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Non-Regenerative DC Bus Supply Unit

1. Publication 2364E 5 01 April 2002 Chapter 3 Your 350A DC NRU Current Code B Input Voltage Rated DC Bus This chapter provides the following information for the 350A DC V AC kW NRU 230 109 atypical cabinet layout diagram Figure 3 1 T 775 gram Fig 460 217 atypical electrical schematic Figure 3 2 575 271 asymbol to component reference table for interpreting the electrical schematic Table 3 A 350A DC System Layout Figure 3 1 Typical 350A DC NRU Layout o 79 SP4 a a 2 N 3 it Publication 2364E 5 01 April 2002 3 2 Your 350A NRU Current Code 350A DC NRU Electrical Schematic Figure 3 2 Typical 350A DC NRU Schematic 3 Phase AC Input Powermonitor 11 MASTER MODULE BULL 1403 MM05A 115 VAC NRU CONTROL POWER CURRENT INPUTS BULL 1403 DMA 115 VAC NRU DISPLAY CONTROL VOLTAGE MODULE POWER INPUTS STATUS INPUTS GO TO NEXT PAGE TO POWER TRANSFORMER GROUNDING RESISTOR 1 201822 4 a 115 VAC NRU CONTROL POWER eS em a 0 Ro T T 115VAC NRU I
2. Publication 2364E 5 01 April 2002 5 2 Your 1500A DC NRU Current Code D 1500A DC NRU Electrical Figure 5 2 Schematic Typical 1500A DC NRU Schematic 3 Phase AC Input EA1 Powermonitor Il MASTER MODULE BULL 1403 05 115 VAC NRU CONTROL POWER CURRENT INPUTS BULL 1403 DMA 115 VAC NRU DISPLAY CONTROL VOLTAGE MODULE POWER INPUTS 1403 NSC BULL STATUS INPUTS el GO TO NEXT PAGE TO POWER TRANSFORMER 115 NRU GROUNDING RESISTOR CONTROL _ TB2 1 2 2 115 VAC NRU SENSOR CONTROL TO CONTACTOR POWER 2 MONITORING CIRCUIT INPUT 115 METER RELAY TB1 7 TO CONTACT MONITORING 1 8 wee CIRCUIT TO CONTACTOR MONITORING CIRCUIT a C E 1 ED ND oe ee EMEN Publication 2364E 5 01 April 2002 FROM PREVIOUS PAGE Your 1500A DC NRU Current Code D 5 3 Important The Powermonitor II standard configuration works with grounded wye secondary supplies only For more information on Powermonitor configurations for other supply types consult Powermonitor documentation and the Power Quality and Automation group located in Milwaukee WI USA F6 OPTIONAL REMOTE DC HORIZONTAL BUS TO INV
3. 1 10 Your 180A DC NRU Current Code A 180A DC System Layout 2 1 180A DC NRU Electrical 5 2 2 Your 350A DC NRU Current Code B 350A DC System 3 1 350A DC NRU Electrical 3 2 Your 900A DC NRU Current Code C 900A DC System 4 1 900A DC NRU Electrical Schematic 4 2 Your 1500A DC NRU Current Code D 1500A DC System 5 1 1500A DC Electrical Schematic 5 2 Publication 2364E 5 01 April 2002 toc ii Table of Contents Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Appendix A Publication 2364E 5 01 April 2002 Your 2000A DC NRU Current Code E 2000A DC System 6 1 2000A DC NRU Electrical Schematic 6 2 Your 2500A DC NRU Current Code F 2500A DC System Layout 7 1 2500A DC NRU Electrical Schematic 7 2 Your 3000A DC NRU Current Code G 3000A DC System 8 1 3000A DC Electrical 8 2 Installing Your NRU Before Yow Aout Li otis ERAS 9 1 Documentation 9 1 Equipment te teer et ome Bones 9 1 Tools des See rt erbe eet 9 1 Insta
4. 20 508 1500 0 91 5 2324 55 1270 20 608my 2 200 015 0324 55 1270 20 508 2 250 915 2324 mm 65 1651 20 508 2 91 5 2324 mm 20 508 2 The height of 1500 DC through 3000A DC units includes the 1 5 high required base channel You may choose a base channel for 180A DC 350A DC and 900 A DC units add 1 5 inches to the height if you choose the base channel option Approximate Shipping Weights Table B Approximate Shipping Weights Output Current Unit Width and Complete Unit A DC Code Depth Weight 180 350 25 W x 20 D 675 Ib 306kg 900 30 W x 20 D 1000 Ib 454 kg 1500 2000 55 W x 20 D 1950 Ib 885 kg 2500 3000 65 W x 20 D 3000 Ib 1361 kg Publication 2364E 5 01 April 2002 2 Specifications Electrical Specifications Table C NRU Electrical Specifications Maximum Control Transformer kVA Ratings Nominal Input Continuous Nominal DC Continuous 0 NRU Rated DC Optional Standard Optional Extra Voltage V AC Input Current Bus Voltage BusCurrent Current Bus kW Basic Capacity Capacity for Capacity for Control Bus Control Bus 380 510 2000 10 50 2047 510 2500 20 50 2455 510 3000 20 50 M F 150 22 5o 100 e 180 20 52 100 5 _ amp 3 8 2200 To 36 15 90
5. DCchokethermswitch CS CR Phase loss relay 2 21 1 013 Curentrransormr 1 30005 016 300 1800 EAT jPowermontorl EA2 BusindicatrPCB IEA2F1 2 Bus indicator PCB fuses 1000V 1 3 32 diameter 3 length 500AIC EA3 Line RC suppressor PCB EM Bridge suppressor PCB EAS 6 jArfiowsenorPCB F1 1 Incoming 3 phase line fuses 7 1250 170 F4 F6 Primary fuse for a 2 KVA control 12A KLDR 8A KLDR 6 25A KLDR 5A KLDR transformer Primary fuse for 5 control 30A KLDR 17 5A KLDR 15A KLDR 12 KLDR transformer Primary fuse for 10 gontrol 60A KLDR 35A FRS 25A KLDR 20AKLDR transformer NRU control power fuse HAALKDR Control bus fuse for a 2 KVA 5A KLDR control transformer mees be control transformer pe control transformer F11 13 Phase ossfuses KLDR 14 16 Line RC suppressor fuses 125 KTKR HS1 2 Bridge heatsink Bridgefan 1 1200 MTR1 C_ Bridge fan capacitor 20uFcapacitor MTR2 3 Door mountedfanbychoke 69 9 0 MTR4 6 DoormountedfanbyCB 169 3400 1 1 1 1 O pomenegadpigt LN Uni Not Feud pilot light 120 amber 800MR i HC UR
6. PL1_ D Bus Energized plot ight _ _ 24VACNDG red 00000000000 Un Not Fauted pilot light Hwa amber 800MR tou sensor omer aii power transformer A 1 KVA control transformer is standard 2 KVA and 5 kVA control transformers are available as options This transformer has multiple taps to accommodate 230 380 460 575V AC primary voltages 51 2 Heatsikthermoswtch 12109 E T SPI 3 1 360 275 460J 320VAC 460 320 550 385V AC SPA Neutral to ground MOV 600 550 760 680V AC 760 J 680V 760 680V AC DC bus voltmeter 1 zsovpc 70 0 1000 0 1000 0 2 7 Components marked as being options are part of NRU standard options Not all NRUs will have these components Publication 2364E 5 01 April 2002 Input Voltage Rated DC Bus V AC kW 230 465 380 765 460 930 575 1163 1500A DC System Layout CUSTOMER 3 PHASE AC INPUT Chapter 5 Your 1500A DC NRU Current Code D This chapter provides the following information for the 1500A DC NRU atypical cabinet layout diagram Figure 5 1 atypical electrical schematic Figure 5 2 asymbol to component reference table for interpreting the electrical schematic Table 5 A Figure 5 1 Typical 1500A DC NRU Layout
7. 3 Phase AC Input Powermonitor 11 MASTER MODULE BULL 1403 MM05A POWER CURRENT INPUTS T 115 VAC NRU CONTROL POWER INPUT BULL 1403 DMA 115 VAC NRU DISPLAY CONTROL VOLTAGE MODULE POWER INPUTS STATUS INPUTS GO TO NEXT PAGE DOT PA RURSUS m E ERES CREME RNC TO POWER TRANSFORMER GROUNDING RESISTOR J 1821 1822 115 VAC NRU VM CONTROL 2 POWER INPUT 115 METER RELAY TB1 7 CONTACTOR MONITORING 1 8 TO CONTACTOR CIRCUIT MONITORING CIRCUIT Publication 2364E 5 01 April 2002 FROM PREVIOUS PAGE Your 180A DC NRU Current Code A 2 3 Important The Powermonitor II standard configuation works with grounded wye secondary supplies only For more information on Powermonitor configurations for other supply types consult Powermonitor documentation and the Power Quality and Automation group located in Milwaukee WI USA OPTIONAL REMOTE INTERLOCK 1 2 mn 9 DELL O q 07 syac 2 MTR1 P TB1 9 TB1 10 EA5 CR 115 VAC NRU CONTROL POWER DC HORIZONTAL BUS TO INVERTER UNITS FOOTNOTES Door moun 115 VAC CONTROL BUS TO INVERTER UNITS CR1 1 3 Je
8. CR2 E Note An NRU may have either a door mounted ammeter or a Powermonitor 11 This ed ammeter option Powermonitor II option drawing shows both options for information Powermonitor communication module option Line RC suppressor option Ground fault detection option Air flow sensing option Control bus option Unit not faulted pilot light option DC bus voltmeter option Publication 2364E 5 01 April 2002 2 4 Your 180A DC NRU Current Code Table 2 A 180A DC NRU Symbol to Component Cross Reference Symbol Description Option 230V AC 380VAC 460 1 575 AMI AmmetermontoingLi c11 Bridge suppressor capacitor 3uF 2000V 1 DCchoke 8 Phase loss relay 2 Fautreay 11 073 Current transformer 2005 01 6 450A 1800V D11 Bridge suppressor diode 7 60A 1700V AT jPowemontorll BusindicatorPCB 2 1 2 Bus indicator PCB fuses 1 1000V HVR 1 3 32 diameter 3 length 500AIC AC line RC suppressor PCB EAS AiflowsenorPCB F1 3 Incoming 3 phase line fuses 7 250A 170M faro _ Primary fuse for a 1 control KLDR 4A KLDR 3A KLDR 3A KLDR transformer Primary fusa 2 control o qu KLDR 8A KLDR 6 25A KLDR 5 KLDR transformer primary tusa TOS KVA control 30A
9. A type A 180A DC output B 350A DC output C 900A DC output D 1500A DC outpu E 2000A DC output F 2500A DC output 3000A DC outpu NEMA Type without gaskets and door fan filters J NEMA Type I wi h gaskets and door fan filters A 230V N 380V AC B 460V AC C 575V AC XX Code not applicable CA High AIC instantaneous trip motor circuit protector 180 to 350A DC CM High AIC instantaneous trip circuit breaker with thermal magnetic plug trip function 900 to 3000A DC Control Power Source 6P Standard capacity control transformer for control bus 6PX Extra capacity control transformer for control bus Door Mounted Pilot Lights 4EA Unit Not Faulted Control Bus Power On Pilot Light Metering 710P Analog AC input ammeter 11 Phase only 715P Analog DC bus voltage meter 86MBY Bulletin 1403 Powermonitor II for NRUs powered by a wye secondary supply 86NSC Communication module 1403 NSC for Powermonitor II Protection 88GF Ground fault detection 14AFL Cooling fan air flow loss switch 14LSP Line RC suppressor module Unit Door Nameplates M3EW White background with black lettering phenolic label N3EB Black background with white lettering phenolic label N3ER Red background with white lettering phenolic label Miscellaneous 14WLBL Brady Datab wire labels J12 115V DC 15A duplex receptacle J11 Audio phone jack Publication 2364E 5 01 April 20
10. Allen Bradley Non Regenerative DC Bus Supply Unit NRU Bulletin 2364E User Manual Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Allen Bradley Sales Office or online at http www ab com manuals gi describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will the Allen Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation the Allen Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this man
11. If you need to contact Rockwell Automation for technical assistance please review the product and troubleshooting information in this manual first Then call your local Rockwell Automation representative For the quickest possible response we recommend that you have the catalog numbers of your products available when you call Publication 2364E 5 01 April 2002 P vi Preface This page intentionally left blank Publication 2364E 5 01 April 2002 What is the 2364E Chapter 1 Overview This chapter introduces Rockwell Automation s Bulletin 2364E common DC bus non regenerative unit NRU describes the theory of NRU operation and provides comprehensive lists of NRU features and standard options Appendix A contains specifications on available NRUs Appendix B contains NRU catalog numbers with descriptions Appendix C provides some other details concerning AC input connections bus locations and wireway meter covers We designed the NRU to be our single direction power converter for the front end of a common DC bus drive system Read this section for a general description of NRU functionality and packaging What does the NRU do The NRU converts an incoming 3 phase AC line voltage into acommon DC bus voltage and current e 115 AC NRU control voltage via a basic capacity control transformer Control power source upgrade options allow you to select an increased transformer capacity to supply control power toa 115V
12. Preface Who Should Use This 1 1 Purpose of This 1 Safety Precautions P 1 Contents of this 1 P 3 Related Documentation P 4 Common Techniques Used in this Manual P 5 Drive System Receiving 5 Rockwell Automation Support P 5 Local Product Support 5 Technical Product Assistance 5 Overview What isthe 230467 cabo tat caus pee gated p pe Hem 1 1 What does NRU 4 1 1 How will NRU fit into 2362 drive system 1 2 How will the NRU fit into a drive system packaged in FD86N enclosures 1 2 How Does NRU Work 1 3 Primary Electrical Components of NRU 1 3 NRU Conceptual 1 5 Power Conversion Operation 1 6 Bulletin 2364E NRU Standard Features 1 7 Electrical System Features 1 7 Packaging 1 7 Bulletin 2364E NRU Standard Options 1 9 Electrical System Options 1 9 Packaging Options
13. _ 24V DC 11A 4 aad power transformer 1 KVA control transformer is standard 5 and 10 KVA control transformers are available as options This transformer has multiple taps to accommodate 230 380 460 575V AC primary voltages S1 2 Heatsink thermoswitch 220 F 1 55 6 5 1 3 Line to ine MOVs 7 360J 275VAC 460J 320VAC 460 320V 550J 385V AC SPA Neutral to grouna MOV 7 600J 550VAC 760J 680VAC 760 J 680V AC 760 J 680v AC vmi JDCbusvolimeter 70 02 750VDC i00VDC i00VDC 2 Components marked as being options are part of NRU standard options Not all NRUs will have these components Publication 2364E 5 01 April 2002 Input Voltage Rated DC Bus V AC kW 230 930 380 1530 460 1860 575 2325 3000A DC System Layout Chapter 8 Your 3000A DC NRU Current Code G This chapter provides the following information for the 3000A DC NRU atypical cabinet layout diagram Figure 8 1 atypical electrical schematic Figure 8 2 asymbol to component reference table for interpreting the electrical schematic Table 8 A Figure 8 1 Typical 2000A DC NRU Layout o Publication 2364E 5 01 April 2002 8 2 Your 3000A DC NRU Current Code 3000A DC NRU Electri
14. 1500 2000 2500 3000 EG Sound level determined using A type weighting Publication 2364E 5 01 April 2002 50 122 55 C 131 F Specifications A 7 Figure 3 180A and 350A DC NRU Watts Dissipation versus Load 1800 1600 1400 350A DC NRU 1000 800 600 180A DC NRU Total Watts Loss 400 200 0 10 20 30 40 50 60 70 80 90 100 Load Figure 4 900A DC NRU Watts Dissipation versus Load 4500 4000 3500 3000 900A DC NRU 76 e A e lt t Total Watts Loss 10 20 30 40 50 60 70 80 90 100 Load Publication 2364E 5 01 April 2002 8 Specifications Publication 2364E 5 01 April 2002 Figure 5 1500A and 2000A DC NRU Watts Dissipation versus Load 7000 6000 a 50007 2000A DC NRU 2 4000 1 3000 1500A DC NRU 20004 E 1000 0 0 20 30 40 50 60 70 80 90 100 Load Figure 6 2500A and 3000A DC NRU Watts Dissipation versus Load 12000 10000 a 8000 2 3000A DC NRU 6000 E 2500A DC NRU 5 4000 2000 0 n 1 0 20 30 40 50 60 70 80 90 100 Load Storage Conditions Table NRU Storage Conditions Ambient Temperature 40 to 70 C 40 to 158 F Relative Humidity 5 to 95 non condensing Understanding Catalog Numbers Appendix B NRU Catalog
15. HR 1 3 32 diameter 3 length 500AIC A3 Line RC suppressor PCB EM Bridge suppressor EA5 6 Airfowsensor PCB F1 F1A 3A Incoming 3 phase line fuses 7 1500A 170M F4 F6 Primary fuse for a 2 control 12A KLDR 8A KLDR 6 25A KLDR 5 KLDR transformer Primary fse Ora PORTO BE 30A KLDR 17Z5A KLDR 15A KLDR 0 12A KLDR transformer Primary fuse for a 60A KLDR 35A FRS 25A KLDR 20AKLDR transformer F7 NPU control power fuse 12A KLDR e control transformer control transformer mur mm OOOO control transformer Fi1 13 055 65 KLDR Fi4 16 RC suppressor fuses 25 HS1 2 02 MTRI Brigefan 1200 MTRI C Bridgefancapacitor 20uFcapacitor MTR2 3 Doormountedfanbychoke 169 34CFM MTR4 6 DoormountedfanbyCB sd PLI DC Bus Energzedpilotlignt 24V AC VDC red 80 1 1 2 Unt Not Fault plotlignt 1120 amber lPirfesensor power supply power transformer A 1 KVA control transformer is standard 5 KVA and 10 kVA control transformers are available as options This transformer has multiple taps to accommodate 230 380 460 575V AC p
16. If you do not have a basic understanding of the NRU contact your local Rockwell Automation Drive Systems representative for information before using this product This manual provides installation and software configuration instructions for Rockwell Automation s NRUs The following general precautions apply to Bulletin 2364E NRUs and to drive system lineups ATTENTION Only those familiar with the drive system the products used in the system and the associated machinery should plan or implement the installation startup and future maintenance of the system Failure to comply can result in personal injury and or equipment damage ATTENTION Only connect Rockwell Automation common DC bus AC drives to the NRU s common DC bus output Publication 2364E 5 01 April 2002 P ii Preface Publication 2364E 5 01 April 2002 ATTENTION Verify that all sources of AC and DC power are deenergized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part II ATTENTION The system may contain stored energy devices To avoid the hazard of electrical shock verify thatall voltage on capacitors has been discharged before attempting to service repair or remove a drive system or its components You should only attempt the procedures in this manual if you are qualified to do so and are familiar with solid state control equipment and the safety procedures in publication NFPA 70E ATTENTION An incorrectly applied o
17. Milwaukee WI USA F6 a x1 415 2 1 1 9 1 OPTIONAL REMOTE INTERLOCK 1 2 JMPR Q 1 10 MTR2 MTR3 MTR4 MTR5 MTR6 r 5 EA6 CR CH11 TG 115 VAC NRU CONTROL POWER 115 VAC CONTROL BUS TO INVERTER UNITS HAA RAA FH AFA als OH dL HEAT FIA F2A HEAT SINK SINK BUS f a Bus D1 T Lei D3 D5 HS1 06 us2 EA4 ERST ge 43 16 2 e LED1 Ye x3 Mme E iii eee ay VMAS ea tere DC HORIZONTAL BUS TO INVERTER UNITS FOOTNOTES Note An NRU may have either a door Door mounted ammeter option mounted ammeter or a Powermonitor This Powermonitor II option drawing shows both options for information Powermonitor communication module option Line RC suppressor option Ground fault detection option Air flow sensing option Control bus option Unit not faulted pilot light option DC bus voltmeter option Publication 2364E 5 01 April 2002 7 4 Your 2500A DC NRU Current Code F Table 7 A 2500A DC NRU Symbol to Component Cross Reference Symbol Description 7 Option 230VAC 3800 460 55 Ammeter monitoringLi_ 8 Circuit breaker 7 300A R frame breaker with 2500Aplug Hii 8
18. Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Publication 2364 5 01 April 2002 P N 314387 Supersedes March 1997 Copyright 2002 Rockwell Automation Inc All rights reserved Printed in USA
19. Which Table DoIUse B 4 Significance of Level Numbers B 4 Definition of Terms Used to Describe Qty in Kit B 5 Catalog Number Description B 5 NRU Details Wireway Meter Cover Details C 1 MCC AC Input Entry Area C 3 AC Input Customer Connection Details C 4 Recommended Disconnect Trip Settings C 5 Phase Loss Relay c2 8a p To D a s C 7 Installation and C 7 Monitor C 8 Reset ere eR RR EISE de C 8 MCC Bus Location Details 9 Publication 2364E 5 01 April 2002 toc iv Table of Contents This page intentionally left blank Publication 2364E 5 01 April 2002 Who Should Use This Manual Purpose of This Manual Safety Precautions Preface Read this preface to familiarize yourself with the rest of this manual This preface covers the following topics who should use this manual the purpose of this manual safety precautions contents of this manual related documentation conventions used in this manual drive system receiving e Rockwell Automation support Use this manual if you are responsible for installing or operating a Rockwell Automation non regenerative common DC bus supply unit NRUTM
20. environmental A 5 functional A 3 physical 1 startup See installation storage conditions See specifications environmental T temperature A 5 troubleshooting 10 1 watts dissipation 7 wireway meter cover C 1 www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation 5 Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation Br hlstra e 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 U S Allen Bradley Drives Technical Support
21. Control Transformer Primary Control Bus Phase Loss DC Bus Energized PCB 2364E 5 XFMR 380V AC 510V DC 180 2000 DC adi Fuses Control Control Transformer Primary Control Bus Phase Loss DC Bus Energized 2364 5 XFMR 380V AC 510V DC 2500 3000 DC all Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized PCB 2364E 10 kVA XFMR 380V 510 DC 1500 2000A DC 2308 Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized PCB 2364E 10 380V AC 510V DC 2500 3000A DC 2 1 2 2 2 2 2 2 2 2 2 2 2 1 2 1 each 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 1 2 1 set 2 1 2 AC Line RC Suppressor PCB and Fuses 2364E 180 3000A DC 6 MOV Line to Neutral and Neutral to Ground 2364 380V 510V DC amp 4607 AC 3 1 each 3 1 each 3 1 each 3 1 3 1 Publication 2364E 5 01 April 2002 8 NRU Catalog Numbers and Spare Parts Kits Table C Spare Parts Kits for NRUs with 460V AC Inputs Level Catalog Number Qty in Kit 1 Control Fuses Control Transformer Primary Phase Loss DC Bus Energized PCB 2364E 1 2864 SPES3A 4 kVA XFMR 460V AC 620V DC 180 2000A DC 296 Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 4 2364 SPE34A 2 sets PCB 2364E 2 kVA XFMR 460V AC 620V DC 180 350A DC T Control Fuses C
22. EA6 CR CH11 TG 115 VAC NRU CONTROL POWER 115 VAC CONTROL BUS TO INVERTER UNITS HAA RAA FH AFA als OH dL HEAT FIA F2A HEAT SINK SINK BUS f a Bus D1 T Lei D3 D5 HS1 06 us2 EA4 ERST ge 43 16 2 e LED1 Ye x3 Mme E iii eee ay VMAS ea tere DC HORIZONTAL BUS TO INVERTER UNITS FOOTNOTES Note An NRU may have either a door Door mounted ammeter option mounted ammeter or a Powermonitor This Powermonitor II option drawing shows both options for information Powermonitor communication module option Line RC suppressor option Ground fault detection option Air flow sensing option Control bus option Unit not faulted pilot light option DC bus voltmeter option Publication 2364E 5 01 April 2002 8 4 Your 3000A DC NRU Current Code G Table 8 A 3000A DC NRU Symbol to Component Cross Reference Symbol Description Option 230V AC 380VAC 460VAC 57VAC AMI AmmetrmontrigLi 300A 2 CB1 Circuit breaker 7 000AR framebreakerwith3000Aplug Hii DCchoke NuH CH11 TG DCchokethermswith CR Phaselossrelay CR2 Fautrely 11 017 Cumenttranormr 50005 Di 6 5000 1800 Powemontrl A2 PCB 1 IEA2F1 2 Bus indicator PCB fuses 1000V
23. Figure 9 1 Setting the Ground Fault Detection Installing Your 9 5 NRU Checks Before Power Up ATTENTION You must perform the checks described in this section before turning power on to the system Failure to do so may result in personal injury and or equipment damage ATTENTION You must not turn on the power if the NRU fails any of the checks described in this section Failure to do so may result in personal injury and or equipment damage ATTENTION You must correct all problems before proceeding to the next step Failure to do so may result in personal injury and or equipment damage 1 Verify that the NRU does not have any mechanical damage 2 Verify that the does not have any loose wires or buswork 3 Using an ohmmeter or other continuity testing device verify that shorts do not exist between Source 1 Source 2 Check below if no short exists L1 L2 L1 L3 L2 L3 L1 PE L2 PE L3 PE L1 TE L2 TE L3 TE DC Bus DC Bus DC Bus PE DC Bus PE DC Bus TE DC Bus TE PE TE Note A small short may exist between PE and TE Publication 2364E 5 01 April 2002 9 6 Installing Your NRU NRU Checks After Power Up ATTENTION You must not proceed with regular operation if the NRU fails any of the checks described in this section Failure to do so may result in personal injury and or equipment damage 1 Verify that the incoming phase to phase line volta
24. Numbers and Spare Parts Kits This appendix provides a description of NRU catalog numbers and lists available spare parts kits Catalog numbers consist of various components that make up a 2364 unit Each character of the catalog number helps identify a specific NRU The first four numbers represent the family of products for example 2364 The remaining characters define a specific version or option Determining Catalog Numbers To help you to understand we will provide an example of how to determine a catalog number for a 2364 NRU unit The beginning portion of the catalog number for all 2364 NRU units is 2364E E is for the non regenerative DC bus supply unit The remaining portion of the catalog number will represent the options for which you need to make a selection The options must appear in this order Wiring type Current Enclosure AC input Trip device Options rating line voltage type For example if you were to use the table on the following page to select an NRU that supplies 1500A DC output inputs 460V AC e has a NEMA Type 1 enclosure without gaskets provides circuit breaker input protection e includes the option Analog DC Bus Voltmeter The catalog number would be 2364EA DAB XXCM 715P Publication 2364E 5 01 April 2002 2 NRU Catalog Numbers and Spare Parts Kits NRU Catalog Numbers Bulletin Unit Wiring Current AC Input Line Number Type Type Rating Enclosure Voltage HP A
25. Publication 2364 5 01 April 2002 NRU Catalog Numbers and Spare Parts Kits B 9 Table D Spare Parts Kits for NRUs with 575V AC Inputs Level Catalog Number Qty in Kit 1 Control Fuses Control Transformer Primary Phase Loss DC Bus Energized PCB 2364E 1 2864 SPEASA kVA XFMR 575V AC 775V DC 180 2000A DC 2988 Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 364 5 23646 2 kVA XFMR 575V AC 775V DC 180 900A DC 298 _ Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 2364 5 23646 2 kVA XFMR 575V AC 775V DC 2500 3000A DC SE 5 kVA XFMR 575V AC 775V DC 180 2000A DC Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 2364 5 23646 5 KVA XFMR 575V AC 775V DC 2500 3000A DC 296 Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 2364 SPESOA 23646 10 kVA XFMR 575V AC 775V DC 1500 2000A DC AME Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 2364 SPESTA 93646 10 KVA XFMR 575V AC 775V DC 2500 3000A DC di 1 2364 SPEA47A Control Fuses Control Transformer Primary Phase Loss DC Bus Energized PCB 2364E 2 sets 4 4 2 1 each 1 each 2 sets 2 sets 2 sets 2 sets 2 sets 2 sets 2 sets 1 1 set 1 2300 SPBO1A _ Line RC Suppressor and Fu
26. before attempting to service repair or remove an NRU or its components Publication 2364E 5 01 April 2002 10 2 Troubleshooting Checklist for Troubleshooting The following table provides a checklist to help you identify the Your NRU cause of your NRU problem Figure 10 1 Troubleshooting Chart Type of Problem OF DG Bus Loss of DC Bus Loss of Control Power amp Control Fault Indication Did you check the Power Power Only Power Only 4 8 AC Incoming Power MCP Operation po 1 po 1 PC Control Transformer Fusing Voltage and or Secondary Fusing e BideFa Bridge Fan _ 5 5 Phase Loss Phase Imbalance External Customer Interlocks if present Important Refer to the system schematics Appendix A of this manual and the chapter of this manual that corresponds to your NRU for ratings Publication 2364E 5 01 April 2002 Appendix A Specifications This appendix provides Bulletin 2364E NRU physical electrical environmental and functional specifications Physical Specifications Table A NRU Physical Dimensions Output Current Current Number of ADC Overall Width Overall Depth MCC Sections 180 90 2286 25 635mm 20 608 mm 350 B 90 0286 25 635 20 508 1 90 00 0286 30 762
27. bus voltmeter option Publication 2364E 5 01 April 2002 6 4 Your 2000 NRU Current Code Table 6 A 2000A DC NRU Symbol to Component Cross Reference Symbol Description Option 230V AC 30 60 460 57VAC AMI 099 CB1 Circuit breaker 2000AR framebreekerwth2000A plug Cd CHIT SC CH11 TG_ DCchokethermswitch CRI Phase lossrelay 827 11 017 Curenttransormr 1 20005 Di 6 7 119604 1800 EM jPowermontorl EA2 DCBusindcatrPCB IEA2F1 2 DC Bus indicator PCB fuses 1A 1000V 1 3 32 diameter 3 length 500AIC A3 Line RC suppressor PCB AM suppressor PCB EA5 6 lArf wsenorPCB F1 3 F1A 3A Incoming 3 phase line fuses 1000 170 F4 F6 Primary fuse for 1 control 6 25A KLDR 4A KLDR 3A KLDR 3A KLDR transformer Primary fuse for 3 control 30A KLDR 17 5 KLDR 15A KLDR 12A KLDR transformer Primary fuse for a 10 KVA gontrol 60A KLDR 35A FRS 25A KLDR 20A KLDR transformer NRU control power fuse DAKDDR Control bus fuse for a 1 KVA 4A KLDR control transformer S control transformer mue t O control transformer 11 13 Phase lossfuss KLDR Fi4 16 RC
28. lists such as this one provide information rather than procedural steps Numbered lists provide sequential steps or hierarchical information When you are referred to another location the section name appears in italics The exclamation point inside of a triangle followed the word ATTENTION indicate circumstances that can lead to personal injury death property damage or economic loss You the customer are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company Check the item s that you receive against your purchase order If any items are obviously damaged it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill Should you discover any concealed damage during unpacking you are responsible for notifying the freight agent Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment Rockwell Automation offers support services worldwide with Sales Support Offices authorized distributors and authorized Systems Integrators located throughout the United States plus Rockwell Automation representatives in every major country in the world Local Product Support Contact your local Rockwell Automation representative for e sales and order support e product technical training warranty support e Support service agreements Technical Product Assistance
29. of NRU standard options Not all NRUs will have these components Publication 2364E 5 01 April 2002 Input Voltage Rated DC Bus V AC kW 230 620 380 1020 460 1240 575 1550 2000A DC System Layout Chapter 6 Your 2000A DC NRU Current Code E This chapter provides the following information for the 2000A DC NRU atypical cabinet layout diagram Figure 6 1 atypical electrical schematic Figure 6 2 asymbol to component reference table for interpreting the electrical schematic Table 6 A Figure 6 1 Typical 2000A DC NRU Layout CUSTOMER 3 PHASE INPUT i is CB1 SP2 5 4 T SP3 TB2 781 Publication 2364E 5 01 April 2002 6 2 Your 2000 NRU Current Code E 2000A DC NRU Electrical Figure 6 2 Schematic Typical 2000A DC NRU Schematic 3 Phase AC Input EA1 Powermonitor 11 MASTER MODULE BULL 1403 05 POWER CURRENT 115 VAC NRU CONTROL POWER INPUTS ANALOG INPUT BULL 1403 DMA 115 VAC NRU DISPLAY CONTROL VOLTAGE MODULE POWER INPUTS 1403 NSC STATUS INPUTS el GO TO NEXT PAGE TO POWER TRANSFORMER 115VAC NRU GROUNDING RESISTOR CONTROL TB2 1Q 2 2 115 VAC NRU SENSOR CONTROL POWER TO CONTACTOR 2 MONITORING CIRCUIT INP
30. suppressor fuses 25 HS1 2 Bridge heatsink 0 02 MTR Bridgefan 1 1200 MTRI C Bridge fan capacitor 20uFcapacitor MTR2 3 Door mounted fan bychoke 69 90050 4 Pt Dc Bus Energized pilotligt javA red Unit Not Fauld pilot light 120 amber B00MR PP HOUR VNDC 11A CC Cono power transformer A 1 kVA control transformer is standard 5 kVA and 10 kVA control transformers are available as options This transformer has multiple taps to accommodate 230 380 460 575V AC primary voltages ENSE Heatsink thermoswitch 210 se Choke thermoswitch SP1 3 Line to line MOVs 1960 J 275V AC 460 J 320V AC 460 320V 550 J 385V AC Neutral to ground MOV 600 550V AC 760 J 680V AC 760 J 680V 760 J 680V DC bus voltmeter 750 750V DC 1000V DC 1000V DC vm2 Ground fault detector f RC E Components marked as being options are part of NRU standard options Not all NRUs will have these components Publication 2364E 5 01 April 2002 Input Voltage Rated DC Bus V AC kW 230 775 380 1275 460 1550 575 1938 2500A DC System Layout Chapter Your 2500A DC NRU Current Code F This chapter provides the following information for the 2500A DC NRU atypical cabinet layout diagram Figure 7 1 atypical electrical schematic Figure 7 2 asymbol to component reference
31. table for interpreting the electrical schematic Table 7 A Figure 7 1 Typical 2500A DC NRU Layout o Publication 2364E 5 01 April 2002 7 2 Your 2500A NRU Current Code F 2500A DC NRU Electrical Figure 7 2 Schematic Typical 2500A DC NRU Schematic 3 Phase AC Input EA1 Powermonitor 11 MASTER MODULE BULL 1403 05 POWER CURRENT 115 VAC NRU CONTROL POWER INPUTS ANALOG INPUT BULL 1403 DMA 115 VAC NRU DISPLAY CONTROL VOLTAGE MODULE POWER INPUTS 1403 NSC STATUS INPUTS el GO TO NEXT PAGE TO POWER TRANSFORMER 115VAC NRU GROUNDING RESISTOR CONTROL TB2 1Q 2 2 115 VAC NRU SENSOR CONTROL POWER TO CONTACTOR 2 MONITORING CIRCUIT INPUT 115 METER RELAY 1 7 TO CONTACT SENSOR MONITORING 1 8 CIRCUIT TO CONTACTOR 1 MONITORING CIRCUIT Publication 2364E 5 01 April 2002 FROM PREVIOUS PAGE Your 2500A DC NRU Current Code F 7 3 Important The Powermonitor II standard configuration works with grounded wye secondary supplies only For more information on Powermonitor configurations for other supply types consult Powermonitor documentation and the Power Quality and Automation group located in
32. 02 Trip Device Options NRU Catalog Numbers and Spare Parts Kits B 3 Footnotes System utilization voltages Multiple option numbers must be separated by a dash and added to the base catalog number in ascending order Each NRU includes a basic capacity control transformer that supplies the NRU with control power Control power source options allow you to select a higher capacity control transformer for control bus applications Control power source options include a control bus fuse and control bus Refer to the Electrical Specifications section in Appendix A for capacity values Each NRU may have either one AC input ammeter or one Powermonitor The Powermonitor II options consists of 1403 05 master module a 1403 DMA display module and a master to display cable This standard configuration works with grounded wye secondary supplies For information on Powermonitor II configurations for other supply types consult Powermonitor II documentation and the Power Quality and Automation group located in Milwaukee The 1403 NSC option offers communication links to RIO RS 485 and RS 232 This option may only be selected if 86MBY is selected Power transformer must have a resistive grounded wye secondary where the resistance is 150 300 ohms Units come standard with cloth wire labels Datab labels offer the added protection of a clear plastic cover on top of the labels Customer supplies 115V AC control power and wiring t
33. 1 6 Overview Publication 2364E 5 01 April 2002 Power Conversion Operation The diodes in the rectifier bridge will only permit current flow in one direction from anode to cathode When an AC voltage is applied to a diode the output of that diode is a pulsating DC signal positive half cycles only For any particular phase the anode of the upper diode is positive relative to its cathode during the positive half cycle of the AC input This forward voltage biases the upper diode and it conducts Meanwhile the anode of the lower diode is negative relative to its cathode This reverse biases the lower diode and it does not conduct Similarly during the negative half cycle of the AC input the lower diode conducts and the upper diode does not conduct During the operation of a 3 phase bridge rectifier multiple upper and or lower diodes may simultaneously be biased correctly for conduction A 3 phase bridge provides an average DC output voltage that is approximately 1 35 times the rms line to line voltage Refer to Figure 1 2 for an illustration of the 3 phase AC input signal applied to the bridge rectifier and the DC output Figure 1 2 3 Phase AC Line Voltage and DC Output Voltage and Current _ Typical Output Voltage Waveform From Diode Bridge ia a Average DC Bus Voltage N X V L N Typical DC Choke Current B Tvpical 3 Phase AC Input Waveform Bulletin
34. 1 9 inches in 180 and 350A DC current codes A and B units 16 9 inches in 900 1500 2000 2500 and 3000A DC cur rent codes C D E F and G units Publication 2364E 5 01 April 2002 1 8 Overview Publication 2364E 5 01 April 2002 Ability to connect to other MCC sections on both the right and left sides Top entry AC line input Removable top plate for cutting conduit holes 6 high full section depth horizontal wireway at top of MCC enclosure Note The front half of the top horizontal wireway is typically reserved for the routing of control communication wires Easy accessibility for routine maintenance Motor circuit protector in 180 and 350A DC current codes A and B units and circuit breakers in 900 1500 2000 2500 and 3000A DC current codes C D E F and G units are padlockable 180 and 350A DC current codes A and B units have removable diode power bridge assembly Tin plated copper horizontal power busbars and PE TE busbars Standard power bus bracing rated at 65kAIC Horizontal PE and TE copper bus that is bottom front mounted ASA49 gray baked enamel finish Vented unit door s with door fan s where appropriate Units come standard with cloth wire labels NRUs can connect to FD86N enclosures on either or both sides provided that the NRU is 20 inches deep has 1 5 high base channels has its DC bus and control bus if supplied mounted at a depth of 16 94 inches Bulletin 2364E NRU Stan
35. 10V DC 2500 3000A DC 2908 Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 236 5 PCB 2364E 10 KVA XFMR 230V 310V DC 1500 2000A DC dad Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 2364 SPE22A POB 2364E 10 kVA XFMR 230V AC 310V DC 2500 3000A DC 2308 2 1 2 2 2 2 2 2 2 2 2 2 2 1 each 2 1 each 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 2 sets 2 1 2 1 set 2 1 2 AC Line RC Suppressor PCB and Fuses 2364E 180 3000A DC 6 2 3 1 each 3 1 each 3 1 each 3 1 3 1 Publication 2364E 5 01 April 2002 NRU Catalog Numbers and Spare Parts Kits B 7 Table B Spare Parts Kits for NRUs with 380V AC Inputs Level Catalog Number Qty in Kit 7 Control Fuses Control Transformer Primary Phase Loss DC Bus Energized 2364 1 2364 5 kVA XFMR 380V AC 510V DC 180 2000A DC BRE Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 2364 5 24 2 sets PCB 2364E 2 kVA XFMR 380V AC 510V DC 180 350A DC _ Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 2364 SPE25A 2364 2 KVA XFMR 380V AC 510V DC 900A DC ia Control Fuses Control Transformer Primary Phase Loss DC Bus Energized PCB 2364E 2364 SPE26A KVA XFMR 380V AC 510V DC 2500 3000A DC 250 Control Fuses
36. 2364E NRU Standard Features Overview 1 7 Electrical System Features A 3 phase circuit breaker motor circuit protector rated for 65kAIC 180 and 350A DC units have motor circuit protectors 900 1500 2000 2500 and 3000A DC units have circuit breakers AC line current limiting fuses rated at 600V AC with short circuit protection rated at 65 A six pulse full wave 3 phase diode bridge rectifier unit A DC bus choke with inductance in both legs A basic capacity control power transformer that supplies ONLY the NRU with single phase 115V AC control power Primary and secondary control transformer fusing excluding the control bus fuse that is supplied with the 6P and 6PX control power source upgrade options A DC Bus Energized pilot light that turns on when the bus voltage is above 50V DC Compatible with Bulletin 1336 dynamic braking DB chopper units Note A dynamic braking chopper unit requires an additional cabinet section A bridge suppressor module Configurations available for 230 380 460 and 575V AC inputs with 180 350 900 1500 2000 2500 and 3000A DC outputs Utilization of 16 AWG MTW PVC insulated rated stranded copper control wiring Packaging Features Utilization of Bulletin 2100 CENTERLINE motor control center MCC packaging makes the NRU compatibility with other Bulletin 2100 and 2300 products Unit depth of 20 DC bus and control bus if selected depth at 1
37. 500A DC or Either a maximum of 12 wires or a bus connector 3000A DC at all 3 of the four hole bus tabs per phase Note Refer to Appendix C for additional wiring information and for bus stab hole pattern details Installing Your NRU 9 3 7 Set the trip unit of the motor circuit protector circuit breaker according to manufacturer s instructions or per the recommended settings provided in Appendix C of this manual Reference the system schematics for the rated current levels 8 On the phase loss relay set initial settings on the three knobs as follows UNDERVOLTAGE and TIME DELAY ON UNDER VOLTAGE to minimum CCW IMBALANCE to maximum CW Note Appendix C includes more information about the Phase Loss Relay Publication 2364E 5 01 April 2002 9 4 Installing Your NRU Publication 2364E 5 01 April 2002 Ground Fault Detection Option If the ground fault detection metering option is supplied on your unit perform the following procedures Note The ground fault detection relay can be implemented only if the power transformer has a resistive grounded wye secondary with a resistance of 150 to 300 ohms 1 2 of current during a solid ground fault 1 Connect terminals TB2 1 and TB2 2 across the power transformer grounding resistor in accordance with system schematics and transformer manufacturer specifications 2 Turn the set screw until the black indicator needle aligns with the 0 zero mark as shown in Figure 9 1
38. AC control bus The NRU applies the common bus DC voltage to the system power bus and the 115V AC control voltage to a system control bus if desired The system power bus and the control bus if present then supply the voltage s to the remainder of the system Publication 2364E 5 01 April 2002 1 2 Overview Publication 2364E 5 01 April 2002 How will the NRU fit into a 2362 drive system We packaged the NRU in CENTERLINE Bulletin 2100 motor control centers MCC to be compatible with our existing 2362 AC drive system lineups As an added convenience you can connect other MCCs to both the right and left sides of an NRU How will the NRU fit into a drive system packaged in FD86N enclosures FD86N enclosure options permit direct connection to Bulletin 2100 CENTERLINE MCCs that are 20 deep have 1 5 high base channels have the DC power bus and control bus if selected mounted at a depth of 16 94 from the front of the MCC How Does NRU Work Overview 1 3 To help you to understand the theory behind how an NRU works read this section for descriptions of the primary electrical components a conceptual schematic and a discussion of rectifier bridge operation Primary Electrical Components of the NRU The primary electrical components of the NRU are a3 phase circuit breaker or motor circuit protector depending upon NRU rating line current limiting fuses e asix pulse full wave 3 phas
39. Also indicates whether the documents are available on CD ROM or in multi languages A glossary of industrial automation terms and abbreviations Publication 2364E 5 01 April 2002 Read This Document Document Number 1336T User Manual AC Drive 1336 FORCE 5 12 13368 User Manual 05 600HP 1336 PLUS 5 0 Installation Data HD Dynamic Braking 1336 5 64 Chopper Brake Module Installation Instructions 1336 5 65 PLC 5 Controllers Brochure 1785 1 2 Bulletin 1403 Powermonitor II 1403 5 0 Smart Communications Card 1403 5 1 Instructions Joining and Splicing Vertical 2100 5 1 Instructions Receiving Handling and 2100 5 5 Storing Motor Control Centers Bulletin 2300 Installation Manual 2300 5 1 Drive Tools Software Brochure 9303 1 0 A3000 Binder 3001 A3100 Binder 3053 FD86N Drive Systems Enclosure Hardware 3062 Installation Manual National Electrical Code ANSI NFPA 70 Published by the National Fire Protection Association of Boston MA Standard for Electrical Safety Requirements for ANSI NFPA 70E Employee Workplaces Allen Bradley Publication Index 50499 Industrial Automation Glossary AG 7 1 Common Techniques Used in this Manual Drive System Receiving Rockwell Automation Support Preface P v The following conventions are used throughout this manual e NRU unit configurations are referred to by their catalog string current code Refer to Appendix B for code definition Bulleted
40. ERTER UNITS FOOTNOTES 115 NRU CONTROL POWER 115 VAC CONTROL BUS TO INVERTER UNITS Door moun Powermonit Powermonit Ground fau Control bus ed ammeter option or option or communication module option Line RC suppressor option t detection option Air flow sensing option option DC bus vol meter option Unit not faulted pilot light option Note An NRU may have either a door mounted ammeter or a Powermonitor II This drawing shows both options for information Publication 2364E 5 01 April 2002 5 4 Your 1500A NRU Current Code D Table 5 A 1500A DC NRU Symbol to Component Cross Reference Symbol Description 230V AC 380VAC 460 6 575 AMI AmmetermontoingLi SOON sd 81 Circuit breaker 2000AR framebreekerwith 1600A plug 1 DCchoke O w CH11 TG _ DC choke thermoswiteh CR1 Phase loss relay 2 Fautrelay CT1 Curenttansormr 115005 01 6 Diodes 19604 1800VAC jPowemontorl EA2 BusindicatorPCB 020 2 1 2 Bus indicator PCB fuses _ 1 1000V HVR 1 3 32 diameter 3 length 500AIC Line RC suppressor PCB Ed peses o i 500A 170M F4 F6 inan fuse for a 1 KVA contro 6 25A KLDR 4A KLDR 3A KLDR 3A KLDR transformer Primary fuse fo
41. KLDR 17 5 KLDR 1 KLDR 12A KLDR transformer Fr _NRU con power fuse DAKUR M 2A KLDR 22000 PARR ee transformer control transformer mem control transformer 11 13 Phase lossfuses SS TA KLDR Fi4 16 RCsuppressorfues 25A KTKR 51 2 Bridge heatsink MCP1 Motor circuit protector 7 250A J frame Bridge fan 1560 MTRI C Bridge fan capacitor 2 PLi__ DC Bus Energized pilotlight 124 red Unit Not Faulted pilotlight 7 120 800MR_ o O PS Air flow sensor power supply MVDCOBA Control power transformer A 1 KVA control transformer is standard 2 KVA and 5 KVA control transformers are available as options This transformer has multiple taps to accommodate 230 380 460 575V AC primary voltages RT Bridge suppressorresistor 22ohm 10w __ S O R12 Bridge suppressor resistor 00 0 100 51 2 Heatsink thermoswitcn 2109 7 S5 rhwwth SPI 3 Line to ine MOVs 360 275 460 J 320V AC 460 J 320V AC 550 385V AC SPA Neutral to ground MOV 17 7 600J 550VAC 760 680 760 J 680V 760 680v AC DC bus voltmeter 17 75 02 75000 1000 0 1000 0 Groundfauttdetector Components marked as being options are part of NRU standard options Not all NRUs will have these components
42. NPUT POWER 115VAC METER RELAY TB1 7 FLOW SENSOR TO CONTACTOR MONITORING TB1 8 PE CIRCUIT MONITORING CIRCUIT Publication 2364E 5 01 April 2002 Your 350A NRU Current Code 3 3 Important The Powermonitor II standard configuration works with grounded wye secondary supplies only For more information on Powermonitor configurations for other supply types consult Powermonitor documentation and the Power Quality and Automation group located in Milwaukee WI USA FROM PREVIOUS PAGE 6 4 00000000000 OPTIONAL REMOTE INTERLOCK 1 2 O 115 VAC NRU CONTROL POWER CONTROL BUS TO 115 VAC INVERTER UNITS e E E SSS E ines t a fce H HEAT F1 F2 HEAT SINK SINK BUS gt BUS CR1 D1 TB1 3 TB1 4 FOOTNOTES Note An NRU may have either a door Door mounted ammeter option mounted ammeter or a Powermonitor II This Powermonitor II option drawing shows both options for information Powermonitor II communication module option Line RC suppressor option Ground fault detection option Air flow sensing option Control bus option Unit not faulted pilot light option DC bus voltmeter option DC HORIZONTAL BUS TO INVERTER UNITS Publication 2364E 5 01 April 2002 3 4 Your 350A NR
43. Options Table E Input Currents of NRUs with a Control Power Upgrade Option Continuous Input Current of NRU with Standard Capacity Control Source Continuous Input Current of NRU with Extra Capacity Control Source Upgrade Environmental Specifications of NRU 100 Rated Amps at 40 C 90 80 70 60 50 Specifications A 5 Thru Bus Ratings per Unit Table F Current Ratings of DC Thru Bus Operating Conditions Table G NRU Operating Conditions Altitude 1000 meters 3 300 ft Ambient Temperature O to 40 C 32 to 104 P Relative Humidity 5 to 95 non condensing For altitudes higher than 1000 meters derate using Figure 1 For temperatures greater than 40 C derate using Figure 2 Figure 1 Altitude Derate Curve 01 1000 2000 3000 4000 3 300 ft 6 600 ft 9 900 ft 13 200 ft Altitude Publication 2364E 5 01 April 2002 6 Specifications Figure 2 Temperature Derate Curve of NRU 100 Rated Amps at Sea Level 95 90 85 80 75 0 C 5 C 10 C 15 82 F 41 5609 599 290 250 30 35 C 400 45 68 F 77 86 95 1049 113 Ambient Temperature Table H Operating Sound Level DC Bus Current A DC Current Average Operating Sound Code Level dB 180 350 A B
44. Overview Publication 2364E 5 01 April 2002 Packaging Options Tin plated control bus mounted in rear of cabinet above the power bus Note Control bus is included as part of the control power source upgrade options Depth of DC bus and control bus if supplied at 16 9 inches in 180 and 350A DC current codes A and B units 115V AC 15A duplex receptacle Note Customer supplies single phase 115V AC power and wiring to the duplex receptacle A phone jack Gasketed unit door areas and door fan filters Brady Datab wire labels offering the added protection of a clear plastic cover on top of the labels Note Units come standard with cloth wire labels Input Voltage Rated DC Bus V AC kW 230 56 380 92 460 112 575 140 180A DC System Layout Chapter 2 Your 180A DC NRU Current Code A This chapter provides the following information for the 180A DC NRU atypical cabinet layout diagram Figure 2 1 atypical electrical schematic Figure 2 2 asymbol to component reference table for interpreting the electrical schematic Table 2 A Figure 2 1 Typical 180A DC NRU Layout v n 79 N n 79 e SP4 Publication 2364E 5 01 April 2002 2 2 Your 180A DC NRU Current Code 180A DC NRU Electrical Schematic Figure 2 2 Typical 180A DC NRU Schematic
45. U Current Code Table 3 A 350A DC NRU Symbol to Component Cross Reference Symbol Description Option 230V AC 380VAC 460VAC 575 AMI AmmetermontoingLi 400A c11 Bridge suppressor capacitor 32uF 200V Cd 1 DCchoke 8 CRI Phase loss relay Fautreay CT1 CT3 Curentransormr 1400 5 01 6 7 480A 1800 D11 suppressor diode 7 160 1700V AT jPowemontorll BusindicatorPCB 2 1 2 Bus indicator PCB fuses 1000V HVR 1 3 32 diameter 3 length 500AIC AC line RC suppressor PCB EAS AiflowsenorPCB F1 3 Incoming 3 phase line fuses 7 450A 170M fuse faro _ Primary fuse for a 1 control KLDR 4 KLDR 3A KLDR 3A KLDR transformer Primary fusa 2 control KLDR 8A KLDR 6 25A KLDR 5 KLDR transformer primary tusa TOS KVA control 30A KLDR 17 5 KLDR 1 KLDR 12A KLDR transformer Fr _NRU con power fuse DAKUR M 2A KLDR 22000 PARR ee transformer control transformer coc RN CR RN control transformer 11 13 Phase lossfuses SCS TA KLDR Fi4 16 suppressor fuses 25 51 2 Bridge heatsink MCP1 Motor circuit protector 400 MIRI Biidgefan 15600 MTRI C Bridge fan capacitor 12 g OuFc
46. UT 115 METER RELAY 1 7 TO CONTACT SENSOR MONITORING 1 8 CIRCUIT TO CONTACTOR 1 MONITORING CIRCUIT Publication 2364E 5 01 April 2002 FROM PREVIOUS PAGE Your 2000A DC NRU Current Code E 6 3 Important The Powermonitor II standard configuration works with grounded wye secondary supplies only For more information on Powermonitor configurations for other supply types consult Powermonitor documentation and the Power Quality and Automation group located in Milwaukee WI USA F6 pre E EEE E E INTERLOCK 1 2 JMPR x1 115 2 F7 1 1 10 MTRAMTR3 79 OPTIONAL r REMOTE _EA5 CR EA6 CR_ CH11 TG 653 115 VAC NRU CONTROL POWER 115 VAC CONTROL BUS TO INVERTER UNITS DC HORIZONTAL BUS TO INVERTER UNITS FOOTNOTES Note An NRU may have either a door mounted ammeter or a Powermonitor II Powermonitor communication module option Line RC suppressor option H H H Door mounted ammeter option Powermonitor II option This drawing shows both options for information Ground fault detection option Air flow sensing option Control bus option Unit not faulted pilot light option DC
47. antity of each item described Kits containing 1 PCB 4 uses The Specified quantity of each item as multiple items described 1 set The quantity of the specified items required 5 by NRU per set Catalog Number Description 2364 SP A 1 A Bulletin Spare Part Spare Part Kit Number Revision Number Designator Type Letter Publication 2364E 5 01 April 2002 6 NRU Catalog Numbers and Spare Parts Kits Table A Spare Parts Kits for NRUs with 230V AC Inputs Level Catalog Number Qty in Kit Control Fuses Control Transformer Primary Phase Loss DC Bus Energized PCB 2364E 1 2864 SPETSA 1 kVA XFMR 230V AC 310V DC 180 2000A DC E Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 4 eee 2364 2 kVA XFMR 230V AC 310V DC 180 350A DC TR Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 2364 SPEISA PCB 23646 2 KVA XFMR 230V AC 310V DC 900A DC ids 2364 SPE16A Control Fuses Control Transformer Primary Phase Loss DC Bus Energized PCB 2364E 5 sets 2 kVA XFMR 230V AC 310V DC 2500 3000A DC _ Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 2864 SPETSA 2364E 5 kVA XFMR 230V 310V DC 180 2000A DC di Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 1 2364SPEISA 2364E 5 XFMR 230V AC 3
48. apait r PLI DC Bus Energizedpilotlight 24VACVDC re 80MR Cd Unit Not Faulted pilotlight 120VAC amben800MR o O PS1 Air flow sensor power supply MVDCOBA Control power transformer A 1 KVA control transformer is standard 2 KVA and 5 KVA control transformers are available as options This transformer has multiple taps to accommodate 230 380 460 575V AC primary voltages Bridge suppressor resistor 22ohm 100W R12 Bridge suppressor resistor 51 2 jHeainkthermoswitch 7 7 8 Air fiowswitch Oo MEN SPI 3 1 360 275 460 320V AC 460 320V AC 550 385V AC SPA Neutral to ground MOV 7 600 550 760 J 680V AC 760J 680 AC 760 J 680v AC DC bus voltmeter 1 750VDC t00VDC 1000 0 jGrundfautdetectr 1 y y Components marked as being options are part of NRU standard options Not all NRUs will have these components Publication 2364E 5 01 April 2002 Chapter 4 Your 900A DC NRU Current Code C Input Voltage Rated DC Bus This chapter provides the following information for the 900A DC V AC kW NRU 230 279 atypical cabinet layout diagram Figure 4 1 T gram Fig 460 558 atypical electrical schematic Figure 4 2 575 698 asymbol to compo
49. ations for the 2364E Appendix B NRU Catalog Numbers and Spare Parts Kits Catalog number descriptions of available NRUs Appendix C NRU Details 2 including input connections and wireway meter c Appendix Specifications Publication 2364E 5 01 April 2002 P iv Preface Related Documentation The following documents contain additional information concerning related Rockwell Automation products and related standards To obtain a copy of Rockwell Automation publications contact your local Rockwell Automation office or distributor For Information on the 1336 Force drives Information on the 1336 Plus drives Information on 1336 dynamic braking modules consisting of both chopper and resistors Information on 1336 braking chopper modules PLC 5 information Bulletin 1403 Powermonitor II information Information on the Bulletin 1403 communication module Additional Information on joining and splicing together MCCs Details on receiving handling and storing MCCs Provides procedures for those tasks that need to be done at the customer s site before system start up A description of Drive Tools software Information on SA3000 drives Information on SA3100 drives Information on FD86N enclosures An article on wire sizes and types for grounding electrical equipment An article on safety procedures A complete listing of current documentation including ordering instructions
50. cal Figure 8 2 Schematic Typical 3000A DC NRU Schematic 3 Phase AC Input EA1 Powermonitor 11 MASTER MODULE BULL 1403 05 POWER CURRENT 115 VAC NRU CONTROL POWER INPUTS ANALOG INPUT BULL 1403 DMA 115 VAC NRU DISPLAY CONTROL VOLTAGE MODULE POWER INPUTS 1403 NSC STATUS INPUTS el GO TO NEXT PAGE TO POWER TRANSFORMER 115VAC NRU GROUNDING RESISTOR CONTROL TB2 1Q 2 2 115 VAC NRU SENSOR CONTROL POWER TO CONTACTOR 2 MONITORING CIRCUIT INPUT 115 METER RELAY 1 7 TO CONTACT SENSOR MONITORING 1 8 CIRCUIT TO CONTACTOR 1 MONITORING CIRCUIT Publication 2364E 5 01 April 2002 FROM PREVIOUS PAGE Your 3000A DC NRU Current Code G 8 3 Important The Powermonitor II standard configuration works with grounded wye secondary supplies only For more information on Powermonitor configurations for other supply types consult Powermonitor documentation and the Power Quality and Automation group located in Milwaukee WI USA F6 a x1 415 2 1 1 9 1 OPTIONAL REMOTE INTERLOCK 1 2 JMPR Q 1 10 MTR2 MTR3 MTR4 MTR5 MTR6 r 5
51. d the bridge circuit The DC bus choke also reduces line harmonics Control Power Transformer This transformer steps down 2 phases of the 3 phase AC line voltage to a single phase 115V AC control signal Primary and Secondary Control Transformer Fusing Control transformer fusing protects the transformer and control circuitry from excessive currents 3 Phase AC Incoming Power Overview NRU Conceptual Schematic Customer supplied 3 phase AC power is supplied to the system as shown on the left side of the NRU schematic shown in Figure 1 1 All three phases are fused and then connected to the diode bridge rectifier as shown The diode bridge rectifier is also connected through DC bus chokes to the DC bus Two of the three AC input phases are routed through primary control transformer fusing to the control transformer The secondary of the control transformer which supplies the NRU control power can be connected to the control bus after fusing if the control transformer is sized accordingly The bridge fan is connected to the NRU control power Figure 1 1 Conceptual Schematic of the NRU Diode Bridge DC Choke Circuit Breaker or MCP Fuses This fuse included in control power source upgrade options To Optional 115V AC Control Bus L Bridge Fan 115V AC Motor NRU Control Power Optional Air Flow Sensor ad N Control Transformer O N Publication 2364E 5 01 April 2002
52. dard Options Overview 1 9 Electrical System Options Analog DC bus voltage metering Analog AC input current metering Phase A only Note The bus voltmeter and or AC input ammeter are mounted in a special wireway meter cover that is angled for easy viewing AC input and output power metering kW using Powermonitor II Bulletin 1403 for NRUs powered by 3 phase grounded wye secondary supplies Powermonitor communication module for connecting the Powermonitor II to Remote I O RS 232 or RS 485 devices A door mounted Unit Not Faulted pilot light that monitors air flow sensor s heatsink temperature sensors phase loss relay and an optional remote interlock if supplied by customer A door mounted ground fault detection meter for NRUs powered by 3 phase grounded wye secondary supplies Standard capacity and extra capacity 6PX control power source upgrade options are available to provide 115V AC control bus power Note 6P and 6PX options include control bus fuse and control busbar mounted in cabinet above power bus An air flow loss switch in all Diode Power MCC sections and in 2500 3000A DC Input Power MCC sections This option monitors critical NRU air flows for proper A line RC suppressor module to reduce AC line transients Note The line RC suppressor module is recommended when the primary voltage of the supply transformer is 2300V AC or greater Publication 2364E 5 01 April 2002 1 10
53. e diode bridge rectifier unit aDC bus choke e acontrol power transformer primary and secondary control transformer fusing Motor Circuit Protector The motor circuit protector is the switching device between the NRU and the 3 phase AC source used to turn power to the system on and off it also provides magnetic overload protection Motor circuit protectors are standard features in 180A DC and 350A DC NRUs 3 Phase Circuit Breaker The 3 phase circuit breaker is the switching device between the NRU and the 3 phase AC source used to turn power to the system on and off it also provides overcurrent trip and magnetic overload protection 3 phase circuit breakers are standard features in 900A DC 1500A DC 2000A DC 2500A DC and 3000A DC NRUs AC Line Current Limiting Fuses These fuses are located between the circuit breaker or motor circuit protector and the diode bridge rectifier unit This fusing protects the diodes from excessive currents and provides a current limiting action that permits a circuit breaker or motor circuit protector with a withstand rating less than 65 000A AC fault current available to effectively provide an AIC rating of 65 000A AC Publication 2364E 5 01 April 2002 1 4 Overview Publication 2364E 5 01 April 2002 Six Pulse Full Wave 3 Phase Diode Bridge Rectifier Unit The bridge rectifier converts the 3 phase AC power to DC DC Bus Choke The DC bus choke reduces peak currents in the AC line an
54. ge is within the specified tolerances Nominal AC Input Minimum AC Input Maximum AC Input Voltage V AC Voltage V AC Voltage V AC L wm J M eee 2 The common DC bus voltage will vary based upon the 3 phase AC input voltage Verify that the common DC bus voltage is within the tolerances Voltage V DC Voltage V DC Voltage V DC 0 Note We suggest that you check the bus voltage at the DC bus energized board as shown in Figure 9 2 Figure 9 2 Where to Check the DC Bus Voltage Publication 2364E 5 01 April 2002 Installing Your 9 7 3 Verify that the voltage across X1 to X2 the secondary side of PT2 the control power transformer is within the specified toler ance Nominal AC Control Minimum AC Control Maximum AC Control Voltage V AC Voltage V AC Voltage V AC 4 Verify that the diode bridge fan is running and blowing air over the bridge 5 Verify that the DC Bus Energized pilot light is illumi nated 6 Verify that the Not Faulted pilot light PL2 if supplied is illu minated If it is not illuminated verify that a The phase loss relay CR1 is energized Note If the phase loss relay is not energized disconnect the power and interchange any two input wires and try again b The other contacts of the circuit are closed 7 Perform the set up of the Powermonitor II if supplied per the manufacturer s instructions 8 Ifthe ground fa
55. gg 115 NRU CONTROL INPUT 115 5 PS1 POWER METER RELAY CONTACTOR MONITORING SENSOR CIRCUIT CONTACTOR Publication 2364E 5 01 April 2002 Your 900A NRU Current Code 4 3 Important The Powermonitor II standard configuration works with grounded wye secondary supplies only For more information on Powermonitor II configurations for other supply types consult Powermonitor documentation and the Power Quality and Automation group located in Milwaukee WI USA FROM PREVIOUS PAGE F6 4 T 00000000000 1 1 OPTIONAL REMOTE INTERLOCK 1 2 O JMPR Y 115 VAC NRU CONTROL POWER CONTROL BUS TO 115 INVERTER UNITS FOOTNOTES Note An NRU may have either a door Door mounted ammeter option mounted ammeter or a Powermonitor II This Powermonitor II option drawing shows both options for information Powermonitor communication module option Line RC suppressor option Ground fault detection option Air flow sensing option Control bus option Unit not faulted pilot light option DC bus voltmeter option DC HORIZONTAL BUS INVERTER UNITS Publication 2364E 5 01 April 2002 4 4 Your 900A NRU C
56. gt e 0 70 4 59 3 813 TYP Figure 3 30 Wide Wireway Meter Cover Layout 3 00 Bend Line lt 29 44 gt 27 18 42 i 338 iki gt 0 70 328 3 813 Publication 2364E 5 01 April 2002 NRU Details C 3 MCC AC Input Entry Area MCC top plates are removable for the punching of AC input entry holes Each MCC has a top plate Please refer to the following illustration for information on available entry area and information given in Chapter 9 or the installation instructions Table B MCC Input Entry Area DC Bus Current NRU Current en nea Figure4 Dimension B in Figure 4 180 350 2500 1 2200 1500 2000 2500 n Figure 4 Area Available for Conduit Entry Circuit Breaker Section 4 i gt r 1 50 B Back of Enclosure 1 25 Area Available For Conduit Entry 20 00 Front of Enclosure Publication 2364E 5 01 April 2002 C 4 NRU Details AC Input Customer Connection The type of AC input connection depends upon the NRU current Details rating Table C AC Input Customer Connection Details Typical AC Input Wire Sizing gt a Type of AC Input Connection Phase Based on 125 of Rated Load and 75 C wiring Terminals accommodating AWG 3 0 through 350 kcmil Two AWG 3 0 P ndi ian F
57. igure 5 AWG 4 0 _ Env E Figure 5 Six AWG 250 kcmil Five AWG 350 kcmil Six AWG 250 kcmil or Seven AWG 250 kcmil 2500 F Three bus stubs per phase Seven AWG 500 kcmil or See Figure 5 Eight AWG 400 kcmil 3000 G fre Bus Stubs per phase 5 att ANG S00 Keri See Figure 5 Two bus stubs per phase See 2000 E Figure 5 Figure 5 AC Input Customer Connection Bus in 900 1500 2000 2500 and 3000A DC NRUs 0 83 1844 0 250 E 4 0 88 3 0 563 Diameter 1 750 Publication 2364E 5 01 April 2002 Recommended Disconnect Trip Settings NRU Details C 5 Table D Recommended Disconnect Trip Settings DC Bus Current i uan Disconnect Description Recommended Setting s DC shown in Motor Circuit Protector 250A Figure 6 J frame 350 Motor Circuit Protector 400A Figure 6 K frame Circuit Breaker 1200 Figure 7 R frame with 1200A plug 0 femena 0 Figure 6 180 and 350A DC NRU Recommended Motor Circuit Protector Settings Figure 7 900A DC NRU Recommended Circuit Breaker Settings Digitrip RMS Rating Plug Short Delay 44 6 Digitrip RMS 3 7 Trip Unit 2 8 Pickup Publication 2364E 5 01 April 2002 C 6 NRU Details Figure 8 1500 and 2000A DC NRU Recommended Circuit Breaker Settings Short Delay Pickup 2 e n Figure 9 2500 and 3000A DC NRU Recommended Circuit Breake
58. ing AC voltages rms adevice for measuring DC voltages adevice for continuity testing Publication 2364E 5 01 April 2002 9 2 Installing Your NRU Installation Procedure Publication 2364E 5 01 April 2002 ATTENTION To avoid the hazard of electrical shock verify that all voltages on the system bus network have been discharged before attempting to service the system ATTENTION Be sure to obey all local electrical codes when installing your drive system This installation procedure provides guidelines that can be used in the case that codes do not exist Position and connect the NRU to the remainder of drive lineup per drive system installation procedures in Bulletin 2300 Publications 2100 5 5 and 2300 5 1 FD86N enclosures Publications 2100 5 5 and S 3062 Remove the lifting angle if present that is secured to the top of the NRU Plan where to punch holes for AC input entry Refer to Appendix C for top plate clearance information prior to punching any holes Remove the top plate from the MCC Punch desired holes for AC input entry Connect top plate to NRU Connect the NRU input terminals to the AC rated at input power using have range of AWG 4 350 kcmil have a range of AWG 3 0 250 kcmil Either a maximum of 4 wires or a bus connector MUN DE at the four hole bus tab per phase 1500A DC or Either a maximum of 8 wires or a bus connector 2000A DC at both of the four hole bus tabs per phase 2
59. llation Procedure 9 2 Ground Fault Detection Option 9 4 NRU Checks Before Power 9 5 NRU Checks After Power Up 9 6 Troubleshooting Before Y oU potra E oes 10 1 Documentation 10 1 uia DU eas 10 1 Safety Precautions 10 1 Checklist for Troubleshooting NRU Sa ae NE Set 10 2 Specifications Physical Specifications 1 Approximate Shipping 6 1 Electrical Specifications A 2 Functional Specifications A 3 Input Currents of NRU with Control Source Upgrade Options 4 Thru Bus Ratings per Unit A 5 Environmental Specifications A 5 Operating Conditions A 5 Storage Conditions A 8 Table of Contents toc iii Appendix B Appendix C NRU Catalog Numbers and Spare Parts Kits Understanding Catalog Numbers B 1 Determining Catalog Numbers B 1 NRU Catalog Numbers 24 ti nde ate I ae B 2 Bulletin 2364E NRU Spare Parts e do Ru atas p s B 4 What Does a Spare Parts Kit Include B 4
60. nent reference table for interpreting the electrical schematic Table 4 A 900A DC System Layout Figure 4 1 Typical 900A DC NRU Layout AM1 VM1 EA1 CB1 8 2 EA3 SPICO Sp4c 3 CTI CTS 14 pis E 1 2 F12 F13 CR1 F7 2 HS1 HS2 PS1 EAS F4 F6 MTR1 G CH11 1 Publication 2364E 5 01 April 2002 4 2 Your 900A NRU Current Code 900A DC NRU Electrical Schematic Figure 4 2 Typical 900A DC NRU Schematic 3 Phase AC Input Powermonitor 11 MASTER MODULE BULL 1403 MM05A POWER CURRENT INPUTS ANALOG INPUT 115 VAC NRU CONTROL POWER BULL 1403 DMA MONITORING CIRCUIT 115 VAC NRU DISPLAY CONTROL VOLTAGE MODULE POWER INPUTS STATUS INPUTS 5 GO TO NEXT PAGE T METER TO POWER TRANSFORMER GROUNDING RESISTOR ooo me c tr J 115 VAC NRU CONTROL POWER ee ese ENE OE tpg eon
61. o the duplex receptacle The line RC suppressor is recommended for installations where the primary of the distribution transformer is 2300V AC or greater Publication 2364E 5 01 April 2002 B 4 NRU Catalog Numbers and Spare Parts Kits Bulletin 2364E NRU These spare parts kits are designed to provide you with the necessary Spare Parts Kits parts to repair and maintain your NRU What Does a Spare Parts Kit Include An NRU spare parts kit includes the items in the quantities described in Tables A B C and D In addition each spare parts kit contains installation instructions Which Table Do Use For an NRU with an input voltage of 230V AC Table A 380V AC Table B 460V AC Table C 575V AC Table D Significance of Level Numbers Level numbers are used to recommend stocking locations for the various NRU spare parts kits Level descriptions are as follows Level Number Level Description Recommended Stocking Major Assemblies Large users OEMs distributors and GTS Minor Assemblies Distributors and GTS Discrete Components Publication 2364E 5 01 April 2002 NRU Catalog Numbers and Spare Parts Kits B 5 Definition of Terms Used to Describe Qty in Kit The column Qty in Kit in Tables F G H and J represents how many components you can expect to find as follow Type of Kit Example in Kit Kit Contains Ms containing 1 The specified quantity of the item described one item The specified qu
62. ontrol Transformer Primary Control Bus Phase Loss DC Bus Energized 2364 5 2364E 2 KVA XFMR 460V AC 620V DC 900A DC 2505 gt Control Fuses Control Transformer Primary Phase Loss DC Bus Energized PCB 2364E 2364 5 KVA XFMR 460V AC 620V DC 2500 3000A DC Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized PCB 2364E 5 kVA XFMR 460V 620V DC 180 2000A DC Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 2364 5 23646 5 KVA XFMR 460V 620V DC 2500 3000A DC ue i Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized PERERA PCB 2364E 10 KVA XFMR 460V AC 620V DC 1500 2000A DC Control Fuses Control Transformer Primary Control Bus Phase Loss DC Bus Energized 2364 SPE42A PCB 2364E 10 kVA XFMR 460V AC 620V DC 2500 3000A DC 25819 2 1 each 1 each 2 sets 2 sets 2 sets 2 sets 2 sets 2 sets 2 sets 1 1 set 1 2300 SPBO1A Line RC Suppressor PCB and Fuses 2364E 180 3000A DC LPCBY fuses MOV Line to Neutral and Neutral to Ground 2364E 380V AC 510V DC amp 460V AC 2300 SPJO2A 620V DC 180 3000A DC 1 each 1 each 1 each 1 1 4 k 2364 SPE38A 2 sets 4 4 PMP PM MO PMY MMH P2 P2 5 62
63. oo F 198 20 50 wo a 99 gt a 409 Refer to Table D for AC input NUTS AC line current shown is for NRU with basic capacity control transformer Refer to Table E for AC input current if you have selected a control power source upgrade option Refer to Table D for NRU overload capability Rated DC bus kW is the power available on the DC thru bus This value is independent of control transformer selection To calculate the input kVA use this formula input kVA V A 1 73 V Input Voltage line to line V AC i e from column 1 1000 A Input Current A AC i e from column 2 Publication 2364E 5 01 April 2002 Specifications A 3 Functional Specifications Table D NRU Functional Specifications AC Input Frequency Tolerance 45 to 65 Hz AC Input Voltage Tolerance E 150 maximum DC bus current for 60 seconds DSTI a 20096 for 10 seconds following continuous operation Overload Duty Cycle 1 minute out of 20 minutes at rated load and temperature Minimum Continuous Load Requirement 33 of rated DC bus continuous current If the total continuous DC input current of the load is less than 33 of the rate NRU DC bus continuous current the bus current may become discontinuous Publication 2364E 5 01 April 2002 4 Specifications Nominal Input Voltage V AC Publication 2364E 5 01 April 2002 NRU Current Input Currents of NRU with Control Source Upgrade
64. ormal the red LED will be on Once the unit has responded to an undesirable circuit condition by releasing the output relay the LED will blink Reset Upon the correction of the fault condition the D65 will reset automatically NRU Details 6 9 MCC Bus Location Details Table E provides a list of available DC bus and control bus depths while Figure 11 provides a bus location illustration Table E Available DC Bus and Control Bus Depths Available Depths for DC Bus and Control Bus if selected See dimension X in Figure 10 11 94 inches or 6 94 inches only Figure 11 MCC Bus Locations Y gt DC Bus Current NRU Current A DC Code NRU Input Selection Width See dimension Y in Figure 10 Publication 2364E 5 01 April 2002 10 NRU Details Publication 2364E 5 01 April 2002 This page intentionally left blank altitude 5 B bridge See diode bridge 1 4 Bulletin numbers See catalog numbers C catalog numbers B 1 choke DC bus 1 4 circuit breaker settings C 6 control power fusing 1 4 transformer 1 4 current code See catalog numbers D DC bus choke 1 4 diode bridge 1 4 disconnect settings C 5 E electrical specifications A 2 electrical system features 1 7 options 1 9 enclosure Bulletin 2100 Centerline motor control center 1 2 Bulletin 2362 AC drive in motor control center 1 2 FD86N encl
65. osure 1 2 environmental specifications A 5 Index F FD86N enclosures See enclosures features electrical system 1 7 packaging 1 7 functional specifications A 3 G ground fault detection meter setting 9 4 9 7 H heat dissipation See watts dissipation I installation checks after power up 9 6 checks before power up 9 5 procedure 9 2 L layout 180A DC unit 2 1 350A DC unit 3 1 900A DC unit 4 1 1500A DC unit 5 1 2000A DC unit 6 1 2500A DC unit 7 1 3000A DC unit 8 1 line fusing 1 3 M meter cover See wireway meter cover motor circuit protector 1 3 C 5 motor control center MCC See enclosure 1 2 Publication 2364E 5 01 April 2002 2 Index N NRU catalog numbers See catalog numbers NRU description 1 1 O operating conditions See specifications environmental options electrical system 1 9 options packaging 1 10 packaging features 1 7 options 1 10 parts See spare parts phase loss relay C 7 physical specifications A 1 power conversion 1 6 R related documentation P 4 renewal parts See spare parts S schematic 180A DC unit 2 2 350A DC unit 3 2 900A DC unit 4 2 1500A DC unit 5 2 2000A DC unit 6 2 2500A DC unit 7 2 3000A DC unit 8 2 conceptual 1 5 Publication 2364E 5 01 April 2002 setup See installation shipping weights A 1 sound level A 6 Spare parts B 4 specifications electrical A 2
66. r Settings Long Delay Long Delay Setting 1 Time 1 xl slg T Sec At Q At 6T Test Amps Test Trip Reset Unit Status n nst Setting 2 5 x ls Publication 2364E 5 01 April 2002 Phase Loss Relay NRU Details C 7 The phase loss relay monitors the system for undervoltage overvoltage and phase unbalance occurrences Figure 10 illustrates the phase loss relay wiring diagram and defines the relay terminals Figure 10 Phase Loss Relay Wiring Diagram Phases A Ld 12 14 22 24 Installation and Setup 1 Set initial settings on the three knobs as follows UNDERVOLTAGE and TIME DELAY ON UNDERVOLTAGE to minimum CCW IMBALANCE to maximum CW Connect the fused 3 phase line voltage to terminals A B and C on D65 see Figure 10 A connection to the neutral is not required in Wye systems DO NOT connect wires to the output terminals until later Step 7 Apply Line Voltage The LED indicator should illuminate and stay steady If the LED flashes a fault condition exists and must be corrected Check to see if all phases are present REMOVE LINE VOLTAGE and switch any two of the line voltage connections to insure the phase rotation is correct Reapply line voltage to check for correct phase rotation REMOVE LINE VOLTAGE for Steps 4 6 Set the UNDERVOLATAGE dial Thi
67. r a 5 control 30A KLDR 175A KLDR 15A KLDR 12A KLDR transformer Primary fuse for a 10 control 60A KLDR 35A FRS 25 KLDR 20A KLDR transformer NRU control power fuse MAKLDDR Control bus fuse for a 1 kVA 4A KLDR control transformer c M control transformer RM transformer 11 13 Phase lossfuses KLDR F14 16 suppressor fuses 25 51 2 Bridge heatsink MTR Bridgefan 1200 MTRI C Bridge fan capacitor 20uFcapacitor MTR2 Door mounted fan by choke Cid PL1_ D Bus Energlzed pot ight_ _ 2AVACNOG red 800M Not Faulted pilot light 120 amber 800MR PSI stows ar senor a VDO 14A 0 0 0 0 0 00 0 y O power transformer A 1 KVA control transformer is standard 5 KVA and 10 kVA control transformers are available as options This transformer has multiple taps to accommodate 230 380 460 575V AC primary voltages 222220222 51 2 Heatsink thermoswitch 209 Si __ ss _ 51 3 Line to ine MOVs 1 360 275 460 J 320V AC 460 J 320 1550 J 385V AC 59 Neutral to ground MOV 7 600 550 760 J esov 760 J 680 AC 760 J 680v AC DC bus voltmeter 50002 750 0 1000 0 jGrundfautdetectr Components marked as being options are part
68. r installed drive system can result in component damage and or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply and excessive ambient temperatures can result in the malfunction of the drive equipment ATTENTION This drive system contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing or repairing this assembly Component damage can result if ESD control procedures are not followed If you are not familiar with static control procedures refer to Rockwell Automation publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook Preface P iii Contents of this Manual Chapter Contents Purpose background and scope of this manual Theory of operation features and standard options Schematics and connection diagrams for the 180A DC NRU Schematics and connection diagrams for the 350A DC NRU Schematics and connection diagrams for the 900A DC NRU Schematics and connection diagrams for the 1500A DC NRU Schematics and connection diagrams for the 2000A DC NRU Schematics and connection diagrams for the 2500A DC NRU Schematics and connection diagrams for the 3000A DC NRU NRU wiring information and installation procedures Checklist for identifying problems with your 2364E system Physical electrical environmental and functional specific
69. rimary voltages 51 2 Heatsink thermoswitch Sone tama i cl 5 1 3 Line toline MOVs 000 13604 275 460J 320V 460J 320V AC 550 J 385V AC SPA Neutal to ground MOV 7 16002 550VAC 760J 680V 760J 680v 760 J 680V AC M1 DCbusvotmter 750VDC 100VDC 1000 00 2 jGrundfadtdetector ooo Components marked as being options are part of NRU standard options Not all NRUs will have these components Publication 2364E 5 01 April 2002 Before You Begin Chapter 9 Installing Your NRU This chapter provides the following information for the NRU NRU installation procedure checks before power up NRU checks after power up Before you begin be sure to have the items in the following list and all items required by referenced procedures Documentation drive system schematics e this manual e Rockwell Automation publication 2300 5 1 if using a 2300 system or Rockwell Automation publication S 3062 if using FD86N cabinets Rockwell Automation publication 2100 5 5 Equipment the drive system lineup wire or bus sized per local electrical codes to connect AC line power to the drive system Tools tools for fastening and removing bolts ameans to punch holes into sheet metal for the routing of conduit e ameans to connect AC line power to the drive system adevice for measur
70. s setting should be the same as the minimum operating voltage for the equipment to be adequately protected Set the TIME DELAY ON UNDERVOLTAGE dial This is the maximum time period that an undervoltage condition should exist Too short a setting will cause nuisance tripping if there are momentary dips in the line voltage Too long a setting could cause damage to the equipment Note that the setting should be at least slightly longer than the time a 3 phase motor is drawing its inrush current This will void a nuisance tripping caused by the starting current Publication 2364E 5 01 April 2002 C 8 NRU Details Publication 2364E 5 01 April 2002 6 Setthe IMBALANCE dial This setting should be the maximum allowable imbalance in phase voltage that the 3 phase system can tolerate Too low of a setting can cause nuisance tripping Too high of a setting may not adequately protect the system 7 Connect the output terminals as shown in Figure 10 8 When all connections have been made apply Line Voltage The light emitting diode LED indicator will illuminate steady the internal relay will energize and the 3 phase system will become operational 9 Ifthe LED flashes during regular operation one of the four fault conditions has occurred REMOVE LINE VOLTAGE and check for presence of all three phases phase imbalance and low voltage conditions Correct if necessary Monitor Operation When the voltage input parameters to the D65 are n
71. ses 2364 180 3000A DC TCE SG fuses 2300 SPJO3A ind Line to Neutral and Neutral to Ground 2364E 575V AC 775V DC 180 3000A 1 each 1 each 1 each 1 1 POPP PP PMP PM MMH P2 5 MPM P5 P2 gt Publication 2364E 5 01 April 2002 10 NRU Catalog Numbers and Spare Parts Kits This page intentionally left blank Publication 2364E 5 01 April 2002 Appendix NRU Details This appendix provides Bulletin 2364E NRU details e wireway meter cover details input connections Wireway Meter Cover Details Figure 1 shows the location and sizes of holes that can be made for the mounting of meters in the wireway meter cover Figure 1 Details of Meter Mounting Holes 2 250 0 140 Diameter 1125 gt 7 Holes 2 813 Diameter Hole 1 125 2375 2250 1 368 2736 gt Publication 2364E 5 01 April 2002 C 2 NRU Details The quantity of meters that can be mounted on any given meter cover depends upon the meter cover width Table A Meter Wireway Cover Description DC Bus Current NRU Current For wireway meter cover A DC Code See 180 350 o 2 1500 2000 2500 lt ce Fee Figure 2 25 Wide Wireway Meter Cover Layout 2444 gt 3 00 Bend Line 22 18 4286 MOCO Th 14
72. ual in whole or in part without written permission of the Allen Bradley Company is prohibited Throughout this manual we use notes to make you aware of safety considerations circumstances that can lead to personal injury or death property ATTENTION Identifies information about practices or damage or economic loss Attentions help you e identify a hazard e avoid the hazard e recognize the consequences Important Identifies information that is especially important for successful application and understanding of the product Shock Hazard labels may be located on or inside the drive to h alert people that dangerous voltage may be present Updated Information Updates and Additions Summary of Changes This manual incorporates the information found in the previous two manuals e Non Regenerative DC Bus Supply Publication 2364E 5 01 August 1997 e Non Regenerative DC Bus Supply Publication 2364E 5 01 March 1998 It also contains new information The information below summarizes the changes to this manual since its last release Page Description C 7 Replaced two figures for one graphic Figure 10 Phase Loss Relay Wiring Diagram C 8 Section Setting Jumpuers for The Phase Loss Relay removed Publication 2364E 5 01 April 2002 2 soc Summary of Changes End of Summary of Changes Publication 2364E 5 01 April 2002 Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Table of Contents
73. ult detection meter is supplied set the red warning indicator needle 50V higher than the maximum value measured by the black needle up to 200V maximum Figure 9 3 Setting The Warning Trip Voltage Important The black needle of the ground fault detection meter should typically read a low value between 80 and 100V when the inverters on the DC bus are modulating This voltage is produced by capacitively coupled currents to ground in the motor s cables and windings Publication 2364E 5 01 April 2002 9 8 Installing Your NRU Publication 2364E 5 01 April 2002 This page intentionally left blank Before You Begin Safety Precautions Chapter 10 Troubleshooting This chapter provides a checklist to use when troubleshooting your NRU Before you begin be sure to have the items in the following list Documentation e drive system schematics e this manual Tools ameans to connect AC line power to the drive system e adevice for measuring AC voltages rms e adevice for measuring DC voltages e a device for measuring AC currents e a device for measuring DC currents adevice for continuity testing ATTENTION To avoid the hazard of electrical shock verify that all voltages on the system bus network have been discharged before attempting to service the system ATTENTION The NRU contains stored energy devices To avoid the hazard of electrical shock verify thatall voltage on capacitors has been discharged
74. urrent Code Table 4 A 900A DC NRU Symbol to Component Cross Reference Symbol Description Option 230VAC 380VAC 460VAC 575 AmmetermontoingLi tooo 81 Circuit Breaker 1200A R frame breaker with i200Aplug Hii DCchoke 008 Phase loss relay Faultrelay CC CT1 CT3 Current transformer 10005 01 6 3 180 AT jPowemontorll A2 jBusindiatrPCB 022 EA2F1 2 Bus indicator PCB fuses 11 1000 HVR 1 3 32 diameter 3 length 500AIC AC line RC suppressor PCB EA4 Bridge suppressor PCB EAS Airfowsensor PCB F1 3 Incoming 3 phase line fuses 1000A 170M _ Primary 1080 fora 1 control KLDR 4A KLDR 3A KLDR 3A KLDR transformer Primary fuse for 2 kVA control o qu KLDR 8A KLDR 6 25A KLDR 5A KLDR transformer Primary fuse for 5 KVA control 30A KLDR 175A KLDR 15A KLDR 12A KLDR transformer NRU control power fuse Control bus fuse for a 1 5A KLDR transformer 21 transformer come e ore transformer 11 13 Phase lossfuses SS KLDR Fi4 16 suppressor fuses 25 51 2 Bridge heatsink MTIR Bridgefan 42 700 IMTR1 C Bridge fan capacitor 2 16uFcapacitor

Non-Regenerative DC Bus Supply Unit

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