is disabled). If it is not changed, the inverter may not stop within set decel time.
20 18
Fault
Contact
Fig. 15 For Models CIMR−G5:2011 to −G5:2015 (200 V Class 11, 15 kW)
3. WIRING
 Use sequencer to break ¨ ¨0 P
power supply side on over-
load relay trip contact of Braking Resistor
braking resistor unit. Unit (Option)[
Braking Unit ©0 B
Level
Detection 1 2
©
Short−circuit Bar Overload Relay Trip Contact
(Provided as 3 4
Standard)

MCCB ¨1 ¨2 ¨3 ©
MC
Motor
3−Phase R L1 (R) U (T1)
Power Supply
200 to 230 V S L2 (S) V (T2) IM

36
50/60 Hz
T L3 (T) W (T3)
r (ℓ 1)
M Cooling Fan
THRX OFF ON MC
(ℓ 2)
MC VS−616G5
SA
Overload Relay Trip Contact Ground (200V Class : 100Ω or less
of Braking Resistor Unit 400V Class : 10Ω or less)
THR
1 2
SA
≈ ≈
MC TRX
: Where : is “E” or “V”.
SA [ When using the braking resistor unit, set constant L3−04 to “0” (stall prevention selection during
TRX decel is disabled). If it is not changed, the inverter may not stop within set decel time.

20 18
Fault
Contact Fig. 16 For Models CIMR−G5:2018 to −G5:2022 (200 V Class 18.5, 22 kW)
 ¨ ¨0 P
Use sequencer to break
power supply side on over- Braking Resistor
load relay trip contact of Unit (Option)[
braking resistor unit. Braking Unit ©0 B
Level
Detection
1 2
©

Short−circuit Bar Overload Relay Trip Contact

(Provided as 3 4
Standard)

MCCB ¨1 ¨2 ¨3 ©
MC
3−Phase R L1 (R) Motor
Power Supply U (T1)
380 to 460 V S L2 (S) V (T2)
50/60 Hz IM

37
T L3 (T) W (T3)
400/200V r (ℓ 1)
Voltage
M Cooling Fan
THRX ON MC Selection
OFF (ℓ 2)
MC 460/440/415/
SA 400/380V
Overload Relay Trip Contact Ground (200V Class : 100Ω or less
of Braking Resistor Unit
THRX VS−616G5 400V Class : 10Ω or less)

1 2
≈ ≈
SA
MC TRX : Where : is “E” or “V”.

SA [ When using the braking resistor unit, set constant L3−04 to “0” (stall prevention selection during
TRX decel is disabled). If it is not changed, the inverter may not stop within set decel time.

20 18 Fault
Contact Fig. 17 For Models CIMR−G5:4018 to −G5:4045 (400 V Class 18.5 to 45 kW)
3. WIRING
 ¨ ¨0 P

Use sequencer to break Braking Resistor

power supply side on over- Unit (Option)[
load relay trip contact of Braking Unit ©0 B
braking resistor unit. Level
Detection 1 2

©
Overload Relay Trip Contact
3 4 (Thermal Protector Contact:
230VAC, 1A or less)

Cooling Fin Overheat Contact

(Thermoswitch Contact:
¨3 © 250VAC, 1A or less
MCCB MC 30VDC, 1A or less)
3−Phase R L1 (R) U (T1)
Power Supply VS−616G5
380 to 460 V S L2 (S) V (T2) IM Motor

38
50/60 Hz T L3 (T) W (T3)
400/200V r (ℓ 1)
Voltage
M Cooling Fan
Selection
THRX OFF ON MC 400 (ℓ 2 400)
MC 460/440/415/
SA 400/380V
Overload Relay Trip Contact Ground (200V Class : 100Ω or less
of Braking Resistor Unit 400V Class : 10Ω or less)
THRX
1 2
≈
SA
≈
MC TRX
: Where : is “E” or “V”.
SA [ When using the braking resistor unit, set constant L3−04 to
TRX “0” (stall prevention selection during decel is disabled).
If it is not changed, the inverter may not stop within set decel time.
20 18
Fault
Contact
Fig. 18 For Models CIMR−G5:4055 to −G5:4160 (400 V Class 55 to 160 kW)
 Use sequencer to break
power supply side on over- ¨ ¨0 P
load relay trip contact of Braking Resistor
braking resistor unit. ©0 B Unit (Option)[
Braking Unit
Level
Detection 1 2
©
Overload Relay Trip Contact
3 4 (Thermal Protector Contact:
230VAC, 1A or less)
Cooling Fin Overheat Contact
¨3 © (Thermoswitch Contact:
MCCB MC 250VAC, 1A or less
R 30VDC, 1A or less)
3−Phase L1 (R) U (T1)

39
Power Supply VS−616G5
200 to 230 V S L2 (S) V (T2) IM Motor
50/60 Hz L3 (T)
T W (T3)
r (ℓ 1)
M Cooling Fan
THRX OFF ON MC (ℓ 2)
MC
SA Ground (200V Class : 100Ω or less
Overload Relay Trip Contact
of Braking Resistor Unit 400V Class : 10Ω or less)
THRX
1 2
SA
≈ ≈
MC TRX : Where : is “E” or “V”.
[ When using the braking resistor unit, set constant L3−04 to
SA “0” (stall prevention selection during decel is disabled).
TRX If it is not changed, the inverter may not stop within set decel time.

20 18
Fault Fig. 19 For Models CIMR−G5:2030 to −G5:2075 (200 V Class 30 to 75 kW)
3. WIRING

Contact
 Use sequencer to break
power supply side on over-
¨ ¨0 P
load relay trip contact of Braking Resistor
braking resistor unit. Unit (Option)[
©0 B
Braking Unit
Level
Detection 1 2
©
Overload Relay Trip Contact
3 (Thermal Protector Contact:
4
230VAC, 1A or less)
Cooling Fin Overheat Contact
MCCB ¨1 ¨3 © (Thermoswitch Contact:
MC 250VAC, 1A or less
30VDC, 1A or less)
3−Phase R L1 (R) U (T1)
Power Supply

40
380 to 460 V S L2 (S) VS−616G5 V (T2) IM Motor
50/60 Hz L3 (T)
T W (T3)
400/200V r (ℓ 1) Cooling Fan
Voltage
Selection M
THRX OFF ON MC 400 (ℓ 2 400)
MC 460/440/415/
SA Ground (200V Class : 100Ω or less
Overload Relay Trip Contact 400/380V
of Braking Resistor Unit 400V Class : 10Ω or less)
THRX
1 2
≈ ≈
SA
MC : Where : is “E” or “V”.
TRX
[ When using the braking resistor unit, set constant L3−04 to
“0” (stall prevention selection during decel is disabled).
SA
If it is not changed, the inverter may not stop within set decel time.
TRX

20 18 Fault
Fig. 20 For Models CIMR−G5:4185 to −G5:4220 (400 V Class 185 to 220 kW)
Contact
 4. OPERATION

4. OPERATION

4.1 ADJUSTMENT

The braking resistor unit and braking unit do not have to be adjusted.
Especially, do not readjust the braking unit except in the case described in Par. 4.2,
“Power Supply Voltage Selection Connector Setting.”

4.2 POWER SUPPLY VOLTAGE SELECTION CON-

NECTOR SETTING

It may be necessary to select power supply voltage selection connector for braking
unit according to main circuit power supply type. Table 3 shows the relationship
between the power supply voltage selection connector and braking start voltage.
The following is the setting prior to shipment:
S 200V class : 220V

S 400V class : 440V

S 575V class : 575V

For removing the terminal cover and the indicating cover, refer to Par. 3.1.

41
 200V class
BRAKING UNIT MODEL:CDBR( 2015B
200V CLASS FOR 15kW

WARNING
200V
208V
220V
May cause injury or electric
shock.
230V
Please follow the instructions in
the manual before installation or
operation.
Disconnect all power before opening
front cover of unit. Wait 3 minutes

400V class
until DC Bus capacitors discharge.

Use proper grounding techniques.

380V
400V
415V
© ¨ ¨0 ©0 1 2 5 6 440V
460V

Fig. 21 Braking Unit Power Supply Voltage Selection

(Models CDBR−2015B, −2022B, −4030B, −4045B, Terminal Cover and
Indicating Cover Removed)

42
 4. OPERATION

200V class 400V class

380V
200V 400V
208V 415V
220V 440V
230V 460V

575V class

500V

575V

Fig. 22 Braking Unit Power Supply Voltage Selection

(Models CDBR−2045B, −2110B, −4090B, −5037B, −5110B, −5300B,
Indicating Cover Removed)

Table 3 Power Supply Voltage Selection Connector and Braking Start Voltage
200V 400V 575V
Braking Start Braking Start Braking Start
Class* Class* Class*
Voltage Voltage Voltage
Power Power Power
(PN Bus−bar (PN Bus−bar Supply (PN Bus−bar
Supply Supply
Voltage) Voltage) Voltage Voltage)
Voltage Voltage
230V 380V (TYP) 460V 760V (TYP) 575V 950V (TYP)
220V 365V (TYP) 440V 730V (TYP) − −
208V 345V (TYP) 415V 690V (TYP) − −
200V 330V (TYP) 400V 660V (TYP) 500V 825V (TYP)
− − 380V 630V (TYP) − −
*Allowable voltage fluctuation is ±10%

43
4.3 MASTER/SLAVE SELECTION CONNECTOR SETTING

Selection Connector Setting MASTER side is selected prior to shipment. Use the
units without changing the setting.
SLAVE side is selected when more than one braking unit is combined to use and
braking start levels must coincide. Refer to Par. 4.4, “Parallel Connection of Brak-
ing Unit” for details.

4.4 PARALLEL CONNECTION OF BRAKING UNIT

For using more than one parallel−connected braking unit, connect and select the
connectors as follows. (See Fig. 23.)

S Braking units have a MASTER/SLAVE selection connector. (See Fig.

10.) Select MASTER side only for braking unit 1 and select SLAVE side
for braking units 2 and 3.

S Connect thermal protector on the braking resistor unit and thermoswitch

on the braking unit in parallel. Refer to Figs. 15 and 18 for proper wiring.
S Use properly rated wire in accordance with table 2 on page 31.

S Use twisted−pair wires of 1mm or less for connection between 5, 6 and

1, 2 of the braking units.

S Parallel connection of braking unit is possible up to a maximum of 10

units.

44
 4. OPERATION

Braking Resistor Braking Resistor Braking Resistor

Overheat Contact Overheat Contact Overheat Contact
(Thermal Relay Trip Contact) (Thermal Relay Trip Contact) (Thermal Relay Trip Contact)
¨3 ©
1 2 1 2 1 2
Braking Braking Braking
Resistor Resistor Resistor
Inverter Unit Unit Unit
P B P B P B
Unit
© ¨ ¨0 ©0 © ¨ ¨0 ©0 © ¨ ¨0 ©0
MASTER MASTER
MASTER
Detection
Level

SLAVE SLAVE SLAVE

+15 5 1 Braking Unit 2 Braking Unit 3
1 5 1 5
P P
6 2 6 2 6
2

Braking Unit 1 3 4 3 4 3 4
Cooling Fin Cooling Fin Cooling Fin
Overheat Contact Overheat Contact Overheat Contact
(Thermoswitch Contact) (Thermoswitch Contact) (Thermoswitch Contact)

Fig. 23 Example of Parallel Connection of Three Braking Units

4.5 OPERATION

Check that required deceleration characteristics can be obtained. While the braking
unit is operating, BRAKE lamp lights for easy check of operation.

NOTE High voltage is applied to the braking unit. At normal operation, do

not operate the unit without cover.

45
5. TROUBLESHOOTING

Only authorized personnel should be permitted to perform maintenance and inspec-

tions or replace parts.
No. Fault Status Cause Corrective Action
S Without braking unit
Inverter built−in main circuit dis- Replace the inverter.
Braking resistor charging transistor short circuited
unit overload S With braking unit
relay (or thermal Braking unit main circuit discharging Replace the unit.
1
p
overload protec- transistor short circuited
t ) ttrips
tor) i whenh nott Improper braking unit power supply
decelerating. voltage selection connector setting
Set it again.
(Power supply voltage > power sup-
ply voltage selection position)
Insufficient braking resistor unit ca- Examine the braking
Inverter trips at pacity conditions again.
2
overvoltage (OV). Improper wiring Check and repair.
Braking unit fault Replace the unit.
Braking resistor
unit overload
Insufficient braking resistor unit ca- Examine the braking
3 relay (or thermal
pacity conditions again.
protector) some-
times trips.
Excessive start/stop switching fre-
quency Examine the operat-
Braking unit trips ing conditions again.
again
Excessive load inertia
4 by heat sink over-
heat. Improper combination of braking
Reset.
unit and braking resistor unit
Ambient temperature 104_F (40_C) Reduce it.

46
 6. SPECIFICATIONS

6. SPECIFICATIONS

6.1 BRAKING UNIT AND BRAKING RESISTOR UNIT

APPLICATION LIST

200 to 230V
Inverter Braking Unit Braking Resistor Unit Approx.
Braking
Max Applicable Model Model Torque
Motor Capacity Unit Resistor Spec. Unit
(CDBR Q’ty (LKEB Q’ty (10%ED)
HP(kW) − j) − j) (per unit)
%
0.5 (0.4) − − 20P7 70W 200Ω 1 220
1 (0.75) − − 20P7 70W 200Ω 1 125
2 (1.5) − − 21P5 260W 100Ω 1 125
3 (2.2) − − 22P2 260W 70Ω 1 120
5 (3.7) − − 23P7 390W 40Ω 1 125
7.5 (5.5) − − 25P5 520W 30Ω 1 115
10 (7.5) − − 27P5 780W 20Ω 1 125
15 (11) 2015B 1 2011 2400W 13.6Ω 1 125
20 (15) 2015B 1 2015 3000W 10Ω 1 125
25 (18.5) 2022B 1 2018 4800W 8Ω 1 125
30 (22) 2022B 1 2022 4800W 6.8Ω 1 125
40 (30) 2015B 2 2015 3000W 10Ω 2 125
50 (37) 2015B 2 2015 3000W 10Ω 2 100
60 (45) 2022B 2 2022 4800W 6.8Ω 2 120
75 (55) 2022B 2 2022 4800W 6.8Ω 2 100
100 (75) 2110B 1 2022 4800W 6.8Ω 3 110
120 (90) 2110B 1 2022 4800W 6.8Ω 4 120
150 (110) 2110B 1 2022 4800W 6.8Ω 5 100

47
380 to 460V
Inverter Braking Unit Braking Resistor Unit Approx.
Braking
Max Applicable Model Model Torque
Motor Capacity Unit Resistor Spec. Unit
(CDBR Q’ty (LKEB Q’ty (10%ED)
HP(kW) − j) − j) (per unit)
%
0.5 (0.4) − − 40P7 70W 750Ω 1 230
1 (0.75) − − 40P7 70W 750Ω 1 130
2 (1.5) − − 41P5 260W 400Ω 1 125
3 (2.2) − − 42P2 260W 250Ω 1 135
5 (3.7) − − 43P7 390W 150Ω 1 135
7.5 (5.5) − − 45P5 520W 100Ω 1 135
10 (7.5) − − 47P5 780W 75Ω 1 130
15 (11) − − 4011 1040W 50Ω 1 135
20 (15) − − 4015 1560W 40Ω 1 125
25 (18.5) 4030B 1 4018 4800W 32Ω 1 125
30 (22) 4030B 1 4022 4800W 27.2Ω 1 125
40 (30) 4030B 1 4030 6000W 20Ω 1 125
50 (37) 4045B 1 4037 9600W 16Ω 1 125
60 (45) 4045B 1 4045 9600W 13.6Ω 1 125
75 (55) 4030B 2 4030 6000W 20Ω 2 135
100 (75) 4045B 2 4045 9600W 13.6Ω 2 145
150 (110) 4030B 3 4030 6000W 20Ω 3 100
200 (160) 4220B 1 4045 9600W 13.6Ω 4 140
300 (220) 4220B 1 4037 9600W 16Ω 5 110
400 (300) 4220B 2 4045 9600W 13.6Ω 6 110
800 (600) 4220B 4 4045 9600W 13.6Ω 12 110

48
 6. SPECIFICATIONS

6.2 BRAKING UNIT FOR 575V CLASS APPLICATION LIST

Inverter Braking Unit Braking Resistor Unit Approx.

Braking
Max Applicable Torque
Model
Motor Capacity Unit Q’ty Resistor Spec. (10%ED)
(CDBR− j)
HP(kW) %
5 (3.7) − − 560W 150Ω 180
7.5 (5.5) − − 560W 150Ω 125
10 (7.5) − − 750W 100Ω 140
15 (11) − − 1100W 75Ω 125
20 (15) − − 1500W 50Ω 140
25 (18.5) − − 2300W 40Ω 140
30 (22) 5037B 1 2800W 38Ω 125
40 (30) 5037B 1 3900W 33Ω 110
50 (37) 5037B 1 4900W 27Ω 110
60 (45) 5037B 2 5900W 22Ω 110
75 (55) 5037B 2 7200W 18Ω 110
100 (75) 5110B 1 9800W 13.6Ω 105
120 (90) 5110B 1 12000W 11Ω 110
150 (110) 5110B 1 15000W 9Ω 110
200 (160) 5300B 1 21000W 6.8Ω 100

49
6.3 LIST OF APPLICABLE/NOT APPLICABLE COMBINA-
TIONS WITH CONVENTIONAL MODELS (VS−616HII/
H3, VS−616GII/G3, VS−676)
Applicable/
Conventional Braking Braking Re- Not Appli- Remarks
Model Unit sistor Unit cable
VS−616HII/H3 Model
LKEB−20P7 See connection exam-
VS−616GII/G3 − Applicable
etc. ples of Fig 14.
VS−676
Use sequencer to break
VS−616HII/H3 Model Model power supply side on
VS−616GII/G3 CDBR−15H LKEB−2015 Applicable thermal protector of
VS−676 etc. etc. the braking resistor
unit side.
VS−616HII/H3 Models
Model No thermal protective
CDBR Not applica- function of braking re-
VS−616GII/G3 LKEB−4.8K
−2015, ble
VS−676 etc. sistor unit.
−2015B etc.
VS−616HII/H3 Models
Model
CDBR See connection exam-
VS−616GII/G3 LKEB−2015 Applicable
−2015, ples of Figs. 15 to 18.
VS−676 etc.
−2015B etc.

50
 6. SPECIFICATIONS

6.4 BRAKING UNIT SPECIFICATIONS

200V to 300V 380V to 460V 500V to 575V

Braking Unit Model
CDBR− 2015 2022 2045 2110 4030 4045 4090 4220 5037 5110 5300
B B B B B B B B B B B
Applicable Motor Output 20 30 60 150 40 60 120 300 57 150 400
HP (kW) (15) (22) (45) (110) (30) (45) (90) (220) (37) (110) (300)
Max. Discharge
Current(A) 40 60 100 250 40 60 100 250 40 100 250
(peak value) *
Output Rated Discharge
15 20 30 80 15 18 30 80 15 30 80
charac- Current (A)
teristics Braking Start
330/345/365/380V ±3V 630/660/690/730/760V ±6V 825V/ 950V ±8V
Voltage
Max. Hysteresis Approx.
Approx. 8V Approx. 16V
Error 20V
Power 243 (1.35×200×0.9) to 400V 460 (1.35×380×0.9) to 800V 607 (1.35×500×0.9)
VDC
Supply peak peak to 1000V
Protec- Fin Overheat Thermostat
tive
Func- Power Charge
Charge lamp stays ON until bus voltage drops below 50V.
tions Indication
Location Indoor (protected from corrosive gases and dust)
Envion- Altitude 1000m max.
mental Ambient
+14 to 104_F (−10 to +40_C) (not frozen)
Condi- Temperature
tions Storage
Transportation −4 to 140_F (−20 to +60_C)
Temperature
Humidity 90%RH (non−condensing)
Vibration 1G at 10 to less than 20Hz, up to 0.2G at 20 to 50 Hz
Protective Configuration Wall−mounted enclosed type
Heat Loss (W) 32 38 31 64 54 59 35 71 22 53 116

* Loading time rate can be used below 10% ED (max. 10 sec.)

51
6.5 BRAKING RESISTOR UNIT SPECIFICATIONS
Allowable Allowable
Model Average Average Allowable
(LKEB Specifications Dissipated Current Ambient
− j) Power (Effective Value) Temperature
(W) (A)
20P7 70W 200Ω 30 0.39
21P5 260W 100Ω 60 0.77
22P2 260W 70Ω 89 1.1
23P7 390W 40Ω 150 1.9
25P5 200 520W 30Ω 220 2.7
to
27P5 780W 20Ω 300 3.9
230V
2011 2400W 13.6Ω 440 5.7
2015 3000W 10Ω 600 7.7
2018 4800W 8Ω 740 9.6
2022 4800W 6.8Ω 880 11.4
40P7 70W 750Ω 30 0.20
41P5 260W 400Ω 60 0.39 +14 to 122_F
((−10
10 to +50_C)
42P2 260W 250Ω 89 0.60
43P7 390W 150Ω 150 1.0
45P5 520W 100Ω 220 1.5
47P5 380 780W 75Ω 300 2.0
4011 to 1040W 50Ω 440 3.0
4015 460
460V 1560W 40Ω 600 3.9
4018 4800W 32Ω 740 4.8
4022 4800W 27.2Ω 880 5.7
4030 6000W 20Ω 1200 7.7
4037 9600W 16Ω 1500 9.7
4045 9600W 13.6Ω 1800 11.5

52
 6. SPECIFICATIONS

6.6 MODELS AND CODE NOS. OF BRAKING UNIT AND

BRAKING RESISTOR UNIT

(1) Braking Unit

Inverter
Model Code No.
No
Voltage HP (kW)
20 (15) CDBR−2015B 72600−R2150B
200 to 30 (22) CDBR−2022B 72600−R2220B
230V 60 (45) CDBR−2045B 72600−R2450B
150 (110) CDBR−2110B 72600−R21100B
40 (30) CDBR−4030B 72600−R4300B
380 to 60 (45) CDBR−4045B 72600−R4450B
460V 120 (90) CDBR−4090B 72600−R4900B
300 (220) CDBR−4220B 72600−R42200B
50 (37) CDBR−5037B 72600−R5370B
500 to
150 (110) CDBR−5110B 72600−R51100B
575V
400 (300) CDBR−5300B 72600−R53000B

53
(2) Braking Resistor Unit
Inverter Resistor Spec.
(per unit) Model Code No.
No
Voltage HP(kW)
1 (0.75) 70W 200Ω LKEB−20P7 72600−K2P70
2 (1.5) 260W 100Ω LKEB−21P5 72600−K2010
3 (2.2) 260W 70Ω LKEB−22P2 72600−K2020
5 (3.7) 390W 40Ω LKEB−23P7 72600−K2030
200 to 7.5 (5.5) 520W 30Ω LKEB−25P5 72600−K2050
230V 10 (7.5) 780W 20Ω LKEB−27P5 72600−K2070
15 (11) 2400W 13.6Ω LKEB−2011 72600−K2110
20 (15) 3000W 10Ω LKEB−2015 72600−K2150
25 (18.5) 4800W 8Ω LKEB−2018 72600−K2180
30 (22) 4800W 6.8Ω LKEB−2022 72600−K2220
1 (0.75) 70W 750Ω LKEB−40P7 72600−K4P70
2 (1.5) 260W 400Ω LKEB−41P5 72600−K4010
3 (2.2) 260W 250Ω LKEB−42P2 72600−K4020
5 (3.7) 390W 150Ω LKEB−43P7 72600−K4030
7.5 (5.5) 520W 100Ω LKEB−45P5 72600−K4050
10 (7.5) 780W 75Ω LKEB−47P5 72600−K4070
380 to
15 (11) 1040W 50Ω LKEB−4011 72600−K4110
460V
20 (15) 1560W 40Ω LKEB−4015 72600−K4150
25 (18.5) 4800W 32Ω LKEB−4018 72600−K4180
30 (22) 4800W 27.2Ω LKEB−4022 72600−K4220
40 (30) 6000W 20Ω LKEB−4030 72600−K4300
50 (37) 9600W 16Ω LKEB−4037 72600−K4370
60 (45) 9600W 13.6Ω LKEB−4045 72600−K4450

54
FOR VARISPEED-600 SERIES INVERTER
BRAKING UNIT
BRAKING RESISTOR UNIT
INSTRUCTIONS
IRUMA BUSINESS CENTER (SOLUTION CENTER)
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Phone 81-4-2962-5696 Fax 81-4-2962-6138
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Phone 44-1236-735000 Fax 44-1236-458182
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Phone 86-21-5385-2200 Fax 86-21-5385-3299
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Phone 886-2-2502-5003 Fax 886-2-2505-1280

YASKAWA ELECTRIC CORPORATION

YASKAWA
In the event that the end user of this product is to be the military and said product is to be
employed in any weapons systems or the manufacture thereof, the export will fall under
the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade
Regulations. Therefore, be sure to follow all procedures and submit all relevant
documentation according to any and all rules, regulations and laws that may apply.
Specifications are subject to change without notice
MANUAL NO. TOBP C720600 00A
for ongoing product modifications and improvements. Printed in Japan February 2007 05-3 3 -0
© 2005-2007 YASKAWA ELECTRIC CORPORATION. All rights reserved. 05-7⑦