Hitachi RCU- 2015, RCU- 2011, RCU- 2022, RCU- 4011, RCU- 4015 Instruction Manual

Hit achi America, Lt d.

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RCU Series

Regenerative Converter Unit

Instruction Manual

NOTE: REFER ALSO TO APPLICABLE

INVERTER INSTRUCTION MANUAL

Manual Number: HAL1057A

May 2010

Hitachi America, Ltd.

After reading this manual,

keep it handy for future

reference.

RCU Series Regenerative Converter

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TABLE OF CONTENTS

SAFETY ........................................................................................................................................................................ 4

WARNINGS .................................................................................................................................................................. 4

INTRODUCTION ........................................................................................................................................................ 6

BENEFITS .................................................................................................................................................................... 6

MAIN POWER CONNECTION DIAGRAM ........................................................................................................... 6

POWER AND CONTROL CONNECTIONS ............................................................................................................ 7

CONTROL TE RMINAL FUNCTIONS ..................................................................................................................... 8

POWER WIRING ........................................................................................................................................................ 9

DISPLAY ...................................................................................................................................................................... 9

OUTPUT CURRENT AND LINE VOLTAGE WAVEFORMS .............................................................................. 10

ELECTRICAL SPECIFICATIONS ......................................................................................................................... 10

DIMENSIONS ............................................................................................................................................................ 1 1 

The contents of this manual are subject to

change without notice.

May 2010

Revision History

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Rev A, May 2010 – Miscellaneous corrections throughout. Added coo ling clearance drawing.

1. Safety

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ONLY A COMPETENT ELECTRICIAN SHOULD CARRY OUT

1.1 Warning

THE ELECTRICAL INSTALLATION.

Internal Components and circuit boards (except the isolated I/O terminals)
carry high voltage when the RCU Regenerative Converter is connected to the

1

main power supply and/or inverter DC bus. This voltage is extremely
dangerous and may cause death or severe injury if you come in contact with it.

When the RCU Regenerative Converter is connected to the main power,
current is flowing in the AC line connection (R (L1), S (L2), T (L3)) and the

2

inverter’s DC-Link (P, N).
The voltage on the RCU components is extremely dangerous and may cause

3

death or severe injury if you come in contact with it.
The control I/O terminals are isolated from the main voltage, but the relay

outputs and other I/O terminals may have dangerous voltage connected even if

4

the power is disconnected from the RCU Regenerative Converter.
The installer of the RCU Regenerative Converter is responsible to ensure it is

installed with appropriate main switches or disconnects, and appropriate power

5

fusing.

Spare parts and service should only be obtained through Hitachi America, Ltd.

6

1.2 Safety Instructions

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1

2

3

DO NOT make any connections when the Regenerative Converter is
connected to the main voltage or energized inverter DC bus.

DO NOT make any measurements when the Regenerative Converter is
connected to the main voltage and energized inverter DC bus.

After disconnecting the main power, wait until the cooling fan stops and the
indicator goes out. Wait a further 3 minutes before doing any work on the
Regenerative Converter connections. Do NOT open the cover during this

!

Ground Warning Symbols

The ground terminal of Regenerative Converter
must be connected to a proper ground.

Grounding of the Regenerative Converter

reduces the risk of high voltage shock, injury or
death.

time.

DO NOT make any voltage withstand tests on any parts of the Regenerative

4

Converter. Damage to the unit may result.

DO NOT touch the integrated circuits or other components on the internal

6

circuit boards. Static voltage discharge may destroy the components.

Make sure that the cover of RCU Regenerative Converter is closed before

7

connecting the main voltage.

Please observe special caution where the
following warning symbols appear
throughout this manual.

= Dangerous Voltage

= General Warning

2. Introduction

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• Vertical lifting machinery or high inertia loads like elevators, cranes, centrifugal fans
and centrifuges contain potential energy and inertial energy when operating. When
the motor is operated by an inverter, this ener gy is converted back into electrical
energy when the devices decelerate, lower or stop the load. This electrical energy,
called regeneration, flows back into the inverter’s DC bus, causing the voltage to rise.

• Traditionally, this regenerative energy is dissipated as heat through dynamic braking

resistors, and is therefore wasted.

• The RCU series Regenerative Converter can provide up to 40% energy savings, by

reclaiming that regenerative energy and feeding it back into the AC supply .

3. Benefits

• The RCU Regenerative Converter reduces electric power consumption by returning

the otherwise wasted energy to the AC power distribution network for use by other
loads.

• Because there is no heat generated by braking resistors, the capacity of air

conditioning systems in the electrical room can be reduced, further reducing electric
power consumption.

• Heat generated by braking resistors can cause secondary overheating problems for

adjacent systems should the equipment room air conditioner system have a problem.

4. Main Power Connection Diagram

L1

VFD

5. Power and Control Connections

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RCU Series

Shielded

Control Terminal Functions

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Input Signals

7: RUN
When RUN input is given and DC bus voltage is higher than the RCU operating voltage,
regeneration is started.

9: RCU ENABLE
When RCU ENABLE input is given, RCU operation is possible.

10: EXTERNAL FAULT (A)
When EXTERNAL FAULT (A) input is given, the RCU cuts output power, and
regenerative converter operation is stopped.

12: FAULT RESET
If FAULT RESET input is given, the RCU fault condition is cleared.

11, 16: COMMON
Common terminal for input signals

Note: When terminals 7, 9, and 11 are jumpered together, regenerative operation
automatically starts when the inverter’s DC bus voltage is above the RCU operating
voltage. These jumper wires are factory pre-installed for your convenience.

Output Signals

Fault Relay
This relay is activated when fault trip has occurred.

21 (A): Regenerative Converter error A contact (NO)

22 (B): Regenerative Converter error B contact (NC)

23 (COM): Regenerative Converter error common

Converter Ready Relay
This relay is activated when the regenerative converter is ready to operate.

24 (A): Regenerative Converter Ready A contact (NO)

25 (B): Regenerative Converter Ready B contact (NC)

26 (COM): Regenerative Converter Ready common

6. Power Wiring

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 P : DC-Link P
 N : DC-Link N
 R(L1) , S(L2), T(L3) : 3-phase main power

 FG : Earth

7. Display

(Phase sequence: Automatic recognition)

• rdy (Ready) : Regenerative Converter is ready

• 000.0: Current value during regeneration (000.0A)

• F00 : Fault Code

8. Output Current and Line Voltage Waveforms

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9. Electrical Specifications

Models

200 V Class 400 V Class Power Rating

RCU-2011 RCU-4011 11 kW
RCU-2015 RCU-4015 15 kW
RCU-2022 RCU-4022 22 kW

RCU-4030 30 kW

Range

Applicable AC Power

Frequency

Efficiency

Operating Voltage

(DC-LINK)

Display and Protection

Protection : Overheat, Over current, Arm-short, Over Voltage, Low voltage, and

Filter

200 - 230VAC / 380VAC - 460VAC

3 Phase 200 - 230V / 380V - 460V

50Hz/60 Hz

Over 95%

Automatically set by input voltage

Display : ready, regenerative current, fault codes

Phase Error etc.

Built-in reactor and noise filter

Wiring

Environmental

Conditions

Input R, S, T / DC Bus P, N / Ground

Operation: -10°C to 40°C

Storage: -20°C to 65°C

< 90% relative humidity, non-condensing

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10. Dimensions

11 kW and 15 kW Models

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Dimensions (cont’d)

22 kW and 30 kW Models

Dimension (cont’d)

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Be sure to observe the mounting clearances shown below to allow adequate air flow for cooling of the
units.

b

a

a

c

Distance(mm)

a a2* b c

30 10 160 80

*a2 is the distance between adjacent RCUs