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1. Dynamic Braking Unit HDBU Series User manual S hamonk HDBU Series Dynamic Braking Unit User manual FOREWORD Thank you for purchasing HDBU series dynamic braking unit manufactured by Shenzhen Hpmont Technology Co Ltd HDBU series dynamic braking unit hereinafter referred to as braking unit are used with inverter to consume the feedback energy in the motor slowdown process and to achieve fast braking control This User Manual describes how to use the braking unit and its installation wiring troubleshooting and daily maintenance etc Before using the product please read through this User Manual carefully In addition please do not use this product until you have fully understood safety precautions Note Preserve this Manual for future Due to product upgrade or specification change and for the purpose of improving convenience and accuracy of this manual this manual s contents may be modified If you need the User Manual due to damage loss or other reasons please contact the regional distributor of our company or directly contact our company Technical Service Center For the first time using the user should carefully read this manual If you still have some problems during use please contact our company Technical Service Center Telephone 4008 858 959 or 189 4871 3800 The product warranty is on the last page of this Manual please preserve it for future CONTENTS Chapter 1 Safety2. 3 SK2 terminal function description Identification Terminal name Function description RA RB RC Fault output terminal Relay of 1c contact output RC RA Normally open contact RC RB Normally closed contact Contact rating 250VAC 3A or 30VDC 1A HDBU Series Dynamic Braking Unit User Manual Chapter 4 Electrical Installation 4 3 3 SW1 Dial Switch Description According to the different power supply voltage of adaptive inverter it need set the braking unit s braking voltage threshold via the SW1 dial switch To set the dial switch it should be under the braking unit power off condition The relation between the braking voltage threshold and the dial switch is shown as Table 4 4 Shenzhen Hpmont Technology Co Ltd Table 4 4 Set the voltage Power supply voltage of DC voltage for braking Product model SW1 switch setting adaptive inverter VAC action VDC ON 690 H E mi HDBU 4T050 123 HDBU 4T075 380 460 ON HDBU 4T100 750 HRH 123 ON L 200 240 380 A a la 123 ON HDBU 4T150 n 690 H DC HDBU 4T250 123 380 460 ON 750 H E H 123 ON HDBU 6T150 600 690 1190 T E m HDBU 6T250 123 4 3 4 Indicator Description Table 4 5 Indicator description Identification Name Function description On The braking unit is at power on state POWER Braking unit power on indicator A Off The brak
3. Information and Precautions 11 Safety Definition sees iss ss cae cca dias cae eiii iaa dana retir 1 2 PreCautions epes raat eerie diet eects area ee le A elu 1 Chapter 2 Product Information 2 2 MiParti NaMe iaaa st von redline aw E EOE EEE AOR ater eee 2 ee ER el ET TEE 2 PA RO 3 2 4 Fuse EXplamatiOn cc io E E 4 Chapter 3 Mechanical InstallatioN ooooooccccnnnancccconnnnnnnanaconcnonnnanancnnnnnnnnanacon nn nnnnnnn cnn cnn rnnnanennos 1 3 1 Installation Precautions tivos tit IA ds 1 3 2 Requirement for the Installation Site ooonnoocccccnnnoccooccnncconononcnoncconnnonancnnnnonnnnnncncnncnns 1 3 3 Installation Direction al Space cocinan aed ewes 2 3 4 Dimensions and Mounting Size Chapter 4 Electrical Installation sek 4 4 1 Wiring Requirements 4 2 Power Terminal Description 5 4 3 Control Terminal Description deed caia dE ENEE Ne 6 4 3 1 SK1 Terminal DESCUIDO c ssia5ccectcsiecastecbaccdicesseccicscaeucieesteaasaacsaeecaacizansaicizacszaes 6 4 3 2 5K2 Terminal DesScrptiON ee a Ai 7 4 3 3 SW1 Dial Switch Description ccccscccccssssssessceeesesssenssecssesssensceeesessseeeseeeeees 8 4 3 4 Indicator Description sucio idad KEERA 8 Chapter 5 Typical Application ccccseceeeeeeeeeseeeeeeeeeeeeseeeeeeeeeeneeeeeeesenseeeseeeesceeeesseneeeeseeeeeseeeeeees 9 SL Sindle ele TEE 9 5 2 Two Braking Units for Parallel Application oooooooninicinnnccnnnocccnoncccnnnaccnn
4. if the abnormal conditions such as crack existing on fan vanes and other parts When the braking unit is switched on check if braking unit running is normal and check if there is any abnormal oscillation 7 4 Unwanted Braking Unit Disposal When disposing the braking unit please pay attention to the following factors The capacitors may explode if they are burnt Poisonous gas may be generated when the plastic parts like front covers are burnt Disposing method Please dispose unwanted braking unit as industrial waste 14 HDBU Series Dynamic Braking Unit User Manual NY hamant Shenzhen Hpmont Technology Co Ltd Product Warranty Card Unit Q 3 Add Of unit 2 3 BC Contact person o Tel Fax 3 Barcode on the product body paste here e Q Power Model s Contrat number Purchasing date H Service unit lt SN Contact person Tel Cc 2 Maintenance staff Tel Maintenance date User s quality evaluation for the service LI Better H Good O Common LI Poor Other opinions User signature Date Interview record of Customer Service Center O Interviewed by telephone O Interviewed by letters Others Technical service engineer signature Date S hamant Shenzhen Hpmont Technology Co Ltd Warranty Agreement 1 The warranty period of the product is 18 months refer to the barcode on the product body During the warranty period if the produ
5. resistor HDBU Series Dynamic Braking Unit User Manual 9 Chapter 5 Typical Application Shenzhen Hpmont Technology Co Ltd 5 2 Two Braking Units for Parallel Application When the output capacity of one braking unit can not satisfy the application requirement you can use two braking units in parallel to increase the braking output capacity Please according to Figure 5 2 connect two braking units for parallel application Set one braking unit as master and set another braking unit as slave then the slave one will auto track the master one to brake synchronously HDBU Master Inverter Type selection of temperature switch A HDBU Slave Type selection of temperature switch Faut reset Figure 5 2 Two braking units for parallel application In the above figure connect the braking state output terminal BRO of the master braking unit with the braking command input terminal BRI of the slave one And it need short connect the braking command source selective terminal BRS of the slave braking unit with the signal ground COM and signal grounds of the master and the slave should be connected at the same time HDBU Series Dynamic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd 5 3 Three Braking Units for Parallel Applicat
6. Ee Dimension mm Mounting size mm Gross weight odel W H D WI H1 H2 d kg HDBU 4T050 HDBU 4T075 138 190 140 120 180 176 4 5 3 HDBU 4T100 HDBU 4T150 HDBU 4T250 185 305 180 120 292 284 5 8 HDBU 6T150 HDBU 6T250 HDBU Series Dynamic Braking Unit User Manual Chapter 4 Electrical Installation Shenzhen Hpmont Technology Co Ltd Chapter 4 Electrical Installation Danger Only qualified electrical engineer can perform wiring job Bare metallic part of the power terminal wiring should be with insulating tape to wrap up Only when the power supply is completely cut off can you do the wiring job You can t open the braking unit s cover to do wiring operation until the power is cut off 10 minutes later Do not wire or detach the braking unit s internal devices at power on situation Do not do wiring operation until the internal charge indicator of the braking unit is off and the voltage between and of the main circuit terminals is below 36V The earth terminal PE of the braking unit must be reliable earthing It must use two separate earth wire due to the leakage current from the braking unit to ground Do not touch the wire terminals of the braking unit when it is live The main circuit terminals is neither allowed connecting to the enclosure nor short circuiting A Warning Make sure the inverter s power supply voltage is the same as the braking unit s rated vol
7. HDBU 4T075 and HDBU 4T100 of power terminal layout are shown as Figure 4 1 Chapter 4 Electrical Installation HDBU 4T150 HDBU 4T250 HDBU 6T150 and HDBU 6T250 of power terminal layout are shown as Figure 4 2 The descriptions are shown as Table 4 1 Figure 4 1 Power terminal layout 1 of braking unit Figure 4 2 Power terminal layout 2 of braking unit Table 4 1 Power terminal function description of braking unit Terminal identification Terminal name Function description DC bus input terminal Respectively connect to the inverter DC bus and BR1 BR2 Terminal of connect to the braking resistor Connect to the braking resistor PE Terminal of protective earth Connect to the protective earth HDBU Series Dynamic Braking Unit User Manual Chapter 4 Electrical Installation Shenzhen Hpmont Technology Co Ltd 4 3 Control Terminal Description The control terminals the dial switch and indicators are on the control board shown as Figure 4 3 o POWER OO indicator uuu ALM indicator FO onon BRK indicator TO sw1 HHA dial switch OO X Bal SK2 Figure 4 3 Position layout on the control board 4 3 1 SK1 Terminal Description TNO TNC FRS COM BRS ERIJBRO COM Figure 4 4 SK1 terminal layout 6 HDBU Series Dy
8. all at the location with good ventilation or cooling devices do not install the braking resistor mounted in proximity to the inlet of the braking unit Chapter 3 Mechanical Installation Shenzhen Hpmont Technology Co Ltd 3 3 Installation Direction and Space When install several braking unit it should consider the heat dissipation of air flow To achieve good cooling efficiency install the barking unit perpendicularly wall mounted side by side and always provide the following space to allow normal heat dissipation Just as shown in Figure 3 1 gt 50mm 2100mm 2 O rower e am o mm STORED CHARGE o e eje E Power o a a mn A STORED CHARGE 250mm e TA TT TL 2100mm SET Figure 3 1 Installation of braking unit When one braking unit is mounted on the top of the other the distance between the top and the next should exceed 300mm Just as shown in Figure 3 2 Figure 3 2 Installation of several braking units HDBU Series Dynamic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd 3 4 Dimensions and Mounting Size Chapter 3 Mechanical Installation W WI 4 d D A Y ji p f O POWER O AM N x BRK a eg A STORED CHARGE q b D Fl TU I Figure 3 3 Braking unit dimensions Table 3 1 Braking unit dimension descriptions
9. angjingkeng Industry Park Xili Dakan Nanshan District Shenzhen China Telephone 4008 858 959 or 189 4871 3800 P C 518055 Http www hpmont com E mail marketing hpmont com
10. cover Warning For the braking unit stored for more than 2 years please use voltage regulator to increase the input voltage gradually Do not leave metal parts like screws or pads inside the braking unit Do not make modification on the inside of braking unit without instruction from the supplier There are IC components inside the braking unit which are sensitive to static electricity Directly touch the components on the PCB board is forbidden 7 1 Daily Maintenance Some unexpected accidents may occur during operation Therefore you should maintain the braking unit conditions according to the Table 7 1 record the operation data and investigate problems immediately Table 7 1 Daily checking items Items Content Criteria Temperature and humidity 10 40 C derating at 40 50 C Operatin p 9 Dust and water dripping No water dripping environment Gas No strange smell Stable oscillation and proper A Oscillation and heating poe Braking unit temperature Noise No abnormal sound HDBU Series Dynamic Braking Unit User Manual 13 Chapter 7 Maintenance Shenzhen Hpmont Technology Co Ltd 7 2 Periodical Maintenance Customer should check the braking unit in short time or every 3 to 6 months according to the actual environment so as to avoid hidden problems and make sure the braking unit runs well for a long time General Inspection Check whether the screws
11. ct fails or it is damaged under condition of normal use by following the user s manual our company will be responsible for free maintenance 2 The starting time of the warranty period is manufacturing date see the barcode on the product body but we could negotiate settlement under special condition 3 Within warranty period maintenance will be charged for damages caused by the following reasons A The damage is caused by improper use or repair modification without prior permission B The damage is caused by abnormal voltage fire flood other disasters and second disasters C The damage is caused by dropped or transportation after purchase D The damage is caused by the operation not following this user s manual E The damage or failure is caused by the trouble out of the equipment e g external device 4 If there is any failure or damage to the product please correctly fill out the Product Warranty Card in detail 5 The maintenance fees are charged according to the newly adjusted Maintenance Price List by our company 6 In general the warranty card will not be reissued Please keep the card and present it to the maintenance personnel when asking for maintenance 7 If there is any problem during the service please contact the agent of our company or our company directly 8 This agreement should be interpreted by Shenzhen Hpmont Technology Co Ltd Shenzhen Hpmont Technology Co Ltd Address 3F Building 28 W
12. eck the fan or change the work environment of braking unit Please contact the manufacture Braking unit does not operate all the time and no fault is displayed The internal fuse has been fused The external locked signal is enabled The inverter s deceleration time is too long which does not meet the braking working conditions Change the fuse Please relieve the external locked signal Please decrease the inverter s deceleration time Braking resistor overheated protection The braking resistor power is too small The heat dissipation condition of braking resistor is too bad The braking unit internal over temperature protection circuit is faulty Please select larger power braking resistor Improve the braking resistor working environment Please contact the manufacture HDBU Series Dynamic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd Chapter 7 Maintenance Chapter 7 Maintenance Danger Only a trained and qualified professional person can maintain the braking unit Maintenance personnel should take off all metal jewellery before carrying out maintenance or internal measurements in braking unit Suitable clothes and tools must be used High voltage still exists at the internal when the braking unit is powered up or running Checking and maintaining can only be done after braking unit s AC power is cut off And wait for at least 10 minutes if maintain the
13. ing unit is not at power on state ALM Braking unit s fault alarm state On The braking unit is faulty indicator Off The braking unit is not faulty On The braking unit is at braking state BRK Braking unit s state indicator 3 9 Off The braking unit is at standby state HDBU Series Dynamic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd Chapter 5 Typical Application Chapter 5 Typical Application A Danger Only when the braking terminal cover has been fitted can you switch on AC power source Do not remove the cover after power is switched on A Warning Do not check or detect the signal during the braking unit operation Do not touch the energy consumption braking resistor due to the high temperature 5 1 Single Application According to Figure 5 1 connect the inverter braking unit and braking resistor when use one braking unit And according to the inverter s voltage class in Table 4 4 set the braking voltage threshold of braking unit Inverter Type selection of temperature switch Faut reset Figure 5 1 Single application connection The braking resistor selection cannot exceed the braking unit output capacity range Please refer to Table 2 1 for proper braking resistor Due to the braking resistor of large power consumption it is suggested that over temperature protective switch should be mounted to achieve overheated protection for the braking
14. ion 3 1 Installation Precautions Chapter 3 Mechanical Installation A Danger Do not install if the braking unit is imcomplete or impaired Make sure that the braking unit is far from the explosive and combustible things Only when the power supply is completely cut off 10 minutes later can you do the wiring job A Warning It is required not only carry the display panel and the cover but also the bottom enclosure of the braking unit Do not play metal into the braking unit when installing 3 2 Requirement for the Installation Site Ensure the installation site meeting the following requirements Do not install at the direct sunlight moisture water droplet location Do not install at the combustible explosive corrosive gas and liquid location Do not install at the oily dust fiber and metal powder location Be vertical installation on fire retardant material with a strong support Make sure adequate cooling space for the braking unit so as to keep the ambient temperature among 10 40 C Install at where the vibration is less than 5 9m s 0 6g Note 1 It needs derating use if the braking unit operation temperature exceeds 40 C The derating HDBU Series Dynamic Braking Unit User Manual value of braking unit shall be 2 for each degree centigrade Max allowed temperature is 50 2 Keep ambient temperature among 10 40 C It can improve the braking unit operation performance if inst
15. ion Chapter 5 Typical Application According to Figure 5 3 connect the three braking units for parallel application Set one braking unit as the master and the other two as the slaves and then the two slaves will auto track the master one to brake synchronously X Type selection of Weem switch Fault output HDBU Slave 2 Type selection of d switch x EEO Fault output HDBU Slave 1 KL Faultreset FRS VW Y temperature switch Type selection of EEO Fault output HDBU Series Dynamic Braking Unit User Manual Figure 5 3 Three braking unit for parallel application Chapter 6 Troubleshooting Shenzhen Hpmont Technology Co Ltd Chapter 6 Troubleshooting When fault alarm occurs please take proper action according to the Table 6 1 Table 6 1 Fault alarm description and counter measures Fault name Possible reasons of fault Counter measures Overvoltage at inverter braking The braking resistor value is too big The inverter preset deceleration time is too short Decrease the braking resistor value Properly increase the deceleration ime Braking unit fault The heatsink temperature is too high The power module of braking unit is faulty Please ch
16. kW HDBU 4T250 1 Single 380 460 VAC 220 315kW HDBU 4T250 2 Parallel 380 460 VAC 355 400kW HDBU 4T250 3 Parallel 600 690 VAC 75 110kW HDBU 6T150 1 Single 600 690 VAC 132 220kW HDBU 6T250 1 Single 600 690 VAC 250 400kW HDBU 6T250 2 Parallel 2 3 Nameplate Product model MODEL HDBU 4T150 Input voltage INPUT 250 800VDC Braking curren OUTPUT 0 150A Shenzhen Hpmont Technology Co Ltd HDBU Series Dynamic Braking Unit User Manual 3 Chapter 2 Product Information Shenzhen Hpmont Technology Co Ltd 2 4 Fuse Explanation The DC bus input side of braking unit is built in fuse whose location is shown as Figure 2 1 Fuse ollo o 0 o 05 o elo O o O oj joj JO oj O op D oL _ BR1 BR2 PEfs N N Figure 2 1 Location of fuse If the braking unit is damaged by accident this fuse can break off the electrical connection between braking unit and inverter s DC bus so as to avoid inverter damage When the fuse is damaged please use another fuse which is the same as the damaged one such as the same brand and model If have any question please contact us or our suppliers HDBU Series Dynamic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd Chapter 3 Mechanical Installat
17. namic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd Chapter 4 Electrical Installation Table 4 2 SK1 terminal function description Identification Terminal name Function description Normally open terminal for Normally open temperature switch for overheated TNO braking resistor s overheated protection input This function is enabled when short protection connected with COM Normally closed temperature switch for overheated Normally closed terminal for protection input This function is enabled when TNC braking resistor s overheated disconnected with COM protection Note it need connect the TNO to the COM at the same time FRS Faiitresst terminal When the braking unit is faulty connect the FRS to the COM to achieve fault reset function When the BRS terminal is suspension the braking unit s braking command is decided by the DC bus input BRS Terminal for selective braking voltage automatic detection value command source When the BRS and the COM are short connected the braking unit s braking command is decided by the BRI terminal BRI Input terminal for braking When the BRI and the COM are short connected the command braking unit starts to operate BRO Output terminal for braking When the braking unit is at the braking state this state terminal output is enabled COM Signal ground Signal reference ground 4 3 2 SK2 Terminal Description RA RB Ter Figure 4 5 SK2 terminal layout Table 4
18. nrccnonrrcononnncnnnnnns 5 3 Three Braking Units for Parallel Application Chapter 6 Troubleshooting ccesecceseeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeseeeneseeeeeseeeeseseeeaeseeeeeesneeseeneeeeeeees 12 Chapter 7 EA daa aaa daraa daaa aaa anaandaa SAET ARa AAAI A anA EAE REESE A EER Ra AaS 13 Te HEET EE 7 2 Periodical Maintenance 1 3 Replacing DAMIGEd PS iii 14 7 4 Unwanted Braking Unit Disposal oooococccnnocccinoccccnnoccccnoncccononcconanncnnnnnccnnnn nc nano co nannncnnnons 14 Shenzhen Hpmont Technology Co Ltd Chapter 1 Safety Information and Precautions Chapter 1 Safety Information and Precautions 1 1 Safety Definition AN Danger A Danger contains information which is critical for avoiding safety Danger hazard A N Warning A Warning contains information which is essential for avoiding a Warning risk of damage to product or other equipments Note A Note contains information which helps to ensure correct operation E of the product 1 2 Precautions Before delivering this product has been strictly checked and reliably packaged Due to handling loading and unloading in transit it may cause damage Therefore after open the package please check product integrality carefully Check items Check methods Check the overall appearance check if there Whether there is damage to parts or damaged gt y is damage in transit If there is loose screws or other fasten parts If necessary use the scre
19. of control terminals are loose If so tighten them with a screw driver Check whether the main circuit terminals are properly connected whether the mains cables are over heated Check whether the power cables and control cables are damaged especially check for any wear on the cable tube Check whether the insulating tapes around the cable lugs are stripped and for signs of overheating near terminations Note 1 Dielectric strength test of braking unit has already been conducted in the factory Do not do the test again Otherwise the braking unit might be damaged 2 If insulation test to braking unit is necessary it must be done to the ground after all input output terminals are short connected by conductors It is forbidden for each terminal to ground test It is recommended to use the 500V megger 3 For braking unit stored for a long time it must be powered up every 2 years When supplying AC power to braking unit use a voltage regulator to gradually raise the input voltage to rated input voltage at least 5 hours 7 3 Replacing Damaged Parts The easily damaged component is the cooling fan The lifetime depends largely on the application environment and preservation The user can decide the time when the components should be replaced according to their service time Generally due to the wear of bearing and aging of the fan vanes the life of fan is 60 000 hours Criteria After the braking unit is switched off check
20. tage Do not do dielectric strength test on the inverter Do wiring connection of the braking resistor or the braking unit according to the wiring figure Do not connect the braking resistor to DC terminals and of the braking unit Make sure that the terminals are fixed tightly Do not play screws washers and metal bars etc metal into the braking unit when installing Do not mount the braking unit at the water pipe where may have a water droplet splash Do not supply the damage or parts of insufficiency of the braking unit with power 4 1 Wiring Requirements 1 For the two power terminals wiring between the inverter and the braking unit it is suggested to use the red and the black of 600V voltage level cable to prevent the DC bus terminal wiring error 2 For the wiring between the braking unit and the braking resistor please use the 600V voltage level of high temperature cable 3 The two lines should be closed and used twisted pair when connect the inverter with the braking unit so as to reduce the current loop It suggests that the length of wiring should be less than 5m and not exceed 10m 4 The interval distance between the control terminal wiring and the power terminal wiring should be greater than 0 3m so as to reduce the interference to control terminal signal 4 HDBU Series Dynamic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd 4 2 Power Terminal Description HDBU 4T050
21. wdriver to check Whether the manual intact Check the manual If has lacked please contact manufacturer HDBU Series Dynamic Braking Unit User Manual le Chapter 2 Product Information Shenzhen Hpmont Technology Co Ltd Chapter 2 Product Information 2 1 Part Name Mounting hole Bottom enclosure Certification Nameplate 2 2 Model Explanation HDBU 4 T 150 Max continuous braking current Voltage class of adaptive inverter 4 380 460V 200 240V 6 600 690V Product series Dynamic braking unit Table 2 1 Braking unit specifications Max continuous Braking resistance Voltage class of DC input voltage Model voc braking current range adaptive inverter A Q VAC HDBU 4T050 50 215 HDBU 4T075 450 800 75 10 380 460 HDBU 4T100 100 27 HDBU 4T150 150 25 250 800 380 460 200 240 HDBU 4T250 250 3 HDBU 6T150 150 28 850 1200 500 690 HDBU 6T250 250 5 2 HDBU Series Dynamic Braking Unit User Manual Shenzhen Hpmont Technology Co Ltd Chapter 2 Product Information Table 2 2 Selection for the braking unit Inverter Braking unit Voltage class Power class Model Number Configuration 380 460 VAC 11 22kW HDBU 4T050 1 Single 380 460 VAC 30 37kW HDBU 4T075 1 Single 380 460 VAC 45 55kW HDBU 4T100 1 Single 380 460 VAC 75 110kW HDBU 4T150 1 Single 380 460 VAC 132 200
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