Rockwell Automation 9101-1183 User Manual

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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.

The passive shunt (Catalog No. 9101-1183, formerly 9101-1079) can be used with the following products:

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

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.

Publication 2090-IN003A-EN-P — November 2002

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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).

Publication 2090-IN003A-EN-P — November 2002

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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)

Ω ± 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

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

Rockwell Automation 9101-1183 User Manual

Installing the Shunt

Orientation and Clearance

Figure 1 Shunt Module Spacing Requirements Within an Enclosure

200 Watt Continuous Dissipation Cabinet Layout

Figure 2 Typical Shunt Module Position and Conductor Routing for 200W Continuous Dissipation

Securing the Passive Shunt Module

Wiring the Passive Shunt Module to a Drive

Connecting to the Shunt Terminal Block

Figure 3 TB2 Terminal Block and Shunt Connection Schematic

Connecting to the Ground Terminal

Product Specifications

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