MITSUBISHI VARIABLEFREQUENCYDRIVE INVERTER Option Instruction Manual
BRAKE UNIT TYPE FR-BU (C) RESISTORUNIT TYPE FR-BR (C)
Thank you for choosing this option unit for the Mitsubishi FREQROL transistorized inverters.Thismanualgiveshandlinginformationandinstructionsforuse of this to use the equipment to its maximum option unit. Please read this manual carefully capability. This manual covers the FR-BU-C brake unit and FR-BR-C resistor unit.
f
Brake Unit (FR-BU-C) This option unit is used for applications where a motor driven by the FRZ260 inverters requires large brake torque, e.g. when the motor is rotated by a load or must be decelerated suddenly.
CONTENTS
1. UNPACKING AND CHECKING
...............................................................................
2. STRUCTURE ..............................................................................................................
1
2
......................................................................................................... 3 ....................................................................................................................... 5 OPERATION ............................................................................................................... 10 SPECIFICATIONS ..................................................................................................... 11 SELECTION ............................................................................................................... 12 OUTLINE DRAWING ................................................................................................ 13
3. INSTALLATION
4. WIRING
5. 6.
7. 8.
pXiE%-l
The discharge resistor used with this brake unit must be any of the following resistor units. Do not use together the previous BU type brake unit and the FR-BU type brake unit. Combination table Brake Unit Model Reslstor Unit Model FR-BR-C3.7K FR-BU-C7.5K
FR-BR-C55K FR-BU-C55K
FR-BR-C7.5K FR-BR-C22K
1. UNPACKING AND CHECKING After unpacking, check the following: ( 1 ) Check the rating plates on the brake unit and resistor unit covers and make sure that the models agree with your order. (2) Check that the units have not been damaged during transportation.
If you have any question on the above or found damage, etc., please contact your sales representative.
Model
ISynf
I
DescripUon
Brake unit
1I
S
y
I
L I M V O ~
575V series
Resistor unlt
-1-
[
1 1 Sy3yl
Units Capacity
7,5
Represents capaclty In kW
1
2. STRUCTURE
I Brake Unit 1 Right side view
Front view
I
FR5U
I
P
n
I
r
I
I
I1
Terminal block arrangement TB1-1
f+L%
Display window
TB1-2 C7.5K, C22K
I I
I1
//--+-I1 I1
Terminal block *TB2 TB1-1 TB1-2 Front cover mounting screw
4
/ S I
j R /
I
IN/-/
IPR
]P/+I C55K
r-l
Rating plate
Right side view
Front view &
&
Terminal block arrangement
r
Rating plate
I U
---------
Caution plate Terminal block TB1
j
PR
1
TB1 I TB2
Terminal block TB2
-2-
P
/
3. INSTALLATION 3.1 Handling
During transportation, handle the brake unit and resistor unit carefully to protect them from damage. When holding the brake unit and resistor unit, do not apply force only to their front covers.
3.2 Place of Installation
(1) Do not install the brake unit and resistor unit where they are subjected to di-
rectsunlight,hightemperature,highhumidity,oilmist,flammablegases, fluff,dust,dirt,etc.Installtheunitinacleanplace or insideatotallyenclosed panel which does not accept any suspended matter. Note: When the brake unit or resistor unit is installed in a panel, the cooling method and panel dimensions should be determined so that the ambient temperature of the unit is within the permissible range (as specified on page 4). Extreme care should be taken when two or more brake units or resistor units are installed in the same panel or when a ventilation fan is mounted in the panel. If the units and/or ventilation fan is installed in an improper position, the ambient temperature of the units will rise and ventilation effect will reduce.
t
(Incorrect)
(Correct)
Installation of Two or More Unlts
t
(Incorrect) (Correct) Posltlon of Ventllatlon
(2) Install the brake and resistor units where they are not subjected
outside of permissible range.
to vibration
3.3 Installation Direction and Clearances
(1) Install the brake unit and resistor unit on an even surface securely and verti-
cally (so that the letters FR-BU of the brake unit and FR-BR of the resistor unit are situated at the front) with screws or bolts. (2) Leave sufficient clearance around the brake unit and resistor unit for adequate heat dissipation. (3) If they are repeatedly operated, the rear surface temperature of the brake unit and resistor unit may rise (up to about 150°C),so install the units on incombustible backplate (such as metal and earth the backplate).
-3-
-
Leave sufficient clearances above and under the unit to ensure proper venttlatton
Clearances Around the FR-BU and FR-BR
/
Notes on Ambient Temperature Theambienttemperature of installationmust not exceed the permissible value (50% 122°F) as it greatly influences the life of the unit. Check that the ambient temperature is within the permissiblerangein the positions shown on the right.
-4-
4-b
%
FR-BU
50mm 50mm
5 0 m m r
I
Measurement posltlon
Measurement posltlon
4. WIRING 4.1Terminals 4.1.1 Brakeunit
I
Main clrcult
s
I
terminals
60HZ
&Converter terminals
-
N/-
IPR Control HE clrcult HC
1
Reslstor unlt ternlnal Alarm output termlnals
,c
contact
,230VAC 0 3A 30VDC 3A
Terminals connected wlth the inverter terminals P , N Reler to p 7 Terminal connected w~ththe reslstor unit term&
1 Outputslgnalmdlcatlng
PR
that the protective clrcult has
Operated
Normal. HE-HC connected, HA-HC dlsconnected Alarm HE-HCdlsconnected,HA-HCconnected
Terminal arrangement Terminal screw sizes
AC power input terminal block
Model FR-EU-C7 5K
Converter terminal block
C55K
TB1-2
Alarm outwt terminal block /HAiHBIHC/ TB2
-5-
1 Tn-1i TBI-2 1 iM4
TB2
1 ~ 4
'M3
FR-EU-CPPK
M4
lM4
IM3
FR-BU-C55K
M4
1M5
lM3
4.1.2
1
Resistor unit ]
Symbol Main circuit
P
1
&--
Control TH1 TH2
Terminal Name
Rating
Resistor unlt input terminals
110VAC 5A 220VAC 3A
Alarm ourpur circuit
Deecrlptlon Terminals connected wlth the brake unit terminals Pi+, PR Output signal lndloaong that the resistor has overheated disconnected Normal connected Alarm
Terminal arrangement Terminal screw sizes
Resistor unit inDut terminal block PR
I
TB1
I
P
I
/
1
TB2
I
TB1
I
TB2
FR-BR-C7.5K
Alarm output terminal block ~THI
Model FR-BR-C3 7K FR-BR-CZ2K
I TH2 1
FR-BR-CBBK
-6-
M5
M3
I
4.2 External Connection Example No-fuse Magnetic breaker contactor
nIveerir FR-Z260 Motor
THl
(Note
TH2
L Brake unit FR-BU-C
1
Reslstor unit FR-BR-C
Note: Connect FR-BU-C R, S with inverter R, S, supplying power to FR-BUC control circuit. For prevention of the discharge resistor from burning out due to brake unit fault ] Design the circuit so that if the transistor in the brake unit should be damaged, an alarm signal from the brake unit or an overheat signal given by the thermal relay in the resistor unit switches off the input power supply. This prevents the temperature of thedischargeresistorfromrisingabnormally, thereby protecting the discharge resistor from burnout. The external connection diagram is shown below. T(57512WV)
Brake unit
-7-
-
4.3 Wiring Instructions 4.3.1 Recommended cable core sizes Brake Unit Model
FR-BR-C7
5K
Cables
FR-BR-C3 FR-BU-C7 5K
7K
FR-BU-C7
5K
3 5mm2
FR-BR-CPPK
3 5mm2
FR-BU-CPPK FR-BR-C55K
Realstor Unit Model
FR-BU-C55K
Thecoresize of thecablesusedshouldbeequal above indicated recommended size.
to orlargerthanthe
4.3.2 Instructions
( 1 ) Correctlyconnecttheterminals
Pi+ and N/- withtheinverterterminals and N. Miswiring will cause damage to the brake unit. Check the connection before applying power to the unit.
P
connection] connection] [Wrong [Correct
R,S withinverterterminals R,S (575VAC single phase power supply). Miswiring, such as connection with inverter terminals P, N or resistorunitterminal PR, willcausedamage to thebrake unit (the internal transformer may burn out).
(2) Connect the brake unit terminals
(3) The temperature of the resistor unit rises up to approximately 150°C.
Therefore, the cables used should be heat-resistance cables (such as glassbraided cables) or covered with silicone tubes.
-8-
( 4 ) The cable length between the inverter and brake unit and between the resistor unit and brake unit should be as short as possible. If the cable length is longer than 2m, the wiring must be twisted. (Even when the wiring is twisted, the cable length must not exceed 5m.) Thesize of thecablesusedshouldbeequal to or largerthantherecommended size (see page 8). The different color cables twisted is recommended to prevent miswiring (ex. P ....red, N ....blue).
( 5 ) Do not allow wire offcuts to enter the unit, e.g. cover the vent hole at the top only during wiring operation. (6) When connecting the FR-BEL power factor improving DC reactor (option), the brake unit terminal P i t must be connected to the inverter terminal P.
L----J
L----J
FR-BEL
FR-BEL
[Wrong connectlon]
[Correct connection]
-9-
5. OPERATION 5.1 Display 7-Segments LED Display
Remarks
Description
(0)
Dlspiayed at p o w w o n
B, B,H
For description, see the table given Brake translsto below
IS dlsplayed durtng braking operation
to (1, 2 to 9, A)
Indicates that the brake translstor is faulty
.
Indicates that braklng operation has been performed tn excess 01 permlsslble brake translstor duty
(F) (Note)
Note:
Alarm output
IS
provided
output is not provided
The brake unit selkesets after sufflclent cooling time has elapsed At thls tlme. 0 IS dlsolaved.
When this (F)is lit, the brake unit stops operating. So the overcurrent or overvoltage protective function of the inverter will be activated. To resume operation, check and remove the cause, then reset the inverter. Poweringdownandresettingthebrakeunitclearsthebrakeduty dataaccumulated.Notethatrepeatingresetwillcausetheresistor unit to overheat. Connecting the brake unit terminals R,S with a.c. power supply different from that of the inverter main circuit allows the alarm display,signal and the brake duty data to be retained.
Relationship between brake transistor duty during Braking and LED display .~ - Operation . Brake transistor duty 7-Segments Display LED Remarks 0 to 1
I
I
1
t to 2
2
2 to 3
3
9 to
io
10 and up
A
F
- 10-
I
I
When there is sulilclent cooling time, the value dlsplayed on theLED decreases
6. SPECIFICATIONS
I Brake Unit I
Model FR-BU-• Input voltage
I Refer to D
Brakinatoraue %ED
Reslstor oveheat, brake transistor fault
Ambient temperature -1O'C to +50'C Ambient humidity Amblence Altitude. vlbration Coollng
cwIin(l
Realator Unlt Model FR-BR-C3.7K FR-BR47.5K FR-BR-CZ2K FR-BR-C55K
r
QO%RHor less
Storage temperature
Protectlve structure
I
-
Brake transistor dutv. Alarm code (bv 7 seaments LED)
Dlsplav
system
on themotor taoacitvand%ED I
Alarm outputs ( I C contact)
Protecbve functlons
W
12.(Braklnatorauedeoends
Mibubishi transistorlzd Inverter FR-2260 senes
110 slgnals
E
1575 VAClt10°/~,60Hz 12
Refer to p 12 (%ED depends on me motor capacity and braking torque )
Applicable controllers
E
C55K
C22K
11WOVDC or less
R-S
I Refer to p
Applicable motor capacity
ad
C7.5K P-N
-wc
to +65@c
No corrosive gases, oil mist. flammable gases, dust and dirt Indoors
lWOm or less above the sea, vlbration 5 9m/s2(0 6G)or less (conforming to JIS CO911)
NFMAl
I
1 Natural air
Remarks
Dl8charglng Reslator Spclflullona
3Ww 50C2 4 s
Resistance value tolerance i3Y0 S serles
3 W w 5 0 04S2P 3Ww 31i2 4S4P
P parallels
3Ww 260 4S8P
- 11 -
7. SELECTION ( 1 ) Selection of the brake unit
1) Select the brake unit according to the motor capacity. or more ranks higher, braking torque and %ED are as indicated below.
2 ) If only the inverter capacity is one
Allowable %ED at 100% braking torque (short duration rating)
Note:
*
Indicates the case combined with the FR-BR43.7K.
Maximum braking torque (short duration rating)
Note:
*
at 10%ED and tb=15 seconds
Indicates the case combined with the FR-BR-C3.7K.
tb
%ED = - X 100 (%)
tc
(Oh)
Regenerative load time rate effective duty frequency of operations
t b 45
seconds (continuous operation time)
Example 1: Forward operation b
Example 2: Elevating operation b
tb=tl +tZ+t3+t4
(2)Selection of the resistor unit Select the resistor unit according to the brake unit as shown in the left table.
- 12-
8. OUTLINE DRAWINGS
I Brake Unit I +
&
a
E
I
C
1-
AA A
7-
E
(Unit: mm)
Note: The vent holes are furnished at the side plates.
- 13-
I
1
ResistorUnit
/
-#
2-@
r l
.1
+-
I
I
I
I
I
I I
q$ : ,
I
I
I
'f
Eye bolk are provided for me FR-BR-C55K (See below.)
(Unit: mm)
I
C
Note: The vent holes are furnished at the
*
front and side plates.
Indicates the eye bolts are provided at two places.
- 14-
REVISION RECORD
* The instruction manual number has been given on of the back cover of this manual.
Print Date Dec, 1992
nstruction Aanual Number 4 IB(NA)-66403-A
Revision irst edition printed.
-15-
the bottom left
A MITSUBISHIELECTRICCORPORATION HEAD OFFICE MITSUBISHI DENKI BLDG M A R U N O U C H I TOKYO 1 0 0
6 M OIB 3-A INAI
192121 MEE
Printed in Japan
-
Specli~cat~ons subject l o c h a n g e w ~ t h o u notlce t