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3G3AX-RBU
User Guide
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OMRON 3G3AX-RBU User Guide

Cat. No. I563-E1-01
USER’S MANUAL
3G3AX-RBU
Regenerative Braking Unit

Introduction

zThis manual should be delivered to the actual end user of the product. zAfter reading this manual, keep it handy for future reference. zThis manual describes the specifications and functions of the product as well as the relations
between them. You should assume that anything not described in this manual is not possible with the product.
zIntended readers
This manual is intended for: Those with knowledge of electrical systems (qualified electrical engineers or the equivalent), and also in charge of:
• Introducing the control equipment
• Designing the control system
• Installing and/or connecting the control equipment
• Field management
Introduction
1

Read and Understand This Manual

Read and Understand This Manual
Please read and understand this manual before using the product. Please consult your OMRON representative if you have any questions or comments.

Warranty and Limitations of Liability

WARRANTY
OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.
In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
2
Read and Understand This Manual

Application Considerations

SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's application or use of the products.
At the customer's request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this manual.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user's programming of a programmable product, or any consequence thereof.
3
Read and Understand This Manual

Disclaimers

CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other reasons.
It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the products may be changed without any notice. When in doubt, special model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.
PERFORMANCE DATA
Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of OMRON's test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and Limitations of Liability.
ERRORS AND OMISSIONS
The information in this manual has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
4

Safety Precautions

Safety Precautions
Indications and Meanings of Safety Information
In this user’s manual, the following precautions and signal words are used to provide information to ensure the safe use of the Regenerative Braking Unit 3G3AX-RBU. The information provided here is vital to safety. Strictly observe the precautions provided.
Meanings of Signal Words
Indicates an imminently hazardous situation which, if not
WARNING
CAUTION
avoided, is likely to result in serious injury or may result in death. Additionally there may be severe property damage.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or in property damage.
Alert Symbols in This Document
Turn off the power supply and implement wiring correctly. Not doing so may result in a serious injury due to an electric shock.
Wiring work must be carried out only by qualified personnel. Not doing so may result in a serious injury due to an electric shock.
Be sure to ground the unit. Not doing so may result in a serious injury due to an electric shock or fire.
Do not remove the front cover during the power supply and 10 minutes after the power shutoff. Doing so may result in a serious injury due to an electric shock.
Do not operate the switches with wet hands. Doing so may result in a serious injury due to an electric shock.
Do not touch the inside of the Regenerative Braking Unit or terminals, and do not check a signal, wire, put on or take off the connectors while the power is being supplied. Doing so may result in a serious injury due to an electric shock or fire.
WARNING
Do not remove the front cover during the power supply. Doing so may result in a serious injury due to an electric shock. Be sure to put on the front cover before turning on the input power.
Turn off the input power of the Inverter and wait for more than 10 minutes before changing wiring or operating the DIP switch. Not doing so may result in a serious injury due to an electric shock.
5
Safety Precautions
Place covers on the openings or take other precautions to make sure that no metal objects such as cutting bits or lead wire scraps go inside when installing and wiring.
Install a stop motion device to ensure safety. Not doing so might result in a minor injury.
Be sure to use a specified type of Braking Resistor/Regenerative Braking Unit. In case of a Braking Resistor, install a thermal relay that monitors the temperature of the Resistor. Not doing so might result in a moderate burn due to the heat generated in the Braking Resistor/ Regenerative Braking Unit. Configure a sequence that enables the Inverter power to turn off when unusual overheating is detected in the Braking Resistor/Regenerative Braking Unit.
Do not connect Resistors to the DC terminals (P, N) directly. Doing so might result in a small-scale fire, heat generation or damage to the unit.
CAUTION
Do not touch the fins, Braking Resistors, which become too hot during the power supply and for some time after the power shutoff. Doing so may result in a burn.
The models of 3G3AX-RBU23/-RBU24/-RBU42/-RBU43 do not have terminals for the alarm input (R1, R2). Configure a sequence that enables the Inverter power to turn off when unusual overheating is detected.
The 3G3AX-RBC Braking Resistor does not have a built-in thermal fuse. Be sure to use the alarm contact terminals (AL1, AL2) of the Resistor and configure a sequence that enables the Inverter power to turn off when unusual overheating is detected. Not doing so might result in a small-scale fire, heat generation or damage to the unit.
Do not dismantle, repair or modify the product. Doing so may result in an injury.
6
Installation and Wiring
Turn off the power supply and implement wiring correctly. Not doing so may result in a serious injury due to an electric shock.
Wiring work must be carried out only by qualified personnel. Not doing so may result in a serious injury due to an electric shock.
Be sure to ground the unit. Not doing so may result in a serious injury due to an electric shock or fire.
Safety Precautions
WARNING
CAUTION
Place covers on the openings or take other precautions to make sure that no metal objects such as cutting bits or lead wire scraps go inside when installing and wiring.
Install a stop motion device to ensure safety. Not doing so might result in a minor injury.
Be sure to use a specified type of Braking Resistor/Regenerative Braking Unit. In case of a Braking Resistor, install a thermal relay that monitors the temperature of the Resistor. Not doing so might result in a moderate burn due to the heat generated in the Braking Resistor/ Regenerative Braking Unit. Configure a sequence that enables the Inverter power to turn off when unusual overheating is detected in the Braking Resistor/Regenerative Braking Unit.
Do not connect Resistors to the DC terminals (P, N) directly. Doing so might result in a small-scale fire, heat generation or damage to the unit.
7
Safety Precautions
Operation
Do not remove the front cover during the power supply and 10 minutes after the power shutoff. Doing so may result in a serious injury due to an electric shock.
Do not operate the switches with wet hands. Doing so may result in a serious injury due to an electric shock.
Do not touch the inside of the Regenerative Braking Unit or terminals, and do not check a signal, wire, put on or take off the connectors while the power is being supplied. Doing so may result in a serious injury due to an electric shock or fire.
WARNING
CAUTION
Do not touch the fins, Braking Resistors, which become too hot during the power supply and for some time after the power shutoff. Doing so may result in a burn.
The models of 3G3AX-RBU23/-RBU24/-RBU42/-RBU43 do not have terminals for the alarm input (R1, R2). Configure a sequence that enables the Inverter power to turn off when unusual overheating is detected.
The 3G3AX-RBC Braking Resistor does not have a built-in thermal fuse. Be sure to use the alarm contact terminals (AL1, AL2) of the Resistor and configure a sequence that enables the Inverter power to turn off when unusual overheating is detected. Not doing so might result in a small-scale fire, heat generation or damage to the unit.
8
Maintenance and Inspection
Do not remove the front cover during the power supply. Doing so may result in a serious injury due to an electric shock. Be sure to put on the front cover before turning on the input power.
Turn off the input power of the Inverter and wait for more than 10 minutes before changing wiring or operating the DIP switch. Not doing so may result in a serious injury due to an electric shock.
Do not touch the fins, Braking Resistors, which become too hot during the power supply and for some time after the power shutoff. Doing so may result in a burn.
Safety Precautions
WARNING
CAUTION
Do not dismantle, repair or modify the product. Doing so may result in an injury.
9

Precautions for Safe Use

Precautions for Safe Use
Installation and Storage
Do not store or use the product in the following places.
• Locations subject to direct sunlight.
• Locations subject to ambient temperature exceeding the specifications.
• Locations subject to relative humidity exceeding the specifications.
• Locations subject to condensation due to severe temperature fluctuations.
• Locations subject to corrosive or flammable gases.
• Locations subject to exposure to combustibles.
• Locations subject to dust (especially iron dust) or salt.
• Locations subject to exposure to water, oil, or chemicals.
• Locations subject to shock or vibration.
Transportation, Installation, and Wiring
Observe the following instructions during transportation, installation, and wiring.
• Do not drop or apply a strong impact on the product. Doing so may result in damaged parts or malfunction.
• Do not hold by the front cover, but hold by the fins during transportation.
• The specified wire size or larger one must be used for the power lines.
Model
(3G3AX-)
RBU21 17 Ω min. 3.5 mm2 min.
RBU22 17 Ω min. 3.5mm
RBU23
RBU24
RBU41 34 Ω min. 3.5 mm
RBU42
RBU43
Connectable
resistance
8 Ω min. 5.5 mm
5 to 7.9 Ω 8 mm
4 to 4.9 Ω 14 mm
4 Ω min. 14 mm
3 to 3.9 Ω 22 mm
2 to 2.9 Ω 38 mm
17 Ω min. 3.5 mm
13 to 16.9 Ω 5.5 mm
10 to 12.9 Ω 8 mm
10 Ω min. 8 mm
7.5 to 9.9 Ω 14 mm
6 to 7.4 Ω 22 mm
P, RB, N
connection wires
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
2
min.
SL1, SL2, MA1, MA2
connection wires
2
0.75 mm
min. 5.5 mm2 min.
Ground wire
10
Note 1. For wires connecting to the P, RB and N terminals use an MLFC wire (flame retardant
Polyflex wire, dielectric strength of 600 V).
Note 2. If the wiring length between the Regenerative Braking Unit and Braking Resistor exceeds
10 m, use the wire size larger than the specified one.
A wire of more than 10 m to 25 m : One rank higher wire size
A wire of more than 25 m to 50 m : Two ranks higher wire size For the 3G3AX-RBU42 model, keep the wiring length between the Regenerative Braking Unit and Braking Resistor within 5 m.
Maintenance and Inspection
Be sure to confirm safety before conducting maintenance, inspection or parts replacement.
Precautions for Safe Use
11

Precautions for Correct Use

Precautions for Correct Use
Installation
Mount the product on the vertical wall. The material of the wall has to be nonflammable such as a metal plate, and do not place flammable materials nearby.
3G3AX-RBU21/RBU22/RBU41/RBU42
10 cm min.
10 cm min.
5 cm min.5 cm min.
10 cm min.
3G3AX-RBU23/RBU24/RBU43
5 cm min.5 cm min.
10 cm min.
10 cm min.
5 cm min.5 cm min.
Note. The product cannot be mounted horizontally, but vertically only.
Rated Voltage
Confirm that the rated voltage of the product is the same as that of the Inverter to be used.
12
10 cm min.
Product Disposal
Comply with the local ordinance and regulations when disposing of the product.
Warning Labels
Warning labels are located on the product as shown in the following illustration. Be sure to follow the instructions.
Precautions for Correct Use
Warning Description
13

Checking Before Unpacking

Checking Before Unpacking
Checking the Product
On delivery, be sure to check that the delivered product is the Regenerative Braking Unit 3G3AX-RBU model that you ordered. Should you find any problems with the product, immediately contact your nearest local sales representative or OMRON sales office.
Checking the Nameplate
Regenerative Braking Unit
model name
Voltage specifications
Checking the Model
3G3AX− RBU21
Checking the Accessories
Note that this manual is the only accessory included with the Regenerative Braking Unit 3G3AX-RBU model. Mounting screws and other necessary parts must be provided by the user.
Serial number
Maximum applicable motor capacity
24200-V class
400-V class
Regenerative Braking Unit
14

Revision History

e
A manual revision code appears as a suffix to the catalog number located at the lower left of the front and back covers.
Revision History
Cat.No.
Revision
code
01 April 2008 First printing
Revision date Changes and revision pages
I563-E1-01
Revision cod
15

About This Manual

About This Manual
This User's Manual is compiled chapter by chapter for user's convenience as follows: Understanding the following configuration ensures more effective use of the product.
Chapter Overview
Chapter 1 Design
Chapter 2 Functions Describes the DIP switch settings.
Chapter 3
Chapter 4
Chapter 5 Specifications Describes the product specifications and dimensions.
Maintenance Operations
Inspection and Maintenance
Describes installation and wiring procedures, terminal names and other information required for design.
Describes the analysis of possible trouble causes as well as troubleshooting methods.
Describes items for periodic inspection and/or maintenance for the product.
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