Rockwell Automation Reliance Electric SR3000 User manual

$R3000 Snubber Resistor Braking Kits
for 230 V and 460 V GV3000/SE Drives
230 VAC Model Number 2SR20450
460 VAC Model Number 28R40700
Instruction Manual D2- 3401
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ATTENTION: Only qualified electrical personnel familiar with the construction and
operation of this equipment and the hazards involved should install, adjust, operate,
and/or service this equipment. Read and understand this manual and other .
applicable manuals in their entirety before proceeding. Failure to observe this
precaution could result in severe bodily injury orloss of life.
The products described in this manual are manufactured or distributed by Reliance Electric Industrial
Company.
Product Description
The SR3000 Snubber Resistor Braking Unit connects to 230 V GV3000/SE drives of 15 HP or largerand
460 V GV3000/SE drives. It is used to dissipate the power regenerated by the motor during rapid
deceleration or during overhauling load conditions.
The regenerated energy is normally consumed, as shown in figure 1, by mechanical loss, by themotor,
and by the drive. The remaining energy is stored in the drive's DC bus capacitor. If the remaining energy
causes the capacitor voltage to rise above the normal operating range, the Braking Unit will discharge the
regenerated energy before the drive voltage becomes excessive. Two units can be connected (paralleled)
io provide increased wait dissipation.
Wo ee ee eee eee py Discharge of
Energy \,| Regenerated
Regenerated Energy at
by the Motor ,’ |SR3000 Series
roe 1 Braking Unit
wn “F; xT - v7 , x7 Vv
x “ Sy s ° os A *s “
ConsumptionConsumption Consumption Storage in
by Mechanical in the Motor by the Drive Capacitor of
Loss liself (approx. itself the Drive
10 to 15% of
Output}
GV3000/SE and Reliance are trademarks of Rockwell Automation.
© 1997 Rockwell International Corporation.
Figure 1 - Dissipation of Energy Regenerated by the Motor
@&® Rockwell automation
Reliance Electric

Overload protection of the snubber resistor is provided via the terminal strip I/O on the faceplate for
connection to a user-supplied protection circuit and by the status LEDs. If an overload fault occurs, the
Braking Unit will shut down. Figure 2 shows the faceplate of the Braking Unitwith the terminal strip cover
removed. Refer to table 1 for a description of the LEDs.
O O
® ®
SRASOoO —
BUS~ SNURBEA
Selector Switch
a See table 2.
Display Lamps
See table 1,
Main Terminal Block
See table 3.
Connector
Control Terminal Block
See table 4.
Ground Terminal
Front Cover Removed
Figure 2 - Front Panel of the SR3000 Snubber Resistor Braking Unit
Table 1- LED Descriptions
LED Description
P/S The P/S LED will turn on when DC bus voltage of the drive is charged and DC power is supplied to
the Braking Unit.
SNB The SNB LED will turn on to indicate that regenerated power is being discharged.
FLT TheFLT LED will turn on if the overload condition on the Braking Unit occurs.
ALM The ALM LED will turn on at approximately 80% of the Braking Unit overload detection level.

Installing the Snubber Resistor Braking Unit
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait five (5) minutes for the DC bus
capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus
capacitors are discharged before touching any internal components. Failure to observe
this precaution could result in severe bodily injury or loss of life.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Installing the Braking Unit consists of the following steps:
Mounting the Braking Unit
e Selecting an external resistor, if required
@ Installing an external resistor, if required
e@ Setting the snubber resistor overload detection level
e Wiring the Braking Unit
Mounting the Braking Unit
Refer to the dimensions in figure 3 and use the following guidelines when mounting the Braking Unit:
e Leave a minimum of 50 mm (2 in} clearance between the Braking Unit and the drive.
@ Leave a minimum of 80 mm (3.1 in) clearance above and below the Braking Unit.
e if two Braking Units are installed in parallel, leave a minimum of 50 mm (2 in) clearance between each
unit.
e Do not install the Braking Unit under the drive.
Grounding the Braking Unit
Use the following steps to ground the Braking Unit:
@ Remove the front cover from the front panel.
e Runa suitable equipment grounding conductor unbroken from the Braking Unit ground terminal to the
earth ground. See figure 2 for the location of the Braking Unit ground terminal.
@ Re-attach the front cover.

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All dimensions shown in mm in.}
Bottom View
Figure 3 - Model 2SR20450 and Model 25R40700 Braking Unit Mounting Dimensions
Selecting an External Resistor, If Required
ATTENTION: When an external resistor is installed, first disconnect the power to the drive
and wait five (5) minutes for the DC bus capacitors to discharge. Then check thevoltage with
a voltmeter to ensure the DC bus capacitors are discharged before touching any internal
components. Failure to observe this precaution could result in severe bodily injury or loss of
life.
if it is possible for the drive to regenerate more energy than the Braking Unit's built-in resistor can dissipate
(The internal energy dissipation capability of Model 2SR20450 is 450 W and that of 2SR40700 is 700 W),
you must install an external resistor. The SR3000 Braking Unit can continuously dissipate the regenerated
energy shown in table 2 by adding an external resistor. When two Braking Units are installed in parallel (to
increase watt dissipation), install external resistors having the same capacity in both units. In this case,
thewatt dissipation value shown in table 2 must be doubled.
Use the following procedure to select a resistor:
Step 1. Calculate the regenerated power P,,, from the load and pattern of operation.
Step 2. Obtain thewatt dissipation of the resistor Pg, deducting 15% of rated output of the motor (as the
consumption by the machine or the motor) from the P.,,. value calculated in step 1 above.
Step 3 Select the resistor watt dissipation P, as follows in consideration of heat generated by the
resistor.
P,[W] = 3to4 x Py

An example of calculating the regenerated power in the case of repeated operation underinertial toad is
shown as "R" in figure 4 and its average power P,,, is calculated as follows:
Pave [WW] = 1/2 x Py x tT
where t (regeneration time} should be less than or equal to 0.5 seconds for the built-in resistor.
Speed
Time
Figure 4 - An Exarnple of Repeated Operation Under Inertial Load -
installing the External Resistor, if Required
To install the selected external resistor, first remove the jumper between terminals +(P) and RB1. Install
the external resistor between terminals +(P} and RB2. See figure 5, 6, 7 or 8. Refer to table 3 and 4 fora
description of the terminal strip connections. Note that the internalresistor is not used if the external
resistor option is selected.
The cabie length for connecting the external resistor should not exceed 5 m (16.4 feet).
Setting the Snubber Resistor Overload Detection Level
The W/S switch on the faceplate is used to select the maximum watt dissipation level of the selected
resistor (built-in or external). Set the switch to match the dissipation capacity P, of the resistor. If the
resistor rating falls in between theswitch setting levels, select the lower of the two settings. If you are
connecting two units in parallel, both units must be set to the same switch setting. Table 2 shows the
overload detection level settings. For assistance in calculating the appropriate resistor value, refer to
Selecting a Resisior.
Table2 - W/S Switch Settings for Braking Unit Overload Detection Level
Resistor Used W/S Switch Waitt Dissipation 7 Minimum Ohm Rating Maximum Ohm Rating
Setting 2SR20450 2SR40700 2SR20450 2SR40700 2SR20450 28R40700
1 500 800 3.9 7.5 33 60
2 550900 3.9 7.5 33 60
3 600 1000 3.9 7.5 33 60
External Resistor 4 1400 2500 3.97.5 33 60
5 1600 3000 3.97.5 22 30
6 4000 7500 3.97.5 11 15
7 8000 15000 3.9 - 7.5 5 10
Built-in Resistor 07 450 700 N/AN/AN/AN/A
1 Factory-default setting.
2 Watt dissipation of the external resistor shows the value set as calculated in Selecting a Resistor.

Wiringthe Braking Unit
When only one Braking Unit is installed, install wiring between the drive and the Braking Unit according to
figure 5 for 230 V GV3000/SE drives or figure 7 for 460 V GV3000/SE drives.
If two Braking Units are paralleled, install wiring according to figure 6 for 230 V GV3000/SE drives or figure
8 for 460 V GV3000/SE drives.
The recommended wire size for the connection between the drive and the Braking Unit is 8 mm? (AWG 8),
and the cable length should not exceed 2 m (6.5 feet).
A user-supplied interlocking circuit consisting of two relays and a pushbutton should be provided as shown
in the following wiring diagrams.
When external resistors are used, be sure to install a Resistor Overheat Protection Kit for each braking
unitat the largest heat generating portion to protect the resistor from burning. For wiring thermostat of this
kit, use 200°C (392°F) /600 V UL wire. {Keep the wiring away from the resistor as far as possible.) Table
5 lists recommended bus line fuses.
All input/output connections to the Braking Unit are made at the terminal strip. Remove the front cover and
route the cable through the hole at the bottom of the cover. Connect to the terminal strip as described in
table 3 and table 4. Tighten theterminals fo 1.2 N-m (11 lb-in}. Replace the cover after all of the terminal
strip connections have been made. Do not touch the terminals while the Braking Unit is connected io a
live DC bus.
ATTENTION: Connect 2SR20450 to 230 V GV3000/SE drive and 2SR40700 to 460 V
GV3000/SE drive. Connecting 25R20450 to 460 V GV3000/SE drive and connecting
28R40700 to 230 V GV3000/SE drive could result in damage to, or destruction of, the Braking
Units.
When and How to Connect Parallel Units
To connect two Braking Units in parallel, connect the CN1 connectors of the both Braking Units with the
CN1-Cable MC-B6004 (see table 8) which is available as an optional item. See figures 6 and 8 and
table 8.
Connecting 2SR20450 to 230 V GV3000 drive
it is recommended to use one 2SR20450 Braking Unit for 15 HP to 40 HP drives, and to connect two
Braking Units in parallel for 50 HP, 60 HP and 75 HP drives. A single SR3000 Braking Unit has an
instantaneous handling capacity up to 40 kW and a continuous handling capacity up to 8 kW.
For drives larger than 40 HP, a single Braking Unit can be used by connecting an external resistor, if no
rapid deceleration of the motor is expected. But if rapid deceleration is a consideration, it is recommended
that the parallel Braking Units be used. The instantaneous handling capacity for two parallel Braking Units
is up to 80 kW.
For drives of 100 HP or larger, two parallel units are recommended. But in this case, deceleration of the
motor may be limited.
Connecting 2SR40700 to 460 V GV3000/SE drive
It is recommended to use one Braking Unit for drives up to 75 HP drives, and to connect two Braking Units
in paraltel for 100 HP, 125 HP and150 HP drives. A single SR3000 Braking Unit has an instantaneous
handling capacity up to 75 kW and a continuous handling capacity up to 15 kW.
For drives larger than 75 HP,a single Braking Unit can be used by connecting an external resistor, if no
rapid deceleration of the motor is expected. But if rapid deceleration is a consideration, it is recommended
thatthe parallel Braking Units be used. The instantaneous handling capacity for two parallel Braking Units
is up to 150 kW.
For drives of 200 HP or larger, two parallel units are recommended. But in this case, deceleration of the
motor may be limited.

Table 3 - Main Terminal Strip Connections
Terminal Faceplate wat
Name Symbol Description
OVERHEAT OH This terminal is used to input an overtemperature signal from the thermostat of a
ov Resistor Overheat Protection Kit (M/N MB-B5071)} if the external resistor
overheats. Connect to the external resistor's thermostat.
DC Supply +(P) This terminal is used to input the DC bus voltage. Connect to the + and — DC bus
—(N} terminals on the GV3000/SE drive or the SP500 drive.
RB RB1 These terminals select which resistor will be used to dissipate energy.
RB2 @ |fthe built-in resistor is used, leave the jumper bar connected to +(P)} and RB1
as shipped from the factory. RB2 should be kept open.
e If an extemal resistor is used, connect the resistor between +(P) and RB2. RB4
should be kept open.
GNDGND Ground (earth) terminal.
Table 4 - Control Terminai Strip Connections
Terminal Faceplate sae
Name Symbol Description
24Vi 24V This terminal is a 24V isolated power supply. The output current is 0.1A.
FAULT FLT This terminal provides an output fault signal if an overload condition occurs. The
open collector signal will be on when any fault occurs, and the Braking Unit will
shut down. This terminal should be tied in series with the function loss terminals
(terminals 16 and20 on the GV3000/SE drive orterminals 10 and 11 on the SP500
drive.)
Output capacity of signal:
@ Allowable voltage: 12 to 30 V (externally supplied)
@ Allowable current: 0.05 A
ALARM ALM This terminal provides an output alarm signal when 80% of snubber overload
detection level (set by the W/S switch on the faceplate) has been reached. The
open collectorsignal will be on when the alarm level is exceeded.
Output capacity of signal:
@ Allowable voltage: 12 to 30 V (externally supplied}
e@ Allowable current: 0.05 A
Ovi OV Signal common.
RESET RST This terminal provides a RESET input to clear alarms and faults. Connect RST to
terminal OV to reset the Braking Unit.
EXTERNAL EXF This terminal is used to enter external fault.
FAULT
Ovi OV Signal common.
Table5 - Recommended Bus Line Fuses
Description Specification Vendor Part No.
Fut, FU2 Fuse A7OP80 Gould —_
Holder P243C Gould ~

Control
Terminats
Power Terminals
PALA SYL2|T/L3] +
230 V GV3000/SE Drive
Fu
Model 2SA20450 Snubber Resistor Braking Unit
Al
3.90, 1 KW
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SNUB-002
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GvUe4snsons
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R 8S T
—_
200 to 230 VAC
Three-phase
AWGB
8 mm
Extemal Resistor <1
>1 Use an Overheat Protection Kit each Braking Unit.
PBi
4 4 —
Lag
Fil} (R2
Ri Ri R2 R2
Interlocking
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Figure 5 - Wiring Diagram for 230 V GV3000/SE Drives (Connecting One Braking Unit}
200 to 230 VAG
Three-phase
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Model 2SR20450 Mode! 2SR20450
Braking Unit Braking Unit
OHOH
ov Ov FU2
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RB1 RB1
wo foccccc r RB2RB2 }------ 7
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-{(N)
awas L GND GND
8mm Control Board Control Board
SNUB-D02SNUB-002 =
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TH 24v 2av || 8mm?
Ri — 7 ELT FLT
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ov CNi | h CNI OV
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ov 3 8 Se ov
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>1 Use an Overheat Protection Kit each Braking Unit.
CN1-Cablel (Optional)
Extemal
Resistor
<1
Figure 6 - Wiring Diagram for 230 V GV3000/SE Drives (Connecting Two Braking Units in Parallel)

460 V GV3000/SE Drive
Model 2SR40760 Snubber Resistor Braking Unit
aE CNa
iE cn2
Control Board
SNUB-002
cN1
3.cN4
geoventona
24v|FLTIALM ov /RST[EXF| ov |
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17| & 7.59, 2kW
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380 to 460 VAC
Three-phase
External Resistor <1
LL PBI
GS , Los
8 mm? Rl} (R2
R1 Ri Re Ae '
Interlocking
Circuit
>1 Use an Overheat Protection Kit each Braking Unit.
Figure 7 - Wiring Diagram for 460 V GV3000/SE Drive (Connecting One Braking Unit)
Model 2SR40700
Braking Unit
380 to 460 VAC
Three-phase OH
—
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RST eH HP}
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Power Terminals wae =
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SNUB-002 =
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ov
RST
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ov
>1 Use anOverheat Protection Kit each Braking Unit.
CN1-Cablel (Optional)
Figure 8 - Wiring Diagram for 460 V GV3000/SE Drives (Connecting Two Braking Units in Parallel)

Technical Specifications
Table 6 - Braking Unit Specifications
Number of Braking Units Connected One Unit Two Units
Connected in Parallel
Model Number 2SR20450 28R40700 2SR20450 25R40700
Voltage Class 150 ~ 430 300 ~ 800 150 ~ 430 300 ~ 800
Rated Output (kW)
{using external resistor) 8 15 Sx2 1x2
Output
Instantaneous Maximum Output
40 75 40x2 75 x2
(kW)
Turn-On Voltage 400 +12 VDC} 750 = 12 VDC 400 +12 VDG|750 +12 VDC
Resistor Capacity (W} 1000 2000 1000 x2 2000 x2
_ Continuous Handling Capacity (W) 450 700 450 x2 700 x2
Regeneration Instantaneous Maximum Handling
Discharge
9° capacity (kW) (within 0.5 seconds) 40 %s 40 x2 Ke
Minimum Resistance (Ohm) 3.9 7.53.97.5
Protection Functions Overcurrent
Alarm and Fault Signals
Open collector, two outputs (allowable voltage 12 to 30 VDC,
allowable current 0.05 A). To be used asan alarm/fault
signal for overload conditions.
Cooling Method
Forced ventilation with DC brushless fan.
Location In control cabinet (free from corrosive or dangerous gas).
Ambient Temperature
Operating: -10° to 55°C (14° to 131°F)
Storage: -40° to 65°C (-40° to 149°F)
Environment
Ambient
Humidity
5 to 95%, non-condensing
Elevation 1000 meter or lower above sea level
Vibration Less than 1 G (25 Hz)
Shock Less than 2 G
Weight 8kg | 11.3k9 | 8kg 11.3 kg
Replacement and Optional Parts
Table 7 - Replacement Parts
_. Required Quantity
Description Part Number 28R20450 2S5R40700
Control Board SNUB-002 230 V 827709 (230 V) 1 -
Control Board SNUB-002 460 V 827709 (460 V} - 1
IGBT Transistor 529208 1 1
Current Sensor 556072 1 1
Snubber Capacitor 459604 1 1
Snubber Diode 502505 t 1
Snubber Resistor 429052 1 1
DC Brushless Fan (24 VDC} 373653 1 1
Regenerative Resistor 429723 1 -
Regenerative Resistor 429724 - 2
Note: Specify 230 V or 460 V for the voltage of the braking unit when you order a control board SNUB-002 since the board is
different for 230 V or 460 V though the part number is the same.
10

Table 8 - Optional Htems
Description Model Number Part Number
CN1-Cable MC-B6004 171127
External Resistors
Table 9 - External Resistor Specifications
Reliance Part Modei Continuous Waitt Rated Resistance Weight
NumberNumber Dissipation (W) Power (kW) (Ohm) (kg (Ibs.))
428302 85161/1612 400 1.2 1.5 2.2 (4.9)
428301 85161/720 600 0.70.7 3.5 (7.2)
Table10 - Model MB-B5071 Coil Resistor Overheat Protection Kit
Model Number
Overheat detection level
MB-B5071
130°C (266°F)
Table 11.1 - Examples of External Rsistor Combinations for 2SR20450
Composite Resistors Resistor Circuit Connections Continuous Instantaneous Setting of
Ohm / Watt . Watt Watt W/S Switch
In Series In Parallel Total Number | Dissipation (kW) Dissipation (kW)
1.5/1200 3 03 1.2 35
0.7 / 2000 6 06 4.0 38
Table 11.2 - Examples of External Resistor Combinations for 2SR20700
Composite Resistors Resistor Circuit Connections Continuous Instantaneous Settingof
Ohm / Watt Watt Watt WIS Switch
In Series In Parallel Total Number | Dissipation (kW) Dissipation (kW)
1.5 / 1200 5 05 2.0 75 4
0.7 / 2000 1 0 11 6.6 73 6
11

Reliance Electric / 24703 Euclid Avenue / Cleveland, Ohio 44117 / [phone]
@® Rockwell Automation
Reliance Electric
Printed in Japan D2-3401 November 1997