Sharp R-220KW(D) Instruction manual

Instruction Manual
DB Unit
Dynamic Braking Unit
200V Series
37kW /BU37-2C
to 90kW /BU90-2C
400V Series
37kW /BU37-4C
to 220kW /BU220-4C
 CAUTION
■ Ensure that this instruction manual is made
available to the final user of the DB unit.
■ Read and understand all operating instructions
before installing, connecting (wiring), operating,
maintaining or inspecting the DB unit.
■ Keep this manual up to disposing the DB unit
carefully.
■ The product is subject to change without notice.
INR-HF51196c-E
Preface
Thank you for purchasing our dynamic braking unit (DB unit). This product is a device to discharge the braking
power to a resistor in a braking operation of the Fuji's inverter for general industry. The applicable inverter
models should be referred to Table A.
Read this manual carefully before using, understand the treatment method and use the DB unit correctly.
Incorrect use may result in obstruction of normal operation, shortening of the life or cause of failure. Keep this
manual carefully even after using.
As this manual does not cover the use of inverter, refer to relevant manuals for the inverter to be used.
Table A Applicable inverter models
Series
200V
General-purpose inverter
400V
Vector inverter
General-purpose inverter
Vector inverter
Model
FRENIC5000 G5/P5,G7/P7,G9S/P9S,G11S/P11S series
FRENIC-Eco series
FRENIC5000 VG3,VG5,VG7S series
FRENIC5000 G9S/P9S,G11S/P11S series
FRENIC-Eco series
FRENIC5000 VG5,VG7S series
As following the old model is applicable to DB unit by special tuning before shipment, please
contact your local distributor or nearest Fuji Electric's sales office.
Series
Model
200V
Vector inverter
FRENIC5000 VG series
400V
General-purpose inverter FRENIC5000 G5/P5, G7/P7 series
Vector inverter
FRENIC5000 VG,VG3 series
Safety instructions
Read this manual carefully before installing, connecting (wiring), operating, maintaining, or inspecting the DB
unit and use it correctly.
Familiarize yourself with all knowledge of the device, safety information and instructions before using.
In this manual, safety messages are classified as follows.
Denotes operating procedures and practices that may result in personal injury or
loss of life if not correctly followed.
Denotes operating procedures and practices that may result in slight to medium
personal injury or property damage if not correctly followed.
Situation more serious than those covered by CAUTION will depend on prevailing circumstances.
Always follow the instructions as important contents are described in these.
 WARNING
 CAUTION
Instruction on use
 WARNING
・ This DB unit is designed to discharge the braking power to a resistor in a braking operation of the Fuji's
inverter for general industry. It cannot be used for others.
Fire may result.
・ This DB unit may not be used (as is) as a component of a life-support system or other medical device
directly affecting the personal welfare of the user.
・ This product is manufactured under strict quality control standards. However, safety equipment must be
installed if the failure of this device may result in heavy accident and/or property damage.
There is a risk of accident.
Instruction on installation
 WARNING
・ Mount this DB unit on an material such as metal.
Fire may result.
・ Do not place combustible or flammable material near this DB unit。
Fire may result.
・ Contain the DB unit into a panel etc. so as not to be able to touch it easily.
Electric shock or accident may result.
・ Ensure that the specified bolts are used when installing the DB unit.
There is a risk of accident or injury.
 CAUTION
・ Do not hold the front cover when carrying the DB unit.
Injury by dropping may result.
・ Ensure that the DB unit and cooling fins are kept free if foreign matters such as lint, paper, small chips of
wood or metal, or dust.
Fire or accident may result.
・ Do not install or operate a damaged DB unit or a DB unit missing parts.
Injury may result.
Instruction on wiring
 WARNING
・ Use wires of the specified size for wiring.
Fire may result.
・ Do not connect the DC terminals (P(+) and N(-)) to the connection terminals on the inverter side in
mistake for the polarity (+ and –).
Fire may result.
・ Ensure that the grounding wire is connected.
Electric shock or fire may result.
・ A licensed specialist must perform the wiring works.
Electric shock may result.
・ Turn off the power before starting the wiring work.
Electric shock may result.
・ Wire after the installation of the DB unit is complete.
Electric shock or fire may result.
 CAUTION
・ Check that the rated voltage of the product complies with that of the inverter.
Injury may result.
・ Do not directly connect DC terminals (P(+) and N(-)) to the braking resistor.
Fire may result.
・ The DB unit and wiring generate noise. Take care the malfunction of the sensors and devices in
surroundings.
Accident may occur.
Instruction on operation
 WARNING
・ Ensure that the power is turned on (close) after attaching the front cover. In energized status, do not
remove the cover.
Electric shock may result.
・ Do not touch the terminals of the DB unit in energized state of the inverter even if the inverter has stopped.
Electric shock may result.
 CAUTION
・ Do not start and stop the inverter by turning on/off the main circuit power supply.
Failure may result.
・ Do not touch the cooling fins and braking resistor since they become very hot.
Burns may result.
・ The braking with this DB unit cannot function as mechanical holding.
Injury may result.
Instruction on maintenance, inspection, and parts replacement
 WARNING
・ Wait a minimum ten minutes after the power has been turned off (open) before starting inspection.
Further, check that the charge lamp is turned off and that the DC voltage between the terminals P(+) and
N(-) do not exceed 25V.
Electric shock may result.
・ Only authorized personnel should perform maintenance, inspection, and replacement operations.
Take off metal jewelry such as watches and rings.
Use insulated tools.
Electric shock or injury may result.
Instruction on disposal
 CAUTION
・ Treat the DB unit as industrial waste when disposing it.
Injury may result.
Other instructions
 WARNING
・ Never modify the product.
Electric shock or injury may result.
Conformity to Low Voltage Directive in Europe
 CAUTION
・ Ensure that the DB unit is grounded.
・ When wiring to the main circuit terminals and terminal for grounding of the inverter, use round terminals for the
cable.
・ Use a single cable to connect the grounding terminal  G of the DB unit. (Do not use two or more wires
for the wiring.)
・ Use the DB unit under overvoltage category III conditions and maintain Pollution degree 2 or better as
specified in IEC 664. To maintain Pollution degree 2 or better, install the DB unit in a control panel (IP54 or
higher level) having a structure free from water, oil, carbon, dust, etc.
・ For the input-output wiring of the DB unit, use cable (wire diameter and type) as specified in Appendix C in
EN 60204.
・ To prevent electric shock at terminals or live parts, install the braking resistor as follows:
1) Install inside an IP4X cabinet or a barrier if electrical parts are exposed.
2) Install inside an IP2X cabinet or a barrier if electrical parts are not exposed.
GENERAL ATTENTION
Some illustrations in this manual are drawn in the status with removed cover or block for safety to describe in
detail. When operating the product, ensure that the cover or block is returned to the original as the
specification, and operate in accordance with the manual.
Compliance with UL/cUL standards [Applicable to products with UL/cUL mark]
]
1.General
UL(Underwriters Laboratories Inc.) standards is safety standards for prevention of fire and other accident, and protect
user, maintenance man and people.
UL standards
cUL standards is fixed standards conform with CSA standards. The products approved by cUL is equivalent
to approval of CSA.
2.Notice
When using DB unit according to UL/cUL standards, please refer to following notice.
CAUTION for UL/cUL requirements
 CAUTION
・ Hazard of electrical shock. Disconnect incoming power before working on this control.
・ Dangerous voltage exists until charge lights is off.
・ More than one live circuit.
・ Use 60/75℃ or 90℃ copper wire only.
・ A Class 2 circuit wired with class1 wire.
・ Field wiring connection must be made by a UL Listed and CSA Certified closed-loop terminal
connector sized for the wire gauge involved. connector must be fixed using the crimp tool
specified by the connector manufacturer.
・ For use with 3ph 200-220V/50Hz, 200-230V/60Hz Inverter Drives for models with suffix -2C.
・ For use with 3ph 380-440V/50Hz, 380-480V/60Hz Inverter Drives for models with suffix -4C.
 CAUTION
Tightening torque and wire range
1.60℃/75℃ copper wire
Voltage
Applied
Motor
(kW)
30
TYPE
BU37-2C
37
200V
45
TYPE
Resistance
value(Ω)
Q’ty
Main
terminal
Ground
-ing
1
DB30-2C
4.0
1
1
DB37-2C
3.0
1
31.0
(3.5)
31.0
(3.5)
10
(5.3)
Required torque [lb-inch](N.m)
Braking resistor
1
DB45-2C
2.5
1
55
1
DB55-2C
2.0
1
75
1
DB75-2C
1.6
1
1
DB110-2C
1.2
1
1
DB30-4C
15
1
1
DB37-4C
12
1
1
DB45-4C
10
1
55
1
DB55-4C
7.5
1
75
1
DB75-4C
6.5
1
BU55-2C
BU90-2C
90
30
BU37-4C
37
45
400V
Q’ty
Wire range
[AWG] (mm2)
Main
Control
Control
terminal
DB Unit
BU55-4C
BU90-4C
90
110
1
BU132-4C
132
160
200
BU220-4C
220
DB110-4C
4.7
15.9
(1.8)
51.3
(5.8)
1
DB132-4C
3.9
1
1
DB160-4C
3.2
1
1
DB200-4C
2.6
1
1
DB220-4C
2.2
1
119
(13.5)
31.0
(3.5)
4
(21.2)
14
(2.1)
6.2
(0.7)
12
(3.3)
51.3
(5.8)
10
(5.3)
119
(13.5)
119
(13.5)
6
(13.3)
239
(27)
239
(27)
3
(26.7)
1
1
1
119
(13.5)
8
(8.4)
24
(0.2)
2.90℃ copper wire
Voltage
Q’ty
TYPE
Resistance
value(Ω)
Q’ty
Main
terminal
Ground
-ing
Wire range
[AWG] (mm2)
Main
Control
Control
terminal
1
DB30-2C
4.0
1
1
DB37-2C
3.0
1
31.0
(3.5)
31.0
(3.5)
14
(2.1)
1
DB45-2C
2.5
1
55
1
DB55-2C
2.0
1
75
1
DB75-2C
1.6
1
1
DB110-2C
1.2
1
Applied
Motor
(kW)
30
DB Unit
TYPE
BU37-2C
37
200V
45
BU55-2C
BU90-2C
90
30
400V
Required torque [lb-inch](N.m)
Braking resistor
1
DB30-4C
15
1
37
1
DB37-4C
12
1
45
1
DB45-4C
10
1
55
1
DB55-4C
7.5
1
75
1
DB75-4C
6.5
1
BU37-4C
BU55-4C
BU90-4C
90
1
110
1
BU132-4C
DB110-4C
4.7
1
1
DB132-4C
3.9
1
160
1
DB160-4C
3.2
1
1
DB200-4C
2.6
1
1
DB220-4C
2.2
1
220
BU220-4C
15.9
(1.8)
51.3
(5.8)
119
(13.5)
31.0
(3.5)
6
(13.3)
6.2
(0.7)
14
(2.1)
51.3
(5.8)
12
(3.3)
119
(13.5)
119
(13.5)
8
(8.4)
239
(27)
239
(27)
4
(21.2)
1
132
200
119
(13.5)
10
(5.3)
24
(0.2)
Contents
1
2
Before Using This Product
1-1 Inspection at receiving the unit
1-2 Appearance
1-3 Handling of the product
1-4 Carrying
1-5 Storage
1-1
1-1
1-2
1-2
1-2
Installation and Connection
2-1 Operating environment
2-2 Installation method
2-3 Connection
2-3-1 Basic connection
2-3-2 Connecting the main circuit and
grounding terminal s
2-3-3 Connecting the control terminals
2-3-4 Terminal arrangement
2-3-5 Applicable devices and wire size as standard
2-1
2-1
2-1
2-2
2-2
2-4
2-5
2-7
2-8
3
Operation
3-1 Inspection and preparation before operation
3-1
3-1
4
Protective Operation
4-1 Protective operations
4-2 Alarm reset
4-1
4-1
4-1
5
Maintenance and Inspection
5-1 Daily inspection
5-2 Periodical inspection
5-3 Insulation test
5-4 Parts replacement
5-5 Inquiries about product and product guarantee
5-1
5-1
5-1
5-2
5-3
5-3
6
Specifications
6-1 Standard specifications
6-1-1 DB unit
6-1-2 Braking resistor
6-2 Outline dimensions
6-2-1 DB unit
6-2-2 Braking resistor
6-1
6-1
6-1
6-2
6-3
6-3
6-4
7
Option Fan
7-1 Specification
7-2 Attaching
7-2-1 Attaching
7-2-2 Wiring
7-3 Outline dimensions
7-3-1 Option fan unit
7-1
7-1
7-1
7-1
7-1
7-2
7-2
1 Before Using This Product
1-1 Inspection at receiving the unit
Unpack and inspect the unit for the following items.
If there are doubtable or complained items, contact the
distributor where the unit was purchased or the Company's
sales office nearby.
Front cover
① Check for the unit to be the ordered product by
inspecting the ratings nameplate.
Under of Unit(Mounting bord)
TYPE
: Type of the dynamic braking unit
Fig. 1-1-1 Ratings nameplate
BU 37 - 4 C
Standard series: C
AC power supply voltage series: 2→200V series、4→400V series
Rated output of the applied motor for the inverter as standard: 37→37kW
Product type
COOLING : Cooling system
SOURCE : Power rating
OUTPUT : Output rating
MASS
: Mass of the product
SER.No. : Serial number
4 3 HH12345R678-001H
Production lot serial number:
Production month: 1--9 →Jan. --Sep.
X→Oct. Y→Nov. Z→Dec.
Production year
: Last digit of year 8→1998
② Inspect if shipping damage such as damage or fall-off of the parts and depression of the cover or body.
③ Braking resistor is not attached. Prepare a resistor conforming with the specification separately.
1-2 Appearance
Front
cover
Warning
label
Nameplate
Fig. 1-2-1 Appearance
Fig. 1-2-2 Warning label
1-1
1-3 Handling of the product
(1) Removing the front cover
Loosen the mounting screws of front cover and remove the front cover by holding its upper part with
hands as shown in Fig. 1-3-1.
Mounting screws
of front cover
Fig. 1-3-1 Removing the front cover
1-4 Carrying
When carrying the product, hold only the main body of the product surely.
If holding the cover or parts, it may result in damage or fall-off.
1-5 Storage
Storage the products in the environment as shown in Table 1-5-1.
Table 1-5-1 Storage environment
Item
Specification
Ambient.
–10 to +50°C
temperature
The location without condensation or freezing by sharp
∗1
Storage
temperature change
–25 to +65°C
temperature
∗2
Relative humidity
5 to 95%
Without dust, direct sunlight, corrosive gas, inflammable gas, oil mist, vapor,
Atmosphere
water drop and vibration
Not including too much of salt
∗1:
The storage temperature means in a case of a short time such as transport.
∗2:
Although the humidity conforms to the specified value, condensation or freezing occurs in a
location of large temperature change. Avoid such location.
① Do not put the product directly on a floor.
② If the surrounding atmosphere is not good, store the product packed with a vinyl sheet etc.
③ If the humidity may affect the product, put a desiccant ( such as silica gel) into the package as shown
in .
1-2
2 Installation and Connection
2-1 Operating environment
Install the DB unit in the environment shown in Table 2-1-1.
Table 2-1-1 Operating environment
Item
Specifications
Location
Indoor
Ambient
–10 to +50℃
temperature
Relative
5 to 95% (no condensation)
humidity
Without dust, direct sunlight, corrosive gas, oil mist and vapor, water drop
Atmosphere Not including too much of salt
Without condensation by sharp temperature change
1,000m or less
Altitude
(When exceeding 1,000m, decrease the inverter output in accordance with Instruction
Manual of the inverter.)
2
2
2
Vibration
3.0mm at 2 to 9Hz, 9.8m/s at 10 to 20Hz, 4.9m/s at 20 to 55Hz, 1.0m/s at 55 to 200Hz
2-2 Installation Method
① Securly fasten the DB unit in an upright position on a solid structure
such that the characters of the label is facing the front. Do not turn the
DB unit
upside down or install in a horizontal position.
② As heat is generated during DB unit operation, the spaces shown
in Fig. 2-2-1 are required to ensure sufficient cooling pass. As
heat radiates upward, do not install the DB unit beneath a device
sensitive to heat.
Top
100m m
Right
Left
50mm
or more
③ As the cooling fins may reach a temperature of 90℃ during DB
unit operation, ensure that the material of the attaching face at
back of the DB unit can withstand this temperature.
DB Unit
50mm
or more
Bottom 100mm
Fig. 2-2-1
 WARNING
Install the DB uint on nonflammable material such as metal.
Fire may result.
④ When installing the DB unit in a control panel, consider sufficient ventilation to prevent ambient
temperature of the DB unit from exceeding the specified value. Do not install in a small tightly closed box.
⑤ If installing two or more inverters or DB units in the same device or control panel, arrange them horizontally
to minimize the effect of heat. If they must be installed vertically, place isolation plates between them to
minimize the effect of heat.
 CAUTION
Ensure that the DB unit and cooling fins are kept free of foreign matter such as lint,
paper dust, small chips of wood or metal, and dust.
Fire or accident may result.
2-1
2-3 Connection
When removing the front cover, the terminal blocks appear (see Fig. 2-3-1). Connect the cables without
mistake caring the following items.
2-3-1 Basic connection
① Connect the link circuit connection terminals (P(+), N(-)) of the DB unit to the link circuit connection
terminals (P(+), N(-)) of the inverter. If mistaking the polarity or connecting to the other terminal, the
DB unit may be damaged. Further, check the power supply voltage for conforming to the inverter
specification.
② Ensure to ground the grounding terminal to prevent disasters such as electric shock and fire and to
minimize noise.
③ Use a reliable crimp terminal for connection between a terminal and a cable.
④ After terminating the connection (wiring), check the followings:
a. Check that the connection is correct.
b. Check that all necessary connections have been made.
c. Check that there is no short-circuit or ground fault between terminals and cables.
⑤ Connection modification after power-on
The smoothing capacitor in the direct current portion of the main circuit cannot be discharged
immediately after the power is turned off. To ensure safety, use a multimeter to check that the voltage
of the direct current (DC) is lowered to the safety range (25V DC or less) after the charge lamp goes
off. Also, check that the voltage is zero before short-circuiting. The residual voltage (electric charge)
may causes sparks.
 WARNING
・ Always connect a grounding wire.
Electric shock or fire may result.
・ Ensure that a licensed specialist performs all wiring works.
・ Check that the power is turned off (open) before commencing wiring operations.
Electric shock may result.
Front view of inside the unit
Fig. 2-3-1
Front view after removing the front cover
2-2
■ Basic connection diagram
1) In case of using one DB unit and one braking resistor
Wire length
10m or less
Wire length 5m or less
Inverter
DB unit
P1
P(+)
Braking
resistor
P(+)R
P
DB
DB
P(+)
+
+
M
(*4)
CHARGE
G 1
N(-)
Main circuit
N(-)
1
2
3
G
i1 i2 o1 o2
2
SW1 CN5,6
Option
fan
1 2
(*2)
Control circuit
External
(*1)
alarm Input
CM
Fig. 2-3-2-1
2) In case of using two DB units and two braking resistors (∗3)
Wire length
10m or less
Wire length 5m or less
Inverter
P1
DB unit[Master]
P(+)
Braking
resistor
P(+)R
P
DB
DB
P(+)
+
+
M
(*4)
CHARGE
G 1
N(-)
Main circuit
N(-)
1
2
3
G
i1 i2 o1 o2
Control circuit
External
(*1)
alarm Input
2
SW1 CN5,6
Option
fan
1 2
Wire length
1.5m or less
CM
(*2)
Applied inverter series
200V class
FRENIC5000 G5/P5,G7/P7,G9S/P9S
,G11S/P11S series
FRENIC-Eco
FRENIC5000 VG3,VG 5,VG7S
400V class
FRENIC5000 G9S/P9S
,G11S/P11S series
FRENIC-Eco
FRENIC5000 VG5,VG7S
i1 i2 o1 o2
1
2
3
Option
fan
1 2
SW1
CN5,6
P(+)R
P
DB
DB
2
1
P(+)
+
CHARGE
N(-)
G
DB unit[Slave]
G
Braking
resistor
Fig. 2-3-2-2
(∗1) Among the inverters. assignment to the digital input terminals can be arbitrarily changed
in some inverters. Select the external alarm input by function setting.
(∗2) Do not short-circuit the not using terminals of the control PCB in the DB unit.
(∗3) The parallel connection of the DB units is up to two units.
When necessary to connect 3 or more DB units, contact us separately.
(∗4) Connect a lump-sum alarm output of the DB unit and braking resistor to the external alarm
input, and construct a sequence to open the electromagnetic contactor by the lump-sum
alarm output of the inverter.
2-3
2-3-2 Connecting the main circuit and grounding terminals
Table 2-3-1Functions of the main circuit terminals and grounding terminal
Terminal
Name of terminal
Description
marking
P(+), N(-)
DC link circuit terminals
Connecting to the DC link circuit voltage of the inverter
Connection terminals for
Connecting to the braking resistor
P(+)R, DB
braking resistor
G
Terminal for grounding DB unit Grounding terminal of the chassis (case) of the DB unit
(1) DC link circuit terminals (P(+) and N(-))
① Connect the DC link circuit terminals P(+) and N(-) of the inverter to the terminals P(+) and N(-) of the
DB unit.
② Arrange the wire rout so that the wire length is less than 5m. Further, arrange the two wires to be twisted
or closely contacted (parallel) wiring.
③ Do not connect to an AC power supply.
(2) Connection terminals for braking resistor (P(+)R and DB)
① Connect the terminals P and DB of the braking resistor to the terminals P(+)R and DB of the DB unit.
② Arrange the wire rout so as the wire length is less than 10m. Further, arrange the two wires to be twisted
or closely contacted (parallel) wiring.
③ Do not connect to an AC power supply.
(3) Terminal for grounding DB unit ( G)
Ensure that the terminal  G for grounding DB unit is grounded because of safety and countermeasure for
noise. To prevent disasters such as electric shock and fire, the Electric Facility Technical Standard specifies
on the grounding work for a metallic frame of electrical equipment.
Perform the connection as follows:
① In accordance with the Electric Facility Technical Standard, connect the terminal to a grounding pole
made by type D grounding for 200V series and to a grounding pole made by type C grounding for 400V
series.
② Use a suitable cable (thick and short) to connect the grounding terminal to the grounding pole specific
for the inverter system.
Table 2-3-2
Voltage
series
200V
400V
Sort of the grounding work
 CAUTION
Type D grounding
Type C grounding
Grounding
resistance
100Ωor less
10Ω or less
・ Do not connect an AC power supply to the DC link circuit terminals (P(+) and
N(-)).
Damage may result.
・ Do not directly connect the braking resistor to the DC link circuit terminals (P(+)
and N(-)).
・ Check that the product specification complies with the inverter to be connected.
・ When the DB unit is damaged, the braking resistor may abnormally heated.
Make a sequence to interrupt the power supply on the inverter side by an alarm
signal.
Fire may result.
2-4
2-3-3 Connecting the control terminals
Function descriptions of the control terminals are shown in Table 2-3-3.
Table 2-3-3
Terminal
marking
Name of terminal
Function description
Connecting the DB drive signal wire of the unit on the
slave unit (∗1) side when using the units in parallel
Connecting the DB drive signal wire of the unit on the
DB driving signal output terminals
o 1, o 2
master unit (∗2) side when using the units in parallel
Outputting the alarm for overheat and blown fuse of
1, 2
DB unit lump-sum alarm output
DB driving IGBT and braking resistor, and conduction
abnormal of DB driving IGBT
Connectors for power supply of
Connecting power supply of option fans when installing
CN5, CN6
option fans
them
(∗1) The unit operating by receiving DB driving signal from the unit on the master side
(∗2) The unit operating by detecting DB operation level by itself from the link circuit voltage
i1, i2
DB driving signal input terminals
(1) DB driving signal input terminals (i1 and i2)
DB driving signal output terminals ( o 1 and o 2)
① These terminals connect between master and slave
when using 2 DB units.
② To reduce the noise effect from outside, use twisted
wires as short as possible (1.5m or less).
③ Change over the settings of master and slave in the DB
units with SW1 on the PCB as shown in Fig. 2-3-3.
④ When using single DB unit, set the SW1 as shown in a).
⑤ Do not short-circuit not used terminals.
(2) DB unit lump-sum alarm output (1 and 2)
① Connect the terminals of the DB units and braking
resistors in series in the order of 1212 to the
contact input terminals of the inverter which are
assigned external alarm input to.
When used a short-circuit conductor on the contact
input terminals to be connected on the inverter side,
remove the short-circuit conductor.
(3) Connectors for power supply of option fans (CN5 and
CN6)
① When using option fans, the power supply lines of the
fans are connected to these terminals.
② Connectors CN5 and CN6 have a same function.
③ Do not short-circuit these connectors because of power
supply connection.
a)Unit connecting
the terminals o1 and o2(Master side)
SW1
1
2
3
SW1
b)Unit connecting
the terminals i1 and i2(Slave side)
SW1
1
2
3
SW1
Fig. 2-3-3 Changeover of SW1
Switch
SW1
Control
(4) Others
circuit
block
① Perform the wiring of the control terminals separating
from the wiring of the main circuit as far as possible.
Otherwise, malfunction by noise may be caused.
② Fix the control wiring inside the unit so as not to directly
CN5 CN6
contact with a live part of the main circuit (e. g. main
circuit terminal block).
Fig 2-3-4 Control PCB
③ The parallel connection of the DB units is up to two units.
When necessary to connect 3 or more DB units, contact
us separately.
• Since the insulation of control cable is generally not of reinforced insulation,
high voltage may intrude into the control signal if insulation sheath is broken by
any cause.
Electric shock may result.
• A noise is generated from inverter, motor,wiring. etc. Take care on malfunction
of sensors and devices in the surroundings.
• Be sure not to move the setting of the variable resistor VR1 on the control PCB
since it has been adjusted.
Accident may result.
 WARNING
 CAUTION
2-5
(5) Wiring of the control circuit
① Lead out the cable along the left side panel as shown in Fig. 2-3-5.
② Secure the cable to cable-tie holder on the left wall of the main circuit terminal block on the way of lead out
using a cable-tie (e. g. insulock). The cable-tie must not exceed 3.5mm or less in width and 1.5 mm or less
in thickness to pass through a rectangular hole (3.8×1.5).
Cables of
control circuit
Cable-tie
Cables
Cable-tie
holder
Side panel (LEFT)
Fig. 2-3-5
Route of control circuit wiring
2-6
2-3-4 Terminal arrangement
(1) Main circuit terminals
BU220-4C
BU37-2C
Screw size M5
P(+)
N(-) P(+)R
Screw size M10
DB
P(+)
N(-)
P(+)R
DB
G G
G
Screw size M5
BU37-4C
(2) Control terminals
Screw size M4
P(+)
N(-)
Screw size M3
P(+)R
DB
i1
G G
Screw size M5
BU55-2C
Screw size M8
P(+)
N(-) P(+)R
DB
G G
Screw size M8
BU55-4C
Screw size M6
P(+)
Screw size M6
N(-)
G G
P(+)R
DB
Screw size M5
BU90-2C
BU-132-4C
Screw size M8
P(+)
N(-)
G
P(+)R
DB
G
BU90-4C
Screw size M6
P(+)
G
N(-)
G G
P(+)R
DB
2-7
i2
o1
o2
1
2
2-3-5 Applicable devices and wire size as standard
Voltag
e
200V
400V
Applied
motor
(kW)
30
37
45
55
75
90
30
37
45
55
75
90
110
132
160
200
220
DB unit
Type
BU37-2C
BU55-2C
BU90-2C
BU37-4C
BU55-4C
BU90-4C
BU132-4C
BU220-4C
Tightening torque
Recommended wire size
2
(N・m)
(mm ) ∗1)
Resistance
Main GroundDB cct.(P(+), Ground.
No.
Control
Control
N(-),P(+)R,DB) ( G)
circuit
ing
value (Ω)
4.0
1
2
3.5
3.0
1
3.5
2.5
1
1.25
0.7
2.0
1
5.5
13.5
1.6
1
8
1.2
1
14
15
1
1.8
12
1
3.5
2
10
1
5.8
7.5
1
6.5
1
3.5
1
0.7
1.25
4.7
1
13.5
5.5
3.9
1
3.2
1
8
2.6
1
27
14
2.2
1
Braking resistor
No.
Type
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DB30-2C
DB37-2C
DB45-2C
DB55-2C
DB75-2C
DB110-2C
DB30-4C
DB37-4C
DB45-4C
DB55-4C
DB75-4C
DB110-4C
DB132-4C
DB160-4C
DB200-4C
1 DB220-4C
∗2)
∗1) The type of using wire is 75°C 600V Grade heat-resistant
polyvinyl chloride insulated wire (HIV).
The above-mentioned wire sizes are the recommended size
under the condition of the ambient temperature 50°C or lower.
∗2) A DB220-4C set is constructed by 2 cabinets.
These 2 resistors are used connecting in parallel.
2-8
3 Operation
3-1 Inspection and preparation before operation
Inspect the following items before operation
DB unit
① Check that the connection is correct.
In particular, check the following points:
 G, P(+), N(-), P(+)R, DB
a. Check that the AC power supply is not connected to
any of DC link circuit terminals P(+) and N(-) or
connection terminals for braking resistor P(+)R and DB.
DB
P(+)
P
b. Check that the DC link circuit voltage is not connected
to the connection terminals for braking resistor P(+)R
and DB.
N(-)
Inverter
c. Check that
grounded.
Fig. 3-1-1 DB unit connection diagram
the
grounding
terminal
is
securely
Braking
resister
② Check for short-circuits and ground faults between the
terminals and live sections.
③ Check for loose terminals, connectors, or screws.
Check the followings after power-on.
① Check that no external alarm message is displayed on the inverter.
② Check that the CHARGE lamp is turned off.
③ Check that the fans are rotating (when using option fans).
 WARNING
• Be sure to put on the front cover before turning on the power (close). Never
remove the cover while the power is applied to the inverter.
Electric shock may result.
3-1
4 Protective Operation
4-1 Protective operations
In the event of abnormality as shown in Table 4-1, the DB unit stops DB driving signal and outputs a lump-sum
alarm signal from the terminals 1 and 2 (The lump-sum alarm signal has no distinction of the abnormality
contents.).
By this alarm signal, the protective function of the inverter will be immediately activated to trip the inverter and
display the external alarm on the keypad panel, and the motor coasts-to-a stop.
Since the braking resistor may be overheated when the DB unit is out of order, construct a sequence to trip the
power supply in the case of activation of the inverter protective function.
Table 4-1
Abnormality
Blown fuse
Contents
If the fuse in the main circuit of the DB unit is blown out following a short-circuit in
the circuit or damage, the protective function is activated.
Overheating of the
If the cooling fins overheat following frequent use of braking exceeding the
cooling fins
specification, high ambient temperature or clog of the fins, the protective function
is activated.
Conduction abnormal of If detecting conduction of IGBT (switching element) although stopping of the DB
IGBT(switching element) driving signal, the protective function is activated.
Overheating of the
If the braking resistor overheats following high-frequent use of the braking
braking resistor
resistor, the protective function is activated.
4-2 Alarm reset
If becoming the trip status, release the trip in accordance with the instruction of the inverter Instruction Manual
after removing the cause of the trip.
When releasing the trip status, set the operation command to OFF. Take care, if the operation command is set
to ON, the inverter starts operation after resetting.
 WARNING
If the alarm reset is activated with the operation signal ON, the inverter will restart
suddenly, which may be dangerous. To ensure safety, release the trip status after
checking the operation signal OFF.
Accident may result.
4-1
5
Maintenance and Inspection
Proceed with the daily inspection and periodic inspection to prevent malfunction and ensure long-term reliability.
Note the followings in the inspection works.
5-1 Daily inspection
During opera t ion of the inverter, a visual inspection for abnormality is performed externally without removing the
covers.
The inspection usually covers the followings:
① The performance (satisfying the standard specification) is as expected.
② The environment satisfies the standard specification.
③ There are abnormal sounds, vibrations, or odors.
④ There are no indications of overheating or no discoloration.
5-2 Periodical inspection
Periodical inspection must be performed after stopping operations, turning off the power supply, and removing
the front cover.
Note that after turning off the power supply, the smoothing capacitor in the DC section in the main circuit takes
the time to discharge. To prevent electric shock, check that the voltage has dropped below the safety value (25V
DC or below) using a multimeter after the charge lamp (CHARGE) goes off.
• Start the inspection at least ten minutes after turning off the power supply.
Further check that the charge lamp (CHARGE) goes off, and that the voltage is
25V DC or below between the terminals P(+) and N(-).
Electric shock may result.
• Only authorized personnel should perform maintenance and component
replacement operation.
Take off metal jewelry such as watches and rings.
Use insulated tools.
Never modify the product.
Electric shock or injury may result.
 WARNING
Table 5-2-1
Periodical inspection list
Check part
Environment
Voltage
Check items
How to inspect
Check the ambient temperature, humidity,
vibration, atmosphere (dust, gas, oil mist, water
drops).
Is the area surrounding the equipment is clear
without left foreign body such as tool or
dangerous body.
Are the voltages in the main and control circuits
normal?
Is there abnormal sound or vibration?
Main circuit
Structure such
Are nuts or bolts loose?
as a frame or
Is there deformation or damage?
cover
Is there discoloration as a result of overheating?
Are there stains and dust?
Are there loose or missing nuts or bolts?
Are there deformation, crack, damage, and
Common discoloration due to overheating or deterioration
in the equipment and insulation?
Are there stains and dust?
Is there discoloration or distortion a conductor
Conductor due to overheating?
Are there cracks, crazing or discoloration of the
and wire
cable sheath?
Terminal
block
Is there damage?
Evaluation criteria
Conduct visual
inspection and use the
meter.
The specified
standard value must
be satisfied.
Visual inspection
The area is clear.
Measure using the
multimeter.
Visual and aural
inspection
Tighten.
The specified standard
value must be satisfied.
Not abnormal
Visual inspection
Not abnormal
Tighten.
Not abnormal
Not abnormal
Note: Discoloration of
the bus bar does not
indicate a problem.
Visual inspection
Not abnormal
Visual inspection
Not abnormal
Visual inspection
Not abnormal
Visual inspection
Not abnormal
Is there electrolyte leakage, discoloration,
Smoothing crazing or swelling of the case?
capacitor Is the safety valve not protruding or are valves
protruding too far?
5-1
Cooling circuit
Control circuit
Main circuit
(continued)
Is there unusual odor or damage to the insulation Olfactory and visual
by overheating?
inspection
Conduct a visual
Resistor
inspection or use a
Is there an open circuit?
multimeter by removing
the connection on one
side.
Are there any loose screws or connectors?
Tighten
Is there unusual odor or discoloration?
Control
Olfactory and visual
Are there cracks, damage, deformation, or
PCB and
inspection
excessive rust?
connector
Is there electrolyte leakage or deformation to the Visual inspection
capacitor?
Aural and visual
inspection. Turn it
Is there abnormal sound or vibration?
manually. (Check the
Cooling fan
power supply is off.)
Are nuts or bolts loose?
Tighten
Is there discoloration due to overheating?
Visual inspection
Is there foreign matter on the fins or intake and
Ventilation
Visual inspection
exhaust ports?
Not abnormal
Less than about ±10%
of the indicated
resistance value
Not abnormal
The fan must rotate
smoothly.
Not abnormal
Not abnormal
Not abnormal
Note: If the equipment stained, wipe with a cleaning cloth of chemical neutrality. Vacuum the dust.
5-3 Insulation test
Avoid testing the DB unit with a megger because an insulation test is completed at the factory. If a megger test
must be conducted, proceed as described below. Use of an incorrect test method may result in product damage.
If the specifications for dielectric strength test are not followed, the product may be damaged. If a dielectric
strength test must be performed, contact your local distributor or nearest Fuji Electric's sales office.
(1) Megger test for the main circuit
① Use a 500V DC type megger and isolate the main power supply before commencing measurement.
② If the test voltage is applicable to the control circuit, remove all connection cables to the control circuit.
③ Connect the main circuit terminals using common cables as shown in Fig. 5-3-1.
④ Execute the megger test only between the common cables connected to the main circuit and the ground
(terminal  G).
⑤ A megger indicating 5MΩ or more is normal. (This is the value measured with a DB unit only.)
G
N(-)
-
+
-
P(+)
P(+)R
DB
+
Megger
Fig. 5-3-1
Megger test
(2) Insulation test for the control circuit
A megger test and a dielectric test must not be performed in the control circuit. Prepare a high resistance
range multimeter for the control circuit.
① Remove all external cables from the control circuit terminals.
② Conduct a continuity test between the control circuits and the ground. A result of 1 MΩ or more is
normal.
(3) Exterior main circuit and sequence control circuit
Remove all cables from the terminals to ensure the test voltage is not applied to the DB unit.
5-2
5-4 Parts replacement
Each part has a life determined by the sort of the part.
Since the life expectancy of a part differs depending on the environment and using conditions. It is
recommended to replace parts at the timing shown in Table 5-4-1 as standard.
As for replacement method, contact your local distributor or nearest Fuji Electric's sales office separately.
Table 5-4
Parts replacement
Part name
Cooling fan
Smoothing capacitor
Electrolytic capacitor on the PCB
Fuse
Other parts
Standard period
Comments
for replacement
3 years
Exchange for a new part
Exchange for a new part
5 years
(determined after checking)
Exchange for a new part
7 years
(determined after checking)
10 years
Exchange for a new part
Determined after checking
-
5-5 Inquiries about product and product guarantee
(1) Inquiries
If there is damage or failure in the product, or questions concerning the product, contact your local
distributor or nearest Fuji Electric's sales office with following items.
a. DB unit type
b. SER NO.(Manufacturer's serial number))
c. Purchased time
d. Inquiry details (e. g. location and extent of damage, questions, and status of failure)
(2) Product guarantee
The product guarantee term is one year after purchase or 18 month from the year and month of
manufacture on the nameplate, whichever expires first. However, the guarantee will not apply in the
following cases, even if the guarantee term has not expired.
① Damage was caused by incorrect use or inappropriate repair and modification.
② The product was used outside the standard specified range.
③ Damage was caused by dropping the product or damage during transportation after purchasing.
④ Damage was caused by an earthquake, fire, storm and flooding, lightening, abnormal voltage or
other natural calamities and their secondary disasters.
5-3
5-4
6 Specifications
6-1 Standard specifications
6-1-1 DB unit
Series
200V
400V
Type
BU37-2C BU55-2C BU90-2C BU37-4C BU55-4C BU90-4C BU132-4C BU220-4C
Min. connectable
3.0
2.0
1.2
12
7.5
4.7
3.0
1.9
resistance (Ω)
Max. braking power
37
56
90
37
56
90
135
240
(kW)
Generated loss
40
50
60
35
40
50
60
80
(10%ED) (W)
Rated current
25
37
61
12
19
31
47
79
(A r.m.s)
Mass (kg)
4
6
9
4
5.5
5.5
9
13
Braking torque
100% (at standard applying to G11S)
Duty factor
10%ED (30%ED when using option fans)
∗1, ∗2
Braking time
10s: Period of 100s (30s when using option fans)
∗1, ∗2
Operating voltage (V)
365
758
When detecting abnormalities described left,
• Blown fuse
the operation of the IGBT in the DB unit is
• Cooling fin overheat
• Abnormal operation of IGBT stopped, and an alarm is output to the inverter
Protection function
unit
(Switching element)
• Braking resistor overheat
Cooling system
Self-ventilation (forced ventilation when using option fans)
Indoor
Installation location
Altitude of 1000m or less
Free from corrosive gas. dust and direct sunlight
Ambient temperature
−10℃ to +50℃
∗1) Duty factor (%ED) and braking time are converted into the condition of deceleration braking as shown
below.
Duty factor %ED=( T1/T0 ) X 1 00%
T1 : Braking time (10s)
Braking
power
T0 : Repetitive period (100s)
Max.
Braking power
T1
T1
T0
The rated current value is an r.m.s value of the current in TD section.
∗2) When using the option fans, the duty factor (%ED) is calculated making the braking time (T1) 30s.
※ This DB unit are applicable to the following inverter units.
・200V series: FRENIC5000 G5/P5,G7/P7,G9S/P9S,G11S/P11S series
FRENIC-Eco series, FRENIC5000 VG3,VG 5, VG7S series
・400V series: RENIC5000 G9S/P9S,G11S/P11S series, FRENIC-Eco series
FRENIC5000 VG5 series
6-1
6-1-2 Braking resistor
200V series
Type
DB30-2C DB37-2C DB45-2C DB55-2C DB75-2C DB110-2C
Nominal applied
30
37
45
55
75
90,110
motor (kW)
Resistance value
4.0
3.0
2.5
2.0
1.6
1.2
(Ω)
Max. capacity (kW)
30
37
45
55
83
113
Flowing current (A)
19
25
30
37
48
61
Mass (kg)
10
13
18
22
35
32
400Vseries
Type
DB30-4C DB37-4C DB45-4C DB55-4C DB75-4C DB110-4C DB132-4C DB160-4C DB200-4C DB220-4C
Nominal applied
30
37
45
55
75
90,110
132
160
200
220
motor (kW)
Resistance value
15
12
10
7.5
6.5
4.7
3.9
3.2
2.6
2.2
(Ω)
Max. capacity (kW)
30
37
45
55
83
113
135
165
200
240
Flowing current (A)
10
12
15
19
24
34
41
50
62
71
Mass (kg)
11
14
19
21
26
30
41
57
43
74
Duty factor
Braking time
Ambient
temperature
10%ED (refer to DB unit standard specifications ∗1)
∗3
10s: Period of 100s (refer to DB unit standard specifications ∗1) ∗4
−10°C to +50°C
∗3) When using option fans, the duty factor become 30%ED.
∗4) When using option fans, the braking time becomes 30s.
6-2
6-2 Outline dimensions
6-2-1 DB unit
FIG. B
図B
2-ØC
C
W2
H4
H2
H1
H
W2
H3
D1
H1
W
H4
H3
W1
D
H2
ØC
W
D1
C
M OU NT IN G D IM EN SIO NS
取付寸法
M OU NT ING DIM EN SIONS
3- 取付ボルト
HO LE S FO R
FIXIN G BOLTS
取付寸法
4- 取付ボルト
HO LES FO R
FIXING BO LTS
W2
H1
H1
W3
D
H
FIG. A
図A
W2
[200 V series]
TYPE
BU37-2C
BU55-2C
BU90-2C
FIG
A
B
DIMENSIONS
W W1 W2 W3 H
150 75 100 50
240
230
130
-
-
250
150
370
[mm]
H1
H2
225
210
355
340
H3 H4
7.5
15
D
160
D1
1.2
BOLT
MASS
(kg)
M5
4
6
9
BOLT
MASS
(kg)
C
6
2.4
[400 V series]
TYPE
BU37-4C
BU55-4C
BU90-4C
BU132-4C
BU220-4C
DIMENSIONS
FIG
W W1 W2 W3
150
100
B
230
250
-
130
150
[mm]
H
H1
H2
280
265
250
H3 H4
D
D1
C
4
-
1.2
7.5 15 160
370
450
355
435
340
420
6-3
6
2.4
M5
5.5
9
13
6-2-2 Braking resistor
Main circuit
Terminal
Control circuit
Terminal
1. 6
H
FIG. A
W1
D1
4- φ C
W
D
Control circuit
Terminal
Main circuit
Terminal
H
H1
FIG. B
W1
W
D1
4- φ C
D
[200V series]
TYPE
DB30-2C
DB37-2C
DB45-2C
DB55-2C
DB75-2C
DB110-2C
FIG
A
B
W
660
750
450
550
DIMMENSIONS [mm]
W1
H
H1
140
628
—
240
718
420
283
43
520
SCREW
D
D1
C
MAIN CONTROL
CIRCUIT CIRCUIT
BOLT
M5
400
368
10
M4
M8
M3.5
M10
M6
440
250
12
M8
MASS
[kg]
10
13
18
22
35
32
[400V series]
TYPE
FIG
W
DIMMENSIONS [mm]
W1
H
H1
140
628
—
240
718
SCREW
D
D1
C
MAIN CONTROL
CIRCUIT CIRCUIT
DB30-4C
M4
660
420
DB37-4C
A
388
10
M4
DB45-4C
M5
DB55-4C
750
425
DB75-4C
M8
550
520
DB110-4C
DB132-4C
650
620
283
43
440
250
12
B
M3.5
DB160-4C
M10
750
720
DB200-4C
DB220-4C※
600
570
※ DB220-4C becomes a product with two blocks of the above-mentioned size.
6-4
BOLT
MASS
[kg]
11
14
M8
19
21
26
30
41
M10
57
43
74(37×2)
7 Option Fan
In this DB unit, the braking time and duty factor can be rise by using option fans.
Standard specification
When using option fans
Braking time
10s
30s
Duty factor
10%ED
30%ED
(Refer to Chapter 6 DB unit standard specifications, ∗1 and ∗2)
7-1 Specification
Type
Mass
Ambient temperature
BU-F
230g
−10°C to +50°C
7-2 Attachment
7-2-1 Attachment (Fig. 7-2-1)
① Fix a fan unit on the upper part of the UB unit with fixing screws for the fan unit (at 2 positions).
(The fixing screws for the fan unit are attached on the upper part of the fan unit.)
② Since the wiring hole is closed, open the hole so that the cable can pass through.
Optional Fan unit
Fixing screws
Cables
Inlet hole
Top cover
Fig. 7-2-1 Attaching the option fan unit
7-2-2 Wiring (Fig. 7-2-2)
① Pull in power supply connectors for the fans with cables through the wiring hole on the upper part
of the UB unit.
② Connect the power supply connectors for the fans to connectors CN5 and CN6 on the control PCB.
③ Secure the cable to a cable-tie holders at near the wiring hole and left lower part of the control PCB
using cable-ties (e.g. insulock).
The cable-tie must not exceed 3.5 mm or less in width and 1.5mm or less in thickness to pass
through a rectangular hole (3.8×1.5).
Cable-tie
Cables
Cable-tie holder
Cables
Cable-tie
Power supply C onnectors
(CN5, CN6)
Cable-tie holder
Fig. 7-2-2 Wiring of the option fans
7-1
7-3 Dimensions
7-3-1 Option fan unit
FAN UNIT
DB UNIT + FAN UNIT
W
W5
D
D3
H6
W6
H5
H
H7
L
D2
W4
[Fan unit]
TYPE
BU-F
W4
149
DIMENSIONS
H5
D2
44
76
[mm]
L(Power supply)
320
[DBunit + Fan unit]
[200V series]
TYPE
BU37-2C+BU-F
BU55-2C+BU-F
BU90-2C+BU-F
W
150
230
250
W5
135
DIMENSIONS
W6
H
H6
7.5
240
30
47.5
57.5 370
H7
270
D
D1
[mm]
D3
160
1.2
64
D
D1
[mm]
D3
160
1.2
64
400
[400V series]
TYPE
BU37-4C+BU-F
BU55-4C+BU-F
BU90-4C+BU-F
BU132-4C+BU-F
BU220-4C+BU-F
W
150
230
250
W5
135
DIMENSIONS
W6
H
H6
7.5
280
47.5
30
370
57.5
450
7-2
H7
310
400
480
D1
Edition history
Edition
–
a
b
c
Date of issue
Sep. 1999
Oct. 2001
Oct. 2003
May 2004
Content
First edition
Correct : Section 2 Fig 2-3-3(Terminal Name)
Change the corporation name
Change the corporation logotype
Change the “Table A Applicable inverter models”
Add the “Compliance with UL/cUL standards[Applicable to products with UL/cUL
mark]”
Correct : Section 2-3-1 Fig.No. Fig.2-3-2 → Fig.2-3-2-1, Fig.2-3-3 → Fig.2-3-2-2
Section 6-2-2 FIG. B(Terminal Name)
Preface, Section 2, Section 5, Section 6, Section 7
Misprint
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome
Shinagawa-ku, Tokyo 141-0032, Japan
Phone: +81-3-5435-7139 Fax: +81-3-5435-7458
2