Rockwell Automation 9101-1183 User Manual

Page 1
Installation Instructions
200 Watt Passive Shunt Module
(Catalog Number 9101-1183)
Drives can require external power dissipation when large inertial loads are present. To ensure that faults due to excessive bus voltage do not occur, loads requiring power dissipation that exceed the internal shunt capability require the use of external shunt resistor.
Drive Catalog No.
ULTRA 200™ Drives 1398-DDM-010, -010X, -020, -020X, -030, -030x,-075, and
-075X
ULTRA Plus™ Drives 1398-PDM-010, -020, -030, and -075
Ultra3000™ Drives 2098-DSD-030, -030-SE, -030-DN, -030X, -030X-DN, -075,
-075DN, -075X, and -075X-DN
Ultra5000™ Drives 2098-IPD-030, -030-DN, -075, and -075-DN
ATTENTION
Using the passive shunt with modules not listed can cause equipment damage or personal injury.
!
As a motor decelerates, power is returned from the motor to the drive, causing the bus voltage to increase. Ultra servo amplifier products have circuitry that senses the voltage on the DC bus and dissipates power when needed. When the bus voltage reaches the shunt turn-on voltage, the internal shunt circuitry allows the excessive regenerated power to be dissipated through an external resistor. After the bus voltage is reduced to the turn-off voltage level, the shunt transistor turns-off and no additional power is dissipated by the shunt resistor.
1 Publication 2090-IN003A-EN-P — November 2002
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2 200 Watt Passive Shunt Module

Installing the Shunt

Orientation and Clearance

The following enclosure restrictions must be considered because the shunt module dissipates excess regenerative power in the form of heat. Refer to Figure 1 for shunt module spacing requirements.
Figure 1 Shunt Module Spacing Requirements Within an Enclosure
Do not mount temperature sensitive components above shunt module
87 mm (3.4 in.) min. of clearance on
each side of the shunt module.
Do not mount shunt module
on its side
ATTENTION
!
ATTENTION
!
The shunt module can release a large amount of heat over time.
Any materials above the shunt module 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.
Ensure there is enough ventilation so as the maximum ambient temperature of 50° C (122° F) is not exceeded.
Failure to observe this precaution could result in damage to the shunt module.
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200 Watt Passive Shunt Module 3
If the work environment dictates, mount the shunt module in an enclosure providing protection against dust and splashing water (IP54), or dust free and protected against water jets (IP65).
ATTENTION
!
Many NEMA (National Electrical Manufacturers Association) Type 4 cabinets provide this level of protection.
ATTENTION
Avoid contaminating electronic components.
Provide a quality air source to cabinets; free of debris, oil, corrosives, or electrically conductive contaminates. All cabinets should have scheduled inspections and be cleaned as needed.
Failure to observe these safety procedures could result in breakdown and damage to equipment.
If you mount the shunt module inside a cabinet, you must make sure that the ambient temperature inside the cabinet does not exceed 50° C (122° F).
!
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4 200 Watt Passive Shunt Module

200 Watt Continuous Dissipation Cabinet Layout

Figure 2 details the proper position and cable separation for mounting a drive with a shunt module inside a cabinet.
IMPORTANT
Figure 2 Typical Shunt Module Position and Conductor Routing for 200W Continuous Dissipation
Motor power cable AC power cable
Unshielded conductors
Twist conductors
(2 twists per
foot min.)
Shielded metal conduit, and ferrite filters are also recommended for reducing the effects of EMI.
Only one passive shunt module can be used per drive or damage to the drive will result.
87 mm (3.4 in.) minimum clearance on all sides of the shunt module
Always separate low voltage signal wiring from high voltage power wiring to reduce affects of EMI.
Publication 2090-IN003A-EN-P — November 2002
When shielding is used, the shield must be grounded to the shunt and drive as is the motor power cable.
Low voltage communications,
control I/O, and motor feedback cables
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200 Watt Passive Shunt Module 5

Securing the Passive Shunt Module

The following procedure assumes you have prepared your mounting panel. To mount your passive shunt module:
1. Install the top two mounting fasteners on the sub panel for the
shunt module. Refer to Product Specifications on page 7 for mounting hardware specifications.
2. Mount the shunt module on the two fasteners.
3. Install the lower fastener.
4. Tighten all mounting fasteners.

Wiring the Passive Shunt Module to a Drive

ATTENTION
!
90° C (194° F), 600V, 2.5 mm2 (14 AWG) copper wire is supplied with the shunt. The maximum length of the wire should be 914.4 mm (36.0 in.).
Two recommended methods for wiring to reduce EMI noise can be used to connect the passive shunt module with your drive:
Twisted conductors (2 twists per foot minimum) with ferrite filters,
Shield the shunt-to-drive wiring by enclosing in grounded metal
conduit.
DC bus capacitors may retain hazardous voltages after input power has been removed, but will normally discharge in several seconds.
Before working on the drive, measure the DC bus voltage to verify it has reached a safe level or wait a full 5 minutes to ensure that all voltages on the system bus have discharged.
Failure to observe this precaution could result in severe bodily injury or loss of life.
Always keep unshielded wiring as short as possible. When shielding is used, the shield must be grounded to the shunt and drive chassis ground as is the motor power cable.
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6 200 Watt Passive Shunt Module

Connecting to the Shunt Terminal Block

1. Locate the external shunt terminal block (TB2) on your drive.
Figure 3 TB2 Terminal Block and Shunt Connection Schematic
Shunt
Module
TB2
4.5A 600V slow blow
321
25 Ohm
Drive
IMPORTANT
Ensure that power is not applied to the drive.
2. Remove the factory installed internal shunt jumper between
terminals 1 and 2 of TB2.
3. Connect the lead wires to terminals 1 and 3 of TB2. Tighten screws
to 1.25 Nm (11 in.-lbs).
4. Gently pull on each wire to make sure it does not release from its
terminal.
5. Re-insert and tighten any loose wires.
6. Connect the lead wires to the terminal block on the bottom of the
external shunt. Polarity is not important. Tighten screws to 2.25 Nm (20 lb-in.).

Connecting to the Ground Terminal

Publication 2090-IN003A-EN-P — November 2002
1. Locate the ground terminal stud for the shunt module. Refer to
Figure 4 on page 8 location.
2. Connect a system level ground wire to the ground terminal.
Tighten the terminal nut to 2.25 Nm (20 lb-in.).
3. Connect the other end of the ground wire to the system ground
bus.
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200 Watt Passive Shunt Module 7

Product Specifications

Specifications for the passive shunt module are provided in the following tables. Physical measurements are shown in Figure 4 on page 8.
General Specifications Description
Weight net 1.1 kg (2.5 lbs)
Resistance 25
Power rating peak 6000 W
Fuse 4.5 Amp, 600 VDC, slow acting
Environmental Conditions Value
Vibration 2g at 10 to 2000 Hz
Shock 15g 11 msec half sine
Altitude 1500 m (5000 ft)
Humidity 5% to 95% non-condensing
Ambient operating temperature 0° to 50° C (32° to 122° F)
shipping 2.1 kg (4.5 lbs)
± 10%
continuous 200 W
(Littelfuse® CCMR type)
Air flow clearances 87 mm (3.4 in.) on all sides for air flow.
Mounting Hardware Size
Hex cap screws 1/4 in. - 20
Hex cap screws (metric) M6
Wiring Size
2
90°C (194° F), 600V copper wire 2.5 mm
Maximum length 914.4 mm (36.0 in.)
Terminal Block Screws Torque
Chrome plated brass 2.25 Nm (20 lb-in.)
(14 AWG)
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8 200 Watt Passive Shunt Module
218.4 (8.6)
Figure 4 200 Watt Passive Shunt Module Dimensions
77.5
(3.05)
50.8 (2.0)
25.4 (1.0)
12.7
(0.50)
6.3
(0.25)
Note: Cover removed
101.6 (4.75)
Measurements are in millimeters and (inches).
132.0 (5.2)
fuse holder
6-32 terminal nut with spring washer for system level ground
120.6 (4.75)
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200 Watt Passive Shunt Module 9

Related Documentation

The following documents contain additional information concerning related Allen-Bradley® products. To obtain a copy, contact your local Rockwell Automation office or distributor, or access on-line at:
www.theautomationbookstore.com
For information about: Read this document: Publication Number
Other External Shunts
Connecting to an ULTRA 200 drive
Connecting to an ULTRA Plus drive
Connecting to an Ultra5000 drive
Connecting to an Ultra3000 drive
Commissioning and troubleshooting an Ultra3000 drive
A glossary of industrial automation terms and abbreviations
How to minimize and control system-level noise
An overview of Allen-Bradley motion controls and systems.
900 Watt Passive Shunt Module Installation Manual
300 Watt Active Shunt Regulator Installation Manual
2090 Series (460V) Passive Shunts Installation Manual
ULTRA 200 Digital Servo Drives Installation Manual
ULTRA Plus Series Positioning Drive Module Installation Manual
Ultra5000 Intelligent Positioning Drives Installation Manual
Ultra3000 Digital Servo Drives Installation Manual
Ultra3000 Digital Servo Drives Integration Manual
Allen-Bradley Industrial Automation Glossary
System Design for Control of Electrical Noise
Motion Control Selection Guide
or
www.ab.com/manuals/gmc
2090-IN001x-EN-P
2090-IN002x-EN-P
2090-IN004x-EN-P
1398-5.0
1398-5.1
2098-IN001x-EN-P
2098-IN003x-EN-P
2098-IN005x-EN-P
AG-7.1
GMC-RM001x-EN-P
GMC-SG001x-EN-P
.
Publication 2090-IN003A-EN-P — November 2002
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10 200 Watt Passive Shunt Module
Notes
Publication 2090-IN003A-EN-P — November 2002
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200 Watt Passive Shunt Module 11
Publication 2090-IN003A-EN-P — November 2002
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Allen-Bradley is a registered trademark of Rockwell Automation. ULTRA 200, ULTRA Plus, Ultra3000, and Ultra5000 are trademarks of Rockwell Automation. Littlefuse is a registered trademark of Littelfuse, Inc.
Publication 2090-IN003A-EN-P — November 2002 PN 0013-2061-002-01
Supersedes Publication 1398-5.13 — May 1999 © 2002 RockwellAutomation. All rights reserved. Printed in the U.S.A.
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