Rockwell Automation 2364P User Manual

Allen-Bradley

Parallel DC
Bus Supply

User

Configurations

(Using Bulletin 2364E NRUs
and Bulletin 2364F RGUs)

Bulletin 2364P

Manual

Important User Information Solid-State equipment has operational characteristics differing from

those of electro m echan i ca l equ ip me nt. “Saf ety G u ide lines for the
Application, Installation and Maintenance of Solid-State Controls”

(Publication SGI-1.1) describes some important differences between
solid-state equi pment and hard-wired electromechanic al 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 th emse lves that e ach inte nded appl ication
of this equipment is acceptable .

In no event will Rockwell Automation be responsible or liable for
indirect or consequential damages resulting from the use of
application of this equipment.

The examples and diagrams in this manual are included solely for
illustrati ve purpose s. Bec ause of th e many var iable s and requi rements
associated with any partic ular installation, the Rockwe ll Automation
cannot assume responsibility or liability for actua l use based on the
examples and diagrams.

No patent liability is assumed by Rockwell Automation with respect
use of information, circuits, equipment, or software des cribed in this
manual.

Reproduction of the conten ts of this manual, in whole or in part,
without written permission of Rockwell Automation is prohibit ed.

Throughout this manual we use notes to make you aware of safety
considerations:

ATTENTION: Identifies infor mation about practi ces
or circums tan ce s tha t can lead to p erso n al inj ury or

!

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequenc es

Datab is a trademark of W . H. Brady Company

NRU, RGU, HIM, Remote I/O, DeviceNet, and ControlNet are trademarks of Rockwell International or its
subsidiaries.

death, property damage or economic loss.

Table of Contents

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

Receiving Your Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5

Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . . . . . . P-5

Chapter 1 Theory of Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

RGU//RGU Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Output of RGU//RGU Configurations . . . . . . . . . . . . . . . . . . . 1-4

NRU//RGU Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Output of NRU//RGU Configurations . . . . . . . . . . . . . . . . . . 1-7

Precharge Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Chapter 2 R1 and S1-Code Parallel Configurations

R1-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

S1-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Chapter 3 R2 and S2-Code Parallel Configurations

R2-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

S2-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Chapter 4 R3 and S3-Code Parallel Configurations

R3-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

S3-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

toc–ii Table of Contents

Chapter 5 R4 and S4-Code Parallel Configurations

R4-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

S4-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Chapter 6 T1 and V1-Code Parallel Configurations

T1-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

V1-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Chapter 7 T2 and V2-Code Parallel Configurations

T2-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

V2-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Chapter 8 T3 and V3-Code Parallel Configurations

T3-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

V3-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Chapter 9 T4 and V4-Code Parallel Configurations

T4-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

V4-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Chapter 10 T5 and V5-Code Parallel Configurations

T5-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

V5-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Chapter 11 T6 and V6-Code Parallel Configurations

T6-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

V6-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

Chapter 12 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4

Chapter 14 W3-Code Parallel Configurations

W2-Code Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4

Chapter 15 Installation

Receiving, Handling, and Installing the Parallel Configuration . . 15-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

Overhead Bus Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

Ground-Fault Detection Option . . . . . . . . . . . . . . . . . . . . . . . 15-5

Phase-Loss Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

RGU-to-RGU (R2R) Communications . . . . . . . . . . . . . . . . . . . 15-9

Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11

Analog Input/Output (RGU Main Control Board) . . . . . . . . . . 15-11

SCANport (RGU Main Control Board) . . . . . . . . . . . . . . . . . . 15-12

Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13

Configuring the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15

Connecting the AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

MOV Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Feeder Bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17

Testing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18

Prepower Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18

Testing The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18

Table of Contents toc–iii

toc–iv Table of Contents

Chapter 16 Setting Up the Parallel Configuration

Introduction to the

Human Interface Module (HIM) . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Basic Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3

Starting the RGU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3

Programming the RGU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4

Enabling the RGU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6

Advanced Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7

Appendix A Specifications

Watts Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Physical Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Appendix B Catalog Numbers and Spare Parts Kits

Understanding Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . B-1

Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Glossary

Index

Preface

Preface

Who Should Use This Manual This manual is intende d for those who are re sponsible for instal ling 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 m anual. Contact your local Rockwell Automation Drive
Systems represent ative if you have questions about th e conte nt of this
manual or the product.

Purpose of This Manual This manual contains specifications, installation instructions, and

operating instru ctions for the 2364P parallel configuration.

Safety Precautions The following general precautions apply when installing, servicing,

or operating paralle l configurations and drive system li neups:

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: Verify tha t al l 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 ener gy
devices. To avoid the hazard of elec tric al shock, ve rify
that all voltage on capacitors has b een discharge d 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 ANSI/NFPA 70E.

P-2

ATTENTION: An incorrectly applied or incorrectly
installed drive system can res ult in component damage

!

and/or a reduction in product life. Wiring or application

errors–such as undersizing the motor, incorre ct 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 (elec trostatic
discharge). Static control precautions a re required
when installing, testing, or repairing this assembly.
Component damage can result if ESD control
procedures are not followed. I f you are not familiar with
static control procedur es, refer to Rockwell Automation
publication 8000-4. 5.2, Guardi ng Against Electr ostatic
Damage, or another adequate handbook on ESD
protection.

Publication 2364P- 5.01 December 1999

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.

3 R2 and S2-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the R2 and

S2-code parallel configurations.

4 R3 and S3-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the R3 and

S3-code parallel configurations.

5 R4 and S4-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the R4 and

S4-code parallel configurations.

6 T1 and V1-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the T1 and

V1-code parallel configurations.

7 T2 and V2-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the T2 and

V2-code parallel configurations.

8 T3 and V3-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the T3 and

V3-code parallel configurations.

9 T4 and V4-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the T4 and

V4-code parallel configurations.

10 T5 and V5-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the T5 and

V5-code parallel configurations.

11 T6 and V6-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the T6 and

V6-code parallel configurations.

12 W1-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the W1-code

parallel configurations.

13 W2-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the W2-code

parallel configurations.

14 W3-Code Parallel Configurations Schematics, component layout, and overhead bus configuration for the W3-code

parallel configurations.

15 Installation Instructions for installing, wiring, and testing the parallel configuration.

P-3

16 Setting Up the Parallel Configuration Instructions for setting the RGU parameters in the parallel configuration.

A Specifications Operational, environmental, and electrical specifications for the parallel

configuration.

B Catalog Numbers and Spare Parts Kits Information concerning the parallel configuration catalog numbers and spare parts

kits.

C Physical Details Enclosure dimensions and sound levels.

Index

Publication 2364P-5.01 December 1999

P-4

Related Documentation The following documents include information that may be helpful

when installing or servic es components in your drive system. To
obtain a copy of any of the Rockwell Automation publ ications,
contact your local Rockwell Autom ation office or distibutor.

For Read This Document Document Number

NRU layout diagrams, schematics, component information, and installation/
setup instructions.

RGU layout diagrams, schematics, component information, installation/setup
instructions, and parameter listings.

Troubleshooting information, testing procedures, and fault descriptions for
the RGU.

Instructions for installing an overhead bus assembly. Overhead Bus Installation Instructions for Bulletin

Information for operating and understanding the Graphic Programming
Terminal (GPT).

Information for installing and configuring the Remote I/O (RIO)
Communications Module.

Information for installing and configuring the DeviceNet Communications
Module.

Information for installing and configuring the Series Communications Module. Bulletin 1203 Series Communications Module–

Information for installing, configuring, programming, and troubleshooting the
1336 FORCE adjustable frequency AC drive.

Information for installing, configuring, programming, and troubleshooting the
1336 PLUS adjustable frequency AC drive.

Instructions for properly handling and moving motor control centers. Receiving, Handling, and Storing Motor Control

Instructions for enclosure and busbar assembly. Bulletin 2300 Family of Drive Systems–Installation

Information for installing, configuring, and programming the SA3000 AC
drive.

Information for installing, configuring, and programming the SA3100 AC
drive.

Instructions for working with FD86N enclosures. FD86N Drive Systems Enclosure Hardware–

Electrical specifications established by the National Fire Protection
Association (NFPA), Boston, MA.

List of documentation available through Allen-Bradley. Allen-Bradley Publication Index SD499

Non-Regenerative DC Bus Supply Unit (NRU)–User
Manual

Regenerative DC Bus Supply Unit (RGU)–User
Manual

Regenerative DC Bus Supply Unit (RGU)–
Troubleshooting Guide

2300 MCCs
Bulletin 1201 Graphic Programming Terminal–

User Manual
Bulletin 1203 Remote I/O Communications

Module–Getting Started Manual
Bulletin 1203 DeviceNet Communications

Module–User Manual

User Manual
1336 FORCE Adjustable Frequency AC Drive–User

Manual
1336 PLUS Adjustable Frequency AC Drive–User

Manual

Centers–Instructions

Manual
SA3000 Binder S-3001

SA3100 Binder S-3053

Installation Manual
National Electrical Code ANSI/NFPA70

2364E-5.01

2364F-5.01

2364F-5.05

2364P-5.10

1201-5.0

1203-5.1

1203-5.3

1203-5.5

1336 FORCE-5.12

1336 PLUS-5.0

2100-5.5

2300-5.1

S-3062

Dictionary of terms that are common to industrial automation. Industrial Automation Glossary AG-7.1

Publication 2364P- 5.01 December 1999

P-5

Receiving Your Drive System The Customer is responsibl e for thoroughly inspe cting the equipment

before accepting the shipment from the freight company. Check the
item(s) that you r eceive 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 unpac king, you are responsible for
notifying the freight agent. In such a case, leave the shipping
container intact and request that the freight agent make a visua l
inspection of the equipment.

Rockwell Automation Support Rockwell Automation offers support services worldwide, with Sales/

Support Office s, a uthorized distributors, and authorized Systems
Integrators loc ated throughout the United States, plus Rockwell
Automation representa tives in every major country in the world.

Local Product Support

Please 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 cont act us fo r tech n ical assis ta nce, pleas e rev iew th e
product and troubleshooting information in this manual first.

When you do contact us, please have the catalog numbers of your
products ready when you call so we c an provi de the qui ckest response
for your situation.

Publication 2364P-5.01 December 1999

P-6

Publication 2364P-5.01 December 1999

Chapter 1

Theory of Operation

Introduction The parallel configuration, a DC bus supply front-end with

regenerative c apability, is used to supply DC power for AC digital
drive inverter unit s in a common bus drive syste m. Twenty-three
different parallel configurations provide a spectrum of different
supply and regenerative capabilities.

Figure 1.1
Parallel Configuration

3-Phase

AC Line

NRU

RGU RGU

DC Supply for

Drive Lineup

DC

AC

Inverters

DC

AC

DC

AC

Publication 2364P-5.01 December 1999

1-2 Theory of Operation

Parallel configur ations use the following front-end units:

• Regenerative DC Bus Supply Unit ( RGU)

• Non-Regenerative DC Bus Supply Unit (NRU)

Each parallel config uration will include one, two, or three
Regenerative DC Bus Supply Units (RGUs). The se units are used to
supply motoring current to the DC bus, and are used to regenerate
current back onto the AC line.

Most of the parallel configur ations will also include a
Non-Regenerative DC Bus Supply Unit (NRU) to supply the
motoring current to the DC bus.

Note: When there is an NRU in the configuration, the NRU
supplies motoring curr ent while the RGUs regenerate most of the
excess capacity (the RGU also cont ributes 10% of its rated
motoring current to the DC bus).

Figure 1.2
NRU and RGU Operation

NRU//RGU Configuration

3-Phase

AC Line

RGU//RGU Configuration

3-Phase

AC Line

Motoring

Current

Motoring

Current

NRU RGU

RGU

Regenerating

Current

10%

Motoring

Current

Motoring

Current

RGU

Regenerating

Current

DC Supply for
Drive Lineup

Regenerating

Current

DC Supply for
Drive Lineup

Publication 2364P-5.01 December 1999

Parallel Configuration RGU//RGU Configurations

In an RGU//RGU configuration, each RGU supplies 100% motoring
current and 100% regenerative curr ent. When operating, the master
RGU evaluates the bus voltage and sends cur rent c ommands to the
slave RGUs through an RGU-to-RGU (R2R) communicati on
network. This allows the RGUs to operate together to supply the
appropriate current while maintaining a constant voltage on the DC
bus.

Figure 1.3
RGU//RGU Configuration

3-Phase

AC Line

RGU

RGU-to-RGU

Communications

Each RGU//RGU configuration has one master RGU in parallel with
either one or two slave RGUs. Each slave RGU includes a common
mode choke accommodate for minor switchi ng differences between
the RGUs and to reduce c irculat ing cur rents bet ween the master RGU
and the slave RGUs.

RGU RGU

Theory of Operation 1-3

DC Supply for

Drive Lineup

Master

3-Phase

AC Line

Figure 1.4
RGU//RGU Configuration–Master/Slave

Common Mode Choke

RGU RGU

R2R

Communication

Slave

DC Supply

for Drive

Lineup

Publication 2364P-5.01 December 1999

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 pr ocess, t he maste r R GU evaluat es the bu s vol tage and se nds a
current com ma n d (whi ch is used t o corr ect the bu s voltag e ) to the
slave RGUs. Each RGU switches its IGBTs to regulate the current
(motoring or regenerative) needed to mainta in the bus voltage.

Figure 1.5
RGU//RGU Bus Voltage–Motoring or Regenerating

~1.52 x V AC

DC Bus Voltage

0 V DC

0%

% Load

100%

When the RGUs are not enabled, power is supplied through the free­wheeling diodes. The diode bridge produces a voltage of 1.35 tim es
the input voltage with no load, and decre ases to 1.22 times the input
voltage at full load. During this operation, the RGUs do not regulate
the voltage or regenerat e any curr ent.

Figure 1.6
RGU//RGU Bus Voltage–Diode Bridge Operation (RGU Not Enabled)

1.35 x V AC

1.22 x V AC

DC Bus Voltage

0 V DC

0%

% Load

100%

Publication 2364P-5.01 December 1999

3-Phase

AC Line

Theory of Operation 1-5

NRU//RGU Configurations

In the NRU//RGU configura tion, the NRU is used to supply m otoring
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 ope rate to supply 10% of their
maximum motoring current to the DC bus. When regenerating, the
NRU’s diode bridge stops operating, and the RGUs regener ate the
current back onto the AC line.

Figure 1.7
NRU//RGU Configuration

NRU

RGU RGU

RGU-to-RGU

Communications

DC Supply for

Drive Lineup

The NRU supplies motoring c urrent through its diode bridge, and the
RGU supplies motoring and regenerative current through its power
structure.

Figure 1.8
Line Waveform–NRU//RGU Configuration

Line Voltage

Line Current

Publication 2364P-5.01 December 1999

1-6 Theory of Operation

In the NRU//RGU configuration, the NRU has chokes on the DC bus.
These chokes reduce cir culating c urrent 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 1.9
NRU//RGU Configuration–Basic Components

Pow er Structure

(w ith IG BTs)

3-Phase

AC Line

NRU RGU

Diode Bridge

DC Supply

for Drive

Lineup

Chokes

The RGU evaluates the bus vo ltage and adjusts it s cu rrent to mai ntain
the nominal bus voltage. If there are two RGUs in the configuration,
the master RGU eva luates the vol tage and sends cur rent commands to
the slave RGU, and both RGUs will switch their IGBTs to regulate
the necessary current on the DC bus.

Publication 2364P-5.01 December 1999

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 regula te 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

smaller voltage

No

Current

v

RGUNRU

Current

(Up to 1 0% of the

RGU rating)

greater voltage

V

1.52 x AC Line
Voltage

When the load increases beyond the fir st 10%, the RGU is no longe r
able to regu late the voltage (since the current limit is set to 10%), a nd
the bus voltage drops to a level where the diode s in the NRU can
conduct. The NRU then supplies the motoring current for the
remainder of the load, resulting in a bus voltage of 1.35 times the line
voltage.

Figure 1.11
RGU and NRU Motoring–Load Over 10% of RGU Rating

3-Phase

AC Line

Current

V

RGUNRU

v

Current
(10% of th e
RGU rating)

1.35 x AC Line
Voltage

When the load drops under the 10% capabilit y of the RGUs, the
RGUs will begin to regulate the bus voltage again to 1.52 times the
line voltage, and the diodes in the NRU will stop c onducting.

Publication 2364P-5.01 December 1999

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 NR Us su ppl y cu rren t fo r the rem ai nd er o f the
load (while the RGU current is limited to 10% of the RGU rating).

Figure 1.12
NRU//RGU Bus Voltage–Motoring

1.52 x V AC

1.35 x V AC

DC Bus Voltage

0 V DC

0%

10%

(of RGU rating)

% Load

100%
(Total NRU rating +
10% of RGU rating)

When the load is under 10% of the maximum motoring current, the
RGUs can regulate (or maintain) the bus voltage. The RGU (master
RGU) will evaluate the voltage on the bus, and will calculate the
current needed to maintai n the bus voltage. If a regenerative current
is needed to m aintain the voltage, the RGUs will begin switching
their IGBTs to regenerate current onto the AC line. The diodes in the
NRU will still not conduct current.

Figure 1.13
RGU Regenerating

3-Phase

AC Line

No

Current

v

RGUNRU

V

Current

(Up to 100% of the

RGU rating)

1.52 x AC Line
Voltage

Publication 2364P-5.01 December 1999

Theory of Operation 1-9

The diagram below shows the NRU//RGU regenerative bus volta ge.
The RGUs regenerate up to 100% of their rated curre nt to the AC line
while the NRU diode bridge stops conduct ing.

Figure 1.14
NRU//RGU Bus Voltage–Regenerating

1.52 x V AC

DC Bus Voltage

0 V DC

0%

% Load

100%

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. During this
operation, the RGUs do not regulate the voltage or regenerate any
current.

Figure 1.15
NRU//RGU Bus Voltage–RGUs Not Enabled

1.35 x V AC

1.22 x V AC

DC Bus Voltage

0 V DC

0%

% Load

100%

Publication 2364P-5.01 December 1999

1-10 Theory of Operation

Motoring - Up to 10% of RGU Rated Amperes

3-Phase

AC Line

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 regula te the bus voltage. The master RGU will evaluate
the bus voltage, and will determine the current required to maintai n
the nominal bus voltage (1.52 times the line voltage). The master
RGU will send a current command to the slave RGU, and both R GUs
will begin switching their IGBTs to provide the proper motoring or
regenerative current.

Figure 1.16
NRU With Two RGUs–Motoring

v

No

Current

NRU

V

Current

(Up to 10% of

RGU rated

amperes)

RGU RGU

RGU-to-RGU

Communications

Current
(Up to 10% of
the RGU rated

amperes)

1.52 x AC Line
Voltage

Motoring - Over 10% of RGU Rated Amperes

3-Phase

AC Line

Current

(Up to 100% of

the NRU rated

amperes)

V

NRU

v

Figure 1.17
NRU With Two RGUs–Regenerating

3-Phase

AC Line

No

Current

v

NRU

V

Current

(10% of
RGU rated
amperes )

Current

(Up to 100%
of RGU rated

amperes)

RGU RGU

RGU-to-RGU

Communications

RGU RGU

RGU-to-RGU

Communications

Current

(10% of the

RGU rated

amperes)

1.35 x AC Line

Current

(Up to 100% of

the RGU rated

amperes)

1.52 x AC Line

Voltage

Voltage

Publication 2364P-5.01 December 1999

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.

T wo contactors (M1 and M2) are used to perform the precharge
operation in the K, L, a nd M-code RGUs (the N-code RGU precharge
circuit is slightly different).

When the disconnect ( MCP1 or CB1) is closed and the start switch is
turned on, the main contactor (M1) remains open, the precharge
contactor (M2) closes, and c urrent begins to flow through the
precharge circuit (bypassing the main 3-phase circuit). This
precharge circuit (which has a resistive load) charges up the capacitor
bank. As the bank approaches capacity, the main contactor (M1)
closes, the precharge contactor (M2) opens, the NRU circuit breaker
closes, and normal operation begins.

Circuit Breaker or

MCP

(CB1 or MCP1)

Precharge

Contactor

(M2)

Main

Contactor

(M1)

Figure 1.18
Precharge Circuit

Precharge Circuit

R

Note:

The precharge circuitry is slightly
different in the N-code RGU. See the product
schematics for further details.

Publication 2364P-5.01 December 1999

1-12 Theory of Operation

The RGUs will precharge the capa citors on the bus until the bus
voltage rises to be equal to the lin e volt age. Then, the precharge
circuit will open, the main circuit will close, the NRU circuit breake r
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 f or normal operation, resul ting
in damage to equipment.

Figure 1.19
Precharge Voltage

1.35 x V AC

DC Bus Voltage

1 x V AC

0 V DC

0 sec

Precharging

Time

Normal Diode-Bridge

Operation

Unable to Precharge

(Too many inv erters)

t

Publication 2364P-5.01 December 1999

Chapter 2

R1 and S1-Code Parallel Configurations

R1-Code Parallel Configuration The R1-code parallel configur ation is a common DC bus front-end

unit consisting of an D-code NRU in parall el with a K-code RGU.

Figure 2.1
R1-Code Parallel Configuration–Information

R1-code Parallel ConfigurationR1-code Ratings

Input Voltage

(V AC)

380 1520
460
575

DC Bus Current

(A DC)

1520
1520

Rated DC Bus

kW

780
944

1180

D-code

NRU

K-code
RGU

S1-Code Parallel Configuration The S1-code parallel configuration is a common DC bus front-end

unit consisting of an E-code NRU in parallel with a K-code RGU.

Figure 2.2
S1-Code Parallel Configuration–Information

S1-code Parallel ConfigurationS1-code Ratings

Input Voltage

(V AC)

380 2020
460
575

DC Bus Current

(A DC)

2020
2020

Rated DC Bus

kW

1036
1254
1568

E-code

NRU

K-code
RGU

Note: Information for the D-code NRU and E-code NRU can be
found in publication 2364E-5.01. Information for the K-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

2-2 R1 and S1-Code Parallel Configurations

Component Layout Figure 2.3

Enclosure Layout

Front View

Shipping Split

101.25"

91.5"

Cutaway View

30" 30" 25" 25" 20"

Customer Supplied

AC Input Lines

Publication 2364P-5.01 December 1999

Feeder D-code NRU (1500A) K-code RGU

Figure 2.4
Overhead Bus Assembly

Feeder

Splice Kit

R1 and S1-Code Parallel Configurations 2-3

30" Overhead
Bus Assembly

End Cap

4" Bus Tabs

To Feeder Buswork

To NRU circuit breaker

Flex Bus

Drop Tabs

New and Revised NRU and RGU Components in the R1 and S1 Configurations

NRU

RGU

CB1 2000A, RD-frame with motor operator, aux contact (2NO/2NC)
EA10
F4, F6

Control power filter, 4kHz
Primary fuse for 5kVA control transformer

Primary fuse for 10kVA control transformer (Opt 6P)

25A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

PT1
TB10

CR4
F4, F6

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)
Control power transformer, 5kVA
Control terminal block, 30A, 600V

Precharge Lockout Relay (2NO/2NC)
Primary fuse for 2kVA transformer

Control power transformer, 10kVA (Opt 6P)

10A, KLDR (for 380V AC input)
9A, KLDR (for 460V AC input)
8A, KLDR (for 575V AC input)

F21, F22 DC bus fuses, 250A, 700V, 170M
F25
PT1
TR1

TB4

Fuse, NRU CB1 motor operator, 10A, KLDR
Control power transformer, 2kVA
Timer relay (3NO/1NC)

Control Terminal block, 30A, 600V

35A, KLDR (for 380V AC input)

The RGU AC line is connected to the
bus stubs on the NRU circuit breaker

Overhead bus assembly

Publication 2364P-5.01 December 1999

2-4 R1 and S1-Code Parallel Configurations

Schematics Figure 2.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

4KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2

Choke Comp.

MTR3

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

R1 and S1-Code Parallel Configurations 2-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

S5

Y
R
B

Flow

Sensor

D5

EA4

Bridge Suppressor

EA2

Bus Indicator PCB

+Bus

-Bus

(X4)

CH11 CH11

(X3)

DC Horizontal Bus To

LED1
LED2

VM1

DC Bus Voltage

Inverter Units

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

(X2)

Publication 2364P-5.01 December 1999

2-6 R1 and S1-Code Parallel Configurations

Figure 2.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

CR4

TR1

From

A

3-phase
AC Input

CB1-RGU

4KHZ Control Power Filter

EA10

SP4

SP1

SP2

PE

SP3

F4

460VAC

F7

(X1)

115VAC

(X2)

F25

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

F6

PT1

MTR1

RGU Door Fan

MTR2

RGU Door Fan

CR2

Fault

PL2

A

Not

Faulted

PE

TB1-9

TB1-10

Fault

C

To RGU Input

Fuses

CR2

TB1

TR1

Precharge

11

CR4

12

TB1

CR3

CR4

Timer

M2

Precharge

(20 sec)

TB1-5 TB1-6

Avail able f o r

Customer Use

6

TB6

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

M1

TB6

TB4-4

9

TB10-7

E

CB1-NRU-A

To RGU

Control

Circuitry

TB10-8

TB4-5

CR3

Pilot

CR4

Precharge

Lockout

M1

Main

External M ain

Enable

F

Isolation Board

To RGU

D

Control Power

From RGU

R1 and S1-Code Parallel Configurations 2-7

TB4-8

CB1-NRU

PE

TR1

CR3

TR1

Spring Windup

Wht/Red

TB4-6

TB10-1

Blu

TB4-9

TB10-3

TB4-7 TB10-4

TB4-3

TB10-5

TB10-7

TB4--4 TB4-5

Blk

Red

Blk

LS

X

Y

Y

Y
X

X

LS

M

Y

X

CB1-NRU-A

CB1-NRU-B

Blk

TB10-10

CB1-NRU-A

CB1-NRU-B

TB4-1

Not

Used

TB4-2

Open

Motor

Close

UVR

TB10-2

Wht

TB10-6

Red

TB10-8

Blu

TB10-9

Red

TB10-11

Blu

TB10-12

Publication 2364P-5.01 December 1999

2-8 R1 and S1-Code Parallel Configurations

Figure 2.7
Schematics (cont.)

B

From RGU

AC Line

From RGU

Control

Circuitry

AC
Rtn

R10

F2

R11

F3

F4

R12

CT1

F17
F18
F19

Bridge

Fan

Rs
Ss
Ts

0

6

2

2

1

1

-

-

-

1

1

1

J

J

J

CT3

To

PE

Gnd

J7

P1

1

6

-

-

1

1

J

J

M2

CH11

F1

M1

F2

F3

From RGU

E

Control Power

CH1
CH2
CH3

Isolation
Board

TB5

1

Fault

F

Reset

S11

Enable

2

Fault Reset

3

External Main

4

Common

SW1 Settings

115VAC

OffX

24VDCOn

For TB5-1, -2, -3

Burden Resistors

1

TB1

Publication 2364P-5.01 December 1999

To RGU

Control

Circuitry

To RGU

Control

Circuitry

TB6

1

3

4

6

8

9

Aux Control
Fault

Bus
Control

TB2

TB3

3

1

TB2 Resistor
Not Required

3

1

3

J2

R1 and S1-Code Parallel Configurations 2-9

d

r

a

o
B
r

e

b

b

u

n
S

To System Network

UP

C1

G

E1

UN

C1

G

E1

J7

Main Bus

DC-DC

Converter

TP3

-t

J6

Bridge Thermal

Sensor (NTC)

J12

Gate Drivers

TP5

-15V+24V +15V

Shd

(+)

Horizontal

DC Bus

(-)

F1

G

G

24V

DC-DC

Aux 24V

J10

WP

C1

E1

Cap

Bank

WN

C1

E1

J10

+15V

-15V
+5V
+12V

-12V

J1

J3

J7

d

r

a

o
B

G

r

e

b

E1

b

u

n
S

VN

C1

G

E1

J8

F1

d

r

a

o

B

r

e

b

b

u

n

S

Gate Driver Board

+24V

VP

C1

Converter

TP8TP4TP6

TP9

+12V+5V -12V

Main Control Bo a rd

J2

RIO Adapter Option

1

1203-GM1

2
3

Y

R

YY

SW1

SW2

J4

Blu

1

SW3

Shd

Clr

2

Off
On

Off
On

Off
On

J1
J8 J9

2

Power

B
T

Supply

Filter

1

Board

B
T

J11

TB7

P13

TB4

TB1

+

-

PE

TE

2
1

1
2

1
2
3
4
5
6
7
8
9

10

+Bus

-Bus

+

-

- Analog In 1
+ Analog In 1
Analog In 1 Common

- Analog In 2
+ Analog In 2
Analog In 2 Common
Analog Out 1
Analog Out 1 Common
Analog Out 2
Analog Out 2 Common

Horizontal DC Bus

To Inve rter Units

EA2

Bus Indicator Board

EA4

Bus Suppressor

LED1
LED2

PL1

R

DC Bus
Energized

RIO Ext SCANport 1 SCANport 2 R2R Comm

Publication 2364P-5.01 December 1999

2-10 R1 and S1-Code Parallel Configurations

Publication 2364P-5.01 December 1999

Chapter 3

R2 and S2-Code Parallel Configurations

R2-Code Parallel Configuration The R2-code parallel configur ation is a common DC bus front-end

unit consisting of an D-code NRU in parall el with a L-code RGU.

Figure 3.1
R2-Code Parallel Configuration–Information

R2-code Parallel ConfigurationR2-code Ratings

Input Voltage

(V AC)

380 1536
460
575

DC Bus Current

(A DC)

1536
1533

Rated DC Bus

kW

788
954

1190

D-code

NRU

L-code
RGU

S2-Code Parallel Configuration The S2-code parallel configuration is a common DC bus front-end

unit consisting of an E-code NRU in parallel with a L-code RGU.

Figure 3.2
S2-Code Parallel Configuration–Information

S2-code Parallel ConfigurationS2-code Ratings

Input Voltage

(V AC)

380 2036
460
575

DC Bus Current

(A DC)

2036
2033

Rated DC Bus

kW

1045
1265
1578

E-code

NRU

L-code
RGU

Note: Information for the D-code NRU and E-code NRU can be
found in publication 2364E-5.01. Information for the L-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

3-2 R2 and S2-Code Parallel Configurations

Component Layout Figure 3.3

Enclosure Layout

Front View

Shipping Split

101.25"

91.5"

30" 30" 25" 30" 25"

Cutaway View

Note: The D-code NRU has only

one AC line fuse per phase.

Customer Supplied

AC Input Lines

Feeder D-code NRU (1500A) or E-code NRU (2000A) L-code RGU

Publication 2364P-5.01 December 1999

Figure 3.4
Overhead Bus Assembly

Feeder

Splice Kit

R2 and S2-Code Parallel Configurations 3-3

30" Overhead
Bus Assembly

End Cap

4" Bus Tabs

To Feeder Buswork

To NRU circuit breaker

Flex Bus

Drop Tabs

New and Revised NRU and RGU Components in the R2 and S2 Configurations

NRU CB1 2000A, RD-frame with motor operator, aux contact (2NO/2NC)

RGU

EA10
F4, F6

PT1
TB10

CR4
F4, F6

F21, F22 DC bus fuses, 500A, 700V, 170M
F25
PT1
TR1

TB4

Control power filter, 2kHz
Primary fuse for 5kVA control transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)
Control power transformer, 5kVA
Control terminal block, 30A, 600V

Precharge Lockout Relay (2NO/2NC)
Primary fuse for 5kVA transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

Fuse, NRU CB1 motor operator, 10A, KLDR
Control power transformer, 5kVA
Timer relay (3NO/1NC)

Control Terminal block, 30A, 600V

Primary fuse for 10kVA control transformer (Opt 6P)

35A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

Control power transformer, 10kVA (Opt 6P)

The RGU AC line is connected to the
bus stubs on the NRU circuit breaker

Overhead bus assembly

Publication 2364P-5.01 December 1999

3-4 R2 and S2-Code Parallel Configurations

Schematics Figure 3.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

2KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2

Choke Comp.

MTR3

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

R2 and S2-Code Parallel Configurations 3-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

S5

Y
R
B

Flow

Sensor

D5

EA4

Bridge Suppressor

EA2

Bus Indicator PCB

+Bus

-Bus

(X4)

CH11 CH11

(X3)

DC Horizontal Bus To

LED1
LED2

VM1

DC Bus Voltage

Inverter Units

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

(X2)

Publication 2364P-5.01 December 1999

3-6 R2 and S2-Code Parallel Configurations

Figure 3.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

CR4

TR1

From

A

3-phase
AC Input

CB1-RGU

2KHZ Control Power Filter

EA10

SP4

SP1

SP2

PE

SP3

F4

460VAC

F7

(X1)

115VAC

(X2)

F25

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

F6

PT1

MTR1,2

Bay Door Fans

MTR3,4

Bay 1 Door Fans

CR2

Fault

PL2

A

Not

Faulted

PE

TB1-9

TB1-10

Fault

C

To RGU Input

Fuses

CR2

TB1

TR1

Precharge

11

CR4

12

TB1

CR3

CR4

Timer

M2

Precharge

(20 sec)

TB1-5 TB1-6

Avail able f o r

Customer Use

6

TB6

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

M1

TB6

TB4-4

9

E

CB1-NRU-A

TB10-7 TB10-8

To RGU

Control

Circuitry

TB4-5

CR3

Pilot

CR4

Precharge

Lockout

M1

Main

External M ain

Enable

F

Isolation Board

To RGU

D

Control Power

From RGU

R2 and S2-Code Parallel Configurations 3-7

TB4-8

CB1-NRU

PE

TR1

CR3

TR1

Spring Windup

Wht/Red

TB4-6

TB10-1

Blu

TB4-9

TB10-3

TB4-7 TB10-4

TB4-3

TB10-5

TB4-4 TB4-5

TB10-7

Blk

Red

Blk

LS

X

Y

Y

Y
X

X

LS

M

Y

X

CB1-NRU-A

CB1-NRU-B

Blk

TB10-10

CB1-NRU-A

CB1-NRU-B

TB4-1

Not

Used

TB4-2

Open

Motor

Close

UVR

TB10-2

Wht

TB10-6

Red

TB10-8

Blu

TB10-9

Red

TB10-11

Blu

TB10-12

Publication 2364P-5.01 December 1999

3-8 R2 and S2-Code Parallel Configurations

Figure 3.7
Schematics (cont.)

B

From RGU

AC Line

From RGU

Control

Circuitry

AC
Rtn

R10

F2

R11

F3

F4

R12

CT1

F17
F18
F19

Bridge

Fan

Rs
Ss
Ts

0

6

2

2

1

1

-

-

-

1

1

1

J

J

J

CT3

To

PE

Gnd

J7

P1

1

6

-

-

1

1

J

J

M2

F1

M1

F2

F3

From RGU

E

Control Power

CH1
CH2
CH3

CH11

Isolation
Board

TB5

1

Fault

F

Reset

S11

Enable

2

Fault Reset

3

External Main

4

Common

SW1 Settings

115VAC

OffX

24VDCOn

For TB5-1, -2, -3

Burden Resistors

1

TB1

Publication 2364P-5.01 December 1999

To RGU

Control

Circuitry

To RGU

Control

Circuitry

TB6

1

3

4

6

8

9

Aux Control
Fault

Bus
Control

TB2

TB3

3

1

TB2 Resisto r
Not Required

3

1

3

J2

R2 and S2-Code Parallel Configurations 3-9

e

c

e

a

t

f

a

r

e

G

t

n

I

e

c

e

a

t

f

r

a

e

G

t

n

I

To System Network

C1

G

E1

C1

G

E1

J7

Main Bus

DC-DC

Converter

TP3

-t

J6

Bridge Thermal

Sensor (NTC)

J12

UP

DETAIL

UN

Gate Drivers

TP5

-15V+24V +15V

Shd

(+)

Horizontal

DC Bus

(-)

F1

See U

r

Phase

e

b

b

Detail

u

n
S

VP

See U
Phase
Detail

VN

J8

F1

J2

J4

Blu

1

Shd

Clr

2

TP8TP4TP6

TP9

+12V+5V -12V

RIO Adapter Option

1
2
3

SW1

SW2

SW3

+24V

1203-GM1

R

J1
J8 J9

See U

r

Phase

e

b

b

Detail

u

n
S

WP

See U
Phase

Detail

WN

Gate Driver Board

24V

DC-DC

Converter

Aux 24V

Main Control Bo a rd

Y

YY

Off
On

Off
On

Off
On

J10

r

e

b

b

u

n
S

Cap

Bank

J10

+15V

-15V
+5V
+12V

-12V

J1

J3

J7

2

Power

B
T

Supply

Filter

1

Board

B
T

J11

TB7

P13

TB4

TB1

+

-

PE

TE

2
1

1
2

1
2
3
4
5
6
7
8
9

10

+Bus

-Bus

+

-

- Analog In 1
+ Analog In 1
Analog In 1 Common

- Analog In 2
+ Analog In 2
Analog In 2 Common
Analog Out 1
Analog Out 1 Common
Analog Out 2
Analog Out 2 Common

Horizontal DC Bus

To Inve rter Units

EA2

Bus Indicator Board

EA4

Bus Suppressor

LED1
LED2

PL1

R

DC Bus
Energized

RIO Ext SCANport 1 SCANport 2 R2R Comm

Publication 2364P-5.01 December 1999

3-10 R2 and S2-Code Parallel Configurations

Publication 2364P-5.01 December 1999

Chapter 4

R3 and S3-Code Parallel Configurations

R3-Code Parallel Configuration The R3-code parallel configur ation is a common DC bus front-end

unit consisting of an D-code NRU in parall el with an M-code RGU.

Figure 4.1
R3-Code Parallel Configuration–Information

R3-code Parallel ConfigurationR3-code Ratings

Input Voltage

(V AC)

380 1575
460
575

DC Bus Current

(A DC)

1575
1569

Rated DC Bus

kW

808
978

1218

D-code

NRU

M-code
RGU

S3-Code Parallel Configuration The S3-code parallel configuration is a common DC bus front-end

unit consisting of an E-code NRU in parallel with an M-code RGU.

Figure 4.2
S3-Code Parallel Configuration–Information

S3-code Parallel ConfigurationS3-code Ratings

Input Voltage

(V AC)

380 2075
460
575

DC Bus Current

(A DC)

2075
2069

Rated DC Bus

kW

1064
1289
1606

E-code

NRU

M-code
RGU

Note: Information for the D-code NRU and E-code NRU can be
found in publication 2364E-5.01. Information for the M-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

4-2 R3 and S3-Code Parallel Configurations

Component Layout Figure 4.3

Enclosure Layout

Front View

Shipping Split

101.25"

91.5"

30" 30" 25" 35" 35"

Cutaway View

Note:

The D-code NRU has only
one AC line fuse per phase.

Customer Supplied

AC Input Lines

Feeder D-code NRU (1500A) or E-code NRU (2000A) M-code RGU

Publication 2364P-5.01 December 1999

R3 and S3-Code Parallel Configurations 4-3

Figure 4.4
Overhead Bus Assembly

Feeder

Splice Kit

To Feeder Buswork

30" Overhead
Bus Assembly

4" Bus Tabs

Flex Bus

Drop Tabs

To NRU circuit breaker

25" Overhead

Bus Assembly

Joiner-Splice Kits

New and Revised NRU and RGU Components in the R3 and S3 Configurations

NRU CB1 2000A, RD-frame with motor operator, aux contact (2NO/2NC)

EA10
F4, F6

PT1
TB10

Control power filter, 2kHz
Primary fuse for 5kVA control transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)
Control power transformer, 5kVA
Control terminal block, 30A, 600V

35" Overhead
Bus Assembly

End

Cap

2" Bus Tabs

Flex Bus

Drop Tabs

To RGU circuit breaker

Primary fuse for 10kVA control transformer (Opt 6P)

35A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

Control power transformer, 10kVA (Opt 6P)

RGU

CR4
F4, F6

Precharge Lockout Relay (2NO/2NC)
Primary fuse for 5kVA transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

F21, F22 DC bus fuses, 500A, 700V, 170M
21A, 22A

F25
PT1
TR1

TB4

Fuse, NRU CB1 motor operator, 10A, KLDR
Control power transformer, 5kVA
Timer relay (3NO/1NC)

Control Terminal block, 30A, 600V

Overhead bus assembly

Publication 2364P-5.01 December 1999

4-4 R3 and S3-Code Parallel Configurations

Schematics Figure 4.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

2KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2

Choke Comp.

MTR3

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

R3 and S3-Code Parallel Configurations 4-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

S5

Y
R
B

Flow

Sensor

D5

EA4

Bridge Suppressor

EA2

Bus Indicator PCB

+Bus

-Bus

(X4)

CH11 CH11

(X3)

DC Horizontal Bus To

LED1
LED2

VM1

DC Bus Voltage

Inverter Units

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

(X2)

Publication 2364P-5.01 December 1999

4-6 R3 and S3-Code Parallel Configurations

Figure 4.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

F7

Choke

Thermoguards

S1 - 3

CR4

TR1

EA10

F25

11

TB1

CR4

CR4

2KHZ Control Power Filter

460VAC

(X1)

115VAC

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

12

TB1

CR3

SP4

PE

PT1

(X2)

Bay 1 Door Fan

Bay 1 Internal Fan

RGU Door Fans

Precharge

Precharge

F4

F6

MTR2

MTR3

MTR1

CR2

Fault

PL2

A

Not

Faulted

TR1

Timer

M2

SP1

SP2

SP3

PE

TB1-9

TB1-10

(20 sec)

From
3-phase
AC Input

A

Fault

CR2

TB1-5 TB1-6

Avail able f o r

Customer Use

CB1-RGU

C

To RGU Input

Fuses

6

TB6

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

M1

TB6

TB4-4

9

E

CB1-NRU-A

TB10-7 TB10-8

To RGU

Control

Circuitry

TB4-5

CR3

Pilot

CR4

Precharge

Lockout

M1

Main

External Main

Enable

F

Isolation Board

To RGU

D

From RGU

Control Power

R3 and S3-Code Parallel Configurations 4-7

TB4-8

CB1-NRU

PE

TR1

CR3

TR1

Spring Windup

Wht/Red

TB4-6

TB10-1

Blu

TB4-9

TB10-3

TB4-7 TB10-4

TB4-3

TB10-5

TB10-7

TB4-4 TB4-5

Blk

Red

Blk

LS

X

Y

Y

Y

X

X

LS

M

Y

X

CB1-NRU-A

CB1-NRU-B

Blk

TB10-10

CB1-NRU-A

CB1-NRU-B

TB4-1

Not

Used

TB4-2

Open

Motor

Close

UVR

TB10-2

Wht

TB10-6

Red

TB10-8

Blu

TB10-9

Red

TB10-11

Blu

TB10-12

Publication 2364P-5.01 December 1999

4-8 R3 and S3-Code Parallel Configurations

Figure 4.7
Schematics (cont.)

B

From RGU

AC Line

From RGU

Control

Circuitry

M2

F1

M1

F2

F3

From RGU

E

Control Power

Fault

F

Reset

CH1
CH2
CH3

S11

F2

F3

F4

AC
Rtn

Isolation
Board

TB5

1

Enable

2

Fault Reset

3

External Main

4

Common

R10, R10A

R11, R11A

R12, R12A

CH

F17
F18
F19

Bridge

Fan

CT1

CT2

Rs
Ss
Ts

0

6

2

2

1

1

-

-

-

1

1

1

J

J

J

SW1 Settings

For TB5-1, -2, -3

CT3

CT Power

Supply

CR

To

PE

Gnd

J7

P1

115VAC

OffX

24VDCOn

Burden Resistors

1

TB1

1

6

-

-

1

1

J

J

Publication 2364P-5.01 December 1999

To RGU

Control

Circuitry

To RGU

Control

Circuitry

TB6

1

3

4

6

8

9

Aux Control
Fault

Bus
Control

TB2

TB3

3

1

3

1

3

J2

R3 and S3-Code Parallel Configurations 4-9

e

c

e

a

t

f

a

r

e

G

t

n

I

e

c

e

a

t

f

r

a

e

G

t

n

I

To System Networ k

C1
G

E1

C1
G

E1

J7

Main Bus

DC-DC

Converter

TP3

-t

J6

Bridge Thermal

Sensor (NTC)

J12

UP1

DETAIL

UP2

C1

G

E1

UN1

UN2

C1

G

E1

Gate Drivers

TP5

(+)

Horizontal

DC Bus

(-)

+

See U

r

Phase

e

b

b

Detail

u

n
S

VP1
VP2

See U
Phase
Detail

VN1
VN2

J8

F1

-15V+24V +15V

J2

J4

Blu

1

Shd

Shd

Clr

2

TP8TP4TP6

TP9

+12V+5V -12V

RIO Adapter Option

1
2
3

SW1

SW2

SW3

+24V

1203-GM1

R

J1
J8 J9

See U

r

Phase

e

b

b

Detail

u

n
S

WP1
WP2

See U
Phase

Detail

WN1
WN2

Gate Driver Board

24V

DC-DC

Converter

Aux 24V

Main Control Bo a rd

Y

YY

Off
On

Off
On

Off
On

J10

r

e

b

b

u

n
S

Cap

+15V

-15V
+5V
+12V

-12V

Bank

J10

J1

J3

J7

2

Power

B
T

Supply

Filter

1

Board

B
T

J11

TB7

P13

TB4

TB1

-

PE

TE

2
1

1
2

1
2
3
4
5
6
7
8
9

10

+Bus

-Bus

+

-

- Analog In 1
+ Analog In 1
Analog In 1 Common

- Analog In 2
+ Analog In 2
Analog In 2 Common
Analog Out 1
Analog Out 1 Common
Analog Out 2
Analog Out 2 Common

Horizontal DC Bus

To Inve rter Units

EA2

Bus Indicator Board

EA4

Bus Suppressor

LED1
LED2

PL1

R

DC Bus
Energized

RIO Ext SCANport 1 SCANport 2 R2R Comm

Publication 2364P-5.01 December 1999

4-10 R3 and S3-Code Parallel Configurations

Publication 2364P-5.01 December 1999

Chapter 5

R4 and S4-Code Parallel Configurations

R4-Code Parallel Configuration The R4-code parallel configur ation is a common DC bus front-end

unit consisting of an D-code NRU in parall el with an N-code RGU.

Figure 5.1
R4-Code Parallel Configuration–Information

R4-code Parallel ConfigurationR4-code Ratings

Input Voltage

(V AC)

380 1600
460
575

DC Bus Current

(A DC)

1600
1591

Rated DC Bus

kW

821
994

1235

D-code

NRU

N-code
RGU

S4-Code Parallel Configuration The S4-code parallel configuration is a common DC bus front-end

unit consisting of an E-code NRU in parallel with an N-code RGU.

Figure 5.2
S4-Code Parallel Configuration–Information

S4-code Parallel ConfigurationS4-code Ratings

Input Voltage

(V AC)

380 2100
460
575

DC Bus Current

(A DC)

2100
2091

Rated DC Bus

kW

1077
1304
1623

E-code

NRU

N-code
RGU

Note: Information for the D-code NRU and E-code NRU can be
found in publication 2364E-5.01. Information for the N-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

5-2 R4 and S4-Code Parallel Configurations

9

Component Layout Figure 5.3

Enclosure Layout

Front View

101.25"

Shipping Split

Cutaway View

30" 30" 25" 35" 35"

Customer Supplied

AC Input Lines

20"

Feeder D-code NRU (1500A) or E-code NRU (2000A) N-code RGU

Publication 2364P-5.01 December 1999

R4 and S4-Code Parallel Configurations 5-3

20" Overhead

Figure 5.4
Overhead Bus Assembly

Feeder

Splice Kit

To Feeder Buswork

30" Overhead
Bus Assembly

4" Bus Tabs

Flex Bus

Drop Tabs

To NRU circuit breaker

25" Overhead
Bus Assembly

Bus Assembly

Joiner-Splice Kits

New and Revised NRU and RGU Components in the R4 and S4 Configurations

NRU CB1 2000A, RD-frame with motor operator, aux contact (2NO/2NC)

EA10
F4, F6

PT1
TB10

Control power filter, 2kHz
Primary fuse for 5kVA control transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)
Control power transformer, 5kVA
Control terminal block, 30A, 600V

Primary fuse for 10kVA control transformer (Opt 6P)

35A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

Control power transformer, 10kVA (Opt 6P)

35" Overhead
Bus Assembly

End
Cap

2" Bus Tabs

Flex Bus

Drop Tabs

To RGU circuit breaker

RGU

CR3 Pilot Relay (2NO/2NC) with aux contact (1NO/1NC)
CR4
F4, F6

Precharge Lockout Relay (2NO/2NC)
Primary fuse for 5kVA transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

F21, F22

DC bus fuses, 500A, 700V, 170M

21A, 22A
F25

PT1
TR1
TB4

Fuse, NRU CB1 motor operator, 10A, KLDR
Control power transformer, 5kVA
Timer relay (3NO/1NC)

Control Terminal block, 30A, 600V

Overhead bus assembly

Publication 2364P-5.01 December 1999

5-4 R4 and S4-Code Parallel Configurations

Schematics Figure 5.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

2KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2

Choke Comp.

MTR3

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

R4 and S4-Code Parallel Configurations 5-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

S5

Y
R
B

Flow

Sensor

D5

EA4

Bridge Suppressor

EA2

Bus Indicator PCB

+Bus

-Bus

(X4)

CH11 CH11

(X3)

DC Horizontal Bus To

LED1
LED2

VM1

DC Bus Voltage

Inverter Units

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

(X2)

Publication 2364P-5.01 December 1999

5-6 R4 and S4-Code Parallel Configurations

Figure 5.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

F7

Choke

Thermoguards

S1 - 3

CR4

TR1

EA10

F25

11

TB1

CR4

CR4

PE

2KHZ Control Power Filter

460VAC

(X1)

115VAC

F5

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

12

TB1

CR3

SP4

(X2)

SP1

SP2

SP3

F4

F6

PT1

MTR6

Bay 1 Door Fan

MTR4,5

Bay 2 Fan

MTR1,2,3

RGU Door Fans

CR2

Fault

PL2

A

Not

Faulted

TR1

Precharge

Timer

M2

Precharge

TB1-9

TB1-10

(20 sec)

PE

From

3-phase

AC Input

A

G

To RGU

Precharge

Circuitry

TB1-5 TB1-6

CB1-RGU

CB2-RGU

Fault

CR2

Avail able for

Customer Use

C

To RGU Input

Fuses

6

TB6

CB1-RGU

TB3-7

CR3

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

TB3-8

TB3-7

TB3-10

9

TB6

TB4-4

CB1-RGU

E

CB1-NRU-A

TB10-7 TB10-8

UVR

To RGU

Control

Circuitry

TB4-5

TB3-8
TB3-9
TB3-11
TB3-12

CR3

Pilot

CR4

Precharge

Lockout

External Main

Enable

To RGU

F

Isolation Board

D

From RGU

Control Power

R4 and S4-Code Parallel Configurations 5-7

TB4-8

CB1-NRU

PE

TR1

CR3

TR1

Spring Windup

Wht/Red

TB4-6

TB10-1

Blu

TB4-9

TB10-3

TB4-7 TB10-4

TB4-3

TB10-5

TB10-7

TB4-4 TB4-5

Blk

Red

Blk

LS

X

Y

Y

Y

X

X

LS

M

Y

X

CB1-NRU-A

CB1-NRU-B

Blk

TB10-10

CB1-NRU-A

CB1-NRU-B

TB4-1

Not

Used

TB4-2

Open

Motor

Close

UVR

TB10-2

Wht

TB10-6

Red

TB10-8

Blu

TB10-9

Red

TB10-11

Blu

TB10-12

Publication 2364P-5.01 December 1999

5-8 R4 and S4-Code Parallel Configurations

Figure 5.7
Schematics (cont.)

G

From

RGU-CB1

B

From RGU

AC Line

From RGU

Control

Circuitry

M2

F1

M1

F2

F3

From RGU

E

Control Power

Fault

F

Reset

CH1
CH2
CH3

S11

F2

F3

F4

AC
Rtn

Isolation
Board

TB5

1

Enable

2

Fault Reset

3

External Main

4

Common

R10, R10A

R11, R11A

R12, R12A

CH

F17
F18
F19

Bridge

Fan

CT1

CT2

Rs
Ss
Ts

0

6

2

2

1

1

-

-

-

1

1

1

J

J

J

SW1 Settings

For TB5-1, -2, -3

CT3

CT Power

Supply

CR

To

PE

Gnd

J7

P1

115VAC

OffX

24VDCOn

Burden Resistors

1

TB1

1

6

-

-

1

1

J

J

Publication 2364P-5.01 December 1999

To RGU

Control

Circuitry

To RGU

Control

Circuitry

TB6

1

3

4

6

8

9

Aux Control
Fault

Bus
Control

TB2

TB3

3

1

3

1

3

J2

R4 and S4-Code Parallel Configurations 5-9

e

c

e

a

t

f

a

r

e

G

t

n

I

e

c

e

a

t

f

r

a

e

G

t

n

I

To System Networ k

C1

DETAIL

G

E1

C1
G

E1

J7

Main Bus

DC-DC

Converter

TP3

-t

J6

Bridge Thermal

Sensor (NTC)

J12

UP1

UP2

C1

G

E1

UN1

UN2

C1

G

E1

Gate Drivers

TP5

(+)

Horizontal

DC Bus

(-)

+

See U

r

Phase

e

b

b

Detail

u

n
S

VP1
VP2

See U
Phase
Detail

VN1
VN2

J8

F1

-15V+24V +15V

J2

J4

Blu

1

Shd

Shd

Clr

2

TP8TP4TP6

TP9

+12V+5V -12V

RIO Adapter Option

1
2
3

SW1

SW2

SW3

+24V

1203-GM1

R

J1
J8 J9

See U

r

Phase

e

b

b

Detail

u

n
S

WP1
WP2

See U
Phase

Detail

WN1
WN2

Gate Driver Board

24V

DC-DC

Converter

Aux 24V

Main Control Bo a rd

Y

YY

Off
On

Off
On

Off
On

J10

r

e

b

b

u

n
S

Cap

+15V

-15V
+5V
+12V

-12V

Bank

J10

J1

J3

J7

2

Power

B
T

Supply

Filter

1

Board

B
T

J11

TB7

P13

TB4

TB1

-

PE

TE

2
1

1
2

1
2
3
4
5
6
7
8
9

10

+Bus

-Bus

+

-

- Analog In 1
+ Analog In 1
Analog In 1 Common

- Analog In 2
+ Analog In 2
Analog In 2 Common
Analog Out 1
Analog Out 1 Common
Analog Out 2
Analog Out 2 Common

Horizontal DC Bus

To Inve rter Units

EA2

Bus Indicator Board

EA4

Bus Suppressor

LED1
LED2

PL1

R

DC Bus
Energized

RIO Ext SCANport 1 SCANport 2 R2R Comm

Publication 2364P-5.01 December 1999

5-10 R4 and S4-Code Parallel Configurations

Publication 2364P-5.01 December 1999

Chapter 6

T1 and V1-Code Parallel Configurations

T1-Code Parallel Configuration The T1-code paralle l configuration is a common DC bus front-end

unit consisting of an F-code NRU in paralle l with a K-code RGU.

Figure 6.1
T1-Code Parallel Configuration–Information

T1-code Parallel ConfigurationT1-code Ratings

Input Voltage

(V AC)

380 2520
460
575

DC Bus Current

(A DC)

2520
2520

Rated DC Bus

kW

1293
1565
1956

F-code

NRU

K-code
RGU

V1-Code Parallel Configuration The V1-code parallel configuration is a common DC bus front-end

unit consisting of an G-code NRU in parall el with a K-code RGU.

Figure 6.2
V1-Code Parallel Configuration–Information

V1-code Parallel ConfigurationV1-code Ratings

Input Voltage

(V AC)

380 3000
460
575

DC Bus Current

(A DC)

3000
3000

Rated DC Bus

kW

1539
1863
2329

G-code

NRU

K-code
RGU

Note: Information for the F-code NRU and G-code NRU can be
found in publication 2364E-5.01. Information for the K-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

6-2 T1 and V1-Code Parallel Configurations

Component Layout Figure 6.3

Enclosure Layout

Front View

Shipping Split

101.25"

91.5"

Cutaway View

30" 30" 35" 25" 20"

Customer Supplied

AC Input Lines

Feeder F-code (2500A) or G-code (3000A) NRU K-code RGU

Publication 2364P-5.01 December 1999

Figure 6.4
Overhead Bus Assembly

Feeder

Splice Kit

T1 and V1-Code Parallel Configurations 6-3

30" Overhead
Bus Assembly

End Cap

4" Bus Tabs

To Feeder Buswork

To NRU circuit breaker

Flex Bus

Drop Tabs

New and Revised NRU and RGU Components in the T1 and V1 Configurations

NRU CB1 (T1 config) 2500A, SPB-frame with motor operator

(V1 config) 3000A, SPB-frame with motor operator

RGU

EA10
F4, F6

PT1
TB10

CR4
F4, F6

F21, F22 DC bus fuses, 250A, 700V, 170M
F25
PT1

TR1
TB4

Control power filter, 4kHz
Primary fuse for 5kVA control transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

Control power transformer, 5kVA
Control terminal block, 30A, 600V

Precharge Lockout Relay (2NO/2NC)
Primary fuse for 2kVA transformer

10A, KLDR (for 380V AC input)
9A, KLDR (for 460V AC input)
8A, KLDR (for 575V AC input)

Fuse, NRU CB1 motor operator, 10A, KLDR
Control power transformer, 2kVA
Timer relay (3NO/1NC)

Control Terminal block, 30A, 600V

Primary fuse for 10kVA control transformer (Opt 6P)

35A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

Control power transformer, 10kVA (Opt 6P)

The RGU AC line is connected to the
bus stubs on the NRU circuit breaker

Overhead bus assembly

Publication 2364P-5.01 December 1999

6-4 T1 and V1-Code Parallel Configurations

Schematics Figure 6.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

4KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2,3

Choke Comp.

MTR4,5,6

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

T1 and V1-Code Parallel Configurations 6-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

EA6

J2

In15

Sig 1

+5 2

In26

Com 3

J11

S5

Y
R
B

Flow

Sensor

S6

Y
R
B

Flow

Sensor

CH11

(X4)

(X3)

+Bus

-Bus

D5

EA2

EA4

Bus Indicator PCB

VM1

DC Bus Voltage

DC Horizontal Bus To

Inverter Units

Bridge Suppressor

LED1
LED2

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

CH11

(X2)

Publication 2364P-5.01 December 1999

6-6 T1 and V1-Code Parallel Configurations

Figure 6.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

CR4

TR1

From

A

3-phase
AC Input

CB1-RGU

4KHZ Control Power Filter

EA10

SP4

SP1

SP2

PE

SP3

F4

460VAC

F7

(X1)

115VAC

(X2)

F25

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

F6

PT1

MTR1

RGU Door Fan

MTR2

RGU Door Fan

CR2

Fault

PL2

A

Not

Faulted

PE

TB1-9

TB1-10

Fault

C

To RGU Input

Fuses

CR2

TB1

TR1

Precharge

11

CR4

12

TB1

CR3

CR4

Timer

M2

Precharge

(20 sec)

TB1-5 TB1-6

Avail able f o r

Customer Use

6

TB6

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

M1

TB6

TB4-4

9

TB10-7

E

CB1-NRU-A

TB10-8

To RGU

Control

Circuitry

TB4-5

CR3

Pilot

CR4

Precharge

Lockout

M1

Main

External Main

Enable

F

Isolation Board

To RGU

D

From RGU

Control Power

T1 and V1-Code Parallel Configurations 6-7

TB4-8

CB1-NRU

PE

TR1

TR1

TB4-1

Spring

Windup

TB4-2

CR3

TB4-3

TB4-4 TB10-7 TB4-5TB10-8

TB10-1

TB10-3

A12

Wht/Red

D9

Wht

D10

A6

A3

A1

B2

Digitrip

Blk

Blu

Org

Brn

SR

Spring

Release

Resistor When Required
(Not on 120 VAC)

Blk

Y

ARM

b

CB1-NRU-A

UVR

LC

Grn

SC

(Bot)

SC

CB1-NRU-B

CB1-NRU-A

TB10-10

B5

Blk

CB1-NRU-B

TB4-6

CB1-NRU-A

TB4-7

Not

Used

TB10-13

B8

Blk

CB1-NRU-B

TB4-9

CB1-NRU-A

TB10-16

B11

Blk

CB1-NRU-B

Red

Blu

Red

Blu

Red

Blu

Red

Blu

Red

A11

A2

B7

B9

B10

B12

TB10-2

TB10-5

B1

B3

TB10-9

B4

TB10-11

B6

TB10-12

TB10-14

Available For

Customer Use

TB10-15

TB10-17

TB10-18

Publication 2364P-5.01 December 1999

6-8 T1 and V1-Code Parallel Configurations

Figure 6.7
Schematics (cont.)

B

From RGU

AC Line

From RGU

Control

Circuitry

AC
Rtn

R10

F2

R11

F3

F4

R12

CT1

F17
F18
F19

Bridge

Fan

Rs
Ss
Ts

0

6

2

2

1

1

-

-

-

1

1

1

J

J

J

CT3

To

PE

Gnd

J7

P1

1

6

-

-

1

1

J

J

M2

CH11

F1

M1

F2

F3

From RGU

E

Control Power

CH1
CH2
CH3

Isolation
Board

TB5

1

Fault

F

Reset

S11

Enable

2

Fault Reset

3

External Main

4

Common

SW1 Settings

115VAC

OffX

24VDCOn

For TB5-1, -2, -3

Burden Resistors

1

TB1

Publication 2364P-5.01 December 1999

To RGU

Control

Circuitry

To RGU

Control

Circuitry

TB6

1

3

4

6

8

9

Aux Control
Fault

Bus
Control

TB2

TB3

3

1

TB2 Resistor
Not Required

3

1

3

J2

T1 and V1-Code Parallel Configurations 6-9

d

r

a

o
B
r

e

b

b

u

n
S

To System Network

UP

C1

G

E1

UN

C1

G

E1

J7

Main Bus

DC-DC

Converter

TP3

-t

J6

Bridge Thermal

Sensor (NTC)

J12

Gate Drivers

TP5

-15V+24V +15V

Shd

(+)

Horizontal

DC Bus

(-)

F1

G

G

24V

DC-DC

Aux 24V

J10

WP

C1

E1

Cap

Bank

WN

C1

E1

J10

+15V

-15V
+5V
+12V

-12V

J1

J3

J7

d

r

a

o
B

G

r

e

b

E1

b

u

n
S

VN

C1

G

E1

J8

F1

d

r

a

o

B

r

e

b

b

u

n

S

Gate Driver Board

+24V

VP

C1

Converter

TP8TP4TP6

TP9

+12V+5V -12V

Main Control Bo a rd

J2

RIO Adapter Option

1

1203-GM1

2
3

Y

R

YY

SW1

SW2

J4

Blu

1

SW3

Shd

Clr

2

OF

F

O

N

OF

F

O

N

OF

F

O

N

J1
J8 J9

2

Power

B
T

Supply

Filter

1

Board

B
T

J11

TB7

P13

TB4

TB1

+

-

PE

TE

2
1

1
2

1
2
3
4
5
6
7
8
9

10

+Bus

-Bus

+

-

- Analog In 1
+ Analog In 1
Analog In 1 Common

- Analog In 2
+ Analog In 2
Analog In 2 Common
Analog Out 1
Analog Out 1 Common
Analog Out 2
Analog Out 2 Common

Horizontal DC Bus

To Inve rter Units

EA2

Bus Indicator Board

EA4

Bus Suppressor

LED1
LED2

PL1

R

DC Bus
Energized

RIO Ext SCANport 1 SCANport 2 R2R Comm

Publication 2364P-5.01 December 1999

6-10 T1 and V1-Code Parallel Configurations

Publication 2364P-5.01 December 1999

Chapter 7

T2 and V2-Code Parallel Configurations

T2-Code Parallel Configuration The T2-code paralle l configuration is a common DC bus front-end

unit consisting of an F-code NRU in paralle l with a L-code RGU.

Figure 7.1
T2-Code Parallel Configuration–Information

T2-code Parallel ConfigurationT2-code Ratings

Input Voltage

(V AC)

380 2536
460
575

DC Bus Current

(A DC)

2536
2536

Rated DC Bus

kW

1301
1575
1966

F-code

NRU

L-code
RGU

V2-Code Parallel Configuration The V2-code parallel configuration is a common DC bus front-end

unit consisting of an G-code NRU in parall el with a L-code RGU.

Figure 7.2
V2-Code Parallel Configuration–Information

V2-code Parallel ConfigurationV2-code Ratings

Input Voltage

(V AC)

380 3000
460
575

DC Bus Current

(A DC)

3000
3000

Rated DC Bus

kW

1539
1863
2329

G-code

NRU

L-code
RGU

Note: Information for the F-code NRU and G-code NRU can be
found in publication 2364E-5.01. Information for the L-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

7-2 T2 and V2-Code Parallel Configurations

Component Layout Figure 7.3

Enclosure Layout

Front View

Shipping Split

101.25"

91.5"

30" 25"30" 30" 35"

Cutaway View

Customer Supplied

AC Input Lines

Feeder F-code (2500A) or G-code (3000A) NRU

L-code RGU

Publication 2364P-5.01 December 1999

Figure 7.4
Overhead Bus Assembly

Feeder

Splice Kit

T2 and V2-Code Parallel Configurations 7-3

30" Overhead
Bus Assembly

End Cap

4" Bus Tabs

To Feeder Buswork

To NRU circuit breaker

Flex Bus

Drop Tabs

New and Revised NRU and RGU Components in the T2 and V2 Configurations

NRU CB1 (T1 config) 2500A, SPB-frame with motor operator

(V1 config) 3000A, SPB-frame with motor operator

RGU

EA10
F4, F6

PT1
TB10

CR4
F4, F6

F21, F22 DC bus fuses, 500A, 700V, 170M
F25
PT1

TR1
TB4

Control power filter, 2kHz
Primary fuse for 5kVA control transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

Control power transformer, 5kVA
Control terminal block, 30A, 600V

Precharge Lockout Relay (2NO/2NC)
Primary fuse for 5kVA transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

Fuse, NRU CB1 motor operator, 10A, KLDR
Control power transformer, 5kVA
Timer relay (3NO/1NC)

Control Terminal block, 30A, 600V

Primary fuse for 10kVA control transformer (Opt 6P)

35A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

Control power transformer, 10kVA (Opt 6P)

The RGU AC line is connected to the
bus stubs on the NRU circuit breaker

Overhead bus assembly

Publication 2364P-5.01 December 1999

7-4 T2 and V2-Code Parallel Configurations

Schematics Figure 7.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

2KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2,3

Choke Comp.

MTR4,5,6

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

T2 and V2-Code Parallel Configurations 7-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

EA6

J2

In15

Sig 1

+5 2

In26

Com 3

J11

S5

Y
R
B

Flow

Sensor

S6

Y
R
B

Flow

Sensor

D5

EA4

Bridge Suppressor

EA2

Bus Indicator PCB

+Bus

-Bus

(X4)

CH11 CH11

(X3)

DC Horizontal Bus To

LED1
LED2

VM1

DC Bus Voltage

Inverter Units

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

(X2)

Publication 2364P-5.01 December 1999

7-6 T2 and V2-Code Parallel Configurations

Figure 7.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

CR4

TR1

From

A

3-phase

AC Input

CB1-RGU

2KHZ Control Power Filter

EA10

SP4

SP1

SP2

PE

SP3

F4

460VAC

F7

(X1)

115VAC

(X2)

F25

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

F6

PT1

MTR1,2

Bay Door Fans

MTR3,4

Bay 1 Door Fans

CR2

Fault

PL2

A

Not

Faulted

PE

TB1-9

TB1-10

Fault

C

To RGU Input

Fuses

CR2

TB1

TR1

Precharge

11

CR4

12

TB1

CR3

CR4

Timer

M2

Precharge

(20 sec)

TB1-5 TB1-6

Avail able f o r

Customer Use

6

TB6

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

M1

TB6

TB4-4

9

TB10-7

E

CB1-NRU-A

To RGU

Control

Circuitry

TB10-8

TB4-5

CR3

Pilot

CR4

Precharge

Lockout

M1

Main

External M ain

Enable

F

Isolation Board

To RGU

D

From RGU

Control Power

T2 and V2-Code Parallel Configurations 7-7

TB4-8

CB1-NRU

PE

TR1

TR1

TB4-1

Spring

Windup

TB4-2

CR3

TB4-3

TB4-4 TB10-7 TB4-5TB10-8

TB10-1

TB10-3

A12

Wht/Red

D9

Wht

D10

A6

A3

A1

B2

Digitrip

Blk

Blu

Org

Brn

SR

Spring

Release

Resistor When Required
(Not on 120 VAC)

Blk

Y

ARM

b

CB1-NRU-A

UVR

LC

Grn

SC

(Bot)

SC

CB1-NRU-B

CB1-NRU-A

TB10-10

B5

Blk

CB1-NRU-B

TB4-6

CB1-NRU-A

TB4-7

Not

Used

TB10-13

B8

Blk

CB1-NRU-B

TB4-9

CB1-NRU-A

TB10-16

B11

Blk

CB1-NRU-B

Red

Blu

Red

Blu

Red

Blu

Red

Blu

Red

A11

B10

B12

TB10-2

A2

TB10-5

B1

B3

TB10-9

B4

TB10-11

B6

TB10-12

B7

TB10-14

Available For

B9

Customer Use

TB10-15

TB10-17

TB10-18

Publication 2364P-5.01 December 1999

7-8 T2 and V2-Code Parallel Configurations

Figure 7.7
Schematics (cont.)

B

From RGU

AC Line

From RGU

Control

Circuitry

AC
Rtn

R10

F2

R11

F3

F4

R12

CT1

F17
F18
F19

Bridge

Fan

Rs
Ss
Ts

0

6

2

2

1

1

-

-

-

1

1

1

J

J

J

CT3

To

PE

Gnd

J7

P1

1

6

-

-

1

1

J

J

M2

F1

M1

F2

F3

From RGU

E

Control Power

CH1
CH2
CH3

CH11

Isolation
Board

TB5

1

Fault

F

Reset

S11

Enable

2

Fault Reset

3

External Main

4

Common

SW1 Settings

115VAC

OffX

24VDCOn

For TB5-1, -2, -3

Burden Resistors

1

TB1

Publication 2364P-5.01 December 1999

To RGU

Control

Circuitry

To RGU

Control

Circuitry

TB6

1

3

4

6

8

9

Aux Control
Fault

Bus
Control

TB2

TB3

3

1

TB2 Resisto r
Not Required

3

1

3

J2

T2 and V2-Code Parallel Configurations 7-9

e

c

e

a

t

f

a

r

e

G

t

n

I

e

c

e

a

t

f

r

a

e

G

t

n

I

To System Network

C1

G

E1

C1

G

E1

J7

Main Bus

DC-DC

Converter

TP3

-t

J6

Bridge Thermal

Sensor (NTC)

J12

UP

DETAIL

UN

Gate Drivers

TP5

-15V+24V +15V

Shd

(+)

Horizontal

DC Bus

(-)

F1

See U

r

Phase

e

b

b

Detail

u

n
S

VP

See U
Phase
Detail

VN

J8

F1

J2

J4

Blu

1

Shd

Clr

2

TP8TP4TP6

TP9

+12V+5V -12V

RIO Adapter Option

1
2
3

SW1

SW2

SW3

+24V

1203-GM1

R

J1
J8 J9

See U

r

Phase

e

b

b

Detail

u

n
S

WP

See U
Phase

Detail

WN

Gate Driver Board

24V

DC-DC

Converter

Aux 24V

Main Control Bo a rd

Y

YY

Off
On

Off
On

Off
On

J10

r

e

b

b

u

n
S

Cap

Bank

J10

+15V

-15V
+5V
+12V

-12V

J1

J3

J7

2

Power

B
T

Supply

Filter

1

Board

B
T

J11

TB7

P13

TB4

TB1

+

-

PE

TE

2
1

1
2

1
2
3
4
5
6
7
8
9

10

+Bus

-Bus

+

-

- Analog In 1
+ Analog In 1
Analog In 1 Common

- Analog In 2
+ Analog In 2
Analog In 2 Common
Analog Out 1
Analog Out 1 Common
Analog Out 2
Analog Out 2 Common

Horizontal DC Bus

To Inve rter Units

EA2

Bus Indicator Board

EA4

Bus Suppressor

LED1
LED2

PL1

R

DC Bus
Energized

RIO Ext SCANport 1 SCANport 2 R2R Comm

Publication 2364P-5.01 December 1999

7-10 T2 and V2-Code Parallel Configurations

Publication 2364P-5.01 December 1999

Chapter 8

T3 and V3-Code Parallel Configurations

T3-Code Parallel Configuration The T3-code paralle l configuration is a common DC bus front-end

unit consisting of an F-code NRU in paralle l with a M-code RGU.

Figure 8.1
T3-Code Parallel Configuration–Information

T3-code Parallel ConfigurationT3-code Ratings

Input Voltage

(V AC)

380 2575
460
575

DC Bus Current

(A DC)

2575
2575

Rated DC Bus

kW

1321
1599
1994

F-code

NRU

M-code
RGU

V3-Code Parallel Configuration The V3-code parallel configuration is a common DC bus front-end

unit consisting of an G-code NRU in parall el with a M-code RGU.

Figure 8.2
V3-Code Parallel Configuration–Information

V3-code Parallel ConfigurationV3-code Ratings

Input Voltage

(V AC)

380 3000
460
575

DC Bus Current

(A DC)

3000
3000

Rated DC Bus

kW

1539
1863
2329

G-code

NRU

M-code
RGU

Note: Information for the F-code NRU and G-code NRU can be
found in publication 2364E-5.01. Information for the M-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

8-2 T3 and V3-Code Parallel Configurations

Component Layout Figure 8.3

Enclosure Layout

Front View

101.25"

30" 30" 35"

Shipping Split

91.5"

35" 35"

Cutaway View

Customer Supplied

AC Input Lines

Feeder F-code (2500A) or G-code (3000A) NRU

M-code RGU

Publication 2364P-5.01 December 1999

T3 and V3-Code Parallel Configurations 8-3

Figure 8.4
Overhead Bus Assembly

Feeder

Splice Kit

To Feeder Buswork

30" Overhead
Bus Assembly

4" Bus Tabs

Flex Bus

Drop Tabs

To NRU circuit breaker

35" Overhead
Bus Assembly

Joiner-Splice Kits

New and Revised NRU and RGU Components in the T3 and V3 Configurations

NRU CB1 (T1 config) 2500A, SPB-frame with motor operator

(V1 config) 3000A, SPB-frame with motor operator
EA10
F4, F6

PT1
TB10

Control power filter, 2kHz

Primary fuse for 5kVA control transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

Control power transformer, 5kVA

Control terminal block, 30A, 600V

35" Overhead
Bus Assembly

End
Cap

2" Bus Tabs

Flex Bus

Drop Tabs

To RGU circuit breaker

Primary fuse for 10kVA control transformer (Opt 6P)

35A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

Control power transformer, 10kVA (Opt 6P)

RGU

CR4
F4, F6

Precharge Lockout Relay (2NO/2NC)

Primary fuse for 5kVA transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

F21, F22 DC bus fuses, 500A, 700V, 170M

21A, 22A

F25
PT1
TR1

Fuse, NRU CB1 motor operator, 10A, KLDR

Control power transformer, 5kVA

Timer relay (3NO/1NC)
TB4 Control Terminal block, 30A, 600V

Overhead bus assembly

Publication 2364P-5.01 December 1999

8-4 T3 and V3-Code Parallel Configurations

Schematics Figure 8.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

2KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2,3

Choke Comp.

MTR4,5,6

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

T3 and V3-Code Parallel Configurations 8-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

EA6

J2

In15

Sig 1

+5 2

In26

Com 3

J11

S5

Y
R
B

Flow

Sensor

S6

Y
R
B

Flow

Sensor

D5

EA4

Bridge Suppressor

EA2

Bus Indicator PCB

+Bus

-Bus

(X4)

CH11 CH11

(X3)

DC Horizontal Bus To

LED1
LED2

VM1

DC Bus Voltage

Inverter Units

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

(X2)

Publication 2364P-5.01 December 1999

8-6 T3 and V3-Code Parallel Configurations

Figure 8.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

F7

Choke

Thermoguards

S1 - 3

CR4

TR1

EA10

F25

11

TB1

CR4

CR4

2KHZ Control Power Filter

460VAC

(X1)

115VAC

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

12

TB1

CR3

SP4

PE

PT1

(X2)

Bay 1 Door Fan

Bay 1 Internal Fan

RGU Door Fans

Precharge

Precharge

F4

F6

MTR2

MTR3

MTR1

CR2

Fault

PL2

A

Not

Faulted

TR1

Timer

M2

SP1

SP2

SP3

PE

TB1-9

TB1-10

(20 sec)

From

3-phase

AC Input

A

Fault

CR2

TB1-5 TB1-6

Avail able f o r

Customer Use

CB1-RGU

C

To RGU Input

Fuses

6

TB6

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

M1

TB6

TB4-4

9

TB10-7

E

CB1-NRU-A

To RGU

Control

Circuitry

TB10-8

TB4-5

CR3

Pilot

CR4

Precharge

Lockout

M1

Main

External M ain

Enable

F

Isolation Board

To RGU

D

Control Power

From RGU

T3 and V3-Code Parallel Configurations 8-7

TB4-8

CB1-NRU

PE

TR1

TR1

TB4-1

Spring

Windup

TB4-2

CR3

TB4-3

TB4-4 TB10-7 TB4-5TB10-8

TB10-1

TB10-3

A12

Wht/Red

D9

Wht

D10

A6

A3

A1

B2

Digitrip

Blk

Blu

Org

Brn

SR

Spring

Release

Resistor When Required
(Not on 120 VAC)

Blk

Y

ARM

b

CB1-NRU-A

UVR

LC

Grn

SC

(Bot)

SC

CB1-NRU-B

CB1-NRU-A

TB10-10

B5

Blk

CB1-NRU-B

TB4-6

CB1-NRU-A

TB4-7

Not

Used

TB10-13

B8

Blk

CB1-NRU-B

TB4-9

CB1-NRU-A

TB10-16

B11

Blk

CB1-NRU-B

Red

Blu

Red

Blu

Red

Blu

Red

Blu

Red

A11

B10

B12

TB10-2

A2

TB10-5

B1

B3

TB10-9

B4

TB10-11

B6

TB10-12

B7

TB10-14

Available For

B9

Customer Use

TB10-15

TB10-17

TB10-18

Publication 2364P-5.01 December 1999

8-8 T3 and V3-Code Parallel Configurations

Figure 8.7
Schematics (cont.)

B

From RGU

AC Line

From RGU

Control

Circuitry

M2

F1

M1

F2

F3

From RGU

E

Control Power

Fault

F

Reset

CH1
CH2
CH3

S11

F2

F3

F4

AC
Rtn

Isolation
Board

TB5

1

Enable

2

Fault Reset

3

External Main

4

Common

R10, R10A

R11, R11A

R12, R12A

CH

F17
F18
F19

Bridge

Fan

CT1

CT2

Rs
Ss
Ts

0

6

2

2

1

1

-

-

-

1

1

1

J

J

J

SW1 Settings

For TB5-1, -2, -3

CT3

CT Power

Supply

CR

To

PE

Gnd

J7

P1

115VAC

OffX

24VDCOn

Burden Resistors

1

TB1

1

6

-

-

1

1

J

J

Publication 2364P-5.01 December 1999

To RGU

Control

Circuitry

To RGU

Control

Circuitry

TB6

1

3

4

6

8

9

Aux Control
Fault

Bus
Control

TB2

TB3

3

1

3

1

3

J2

T3 and V3-Code Parallel Configurations 8-9

e

c

e

a

t

f

a

r

e

G

t

n

I

e

c

e

a

t

f

r

a

e

G

t

n

I

To System Networ k

C1

DETAIL

G

E1

C1
G

E1

J7

Main Bus

DC-DC

Converter

TP3

-t

J6

Bridge Thermal

Sensor (NTC)

J12

UP1

UP2

C1

G

E1

UN1

UN2

C1

G

E1

Gate Drivers

TP5

(+)

Horizontal

DC Bus

(-)

+

See U

r

Phase

e

b

b

Detail

u

n
S

VP1
VP2

See U
Phase
Detail

VN1
VN2

J8

F1

-15V+24V +15V

J2

J4

Blu

1

Shd

Shd

Clr

2

TP8TP4TP6

TP9

+12V+5V -12V

RIO Adapter Option

1
2
3

SW1

SW2

SW3

+24V

1203-GM1

R

J1
J8 J9

See U

r

Phase

e

b

b

Detail

u

n
S

WP1
WP2

See U
Phase

Detail

WN1
WN2

Gate Driver Board

24V

DC-DC

Converter

Aux 24V

Main Control Bo a rd

Y

YY

Off
On

Off
On

Off
On

J10

r

e

b

b

u

n
S

Cap

+15V

-15V
+5V
+12V

-12V

Bank

J10

J1

J3

J7

2

Power

B
T

Supply

Filter

1

Board

B
T

J11

TB7

P13

TB4

TB1

-

PE

TE

2
1

1
2

1
2
3
4
5
6
7
8
9

10

+Bus

-Bus

+

-

- Analog In 1
+ Analog In 1
Analog In 1 Common

- Analog In 2
+ Analog In 2
Analog In 2 Common
Analog Out 1
Analog Out 1 Common
Analog Out 2
Analog Out 2 Common

Horizontal DC Bus

To Inve rter Units

EA2

Bus Indicator Board

EA4

Bus Suppressor

LED1
LED2

PL1

R

DC Bus
Energized

RIO Ext SCANport 1 SCANport 2 R2R Comm

Publication 2364P-5.01 December 1999

8-10 T3 and V3-Code Parallel Configurations

Publication 2364P-5.01 December 1999

Chapter 9

T4 and V4-Code Parallel Configurations

T4-Code Parallel Configuration The T4-code paralle l configuration is a common DC bus front-end

unit consisting of an F-code NRU in paralle l with a N-code RGU.

Figure 9.1
T4-Code Parallel Configuration–Information

T4-code Parallel ConfigurationT4-code Ratings

Input Voltage

(V AC)

380 2600
460
575

DC Bus Current

(A DC)

2600
2591

Rated DC Bus

kW

1334
1615
2012

F-code

NRU

N-code
RGU

V4-Code Parallel Configuration The V4-code parallel configuration is a common DC bus front-end

unit consisting of an G-code NRU in parall el with a N-code RGU.

Figure 9.2
V4-Code Parallel Configuration–Information

V4-code Parallel ConfigurationV4-code Ratings

Input Voltage

(V AC)

380 3000
460
575

DC Bus Current

(A DC)

3000
3000

Rated DC Bus

kW

1539
1863
2329

G-code

NRU

N-code
RGU

Note: Information for the F-code NRU and G-code NRU can be
found in publication 2364E-5.01. Information for the N-code
RGU can be found in publication 2364F-5.01.

Publication 2364P-5.01 December 1999

9-2 T4 and V4-Code Parallel Configurations

Component Layout Figure 9.3

Enclosure Layout

Front View

101.25"

30" 30" 35"

Shipping Split

20"

91.5"

35" 35"

Cutaway View

Customer Supplied

AC Input Lines

Feeder F-code (2500A) or G-code (3000A) NRU

N-code RGU

Publication 2364P-5.01 December 1999

T4 and V4-Code Parallel Configurations 9-3

20" Overhead

Figure 9.4
Overhead Bus Assembly

Feeder Splice

Assembly

To Feeder Buswork

30" Overhead
Bus Assembly

4" Bus Tabs

Flex Bus

Drop Tabs

To NRU circuit breaker

35" Overhead
Bus Assembly

Bus Assembly

Joiner-Splice

Assemblies

New and Revised NRU and RGU Components in the T4 and V4 Configurations

NRU CB1

EA10
F4, F6

PT1
TB10

(T1 config) 2500A, SPB-frame with motor operator
(V1 config) 3000A, SPB-frame with motor operator

Control power filter, 2kHz
Primary fuse for 5kVA control transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

Control power transformer, 5kVA
Control terminal block, 30A, 600V

Primary fuse for 10kVA control transformer (Opt 6P)

35A, KLDR (for 380V AC input)

30A, KLDR (for 460V AC input)

25A, KLDR (for 575V AC input)

Control power transformer, 10kVA (Opt 6P)

35" Overhead
Bus Assembly

End

Cap

2" Bus Tabs

Flex Bus

Drop Tabs

To RGU circuit breaker

RGU

CR3 Pilot relay (2NO/2NC) with aux contact (1NO/1NC)
CR4
F4, F6

Precharge Lockout Relay (2NO/2NC)
Primary fuse for 5kVA transformer

25A, KLDR (for 380V AC input)

20A, KLDR (for 460V AC input)

17.5A, KLDR (for 575V AC input)

F21, F22 DC bus fuses, 500A, 700V, 170M

21A, 22A

F25
PT1
TR1

Fuse, NRU CB1 motor operator, 10A, KLDR
Control power transformer, 5kVA
Timer relay (3NO/1NC)

TB4 Control Terminal block, 30A, 600V

Overhead bus assembly

Publication 2364P-5.01 December 1999

9-4 T4 and V4-Code Parallel Configurations

Schematics Figure 9.5

Schematics

NRU

TB1-1

Optional
Remote
Interlock

(JMPR)

TB1-2

Airflow Loss

Bridge Bay

1

EA5-CR

CB Bay

Overtemp

SP4

EA3

Line RC
Suppressor

Com

L1

L2

L3

SP1

F14
F15
F16

SP2

PE

SP3

2KHZ Control Power Filter

EA10

F4

F8

F7

(X1)

460VAC

115VAC

PT1

(X2)

MTR1

Rect. Bridge

MTR2,3

Choke Comp.

MTR4,5,6

CB Bay

CR2

Right

Choke

Overtemp

CH11-TG

CR1

Airflow Loss

3

CB Bay

13

EA6-CR

Heatsink

Overtemp

Left

Heatsink

Overtemp

F6

PE

TB1-9

TB1-10

Publication 2364P-5.01 December 1999

S3

Phase Loss

TB1-3

S1

To Ground Fault Detector

B

and Airflow Sensors

CR1

TB1-4 TB1-5 TB1-6

S2

Fault

CR2

Fault

PL2

A

Not

Faulted

1

L

­C
A
V

0

2

1

115VAC

Control Bus To

Inverter Units

N

­C
A
V

0

2

1

T4 and V4-Code Parallel Configurations 9-5

Customer Supplied

3-phase Input

-Bus

Heat
Sink

D1

D3

CT1

F1 F2 F3

M

CB1- NRU

Note:

Control power for this
motorized breaker originates
in the RGU. Do not operate
this breaker manually.

AC Line
Current

AM1

F11

F12

F13

Heat
Sink

D2

D4

A

B

CR

C

+Bus

A

To RGU

AC Input

CR1

Phase

Loss

Relay

B

From NRU

Control Power

B

From NRU

Control Power

7

115VAC

ACN-ACL +

ACG

To Grounding

9

PS1

Resistor

Input

624

TB1-8

TB1-7

1012

Ground Fault

Detector

VM2

J2

3

J2

3

To Cust omer

Monitoring Device

EA5

J2

In15

Sig 1

In26

+5 2

Com 3

J11

EA6

J2

In15

Sig 1

+5 2

In26

Com 3

J11

S5

Y
R
B

Flow

Sensor

S6

Y
R
B

Flow

Sensor

D5

EA4

Bridge Suppressor

EA2

Bus Indicator PCB

+Bus

-Bus

(X4)

CH11 CH11

(X3)

DC Horizontal Bus To

LED1
LED2

VM1

DC Bus Voltage

Inverter Units

D6HS1 HS2

DC Bus
Energized

R

PL1

(X1)

(X2)

Publication 2364P-5.01 December 1999

9-6 T4 and V4-Code Parallel Configurations

Figure 9.6
Schematics (cont.)

RGU

D

To

CB1-NRU

circuitry

TB1-1

Optional

Remote

Interlock

(JMPR)

RGU/DC Bus

Supply

Off On

S12

TB1-2

TR1

F7

Choke

Thermoguards

S1 - 3

CR4

TR1

EA10

F25

11

TB1

CR4

CR4

PE

2KHZ Control Power Filter

460VAC

(X1)

115VAC

F5

RGU Uni t Not

Faulted

14

TB6 TB6

Isolat i on Boa rd

12

TB1

CR3

SP4

(X2)

SP1

SP2

SP3

F4

F6

PT1

MTR6

Bay 1 Door Fan

MTR4,5

Bay 2 Fan

MTR1,2,3

RGU Door Fans

CR2

Fault

PL2

A

Not

Faulted

TR1

Precharge

Timer

M2

Precharge

TB1-9

TB1-10

(20 sec)

PE

From

3-phase

AC Input

A

G

To RGU

Precharge

Circuitry

TB1-5 TB1-6

CB1-RGU

CB2-RGU

Fault

CR2

Avail able for

Customer Use

C

To RGU Input

Fuses

6

TB6

CB1-RGU

TB3-7

CR3

CR3

Publication 2364P-5.01 December 1999

Bus Control

Isolation Board

CR3

CR4

TB3-8

TB3-7

TB3-10

9

TB6

TB4-4

CB1-RGU

TB10-7

E

CB1-NRU-A

UVR

To RGU

Control

Circuitry

TB10-8

TB4-5

TB3-8
TB3-9
TB3-11
TB3-12

CR3

Pilot

CR4

Precharge

Lockout

External Main

Enable

To RGU

F

Isolation Board