Rockwell Automation 2090-SRxxx User Manual

Installation Instructions

External Shunt Modules

Catalog Numbers
1394-SR9A, 1394-SR9AF, 1394-SR36A, 1394-SR36AF,
2090-SR120-09, 2090-SR040-09, 2090-SR040-18

Topic Page

About the External Shunt Modules 1
Important User Information 2
Catalog Number Explanation 3
Before You Begin 3
Install the External Shunt Module 13
Replace the Shunt Module Fuse 20
External Shunt Module Specifications 21
Additional Resources 22

About the External Shunt Modules

These externally-mounted passive shunt modules provide a means for
servo drives to dissipate excess regenerative energy from the DC bus.
This is needed when system loads require power dissipation beyond
the capability of the shunt resistor internal to the servo drive. These
are passive shunt resistors and require transistor activation by the
servo drive.

A properly-sized shunt module regulates excessive bus voltage by
passing current through a resistor, which dissipates the current as heat
and minimizes drive faults caused by excess bus voltage.

Shunt Module Compatibility

Shunt Cat. No. Drive Cat. No.

2090-SR120-09 2098-xxx-HV030 and 2098-xxx-HV050
2090-SR040-09 2098-xxx-HV100
2090-SR040-18 2098-xxx-HV100
1394-SR9A
1394-SR9AF
1394-SR36A
1394-SR36AF

(1)

The 2094-BSP2 shunt module is mounted on the Bulletin 2094 power rail and
provides connections to an external shunt module.

2094-BSP2
1394x-SJT22-x

(1)

and

2 External Shunt Modules

WARNING

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Important User Information

Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation and
Maintenance of Solid State Controls (publication SGI-1.1
Automation sales office or online at http://literature.rockwellautomation.com
some important differences between solid state equipment and hard-wired
electromechanical devices. Because of this difference, and also because of the wide variety
of uses for solid state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is acceptable.

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

The examples and diagrams in this manual are included solely for illustrative purposes.
Because of the many variables and requirements associated with any particular installation,
Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on
the examples and diagrams.

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

Reproduction of the contents of this manual, in whole or in part, without written permission
of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety
considerations.

available from your local Rockwell

) describes

Identifies information about practices or circumstances that can cause
an explosion in a hazardous environment, which may lead to personal
injury or death, property damage, or economic loss.

Identifies information that is critical for successful application and
understanding of the product.

Identifies information about practices or circumstances that can lead
to personal injury or death, property damage, or economic loss.
Attentions help you to identify a hazard, avoid a hazard, and recognize
the consequences.

Labels may be on or inside the equipment, for example, a drive or
motor, to alert people that dangerous voltage may be present.

Labels may be on or inside the equipment, for example, a drive or
motor, to alert people that surfaces may reach dangerous
temperatures.

Publication 2090-IN004B-EN-P — June 2008

External Shunt Modules 3

1394 - SR xxxx

Bulletin Number

SR = Shunt Resistor

kW Rating

9A = 300 W continuous, 4 Ω , no fan
9AF = 900 W continuous, 4 Ω , no fan
36A = 1800 W continuous, 4 Ω , no fan
36AF = 3600 W continuous, 4 Ω , fan-cooled, thermal switch

2090 - SR

xxx - xx

Bulletin Number

Resistance Rating

120 = 120 Ω
040 = 40 Ω

SR = Shunt Resistor

Continuous Power Rating

09 = 900 W continuous, no fan
18 = 1800 W continuous, no fan

Catalog Number Explanation

Catalog numbers consist of various characters, each of which
identifies a specific version or option for that component. Use the
catalog numbering charts below to understand the configuration of
your shunt module.

Bulletin 1394 External Shunt Modules

Bulletin 2090 External Shunt Modules

Before You Begin

Before you begin mounting your shunt module, make sure you:

• have the required tools and materials.

• understand the mounting requirements.

• understand high-frequency bonding.

• know how to establish noise zones.

Required Tools and Materials

These tools and materials are required to complete the installation of
an external shunt module:

• Screwdrivers

• User-supplied power wiring

• Mounting fasteners

Publication 2090-IN004B-EN-P — June 2008

4 External Shunt Modules

ATTENTION

Mounting Requirements

Plan the installation of your system so that you can perform all cutting,
drilling, tapping, and welding with the system removed from the
enclosure. Because the system is of the open type construction, be
careful to keep any metal debris from falling into it. Metal debris or
other foreign matter can become lodged in the circuitry, which can
result in damage to components.

These requirements apply when preparing to mount your shunt
module:

• Mo

unt the shunt in an enclosure providing protection against
dust and splashing water (IP54), or dust free and protected
against water jets (IP65).

Many NEMA (National Electrical Manufacturers Association)

ype 4 cabinets provide this level of protection.

T

• Install

the panel for mounting your system components inside
the enclosure on a flat, rigid, vertical surface that won’t be
subjected to shock, vibration, moisture, oil mist, dust, or
corrosive vapors.

Refer to

Environmental Specifications on page 21 for specific

recommendations.

• Maintain minimum clearances for proper airflow, easy module

access, and proper bend radius for the cables as shown in the
figures beginning on page 5

.

• Use high-frequency (HF) bonding techniques to connect the

module, enclosure, machine frame, and motor housing, and to
provide a low-impedance return path for high-frequency (HF)
energy and reduce electrical noise.

Refer to HF Bonding Your Shunt Module, on page 6, for more
information.

Publication 2090-IN004B-EN-P — June 2008

• Se

gregate DC-bus wiring from control wiring and motor
feedback cables. Do not run shunt wiring in wireways. Use
twisted pair cable from the drive to external shunt module.

Refer to

Establishing Noise Zones, beginning on page 6, for

specific recommendations.

IMPORTANT

Mount the shunt module in an upright position. Do not mount the

150 mm (6.0 in.) clearance

for airflow and installation.

150 mm (6.0 in.) clearance

for airflow and installation.

150 mm (6.0 in.) clearance
for airflow and installation.

150 mm (6.0 in.) clearance

for airflow and installation.

Enclosure

Bulletin 1394 and 2090
External Shunt Modules
(1394-SR9Ax module is
shown in this example.)

BURN HAZARD

ATTENTION

shunt module on its side.

Minimum Clearance Requirements (within an enclosure)

Shunt Module

ALLEN-BRADLEY

R

BULLETIN 1394 300W SHUNT MODULE
CAT. PART SER.
INPUT DC INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

External Shunt Modules 5

The shunt resistors can reach temperatures in excess of 350 °C
(662 °F). Do not handle a shunt module that has been operational until
it has cooled sufficiently.

Combustible materials above the shunt module or its enclosure may
need the protection of a metal plate to shield them from the heat.

Failure to observe these precautions could result in damage to
surrounding materials, possibly leading to a fire or personal injury.

The shunt resistors release large amounts of heat. When mounted
inside an enclosure, you must provide adequate ventilation so the
maximum ambient temperature of 50 °C (122 °F) is not exceeded.
Failure to observe this precaution could result in damage to the
module.

Publication 2090-IN004B-EN-P — June 2008

6 External Shunt Modules

1394 Digital Servo Controller

3600W Shunt Module

BULLETIN 1394 3600W SHUNT MODULE

ALLEN-BRADLEY

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

CAT. PART SER.
INPUT DC INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.

R

150 mm (6.0 in.) clearance
for airflow and installation.

150 mm (6.0 in.) clearance

for airflow and installation.

150 mm (6.0 in.) clearance

for airflow and installation.

254 mm (10.0 in.) clearance
for airflow and installation.

Bulletin 1394 and 2090
External Shunt Modules
(1394-SR36Ax module is
shown in this example.)

IMPORTANT

Minimum Clearance Requirements (outside the enclosure)

HF Bonding Your Shunt Module

Bonding is the practice of connecting metal chassis, assemblies,
frames, shields, and enclosures to reduce the effects of
electromagnetic interference (EMI). For more information on the
concept of high-frequency (HF) bonding, the ground plane principle,
and electrical noise reduction, refer to System Design for Control of
Electrical Noise Reference Manual, publication

To improve the bond between the drive system and subpanel,
construct your subpanel out of zinc plated (paint-free) steel.

GMC-RM001.

Establishing Noise Zones

This table provides the zoning requirements of cables connecting to
the external shunt module.

Zone Method

Wire/Cable

COL, DC+ (shielded option) X X
COL, DC+ (unshielded option) X
Thermal switch X X
Fan (if present) X

Very
Dirty

Dirty Clean

Ferrite
Sleeve

Shielded

Cable

Publication 2090-IN004B-EN-P — June 2008

External Shunt Modules 7

C

D

D

D

D

D

VD

C

VD

D

1394 Digital Servo Controller

300W Shunt Module

BULLETIN 1394 300W SHUNT MODULE

ALLEN-BRADLEY

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

CAT. PART SER.

INPUT DC INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.

R

(1)

Line Interface Module

Kinetix 6000
Drive System

Dirty Wireway

Clean Wireway

Motor Power Cables

Very Dirty Connections Segregated

(not in wireway)

Customer-supplied

Metal Enclosure

150 mm (6.0 in.)

clearance, min on all four

sides of the shunt module.

Enclosure

2094-BSP2
Shunt Module

Shunt DC-bus Wiring Methods:

Twisted pair in conduit (1st choice).

Shielded twisted pair (2nd choice).

Twisted pair, two twists per foot, min (3rd choice).

Metal Conduit
(where required
by local code)

I/O and Feedback Cables

Shunt Thermal Switch and Fan Wires (when present)

No sensitive

equipment within

150 mm (6.0 in.).

Route 24V DC I/O
shielded cable.

Route encoder/analog/registration

shielded cables.

Noise Zones for Kinetix 6000 Drives

Observe these guidelines when mounting your external shunt module
outside the enclosure:

• Mount circuit components and wiring in the very dirty zone or

in an externally shielded enclosure. Run shunt DC-bus and fan
wiring inside metal conduit to minimize the effects of EMI and
RFI.

• Mount resistors (other than metal-clad) in a shielded and

ventilated enclosure outside the cabinet.

• Keep unshielded wiring as short as possible. Keep shunt DC-bus

wiring as flat to the cabinet as possible.

• Route thermal switch and fan wires separate from shunt DC-bus.

External Shunt Module Mounted Outside the Enclosure

Publication 2090-IN004B-EN-P — June 2008

8 External Shunt Modules

C

D

D

D

D

D

VD

C

VD

1394 Digital Servo Controller

300W Shunt Module

BULLETIN 1394 300W SHUNT MODULE

ALLEN-BRADLEY

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

CAT. PART SER.
INPUT DC INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.

R

D

Line Interface Module

Kinetix 6000
Drive System

Dirty Wireway

Clean Wireway

Motor Power Cables

Enclosure

2094-BSP2
Shunt Module

I/O and Feedback Cables

150 mm (6.0 in.)

clearance, min on all four

sides of the shunt module.

Shunt Thermal Switch and Fan Wires (when present)

Very Dirty Connections Segregated

(not in wireway)

Shunt DC-bus Wiring Methods:

Twisted pair in conduit (1st choice).
Shielded twisted pair (2nd choice).
Twisted pair, two twists per foot, min (3rd choice).

No sensitive

equipment within

150 mm (6.0 in.).

Route 24V DC I/O
shielded cable.

Route encoder/analog/registration

shielded cables.

When mounting your shunt module inside the enclosure, follow these
additional guidelines:

• Metal-clad modules can be mounted anywhere in the dirty zone,

but as close to the Kinetix 6000 system as possible.

• Shunt DC-bus wires can be run with motor power cables.

• Keep unshielded wiring as short as possible. Keep shunt wiring

as flat to the cabinet as possible.

• Separate shunt DC-bus cables from other sensitive, low voltage

signal cables.

External Shunt Module Mounted Inside the Enclosure

Publication 2090-IN004B-EN-P — June 2008