4-2 Braking Resistor Unit
Contents
1. 0 75 1 1 5 2 2 2 3 3 7 5 5 5 7 5 7 5 10 11 15 15 20 18 5 25 22 30 30 40 37 50 45 60 55 75 75 100 110 150 160 200 185 250 220 300 300 400 10 3 Specifications Chapter 10 10 2 Braking Unit Specifications Voltage 200 V class 400 V class 3G3IV PCDBR Model Max applicable motor capacity kW 2015B 2022B 22 4030B 4045B 30 45 Max discharge current A peak value see note 60 40 60 Rated discharge current A continuous 20 15 18 Braking start voltage 330 345 365 380 V 3 V 630 660 690 730 760 V 6 V Max hysteresis Approx 8 V Approx 16 V Power Supply VDC 243 1 35 x 200 x 0 9 to 400 V peak 400 1 35 x 380 x 0 9 to 800 V peak Protective functions Cooling fins overheating Thermostat Power charging indicator Charging indicator stays ON until bus voltage drops below 50 V Environ mental conditions Location Indoor without no corrosive gases or dust Ambient temperature 10 to 40 C no icing Storage temperature 20 to 60 C Humidity 90 RH no condensation Vibration 9 8 m s 1G at 10 to 20 Hz 2 m s 0 2G at 20 to 50 Hz Degree of pr2. 5 1 Wiring Lead in Method an sn bah bed ee b dA Ha 5 2 Separation from Signal Lines 2 22 esr ee eed Pe eee He 866 x4 3 0 IS sda RO AC Ha RPA ee ee hd a Bin h an 5 5 Wiring between Units 24 4 a a 0v 5 2 5 2 5 2 5 2 5 3 Chapter 6 Settings 6 1 6 1 Power Supply Selection Connector 6 2 Master Slave Selection Connector 6 2 6 3 Chapter 7 Connecting Braking Units in Parallel 7 1 Chapter 8 Operafion 8 1 Chapter 9 Troubleshooting Chapter 10 Specifications 10 1 Braking Unit Braking Resistor Unit Application List 10 2 Braking Unit Speclflcatlons 10 3 Braking Resistor Unit Speclflcatlons Chapter 1 Comparison to Previous Models Comparison to Previous Models Chapter 1 The following table lists the differences between Braking Unit models Previous models 3G3IV PCDBR2015 3G3IV PCDBR2022 3G3IV PCDBR4030 3G3IV PCDBR4045 New models 3G3IV PCDBR2015B 3G3IV PCDBR2022B 3G3IV PCDBR4030B 3G3IV PCDBR4045B Dimensions W x H x D 140 x 280 x 160 mm 140 x 150 x 138 5 mm Weight 15 kg 1 8 kg Terminal labels N
3. gt Braking Resistor Unit Braking Unit 1 P o Thermal relay To trip contacts 2 d B M O Q 3 j Thermal relay trip contacts Note Connect a 400 200 transformer for 400 V class Inverters r Chapter 6 Settings 6 1 Power Supply Selection Connector 6 2 Master Slave Selection Connector Settings Chapter 6 There is no need to adjust the Braking Unit or Braking Resistor Unit Do not perform any adjustments to the Units except to set the power supply selec tion connector on the Braking Unit 6 1 Power Supply Selection Connector The power supply selection connector may need to be changed depending on the power supply voltage of the main circuits The relationship between the power supply voltage and the settings of the selection connector is shown in the following tables Set the connector in the correct position for the power supply voltage being used The factory setting is as follows e200 V class 220 V e400 V class 440 V Refer to Chapter 3 Braking Unit Covers for information on removing the terminal cover and inner cover 200 V class power Braking start 400 V class power Braking start supply voltage voltage PN bus supply voltage voltage PN bus bar voltage bar voltage 380 V typical 760 V typical 365 V typical 730 V typical 345 V typical 690 V typical 330 V typical 660 V typical 63
4. P o So Position of power supply voltage selection tap Refer to Chapter 4 Nomenclature Terminal layout Refer to Chapter 4 Nomenclature Note There are no changes to the Braking Resistor Unit in comparison to previous models 1 2 Chapter 2 Installation 2 1 Installation Site Precautions 2 2 Braking Unit Mounting Dimensions 2 3 Braking Resistor Unit Mounting Dimensions Installation Chapter 2 2 1 Installation Site Precautions Do not install the Braking Unit or Baking Resistor Unit in locations subject to the follow ing conditions eRain water drops or oil drops e Direct sunlight eHarmful gases or liquids e Excessive dust salt or iron particles eExcessive vibration e Temperatures or humidities outside of the specified ranges eExcessive electromagnetic noise such as occurs near welding machines e Radioactive materials eFlammable materials To take full advantage of the functions of the Braking Unit and Braking Resistor Unit install the Units in a location satisfying the following conditions eEnsure that there is sufficient soace between the Units and surrounding objects as shown in the installation diagram e The Braking Resistor Unit generates heat Provide sufficient space between the Units and devices that are sensitive to heat e Install the Units in the orientation shown in the installation diagrams 2 2 Braking Unit Mounting Dimensio
5. 5 4 5 5 Wiring Lead in Method Separation from Signal Lines Wiring Distance Grounding Wiring between Units Wiring Chapter 5 5 1 Wiring Lead in Method Lead in the wires through the knockout holes at the Unit bottom The knockout holes are provided with rubber bushes cut the rubber bush crosswise in the middle with a blade and lead the wires through 5 2 Separation from Signal Lines A strong noise component is superimposed on the Braking Resistor Unit and Braking Unit wiring Separate the Units from signal lines that are sensitive to noise 5 3 Wiring Distance The wiring distance between the Braking Resistor Unit and Braking Unit or Braking Unit and Inverter must as shown in the following diagram Make sure to bundle the wires between the Units Braking Resistor Unit Braking Unit Inverter a gt 10 m max 5m max 5 4 Grounding e Mount the Braking Resistor Unit to a grounded metallic plate When the Unit cannot be mounted to a grounded metallic plate pull out the lead wire from the mounting screw section to ground e he Braking Unit ground terminal must be provide with a class 3 ground ground resis tance 100 Q max for 200 V class Inverters and a special class 3 ground ground resistance 10 Q max for 400 V class Inverters e Use the sizes specified in the Internal Connection Specifications see note for ground cables Note The Internal Connection Specifications is for use in Japan
6. overload relay or thermal protector sometimes trips Insufficient Braking Resistor Unit capacity Check the braking conditions again Braking Unit trips due to heat sink overheat 9 2 Excessive start stop switching frequency Excessive load inertia Check the operating conditions again Improper combination of Braking Unit and Braking Resistor Unit Check the combination Ambient temperature above 40 C Reduce the ambient temperature Chapter 10 e Specifications 10 1 Braking Unit Braking Resistor Unit Application List 10 2 Braking Unit Specifications 10 3 Braking Resistor Unit Specifications Specifications Chapter 10 10 1 Braking Unit Braking Resistor Unit Application List e 200 V Class Inverter Braking Unit Braking Resistor Unit Braking Voltage Max appli Model Number Model Resistor Number torque cable 3G3IV used 3G3IV specifica used WB ED Motor Unit PCDBR PLKEB tions HP kW B 0 4 0 5 0 75 1 1 5 2 2 2 3 3 7 5 10 2 Specifications Chapter 10 Inverter Braking Unit Braking Resistor Unit Braking Voltage Max appli Model Number Model Resistor Number torque cable 3G3IV used 3G3IV specifica used 10 ED Motor Unit PCDBR PLKEB tions HP kW B 0 4 0 5
7. 0 V typical Note 1 The allowable voltage fluctuation is 10 Note 2 The diagram shows the Unit with the terminal cover and inner covers removed 200 V class o o o 200V o o 208 V 220 V o oj 230 V 400 V class o o 380V EEIEEEEJ JELEEI N a 440 V SNOG BE fs o o 460 V 6 2 Settings Chapter 6 6 2 Master Slave Selection Connector The Unit is factory set as a master The Unit can normally be used without changing the setting of this connector The slave setting is used when connecting Braking Units in parallel so that the braking start voltages are the same Refer to Chapter 7 Connecting Braking Units in Parallel for details 6 3 7 Connecting Braking Units in Parallel Connecting Braking Units in Parallel Chapter 7 When connecting two or more Braking Units in parallel connect the Units and set the master slave selection connector as follows eBraking Units have a master slave selection connector Set the selection connecter to the master setting on only one of the Braking Units Braking Unit 1 below Set the selection connector to the slave setting on the other Braking Units Braking Units 2 and 3 below Connect the thermal relays on the Braking Resistor Units in parallel and the thermal relays on the Braki
8. Do not change wiring attach a connector or remove a connector while power is being supplied Doing so may result in electric shock Internal boards contain CMOS ICs which must be handled with care Do not touch these boards or ICs directly with your bare hands Static electricity from your hands may destroy the ICs A Caution Other WARNING Periodically check the operation of the circuits that stop Inverter operation with the thermal relays on the Braking Resistor Units and Braking Units Functional failure e g malfunction of the thermal relays broken wiring contact faults etc may result in fire Never attempt to modify a Unit in any way Doing so may result in electric shock or injury Table of Contents Chapter 1 Comparison to Previous Models Chapter 2 Installation 2 1 2 1 Installation Site Precautions a a k 2 2 Braking Unit Mounting Dimensions lt 2 3 Braking Resistor Unit Mounting Dimensions 5 2 2 2 2 2 3 Chapter 3 Braking Unit Covers 3 1 3 1 Removing and Replacing the Terminal Cover 3 2 Removing and Replacing the Inner Cover 3 2 3 2 Chapter 4 Nomenclature 4 1 4 1 Braking Unit svs os ka bates a Va sseai sMiAo 4 2 Braking Resistor Unit s s a 3 605 weve RA tes eee ares 4 2 4 3 Chapter 5 Wiring
9. Lead wire outlet 3 places with rubber bushes Tightening torque in N m Nomenclature Chapter 4 4 2 Braking Resistor Unit e 3G3IV PLKEB20P7 to 27P5 and 3G3IV PLKEB40P7 to 4015 Braking Resistor Units Note The diagram shows the Unit with the front cover removed Lead wire outlet rubber bush e Circuits and Wiring Specifications Circuits Main circuits Terminal labels Wire size in mm AWG 3 5 to 5 5 12 to 10 Control circuits 0 75 to 2 18 to 14 Thermal overload relay automatically reset External terminals B P 1 2 Wire type 600 V vinyl sheathed wire Terminal screws Tightening torque in N m 4 3 Nomenclature Chapter 4 e 3G3IV PLKEB2011 to 2022 and 3G3IV PLKEB4018 to 4045 Braking Resistor Units Note The diagram shows the Unit with the front cover removed Resistor TA 1 BN J 9 l 18 EZ Lead wire outlet rubber bush 9 Circuits and Wiring Specifications Circuits Main circuits Terminal labels Wire size in mm AWG 3 5 to 5 5 12 to 10 Control circuits 4 4 0 75 to 2 18 to 14 External terminals B P 1 2 Wire type 600 V vinyl sheathed wire Thermal overload protector Terminal screws Tightening torque in N m II LL Chapter 5 Wiring 5 1 5 2 5 3
10. Use the size of ground cable specified in local regulations 5 2 Wiring Chapter 5 5 5 Wiring between Units The following diagrams show examples of wiring between the Braking Unit Braking Resistor Unit and Inverter Thoroughly read the information on the previous page and confirm that all wiring is designed and executed correctly Note Even if a non OMRON braking resistor unit is used it must be provided with ther mal overload relay protection e Connecting the Braking Resistor Unit Power XA Inverter MCCB 200 V class 200 to 230 VAC supply ME VN Single phase 50 60 Hz M SR 400 V class 380 to 460VAC three C 2 M TR pe phase 50 60 Hz co 5 6 0OT 3 See note XB OFF ON ele E 5 A SA AAS x8 1 1 SA a iaa edi hiene T B1 2 Braking Resistor Unit Thermal relay trip contacts 2 O B Note Connect a 400 200 transformer for 400 V class Inverters 5 3 Wiring Chapter 5 e Connecting the Braking Unit and Braking Resistor Unit 200 V class 200 to 230 VAC single phase 50 60 Hz Power Inverter su MCCB 400 V class 380 to 460VAC three SP ss MM s i phase 50 60 Hz a sto M oto ibs 2 so 5 Obras See note ot ee XB OFF ON I Voltage i oe oje xs selection ees oe SA 1 oO GB l
11. ance Although care has been given in documenting the product please contact your OMRON representative if you have any suggestions on improving this manual The product contains potentially dangerous parts under the covers Do not use the product with the covers open Doing so may result in injury or death and may damage the product Never attempt to repair or disassemble the product We recommend that you add the following precautions to any instruction manuals you prepare for the system into which the product is being installed e Precautions on the dangers of high voltage equipment e Precautions on touching the terminals of the product Specifications and functions may be changed without notice in order to improve product performance Items to Check Before Unpacking Check the following items before removing the product from the package e Has the correct product been delivered i e the correct model number and specifications e Has the product been damaged in shipping e Are any screws or bolts loose Notice OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual The following conventions are used to indicate and classify precautions in this manual Always heed the information provided with them Failure to heed precautions can result in injury to people or damage to the product WARNING Indicates information that if not
12. duct Confirmation A Caution Do not install or operate a Braking Unit or Braking Resistor Unit that is damaged or is missing parts Doing so may result in injury Transportation and Installation J RN Caution A Caution A Caution N Caution Wiring A WARNING WARNING WARNING WARNING N Caution N Caution Do not hold the Unit by the front cover when carrying it Always hold the bottom of the case If the Unit is held by the cover the main body of the Unit may fall possibly resulting in injury Do not install a Unit near flammable objects The Unit generates heat and may cause fire if installed near flammable objects Install cooling fans or other means of cooling when installing more than one Unit in the same enclosure to ensure that the temperature of the air entering a Braking Resistor Unit or Braking Unit is 40 C maximum Fire or other accidents may be caused by overheating Do not conduct withstand voltage test on a Braking Resistor Unit or Braking Unit Doing so may damage semiconductor elements inside the Units Always confirm that the input power supply is OFF before wiring a Braking Resistor Unit or Braking Unit Wiring a Unit while the power is being supplied may result in electric shock or fire The Braking Resistor Unit and Braking Unit have high voltage terminals which can be extremely dangerous if touched Do not touch the terminals Touching these terminals may result in electric shoc
13. ed or the Brak ing Resistor Unit is used Set n070 Stall prevention during deceleration to 0 Disabled Deceleration as set 3G3EV series Inverters Set n33 Stall prevention during deceleration to 1 Disabled Deceleration as set Note 1 L8 01 or n079 is enabled when using a braking resistor without thermal relay trip contacts Note 2 Stall prevention L3 04 n070 or n33 is enabled when a Braking Resistor Unit is not used and the deceleration time can not be reduced 8 2 r LT Chapter 9 Troubleshooting Troubleshooting Fault status Braking Resistor Unit overload relay or thermal overload protector trips when not decelerating e Without Braking Unit The main circuit discharge transistor in the Inverter is short circuited Chapter 9 Corrective action Replace the Inverter e With Braking Unit The main circuit discharge transistor in the Braking Unit is short circuited Replace the Unit Improper Braking Unit power supply selection connector setting The power supply voltage is greater than the voltage set on the power supply voltage selection connector Set the power supply selection connector again Inverter trips at overvoltage OV Insufficient Braking Resistor Unit capacity Check the braking conditions again Improper wiring Check and repair the wiring Braking Unit fault Replace the Unit Braking Resistor Unit
14. es OMRON USER S MANUAL 3G3IV PLKEB2000 4000 Braking Resistor Units 3G3IV PCDBR2 B 4 B Braking Units Thank you for choosing an OMRON Braking Resistor Unit and Braking Unit Proper use and handling of the product will ensure proper product performance will length product life and may prevent possible accidents Please read this manual thoroughly and handle and operate the product with care Please keep this manual in a safe place The 3G3IV PLKEB2 4 Braking Resistor Units and the 3G3IV PCDBR2 B 4 B Braking Units are designed to increase the braking capabilities of a SYSDRIVE system when using a general purpose SYSDRIVE Inverter to drive a 3 phase motor The Braking Resistor Unit works by consuming regenerative energy from the motor when decelerating NOTICE This manual describes the functions of the product and relations with other products You should assume that anything not described in this manual is not possible If you intend on using the product in devices or systems relat ing to atomic power control transportation combustion devices medical equipment amusement rides safety devices or in other applications directly related to human life allow sufficient leeway in rating and perfor mance install fail safe systems and other safety measures confirm specifi cations and consult with your OMRON representative in adv
15. he terminal cover grasp the cover at 1 on both sides and then lift in the direction of 2 To replace the cover reverse the procedure 3 2 Removing and Replacing the Inner Cover To remove the inner cover remove the terminal cover first then press down on the lever in the direction of 1 and lift the cover in the direction of 2 To replace the cover reverse the procedure Inner cover 3 2 l 4 Chapter 4 Nomenclature 4 1 Braking Unit 4 2 Braking Resistor Unit Nomenclature Chapter 4 4 1 Braking Unit e 3G3IV PCDBR2015B Braking Unit Example Note The diagram shows the Unit with the terminal cover and inner cover removed A BRAKING UNIT AA Su Wa JEF 5EISEEEEETSE CHRO Oda 2561 LSI l LOG 20 fe Charge indicator External terminals O Bo So e Circuits and Wiring Specifications Circuits Main circuits Terminal labels O Go So Wire size in mm AWG 3 5 to 5 5 12 to 10 i Power supply selection connector Master Slave selection connector External terminals 1 to 6 Wire type 600 V vinyl sheathed wire Control circuits 4 2 1 2 3 4 5 6 0 75 to 2 18 to 14 Terminal screws Calibration resistor Adjusted prior to shipment Operation indicator Lights when discharging
16. heeded could possibly result in loss of life or serious injury N Caution Indicates information that if not heeded could result in relatively serious or minor injury damage to the product or faulty operation OMRON Product References OMRON products are capitalized in this manual The word Unit is also capitalized when it refers to aa OMRON product regardless of whether or not it appears in the proper name of the product Visual Aids The following headings appear in the left column of the manual to help you locate different types of information Note Indicates information of particular interest for efficient and convenient operation of the product OMRON 1998 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical electronic photocopying recording or otherwise without the prior written permission of OMRON No patent liability is assumed with respect to the use of the information contained herein Moreover because OMRON is constantly striving to improve its high quality products the information contained in this manual is subject to change without notice Every precaution has been taken in the preparation of this manual Never theless OMRON assumes no responsibility for errors or omissions Neither is any liability assumed for dam ages resulting from the use of the information contained in this publication Pro
17. k Allow wiring work to be performed only by a qualified electrician Improper wiring may result in electric shock or fire Always ground the ground terminal properly to a ground resistance of 100 Q maximum for 200 V class systems and to a ground resistance of 10 maximum for 400 V class systems The thermal relays on the Braking Resistor Units and Braking Units must be wired to circuits that will stop Inverter operation Always check the wiring and check opera tion after completing wiring work The user is responsible for wiring Fire may result if these relays are not connected properly Do not allow physical stress to be applied to the wiring Physical stress on the wiring can cause broken wires or contact faults possibly resulting in fire A Caution A Caution Operation WARNING N Caution N Caution Confirm that the power supply voltage is the same as the rated voltage of the Braking Resistor Units and Braking Units Check the setting of the power supply selection connector on the Braking Units Incorrect power supply voltages may result in injury or fire Tighten all terminals to the specified tightening torque Improperly tightened termi nals may result in fire Always attach the front cover before turning ON the power supply and do not remove the front cover while power is being supplied Operating without the front cover in place may result in electric shock Do not touch the cooling fins and discharge
18. ng Units in parallel Wire correctly according to instructions in 5 5 Wiring between Units e Use twisted pair wires of 1 m or less to connect terminals 5 and 6 to terminals 1 and 2 of the Braking Units eUp to 10 Braking Units can be wired in parallel Thermal relay trip contacts Thermal relay trip contacts Thermal relay trip contacts 7 Braking Resistor Unit Inverter MASTER SLAVE Thermal relay Thermal relay Thermal relay trip contacts trip contacts trip contacts 7 2 Operation 2 M u er 8 Operation Chapter 8 Confirm that the desired braking characteristics are being obtained The operation indi cator on the Braking Unit will light when the Unit is operating Use this indicator to con firm operation e High Voltages NWARNING High voltages are present both inside the Braking Unit and on the terminal block Always operate the Unit with the covers attached Operation without the covers attached presents an immediate danger of electric shock e Parameters The following Inverter parameters must be set when using a Braking Resistor Unit 3G3FV series Inverters Set L8 01 DB resistor protection to 0 Disabled Braking resistor is not used or the Braking Resistor Unit is used Set L3 04 Stall prevention during deceleration to 0 Disabled Deceleration as set 3G3HV series Inverters Set n079 DB resistor protection to 0 Disabled Braking resistor is not us
19. ns Unit mm U Mounting direction 4 M4 mount ing holes 100 min 100 min Three lead wire outlets 22 dia rubber bushing Installation Diagram 2 2 Installation Chapter 2 The terminal labels have changed between previous Braking Unit models and the new Baking Unit models as shown in the following table Previous models New models 3G3IV PCDBRL_ 3G3IV PCDBR Terminal labels 2 3 Braking Resistor Unit Mounting Dimensions e Braking Resistor Units for 0 4 to 7 5 kW Inverters Unit mm Mounting holes for E a 3G3IV PLKEB20P7 40P7 b 3G3IV PLKEB21P5 to 27P5 and 41P5 to 47P5 150 min 150 min Braking Resistor Dimensions in mm Unit Model 6 D 3G3IV PLKEB 2 3 Installation e Braking Resistor Units for 11 to 45 kW Inverters Mounting direction 1 Mounting holes for E o A Braking Resistor Dimensions in mm Chapter 2 Unit mm Unit model 0 3G3IV PLKEB D 2 4 l 1 Chapter 3 e Braking Unit Covers 3 1 Removing and Replacing the Terminal Cover 3 2 Removing and Replacing the Inner Cover Braking Unit Covers Chapter 3 3 1 Removing and Replacing the Terminal Cover To remove t
20. otective Wall mounted enclosed structure NEMA1 Heat loss W Note Loading time rate for the maximum discharge current must be 10 ED or less for a maximum of 10 sec 10 4 Specifications Chapter 10 10 3 Braking Resistor Unit Specifications Specifications Allowable Allowable Allowable average average cur ambient power con rent effec temperature sumption tive value W A 700 W 200 Q 10 to 50 C 260 W 100 2 260 W 70 Q 390 W 40 Q 520 W 30 Q 780 W 20 Q 2 400 W 13 6 Q 3 000 W 10 2 4 800 W8Q 4 800 6 8 Q 70 W 750 Q 260 W 400 Q 260 W 250 Q 390 W 150 520 W 100 780 W 75 Q 1 040 W 50 Q 1 560 W 40 Q 4 800 W 32 Q 4 800 W 27 2 Q 6 000 W 20 Q 9 600 W 16Q 9 600 W 13 6 Q
21. resistors which become very hot Touching the cooling fins or discharge resistors may result in burns Although the Braking Resistor Unit and Braking Unit are set to the normal settings at the factory you must check the settings according to the contents of the manual and change any settings as required by the system before starting operation Operating with incorrect settings may result in burns or fire Inspection and Maintenance WARNING WARNING WARNING WARNING WARNING N Caution The Braking Resistor Unit and Braking Unit have high voltage terminals which can be extremely dangerous if touched Do not touch the terminals Touching these terminals may result in electric shock Always keep the protective covers attached while power is being supplied and use a MCCB to interrupt the power supply before removing a protective cover Having the protective cover removed while power is supplied may result in electric shock After turning OFF the main power supply always confirm that the charge indicator turns OFF before performing any inspection or maintenance work The capacitors will retain a charge and can cause electric shock if not completely discharged Allow maintenance inspections and part replacements to be performed only by specified personnel Remove all metal objects watches wrist bands etc before starting work and use insulated tools Improper or unqualified work may result in electric shock
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