Fuji Electric BU22-2C User manual

Instruction Manual
DB Unit
Braking unit
200V class 11-22kW / BU22-2C
400V class 11-22kW / BU22-4C
CAUTION
■ Deliver this instruction manual without fail to
those who actually operate the equipment.
■ Read this operation manual and understand
the description before installing, connecting
(wiring), operating or performing
maintenance and inspection of the braking
unit.
■ Keep this instruction manual in a safe place
until the braking unit is discarded.
■ The product is subject to change without
prior notice.
Fuji Electric FA Components & Systems Co., Ltd. INR-SI47-0845a-E

Introduction
Thank you for purchasing our braking unit. This equipment discharges the braking force in braking
operation of Fuji’s general purpose inverter to a resistor. For applicable inverter models, refer to
Table A.
Before starting operation, read through this operation manual to understand the handling method
and operate correctly. An incorrect handling will obstruct correct operation or cause a reduced life or
failure. Keep the instruction manual in a safe place even after operation is started.
This operation manual does not cover the inverter handling. For the handling of the inverter, refer to
the applicable inverter instruction manual.
Table A. Applicable Inverter Models
Class Model
200V General-purpose
inverter FRENIC5000 G11S/P11S Series
FRENIC5000 G11UD Series
400V General-purpose
inverter FRENIC5000 G11S/P11S Series
FRENIC5000 G11UD Series
Safety Precautions
Read through this operation manual carefully before installing, connecting, (wiring), operating or
performing maintenance and inspection for correct usage.
Be familiar with all the devices, safety information, and cautionary items.
In this operation manual, safety precautions are described under the following titles.
WARNING
Wrong handling may cause danger possibly accompanying deaths or serious
injuries.
CAUTION
Wrong handling may cause danger possibly accompanying minor or
moderate injuries or material losses.
Precautions described in the caution category may cause serious results in some circumstances.
Both precautions are important; observe the description without fail.
Application WARNING
・ This unit discharges the braking force in braking operation of Fuji’s general purpose inverter to a
resistor. It cannot be used for other applications.
Risk of fire
・ This unit cannot be used for applications directly related to personal danger such as a life
support system.
・ This product is manufactured under strict quality control. However, if it is used for equipment
where serious accidents or losses may occur in case of failure of this product, install a safety
device.
Risk of accident

Installation WARNING
・ Install to nonflammable matter such as metals.
Risk of fire
・ Do not place flammable matter nearby.
Risk of fire
・ Contain the unit inside a distribution panel or the like so that it cannot be touched easily.
Risk of electric shock or accident
・ Use bolts of the specified sizes for installation without fail.
Risk of accident or injuries
CAUTION
・ Do not hold the front cover when carrying.
Risk of drop and injuries
・ Do not allow lint, paper, wood dust, other dust, metallic dust or other types of foreign matter to
intrude in the braking unit or do not allow them to be stuck on the heat sink.
Risk of fire or accident
・ Do not install and operate the braking unit if it is damaged or some parts are missing.
Risk of injuries
Wiring WARNING
・ Use the designated size for wiring cables.
Risk of fire
・ Do not make a mistake in the polarity (+, -) of the DC terminals (P(+), N(-)) and inverter
connection terminals.
Risk of fire
・ Be sure to connect the grounding cable.
Risk of electric shock or fire
・ Have the wiring work conducted by a qualified electrician.
Risk of electric shock
・ Check that the power is turned off (opened).
Risk of electric shock
・ Be sure to install the main body first before starting wiring.
Risk of electric shock or injuries
CAUTION
・ Check that the rated voltage of the product conforms to the rated voltage of the inverter.
Risk of injuries
・ Do not connect the braking resistor directly to the DC terminals (P(+), N(-)).
Risk of fire
・ Noise is generated from the unit and wiring. Be careful of malfunction of nearby sensors or
devices.
Risk of accident

Operation WARNING
・ Be sure to install the surface cover before turning the power on (closing). Do not remove the
cover while the power is turned on.
Risk of electric shock
・ Do not touch the terminals of the braking unit while the power is supplied to the inverter or even if
the unit is stopped.
Risk of electric shock
CAUTION
・ Do not use the main circuit ON/OFF switch to start or stop the inverter.
Risk of failure
・ Do not touch the heat sink and braking resistor because they become hot.
Risk of burns
・ The braking function of this unit does not guarantee mechanical suspension.
Risk of injuries
Maintenance, inspection and parts replacement
WARNING
・ Turn the power off (open) and wait for at least 10 minutes before starting inspection.
Check that the charge lamp is unlit and check that the DC voltage across the P(+) and N(-)
terminals is 25V or lower.
Risk of electric shock
・ Do not perform maintenance, inspection or parts replacement if you are not the appointed
person.
Take off metallic objects such as watches and rings before starting work.
Use insulated tools.
Risk of electric shock or injuries
Disposal CAUTION
・ When discarding the product, handle it as an industrial waste.
Risk of injuries
Others WARNING
・ Never remodel.
Risk of electric shock or injuries
General Precautions
Schematic drawings found in this operation manual may indicate a view without covers or safety
shields for explanation of details.
When operating the product, restore the covers and shields and observe the operation manual.

Table of contents
1. Before Starting Operation
1-1 Shipment Inspection ··································· 1-1
1-2 Appearance of Product······························· 1-1
1-3 Handling the Product ·································· 1-2
1-4 Transportation············································· 1-2
1-5 Storage························································ 1-2
2. Installation and Connection······································ 2-1
2-1 Operating Environment······························· 2-1
2-2 Installation Method······································ 2-1
2-3 Connection·················································· 2-2
2-3-1 Basic Connection ······························ 2-2
2-3-2 Connection of Main
Circuit and Grounding Terminal········ 2-4
2-3-3 Connection of Control Terminal ········ 2-4
2-3-4 Terminal Layout································· 2-5
2-3-5 Standard applied device
and cable size··································· 2-5
3. Operation·································································· 3-1
3-1 Inspection and Preparation
Before Operation········································· 3-1
4. Protective Action ······················································ 4-1
4-1 Protective Action········································· 4-1
4-2 Alarm Reset ················································ 4-1
5. Maintenance and Inspection ··································· 5-1
5-1 Daily inspection··········································· 5-1
5-2 Periodic Inspection······································ 5-1
5-3 Insulation Test············································· 5-2
5-4 Replacement Parts ····································· 5-3
5-5 Inquiry About Product and Guarantee········ 5-3
6. Specifications ··························································· 6-1
6-1 Standard Specifications······························ 6-1
6-1-1 Braking Unit······································· 6-1
6-1-2 Braking Resistor································ 6-2
6-2 External Dimensions··································· 6-3
7. Optional Fan····························································· 7-1
7-1 Specifications of Optional Fan···················· 7-1
7-2 Installation of Optional Fan Unit·················· 7-1
7-2-1 Installation ······································· 7-1
7-2-2 Optional Fan Wiring··························· 7-1
7-3 External Dimensions··································· 7-2

1-1
1 Before Starting Operation
1-1 Shipment Inspection
Unpack and check the following items.
If you have any question or trou le, contact
the store of purchase or nearest Fuji’s sales
office.
(1) Refer to the rating nameplate to check if
the delivered product is the ordered one.
TYPE : Type of raking unit
SOURCE : Power source rating
OUTPUT : Output rating
SER.No. : Serial num er
(2) Check if there are any missing or roken parts or dents or other transportation damage in
the cover and main ody.
(3) The raking resistor is not attached. Prepare a suita le resistor matching the
specifications separately.
1-2 Appearance of Product
Fig. 1-2-1. Appearance of Product Fig. 1-2-2
3 1 1234R0001
Serial manufacturing lot num er
Manufacturing month: 1 to 9 → January to Septem er
X → Octo er. Y → Novem er. Z → Decem er
Manufacturing year: The last one digit of year. 3 → Year 2003
Fig. 1-1-1. Rating Nameplate
BU 22 - 2 C
Standard series : C
Power source voltage class of the inverter: 2 → 200V class. 4 → 400V class
Standard applied motor capacity of inverter : 22→22kW
Product type

1-2
1-3 Handling the Product
(1) Removal of terminal cover
Loosen the mounting screws of the terminal cover and, while holding the terminal cover,
remove it as shown in Fig. 1-3-1
Fig. 1-3-1. Removal of Terminal Cover and Surface Cover
1-4 Transportation
Be sure to hold the main ody when transporting.
If the cover or parts are held, there is danger of raking or dropping.
1-5 Storage
Store the product in an environment specified in Ta le 1-5-1.
Ta le 1-5-1 Storage Environment
Item Specifica
tion
Am ient
temperature –10 ~ +50°C
Storage
temperature NOTE1
–25 ~ +65°C
Relative humidity 5 ~ 95% Note 2
Place free from condensation or icing caused y
a rupt temperature changes
Atmosphere Free from dust, direct sunshine, corrosive or flamma le gases, oil mist,
vapor, water drops or vi ration. Free from much salt
Note 1: The storage temperature indicates the temperature in short period such as during
transportation.
Note 2: Even if the temperature satisfies the specification values, condensation or icing
occurs at places with steep temperature changes. Avoid such places.
(1) Do not place directly on the floor.
(2) If the am ient atmosphere is adverse, pack the unit with a vinyl sheet or the like to store.
(3) If moisture may cause ill effects, place a drying agent such as silica gel inside the package
efore packing as descri ed at (2).

2-1
2 Installation and Connection
2-1 Operating Environment
Install the unit in the environment shown in Table 2-1-1.
Table 2-1-1. Operating Environment
Item Specification
Site Indoors
mbient
temperature
–10 ~ +50℃
Relative
humidity
5 ~ 95% (Without condensation)
tmosphere Free from dust, direct sunshine, corrosive gases, oil mist, vapor or water
drops.
Free from much salt.
Free from condensation caused by abrupt temperature changes
ltitude 1,000m maximum
(If 1,000m is exceeded, reduce the inverter output according to the inverter
operation manual.)
Vibration 3.0mm at 2～9Hz, 9.8m/s2 at 10～20Hz, 4.9m/s2 at 20～55Hz, 1.0m/s2 at 55
～200Hz
2-2 Installation Method
(1) Install the braking unit on a solid structure
securely with bolts and vertically so that the label
characters are seen in front.
(2) The braking unit generates heat during
operation. Reserve space shown in Fig. 2-2-1 to
assure passage of cooling air. Because the
generating heat is radiated above, do not install
below a device susceptible to heat.
(3) The temperature of the heat sink rises up to
about 90°C during operation of the braking unit.
The material of the mounting face at the back of
the braking unit must bear the temperature rise
with a sufficient margin.
W RNING
Install on nonflammable matter such as metals.
Risk of fire
(4) When the unit is installed inside the control panel or the like, take sufficient care of
ventilation so that the ambient temperature of the braking unit does not exceed the
specification value. Do not house in an ill-ventilated small airtight container.
(5) When two or more inverters and the braking unit are housed in the same equipment or
inside the control panel, side-to-side installation is recommended to reduce the mutual
effects of heat. If the units must be installed vertically for unavoidable reason, install a
partition plate or the like so that the heat generating at the lower unit does not give ill
effects on the upper unit.
C UTION
Do not allow lint, paper, wood dust, other dust, metallic dust or other
foreign matter to intrude inside the unit or do not allow them to be stuck on
the heat sink.
Risk of fire or accident
D B U n it
本 体
上
下
右左
1 0 0 m m
1 0 0 m m
5 0 m m
以 上
5 0 m m
以 上
Fig. 2-2-1
Left
50mm
minimum
Up
Right
Down
50mm
minimum
Main body

2-2
2-3 Connection
fter the terminal cover is removed, each terminal block becomes visible (see Fig. 2-3-1).
Take care of the following items and connect without mistakes.
2-3-1 Basic Connection
(1) Connect the DC link connection terminals (P(+), N(-)) with the DC link circuit terminals
(P(+), N(-)) of the inverter. The unit and the inverter will be damaged if the polarity is
incorrect or other terminals are connected. s well, check that the source voltage
conforms to the specification of the connected inverter.
(2) Be sure to ground the grounding terminal to avoid disasters such as electric shock
and fire and to reduce noise.
(3) Use crimp terminals with high connection reliability for the connection between the
terminal and cable.
(4) fter finishing connection (wiring) work, check the following.
a. Correct connection
b. Failure to connect
c. Short circuit or ground fault of terminals and cables
(5) To change connection after power application
fter the power is turned off, it takes time until the smoothing capacitor in the DC
circuit of the main circuit is discharged. Before starting work, wait until the charge
lamp is unlit and check that the DC voltage has dropped to a safe voltage (25Vdc or
lower) with a multimeter or the like to avoid danger. In addition, short circuiting may
cause sparks if there is a remaining voltage (charge). Wait until the voltage becomes
low.
W RNING
・ Be sure to connect the grounding cable.
Risk of electric shock or fire
・ Have wiring work done by a qualified electrician.
・ Check that the power is turned off (opened) before starting work.
Risk of electric shock
Inside unit
Fig. 2-3-1 Inside unit

2-3
■
■■
■Basic Connection Diagram
インバータ 制動ユニット 制動抵抗器
P(+)R
P(+)
N(-)
DB
G
G1 2
1 2
ｵﾌﾟｼｮﾝ
ﾌｧﾝ*4
P(+)
N(-)
外部ｱﾗｰﾑ入力(*1)
CM
制御回路
主回路
P1
Ｍ
線長５ｍ以下
P
DB
(*3)
+
(*2) (*3)
線長５ｍ以下
G
Fig. 2-3-2
(*1) The inverter may allow arbitrary assignment of digital input terminals.
Use the function setting of the inverter to select external alarm input.
(*2) Connect the batch alarm output of the braking unit and braking resistor to the
external alarm input of the inverter and build a sequence that opens the
electromagnetic contactor with the batch alarm output of the inverter.
(*3) Be sure to twist or route in close contact (in parallel) the two cables connecting
the inverter with the braking unit and that connecting the braking unit with the
braking resistor.
(*4) The optional fan needs separate power supply. The source voltage varies
according to the optional fan to be used. BU-F1S (single-phase 100Vac),
BU-F2S (single-phase 200Vac)
Inverter
Cable
length: 5m or
Braking unit
Braking
resistor
Cable length:
5m or less
Main circuit
Control circuit
External alarm input (*1)
Optional fan*4