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1 Publication 2090-IN002B-EN-P — February 2006

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

recommended.

The active shunt (catalog number 2090-UCSR-A300

or 1398-SR3AF)

can be used with the following drive products.

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

Drive Family Cat. No.

Ultra3000 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

Ultra5000 Drives 2098-IPD-005, -005-DN, -010, -010-DN, -020, and -020-DN

ULTRA 100 Drives

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

-009X, -009X-DN, -019X, and -019X-DN

Voltage Drop for 1.0 ms, min

Time

Actual Shunt Time

Activation Level

Bus Voltage

Summary of content (12 pages)

PAGE 1
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 recommended.
PAGE 2
300 W Active Shunt Regulator 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. Performance 380V 36 Ω 2 4011 W 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.
PAGE 3
00 W Active Shunt Regulator 3 If the required average shunt power over the machine cycle is ≤300 W and the 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.
PAGE 4
300 W Active Shunt Regulator Install the Shunt Refer to Figure 4 for shunt module spacing requirements. Adjust Do not mount shunt module on its side. Do not mount temperature sensitive components above the shunt module. Overtemp DC Bus Active Active Shunt Figure 4 Shunt Module Spacing Requirements within an Enclosure UltraSeries Allen Bradley 5 mm (2 in.) min clearance above the shunt module. 2.5 mm (1.0 in.) min clearance in front of the shunt module.
PAGE 5
300 W Active Shunt Regulator 5 If the work environment dictates, the shunt module should be in an enclosure providing protection against dust and splashing water (IP54), or dust free and protection against water jets (IP65). 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.
PAGE 6
300 W Active Shunt Regulator Wire the Active Shunt Module to a Drive It is recommended to use shielded, high temperature (75 °C, 600V), 4.0 to 2.5 mm2 (12 to 14 AWG) copper wire, or run the wire through shielded conduit. The maximum length of each wire should be 3.05 m (10 ft) with the shield grounded at both ends. Unshielded wiring should be kept as short as possible. 1. Locate the terminal block on your active shunt. 2.
PAGE 7
300 W Active Shunt Regulator Product Specifications 7 Specifications for the active shunt module are provided in the following tables. Physical measurements are shown in 300 W Active Shunt Regulator Mounting Dimensions on page 8. General Specifications Value Weight 1.51 kg (3.34 lb) Vibration 2 g at 10...2000 Hz Shock 15 g 11 ms half sine Altitude 1500 m (5000 ft) Humidity 5...95% noncondensing Ambient operating temperature (1) 0...40 °C (32...104 °F) Air flow clearances 50 mm (2.0 in.
PAGE 8
300 W Active Shunt Regulator Figure 5 300 W Active Shunt Regulator Mounting Dimensions 65.1 (2.5) 13.21 (0.5) 38.1 (1.5) 18.6 (0.7) 6.35 (0.25) Clearance holes for #10 (M5) screws. 129 (5.0) UltraSeries Allen Bradley Active Shunt Adjust Overtemp DC Bus Active Dimensions are in mm (in.) 186.7 (7.3) 198 (7.8) 97.3 (3.8) 5.6 (0.22) Publication 2090-IN002B-EN-P — February 2006 143 (5.
PAGE 9
300 W Active Shunt Regulator ULTRA 100 Radiated Emissions CE Compliance 9 In order for the ULTRA 100 drive to comply with the CE radiated emissions standards, ferrites must be added to the ends of the twisted dc bus wires when using an active shunt. Route both wires through the ferrites. Ferrites with an impedance at 100 MHz between 100 to 200 Ω were found to be effective. The following table lists some readily available ferrites with effective impedance ratings.
PAGE 10
300 W Active Shunt Regulator Maintain the Active Shunt Figure 7 shows information relating to the adjust screw and the LEDs that show shunt activity. Refer to Troubleshoot on page 11 for more information. Figure 7 Shunt Module Adjustment Screw and LEDs Active Shunt Adjust Overtemp DC Bus Active Adjust (screw) The Adjust screw sets the activation level of the shunt. It is set at the factory and ordinarily will not need adjustment.
PAGE 11
300 W Active Shunt Regulator 11 Troubleshoot Active Shunt If this fault appears Then Overtemp light is on The internal thermostat in the shunt unit is getting too hot. To fix this problem: • reduce the average shunt power, • reduce the ambient temperature of the air around the shunt, or • increase the amount of air passing over the heat-sink fins. Once this LED turns on, only removing power will shut it off; even when the active shunt unit has cooled and is functioning again.
PAGE 12
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