Multipurpose Brake
Installation & Operating Manual
7/02
MN802
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multipurpose Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection of Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving, Inspection and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Startup and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cell Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5
Specifications and Product Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Size 16A-80A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Size 135A - 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque and Wire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions / Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Size 16A to 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Size 55A and 80A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Size 135A and 250A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Size 420A and 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MN802
1-1
1-1
1-2
1-2
1-4
1-5
2-1
2-1
2-1
2-2
2-2
2-2
2-3
2-4
2-4
2-6
2-8
3-1
3-1
3-1
3-1
3-1
4-1
4-1
4-2
4-3
5-1
5-1
5-2
5-4
5-4
5-5
5-6
5-6
5-7
5-7
5-8
5-9
5-10
Table of Contents i
ii Table of Contents
MN802
Section 1
General Information
Multipurpose Brake Operation
The Baldor Multipurpose brake provides smooth frictionless braking to standard three
phase AC induction motors. The brake can be used with a standard magnetic starter or
with a solid state reduced voltage starter and contactor. Braking is accomplished by
applying an adjustable DC current to the motor windings. This current sets up a stationary
magnetic field in the motor. The magnetic field causes the motor to come to a smooth
frictionless stop. The brake electronically senses when the motor has stopped and
removes the DC current (disengages the brake). (See Figure 1-1).
AC motors, when turned off, have residual magnetism that causes voltage to be present
inside the motor. Large surge currents could occur if DC is applied to the motor before
the voltage in the motor reaches a safe level. The traditional method of a fixed time delay
does not allow for the variations of motors or changes in a motor under different load
conditions. Baldor’s dynamic brake monitors the voltage in the motor and waits for the
motor voltage to drop to a safe level before applying DC braking.
The Multipurpose Brake verifies that the DC contactor has opened before allowing the AC
contactor (starter) to close. Zero speed sensing will quickly shut off the DC brake when
the motor stops. This prevents excess motor heating.
The multipurpose Brake, with its three operating modes and zero speed sensing, makes
it flexible for many applications. Sensing motor voltage and checking for the DC
contactor opening eliminates the most common failures of solid state brakes caused by
high surge currents resulting in blown AC starter fuses and welded contacts of the AC
contactor.
Figure 1-1 Typical Operation
Motor
Voltage
Motor Voltage VACRMS
Motor
Speed
Motor Speed
DC Voltage
Legend
ABCDE-
Motor AC contactor opens.
Motor voltage decreases and motor begins to slow down.
DC braking begins after a safe motor voltage level is reached.
The control senses the motor has stopped.
DC braking is turned off.
Motor Voltage
Safe Level
A B C
MN802
DE
t
General Information 1-1
Section 1
General Information
Additional Information
Stopping Time
Depending on the load, the Baldor dynamic brake can stop the motor faster than the
motor will start (at 460VAC). However, this can cause damage to the motor or the driven
machinery.
Motor Sizing
Each stop (with the dynamic brake) should be treated as a start for calculating duty cycle
and for sizing the motor. The brake does not have a duty cycle limit.
Holding Brake
A solid state brake is not a substitute for a mechanical holding brake.
Brake Sizing
Use the motor FLA and operating voltage to size the brake. All Baldor Multipurpose
Brakes can be used on high inertia loads.
Selection of Operating Mode
Three operating modes are available in the Multipurpose Dynamic Brake control. These
operating modes define sequence of braking cycle, connections of control and power
devices, setting and adjustments. Selection of Operating Mode is done by setting Dip
switch (S1) on the Brake Control Board. Available operating modes include:
Basic Mode
Master Mode
Pre-stop Mode
Basic Mode
Basic Mode features automatic sensing of motor terminal line voltage. Brake activates
automatically when voltage on the motor terminal decreases to a save level. Separate
motor starter controls govern start and stop cycle. Brake release function provides
immediate means of opening the brake contactor. This feature adds operational flexibility
and a safety factor as well.
Figure 1-2 Functional Diagram – Basic Mode
Optional
Emergency Stop Push Button
and Brake Release Switch
Full Voltage
Non-Reversing
Controller
Start/Stop
Push Buttons
Brake
Motor
1-2 General Information
MN802
Section 1
General Information
Master Mode
In Master mode, the Brake controls the motor starter operation through the Motor
Interlock. Motor Start and Stop pushbuttons are wired to the Brake Control Board.
Master Mode initiates the brake cycle when the Stop or Emergency Stop push buttons
are pressed. Extended brake times allows the motor to come to a controlled full stop
before the brake shuts off, thus avoiding uncontrolled coasting. Also, Master Mode
allows the Jog function. Jog allows conventional jogging push button control of the motor
starter contactor with motor coasting with brake action disabled. Brake release function
provides immediate means of opening the brake contactor. This feature adds operational
flexibility and a safety factor as well.
Figure 1-3 Functional Diagram – Master Mode
Emergency Stop Push Button
and Brake Release Switch
Start/Stop/Jog
Push Buttons
Full Voltage
Non-Reversing
Controller
Brake
Motor
Pre-stop Mode
In Pre-stop mode, the Brake controls the motor starter operation through the Motor
Interlock. Motor Start and Stop pushbuttons are wired to the Brake Control Board.
Pre-stop Mode initiates the brake cycle when the Start push button is pressed. The
Brake cycle includes opening of a motor starter contactor, sensing the safe voltage level,
closing the brake contactor, injecting DC current into motor winding (brake action), then
sensing zero speed and opening the brake contactor. The sequence ensures that the
motor is first stopped before starting the motor. Stop push button open the motor starter
contactor and motor coast to stop. Zero speed sensing followed by brake shut off
eliminates unnecessary heat in the motor winding.
Figure 1-4 Functional Diagram – Pre-stop Mode
Emergency Stop Push Button
and Brake Release Switch
Start/Stop
Push Buttons
Full Voltage
Non-Reversing
Controller
Brake
Motor
MN802
General Information 1-3
Safety Notice
This equipment contains voltages that may be as high as 600 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 start-up procedure or troubleshoot this equipment.
PRECAUTIONS
WARNING: A solid state Multipurpose brake is not suitable for use as a
mechanical holding brake. Because the solid state Multipurpose
brake requires AC power for braking, if power is interrupted no
braking is provided. This can be hazardous to personnel or
equipment.
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.
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: 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.
1-4 General Information
Caution:
To prevent equipment damage, be certain that the electrical service
is not capable of delivering more than the maximum line short
circuit current amperes listed for the control rating.
Caution:
Do not “Megger” test the motor while it is connected to the brake.
Failure to disconnect motor will result in extensive damage to the
brake. The brake is tested at the factory for high voltage / leakage
resistance as part of Underwriter Laboratory requirements.
Caution:
Do not connect power factor correction capacitors to motor
terminals or brake output terminals.
MN802
Limited Warranty
For a period of two (2) years from the date of original purchase, BALDOR will
repair or replace without charge controls and accessories which our
examination proves to be defective in material or workmanship. This
warranty is valid if the unit has not been tampered with by unauthorized
persons, misused, abused, or improperly installed and has been used in
accordance with the instructions and/or ratings supplied. This warranty is in
lieu of any other warranty or guarantee expressed or implied. BALDOR
shall not be held responsible for any expense (including installation and
removal), inconvenience, or consequential damage, including injury to any
person or property caused by items of our manufacture or sale. (Some
states do not allow exclusion or limitation of incidental or consequential
damages, so the above exclusion may not apply.) In any event, BALDOR’s
total liability, under all circumstances, shall not exceed the full purchase
price of the control. Claims for purchase price refunds, repairs, or
replacements must be referred to BALDOR with all pertinent data as to the
defect, the date purchased, the task performed by the control, and the
problem encountered. No liability is assumed for expendable items such as
fuses.
Goods may be returned only with written notification including a BALDOR
Return Authorization Number and any return shipments must be prepaid.
MN802
General Information 1-5
1-6 General Information
MN802
Section 2
Receiving & Installation
Receiving, Inspection and Storage
When you receive your control, there are several things you should do immediately.
1.
Observe the condition of the shipping container and report any damage
immediately to the commercial carrier that delivered your control.
2.
Verify that the part number of the control you received is the same as the part
number listed on your purchase order.
3.
If the control is to be stored for several weeks before use, be sure that it is
stored in a location that is clean, dry and free from corrosives and
contaminants. Storage temperatures must not exceed 140°F (60°C).
Quick Reference Chart
LED Indicators:
Switch (S1):
S1-1
S1-2
Brake Timer Range
OFF
OFF
ON
ON
OFF
ON
OFF
ON
1 to 17 seconds
15 to 32 seconds
30 to 47 seconds
45 to 62 seconds
S1-3
S1-4
Brake Operating Mode
OFF
ON
ON
ON
OFF
ON
Master Brake Mode
Pre-Stop Brake Mode
Basic Brake Mode
Zero Speed Sensor Disable
OFF
ON
Brake zero speed sensor ON
Brake zero speed sensor OFF
S1-6
Brake Status and Reset
OFF
ON
Brake is operational
Brake is disabled and reset
MN802
PWR
RDY RUN
BRK
12 345 6
S1
MAG1
MAG2
TIME
J6
J7
J4
BALDOR ELECTRIC
TB1
1
2
3
4
5
6
7
8
9
10
P1 P3 P2
Adjustments:
MAG1
(P1)
CCW
0
S1-5
J3
ON indicates brake contactor (BC) is closed.
J8
BRK
J2
On indicates M contactor is closed or enabled
(TB1 terminals 7 and 8 closed).
Brake ON
RUN
J5
On indicates Brake ready.
Flashing indicates error detected.
2 flashes- Improper line voltage
3 flashes- Motor contactor (M) failed to open
4 flashes- Brake contactor (BC) failed to open
5 flashes- Improper line frequency
Motor Run
RDY
Brake Ready
On indicates 115VAC input is present
Brake Logic Power ON
PWR
J1
Brake Control Board (BRDT-B2)
MAG2
(P3)
CCW
0
Time
(P2)
CCW
0
CW
100
CW
100
CW
100
Brake Magnitude Adjustment (0-100%)
Adjustment for brake torque with a motor stop push
button. See operation chart (in Section 1) for more
information.
Emergency Brake Magnitude (0-100%)
Adjustment for brake torque for emergency stop
push button. See operation chart (in Section 1) for
more information.
Brake Timer Adjustment (0-100%)
Adjusts the maximum amount of Brake Time.
When zero speed sensing is ON, timer must be
set to the longest stopping time.
Receiving & Installation 2-1
Installation
Considerations
Installation, troubleshooting and repair of this equipment should only be performed by
qualified personnel familiar with the safe operation of this device.
It should be installed in an area that is protected from direct sunlight, corrosives, harmful
gases or liquids, dust, metallic particles, and vibration. Exposure to these elements can
reduce the operating life and degrade performance of the control. When installing a
Multipurpose Brake, several factors should be considered:
Checklist
1.
Verify horsepower, line voltage, and current rating of control and motor match
the ratings of the brake panel.
2.
Verify environmental conditions are compatible with the brake panel.
3.
Examine the associated motor combination controller and verify that controller
rating and type is compatible with DC single winding injection braking for a
three phase induction motor.
4.
Verify that the power source has good line voltage regulation and that DC
injection braking will not reduce the line-to-line voltage to less than 75% of
nominal value. Line voltages less than 75% of nominal may cause brake
contactor chatter which may also result in SCR or diode damage.
5.
Determine which operating mode will be used (Basic, Master or Pre-Stop).
Refer to the Control Wiring Diagrams on the following pages to determine which
mode is right for your configuration. The existing motor control wiring and the
additional connections required for the brake panel are shown in Figures 2-5,
2-6 and 2-7.
Table 2-1 Branch-Circuit Short-Circuit and Ground-Fault Protective Device Ratings
Brake Size
(Amperes)
16A
25
30
55
80
135
160
250
420
600
2-2 Receiving & Installation
Fuse
Size
(Amperes)
60A
100A
110A
175A
175A
400A
400A
400A
800A
800A
Class
J
J
J
J
J
J
RK1 or RK5
RK1 or RK5
J or L
J or L
Instantaneous Trip
Breaker Size
(Amperes)
20A
20A
50A
100A
100A
300A
300A
300A
MN802
Procedure
1.
Mount the panel in vertical position. Refer to Section 5 for mounting
dimensions.
2.
Verify that associated combination controller is a full voltage nonreversing type
with control coil operation at 115V, 50/60Hz. Connect the line and load
terminals with proper size wire to line and load side terminals of associated
controller. Refer to schematic and torque and wire specifications in Section 5.
Do not change phase rotation. See Figure 2-5, 2-6 or 2-7.
3.
Verify that the maximum rating or setting of the motor Branch-Circuit
Short-Circuit and Ground-Fault protective devices meets the ratings shown in
Table 2-1.
Note: The M contactor must have a surge suppressor installed across its coil.
4.
Refer to Operating Chart choose the operating mode and wire remote control
switches or pushbuttons as shown on wiring diagrams (Figures 2-5, 2-6 and
2-7) for each selected specific operating mode. Route control wiring separate
from power wiring.
5.
Verify line voltage and adjust jumper on control power transformer (CPT)
primary taps.
6.
Verify correct phasing of all power connections.
7.
Apply power with motor leads disconnected and verify that motor starter
contactor and brake contactor do not close at the same time and confirm that
there is no phase to phase short circuit condition.
8.
Refer to Operation Chart; confirm chosen operating mode is set, select and set
brake time range.
9.
Set brake magnitude MAG1 adjustment potentiometer P1 to 0% (full CCW).
10. If Emergency braking is required and emergency Stop Push Button is wired, set
emergency brake magnitude MAG2 adjustment potentiometer P2 to 0%
(full CCW).
11. Set brake time potentiometer P3 to 100% (full CW).
12. Energize the motor without load and confirm that brake operates properly.
13. Energize motor at full load and stop with brake. Observe deceleration and
adjust brake magnitude and stopping time to the required sequence.
MN802
Receiving & Installation 2-3
Control Wiring Diagrams
Basic Mode
Basic Mode features automatic sensing of motor terminal line voltage. Brake activates
automatically when voltage on the motor terminal decreases to a save level. Separate
motor starter controls govern start and stop cycle. Brake release function provides
immediate means of opening the brake contactor. This feature adds operational flexibility
and a safety factor as well.
Figure 2-5 shows the Basic mode connections into an existing motor combination
controller and motor.
Use MAG1 potentiometer P1 to adjust braking magnitude for stop.
Description of Control Board Connections (Refer to Figure 2-5)
Terminal
Description
TB1-4
OPEN initiates emergency stop braking with magnitude MAG2(P3). (Open M contactor, close brake
contactor, apply DC to motor (T1, T2) with MAG2(P3), and open brake contactor at zero speed or end of
brake timer).
CLOSED allows normal operation.
TB1-6
OPEN Brake enabled (closes brake contactor).
CLOSED releases Brake (opens brake contactor).
TB1-7 & 8
Motor interlock is rated 5A at 125VAC. Motor Interlock is energized when 115VAC is applied to Brake
Control Board.
Note: For brake panels that have a higher current rating, relay R2 is installed to provide a 10 Amp rating for the
M contactor. The relay is shown but is not installed in all brake panels.
If R2 is installed, connect the Start switch and M contactor outputs to R2 terminals 1 and 3 (10 Amp,
240VAC rating).
If R2 is not installed, connect the Start switch and M contactor outputs to TB1 terminals 7 and 8 (10 Amp,
125VAC rating).
Switch (S1):
Adjustments
MAG1
(P1)
Brake Magnitude Adjustment (0-100%)
Adjusts brake torque for normal motor stop.
CCW
0
MAG2
(P3)
Emergency Brake Magnitude (0-100%)
Adjusts brake torque for emergency motor stop.
CCW
0
Time
(P2)
CW
100
CCW
0
CW
100
CW
100
Brake Timer Adjustment (0-100%)
Adjusts the maximum amount of Brake Time.
When zero speed sensing is ON, timer must be
set to the longest stopping time.
2-4 Receiving & Installation
S1-1
S1-2
Brake Timer Range
OFF
OFF
ON
ON
OFF
ON
OFF
ON
1 to 17 seconds
15 to 32 seconds
30 to 47 seconds
45 to 62 seconds
S1-3
S1-4
Brake Operating Mode
ON
ON
Basic Mode
S1-5
Zero Speed Sensor
OFF
ON
Brake zero speed sensor ON
Brake zero speed sensor OFF
S1-6
Brake Status
OFF
ON
Brake is operational
Brake is disabled and reset
MN802
Control Wiring Diagrams Continued
Figure 2-5 Basic Mode Diagram
Refer to the operation chart for the use of inputs and switches.
All switches and contacts wired to TB1 terminals 1 - 6 must be dry isolated contact type.
All control wiring must be installed in a separate conduit and routed away from the line
voltage and motor lead conduits for noise reduction.
In Basic mode, braking is activated when the voltage at the motor terminals decreases
to a safe level (80% of nominal Line voltage). P1 adjusts brake magnitude. Braking time
is controlled by timer or zero speed sensing.
If the emergency stop switch is not used, place jumper wire from TB1-4 to TB1-1.
Phase A
L2
Phase B
Phase C
Circuit
Breakers
or
Fused Inputs
L2
OL
T1
M
OL
T2
M
OL
Motor
T3
Brake Assembly
2
3
4 Emergency Stop
5
6 Brake Release
7
Motor Interlock
8
T1 T2 T3
F2
Control Board
BC
208V
230V
L1
Existing
Site Wiring
M
P1
P3
P2
TB1
1 Common
Brake Connection Diagram – Basic Mode
L1
Brake Control Board
(BRDT-B2)
S1
MAG1 MAG2 TIME
12 345 6
Notes:
J5
Notes:
460V
F1
TB1
CPT
1
7
4
R2
8
6
3
1
4 6
8
5
Fuse
Stop
Start
OL
M
M
Noise Suppressor
Relay R2 is only installed on
large brake assemblies to
provide 10A contact for
connection to M contactor.
If Relay R2 is installed,
connections should be made
to R2 pins 1 and 3.
If Relay R2 is not installed,
connections should be made
to Control Board pins 7 and 8.
Add surge suppressor if not
included in contactor coil.
Operating Modes
Basic Mode
Emergency Stop (TB1Ć4) 1. Open motor contactor
2. Close brake contactor
3. Apply DC to motor (T1, T2)
(using Magnitude 2 Ć P3)
4. Open brake contactor at zero
speed or at end of brake timer
Brake Release
1. Open brake contactor
Zero Speed Sense
Braking will stop when the motor
(S1Ć5)
stops rotating
Magnitude 1 (P1)
Adjustment for brake magnitude with
standard stop switch
Magnitude 2 (P3)
Adjustment for brake magnitude with
emergency stop switch
Time (P2)
Adjustment for time brake is applied if
zero speed sense is enabled (S1Ć5)
Operation
MN802
Receiving & Installation 2-5
Section 1
General Information
Control Wiring Diagrams Continued
Master Mode
Master Mode initiates the brake cycle when the Stop or Emergency Stop push buttons
are pressed. Extended brake times allows the motor to come to a controlled full stop
before the brake shuts off, thus avoiding uncontrolled coasting. Also, Master Mode
allows the Jog function. Jog allows conventional jogging push button control of the motor
starter contactor with motor coasting with brake action disabled. Brake release function
provides immediate means of opening the brake contactor. This feature adds operational
flexibility and a safety factor as well.
Figure 2-6 shows the Master mode connections into an existing motor combination
controller and motor.
Description of Control Board Connections (Refer to Figure 2-6)
Terminal
Description
TB1-2
OPEN allows normal operation.
CLOSED starts motor (closes M contactor).
TB1-3
Momentary OPEN stops motor (open the M contactor, closes brake contactor, apply DC to motor (T1, T2)
with MAG1 (P1), and open brake contactor at zero speed or end of brake timer).
TB1-4
OPEN initiates emergency stop braking with magnitude MAG2(P3). (Open M contactor, close brake
contactor, apply DC to motor (T1, T2) with MAG2(P3), and open brake contactor at zero speed or end of
brake timer).
CLOSED allows normal operation.
TB1-5
Momentary CLOSED starts motor (closes M contactor) while switch is closed.
When switch is released, M contactor opens without braking (motor coasts to stop).
TB1-6
OPEN Brake enabled (closes brake contactor).
CLOSED releases Brake (opens brake contactor).
TB1-7 & 8
Motor interlock is rated 5A at 125VAC. Motor Interlock is energized when 115VAC is applied to Brake
Control Board.
Note: For brake panels that have a higher current rating, relay R2 is installed to provide a 10 Amp rating for the
M contactor. The relay is shown but is not installed in all brake panels.
If R2 is installed, connect the Start switch and M contactor outputs to R2 terminals 1 and 3 (10 Amp rating).
If R2 is not installed, connect the Start switch and M contactor outputs to TB1 terminals 7 and 8 (5 Amp rating).
Switch (S1):
Adjustments
MAG1
(P1)
Brake Magnitude Adjustment (0-100%)
Adjusts brake torque for normal motor stop.
CCW
0
MAG2
(P3)
Emergency Brake Magnitude (0-100%)
Adjusts brake torque for emergency motor stop.
CCW
0
Time
(P2)
CW
100
CCW
0
CW
100
CW
100
Brake Timer Adjustment (0-100%)
Adjusts the maximum amount of Brake Time.
When zero speed sensing is ON, timer must be
set to the longest stopping time.
2-6 Receiving & Installation
S1-1
S1-2
Brake Timer Range
OFF
OFF
ON
ON
OFF
ON
OFF
ON
1 to 17 seconds
15 to 32 seconds
30 to 47 seconds
45 to 62 seconds
S1-3
S1-4
Brake Operating Mode
OFF
ON
Master Mode
S1-5
Zero Speed Sensor
OFF
ON
Brake zero speed sensor ON
Brake zero speed sensor OFF
S1-6
Brake Status
OFF
ON
Brake is operational
Brake is disabled and reset
MN802
Section 1
General Information
Control Wiring Diagrams Continued
Figure 2-6 Master Mode Diagram
Refer to the operation chart for the use of inputs and switches.
All switches and contacts wired to TB1 terminals 1 - 6 must be dry isolated contact type.
All control wiring must be installed in a separate conduit and routed away from the line
voltage and motor lead conduits. This will reduce the electromagnetic noise induction
that will cause erratic operation.
If non-momentary 2 wire control is used, place jumper wire from TB1-3 to TB1-2.
If the emergency stop switch is not used, place jumper wire from TB1-4 to TB1-1.
Phase A
L2
Phase B
Phase C
L2
Fuse
T1
OL
T2
M
OL
Motor
T3
Brake Assembly
T1 T2 T3
Control Board
2
3
4
5
6
7
8
Start
Stop
Emergency Stop
Jog
Brake Release
Motor Interlock
208V
230V
L1
Existing
Site Wiring
OL
M
F2
BC
Circuit
Breakers
or
Fused Inputs
M
P1
P3
P2
TB1
1 Common
Brake Connection Diagram – Master Mode
L1
Brake Control Board
(BRDT-B2)
S1
MAG1 MAG2 TIME
12 345 6
Notes:
J5
460V
F1
CPT
1
TB1
2
3
4
Start
Stop
Emergency Stop
Jog
Brake Release
5
6
7
R2
8
3
1
4 6
Notes:
8
5
OL
M
Noise Suppressor
Relay R2 is only installed on
large brake assemblies to
provide 10A contact for
connection to M contactor.
If Relay R2 is installed,
connections should be made
to R2 pins 1 and 3.
If Relay R2 is not installed,
connections should be made
to Control Board pins 7 and 8.
Add surge suppressor if not
included in contactor coil.
Operation
Start (TB1Ć2)
Stop (TB1Ć3)
Master Mode
1. Close motor contactor
1. Open motor contactor
2. Close brake contactor
3. Apply DC to motor (T1, T2)
(using Magnitude 1 Ć P1)
4. Open brake contactor at zero
speed or at end of brake timer
Emergency Stop (TB1Ć4) 1. Open motor contactor
2. Close brake contactor
3. Apply DC to motor (T1, T2)
(using Magnitude 2 Ć P3)
4. Open brake contactor at zero
speed or at end of brake timer
JOG (TB1Ć5)
1. Close motor contactor while
switch is closed
2. M contactor opens without braking,
motor coasts to stop
Brake Release
1. Open brake contactor
Zero Speed Sense
Braking will stop when the motor
(S1Ć5)
stops rotating
Magnitude 1 (P1)
Adjustment for brake magnitude with
standard stop switch
Magnitude 2 (P3)
Adjustment for brake magnitude with
emergency stop switch
Time (P2)
Adjustment for time brake is applied if
zero speed sense is enabled (S1Ć5)
MN802
Receiving & Installation 2-7
Control Wiring Diagrams Continued
Pre-Stop Mode
Pre-stop Mode initiates the brake cycle when the Start push button is pressed. The Brake cycle
includes opening of a motor starter contactor, sensing the safe voltage level, closing the brake
contactor, injecting DC current into motor winding (brake action), then sensing zero speed and
opening the brake contactor. The sequence ensures that the motor is first stopped before starting
the motor. Stop push button open the motor starter contactor and motor coast to stop. Zero
speed sensing followed by brake shut off eliminates unnecessary heat in the motor winding.
Figure 2-7 shows the Pre-Stop mode connections into an existing motor combination controller
and motor.
Description of Control Board Connections (Refer to Figure 2-7)
Terminal
Description
TB1-2
OPEN allows normal operation.
CLOSED starts motor (close brake contactor, apply DC to motor (T1, T2), open brake contactor and
closes M contactor).
TB1-3
Momentary OPEN stops motor (open the M contactor, motor coasts to stop).
TB1-4
OPEN initiates emergency stop braking with magnitude MAG2(P3). (Open M contactor, close brake
contactor, apply DC to motor (T1, T2) with MAG2(P3), and open brake contactor at zero speed or end of
brake timer).
CLOSED allows normal operation.
TB1-6
OPEN Brake enabled (closes brake contactor).
CLOSED releases Brake (opens brake contactor).
TB1-7 & 8
Motor interlock is rated 5A at 125VAC. Motor Interlock is energized when 115VAC is applied to Brake
Control Board.
TB1-9 & 10 115VAC input is factory wired from control power transformer.
Note: For brake panels that have a higher current rating, relay R2 is installed to provide a 10 Amp rating for the
M contactor. The relay is shown but is not installed in all brake panels.
If R2 is installed, connect the Start switch and M contactor outputs to R2 terminals 1 and 3 (10 Amp rating).
If R2 is not installed, connect the Start switch and M contactor outputs to TB1 terminals 7 and 8 (5 Amp rating).
Switch (S1):
Adjustments
MAG1
(P1)
Brake Magnitude Adjustment (0-100%)
Adjusts brake torque for normal motor stop.
CCW
0
MAG2
(P3)
Emergency Brake Magnitude (0-100%)
Adjusts brake torque for emergency motor stop.
CCW
0
Time
(P2)
CW
100
CCW
0
CW
100
CW
100
Brake Timer Adjustment (0-100%)
Adjusts the maximum amount of Brake Time.
When zero speed sensing is ON, timer must be
set to the longest stopping time.
2-8 Receiving & Installation
S1-1
S1-2
Brake Timer Range
OFF
OFF
ON
ON
OFF
ON
OFF
ON
1 to 17 seconds
15 to 32 seconds
30 to 47 seconds
45 to 62 seconds
S1-3
S1-4
Brake Operating Mode
ON
OFF
Pre-Stop Mode
S1-5
Zero Speed Sensor
OFF
ON
Brake zero speed sensor ON
Brake zero speed sensor OFF
S1-6
Brake Status
OFF
ON
Brake is operational
Brake is disabled and reset
MN802
Control Wiring Diagrams Continued
Figure 2-7 Pre-Stop Mode Diagram
Refer to the operation chart for the use of inputs and switches.
All switches and contacts wired to TB1 terminals 1 - 6 must be dry isolated contact type.
All control wiring must be installed in a separate conduit and routed away from the line
voltage and motor lead conduits. This will reduce the electromagnetic noise induction
that will cause erratic operation.
If the emergency stop switch is not used, place jumper wire from TB1-4 to TB1-1.
L2
Phase B
Phase C
L2
T1
OL
T2
M
OL
T3
Brake Assembly
Start
Stop
Emergency Stop
Brake Release
Motor Interlock
T1 T2 T3
208V
230V
J5
460V
F1
CPT
1
TB1
2
3
4
Start
Stop
Emergency Stop
Fuse
Motor
2
3
4
5
6
7
8
Control Board
L1
Existing
Site Wiring
OL
M
F2
BC
Circuit
Breakers
or
Fused Inputs
M
P1
P3
P2
TB1
1 Common
Brake Connection Diagram – Pre-Stop Mode
L1
Phase A
Brake Control Board
(BRDT-B2)
S1
MAG1 MAG2 TIME
12 345 6
Notes:
5
6
7
R2
8
3
1
4 6
Notes:
8
5
Brake Release
OL
M
Noise Suppressor
Relay R2 is only installed on
large brake assemblies to
provide 10A contact for
connection to M contactor.
If Relay R2 is installed,
connections should be made
to R2 pins 1 and 3.
If Relay R2 is not installed,
connections should be made
to Control Board pins 7 and 8.
Add surge suppressor if not
included in contactor coil.
Operation
Start (TB1Ć2)
Pre-Stop Mode
1. Close brake contactor
2. Apply DC to motor (T1, T2)
3. Open brake contactor
4. Close motor contactor
Stop (TB1Ć3)
1. Open motor contactor (motor
coasts to stop)
Emergency Stop (TB1Ć4) 1. Open motor contactor
2. Close brake contactor
3. Apply DC to motor (T1, T2)
(using Magnitude 2 Ć P3)
4. Open brake contactor at zero
speed or at end of brake timer
Brake Release
1. Open brake contactor
Zero Speed Sense
Braking will stop when the motor
(S1Ć5)
stops rotating
Magnitude 1 (P1)
Adjustment for brake magnitude with
standard stop switch
Magnitude 2 (P3)
Adjustment for brake magnitude with
emergency stop switch
Time (P2)
Adjustment for time brake is applied if
zero speed sense is enabled (S1Ć5)
MN802
Receiving & Installation 2-9
2-10 Receiving & Installation
MN802
Section 3
Startup and Maintenance
Overview
Before the Multipurpose Brake is placed into service, adjustment of its operating
characteristics is required. None of the adjustments are preset at the factory. Be careful
not to damage the potentiometers during adjustment. They have a maximum rotation
span of 270 degrees. Use the adjustment wand provided and do not force the
adjustments beyond the stops. Two tools are needed for these adjustments.
Initial Adjustments
Operation Checks
Maintenance
Volt ohm meter (VOM) - at least 20kW per volt.
Adjustment wand provided with the Multipurpose Brake.
Use this procedure as a guideline to match the braking characteristics to the motor load.
1.
Confirm operating mode, time range switch settings and external pushbutton
and selector switch connections.
2.
Set MAG1 potentiometer P1 to 0 (full CCW).
3.
Set brake TIME potentiometer P2 to 100% (full CW).
4.
Adjust MAG1 and TIME as needed to obtain correct stop sequence.
After the initial adjustments are complete, these operation checks should be performed to
ensure optimum operation of the control.
1.
Measure the line voltage at the control L1 and L2 terminals during acceleration.
The line voltage should never be less than the minimum operating voltage.
2.
Measure the voltage at TB1-9 and TB1-10 of the Brake Control Board.
It should be 120VAC (±10%).
The control should be checked at regular intervals.
Disconnect all input power before any maintenance checks are performed.
MN802
Check all connections for tightness and signs of overheating.
Check for cracked or damaged insulators and terminal blocks.
Inspect heat sinks for cleanliness. Be sure to remove dust or dirt buildup and to
maintain proper ventilation.
Remove dust and dirt by vacuuming. Do not wash or use solvents.
Startup and Maintenance 3-1
Section 1
General Information
3-2 Startup and Maintenance
MN802
Section 4
Troubleshooting
Preliminary Checks
In the event of trouble disconnect all input power to the control and perform these
preliminary checks.
Check all electrical connections to verify they are proper for the operating mode
selected. (Refer to Installation Section 2 and Control Wiring Diagrams in
Sections 2 and 5 of this manual.)
Verify that DIP switches are correctly set for the operating mode selected.
(Refer to Installation Section 2 of this manual.)
Verify that the Motor Interlock (TB1-7 and TB1-8) are properly connected in
series with the Motor Contractor coil.
Verify TIME (P2) is fully CCW, 0% braking time.
Verify MAG1 (P1) is fully CCW, 0% braking magnitude.
Verify MAG2 (P3) is fully CW, 100% braking.
Check all connections for tightness and signs of overheating.
Check for cracked or damaged insulators and terminal blocks.
Check all motor connections from the control to the motor.
Verify transformer primary line connections are proper for line voltage.
(See transformer nameplate).
LED Indicators (Brake Control Board)
RDY- Ready LED should be continuously on. If the RDY LED is flashing, it is signaling an
error condition. The number of flashes indicates one of the following:
2 flashes Improper line voltage.
3 flashes Motor contactor (M) failed to open.
4 flashes Brake contactor (BC) failed to open.
5 flashes Improper line frequency.
Resistance checks:
Be sure that all power to the control is still disconnected. Use a VOM (at least 20kW per
volt) and check the resistance at the following terminals. The measured resistance
should be greater than 10kW for each measurement on the power cell.
KS to AA (SCR cathode to common anode)
AA to KD (common anode to diode cathode)
If the measured resistance is less than 10kW for any measurement, a power cell (SCR
and Diode pair) is defective. If a shorted SCR is found, be sure to check for shorted
connections, system grounds, or any other condition that may cause the short.
Replacement of an SCR without determining the cause of failure may result in repeat
failures.
MN802
Troubleshooting 4-1
Control Board Checks
Several steps need to be performed before testing the control board.
1.
Disconnect all input power.
2.
Disconnect all motor leads.
3.
Disconnect wires to the control board terminals TB1-7 and TB1-10.
Figure 4-1 Control Board (BRDT-B2) Resistance Measurements
Circuit
Rating
Rating
016-080
135-250
Resistance
Gate to Anode (SCR)
J8 - J4
J8 - AA
Greater than 10 K ohms
Cathode to Anode (SCR)
J3 - J4
J3 - AA
Greater than 10 K ohms
Anode to Cathode (SCR)
J4 - J3
AA - J3
Greater than 10 K ohms
Anode to Cathode (Diode)
J4 - J2
AA - J2
Greater than 10 K ohms
Cathode to Anode (Diode)
J2 - J4
J2 - AA
Greater than 10 K ohms
BRDT-B2 to KD
J2 - KD
J2 - KD
Less than 5 ohms
BRDT-B2 to KS
J3 - KS
J3 - KS
Less than 5 ohms
BRDT-B2 to AA
J4 - AA
NA
Less than 5 ohms
BRDT-B2 to GK
J8 - GK
J8 - GK
Less than 5 ohms
Motor Interlock
TB1-7 to TB1-8
Greater than 10 K ohms
Power Supply XFMR
TB1-9 to TB1-10
350 to 450 ohms
Brake Power Cell
(BPC)
CS
AA
RS
AA
5 to 30 ohms
KS
KS
J8 - J3
KD
J8 - J3
SCR
Gate to Cathode (SCR)
SCR
Measurement
GK
Brake Control Board (BRDT-B2)
Diode
J6
J7
J4
J3
J8
J2
J5
J1
KD
BALDOR ELECTRIC
PWR
RDY RUN
BRK
12 345 678
MAG1
4-2 Troubleshooting
MAG2
TIME
TB1
1
2
3
4
5
6
7
8
9
10
MN802
Power Cell Checks
Several steps need to be performed before testing the power cell.
1.
Disconnect all input power.
2.
Disconnect all motor leads.
3.
Inspect all connections for tightness and indications of overheating.
4.
Snubber capacitors should be replaced if there is any sign of leakage.
Brakes size 16A to 80A have snubber capacitors on the control board.
Larger brakes have capacitors installed on power cells.
5.
SCR clamps should be inspected for cracks and tightened evenly using a clamp
gauge. A clamp gauge is available from Baldor or shipped with the replacement
SCR/Diode kit.
6.
Heat sinks and insulated surfaces must be clean and free of debris. Air flow
must not be obstructed.
Figure 4-2 Power Cell (BPC) -SCR Resistance Measurements
BPC
Resistance
Gate to Anode (SCR)
GK - AA
Greater than 10 K ohms
Cathode to Anode (SCR)
KS - AA
Greater than 10 K ohms
Anode to Cathode (SCR)
AA - KS
Greater than 10 K ohms
Anode to Cathode (Diode)
AA - KD
Greater than 10 K ohms
Cathode to Anode (Diode)
KD - AA
Greater than 10 K ohms
CS
AA
KS
AA
5 to 30 ohms
KS
GK - KS
RS
KD
Gate to Cathode (SCR)
SCR
Circuit
SCR
Measurement
GK
Diode
KD
MN802
Troubleshooting 4-3
Section 1
General Information
4-4 Troubleshooting
MN802
Section 5
Specifications and Product Data
Identification
B Q 7 – 030 – C B
–***
Control Type
B- Dynamic Brake
Custom Product Part Number
Brake Type
Q- 3 Operating Modes
Input Voltage Code 7208/230/460VAC (50/60Hz)
8220/230/460/575VAC (50/60Hz)
9380/415VAC (50/60Hz)
Enclosure
BNEMA1
CNEMA12
PPanel / Open
DNEMA4
Ampere Rating 01616 Amp
03030 Amp
05555 Amp
08080 Amp
135135 Amp
160160 Amp
250250 Amp
420420 Amp
600600 Amp
Configuration
CIncludes control power
transformer The brake must have a separate 115VAC input. The inpur voltage code is the range of voltages over which the
brake will operate. For example, voltage code “7” will operate between 208 - 460VAC.
Use rated motor full load current (FLA) to select the proper size brake.
Stocked multi-purpose dynamic brakes are shipped with control power transformer included. Be sure to set the
primary voltage tap jumper to match the applied line voltage.
MN802
Specifications and Product Data 5-1
General Specifications
Output Ratings
Output Horsepower and Current by Model Number
Input
Voltage
VAC
BQXĆ016ĆCY
Q
BQXĆ030ĆCY
Q
BQXĆ055ĆCY
Q
BQXĆ080ĆCY
Q
BQXĆ135ĆCY
Q
BQXĆ160ĆCY
Q
BQXĆ250ĆCY
Q
BQXĆ420ĆCY
Q
BQXĆ600ĆCY
Q
BQXĆ016ĆCY
HP
A
BQXĆ030ĆCY
HP
A
BQXĆ055ĆCY
HP
A
BQXĆ080ĆCY
HP
A
BQXĆ135ĆCY
HP
A
BQXĆ160ĆCY
HP
A
BQXĆ250ĆCY
HP
A
BQXĆ420ĆCY
HP
A
BQXĆ600ĆCY
HP
A
4
5
10
10
10
10
20
25
20
20
40
50
25
30
60
75
40
50
100
125
50
60
125
150
75
100
200
250
150
150
350
400
200
250
500
600
208
230
460
575
16
16
16
16
30
30
30
30
55
55
55
55
80
80
80
80
135
135
135
135
160
160
160
160
250
250
250
250
420
420
420
420
600
600
600
600
Input Ratings
Input Frequency
50/60 HZ ± 5%
Input Voltage
± 10% of Input Voltage Rating (208, 230, 460 or 575 VAC)
Input Current
16, 30, 55, 80,135, 160, 250, 420 or 600 Amperes (see Output
Ratings table)
Note: Use rated motor full load current (FLA) to select the proper
Multi-Purpose Brake model number for your application.
Phase
Three (3) Phase
Service Factor
1.0
Duty
Continuous
Operating Conditions
Ambient Operating Temperature:
30-113°F (0 to +45 °C) enclosed
30-122°F (0 to +50 °C) open panel
Derate Output 1.5% per 1°C over maximum ambient
Rated Storage Temperature:
– 30 °C to +65 °C
Humidity:
90% RH Non-Condensing
Altitude:
Sea level to 3300 Feet (1000 Meters)
Derate 1% per 330 Feet (100 Meters) above 3300 Feet
Enclosure:
Open Panel
NEMA 1
NEMA 12
NEMA 4
Heat Loss
1 Watt per running ampere of input current while braking.
5-2 Specifications and Product Data
(Indoor)
(Industrial indoor, general purpose)
(Industrial indoor, dust proof)
(Outdoor)
MN802
Control Specifications
Control Method
Common Anode SCR and Diode to achieve DC
Peak Inverse Voltage
1200V - for 460VAC controls; 1600V - for 575VAC controls
Brake Magnitude
Two (2) adjustable brake magnitudes
Brake Timer Ranges
1-17 seconds; 15-32 seconds; 30-47 seconds; 45-62 seconds
Zero Speed Sensor
Selectable (Brake disengages when motor stops rotating)
Motor Interlock Contact Rating
10 Amperes at 125VAC
Status LED’s
Power, Ready, Run and Braking
Error Indications
Improper line voltage; Improper line frequency;
Motor contact failed to open; Brake contactor failed to open;
Listings
UL and cUL
MN802
Specifications and Product Data 5-3
Control Wiring Diagrams
Size 16A-80A
Multipurpose Brake
Line Input
L1
12 345 6
MAG1 MAG2 TIME
1
2
3
4
5
6
7
8
9
10
J7
Brake
P1
Control
P3
Board
P2
TB1
Common
Start
Stop
Emergency Stop
Jog
Brake Release
CS
RS
L3
CB
J6
S1
L2
L2
L1
BC
BC
J2
J1
J4
SCR
J3
J8
3
1
KS
GK
CS
MOV
AA
M
M
RS
OL
OL
MOV
Motor Interlock
KD
115VAC Input
F3
X2
115VAC
CPT
J5
H1-460V
H2-230V
F1
TB2
T1
T2
T3
Motor
H3-208V
F2
X1
Note: F1 is connected to H1 for 460VAC operation.
For 230VAC remove the wire from H1 and connect it to H2.
For 208VAC operation remove the wire from H1 and connect it to H3.
LEGEND
AAAnode (Diode & SCR)
BCBrake Contactor
BCBBrake Control Board
CBCMotor Circuit Breaker
CPTControl Power Transformer
CSSnubber Capacitor
F1,2Transformer Primary Fuses
F3Transformer Secondary Fuse
KDDiode (Cathode)
KSSCR (Cathode)
MMotor Contactor
MOVMetal Oxide Varistor
OLMotor Overload
P1, P2, P3- Potentiometer
RSSnubber Resistor
S1Switch
SCRBrake SCR/Diode Assembly
TB1Brake Control Terminals
TB2Brake Output Terminals
5-4 Specifications and Product Data
Caution:
Do not connect power factor correction
capacitors to the brake output terminals.
Note: Refer to Section 2 of this manual for TB1 wiring and
motor contactor coil connection information.
Power wiring between motor controller and motor conduit box.
Refer to local codes and NEC for required wire sizing and wire practice.
Power wiring between brake and motor controller or between brake and
motor conduit box. Refer to the Torque and Wire Specifications table in
this manual for load wire sizing.
Zero Speed sensing and low voltage sensing input conductor. When motor
is located more than 50 feet from brake and zero speed sensing is used to
stop braking action, use #14 AWG or larger wire for this connection. If it
does not violate local electrical code, run this control wire in a separate
conduit from T1 and T2 DC Brake power wires.
MN802
Control Wiring Diagrams Continued
Size 135A - 600A
Multipurpose Brake
3
2
R2
R1
Line Input
7
L2
L1
1
J6
12 345 6
R2
4
MAG1 MAG2 TIME
6
R2
8
1
R2
5
Relay R2 Terminals
2
R2
7
2
3
4
5
6
7
8
9
10
J7
BC
1
L2
L3
CB
BC
S1
Brake
P1
Control
P3
Board
P2
TB1
Common
Start
Stop
Emergency Stop
Jog
Brake Release
CS
J2
J1
J4
KS
BPC
RS
J3
J8
3
1
MOV
GK
CS
CS
SCR
M
M
RS
RS
OL
OL
AA
MOV
Diode
Motor Interlock
KD
115VAC Input
J5
TB2
R1
L1
F3
X2
3
115VAC
CPT
H1-460V
H2-230V
T2
T3
Motor
F1
H3-208V
X1
T1
F2
Note: Connect F1 to H1 for 460VAC operation or remove the wire from H1
and connect it to H2 for 230VAC or to H3 for 208VAC operation.
LEGEND
AAAnode (Diode & SCR)
BCBrake Contactor
Caution:
Do not connect power factor correction
BCBBrake Control Board
BCPBrake Power Cell
capacitors to the brake output terminals.
CBMotor Circuit Breaker
CPTControl Power Transformer
Note: Refer to Section 2 of this manual for TB1 wiring and
CSSnubber Capacitor
motor contactor coil connection information.
F1,2Transformer Primary Fuses
F3Transformer Secondary Fuse
GKGate (SCR)
KDDiode Cathode
Power wiring between motor controller and motor conduit box.
KSSCR Cathode
Refer to local codes and NEC for required wire sizing and wire practice.
L1,2AC Power Input
MMotor Contactor
Power wiring between brake and motor controller or between brake and
MOVMetal Oxide Varistor
motor conduit box. Refer to the Torque and Wire Specifications table in
OLMotor Overload
this manual for load wire sizing.
P1, P2, P3- Potentiometer
Zero Speed sensing and low voltage sensing input conductor. When motor
R1Brake Contactor Relay
is located more than 50 feet from brake and zero speed sensing is used to
R2Motor Interlock Relay
RSSnubber Resistor
stop braking action, use #14 AWG or larger wire for this connection. If it
S1Switch
does not violate local electrical code, run this control wire in a separate
SCRBrake SCR/Diode Assembly
conduit from T1 and T2 DC Brake power wires.
T1,2,3- Motor Leads
TB1Brake Control Terminals
TB2Brake Output Terminals
MN802
Specifications and Product Data 5-5
Torque and Wire Specifications
Ampere
Rating
16
30
55
80
135
160
250
420
600
TB1
Torque
Lb-in
Nm
9
1
9
1
9
1
9
1
9
1
9
1
9
1
9
1
9
1
Line
Wire Size
AWG
mm2
12-22
3.31-0.326
12-22
3.31-0.326
12-22
3.31-0.326
12-22
3.31-0.326
12-22
3.31-0.326
12-22
3.31-0.326
12-22
3.31-0.326
12-22
3.31-0.326
12-22
3.31-0.326
Torque
Lb-in
Nm
Refer to tightening
torque specified on
terminal label.
Load
Wire Size
AWG
mm2
10
5.26
6
13.3
4
21.3
3
26.7
3/0
85.0
3/0
85.0
350MCM
177
(2) 300MCM (2) 152
(2) 300MCM (2) 152
Torque
Lb-in
Nm
Refer to tightening
torque specified on
terminal label.
Wire Size
AWG
mm2
10
5.26
6
13.3
4
21.3
3
26.7
3/0
85.0
3/0
85.0
350MCM
177
(2) 300MCM (2) 152
(2) 300MCM (2) 152
Mounting Dimensions
Ampere
Rating
16
30
55
80
135
160
250
420
600
H
14.75
14.75
14.75
14.75
21.0
21.0
21.0
33.0
33.0
Panel / Open
D
a
5.0
14.25
5.0
14.25
6.0
14.25
6.0
14.25
8.0
19.24
8.0
19.24
8.0
19.24
9.75
31.24
9.75
31.24
W
12.88
12.88
12.88
12.88
21.0
21.0
21.0
33.0
33.0
b
12.26
12.26
12.26
12.26
19.24
19.24
19.24
31.24
31.24
dia.
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.50
0.50
H
16.0
16.0
16.0
16.0
24.0
24.0
24.0
36.0
36.0
W
14.0
14.0
14.0
14.0
24.0
24.0
24.0
36.0
36.0
Panel / Open
D
b
12.0
12.0
12.0
12.0
18.0
18.0
18.0
30.0
30.0
dia.
0.31
.031
0.31
0.31
0.44
0.44
0.44
0.44
0.44
NEMA 12 Enclosure
b
H
NEMA 12
D
a
6.3
16.75
6.3
16.75
6.3
16.75
6.3
16.75
10.0
25.24
10.0
25.24
10.0
25.24
12.0
37.24
12.0
37.24
D
a
b
H
a
dia.
dia.
W
5-6 Specifications and Product Data
W
MN802
Dimensions / Panel Layout
Size 16A to 30A
12.88
12.26
Depth = 5″
CPT
L1
F1
0.25″
Holes
L2
F2
BC
14.75
F3
J1
BCB
J2
SCR
J8
J3
GK
BALDOR ELECTRIC
14.25
J5
KD
KS
AA
TB2
J4
J7
J6
T1 T2 T3
GND
Legend:
AA
BC
BCB
BPC
CPT
F1,2,3
GK
GND
KD
KS
L1,2
R1
R2
SCR
T1,2,3
TB2
MN802
Anode (Diode & SCR)
Brake Contactor
Brake Control Board
Brake Power Cell
Control Power Transformer
Fuses F1, F2 F3
Gate (SCR)
Earth (Ground)
Cathode (Diode)
Cathode (SCR)
AC Power lines
Brake Contactor Relay
Motor Interlock Relay
Silicon Controlled Rectifier
Motor Leads
Terminal Strip for motor leads
Specifications and Product Data 5-7
Dimensions / Panel Layout Continued
Size 55A and 80A
12.88
12.26
Depth = 6″
GND
0.25″
Holes
TB2
CPT
T1 T2 T3
L1
L2
F1
F2
14.75
BC
14.25
F3
SCR
GK
KD
KS
AA
J4
J7
J6
J8
J3
J2
J5
J1
BCB
BALDOR ELECTRIC
Legend:
AA
BC
BCB
BPC
CPT
F1,2,3
GK
GND
KD
KS
L1,2
R1
R2
SCR
T1,2,3
TB2
Anode (Diode & SCR)
Brake Contactor
Brake Control Board
Brake Power Cell
Control Power Transformer
Fuses F1, F2 F3
Gate (SCR)
Earth (Ground)
Cathode (Diode)
Cathode (SCR)
AC Power lines
Brake Contactor Relay
Motor Interlock Relay
Silicon Controlled Rectifier
Motor Leads
Terminal Strip for motor leads
5-8 Specifications and Product Data
MN802
Dimensions / Panel Layout Continued
Size 135A and 250A
21
19.24
BPC
KS
0.25″
Holes
Depth =8″
G
GND
CS
L1
T1
RS
T2
L2
T3
KS
SCR
AA
TB2
21
BC
Diode
19.24
KD
BALDOR
J4
J7
J6
J8
J3
CPT
J2
J5
J1
BCB
R1
BALDOR ELECTRIC
R2
F1
F2
F3
Legend:
AA
BC
BCB
BPC
CPT
F1,2,3
G
GK
GND
KD
KS
L1,2
R1
R2
RS
SCR
T1,2,3
TB2
MN802
Anode (Diode & SCR)
Brake Contactor
Brake Control Board
Brake Power Cell
Control Power Transformer
Fuses F1, F2 F3
Gate (SCR)
Earth (Ground)
Cathode (Diode)
Cathode (SCR)
AC Power lines
Brake Contactor Relay
Motor Interlock Relay
Snubber Resistor
Silicon Controlled Rectifier
Motor Leads
Terminal Strip for motor leads
Specifications and Product Data 5-9
Dimensions / Panel Layout Continued
Size 420A and 600A
33.00
31.24
GND
Depth =9.75″
0.50″
Holes
BPC
A
B
L1
T2
L2
T3
SCR
T1
TB2
33.00
S
BC
SCR
31.24
T
GT
SA
SB
GL
L
CS
RS
R1
R2
CPT
BALDOR ELECTRIC
J4
J7
J6
J8
J3
J2
J5
J1
BCB
F1
F2
F3
Legend:
AA
BC
BCB
BPC
CPT
F1,2,3
G
GK
GND
KD
KS
L1,2
R1
R2
RS
SCR
T1,2,3
TB2
Anode (Diode & SCR)
Brake Contactor
Brake Control Board
Brake Power Cell
Control Power Transformer
Fuses F1, F2 F3
Gate (SCR)
Earth (Ground)
Cathode (Diode)
Cathode (SCR)
AC Power lines
Brake Contactor Relay
Motor Interlock Relay
Snubber Resistor
Silicon Controlled Rectifier
Motor Leads
Terminal Strip for motor leads
5-10 Specifications and Product Data
MN802
BALDOR ELECTRIC COMPANY
P.O. Box 2400
Ft. Smith, AR 72902–2400
(479) 646–4711
Fax (479) 648–5792
 Baldor Electric Company
MN802
Printed in USA
7/02 C&J 1000