Installation Instructions External Shunt Modules Catalog Numbers 1394-SR9A, 1394-SR9AF, 1394-SR36A, 1394-SR36AF, 2090-SR120-09, 2090-SR040-09, 2090-SR040-18 Topic Page About the External Shunt Modules 1 Important User Information 2 Catalog Number Explanation 3 Before You Begin 3 Mounting Requirements 4 Install the External Shunt Module 7 Replace the Shunt Module Fuse 14 External Shunt Module Specifications 15 Additional Resources 16 About the External Shunt Modules These externally-mounted passive shunt modules provide a means for servo drives to dissipate excess regenerative energy from the DC bus. This is needed when system loads require power dissipation beyond the capability of the shunt resistor internal to the servo drive. These are passive shunt resistors and require transistor activation by the servo drive. A properly-sized shunt module regulates excessive bus voltage by passing current through a resistor that dissipates the current as heat and minimizes drive faults. 2 External Shunt Modules Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards. Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited. Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Labels may also be on or inside the equipment to provide specific precautions. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Rockwell Automation Publication 2090-IN004C-EN-P - May 2014 External Shunt Modules 3 Catalog Number Explanation Catalog numbers consist of various characters, each of which identifies a specific version or option for that component. Use the catalog numbering charts below to understand the configuration of your shunt module. Table 1 - Bulletin 1394 External Shunt Modules 1394 - SR xxxx kW Rating 9A = 300 W continuous, 4 Ω, no fan 9AF = 900 W continuous, 4 Ω, no fan 36A = 1800 W continuous, 4 Ω, no fan 36AF = 3600 W continuous, 4 Ω, fan-cooled, thermal switch SR = Shunt Resistor Bulletin Number Table 2 - Bulletin 2090 External Shunt Modules 2090 - SR xxx - xx Continuous Power Rating 09 = 900 W continuous, no fan 18 = 1800 W continuous, no fan Resistance Rating 120 = 120 Ω 040 = 40 Ω SR = Shunt Resistor Bulletin Number Before You Begin Before mounting your shunt module, make sure you do the following: • Have the required tools and materials • Understand the mounting requirements • Understand high-frequency bonding • Know how to establish noise zones For more information on high-frequency bonding and routing of cables within established noise zones, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001. For the user manual with information specific to your servo drive family, refer to Additional Resources on page 16. Rockwell Automation Publication 2090-IN004C-EN-P - May 2014 4 External Shunt Modules Required Tools and Materials These tools and materials are required to complete the installation of an external shunt module: • Screwdrivers • User-supplied power wiring • Mounting fasteners Mounting Requirements 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 and result in damage to components. These requirements apply when preparing to mount your shunt module: • Mount the shunt in an enclosure providing protection against dust and splashing water (IP54), or dust free and protected against water jets (IP65). Many NEMA (National Electrical Manufacturers Association) Type 4 cabinets provide this level of protection. • Install the panel for mounting your system components inside the enclosure on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors. Refer to Environmental Specifications on page 15 for specific recommendations. • Maintain minimum clearances for proper airflow, easy module access, and proper bend radius for the cables as shown in the figures beginning on page 5. • Use high-frequency (HF) bonding techniques to connect the module, enclosure, machine frame, and motor housing, and to provide a low-impedance return path for high-frequency (HF) energy and reduce electrical noise. Refer to HF Bonding Your Shunt Module, on page 6, for more information. • Segregate DC-bus wiring from control wiring and motor feedback cables. Do not run shunt wiring in wireways. Use twisted pair cable from the drive to external shunt module. Refer to Cable Noise Zone Categories, beginning on page 6, for specific recommendations. IMPORTANT Mount the shunt module in an upright position. Do not mount the shunt module on its side. Rockwell Automation Publication 2090-IN004C-EN-P - May 2014 External Shunt Modules 5 Figure 1 - Minimum Clearance Requirements (within an enclosure) 150 mm (6.0 in.) clearance for airflow and installation. 150 mm (6.0 in.) clearance for Shunt Module 150 mm (6.0 in.) clearance for airflow and installation. airflow and installation. ALLEN-BRADLEY BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO. FOR USE WITH 1394-SJT22-X SYSTEM MODULE Bulletin 1394 and 2090 External Shunt Modules Enclosure 150 mm (6.0 in.) clearance for (1394-SR9Ax module is airflow and installation. shown in this example.) BURN HAZARD: The shunt resistors can reach temperatures in excess of 350 °C (662 °F). Do not handle a shunt module that has been operational until it has cooled sufficiently. Shield combustible materials above the shunt module or its enclosure with a metal plate to protect them from the heat. Failure to observe these precautions could result in damage to surrounding materials, possibly leading to a fire or personal injury. ATTENTION: The shunt resistors release large amounts of heat. When mounted inside an enclosure, you must provide adequate ventilation so the maximum ambient temperature of 50 °C (122 °F) is not exceeded. Failure to observe this precaution could result in damage to the module. Rockwell Automation Publication 2090-IN004C-EN-P - May 2014 6 External Shunt Modules Figure 2 - Minimum Clearance Requirements (outside the enclosure) 254 mm (10.0 in.) clearance for airflow and installation. 1394 Digital Servo Controller 3600W Shunt Module 150 mm (6.0 in.) clearance for 150 mm (6.0 in.) clearance for airflow and installation. airflow and installation. ALLEN-BRADLEY BULLETIN 1394 3600W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO. FOR USE WITH 1394-SJT22-X SYSTEM MODULE Bulletin 1394 and 2090 External Shunt Modules 150 mm (6.0 in.) clearance for (1394-SR36Ax module is airflow and installation. shown in this example.) HF Bonding Your Shunt Module Bonding is the practice of connecting metal chassis, assemblies, frames, shields, and enclosures to reduce the effects of electromagnetic interference (EMI). For more information on the concept