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User

Manual

Parallel DC

Bus Supply

Configurations

(Using Bulletin 2364E NRUs

and Bulletin 2364F RGUs)

Bulletin 2364P

Allen-Bradley

Summary of content (217 pages)

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Allen-Bradley Parallel DC Bus Supply Configurations (Using Bulletin 2364E NRUs and Bulletin 2364F RGUs) Bulletin 2364P User Manual
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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) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
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Table of Contents Preface Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiving Your Drive System . . . . . . . . . . . . . . . .
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toc–ii Chapter 5 Table of Contents R4 and S4-Code Parallel Configurations R4-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . S4-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 6 T1 and V1-Code Parallel Configurations T1-Code Parallel Configuration . . . . .
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Table of Contents Chapter 12 toc–iii W1-Code Parallel Configuration W1-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Chapter 13 W2-Code Parallel Configurations W2-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Component Layout . . . . . . . . . . . . . .
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toc–iv Chapter 16 Table of Contents Setting Up the Parallel Configuration Introduction to the Human Interface Module (HIM) . . . . . . . . . . . . . . . . . . . . . . . . . Basic Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the RGU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming the RGU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enabling the RGU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Preface Preface Who Should Use This Manual This manual is intended for those who are responsible for installing or operating an Allen-Bradley parallel DC bus supply configuration. If you do not have a basic understanding of this product, please read through this manual. Contact your local Rockwell Automation Drive Systems representative if you have questions about the content of this manual or the product.
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P-2 ! ATTENTION: An incorrectly applied or incorrectly 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 parts and assemblies that are sensitive to ESD (electrostatic discharge).
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P-3 Contents of this Manual Chapter Title Contents Preface Safety precautions, reference tables, and support information. 1 Theory of Operation Overview of the parallel configurations. Includes basic theory and operational information. 2 R1 and S1-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the R1 and S1-code parallel configurations.
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P-4 Related Documentation The following documents include information that may be helpful when installing or services components in your drive system. To obtain a copy of any of the Rockwell Automation publications, contact your local Rockwell Automation office or distibutor. For Read This Document NRU layout diagrams, schematics, component information, and installation/ setup instructions. Non-Regenerative DC Bus Supply Unit (NRU)–User Manual Document Number 2364E-5.
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P-5 Receiving Your Drive System The Customer is 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, do not accept the 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.
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P-6 Publication 2364P-5.
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1 Chapter Theory of Operation Introduction The parallel configuration, a DC bus supply front-end with regenerative capability, is used to supply DC power for AC digital drive inverter units in a common bus drive system. Twenty-three different parallel configurations provide a spectrum of different supply and regenerative capabilities. Figure 1.1 Parallel Configuration 3-Phase AC Line NRU R GU RG U Inverters DC Supply for Drive Lineup DC DC AC DC AC AC Publication 2364P-5.
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1-2 Theory of Operation Parallel configurations use the following front-end units: • Regenerative DC Bus Supply Unit (RGU) • Non-Regenerative DC Bus Supply Unit (NRU) Each parallel configuration will include one, two, or three Regenerative DC Bus Supply Units (RGUs). These units are used to supply motoring current to the DC bus, and are used to regenerate current back onto the AC line.
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Theory of Operation Parallel Configuration 1-3 RGU//RGU Configurations In an RGU//RGU configuration, each RGU supplies 100% motoring current and 100% regenerative current. When operating, the master RGU evaluates the bus voltage and sends current commands to the slave RGUs through an RGU-to-RGU (R2R) communication network. This allows the RGUs to operate together to supply the appropriate current while maintaining a constant voltage on the DC bus. Figure 1.
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1-4 Theory of Operation Output of RGU//RGU Configurations In an RGU//RGU configuration, each RGU (when enabled) switches its IGBTs to maintain a constant voltage on the DC bus (which is typically 1.52 times the input voltage). In this process, the master RGU evaluates the bus voltage and sends a current command (which is used to correct the bus voltage) to the slave RGUs. Each RGU switches its IGBTs to regulate the current (motoring or regenerative) needed to maintain the bus voltage. Figure 1.
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Theory of Operation 1-5 NRU//RGU Configurations In the NRU//RGU configuration, the NRU is used to supply motoring current to the DC bus, while the RGUs are used to regenerate current to the AC line. When motoring, the NRU operates to supply its maximum motoring current to the DC bus, and the RGUs operate to supply 10% of their maximum motoring current to the DC bus. When regenerating, the NRU’s diode bridge stops operating, and the RGUs regenerate the current back onto the AC line. Figure 1.
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1-6 Theory of Operation In the NRU//RGU configuration, the NRU has chokes on the DC bus. These chokes reduce circulating current between the RGU and NRU. If a slave RGU is in the configuration, the slave RGU will have a common mode choke installed on its AC line. Figure 1.
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Theory of Operation 1-7 Output of NRU//RGU Configurations The RGUs supply up to 10% of their rated amperes as motoring current. In this first 10%, the RGUs will regulate the voltage to 1.52 times the line voltage, the voltage on the DC bus will be greater than the AC line, and the diodes in the NRU will not conduct. Figure 1.10 RGU Motoring–Load Up To 10% of RGU Rating 3-Phase AC Line v smaller voltage No Curre nt NRU R GU C urrent (Up to 1 0% of the R GU ra ting) V 1.
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1-8 Theory of Operation The diagram below shows the NRU//RGU motoring bus voltage. The RGUs regulate the bus voltage for the first 10% of the rated current for the RGUs, then the NRUs supply current for the remainder of the load (while the RGU current is limited to 10% of the RGU rating). Figure 1.12 NRU//RGU Bus Voltage–Motoring DC Bus Voltage 1.5 2 x V AC 1.
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Theory of Operation 1-9 The diagram below shows the NRU//RGU regenerative bus voltage. The RGUs regenerate up to 100% of their rated current to the AC line while the NRU diode bridge stops conducting. Figure 1.14 NRU//RGU Bus Voltage–Regenerating DC Bus Voltage 1.5 2 x V AC 0 V DC 0% 10 0% % Load When the RGUs are not enabled, only the NRU supplies current to the DC bus. The bus voltage is 1.35 times the line voltage at no load, and decreases to 1.22 times the line voltage at full load.
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1-10 Theory of Operation If there are two RGUs in the configuration, each RGU will supply up to 10% of its rated motoring current. If the load is in this 10%, the RGUs will regulate the bus voltage. The master RGU will evaluate the bus voltage, and will determine the current required to maintain the nominal bus voltage (1.52 times the line voltage).
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Theory of Operation 1-11 Precharge Operation When the disconnects are closed and the start switch is turned on, each RGU in the parallel configuration will begin its precharge routine. This routine charges the capacitors on the DC bus (the RGU capacitor bank and inverter capacitors) in a controlled fashion. Two contactors (M1 and M2) are used to perform the precharge operation in the K, L, and M-code RGUs (the N-code RGU precharge circuit is slightly different).
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1-12 Theory of Operation The RGUs will precharge the capacitors on the bus until the bus voltage rises to be equal to the line voltage. Then, the precharge circuit will open, the main circuit will close, the NRU circuit breaker will close, and the DC bus voltage will rise to 1.35 times the line voltage. ATTENTION: If there is too much capacitance on the DC bus, the RGUs may not be able to raise the bus voltage to the threshold for normal operation, resulting in damage to equipment. ! Figure 1.
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Chapter 2 R1 and S1-Code Parallel Configurations R1-Code Parallel Configuration The R1-code parallel configuration is a common DC bus front-end unit consisting of an D-code NRU in parallel with a K-code RGU. Figure 2.
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2-2 R1 and S1-Code Parallel Configurations Component Layout Figure 2.3 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" Cutaway View 30" 25" 25" 20" Customer Supplied AC Input Lines Feeder Publication 2364P-5.
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R1 and S1-Code Parallel Configurations 2-3 Figure 2.
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2-4 R1 and S1-Code Parallel Configurations Schematics Figure 2.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 4KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2 3 Choke Comp.
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R1 and S1-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 2-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
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2-6 R1 and S1-Code Parallel Configurations Figure 2.6 Schematics (cont.
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R1 and S1-Code Parallel Configurations D 2-7 From RGU Control Power TB4-8 PE CB1-NRU Wht/Red UVR TB4-6 TR1 TB10-1 LS X Blu TB4-9 TB10-3 Y TB10-2 Y Open Y M Blk X TB4-7 CR3 TB10-4 X Red TB4-3 TB10-5 LS Y Motor X Wht Close TB10-6 CB1-NRU-A Blk Red TB10-7 TB4--4 TB10-8 TB4-5 CB1-NRU-B Blu TB10-9 CB1-NRU-A Blk Red TB10-10 TR1 TB10-11 CB1-NRU-B Blu TB4-1 Spring Windup Not Used TB10-12 TB4-2 Publication 2364P-5.
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2-8 R1 and S1-Code Parallel Configurations Figure 2.7 Schematics (cont.
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R1 and S1-Code Parallel Configurations (+) 2-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) F1 G E1 VP C1 C1 Snubber Board UP Snubber Board Snubber Board + C1 G E1 WP G E1 Cap Bank - UN VN C1 G C1 G E1 WN TB1 C1 TB2 EA2 Bus Indicator Board G E1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor E1 + PE TE J10 J7 J8 Gate Driver Board Gate Drivers TB7 2 1 P13 F1 +24V Main Bus DC-DC Converter 24V DC-DC Converte
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2-10 R1 and S1-Code Parallel Configurations Publication 2364P-5.
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Chapter 3 R2 and S2-Code Parallel Configurations R2-Code Parallel Configuration The R2-code parallel configuration is a common DC bus front-end unit consisting of an D-code NRU in parallel with a L-code RGU. Figure 3.
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3-2 R2 and S2-Code Parallel Configurations Component Layout Figure 3.3 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" Cutaway View 30" 25" 30" 25" Customer Supplied AC Input Lines Note: The D-code NRU has only one AC line fuse per phase. Feeder Publication 2364P-5.
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R2 and S2-Code Parallel Configurations 3-3 Figure 3.
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3-4 R2 and S2-Code Parallel Configurations Schematics Figure 3.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2 3 Choke Comp.
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R2 and S2-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 3-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
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3-6 R2 and S2-Code Parallel Configurations Figure 3.6 Schematics (cont.
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R2 and S2-Code Parallel Configurations D 3-7 From RGU Control Power TB4-8 PE CB1-NRU Wht/Red UVR TB4-6 TR1 TB10-1 LS X Blu TB4-9 TB10-3 Y TB10-2 Y Open Y M Blk X TB4-7 CR3 TB10-4 X Red TB4-3 TB10-5 LS Y Motor X Wht Close TB10-6 CB1-NRU-A Red Blk TB4-4 TB10-7 TB10-8 TB4-5 CB1-NRU-B Blu TB10-9 CB1-NRU-A Blk Red TB10-10 TR1 TB10-11 CB1-NRU-B Blu TB4-1 Not Used Spring Windup TB10-12 TB4-2 Publication 2364P-5.
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3-8 R2 and S2-Code Parallel Configurations Figure 3.7 Schematics (cont.
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R2 and S2-Code Parallel Configurations (+) 3-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) F1 + G E1 See U Phase Detail Snubber See U Phase Detail Snubber Gate Interface DETAIL VP WP Snubber UP C1 Cap Bank - G See U Phase Detail See U Phase Detail VN WN E1 TB1 UN C1 Gate Interface TB2 EA2 Bus Indicator Board Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J7 J8 Gate Driver Board Gate Drivers TB7 2 1
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3-10 R2 and S2-Code Parallel Configurations Publication 2364P-5.
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Chapter 4 R3 and S3-Code Parallel Configurations R3-Code Parallel Configuration The R3-code parallel configuration is a common DC bus front-end unit consisting of an D-code NRU in parallel with an M-code RGU. Figure 4.
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4-2 R3 and S3-Code Parallel Configurations Component Layout Figure 4.3 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" Cutaway View 30" 25" 35" 35" Customer Supplied AC Input Lines Note: The D-code NRU has only one AC line fuse per phase. Feeder Publication 2364P-5.
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R3 and S3-Code Parallel Configurations 4-3 Figure 4.
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4-4 R3 and S3-Code Parallel Configurations Schematics Figure 4.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2 3 Choke Comp.
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R3 and S3-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 4-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
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4-6 R3 and S3-Code Parallel Configurations Figure 4.6 Schematics (cont.
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R3 and S3-Code Parallel Configurations D 4-7 From RGU Control Power TB4-8 PE CB1-NRU Wht/Red UVR TB4-6 TR1 TB10-1 LS X Blu TB4-9 TB10-3 Y TB10-2 Y Open Y M Blk X TB4-7 CR3 TB10-4 X Red TB4-3 TB10-5 LS Y Motor X Wht Close TB10-6 CB1-NRU-A Blk TB4-4 Red TB10-7 TB10-8 TB4-5 CB1-NRU-B Blu TB10-9 CB1-NRU-A Blk Red TB10-10 TR1 TB10-11 CB1-NRU-B Blu TB4-1 Spring Windup Not Used TB10-12 TB4-2 Publication 2364P-5.
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4-8 R3 and S3-Code Parallel Configurations Figure 4.7 Schematics (cont.
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R3 and S3-Code Parallel Configurations (+) 4-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J
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4-10 R3 and S3-Code Parallel Configurations Publication 2364P-5.
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Chapter 5 R4 and S4-Code Parallel Configurations R4-Code Parallel Configuration The R4-code parallel configuration is a common DC bus front-end unit consisting of an D-code NRU in parallel with an N-code RGU. Figure 5.
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5-2 R4 and S4-Code Parallel Configurations Component Layout Figure 5.3 Enclosure Layout Shipping Split Front View 101.25" 9 30" 30" 25" 20" 35" Cutaway View Customer Supplied AC Input Lines Feeder D-code NRU (1500A) or E-code NRU (2000A) Publication 2364P-5.
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R4 and S4-Code Parallel Configurations 5-3 Figure 5.
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5-4 R4 and S4-Code Parallel Configurations Schematics Figure 5.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2 3 Choke Comp.
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R4 and S4-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 5-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
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5-6 R4 and S4-Code Parallel Configurations Figure 5.6 Schematics (cont.
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R4 and S4-Code Parallel Configurations D 5-7 From RGU Control Power TB4-8 PE CB1-NRU Wht/Red UVR TB4-6 TR1 TB10-1 LS X Blu TB4-9 TB10-3 Y TB10-2 Y Open Y M Blk X TB4-7 CR3 TB10-4 X Red TB4-3 TB10-5 LS Y Motor X Wht Close TB10-6 CB1-NRU-A Blk TB4-4 Red TB10-7 TB10-8 TB4-5 CB1-NRU-B Blu TB10-9 CB1-NRU-A Blk Red TB10-10 TR1 TB10-11 CB1-NRU-B Blu TB4-1 Spring Windup Not Used TB10-12 TB4-2 Publication 2364P-5.
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5-8 R4 and S4-Code Parallel Configurations Figure 5.7 Schematics (cont.
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R4 and S4-Code Parallel Configurations (+) 5-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J
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5-10 R4 and S4-Code Parallel Configurations Publication 2364P-5.
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Chapter 6 T1 and V1-Code Parallel Configurations T1-Code Parallel Configuration The T1-code parallel configuration is a common DC bus front-end unit consisting of an F-code NRU in parallel with a K-code RGU. Figure 6.
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6-2 T1 and V1-Code Parallel Configurations Component Layout Figure 6.3 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" 30" 35" 25" 20" Cutaway View Customer Supplied AC Input Lines Feeder Publication 2364P-5.
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T1 and V1-Code Parallel Configurations 6-3 Figure 6.
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6-4 T1 and V1-Code Parallel Configurations Schematics Figure 6.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 4KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2,3 3 Choke Comp.
PAGE 69
T1 and V1-Code Parallel Configurations To RGU AC Input A Customer Supplied 3-phase Input 6-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
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6-6 T1 and V1-Code Parallel Configurations Figure 6.6 Schematics (cont.
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T1 and V1-Code Parallel Configurations D 6-7 From RGU Control Power TB4-8 PE CB1-NRU TR1 A12 A11 Wht/Red UVR TB4-1 TB10-2 Spring Windup TB4-2 D9 Wht D10 Blk A6 Blu Grn Digitrip TB10-1 ARM SC A3 Org CR3 A1 TB4-3 Brn Y b LC A2 Red Spring Release TB10-3 SC (Bot) SR TB10-5 Resistor When Required (Not on 120 VAC) B2 TB4-4 CB1-NRU-A Blk Red B1 TB10-7 TB10-8 CB1-NRU-B Blu TB4-5 B3 TB10-9 B5 CB1-NRU-A Blk Red B4 TB10-11 TB10-10 CB1-NRU-B Blu B6 TB10-12 TB4-6 B8 TB4-7
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6-8 T1 and V1-Code Parallel Configurations Figure 6.7 Schematics (cont.
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T1 and V1-Code Parallel Configurations (+) 6-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) F1 G E1 VP C1 C1 Snubber Board UP Snubber Board Snubber Board + C1 G E1 WP G E1 Cap Bank - UN VN C1 G C1 G E1 WN TB1 C1 TB2 EA2 Bus Indicator Board G E1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor E1 + PE TE J10 J7 J8 Gate Driver Board Gate Drivers TB7 2 1 P13 F1 +24V Main Bus DC-DC Converter 24V DC-DC Converte
PAGE 74
6-10 T1 and V1-Code Parallel Configurations Publication 2364P-5.
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Chapter 7 T2 and V2-Code Parallel Configurations T2-Code Parallel Configuration The T2-code parallel configuration is a common DC bus front-end unit consisting of an F-code NRU in parallel with a L-code RGU. Figure 7.
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7-2 T2 and V2-Code Parallel Configurations Component Layout Figure 7.3 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" 30" 35" 30" 25" Cutaway View Customer Supplied AC Input Lines Feeder Publication 2364P-5.
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T2 and V2-Code Parallel Configurations 7-3 Figure 7.
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7-4 T2 and V2-Code Parallel Configurations Schematics Figure 7.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2,3 3 Choke Comp.
PAGE 79
T2 and V2-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 7-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
PAGE 80
7-6 T2 and V2-Code Parallel Configurations Figure 7.6 Schematics (cont.
PAGE 81
T2 and V2-Code Parallel Configurations D 7-7 From RGU Control Power TB4-8 PE CB1-NRU TR1 A12 A11 Wht/Red UVR TB4-1 TB10-2 Spring Windup TB4-2 D9 Wht D10 Blk A6 Blu Grn Digitrip TB10-1 ARM SC A3 Org CR3 A1 TB4-3 Brn Y b LC A2 Red Spring Release TB10-3 SC (Bot) SR TB10-5 Resistor When Required (Not on 120 VAC) B2 TB4-4 CB1-NRU-A Blk Red B1 TB10-7 TB10-8 CB1-NRU-B Blu TB4-5 B3 TB10-9 B5 CB1-NRU-A Blk Red B4 TB10-11 TB10-10 CB1-NRU-B Blu B6 TB10-12 TB4-6 B8 TB4-7
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7-8 T2 and V2-Code Parallel Configurations Figure 7.7 Schematics (cont.
PAGE 83
T2 and V2-Code Parallel Configurations (+) 7-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) F1 + G E1 See U Phase Detail Snubber See U Phase Detail Snubber Gate Interface DETAIL VP WP Snubber UP C1 Cap Bank - G See U Phase Detail See U Phase Detail VN WN E1 TB1 UN C1 Gate Interface TB2 EA2 Bus Indicator Board Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J7 J8 Gate Driver Board Gate Drivers TB7 2 1
PAGE 84
7-10 T2 and V2-Code Parallel Configurations Publication 2364P-5.
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Chapter 8 T3 and V3-Code Parallel Configurations T3-Code Parallel Configuration The T3-code parallel configuration is a common DC bus front-end unit consisting of an F-code NRU in parallel with a M-code RGU. Figure 8.
PAGE 86
8-2 T3 and V3-Code Parallel Configurations Component Layout Figure 8.3 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" 30" 35" 35" 35" Cutaway View Customer Supplied AC Input Lines Feeder Publication 2364P-5.
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T3 and V3-Code Parallel Configurations 8-3 Figure 8.
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8-4 T3 and V3-Code Parallel Configurations Schematics Figure 8.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2,3 3 Choke Comp.
PAGE 89
T3 and V3-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 8-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
PAGE 90
8-6 T3 and V3-Code Parallel Configurations Figure 8.6 Schematics (cont.
PAGE 91
T3 and V3-Code Parallel Configurations D 8-7 From RGU Control Power TB4-8 PE CB1-NRU TR1 A12 A11 Wht/Red UVR TB4-1 TB10-2 Spring Windup TB4-2 D9 Wht D10 Blk A6 Blu Grn Digitrip TB10-1 ARM SC A3 Org CR3 A1 TB4-3 Brn Y b LC A2 Red Spring Release TB10-3 SC (Bot) SR TB10-5 Resistor When Required (Not on 120 VAC) B2 TB4-4 CB1-NRU-A Blk Red B1 TB10-7 TB10-8 CB1-NRU-B Blu TB4-5 B3 TB10-9 B5 CB1-NRU-A Blk Red B4 TB10-11 TB10-10 CB1-NRU-B Blu B6 TB10-12 TB4-6 B8 TB4-7
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8-8 T3 and V3-Code Parallel Configurations Figure 8.7 Schematics (cont.
PAGE 93
T3 and V3-Code Parallel Configurations (+) 8-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J
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8-10 T3 and V3-Code Parallel Configurations Publication 2364P-5.
PAGE 95
Chapter 9 T4 and V4-Code Parallel Configurations T4-Code Parallel Configuration The T4-code parallel configuration is a common DC bus front-end unit consisting of an F-code NRU in parallel with a N-code RGU. Figure 9.
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9-2 T4 and V4-Code Parallel Configurations Component Layout Figure 9.3 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" 30" 35" 20" 35" Cutaway View Customer Supplied AC Input Lines Feeder F-code (2500A) or G-code (3000A) NRU Publication 2364P-5.
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T4 and V4-Code Parallel Configurations 9-3 Figure 9.
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9-4 T4 and V4-Code Parallel Configurations Schematics Figure 9.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2,3 3 Choke Comp.
PAGE 99
T4 and V4-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 9-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
PAGE 100
9-6 T4 and V4-Code Parallel Configurations Figure 9.6 Schematics (cont.
PAGE 101
T4 and V4-Code Parallel Configurations D 9-7 From RGU Control Power TB4-8 PE CB1-NRU TR1 A12 A11 Wht/Red UVR TB4-1 TB10-2 Spring Windup TB4-2 D9 Wht D10 Blk A6 Blu Grn Digitrip TB10-1 ARM SC A3 Org CR3 A1 TB4-3 Brn Y b LC A2 SR Red Spring Release TB10-3 SC (Bot) TB10-5 Resistor When Required (Not on 120 VAC) B2 TB4-4 CB1-NRU-A Blk Red B1 TB10-7 TB10-8 CB1-NRU-B Blu TB4-5 B3 TB10-9 B5 CB1-NRU-A Blk Red B4 TB10-11 TB10-10 CB1-NRU-B Blu B6 TB10-12 TB4-6 B8 TB4-
PAGE 102
9-8 T4 and V4-Code Parallel Configurations Figure 9.7 Schematics (cont.
PAGE 103
T4 and V4-Code Parallel Configurations (+) 9-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J
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9-10 T4 and V4-Code Parallel Configurations Publication 2364P-5.
PAGE 105
Chapter 10 T5 and V5-Code Parallel Configurations T5-Code Parallel Configuration The T5-code parallel configuration is a common DC bus front-end unit consisting of an F-code NRU in parallel with two M-code RGUs. Figure 10.
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10-2 T5 and V5-Code Parallel Configurations Component Layout Figure 10.3 Enclosure Layout Front View Shipping Split Shipping Split 101.25" 91.5" 30" 30" 35" 35" 35" 35" 20" Cutaway View Customer Supplied AC Input Lines Feeder F-code (2500A) or G-code (3000A) NRU Publication 2364P-5.
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T5 and V5-Code Parallel Configurations 10-3 Figure 10.
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10-4 T5 and V5-Code Parallel Configurations Schematics Figure 10.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2,3 3 Choke Comp.
PAGE 109
T5 and V5-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 10-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
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10-6 T5 and V5-Code Parallel Configurations Figure 10.6 Schematics (cont.
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T5 and V5-Code Parallel Configurations D 10-7 From RGU Control Power TB4-8 PE CB1-NRU TR1 A12 A11 Wht/Red UVR TB4-1 TB10-2 Spring Windup TB4-2 D9 Wht D10 Blk A6 Blu Grn Digitrip TB10-1 ARM SC A3 Org CR3 A1 TB4-3 Brn Y b LC A2 Red Spring Release TB10-3 SC (Bot) SR TB10-5 Resistor When Required (Not on 120 VAC) B2 TB4-4 CB1-NRU-A Blk Red B1 TB10-7 TB10-8 CB1-NRU-B Blu TB4-5 B3 TB10-9 B5 CB1-NRU-A Blk Red B4 TB10-11 TB10-10 CB1-NRU-B Blu B6 TB10-12 TB4-6 B8 TB4-
PAGE 112
10-8 T5 and V5-Code Parallel Configurations Figure 10.7 Schematics (cont.
PAGE 113
T5 and V5-Code Parallel Configurations (+) 10-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + UP1 C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber DETAIL Snubber Gate Interface C1 WP1 WP2 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J
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10-10 T5 and V5-Code Parallel Configurations Figure 10.8 Schematics (cont.
PAGE 115
T5 and V5-Code Parallel Configurations I 10-11 From RGU Control Circuitry (Slave) RGU/DC Bus Supply (From Master) TR1 TR1 TB4-10, TB4-11, 14 15 CR4 TR1 11 12 TB1 TB1 CR4 TR1 (20 sec) Precharge Timer CR3 M2 Precharge CR4 CR3 Bus Control 6 TB6 9 TB6 Pilot Isolation Board CR3 CR4 CR4 Precharge Lockout M1 CB1-NRU-A TB4-4 TB4-5 J To RGU Isolation Board (Slave) M1 CR3 Main K To RGU Control Circuitry (Slave) Publication 2364P-5.
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10-12 T5 and V5-Code Parallel Configurations Figure 10.9 Schematics (cont.
PAGE 117
T5 and V5-Code Parallel Configurations (+) 10-13 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE
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10-14 T5 and V5-Code Parallel Configurations Publication 2364P-5.
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Chapter 11 T6 and V6-Code Parallel Configurations T6-Code Parallel Configuration The T6-code parallel configuration is a common DC bus front-end unit consisting of an F-code NRU in parallel with two N-code RGUs. Figure 11.
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11-2 T6 and V6-Code Parallel Configurations Component Layout Figure 11.3 Enclosure Layout Shipping Split Front View Shipping Split 101.25" 91.5" 30" 30" 35" 20" 35" 35" 20" 35" 25" Cutaway View Customer Supplied AC Input Lines Feeder F-code (2500A) or G-code (3000A) NRU Publication 2364P-5.
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T6 and V6-Code Parallel Configurations 11-3 Figure 11.
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11-4 T6 and V6-Code Parallel Configurations Schematics Figure 11.5 Schematics NRU EA3 F14 Line RC L1 Suppressor F15 L2 F16 L3 Com SP4 SP1 SP2 PE SP3 EA10 2KHZ Control Power Filter F4 F8 F6 460VAC PT1 F7 (X1) 115VAC (X2) PE MTR1 TB1-9 TB1-1 Optional Remote Interlock (JMPR) Rect. Bridge TB1-2 Airflow Loss Bridge Bay Airflow Loss CB Bay 1 1 3 EA5-CR CB Bay Overtemp Choke Overtemp TB1-10 MTR2,3 3 Choke Comp.
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T6 and V6-Code Parallel Configurations A Customer Supplied 3-phase Input To RGU AC Input 11-5 To Grounding Resistor B M CB1-NRU Note: Control power for this motorized breaker originates in the RGU. Do not operate this breaker manually.
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11-6 T6 and V6-Code Parallel Configurations Figure 11.6 Schematics (cont.
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T6 and V6-Code Parallel Configurations D 11-7 From RGU Control Power TB4-8 PE CB1-NRU TR1 A12 A11 Wht/Red UVR TB4-1 TB10-2 Spring Windup TB4-2 D9 Wht D10 Blk A6 Blu Grn Digitrip TB10-1 ARM SC A3 Org CR3 A1 TB4-3 Brn Y b LC A2 SR Red Spring Release TB10-3 SC (Bot) TB10-5 Resistor When Required (Not on 120 VAC) B2 TB4-4 CB1-NRU-A Blk Red B1 TB10-7 TB10-8 CB1-NRU-B Blu TB4-5 B3 TB10-9 B5 CB1-NRU-A Blk Red B4 TB10-11 TB10-10 CB1-NRU-B Blu B6 TB10-12 TB4-6 B8 TB4
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11-8 T6 and V6-Code Parallel Configurations Figure 11.7 Schematics (cont.
PAGE 127
T6 and V6-Code Parallel Configurations (+) 11-9 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE
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11-10 T6 and V6-Code Parallel Configurations Figure 11.8 Schematics (cont.
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T6 and V6-Code Parallel Configurations To RGU Control Circuitry K CB1-RGU TB3-7 11-11 CB1-NRU-A TB3-8 TB4-4 TB4-5 L To RGU Isolation Board CB1-RGU UVR CR3 CR3 TB3-8 TB3-7 TB3-9 TB3-11 TB3-10 TB3-12 M To RGU Control Circuitry Publication 2364P-5.
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11-12 T6 and V6-Code Parallel Configurations Figure 11.9 Schematics (cont.
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T6 and V6-Code Parallel Configurations (+) 11-13 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE
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11-14 T6 and V6-Code Parallel Configurations Publication 2364P-5.
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Chapter 12 W1-Code Parallel Configuration W1-Code Parallel Configuration The W1-code parallel configuration is a common DC bus front-end unit consisting of two M-code RGUs. Figure 12.1 W1-Code Parallel Configuration–Information W1-code Ratings W1-code Parallel Configuration Input Voltage (V AC) DC Bus Current (A DC) Rated DC Bus kW 380 1492 1498 1372 865 1049 1163 460 575 M-code RGU (Master) M-code RGU (Slave) Note: Information for the M-code RGU can be found in publication 2364F-5.01.
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12-2 W1-Code Parallel Configuration Component Layout Figure 12.2 Enclosure Layout Front View Shipping Split 101.25" 91.5" 30" 35" 35" 35" 20" Cutaway View Customer Supplied AC Input Lines Feeder Publication 2364P-5.
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W1-Code Parallel Configuration 12-3 Figure 12.
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12-4 W1-Code Parallel Configuration Schematics Figure 12.
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W1-Code Parallel Configuration D 12-5 From RGU Control Power TR1 TB4-1 Spring Windup TB4-2 Not Used CR3 TB4-3 TB4-6 TB4-7 Not Used TR1 TB4-9 Publication 2364P-5.
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12-6 W1-Code Parallel Configuration Figure 12.5 Schematics (cont.
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W1-Code Parallel Configuration (+) 12-7 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + UP1 C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber DETAIL Snubber Gate Interface C1 WP1 WP2 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J7
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12-8 W1-Code Parallel Configuration Figure 12.6 Schematics (cont.
PAGE 141
W1-Code Parallel Configuration G 12-9 From RGU Control Circuitry (Slave) RGU/DC Bus Supply (From Master) TR1 TR1 TB4-14 TB4-15 Precharge Timer CR4 TR1 11 12 TB1 TB1 CR4 TR1 CR3 (20 sec) M2 Precharge CR4 CR3 Bus Control 6 TB6 9 TB6 Pilot Isolation Board CR3 CR4 CR4 Precharge Lockout M1 External Main H Enable To RGU Isolation Board (Slave) M1 CR3 Main I To RGU Control Circuitry (Slave) Publication 2364P-5.
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12-10 W1-Code Parallel Configuration Figure 12.7 Schematics (cont.
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W1-Code Parallel Configuration (+) 12-11 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J7
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12-12 W1-Code Parallel Configuration Publication 2364P-5.
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Chapter 13 W2-Code Parallel Configurations W2-Code Parallel Configuration The W2-code parallel configuration is a common DC bus front-end unit consisting of two N-code RGUs. Figure 13.1 W2-Code Parallel Configuration–Information W2-code Ratings W2-code Parallel Configuration Input Voltage (V AC) DC Bus Current (A DC) Rated DC Bus kW 380 1994 2000 1828 1157 1400 1550 460 575 N-code RGU (Master) N-code RGU (Slave) Note: Information for the N-code RGU can be found in publication 2364F-5.01.
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13-2 W2-Code Parallel Configurations Component Layout Figure 13.2 Enclosure Layout Shipping Split Front View 101.25" 91.5" 30" 20" 35" 35" 20" 35" 25" Cutaway View Customer Supplied AC Input Lines Feeder Publication 2364P-5.
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W2-Code Parallel Configurations 13-3 Figure 13.
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13-4 W2-Code Parallel Configurations Schematics Figure 13.
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W2-Code Parallel Configurations D 13-5 From RGU Control Power TR1 TB4-1 Spring Windup TB4-2 Not Used CR3 TB4-3 TB4-6 TB4-7 Not Used TR1 TB4-9 Publication 2364P-5.
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13-6 W2-Code Parallel Configurations Figure 13.5 Schematics (cont.
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W2-Code Parallel Configurations (+) 13-7 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J7
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13-8 W2-Code Parallel Configurations Figure 13.6 Schematics (cont.
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W2-Code Parallel Configurations I To RGU Control Circuitry CB1-RGU TB3-7 13-9 External Main TB3-8 Enable J To RGU Isolation Board CB1-RGU UVR CR3 CR3 TB3-8 TB3-7 TB3-9 TB3-11 TB3-10 TB3-12 K To RGU Control Circuitry Publication 2364P-5.
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13-10 W2-Code Parallel Configurations Figure 13.7 Schematics (cont.
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W2-Code Parallel Configurations (+) 13-11 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J
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13-12 W2-Code Parallel Configurations Publication 2364P-5.
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Chapter 14 W3-Code Parallel Configurations W2-Code Parallel Configuration The W3-code parallel configuration is a common DC bus front-end unit consisting of three N-code RGUs. Figure 14.
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14-2 W3-Code Parallel Configurations Component Layout Figure 14.2 Enclosure Layout Front View Shipping Split Shipping Split 101.25" 91.5" 30" 20" 35" 35" 20" 35" 25" 35" 20" 35" 25" Cutaway View Customer Supplied AC Input Lines Feeder N-code RGU (Master) Publication 2364P-5.
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W3-Code Parallel Configurations 14-3 Figure 14.
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14-4 W3-Code Parallel Configurations Schematics Figure 14.
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W3-Code Parallel Configurations D 14-5 From RGU Control Power TR1 TB4-1 Spring Windup TB4-2 Not Used CR3 TB4-3 TB4-6 TB4-7 Not Used TR1 TB4-9 Publication 2364P-5.
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14-6 W3-Code Parallel Configurations Figure 14.5 Schematics (cont.
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W3-Code Parallel Configurations (+) 14-7 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 Snubber Gate Interface DETAIL G E1 WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J7
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14-8 W3-Code Parallel Configurations Figure 14.6 Schematics (cont.
PAGE 165
W3-Code Parallel Configurations I To RGU Control Circuitry CB1-RGU TB3-7 14-9 External Main TB3-8 Enable J To RGU Isolation Board CB1-RGU UVR CR3 CR3 TB3-8 TB3-7 TB3-9 TB3-11 TB3-10 TB3-12 K To RGU Control Circuitry Publication 2364P-5.
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14-10 W3-Code Parallel Configurations Figure 14.7 Schematics (cont.
PAGE 167
W3-Code Parallel Configurations (+) 14-11 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J
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14-12 W3-Code Parallel Configurations Figure 14.8 Schematics (cont.
PAGE 169
W3-Code Parallel Configurations O To RGU Control Circuitry CB1-RGU TB3-7 14-13 External Main TB3-8 Enable P To RGU Isolation Board CB1-RGU UVR CR3 CR3 TB3-8 TB3-7 TB3-9 TB3-11 TB3-10 TB3-12 Q To RGU Control Circuitry Publication 2364P-5.
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14-14 W3-Code Parallel Configurations Figure 14.9 Schematics (cont.
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W3-Code Parallel Configurations (+) 14-15 Horizontal DC Bus To Inverter Units Horizontal DC Bus (-) + C1 See U Phase Detail G VP1 VP2 E1 See U Phase Detail Snubber UP2 G E1 Snubber Gate Interface DETAIL WP1 WP2 Snubber UP1 C1 Cap Bank - UN2 G C1 E1 See U Phase Detail See U Phase Detail VN1 VN2 WN1 WN2 G E1 TB1 C1 Gate Interface TB2 EA2 Bus Indicator Board UN1 Power Supply Filter Board +Bus LED1 -Bus LED2 PL1 R DC Bus Energized EA4 Bus Suppressor + PE TE J10 J
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14-16 W3-Code Parallel Configurations Publication 2364P-5.
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Chapter 15 Installation The instructions in this chapter will guide you in properly installing the parallel configuration. The processes include receiving and installing the unit at the designated site, joining enclosures and buswork, installing the overhead bus, connecting internal communications and power wiring, connecting all customer wiring, and connecting AC input. This chapter includes instructions for testing the parallel configuration.
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15-2 Installation Safety Precautions The following general precautions apply when installing, servicing, or operating parallel configurations and 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.
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Installation Overhead Bus Installation 15-3 The overhead bus provides a common input for all the units in the parallel configuration. If top entry will be used for the feeder bay, make sure to remove the top plate, cut or punch the appropriate area for the AC wiring, and replace the top plate before installing the overhead bus. To install the overhead bus, refer to the instructions in publication 2364P-5.10, titled Overhead Bus Installation.
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15-4 Installation Figure 15.1 PE and TE Busbars PE TE Top View of B ay PE TE Figure 15.2 Grounding Pow er Transform er G rounded-W ye Secondary PE PE TE Parallel Configuration Inverter Lineup 10 feet or m ore For specific grounding instructions for inverters, motors, and other system components, refer to the system schematics or the designated component manuals. Publication 2364P-5.
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Installation 15-5 Ground-Fault Detection Option The parallel configuration may include the optional ground-fault detector. When configured properly, this detector will indicate the ground voltage on the door-mounted meter, and will energize the relay (with NO/NC contacts) in the event of an excessive ground voltage.
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15-6 Installation To calibrate the meter, turn the zero adjuster until the voltage indicator needle (black) is aligned with the zero mark. To set the trip point (for the detector relay), turn the high-set adjuster until the orange needle points to the appropriate trip voltage. The trip voltage should be approximately 50V higher than the maximum reading on the meter when all the common bus inverters are modulating. Figure 15.
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Installation 15-7 Phase-Loss Relay An NRU in the parallel configuration will be equipped with a phaseloss relay, which is used to indicate phase loss, phase unbalance, undervoltage, phase reversal conditions in the 3-phase AC line. The relay has NO/NC contacts, connections for a reset control, and jumper connections for setting undervoltage and phase unbalance tolerances. The relay LEDs indicate AC line conditions and change of state in the relay. Figure 15.
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15-8 Installation The phase unbalance and undervoltage thresholds are set by the jumper configuration across terminals 6 through 10. The following illustration shows how to jumper the relay for different threshold settings. Figure 15.6 Jumpers Settings for Phase Imbalance and Undervoltage Thresholds Phase Unbalance Threshold 6 7 Terminal Numbers 8 9 10 Undervoltage Threshold 5.0% 10.0% 6.5% 14.0% 8.0%* 17.0%* 10.0% 20.0% * Typical factory setting is 8.0%.
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Installation 15-9 RGU-to-RGU (R2R) Communications If more than one RGU is in the parallel configuration, an RGU-to-RGU (R2R) communications link will be used to transmit current commands and status information from the master unit to the slave unit(s). The fiber optic cables for R2R communications will be coiled in the slave RGUs. When working with the fiber optic cables, please note the precautions in Figure 15.7. Figure 15.
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15-10 Installation Figure 15.9 RGU-to-RGU (R2R) Communication Wiring R2R Communications - Master With One Slave T5, T6, W1, and W2 configurations Master Unit Slave Unit J1 J1 R2R TIO R2R TIO U3 U4 U5 U6 U3 U4 U5 U6 Tx Rx Tx Rx Tx Rx Tx Rx Master to Slave Cable length 26 feet (7.
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Installation Customer Connections 15-11 Analog Input/Output (RGU Main Control Board) Analog input and output connections are available on TB1 of the main control board (RGU). Figure 15.10 Customer Connections–TB1 (RGU Main Control Board) 1k 10k 1k AG ND - + .1 TP27 1k 20k - 1k AG N D 1k AG N D 20k .1 - + - 0.04 7uf 20k 56 0pf + 20k 0.04 7uf A GN D 20k + A GN D 560pf -15V 20k 0.04 7uf 10k .1 A GN D 20k + 20k + .
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15-12 Installation SCANport (RGU Main Control Board) The RGU main control board has three available ports for SCANport connections. Port 6 is designed for use with a SCANport interface board. Figure 15.11 Customer Connections–SCANport (RGU Main Control Board) Mounting an optional communication board RGU Main Control Board J9 (Port 2) J10 (Port 1) J8 (Port 6) Table 15.
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Installation 15-13 Terminal Blocks Figure 15.
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15-14 Installation Figure 15.
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Installation Configuring the System 15-15 At this point, complete the installation for all the inverters as indicated in the appropriate instruction manuals (but do not connect any power to the inverters at this time). • Properly install any additional line reactors, fuses, MOVs, filters, controls, or other components, as necessary. • Complete all internal wiring, grounding, and synchronous communications wiring between drives, as necessary.
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15-16 Installation Connecting the AC Input Isolation Transformer The parallel configuration should be supplied with a balanced 3-phase input providing the nominal AC line voltage (plus or minus the tolerance). To ensure that the AC input is balanced and isolated, an isolation transformer is recommended. MOV Protection The units in the parallel configuration are supplied with MOVs to handle voltage surges, high phase-to-phase voltages, and high phaseto-ground voltages.
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Installation 15-17 Input Wiring Select input wiring which is suitable for the input current and application environment of the parallel configuration, in accordance with all applicable codes. Table 15.
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15-18 Installation Testing the System Prepower Checks 1. Using a meter, check that the line-to-line voltage readings are within the tolerance given in Appendix A. 2. Check the line-to-line and line-to-ground (PE) resistance for each unit. All readings should show a high resistance or open circuit. Testing The System Before testing the system, verify that all the circuit breakers are in the off position and that the start switch on the parallel configuration is turned to off.
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Chapter 16 Setting Up the Parallel Configuration This chapter will guide you through the setup procedures for the parallel configuration. If you need more information about RGU parameters, please see publication 2364F-5.01. Introduction to the Human Interface Module (HIM) The Human Interface Module (HIM), shown in Figure 16.1, can be used to program and set up the RGU. The table below shows the function of the keys. Figure 16.
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16-2 Setting Up the Parallel Configuration Figure 16.
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Setting Up the Parallel Configuration Basic Startup Procedure 16-3 The basic startup procedure must be performed when starting a new unit to configure the essential parameters for operating the unit. The following items will be needed when starting up the RGU: • a multimeter (for reading voltage and resistance) • a HIM, GPT, or other programming device ! ATTENTION: The basic startup must be performed when starting a new unit, replacing the main control board, or upgrading firmware.
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16-4 Setting Up the Parallel Configuration Programming the RGU Using a HIM, GPT, or other programming device, enter the linear parameter list. The startup procedure below will guide you through several parameters that need to be configured before operating the parallel configuration. Program each RGU in the configuration.
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Setting Up the Parallel Configuration Utility AC Line Frequency [P13] Set the Utility AC Line Frequency (P13) to the frequency of the AC line. 16-5 Utilty AC Freq 60 Hz Measured AC Line Voltage [P14] Using a meter, measure the AC line voltage. Compare the Measured AC Line Voltage (P14) with the meter reading. Determine the adjustment that needs to be made in the RGU (by percent). Line Voltage +477 Vrms AC Line Voltage Calibration [P15] Set this parameter to adjust the value in P14.
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16-6 Setting Up the Parallel Configuration External Capacitance [P203] Determine the maximum amount of capacitance that is expected to be on the DC bus at any one time (a table of inverter capacitances are given in Appendix A). The total external capacitance must be divided among the number of RGUs in the configuration. Ext Capacitance 3300 u/10 Important: If additional inverters are added in the future, this parameter must be updated.
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Setting Up the Parallel Configuration Advanced Startup Procedure 16-7 This advanced startup procedure may be performed to set the RGU for optimum performance. A HIM, GPT, or other programming device will be required to complete the procedure below. Id Current Command [P102] The Id current command determines the amount of reactive current that the RGU should allow. Typically, this value should be set to 0.0% (default). Id Command 0.
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16-8 Setting Up the Parallel Configuration Voltage Loop Bandwidth [P205] The voltage loop bandwidth determines the dynamic behavior of the voltage loop. The voltage loop becomes more responsive and is able to track faster as the bandwidth is increased. However, note that system limitations and excessive noise may adversely affect the performance of the RGU if the bandwidth is set too high. Bus Volt BW 200 rad/s Set master and slave RGUs with same value.
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Appendix A Specifications Table A: Functional Specifications AC Input Frequency Tolerance 45 to 65 Hz AC Input Voltage Tolerance ±10% Overload Capability 150% for 60 sec Overload Duty Cycle 60 sec every 20 min Output Voltage Variation 10% max for 100% step load Resolution of Output Voltage Selection 1.
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A-2 Specifications Figure 1 Altitude Derating Curve % of NRU 100% Rated Amps at 40 °C 90% 80% 70% 60% 50% 0m (0 ft) 1000 m (3,300 ft) 2000 m (6,600 ft) 3000 m (9,900 ft) 4000 m (13,200 ft) Altitude Figure 2 Temperature Derating Curve % Rated RGU 100% Current at 95% Sea Level 90% 85% 80% 75% 0 (32) 5 (41) 10 (50) 15 (59) 20 (68) 25 (77) 30 (86) 35 (95) Ambient Temperature Table C: Operating Sound Level Publication 2364P-5.01 December 1999 Configuration Sound Level (dB) R1, S1 78.
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Specifications A-3 Table D: Electrical Specifications–380V AC Input Catalog Number (2364P-) Nominal Input Voltage (V AC) Input Power (kVA) Nominal DC Bus Voltage (V DC) Rated DC Bus Power (kW) R1AN 380 820 513 R2AN 380 829 513 R3AN 380 852 R4AN 380 867 S1AN 380 S2AN 380 S3AN S4AN Maximum Line Current (A AC) Maximum Bus Current (A DC) Motoring Regenerating Motoring Regenerating 780 1245 182 1520 200 788 1260 330 1536 363 513 808 1295 678 1575 746 513 821 1318
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A-4 Specifications Table E: Electrical Specifications–460V AC Input Catalog Number (2364P-) Nominal Input Voltage (V AC) Input Power (kVA) Nominal DC Bus Voltage (V DC) Rated DC Bus Power (kW) R1AB 460 992 621 R2AB 460 1004 R3AB 460 1032 Maximum Line Current (A AC) Maximum Bus Current (A DC) Motoring Regenerating Motoring Regenerating 944 1245 182 1520 201 621 954 1260 330 1536 364 621 978 1295 678 1575 749 R4AB 460 1050 621 994 1318 906 1600 1000 S1AB 460 13
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Specifications A-5 Table F: Electrical Specifications–575V AC Input Catalog Number (2364P-) Nominal Input Voltage (V AC) Input Power (kVA) Nominal DC Bus Voltage (V DC) Rated DC Bus Power (kW) R1AC 575 1239 776 R2AC 575 1249 776 R3AC 575 1281 R4AC 575 1301 S1AC 575 S2AC 575 S3AC S4AC Maximum Line Current (A AC) Maximum Bus Current (A DC) Motoring Regenerating Motoring Regenerating 1180 1244 182 1520 201 1190 1255 286 1533 326 776 1218 1286 602 1569 686 776 1235
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A-6 Specifications Table G: Typical Capacitor Bank Values in uf/10 (For 380/460V AC Lineups) Õ HP Õ 0.5-1 Frame Size 1336 FORCE/SA3100 A 1.5 2 3 B 5 7.510 15-20 1 3 7.
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Specifications This section provides watts dissipation charts for the individual units in the parallel configuration. 1500A NR U (D-code) Watts Loss Figure 3 Watts Dissipation vs. Load–NRU Watts Loss 2000A NR U (E-code) 2500A NR U (F-code) 5.0 4.0 3.0 2.0 1.0 0.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.
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A-8 Specifications K-code R GU 380/460V AC Input 575V AC Input Watts Loss Figure 4 Watts Dissipation vs. Load–RGU 3.0 k 2.0 k 1.0 k 0.0 k 0 10 20 30 40 50 60 % Load 70 80 90 100 0 10 20 30 40 50 60 % Load 70 80 90 100 0 10 20 30 40 50 60 % Load 70 80 90 100 0 10 20 30 40 70 80 90 100 5k L-code R GU Watts Loss 4k 3k 2k 1k 0k M -code RG U 12 k 10 k Watts Loss 8k 6k 4k 2k 0k N -code R GU 12 k 10 k Watts Loss 8k 6k 4k 2k 0k 50 % Load Publication 2364P-5.
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Specifications Physical Details A-9 Table K: Dimensions Configuration Overall Height Overall Width OverallDepth MCC Sections R1, S1 101.25” 130” 20” 5 R2, S2 101.25” 140” 20” 5 R3, S3 101.25” 155” 25” 5 R4, S4 101.25” 175” 25” 6 T1, V1 101.25” 140” 20” 5 T2, V2 101.25” 150” 20” 5 T3, V3 101.25” 165” 25” 5 T4, V4 101.25” 185” 25” 6 T5, V5 101.25” 260” 25” 8 T6, V6 101.25” 300” 25” 10 W1 101.25” 195” 25” 6 W2 101.25” 235” 25” 8 W3 101.
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A-10 Specifications Figure 5 Typical Bus Architecture PE L1 N + - PE TE Publication 2364P-5.
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Appendix B Catalog Numbers and Spare Parts Kits Understanding Catalog Numbers A catalog number is used to define the components and configuration of a parallel unit. The catalog number is arranged as shown in the following diagram.
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B-2 Catalog Numbers and Spare Parts Kits Bulletin N um ber Unit Type 2364 P Current Rating Code W iring Type Enclosure AC Input Line Voltage Options ó A P = Parallel See next page.
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Catalog Numbers and Spare Parts Kits Available on 2364P Configuration Type(s): (1) NRU + (1) RGU Current Rating Codes: Control Power Source 6P = Standard capacity control transformer for 9 10 This option is applied: (2) RGUs or or (1) NRU + (2) RGUs (3) RGUs Rx, Sx, Tx, Vx Wx x x x x x x On ce On per c co On e pe nfig ce r e ura On pe ach tio ce r ea un n pe ch it r e RG ac U hN RU Options: B-3 control bus 2 Door-Mounted Pilot Lights 4EA = Unit-Not-Faulted / Control Bus Power On Pil
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B-4 Catalog Numbers and Spare Parts Kits Footnotes: 1 The configurations presented are the only standard configurations available. You may not change the order of any units or individual bays within a configuration. 2 Each parallel configuration includes a basic capacity control transformer(s) to supply only the parallel configuration with power. Control power source option(s) allow you to select a higher capacity control transformer for control bus applications.
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Glossary Control Power Filter A filter used to reduce harmonics and noise in the 115V AC control power. Disable When a unit is disabled, the control logic is not directing current flow operations. A unit is typically disabled by a disable command or by a fault condition. Disconnect A circuit breaking device. Enable When a unit is enabled, the control logic is directing the motoring or regenerative current by modulating its hardware (IGBTs).
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G-2 Motoring Current Current which is being supplied to the inverters (through the DC bus) for motoring. Non-Regenerative DC Bus Supply Unit (NRU) A six-pulse DC power supply produced by Rockwell Automation The NRU is typically used as a front end power supply on a drive system lineup. NRU//RGU Configuration A parallel configuration of one or two RGUs connecting to an NRU. Overload A condition where the unit is supplying current above its rated current.
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Index A AC input connection, 15-16 AC line reactors, 16-4 C Capacitance, 16-6, A-5 Catalog numbers, B-1 Catalog string, 16-4 Cautions, P-1, 15-2 Current regulation, 16-7 D Derating, A-2 Description of Operation, 1-1 G Ground-fault detection option, 15-5 Grounding, 15-3 P Parameters, 16-2 Phase-loss relay, 15-7 Power factor, 16-7 Precharge, 1-11 Product Overview, 1-1 Programming, 16-1 R R1-code configuration, 2-1 R2-code configuration, 3-1 R3-code configuration, 4-1 R4-code configuration, 5-1 Reactive curr
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I–2 Index T T1-code configuration, 6-1 T4-code configuration, 9-1 T6-code configuration, 11-1 Testing the system, 15-18 V V1-code configuration, 6-1 V4-code configuration, 9-1 V6-code configuration, 11-1 Voltage regulation, 16-8 W W1-code configuration, 12-1 W3-code configuration, 14-1 Publication 2364P-5.
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Publication 2364P-5.01 December 1999 PN 192329(01) ©1999 Rockwell International Corporation. Printed in the U.S.A.