Regenerative Braking Unit USER`S MANUAL
Contents
1. Ground terminal a Screw size M5 FAN 7878 IA 5 6 suol eaoadsS 5 2 Dimensional Drawing 3G3AX RBU43 Eee m Ground terminal Screw size M5 N D 258 7 c O 2 O O Q o YN 5 7 Authorized Distributor2. Maintenance Operations 3 1 Precautions before Operation csccsessee 3 1 3 2 When the Alarm Contact is Activated 3 2 3 3 When an Inverter Overvoltage Trip Occurs 3 3 Maintenance Operations 3 1 Precautions before Operation 3 1 Precautions before Operation Before operation check the following items e There is no incorrect wiring Incorrect wiring may result in damage or malfunction of the Regenerative Braking Unit e Check for grounding of any terminal other than the ground terminal Improper grounding may result in damage or malfunction of the Regenerative Braking Unit e Check for any short circuits caused by a wire scrap or crimp terminal left in the unit after wiring work A short circuit may result in damage or malfunction of the Regenerative Braking Unit e There is no short circuit or ground fault A short circuit or ground fault may result in damage or malfunction of the Regenerative Braking Unit 3 1 3 2 When the Alarm Contact is Activated 3 2 When the Alarm Contact is Activated In principle the alarm contacts of the Regenerative Braking Unit are activated when the Braking Re sistor is overheated by excessive regenerative energy or frequent braking As a countermeasure review the capacity of the Braking Resistor model and number of Regener ative Braking Units as well as Inverter deceleration time Incorrect wiring and improper receiving voltage can be also cons
3. 3 12V DC 500 mA R load O 42V DC 200 mA R load a e Minimum load 1 mA Ambient 10 C to 50 C temperature Amplenbsiorage 20 C to 65 C short time temperature during transport temperature Humidity 20 to 90 with no condensation Vibration 5 9 m s 0 6G 10 to 55 Hz Location At a maximum altitude of 1000m indoors without corrosive gases or dust Operating environment U Q 2 O Munsell 5Y7 1 cooling fan aluminum ground color mb To use the Braking Resistor 3G3AX RAB RBB RBC for the 400 V class Regenerative Braking Unit be sure to remove the built in resistor and connect two resistors of the same model in series If the 400 V class Regenerative Braking Unit is operated with a single Braking Resistor the Braking Resistor may be damaged 2 Set the DIP switches 9 1 3 5 1 Standard Specification List The built in resistor has a thermal fuse If the alarm terminal is not connected the fuse may blow out in order to prevent the resistor from burning due to overheating If the fuse blows out the built in resistor must be replaced 9 2 suolne91j1nads Specifications 5 1 Standard Specification List Models without a Built in Resistor 3G3AX RBU23 RBU24 RBU42 RBU43 Voltage class 3 phase 200 V class 3 phase 400 V class Model 3G3AX RBU23 RBU24 RBU42 RBU43 operation Short time 4 Q min 2 Q min 10 Q min 6 Q min operation Cycle 1 5 Cyc
4. O OS L2 oo O T l Si0 O DOD q LS WI30 y 3G3AX RBA A RBB RBC RBU43 Master MAI MA2 elas 3G3AX RBA PAL RBO RBB RBC e 3G3AX RBU42 Ber O1 1 RB Do O 2 AL2 P O RBU43 Slave MA1 MA2 O O A voltage of 800 V DC max is applied to the Braking Resistor Check the rated dielectric strength of the resistor to be connected eTo use the optional Braking Resistor 3G3AX RBA RBB RBC be sure to connect two resistors of the same model in series If the 3G3AX RBUA2 or RBUA3 is operated with a single resistor the Braking Resistor may have a fault To prevent overheating be sure to connect the alarm contacts 1 AL1 and 2 AL2 of the Braking Resistor The models of 3G3AX 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 1 To select RY check the MC coil and RY contact specifications Chapter 2 Functions 2 1 DIP Switch Setting ca een 2 1 Functions 2 1 DIP Switch Setting 2 1 DIP Switch Setting Set up operating voltage level and parallel operation with the DIP switches Note Be sure to turn off the power supply before setting the DIP switches Operating voltage level setting SW1 SW2 The operating voltage of the Regenerative Braking Unit can be set at 3 levels Standard default setting 5 and 10 by the
5. OMRON USER S MANUAL 3G3AX RBU Regenerative Braking Unit Introduction Introduction Thank you for choosing the Regenerative Braking Unit 3G3AX RBU This User s Manual hereinafter called this manual describes the installation wiring of the 3G3AX RBU model as well as troubleshooting and inspection methods This manual should be delivered to the actual end user of the product O After reading this manual keep it handy for future reference O This 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 Intended readers This manual is intended for Those with knowledge of electrical systems qualified electrical engineers or the equivalent and also in charge of e Introducing the control equipment e Designing the control system e Installing and or connecting the control equipment e Field management 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
6. 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 gt 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 gt Do not dismantle repair or modify the product Doing so may result in an injury Safety Precautions Installation and Wiring A N WARNING 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 A N 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 resu
7. 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 Safety Precautions Maintenance and Inspection A N 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 A N 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 Do not dismantle repair or modify the product Doing so may result in an injury Precautions for Safe Use Precautions for Safe Use Minstallation and Storage Do nat 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 exceedin
8. DIP switch settings This function is useful in preventing an overvoltage trip by lowering the operating voltage of the Re generative Braking Unit when an overvoltage trip occurs due to the receiving voltage deceleration time or other factor Depending on the receiving voltage however the Regenerative Braking Unit will operate continu ously even by just turning on the Inverter power supply When you change the DIP switch settings use thorough caution in regards to the receiving voltage Receiving voltage x V2 20 V lt Operating voltage Parallel operation settings SW3 SW4 2 1 Interlocking operation can be performed by two units master and slave units in parallel connection via the signal lines MA1 MA2 SL1 SL2 connection between the units and the DIP switch setting When a unit is set as the slave using the DIP switches the operating voltage of the slave unit de pends on the master unit settings The DIP switch settings are as follows Note The DIP switches are located at the upper left of the PCB in the Regenerative Braking Unit The switch numbers are indicated on the switch body DIP switch setting Sun MINE X Either ON or OFF is acceptable Nele Master unit Operating voltage level Standard Default setting Master unit Operating voltage level 5 Master unit Operating voltage level 10 Operating voltage of the slave unit depends on the master unit settings Slave unit Chapter 3
9. Disclaimers CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons lt 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 Safety Precautions Safety Precautions Mindications and Meanings of Safety Information In this user s manual the f
10. 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 INNO 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 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 t
11. 2UeUu3 UIe y pue uono dsu Inspection and Maintenance 4 2 Daily Inspection and Periodic Inspection Inspec tion part Inspec tion item Main ur Resistor circuit Control circuit Protec tion circuit General Smooth ing ca pacitor on the PCB Inspection period 1 Inspection point Inspection method Visual inspection Cement resistor wire wound resis tor etc There are no crack or discolor ation Disconnect one end of the cable and measure the resistance using a tester Check that there are no errors in protection and Simulate the display circuits protection circuit through sequence output protection operation Check for any wire breakage Check that there are no abnormal odors discolora tion or significant rusting Visual inspection Check that there is no liquid leak age Check that the safety valve has not come out and that there are no bulges Visual inspection Criteria No faults Tester Digital Error must be within multimeter 10 of the nominal resistance Error is found in the se quence No faults No faults Standard replacement period 5 years 1 1 The life of the capacitor depends on ambient temperatures Refer to 4 5 Capacitor Life Curve Page 4 6 for the replacement reference A 4 3 Unit Do not conduct a withstand voltage test on any part of the Regenerative Braking The Regenerative Braking U
12. A RBB RBC Two resistors connected in series Temperature relay i O O O O O ee O1 AL1 RB O dy 3G3AX RBU41 Rid 2 AL2 P L Slave MA1MA2 OL Built in resistance temperature relay O2 AL2 O 1 O1 AL1 RB O O2 AL2 O 3G3AX RBA RBB RBC Two resistors connected in series O R20 1 To select RY check the MC coil and RY contact specifications ubisag c 2 7 Q A 1 4 Connection A eTo use the Braking Resistor 3G3AX RBA RBB RBC be sure to remove the built in resistor If the Braking Resistor 3G3AX RBA RBB RBC is used with the built in resistor connected it may cause the built in resistor to burn due to overheating or result in an overheating detection failure when the Braking Resistor temperature relay is activated To use the Braking Resistor 3G3AX RBA RBB RBC for 3G3AX RBU41 be sure to connect two resistors of the same model in series If the 3G3AX RBU41 is operated with a single resistor the Braking Resistor may have a fault To prevent overheating be sure to connect the alarm contacts 1 AL1 and 2 AL2 of the Braking Resistor 1 4 Connection 3G3AX RBU23 RBU24 Connection Example Mi When the optional Braking Resistor 3G3AX RBA RBB RBC is used The following is an example of connections using the Braking Resistor 3G3AX RBA RBB RBC Up to two units can be connected in parallel For parallel connection use B
13. curs 3 3 When an Inverter Overvoltage Trip Occurs In principle an Inverter overvoltage trip occurs when the Inverter cannot completely absorb a volt age rise due to excessive regenerative energy As a countermeasure review the resistance of the Braking Resistor model and number of Regen erative Braking Units as well as Inverter deceleration time Wire breakage in the Breaking Resistor incorrect wiring and or improper DIP switch settings can be also considered as a cause of an In verter overvoltage trip Use the flowchart to diagnose the problem Overvoltage trip occurs During Inverter deceleration is the operation LED indicator lit The Braking Resistor model selection is improper Review resistor selection or extend the inverter deceleration time There may be a wire breakage in the Braking Resistor Is the operation LED indicator on the master unit or the unit in Single operation unlit NO Are the DIP switches set to Are the DIP switches set to Slave master YES E Set the DIP as Set the DIP Switches to master Switches to slave Be sure to wire correctly and securely Is wiring between the P and N terminals as well as the contro circuit terminals connection correct The Regenerative Braking Unit is defective Replace or repair the unit 3 3 Chapter 4 Inspection and Maintenance 4 1 Inspection and Maintenance uu 2 4 1 4 2 Daily Inspection and Perio
14. dic Inspection 4 2 4 3 2 Megger Testo ee 4 4 4 4 Checking the Main Element 4 5 4 5 Capacitor Life Curve uuuunnanunnnnnnnnnnnnnnnnnnnnnnnnn 4 6 Q am 19 sj E Lo 4 Sc O Q Q Y 4 1 Inspection and Maintenance 4 1 Inspection and Maintenance Daily Inspection Basically check the following during operation 1 There are no errors in the installation environment 2 There are no errors in the cooling system 3 There are no abnormal vibrations or sounds 4 There are no abnormal overheat or discoloration 5 There are no abnormal odors Cleaning Always keep the Regenerative Braking Unit clean for operation Lightly remove any dirt with a soft cloth moistened with a neutral detergent Note Do not use such solutions as acetone benzene toluene or alcohol for cleaning Doing so may cause the Regenerative Braking Unit surface to dissolve or its coating to come off Periodic Inspection 4 1 Check the parts that cannot be checked without stopping operation as well as those that require periodic inspection 1 Check that there are no errors in the cooling system Clean the air filter 2 Check that all parts that need tightening are secure Screws and bolts may become loose because of vibration or temperature change 3 Check that there is no corrosion or damage to the conductors and or insulators 4 Measurement of insulation resista
15. el 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 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 MW3G3AX RBU21 RBU22 RBU41 RBU42 10 cm min 5 cm min 5 cm min 5 cm min 10 cm min 10 cm min W3G3AX RBU23 RBU24 RBU43 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 Precautions for Correct Use 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 Warning Description SER AWARNING to AREORTNEY HEAT ITED AIL TREE RAT O o t BEX RUER el AUNAR NR ERICA amp fT HAZARD OF rn INJURY OR ELECTRIC SHOCK Read the instruction manual carefully before installation and operation and follow the instructions exactly Disconnect incoming power and wait 10 minutes before removing cover ed sure to ground
16. g 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 NW Transportation Installation and Wiring Observe the following instructions during transportation installation and wiring Do nat 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 e The specified wire size or larger one must be used for the power lines Model Connectable P RB N SL1 SL2 MA1 MA2 Ground wire 3G3AX resistance connection wires connection wires 8 Q min 5 5 mm min 4 Q min 14 mm min RBU24 3 to 3 9 Q 22 mm min 0 75 mm min 5 5 mm min RBU42 5 5 mm min 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 10 m use the wire size larger than the specified one Precautions for Safe Use 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 RBUA2 mod
17. he 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 e Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this manual e 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 e 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 Read and Understand This Manual
18. idered as a cause of an alarm Use the flowchart to diagnose the problem ES Alarm contact is activated Is the main element IGBT defective 1 Regenerative Braking Unit is defective Replace or repair the unit NO Review the resistor selection YES Is the resistance higher than connectable resistance selected Are the units in parallel operation NO During operation are the NO operation LED indicators of all units lit u Check the wiring and DIP switch settings are correct Does either the master or slave unit have a wire breakage NO suone1ado s9ueuajuIen YES ss y Replace the resistor Review resistor selection Is the Inverter s receiving voltage YES outside 10 of the rated J NO voltage 5 Correctthe voltage N Is the operation LED indicator lit in any other status than Inverter deceleration during Inverter acceleration or in standby status Is the control circuit terminals NO correctly wired For single operation this terminal need not be connected Be sure to wire correctly and securely Is the main circuit terminals YES YES AS correctly wired Be sure to wire correctly and securely The Regenerative Braking Unit is defective Replace or repair the unit 1 For the IGBT check procedure refer to 4 4 Checking the Main Element Page 4 5 3 2 Maintenance Operations 3 3 When an Inverter Overvoltage Trip Oc
19. 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 14 Revision History Revision History A manual revision code appears as a suffix to the catalog number located at the lower left of the front and back covers Cat No 1563 E1 02 to Revision code April 2008 First printing March 2009 Pages 1 12 1 13 Minor Changes 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 Describes installation and wiring procedures terminal names and Chapter 1 Design other information required for design Chapter2 Functions Describes the DIP switch settings Maintenance Describes the analysis of possible trouble causes as well as Chapter 3 i Operations troubleshooting methods Inspection and Describes items for periodic inspection and or maintenance for the Chapter 4 Maintenance product Chapter 5 Specifications Describes the product specifications and dimensions Contents HAI OCUIC HOM a ra italia 1 Read and Understand This Manual cooccoocccncccccccncconnconncnnnnnnnnnnnnnnnnnoos 2 Sale PIECAU ONS rer ae een 5 Precautions for Sale SO ii da 10 Precautions Or Correct User 12 Checking Before Unpacking ccccccoccccccocn
20. itch Setting page 2 1 MC1 MC2 O OO RY BSS RY BS O O O Q A VEF MCB MC1 MC2 Inverter oN R ic 3 phase oN 200 V S 010 AS OL O Q p SL1SL2 ALIAL2 pp OP 3G3AX RBU21 N rBu22 RIO Master MAIMA2 amp R2Q O O Alarm terminal internal connections i O U O U op SLISL2 AL1AL2 RB Ei P 3G3AX RBU21 RBU22 RIO Slave MAIMA2 D RO Built in resistance temperature relay O O O O dp SL1SL2 ALTAL2 apd Br 3G3AX RBU21 RBU22 R Slave MAIMA2 amp 20 OL E O 1 To select RY check the MC coil and RY contact specifications 1 7 1 4 Connection MN When the optional Braking Resistor 3G3AX RBA RBB RBC is used KN The following is an example of connections using the Braking Resistor 3G3AX RBA RBB RBC Up to five units can be connected in parallel For parallel connection use Braking Resistors with the same resistance Be sure to remove the built in resistor from the bottom of the Regenerative Braking Unit For DIP switch settings refer to 2 1 DIP Switch Setting page 2 1 ubisag MC1 MC2 RY O 0 0 C i BSS RY nd Q O 4 EF MCB A tici MC2 Inverter on l R 0 0 SDO 3 phase As l O 4 7 Baht 3G3AX RBA pSL1SL2 AL1LAL2 ppd RBB RBC 3G 3AX RBU21 O RBU22 Rl E 1 AL1 RB do O 2 AL2 P Master MAIMA2 amp R29 OL 3G3AX RBA RBB RBC Alarm terminal in
21. l connections O O O O O O OPSLISL2 ALLAL2 ppd OP AN 3G3AX RBU41 Slave MAIMA2 OO R1O O R20 Built in resistance temperature relay O O pSL1SL2 ALTAL2 ppd O OP 9P 3G3AX RBU41 Slave MAIMA2 O O R10 O R20 1 To select RY check the MC coil and RY contact specifications 1 9 1 4 Connection WWhen the optional Braking Resistor 3G3AX RBA RBB RBC is used The following is an example of connections using the Braking Resistor 3G3AX RBA RBB RBC Up to five units can be connected in parallel For parallel connection use Braking Resistors with the same resistance Be sure to remove the built in resistor from the bottom of the Regenerative Braking Unit For DIP switch settings refer to 2 1 DIP Switch Setting page 2 1 MC1 MC2 RY 1 MEL MCZ OS y BSS RY 200 V 50 60 Hz hs O 0 wc 220 V 60 Hz DI Operation 102 power supply MCB MC1 MC2 Inverter oN 1 NI R 6 0 O O O D OR L1 U T1 3 phase As Loa a m 1O OS L2 T 61OSIO SD OT L3 er O O l 1 UU IT pSL1SL2 ALTAL2 pp O p u RB O N 3G3AX RBU41 pi d_ 42112 Master O O D R20 MAIMA2 OO 3G3AX RBA RBB RBC Two resistors connected in series Alarm terminal internal connections aa o A 9 SL1SL2 ALL AL2 pp ua RY e RB 3G 3AX RBA gt ar EN 3G3AX RBU41 pid I dara O Slave O MAIMA2 O R2Q o OO O O1 AL1 RB O O2 AL2 O 3G3AX RB
22. le Inverter For connections of the Regenerative Braking Unit Inverter and Braking Resistor P RB and N ter minals use cables with the following length Model Between Regenerative Braking Unit and 3G3AX Inverter Braking Resistor The wiring must be routed at the shortest distance Be sure not to coil up any surplus cables Doing SO may cause a fault in the equipment The cable connected to the P and N terminals for wiring between the Regenerative Braking Unit and the Inverter as well as the cable connected to the P and RB terminals for wiring between the Regenerative Braking Unit and the Braking Resistor must be bundled with a tie band so that these cables are not placed at a distance Regenerative Braking Braking Unit Resistor Regenerative AN Braking Inverter i l Incorrect example Braking Unit Resistor 1 1 In order to prevent the Braking Register in the Regenerative Braking Unit from burning due to over heating be sure to connect the alarm contacts AL1 and AL2 and provide a circuit to turn off the primary power supply for the Inverter When several Regenerative Braking Units are connected in parallel the length of the signal cables MA1 MA2 SL1 SL2 between individual Regenerative Braking Units must be 5 m or less and the cable size must be 0 75 mm or more Be sure to separate the signal cables from the main circuit cable Main circuit Signal cable cable 10 cm min 1 1 Wiring When multiple
23. le 1 5 Cycle 1 10 Cycle 1 5 Allowable operation 2 min ON 2 min ON 10 s ON 2 min ON cycle Allowable 8 min OFF 8 min OFF 90 s OFF 8 min OFF continuous ON time 2 min 2 min 10s 2 min Connectable resistance Operating voltage ON 362 5 5 V OFF 355 5 V ON 725 5 V OFF 710 5V ON OFF 5 or 10 setting available 5 or 10 setting available Operation indication LED ON Lit Maximum number of units in parallel 2 units operation U Cc Built in relay specifications S Built in power e The temperature relay operates if the cooling fin reaches approx 100 C or more module overheat e Rating of contact 240 V AC 3 A R load protection 36 VDC 2 A R load D e Minimum load 5VDC 50 mA R load O a Ambient 10 C to 50 C temperature Ambient storage 20 C to 65 C short time temperature during transport temperature Humidity 20 to 90 with no condensation 4 9 m s 0 5G 10 to 55 Hz At a maximum altitude of 1000m indoors without corrosive gases or dust Paint color Munsell 5Y7 1 cooling fan aluminum ground color Operating environment 1 To use the Braking Resistor 3G3AX RAB RBB RBC for the 400 V class Regenerative Braking Unit be sure to connect two resistors of the same model in series If the 400 V class Regenerative Braking Unit is operated with a single Braking Resistor the Braking Resistor may be damaged 2 Set the DIP switches 9 3 5 1 Standard S
24. lt 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 Safety Precautions Operation A N WARNING 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 A N 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
25. nal Connect to the SL1 and SL2 terminals of a slave unit when used as master unit terminals in parallel operation The alarm output terminals for the Regenerative Braking Unit AL1 Provide a circuit to turn off the primary power supply for the Invert er when the temperature relay of the built in resistor or optional Braking Resistor is activated Alarm terminal Connect to the AL1 AL2 1 2 terminals of the Braking Resistor when the optional Braking Resistor is used Short circuit between the AL1 and AL2 terminals when the option al Braking Resistor is not used Only for the models 3G3AX RBU21 RBU22 RBU41 1 5 1 3 Removing the Built in Resistor 1 3 Removing the Built in Resistor Eu To remove the built in resistor follow the procedure described below 3G3AX RB21 RBU22 RBU41 only ubisag 1 Disconnect the lead wires connected from the built in resistor to the P and RB ter minals on the PCB and to the R1 and R2 terminals on the fin D 2 Remove the built in resistor from the bottom of the unit 3 Reconnect the wiring between the AL1 and R1 terminals and between the AL2 and R2 terminals on the fin 1 6 1 4 Connection 1 4 Connection 3G3AX RBU21 RBU22 Connection Example c 2 7 Q m WWhen the built in resistor is used The following is an example of connections using the built in resistor Up to five units can be connected in parallel For DIP switch settings refer to 2 1 DIP Sw
26. nccoccnconoconononnnnononononnnconononcnnnns 14 REVISION RUSO espro ri aan Er 15 ABOUE IHIS M Anlasser ee 16 Chapter 1 Design 121 WNO ecieci eeen 1 1 12 TemNalS sssaaa aa aa aaa aAa 1 3 1 3 Removing the Built in Resistor ccooococonccocnnoconnccononocononanconanonnannnns 1 6 o A 1 7 Chapter 2 Functions 21 DIP SWITCH Seting A a 2 1 Chapter 3 Maintenance Operations 3 1 Precautions before OperatiON ccccoonccnccccnnncoconnonononcnnonennnnnnnannnnnnannnnnss 3 1 3 2 When the Alarm Contact is Activated occcccoconccncconcnncccoconoccnnnnnonononnnss 3 2 3 3 When an Inverter Overvoltage Trip Occurs occcooccccccccnccnccncnononononenonanonoss 3 3 Chapter 4 Inspection and Maintenance 4 1 Inspection and Maintenance ooccccnccccoccncnncncnncnnnnnnnoncnnnncnonnnnnonnnonnnnennnnoss 4 1 4 2 Daily Inspection and Periodic INSPECTION occccocnccccnccncnccncnncnnononannnnanoss 4 2 4 3 Megger Tesla ai 4 4 4 4 Checking the Main Element oocccccccnnccccnnccoccncnoncnononononnncnnnnnnnnonanonoss 4 5 45 Capacitor ile CUNE ean r ade 4 6 Chapter 5 Specifications 5 1 STAM SIGS DSCC AON LS ee 5 1 5 2 Dimensional DrAWING eo tvivomeicitaicacclcla aisladas 5 5 17 Contents Chapter 1 Design 1 1 1 2 1 3 1 4 O Ca ee ee e aai 1 1 A SEE ee ee Rear 1 3 Removing the Built in Resistor 1 6 A A a E 1 7 1 1 Wiring EN 1 1 Wiring Design Correct examp
27. nce 5 Check and replace the capacitor 4 2 Daily Inspection and Periodic Inspection Inspec tion part General Main circuit Inspec tion item Ambient environ ment Entire device General Connec tion con ductor and wire Inspection period Inspection point Inspection method Criteria Meter Ambient temperature 10 C to 50 C no freezing Thermom eter Hygrome ter Recorder Check ambient temperature as Refer to Installa well as humidity tion Page 12 and dust levels Ambient humidity 90 max no condensa tion Check that there are no abnormal Visual or acoustic l l No faults vibrations or inspection sounds Disconnect the wir ings of the main and the control cir cuit terminals use Megger test a megger to mea between main 99 5 MQ min sure the resistance circuit terminal Refer to 4 3 Megger between the i and ground Test terminal ground terminal and the short cir cuited parts of main circuit terminals P RB and N Check that any parts which may need tightening Tighten securely are secure No faults Check that no parno nae Visual inspection tions of overheat Ing Check that there is no distortion with the conduc tor Visual inspection No faults Check that there is no tearing inthe wire coverings 500 V DC megger Terminal Check that there i Visual inspection No faults block is no damage 4 2 32
28. nit uses semiconductors in the main circuit If the unit undergoes a withstand voltage test it may cause semiconductor deterioration 4 3 Megger Test Megger Test For a megger test of the external circuit be sure to disconnect all the terminals of the Regenerative Braking Unit so as not to apply the test voltage to the Regenerative Braking Unit Use a high resistance tester for a power distribution test of the control circuit Do not use a megger or buzzer Conduct a Regenerative Braking Unit megger test only to the main circuit not to the control circuit Use a 500 V DC megger for a megger test Gradually increase the applied voltage and reduce it to O V To conduct a megger test for the main circuit short circuit the P RB and N terminals with a wire Regenerative Braking Unit 500 V DC megger Ground terminal Applied voltage Applied voltage a lt gt Time Time es 0 15 min 01 S min Note Do not connect the power cable 4 4 392UeUu3 UIe y pue uono dsu 4 4 Checking the Main Element 4 4 Checking the Main Element The quality of the main element can be checked using a tester Preparation Make preparations for the check by following the procedure below 1 Disconnect the cables N RB P and P terminals and the built in resistor cable RB and P terminals 2 Prepare a tester Usable range is 1 2 measurement resistance Q Checking method c The quality can be judged by mea
29. njury due to an electric shock Be sure to put on the front cover before turning on the input power Ly Turn off the input power of the Inverter and wait for more than 10 minutes before changing wiring or 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 gt operating the DIP switch Not doing so may result in a serious injury due to an electric shock Safety Precautions A N CAUTION Install a stop motion device to ensure safety Not doing so might result in a minor injury 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 gt 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 gt 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 gt Do not touch the fins
30. ollowing 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 AN WA R N i N G avoided is likely to result in serious injury or may result in death Additionally there may be severe property damage CA UTI O N Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or in property damage MAlert Symbols in This Document WARNING 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 gt Be sure to ground the unit Not doing so may result in a serious injury due to an electric shock or fire gt O Do not operate the switches with wet hands Doing so may result in a serious injury due to an electric shock gt 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 gt serious injury due to an electric shock or fire Do not remove the front cover during the power supply Doing so may result in a serious i
31. oration 4 6 392UeUu3 UIe y pue uon9adsu 4 5 Capacitor Life Curve 32UeU3 UIE Y pue UO DedsSuU 4 7 Chapter 5 Specifications 5 1 Standard Specification List usnunnnnenennnnnne 5 1 5 2 Dimensional DraWiNQ oonccocncconccconccenancnnannnnannns 5 5 Specifications 5 1 Standard Specification List 5 1 Standard Specification List Models with a Built in Resistor 3G3AX RBU21 RBU22 RBU41 Voltage class 3 phase 200 V class 3 phase 400 V class Model 3G3AX RBU21 RBU22 RBU41 Operating voltage ON 725 5 V ON OFF te A 2 i OFF 710 5V 5 or 10 setting available Do Bl I setting available Operation indication LED ON Lit Maximum number of units in parallel 5 units operation Built in resistance 120 W 1800 120 W 200 120 W 180 Q x 2 in series S a h 10s max 0 5s max 10s max Y tive ON time Allowable opera Cycle 1 10 Cycle 1 80 Cycle 1 10 tion cycle 10s ON 90s OFF 0 5s ON 40s OFF 10s ON 90s OFF m Power Instantaneous 0 73 kW Instantaneous 6 6 kW Instantaneous 1 46 kW consumption Short time rating 120 W Short time rating 120 W Short time rating 240 W P Built in relay specifications e The temperature relay operates if the built in resistor reaches approx 200 C or more and recovers at approx 170 C or less 3 Built in resistance e Built in thermal fuse recovery impossible E S overheat protection e Rating of contact 250 VAC 200 mA R load
32. pecification List Specifications of Braking Resistors 3G3AX RBA RBB RBC Model Resistance Q Capacity W Allowable brak ing frequency ED Allowable con mi braking time s 3G3AX RBA 3G3AX RBB 3G3AX RBC IES Cee ee 10 1200 5 4 suolne91j1nads Specifications 5 2 Dimensional Drawing 5 2 Dimensional Drawing 3G3AX RBU21 RBU22 RBU41 Ground terminal Screw size M5 3G3AX RBU23 aa i ne ae ee a re ae 217 gt 4 68 mn O ERA BO dl RN Laos loa eee eee as ee O O ri V Y 250 A 109 penne eee Ground terminal Screw size M5 15 o E LA 258 _ 9 9 N m LA m 5 2 Dimensional Drawing 3G3AX RBU24 3G3AX RBU42 Ground terminal Screw size M5
33. raking Resistors with the same resistance For DIP switch settings refer to 2 1 DIP Switch Setting page 2 1 MC1 MC2 1 O OO O RY a gt 88 z ic O O BS lt Er 3 phase 200 V be lL al O O pSL1 SL2 AL1 AL2 ae 3G3AX RBU23 RBU24 Master Oe MA1MA2 D all d 3G3AX RBA PSL1 SL2 ALT AL2 RBA RBB RBC 3G3AX RBA op QP 3G3AX RBU23 RBU24 O 1 AL1 O MAMA O PAAL O Q O 1 To select RY check the MC coil and RY contact specifications of the Braking Resistor The models of 3G3AX RBU23 RBU24 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 eTo prevent overheating be sure to connect the alarm contacts 1 AL1 and 2 AL2 ubisag 1 4 Connection 3G3AX RBU42 RBU43 Connection Example Mi When the optional Braking Resistor 3G3AX RBA RBB RBC is used The following is an example of connections using the Braking Resistor 3G3AX RBA RBB RBC Up to two units can be connected in parallel For parallel connection use Braking Resistors with the same resistance For DIP switch settings refer to 2 1 DIP Switch Setting page 2 1 c 2 7 Q A MC1 MC2 nu RY BSS RY 200 V 50 60 Hz a Mc 220 V 60 Hz ca Operation power supply o O MCB MC1 MGa Inverter R OS 5 R L1 U T1 N DO O 400 V a
34. rcuit terminals Screw size M5 Tightening torque 3 4 to 3 7 N m nefe Control circuit terminals screw size M3 Tightening torque 0 6 to 0 9 N m sa sa ona mae a we 1 2 Terminals W3G3AX RBU23 RBU43 Main circuit terminals screw size M8 Tightening torque 12 to 13 5 N m Control circuit terminals Screw size M 3 Tightening torque 0 6 to 0 9 N m rau se wa Alarm terminals screw size M3 Tightening torque 0 6 to 0 9 N m ae a MW3G3AX RBU24 Main circuit terminals screw size M10 Tightening torque 25 to 28 N m Control circuit terminals screw size M 3 Tightening torque 0 6 to 0 9 N m Alarm terminals screw size M3 Tightening torque 0 5 to 0 6 N m 1 4 ubisag 1 2 Terminals EN Terminal Description Design Terminal symbol Description Terminal name Connect to the N terminal of the Inverter Z DT gt zZZ O BE Connect to the Braking Resistor With the default connection this terminal is connected to the built in resistor Main circuit Only for the models 3G3AX RBU21 RBU22 RBU41 terminal Connect to the P 2 terminal of the Inverter Connect to the Braking Resistor With the default connection this terminal is connected to the built in resistor Only for the models 3G3AX RBU21 RBU22 RBU41 SL1 Connect to the MA1 and MA2 terminals of a master unit when Control circuit used as slave unit terminals in parallel operation termi
35. resistors are used in combination a voltage rise during switching is increased due to the internal inductive components of the resistor In this case increase the cable size or twist the cable For the Braking Resistor use a non inductive resistor Do not use six or more resistors in combina tion For connections on the PCB terminal block be sure to use crimp terminals with insulation coating g D 2 Q 5 To use the optional Braking Resistor select the model with combined resistance higher than the specified connectable resistance If a resistor whose resistance is less than the connectable resis tance is used it may result in a fault of the Regenerative Braking Unit Use thorough caution in re gards to the resistance When using these Braking Resistors be sure to remove the built in resistor 3G3AX RBU21 RBU22 RBU41 only Rare Connectable resistance RBU21 17 Q min RBU22 17 Q min RBU23 4 Q min RBU24 2 Q min RBU41 34 Q min RBU42 10 Q min RBU43 6 Q min 1 2 1 2 Terminals ES 1 2 Terminals Design Terminal Position and Arrangement The terminal arrangement on the Regenerative Braking Unit is shown below W3G3AX RBU21 RBU22 RBU41 Main circuit terminals screw size M 4 Tightening torque 1 2 to 1 3 N m Control circuit terminals Screw size M 3 Tightening torque 0 6 to 0 9 N m sa wat ma Alarm terminals screw size M3 Tightening torque 0 5 to 0 6 N m pepe e Main ci
36. suring the conduction state of the N RB and P terminals on the Regenerative Braking Unit terminal block main circuit terminals while alternating the tester polar ity a P Lo FD flywheel diode e c 2 O IGBT 4 1 main element Y N e First measure the voltage between the P and N terminals in the DC voltage range Then make sure that there is no residual voltage before performing the check e A nearly infinite value is shown in a no conduction state The value shown ranges from a few to a few dozen Q in a conduction state If the measurement result for each item is as listed below the quality is judged as being acceptable Tester polarity No conduction Conduction No conduction 4 5 4 5 Capacitor Life Curve 4 5 Capacitor Life Curve Ambient temperature C 50 12 hour operation day 40 30 20 10 24 hour operation day 0 10 1 2 3 4 5 6 7 8 9 10 Capacitor life year Note 1 Ambient temperature refers to the surrounding atmospheric temperature of the Regenerative Braking Unit or the temperature inside if it s encased or installed in an enclosure Note 2 The smoothing capacitor which will waste because of the internal chemical reaction should normally be replaced once every 5 years If the ambient temperature is high however frequent operation of the Regenerative Braking Unit will cause its service life to be significantly shortened due to capacitor deteri
37. ternal connections 3G3AX RBA O RBB RBC RBU22 R1 1 AL1 o O o R20 0 2 AL2 P O Built in resistance MAI MA2 temperature relay Ad 3G 3AX RBA Temperature relay p SL1 SL2 AL1AL2 p p RBB RBC QP 3G3AX RBU21 ON RBU22 R1 AS Slave T MAIMA2 O R20 0 2 AL2 O O O 1 To select RY check the MC coil and RY contact specifications eTo use the Braking Resistor 3G3AX RBA RBB RBC be sure to remove the built in resistor If the Braking Resistor 3G3AX RBA RBB RBC is used with the built in resistor connected it may cause the built in resistor to burn due to overheating or result in an overheating detection failure when the Braking Resistor temperature relay is activated To prevent overheating be sure to connect the alarm contacts 1 AL1 and 2 AL2 of the Braking Resistor 1 8 1 4 Connection 3G3AX RBU41 Connection example MW When the built in resistor is used The following is an example of connections using the built in resistor Up to five units can be connected in parallel For DIP switch settings refer to 2 1 DIP Switch Setting page 2 1 c 2 7 Q A MC1 MC2 ee gt BSS RY 200 V 50 60 Hz BS wc 220 V 60 Hz 1 Operation power __ supply O O MCB MCI1 MC2 Inverter oN R O 0 O 3 ph AS hoy SiO O 100 N 3G3AX RBU41 Master MAIMA2 O Alarm terminal interna
38. the grounding terminals Can cause a fire and or burns Install on the steel sheeting or other nonflammable material Hazardous heat Fat B OBTNHY _ _ Bui geno TRANMERE ETE 2 BEHR UERENK 1 ONUA NERO ERKEL HAZARD OF PERSONAL INJURY OR ELECTRIC SHOCK Read the instruction manual carefully before installation and operation and follow the instructions exactly Disconnect incoming power and wait 10 minutes before removing cover ls sure to ground the grounding terminals A CAUTION DETRAS ee SZ ORRMICMHITS C Eat HAZARD OF FIRE AND OR ane Can cause a fire and or burns Install on the steel sheeting or other nonflammable material Hazardous heat 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 REGENERATIVE BRAKING UNIT Voltage specifications DC 200 400 V LOT NO 19208 S N 16206520000000 NE17968 01 OMRON Corporation MADE IN JAPAN Checking the Model 3G3AX RBU21 L Serial number Maximum applicable motor capacity 200 V class 4 400 V class Regenerative Braking Unit Checking the Accessories Note that this manual
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