Rockwell Automation Allen-Bradley Bulletin 2364E User manual

User Manual
Non-Regenerative
DC Bus Supply Unit
(NRU)
Bulletin 2364E

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 manual, 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.
Attentions help you:
•identify a hazard
•avoid the hazard
•recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
!
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss.
Shock Hazard labels may be located on or inside the drive to
alert people that dangerous voltage may be present.

Publication 2364E-5.01 April 2002
Summary of Changes
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

Publication 2364E-5.01 April 2002
2-soc Summary of Changes
End of Summary of Changes

Table of Contents
Publication 2364E-5.01 April 2002
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 2 Your 180A DC NRU (Current Code A)
180A DC System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
180A DC NRU Electrical Schematic . . . . . . . . . . . . . . . . . . 2-2
Chapter 3 Your 350A DC NRU (Current Code B)
350A DC System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
350A DC NRU Electrical Schematic . . . . . . . . . . . . . . . . . . 3-2
Chapter 4 Your 900A DC NRU (Current Code C)
900A DC System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
900A DC NRU Electrical Schematic . . . . . . . . . . . . . . . . . . 4-2
Chapter 5 Your 1500A DC NRU (Current Code D)
1500A DC System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
1500A DC NRU Electrical Schematic . . . . . . . . . . . . . . . . . 5-2

toc–ii Table of Contents
Publication 2364E-5.01 April 2002
Chapter 6 Your 2000A DC NRU (Current Code E)
2000A DC System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
2000A DC NRU Electrical Schematic . . . . . . . . . . . . . . . . . 6-2
Chapter 7 Your 2500A DC NRU (Current Code F)
2500A DC System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
2500A DC NRU Electrical Schematic . . . . . . . . . . . . . . . . . 7-2
Chapter 8 Your 3000A DC NRU (Current Code G)
3000A DC System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
3000A DC NRU Electrical Schematic . . . . . . . . . . . . . . . . . 8-2
Chapter 9 Installing Your NRU
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Ground-Fault Detection Option . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
NRU Checks Before Power Up . . . . . . . . . . . . . . . . . . . . . . 9-5
NRU Checks After Power Up . . . . . . . . . . . . . . . . . . . . . . . 9-6
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

Table of Contents toc–iii
Publication 2364E-5.01 April 2002
Appendix B NRU Catalog Numbers and Spare Parts Kits
Understanding Catalog Numbers . . . . . . . . . . . . . . . . . . . . . B-1
Determining Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . .B-1
NRU Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Bulletin 2364E NRU
Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
What Does a Spare Parts Kit Include? . . . . . . . . . . . . . . . . . . . .B-4
Which Table Do I Use? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Significance of Level Numbers . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Definition of Terms Used to Describe "Qty in Kit" . . . . . . . . . .B-5
Catalog Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Appendix C 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
Monitor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8
MCC Bus Location Details . . . . . . . . . . . . . . . . . . . . . . . . . C-9

toc–iv Table of Contents
Publication 2364E-5.01 April 2002
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Publication 2364E-5.01 April 2002
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
• Rockwell Automation support
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™).
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.
Purpose of This Manual This manual provides installation and software configuration
instructions for Rockwell Automation’s NRUs.
Safety Precautions 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
!
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
that all 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 or 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.

Publication 2364E-5.01 April 2002
Preface P-iii
Contents of this Manual
Chapter Title Contents
Preface Purpose, background, and scope of this manual
1 Overview Theory of operation, features, and standard options
2 Your 180A DC NRU (Current Code A) Schematics and connection diagrams for the 180A DC NRU
3 Your 350A DC NRU (Current Code B) Schematics and connection diagrams for the 350A DC NRU
4 Your 900A DC NRU (Current Code C) Schematics and connection diagrams for the 900A DC NRU
5 Your 1500A DC NRU (Current Code D) Schematics and connection diagrams for the 1500A DC NRU
6 Your 2000A DC NRU (Current Code E) Schematics and connection diagrams for the 2000A DC NRU
7 Your 2500A DC NRU (Current Code F) Schematics and connection diagrams for the 2500A DC NRU
8 Your 3000A DC NRU (Current Code G) Schematics and connection diagrams for the 3000A DC NRU
9 Installing Your NRU NRU wiring information and installation procedures
10 Troubleshooting Checklist for identifying problems with your 2364E system
Appendix A Specifications Physical, electrical, environmental, and functional specifications
for the 2364E
Appendix B NRU Catalog Numbers and Spare Parts Kits Catalog number descriptions of available NRUs
Appendix C NRU Details NRU details including AC input connections and wireway meter
covers

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 Read This Document Document Number
Information on the 1336 Force™ drives 1336T User Manual — AC Drive 1336 FORCE-5.12
Information on the 1336 Plus drives 1336S User Manual — .05-600HP 1336 PLUS-5.0
Information on 1336 dynamic braking modules
consisting of both chopper and resistors
Installation Data — HD Dynamic Braking 1336-5.64
Information on 1336 braking chopper modules Chopper Brake Module Installation Instructions 1336-5.65
PLC-5™ information PLC-5 Controllers Brochure 1785-1.2
Bulletin 1403 Powermonitor II information Bulletin 1403 Powermonitor II 1403-5.0
Information on the Bulletin 1403 communication
module
Smart Communications Card 1403-5.1
Additional Information on joining and splicing
together MCCs
Instructions — Joining and Splicing Vertical 2100-5.1
Details on receiving, handling, and storing MCCs Instructions — Receiving, Handling, and
Storing Motor Control Centers
2100-5.5
Provides procedures for those tasks that need to
be done at the customer’s site before system start
up
Bulletin 2300 Installation Manual 2300-5.1
A description of Drive Tools™ software Drive Tools Software Brochure 9303-1.0
Information on SA3000 drives SA3000 Binder S-3001
Information on SA3100 drives SA3100 Binder S-3053
Information on FD86N enclosures FD86N Drive Systems Enclosure Hardware
Installation Manual
S-3062
An article on wire sizes and types for grounding
electrical equipment
National Electrical Code ANSI / NFPA 70 Published
by the National Fire
Protection Association of
Boston, MA
An article on safety procedures Standard for Electrical Safety Requirements for
Employee Workplaces
ANSI / NFPA 70E
A complete listing of current documentation,
including ordering instructions. Also indicates
whether the documents are available on CD-ROM
or in multi-languages
Allen-Bradley Publication Index SD499
A glossary of industrial automation terms and
abbreviations
Industrial Automation Glossary AG-7.1

Publication 2364E-5.01 April 2002
Preface P-v
Common Techniques Used in this
Manual
The following conventions are used throughout this 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.
Local Product Support
Contact your local Rockwell Automation representative for:
• sales and order support
• product technical training
• warranty support
• support service agreements
Technical Product Assistance
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
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Publication 2364E-5.01 April 2002
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.
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.
What does the NRU do?
The NRU converts an incoming 3 phase, AC line voltage into:
• a common DC bus voltage and current
• a 115V 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
to a 115V 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
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

Publication 2364E-5.01 April 2002
Overview 1-3
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.
Primary Electrical Components of the NRU
The primary electrical components of the NRU are:
• a 3 phase circuit breaker or motor circuit protector, depending
upon NRU rating
• AC line, current limiting fuses
• a six pulse, full wave, 3 phase diode bridge rectifier unit
• a DC bus choke
• a control 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
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 and 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.

Publication 2364E-5.01 April 2002
Overview 1-5
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
M
DC
Bus
Bus
Voltage
Light
(Optional Air-Flow
Sensor
DC +
Choke
DC -
Choke
+
-
Diode Bridge
Control
Transformer
Fuses
Circuit
Breaker
or MCP
3-Phase AC
ncoming
Power
L
L
NN
115V AC
NRU Control
Power
To Optional
115V AC
Control Bus
Bridge
Fan
Motor
(This fuse included in control
power source upgrade options
NRU

Publication 2364E-5.01 April 2002
1-6 Overview
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
Average DC Bus Voltage
Typical 3-Phase AC Input Waveform
0
Typical DC Choke Current
0