Hitachi HBU-2015 User manual

Hitachi America, Ltd.
Dynamic Braking Unit
HBU-2015/2030/4015/4030/4045/4220
Instruction Manual
NOTE: REFER ALSO TO APPLICABLE INVERTER INSTRUCTION MANUAL
Hitachi America, Ltd.
Manual Number: HAL7201E
After reading this manual,
keep it handy for future reference.
Se
p
tember 2009

Hitachi America, Ltd.
Tarrytown, NY
2
Revision History
Initial Version – July 2007
Rev A, September 2007 – Added specs, dimensions, terminal configuration, and circuit diagrams
for HBU-4220
Rev B, December 2007 – Changed depth dimension on page 11 for
2015/2030/4015/4030/4045/4220
Rev C, February 2008 – Added missing ratings in tables, pages 8-10; improved descriptions on
pages 4, 14, 15 and 19; added index
Rev D, February 2009 – Added derating curves; AWG wiring sizes; updated web address;
clarification of wiring distance and wiring voltage class on page 18
Rev E, September 2009 – Added warning notes about braking activation default jumper position
on 400 V class units

Hitachi America, Ltd.
Tarrytown, NY
3
Safety Precautions
Please read through this user’s manual before you use our product. Keep this manual handy for future reference.
Definitions used in this manual:
CAUTION! – This indicates a potentially hazardous situation that, if not avoided, can result in minor
to moderate injury, or serious damage to the product.
WARNING! – This indicates a potentially hazardous situation that, if not avoided, can result in serious
injury or death.
I. General Information
The function of the HBU braking unit is to divert into a braking resistor the regenerative energy produced in the
process of decelerating the motor, converting that energy into heat. Regenerative energy flows from the motor into the
inverter DC Bus, manifested as increased bus voltage. The advantage gained using the HBU is improved braking
performance and shorter deceleration time of the load.
Before you use the HBU braking unit, please read through this manual and please contact your distributor if you
have any questions. This manual will provide you the necessary information for installation, operation,
troubleshooting and repair of the HBU braking unit.
A. Inspection
Please check that the model number is the same as what you ordered BEFORE opening the box. Then, check the
contents for any sign of defect or damage during transport. If there is any problem, please contact your Hitachi
distributor immediately.
B. Braking Unit model numbering convention
HBU-□□□□
Braking Unit (@ 10% ED)
Code Inverter Power
015 15 kW
030 30 kW
045 45 kW
220 220 kW
Code
Inverter
Input
Voltage
2 200 VAC
4 400 VAC

Hitachi America, Ltd.
Tarrytown, NY
4
C. HBU Series Technical Specifications
200 V SERIES
Model HBU-2015 HBU-2030
Peak current (A) * 50 90
Continuous current (A) 15 30
Braking Activation Voltage 380 ±10 VDC (not selectable)
Maximum hysteresis ~10 VDC
Input and output
specifications
Multiple units Maximum: 10 HBUs parallel connected
Power supply DC Bus Voltage Range 230-380V
Power ON The red "power" LED will be on whenever the
inverter DC Bus voltage is above ~35VDC
Indication
functions
Braking ON The green "braking" LED will be on during
braking unit conduction
Ambient temperature Minus 10˚C to 40˚C (no frost)
Ambient humidity 90% RH (no dew)
Vibration 10-20hz: 1g, 20-50hz: 0.2g
Protection IP20
Physical data
Weight 2.3 kg/5.1 lbs
400 V SERIES.
Model HBU-4015 HBU-4030 HBU-4045 HBU-4220
Peak current (A) * 25 50 75 250
Continuous current (A) 8 15 25 80
Braking Activation Voltage 630/660/690/730/760V+-16V (jumper selectable) †
Maximum hysteresis About 16V
Input and output
specifications
Multiple units Maximum: 10 HBUs parallel connected
Power supply DC Bus Voltage Range 460-800V
Power ON The red "power" LED will be on whenever the
inverter DC Bus voltage is above ~35VDC
Indication
functions
Braking ON The green "braking" LED will be on during braking
unit conduction
Ambient temperature Minus 10˚C to 40˚C (no frost)
Ambient humidity 90% RH (no dew)
Vibration 10-20hz: 1g, 20-50hz: 0.2g
Protection IP20
Physical data
Weight 2.3 kg/5.1 lbs 11.6 kg/
25.5 lbs
* Peak current is defined as capacity for 10 seconds maximum, and 10% ED
†WARNING: It is critical to set jumper appropriately for the local supply voltage, or damage to the HBU, inverter and or resistors may result.

Hitachi America, Ltd.
Tarrytown, NY
5
D. Braking Resistor Selection Table for HBU braking unit
200 V SERIES
ED = 10%，braking activation voltage = 380 VDC
Power of
Inverter
Model of braking
unit
Quantity
of
braking
unit
Resistors Quantity of
resistors
Braking
torque
(10%ED)
%
0.4 HBU-2015 1 70W 200Ω1 220
0.75 HBU-2015 1 70W 200Ω1 125
1.5 HBU-2015 1 260W 100Ω1 125
2.2 HBU-2015 1 260W 70Ω1 120
3.7 HBU-2015 1 390W 40Ω1 125
5.5 HBU-2015 1 520W 30Ω1 115
7.5 HBU-2015 1 780W 20Ω1 125
11 HBU-2015 1 2400W 13.6Ω1 125
15 HBU-2015 1 3000W 10Ω1 125
18.5 HBU-2015 2 2400W 16Ω2 125
22 HBU-2015 2 2400W 13.6Ω2 125
30 HBU-2015 2 3000W 10Ω2 125
37 HBU-2015 2 3000W 10Ω2 100
45 HBU-2015 3 3000W 10Ω3 120
55 HBU-2030 2 4800W 6.8Ω2 100
75 HBU-2030 3 4800W 6.8Ω3 110
90 HBU-2030 4 4800W 6.8Ω4 120
110 HBU-2030 5 4800W 6.8Ω5 100

Hitachi America, Ltd.
Tarrytown, NY
6
200 V SERIES
ED = 20%，braking activation voltage = 380 VDC
Power of
Inverter
Model of braking
unit
Quantity
of
braking
unit
Resistors Quantity of
resistors
Braking
torque
(20%ED)
%
0.4 HBU-2015 1 140W 200Ω1 220
0.75 HBU-2015 1 140W 200Ω1 125
1.5 HBU-2015 1 520W 100Ω1 125
2.2 HBU-2015 1 520W 70Ω1 120
3.7 HBU-2015 1 780W 40Ω1 125
5.5 HBU-2015 1 1KW 30Ω1 115
7.5 HBU-2015 1 1.5KW 20Ω1 125
11 HBU-2015 1 4.8KW 13.6Ω1 125
15 HBU-2015 2 3KW 20Ω2 125
18.5 HBU-2030 1 9.6KW 8Ω1 125
22 HBU-2030 1 9.6KW 6.8Ω1 125
30 HBU-2030 3 4KW 15Ω3 125
37 HBU-2030 2 6KW 10Ω2 100
45 HBU-2030 2 9.6KW 6.8Ω2 120
55 HBU-2030 3 6.4KW 10.2Ω3 100
75 HBU-2030 4 7.2KW 9Ω4 110
90 HBU-2030 4 9.6KW 6.8Ω4 120
110 HBU-2030 5 9.6KW 6.8Ω5 100

Hitachi America, Ltd.
Tarrytown, NY
7
200 V SERIES
ED = 40%，braking activation voltage = 380 VDC
Power of
Inverter
Model of braking
unit
Quantity
of
braking
unit
Resistors Quantity of
resistors
Braking
torque
(40%ED)
%
0.4 HBU-2015 1 240W 200Ω1 220
0.75 HBU-2015 1 450W 200Ω1 125
1.5 HBU-2015 1 900W 100Ω1 125
2.2 HBU-2015 1 1.3KW 70Ω1 120
3.7 HBU-2015 1 2.2KW 40Ω1 125
5.5 HBU-2015 1 3.3KW 30Ω1 115
7.5 HBU-2015 1 4.5KW 20Ω1 125
11 HBU-2015 2 3.3KW 27.2Ω2 125
15 HBU-2030 1 9KW 10Ω1 125
18.5 HBU-2030 2 6KW 16Ω2 125
22 HBU-2030 2 6.6KW 13.6Ω2 125
30 HBU-2030 2 9KW 10Ω2 125
37 HBU-2030 3 7.5KW 15Ω3 100
45 HBU-2030 3 9KW 10.2Ω3 120
55 HBU-2030 4 8.5KW 13.2Ω4 100
75 HBU-2030 4 12KW 9Ω4 110
90 HBU-2030 6 9KW 10.2Ω6 120
110 HBU-2030 8 8.5KW 10.8Ω8 100

Hitachi America, Ltd.
Tarrytown, NY
8
400 V SERIES
ED = 10%，braking activation voltage = 760 VDC†
Power of
Inverter
Model of braking
unit
Quantity
of
braking
unit
Resistors Quantity of
resistors
Braking
torque
(10%ED)
%
0.4 HBU-4015 1 70W 750Ω1 230
0.75 HBU-4015 1 70W 750Ω1 130
1.5 HBU-4015 1 260W 400Ω1 125
2.2 HBU-4015 1 260W 250Ω1 135
3.7 HBU-4015 1 390W 150Ω1 135
5.5 HBU-4015 1 520W 100Ω1 135
7.5 HBU-4015 1 780W 75Ω1 130
11 HBU-4015 1 1040W 50Ω1 135
15 HBU-4015 1 1560W 40Ω1 125
18.5 HBU-4030 1 4800W 32Ω1 125
22 HBU-4030 1 4800W 27.2Ω1 125
30 HBU-4030 1 6000W 20Ω1 125
37 HBU-4045 1 9600W 16Ω1 125
45 HBU-4045 1 9600W 13.6Ω1 125
55 HBU-4045 2 6000W 20Ω2 135
75 HBU-4045 2 9600W 13.6Ω2 145
90 HBU-4045 2 9600W 13.6 Ω2 100
110 HBU-4045 3 9600W 13.6Ω3 100
132 HBU-4220 1 16KW 3.6Ω1 120
160 HBU-4220 1 40KW 3Ω1 140
220 HBU-4220 1 60KW 2.5Ω1 110
300 HBU-4220 2 40KW 3Ω2 110
600 HBU-4220 4 40KW 3Ω4 110
† WARNING: It is critical to set the jumper appropriately for the local supply
voltage, or damage to the HBU, inverter and or resistors may result. Factory
default setting may not be appropriate for your installation!
.

Hitachi America, Ltd.
Tarrytown, NY
9
400 V SERIES
ED = 20%，braking activation voltage = 760 VDC†
Power of
Inverter
Model of braking
unit
Quantity
of
braking
unit
Resistors Quantity
of resistors
Braking
torque
(20%ED)
%
0.4 HBU-4015 1 140W 750Ω1 230
0.75 HBU-4015 1 140W 750Ω1 130
1.5 HBU-4015 1 520W 400Ω1 125
2.2 HBU-4015 1 520W 250Ω1 135
3.7 HBU-4015 1 780W 150Ω1 135
5.5 HBU-4015 1 1040W 100Ω1 135
7.5 HBU-4015 1 1560W 75Ω1 130
11 HBU-4015 1 2KW 50Ω1 135
15 HBU-4030 1 3KW 40Ω1 125
18.5 HBU-4030 1 9600W 32Ω1 125
22 HBU-4030 1 9600W 27.2Ω1 125
30 HBU-4045 1 12KW 20Ω1 125
37 HBU-4045 1 20KW 16Ω1 125
45 HBU-4030 2 10KW 27.2Ω2 125
55 HBU-4045 2 12KW 20Ω2 135
75 HBU-4045 3 18KW 20.4Ω3 145
90 HBU-4045 4 12KW 21.2Ω4 120
110 HBU-4045 4 15KW 18Ω4 100
132 HBU-4220 1 48KW 3.6Ω1 120
160 HBU-4220 1 80KW 3Ω1 140
220 HBU-4220 2 60KW 5Ω2 110
300 HBU-4220 2 80KW 3Ω2 110
600 HBU-4220 4 80KW 3Ω4 110
† WARNING: It is critical to set the jumper appropriately for the local supply
voltage, or damage to the HBU, inverter and or resistors may result. Factory
default setting may not be appropriate for your installation!
.

Hitachi America, Ltd.
Tarrytown, NY
10
400 V SERIES
ED = 40%，braking activation voltage = 760 VDC†
Power of
Inverter
Model of braking
unit
Quantity
of
braking
unit
Resistors
Quantity
of
resistors
Braking
torque
(40%ED)
%
0.4 HBU-4015 1 240W 750Ω1 230
0.75 HBU-4015 1 450W 750Ω1 130
1.5 HBU-4015 1 800W 400Ω1 125
2.2 HBU-4015 1 1.32KW 250Ω1 135
3.7 HBU-4015 1 2.2KW 150Ω1 135
5.5 HBU-4015 1 3.3KW 100Ω1 135
7.5 HBU-4015 1 4.5KW 75Ω1 130
11 HBU-4030 1 6.6KW 50Ω1 135
15 HBU-4030 1 9KW 40Ω1 125
18.5 HBU-4045 1 11KW 32Ω1 125
22 HBU-4045 1 13.2KW 27.2Ω1 125
30 HBU-4030 2 10KW 40Ω2 125
37 HBU-4045 2 11KW 32Ω2 125
45 HBU-4045 2 13.5KW 27.2Ω2 125
55 HBU-4045 3 12KW 30Ω3 135
75 HBU-4045 4 11KW 27.2Ω4 145
90 HBU-4220 1 54KW 5.3Ω1 120
110 HBU-4220 1 66KW 4.4Ω1 100
132 HBU-4220 2 40KW 10Ω2 130
160 HBU-4220 2 48KW 6Ω2 140
220 HBU-4220 2 66KW 5Ω2 110
300 HBU-4220 3 60KW 4.5Ω3 110
600 HBU-4220 6 60KW 4.5Ω6 110
† WARNING: It is critical to set the jumper appropriately for the local supply
voltage, or damage to the HBU, inverter and or resistors may result. Factory
default setting may not be appropriate for your installation!
.