Fuji Electric BUC-D Series User manual

Instruction Manual
Stack Type Dynamic Braking Unit
BUC-D Series (690V Type)
Thank you for purchasing our dynamic braking unit (BUC-D Series).
• 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. Read through this instruction manual to become familiar with proper handling and correct use.
• Improper handling might result in incorrect operation, a short life, or even a failure of this product.
• Deliver this manual to the end user of this product. Keep this manual in a safe place until this product is discarded.
• For the installation and selection of peripheral equipment exclusive to the stack type of inverters, refer to the
FRENIC-VG User's Manual (Stack Type Edition).
• For the configuration of the inverter functions and operating procedure, refer to the FRENIC-VG User's Manual (Unit
Type / Function Codes Edition).
• For details about PWM converters and diode rectifiers, refer to the FRENIC-VG User's Manual (Stack Type Edition).
Fuji Electric Co., Ltd. INR-SI47-1846-E

Copyright © 2014 Fuji Electric Co., Ltd.
All rights reserved.
No part of this publication may be reproduced or copied without prior written permission
from Fuji Electric Co., Ltd.
All products and company names mentioned in this manual are trademarks or registered
trademarks of their respective holders.
The information contained herein is subject to change without prior notice for
improvement.

Preface
Thank you for purchasing our dynamic braking unit (BUC-D Series).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.
Read through this instruction manual to become familiar with proper handling for correct use. Improper handling might result
in incorrect operation, a short life, or even a failure of this product as well as the motor.
The related documents are subject to change without notice. Be sure to obtain the latest editions for use.
List of applicable inverters
The table below lists the inverters that can be used in combination with this product.
Inverter series Capacity Inverter type Stack/unit type
VG series All capacities FRNSVG1S-69Stack type
Table of Contents
Preface i
Safety precautions ................................................................................................................................................................. iii
Chapter 1 BEFORE USE ......................................................................................................................................................... 1
1.1 Acceptance Inspection.................................................................................................................................................. 1
1.2 External Appearance..................................................................................................................................................... 2
1.3 Precautions for Using dynamic breaking unit............................................................................................................... 3
1.3.1 Installation environment .......................................................................................................................................3
1.3.2 Storage environment .............................................................................................................................................5
[ 1 ] Temporary storage ................................................................................................................................................5
[ 2 ] Long-term storage.................................................................................................................................................5
Chapter 2 MOUNTING AND WIRING .................................................................................................................................. 6
2.1 Mounting the dynamic breaking unit............................................................................................................................ 6
2.1.1 Terminal Arrangement and Screw Sizes (Main circuit terminals).........................................................................7
[ 1 ] Rank 4 (500 kW)................................................................................................................................................7
2.2 Wiring........................................................................................................................................................................... 8
2.2.1 Connection diagram..............................................................................................................................................8
2.2.2 Removing and mounting the front cover and the wiring guide...........................................................................10
2.2.3 Basic Connections...............................................................................................................................................11
2.2.4 Main circuit terminals.........................................................................................................................................11
[ 1 ] Screw specifications and recommended wire sizes (main circuit terminals) ....................................................11
[ 2 ] Terminal functions (main circuit terminals) .....................................................................................................12
2.2.5 Control circuit terminals .....................................................................................................................................12
[ 1 ] Screw specifications and recommended wire sizes (control circuit terminals)................................................12
[ 2 ] Terminal arrangement (control circuit terminals) .............................................................................................12
[ 3 ] Detailed functions of control circuit terminals .................................................................................................13
[ 4 ] Wiring for the control circuit............................................................................................................................16
2.2.6 Setting up the slide switches ...............................................................................................................................18
2.2.7 Fan power switching connector CN UX .............................................................................................................19
2.2.8 Connecting optical fiber cable ............................................................................................................................20
Chapter 3 TEST RUN PROCEDURE.................................................................................................................................... 21
3.1 Checking Prior to Powering On.................................................................................................................................. 21
3.2 Powering ON and Checking ....................................................................................................................................... 21
Chapter 4 TROUBLESHOOTING ........................................................................................................................................ 21
4.1 Protective Functions ................................................................................................................................................... 21
4.2 Before Proceeding with Troubleshooting ................................................................................................................... 21
4.3 Troubleshooting.......................................................................................................................................................... 22
4.3.1 List of Protective Functions................................................................................................................................22
4.3.2 Possible causes of alarms, checks and measures.................................................................................................22
[ 1 ] Overcurrent ......................................................................................................................................................22
[ 2 ] Overvoltage ......................................................................................................................................................23
[ 3 ] DC Fuse blown.................................................................................................................................................23
[ 4 ] Memory error ...................................................................................................................................................23
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ii
[ 5 ] CPU error .........................................................................................................................................................23
[ 6 ] Hardware error .................................................................................................................................................24
[ 7 ] Heat sink overheat............................................................................................................................................24
[ 8 ] Dynamic breaking unit internal overheat..........................................................................................................24
[ 9 ] Inter- dynamic breaking unit communications link error .................................................................................24
Chapter 5 MAINTENANCE AND INSPECTION ................................................................................................................ 25
5.1 Inspection Interval ...................................................................................................................................................... 25
5.2 Daily Inspection.......................................................................................................................................................... 25
5.3 Periodic Inspection ..................................................................................................................................................... 26
5.4 List of Periodic Replacement Parts............................................................................................................................. 27
5.5 Insulation Test............................................................................................................................................................. 27
5.6 Inquiries about Product and Guarantee....................................................................................................................... 28
5.6.1 When making an inquiry.....................................................................................................................................28
5.6.2 Product warranty.................................................................................................................................................28
[ 1 ] Free of charge warranty period and warranty range .........................................................................................28
[ 2 ] Exclusion of liability for loss of opportunity, etc. ............................................................................................29
[ 3 ] Repair period after production stop, spare parts supply period (holding period)..............................................29
[ 4 ] Transfer rights ..................................................................................................................................................29
[ 5 ] Service contents................................................................................................................................................29
[ 6 ] Applicable scope of service..............................................................................................................................29
Chapter 6 SPECIFICATIONS................................................................................................................................................ 29

Safety precautions
Read this manual thoroughly before proceeding with installation, connections (wiring), operation, or maintenance and
inspection. Ensure you have sound knowledge of the device and familiarize yourself with all safety information and
precautions before proceeding to operate the inverter.
Safety precautions are classified into the following two categories in this manual.
Failure to heed the information indicated by this symbol may lead to dangerous conditions,
possibly resulting in death or serious bodily injuries.
Failure to heed the information indicated by this symbol may lead to dangerous conditions,
possibly resulting in minor or light bodily injuries and/or substantial property damage.
Failure to heed the information contained under the CAUTION title can also result in serious consequences. These safety
precautions are of utmost importance and must be observed at all times.
Application
• This product 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 or an accident could occur.
• The dynamic braking unit may not be used for a life-support system or other purposes directly related to the human
safety.
• Though the dynamic braking unit is manufactured under strict quality control, install safety devices for applications
where serious accidents or property damages are foreseen in relation to the failure of it.
An accident could occur.
Installation
• Install the dynamic braking unit on a base made of metal or other non-flammable material.
Otherwise, a fire could occur.
• Do not place flammable object nearby.
Doing so could cause fire.
• The dynamic braking unit whose protective structure is IP00 involves a possibility that a human body may touch the
live conductors of the main circuit terminal block. Install the dynamic braking unit in an inaccessible place.
Otherwise, electric shock or injuries could occur.
• Do not support the dynamic braking unit by its front cover during transportation.
Doing so could cause a drop of the inverter and injuries.
• Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the dynamic
braking unit or from accumulating on the heat sink.
• When installing the dynamic braking unit, use screws and bolts specified in the installation procedure and tighten
them with the specified tightening torque.
Otherwise, a fire or an accident might result.
• Do not install or run an dynamic braking unit that is damaged or lacking parts.
Doing so could cause fire, an accident or injuries.
iii

Wiring
• Do not connect the DC terminals (P(+) and N(-)) to the connection terminals on the inverter side in mistake for the
polarity （+ and –）.
• Use wires in the specified size.
• Tighten terminals with specified torque.
Otherwise, a fire could occur.
• Be sure to ground the grounding terminals ( G).
Otherwise, an electric shock or a fire could occur.
• Qualified electricians should carry out wiring.
• Be sure to perform wiring after turning the power OFF.
• Be sure to perform wiring after installing the inverter unit.
Otherwise, an electric shock could occur.
• In general, sheaths of the control signal wires are not specifically designed to withstand a high voltage (i.e.,
reinforced insulation is not applied). Therefore, if a control signal wire comes into direct contact with a live
conductor of the main circuit, the insulation of the sheath might break down, which would expose the signal wire to
a high voltage of the main circuit. Make sure that the control signal wires will not come into contact with live
conductors of the main circuit.
Doing so could cause an accident or an electric shock.
• Before changing the slide switches on the control printed circuit board, turn the power OFF, wait at least ten
minutes, and make sure that the charging lamp are turned OFF. Further, make sure, using a multimeter or a similar
instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped to the safe level (+25 VDC
or below).
An electric shock could occur.
• The PWM converter, inverter, motor and wiring generate electric noise. Be careful about malfunction of the nearby
sensors and devices. To prevent them from malfunctioning, implement noise control measures.
Otherwise an accident could occur.
Operation
• Be sure to mount the front cover before turning the power ON. Do not remove the cover when the inverter power is
ON.
Otherwise, an electric shock could occur.
• Do not operate switches with wet hands.
• Do not touch the terminals of the dynamic braking unit in energized state of the inverter even if the inverter has
stopped.
Doing so could cause electric shock.
• Do not touch the heat sink because it becomes very hot.
Doing so could cause burns.
• The braking with this dynamic braking unit cannot function as mechanical holding.
Injuries could occur.
iv

Maintenance and inspection, and parts replacement
• Before changing the slide switches on the control printed circuit board in maintenance or inspection, turn the
power OFF, wait at least ten minutes, and make sure that the charging lamp are turned OFF. Further, make sure,
using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has
dropped to the safe level (+25 VDC or below).
Otherwise, an electric shock could occur.
• Maintenance, inspection, and parts replacement should be made only by qualified persons.
• Take off the watch, rings and other metallic objects before starting work.
• Use insulated tools.
Otherwise, an electric shock or injuries could occur.
• Never modify the inverter.
Doing so could cause an electric shock or injuries.
Disposal
• Treat the dynamic braking unit as an industrial waste when disposing of it.
Otherwise injuries could occur.
General precautions
Drawings in this manual are illustrated without the front cover or safety shields for explanation of detail parts. Do not turn
the power ON when the dynamic braking unit is as shown in drawings. Be sure to restore the covers and shields in the
original state before running the dynamic braking unit.
Icons
The following icons are used throughout this manual.
This icon indicates information which, if not heeded, can result in the dynamic braking unit not operating to full
efficiency, as well as information concerning incorrect operations and settings which can result in accidents.
This icon indicates information that can prove handy when performing certain settings or operations.
This icon indicates a reference to more detailed information.
v

Chapter 1 BEFORE USE
1.1 Acceptance Inspection
Unpack the package and check the following:
(1) A dynamic braking unit and the following accessories are contained.
Accessories - Instruction manual (this document)
(2) The dynamic braking unit has not been damaged during transportation—there should be no dents or parts missing.
(3) The dynamic braking unit is the type you ordered. You can check the type and specifications on the main and sub
nameplates. (The main and sub nameplates are attached to the dynamic braking unit as shown in Figures 1.2-1.)
1
(a) Main Nameplate (b) Sub Nameplate
Figure 1.1-1 Nameplates
BUC500S-69D
- -
1093V DC
594A
- -
- - -
500kW CONT.
135 kg
BUC50
0S
-
69D
TYPE: Type of the dynamic breaking unit
BUC 500 69 DS
Product Type：BUC
Rated output
Structure： S→stack type Voltage class： 69→690V
Series name：BUC-D series
SOURCE : Power ratings
OUTPUT : rated output capacity
MASS : Mass of the dynamic breaking unit in kilogram
SER. No. : Product number
2 8 A 4 5 6 A 0 0 0 1 AA 23 2
Production week
This indicates the week number that is numbered
from the 1st week of January.
The 1st week of January is indicated as "01."
Production year: Last digit of year
Product version
If you suspect the product is not working properly or if you have any questions about your product, contact your Fuji Electric
representative.

1.2 External Appearance
(1) Outside and inside views
Keypad
enclosure
Hoist hole
φ26
Cooling fans
N(-) bar
P(+) barHandle
Warning
plate
Handle
Front cover Hoist holes
φ26
Controle circuit
terminal block
Casters
Sub nameplate
Hoist hole
φ26
Main nameplate
Charge
lamp
Figure 1.2-1 Rank 4 (500 kW)
(2) Warning plates and label
Figure 1.2-2 Warning Plates and Label
2