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1 Multipurpose BrakeInstallation & Operating Manual7/02MN802 Table of ContentsTable of Contents iMN802 Section 1 General Information1-1.. Multipurpose Brake Operation1-1.. Additional Information1-2.. Selection of Operating Mode1-2.. Safety Notice1-4.. Limited Warranty1-5.. Section 2 Receiving & Installation2-1.. Receiving, Inspection and Storage2-1.. Quick Reference Chart2-1.. Installation2-2.. Considerations2-2.. Checklist2-2.. Procedure2-3.. control Wiring Diagrams2-4.. Basic Mode2-4.. Master Mode2-6.. Pre-Stop Mode2-8.. Section 3 Startup and Maintenance3-1.. Overview3-1.. Initial Adjustments3-1.. Operation Checks3-1.. Maintenance3-1.. Section 4 Troubleshooting4-1.. Preliminary Checks4-1.. control Board Checks4-2.. Power Cell Checks4-3.. Section 5 Specifications and Product Data5-1.. Identification5-1.. General Specifications5-2.. control Wiring Diagrams5-4.. Size 16A-80A5-4.. Size 135A - 600A5-5.. Torque and Wire Specifications5-6.. Mounting Dimensions5-6.

2 Dimensions / Panel Layout5-7.. Size 16A to 30A5-7.. Size 55A and 80A5-8.. Size 135A and 250A5-9.. Size 420A and 600A5-10.. ii Table of ContentsMN802 Section 1 General InformationGeneral Information 1-1MN802 Multipurpose Brake OperationThe baldor Multipurpose Brake provides smooth frictionless braking to standard threephase AC induction motors. The Brake can be used with a standard magnetic starter orwith a solid state reduced voltage starter and contactor. Braking is accomplished byapplying an adjustable DC current to the motor windings. This current sets up a stationarymagnetic field in the motor. The magnetic field causes the motor to come to a smoothfrictionless stop. The Brake electronically senses when the motor has stopped andremoves the DC current (disengages the Brake ). (See Figure 1-1).AC motors, when turned off, have residual magnetism that causes voltage to be presentinside the motor. Large surge currents could occur if DC is applied to the motor beforethe voltage in the motor reaches a safe level.

3 The traditional method of a fixed time delaydoes not allow for the variations of motors or changes in a motor under different loadconditions. baldor s dynamic Brake monitors the voltage in the motor and waits for themotor voltage to drop to a safe level before applying DC Multipurpose Brake verifies that the DC contactor has opened before allowing the ACcontactor (starter) to close. Zero speed sensing will quickly shut off the DC Brake whenthe motor stops. This prevents excess motor Multipurpose Brake , with its three operating modes and zero speed sensing, makesit flexible for many applications. Sensing motor voltage and checking for the DCcontactor opening eliminates the most common failures of solid state brakes caused byhigh surge currents resulting in blown AC starter fuses and welded contacts of the 1-1 Typical Operation A B C D EtMotor VoltageSafe LevelMotorVoltageMotor SpeedMotor SpeedMotor Voltage VACRMSDC VoltageLegendA - Motor AC contactor - Motor voltage decreases and motor begins to slow - DC braking begins after a safe motor voltage level is - The control senses the motor has - DC braking is turned 1 General Information1-2 General InformationMN802 Additional InformationStopping TimeDepending on the load, the baldor dynamic Brake can stop the motor faster than themotor will start (at 460 VAC).

4 However, this can cause damage to the motor or the SizingEach stop (with the dynamic Brake ) should be treated as a start for calculating duty cycleand for sizing the motor. The Brake does not have a duty cycle BrakeA solid state Brake is not a substitute for a mechanical holding SizingUse the motor FLA and operating voltage to size the Brake . All baldor MultipurposeBrakes can be used on high inertia of Operating ModeThree operating modes are available in the Multipurpose Dynamic Brake control . Theseoperating modes define sequence of braking cycle, connections of control and powerdevices, setting and adjustments. Selection of Operating Mode is done by setting Dipswitch (S1) on the Brake control Board. Available operating modes include: Basic Mode Master Mode Pre-stop ModeBasic ModeBasic Mode features automatic sensing of motor terminal line voltage. Brake activatesautomatically when voltage on the motor terminal decreases to a save level. Separatemotor starter controls govern start and stop cycle.

5 Brake release function providesimmediate means of opening the Brake contactor. This feature adds operational flexibilityand a safety factor as 1-2 Functional Diagram Basic Mode Full Voltage Non-ReversingControllerStart/StopPush ButtonsMotorBrakeOptional Emergency Stop Push Buttonand Brake Release SwitchSection 1 General InformationGeneral Information 1-3MN802 Master ModeIn Master mode, the Brake controls the motor starter operation through the MotorInterlock. Motor Start and Stop pushbuttons are wired to the Brake control Mode initiates the Brake cycle when the Stop or Emergency Stop push buttonsare pressed. Extended Brake times allows the motor to come to a controlled full stopbefore the Brake shuts off, thus avoiding uncontrolled coasting. Also, Master Modeallows the Jog function. Jog allows conventional jogging push button control of the motorstarter contactor with motor coasting with Brake action disabled. Brake release functionprovides immediate means of opening the Brake contactor.

6 This feature adds operationalflexibility and a safety factor as 1-3 Functional Diagram Master Mode Full Voltage Non-ReversingControllerStart/Stop/JogPus h ButtonsMotorBrakeEmergency Stop Push Buttonand Brake Release SwitchPre-stop ModeIn Pre-stop mode, the Brake controls the motor starter operation through the MotorInterlock. Motor Start and Stop pushbuttons are wired to the Brake control Mode initiates the Brake cycle when the Start push button is pressed. TheBrake 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), thensensing zero speed and opening the Brake contactor. The sequence ensures that themotor is first stopped before starting the motor. Stop push button open the motor startercontactor and motor coast to stop. Zero speed sensing followed by Brake shut offeliminates unnecessary heat in the motor 1-4 Functional Diagram Pre-stop Mode Full Voltage Non-ReversingControllerStart/StopPush ButtonsMotorBrakeEmergency Stop Push Buttonand Brake Release Switch1-4 General InformationMN802 Safety NoticeThis equipment contains voltages that may be as high as 600 volts!

7 Electrical shock cancause serious or fatal injury. Only qualified personnel should attempt the start-upprocedure or troubleshoot this equipment may be connected to other machines that have rotating parts or partsthat are driven by this equipment. Improper use can cause serious or fatal injury. Onlyqualified personnel should attempt the start-up procedure or troubleshoot this WARNING: A solid state Multipurpose Brake is not suitable for use as amechanical holding Brake . Because the solid state Multipurposebrake requires AC power for braking, if power is interrupted nobraking is provided. This can be hazardous to personnel orequipment. WARNING: Do not touch any circuit board, power device or electricalconnection before you first ensure that power has beendisconnected and there is no high voltage present from thisequipment 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 ofthis equipment.

8 This equipment may be connected to othermachines that have rotating parts or parts that are controlled bythis equipment. Improper use can cause serious or fatal qualified personnel should attempt the start-up procedure ortroubleshoot this equipment. WARNING: Be sure the system is properly grounded before applying not apply AC power before you ensure that all groundinginstructions have been followed. Electrical shock can causeserious or fatal injury. Caution:To prevent equipment damage, be certain that the electrical serviceis not capable of delivering more than the maximum line shortcircuit current amperes listed for the control rating. Caution:Do not Megger test the motor while it is connected to the to disconnect motor will result in extensive damage to thebrake. The Brake is tested at the factory for high voltage / leakageresistance as part of Underwriter Laboratory requirements. Caution:Do not connect power factor correction capacitors to motorterminals or Brake output Information 1-5MN802 Limited WarrantyFor a period of two (2) years from the date of original purchase, baldor willrepair or replace without charge controls and accessories which ourexamination proves to be defective in material or workmanship.

9 Thiswarranty is valid if the unit has not been tampered with by unauthorizedpersons, misused, abused, or improperly installed and has been used inaccordance with the instructions and/or ratings supplied. This warranty is inlieu of any other warranty or guarantee expressed or implied. baldor shall not be held responsible for any expense (including installation andremoval), inconvenience, or consequential damage, including injury to anyperson or property caused by items of our manufacture or sale. (Somestates do not allow exclusion or limitation of incidental or consequentialdamages, so the above exclusion may not apply.) In any event, baldor stotal liability, under all circumstances, shall not exceed the full purchaseprice of the control . Claims for purchase price refunds, repairs, orreplacements must be referred to baldor with all pertinent data as to thedefect, the date purchased, the task performed by the control , and theproblem encountered.

10 No liability is assumed for expendable items such may be returned only with written notification including a BALDORR eturn Authorization Number and any return shipments must be General InformationMN802 Section 2 Receiving & InstallationReceiving & Installation 2-1MN802 Receiving, Inspection and StorageWhen you receive your control , there are several things you should do the condition of the shipping container and report any damageimmediately to the commercial carrier that delivered your that the part number of the control you received is the same as the partnumber listed on your purchase the control is to be stored for several weeks before use, be sure that it isstored in a location that is clean, dry and free from corrosives andcontaminants. Storage temperatures must not exceed 140 F (60 C).Quick Reference Chart12 3456S1TB1 MAG1 MAG2 TIMEBALDOR ELECTRICB rake ONMotor RunBrake ReadyBrake Logic Power ONJ1J5J2J8J3J4J7J612 3 4567 8910 PWR RDY RUN BRKP1 P3 P2 Brake control Board (BRDT-B2)LED Indicators:PWR On indicates 115 VAC input is presentRDYOn indicates Brake ready.