Hitachi BRD-E2-30K Operation Manual Download

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HITACHI DYNAMIC BRAKING UNIT (BRD SERIES)

200V Class (BRD-E2-30K/55K)
400V Class (BRD-EZ2-30K/55K/110K)

OPERATION MANUAL

NB4882CX

CONTENTS

1. UNPACKING INSPECTION.....................................................................

2. IMPORTANT NOTICES...........................................................................

3. INSTALLATION.......................................................................................

4. WIRING AND FUNCTION SETTING......................................................

4.1

Wiring Notices.........................................................................................................

4.2

Functional Setting ....................................................................................................

4.3

Example of External Connection ..............................................................................

4.4

Example of External Connection
(Parallel Connection Operation) ...............................................................................

5. TROUBLESHOOTING .............................................................................

5.1

Alarm contact is activated and the inverter stops ......................................................

5.2

When the inverter trips the 0V during inverter deceleration......................................

6. PRE-START CHECKS..............................................................................

7. SPECIFICATIONS....................................................................................

7.1

Standard Specifications ............................................................................................

8. INTERNAL CIRCUITS.............................................................................

9. SELECTION OF DYNAMIC BRAKING UNITS AND

DISCHARGING RESISTORS...................................................................

9.1

Braking Energy without a Dynamic Braking Unit .....................................................

9.2

Using the Dynamic Braking Unit..............................................................................

9.3

General Formulas Use for Estimation .......................................................................

10.MAINTENANCE AND CHECKS .............................................................

10.1 Notices on Maintenance and Checks.........................................................................

10.2 Check Items .............................................................................................................

11.PARTS ORDERING AND INQUIRY .......................................................

APPENDIX ....................................................................................................

Summary of Contents for BRD-E2-30K

Page 1: ...onnection Operation 7 5 TROUBLESHOOTING 9 5 1 Alarm contact is activated and the inverter stops 9 5 2 When the inverter trips the 0V during inverter deceleration 10 6 PRE START CHECKS 11 7 SPECIFICATIONS 12 7 1 Standard Specifications 12 8 INTERNAL CIRCUITS 16 9 SELECTION OF DYNAMIC BRAKING UNITS AND DISCHARGING RESISTORS 20 9 1 Braking Energy without a Dynamic Braking Unit 21 9 2 Using the Dynami...

Page 2: ...f the warrantor is solely to repair or replace the device The warrantor is not liable for any incidental or consequential damages caused by any defects of this device This warranty is valid only in Japan REPAIR COST Repairs for normal wear accidental damage or inspection of this device outside the warranty period one year will be at the owners expense Repairs not described in the above warranty ar...

Page 3: ...No Description Date of revision Manual No 1 Two manuals have been combined and the contents reviewed 98 4 25 NB4882C Misspellings missing characters ambiguous descriptions and similar errors are corrected without notice ...

Page 4: ...u see these symbols Also read and follow the instructions for all Notes and Remarks 1 Installation Title Triangle eps Creator Adobe Illustrator TM 5 5 CreationDate 98 4 21 9 42 CAUTION l Mount the dynamic braking unit on a fireproof wall e g metallic wall or a fire may occur See page 2 l Keep the dynamic braking unit away from combustible or flammable materials or a fire may occur See page 2 l Nev...

Page 5: ...off primary power to the inverter This is to prevent burning out the external resistor due to overheating if the dynamic braking unit malfunctions See page 3 For actual connections see 4 3 and 4 4 See page 3 Title Triangle eps Creator Adobe Illustrator TM 5 5 CreationDate 98 4 21 9 42 CAUTION l Make sure the voltage rating of the dynamic braking unit is equal to that of the inverter to prevent fir...

Page 6: ...eceive an electric shock or cause a fire See page 3 Title Triangle eps Creator Adobe Illustrator TM 5 5 CreationDate 98 4 21 9 42 CAUTION l The heat radiating fins and the discharging resistors during use are hot and can cause burns Do not touch See page 3 4 Maintenance inspection and part replacement Title Danger eps Creator Adobe Illustrator TM 7 0 CreationDate 1 26 0 5 10 PM DANGER l Be sure to...

Page 7: ...c braking unit Improper servicing may cause serious electric shock and or personal injury See page 1 For simplicity some figures and illustrations in this manual are shown without the cover or peripheral parts of the device Be sure to remount the cover and other safety features before running the dynamic braking unit GENERAL NOTICES ...

Page 8: ...ous electric shock and or personal injury Note Do not use the BRD E2 E2Z braking unit in combination with earlier versions e g BRD VZ or BRD C1 The operating voltages and terminal configurations are different and may cause the dynamic braking units to malfunction Note Set the DIP switches and connect the wires correctly when setting or changing the operating voltage or when running devices in a pa...

Page 9: ... dynamic braking unit in hot damp or wet locations Don t use the braking unit in the presence of dust corrosive gases explosive gases flammable gases oil mist or salt Keep the braking unit out of direct sunlight To insure ventilation mount the dynamic braking unit on the wall with at least 10 cm clearance above and below the unit and at least 5 cm clearance on the left and right sides of the unit ...

Page 10: ...g if the dynamic braking unit malfunctions For actual connections see 4 3 and 4 4 Title Triangle eps Creator Adobe Illustrator TM 5 5 CreationDate 98 4 21 9 42 CAUTION l Make sure the voltage rating of the dynamic braking unit is equal to that of the inverter to prevent fire and personal injury l Do not connect resistors directly to the D C terminals P and N or fire may occur l Tighten screws at t...

Page 11: ...and supported firmly so there is no excessive load on the dynamic braking unit 3 When the parallel connection interlocking function is used signal cables MA1 MA2 SL1 and SL2 between the dynamic braking units must be no more than five meters in length and no more than 0 75 mm2 in width in its section area The signal cable must be fully separated from the main circuit cable 10 cm or more Signal cabl...

Page 12: ...ing voltage ã 2 20 V Operating voltage 2 Parallel connection interlocking function You can run two parallel connected dynamic braking units interlocked by connection of their signal wires MA1 MA2 SL1 and SL2 and setting of the DIP switches You can use one of the dynamic braking units as a sub unit and allow it to work at the operating voltage level of the main unit by setting the dynamic braking u...

Page 13: ...ermal relay and Table 4 2 shows a list of applicable wires Note 1 Select relay RY according to the coil Mg and contact RY specifications Note 2 R0 T0 terminals depend on inverter model External resistor Thermal relay Note 2 Note 1 Dynamic braking unit Main unit Thermal relay Usually closed b contact and opens when it is working Motor Inverter 3 phase power supply 200V class 3 phase power supply 40...

Page 14: ... primary power of the inverter when the thermal relay is operating Figure 4 3 shows the connection of a thermal relay and Table 4 3 shows a list of applicable wires Note 1 Select relay RY according to the coil Mg specifications and the contact RY specifications Note 2 R0 T0 terminals depend on inverter model External resistor External resistor Thermal relay Thermal relay Note 2 Note 1 Dynamic brak...

Page 15: ...mm2 or more EZ2 110K 6Ω or more 22mm2 or more 4Ω to 5 9Ω 38mm2 or more 400V class 3Ω to 3 9Ω 60mm2 or more Note 1 The wire for P RB and N connections should be MLFC wire flame retardant poly flex wire able to withstand voltage of 600 V If the distance between the dynamic braking unit and a discharging resistor is 10 meters or more use a cable thicker than the specified wire size Table 4 2 shows si...

Page 16: ...king that result in the overheating of the discharging resistor To prevent this event check and correct resistances of the discharging resistors the number of dynamic braking units in use and the deceleration time This event also occurs when incorrect connections are made or when the voltage is inappropriate Follow the instructions below to check and repair ...

Page 17: ...ease in voltage To prevent this problem check and correct the resistances of the discharging resistors the number of dynamic braking units in use and the deceleration time This problem occurs also when the discharging resistor is disconnected when wrong connections are made or when the DIP switch setting is improper Follow the instructions below to inspect and repair ...

Page 18: ...ower is on or you may receive an electric shock or cause a fire Title Triangle eps Creator Adobe Illustrator TM 5 5 CreationDate 98 4 21 9 42 CAUTION l The heat radiating fins and the discharging resistors during use are hot and can cause burns Do not touch Notes 1 Check the wiring and connections Wrong wiring or incorrect connection may cause the dynamic braking unit to malfunction or cause damag...

Page 19: ... Protection of power modules against overheating Thermal relay for protection Operates at a cooling fin temperature of 100 C Usually closed b contact Contact rating 240 VAC 3A R load 0 2A L load 36 VDC 2A R load Minimum load 15 VDC 50 mA R load Ambient temperature 10 to 50 C Storage temperature 10 to 60 C Relative humidity 20 to 90 Non condensing Vibration 5 4 9m s2 0 5G 10 to 55Hz 2 0m s2 0 2G 10...

Page 20: ...idth 6 M3 screw SL1 SL2 MA1 MA2 AL1 AL2 TM3 terminal width 13 M5 screw N RB P P DIMENSION in mm Type Model TYPE FORM Operating voltage Weight kg BRD EZ2 30K HP DM 725 5 2 Grounding terminal M5 screw Figure 7 1 Dimensions ...

Page 21: ...ltage Weight kg BRD E2 30K HP DM 362 5 5 6 BRD EZ2 55K HP DM 725 5 6 TM1 terminal width 6 4 M3 screw SL1 SL2 MA1 MA2 2 1 Note Leave terminals 1 and 2 disconnected TM2 terminal width 23 M8 screw N RB P P TM3 terminal width 5 9 M3 screw AL2 AL1 DIMENSION in mm Figure 7 2 Dimensions ...

Page 22: ...2 55K HP DM 362 5 5 8 BRD EZ2 110K HP DM 725 5 10 TM1 terminal width 6 4 M3 screw SL1 SL2 MA1 MA2 2 1 Note Leave terminals 1 and 2 disconnected TM2 terminal width 33 M10 screw N RB P P TM3 terminal width 7 5 M3 screw AL2 AL1 The value in parentheses is for EZ2 110K DIMENSION in mm Figure 7 3 Dimensions ...

Page 23: ...30K 55K and EZ2 55K 110K 1 TM1 MA1 MA2 SL1 and SL2 Control signals for parallel interlocking connection 2 TM2 P DC voltage P RB Resistance N DC voltage 3 TM3 AL1 AL2 Alarm contacts 2 Terminals of the EZ2 30K 1 TM2 MA1 MA2 SL1 and SL2 Control signals for parallel interlocking connection AL1 AL2 Alarm contacts 2 TM3 P DC voltage P RB Resistance N DC voltage For actual terminal layouts and screw size...

Page 24: ... 17 200V class inverter Figure 8 1 Internal circuit ...

Page 25: ... 18 400V class inverter Figure 8 2 Internal circuit ...

Page 26: ... 19 400V class inverter Figure 8 3 Internal circuit ...

Page 27: ... by the difference between their voltage vs frequency ratios Speed Torque vs speed curve at frequency f3 Torque vs speed curve at frequency f2 Torque vs speed curve at frequency f1 Output voltage V Frequency f Figure 9 1 Frequency change and motor torque Figure 9 2 Voltage vs frequency characteristics In this status the motor operates as a generator The rotational energy of the motor is converted ...

Page 28: ...etermined by the resistance of RB and the capacitance of RB in the dynamic braking unit will determine the braking torque This is because the torque generated by the motor is dependent upon the current passing through Tr and RB Do not combine any items which are blank in Table 9 1 to Table 9 3 1 For use in one dynamic braking unit Table 9 1 For use in a single dynamic braking unit 4 poles Motor Hi...

Page 29: ...mum torque of the motor Table 9 3 shows the braking torques of the inverters whose capacity is increased by one The motor capacity must be raised when 135 or more braking is required Table 9 3 Requirements for maximizing the braking torque of motor when the inverter capacity is increased by one Requirement Mean braking torque 135 To 1 35 A Increasing the inverter capacity by one B TB B 0 5 TB A C ...

Page 30: ...esistance relative to the inverter If this value is under the minimum value of a BRD two or more BRDs are required 0 105 TB N1 R 1 Von 2 1 2 where Von BRD operating voltage 362 5 V for the 200V class or 725V for the 400V class 4 Mean discharging capacity PL W The capacity of the discharging resistor should be 2 5 to 3 times the result of the formula below 2 PL 0 105 TB 0 2 TM N1 N2 tC tB where tC ...

Page 31: ...minals and connectors firmly 2 Keep this device away from wet oily or dusty locations Metallic filings in the product can easily cause short circuits damage the unit or start a fire 10 2 Check Items 1 Daily checks 2 Periodic checks every one year See Page 25 3 Insulation resistance test and dielectric strength test Connect the terminals as shown below and test under the following conditions Insula...

Page 32: ...ng torques in N m M3 0 6 to 0 9 M8 10 to 13 5 M4 1 5 to 2 1 M10 21 to 28 M5 2 8 to 3 9 M6 4 1 to 5 3 500V meggar Terminal board Check for damages and breaks Visually No problem should be detected Smoothing capacitor on the PC board 1 Check for electrolyte leaks 2 Check whether the capacitor is swollen 1 2 Visually 1 2 No problem should be detected 5 years Note Main circuit Resistor 1 Check for cra...

Page 33: ...ffice 1 Model number 2 Manufacturing number MFG No 3 Symptom or details of the trouble in detail If the label is hard to be read report the external view or appearance of the replacement part and a short explanation of the trouble together with the ordering sheet It is recommended for you to have another product as an auxiliary device your work will not be disrupted ...

Page 34: ...or Life characteristics The ambient temperature affects the service life of the aluminum electrolytic capacitor See Appendix Figure 1 Periodically check the capacitor and make sure it is free from leaks deformations etc If the dynamic braking unit is frequently used in a hot location the capacitor will quickly deteriorate and consequently the service life of the dynamic braking unit may be shorten...

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