HNC Electric HBU Series User manual

HBU Series Braking Unit
User’s Manual
HNC Electric Limited

1
Contents
Preface......................................................................................3
Open-case inspection announcements...................................4
Simple test methods ................................................................4
Chapter 1 Safety Information...........................................6
1.1 Definition of safety..........................................................6
1.2 Installation and wiring announcements ...........................6
1.3 Caution ............................................................................7
1.4 Others ..............................................................................7
Chapter 2 Product Models and Specification....................8
2.1 Model Specifications .......................................................8
2.2 Product Tech Specification..............................................8
2.3 current temperature curve................................................11
2.4 Product installation dimension ........................................12
Chapter 3 Product Installation guidance.........................16
3.1 Installation of the brake unit..........................................16
3.2 Braking unit terminal arrangement in major loop .........18
3.3 major loop connecting method ......................................19
3.4 wiring specification of major loop ................................23

2
Chapter 4 Description of operation Panel .......................24
4.1 Operation panel illustration ...........................................24
4.2 Status Indication ............................................................25
4.3 Description Digital display............................................26
4.4 Descriptions of buttons..................................................27
4.5 Switch over between parallel sockets and master-slave
mode ....................................................................................28
Chapter 5 Brake unit model selection ..............................29
5.1 Fast model selection for normal load ............................29
5.2 Model selection of periodical braking load ...................31
Chapter 6 Normal malfunction elimination ....................33
6.2 No braking sound ..........................................................33
6.3 Braking resistor too hot .................................................33
6.4 Resistor keep heating when inverter stop working........33
6.5 Over-current protection occurred during braking..........34
6.6 Inverter could not get powered on.................................34
6.7 Brake unit is too hot ......................................................34
Chapter 7 Quality Guarantee ..............................................35

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Preface
Thanks for choosing HBU series of dynamic braking units
manufactured by HNC.
HBU series of dynamic braking units are high
performance brake products joint manufactured with Germany
and Tongji University. Now these series are widely used in
CNC machine tools, high power manufacturing machinery,
elevators, centrifuges, crane and mining hoist, oil field
pumping units, etc.
HNC HBU adopts brake resistor to release the
regeneration energy produced in the process of motor speed
regulation, obtain enough braking torque to keep the frequency
converter running well.
This user’s manual provides information on installation &
wiring, parameters set-up and malfunction diagnosis etc.
Please read the user’s manual in detail to make sure install and
operate correctly.
This user’s manual is attached to the device for free,
please give it to device users and keep it well.

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Open-case inspection announcements
Please check the following during introspection
Wear out or not.
If it is nameplate fit with your order.
If the product and package have been checked strictly,
please contact us or the dealer if missing something.
Simple test methods
After unpacking, use digital multi-meter to simply test
whether device is good or not by respectively connect red and
black pen of diode switch to four terminal (DC(+), DC(-), RL1,
RL2), the results show as belo
Table 1HBU-3HA/4HA/5HA test result
Red pen
Black pen
Normal test result
DC(+)
DC(-)
Pressure drop increases from zero eventually,
stabilizes at infinity gradually.
DC(-)
DC(+)
Pressure drop ranges between 300 – 700mV
RL1
RL2
Pressure drop gradually increases from zero
to infinity
RL2
RL1
Pressure drop ranges between 200 – 500mV
Table 2 HBU-1L/1SA/3SA test result
Red pen
Black pen
Normal test result
DC(+)
DC(-)
Pressure drop is infinity
DC(-)
DC(+)
Pressure drop ranges between 600-900mV

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RL1
RL2
Pressure drop is infinity
RL2
RL1
Pressure drop ranges between 300-600mV
Remarks: Above test methods are only used to test whether module is
good or not, not test full unit.

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Chapter 1 Safety Information
1.1 Definition of safety
This sign means operator will be in danger if
operator does not follow guidance.
This sign means it will cause damage or
malfunction if operator does not follow guidance.
This sign means there is tips on how to use
device better.
1.2 Installation and wiring announcements
Wiring has to be operated by professionally qualified person
because there is danger of electric shock.
When installing and wiring, braking units, inverter and other
devices which are connected with braking unit must be cut off power
supply. Waiting for five minutes until capacitance inside each device
get fully discharged.
Make sure grounding terminal of braking unit connects to ground;
otherwise there is danger of electric shock.

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Pole “+” & “– “of AC bus of braking unit cannot be reversely
connected, or it would not work even damage the unit and related
device, and might cause fire.
Install braking unit in a well-ventilated environment, otherwise it
can’t work well even be damaged.
1.3 Caution
After power on each component of braking units has high voltage
(HV). It is very dangerous for people to touch, even losing life.
Avoid dropping screw, spacer etc. metal into braking unit,
otherwise cause damage to device.
Make sure housing and lid of device properly fit together during
operation.
1.4 Others
Scrap machine should be disposed as industrial wastes, no burning
because it would cause explosion.

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Chapter 2 Product Models and Specification
2.1 Model Specifications
Table 2.1 Specifications of braking energy unit
Model
Specifications
Usage Occasion
Power Range
Rated
Current
Peak
Current
General Mode
HBU-1L
dynamic raking
0.75-18KW
6A
33A
HBU-1SA
dynamic raking
22-37 KW
9A
50A
HBU-3SA
dynamic raking
45-55 KW
10A
100A
HBU-3HA
dynamic braking
75-90KW
70A
150A
HBU-4HA
dynamic braking
110-132 KW
85A
200A
HBU-5HA
dynamic braking
160-200 KW
120A
300A
HBU-6HA
dynamic braking
220-280KW
160A
400A
Rated current is maximum average current when braking
unit working. Peak current is maximum current allowed during
working, its running time should last less than 20 seconds.
2.2 Product Tech Specification
Table 2.2 Product Technical Specification
item
specification
Power supply
Network
voltage
Tri-phase 220V/380V/460/660V
（depend on models）
Network
frequency
45Hz～65Hz

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Control
Brake mode
Automatic voltage trace
Reaction time
Within 1mS, multiple noise filter
algorithm
Operation
voltage
Depend on different models
Hysteresis
voltage
less than 10V
Protection
function
Over-heat, over-current, short
circuit
Overheat
protection
75℃
Digit input port
*1pcs, set up functions by
software
Digit input port
*1pcs, set up functions by
software

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Display and
Settings
Status indicator
There are power indicator &
working indicator for all models.
And power indicator,
malfunctions indicator, fuse-break
indicator and brake-status
indicator for some models in
operation panel.
Operation
monitoring &
controlling
Some models with operation
panels have operation parameters
to monitor AC bus-bar voltage &
internal temperature etc.
Operation
voltage set-up
HBU-3HA/4HA/5HA set up via
operation panel, and others set up
when leaving factory.
Environment
Installing place
Indoor, elevation no more than
1000m, no sunshine, no
electro-conductive powder &
corrosive gas
temperature
-10~40℃，well-ventilated
humidity
Under 90％RH No dew
Vibration angle
Under 0.5g
:
Items marked with * are effective for DR-3HA/4HA/5HA only.

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2.3 current temperature curve
Allowed maximum current changes when internal heat
sink temperature of braking unit changes. Relationship
between maximum current and temperature is shown as below.
Table 2.1 Relation between current &temperature
From above Table, allowed maximum current drops down
when heat sink’s temperature is above 75 ℃, so working
temperature of braking unit has to be limited.

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2.4 Product installation dimension
HBU-1L dimension

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HBU-1SA/3SA dimension

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HBU-3HA/4HA/5HA/6HA dimension

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Table 2.3 HBU series mechanical parameter list (unit: mm)
Type
External
dimension
L*W*H
Installation
dimension
L1*L2*L3
Mounting
hole size
HBU-1L
215×135×65
200×32.5
M5×2
HBU-1SA
215×111×110
200×78
M6×4
HBU-3SA
HBU-3HA
420×186×210
400*140
M6×4
HBU-4HA
HBU-5HA
HBU-6HA

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Chapter 3 Product Installation guidance
3.1 Installation of the brake unit
Install braking unit vertically onto noncombustible &
solid surface. Because of heat energy generated by braking unit
itself, users must choose well-ventilated, heat dissipation and
safe installation environment. Leave enough space around
braking unit, minimum ventilation space is top & bottom
100mm, left & right 30mm.
Table 3.1 Installation space requirements of HBU series

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To more than one braking units have to be installed in
arrangement of up & down, vertical distance between each
braking unit is 200mm at least, and plus stream-guided baffle
to protect above braking unit from heat energy generated by
underneath braking unit. Installing method is shown as below.
Table 3.2 Installation instruction for two up & down braking units
Braking unit must be installed in well-ventilated
environment. If brake unit need to be installed inside cabinet,
make sure there is suitable hole for heat dissipation in the
cabinet, if necessary, install ventilator in suitable place.
During operation, braking resistor connects with braking
unit generate high heat, so must be not installed together with
inverter, braking unit and other device. An inappropriate
installation site of resistor might cause malfunction or damage
of other device.

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Do not put braking resistor near the explosive &
flammable stuffs, keep beyond the scope of touch.
3.2 Braking unit terminal arrangement in major
loop
3.2.1 HBU-1L Brake unit terminal arrangement
3.2.2 HBU-1SA/3SA Brake unit terminal arrangement

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3.2.3 HBU-3/4/5/6HA Brake unit terminal arrangement
3.3 major loop connecting method
3.3.1 Power input terminals
DC( ＋) & DC(-) are positive and negative input
respectively for braking unit’s DC bus, please connect with
positive and negative input of Inverter’s DC bus correctly.
When inverter connects with DC electric reactor externally,
positive connecting point of braking unit’s DC bus should
behind DC electrical reactor. Cable between DC bus and brake
unit should be as short as possible.