HITACHI DYNAMIC BRAKING UNIT (BRD SERIES)
200V Class (BRD-E2-30K/55K)
400V Class (BRD-EZ2-30K/55K/110K)
OPERATION MANUAL
CONTENTS
1. |
UNPACKING INSPECTION..................................................................... |
1 |
|
2. |
IMPORTANT NOTICES........................................................................... |
1 |
|
3. |
INSTALLATION....................................................................................... |
2 |
|
4. |
WIRING AND FUNCTION SETTING...................................................... |
3 |
|
|
4.1 |
Wiring Notices......................................................................................................... |
3 |
|
4.2 |
Functional Setting .................................................................................................... |
5 |
|
4.3 |
Example of External Connection .............................................................................. |
6 |
4.4Example of External Connection
|
|
(Parallel Connection 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 Dynamic Braking Unit.............................................................................. |
21 |
|
9.3 |
General Formulas Use for Estimation ....................................................................... |
23 |
10.MAINTENANCE AND CHECKS ............................................................. |
24 |
||
|
10.1 |
Notices on Maintenance and Checks......................................................................... |
24 |
|
10.2 |
Check Items ............................................................................................................. |
24 |
11.PARTS ORDERING AND INQUIRY ....................................................... |
26 |
||
APPENDIX .................................................................................................... |
27 |
||
Read and Save this Instruction Manual.
NB4882CX
IMPORTANT NOTICES
Keep this manual handy for quick reference.
Read this manual carefully before installing, operating or maintaining the dynamic braking unit. Familiarize yourself with the device specifications, safety precautions, and handling and operating procedures and use this device correctly.
For maximum efficiency and safety, use this device at the specified operating rates for which it is designed. Inspect and maintain this device at specified regular intervals to insure safe and maximum performance and to prevent malfunction.
LIMITED WARRANTY
Your product is warranted against defective material or workmanship for a period of one year from the date of installation. Hitachi will repair or replace this device free of charge if any defective parts or workmanship covered within the limitations of this warranty are found.
The following are not covered by this warranty and will be charged accordingly:
(1)Abnormal handling or use of this device
(2)Failure caused by reasons unrelated to this device
(3)Improper servicing, alteration or modification by any unauthorized personnel
(4)Malfunction and failure caused by natural disasters such as fire and earthquakes
The obligation of 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 are possible. For more information on repair cost and inspections, call your local Hitachi distributor or service center.
ORDERING REPLACEMENT PARTS AND INQUIRY
In the case of device failure, please report the following to your local Hitachi distributor or service center:
(1)Model number
(2)Date of purchase
(3)Manufacturing number (MFG. No.)
(4)Details of the malfunction
It is recommended you install a back-up device so that your work is not disrupted.
MISCELLANEOUS
•This manual is subject to change without prior notice.
•This manual is included with the device. There is no other manual. Keep this manual handy.
•Reproduction or use of any portion of this manual, without express written permission from Hitachi is prohibited.
•Every effort has been made to supply complete and accurate information. However, errors and inaccurate information may exist. Please inform us of these errors. Your comments are always welcome.
•Hitachi assumes no responsibility for any results caused by the use of this manual
History revisions
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.
SAFETY PRECAUTIONS
Carefully read this manual and other precautionary documents that came with the dynamic braking unit before installing, operating or maintaining this unit. Familiarize yourself with the device specifications, safety precautions, and handling and operating procedures and use this device correctly.
This manual uses two symbols, the first informs of malfunctions and the second indicates danger of personal injury or property damage.
|
|
|
: This safety reminder indicates potentially life-threatening situations. |
|
CreatTitle: |
|
|
|
DANGER |
If these instructions are not followed serious injury and in extreme |
|
|
Creat |
|
cases, death could occur. |
|
|
||
|
|
|
: This safety reminder indicates potential danger to body and property. |
|
|
|
|
|
|
|
|
|
Title: |
CAUTION |
If these instructions are not followed minor or serious injury and/or |
|
Creat |
|
property damage could occur. |
|
|
|
Be sure to follow these instructions carefully when you see these symbols.
Also read and follow the instructions for all "Notes" and "Remarks."
1. Installation
Title:Creat CAUTION
•Mount the dynamic braking unit on a fireproof wall (e.g. metallic wall) or a fire may occur.
(See page 2.)
•Keep the dynamic braking unit away from combustible or flammable materials or a fire may occur.
(See page 2.)
•Never hold the dynamic braking unit by the front cover when carrying it. It could fall and an injury could occur.
(See page 2.)
•Never allow any wires, dust, welding spatters, iron filings, or other materials to get into the unit or a fire may occur.
(See page 2.)
•The dynamic braking unit is very heavy. Install the unit on a solid rigid wall strong enough to support it. Otherwise, it could fall and an injury may occur.
(See page 2.)
• Do not use any inverter that is partially damaged or incomplete or an injury may occur. (See page 2.)
•Avoid any dangerous environment
Do not place the dynamic braking unit in hot, damp, or wet locations. Don't use the dynamic braking unit in the presence of dust, corrosive gases, explosive gases, flammable gases, oil mist, or salt. Keep the dynamic braking unit out of direct sunlight.
(See page 2.)
i
2. Wiring
Title:Creat DANGER
Creat
•Always connect the grounding wire to the dynamic braking unit to prevent electric shock or fire.
(See page 3.)
• All wiring should be done by a qualified electrician or electric shock or fire may occur. (See page 3.)
•Before wiring, make sure the supply power is off (or the P-N voltage is 45 V or less) to prevent electric shock or fire.
(See page 3.)
•Always install the dynamic braking unit on the wall before wiring to prevent electric shock and personal injury.
(See page 3.)
•Be sure to provide a thermal relay and a circuit, which shuts 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:Creat CAUTION
•Make sure the voltage rating of the dynamic braking unit is equal to that of the inverter to prevent fire and personal injury.
(See page 3.)
• Do not connect resistors directly to the D.C. terminals (P and N) or fire may occur. (See page 3.)
•Tighten screws at their correct specified torque (see table on right). Make sure every screw is firmly tightened or fire may occur.
(See page 3.)
•The power cables should be MLFC flame-retardant poly-flex wire, allowing a voltage of 600 V and capable of the specified amperage or fire may occur.
(See page 3.)
ii
3. Control and operation
Title:Creat DANGER
Creat
•Be sure the front cover on the dynamic braking unit is attached before turning on the power. Never remove the cover of the dynamic braking unit or you may receive an electric shock
(See page 11.)
• Do not operate with wet hands or you may receive an electric shock.
(See page 3.)
•Never touch any terminal of the dynamic braking unit while the unit power is on (even when the unit has stopped) or you may receive an electric shock.
(See page 3.)
•Never touch any part or put anything in the dynamic braking unit while the unit's power is on or you may receive an electric shock or cause a fire.
(See page 3.)
Title:Creat CAUTION
•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:Creat DANGER
Creat
•Be sure to turn off the supply power. terminals P and N is 45 volts or less.) shock.
(Make sure that the DC voltage between Otherwise, you may receive a serious electric
(See page 24.)
•Only an authorized electrician is allowed to check, maintain, and replace parts of the dynamic braking unit.
(Take off all metallic accessories such as watches and jewelry before operating.) (Use the insulated tools.)
Otherwise, you may receive a serious electric shock or personal injury.
(See page 24.)
iii
5. Appendix
Title:Creat DANGER
Creat
•Never alter or modify the dynamic braking unit.
Improper servicing may cause serious electric shock and/or personal injury.
(See page 1.)
GENERAL NOTICES
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.
iv
1. UNPACKING INSPECTION
Handle the product with care when unpacking. Do not use any excessive force (impacts, vibration, etc.) on the package. Check the following:
(1)Package damage occurring during delivery
(2)Model name, voltage, etc. (order confirmation)
(3)List of accessories (including operation manual)
2.IMPORTANT NOTICES
Note the following to improve and perform safe operation of the dynamic braking unit:
DANGER
•Never alter or modify the dynamic braking unit.
Improper servicing may cause serious 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 parallel connection. Be sure to turn off power to the dynamic braking unit before setting the DIP switches and the connecting wires. (For more information, see "4. Wiring and Function Setting.")
Note: Check wirings and connections carefully. If they are correct you can turn on the power to the inverter.
- 1 -
3. INSTALLATION
Title:Creat CAUTION
•Mount the dynamic braking unit on a fireproof wall (e.g. metallic wall) or a fire may occur.
•Keep the dynamic braking unit away from combustible or flammable materials or a fire may occur.
•Never hold the dynamic braking unit by the front cover when carrying it. It could fall and an injury could occur.
•Never allow any wires, dust, welding spatters, iron filings, or other materials to get into the unit or a fire may occur.
•The dynamic braking unit is very heavy. Install the unit on a solid rigid wall strong enough to support it. Otherwise, it could fall and an injury may occur.
•Do not use any inverter that is partially damaged or incomplete or an injury may occur.
•Avoid any dangerous environment
Do not place the 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 as shown in Figure 3.1, Figure 3.2 (a), and Figure 3.2 (b).
Do not place the dynamic braking unit with its ventilation openings facing left and right (horizontally).
Required clearance surrounding the dynamic braking unit
10 cm or more
5 cm or more
10 cm or more
10 cm or more
|
|
10 cm or more |
5 cm or more |
5 cm or more |
5 cm or more |
10 cm or more
(Never place the dynamic braking unit with its ventilation openings facing left and right.)
Figure 3.1 Clearance around dynamic braking units E2-30K/55K and EZ2-55K/110K
10 cm or more
(a) Horizontal installation |
(b) Vertical installation |
Figure 3.2 Clearance around dynamic braking units EZ2-30K
- 2 -
4. WIRING AND FUNCTION SETTING
4.1Wiring Notices
Title:Creat DANGER
Creat
•Always connect the grounding wire to the dynamic braking unit to prevent electric shock or fire.
•All wiring should be done by a qualified electrician or electric shock or fire may occur.
•Before wiring, make sure the supply power is off (or the P-N voltage is 45 V or less) to prevent electric shock or fire.
•Always install the dynamic braking unit on the wall before wiring to prevent electric shock and personal injury.
•Be sure to provide a thermal relay and a circuit, which shuts off primary power to the inverter. This is to prevent burning-out the external single resistor due to overheating if the dynamic braking unit malfunctions.
For actual connections, see 4.3 and 4.4.
Title: |
CAUTION |
Creat |
|
• Make sure the voltage rating of the dynamic braking unit is equal to that of the inverter
to prevent fire and personal injury. |
Screw size |
Tightening |
|
• Do not connect resistors directly to the D.C. terminals |
|||
torque (N.m) |
|||
|
|||
(P and N) or fire may occur. |
|
|
|
M3 |
0.6 to 0.9 |
||
• Tighten screws at their correct specified torque (see |
|||
|
|
||
M5 |
2.8 to 3.9 |
||
table on right). Make sure every screw is firmly |
|||
|
|
||
M8 |
10 to 13.5 |
||
tightened or fire may occur. |
|||
• The power cables should be MLFC flame-retardant |
M10 |
21 to 28 |
|
poly-flex wire, allowing a voltage of 600 V and capable |
|
|
|
of the specified amperage or fire may occur. |
|
|
Notes:
1.Be sure to provide alarm contacts (AL1 and AL2) and a circuit, which shuts off primary power to the inverter to prevent overheating and burning if the dynamic braking unit malfunctions.
- 3 -
2.Use cables at their specified ratings as short as possible: up to 5 meters between the dynamic braking unit and the inverter (P, N) and up to 50 meters between the dynamic braking unit and the discharging resistor (P, RB) (or up to 5 meters for the EZ2-30K). Also make the wire connections as short as possible. Do not loop extra cable.
|
Up to |
|
Up to |
|
Example of correct wiring |
5 meters |
Dynamic |
50 meters |
Discharging |
Inverter |
braking unit |
(up to 5 |
resistor |
|
|
|
|||
|
|
|
meters)* |
|
*In the EZ2-30K system, the cable between the dynamic braking unit and the discharging resistor must be 5 meters or shorter.
Example of incorrect wiring |
Inverter |
Dynamic |
Discharging |
|
braking unit |
resistor |
|||
|
|
The cables must be tied together 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.
Main circuit cable |
Signal cable |
10 cm or more
4.When a combination of various resistors are used, the inductance in the resistors may raise the surge voltage during the switching operation. To prevent this, use larger cables or twist them.
Always use up to six non-induction resistors as external resistors.
5.Use insulated crimping terminals to connect the cables to the terminal board TM1 (or TM2 of the EZ2).
6.Use closed-loop terminals with insulated caps to connect cables to the terminal board TM2 (or TM3 of the EZ2).
- 4 -
Loading...