Installation Instructions Regenerative DC Bus Supply Unit (RGU) Upgrade Kit Contents This kit is used to upgrade an M or N frame Regenerative DC Bus Supply Unit (RGU). It is necessary for Master / Slave parallel configurations of these RGUs. It is not necessary for Non-Regenerative DC Bus Supply Unit (NRU) / RGU parallel configurations, however, for compatibility of roll-in modules and spare parts, it is recommended that you have other M or N frame RGUs in your facility. What This Kit Contains LEM (current sensor) Cabinet door Main Control Board Isolator Board Power Supply Power Supply Filter Board Assembly See Component List on page 10 for a complete list of components included in this kit. Safety Precautions The following general precautions apply to RGUs and their respective drive systems:!!!! 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 that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the +DC & DC terminals of the Power Terminal Block. The voltage must be zero. ATTENTION: The system may contain stored energy devices. To avoid the hazard of electrical shock, verify that all voltage on capacitors has been discharged before attempting to service, repair, or remove a drive system or its components. You should only attempt the procedures in this manual if you are qualified to do so and are familiar with solid-state control equipment and the safety procedures in publication NFPA 70E. ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, Guarding Against Electrostatic Damage or other applicable ESD protection handbook.
2 Regenerative DC Bus Supply Unit (RGU) Upgrade Kit What You Need To Do You will make the following changes to the RGU module with this kit: Add a LEM (current sensor) to the S phase leg of the RGU module. Replace the door on the module, which holds the main control board, power supply, gate driver board, and isolation board. The new door has been modified for mounting the power supply and the torroid board assembly. Replace the main control board with a new board, which uses the signal from the third LEM. Add a ferrite core clamp to the ribbon cable which connects the main control board to the gate driver board. Replace the isolation board with a board that handles the burden resistor needed for the third LEM. Add a power supply needed for the third LEM. Add a power supply filter board assembly for the power supply on the gate driver board. Tools That You Need #1 and #2 Phillips screwdrivers 3/16 flat blade screwdriver Adjustable wrench Torque wrench with 75 in-lb (8.5 n-m) capability Wire cutters and strippers Phillips is a registered trademark of Phillips Screw Company Before You Begin Review the list of parts to insure all items are present before starting the upgrade. This upgrade should take approximately 4 hours to complete. Step 1. Adding The Third LEM 1. Turn off and lock out input power. Wait five minutes. L1 L2 L3 I O 2. Disconnect all sources of power to the unit being modified. 3. Check with a voltmeter to verify that the DC bus voltage has dropped below 10Vdc.
Regenerative DC Bus Supply Unit (RGU) Upgrade Kit 3 4. As shown in Figure 1 below, remove the cables connected to the R, S, and T connections on the RGU. Pull the cables away from the bus bar connection studs to allow access to the pan head screws that hold the three-stepped bus bars to the main bus bars which go through the LEMs. 5. Remove the six (6) pan head screws which hold the three-stepped bus bars to the main bus bars which go through the LEMs. Discard the three-stepped bus bars. Figure 1 4. Remove cables from R, S, and T connections 5. Remove six pan head screws 6. Remove the three (3) pan head screws that hold the main bus bars to the red, L-shaped insulator bar at the bottom of the cabinet. 7. Remove the two (2) pan head screws which hold the red, L-shaped insulator bar to the frame and set the screws aside. Please note that when the insulator bar is removed, the main bus bars will drop about 1 inch (25 mm). See Figure 2 below. Figure 2 6. Remove three (3) screws that hold the main bus bars to the red, L-shaped insulator bar 7. Remove two (2) screws that hold the red, L-shaped insulator bar to the frame
4 Regenerative DC Bus Supply Unit (RGU) Upgrade Kit 8. Slide the LEM board assembly onto the S phase (middle) main bus bar of the RGU. 9. Center a new two-stepped bus bar (P/N 192396) on the S phase (middle) main bus bar and attach it using a new hex/phillips combination head screw in the top mounting hole, and an existing pan head screw (removed in step 6 above) in the bottom mounting hole. Tighten to 75 in-lb (8.5 n-m). See Figure 3 below. Figure 3 8. Slide LEM board assembly onto S phase (middle) main bus bar 9. Attach top of S phase, two-stepped bus bar with screw provided 9. Attach bottom of S phase, two-stepped bus bar with existing screw (not shown in photo) 10. Reattach the red, L-shaped insulator bar to the frame using two (2) pan head screws removed in step 7 above. Tighten to 75 in-lb (8.5 n-m). 11. Reattach the main bus bars to the red insulator bar using the three (3) pan head screws removed in step 6 above. Note that the main bus bars may need to be pushed up to allow the screw holes to line up with the screws. Tighten to 75 in-lb (8.5 n-m).
Regenerative DC Bus Supply Unit (RGU) Upgrade Kit 5 12. Attach the new two-stepped bus bars (P/N 192396), one (1) to the R phase main bus bar and one (1) to the T phase main bus bar, using a new hex/phillips combination head screw in the top mounting hole and an existing pan head screw (removed in step 6 above) in the bottom mounting hole. Do NOT tighten the screws. See Figure 4 below. 13. Shift the R phase two-stepped bus bar to the left, shift the T phase two-stepped bus bar to the right, and attach the LEM board assembly plate to the top of the R and T phase two-stepped bus bars, using two (2) of the new hex/phillips combination head screws. Do NOT tighten these two screws. Figure 4 14. Tighten the four (4) R and T phase main bus bar screws to 75 in-lb (8.5 n-m). 15. Slip the clear plastic cover (P/N 192398) over the LEM board assembly and under the two screws which attach it to the R and T phase two-stepped bus bars. Tighten the screws to 75 in-lb (8.5 n-m). See Figure 5. Figure 5 12. Attach top of R and T phase two-stepped bus bars with screws provided - do NOT tighten 12. Attach bottom of R and T phase two-stepped bus bars with existing screws - do NOT tighten (not shown in photo) 13. Attach LEM board assembly to R and T phase two-stepped bus bars with screws provided - do NOT tighten 14. Tighten top screws on R and T phase bus bar to 75 in-lb (8.5 n-m) 14. Tighten bottom screws on R and T phase bus bar to 75 in-lb (8.5 n-m) (not shown in photo) 15. Slip clear plastic cover over LEM board assembly and under therandtphaselem
6 Regenerative DC Bus Supply Unit (RGU) Upgrade Kit Step 2. Replacing the Module Door 1. Unplug or remove all of the connections made between the boards mounted on the module door and the rest of the RGU in order to remove the door assembly from the module. This includes the main control board, gate driver board and the isolator board. Note the connections before removing them so that they can be replaced correctly. 2. Swing the door assembly open to the right and lift up on the door to remove it from the module frame. 3. Carefully unpack the new door from the upgrade kit. Note that the power supply, harness and relay assembly, and isolator board are already attached to the new door. See Figure 6. Figure 6 New door with power supply, harness and relay board 4. Remove the old main control board (P/N 185557) from the old door assembly and discard the board, retaining the insulator sheet and the mounting plate for use with the new main control board. 5. Remove and retain the two burden resistors from the screw terminal blocks located on the right hand side of the old isolator board on the old door assembly. 6. Carefully remove the gate driver board from the old door assembly by turning the slotted plastic screw heads on the plastic standoffs holding the board a quarter turn. Transfer the gate driver board to the new door. The rest of the old door assembly with the old isolator board (P/N 170589) can be discarded. 7. Unpack the new main control board from the kit and install it on the mounting plate saved from step 4 above. Mount this assembly onto the new door.
Regenerative DC Bus Supply Unit (RGU) Upgrade Kit 7 8. The new isolator board requires three burden resistors - two removed from the old isolator board in step 5 above, and a third from the set of four resistors found in a packet with this kit. Match the third new resistor to the two existing resistors: M frame, 460V P/N 173205, 4.02 Ohms M frame, 575V P/N 173206, 4.53 Ohms N frame, 460V P/N 173203, 3.01 Ohms N frame, 575V P/N 173204, 3.40 Ohms 9. Each resistor requires a short piece of tubing on its leads to prevent it from coming in contact with another conductor or other burden resistor. Install tubing (P/N 113246) on the leads of each burden resistor. 10. Place the ferrite clip (P/N 22530-907-01) over the middle of the ribbon cable which connects the main control board to the gate driver board. Plug the ribbon cable into J3 of the two boards. See Figure 7. Figure 7 10. Plug ribbon cable into J3 of the main control board and gate driver board 11. Place the new door onto the module frame. 12. Replace all of the connections made between the boards mounted on the module door and the rest of the RGU.
8 Regenerative DC Bus Supply Unit (RGU) Upgrade Kit 13. Place the cover and standoffs for the cover onto the new isolator board. See Figure 8. The new wire harness has a new connector for the LEM that was added in Step 1 - Adding The Third LEM. It may also need the short harness to supply 120Vac to the power supply. Figure 8 New isolator board mounted to door Step 3. Installing the Power Supply Filter Board and Bracket Assembly 1. Carefully unpack the power supply filter board (P/N 192424) and bracket (P/N 192418) assembly. Using the two (2) screws provided, attach the bracket of this assembly to the new door assembly. See Figure 9 below. 2. Remove the four (4) screws that hold the clear lexan cover (P/N 192425) on the filter board assembly. Remove the lexan cover in order to access the two terminal blocks. See Figure 9 below. Figure 9 1. Attach filter board bracket to the new door assembly 2. Remove clear Lexan cover
Regenerative DC Bus Supply Unit (RGU) Upgrade Kit 9 3. Locate the twisted red/black pair of wires that connect the capacitor bank assembly (located behind the door) to J10 on the gate driver board. Cut the pair of wires at both sides of the label on the wires (close to the middle of the harness). The label on the twisted pair of wires reads 74101-495-54. 4. Strip the cut ends of each wire about ¼ inch (7 mm) and connect them to the terminal blocks as shown in Figure 10 below. The wires from the capacitor bank connect to the bottom terminal block (TB1) on the power supply filter board. TB1-1 is plus (red wire) and TB1-3 is negative (black wire). The wires from J10 connect to the top terminal block (TB2). TB2-1 is plus (red wire) and TB2-3 is negative (black wire). See Figure 10. Figure 10 TB2 4. Connect twisted red and black wires to power supply filter board terminal blocks as shown TB1 5. Replace the clear lexan cover (P/N 192425) to the filter board assembly. Step 4. Ordering a New Data Name Plate Contact the factory with the information from the old Data Name Plate. A new Data Name Plate will be issued. Attach the new Data Name Plate to the bottom of the Module Door.
Component List Following is a complete list of components included in this kit: Item Number Description Qty 192454-9 Drawing - RGU, 3rd LEM kit 1 192454-EB Engineering Bill of Materials 1 192667 Manual - Insert Spare RGU Power Structure 2364F-5.20 1 22530-907-01 Ferrite Core 1 317809 Relay - GP RY42S Min. w/pilot Light 1 139663 Socket Relay - 14 Blade for B type HC Relay, Series B 1 127107 Spring-Clip Relay - Hold-down, type HC & HF32 Relay 1 135127 Resistor - 1.0W, 215 Ohm, MF, 1% 1 173205 Resistor - MF 4.02 Ohm, 1W, 1%, Axial 1 173206 Resistor - 1W, MF, 4.53 Ohm, 0.5% 1 173203 Resistor - 1W, MF, 3.01 Ohm, 0.5% 1 173204 Resistor - MF, 3.40 Ohm, 1W, 0.5% 1 192420 Assembly PCB - RGU Isolation Board 1 192639 Kit, PCB - RGU Main Control 3 LEM w/revision 3.xx firmware 1 157907 DC Power Supply - Dual Output +/-15Vdc, 1.6A, UL 1 25503-011-01 Current Transducer - 1:4000 1500A 1 192424 Assembly - PCB Gate Driver Board Power Supply Filter 1 136019 Standoff - M/F 6m x 13mm long 4 x 0.7m Threaded Aluminum 4 192422 Wire Harness Assembly - Power Supply to LEMS, RGU, G-H Frm, Serb. 1 22112-114-04 Terminal Block -Terminal Block Screw, Clamp 2 pos. 1 192396 Terminal Bus for LEM PCB - 500HP Drive, Bulletin 1336 3 74103-863-02 Panel - Front Door Frame, 800HP Drive, Bulletin 1336 1 192397 Glastic Support for LEM PCB - 500HP Drive, Bulletin 1336 1 192418 Bracket - PCB, Common Mode 1 192398 Lexan Guard for LEM PCB - 500HP Drive, Bulletin 1336 1 192425 Guard, Lexan - PCB DC Bus Torroid 1 192419 Insulator - PCB, Common Mode 1 113246 Tubing - Insulated #16 PVC Clear.053 ID,.016 Wall 6 74101-570-01 Label - Servicing, Bulletin 1336, 60-125HP 1 74101-519-01 Nameplate - 1 x 3 White Thermal Printer 1 74101-511-01 Mylar Insulator 1 22805-031-06 Spacer - Board Support, Nylon 1.00 x 0.156 5 201754 Box - Cardboard, 12 x 9 x 2 with Anti-Static Foam 1 173629 Package Box - Corrugated Kit, 4.5 x 4.13 x 4.88 Systems Drive 1 109842 Screw - Pan Phillips head, 8-32 x.38 SEMS, YEL CHR 4 29164-201-05 Screw - Pan head, Steel, SEMS M4 x 0.7 x 12mm 4 29164-201-06 Screw - Pan head, Steel, SEMS M4 x 0.7 x 24mm 2 419064-1SG Washer - Flat, M4 Steel Per DIN 125A 4 140300 Nut - KEPS M4 x 0.7 4 29164-251-01 Screw - Pan Head, Steel, SMES M5 x 0.8 x 10mm 4 419064-1HJM Screw - Washer Head, M6 x 25mm Grade 4.8+, Zinc 8 22805-057-02 Spacer - Board, 1/4 Turn ML Polysulfone, 0.25 x 0.952 20 www.rockwellautomation.com Power, Control and Information Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication 2364-IN004A-EN-P October, 2005 P/N 192454-9 Copyright 2005 Rockwell Automation. All rights reserved. Printed in USA.