Brake units manual
Contents
1. PDF 4HE pdfFactory Pro iH ARA GUE www fineprint com cn 10 1 2 The brake unit has host slave switch Set the brake unit 1 to be M the brake unit 2 and 3 to be S Connect separately Ml M2 of the brake unit 1 with S1 S2 of the brake unit 2 Connect separately Ml M2 of the brake unit 2 with Sl S2 of the brake unit 3 Etc Note Double wind the Ml M2 and S1 S2 and please make it as short as you can the maximum paralleled brake units is only 10 11 Section VII Voltage Set and Calculation Volta Input power voltage of inverter Brake start voltage PN voltage 380V 370VAC 450VAC 670VDC 3 7 1 Why brake voltage 670V Brake unit voltage is from 630V to 700V how to select the right voltage In China it should select according to Chinese electric net Brake voltage should be on the following 2 standards 1 Brake voltage should be large enough and not lead the brake unit misact because of the raised voltage of the electric net The electric net fluctuates in China Some places the voltage will be over AC 450V the inverter DC voltage is 640V the safe voltage should be larger than that If the brake voltage is set low the brake resistors may be burned The actual fluctuation is 20 2 Brake unit voltage should be low enough make the inverter run at about the rated voltage ensure the safe running of the equipments High brake voltage could ensure that the brake uni2. C 40 C 0 C 40 C 2 Prevent dropping dust powder cotton fiber or fine metal powder from entering it 3 Prevent oil salt and corrosive gas from entering it 4 Avoid vibration 5 Avoid high temperature and moisture and avoid being wetted due to raining with the humidity below 90 RH not dewing 6 Prohibit the use in the dangerous environment where inflammable or combustible or explosive gas liquid or solid exists 3 2 Sharp size PB7014 5 PB7034 6 PDF 4HE pdfFactory Pro iH ARA CIE www fineprint com cn 3 3 Main circuit specification NOTE 1 2 3 4 rome BRAKING UNIT Inverter ALL brand N P N RB RB e e I ea m N N Rb Connection diagram of Brake unit and Inverter The distance of the connection between the inverter and brake unit should as short as possible less than 2cm No limitation to the distance between the brake resistor Rb and brake unit but the shorter distance may cause less faults because of the broken cable P Nis the of the DC bus in the inverter P is positive N is negative The DC cables should be winded to reduce the radiation and inductance Warning Incorrect connection of the main circuit will lead the damage to the brake uni
3. other section could waste some energy but capacitor could accumulate electric charge for a short time and forms pumps raise voltage to enlarge the DC bus voltage Too high DC voltage will damage the spares So to manage such regeneration energy brake unit resistor should be used to waste them otherwise the inverter will be OU or faulted 7 4 Brake current calculation Brake current is the DC current in the brake unit and brake resistor 380V Standard AC motor PSS Motor power k Conversion efficiency of the machine energy when feedback comes Usually 0 7 applicable for most 13 occasion DC working voltage 670V aAA Brake current Calculation norm Motor electricity regeneration should be absorbed completely by resistor Motor electricity regeneration 1000 P K Resistor absorbing power 7 5 Brake resistor calculation and selection Resistor value indirectly decides the system control moment Too small brake moment will lead inverter OU 380V Standard DC motor p Motor power jal Conversion efficiency of the machine energy when feedback comes Usually 0 7 applicable for most occasion se DC working voltage 670V RSS Brake resistor equivalent value Q Brake resistor rated waste power 57 Brake resistor waste power safety coefficient 1 4 komar The proportion of regeneration in the motor working procession evaluate according to the load Normal Kc Value as below Cen
4. Foreword Thank you very much for purchasing Powtran Brake Unit Please read the manual carefully before the installation of the product in order to ensure that it can be correctly installed and operated The function of brake unit and brake resistor is to feed back the regenerative consumption of motor to the brake resistor when the motor decelerates enhances the brake capability of the inverter ensures the motor to stop ina short time in the setting time This product is not only suitable for Powtran inverter but also to all other brand inverters User could select the right capacity brake unit according to the inverter s capacity and brake capability Please keep this user s manual in good condition for it will be helpful to the repair maintenance and applications in the future Powtran 2009 04 POF SAFE pdfFactory Pro iFAheAN es www fineprint com cn tes fer DO PB70 Series Function For all brands inverter 200V 380V 440V 480V It could be paralleled connected no capacity limited Allowable for the occasion with electricity fluctuation Special design the ordinary resistor could be used so no need to use senseless resistor Resistor box could be specially ordered Ensure the brake IGBT in saturation Protection short circuit low voltage over voltage fast fuse over heated Automatic track during the whole process Noise filtrated within all frequency range no disturbance to other
5. N ensure there is no voltage between PN when use and inspect the unit This unit control circuit is not isolated circuit PDF SCFI pdfFactory Pro WARRE a www fineprint com cn 16 Section IX Standard specification 9 1 Model specification 400V 380 415 Type Sharp size Allowed max brake current 65 C PB7014 A 40A PB7024 B 75A PB7034 B 100A NOTE The allowed maximum current of the power spares IGBT inside the brake unit with the certain temperature 9 2 Model designation PB 701 2 i e 2 220v 4 400v e 1 capacity No e 7 Design 2007 L e PB Powtran Brake unit 9 3 400V specification and selection reference 17 Brake resistor 150 brake Brake Unit KW torque Type Qty pe Type Qty pe 5 5 1 75 Q 780W 1 7 5 1 50 Q 1040W 1 11 1 50 Q 1040W 1 15 PB7014 1 40 Q 1560W 1 18 5 1 32 Q 4800W 1 22 1 27 2 Q 4800W 1 30 1 20 Q 6000W 1 37 i 16 Q 9600W 1 45 PB7024 1 13 6 Q 9600W 1 55 1 10 Q 12000W 1 75 1 6 8 Q 12000W 1 93 PB7034 1 6 8 Q 12000W 1 110 1 6 8 2 12000W 1 132 2 6 8 2 12000W 2 160 PB7034 2 6 8 Q 12000W 2 187 3 6 8 Q 12000W 3 200 3 6 8 Q 12000W 3 220 3 6 8 Q 12000W 3 250 PEIR 3 6 8 Q 12000W 3 280 3 6 8 Q 12000W 3 9 4 Brake resistor selection 1 2 3 PB7014 an
6. S I sos N N Rb Connection diagram of single brake unit and inverter When 1 unit is used please refer to the above diagram connect the inverter brake unit and brake resistor and run it 8 PDF HHE pdfFactory Pro WARRE CIE www fineprint com cn Section VI Paralleled running M S1 S2 Inverter Brake Unit Brake Unit Brake Unit All Brands M1 S1 M1 S1 1 M2 82 M2 s2 s P N RB RB P N RB RB P N RB RB Rb Rb Rb MS MS MS Jap JUF Ba M OFF 1 2 S1 OFF 1 2 S2 OFF 1 2 Parameters setting switch Parameters setting switch Parameters setting switch Diagram of the connection of paralleled running brake unit and inverter Only PB7034 with this function If 2 above brake or more over brake units are paralleled please refer to the diagram and connect the inverters multiple brake units and resistors 6 1 Host and slave select of function setting 1 2 The factory setting of the brake unit is set to be the host M do not modify the factory setting if only one brake unit is used When 2 or more over brake units are paralleled the control terminal S is used Please refer to the Host and slave control connection 6 2 Host and slave control connection
7. d 30KW inverter the brake resistor should be with 130 brake torque Not any earthing accident allowed to the brake resistor otherwise it will lead the serious damage to the unit and inverter Selection of the brake resistor capacity is for reference it depends on the load intertia brake frequency etc characteristic Please inquire Powtran when you have questions 18 PDF SFE pdfFactory Pro iAAheae a www fineprint com cn
8. equipments Contents Section I Safety Precautions 0000 eee 1 Section Re 4 IU notele ci EERE 5 Section IV Function Parameter Description 8 Section V Single Unit Running 000 eee 9 Section VI Paralleled running 10 Section VII Voltage Set and Calculation 00000 12 Section VIII Fault Diagnosis and Solutions 16 Section IX Standard specification 0 cee 17 PDF SFE pdfFactory Pro WARES et www fineprint com cn Section I Safety Precautions Please read the manual before the installation operation and inspection of the product For the safe operation remind you to pay special attention to the Warning and Attention in the manual Attention The potential danger will lead to slight or medium life harm or equipment damage It could also warn the violate operation Warning The potential danger could lead to life harm or private loss Attention e Do not use any brake unit and brake resistor lack of or with damaged spares Do not touch the internal spares for there are CMOS spares on the control card of the brake unit Otherwise it will damage the spares Please add the fan or other cooling equipment when multiple brake units installed parallel in the one cabinet Attention e Ensure the right setting of brake unit and brake resistor e Do not make voltage resistance test on the brake unit or it will lead semiconduc
9. justed and repaired e During the running do not touch any spares inside Warning e Please refer to the content in the manual when analyze and manage the fault of the brake unit Any modification to the brake unit is not allowed otherwise the life harm and property loses will not be burdened by Powtran e This product is the accessories of the inverter if it is used improperly which would not only do damage to itself but also to the inverter Please pay much attention to this Section II Inspection Powtran Brake Unit has been tested and inspected before leaving the manufacturer Before unpacking the product please check if the package is damaged due to careless transportation and if the specifications and type of the product complies with the order Please contact the supplier of Powtran products if any problems are found Only the well trained personnel are allowed to use this unit and such personnel must read through the parts of this manual relating to the safety installation operation and maintenance before using the unit The safe operation of this unit depends on correct transport installation operation and aintenance 4 PDF SAFI pdfFactory Pro iFAWeAaG a www fineprint com cn Section III Installation 3 1 Conditions for Use Hangging Brake unit should be installed inside the house where is ventilative Ambient condition should accord with the followings 1 Ambient temperature 10
10. t and inverter Section IV Function Parameter Description Description of control circuit terminal of the brake unit Terminal Specification Note O 0 Slave and host selection switch when Factory MS 1 M is ON the brake unit is set to be setting 3 Powman l ala a an host brake unit ON OFF L1 2 itch Slave and host selection switch when Factory BRAKING UNIT switc Parameters Setting Swich 2 S is ON the brake unit is set to be setting SE Sl eleen slave brake unit OFF a M1 M2 Slave and host control terminal Si ro O 5 S1 S2 Slave and host control terminal amp THL T l 2aGaG08 Ho OH protection switch always close S1 S2 M1 M2 THI TH2 T GA SISIS S epg T Cable terminal 5 Z 5 z ee Section V Single Unit Running N N Parameter setting switch and control terminal Q Q Note Only PB7034 have M S slave and host selection but other type J roma no The voltage class is set OK during the factory setting BRAKING UNIT Inverter 3 ALL brand Np arning Incorrect selection of the slave and host will lead abnormal running and damage N P N RB RB acla 1
11. t would not misact but too high voltage will do damage to the long running equipments especially to the inverter with spares of low voltage At the same time high voltage will also make the motor voltage saturated motor waste and decline control precision 7 2 PB70 brake unit characteristic 1 Special circuit design for any resistor in the market no need for senseless resistor 2 When abnormal working no damage to the inverter P N will not be 12 PDF SAFE pdfFactory Pro iFAheAs es www fineprint com cn short circuited if the cable connection is good 3 Suitable for domestic electric net normal running in 300V to 460V 4 Profession manufacture keeps improving 7 3 Brake unit function In the system of frequency conversion motor decelerates and stops by reducing the frequency At the moment of frequency reduction motor s synchronization rotate speed declines and because of machinery inertia motor rotor rotate speed remains When synchronization rotate speed is smaller than rotor rotate speed the phase of rotor current almost becomes 180 motor turns from electromotion to electricity generation Meanwhile torque of motor axis changes to brake torque and decelerate the motor speed quickly motor is during regeneration brake motor regeneration energy feedback to DC bus via fly wheel diode Because the energy in the DC circuit could not feedback to electric net by diode bridge but only absorbed by inverter although
12. tor spares damaged in the main circuit of the brake unit eFix the srew when connecting or the loose connection will lead fire or creepage Attention e Do not touch the brake unit the internal spares and printing board after the brake unit is connected otherwise it will lead to electric shock There is high voltage direct current inside Attention eDo not touch the heat sink of the brake unit and the brake resistors otherwise it will lead to scald or electric shock There is high temperature and heated spares inside after the brake unit is connected Attention eThe brake resistor should be with temperature and other protection Because the brake unit is defective when the brake resistor keeps heated it should have been isolated itself Powtran will not take the responsibility of such accident caused by no automatic isolation MWarning e The unit and brake resistor should be installed on the medium with flame retardancy e Connection is allowed only when the power is switched off and completely out of power e Only well trained personnel are allowed to use this unit Warning e Ensure the correct connection before running e Ensure the right host and slave selection and voltage class before running 2 PDF 4HE pdfFactory Pro iH PRA GUE www fineprint comcn e Only when the charge light is off and ensure the charge voltage is O with the multimeter the brake unit could be ad
13. trifuge Kc 5 20 Elevator Kc 10 15 Oil field JH HAKL Ke 10 20 Crane lower than 100m Kc 20 40 Occasional brake load Kc 5 Others Kc 10 Calculation norm Motor electricity regeneration should be absorbed 14 PDF SFE pdfFactory Pro iFAheAae a www fineprint com cn completely by resistor Motor regeneration energy 1000 P K resistor absorptivity V V R Resistor power calculation norm otor electricity regeneration should be absorbed completely by resistor and transfer to heat energy Q P K Kc S P0 7 Kc 1 4 Approximately Q P Kc And resistor power motor power Kc 7 6 Brake unit safty limit Current in brake unit is 670 R Such current should not be larger than that the allowable maximum current Section VIII Fault Diagnosis and Solutions No Fault Possible cause Main circuit power IGBT of The brake the unit short circuit resistor Incorrect selection of the 1 heated brake unit voltage badly when it brakes Brake unit faulted 2 Inverter OU Lack of braking of the brake resistor Not suited brake unit voltage Brake unit faulted Brake resistor short or open circuit 3 No brake sound Cable connection not good Brake unit fault relay 4 action over Heat sink temperature over heat 80 C protection NOTE The electric net voltage is too high please select the high voltage setting N Warning Open the P and
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