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NOTE: BRD-EZ2-110K is replaced by BRD-EZ3-110K
HITACHI DYNAMIC BRAKING UNIT (BRD SERIES)
200V Class (BRD-E2-30K/55K)
400V Class (BRD-EZ2-30K/55K/110K)
OPERATION MANUAL
1. UNPACKING INSPECTION.....................................................................
2. IMPORTANT NOTICES...........................................................................
3. INSTALLATION.......................................................................................
4. WIRING AND FUNCTION SETTING......................................................
4.1
Wiring Notices.........................................................................................................
4.2
Functional Setting ....................................................................................................
4.3
Example of External Connection ..............................................................................
4.4
(Parallel Connection Operation) ...............................................................................
5. TROUBLESHOOTING .............................................................................
5.1
Alarm contact is activated and the inverter stops ......................................................
5.2
When the inverter trips the 0V during inverter deceleration......................................
6. PRE-START CHECKS..............................................................................
7. SPECIFICATIONS....................................................................................
7.1
Standard Specifications ............................................................................................
8. INTERNAL CIRCUITS.............................................................................
DISCHARGING RESISTORS...................................................................
9.1
Braking Energy without a Dynamic Braking Unit .....................................................
9.2
Using the Dynamic Braking Unit..............................................................................
9.3
General Formulas Use for Estimation .......................................................................
10.MAINTENANCE AND CHECKS .............................................................
10.1 Notices on Maintenance and Checks.........................................................................
10.2 Check Items .............................................................................................................
11.PARTS ORDERING AND INQUIRY .......................................................
APPENDIX ....................................................................................................
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CONTENTS
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NB4882CX
Table of Contents
Related Manuals for Hitachi BRD-E2-30K
Summary of Contents for Hitachi BRD-E2-30K
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Page 1: Table Of Contents
NOTE: BRD-EZ2-110K is replaced by BRD-EZ3-110K HITACHI DYNAMIC BRAKING UNIT (BRD SERIES) 200V Class (BRD-E2-30K/55K) 400V Class (BRD-EZ2-30K/55K/110K) OPERATION MANUAL CONTENTS 1. UNPACKING INSPECTION..............2. IMPORTANT NOTICES................3. INSTALLATION..................4. WIRING AND FUNCTION SETTING............Wiring Notices......................Functional Setting ....................Example of External Connection ................ -
Page 2: Limited Warranty
Your product is warranted against defective material or workmanship for a period of one year from the date of installation. Hitachi will repair or replace this device free of charge if any defective parts or workmanship covered within the limitations of this warranty are found. - Page 3 History revisions Description Date of revision Manual No. Two manuals have been combined and the contents reviewed. '98-4-25 NB4882C Misspellings, missing characters, ambiguous descriptions, and similar errors are corrected without notice.
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Page 4: Safety Precautions
SAFETY PRECAUTIONS Carefully read this manual and other precautionary documents that came with the dynamic braking unit before installing, operating or maintaining this unit. Familiarize yourself with the device specifications, safety precautions, and handling and operating procedures and use this device correctly. - Page 5 2. Wiring Title: (Danger.eps) DANGER Creator: Adobe Illustrator(TM) 7.0 CreationDate: (1/26/0) (5:10 PM) Always connect the grounding wire to the dynamic braking unit to prevent electric shock or fire. (See page 3.) All wiring should be done by a qualified electrician or electric shock or fire may occur. (See page 3.) Before wiring, make sure the supply power is off (or the P-N voltage is 45 V or less) to prevent electric shock or fire.
- Page 6 3. Control and operation Title: (Danger.eps) DANGER Creator: Adobe Illustrator(TM) 7.0 CreationDate: (1/26/0) (5:10 PM) Be sure the front cover on the dynamic braking unit is attached before turning on the power. Never remove the cover of the dynamic braking unit or you may receive an electric shock (See page 11.) Do not operate with wet hands or you may receive an electric shock.
- Page 7 5. Appendix Title: (Danger.eps) DANGER Creator: Adobe Illustrator(TM) 7.0 CreationDate: (1/26/0) (5:10 PM) Never alter or modify the dynamic braking unit. Improper servicing may cause serious electric shock and/or personal injury. (See page 1.) GENERAL NOTICES For simplicity, some figures and illustrations in this manual are shown without the cover or peripheral parts of the device.
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Page 8: Unpacking Inspection
1. UNPACKING INSPECTION Handle the product with care when unpacking. Do not use any excessive force (impacts, vibration, etc.) on the package. Check the following: (1) Package damage occurring during delivery (2) Model name, voltage, etc. (order confirmation) (3) List of accessories (including operation manual) 2. -
Page 9: Installation
3. INSTALLATION Title: (Triangle.eps) CAUTION Creator: Adobe Illustrator(TM) 5.5 CreationDate: (98.4.21) (9:42) Mount the dynamic braking unit on a fireproof wall (e.g. metallic wall) or a fire may occur. Keep the dynamic braking unit away from combustible or flammable materials or a fire may occur. -
Page 10: Wiring And Function Setting
4. WIRING AND FUNCTION SETTING Wiring Notices Title: (Danger.eps) DANGER Creator: Adobe Illustrator(TM) 7.0 CreationDate: (1/26/0) (5:10 PM) Always connect the grounding wire to the dynamic braking unit to prevent electric shock or fire. All wiring should be done by a qualified electrician or electric shock or fire may occur. Before wiring, make sure the supply power is off (or the P-N voltage is 45 V or less) to prevent electric shock or fire. - Page 11 2. Use cables at their specified ratings as short as possible: up to 5 meters between the dynamic braking unit and the inverter (P, N) and up to 50 meters between the dynamic braking unit and the discharging resistor (P, RB) (or up to 5 meters for the EZ2-30K). Also make the wire connections as short as possible.
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Page 12: Functional Setting
Functional Setting You can select "Main unit," "Sub-unit," and an operating voltage level with the DIP switch. Note: Be sure to turn off the dynamic braking unit when setting the DIP switch. (1) Operating Voltage Set/Change function The dynamic braking unit supports three operating voltage levels: Standard (factory-set), - 5%, and -10%. -
Page 13: Example Of External Connection
Example of External Connection Figure 4.1 shows an example of a connection of a motor control system containing only one dynamic braking unit. Always use discharging resistors equal to or more than the resistance specified. If the resistance is insufficient, the dynamic braking unit may be damaged. To prevent overheating and burning during any malfunction of the dynamic braking unit, devise a circuit to shut off the primary power of the inverter by connecting this circuit to the alarm contact terminals (AL1 and AL2). -
Page 14: Example Of External Connection (Parallel Connection Operation)
Example of External Connection (Parallel Connection Operation) Figure 4.3 shows a connection example of a motor control system, which uses the parallel connection interlocking function. In this case, both the main unit and the sub-unit must use external resistors of the same resistance. - Page 15 Table 4.2 Applicable wires Connection Wire for P, RB, and SL1, SL2, Model Grounding wire resistance N connections (Note1) MA1, MA2 E2-30K 8 or more 5.5mm or more 0.75mm or more 5.5mm or more 5 to 7.9 or more 4 to 4.9 14mm or more 200V class...
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Page 16: Troubleshooting
5. TROUBLESHOOTING Alarm contact is activated and the inverter stops This event may be caused by a large amount of regeneration energy or a frequently breaking that result in the overheating of the discharging resistor. To prevent this event, check and correct resistances of the discharging resistors, the number of dynamic braking units in use, and the deceleration time. -
Page 17: When The Inverter Trips The 0V During Inverter Deceleration
When the inverter is tripped by overvoltage during inverter deceleration This event may be caused by too much regeneration energy, which is unable to handle the increase in voltage. To prevent this problem, check and correct the resistances of the discharging resistors, the number of dynamic braking units in use, and the deceleration time. -
Page 18: Pre-Start Checks
6. PRE-START CHECKS Follow the safety instructions below before operating this device. Title: (Danger.eps) DANGER Creator: Adobe Illustrator(TM) 7.0 CreationDate: (1/26/0) (5:10 PM) Be sure the front cover on the dynamic braking unit is attached before turning on the power. Never remove the cover of the braking unit or you may receive an electric shock. -
Page 19: Specifications
7. SPECIFICATIONS Standard Specifications Table 7.1 shows the standard specifications of the dynamic braking unit. However, user's specifications (if any) should be used preferentially. Table 7.1 Standard Specifications Model E2-30K E2-55K EZ2-30K EZ2-55K EZ2-110K Enclosure Open type Voltage class applicable 200V-class 400V-class Operating voltage (ON/OFF) - Page 20 Type Model Operating voltage Weight (kg) TYPE FORM BRD-EZ2-30K 725 5 TM2, terminal width 6, M3 screw Grounding terminal (M5 screw) TM3, terminal width 13, M5 screw DIMENSION in mm Figure 7.1 Dimensions - 13 -...
- Page 21 Type Model Operating voltage Weight (kg) TYPE FORM BRD-E2-30K 362.5 5 BRD-EZ2-55K 725 5 Mounting hole Grounding terminal M5 screw TM1, terminal width 6.4, M3 screw Note: Leave terminals 1 and 2 disconnected. TM2, terminal width 23, M8 screw TM3, terminal width 5.9, M3 screw DIMENSION in mm Figure 7.2 Dimensions - 14 -...
- Page 22 Type Model Operating voltage (V) Weight (kg) TYPE FORM BRD-E2-55K 362.5 5 BRD-EZ2-110K 725 5 Mounting hole Grounding terminal M5 screw TM1, terminal width 6.4, M3 screw Note: Leave terminals 1 and 2 disconnected. TM2, terminal width 33, M10 screw TM3, terminal width 7.5, M3 screw The value in parentheses is for EZ2-110K.
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Page 23: Internal Circuits
8. INTERNAL CIRCUITS Internal circuits of the dynamic braking units E2-30K/55K, EZ2-30K, and EZ2-55K/110K are shown respectively in Figures 8.1 to 8.3. See 4.3 and 4.4 on how to connect the terminals. 1. Terminals of the E2-30K/55K and EZ2-55K/110K (1) TM1 MA1, MA2, SL1, and SL2: Control signals for parallel interlocking connection (2) TM2 DC voltage (+) - Page 24 Figure 8.1 Internal circuit - 17 -...
- Page 25 Figure 8.2 Internal circuit - 18 -...
- Page 26 Figure 8.3 Internal circuit - 19 -...
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Page 27: Selection Of Dynamic Braking Units And Discharging Resistors
9. SELECTION OF DYNAMIC BRAKING UNITS AND DISCHARGING RESISTORS The synchronous speed of the motor decreases relative to a decrease in set frequency. When this happens, the synchronous speed of the motor is less than the rotational speed of the rotor and the slip becomes negative. -
Page 28: Braking Energy Without A Dynamic Braking Unit
Do not combine any items which are blank in Table 9.1 to Table 9.3. (1) For use in one dynamic braking unit Table 9.1 For use in a single dynamic braking unit (Common conditions) Motor: Hitachi standard 3-phase squirrel-cage (4 poles) totally-enclosed fan-cooled motor • … 0.2 •... - Page 29 (2) For use in two dynamic braking units Table 9.2 For use in two dynamic braking units Motor torque ratio % Rated torque of the motor Moment of inertia J Motor Inverter To: N . m (kgf . m) for one motor (GD 110K (kW) (kW)
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Page 30: General Formulas Use For Estimation
General Formulas Use for Estimation The example below calculates the braking torque and the discharging resistance of a motor for traveling machine. (N . m) (1) Rated motor torque T = 9550 where : Rated capacity of the motor (kW) : Rated revolutions per minutes of the motor (r.p.m.) (N . -
Page 31: Maintenance And Checks
10. MAINTENANCE AND CHECKS 10.1 Notices on Maintenance and Checks Title: (Danger.eps) DANGER Creator: Adobe Illustrator(TM) 7.0 CreationDate: (1/26/0) (5:10 PM) Be sure to turn off the supply power. (Make sure that the DC voltage between terminals P and N is 45 volts or less.) Otherwise, you may receive a serious electric shock. - Page 32 Table 10.1 Daily and Periodic Checks Check cycle Typical part Check Check item Checking Checking method Requirement replacement Testing tools point Daily Periodic timing • › Environment Check ambient temperature, relative humidity, and Visually and audibly The ambient temperature should be - concentration of dust, toxic gases, and oil mist.
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Page 33: Parts Ordering And Inquiry
11. PARTS ORDERING AND INQUIRY When inquiring or ordering replacement parts, please provide the following information to your local Hitachi distributor or service office: (1) Model number (2) Manufacturing number (MFG. No.) (3) Symptom or details of the trouble (in detail) If the label is hard to be read, report the external view or appearance of the replacement part and a short explanation of the trouble, together with the ordering sheet. -
Page 34: Appendix
APPENDIX Service life of capacitor Running time: Continuous (24 hours a day) Duty ratio: 10% Ed Duty ratio: 100% Ed (Continuous regeneration) Service life Appendix Figure 1 Ambient Temperature vs. Capacitor Life characteristics The ambient temperature affects the service life of the aluminum electrolytic capacitor. (See Appendix Figure 1.) Periodically check the capacitor and make sure it is free from leaks, deformations, etc.