Hitachi Dynamic Braking Unit Instruction Manual
Contents
1. Po O O lt 81 lt 0 R b lt PB lt 1 NO D Wiring 1 The wiring to the HBU should be passed through the wiring hole provided on the bottom of the unit 2 The wires from the HBU to the inverter and to the resistor carry high current with significant harmonic content To minimize the chance for interference lay out signal wire as far away as possible from these high current wires Use shielded signal wires as necessary to eliminate interference 3 The wiring distance between braking unit and braking resistor and between braking unit and inverter should meet the requirements as followed pictures Please do make sure that the connections between those units are in a bundle and they should be shielded or twisted pair 4 For 400 V class units 1000 V rated wire should be used For 200 V class 600 V rated wire is sufficient Braking Resistor lt gt 10 meters maximum 2 3 gt Braking Unit lt gt 5 meters maximum lt gt Inverter Hitachi America Ltd Tarrytown NY E Operation 1 Recheck all wiring and connections before applying power to the inverter 2 Operation of the HBU is automatic once installed It will turn on when the voltage of the inverter DC Bus exceeds the activation voltage setting When activated the HBU draws current off the DC Bus and passes it to the braking resistor s In so doing2. it will dissipate the regenerative energy from the motor load as heat 3 Do not touch the braking resistor while the inverter is operating The resistor may become very hot during normal operation 4 Inside the HBU front metal cover on the internal printed circuit board there are two LED indicators The red LED POWER will be ON when the voltage between the DC Bus P and N of inverter is higher than 35V and the green LED BRAKING will be ON when the DC bus level is above the activation voltage and the braking unit is therefore passing current to the resistor s A WARNING Do not disassemble the HBU when it is connected to an inverter and the power is applied A CAUTION Do not touch the braking resistor while the inverter is energized Its surface may be very hot during normal operation and there is risk of injury Hitachi America Ltd Tarrytown NY IV Troubleshooting The internal protection circuit of the braking unit will cause it to shut down in the case of any internal malfunction Should this occur it would likely result in an over voltage trip on the inverter In case of difficulty use the table below to try to find possible solutions Should this not resolve the problem please contact your Hitachi distributor for further assistance Item Symptom Possible Cause Solution The POWER light of the braking Wiring error Check the wiring 1 u
3. 1 3 3KW 1000 135 7 5 HBU 4015 1 4 5KW 750 1 130 11 HBU 4030 1 6 6KW 500 1 135 15 HBU 4030 1 9KW 400 1 125 18 5 HBU 4045 1 320 1 125 22 HBU 4045 1 13 2KW 27 20 1 125 30 HBU 4030 2 10KW 40Q 2 125 37 HBU 4045 2 LI KW 320 2 125 45 HBU 4045 2 13 5KW 27 20 2 125 55 HBU 4045 3 12KW 300 3 135 75 HBU 4045 4 11KW 27 20 4 145 90 HBU 4220 1 54KW 530 1 120 110 HBU 4220 1 66KW 4 40 1 100 132 HBU 4220 2 40KW 10 2 130 160 HBU 4220 2 48KW 6Q 2 140 220 HBU 4220 2 66KW 50 2 110 300 HBU 4220 3 60KW 4 50 3 110 600 HBU 4220 6 60KW 4 50 6 110 WARNING It is critical to set the jumper appropriately for the local supply voltage or damage to the HBU inverter and or resistors may result Factory default setting may not be appropriate for your installation Il Mounting A External dimensions of HBU 2015 2030 4015 4030 4045 4220 2 2 2 2 Z Z 2 2 Figure 1 Hitachi America Ltd MOON MOO Tarrytown NY Model Mounting Hole Terminal Wire Size Wire Size Size mm Screw Size mm AWG 2015 2030 4015 4030 4045 6 M4 4 6 10 8 4220 8 M8 16 36 4 2 Hitachi America Ltd Tarrytown NY B Braking Unit Front Panel 1 Front Cover Removal Grasp the two sides of the front panel firmly Remove the two attachment screws at the bottom of the cover by turning counterclockwise Remove the cover by lifting it upward from the bottom Figure 2 A 2 Front Cover Re attachmen
4. life and reliability of the braking unit please install it in a well ventilated area If you install braking units in an enclosure be sure to size the panel properly and provide adequate cooling ventilation as necessary to ensure the internal temperature remains lower than 40 C 3 Other precautions for installation Before installation cover the ventilation grills on the braking unit with tape to keep out dust and metal fragments After installation is completed be sure to remove any tape or other coverings from the ventilation grills 4 Mounting clearance Provide adequate top bottom and side clearance around the HBU according to the following diagram Figure 3 Hitachi America Ltd Tarrytown NY lll Installation and Operation A WARNING A 1 The inverter DC Bus can hold a dangerous electrical charge for some time after AC power had been removed Make sure that the inverter input power has been turned off for at least 10 minutes before you attempt to make any wiring connections to the HBU 2 Wiring should be done by a licensed electrician following applicable codes and generally accepted wiring practices 3 Do not touch the terminals or internal components of the braking unit while the DC bus is charged 4 Make sure that no wire strands contact the metal case of the HBU or cause a short circuit between the terminals A CAUTION 1 Be sure to connect the braking resistors braking unit and inv
5. Hitachi America Ltd Dynamic Braking Unit HBU 2015 2030 4015 4030 4045 4220 Instruction Manual NOTE REFER ALSO TO APPLICABLE INVERTER INSTRUCTION MANUAL Manual Number HAL7201E After reading this manual keep it handy for future reference September 2009 Hitachi America Ltd Hitachi America Ltd Tarrytown NY Revision History Initial Version July 2007 Rev A September 2007 Added specs dimensions terminal configuration and circuit diagrams for HBU 4220 Rev B December 2007 Changed depth dimension on page 11 for 2015 2030 4015 4030 4045 4220 Rev C February 2008 Added missing ratings in tables pages 8 10 improved descriptions on pages 4 14 15 and 19 added index Rev D February 2009 Added derating curves AWG wiring sizes updated web address clarification of wiring distance and wiring voltage class on page 18 Rev E September 2009 Added warning notes about braking activation default jumper position on 400 V class units Hitachi America Ltd Tarrytown NY Safety Precautions Please read through this user s manual before you use our product Keep this manual handy for future reference Definitions used in this manual CAUTION This indicates a potentially hazardous situation that if not avoided can result in minor p y to moderate injury or serious damage to the product WARNING This indicates a potentially hazardous situation that if not avoided can result
6. U 2015 1 140W 2000 1 125 1 5 HBU 2015 1 520W 10002 1 125 2 2 HBU 2015 1 520W 700 1 120 37 HBU 2015 1 780W 400 1 125 5 5 HBU 2015 1 IKW 300 1 115 7 5 HBU 2015 1 1 5KW 200 1 25 11 HBU 2015 1 4 8KW 13 60 1 125 15 HBU 2015 2 3KW 200 2 125 18 5 HBU 2030 1 9 6KW 80 1 125 22 HBU 2030 1 9 6KW 6 80 1 125 30 HBU 2030 3 4KW 150 3 125 37 HBU 2030 2 6KW 100 2 100 45 HBU 2030 2 9 6KW 6 80 2 120 55 HBU 2030 3 6 4KW 10 20 3 100 75 HBU 2030 4 7 2K W 90 4 110 90 HBU 2030 4 9 6KW 6 80 4 120 110 HBU 2030 5 9 6KW 6 80 5 100 200 V SERIES ED 4096 braking activation voltage 380 VDC Hitachi America Ltd Tarrytown NY Quantity Braking Power of Model of braking of i Quantityof torque Inverter unit braking Sone resistors 40 ED unit 0 4 HBU 2015 1 240W 2000 1 220 0 75 HBU 2015 1 450W 2000 1 125 1 5 HBU 2015 1 900W 1009 1 125 2 2 HBU 2015 1 1 3KW 700 1 120 3 7 HBU 2015 1 2 2KW 409 1 125 5 5 HBU 2015 1 3 3KW 300 1 115 7 5 HBU 2015 1 4 5K W 20 1 25 11 HBU 2015 2 3 3KW 27 20 2 125 15 HBU 2030 1 9KW 100 1 125 18 5 HBU 2030 2 6KW 16Q 2 125 22 HBU 2030 2 6 6KW 13 6Q 2 125 30 HBU 2030 2 9KW 100 2 125 37 HBU 2030 3 7 5KW 150 3 100 45 HBU 2030 3 9KW 10 20 3 120 55 HBU 2030 4 8 5KW 13 20 4 100 75 HBU 2030 4 I2KW 90 4 110 90 HBU 2030 6 9KW 10 20 6 120 110 HBU 2030 8 8 5KW 10 80 8 100 400 V SERIES ED 10 braking activation voltage 760 VDC Hi
7. al temperature is too high Figure 4 Typical Alarm and Safety REQUIRED Q Circuit FOR SAFETY WARNING Be sure to utilize a power disconnection method as shown in Figure 4 above which removes power from the inverter should the braking resistor overheat Failure to do so may result in risk of fire injury or death WARNING On 400 V class be certain to verify the correct jumper position for braking activation level BEFORE applying power to the system Otherwise there is risk of damage to the HBU the inverter and or the resistor s Hitachi America Ltd Tarrytown NY Jumper block D Ec m CE d qm Factory Default Position for Normally Position for Normally Closed N C Open N O Operation recommended Operation not recommended Jumper J8 Setting Figure 5 Hitachi America Ltd Tarrytown NY B Connecting Multiple HBU Units Connection Diagram for HBU 2015 2030 4015 4030 4045 Resistor o DC380V MASTER INVERTER v Ic JV SLAVE DC760V 3B0V AC Input HBU 4220 HBU 4220 38Dv AC Input Braking Braking Activation Activation Volt MASTER Voltage MASTER e SH SLAVE Resistor Resistor Figure 6 17 C Simplified circuit diagram of the braking unit R S Ta b J Te N P pi HBU 4220 Hitachi America Ltd Tarrytown NY IN IN OUT OUT b Te N P pi PB HBU 2015 2030 4015 4030 4045 Figure 7
8. erter according to the connection diagram 2 Tighten the terminal screws according the specified torque A General instructions Use wire gauge gt 4 mm on power supply connection and resistor connection Check that the connections are correct before you connect to the power supply Refer to the wiring diagram in Figure 4 for the necessary connections for P and N and recommended use of fault alarm functions The terminal arrangement is shown in Figure 7 The HBU incorporates internal fault detection which can be monitored externally through the relay alarm output terminals marked Tb and Tc Should the HBU detect an internal fault the relay will energize and the state of the Tb Tc output will change These terminals should be wired to a safety circuit as appropriate In the factory default configuration the Tb Tc output will CLOSE when the HBU detects a high internal temperature and will be OPEN otherwise An HBU fault will cause an external trip fault in the inverter Note Jumper J8 will change the logic sense of the Tb Tc output from NO to NC Figure 5 should your system so require However it is recommended to use the factory default setting as described Refer to the Inverter Instruction Manual for more specific details about how to wire and set up an external trip input The resistor s must incorporate an internal thermal switch usually open on fault type and this must be wired with a safety circuit that will remove powe
9. erter unit braking SOS of resistors 20 ED unit 0 4 HBU 4015 1 140W 7500 1 230 0 75 HBU 4015 1 140W 7500 1 130 1 5 HBU 4015 1 520W 4009 1 125 2 2 HBU 4015 1 520W 250 1 135 3 7 HBU 4015 1 780W 1500 1 135 5 5 HBU 4015 1 1040W 1009 1 135 7 5 HBU 4015 1 1560W 759 1 130 11 HBU 4015 1 2KW 50Q 1 135 15 HBU 4030 1 3KW 400 1 125 18 5 HBU 4030 1 9600W 320 1 125 22 HBU 4030 1 9600W 27 20 1 125 30 HBU 4045 1 12KW 200 1 125 37 HBU 4045 1 20KW 160 1 125 45 HBU 4030 2 10KW 27 20 2 125 55 HBU 4045 2 12KW 200 2 135 75 HBU 4045 3 18KW 20 40 3 145 90 HBU 4045 4 12KW 21 20 4 120 110 HBU 4045 4 ISKW 180 4 100 132 HBU 4220 1 48KW 3 6Q 1 120 160 HBU 4220 1 80KW 30 1 140 220 HBU 4220 2 60KW 5Q 2 110 300 HBU 4220 2 80KW 30 2 110 600 HBU 4220 4 80KW 30 4 110 WARNING It is critical to set the jumper appropriately for the local supply voltage or damage to the HBU inverter and or resistors may result Factory default setting may not be appropriate for your installation 400 V SERIES ED 40 braking activation voltage 760 VDC Hitachi America Ltd Tarrytown NY Quantity Braking Power of Model of braking of NILUS torque Inverter unit braking ee 2 40 ED unit resistors 0 4 HBU 4015 1 240W 7509 1 230 0 75 HBU 4015 1 450W 7509 1 130 1 5 HBU 4015 1 800W 400 1 125 2 2 HBU 4015 1 1 32KW 2500 1 135 3 7 HBU 4015 1 2 2KW 1500 1 135 5 5 HBU 4015
10. for 10 seconds maximum and 10 ED T WARNING It is critical to set jumper appropriately for the local supply voltage or damage to the HBU inverter and or resistors may result Hitachi America Ltd D Braking Resistor Selection Table for HBU braking unit 200 V SERIES ED 10 braking activation voltage 380 VDC Tarrytown NY Quantity Braking Power of Model of braking of Quantity of torque Inverter unit braking resistors 10 ED unit 0 4 HBU 2015 1 70W 2000 1 220 0 75 HBU 2015 1 70W 2000 1 125 1 5 HBU 2015 1 260 1000 1 125 2 2 HBU 2015 1 260W 7002 1 120 3 7 HBU 2015 1 390W 400 1 125 5 5 HBU 2015 1 520W 309 1 115 7 5 HBU 2015 1 780W 2002 1 125 11 HBU 2015 1 2400W 13 6Q 1 125 15 HBU 2015 1 3000W 100 1 125 18 5 HBU 2015 2 2400W 160 2 125 22 HBU 2015 2 2400W 13 60 2 125 30 HBU 2015 2 3000W 100 2 125 37 HBU 2015 2 3000W 100 2 100 45 HBU 2015 3 3000W 100 3 120 55 HBU 2030 2 4800W 6 80 2 100 75 HBU 2030 3 4800W 6 8Q 3 110 90 HBU 2030 4 4800W 6 80 4 120 110 HBU 2030 5 4800W 6 80 5 100 200 V SERIES ED 20 braking activation voltage 380 VDC Hitachi America Ltd Tarrytown NY Quantity Braking Power of Model of braking of i Quantityof torque Inverter unit braking Sones resistors 20 ED unit 0 4 HBU 2015 1 140W 20002 1 220 0 75 HB
11. in serious injury or death l General Information The function of the HBU braking unit is to divert into a braking resistor the regenerative energy produced in the process of decelerating the motor converting that energy into heat Regenerative energy flows from the motor into the inverter DC Bus manifested as increased bus voltage The advantage gained using the HBU is improved braking performance and shorter deceleration time of the load Before you use the HBU braking unit please read through this manual and please contact your distributor if you have any questions This manual will provide you the necessary information for installation operation troubleshooting and repair of the HBU braking unit A Inspection Please check that the model number is the same as what you ordered BEFORE opening the box Then check the contents for any sign of defect or damage during transport If there is any problem please contact your Hitachi distributor immediately B Braking Unit model numbering convention HBU LILIDIEI Braking Unit 10 ED Code Inverter Power Tavertet 015 15 kW Code Input oan Voltage 045 45 kW 200 VAC 220 220 kW 400 VAC C HBU Series Technical Specifications Hitachi America Ltd Tarrytown NY 200 V SERIES Model HBU 2015 HBU 2030 Peak curre
12. nit is not illuminated when the Confirm that the jumper is inverter is energized HBU set for SLAVE set for MASTER Short circuit on Braking unit Change the braking unit IGBT 5 The BRAKING light is on all the Wrong connection of the Examine the braking time braking resistor resistance and its connection AC Input to the inverter is Check that AC supply is high within spec Wiring error Recheck connections a E The capacity of braking unit f 3 Over voltage trip on inverter Examine the design and and braking resistor is not recalculate it enough Braking usage rate is Examine the design and T too high recalculate it The braking unit trips because the 4 f Reduce the ambient temperature of resistor is too high The ambient temperature is E temperature where the HBU over 40 C Fah is installed 20 Hitachi America Ltd Tarrytown NY HBU DYNAMIC BRAKING UNIT DERATING CURVES HBU 2015 HBU 4015 HBU 4030 67 A 50 0 Tc 50 100 150 C 200 Tc 50 100 150 C 200 21 Hitachi America Ltd Tarrytown NY HBU 4220 175 Vae 2 15 V A Alarm relay 14 Ambient temperature 13 C Cover installation 12 Cover removal 12 D Derating Curves 21 22 Dimensions 11 Distance wiring 18 F Fault detection 14 G Grounding 15 I Internal circuit 18 J Jum
13. nt A 50 90 Continuous current A 15 30 and yee Braking Activation Voltage 380 10 VDC not selectable specifications Maximum hysteresis 10 VDC Multiple units Maximum 10 HBUs parallel connected Power supply DC Bus Voltage Range 230 380V Power ON The red power LED will be on whenever the Indication inverter DC Bus voltage is above 35 VDC The green braking LED will be on during Braking ON i braking unit conduction Ambient temperature Minus 10 C to 40 C no frost Ambient humidity 90 RH no dew Physical data Vibration 10 20hz 1g 20 50hz 0 2g Protection IP20 Weight 2 3 kg 5 1 165 400 V SERIES Model HBU 4015 HBU 4030 HBU 4045 HBU 4220 Peak current A 25 50 75 250 Continuous current A 8 15 25 80 Input and output 2 zum i Braking Activation Voltage 630 660 690 730 760V 16V jumper selectable T specifications Maximum hysteresis About 16V Multiple units Maximum 10 HBUs parallel connected Power supply DC Bus Voltage Range 460 800V The red power LED will be on whenever the 2 Power ON Indication inverter DC Bus voltage is above 35VDC functions The green braking LED will be on during braking g g Braking ON unit conduction Ambient temperature Minus 10 C to 40 C no frost Ambient humidity 90 RH no dew Physical dite Vibration 10 20hz 1g 20 50hz 0 2g Protection IP20 Weight 2 3 kg 5 1 Ib ipd iis 25 5 Ibs Peak current is defined as capacity
14. per activation voltage 4 8 9 10 15 Jumper alarm contact 16 L LED indicators 19 Hitachi America Ltd Tarrytown NY INDEX M Model numbering 3 Mounting 11 Mounting Clearance 13 Multiple unit connection 17 0 Operation 19 P Power requirements 15 R Resistor Selection 5 6 7 8 9 10 Revision History 2 S Safety Circuit 15 Safety Precautions 3 Specifications 4 T Terminal arrangement 18 Themal protection resistor 14 Troubleshooting 20 W Wire gauge 11 14 Wiring 18 Wiring schematic 15 23 24 Hitachi America Ltd Hitachi America Ltd 50 Prospect Avenue Tarrytown NY 10591 For Technical Support contact your Hitachi Distributor Or visit www hitachi america us inverters Hitachi America Ltd Manual Number HAL7201E September 2009 Tarrytown NY
15. r to the inverter A typical configuration is shown in Figure 4 In this way a resistor over temperature condition or a break in the alarm wiring will cause power to be removed from the inverter IMPORTANT NOTE On 400 V models only there are five voltage settings 630V 660V 690V 730V and 760V for unit activation The braking voltage MUST be set to meet the needs of the application Set the voltage by moving the jumper on inside the HBU to the pair of pins that correspond to the activation voltage desired Note Hitachi America Ltd Tarrytown NY On 200 V models the activation voltage is fixed at 380 VDC 6 When using multiple HBU units please refer to section III B on page 16 The first braking unit should have its jumper set to the MASTER position and braking units number 2 through N should have their jumpers in the SLAVE position 7 Ensure that the case of braking unit is well grounded 8 All units except the HBU 4220 are completely powered from the DC bus P and N terminals of the inverter The HBU 4220 also requires single phase AC power to operate The HBU 4220 also includes terminals marked R and S which must be connected to the corresponding terminals on the AC input side of the inverter as shown below HBU 4220 Only HBU RESISTOR P1 I N PB R2 om L3 Intelligent Input Resistor Fault relay Thermal Fol energizes when Switch HBU intern
16. t Insert the top tongue of the front cover under the coping Push the front cover down until it is fully seated Reinstall the attachment screws at the bottom of the front cover 3 5N M Figure 2B Figure 2 Front cover removal and reinstallation of HBU braking unit C Cautions for Installation CAUTION 1 Please install the braking unit on a non flammable wall or panel Otherwise there is risk of fire 2 If you install braking units in an enclosure be sure to size the panel properly and provide adequate cooling ventilation as necessary to ensure the internal temperature remains lower than 40 C 3 It is normal for this braking unit to become hot during operation Therefore be sure nothing flammable or explosive comes in contact with it while it is in use Otherwise there is risk of fire 1 Installation considerations o If installed in a cabinet the cabinet should be adequately ventilated o Ambient temperature should be between 10 C and 40 C or if NOT in a cabinet between 10 C and 50 C no frost Humidity lt 90 RH non condensing Do not install the braking unit on wooden board or any flammable surface Do not install where the unit will be exposed to direct sunlight Do not install near flammable explosive or caustic gases or liquids Protect from dust and strong electromagnetic fields Hitachi America Ltd Tarrytown NY 2 Ambient temperature In order to improve the
17. tachi America Ltd Tarrytown NY Quantity Braking Power of Model of braking of Quantity of torque Inverter unit braking fos resistors 10 ED unit 0 4 HBU 4015 1 70W 7500 1 230 0 75 HBU 4015 1 70W 75002 1 130 1 5 HBU 4015 1 260W 4000 1 125 2 2 HBU 4015 1 260W 2500 1 135 3 7 HBU 4015 1 390W 1500 1 135 5 5 HBU 4015 1 520W 1009 1 135 7 5 HBU 4015 1 780W 750 1 130 11 HBU 4015 1 1040W 50Q 1 135 15 HBU 4015 1 1560W 400 1 125 18 5 HBU 4030 1 4800W 320 1 125 22 HBU 4030 1 4800W 27 20 1 125 30 HBU 4030 1 6000W 209 1 125 37 HBU 4045 1 9600W 169 125 45 HBU 4045 1 9600W 13 60 1 125 55 HBU 4045 2 6000W 200 2 135 75 HBU 4045 2 9600W 13 60 2 145 90 HBU 4045 2 9600W 13 6 Q 2 100 110 HBU 4045 3 9600W 13 69 3 100 132 HBU 4220 1 16KW 3 69 1 120 160 HBU 4220 1 40K W 1 140 220 HBU 4220 1 60KW 2 50 1 110 300 HBU 4220 40K W 110 600 HBU 4220 4 40K W 4 110 WARNING It is critical to set the jumper appropriately for the local supply voltage or damage to the HBU inverter and or resistors may result Factory default setting may not be appropriate for your installation 400 V SERIES ED 20 braking activation voltage 760 VDC Hitachi America Ltd Tarrytown NY Quantity Braking Power of Model of braking of Quantity torque Inv
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