Hitachi RCU Series User manual

1
RCU Series
Regenerative Converter Unit
Instruction Manual
NOTE: REFER ALSO TO APPLICABLE
INVERTER INSTRUCTION MANUAL
Hitachi America, Ltd.
Manual Number: HAL1057C
May 2012
After reading this manual,
keep it handy for future
reference.
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Hitachi America Ltd. RCU SERIES
2
Revision History
Rev A, May 2010 –Miscellaneous corrections throughout. Added cooling clearance drawing.
Rev B, June 2010 –Significant updated information.
Rev C May 2012–Redesigned manual format
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Hitachi America, Ltd. RCU SERIES
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3
1. SAFETY
ONLY A COMPETENT ELECTRICIAN SHOULD CARRY OUT THE
ELECTRICAL INSTALLATION.
1.1 WARNINGS
1
Internal Components and circuit boards (excepting the isolated I/O
terminals) apply an electric current when the RCU is connected to the
main voltage. This voltage is extremely dangerous and may cause
death or severe injury if you come in contact with it.
2
When the RCU is connected to the main power, current is flowing in
the DC-Link (P, N) and output terminals (R, S, T) even if the RCU is
not operating.
3
RCU has a large capacitive leakage current.
4
The control I/O terminals are isolated from the I/O voltage but the
relay outputs and other I/Os may have dangerous voltage even if the
power is disconnected from the RCU
5
User should install Fuse which can be blown fast between output
terminals (R, S, T) and main power source of the RCU
6
Spare parts can be delivered only by Hitachi America, Ltd.
1.2 SAFETY INSTRUCTIONS
!
1
Do NOT make any connections when the RCU is connected to main
voltage.
2
Do NOT make any measurements when the RCU is connected to
main voltage.
3
After disconnecting main power, wait until the cooling fan stops and
the indicator on display goes out. Wait a further 5 minutes before
doing any work on the RCU connections. Do NOT open even the
cover within this time.
4
Do NOT make any voltage withstand tests on any parts of the RCU.
5
Make sure that the cover of the RCU is closed before connecting
main voltage.
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Hitachi America Ltd. RCU SERIES
4
Ground Warning Symbols
The ground terminal of the RCU
has to be connected to ground wire .
Grounding of the RCU prevents high
voltage accidents that are caused by
switching.
Please be more cautious for the following
warning symbols for user’s safety
= Dangerous Voltage
!
= General Warning
1.3 Wiring
1
Do not supply overvoltage which over permissible voltage level for
the RCU output side terminals (R, S, T)
2
Link the RCU output-side terminals (R, S, T) to the exact order
3
Link the RCU output-side terminals (R, S, T) between main input
power and input AC reactor of inverter
4
Only a competent electrician should perform wiring and inspection
This manual explains specifications, installation, operation, features and maintenance of
RCU. This is a manual for users who have prior experience with RCU.
Please read this manual carefully before operating the RCU. Retain it for future reference.
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Hitachi America, Ltd. RCU SERIES
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5
2. Upon Receipt of Products
2.1 Initial Inspection
Each RCU has been subjected to demanding factory tests before release. After unpacking,
check that the unit does not show any signs of damage or missing parts. (Refer to the RCU
Label in Figure 2.1 and RCU Type in Figure 2.2).
In the event of damage, or if the product does not correspond with your order, please contact
your supplier immediately.
TYPE
RCU4022
RCU Model
Serial No.
0901001P
Serial Number
Power Rating
22[kW], 25[%ED]
RCU Nominal Power(Motor Capacity)
INPUT
DC513~650V, DC43A (AVG)
RCU Rated Input
OUTPUT
3Φ, AC 380~460V rms,
50/60Hz, AC 40A rms 100s
RCU Rated Output
Hitachi America, Ltd.
Figure 2.1 RCU Label (This is attached to the side of the RCU)
2.2 RCU Type
RCU
4
0
2
2
REGENERATIVE Converter UNIT
2=200Vac~230Vac
4=380Vac~460Vac
Motor Capacity [kW]
Figure 2.2 RCU Type
2.3 Storage and Warranty
Check the ambient conditions in the storage room before making the first trial run
(temperature: -25ºC~+60ºC, relative humidity: 5~95%, condensation is not allowed).
Hitachi America, Ltd. will not be responsible for the damage caused by ambient conditions.
The period of the product warranty under normal installation and handling conditions
is 12 months from the date of installation or 18 months from date of shipment,
whichever occurs first. Warranty remedy is limited to either repair at Hitachi’s
designated service center, or replacement, of the only the RCU in question, at Hitachi
America’s sole discretion. The warranty does not cover damage to associated
equipment, or damage caused by improper installation, unauthorized modification, fire,
flood, etc.
Contact Hitachi America for a copy of the complete warranty terms and conditions which
govern this sale. If any questions concerning warranty arise, please contact your distributor.
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Hitachi America Ltd. RCU SERIES
6
2.4 Power rating
2.4.1 200V RCU output rating
Id= rated DC input current, In = rated AC output current (100sec per 400sec, or 25%ED)
Ic = continuous AC output current, * = ask factory for detail
Main Voltage 200V - 230V, 50/60Hz RCU Series
RCU Model
Rated power and Rated current
Size
Dimension
W×H×D
(mm)
Weight
(kg)
P [kW]
Id [Aavg]
In [Arms]
Ic [Arms]
RCU2011
RCU2015
RCU2022
11
15
22
36
48
72
30
40
60
15
20
30
KE3
195×425×210
12
Table 2.4-1 200V series RCU Power ratings and dimensions
2.4.2 400V RCU output rating
Id= rated DC input current, In = rated AC output current (100sec per 400sec, )
Ic = continuous AC output current , *=ask factory for detail
Main Voltage 380V - 460V, 50/60Hz RCU Series
RCU Model
Rated power and Rated current
Size
Dimension
W×H×D
(mm)
Weight
(kg)
P [kW]
Id [Aavg]
In [Arms]
Ic [Arms]
RCU4011
RCU4015
11
15
22
29
20
27
16
21.6
KE2
195×425×195
12
RCU4022
22
43
40
32
KE3
195×425×210
RCU4030
30
58
54
43.2
KE4
195×455×210
13.5
Table 2.4-2 400V series RCU Power ratings and dimensions
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Hitachi America, Ltd. RCU SERIES
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7
2.5 Mounting
The RCU should be mounted in a vertical position on the wall or on the back plane of a
cubicle. Follow the requirement for cooling. See chapter 3.2 for dimensions.
In order to ensure a safe installation, make sure that the mounting surface is relatively flat.
Fixing is done with four or more screws or bolts depending on the size of the unit. See Figure
2.5-1 ~ 2.5-3.
2.5.1 KE2
class
Model
400V
RCU4011
RCU4015
Figure 2.5-1 KE2 Mounting dimension
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Hitachi America Ltd. RCU SERIES
8
2.5.2 KE3
Class
Model
Class
Model
400V
RCU4022
200V
RCU2011
200V
RCU2015
200V
RCU2022
Figure 2.5-2 KE3 Mounting dimension.
2.5.3 KE4
Class
Model
400V
RCU4030
Figure 2.5-3 KE4 Mounting dimension.
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Hitachi America, Ltd. RCU SERIES
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9
2.6 Specification
Main
Connection
Output (AC Source)
( R, S, T ) 3-phase 200Vac∼230Vac, 380Vac∼460Vac/
45~65Hz
allowable voltage fluctuation ±10%
allowable imbalance rate between phase ≤2%
Input (DC Source)
AC line voltage X 1.414
Rated
Output
Regenerative Torque
150% for 30sec, 100% for 100sec, 80% continuous
%ED Rating
25% ED
Terminal
Characteristics
Control Method
PWM current control method
Input Signal
Run / Enable / Ex. Fault / Fault Reset
Fault Relay
Output 1(DO1)
AC 250V, 1A or DC 30V, 1A / N.O/N.C output
Healthy Relay
Output 2(DO2)
AC 250V, 1A or DC 30V, 1A / N.O/N.C output
Protection
Function
Instantaneous
over current
Stops at ~ 200% of the current on power side
(Protected by Software)
Blown fuse
Motor stops by blown fuse (when over current
occured)
Overvoltage (DC)
Stops at ~ 800 VDC
Overload
Stops after 100% for 100sec, 150% for 30sec
Current limitation
Stops at 150% of rated current operating condition
Overheat
Protected by thermistor at overheat condition (95℃)
Imbalance between
phases
In case that imbalance rate between three phases
(R, S, T) exceeds 2%.
External Emergency
Stop Signal
Protected by external input signal
Environmental
Conditions
Location
Indoor (Protected from corrosive gases and dust)
Ambient temperature
-10℃∼+40℃(operating temperature), -20℃~ +65℃
(storage temperature)
Humidity
< 90%, (non-condensing)
Vibration
Up to 9.8 ㎨(1G), less than 15Hz, up to 1.96 ㎨
(0.2G) at 15 to 60Hz
*Caution:
1. RCU cannot be used with single-phase power supply. Use three-phase power supply.
2. RCU capacity is used to select the motor with the same capacity.
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Hitachi America Ltd. RCU SERIES
10
3. Installation
3.1 Installation Conditions
Please install the RCU in a location satisfying the following conditions.
1
Avoid rain, high temperature and high humidity.
2
Avoid direct sunlight.
3
The RCU should be protected from dirt, metal dust, and welding
flame.
4
Avoid mounting where excessive vibration exists.
5
Defective main power may cause the RCU damages.
- Using the same power source with welding machine.
- Using a generator as the power source.
- Sudden changes in the main voltage.
6
Keep away from flammable materials.
7
Install on nonflammable surfaces only.
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Hitachi America, Ltd. RCU SERIES
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11
3.2 Cooling
b
aa
c
Figure 3.2 Installation space
The specified space around the RCU ensures proper cooling air circulation. See table 3.2 for
dimensions. If multiple units are to be installed above each other, the distance between the
units must be b+c and air from the outlet of the lower unit must be directed away from the
inlet of the upper unit.
Size
Dimension(mm)
a
a2
b
c
KE2 / KE3/ KE4
30
10
160
80
Table 3.2 Installation space dimension
a2 = distance from the RCU to other RCU
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Hitachi America Ltd. RCU SERIES
12
4. Wiring
4.1 Cautions in wiring
1
Connect the ground cable surely.
If multiple units are to be installed, Do not make the loop with the
ground cables like figure (b) below.
RCU
#1 RCU #2 RCU #3 RCU #1 RCU #2 RCU
#3
( O ) ( X )
(a) GOOD (b) NOT GOOD
2
Only a competent electrician should carry out the wiring.
3
Make sure that the input main voltage is switched off.
4
Fasten the terminal screws to the relevant torque value and make
sure that there are not loose terminals.
5
The signal cables must be isolated from the power cables. For an
unavoidable case, install perpendicular to each other as shown below.
6
Link the RCU output-side terminals (R, S, T) between main input
power and input AC reactor or filter of the inverter. Otherwise,
malfunction of the RCU or inverter could result.
Main
Power INV
RCU
( O )
Main
Power INV
RCU
( X )
(a) GOOD (b) NOT GOOD
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Hitachi America, Ltd. RCU SERIES
`
13
4.2 Wiring Diagram
S T
P
R
N
Ground
DI 1:
7
9
10
12
11
DI 3:
DI 4:
DI5:
COM: Common for I/O
DO1.A
Fault_a
AC 1A/250V
DC 1A/30V
DO1.C
DO1.B
21 (B)
23 (COM)
22 (A)
FG
High Speed Fuse
(recommendation)
Run
Enable
External Fault
(A)
Fault Reset
SOHO RCU
*) caution 1 : The cable length between DC Link terminal of inverter and terminal of RCU should be less than 7m. P-N of RCU
and DC Link terminal P(+), N(-) of inverter should correspond.
SOHO VD INVERTER
19
20
IC : 50mA
Ready Relay
24Vout
DC3
21
22
23
DO1.A
DO1.C
DO1.B
Brake Contact
Output
(Open & Close)
AC 1A/250V
DC 1A30V
24
25
26
DO2.A
DO2.C
DO2.B
Fault Contact
Output
AC 1A/250V
DC 1A30V
Forward Run/Stop
Reverse Run/Stop
Enable
External Fault
Fault Reset
Multi-Step Speed Setting 1
Multi-Step Speed Setting 2
Multi-Step Speed Setting 3
7
8
9
10
11
12
13
14
15
16
DI1
DI2
DI3
DI8
DI7
DI6
DI5
DI4
COM
COM Multi-function
Contact Input
MCMCCB
R
S
T
3-Phase
Power
Supply
380~460V
50/60Hz
Shield
Multi-function
Analog Output
-10 to +10V 2mA
(Output Current)
17
18
0(4)~20mA
lout+
shield
1k ~10kΩ0.5W 1
2
3
4
5
6
10Vref COM
+10Vref : 10Vdc
Vin1 / lin2+
lin1-
Vin2 / lin2+
lin2-
L2 L3L1
V WU
IM
P N
*) caution 1
*) caution 2
High Speed Fuse
(recommendation)
*) caution 2 : Install Fuse between RCU output terminal (R, S, T) and power supply.
(Refer to chapter 4.5 for wire and fuse specification)
RCU #23 RCU #21
INVERTER #9-1
INVERTER #9-2
#9-1#9-2
*) caution
3
*) caution 3 : When you want to connect inverter with RCU, Connect Healthy (A_contact) signal of RCU with Enable signal of
inverter.
Iout-
16 COM: Common for I/O
Healthy
AC 1A/250V
DC 1A/30V
DO2.C
DO2.B
26 (COM)
25 (A)
DO1.A
DO2.A 24 (B)
*) caution 4
*) caution 4 : You should install a AC input reactor to prevent the regenerated power from flowing to inverter.
ACL
*) caution 5
*) caution 5 : You should link RCU output-side terminals (R, S, T) between main input power and input AC reactor of inverter.
Figure 4.1 RCU typical wiring diagram
RCU
INVERTER
(typical)
Closed in
healthy
condition
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Hitachi America Ltd. RCU SERIES
14
4.3 Control terminal specific
7
9
10
12
11,16
23
21
22
No Content
RCU operation signal
RCU preparation of operation signal
External fault input signal
RCU fault reset signal
Fault A contact output
Fault B contact output
Terminal
DI. 01
DI. 02
DI. 03
DI. 04
DI. COM
DO1. B
DO1. A
DO1. C
Signal
Contact Input 1
Contact Input 2
Contact Input 3
Contact Input 4
Contact input (common
terminal)
Contact output 1 (b-contact)
Contact output 1 (a-contact)
Contact ouput 1 (common
terminal)A, B contact common terminal
AC 1A/250V
DC 1A/30V
Contact
Input
Contact
Output
Catalog
26
24
25
Healthy A contact output
Healthy B contact output
DO2. B
DO2. A
DO2. C
Contact output 1 (b-contact)
Contact output 1 (a-contact)
Contact output 1 (common
terminal)A, B contact common terminal
AC 1A/250V
DC 1A/30V
Contact
Output
Figure 4.2 Control terminal specific
Refer to figure 4.1 for basic connection.
The control cables should be at least 0.5mm2shielded cables. The maximum wire size fitting
in the terminals is 2.5mm2.
4.4 Terminal block and Screw type (According to Mounting Dimension)
SIZE
Input/Output Wiring
Terminal Block type
Width
(inside)
Screw
type
Signed
Torque
(N•m)
KE2P
KE3P
KE4P
12mm
M5
3~4
Table 4.1 RCU Terminal Block and Screw type
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Hitachi America, Ltd. RCU SERIES
`
15
4.5 I/O Power line and Connection of Fuse
For power lines, use copper wire rated 600V, +75ºC. Wire gauge and fuse capacity must be
sized based on rated output current of RCU. Please refer to Table 4.2 for the minimum size
of power lines (copper) and following fuse capacity. When three or more parallel wires are
used, please pay attention to avoid overloading.
Voltage
Capacity
[kW]
I/O
cable
[mm2]
Ground
cable
[mm2]
FUSE [A]
P , N
(800Vdc)
R , S , T
(500Vac)
200V
11
8
4
45
15
10
5
60
22
16
8
90
400V
11
4
2
30
15
4
2
40
22
8
4
60
30
8
4
80
Table 4.2 Wire, according to capacity and Fuse recommendation
C
A
U
T
I
O
N
S
1) Use copper wire rated for 600V, 75ºC.
2) Use only fast-blow fuses.
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16
5. Operation
5.1 Display description
Figure 5.1 keypad display description
5.2 Operation
1
Refer to wiring diagram in Chapter 4.2 and connect inverter, RCU, and control I/O
Check the RCU P (+) terminal is connected to the inverter DC Link (+) and the RCU
N (-) terminal is connected to the inverter DC Link (-). If this condition were not
satisfied, RCU could be broken.
2
After power is supplied to inverter, Check if RCU display on keypad behaves
properly. If the display is not good, please check wiring with the inverter.
3
Enter the DI 1-RUN and DI 2-Enable signal to RCU.
4
When regenerative energy is generated by inverter driving mode, RCU has a
regenerative state. If the magnitude of the regenerative current is not displayed or
fault code (Fxx) is displayed, check the operation status and the status of the wiring
and control signal input, please.
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Hitachi America, Ltd. RCU SERIES
`
17
5.3 Fault Codes
When RCU fault occurs, the Fault LED on the keypad will be lit. According to the fault states,
fault code is displayed such as below. When Fault occurs, Reset should be performed by DI5.
Fault
Code
Function
Fault Description
F 01
Overload Protection
Occurs after 100% for 100sec, 150% for 30sec
F 02
Overcurrent
Protection
Occurs at approx, 200% of the current on power side (Protected by Software)
F 07
Overvoltage
Protection
Threshold at approx, 800 VDC
F21
Overheating
Protection
Protected by thermistor at overheat condition(95℃)
F 22
ShortCircuit
Protection
Detects overcurrentandprotectsRCUbyhardware
F 25
External Emergency
Input Signal
Fault generated by external input signal
F32
ACSupplyOpen
The RCU detects no, or under voltage at the AC line terminals
F35
PhaseImbalance
Protection
Imbalance between phases (R, S, T) exceeds 2%.
Table 5.1 Fault code / Fault Description
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Hitachi America Ltd. RCU SERIES
18
7. Check for Maintenance
Check
Part
Check Item
Check Point
Check Period
Check Method
Standards of
judgment
Daily
Regular
The
Whole
Ambient
Environment
Ambient
temperature,
Humidity, Dust,
Hazardous
gases,
Oil residue
Etc.
○
seeing
tasting
thermometer
hygrometer
freezing is not
allowed (ambient
temperature
range : –10∼40℃)
condensation is
not allowed at RH
(ambient
humidity :
20∼90 %)
The whole
Equipment
Strange
vibration,
Strange Sound
○
Seeing, Hearing
No problem
Voltage
Source
Voltage
fluctuations and
Voltage drop
○
Inverter
Input voltage
measurement
Within ±10% of
rated voltage
Main
Circuit
Overall
Point
Insulated
resistance
○
Main Circuit
Terminal to
Ground Terminal
(500V-Mega use)
No problem
Screw
extracting
○
Seeing
Sign
of overheating
○
Seeing
Terminal
Block
Damage
○
Seeing
No damage
Smoothing
Condenser
Leaking, Strain
○
Seeing, Hearing
Relay
Trembling
phenomenon
○
Hearing
Resistor
Crack,
Discoloration
○
Seeing
Cooling Fan
Vibration
Strange sound
○
Hearing
< Next >
< Continued >
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Hitachi America, Ltd. RCU SERIES
`
19
Check
Part
Check Item
Check Point
Check Period
Check Method
Standards of
judgment
Daily
Regular
Main
Circuit
Cooling
System
Dust, Stink
○
Seeing
Wire
Strain
peeled
○
Seeing
RCU Output
3phase output
○
TESTER
Voltmeter
3 phase output
within
variation allowed
Control
Circuit
Operation
Protection
Circuit
○
Random
behavior
No problem
Connection
Captive state
○
Seeing, Touching
No problem
KEYPAD
Display,
Operation state
○
Seeing, Touching
No problem
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Hitachi America Ltd. RCU SERIES
20
Hitachi America, Ltd.
50 Prospect Avenue
Tarrytown, NY 10591
For Technical Support, contact your Hitachi Distributor,
Or visit:
www.hitachi-america.us/inverters
© Hitachi America, Ltd.
Manual Number: HAL1057C –May 2012
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