Mitsubishi Electric FR-ABR-(H)0.4K User manual

TRANSISTORIZED INVERTER
INSTRUCTION MANUAL
FR-ABR-(H)0.4K to 15K
HIGH-DUTY BRAKE RESISTOR
F
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A-1
Thank you for choosing the Mitsubishi transistorized inverter option
unit.
This instruction manual gives handling information and precautions for
use of this equipment.
Incorrect handling might cause an unexpected fault. Before using the
equipment, please read this manual carefully to use the equipment to
its optimum.
Please forward this instruction manual to the end user.
1. Electric Shock Prevention
Safety Instructions
Do not attempt to install, operate, maintain or inspect this product
until you have read through this instruction manual and appended
documents carefully and can use the equipment correctly.
Do not use this product until you have a full knowledge of the
equipment, safety information and instructions.
In this manual, the safety instruction levels are classified into
"WARNING" and "CAUTION".
Denotes that incorrect handling may cause
hazardous conditions, resulting in death or
severe injury.
Denotes that incorrect handling may cause
hazardous conditions, resulting in medium or
slight injury, or may cause physical damage only.
Note that even the level may lead to a serious
consequence under some circumstances. Please follow the
instructions of both levels as they are important to personnel safety.
SAFETY INSTRUCTIONS
WARNING
•Before starting wiring or inspection, switch power off, wait for
more than 10 minutes, and check for no residual voltage with a
meter etc.
•Any person who is involved in the wiring or inspection of this
equipment should be fully competent to do the work.
WARNING
CAUTION
CAUTION
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2. Fire Prevention
3. Injury Prevention
4. Additional Instructions
Also note the following points to prevent an accidental failure, injury,
electric shock, etc.:
(1) Transportation and installation
(2) Usage
(3) Disposal
(4) General instructions
CAUTION
•Mount the brake resistor on a non-combustible surface. Installing
it directly on or near a combustible surface could cause a fire.
•Use the alarm signal to switch power off. A failure to do so can
overheat the brake resistor due to a brake transistor failure etc.,
causing a fire.
CAUTION
•Ensure that the cables are connected to the correct terminals.
Otherwise, damage, etc. may occur.
•While power is on or for some time after power-off, do not touch
the brake resistor as it is hot. Touching it can cause burns.
CAUTION
•Transport products in a correct manner according to their weights.
Not doing so can cause injury.
•Install the product in a place secure enough to withstand its weight
according to the instruction manual.
WARNING
•Do not modify the equipment.
CAUTION
•Dispose of this product as general industrial waste.
Many of the diagrams and drawings in this instruction manual show
the inverter without a cover, or partially open. Never run the inverter
like this. Always replace the cover and follow the instruction manual
when operating the inverter.
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INSTALLATION INSTRUCTIONS FOR COMPLIANCE WITH UL
Install the FR-ABR brake resistors as follows:
•The resistor may be mounted horizontally or vertically, depending on a
suitable surface location.
•When the resistor is mounted externally to the enclosure housing the
inverter, install a solid Type 1 enclosure at least 8 times the volume size
of the resistor that incorporates mesh or perforated steel type ventilation
openings at each end of the resistor. Note, the vent openings shall not be
greater than 10 mm diameter.
•Secure the enclosure to a non-combustible surface only, such as metal or
concrete.
•Mount the resistor inside the Type 1 enclosure and wire it in accordance
with the NEC for North America installations or any other local codes.
Note, when the resistor and inverter are mounted together within a suitable
enclosure, the mesh covering is not required. Please take care that the
Inverter unit / resistor internal enclosure ambient does not exceed 50 deg. C.
Enclosure surface presents a possible burn hazard. After installation, the
following marking in minimum 3 mm (1/8 in.) sized lettering shall be provided
on the enclosure where visible:
CAUTION : HOT SURFACE. TO REDUCE RISK OF BURN - DO NOT TOUCH.
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1. UNPACKING AND CHECKING THE MODEL AND
APPLICABLE INVERTERS
Take the brake resistor out of the package and confirm that the product is
as you ordered and intact.
The FR-ABR Series brake resistors are a UL Listed Accessory for use
only with the following inverter models:
High-Duty Brake Resistor Model Applicable Inverter Models
200V Class
FR-ABR-0.4K
FR-A520-0.4K(-**)
FR-E520-0.4K(C)(-**), FR-E520S-0.4K(-**),
FR-E510W-0.4K(-**)
FR-A024-0.4K(-**)
FR-S520E-0.4K(-**)
FR-ABR-0.75K
FR-A520-0.75K(-**)
FR-E520-0.75K(C)(-**), FR-E520S-0.75K(-**),
FR-E510W-0.75K(-**)
FR-A024-0.75K(-**)
FR-S520E-0.75K(-**)
FR-ABR-2.2K
FR-A520-1.5K(-**), FR-A520-2.2K(-**)
FR-E520-1.5K(C)(-**), FR-E520-2.2K(C)(-**)
FR-V520-1.5K(-**), FR-V520-2.2K(-**)
FR-A024-1.5K(-**), FR-A024-2.2K(-**)
FR-S520E-1.5K(-**), FR-S520E-2.2K(-**)
FR-ABR-3.7K
FR-A520-3.7K(-**)
FR-E520-3.7K(C)(-**)
FR-V520-3.7K(-**)
FR-A024-3.7K(-**)
FR-S520E-3.7K(-**)
FR-ABR-5.5K
FR-A520-5.5K(-**)
FR-E520-5.5K(C)(-**)
FR-V520-5.5K(-**)
FR-ABR-7.5K
FR-A520-7.5K(-**)
FR-E520-7.5K(C)(-**)
FR-V520-7.5K(-**)
FR-ABR-11K FR-V520-11K(-**)
FR-ABR-15K FR-V520-15K(-**)
Note : ** indicates alpha numeric combination.
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400V Class
FR-ABR-H0.4K
FR-A540-0.4K(-**)
FR-E540-0.4K(C)(-**)
FR-A044-0.4K(-**)
FR-ABR-H0.75K
FR-A540-0.75K(-**)
FR-E540-0.75K(C)(-**)
FR-A044-0.75K(-**)
FR-ABR-H1.5K
FR-A540-1.5K(-**)
FR-E540-1.5K(C)(-**)
FR-V540-1.5K(-**)
FR-A044-1.5K(-**)
FR-ABR-H2.2K
FR-A540-2.2K(-**)
FR-E540-2.2K(C)(-**)
FR-V540-2.2K(-**)
FR-A044-2.2K(-**)
FR-ABR-H3.7K
FR-A540-3.7K(-**)
FR-E540-3.7K(C)(-**)
FR-V540-3.7K(-**)
FR-A044-3.7K(-**)
FR-ABR-H5.5K
FR-A540-5.5K(-**)
FR-E540-5.5K(C)(-**)
FR-V540-5.5K(-**)
FR-ABR-H7.5K
FR-A540-7.5K(-**)
FR-E540-7.5K(C)(-**)
FR-V540-7.5K(-**)
FR-ABR-H11K FR-V540-11K(-**)
FR-ABR-H15K FR-V540-15K(-**)
Note : ** indicates alpha numeric combination.
High-Duty Brake Resistor Model Applicable Inverter Models
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2. GENERAL INSTRUCTIONS FOR INSTALLATION
(If you need to meet UL requirement refer to page A-3)
•Never mount the resistor near wood, paper or any other combustible
material. Doing so can cause a fire.
•To prevent burns, do not install the resistor in a place where it is readily
accessible. If it is easily accessible, mount in a well-ventilated
enclosure (e.g. punched metal), suitable for the environment.
•Mount the resistor carefully so that the leads do not come from the top
of the resistor.
•Avoid contact with the resistor when running the leads of the resistor
and any other wiring.
Install the resistor in a place with good heat dissipation. The reason for
this is that the surface temperature of the resistor may exceed 360°C in
an operation pattern where the resistor is used frequently.
To increase the heat dissipation effect, we recommend you to install the
resistor on a metal surface outside the enclosure.
Provide an enclosure with good
heat dissipation to prevent
hazards such as burns.
Use a cooling fan
if required.
High-duty brake resistor
How to Install the Resistor
Leave at least 3cm
Interval between resistors Installed
High-duty brake resistor
No contact with
the resistor
Orientation of installed resisto
r
Other wiring
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3. INSTRUCTIONS FOR WIRING
When the regenerative brake transistor is damaged, the wiring sequence
as shown in the following diagrams is recommended to prevent
overheating and burnout of the brake resistor.
•Remove the link from across the PR-PX terminals of the inverter. (*1)
This disables (switches off) the built-in brake resistor. (Refer to the
instruction manual of the inverter for details.)
Note that the built-in brake resistor need not be removed. The leads of
the built-in brake resistor need not be disconnected from the terminals.
*1 When you use the FR-E500 series inverter, the FR-V500 series-7.5K or more
inverter and the FR-A500 series-11K or more inverter, you need not remove the
jumper since that inverter does not have the PX terminals. (Refer to the
instruction manual of the inverter.)
*2 For the 400V class power supply, install a voltage-reducing transformer.
*3 When using the (H)11K or 15K, install a thermal relay.
Refer to the following table for the thermal relay model number and to the
following diagram for connection.
Capacity Thermal relay (OCR) Contact Rating
11K/15K TH-N20CXHZ-11A AC110V 5A,
AC220V 2A
(AC11 class)
DC110V 0.5A,
DC220V 0.25A
(DC11 class)
H11K/H15K TH-N20CXHZ-6.6A
MC
MC
T(*2)
MC
R
PX
PR
P
S
T
R
ON
OFF
B
C
F
<Example 1>
Power
Supply
Inverter
Disconnect jumper. (*1)
High-duty brake resisto
r
(FR-ABR)
Thermal relay
(OCR)(*3)
OCR
Contact
MC Inverter
MC
T(*2)
MC
R
PX
PR
P
Disconnect jumper. (*1)
High-duty brake resisto
r
(FR-ABR)
Thermal relay
(OCR)(*3)
S
T
R
ON
OFF
OCR
Contact
Power
Supply
F
<Example 2>
To the inverter
P terminal
To the ABR
TH-N20
1/L15/L3
2/T16/T3
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•Connect the leads of the high-duty brake resistor to the P and PR
terminals of the inverter. When using the 15K inverter, connect two
high-duty brake resistors (18Ω) in parallel. When using the H15K
inverter, connect two high-duty brake resistors (18Ω) in series using the
terminal block enclosed.
•If the resistor lead length is not sufficient to reach the inverter terminals,
additional lead wire, sized as noted below and not exceeding 5 m in
length, may be used. Installation shall be in accordance with the North
American or Canadian Electrical Code.
4. INSTRUCTIONS FOR USE
•Setting of inverter parameters
1) The parameter setting method varies with the inverter series.
Refer to the instruction manual of the inverter.
CAUTION
1. The high-duty brake resistor cannot be used with a brake
unit, high power factor converter, power return converter,
built-in brake etc.
2. Twist the leads of the high-duty brake resistor when increas-
ing their length 2m or more. (The wire size used should be
minimum 14 AWG (2.1mm2)).
Note that even the twisted leads cannot be made longer than
5m. Doing so can cause an inverter failure.
3. The FR-ABR-(H)11K, 15K can not be used with the FR-A500
series.
To the inverter PR terminal
Terminal block
enclosed
FR-ABR-H15K brake resistor
To the inverter P terminal
(To the thermal relay T3terminal.)
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5. SPECIFICATIONS
1) Permissible duty and torque
* The permissible duty represents the braking capability including the motor
loss.The actual duty of the resistor is slightly lower than that.
6. OUTLINE DIMENSIONS
FR-ABR-0.4K to 7.5K, H0.4K to H7.5K
*1 Used for 1.5K and 2.2K.
Item FR-ABR- (200V Class) FR-ABR-H (400V Class)
0.4K 0.75K 2.2K 3.7K 5.5K 7.5K 11K 15K 0.4K 0.75K 1.5K 2.2K 3.7K 5.5K 7.5K 11K 15K
Braking
torque 150% 5s 100% 5s 100% 5s
Permissib
le duty* 10%ED 6%ED 10%ED 6%ED
Brake Resistor Model
Dimensions (Unit: mm) Resistance
(Ω)
Crimping Terminal
(Unit: mm)
W W1W2D H A1A2
B d B1d1
200V Class
FR-ABR-0.4K 140 125 100 40 21 200
7.0 4.3 7.0 4.3
FR-ABR-0.75K 215 200 175 40 21 100
FR-ABR-2.2K*1240 225 200 50 26 60
FR-ABR-3.7K 215 200 175 61 33 40
FR-ABR-5.5K 335 320 295 61 33 25 9.5 5.3 9.5 5.3
FR-ABR-7.5K 400 385 360 80 40 20
400V Class
FR-ABR-H0.4K 115 100 75 40 21 1200
7.0 4.3 7.0 4.3
FR-ABR-H0.75K 140 125 100 40 21 700
FR-ABR-H1.5K 215 200 175 40 21 350
FR-ABR-H2.2K 240 225 200 50 26 250
FR-ABR-H3.7K 215 200 175 61 33 150
FR-ABR-H5.5K 335 320 295 61 33 110 9.5 5.3 9.5 5.3
FR-ABR-H7.5K 400 385 360 80 40 75
W
W1
± 1
W2
5.3
500
+ 20
0
D
H
2.5
φ d
B
A1
A1
φ d1
B1
A2
A2
Glass-braided cable
2.0mm
2
white
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