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Non-Regenerative DC Bus Supply Unit: Bulletin 2364E
Non-Regenerative DC Bus Supply Unit: Bulletin 2364E
User Manual
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.
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.
identify a hazard
Updated Information This manual incorporates the information found in the previous two
manuals:
Non-Regenerative DC Bus Supply, Publication 2364E-5.01
August 1997
Non-Regenerative DC Bus Supply, Publication 2364E-5.01
March 1998
It also contains new information.
Updates and Additions 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
Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Common Techniques Used in this Manual . . . . . . . . . . . . . P-5
Drive System Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . P-5
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Chapter 1 Overview
What is the 2364E? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
What does the NRU do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How will the NRU fit into a 2362 drive system? . . . . . . . . . . . . 1-2
How will the NRU fit into a drive system packaged in
FD86N enclosures? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How Does An NRU Work? . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Primary Electrical Components of the NRU . . . . . . . . . . . . . . . 1-3
NRU Conceptual Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Power Conversion Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Bulletin 2364E NRU Standard Features . . . . . . . . . . . . . . 1-7
Electrical System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Packaging Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Bulletin 2364E NRU Standard Options . . . . . . . . . . . . . . 1-9
Electrical System Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Packaging Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Chapter 10 Troubleshooting
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Checklist for Troubleshooting
Your NRU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Appendix A Specifications
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Approximate Shipping Weights . . . . . . . . . . . . . . . . . . . . . . A-1
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Input Currents of NRU with Control Source Upgrade Options A-4
Thru Bus Ratings per Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . A-5
Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Who Should Use This Manual Use this manual if you are responsible for installing or operating a
Rockwell Automation non-regenerative, common DC bus supply unit
(NRU).
Purpose of This Manual This manual provides installation and software configuration
instructions for Rockwell Automations NRUs.
Safety Precautions The following general precautions apply to Bulletin 2364E NRUs and
to drive system lineups:
Common Techniques Used in this The following conventions are used throughout this manual:
Manual
NRU unit configurations are referred to by their catalog string
current code (Refer to Appendix B for code definition.).
Bulleted 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 by the word
"ATTENTION" indicate circumstances that can lead to personal
injury, death, property damage, or economic loss.
Drive System Receiving 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 Support 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.
What is the 2364E? 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.
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:
How Does An NRU Work? 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.
DC Bus Choke
The DC bus choke reduces peak currents in the AC line and the
bridge circuit. The DC bus choke also reduces line harmonics.
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
3-Phase AC Bus
DC
Incoming Voltage
Light Bus
Power
DC -
Choke
-
(This fuse included in control
power source upgrade options)
L
L
Bridge To Optional
Fan 115V AC 115V AC
M Motor NRU Control Control Bus
Power
(Optional Air-Flow
Sensor)
N N
Control
Transformer
NRU
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.
Figure 1.2
3-Phase AC Line Voltage and DC Output Voltage and Current
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
11.9 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
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.
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.
AM1 VM1
EA1
TB2
MCP1
TB1
EA3
F8
SP1
F1
SP2 S1 S2
SP3
SP4 F2
CR1
F3
HS1 HS2
CR2 F7 (-) (+)
MTR1-C
PS1 EA5
F4,
F6
MTR1
EA2
CH11
PT1
MCP1
Powermonitor II EA1
MASTER MODULE
BULL 1403-MM05A
I2- CURRENT
H1 X1 X1 AIN
H1 I3+ INPUTS ANALOG
INPUT ACOM
I3-
CT1 CT3
I4+ R14
X2 X2
I4- R11
R12
PE
R24
R21
R22
EA1-A
F14 F11
EA3
L1 V1 BULL
1403-DMA
F15 F12 115 VAC NRU
TX TX L1(+)
L2 V2 DISPLAY CONTROL
VOLTAGE MODULE RX RX L2 (-) POWER
F16 F13 INPUTS
L3 V3
COMMON
A B C 1403-NSC
N BULL
SP4 SP1
PE
CR1
1
SP2
RIO 2
PE S1
SP3 SHLD
S2
STATUS
S3 INPUTS +
S4 RS-485 -
SCOM SHLD
TXD
A RS-232
RXD
SHLD
TO POWER TRANSFORMER
GROUNDING RESISTOR
PE
TB2-1 TB2-2
115 VAC NRU
VM CONTROL
POWER
2 10 12 9 7 115VAC NRU
(INPUT) (115VAC) CONTROL
EA5 PS1 POWER
METER RELAY S5 J2 J2 ACL ACN
Y 1 5 +
2 4 6 R 2 6 - ACG
24 VDC
TB1-7 B 3
TO CONTACTOR FLOW J1 1 3
MONITORING PE SENSOR
TB1-8 TO CONTACTOR
CIRCUIT MONITORING
CIRCUIT
F6
F4
PT1
(X1) (X2)
115 VAC
F8 F7
MTR1 PE
TB1-9
TB1-10
OPTIONAL
REMOTE
EA5-CR CR1 CR2
TB1-1 INTERLOCK TB1-2 S1 S2
1 3
(JMPR)
PL2
N
L1
115 VAC
CONTROL BUS TO
INVERTER UNITS
HEAT F1 F2 F3 HEAT
SINK SINK
-BUS +BUS CR1
D1 D2
TB1-3 TB1-4
D3 D4
CR2
D5 HS1 D6 HS2
TB1-5 TB1-6
D11
C11
R11
R12
EA2
F1 R1
+BUS LED1
F2 R2 FOOTNOTES:
-BUS LED2 PL1
(X3) (X1) Note: An NRU may have either a door-
Door-mounted ammeter option. mounted ammeter or a Powermonitor II. This
CH11 CH11
Powermonitor II option. drawing shows both options for information.
(X4) (X2)
Powermonitor II communication module option.
Line RC suppressor option.
Ground-fault detection option.
VM1 Air-flow sensing option.
Control bus option.
Unit-not-faulted pilot light option.
DC bus voltmeter option.
DC HORIZONTAL BUS TO INVERTER UNITS
AM1 VM1
EA1
TB2
MCP1
TB1
EA3
F8
SP1
F1
SP2 S1 S2
SP3
SP4 F2
CR1
F3
HS1 HS2
CR2 F7 (-) (+)
MTR1-C
PS1 EA5
F4,
F6
MTR1
EA2
CH11
PT1
MCP1
Powermonitor II EA1
MASTER MODULE
BULL 1403-MM05A
I2- CURRENT
H1 X1 X1 AIN
H1 I3+ INPUTS ANALOG
INPUT ACOM
I3-
CT1 CT3
I4+ R14
X2 X2
I4- R11
R12
PE
R24
R21
R22
F14 EA1-A
F11
EA3
L1 V1 BULL
1403-DMA
F15 F12 115 VAC NRU
TX TX L1(+)
L2 V2 DISPLAY CONTROL
VOLTAGE MODULE RX RX L2 (-) POWER
F16 F13 INPUTS
L3 V3
COMMON
A B C 1403-NSC
N BULL
SP4 SP1
PE
CR1
1
SP2
RIO 2
PE S1
SP3 SHLD
S2
STATUS
S3 INPUTS +
S4 RS-485 -
SCOM SHLD
TXD
A RS-232
RXD
SHLD
TO POWER TRANSFORMER
GROUNDING RESISTOR
PE
TB2-1 TB2-2
115 VAC NRU
VM CONTROL
POWER
2 10 12 9 7 115VAC NRU
(INPUT) (115VAC) CONTROL
EA5 PS1 POWER
METER RELAY S5 J2 J2 ACL ACN
Y 1 5 +
2 4 6 R 2 6 - ACG
24 VDC
TB1-7 B 3
TO CONTACTOR FLOW J1 1 3
MONITORING PE SENSOR
TB1-8 TO CONTACTOR
CIRCUIT MONITORING
CIRCUIT
F6
F4
PT1
(X1) (X2)
115 VAC
F8 F7
MTR1 PE
TB1-9
TB1-10
OPTIONAL
REMOTE
EA5-CR CR1 CR2
TB1-1 INTERLOCK TB1-2 S1 S2
1 3
(JMPR)
PL2
N
L1
115 VAC
CONTROL BUS TO
INVERTER UNITS
HEAT F1 F2 F3 HEAT
SINK SINK
-BUS +BUS CR1
D1 D2
TB1-3 TB1-4
D3 D4
CR2
D5 HS1 D6 HS2
TB1-5 TB1-6
D11
C11
R11
R12
EA2
F1 R1
+BUS LED1
F2 R2 FOOTNOTES:
-BUS LED2 PL1
(X3) (X1) Note: An NRU may have either a door-
Door-mounted ammeter option. mounted ammeter or a Powermonitor II. This
CH11 CH11
Powermonitor II option. drawing shows both options for information.
(X4) (X2)
Powermonitor II communication module option.
Line RC suppressor option.
Ground-fault detection option.
VM1 Air-flow sensing option.
Control bus option.
Unit-not-faulted pilot light option.
DC bus voltmeter option.
DC HORIZONTAL BUS TO INVERTER UNITS
AM1 VM1
EA1
CB1
SP1
EA3 SP2
SP3
SP4
CT1 CT3
F14
TB2 F15
TB1 F16
F1 F2 F3
F8 F11
F12
F13
CR1
F7
CR2
HS1 HS2
PS1
EA5
F4
F6
MTR1
EA2
CH11
PT1
CB1
Powermonitor II EA1
MASTER MODULE
BULL 1403-MM05A
I2- CURRENT
H1 X1 X1 AIN
H1 I3+ INPUTS ANALOG
INPUT ACOM
I3-
CT1 CT3
I4+ R14
X2 X2
I4- R11
R12
PE
R24
R21
R22
F14 EA1-A
F11
EA3
L1 V1 BULL
1403-DMA
F15 F12 115 VAC NRU
TX TX L1(+)
L2 V2 DISPLAY CONTROL
VOLTAGE MODULE RX RX L2 (-) POWER
F16 F13 INPUTS
L3 V3
COMMON
A B C 1403-NSC
N BULL
SP4 SP1
PE
CR1
1
SP2
RIO 2
PE S1
SP3 SHLD
S2
STATUS
S3 INPUTS +
S4 RS-485 -
SCOM SHLD
TXD
A RS-232
RXD
SHLD
TO POWER TRANSFORMER
GROUNDING RESISTOR
PE
TB2-1 TB2-2
115 VAC NRU
VM CONTROL
POWER
2 10 12 9 7 115VAC NRU
(INPUT) (115VAC) CONTROL
EA5 PS1 POWER
METER RELAY S5 J2 J2 ACL ACN
Y 1 5 +
2 4 6 R 2 6 - ACG
24 VDC
TB1-7 B 3
TO CONTACTOR FLOW J1 1 3
MONITORING PE SENSOR
TB1-8 TO CONTACTOR
CIRCUIT MONITORING
CIRCUIT
F6
F4
PT1
(X1) (X2)
115 VAC
F8 F7
MTR1 PE
TB1-9
TB1-10
OPTIONAL
REMOTE
EA5-CR CR1 CR2
TB1-1 I N T E R L O C K TB1-2 S1 S2
1 3
(JMPR)
PL2
N
L1
115 VAC
CONTROL BUS TO
INVERTER UNITS
HEAT F1 F2 F3 HEAT
SINK SINK
-BUS +BUS CR1
D1 D2
TB1-3 TB1-4
D3 D4
CR2
D5 HS1 D6 HS2
TB1-5 TB1-6
EA4
EA2
F1 R1
+BUS LED1
F2 R2 FOOTNOTES:
-BUS LED2 PL1
(X3) (X1) Note: An NRU may have either a door-
Door-mounted ammeter option. mounted ammeter or a Powermonitor II. This
CH11 CH11
Powermonitor II option. drawing shows both options for information.
(X4) (X2)
Powermonitor II communication module option.
Line RC suppressor option.
Ground-fault detection option.
VM1 Air-flow sensing option.
Control bus option.
Unit-not-faulted pilot light option.
DC bus voltmeter option.
DC HORIZONTAL BUS TO INVERTER UNITS
VM1 AM1
CUSTOMER
3-PHASE AC
INPUT
EA4
HS1 HS2
(-) (+)
S1 S2
CB1
Phase A
CT1 S3 CT3
F3
Phase C
EA3
F2
SP2 SP4 F14,
SP1 F15,
F16
SP3 S5
F1
F4,
F6 F8
MTR1-C
PS1 EA5
MTR3
EA1 CH11
PT1
3-Phase
AC Input
CB1
Powermonitor II EA1
MASTER MODULE
BULL 1403-MM05A
I2- CURRENT
X1 X1 AIN
H1 H1 I3+ INPUTS ANALOG
INPUT ACOM
I3-
CT1 CT3
I4+ R14
X2 X2
I4- R11
R12
PE
R24
R21
R22
EA1-A
EA3 F14 F11
L1 V1 BULL
1403-DMA
F15 F12 115 VAC NRU
TX TX L1(+)
L2 V2 DISPLAY CONTROL
VOLTAGE MODULE RX RX L2 (-) POWER
F16 F13 INPUTS
L3 V3
COMMON
A B C 1403-NSC
N BULL
SP4 SP1
PE
CR1
1
SP2
RIO 2
PE S1
SHLD
SP3 S2
STATUS
S3 INPUTS +
S4 RS-485 -
SCOM SHLD
TXD
A RS-232
RXD
SHLD
PE
EA5
S5 J2 J2
Y 1 5
R 2 6
2 4 6
B 3
TB1-7 FLOW J1 1 3
TO CONTACT SENSOR
MONITORING PE
TB1-8
CIRCUIT TO CONTACTOR
MONITORING CIRCUIT
F6
F4
PT1
(X1) (X2)
115 VAC
F8 F7
MTR1 PE
TB1-9
TB1-10
MTR2
OPTIONAL
REMOTE
I N T E R L O C K TB1-2 EA5-CR EA6-CR CH11-TG S3
TB1-1
1 3 1 3
(JMPR)
CR1 CR2
S1 S2
N
L1
PL2
115 VAC
CONTROL BUS TO
INVERTER UNITS
HEAT F1 F2 F3 HEAT
SINK SINK
-BUS +BUS CR1
D1 D2
TB1-3 TB1-4
D3 D4
CR2
D5 HS1 D6 HS2
TB1-5 TB1-6
EA4
EA2
F1 R1
+BUS LED1 FOOTNOTES:
F2 R2
-BUS LED2 PL1
Note: An NRU may have either a door-
(X3) (X1) Door-mounted ammeter option. mounted ammeter or a Powermonitor II. This
CH11 CH11 Powermonitor II option. drawing shows both options for information.
(X4) (X2) Powermonitor II communication module option.
Line RC suppressor option.
Ground-fault detection option.
VM1 Air-flow sensing option.
Control bus option.
Unit-not-faulted pilot light option.
DC bus voltmeter option.
DC HORIZONTAL BUS TO INVERTER UNITS
VM1 AM1
CUSTOMER
3-PHASE AC
INPUT
EA4
HS1 HS2
(-) (+)
S1 S2
CB1
Phase A
CT1 S3 CT3
F3
Phase C
EA3 F3A
F2
SP2 SP4 F14,
SP1 F15,
F16 F2A
SP3 S5
F1
F4,
F6 F8 F1A
MTR1-C
PS1 EA5
MTR3
EA1 CH11
PT1
3-Phase
AC Input
CB1
Powermonitor II EA1
MASTER MODULE
BULL 1403-MM05A
I2- CURRENT
X1 X1 AIN
H1 H1 I3+ INPUTS ANALOG
INPUT ACOM
I3-
CT1 CT3
I4+ R14
X2 X2
I4- R11
R12
PE
R24
R21
R22
EA1-A
EA3 F14 F11
L1 V1 BULL
1403-DMA
F15 F12 115 VAC NRU
TX TX L1(+)
L2 V2 DISPLAY CONTROL
VOLTAGE MODULE RX RX L2 (-) POWER
F16 F13 INPUTS
L3 V3
COMMON
A B C 1403-NSC
N BULL
SP4 SP1
PE
CR1
1
SP2
RIO 2
PE S1
SHLD
SP3 S2
STATUS
S3 INPUTS +
S4 RS-485 -
SCOM SHLD
TXD
A RS-232
RXD
SHLD
PE
EA5
S5 J2 J2
Y 1 5
R 2 6
2 4 6
B 3
TB1-7 FLOW J1 1 3
TO CONTACT SENSOR
MONITORING PE
TB1-8
CIRCUIT TO CONTACTOR
MONITORING CIRCUIT
F6
F4
PT1
(X1) (X2)
115 VAC
F8 F7
MTR1 PE
TB1-9
TB1-10
MTR2,MTR3
OPTIONAL
REMOTE
I N T E R L O C K TB1-2 EA5-CR EA6-CR CH11-TG S3
TB1-1
1 3 1 3
(JMPR)
CR1 CR2
S1 S2
N
L1
PL2
115 VAC
CONTROL BUS TO
INVERTER UNITS
F1 F2 F3 F3A
D5 HS1 D6 HS2
TB1-5 TB1-6
EA4
EA2
F1 R1
+BUS LED1 FOOTNOTES:
F2 R2
-BUS LED2 PL1 Note: An NRU may have either a door-
(X3) (X1) Door-mounted ammeter option. mounted ammeter or a Powermonitor II. This
CH11 CH11 Powermonitor II option. drawing shows both options for information.
(X4) (X2) Powermonitor II communication module option.
Line RC suppressor option.
Ground-fault detection option.
VM1 Air-flow sensing option.
Control bus option.
Unit-not-faulted pilot light option.
DC bus voltmeter option.
DC HORIZONTAL BUS TO INVERTER UNITS
AM1 VM1
EA4
Phase A
EA2
CB1 Phase B
Phase C
EA3
S6
Phase Phase
F14, Phase
F15, A B C
F16 CT1 CT3
PS1
TB2 SP1 SP3
F11, S3 F3
TB1 F12,
F13 SP2 SP4 F3A EA6
MTR1-C
F7 CR1 CR2 F2
MTR1
F2A
F8
F4, F1
F6
EA5 F1A
S5 CH11
EA1
PT1
3-Phase
AC Input
CB1
Powermonitor II EA1
MASTER MODULE
BULL 1403-MM05A
I2- CURRENT
X1 X1 AIN
H1 H1 I3+ INPUTS ANALOG
INPUT ACOM
I3-
CT1 CT3
I4+ R14
X2 X2
I4- R11
R12
PE
R24
R21
R22
EA1-A
EA3 F14 F11
L1 V1 BULL
1403-DMA
F15 F12 115 VAC NRU
TX TX L1(+)
L2 V2 DISPLAY CONTROL
VOLTAGE MODULE RX RX L2 (-) POWER
F16 F13 INPUTS
L3 V3
COMMON
A B C 1403-NSC
N BULL
SP4 SP1
PE
CR1
1
SP2
RIO 2
PE S1
SHLD
SP3 S2
STATUS
S3 INPUTS +
S4 RS-485 -
SCOM SHLD
TXD
A RS-232
RXD
SHLD
PE
EA5
S5 J2 J2
Y 1 5
R 2 6
2 4 6
B 3
TB1-7 FLOW J1 1 3
TO CONTACT SENSOR
MONITORING PE
TB1-8
CIRCUIT TO CONTACTOR
MONITORING CIRCUIT
F6
F4
PT1
(X1) (X2)
115 VAC
F8 F7
MTR1 PE
TB1-9
TB1-10
MTR2,MTR3
OPTIONAL
REMOTE MTR4,MTR5,MTR6
I N T E R L O C K TB1-2 EA5-CR EA6-CR CH11-TG
TB1-1
1 3 1 3
(JMPR)
CR1 CR2
S3 S1 S2
N
L1
PL2
115 VAC
CONTROL BUS TO
INVERTER UNITS
F1 F2 F3 F3A
D5 HS1 D6 HS2
TB1-5 TB1-6
EA4
EA2
F1 R1 FOOTNOTES:
+BUS LED1
F2 R2
-BUS LED2 PL1 Note: An NRU may have either a door-
(X3) (X1)
Door-mounted ammeter option. mounted ammeter or a Powermonitor II. This
Powermonitor II option. drawing shows both options for information.
CH11 CH11
Powermonitor II communication module option.
(X4) (X2)
Line RC suppressor option.
Ground-fault detection option.
VM1 Air-flow sensing option.
Control bus option.
Unit-not-faulted pilot light option.
DC bus voltmeter option.
DC HORIZONTAL BUS TO INVERTER UNITS
AM1 VM1
EA4
Phase A
EA2
CB1 Phase B
Phase C
EA3
S6
Phase Phase
F14, Phase
F15, A B C
F16 CT1 CT3
PS1
TB2 SP1 SP3
F11, S3 F3
TB1 F12,
F13 SP2 SP4 F3A EA6
MTR1-C
F7 CR1 CR2 F2
MTR1
F2A
F8
F4, F1
F6
EA5 F1A
S5 CH11
EA1
PT1
3-Phase
AC Input
CB1
Powermonitor II EA1
MASTER MODULE
BULL 1403-MM05A
I2- CURRENT
X1 X1 AIN
H1 H1 I3+ INPUTS ANALOG
INPUT ACOM
I3-
CT1 CT3
I4+ R14
X2 X2
I4- R11
R12
PE
R24
R21
R22
EA1-A
EA3 F14 F11
L1 V1 BULL
1403-DMA
F15 F12 115 VAC NRU
TX TX L1(+)
L2 V2 DISPLAY CONTROL
VOLTAGE MODULE RX RX L2 (-) POWER
F16 F13 INPUTS
L3 V3
COMMON
A B C 1403-NSC
N BULL
SP4 SP1
PE
CR1
1
SP2
RIO 2
PE S1
SHLD
SP3 S2
STATUS
S3 INPUTS +
S4 RS-485 -
SCOM SHLD
TXD
A RS-232
RXD
SHLD
PE
EA5
S5 J2 J2
Y 1 5
R 2 6
2 4 6
B 3
TB1-7 FLOW J1 1 3
TO CONTACT SENSOR
MONITORING PE
TB1-8
CIRCUIT TO CONTACTOR
MONITORING CIRCUIT
F6
F4
PT1
(X1) (X2)
115 VAC
F8 F7
MTR1 PE
TB1-9
TB1-10
MTR2,MTR3
OPTIONAL
REMOTE MTR4,MTR5,MTR6
I N T E R L O C K TB1-2 EA5-CR EA6-CR CH11-TG
TB1-1
1 3 1 3
(JMPR)
CR1 CR2
S3 S1 S2
N
L1
PL2
115 VAC
CONTROL BUS TO
INVERTER UNITS
F1 F2 F3 F3A
D5 HS1 D6 HS2
TB1-5 TB1-6
EA4
EA2
F1 R1 FOOTNOTES:
+BUS LED1
F2 R2
-BUS LED2 PL1 Note: An NRU may have either a door-
(X3) (X1)
Door-mounted ammeter option. mounted ammeter or a Powermonitor II. This
Powermonitor II option. drawing shows both options for information.
CH11 CH11
Powermonitor II communication module option.
(X4) (X2)
Line RC suppressor option.
Ground-fault detection option.
VM1 Air-flow sensing option.
Control bus option.
Unit-not-faulted pilot light option.
DC bus voltmeter option.
DC HORIZONTAL BUS TO INVERTER UNITS
Before You Begin Before you begin, be sure to have the items in the following list and
all items required by referenced procedures.
Documentation
drive system schematics
this manual
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
a means to punch holes into sheet metal for the routing of conduit
a means to connect AC line power to the drive system
a device for measuring AC voltages (rms)
a device for measuring DC voltages
a device for continuity testing
Installation Procedure
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.
1.
2. Remove the lifting angle (if present) that is secured to the top of
the NRU.
3. Plan where to punch holes for AC input entry. Refer to
Appendix C for top plate clearance information prior to punching
any holes.
4. Remove the top plate from the MCC.
5. Punch desired holes for AC input entry.
6. Connect top plate to NRU.
1. Verify that the NRU does not have any mechanical damage.
2. Verify that the NRU does not have any loose wires or buswork.
3. Using an ohmmeter or other continuity testing device, verify that
shorts do not exist between:
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:
Nominal DC Bus Minimum DC Bus Maximum DC Bus
Voltage (V DC) Voltage (V DC) Voltage (V DC)
310 279 341
510 459 561
620 558 682
775 698 852
Figure 9.2
Where to Check the DC Bus Voltage
4. Verify that the diode bridge fan is running and blowing air over
the bridge.
5. Verify that the "DC Bus Energized" pilot light (PL1) 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.
Before You Begin Before you begin, be sure to have the items in the following list:
Documentation
drive system schematics
this manual
Tools
a means to connect AC line power to the drive system
a device for measuring AC voltages (rms)
a device for measuring DC voltages
a device for measuring AC currents
a device for measuring DC currents
a device for continuity testing
Safety Precautions
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
Loss of DC Bus
Loss of DC Bus Loss of Control
Power & Control Fault Indication Did you check the:
Power Only Power Only
Power
3-Phase AC Incoming Power
Circuit Breaker or MCP Operation
3-Phase Fusing
Diode Bridge
DC Choke
Control Transformer Fusing
Control Transformer Secondary
Voltage and/or Secondary Fusing
Bridge Fan
Over-Temperature Switch
Phase Loss
Phase Imbalance
External Customer Interlocks
(if present)
The height of 1500 A 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.
Functional Specifications
Table D: NRU Functional Specifications
AC Input Frequency Tolerance 45 to 65 Hz
AC Input Voltage Tolerance 10%
150% maximum DC bus current for 60 seconds,
Overload Capability
200% for 10 seconds following continuous operation
1 minute out of 20 minutes at rated load and
Overload Duty Cycle
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.
NRU Continuous Input Current of NRU with Continuous Input Current of NRU with
Nominal Input
Current Standard Capacity Control Source Extra Capacity Control Source Upgrade
Voltage (V AC)
Code Upgrade Option 6P (A AC) Option 6PX (A AC)
Figure 1
Altitude Derate Curve
% of NRU 100%
Rated Amps
at 40 C
90%
80%
70%
60%
50%
0m 1000 m 2000 m 3000 m 4000 m
(0 ft) (3,300 ft) (6,600 ft) (9,900 ft) (13,200 ft)
Altitude
Figure 2
Temperature Derate Curve
% of NRU 100%
Rated Amps
at Sea Level
95%
90%
85%
80%
75%
0C 5C 10C 15C 20C 25C 30C 35C 40C 45C 50C 55C
(32F) (41F) (50F) (59F) (68F) (77F) (86F) (95F) (104F) (113F) (122F) (131F)
Ambient Temperature
Figure 3
180A and 350A DC NRU Watts Dissipation versus % Load
1800
1600
1400
800
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
Total Watts Loss
3000
2500
2000
900A DC NRU
1500
1000
500
0
10 20 30 40 50 60 70 80 90 100
% Load
Figure 5
1500A and 2000A DC NRU Watts Dissipation versus % Load
7000
6000
5000
4000
3000
1500A DC NRU
2000
1000
0
10 20 30 40 50 60 70 80 90 100
% Load
Figure 6
2500A and 3000A DC NRU Watts Dissipation versus % Load
12000
10000
Total Watts Loss
8000
3000A DC NRU
6000
2500A DC NRU
4000
2000
0
10 20 30 40 50 60 70 80 90 100
% Load
Storage Conditions
Table I: NRU Storage Conditions
Ambient Temperature -40 to 70 C (-40 to 158 F)
Relative Humidity 5% to 95%, non-condensing
Understanding Catalog Numbers 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.
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.
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
has a NEMA Type 1 enclosure without gaskets
provides circuit breaker input protection
includes the option:
Analog DC Bus Voltmeter
The catalog number would be:
2364EA-DAB-XXCM-715P
2364 E A XX
E = NRU
A = A type
A = 180A DC output
B = 350A DC output
C = 900A DC output
D = 1500A DC output
E = 2000A DC output
F = 2500A DC output
G = 3000A DC output
A = 230V AC
N = 380V AC
B = 460V AC
C = 575V AC
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
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
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 II. The Powermonitor II
options consists of a 1403-MM05A 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 to the duplex receptacle.
The line RC suppressor is recommended for installations where the primary of the distribution
transformer is 2300V AC or greater.
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.
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
1.125 (7 Holes)
2.813 Diameter Hole
1.125 2.375
2.250
0.797
1.368
2.736
The quantity of meters that can be mounted on any given meter cover
depends upon the meter cover width.
Figure 2
25-Wide Wireway Meter Cover Layout
3.38 Ref
0.70
4.59 3.813
TYP
Figure 3
30-Wide Wireway Meter Cover Layout
3.38 Ref
0.70
3.28 3.813
TYP
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.
Figure 4
Area Available for Conduit Entry in Circuit Breaker Section
A
1.50" B 1.25"
(Back of Enclosure)
20.00"
9.00"
PE
(Front of Enclosure)
AC Input Customer Connection The type of AC input connection depends upon the NRU current
Details rating.
Figure 5
AC Input Customer Connection Bus in 900, 1500, 2000, 2500, and 3000A DC
NRUs
0.83 1.844 0.250
0.88
0.563 Diameter
TYP
1.750
Figure 6
180 and 350A DC NRU Recommended Motor Circuit Protector Settings
E E F E D
F D F D
G C G C G C
Push to Trip
H B H B H B
I A I A I A
Figure 7
900A DC NRU Recommended Circuit Breaker Settings
Figure 8
1500 and 2000A DC NRU Recommended Circuit Breaker Settings
Short Delay
Pickup
2 I
n
Figure 9
2500 and 3000A DC NRU Recommended Circuit Breaker Settings
Breaker Trips
At 6T
Test Amps
3 I
n
Test
Trip Reset
Unit Status
Inst
Setting
2.5 x I
n
Phase-Loss Relay 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 B C
A B C 11 21
12 14 22 24
Monitor Operation
When the voltage input parameters to the D65 are normal, 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.
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.
Figure 11
MCC Bus Locations
Y
20
12.59
3.41
0.75 1.75
2.88
4.00
91.5 90 9.00
X 4.00
36.29
1.50
12.59
4.36
A F
altitude, A-5 FD86N enclosures
See enclosures
B features,
electrical system, 1-7
bridge,
packaging, 1-7
See diode bridge 1-4
functional specifications, A-3
Bulletin numbers,
See catalog numbers
G
C ground fault detection meter,
setting, 9-4, 9-7
catalog numbers, B-1
choke, DC bus 1-4
H
circuit breaker,
settings, C-6 heat dissipation,
See watts dissipation
control power,
fusing, 1-4
transformer, 1-4 I
current code, installation,
See catalog numbers checks after power up, 9-6
checks before power up, 9-5
procedure, 9-2
D
DC bus,
choke, 1-4 L
diode bridge, 1-4 layout,
180A DC unit, 2-1
disconnect settings, C-5
350A DC unit, 3-1
900A DC unit, 4-1
E 1500A DC unit, 5-1
electrical specifications, A-2 2000A DC unit, 6-1
2500A DC unit, 7-1
electrical system,
3000A DC unit, 8-1
features, 1-7
options, 1-9 line fusing, 1-3
enclosure,
Bulletin 2100 Centerline motor control M
center, 1-2 meter cover,
Bulletin 2362 AC drive in motor control See wireway meter cover
center, 1-2
motor circuit protector, 1-3, C-5
FD86N enclosure 1-2
motor control center (MCC),
environmental specifications, A-5
See enclosure 1-2
N setup,
NRU catalog numbers, See installation
See catalog numbers shipping weights, A-1
NRU, sound level, A-6
description, 1-1 spare parts, B-4
specifications,
O electrical, A-2
operating conditions, environmental, A-5
See specifications, environmental functional, A-3
physical, A-1
options
electrical system 1-9 startup,
See installation
options,
packaging, 1-10 storage conditions
See specifications,environmental
P
T
packaging,
features, 1-7 temperature, A-5
options, 1-10 troubleshooting, 10-1
parts,
See spare parts W
phase-loss relay, C-7 watts dissipation, A-7
physical specifications, A-1 wireway meter cover, C-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
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