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
This page intentionally left blank.

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.