Shangchin Electronics Corp.

GENERAL-PURPOSE
INVERTER WITH FLUX
VECTOR CONTROL

TOPGIN

TG
TG

300
600

220V 0.75 ~ 75KW

440V 2.2 ~ 300KW

BRAKING UNIT

INSTRUCTION MANUAL

THIS INSTRUCTION MANUAL WILL BE OF GREAT HELP

FOR DAILY MAINTENANCE, INSPECTION AND TROBLESHOOTING.
265, SEC. 3, CHANG MEI ROAD, HO MEI ZHEN
CHANG-HUA HSIEN, TAIWAN, R.O.C.
TEL : 886-4-7564838
FAX : 886-4-7565521
E-MAIL: topgin@topgin.com.tw
http:// www.topgin.com.tw

Before using the braking unit, a thorough understanding of this manual

recommended for daily maintenance, troubleshooting and inspection.

CONTENTS
1 RECEIVING -------------------------------------------------------- 2
2 STORAGE---------------------------------------------------------- 2
3 INSTALLATION--------------------------------------------------- 3
4 WIRING------------------------------------------------------------- 4
4.1 PART NAMES ------------------------------------------------ 4
4.2 CIRICUITS AND WIRING ----------------------------------4
4.3 WIRING PRECAUTIONS ----------------------------------- 5
4.4 WIRING DIAGRAM ----------------------------------------- 6
5 OPERATION ------------------------------------------------------- 7
5.1 ADJUSTMENT ------------------------------------------------ 7
5.2 INPUT VOLTAGE SETTING ------------------------------ 7
5.3 MASTER / SLAVE SETTING ------------------------------ 7
5.4 PARALLEL USAGE OF BRAKING UNITS ------------ 8
5.5 OPERATION --------------------------------------------------- 8
6 TROUBLE-SHOOTING ------------------------------------------ 9
7 BRAKING UNIT APPLICATION LIST ---------------------- 10
8 SEPARATELY-INSTALLED TYPE BRAKING RESISTOR --------- 11
9 SPECIFICATIONS -------------------------------------------------12
10 MODEL DESCRIPTION ----------------------------------------- 12

1-

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

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

CAUTION
1No withstand voltage tests to the braking units
2No unnecessary adjustments to the calibration resistor (RVI)
3Ground the grounding terminal " E "
4Be sure to close the cover when the braking unit is applied internally
to high voltage. Once the cover is open, please turn off the inverter
main circuit power supply and check the "CHARGE" LED has been
extinguished.
5Make sure the power has been turned off before changing the INPUT
VOLTAGE SELECTOR (CP1) or MASTER / SLAVE SELECTOR
(CP2)

2-

3 INSTALLATION
Location of the braking unit is important to achieve proper performance.
Please install the braking unit to comply with the requirements below. Fig. 1
shows the size of braking unit and mounting space needed.
1Provide the mounting space shown in Fig. 1.
2Devices sensitive to heat should be kept away from the braking
resistor generating heat.
3The braking unit must be installed at places meeting the requirements
in Par. 2 STORAGE.
4Install the braking unit in the direction shown in Fig. 1 to avoid
ventilation problems.

Fig. 1 Braking Unit Dimensions in mm

3-

4 WIRING
4.1 PART NAMES

CHARGE
LED

INPUT
VOLTAGE
SELECTOR
MASTER /
SLAVE

CALIBRATION
RESISTOR
BRAKE LED

GROUNDING TERMINAL

Fig. 2
4.2 CIRCUITS AND WIRING
TABLE 1

Circuit

Terminal Wire Size AWG (m)

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

Control Circuit

1 2 3
4 5 6

18 - 14 ( 0.75 - 2 )

4-

Wire Type

Screw

600V Vinyl
Sheathed lead
or equivalent

M4

4.3 WIRING PRECAUTIONS

4.3.1 RUBBER BUSH
Lead in the wire through the rubber bush on the bottom of the braking unit
to get better insulation.
4.3.2 SEPARATION FROM SIGNAL LINES
Separating the braking unit and braking resistor from signal lines can
reduce the noise interference to signal lines.
4.3.3 WIRING DISTANCE
Connect the braking resistor, braking unit and inverter to comply with the
requirement shown in Fig. 3.

TG600
L200

BR

TGL 400
Max 10M

INVERTER

Max 5M

BRAKING UNIT

BRAKING RESISTOR UNIT

Fig. 3 Wiring Distance

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

5-

4.4

WIRING DIAGRAM
Fig. 4 shows the interconnection between the braking unit, braking resistor
and TG600.
Braking
Resistor
Unit

Braking
Unit

AC 250V below 1A
DC30V below 1A

Fig. 4 Wiring Diagram

6-

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

5.2 INPUT VOLTAGE SETTING

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

CHARGE
LED

220V Class
230V
220V
208V
200V

INPUT
VOLTAGE
SELECTOR

MASTER /
SLAVE

440V Class

CALIBRATION
RESISTOR

460V
440V
415V
400V
380V

BRAKE LED

GROUNDING TERMINAL

Fig. 5 Input Voltage Selector CP1

TABLE 2
Input Voltage 220V Class
* Braking Start Voltage
Input Voltage 440V Class
* Braking Start Voltage

230V

220V

208V

200V

380V(TYP) 365V(TYP)45V(TY 330V(TYP)

460V

440V

415V

400V

--------------380V

760V(TYP) 730V(TYP)90V(TY 660V(TYP) 630V(TYP)

*Allowable voltage fluctuation is 10%

5.3 MASTER / SLAVE SETTING

The factory setting for CP2 (MASTER / SLAVE SELECTOR) is on
MASTER side. Only when more than one braking unit is used and the
braking start voltage must coinside , CP2 has to be set on SLAVE side.
Refer to Sec. 5.4 PARALLEL USAGE OF BRAKING UNITS for details.
7-

5.4 PARALLEL USAGE OF BRAKING UNITS

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

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

5.5 OPERATION
Check the required decelerating performance can be achieved.

DANGER
High voltage is applied to the braking unit. DO NOT
operate the braking unit with cover opened.

8-

6 TROUBLE - SHOOTING
No.

Failure Mode
The overload relay or
thermal protector
(option) for braking
resistor trips when
motor doesn't
decelerate.

Causes

Action to be taken

Without braking unit :

The built-in main circuit braking
transistor of inverter is shortcircuited.

Replace the inverter

With braking unit :

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

Replace the braking unit

The INPUT VOLTAGE SELECTOR

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

The inverter trips and

displays OV (Over
Voltage)

Braking resistor capacity is insufficient

Check the braking conditions

Improper wiring

Check wiring

Braking unit faults

Replace the braking unit

The overload relay or Braking resistor capacity is insufficient

thermal protector
(option) for braking
resistor trips sometimes
Excessive START/STOP switching
frequency

The braking unit trips

by the overheated heat
Excessive load inertia
sink

Check the braking conditions

Check the working

conditions

Improper combination of braking unit and

Select again
braking resistor
Ambient temperature is higher than 104
(40)

9-

Reduce temperature

7BRAKING UNIT APPLICATION LIST

SEPARATELY - INSTALLED TYPE

INVERTER INVERTER - MOUNTED TYPE

Resistor
MAX.
VOL- Applicable
Resistance CODE
TAGE Motor
Q'TY
(150W)
No.
(HP)

220V
Class

440V
Class

Resistor

Braking Unit

Braking
Torque
(3%ED)%

MODEL
No.

Q'TY

CODE
No.

Resistance
(per unit)

Min.
Max.
Connectable Resistance
Q'TY table Q'TY

Braking
Torque
(10%ED)%

0.5

200

TG24

220

TG1

70W 200

48

220

200

TG25

125

TG1

70W 200

48

125

100

TG26

125

TG2

260W 100

16

125

70

TG27

120

TG3

260W 70

16

120

62

TG28

100

TG4

390W 40

16

125

7.5

TG5

520W 30

9.6

115

10

TG6

780W 20

9.6

125

15

TGL-400

TG7

2400W 13.6

9.6

125

20

TGL-400

TG8

3000W 10

9.6

125

25

TGL-600

TG9

4800W 8

6.4

125

30

TGL-600

TG10

4800W 6.8

6.4

125

40

TGL-400

TG8

3000W 10

9.6

125

50

TGL-400

TG8

3000W 10

9.6

100

60

TGL-600

TG9

4800W 6.8

6.4

120

75

TGL-600

TG9

4800W 6.8

6.4

100

100

TGL-600

TG10

4800W 6.8

1.6

110

0.5

750

TG29

230

TG11

75W 750

64

230

750

TG30

130

TG11

75W 750

64

130

400

TG31

125

TG12

260W 400

64

125

300

TG32

115

TG13

260W 250

32

135

TG14

390W 150

32

135

7.5

TG15

520W 100

32

135

10

TG16

780W 75

32

130

15

TG17

1040W 50

20

135

20

TG18

1560W 40

20

125

25

TGH-400

TG19

4800W 32

19.2

125

30

TGH-400

TG20

4800W 27.2

19.2

125

40

TGH-400

TG21

6000W 20

19.2

125

50

TGH-600

TG22

9600W 16

12.8

125

60

TGH-600

TG23

9600W 13.6

12.8

125

75

TGH-400

TG21

6000W 20

19.2

135

100

TGH-600

TG23

9600W 13.6

12.8

145

150

TGH-400

TG21

6000W 20

3.2

100

200

TGH-600

TG23

9600W 13.6

3.2

140

250

TGH-400

TG23

9600W 13.6

3.2

120

300

TGH-600

TG23

9600W 13.6

3.2

125

400

TGH-600

TG23

9600W 13.6

3.2

110

10

8 SEPARATELY - INSTALLED TYPE BRAKING RESISTOR

220V
Class

440V
Class

Size(mm)

Code
no.

Screw

Resistor Spec.
(per unit)

TG1
TG2
TG3
TG4
TG5
TG6
TG7
TG8
TG9
TG10
TG11
TG12
TG13
TG14
TG15
TG16
TG17
TG18
TG19
TG20
TG21
TG22
TG23

120
120
120
120
155
155
340
380
380
380
80
120
120
120
150
150
150
170
380
380
440
440
440

180
260
260
320
340
415
425
425
485
485
140
260
260
320
340
415
425
425
485
485
640
790
790

M5*2
M5*4
M5*4
M5*4
M9*4
M9*4
M9*8
M9*8
M9*8
M9*8
M5*4
M5*4
M5*4
M5*4
M9*4
M9*4
M9*4
M9*4
M9*8
M9*8
M9*8
M9*8
M9*8

70W 200
260W 100
260W 70
390W 40
520W 30
780W 20
2400W 13.6
3000W 10
4800W 8
4800W 6.8
70W 750
260W 400
260W 250
390W 150
520W 100
780W 75
1040W 50
1560W 40
4800W 32
4800W 27.2
6000W 20
9600W 16
9600W 13.6

Applicable
Voltage

Resistor
Wiring
Applicable HP
no. (per
diagram
unit)

1
2
2
2
2
2
4
4
4
4
2
2
2
2
2
2
2
2
4
4
4
4
4

1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
3
3
2
2
2

1
2
3
5
7.5
10
15
20
25
30
1
2
3
5
7.5
10
15
20
25
30
40
50
60

MOUNTING SPACE
200mm(Min.)

NoteA and B are the approximate length

for the resistor unit

B
A

200mm(Min.)

mm
260

Wiring Diagram

R1

R2

1
P

B
R1

R1

R2

R2

R3

R4

R3

2
PP

R4

11

9 SPECIFICATIONS
TGL-400

TGL-600

TGH-400

TGH-600

Max. Applicable Motor Output HP

20

30

40

60

40

60

40

60

15

20

15

18

Output Characteristics

Braking Unit Model No.

Max. Braking Current (A)

( Peak Value ) *
Rated Braking Current (A)
Braking Start Voltage

330/345/365/380V 3V

630/660/690/730/760V 6V

about 8V

about 16V

243~400 VDC

460~800 VDC

Max. Hysteresis Error

DC Power Supply
Cooling Fin Overheat Protection
Environmental
Conditions

Power Charge Indication

Protected by thermoswitch
Charge lamp stays ON until main circuit DC voltage >= 50

Location

Indoor ( Protected from corrosive gases and dust )

Ambient Temperature

+14 to 104 (-10 to 40 ) ( not frozen )

Storage Temperature

-4 to 140 ( -20 to 60 )

Humidity

90% RH or less ( non-condensing )

Up to 9.8 m/S 2 (1G) at less than 20 Hz

Vibration

Up to 2 m/S 2 (0.2G) at 20 to 50Hz

Enclosed wall-mounted type

Protective Configuration

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

10 DEFINITION OF ED%

100%

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

T1

T0

12 -