Rockwell Automation 2090-XBxxx User Manual

Installation Instructions

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Resistive Brake Module

Unpacking Your Resistive Brake Module

(Catalog Numbers 2090-XB33-16, 2090-XB33-32,
2090-XB120-01, 2090-XB120-03, and 2090-XB120-06

This publication provides installation instructions for the
Allen-Bradley
instructions for mounting your RBM to the panel and wiring it to a drive
system. For installation and integration instructions specific to a drive
system, refer to Related Documentation on page 24.

Refer to the System Design for Control of Electrical Noise (publication
GMC-RM001x-EN-P) for greater detail on reducing electrical noise
when mounting your RBM.

There are no field replaceable components in an RBM.

Remove all packing material, wedges, and braces from within and
around the components. After unpacking, check the catalog number on
the item(s) nameplate against the purchase order.

Each RBM ships with:

• This installation sheet (publication 2090-IN009x-EN-P).

• One set of connectors for wiring the RBM to a drive:

• TB1 - Drive Connection

• TB2 - Motor Connection

• TB3 - I/O Connection

• TB4 - 230VAC Aux Power Connection (2090-XB120-xx only)

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Bulletin 2090 Resistive Brake Module (RBM). Use these

Note: Power and I/O cables are not provided with the RBM. Refer to

Accessory Equipment on page 23 for catalog numbers of items
available from Rockwell Automation. I/O cables must be
supplied by the user.

ATTENTION

To avoid hazard of electrical shock, perform all
mounting and wiring prior to applying power to the
RBM or the drive system it connects to. Once power
is applied, connector terminals may have voltage
present even when not in use.

Publication 2090-IN009F-EN-P — November 2004

2 Resistive Brake Module Installation Instructions

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Important User Information

Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that each
application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this
guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation,
Allen-Bradley
intellectual property liability) for actual use based upon the examples shown in
this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation
and Maintenance of Solid-State Control (available from your local Allen-Bradley
office), describes some important differences between solid-state equipment
and electromechanical devices that should be taken into consideration when
applying products such as those described in this publication.

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

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

®

does not assume responsibility or liability (to include

ATTENTION

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

IMPORTANT

Identifies information about practices or circumstances
that can lead to personal injury or death, property damage
or economic loss.

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

Publication 2090-IN009F-EN-P — November 2004

Resistive Brake Module Installation Instructions 3

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Understanding Your Resistive Brake Module

The RBM provides an alternative way to brake a drive system. It provides the
control system engineer with the opportunity to design safety controls into a
machine’s drive system that have two key features:

• Physically and electrically separate the drive power output from its

corresponding motor.

• Reduce the stopping time for a motor and its load should a failure occur to

the machine in which it is installed.

Drive commands are the preferred and quickest way to bring a drive system to
a controlled stop. The RBM provides a non-mechanical method for braking a
drive system, by draining motor energy through a resistive load that dissipates
the energy as waste heat.

The RBM can resistively brake a motor once per minute with the following
inertia mismatch:

Resistive Brake Module Inertia Mismatch

2090-XB33-16, 2090-XB33-32

2090-XB120-01, 2090-XB120-03, 2090-XB120-06

Refer to the Motion Control Selection Guide (publication GMC-SG001x-EN-P)
for details on applicable RBM and motor combinations.

15:1 inertia mismatch

A contactor in the RBM physically and electrically separates the motor leads
from the drive output, and provides status outputs to a customer designed
safety circuit. To maximize the stopping speed, braking resistors are sized to
match the motor and load for a specific axis of the drive system. The resistors
are placed across the phases and brake the motor by quickly dissipating the
energy stored there.

ATTENTION

Implementation of safety circuits and risk assessment is the
responsibility of the machine builder. Reference
international standards EN1050 and EN954 estimation and
safety performance categories. For more information refer
to Understanding the Machinery Directive (publication
SHB-900).

Publication 2090-IN009F-EN-P — November 2004

4 Resistive Brake Module Installation Instructions

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System Mounting Requirements

There are several things that you need to take into account when preparing to
mount the Resistive Brake Module:

IMPORTANT

• The panel on which you install your components must be a flat, rigid,

vertical surface that is not subject to shock, vibration, moisture, oil mist,
dust, or corrosive vapors.

• The RBM must be enclosed in a grounded conductive enclosure offering

protection as defined in standard EN 60529 (IEC 529) to IP55 such that it
is not accessible to an operator or unskilled person, in order to comply
with UL
requirements providing protection to IP66.

ATTENTION

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.

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and CE requirements. A NEMA 4X enclosure exceeds these

We recommend that all equipment and components of
a machine or process system have a common earth
ground point connected to their chassis.

A grounded system provides a ground path for short
circuit protection. Grounding your modules and panels
minimizes the shock hazard to personnel and damage
to equipment caused by short circuits, transient
overvoltages, and accidental connection of energized
conductors to the equipment chassis.

Publication 2090-IN009F-EN-P — November 2004

For CE grounding requirements, refer to the
appropriate drive system installation manual listed in
Related Documentation.

• The ambient temperature of the enclosure in which you install the RBM

must not exceed 50° C (122° F).

• You need to maintain minimum clearances (refer to Figure 2 and 3) for

proper airflow, easy module access, and proper cable bend radius.

• The RBM can operate at elevations to 1500 m (5000 ft) without derating,

however, the continuous current rating must be de-rated by 3% for each
additional 300 m (1000 ft) up to 3000 m (10,000 ft). Consult your local
Allen-Bradley representative prior to operating at over 3000 m (10,000 ft).

Refer to Specifications on page 19 for mounting dimensions, power dissipation,
and environmental specifications for the RBM.

Resistive Brake Module Installation Instructions 5

Establishing Noise Zones

The figure below depicts noise zones for routing wiring. All wiring for the
RBM should be routed in a dirty zone. Refer to the appropriate drive system
installation manual listed in Related Documentation.

Figure 1
Noise Zones for Electrical Wiring

Dirty Wireway

Clean Wireway

Brake I/O Cables
230 VAC Power Cables

Resistive Brake Modules

One (1) 2090-XB120-xx
and
Two (2) 2090-XB33-xx

Power Cable
Shield Clamp

Motor Power Cables

Brake I/O Cables

Drive/System Modules

I/O and Feedback Cables

Route Encoder/Analog/Registration

Route 24V dc I/O
Shielded Cable

1 If system I/O cables contain dirty (relay, etc.) wires, route these signals with a separate cable in the dirty wireway.

1

Shielded Cable

Publication 2090-IN009F-EN-P — November 2004

6 Resistive Brake Module Installation Instructions

Dimensions and Clearance Requirements

Mounting dimensions and clearance requirements for the 2090-XB33-xx are
shown in Figures 2 and 3, and for the 2090-XB120-xx in Figures 4 and 6.

IMPORTANT

The RBM must be mounted vertically, as shown, to ensure
proper contactor operation. The vertical mounting
tolerance is ±2°.

Figure 2
2090-XB33-xx Mounting Dimensions

198.6
(7.82)

6.1

(0.24)

205.4
(8.09)

11.7

(0.46)

70.0

(2.76)

226.5
(8.92)

238.3
(9.38)

190.6
(7.50)

Dimensions are in millimeters (inches).

Figure 3
2090-XB33-xx Minimum Clearance Requirements

50 mm (1.97 in.)

clearance for airflow

Clearance left
of RBM is not

required

50 mm (1.97 in.)

clearance for airflow

Clearance right
of RBM is not
required

10.0

(0.40)

20.0

(0.79)

35.0

(1.38)

4.6

(0.18)

Publication 2090-IN009F-EN-P — November 2004

195.0
(7.68)

Resistive Brake Module Installation Instructions 7

Figure 4
2090-XB120-xx Mounting Dimensions

7.8

16.0

(0.31)

(0.63)

110.9
(4.37)

190.3
(7.49)

305.6

(12.03)

10.4

(0.41)

18.05
(0.71)

25.66
(1.01)

55.6

(2.19)

Dimensions are in millimeters (inches).

Figure 5
2090-XB120-xx Minimum Clearance Requirements

50 mm (1.97 in.)

clearance for airflow

328.17
(12.92)

339.8

(13.38)

4.57

(0.18)

Clearance left

of RBM is not

required

Clearance right
of RBM is not
required

50 mm (1.97 in.)

clearance for airflow

Publication 2090-IN009F-EN-P — November 2004

8 Resistive Brake Module Installation Instructions

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Installing Your Resistive Brake Module

These procedures assume you have prepared your panel and understand how
to bond the groundplane of your system.

ATTENTION

Refer to the System Design for Control of Electrical Noise Reference Manual
(publication GMC-RM001x-EN-P) for HF bonding techniques.

The RBM contains ESD (Electrostatic Discharge) sensitive
parts and assemblies. You are required to follow static
control precautions when you install, test, service, or repair
this assembly. If you do not follow ESD control
procedures, components can be damaged. If you are not
familiar with static control procedures, refer to
Allen-Bradley publication 8000-4.5.2, Guarding Against
Electrostatic Damage or any other applicable ESD Protection
Handbook.

Attaching Your Resistive Brake Module to the Panel

To mount your RBM:

1. Layout the position for your RBM in the enclosure.

IMPORTANT

Refer to the mounting dimensions and clearance requirements for each
type of RBM as listed below.

Dimensions for:

Mounting Figure 2 on page 6 Figure 4 on page 7

Clearance Figure 3 on page 6 Figure 5 on page 7

2. Attach the RBM to the cabinet. The recommended mounting hardware is
two M6 (1/4 in. - 20) bolts. A key-hole tab is at the top of the unit, and a
slotted mounting tab is at the bottom of the unit.

To improve EMC performance, mount the RBM on
the same panel as the drive system, and as close to the
drive as possible.

Typically the RBM should be positioned immediately
above the module it supports. Refer to Related
Documentation on page 24 for mounting instructions
and restrictions specific to a drive system, and
information on use with safety relays.

2090-XB33-xx 2090-XB120-xx

Publication 2090-IN009F-EN-P — November 2004