Rockwell Automation 2090-UCSR-A300 User Manual

Installation Instructions

300 W Active Shunt Regulator

The 300 W Active Shunt Regulator is used in systems that see significant dc voltage regeneration from large inertial load applications. The Allen-Bradley Ultra3000, Ultra5000, and ULTRA 100 drives (see table below) do not have internal shunt circuitry to dissipate excess energy, resulting in overvoltage faults. For the smooth braking of large inertial loads, the use of a shunt regulator is recommen ded.

The active shunt (catalog number 2090-UCSR-A300

or 1398-SR3AF) can be

used with the following drive products.

Drive Family Cat. No.

Ultra3000 Drives Ultra5000 Drives 2098-IPD-005, -005-DN, -010, -010-DN, -020, and -020-DN ULTRA 100 Drives

2098-DSD-005, -005-SE, -005-DN, -010, -010-SE, -010-DN, -020, -020-SE,

-020-DN, -005X, -005X-DN, -010X, -010X-DN , -020X and -020X-DN

1398-DDM-005, -005-DN, -009, -009-DN, -019, -019-DN, -005X, -005X-DN,

-009X, -009X-DN, -01 9 X, and -019X-DN

The active shunt monitors the dc bus voltage of the drive. If the voltage reaches activation level, the shunt drops the dc bus voltage and dissipates the

energy as heat. Figure 1 illustrates the drop in dc bus voltage.

Figure 1 Shunt Activation on DC Bus Voltage

Voltage Drop for 1.0 ms, min

Activation Level

Bus Voltage

Actual Shunt Time

Time

1 Publication 2090-IN002C-EN-P — June 2007

2 300 W Active Shunt Regulator

Performance

The peak shunting capability is a direct result of using a 36 Ω shunt resistor. The peak shunt power can be calculated by dividing bus voltage squared, by

36. For example, if the bus voltage is 380V when the shunt is energized, the shunt power is 4,011 W.

380V

4011 W

36 Ω

Continuous Shunt Capability

A shunt regeneration profile is defined by shunt time, cycle time, and peak power level. Figure 2 illustrates a profile of regeneration during a machine cycle.

• Shunt power is the peak shunt power during the shunt time.

• Shunt time is the time the power pulse is dissipated by the shunt.

• Cycle time is the time from the beginning of one shunt time to the

beginning of the next shunt time.

Figure 2 Shunt Regeneration Profile

Shunt Power

(watts)

Area = Shunt Energy (joule s)

Shunt Time

(seconds)

Cycle Time or

Machine Cycle

Publication 2090-IN002C-EN-P — June 2007

300 W Active Shunt Regulator 3

If the required average shunt power over the machine cycle is ≤ 300 W and t he cycle time is ≤ 300 seconds, the active shunt can handle the application. Figure 3 illustrates the capability of an active shunt at 40 ºC (104 ºF) ambient temperature. The different lines represent different cycle times (rates). The x-axis is the shunt power during the shunt time and the y-axis is the maximum shunt time for that power and cycle time. For example, the bottom line is a 5 second cycle time (meaning the shunt pulse comes every 5 seconds) and it intersects the 800 W pulse for 2 seconds every five seconds in a 40 ºC (104 ºF) or less environment. This means that the shunt can handle an 800 W pulse lasting for two seconds, every 5 seconds if the ambient temperature is not above 40 ºC (104 ºF).

IMPORTANT

The limiting factor on how much average power can be dissipated is temperature. The shunt power capability increases approximately 5.5 W for every

1.0 ºC drop in ambient temperature (3.1 W/ ºF). Increasing the air flow across the heat sink can increase the continuous shunt capability significantly, although obstructing air flow can decrease it significantly.

Figure 3 Active Shunt Module Thermal Capacity

Pulse Time versus Pulse Power

Different Cycle Ti mes for the Active Shunt

Lower left of lines is safe, upper ri ght is unsafe.

Graph assumes 40 ºC (104 ºF) ambient.

Shunt Cycle Times

One-Shot 5 Minute Cycle

2 Minute Cycle

(showing seconds)

30 Second Cycle

Shunt Time (seconds)

5 Second Cycle

Shunt Power (watts)

Publication 2090-IN002C-EN-P — June 2007

4 300 W Active Shunt Regulator

Install the Shunt

Do not mount shunt

module on its side.

Refer to Figure 4 for shunt module spacing requirements.

Figure 4 Shunt Module Spacin g Requirements within an Enclosure

Active Shunt

Adjust

Overtemp

DC Bus

Active

lle

25 mm (1.0 in.) min clearance in

front of the shunt module.

12.5 mm (0.5 in.) min clearance on each side of the shunt module.

50 mm (2.0 in.) min clearance

above the shunt module.

Adjust

y le

Overtemp

DC Bus

Active

e S a

lle

l U

Do not mount temperature sensitive components above the shunt module.

Active Shunt

12.5 mm (0.5 in.) min clearan c e on each side of the shunt module.

ATTENTION

50 mm (2.0 in.) min clearance

below the shunt module.

The shunt module can release a large amount of heat over time.

Any materia ls above the shunt mo dule or its enclosure may need the protection of a metal plate to keep from deteriorating.

Failure to observe this precaution could result in damage to surrounding materials, possibly leading to fire.

The shunt module can release a large amount of heat inside an enclosure.

Be sure there is enough ventilation so as the maximum ambient temperature of 40 °C (104 °F) is not exceeded. Power performance must be decreased 5.5 W for every 1.0 °C (3.1 °F) of increasing ambient temperature.

Publication 2090-IN002C-EN-P — June 2007

Failure to observe this precaution could result in damage to the shunt module.

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