RBU

Operation Manual

z Thank you very much for your buying RBU series regenerative break unit.
z Before use, please read this manual thoroughly to ensure proper usage. Keep this
manual at an easily accessible place so that can refer anytime as necessary.
 Safety Precautions
Please read this operation manual carefully before installation, operation, maintenance or
inspection.

In this manual, the safety precautions were sorted to “WARNING” or “CAUTION”.

Indicates a potentially dangerous situation which, if can not
WARNING avoid will result in death or serious injury.

Indicates a potentially dangerous situation which, if can not

CAUTION
avoid will cause minor or moderate injury and damage the
device. This
Symbol is also used for warning any un-safety operation.

In some cases, even the contents of “CAUTION” still can cause serious accident.
Please follow these important precautions in any situation.

★ NOTE indicate the necessary operation to ensure the device run properly.

I
 TABLE OF CONTENTS

TABLE OF CONTENTS ............................................................................................ II

LIST OF FIGURES ................................................................................................... III
1. INTRODUCTION................................................................................................. 1
1.1 Technology Features .................................................................................... 1
1.2 Description of Name Plate ........................................................................... 2
1.3 Selection Guide ............................................................................................ 2
1.4 External Dimension ...................................................................................... 3
2. INSPECTION ...................................................................................................... 4
3. INSTALLATION................................................................................................... 5
3.1 Environmental Requirement......................................................................... 6
3.2 Installation Space ......................................................................................... 7
3.3 Dimensions of External Keypad ................................................................... 7
3.4 Disassembly ................................................................................................. 8
4. WIRING ............................................................................................................... 9
4.1 Terminal Configuration ............................................................................... 10
4.1.1 Main Circuit Terminals ..................................................................... 10
4.1.2 Control Circuit Terminals ................................................................. 10
4.2 Wiring Daragram ........................................................................................ 12
5. OPERATION.................................................................................................... 13
5.1 Keypad Description .................................................................................... 13
5.1.1 Keypad schematic diagram ............................................................. 13
5.1.2 Key function description .................................................................. 13
5.1.3 Indicator light description................................................................. 14
5.2 Function parameters .................................................................................. 14
5.3 Detailed function description ...................................................................... 17
6. TROUBLE SHOOTING ....................................................................................... 19
7. MAINTENANCE .............................................................................................. 21
7.1 Daily Maintenance...................................................................................... 21
7.2 Periodic Maintenance................................................................................. 21
8.3 Replacement of wearing parts ................................................................... 22

II
 LIST OF FIGURES

Figure 1.1 Nameplate of RBU......................................................................................... 2

Figure1.2 External dimensions. ...................................................................................... 3
Figure 3.1 Relationship between output current and altitude. ........................................ 6
Figure 3.2 Safety space.................................................................................................. 7
Figure 3.3 Dimension of big keypad. .............................................................................. 7
Figure 3.4 Disassembly of cover. ................................................................................... 8
Figure 4.1 Main circuit terminals................................................................................... 10
Figure 4.2 Control circuit terminals. .............................................................................. 10
Figure 4.3 Wiring Diagram............................................................................................ 12
Figure 5.1 Keypad schematic diagram. ........................................................................ 13

III
 Introduction

1. INTRODUCTION
1.1 Technology Features

Voltage Range 380V

Break Moment 60s with 100% of rated torque (25% Duty cycle), can
continuously run with 80% of rated torque.

AC Power 380VAC, 50/60Hz

AC Voltage Range ＋10％ to －15％, the imbalance between phases less than
2%.

AC Frequency Range Less than 3Hz

Control Mode Current Control with 120°

AC Power Factor Higher than 0.9

Overload Capacity 30s with 150% of rated current

Operation Mode External terminal, Keyboard

Fault Output Relay output

Status Display LED Keyboard

Analog Output Voltage (0－10V)

Over current Protection 220％ rated current

Over load protection 30s with 150% of rated current

Over voltage DC: 800V

Overtemperature Temperature resistance detection

AC phase failure fault AC phase failure

AC frequency failure Fluctuating higher than 3Hz

fault

Power light display DC: higher than 50V

1
Introduction

1.2 Description of Name Plate

Figure 1.1 Nameplate of RBU.

1.3 Selection Guide

Rated
Input DC rated DC rated
Model No. Power Size
voltage current (A) current (A)
(KW)

RBU-7R5-4 380V 7.5 13 10

RBU-011-4 380V 11 19 15

RBU-015-4 380V 15 26 20

RBU-018-4 380V 18.5 32 25

RBU-022-4 380V 22 37 30

RBU-030-4 380V 30 51 40

RBU-037-4 380V 37 64 50

RBU-045-4 380V 45 77 60

RBU-055-4 380V 55 96 75

RBU-075-4 380V 75 128 100

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 Introduction

1.4 External Dimension

Figure1.2 External dimensions.

A B L W D
Installation
Power (mm) (mm) (mm) (mm) (mm)
Hole
(kW) Installation
External Dimension (mm)
Dimension
7.5-22 In developing

30-75 140 130 577 220 236 6

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Inspection

2. INSPECTION

CAUTION
● Don’t install or use any RBU that is damaged or have fault part, otherwise may
cause injury.

Check the following items when unpacking the RBU,

1． Inspect the entire exterior of the RBU to ensure there are no scratches or other
damage caused by the transportation.
2． Ensure there is operation manual and warranty card in the packing box.
3． Inspect the nameplate and ensure it is what you ordered.
4． Ensure the optional parts are what you need if have ordered any optional parts.

Please contact the local agent if there is any damage in the RBU or optional parts.

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 Installation

3. INSTALLATION

WARNING
● The person without passing the training manipulate the device or any rule in the

“Warning” being violated, will cause severe injury or property loss. Only the person,
who has passed the training on the design, installation, commissioning and

operation of the device and gotten the certification, is permitted to operate this

equipment.

● Input power cable must be connected tightly, and the equipment must be grounded

securely.

● Even if RBU is not running, the following terminals still have dangerous voltage:
- Power Terminals: R, S, T

- Motor Connection Terminals: U, V, W.

● When power off, should not install the RBU until 5 minutes after, which will ensure the
device discharge completely.

● The section area of grounding conductor must be no less than that of power supply

cable.

CAUTION
●When moving the RBU please lift by its base and don’t lift by the panel. Otherwise

may cause the main unit fall off which may result in personal injury.

● Install the RBU on the fireproofing material (such as metal) to prevent fire.

● When need install two or more RBU in one cabinet, cooling fan should be provided to

make sure that the air temperature is lower than 45°C. Otherwise it could cause fire

or damage the device.

5
Installation

3.1 Environmental Requirement

3.1.1 Temperature
Environment temperature range: -10°C ~ +40°C. RBU will be derated if ambient
temperature exceeds 40°C.
3.1.2 Humidity
Less than 95% RH, without dewfall.
3.1.3 Altitude
RBU can output the rated power when installed with altitude of lower than 1000m. It will
be derated when the altitude is higher than 1000m. For details, please refer to the
following figure:

(m)
Figure 3.1 Relationship between output current and altitude.
3.1.4 Impact and Oscillation
It is not allowed that the RBU falls down or suffers from fierce impact or the RBU installed
at the place that oscillation frequently.
3.1.5 Electromagnetic Radiation
Keep away from the electromagnetic radiation source.
3.1.6 Water
Do not install the RBU at the wringing or dewfall place.
3.1.7 Air Pollution
Keep away from air pollution such as dusty, corrosive gas.
3.1.8 Storage
Do not store the RBU in the environment with direct sunlight, vapor, oil fog and vibration.

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 Installation

3.2 Installation Space

Figure 3.2 Safety space.

Notice: Add the air deflector when apply the up-down installation.
3.3 Dimensions of External Keypad

Figure 3.3 Dimension of big keypad.

7
Installation

3.4 Disassembly

Figure 3.4 Disassembly of cover.

8
 Wiring

4. WIRING

WARNING
● Wiring must be performed by the person certified in electrical work.
● Forbid testing the insulation of cable that connects the RBU with high-voltage
insulation testing devices.
● Cannot install the RBU until discharged completely after the power supply is switched
off for 5 minutes.
● Be sure to ground the ground terminal.
400V class: Ground resistance should be 10Ω or less,
Otherwise, it might cause electric shock or fire.
● Connect input terminals (R, S, T) and output terminals (U, V, W) correctly.
Otherwise it will cause damage the inside part of RBU.
● Do not wire and operate the RBU with wet hands.
Otherwise there is a risk of electric shock.

CAUTION
●Check to be sure that the voltage of the main AC power supply satisfies the rated
voltage of the RBU.
Injury or fire can occur if the voltage is not correct.
● Connect power supply cables and regenerative cables tightly.

9
Wiring

4.1 Terminal Configuration

4.1.1 Main Circuit Terminals

Figure 4.1 Main circuit terminals.

Main circuit terminal functions are summarized according to the terminal symbols in the
following table. Wire the terminal correctly for the desired purposes.

Terminal Symbol Function Description

R、S、T Terminals of 3 phase main power

(+)、(-) Input terminals of power regenerative

Terminal of ground (PE)

4.1.2 Control Circuit Terminals

Figure 4.2 Control circuit terminals.

Control circuit terminals

Terminal Description
ON-OFF signal input, optical coupling with +24V and COM. Short
connect with COM.
S1: When terminal control is valid, automatical input;
S1~S4
S2: When terminal control is un-valid, manual input;
S3: Multi-function terminal (Default is external fault input)
S4: Multi-function terminal (Default is fault reset input)

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 Wiring

Terminal Description
Common ground terminal for digital signal and +24V (or external
COM
power supply).
Open collector output terminal, The corresponding common
ground terminal is COM.
Y
External voltage range: 0~24V
Output current range: 0~50mA
Provide output power supply of +24V.
+24V
Maximum output current: 150mA
AO Analog output terminal. Output range: 0~10V
Common ground terminal of analog signal and AO.
GND
GND must isolated from COM.
RO1A、 RO1 relay output: RO1A—common; RO1B—NC; RO1C—NO.
RO1B、RO1C Contact capacity: AC 250V/3A, DC 30V/1A.

11
Wiring

4.2 Wiring Daragram

AC Reactor U
R
Electromagnetism contactor V M
S INVERTER
W
T (+)/P (-)/N
PE
Suggest to use FU

(+) (-)
R
S RBU
T

Automatic running S1

Manual running S2
Interface for
CN9 external keyboard
External fault S3

Faulty reset S4 AO ～ Analog output

0-10V/0-20mA
GND

COM
Y
+24V Open collector
output
COM

PE
ROA1

ROB1 Relay
output 1
ROC1

Figure 4.3 Wiring Diagram.

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 Operation

5. OPERATION
5.1 Keypad Description

5.1.1 Keypad schematic diagram

Figure 5.1 Keypad schematic diagram.

5.1.2 Key function description

Key Name Function Description

Programming
Entry or escape of first-level menu.
Key

Enter Key Progressively enter menu and confirm parameters.

UP Increment
Progressively increase data or function codes.
Key

DOWN
Progressive decrease data or function codes.
Decrement Key

In parameter setting mode, press this button to

Shift Key select the bit to be modified. In other modes,
cyclically displays parameters by right shift

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Operation

Run Key Start to run the inverter in keypad control mode.

In running status, restricted by P7.04, can be used to

STOP/RESET stop the inverter.
Key When fault alarm, can be used to reset the inverter
without any restriction.

5.1.3 Indicator light description

1) Function Indicator Light Description

Function indicator Description
Extinguished: stop status
RUN/TUNE
Light on: operating status
Extinguished: keypad control
LOCAL/REMOT Flickering: terminal control
Light on: communication control
Extinguished: normal operation status
TRIP
Flickering: overload pre-warning status

2） Unit Indicator Light Description

Unit indicator Description

Hz Frequency unit
A Current unit
V Voltage unit
RPM Rotating speed unit
% Percentage

3) Digital Display
Have 5 digit LED , which can display all kinds of monitoring data and alarm codes such as
mains voltage, bus voltage, output current and so on.

5.2 Function parameters

Function Factory Serial

Name Description Modify
Code Setting No.

P0 Group: Basic Function

0~1
0: Keyboard control
P0.00 Control mode 1: Terminal control 1  0
S1 valid: automatical mode
S2 valid: manual mode

Keyboard control 0~1

P0.01 0: Automatical mode 0  1
mode
1: Manual mode

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 Operation

Function Factory Serial

Name Description Modify
Code Setting No.

P0.02 ON/OFF filter times 1~10 1  2

Current protection 0.5~30.0%

P0.03 5.0% O 3
threshold of trip-free

Regenerative voltage
P0.04 400.0~760.0V 650.0V O 4
of start

Regenerative voltage
P0.05 0.0~60.0V 12.0V O 5
range

Regenerative stop
P0.06 0.1~10.0S 1.0S O 6
time

0~1
P0.07 Input frequency 0: 50HZ 0  7
1: 60HZ

1~15
3: Valid when short connect S3 and 3 (External
P0.08 S3 terminal function  8
COM fault))
Others, reserved

1~15
2: Valid when short connect S4 and
P0.09 S4 terminal function 2 (Fault reset))  9
COM
Others, reserved

P0.10 Reserved 1 O 10

0~8
0: DC bus line voltage (0~1000V)
P0.11 AO function selection 1 O 11
1: Output current (0~200.0%)
2~8: Reserved

P0.12 AO lower limit 0.0%~100.0% 0.0% O 12

AO lower limit
P0.13 0.00V ~10.00V 0.00V O 13
corresponding output

P0.14 AO upper limit 0.0%~100.0% 100.0% O 14

AO upper limit
P0.15 0.00V ~10.00V 10.00V O 15
corresponding output

0~1
Cooling fan running 0: Run after start
P0.16 1 O 16
mode 1: Start when temperature higher
than 45℃

Y ON/OFF output 0~15

P0.17 0 O 17
selection 0: no output

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Operation

Function Factory Serial

Name Description Modify
Code Setting No.

1: Running command is valid

2: Regenerative running
Relay output
P0.18 3: Reserved 4 (Fault output) O 18
selection
4: Fault output
5~15: Reserved

Under voltage
P0.19 300.0V ~400.0V 380.0V O 19
protection

P0.20 Fault reset times 0~3 0  20

P0.21 Fault reset time 0.1~10.0S 3.0S  21

AC 0~1
P0.22 input phase-failure 0: Unvalid 1  22
protection 1: Valid

AC
P0.23 input phase-failure 0.5~10.0S 1.0S  23
protection time

P0.24 Running time 0~XXXXXH ● 24

0~2
Restore function
0: no change
P0.25 parameters, 0  25
1: Restore factory setting
clear fault record
2: Clear fault record

P0.26 Software version ● 26

Fourth latest fault 0~26

P0.27 ● 27
type
0: No fault
Third latest 1: Reserved
P0.28 ● 28
fault type 2: Reserved
Second latest 3: IGBT protection(OUT3)
P0.29 4: Reserved ● 29
fault type

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 Operation

Function Factory Serial

Name Description Modify
Code Setting No.

5: Reserved
6: Over-current (OC3)
7: Reserved
8: Reserved
9: Over-voltage (OV3)
10: DC bus Under-voltage(UV)
11: Reserved
12: Inverter overload (OL2)
13: Reserved
14: Input phase failure (SPI)
Latest 15: Reserved
P0.30 ● 30
fault type 16: IGBT overheat (OH2)
17: External fault (EF)
18: Reserved
19: Current detection fault (ITE)
20: Reserved
21: EEPROM fault (EEP)
22: Reserved
23: Reserved
24: Reserved
25: Control power fault (CP)
26: Parameter setting wrong (PEr)

Output current at
P0.31 ● 31
current fault

DC bus voltage at
P0.32 ● 32
current fault

0~1
P0.33 Parameter locked 0: No locked 0 O 33
1: Locked

P0.34 Factory password 0~65535 *****  34

5.3 Detailed function description

Function Factory Serial

Name Description Modify
Code Setting No.

0~1
0: Keyboard control
P0.00 Control mode 1: Terminal control 1  0
S1 valid: automatical mode
S2 valid: manual mode

Keyboard control 0~1

P0.01 0: Automatical mode 0  1
mode
1: Manual mode

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 Operation

Automatical mode:
When in automatical mode, RBU detects the bus line voltage and realizes start and stop
automatically.
When the bus voltage is higher than P0.04, start the regeneration.
When the bus voltage is lower than P0.04, stop the regeneration.

Manual mode:
When start the running command, RBU regenerates all the time.

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 Trouble Shooting

6. TROUBLE SHOOTING
Fault
Fault Type Reason Solution
Code

1. Inspect external
1. IGBT module fault.
equipment and eliminate
2. Malfunction caused by
OUT IGBT fault interference. Press
interference.
STOP/RST to reset
3. Grounding is not properly.
2. Ask for support.

1. Decrease the sudden

change of regenerative
1．Sundden change of
Over-current power
OC regenerative power
when running 2. Use RBU with higher
2．Lower power of RBU
power
3. Ask for support

1. Set
1. Sundden change of 2. Decrease
regenerative power regenerative voltage
Over-voltage
OV 2. More higher threshold threshold
when running
setting of RBU 3. Use RBU with higher
3. No enough capacity of RBU power
4. Ask for support

1. Select variable
1. More lower threshold frequency motor.
setting of RBU 2. Check and adjust V/F
OL RBU overload 2. Sundden change of curve.
regenerative power 3. Check and adjust
3. More lower power of RBU PB.03
4. Check the load.
1. Check AC input
Input phase
SPI Power off at AC input power supply.
failure
2. Ask for support
S3: External fault input Inspect external
EF External fault
terminal take effect. equipment.

1. Cooling fans of inverter 1. Install cooling unit.

stop or damaged. 2. Remove heat source.
2. Obstruction of ventilation 3. Replace cooling fan
OH IGBT overheat
channel 4. Clear the ventilation
3. Ambient temperature is too channel.
high. 5. Ask for support

19
Trouble Shooting

1. Improper baud rate setting. 1. Set proper baud rate.

Communication 2. Receive wrong data. 2. Check communication
CE
fault 3. Communication is devices and signals.
interrupted for Long time
Current Wires or connectors of control 1. Check the wiring.
ITE
detection fault board are loose 2. Ask for support.
Press STOP/RESET to
Read/Write fault of control
EEP EEPROM fault reset
parameters
Ask for support
Control power
CP Auxiliary power damaged Ask for support
fault
Parameters
PER
setting wrong

20
 Maintenance

7. MAINTENANCE

WARNING
● Maintenance must be performed according to designated maintenance
methods.
● Maintenance, inspection and replacement of parts must be performed only by
certified person.
● After turning off the main circuit power supply, wait for 10 minutes before
maintenance or inspection.
● DO NOT directly touch components or devices of PCB board. Otherwise
inverter can be damaged by electrostatic.
● After maintenance, all screws must be tightened.

7.1 Daily Maintenance

In order to prevent the fault of RBU to make it operate smoothly in high-performance for a
long time, user must inspect the RBU periodically (within half year). The following table
indicates the inspection content.

Check Item Content

Ensure the environmental temperature is between
Temperature/Humidity 0℃~50℃, and humidity is between 20~90%.

Oil mist and dust Ensure there are no oil mist and dust in the RBU.
Inspect RBU to ensure whether there are abnormity
RBU heat and vibration.
Fan Ensure the fan is running well, nothing inside to block it.
Ensure the input power voltage and frequency is in
Input Power allowed range.

7.2 Periodic Maintenance

In order to prevent the fault of RBU to make it operate smoothly in high-performance

for a long time, user must inspect the RBU periodically (within half year). The following
table indicates the inspection content.

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Maintenance

Inspection Item Inspection Content Solution

Screw of external
Screws are loose or not? Tighten up
terminal
Clean them completely by dry
PCB Board Dust, Dirty object
compressed air
Abnormity noise and vibration,
1. Clean them
Fan cumulative time is over 20,000
2. Replace the fan
hours or not?
Electrolytic Color changed or not, any
Replace electrolytic capacitor
Capacitor peculiar smell?
Clean them completely by dry
Heat emission Dust, dirty object
compressed air
Clean them completely by dry
Power Components Dust, dirty object
compressed air

8.3 Replacement of wearing parts

Fans and electrolytic capacitors are wearing part, please make periodic replacement to
ensure long term, safety and failure-free operation. The replacement periods are as
follows:
◆Fan: Must be replaced when using up to 20,000 hours;

◆Electrolytic Capacitor: Must be replaced when using up to 30,000~40, 000 hours.

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