Mitsubishi FR-BU2-1.5K User manual

FR-BU2 INSTRUCTION MANUAL
A
INVERTER
INVERTER
INSTRUCTION MANUAL
HEAD OFFICE:TOKYO BLDG MARUNOUCHI TOKYO 100-8310
FR-BU2-1.5K to 55K
FR-BU2-H7.5K to H75K
Brake Unit
IB(NA)-0600292ENG-A(0609)MDOC Printed in Japan Specifications subject to change without notice.

A-1
Thank you for choosing this Mitsubishi 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 performance.
Please forward this manual to the end user.
1. Electric Shock Prevention
2. Fire Prevention
3. Injury Prevention
This section is specifically about safety matters
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 instruction manual, the safety instruction levels are classified into "WARNING" and
"CAUTION".
Assumes that incorrect handling may cause hazardous conditions,
resulting in death or severe injury.
Assumes 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 according to conditions.
Please follow the instructions of both levels because they are important to personnel safety.
WARNING
CAUTION
CAUTION
SAFETY INSTRUCTIONS
WARNING
• While power is on or when the brake unit is
running, do not open the front cover. You
may get an electric shock.
• Do not run the brake unit with the front
cover removed. Otherwise, you may access
the exposed high-voltage terminals and
charging part and get an electric shock.
• Even if power is off, do not remove the front
cover except for wiring or periodic
inspection. You may access the charged
inverter connected to the brake unit and get
an electric shock.
• Before starting wiring or inspection, check
to make sure that the 3-digit LED brake unit
monitor is off, wait for at least 10 minutes
after the power supply has been switched
off, and check to make sure that there are
no residual voltage using a tester or the
like. The brake unit connected to the brake
unit is charged with high voltage for some
time after power off and it is dangerous.
• Must be earthed (grounded).
• Any person who is involved in the wiring or
inspection of this equipment should be fully
competent to do the work.
• Always install the brake unit before wiring.
Otherwise, you may get an electric shock or
be injured.
• Do not operate a switch with wet hands.
You may get an electric shock.
• Do not subject the cables to scratches,
excessive stress, heavy loads or pinching.
Otherwise you may get an electric shock.
CAUTION
•Mount the brake unit and resistor unit to
incombustible material. Installing it to
combustible materials directly or near
combustible materials can cause a fire.
•Turn off power when an alarm signal is
output. Otherwise, the brake resistor may
excessively overheat due to damage of the
brake transistor and such, causing a fire.
•Do not connect the resistor unit directly to
the DC terminals P/+ and N/-. This could
cause a fire.
CAUTION
•Apply only the voltage specified in the
instruction manual to each terminal.
Otherwise, burst, damage, etc. may occur.
•Ensure that the cables are connected to
the correct terminals. Otherwise, burst,
damage, etc. may occur.
•Always make sure that polarity is correct
to prevent damage, etc. Otherwise, burst,
damage may occur.
•While power is on or for some time after
power-off, do not touch the brake resistor as
it will be extremely hot. Doing so can cause
burns.

A-2
4. Additional Instructions
Also note the following points to prevent an
accidental failure, injury, electric shock, etc.
1) Transportation and mounting
(2) Trial run
3) Usage
(4) Emergency stop
(5) Maintenance, inspection and parts
replacement
(6) Disposal
(7) General instruction
CAUTION
•Transport the product using the correct
method that corresponds to the weight.
Failure to observe this could lead to
injuries.
•Do not stack the brake unit boxes higher
than the number recommended.
•Install the product in a place which can
withstand its weight according to the
information in the instruction manual.
•Do not install or operate the option unit if it
is damaged or has parts missing.
•When carrying the brake unit, do not hold
it by the front cover. It may fall off or fail.
•Do not stand or rest heavy objects on the
product.
•Check that the mounting orientation is
correct.
•Prevent screws, metal fragments or other
conductive bodies or oil or other
flammable substance from entering the
brake unit.
•As this brake unit is a precision
instrument, do not drop or subject it to
impact.
•Use the brake unit under the following
environmental conditions: Failure to fallow
may damage the product.
*1Temperature applicable for a short time,
e.g. in transit.
CAUTION
•Before starting operation, confirm and
adjust the parameters. Setting parameter
different from the one set in the resistor
connected may not exhibit the best
performance or may cause resistor
overheat or alarm.
Environment
Ambient
temperature
-10°C to 50°C
(non-freezing)
Ambient
humidity
90% RH or less
(non-condensing)
Storage
temperature -20°C to 65°C *1
Atmosphere
Indoors (free from
corrosive gas, flammable
gas, oil mist, dust and
dirt)
Altitude/
vibration
Maximum 1000m above
sea level, 5.9m/s2or less
(conforms to JIS C
60068-2-6)
WARNING
•Do not modify the equipment.
•Do not perform parts removal which is not
instructed in this manual. Doing so may
lead to fault or damage of the product.
CAUTION
•Provide a safety backup such as an
emergency brake which will prevent the
machine and equipment from hazardous
conditions if the inverter and brake unit
fail.
WARNING
•Do not test the brake unit with a megger
(measure insulation resistance).
CAUTION
•Treat as industrial waste.
Many of the diagrams and drawings in this
Instruction Manual show the products
without a cover, or partially open. Never
operate the products in this manner.
Always replace the cover and follow this
Instruction Manual when operating the
products.

Brake unit (FR-BU2 type)
When running the motor with the FR series inverter, use this option unit
when a large brake torque is necessary such as when the motor is made to
run by the load, quick decerelation is required, etc.
Following three types of brake resistor as in the table below can be
connected to this option unit. FR-BU2 type break unit can be used as
substitute of the existing brake units (BU type, FR-BU-(H) type, MT-BU5
type).
Do not operate the conventional brake unit and FR-BU2 in parallel. Doing so
could cause an alarm or failure. Change all units to the FR-BU2 to operate in
parallel and connect the master/slave signal.
Perform wiring and parameter setting referring to page 15
 as the wiring
method and parameter setting method differ according to the brake resistor
combined.
Compatible Brake Resistor and
Resistor Unit Conventional Brake Unit
GRZG type brake resistor BU type
FR-BR-(H) type resistor unit FR-BU-(H)
MT-BR5 type resistor unit MT-BU5 type

I
CONTENTS
1PRODUCT CHECKING AND PARTS IDENTIFICATION.................. 1
2INSTALLATION................................................................................. 2
3WIRING ............................................................................................. 4
3.1 Terminals............................................................................................ 4
3.1.1 Brake unit............................................................................................... 4
3.1.2 Resistor unit......................................................................................... 11
3.2 Combinations of Brake Resistors for Brake
Unit and Used Wires......................................................................... 13
3.3 External Connection Diagram........................................................... 14
3.3.1 Connection with the inverter ................................................................ 14
3.4 Connection Example with the GRZG Type Brake Resitor ............... 16
3.4.1 When connecting one inverter and one brake unit ............................. 16
3.4.2 When connecting several brake units to one inverter.......................... 18
3.4.3 Master/slave operation when connecting several brake units ............. 19
3.5 FR-BR-(H) Connection Example with Resistor Unit ........................21
3.5.1 When connecting one inverter and one brake unit .............................. 21
3.5.2 When connecting several brake units to one inverter.......................... 22
3.5.3 Master/slave operation when connecting several brake units ............. 23
3.6 Connection Example with MT-BR5 Type Resistor Unit ................... 24
3.6.1 When connecting one inverter and one brake unit .............................. 24
3.6.2 When connecting several brake units to one inverter.......................... 25
3.6.3 Master/slave operation when connecting several brake units ............. 26
3.7 Wiring Instructions ............................................................................ 28
4OPERATION ................................................................................... 30
4.1 Control Panel.................................................................................... 30
4.2 Basic Operation ................................................................................ 31
4.3 Parameter List .................................................................................. 32
4.3.1 Mode switchover (Pr.0)........................................................................ 33
4.3.2 Multi-function monitor display (Pr.1, Pr.78).......................................... 34
4.3.3 Input terminal function selecttion (Pr.2, Pr.3)....................................... 36
4.3.4 Parameter write disable selection (Pr. 77) ........................................... 37
4.3.5 Parameter clear ................................................................................... 38
4.3.6 Alarm history clear ............................................................................... 39
5PROTECTIVE FUNCTIONS ........................................................... 40
5.1 Causes and Corrective Actions ........................................................ 40

II
5.2 Correspondence Between Digital and Actual Characters ................ 42
6SPECIFICATIONS .......................................................................... 43
6.1 Brake Unit ........................................................................................ 43
6.2 Brake Resistor/Resistor Unit ............................................................ 43
7PRECAUTIONS FOR MAINTENANCE AND INSPECTION ........... 44
7.1 Precautions for Maintenance and Inspection ................................... 44
7.2 Inspection Item................................................................................. 44
7.3 Periodic Inspection........................................................................... 45
7.4 Daily and Periodic Inspection........................................................... 46
7.5 Replacement of Parts....................................................................... 47
8SELECTION .................................................................................... 48
9OUTLINE DIMENSION DRAWINGS............................................... 51
10INSTRUCTIONS FOR UL, CSA STANDARD COMPLIANCE........ 56

MEMO

1
PRODUCT CHECKING AND
PARTS IDENTIFICATION
1PRODUCT CHECKING AND PARTS
IDENTIFICATION
(1) Unpack the option unit and confirm that the product is as you ordered
and intact.
(2) Make sure that the package includes all accessories.
Brake unit (FR-BU2).........................1 Instruction manual ........................... 1
•Removal and reinstallation of the
front cover
Remove the front cover by pulling it
toward you in the direction of arrow.
To reinstall, match the cover to the
brake unit front and install it straight.
•Removal and reinstallation of the
wiring cover
The cover can be removed easily by
pulling it toward you.
To reinstall, fit the cover to the brake
unit along the guides.
MITSUBISHI BRAKE UNIT
MODEL FR-BU2-15K
for 200V class INVERTER
SERIAL :XXXX
MITSUBISHI ELECTRIC CORPORATION
MADE IN JAPAN
Operation
panel
Front
cover
Wiring cover
Rating plate
Capacity
plate
MODEL FR-BU2- H □□ K
Applied motor
capacity (kW)
Applied power
supply voltage
No.
Not used
H
200V class
400V class
Brake unit type SERIAL number
FR-BU2-15K XXXXXX
Wiring cover

2
INSTALLATION
2INSTALLATION
•Install the brake unit under the following conditions.
When encasing multiple
brake units, install them
in parallel as a cooling
measure.
Encasing multiple brake units
Remove the
front cover and
wiring cover to
fix the brake unit
to the surface.
Enclosure surface mounting
Leave enough clearances as
a cooling measure.
Vertical mounting
Vertical
Clearances
10cm or more
10cm or more
Temperature: -10 to 50
Humidity: 90%RH maximum
Ambient temperature
and humidity
5cm5cm
5cm
Brake unit
Measurement
position
Measurement
position
Brake units
can be closely
attached when
mounting in
lateral direction.*
* Permissible ambient
temperature is -10 to 40
when mounting brake units
closely-attached. When
ambient temperature exceeds
40 , clearances
between brake units should be
1cm or more.

3
INSTALLATION
• The brake unit consists of precision mechanical and electronic parts. Never
install or handle it in any of the following conditions as doing so could cause
an operation fault or failure.
CAUTION
Mount the brake unit and resistor unit to incombustible material.
Installing it to combustible materials directly or near combustible
materials can cause a fire.
Direct sunlight
Vibration
(5.9m/s
2
or more)
High temperature,
high humidity
Oil mist,
flammable gas,
corrosive gas,
fluff, dust, etc.
Horizontal
placement
Vertical mounting
(when mounting
inside an enclosure)
Mounting to
combustible
material
Transportation by
holding the front
cover

4
WIRING
3WIRING
3.1 Terminals
3.1.1 Brake unit
Terminal Symbol Terminal Name Description Rating
Main circuit
P/+ Brake unit input
terminal
Connect to the inverter
terminal P and N.
---
N/-
PR*1
Resistor
connection
terminal
Connect the brake resistor.
Earth (Ground)
For earthing (grounding) the
brake unit. Must be earthed
(grounded).
Control circuit
Contact
input
BUE
Brake operation
permission
signal
Controls the brake operation.
Turning on the signal enables
brake operation. *2
Voltage at
opening :
21 to 27VDC
Controls by open
collector output
or no voltage
contact signal.
RES Reset input
Used to reset alarm output
provided when protective
circuit is activated. Turn on the
RES signal for more than 0.1s,
then turn it off.
SD
*3
Contact input
common
Common terminal of the
control input
Brake transister driving signal
common
(for master/slave operation,
when connecting several brake
units to one inverter in parallel,
connect this signal to terminals
of other brake units.)
Master/
slave
signal
MSG
*3
Brake
transistor
driving signal
Brake transistor driving signal
terminal
(For master/slave operation,
when connecting several brake
units to on inverter in parallel,
connect this signal to terminals
of other brake units.)
---
*1 Only a brake resistor should be connected to terminal PR. Doing so may damage the
brake unit.
*2 BUE-SD is connected with a jumper in the initial status. Remove a jumper when
using this signal. (When terminals are open, brake unit is not operated.)
*3 Do not connect terminals SD, PC and MSG each other or to the ground. Doing so
may damage the brake unit.
For sink logic (initial status), terminal SD acts as the common terminal of contact
input. For source logic (initial status), terminal PC acts as the common terminal of
contact input.

5
WIRING
Control circuit
PC *3
External
transistor
common,
Contact input
common
(source)
When connecting the transistor
output (open collector output),
such as a programmable
controller (PLC), connect the
positive external power supply
for transistor output to this
terminal to prevent a
malfunction caused by
undesirable currents.
When source logic has been
selected, this terminal serves
as a contact input common
terminal.
---
Relay
output
A
Relay output 1
(Alarm output)
1 changeover contact output
indicates that the brake unit
protective function has
activated.
• Normal
Across B-C: Continuity
Across A-C: Discontinuity
•Alarm
Across B-C: Disontinuity
Across A-C: Continuity
230VAC 0.3A
30VDC 0.3A
B
C
*3 Do not connect terminals SD, PC and MSG each other or to the ground.
Doing so may damage the brake unit.
For sink logic (initial status), terminal SD acts as the common terminal of contact
input. For source logic (initial status), terminal PC acts as the common terminal of
contact input.
Terminal Symbol Terminal Name Description Rating

6
WIRING
•Terminal arrangement of the main circuit terminal
Cable size of the main circuit terminal
Brake Unit Type
Main
Circuit
Te r m in a l
Screw
Size
Crimping
Te r m in a l Tightening
To r q ue
(N •m)
Cable Size
HIV cables,
etc. (mm2)AWG PVC cables, etc. (mm2)
N/-
P/+, PR
N/-
P/+, PR
N/-
P/+, PR
N/-
P/+, PR
200V
FR-BU2-1.5K/
3.7K M4 2-4 1.5 2 14 2.5
FR-BU2-7.5K M4 5.5-4 1.5 3.5 12 4
FR-BU2-15K M4 5.5-4 1.5 3.5 12 4
FR-BU2-30K M5 5.5-5 2.5 5.5 10 6
FR-BU2-55K M6 14-6 4.4 14 6 16
400V
FR-BU2-H7.5K M4 2-4 1.5 2 14 2.5
FR-BU2-H15K M4 5.5-4 1.5 3.5 12 4
FR-BU2-H30K M4 5.5-4 1.5 3.5 12 4
FR-BU2-H55K M5 5.5-5 2.5 5.5 10 6
FR-BU2-H75K M6 14-6 4.4 14 6 16
N/- PR P/+

7
WIRING
• Control circuit terminal layout
* Information on bar terminals
Introduced products (as of June, 2006) : Phoenix Contact Co.,Ltd.
Bar terminal crimping tool: CRIMPFOX ZA3 (Phoenix Contact Co., Ltd.)
Control circuit terminal block
Loosen the terminal screw and insert the cable into the
terminal.
Screw size : M3
Tightening torque : 0.5N•m to 0.6N•m
Cable size : 0.3mm2to 0.75mm2
Screwdriver : Small flat-blade screwdriver
(Tip thickness : 0.4mm / tip width : 2.5mm)
Terminal Screw Size
Bar Terminal Model
(with insulation
sleeve)
Bar Terminal Model
(without insulation
sleeve) Cable Size (mm2)
M3 Al 0.5-6WH A 0.5-6 0.3 to 0.5
Al 0.75-6GY A 0.75-6 0.5 to 0.75
CAUTION
When using the bar terminal (without insulation sleeve), use care so that the twisted
wires do not come out.
AB
RES
Jumper
SD SD SD
MSGMSG
C
PC BUE SD
CAUTION
Undertightening can cause cable disconnection
or malfunction. Overtightening can cause a
short circuit or malfunction due to damage to
the screw or unit.
6mm
Cable stripping size
Wire the stripped cable
after twisting it to
prevent it from
becoming loose.
In addition, do not
solder it.*

8
WIRING
•Changing the control logic
The input signals are set to sink
logic when shipped from the
factory.
To change the control logic, the
jumper connector under the control
panel must be moved to the other
position.
•Change the jumper connector in
the sink logic position to source
logic position using tweezers, a
pair of long-nose pliers etc.
Change the jumper connector
position before switching power
on.
CAUTION
•Fully make sure that the front cover has been reinstalled securely.
•The front cover is fitted with the capacity plate and the brake unit with the
rating plate. Before reinstalling the front cover, check the serial numbers to
ensure that the cover removed is reinstalled to the brake unit from where it
was removed.
•The sink-source logic change-over jumper connector must be fitted in only
one of those positions. If it is fitted in both positions at the same time, the
brake unit may be damaged.

9
WIRING
1) Sink logic type
•In sink logic, a signal switches on when a current flows from the
corresponding signal input terminal.
Terminal SD is common to the contact input signals.
•Connecting a positive terminal of
the external power supply for
transistor output to terminal PC
prevents a malfunction caused by
undesirable currents. (Do not
connect terminal SD of the brake
unit with terminal 0V of the external
power supply.)
Power supply
RES
BUE
SD
R
R
AY40 type
transistor
output unit
1
2
10
24VDC
SD
PC
RES
BUE
Brake unit
24VDC
(SD)
9
Current flow

10
WIRING
2) Source logic type
•In this logic, a signal switches on when a current flows into the
corresponding signal input terminal.
Terminal PC is common to the contact input signals.
•Connecting a 0V terminal of the
external power supply for transistor
output to terminal SD prevents a
malfunction caused by undesirable
currents.
Power
supply BUE
RES
PC
R
R
AY80 type
transistor
output unit
9
1
2
10
PC
BUE
RES
SD
Brake unit
24VDC
(SD)
24VDC
Current flow

11
WIRING
3.1.2 Resistor unit
(1) FR-BR-(H)
•Terminal arrangement
Resistor unit input terminal
Control circuit terminal block
arrangement
•Terminal screw size
Terminal
Symbol Terminal Name Description Rating
Main
circuit
PResistor unit
input resistance
Connect to terminal P and PR of the brake
unit. ---
PR
Control
circuit
TH1 Alarm output
terminal Output signal indicates resistor overheart
1NC contact
110VAC, 5A
220VAC, 3A
TH2
PR P
TB1
TH1 TH2
TB2
Model TB1 TB2
200V
FR-BR-15K M4 M3
FR-BR-30K M5 M3
FR-BR-55K M6 M3
400V
FR-BR-H15K M3 M3
FR-BR-H30K M4 M3
FR-BR-H55K M5 M3
TB1
TB2
<FR-BR resistor unit>

12
WIRING
(2) MT-BR5
•Terminal arrangement
Resistor unit input terminal
Control circuit terminal block
arrangement
•Terminal screw size (MT-BR5)
Terminal
Symbol Terminal Name Description Rating
Main
circuit
PResistor unit
input terminal
Connect to terminal P and PR of the
brake unit. ---
PR
EEarth terminal For earthing (grounding) of the resistor unit. Must be
earthed (grounded).
Control
circuit
TH1 Alarm output
terminal
Output signal indicates resistor
overheart.
1 NO contact,
110VAC, 5A
220VAC, 3A
TH2
PPR
TB1
TH1 TH2 E
TB2
Model TB1 TB2
MT-BR5-55K M6 M4
MT-BR5-H75K M6 M4
TB1
<MT-BR5 resistor unit>
TB2
NP

13
WIRING
3.2 Combinations of Brake Resistors for Brake
Unit and Used Wires
Brake Unit Type Brake Resistor, Resistor
Unit Type Cable Size (mm2)
200V class
FR-BU2-1.5K GZG 300W-50Ω (one) 2
FR-BU2-3.7K GRZG 200-10Ω (three in series) 2
FR-BU2-7.5K GRZG 300-5Ω(four in series) 3.5
FR-BU2-15K GRZG 400-2Ω(six in series) 3.5
FR-BR-15K
FR-BU2-30K FR-BR-30K 5.5
FR-BU2-55K FR-BR-55K 14
MT-BR5-55K
400V class
FR-BU2-H7.5K GRZG 200-10Ω(six in series) 2
FR-BU2-H15K GRZG 300-5Ω(eight in series) 3.5
FR-BR-H15K
FR-BU2-H30K GRZG 400-2Ω(twelve in series) 3.5
FR-BR-H30K
FR-BU2-H55K FR-BR-H55K 5.5
FR-BU2-H75K MT-BR5-H75K 14