MBC2K - 2kW Motor Brake Controller
Contents
1. The three menu pages are the following a Brake intervention threshold VTH setup b Hysteresis around the brake intervention threshold voltage c Master Slave mode used for parallel connection up to four modules see chapter 3 In order to set the parameters for menu page a and b refer to Figure 3 to adjust the parameters Hysteresis lt Z O z IBRAKE lt lt Brake Time Figure 3 Typical braking waveforms Pag 8 12 Menu page a Brake intervention threshold Figure 3 VTH represents the brake intervention point VTH shall be alwaysgreater than the nominal DC Bus voltage avoid continuous intervention of the MBC2K The user can set the Brake intervention threshold VTH through menu page a in a range from 27Vdc to 106Vdc in 20 steps The VTH value is shown on the LED display and can by adjusted using the SET RESET button Once the required VTH value is chosen go to the next menu page by pressing MENUbutton During the VTH selection the DC Bus voltage is measured by the MBC2K the user selection is accepted only if VTH gt VBUS 3V otherwise the display blinks and the user must select a higher voltage Menu page b Hysteresis Page b allows to set the hysteresis value refer to Figure 2 The Hysteresis can be set to 2 values Lo 3V Hi 6V It is recommended to use the Hi setting when DC Bus voltages are higher than 50Vdc to increase the noise immunity of the MBC2K and avoiding spurious high fre2. LAVE 1 SLAVE 2 SLAVE 3 Figure 4 Typical connection of 4 MBC2K units using the Synchronization Bus Pag 12 12
3. MBC2K 2kW Motor Brake Controller USER MANUAL Technical Data Order Information Dimensions Mounting dismounting Block diagram General Info Cap 1 MBC2K Description Front view amp functions Cap 2 Setup Menu setup Cap 3 Protections error codes Cap 4 Parallel connection NO OONDOBRW WDM DY Pag 1 12 ORDERING model code INFORMATION Standard version MBC2K XMBC2K TECHNICAL DATA Nominal DC BUS 24 110Vdc Voltage range Maximum braking 27 106V threshold adjustable in 20 steps 2 setup push buttons SET RESET and MENU 2 x 7 segment LED displays 1 LED for general alarm indication 1 SPDT dry contact for general alarm remote warning Undervoltage on DC BUS lt 22Vdc Overvoltage on DC BUS gt 110Vdc Brake resistor overtemperature if the temperature sensor is present Protections Module Internal overtemperature gt 90 C 194 F Brake resistor interrupted or not connected Short circuit braking current gt 80A Overload braking time gt 1sec Parallekecanection Up to 4 units can be connected in parallel through synchronization bus for a total braking power of 8kW 4 x 2kW braking resistors are needed GENERAL TECHNICAL DATA power greater than 60Vdc is not classifiable as SELV Input DC Bus PE 3 poles pluggable 2 5mm 5 08mm pitch Output Brake resistor 2 poles pluggable 2 5mm7 5 08mm pitch Resistor temp sensor 2 poles pluggable 1 5mm 3 81mm pitch Alarm dry contact 3po
4. age VTL see fig 3 On top of that the MBC2K provides several protections to ensure reliable operation see Chapter 3 We recommend to provide MBC2K with a N C type Klixon temperature sensor for resistor protection MBC2K can be connected to any DC Bus within 24Vdc and 100Vdc The simplified application diagram is shown in Figure 1 while the unit front view with all its controls is shown in Figure 2 Up to 4 MBC2K units can be connected in parallel to increase the braking power up to 8kW max see Chapter 4 The MBC2kK is provided with a 2 5 digits 7 segments LED display used to display the DC Bus voltage with 1V accuracy to help the user during the setup phase and or to show error messages DC power supply DC Motor drive 24Vdc 100Vdc MBC2K R Brake lt 2kW Figure 1 Simplified application diagram Pag 6 12 1 SET RESET button used to reset the protections and to change setup values in setup mode see Chapter 2 2 MENU button used to enter into setup mode and to navigate trough menu pages see chapter 2 3 Synchronization bus connector used to parallel up to 4 units see chapter 4 ali SYNC 4 Resistor temperature sensor connector used to connect the brake resistor temperature H T SENSE sensor N C Klixon type if not used connect the 2 terminals with a jumper wire O ALARM 5 Alarm dry contact connector an SPDT contact ZEA i provide remote failure signal see chapter 3 6 Brak
5. e device if surrounding air temperature is gt 60 C 140 F along with continuous full load or overload operation The MBC2K needs a manual reset of the protection even after cooling down To get normal operation reduce the air temperature surrounding the MBC2K 8 Parallel connectionUp to 4 MBC2K can be connected in parallel to increase the braking power up to 8kW peak See Chapter4 for details 9 Warranty MBC2K Motor brake controllers are guaranteed to be free from factory defects for 3 years from delivery date Failures caused by misuse external and or abnormal events e g mains overvoltages surges etc or non respect of above points are not covered by warranty Opening the housing of the MBC2K voids the warranty Warning Non respect of above indications may result dangerous and reduces safety and performances 10 Technical data unless specified all technical data are typical and measured at 25 C 77 F For continuous product improvement CABUR has the right to change product specifications ratings and data without previous advice Pag 5 12 1 MBC2K Description The MBC2kK is a device controlled by a microprocessor that can automatically insert a power resistor into the DC BUS for braking a motor fed by the same DC Bus trough a motor drive The function of the MBC2K is to dissipate the energy delivered by the motor in an external resistor thus damping the resulting overvoltage on the DC Bus The resistor is disconnected when the DC volt
6. e resistor connector used to connect the brake resistor wires 2 5mm XMBCZK 7 DC Bus connector used to connect the MBC2K BRAKE CONTROLLER unit to the power supply Bus 24 100Vdc 8 Protective earth PE connection to connect the module to the protective earth ii R BRAKE 9 LED display 100 s indicator used to display T DC IN numbers gt 99 on 2 digits when this indicator is _ 24 100Ydc lit and the display shows 03 this means 103V PE 10 Brake indicator LED used to display braking activity when lit it means that there is a current flow trough the brake resistor 2 5 digits 7 segment display in operating mode it shows the voltage measured on the DC Bus accuracy 1V it s used also to show Figure 2 MBC2K Front View menu items and error codes see Chapters 2 3 12 Alarm LED used to indicate a fault condition of the unit see Chapters 2 and 3 Pag 7 12 2 MBC2K Setup The MBC2K unit needs to be set up before operating The setup mode is accessed by pressing the MENU button for more than 2 seconds Once the setup mode is accessed the Alarm LED lights on and the Alarm relay is open This means that during the setup phase the MBC2K is not ready to operate it will be ready as soon as the setup phase is finished The setup phase consists of 3 menu pages The user can navigate trough the menu pages by pressing the MENUbutton and the values on each menu page can be changed by pressing SET RESET button
7. g 2 5mm 1 5mm stranded pluggable screw type terminal blocks wire isolation stripping length 7mm tightening torque 0 5 0 6Nm use only 60 75 Class1 copper wires Warning disconnect DC IN wait 60s before operating on device 3 Mounting snap on clamp on IEC60715 H35 7 5 rail for better device stability fix the rail right on the point where the device is to be mounted to remove the device push towards bottom and then rotate it towards the top 4 Configuration the MBC2K needs to be configured before operating depending on the DC Bus voltage and the motor brake resistor characteristics See Chapter2 for a complete description 5 Circuit protections Every abnormal event requires the operator intervention to reset the protection an error message is displayed on the LED display See Chapter3 for a complete description 6 Status signals Alarm LED OFF normal operation Alarm LED blinking the unit is in protection mode and the corresponding error message is displayed AlarmLED ON the unit is in setup mode MBC2K has an internal relay with SPDT contact 1A 24Vdc remote failure alarm and 1 5mm connection terminal blocks The relay is turned on only when the unit is ready to operate i e when it is neither in protection mode nor in setup mode 7 Cooling mount the MBC2K in vertical position keep 2 inches 50 mm free spacing on upper and lower sides 0 8 inch 20 mm free spacing to adjacent devices The thermal protection turns off th
8. he MBC2K unit should be now operational Note The resistor overtemp protection sensor is designed to be normally closed This means that when the resistor temperature is within safe limits the contact connected on T SENSE terminals should be closed Pag 10 12 Internal Overtemperature Overload The MBC2K internal temperature is grater than 90 C There is current flow through the brake resistor for more than 1s continuously Pag 11 12 The MBC2K unit is operating in a too hot environment of with not enough cooling air flow Change the position of the MBC2kK unit in order to reduce the operating temperature Press SET RESET button The MBC2K unit should be now operational The brake intervention threshold is set too low see Chapter 3 increase this value Press SET RESET button The MBC2K unit should be now operational 4 Paralleling up to 4 MBC2K units The MBC2K brake controller provides a feature allowing connecting up to 4 identical MBC2K units to increase the peak braking power up to 8kWn any case every MBC2K unit can handle only 2kW of peak braking power therefore every MBC2K unit need its own 2kW brake resistor To realize this feature the MBC2K is equipped with a Synchronization Bus used to synchronize the operation of all the units connected to the synchronization bus The principle of operation relies on one MBC2K unit configured as the master and others MBC2K units up to 3 configu
9. les pluggable 1 5mm 3 81mm pitch Synchronization Bus 2poles pluggable 1 5mm 3 81mm pitch Aluminium H x W x D 115 x 40 x 130 mm 4 52 x 1 57 x 5 11 User interface Connection terminal blocks Pag 2 12 Dimensions millimeters inches Vertical position 100 4 0 op 0 8 cd A e a Mounting on rail Operations Oo instructions _ _ _ _ _ Push the power supply downwards 1 Place the upper part of the clamp onto the rail Rotate the power supply as shown in the Press the power supply downwards and drawing 1 push it towards the rail until the lower part is hooked on Release the power supply and check that the hooking has been performed properl Not For increased stability it is advised to fix the rail Note on to the panel in a position corresponding to the center of the power supply Pag 3 12 Block Diagram Sync T sense R Brake Synchronization Display and bus driver and receiver DC DC power supply Micro Mosfet processor _ 4 driver and short circuit protection Pag 4 12 1 DC Bus voltage DC IN 24100Vdc range 22 110Vdc connect PE GND wire before connecting wires and keep it as short as possible PE GND wire must have cross section equal on higher than wires 2 Wirin
10. quency oscillations of the MBC2K power stage Once the desired Hysteresis value is chosen go to the next menu page by pressing MENUbutton Menu page c Operating mode Page c sets the operating mode of the MBC2K When the MBC2kK is used as a single unit not paralleled with other devices the master mode shall be selected If more than one MBC2K are used in parallel on the same DC Bus to reach 8kW of peak breaking power refer to Chapter 4 for more details about the parallel connection The two options are MA Master Modeand SL Slave Mode Once the desired operating mode is chosen pressing MENUbutton saves the selected values in an internal EEPROM memory switch off the Alarm LED and close the Alarm relay This means that the MBC2K is now ready to operate with the selected values The internal EEPROM memory allows saving the selected values so that even if the DC Bus is removed the last programmed configuration is used Pag 9 12 3 MBC2K protection and error codes The MBC2K unit integrates several active protections to guarantee reliable operations in normal conditions As soon as a faulty event is detected the MBC2K power stage is switched off so that no uncontrolled current flow trough the brake resistor is possible A fault condition is indicated by the continuous blinking of the Alarm LED Remote sensing of the status of the MBC2K unit is possible thanks to the Alarm relay dry contact To help the user to understand which faulty even
11. red as slave see Chapter 2 menu page c The master measures the DC Bus voltage and decides when to insert its brake resistor in the circuit on top of that it sends a command on the synchronization bus The slaves connected on the synchronization bus are waiting for the command sent by the master when they receive the command they insert their brake resistors in the circuit too Please note that even when the MBC2kK is configured in slave mode all its circuits protections are functional In operation mode with paralleled MBC2K units the units configured as the master continuously shows the DC Bus voltage on its LED display while the slaves show SL on their LED displays informing the user they are in slave mode Please note that when only oneMBC2K unit is used it is mandatory to configure it as mastestherwise it will never be able to perform the braking action Note keep the synchronization bus wires shorter than 1m and twist together the two wires to improve noise immunity In Figure 4 the typical connection for MBC2K parallel connection is shown Rbrake 1 Rbrake 2 Rbrake 3 Rbrake 4 Max 2kW Max 2kW Max 2kW Max 2kW SET SET o im 5 o y 7 Oo MENU ALARM aLarm oe re se swe H a T SENSE a T SENSE a T SENSE gr T SENSE Z ALAR M a a a EH A AVDA MBC2K XMBC2K XMBC2K Toir IBC n BRAKE CONTROLLER BRAKE CONTROLLER ae CONTROLLER Uae ee DC Mot be rows E B aie Fo Supply pe G 24 100Vde drive MASTER S
12. t occurred an error code is displayed on the 7 segments LED display Every protection is latched so that to put back the MBC2K unit in operation mode to push the SET RESET button is needed to reset the protection event In the following table all the protections and corresponding error codes are described Protection Error code on Cause of failure System restore event LED display Undervoltage The DC Bus voltage Increase Bus voltage to at least is below 22Vdc 24Vdc gt Press SET RESET button The MBC2K unit should be now operational Overvoltage The DC Bus voltage Decrease Bus voltage to max is above 110Vdc 100Vdc Press SET RESET button The MBC2K unit should be now operational Overcurrent The current trough Check for short circuits on the the brake resistor is brake resistor connections and greater than 80A fix the problem After that event the Press SET RESET button power stage is The MBC2K unit should be now switched off in operational maximum 2us to avoid damaging the MBC2K unit Brake resistor The brake resistor is Check for open circuits on the connection not properly brake resistor connections and connected to the fix the problem MBC2kK unit Press SET RESET button The MBC2K unit should be now operational Resistor The brake resistor Check the brake resistor Overtemperature temperature is too temperature high Wait until the resistor temperature decreases Press SET RESET button T
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