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.
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.
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.
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.
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.
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 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.
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 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.
1-3 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.
2 Installation and Connection 2-1 Operating environment Install the DB unit in the environment shown in Table 2-1-1.
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.
■ 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 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
2-3-3 Connecting the control terminals Function descriptions of the control terminals are shown in Table 2-3-3.
(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.
2-3-4 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(+)
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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